Desamble Motor 3054

Engine Design SMCS - 1000

Type 1 Engines and 9RM Engines E ngines -------------------------------------------------------------------------------Ver imagen

-------------------------------------------------------------------------------Illustration 1 g00296342 Cylinder and valve location for Type 1 engines and 9RM engines (A) Exhaust valves (B) Inlet valves

Note: Type Type 1 engines can be identified in two ways. The first method refers to Illustration 1. When the valve cover is removed, look at the cylinder head valves. Type 1 engines have two exhaust valves in a row and two inlet valves that are in a row. The second method does not require the removal of the valve cover. cover. Refer to the inlet manifold and the exhaust manifold. man ifold. Type Type 1 engines have two exhaust ports in a row and two inlet ports that are in a row.

Type ... Four cylinder and four stroke Combustion system ... Direct injection Nominal Bore ... 100 mm (3.937 inch) Stroke ... 127 mm (5.00 inch) Capacity ... 4 liters (243 in3) Compression Ratio ... 16:1 Number of cylinders ... 4 Arrangement of cylinders ... in-line Firing Order ... 1, 3, 4, 2 Valve Lash Inlet valve ... 0.20 mm (.008 inch) Exhaust valve ... 0.45 mm (.018 inch) When the crankshaft is viewed from the front of the engine, the crankshaft rotates in the following direction: ... Clockwise When the camshaft is viewed v iewed from the front of the engine, the camshaft rotates in the following direction: ... Clockwise Note: The front end of the engine is opposite the flywheel end. The left side and the right side of the engine are viewed from the flywheel end. The No. 1 cylinder is the front cylinder.

Type 2 Engines and 7BJ Engines -------------------------------------------------------------------------------Ver imagen

Type ... Four cylinder and four stroke Combustion system ... Direct injection Nominal Bore ... 100 mm (3.937 inch) Stroke ... 127 mm (5.00 inch) Capacity ... 4 liters (243 in3) Compression Ratio ... 16:1 Number of cylinders ... 4 Arrangement of cylinders ... in-line Firing Order ... 1, 3, 4, 2 Valve Lash Inlet valve ... 0.20 mm (.008 inch) Exhaust valve ... 0.45 mm (.018 inch) When the crankshaft is viewed from the front of the engine, the crankshaft rotates in the following direction: ... Clockwise When the camshaft is viewed v iewed from the front of the engine, the camshaft rotates in the following direction: ... Clockwise Note: The front end of the engine is opposite the flywheel end. The left side and the right side of the engine are viewed from the flywheel end. The No. 1 cylinder is the front cylinder.

Type 2 Engines and 7BJ Engines -------------------------------------------------------------------------------Ver imagen

-------------------------------------------------------------------------------Illustration 2 g00296424 Cylinder and valve location for Type 2 engines and 7BJ engines (A) Exhaust valves (B) Inlet valves

Note: Type Type 2 engines can be identified in two ways. The first method refers to Illustration 2. When the valve cover is removed, look at the cylinder head valves. Type 2 engines alternate the exhaust valves and the inlet inle t valves. The second method does not require the removal of the valve cover. cover. Refer to the inlet manifold and the exhaust manifold. man ifold. Type Type 2 engines alternate the exhaust ports and the inlet ports. Type ... Four cylinder and four stroke Combustion system ... Direct injection Nominal Bore ... 100 mm (3.937 inch) Stroke ... 127 mm (5.00 inch) Capacity ... 4 liters (243 in3) Compression Ratio ... 17.25:1

Number of cylinders ... 4 Arrangement of cylinders ... in-line Firing Order ... 1, 3, 4, 2 Valve Lash Inlet valve ... 0.20 mm (.008 inch) Exhaust valve ... 0.45 mm (.018 inch) When the crankshaft is viewed from the front of the engine, the crankshaft rotates in the following direction: ... Clockwise When the camshaft is viewed from the front of the engine, the camshaft rotates in the following direction: ... Clockwise Note: The front end of the engine is opposite the flywheel end. The left side and the right side of the engine are viewed from the flywheel end. The No. 1 cylinder is the front cylinder.

Fuel Filter Base - Remove and Install SMCS - 1262-010 Removal Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. Ver imagen

Illustration 1 g00556872 Typical example Disconnect two fuel lines (1) at the fuel injection pump. Cap the lines or plug the lines immediately. Ver imagen

Illustration 2 g00556873 Typical example Disconnect fuel return line (2) . Cap the lines or plug the lines immediately. Ver imagen

Illustration 3 g00556874 Typical example Disconnect two fuel lines (3) . Cap the lines or plug the lines immediately. Verimagen

Illustration 4 g00556875 Typical example Remove three bolts (4) that hold two fuel lines (3) on the rear of the engine. Ver imagen

Illustration 5 g00556876 Typical example Remove two bolts (5) . Remove fuel filter base (6) . Note: Use the following steps in order to remove fuel filter (9). The fuel filter assembly has a bayonet type lock ring that allows the fuel filter to drain into the canister for easy removal. Remove cap (7). Remove the top plate, the O-ring, and the bayonet type lock ring from fuel filter (9). This will allow fuel to flow into the canister of the fuel filter. Turn collar (8) in the counterclockwise direction in order to remove fuel filter (9) . Pull fuel filter (9) from fuel filter base (6) . Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Ver imagen

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Illustration 6 g00556876 Typical example

Install fuel filter base (6) on the engine. Install two bolts (5) . Note: If the fuel filter was removed, use the following steps to install the fuel filter.

Replace the seal on fuel filter base (6) . Insert fuel filter (9) in fuel filter base (6) . Install collar (8). Turn the collar in the clockwise direction in order to lock fuel filter (9) in place. Install the bayonet type lock ring, the O-ring, and the top plate in fuel filter (9). Install cap (7) . Ver imagen


Install three bolts (4) that hold the fuel lines to the rear of the engine. Ver imagen


Connect two fuel lines (3) . Ver imagen

Illustration 9 g00556873

Connect fuel return line (2) . Ver imagen


Connect two fuel lines (1) at the fuel injection pump.

Fuel Transfer Pump - Remove SMCS - 1256-011 Removal Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

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

Illustration 1 g00543616 Typical example Disconnect two fuel lines (1) from fuel transfer pump (2). Plug all openings immediately. Remove four bolts (3) that mount fuel transfer pump (2) to the cylinder block. Remove two lock plates (4) . Remove fuel transfer pump (2) and the gasket. Note: If the fuel transfer pump is difficult to remove, rotate the crankshaft until the rocker arm of the fuel transfer pump is not under pressure.

Fuel Transfer Pump - Disassemble SMCS - 1256-015 Disassembly Procedure Start By: Remove the fuel transfer pump. Refer to Disassembly and Assembly, "Fuel Transfer Pump - Remove". 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 Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. Ver imagen

Illustration 1 g00544796 Place an identification mark on each half of the fuel transfer pump for the assembly procedure. Remove the screw that holds cover (1) . Remove cover (1) and the gasket. Remove gauze (2) . Remove the screws that hold the two halves of the fuel transfer pump together. Rotate diaphragm assembly (5) at 90 degrees in order to remove the pull rod from link arm (8) . Remove diaphragm assembly (5) . Remove stem seal (6), spring seat washer (7), and diaphragm spring (12) from the pull rod. Note: Diaphragm assembly (5) and the pull rod are not serviced parts. Use a suitable lever in order to remove valves (4) and seat washers (3). The valves are peened in. Note: Some of the metal that is peened may need to be removed in order to remove valves (4) . Hold rocker lever (11) in a vise and hit the body of the fuel transfer pump with a soft hammer in order to release retainers (10). This will allow you to remove link arm (8) . NOTICE Do not damage the face on the body of the fuel transfer pump. Remove the following items: rocker lever (11), pin (9), link arm (8) and the return spring.

Fuel Transfer Pump - Assemble SMCS - 1256-016 Assembly Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Inspect the components of the fuel transfer pump for damage. Replace the components, if necessary. Clean all of the components before assembly. Ver imagen


Install seat washers (3) . Push valves (4) into position. Note: It is possible for the valves to be installed incorrectly. Refer to Illustration 1 for the correct installation.

When valves (4) are installed, peen the edge of the valve housing evenly in six places. This will keep valves (4) in position. Install rocker lever (11), pin (9), and link arm (8) into the bottom half of the fuel transfer pump. Install the return spring and ensure that the ends of the spring are installed correctly. Using a soft hammer and a suitable adapter install two retainers (10) into the grooves. Ensure that retainers (10) fasten the pin. Peen the open ends of the grooves in order to fasten the retainers in position. Install the diaphragm spring (12) under diaphragm assembly (5). Place spring seat washer (7) and stem seal (6) on the pull rod.

NOTICE Ensure that the small diameter at the top of the seal is on the round section of the pull rod. Place diaphragm assembly (5) over the lower half of the body of the fuel transfer pump. Ensure that the blade of the pull rod is aligned with the slot of link arm (8) . Press lightly on diaphragm assembly (5) until the notch in the pull rod is in the slot of link arm (8). Rotate diaphragm assembly (5) at 90 degrees in either direction. This will engage the pull rod in the slot of link arm (8) . Push rocker lever (11) toward the body of the fuel transfer pump. Push rocker lever (11) until diaphragm assembly (5) is level with the flange on the body of the fuel transfer pump. Install the top half of the body of the fuel transfer pump and align the marks on the flanges. Keep pressure on rocker lever (11). Install spring washers and the screws. Tighten the screws evenly. Install gauze (2) . Install the gasket and cover (1) . Note: Refer to the Testing and Adjusting, "Fuel Transfer Pump Pressure Test" for the correct procedure. End By: Install the fuel transfer pump. Refer to Disassembly and Assembly, "Fuel Transfer Pump - Install".

Fuel Transfer Pump - Install SMCS - 1256-012

Installation Procedure

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

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


Inspect the condition of the gasket. Replace the gasket, if necessary. Ensure that the rocker arm for the fuel transfer pump is not under pressure. Install the gasket and fuel transfer pump (2). If fuel transfer pump (2) is difficult to install, rotate the crankshaft. Install two lock plates (4) . Install four bolts (3). Tighten the bolts to a torque of 22 Nm (16 lb ft). Connect two fuel lines (1) . Loosen the vent screw on the top of the fuel filter and operate the priming lever on the fuel transfer pump in order to remove the air from the fuel system. When only fuel comes out of the vent screw, tighten the vent screw. Start the engine and check the fuel system for fuel leaks and for air leaks.

Fuel Injection Lines - Remove and Install SMCS - 1252-010 Removal Procedure Start By: Remove the fuel filter base. Refer to Disassembly and Assembly, "Fuel Filter Base 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 Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. Ver imagen

Illustration 1 g00545081 Disconnect four fuel injection lines (1) from the fuel injection nozzles. Cap all openings or plug all openings immediately. Disconnect four fuel injection lines (1) from the fuel injection pump. Plug all openings immediately. Note: Secure fittings (4) with a wrench when you remove fuel injection lines (1) at the fuel injection pump. Remove four fuel injection lines (1) from the engine. Remove four bolts (2) and eight washers. Remove fuel return line (3) .

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

Illustration 2 g00545081 Install fuel return line (3) . Install four bolts (2) and eight new washers. Install four fuel injection lines (1) . Connect four fuel injection lines (1) at the fuel injection pump. Note: Secure fittings (4) with a wrench when you connect fuel injection line (1) at the fuel injection pump.

Connect four fuel injection lines (1) to the fuel injection nozzles. Tighten the fuel injection lines to a torque of 18 Nm (13 lb ft). End By: Install the fuel filter base. Refer to Disassembly and Assembly, "Fuel Filter Base - Remove and Install".

Fuel Injection Nozzles - Remove - Type 1 Engines and 9RM Engines SMCS - 1254-011 Removal Procedure Start By: Remove the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Remove and Install". Note: For a complete description of Type 1 and Type 2 Engines, refer to the Disassembly and Assembly, "Engine Design" topic. 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 Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. Ver imagen

Illustration 1 g00545199 Remove two bolts (1) and clamp (2) from the cylinder head. Remove clamp (2) .Ver imagen

Illustration 2 g00545200 Remove fuel injection nozzle (3) and the seat washer that is on the end of fuel injection nozzle (3) . Remove dust seal (5) and spacer (4) .

Fuel Injection Nozzles - Remove SMCS - 1254-011 Removal Procedure Start By: Remove the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - 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 Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.


Loosen threaded nut (1) on the fuel injection nozzle. Ver imagen


Remove fuel injection nozzle (2) from the cylinder block. Remove seat washer (3) . Note: If the original seat washer is not removed, the projection of the fuel injection nozzle will be incorrect when a new seat washer is installed.

Fuel Injection Nozzles - Install SMCS - 1254-012 Installation ProcedureNOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Ver imagen

Illustration 1 g00903765 Thoroughly clean the threads on threaded nut (1) and the cylinder head. Install a new seat washer (3) into the recess in the cylinder head. Note: If the original seat washer is reused, the projection of the fuel injection nozzle will be incorrect. Put a 2.0 mm (0.08 inch) bead of 4C-5591 Anti-Seize Compound on the first two threads of threaded nut (1) . Ver imagen


Ver imagen

Illustration 3 g00903704 Put fuel injection nozzle (2) into position in the cylinder head. Make sure that the detent ball in the fuel injection nozzle (2) is aligned correctly with ball Detent (X) in the cylinder head. Ver imagen

Illustration 4 g00902563 Carefully tighten threaded nut (1) to a torque of 30 Nm (22 lb ft). Remove any excess Anti-Seize Compound from fuel injection nozzle. Note: Do not rotate the fuel injection nozzle after installation. The seal which is made by the anti-seize compound may break. A broken seal may allow leakage past the seat of the fuel injection nozzle. End By: Install the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Remove and Install".

Fuel Injection Nozzles - Install - Type 1 Engines and 9RM Engines SMCS - 1254-012 Installation Procedure Note: For a complete description of Type 1 and Type 2 Engines, refer to the Disassembly and Assembly, "Engine Design" topic. 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 Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. Ver imagen


Install dust seal (5) and spacer (4) .

Install the seat washer on the end of fuel injection nozzle (3) . Install fuel injection nozzle (3) into the cylinder head. Ver imagen


Install clamp (2) and bolts (1). Tighten bolts (1) to a torque of 12 Nm (9 lb ft). End By: Install the fuel injection lines. Refer to Disassembly and Assembly A ssembly,, "Fuel Injection Lines - Remove and Install

Fuel Injection Pump - Remove - Type 2 Engines and 7BJ Engines SMCS - 1251-011 Removal Procedure Table 1 Required Tools Tool A

Part Number

150-3993

B

171-1085 or 173-9774

Part Description

Timing Pin (2)

Qty

1

Tamper Resistant Tool Tool

( 1 ) Tool (A) is required in ord order er to remove Bosch fuel injection pumps. ( 2 ) Tool (A) is required in order order to remove Delphi (Lucas) and Stanadyne fuel injection pumps.

Start By: Remove the water pump. Refer to Disassembly Disassembl y and Assembly, "Water Pump - Remove". Remove the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - 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 an d repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, NENG2500 , "Caterpillar Tools Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

Ensure that the No. 1 cylinder is at the top center position on the compression stroke. Refer to the Testing Testing and Adjusting, "Fuel System" topic for additional information. Ver imagen


Loosen locking screw (2) (if equipped) until locking spacer (1) moves freely. freely. Move locking spacer (1) into position (B). Tighten locking screw (2) to a torque of 10 Nm (7 lb ft). Ver imagen


Note: Do not remove hub nut (4) from the shaft of the fuel injection pump. The hub of the fuel injection pump is installed in the correct position from the factory in order to ensure proper timing. If hub nut (4) is removed and the hub is removed, the hub will need to be accurately installed on the shaft of the fuel injection pump by the use of special equipment. Refer to your Caterpillar Dealer for more information. Note: Do not release Torx screws (5) (if equipped). If the Torx screws are released and the timing plate is moved, the timing position that is set at the factory will be lost. If the Torx screws are released, the No. 1 cylinder must be set to the top center position on the compression stroke before the Torx screws are tightened.

Slowly rotate the crankshaft until hole (6) in the timing gear and hole (7) in the hub are in alignment with hole (8) in the fuel injection pump body. Note: The location of Tool (A) for Bosch fuel injection pumps will be located toward the top of the fuel injection pump. The location of Tool (A) for Delphi (Lucas) and Stanadyne fuel injection pumps will be located toward the bottom of the fuel injection pump.

Install Tool (A) through hole (6) in the timing gear and hole (7) in the hub. Push Tool (A) into position in hole (8) in the fuel injection pump body. If Tool (A) can be fully seated, the fuel injection pump timing is correct. No resistance should be felt w hen the timing pin is inserted into hole (8) of the fuel injection pump body. Note: Some fuel injection pumps are installed with tamper proof bolts. Tool (B) may be necessary in order to remove the tamper proof bolts.

Remove four bolts (3) that fasten the fuel injection pump gear to the fuel injection pump. Timing gear (9) should be free from the fuel injection pump shaft. Ver imagen

Illustration 3 g00808376 Typical example Remove three flange nuts (10) and fuel injection pump (11) from the engine. Ver imagen


Remove O-ring seal (12) from fuel injection pump (11) .

Fuel Injection Pump - Remove - Type 1 Engines and 9RM Engines SMCS - 1251-011 Table 1 Required Tools Tool

Part Number

Part Description

Qty

A

173-9774

Bolt Remover (1)

1

B

9U-6198

Crankshaft Turning Tool

1

Bolt

2

C

8S-4712

( 1 ) The bolt remover is required in order to remove the tamper proof bolts on the access cover for the fuel injection pump. Start By: Remove the water pump. Refer to Disassembly and Assembly, "Water Pump - Remove". Remove the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Remove and Install". Note: For a complete description of Type 1 and Type 2 engines, refer to the Disassembly and Assembly, "Engine Design" topic.

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 Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. Ver imagen

Illustration 1 g00545256 Remove four bolts (1) . Note: Some engines may have four tamper proof bolts (1). Use Tool (A) in order to remove the tamper proof bolts bolts.

Remove cover (2) . Ver imagen


Remove nut (3) and the lockwasher.

Ver imagen

Illustration 3 g00571370 Use Tool (B) to rotate the crankshaft until keyway (X) is at 30 degrees from the vertical centerline. Ver imagen

Illustration 4 g00571373 Install Tool (C) . Disengage the gear from the fuel injection pump. Ver imagen

Illustration 5 g00545262 Disconnect hose (7) from the fuel injection pump. Remove three nuts (6) that hold fuel injection pump (5) in position. Remove fuel injection pump (5) and the gasket. Note: Ensure that you do not lose the key when the fuel injection pump is removed. Also notice the position of marks (4) in order to ensure proper alignment of fuel injection pump (5) during installation.

Fuel Injection Pump - Install - Type 2 Engines and 7BJ Engines SMCS - 1251-012 Table 1 Required Tools Tool A

B

Part Number

150-3993 171-1085 or 173-9774

Part Description

Qty

Timing Pin (2)

1

Tamper Resistant Tool Gp

1

( 1 ) Tooling (A) is required in order to install Bosch fuel injection pumps. ( 2 ) Tooling (A) is required in order to install Dephi (Lucas) and Stanadyne fuel injection pumps. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Ver imagen

lustration 1 g01059878 Typical example Check the condition of O-ring seal (13) on fuel injection pump (12). If the seal is worn or damaged, replace the seal. Lightly lubricate O-ring seal (13) with clean engine oil. Install O-ring seal (13) on fuel injection pump (12) .

NOTICE The No. 1 cylinder must be at the top center position on the compression stroke before the fuel injection pump is installed. If the crankshaft needs to be rotated, the fuel injection pump must be mounted temporarily or the loose gear could cause damage to the front housing. Ver imagen

Illustration 2 g00808376 Typical example Put fuel injection pump (12) in position on the engine. Ensure that the timing gear is aligned with the hub of fuel injection pump (12). Install three flange nuts (11) and tighten the flange nuts to a torque of 28 Nm (21 lb ft). Ver imagen

Illustration 3 g00808370 Typical example Position gear (9) on the shaft of the fuel injection pump. Note: Some fuel injection pumps are installed with tamper proof bolts. Tooling (B) may be necessary in order to install the tamper proof bolts. Put the timing gear plate in position and install four bolts (3). Tighten the four bolts finger tight. Note: The fuel injection pump gear will only fit in one position. Install the gear with the letters "C" and "M" facing away from the engine. Ver imagen

Illustration 4 g00808245 Typical example Loosen locking screw (2) (if equipped) until locking spacer (1) moves freely. Move locking spacer (1) into position (A). Tighten locking screw (2) to a torque of 10 Nm (7 lb ft). Note: The location of Tooling (A) for Bosch fuel injection pumps will be located toward the top of the fuel injection pump. The location of Tooling (A) for Dephi (Lucas) and Stanadyne fuel injection pumps will be located toward the bottom of the fuel injection pump. Install Tooling (A) through hole (6) in the timing gear and hole (7) in the hub. Push Tooling (A) into position in hole (8) in the fuel injection pump body. If Tooling (A) can be fully seated, the fuel injection pump timing is correct. No resistance should be felt when the timing pin is inserted into hole (8) of the fuel injection pump body. NOTICE The fuel injection pump may be supplied with the fuel injection pump shaft in the locked position. The drive shaft of the fuel injection pump must not be rotated without the spacer in position under the locking screw. Damage to the drive shaft of the fuel injection pump will result. When the timing plate is installed, rotate gear (9) by hand in a counterclockwise direction in order to remove the backlash between gear (9) and the idler gear. Do not rotate the crankshaft or the fuel injection pump shaft. Tighten bolts (3) to a torque of 28 Nm (21 lb ft). Remove Tooling (A) from the fuel injection pump gear. End By: Install the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines Remove and Install". Install the water pump. Refer to Disassembly and Assembly, "Water Pump - Install".

Fuel Injection Pump - Install - Type 1 Engines and 9RM Engines SMCS - 1251-012 Table 1 Required Tools Tool A

Part Number

Part Description

Qty

173-9774

Bolt Remover (1)

1

( 1 ) The bolt remover is required in order to install the tamper proof bolts on the access cover for the fuel injection pump. Note: For a complete description of Type 1 and Type 2 Engines, refer to the Disassembly and Assembly, "Engine Design" topic. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Inspect the condition of the gasket for the fuel injection pump. Replace the gasket, if necessary. Ver imagen


Install the gasket and fuel injection pump (5) . Note: Align marks (4) that are on fuel injection pump (5) and the timing gear cover.

Install the key.

Install three nuts (6) that hold fuel injection pump (5) in position. Connect hose (7) to fuel injection pump (5) . Engage the gear with the fuel injection pump.

Ver imagen


Install the lockwasher and nut (3) . Ver imagen


Install cover (2) and four bolts (1) . Note: Some engines have four tamper proof bolts (1). Use Tool (A) in order to install the four bolts.

Set the timing of the fuel injection pump. Refer to the Testing and Adjusting Module for the correct procedure. End By: Install the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines Install". Install the water pump. Refer to Disassembly and Assembly, "Water Pump - Install".

Turbocharger - Remove SMCS - 1052-011 Removal Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. Ver imagen

Illustration 1 g00545445 Typical example Loosen two clamps (1) . Slide hose (2) away from turbocharger (3) . Remove two bolts (4) and the gasket. Disconnect oil return line (6) from the cylinder block and remove the gasket. Remove nuts (5) . Ver imagen

Illustration 2 g00545446 Typical example Remove three bolts (7) . Remove turbocharger (3) and the gaskets. Plug all openings immediately.

Turbocharger - Disassemble SMCS - 1052-015 Disassembly Procedure Start By: Remove the turbocharger. Refer to Disassembly and Assembly, "Turbocharger Remove". 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 Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. Place an index mark on all of the components for the assembly procedure. Ver imagen

Illustration 1 g00545460 Typical example Remove elbow (1) and the O-ring seal. Remove two bolts (2) . Remove hose assembly (3) and the gasket. Ver imagen

Illustration 2 g00545463 Typical example Remove six bolts (4) . Remove three clamps (5) . Separate compressor housing (6) from cartridge (7) . Ver imagen

Illustration 3 g00545464 Typical example Ver imagen

Illustration 4 g00545505 Typical example Remove six bolts (8) . Remove three clamps (9) . Separate cartridge (7) from turbine housing (10) .

Turbocharger - Assemble SMCS - 1052-016

Assembly Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Inspect the condition of the gaskets. Replace the gaskets, if necessary. Ver imagen



Typical example Assemble cartridge (7) and turbine housing (10) . Install three clamps (9) . Apply 5P-3931 Anti-Seize Compound to six bolts (8). Tighten the bolts to a torque of 19 ± 1 Nm (14 ± 1 lb ft). Ver imagen

Illustration 3 g00545463 Typical example Assemble compressor housing (6) and cartridge (7) . Install three clamps (5) . Appy 5P-3931 Anti-Seize Compound to six bolts (4). Tighten the bolts to a torque of 15 ± 4 Nm (11 ± 3 lb ft). Ver imagen

Illustration 4 g00545460 Typical example Install hose assembly (3) and the gasket. Install two bolts (2) . Install elbow (1) and the O-ring seals. End By: Install the turbocharger. Refer to Disassembly and Assembly, "Turbocharger Install".

Turbocharger - Install SMCS - 1052-012 Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Inspect the condition of all gaskets. Replace the gaskets, if necessary. Ver imagen

Illustration 1 g00545446 Typical example Install turbocharger (3) and the gaskets. Install three bolts (7) . Ver imagen


Typical example Apply 5P-3931 Anti-Seize Compound to nuts (5). Tighten the nuts to a torque of 55 ± 5 Nm (40 ± 4 lb ft). Install the gasket and oil return line (6) . Install two bolts (4) . Slide hose (2) onto the turbocharger (3) . Tighten two clamps (1) .

Exhaust Manifold - Remove and Install - Type 2 Engines and 7BJ Engines SMCS - 1059-010 Removal Procedure Start By: Remove the turbocharger. Refer to Disassembly and Assembly, "Turbocharger Remove". Remove the air inlet manifold. Refer to Disassembly and Assembly, "Air Inlet Manifold Remove and Install". Note: For a complete description of Type 1 and Type 2 Engines, refer to the Disassembly and Assembly, "Engine Design" topic. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Ver imagen


Illustration 2 g00557337 Remove exhaust manifold nuts or bolts (1) in reverse order of the numbered sequence. Remove exhaust manifold (2) from the engine. Ver imagen


Remove exhaust manifold gaskets (3) from the engine. Remove old sealant from stud threads.



Inspect the condition of the gaskets. If the gaskets are damaged, use new parts for replacement. Install exhaust manifold gaskets (3) on the cylinder head. Apply 4C-9507 Retaining Compound to the stud threads. Ver imagen



NOTICE Damage to the exhaust manifold can occur if the exhaust manifold is not aligned and tightened correctly.

Install exhaust manifold (2) on the cylinder head. Note: Some of the exhaust manifolds have large clearance holes for the bolts. If a new exhaust manifold is installed ensure that the 148-7132 Ferrule mountings that are supplied with the exhaust manifold are installed.

Install exhaust manifold nuts or bolts (1). Tighten the exhaust manifold nuts or bolts in the numerical sequence to a torque of 44 Nm (33 lb ft). End By: Install the air inlet manifold. Refer to Disassembly and Assembly, "Air Inlet Manifold Remove and Install". Install the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Install".

Exhaust Manifold - Remove and Install - Type 1 Engines and 9RM Engines SMCS - 1059-010 Removal Procedure Start By: Remove the turbocharger. Refer to Disassembly and Assembly, "Turbocharger Remove". Note: For a complete description of Type 1 and Type 2 Engines, refer to the Disassembly and Assembly, "Engine Design" topic. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Ver imagen

Illustration 1 g00542541 Typical example Remove exhaust manifold nuts (1) . Remove exhaust manifold (2) and the gasket. Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Ver imagen


Inspect the condition of the gasket. Replace the gasket, if necessary. Install the gasket and exhaust manifold (2) . Install exhaust manifold nuts (1). Tighten the plated nuts to a torque of 44 Nm (32 lb ft). Tighten the nuts that are not plated to a torque of 50 Nm (37 lb ft). End By: Install the turbocharger. Refer to Disassembly and Assembly, "Turbocharger Install".

Inlet Manifold - Remove - Type 2 Engines and 7BJ Engines SMCS - 1058-011 Removal Procedure Note: For a complete description of Type 1 and Type 2 engines, refer to Disassembly and Assembly, "Engine Design". 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 Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. Ver imagen

Illustration 1 g00557838 Typical example Disconnect tube (1) from the air inlet heater. Loosen hose clamps (3) and slide the hose toward the turbocharger.

Remove four bolts (2) and remove elbow (4) from the air inlet manifold. Ver imagen


Remove bolts (5) that fasten air inlet manifold (6) to the engine. Remove air inlet manifold (6) .

Inlet Manifold - Remove - Type 1 Engines and 9RM Engines SMCS - 1058-011

Removal Procedure Note: For a complete description of Type 1 and Type 2 engines, refer to Disassembly and Assembly, "Engine Design". 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 Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. Ver imagen


Ver imagen

Illustration 2 g00545514 Typical example Disconnect electrical connector (5) for the air inlet heater. Disconnect fuel line (6) to the air inlet heater. Remove two bolts (7) that hold the bracket for fuel line (6) in position. Loosen two hose clamps (8) and slide hose (9) toward the turbocharger. Remove four bolts (3) in order to remove elbow (2) and gasket (4) . Disconnect boost pressure hose (10) . Remove bolts (12) that hold the turbocharger support to air inlet manifold (14) . Remove bolts (13) that hold air inlet manifold (14) to the cylinder head. Remove air inlet manifold (14) and gaskets (11) . Remove seal (1) .

Inlet Manifold - Install - Type 1 Engines and 9RM Engines SMCS - 1058-012 Installation Procedure Note: For a complete description of Type 1 and Type 2 engines, refer to Disassembly and Assembly, "Engine Design". NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Inspect the gaskets for wear or damage. If the gaskets are worn or damaged, use new parts for replacement. Ver imagen



Install seal (1) on the engine. Position gaskets (11) and air inlet manifold (14) on the engine. Note: Ensure that the front gaskets and the rear gaskets are installed with the notch at the top left side. The center gasket can be installed in either direction. Install bolts (13) . Position the turbocharger support on air inlet manifold (14) and install bolts (12) . Connect boost pressure hose (10) . Install gasket (4) and elbow (2) with four bolts (3) . Slide hose (9) in position and tighten hose clamps (8) . Place the bracket for fuel line (6) in position and install two bolts (7) . Connect fuel line (6) to the air inlet heater. Connect electrical connector (5) for the air inlet heater

Inlet Manifold - Install - Type 2 Engines and 7BJ Engines

SMCS - 1058-012

Installation Procedure Note: For a complete description of Type 1 and Type 2 engines, refer to Disassembly and Assembly, "Engine Design". NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Inspect the gaskets for wear or damage. If the gaskets are worn or damaged, use new parts for replacement. Ver imagen

Illustration 1 g00558245 Typical example Install the gasket and air inlet manifold (6) with bolts (5) . Tighten bolts (5) to a torque of 33 Nm (24 lb ft). Ver imagen


Put the gasket and elbow (4) in position on the air inlet manifold. Install four bolts (2) . Slide the hose into position and tighten hose clamps (3) . Connect tube (1) to the air inlet heater.

Inlet and Exhaust Valve Springs - Remove and Install SMCS - 1108-010 Table 1 Required Tools Tool

Part Number

Part Description

Qty

A

9U-6195

Valve Spring Compressor

1

Start By: Remove the rocker shaft. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod - Remove". NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Note: Before you begin the removal of the valve springs, refer to the Specifications Module, "Cylinder Head Valves" topic for appropriate information on the valve springs. Ensure that the piston is at the top center position. Note: If the rocker arm assembly has not been removed, rotate the crankshaft in the normal direction of rotation until the inlet valve of the appropriate cylinder has just opened and the exhaust valve has not fully closed. If the rocker arm assembly has been removed, go to Step 2. NOTICE Do not turn the crankshaft while the valve springs are removed. Ver imagen

Illustration 1 g00762206 Install Tool (A) . Compress the valve springs in order to open the valve. Turn the crankshaft until the piston touches the valve. Continue to turn the crankshaft and release the pressure of Tool (A) until the piston is at the top center position. Ver imagen

Illustration 2 g00762210 Install Tool (A) . Compress valve springs (1). Remove two valve keepers (2) . NOTICE Ensure that the valve spring is compressed squarely or damage to the valve stem may occur.

Release the pressure on Tool (A). Remove valve spring retainer (3) and valve springs (1) . Note: If you are replacing all of the valve springs, the procedure can be done on two cylinders at the same time. The procedure can be done on cylinder 1 and cylinder 4, or on cylinder 2 and cylinder 3. NOTICE Do not turn the crankshaft while the valve springs are removed.

Table 2

Required Tools Tool

Part Number

Part Description

Qty

A

9U-6195


1

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Place the new valve springs into position. Note: Ensure that the closed damper coils are toward the cylinder head if double valve springs are used. Ver imagen

Illustration 3 g00762210 Install valve spring retainer (3) . Install Tool (A). Compress valve springs (1) . NOTICE Ensure that the valve spring is compressed squarely or damage to the valve stem may occur. Install two valve keepers (2) . Release the pressure slowly on Tool (A). Remove Tool (A). Strike the top of the valves with a soft faced hammer in order to ensure that the valve keepers are properly installed. Note: If you are replacing all of the valve springs the procedure can be done on two cylinders at the same time. The procedure can be done on cylinder 1 and cylinder 4, or on cylinder 2 and cylinder 3. End By: Install the rocker shaft. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod - Install".

Inlet and Exhaust Valves - Remove and Install SMCS - 1105-010 Table 1 Required Tools Tool

Part Number

Part Description

Qty

A

9U-6195


1

Start By: Remove the cylinder head assembly. Refer to Disassembly and Assembly, "Cylinder Head - Remove". NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Clean the bottom face of the cylinder head. Use a dial indicator to check the depth of the valves below the face of the cylinder head before the valve springs are removed. Refer to Specifications, RENR2401, "Cylinder Head Valves" for the correct dimensions. Place an index mark on the heads of the inlet valves and the exhaust valves for installation purposes. Ver imagen

Illustration 1 g00545731 Use Tooling (A) to compress inner springs (3) and outer springs (4) . Note: Some engines may have only a single inlet valve spring and a single exhaust valve spring. Remove valve keepers (1) . The valve keepers can be thrown from the valve when the valve spring compressor is released. Ensure that the valve keepers are properly installed on the valve stem. To help prevent personal injury, keep away from the front of the valve keepers and valve springs during the installation of the valves. Slowly release the pressure on Tooling (A) and remove Tooling (A) . Remove valve spring retainers (2) . ReMove inner springs (3) and outer springs (4) . Remove seals (5) . Remove valve spring seat washers (6) .

Remove inlet valves (7) and exhaust valves (7) . Installation Procedure Table 2 Required Tools Tool

Part Number

Part Description

Qty

A

9U-6195


1

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

Illustration 2 g00545731 Lubricate the stems of inlet valves (7) and the stems of exhaust valves (7) with clean engine oil. Install inlet valves (7) and exhaust valves (7) in the respective positions. Install valve spring seat washers (6) . Install new seals (5) . Install inner springs (3) and outer springs (4) . Note: Install inner springs (3) and outer springs (4) on the valve spring seat washers with the damper coils toward the cylinder head. This is done with double valve springs. If single valve springs are used, the springs can be installed in either way. Install valve spring retainers (2) . The valve keepers can be thrown from the valve when the valve spring compressor is released. Ensure that the valve keepers are properly installed on the valve stem. To help prevent personal injury, keep away from the front of the valve keepers and valve springs during the installation of the valves. Use Tooling (A) to compress inner springs (3) and outer springs (4) . Note: Some engines may have only a single inlet valve spring and a single exhaust valve spring. Install valve keepers (1) . Slowly release the pressure on Tooling (A) and remove Tooling (A). Strike the top of the valves with a soft hammer in order to ensure that the valve keepers are properly installed. Note: Refer to Specifications, RENR2401, "Cylinder Head Valves" for more information on inlet valves and exhaust valves. Use a dial indicator to check the depth of the new valves below the cylinder head. If the depth of the new valves is below the correct depth, the valve seat inserts must be replaced. Refer to Disassembly and Assembly, "Inlet and Exhaust Valve Seat Inserts Remove and Install". End By: Install the cylinder head assembly. Refer to Disassembly and Assembly, "Cylinder Head - Install".

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

Removal Procedure Table 1 Required Tools Tool

A

Part Number 1U-9169

Part Description Valve Guide Driver

Qty

1

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


Ver imagen

g006321 75

Illustratio n1

Typical example

1. Use Tooling (A) in order to remove the valve guides from the cylinder head. 1. Repeat the procedure for the remaining valve guides.

Installation Procedure Table 2 Required Tools Tool

Part Number

Part Description

Qty

A

1U-9169

Valve Guide Driver

1

B

9U-6220

Stop Collar

1

C

157-3720

Valve Seat Cutter

1


Illustratio

g006321

n2

76

Typical example

1. Put the valve guide in position. Carefully tap the valve guide in order to start the installation. Use Tooling (A) and Tooling (B) to seat the valve guide in the cylinder head. Note: After installing the unfinished valve guides and valve seat inserts, you must ream the valve guides and valve seat inserts to the finished diameter. The valve guides and valve seat inserts are cut and reamed in one operation. This operation is performed by using the 157-3720 Valve Seat Cutter. Refer to Specifications, RENR2401, "Cylinder Head Valves" for the finished diameter of the valve guides and valve seat inserts. 1. Check the protrusion of the valve guides. The valve guides should protrude 14.85 to 15.15 mm (0.585 to 0.597 inch) above the valve spring recess. 1. Repeat the procedure for the remaining valve guides. End By: Install the inlet valves and the exhaust valves. Refer to Disassembly and Assembly, "Inlet and Exhaust Valves - Remove and Install".

Inlet and Exhaust Valve Seat Inserts - Remove and Install

SMCS - 1103-010 Start By: Remove the inlet valves and the exhaust valves. Refer to Disassembly and Assembly, "Inlet and Exhaust Valves - Remove and Install". NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Ver imagen Table 1 Required Tools Tool A

Part Number

9S-3095

Part Description

Qty

Puller Handle

1

Illustration 1 g00545912 Ver imagen Table 2 Required Tools Tool A

Part Number

157-3717

Part Description

Qty

Valve Seat Driver (1)

1


Use Tooling (A) with appropriate extractor (2) and channel (3) in order to remove valve seat inserts (1) . Remove valve seat inserts (1) from the cylinder head. Repeat the procedure for the remaining valve seat inserts.

( 1 ) This tool is used for valve guides and valve seats that are not finished.



Use the appropriate parts of Tooling (A) in order to install the valve seat insert into the cylinder head assembly. Repeat the procedure for the remaining valve seat inserts. Note: Refer to the Specifications Module for more information on the valve seat inserts. End By: Install the inlet valves and the exhaust valves. Refer to Disassembly and Assembly, "Inlet and Exhaust Valves - Remove and Install".

Engine Oil Filter Base - Remove SMCS - 1306-011

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



Loosen two hose clamps (1) and disconnect the hoses. Remove three bolts (2) . Remove nut (3) that holds the hose clamp and move the hose clamp. Remove engine oil filter base (4) from the engine block. Plug all openings immediately.

Engine Oil Filter Base - Disassemble SMCS - 1306-015 Disassembly Procedure Start By:

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



Remove engine oil filter (1) from engine oil filter base (2) . Remove cap (3) from engine oil cooler (4) (if equipped). Remove engine oil cooler (4) from engine oil filter base (2), if necessary.

Engine Oil Filter Base - Assemble SMCS - 1306-016 Assembly Procedure NOTICE

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


Install engine oil cooler (4) on engine oil filter base (2) . Place cap (3) on engine oil cooler (4) (if equipped). Install engine oil filter (1) on engine oil filter base (2) . End By: Install the engine oil filter base. Refer to Disassembly and Assembly, "Engine Oil Filter Base - Install".

Engine Oil Filter Base - Install SMCS - 1306-012



Install engine oil filter base (4) on the engine block. Place the hose clamp in position and install nut (3) . Install three bolts (2) . Connect two hoses and tighten two hose clamps (1) .

Engine Oil Relief Valve - Remove and Install SMCS - 1315-010 Removal Procedure Start By:

Remove the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan Remove". NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Ver imagen

Illustration 1 g00552240 Remove two bolts (1) that fasten the engine oil relief valve to the engine oil pump. Remove bolt (3) that holds engine oil relief valve (4) in position. Remove engine oil relief valve (4) and the gasket from the engine. Inspect the condition of the gasket. Replace the gasket, if necessary. Disconnect oil tube (2) and remove the O-ring seals from the oil tube. Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Ver imagen

Illustration 2 g00552240 Install new O-ring seals on oil tube (2) and connect oil tube (2) to the engine oil pump. Put the gasket in position and install engine oil relief valve (4) on the engine. Install bolt (3) that holds engine oil relief valve (4) in position. Tighten bolt (3) to a torque of 44 Nm (33 lb ft). Install two bolts (1) that fasten the engine oil relief valve to the engine oil pump. End By: Install the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan Install".

Engine Oil Pump - Remove SMCS - 1304-011 Table 1 Required Tools Tool

Part Number

A

1P-1855

Retaining Ring Pliers

1

B

9U-6282

Torque Wrench Extension

1

Start By:

Part Description

Qty

Remove the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan Remove and Install". Remove the front housing. Refer to Disassembly and Assembly, "Housing (Front) Remove". Note: The engine oil pump is mounted on the No. 1 crankshaft main bearing cap. The engine oil pump can be removed without removing the front housing if the No. 1 crankshaft main bearing cap is removed. Use Tool (B) in order to remove the No. 1 crankshaft main bearing cap. The engine oil pump is then removed from the No. 1 crankshaft main bearing cap.

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 Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. Ver imagen


Remove two bolts (1) that fasten the strainer and suction pipe to the engine oil pump.

Remove bolt (2) that holds the strainer in position. Remove the strainer, suction pipe (3), and the gasket from the engine. Remove the engine oil relief valve. Refer to the Disassembly and Assembly Module, "Engine Oil Relief Valve - Remove". Ver imagen


Use Tool (A) to remove retaining ring (4) from the idler gear shaft. Remove idler gear (5) from the idler gear shaft. Inspect the idler gear shaft for wear or damage. If the idler gear shaft is worn or damaged, use a new part for replacement. Use a suitable press to remove the idler gear shaft from the No. 1 main bearing cap. Ver imagen


Remove three bolts (6) from the No. 1 main bearing cap. Remove engine oil pump (7) from the engine.

Engine Oil Pump - Install SMCS - 1304-012 Table 1 Required Tools Tool

Part Number

Part Description

Qty

A

1P-1855

Retaining Ring Pliers

1

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. NOTICE If any of the parts on the engine oil pump are worn or damaged, the entire pump must be replaced. Note: If the No. 1 crankshaft main bearing cap was removed, install the No. 1 crankshaft main bearing cap with the engine oil pump. Tighten the bolts for the No. 1 crankshaft

main bearing cap to a torque of 265 Nm (195 lb ft). If the shaft for the idler gear on the engine oil pump was removed, remove the excess Loctite 603. Apply a new layer of Loctite 603 to the bore in the main bearing cap and install the shaft. Ver imagen

Illustration 1 g00545972 Fill engine oil pump (7) with clean engine oil. Install engine oil pump (7) on the engine. Install three bolts (6). Tighten the bolts to a torque of 22 Nm (16 lb ft). Ver imagen

Illustration 2 g00545971 Install idler gear (5) . Use Tool (A) to install retaining ring (4) . Note: After you install the engine oil pump and the idler gear, ensure that there is a minimum of 0.08 mm (.003 inch) backlash between the gear on the engine oil pump and the idler gear. Install the engine oil relief valve. Refer to Disassembly and Assembly, "Engine Oil Relief

Valve - Install". Ver imagen

Illustration 3 g00552238 Install the strainer, suction pipe (3), and the gasket. Install bolt (2). Tighten the bolt to a torque of 22 Nm (16 lb ft). Install two bolts (1). Tighten the bolts to a torque of 22 Nm (16 lb ft). End By: Install the front housing. Refer to Disassembly and Assembly, "Housing (Front) Install".

Water Pump - Remove SMCS - 1361-011 Removal Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. Drain the coolant from the cooling system into a suitable container for storage or disposal. Ver imagen

Illustration 1 g00556675 Typical example Remove eight bolts (1) and two nuts (2) that fasten the water pump to the front housing. Tap water pump (3) with a soft hammer in order to loosen water pump (3) . Remove water pump (3) and the gasket.

Water Pump - Disassemble - Type 1 Engines and 9RM Engines SMCS - 1361-015 Table 1 Required Tools Tool

Part Number

A

7X-0290

Part Description

Bolt

Qty

2

Start By: Remove the water pump. Refer to Disassembly and Assembly, "Water Pump - Remove". Note: For a complete description of Type 1 and Type 2 engines, refer to the Disassembly and Assembly, "Engine Design" topic.



Illustration 1 g00546103 Remove six bolts (1). Remove cover (2) and the gasket. Ver imagen


Remove O-ring seal (3) . Ver imagen

Illustration 3 g00546126 Install Tool (A). Remove gear (4) . Ver imagen

Illustration 4 g00546127 Use a suitable lever in order to remove seal (5) . Ver imagen

Illustration 5 g00546128 Use a suitable press in order to remove shaft (6), seal (7), and impeller (8) from housing (9) . Note: The water pump for Type 2 Engines and 7BJ Engines is not serviceable. Contact your Caterpillar dealer for more replacement information.

Water Pump - Assemble - Type 1 Engines and 9RM Engines

SMCS - 1361-016 Assembly Procedure Note: For a complete description of Type 1 and Type 2 engines, refer to the Disassembly and Assembly, "Engine Design" topic. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Note: The water pump for Type 2 Engines and 7BJ Engines is not serviceable. Contact your Caterpillar dealer for more replacement information. Clean the inside of the pump body. Ensure that the bearing bore and the counterbore for the water seal are particularly clean. Apply 4C-9507 Retaining Compound to the outer surface of the bearing. Keep the compound away from the ends of the bearing. Ver imagen

Illustration 1 g00546128 Support the gear end of the water pump body. Place the bearing and shaft (6) square in the pump body. Ensure that the shortest end of shaft (6) is in housing (9) . Use a suitable press and a suitable adapter that will apply force to the bearing. The adapter should not apply force to the shaft. Press the bearing onto the shaft until the end of the bearing is level with the bottom of the counterbore for the water seal. Note: Remove the excess compound from the end of the bearing. Install seal (7) .

Ver imagen


NOTICE Ensure that the water seal is not contaminated by oil or grease. Hold the seal only by the edge of the flange. Do not damage the ring of green sealant that is applied to the body of the water seal behind the flange. Hold water seal (5) by the edge of the flange. Push the seal onto shaft (6) until the seal is against the chamfer of the counterbore. Only apply force to the outer flange of the seal. Note: Ensure that the wide end of the seal is toward the bearing and that the seal is square with the counterbore. Continue to apply force and hold water seal (5) for ten seconds. This ensures that the water seal will remain in place. Hold the water pump with the gear end of the shaft on a suitable support. Use a flat bar in order to press impeller (8) onto shaft (6) to a depth of 8.30 ± 0.20 mm (.320 ± .010 inch). After installation, ensure that the impeller will turn freely. Note: Apply 4C-9507 Retaining Compound to impeller (8) if the original impeller is used. Remove excess compound after assembly. Ver imagen

Illustration 3 g00546587 Lubricate oil seal (3) with clean engine oil. Install oil seal (3) with the flat surface toward the bearing. Press oil seal (3) into the body with a suitable adapter until the rear of the seal is level with the end of the pump. Continue to apply force and hold oil seal (3) in position for ten seconds. This ensures that the seal will remain in place. Press gear (4) onto shaft (6) to a depth of 1.60 ± 1.00 mm (.015 ± .005 inch) . Note: Apply 4C-9507 Retaining Compound to gear (4) if the original gear is used. Remove excess compound after assembly. Ver imagen

Illustration 4 g00546103 Install a new gasket and cover (2) on the pump body. Install six bolts (1). Tighten the bolts to a torque of 9 Nm (80 lb in). End By: Install the water pump. Refer to Disassembly and Assembly, "Water Pump Install".

Water Pump - Install SMCS - 1361-012 Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Inspect the condition of the gasket. Replace the gaskets, if necessary. Ver imagen


Install the gasket and water pump (3) to the front housing. Install eight bolts (1) and install two nuts (2) that fasten the water pump (3) to the front housing. Fill the cooling system. If the engine uses diesel engine antifreeze/coolant, refer to Operation and Maintenance Manual, "Cooling System Coolant (DEAC) - Change". If the engine uses extended life coolant, refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change".

Water Outlet Manifold - Remove SMCS - 1362-011 Removal Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. Drain the coolant from the cooling system into a suitable container for storage or disposal. Ver imagen

Illustration 1 g00553901 Typical example Remove clamp (1) for the boost line. Loosen clamp (2) and disconnect hose (3) . Ver imagen

Illustration 2 g00553902 Typical example Remove all bolts (4) that hold water outlet manifold (5) in position. Remove water outlet manifold (5) and the gasket.

Water Outlet Manifold - Install

SMCS - 1362-012

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

Ver imagen

Illustration 1 g00553902 Typical example Inspect the condition of the gasket. Replace the gasket, if necessary. Put water outlet manifold (5) and the gasket in position on the engine. Install bolts (4) that secure water outlet manifold (5) to the engine. Ver imagen

Illustration 2 g00553901 Typical example Connect hose (3) and tighten clamp (2) . Install clamp (1) for the boost line. Install the upper radiator hose and fill fi ll the cooling system with coolant to the correct level. Refer to the Operation and Maintenance Manual for the correct procedure.

Electric Starting Motor SMCS - 1453 12 Volt Starting Motor Ver imagen

Illustration 1 g00295928 - Starting Motor (Side View) Ver imagen

Illustration 2 g00295930 End view of the starting motor which shows the electrical connections No load conditions at 25 °C (77 °F) Rpm of shaft ... 7000 minimum Current draw ... 130 amperes maximum Voltage ... 11.5 volts Rated voltage ... 12 volts (1) Tighten the battery terminal nut to the following torque: ... 24 to 32 Nm (18 to 24 lb ft) (2) Tighten the nut for the switch terminal to the following torque: ... 1.0 to 1.3 Nm (9 to 12 lb in) Tension of the spring for the motor brush ... 8.34 to 11.00 N (1.9 to 2.5 lb) Minimum resistance of the starter cable at 200 °C (392 °F) and at 12 volts ... 0.0017 ohms

Start Relays 9G-4368 Relay Ver imagen

Illustration 3 g00731492 Voltage ... 12 VDC Resistance between "W1" terminal and "W2" terminal ... 15 ± 1.5 ohms 069-5466 Relay Ver imagen


Voltage ... 6 VDC Resistance between terminal "A" and terminal "B" ... 30 to 34 ohms 2 4Volt Starting Motor No load conditions at 25 °C (77 °F) Rpm of shaft ... 7000 minimum Current draw ... 85 amperes maximum Voltage ... 23 volts Rated voltage ... 24 volts Minimum pull-in voltage ... 18 volts Brush length: Minimum brush length ... 15.5 mm (0.61 inch) Armature end play ... 0.1 to 0.3 mm (0.004 to 0.012 inch) Install shims or remove shims in order to adjust the armature end play to the correct specification. Commutator New diameter ... 45 mm (1.77 inch) Minimum diameter ... 42.5 mm (1.67 inch)

Desamble Motor 3054

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