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RENR7458-09

August 2008

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

SAFETY.CAT.COM
i01658146

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. 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 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.
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. If a tool,
procedure, work method or operating technique that is not specifically recommended by Caterpillar
is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that
the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
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. Caterpillar dealers have the most current information available.

When replacement parts are required for this


product Caterpillar recommends using Caterpil-
lar replacement parts or parts with equivalent
specifications including, but not limited to, phys-
ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema-


ture failures, product damage, personal injury or
death.
RENR7458-09 3
Table of Contents

Table of Contents Lifter Group - Remove and Install ......................... 43


Camshaft - Remove .............................................. 45
Camshaft - Install .................................................. 45
Camshaft Gear - Remove and Install .................. 46
Disassembly and Assembly Section Camshaft Bearings - Remove and Install ............ 47
Engine Oil Pan - Remove and Install ................... 48
Fuel Priming Pump - Remove and Install .............. 4
Piston Cooling Jets - Remove and Install ............. 49
Fuel Filter Base - Remove and Install .................... 4
Pistons and Connecting Rods - Remove .............. 50
Fuel Transfer Pump - Remove ................................ 5
Pistons and Connecting Rods - Disassemble ....... 51
Fuel Transfer Pump - Install .................................... 6
Pistons and Connecting Rods - Assemble ........... 51
Unit Injector - Remove ............................................ 7
Pistons and Connecting Rods - Install .................. 53
Unit Injector - Install ................................................ 8
Connecting Rod Bearings - Remove .................... 54
Unit Injector Sleeve - Remove ................................ 9
Connecting Rod Bearings - Install ........................ 54
Unit Injector Sleeve - Install .................................. 10
Crankshaft Main Bearings - Remove .................... 55
Unit Injector Hydraulic Pump - Remove ................. 11
Crankshaft Main Bearings - Install ........................ 56
Unit Injector Hydraulic Pump - Install ..................... 11
Crankshaft - Remove ............................................ 57
Modulating Valve - Remove and Install ................ 12
Crankshaft - Install ................................................ 58
Turbocharger - Remove ........................................ 12
Crankshaft Gear - Remove and Install ................ 59
Turbocharger - Install ............................................ 13
Bearing Clearance - Check ................................... 60
Exhaust Manifold - Remove and Install ............... 14
Atmospheric Pressure Sensor - Remove and
Air Inlet Heater Solenoid - Remove and Install .... 15
Install ................................................................... 61
Inlet and Exhaust Valves - Remove and Install .... 15
Coolant Temperature Sensor - Remove and
Inlet and Exhaust Valve Guides - Remove and
Install ................................................................... 61
Install ................................................................... 17
Engine Oil Pressure Sensor - Remove and Install
Inlet and Exhaust Valve Seat Inserts - Remove and
............................................................................. 62
Install ................................................................... 18
Injection Actuation Pressure Sensor - Remove and
Engine Oil Filter Base and Oil Cooler - Remove .. 19
Install ................................................................... 62
Engine Oil Filter Base - Disassemble ................... 19
Speed/Timing Sensor - Remove and Install ........ 62
Engine Oil Filter Base - Assemble ........................ 20
Boost Pressure Sensor - Remove and Install ....... 63
Engine Oil Filter Base and Oil Cooler - Install ..... 20
Inlet Air Temperature Sensor - Remove and
Engine Oil Pump - Remove .................................. 22
Install ................................................................... 63
Engine Oil Pump - Disassemble ........................... 22
Fan Drive Mounting Group - Remove and Install .. 64
Engine Oil Pump - Assemble ................................ 23
Engine Control Module - Remove and Install ....... 65
Engine Oil Pump - Install ...................................... 24
Alternator - Remove and Install ........................... 65
Water Pump - Remove ......................................... 24
Electric Starting Motor - Remove and Install ....... 66
Water Pump - Disassemble ................................. 25
Air Compressor - Remove and Install .................. 67
Water Pump - Assemble ...................................... 25
Air Compressor Drive Gear - Remove .................. 68
Water Pump - Install ............................................. 26
Air Compressor Drive Gear - Install (Two
Water Temperature Regulator - Remove and Install
Cylinder) .............................................................. 69
............................................................................. 26
Air Compressor Drive Gear - Install ...................... 70
Flywheel - Remove ............................................... 27
Flywheel - Install ................................................... 27
Crankshaft Rear Seal - Remove ........................... 28 Index Section
Crankshaft Rear Seal - Install ............................... 28
Flywheel Housing - Remove and Install .............. 29 Index ..................................................................... 71
Vibration Damper and Pulley - Remove and Install
............................................................................. 30
Crankshaft Front Seal - Remove .......................... 31
Crankshaft Front Seal - Install .............................. 32
Front Cover - Remove .......................................... 32
Front Cover - Install .............................................. 32
Housing (Front) - Remove .................................... 33
Housing (Front) - Install ........................................ 34
Camshaft Idler Gear - Remove and Install ........... 35
Valve Mechanism Cover - Remove and Install ..... 36
Valve Mechanism Cover Base - Remove and
Install ................................................................... 36
Rocker Shaft and Pushrod - Remove ................... 37
Rocker Shaft - Disassemble ................................ 38
Rocker Shaft - Assemble ..................................... 38
Rocker Shaft and Pushrod - Install ....................... 39
Cylinder Head - Remove ...................................... 40
Cylinder Head - Install .......................................... 41
4 RENR7458-09
Disassembly and Assembly Section

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

Section Installation Procedure


i02581591

Fuel Priming Pump - Remove


and Install
SMCS Code: 1258-010

Removal Procedure

Fuel leaked or spilled onto hot surfaces or elec-


trical components can cause a fire. To help pre-
vent possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.

NOTICE
Care must be taken to ensure that fluids are contained Illustration 2
g00987651
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to 1. Position the gasket and fuel priming pump (1) on
collect the fluid with suitable containers before open- the fuel filter base.
ing any compartment or disassembling any compo-
nent containing fluids. 2. Install bolts (2). Tighten bolts (2) to a torque of
25 6 Nm (18 4 lb ft).
Refer to Special Publication, NENG2500, Caterpillar
Dealer Service Tool Catalog for tools and supplies
suitable to collect and contain fluids on Caterpillar i01921666
products.
Fuel Filter Base - Remove and
Dispose of all fluids according to local regulations and Install
mandates.
SMCS Code: 1262-010

Removal Procedure

Fuel leaked or spilled onto hot surfaces or elec-


trical components can cause a fire. To help pre-
vent possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.

g00987651
Illustration 1

1. Remove bolts (2).


RENR7458-09 5
Disassembly and Assembly Section

Installation Procedure
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent 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.

g00987754
Illustration 4

1. Position fuel filter base (4) on the engine.

2. Install bolts (2).

3. Connect tube assembly (1) and tube assembly (3).

i02226208

Fuel Transfer Pump - Remove


SMCS Code: 1256-011

g00987754
Removal Procedure
Illustration 3
Table 1
1. Disconnect tube assembly (1) and tube assembly
Required Tools
(3).
Part
2. Remove bolts (2). Tool Number Part Description Qty
A 218-8171 Bolt 1
3. Remove fuel filter base (4).

Start By:

a. Remove the unit injector hydraulic pump. Refer


to Disassembly and Assembly, Unit Injector
Hydraulic Pump - Remove.

Note: Tooling (A) is required for replacement of the


fuel transfer pump.
6 RENR7458-09
Disassembly and Assembly Section

7. Remove fuel transfer pump (2).


NOTICE
Care must be taken to ensure that fluids are contained
i02226252
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to Fuel Transfer Pump - Install
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo- SMCS Code: 1256-012
nent containing fluids.

Refer to Special Publication, NENG2500, Caterpillar Installation Procedure


Tools and Shop Products Guide for tools and supplies
Table 2
suitable to collect and contain fluids on Caterpillar
products. Required Tools
Part
Dispose of all fluids according to local regulations and Tool Number Part Description Qty
mandates.
A 218-8171 Bolt 1

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened


component life.

g01123057
Illustration 5

1. Mount the unit injector hydraulic pump in a vertical


position on a work bench.

Note: Failure to maintain a vertical position results in


misalignment of the internal components.
g01123057
Illustration 6
2. Remove bolts (3).

3. Remove tie bolt (1) that is located in the top left 1. Position fuel transfer pump (2) on the unit injector
corner of the pump first. hydraulic pump. Be sure to align the drive tang of
the fuel transfer pump to the drive slot in the end
4. Replace tie bolt (1) with Tooling (A). of the pump shaft.

Note: Tooling (A) has an undersized bolt head. 2. Install tie bolts (4). Tighten the bolts to a snug fit.
Tooling (A) will prevent the body of the unit injector
hydraulic pump from separating during service. 3. Remove Tooling (A) that is located in the upper left
hole and install remaining tie bolt (1) to a snug fit.
5. Tighten Tooling (A) to a torque of 10 Nm (89 lb in).
4. Install bolts (3) for fuel transfer pump (2). Tighten
6. Start with tie bolt (4) in the lower left corner the bolts to a snug fit.
and remove the remainder of the bolts from fuel
transfer pump (2).
RENR7458-09 7
Disassembly and Assembly Section

5. Start in the lower left corner of the unit injector 2. Remove socket head bolts (1) from unit injector
hydraulic pump and tighten tie bolts (4) to a torque (2).
of 28 2 Nm (21 1 lb ft) in a crisscross pattern.
Torque the bolts again.

6. Tighten bolts (3) to a torque of 8.0 0.4 Nm


(71 4 lb in).

End By:

a. Install the unit injector hydraulic pump. Refer


to Disassembly and Assembly, Unit Injector
Hydraulic Pump - Install.

i02325874

Unit Injector - Remove


SMCS Code: 1290-011

Removal Procedure
Table 3
g01161909
Illustration 8
Required Tools
Part 3. Use Tooling (A) and Tooling (B) to remove unit
Tool Number Part Description Qty injector (2) from the cylinder head.
A 152-1057 Fuel Injector Installer As 1
Note: Do not use a wire brush on the tip of the unit
B 274-9198 Leg 2 injector. Damage to the unit injector will occur.

Start By:

a. Remove the valve mechanism cover. Refer to


Disassembly and Assembly, Valve Mechanism
Cover - Remove and Install.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened


component life.

g01123753
Illustration 9

4. Remove O-ring seal (6), O-ring seal (7), and


O-ring seal (8) from unit injector (2).

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


g01123748 backup ring (9).
Illustration 7

1. Disconnect harness assembly (3).


8 RENR7458-09
Disassembly and Assembly Section

i02325908 The following procedure is the preferred method


of cleaning the sleeve bore.
Unit Injector - Install
Place a 38 mm (1.5 inch) square piece of Scotch
SMCS Code: 1290-012 Brite material on the end of Tooling (K). Twist
Tooling (K) with Tooling (M) against the lower
Installation Procedure surface of the sleeve bore.

Table 4 The surface should be cleaned until the surface is


Required Tools smooth and shiny. The entire sleeve bore should
be cleaned in order to remove any loose carbon
Part particles.
Tool Number Part Description Qty
A 152-1057 Fuel Injector Installer As 1 Note: Tooling (L) is available to clean loose material
from the sleeve bore and the cylinder.
C 272-1149 Leg 2
D - Scotch Brite 1 NOTICE
E 149-2955 Seal Protector 1 The correct procedures and tooling specifications
must always be used. Failure to follow any of the
F 149-2956 Seal Installer 1 procedures may result in damage, malfunction, or
1U-5718 Vacuum Pump 1
possible engine failure.

G 4C-4057 Bottle Assembly 1


NOTICE
169-7372 Clear Plastic Tubing 1 The O-ring seals and the backup rings must be in-
H 9U-5470 Reamer 1 stalled in the correct orientation. Damaged seals will
result in excessive oil consumption or excessive leak-
J 4C-6161 Tube Brush 1 age under the valve cover. Use care to prevent nicks
K 9U-6862 Tapered Brush 1 or damage to the seals.
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 unit injector.
Several evacuations may be necessary. Use
Tooling (G) to remove the fuel and oil from the
cylinder.

Note: Tooling (L) is available to clean loose material


from the sleeve bore and the cylinder.

2. Clean the carbon from the sleeve, the sleeve bore


and the end of the unit injector. Clean the carbon g01123753
Illustration 10
from the seat area that is inside of the cylinder
head. A fine grade of Tooling (D) is preferred.
3. Lubricate O-ring seal (6), O-ring seal (7), O-ring
Clean the carbon from the cylinder head. If the
seal (8), and the sleeve bore of the unit injector
sleeve of the unit injector has been removed from
sparingly with clean engine oil.
the engine, use Tooling (H) to remove only carbon
from the surface of the sleeve. If the sleeve of the
4. Use Tooling (E) and Tooling (F) to install backup
unit injector is installed in the engine, use Tooling
ring (4), backup ring (5), O-ring seal (6), backup
(J) to clean the carbon deposit from the inside of
ring (9), and O-ring seal (8).
the sleeve.
5. Install O-ring seal (7).
RENR7458-09 9
Disassembly and Assembly Section

6. Lubricate the O-ring seals and the backup rings 9. Install socket head bolt (1) on the exhaust side of
on the unit injector with clean engine oil before the bracket. Tighten the exhaust side of socket
installation. head bolt (1) until the bolt is seated. Tighten the
inlet side of socket head bolt (1) to a torque of
Note: Proper installation of the unit injector is very 12 1 Nm (9 1 lb ft).
important. Damage to the upper high pressure seals
can cause excessive oil leakage under the valve 10. Connect harness assembly (3).
cover. This may cause the engine not to start due
to a low actuation pressure. Damage to the lower End By:
high pressure seals may allow high pressure oil to
leak into the fuel supply passage. This will result in a. Install the valve mechanism cover. Refer to
excessive oil consumption. Disassembly and Assembly, Valve Mechanism
Cover - Remove and Install.
Note: Do not hit or strike the unit injector during
installation.
i02300862

7. Record the serial number for the injector and


the injector confirmation code. When you install
Unit Injector Sleeve - Remove
a new unit injector the E-Trim value must be SMCS Code: 1713-011
programmed into the Engine Control Module.
For more information, refer to Troubleshooting,
Injector Code - Calibrate. Removal Procedure
Table 5
Required Tools
Part
Tool Number Part Description Qty
A 1P-3042 Plug Tap 1
9U-6858 Bridge Plate 1
221-9778 Puller Stud 1
B 4K-0367 Full Nut 1
5P-8247 Hard Washer 1
9U-6877 Thrust Bearing 1
C 221-9803 Rubber Stopper 1

Start By:

a. Remove the unit injectors. Refer to Disassembly


and Assembly, Unit Injector - Remove.
g01162006
Illustration 11
NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened


component life.

1. Drain the coolant from the cooling system into a


suitable container for storage or disposal. Refer
to Operation and Maintenance Manual, Cooling
System Coolant - Change.

2. Position Tooling (C) at the bottom of the unit


injector sleeve.
g01123748
Illustration 12

8. Use Tooling (A) and Tooling (C) to install unit


injector (2) into the cylinder head.
10 RENR7458-09
Disassembly and Assembly Section

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened


component life.

1. Thoroughly clean the unit injector sleeves and


the bores for the unit injectors. Tooling (F) may
be used on the bores.

g01123847
Illustration 13

3. Coat Tooling (A) with clean grease. Use Tooling


(A) to cut threads into the unit injector sleeve.

g01618682
Illustration 15
g01123850
Illustration 14
2. Apply Tooling (G) to bores prior to installation.
4. Use Tooling (B) to remove the unit injector sleeve.
3. Apply a thin coating of Tooling (E) around the
outer circumference of unit injector sleeve (1) at
i03145071 Area (C).

Unit Injector Sleeve - Install 4. Use Tooling (D) and a hammer to position the unit
injector sleeve in the cylinder head.
SMCS Code: 1713-012
Note: Allow Tooling (E) to cure for two hours at 21 C
Installation Procedure (70 F) before filling the engine with fuel or coolant.
Longer curing time is required for lower temperatures.
Table 6
5. Fill the cooling system. Refer to Operation and
Required Tools
Maintenance Manual, Cooling System Coolant
Part - Change.
Tool Number Part Description Qty
End By:
D 221-9777 Sleeve Installer 1
E 4C-9506 Retaining Compound 1 a. Install the unit injectors. Refer to Disassembly and
Assembly, Unit Injector - Install.
F 4C-5552 Large Bore Brush 1
G 6V-6640 Sealant 1
RENR7458-09 11
Disassembly and Assembly Section

i02227961 3. Disconnect harness assembly (2) from unit


injector hydraulic pump (1).
Unit Injector Hydraulic Pump -
Remove
SMCS Code: 1714-011

Removal Procedure
Table 7
Required Tools
Part
Tool Number Part Description Qty
A 192-5092 Removal Tool 1

g01127845
Illustration 17
NOTICE
Keep all parts clean from contaminants. 4. Remove bolts (7). Remove unit injector hydraulic
pump (1).
Contaminants may cause rapid wear and shortened
component life.
i02227969

NOTICE Unit Injector Hydraulic Pump


Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
- Install
ing, adjusting and repair of the product. Be prepared to
SMCS Code: 1714-012
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids. Installation Procedure
Refer to Special Publication, NENG2500, Caterpillar NOTICE
Tools and Shop Products Guide for tools and supplies Keep all parts clean from contaminants.
suitable to collect and contain fluids on Caterpillar
products. Contaminants may cause rapid wear and shortened
component life.
Dispose of all fluids according to local regulations and
mandates.

g01127845
Illustration 18
g01127843
Illustration 16
1. Position unit injector hydraulic pump (1) in the
front housing.
1. Disconnect tube assembly (4), tube assembly (5),
and tube assembly (6). 2. Install bolts (7).
2. Use Tooling (A) in order to disconnect hose
assembly (3).
12 RENR7458-09
Disassembly and Assembly Section

Installation Procedure
Table 8
Required Tools
Part
Tool Number Part Description Qty
A 5P-3975 Rubber Lubricant 1

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


seals prior to installation of the solenoid.

g01127843
Illustration 19

3. Connect hose assembly (3).

4. Connect tube assembly (4), tube assembly (5),


and tube assembly (6).

5. Connect harness assembly (2) to unit injector


hydraulic pump (1).

i02228143
g01124071
Modulating Valve - Remove Illustration 21

and Install Note: Make sure that nut (3) is loose prior to
installation.
SMCS Code: 3139-010
2. Install valve assembly (1) and solenoid assembly
(2). Tighten the valve assembly to a torque of
Removal Procedure 50 5 Nm (37 4 lb ft).

3. Tighten nut (3) to a torque of 13 2 Nm


(115 18 lb in).

4. Connect the harness assembly to solenoid


assembly (2).

i02236344

Turbocharger - Remove
SMCS Code: 1052-011

Illustration 20
g01124071 Removal Procedure
1. Disconnect the harness assembly from solenoid NOTICE
assembly (2). Keep all parts clean from contaminants.

2. Loosen nut (3) in order to allow solenoid assembly Contaminants may cause rapid wear and shortened
(2) to rotate around valve assembly (1) during the component life.
removal procedure.

3. Loosen valve assembly (1). Remove valve


assembly (1) and solenoid assembly (2).
RENR7458-09 13
Disassembly and Assembly Section

NOTICE NOTICE
Care must be taken to ensure that fluids are contained Keep all parts clean from contaminants.
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to Contaminants may cause rapid wear and shortened
collect the fluid with suitable containers before open- component life.
ing any compartment or disassembling any compo-
nent containing fluids.
1. Apply Tooling (A) on the threads of the mounting
Refer to Special Publication, NENG2500, Caterpillar studs for the turbocharger.
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.

g01031231
Illustration 23

2. Position the turbocharger gasket and turbocharger


(4) on the exhaust manifold. Install nuts (2).

3. Tighten nuts (2) to a torque of 54 5 Nm


g01031231 (40 4 lb ft).
Illustration 22
4. Connect tube assembly (3) and tube assembly (5).
1. Disconnect hose assembly (1), if necessary.
5. Connect hose assembly (1).
2. Disconnect tube assembly (3) and tube assembly
(5).

3. Remove nuts (2), turbocharger (4), and the gasket


from the exhaust manifold.

i02228177

Turbocharger - Install
SMCS Code: 1052-012

Installation Procedure
Table 9
Required Tools
Part
Tool Number Part Description Qty
A 5P-3931 Anti-Seize Compound 1
14 RENR7458-09
Disassembly and Assembly Section

i02228217

Exhaust Manifold - Remove


and Install
SMCS Code: 1059-010

Removal Procedure

g01124147
Illustration 25

1. Apply Tooling (A) to the outside diameter of the


male ends of exhaust manifold (2). Assemble
exhaust manifold (2) and remove the excess
sealer from the joints.

2. Apply Tooling (B) to the threads of bolts (1). Attach


g01124147
a suitable lifting device to exhaust manifold (2) and
Illustration 24 the turbocharger. The weight of exhaust manifold
(2) and the turbocharger is approximately 40 kg
1. Disconnect tube assembly (3) and tube assembly (88 lb). Position the gaskets, exhaust manifold
(5). (2), and the turbocharger on the cylinder head
assembly. Install locks (4) and bolts (1).
2. Attach a suitable lifting device to exhaust manifold
(2) and the turbocharger. The weight of exhaust 3. Connect tube assembly (3) and tube assembly (5).
manifold (2) and the turbocharger is approximately
40 kg (88 lb).

3. Remove bolts (1) and locks (4).

4. Remove exhaust manifold (2), the turbocharger,


and the gaskets from the cylinder head assembly.

Installation Procedure
Table 10
Required Tools
Part
Tool Number Part Description Qty
g00617739
Illustration 26
A 2P-2333 High Temperature Sealer 1
B 5P-3931 Anti-Seize Compound 1 4. Tighten Bolt (1) through Bolt (12) in a numerical
sequence.
NOTICE Tighten bolts to the following torque. .... 4 1 Nm
Excessive use of sealant can cause damage to com- (35 9 lb in)
ponents.
5. Tighten Bolt (1) through Bolt (12) in a numerical
To avoid component damage use only the amount of sequence.
sealant necessary for the application.
RENR7458-09 15
Disassembly and Assembly Section

Tighten bolts to the following torque. .. 45 5 Nm Installation Procedure


(33 4 lb ft)

6. Bend the locking tab over the flat of each bolt


head.

Note: Prior to starting or running the engine, allow


the sealant in the exhaust manifold joints to air dry
for 24 hours.

i02228257

Air Inlet Heater Solenoid -


Remove and Install
SMCS Code: 1090-010-OD

Removal Procedure

g01124203
Illustration 28
Disconnect batteries before performance of any
service work.
1. Position solenoid (1) on the engine.

1. Disconnect the battery. Refer to Operation and 2. Connect harness assemblies (2) and harness
Maintenance Manual, Battery or Battery Cable assemblies (3).
- Disconnect.
3. Connect the battery. Refer to Operation and
Maintenance Manual, Battery or Battery Cable
- Disconnect.

i02228289

Inlet and Exhaust Valves -


Remove and Install
SMCS Code: 1105-010

Removal Procedure
Table 11
Required Tools
Part
Tool Number Part Description Qty
A 5S-1330 Valve Spring Compressor 1
g01124203
Illustration 27
Start By:
2. Disconnect harness assemblies (2) and harness
assemblies (3). a. Remove the cylinder head assembly. Refer to
Disassembly and Assembly, Cylinder Head -
3. Remove solenoid (1). Remove.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened


component life.
16 RENR7458-09
Disassembly and Assembly Section

g01127720 g01127720
Illustration 29 Illustration 30

The valve spring keepers can be thrown from Improper assembly of parts that are spring loaded
the valve when the valve spring compressor is can cause bodily injury.
released. Ensure that the valve spring keepers
are properly installed on the valve stem. To help To prevent possible injury, follow the established
prevent personal injury, keep away from the front assembly procedure and wear protective equip-
of the valve spring keepers and valve springs ment.
during the installation of the valves.
1. Lubricate valve (2) with clean engine oil. Install
Note: The following components of the exhaust valve (2) in the cylinder head assembly. Install
valves are different from the components of the inlet new valve seal (1) against the valve guide.
valves: spring retainer (5), valve spring (4), and valve
(2). 2. Place the following items on the valve stem:
washer (3), valve spring (4), and spring retainer
1. Use Tooling (A) to compress valve spring (4). (5).
Remove retainer locks (6).
Note: A small amount of grease can be used to hold
2. Remove Tooling (A). Remove spring retainer (5), the retainer locks in position during installation.
valve spring (4), and washer (3).
3. Use Tooling (A) to compress valve spring (4).
3. Remove valve seal (1) and valve (2). Install retainer locks (6).

End By:
Installation Procedure
Table 12 a. Install the cylinder head assembly. Refer to
Disassembly and Assembly, Cylinder Head -
Required Tools Install.
Part
Tool Number Part Description Qty
A 5S-1330 Valve Spring Compressor 1

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened


component life.
RENR7458-09 17
Disassembly and Assembly Section

i02228414 Installation Procedure


Inlet and Exhaust Valve Guides Table 14

- Remove and Install Required Tools


Part
SMCS Code: 1104-010 Tool Number Part Description Qty
A 1U-7793 Valve Guide Driver 1
Removal Procedure
B 9U-6895 Valve Guide Driver 1
Table 13
C 1U-7792 Guide Collar 1
Required Tools
D 149-4008 Guide Collar 1
Part
Tool Number Part Description Qty
NOTICE
A 1U-7793 Valve Guide Driver 1
Keep all parts clean from contaminants.
B 9U-6895 Valve Guide Driver 1
Contaminants may cause rapid wear and shortened
component life.
Start By:

a. 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.

Contaminants may cause rapid wear and shortened


component life.

g01124397
Illustration 32

Note: Position the valve guides and tap on the top of


the valve guides. This is done in order to start the
valve guides into the cylinder head assembly.

1. Use Tooling (A) and Tooling (C) to install inlet valve


guides (1). Install inlet valve guides (1) until the
protrusion is 23.0 0.50 mm (0.90 0.020 inch)
above the cylinder head assembly.
g01124395
Illustration 31 2. Use Tooling (B) and Tooling (D) to install the
exhaust valve guides. Install the exhaust valve
1. Use Tooling (A) to remove the inlet valve guides guides until the protrusion is 17.8 0.50 mm
from the cylinder head assembly. Use Tooling (0.70 0.020 inch) above the cylinder head
(B) to remove the exhaust valve guides from the assembly.
cylinder head assembly.
End By:

a. Install the inlet and exhaust valves. Refer to


Disassembly and Assembly, Inlet and Exhaust
Valves - Remove and Install.
18 RENR7458-09
Disassembly and Assembly Section

i02954230 Installation Procedure


Inlet and Exhaust Valve Seat Table 16

Inserts - Remove and Install Required Tools


Part
SMCS Code: 1103-010 Tool Number Part Description Qty
149-6115 Installer 1
Removal Procedure B
133-9306 Valve Guide 1
Table 15
Required Tools NOTICE
Part Keep all parts clean from contaminants.
Tool Number Part Description Qty
Contaminants may cause rapid wear and shortened
6V-4194 Valve Seat Extractor(2) 1
component life.
165-5647 Valve Seat Extractor(3) 1
A(1) 6V-4804 Handle 1
6V-4192 Shaft 1
6V-4199 Lifting Bracket 1
(1) Part of the 166-7441 Valve Seat Extractor Tool Group
(2) Use for removal of the exhaust valve seats
(3) Use for removal of the inlet valve seats

Start By:

a. Remove the inlet and exhaust valves. Refer to


Disassembly and Assembly, Inlet and Exhaust
Valves - Remove and Install.
g01475612
Illustration 34
NOTICE
Keep all parts clean from contaminants. 1. Lower the temperature of new valve seat inserts
(1).
Contaminants may cause rapid wear and shortened
component life. 2. Use Tooling (B) and a suitable press to install the
new valve seat inserts in the cylinder head.

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.

End By:

a. Install the inlet valves and exhaust valves. Refer


to Disassembly and Assembly, Inlet and Exhaust
Valves - Remove and Install.

g01124436
Illustration 33

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


RENR7458-09 19
Disassembly and Assembly Section

i02519791

Engine Oil Filter Base and Oil


Cooler - Remove
SMCS Code: 1306-011; 1378-012

Removal Procedure
Table 17
Required Tools
Part
Tool Number Part Description Qty
g01261010
A 185-3630 Strap Wrench Assembly 1 Illustration 36

3. Remove bolts (4). Remove engine oil filter base


NOTICE (5) and the gasket.
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent 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.
g01261014
1. Drain the coolant system. Refer to Operation Illustration 37
and Maintenance Manual, Refill Capacities and
Recommendations. 4. Remove oil cooler (6) and the gasket. Remove
O-ring seals (7).

i02229026

Engine Oil Filter Base -


Disassemble
SMCS Code: 1306-015

Disassembly Procedure
Start By:

g01261004
a. Remove the engine oil filter base and the oil
Illustration 35 cooler. Refer to Disassembly and Assembly,
Engine Oil Filter Base and Oil Cooler - Remove.
2. Remove nuts (1). Remove bracket (2) and the
hose assembly. Use Tooling (A) and remove oil
filter (3). NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened


component life.
20 RENR7458-09
Disassembly and Assembly Section

g01124604 g01124604
Illustration 38 Illustration 39

Personal injury can result from being struck by Improper assembly of parts that are spring loaded
parts propelled by a released spring force. can cause bodily injury.

Make sure to wear all necessary protective equip- To prevent possible injury, follow the established
ment. assembly procedure and wear protective equip-
ment.
Follow the recommended procedure and use all
recommended tooling to release the spring force.
(1) Oil cooler bypass valve

(1) Oil cooler bypass valve (2) Oil filter bypass valve

(2) Oil filter bypass valve End By:

a. Install the engine oil filter base and the oil cooler.
i02229174
Refer to Disassembly and Assembly, Engine Oil
Engine Oil Filter Base - Filter Base and Oil Cooler - Install.

Assemble i02519800

SMCS Code: 1306-016 Engine Oil Filter Base and Oil


Assembly Procedure Cooler - Install
SMCS Code: 1306-012; 1378-012
NOTICE
Keep all parts clean from contaminants.
Installation Procedure
Contaminants may cause rapid wear and shortened Table 18
component life.
Required Tools
Part
Tool Number Part Description Qty
A 185-3630 Strap Wrench Assembly 1
RENR7458-09 21
Disassembly and Assembly Section

g01261018
Illustration 40

Note: Check O-ring seals for wear or for damage. If


necessary, replace the O-ring seals.

1. Install O-ring seals (7). Install oil cooler (6) and


the gasket.

g01261020
Illustration 42

3. Tighten bolts (4) in a numerical sequence to


a torque of 15 Nm (11 lb ft). Tighten bolts (4)
in a numerical sequence to a torque of 28 Nm
(21 lb ft).

g01261019
Illustration 41

2. Install the gasket and engine oil filter base (5).


Install bolts (4).

g01261022
Illustration 43

4. Install oil filter (3) with Tooling (A). Install the hose
assembly and bracket (2). Install nuts (1).

5. Fill the coolant system. Refer to Operation and


Maintenance Manual, Refill Capacities and
Recommendations.
22 RENR7458-09
Disassembly and Assembly Section

i02229240 i02229280

Engine Oil Pump - Remove Engine Oil Pump - Disassemble


SMCS Code: 1304-011 SMCS Code: 1304-015

Removal Procedure Disassembly Procedure


Start By: Table 19
Required Tools
a. Remove the engine oil pan. Refer to Disassembly
and Assembly, Engine Oil Pan - Remove and Part
Install. Tool Number Part Description Qty
A 8B-7554 Bearing Cup Puller Gp 1
NOTICE B 1P-0510 Driver Gp 1
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened Start By:


component life.
a. Remove the engine oil pump. Refer to
Disassembly and Assembly, Engine Oil Pump
- Remove.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened


component life.

g00987795
Illustration 44

1. Remove bolts (1) and bolt (2). g01127669


Illustration 45

2. Remove engine oil pump (3).


1. Remove bolts (1), oil pickup tube (2), and the
gasket from the engine oil pump. Remove bolt (3)
3. Remove the O-ring seals.
and outlet elbow (4) from the engine oil pump.
RENR7458-09 23
Disassembly and Assembly Section

g01127673 g01127673
Illustration 46 Illustration 47

2. Remove bolt (5).

3. Remove idler gear (7) from shaft (8).

4. Use Tooling (B) and remove bearing (6) from idler


gear (7).

5. Use Tooling (A) to remove drive gear (9) from


engine oil pump (10).

i02229316

Engine Oil Pump - Assemble


g01127669
Illustration 48
SMCS Code: 1304-016
1. Use Tooling (B) and press drive gear (9) on the
Assembly Procedure shaft assembly until drive gear (9) is flush with the
end of the shaft assembly.
Table 20
Required Tools 2. Install bearing (6) in idler gear (7). Install bearing
(6) so the distance between the hub bolt face
Part of idler gear and bearing (6) is 0.75 0.25 mm
Tool Number Part Description Qty (0.030 0.010 inch).
B 1P-0510 Driver Gp 1
3. Install idler gear (7) on shaft (8). Install bolt
(5). Tighten bolt (5) to a torque of 70 15 Nm
NOTICE (52 11 lb ft).
Keep all parts clean from contaminants.
4. Position the gasket and oil pickup tube (2) onto
Contaminants may cause rapid wear and shortened engine oil pump (10). Install bolts (1).
component life.
5. Position the O-ring seal and outlet elbow (4) onto
engine oil pump (10). Install bolt (3).

End By:

a. Install the engine oil pump. Refer to Disassembly


and Assembly, Engine Oil Pump - Install.
24 RENR7458-09
Disassembly and Assembly Section

i02229347
NOTICE
Engine Oil Pump - Install Keep all parts clean from contaminants.
SMCS Code: 1304-012 Contaminants may cause rapid wear and shortened
component life.
Installation Procedure
NOTICE NOTICE
Keep all parts clean from contaminants. Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
Contaminants may cause rapid wear and shortened ing, adjusting and repair of the product. Be prepared to
component life. collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.

Refer to Special Publication, NENG2500, Caterpillar


Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and


mandates.

1. Drain the coolant system. Refer to Operation


and Maintenance Manual, Refill Capacities and
Recommendations.

g00987795
Illustration 49

1. Install the O-ring seals. Position engine oil pump


(3) on the cylinder block.

2. Install bolts (1) and bolt (2).


g01124776
End By: Illustration 50

a. Install the engine oil pan. Refer to Disassembly 2. Remove bolts (1). Remove support bracket (2).
and Assembly, Engine Oil Pan - Remove and
Install. 3. Disconnect hose (3).

4. Remove bolts (4). Remove water pump (5).


i02229479

Water Pump - Remove


SMCS Code: 1361-011

Removal Procedure
Start By:

a. Remove the alternator. Refer to Disassembly and


Assembly, Alternator - Remove and Install.
RENR7458-09 25
Disassembly and Assembly Section

i02229484 i02229489

Water Pump - Disassemble Water Pump - Assemble


SMCS Code: 1361-015 SMCS Code: 1361-016

Disassembly Procedure Assembly Procedure


Table 21 Table 22
Required Tools Required Tools
Part Part
Tool Number Part Description Qty Tool Number Part Description Qty
A 1P-0510 Driver Group 1 A 1P-0510 Driver Gp 1
B 5P-9722 Seal Driver 1
Start By:

a. Remove the water pump. Refer to Disassembly NOTICE


and Assembly, Water Pump - Remove. Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened


component life.

g01124833
Illustration 51

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


cover (3). Illustration 52
g01124833

2. Remove gasket (4). 1. Use Tooling (A) and a suitable press to install
pulley (9) on shaft assembly (8).
3. Use Tooling (A) and a suitable press to remove
shaft assembly (8) from impeller (5) and housing 2. Use Tooling (B) and a suitable press to install seal
(7). assembly (6) in housing (7).

4. Use Tooling (A) and a suitable press to remove 3. Use Tooling (A) and a suitable press to install
seal assembly (6) from housing (7). shaft assembly (8) into housing (7). Install the
shaft assembly until the bearing is flush with the
5. Use Tooling (A) and a suitable press to remove housing.
pulley (9) from shaft assembly (8).
4. Use Tooling (A) and a suitable press to install
impeller (5) on shaft assembly (8). Install the
impeller until the distance between the impeller
and the machined surface of the water pump is
0.75 0.25 mm (0.030 0.010 inch).
26 RENR7458-09
Disassembly and Assembly Section

5. Install new gasket (4). i02301675

6. Position cover (3) and install bolts (2). Install new Water Temperature Regulator -
O-ring seals (1). Remove and Install
End By: SMCS Code: 1355-010
a. Install the water pump. Refer to Disassembly and
Assembly, Water Pump - Install. Removal Procedure
NOTICE
i02229490
Keep all parts clean from contaminants.
Water Pump - Install Contaminants may cause rapid wear and shortened
SMCS Code: 1361-012 component life.

Installation Procedure NOTICE


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

Refer to Special Publication, NENG2500, Caterpillar


Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and


mandates.

1. 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.

g01124776
Illustration 53

1. Position water pump (5) on the front of the engine.


Install bolts (4).

2. Connect hose (3).

3. Position support bracket (2). Install bolts (1).

4. Refill the cooling system. Refer to Operation


and Maintenance Manual, Refill Capacities and
Recommendations.
g01152619
Illustration 54
End By:
2. Remove bolts (1), pipe (2), and the gasket from
a. Install the alternator. Refer to Disassembly and water temperature regulator housing (3).
Assembly, Alternator - Remove and Install.
3. Remove the water temperature regulators.
RENR7458-09 27
Disassembly and Assembly Section

Installation Procedure
NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened


component life.

g01125043
Illustration 56

1. Install Tooling (A) and a suitable lifting device


on flywheel (2). The weight of flywheel (2) is
approximately 23 kg (50 lb).

2. Remove top bolt (1). Install Tooling (B). Remove


Illustration 55
g01152619 remaining bolts (1).

1. Position the water temperature regulators in water 3. Remove flywheel (2) from Tooling (B).
temperature regulator housing (3).
4. Replace ring gear (3), if necessary. Use a hammer
2. Install a gasket and pipe (2) on water temperature and a punch in order to remove the flywheel ring
regulator housing (3). gear.

3. Install bolts (1). i02230456

4. Fill the cooling system. Refer to Operation and Flywheel - Install


Maintenance Manual, Cooling System Coolant
- Change. SMCS Code: 1156-012

i02230441 Installation Procedure


Flywheel - Remove Table 24
Required Tools
SMCS Code: 1156-011
Part
Tool Number Part Description Qty
Removal Procedure
A 138-7573 Link Bracket 2
Table 23
Guide Bolt
Required Tools B - (M12 X 1.75 by 120 1
mm)
Part
Tool Number Part Description Qty C 9S-3263 Thread Lock Compound 1
A 138-7573 Link Bracket 2
Guide Bolt
B - (M12 X 1.75 by 120 1
mm)
28 RENR7458-09
Disassembly and Assembly Section

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened


component life.

1. Use Tooling (A) to drill three evenly spaced holes


in the crankshaft rear seal.

g01125043
Illustration 57

1. Raise the temperature of ring gear (3).

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

2. Position ring gear (3) on flywheel (2) with the part


number toward the crankshaft. Use a soft hammer
in order to seat the ring gear against the shoulder
of the flywheel. Allow the ring gear to cool.

3. Install Tooling (A) and a suitable lifting device


on flywheel (2). The weight of flywheel (2) is
approximately 23 kg (50 lb).

4. Position flywheel (2) on Tooling (B).


g00989088
Illustration 58
5. Apply Tooling (C) to the threads of bolts (1).
2. Use Tooling (B) to remove crankshaft rear seal (1).
6. Install bolts (1). Remove Tooling (B) and install
remaining bolt (1). Tighten the bolts evenly to a
torque of 120 20 Nm (90 15 lb ft). i03171818

7. Check the flywheel runout. Refer to Testing and Crankshaft Rear Seal - Install
Adjusting, Flywheel - Inspect.
SMCS Code: 1161-012

i02230478
Installation Procedure
Crankshaft Rear Seal - Remove Table 26
SMCS Code: 1161-011 Required Tools
Part
Removal Procedure Tool Number Part Description Qty

Table 25 C 1U-7598 Seal Installer Gp 1

Required Tools
NOTICE
Part
Tool Number Part Description Qty
Keep all parts clean from contaminants.

A 1U-8145 Drill Bit 1 Contaminants may cause rapid wear and shortened
B 1U-7600 Slide Hammer Puller 1
component life.

Start By: Note: Replacement rear seals are supplied with a


wear sleeve. This wear sleeve must be installed with
a. Remove the flywheel. Refer to Disassembly and the rear seal. New engines from the factory do not
Assembly, Flywheel - Remove. have a wear sleeve. Do not install the rear seal if any
of the following conditions exist:
RENR7458-09 29
Disassembly and Assembly Section

The crankshaft rear seal has been separated from


the wear sleeve. NOTICE
Keep all parts clean from contaminants.
The rear seal group appears to be damaged.
Contaminants may cause rapid wear and shortened
The crankshaft rear seal has been lubricated. The component life.
seal is designed to be installed dry.

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent 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.

g01125095
Illustration 59

1. Use Tooling (C) to install crankshaft rear seal (1).

End By:

a. Install the flywheel. Refer to Disassembly and


Assembly, Flywheel - Install.

g00987190
i02230508 Illustration 60

Flywheel Housing - Remove 1. Fasten Tooling (A) and a suitable lifting device
and Install to flywheel housing (1). The weight of flywheel
housing (1) is approximately 25 kg (55 lb).
SMCS Code: 1157-010
2. Remove bolts (2) and bolt (3). Remove bolts (4).
Removal Procedure 3. Remove bolts (5) that fasten the engine oil pan to
flywheel housing (1). Remove flywheel housing
Table 27
(1).
Required Tools
Part Installation Procedure
Tool Number Part Description Qty
Table 28
A 138-7573 Link Bracket 2
Required Tools
Start By: Part
Tool Number Part Description Qty
a. Remove the flywheel. Refer to Disassembly and A 138-7573 Link Bracket 2
Assembly, Flywheel - Remove.
B 1U-8846 Sealant -
30 RENR7458-09
Disassembly and Assembly Section

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened


component life.

1. Apply Tooling (B) to the entire mounting face of


the flywheel housing prior to installation.

g00991061
Illustration 62

2. Remove bolts (2) and crankshaft vibration damper


Illustration 61
g00987190 (1) from the crankshaft pulley.

2. Fasten Tooling (A) and a suitable lifting device


to flywheel housing (1). The weight of flywheel
housing (1) is approximately 25 kg (55 lb). Position
the flywheel housing on the cylinder block. Install
bolts (5) that fasten the engine oil pan to the
flywheel housing.

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

4. Check the flywheel housing runout. Refer to


the Testing and Adjusting, Flywheel Housing -
Inspect.

End By:

a. Install the flywheel. Refer to Disassembly and


Assembly, Flywheel - Install.

i02230536

Vibration Damper and Pulley - Illustration 63


g00991062

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

SMCS Code: 1205-010 4. Remove crankshaft pulley (5).

Removal Procedure
1. Remove the belts.
RENR7458-09 31
Disassembly and Assembly Section

Installation Procedure i02230550

Crankshaft Front Seal -


Remove
SMCS Code: 1160-011

Removal Procedure
Table 29
Required Tools
Part
Tool Number Part Description Qty
A 1U-7600 Slide Hammer Puller 1
B 1U-8145 Drill Bit 1

Start By:

a. Remove the vibration damper and the pulley.


g00991062 Refer to Disassembly and Assembly, Vibration
Illustration 64
Damper and Pulley - Remove and Install.
1. Position crankshaft pulley (5) on the crankshaft.
Position plate (4) and install bolts (3). Tighten bolts NOTICE
(3) to a torque of 200 25 Nm (148 18 lb ft). Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened


component life.

g00991061
Illustration 65

2. Install crankshaft vibration damper (1). Tighten


bolts (2) to a torque of 55 10 Nm (40 7 lb ft). Illustration 66
g00989224

3. Install the belts. 1. Use Tooling (B) and carefully drill three evenly
spaced holes in crankshaft front seal (1).

2. Use Tooling (A) to remove crankshaft front seal


(1).
32 RENR7458-09
Disassembly and Assembly Section

i02230558 i02230581

Crankshaft Front Seal - Install Front Cover - Remove


SMCS Code: 1160-012 SMCS Code: 1166-011

Installation Procedure Removal Procedure


Table 30 Start By:
Required Tools
a. Remove the fan drive mounting group. Refer to
Part Disassembly and Assembly, Fan Drive Mounting
Tool Number Part Description Qty Group - Remove and Install.
C 1U-7430 Front Seal Installer 1
NOTICE
NOTICE Keep all parts clean from contaminants.
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
Contaminants may cause rapid wear and shortened component life.
component life.

g00991101
Illustration 68
g00989228
Illustration 67
1. Remove bolts (2), (3), and (4). Remove front cover
Note: The crankshaft seal is designed to be installed (1) and the gasket from the front housing.
dry.
i02230634
1. Use Tooling (C) to install crankshaft front seal (1).
Front Cover - Install
End By:
SMCS Code: 1166-012
a. Install the vibration damper and the pulley. Refer
to Disassembly and Assembly, Vibration Damper Installation Procedure
and Pulley - Remove and Install.
NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened


component life.
RENR7458-09 33
Disassembly and Assembly Section

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent 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.

g00991101
Illustration 69

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


housing. Install bolts (2), (3), and (4) in front cover
(1).

End By:

a. Install the fan drive mounting group. Refer to


Disassembly and Assembly, Fan Drive Mounting
Group - Remove and Install.

i02230639

Housing (Front) - Remove


SMCS Code: 1151-011 Illustration 70
g00989343

Removal Procedure 1. Support the weight of the front of the engine.


Remove bolts (1) and remove front engine support
Start By: (2).

a. Remove the camshaft. Refer to Disassembly and


Assembly, Camshaft - Remove.

b. Remove the unit injector hydraulic pump. Refer


to Disassembly and Assembly, Unit Injector
Hydraulic Pump - Remove.

c. Remove the air compressor. Refer to Disassembly


and Assembly, Air Compressor - Remove and
Install.
34 RENR7458-09
Disassembly and Assembly Section

g01125215 g01125215
Illustration 71 Illustration 72

2. Remove bolts (3) and (5). Remove front housing 1. Clean the joint face on front housing (4) with
(4). Tooling (A).

2. Apply Tooling (B) to the joint face. Allow the primer


i02230647
to dry for at least three to five minutes.
Housing (Front) - Install 3. Apply Tooling (C) to the joint face. Spread the
SMCS Code: 1151-012 sealant uniformly. Front housing (4) must be
installed within ten minutes of applying the sealant.

Installation Procedure 4. Position front housing (4) on the cylinder block.


Table 31
5. Install bolts (3) and (5).
Required Tools
Part
Tool Number Part Description Qty
A 8T-9011 Component Cleaner 1
B 4C-9500 Quick Cure Primer 1
C 1U-8846 Gasket Sealant 1

g00989343
Illustration 73

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


(1).
RENR7458-09 35
Disassembly and Assembly Section

End By: 3. Remove bolt (7) and idler shaft (3) from the
cylinder block. Remove thrust plate (5).
a. Install the air compressor. Refer to Disassembly
and Assembly, Air Compressor - Remove and 4. Use Tooling (A) and a suitable press to remove
Install. bearing (6) from camshaft idler gear (2).

b. Install the unit injector hydraulic pump. Refer


to Disassembly and Assembly, Unit Injector
Installation Procedure
Hydraulic Pump - Install. Table 33

c. Install the camshaft. Refer to Disassembly and Required Tools


Assembly, Camshaft - Install. Part
Tool Number Part Description Qty
i02230724 A 1P-0520 Driver Group 1

Camshaft Idler Gear - Remove


NOTICE
and Install Keep all parts clean from contaminants.
SMCS Code: 1206-010 Contaminants may cause rapid wear and shortened
component life.
Removal Procedure
Table 32
Required Tools
Part
Tool Number Part Description Qty
A 1P-0520 Driver Group 1

Start By:

a. Remove the front housing. Refer to Disassembly


and Assembly, Housing (Front) - Remove.

NOTICE Illustration 75
g01125304
Keep all parts clean from contaminants.
1. Use Tooling (A) and a suitable press to install
Contaminants may cause rapid wear and shortened bearing (6) in camshaft idler gear (2). Install the
component life. bearing until the bearing is 1.080 0.250 mm
(0.0425 0.0098 inch) below the front face of
camshaft idler gear (2).

2. Position thrust plate (5) and idler shaft (3) on the


cylinder block. Install bolt (7). Tighten the bolt to a
torque of 70 15 Nm (51 11 lb ft).

3. Install camshaft idler gear (2) on idler shaft (3).


Ensure that timing mark (8) is facing outward.
Align timing mark (8) with timing mark (9) on
crankshaft drive gear (10).

4. Position plate (1) and install bolts (4). Tighten the


bolts to a torque of 70 15 Nm (51 11 lb ft).

Illustration 74
g01125301 End By:

1. Remove bolts (4) and retaining plate (1). a. Install the front housing. Refer to Disassembly and
Assembly, Housing (Front) - Install.
2. Remove camshaft idler gear (2).
36 RENR7458-09
Disassembly and Assembly Section

i02230894

Valve Mechanism Cover -


Remove and Install
SMCS Code: 1107-010

Removal Procedure
NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened


component life. g00945775
Illustration 78

1. Position valve mechanism cover (2) on the engine.

2. Install bolts (1). Tighten bolts (1) in a numerical


sequence to a torque of 15 3 Nm (11 2 lb ft).

i02231006

Valve Mechanism Cover Base -


Remove and Install
SMCS Code: 1120-010

Illustration 76
g01125461 Removal Procedure
1. Remove bolts (1). Start By:

2. Remove valve mechanism cover (2). a. Remove the valve mechanism cover. Refer to
Disassembly and Assembly, Valve Mechanism
Cover - Remove and Install.
Installation Procedure
NOTICE
NOTICE Keep all parts clean from contaminants.
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
Contaminants may cause rapid wear and shortened component life.
component life.

1. Disconnect the harness assembly from the valve


mechanism cover base.

g01125461
Illustration 77

g01125477
Illustration 79
RENR7458-09 37
Disassembly and Assembly Section

2. Disconnect harness assemblies (1). i02231087

3. Remove bolts (2) and valve mechanism cover Rocker Shaft and Pushrod -
base (3) from the cylinder head. Remove
Installation Procedure SMCS Code: 1102-011; 1208-011

Removal Procedure
Start By:

a. Remove the valve mechanism cover. Refer to


Disassembly and Assembly, Valve Mechanism
Cover - Remove and Install.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened


component life.
g01125477
Illustration 80
1. Put identification marks on each rocker arm and
on each pushrod in order to identify the proper
location in the engine for installation.

g01127431
Illustration 81

1. Position valve mechanism cover base (3) on the


cylinder head. Install bolts (2) and tighten bolts (2)
in a numerical sequence.

2. Connect harness assemblies (1).

3. Connect the harness assembly to the valve


mechanism cover base.
g00987758
Illustration 82
End By:
2. Loosen all rocker arm adjustment screws (4).
a. Install the valve mechanism cover. Refer to
Disassembly and Assembly, Valve Mechanism 3. Remove bolts (1), bolts (2), and rocker shaft (3).
Cover - Remove and Install.
38 RENR7458-09
Disassembly and Assembly Section

Personal injury can result from parts and/or cov-


ers under spring pressure.

Spring force will be released when covers are re-


moved.

Be prepared to hold spring loaded covers as the


bolts are loosened.

Note: Place an identification mark on each of the


components of the rocker shaft for installation
purposes.

1. Remove retaining ring (2).

2. Remove stand (3), inlet rocker arms (4), exhaust


rocker arms (5), stands (6), and springs (7) from
the rocker shaft.
g00987759
Illustration 83
3. Remove dowel pin (8) and stand (9) from the
4. Remove inlet valve bridges (5) and pushrods (6). rocker shaft.

4. Remove plug (1).


i02307337

Rocker Shaft - Disassemble i02307338

SMCS Code: 1102-015 Rocker Shaft - Assemble


SMCS Code: 1102-016
Disassembly Procedure
Start By: Assembly Procedure
a. Remove the rocker shaft. Refer to Disassembly NOTICE
and Assembly, Rocker Shaft and Pushrod - Keep all parts clean from contaminants.
Remove.
Contaminants may cause rapid wear and shortened
NOTICE component life.
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened 1. Lubricate all of the components of the rocker shaft
component life. with clean engine oil.

g01155738
Illustration 85
g01155738
Illustration 84
RENR7458-09 39
Disassembly and Assembly Section

Improper assembly of parts that are spring loaded


can cause bodily injury.

To prevent possible injury, follow the established


assembly procedure and wear protective equip-
ment.

2. Install plug (1).

3. Install stand (9) and dowel pin (8) on the rocker


shaft.

4. Install springs (7), stands (6), exhaust rocker arms


(5), inlet rocker arms (4), and stand (3) on the
rocker shaft.

5. Install retaining ring (2).

End By: Illustration 86


g00987759

a. Install the rocker shaft. Refer to Disassembly and 1. Apply Tooling (A) to both ends of pushrods (6).
Assembly, Rocker Shaft and Pushrod - Install.
2. Lubricate pushrods (6) with clean engine oil.
i02231166
Install pushrods (6) and inlet valve bridges (5).

Rocker Shaft and Pushrod -


Install
SMCS Code: 1102-012; 1208-012

Installation Procedure
Table 34
Required Tools
Part
Tool Number Part Description Qty
A 8T-2998 Lubricant 1

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened


component life. g00987758
Illustration 87

3. Position rocker shaft (3). Install bolts (1) and (2).


Finger tighten bolts (1) and (2). Tighten bolts (2)
to a torque of 100 20 Nm (74 15 lb ft). Tighten
bolts (1) to a torque of 28 7 Nm (21 5 lb ft).

4. Apply Tooling (A) to each of the button faces of


the rocker arms.

5. Adjust the valve lash of the rocker arm by turning


rocker arm adjustment screws (4). Refer to
Testing and Adjusting, Engine Valve Lash -
Inspect/Adjust.
40 RENR7458-09
Disassembly and Assembly Section

End By:

a. Install the valve mechanism cover. Refer to


Disassembly and Assembly, Valve Mechanism
Cover - Remove and Install.

i02231291

Cylinder Head - Remove


SMCS Code: 1100-011

Removal Procedure
g01125661
Start By: Illustration 88

a. Remove the valve mechanism cover base. Refer 1. Disconnect harness assembly (1), harness
to Disassembly and Assembly, Valve Mechanism assembly (2), harness assembly (3), and harness
Cover Base - Remove and Install. assembly (4).

b. Remove the rocker shaft and pushrods. Refer to 2. Remove tube assembly (7).
Disassembly and Assembly, Rocker Shaft And
Pushrod - Remove. 3. Disconnect hose (6).

c. Remove the unit injectors. Refer to Disassembly 4. Disconnect harness assembly (5).
and Assembly, Unit Injector - Remove.

d. Remove the fan drive mounting group. Refer to


Disassembly and Assembly, Fan Drive Mounting
Group - Remove and Install.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened


component life.

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

Refer to Special Publication, NENG2500, Caterpillar Illustration 89


g01125664
Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar 5. Remove tube assembly (8) and tube assembly (9).
products.

Dispose of all fluids according to local regulations and


mandates.
RENR7458-09 41
Disassembly and Assembly Section

i02231335

Cylinder Head - Install


SMCS Code: 1100-012

Installation Procedure
Table 35
Required Tools
Part
Tool Number Part Description Qty
A 6V-4876 Lubricant 1
B 4C-5590 Anti-Seize Compound 1

NOTICE
Keep all parts clean from contaminants.

g01125672
Contaminants may cause rapid wear and shortened
Illustration 90 component life.
6. Disconnect tube assembly (10) and tube assembly
(12) from turbocharger (11). 1. Install a new cylinder head gasket.

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

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


The weight of the cylinder head is approximately
175 kg (385 lb). Position the cylinder head
assembly onto the cylinder block.

g01125676
Illustration 91

8. Remove bolts (13) and bolts (14). Remove the


cylinder head and the gasket from the cylinder
block.
g01125676
Illustration 92
42 RENR7458-09
Disassembly and Assembly Section

g01125720
Illustration 93

3. Apply Tooling (A) to the threads and both sides


of the washers of bolts (13). Apply Tooling (B) to
the threads and both sides of the washers of bolts
(14). Install bolts (13) and bolts (14).
g01125672
Illustration 94
4. Tighten the cylinder head bolts according to the
following procedure:
5. Connect tube assembly (10) and tube assembly
a. Tighten Bolt (1) through Bolt (14) in a numerical (12) onto turbocharger (11).
sequence to a torque of 300 15 Nm
(221 11 lb ft).

b. Loosen Bolt (1) through Bolt (14) until the


washers are loose under the bolt heads.

c. Tighten Bolt (1) through Bolt (14) again in a


numerical sequence to a torque of 130 15 Nm
(95 11 lb ft).

d. Again tighten Bolt (1) through Bolt (14) in a


numerical sequence to a torque of 130 15 Nm
(95 11 lb ft).

e. Turn Bolt (1) through Bolt (14) in a numerical


sequence for an additional 90 (1/4 turn).

f. Tighten Bolt (15) through Bolt (20) in a


numerical sequence to a torque of 55 7 Nm
(41 5 lb ft).
g01125664
Illustration 95

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


RENR7458-09 43
Disassembly and Assembly Section

c. Remove the unit injector hydraulic pump. Refer


to Disassembly and Assembly, Unit Injector
Hydraulic Pump - Remove.

d. Remove the air compressor. Refer to Disassembly


and Assembly, Air Compressor - Remove and
Install.

e. Remove the speed/timing sensors. Refer to


Disassembly and Assembly, Speed/Timing
Sensor - Remove and Install.

f. Remove the engine control module (ECM). Refer


to Disassembly and Assembly, Engine Control
g01125661
Module - Remove and Install.
Illustration 96

7. Connect harness assembly (5). NOTICE


Keep all parts clean from contaminants.
8. Connect hose (6).
Contaminants may cause rapid wear and shortened
9. Install tube assembly (7). component life.

10. Connect harness assembly (1), harness assembly


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

End By:

a. Install the fan drive mounting group. Refer to


Disassembly and Assembly, Fan Drive Mounting
Group - Remove and Install.

b. Install the unit injectors. Refer to Disassembly and


Assembly, Unit Injector - Install.

c. Install the rocker shaft and pushrods. Refer to


g01125745
Disassembly and Assembly, Rocker Shaft And Illustration 97
Pushrod - Install.
1. Remove bolts (1).
d. Install the valve mechanism cover base. Refer to
Disassembly and Assembly, Valve Mechanism 2. Remove side covers (2).
Cover Base - Remove and Install.

i02231540

Lifter Group - Remove and


Install
SMCS Code: 1209-010

Removal Procedure
Start By:

a. Remove the fuel filter base. Refer to Disassembly Illustration 98


g01125748
and Assembly, Fuel Filter Base - Remove and
Install. 3. Place identification marks on each lifter in order to
identify the proper location on the side cover for
b. Remove the rocker arms and pushrods. Refer to installation.
Disassembly and Assembly, Rocker Shaft and
Pushrod - Remove.
44 RENR7458-09
Disassembly and Assembly Section

Note: Ensure that the sleeves of the side covers


remain in the side covers.

4. Remove bolts (3) and the dowels that hold lifter


arms (4) and lifter shaft (5) to each side cover.
Remove seal (6).

Installation Procedure
Table 36
Required Tools
Part
Tool Number Part Description Qty
A 9S-3263 Thread Lock Compound 1 g01125745
Illustration 100

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


NOTICE bolts (1).
Keep all parts clean from contaminants.
End By:
Contaminants may cause rapid wear and shortened
component life. a. Install the engine control module (ECM). Refer
to Disassembly and Assembly, Engine Control
Module - Remove and Install.

b. Install the speed/timing sensors. Refer to


Disassembly and Assembly, Speed/Timing
Sensor - Remove and Install.

c. Install the air compressor. Refer to Disassembly


and Assembly, Air Compressor - Remove and
Install.

d. Install the unit injector hydraulic pump. Refer


to Disassembly and Assembly, Unit Injector
Hydraulic Pump - Install.
g01125748
Illustration 99 e. Install the rocker arms and pushrods. Refer to
Disassembly and Assembly, Rocker Shaft and
1. Install seal (6). Pushrod - Install.

2. Install lifter arms (4) on lifter shaft (5). f. Install the fuel filter base. Refer to Disassembly
and Assembly, Fuel Filter Base - Remove and
3. Position lifter shaft (5) over the dowels on the side Install.
cover. Ensure that the oil holes in the lifter shaft
are facing the side cover. Apply Tooling (A) on the
threads of bolts (3) that hold lifter shaft (5) to the
side cover. Install bolts (3). Tighten bolts (3) to a
torque of 13 3 Nm (10 2 lb ft). Tighten the two
center bolts. Then tighten the end bolts.

4. Lubricate the lifters with clean engine oil.


RENR7458-09 45
Disassembly and Assembly Section

i02231590

Camshaft - Remove
SMCS Code: 1210-011

Removal Procedure
Table 37
Required Tools
Part
Tool Number Part Description Qty
136-4632 Timing Pin 1
A
139-7063 Timing Pin Adapter 1
B FT-2730 Puller 12

Start By:

a. Remove the vibration damper and the pulley. g01125899


Illustration 101
Refer to Disassembly and Assembly, Vibration
Damper and Pulley - Remove and Install.
4. Rotate camshaft gear (1) in order to access bolts
(2). Remove bolts (2).
b. Remove the rocker arms and the pushrods. Refer
to Disassembly and Assembly, Rocker Shaft and
5. Remove thrust plate (3).
Pushrod - Remove.
6. Remove camshaft (4) from the cylinder block.
c. Remove the front cover. Refer to Disassembly and
Assembly, Front Cover - Remove.
i02232349

NOTICE
Keep all parts clean from contaminants.
Camshaft - Install
SMCS Code: 1210-012
Contaminants may cause rapid wear and shortened
component life.
Installation Procedure
1. Use Tooling (B) to reposition the valve lifters out
of the way. NOTICE
Keep all parts clean from contaminants.
2. Ensure that the No. 1 cylinder is at the top
center compression stroke. Refer to Testing and Contaminants may cause rapid wear and shortened
Adjusting, Finding Top Center Position for No. 1 component life.
Piston. Install Tooling (A) in the flywheel.

3. Ensure that the timing marks on the following


gears are aligned: the camshaft drive gear, the
idler gear, and the crankshaft gear.
46 RENR7458-09
Disassembly and Assembly Section

i02235225

Camshaft Gear - Remove and


Install
SMCS Code: 1210-010-GE

Removal Procedure
Start By:

a. Remove the camshaft. Refer to Disassembly and


Assembly, Camshaft - Remove.

1. Wrap the camshaft with a protective covering in


order to prevent damage to the camshaft.

g01125899
Illustration 102

1. Carefully install camshaft (4) in the cylinder block.

2. Install thrust plate (3).

3. If necessary, rotate camshaft gear (1) in order to


access thrust plate (3). Install bolts (2).

4. Ensure that the No. 1 cylinder is at the top


center compression stroke. Refer to Testing and Illustration 103
g00987675
Adjusting, Finding Top Center Position for No. 1
Piston.
NOTICE
5. Ensure that the timing marks on the following Do not allow the camshaft to fall to the floor when
gears are aligned: the camshaft drive gear, the pressing it from the drive gear. Also make sure that
idler gear, and the crankshaft gear. the camshaft lobes do not catch on the press plates.

End By: 2. Place the camshaft assembly in a suitable press.


Press camshaft (2) from camshaft gear (1).
a. Install the front cover. Refer to Disassembly and
Assembly, Front Cover - Install. 3. If necessary, remove key (3) from the camshaft.
b. Install the rocker arms and the pushrods. Refer to
Disassembly and Assembly, Rocker Shaft and Installation Procedure
Pushrod - Install.
1. Raise the temperature of the camshaft gear.
c. Install the vibration damper and the pulley. Refer
to Disassembly and Assembly, Vibration Damper Note: Do not use a torch to heat the camshaft gear.
and Pulley - Remove and Install.
RENR7458-09 47
Disassembly and Assembly Section

g00987675 g00989974
Illustration 104 Illustration 105

2. Align key (3) in the camshaft with the groove 1. Use Tooling (A) to remove camshaft bearing (1)
(keyway) in the camshaft gear. from the front of the cylinder block. Remove the
remaining camshaft bearings (2) from the cylinder
3. Install camshaft gear (1) on the end of camshaft block.
(2).

End By:
Installation Procedure
Table 39
a. Install the camshaft. Refer to Disassembly and
Assembly, Camshaft - Install. Required Tools
Part
Tool Number Part Description Qty
i02232381
Camshaft Bearing Tool
Camshaft Bearings - Remove A 8S-2241
Group
1

and Install
NOTICE
SMCS Code: 1211-010 Keep all parts clean from contaminants.

Removal Procedure Contaminants may cause rapid wear and shortened


component life.
Table 38
Required Tools
Part
Tool Number Part Description Qty
Camshaft Bearing Tool
A 8S-2241 1
Group

Start By:

a. Remove the camshaft. Refer to Disassembly and


Assembly, Camshaft - Remove.

NOTICE
Keep all parts clean from contaminants. Illustration 106
g00990062

Contaminants may cause rapid wear and shortened 1. Use Tooling (A) to install all of the camshaft
component life. bearings (2) except for the front camshaft bearing.
Locate the oil hole in each bearing so that oil
Note: Note the oil hole orientation in each camshaft hole (3) is located at the top of the bore. Refer to
bearing prior to removal for assembly purposes. Specifications for more information.
48 RENR7458-09
Disassembly and Assembly Section

1. Drain the engine oil into a suitable container


for storage or disposal. Refer to Operation and
Maintenance Manual for the correct procedure.

g00989938
Illustration 107

2. Use Tooling (A) to install front camshaft bearing


(1). Align oil hole (5) in the front camshaft bearing
with the oil hole in the cylinder block. Locate
joint (4) in the front camshaft bearing in the
proper position. Refer to Specifications for more
information.

End By: g00987883


Illustration 108
a. Install the camshaft. Refer to Disassembly and
Assembly, Camshaft - Install. Note: Do not pry or gouge the sealing surface of the
engine oil pan. Use a rubber mallet to tap lightly on
the engine oil pan, if it is necessary.
i02232558
2. Remove bolts (2). Remove engine oil pan (1) and
Engine Oil Pan - Remove and the gasket.
Install
Installation Procedure
SMCS Code: 1302-010
NOTICE
Removal Procedure Keep all parts clean from contaminants.

NOTICE Contaminants may cause rapid wear and shortened


Keep all parts clean from contaminants. 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, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent 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.
RENR7458-09 49
Disassembly and Assembly Section

5. Fill the engine with oil to the correct level. Refer


to Operation and Maintenance Manual for the
correct filling procedure.

i02232665

Piston Cooling Jets - Remove


and Install
SMCS Code: 1331-010

Removal Procedure
Start By:

a. Remove the engine oil pump. Refer to


Disassembly and Assembly, Engine Oil Pump
- Remove.

g00987883 NOTICE
Illustration 109
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened


component life.

g00987444
Illustration 111

g00987889 1. Remove bolt (2) and piston cooling jet (1) from
Illustration 110
each cylinder.
Note: Do not put liquid gasket material on the oil pan
gasket or on the gasket surface of engine oil pan (1). Installation Procedure
1. Position a new gasket and engine oil pan (1) on NOTICE
the cylinder block. Keep all parts clean from contaminants.

2. Install bolts (2). Tighten Bolts (X) to a torque of Contaminants may cause rapid wear and shortened
31 3 Nm (23 2 lb ft). component life.

3. Start at Position (Z) and tighten the remaining


bolts (2) in a counterclockwise direction. Tighten
the remaining bolts (2) to a torque of 31 3 Nm
(23 2 lb ft).

4. Start at Position (Z) and tighten bolts (2) again in


a counterclockwise direction. Tighten bolts (2) to a
torque of 31 3 Nm (23 2 lb ft).
50 RENR7458-09
Disassembly and Assembly Section

g00987444
Illustration 112

1. Position piston cooling jet (1) in the cylinder block.


Install bolt (2). Tighten bolt (2) to a torque of
28 7 Nm (21 5 lb ft).

End By: g01126088


Illustration 113

a. Install the engine oil pump. Refer to Disassembly


and Assembly, Engine Oil Pump - Install. 1. Turn the crankshaft until the connecting rod caps
are at the bottom center.

i02232678 2. Place a identification mark on the connecting rod


and connecting rod cap (2). The number should
Pistons and Connecting Rods match the cylinder number.
- Remove 3. Remove bolts (1) and connecting rod cap (2).
SMCS Code: 1225-011

Removal Procedure
Start By:

a. Remove the cylinder head. Refer to Disassembly


and Assembly, Cylinder Head - Remove.

b. Remove the engine oil pump. Refer to


Disassembly and Assembly, Engine Oil Pump
- Remove.

c. Remove the piston cooling jets. Refer to


Disassembly and Assembly, Piston Cooling Jets Illustration 114
g01126089

- Remove and Install.


4. Remove the lower half of connecting rod bearing
NOTICE (4) from connecting rod cap (2).
Keep all parts clean from contaminants.
5. Push the piston and the connecting rod away
Contaminants may cause rapid wear and shortened from the crankshaft. Remove the upper half of
component life. connecting rod bearing (4) from connecting rod
(3).

6. Remove the piston and connecting rod (3) from


the cylinder block.
RENR7458-09 51
Disassembly and Assembly Section

i02232839 i02233056

Pistons and Connecting Rods Pistons and Connecting Rods


- Disassemble - Assemble
SMCS Code: 1225-015 SMCS Code: 1225-016

Disassembly Procedure Assembly Procedure


Table 40 Table 41
Required Tools Required Tools
Part Part
Tool Number Part Description Qty Tool Number Part Description Qty
A 4C-3601 Piston Ring Expander 1 A 4C-3601 Piston Ring Expander 1
B 1P-1861 Retaining Ring Pliers 1 B 1P-1861 Retaining Ring Pliers 1
Hydraulic Press
Start By: 5P-8639 (CONNECTING ROD 1
BEARING)
a. Remove the pistons and the connecting rods. 8F-0024 Hose As 1
Refer to Disassembly and Assembly, Pistons and
Connecting Rods - Remove. 1P-2375 Quick Connect Coupler 1
C 1P-2376 Quick Connect Coupler 1
NOTICE 4C-9751 1
Spacer
Keep all parts clean from contaminants.
4C-9749 Bushing Adapter 1
Contaminants may cause rapid wear and shortened 4C-9750 Bushing Adapter 1
component life.
9U-6600 Hand Hydraulic Pump 1

Note: Prior to removal from the engine, the pistons


and connecting rod assemblies were marked.
The components must be reassembled together.
The components must be installed in the original
location in the engine. Do not interchange any of the
components.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened


component life.
g01126141
Illustration 115

1. Use Tooling (B) to remove retaining ring (2).

2. Remove piston pin (5) and separate piston (1)


from connecting rod (3).

3. Use Tooling (A) to remove piston rings (4).


52 RENR7458-09
Disassembly and Assembly Section

g01126141
Illustration 118

2. Use the following procedure to install piston rings


(4).

a. Position the spring for the oil control ring in the


g01126305 oil ring groove in the piston body assembly.
Illustration 116

b. Position the oil control ring over the spring.


Position the oil control ring so that the gap is
180 degrees from the joint in the spring. Use
Tooling (A) to install the oil control ring on the
piston.

c. Use Tooling (A) to install the intermediate piston


ring with the side that has the identification
UP-2 toward the top of the piston.

d. Use Tooling (A) to install the top piston ring


with the side that has the identification UP-1
toward the top of the piston.

Illustration 117
g01126306 e. Position piston rings (4) so the gaps are 120
degrees from each other.
1. Use Tooling (C) to remove the old bearing and
install the new bearing (6) at the same time. The 3. Check the clearance between the ends of piston
adapter of Tooling (C) should make full contact rings (4). Refer to Specifications, Piston And
with the surfaces of connecting rod (3). Rings.

Note: Orient the bearing joint within 12 5 degrees 4. Position piston (1) on connecting rod (3). Apply
of either Location (X). clean engine oil to piston pin (5) and install the
piston pin. Use Tooling (B) to install retaining ring
(2). Make sure that the retaining rings are fully
NOTICE seated in the grooves of the piston assembly.
The connecting rod must be heated for the installation
of the piston pin bearing. Do not use a torch. End By:

a. Raise the temperature of connecting rod (3) a. Install the pistons and the connecting rods. Refer
along Length (Y). to Disassembly and Assembly, Pistons and
Connecting Rods - Install.
(Y) Maximum Length for heating the
connecting rod .. 75 5 mm (3.0 0.2 inch)

b. Allow the connecting rod and the bearing to


cool to room temperature.
RENR7458-09 53
Disassembly and Assembly Section

i02233160 4. Line up the piston and the connecting rod with


the crankshaft. Use a soft faced hammer and tap
Pistons and Connecting Rods the piston into the cylinder bore until Tooling (A)
- Install comes off of the piston.

SMCS Code: 1225-012

Installation Procedure
Table 42
Required Tools
Part
Tool Number Part Description Qty
A 173-5529 Piston Ring Compressor 1
B 4C-5593 Anti-Seize Compound 1

g01126089
NOTICE Illustration 120
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened


component life.

1. Apply clean engine oil to the pistons, the piston


rings, and the cylinder bore.

g01126088
Illustration 121
g00954373
Illustration 119
5. Before connecting rod (3) comes in contact with
2. Position the piston rings so that the end gaps the crankshaft, install the upper half of connecting
are located 120 degrees from each other. Install rod bearing (4). Ensure that the bearing tab
Tooling (A) in order to compress the piston rings. engages with the slot in connecting rod (3).

Note: Install the piston and connecting rod so that 6. Apply clean engine oil to the surface of the upper
the forging number on the connecting rod points half of connecting rod bearing (4). Use a soft
toward the flywheel end of the engine. faced hammer in order to tap the piston into the
cylinder bore while you guide connecting rod (3)
3. With the number one crankshaft throw at the onto the crankshaft.
bottom center, install the piston and connecting
rod in the engine. Ensure that the proper piston 7. Place the lower half of connecting rod bearing (4)
and connecting rod are in the corresponding in corresponding connecting rod cap (2). Ensure
cylinder with the bearing retainer notch toward the that the bearing tab engages with the groove in
right side of the engine. connecting rod cap (2).
54 RENR7458-09
Disassembly and Assembly Section

8. Apply clean engine oil to the surface of the


lower half of connecting rod bearing (4). Install
connecting rod bearing cap (2) on connecting rod
(3). Ensure that the number on connecting rod cap
(2) matches the number on connecting rod (3).
Ensure that the numbers are on the same side.

9. Lubricate the new connecting rod bolts with


Tooling (B).

10. Install new bolts (1). Tighten bolts (1) to a torque


of 70 5 Nm (52 4 lb ft).

11. Place an index mark on each bolt. Tighten each


bolt (1) for an additional 120 5 degrees (1/3 turn). g01126410
Illustration 122
End By:
1. Turn the crankshaft until the connecting rod
a. Install the piston cooling jets. Refer to the bearing caps are accessible.
Disassembly and Assembly Manual, Piston
Cooling Jets - Remove and Install. 2. Place an identification mark on connecting rod (3)
and connecting rod bearing cap (2). The number
b. Install the engine oil pump. Refer to the should match the cylinder number.
Disassembly and Assembly Manual, Engine Oil
Pump - Install. 3. Remove bolts (1) and connecting rod bearing cap
(2) from connecting rod (3). Remove the lower
c. Install the cylinder head. Refer to the Disassembly half of connecting rod bearing (4) from connecting
and Assembly Manual, Cylinder Head - Install. rod bearing cap (2).

4. Push the connecting rod away from the crankshaft.


i02233237 Remove the upper half of connecting rod bearing
(4) from connecting rod (3).
Connecting Rod Bearings -
Remove i02307308

SMCS Code: 1219-011 Connecting Rod Bearings -


Install
Removal Procedure
SMCS Code: 1219-012
Start By:

a. Remove the engine oil pump. Refer to Installation Procedure


Disassembly and Assembly, Engine Oil Pump
- Remove. 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.
RENR7458-09 55
Disassembly and Assembly Section

i02304516

Crankshaft Main Bearings -


Remove
SMCS Code: 1203-011

Removal Procedure
Table 43
Required Tools
Part
Tool Number Part Description Qty
g01126410
Illustration 123 A 2P-5518 Main Bearing Tool 1

Note: Install the connecting rod bearings dry


when clearance checks are performed. Refer to Start By:
Disassembly and Assembly, Bearing Clearance -
Check. Apply clean engine oil on the connecting rod a. Remove the engine oil pump. Refer to
bearings for final assembly. Disassembly and Assembly, Engine Oil Pump
- Remove.
1. Install a new lower half of connecting rod bearing
(4) in connecting rod bearing cap (2). NOTICE
Keep all parts clean from contaminants.
2. Install a new upper half of connecting rod bearing
(4) in connecting rod (3). Contaminants may cause rapid wear and shortened
component life.
3. Pull connecting rod (3) onto the crankshaft.

4. Install connecting rod bearing cap (2) and bolts


(1). Ensure that the number on the side of
connecting rod bearing cap (2) is on the same
side as the number on connecting rod (3).

5. Tighten bolts (1) to a torque of 70 5 Nm


(52 4 lb ft).

6. Place an index mark on each bolt. Tighten each


bolt (1) for an additional 120 5 degrees (1/3 turn).

End By:

a. Install the engine oil pump. Refer to Disassembly


and Assembly, Engine Oil Pump - Install.

g00988316
Illustration 124

1. Remove bolts (1) that hold crankshaft main


bearing cap (2). Remove crankshaft main bearing
cap (2).

2. Remove the lower half of the crankshaft main


bearing from crankshaft main bearing cap (2).
56 RENR7458-09
Disassembly and Assembly Section

i02307306

Crankshaft Main Bearings -


Install
SMCS Code: 1203-012

Installation Procedure
Table 44
Required Tools
Part
Tool Number Part Description Qty
A 2P-5518 Main Bearing Tool 1
B 8T-5096 Dial Indicator Group 1

NOTICE
Keep all parts clean from contaminants.
g00988318
Illustration 125
Contaminants may cause rapid wear and shortened
NOTICE component life.
If the crankshaft is turned in the wrong direction, the
tab of the crankshaft main bearing will be pushed be- Note: Install the crankshaft main bearings dry
tween the crankshaft and the cylinder block. this can when clearance checks are performed. Refer to
cause damage to either or both the crankshaft and the Disassembly and Assembly, Bearing Clearance -
cylinder block. Check. Apply clean engine oil on the crankshaft
main bearings for final assembly.
3. Use the following steps in order to remove the
upper half of crankshaft main bearings: Note: Ensure that the tabs on the back side of the
crankshaft main bearings fit in the grooves of the
crankshaft main bearing caps and the cylinder block.
a. Turn the crankshaft until Tooling (A) can
be installed in the crankshaft journal. Install
Tooling (A).

b. Turn the crankshaft in order to remove the


upper half of the crankshaft main bearing.
Tooling (A) must first contact the crankshaft
main bearing opposite the tab end of the
crankshaft main bearing. In order to get the tab
out first, the crankshaft must be turned in the
correct direction.

c. Check the condition of the crankshaft main


bearings. Refer to the Guideline For Reusable
Parts, SEBF8009, Main and Connecting
Rod Bearings or refer to the Guideline For
Reusable Parts, SEBV0544, Engine Bearings
and Crankshafts.

g00988318
Illustration 126

1. Use Tooling (A) and install the upper halves of the


crankshaft main bearings in the cylinder block. Do
not apply oil on the back of the crankshaft main
bearing.
RENR7458-09 57
Disassembly and Assembly Section

i02236686

Crankshaft - Remove
SMCS Code: 1202-011

Removal Procedure
Start By:

a. Remove the connecting rod bearings. Refer to


Disassembly and Assembly, Connecting Rod
Bearings - Remove.

b. Remove the front housing. Refer to Disassembly


and Assembly, Housing (Front) - Remove.

c. Remove the flywheel housing. Refer to


Disassembly and Assembly, Flywheel Housing
- Remove and Install.
g00988316
Illustration 127 NOTICE
Keep all parts clean from contaminants.
2. Install the lower halves of the crankshaft main
bearings in crankshaft main bearing caps (2). Do Contaminants may cause rapid wear and shortened
not apply oil on the back of the crankshaft main component life.
bearing.

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

3. Place crankshaft main bearing caps (2) in position


on the cylinder block. Apply clean engine oil or
Molylube on the bolt threads and on the washer
face. Install bolts (1).

4. Tighten bolts (1) to a torque of 54 7 Nm


(40 5 lb ft). Tighten each bolt (1) for an additional
90 5 degrees (1/4 turn).

5. Check the end play of the crankshaft with Tooling


(B). The end play must be 0.07 to 0.32 mm
g01128041
(0.003 to 0.013 inch). Illustration 128

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

a. Install the engine oil pump. Refer to Disassembly 2. Attach a suitable lifting device to each end of
and Assembly, Engine Oil Pump - Install. crankshaft (1). The weight of crankshaft (1) is
approximately 62 kg (137 lb). Carefully remove
crankshaft (1) from the cylinder block.

3. Remove the main bearings from the cylinder


block. Remove the main bearings from the main
bearing caps.
58 RENR7458-09
Disassembly and Assembly Section

i02236693

Crankshaft - Install
SMCS Code: 1202-012

Installation Procedure
Table 45
Required Tools
Part
Tool Number Part Description Qty
A 8T-5096 Dial Indicator Group 1

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened


component life.
g01128041
Illustration 129

NOTICE 3. Put clean engine oil on the journals of the


Ensure that the crankshaft main bearing tabs engage crankshaft bearing. Attach a suitable lifting device
with the grooves in the block and the crankshaft main onto crankshaft (1). The weight of crankshaft
bearing cap. (1) is approximately 62 kg (136 lb). Align the
identification marks on the gear train. Carefully
1. Check the condition of the main bearings. Refer install crankshaft (1) in the cylinder block.
to Guideline For Reusable Parts, SEBF8009,
Main and Connecting Rod Bearings or refer 4. Clean the bearing surface of the main bearing
to Guideline For Reusable Parts, SEBV0544, caps. Install the lower main bearing in the
Engine Bearings and Crankshafts. crankshaft main bearing caps. Ensure that the
tab on the back side of the bearing engages with
Note: The number six main bearing is the thrust the groove in the main bearing cap. Apply clean
bearing. engine oil on the lower main bearing. Do not put
engine oil on the back side of the bearing surfaces.
2. Clean the bearing surfaces in the cylinder block for
the main bearings. Apply clean engine oil on the 5. Install crankshaft main bearing caps with the part
upper main bearing. Do not put engine oil on the numbers toward the right hand side of the cylinder
back side of the bearing surfaces. Install the upper block. Ensure that crankshaft main bearing caps
main bearing in the cylinder block. Ensure that the have numbers 1 through 7. The numbers should
tab on the back side of the bearing engages with start at the front of the engine. Place clean
the groove in the cylinder block. engine oil or Molylube on the bolt threads and
the washers.

Note: When the bolts for the rear main bearing cap
are tightened, slide the main bearing cap as far
forward as possible until the cap is against the bolts.
Hold the main bearing cap in this position and tighten
the bolts.

6. Install bolts (2) for main bearing caps (3). Tighten


bolts (2) to a torque of 54 7 Nm (40 5 lb ft).

7. Turn bolts (2) for an additional 90 5 degrees


(1/4 turn).

8. Check the end play of crankshaft (1) with Tooling


(A). The end play must be 0.07 mm to 0.32 mm
(0.003 inch to 0.013 inch).
RENR7458-09 59
Disassembly and Assembly Section

End By:

a. Install the flywheel housing. Refer to Disassembly


and Assembly, Flywheel Housing - Remove and
Install.

b. Install the front housing. Refer to Disassembly and


Assembly, Housing (Front) - Install.

c. Install the connecting rod bearings. Refer to


Disassembly and Assembly, Connecting Rod
Bearings - Install.

i02307746

Crankshaft Gear - Remove and


Install
SMCS Code: 1204-010-GE

Removal Procedure Illustration 130


g00988783

Table 46 1. Use Tooling (A) in order to remove crankshaft gear


Required Tools (3) from crankshaft (1).

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


Tool Number Part Description Qty
8B-7551 Bearing Puller 1 Installation Procedure
8B-7549 Puller Leg 2
NOTICE
3H-0465 Push-Puller Plate 4
Keep all parts clean from contaminants.
A 6B-6682 Full Nut 2
Contaminants may cause rapid wear and shortened
8B-7560 Step Plate 1
component life.
1P-0820 Hydraulic Puller 1
9U-6600 Hand Hydraulic Pump 1

Start By:

a. Remove the crankshaft. Refer to Disassembly and


Assembly, Crankshaft - Remove.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened


component life.

g00988783
Illustration 131
60 RENR7458-09
Disassembly and Assembly Section

Note: The measurements should be within


specifications and the correct bearings should
be used. If the crankshaft journals and the bores
Hot oil and hot components can cause personal
for the block and the rods were measured during
injury. Do not allow hot oil or hot components to
disassembly, no further checks are necessary.
contact the skin.
However, if the technician still wants to measure the
bearing clearances, Tooling (A) is an acceptable
1. Position woodruff key (2) in crankshaft (1). method. Tooling (A) is less accurate on journals with
small diameters if clearances are less than 0.10 mm
2. Raise the temperature of crankshaft gear (3). (0.004 inch).
Install crankshaft gear (3) on crankshaft (1).
NOTICE
End By: Lead wire, shim stock or a dial bore gauge can dam-
age the bearing surfaces.
a. Install the crankshaft. Refer to Disassembly and
Assembly, Crankshaft - Install.
The technician must be very careful to use Tooling (A)
correctly. The following points must be remembered:
i02717761

Bearing Clearance - Check Ensure that the backs of the bearings and the
bores are clean and dry.
SMCS Code: 1203-535; 1219-535
Ensure that the bearing locking tabs are properly
seated in the tab grooves.
Measurement Procedure
The crankshaft must be free of oil at the contact
Table 47 points of Tooling (A).
Required Tools
1. Put a piece of Tooling (A) on the crown of the
Part
bearing that is in the cap.
Tool Number Part Description Qty
198-9142 Plastic Gauge (Green) Note: Do not allow Tooling (A) to extend over the
0.025 to 0.076 mm 1 edge of the bearing.
(0.001 to 0.003 inch)
198-9143 Plastic Gauge (Red) 2. Use the correct torque-turn specifications in order
0.051 to 0.152 mm 1 to install the bearing cap. Do not use an impact
(0.002 to 0.006 inch) wrench. Be careful not to dislodge the bearing
A when the cap is installed.
198-9144 Plastic Gauge (Blue)
0.102 to 0.229 mm 1
Note: Do not turn the crankshaft when Tooling (A)
(0.004 to 0.009 inch)
is installed.
198-9145 Plastic Gauge (Yellow)
0.230 to 0.510 mm 1 3. Carefully remove the cap, but do not remove
(0.009 to 0.020 inch) Tooling (A). Measure the width of Tooling (A)
while Tooling (A) is in the bearing cap or on the
Note: Plastic gauge may not be necessary when the crankshaft journal. Refer to Illustration 132.
engine is in the chassis.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened


component life.

Note: Caterpillar does not recommend the checking


of the actual bearing clearances particularly on
small engines. This is because of the possibility of
obtaining inaccurate results and the possibility of
damaging the bearing or the journal surfaces. Each
Caterpillar engine bearing is quality checked for
specific wall thickness.
RENR7458-09 61
Disassembly and Assembly Section

g01128083
Illustration 133

(1) Atmospheric pressure sensor ............ 10 2 Nm


(90 18 lb in)
g01152855
Illustration 132
Typical Example i02237408

4. Remove all of Tooling (A) before you install the Coolant Temperature Sensor -
bearing cap. Remove and Install
Note: When Tooling (A) is used, the readings can SMCS Code: 1906-010
sometimes be unclear. For example, all parts of
Tooling (A) are not the same width. Measure the NOTICE
major width in order to ensure that the parts are Care must be taken to ensure that fluids are contained
within the specification range. Refer to Specifications during performance of inspection, maintenance, test-
Manual, Connecting Rod Bearing Journal and ing, adjusting and repair of the product. Be prepared to
Specifications Manual, Main Bearing Journal for the collect the fluid with suitable containers before open-
correct clearances. ing any compartment or disassembling any compo-
nent containing fluids.
i02236791
Refer to Special Publication, NENG2500, Caterpillar
Atmospheric Pressure Sensor Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar
- Remove and Install products.
SMCS Code: 1923-010
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.

g01128268
Illustration 134

(1) Coolant temperature sensor .............. 20 5 Nm


(15 4 lb ft)
62 RENR7458-09
Disassembly and Assembly Section

i02236802 i02236851

Engine Oil Pressure Sensor - Injection Actuation Pressure


Remove and Install Sensor - Remove and Install
SMCS Code: 1924-010 SMCS Code: 1925-010

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

Refer to Special Publication, NENG2500, Caterpillar Refer to Special Publication, NENG2500, Caterpillar
Tools and Shop Products Guide for tools and supplies Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar suitable to collect and contain fluids on Caterpillar
products. products.

Dispose of all fluids according to local regulations and Dispose of all fluids according to local regulations and
mandates. mandates.

g01128091 g01128104
Illustration 135 Illustration 136

(1) Engine oil pressure sensor ................ 10 2 Nm (1) Injection actuation pressure sensor ... 20 2 Nm
(90 18 lb in) (15 1.5 lb ft)

i02237012

Speed/Timing Sensor -
Remove and Install
SMCS Code: 1907-010; 1912-010

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened


component life.
RENR7458-09 63
Disassembly and Assembly Section

g01128114 g01128200
Illustration 137 Illustration 138

Note: The speed/timing sensors must be replaced (1) Boost pressure sensor ....................... 10 2 Nm
as a pair. (90 18 lb in)

(1) Torque for bolt ................ 28 7 Nm (21 5 lb ft)


i02237329

i02237316 Inlet Air Temperature Sensor -


Boost Pressure Sensor - Remove and Install
Remove and Install SMCS Code: 1921-010

SMCS Code: 1917-010 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.

g01128213
Illustration 139
64 RENR7458-09
Disassembly and Assembly Section

(1) Inlet air temperature sensor ............... 20 5 Nm Two-Piece Fan Drive Mounting (If
(15 4 lb ft) Equipped)

i02237494

Fan Drive Mounting Group -


Remove and Install
SMCS Code: 1359-010

Removal Procedure
Start By:

a. Remove the alternator. Refer to Disassembly and


Assembly, Alternator - Remove and Install.

One-Piece Fan Drive Mounting (If


Equipped)

g01128365
Illustration 141

1. Remove bolts (5) and bolts (10). Remove support


assembly (9).

2. Remove screws (6).

3. Remove bolts (8).

4. Remove fan drive mounting (7).

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

g01128363
Illustration 140

1. Remove screws (1).

2. Remove bolts (2).

3. Remove bolts (3).

4. Remove fan drive mounting (4).

g01128363
Illustration 142
RENR7458-09 65
Disassembly and Assembly Section

1. Position fan drive mounting (4) on the engine. i02237475


Install bolts (2) and bolts (3). Tighten bolts (2) and
bolts (3) finger tight. Engine Control Module -
Remove and Install
2. Tighten bolts (2) to a torque of 55 10 Nm
(40 7 lb ft). SMCS Code: 1901-010
3. Tighten bolts (3) to a torque of 28 7 Nm
(20 5 lb ft).

4. Install screws (1).

Two-Piece Fan Drive Mounting (If


Equipped)

g01128321
Illustration 144

(1) Harness assembly .......... 6 1 Nm (53 9 lb in)

i02528409

Alternator - Remove and Install


Illustration 143
g01128365 SMCS Code: 1405-010

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


2. Install bolts (8) and screws (6). Tighten bolts (8) 1. Disconnect the battery cables from the battery.
and screws (6) finger tight. Refer to Operation and Maintenance Manual,
Battery or Battery Calbes - Disconnect.
3. Position support assembly (9) on fan drive
mounting (7). 2. Remove the drive belt.
4. Install bolts (5) and bolts (10). Tighten bolts (5)
and bolts (10) finger tight.

5. Tighten bolts (8) and screws (6) to standard


torque.

6. Tighten bolts (5) and bolts (10) to standard torque.

End By:

a. Install the alternator. Refer to Disassembly and


Assembly, Alternator - Remove and Install.

g01128834
Illustration 145
66 RENR7458-09
Disassembly and Assembly Section

3. Place an index mark on all harness assemblies


that are connected to alternator (1). Disconnect all
harness assemblies from alternator (1).

4. Remove bolts (2).

5. Remove alternator (1).

Installation Procedure

g01063153
Illustration 147

1. Place an index mark on all of the harness


g01128834
Illustration 146 assemblies. Disconnect the harness assemblies
from electric starting motor (1).
1. Position alternator (1) on the mounting bracket.
Install bolts (2). 2. Fasten a suitable lifting device to electric starting
motor (1). The weight of electric starting motor (1)
2. Install the drive belt. is approximately 35 kg (77 lb).

3. Connect all harness assemblies to alternator (1). 3. Remove bolts (2).


Use the index marks to correctly connect the
harness assemblies. 4. Remove electric starting motor (1) and the gasket
from the flywheel housing.
4. Connect the battery cables to the battery. Refer to
Operation and Maintenance Manual, Battery or
Battery Calbes - Disconnect.
Installation Procedure

i02276552

Electric Starting Motor -


Remove and Install
SMCS Code: 1453-010

Removal Procedure

Personal injury can result from failure to discon-


nect the battery.

First, disconnect the negative battery cable. Then,


disconnect the positive battery cable.

A positive power lead can cause sparks if the bat-


g01063153
tery is not disconnected. Sparks can possibly re- Illustration 148
sult in battery explosion or fire.
RENR7458-09 67
Disassembly and Assembly Section

1. Fasten a suitable lifting device to electric starting


motor (1). The weight of electric starting motor (1)
is approximately 35 kg (77 lb).

2. Position the gasket and electric starting motor (1)


in the flywheel housing. Install bolts (2).

3. Connect the harness assemblies to electric


starting motor (1). Refer to Specifications, Electric
Starting Motor.

i02237659

Air Compressor - Remove and


Install
SMCS Code: 1803-010

Removal Procedure
Table 48 g00992674
Illustration 149
Required Tools
Part
Tool Number Part Description Qty
A 138-7573 Link Bracket 1

Do not disconnect the air lines until the air pres-


sure in the system is at zero. If hose is disconnect-
ed under pressure it can cause personal injury.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened


component life.

NOTICE g00992677
Illustration 150
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to 2. Disconnect hose assembly (1), hose assembly
collect the fluid with suitable containers before open- (3), hose assembly (6), and hose (2).
ing any compartment or disassembling any compo-
nent containing fluids. 3. Remove bolts (7).

Refer to Special Publication, NENG2500, Caterpillar 4. Remove bolt (8).


Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar 5. Install Tooling (A) and a suitable lifting device to
products. air compressor (4). The weight of air compressor
(4) is approximately 27 kg (60 lb).
Dispose of all fluids according to local regulations and
mandates. 6. Remove bolts (5).

7. Remove air compressor (4) and the gasket.


1. Remove the air pressure from the air tank and
drain the coolant from the cooling system.
68 RENR7458-09
Disassembly and Assembly Section

Installation Procedure 1. Install Tooling (A) and a suitable lifting device to


air compressor (4). The weight of air compressor
Table 49 (4) is approximately 27 kg (60 lb).
Required Tools
2. Position air compressor (4) in the front housing.
Part
Tool Number Part Description Qty Note: Bolts (5) must be installed prior to bolts (7).
A 138-7573 Link Bracket 1
3. Apply Tooling (B) to the threads of bolts (5). Install
B 9S-3263 Thread Lock Compound 1 bolts (5).

NOTICE 4. Install bolts (7).


Keep all parts clean from contaminants.
5. Install bolt (8).
Contaminants may cause rapid wear and shortened
component life. 6. Connect hose assembly (1), hose assembly (3),
hose assembly (6), and hose (2).

7. Fill the cooling system with coolant to the


correct level. Refer to the Operation and
Maintenance Manual, Refill Capacities and
Recommendations.

i02237680

Air Compressor Drive Gear -


Remove
SMCS Code: 1803-011-GE

Removal Procedure
Table 50
Required Tools
Part
Tool Number Part Description Qty
g00992674
Illustration 151 A 132-5451 Holding Fixture 1

Start By:

a. Remove the air compressor. Refer to Disassembly


and Assembly, Air Compressor - Remove and
Install.

g00992677
Illustration 152
RENR7458-09 69
Disassembly and Assembly Section

g01128545 g01148907
Illustration 153 Illustration 154

1. Install Tooling (A) on air compressor drive gear (1). 1. Install air compressor drive gear (1) on the air
compressor.
2. Remove nut (2).
2. Install Tooling (A) on air compressor drive gear (1).
3. Remove air compressor drive gear (1).
3. Install nut (2).
i02294313
Tapered Shaft on Bendix Air Compressor
Air Compressor Drive Gear -
1. Tighten nut (2) to a torque of 160 15 Nm
Install (118 11 lb ft).
(Two Cylinder)
2. Tap the gear axially with a soft faced hammer in
SMCS Code: 1803-012-GE order to seat the gear onto the tapered crankshaft.

3. Tighten the nut again to a torque of 160 15 Nm


Installation Procedure (118 11 lb ft).
Table 51
Straight Shaft on Bendix Air Compressor
Required Tools
Part 1. Tighten nut (2) to a torque of 460 60 Nm
Tool Number Part Description Qty (340 44 lb ft).
A 132-5451 Holding Fixture 1
Wabco 250 Air Compressor
Note: Caterpillar may use air compressors that have 1. Tighten nut (2) to a torque of 150 5 Nm
a tapered shaft or a straight shaft. The torque for the (111 4 lb ft).
nut on the air compressor crankshaft is different for
each type of crankshaft. 2. Place an index mark on the nut and rotate nut (2)
for an additional turn of 60 5 degrees.
Note: Identify the manufacturer of the air compressor
for your particular application. End By:

a. Install the air compressor. Refer to Disassembly


and Assembly, Air Compressor - Remove and
Install.
70 RENR7458-09
Disassembly and Assembly Section

i02967460

Air Compressor Drive Gear -


Install
SMCS Code: 1803-012-GE

Installation Procedure
Table 52
Required Tools
Part
Tool Number Part Description Qty
A 132-5451 Holding Fixture 1

g01128545
Illustration 155

Note: Caterpillar may use air compressors that have


a tapered shaft or a straight shaft. The torque for the
nut on the air compressor crankshaft is different for
each type of crankshaft. Identify the manufacturer of
the air compressor for your particular application.

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


compressor.

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

3. Install nut (2).

4. Refer to Specifications, Air Compressor Drive


Gear - Install for the correct torque for the nut (2).

5. Remove Tooling (A).

End By:

a. Install the air compressor. Refer to Disassembly


and Assembly, Air Compressor - Remove and
Install.
RENR7458-09 71
Index Section

Index
A Crankshaft Gear - Remove and Install .................. 59
Installation Procedure ........................................ 59
Air Compressor - Remove and Install.................... 67 Removal Procedure ........................................... 59
Installation Procedure ........................................ 68 Crankshaft Main Bearings - Install......................... 56
Removal Procedure ........................................... 67 Installation Procedure ........................................ 56
Air Compressor Drive Gear - Install....................... 70 Crankshaft Main Bearings - Remove..................... 55
Installation Procedure ........................................ 70 Removal Procedure ........................................... 55
Air Compressor Drive Gear - Install (Two Crankshaft Rear Seal - Install................................ 28
Cylinder) .............................................................. 69 Installation Procedure ........................................ 28
Installation Procedure ........................................ 69 Crankshaft Rear Seal - Remove............................ 28
Air Compressor Drive Gear - Remove................... 68 Removal Procedure ........................................... 28
Removal Procedure ........................................... 68 Cylinder Head - Install ........................................... 41
Air Inlet Heater Solenoid - Remove and Install...... 15 Installation Procedure ........................................ 41
Installation Procedure ........................................ 15 Cylinder Head - Remove ....................................... 40
Removal Procedure ........................................... 15 Removal Procedure ........................................... 40
Alternator - Remove and Install ............................. 65
Installation Procedure ........................................ 66
Removal Procedure ........................................... 65 D
Atmospheric Pressure Sensor - Remove and
Install ................................................................... 61 Disassembly and Assembly Section........................ 4

B E

Bearing Clearance - Check ................................... 60 Electric Starting Motor - Remove and Install ......... 66
Measurement Procedure ................................... 60 Installation Procedure ........................................ 66
Boost Pressure Sensor - Remove and Install........ 63 Removal Procedure ........................................... 66
Engine Control Module - Remove and Install ........ 65
Engine Oil Filter Base - Assemble......................... 20
C Assembly Procedure.......................................... 20
Engine Oil Filter Base - Disassemble .................... 19
Camshaft - Install................................................... 45 Disassembly Procedure ..................................... 19
Installation Procedure ........................................ 45 Engine Oil Filter Base and Oil Cooler - Install ....... 20
Camshaft - Remove............................................... 45 Installation Procedure ........................................ 20
Removal Procedure ........................................... 45 Engine Oil Filter Base and Oil Cooler - Remove ... 19
Camshaft Bearings - Remove and Install .............. 47 Removal Procedure ........................................... 19
Installation Procedure ........................................ 47 Engine Oil Pan - Remove and Install..................... 48
Removal Procedure ........................................... 47 Installation Procedure ........................................ 48
Camshaft Gear - Remove and Install .................... 46 Removal Procedure ........................................... 48
Installation Procedure ........................................ 46 Engine Oil Pressure Sensor - Remove and Install.. 62
Removal Procedure ........................................... 46 Engine Oil Pump - Assemble................................. 23
Camshaft Idler Gear - Remove and Install ............ 35 Assembly Procedure.......................................... 23
Installation Procedure ........................................ 35 Engine Oil Pump - Disassemble............................ 22
Removal Procedure ........................................... 35 Disassembly Procedure ..................................... 22
Connecting Rod Bearings - Install ......................... 54 Engine Oil Pump - Install ....................................... 24
Installation Procedure ........................................ 54 Installation Procedure ........................................ 24
Connecting Rod Bearings - Remove ..................... 54 Engine Oil Pump - Remove ................................... 22
Removal Procedure ........................................... 54 Removal Procedure ........................................... 22
Coolant Temperature Sensor - Remove and Exhaust Manifold - Remove and Install ................. 14
Install ................................................................... 61 Installation Procedure ........................................ 14
Crankshaft - Install................................................. 58 Removal Procedure ........................................... 14
Installation Procedure ........................................ 58
Crankshaft - Remove............................................. 57
Removal Procedure ........................................... 57 F
Crankshaft Front Seal - Install ............................... 32
Installation Procedure ........................................ 32 Fan Drive Mounting Group - Remove and Install .. 64
Crankshaft Front Seal - Remove ........................... 31 Installation Procedure ........................................ 64
Removal Procedure ........................................... 31 Removal Procedure ........................................... 64
Flywheel - Install.................................................... 27
Installation Procedure ........................................ 27
72 RENR7458-09
Index Section

Flywheel - Remove................................................ 27 P
Removal Procedure ........................................... 27
Flywheel Housing - Remove and Install ................ 29 Piston Cooling Jets - Remove and Install.............. 49
Installation Procedure ........................................ 29 Installation Procedure ........................................ 49
Removal Procedure ........................................... 29 Removal Procedure ........................................... 49
Front Cover - Install ............................................... 32 Pistons and Connecting Rods - Assemble ............ 51
Installation Procedure ........................................ 32 Assembly Procedure.......................................... 51
Front Cover - Remove ........................................... 32 Pistons and Connecting Rods - Disassemble ....... 51
Removal Procedure ........................................... 32 Disassembly Procedure ..................................... 51
Fuel Filter Base - Remove and Install ..................... 4 Pistons and Connecting Rods - Install................... 53
Installation Procedure .......................................... 5 Installation Procedure ........................................ 53
Removal Procedure ............................................. 4 Pistons and Connecting Rods - Remove............... 50
Fuel Priming Pump - Remove and Install ................ 4 Removal Procedure ........................................... 50
Installation Procedure .......................................... 4
Removal Procedure ............................................. 4
Fuel Transfer Pump - Install .................................... 6 R
Installation Procedure .......................................... 6
Fuel Transfer Pump - Remove ................................ 5 Rocker Shaft - Assemble....................................... 38
Removal Procedure ............................................. 5 Assembly Procedure.......................................... 38
Rocker Shaft - Disassemble .................................. 38
Disassembly Procedure ..................................... 38
H Rocker Shaft and Pushrod - Install........................ 39
Installation Procedure ........................................ 39
Housing (Front) - Install ......................................... 34 Rocker Shaft and Pushrod - Remove.................... 37
Installation Procedure ........................................ 34 Removal Procedure ........................................... 37
Housing (Front) - Remove ..................................... 33
Removal Procedure ........................................... 33
S

I Speed/Timing Sensor - Remove and Install .......... 62

Important Safety Information ................................... 2


Injection Actuation Pressure Sensor - Remove and T
Install ................................................................... 62
Inlet Air Temperature Sensor - Remove and Table of Contents..................................................... 3
Install ................................................................... 63 Turbocharger - Install ............................................ 13
Inlet and Exhaust Valve Guides - Remove and Installation Procedure ........................................ 13
Install ................................................................... 17 Turbocharger - Remove ........................................ 12
Installation Procedure ........................................ 17 Removal Procedure ........................................... 12
Removal Procedure ........................................... 17
Inlet and Exhaust Valve Seat Inserts - Remove and
Install ................................................................... 18 U
Installation Procedure ........................................ 18
Removal Procedure ........................................... 18 Unit Injector - Install................................................. 8
Inlet and Exhaust Valves - Remove and Install ..... 15 Installation Procedure .......................................... 8
Installation Procedure ........................................ 16 Unit Injector - Remove............................................. 7
Removal Procedure ........................................... 15 Removal Procedure ............................................. 7
Unit Injector Hydraulic Pump - Install ..................... 11
Installation Procedure ......................................... 11
L Unit Injector Hydraulic Pump - Remove ................. 11
Removal Procedure ............................................ 11
Lifter Group - Remove and Install.......................... 43 Unit Injector Sleeve - Install................................... 10
Installation Procedure ........................................ 44 Installation Procedure ........................................ 10
Removal Procedure ........................................... 43 Unit Injector Sleeve - Remove................................. 9
Removal Procedure ............................................. 9

M
V
Modulating Valve - Remove and Install ................. 12
Installation Procedure ........................................ 12 Valve Mechanism Cover - Remove and Install...... 36
Removal Procedure ........................................... 12 Installation Procedure ........................................ 36
Removal Procedure ........................................... 36
RENR7458-09 73
Index Section

Valve Mechanism Cover Base - Remove and


Install ................................................................... 36
Installation Procedure ........................................ 37
Removal Procedure ........................................... 36
Vibration Damper and Pulley - Remove and
Install ................................................................... 30
Installation Procedure ........................................ 31
Removal Procedure ........................................... 30

Water Pump - Assemble........................................ 25


Assembly Procedure.......................................... 25
Water Pump - Disassemble ................................... 25
Disassembly Procedure ..................................... 25
Water Pump - Install .............................................. 26
Installation Procedure ........................................ 26
Water Pump - Remove .......................................... 24
Removal Procedure ........................................... 24
Water Temperature Regulator - Remove and
Install ................................................................... 26
Installation Procedure ........................................ 27
Removal Procedure ........................................... 26
74 RENR7458-09
Index Section
RENR7458-09 75
Index Section
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