3114-3116-3126-disassembly-and-assembly.pdf

SENR9518-03

Disassembly and Assembly 3114, 3116 and 3126 Engines S/N

1ZG00001-UP

from the Library of Barrington Diesel Club

_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03

Content.

Use the bookmarks to navigate through the manual.

2


Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP

Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03

Publication Date -01/09/2005

Date Updated -03/10/2005

i01928280

Fuel Filter Base - Remove and Install SMCS - 1262-010

Removal Procedure Table 1 Required Tools Tool

Part Number

A

185-3630

Part Description

Qty

Strap Wrench As

1

Start By:

A. Remove the crankcase breather. Refer to Disassembly and Assembly, "Crankcase Breather - Remove and Install".

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

NOTICE Care must be taken to ensure that fluids are contained during performance ofBe inspection, adjusting repair of the product. preparedmaintenance, to collect the testing, fluid with suitableand containers before opening any compartment or disassembling any c omponent containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

3


Illustration 1

g00629777

Typical example

1. Use Tooling (A) to remove fuel filter (5) . 2. Disconnect tube assemblies (1) and (2) from fuel filter base (4) . 3. Remove bolts (3) from fuel filter base (4) . 4. Remove fuel filter base (4) and the gasket from the engine.

Illustration 2

g00629788

5. Remove fuel pressure relief valve (7) from fuel filter base (4), if necessary.

Installation Procedure 4


Table 2 Required Tools Tool A

Part Number

185-3630

Part Description

Strap Wrench As

Qty

1


Illustration 3

g00629788

1. Install fuel pressure relief valve (7) on fuel filter base (4) .

5


Illustration 4

g00629777

Typical example

2. Inspect the condition of the gasket. Replace the gasket, if necessary. 3. Position the gasket and fuel filter base (4) on the engine. 4. Install bolts (3) that secure fuel filter base (4) on the engine. 5. Connect tube assemblies (1) and (2) to fuel filter base (4) . 6. Use Tooling (A) to install fuel filter (5) . 7. Install O-ring seal (6) on fuel filter base (4) . End By: Install the crankcase breather. Refer to Disassembly and Assembly, "Crankcase Breather - Remove and Install".

6






i01928293

Fuel Priming Pump and Primary Fuel Filter - Remove and Install SMCS - 1258-010; 1260-010

Removal Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disasse mbling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

7

_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03 Illustration1

g00678475

1. Disconnect tube assembly (2) from primary fuel filter base (1) .

Illustration2

g00678476

2. Remove bolts (4) from the fuel priming pump (3) . 3. Remove fuel priming pump (3) from the primary fuel filter base.

Illustration3

g00678479

4. Remove bolt (5) from the primary fuel filter base. 5. Remove filter element (6) and housing (7) from the primary fuel filter base.

8


Illustration4

g00773124

6. Remove bolts (8) from the primary fuel filter base (1) . 7. Remove primary fuel filter base (1) from the engine.

Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration5

g00773124

1. Install bolts (8) that secure primary fuel filter base (1) to the engine.

9


Illustration6

g00678479

2. Install filter element (6) and housing (7) to the primary filter base with bolt (5) .

Illustration7

g00678476

3. Install bolts (4) that secure fuel priming pump (3) to the primary fuel filter base.

Illustration8

g00678475

4. Connect tube assembly (2) to primary fuel filter base (1) .

10






i01928670

Fuel Transfer Pump - Remove SMCS - 1256-011

Removal Procedure Note: The governor and the fuel transfer pump have been removed from the engine for photographic purposes only. This procedure may be done with the governor on the engine.

Illustration 1

g00623633

11


Illustration 2

g00623671

Personal injury can result from parts and/or covers under spring pressure. Spring force will be released when covers are removed. Be prepared to hold spring loaded covers as the bolts are loosened.

1. Hold cover (1) in place an d remove bolts (2) in order to release the spring beneath cover (1). Remove cover (1) .

Illustration 3

g00623686

2. Remove fitting (3) and the check valve from cover (1). Remove the filter screen (i f equipped) from fitting (3) . 12


Illustration 4

g00623687

3. Remove spring (4) and piston (5) . 4. Remove upper O-ring seal (6) .

Illustration 5

g00623714

5. Remove sleeve assembly (7). Inspect the face of lifter (8) fo r excessive wear. Inspect the surface of the camshaft that is inside of the governor for excessive wear or damage. 6. Remove lower O-ring seal (9) .

Illustration 6

g00623719

7. Remove fitting (10) and the check valve. 13


Note: For information on reusability of the components in the fuel transfer pump, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8434, "3100 Governor Inspection and General Information for Mechanical Governor Groups Used in 3114, 3116, and 3126 Engines Equipped with Mechanical Unit Injectors (MUI)".

14






i01928343

Fuel Transfer Pump - Install SMCS - 1256-012

Installation Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

A

8T-2998

Lubricant

1


Note: For information on reusability of the components in the fuel transfer pump, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8434, "3100 Governor Inspection and General Information for Mechanical Governor Groups Used in 3114, 3116, and 3126 Engines Equipped with Mechanical Unit Injectors (MUI)".

Illustration 1

g00623719

1. Lubricate fitting (10) and the bore with clean engine oil. Install the check valve and fitting (10) . 15


Illustration 2

g00623714

2. Inspect the condition of the O-ring seal. Replace the O-ring seal, if necessary. Install lower O-ring seal (9) . 3. Apply Tooling (A) on the face o f lifter (8). Install sleeve assembly (7). Ensure that the flat on t he sleeve aligns with the flat in the bore of the housing.

Illustration 3

g00623687

4. Lubricate piston (5) with clean engine oil. Install piston (5) and spring (4) .

Illustration 4

g00623686

5. Lubricate fitting (3) and the bore for the check valve with clean engine oil. Install the check valve with the sealing face toward the fitting. 16


6. Install the O-ring seal and fitting (3) .

Illustration 5

Illustration 6

g00623671

g00623633

Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

7. Place cover (1) over spring (4). Install bolts (2) in order to compress spring (4) . 17






i01928366

Fuel Shutoff Solenoid - Remove and Install SMCS - 1259-010


Part Number

Part Description

Qty

A

9U-5120

Spanner Wrench (1)

1

(1)

This tool is part of the 128-8822 Fuel System and Governor Tool Group .


NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any c omponent containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

18


Illustration1

g00585831

1. Disconnect the harness assembly (2) from fuel shutoff solenoid (1) . 2. Use Tooling (A) to remove the fuel shutoff solenoid from the governor. 3. Remove the O-ring seal from the shutoff solenoid .


A (1)

Part Number

9U-5120

Part Description

Spanner Wrench

(1)

Qty

1




19


Illustration2

g00585831

1. Inspect the O-ring seal on the fuel shutoff solenoid. If the O-ring seal is worn or damaged, use new parts for replacement. 2. Install the O-ring seal on th e fuel sh utoff solenoid. 3. Install the fuel shutoff solenoid in the governor. Use Tooling (A) and a suitable torque wrench to tighten the fuel shutoff solenoid to the following torque 30 ± 5 N·m (22 ± 4 lb ft). 4. Connect the harness assembly to the fuel shutoff solenoid.

20






i01928381

Governor - Remove SMCS - 1264-011


Part Number

A

136-4149

(1)

Part Description

Governor Pliers

Qty

(1)

1


Start By:

A. Remove the fuel shutoff solenoid. Refer to Disassem bly and Assembly, "Fuel Shutoff Solenoid - Remove and Install".


21


Illustration1

g00613041

1. Disconnect the governor control cable. 2. Remove oil tube assembly (1). Remove tube assembly (2) and tube assembly for fuel ratio control (3), if equipped. Plug and cap all connections.

Illustration 2

g00613071

3. Remove clip (4) .

Illustration 3

g00655975

22


4. Use Tooling (A) to slide tube assembly (5) into the cylinder head.

Illustration 4

g00613149

5. Remove the clip and use Tooling (A) to remove the clevis pin (6) . Note: Clevis pin (6) must stay with the governor in order to be adjusted.

Illustration 5

g00613563

6. Remove bolts (7) and the washers that hold the governor in position.

Illustration 6

g00673182

7. Remove the governor from the engine. 23


Illustration 7

g00673180

8. Remove O-ring seal (3) on the governor.

Illustration 8

g00672742

9. Remove the O-ring seal and tube assembly (5) from the cylinder head.

Illustration 9

g00672733

10. Remove O-ring seal (2) on the tube assembly (5) .

24


Illustration10

g00673178

11. Remove O-ring seal (1) from the cylinder head. Note: For more information on the governor, refer to Service Manual, SENR6454, "3114, 3116, & 3126 Engine Governors". The Service Manual, SENR6454 requires the use of a 1U-7326 Governor Calibration Bench. For information on reusability of components in the governor, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8434, "3100 Governor Inspection and General Information for Mechanical Governor Groups Used in 3114, 3116, and 3126 Engines Equipped with Mechanical Unit Injectors (MUI)".

25






i01928419

Governor - Install SMCS - 1264-012


Part Number

Part Description

A

136-4149

Governor Pliers

128-8827

Pin (1)

1

Pin Pilot (1)

1

(1)

Qty

1

B 1U-7523 (1)

This tool is part of the 128-8822 Governor Tool Group .


Note: For more information on the governor, refer to Service Manual, SENR6454, "3114, 3116, & 3126 Engine Governors". The Service Manual, SENR6454 requires the use of a 1U-7326 Governor Calibration Bench. For information on reusability of components in the governor, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8434, "3100 Governor Inspection and General Information for Mechanical Governor Groups Used

in 3114, 3116, and 3126 Engines Equipped with Mechanical Unit Injectors (MUI)".

26


Illustration 1

g00673178

1. Apply lubricant to the new O-ring seal (1). Install new O-ring seal (1) in the cylinder head.

Illustration 2

g00672733

2. Apply lubricant to the new O-ring seal (2). Install new O-ring seal (2) on the tube assembly (5) .

Illustration 3

g00672742

3. Install the O-ring seal and tube assembly (5) in the cylinder head.

27


Illustration 4

g00673180

4. Apply lubricant to the new O-ring seal (3). Install new O-ring seal (3) on the governor.

Illustration 5

g00673182

5. Place the governor in position on the engine.

Illustration 6

g00613563

6. Install the washers and bolts (7) that hold the governor in place.

28


Illustration 7

g00672755

7. Install clevis pin (6) in Tooling (B) .

Illustration 8

g00672752

8. Use Tooling (B) to install clevis pin (6) and the clip. 9. Check the fuel setting adjustment. Refer to Testing and Adjusting, SENR5118.

Illustration 9

g00655975

29


10. Use Tooling (A) to slide tube assembly (5) into the governor.

Illustration10

g00613071

11. Install clip (4) .

Illustration11

g00613041

12. Install oil tube assembly (1). Install tube assembly (2) an d tube assembly for fuel ratio cont rol (3), if equipped. Plug and cap all connections. 13. Install the governor control cable. End By: Install the fuel shutoff solenoid. Refer to Disassembly and Assembly, "Fuel Shutoff Solenoid - Remove and Install".

30






i01928445

Fuel Injection Control Linkage - Remove SMCS - 1298-011


Part Number

Part Description

Qty

A

136-4149

Governor Pliers

1

Start By:

A. Remove the rocker shaft and the pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod Remove".


Illustration 1

g00613071

1. Remove clip (4). Clip (4) is located between the governor and the cylinder head. 31


Illustration 2

g00655975

2. Use Tooling (A) to slide tube assembly (5) into the cylinder head.

Illustration 3

g00613149

3. Remove the clip and use Tooling (A) to remove the clevis pin (6). Clevis pin (6) connects the governor to the control lever of the fuel injection control linkage. Note: Clevis pin (6) must stay with the governor in order to be adjusted.

32

_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03 Illustration 4

g00630566

4. Remove bolts (1) and remo ve fuel injection control linkage (2). Control lever (3) connects the fuel injecti on control linkage (2) to the governor. Note: For information on the inspection procedure for control lever (3), refer to Special Instruction, REHS0601, "Inspection and Modification of the 102-7459 Fuel Injection Control Linkage and the 4P-9048 Fuel Injection Control Linkage".

33






i01928573

Fuel Injection Control Linkage - Install SMCS - 1298-012


Part Number

Part Description

Qty

A

136-4149

Governor Pliers

128-8827

Pin (1)

1

Pin Pilot (1)

1 6

(1)

1

B 1U-7523 C

1U-6675

Spring Compressor (1)

D

128-8822

Fuel System and Governor Tool Gp

(1)

1

This tool is part of the 128-8822 Governor Tool Group .

Illustration 1

g00661331

Note: For information on the inspection procedure for control lever (3), refer to Special Instruction, 34


REHS0601, "Inspection and Modification of the 102-7459 Fuel Injection Control Linkage and the 4P-9048 Fuel Injection Control Linkage". 1. Loosen setscrews (4) on each bracket. 2. Install fuel control linkage (2) and install bolts (1). Use the following sequence in order to tighten the bolts. 3. Tighten bracket (A) and (D) to a torque of 12 ± 3 N·m (106 ± 27 lb in). 4. Tighten brackets (B) and (C) to a torque of 12 ± 3 N·m (106 ± 27 lb in). 5. Position brackets (B) and (C) in order to allow free rotation of the fuel control rod. 6. Use a 2.5 mm (0.10 inch) wrench to tighten setscrews (4). Tighten the setscrews to a torque of 3.5 ± 0.2 N·m (31 ± 2 lb in). Do not overtighten the setscrews. Ensure that the control rod rotates freely. 7. The control rod should rotate freely when a force of 4.4 N (1 lb ) or less is applie d to control lever (3) .

Illustration 2

g00750163

8. Rotate the unit injectors in order to engage the injector rack bar (5) with the fuel injection control linkage (2) . Note: If the unit injectors are not installed, refer to the Disassembly and Assembly, "Unit Injector - Install".

9. Install Tooling (C) on the unit injectors and compress the springs. Note: For the procedure to install Tooling (C), refer to Tool Operating Manual, NEHS0610, "Using the 1288822 Tool Group on 3114, 3116, and 3126 Engines with Mechanical Unit Injectors (MUI)".

35


Illustration 3

g00672755

10. Install clevis pin (6) in Tooling (B). Clevis pin (6) attaches the control lever (3) to the governor.

Illustration 4

g00672752

11. Use Tooling (B) to install clevis pin (6) and the clip. 12. Use Tooling (D) to set the unit injector synchronization. Note: For the procedure to use Tooling (D), refer to Tool Operating Manual, NEHS0610, "Using the 128-8822 Tool Group on 3114, 3116, and 3126 Engines with Mechanical Unit Injectors (MUI)".

13. Remove Tooling (C) from the unit injectors.

36


Illustration 5

g00655975

14. Use Tooling (A) to slide tube assembly (5) into the governor.

Illustration 6

g00613071

15. Install clip (4) . End By: Install the rocker arm assemblies and the pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod - Install".

37






i02834896

Unit Injector - Remove SMCS - 1290-011


Part Number

Part Description

Qty

A

5P-0302

Bar

1

Start By:

A. Remove the rocker shaft and the pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod Remove".


NOTICE Care must be taken to ensure that fluids are contained during performance ofBe inspection, adjusting repair of the product. preparedmaintenance, to collect the testing, fluid with suitableand containers before opening any compartment or disassembling any c omponent containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

Note: For determining the ability to reuse a unit injector, refer to Special Instruction, SEHS9787, "Test Procedure For Caterpillar 3114, 3116 And 3126 Mechanical Unit Injectors". 38


Illustration 1

Illustration 2

g00775441

g00625237

1. Remove fuel injector hold-down bolt (1) . Note: Do not pry on the injector hold-down bracket. Damage to the unit injector could occur. The unit injector has a notch on the opposite side of the rack. This notch is used for prying the unit injector loose. Some fuel injector racks move freely when the spring is not compressed. Do not move the fuel injector rack without compressing the fuel injector spring slightly. Damage may occur to the unit injector.

2. Use Tooling (A) to loosen the unit injector. Rotate the unit injector in order to disengage injector rack bar (3) from fuel injection control linkage (2) . 3. Remove the unit injector. Ensure that two O-ring seals are on the unit injector.

39






i02834915

Unit Injector - Install SMCS - 1290-012


Part Number

Part Description

Qty

B

4C-5553

Injector Seat Cleaning Brush

C

173-1530

Injector Seating Tool

1

D

143-2099

Unit Injector Tool Group (Sleeve Replacement)

1

1


Note: For determining the ability to reuse a unit injector, refer to Special Instruction, SEHS9787, "Test Procedure For Caterpillar 3114, 3116 And 3126 Mechanical Unit Injectors".

1. Inspect the unit injector sleeve for pitting and for carbon tracking. Used unit injector sleeves do not need to be reamed unless the seated area is pitted or eroded. If the seated area has excessive carbon deposits, the used unit injector sleeves need to be reamed. Refer to Tool Operating Manual, NEHS0675, "Using the 143-2099 Sleeve Replacement Tool Group on 3114, 3116, and 3126 Engines". Use Tooling (D) to ream injector sleeves. 2. Inspect the condition of the O-ring seals on the unit injector. Replace the seals, if necessary. 3. Lubricate the O-ring seals with clean engine oil.

40


Illustration 1

g00775441

4. Position the unit injector in the cylinder head and rotate the unit injector in order to engage injector rack bar (3) with fuel injection control linkage (2) . Push down on the unit injector and ensure that the unit injector is properly seated in the cylinder head. Note: Do not use fuel injector hold-down bolt (1) to pull the unit injector into the cylinder head.

5. Install a new fuel injector hold-down bolt (1) in the hold-down bracket for the unit injector. Tighten fuel injector hold-down bolt (1) to a torque of 12 ± 3 N·m (106 ± 27 lb in). Note: Do not overtighten fuel injector hold-down bolt (1) . Excessive torque may cause damage to the unit injector and the unit injector may seize.

6. Refer to the Tool Op erating Manual, NEHS0738, "Using the 173-1530 Injector Seating Tool Group on 3114, 3116, and 3126 MUI or 3126 HEUI 2-Valve Engines" for the remaining steps on installing the unit injector. End By:

a. Install the rocker shaft and the pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod Install". b. Synchronize the unit injectors. Refer to Testing and Adjusting, "Unit Injector Synchronization - Adjust".

41




Publication Date -01/09/ 2005


i01928597

Unit Injector Sleeve - Remove SMCS - 1713-011


Part Number

Part Description

Qty

A

143-2099

Unit Injector Tool Group

1

Start By:

A. Remove the unit injector. Refer to Disassembly and Assembly, "Unit Injector - Remove".


NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. to collect the f luid withany suitable containers before opening Be anyprepared compartment or disassembling c omponent containing fluids. Refer to Speci al Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

42


Illustration 1

g00627676

1. Use Tooling (A) to remove unit injector sleeve (1) from the cylinder head. Refer to Tool Operating Manual, NEHS0675, "Using the 143-2099 Sleeve Replacement Tool Group on 3114, 3116, and 3126 Engines" for the correct procedure.

43






i01928606

Unit Injector Sleeve - Install SMCS - 1713-012


Part Number

Part Description

Qty

A

143-2099

Unit Injector Tool Group

1


44


Illustration 1

g00627676

1. Inspect the condition of the existing sleeve and ream out the existing sleeve, if necessary. When you are replacing the existing injector sleeve, use a new brass sleeve. It is not necessary to ream the new brass sleeves. Use Tooling (A) to install unit injector sleeve (1) into the cylinder head. Refer to Tool Operating Manual, NEHS0675, "Using the 143-2099 Sleeve Replacement Tool Group on 3114, 3116, and 3126 Engines" for the correct procedure. End By: Install the unit injector. Refer to Disassembly and Assembly, "Unit Injector - Install".

45






i01928645

Turbocharger - Remove SMCS - 1052-011


NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the f luid with suitable containers before opening any compartment or disassembling any c omponent containing fluids. Refer to Speci al Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

Note: For information on the reusability of components of the turbocharger, refer to Guideline For Reusable Parts

And Salvage Operations, SEBF8018, "Turbochargers". information on theSEBF8071, salvage of "Procedures components to of Salvage the turbocharger, refer to Guideline For Reusable Parts AndFor Salvage Operations, Turbocharger Components".

46


Illustration1

g00617515

Illustration2

g00617565

1. Disconnect oil supply tube assembly (5) from turbocharger (6) . 2. Remove bolts (1) and disconnect oil drain tube assembly (2) from turbocharger (6) . 3. Remove bolts (3) . 4. Remove locknuts (4) . 5. Remove turbocharger (6) and the gasket from the exhaust manifold. Note: Place index marks on the turbocharger cartridge and the housing.

6. Remove the end housing from the cartridge. Note: The wastegate is part of the turbine housing and the wastegate is preset at the factory. The wastegate is nonserviceable.

47






i01928659

Turbocharger - Install SMCS - 1052-012


Part Number

Part Description

Qty

A

5P-3931

Anti-Seize Compound

1


Note: For information on the reusability of components of the turbocharger, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8018, "Turbochargers". For information on the salvage of components of the turbocharger, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8071, "Procedures to Salvage Turbocharger Components".

1. Inspect the turbocharger gasket for wear or damage. If the turbocharger gasket is worn or damaged, use a new part for replacement. 2. Apply Tooling (A) on the threads of the mounting studs for the turbocharger.

48


Illustration 1

g00617565

3. Position the turbocharger gasket and turb ocharger (6) on the exhaust man ifold. Install nuts (4) and tighten nu ts (4) to a torque of 54 ± 5 N·m (40 ± 4 lb ft).

Illustration 2

g00617515

4. Inspect the gaskets for oil supply tube assembly (5) and oil drain tube assembly (2). If the gaskets are worn or damaged, use a new part for replacement. 5. Position oil drain tube assembly (2) and the gasket on tur bocharger (6). Install bolts (1) on the tur bocharger and install bolts (3) on the cylinder block. 6. Install the gasket for oil su pply tube assembly (5) and connect oil supply tube assembly (5) to turbocharger (6) .

49






i01928788

Exhaust Manifold - Remove and Install SMCS - 1059-010

Removal Procedure Start By:

A. Remove the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Remove".

Illustration1

g00652578

Typical example

1. Remove bolts (1), exhaust manifold (2), locks and the gaskets from the cylinder head assembly. 2. If the engine is equi pped with a three-piece exh aust manifold, disassemble exhaust manifold (2) into three pieces. 3. Remove mounting studs (3) from exhaust manifold (2), if necessary.


Part Number

Part Description

Qty

A

5P-3931

Anti-Seize Compound

1 50


B

2P-2333

High Temperature Sealer

Illustration2

1

g00652578

Typical example

1. Apply Tooling (A) to the threads of mounting studs (3) . 2. Install mounting studs (3). Tighten mounting studs (3) to a torque of 35 ± 5 N·m (26 ± 4 l b ft). 3. If the engine is equipped with a three-piece exhaust manifold, apply a thin coat of Tooling (B) to the male ends of exhaust manifold (2). Coat the inside of the female ends of exhaust manifold (2) with clean engine oil. Assemble exhaust manifold (2) and remove the excess sealant from the joints. 4. Install new exhaust manifold gaskets. 5. Apply Tooling (A) to the threads of bolts (1) . Position the gaskets and ex haust manifold (2) on the cylinder head assembly. Install locks and bolts (1) .

Illustration 3

g00617739

Typical example of a three-piece exhaust manifold

51


Illustration 4

g00641026

Exhaust manifold for a Four cylinder engine

Illustration 5

g00641092

Water cooled exhaust manifold

6. Tighten bolts (1) in a numerical sequence to a torque of 4 ± 1 N·m (35 ± 9 lb in). 7. Tighten bolts (1) in a numerical sequence to a torque of 45 ± 5 N·m (33 ± 4 lb ft).

52


Illustration6

g00675760

Typical example of locking tabs

8. Bend the locking tabs (4) over the flat of each bolt head. End By: Install the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Install".

53






i01328419

Inlet Manifold - Remove SMCS - 1058-011


A. Remove the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install".



1. Disconnect air inlet piping from the turbocharger to the aftercooler, if necessary.

54


Illustration1

g00629952

2. Remove bolts (1) and disconnect air inlet heater solenoid (3) . 3. Remove air inlet elbows (2) from air inlet manifold (5) . 4. Remove bolts (4) from air inlet manifold (5) . 5. Remove air inlet manifold (5) and the gasket.

55






i01414226

Inlet Manifold - Install SMCS - 1058-012



56


g00675794

1. Install a new gasket (6) on the cylinder head.

Illustration2

g00629952

2. Position the air inlet manifold (5) on the engine. 3. Install bolts (4). Tighten the bolts to a torque of 28 ± 7 N·m (21 ± 5 lb ft). 4. Install air inlet elbows (2) on air inlet manifold (5) . 5. Install bolts (1) and connect air inlet heater solenoid (3) . End By: Install the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover -

Remove and Install".

57






i01943334

Inlet and Exhaust Valves - Remove and Install SMCS - 1105-010


Part Number

Part Description

Qty

A

5S-1330

Valve Spring Compressor

1

Start By:

A. Remove the cylinder head assembly. Refer to Disassembly and Assembly, "Cylinder Head - Remove".


Note: For information on the reusability of the inlet valves, the exhaust valves and the springs, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8002, "Valves, Valve Springs, Valve Rotators, and Locks", Guideline For Reusable Parts And Salvage Operations, SEBF8034, "Valve and Valve Spring Specifications", and Guideline For Reusable Parts And Salvage Operations, SEBF8162, "Specifications to Measure and Salvage Cylinder Head Assemblies and Related Components".

58


Illustration 1

g01011225

Note: The following components of the exhaust valves are different from the components of the inlet valves: spring retainer (2), valve spring (3) and valve (5).

Illustration2

g01011269

1. Use Tooling (A) to compress valve spring (3). Remove retainer lock (1) . 2. Remove Tooling (A) . 3. Remove spring retainer (2). Remove valve spring (3) . 4. Remove valve seal (4) and valve (5) . 5. Repeat Steps 1 through 4 in order to remove the remaining inlet valves and exhaust valves.



Table 2 Required Tools Tool

Part Number

Part Description

Qty

A

5S-1330

Valve Spring Compressor

1


Note: For information on the reusability of the inlet valves, the exhaust valves and the springs, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8002, "Valves, Valve Springs, Valve Rotators, and Locks", Guideline For Reusable Parts And Salvage Operations, SEBF8034, "Valve and Valve Spring Specifications", and Guideline For Reusable Parts And Salvage Operations, SEBF8162, "Specifications to Measure and Salvage Cylinder Head Assemblies and Related Components".

Illustration 3

g01011225

1. Lubricate valve (5) with clean en gine oil. Install valve (5) in the cylinder head assembly. Install new valve seal (4) against the valve guide. 2. Place the following items on the valve stem: valve spring (3) and spring retainer (2) .

60


The valve keepers can be thrown from the valve when the valve spring compressor is released. Ensure that the valve keepers are properly installed on the valve stem. To help prevent personal injury, keep away from the front of the valve keepers and valve springs during the installation of the valves.

Note: A small amount of grease can be used to hold retainer locks (1) in position during installation.

Illustration4

g01011269

3. Use Tooling (A) to compress valve spring (3). Install retainer lock (1) . 4. Repeat Steps 1 through 3 in order to install the remaining inlet valves and exhaust valves. End By: Install the cylinder head assembly. Refer to Disassembly and Assembly, "Cylinder Head - Install".

61






i01961680

Inlet and Exhaust Valve Guides - Remove and Install SMCS - 1104-010


Part Number

Part Description

Qty

A

1U-7793

Valve Guide Driver (1)

1

(1)

Part of 1U-6685 Valve Guide Tool Kit

Start By:

A. Remove the inlet and exhaust valves. Refer to Disassembly and Assembly, "Inlet and Exhaust Valves - Remove and Install".


Note: For information on the reusability of the valve guides, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8218, "Specifications for Cylinder Head Asseblies 3114, 3116, and 3126 Engines" and Guideline For Reusable Parts And Salvage Operations, SEBF8162, "Procedure to Measure and Salvage Cylinder Head Assemblies and Related Components".

62


Illustration1

g00745735

Typical example

1. Use Tooling (A) to remove the inlet valve guides from the cylinder head assembly. Use Tooling (A) to remove the exhaust valve guides from the cylinder head assembly.


A

Part Number

1U-7793

Part Description

Valve Guide Driver (1)

B

1U-7792

Guide Collar

C

9U-6895

Valve Guide Driver

D

1 49-4008

(1)

Guide Collar

Qty (1)

1 1 1 1

Part of 1U-6685 Valve Guide Tool Kit

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Note: For information on the reusability of the valve guides, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8218, "Specifications for Cylinder Head Assemblies 3114, 3116, and 3126 Engines" and Guideline For Reusable Parts And Salvage Operations, SEBF8162, "Procedure to Measure and Salvage Cylinder Head Assemblies and Related Components".

63


Illustration2

g00745782

Typical example

1. Position inlet valve guide (1) and tap on the top of inlet valve guide (1). This is done in order to start inlet valve guide (1) into the cylinder head assembly. 2. Use Tooling (A) and Tooling (B) to install inlet valve guid e (1). Install inlet va lve guides (1) until tooling (B) contacts the cylinder head.

Illustration3

g00745672

Typical example

3. Position exhaust valve guide (2) and tap on the top of exhaust valve guide (2). This is done in order to start the exhaust valve guide into the cylinder head assembly. Note: Some of the early engines have inlet valves and exhaust valves that are identical in size. Use the same specifications and the same tools for both valves. Proceed to Step 4 if the valves are not the same size.

4. Use Tooling (C) and Tooling (D) to install exhaust valve guide (2). Install inlet valve guides (2) until tooling (D) contacts the cylinder head.

64


End By: Install the inlet and exhaust valves. Refer to Disassembly and Assembly, "Inlet and Exhaust Valves Remove and Install".

65






i01929146

Inlet and Exhaust Valve Seat Inserts - Remove and Install SMCS - 1103-010


Part Number

A (1)

6V-4194

B (1)

165-5647

(1) C6V-4804

Part Description

Qty

Valve Seat Extractor

1

Valve Seat Extractor

1

Handle

1

D (1) 6V-4192

Threaded Shaft

1

E (1) 6V-4199

Lifting Bracket

1

(1)

Part of the 166-7441 Valve Seat Extractor Tool

Start By:

A. Remove the inlet and exhaust valves. Refer to Disassembly and Assembly, "Inlet and Exhaust Valves - Remove and Install".


Note: For information on the reusability of the valve seats, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8218, "Specifications for Cylinder Head Assemblies 3114, 3116, and 3126 Engines".

66


Illustration 1

Illustration2

g00615519

g00656459

Note: Replace Tooling (A) with Tooling (B) for the removal of the inlet valve seat insert.

1. Install Tooling (A) in the exh aust valve seat ins ert. 2. Install Tooling (C) and Tooling (D) in Tooling (A). Hand tighten Tooling (D). Tooling (A) will expand below the edge of valve seat insert (1) .

67


Illustration3

g00656462

3. Install Tooling (E) on the cylinder head under Tooling (C). Hold Tooling (D) while you turn Tooling (C). Remove valve seat insert (1) .


Part Number

Part Description

Qty

F

1U-6685

Guide and Insert Tool Group

1


Note: For information on the reusability of the valve seats, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8218, "Specifications for Cylinder Head Assemblies 3114, 3116, and 3126 Engines".

1. Cool the valve seat inserts for eas ier installation.

68


Illustration4

g01003799

2. Turn Tooling (F) upside-down and use Tooling (F) and a press to insta ll the valve seat inserts in the cylinder head assembly. 3. After the valve seat inserts are installed, grind the inserts to the final sp ecification. Refer to Guideline for Reusable Parts and Salvage Operation, SEBF8218, "Specifications for Cylinder Head Assemblies 3114, 3116, and 3126 Engines" for the specifications. End By: Install the inlet valves and exhaust valves. Refer to Disassembly and Assembly, "Inlet and Exhaust Valves Remove and Install".

69






i01929163

Engine Oil Filter Base - Remove SMCS - 1306-011


Part Number

A

185-3630

Part Description

Qty

Strap Wrench

1

Start By:

A. Remove the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Remove".


NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. to collect the fluid withany suitable containers before opening Be anyprepared compartment or disasse mbling component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

70


Illustration1

g01009468

1. Use Tooling (A) to remove engine oil filter (3) . 2. Disconnect the tube assembly for the turbocharger inlet (1) from the engine oil filter base (4) . 3. Remove bolts (2) and the washers that hold engine oil filter base (4) to the cylinder block. 4. Remove engine oil filter base (4) and the gasket.

71






i01929612

Engine Oil Filter Base - Disassemble SMCS - 1306-015

Disassembly Procedure Start By:

A. Remove the engine oil filter base. Refer to Disassembly and Assembly, "Engine Oil Filter Base - Remove".

Illustration1

g01011623

Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force.

1. Remove plugs (1) and (3) from oil filter base (2) .

72


Illustration2

g01011627

2. Remove springs (4) and valves (6). Remove O-ring seals (5) from p lugs (1) and (3). Inspect the parts for wear or damage. If the parts are worn or damaged, use new parts for replacement.

73






i01929615

Engine Oil Filter Base - Assemble SMCS - 1306-016

Assembly Procedure

Illustration1

g01011627

1. Install O-ring seals (5) onto plugs (1) and (3). Install valves (6) and springs (4) .

Illustration2

g01011623

74



2. Install plugs (1) and (3) onto oil filter base (2) . End By: Install the engine oil filter base. Refer to Disassembly and Assembly, "Engine Oil Filter Base - Install".

75






i02376426

Engine Oil Filter Base - Install SMCS - 1306-012


Illustration1

g01009468

76


Illustration 2

Illustration3

g01185803

g00676791

1. Position the gasket and engine oil filter base (4) on the cylinder block. 2. Install the washers and bolts (2) that hold engine oil filter base (4) to the cylinder block. Tighten the bolts according to the following procedure: a. Tighten Bolt (1) through Bolt (15) in a numerical sequence to a torque of 15 N·m (11 lb ft). b. Tighten Bolt (1) through Bolt (15) in a numerical sequence to a torque of 28 N·m (21 lb ft). 3. Apply lubricant to new O-ring seal (5) . Install O-ring seal (5) in the fitting on the engine oil filter base. 4. Connect tube assembly (1) to engine oil filter base (4) . Note: Never install an oil filter with a wrench. Follow the instructions on the oil filter.

5. Put a coat of fresh oil on the O-ring seal for the engine oil filter. Install engine oil filter (3) on engine oil filter base (4) by hand. 6. After the O-ring seal contacts engine oil filter base (4) , turn engine oil filter (3) for 3/4 of a turn. End By: Install the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Install".

77






i01943853

Engine Oil Filter Bypass Valve - Remove and Install SMCS - 1308-010-BV



78


g00630032

Illustration2

g00629985


1. Remove plug (1) and the O-ring seal from the engine oil filter base. 2. Remove valve spring (2) and bypass valve (3) from the engine oil filter base.


Illustration3

g00630032

79


Illustration4

g00629985


1. Inspect the condition of the O-ring seal. Replace the seal, if necessary. 2. Install bypass valve (3) and valve spring (2) in the engine oil filter base. 3. Install plug (1) in the engine oil filter base.

80






i01944039

Engine Oil Cooler Bypass Valve - Remove and I nstall SMCS - 1314-010



81


g00629979

Illustration2

g00629985


1. Remove plug (1) and the O-ring seal from the engine oil cooler. 2. Remove valve spring (2) and bypass valve (3) from the engine oil cooler.


Illustration3

g00629985

82


Illustration4

g00629979


1. Inspect the condition of the O-ring seal. Replace the seal, if necessary. 2. Install bypass valve (3) and valve spring (2) in the engine oil cooler. 3. Install plug (1) in the engine oil cooler.

83






i01929226

Engine Oil Cooler - Remove SMCS - 1378-011


A. Remove the engine oil filter base. Refer to Disassembly and Assembly, "Engine Oil Filter Base - Remove".



Note: For information on the reusability of the engine oil cooler, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8077, "Engine Oil Coolers".

84


Illustration1

g00677082

1. Remove engine oil cooler (1) and the gasket.

Illustration2

g00677084

2. Remove O-ring seals (2) .

85






i01929231

Engine Oil Cooler - Install SMCS - 1378-012


Note: For information on the reusability of the engine oil cooler, refer to Guideline For Reusable Parts And Salvage

Operations, SEBF8077, "Engine Oil Coolers".

Illustration1

g00677084

1. Install new O-ring seals (2) .

86


Illustration2

g00677107

2. Install new gasket (3) on the engine oil cooler (1) .

Illustration3

g00677082

Note: Installation can be simplified by the use of guide bolts.

3. Install the gasket and engine oil cooler (1) . End By: Install the engine oil filter base. Refer to Disassembly and Assembly, "Engine Oil Filter Base - Install".

87






i01929340

Engine Oil Pump - Remove SMCS - 1304-011


A. Remove the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove and Install".



Note: For information on the reusability of the engine oil pump, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8167, "Reconditioning Procedures 3114 and 3116 Engines".

88


Illustration1

g00894501

1. Remove bolts (1) and bolt (2) . 2. Remove engine oil pump (3) . 3. Remove the O-ring seal that is located between the cylinder block and the outlet elbow.

89






i01944046

Engine Oil Pump - Disassemble SMCS - 1304-015

Disassembly Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

A

1P-0510

Driver Gp

1

B

1P-2320

Combination Puller

1

Start By:

A. Remove the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump - Remove".



Note: For information on the reusability of the engine oil pump, refer to Guideline For Reusable Parts And Salvage 90


Operations, SEBF8167, "Reconditioning Procedures 3114 and 3116 Engines".

Illustration1

g00614664

1. Remove the bolts from tube assembly for the pickup of oil (2), and the gasket from the engine oil pump. Remove the bolt and outlet elbow (1) from the engine oil pump.

Illustration2

g00614677

2. Remove bolt (3), washer (4), and idler gear (5) from the engine oil pump.

Illustration3

g00614683

3. Use Tooling (A) and a suitable press in order to remove the bearing from idler gear (5) . 4. Remove shaft (6) of engine oil pump from oil pump body assembly (7) . 91


5. Use Tooling (B) to remove drive gear (8) .

Illustration4

g00614689

6. Remove bolts (10). Separate oil pump body (9) from oil pump body assembly (7) .

Illustration5

g00614694

NOTICE Before removing the drive shaft from the pump housing, be sure that no burrs exist on the drive shaft. If the drive shaft has burrs on it, the bores in the pump housing may be scratched.

7. Remove shaft assembly (11) and shaft assembly (12) from oil pump body (9) .

92


Illustration6

g00824021

Personal injury can result from parts and/or covers under spring pressure. Spring force will be released when covers are removed. Be prepared to hold spring loaded covers as the bolts are loosened.

8. Remove the following items from oil pump body assembly (7) : the bolt an d the washer, spring (14) and oil pressure relief plunger (13)

93






i01944064

Engine Oil Pump - Assemble SMCS - 1304-016

Assembly Procedure Table 1 Required Tools Tool

Part Number

A

1P-0510

Part Description

Driver Gp

Qty

1


Note: For information on the reusability of the engine oil pump, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8167, "Reconditioning Procedures 3114 and 3116 Engines".

1. Ensure that all of the pa rts of the engine oil pump are thoroughly clean prior to assembly. Note: Lubricate all internal parts of the engine oil pump with clean engine oil.

Illustration1

g00824021

94



2. Install oil pressure relief plunger (13) and spring (14) in oil pump body assembly (7). Install the washer and the bolt.

Illustration2

g00614694

Illustration3

g00614689

3. Install shaft assembly (12) in oil pump body (9) . 4. Install shaft assembly (11) in oil pump body (9) . 5. Position oil pump body (9) on oil pump body assembly (7) and install bolts (10) .

95


Illustration4

g00614683

6. Press drive gear (8) on shaft as sembly (11) until drive gear (8) is flush with the end of shaft assembly (11) . 7. Install oil pump shaft (6). Install the bearing in idler gear (5) with Tooling (A). Install the bearing so the distance between the hub bolt face of idler gear (5) and the bearing is 0.75 ± 0.25 mm (0.030 ± 0.010 inch).

Illustration5

g00614677

8. Install idler gear (5) on oil pump shaft (6). Install washer (4) and bolt (3). Tighten bolt (3) to 70 ± 15 N·m (52 ± 11 lb ft).

Illustration6

g00614664

9. Check the condition of the gasket that is used in tube assembly for the pickup of oil (2). If the gas ket is damaged, replace the gasket. Install the gasket and tube assembly for the pickup of oil (2) . 10. Check the condition of the O-ring seal that is used in outlet elbow (1). If the O-ring seal is damaged, replace the 96


O-ring seal. Install the O-ring seal and outlet elbow (1) . End By: Install the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump - Install".

97






i01981031

Engine Oil Pump - Install SMCS - 1304-012


Note: Ensure that the mounting surfaces for the engine oil pump are thoroughly clean.

Illustration 1

g01029320

98


1. Install the O-ring seal. Position engine oil pump (3) on the cylinder block. 2. Install bolts (1) and bolt (2) . End By: Install the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove and Install".

99






i01929373

Water Pump - Remove SMCS - 1361-011

Removal procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.


Personal injury can result from hot coolant, steam and alkali. At operating temperature, engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns. Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system pressure cap is cool enough to touch with your bare hand. Do not attempt to tighten hose connections when the coolant is hot, the hose can come off causing burns. 100


Cooling System Coolant Additive contains alkali. Avoid contact with skin and eyes.

1. Drain the coolant from the cooling system into a suitable container for storage or for disposal. 2. Use hole (4) to remove tension from the V-belt.

Illustration1

g01004978

3. Loosen bolts (3) and (6) on idler pulley assembly (7) . Note: For information on the reusability of idler pulley assembly (7), refer to Guideline For Reusable Parts And Salvage Operations, SEBF8046, "Cast Iron and Steel Pulleys".

4. Remove water pump V-belt (5) . 5. Loosen hose clamps (1). Disconnect the hose assembly between the water pump and the water temperature regulator housing. 6. Remove bolts (2) that hold the water pump to the front of the engine. Carefully remove the water pump and two O-ring seals from the front of the engine.

101






i01929375

Water Pump - Disassemble SMCS - 1361-015


Part Number

Part Description

Qty

A

1P-0510

Driver Group

1

B

1P-0520

Driver Group

1

Start By:

A. Remove the water pump. Refer to Disassembly and Assembly, "Water Pump - Remove".


102


Illustration1

g00614231

1. Remove O-ring seals (1) from the rear cover of the water pump. Remove bolts (2) and the washers. Remove the rear cover and the gasket.

Illustration2

g00614234

2. Position the water pump in a press. Use spacer plates to level the water pump. 3. Push the shaft and pulley (3) out of impeller (4) with a suitable drive plate from Tooling (A) and a press. Remove the impeller. Note: For information on the reusability of pulley (3), refer to Guideline For Reusable Parts And Salvage Operations, SEBF8046, "Cast Iron and Steel Pulleys". Note: The new 7E-0321 Pump Impeller, 153-9123 Impeller and a 109-5324 Impeller can be removed with a bolt. Insert a bolt 0.75inch into the thread insert of the impeller. Turn the bolt inward toward the shaft. Twist and pull the impeller out of the pump.

103


g00614238

Note: Do not allow the shaft and the pulley to fall to the floor when the shaft and the pulley are removed.

4. Continue to push the shaft and pulley (3) out of seal (5) and the water pump housing.

Illustration4

g00614253

5. Remove seal (5) from th e water pump housing with the handle from Tooling (B) and a press.

Illustration5

g00614261

6. Remove the shaft and the bearing from pulley (3) with a press.

104






i01929381

Water Pump - Assemble SMCS - 1361-016


Part Number

C

5P-9722

Part Description

Seal Driver

Qty

1


Illustration1

g00614283

1. Install the shaft and the bearing into pulley (3) with a press. Install the shaft until the shaft is flu sh with the end of pulley (3) . 2. Press the shaft, the bearing, and pulley (3) as a unit into th e water pump housing. The distance between the front of pulley (3) and the machined surface of the water pump housing must be 103.8 ± 0.3 mm (4.09 ± 0.01 inch). 105


Note: For information on the reusability of pulley (3), refer to Guideline For Reusable Parts And Salvage Operations, SEBF8046, "Cast Iron and Steel Pulleys".

Illustration2

g01004707

3. Install seal (5) in the water pump housing with Tooling (C) .

Illustration 3

g00614288

106


4. Install impeller (4) on the shaft of the water pump with a press. Install the impeller until the distance between the impeller and the machined surface of the water pump is 0.75 ± 0.25 mm (0.030 ± 0.010 inch).

Illustration4

g00614231

5. Install a new gasket between the rear cover of the water pump and the water pump housing. Position the gasket and the cover on the water pump housing. Install bolts (2) and the washers. 6. Install new O-ring seals (1) in the rear cover. End By: Install the water pump. Refer to Disassembly and Assembly, "Water Pump - Install".

107






i01929434

Water Pump - Install SMCS - 1361-012

Installation procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.


Illustration1

g01004978

108


1. Install new O-ring seals in the cover of the water pump. Position the water pump on the front of the engine. Install bolts (2) . 2. Connect the hose assemb ly between the water pump and the wat er temperature regulator housing. Tighten hose clamps (1) that hold the hose in position. 3. Position V-belt (5) on the idler pulley assembly (7) . Note: For information on the reusability of idler pulley assembly (7), refer to Guideline For Reusable Parts And Salvage Operations, SEBF8046, "Cast Iron and Steel Pulleys".

4. Adjust the tension on the water pump V-belt (5) . 5. Use hole (4) to apply tension to the V-belt. Refer to Specifications, "Belt Tensioner Chart" for the correct tension on the belt. 6. Fill the cooling system to the correct level. Refer to the Operation and Maintenance Manual, "Refill Capacities" topic for the correct fluid and the correct filling procedure.

109






i01929437

Water Temperature Regulator Housing - Remove and Install SMCS - 1393-010



1. Drain the coolant from the cooling system into a suitable container for storage or disposal.

110


Illustration1

g00747272

2. Loosen clamp (3) . 3. Remove bolts (2) . 4. Remove water temperature regulator housing (1) and the gasket from the cylinder head.


Illustration2

g00747272

1. Install a new gasket and water temperature regulator housing (1) on the cylinder head. 2. Install bolts (2) . 3. Tighten clamp (3) . 4. Fill the cooling system with coolant to the correct level. Refer to the Operation and Maintenance Manual for the correct procedure.

111






i01929442

Water Temperature Regulator - Remove and Install SMCS - 1355-010



Illustration1

g00623238

Typical Example

2. Remove bolts (1) . 3. Remove pipe assembly for the water outlet (2) and remove the gasket from the water temperature regulator housing.

112


Illustration2

g00745103

4. Remove water temperature regulator (3) from the water temperature regulator housing.


Illustration3

g00745103

1. Install water temperature regulator (3) in the water temperature regulator housing.

113


g00623238

2. Install a new gasket, and pipe assembly for the outlet (2) on the water temperature regulator housing. 3. Install bolts (1) . 4. Fill the cooling system with coolant to the correct level. Refer to the Operation and Maintenance Manual for the correct procedure.

114






i01929472

Aftercooler - Remove SMCS - 1063-011


Part Number

Part Description

Qty

A

8T-0292

Bolt

2



At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. 115


Check the coolant level only after the engine has been stopped and the fill cap is cool enough to touch with your bare hand. Remove the fill cap slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury.

Note: Put identification marks on all hose assemblies, on all wires, and on all tube assemblies for installation purposes. Plug all hose assemblies and tube assemblies. This helps to prevent fluid loss and this helps to keep contaminants from entering the system.


Illustration1

g00508835

Illustration2

g00508837

2. Remove bolts (2). Remove exhaust elbow (1) and exhaust pipe assembly (3) .

116


Illustration3

g00746355

3. Loosen clamp (4) . 4. Disconnect coupling (5) .

Illustration 4

g00746356

5. Loosen clamps (6) and (7) . 6. Remove two top bolts (8) and install Tooling (A). Remove remaining bolts (8). Remove aftercooler (10) . 7. Remove gasket (9) from aftercooler (10) .

117






i01929554

Aftercooler - Install SMCS - 1063-012


Part Number

Part Description

Qty

A

4C-9502

Gasket Sealant

1

B

5P-3931

Anti-Seize Compound

1


Note: Use a new gasket in order to install the aftercooler.

118


Illustration 1

g00746356

Note: Apply Tooling (A) to the threads of the bottom bolts before installation.

1. Install gasket (9) on the engine. Install aftercooler (10). Install bolts (8) . 2. Tighten clamp (6) and tighten clamp (7) .

Illustration2

g00746355

3. Tighten clamp (4). 4. Connect coupling (5) .

119


Illustration3

g00508837

Illustration4

g00508835

Note: Apply Tooling (B) to the threads of the exhaust elbow bolts.

5. Install exhaust elbow (1) and exhaust pipe (3). Install bolts (2) . 6. Fill the cooling system. Refer to Operat ion and Maintenance Manual, SEBU7098, "Cooling System Level Check" for the correct procedure.

120






i01929596

Engine Lifting Bracket - Remove and Install SMCS - 1122-010

Removal Procedure

Illustration1

g00623010

1. Remove bolts (2) and the washers. 2. Remove engine lifting bracket (1) from the front of the engine.

Illustration2

g00623016

3. Remove bolts (4) and the washers. 121


4. Remove engine lifting bracket (3) from the rear of the engine.

Installation Procedure

Illustration3

g00623016

1. Position engine lifting bracket (3) on the rear of the engine. 2. Install the washers and bolts (4) .

Illustration4

g00623010

3. Position engine lifting bracket (1) on the front of the engine. 4. Install the washers and bolts (2) .

122






i01929610

Flywheel - Remove SMCS - 1156-011


Part Number

Part Description

Qty

A

138-7573

Link Bracket

B

-

Guide Bolt (M16 x 2 by 4 inch)

2 1

Note: For information on the reusability of the flywheel on 3116 engines, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8207, "Flywheel Specifications for 3116 Engines".

1. Support the engine with blocks or a suitable lifting device. 2. Install Tooling (A) on the flywheel. Fasten a suitable lifting device to the flywheel.

3. Remove top bolt (1) and the washers. Install Tooling (B). Remove remaining bolts (1) and the washers. 4. Remove flywheel (2) from Tooling (B). The weight of flywheel (2) is approximately 23 kg (50 lb). 5. Inspect the flywheel ring gear. Replace the ring gear, if necessary. Place the flywheel on a wood block. Use a 123


hammer and a punch in order to remove the flywheel ring gear.

124






i01944113

Flywheel - Install SMCS - 1156-012


Part Number

A

138-7573

B

-

C

9S-3263

Part Description

Qty

Link Bracket

2

Guide Bolt (M16 x 2 by 4 inch)

1

Thread Lock Compound

1

Note: For information on the reusability of the flywheel on 3116 engines, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8207, "Flywheel Specifications for 3116 Engines". Note: Drill and tap the new flywheel ring gear if the outer bolt holes of the flywheel are used. Use the flywheel as a template and drill twelve holes to a diameter of 8.2 mm (0.32 inch). Thread the holes with a tap.

1. Raise the temperature of the flywheel ring gear to a maximum temperature of 204 °C (400 °F). Do not use a torch to heat the flywheel ring gear. Install the flywheel ring gear on the flywheel. Position the flywheel ring gear with the part number toward the crankshaft. Allow the flywheel ring gear to cool. Use a soft hammer in order to seat the flywheel ring gear against the shoulder of the flywheel.

Illustration1

g00613482

125


2. Install Tooling (A) on flywheel (2). Fasten a suitable lifting device to flywheel (2) . 3. Place flywheel (2) in the srcin al position on Tooling (B). Align the arrows on fly wheel (2) and the crankshaft. 4. Apply Tooling (C) to the threads of bolts (1) . 5. Install bolts (1) and the washers. Remove Tooling (B) and install remaining bolt (1) and the washer. Tighten the bolts evenly to a torque of 120 ± 20 N·m (90 ± 15 lb ft). 6. Check the flywheel runout. Refer to Testing and Adjusting, "Basic Block" for the correct procedure.

126






i01980554

Crankshaft Rear Seal - Remove SMCS - 1161-011


Part Number

Part Description

Qty

A

1U-8145

Drill Bit

1

B

1U-7600

Slide Hammer Puller Gp

1

C

4C-4869

Distorter Ring

1

D

5P-7312

Seal Distorter

1

Start By:

A. Remove the flywheel. Refer to Disassembly and Assembly, "Flywheel - Remove".


1. Use Tooling (A) to drill three evenly spaced holes in the crankshaft rear seal.

127


Illustration 1

g00989088

2. Carefully remove crankshaft rear seal (1) by al ternating the position of Tooling (B) from hole to hole. This will allow crankshaft rear seal (1) to be removed evenly without damage to the rear flange surface of the crankshaft. Note: New engines from the factory do not have a wear sleeve. Engines with seals that have been replaced will be equipped with a wear sleeve. If the crankshaft of the engine is equipped with a wear sleeve, refer to Disassembly and Assembly, "Crankshaft Wear Sleeve (Rear) - Remove" in order to remove the wear sleeve.

3. Use Tooling (C) and Tooling (D) to remove the wear sleeve (if equipped).

128






i01980581

Crankshaft Rear Seal - Install SMCS - 1161-012


Part Number

Part Description

Qty

E

1U-7598

Seal Installer Gp

1


Note: Replacement rear seals are supplied with a wear sleeve. This wear sleeve must be installed with the rear seal. New engines from the factory do not have a wear sleeve. Do not install the rear seal if any of the following conditions exist: 

The crankshaft rear seal has been separated from the wear sleeve.



The rear seal group appears to be damaged.



The crankshaft rear seal has been lubricated. The seal is designed to be installed dry.

1. Ensure that the rear of the cran kshaft is thoroughly clean and dry prior to the installation of the crankshaft rear seal.

129


Illustration 1

g01026625

Typical example

2. Use Tooling (E) to install crankshaft rear seal (1 ) . End By: Install the flywheel. Refer to Disassembly and Assembly, "Flywheel - Install".

130






i01987820

Crankshaft Rear Seal Carrier - Remove and Install SMCS - 1161-010-C3


A. Remove the flywheel ho using. Refer to Disassem bly and Assembly, "Flywheel Housing - Remove and Inst all".


131


Illustration 1

g01027007

1. Remove bolts (1) . 2. Remove rear seal carrier (2) .


Part Number

Part Description

Qty

A

138-8440

Component Cleaner

B

169-5464

Quick Cure Primer

C

1U-8846

Gasket Sealant

D

9S-3263



132


Illustration 2

g01027007

1. Clean the joint face of rear seal carrier (2) and the cylinder block with Tooling (A) . 2. Apply Tooling (B) to the joint face of rear seal carri er (2). Allow the primer to air dry for three to five minutes. Note: Tooling (C) is used on the joint face of rear seal carrier (2). Do not allow the sealant to get into the oil passage in the mounting face of the cylinder block.

3. Apply Tooling (C) to the joint face of rear seal carri er (2). Spread the sealant uniformly. Rear seal carrier (2 ) must be installed within ten minutes of application of the sealant. 4. Position rear seal carrier (2) on the dowels in the rear of the cylinder block. 5. Apply Tooling (D) on the threads of bolts (1). Install bolts (1) that hold rear seal carrier (2) to th e cylinder block. End By: Install the flywheel housing. Refer to Disassembly and Assembly, "Flywheel Housing - Remove and Install".

133






i01929753

Flywheel Housing - Remove and Install SMCS - 1157-010 S/N - 1NJ1-UP S/N - 1SK1-UP S/N - 1ZG1-UP S/N - 1ZJ1-UP S/N - 2MR1-UP S/N - 2SG1-UP S/N - 4KG1-UP S/N - 4PG1-UP S/N - 5EN1-UP S/N - 5JG1-UP S/N - 6AF1-UP S/N - 6MK1-UP S/N - 6MS1-UP S/N - 6SR1-UP S/N - 8NM1-UP S/N - 9ZR1-UP S/N - CKK1-UP


Part Number

Part Description

Qty 134


A

138-7573

Link Bracket

2

Start By:

A. Remove the flywheel. Refer to Disassembly and Assembly, "Flywheel - Remove".



Illustration1

g01011885

1. Fasten Tooling (A) and a suitable lifting device to flywheel housing (1) . 2. Remove bolts (2) and bolt (3) that fastens flywheel housing (1) to the cylinder block. 3. Remove flywheel housing (1). The weight of flywheel housing (1) is approximately 32 kg (70 lb).

Installation Procedure Table 2 Required Tools 135


Tool

Part Number

A

138-7573

B

1U-8846

Part Description

Qty

Link Bracket

2

Gasket Sealant

1


Illustration 2

g00740507

Correct installation of O-ring seal (3). Do not install the O-ring seal in location (4) .

Note: On Improper wet flywheel housings that haveinrear seal carriers, ensure that the O-Ring Seal housing is installed properly. installation will result leakage of torque converter oil 8C-3091 between the flywheel and the cylinder block. Note: Ensure that the mating surface of the flywheel housing and the mounting face of the cylinder block are thoroughly clean.

1. Apply Tooling (B) to the entire mounting face of the flywheel housing prior to installation.

136


Illustration3

g01011885

2. Fasten Tooling (A) and a suit able lifting device to flywheel housing (1). Position flywheel housing (1) on the cylinder block. The weight of flywheel housing (1) is approximately 32 kg (70 lb). 3. Install bolts (2) and bolt (3) tha t fastens flywheel housing (1) to the cylin der block. Refer to the Specifi cation, "Flywheel Housing" for the torque specification. 4. Remove Tooling (A) and the hoist from flywheel housing (1) . 5. Check the flywheel housing runout. Refer to the Sys tems Operation/Testing and Adjusting, "Flywheel and Flywheel Housing". End By: Install the flywheel. Refer to Disassembly and Assembly, "Flywheel - Install".

137






i01929931

Vibration Damper and Pulley - Remove and Install SMCS - 1205-010


NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

Illustration1

g00691836

138


1. Remove bolts (2), crankshaft vibration damper (3), and spacers from the crankshaft pulley. Note: For information on the reusability of the vibration damper on 3114 and 3116 engines, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8220, "Specifications for Damper Inspection 3114 and 3116 Engines".

2. Loosen the tension on water pump drive belt (1). Remove the belt from the crankshaft pulley.

Illustration2

g00691831

3. Remove bolts (4) and the washers. 4. Remove crankshaft pulley (5) . Note: For information on the reusability of the crankshaft pulley, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8046, "Cast Iron and Steel Pulleys".


Illustration3

g00691831

1. Position crankshaft pulley (5) on the crankshaft. Install bolts (4) and tighten the bolts to a torque of 16 0 ± 30 N·m (118 ± 22 lb ft). 139


Note: For information on the reusability of the crankshaft pulley, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8046, "Cast Iron and Steel Pulleys".

Illustration4

g00691836

2. Install water pump drive belt (1) . Note: Check the alignment marks on the rubber vibration dampers for proper alignment. The rubber vibration damper should be replaced if the rubber vibration damper is out of alignment. Refer to Specifications, "Vibration Damper".

3. Install spacers and crankshaft vibration damper (3). Tighten bolts (2) to a torque of 55 ± 10 N·m (40 ± 7 lb ft). Note: For information on the reusability of the vibration damper on 3114 and 3116 engines, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8220, "Specifications for Damper Inspection 3114 and 3116 Engines".

4. Adjust the tension of water pump drive belt (1). Refer to the Specifications Module, "Belt Tension Chart". Also, refer to the Operation and Maintenance Manual, "Belt - Inspect".

140






i01982085

Crankshaft Front Seal - Remove SMCS - 1160-011


Part Number

Part Description

Qty

A

1U-7600

Slide Hammer Puller

1

B

1U-8145

Drill Bit

1

Start By:

A. Remove the vibration damper and the pulley. Refer to Disassembly and Assembly, "Vibration Damper and Pulley - Remove and Install".


141


Illustration 1

g00989224

1. Use Tooling (B) and carefully drill three evenly spaced holes in crankshaft front seal (1) . 2. Alternate between the drilled holes and use Tooling (A) to remove crankshaft front seal (1) .

142






i01982092

Crankshaft Front Seal - Install SMCS - 1160-012


Part Number

Part Description

Qty

C

1U-7430

Front Seal Installer

1


143


Illustration 1

g00989228

1. Use Tooling (C) to install crankshaft front seal (1) . Note: The crankshaft seal is designed to be installed dry. End By: Install the vibration damper and the pulley. Refer to Disassembly and Assembly, "Vibration Damper and Pulley - Remove and Install".

144






i01176651

Front Cover - Remove SMCS - 1166-011

Removal Procedure

Illustration1 Note:

g00629709

It is not necessary to remove the vibration damper and the crankshaft pulley in order to remove the front

cover. 1. Remove bolts (1) from front cover (2) . 2. Remove front cover (2) and the gasket from the front of the engine.

145






i01437510

Front Cover - Install SMCS - 1166-012


Illustration 1

g00752906

1. Install a new gasket (3) on the front cover (2) .

146


Illustration2

g00629709

2. Install the gasket and front cover (2) on the front of the engine. 3. Install bolts (1) in front cover (2) .

147






i01929983

Gear Group (Front) - Remove SMCS - 1206-011


Part Number

A

1P-0520

Part Description

Driver Gp

Qty

1

Start By:

A. Remove the crankshaft vibration damper. Refer to Disassem bly and Assembly, "Vibration Damper and Pulley Remove and Install". B. Remove the crankshaft front seal. Refer to D isassembly and Assembly, "Crankshaft Front Seal - Remove". C. Remove the camshaft. Refer to Disassembly and Assembly, "Camshaft - Remove". D. Remove the front housing. Refer to Disassembly and Assembly, "Housing (Front) - Remove". Note: For information on reusability of the camshaft idler gear, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8045, "Timing Gears for All Engines".

1. Place the engine at the Top Center position. The timing marks should be in line with the crankshaft gear.

148


Illustration 1

g01005265

2. Identify the type of idler gear on the en gine. Remove bolts (1) that hold the idler gear to th e block. Remove plate (7) .

Illustration2

g00677884

3. Identify the location of timing marks (4) and (5) on the camshaft idler gear. Identify the location of timing mark (6) on the crankshaft drive gear. 4. Remove idler shaft (3) and camshaft idler gear (2). Separate idler gear (2) from idler sh aft (3) and remove the sleeve bearing from the camshaft idler gear. 5. Use Tooling (A) and a press to remove the bearing.

149






i01930002

Gear Group (Front) - Install SMCS - 1206-012


Part Number

A

1P-0520

Part Description

Driver Gp

Qty

1

Note: For information on reusability of the camshaft idler gear, refer to Guideline For Reusable Parts And Salvage

Operations, SEBF8045, "Timing Gears for All Engines".

150


Illustration 1

g00643979

Type 1

1. Use Tooling (A) and a suitable press to install the sleeve bearing in the camshaft idler gear. 2. Install the bearing sleeve to a depth of 0.40 ± 0.25 mm (0.016 ± 0.010 inch) below the front face of the gear. 3. Place the idler shaft (3) on the cylinder block. Install bolts (1) that hold the idler shaft to the cylinder block. Tighten the bolts to a torque of 70 ± 15 N·m (51 ± 11 lb ft). 4. Install camshaft idler gear (2) on idler shaft (3). The timing marks should face outward. 5. Align the timing marks on camshaft idler gear (2) with the timing marks on the crankshaft drive gear.

151


Illustration 2

g00644057

Type 2

1. Use Tooling (A) and a suitable press and install the sleeve bearing in the camshaft idler gear. 2. Install plate (4) on the back of idler sh aft (3). Position idler gear assembly on the cylinder block. Install bolts that hold the idler gear to the engine block. Tighten the bolts to a torque of 70 ± 15 N·m (51 ± 11 lb ft). 3. Install camshaft idler gear (2) on idler shaft (3). The timing marks should face outward. 4. Align the timing marks on camshaft idler gear (2) with the timing marks on the crankshaft drive gear.

152


Illustration 3

g00644128

Type 3

1. Position idler shaft (3) on the cylinder block. Install the shortest bolt in the recessed h ole in idler shaft (3). This bolt will hold the shaft in position on the cylinder block. 2. Install camshaft idler gear (2) on idler shaft (3). The timing marks should face outward. 3. Align the timing marks on idler gear (2) with the timing marks on the camshaft drive gear. 4. Position plate (4) over the gear and i nstall the remaining bolts (1). Tighten bolts (1) to a torque o f 70 ± 15 N·m (51 ± 11 lb ft). End By:

a. b. c. d.

Install the front housing. Refer to Disassembly and Assembly, "Housing (Front) - Install". Install the camshaft. Refer to Disassembly and Assembly, "Camshaft - Install". Install the crankshaft front seal. Refer to Disassembly and Assembly, "Crankshaft Front Seal - Install". Install the cran kshaft vibration damper and pulley. Refer to Disassembly and Assembly, "Vibration Damper and Pulley -Remove and Install".

153






i01944129

Housing (Front) - Remove SMCS - 1151-011


A. Remove the crankshaft vibration damper. Refer to Disassem bly and Assembly, "Vibration Damper and Pulley Remove and Install". B. Remove the crankshaft front seal. Refer to D isassembly and Assembly, "Crankshaft Front Seal - Remove". C. Remove the camshaft. Refer to Disassembly and Assembly, "Camshaft - Remove".

NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

1. Remove any external components, if equipped. 2. Support the front of the engine.

154


Illustration1

g01011903

3. Remove bolts (2) and re move front engine support. 4. Remove bolts (1) and belt tightener (3) .

Illustration 2

g01011906

5. Remove bolts (5) that fasten front housing (4) to the cylinder block and to the engine oil pan. Remove front housing (4). Clean the sealant from front housing (4) and the cylinder block.

155






i01944143

Housing (Front) - Install SMCS - 1151-012

Installation Procedure Table 1 Required Tools Tools

Part Number

Part Description

Qty

A

138-8440

Component Cleaner

1

B

169-5464

Quick Cure Primer

1

C

1U-8846

Gasket Sealant

1

156


Illustration 1

g01011906

1. Clean the joint face on front housing (4) with Tooling (A) . 2. Apply Tooling (B) to the joint face. Allow the primer to dry for at least thre e to five minutes. Note: Do not allow Tooling (C) to seal the main oil passage on front housing (4) .

3. Apply Tooling (C) to the joint face. Sprea d the sealant uniformly. The front housing must be installed within ten minutes of applying the sealant. 4. Position the front housing on the cylinder block. 5. Install bolts (5) that fasten the front housing to the cylinder block and the engine oil pan.

Illustration2

g01011903

6. Position belt tightener (3) and install bolts (1) . 157


7. Position the front engine support and install bolts (2) . 8. Install any external components, if equipped. End By:

a. Install the camshaft. Refer to Disassembly and Assembly, "Camshaft - Install". b. Install the crankshaft front seal. Refer to Disassembly and Assembly, "Crankshaft Front Seal - Install". c. Install the crankshaft vibration damper. Refer to Disassem bly and Assembly, "Vibration Damper and Pulley Remove and Install".

158






i01176330

Crankcase Breather - Remove and Install SMCS -

1317-010

Removal Procedure

Illustration1

g00629572

1. Remove bolt (4) and the clip from the engine block. 2. Loosen clamp (2) and remove the hose from crankcase breather (3) . 3. Remove bolt (1) and remove crankcase breather (3) from the fuel filter base.


159


g00629572

1. Inspect the filter in crankcase breather (3). Replace the filter, if necessary. 2. Position crankcase breather (3) on the fuel filter base and i nstall bolt (1). Tighten the bolt to a torque of 7 ± 2 N·m (62 ± 18 lb in). 3. Install the hose on crankcase breather (3) and tighten clamp (2) . 4. Install the clip and bolt (4) on the hose.

160






i01930088

Valve Mechanism Cover - Remove and Install SMCS - 1107-010


Part Number

Part Description

A

138-8440

Component Cleaner

Qty

1


161


Illustration 1

g00886209

1. Remove engine oil filler cap (if equipped). 2. Remove bolts (1) and washers (2) from valve mechanism cover (3) . 3. Remove valve mechanism cover (3) and gasket (4) . 4. Clean valve mechanism cover (3) with Tooling (A) .


Part Number

Part Description

B

154-8874

Adhesive Kit

Qty

1


162


Illustration 2

g00886209

Note: For later valve cover gaskets which have a rubber bead on one side, no adhesive is required. The gasket is designed to be installed dry.

1. Apply adhesive to valve mechanism cover (3) with Tooling (B) . 2. Install new gasket (4) and valve mechanism cover (3) . 3. Install washers (2) and bolts (1) .

Illustration 3

g00611545

Tightening sequence for the engine valve covers

163

_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03 (A) Rear (B) Front

4. Tighten the bolts in sequence to a torque of 12 ± 3 N·m (106 ± 27 lb in). 5. Install engine oil filler cap (if equipped).

164






i01930098

Rocker Shaft and Pushrod - Remove SMCS - 1102-011; 1208-011




Note: For information on reusability of components of the rocker shaft, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8267, "Rocker Arms and Rocker Arm Shafts for 3114 and 3116 Engines".

Illustration1

g00629575

1. Loosen all rocker arm adjustment screws (3) . 2. Remove bolts (1) from the rocker shaft assembly (2) . 3. Remove rocker shaft assembly (2) from the cylinder head. 165


4. Repeat the pr ocedure for each ro cker shaft as sembly. 5. Remove the pushrods.

166






i01930098

Rocker Shaft and Pushrod - Remove SMCS - 1102-011; 1208-011





Illustration1

g00629575

1. Loosen all rocker arm adjustment screws (3) . 2. Remove bolts (1) from the rocker shaft assembly (2) . 3. Remove rocker shaft assembly (2) from the cylinder head. 167


4. Repeat the pr ocedure for each ro cker shaft as sembly. 5. Remove the pushrods.

168






i01930194

Rocker Shaft - Assemble SMCS - 1102-016

Assembly Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Note: For information on reusability of components of the rocker shaft, refer to Guideline For Reusable Parts And

Salvage Operations, SEBF8267, "Rocker Arms and Rocker Arm Shafts for 3114 and 3116 Engines".

Illustration1

g00630277

1. Install button (6) and the retaining ring, if necessary. 2. Place clean engine oil on a new bearing (5) prior to installation. 3. Ensure that the oil hole in bearing (5) is aligned with the oil hole in the rocker arm. Hone the bearing, if necessary. Refer to the Specifications Module for the correct dimensions.

169


Illustration2

g00629612

4. Lubricate rocker shaft assembly (4) with clean engine oil. 5. Install valve rocker arms (2) and unit injector rocker arm (3) on rocker shaft assembly (4) . 6. Install support bracket (1) on rocker shaft assembly (4) . End By: Install the rocker shaft and the pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod Install".

170






i02736495

Rocker Shaft and Pushrod - Install SMCS - 1102-012; 1208-012


Part Number

A

146-2597

Part Description

Qty

Pushrod Holder

1



1. Install the pushrods in the engine. The base of the pushrod should be in the seat of the pushrod lifter. 2. Install Tooling (A) .

Illustration1

g00629575

171


3. Position rocker shaft assembly (2) in the engine. Line up the pushrods with the rocker arms. 4. Install bolts (1) in rocker shaft assembly (2) . Tighten the bolts to a torque of 28 ± 7 N·m (21 ± 5 lb ft). 5. Remove Tooling (A) from the pushrods. 6. Adjust the valve lash on all of the adjustment screws. Refer to Testing and Adjusting, "Engine Valve Lash Inspect/Adjust". 7. Repeat the procedure for the remaining rocker shaft assemblies. End By: Install the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover Remove and Install".

172






i01935828

Cylinder Head - Remove SMCS - 1100-011


A. Remove the fuel filter b ase. Refer to Disassembly and Assembly, "Fuel Filter Base - Remove an d Install". B. Remove the governor. Refer to Disassembly and Assembly, "Governor - Remove". C. Remove the fuel contro l linkage. Refer to Disassembly and Assembly, "Fuel Injection Control Linkage Remove". D. Remove the unit injectors. Refer to Disassembly and Assembly, "Unit Injector - Remove". E. Remove the water temper ature regulator housing. Refer to Disassembly and Assembly, "Water Temperature Regulator Housing - Remove and Install". F. Remove the exhaust inlet manifold. Refer to Disassembly Assembly, "Inlet Manifold - Remove". G. Remove the man ifold. Refer to Disassemband ly and Assembly, "Exhaust Manifold - Remove and Inst all".



Note: For information on the reusability of the cylinder head, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8218, "Specifications for Cylinder Head Assemblies 3114, 3116, and 3126 Engines" and Guideline For Reusable Parts And Salvage Operations, SEBF8162, "Procedure to Measure and Salvage Cylinder Head 173


Assemblies and Related Components".

Illustration1

g01007597

Typical example

1. Attach a suitable lifting device to the cylinder head.

Illustration 2

g00654709

2. Remove bolts (1) and (2) that hold the cylinder head to the cylinder block. Carefully remove the cylinder head from the cylinder block. The cylinder head for the 3116 engine weighs approximately 85 kg (187 lb).

174


Illustration3

g00611342

3. Remove cylinder head gasket (3) .

175






i01930413

Lifter Group - Remove and Install SMCS - 1209-010


A. Remove the rocker shaft and th e pushrods. Refer to Disas sembly and Assembly, "Rocker Shaft and Pushrod Remove".



Note: For information on reusability of components of the lifter group, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8264, "Camshaft Roller Followers Used in 3114 and 3116 Engines" and Guideline For Reusable Parts And Salvage Operations, SEBF8067, "Slipper Followers and Camshaft Roller Followers".

176


Illustration1

g00747310

1. Remove bolts (1) from cover (2) . 2. Carefully remove cover (2) and the gasket. Note: It may be necessary to remove the governor in order to remove the cover at the front of the engine.

Illustration2

g00629677

3. Remove bolts (4), lifter shaft (5), and lifters (3) from cover (2) .


Note: For information on reusability of components of the lifter group, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8264, "Camshaft Roller Followers Used in 3114 and 3116 Engines" and Guideline For Reusable Parts And Salvage Operations, SEBF8067, "Slipper Followers and Camshaft Roller Followers".

177


Illustration3

g00629677

1. Position lifters (3) and lifter shaft (5) on cover (2). Install bolts (4) .

Illustration4

g00747310

2. Position the gasket and cover (2) on the engine. 3. Install bolts (1) in cover (2) . End By: Install the rocker shaft and the pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod Install".

178






i01930426

Camshaft - Remove SMCS - 1210-011


A. Remove the governor. Refer to Disassembly and Assembly, "Governor - Remove". B. Remove the side covers. Refer to Disassembly and Assembly, "Lifter Group - Remove and Install". C. Remove the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove".



Note: For information on reusability of the camshaft, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8097, "Camshaft Measurement", Guideline For Reusable Parts And Salvage Operations, SEBF8146, "Visual Inspection of Camshafts", and Guideline For Reusable Parts And Salvage Operations, SEBF8251, "Specifications for Measurement of Camshafts in 3114/3116 Engines". For information on reusability of the camshaft gear, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8045, "Timing Gears for All Engines". Note: The air compressor was removed in order to accommodate the engine repair stand. Note: It is not necessary to remove the cylinder head for removal of the camshaft. 179


1. Turn the crankshaft to top center compression stroke for the No. 1 piston . Install the timin g bolt in the flywh eel. This is for timing during installation.

Illustration1

g01007643

Typical example

2. Ensure that timing mark (1) on the camshaft gear is aligned with timing mark (2) on the idler gear.

Illustration 2

g01007645

3. Remove bolts (4) and camshaft retainer plate (6) . 4. Remove camshaft gear (5) and camshaft (3) from the cylinder block.

180






i01930093

Camshaft - Install SMCS - 1210-012 S/N - 1NJ1-UP S/N - 1SK1-UP S/N - 1ZG1-UP S/N - 1ZJ1-UP S/N - 2MR1-UP S/N - 2SG1-UP S/N - 4KG1-UP S/N - 4PG1-UP S/N - 5EN1-UP S/N - 5JG1-UP S/N - 6AF1-UP S/N - 6MK1-UP S/N - 6MS1-UP S/N - 6SR1-UP S/N - 8NM1-UP S/N - 9ZR1-UP S/N - CKK1-UP

Installation Procedure NOTICE

Keep all parts clean from contaminants. 181


Contaminants may cause rapid wear and shortened component life.

Note: For information on reusability of the camshaft, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8097, "Camshaft Measurement", Guideline For Reusable Parts And Salvage Operations, SEBF8146, "Visual Inspection of Camshafts", and Guideline For Reusable Parts And Salvage Operations, SEBF8251, "Specifications for Measurement of Camshafts in 3114/3116 Engines". For information on reusability of the camshaft gear, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8045, "Timing Gears for All Engines".

1. Lubricate the camshaft and the camshaft bearings with clean engine oil.

Illustration 1

g00654762

2. Carefully install camshaft (4) and camshaft gear (1) in the engine.

NOTICE When installing the camshaft, make sure the number one cylinder is at top center of the compression stroke with the timing bolt installed in the flywheel. The camshaft timing is very important. The timing mark on the camshaft drive gear must line up with the timing mark on the idler gear. Refer to the Specifications Manual for more information.

Illustration2

g00677700

182

_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03 Typical example

3. Ensure that timing mark (5) on the camshaft gear is aligned with timing mark (6) on the idler gear. 4. Install camshaft retainer plate (2) and bolts (3) . End By:

a. Install the front cover. Refer to Disassembly and Assembly, "Front Cover - Install". b. Install the side cover. Refer to Disassembly and Assembly, "Lifter Group - Remove and Install". c. Install the Unit Injecto r Hydraulic Pump. Refer to Disassembly and Assembly, "Unit Injector Hydraulic Pump Install". d. Install the Rocker Shaft and Pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod Install".

183






i01171077

Camshaft Gear - Remove and Install SMCS - 1210-010-GE


A. Remove the camshaft. Refer to Disassembly and Assembly, "Camshaft - Remove". Note: For information on reusability of the camshaft gear, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8045, "Timing Gears for All Engines".

1. Wrap the camshaft with a protective covering in order to prevent damage to the camshaft.

Illustration1

g00611152

NOTICE Do not allow the camshaft to fall to the floor when pressing it from the drive gear. Also make sure that the camshaft lobes do not catch on the press plates.

2. Place the camshaft and camshaft gear (1) in a suitable press. Press the camshaft from camshaft gear (1) .



Note: For information on reusability of the camshaft gear, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8045, "Timing Gears for All Engines".

Illustration2

g00611152

1. Heat the camshaft gear to a maximum temperature of 315 °C (600 °F). 2. Align the key in the camshaft with the groove (keyway) in the camshaft gear. 3. Install the camshaft gear on the end of the camshaft. End By: Install the camshaft. Refer to Disassembly and Assembly, "Camshaft - Install".

185






i02183087

Camshaft Bearings - Remove and Install SMCS - 1211-010


Part Number

Part Description

Qty

A

8S-2241

Camshaft Bearing Tool Group

1

Start By:

A. Remove the camshaft. Refer to Disassembly and Assembly, "Camshaft - Remove".


NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. to collect the fluid withany suitable containers before opening Be anyprepared compartment or disasse mbling component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

Note: Note the oil hole orientation in each camshaft bearing prior to removal for assembly purposes.

1. Use Tooling (A) to remove the camshaft bearings from the cylinder block. 186



Part Number

Part Description

Qty

A

8S-2241

Camshaft Bearing Tool Group

1


Illustration 1

g01104577

187


Illustration 2

g01104579

1. Use Tooling (A) to install all of the cam shaft bearings except for the front bearing. Orient oil hole (1) in each bearing so that oil hole (1) is located at the top of the bore. 2. Use Tooling (A) to install the front camshaft bearing. Align oil hole (1) in the front camshaft bearing with the oil hole in the cylinder block. Locate joint (2) in the front camshaft bearing in the proper position. End By: Install the camshaft. Refer to Disassembly and Assembly, "Camshaft - Install".

188






i01572486

Engine Oil Pan - Remove and Install SMCS - 1302-010 S/N - 1NJ1-UP S/N - 1ZG1-UP S/N - 2MR1-UP S/N - 2SG1-UP S/N - 2WG1-UP S/N - 4PG1-UP S/N - 5EF1-UP S/N - 5EN1-UP S/N - 5JG1-UP S/N - 6AF1-UP S/N - 6MS1-UP S/N - 9ZR1-UP S/N - CKK1-UP


NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair 189


of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disasse mbling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

Illustration1

g00596538

Note: Drain engine oil into a suitable container for disposal.

1. Remove bolts (1) and the washers that hold engine oil pan (2) to the cylinder block. 2. Remove engine oil pan (2) and the gasket. Use a rubber mallet to tap lightly on engine oil pan (2) if it is necessary. Note: Do not pry on the engine oil pan.

Installation Procedure 1. Clean the mating surfaces of the engine oil pan and the cylinder block. Note: Do not put liquid gasket material on the oil pan gasket or on the gasket surface of the engine oil pan.

2. Put the gasket and the engine oil pan (2) in position on the cylinder block. Install bolts (1) and washers.

190


Illustration 2

g00596576

Typical drawing (6 cylinder engine)

3. Tighten four bolts (3). Start with bol t (4) and tighten th e remaining bolts in a counterclockwise sequence. 4. Tighten bolts to a torque of 31 ± 3 N·m (23 ± 2 lb ft). 5. Fill the crankcase with engine oil to the proper level. Refer to Operation and Maintenance Manual, "Refill Capacities".

191






i01930590

Engine Balancer Shaft - Remove and Install Removal Procedure Start By:

A. Remove the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove and Install".



Note: The Balancer shafts are used on the 3114 Engines.

192


Illustration1

g00596194

314 engine

1. Remove oil tube assembly (1) . 2. Remove bolts (2) and the washers that hold the balancer group in position. 3. Remove the balancer group and the engine oil pump as a unit.


Illustration 2

g00596364


1. Turn the engine in the counterclockwise direction and place the number one piston at the top center (TC) of the compression stroke. Install the timing bolt in the flywheel housing. 2. Align the timing marks on the balancer gears (3) with oil holes (4) in the eng ine oil pump. Position the balancer group in the cylinder block. Install the washers and bolts (2) . 193


Illustration3

g00596194

3. Check the condition of the O-ring seals in oil tube assembly (1). Replace the O-ring seal, if necessary. 4. Remove the timing bolt from the flywheel housing. End By: Install the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove and Install".

194






i01411264

Piston Cooling Jets - Remove and Install SMCS - 1331-010


A. Remove the engine balan cer shaft on the 311 4 engines only. Refer to Disa ssembly and Assembly, "Engine Balancer Shaft - Remove and Install". B. Remove the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump - Remove".


195


Illustration 1

g00642470

1. Remove bolt (1) and piston cooling jet (2) . 2. Remove the remainder of the piston cooling jets.


Illustration 2

g00642470

NOTICE Ensure that the piston cooling jet is seated properly prior to tightening the bolt.

1. Position piston cooling jet (2) in the cylinder block. 2. Ensure that the piston cooling jet is seated pro perly and install bolt (1) that holds the piston cooling jet in position. 196


NOTICE Hold piston cooling jet in position when the mounting bolt is tightened. If the cooling tube is not held in position, the cooling tube may bend or the cooling tube may break.

3. Install the remainder of the piston cooling jets. End By:

a. Install the engine balancer shaft on the 3114 engine. Refer to Disassembly and Assembly, " Engine Balancer Shaft - Remove and Install". b. Install the oil pump. Refer to Disassembly and Assembly, " Engine Oil Pump - Install".

197






i01580049

Pistons and Connecting Rods - Remove SMCS - 1225-011


A. Remove the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Remove". B. Remove the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump - Remove". C. Remove the piston cooling jets. Refer to Disassembly and Assembly, "Piston Cooling Jets - Remove and Install".


Note: For information on reusability of the pistons, refer to the following list. 





Guideline For Reusable Parts And Salvage Operations, SEBF8049, "Pistons" Guideline For Reusable Parts And Salvage Operations, SEBF8228, "Procedure to Clean and Inspect One and Two-Piece Pistons in 3114/3116 Engines" Guideline For Reusable Parts And Salvage Operations, SEBF8290, "Visual Inspection of Two-Piece Pistons"

Note: For information on reusability of the connecting rods, refer to the following list. 





Guideline For Reusable Parts And Salvage Operations, SEBF8206, "Specifications for Connecting Rods on 3116 Engines" Guideline For Reusable Parts And Salvage Operations, SEBF8063, "Visual Inspection of Connecting Rods" Guideline For Reusable Parts And Salvage Operations, SEBF8064, "Salvage of Non-Serrated Connecting Rods"

Note: For information on reusability of the piston pins, refer to the following list. 

Guideline For Reusable Parts And Salvage Operations, SEBF8051, "Piston Pins and Retaining Rings"



Guideline For Reusable Parts And Salvage Operations, SEBF8303, "Procedure to Inspect Piston Pins" 198


Note: For information on reusability of the rod eye bushing, refer to the following list. 



Guideline For Reusable Parts And Salvage Operations, SEBF8242, "Verification of Connecting Rod Eye Bushing Retention Using 5P-8639 Connecting Rod Bushing Press Group" Guideline For Reusable Parts And Salvage Operations, SEBF8274, "Using Rod Eye Bushing Installation and Removal Tools"

Note: For information on reusability of the cylinder block and salvage procedures, refer to the following list. 



Guideline For Reusable Parts And Salvage Operations, SEBF8192, "Specifications and Salvage for Cylinder Blocks on 3114, 3116, 3126 Engines" Guideline For Reusable Parts And Salvage Operations, SEBF8261, "Installing a 7C-6208 Cylinder Sleeve in 3114, 3116 Engines and a 107-7604 Cylinder Sleeve in 3126 Engines"



Special Instruction, GMG00981, "Using 1P-3537 Dial Bore Gauge Group to Check Cylinder Bore Size"



Special Instruction, SMHS7606, " Use of 1P-4000 Line Boring Tool Group"



Special Instruction, SEHS8841, " Using the Ironstitch Procedure for Casting Salvage"



Special Instruction, SEHS8919, "Salvage Weld Procedure for Cast Iron Cylinder Blocks"





Guideline For Reusable Parts And Salvage Operations, SEBF8076, "Specifications to Salvage Cylinder Block Contact Surfaces" Special Instruction, SEHS8869, "Cylinder Block Salvage Procedure Using Belzona Ceramic R Metal"

Illustration1

g00610269

1. Inspect the connecting rod and connecting rod cap (2) for the prope r identification mark. The connecting rod and connecting rod cap (2) should have an etched number on the side that is toward the right side of the engine. The number should match the cylinder number. Mark the connecting rod and connecting rod cap (2), if necessary.

199


Illustration 2

g00610272

2. Remove connecting rod cap nuts (1), bolts (5), and connecting rod cap (2) . 3. Remove the lower half of bearing (4) from connecting rod cap (2) .

NOTICE Install short pieces of rubber hose over both connecting rod bolts in order to protect the crankshaft from the threaded portion of the connecting rod bolts.

Illustration 3

g00610272

4. Push the piston and connecting rod away from the crank shaft. Remove the upper half of connecti ng rod bearing (4) from connecting rod (3) . 5. Remove the piston and connecting rod (3) from the cylinder block. 6. Repeat Steps 1 through 5 for the remaining pistons and connecting rods. 200






i01983492

Pistons and Connecting Rods - Disassemble SMCS - 1225-015


Part Number

Part Description

Qty

A

1U-6683

Ring Expander

1

B

1P-1861

Retaining Ring Pliers

1

Start By:

A. Remove the pistons and the connecting rods. Refer to Disassem bly and Assembly, "Pistons and Connecting Rods - Remove".


201


Illustration 1

g00988677

1. Use Tooling (B) to remove retaining ring (2). Remove piston pin (4) and separate piston (1) from connecting rod (3) .

202

_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03 Illustration 2

g00988681

2. Use Tooling (A) to remove piston rings (5) .

203






i01930637

Pistons and Connecting Rods - Assemble SMCS - 1225-016


Part Number

Part Description

Qty

A

1U-6683

Ring Expander

1

B

1P-1861

Retaining Ring Pliers

1


NOTICE Verify correct assembly of the pistons and the connecting rods. Ensure that the etched numbers on the rod and the rod cap are in the correct positions. The etched number on the rod and the rod cap correspond to the cylinder in which it should be installed.








Guideline For Reusable Parts And Salvage Operations, SEBF8049, "Pistons" Guideline For Reusable Parts And Salvage Operations, SEBF8228, "Procedure to Clean and Inspect One and Two-Piece Pistons in 3114/3116 Engines" Guideline For Reusable Parts And Salvage Operations, SEBF8290, "Visual Inspection of Two-Piece Pistons" Tool Operating Manual, NEHS0775, "Using the 186-0137 Pston Ring Gauge on Steel Crown, Two-Piece Pistons used in 3126 Engines" 204







Guideline For Reusable Parts And Salvage Operations, SEBF8206, "Specificatios for ConnectingRods on 3116 Engines" Guideline For Reusable Parts And Salvage Operations, SEBF8063, "Visual Inspection of Connecting Rods" Guideline For Reusable Parts And Salvage Operations, SEBF8064, "Salvage of Non-Serrated Connecting Rods"





Guideline For Reusable Parts And Salvage Operations, SEBF8303, "Procedure to Inspect Piston Pins" Note: For information on reusability of the rod eye bushing, refer to the following list. 




Illustration1

g00610428

1. Check the clearance between the ends of piston rings (5). Refer to the Specifications Manual, "Pistons and Rings". Note: The oil ring must be installed over the spring with the end gap 180 degrees from the oil ring spring joint.

2. Install the oil control piston ring with Tooling (A). The ends of the spring should be rotated 180 degrees from the ring end gap. 3. Install the intermediate piston ring with the side marked "UP-2" toward the top of the piston. Use Tooling (A) in order to install the ring. 4. Install the top piston ring with the side marked "UP-1" toward the top of the piston. Use Tooling (A) in order to install the ring.

205


Illustration2

g00610498

5. Replace rod bearing (6) by pressing a new bearing into the connecting rod. Refer to Special Instruction, SEHS7295 for the correct tooling and the correct installation procedure.

Illustration 3 One piece piston

g00641764

206


Illustration4

g00610503

6. This piston is a two-piece assembly. This piston consists of piston crown (7) and piston skirt (8). Inspect bearing (9) in the piston crown (7). The piston crown must be replaced if the piston crown is worn or damaged. Bearing (9) is nonserviceable.

Illustration5

g00678083

7. Position piston (1) on connecting rod (3). Coat piston pin (4) with clean engine oil and install piston pin (4) .

Illustration6

g00678081

8. Use Tooling (B) to install the retaining ring.

207


Illustration7

g00610426

9. Ensure that retainer rings (2) are in the grooves of piston (1) . End By: Install the pistons and the connecting rods. Refer to Disassembly and Assembly, "Piston and Connecting Rods - Install".

208






i03478580

Pistons and Connecting Rods - Install SMCS - 1225-012


Part Number

Part Description

Qty

187-1462

Piston Ring Compressor

(1)

1

173-5529

Piston Ring Compressor

(2)

1

4C-5593

Anti-Seize Compound

A

B (1)

Used for 3114 and 3116 Engines

(2)

Used for 3126 Engines

1



Guideline For Reusable Parts And Salvage Operations, SEBF8049, "Pistons"



Guideline For Reusable Parts And Salvage Operations, SEBF8290, "Visual Inspection of Two-Piece Pistons"



Tool Operating Manual, NEHS0775, "Using the 186-0190 Piston Ring Gauge on Steel Crown, Two-Piece Pistons used in 3126 and 3126B Engines"




Guideline For Reusable Parts And Salvage Operations, SEBF8063, "Visual Inspection of Connecting Rods" Guideline For Reusable Parts And Salvage Operations, SEBF8064, "Salvage of Non-Serrated Connecting Rods"

209






Guideline For Reusable Parts And Salvage Operations, SEBF8303, "Procedure to Inspect Piston Pins"

Note: For information on reusability of the rod eye bushing, refer to the following list. 




Illustration1

g00678193

1. Install the bolts (5) and the upper half of connecting rod bearing (4) . Ensure that the bearing tab engages with the slot in connecting rod (3) .

Illustration2

g00678195

2. Install the lower half of connecting rod bearing (4) . Ensure that the bearing tab engages with the slot in connecting rod cap (2) . 3. Place clean engine oil on the follo wing items: the pistons, the piston rings, the cylinder bore, the upper half of the connecting rod bearing and the lower half of the connecting rod bearing.

NOTICE 210


Install short pieces of rubber hose over both connecting rod bolts in order to protect the crankshaft from the threaded portion of the connecting rod bolts.

Illustration3

g00746584

4. Install short pieces of rubber hose (6) over both connecting rod bolts.

Illustration4

g00634923

Note: Each piston ring end gap must be positioned 120 degrees from each other.

5. Install Tooling (A) in order to compress the piston rings. 6. With the number one crankshaft throw at the bottom cent er, install the piston and connecting rod in the engin e. Ensure that the proper piston and connecting rod are in the corresponding cylinder with the bearing retainer notch toward the right side of the engine. Note: The etched number on the connecting rod must be on the right side of the engine in the corresponding cylinder.

7. Line up the piston and the connecting rod with the crankshaft. Use a soft hammer and tap the piston into the cylinder bore until Tooling (A) comes off of the piston. 8. Use a soft hammer in order to tap t he piston into the cylinder bore while you guide the connecting rod onto the crankshaft. 9. Remove the hoses that were installed in Step 4 from the connecting rod bolts.

211


Illustration5

g00678200

10. Install connecting rod bearing cap (2) on th e connecting rod (3) . Ensure that the number on connecting rod bearing cap (2) matches the number on the connecting rod (3) . Ensure that the numbers are on the same side. 11. Lubricate connecting rod cap bolts with Tooling (B) .

Illustration 6

g00610272

NOTICE Loose connecting rod nuts can result in the separation of the rod cap and result in major engine damage.

Note: Later connecting rods will have bolts in place of the bolts and nuts.

12. Install connecting rod cap nuts (1) . Tighten nuts (1) to the torque that is specified in Table 2. Table 2 Torque Specifications

Machined Connecting

Tighten nuts (1) to a torque of 54 ± 7 N·m (40 ± 5 lb ft) plus an additional 60 ± 212


Rods

5 degrees.

Fractured Connecting Rods

Tighten nuts (1) to a torque of 70 ± 5 N·m (52 ± 4 lb ft) plus an additional 120 ± 5 degrees.

13. Repeat Steps 1 through 12 for the remaining pistons and connecting rods. End By:

a. Install the piston cooling jets. Refer to Dis assembly and Assembly, "Piston Cooling Jets - Remove and Ins tall". b. Install the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump - Install". c. Install the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Install".

213






i01931297

Crankshaft Main Bearings - Remove SMCS - 1203-011


Part Number

A

2P-5518

Part Description

Bearing Tool

Qty

1

Start By:

A. Remove the engine balancer shaft on 31 14 engines. Refer to Disasse mbly and Assembly, "Engine Balancer Shaft - Remove and Install". B. Remove the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump - Remove".


Illustration1

g00610152

214


1. Remove bolts (1) that hold crankshaft main bearing cap (2). Remove crankshaft main bearing cap (2) . 2. Remove the lower half of the crankshaft main bearing from crankshaft main bearing cap (2) .

Illustration2

g00516920

NOTICE If the crankshaft is turned in the wrong direction, the tab of the crankshaft main bearing will be pushed between the crankshaft and the cylinder block. this can cause damage to either or both the crankshaft and the cylinder block.

Note: Some crankshaft main bearing journals do not have an oil hole. Place a thin piece of soft material that will not damage the journal against the end of the bearing. Ensure that the material is on the opposite side of the bearing tab. Hit the bearing with the soft material until the bearing tab is free from the bearing tab groove in the cylinder block.

3. Use the following steps in order to remove the upper half of crankshaft main bearings: a. Turn the crankshaft until Tooling (A) can be installed in the crankshaft journal. Install Tooling (A) . b. Turn the crankshaft in order to remove the upper half of the crankshaft main bearing. In order to get the tab out first, the crankshaft must be turned in the correct direction. c. Check the condition of the crankshaft main bearings. Refer to the Guideline For Reusable Parts And Salvage Operations, SEBF8009, "Main and Connecting Rod Bearings" and Special Publication, SEBD0531, "Engine Bearings and Crankshafts".

215






i01931316

Crankshaft Main Bearings - Install SMCS - 1203-012


Part Number

Part Description

Qty

A

2P-5518

Bearing Tool

1

B

8T-5096

Dial Indicator Group

1


Note: For information on the reusability of the crankshaft main bearings, refer to the Guideline For Reusable Parts And Salvage Operations, SEBF8009, "Main and Connecting Rod Bearings". Note: Place clean engine oil on the crankshaft main bearings prior to assembly. Ensure that the tabs on the back side of the crankshaft main bearings fit in the grooves of the crankshaft main bearing caps and the cylinder block.

216


g00516920

1. Use Tooling (A) and install the upper halves of the crankshaft main bearings in the cylinder block. Do not put oil on the back of the crankshaft main bearing.

Illustration2

g00610152

2. Install the lower halves of the crankshaft main bearings in crankshaft main bearing caps (2). Do not put oil on the back of the crankshaft main bearing.

Illustration 3

g00639559

Six cylinder engine with oil grooves in the cylinder block

217


Illustration 4

g00639623

Six cylinder engine with no oil grooves in the cylinder block

NOTICE Crankshaft main bearing caps should be installed with the part number toward the right side of the engine. Crankshaft main bearing caps are to be identified by stamped numbers 1 through 7 located on the bottom surface. The thrust plate is used on the number 6 crankshaft main bearing only.

3. Oil grooves are machined in the saddles of the cylinder blocks of all 3114 engines and earlier 3116 engines. No oil grooves are machined in the saddles of the cylinder block on later 3116 engines and all 3126 engines. 4. Install the bearing caps with the sequence number to the right. A six cylinder engine has an order of 1 through 7 (front to rear). A four cylinder engine has an order of 1 through 5 (front to rear). Place crankshaft main bearing caps (2) in position on the cylinder block. Place clean engine oil or Molylube on the bolt threads and the washer face. Install bolts (1) . 5. Tighten bolts (1) to a torque of 54 ± 7 N ·m (40 ± 5 lb ft). Tighten each bolt (1) for an additional 90 ± 5 degrees (1/4 turn).

Illustration5

g00517003

6. Check the end play of the crankshaft with Tooling (B). The end play must be 0.07 mm (0.003 inch) to 0.32 mm 218


(0.013 inch). End By:

a. Install the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump - Install". b. Install the engine balancer shaft on 3114 engines. Refer to Disassembly and Assembly, "Engine Balancer Shaft - Remove and Install".

219






i01935937

Crankshaft - Remove SMCS - 1202-011


A. Remove the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Remove". B. Remove the crankshaft seal carrier. Refer to Disassembly and Assembly, "Crankshaft Rear Seal Carrier Remove and Install". C. Remove the front gear group. Refer to Disassembly and Assembly, "Gear Group (Front) - Remove". D. Remove the piston and the connecting rods. Refer to Disassemb ly and Assembly, "Piston and Connecting Rods-Remove".



Note: For information on reusability of the crankshaft, refer to the following list. 



Guideline For Reusable Parts And Salvage Operations, SEBF8041, "Crankshaft Measurement" Guideline For Reusable Parts And Salvage Operations, SEBF8054, "Procedure to Measure and Straighten Bent Crankshafts" 220

_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03 

Guideline For Reusable Parts And Salvage Operations, SEBF8094, "Procedure to Grind Crankshafts"



Guideline For Reusable Parts And Salvage Operations, SEBF8043, "Visual Inspection of Crankshafts"



Guideline For Reusable Parts And Salvage Operations, SEBF8039, "Inspection of Crankshafts for Cracks"



Guideline For Reusable Parts And Salvage Operations, SEBF8042, "Procedure to Polish Crankshafts"

Note: For information on reusability of the crankshaft main bearings, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8009, "Main and Connecting Rod Bearings". Note: For information on reusability of the cylinder block and salvage procedures, refer to the following list. 

Guideline For Reusable Parts And Salvage Operations, SEBF8192, "Specifications and Salvage for Cylinder Blocks on 3114, 3116, and 3126 Engines"



Guideline For Reusable Parts And Salvage Operations, SEBF8261, "Installing a 7C-6208 Cylinder Sleeve in 3114, 3116 Engines and a 107-7604 Cylinder Sleeve in 3126 Engines"



Special Instruction, SEHS8869, "Cylinder Block Salvage Procedure Using Belzona Ceramic R Metal"









Special Instruction, SEHS8841, " Using the Ironstitch Procedure for Casting Salvage"



Special Instruction, SEHS8919, "Salvage Weld Procedure for Cast Iron Cylinder Blocks"



Guideline For Reusable Parts And Salvage Operations, SEBF8076, "Specifications to Salvage Cylinder Block Contact Surfaces"

Illustration1

g00625767

Note: The weight of the crankshaft for the 3114 Engine is 37 kg (82 lb). The weight of the crankshaft for 3116 and 3126 Engines is 62 kg (137 lb).

1. Use a suitable lifting device. Remove bolts (2), the washers and main bearing caps (3). Carefully remove crankshaft (1) from the cylinder block.

221


Illustration2

g00625782

2. Remove upper main bearing (4) from the cylinder block. 3. Remove the main bearings from the main bearing caps.

222






i01931442

Crankshaft Wear Sleeve (Rear) - Remove - If E quipped SMCS - 1161-011-ZV


Part Number

Part Description

Qty

A

4C-4869

Distorter Ring

1

B

5P-7312

Seal Distorter

1

Start By:

A. Remove the crankshaft rear seal. Refer to Disassembly and Assembly, "Crankshaft Rear Seal - Remo ve".


Illustration1

g00614029

223


Note: Wear sleeves are not installed at the factory. The wear sleeve is included with the replacement rear seal.

1. Install Tooling (A) in the bore of the crankshaft rear sleeve. 2. Install Tooling (B) between Tooling (A) and the crankshaft wear sleeve. Turn Tooling (B) until the edge of Tooling (B) makes a crease in the crankshaft wear sleeve. Make a crease in the crankshaft wear sleeve at two other locations around the crankshaft wear sleeve until the crankshaft wear sleeve is loose. 3. Remove Tooling (B), Tooling (A), and the crankshaft wear sleeve from the end of the crankshaft.

224






i01929732

Crankshaft Wear Sleeve (Rear) - Install SMCS - 1161-012-ZV


Part Number

C (1) 132-8772 (1) D1U-7596

Part Description

Seal Locator Bolt

Qty

1 2

E (1) 1U-7597

Sleeve Ring

1

F (1) 1U-7594

Seal Installer

1

(1) G9S-8858 (1)

Nut

1

Part of the 1U-7598 Seal Installer


1. Ensure that the rear of the cran kshaft is thoroughly clean and dry prior to the installation of the crankshaft rear seal.

225


Illustration1

g01003875

2. Fasten Tooling (C) to the rear of the cran kshaft with Tooling (D). Hand tighten Tooling (D) . 3. Position the crankshaft rear seal and crank shaft rear sleev e (1) on Tooling (C). Position Tooling (E) on Tooling (C) .

Illustration2

g01003866

Typical example

4. Position Tooling (F) over Tooling (C) and Tooling (E). Install To oling (G). Tighten Tooling (G) in order to install the crankshaft rear seal and the crankshaft wear sleeve. 5. Remove Tooling (G), Tooling (F), and Tooling (E). Turn over Tooling (E). Install Tooling (E), Tooling (F), and Tooling (G). Tighten Tooling (G) in order to complete the installation of the crankshaft rear seal and the crankshaft wear sleeve. 6. Remove Tooling (G) and Tooling (F). Check Tooling (E) and Tooling (C). The faces of Tooling (E) and Tooling (C) will be flush if the crankshaft rear seal and the crankshaft wear sleeve are properly installed. Refer to the Specifications module for more information. 7. Remove Tooling (E), Tool (E), and Tooling (C) . End By: Install the flywheel. Refer to Disassembly and Assembly, "Flywheel - Install".

226






i01931335

Crankshaft - Install SMCS - 1202-012


Part Number

Part Description

Qty

A

8T-5096

Dial Indicator Group

1


NOTICE Ensure that the crankshaft main bearing tabs engage with the grooves in the block and the crankshaft main bearing cap.

Note: For information on reusability of the crankshaft, refer to the following list. 



Guideline For Reusable Parts And Salvage Operations, SEBF8041, "Crankshaft Measurement" Guideline For Reusable Parts And Salvage Operations, SEBF8054, "Procedure to Measure and Straighten Bent Crankshafts"



Guideline For Reusable Parts And Salvage Operations, SEBF8094, "Procedure to Grind Crankshafts"



Guideline For Reusable Parts And Salvage Operations, SEBF8043, "Visual Inspection of Crankshafts"



Guideline For Reusable Parts And Salvage Operations, SEBF8039, "Inspection of Crankshafts for Cracks"



Guideline For Reusable Parts And Salvage Operations, SEBF8042, "Procedure to Polish Crankshafts"

227


Note: For information on reusability of the cylinder block and salvage procedures, refer to the following list. 



Guideline For Reusable Parts And Salvage Operations, SEBF8192, "Specifications and Salvage for Cylinder Blocks on 3114, 3116, and 3126 Engines" Guideline For Reusable Parts And Salvage Operations, SEBF8261, "Installing a 7C-6208 Cylinder Sleeve in 3114, 3116 Engines and a 107-7604 Cylinder Sleeve in 3126 Engines"



Special Instruction, SEHS8869, "Cylinder Block Salvage Procedure Using Belzona Ceramic R Metal"









Special Instruction, SEHS8841, " Using the Ironstitch Procedure for Casting Salvage" 



Special Instruction, SEHS8919, "Salvage Weld Procedure for Cast Iron Cylinder Blocks" Guideline For Reusable Parts And Salvage Operations, SEBF8076, "Specifications to Salvage Cylinder Block Contact Surfaces"

1. Check the condition of the crankshaft main bearings. Refer to the Guideline For Reusable Parts And Salvage Operations, SEBF8009, "Main and Connecting Rod Bearings" and Special Publication, SEBD0531, "Engine Bearings and Crankshafts". Note: The number four main bearing in 3114 Engines is the thrust bearing. The number six main bearing in the six cylinder engines is the thrust bearing.

2. Clean the bearing surfaces in the cylinder block for the main bearings.

Illustration1

g00678393

3. Install the upper main bearings (4) in the cylinder block. Ensure that the tab on t he back side of the bearing engages with the groove in the cylinder block. Apply clean engine oil on the upper main bearing. Do not put engine oil on the back side of the bearing surfaces.

228


Illustration2

g00610100

Typical example

4. Put clean engine oil on the journals of the crankshaft bearing. Fasten lifting straps and a hoist to crankshaft (1). Carefully install the crankshaft in the cylinder block. 5. Clean the bearing surface of the main bearing caps.

Illustration3

g00678394

6. Install the lower main bearings (5) in the crankshaft main bearing caps (3). Ensure that the tab on the back side of the bearing engages with the groove in the main bearing cap. Apply clean engine oil on the lower main bearing. Do not put engine oil on the back side of the bearing surfaces. 7. Install crankshaft main bearing caps with the part numbers toward the right hand side of the cylinder block. Ensure that crankshaft main bearing caps have numbers 1 through 7. The numbers should start at the front of the engine. Place clean engine oil or Molylube on the bolt threads and the washers. Note: When the bolts for the rear main bearing cap are tightened, slide the main bearing cap as far forward as

possible until the cap is against the bolts. Hold the main bearing cap in this position and tighten the bolts.

229


Illustration4

g00609985

Typical example

8. Install bolts (2) and the washers for main bearing caps (3). Tighten bolts (2) to a torque of 54 ± 7 N·m (40 ± 5 lb ft). 9. Turn bolts (2) for an additional 90 ± 5 degrees (1/4 turn).

Illustration5

g00610119

Typical example

10. Check the end play of crankshaft (1) with Tooling (A). The end play must be 0.07 mm (0.003 inch) to 0.32 mm (0.013 inch). End By:

a. Install the pistons and connecting rods. Refer to Disassembly and Assembly, "Pistons and Connecting Rods Install". b. Install the front gear group. Refer to Disassembly and Assembly, "Gear Group (Front) - Install". c. Install the crankshaft seal carrier. R efer to Disassembly and Assembly, "Crankshaft Rear Seal Carrier- Remove and Install". d. Install the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Install".

230

_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03 Shutdown SIS

Previous Screen





i01944203

Crankshaft Gear - Remove and Install SMCS - 1204-010-GE


A. Remove the front gear group. Refer to Disassembly and Assembly, "Gear Group (Front) - Remove".



1. Place alignment marks on the crankshaft gear and on the crankshaft. The alignment marks will ensure that the camshaft gear is aligned properly during installation.

Illustration1

g00630476

2. Heat crankshaft gear (1). Remove crankshaft gear (1) from crankshaft (2) .





Illustration2

g00630476

1. Heat crankshaft gear (1) to a maximum temperature of 204 °C (400 °F) for no longer than 1 hour for installation. 2. Align the timing marks on the crankshaft and on crankshaft gear (1). Install crankshaft gear (1) on cra nkshaft (2) . Note: Ensure that crankshaft gear (1) is flush against the shoulder of crankshaft. If the gear is not flush damage to the gear may occur. End By: Install the front gear group. Refer to Disassembly and Assembly, "Gear Group (Front) - Install".

232






i02717761

Bearing Clearance - Check SMCS - 1203-535; 1219-535 S/N - 1SK1-UP S/N - 1ZG1-UP S/N - 1ZJ1-UP S/N - 2MR1-UP S/N - 2SG1-UP S/N - 2WG1-UP S/N - 4KG1-UP S/N - 4PG1-UP S/N - 5EF1-UP S/N - 5EN1-UP S/N - 5JG1-UP S/N - 6AF1-UP S/N - 6MK1-UP S/N - 6MS1-UP S/N - 6SR1-UP S/N - 8NM1-UP S/N - 9ZR1-UP S/N - CKK1-UP

Measurement Procedure Table 1 Required Tools 233


Tool

Part Number

Part Description

Qty

198-9142

Plastic Gauge (Green) 0.025 to 0.076 mm (0.001 to 0.003 inch)

1

198-9143

Plastic Gauge (Red) 0.051 to 0.152 mm (0.002 to 0.006 inch)

1

198-9144

Plastic Gauge (Blue) 0.102 to 0.229 mm (0.004 to 0.009 inch)

1

198-9145

Plastic Gauge (Yellow) 0.230 to 0.510 mm (0.009 to 0.020 inch)

1

A

Note: Plastic gauge may not be necessary when the engine is in the chassis.


Note: Caterpillar does not recommend the checking of the actual bearing clearances particularly on small engines. This is because of the possibility of obtaining inaccurate results and the possibility of damaging the bearing or the

journal surfaces. Each Caterpillar engine bearing is quality checked for specific wall thickness. Note: The measurements should be within specifications and the correct bearings should be used. If the crankshaft journals and the bores for the block and the rods were measured during disassembly, no further checks are necessary. However, if the technician still wants to measure the bearing clearances, Tooling (A) is an acceptable method. Tooling (A) is less accurate on journals with small diameters if clearances are less than 0.10 mm (0.004 inch).

NOTICE Lead wire, shim stock or a dial bore gauge can damage the bearing surfaces.

The technician must be very careful to use Tooling (A) correctly. The following points must be remembered: 

Ensure that the backs of the bearings and the bores are clean and dry.



Ensure that the bearing locking tabs are properly seated in the tab grooves.



The crankshaft must be free of oil at the contact points of Tooling (A) .

1. Put a piece of Tooling (A) on the crown of the bearing that is in the cap. Note: Do not allow Tooling (A) to extend over the edge of the bearing.

2. Use the correct torque-turn specifications in order to install the bearing cap. Do not use an impact wrench. Be careful not to dislodge the bearing when the cap is installed. Note: Do not turn the crankshaft when Tooling (A) is installed. 234


3. Carefully remove the cap, but do not remove Tooling (A) . Measure the width of Tooling (A) while Tooling (A) is in the bearing cap or on the crankshaft journal. Refer to Illustration 1.

Illustration1

g01152855

Typical Example

4. Remove all of Tooling (A) before you install the bearing cap. Note: When Tooling (A) is used, the readings can sometimes be unclear. For example, all parts of Tooling (A) are not the same width. Measure the major width in order to ensure that the parts are within the specification range. Refer to Specifications Manual, "Connecting Rod Bearing Journal" and Specifications Manual, "Main Bearing Journal" for the correct clearances.

235






i01931368

Engine Oil Pressure Sensor - Remove and Install SMCS - 1924-010

Removal Procedure NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disasse mbling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Check the coolant level only after the engine has been stopped and the filler cap is cool enough to touch with the bare hand. Remove the filler cap slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with skin and eyes to prevent personal injury.

Note: Put identification on all hose assemblies, wires, and tube assemblies for installation purposes. Install a cap or plug on all hose assemblies and tube assemblies in order to prevent foreign material from entering the system. Note: Drain all fluids into a suitable container for storage or disposal.

236


Illustration1

g00678580

1. Disconnect harness assembly (2) at the clip.

Illustration2

g00678582

2. Remove oil pressure sensor (1) and O-ring seal (3) .


Illustration3

g00678582

1. Install a new O-ring seal (3) on oil pressure sensor (1). Install oil pressure sensor (1) .

237


Illustration4

g00678580

2. Connect harness assembly (2) at the clip. Note: Refer to the Operation and Maintenance Manual for all fluid capacities and the proper filling procedures.

238






i01200681

Ether Atomizer - Remove and Install SMCS - 1456-010

Removal Procedure

Illustration 1

g00642608


1. Remove ether atomizer (1) from the top of the air inlet manifold.


239


Illustration 2

g00642608

Note: Install the ether atomizer so that the direction of the spray is parallel to the air inlet heater, If equipped. The ether atomizer has an indicator in order to show the direction of the spray. Note: The ether atomizer has two ports that are separated by 180 degrees. The two ports must be aimed parallel to the length of the block.

1. Install ether atomizer (1). The minimum torque for the ether atomizer is 2.8 N·m (25 lb in).

240






i01930316

Belt Tensioner - Remove and Install SMCS -

1358-010

Removal Procedure

Illustration1

g01011962

1. Use a breaker bar to release the tension on belt tensioner (1). Remove the drive belt. 2. Remove bolt (2) and belt tensioner (1) .


241


Illustration2

g01011962

1. Position belt tensioner (1) on the cylinder block. Install bolt (2) . 2. Install the drive belt. Use a breaker bar to release tension on belt tensioner (1) .

242






i01930317

Belt Tightener - Remove SMCS - 1358-011

Removal Procedure

Illustration1

g00619355

1. Remove bolts (1) that hold water pump belt tightener (3) to the timing gear housing. 2. Remove V-belt (2) from the pulley of water pump belt tightener (3). Remove water pump belt tightener (3) .

243






i01930280

Belt Tightener - Install SMCS - 1358-012


Illustration1

g00619355

1. Position water pump belt tightener (3) and install V-belt (2) on the pulley of water pump belt tightener (3) . 2. Install bolts (1) that hold water pump belt tightener (3) to the timing gear housing. 3. Adjust the tension of V-belt (2). Refer to Op eration and Maintenance Manual, "Belt Tension Chart".

244






i01930386

Alternator - Remove and Install SMCS - 1405-010


Part Number

Part Description

A

168-0383

Circuit Breaker Bar

Illustration1

Qty

1

g00609523

Typical Example

Note: Release the tension on the belt at the belt tightener, if the engine is not equipped with a belt tensioner.

1. Use Tooling (A) to release the tension on belt tensioner (5) . 2. Remove drive belt (4) from the drive pulley on alternator (3) . 3. Place an index mark on the wires of harness assembly (1) that are connected to the alternator. Disconnect harness assembly (1) from the alternator. 4. Remove bolts (2) . 5. Remove alternator (3) fro m the mounting bracket. 245



Part Number

Part Description

A

168-0383

Circuit Breaker Bar

Illustration2

Qty

1

g00609523

Typical example

1. Position alternator (3) on the mounting bracket. Install bolts (2) . 2. Use Tooling (A) to install drive belt (4) on the drive pulley of the alternator. Note: Adjust the tension on the drive belt if the engine is not equipped with a belt tensioner. Refer to the Operation and Maintenance Manual for the correct adjusting procedure.

3. Connect harness assembly (1) to the alternator. Use the index marks to correctly connect the harness assembly. Tighten the mounting bolt for the ground wire to a torque of 6.2 ± 0.6 N·m (54 ± 5 lb in). Tighten the mounting bolt for the battery wire to a torque of 11.3 ± 2.3 N·m (100 ± 20 lb in).

246






i03904991

Electric Starting Motor - Remove and Install SMCS - 1453-010

Removal Procedure

Personal injury can result from failure to disconnect the battery. First, disconnect the negative battery cable. Then, disconnect the positive battery cable. A positive power lead can cause sparks if the battery is not disconnected. Sparks can possibly result in battery explosion or fire.

Illustration1

g02146813

1. Disconnect cable strap (1) . 2. Place an index mark on all of the harness assemblies. Disconnect the harness assemblies from electric starting motor (2) . 3. Fasten a suitable lifting device to electric starting motor (4). The weight of electric starting motor (4) is approximately 35 kg (77 lb). 4. Remove bolts (3) . 247


5. Remove electric starting motor (4) and the gasket from the flywheel housing.

Installation Procedure 1. Install electric starting motor (4) in reverse order.

248






i01931416

Air Compressor - Remove and Install SMCS - 1803-010

Removal Procedure

Do not disconnect the air lines until the air pressure in the system is at zero. If hose is disconnected under pressure it can cause personal injury.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.


1. Remove the air pressure from the air tank and drain the coolant from the cooling system.

249


Illustration1

g00484206

Typical example

2. Disconnect hose assemblies (1), (2) and (9) from the air com pressor. Remove tube assembly (4) from the air compressor. 3. Remove bolt (5) and the washer. Remove clamp (7) from tube assembly for the breather. Move the tube assembly for the breather aside. 4. Remove bolts (3) and the washers that hold the air compressor to the timing gear housing. 5. Remove bolts (6) and remove air compressor (8) and the gasket from the engine.


Part Number

Part Description

Qty

A

4C-4030


1


Note: Check the condition of the gaskets and O-ring seals. If gaskets or O-ring seals are damaged, use new parts for replacement.

250


Illustration2

g00484206

Typical example

1. Use bolts (3) and the washers to install air compressor (8). Apply Tooling (A) to the threads of bolts (6). Torque bolts (6) to 160 ± 30 N·m (118 ± 22 lb ft). 2. Install clamp (7) for the tube assembly for the breather with bolt (5) and the washer. 3. Install tube assembly (4) and connect hose assemblies (9), (2) and (1) to air compressor (8) .

251






i01931465

Air Compressor Drive Gear - Install SMCS - 1803-012-GE


Part Number

Part Description

Qty

A

132-5451

Holding Fixture

1

B

138-8440

Component Cleaner

1


Illustration1

g00609907

Typical example

1. Use Tooling (B) in order to clean the inside diameter of air com pressor drive gear (4) and the outside diameter of the drive shaft for the air compressor. 252


2. Lubricate washer (3) and the threads on the drive shaft with clean engine oil. 3. Mount air compressor (1) in a bench vise.

NOTICE A loose air compressor drive gear can lead to immediate loss of hydraulic power to vehicle systems

4. Install Tooling (B) . 5. Install air compressor drive gear (4) on the air compressor crankshaft. 6. Install washer (3) and nut (2) . 7. Tighten nut (2) to a torque of 170 ± 15 N·m (125 ± 11 lb ft). 8. Use a soft faced ham mer and tap the air compressor drive gear. Again tighten the nut to a torque of 170 ± 15 N·m (125 ± 11 lb ft). End By: Install the air compressor. Refer to Disassembly and Assembly, "Air Compressor - Remove and Install".

from the Library of Barrington Diesel Club

253

3114-3116-3126-disassembly-and-assembly.pdf

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