c7 Assembly

RENR7458-09 August 2008

Disassembly and Assembly C7 On-Hig hway Engine YPG1-Up (Engine) NPH1-Up ( Engine) KAL1-Up (Engine) LBM1-Up SAP1-Up ((Engine Engine)) C7T1-Up (Engine) WAX1-Up (Engine)

SAFETY.CAT.COM

i01658146

Important Safety Information Most accidents t hat involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necess ary training, skills and tools to perform these functions properly. Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate o r perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair informatio n. Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded , bodily injury or death could occur to you or to other persons. The hazards are identi fied by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows: Attention ! Become Alert! Your Safety is Involved. The message that appears under the warning explains the hazard and can be either written or pictorially presented. Operations that may cause product damage are identi this publication.

fied

by “NOTICE” labels on the product and in

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method or operating technique that is not specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product w ill not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose. The information, speci fications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written. The speci fications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any jo b. Caterpillar dealers have the most current information available.

When replac ement parts are required for this product Caterpillar recommends using Caterpillar replac ement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength and material. Failure to heed this warning can lead to premature failures, product damage, personal injury or death.

RENR7458-09

Table of Contents Disassembly and Assembly Section Fuel Priming Pump - Remove and Install .............. 4 Fuel Filter Base - Remove a nd Install .................... 4 Fuel Transfer Pump - Remove ................................ 5 Fuel Transfer Pump - Install .................................... 6 Unit Injector - Remove .................... ........................ 7 Unit Injector - Install .................... ............................ 8 Unit Injector Sleeve - Remove ................................ 9 Unit Injector Sleeve - Install .................................. 10 Unit Injector Hydraulic Pump - Remove ................. 11 Unit Injector Hydraulic Pump - Install ..................... 11 Modulating Valve - Remove and Install ................ 12 Turbocharger - Remove .............. .......................... 12 Turbocharger - Install ................ ............................ 13 Exhaust Manifold - Remove and Install ............... 14 Air Inlet Heater Solenoid - Remove and Install .... 15 Inlet and Exhaust Valves - Remove and Install .... 15 Inlet and Exhaust Valve Guides - Remove and Install ................................................................... 17 Inlet and Exhaust Valve Seat Inserts - Remove and Install ................................................................... 18 Engine Oil Filter Base and Oil Cooler - Remove .. 19 Engine Oil Filter Base - Disassemble ................... 19 Engine Oil Filter Base - Assemble ........................ 20 Engine Oil Filter Base and Oil Cooler - Install ..... 20 Engine Oil Pump - Remove .................................. 22 Engine Oil Pump - Disassemble ................... ........ 22 Engine Oil Pump - Assemble ................. ............... 23 Engine Oil Pump - Install ...................................... 24 Water Pump - Remove ......................................... 24 Water Pump - Disassemble ................................. 25 Water Pump - Assemble ...................................... 25 Water Pump - Install ............................................. 26 Water Temperature Regulator - Remove and Install ............................................................................. 26 Flywheel - Remove ...................... ......................... 27 Flywheel - Install ................................................... 27 Crankshaft Rear Seal - Remove ........................... 28 Crankshaft Rear Seal - Install . .............................. 28 Flywheel Housing - Remove and Install .............. 29 Vibration Damper and Pulley - Remove and Install ............................................................................. 30 Crankshaft Front Seal - Remove .......................... 31 Crankshaft Front Seal - Install .............................. 32 Front Cover - Remove .......................................... 32 Front Cover - Install .............................................. 32 Housing (Front) - Remove .................................... 33 Housing (Front) - Install ........................................ 34 Camshaft Idler Gear - Remove and Insta ll ........... 35 Valve Mechanism Cover - Remove and Install ..... 36 Valve Mechanism Cover Base - Remove and Install ................................................................... 36 Rocker Shaft and Pushrod - Remove ................... 37 Rocker Shaft - Disassemble ................................ 38 Rocker Shaft - Assemble ..................................... 38 Rocker Shaft and Pushrod - Install ....................... 39 Cylinder Head - Remove ...................................... 40 Cylinder Head - Install .......................................... 41

3 Table of Contents

Lifter Group - Remove and Install ......................... 43 Camshaft - Remo ve .............................................. 45 Camshaft - Install ................. ................................. 45 Camshaft Gear - Remove and Install .................. 46 Camshaft Bearings - Remov e and Ins tall ............ 47 Engine Oil Pan - Remove and In stall ................... 48 Piston Cooling Jets - Remove and Install ............. 49 Pistons and Conn ecting Rods - Remove .............. 50 Pistons and Connecting Rods - Disassemble ....... 51 Pistons and Connecting Rods - Assemble ........... 51 Pistons and Conn ecting Rods - Install .................. 53 Connecting Rod Bearings - Remove .................... 54 Connecting Rod Bearings - Install ........................ 54 Crankshaft Bearings-- Remove .................... Crankshaft Main Main Bearings Install ............. ...........55 56 Crankshaft - Remove ............... ............................. 57 Crankshaft - Install ................................................ 58 Crankshaft Gear - Remove and Install ................ 59 Bearing Clearanc e - Check ................................... 60 Atmospheric Pressure Sensor - Remove and Install ................................................................... 61 Coolant Temperature Sensor - Remove and Install ................................................................... 61 Engine Oil Pressure Sensor - Remove and Install ............................................................................. 62 Injection Actuation Pressure Sensor - Remove and Install ................................................................... 62 Speed/Timing Sensor - Remove and Install ........ 62 Boost Pressure Sen sor - Remove and Install ....... 63 Inlet Air Temperature Sensor - Remove and Install ................................................................... 63 Fan Drive Mounting Group - Remove and Install .. 64 Engine Control Module - Remove and Install ....... 65 Alternator - Remove and Install ........................... 65 Electric Starting M otor - Remove and Install ....... 66 Air Compressor - Remove and Install .................. 67 Air Compressor Drive Gear - Remove .................. 68 Air Compressor Drive Gear - Install (Two Cylinder) .............................................................. 69 Air Compressor Drive Gear - Install ...................... 70

Index Section Index ..................................................................... 71

4 Disassembly and Assembly Section

RENR7458-09

Disassembly and Assembly Section

2. Remove fuel priming pump (1) and the gasket.

Installation Procedure

i02581591

Fuel Priming Pump - Remove and Install SMCS Code: 1258-010

Removal Procedure

Fuel leaked o r spilled onto hot surfaces or electrical components can cause a fire. To help prevent possible injury, turn the start switch off when changing fuel filters or water separator elements. Clean up fuel spills immediate ly. 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 Publicat ion, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fl uids according to local regulations and mandates.

Illustration 2

g00987651

1. Position the gasket and fuel priming pump (1) on the fuel filter base. 2. Install bolts (2). Tighten bolts (2) to a torque of 25 ± 6 N·m (18 ± 4 lb ft).

i01921666

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

Removal Procedure

Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help prevent possible injury, turn the start switch off when changing fuel fi lters or water separator elements. Clean up fuel spills immediately.

Illustration 1

1. Remove bolts (2).

g00987651

RENR7458-09


Installation Procedure NOTICE Care must be taken to ensure that fluids are contained during perform ance of inspection, maintenance , testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compar tment or disassembling any component 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 fl uids according to local regulations and mandates.

g00987754

Illustration 4

1. Position fuel fi lter base (4) on the engine. 2. Install bolts (2). 3. Connect tube assembly (1) and tube assembly (3). i02226208

Fuel Transfer Pump - Remove SMCS Code: 1256-011

g00987754

Illustration 3

Removal Procedure Table 1

1. Disconnect tube assembly (1) and tube assembly (3). Tool

2. Remove bolts (2). 3. Remove fuel

fi lter

Required Tools Part N u mb e r

base (4).

A

218-8171 Bolt

P a rt De sc r ip t ion

Q ty

1

Start By: a. Remove the unit injector hydraulic pump. Refer to Disassembly and Assembly, “Unit Injector Hydraulic Pump - Remove”. Note: Tooling (A) is required for replacement of the fuel transfer pump.


RENR7458-09

7. Remove fuel transfer pump (2). NOTICE Care must be taken to ensure that fluids are contained during perform ance of inspection, maintenance , testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compar tment or disassembling any component 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 fl uids according to local regulations and mandates.

i02226252

Fuel Transfer Pump - Install SMCS Code: 1256-012

Installation Procedure Table 2


Tool A

218-8171 Bolt

P a r t D e s c r i p t io n

Qty

1

NOTICE Keep all parts c lean from contaminants. Contaminants may cause rapid wear and shortened component lif e.

Illustration 5

g01123057

1. Mount the unit injector hydra ulic pump in a vertical position on a work bench. Note: Failure to maintain a vertical position results in misalignment of the internal components. 2. Remove bolts (3). 3. Remove tie bolt (1) that is located in the top left corner of the pump first. 4. Replace tie bolt (1) with Tooling (A). Note: Tooling (A) has an undersized bolt head. Tooling (A) will prevent the body of the unit injector hydraulic pump from separating during service. 5. Tighten Tooling (A) to a torque of 10 N·m (89 lb in). 6. Start with tie bolt (4) in the lower left corner and remove the remainder of the bolts from fuel transfer pump (2).

Illustration 6

g01123057

1. Position fuel transfer pump (2) on the unit injector hydraulic pump. Be sure to align the drive tang of the fuel transfer pump to the drive slot in the end of the pump shaft. 2. Install tie bolts (4). Tighten the bolts to a snug

fi t.

3. Remove Tooling (A) that is located in the upper left hole and install remaining tie bolt (1) to a snug fi t. 4. Install bolts (3) for fuel transfer pump (2). Tighten the bolts to a snug fi t.

RENR7458-09


5. Start in the lower left corner of the unit injector hydraulic pump and tighten tie bolts (4) to a torque of 28 ± 2 N·m (21 ± 1 lb ft) in a crisscross pattern. Torque the bolts again.

2. Remove socket head bolts (1) from unit injector (2).

6. Tighten bolts (3) to a torque of 8.0 ± 0.4 N·m (71 ± 4 lb in). End By: a. Install the un it injector hydraulic pump. Refer to Disassembly and Assembly, “Unit Injector Hydraulic Pump - Install”. i02325874

Unit Injector - Remove SMCS Code: 1290-011

Removal Procedure Table 3 Illustration 8

Required Tools Tool

Part N u mb e r

A

152-1057

B

274-9198 Leg

P a r t D e sc r ip t io n Fuel Injector Installer As

Qty 1

2

g01161909

3. Use Tooling (A) and Tooling (B) to remove unit injector (2) from the cylinder head. Note: Do not use a wire brush on the tip of the unit injector. Damage to the unit injector will occur.

Start By: a. Remove the valve mechanism cover. Refer to Disassembly and Assembly, “Valve Mechanism Cover - Remove and Install”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 9

g01123753

4. Remove O-ring seal (6), O-ring seal (7), and O-ring seal (8) from unit injector (2).

Illustration 7

1. Disconnect harness assembly (3).

g01123748

5. Remove backup ring (4), backup ring (5), and backup ring (9).


RENR7458-09

i02325908

Unit Injector - Install

Place a 38 mm (1.5 inch) square piece of Scotch Brite materia l on the end of Tooling (K). Twist Tooling (K) with Tooling (M) against the lower surface of the sleeve bore.

SMCS Code: 1290-012


The surface should be cleaned until the surface is smooth and shiny. The entire sleeve bore should be cleaned in order to remove any loose carbon particles.

Table 4

Required Tools Tool

Part N u m be r

A

152-1057

C

272-1149 Leg

D

-

P a r t D e s cr ip t i on

Qty

Fuel Injector Installer As

1

ScotchBrite

149-2955Seal Protector

F

149-2956

1 1

Seal Installe r

1

1U-5718 VacuumPump

1

4C-4057 Bottle Assembly 169-7372

Note: Tooling is available to clean loose material from the sleeve(L) bore and the cylinder.

2

E

G

The following procedure is the preferred method of cleaning the sleeve bore.

1

Clear Plastic Tubing

H

9U-5470 Reamer

J

4C-6161TubeBrush

K

9U-6862 TaperedBrush

L

4C-6774

M

4C-5027TapWrench

NOTICE The correct procedures and tooling speci fications must always be used. Failure to follow any of the procedures may result in damage, malfunction, or possible engine failure.

1 1 1 1

VacuumGun Kit

NOTICE The O-ring seals and the backup rings must be installed in the correct orientation. Damaged seals will result in excessive oil consumption or excessive leakage under the valve cover. Use care to prevent nicks or damage to the seals.

1 1

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Evacuate as much fuel and oil as possible from the cylinder head before installing the unit injector. Several evacuations may be necessary. Use Tooling (G) to remove the fuel and oil from the cylinder. Note: Tooling (L) is available to clean loose material from the sleeve bore and the cylinder. 2. Clean the carbon from the sleeve, the sleeve bore and the end of the unit injector. Clean the carbon from the seat area that is inside of the cylinder head. A fine grade of Tooling (D) is preferred. Clean the carbon from the cylinder head. If the sleeve of the unit injector has been removed from the engine, use Tooling (H) to remove only carbon from the surface of the sleeve. If the sleeve of the unit injector is installed in the engine, use Tooling (J) to clean the carbon deposit from the inside of the sleeve.

Illustration 10

g01123753

3. Lubricate O-ring (6),bore O-ring seal (7),injector O-ring seal (8), and the seal sleeve of the unit sparingly with clean engine oil. 4. Use Tooling (E) and Tooling (F) to install backup ring (4), backup ring (5), O-ring seal (6), backup ring (9), and O-ring seal (8). 5. Install O-ring seal (7).

RENR7458-09


6. Lubricate the O-ring seals and the backup rings on the unit inje ctor with clean engine oil before installation. Note: Proper i nstallation of the unit injector is very important. Damage to the upper high pressure seals can cause excessive oil leakage under the valve cover. This m ay cause the engine not to start due to a low actuation pressure. Damage to the lower high pressure seals may allow high pressure oil to leak into the fuel supply passage. This will result in excessive oil consumption.

9. Install socket head bolt (1) on the exhau st side of the bracket. Ti ghten the exhaust side of socket head bolt (1) until the bolt is seated. Tighten the inlet side of socket head bolt (1) to a torque of 12 ± 1 N·m (9 ± 1 l b ft). 10. Connect harness assembly (3). End By: a. Install the va lve mechanism cover. Refer to Disassembly and Assembly, “Valve Mechanism Cover - Remove and Install”.

Note: Do not h it or strike the unit injector during installation. i02300862

7. Record the se rial number for the injector and the injector con firmation code. When you install a new unit injector the E-Trim value must be programmed into the Engine Control Module. For more information, refer to Troubleshooting, “Injector Code - Calibrate”.

Unit Injector Sleeve - Remove SMCS Code: 1713-011


Required Tools Part Nu mb e r

Tool A

tion Pa rt D e s c r ip

1P-3042PlugTap

Qty 1

9U-6858BridgePlate

1

221-9778PullerStud

B

4K-0367Full Nut 5P-8247 HardWasher

C

1 1 1

9U-6877 Thrust Bearing

1

221-9803Rubber Stopper

1

Start By: a. Remove the unit injectors. Refer to Disassembly and Assembly, “Unit Injector - Remove”. Illustration 11

g01162006

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Drain the coolant from the cooling system into a suitable container for storage or disposal. Refer to Operati on and Maintenance Manual, “Cooling System Coolant - Change”. 2. Position Tooling (C) at the bottom of the unit injector sleeve. Illustration 12

g01123748

8. Use Tooling (A) and Tooling (C) to install unit injector (2) into the cylinder head.


RENR7458-09

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Thoroughly clean the unit injector sleeves and the bores for the unit injectors. Tooling (F) may be used on the bores.

g01123847

Illustration 13

3. Coat Tooling (A) with clean grease. Use Tooling (A) to cut threads into the unit injector sleeve.

Illustration 15 Illustration 14

g01123850

4. Use Tooling (B) to remove the unit injector sleeve . i03145071

Unit Injector Sleeve - Install

g01618682

2. Apply Tooling (G) to bores prior to installation. 3. Apply a thin coating of Tooling (E) around the outer circumference of unit injector sleeve (1) at Area (C). 4. Use Tooling (D) and a hammer to position the unit injector sleeve in the cylinder head.

SMCS Code: 1713-012 Note: Allow Tooling (E) to cure for two hours at 21 °C (70 °F) before filling the engine with fuel or coolant. Longer curing time is required for lower temperatures.


5. Fill the cooling system. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Change”.

Required Tools Tool

Part Nu mber

D

221-9777

E

4C-9506

F

4C-5552

G

6V-6640 Sealant


Qty 1

Sleeve Installer

1

Retaining Compound Large Bore Brush

1 1

End By: a. Install the unit injectors. Refer to Disasse mbly and Assembly, “Unit Injector - Install”.

RENR7458-09


i02227961

Unit Injector Hydraulic Pump Remove

3. Disconnect harness assembly (2) from unit injector hydraulic pump (1).

SMCS Code: 1714-011


Required Tools Tool A

Part N u mb e r

P a r t D e s c r i pion t

192-5092 RemovalTool

Qty 1 g01127845

Illustration 17

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

4. Remove bolts (7). Remove unit injector hydraulic pump (1). i02227969

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.

Unit Injector Hydraulic Pump - Install SMCS Code: 1714-012


Refer to Special Publicat ion, NENG2500, “Caterpillar Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fl uids according to local regulations and mandates.



g01127843

1. Disconnect tube assembly (4), tube assembly (5), and tube assembly (6). 2. Use Tooling (A) in order to disconnect hose assembly (3).

g01127845

1. Position unit injector hydraulic pump (1) in the front housing. 2. Install bolts (7).


RENR7458-09


Required Tools Tool

Part N u mb e r

A

5P-3975

P a r t De sc r ip t ion

Qty

Rubber Lubricant

1

1. Apply a small amount of Tooling (A) to the O-ring seals prior to installation of the solenoid.

Illustration 19

g01127843

3. Connect hose assembly (3). 4. Connect tube assembly (4), tube assembly (5), and tube assembly (6). 5. Connect harness assembly (2) to unit injector hydraulic pump (1). i02228143

Modulating Valve - Remove and Install

Illustration 21

g01124071

Note: Make sure that nut (3) is loose prior to installation.

SMCS Code: 3139-010 2. Install valve assem bly (1) and solenoid assemb ly (2). Tighten the valve assembly to a torque of 50 ± 5 N·m (37 ± 4 lb ft).

Removal Pro cedure

3. Tighten nut (3) to a torque of 13 ± 2 N·m (115 ± 18 lb in). 4. Connect th e harness assembly to solenoid assembly (2). i02236344

Turbocharger - Remove SMCS Code: 1052-011

Illustration 20

g01124071

Removal Procedure

1. Disconnect the harness assembly from solenoid assembly (2).

NOTICE Keep all parts clean from contaminants.

2. Loosen nut (3) in order to allow solenoid assembly (2) to rotate around valve assembly (1) during the removal procedure.

Contaminants may cause rapid wear and shortened component life.

3. Loosen valve assembly (1). Remove valve assembly (1) and solenoid assembly (2).

RENR7458-09


NOTICE Care must be taken to ensure that fluids are contained during perform ance of inspection, maintenance , testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compar tment or disassembling any component 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.

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Apply Tooling (A) on the threads of the mounting studs for the turbocharger.

Dispose of all fl uids according to local regulations and mandates.

Illustration 23

g01031231

2. Position the turbocharger gasket and turbocharger (4) on the exhaust manifold. Install nuts (2).

g01031231

Illustration 22

4. Connect tube assembly (3) and tube assembly (5).

1. Disconnect hose assembly (1), if necessary. 2. Disconnect tube assembly (3) and tube assembly (5). 3. Remove nuts (2), turbochar ger (4), and the gasket from the exhaust manifold. i02228177

Turbocharger - Install SMCS Code: 1052-012


Required Tools Tool

Part N u mb e r

A

5P-3931

P ar t D e s cri p t i on Anti-Seize Compound

3. Tighten nuts (2) to a torque of 54 ± 5 N·m (40 ± 4 lb ft).

Qty 1

5. Connect hose assembly (1).


RENR7458-09

i02228217

Exhaust Manifold - Remove and Install SMCS Code: 1059-010

Removal Procedure

Illustration 25

g01124147

1. Apply Tooling (A) to the outside diameter of the male ends of exhaust manifold (2). Assemble exhaust manifold (2) and remove the excess sealer from the joints.

g01124147

Illustration 24

1. Disconnect tube assembly (3) and tube assembly (5). 2. Attach a suitable lifting device to exhaust manifo ld (2) and the turbocharger. The weight of exhaust manifold (2) and the turbocharger is approximately 40 kg (88 lb).

2. Apply Tooling (B) to the threads of bolts (1). Attach a suitable lifting device to exhaust manifold (2) and the turbocharge r. The weight of exhaust manifold (2) and the turbocharger is approximately 40 kg (88 lb). Position the gaskets, exhaust manifold (2), and the turbocharger on the cylinder head assembly. Install locks (4) and bolts (1). 3. Connect tube assembly (3) and tube assembly (5).

3. Remove bolts (1) and locks (4). 4. Remove exhaust manifold (2), the turbocharg er, and the gaskets from the cylinder head assembly.


Required Tools Tool

Part N u mb e r

A

2P-2333

High Temperature Sealer

1

B

5P-3931

Anti-Seize Compound

1

P a rt D es c r i pt ion

Qty

NOTICE Excessive use of sealant can cause damage to components. To avoid component damage use only the amount of sealant necessary for the application.

Illustration 26

g00617739

4. Tighten Bolt (1) through Bolt (12) in a numerical sequence. Tighten bolts to the following torque. .... 4 ± 1 N·m (35 ± 9 lb in) 5. Tighten Bolt (1) through Bolt (12) in a numerical sequence.

RENR7458-09


Tighten bolts to the following torque. .. 45 ± 5 N·m (33 ± 4 lb ft) 6. Bend the locking tab over the head.

flat


of each bolt

Note: Prior to starting or running the engine, allow the sealant in the exhaust manifold joints to air dry for 24 hours. i02228257

Air Inlet Heater Solenoid Remove and Install SMCS Code: 1090-010-OD

Removal Procedure g01124203

Disconnect b atteries before performance of any service work.

Illustration 28

1. Disconnect t he battery. Refer to Operation and Maintenance Manual, “Battery or Battery Cable - Disconnect”.

2. Connect harness assemblies (2) and harness assemblies (3).

1. Position solenoid (1) on the engine.

3. Connect the battery. Refer to Operation and Maintenance Manual, “Battery or Battery Cable - Disconnect”. i02228289

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


Required Tools

Illustration 27

Tool

Part N u mb e r

P ar t De s c ri pt io n

A

5S-1330

Valve Spring Compressor

Qty 1

g01124203

Start By:

2. Disconnect harness assembl ies (2) and harness assemblies (3). 3. Remove solenoid (1).

a. Remove the cylinder head assembly. Disassembly and Assembly, “CylinderRefer HeadtoRemove”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.


RENR7458-09

g01127720

Illustration 29

The valve spring keepers can be thrown from the valve whe n the valve spring compressor is released. Ensure that the valve spring keepers are properly installed on the valve stem. To help prevent personal injury, keep away from the front of the valve spring keepers and valve springs during the installation of the valves. Note: The following components of the exhaust valves are different from the components of the inlet valves: spring retainer (5), valve spring (4), and valve (2). 1. Use Tooling (A) to compress valve spring (4). Remove retainer locks (6). 2. Remove Tooling (A). Remove spring retainer (5), valve spring (4), and washer (3).

Required Tools

5S-1330

P a r t D e s c r i pt i o n Valve Spring Compressor

To prevent possible injury , follow the established assembly pr ocedure and wear protective equipment. 1. Lubricate v alve (2) with clean engine oil. Install valve (2) in the cylinder head assembly. Install new valve seal (1) against the valve guide. 2. Place the following items on the valve stem: washer (3), valve spring (4), and spring retainer (5). Note: A small amount of grease can be used to hold the retain er locks in position during installa tion.

a. Install the cylinder head assembly. Refer to Disassembly and Assembly, “Cylinder Head Install”.

Table 12

A

Improper assembly of parts that are spring loade d can cause bod ily injury.

End By:


Part N u mb er

g01127720

3. Use Tooling (A) to compress valve spring (4). Install re tainer locks (6).

3. Remove val ve seal (1) and valve (2).

Tool

Illustration 30

Qty 1


RENR7458-09


i02228414

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


Required Tools Tool

Part Nu mb e r

A

1U-7793

Valve Guide Driver

1

B

9U-6895

Valve Guide Driver

1


Qty


Required Tools Tool

Part N u mb e r

A

1U-7793

Valve Guide Driver Valve Guide Driver


Qty 1

B

9U-6895

C

1U-7792GuideCollar

1

1

D

149-4008 GuideCollar

1


Start By: a. Remove the inlet and exhaust valves. Refer to Disassembly and Assembly, “Inlet and Exhaust Valves - Remove and I nstall”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 32

g01124397

Note: Position the valve guides and tap on the top of the valve guides. This is done in order to start the valve guide s into the cylinder head assembly. 1. Use Tooling (A) and Tooling (C) to install inlet valve guides (1). Install inlet valve guides (1) until the protrusion is 23.0 ± 0.50 mm (0.90 ± 0.020 inch) above the cylinder head assembly. Illustration 31

g01124395

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

2. Use Tooling (B) and Tooling (D) to install the exhaust valve guides. Install the exhaust valve guides until the protrusion is 17.8 ± 0.50 mm (0.70 ± 0.020 inch) above the cylinder head assembly. End By: a. Install th e inlet and exhaust valves. Refer to Disassembly and Assembly, “Inlet and Exhaust Valves - Remove and Install”.


RENR7458-09

i02954230

Inlet and Exhaust Valve Seat Inserts - Remove and Install


Required Tools

SMCS Code: 1103-010

Tool

Removal Procedure

B

Part N u mb e r

P a r t D es c r ip t io n

149-6115 Installer 133-9306 ValveGuide

Qty

1 1

Table 15

Required Tools P a r t D e s c r i pion t

6V-4194

Valve Seat Extractor (2)

165-5647

Valve Seat Extractor (3)

Tool

A(1)

6V-4804 Handle

(3)

1


1

1

6V-4199 Lifting Bracket

(2)

Qty

1

6V-4192 Shaft

(1)


Part N u mb er

1

Part of the 166-7441Valve Seat Extractor Tool Group Use for remova l of the exhaust valve seats Use for removal of the inlet valve seats

Start By: a. Remove the inl et and exhaust valves. Refer to Disassembly and Assembly, “Inlet and Exhaust Valves - Remove and I nstall”. Illustration 34


g01475612

1. Lower the temperature of new valve seat inserts (1). 2. Use Tooling (B) and a suitable press to install the new valve seat inserts in the cylinder head. Note: Do not machine the pre finished valve seat inserts in order to correct the valve stem projection. An excessive valve stem projection indicates that the valve seat insert is not seated or material was not cleaned from the bottom of the counterbore. End By: a. Install the inlet valves and exhaust valves. Refer to Disassembly and Assembly, “Inlet and Exhaust Valves - Remove and Install”.

Illustration 33

g01124436

1. Use Tooling (A) to remove valve seat inserts (1).

RENR7458-09


i02519791

Engine Oil Filter Base and Oil Cooler - Remove SMCS Code: 1306-011; 1378-012


Required Tools Tool

Part N u mb e r

A

185-3630

P a r t D e s c r i pion t Strap Wrench Assembly

Qty 1

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.

Illustration 36

3. Remove bolts (4). Remove engine oil (5) and the gasket.

g01261010

fi lter base

Refer to Special Publicat ion, NENG2500, “Caterpillar Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fl uids according to local regulations and mandates. 1. Drain the coolant system. Refer to Operation and Maintenance Manual, “Re fill Capacities and Recommendations”.

Illustration 37

g01261014

4. Remove oil cooler (6) and the gasket. Remove O-ring sea ls (7). i02229026

Engine Oil Filter Base Disassemble SMCS Code: 1306-015

Disassembly Procedure Start By: Illustration 35

g01261004

2. Remove nuts (1). Remove bracket (2) and the hose assembly. Use Tooling (A) and remove oil filter (3).

a. Remove the engine oil filter base and the oil cooler. Refer to Disassembly and Assembly, “Engine Oil Filter Base and Oil Cooler - Remove”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.


Illustration 38

RENR7458-09

g01124604

g01124604

Illustration 39

Personal injury can result from being struck by parts propelled by a released spring force.

Improper assembly of parts that are spring loade d can cause bodily injury.

Make sure to wear all necessary protectiv e equipment.

To prevent possible injury , follow the established assembly procedure and wear protective equipment.

Follow the recommended procedure and use all recommended tooling to release the spring force. (1) Oil cooler bypass valve (1) Oil cooler bypass valve (2) Oil

(2) Oil

filter bypass valve

filter bypass valve

End By: i02229174

Engine Oil Filter Base Assemble SMCS Code: 1306-016

Assembly Procedure

a. Install the engine oil fi lter base and the oil cooler. Refer to Disassembly and Assembly, “Engine Oil Filter Base and Oil Cooler - Install”. i02519800

Engine Oil Filter Base and Oil Cooler - Install SMCS Code: 1306-012; 1378-012



Required Tools Tool

Part N u m ber

A

185-3630

P a r t D es c r ip t i on Strap Wre nch Assembly

Qty 1

RENR7458-09


g01261018

Illustration 40

Note: Check O-ring seals for wear or for damage. If necessary, replace the O-ring seals. 1. Install O-ring seals (7). Install oil cooler (6) and the gasket.

Illustration 42

g01261020

3. Tighten bolts (4) in a numerical sequence to a torque o f 15 N·m (11 lb ft). Tighten bolts (4) in a numerical sequence to a torque of 28 N·m (21 lb ft).

g01261019

Illustration 41

2. Install the gasket and engine oil Install bo lts (4).

filter

base (5).

Illustration 43

g01261022

4. Install oil fi lter (3) with Tooling (A). Install the hose assembly and bracket (2). Install nuts (1). 5. Fill the coolant system. Refer to Operation and Maintenance Manual, “Re fill Capacities and Recommendations”.


RENR7458-09

i02229240

i02229280

Engine Oil Pump - Remove

Engine Oil Pump - Disassemble

SMCS Code: 1304-011

SMCS Code: 1304-015

Removal Procedure

Disassembly Procedure

Start By:

Table 19

a. Remove the engine oil pan. Refer to Disassembly and Assembly, “Engine Oil Pan - Remove and Install”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Required Tools Tool

Part N u mb e r

A

8B-7554

B

1P-0510DriverGp

P a rt De sc r ip t io n

Q ty

Bearing Cup Puller Gp

1 1

Start By: a. Remove the engine oil pump. Refer to Disassembly and Assembly, “Engine Oil Pump - Remove”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 44

1. Remove bolts (1) and bolt (2). 2. Remove engine oil pump (3). 3. Remove the O-ring seals.

g00987795

Illustration 45

g01127669

1. Remove bolts (1), oil pickup tube (2), and the gasket from the engine oil pump. Remove bolt (3) and outlet elbow (4) from the engine oil pump.

RENR7458-09


g01127673

Illustration 46

Illustration 47

g01127673

2. Remove bolt (5). 3. Remove idler gear (7) from shaft (8). 4. Use Tooling (B) and remove bearing (6) from idler gear (7). 5. Use Tooling (A) to remove drive gear (9) from engine oil pump (10). i02229316

Engine Oil Pump - Assemble Illustration 48

SMCS Code: 1304-016

g01127669

1. Use Tooling (B) and press drive gear (9) on the shaft assembly until drive gear (9) is end of the shaft assembly.

Assembly Procedure

fl ush with the

Table 20

Required Tools Tool

Part N u mb e r

B

1P-0510

P a r t D e s c rption i Driver Gp

Qty 1


2. Install bearing (6) in idler gear (7). Install bearing (6) so the distance between the hub bolt face of idler gear and bearing (6) is 0.75 ± 0.25 mm (0.030 ± 0.010 inch). 3. Install idler gear (7) on shaft (8). Install bolt (5). Tighten bolt (5) to a torque of 70 ± 15 N·m (52 ± 11 lb ft). 4. Position the gasket and oil pickup tube (2) onto engine oil pump (10). Install bolts (1). 5. Position the O-ring seal and outlet elbow (4) onto engine oil pump (10). Install bolt (3). End By: a. Install the engine oil pump. Refer to Disassembly and Assembly, “Engine Oil Pump - Install”.


RENR7458-09

i02229347


Engine Oil Pump - Install SMCS Code: 1304-012


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

NOTICE Care must be taken to ensure that fluids are contained during perform ance of inspection, maintenanc e, testing, adjusting and repair of the product. Be prepared to collect the fl uid with suitable containers before opening compar tment nentany containing fluids. or disassembling any compoRefer 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 fl uids according to local regulations and mandates. 1. Drain the coolant system. Refer to Operation and Maintenance Manual, “Re fill Capacities and Recommendations”.

Illustration 49

g00987795

1. Install the O-ring seals. Position engine oil pump (3) on the cylinder block. 2. Install bolts (1) and bolt (2). g01124776

End By:

Illustration 50

a. Install the engine oil pan. Refer to Disassembly and Assembly, “Engine Oil Pan - Remove and Install”.

2. Remove bolts (1). Remove support brack et (2). 3. Disconnect hose (3). 4. Remove bolts (4). Remove water pump (5).

i02229479

Water Pump - Remove SMCS Code: 1361-011

Removal Procedure Start By: a. Remove the alternato r. Refer to Disassembly and Assembly, “Alternator - Remove and Install”.

RENR7458-09


i02229484

i02229489

Water Pump - Disassemble

Water Pump - Assemble

SMCS Code: 1361-015

SMCS Code: 1361-016


Assembly Procedure

Table 21

Table 22


Part N u mb e r

Required Tools

P a rt D e s cr ipt io n

1P-0510DriverGroup

Qty 1

Tool

Part N u mb e r


A

1P-0510DriverGp

B

5P-9722SealDriver

Qty 1 1

Start By: a. Remove the water pump. Refer to Disassembly and Assembly, “Water Pump - Remove”.

NOTICE Keep all parts c lean from contaminants. Contaminants may cause rapid wear and shortened component lif e.

Illustration 51

g01124833

1. Remove O-ring seals (1). Remove bolts (2) and cover (3). 2. Remove gasket (4).

Illustration 52

g01124833

1. Use Tooling (A) and a suitable press to install pulley (9) on shaft assembly (8).

3. Use Tooling (A) and a suitable press to remove shaft assembly (8) from impeller (5) and housing (7).

2. Use Tooling (B) and a suitable press to install seal assembly (6) in housing (7).

4. Use Tooling (A) and a suitable press to remove

3. Use Tooling (A) and a suitable press to install

seal assembly (6) from housing (7). 5. Use Tooling (A) and a suitable press to remove pulley (9) from shaft assembly (8).

shaft assembly assembly until (8) into the the shaft thehousing bearing (7). is flInstall ush with housing. 4. Use Tooling (A) and a suitable press to install impeller (5) on shaft assembly (8). 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).


RENR7458-09

5. Install new gasket (4).

i02301675

6. Position cover (3) and install bolts (2). Install new O-ring seals (1).

Water Temperature Regulator Remove and Install

End By:

SMCS Code: 1355-010

a. Install the wa ter pump. Refer to Disassembly and Assembly, “Water Pump - Install”.

Removal Procedure

i02229490


Water Pump - Install Contaminants component life.m ay cause rapid wear and shortened

SMCS Code: 1361-012

Installation 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 andrepa ir of the product. Be prepared to collect the fl uid with suitable containers before opening any compartment or disassembling any component contain ing 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 fl uids according to local regulations and mandates.

1. Drain thecontainer coo lant from the cooling systemRefer into a suitable for storage or disposal. to Operation and Maintenance Manual, “Cooling System Cool ant - Change”.

Illustration 53

g01124776

1. Position water pump (5) on the front of the engine. Install bolts (4). 2. Connect hose (3). 3. Position support bracket (2). Install bolts (1). 4. Refill the cooling system. Refer to Operation and Mainte nance Manual, “Re fill Capacities and Recommendations”. End By: a. Install the alternator. Refer to Disassembly and Assembly, “Alternator - Remove and Install”.

Illustration 54

g01152619

2. Remove bolts (1), pipe (2), and the gasket from water temperature regulator housing (3). 3. Remove the water temperature regulat ors.

RENR7458-09


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

g01125043

Illustration 56

1. Install Tooling (A) and a suitable lifting device on flywheel (2). The weight of flywheel (2) is approximately 23 kg (50 lb).

g01152619

Illustratio n 55

1. Position the water temperature regulators in water temperature regulator housing (3). 2. Install a gasket and pipe (2) on water temperature regulator housing (3).

2. Remove top bolt (1). Install Tooling (B). Remove remaining bolts (1). 3. Remove fl ywheel (2) from Tooling (B). 4. Replace ring gear (3), if necessary. Use a hammer and a punch in order to remove the flywheel ring gear.

3. Install bolts (1).

i02230456

Flywheel - Install

4. Fill the cooling system. Refer to Operation and Maintenance - Change”. Manual, “Cooling System Coolant i02230441

Flywheel - Remove

SMCS Code: 1156-012


Required Tools

SMCS Code: 1156-011 Tool

Removal Procedure

A

Part N u m ber

Table 23

Required Tools Tool A B

Part N u mb er

P a rt De sc r ip t io n

138-7573LinkBracket

-

Guide Bolt (M12 X 1.75 by 120 mm)

Qty 2 1

P a r t D e s ciption r

138-7573LinkBracket

B

-

C

9S-3263

Qty 2

Guide Bolt (M12 X 1.75 by 120 mm)

1

Thread Lock Compound

1


RENR7458-09

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Use Tooling (A) to drill three evenly spaced holes in the crankshaft rear seal.

g01125043

Illustration 57

1. Raise the temperature of ring gear (3). Note: Do not use a torch to heat the ring gear. 2. Position ring gear (3) on fl ywheel (2) with the part number toward the crankshaft. Use a soft hammer in order to seat the ring gear against the shoulder of the fl ywheel. Allow the ring gear to cool. 3. Install Tooling (A) and a suitable lifting device on flywheel (2). The weight of flywheel (2) is approximately 23 kg (50 lb). 4. Position flywheel (2) on Tooling (B). g00989088

Illustration 58

5. Apply Tooling (C) to the threads of bolts (1). 6. Install bolts (1). Remove Tooling (B) and install remaining bolt (1). Tighten the bolts evenly to a torque of 120 ± 20 N·m (90 ± 15 lb ft).

2. Use Tooling (B) to remove crankshaft rear seal (1). i03171818

7. Check the flywheel runout. Refer to Testing and Adjusting, “Flywheel - Inspect”. i02230478

Crankshaft Rear Seal - Remove

Crankshaft Rear Seal - Install SMCS Code: 1161-012


SMCS Code: 1161-011

Required Tools

Removal Pr ocedure Table 25

Tool

Part N u mb e r

C

1U-7598

P a rt D es c r ip t io n Seal Installer Gp

Qty 1

Required Tools


Part Tool A B

N u mb e r

1U-8145DrillBit 1U-7600

P a rt De sc r ip t io n 1

Slide Hammer Puller

Qty 1

Start By: a. Remove the flywheel. Refer to Disassembly and Assembly, “Flywheel - Remove”.

Contaminants may cause rapid wear and shortened component life. 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:

RENR7458-09


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

•


The rear seal group app ears to be damaged.

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

Contaminants may cause rapid wear and shortened component life. NOTICE Care must be taken to ensure that fluids are contained during perform ance of inspection, maintenanc e, testing, adjusting and repair of the product. Be prepared to collect the fl uid with suitable containers before opening compar tment nentany containing fluids. or disassembling any compoRefer 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 fl uids according to local regulations and mandates.

g01125095

Illustration 59

1. Use Tooling (C) to install crankshaft rear seal (1). End By: a. Install the flywheel. Refer to Disassembly and Assembly, “Flywheel - Install”. i02230508

Flywheel Housing - Remove and Install

g00987190

Illustration 60

1. Fasten Tooling (A) and a suitable lifting device to fl ywheel housing (1). The weight of flywheel housing (1) is approximately 25 kg (55 lb).

SMCS Code: 1157-010

2. Remove bolts (2) and bolt (3). Remove bolts (4).

Removal Procedure

3. Remove bolts (5) that fasten the engine oil pan to flywheel housing (1). Remove flywheel housing (1).

Table 27


Part N u mb e r

Installation Procedure P a r t D e s c r i pt i o n

138-7573LinkBracket

Qty 2

Table 28

Required Tools

Start By: a. Remove the flywheel. Refer to Disassembly and Assembly, “Flywheel - Remove”.

Tool A B

Part N u mb e r

Pa r t D e s c ri pt i on

138-7573LinkBracket 1U-8846

Sealant

Qty 2 -


RENR7458-09

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Apply Tooling (B) to the entire mounting face of the fl ywheel housing prior to installation.

Illustration 62

Illustration 61

g00987190

g00991061

2. Remove bolts (2) and crankshaft vibration damper (1) from the crankshaft pulley.

2. Fasten Tooling (A) and a suitable lifting device to flywheel housing (1). The weight of flywheel housing (1) is approximately 25 kg (55 lb). Position the fl ywheel housing on the cylinder block. Install bolts (5) th at fasten the engine oil pan to the flywheel housing. 3. Install bolts (2) and bolt (3). Install bolts (4). 4. Check the flywheel housing runout. Refer to the Testing and Adjusting, “Flywheel Housing Inspect”. End By: a. Install the flywheel. Refer to Disassembly and Assembly, “Flywheel - Install”. i02230536

Vibration Damper and Pulley Remove and Install

Illustration 63

SMCS Code: 1205-010

4. Remove crankshaft pulley (5).

Removal Procedure 1. Remove the belts.

3. Remove bolts (3) and plate (4).

g00991062

RENR7458-09



i02230550

Crankshaft Front Seal Remove SMCS Code: 1160-011


Required Tools Tool

Part N u mb er

A

1U-7600

B

1U-8145DrillBit


Qty 1

Slide Hammer Puller 1

Start By:

Illustration 64

g00991062

1. Position crankshaft pulley (5) on the crankshaft. Position plate (4) and install bolts (3). Tighten bolts (3) to a torque of 200 ± 25 N·m (148 ± 18 lb ft).

a. Remove the vibration damper and the pulley. Refer to Disassembly and Assembly, “Vibration Damper and Pulley - Remove and Install”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 65

g00991061

2. Install crankshaft vibration damper (1). Tighten bolts (2) to a torque of 55 ± 10 N·m (40 ± 7 lb ft). 3. Install the belts.

Illustration 66

g00989224

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


RENR7458-09

i02230558

i02230581

Crankshaft Front Seal - Install

Front Cover - Remove

SMCS Code: 1160-012

SMCS Code: 1166-011


Removal Proced ure

Table 30

Start By: Required Tools

Tool

Part N u mb e r

C

1U-7430

P a rt De sc r ip t io n F ront Seal Installer

Qty

a. Remove the fan drive mounting group. Refer to Disassembly and Assembly, “Fan Drive Mounting Group - Remove and Install”.

1





g00991101

g00989228

Note: The crankshaft seal is designed to be installed dry. 1. Use Tooling (C) to install crankshaft front seal (1).

1. Remove bolts (2), (3), and (4). Remove fron t cover (1) and the gasket from the front housing. i02230634

Front Cover - Install

End By: SMCS Code: 1166-012 a. Install the vibration damper and the pulley. Refer to Disassembly and Assembly, “Vibration Damper and Pulley - Remove and Install”.


RENR7458-09


NOTICE Care must be taken to ensure that fluids are contained during perform ance of inspection, maintenanc e, testing, adjusting and repair of the product. Be prepared to collect the fl uid with suitable containers before opening any compar tment or disassembling any component 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 fl uids according to local regulations and mandates.

Illustration 69

g00991101

1. Position the gasket and front cover (1) on the front housing. Install bolts (2), (3), and (4) in front cover (1). End By: a. Install the fan drive mounting group. Refer to Disassembly and Assembly, “Fan Drive Mounting Group - Remove and Install”. i02230639

Housing (Front) - Remove SMCS Code: 1151-011

Removal Procedure Start By: a. Remove the camshaft . Refer to Disassembly and Assembly, “Camshaft - Remove”. b. Remove the unit injector hydraulic pump. Refer to Disassembly and Assembly, “Unit Injector Hydraulic Pump - Remove”. c. Remove the air compressor. Refer to Disassembly and Assembly, “Air Compressor - Remove and Install”.

Illustration 70

g00989343

1. Support the weight of the front of the engine. Remove bolts (1) and remove front engine support (2).


RENR7458-09

g01125215

Illustration 71

2. Remove bolts (3) and (5). Remove front housing (4). i02230647

Housing (Front) - Install

Illustration 72

g01125215

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 three to fi ve minutes.

SMCS Code: 1151-012

3. Apply Tooling (C) to the joint face. Spread the sealant uniformly. Front housing (4) must be installed within ten minutes of applying the sealant.


4. Position front housi ng (4) on the cylinder block .

Table 31

5. Install bolts (3) and (5). Required Tools

Tool

Part N u mb er

A

8T-9011

Component Cleaner

B

4C-9500

Q uick Cure Primer

C

1U-8846 Gasket Sealant

P a r t D es c r ip t ion

Qty 1 1 1

Illustration 73

g00989343

6. Position front engine support (2) and install bolts (1).

RENR7458-09


End By:

3. Remove bolt (7) and idler shaft (3) from the cylinder block. Remove thrust plate (5).

a. Install the air compressor. Refer to Disassembly and Assembly, “Air Compressor - Remove and Install”. b. Install the unit injector hydraulic pump. Refer to Disassembly and Assembly, “Unit Injector Hydraulic Pump - Install”.

4. Use Tooling (A) and a suitable press to remove bearing (6) fr om camshaft idler gear (2).


Required Tools

c. Install the ca mshaft. Refer to Disassembly and Assembly, “Camshaft - Install”. Tool i02230724

Camshaft Idler Gear - Remove and Install SMCS Code: 1206-010

A

Part N u mb e r

P a r t D e s c r i pt i o n

1P-0520DriverGroup

Qty 1



Required Tools Tool

Part N u mb e r

A

1P-0520

P a r t D e s c r ip t i o n Driver Group

Q ty 1

Start By: a. Remove the front housing. Refer-to Disassembly and Assembly, “Housing (Front) Remove”. NOTICE Keep all parts clean from contaminants.

Illustration 75


g01125304

1. Use Tooling (A) and a suitable press to install bearing (6) in camshaft idler gear (2). Install the bearing until the bearing is 1.080 ± 0.250 mm (0.0425 ± 0.0098 inch) below the front face of camshaft idler gear (2). 2. Position thrust plate (5) and idler shaft (3) on the cylinder block. Install bolt (7). Tighten the bolt to a torque of 70 ± 15 N·m (51 ± 11 lb ft). 3. Install camshaft idler gear (2) on idler shaft (3). Ensure that timing mark (8) is facing outward. Align timing mark (8) with timing mark (9) on crankshaft drive gear (10). 4. Position plate (1) and install bolts (4). Tighten the bolts to a torque of 70 ± 15 N·m (51 ± 11 lb ft).

Illustration 74

1. Remove bolts (4) and retaining plate (1). 2. Remove camshaft idler gear (2).

g01125301

End By: a. Install the front housing. Refer to Disassemb ly and Assembly, “Housing (Front) - Install”.


RENR7458-09

i02230894

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

Removal Procedure NOTICE Keep all parts clean from contaminants. Contaminants component life.m ay cause rapid wear and shortened Illustration 78

g00945775

1. Position valve mechanism cover (2) on the engine. 2. Install bolts (1). Tighten bolts (1) in a numerical sequence to a torque of 15 ± 3 N·m (11 ± 2 lb ft). i02231006

Valve Mechanism Cover Base Remove and Install SMCS Code: 1120-010 Illustration 76

g01125461

Removal Pro cedure

1. Remove bolts (1).

Start By:

2. Remove valve mechanism cover (2).

a. Remove the valve mechanism cover. Refer to Disassembly and Assembly, “Valve Mechanism Cover - Rem ove and Install”.




Contaminants may cause rapid wear and shortened component life. 1. Disconnect the harness assembly from the valve mechanism cover base.

Illustration 77

g01125461

Illustration 79

g01125477

RENR7458-09


2. Disconnect harness assemblies (1).

i02231087

3. Remove bolts (2) and valve mechanism cover base (3) from the cylinder head.

Rocker Shaft and Pushrod Remove


SMCS Code: 1102-011; 1208-011

Removal Procedure Start By: a. Remove the valve mechanism cover. Refer to Disassembly and Assembly, “Valve Mechanism Cover - Remove and Install”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Illustration 80

g01125477

1. Put identi fication marks on each rocker arm and on each pushrod in order to identify the proper location in the engine for installation.

Illustration 81

g01127431

1. Position valve mechanism cover base (3) on the cylinder head. Install bolts (2) and tighten bolts (2) in a numerical sequence. 2. Connect harness assemblies (1). 3. Connect the harness assembly to the valve mechanism cover base. Illustration 82

g00987758

End By: 2. Loosen all rocker arm adjustment screws (4). a. Install the valve mechanism cover. Refer to Disassembly and Assembly, “Valve Mechanism Cover - Remove and Install”.

3. Remove bolts (1), bolts (2), and rocker shaft (3).


RENR7458-09

Personal injury can result from parts and/or covers under spring pressur e. Spring force will be released when covers are removed. Be prepared to hold spring loaded covers as the bolts are loosened. Note: Place an identi fication mark on each of the components purposes. of the rocker shaft for installation 1. Remove retaining ring (2). 2. Remove stand (3), inlet rocker arms (4), exhaust rocker arms (5), stands (6), and springs (7) from the rocker shaft. Illustration 83

g00987759

4. Remove inlet valve bridge s (5) and pushrods (6).

3. Remove dowel pin (8) and stand (9) from the rocker shaft. 4. Remove plug (1).

i02307337

Rocker Shaft - Disassemble

i02307338

Rocker Shaft - Assemble

SMCS Code: 1102-015


SMCS Code: 1102-016

Start By:

Assembly Procedure

a. Remove the rocker shaft. Refer to Disassembly and Assembly, “Rocker Shaft and Pushrod Remove”.

NOTICE Keep all par ts clean from contaminants. Contaminants may cause rapid wear and shortened component l ife.


Illustration 84

g01155738

1. Lubricate all of the components of the rocker shaft with clean engine oil.

Illustration 85

g01155738

RENR7458-09


Improper assembly of parts that are spring loade d can cause bodily injury . To prevent possible injury, follow the established assembly procedure and wear protective equipment. 2. Install plug (1). 3. Install stand (9) and dowel pin (8) on the rocker shaft. 4. Install spring s (7), stands (6), exhaust rocker arms (5), inlet rocker arms (4), and stand (3) on the rocker shaft. 5. Install retaining ring (2). End By:

Illustration 86

a. Install the rocker shaft. Refer to Disassembly and Assembly, “Rocker Shaft and Pushrod - Install”.

1. Apply Tooling (A) to both ends of pushrods (6).

i02231166

g00987759

2. Lubricate pushrods (6) with clean engine oil. Install pushrods (6) and inlet valve bridges (5).

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



Part Nu mber

P a r t D e s c rption i

8T-2998 Lubricant

Qty 1


Illustration 87

g00987758

3. Position rocker shaft (3). Install bolts (1) and (2). Finger tighten bolts (1) and (2). Tighten bolts (2) to a torque of 100 ± 20 N·m (74 ± 15 lb ft). Tighten bolts (1) to a torque of 28 ± 7 N·m (21 ± 5 lb ft). 4. Apply Tooling (A) to each of the button faces of the rocker arms. 5. Adjust the valve lash of the rocker arm by turning rocker arm adjustment screws (4). Refer to Testing and Adjusting, “Engine Valve Lash Inspect/Adjust”.


RENR7458-09

End By: a. Install the valve mechanism cover. Refer to Disassembly and Assembly, “Valve Mechanism Cover - Remove and Install”. i02231291

Cylinder Head - Remove SMCS Code: 1100-011

Removal Procedure

g01125661

Start By:

Illustration 88

a. Remove the val ve mechanism cover base. Refer to Disassembly and Assembly, “Valve Mechanism Cover Base - Remove and Install”.

1. Disconnect harness assembly (1), harness assembly (2), harness assembly (3), and harness assembly (4).

b. Remove the rocker shaft and pushrods. Refer to Disassembly and Assembly, “Rocker Shaft And Pushrod - Rem ove”.

2. Remove tube assembly (7).

c. Remove the unit injectors. Refer to Disassembly and Assembly, “Unit Injector - Remove”.

4. Disconnect harness assembly (5).

3. Disconnect hose (6).

d. Remove the fan drive mounting group. Refer to Disassembly and Assembly, “Fan Drive Mounting Group - 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 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 Publicat ion, NENG2500, “Caterpillar Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fl uids according to local regulations and mandates.

Illustration 89

g01125664

5. Remove tube assembly (8) and tube assembly (9).

RENR7458-09


i02231335

Cylinder Head - Install SMCS Code: 1100-012


Required Tools Tool

Part N u mb e r


A

6V-4876 Lubricant

B

4C-5590

n Ati-Seize Compound

Qty

1 1

NOTICE Keep all parts clean from contaminants. Illustration 90

g01125672


6. Disconnect tube assembly (10) and tube assembly (12) from turbocharger (11).

1. Install a new cylinder head gasket.

7. Attach a suitable lifting device to the cylinder head. The weight of the cylinder head is approximately 175 kg (385 lb).

Note: To avoid damage to the cylinder head gasket, use guide bolts of an appropriate size to install the cylinder head. 2. Attach a suitable lifting device to the cylinder head. The weight of the cylinder head is approximately 175 kg (385 lb). Position the cylinder head assembly onto the cylinder block.

Illustration 91

g01125676

8. Remove bolts (13) and bolts (14). Remove the cylinder head and the gasket from the cylinder block. Illustration 92

g01125676


Illustration 93

RENR7458-09

g01125720

3. Apply Tooling (A) to the threads and both sides of the washers of bolts (13). Apply Tooling (B) to the threads and both sides of the washers of bolts (14). Install bolts (13) and bolts (14). 4. Tighten the cylinder head bolts according to the following procedure: a. Tighten Bolt (1) through Bolt (14) in a numerical sequence to a torque of 300 ± 15 N·m (221 ± 11 lb ft).

Illustration 94

g01125672

5. Connect tube assembly (10) and tube assembly (12) onto turbocharger (11).

b. Loosen Bolt (1) through Bolt (14) until the washers are loose under the bolt heads. c. Tighten Bolt (1) through Bolt (14) again in a numerical sequence to a torque of 130 ± 15 N·m (95 ± 11 lb ft). d. Again tighten Bolt (1) through Bolt (14) in a numerical sequence to a torque of 130 ± 15 N·m (95 ± 11 lb ft). e. Turn Bolt (1) through Bolt (14) in a numerical sequence for an additional 90° (1/4 turn). f. Tighten Bolt (15) throug h Bolt (20) in a numerical sequence to a torque of 55 ± 7 N·m (41 ± 5 lb ft). Illustration 95

g01125664

6. Install tube assemb ly (8) and tube assembly (9).

RENR7458-09


c. Remove the unit injector hydraulic pump. Refer to Disassembly and Assembly, “Unit Injector Hydraulic Pump - Remove”. d. Remove the air compressor. Refer to Disassembly and Assembly, “Air Compressor - Remove and Install”. e. Remove the speed/timing sensors. Refer to Disassembly and Assembly, “Speed/Timing Sensor - Remo ve and Install”. f. Remove the engine control module (ECM ). Refer Illustration 96

g01125661

to Disassembly and Assembly, Module - Remove and Install”. “Engine Control NOTICE Keep all parts clean from contaminants.

7. Connect harness assembly (5). 8. Connect hose (6).


9. Install tube assembly (7). 10. Connect harness assembly (1), harness assembly (2), harness assembly (3), and harness assembly (4). End By: a. Install the fan drive mounting group. Refer to Disassembly and Assembly, “Fan Drive Mounting Group - Remove and Install”. b. Install the unit injectors . Refer to Disassembly and Assembly, “Unit Injector - Install”. c. Install the rocker shaft and pushrods. Refer to Disassembly and Assembly, “Rocker Shaft And Pushrod - Install”.

Illustration 97

g01125745

1. Remove bolts (1). d. Install the valve mechanism cover base. Refer to Disassembly and Assembly, “Valve Mechanism Cover Base - Remove and Install”.

2. Remove side covers (2).

i02231540

Lifter Group - Remove and Install SMCS Code: 1209-010

Removal Procedure Start By: a. Remove the fuel fi lter base. Refer to Disassembly and Assembly, “Fuel Filter Base - Remove and Install”. b. Remove the rocker arms and pushrods. Refer to Disassembly and Assembly, “Rocker Shaft and Pushrod - Remove”.

Illustration 98

g01125748

3. Place ide ntification marks on each lifter in order to identify the proper location on the side cover for installation.


RENR7458-09

Note: Ensure that the sleeves of the side covers remain in the si de covers. 4. Remove bolts (3) and the dowels that hold lifter arms (4) and li fter shaft (5) to each side cover. Remove seal (6).


Required Tools Part Tool A

Nu mb e r 9S-3263

P a r t D e s c r i pion t Thread Lock Compound

Qty 1

Illustration 100

g01125745

5. Position the gaskets and side covers (2). Install bolts (1).


End By: a. Install the engine control module (ECM). Refer to Disassembly and Assembly, “Engine Control Module - Remove and Install”. b. Install the speed/timing sensors. Refer to Disassembly and Assembly, “Speed/Timing Sensor - Remove and Install”. c. Install the air compressor. Refer to Disassembly and Assembly, “Air Compressor - Remove and Install”. d. Install the unit injector hydraulic pump. Refer to Disassembly and Assembly, “Unit Injector Hydraulic Pump - Install”.

Illustration 99

g01125748

1. Install seal (6). 2. Install lifter arms (4) on lifter shaft (5). 3. Position lifter shaft (5) over the dowels on the side cover. Ensure that the oil holes in the lifter shaft are facing the side cover. Apply Tooling (A) on the threads of bolts (3) that hold lifter shaft (5) to the side cover. Install bolts (3). Tighten bolts (3) to a torque of 13 ± 3 N·m (10 ± 2 lb ft). Tighten the two center bolts. Then tighten the end bolts. 4. Lubricate the lifters with clean engine oil.

e. Install the rocker arms and pushrods. Refer to Disassembly and Assembly, “Rocker Shaft and Pushrod - Install”. f. Install the fuel fi lter base. Refer to Disassembly and Assembly, “Fuel Filter Base - Remove and Install”.

RENR7458-09


i02231590

Camshaft - Remove SMCS Code: 1210-011


Required Tools Part N u mb er

Tool A

P a r t D e s cr i pt i on

136-4632 TimingPin 139-7063

B

Q ty 1

Timing Pin Adap ter

FT-2730 Puller

1 12

Start By: a. Remove the vibration damper and the pulley. Refer to Disassembly and Assembly, “Vibration Damper and Pul ley - Remove and Install”. b. Remove the rocker arms and the pushrods. Refer to Disassembly and Assembly, “Rocker Shaft and Pushrod - Remove”. c. Remove the fr ont cover. Refer to Disassembly and Assembly, “Front Cover - Remove”.

Illustration 101

g01125899

4. Rotate camshaft gear (1) in order to access bolts (2). Remove bolts (2). 5. Remove thrust plate (3). 6. Remove camshaft (4) from the cylinder block. i02232349

NOTICE Keep all part s clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Use Tooling (B) to reposition the valve lifters out of the way. 2. Ensure that the No. 1 cylinder is at the top center compressi on stroke. Refer to Testing and Adjusting, “Finding Top Center Position for No. 1 Piston”. Install Tooling (A) in the flywheel. 3. Ensure that the timing marks on the following gears are aligned: the camshaft drive gear, the idler gear, and the crankshaft gear.

Camshaft - Install SMCS Code: 1210-012



RENR7458-09

i02235225

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

Removal Procedure Start By: a. Remove the camshaft. Refer to Disassembly and Assembly, “Camshaft - Remove”. 1. Wrap the camshaft with a protective covering in order to preve nt damage to the camshaft.

Illustration 102

g01125899

1. Carefully install camshaf t (4) in the cylinder block. 2. Install thrust plate (3). 3. If necessary, rotate camshaft gear (1) in order to access thrust plate (3). Install bolts (2). 4. Ensure that the No. 1 cylinder is at the top center compressi on stroke. Refer to Testing and Adjusting, “Finding Top Center Position for No. 1 Piston”. 5. Ensure that the timing marks on the following gears are aligned: the camshaft drive gear, the idler gear, and the crankshaft gear. End By: a. Install the front cover. Refer to Disassembly and Assembly, “Front Cover - Install”.

Illustration 103

g00987675

NOTICE floor when Do not allow t he camshaft to fall to the pressing it from the drive gear. Also make sure that the camshaft lobes do not catch on the press plates. 2. Place the camshaft assembly in a suitable press. Press camshaft (2) from camshaft gear (1). 3. If necessary, remove key (3) from the camshaft.

b. Install the rocker arms and the pushrods. Refer to Disassembly and Assembly, “Rocker Shaft and Pushrod - Install”.


c. Install the vibration damper and the pulley. Refer to Disassembly and Assembly, “Vibration Damper and Pulley - Remove and Install”.

Note: Do not use a torch to heat the camshaft gear.

1. Raise the temperature of the camshaft gear.

RENR7458-09


g00987675

Illustration 104

2. Align key (3) in the camshaft with the groove (keyway) in the camshaft gear. 3. Install camshaft gear (1) on the end of camshaft (2).

g00989974

Illustration 105

1. Use Tooling (A) to remove camshaft bearing (1) from the front of the cylinder block. Remove the remaining camshaft bearings (2) from the cylinder block.


End By:

Table 39

a. Install the camshaft. Refer to Disassembly and Assembly, “Camshaft - Install”.

Required Tools

i02232381

Camshaft Be arings - Remove and Install

Tool

Part N u m be r

A

8S-2241

P ar t D e s c r ip t io n Camshaft Bearing Tool Group

Qt y 1


SMCS Code: 1211-010

Removal Pr ocedure


Table 38


Part N u mb er 8S-2241

P a r t D es c r ipt i o n Camshaft Bearing Tool Group

Qt y 1

Start By: a. Remove the camshaft . Refer to Disassembly and Assembly, “Camshaft - Remove”. NOTICE Keep all parts clean from contaminants.

g00990062

Illustration 106

Contaminants may cause rapid wear and shortened component life. Note: Note the oil hole orientation in each camshaft bearing prior to removal for assembly purposes.

1. Use Tooling (A) to install all of the camshaft bearings (2) except for the front camshaft bearing. Locate the oil hole in each bearing so that oil hole (3) is located at the top of the bore. Refer to Specifications for more information.


RENR7458-09

1. Drain the engine oil into a suitable container for storage or d isposal. Refer to Operation and Maintenance Manual for the correct procedure.

Illustration 107

g00989938

2. Use Tooling (A) to install front camshaft bearing (1). Align oil hole (5) in the front camshaft bearing with the oil hole in the cylinder block. Locate joint (4) in the front camshaft bearing in the proper position. Refer to Speci fications for more information. End By: Illustration 108

a. Install the camshaft. Refer to Disassembly and Assembly, “Camshaft - Install”.

g00987883

Note: Do not pry or gouge the sealing surface of the engine oil pan. Use a rubber mallet to tap lightly on the engine oil pan, if it is necessary.

i02232558

Engine Oil Pan - Remove and Install SMCS Code: 1302-010

2. Remove bolts (2). Remove engine oil pan (1) and the gasket.


Removal Procedure




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 disassembling any component cont aining fluids. Refer to Special Publicat ion, NENG2500, “Caterpillar Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fl uids according to local regulations and mandates.

RENR7458-09


5. Fill the engine with oil to the correct level. Refer to Operation an d Maintenance Manual for the correct filling procedure. i02232665

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

Removal Procedure Start By: a. Remove the engine oil pump. Refer to Disassembly and Assembly, “Engine Oil Pump - Remove”.

Illustration 109

g00987883


Illustration 111

Illustration 110

g00987889

g00987444

1. Remove bol t (2) and piston cooling jet (1) from each cylinder.

Note: Do not put liquid gasket material on the oil pan gasket or on the gasket surface of engine oil pan (1).


1. Position a new gasket and engine oil pan (1) on the cylinder block.


2. Install bolts (2). Tighten Bolts (X) to a torque of 31 ± 3 N·m (23 ± 2 lb ft).


3. Start at Position (Z) and tighten the remaining bolts (2) in a counterclockwise direction. Tighten the remaining bolts (2) to a torque of 31 ± 3 N·m (23 ± 2 l b ft). 4. Start at Position (Z) and tighten bolts (2) again in a counterclockwise direction . Tighten bolts (2) to a torque of 31 ± 3 N·m (23 ± 2 lb ft).


Illustration 112

RENR7458-09

g00987444

1. Position piston cooling jet (1) in the cylinder block. Install bolt (2). Tighten bolt (2) to a torque of 28 ± 7 N·m (21 ± 5 lb ft). End By:

Illustration 113

a. Install the engine oil pump. Refer to Disassembly and Assembly, “Engine Oil Pump - Install”. i02232678

Pistons and Connecting Rods - Remove

g01126088

1. Turn the cranksha ft until the connecting rod caps are at the bottom center. 2. Place a identi fication mark on the connecting rod and connecting rod cap (2). The number should match the cylinder number. 3. Remove bolts (1) and connecting rod cap (2).

SMCS Code: 1225-011

Removal Procedure Start By: 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”. NOTICE Keep all p arts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 114

g01126089

4. Remove the lower half of connecting rod bearing (4) from connecting rod cap (2). 5. Push the piston and the connecting rod away from the crankshaft. Remove the upper half of connecting rod bearing (4) from connecting rod (3). 6. Remove the piston and connecting rod (3) from the cylinder block.

RENR7458-09


i02232839

i02233056

Pistons and Connecting Rods - Disassemble

Pistons and Connecting Rods - Assemble

SMCS Code: 1225-015

SMCS Code: 1225-016


Assembly Procedure

Table 40

Table 41

Required Tools

Required Tools

Tool

Part N u mb er

Tool

Part N u mb er

A

4C-3601

Piston Ring Expander

1

A

4C-3601

Piston Ring Expander

1

B

1P-1861

Retaining Ring Pliers

1

B

1P-1861

Re taining Ring Pliers

1

5P-8639

Hydraulic Press (CONNECTING ROD BEARING)


Qty

Start By: a. Remove the pis tons and the connecting rods. Refer to Disassembly and Assembly, “Pistons and Connecting Rods - Remove”.

8F-0024Hose As

C


Qty

1 1

1P-2375

Quick Connect Coupler

1

1P-2376

Quick Connect Coupler

1

4C-9751



1

Spacer

4C-9749

Bushing Adapter

1

4C-9750

Bushing Adapter

1

9U-6600

Hand Hydraulic Pump

1

Note: Prior to removal from the engine, the pistons and connecting rod assemblies were marked. The components must be reassembled together. The components must be installed in the srcinal location in the engine. Do not interchange any of the components. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Illustration 115

g01126141

1. Use Tooling (B) to remove retainin g ring (2). 2. Remove piston pin (5) and separate piston (1) from connecting rod (3). 3. Use Tooling (A) to remove piston rings (4).


RENR7458-09

Illustration 118

g01126141

2. Use the following procedure to install piston rings (4).

Illustration 116

g01126305

a. Position the spring for the oil control ring in the oil ring groove in the piston body assembly. b. Position the oil control ring over the spring. Position the oil control ring so that the gap is 180 degrees from the joint in the spring. Use Tooling (A) to install the oil control ring on the piston. c. Use Tooling (A) to install the intermediate piston ring with the side that has the identi fication “UP-2” toward the top of the piston. d. Use Tooling (A) to install the top piston ring with the side that has the identi fication “UP-1” toward the top of the piston.

Illustration 117

g01126306

1. Use Tooling (C) to remove the old bearing and install the new bearing (6) at the same time. The adapter of Tooling (C) should make full contact with the surfaces of connecting rod (3). Note: Orient the bearing joint within 12 ± 5 degrees of either Location (X). NOTICE The connecting rod must be heated for the installation of the piston pin bearing. Do not use a torch. a. Raise the temperature of connecting rod (3) along Length (Y).

e. Position piston rings (4) so the gaps are 120 degrees from each other. 3. Check the clearance between the ends of piston rings (4). Refer to Speci fications, “Piston And Rings”. 4. Position piston (1) on connecting rod (3). Apply clean engine oil to piston pin (5) and install the piston pin. Use Tooling (B) to install retaining ring (2). Make sure that the retaining rings are fully seated in the grooves of the piston assembly. End By: a. Install the pistons and the connecting rods. Refer to Disassembly and Assembly, “Pistons and Connecting Rods - Install”.

(Y) Maximum Length for heating the connecting rod .. 75 ± 5 mm (3.0 ± 0.2 inch ) b. Allow the connecting rod and the bearing to cool to room temperature.

RENR7458-09


i02233160

Pistons and Connecting Rods - Install

4. Line up the piston and the connecting rod with the crankshaft. Use a soft faced hammer and tap the piston into the cylinder bore until Tooling (A) comes off of the piston.

SMCS Code: 1225-012


Required Tools Tool

Part Nu mber

A

173-5529

B

4C-5593


Qty

Piston Ring Compressor

1

Anti-Seize Compound

1


Illustration 120

g01126089

Illustration 121

g01126088

Contaminants may cause rapid wear and shortened component life. 1. Apply clean engine oil to the pistons, the piston rings, and the cylinder bore.

Illustration 119

g00954373

2. Position the piston rings so that the end gaps are located 120 degrees from each other. Install Tooling (A) in order to compress the piston rings. Note: Install the piston and connecting rod so that the forgin g number on the connecting rod points toward the fl ywheel end of the engine. 3. With the nu mber one crankshaft throw at the bottom center, install the piston and connecting rod in the engine. Ensure that the proper piston and connec ting rod are in the corresponding cylinder with the bearing retainer notch toward the right side of the engine.

5. Before connecting rod (3) comes in contact with the crankshaft, install the upper half of connecting rod bearing (4). Ensure that the bearing tab engages with the slot in connecting rod (3). 6. Apply clean engine oil to the surface of the upper half of connecting rod bearing (4). Use a soft faced hammer in order to tap the piston into the cylinder bore while you guide connecting rod (3) onto the crankshaft. 7. Place the lower half of connecting rod bearing (4) in corresponding connecting rod cap (2). Ensure that the bearing tab engages with the groove in connecting rod cap (2).


RENR7458-09

8. Apply clean engine oil to the surface of the lower half of co nnecting rod bearing (4). Install connecting rod bearing cap (2) on connecting rod (3). Ensure that the number on connecting rod cap (2) matches th e number on connecting rod (3). Ensure that the numbers are on the same side. 9. Lubricate th e new connecting rod bolts with Tooling (B). 10. Install new b olts (1). Tighten bolts (1) to a torque of 70 ± 5 N·m (52 ± 4 lb ft). 11.bolt Place x mark on120 each bolt. Tighten each (1)an forinde an additional ±5 degrees (1/3 turn). End By: a. Install the piston cooling jets. Refer to the Disassembly and Assembly Manual, “Piston Cooling Jets - Remove and Install”. b. Install the engine oil pump. Refer to the Disassembly and Assembly Manual, “Engine Oil Pump - Install”. c. Install the cylinder head. Refer to the Disassembly and Assembly Manual, “Cylinder Head - Install”. i02233237

Connecting Rod Bearings Remove

SMCS Code: 1219-011

Removal Procedure Start By: a. Remove the engine oil pump. Refer to Disassembly and Assembly, “Engine Oil Pump - Remove”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 122

g01126410

1. Turn the crankshaft until the connecting rod bearing caps are accessible. 2. Place an identi fication mark on connecting rod (3) and connecting rod bearing cap (2). The number should match the cylinder number. 3. Remove bolts (1) and connecting rod bearing cap (2) from connecting rod (3). Remove the lower half of connecting rod bearing (4) from connecting rod bearing cap (2). 4. Push the connecting rod away from the crankshaft. Remove the upper half of connecting rod bearing (4) from connecting rod (3).

i02307308

Connecting Rod Bearings Install SMCS Code: 1219-012


RENR7458-09


i02304516

Crankshaft Main Bearings Remove SMCS Code: 1203-011


Required Tools

Illustration 123

g01126410

Note: Install the connecting rod bearings dry when clearance checks are performed. Refer to Disassembly and Assembly, “Bearing Clearance Check”. Apply clean engine oil on the connecting rod bearings for final assembly. 1. Install a new lower half of connecting rod bearing (4) in connecting rod bearing cap (2). 2. Install a new upper half of connecting rod bearing (4) in connecting rod (3).

Tool

Part N u mb e r

A

2P-5518


Qty

Main Bearing Tool

1

Start By: a. Remove the engine oil pump. Refer to Disassembly and Assembly, “Engine Oil Pump - Remove”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

3. Pull connecting rod (3) onto the crankshaft. 4. Install connecting rod bearing cap (2) and bolts (1). Ensure that the number on the side of connecting rod bearing cap (2) is on the same side as the number on connecting rod (3). 5. Tighten bolts (1) to a torque of 70 ± 5 N·m (52 ± 4 lb ft). 6. Place an index mark on each bolt. Tighten each bolt (1) for an additional 120 ± 5 degrees (1/3 turn). End By: a. Install the engine oil pump. Refer to Disassembly and Assembly, “Engine Oil Pump - Install”.

Illustration 124

g00988316

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).


RENR7458-09

i02307306

Crankshaft Main Bearings Install SMCS Code: 1203-012


Required Tools Tool

Part N u mb er

A

2P-5518

M ain Bearing Tool

1

B

8T-5096

D ial Indicator Group

1

P a r t D e s c r ipion t

Qty

NOTICE Keep all parts clean from contaminants. Illustration 125

g00988318

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. 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).

Contaminants may cause rapid wear and shortened component life. Note: Install the crankshaft main bearings dry when clearance checks are performed. Refer to Disassembly and Assembly, “Bearing Clearance Check”. Apply clean engine oil on the crankshaft main bearings for fi nal assembly. Note: 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.

b. Turn the crankshaft in order to remove the upper half of the crankshaft main bearing. Tooling (A) must first contact the crankshaft main bearing opposite the tab end 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, SEBF8009, “Main and Connecting Rod Bearings” or refer to the Guideline For Reusable Parts, SEBV0544, “Engine Bearings and Crankshafts”.

Illustration 126

g00988318

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

RENR7458-09


i02236686

Crankshaft - Remove SMCS Code: 1202-011

Removal Proced ure Start By: a. Remove the connecting rod bearings. Refer to Disassembly and Assembly, “Connecting Rod Bearings - Rem ove”. b. Remove the front housing. Refer to Disassembly and Assembly, “Housing (Front) - Remove”. c. Remove the flywheel housing. Refer to Disassembly and Assembly, “Flywheel Housing - Remove and Install”. Illustration 127

g00988316

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


NOTICE Crankshaft main bearing caps sho uld be installed with the part number toward the right side of the engine. Crankshaft main bearing caps are to be identi fied 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. Place crankshaft main bearing caps (2) in position on the cylinder block. Apply clean engine oil or Molylube on the bolt threads and on the washer face. Install bolts (1). 4. 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). 5. Check the end play of the crankshaft with Tooling (B). The end play must be 0.07 to 0.32 mm (0.003 to 0.013 inch).

Illustration 128

End By:

1. Remove bolts (2) and main bearing caps (3).

a. Install the engine oil pump. Refer to Disassembly

2. Attach a suitable lifting device to each end of

and Assembly, “Engine Oil Pump - Install”.

g01128041

crankshaft (1). 62 The of crankshaft (1) is approximately kgweight (137 lb). Carefully remove crankshaft (1) from the cylinder block. 3. Remove the main bearings from the cylinder block. Remove the main bearings from the main bearing caps.


RENR7458-09

i02236693

Crankshaft - Install SMCS Code: 1202-012


Required Tools Tool

Part N u m be r

A

8T-5096

P ar t D es c r ip t ion Dial Indicator Group

Qty 1

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Illustration 129

NOTICE Ensure that the crankshaft main bearing tabs engage with the grooves in the block and the crankshaft main bearing cap. 1. Check the condition of the main bearings. Refer to Guideline For Reusable Parts, SEBF8009, “Main and Connecting Rod Bearings” or refer to Guideline For Reusable Parts, SEBV0544, “Engine Bearings and Crankshafts”. Note: The number six main bearing is the thrust bearing. 2. Clean the bearing surfaces in the cylinder block for the main bearings. Apply clean engine oil on the upper main bearing. Do not put engine oil on the back side of the bearing surfaces. Install the upper main bearing in the cylinder block. Ensure that the tab on the back side of the bearing engages with the groove in the cylinder block.

g01128041

3. Put clean engine oil on the journals of the crankshaft bearing. Attach a suitable lifting device onto crankshaft (1). The weight of crankshaft (1) is approximately 62 kg (136 lb). Align the identification marks on the gear train. Carefully install crankshaft (1) in the cylinder block. 4. Clean the bearing surface of the main bearing caps. Install the lower main bearing in the crankshaft main bearing caps. 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. 5. 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. 6. Install bolts (2) for main bearing caps (3). Tighten bolts (2) to a torque of 54 ± 7 N·m (40 ± 5 lb ft). 7. Turn bolts (2) for an additional 90 ± 5 degrees (1/4 turn). 8. Check the end play of crankshaft (1) with Tooling (A). The end play must be 0.07 mm to 0.32 mm (0.003 inch to 0.013 inch).

RENR7458-09


End By: a. Install the fl ywheel housing. Refer to Disassembly and Assembly, “Flywheel Housing - Remove and Install”. b. Install the front housing. Refer to Disassembly and Assembly, “Housing (Front) - Install”. c. Install the connecting rod bearings. Refer to Disassembly and Assembly, “Connecting Rod Bearings - Install”. i02307746

Crankshaft Gear - Remove and Install SMCS Code: 1204-010-GE g00988783

Removal Procedure

Illustration 130

Table 46

1. Use Tooling (A) in order to remove crankshaft gear (3) from crankshaft (1).


Tool

8B-7551 8B-7549 3H-0465


Qty

Bearing Puller


1

PullerLeg

2. Remove woodruff key (2) from crankshaft (1).

2

Push-Puller Plate


4

6B-6682

A

8B-7560 1P-0820 9U-6600

FullNut Step Plate Hydraulic Puller Hand Hydraulic Pump

2

1


1 1

Start By: a. Remove the cranksha ft. Refer to Disassembly and Assembly, “Crankshaft - Remove”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 131

g00988783


RENR7458-09

Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin. 1. Position woodruff key (2) in crankshaft (1). 2. Raise the temperature of crankshaft gear (3). Install crankshaft gear (3) on crankshaft (1).

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.

End By: a. Install the crankshaft. Refer to Disassembly and Assembly, “Crankshaft - Install”.

The technician must be very careful to use Tooling (A) correctly. The following points must be remembered: i02717761

• Ensure that the backs of the bearings and the

Bearing Clearance - Check

bores are clean and dry.

SMCS Code: 1203-535; 1219-535

•

Measurement Procedure

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

• The crankshaft must be free of oil at the contact

Table 47

points of Tooling (A).

Required Tools Tool

Part N u mb e r 198-9142

198-9143

A

198-9144

198-9145

P ar t De s c r ip t io n

Qty

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.

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

1

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

1

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

1

Note: Do no t turn the crankshaft when Tooling (A) is installed.

Plastic Gauge (Yellow) 0.230 to 0. 510 mm (0.009 to 0.020 inch)

1

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 132.

Note: Plastic gauge may not be necessary when the engine is i n the chassis. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 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.

2. Use the correct torque-turn speci fications 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.

RENR7458-09


Illustration 133

g01128083

(1) Atmospheric pressure sensor ............ 10 ± 2 N·m (90 ± 18 lb in) Illustration 132

g01152855 i02237408

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 speci fication range. Refer to Speci fications Manual, “Connecting Rod Bearing Journal” and Specifications Manual, “Main Bearing Journal” for the correct clearances. i02236791

Atmospheric Pressure Sensor - Remove and Install SMCS Code: 1923-010 NOTICE Keep all parts clean from contaminants.

Coolant Temperature Sensor Remove and Install SMCS Code: 1906-010 NOTICE Care must be taken to ensure that fluids are contained during perf ormance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fl uid with suitable containers before opening any com partment or disassembling any component containing fluids. Refer to Sp ecial Publication, NENG2500, “Caterpillar Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fl uids according to local regulations and mandates.


Illustration 134

g01128268

(1) Coolant temperature sensor .............. 20 ± 5 N·m (15 ± 4 lb ft)


RENR7458-09

i02236802

i02236851

Engine Oil Pressure Sensor Remove and Install

Injection Actuation Pressure Sensor - Remove and Install

SMCS Code: 1924-010

SMCS Code: 1925-010

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 compar tment or disassembling any component containing fluids.

NOTICE Care must be taken to ensure that fluids are contained during perfor mance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fl uid with suitable containers before opening any compar tment or disassembling any component 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.

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.



Illustration 135

g01128091

(1) Engine oil pressure sensor ................ 10 ± 2 N·m (90 ± 18 lb in)

Illustration 136

g01128104

(1) Injection actuation pressure sensor ... 20 ± 2 N·m (15 ± 1.5 lb ft) i02237012

Speed/Timing Sensor Remove and Install SMCS Code: 1907-010; 1912-010 NOTICE Keep all p arts clean from contaminants . Contaminants may cause rapid wear and shortened component life.

RENR7458-09

Illustration 137


g01128114

Note: The speed/timing sensors must be replaced as a pair.

Illustration 138

g01128200

(1) Boost pressure sensor ....................... 10 ± 2 N·m (90 ± 18 lb in)

(1) Torque for bolt ................ 28 ± 7 N·m (21 ± 5 lb ft) i02237329 i02237316

Boost Pressure Sensor Remove and Install SMCS Code: 1917-010 NOTICE Keep all parts clean from contaminants.

Inlet Air Temperature Sensor Remove and Install SMCS Code: 1921-010 NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.


Illustration 139

g01128213


RENR7458-09

(1) Inlet air temperatu re sensor ............... 20 ± 5 N·m (15 ± 4 lb ft)

Two-Piece Fan Drive Mounting (If Equipped)

i02237494

Fan Drive Mounting Group Remove and Install SMCS Code: 1359-010

Removal Procedure Start By: a. Remove the alternato r. Refer to Disassembly and Assembly, “Alternator - Remove and Install”.

One-Piece Fan Drive Mounting (If Equipped)

Illustration 141

g01128365

1. Remove bolts (5) and bolts (10). Remove support assembly (9). 2. Remove screws (6). 3. Remove bolts (8). 4. Remove fan drive mounting (7).

Installation Procedure One-Piece Fan Drive Mounting (If Equipped)

Illustration 140

g01128363

1. Remove screws (1). 2. Remove bolts (2). 3. Remove bolts (3). 4. Remove fan drive mounting (4).

Illustration 142

g01128363

RENR7458-09


1. Position fan drive mounting (4) on the engine. Install bolts ( 2) and bolts (3). Tighten bolts (2) and bolts (3) finger tight. 2. Tighten bolts (2) to a torque of 55 ± 10 N·m (40 ± 7 lb ft).

i02237475

Engine Control Module Remove and Install SMCS Code: 1901-010

3. Tighten bolts (3) to a torque of 28 ± 7 N·m (20 ± 5 lb ft). 4. Install screw s (1).

Two-Piece Fan Drive Mounting (If Equipped)

Illustration 144

g01128321

(1) Harness assembly .......... 6 ± 1 N·m (53 ± 9 lb in) i02528409

Alternator - Remove and Install Illustration 143

g01128365

SMCS Code: 1405-010

1. Position fan drive mounting (7) on the engine.

Removal Procedure

2. Install bolts (8) and screws (6). Tighten bolts (8) and screws (6) finger tight.

1. Disconnect the battery cables from the battery. Refer to Operation and Maintenance Manual, “Battery or Battery Calbes - Disconnect”.

3. Position support assembly (9) on fan drive mounting (7).

2. Remove the drive belt.

4. Install bolts (5) and bolts (10). Tighten bolts (5) and bolts (10) fi nger tight. 5. Tighten bolts (8) and screws (6) to standard torque. 6. Tighten bolts (5) and bolts (10) to standard torque. End By: a. Install the alternator. Refer to Disassembly and Assembly, “Alternator - Remove and Install”.

Illustration 145

g01128834


RENR7458-09

3. Place an index mark on all harness assemblies that are connec ted to alternator (1). Disconnect all harness assemblies from alternator (1). 4. Remove bolts ( 2). 5. Remove alternator (1).


Illustration 147

Illustration 146

g01128834

1. Position alternator (1) on the mounting bracket. Install bolts (2). 2. Install the drive belt. 3. Connect all harness assembli es to alternator (1). Use the index marks to correctly connect the harness assemblies.

g01063153

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

4. Connect the battery cables to the battery. Refer to Operation and Maintenance Manual, “Battery or Battery Calbes - Disconnect”.


i02276552

Electric Starting Motor Remove and Install SMCS Code: 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 ba ttery explosion or fi re.

Illustration 148

g01063153

RENR7458-09


1. Fasten a suitable lifting device to electric starting motor (1). The w eight of electric starting motor (1) is approximately 35 kg (77 lb). 2. Position the g asket and electric starting motor (1) in the fl ywheel housing. Install bolts (2). 3. Connect the ha rness assemblies to electric starting motor (1). Refer to Speci fications, “Electric Starting Motor”. i02237659

Air Compressor - Remove and Install SMCS Code: 1803-010


Illustration 149

g00992674

Illustration 150

g00992677


Part N u mb e r

P a r t D e sc r i pt i on

138-7573LinkBracket

Qt y 1

Do not discon nect 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. 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 Publicat ion, NENG2500, “Caterpillar Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fl uids according to local regulations and mandates. 1. Remove the air pressure from the air tank and drain the coolant from the cooling system.

2. Disconnect hose assembly (1), hose assembly (3), hose assembly (6), and hose (2). 3. Remove b olts (7). 4. Remove bolt (8). 5. Install Tooling (A) and a suitable lifting device to air compressor (4). The weight of air compressor (4) is ap proximately 27 kg (60 lb). 6. Remove bolts (5). 7. Remove air compressor (4) and the gasket.


RENR7458-09


1. Install Tooling (A) and a suitable lifting device to air compressor (4). The weight of air compressor (4) is approximately 27 kg (60 lb).

Table 49

Required Tools Tool

Part N u m be r

2. Position air c ompressor (4) in the front housing.

P ar t D e s c r ip t ion

A

138-7573LinkBracket

B

9S-3263

Thread Lock Compound

Qty

Note: Bolts (5) must be installed prior to bolts (7).

1 1

3. Apply Tooling (B) to the threads of bolts (5). Install bolts (5). 4. Install bolts (7).


5. Install bolt ( 8). 6. Connect hose assembly (1), hose assembly (3), hose assembly (6), and hose (2). 7. Fill the cooling system with coolant to the correct level . Refer to the Operation and Maintenance Manual, “Re fill Capacities and Recommendations”. i02237680

Air Compressor Drive Gear Remove SMCS Code: 1803-011-GE


Required Too ls

Illustration 151

g00992674

Tool

Part N u mb e r

A

132-5451

P a r t D e s cr ip t i on Holding Fix ture

Qty 1

Start By: a. Remove the air compressor. Refer to Disassembly and Assembly, “Air Compressor - Remove and Install”.

Illustration 152

g00992677

RENR7458-09


g01128545

Illustration 153

1. Install Tooling (A) on air compressor drive gear (1).

Illustration 154

g01148907

1. Install air compressor drive gear (1) on the air compressor.

2. Remove nut (2). 2. Install Tooling (A) on air compressor drive gear (1). 3. Remove air compressor drive gear (1). 3. Install nut (2). i02294313

Air Compressor Drive Gear -

Tapered Shaft on Bendix Air Compressor 1. Tighten nut (2) to a torque of 160 ± 15 N·m (118 ± 11 lb ft).

Install (Two Cylinder) SMCS Code: 1803-012-GE

2. Tap the gear axially with a soft faced hammer in order to seat the gear onto the tapered cranksh aft.


3. Tighten the nut again to a torque of 160 ± 15 N·m (118 ± 11 lb ft).

Table 51

Straight Shaft on Bendix Air Compressor


Part N u mb er

P a r t D e s c r i p t i on

132-5451Holding Fixture

Qty 1

Note: Caterpillar may use air compressors that have a tapered shaft or a straight shaft. The torque for the nut on the air compressor crankshaft is different for each type of crankshaft. Note: Identify the manufacturer of the air compressor for your particular application.

1. Tighten nut (2) to a torque of 460 ± 60 N·m (340 ± 44 lb ft).

Wabco 250 Air Compressor 1. Tighten nut (2) to a torque of 150 ± 5 N·m (111 ± 4 lb ft). 2. Place an index mark on the nut and rotate nut (2) for an additional turn of 60 ± 5 degrees. End By: a. Install the air compressor. Refer to Disassembly and Assembly, “Air Compressor - Remove and Install”.


RENR7458-09

i02967460

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



Part N u mb e r


132-5451Holding Fixture

Illustration 155

Qty 1

g01128545

Note: Caterpillar may use air compressors that have a tapered shaft or a straight shaft. The torque for the nut on the air compressor crankshaft is different for each type of crankshaft. Identify the manufacturer of the air compressor for your particular applica tion. 1. Install air compressor drive gear (1) on the air compressor. 2. Install Tooling (A) on air compressor drive gear (1). 3. Install nut (2). 4. Refer to Speci fications, “Air Compressor Drive Gear - Install” for the correct torque for the nut (2). 5. Remove Tooling (A). End By: a. Install the air compressor. Refer to Disassembly and Assembly, “Air Compressor - Remove and Install”.

RENR7458-09

71 Index Section

Index A Air Compressor - Remove and Install.................... Installation Procedure ........................................ Removal Procedure .............. ............................. Air Compressor Drive Gear - Install....................... Installation Procedure ........................................ Air Compressor Drive Gear - Install (Two Cylinder) .............................................................. Installation Procedure ........................................

67 68 67 70 70 69 69

Crankshaft Gear - Remove and In stall .................. 59 Installation Procedure ........................................ 59 Removal Procedure ........................................... 59 Crankshaft Main Bearings - Install......................... 56 Installation Procedure ........................................ 56 Crankshaft Main Bearings - Remove..................... 55 Removal Procedure ........................................... 55 Crankshaft Rear Seal - Install................................ 28 Installation Procedure ........................................ 28 Crankshaft Rear Seal - Remove............................ 28

Air Compressor Drive Gear - Remove................... 68 Removal Procedure .............. ............................. 68 Air Inlet Heater Solenoid - Remove and Install...... 15 Installation Procedure ........................................ 15 Removal Procedure .............. ............................. 15 Alternator - Remove and Install................... .......... 65 Installation Procedure ........................................ 66 Removal Procedure .............. ............................. 65 Atmospheric Pressure Sensor - Remove and Install ................................................................... 61

Removal Procedure ........................................... Cylinder Head - Install ........................................... Installation Procedure ........................................ Cylinder Head - Remove ....................................... Removal Procedure ...........................................

B

E

Bearing Clearance - Check ................................... 60 Measurement Procedure .................... ............... 60 Boost Pressure Sensor - Remove and Install........ 63

C

Electric Start ing Motor - Remo ve and Install ......... 66 Installation Procedure ........................................ 66 Removal Procedure ........................................... 66 Engine Control M odule - Remove and Install........ 65 Engine Oil Filter Base - Assemble......................... 20 Assembly Procedure.......................................... 20

Camshaft - Install................................................... 45 Installation Procedure ........................................ 45 Camshaft - Remov e............................................... 45 Removal Procedure .............. ............................. 45 Camshaft Bearings - Remove and Install.............. 47 Installation Procedure ........................................ 47 Removal Procedure .............. ............................. 47 Camshaft Gear - Remove and Instal l .................... 46 Installation Procedure ........................................ 46 Removal Procedure .............. ............................. 46 Camshaft Idler Gear - Remove and Insta ll ............ 35 Installation Procedure ........................................ 35 Removal Procedure .............. ............................. 35 Connecting Rod Bearings - Install ......................... 54 Installation Procedure ........................................ 54 Connecting Rod Bearings - Remove ..................... 54 Removal Procedure .............. ............................. 54 Coolant Temperature Sensor - Remove and Install ................................................................... 61

Engine Oil Filter Base - Disassemb le .................... 19 Disassembly Procedure...................... ............... 19 Engine Oil Filter Base and Oil Cooler - Insta ll ....... 20 Installation Procedure ........................................ 20 Engine Oil Filter Base and Oil Cooler - Remov e ... 19 Removal Procedure ........................................... 19 Engine Oil Pan - Re move and Install..................... 48 Installation Procedure ........................................ 48 Removal Procedure ........................................... 48 Engine Oil Pressure Sensor - Remove and Install.. 62 Engine Oil Pump - Assemble...... ........................... 23 Assembly Procedure.......................................... 23 Engine Oil Pump - Di sassemble............... ............. 22 Disassembly Procedure...................... ............... 22 Engine Oil Pump - Install....................................... 24 Installation Procedure ........................................ 24 Engine Oil Pump - Remove................................... 22 Removal Procedure ........................................... 22 Exhaust Manifold - R emove and Install................. 14 Installation Procedure ........................................ 14

Crankshaft - Install................................................. 58 Installation Procedure ........................................ 58 Crankshaft - Remove............................................. 57 Removal Procedure .............. ............................. 57 Crankshaft Front Seal - Install............................... 32 Installation Procedure ........................................ 32 Crankshaft Front Seal - Remove................. .......... 31 Removal Procedure .............. ............................. 31

28 41 41 40 40

D Disassembly and Assembly Section........................ 4

Removal Procedure ........................................... 14 F Fan Drive Mounting Group - Remove and Install .. Installation Procedure ........................................ Removal Procedure ........................................... Flywheel - Install....... ............................................. Installation Procedure ........................................

64 64 64 27 27

72 Index Section

RENR7458-09

Flywheel - Remove......... ....................................... 27 Removal Procedure ........................................... 27 Flywheel Housing - Remove and Install ................ 29 Installation Procedure ........................................ 29 Removal Procedure ........................................... 29 Front Cover - Install.................... ........................... 32 Installation Procedure ........................................ 32 Front Cover - Rem ove...................... ..................... 32 Removal Procedure .............. ............................. 32 Fuel Filter Base - Remove and Install ..................... 4 Installation Procedure .......................................... 5 Removal Procedure .............. ............................... 4 Fuel Priming Pump - Remove and Install................ 4 Installation Procedure .......................................... Removal Procedure .............. ............................... Fuel Transfer Pump - Install .................................... Installation Procedure .......................................... Fuel Transfer Pump - Remove ................................ Removal Procedure .............. ...............................

4 4 6 6 5 5

H Housing (Front) - Install.................. ....................... Installation Procedure ........................................ Housing (Front) - R emove.................... ................. Removal Procedure .............. .............................

34 34 33 33

P Piston Cooling Jets - Remove and Install.............. 49 Installation Procedure ........................................ 49 Removal Procedure ........................................... 49 Pistons and Connecting Rods - Assemble ............ 51 Assembly Procedure.......................................... 51 Pistons and Con necting Rods - Disassemble ....... 51 Disassembly Procedure...................... ............... 51 Pistons and Connectin g Rods - Install.......... ......... 53 Installation Procedure ........................................ 53 Pistons and Connecting Rods - Remove............... 50 Removal Procedure ........................................... 50

R Rocker Shaft - Assemble................ ....................... 38 Assembly Procedure.......................................... 38 Rocker Shaft - Dis assemble .................................. 38 Disassembly Procedure...................... ............... 38 Rocker Shaft and Pushrod - Install........................ 39 Installation Procedure ........................................ 39 Rocker Shaft and Pushrod - Remove.................... 37 Removal Procedure ........................................... 37

S I

Speed/Timing Sensor - Remove and Insta ll .......... 62

Important Safety I nformation ................................... 2 Injection Actuation Pressure Sensor - Remove and

T

Install 62 Inlet Air................................................................... Temperat ure Sensor - Remove and Install ................................................................... 63 Inlet and Exhaust Valve Guides - Remove and Install ................................................................... 17 Installation Procedure ........................................ 17 Removal Procedure .............. ............................. 17 Inlet and Exhaust V alve Seat Inserts - Remove and Install ................................................................... 18 Installation Procedure ........................................ 18 Removal Procedure ........................................... 18 Inlet and Exhaust Valves - Remove and Install ..... 15 Installation Procedure ........................................ 16 Removal Procedure ........................................... 15

L Lifter Group - Remove and Install....... ................... 43 Installation Procedure ........................................ 44 Removal Procedure .............. ............................. 43

Table of Contents..................................................... 3 Turbocharger - Install ............... ............................. 13 Installation Procedure ........................................ 13 Turbocharger - Remove ................. ....................... 12 Removal Procedure ........................................... 12

U Unit Injector - In stall............. .................................... 8 Installation Procedure .......................................... 8 Unit Injector - Remove......... .................................... 7 Removal Procedure ............................................. 7 Unit Injector Hydraulic Pump - Install ..................... 11 Installation Procedure ......................................... 11 Unit Injector Hydr aulic Pump - Remove ................. 11 Removal Procedure ............................................ 11 Unit Injector Sleeve - Install........ ........................... 10 Installation Procedure ........................................ 10 Unit Injector Sleeve - Remove......... ........................ 9 Removal Procedure ............................................. 9

M V Modulating Valve - Remove and Install ................. 12 Installation Procedure ........................................ 12 Removal Procedure .............. ............................. 12

Valve Mechanism Cover - Remove and Install...... 36 Installation Procedure ........................................ 36 Removal Procedure ........................................... 36

RENR7458-09

Valve Mechanism Cover Base - Remove and Install ................................................................... Installation Procedure ........................................ Removal Procedure .............. ............................. Vibration Damp er and Pulley - Remove and Install ................................................................... Installation Procedure ........................................ Removal Procedure ...........................................

73 Index Section

36 37 36 30 31 30

W Water Pump - Assemble.............. .......................... 25 Assembly ............................. Water Pump Procedure............. - Disassemble.............. ..................... Disassembly Procedure ..................................... Water Pump - Inst all .............................................. Installation Procedure ........................................ Water Pump - Remove .......................................... Removal Procedure ........................................... Water Temperature Regulator - Remove and Install ................................................................... Installation Procedure ........................................ Removal Procedure .............. .............................

25 25 25 26 26 24 24 26 27 26

74 Index Section

RENR7458-09

RENR7458-09

75 Index Section

©2008 Caterpillar All Rights Reserved

Cat, Caterpill ar, their respective logos, “Caterpillar Yellow” and the Power edge trade dress, as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission.

Printed in U.S.A.

c7 Assembly

Recommend Documents