C9 Disassembly Assembly

RENR8633-02 January 2013

Disassembly and Assembly C9 Petroleum Engines P9L 1-Up (Engine) KLW 1-Up (Engine) P7Z 1-Up (Engine)

SAFETY.CAT.COM

i05086812

Important Safety Information Most accidents that 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, including human factors that can affect safety. This person should also have the necessary 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 or perform any lubrication, maintenance or repair on this product, until you verify that you are authorized to perform this work, and have read and understood the operation, lubrication, maintenance and repair information. 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 identified 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. A non-exhaustive list of operations that may cause product damage are identified by “NOTICE” labels on the product and in this publication. 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. You must not use this product in any manner different from that considered by this manual without first satisfying yourself that you have considered all safety rules and precautions applicable to the operation of the product in the location of use, including site-specific rules and precautions applicable to the worksite. 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 you are authorized to perform this work, and that the product will not be damaged or become unsafe by the operation, lubrication, maintenance or repair procedures that you intend to use. The information, specifications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written. The specifications, 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 job. Cat dealers have the most current information available.

When replacement parts are required for this product Caterpillar recommends using Cat replacement 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. In the United States, the maintenance, replacement, or repair of the emission control devices and systems may be performed by any repair establishment or individual of the owner's choosing.

RENR8633

3 Table of Contents

Table of Contents Disassembly and Assembly Section Fuel Priming Pump - Remove and Install ..... .... 5 Fuel Filter Base - Remove and Install........ ....... 6 Electronic Unit Injector - Remove ........... .......... 8 Electronic Unit Injector - Install ............. ............ 9 Electronic Unit Injector Sleeve - Remove .... ....11 Electronic Unit Injector Sleeve - Install ...... ..... 12 Unit Injector Hydraulic Pump - Remove..... ..... 12 Unit Injector Hydraulic Pump - Install....... ....... 13 Turbocharger - Remove................. ................. 14 Turbocharger - Remove................. ................. 15 Turbocharger - Install................... ................... 15 Turbocharger - Install................... ................... 16 Air Lines - Remove and Install............ ............ 17 Exhaust Manifold - Remove and Install ..... ..... 18 Exhaust Manifold - Remove and Install ..... ..... 19 Air Inlet Heater - Remove ................ ............... 20 Air Inlet Heater - Install .................. ................. 21 Inlet and Exhaust Valve Springs - Remove and Install............................... .............................. 22 Inlet and Exhaust Valves - Remove and Install 24 Inlet and Exhaust Valve Guides - Remove and Install............................... .............................. 25 Inlet and Exhaust Valve Seat Inserts - Remove and Install........................... ........................... 26 Engine Oil Filter Base and Oil Cooler Remove ............................ ............................ 27 Engine Oil Filter Base and Oil Cooler - Install. 28 Engine Oil Pump - Remove .............. .............. 29 Engine Oil Pump - Disassemble........... .......... 31 Engine Oil Pump - Assemble............. ............. 32 Engine Oil Pump - Install ................ ................ 33 Water Pump - Remove .................. ................. 34 Water Pump - Disassemble.............. .............. 35 Water Pump - Assemble................. ................ 35 Water Pump - Install .................... ................... 36 Water Temperature Regulator - Remove and Install............................... .............................. 37 Water Temperature Regulator - Remove and Install............................... .............................. 39 Auxiliary Water Pump - Remove........... .......... 41 Auxiliary Water Pump - Disassemble ....... ...... 42 Auxiliary Water Pump - Disassemble (Type 2) 43 Auxiliary Water Pump - Assemble ......... ......... 47 Auxiliary Water Pump - Assemble (Type 2) .. . 49 Auxiliary Water Pump - Install............. ............ 53 Aftercooler - Remove................... ................... 53

Aftercooler - Install..................... ..................... 54 Flywheel - Remove and Install............ ............ 55 Crankshaft Rear Seal - Remove........... .......... 56 Crankshaft Rear Seal - Install............. ............ 57 Flywheel Housing - Remove and Install ..... .... 57 Vibration Damper and Pulley - Remove and Install............................... .............................. 58 Crankshaft Front Seal - Remove .......... .......... 59 Crankshaft Front Seal - Install ............ ............ 60 Front Cover - Remove and Install.......... ......... 60 Gear Group (Front) - Remove ............ ............ 61 Gear Group (Front) - Install............... .............. 62 Housing (Front) - Remove ............... ............... 63 Housing (Front) - Install ................. ................. 64 Crankcase Breather - Remove and Install... ... 65 Cylinder Block Cover - Remove and Install .. .. 66 Valve Mechanism Cover - Remove and Install 67 Valve Mechanism Cover Base - Remove and Install............................... .............................. 68 Rocker Arm and Shaft - Remove.......... .......... 69 Rocker Arm - Disassemble............... .............. 70 Rocker Arm - Assemble................. ................. 70 Rocker Arm and Shaft - Install............ ............ 71 Cylinder Head - Remove ................ ................ 72 Cylinder Head - Install .................. .................. 73 Lifter Group - Remove and Install.......... ......... 75 Camshaft - Remove.................... .................... 76 Camshaft - Install...................... ...................... 77 Camshaft Gear - Remove and Install ....... ...... 78 Camshaft Bearings - Remove ............ ............ 78 Camshaft Bearings - Install............... .............. 79 Engine Oil Pan - Remove and Install....... ....... 80 Cylinder Liner - Remove ................. ................ 82 Cylinder Liner - Install ................... .................. 82 Piston Cooling Jets - Remove and Install.... ... 83 Pistons and Connecting Rods - Remove.... .... 83 Pistons and Connecting Rods - Disassemble 84 Pistons and Connecting Rods - Assemble ... .. 85 Pistons and Connecting Rods - Install...... ...... 86 Connecting Rod Bearings - Remove ....... ....... 88 Connecting Rod Bearings - Install ......... ......... 88 Crankshaft Main Bearings - Remove....... ....... 89 Crankshaft Main Bearings - Install......... ......... 90 Crankshaft - Remove................... ................... 91 Crankshaft - Install..................... ..................... 91 Bearing Clearance - Check .............. .............. 92 Atmospheric Pressure Sensor - Remove and Install............................... .............................. 93 Atmospheric Pressure Sensor - Remove and Install............................... .............................. 94

4 Table of Contents

Coolant Temperature Sensor - Remove and Install............................... .............................. 95 Coolant Temperature Sensor - Remove and Install............................... .............................. 96 Engine Oil Pressure Sensor - Remove and Install............................... .............................. 97 Engine Oil Pressure Sensor - Remove and Install............................... .............................. 98 Fuel Pressure Sensor - Remove and Install.. . 99 Fuel Pressure Sensor - Remove and Install. 100 Injection Actuation Pressure Sensor - Remove and Install.......................... .......................... 101 Injection Actuation Pressure Sensor - Remove and Install.......................... .......................... 102 Speed/Timing Sensor - Remove and Install . 103 Speed/Timing Sensor - Remove and Install . 105 Turbocharger Outlet Pressure Sensor - Remove and Install.......................... .......................... 106 Turbocharger Outlet Pressure Sensor - Remove and Install.......................... .......................... 107 Inlet Air Temperature Sensor - Remove and Install.............................. ............................. 108 Inlet Air Temperature Sensor - Remove and Install.............................. ............................. 109 Fan Drive Mounting Group - Remove and Install.............................. ..............................110 Fan Drive - Remove.................... ...................110 Fan Drive - Disassemble ............... ................ 111 Fan Drive - Assemble .................. ..................112 Fan Drive - Install...................... .....................113 Pump Drive - Remove ................. ..................114 Pump Drive - Install ................... ....................114 Electronic Control Module - Remove and Install.............................. ..............................115 Alternator - Remove and Install .......... ...........116 Electric Starting Motor - Remove and Install .117 Air Compressor - Remove and Install...... ......118

Index Section Index............................... .............................. 121

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5

RENR8633

Disassembly and Assembly Section

Disassembly and Assembly Section i02538070

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

Removal Procedure NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or 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. Illustration 1

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

g01270491

1. Remove bolts (3) and the washers. 2. Remove fuel priming pump (2) and the gasket from fuel filter base (1).

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

6

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Disassembly and Assembly Section

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.

Illustration 2

g01270491

1. Position the gasket and fuel priming pump (2) on fuel filter base (1). 2. Install bolts (3) and the washers. 3. Purge the air from the fuel system. i02538087

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

Removal Procedure Table 1 Required Tools Tool A

Part Number 185-3630

Part Description Strap Wrench Assembly

Qty 1

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

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Disassembly and Assembly Section

Illustration 3

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Illustration 5

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Illustration 4

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Illustration 6

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1. Use Tooling (A) to remove fuel filter (2). 2. Disconnect hose assemblies (4) and (5) from fuel filter base (1). Immediately cap all openings or plug all openings in order to prevent contamination.

1. Position fuel filter base (1) on the bracket. Install bolts (6) and the washers. 2. Connect hose assemblies (4) and (5) to fuel filter base (1).

3. Disconnect fuel sensor (3) from fuel filter base (1).

3. Connect fuel sensor (3) to the fuel filter base.

4. Remove bolts (6) and the washers from fuel filter base (1). Remove fuel filter base (1) from the bracket.

4. Install fuel filter (2). Refer to the Operation and Maintenance Manual, “Fuel System Secondary Filter - Replace” topic for more information.

Installation Procedure

5. Prime the fuel system. Refer to the Operation and Maintenance Manual, “Fuel System - Prime” topic for more information.

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Disassembly and Assembly Section

i04893121

Electronic Unit Injector Remove SMCS Code: 1290-011

Removal Procedure Table 2

Required Tools Tool

Part Number

A

367-3070

Part Description Fuel Injector Installer and Removal Tooling

Qty 2

Start By: Remove the valve mechanism cover. Refer to Disassembly and Assembly, “Valve Mechanism Cover - Remove and Install”. 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 7

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2. Use a small flat head screwdriver to disconnect harness assembly (2) from electronic unit injector (1). 3. Remove socket head bolts (3).

Refer to Special Publication, NENG2500, “Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Cat products. Dispose of all fluids according to local regulations and mandates. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Remove the plug at the rear of the cylinder head. Allow the engine oil to drain from the hole in the cylinder head before the electronic unit injector is removed.

Illustration 8

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4. Use Tooling (A) to remove electronic unit injector (1) from the cylinder head. Note: Do not use a wire brush on the tip of the electronic unit injector. Damage to the electronic unit injector will occur.

RENR8633

9 Disassembly and Assembly Section (Table 3, contd) J

4C-6161

Tube Brush

1

K

9U-6862

Tapered Brush

1

L

4C-6774

Vacuum Gun Kit

1

M

4C-5027

Tap Wrench

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 electronic unit injector. Several evacuations may be necessary. Use Tooling (G) to remove the fuel and oil from the cylinder head. Note: Tooling (L) is available to clean loose material from the sleeve bore and the cylinder. 2. Inspect the electronic unit injector sleeve for damage and carbon deposits. Illustration 9

g01137291

5. Remove O-ring seals (6), (7), and (8) from electronic unit injector (1). Remove backup rings (4), (5), and (9) from electronic unit injector (1). i04892357

Electronic Unit Injector - Install SMCS Code: 1290-012

Note: Using power tools in order to rotate the material should not be necessary. The carbon in the sleeve is more removable than the carbon at locations that are exposed to higher temperatures.

Installation Procedure Table 3 Required Tools Part Description

Qty

Tool

Part Number

A

367-3070

Fuel Injector Installer As

2

E

149-2955

Seal Protector

1

F

149-2956

Seal Installer

1

1U-5718

Vacuum Pump

1

169-7372

Bottle Assembly

1

4C-4057

Clear Plastic Tubing 7.92 mm (0.312 inch) OD

1

4C-4055

Clear Plastic Tubing 6.35 mm (0.250 inch) OD

1

9U-5470

Reamer

1

G

H

3. Clean the carbon from the sleeve, the sleeve bore, and the end of the electronic unit injector, if the electronic unit injector is being reused. Clean the carbon from the seat area that is inside of the cylinder head. A fine grade of Scotch Brite material is preferred. Use Tooling (H) to clean the bore of the electronic unit injector tip. Use the Surface Reconditioning Pad in order to clean the carbon in the cylinder head. Use Tooling (J) in order to remove the carbon from the surface of the sleeve.

(continued)

The following procedure is the preferred method of cleaning the sleeve bore. Place a 38 mm (1.5 inch) square piece of Scotch Brite material on the end of Tooling (K). Twist Tooling (K) with Tooling (M) against the lower surface of the sleeve bore. 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. Note: Tooling (J) is available to clean loose material from the sleeve bore and the cylinder.

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Disassembly and Assembly Section

NOTICE The correct procedures and tooling specifications must always be used. Failure to follow any of the procedures may result in damage, malfunction, or possible engine failure. Note: New seals should be installed after each removal of the electronic unit injector from the engine. To order O-ring seals for the electronic unit injector, refer to the Parts Manual. 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.

8. Lubricate the O-ring seals and the backup rings on electronic unit injector (1) with clean engine oil before installation. Note: Proper installation of the electronic unit injector is important. Damage to the upper high-pressure seals can cause excessive oil leakage under the valve cover. This may 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. Note: Do not hit or strike the electronic unit injector during installation. Do not use a wire brush to clean the tip of the electronic unit injector. Damage to the electronic unit injector will occur. 9. When you install a new electronic unit injector the E-Trim value must be programmed into the Electronic Control Module. The E-Trim value is a six digit alphanumeric code that is supplied with the data sheet that comes with the new electronic unit injectors. Use the following menu to program the E-Trim value. • ECM Summary Screen •

Service Menu

• Calibration • Injector Code Calibration

Illustration 10

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

Illustration 11

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10. Use Tooling (A) to install electronic unit injector (1) in the cylinder head.

RENR8633

11 Disassembly and Assembly Section Start By: Remove the electronic unit injectors. Refer to Disassembly and Assembly, “Electronic Unit Injector - Remove”. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. 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.

Illustration 12

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11. Install socket head bolt (3) on the exhaust side of the bracket. Tighten the exhaust side of socket head bolt (3) until the bolt is seated. Tighten the inlet side of socket head bolt (3) to a torque of 12 ± 1 N·m (106 ± 9 lb in) . 12. Connect harness assembly (2) to electronic unit injector (1). 13. Install the plug at the rear of the cylinder head.

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Position Tooling (C) at the bottom of the electronic unit injector sleeve. This will prevent debris from entering the cylinder during the removal of the electronic unit injector sleeve. 2. Coat the plug tap in Tooling (A) with clean grease. Use Tooling (A) to cut threads into electronic unit injector sleeve (1).

End By: Install the valve mechanism cover. Refer to Disassembly and Assembly, “Valve Mechanism Cover - Remove and Install”. i02878003

Electronic Unit Injector Sleeve - Remove SMCS Code: 1713-011

Removal Procedure Table 4 Required Tools Tool

Part Number

Part Description

Qty

1P-3042

Plug Tap

1

221-0052

Guide Sleeve

1

9U-6858

Bridge Plate

1

9U-6891

Injector Tool Group

1

C

221-9803

Rubber Stopper

1

D

4C-6774

Vacuum Gun Kit

1

A

B Illustration 13

g01432481

3. Install Tooling (B) in electronic unit injector sleeve (1).

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Disassembly and Assembly Section

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

3. Apply a thin coating of Tooling (G) around the outer circumference of electronic unit injector sleeve (1) at Area (X).

5. Remove Tooling (B) and Tooling (C) from electronic unit injector sleeve (1).

4. Place electronic unit injector sleeve (1) on Tooling (E).

Note: Do not reuse the electronic unit injector sleeve.

5. Position the electronic unit injector sleeve in the cylinder head. Use a hammer and Tooling (E) to install the electronic unit injector sleeve in the cylinder head.

6. Use Tooling (D) to remove any debris from the bore for the electronic unit injector sleeve. i02878055

Electronic Unit Injector Sleeve - Install SMCS Code: 1713-012

Note: Allow Tooling (G) 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. End By: Install the electronic unit injectors. Refer to Disassembly and Assembly, “Electronic Unit Injector - Install”.

Installation Procedure Table 5

i01991043

Required Tools Tool

Part Number

E

221-9777

Sleeve Installer

1

Unit Injector Hydraulic Pump Remove

F

4C-5552

Large Bore Brush

1

SMCS Code: 1714-011

4C-9507

Retaining Compound

-

G

Part Description

Qty

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Use Tooling (F) to clean the bore for the electronic unit injector sleeve.

Removal Procedure NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or 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. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 14

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2. Install new O-ring seals (2) on the new electronic unit injector sleeve (1). Lubricate the O-ring seals with clean engine oil.

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13 Disassembly and Assembly Section

Illustration 15

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1. Remove tube assembly (3) and tube assembly (6). 2. Remove tube assembly (4) and tube assembly (5). 3. Disconnect harness assembly (2) from unit injector hydraulic pump (1).

Illustration 17

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5. Remove O-ring seal (8) from unit injector hydraulic pump (1). i04941691

Unit Injector Hydraulic Pump Install SMCS Code: 1714-012

Installation Procedure Table 6 Required Tools Tool

Part Number

A

9S-3263 or -(1)

(1)

Illustration 16

g01031311

4. Support unit injector hydraulic pump (1) by hand and remove bolts (7) through the front housing. Remove the unit injector hydraulic pump.

Part Description Loctite 243 Threadlocker Med. Strength

Qty -

EAME

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

14

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Disassembly and Assembly Section 5. Prime the fuel system. Refer to Operation and Maintenance Manual, “Fuel System - Prime”. i02538337

Turbocharger - Remove SMCS Code: 1052-011 S/N: KLW1–Up S/N: P7Z1–Up

Removal Procedure Illustration 18

g01031329

1. Install O-ring seal (8) onto unit injector hydraulic pump (1).

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.

Illustration 19

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Illustration 20

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Dispose of all fluids according to local regulations and mandates.

2. Position unit injector hydraulic pump (1) and install bolts (7) through the front housing. 3. Apply Tooling (A) to the threads of tube assemblies (3), (6), (4), and (5) and install the tube assemblies. 4. Connect harness assembly (2).

Illustration 21

1. Disconnect hose assembly (2).

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15 Disassembly and Assembly Section

2. Remove bolts (5) and tube assembly (4). 3. Attach a suitable lifting device onto turbocharger (1). The weight of turbocharger (1) is approximately 27 kg (60 lb). Remove nuts (3). Remove turbocharger (1) and the gasket. i02898089

Turbocharger - Remove SMCS Code: 1052-011 S/N: P9L1–Up S/N: P7Z1–Up

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

Illustration 22

g01443159

2. Loosen hose clamp (2) and disconnect hose (3). 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.

3. Remove tube assembly (1).

Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products.

7. Attach a suitable lifting device onto turbocharger (4). The weight of turbocharger (4) is approximately 23 kg (50 lb). Remove nuts (5). Remove turbocharger (4) and the gasket.

Dispose of all fluids according to local regulations and mandates. 1. Drain the coolant from the cooling system to a level below the turbocharger into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, “Cooling System Coolant Change”.

4. Remove the bolts and hose assembly (7). 5. Disconnect hose assembly (6). 6. Disconnect the bolts and tube assembly (8).

8. If necessary, remove the studs for the turbocharger. i04000980

Turbocharger - Install SMCS Code: 1052-012 S/N: P9L1–Up S/N: P7Z1–Up

Installation Procedure Table 7 Required Tools Tool

Part Number

A

5P-3931

Part Description Anti-Seize Compound

Qty -

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Disassembly and Assembly Section

i04000979

NOTICE Keep all parts clean from contaminants.

Turbocharger - Install

Contaminants may cause rapid wear and shortened component life.

SMCS Code: 1052-012 S/N: KLW1–Up

1. If necessary, install the studs for the turbocharger. Tighten the studs to a torque of 35 ± 5 N·m (26 ± 4 lb ft).

S/N: P7Z1–Up

Installation Procedure Table 8 Required Tools Tool

Part Number

A

5P-3931

Part Description

Qty

Anti-Seize Compound

-

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

Illustration 23

g01443159

2. Attach a suitable lifting device to turbocharger (4). The weight of turbocharger (4) is approximately 23 kg (50 lb). Position the gasket and turbocharger (4) on the exhaust manifold. Note: Discard the nuts after use. Use new nuts for installation. 3. Apply Tooling (A) to the threads of nuts (5). Install nuts (5). Tighten nuts (5) to a torque of 54 ± 5 N·m (40 ± 4 lb ft). 4. Position tube assembly (8) and install the bolts. 5. Connect hose assembly (6). 6. Position hose assembly (7) and install the bolts. 7. Install tube assembly (1). 8. Connect hose (3) and tighten hose clamp (2). 9. Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Change”.

Illustration 24

g01270689

2. Attach a suitable lifting device to turbocharger (1). The weight of turbocharger (1) is approximately 27 kg (60 lb). Position the gasket and turbocharger (1) on the exhaust manifold. Note: Discard the nuts after use. Use new nuts for installation. 3. Install nuts (3). Tighten nuts (3) to a torque of 54 ± 5 N·m (40 ± 4 lb ft). 4. Position tube assembly (4) and install bolts (5).

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17 Disassembly and Assembly Section

Installation Procedure 5. Connect hose assembly (2).

Table 9 Required Tools i02900541

Air Lines - Remove and Install SMCS Code: 1071-010 S/N: P9L1–Up

Tool

Part Number

A

5P-3975

Part Description Rubber Lubricant

Qty -

S/N: P7Z1–Up

NOTICE Keep all parts clean from contaminants.

Removal Procedure

Contaminants may cause rapid wear and shortened component life.

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

Illustration 26

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1. Install the bracket assembly and nuts (4), if necessary. Illustration 25

g01444013

1. Remove bolts (10) and retainers (9). 2. Loosen hose clamps (1). Slide hose (2) onto tube (3). 3. Remove the bolts, clips (5), and the air lines group. 4. Loosen hose clamps (6). Remove hose (7) from tube (3) and tube assembly (8). 5. Remove the O-ring seals from tube assembly (8). 6. Remove nuts (4) and the bracket assembly, if necessary.

2. Install the O-ring seals on tube assembly (8). Apply Tooling (A) to the O-ring seals. 3. Install hose (7) on tube (3) and tube assembly (8). Tighten hose clamps (6). 4. Install the air lines group, clips (5), and the bolts. 5. Slide hose (2) into position. Tighten hose clamps (1). 6. Install retainers (9) and bolts (10).

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Disassembly and Assembly Section

i04000972

Installation Procedure

Exhaust Manifold - Remove and Install

NOTICE Keep all parts clean from contaminants.

SMCS Code: 1059-010

Contaminants may cause rapid wear and shortened component life.

S/N: KLW1–Up S/N: P7Z1–Up

Removal 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.

Illustration 28

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Typical Example 1. Check the condition of studs (1). Replace studs (1), if necessary.

Illustration 27

g00949916

Typical Example 1. Remove nuts (2), the washers, and the spacers from studs (1). 2. Remove the exhaust manifold assembly and the gaskets from the cylinder head assembly. 3. Disassemble the exhaust manifold assembly into three pieces (3), (4), and (5). Illustration 29

g00949916

Typical Example Note: Discard the nuts after use. Use new nuts for installation.

RENR8633

19 Disassembly and Assembly Section

2. Install the new gaskets with the tabs upward. Assemble three pieces (3), (4), and (5) into the exhaust manifold assembly. Position the gaskets and the exhaust manifold assembly on the cylinder head assembly. Install the spacers, the washers, and nuts (2). 3. Tighten nuts (2) to a torque of 55 ± 10 N·m (41 ± 7 lb ft). End By: Install the turbocharger. Refer to Disassembly and Assembly, “Turbocharger - Install”. i02898234

Exhaust Manifold - Remove and Install SMCS Code: 1059-010 S/N: P9L1–Up

Illustration 30

S/N: P7Z1–Up

2. Disconnect hose assembly (1) and hose assemblies (4) from exhaust manifold (2).

Removal Procedure

3. Remove hose assembly (5), hose assembly (6), hose assembly (7), and hose assembly (8) from the engine.

Table 10 Required Tools Tool

Part Number

A

138-7573

Part Description Link Bracket

g01443332

Qty 1

4. Install Tooling (A) and a suitable lifting device on exhaust manifold (2). The weight of exhaust manifold (2) is approximately 30 kg (66 lb).

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.

5. Remove bolts (3) and remove exhaust manifold (2) from the cylinder head. 6. Remove the exhaust manifold gasket from the cylinder head.

Installation Procedure Table 11 Required Tools

1. Drain the coolant from the cooling system into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Change”.

Tool

Part Number

A

138-7573

B

-

Part Description

Qty

Link Bracket

1

Guide Stud (M10 x 1.50 x 200 mm)

2

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

20

RENR8633

Disassembly and Assembly Section

3. Install Tooling (A) and a suitable lifting device on exhaust manifold (2). The weight of exhaust manifold (2) is approximately 30 kg (66 lb). 4. Install exhaust manifold (2) on Tooling (B). Install bolts (3). Tighten the bolts finger tight. Remove Tooling (A) and Tooling (B) and install remaining bolts (3). Tighten the bolts by using the following procedure: Note: The bolts that are Marked “X” are 200 mm (7.9 inch) long. The rest of the bolts are 170 mm (6.7 inch) long. a. Tighten Bolt (1) through Bolt (16) in a numerical sequence. Tighten the bolts to a torque of 4 ± 1 N·m (35 ± 9 lb in).

Illustration 31

g01443509

b. Tighten Bolt (1) through Bolt (16) in a numerical sequence to a torque of 55 ± 5 N·m (41 ± 4 lb ft). c. Tighten Bolt (1) through Bolt (16) again in a numerical sequence to a torque of 55 ± 5 N·m (41 ± 4 lb ft). 5. Install hose assembly (8), hose assembly (7), hose assembly (6), and hose assembly (5) on the engine. 6. Connect hose assemblies (4) and hose assembly (1) to exhaust manifold (2). 7. Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Change”. End By: Install the turbocharger. Refer to Disassembly and Assembly, “Turbocharger - Install”. i02878379

Illustration 32

g01443332

Air Inlet Heater - Remove SMCS Code: 1090-011 S/N: KLW1–Up S/N: P7Z1–Up

Removal Procedure Illustration 33

g01443573

1. Install Tooling (B) in the cylinder head. Install Tooling (B) at Locations (Y). 2. Install the exhaust manifold gasket on Tooling (B) and the cylinder head.

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Turn the disconnect switch to the OFF position.

RENR8633

21 Disassembly and Assembly Section

i02908772

Air Inlet Heater - Install SMCS Code: 1090-012 S/N: KLW1–Up S/N: P7Z1–Up

Installation Procedure Table 12 Required Tools Part Description

Qty

Tool

Part Number

A

4C-9500

Quick Cure Primer

1

B

8C-8422

Sealant

1

NOTICE Keep all parts clean from contaminants. Illustration 34

g01271053

2. Disconnect cable assembly (2).

Contaminants may cause rapid wear and shortened component life.

3. Disconnect harness assembly (1). 4. Remove nut (4) and disconnect ground strap (3). 5. Remove bolts (5) and remove air inlet elbow (6).

Illustration 36

Illustration 35

6. Remove air inlet heater (7).

g01271055

g01271055

1. Clean the face of air inlet heater (7) with cleaning solvent. Apply Tooling (A) to the face of air inlet heater (7). Allow Tooling (A) to dry for 3 to 5 minutes. Apply Tooling (B) to the joint face and spread uniformly. Air inlet heater (7) must be installed and tightened within 10 minutes.

22

RENR8633

Disassembly and Assembly Section Start By: Remove the rocker arm and shaft. Refer to Disassembly and Assembly, “Rocker Arm and Shaft - Remove”. Remove the electronic unit injector. Refer to Disassembly and Assembly, “Electronic Unit Injector - Remove”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Note: The following procedure is for the removal of the inlet valve springs and the exhaust valve springs without removing the cylinder head. This procedure can be performed on only one cylinder at a time. This will prevent the inlet valves and the exhaust valves from falling into the cylinder. Illustration 37

g01271053

2. Position air inlet elbow (6). Install bolts (5).

1. Rotate the crankshaft in order to bring the piston to the top center position in the cylinder.

3. Connect ground strap (3) and install nut (4). 4. Connect harness assembly (1). 5. Connect cable assembly (2). 6. Turn the disconnect switch to the ON position. i02878461

Inlet and Exhaust Valve Springs - Remove and Install SMCS Code: 1108-010

Removal Procedure Table 13 Required Tools Tool

Part Number

A

176-5487

Part Description Valve Spring Compressor

Qty 1

Illustration 38

g01167733

Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force. 2. Use Tooling (A) in order to compress the inlet valve springs and the exhaust valve springs.

RENR8633

23 Disassembly and Assembly Section

3. Remove retainer locks (2). 4. Remove Tooling (A). 5. Remove spring retainer (3). 6. Remove inner valve spring (4) and outer valve spring (5) from each valve (1). Remove the valve spring seats from the cylinder head. 7. Install the inlet valve springs and the exhaust valve springs before you rotate the crankshaft.

Installation Procedure Table 14 Required Tools Tool

Part Number

A

176-5487

Part Description Valve Spring Compressor

Qty 1

NOTICE Keep all parts clean from contaminants.

Illustration 39

g01167733

Contaminants may cause rapid wear and shortened component life. 1. Install the valve spring seats for the inlet valve springs and the exhaust valve springs.

Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment. 2. Install inner valve spring (4) and outer valve spring (5) on each valve (1). 3. Install spring retainer (3). 4. Use Tooling (A) in order to compress the inlet valve springs and the exhaust valve springs. 5. Install retainer locks (2). End By: Install the electronic unit injector. Refer to Disassembly and Assembly, “Electronic Unit Injector - Install”. Install the rocker arm and shaft. Refer to Disassembly and Assembly, “Rocker Arm and Shaft - Install”.

24

RENR8633

Disassembly and Assembly Section

i02550198

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

Removal Procedure Table 15 Required Tools Tool

Part Number

A

5S-1330

Part Description Valve Spring Compressor

Qty 1

Start By: Remove the cylinder head. Refer to Disassembly and Assembly, “Cylinder Head - Remove”. NOTICE Keep all parts clean from contaminants.

Illustration 40

g01137560

Contaminants may cause rapid wear and shortened component life. Personal injury can result from being struck by parts propelled by a released spring force. The valve spring keepers can be thrown from the valve when 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.

Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force. 1. Use Tooling (A) to compress valve springs (3). Remove retainer locks (1). 2. Remove Tooling (A). Remove spring retainer (2) and valve springs (3). 3. Remove valve stem seal (4), spring seat washer (5), and valves (6).

Installation Procedure Table 16 Required Tools Tool

Part Number

A

5S-1330

Part Description Valve Spring Compressor

Qty 1

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

RENR8633

25 Disassembly and Assembly Section

i05165105

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

Removal Procedure Table 17 Required Tools

(1)

Tool

Part Number

A

9U-6895 or 4C-6366(1)

Part Description

Valve Guide Driver

Qty

1

If necessary, use Tooling on inlet valve guides.

Start By:

Illustration 41

g01137560

Remove the inlet and exhaust valves. Refer to Disassembly and Assembly, “Inlet and Exhaust Valves - Remove and Install”. NOTICE Keep all parts clean from contaminants.

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

Contaminants may cause rapid wear and shortened component life.

To prevent possible injury, follow the established assembly procedure and wear protective equipment. 1. Lubricate valves (6) with clean engine oil. Install valves (6) in the cylinder head assembly. Install new valve stem seal (4) against the valve guide. 2. Install spring seat washer (5), valve springs (3), and spring retainer (2).

The valve spring keepers can be thrown from the valve when 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: A small amount of grease can be used to hold the valve keepers in position during installation. 3. Use Tooling (A) to compress valve springs (3). Install retainer locks (1).

Illustration 42

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

Installation Procedure Table 18 Required Tools Tool

Part Number

A

9U-6895 or 4C-6366(1)

End By: Install the cylinder head. Refer to Disassembly and Assembly, “Cylinder Head - Install”.

g01137612

Part Description

Valve Guide Driver

Qty

1

(continued)

26

RENR8633

Disassembly and Assembly Section (Table 18, contd)

(1)

i04420274

B

173-5524

Guide Collar

1

C

342-6109

Guide Collar

1

If necessary, use Tooling on inlet valve guides.

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

NOTICE Keep all parts clean from contaminants.

Removal Procedure

Contaminants may cause rapid wear and shortened component life.

Table 19 Required Tools Tool

Part Number

A

9S-3095

B (1) (2)

Part Description

Qty

Puller Handle

1

6V-4194(1)

Valve Seat Extractor

1

1U-9167(2)

Valve Seat Extractor

1

For use with Exhaust Valve Seat For use with Intake Valve Seat

Start By: Remove inlet and exhaust valves. Refer to Disassembly and Assembly, “Inlet and Exhaust Valves - Remove and Install”.

Illustration 43

g03317961

1. Position the inlet valve guide and exhaust valve guide in the cylinder head. Tap on the top of the valve guides in order to start the inlet valve guides and exhaust valve guides into the cylinder head assembly. 2. Use Tooling (A) and Tooling (B) to install the Exhaust valve guide. Use Tooling (A) and Tooling (C) to install the Intake valve guide. Install the valve guides until the protrusion is Distance (X). Distance (X) is 12.0 ± 0.5 mm (0.47 ± 0.02 inch) above the cylinder head assembly.

Illustration 44

g01137634

End By:

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

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

Installation Procedure Table 20 Required Tools Tool

Part Number

Part Description

Qty

4C-6372(1)

Valve Seat Driver

1

364-4009(2)

Valve Seat Driver

1

C (1) (2)

For use with Exhaust Valve Seat For use with Intake Valve Seat

RENR8633

27 Disassembly and Assembly Section

NOTICE Keep all parts clean from contaminants.

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

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. 1. Drain the coolant from the cooling system into a suitable container for storage or for disposal. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Change”.

Illustration 45

g01137637

Note: Do not machine the prefinished 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. 1. Lower the temperature of new valve seat inserts (1). Use Tooling (C) to install valve seat inserts (1) into the cylinder head. End By: Install the inlet and exhaust valves. Refer to Disassembly and Assembly, “Inlet and Exhaust Valves - Remove and Install”. i02539716

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

Illustration 46

Removal Procedure

2. Use Tooling (A) to remove engine oil filter (1).

Table 21 Required Tools Tool

Part Number

A

185-3630

Part Description Strap Wrench Assembly

Qty 1

g01171123

28

RENR8633

Disassembly and Assembly Section

i02879382

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

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

Illustration 47

g01271362

3. Disconnect hose assembly (2). Remove bolts (4). Remove engine oil filter base (3) and the oil seal.

Illustration 49

1. Install the gasket and engine oil cooler (5).

Illustration 48

g01150963

4. Remove engine oil cooler (5) and the gasket.

g01150963

RENR8633

29 Disassembly and Assembly Section

Illustration 50

g01271362

Illustration 52

g01171123

3. Install engine oil filter (1). 4. Fill the engine with coolant to the correct level. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Change”. i02879910

Engine Oil Pump - Remove SMCS Code: 1304-011

Removal Procedure Table 22 Required Tools Tool

Part Number

A

1P-0510

Part Description Driver Gp

Qty 1

Start By: Illustration 51

g01104432

2. Apply clean engine oil to the oil seal. Install the oil seal in engine oil filter base (3). Position engine oil filter base (3) over the engine oil cooler. Install bolts (4). Tighten the bolts in a numerical sequence. Tighten the bolts again in a numerical sequence. Connect hose assembly (2).

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.

30

RENR8633

Disassembly and Assembly Section

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.

Illustration 54

g01172397

5. Remove bolts (7), outlet elbow (8), and the O-ring seal. 6. Remove bolts (5). Remove oil pickup tube (6) and the gasket.

Illustration 53

g01172390

1. Remove bolts (4). 2. Remove bolt (3). 3. Remove bolts (2) and remove engine oil pump (1). 4. Remove the O-ring seal that is located between the cylinder block and the outlet elbow.

Illustration 55

g01172401

7. Remove bolt (12) and the washer. Remove idler gear (11). Use Tooling (A) in order to remove bearing (10) from idler gear (11). Remove shaft (9) from engine oil pump (1).

RENR8633

31 Disassembly and Assembly Section

i02879644

Engine Oil Pump Disassemble SMCS Code: 1304-015

Disassembly Procedure Table 23 Required Tools Tool

Part Number

A

1P-2320

Part Description Combination Puller

Qty 1 Illustration 56

g01433238

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

1. Use Tooling (A) to remove drive gear (1) from oil pump body assembly (2).

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.

Illustration 57

g01433241

2. Remove bolts (5). Separate oil pump body (4) from oil pump body assembly (2). NOTICE Before removing the drive shaft from the pump housing, be sure that no burrs exist on the drive shaft. If the drive shaft has burrs on it, the bores in the pump housing may be scratched. 3. Remove shaft assembly (3) and shaft assembly (6) from oil pump body assembly (2).

32

RENR8633

Disassembly and Assembly Section

Illustration 58

g01433243

Illustration 59

g01433243

Personal injury can result from parts and/or covers under spring pressure.

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

Spring force will be released when covers are removed.

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

Be prepared to hold spring loaded covers as the bolts are loosened. 4. Remove the following items from oil pump body assembly (2): oil plug (9), spring (8) and oil pressure relief plunger (7).

2. Install oil pressure relief plunger (7) and spring (8) in oil pump body assembly (2). Install oil plug (9).

i02879747

Engine Oil Pump - Assemble SMCS Code: 1304-016

Assembly Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure that all of the parts of the engine oil pump are thoroughly clean prior to assembly. Note: Lubricate all internal parts of the engine oil pump with clean engine oil.

Illustration 60

3. Install shaft assembly (6) in oil pump body assembly (2).

g01433241

RENR8633

33 Disassembly and Assembly Section

4. Install shaft assembly (3) in oil pump body (4). 5. Position oil pump body (4) on oil pump body assembly (2) and install bolts (5).

Illustration 61

g01433238

6. Use a suitable press in order to install drive gear (1) on the shaft assembly of oil pump body assembly (2) until drive gear (1) is flush with the end of the shaft assembly. End By: Install the engine oil pump. Refer to Disassembly and Assembly, “Engine Oil Pump - Install”.

Illustration 62

g01172401

1. Install shaft (9) onto engine oil pump (1). Use Tooling (A) and a suitable press in order to install bearing (10) into idler gear (11). Install the bearing so the distance between the hub bolt face of idler gear (11) and the bearing is 0.75 ± 0.25 mm (0.030 ± 0.010 inch). Position idler gear (11) on shaft (9). Install the washer and bolt (12).

i02879939

Engine Oil Pump - Install SMCS Code: 1304-012

Installation Procedure Table 24 Required Tools Tool

Part Number

A

1P-0510

Part Description Driver Gp

Qty 1

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

Illustration 63

g01172397

2. Inspect the condition of the gasket. Replace the gasket, if necessary. Position the gasket and oil pickup tube (6). Install bolts (5). 3. Inspect the condition of the O-ring seal. Replace the O-ring seal, if necessary. Position the O-ring seal and outlet elbow (8). Install bolts (7).

34

RENR8633

Disassembly and Assembly Section

i02879976

Water Pump - Remove SMCS Code: 1361-011

Removal Procedure Start By: Remove the alternator, if necessary. Refer to Disassembly and Assembly, “Altenator Remove and Install”.

Personal injury can result from hot coolant, steam and alkali. At operating temperature, engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns. Illustration 64

g01172390

Note: Ensure that the mounting surfaces for the engine oil pump are thoroughly clean. 4. Inspect the condition of the O-ring seal. Replace the O-ring seal, if necessary. Install the O-ring seal that is located between the cylinder block and the outlet elbow. Position engine oil pump (1) on the cylinder block.

Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system pressure cap is cool enough to touch with your bare hand. Do not attempt to tighten hose connections when the coolant is hot, the hose can come off causing burns. Cooling System Coolant Additive contains alkali. Avoid contact with skin and eyes.

5. Install bolts (2). 6. Install bolt (3). 7. Install bolts (4). End By: Install the engine oil pan. Refer to Disassembly and Assembly, “Engine Oil Pan - Remove and Install”.

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. 1. Drain the coolant from the cooling system into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, “Cooling System Coolant (ELC) - Change”. 2. Remove the belt. Refer to Operation and Maintenance Manual, “Belts - Inspect/Replace”.

RENR8633

35 Disassembly and Assembly Section

Illustration 65

g01151111

Illustration 66

g01156016

3. Loosen hose clamps (1).

1. Remove O-ring seals (1) and (2).

4. Disconnect hose (2).

2. Remove bolts (3). Remove rear cover (4) and gasket (5).

5. Remove bolts (4), elbow assembly (5), and the gasket.

3. Use Tooling (A) and a suitable press in order to remove impeller (6) from shaft assembly (9).

6. Remove bolts (6). 7. Remove water pump (3). i02880103

Water Pump - Disassemble SMCS Code: 1361-015

Note: Do not allow the shaft assembly to fall when the shaft assembly is removed. 4. Use Tooling (A) and a suitable press in order to remove shaft assembly (9) from water pump housing (8). 5. Use Tooling (A) to remove seal (7) from water pump housing (8).

Disassembly Procedure i04553969

Table 25

Water Pump - Assemble

Required Tools Tool

Part Number

A

1P-0510

Part Description Driver Gp

Qty

SMCS Code: 1361-016

1

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

Table 26 Required Tools Part Description

Qty

Tool

Part Number

A

1P-0510

Driver Gp

1

B

183-4028

Seal Driver

1

36

RENR8633

Disassembly and Assembly Section

i02880170

NOTICE Keep all parts clean from contaminants.

Water Pump - Install

Contaminants may cause rapid wear and shortened component life.

SMCS Code: 1361-012

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

Illustration 67

g01156016

1. Use Tooling (A) and a suitable press in order to install shaft assembly (9) in water pump housing (8). After installation, the bearing on shaft assembly (9) should be flush with the face of water pump housing (8). Illustration 68

2. Use Tooling (B) to install seal (7) over shaft assembly (9) and into water pump housing (8). 3. Use Tooling (A) and a suitable press in order to install impeller (6) onto shaft assembly (9). Install impeller (6) until the distance between impeller (6) and the machined surface of water pump housing (8) is 0.75 ± 0.25 mm (0.030 ± 0.010 inch). 4. Position gasket (5) and rear cover (4) on water pump housing (8). Install bolts (3). Note: Check the O-ring seals for wear or for damage. If necessary, replace the O-ring seals. 5. Install O-ring seals (1) and (2). End By: Install the water pump. Refer to Disassembly and Assembly, “Water Pump - Install”.

g01151111

1. Position water pump (3) on the engine block. Install bolts (6). 2. Install the gasket, elbow assembly (5), and bolts (4). 3. Connect hose (2). 4. Tighten hose clamps (1) to a torque of 7 ± 1 N·m (62 ± 9 lb in). 5. Install the belt. Refer to Operation and Maintenance Manual, “Belts - Inspect/Replace”. 6. Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, “Cooling System Coolant (ELC) - Change”.

RENR8633

37 Disassembly and Assembly Section

i02540514

Water Temperature Regulator Remove and Install SMCS Code: 1355-010 S/N: KLW1–Up S/N: P7Z1–Up

Removal Procedure

Personal injury can result from hot coolant, steam and alkali. At operating temperature, engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns. Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system pressure cap is cool enough to touch with your bare hand.

Illustration 69

g01173069

2. Remove bolts (1) from water temperature regulator housing (2).

Do not attempt to tighten hose connections when the coolant is hot, the hose can come off causing burns. Cooling System Coolant Additive contains alkali. Avoid contact with skin and eyes. 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. 1. Drain the coolant from the cooling system into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, “Cooling System Coolant (ELC) - Change”.

Illustration 70

g01173071

3. Remove water temperature regulator housing (2). Remove gasket (3). Remove water temperature regulators (4).

38

RENR8633

Disassembly and Assembly Section

Illustration 71

g01173074

4. Remove seal (5) from water temperature regulator housing (2).

Installation Procedure Table 27 Required Tools Tool

Part Number

A

221-8647

Part Description Seal Installer

Qty 1

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Clean the mating surfaces of the water temperature regulator housings.

Illustration 72

g01173077

2. Use Tooling (A) and install seal (5) into water temperature regulator housing (2).

RENR8633

39 Disassembly and Assembly Section

i02880244

Water Temperature Regulator Remove and Install SMCS Code: 1355-010 S/N: P9L1–Up S/N: P7Z1–Up

Removal Procedure

Personal injury can result from hot coolant, steam and alkali. At operating temperature, engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns. Illustration 73

g01173071

Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system pressure cap is cool enough to touch with your bare hand. Do not attempt to tighten hose connections when the coolant is hot, the hose can come off causing burns. Cooling System Coolant Additive contains alkali. Avoid contact with skin and eyes. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 74

g01173069

3. Install water temperature regulators (4). Install a new gasket (3). 4. Position water temperature regulator housing (2). Install bolts (1). 5. Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, “Cooling System Coolant (ELC) - Change” and Operation and Maintenance Manual, “Capacities (Refill)”.

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. 1. Drain the coolant from the cooling system into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, “Cooling System Coolant (ELC) - Change”.

40

RENR8633

Disassembly and Assembly Section

Illustration 77

g01433675

4. Remove seal (5) from water temperature regulator housing (2).

Installation Procedure Illustration 75

g01433672

Table 28 Required Tools

2. Remove bolts (1) from water temperature regulator housing (2).

Tool

Part Number

A

221-8647

Qty

Part Description Seal Installer

1

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Clean the mating surfaces of the water temperature regulator housing.

Illustration 76

g01433673

3. Remove water temperature regulator housing (2). Remove gasket (3). Remove water temperature regulators (4). Illustration 78

g01433675

2. Use Tooling (A) and install seal (5) into water temperature regulator housing (2).

RENR8633

41 Disassembly and Assembly Section

i01995668

Auxiliary Water Pump Remove SMCS Code: 1371-011 S/N: P9L1–Up S/N: P7Z1–Up

Removal Procedure NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Illustration 79

g01433673

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

Illustration 80

g01433672

3. Install water temperature regulators (4). Install a new gasket (3). 4. Position water temperature regulator housing (2). Install bolts (1). 5. Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, “Cooling System Coolant (ELC) - Change”.

Illustration 81

g01032968

1. Disconnect hose (2) and hose (4) from auxiliary water pump (3). 2. Remove bolts (1). 3. Remove auxiliary water pump (3) from the front housing. 4. Remove the integral seal from the face of the auxiliary water pump.

42

RENR8633

Disassembly and Assembly Section

i02880484

Auxiliary Water Pump Disassemble SMCS Code: 1371-015 S/N: P9L1–Up S/N: P7Z1–Up

Disassembly Procedure Table 29 Required Tools Part Description

Qty

Tool

Part Number

A

1P-1855

Retaining Ring Pliers

1

B

1P-1861

Retaining Ring Pliers

1

C

1P-0510

Driver Group

1

D

1U-6400

Three Jaw Puller

1

E

9S-9152

Bearing Puller Gp

1

F

8S-6470

Forcing Screw

1

Start By: Remove the auxiliary water pump. Refer to Disassembly and Assembly, “Auxiliary Water Pump - Remove”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 82

g01032983

1. Remove integral seal (9), if necessary. 2. Remove bolts (1) and remove elbow (2). Remove O-ring seal (3) from the elbow. 3. Remove bolts (10) and remove elbow (12). Remove O-ring seal (11) from the elbow. 4. Remove nut (5) and washer (4). Use Tooling (D) to remove gear (8). 5. Remove bolts (7) and remove cover (6).

Note: Your specific auxiliary water pump may vary. Refer to Parts Information for more information.

Illustration 83

g01033085

6. Remove O-ring seal (22) from housing (15).

RENR8633

43 Disassembly and Assembly Section

7. Remove bolt (16). Remove the O-ring seal from the bolt. 8. Use Tooling (F) to remove impeller (21) from shaft (19). 9. Remove cam (17) from the housing. 10. Remove stainless key (18) from the shaft. 11. Remove bolts (14) and remove adapter (13) from housing (15). 12. Use Tooling (C) and a suitable press to remove pump seal (20) from the adapter. Illustration 85

g01039081

17. Use Tooling (C) and a suitable press to remove pump seal assembly (27) from the housing.

Illustration 86 Illustration 84

g01039021

13. Use Tooling (B) to remove retaining ring (23) from housing (15). 14. Use Tooling (A) to remove retaining ring (26) from shaft (19). 15. Remove washer (25) and plate assembly (24). 16. Use a suitable press to remove shaft (19) out of the water pump housing. Press on shaft (19) from the impeller end of the water pump housing.

g01033150

18. Use Tooling (A) to remove retaining ring (28). Remove washer (29) from shaft (19). 19. Use Tooling (A) to remove retaining ring (34). Remove washer (33) from shaft (19). 20. Use Tooling (E) and a suitable press to remove ball bearing (30), spacer (32), and ball bearing (31) from shaft (19). i04161770

Auxiliary Water Pump Disassemble (Type 2) SMCS Code: 1371-015 S/N: P9L1–Up S/N: P7Z1–Up

44

RENR8633

Disassembly and Assembly Section

Disassembly Procedure

4. Remove nut (5) and washer (4). Use Tooling (D) to remove gear (8).

Table 30 Required Tools Part Description

Qty

Tool

Part Number

A

1P-1855

Retaining Ring Pliers

1

B

1P-1861

Retaining Ring Pliers

1

C

1P-0510

Driver Group

1

D

1U-6400

Three Jaw Puller

1

E

9S-9152

Bearing Puller Gp

1

F

8S-6470

Forcing Screw

1

5. Remove bolts (7). Remove cover (6) and the O-ring seal (not shown).

Start By: Remove the auxiliary water pump. Refer to Disassembly and Assembly, “Auxiliary Water Pump - Remove”. Illustration 88

NOTICE Keep all parts clean from contaminants.

g02423496

6. Remove bolt (13) and remove the O-ring seal.

Contaminants may cause rapid wear and shortened component life. Note: Your specific auxiliary water pump may vary. Refer to Parts Information for more information.

Illustration 89

g02423539

7. Use Tooling (F) in order to remove impeller (14).

Illustration 87

g01032983

1. Remove integral seal (9), if necessary. 2. Remove bolts (1) and remove elbow (2). Remove O-ring seal (3) from the elbow. 3. Remove bolts (10) and remove elbow (12). Remove O-ring seal (11) from the elbow.

Illustration 90

8. Remove cam (15) from the housing.

g02423598

45

RENR8633

Disassembly and Assembly Section

Illustration 91

g02423617

9. Remove key (16) from the shaft.

Illustration 92

Illustration 94

g02424378

12. Use Tooling (B) in order to remove retaining ring (20).

g02424256 Illustration 95

10. Remove bolts (17) and remove adapter (18) from the housing.

13. Remove plate assembly (21).

Illustration 93

Illustration 96

g02424359

11. Use Tooling (C) and a suitable press in order to remove pump seal (19) from the adapter.

g02425036

g02425078

14. Use Tooling (C) and a suitable press in order to remove shaft (22) from water pump housing (23).

46

RENR8633

Disassembly and Assembly Section

Illustration 97

g02425137

Cutaway view of the pump housing showing the removal of the pump seal assembly. 15. Use Tooling (C) and a suitable press in order to remove pump seal assembly (24) from the housing.

Illustration 98

16. Use Tooling (E) or Tooling (C) in order to remove ball bearing (25) from shaft (22). Bearing (25) should be removed from the gear end of the shaft. 17. Use Tooling (A) in order to remove retaining ring (26). Remove spacer (27) and slinger (29) from the shaft (22).

g02355584

18. Use Tooling (E) and a suitable press in order to remove ball bearing (28) from shaft (22) toward the gear end.

47

RENR8633

Disassembly and Assembly Section

i02880898

Auxiliary Water Pump Assemble SMCS Code: 1371-016 S/N: P9L1–Up S/N: P7Z1–Up

Assembly Procedure Table 31 Required Tools Part Description

Qty

Tool

Part Number

A

1P-1855

Retaining Ring Pliers

1

B

1P-1861

Retaining Ring Pliers

1

C

1P-0510

Driver Group

1

G

323-3526

Seal Installer Tool

1

H

1U-6396

O-Ring Assembly Compound

-

NOTICE Keep all parts clean from contaminants.

Illustration 100

g01039556

4. Use a suitable press to install shaft (19) in housing (15). 5. Use Tooling (B) to install retaining ring (23) in the housing.

Contaminants may cause rapid wear and shortened component life. Note: Your specific auxiliary water pump may vary. Refer to Parts Information for more information.

Illustration 99

g01033150 Illustration 101

g01110719

1. Use Tooling (A) to install retaining ring (34) on shaft (19). Install washer (33) on the shaft.

6. Use Tooling (G) to install pump seal assembly (27).

2. Raise the temperature of the ball bearings. Install ball bearing (31), spacer (32), and ball bearing (30) on shaft (19).

7. Install plate assembly (24) in housing (15). Ensure that locator pin (35) is aligned with the slot in the housing.

3. Install washer (29) on shaft (19). Use Tooling (A) to install retaining ring (28) on the shaft.

8. Install washer (25) on pump shaft (19). Use Tooling (A) to install retaining ring (26) on the shaft.

48

RENR8633

Disassembly and Assembly Section

Illustration 102

g01039601

Illustration 104

g01039609

9. Position cam (17) in housing (15) and install the Oring seal and bolt (16).

12. Install adapter (13) over shaft (19) on housing (15). Install bolts (14).

10. Install stainless key (18) and impeller (21) on shaft (19).

13. Lubricate O-ring seal (22) with Tooling (H). Install the O-ring seal on the housing.

Illustration 103

Illustration 105

g01033399

11. Use Tooling (C) and a suitable press to install pump seal (20) in adapter (13).

g01039620

14. Position cover (6) on housing (15) and install the washers and bolts (7). 15. Position gear (8) on the shaft. Install washer (4) and nut (5). Tighten the nut to a torque of 63 ± 7 N·m (47 ± 5 lb ft). 16. Install integral seal (9), if necessary.

RENR8633

49 Disassembly and Assembly Section (Table 32, contd) B

1P-1861

Retaining Ring Pliers

1

C

1P-0510

Driver Group

1

G

-

LOCTITE 262

-

H

1U-6396

O-Ring Assembly Compound

-

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Note: Your specific auxiliary water pump may vary. Refer to Parts Information for more information.

Illustration 106

g01039624

17. Lubricate O-ring seal (11) with Tooling (H). Install the O-ring seal in elbow (12). Position the elbow on housing (15) and install bolts (10). Tighten the bolts to a torque of 15 ± 3 N·m (11± 2 lb ft). 18. Lubricate O-ring seal (3) with Tooling (H). Install the O-ring seal in elbow (2). Position the elbow on the housing and install bolts (1). Tighten the bolts to a torque of 15 ± 3 N·m (11± 2 lb ft). End By: Install the auxiliary water pump. Refer to Disassembly and Assembly, “Auxiliary Water Pump - Install”. i04162513

Auxiliary Water Pump Assemble (Type 2) SMCS Code: 1371-016 S/N: P9L1–Up S/N: P7Z1–Up

Assembly Procedure Table 32 Required Tools Tool

Part Number

A

1P-1855

Part Description Retaining Ring Pliers

Qty 1

(continued)

50

RENR8633

Disassembly and Assembly Section

Illustration 107

g02355584

1. Raise the temperature of the ball bearings. Install ball bearing (28) and spacer (27) slightly past the retaining ring groove that accepts retaining ring (26). 2. Use Tooling (A) in order to install retaining ring (26) on shaft (22). Press bearing (28) and spacer (27) against retaining ring (26). 3. Install bearing (25) onto shaft (22) and press the bearing against retaining ring (26). Slide slinger (29) onto the impeller side of shaft (22).

Illustration 109

g02424378

5. Use Tooling (B) to install retaining ring (20) into the housing.

Illustration 108

g02427496

4. Use a suitable press to install shaft (22) in housing (23).

RENR8633

51 Disassembly and Assembly Section

Illustration 110

g02427596

The illustration is a cutaway view of the pump housing on a shop press showing the pump seal assembly.

Illustration 112

g02424359

8. Use Tooling (C) and a suitable press to install pump seal (19) into the adapter.

Note: The Water Seal Tooling is a one time use tool that is supplied in the water seal assembly kit. 6. Use the Water Seal Tooling (not shown) to press the spring loaded mechanical seal (24b), with the black seal face toward the impeller, into the housing. Pilot the seal seat (24a) onto shaft (22) with the seat face toward the face on the mechanical seal (24b). Use the Water Seal Tooling (not shown) to press the seal seat along the shaft and against the mechanical seal (24a) until the Water Seal Tooling presses against the shoulder of the mechanical seal (24b). The tool compresses the water seal (24a) and (24b) to the proper seal spring height. Illustration 113

g02424256

9. Install adapter (18) over the shaft. 10. Apply Tooling (G) to the threads of bolts (17). Tighten bolts (17) to a torque of 24 ± 7 N·m (212 ± 62 lb in).

Illustration 111

g02425036

7. Install plate assembly (21) into the housing. Ensure that the locator pin is aligned with the slot in the housing.

Illustration 114

11. Install key (16) onto the shaft.

g02423617

52

RENR8633

Disassembly and Assembly Section

Illustration 115

g02423598

Illustration 118

g02428561

15. Position cover (6) and the O-Ring Seal onto the housing. Install the washers and bolts (7). Tighten bolts (7) to a torque of 9 ± 2 N·m (80 ± 18 lb in). 16. Position gear (8) on the shaft. Install washer (4) and nut (5). Tighten the nut to a torque of 63 ± 7 N·m (47 ± 5 lb ft). 17. Install integral seal (9), if necessary.

Illustration 116

g02428122

12. Position cam (15) into the housing. 13. Install the O-ring seal onto bolt (13). Install bolt (13) and tighten to a torque of 9 ± 2 N·m (80 ± 18 lb in).

Illustration 119

g02428683

18. Lubricate O-ring seal (11) with Tooling (H). Install the O-ring seal in elbow (12). Position the elbow on the housing and install bolts (10). Tighten the bolts to a torque of 15 ± 3 N·m (11± 2 lb ft). Illustration 117

14. Install the impeller (14) onto the shaft.

g02428145

19. Lubricate O-ring seal (3) with Tooling (H). Install the O-ring seal in elbow (2). Position the elbow on the housing and install bolts (1). Tighten the bolts to a torque of 15 ± 3 N·m (11± 2 lb ft).

RENR8633

53 Disassembly and Assembly Section

Removal Procedure

End By: Install the auxiliary water pump. Refer to Disassembly and Assembly, “Auxiliary Water Pump - Install”. i02880922

Auxiliary Water Pump - Install SMCS Code: 1371-012 S/N: P9L1–Up

Table 33 Required Tools Tool

Part Number

Part Description

Qty

A

-

Guide Stud (M10 x 1.50 x 60 mm)

2

B

-

Guide Stud (M8 x 1.25 x 90 mm)

2

S/N: P7Z1–Up

NOTICE Keep all parts clean from contaminants.

Installation Procedure

Contaminants may cause rapid wear and shortened component life.

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

Illustration 120

g01032968

1. Install the integral seal on the face of auxiliary water pump (3). 2. Position auxiliary water pump (3) in the front housing. Install bolts (1). 3. Connect hose (2) to the auxiliary water pump. 4. Connect hose (4) to the auxiliary water pump. i02896897

Aftercooler - Remove SMCS Code: 1063-011

Illustration 121

g01442381

1. Remove the hose from adapter (6). Remove bolts (7) and adapter (6) from cover (1). 2. Remove bolts (8) and tube assembly (9) from cover (1). 3. Remove bolts (4) and adapter (5) from the base assembly. 4. Attach a suitable lifting device to core assembly (3) at Location (X). The weight of core assembly (3) is approximately 35 kg (77 lb).

S/N: P9L1–Up

5. Remove two bolts (2). Install Tooling (A) into the base assembly.

S/N: P7Z1–Up

6. Remove remaining bolts (2). 7. Remove cover (1). Remove the gasket from cover (1).

54

RENR8633

Disassembly and Assembly Section 8. Remove core assembly (3).

(Table 34, contd)

9. Remove Tooling (A) from the base assembly. Remove the gasket from the base assembly.

Guide Stud (M8 x 1.25 x 90 mm)

2

4C-9500

Quick Cure Primer

-

1U-8846

Gasket Sealant

-

B

-

C D

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Thoroughly clean the mating surfaces of the cylinder head and the base assembly.

Illustration 122

g01442382

10. Disconnect the harness assembly from sensor assembly (10). 11. Remove two bolts (11). Install Tooling (B) into the cylinder head. 12. Remove remaining bolts (11) and bolts (13). 13. Remove base assembly (12). The weight of base assembly (12) is approximately 23 kg (50 lb). Illustration 123

14. Remove Tooling (B) from the cylinder head. i02897897

Aftercooler - Install

g01443022

2. Install Tooling (B) in the cylinder head at Location (Z). 3. Apply Tooling (C) to base assembly (12).

SMCS Code: 1063-012

4. Allow Tooling (C) to dry for three to five minutes.

S/N: P9L1–Up S/N: P7Z1–Up

5. Apply Tooling (D) to base assembly (12) and install base assembly (12) on Tooling (B).

Installation Procedure

Note: The base assembly must be installed within ten minutes of applying Tooling (D).

Table 34 Required Tools Tool

Part Number

A

-

Part Description Guide Stud (M10 x 1.50 x 60 mm)

Qty 2

(continued)

6. Position base assembly (12) on Tooling (B). The weight of base assembly (12) is approximately 23 kg (50 lb). 7. Install bolts (11) and bolts (13) finger tight. 8. Remove Tooling (B) and install remaining bolts (11). Tighten bolts (11) and bolts (13).

55

RENR8633

Disassembly and Assembly Section 9. Connect the harness assembly to sensor assembly (10). 10. Install Tooling (A) in base assembly (12) at Location (Y). Install the gasket on Tooling (A).

i02881237

Flywheel - Remove and Install SMCS Code: 1156-010

Removal Procedure Table 35 Required Tools

Illustration 124

Tool

Part Number

A

-

Part Description Guide Bolt M16 x 2 by 200 mm

Qty 1

g01442381

11. Attach a suitable lifting device to core assembly (3) at Location (X) and install the core assembly on the base assembly and Tooling (A). The weight of core assembly (3) is approximately 35 kg (77 lb). 12. Install the gasket on core assembly (3). Position cover (1) onto Tooling (A). Illustration 125

g01173265

Illustration 126

g01173268

13. Install bolts (2). 14. Remove Tooling (A). Install remaining bolts (2). 15. Install adapter (5) and bolts (4) in the base assembly. 16. Install tube assembly (9) and bolts (8) in cover (1). 17. Install adapter (6) and bolts (7) in cover (1). Install the hose onto adapter (6).

56

RENR8633

Disassembly and Assembly Section 1. Remove one bolt (1). Install Tooling (A). Remove remaining bolts (1). 2. Attach a suitable lifting device to flywheel (2). The weight of flywheel (2) is approximately 60 kg (132 lb). Remove flywheel (2). 3. Inspect the ring gear. Replace the ring gear, if necessary. Place the flywheel on a wood block. Use a hammer and a punch in order to remove the ring gear.

Installation Procedure Table 36 Required Tools Tool

Part Number

A

-

Part Description Guide Bolt M16 x 2 by 200 mm

Qty 1

1. Raise the temperature of the ring gear. Install the ring gear on the flywheel. Position the ring gear with the part number toward the crankshaft. Allow the ring gear to cool. Use a soft hammer in order to seat the ring gear against the shoulder of the flywheel.

Illustration 128

g01173265

3. Position flywheel (2) on the engine. Align the arrows on the flywheel and the crankshaft. Install bolts (1). Remove Tooling (A) and install the remaining bolt. Tighten the bolts evenly to a torque of 300 ± 40 N·m (221 ± 30 lb ft). 4. Check the flywheel runout. Refer to Testing and Adjusting, “Flywheel - Inspect”. i02540744

Crankshaft Rear Seal - Remove SMCS Code: 1161-011

Removal Procedure Start By: Remove the flywheel. Refer to Disassembly and Assembly, “Flywheel - Remove and Install”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Illustration 127

g01173268

2. Install Tooling (A) in the crankshaft. Attach a suitable lifting device to flywheel (2). The weight of flywheel (2) is approximately 60 kg (132 lb). Note: Use new bolts for installation.

57

RENR8633

Disassembly and Assembly Section

Illustration 129

g01140085

1. Remove bolts (2).

Illustration 130

g01140085

1. Lubricate the O-ring seal with clean engine oil. Position the O-ring seal on the back of crankshaft rear seal (1).

2. Remove crankshaft rear seal (1) from the crankshaft. i02540835

Crankshaft Rear Seal - Install SMCS Code: 1161-012

2. Position crankshaft rear seal (1) and the shipping sleeve over the crankshaft. Push crankshaft rear seal (1) in place. This will dislodge the shipping sleeve. 3. Install bolts (2). Tighten the bolts to a torque of 12 ± 3 N·m (106 ± 27 lb in).

Installation Procedure

End By:

NOTICE Keep all parts clean from contaminants.

Install the flywheel. Refer to Disassembly and Assembly, “Flywheel - Remove and Install”.

Contaminants may cause rapid wear and shortened component life. Note: Leave the shipping sleeve in place in order to install the crankshaft rear seal. The crankshaft rear seal must be installed dry.

i02881528

Flywheel Housing - Remove and Install SMCS Code: 1157-010

Removal Procedure Table 37 Required Tools Tool

Part Number

A

138-7575

B

-

Part Description

Qty

Link Bracket

2

Guide Bolts M12 x 1.75 by 120 mm

2

58

RENR8633

Disassembly and Assembly Section Start By: Remove the crankshaft rear seal. Refer to Disassembly and Assembly, “Crankshaft Rear Seal - Remove”. Remove the electric starting motor, if necessary. Refer to Disassembly and Assembly, “Electric Starting Motor - Remove and Install”.

Illustration 132

g01434695

2. Install Tooling (B) in the cylinder block. 3. Attach Tooling (A) and a suitable lifting device to flywheel housing (1). The weight of flywheel housing (1) is approximately 55 kg (121 lb). Position flywheel housing (1) on Tooling (B). Illustration 131

g01434695

1. Remove two bolts (2). Install Tooling (B) in the cylinder block. 2. Attach Tooling (A) and a suitable lifting device to flywheel housing (1). The weight of flywheel housing (1) is approximately 55 kg (121 lb).

4. Install bolts (2). Remove Tooling (B) and install remaining bolts (2). 5. Install bolts (3) (not shown) that fasten the engine oil pan to flywheel housing (1). End By:

3. Remove remaining bolts (2).

Install the electric starting motor, if necessary. Refer to Disassembly and Assembly, “Electric Starting Motor - Remove and Install”.

4. Remove bolts (3) (not shown) that fasten the engine oil pan to flywheel housing (1). Remove flywheel housing (1).

Install the crankshaft rear seal. Refer to Disassembly and Assembly, “Crankshaft Rear Seal - Install”.

Installation Procedure

i02540969

Table 38 Required Tools Tool

Part Number

A

138-7575

B

-

C

1U-8846

Part Description

Qty

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

Link Bracket

2

Guide Bolts M12 x 1.75 by 120 mm

2

Removal Procedure

Gasket Sealant

1

1. Remove the belt. Refer to Operation and Maintenance Manual, “Belts - Inspect/Replace”.

1. Apply Tooling (C) to the entire mounting surface of the flywheel housing prior to installation. The flywheel housing must be installed within 10 minutes of application.

RENR8633

59 Disassembly and Assembly Section

i02549880

Crankshaft Front Seal Remove SMCS Code: 1160-011

Removal Procedure Table 39 Required Tools Qty

Part Description

Tool

Part Number

A

1U-7600

Slide Hammer Puller

1

B

1U-8145

Drill Bit

1

Start By:

Illustration 133

g01151434

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

2. Remove bolts (2) from crankshaft vibration damper (1). Remove crankshaft vibration damper (1) from the crankshaft pulley. 3. Remove bolts (3). Remove crankshaft pulley (4).

Installation Procedure

Illustration 135

g01276176

1. Use Tooling (B) to carefully drill three evenly spaced holes in crankshaft front seal (1). 2. Alternate between the drilled holes and use Tooling (A) to remove crankshaft front seal (1). Illustration 134

g01151434

1. Position crankshaft pulley (4) on the crankshaft. Install bolts (3). 2. Position crankshaft vibration damper (1) on crankshaft pulley (4). Install bolts (2). 3. Install the belt. Refer to Operation and Maintenance Manual, “Belts - Inspect/Replace”.

60

RENR8633

Disassembly and Assembly Section

i02550042

Crankshaft Front Seal - Install SMCS Code: 1160-012

i02882225

Front Cover - Remove and Install SMCS Code: 1166-010

Installation Procedure

Removal Procedure

Table 40 Required Tools Tool

Part Number

C

1U-7430

Part Description Front Seal Installer

Start By: Qty 1

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

Remove the vibration damper and the pulley. Refer to Disassembly and Assembly, “Vibration Damper and Pulley - Remove and Install”. Remove the fan drive, if necessary. Refer to Disassembly and Assembly, “Fan Drive Remove”. Remove the unit injector hydraulic pump. Refer to Disassembly and Assembly, “Unit Injector Hydraulic Pump - Remove”. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, “Caterpillar 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.

Illustration 136

g01276301

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

RENR8633

61 Disassembly and Assembly Section

Illustration 137

g01173620

Illustration 138

g01173620

1. Support the attachment for the accessory drive and remove bolts (2).

1. Position the gasket and front cover (3) on the engine.

2. Remove bolts (1). Remove front cover (3) and the gasket.

2. Install bolts (1).

Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Note: The rear face of the front cover and the front face of the front housing must be clean.

3. Install bolts (2). Remove the support from the attachment for the accessory drive. End By: Install the unit injector hydraulic pump. Refer to Disassembly and Assembly, “Unit Injector Hydraulic Pump - Install”. Install the fan drive, if necessary. Refer to Disassembly and Assembly, “Fan Drive Install”. Install the vibration damper and the pulley. Refer to Disassembly and Assembly, “Vibration Damper and Pulley - Remove and Install”. i02882866

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

Removal Procedure Table 41 Required Tools Tool

Part Number

A

1P-0510

Part Description Driver Gp

Qty 1

62

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Disassembly and Assembly Section Start By: Remove the front housing. Refer to Disassembly and Assembly, “Housing (Front) - Remove”.

7. Check the condition of the bearing in idler gear assembly (10). If the bearing is worn or damaged, replace the idler gear assembly.

NOTICE Keep all parts clean from contaminants.

i02883096

Contaminants may cause rapid wear and shortened component life.

Gear Group (Front) - Install

1. Set the No. 1 piston to top center on the compression stroke. Refer to Testing and Adjusting, “Finding Top Center Position for No. 1 Piston”.

Installation Procedure

SMCS Code: 1206-012

Table 42 Required Tools Tool

Part Number

A

1P-0510

Part Description Driver Gp

Qty 1

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

Illustration 139

g01435071

2. Mark the orientation of each of the gears for installation purposes. 3. Remove bolts (4), bolt (6), and retaining plate (7). 4. Remove idler gear assembly (3), idler shaft (2), and thrust plate (1) from the cylinder block. 5. Use Tooling (A) to remove bearing (5) from idler gear assembly (3). Note: Removal of the engine oil pan may be necessary in order to remove the idler gear assembly for the engine oil pump. 6. Remove bolt (8), retaining plate (9), and idler gear assembly (10).

Illustration 140

g01435071

Note: Removal of the engine oil pan may be necessary in order to install the idler gear assembly for the engine oil pump. 1. Install idler gear assembly (10) and retaining plate (9) on the engine oil pump. Install bolt (8).

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63 Disassembly and Assembly Section

2. Check the end play for the idler gear assembly. The end play for the idler gear assembly is 0.05 to 0.35 mm (0.002 to 0.014 inch). 3. Use Tooling (A) to install bearing (5) in idler gear assembly (3). 4. Align the timing marks on idler gear assembly with the holes on the camshaft gear and the crankshaft gear. Install thrust plate (1), idler shaft (2), idler gear assembly (3), and retaining plate (7) on the cylinder block. Install bolts (4) and bolt (6). Tighten the bolts to a torque of 70 ± 15 N·m (52 ± 11 lb ft). 5. Calibrate the speed/timing sensor. Refer to Troubleshooting, “Engine Speed/Timing Sensor Calibrate” for the calibration procedure. End By: Install the front housing. Refer to Disassembly and Assembly, “Housing (Front) - Install”.

i02883368

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

Removal Procedure Start By: Remove the fan drive, if necessary. Refer to Disassembly and Assembly, “Fan Drive Remove”. Remove the fuel filter base. Refer to Disassembly and Assembly, “Fuel Filter Base - Remove and Install”. Remove the unit injector hydraulic pump. Refer to Disassembly and Assembly, “Unit Injector Hydraulic Pump - Remove”. Remove the auxiliary water pump, if necessary. Refer to Disassembly and Assembly, “Auxiliary Water Pump - Remove”. Remove the air compressor, if necessary. Refer to Disassembly and Assembly, “Air Compressor Remove and Install”. Remove the crankshaft front seal. Refer to Disassembly and Assembly, “Crankshaft Front Seal - Remove”. Remove the camshaft. Refer to Disassembly and Assembly, “Camshaft - Remove”. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, “Caterpillar 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.

64

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Disassembly and Assembly Section (Table 43, contd) A

138-8440

Component Cleaner

1

B

4C-9500

Quick Cure Primer

1

C

1U-8846

Gasket Sealant

1

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

Illustration 141

g01151885

1. Disconnect harness assemblies (1) and (2).

Illustration 143

g01151892

1. Clean the joint face on front housing (4) with Tooling (A). Illustration 142

g01151892

2. Remove bolts (5).

2. Apply Tooling (B) to the joint face. Note: Do not allow Tooling (C) to seal the main oil passage on front housing (4). 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.

3. Remove bolts (3). 4. Remove front housing (4). i02883411

Housing (Front) - Install

4. Position front housing (4) on the cylinder block. 5. Install bolts (3).

SMCS Code: 1151-012 6. Install bolts (5).

Installation Procedure Table 43 Required Tools Tool

Part Number

Part Description

Qty

(continued)

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65 Disassembly and Assembly Section

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. Illustration 144

g01151885

7. Connect harness assemblies (1) and (2). End By: Install the camshaft. Refer to Disassembly and Assembly, “Camshaft - Install”. Install the crankshaft front seal. Refer to Disassembly and Assembly, “Crankshaft Front Seal - Install”. Install the air compressor, if necessary. Refer to Disassembly and Assembly, “Air Compressor Remove and Install”. Install the auxiliary water pump, if necessary. Refer to Disassembly and Assembly, “Auxiliary Water Pump - Install”. Install the unit injector hydraulic pump. Refer to Disassembly and Assembly, “Unit Injector Hydraulic Pump - Install”. Install the fuel filter base. Refer to Disassembly and Assembly, “Fuel Filter Base - Remove and Install”. Install the fan drive, if necessary. Refer to Disassembly and Assembly, “Fan Drive Install”.

Illustration 145

g01435395

1. Remove bolt (2) and the washer from breather assembly (1). 2. Loosen hose clamp (3) and hose clamp (5). Remove hose assembly (4).

i02883484

Crankcase Breather - Remove and Install SMCS Code: 1317-010

Removal Procedure

3. Remove breather assembly (1) and the O-ring seal. 4. Remove the bolts and fumes disposal group (6), if necessary.

Installation Procedure

NOTICE Keep all parts clean from contaminants.

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Contaminants may cause rapid wear and shortened component life.

66

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Disassembly and Assembly Section

i02883660

Cylinder Block Cover - Remove and Install SMCS Code: 1201-010-CH

Removal Procedure Start By: Remove the electronic control module. Refer to Disassembly and Assembly, “Electronic Control Module - Remove and Install”. 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 146

g01435395

1. Install fumes disposal group (6) and the bolts, if necessary.

Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products.

2. Check the condition of the O-ring seal. Replace the O-ring seal if the O-ring seal is damaged.

Dispose of all fluids according to local regulations and mandates.

3. Install the O-ring seal and breather assembly (1). 4. Install bolt (2) and the washer. Tighten bolt (2) to a torque of 15 ± 3 N·m (11 ± 2 lb ft). 5. Install hose assembly (4). Tighten hose clamp (5) and hose clamp (3).

Illustration 147

g01435498

1. Loosen hose clamp (1) and disconnect hose assembly (2). 2. Disconnect tube assembly (3). 3. Disconnect hose assembly (7). 4. Disconnect harness assembly (6).

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67 Disassembly and Assembly Section

5. Remove bolts (4). Remove cylinder block cover (5). Remove the O-ring seals and the gasket from the cylinder block.

Installation Procedure

b. Tighten the bolts again in a numerical sequence. 3. Connect harness assembly (6). 4. Connect hose assembly (7). 5. Connect tube assembly (3). 6. Connect hose assembly (2) and tighten hose clamp (1). End By: Install the electronic control module. Refer to Disassembly and Assembly, “Electronic Control Module - Remove and Install”. i02580032

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

Removal Procedure Illustration 148

g01435498

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

Illustration 150

Illustration 149

g01435572

Note: Check the condition of the O-ring seals and the gasket. Replace the O-ring seals and the gasket, if necessary. 1. Install the O-ring seals and the gasket on the cylinder block. Position cylinder block cover (5). 2. Install bolts (4). Tighten bolts (4) by using the following procedure: a. Tighten the bolts in a numerical sequence.

g01152102

1. Remove bolts (1). 2. Remove valve mechanism cover (2) and seal (3).

Installation Procedure Table 44 Required Tools Tool

Part Number

A

4C-9612

Part Description Silicone Sealant

Qty 1

68

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Disassembly and Assembly Section

i02409213

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

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

Removal Procedure Start By: 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 151

g01152102

Illustration 152

g01138382

1. Position seal (3) in valve mechanism cover (2). Apply Tooling (A) to both sides of the seal joint. Position valve mechanism cover (2) and seal (3) on the valve cover base. 2. Install bolts (1). Tighten bolts (1) in a numerical sequence to a torque of 20 ± 3 N·m (15 ± 2 lb ft).

Illustration 153

g01140735

1. Disconnect sensor (4) and harness assembly (6) from valve cover base (5). 2. Remove bolt (1) and the clip that holds the harness assembly. 3. Disconnect harness assemblies (3). 4. Remove bolts (2), the washers, and the springs. 5. Remove valve cover base (5) and the seal.

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69 Disassembly and Assembly Section

Installation Procedure

5. Connect harness assembly (6) to valve cover base (5). Tighten the bolts to a torque of 6 ± 1 N·m (53 ± 9 lb in).

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

6. Connect sensor (4) to valve cover base (5). End By: Install the valve mechanism cover. Refer to Disassembly and Assembly, “Valve Mechanism Cover - Remove and Install”. i02884496

Rocker Arm and Shaft Remove SMCS Code: 1102-011

Removal Procedure Start By: Remove the valve mechanism cover. Refer to Disassembly and Assembly, “Valve Mechanism Cover - Remove and Install”. NOTICE Keep all parts clean from contaminants.

Illustration 154

g01140735

Contaminants may cause rapid wear and shortened component life. 1. Place identification marks on each of the rocker arms in order to identify the proper location for installation.

Illustration 155

g01061297

1. Position the seal and valve cover base (5) on the cylinder head. 2. Install the springs, the washers, and bolts (2). Tighten bolts (2) in a numerical sequence. 3. Connect harness assemblies (3). 4. Install the clip and bolt (1) that holds the harness assembly.

Illustration 156

g00953116

2. Loosen nuts (3) and rocker arm adjustment screws (2).

70

RENR8633

Disassembly and Assembly Section 3. Remove bolts (1) and rocker shaft (4). 4. Remove the pushrods and the valve bridges.

2. Remove stand (6), inlet rocker arm (5), spring (4), and exhaust rocker arm (3) from rocker shaft (1).

i02544763

i02544772

Rocker Arm - Disassemble

Rocker Arm - Assemble

SMCS Code: 1123-015

SMCS Code: 1123-016

Disassembly Procedure

Assembly Procedure

Start By: Remove the rocker arm and shaft. Refer to Disassembly and Assembly, “Rocker Arm and Shaft - Remove”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Lubricate all components of the rocker arm shaft with clean engine oil.

Note: Place an identification mark on each of the components of the rocker shaft for installation purposes.

Illustration 158

Illustration 157

g01160012

g01160012

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

Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force. 1. Remove plug (2) from rocker shaft (1).

2. Install exhaust rocker arm (3), spring (4), inlet rocker arm (5), and stand (6) on rocker shaft (1). 3. Install plug (2) into rocker shaft (1).

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71 Disassembly and Assembly Section

End By: Install the rocker arm and shaft. Refer to Disassembly and Assembly, “Rocker Arm and Shaft - Install”. i02884290

Rocker Arm and Shaft - Install SMCS Code: 1102-012

Installation Procedure Table 45 Required Tools Tool

Part Number

A

8T-2998

Part Description

Qty

Lubricant

1

NOTICE Keep all parts clean from contaminants.

Illustration 159

g00953116

Illustration 160

g01435984

Contaminants may cause rapid wear and shortened component life. 1. Apply Tooling (A) to both ends of the pushrods. 2. Lubricate the pushrods with clean engine oil. Install the pushrods and the valve bridges.

3. Position rocker shaft (4) on the cylinder head. Install bolts (1). Tighten the bolts in a numerical sequence. 4. Apply Tooling (A) to each of the bottom faces of the rocker arms. 5. Position rocker arm adjustment screws (2) and tighten nuts (3). Adjust the valve lash of the rocker arms. Refer to Testing and Adjusting, “Engine Valve Lash - Inspect/Adjust”. End By: Install the valve mechanism cover. Refer to Disassembly and Assembly, “Valve Mechanism Cover - Remove and Install”.

72

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Disassembly and Assembly Section

i02884464

Cylinder Head - Remove SMCS Code: 1100-011

Removal Procedure Start By: Remove the valve mechanism cover base. Refer to Disassembly and Assembly, “Valve Mechanism Cover Base - Remove and Install”. Remove the rocker arm and shaft. Refer to Disassembly and Assembly, “Rocker Arm and Shaft - Remove”. Illustration 161

Remove the electronic unit injectors. Refer to Disassembly and Assembly, “Electronic Unit Injector - Remove”. Remove the exhaust manifold. Refer to Disassembly and Assembly, “Exhaust Manifold - Remove and Install”. Remove the aftercooler. Refer to Disassembly and Assembly, “Aftercooler - Remove”.

g01140934

1. Disconnect coolant temperature sensor (1). 2. Disconnect inlet air temperature sensor (3). 3. Disconnect inlet air pressure sensor (2). 4. Disconnect fuel return tube assembly (4).

Remove the fuel filter base. Refer to Disassembly and Assembly, “Fuel Filter Base - Remove and Install”. Remove the fan drive. Refer to Disassembly and Assembly, “Fan Drive - Remove”. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, “Caterpillar 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. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 162

g01436177

5. Disconnect injection actuation pressure sensor (6). 6. Disconnect harness assembly (5). 7. Disconnect harness assembly (7) and harness assembly (8).

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73 Disassembly and Assembly Section

Illustration 163

g01027265

8. Remove tube assembly (9) from cylinder head (10).

Illustration 165

g01141531

11. Remove plug assemblies (13) and plug assemblies (14) from the cylinder head. Remove the O-ring seal from the plug assemblies. 12. Remove pipe plugs (15) from the cylinder head. 13. If necessary, remove cup plugs (12) from the cylinder head. i02884958

Cylinder Head - Install SMCS Code: 1100-012

Installation Procedure Table 46 Illustration 164

Required Tools

g01140918

9. Remove cylinder head bolts (11). Attach a suitable lifting device to cylinder head (10). The weight of cylinder head (10) is approximately 100 kg (220 lb). Remove the cylinder head from the cylinder block. 10. Remove the cylinder head gasket assembly from the cylinder block.

Tool

Part Number

A

6V-6640

B

-

C

8T-3052

Part Description

Qty

Sealant

-

Guide Stud (M16 x 2.0 x 200 mm)

2

Degree Wheel

1

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

74

RENR8633

Disassembly and Assembly Section

Illustration 168

g01140758

9. Tighten the cylinder head bolts according to the following procedure:

Illustration 166

g01141531

1. Apply Tooling (A) to cup plugs (12). Install the cup plugs in the cylinder head.

a. In a numerical sequence, tighten Bolts 1 through 26 to a torque of 130 ± 15 N·m (96 ± 11 lb ft).

2. Install pipe plugs (15) in the cylinder head.

b. In a numerical sequence, tighten Bolts 1 through 26 again to a torque of 130 ± 15 N·m (96 ± 11 lb ft).

3. Install the O-rings on plug assemblies (13) and plug assemblies (14). Install the plug assemblies in the cylinder head.

c. In a numerical sequence, tighten Bolts 1 through 26 for an additional 90 ± 5 degrees (1/ 4 turn).

4. Thoroughly clean the mating surfaces of the cylinder head and the cylinder block.

Note: If Tooling (C) is not used, place an index mark on the bolt and the cylinder head. d. Completely loosen Bolts 1 through 26.

5. Install Tooling (B) in the cylinder block. 6. Install a new cylinder head gasket assembly on the cylinder block.

e. In a numerical sequence, tighten Bolts 1 through 26 to a torque of 130 ± 15 N·m (96 ± 11 lb ft). f. In a numerical sequence, tighten Bolts 1 through 26 again to a torque of 130 ± 15 N·m (96 ± 11 lb ft). g. In a numerical sequence, tighten Bolts 1 through 26 for an additional 90 ± 5 degrees (1/ 4 turn). Note: If Tooling (C) is not used, place an index mark on the bolt and the cylinder head. h. In a numerical sequence, tighten Bolts 27 through 31 to a torque of 28 ± 7 N·m (21 ± 5 lb ft).

Illustration 167

g01140918

7. Attach a suitable lifting device to cylinder head (10). The weight of cylinder head (10) is approximately 100 kg (220 lb). Position the cylinder head on Tooling (B). 8. Apply clean engine oil to the threads of cylinder head bolts (11) and under the bolt head. Install cylinder head bolts (11). Remove Tooling (B). Install the remaining cylinder head bolts.

75

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Disassembly and Assembly Section

16. Connect inlet air temperature sensor (3). 17. Connect coolant temperature sensor (1). End By: Install the fan drive. Refer to Disassembly and Assembly, “Fan Drive - Install”. Install the fuel filter base. Refer to Disassembly and Assembly, “Fuel Filter Base - Remove and Install”. Install the aftercooler. Refer to Disassembly and Assembly, “Aftercooler - Install”. Illustration 169

g01027265

10. Install tube assembly (9) to cylinder head (10).

Install the exhaust manifold. Refer to Disassembly and Assembly, “Exhaust Manifold - Remove and Install”. Install the electronic unit injectors. Refer to Disassembly and Assembly, “Electronic Unit Injector - Install”. Install the rocker arm and shaft. Refer to Disassembly and Assembly, “Rocker Arm and Shaft - Install”. Install the valve mechanism cover base. Refer to Disassembly and Assembly, “Valve Mechanism Cover Base - Remove and Install”. i02281186

Lifter Group - Remove and Install Illustration 170

g01436177

11. Connect harness assembly (7) and harness assembly (8).

SMCS Code: 1209-010

Removal Procedure Start By:

12. Connect harness assembly (5). 13. Connect injection actuation pressure sensor (6).

Remove the cylinder head. Refer to Disassembly and Assembly, “Cylinder Head - Remove”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 171

14. Connect fuel return tube assembly (4). 15. Connect inlet air pressure sensor (2).

g00976251

76

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Disassembly and Assembly Section End By: Install the cylinder head. Refer to Disassembly and Assembly, “Cylinder Head- Install”. i02545092

Camshaft - Remove SMCS Code: 1210-011

Removal Procedure Table 48 Required Tools Illustration 172

g01141708

1. Remove valve lifter (1) from the cylinder block. 2. Put identification marks on the valve lifter for installation purposes.

Tool

Part Number

A

FT-2730

Part Description

Qty

Hook

12

Start By: Remove the rocker arm and the shaft. Refer to Disassembly and Assembly, “Rocker Arm and Shaft - Remove”.

Installation Procedure Table 47 Required Tools Tool

Part Number

A

8T-2998

Part Description Lubricant

Qty -

NOTICE Keep all parts clean from contaminants.

Remove the front cover. Refer to Disassembly and Assembly, “Front Cover - Remove and Install”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Contaminants may cause rapid wear and shortened component life.

1. Use Tooling (A) to reposition the valve lifters out of the way of the camshaft. 2. Set the No. 1 piston to top center on the compression stroke. Refer to Testing and Adjusting, “Finding Top Center Position for No. 1 Piston”.

Illustration 173

g01141708

1. Lubricate the camshaft lobe and the valve lifter bore with a 50/50 mixture of Tooling (A) and clean engine oil. Illustration 174

2. Install valve lifter (1) in the original location in the cylinder block.

g01032348

3. Ensure that the timing marks on camshaft gear (1) and idler gear (2) are aligned.

77

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Disassembly and Assembly Section 4. Remove bolts (3) and thrust plate (4) from the cylinder block.

Illustration 176

Illustration 175

g01032349

NOTICE Do not damage the lobes or the bearings when the camshaft is removed or installed. 5. Remove camshaft (5) from the cylinder block. i02885302

Camshaft - Install

g01032349

NOTICE Do not damage the lobes or the bearings when the camshaft is removed or installed. Note: During the installation of the camshaft, rotate the camshaft in both directions in order to prevent binding in the camshaft bearing bores. 1. Lubricate the camshaft lobes and the valve lifter bore with a 50/50 mixture of Tooling (B) and clean engine oil. Apply clean engine oil on the camshaft bearing journals. Carefully install camshaft (5) in the cylinder block.

SMCS Code: 1210-012

Installation Procedure Table 49 Required Tools Part Description

Tool

Part Number

A

FT-2730

Hook

B

8T-2998

Lubricant

Qty 12 -

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

Illustration 177

g01032348

NOTICE When installing the camshaft, make sure the number one cylinder is at top center of the compression stroke with the timing bolt installed in the flywheel. The camshaft timing is very important. The timing mark on the camshaft drive gear must line up with the timing mark on the idler gear. Refer to the Specifications Manual for more information. 2. Ensure that the timing marks on camshaft gear (1) and idler gear (2) are aligned.

78

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Disassembly and Assembly Section 3. Install thrust plate (4) and bolts (3). 4. The maximum permissible end play for a worn camshaft is 0.46 mm (0.018 inch). The maximum permissible end play for a new camshaft is 0.13 ± 0.08 mm (0.005 ± 0.003 inch). 5. Use Tooling (A) to position the valve lifters in the cylinder block.

2. Use a suitable press to remove the camshaft from camshaft gear (1).

Installation Procedure Note: The temperature of the camshaft gear must not exceed 177 °C (350 °F) during installation. 1. Raise the temperature of the camshaft gear up to a temperature of 177 °C (350 °F).

6. Calibrate the speed/timing sensor. Refer to Troubleshooting, “Engine Speed/Timing Sensor Calibrate”.

2. Align the key in the camshaft with the groove (keyway) in the camshaft gear.

End By:

3. Install the camshaft gear on the end of the camshaft.

Install the front cover. Refer to Disassembly and Assembly, “Front Cover - Remove and Install”. Install the rocker arm and the shaft. Refer to Disassembly and Assembly, “Rocker Arm and Shaft - Install”.

End By: Install the camshaft. Refer to Disassembly and Assembly, “Camshaft - Install”. i02545687

i02408922

Camshaft Gear - Remove and Install

Camshaft Bearings - Remove SMCS Code: 1211-011

Removal Procedure

SMCS Code: 1210-010-GE

Table 50

Removal Procedure

Required Tools

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

Tool

Part Number

Part Description

Qty

A

8S-2241

Camshaft Bearing Tool Group

1

Start By: Remove the camshaft. Refer to Disassembly and Assembly, “Camshaft - Remove”. Remove the flywheel housing. Refer to Disassembly and Assembly, “Flywheel Housing- Remove and Install”. Note: Note the oil hole orientation in each camshaft bearing prior to removal for assembly purposes. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 178

g01142107

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

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79 Disassembly and Assembly Section

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. Illustration 180

g00884735

1. Refer to Illustration 180 for the locations of the bearings. (1) Installation Dimension (A) for bearing (1) ............................. 816.5 ± 0.8 mm (32.15 ± 0.03 inch) (2) Installation Dimension (B) for bearing (2) ............................. 536.5 ± 0.8 mm (21.12 ± 0.03 inch) (3) Installation Dimension (C) for bearing (3) ..............................294.5 ± 0.8 mm (11.59 ± 0.03 inch) (4) Installation Dimension (D) for bearing (4) ........................... 0.50 ± 0.25 mm (0.020 ± 0.010 inch) Illustration 179

g00633159

1. Use Tooling (A) to remove the camshaft bearings from the cylinder block. i02545718

Camshaft Bearings - Install SMCS Code: 1211-012

Installation Procedure Table 51 Required Tools Tool

Part Number

Part Description

Qty

A

8S-2241

Camshaft Bearing Tool Group

1

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. NOTICE Camshaft bearings must be installed into their correct position. Failure to do so will result in engine damage.

80

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Disassembly and Assembly Section

Illustration 181

g00884754

2. Use Tooling (A) to install bearings (1), (2), and (3) that are behind the front bearing. Install the bearings to the proper depths. Refer to Illustration 180 and refer to Step 1. Orient the bearings so that oil holes (5) are located at the tops of the bores and joints (6) are positioned, as shown.

Illustration 182

g00884758

3. Install front bearing (4). Carefully locate oil hole (8) at the oil gallery. Orient joint (7), as shown. End By: Install the flywheel housing. Refer to Disassembly and Assembly, “Flywheel Housing - Remove and Install”. Install the camshaft. Refer to Disassembly and Assembly, “Camshaft - Install”. i02885733

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

Removal Procedure

Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin.

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81 Disassembly and Assembly Section

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.

Illustration 184

g01436507

Illustration 185

g01436512

Dispose of all fluids according to local regulations and mandates. 1. Drain the engine oil into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, “Engine Oil - Change”.

(A) Front (B) Left (C) Rear (D) Right

Illustration 183

g01436507

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

Installation Procedure Required Tools Part Number

A

230-6352

Part Description Silicone Sealant

2. Place a new gasket and engine oil pan (1) on the cylinder block. 3. Tighten four Oil Pan Bolts (X).

Table 52

Tool

1. Clean the mating surface of engine oil pan (1) and the cylinder block. Apply Tooling (A) to four areas on the sealing surface of the engine oil pan at the mating surfaces of the front housing, the flywheel housing, and the engine oil pan. The areas are Marked Location (Y).

Qty 1

4. Start with Bolt (Z) and tighten all remaining bolts (2) in a counterclockwise sequence. 5. Tighten bolts (2) to a torque of 31 ± 3 N·m (23 ± 2 lb ft).

NOTICE Keep all parts clean from contaminants.

6. Start again with Bolt (Z) and tighten all remaining bolts in a counterclockwise sequence.

Contaminants may cause rapid wear and shortened component life.

7. Tighten bolts (2) again to a torque of 31 ± 3 N·m (23 ± 2 lb ft).

82

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Disassembly and Assembly Section 8. Fill the engine with oil to the correct level. Refer to Operation and Maintenance Manual, “Engine Oil Change”.

i02274286

Cylinder Liner - Install SMCS Code: 1216-012

i02549523

Installation Procedure

Cylinder Liner - Remove

Table 54

SMCS Code: 1216-011

Required Tools

Removal Procedure

Part Description

Qty

Tool

Part Number

Table 53

B

2P-8260

Cylinder Liner Installer

1

Required Tools

C

5P-3975

Rubber Lubricant

1

Tool

Qty

Part Description

Part Number 173-5527(1)

Cylinder Pack Puller

1

1U-9897(1)

Bridge

1

A (1)

5P-8665Cylinder Liner Puller Gp is an optional Tool for removing the cylinder liner.

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

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Check the cylinder liner projection. Refer to Testing and Adjusting, “Cylinder Liner Projection - Inspect”.

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

Illustration 187

g01139009

2. Apply Tooling (C) to new seal (2). Install new seal (2) in the machined groove on cylinder liner (1).

Illustration 186

g01138987

1. Use Tooling (A) to remove cylinder liners (1). 2. Remove the seals from cylinder liners (1).

3. Lubricate the lower portion of cylinder liner (1) with clean engine oil. Ensure that the corresponding crankshaft throw is at the bottom center. Use Tooling (B) to install cylinder liner (1). End By: Install the pistons and connecting rods. Refer to Disassembly and Assembly, “Pistons and Connecting Rods - Install”.

RENR8633

83 Disassembly and Assembly Section

i03433580

Piston Cooling Jets - Remove and Install

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

SMCS Code: 1331-010

Removal Procedure Table 55

Required Tools Tool

Part Number

A

9S-9082

Part Description Engine Turning Tool

Qty 1

Start By: Remove the engine oil pan. Refer to Disassembly and Assembly, “Engine Oil Pan - Remove and Install”. NOTICE Keep all parts clean from contaminants.

Illustration 189

Contaminants may cause rapid wear and shortened component life.

1. Use Tooling (A) to rotate the crankshaft in order to gain access to the piston cooling jet.

g01144041

Note: Engine damage may occur if the piston cooling jet is not installed properly. Install the piston cooling jet by hand. 2. Position piston cooling jet (2) in the cylinder block. Ensure that piston cooling jet (2) is flush with the cylinder block. Install bolt (1). Tighten bolt (1) to a torque of 28 ± 7 N·m (21 ± 5 lb ft). End By: Install the engine oil pan. Refer to Disassembly and Assembly, “Engine Oil Pan - Remove and Install”. i02886266 Illustration 188

g01144041

1. Use Tooling (A) to rotate the crankshaft in order to gain access to the piston cooling jet. 2. Remove bolt (1) and remove piston cooling jet (2).

Installation Procedure

Pistons and Connecting Rods Remove SMCS Code: 1225-011

Removal Procedure Table 57

Table 56

Required Tools

Required Tools Tool

Part Number

A

9S-9082

Part Description Engine Turning Tool

Qty 1

Tool

Part Number

A

9S-9082

Part Description Engine Turning Tool

Qty 1

84

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Disassembly and Assembly Section Start By: Remove the cylinder head. Refer to Disassembly and Assembly, “Cylinder Head - Remove”. Remove the engine oil pump. Refer to Disassembly and Assembly, “Engine Oil Pump - Remove”. Remove the piston cooling jets. Refer to Disassembly and Assembly, “Piston Cooling Jets - Remove and Install”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Note: This engine has fractured connecting rods. Fractured connecting rods must be handled with care. Use a soft faced hammer in order to tap the connecting rod cap, if necessary. 3. Loosen connecting rod cap bolts (2). Remove connecting rod cap bolts (2) and connecting rod cap (1). 4. Remove the lower half of connecting rod bearing (5) from connecting rod cap (1). 5. Push the piston and connecting rod (3) 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 liner. i02549610

Pistons and Connecting Rods Disassemble SMCS Code: 1225-015

Disassembly Procedure Table 58 Required Tools Illustration 190

Part Description

Qty

Tool

Part Number

A

4C-3601

Piston Ring Expander

1

B

1P-1861

Retaining Ring Pliers

1

g01139028

Start By: Remove the pistons and connecting rods. Refer to Disassembly and Assembly, “Pistons and Connecting Rods - Remove”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Illustration 191

g01139029

1. Use Tooling (A) to turn the crankshaft until two of the connecting rod caps are at the bottom center. 2. Inspect connecting rod (3) and connecting rod cap (1) for the proper identification mark. Connecting rod (3) and connecting rod cap (1) should have an etched number on the side that is toward the camshaft. The number should match the cylinder number. Mark connecting rod (3) and connecting rod cap (1), if necessary.

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85 Disassembly and Assembly Section

Illustration 194

g01139053

NOTICE The connecting rod must be heated for the installation of the piston pin bearing. Do not use a torch. Illustration 192

g01139072

5. Raise the temperature of connecting rod (1) along Length (X). The maximum distance of Length (X) is 83.0 mm (3.27 inch). Length (X) should raise the temperature from 175° to 260°C (347 to 500°F) in order to assemble bearing. 6. Remove old bearing (8) and install new bearing (8) at the same time. 7. The bearing joint must be within 5 degrees of one of the locations that are indicated by the arrows. i02546083

Pistons and Connecting Rods Assemble SMCS Code: 1225-016

Assembly Procedure Table 59 Illustration 193

g01139074

Note: This engine has fractured connecting rods. Fractured connecting rods must be handled with care. When possible, the connecting rod assembly should be kept bolted together in order to protect the fractured surface when the connecting rod is out of the engine. 1. Use Tooling (B) in order to remove retaining rings (3) from piston skirt (2). 2. Remove piston pin (4) and separate piston skirt (2) and piston crown (6) from connecting rod (1). 3. Inspect bearings (7) in the piston crown (6). 4. Use Tooling (A) to remove piston rings (5).

Required Tools Part Description

Qty

Tool

Part Number

A

4C-3601

Piston Ring Expander

1

B

1P-1861

Retaining Ring Pliers

1

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

86

RENR8633

Disassembly and Assembly Section

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

1. Check the clearance between the ends of piston rings (5). Refer to Specifications, “Piston and Rings”. 2. Install the oil control piston ring with Tooling (A). The ends of the spring should be rotated 180 degrees from the ring end gap. 3. Install the intermediate piston ring with the side marked “UP-2” toward the top of the piston. Use Tooling (A) to install the ring. 4. Install the top piston ring with the side marked “UP-1” toward the top of the piston. Use Tooling (A) to install the ring. 5. Inspect bearings (7) in piston crown (6). The piston crown must be replaced if the piston crown is worn or damaged. 6. Position piston skirt (2) and piston crown (6) on connecting rod (1). Apply clean engine oil to pin (4) and install pin (4). Use Tooling (B) to install retaining rings (3). Ensure that retaining rings (3) are in the grooves of piston skirt (2). End By:

Illustration 195

g01139074

Install the pistons and connecting rods. Refer to Disassembly and Assembly, “Pistons and Connecting Rods - Install”. i03120985

Pistons and Connecting Rods Install SMCS Code: 1225-012

Installation Procedure Table 60

Required Tools

Illustration 196

g01139072

Note: This engine has fractured connecting rods. Fractured connecting rods must be handled with care. Hold the connecting rod in a soft jawed vise. Then assemble the piston pin to the connecting rod, the piston skirt, and the piston crown.

Tool

Part Number

A

9S-9082

B

-

C

173-5528

Part Description

Qty

Engine Turning Tool

1

Plastic Cap

2

Piston Ring Compressor

1

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

RENR8633

87 Disassembly and Assembly Section

NOTICE The joint between the connecting rod and the connecting rod cap is produced by fracturing. The connecting rod assembly must be handled with care in order to avoid damage to the mating surfaces. The connecting rod assembly must be replaced if any damage occurs to the mating surfaces. New connecting rod assemblies come with the connecting rod caps bolted on the connecting rod. Use only a soft jawed vise to hold the connecting rod assembly when removing the connecting rod cap bolts. Use only a soft faced hammer to tap the connecting rod cap when separating the connecting rod cap from the connecting rod. Failure to use a soft jawed vise and a soft faced hammer may result in damage to the connecting rod assembly. 1. Apply clean engine oil to the pistons, the piston rings, and the cylinder bore.

Illustration 198

g01139029

4. With the crankshaft throw at the bottom center, install the piston and connecting rod (3) in the engine. Ensure that the proper piston and connecting rod are in the corresponding cylinder with the identification mark on the connecting rod on the side that is toward the camshaft. Note: The forged part number on the connecting rod must be installed toward the flywheel end of the engine. 5. Line up the piston and connecting rod (3) with the crankshaft. Use a soft faced hammer and tap the piston into the cylinder bore until Tooling (C) comes off of the piston.

Illustration 197

g00828435

Typical Example 2. Place Tooling (B) over both fractured ends of the connecting rod. 3. Position the piston rings so that the end gaps are located 120 degrees from each other. Use Tooling (C) to compress the piston rings.

6. Before connecting rod (3) comes in contact with the crankshaft, remove Tooling (B) and install the upper half of connecting rod bearing (4). Ensure that the bearing tab engages with the slot in connecting rod (3). 7. 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. 8. Place the lower half of connecting rod bearing (5) in corresponding connecting rod cap (1). Ensure that the bearing tab engages with the groove in connecting rod cap (1). 9. Apply clean engine oil to the surface of the lower half of connecting rod bearing (5). Install connecting rod cap (1) on connecting rod (3). Ensure that the number on connecting rod cap (1) matches the number on connecting rod (3). Ensure that the numbers are on the same side. 10. Install NEW connecting rod cap bolts (2). Tighten NEW connecting rod cap bolts (2) to a torque of 50 ± 5 N·m (37 ± 3 lb ft).

88

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Disassembly and Assembly Section 11. Place an index mark on each connecting rod cap bolt. Tighten each connecting rod cap bolt (2) for an additional 90 ± 5 degrees (1/4 turn). 12. Use Tooling (A) to rotate the crankshaft in order to ensure that the crankshaft turns freely. End By: Install the piston cooling jets. Refer to Disassembly and Assembly, “Piston Cooling Jets - Remove and Install”. Install the engine oil pump. Refer to Disassembly and Assembly, “Engine Oil Pump - Install”. Install the cylinder head. Refer to Disassembly and Assembly, “Cylinder Head - Install”. i02886516

Connecting Rod Bearings Remove Removal Procedure Required Tools

A

9S-9082

Part Description Engine Turning Tool

3. Remove connecting rod cap bolts (2) and connecting rod cap (1) from connecting rod (3). Remove the lower half of connecting rod bearing (5) from connecting rod cap (1). Note: This engine has fractured connecting rods. Fractured connecting rods must be handled with care. Use a soft faced hammer in order to tap the connecting rod cap, if necessary. Note: Do not place the fractured faces of the connecting rod cap on any surface. The connecting rod cap must be laid flat on the side in order to prevent damage to the fractured faces of the connecting rod cap.

Note: Do not damage the fractured faces of the connecting rod. Place a suitable protective cap on the ends of the connecting rod in order to prevent damage to the fractured faces of the connecting rod.

Table 61

Part Number

2. Check connecting rod (3) and connecting rod caps (1) for identification and for the location.

4. Push connecting rod (3) away from the crankshaft. Remove the upper half of connecting rod bearing (4) from connecting rod (3).

SMCS Code: 1219-011

Tool

1. Use Tooling (A) to turn the crankshaft until the connecting rod bearing caps are accessible.

Qty i02886537

1

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

Connecting Rod Bearings Install SMCS Code: 1219-012

Installation Procedure

NOTICE Keep all parts clean from contaminants.

Table 62 Required Tools

Contaminants may cause rapid wear and shortened component life.

Tool

Part Number

A

9S-9082

Part Description Engine Turning Tool

Qty 1

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

Illustration 199

g01139029

RENR8633

89 Disassembly and Assembly Section

NOTICE The joint between the connecting rod and the connecting rod cap is produced by fracturing. The connecting rod assembly must be handled with care in order to avoid damage to the mating surfaces. The connecting rod assembly must be replaced if any damage occurs to the mating surfaces. New connecting rod assemblies come with the connecting rod caps bolted on the connecting rod.

Note: Ensure that the number on the connecting rod cap matches the number on the connecting rod. Make sure that both of the numbers are located on the same side. 5. Install connecting rod cap (1) and connecting rod cap bolts (2). 6. Check the bearing clearance. Refer to Disassembly and Assembly, “Bearing Clearance Check”.

Use only a soft faced hammer to tap the connecting rod cap when separating the connecting rod cap from the connecting rod.

7. Tighten connecting rod cap bolts (2) to a torque of 50 ± 5 N·m (37 ± 3 lb ft).

Failure to use a soft faced hammer may result in damage to the fractured surfaces of the connecting rod assembly.

8. Place an index mark on each connecting rod cap bolt (2). Tighten each bolt for an additional 90 ± 5 degrees (1/4 turn).

1. Use Tooling (A) to turn the crankshaft until the connecting rod bearing cap is accessible.

9. Use Tooling (A) to rotate the crankshaft in order to ensure that the crankshaft turns freely. End By: Install the engine oil pump. Refer to Disassembly and Assembly, “Engine Oil Pump - Install”. i02304108

Crankshaft Main Bearings Remove SMCS Code: 1203-011

Removal Procedure Table 63 Required Tools Illustration 200

g01139029

Note: Install the connecting rod bearings dry when clearance checks are performed. Apply clean engine oil to the connecting rod bearings for final assembly. 2. Remove the protective caps from the end of the connecting rod and install the upper half of connecting rod bearing (4). Ensure that the bearing tab engages with the slot in connecting rod (3). 3. Pull the piston and connecting rod assembly onto the crankshaft. 4. Install the lower half of connecting rod bearing (5) into connecting rod cap (1). Ensure that the bearing tab engages with the slot in connecting rod cap (1). Note: Do not place the fractured faces of the connecting rod cap on any surface. The connecting rod cap must be laid flat on the side in order to prevent damage to the fractured faces of the connecting rod cap.

Tool

Part Number

A

2P-5518

Part Description Bearing Tool

Qty 1

Start By: 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.

90

RENR8633

Disassembly and Assembly Section Note: Place clean engine oil on the crankshaft main bearings prior to assembly. Ensure that the tabs on the back side of the crankshaft main bearings fit in the grooves of the crankshaft main bearing caps and the cylinder block.

Illustration 201

g01153704

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

Illustration 202

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. Install Tooling (A) in the crankshaft journal. 4. Turn the crankshaft in order to remove the upper half of the crankshaft main bearing. i02408967

Crankshaft Main Bearings Install SMCS Code: 1203-012

g01153704

1. Use Tooling (A) and install the upper halves of the crankshaft main bearings in the cylinder block. Do not put oil on the back of the crankshaft main bearing. 2. Install the lower halves of the crankshaft main bearings in crankshaft main bearing caps (2). Do not put oil on the back of the crankshaft main bearing. NOTICE Crankshaft main bearing caps should be installed with the part number toward the front of the engine. Crankshaft main bearing caps are to be identified by stamped numbers 1 through 7 that are located on the bottom surface of the bearing cap. The thrust plate is used on the number 6 main bearing. 3. Place crankshaft main bearing caps (2) in position on the cylinder block. Place clean engine oil or Molylube on the bolt threads and the washer face. Install bolts (1).

Installation Procedure Table 64 Required Tools Part Description

Qty

Tool

Part Number

A

2P-5518

Bearing Tool

1

B

8T-5096

Dial Indicator Group

1

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

4. Tighten each bolt (1) to a torque of 95 ± 5 N·m (70 ± 4 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 0.21 - 0.60 mm (0.008 - 0.024 inch). End By: Install the engine oil pump. Refer to Disassembly and Assembly, “Engine Oil Pump - Install”.

RENR8633

91 Disassembly and Assembly Section

i02274621

3. Remove the thrust plates from the cylinder block.

Crankshaft - Remove SMCS Code: 1202-011

Removal Procedure Table 65 Required Tools Tool

Part Number

A

138-7575

Part Description Link Bracket

Qty 2

Start By: Remove the front housing. Refer to Disassembly and Assembly, “Housing (Front) - Remove”. Remove the flywheel housing. Refer to Disassembly and Assembly, “Flywheel Housing - Remove and Install”. 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 204

g00953328

4. Fasten Tooling (A) and a suitable lifting device to crankshaft (3). The weight of crankshaft (3) is approximately 79 kg (175 lb). 5. Remove crankshaft (3).

1. Ensure that the No. 1 cylinder is at the top center compression stroke. Refer to Testing and Adjusting, “Finding Top Center Position for No. 1 Piston”.

i02274650

Crankshaft - Install SMCS Code: 1202-012

Installation Procedure Table 66 Required Tools Tool

Part Number

A

138-7575

Part Description Link Bracket

Qty 2

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. NOTICE Ensure that the crankshaft main bearing tabs engage with the grooves in the block and the crankshaft main bearing cap. Illustration 203

g00964659

2. Remove connecting rod caps (1) and crankshaft main bearing caps (2).

92

RENR8633

Disassembly and Assembly Section

a. Tighten each bolt to a torque of 50 ± 5 N·m (37 ± 3 lb ft). b. Place an index mark on each bolt. Tighten each bolt for an additional 90 ± 5 degrees (1/4 turn). 5. Tighten the bolts for crankshaft main bearing caps (2) by using the following procedure: a. Tighten each bolt to a torque of 95 ± 5 N·m (70 ± 4 lb ft). b. Place an index mark on each bolt. Tighten each bolt for an additional 90 ± 5 degrees (1/4 turn). End By: Install the engine oil pump. Refer to Disassembly and Assembly, “Engine Oil Pump - Install”. Illustration 205

g00953328

1. Fasten Tooling (A) and a suitable lifting device to crankshaft (3). The weight of crankshaft (3) is approximately 79 kg (175 lb). Align the timing marks and position crankshaft (3) in the cylinder block. 2. Apply clean engine oil to the thrust plates and install the thrust plates in the cylinder block.

Install the flywheel housing. Refer to Disassembly and Assembly, “Flywheel Housing - Remove and Install”. Install the front housing. Refer to Disassembly and Assembly, “Housing (Front) - Install”. i02717761

Bearing Clearance - Check SMCS Code: 1203-535; 1219-535

Measurement Procedure Table 67

Required Tools Tool

Part Number 198-9142

198-9143

A

198-9144

198-9145

Illustration 206

Part Description

Qty

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

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

1

g00964659

3. Install connecting rod caps (1) and crankshaft main bearing caps (2). 4. Tighten the bolts for connecting rod caps (1) by using the following procedure:

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

RENR8633

93 Disassembly and Assembly Section

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. Note: The measurements should be within specifications and the correct bearings should be used. If the crankshaft journals and the bores for the block and the rods were measured during disassembly, no further checks are necessary. However, if the technician still wants to measure the bearing clearances, Tooling (A) is an acceptable method. Tooling (A) is less accurate on journals with small diameters if clearances are less than 0.10 mm (0.004 inch). NOTICE Lead wire, shim stock or a dial bore gauge can damage the bearing surfaces. The technician must be very careful to use Tooling (A) correctly. The following points must be remembered: • Ensure that the backs of the bearings and the bores are clean and dry.

Illustration 207

g01152855

Typical Example 4. Remove all of Tooling (A) before you install the bearing cap. Note: When Tooling (A) is used, the readings can sometimes be unclear. For example, all parts of Tooling (A) are not the same width. Measure the major width in order to ensure that the parts are within the specification range. Refer to Specifications Manual, “Connecting Rod Bearing Journal” and Specifications Manual, “Main Bearing Journal” for the correct clearances. i02887760

• Ensure that the bearing locking tabs are properly seated in the tab grooves. • The crankshaft must be free of oil at the contact points of Tooling (A). 1. Put a piece of Tooling (A) on the crown of the bearing that is in the cap.

Atmospheric Pressure Sensor - Remove and Install SMCS Code: 1923-010 S/N: P9L1–Up S/N: P7Z1–Up

Note: Do not allow Tooling (A) to extend over the edge of the bearing. 2. Use the correct torque-turn specifications in order to install the bearing cap. Do not use an impact wrench. Be careful not to dislodge the bearing when the cap is installed. Note: Do not turn the crankshaft when Tooling (A) is installed. 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 207 .

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

94

RENR8633

Disassembly and Assembly Section

Illustration 208

g01437326

1. Disconnect harness assembly (1) from atmospheric pressure sensor (2). 2. Remove atmospheric pressure sensor (2) and the O-ring seal.

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

Illustration 209

g01437326

Note: Check the O-ring seal for wear or for damage. If necessary, replace the O-ring seal. 1. Install the O-ring seal onto atmospheric pressure sensor (2). 2. Install atmospheric pressure sensor (2) and the Oring seal. Tighten atmospheric pressure sensor (2) to a torque of 10 ± 2 N·m (88 ± 18 lb in). 3. Connect harness assembly (1) to atmospheric pressure sensor (2). i02547038

Atmospheric Pressure Sensor - Remove and Install SMCS Code: 1923-010 S/N: KLW1–Up S/N: P7Z1–Up

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

RENR8633

95 Disassembly and Assembly Section

Illustration 210

g01175386

1. Disconnect harness assembly (1) from atmospheric pressure sensor (2). 2. Remove atmospheric pressure sensor (2) and the O-ring seal.

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

Illustration 211

g01175386

Note: Check the O-ring seal for wear or for damage. If necessary, replace the O-ring seal. 1. Install the O-ring seal onto atmospheric pressure sensor (2). 2. Install atmospheric pressure sensor (2) and the Oring seal. Tighten atmospheric pressure sensor (2) to a torque of 10 ± 2 N·m (88 ± 18 lb in). 3. Connect harness assembly (1) to atmospheric pressure sensor (2). i02353549

Coolant Temperature Sensor Remove and Install SMCS Code: 1906-010 S/N: KLW1–Up S/N: P7Z1–Up

Removal Procedure

96

RENR8633

Disassembly and Assembly Section

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. 1. Drain the coolant into a suitable container for storage or for disposal. Drain the coolant to a level that is below the coolant temperature sensor. Refer to Operation and maintenance Manual, “Cooling System Coolant (ELC) - Change”. Illustration 213

g01175490

Note: Check the O-ring seal for wear or for damage. If necessary, replace the O-ring seal. 1. Install the O-ring seal onto coolant temperature sensor (2). 2. Install coolant temperature sensor (2) into the engine. Tighten coolant temperature sensor (2) to a torque of 20 ± 5 N·m (15 ± 4 lb ft). 3. Connect harness assembly (1) onto coolant temperature sensor (2). 4. Fill the cooling system. Refer to Operation and maintenance Manual, “Cooling System Coolant (ELC) - Change”. i02887781

Illustration 212

g01175490

2. Disconnect harness assembly (1) from coolant temperature sensor (2). 3. Remove coolant temperature sensor (2) from the engine.

Installation Procedure

Coolant Temperature Sensor Remove and Install SMCS Code: 1906-010 S/N: P9L1–Up S/N: P7Z1–Up

Removal Procedure

RENR8633

97 Disassembly and Assembly Section

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. 1. Drain the coolant into a suitable container for storage or for disposal. Drain the coolant to a level that is below the coolant temperature sensor. Refer to Operation and maintenance Manual, “Cooling System Coolant (ELC) - Change”. Illustration 215

g01437341

Note: Check the O-ring seal for wear or for damage. If necessary, replace the O-ring seal. 1. Install the O-ring seal onto coolant temperature sensor (2). 2. Install coolant temperature sensor (2) into the engine. Tighten coolant temperature sensor (2) to a torque of 20 ± 3 N·m (15 ± 2 lb ft). 3. Connect harness assembly (1) onto coolant temperature sensor (2). 4. Fill the cooling system. Refer to Operation and maintenance Manual, “Cooling System Coolant (ELC) - Change”. i02547060

Illustration 214

g01437341

2. Disconnect harness assembly (1) from coolant temperature sensor (2). 3. Remove coolant temperature sensor (2) from the engine.

Installation Procedure

Engine Oil Pressure Sensor Remove and Install SMCS Code: 1924-010 S/N: KLW1–Up S/N: P7Z1–Up

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

98

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Disassembly and Assembly Section

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.

Illustration 217

g01175537

Note: Check the O-ring seal for wear or for damage. If necessary, replace the O-ring seal. 1. Install the O-ring seal on engine oil pressure sensor (2). 2. Install engine oil pressure sensor (2). Tighten engine oil pressure sensor (2) to a torque of 10 ± 2 N·m (88 ± 18 lb in). 3. Connect harness assembly (1) onto engine oil pressure sensor (2). i02887824 Illustration 216

g01175537

1. Disconnect harness assembly (1) from engine oil pressure sensor (2). 2. Remove engine oil pressure sensor (2) and the Oring seal.

Installation Procedure

Engine Oil Pressure Sensor Remove and Install SMCS Code: 1924-010 S/N: P9L1–Up S/N: P7Z1–Up

Removal Procedure

NOTICE Keep all parts clean from contaminants.

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Contaminants may cause rapid wear and shortened component life.

RENR8633

99 Disassembly and Assembly Section

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.

Illustration 219

g01437373

Note: Check the O-ring seal for wear or for damage. If necessary, replace the O-ring seal. 1. Install the O-ring seal on engine oil pressure sensor (2). 2. Install engine oil pressure sensor (2). Tighten engine oil pressure sensor (2) to a torque of 10 ± 2 N·m (88 ± 18 lb in). 3. Connect harness assembly (1) onto engine oil pressure sensor (2). i02887933 Illustration 218

g01437373

1. Disconnect harness assembly (1) from engine oil pressure sensor (2). 2. Remove engine oil pressure sensor (2) and the Oring seal.

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

Fuel Pressure Sensor Remove and Install SMCS Code: 7414-010 S/N: P9L1–Up S/N: P7Z1–Up

100

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Disassembly and Assembly Section

Removal Procedure

Installation Procedure

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

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

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

Illustration 221

g01437527

Note: Check the O-ring seal for wear or for damage. If necessary, replace the O-ring seal. 1. Install a new O-ring seal on fuel pressure sensor (2). 2. Install fuel pressure sensor (2) and tighten to a torque of 10 ± 2 N·m (89 ± 18 lb in). 3. Connect harness assembly (1). i02353671

Illustration 220

g01437527

1. Disconnect harness assembly (1). 2. Remove fuel pressure sensor (2) from the fuel filter base. 3. Remove the O-ring seal from fuel pressure sensor (2).

Fuel Pressure Sensor Remove and Install SMCS Code: 7414-010 S/N: KLW1–Up S/N: P7Z1–Up

RENR8633

101 Disassembly and Assembly Section

Removal Procedure

Installation Procedure

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

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

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

Illustration 223

g01175571

Note: Check the O-ring seal for wear or for damage. If necessary, replace the O-ring seal. 1. Install a new O-ring seal on fuel pressure sensor (2). 2. Install fuel pressure sensor (2) and tighten to a torque of 10 ± 2 N·m (89 ± 18 lb in). 3. Connect harness assembly (1). i02888006

Illustration 222

g01175571

1. Disconnect harness assembly (1). 2. Remove fuel pressure sensor (2) from the fuel filter base. 3. Remove the O-ring seal from fuel pressure sensor (2).

Injection Actuation Pressure Sensor - Remove and Install SMCS Code: 1925-010 S/N: P9L1–Up S/N: P7Z1–Up

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

102

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Disassembly and Assembly Section

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.

Illustration 225

g01437618

Note: Check the O-ring seal for wear or for damage. If necessary, replace the O-ring seal. 1. Install the O-ring seal on injection actuation pressure sensor (2). 2. Install injection actuation pressure sensor (2). Tighten injection actuation pressure sensor (2) to a torque of 20 ± 2 N·m (15 ± 1 lb ft). 3. Connect harness assembly (1). i02353707

Illustration 224

g01437618

Injection Actuation Pressure Sensor - Remove and Install

1. Disconnect harness assembly (1).

SMCS Code: 1925-010

2. Remove injection actuation pressure sensor (2).

S/N: KLW1–Up

3. Remove the O-ring from injection actuation pressure sensor (2).

S/N: P7Z1–Up

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

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

RENR8633

103 Disassembly and Assembly Section

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.

Illustration 227

g01175585

Note: Check the O-ring seal for wear or for damage. If necessary, replace the O-ring seal. 1. Install the O-ring seal on injection actuation pressure sensor (2). 2. Install injection actuation pressure sensor (2). Tighten injection actuation pressure sensor (2) to a torque of 20 ± 2 N·m (15 ± 1 lb ft). 3. Connect harness assembly (1). i02888045

Illustration 226

g01175585

Speed/Timing Sensor Remove and Install

1. Disconnect harness assembly (1).

SMCS Code: 1907-010; 1912-010

2. Remove injection actuation pressure sensor (2).

S/N: P9L1–Up

3. Remove the O-ring from injection actuation pressure sensor (2).

S/N: P7Z1–Up

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

Removal Procedure

104

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Disassembly and Assembly Section

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

Illustration 228

g01437674

1. Disconnect harness assemblies (2) from speed/ timing sensors (1).

Illustration 230

g01175674

Note: Check the O-ring seals for wear or for damage. If necessary, replace the O-ring seals. 1. Apply Tooling (A) to the O-ring seals prior to installation. Install speed/timing sensors (1). 2. Position bracket (5) and install bolt (3) and washer (4). Tighten bolt (3) to a torque of 28 ± 7 N·m (21 ± 5 lb ft).

Illustration 229

g01175674

2. Remove bolt (3), washer (4), and bracket (5). Remove speed/timing sensors (1). Remove the Oring seals from speed/timing sensors (1).

Installation Procedure Table 68 Required Tools Tool

Part Number

A

5P-3975

Part Description Rubber Lubricant

Qty 1

RENR8633

105 Disassembly and Assembly Section

Illustration 231

g01437674

3. Connect harness assemblies (2) onto speed/timing sensors (1).

Illustration 232

g01175595

1. Disconnect harness assemblies (2) from speed/ timing sensors (1).

i02354157

Speed/Timing Sensor Remove and Install SMCS Code: 1907-010; 1912-010 S/N: KLW1–Up S/N: P7Z1–Up

Removal Procedure

Illustration 233

g01175674

2. Remove bolt (3), washer (4), and bracket (5). Remove speed/timing sensors (1). Remove the Oring seals from speed/timing sensors (1).

Installation Procedure Table 69 Required Tools Tool

Part Number

A

5P-3975

Part Description Rubber Lubricant

Qty 1

106

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Disassembly and Assembly Section

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

Illustration 235

g01175595

3. Connect harness assemblies (2) onto speed/timing sensors (1). i02888118 Illustration 234

g01175674

Note: Check the O-ring seals for wear or for damage. If necessary, replace the O-ring seals. 1. Apply Tooling (A) to the O-ring seals prior to installation. Install speed/timing sensors (1). 2. Position bracket (5) and install bolt (3) and washer (4). Tighten bolt (3) to a torque of 28 ± 7 N·m (21 ± 5 lb ft).

Turbocharger Outlet Pressure Sensor - Remove and Install SMCS Code: 1917-010 S/N: P9L1–Up S/N: P7Z1–Up

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 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.

RENR8633

107 Disassembly and Assembly Section 2. Install turbocharger outlet pressure sensor (2). Tighten turbocharger outlet pressure sensor (2) to a torque of 10 ± 2 N·m (88 ± 18 lb in). 3. Connect harness assembly (1) to turbocharger outlet pressure sensor (2). i02547010

Turbocharger Outlet Pressure Sensor - Remove and Install SMCS Code: 1917-010 S/N: KLW1–Up S/N: P7Z1–Up

Removal Procedure Illustration 236

g01437751

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

1. Disconnect harness assembly (1) from turbocharger outlet pressure sensor (2). 2. Remove turbocharger outlet pressure sensor (2) and the O-ring seal.

Installation Procedure

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

Illustration 237

g01437751

Note: Check the O-ring seal for wear or damage. If necessary, replace the O-ring seal. 1. Install the O-ring seal on turbocharger outlet pressure sensor (2).

108

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Disassembly and Assembly Section 2. Install turbocharger outlet pressure sensor (2). Tighten turbocharger outlet pressure sensor (2) to a torque of 10 ± 2 N·m (88 ± 18 lb in). 3. Connect harness assembly (1) to turbocharger outlet pressure sensor (2). i02888135

Inlet Air Temperature Sensor Remove and Install SMCS Code: 1921-010 S/N: P9L1–Up S/N: P7Z1–Up

Removal Procedure Illustration 238

g01175712

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

1. Disconnect harness assembly (1) from turbocharger outlet pressure sensor (2). 2. Remove turbocharger outlet pressure sensor (2) and the O-ring seal.

Installation Procedure

Illustration 240

g01437770

1. Disconnect harness assembly (1) from inlet air temperature sensor (2). Illustration 239

g01175712

Note: Check the O-ring seal for wear or damage. If necessary, replace the O-ring seal. 1. Install the O-ring seal on turbocharger outlet pressure sensor (2).

2. Remove inlet air temperature sensor (2). Remove the O-ring seal from inlet air temperature sensor (2).

Installation Procedure

RENR8633

109 Disassembly and Assembly Section

Illustration 241

g01437770

Note: Check the O-ring seal for wear or for damage. If necessary, replace the O-ring seal. 1. Install the O-ring seal onto inlet air temperature sensor (2). 2. Install inlet air temperature sensor (2). Tighten inlet air temperature sensor (2) to a torque of 20 ± 3 N·m (15 ± 2 lb ft).

Illustration 242

g01175809

1. Disconnect harness assembly (1) from inlet air temperature sensor (2). 2. Remove inlet air temperature sensor (2). Remove the O-ring seal from inlet air temperature sensor (2).

Installation Procedure

3. Connect harness assembly (1) onto inlet air temperature sensor (2). i02547027

Inlet Air Temperature Sensor Remove and Install SMCS Code: 1921-010 S/N: KLW1–Up S/N: P7Z1–Up

Removal Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Illustration 243

g01175809

Note: Check the O-ring seal for wear or for damage. If necessary, replace the O-ring seal. 1. Install the O-ring seal onto inlet air temperature sensor (2).

110

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Disassembly and Assembly Section 2. Install inlet air temperature sensor (2). Tighten inlet air temperature sensor (2) to a torque of 20 ± 5 N·m (15 ± 4 lb ft). 3. Connect harness assembly (1) onto inlet air temperature sensor (2). i02888365

Fan Drive Mounting Group Remove and Install SMCS Code: 1359-010 S/N: P9L1–Up S/N: P7Z1–Up

Removal Procedure Illustration 245

g01438065

1. Position fan drive mounting group (1) on the engine. 2. Install bolts (2). i02354656

Fan Drive - Remove SMCS Code: 1359-011 S/N: KLW1–Up S/N: P7Z1–Up

Removal Procedure Illustration 244

1. Remove bolts (2). 2. Remove fan drive mounting group (1).

Installation Procedure

g01438065

1. Remove the belt. Refer to Operation and Maintenance Manual, “Belts - Inspect/Replace”.

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111 Disassembly and Assembly Section

Disassembly Procedure Table 70 Required Tools Tool

Part Number

A

1P-0510

Part Description Driver Gp

Qty 1

Start By: Remove the fan drive. Refer to Disassembly and Assembly, “Fan Drive - Remove”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 246

g01175900

2. Remove bolts (1) and remove pulley (2).

Illustration 248

g01176090

1. Remove bolts (2) and washers (3). 2. Remove shaft assembly (4) from fan drive bracket (1). Illustration 247

g01175906

3. Remove bolts (3) and remove fan drive (4). i02547150

Fan Drive - Disassemble SMCS Code: 1359-015 S/N: KLW1–Up S/N: P7Z1–Up

112

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Disassembly and Assembly Section

Assembly Procedure Table 71 Required Tools Part Description

Qty

Tool

Part Number

A

1P-0510

Driver Gp

1

B

8T-1807

Bearing Lubricant

1

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

Illustration 249

g01176110

Illustration 250

g01274943

3. Remove bolts (5) and plate (6) from shaft (9). 4. Position shaft assembly into a suitable press. If necessary, use Tooling (A) or a suitable press and remove shaft (9) from retainer (8) and bearing (7). i02547173

Fan Drive - Assemble SMCS Code: 1359-016 S/N: KLW1–Up S/N: P7Z1–Up

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113 Disassembly and Assembly Section

Illustration 251

g01176172

Illustration 253

g01176090

4. Install shaft assembly (4), bolts (2), and washers (3) into fan drive bracket (1). Tighten bolts (2) to a torque of 28 ± 7 N·m (21 ± 5 lb ft). End By: Install the fan drive. Refer to Disassembly and Assembly, “Fan Drive - Install”. i02547382

Fan Drive - Install SMCS Code: 1359-012 S/N: KLW1–Up S/N: P7Z1–Up

Installation Procedure Illustration 252

g01176110

Note: Cool the shaft before pressing bearing onto the shaft. 1. Apply Tooling (B) to the outside of shaft (9). 2. Use Tooling (A) and a suitable press. Position bearing (7) and press into retainer (8) and onto shaft (9). 3. Install bolts (5) and plate (6) into shaft (9). Tighten bolts (5) to a torque of 28 ± 7 N·m (21 ± 5 lb ft).

114

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Disassembly and Assembly Section

i02548204

Pump Drive - Remove SMCS Code: 3108-011

Removal Procedure Table 72 Required Tools

Illustration 254

Tool

Part Number

A

1P-0510

Part Description Driver Gp

Qty 1

g01175906

1. Position fan drive (4) and install bolts (3). Tighten bolts (3) to a torque of 28 ± 7 N·m (21 ± 5 lb ft).

Illustration 256

g01178705

1. Remove bolts (10), cover (6), and gasket (5) from adapter assembly (9). Remove bolts (4), adapter assembly (9), and O-ring seal (8). Remove gear assembly (7) from adapter assembly (9). Use Tooling (A) to remove bearing (3). Remove bearing (2) from flywheel housing (1). 2. Repeat this same procedure to remove accessory pump drive (11). Illustration 255

g01175900

2. Position pulley (2) and install bolts (1). Tighten bolts (1) to a torque of 28 ± 7 N·m (21 ± 5 lb ft).

i02888589

Pump Drive - Install SMCS Code: 3108-012

3. Install the belt. Refer to Operation and Maintenance Manual, “Belts - Inspect/Replace”.

Installation Procedure Table 73 Required Tools Tool

Part Number

A

1P-0510

Part Description Driver Gp

Qty 1

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115 Disassembly and Assembly Section

Illustration 257

g01179033

Illustration 259

g01275405

(Y) 2.5 ± 0.5 mm (0.10 ± 0.02 inch)

1. Use Tooling (A) to install bearing (2) to the depth of Dimension (Y) in flywheel housing (1).

3. Install gear assembly (7). Install O-ring seal (8). Install adapter assembly (9) in flywheel housing (1). Install bolts (4). 4. Install gasket (5). Install cover (6). Install bolts (10). 5. Repeat the same procedure to install accessory pump drive (11). i02888640

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

Removal Procedure Start By: Remove the fumes disposal group, if necessary. Refer to Disassembly and Assembly, “Crankcase Breather - Remove and Install”.

Illustration 258

g01178992

(W) 3.5 ± 0.5 mm (0.14 ± 0.02 inch) (X) 15 ± 5 degrees

2. Orient bearing (3) to Dimension (X). Use Tooling (A) to install bearing (3) into adapter assembly (9). Install bearing (3) to Dimension (W).

116

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Disassembly and Assembly Section

3. Connect harness assemblies (1). Tighten allen head screws (5) to a torque of 6 ± 1 N·m (53 ± 9 lb in). End By: Install the fumes disposal group, if necessary. Refer to Disassembly and Assembly, “Crankcase Breather - Remove and Install”. i02548664

Alternator - Remove and Install SMCS Code: 1405-010

Removal Procedure

Illustration 260

g01275421

1. Loosen allen head screws (5) until harness assemblies (1) can be disconnected. Disconnect harness assemblies (1).

Personal injury can result from failure to disconnect the battery. First, disconnect the negative battery cable. Then, disconnect the positive battery cable.

2. Disconnect hose assemblies (3).

A positive power lead can cause sparks if the battery is not disconnected. Sparks can possibly result in battery explosion or fire.

3. Remove bolts (2), the washers, and the spacers. Remove electronic control module (4).

1. Disconnect the batteries.

Installation Procedure

2. Place identification marks on all of the harness assemblies and disconnect the harness assemblies. 3. Remove the belt. Refer to Operation and Maintenance Manual, “Belts - Inspect/Replace”.

Illustration 261

g01275421

1. Position electronic control module (4) onto the cylinder block. Install bolts (2), the washers, and the spacers. 2. Connect hose assemblies (3).

RENR8633

117 Disassembly and Assembly Section 4. Connect the harness assembly to alternator (2) and install the bolt. Refer to Specifications, “Alternator and Regulator” for the proper torque for your alternator. 5. Connect the harness assembly to alternator (2) and install the nut. Refer to Specifications, “Alternator and Regulator” for the proper torque for your alternator. 6. Connect the batteries. i03904991

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

Removal Procedure Illustration 262

g01176687

4. Remove bolts (1) and alternator (2).

Personal injury can result from failure to disconnect the battery.

Installation Procedure

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

Illustration 263

g01176687

1. If necessary, install the pulley on alternator (2). Install the nut. Refer to Specifications, “Alternator and Regulator” for the proper torque for your alternator. 2. Position alternator (2) on the alternator mounting bracket. Install bolts (1). 3. Install the belt. Refer to Operation and Maintenance Manual, “Belts - Inspect/Replace”.

Illustration 264

g02146813

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

118

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

Installation Procedure 1. Install electric starting motor (4) in reverse order. i02889233

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

Removal Procedure Table 74 Required Tools Tool

Part Number

A

138-7573

Part Description Link Bracket

Qty 1 Illustration 265

Do not disconnect the air lines until the air pressure in the system is at zero. If hose is disconnected under pressure it can cause personal injury. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

g01028440

2. Disconnect hose assembly (1) and hose assembly (3) from the air compressor. 3. Disconnect hose assembly (2) and hose assembly (4) from the air compressor. 4. Attach Tooling (A) and a suitable lifting device to the air compressor. The weight of the air compressor is approximately 23 kg (51 lb). 5. Remove the mounting bracket for the air compressor by using the following procedure:

NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or 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. 1. Remove the air pressure from the air tank and drain the coolant from the cooling system. Illustration 266

g01028442

a. Remove bolts (5) that fasten the mounting bracket to the air compressor.

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119 Disassembly and Assembly Section

b. Remove bolts (6) that fasten the mounting bracket to the cylinder block. Remove the mounting bracket for the air compressor.

Illustration 268

g01028444

1. Install Tooling (A) and a suitable lifting device to the air compressor. The weight of the air compressor is approximately 23 kg (51 lb). Illustration 267

g01028444

2. Inspect the condition of the integral seal. Replace the integral seal, if necessary. Install the integral seal between air compressor (8) and the timing gear housing.

6. Remove bolts (7), air compressor (8), and the integral seal from the timing gear housing.

Installation Procedure

3. Position air compressor (8) in the front housing. Ensure that the drive gear engages correctly with the gear in the front housing.

Table 75 Required Tools Part Description

Qty

Tool

Part Number

A

138-7573

Link Bracket

1

B

9S-3263

Thread Lock Compound

1

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

4. Apply Tooling (B) to the threads of bolts (7). Install bolts (7). Tighten bolts (7) to a torque of 100 ± 20 N·m (75 ± 15 lb ft). 5. Install the mounting bracket for the air compressor by using the following procedure:

120

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Disassembly and Assembly Section

Illustration 269

g01028442 Illustration 270

a. Position the bracket for the air compressor and install bolts (5) and bolts (6) finger tight. NOTICE A loose compressor bracket can lead to a broken front cover and can cause damage to the front gear train of the engine. b. Tighten bolts (5) to a torque of 60 ± 12 N·m (44 ± 9 lb ft). Tighten bolts (6) to a torque of 60 ± 12 N·m (44 ± 9 lb ft). Remove the suitable lifting device and Tooling (A).

g01028440

6. Connect hose assembly (4) to the air compressor. Connect the clip that holds hose assembly (4) to the air compressor, if necessary. Tighten the bolt that holds the clip for the oil hose assembly to a torque of 28 ± 7 N·m (21 ± 5 lb ft). 7. Connect hose assembly (1) and hose assembly (3) to the air compressor. 8. Connect hose assembly (2) to the air compressor. 9. Fill the cooling system with coolant to the correct level. Refer to the Operation and Maintenance Manual for the correct filling procedure.

RENR8633

121 Index Section

Index A Aftercooler - Install........................................... 54 Installation Procedure .................................. 54 Aftercooler - Remove....................................... 53 Removal Procedure ..................................... 53 Air Compressor - Remove and Install.............118 Installation Procedure .................................119 Removal Procedure ....................................118 Air Inlet Heater - Install .................................... 21 Installation Procedure .................................. 21 Air Inlet Heater - Remove ................................ 20 Removal Procedure ..................................... 20 Air Lines - Remove and Install......................... 17 Installation Procedure .................................. 17 Removal Procedure ..................................... 17 Alternator - Remove and Install ......................116 Installation Procedure .................................117 Removal Procedure ....................................116 Atmospheric Pressure Sensor - Remove and Install................................................. 93–94 Installation Procedure ............................ 94–95 Removal Procedure ............................... 93–94 Auxiliary Water Pump - Assemble ................... 47 Assembly Procedure.................................... 47 Auxiliary Water Pump - Assemble (Type 2) ..... 49 Assembly Procedure.................................... 49 Auxiliary Water Pump - Disassemble .............. 42 Disassembly Procedure............................... 42 Auxiliary Water Pump - Disassemble (Type 2).................................................................... 43 Disassembly Procedure............................... 44 Auxiliary Water Pump - Install.......................... 53 Installation Procedure .................................. 53 Auxiliary Water Pump - Remove...................... 41 Removal Procedure ..................................... 41

B Bearing Clearance - Check ............................. 92 Measurement Procedure ............................. 92

C Camshaft - Install............................................. 77 Installation Procedure .................................. 77 Camshaft - Remove......................................... 76 Removal Procedure ..................................... 76 Camshaft Bearings - Install.............................. 79

Installation Procedure .................................. 79 Camshaft Bearings - Remove ......................... 78 Removal Procedure ..................................... 78 Camshaft Gear - Remove and Install .............. 78 Installation Procedure .................................. 78 Removal Procedure ..................................... 78 Connecting Rod Bearings - Install ................... 88 Installation Procedure .................................. 88 Connecting Rod Bearings - Remove ............... 88 Removal Procedure ..................................... 88 Coolant Temperature Sensor - Remove and Install........................................................ 95–96 Installation Procedure ............................ 96–97 Removal Procedure ............................... 95–96 Crankcase Breather - Remove and Install....... 65 Installation Procedure .................................. 65 Removal Procedure ..................................... 65 Crankshaft - Install........................................... 91 Installation Procedure .................................. 91 Crankshaft - Remove....................................... 91 Removal Procedure ..................................... 91 Crankshaft Front Seal - Install ......................... 60 Installation Procedure .................................. 60 Crankshaft Front Seal - Remove ..................... 59 Removal Procedure ..................................... 59 Crankshaft Main Bearings - Install................... 90 Installation Procedure .................................. 90 Crankshaft Main Bearings - Remove............... 89 Removal Procedure ..................................... 89 Crankshaft Rear Seal - Install.......................... 57 Installation Procedure .................................. 57 Crankshaft Rear Seal - Remove...................... 56 Removal Procedure ..................................... 56 Cylinder Block Cover - Remove and Install ..... 66 Installation Procedure .................................. 67 Removal Procedure ..................................... 66 Cylinder Head - Install ..................................... 73 Installation Procedure .................................. 73 Cylinder Head - Remove ................................. 72 Removal Procedure ..................................... 72 Cylinder Liner - Install ...................................... 82 Installation Procedure .................................. 82 Cylinder Liner - Remove .................................. 82 Removal Procedure ..................................... 82

D Disassembly and Assembly Section ................. 5

122

RENR8633

Index Section

E Electric Starting Motor - Remove and Install ..117 Installation Procedure .................................118 Removal Procedure ....................................117 Electronic Control Module - Remove and Install.............................................................115 Installation Procedure .................................116 Removal Procedure ....................................115 Electronic Unit Injector - Install .......................... 9 Installation Procedure .................................... 9 Electronic Unit Injector - Remove ...................... 8 Removal Procedure ....................................... 8 Electronic Unit Injector Sleeve - Install ............ 12 Installation Procedure .................................. 12 Electronic Unit Injector Sleeve - Remove .........11 Removal Procedure ......................................11 Engine Oil Filter Base and Oil Cooler - Install.. 28 Installation Procedure .................................. 28 Engine Oil Filter Base and Oil Cooler Remove ......................................................... 27 Removal Procedure ..................................... 27 Engine Oil Pan - Remove and Install............... 80 Installation Procedure .................................. 81 Removal Procedure ..................................... 80 Engine Oil Pressure Sensor - Remove and Install........................................................ 97–98 Installation Procedure ............................ 98–99 Removal Procedure ............................... 97–98 Engine Oil Pump - Assemble........................... 32 Assembly Procedure.................................... 32 Engine Oil Pump - Disassemble...................... 31 Disassembly Procedure............................... 31 Engine Oil Pump - Install ................................. 33 Installation Procedure .................................. 33 Engine Oil Pump - Remove ............................. 29 Removal Procedure ..................................... 29 Exhaust Manifold - Remove and Install ..... 18–19 Installation Procedure ............................ 18–19 Removal Procedure ............................... 18–19

F Fan Drive - Assemble .....................................112 Assembly Procedure...................................112 Fan Drive - Disassemble ................................111 Disassembly Procedure.............................. 111 Fan Drive - Install............................................113 Installation Procedure .................................113 Fan Drive - Remove........................................110 Removal Procedure ....................................110

Fan Drive Mounting Group - Remove and Install.............................................................110 Installation Procedure .................................110 Removal Procedure ....................................110 Flywheel - Remove and Install......................... 55 Installation Procedure .................................. 56 Removal Procedure ..................................... 55 Flywheel Housing - Remove and Install .......... 57 Installation Procedure .................................. 58 Removal Procedure ..................................... 57 Front Cover - Remove and Install.................... 60 Installation Procedure .................................. 61 Removal Procedure ..................................... 60 Fuel Filter Base - Remove and Install................ 6 Installation Procedure .................................... 7 Removal Procedure ....................................... 6 Fuel Pressure Sensor - Remove and Install.. 99– 100 Installation Procedure ........................ 100–101 Removal Procedure ........................... 100–101 Fuel Priming Pump - Remove and Install .......... 5 Installation Procedure .................................... 5 Removal Procedure ....................................... 5

G Gear Group (Front) - Install.............................. 62 Installation Procedure .................................. 62 Gear Group (Front) - Remove ......................... 61 Removal Procedure ..................................... 61

H Housing (Front) - Install ................................... 64 Installation Procedure .................................. 64 Housing (Front) - Remove ............................... 63 Removal Procedure ..................................... 63

I Important Safety Information ............................. 2 Injection Actuation Pressure Sensor Remove and Install .............................. 101–102 Installation Procedure ........................ 102–103 Removal Procedure ........................... 101–102 Inlet Air Temperature Sensor - Remove and Install.................................................... 108–109 Installation Procedure ........................ 108–109 Removal Procedure ........................... 108–109 Inlet and Exhaust Valve Guides - Remove and Install....................................................... 25

RENR8633

123 Index Section

Installation Procedure .................................. 25 Removal Procedure ..................................... 25 Inlet and Exhaust Valve Seat Inserts Remove and Install ........................................ 26 Installation Procedure .................................. 26 Removal Procedure ..................................... 26 Inlet and Exhaust Valve Springs - Remove and Install....................................................... 22 Installation Procedure .................................. 23 Removal Procedure ..................................... 22 Inlet and Exhaust Valves - Remove and Install.............................................................. 24 Installation Procedure .................................. 24 Removal Procedure ..................................... 24

L Lifter Group - Remove and Install.................... 75 Installation Procedure .................................. 76 Removal Procedure ..................................... 75

P Piston Cooling Jets - Remove and Install........ 83 Installation Procedure .................................. 83 Removal Procedure ..................................... 83 Pistons and Connecting Rods - Assemble ...... 85 Assembly Procedure.................................... 85 Pistons and Connecting Rods Disassemble .................................................. 84 Disassembly Procedure............................... 84 Pistons and Connecting Rods - Install............. 86 Installation Procedure .................................. 86 Pistons and Connecting Rods - Remove......... 83 Removal Procedure ..................................... 83 Pump Drive - Install ........................................114 Installation Procedure .................................114 Pump Drive - Remove ....................................114 Removal Procedure ....................................114

R Rocker Arm - Assemble................................... 70 Assembly Procedure.................................... 70 Rocker Arm - Disassemble.............................. 70 Disassembly Procedure............................... 70 Rocker Arm and Shaft - Install......................... 71 Installation Procedure .................................. 71 Rocker Arm and Shaft - Remove..................... 69 Removal Procedure ..................................... 69

S Speed/Timing Sensor - Remove and Install ............................................................. 103, 105 Installation Procedure ........................ 104–105 Removal Procedure ........................... 103, 105

T Table of Contents............................................... 3 Turbocharger - Install................................. 15–16 Installation Procedure ............................ 15–16 Turbocharger - Remove............................. 14–15 Removal Procedure ............................... 14–15 Turbocharger Outlet Pressure Sensor Remove and Install .............................. 106–107 Installation Procedure ........................ 107–108 Removal Procedure ........................... 106–107

U Unit Injector Hydraulic Pump - Install............... 13 Installation Procedure .................................. 13 Unit Injector Hydraulic Pump - Remove........... 12 Removal Procedure ..................................... 12

V Valve Mechanism Cover - Remove and Install.............................................................. 67 Installation Procedure .................................. 67 Removal Procedure ..................................... 67 Valve Mechanism Cover Base - Remove and Install....................................................... 68 Installation Procedure .................................. 69 Removal Procedure ..................................... 68 Vibration Damper and Pulley - Remove and Install.............................................................. 58 Installation Procedure .................................. 59 Removal Procedure ..................................... 58

W Water Pump - Assemble.................................. 35 Assembly Procedure.................................... 35 Water Pump - Disassemble............................. 35 Disassembly Procedure............................... 35 Water Pump - Install ........................................ 36 Installation Procedure .................................. 36 Water Pump - Remove .................................... 34 Removal Procedure ..................................... 34

124 Index Section

Water Temperature Regulator - Remove and Install..................................................37, 39 Installation Procedure .............................38, 40 Removal Procedure ................................37, 39

RENR8633

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