It 28 Engine

SENR3611-18
SENR3582-16
SENR3583-13
3114, 3116 and 3126 Engines for built machines
S/N 1CK1-Up
3114, 3116 and 3126 Engines for Caterpillar Built Machines
SENR3582-16
Specifications
SENR3583-13
Systems Operation
SENR3583-13
Testing and Adjusting
SENR3611-18
Disassembly and Assembly
Section Total
Page Page
SENR3582-16
Specifications
INDEX 1 1
Engine Design 5 5
3114 Engine
3116 Engine
3126 Engine
Governor 7 7
Fuel Transfer Pump 8 8
Fuel Filter Lines 9 9
Fuel Filter Base 10 10
Fuel Filter (Primary) 11 11
Fuel Filter and Water Separator 12 12
Ether Starting Aid 13 13
Fuel Injection Control Linkage 14 14
Unit Injector 15 15
Unit Injector Mechanism 16 16
3114 Engines and 3116 Engines
3126 Engines
Valve Rocker Arms and Lifters 18 18
Type 1 ( 3114 and 3116 Engines)
Type 3 ( 3126 Engines)
Valve Mechanism Cover 22 22
Cylinder Head Valves 23 23
Type 1 Cylinder Head
Cylinder Head 32 32
Turbocharger 34 34
Turbine Housing Vee Clamped To Turbocharger
Turbine Housing And Compressor Housing Bolted To Turbocharger
Turbine Housing And Compressor Housing Clamped To Turbocharger
Water Cooled Turbocharger
Aftercooler 36 36
Exhaust Manifold 37 37
Exhaust Elbow 39 39
Camshaft 40 40
Type 1 Camshaft
Type 2 Camshaft
Engine Oil Filter Base 42 42
Engine Mounted Base
Remote Mounted Base
Engine Oil Pump 44 44
Engine Oil Pressure 45 45
Water Temperature Regulator 46 46
Water Pump 48 48
Cylinder Block Cover Group 49 49
Cylinder Block 50 50
Crankshaft 56 56
Crankshaft Seals 57 57
Vibration Damper and Pulley 58 58
Connecting Rod Bearing Journal 59 59
Main Bearing Journal 60 60
Piston and Rings 61 61
One-Piece Piston
Top Ring
Intermediate Ring
Oil Control Ring
Piston Pin
Two-Piece Articulated Piston
Top Ring
Intermediate Ring
Oil Control Ring
Piston Pin Bore
Piston Cooling Jet 66 66
Balancer Group - 3114 Engine Only 67 67
Accessory Drive - Splined 69 69
Front Housing and Covers 70 70
Gear Group (Front) 72 72
Type 1
Type 2
Type 3
Type 4
Rear Power Take-Off (RPTO) 76 76
Flywheel 77 77
Flywheel Housing 78 78
Engine to Transmission Adapter 79 79
Crankshaft Pulley 80 80
Belt Tension Chart 81 81
Belt Tensioner 83 83
Belt Tensioner 84 84
Fan Drive 85 85
Type 1
Type 2
Type 3
Alternator and Regulator 88 88
Electric Starting Motor 98 98
Magnetic Pickup 110 110
Jacket Water Heater 111 111
Jacket Water Heater 113 113
Air Inlet Heater 115 115
Fuel Shutoff Solenoid 117 117
Energize-To-Shutoff (ETS) Latching Type
Energize-To-Run (ETR) Nonlatching Type
Wiring Connections For Fuel Shutoff Solenoid
SENR3583-13
Systems Operation
INDEX 1 120
General Information 5 124
Fuel System 7 126
Fuel System
Fuel Transfer Pump
Fuel Injection Pump (Unit Injector)
Rack Control Linkage For The Fuel Injector
Governor
Fuel Ratio Control
Fuel Shutoff Solenoid
Air Inlet and Exhaust System 14 133
Turbocharger
Valve System Components
Air Inlet Heater (If Equipped)
Typical System Components
Ether Starting Aid
Lubrication System 19 138
Cooling System 21 140
3126 Engine with a Heat Exchanger
Coolant Flow Circuit
Basic Engine 25 144
Cylinder Block and Head
Pistons, Rings, and Connecting Rods
Crankshaft
Camshaft
Vibration Damper
Rubber Damper (If Equipped)
Viscous Damper (If Equipped)
Balancer Shafts (Four Cylinder Engine)
Electrical System 29 148
Engine Electrical System
Charging System Components
Brushless Alternator
Brush Type Alternator
Starting System Components
Solenoid
Starter Motor
Other Components
Circuit Breaker
Magnetic Pickup
Magnetic Switch
SENR3583-13
Fuel System - Inspect 34 153

Initial Inspection Of The Fuel System
Start Up Procedure
Inspection With The Engine Running
Checking The Operation Of Individual Cylinders
Air in Fuel - Test 36 155
Engine Speed - Check 38 157
Finding Top Center Position for No. 1 Piston 39 158
Fuel Quality - Test 41 160
Fuel Ratio Control - Adjust 42 161
Fuel System - Prime 44 163
Fuel System Pressure - Test 45 164
Fuel Pressure Readings
Checking Fuel Pressure
Fuel Timing Dimension - Adjust 47 166
Gear Group (Front) - Time 48 167
Static Check Of The Timing Gear Position
Crankshaft Positions for Valve Lash Setting
Governor - Adjust 51 170
Low Idle Adjustment
High Idle Adjustment
Governor Control Adjustment (If Equipped)
Unit Injector - Adjust 53 172
Unit Injector Synchronization - Adjust 54 173
Air Inlet and Exhaust System - Inspect 57 176
Air Inlet Restriction
Exhaust Restriction
Turbocharger - Inspect 60 179
Inspection of the Compressor and the Compressor Housing
Inspection of the Turbine Wheel and the Turbine Housing
Inspection of the Wastegate
Inlet Manifold Pressure - Test 63 182
Exhaust Temperature - Test 65 184
Engine Crankcase Pressure (Blowby) - Test 66 185
Compression - Test 67 186
Engine Valve Lash - Inspect/Adjust 68 187
Valve Lash Check
Valve Lash Adjustment
Engine Oil Pressure - Test 70 189
Measuring Engine Oil Pressure
Reasons For Low Engine Oil Pressure
Engine Oil Level Is Low
The Engine Oil Pump Is Faulty
The Oil Pickup Tube Has A Leak Or A Restricted Inlet Screen
Engine Oil Is Contaminated
The Engine Oil Bypass Valves Are Open
The Engine Lubrication System Is Open
Piston Cooling Jets
Engine Bearings Have Excessive Clearance
Reason for High Engine Oil Pressure
Excessive Bearing Wear - Inspect 74 193
Excessive Engine Oil Consumption - Inspect 75 194
Oil Leakage On Outside Of Engine
Oil Leakage Into Combustion Area Of Cylinders
Increased Engine Oil Temperature - Inspect 76 195
Cooling System - Check - Overheating 77 196
Cooling System - Inspect 79 198
Cooling System - Test 80 199
Test Tools For Cooling System
Making the Correct Antifreeze Mixtures
Checking the Filler Cap
Testing The Radiator And Cooling System For Leaks
Test For The Water Temperature Gauge
Water Temperature Regulator - Test 86 205
Water Pump - Test 87 206
Piston Ring Groove - Inspect 88 207
Connecting Rod Bearings - Inspect 89 208
Main Bearings - Inspect 90 209
Cylinder Block - Inspect 91 210
Flywheel - Inspect 92 211
Face Runout (Axial Eccentricity) of the Flywheel
Bore Runout (Radial Eccentricity) of the Flywheel
Flywheel Housing - Inspect 94 213
Face Runout (Axial Eccentricity) of the Flywheel Housing
Bore Runout (Radial Eccentricity) of the Flywheel Housing
Vibration Damper - Check 97 216
Rubber Vibration Damper (If Equipped)
Viscous Vibration Damper (If Equipped)
Battery - Test 99 218
Charging System - Test 101 220
Test Tools For The Charging System
8T-0900 Ammeter
6V-7070 Digital Multimeter
Alternator Regulator
Tightening The Alternator Pulley Nut
Electric Starting System - Test 104 223
Pinion Clearance - Adjust 106 225
Electric Starting Motor
SENR3611-18
INDEX 1 226
Fuel Filter Base - Remove and Install 7 232
Removal Procedure
Installation Procedure
Fuel Filter Base - Remove and Install 9 234
Removal Procedure
Fuel Priming Pump and Primary Fuel Filter - Remove and Install 11 236
Removal Procedure
Fuel Transfer Pump - Remove 14 239
Removal Procedure
Fuel Transfer Pump - Install 16 241
Fuel Shutoff Solenoid - Remove and Install 18 243
Removal Procedure
Governor - Remove 20 245
Removal Procedure
Governor - Install 23 248
Fuel Injection Control Linkage - Remove 26 251
Removal Procedure
Fuel Injection Control Linkage - Install 28 253
Unit Injector - Remove 31 256
Removal Procedure
Unit Injector - Install 33 258
Unit Injector Sleeve - Remove 35 260
Removal Procedure
Unit Injector Sleeve - Install 36 261
Turbocharger - Remove 37 262
Removal Procedure
Turbocharger - Install 38 263
Exhaust Manifold - Remove and Install 39 264
Removal Procedure
Inlet Manifold - Remove 41 266
Removal Procedure
Inlet Manifold - Install 42 267
Inlet and Exhaust Valves - Remove and Install 43 268
Removal Procedure
Inlet and Exhaust Valve Guides - Remove and Install 46 271
Removal Procedure
Inlet and Exhaust Valve Seat Inserts - Remove and Install 48 273
Removal Procedure
Engine Oil Filter Base - Remove 51 276
Removal Procedure
Engine Oil Filter Base - Disassemble 52 277
Disassembly Procedure
Engine Oil Filter Base - Assemble 53 278
Assembly Procedure
Engine Oil Filter Base - Install 54 279
Engine Oil Filter Bypass Valve - Remove and Install 55 280
Removal Procedure
Engine Oil Cooler Bypass Valve - Remove and Install 57 282
Removal Procedure
Engine Oil Cooler - Remove 59 284
Removal Procedure
Engine Oil Cooler - Install 60 285
Engine Oil Pump - Remove 61 286
Removal Procedure
Engine Oil Pump - Disassemble 62 287
Engine Oil Pump - Assemble 64 289
Assembly Procedure
Engine Oil Pump - Install 66 291
Water Pump - Remove 67 292
Removal procedure
Water Pump - Disassemble 69 294
Water Pump - Assemble 71 296
Assembly Procedure
Water Pump - Install 73 298
Installation procedure
Water Temperature Regulator Housing - Remove and Install 74 299
Removal Procedure
Water Temperature Regulator - Remove and Install 76 301
Removal Procedure
Aftercooler - Remove 77 302
Removal Procedure
Aftercooler - Install 79 304
Engine Lifting Bracket - Remove and Install 81 306
Removal Procedure
Flywheel - Remove 82 307
Removal Procedure
Flywheel - Install 83 308
Crankshaft Rear Seal - Remove 84 309
Removal Procedure
Crankshaft Rear Seal - Install 85 310
Crankshaft Wear Sleeve (Rear) - Remove - If Equipped 86 311
Removal Procedure
Crankshaft Wear Sleeve (Rear) - Install 87 312
Crankshaft Rear Seal Carrier - Remove and Install 88 313
Removal Procedure
Flywheel Housing - Remove and Install 90 315
Removal Procedure
Vibration Damper and Pulley - Remove and Install 92 317
Removal Procedure
Crankshaft Front Seal - Remove 94 319
Removal Procedure
Crankshaft Front Seal - Install 95 320
Front Cover - Remove 96 321
Removal Procedure
Front Cover - Install 97 322
Gear Group (Front) - Remove 98 323
Removal Procedure
Gear Group (Front) - Install 99 324
Housing (Front) - Remove 102 327
Removal Procedure
Housing (Front) - Install 103 328
Crankcase Breather - Remove and Install 105 330
Removal Procedure
Valve Mechanism Cover - Remove and Install 106 331
Removal Procedure
Rocker Shaft and Pushrod - Remove 108 333
Removal Procedure
Rocker Shaft - Disassemble 109 334
Rocker Shaft - Assemble 111 336
Assembly Procedure
Rocker Shaft and Pushrod - Install 112 337
Cylinder Head - Remove 113 338
Removal Procedure
Cylinder Head - Install 115 340
Lifter Group - Remove and Install 117 342
Removal Procedure
Camshaft - Remove 119 344
Removal Procedure
Camshaft - Install 120 345
Camshaft Gear - Remove and Install 122 347
Removal Procedure
Camshaft Bearings - Remove and Install 123 348
Removal Procedure
Engine Oil Pan - Remove and Install 125 350
Removal Procedure
Engine Balancer Shaft - Remove and Install 127 352
Removal Procedure
Piston Cooling Jets - Remove and Install 129 354
Removal Procedure
Pistons and Connecting Rods - Remove 131 356
Removal Procedure
Pistons and Connecting Rods - Disassemble 133 358
Pistons and Connecting Rods - Assemble 134 359
Assembly Procedure
Pistons and Connecting Rods - Install 137 362
Crankshaft Main Bearings - Remove 140 365
Removal Procedure
Crankshaft Main Bearings - Install 142 367
Crankshaft - Remove 144 369
Removal Procedure
Crankshaft - Install 146 371
Crankshaft Gear - Remove and Install 149 374
Removal Procedure
Bearing Clearance - Check 151 376
Measurement Procedure
Engine Oil Pressure Sensor - Remove and Install 153 378
Removal Procedure
Ether Atomizer - Remove and Install 155 380
Removal Procedure
Belt Tensioner - Remove and Install 156 381
Removal Procedure
Belt Tightener - Remove 157 382
Removal Procedure
Belt Tightener - Install 158 383
Alternator - Remove and Install 159 384
Removal Procedure
Electric Starting Motor - Remove and Install 161 386
Removal Procedure
Air Compressor - Remove and Install 163 388
Removal Procedure
Air Compressor Drive Gear - Remove and Install 165 390
Removal Procedure
1
SENR3582-16
INDEX
Specifications
Specifications
Engine Design INDEX 1
5
3114 Engine
3116 Engine
3126 Engine
Governor 7
Fuel Transfer Pump 8
Fuel Filter Lines 9
Fuel Filter Base 10
Fuel Filter (Primary) 11
Fuel Filter and Water Separator 12
Ether Starting Aid 13
Fuel Injection Control Linkage 14
Unit Injector 15
Unit Injector Mechanism 16
3126 Engines
Valve Rocker Arms and Lifters 18
Valve Mechanism Cover 22
Cylinder Head Valves 23
Cylinder Head 32
Turbocharger 34
Turbine Housing And Compressor Housing Bolted To Turbocharger
Turbine Housing And Compressor Housing Clamped To Turbocharger
Aftercooler 36
Exhaust Manifold 37
Exhaust Elbow 39
Camshaft 40
Type 1 Camshaft
Type 2 Camshaft
Engine Oil Filter Base 42
Engine Mounted Base
SENR3582-16
2
Remote Mounted Base
Engine Oil Pump 44
Engine Oil Pressure 45
Water Temperature Regulator 46
Water Pump 48
Cylinder Block Cover Group 49
Cylinder Block 50
Crankshaft 56
Crankshaft Seals 57
Vibration Damper and Pulley 58
Connecting Rod Bearing Journal 59
Main Bearing Journal 60
Piston and Rings 61
One-Piece Piston
Top Ring
Intermediate Ring
Oil Control Ring
Piston Pin
Top Ring
Intermediate Ring
Oil Control Ring
Piston Pin Bore
Piston Cooling Jet 66
Balancer Group - 3114 Engine Only 67
Accessory Drive - Splined 69
Front Housing and Covers 70
Gear Group (Front) 72
Type 1
Type 2
Type 3
Type 4
Rear Power Take-Off (RPTO) 76
Flywheel 77
Flywheel Housing 78
Engine to Transmission Adapter 79
Crankshaft Pulley 80
Belt Tension Chart 81
Belt Tensioner 83
Belt Tensioner 84
Fan Drive 85
Type 1
Type 2
Type 3
Alternator and Regulator 88
Electric Starting Motor 98
SENR3582-16
3
Magnetic Pickup 110
Jacket Water Heater 111
Jacket Water Heater 113
Air Inlet Heater 115
Fuel Shutoff Solenoid 117
SENR3582-16
4
SENR3582-16
5
001 Specifications
3114, 3116 and 3126 Engines for Caterpillar Built Machines, SENR3582-16
Engine Design
3114 Engine
Illustration 1 g00296424
Cylinder and valve location, (A) Exhaust valves (B) Inlet valves
Bore ... 105.0 mm (4.13 inch)

Stroke ... 127.0 mm (5.00 inch)
Displacement ... 4.4 L (268 in3)
Number of cylinders ... 4
Cylinder arrangement ... In-line
Valves per cylinder ... 2
In order to check the engine valve lash setting, the engine must be cold and the engine must be stopped.
Engine valve lash settings
Inlet ... 0.38 mm (0.015 inch)
Exhaust ... 0.64 mm (0.025 inch)
Type of combustion ... Direct Injection

Firing Order ... 1-3-4-2
The crankshaft rotation is viewed from the flywheel end of the engine. Crankshaft rotation ...
counterclockwise
Note: The front end of the engine is opposite of the flywheel end of the engine. The left side of the
engine and the right side of the engine are viewed from the flywheel end of the engine. The number one
cylinder is the front cylinder.
3116 Engine
001 : Specifications
6
Bore ... 105.0 mm (4.13 inch)

Stroke ... 127.0 mm (5.00 inch)
Inlet ... 0.38 mm (0.015 inch)

Firing Order ... 1-5-3-6-2-4
counterclockwise
3126 Engine
Bore ... 110.0 mm (4.33 inch)

Stroke ... 127.0 mm (5.00 inch)
Inlet ... 0.38 mm (0.015 inch)

Firing Order ... 1-5-3-6-2-4
counterclockwise
7
002 Specifications
Governor
Note: Specifications for the governors are in Service Manual, SENR6454, "3114, 3116, & 3126 Engine
Governors".
8
003 Specifications
Fuel Transfer Pump
Typical example
(1) Tighten the fitting for the fuel inlet to the following torque. ... 17 ± 2 N·m (13 ± 1 lb ft) (2) Inlet
check valve (3) 7C-5294 Spring
Color code ... One brown stripe
Load test
Put the following load on the spring. ... 100 N (22.5 lb)
Compress the spring further by the additional distance. ... 5 mm (0.2 inch)
The load must then be the following value. ... 162.5 ± 4.5 N (36 ± 1 lb)
Free length ... 40.96 mm (1.613 inch)
(4) Tighten the bolt to the following torque. ... 4 ± 1 N·m (35 ± 9 lb in) (5) Tighten the connector to the
following torque. ... 17 ± 2 N·m (13 ± 1 lb ft) (6) Piston assembly
Diameter of new piston ... 17.476 ± 0.004 mm (0.6880 ± 0.0002 inch)
Bore of new sleeve ... 17.500 ± 0.008 mm (0.6890 ± 0.0003 inch)
(7) Outlet check valve (8) Piston check valve (9) Tappet
New tappet diameter ... 5.000 ± 0.005 mm (0.1969 ± 0.0002 inch)
The clearance between the tappet diameter and the new sleeve bore ... 0.00635 ± 0.00381 mm
(0.00025 ± 0.00015 inch)
(10) Cam (11) Fuel passage
9
004 Specifications
Fuel Filter Lines
Typical example
Left side of engine
View A-A
Front of engine
(1) Fuel outlet to tank (2) Fuel inlet (3) Pressure relief valve (4) Cylinder head (5) Drilled passage (6)
Tube assembly (7) Tube assembly (fuel transfer pump to fuel filter) (8) Check valve assembly
Minimum fuel system pressure at low idle ... 50 kPa (7.2 psi)
The check valve assembly (8) maintains the minimum fuel system pressure. The check valve assembly
(8) prevents fuel from draining from the fuel system.
Note: Refer to the System Operation, Testing and Adjusting, "Fuel System - Inspect" for the correct
method of inspecting fuel pressure., (9) Screen assembly (if equipped) (10) Fitting (11) Fuel gallery
(12) The pressure regulating orifice maintains the following fuel system pressure.
Maximum fuel system pressure at rated rpm ... 400 kPa (58 psi)
Minimum fuel system pressure at rated rpm ... 140 kPa (20 psi)
Note: The pressure regulating orifice is a drilled passage (5) in tube assembly (6).
10
005 Specifications
Fuel Filter Base
Typical example
(1) Put 7M-7456 Bearing Mount Compound on the tapered end of the stud to the following distance. ...
7.6 ± 1.5 mm (0.30 ± 0.06 inch) (2) Distance from the sealing surface of the filter base to the end of the
stud ... 24.7 ± 2.3 mm (0.97 ± 0.09 inch) (3) Sealing surface of the stud
Note: Do not damage this surface.
11
006 Specifications
Fuel Filter (Primary)
Typical example
(1) Tighten the nut to the following torque. ... 24.5 ± 4.1 N·m (18 ± 3 lb ft) (2) 7S-9323 Spring
Length of spring under test force ... 27.9 mm (1.10 inch)
Test force ... 125 to 145 N (28 to 33 lb)
Free length after test ... 42.7 mm (1.68 inch)
Outside diameter ... 17.3 mm (0.68 inch)
12
007 Specifications
Fuel Filter and Water Separator
Typical example
(1) Filter element (2) Fuel filter base (3) Bowl (4) Plug (5) Drain
Note: In order to open the self-ventilated drain, turn the plug counterclockwise.
13
008 Specifications
Ether Starting Aid
Dual air inlet tube
(1) Air inlet manifold (2) Atomizer for three rear cylinders
Tighten to the following torque. ... 2.8 N·m (25 lb in)
(3) Atomizer for three front cylinders
Tighten to the following torque. ... 2.8 N·m (25 lb in)
Note: The mark on each orifice indicates the direction of spray. The mark on the front orifice must
point to the front of the engine. The mark on the rear orifice must point to the rear of the engine. The
direction is very important in order to avoid spraying ether on the air inlet heater element., (4) Air inlet
heater (5) Air inlet elbow
14
009 Specifications
Fuel Injection Control Linkage
Typical example
Six cylinder engine is shown.
(1) Bracket for the outer bearing
Tighten the nuts to the following torque. ... 12 ± 3 N·m (9 ± 2 lb ft)
(2) Bracket for the inner bearing
Tighten the nuts to the following torque. ... 12 ± 3 N·m (9 ± 2 lb ft)
(3) Control lever
View A-A
(4) Bearing assembly
Tighten the screws to the following torque. ... 3.5 ± 0.2 N·m (31 ± 2 lb in)
15
010 Specifications
Unit Injector
Typical example
(1) Bolt
Tighten the bolt to the following torque. ... 12 ± 3 N·m (9 ± 2 lb ft)
View A-A
(2) Seal
Note: Lubricate the bore slightly. Use the lubricant that is being sealed.
16
011 Specifications
Unit Injector Mechanism

(1) Injector rocker arm assembly (2) Rocker arm bearing
Bore in rocker arm bearing ... 24.802 ± 0.020 mm (0.9765 ± 0.0008 inch)
(3) Rocker arm shaft
Diameter of new rocker arm shaft ... 24.755 ± 0.010 mm (0.9746 ± 0.0004 inch)
Note: The oil holes in the rocker arm bearing must be aligned with the oil holes in the rocker arm., (4)
Locknut
Tighten the locknut to the following torque. ... 33 ± 7 N·m (24 ± 5 lb ft)
(5) Fuel timing dimension
Note: Use the following references to obtain the correct fuel timing dimension.
¡ Engine Information Plate
¡ TMI (Technical Marketing Information)
¡ Fuel Setting and Related Information Fiche
(6) Support for rocker arm assembly
Height of the support ... 70.6 mm (2.78 inch)
(7) Push rod for injector
The length of the push rod for the injector ... 221 mm (8.7 inch)
Note: The length of the push rod (7) for the injector is a total length. This length is measured from the
top of the concave end to the bottom of the ball end. The dimension was measured with a scale. The
dimension is only a reference dimension., (8) Lifter arm
Bore in the lifter arm ... 15.670 ± 0.013 mm (0.6169 ± 0.0005 inch)
(9) Shaft for lifter arm
Diameter of new shaft for lifter arm ... 15.620 ± 0.018 mm (0.6150 ± 0.0007 inch)
17
3126 Engines
3126 Engines
Note: Refer to System Operation, Testing and Adjusting for the sequence of the installation and
adjustment of the injector mechanism., (1) Injector rocker arm assembly (2) Rocker arm bearing
Bore in rocker arm bearing ... 24.802 ± 0.020 mm (0.9765 ± 0.0008 inch)
Diameter of new rocker arm shaft ... 24.755 ± 0.010 mm (0.9746 ± 0.0004 inch)
Note: The oil holes in the rocker arm bearing must be aligned with the oil holes in the rocker arm., (4)
Locknut
(5) Fuel timing dimension
Note: Use the following references to obtain the correct fuel timing dimension.
¡ Engine Information Plate
¡ TMI (Technical Marketing Information)
¡ Fuel Setting and Related Information Fiche
(6) Support for rocker arm assembly
Height of the support ... 77.2 mm (3.04 inch)
(7) Push rod for injector
The length of the push rod for the injector ... 225 mm (8.9 inch)
Note: The length of the push rod (7) for the injector is a total length. This length is measured from the
top of the concave end to the bottom of the ball end. The dimension was measured with a scale. The
Bore in the lifter arm ... 15.670 ± 0.013 mm (0.6169 ± 0.0005 inch)
Diameter of new shaft for lifter arm ... 15.620 ± 0.018 mm (0.6150 ± 0.0007 inch)
18
012 Specifications
Valve Rocker Arms and Lifters

Note: The rocker arms are different on the Type 1 Engines and the Type 2 Engines. Type 1 Engines
have an anvil for the seat of the rocker arm. Type 2 Engines have a floating button for the seat of the
rocker arm., (1) Rocker arm
Seat ... Anvil
Bore in rocker arm for shaft ... 24.808 ± 0.200 mm (0.9767 ± 0.0079 inch)
Diameter of new shaft ... 24.755 ± 0.010 mm (0.9746 ± 0.0004 inch)
(3) Locknut
(4) Valve lash
Inlet valve ... 0.38 mm (0.015 inch)
Exhaust valve ... 0.64 mm (0.025 inch)
(5) Rocker arm support
Height of the rocker arm support ... 70.60 mm (2.779 inch)
(6) Push rod for valve
Length of the push rod for the valve ... 231 mm (9.1 inch)
Note: The length of the push rod (6) for the valve is a total length. This length is measured from the top
of the concave end to the bottom of the ball end. The dimension was measured with a scale. The
Bore in lifter arm ... 15.670 ± 0.012 mm (0.6169 ± 0.0005 inch)
Diameter of a new shaft for the lifter arm ... 15.620 ± 0.018 mm (0.6150 ± 0.0007 inch)
(9) Bolts for shaft of lifter arm
Tighten the bolts for the shaft of the lifter arm to the following torque. ... 13 ± 3 N·m (9 ± 2 lb ft)
19
View A-A
Typical example
(10) Position of the holes in the lifter shaft (11) Apply 9S-3263 Thread Lock Compound .
Tighten the bolts that are shown above in a numerical sequence to the following torque. ... 13 ± 3
N·m (10 ± 2 lb ft)
Note: The rocker arms are different on the Type 1 Engines and the Type 2 Engines. Type 1 Engines
have an anvil for the seat of the rocker arm. Type 2 Engines have a floating button for the seat of the
rocker arm., (1) Rocker arm
Seat ... Floating button
(3) Locknut
(4) Valve lash
Length of the push rod for the valve ... 228 mm (9 inch)
20
View A-A
Typical example
N·m (10 ± 2 lb ft)
(1) Rocker arm
Seat ... Floating button
(3) Locknut
(4) Valve lash
Length of the push rod for the valve ... 235 mm (9.25 inch)
21
View A-A
Typical example
N·m (10 ± 2 lb ft)
22
013 Specifications
Valve Mechanism Cover
3114 Valve cover
Typical example
3116 and 3126 Valve cover
Typical example
Note: Apply 154-8874 Adhesive Kit in order to bond the gasket to the valve cover.
Tighten the bolts in a numerical sequence. Tighten the bolts to the following torque. ... 12 ± 3 N·m (9 ±
2 lb ft)
23
014 Specifications
Cylinder Head Valves
Type 1 and Type 4, (A) Standard valve spring (B) Standard valve spring
Type 2 and Type 3, (A) Longer valve spring (B) Standard valve spring
, (A) Inside diameter of valve seat insert (X) Distance from valve head to cylinder head face
Table 1
Differences of the Cylinder Head Valves
Type 1 Type 2 Type 3 Type 4
Inlet Valve Spring Standard Standard Standard Standard
Valve Seat Standard Standard Smaller ID Smaller ID

Maximum 2.05 mm (0.081 2.05 mm (0.081 2.05 mm (0.081 2.05 mm (0.081
(X) inch) inch) inch) inch)
Minimum (X) 1.13 mm (0.045 1.13 mm (0.045 1.13 mm (0.045 1.13 mm (0.045
inch) inch) inch) inch)
24
Exhaust Spring Standard Longer Longer Standard

Valve
Valve Seat Standard Standard Standard Standard
Maximum 2.85 mm (0.112 2.85 mm (0.112 2.85 mm (0.112 2.85 mm (0.112
(X) inch) inch) inch) inch)
Minimum (X) 1.50 mm (0.059 1.50 mm (0.059 1.50 mm (0.059 1.50 mm (0.059
inch) inch) inch) inch)

Note: Type 1 cylinder heads have standard valve springs and valve seat inserts. Type 2 cylinder heads
have longer exhaust valve springs and standard valve seat inserts. Type 3 cylinder heads have longer
exhaust valve springs. The inlet valve seat inserts have smaller inside diameters. Type 4 cylinder heads
have standard valve springs. The inlet valve seat inserts have smaller inside diameters.
Note: The inlet and exhaust valve stems must be coated with engine oil prior to installation in the
cylinder head.
Note: The tips of the inlet and exhaust valves must be coated with 8T-2998 Lubricant . The lubricant
must be applied after assembly of the retainer., (1) Exhaust valve (2) Inlet valve (3) 7C-4273 Spring for
inlet valve and Spring for exhaust valve
Assembled length ... 65.9 mm (2.60 inch)
Load at assembled length ... 217 ± 22 N (49 ± 5 lb)
Minimum operating length ... 51.0 mm (2.01 inch)
Load at minimum operating length ... 858 ± 43 N (193 ± 10 lb)
(4) Seal (5) Height to the top of the valve guides ... 23.00 ± 0.50 mm (0.906 ± 0.020 inch)
Diameter of valve guide ... 12.065 mm (0.4750 inch)
Note: Install the valve guide from the spring side of the cylinder head. The 12.065 mm (0.4750 inch)
diameter on the valve guide should be protruding from the spring side of the cylinder head.
Note: Assemble the valve guide. Seat the seal against the top of the valve guide., (6) Valve stem
diameter ( new) ... 8.000 ± 0.008 mm (0.3150 ± 0.0003 inch)
The cylinder head valves can be reused if the minimum dimensions for the valve stems are met.
Minimum diameter of a valve stem ( worn) ... 7.965 mm (0.3136 inch)
After installation into the cylinder head, the valve guide bore is the following value.
25
Diameter of the valve guide bore ( new) ... 8.054 ± 0.026 mm (0.3171 ± 0.0010 inch)
The valve guide can be reused. The valve guide bore must not be larger than the following value.
Maximum diameter of a valve guide bore ( worn) ... 8.130 mm (0.3201 inch), (7) Diameter of the valve
head
Inlet valve ... 47.00 ± 0.13 mm (1.850 ± 0.005 inch)
Exhaust valve ... 40.00 ± 0.13 mm (1.575 ± 0.005 inch)
(8) Angle of the valve faces
Inlet valve ... 29.75 ± 0.25 degrees
Exhaust valve ... 45.00 ± 0.25 degrees
(9) Outside diameter of the valve seat inserts
Diameter of the bore in cylinder head for the valve seat insert
Bore diameter
(10) Inside diameter of valve seat inserts
26
cylinder head.
must be applied after assembly of the retainer., (1) Exhaust valve (2) Inlet valve (3) 6I-2307 Spring for
exhaust valve
(4) 7C-4273 Spring for inlet valve
head
27
Bore diameter
Note: The valve seat insert must be shrunk by reduced temperature before installing in the head., (12)
Angle of the valve seat inserts
(13) Depth of the bore in the head for the valve seat insert ... 10.00 ± 0.13 mm (0.394 ± 0.005 inch)
(14) Outside diameter of the seating face of the valve seat insert
Note: Do not reuse the valve seat inserts if the outside diameter of the valve seat insert is larger than
the specified value. , (15) The valve lips can be reused if the minimum dimensions for the valve lips are
met.
(16) Distance from the head of the valve to the cylinder head face. The valve must be closed.
Inlet valve
Maximum permissible distance ... 2.05 mm (0.081 inch)
Minimum permissible distance ... 1.13 mm (0.045 inch)
Exhaust valve

28
cylinder head.
must be applied after assembly of the retainer., (1) Exhaust valve (2) Inlet valve (3) 6I-2307 Spring for
exhaust valve
(4) 7C-4273 Spring for inlet valve
head
29
Bore diameter
(13) Depth of the bore in the head for the valve seat insert ... 10.00 ± 0.13 mm (0.394 ± 0.005 inch)
(14) Outside diameter of the seating face of the valve seat insert
met.
Inlet valve
Exhaust valve

30
cylinder head.
must be applied after assembly of the retainer., (1) Exhaust valve (2) Inlet valve (3) 7C-4273 Spring for
inlet valve and Spring for exhaust valve
head
31
Bore diameter
(12) Depth of the bore in the head for the valve seat insert ... 10.00 ± 0.13 mm (0.394 ± .005 inch) (13)
Outside diameter of the seating face of the valve seat insert
met.
Inlet valve
Exhaust valve
32
015 Specifications
Cylinder Head
3114 Engines
3116 and 3126 Engines
(1) Large bolts (2) Small bolts
Use the following procedure to install bolts (1) and (2) :
1. Apply engine oil to the threads of the bolts.
2. Tighten large bolts (1) in a numerical sequence.
Tighten the bolts to the following torque. ... 300 ± 15 N·m (221 ± 11 lb ft)
3. Loosen large bolts (1) in a numerical sequence.
4. Tighten large bolts (1) in a numerical sequence.
5. Tighten the large bolts (1) again in a numerical sequence.
6. Turn large bolts (1) in a numerical sequence an additional 90 degrees (1/4 of a turn).
7. Tighten the small bolts (2) in a numerical sequence.
33
Detail A
Typical example
(3) The installation depth of the cup plug is measured from the face of the cylinder head to the top edge
of the plug. Depth of installation ... 1.25 ± 0.25 mm (0.049 ± 0.010 inch) (4) Apply 9S-3263 Thread
Lock Compound to the first three threads of the plugs. Tighten the plugs to the following torque. ... 184
± 18 N·m (136 ± 13 lb ft)
Typical example
Cross section view of the cylinder head
(5) Cylinder head thickness
The thickness of the cylinder head ... 103.00 ± 0.20 mm (4.055 ± 0.008 inch)
The minimum cylinder head thickness that is allowed ... 102.55 mm (4.037 inch)
(6) Unit injector sleeve
Apply 9S-3263 Thread Lock Compound to the cylinder head at location (X) and location (Y).
Note: Thread lock compound is not permitted at location (Z).
34
016 Specifications
Turbocharger
Typical example
(1) Air inlet (2) Bolt
Tighten the bolt for the compressor housing clamp plate to the following torque. ... 7.3 ± 0.5 N·m
(65 ± 4 lb in)
(3) Exhaust outlet (4) Vee clamp
Use the following procedure to install the vee clamp to hold the cartridge to the compressor housing:
1. Tighten the clamp bolts.
Tighten the clamp bolts to the following torque. ... 6.2 ± 0.5 N·m (55 ± 4 lb in)
2. Gently tap the clamps with a soft faced hammer.
3. Again tighten the clamp bolts.
Tighten the clamp bolts to the following torque. ... 6.2 ± 0.5 N·m (55 ± 4 lb in)
(5) Exhaust inlet (6) Nut
Apply 5P-3931 Anti-Seize Compound to the stud.
Tighten the nut to the following torque. ... 54 ± 5 N·m (40 ± 4 lb ft)
Turbine Housing And Compressor Housing Bolted To

Turbocharger
Typical example
(65 ± 4 lb in)
(3) Bolt
Tighten the bolt for the turbine housing clamp plate to the following torque. ... 15.8 ± 0.5 N·m
35
(140 ± 4 lb in)
(4) Nut
Tighten the nut to the following torque. ... 54 ± 5 N·m (40 ± 4 lb ft), (5) Exhaust inlet
Turbine Housing And Compressor Housing Clamped To

Turbocharger
Typical example
(1) Air inlet (2) Clamp
Use the following procedure to install the clamps to hold the compressor housing and the turbine
housing to the cartridge:
1. Tighten the clamp bolts.
Tighten the clamp bolts to the following torque. ... 14 ± 1 N·m (10 ± 1 lb ft)
2. Gently tap the clamps with a soft faced hammer.
3. Again tighten the clamp bolts.
Tighten the clamp bolts to the following torque. ... 14 ± 1 N·m (10 ± 1 lb ft)
(3) Exhaust outlet (4) Exhaust inlet (5) Nut

(65 ± 4 lb in)
(3) Bolt
Tighten the bolt for the turbine housing clamp plate to the following torque. ... 15.8 ± 0.5 N·m
(140 ± 4 lb in)
(4) Nut
Tighten the nut to the following torque. ... 54 ± 5 N·m (40 ± 4 lb ft), (5) Exhaust inlet
36
017 Specifications
Aftercooler
Typical example
(1) Core assembly
The core assembly must withstand the following water pressure. ... 240 kPa (35 psi)
(2) Hose
The hose is the following length. ... 55 ± 5 mm (2.2 ± 0.2 inch)
(3) Water regulator housing (4) Bolt
Put 4C-9505 Gasket Sealant on the threads of bolts (Y) .
Tighten all bolts to the following torque. ... 28 ± 7 N·m (21 ± 5 lb ft), (5) Water pump
Note: Put clean engine oil or glycerin on all O-ring seals and on the seal bores at the time of assembly.
37
018 Specifications
Exhaust Manifold
Typical example of a three-piece exhaust manifold
Six cylinder exhaust manifold is shown.
Use the following procedure to assemble the three-piece exhaust manifold to the cylinder block.
NOTICE
Remove excess sealant from the exhaust manifold after assembly.
Excess sealant left inside the exhaust manifold may damage the
turbocharger.
1. Coat the inside diameter of the female ends of the manifold with engine oil.
2. Apply a thin coat of 2P-2333 High Temperature Sealer to the outside diameter of the male ends. Do
not apply sealer at the tip of the male ends. Remove excess sealer from the assembled joints.
3. Apply 5P-3931 Anti-Seize Compound to the threads of bolt (1) through bolt (12) .
4. Tighten bolt (1) through bolt (12) in a numerical sequence.
Tighten the bolts to the following torque. ... 4 ± 1 N·m (35 ± 9 lb in)
6. Bend tabs (13) over the flats of the twelve bolt heads. This will lock the bolts in position.
7. Tighten studs (14) to a torque of 35 ± 5 N·m (26 ± 4 lb ft).
Typical example of a one-piece exhaust manifold
To assemble the one-piece exhaust manifold to the cylinder block, use step 3 through step 7 of the
preceding procedure.
38
Typical example of a one-piece exhaust manifold
Four cylinder exhaust manifold is shown.
Use the following procedure to assemble the one-piece exhaust manifold to the cylinder block.
4. Bend tabs (9) over the flats of the eight bolt heads. This will lock the bolts in position.
Typical example of a water cooled exhaust manifold
Use the following procedure to assemble the one-piece exhaust manifold to the cylinder block.
39
019 Specifications
Exhaust Elbow
Typical example
(1) Tighten the nut for the clamp to the following torque. ... 12 ± 4 N·m (9 ± 3 lb ft)
40
020 Specifications
Camshaft
Typical example
Type 1 Camshaft
Note: A Type 1 Camshaft has a thrust washer (2) that is 0.05 mm (0.002 inch) thinner than the thrust
washer on the Type 2 Camshaft. (1) Gear
Heat the gear for installation. Do not use a torch. Heat the gear to a maximum temperature. ...
316 °C (600 °F)
(2) Clearance for thrust washer
The distance from the shoulder of the camshaft to the face of the gear ... 4.83 ± 0.05 mm (0.190 ±
0.002 inch)
Thickness of new thrust washer ... 4.65 ± 0.03 mm (0.183 ± 0.001 inch)
End play of a new camshaft ... 0.18 ± 0.08 mm (0.007 ± 0.003 inch)
Maximum permissible end play of a worn camshaft ... 0.64 mm (0.025 inch)
(3) Camshaft journal
Diameter of the camshaft journal ... 65.126 ± 0.013 mm (2.5640 ± 0.0005 inch)
(4) Inlet lobe (5) Injector lobe (6) Exhaust lobe
Type 2 Camshaft
Note: A Type 1 Camshaft has a thrust washer (2) that is 0.05 mm (0.002 inch) thinner than the thrust
washer on the Type 2 Camshaft. (1) Gear
Heat the gear for installation. Do not use a torch. Heat the gear to a maximum temperature. ...
316 °C (600 °F)
(2) Clearance for thrust washer
The distance from the shoulder of the camshaft to the face of the gear ... 4.83 ± 0.05 mm (0.190 ±
0.002 inch)
Thickness of new thrust washer ... 4.70 mm (0.185 inch)
End play of a new camshaft ... 0.13 ± 0.05 mm (0.005 ± 0.002 inch)
Maximum permissible end play of a worn camshaft ... 0.64 mm (0.025 inch)
(3) Camshaft journal
Diameter of the camshaft journal ... 65.126 ± 0.013 mm (2.5640 ± 0.0005 inch)
(4) Inlet lobe (5) Injector lobe (6) Exhaust lobe
41
(7) Specific camshaft lobe lift

7C-4014 Camshaft
7C-4016 Camshaft
Note: Identification is on the end of the camshaft.
Exhaust lobe ... 9.283 ± 0.100 mm (0.3655 ± 0.0039 inch)
Inlet lobe ... 9.283 ± 0.100 mm (0.3655 ± 0.0039 inch)
Injector lobe ... 9.733 ± 0.100 mm (0.3832 ± 0.0039 inch)
6I-4098 Camshaft
101-4538 Camshaft
105-1560 Camshaft
1W-8635 Camshaft
113-6099 Camshaft
100-6300 Camshaft
107-7603 Camshaft
105-1544 Camshaft
115-4131 Camshaft
133-4984 Camshaft
136-0593 Camshaft
To find the lobe lift, use the procedure that follows:
1. Measure the camshaft lobe height (8) .
2. Measure the base circle (9) .
3. Subtract the diameter of the base circle that is found in Step 2 from the lobe height that is found in
Step 1. The difference is the actual camshaft lobe lift (7) .
Note: Use the appropriate Guidelines for Reusable Parts publication in order to determine if the wear
of the camshaft is excessive.
42
021 Specifications
Engine Oil Filter Base

Engine Mounted Base
Typical example
(1) The 9L-9188 Spring is located in the filter bypass valve:
Load at assembled length ... 15.6 ± 1.3 N (3.50 ± 0.30 lb)
(2) The oil filter bypass valve must open at the following pressure. ... 125 ± 30 kPa (18 ± 4.5 psi) (3)
Put 9S-3263 Thread Lock Compound on the last 7.5 ± 1.5 mm (0.30 ± 0.06 inch) of the threads at the
base end of the stud.
Tighten the stud to the following torque. ... 68 ± 7 N·m (50 ± 5 lb ft), (4) Put clean engine oil on the
filter seal. Tighten the filter until the seal contacts the base. After the seal contacts the base, rotate the
filter by 270 degrees.
Remote Mounted Base
Typical example
43
View A-A
(1) Tighten the nut to the following torque. ... 150 ± 20 N·m (111 ± 15 lb ft) (2) Filtered oil (3)
Unfiltered oil
44
022 Specifications
Engine Oil Pump
Section view through pump gears
Typical example
The section view is of the bypass valve that is located in the pump assembly.
(A) Distance between the front face of the gear and the housing ... 43.00 ± 0.25 mm (1.693 ± 0.010
inch) (B) Length of the gears ... 33.00 ± 0.03 mm (1.299 ± 0.001 inch)
Depth of the bores for the gears ... 33.13 ± 0.02 mm (1.304 ± 0.001 inch), (C) Diameter of the gear
shafts ... 15.600 ± 0.005 mm (0.6142 ± 0.0002 inch)
Bores in the pump bodies for the gear shafts ... 15.641 ± 0.008 mm (0.6158 ± 0.0003 inch), (4) 105-
1805 Spring for relief valve
Load at assembled length ... 51.99 ± 1.9 N (12 ± 0.4 lb)
(5) Relief valve plunger
Diameter of the plunger ... 17.000 ± 0.013 mm (0.6693 ± 0.0005 inch)
Bore in the pump body for the plunger ... 17.100 ± 0.025 mm (0.6732 ± 0.0010 inch)
45
023 Specifications
Engine Oil Pressure
Follow all of the steps in this procedure to obtain a usable oil pressure reading.
1. Be sure that the engine is filled to the correct level with SAE 10W-30 oil. The engine oil pressure graph will
not be accurate if incorrect viscosity oil is used.
2. Remove the oil pressure switch. Connect the 1U-5470 Engine Pressure Group to the main oil manifold. Use
the connection at the oil pressure switch location (1) .
3. Run the engine. Allow the engine oil temperature to rise to 99°C (210°F).
Note: A 3°C (5°F) increase in engine oil temperature gives a 7 kPa (1 psi) decrease in engine oil pressure.
Note: Make sure that the engine oil does not rise above a temperature of 115°C (239°F).
4. Keep the engine oil temperature consistent with the engine at the engine's rated rpm and read the pressure
gauge.
5. Use the engine rpm and the oil pressure to locate an intersection on the engine oil pressure graph.
6. The results should fall within the acceptable area of the graph. If the results are not acceptable, find the cause
of the problem and correct the problem. Engine failure or a reduction in engine life can be the result of
continued operation with oil pressure that is outside of the acceptable range.
Note: Keep a record of engine oil pressure at regular intervals. The records can indicate possible engine
problems or damage. A sudden increase or a sudden decrease of 70 kPa (10 psi) in oil pressure should be
inspected, even within the acceptable range of the engine oil pressure graph.
46
024 Specifications
Water Temperature Regulator
Typical example
Note: All water temperature regulators do not have air vent valves (1).
119-3075 Water Temperature Regulator
Fully open temperature of the water temperature regulator ... 94 °C (201 °F)
Begin to open temperature of the water temperature regulator. ... 78 ° to 83 °C (172 ° to 181 °F), (1)
Air vent valve (2) Closed dimension of the water temperature regulator ... 30.5 ± 0.5 mm (1.20 ± 0.02
inch) (3) Minimum stroke of the water temperature regulator at fully open temperature ... 8.75 mm
(0.345 inch)
inch) (3) Minimum stroke of the water temperature regulator at fully open temperature ... 8.0 mm (0.32
inch)
inch)
7E-5254 Water Temperature Regulator
inch)
Fully open temperature of the water temperature regulator ... 93.9 °C (201.0 °F)
Begin to open temperature of the water temperature regulator. ... 81.1 ° to 83.9 °C (178 ° to 183 °F), (1)
Air vent valve (2) Closed dimension of the water temperature regulator ... 31.24 ± 0.76 mm (1.230 ±
0.030 inch) (3) Minimum stroke of the water temperature regulator at fully open temperature ... 8.0 mm
(0.32 inch)
7C-2190 Water Temperature Regulator
47
inch) (3) Minimum stroke of the water temperature regulator at fully open temperature ... 8.13 mm
(0.320 inch)
7E-1420 Water Temperature Regulator
9Y-3088 Water Temperature Regulator
9Y-3365 Water Temperature Regulator
Fully open temperature of the water temperature regulator ... 94.4 °C (202 °F)
0.030 inch) (3) Minimum stroke of the water temperature regulator at fully open temperature ... 8.1 mm
(0.32 inch)
1W-8801 Water Temperature Regulator
inch)
0.010 inch) (3) Minimum stroke of the water temperature regulator at fully open temperature ... 8.13
mm (0.320 inch)
Typical example

6I-4954 Water Temperature Regulator
Begin to open temperature of the water temperature regulator. ... 75 ° to 78 °C (167 ° ± 172 °F), (1)
Minimum stroke of the water temperature regulator at fully open temperature ... 10.4 mm (0.41 inch)
Minimum stroke of the water temperature regulator at fully open temperature ... 10.4 mm (0.41 inch)
48
025 Specifications
Water Pump
Typical example
The impeller cover is not shown.
(1) Clearance between the impeller and the housing ... 0.75 ± 0.25 mm (0.030 ± 0.010 inch) (2) Seal (3)
Height of seal ... 12.83 ± 0.13 mm (0.505 ± 0.005 inch) (4) The filter should not extend beyond the
surface of the housing. (5) Dimension from the front face of the pulley to the face of the housing ...
103.8 ± 0.3 mm (4.09 ± 0.01 inch)
Note: In some applications, a flange is pressed on the shaft of the water pump. The pulley bolts to this
flange.
The distance from the front face of the flange to the housing face is the following dimension. ... 92.4 ±
0.3 mm (3.64 ± 0.01 inch)
49
026 Specifications
Cylinder Block Cover Group
Typical example
Left side view of engine
View A-A
(1) Cylinder block (2) Gasket
Gasket (2) has a bead on one surface. Install the gasket so that the bead is facing side cover (8) ., (3) Length of
two bolts ... 40.0 mm (1.58 inch) (4) Length of the 11 bolts marked location (Y). ... 20.0 mm (0.79 inch)
Length of the ten remaining bolts for the three side covers ... 30.0 mm (1.18 inch), (5) Cover
Clean the face of the cover with solvent. Apply 1U-8846 Liquid Gasket to the cover. Spread uniformly on the
face of the cover and around the bolt holes. The cover must be installed and tightened within ten minutes., (6)
Sleeve (7) extends from the face of cylinder block (1). Distance ... 5.0 ± 0.5 mm (0.20 ± 0.02 inch) (7) Six
sleeves marked location (X). (8) Side cover
Typical example of side cover
Tighten bolts (1 through 8) in a numerical sequence.

50
027 Specifications
Cylinder Block
Six cylinder engine is shown.
(1) The installation depth of the cup plug is measured from the block face to the top edge of the plug.
Distance ... 1.25 ± 0.25 mm (0.049 ± 0.010 inch) (2) The dowels extend past the top face of the
cylinder block. Distance ... 14 ± 2 mm (0.55 ± 0.08 inch) (3) The two large dowels extend past the rear
face of the cylinder block. Distance ... 12.0 ± 0.5 mm (0.47 ± 0.02 inch) (4) The dowels extend past the
front face of the cylinder block. Distance ... 8.0 ± 0.5 mm (0.31 ± 0.02 inch)
View A-A
(5) Bore diameters in the cylinder block for all camshaft bearings except the front bearing
3114 Engines ... 70.38 ± 0.13 mm (2.771 ± 0.005 inch)
3116 Engines ... 69.000 ± 0.038 mm (2.7165 ± 0.0015 inch)
3126 Engines ... 69.000 ± 0.038 mm (2.7165 ± 0.0015 inch)
(6) Locate the bearing oil hole for all camshaft bearings at the top of the bore. The front camshaft
bearing oil hole is not located at the top of the bore.
51
(7) Diameter of cylinder bore
3114 Engines ... 105.025 ± 0.025 mm (4.135 ± 0.0010 inch)
3116 Engines ... 105.025 ± 0.025 mm (4.135 ± 0.0010 inch)
3126 Engines ... 110.025 ± 0.025 mm (4.3317 ± 0.0010 inch)
(8) Distance from the centerline of the crankshaft bore to the top surface of the cylinder block ... 322.00
mm (12.677 inch) (9) Front camshaft bearing joint location (10) Bore diameter in the cylinder block for
the front camshaft bearing ... 70.000 ± 0.025 mm (2.7559 ± 0.0010 inch) (11) Front camshaft bearing
oil hole
Note: The front camshaft bearing is installed with the bearing oil hole (11) in alignment with the oil
hole in the cylinder block and the bearing joint (9) in the position that is shown., (12) Tighten the bolt
to the following torque. ... 70 ± 10 N·m (50 ± 7 lb ft) (13) Bearing cap
Width of the main bearing cap ... 159.995 ± 0.020 mm (6.2990 ± 0.0008 inch)
Width of the cylinder block for the main bearing ... 160.000 ± 0.018 mm (6.2992 ± 0.0007 inch)
(14) Distance from the centerline of the crankshaft bore to the pan rail ... 110.00 mm (4.331 inch) (15)
Location of the sequence number for the bearing cap (16) Main bearing cap bolts
Install the bearing caps with the sequence number to the right. A six cylinder engine has an order of 1
through 7 (front to rear). A four cylinder engine has an order of 1 through 5 (front to rear).
1. Apply 4C-5593 Anti-Seize Compound to the bolt threads (16) and face of the washers.
2. Tighten bolts (16) on each bearing cap.
Tighten to the following torque. ... 54 ± 7 N·m (40 ± 5 lb ft)
3. Tighten bolts (16) on each bearing cap again.
Tighten the bolts by another one quarter of a turn. ... 90 ± 5 degrees
(17) Bore in the cylinder block for the seven main bearings ... 95.000 ± 0.013 mm (3.7402 ± 0.0005
inch)
Six cylinder engine with oil grooves is shown.
52
(18) Oil grooves are machined in the saddles of the cylinder blocks of all 3114 engines and earlier 3116
engines.
Six cylinder engine with no oil grooves is shown.
(19) No oil grooves are machined in the saddles of the cylinder block on later 3116 and all 3126
engines.
Table 1
Chart for Replacement of Main Bearings
3116 Early Model
Cylinder Blocks with Grooved Main Bearing Saddles
Standard Size Oversize or Undersize
Quantity Part Number Bearing
Description Part Number Size
107-7602 - Standard
- 7C-6969 0.50 mm (0.020
inch)
Oversize
- 7C-6970 0.50 mm (0.020
inch)
Undersize
Crankshaft
Thrust Bearing 1 0.50 mm (0.020
inch)
Oversize
- 7C-6966 0.25 mm (0.010
inch)
Undersize
- 7C-6967 0.50 mm (0.020
inch)
Undersize
107-7708 - Standard
- 145-0168 0.50 mm (0.020
inch)
Oversize
- 145-0170 0.50 mm (0.020
inch)
Undersize
Main
3
Bearing 0.50 mm (0.020
inch)
Oversize
- 145-0162 0.25 mm (0.010
inch)
Undersize
- 145-0164
0.50 mm (0.020
53
inch)
Undersize
101-1530 - Standard
- 145-0169 0.50 mm (0.020
inch)
Oversize
- 145-0171 0.50 mm (0.020
inch)
Undersize
Main
3 0.50 mm (0.020
Bearing
inch)
Oversize
- 145-0163 0.25 mm (0.010
inch)
Undersize
- 145-0165 0.50 mm (0.020
inch)
Undersize
Note: A list of part numbers for earlier 3116 cylinder blocks that have oil grooves that are machined in
the saddles is listed below:
¡ 7C-3346
¡ 101-3242
¡ 101-4496
¡ 129-1094
Note: The part number for the cylinder block is located on the right side of the cylinder block. The
exhaust manifold is mounted on the right side.
Note: The bearings for replacement in the table are for earlier 3116 engines. The bearings for
replacement on 3114 and 3126 engines will be found in the appropriate Parts Manual.
54
Table 2
Chart for Replacement of Main Bearings
3116 Late Model
Cylinder Blocks Without Grooved Main Bearing Saddles
Standard Size
Oversize bearings or Undersize
bearings
Quantity Part Number
Part Number
Description Size
107-7602 - Standard
- 7C-6969 0.50 mm (0.020
inch)
Oversize
- 7C-6970 0.50 mm (0.020
inch)
Undersize
Crankshaft
Thrust Bearing 1 0.50 mm (0.020
inch)
Oversize
- 7C-6966 0.25 mm (0.010
inch)
Undersize
- 7C-6967 0.50 mm (0.020
inch)
Undersize
107-7708 - Standard
- 145-0168 0.50 mm (0.020
inch)
Oversize
- 145-0170 0.50 mm (0.020
inch)
Undersize
Main Bearing 6 0.50 mm (0.020

inch)
Oversize
- 145-0162 0.25 mm (0.010
inch)
Undersize
- 145-0164 0.50 mm (0.020
inch)
Undersize
Note: The bearings for replacement in the table are for later 3116 engines. The bearings for
replacement on 3114 and 3126 engines will be found in the appropriate Parts Manual.
Note: Some 3116 cylinder blocks do not have oil grooves in the bearing saddle. The part number of the
cylinder blocks that do not have oil grooves in the bearing saddle are 149-5403 Block Gp .
Note: The part number for the cylinder block is located on the right side of the cylinder block. The
exhaust manifold is mounted on the right side of the cylinder block.
Note: Incorrect bearings cannot be accidentally interchanged between earlier 3116 cylinder blocks and
later 3116 cylinder blocks. The bearing tabs and the tab slots on the cylinder block will not be in
alignment if the incorrect bearings are used.
Note: Additional information on reconditioning procedures can be ordered. Refer to the following
documents:
Guideline For Reusable Parts And Salvage Operations, SEBF8192, "Specifications and Salvage for
55
Cylinder Blocks on 3114, 3116, 3126 and 3126B Engines"
Special Instruction, SEHS9047, "Installation of 7C-6208 Cylinder Sleeve "
Guideline For Reusable Parts And Salvage Operations, SEBF8261, "Installing a 7C-6208 Cylinder
Sleeve in 3114 and 3116 Engines and a 107-7604 Cylinder Sleeve in 3126 Engines"
56
028 Specifications
Crankshaft
(1) For installation of the gear, heat gear to the following temperature. ... 316°C (600°F)
Note: Do not use a torch., (2) Crankshaft end play
3114 Engine ... 0.07 to 0.29 mm (0.0028 to 0.0114 inch)
3116 and 3126 Engines ... 0.07 to 0.32 mm (0.0028 to 0.0126 inch)
57
029 Specifications
Crankshaft Seals
Illustration 1 g00594167 Illustration 2 g00291470

Rear crankshaft seals
The single lip seal is used for dry applications (A) .
The double lip seal is used for wet applications (B) .
(1) Carrier housing and flywheel housing (2) Rear seal

The rear seal (2) is located distance (X) from rear face (4) of the cylinder block on engines for
industrial applications, on engines for marine applications, and on engines for generator sets.
Distance (X) is the following distance. ... 15.4 ± 0.5 mm (0.61 ± 0.02 inch)
The rear seal (2) is located distance (X) from rear face (4) of the cylinder block on engines for
Caterpillar machines. Distance (X) is the following distance. ... 16.0 ± 0.5 mm (0.63 ± 0.02 inch)
Note: The original rear seal runs directly on the crankshaft flange. The original seal assembly does not
contain a wear sleeve. Replacement seal assemblies contain a wear sleeve (7).
Front crankshaft seal
(3) Front seal
The front seal (3) is located distance (Y) from front face (5) of the front housing on marine
engines, industrial engines, generator set engines, and engines for Caterpillar machines. Distance
(Y) is the following distance. ... 2.5 ± 0.5 mm (0.10 ± 0.02 inch)
(4) Rear face of block (5) Front housing (6) Pulley (7) Wear sleeves
Do not remove the wear sleeves from the seal group., (8) Shipping sleeve for the front seal
Install the front seal (3) in the housing. Remove the shipping sleeve (8). Install the pulley (6).
58
030 Specifications
Vibration Damper and Pulley
Typical example
Rubber vibration damper
(1) Pulley (2) Damper assembly
Note: The dash marks on the front of the damper assembly must be in alignment with each other. A
new damper assembly will be needed if the dash marks are not in alignment.
Maximum permissible face runout of the damper assembly ... 0.00 to 2.03 mm (0.000 to 0.080 inch)
59
031 Specifications
Connecting Rod Bearing Journal

Table 1
Diameter Of Crankshaft Journal (Bearing Surface) For Connecting Rod Bearings
Original Size Journal 70.000 ± 0.020 mm (2.7559 ± 0.0008 inch)
Undersize Journal
69.750 ± 0.020 mm (2.7461 ± 0.0008 inch)
0.25 mm (0.010 inch)
Undersize Journal
69.500 ± 0.020 mm (2.7362 ± 0.0008 inch)
0.50 mm (0.020 inch)
Clearance between bearing and new journal ... 0.053 to 0.155 mm (0.0021 to 0.0061 inch)
60
032 Specifications
Main Bearing Journal

Table 1
Diameter Of Crankshaft Journal (Bearing Surface) For Main Bearings
Original Size Journal 90.000 ± 0.020 mm (3.5433 ± 0.0008 inch)
Undersize Journal
89.750 ± 0.020 mm (3.5335 ± 0.0008 inch)
0.25 mm (0.010 inch)
Undersize Journal
89.500 ± 0.020 mm (3.5236 ± 0.0008 inch)
0.50 mm (0.020 inch)
Clearance between bearing and new journal ... 0.071 to 0.173 mm (0.0028 to 0.0068 inch)
61
033 Specifications
Piston and Rings

One-Piece Piston
Note: The word "FRONT" is stamped on the crown of one piece pistons (1). Install the piston with the
word "FRONT" toward the front of the engine. The front of the engine is opposite the flywheel end.
The part number on the connecting rod should be facing the rear of the engine. The rear of the engine is
the flywheel end. Lubricate the entire piston prior to assembly into the cylinder block. Use clean engine
oil.
Typical example
Top Ring
(2) Top ring

The top ring is marked with "UP-1".
Install the top ring with the side marked "UP-1" toward the top of the piston. The colored stripe faces to
the right of the ring end gap.
The ends of the piston ring have a clearance when the piston ring is installed in a cylinder with a
specific bore size.
Cylinder bore size ... 105.025 mm (4.1348 inch)Clearance ... 0.615 ± 0.125 mm (0.0242 ± 0.0049 inch)
62
Increase in clearance between ends of piston ring for each 0.03 mm (0.001 inch) increase in cylinder
bore size ... 0.09 mm (0.0035 inch)
3126 Engines
bore size ... 0.031 mm (0.0012 inch)
Intermediate Ring
(3) Intermediate ring

The intermediate ring is marked with "UP-2".
Install the piston ring with the side marked "UP-2" toward the top of the piston. The colored stripe
faces to the right of the ring end gap.
specific bore size.
3126 Engines
bore size ... 0.031 mm (0.0012 inch)
Oil Control Ring
(4) Oil control ring

The oil control piston ring has a spring that is installed with the ring. The gap in the spring should be a
distance of 180 degrees from the ring end gap when the oil control piston ring is assembled. The
colored portion of the spring must be visible at the ring end gap.
Width of oil control ring groove in new piston ... 4.041 ± 0.013 mm (0.1591 ± 0.0005 inch)
Thickness of new oil control ring ... 3.982 ± 0.008 mm (0.1568 ± 0.0003 inch)
Clearance between a new piston ring groove and a new piston ring ... 0.038 to 0.080 mm (0.0015 to
0.0031 inch)
specific bore size.
3126 Engines
bore size ... 0.031 mm (0.0012 inch)After all the piston rings are installed, check and rotate the rings.
The rotation is necessary to separate the end gaps in order to prevent alignment. The separation is the
following amount. ... 120 degrees
63
Piston Pin
(5) Piston pin

Piston pin bore diameter ... 40.020 ± 0.008 mm (1.5756 ± 0.0003 inch)
Piston pin diameter ... 40.000 ± 0.005 mm (1.5748 ± 0.0002 inch)
Thoroughly lubricate the piston pin with clean engine oil prior to assembly.
(1) Crown assembly (2) Connecting rod
Note: Assemble the connecting rod and piston group. Install the connecting rod and piston group in the
cylinder block. The part number on the connecting rod should be facing the rear of the engine. The rear
of the engine is the flywheel end of the engine. Lubricate the entire piston prior to assembly into the
cylinder block. Use clean engine oil.
Top Ring
(3) The top ring has the mark "UP-1".

Install the top ring with the side marked "UP-1" toward the top of the piston. The colored stripe faces to
the right of the ring end gap.
specific bore size.
Cylinder bore size ... 105.025 mm (4.1348 inch) 105-1746 Piston Ring 107-7548 Piston Ring Note:
These rings have a plasma face coating.Clearance ... 0.660 ± 0.190 mm (0.0260 ± 0.0075 inch) 107-
7787 Piston Ring Note: These rings have a chrome finish.Clearance ... 0.615 ± 0.010 mm (0.0242 ±
0.0004 inch)Increase in clearance between ends of piston ring for each 0.03 mm (0.001 inch) increase
in cylinder bore size ... 0.09 mm (0.0035 inch)
3126 Engines
64
Cylinder bore size ... 110.025 mm (4.3317 inch) 119-2990 Piston Ring Note: These rings have a
plasma face coating.Clearance ... 0.558 ± 0.100 mm (0.0220 ± 0.0039 inch) 119-3011 Piston Ring
Note: These rings have a plasma face coating.Clearance ... 0.628 ± 0.100 mm (0.0247 ± 0.0039 inch)
132-5246 Piston Ring Note: These rings have a chrome finish.Clearance ... 0.528 ± 0.100 mm (0.0208
± 0.0039 inch)Increase in clearance between ends of piston ring for each 0.01 mm (0.0004 inch)
increase in cylinder bore size ... 0.031 mm (0.0012 inch)
Intermediate Ring
(4) The intermediate ring has the mark "UP-2".

Install the piston ring with the side marked "UP-2" toward the top of the piston. The colored stripe
faces to the right of the piston ring end gap.
Tapered Intermediate Ring
specific bore size. 3114 and 3116 EnginesCylinder bore size ... 105.025 mm (4.1348 inch)Clearance ...
0.918 ± 0.125 mm (0.0361 ± 0.0049 inch)Increase in clearance between ends of piston ring for each
0.03 mm (0.001 inch) increase in cylinder bore size ... 0.09 mm (0.0035 inch) 3126 EngineCylinder
bore size ... 110.025 mm (4.3317 inch)Clearance ... 0.904 ± 0.125 mm (0.0356 ± 0.0049 inch)Increase
in clearance between ends of piston ring for each 0.01 mm (0.0004 inch) increase in cylinder bore
size ... 0.031 mm (0.0012 inch)
Rectangular Intermediate Ring
specific bore size.Width of intermediate ring groove in new piston ... 3.043 ± 0.013 mm (0.1198 ±
0.0005 inch)Thickness of new intermediate ring ... 2.980 ± 0.010 mm (0.1173 ± 0.0004 inch)Clearance
between a new piston ring groove and a new piston ring ... 0.040 ± 0.086 mm (0.0016 ± 0.0034 inch)
3114 and 3116 EnginesCylinder bore size ... 105.025 mm (4.1348 inch)Clearance ... 0.915 ± 0.125
mm (0.0360 ± 0.0049 inch)Increase in clearance between ends of piston ring for each 0.03 mm (0.001
inch) increase in cylinder bore size ... 0.09 mm (0.0035 inch) 3126 EngineCylinder bore size ...
110.025 mm (4.3317 inch)Clearance ... 0.904 ± 0.125 mm (0.0356 ± 0.0049 inch)Increase in clearance
between ends of piston ring for each 0.01 mm (0.0004 inch) increase in cylinder bore size ... 0.031 mm
(0.0012 inch)
Oil Control Ring
(5) The oil control piston ring has a spring that is installed with the ring. The gap in the spring should
be a distance of 180 degrees from the ring end gap when the oil control piston ring is assembled. The
colored portion of the spring must be visible at the ring end gap.
Width of oil control ring groove in new piston ... 4.041 ± 0.013 mm (0.1591 ± 0.0005 inch)Thickness
of new oil control ring ... 3.982 ± 0.008 mm (0.1568 ± 0.0003 inch)Clearance between a new piston
ring groove and a new piston ring ... 0.038 to 0.080 mm (0.0015 to 0.0031 inch)The ends of the piston
ring have a clearance when the piston ring is installed in a cylinder with a specific bore size.Cylinder
bore size ... 105.025 mm (4.1348 inch)Clearance ... 0.54 ± 0.15 mm (0.021 ± 0.006 inch)Increase in
clearance between ends of piston ring for each 0.03 mm (0.001 inch) increase in cylinder bore size ...
0.09 mm (0.0035 inch)
3126 Engines
Width of oil control ring groove in new piston ... 4.041 ± 0.013 mm (0.1591 ± 0.0005 inch)Thickness
of the new piston ring ... 3.985 ± 0.010 mm (0.1569 ± 0.0004 inch)Clearance between the oil groove
and the oil control piston ring ... 0.033 ± 0.079 mm (0.0013 ± 0.0031 inch)The ends of the oil control
65
piston ring have a clearance when the ring is installed in a cylinder with a specific bore size.Cylinder
bore size ... 110.025 mm (4.3317 inch)Clearance ... 0.53 ± 0.15 mm (0.021 ± 0.006 inch)Increase in
clearance between ends of piston ring for each 0.01 mm (0.0004 inch) increase in cylinder bore size ...
0.031 mm (0.0012 inch)After all the piston rings are installed, check and rotate the rings. The rotation
is necessary to separate the end gaps in order to prevent alignment. The separation is the following
amount. ... 120 degrees (6) Piston skirt
Lubricate the entire piston in zone (A) prior to assembly into the cylinder block. Use clean engine oil.
Piston Pin Bore
(7) Piston pin

Piston pin bore diameter that is in the crown assembly ... 40.031 ± 0.007 mm (1.5760 ± 0.0003
inch)
Piston pin bore diameter that is in the piston skirt ... 40.020 ± 0.008 mm (1.5756 ± 0.0003 inch)
Piston pin diameter ... 40.000 ± 0.005 mm (1.5748 ± 0.0002 inch)
Thoroughly lubricate the piston pin with clean engine oil prior to assembly.
66
034 Specifications
Piston Cooling Jet
Typical example of two jets per cylinder
(1) Piston cooling jet
The piston cooling jets (1) must be checked for the location of the stream of oil. Insert a drill rod with a
diameter of 1.3 mm (0.05 inch) into the orifice. This drill rod simulates the stream of oil under normal
operating pressure. The drill rod must pass through a circle with a diameter of 5.0 mm (0.20 inch) at
location (A). Place the drill rod in the second orifice. The drill rod must pass through a circle with a
diameter of 13.0 mm (0.51 inch) at location (B). The circles are located at depth (G). The location of
the circles is a distance of 50.0 mm (1.97 inch) below the top of the cylinder block.
Use the following dimensions to locate the piston cooling jet assembly.
Dimension (C) ... 25.9 mm (1.02 inch)
Dimension (D) ... 33.4 mm (1.32 inch)
Dimension (E) ... 26.9 mm (1.06 inch)
Dimension (F) ... 9.8 mm (0.39 inch)
Dimension (G) ... 50.0 mm (1.97 inch)
Typical example of one jet per cylinder
(1) Piston cooling jet
The piston cooling jets (1) must be checked for the location of the stream of oil. Insert a drill rod with a
diameter of 1.90 mm (0.075 inch) into the jet. This drill rod simulates the stream of oil under normal
operating pressure. The drill rod must pass through a circle with a diameter of 5.0 mm (0.20 inch) in
location (A). The circle is located at depth (G). The location of the circle is a distance of 50.0 mm (1.97
inch) below the top of the cylinder block.
Use the following dimensions to locate the piston cooling jet.
Dimension (C) ... 25.9 mm (1.02 inch)
Dimension (D) ... 33.4 mm (1.32 inch)
Dimension (G) ... 50.0 mm (1.97 inch)
67
035 Specifications
Balancer Group - 3114 Engine Only
Front view
Top view
(1) Crankshaft gear (2) Oil pump idler gear (3) Oil pump housing (4) Distance from top surface of
supports to top of sleeves ... 5.0 ± 0.5 mm (0.20 ± 0.02 inch) (5) Timing mark
Turn the crankshaft to top center compression stroke for the No. 1 piston. Align the timing marks on
the balancer gears (11) with the holes (6) in the oil pump body., (6) Holes in oil pump body (7) Oil
pump drive gear (8) Rear support
Diameter of bores ... 48.540 ± 0.025 mm (1.9110 ± 0.0010 inch)
Diameter of balancer shafts ... 48.40 ± 0.02 mm (1.906 ± 0.001 inch)
(9) Center support
Diameter of balancer shafts ... 48.40 ± 0.02 mm (1.906 ± 0.001 inch)
Note: The bearings in the center support must be even with the front face of the support., (10) Oil
pump housing
Diameter of balancer shaft ... 48.40 ± 0.02 mm (1.906 ± 0.001 inch)
(11) Balancer gears
68
Heat the gear to the following temperature for installation. Do not use a torch. ... 315 °C (599 °F)
View A-A
(12) Thrust pin
Diameter at each end ... 5.89 ± 0.13 mm (0.232 ± 0.005 inch) (B) Distance across flats ... 6.86 ±
0.03 mm (0.270 ± 0.001 inch)
(13) Snap ring (14) Plate (15) Isolator
69
036 Specifications
Accessory Drive - Splined
Rear view
Typical example
View A-A
(1) Stud
Tighten the stud to the following torque. ... 35 ± 5 N·m (26 ± 4 lb ft)
(2) Nut
70
037 Specifications
Front Housing and Covers
Typical example
Apply 1U-8846 Liquid Gasket to the front housing sealing surfaces before you assemble the front
housing to the cylinder block. The front housing must be assembled and tightened to the cylinder block
within ten minutes., (1) Cylinder Block (2) Front housing (3) Bolt length marked location (X). ... 50.0
mm (1.97 inch) (4) Bolt length marked location (Y). ... 20.0 mm (0.79 inch)
Typical example
71
Apply 1U-8846 Liquid Gasket to the sealing surfaces of the front housing cover. Assemble the front
housing cover to the front housing. The front housing cover must be assembled and tightened to the
front housing within ten minutes., (5) Front housing cover (6) Bolt length marked location (A). ... 60
mm (2.36 inch) (7) Bolt length marked location (B). ... 30 mm (1.18 inch)
72
038 Specifications
Gear Group (Front)

Type 1
(1) Camshaft idler gear
Distance between the front of the bearing face and the front of the gear face (B) ... 0.40 ± 0.25 mm
(0.016 ± 0.010 inch)
Diameter of new shaft (A) ... 80.00 ± 0.013 mm (3.1496 ± 0.0005 inch), (2) Camshaft gear (3) Tighten
the bolts of the camshaft idler gear to the following torque. ... 70 ± 15 N·m (50 ± 11 lb ft) (4) Align the
timing marks on the camshaft idler gear (1) with the holes on the camshaft and the crankshaft gears (2)
and (5). (5) Crankshaft gear (6) Oil pump drive gear (7) Apply 9S-3263 Thread Lock Compound to the
threads of the oil pump idler gear bolt. Tighten the bolt to the following torque. ... 70 ± 15 N·m (50 ±
11 lb ft) (8) Oil pump idler gear
Distance between the rear of the bearing face and the rear of the gear face (C) ... 0.75 ± 0.25 mm (0.030
± 0.010 inch)
Diameter of new shaft (D) ... 28.644 ± 0.013 mm (1.1277 ± 0.0005 inch)
73
Type 2
Distance between the rear of the bearing face and the rear of the gear face (B) ... 1.08 ± 0.25 mm (0.043
± 0.010 inch)
Diameter of new shaft (A) ... 74.000 ± 0.013 mm (2.9134 ± 0.0005 inch), (2) Camshaft gear (3)
Tighten the bolts of the camshaft idler gear to the following torque. ... 70 ± 15 N·m (50 ± 11 lb ft) (4)
Align the timing marks on the camshaft idler gear (1) with the holes on the camshaft and the crankshaft
gears (2) and (5). (5) Crankshaft gear (6) Oil pump drive gear (7) Apply 9S-3263 Thread Lock
Compound to the threads of the oil pump idler gear bolt. Tighten the bolt to the following torque. ... 70
± 15 N·m (50 ± 11 lb ft) (8) Oil pump idler gear
± 0.010 inch)
Diameter of new shaft (D) ... 28.644 ± 0.013 mm (1.1277 ± 0.0005 inch), (9) Plate
74
Type 3
(0.016 ± 0.010 inch)
± 0.010 inch)
75
Type 4
(0.016 ± 0.010 inch)
± 0.010 inch)
76
039 Specifications
Rear Power Take-Off (RPTO)
Rear Power Take-Off
Install bearing (1) in the bore of the retainer plate. Install the bearing so the notches face toward the
inside of the unit. Place the split in the bearing at the 8 o'clock position., (1) The bearing should
overhang the bore of the retainer plate by the following length. ... 1.52 ± 0.13 mm (0.060 ± 0.005 inch)
(2) Thickness of the thrust washer ... 2.959 ± 0.038 mm (0.1165 ± 0.0015 inch)
End play of the output shaft. ... 0.79 ± 0.29 mm (0.031 ± 0.012 inch), (3) Tighten the four bolts for the
retainer plate to the following torque. ... 80 ± 6 N·m (59 ± 4 lb ft) (4) Retainer plate (5) Install the seal
so the outer surface is level with the face of the retainer plate. (6) Output flange ... SAE J1956, Type S,
Size 1480 (7) Install the bearing in the bore with the split at the 8 o'clock position. (8) Tighten the bolt
to following torque. ... 275 ± 19 N·m (203 ± 14 lb ft)
Lubricate bolt threads and lubricate the face of the washer with engine oil before installation., (9)
Install the idler gear assembly in the gear bore so the bearing does not extend past either face. (10)
Assembly sequence for the idler shaft
Tighten three bolts evenly in order to draw the shaft squarely into the housing bore.
Seat the shaft firmly against the housing with a center driver and hammer.
Tighten the bolts again to the following torque. ... 175 ± 30 N·m (130 ± 22 lb ft), (11) Install the seal to
the following depth. ... 11.5 mm (0.5 inch)
Note: The installed depth for the seal is measured from the inside face of the cover plate., (12) Tighten
the eight bolts to the cover plate to the following torque. ... 30 ± 7 N·m (22 ± 5 lb ft)
77
040 Specifications
Flywheel
Typical example
(1) Tighten the bolts that hold the flywheel to the crankshaft to the following torque. ... 120 ± 20 N·m
(90 ± 15 lb ft)
Note: If the old bolts are used for installation of the flywheel, clean the threads of the bolts and clean
the threads of the crankshaft. Apply 9S-3263 Thread Lock Compound to the threads of the bolts., (2)
Ring gear
78
041 Specifications
Flywheel Housing
Typical example
Note: Refer to Systems Operation, Testing and Adjusting for the correct method of inspecting the
flywheel housing., (1) Torque for the seal plug ... 4 ± 1 N·m (35 ± 9 lb in) (2) Torque for four bolts ... 4
± 1 N·m (35 ± 9 lb in)
79
042 Specifications
Engine to Transmission Adapter
Typical example, (1) Flywheel assembly (2) Flex plate (3) Hub
(4) Torque for eight bolts ... 120 ± 20 N·m (90 ± 15 lb ft)
80
043 Specifications
Crankshaft Pulley
Typical example
(1) Torque for four bolts ... 200 ± 25 N·m (150 ± 18 lb ft)
81
044 Specifications
Belt Tension Chart
Note: Do not use the belt tension charts for belts with tensioners that are spring loaded.
Table 1
Belt Tension Chart
Gauge Reading Kent-Moore Gauge Numbers
Size of Width of Belt
Belt Belt Tension Belt Tension Number of the Number of the
"Initial" (1) "Used" (2) (3) Old Gauge New Gauge
10.72 mm 534 ± 111 N (120 400 ± 22 N (90 ± 5
3/8 BT-33-97 BT 3397
(0.422 inch) ± 25 lb) lb)
13.89 mm 578 ± 111 N (130 445 ± 44 N (100 ±
1/2 BT-33-97 BT 3397
(0.547 Inch) ± 25 lb) 10 lb)
15.88 mm 712 ± 111 N (160 445 ± 44 N (100 ±
5V BT-33-72C BT 3372C
(0.626 Inch) ± 25 lb) 10 lb)
17.48 mm 712 ± 111 N (160 445 ± 44 N (100 ±
11/16 BT-33-72C BT 3372C
(0.688 Inch) ± 25 lb) 10 lb)
19.05 mm 712 ± 111 N (160 445 ± 44 N (100 ±
3/4 BT-33-72C BT 3372C
(0.750 Inch) ± 25 lb) 10 lb)
23.83 mm 712 ± 111 N (160 445 ± 44 N (100 ±
15/16 BT-33-77 BT 3372C
(0.938 Inch) ± 25 lb) 10 lb)
27.82 mm 1068 ± 111 N (240 890 ± 44 N (200 ±
8PK BT-33-109 BT 33109
(1.095 inch) ± 25 lb) 10 lb)
20.94 mm 801 ± 111 N (180 667 ± 44 N (150 ±
6PK BT-33-109 BT 33109
(0.824 Inch) ± 25 lb) 10 lb)
Measure the tension of the belt that is farthest from the engine.
(1) Belt tension "Initial" is for a new belt.
(2) Belt tension "Used" is for a belt that has operated for 30 minutes or more of operation at the rated speed.
(3) If a belt falls below the "Used" belt tension, the belt should be tightened again to the high side of the "Used" belt
tension.
Table 2
For DAYCO Supplied Belts Only
Belt Tension Belt Tension
Size of Belt (1)
"Initial" "Used" (2) (4)
.380 (V-Belt) 623 ± 22 N (140 ± 5 lb) 445 ± 22 N (100 ± 5 lb)
.440 (V-Belt) 667 ± 22 N (150 ± 5 lb) 445 ± 22 N (100 ± 5 lb)
.500 (V-Belt) 712 ± 22 N (160 ± 5 lb) 445 ± 22 N (100 ± 5 lb)
.600 (V-Belt) 779 ± 22 N (175 ± 5 lb) 445 ± 22 N (100 ± 5 lb)
.660 (V-Belt) 890 ± 22 N (200 ± 5 lb) 445 ± 22 N (100 ± 5 lb)
.790 (V-Belt) 890 ± 22 N (200 ± 5 lb) 445 ± 22 N (100 ± 5 lb)
4 - RIB PVK 623 ± 22 N (140 ± 5 lb) 400 ± 22 N (90 ± 5 lb)
5 - RIB PVK 779 ± 22 N (175 ± 5 lb) 445 ± 22 N (100 ± 5 lb)
6 - RIB PVK 934 ± 22 N (210 ± 5 lb) 578 ± 22 N (130 ± 5 lb)
8 - RIB PVK 1157 ± 22 N (260 ± 5 lb) 800 ± 22 N (180 ± 5 lb)
10 - RIB PVK 1557 ± 22 N (350 ± 5 lb) 1023 ± 22 N (230 ± 5 lb)
12 - RIB PVK 1869 ± 22 N (420 ± 5 lb) 1200 ± 22 N (270 ± 5 lb)
15 - RIB PVK 2336 ± 22 N (525 ± 5 lb) 1557 ± 22 N (350 ± 5 lb)
82
(1) Belt tension "Initial" is for a new belt.
(2) Belt tension "Used" is for a belt that has operated for 30 minutes or more of operation at the rated speed.
(4) If a belt falls below the "Used" belt tension, the belt should be tightened again to the "Initial" belt tension.
83
045 Specifications
Belt Tensioner
(1) Fill the bearing cavity with 1P-0808 Multipurpose Grease. (2) Tighten the locknut to the following
torque. ... 35 ± 7 N·m (26 ± 5 lb ft)
Detail A
(3) Lubricate the sealing lip with the lubricant that is being sealed.
84
046 Specifications
Belt Tensioner
(1) Distance from the back of the plate assembly to the middle of the pulley ... 26.0 ± 0.3 mm (1.02 ±
0.012 inch) (2) Distance from the back of the plate assembly to the back of the pulley ... 16.0 ± 0.3 mm
(0.63 ± 0.01 inch) (3) Plate assembly (4) Pulley (5) Apply 9S-3263 Thread Lock Compound to the
pulley bore before assembly. (6) Bolt (7) Washer
Note: The bolt (6) and the washer (7) are not used in some applications. The bolt and the washer are
used when it is necessary to provide an alternate method of applying tension to the water pump belt.
This method is used to adjust belt tension.
85
047 Specifications
Fan Drive
Type 1
Lubricate the fan drive with 1P-0808 Multipurpose Grease. Apply the grease to the following areas.
¡ Seal cavity (1)
¡ Bearing cavity (2)
¡ Fan adapter cavity (3)
Detail A
(4) Seal
Install the seal with the lip in the specified position. Lubricate the seal lip with 1P-0808 Multipurpose
Grease .
86
Type 2
Lubricate the fan drive with 2S-3230 Bearing Lubricant. Apply the grease to the following areas.
¡ Seal cavity (1)
¡ Bearing cavity (2)
¡ Fan adapter cavity (3)
Detail B
(4) Seal
Install the seal with the lip in the specified position. Lubricate the seal lip with 2S-3230 Bearing
Lubricant .
87
Type 3
(1) Fill the bearing cavity with 2S-3230 Bearing Lubricant.
View C-C
(2) Seal
Install the seal with the lip in the specified position. The lip should be facing toward the front of the
engine.
88
048 Specifications
Alternator and Regulator
View A-A
View B-B
3E-7578 Alternator Gp
3T-1888 Alternator Gp
112-5041 Alternator Gp
Note: Load the battery with a carbon pile 4C-4911 Battery Load Tester in order to get the maximum
alternator output.
Voltage rating ... 24 Volt
Polarity ... Negative ground
Rotation ... Either direction
The maximum turn on speed at 25 °C (77 °F) is the following value. ... 2000 RPM
The output voltage at 25 °C (77 °F) is the following value. ... 28 ± 1 Volt
The minimum full load current at 5000 rpm is the following value. ... 47 Amp
89
The minimum full load current at 1500 rpm is the following value. ... 18 Amp, (1) Tighten the shaft nut
to the following torque. ... 102 ± 7 N·m (75 ± 5 lb ft) (2) Tighten the negative ground terminal screw to
the following torque. ... 6.2 ± 0.6 N·m (55 ± 5 lb in) (3) Tighten the positive output terminal nut to the
following torque. ... 13.5 ± 1.3 N·m (120 ± 12 lb in) (4) Regulator
View A-A
3E-8827 Alternator Gp
alternator output.
The output voltage at 25 °C (77 °F) is the following value. ... 14 ± 0.5 Volt
to the following torque. ... 102 ± 7 N·m (75 ± 5 lb ft) (2) Tighten the positive output terminal nut to the
following torque. ... 11.3 N·m (100 lb in) (3) Tighten the negative ground terminal nut to the following
torque. ... 6.2 ± 0.6 N·m (55 ± 5 lb in)
9X-6796 Alternator Gp
alternator output.
following torque. ... 11.3 N·m (100 lb in) (3) Tighten the negative ground terminal nut to the following
torque. ... 6.2 ± 0.6 N·m (55 ± 5 lb in)
90
View A-A
6N-9294 Alternator Gp
alternator output.
following torque. ... 6.2 ± 0.6 N·m (55 ± 5 lb in) (3) Tighten the negative ground terminal nut to the
91
View A-A
alternator output.
to the following torque. ... 102 ± 7 N·m (75 ± 5 lb ft) (2) Tighten the negative ground terminal nut to
8C-6163 Alternator Gp
alternator output.
The output voltage at 25 °C (77 °F) is the following value. ... 14.0 ± 0.5 Volt
to the following torque. ... 102 ± 7 N·m (75 ± 5 lb ft) (2) Tighten the negative ground terminal nut to
92
View A-A
alternator output.
The minimum full load current at 5000 rpm is the following value. ... 27.9 Amp
The minimum full load current at 1500 rpm is the following value. ... 10.8 Amp, (1) Tighten the shaft
nut to the following torque. ... 60 ± 7 N·m (45 ± 5 lb ft) (2) Tighten the positive output terminal nut to
the following torque. ... 4.1 ± 0.4 N·m (36 ± 4 lb in) (3) Tighten the negative ground terminal nut to the
alternator output.
the following torque. ... 4.1 ± 0.4 N·m (36 ± 4 lb in) (3) Tighten the negative ground terminal nut to the
93
View A-A
alternator output.
The minimum full load current at 5000 rpm is the following value. ... 44.6 Amp
the following torque. ... 13.5 ± 1.3 N·m (120 ± 12 lb in) (3) Tighten the negative ground terminal nut to
the following torque. ... 4.4 ± 1.0 N·m (39 ± 9 lb in) (4) Regulator
View A-A
94
alternator output.
Rotation ... Clockwise
9G-9538 Alternator Gp
alternator output.
View A-A
8C-5510 Alternator Gp
alternator output.
95
following torque. ... 3.6 ± 0.8 N·m (32 ± 7 lb in)
View A-A
9W-1082 Alternator Gp
alternator output.
96
View A-A
9W-3043 Alternator Gp
alternator output.
View A-A
alternator output.
97
following torque. ... 6.2 ± 0.6 N·m (55 ± 5 lb in)
98
049 Specifications
3E-1944 Electric Starting Motor

When the electric starting motor is viewed from the pinion end, the motor rotates in the following
direction. ... Clockwise
No load conditions at 25 °C (77 °F)
Speed ... 3628 ± 413 rpm
Current draw ... 84 ± 16 Amp
Voltage ... 23 Volt
(1) Battery terminal nut
Tighten the nut on the battery terminal to the following torque. ... 30.5 ± 3.5 N·m (23 ± 3 lb ft)
(2) Ground terminal nut
Tighten the nut on the ground terminal to the following torque. ... 30.5 ± 3.5 N·m (23 ± 3 lb ft)
(3) Return terminal nut
Tighten the nut on the return terminal to the following torque. ... 2.25 ± 0.25 N·m (20 ± 2 lb in)
(4) Switch terminal
Tighten the nut on the switch terminal to the following torque. ... 2.25 ± 0.25 N·m (20 ± 2 lb in)
(5) Motor terminal nut
Tighten the nut on the motor terminal to the following torque. ... 14.7 ± 3.4 N·m (130 ± 30 lb in)
(6) Motor frame nut
Tighten the nut on the motor frame to the following torque. ... 8 ± 3 N·m (71 ± 27 lb in)
Clearance (X) between the pinion and the housing ... 1.02 ± 0.76 mm (0.040 ± 0.030 inch)
Solenoid
Current draw at 20 Volt and 25 °C (77 °F)
Pull-in windings ... 36 ± 2 Amp
Hold-in windings ... 6.75 Amp maximum

99
106-8559 Electric Starting Motor
Speed ... 8450 ± 1250 rpm
Voltage ... 23 Volt
(4) Switch terminal
(6) Motor frame nut
Clearance (X) between the pinion and the housing ... 4.6 mm (0.18 inch)
Solenoid
Pull-in windings ... 56.5 ± 4.5 Amp
Hold-in windings ... 14.6 Amp
7X-5987 Electric Starting Motor

Speed ... 7018 ± 1517 rpm
Current draw ... 147.5 ± 27.5 Amp
Voltage ... 11 Volt
(4) Switch terminal
Tighten the nut on the motor terminal to the following torque. ... 8 ± 3 N·m (71 ± 27 lb in)
(6) Motor frame nut
Solenoid
Hold-in windings ... 23 ± 2 Amp

Speed ... 4050 ± 750 rpm
100
Voltage ... 24 Volt
(4) Switch terminal
(6) Motor frame nut
Tighten the nut on the motor frame to the following torque. ... 10 ± 3 N·m (7 ± 2 lb ft)
Solenoid
Hold-in windings ... 7.5 ± 0.6 Amp

9W-3748 Electric Starting Motor
Speed ... 3800 rpm minimum
Current draw ... 120 Amp maximum
Voltage ... 23 Volt
Tighten the nut on the motor terminal to the following torque. ... 25 ± 7 N·m (18 ± 5 lb ft)
101
(4) Switch terminal
Tighten the screw on the switch terminal to the following torque. ... 2.25 ± 0.25 N·m (20 ± 2 lb
in)
Solenoid
Pull-in windings ... 50 Amp
Hold-in windings ... 20 Amp

Voltage ... 11 Volt
Tighten the nut on the motor terminal to the following torque. ... 25 ± 7 N·m (18 ± 5 lb ft)
(4) Switch terminal
in)
Solenoid

7T-2266 Electric Starting Motor
102
When the electric starting motor is viewed from the drive end, the motor rotates in the following
Speed ... 5500 rpm maximum
Voltage ... 12 Volt
Tighten the nut on the ground terminal to the following torque. ... 2.25 ± 0.25 N·m (20 ± 2 lb in)
(4) Switch terminal
Tighten the nut on the motor terminal to the following torque. ... 30.5 ± 3.5 N·m (23 ± 3 lb ft)
(6) Motor frame nut
Tighten the nut on the motor frame to the following torque. ... 30.5 ± 3.5 N·m (23 ± 3 lb ft)
Solenoid

8C-4774 Electric Starting Motor
Speed ... 3638 ± 413 rpm
Voltage ... 23 Volt
103
(4) Switch terminal
(6) Motor frame nut
Solenoid

Speed ... 7018 ± 1517 rpm
Voltage ... 11 Volt
(4) Switch terminal
(6) Motor frame nut
Solenoid
Hold-in windings ... 23 ± 2 Amp maximum
104
View A-A

Speed ... 7643 ± 1683 rpm
Current draw ... 76±14.5 Amp
Voltage ... 23 Volt
(4) Switch terminal
(6) Motor frame nut
Solenoid
6V-5821 Electric Starting Motor

Speed ... 7643 ± 1683 rpm
Voltage ... 23 Volt
(4) Switch terminal
105
(6) Motor frame nut
Solenoid

Speed ... 6900 ± 1800 rpm
Voltage ... 11 Volt
(4) Switch terminal
(6) Motor frame nut
Solenoid

Speed ... 6900 ± 1800 rpm
Voltage ... 11 Volt
(4) Switch terminal
(6) Motor frame nut
106
Solenoid
4N-7153 Electric Starting Motor

Speed ... 5000 rpm
Voltage ... 20 Volt
Solenoid
Pull-in windings ... 65 Amp maximum
107

Speed ... 7018 ± 1517 rpm
Voltage ... 11 Volt
(4) Switch terminal
(6) Motor frame nut
Solenoid
Hold-in windings ... 23 ± 2 Amp

Speed ... 3628 ± 413 rpm
Voltage ... 23 Volt
(4) Switch terminal
(6) Motor frame nut
Solenoid
108

Voltage ... 23 Volt
(3) Switch terminal
in)
(5) Motor frame nut
Solenoid
109

Voltage ... 23 Volt
(3) Motor frame nut
(5) Switch terminal
in)
Solenoid
110
050 Specifications
Magnetic Pickup
Typical example of magnetic pickup
While the engine is stopped, install the magnetic pickup. Once the magnetic pickup is in contact with
the flywheel ring gear, turn the magnetic pickup counterclockwise to the following distance. ... 180 ±
36 degrees, (1) Air gap
Clearance between magnetic pickup and flywheel ring gear ... 0.70 ± 0.14 mm (0.028 ± 0.006
inch)
(2) Locknut
Install the locknut and tighten the locknut to the following torque. ... 45 ± 7 N·m (33 ± 5 lb ft)
111
051 Specifications
Jacket Water Heater
Typical example
(1) Turbocharger (2) Cord assembly
Tighten the fastener for the cord to the following torque. ... 8 N·m (70 lb in)
(3) Heater (4) Installation angle
Install the heater at the following angle. ... 43 ± 2 degrees
Note: Use a driver to tap the heater into the cylinder block. Position the heater firmly against the
cylinder block.
Typical example
cylinder block.
112
Element assembly
Typical example
Table 1
Element Rating
120 Volt System 240 Volt System
Power 1250 Watts 1250 Watts
Voltage 120 Volts 240 Volts
Current 10.4 Amp 5.2 Amp
Element assembly
Typical example
Table 2
Element Rating
113
052 Specifications
Jacket Water Heater
Typical example
cylinder block.
Typical example
cylinder block.
114
Element assembly
Typical example
Table 1
Element Rating
Element assembly
Typical example
Table 2
Element Rating
115
053 Specifications
Air Inlet Heater
Section view of the air inlet heater
Note: During assembly of the air inlet heater to the inlet manifold and the air inlet elbow, clean the air
inlet heater's joint faces with solvent. Apply 4C-9500 Quick Cure Primer to the joint faces. Allow the
primer to air dry for a minimum of three to five minutes. Apply 1U-8846 Liquid Gasket to the joint
face and spread the gasket maker uniformly. The heater must be assembled and tightened within ten
minutes.
155-4911 Air Inlet Heater , (1) Air inlet heater (2) Tighten the nuts to the following torque. ... 7.8 ±
1.0 N·m (69 ± 9 lb in)
The air inlet heater has the following specifications:
¡ 11 VDC
¡ 92 Amp
¡ 1012 Watt
1.0 N·m (69 ± 9 lb in)
¡ 22 VDC
¡ 86 Amp
¡ 1892 Watt
Note: During assembly of the air inlet heater to the inlet manifold and the air inlet elbow, clean the air
inlet heater's joint faces with solvent. Apply 4C-9500 Quick Cure Primer to the joint faces. Allow the
primer to air dry for a minimum of five minutes. Apply 1U-8846 Liquid Gasket to the joint face and
spread the gasket maker uniformly. The heater must be assembled and tightened within ten minutes.
1.0 N·m (113 ± 9 lb in)
116
¡ 11 VDC
¡ 92 Amp
¡ 1060 Watt
106-3844 Air Inlet Heater

1.0 N·m (113 ± 9 lb in)
¡ 22 VDC
¡ 98 Amp
¡ 2160 Watt
117
054 Specifications

Note: Push in the button (1) on the latching type solenoid in order to manually shut off the engine. The
solenoid cannot be manually latched in the run position for starting.
155-4651 Solenoid
System voltage ... 12 VDC
Install the solenoid to the governor housing. Tighten to the following torque. ... 30 ± 5 N·m (22 ± 4 lb
ft)
Resistance of pull-in coil at 25 °C (77 °F) ... 0.39 ± 0.04 ohms
Resistance of hold-in coil at 25 °C (77 °F) ... 2.58 ± 0.30 ohms
Hold in force ... 9.6 VDC
The return spring is heat stabilized at the following ambient temperature. ... 121 °C (250 °F)
The return spring is heat stabilized at the following voltage. ... 28.8 VDC
De-energized plunger stroke (A). ... 17.0 mm (0.67 inch)
Energized position (B). ... 26.8 ± 1.0 mm (1.06 ± 0.04 inch)
155-4652 Solenoid
ft)
118
125-5771 Solenoid
ft)
125-5772 Solenoid
ft)

End view of ETS solenoid
(1) Ground terminal
Ground wire size ... 10 gauge
(2) Stop terminal
Wire size to OFF terminal of keyswitch ... 16 gauge
119
(3) Start terminal
Wire size to S (switch) terminal of starter motor ... 10 gauge
End view of ETR solenoid
The solenoid that has two wires has no polarity requirements for the wires.
120
SENR3583-13
INDEX
Systems Operation
Systems Operation
General Information INDEX 120
124
Fuel System 126
Fuel System
Fuel Transfer Pump
Governor
Fuel Ratio Control
Air Inlet and Exhaust System 133
Turbocharger
Ether Starting Aid
Lubrication System 138
Cooling System 140
Basic Engine 144
Crankshaft
Camshaft
Vibration Damper
Electrical System 148
Solenoid
Starter Motor
Other Components
Circuit Breaker
Magnetic Pickup
Magnetic Switch
SENR3583-13
121
Fuel System - Inspect 153
Start Up Procedure
Air in Fuel - Test 155
Engine Speed - Check 157
Finding Top Center Position for No. 1 Piston 158
Fuel Quality - Test 160
Fuel Ratio Control - Adjust 161
Fuel System - Prime 163
Fuel System Pressure - Test 164
Fuel Timing Dimension - Adjust 166
Gear Group (Front) - Time 167
Governor - Adjust 170
Low Idle Adjustment
Unit Injector - Adjust 172
Unit Injector Synchronization - Adjust 173
Air Inlet and Exhaust System - Inspect 176
Exhaust Restriction
Turbocharger - Inspect 179
Inlet Manifold Pressure - Test 182
Exhaust Temperature - Test 184
Engine Crankcase Pressure (Blowby) - Test 185
Compression - Test 186
Engine Valve Lash - Inspect/Adjust 187
Valve Lash Check
Engine Oil Pressure - Test 189
SENR3583-13
122
Piston Cooling Jets
Excessive Bearing Wear - Inspect 193
Excessive Engine Oil Consumption - Inspect 194
Increased Engine Oil Temperature - Inspect 195
Cooling System - Check - Overheating 196
Cooling System - Inspect 198
Cooling System - Test 199
Water Temperature Regulator - Test 205
Water Pump - Test 206
Piston Ring Groove - Inspect 207
Connecting Rod Bearings - Inspect 208
Main Bearings - Inspect 209
Cylinder Block - Inspect 210
Flywheel - Inspect 211
Flywheel Housing - Inspect 213
Vibration Damper - Check 216
Battery - Test 218
Charging System - Test 220
8T-0900 Ammeter
Electric Starting System - Test 223
Pinion Clearance - Adjust 225
SENR3583-13
123
SENR3583-13
124
001 Systems Operation
General Information
Right Side View Of The 3114 Engine (Typical Example), (1) Lifting eye (2) Turbocharger (3) Water temperature regulator
housing (4) Oil filter (5) Jacket water pump (6) Oil drain plug (7) Crankshaft vibration damper
Left Side View Of The 3114 Engine (Typical Example), (6) Oil drain plug (8) Governor (9) Engine crankcase breather
(10) Oil filler (11) Fuel filter (12) Oil level gauge (typical example)
001 : Systems Operation

125
Right Side View Of The 3116 And The 3126 Engine (Typical Example), (1) Lifting eye (2) Turbocharger (3) Water
temperature regulator housing (4) Oil drain plug (5) Oil filter (6) Jacket water pump (7) Crankshaft vibration damper
Left Side View Of The 3116 And The Engine 3126 (Typical Example), (8) Governor (9) Oil filler (10) Engine crankcase
breather (11) Fuel filter (12) Oil level gauge (typical example)
The engine is powered with direct fuel injection. A mechanical governor controls the fuel injection
pump output in order to maintain the engine rpm that is selected by the operator. This provides good
engine response and good fuel economy.
The cooling system consists of the following components:
¡ Centrifugal pump that is driven by belts
¡ Water temperature regulator which regulates the engine coolant temperature
¡ Oil cooler and radiator which incorporates a shunt system
The engine lubricating oil that is supplied is cooled. The engine lubricating oil is also filtered. Bypass
valves provide unrestricted flow of lubrication oil to the engine components during the following
conditions:
¡ High oil viscosity
¡ Plugged oil cooler or plugged oil filter elements (paper cartridge)

126
Fuel System
Fuel System
Fuel System Schematic, (A) Fuel priming pump (if equipped) (1) Screen (if equipped) (2) Inlet check valve (3) Fuel
transfer pump that is integral with the governor (4) Outlet check valve (5) Fuel filter (6) Cylinder head (7) Pressure
regulating valve (8) Check valve (9) Primary fuel filter (if equipped) (10) Pressure relief valve (11) Fuel tank
Fuel from fuel tank (11) is pulled through an in-line screen (1) by fuel transfer pump (3). The fuel
transfer pump is integral with the governor. Fuel is sent from the fuel transfer pump through the
pressure relief valve (10). The pressure relief valve is closed in normal operation. Fuel will enter
through fuel filter (9) to a drilled passage in the cylinder head (6). Once the pressure of the fuel is
greater than the desired range then the pressure relief valve will open. This will allow the fuel to return
to the tank. The drilled passage in the cylinder head intersects a gallery around each unit injector in
order to provide a continuous flow of fuel to all injectors.
When there is air on the inlet side of the fuel system, fuel priming pump (A) (if equipped) may be used
in order to fill the fuel filter and the fuel gallery that is in the cylinder head. This is performed before
the engine is started. When the priming pump is used, check valves that are located in the fuel priming
pump control the movement of the fuel. The fuel is forced through the low pressure side of the fuel
system. This removes air from the fuel lines and components back into the fuel tank.
Lines Group For The Fuel Filter, (3) Fuel transfer pump that is integral with the governor (5) Fuel filter (6) Cylinder head
(10) Pressure relief valve (12) Fuel outlet port to the fuel tank (13) Fuel inlet port to the fuel transfer pump (14) Fuel filter
base (15) Pressure tap for filtered fuel (16) Tube assembly from the fuel filter base to the fuel gallery in the cylinder head
(17) Tube assembly from the transfer pump to the fuel filter base

127
Lines Group For The Fuel Filter, (1) Screen (6) Cylinder head (7) Pressure regulating orifice (8) Check valve (10) Pressure
relief valve (12) Fuel outlet port to the fuel tank (13) Fuel inlet port to the fuel transfer pump (17) Tube assembly from the
transfer pump to the fuel filter base (18) Tube assembly from the fuel passage in the cylinder head to the fuel tank
Fuel Transfer Pump
Fuel Transfer Pump, (A) Inlet flow of fuel (B) Outlet flow of fuel (1) Screen (if equipped) (2) Inlet check valve (3) Spring
(4) Piston assembly (5) Outlet check valve (6) Piston check valve (7) Tappet assembly (8) Camshaft (9) Passage
The fuel transfer pump is located in the front housing of the governor. The pump is activated by
camshaft (8) that is attached to the shaft of the governor drive gear. Piston assembly (4) and tappet
assembly (7) are stroked up and down by the camshaft and spring (3) .
Fuel enters the transfer pump through screen (1) (if equipped) and inlet check valve (2). On the
upstroke of piston assembly (4), check valve (2) closes. Outlet check valve (5) closes in order to
prevent fuel from being pulled back in the pump from the outlet. As pressure increases above piston
assembly (4), piston check valve (6) opens in order to fill the cavity above the piston assembly.
On the downstroke, as the fuel pressure in passage (9) increases, piston check valve (6) is closed and
outlet check valve (5) is opened. This causes fuel to be pushed through the secondary fuel filter and to
the engine. Inlet check valve (2) opens in order to allow fuel to fill the cavity above piston assembly
(4) .
During engine shutdown, the check valves are held closed by springs.

128
Fuel Injection System, (1) Rocker arm (2) Setscrew (3) Floating button (4) Tappet Spring (5) Pushrod (6) Plunger (7) Rack
(8) O-ring (9) Barrel (10) Fuel gallery (11) Sleeve (12) O-ring (13) Lifter (14) Camshaft
The fuel injection pump (unit injector) allows a small amount of fuel to be injected at the proper time
into the combustion chamber. The fuel that is supplied to fuel gallery (10) surrounds each unit injector.
Each of these galleries are connected by a drilled passage in the cylinder head. This passage provides a
continuous flow of fuel to all unit injectors.
The unit injector is isolated from the coolant passages by sleeve (11). The sleeve also provides the
seating surface for the unit injector.
Injection timing is determined by the angular location of camshaft (14) and the vertical location of
plunger (6) in barrel (9). The camshaft gear and the crankshaft gear mesh together at the front of the
engine in order to achieve the angular location of the camshaft. The location of the plunger (fuel
timing) is adjusted by setscrew (2) .
The profile of the camshaft is sent to rocker arm (1) by lifter (13) and pushrod (5), as the camshaft
rotates. The motion of rocker arm (1) is then sent to plunger (6) through the floating button (3).

129
Fuel Injection Pump (Unit Injector), (4) Tappet spring (6) Plunger (7) Rack (8) O-ring (9) Barrel (12) O-ring (15) Gear
(16) Sleeve filter (17) Helix (18) Lower port (19) Upper port (20) Spring (21) Check (needle valve)
At the top of the plunger's stroke, fuel from fuel gallery (10) enters the unit injector around the edges of
sleeve filter (16). The fuel then fills the volume below plunger (6) .
During the plunger's downward motion, fuel beneath the plunger is displaced into the gallery through
the two ports in barrel (9). As upper port (19) is closed by the bottom edge of the plunger, fuel
continues to be displaced through lower port (18). When the lower port is closed, effective stroke
begins. The fuel inside the unit injector becomes pressurized by the continued downward movement of
the plunger. When the fuel pressure is sufficient to open check (21), high pressure fuel will be forced
through orifices at the bottom of the nozzle into the combustion chamber. This will continue until
upper port (19) is uncovered by helix (17) on the plunger. At this instant, effective stroke ends and this
high pressure fuel will spill through upper port (19) into the gallery. This will allow spring (20) to close
check (21), which will end the injection cycle.
The downward motion of the plunger will continue until lifter (13) reaches the nose of the camshaft.
The plunger will be returned upward by tappet spring (4). This will allow the cavity under the plunger
to be refilled from the fuel in the gallery. The unit injector is now ready for the next cycle.
In addition to vertical motion, the plunger can rotate with respect to barrel (9) by gear (15). The gear
slides in order to allow vertical movement of the plunger and the gear meshes with rack (7). The
rotation of the gear changes the relationship between helix (17) and upper port (19). The amount of fuel
that is injected into each combustion chamber then changes. For example, if rack (7) is moved to the
right, then plunger (6) will rotate CCW. (This movement is viewed from the top.) The distance between
the bottom end of the plunger and helix (17) then increases with respect to upper port (19). The
effective stroke is increased and more fuel is injected into the combustion chamber.

130
Unit Injectors and Rack Control Linkage, (1) Lever (2) Torsion spring (3) Shaft (4) Rack (5) Synchronization screw (6)
Clamp (7) Clamp assembly (8) Fuel setting screw (9) Link (10) Lever assembly (11) Unit injector
Unit Injector And Rack Control Linkage, (A) FUEL ON (B) FUEL OFF (1) Lever (3) Shaft (4) Rack (5) Synchronization
screw (6) Clamp (11) Unit injector
The rack control linkage connects the governor output to unit injector (11) at each cylinder. The
governor output shaft is pinned to link (9). The link is connected to lever assembly (10). When the
governor demands more fuel, link (9) and lever assembly (10) cause rotation of shaft (3) and clamps
(6). Shaft (3) and clamps (6) are rotated in a FUEL ON (A) direction. Each clamp then pushes lever (1)
as the shaft rotates. Rack (4) is pulled by lever (1). This will allow more fuel to be injected into the
cylinder.
When the governor requires less fuel, link (9) causes rotation of shaft (3) and clamps (6). Shaft (3) and
clamps (6) are rotated in a FUEL OFF (B) direction. Lever (1) is forced to rotate clockwise by torsion
spring (2). This will push rack (4) toward the shutoff position. A torsion spring is located at each unit
injector. This allows the rack control linkage to go to the shutoff position, even if one fuel injector rack
is stuck open.
The power setting of the unit injector for the No. 1 cylinder is made with fuel setting screw (8) in
clamp assembly (7). As fuel setting screw (8) is turned, shaft (3) rotates to a new position with respect

131
to link (9) and lever assembly (10). Adjusting screws (8) allow synchronization of the injectors to the
unit injector of the No. 1 cylinder.
Governor
The governor transfers the operator's requirements to the fuel injector rack control linkage. The
governor receives the desired engine speed by the position of the throttle. The governor output shaft
immediately moves when the throttle is moved. The motion of the governor output shaft will cause the
fuel injector rack control linkage to rotate. This will move the fuel injector racks. The change in the
position of the fuel injector rack will cause a change in the speed of the engine. As the speed of the
engine changes, the governor will adjust the amount of fuel that is delivered. This will cause the engine
to stabilize at the rpm that corresponds to the throttle position. For further information, refer to,
SENR6454, " 3114, 3116, and 3126 Governor Service Manual".
Fuel Ratio Control
The turbocharged engine uses a fuel ratio control (FRC) in order to control smoke during acceleration
at low boost levels. The FRC restricts the amount of fuel to the combustion chambers until sufficient
boost has been achieved.
Governor Linkage and Fuel Ratio Control Schematic, (A) FUEL ON output (B) FUEL ON input from operator (1)
Governor output shaft (2) Inlet port (3) Fuel ratio control (FRC) (4) Retainer shaft (5) FRC lever (6) Limit lever setscrew
(7) FRC lever setscrew (8) Limit lever
Fuel ratio control (FRC) (3) operates on boost air pressure that is delivered by a tube from the inlet
manifold of the engine to inlet port (2). At low boost, retainer shaft (4) is held stationary by springs that
are inside the FRC. When the operator demands more fuel, governor output shaft (1) moves in the
FUEL ON direction (A). The governor output shaft will move in this direction until limit lever (8)
contacts setscrew (7) of FRC lever (5). When FRC lever (5) is restrained from rotating clockwise or
FUEL ON movement by the FRC, further FUEL ON movement of governor output shaft (1) is stopped.
Thus, overfueling is prevented.
As engine power increases, boost pressure also increases. This pressure acts against a diaphragm inside
the FRC. When boost pressure is sufficient, spring force inside the FRC is overcome and retainer shaft
(4) moves to the right. This movement will allow FRC lever (5) and limit lever (8) to rotate clockwise.
Governor output shaft (1) is now able to move in the FUEL ON direction until the limit lever (8)
contacts limit lever setscrew (6) .
When boost pressure decreases, springs inside fuel ratio control (FRC) (3) will return retainer shaft (4)
to the normal position. FUEL ON movement of governor output shaft (1) is again restricted.

132
, (1) Button (2) Fuel Shutoff Solenoid
The fuel shutoff mechanism is activated by an energize-to-run (ETR) latching solenoid. A spring
loaded plunger inside the solenoid acts on a lever assembly within the front housing of the governor.
This lever assembly pushes the governor output shaft to the FUEL OFF position when the plunger is
released electrically or the plunger is released manually at engine shutdown. At engine start-up, the
solenoid is energized in order to latch in the run position. The governor output shaft is then free to
move to the FUEL ON position.
Engines that are equipped with a latching solenoid can be manually shut off by pushing button (1)
inward. The solenoid CANNOT be manually latched in the run position in order to start the engine.
Wiring diagram of a Typical Fuel Shutoff Solenoid , (2) Fuel Shutoff Solenoid (3) "STOP" Connection (4) "G" Connection
(5) "S" Connection (6) "BAT" Connection (7) Positive Terminal (8) Negative Terminal (9) "GND" Connection (10)
"START" Connection (11) "MTR" Connection (12) Starter Motor (13) Battery

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Air Inlet and Exhaust System
Air Inlet And Exhaust System Schematic, (1) Aftercooler (aftercooled engines) (2) Air inlet manifold (3) Exhaust manifold
(4) Exhaust outlet (5) Turbocharger (6) Air inlet (7) Air cleaner
The components of the air inlet and exhaust system control the quality of the air that is available for
combustion. These components also control the amount of the air that is available for combustion. The
components of the air inlet and exhaust system are listed below:
¡ Air cleaner
¡ Turbocharger
¡ Aftercooler (aftercooled engines)
¡ Cylinder head
¡ Valves and valve system components
¡ Piston and cylinder
¡ Exhaust manifold
Air Inlet And Exhaust System, (1) Aftercooler (aftercooled engines) (3) Exhaust manifold (4) Exhaust outlet (6) Air inlet
(8) Exhaust valve (9) Inlet valve (10) Compressor wheel (11) Turbine wheel
Inlet air is pulled through air cleaner (7). The inlet air is then compressed and heated by the compressor
wheel of turbocharger (5) to about 150°C (300°F). The inlet air is then pushed through one of the
following components: air-to-air aftercooled (ATAAC), jacket water aftercooled (JWAC) and air inlet
cover. The inlet air is forced to air inlet manifold (2). The temperature of the inlet air at the air inlet
manifold is about 43°C (110°F). Cooling of the inlet air increases the combustion efficiency. Increased
combustion efficiency helps to lower fuel consumption. Also, increased combustion efficiency helps to
increase horsepower output.
The air to air aftercooled (ATAAC) system incorporates a separate air to air aftercooler core. This core
is installed in front of the radiator of the engine or the core is installed beside the radiator of the engine.
Air that is ambient temperature is moved across the aftercooler core by the engine fan and by the ram
effect of the vehicle's forward motion. This cools the turbocharged inlet air.
The jacket water aftercooled (JWAC) system uses engine coolant from the water pump in order to cool
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the hot turbocharged air. The JWAC system incorporates a water-to-air system that is mounted to the
air inlet manifold.
Inlet manifold (2) is a one-piece casting that also serves as a base for the valve cover. From the inlet
manifold, the air is forced into the cylinder head in order to fill the inlet ports. Air flow from the inlet
port into the cylinder is controlled by the inlet valves.
There is one inlet valve (9) and one exhaust valve (8) for each cylinder. The inlet valve opens when the
piston moves down on the inlet stroke. When the inlet valve opens, cooled compressed air from the
inlet port is pulled into the cylinder. The inlet valve closes and the piston begins to move up on the
compression stroke. The air in the cylinder is compressed. When the piston is near the top of the
compression stroke, fuel is injected into the cylinder. The fuel mixes with the air and combustion starts.
During the power stroke, the combustion force pushes the piston downward. After the power stroke is
complete, the piston moves upward. This upward movement is the exhaust stroke. During the exhaust
stroke, the exhaust valve opens, and the exhaust gases are pushed through the exhaust port into exhaust
manifold (3). After the piston completes the exhaust stroke, the exhaust valve closes and the cycle
starts again. The complete cycle consists of four stages:
¡ inlet stroke
¡ compression stroke
¡ power stroke
¡ exhaust stroke
Exhaust gases from exhaust manifold (3) enter turbine side of turbocharger (5) in order to turn the
turbine wheel (11). The turbine wheel is connected to a shaft which drives the compressor wheel (10).
Exhaust gases from the turbocharger pass through the exhaust outlet pipe, the muffler and the exhaust
stack.
Turbocharger
Turbocharger, (1) Air inlet (2) Compressor housing (3) Compressor wheel (4) Bearing (5) Oil Inlet port (6) Bearing (7)
Turbine housing (8) Turbine wheel (9) Exhaust outlet (10) Oil outlet port (11) Exhaust inlet
The turbocharger is installed on the center section of the exhaust manifold. All the exhaust gases from
the engine go through the turbocharger. The compressor side of the turbocharger is connected to the
aftercooler by pipe.
The exhaust gases go into turbine housing (7) through exhaust inlet (11). The exhaust gases then push
the blades of turbine wheel (8). The turbine wheel is connected by a shaft to compressor wheel (3) .
Clean air from the air cleaners is pulled through compressor housing air inlet (1) by the rotation of
compressor wheel (3). The action of the compressor wheel blades causes a compression of the inlet air.
This compression gives the engine more power by allowing the engine to burn more air and more fuel
during combustion.
When the load on the engine increases, more fuel is injected into the cylinders. The combustion of this

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additional fuel produces more exhaust gases. The additional exhaust gases cause the turbine and the
compressor wheels of the turbocharger to turn faster. As the compressor wheel turns faster, more air is
forced into the cylinders. The increased flow of air gives the engine more power by allowing the engine
to burn the additional fuel with greater efficiency.
Turbocharger With Waste Gate, (12) Actuating lever (13) Canister (14) Line (boost pressure)
When the engine is operating under conditions of low boost, a spring pushes on a diaphragm in canister
(13). This action moves actuating lever (12) in order to close the valve of the waste gate. Closing the
valve of the waste gate allows the turbocharger to operate at maximum performance.
As the boost pressure through line (14) increases against the diaphragm in canister (13), the valve of
the wastegate is opened. When the valve of the wastegate is opened, the rpm of the turbocharger is
limited by bypassing a portion of the exhaust gases. The exhaust gases are routed through the wastegate
which bypasses the turbine wheel of the turbocharger.
Note: The turbocharger with a waste gate is preset at the factory and no adjustment can be made.
Turbocharger Oil Lines, (15) Oil supply tube (16) Oil drain tube
Bearings (4) and (6) for the turbocharger use engine oil under pressure for lubrication. The oil comes in
through oil supply tube (15) to oil inlet port (5). The oil then goes through passages in the center
section in order to lubricate the bearings. Oil from the turbocharger goes out through oil outlet port (10)
in the bottom of the center section. The oil then goes back to the engine lubrication system through oil
drain tube (16).

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Valve System Components, (1) Rocker arm (2) Spring (3) Valve (4) Pushrod (5) Lifter (6) Camshaft lobe
The valve system components control the flow of inlet air into the cylinders during engine operation.
The valve system components also control the flow of exhaust gases out of the cylinders during engine
operation.
The crankshaft gear drives the camshaft gear through an idler gear. The camshaft must be timed to the
crankshaft in order to get the correct relation between the piston movement and the valve movement.
The camshaft has three camshaft lobes for each cylinder. The lobes operate the following components:
the inlet valves, the exhaust valves and the mechanical unit injector (MUI). As the camshaft turns,
lobes on the camshaft cause lifters (5) to move pushrods (4) up and down. Upward movement of the
pushrods against rocker arms (1) results in downward movement (opening) of valves (3) .
Each cylinder has one inlet valve and one exhaust valve. Valve springs (2) close the valves when the
lifters move down.

The engines may be equipped with an electric heater that is located at the air inlet manifold. The
electric heater has two functions:
¡ aid in starting
¡ aid in white smoke cleanup during start-up
Under the proper conditions, an Electronic Control will turn on the system for the electric heater (if
equipped). The following conditions are evaluated prior to activating the electric heater:
¡ jacket water coolant temperature
¡ oil pressure
¡ ignition switch position
¡ duration of time
Some of the air inlet heaters will have manual controls, while other air inlet heaters will have automatic
controls. The system is capable of delivering heat for 30 seconds prior to start-up and during cranking
of the engine. After the engine has started, the system is capable of delivering heat constantly for
several minutes. This will depend on the control system that is used.
If the air inlet heater malfunctions, the engine will still start and the engine will still run. There may be
a concern regarding the amount of white smoke that is present. Also, there may be a concern regarding
the need for an alternative starting aid.

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, (A) 3114 and 3116 Engines (B) 3126 Engine (1) Inlet manifold (2) Heater element (3) Ground strap
Ether Starting Aid
Location Of Atomizer, (1) Air inlet manifold (2) Atomizer (3) Air inlet elbow
Ether can be used in cold weather to aid in the startability of the engine. Ether is injected into the center
port of the air inlet manifold (1). If the atomizer is not installed correctly, ether could be directed onto
the air inlet heater. Possible extensive damage could occur to the engine, if the ether is directed at the
heater element and the air inlet heater is activated.

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Lubrication System
Lubrication System Schematic, (1) Oil supply to the governor (2) Oil supply to the rocker arms (3) Cylinder head gallery
(4) Piston cooling jets (5) Oil supply to side covers (6) Camshaft bearing (7) Passage in carrier housing (4 cylinder
engines) (8) Main oil gallery (9) Oil supply to the rear support for the balancer unit (4 cylinder engines) (10) Passage in
front housing (11) Main bearings (12) Oil supply to camshaft idler gear bearing (13) Oil supply to turbocharger (14) Oil
supply to oil pump idler gear bearing (6 cylinder engines) (14) Oil supply to the bearings for the oil pump idler gear and
the balancer shaft (4 cylinder engines) (15) Oil filter bypass valve (16) Passage (17) Oil cooler bypass valve (18) Engine
oil filter (19) Engine oil cooler (20) Engine oil pan (21) Oil pump bypass valve (22) Engine oil pump
Engine oil pump (22) is mounted to the bottom of the cylinder block inside the engine oil pan (20). The
engine oil pump pulls oil from engine oil pan. The engine oil is then pushed through passage (16) to the
engine oil cooler (19). Oil then flows through engine oil filter (18). The filtered oil then enters the
turbocharger oil supply line (13) and main oil gallery (8).
Right Side View Of Engine, (13) Turbocharger oil supply line (15) Oil filter bypass valve (17) Oil cooler bypass valve
(18) Engine oil filter (19) Oil cooler (23) Turbocharger oil return tube
The main oil gallery (8) distributes oil to main bearings (11), piston cooling jets (4), and camshaft
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bearing (6). Oil from the main oil gallery exits the front of the block. The oil then enters passage (10)
that is cast in the front housing.
The front housing passage sends the oil flow in two directions. At the upper end of the passage (10), oil
is directed back into the block and up to cylinder head gallery (3). At the lower end of the passage (10),
oil enters passage (14). This passage will send oil to the oil pump idler gear bearing on the 4 cylinder
engine and the 6 cylinder engines, and to the bearing for the front bearing for the balancer shaft on the
4 cylinder engine.
Oil from the main oil gallery is forced through passages to the crankshaft main bearings. Oil enters the
holes in the bearing surfaces (journals) for the main bearing (11). Oil from the front main bearing
enters passage (12) in order to lubricate the camshaft idler gear bearing. Oil passages in the crankshaft
send oil from all the main bearings (11) through the connecting rods to the connecting rod bearings.
Passages connect the bearing surface (journal) for the main bearing with the bearing surface (journal)
for the connecting rod.
On the 4 cylinder engine, some of the oil that goes to the rear main bearing is directed out of the rear
face of the cylinder block to passage (7) in the crankshaft seal carrier. Oil is then directed into passage
(9) in the cylinder block. Oil is supplied to the rear support for the balancer unit in order to lubricate the
rear bearings of the balancer unit. A passage in the balancer shafts now carries the oil from the rear
balancer shaft bearings to the intermediate bearings of the shafts.
Left Side View Of Engine, (1) Governor oil supply line (24) Crankcase breather (25) Location of oil passage for pushrod
lifters inside side covers (26) Hose (27) Plug
Passages (5) send oil from the camshaft bearing (6) to a short oil passage (25) in the side covers. The
oil then enters a hole in the shafts of the pushrod lifters in order to lubricate the roller bearings of the
lifter.
Cylinder head oil gallery (3) provides flow to governor oil supply line (1) and the rocker arm supports.
Holes in the rocker arm supports allow lubrication of the valve and injector components.
After the lubrication oil's work is done, the lubrication oil returns to the engine oil pan.
The oil pump bypass valve (21) limits the pressure of the oil that is coming from the engine oil pump
(22). The engine oil pump can pump more than enough oil into the system. When there is more than
enough oil, the oil pressure increases. When the oil pressure increases, the oil pump bypass valve will
open. This allows the oil that is not needed to go back to the suction side of the engine oil pump.
The bypass valves (15) and (17) will open when the engine is cold (starting conditions). Opening the
bypass valves achieves immediate lubrication of all components. Immediate lubrication is critical when
cold oil with high viscosity causes a restriction to the oil flow through engine oil cooler (19) and engine
oil filter (18). The engine oil pump (22) sends the cold oil through the bypass valves around the engine
oil cooler and the engine oil filter to the turbocharger oil supply line (13) and the main oil gallery (8) in
the cylinder block.
When the oil gets warm, the pressure difference in the bypass valves decreases and the bypass valves
close. After the bypass valves close, there is a normal flow of oil through the engine oil cooler and the
engine oil filter.
The bypass valves will also open when there is a restriction in the engine oil cooler (19) or engine oil
filter (18). This design allows the engine to be lubricated even though the engine oil cooler or the
engine oil filter are restricted.
Crankcase breather (24) allows engine blowby to escape from the crankcase. The engine blowby is
discharged through hose (26) into the atmosphere. This prevents pressure from building up that could
cause seals or gaskets to leak.
Oil pressure to the camshaft and the main bearings should be checked at oil gallery plug (27). This plug
is located on the left side of the cylinder block.
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Cooling System
Cooling System Schematic, (1) Cylinder head (2) Water temperature regulator housing (3) Bypass hose (4) Cylinder block
(5) Oil cooler (6) Water pump (7) Radiator
Water pump (6) is located on the right front side of cylinder block (4). The water pump is belt driven
from the crankshaft pulley. Coolant from the bottom of radiator (7) is pulled into the bottom inlet of the
water pump by the impeller rotation. The rotation of the impeller in the water pump forces the coolant
through the cooling system. The coolant exits the back of the water pump directly into the oil cooler
cavity of the cylinder block.
All of the coolant passes through the core of oil cooler (5) and the coolant then enters the internal water
manifold of cylinder block (4). This manifold distributes the coolant to water jackets that are around
the cylinder walls.
Water Lines Group, (1) Cylinder head (2) Water temperature regulator housing (3) Bypass hose (6) Water pump (8) Outlet
to radiator (9) Water temperature regulator that is partially open (10) Air vent valve that is located in the flange of
thermostat (11) Coolant return from the air compressor (if equipped) (12) Port for water pump outlet pressure for engine
diagnosis
Note: Some commercial engines have a bypass hose (3). This hose is used only on engines which use
an automotive type radiator that is supplied by Caterpillar.

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Note: Later thermostats have an air vent valve (10). This air vent valve allows air to escape from the
cooling system while coolant is added.
Water Lines Group, (2) Water temperature regulator housing (3) Bypass hose (6) Water pump (8) Outlet to radiator (9)
Water temperature regulator that is partially open
Water Pump, (13) Pump outlet pressure (alternate heater supply) (14) Port for coolant supply to aftercooler (if equipped)
(15) Coolant return ports from the heater (16) Alternate pump outlet pressure for engine diagnosis
From the cylinder block, the coolant flows into passages that are in cylinder head (1). These passages
send the flow of coolant around the following items:
¡ Unit injector sleeves
¡ Inlet passages
¡ Exhaust passages
The coolant now enters water temperature regulator housing (2) at the front right side of cylinder block
(4) .
Water temperature regulator (9) controls the direction of flow. If the temperature of the coolant is
below normal, then the water temperature regulator is closed. The coolant is directed through bypass
hose (3) and into the top inlet of water pump (6). When the coolant gets to the correct temperature, the
water temperature regulator will open. Most of the coolant goes through outlet (8) to the radiator for
cooling. The remainder flows through the bypass hose and into the water pump.
Note: Water temperature regulator (9) is an important part of the cooling system. The water
temperature regulator divides the coolant flow between the radiator and the bypass in order to maintain
the proper temperature. If the water temperature regulator is not installed in the system, then there is no
mechanical control, and most of the coolant will take the path of least resistance through the bypass.
This will cause the engine to overheat in hot weather. Any amount of coolant that flows through the
radiator can be too much in cold weather. This will cause the engine not to reach normal operating
temperatures.

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Connections for the Aftercooler, (2) Water temperature regulator housing (6) Water pump (17) Outlet hose (18)
Aftercooler (19) Inlet hose
The aftercooler that is equipped on some engines is connected into the jacket water coolant system.
Inlet hose (19) delivers coolant to aftercooler (18) from a separate outlet of water pump (6). Once the
coolant has circulated through the aftercooler core, the coolant then goes through outlet hose (17) of the
aftercooler to water temperature regulator housing (2) .
Cooling system schematic, (1) Shunt line (2) Pressure cap (3) Expansion tank (4) Vent line (5) Heat exchanger (6)
Cylinder block and cylinder head (7) Water cooled turbocharger (8) Inside bypass line (9) Water pump (10) Oil cooler (11)
Water cooled exhaust manifold (12) Water temperature regulator housing (13) Hot water to heat exchanger
This engine has a pressure type cooling system that is equipped with a shunt line.
A pressure type cooling system offers two advantages:
¡ The cooling system can operate safely at a temperature that is higher than the normal boiling
point of water.
¡ The cooling system prevents cavitation in the water pump.
Cavitation is the sudden formation of low pressure bubbles in liquids by mechanical forces. The
formation of air or steam pockets is more difficult within a pressure type cooling system.
The shunt line prevents cavitation by the water pump. The shunt line provides a constant flow of
coolant to the water pump.
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The water pump is located on the side of the cylinder block. The water pump is belt driven from the
crankshaft pulley.Coolant from the heat exchanger is pulled into the bottom inlet of the water pump by
impeller rotation. The coolant exits the pump directly into the oil cooler cavity.The coolant enters the
internal water manifold of the cylinder block. The manifold disperses the coolant to water jackets
around the cylinder walls.The coolant from the rear of the cylinder block supplies the exhaust manifold
and the turbocharger.The coolant then flows into passages in the cylinder head. The passages send the
flow around the unit injector sleeves and the inlet and the exhaust passages.The coolant exits the
cylinder head and combines with the flow of coolant from the exhaust manifold before entering the
regulator. The coolant then flows through a deaerator in order to purge excess air to the expansion tank.
Air vents are provided on the water outlet of the turbocharger and at the rear of the cylinder head. The
air vents allow the cooling system to fill with coolant. The air vents also remove the air from the
cooling system.Note: The water temperature regulator controls the direction of flow. When the coolant
temperature is below the normal operating temperature, the water temperature regulator is closed. The
coolant is directed from the cylinder head to the inlet of the water pump. When the coolant temperature
reaches the normal operating temperature, the water temperature regulator opens. Coolant then travels
to the heat exchanger for cooling.Note: The water temperature regulator is an important part of the
cooling system. The water temperature regulator divides coolant flow between the heat exchanger and
the bypass in order to maintain the normal operating temperature. If the water temperature regulator is
not installed in the system, there is no mechanical control, and most of the coolant will travel the path
of least resistance through the bypass. This will cause the engine to overheat in hot weather and the
engine will not reach normal operating temperature in cold weather.The shunt line extends from the top
of the water pump to the expansion tank. The shunt line must be routed properly in order to avoid
trapping any air. By providing a constant flow of coolant to the water pump, the shunt line prevents the
water pump from cavitating.

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Basic Engine
The cylinder block for the four cylinder engine has five main bearings that support the crankshaft. The
cylinder block for the six cylinder engine has seven main bearings that support the crankshaft. The
main bearing caps are fastened to the cylinder block with two bolts per cap.The removal of the oil pan
allows access to the following components:
¡ Crankshaft
¡ Main bearing caps
¡ Piston cooling jets
¡ Oil pump
The compartment for the camshaft is accessible through covers on the left side of the cylinder block.
These side covers also support the pushrod lifters. The camshaft is supported by bearings that are
pressed into the cylinder block. There are five camshaft bearings for the four cylinder engine and there
are seven camshaft bearings for the six cylinder engine.
The cylinder head is separated from the cylinder block by a gasket that is made of steel and non-
asbestos fiber. Coolant flows out of the cylinder block through gasket openings and into the cylinder
head. The gasket also seals the oil supply and the drain passages between the cylinder head and the
cylinder block. The air inlet ports are located on the top of the cylinder head. The exhaust ports are
located on the right side of the cylinder head. There is one intake and one exhaust valve for each
cylinder. Valve guides are pressed into the cylinder head. The fuel injector is located between the two
valves. Fuel is injected directly into the cylinders at very high pressure. A system with pushrods and
with rocker arms is used in order to control the valves and the fuel injectors.

One-piece aluminum pistons are used in most applications. Engines with higher cylinder pressures
require two-piece pistons. Refer to the parts manual in order to obtain information about the type of
piston that is used in a specific engine.The one-piece aluminum pistons have an iron band for the top
two rings. This helps to reduce wear on the compression ring grooves. Oil from the piston cooling jets
will spray the underside of the piston. This will cool the piston, which improves the life of the piston
and rings. The piston has two compression rings and one oil ring. All of the rings are located above the
piston pin bore. The oil ring is of the standard or conventional type. Oil will return to the crankcase
through holes that are located in the groove for the oil ring. The design of the compression rings is of
the keystone type, which is tapered. The piston groove is also tapered. Too much carbon deposits can
cause seizure of the piston rings. This is prevented by the action of the rings in the piston grooves.The
two-piece piston consists of an alloy steel crown that is connected to an aluminum skirt by the piston
pin. Oil from the piston cooling jets will spray the underside of the piston crown. This will cool the
piston, which improves the life of the piston and the rings. The piston rings are located in grooves in
the piston crown. Oil will return to the crankcase through holes that are located in the groove for the oil
ring.The connecting rod has a taper on the pin bore end which gives the rod and the piston more
strength in the areas with the most load. The cap is fastened to the connecting rod by two bolts. This
design keeps the rod width to a minimum, so that the piston can be removed through the cylinder.
Crankshaft
The crankshaft converts the combustion forces in the cylinders into rotating torque which powers the
equipment. A vibration damper is used on the front of the crankshaft to reduce torsional vibrations
(twist on the crankshaft) that can cause damage to the engine. The crankshaft drives a group of gears
(front gear train) on the front of the engine. The front gear train provides power for the following

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components:
¡ Engine oil pump
¡ Camshaft
¡ Governor
¡ Air compressor
¡ Power steering pump
In addition, the front belt pulleys on the crankshaft provide power for following components:
¡ Radiator fan
¡ Water pump
¡ Alternator
¡ Refrigerant compressor
Hydrodynamic seals are used at both ends of the crankshaft to control oil leakage. The hydrodynamic
grooves in the seal lip move lubrication oil back into the crankcase as the crankshaft turns. The front
seal is located in the front housing. The rear seal is installed in the flywheel housing.
Schematic of Oil Passages in a 4 Cylinder Engine, (1) Oil gallery (2) Main bearings (3) Connecting rod bearings
Schematic of Oil Passages in a 6 Cylinder Engine, (1) Oil gallery (2) Main bearings (3) Connecting rod bearings
Pressurized oil is supplied to all main bearings through drilled holes in the webs of the cylinder block.
The oil then flows through drilled holes in the crankshaft in order to provide oil to the connecting rod
bearings. The crankshaft is held in position by either five main bearings on the four cylinder engine or
seven main bearings on the six cylinder engines. A thrust main bearing is located next to the rear main
bearing. This type of main bearing is used in order to control the end play of the crankshaft.
Camshaft
The camshaft is located in the upper left side of the cylinder block. The camshaft is driven by an idler
gear that is turned by the crankshaft in the front gear train. Five camshaft bearings support the camshaft
in a four cylinder engine. Seven camshaft bearings support the camshaft in a six cylinder engine. Each
bearing journal is lubricated from the oil manifold in the cylinder block. A thrust pin that is located at
the rear of the block positions the camshaft through a circumferential groove. The groove is machined
at the rear of the camshaft.The camshaft has three lobes at each cylinder that operate the unit injector,

146
the exhaust valves, and the inlet valves. As the camshaft rotates, each lobe moves a lifter assembly.
Each outside lifter assembly moves a pushrod, which will move either an inlet valve or an exhaust
valve. The center lifter assembly moves a pushrod that operates the fuel injector. The camshaft must be
in time with the crankshaft. Timing is the relationship of the camshaft lobes to the crankshaft position,
which will cause the valves and the fuel injector in each cylinder to operate at the correct time. Timing
of the camshaft is accomplished by aligning marks on the following components with each
other:crankshaft gear, idler gear and camshaft gear.
Vibration Damper
The force from combustion in the cylinders will cause the crankshaft to twist. This is called torsional
vibration. If the vibration is too great, the crankshaft will be damaged. The vibration damper limits the
torsional vibrations to an acceptable amount in order to prevent damage to the crankshaft.
Cross Section of a Rubber Vibration Damper, (1) Crankshaft (2) Ring (3) Rubber ring (4) Hub (5) Alignment marks
The rubber vibration damper is installed on the front of crankshaft (1). Hub (4) and ring (2) are isolated
by a rubber ring (3). The vibration damper has alignment marks (5) on the hub and the ring. These
marks give an indication of the condition of the vibration damper.
Cross Section of a Viscous Vibration Damper, (1) Crankshaft (2) Weight (3) Case

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The viscous vibration damper is installed on the front of crankshaft (1). The viscous vibration damper
has a weight (2) in a case (3). The space between the weight and the case is filled with a viscous fluid.
The weight moves in the case in order to limit the torsional vibration.
Engine Balancer Group (Front View), (1) Crankshaft gear (2) Oil pump idler gear (3) Balancer shaft (4) Oil pump drive
gear (5) Oil pump housing
The four cylinder engine is equipped with two balancer shafts. These shafts cancel out the inertial
forces that are typical of four cylinder engines.
Balancer shafts (3) run the full length of the cylinder block. The balancer shafts are mounted by the
following items: oil pump housing (5), intermediate support and rear support. The balancer shafts are
driven by crankshaft gear (1) via oil pump idler gear (2) and oil pump drive gear (4). The balancer
shafts are phased and the shafts are timed to the engine by marked teeth on the gears.

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Electrical System
The electrical system has two separate circuits.
¡ the charging circuit
¡ the starting circuit
Some of the electrical system components are used in more than one circuit. The following items are
common in each of the circuits:
¡ The battery
¡ The circuit breaker
¡ The cables
¡ The wires for the battery
The charging circuit is in operation when the engine is running. An alternator makes electricity for the
charging circuit. A voltage regulator in the circuit controls the electrical output in order to keep the
battery at full charge.
NOTICE
The disconnect switch, if so equipped, must be in the ON position to let
the electrical system function. There will be damage to some of the
charging circuit components if the engine runs with the disconnect with
in the OFF position.
If the engine has a disconnect switch, the starting circuit can operate only after the disconnect switch is
put in the "ON" position.
The starting switch is in operation only when the start switch is activated.
The charging circuit is connected through the ammeter. The starting circuit is not connected through
the ammeter.

The alternator is driven by the crankshaft pulley through a belt that is a Poly-vee type. The alternator is
a three-phase self-rectifying charging unit. The regulator is part of the alternator. The operation of the
brushless alternator and the brush type alternator follow.
NOTICE
Never operate the alternator without the battery in the circuit. Making
or breaking an alternator connection with heavy load on the circuit can
cause damage to the regulator.

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Brushless Alternator (Typical Example), (1) Regulator (2) Roller bearing (3) Stator winding (4) Ball bearing (5) Rectifier
bridge (6) Field winding (7) Rotor assembly (8) Fan
This alternator design has no need for slip rings or for brushes. The only part of this alternator that
moves is the rotor assembly. All of the conductors that carry current are stationary. The following
components are the conductors: the field winding, the stator windings, rectifying diodes and
components of the regulator circuit.
The rotor assembly has many magnetic poles that are similar to fingers with air space between each of
the opposite poles. The poles have residual magnetism that produces a small amount of magnet-like
lines of force (magnetic field). This magnetic field is produced between the poles. As the rotor
assembly begins to turn between the field winding and the stator windings, a small amount of
alternating current (AC) is produced in the stator windings. The alternating current is produced from
the small magnetic lines of force that are created by the residual magnetism of the poles. The AC is
changed into direct current (DC) when the current passes through the diodes of the rectifier bridge.
Most of this current provides the battery charge and the supply for the low amperage circuit. The
remainder of the current is sent to the field windings. The DC current flow through the field windings
(wires around an iron core) increases the strength of the magnetic lines of force. These stronger
magnetic lines of force increase the amount of AC that is produced in the stator windings. The
increased speed of the rotor assembly also increases the current output of the alternator and the voltage
output of the alternator.
Brush Type Alternator (Typical Example), (1) Stator (2) Field coil (rotor) (3) Regulator
This alternator design has a stator (1) that is stationary and a field coil (rotor) (2) that moves. The slip
rings and the brushes are used for supplying excitation current to the rotating field coil.
The brush type alternators can be a battery energized alternator or a self-energizing alternator. The self-
energizing alternators rely on residual magnetism, which is similar to the brushless alternators. The
battery energized alternators have less residual magnetism. These alternators use current from the
batteries for field current in order to produce the magnetic lines of force. When the alternator's voltage
exceeds the battery voltage, the charging system will be self-contained and the battery voltage will not
be needed.
The voltage regulator is a solid-state electronic switch. The voltage regulator senses the voltage of the
150
system. The regulator then uses switches to control the current to the field windings. This controls the
voltage output in order to meet the electrical demand of the system.

Solenoid
A solenoid is an electromagnetic switch that performs two basic functions:

¡ The solenoid closes the high current starter motor circuit with a low current start switch circuit.
¡ The solenoid engages the starter motor pinion with the ring gear.
Typical solenoid schematic
The solenoid has windings (one set or two sets) around a hollow cylinder. A plunger with a spring load
device is inside of the cylinder. The plunger can move forward and backward. When the start switch is
closed and electricity is sent through the windings, a magnetic field is created. The magnetic field pulls
the plunger forward in the cylinder. This moves the shift lever in order for the pinion drive gear to
engage with the ring gear. The front end of the plunger then makes contact across the battery and
across the motor terminals of the solenoid. The starter motor then begins to turn the flywheel of the
engine.
When the start switch is opened, current no longer flows through the windings. The spring now returns
the plunger to the original position. At the same time, the spring moves the pinion gear away from the
flywheel.
When two sets of windings in the solenoid are used, the windings are called the hold-in winding and
the pull-in winding. Both of the windings wind around the cylinder for an equal amount of times. The
pull-in winding uses a wire with a larger diameter in order to produce a stronger magnetic field. When
the start switch is closed, part of the current flows from the battery through the hold-in winding. The
remainder of the current flows through the pull-in windings, to the motor terminal, and then to the
ground. When the solenoid is fully activated, the current is shut off through the pull-in windings. Only
the smaller hold-in windings are in operation for the extended period of time that is necessary for the
engine to be started. The solenoid will now take a smaller amount of current from the battery. Heat that
is created by the solenoid will be kept at an acceptable level.
Starter Motor
Starter motor cross section, (1) Field windings (2) Solenoid (3) Clutch (4) Starter pinion (5) Commutator (6) Brush
assembly (7) Armature

151
The starter motor rotates the engine flywheel at a rate that is fast enough to start the engine.
The starter motor has a solenoid (2). When the start switch is activated, the solenoid will move starter
pinion (4) in order to engage the starter pinion and the ring gear on the engine flywheel. The starter
pinion and the ring gear will engage before the circuit between the battery and the starter motor is
closed by the electric contacts in the solenoid. When the circuit between the battery and the starter
motor is complete, the starter pinion will rotate the engine flywheel. A clutch provides protection for
the starter motor so that the engine cannot turn the starter motor too fast. When the switch is released,
the starter pinion will move away from the ring gear.
Other Components
Circuit Breaker
The circuit breaker is a switch that opens the battery circuit if the current in the electrical system is
higher than the rating of the circuit breaker. The metal disc (2) is activated by heat. If the current in the
electrical system gets too high, the metal disc will get hot. This heat causes a distortion of the metal
disc. A circuit breaker that is open can be reset when the metal disc becomes cooler. Push the reset
button (1) in order to close the contact points and reset the circuit breaker.
NOTICE
Find and correct the problem that causes the circuit breaker to open.
This will help prevent damage to the circuit components from too
much current.
Circuit breaker schematic, (1) Reset button (2) Disc in open position (3) Contacts (4) Disc (5) Battery circuit terminals
Magnetic Pickup
Schematic of Magnetic Pickup, (1) Magnetic lines of force (2) Wire coils (3) Gap (4) Pole piece (5) Flywheel ring gear

152
The magnetic pickup is a permanent magnet generator with a single pole. The magnetic pickup is made
of wire coils (2). The coils go around a permanent magnet pole piece (4) .
As the teeth of the flywheel ring gear (5) cut through the magnetic lines of force (1) around the pickup,
an AC voltage is generated. The frequency of this voltage is directly proportional to engine speed.
Magnetic Switch
A magnetic switch is used for the starter solenoid circuit. The switch electrically operates in the same
manner as the solenoid. The magnetic switch has the function of reducing the low current load that is
on the start switch. The switch also controls the low current to the starting solenoid.

153
001 Testing and Adjusting
Fuel System - Inspect

A problem with the components that send fuel to the engine can cause low fuel pressure. This can
decrease engine performance.
Fuel System, (1) Fuel outlet port to tank (2) Fuel return tube to tank (3) Tube assembly from transfer pump to fuel filter (4)
Tube assembly from fuel filter to cylinder head (5) Fuel inlet port to fuel transfer pump (6) Screen (7) Pressure relief valve
(8) Fuel filter
1. Check the fuel level in the fuel tank. Inspect the cap for the fuel tank. Ensure that the vent in the fuel
cap is not filled with dirt.
2. Check all fuel lines for fuel leakage. The fuel lines must be free from restrictions and faulty bends.
Verify that the fuel return line is not collapsed.
3. Clean screen (6) inside the inlet fitting of the fuel transfer pump.
4. Operate the hand priming pump (if equipped). If excessive resistance is felt, inspect the fuel pressure
regulating valve. Make sure that the pressure regulator is installed correctly, and make sure that the
pressure regulator functions correctly.
5. Install a new fuel filter (8) .
6. Cut the old filter open with the 4C-5084 Oil Filter Cutter. Inspect the filter for excess contamination.
Determine the source of the contamination. Make the necessary repairs.
7. Service the primary fuel filter (if equipped).
8. Inspect the orifice that is in tube (1). Check the orifice for restrictions that would inhibit proper
operation.
9. Operate the hand priming pump (if equipped). If uneven resistance is felt, test for air in the fuel.
Refer to Testing and Adjusting, "Air in Fuel - Test" for more information.
10. Remove any air that may be in the fuel system. Refer to Testing and Adjusting, "Fuel System -
Prime".
Start Up Procedure
Note: Refer to Operation and Maintenance Manual, "Engine Starting" in the Operation Section.After
work has been done on the fuel system, consider the following precautions before you start the engine.
Make sure that you use this starting procedure to start the engine only after the fuel system has been
worked on:
1. Disconnect the air inlet system from the turbocharger.
Be careful when placing the steel plate against the opening on the
turbocharger air inlet. To avoid crushed fingers, do not position fingers
between the steel plate and the opening on the turbocharger air inlet.
001 : Testing and Adjusting
154
Due to excessive suction, the plate can be forcefully pulled against the
opening on the turbocharger air inlet.
2. Another person will need to help as a precautionary step. This person should be ready to use the steel
plate to cover the turbocharger air inlet if a problem occurs.
Note: Make sure that the steel plate is large enough to cover the entire turbocharger air inlet.
3. Start the engine.
Immediately place the steel plate against the opening on the turbocharger air inlet, if the engine
operates in one of the following ways:
n The engine runs too fast.
n The engine runs out of control.
Covering the opening will stop the air supply to the engine, so the engine will stop.

Either too much fuel for combustion or not enough fuel for combustion can be the cause of a problem
in the fuel system. Finding the source of the problem can be difficult, especially when you have smoke
that rises from the exhaust. Therefore, work is often done on the fuel system when the problem is really
with some other part of the engine.When noticeable smoke rises from the exhaust, this problem can be
caused by a damaged unit injector. This unusual smoke can also be caused by one or more of the
reasons that follow:
¡ not enough air for good combustion
¡ an overload at high altitude
¡ oil leakage into combustion chamber
¡ altitude
¡ air inlet and exhaust leaks
¡ not enough compression
Note: Refer to Troubleshooting for more information on the fuel system.

Low temperature at an exhaust manifold port is an indication of no fuel to the cylinder. This can
possibly be an indication of an injector with a defect. An extra high temperature at an exhaust manifold
port can be an indication of too much fuel to the cylinder. High temperatures may also be caused by an
injector with a defect. The difference between cylinders should be no more than 70 °C (158 °F).Refer
to Testing And Adjusting, "Exhaust Temperature - Test" for the procedure for checking the
temperatures in the exhaust manifold port.

155
Air in Fuel - Test
This procedure checks for air in the fuel. This procedure also assists in finding the source of the air.
1. Examine the fuel system for leaks. Ensure that the fuel line fittings are properly tightened. Check the
fuel level in the fuel tank. Air can enter the fuel system on the suction side between the fuel transfer
pump and the fuel tank.
2. Install a 2P-8278 Tube As (SIGHT GAUGE) in the fuel return line. When possible, install the sight
gauge in a straight section of the fuel line that is at least 304.8 mm (12 inches) long. Do not install
the sight gauge near the following devices that create turbulence:
n Elbows
n Relief valves
n Check valves
Observe the fuel flow during engine cranking. Look for air bubbles in the fuel. If there is no fuel in
the sight gauge, prime the fuel system. Refer to Testing and Adjusting, "Fuel System - Prime" for
more information. If the engine starts, check for air in the fuel at varying engine speeds. When
possible, operate the engine under the conditions which have been suspect of air in the fuel.
2P-8278 Tube As (SIGHT GAUGE), (1) A steady stream of small bubbles with a diameter of approximately 1.60 mm
(0.063 inch) is an acceptable amount of air in the fuel. (2) Bubbles with a diameter of approximately 6.35 mm (0.250
inch) are also acceptable if there is two seconds to three seconds intervals between bubbles. (3) Excessive air bubbles in
the fuel are not acceptable.
3. If excessive air is seen in the sight gauge in the fuel return line, install a second sight gauge at the
inlet to the fuel transfer pump. If a second sight gauge is not available, move the sight gauge from
the fuel return line and install the sight gauge at the inlet to the fuel transfer pump. Observe the fuel
flow during engine cranking. Look for air bubbles in the fuel. If the engine starts, check for air in the
fuel at varying engine speeds.
If excessive air is not seen at the inlet to the fuel transfer pump, the air is entering the system after
the fuel transfer pump. Proceed to Step 6.
If excessive air is seen at the inlet to the fuel transfer pump, air is entering through the suction side of
the fuel system.
To avoid personal injury, always wear eye and face protection when
using pressurized air.

156
NOTICE
To avoid damage, do not use more than 55 kPa (8 psi) to pressurize the
fuel tank.
4. Pressurize the fuel tank to 35 kPa (5 psi). Do not use more than 55 kPa (8 psi) in order to avoid
damage to the fuel tank. Check for leaks in the fuel lines between the fuel tank and the fuel transfer
pump. Repair any leaks that are found. Check the fuel pressure in order to ensure that the fuel
transfer pump is operating properly. For information about checking the fuel pressure, see Testing
and Adjusting, "Fuel System Pressure - Test".
5. If the source of the air is not found, disconnect the supply line from the fuel tank and connect an
external fuel supply to the inlet of the fuel transfer pump. If this corrects the problem, repair the fuel
tank or the stand pipe in the fuel tank.
6. If the injector sleeve is worn or damaged, combustion gases may be leaking into the fuel system.
Also, if the O-rings on the injector sleeves are worn, missing, or damaged, combustion gases may
leak into the fuel system.

157
Engine Speed - Check

Table 1
Tools Needed
Part Number Part Name QTY
9U-7400 Multitach Tool Gp 1
or
1U-6602 Photo-Tachometer 1
9U-7400 Multitach Tool Gp
The 9U-7400 Multitach Tool Gp can measure engine speed from a magnetic pickup on the flywheel
housing. The 9U-7400 Multitach Tool Group also has the ability to measure engine speed from visual
engine parts in rotation.
The Operating Instructions, NEHS0605 are included with the 9U-7400 Multitach Tool Group and these
operating instructions contain instructions for the test procedure.
The 1U-6602 Photo-Tachometer is a phototach for general use. The 1U-6602 Photo-Tachometer is a
phototach, so this tachometer only registers basic input frequency on any visible, rotating part. The
basic input frequency equals one revolution per piece of reflective tape. The 1U-6602 Photo-
Tachometer does not replace the 9U-7400 Multitach Tool Group.

158
Finding Top Center Position for No. 1 Piston

Table 1
Tools Needed
Part Number Part Name Quantity
8T-0292 Bolt 1
Timing Hole location (Typical Example), (1) Timing hole plug (not shown) (2) Flywheel housing
Right Side Location, (1) Timing hole plug (2) Flywheel housing
Left Side Location, (1) Timing hole plug (2) Flywheel housing
Note: The timing hole plug (1) can be in one of two positions:
¡ The right front face of the flywheel housing (Illustration 2)
¡ the left front face of the flywheel housing (Illustration 3)
1. Remove timing hole plug (1) that is located on the front side of flywheel housing (2) .
Note: Turn the engine with the four large bolts on the front of the crankshaft. Do not use the eight
small bolts on the front of the crankshaft pulley.

159
2. Put the timing bolt through the timing hole in the flywheel housing (2) .
Turn the flywheel in the direction of normal engine rotation. Turn the flywheel until the timing bolt
engages with the hole in the flywheel.
Note: If the flywheel is turned beyond the point of engagement, the flywheel must be turned in the
direction that is opposite of normal engine rotation. Turn the flywheel by approximately 30 degrees.
Then turn the flywheel in the direction of normal engine rotation until the timing bolt engages with
the threaded hole. When the No. 1 piston is at the top center position, this procedure will remove the
play from the gears.
3. Remove the valve cover.
The inlet valves and the exhaust valve for the No. 1 cylinder are fully closed under two conditions:
n No. 1 piston is on the compression stroke.
n The rocker arms can be moved by hand.
If the rocker arms cannot be moved and the valves are slightly open, the No. 1 piston is on the
exhaust stroke.
Note: Refer to Testing And Adjusting, "Crankshaft Positions for Valve Lash Setting".
4. After the timing bolt has been installed in the flywheel, complete these procedures, as required:
a. Find the cylinders that need to be checked for the stroke position of the crankshaft.
b. Find the cylinders that need to be adjusted for the stroke position of the crankshaft.
5. When the actual stroke position is identified and the other stroke position is needed, remove the
timing bolt from the flywheel.
6. Turn the flywheel by 360 degrees in the direction of normal engine rotation.
Note: The timing bolt hole is used for the following procedures only:
¡ adjustment of the fuel timing dimension
¡ valve lash setting

160
Fuel Quality - Test
This test checks for problems regarding fuel quality. Refer to Diesel Fuels and Your Engine,
SEBD0717 for additional details.
Use the following procedure to test for problems regarding fuel quality:
1. Determine if water and/or contaminants are present in the fuel. Check the water separator (if
equipped). If a water separator is not present, proceed to Step 2. Drain the water separator, if
necessary. A full fuel tank minimizes the potential for overnight condensation.
Note: A water separator can appear to be full of fuel when the water separator is actually full of
water.
2. Determine if contaminants are present in the fuel. Remove a sample of fuel from the bottom of the
fuel tank. Visually inspect the fuel sample for contaminants. The color of the fuel is not necessarily
an indication of fuel quality. However, fuel that is black, brown, and/or similar to sludge can be an
indication of the growth of bacteria or oil contamination. In cold temperatures, cloudy fuel indicates
that the fuel may not be suitable for operating conditions. The following methods can be used to
prevent wax from clogging the fuel filter:
n Fuel heaters
n Blending fuel with additives
n Utilizing fuel with a low cloud point such as kerosene
Refer to Operation and Maintenance Manual, SEBU6251, "Caterpillar Commercial Diesel Engine
Fluids Recommendations", "Fuel Recommendations" for more information.
3. Check fuel API with a 9U-7840 Fluid and Fuel Calibration Gp for low power complaints. The
acceptable range of the fuel API is 30 to 45 when the API is measured at 15 °C (60 °F), but there is a
significant difference in energy within this range. Refer to Tool Operating Manual, NEHS0607 for
API correction factors when a low power problem is present and API is high.
Note: A correction factor that is greater than "1" may be the cause of low power and/or poor fuel
consumption.
4. If fuel quality is still suspected as a possible cause to problems regarding engine performance,
disconnect the fuel inlet line, and temporarily operate the engine from a separate source of fuel that is
known to be good. This will determine if the problem is caused by fuel quality. If fuel quality is
determined to be the problem, drain the fuel system and replace the fuel filters. Engine performance
can be affected by the following characteristics:
n Cetane number of the fuel
n Air in the fuel
n Other fuel characteristics

161
Fuel Ratio Control - Adjust

Table 1
Required Tools
128-8822 (1) Fuel System and Governor Tool Gp 1
(1) This Tool Group replaces the former 1U-6680 Fuel System and Governor Tool Gp .
This is an on engine test that is used to determine if the Fuel Ratio Control (FRC) is set properly. If the
FRC is set properly, no additional procedures will be required. If the FRC is set incorrectly, the
governor must be removed and the governor must be adjusted. The governor is adjusted according to
the procedures that are covered in Service Manual, SENR6454, " 3114, 3116, and 3126 Engine
Governors".
To determine the Fuel Ratio Control setting, complete the following steps:
1. Install the 128-8822 Fuel System and Governor Tool Gp. Refer to Systems Operation Testing and
Adjusting, "Unit Injector - Adjust" for the instructions on the installation of the 128-8822 Fuel
System and Governor Tool Gp .
Note: A digital indicator is recommended for the following test procedures.
Typical Governor, (1) Fuel Ratio Control (FRC) (2) Port (boost line) (3) Low idle screw (4) High idle screw
2. Disconnect the boost line from port (2) for the boost line. Apply air to the port, once the boost line is
disconnected.
Note: A regulated air supply of 140 to 210 kPa (20 to 30 psi) MUST be used in order to avoid
damage to the FRC.
3. While the engine is operating at low idle, quickly actuate the throttle to the high idle position.
4. Record the maximum reading that is observed on the digital indicator as the engine's speed increases
to high idle. This reading is the dynamic maximum fuel setting value. Repeat the procedure several
times and average the values.
Note: Static engine rack values and dynamic engine rack values may vary due to the following
items: the method of fuel setting calibration and the differences in governor settings. When the "on
engine" fuel setting is adjusted statically, a calibration pin is used as the reference dimension to the
governor. This pin is used on all engines regardless of governor settings. This common calibration
point and the different settings in the governor will cause the static engine rack values and dynamic
engine rack values to differ. This difference depends on the part number of the governor since the
load stop setting can have an adjustment between 9.0 mm (0.35 inch) and 10.4 mm (0.41 inch).
When the pin is in place, the governor travel is restricted. When the pin is removed and the engine is
running, the governor is unrestricted. This procedure allows a higher dynamic engine rack value. this
value is higher than one that can be obtained statically with the calibration pin in place.
5. Disconnect the air pressure from the FRC and vent the FRC to the atmosphere.
6. While the engine is operating at low idle, quickly actuate the throttle to the high idle position.
7. Record the maximum reading that is observed on the digital indicator as the engine's speed increases

162
to high idle. This reading is the dynamic maximum fuel setting value. Repeat the procedure several
times and average the values.
8. Subtract the FRC setting value that was obtained in Step 7 from the dynamic maximum fuel setting
value that was obtained in Step 4. This difference is the "on engine" FRC delta.
9. Use the following calculation in order to determine the governor's FRC delta. Subtract the
specification for the FUEL RATIO CONTROL from the specification for the LOAD STOP. This
difference is the governor's FRC delta.
Note: Refer to Technical Marketing Information (TMI)"Governor Bench Performance Data" for the
correct specifications for the FUEL RATIO CONTROL and the LOAD STOP.
10. If the on engine FRC delta is within ± .20 mm ( ± 0.008 inch) of the specifications for the governor's
FRC delta, then the FRC is set properly.
11. If the on engine FRC delta is out of tolerance, the governor will need to be removed from the engine
and the governor will need to be set to specifications. Use the 1U-7326 Governor Calibration Bench
in order to set the governor.
Note: Refer to Service Manual, SENR6454, " 3114, 3116, and 3126 Engine Governors " for the
instructions on the 1U-7326 Governor Calibration Bench .

163
Fuel System - Prime
Fuel Priming Pump (Typical Example), (1) Fuel priming pump (2) Purge valve
The fuel priming pump (1) is located on the top of the water separator.
1. Loosen the air purge valve (2) .
2. Push down on the top of the fuel priming pump plunger and release the fuel priming pump plunger in
order to operate the fuel priming pump. Operate the fuel priming pump plunger in order to fill the
new filter element. Continue to pump until increased resistance is felt or fuel starts to flow from the
air purge valve. This resistance will indicate that the filter element is full of fuel.
3. Tighten the air purge valve.
4. Start the engine. If the engine will not start, further purging of air is necessary. If the engine starts but
the engine continues to misfire, further purging of air is necessary. If the engine starts but the engine
continues to emit smoke, further purging of air is necessary.
5. If the engine starts but the engine runs rough, continue to run the engine at low idle. Continue to run
the engine at low idle until the engine runs smoothly.

164
Fuel System Pressure - Test

Table 1
Tools Needed
1U-5470 Engine Pressure Group 1
3Y-2888 Connector 1
3J-1907 O-Ring Seal 1
Note: The 5P-2720 Probe Adapter (Self-Sealing) and the 164-2192 Probe Adapter Gp may be used
with the tools needed. These tools will be used in order to allow the installation of pressure probes in
the future.
1U-5470 Engine Pressure Group
The 1U-5470 Engine Pressure Group can be used in order to check the fuel pressure of the engine. The
engine pressure group includes Special Instruction, SEHS8907, "Using the 1U-5470 Engine Pressure
Group ". This instruction provides information about the usage of the group.
Fuel Return Line, (1) Cylinder head (2) Pressure regulating orifice (3) Tube assembly (fuel return) (4) Check valve
assembly (5) Pressure relief valve (6) Fuel outlet port (7) Fuel gallery
The typical fuel pressure to fuel gallery (7) that is internal to cylinder head (1) can vary. At rated rpm
and load condition, the fuel pressure to the fuel gallery should be 200 to 400 kPa (29 to 58 psi). At low
idle, pressure regulating orifice (2) in tube assembly (3) maintains a minimum fuel pressure of 50 kPa
(7.3 psi) to the injectors. Check valve (4) prevents fuel from leaving the cylinder head fuel gallery.

165
, (8) Fuel filter base (9) Fuel pressure tap (unfiltered side) (10) Fuel pressure tap (filtered side)
To check the unfiltered fuel pressure, remove the plug from fuel pressure tap (9) from fuel filter base
(8). Install the following tools to the fuel pressure tap: 3J-1907 O-Ring Seal, 3Y-2888 Connector and
1U-5470 Engine Pressure Group. Once the tools are installed, operate the engine in order to obtain the
fuel pressure reading.
To check the fuel pressure of the fuel gallery, remove the plug from fuel pressure tap (10). Install the
following tools to the fuel pressure tap: 3J-1907 O-Ring Seal, 3Y-2888 Connector and 1U-5470
Engine Pressure Group. Once the tools are installed, operate the engine in order to obtain the fuel
pressure reading.
Note: Make sure that the fuel filter is clean before checking the fuel pressure. A fuel filter that is
restricted will cause the fuel pressure at tap (10) to be lower than the fuel pressure at tap (9) .

166
Fuel Timing Dimension - Adjust
Refer to Table 1 for the components of the 128-8822 Fuel System and Governor Tool Group that are
required to check or adjust the fuel timing dimension.
Table 1
Tools Needed
Part Number Description QTY
1U-8869 Dial Indicator (Digital) 1
9U-7269 Timing Gauge Block 1
123-4940 Magnetic Base Group 1
9U-6272 Nylon Screw 1
128-8824 Wrench (16 mm and 18 mm) 1
128-8825 Wrench (17 mm and 19 mm) 1
Contact Point (
9U-7274 1
85 mm (3.35 inch) long)
Refer to Tool Operating Manual, NEHS0610 for instructions on checking or adjusting the fuel timing
dimension.
Note: The Tool Operating Manual, NEHS0610 is included with the 128-8822 Fuel System and
Governor Tool Group .
The 128-8822 Fuel System and Governor Tool Group replaces the former 9U-7305 Fuel System and
Governor Tool Group and the former 1U-6680 Fuel System and Governor Tool Group. The new tools
are available individually in order to update the former groups at a considerable cost savings. The new
tools offer the advantage of tooling that is simplified in order to provide more accurate adjustments in
less time. Refer to Table 2 in order to update the former tool groups with the tools that are required to
complete the fuel timing procedure.
Table 2
Tools That Are Required To Update Former Tool Groups
123-4940 (1) Magnetic Base Group 1
1U-8869 (2) Dial Indicator (Digital) 1
9U-7269 (2) Timing Gauge Block 1
128-8824 (1) Wrench (16 mm and 18 mm) 1
128-8825 (1) Wrench (17 mm and 19 mm) 1
128-8828 (1) Foam Insert Group 1
NEEG2688 (1) Decal 1
NEHS0610 (1) "Tool Operating Manual" 1
(1) Required for the 9U-7305 Fuel System and Governor Tool Group and for the 1U-6680 Fuel System and Governor Tool
Group
(2) Required for the 1U-6680 Fuel System and Governor Tool Group

167
Gear Group (Front) - Time

Front gear group ( 3114 Engine), (1) Camshaft gear (2) Timing marks (3) Camshaft idler gear (4) Crankshaft gear (5) Idler
gear (6) Oil pump gear
Front gear group ( 3116 and 3126 Engines), (1) Camshaft gear (2) Timing marks (3) Camshaft idler gear (4) Crankshaft
gear (5) Idler gear (6) Oil pump gear
The basis for the correct fuel injection timing and the valve mechanism operation is determined by the
alignment of the timing for the front gear group. Align timing marks (2) on camshaft idler gear (3) with
the holes on camshaft gear (1) and crankshaft gear (4). This alignment is required in order to provide
the correct relationship between the piston movement and the valve movement.

168

Table 1
Valve Lash Setting For 3114, 3116, and 3126
Valves Dimension of Gauge
Inlet 0.38 ± 0.08 mm (0.015 ± 0.003 inch)
Exhaust 0.64 ± 0.08 mm (0.025 ± 0.003 inch)
Table 2
3114 Crankshaft Positions for Valve Lash Setting
The rotation of the crankshaft is viewed from the flywheel end.
Rotation Counterclockwise
Check and Adjust with No. 1 Piston On this Stroke. (1) Top Center Compression Stroke (2)
Injectors 3-4
Inlet Valves 1-2
Exhaust Valves 1-3
Check and Adjust with No. 1 Piston On this Stroke. Top Center Exhaust Stroke
Injectors 1-2
Inlet Valves 3-4
Exhaust Valves 2-4
Firing Order 1-3-4-2
(1) Refer to Testing and Adjusting, "Finding Top Center Position for No. 1 Piston" for more information.
(2) Put No. 1 Piston at the top center position. After the top center position is found and the adjustments have been made
for the correct cylinders, remove the top center bolt. Turn the flywheel in a counterclockwise direction by 360 degrees.
This puts No. 1 Piston at the top center position on the other stroke. Install the top center bolt in the flywheel and
complete the adjustments for the cylinders that remain.
Cylinder and Valve Location for the 3114 Engine, (A) Exhaust valves (B) Inlet valves
Note: Check the crankshaft position with the No. 1 piston at the top center position. Refer to Testing
and Adjusting, "Finding Top Center Position for No. 1 Piston" for more information.
Note: Refer to Testing and Adjusting, "Engine Valve Lash - Inspect/Adjust" for more information in
order to adjust the valves.

169
Table 3
3116 and 3126 Crankshaft Positions for Valve Lash Setting
The rotation of the crankshaft is viewed from the flywheel end.
Rotation Counterclockwise
Check and Adjust with No. 1 Piston On this Stroke. (1) Top Center Compression Stroke (2)
Injectors 3-5-6
Inlet Valves 1-2-4
Exhaust Valves 1-3-5
Check and Adjust with No. 1 Piston On this Stroke. Top Center Exhaust Stroke
Injectors 1-2-4
Inlet Valves 3-5-6
Exhaust Valves 2-4-6
Firing Order 1-5-3-6-2-4
(1) Refer to Testing and Adjusting, "Finding Top Center Position for No. 1 Piston" for more information.
(2) Put No. 1 Piston at the top center position. After the top center position is found and the adjustments have been made
for the correct cylinders, remove the top center bolt. Turn the flywheel in a counterclockwise direction by 360 degrees.
This puts No. 1 Piston at the top center position on the other stroke. Install the top center bolt in the flywheel and
complete the adjustments for the cylinders that remain.
Cylinder and Valve Location for the 3116 and 3126 Engines, (A) Exhaust valves (B) Inlet valves
Note: Check the crankshaft position with the No. 1 piston at the top center position. Refer to Testing
and Adjusting, "Finding Top Center Position for No. 1 Piston" for more information.
Note: Refer to Testing and Adjusting, "Engine Valve Lash - Inspect/Adjust" for more information in
order to adjust the valves.

170
Governor - Adjust
The only adjustments that can be made to the governor on the engine are the final low idle setting and
high idle setting. Refer to Testing and Adjusting, "Fuel Ratio Control - Adjust" for the procedure in
order to check the settings for the fuel ratio control (FRC).
Note: All other adjustments for the governor (including the FRC) are performed while the governor is
removed from the engine and installed on the 1U-7326 Governor Calibration Bench. Refer to the
Governor Service Manual, SENR6454 for the procedures and the tools that are required to bench test
the governor and adjust the governor.
Note: The following adjustments are performed while the governor is mounted to the engine: unit
injector, fuel timing dimension and unit injector synchronization. These adjustments are located under
the valve cover. Refer to the following topics for more information: Testing and Adjusting, "Unit
Injector - Adjust", Testing and Adjusting, "Fuel Timing Dimension - Adjust" and Testing and
Adjusting, "Unit Injector Synchronization - Adjust".
Typical Example Of A Governor, (1) Fuel Ratio Control (FRC) (2) Boost line port (3) Low idle screw (4) High idle screw
Note: Refer to the engine information plate or Technical Marketing Information (TMI)"Governor
Bench Performance Data" for the correct low idle speed, high idle speed and the fuel setting.
Low Idle Adjustment

The low idle screw (3) is initially set on the 1U-7326 Governor Calibration Bench. Final low idle
adjustment is set while the governor is mounted on the engine. When the engine is idling, loosen the
locknut and adjust screw (3) to the specified low idle speed. Tighten the locknut and then recheck the
low idle setting.Note: Older governors require a 1U-6672 Rack Adjusting Wrench in order to adjust the
low idle screw. Newer governors require a 1U-7563 Hex Key Wrench (4 mm) and a 6V-9093 Wrench
(13 mm) in order to adjust the low idle screw.

The high idle screw (4) is initially set on the 1U-7326 Governor Calibration Bench. Final high idle
adjustment is set while the governor is mounted on the engine. When the engine is at full throttle and
no load, loosen the locknut and adjust screw (4) to the specified high idle speed. Tighten the locknut
and then recheck the high idle setting.

171
, (1) Governor shaft (2) Governor linkage (3) Linkage for plunger (4) Plunger for solenoid (5) Solenoid (6) Bolts
1. Align the linkage for plunger (3) with governor linkage (2) .
2. Tighten bolts (6) .
3. Place the plunger for solenoid (4) in the full energized position.
4. Adjust the linkage for plunger (3) to 4 ± 2 mm (0.2 ± 0.08 inch) past high idle.
5. Release the plunger for solenoid (4) and manually move plunger (4) through the entire stroke of
plunger.
6. Check for binding in the movement. Make adjustments to bolts (6) if binding occurs.

172
Unit Injector - Adjust
Refer to Table 1 for the components of the 128-8822 Fuel System and Governor Tool Group that are
required to check or adjust the unit injector.
Table 1
Tools Needed
9U-5120 Spanner Wrench 1
1U-8869 Dial Indicator (Digital) 1
9U-7282 Indicator Fixture Group 1
9U-6272 Nylon Screw 1
130-2711 Holding Tool 1
136-4149 Governor Pliers 1
1U-7299 Rack Adjusting Wrench 1
1U-7300 Hex Wrench 1
1U-6673 Wrench 1
128-8827 Pin 1
Refer to Tool Operating Manual, NEHS0610 for instructions on checking or adjusting the unit injector.
Note: The Tool Operating Manual, NEHS0610 is included with the 128-8822 Fuel System and
Governor Tool Group .
The 128-8822 Fuel System and Governor Tool Group replaces the former 9U-7305 Fuel System and
Governor Tool Group and the former 1U-6680 Fuel System and Governor Tool Group. The new tools
are available individually in order to update the former groups at a considerable cost savings. The new
tools offer the advantage of tooling that is simplified in order to provide more accurate adjustments in
less time. Refer to Table 2 in order to update the former tool groups with the new tools that are required
to complete the checking or adjustment procedures for the unit injector.
Table 2
Tools That Are Required To Update Former Tool Groups
128-8827 (1) Pin 1
1U-8869 (2) Dial Indicator (Digital) 1
130-2711 (3) Fuel Setting Holding Tool 1
1U-7299 (1) Rack Adjusting Wrench 1
1U-7300 (1) Hex Wrench 1
128-8828 (1) Foam Insert Group 1
NEEG2688 (1) Decal 1
NEHS0610 (1) Tool Operating Manual 1
(1) Required for the 9U-7305 Fuel System and Governor Tool Group and for the 1U-6680 Fuel System and Governor Tool
Group

173
Unit Injector Synchronization - Adjust
Injector synchronization is the setting of all fuel injector racks to a reference position so that each
injector gives the same amount of fuel to each cylinder. This is done by setting each fuel injector rack
to the same position while the control linkage is in a fixed position.
Always synchronize an injector after the injector has been removed, replaced, or reused. If the No. 1
injector is reused or replaced, synchronization of all injectors must be checked and adjusted.
This entire procedure should be read and understood before you begin any work on the engine.
Note: The procedure that is described in this article is a new procedure that does not involve the use of
gauge blocks in order to adjust the unit injector synchronization. The earlier procedure that utilizes the
gauge blocks may still be used. However, the new procedure will provide the most accurate results.
Note: The following list includes additional parts that need to be supplied in order to perform the new
procedure: 9U-7282 Indicator Fixture Group, 8T-4177 Bolt, 9U-7263 Indicator Contact Point and 1U-
8869 Dial Indicator .
Refer to Table 1 for the tools that are required to check or adjust the unit injector synchronization.
Many of the tools that are required can be found in the 223-2454 Fuel System and Governor Tool Gp.
Table 1
Required Tools (1)
Tool Part Number Description QTY
A 128-8823 Long Nose Pliers 1
B 9U-7282 Indicator Fixture Group 2
C 8T-4177 Bolt 2
D 9U-7263 Indicator Contact Point 2
E 1U-8869 Dial Indicator (Digital) 2
F 1U-6673 Wrench (Fuel Ratio Control) 1
(1) Actual tooling may vary depending on the individual engine arrangement.
The following procedure may be used to synchronize the unit injectors and the following procedure
may be used to adjust the unit injectors.
1. Stop the engine and turn the electrical system to the OFF position.
2. Remove the fuel shutoff solenoid.
Note: If the fuel shutoff solenoid is inaccessible, the following steps may be followed.
a. Turn the engine start switch to the ON position. Briefly engage the starter. Do not start the engine.
Return the engine start switch to the ON position. Do not turn the engine start switch to the OFF
position.
b. Turn the battery disconnect switch to the OFF position or disconnect the negative terminal of the
battery. This will leave the fuel shutoff solenoid in the OPEN position.
3. Remove the valve cover.

174
4. Remove bolts (1) that attach the valve mechanism cover base.
5. Attach Tooling (A) to the rail for the fuel (2) .
6. Install Tooling (B) in hole (3) for the valve mechanism cover base that is near the No. 1 cylinder.
Attach Tooling (D) to Tooling (E). Insert Tooling (E) into the hole in Tooling (B) .
Note: Orient face (4) on Tooling (B) parallel to the crankshaft.
7. Install the other Tooling (B) in hole (3) for the valve mechanism cover base that is near the No. 2
cylinder. Attach Tooling (D) to Tooling (E). Insert Tooling (E) into the hole in Tooling (B) .
Note: Orient face (5) on Tooling (B) parallel to the crankshaft.
8. When the engine is viewed from the flywheel end, rotate Tooling (A) in a counterclockwise
direction. You should feel resistance to a spring. Turn Tooling (A) past the start of the resistance of
the spring. Zero out Tooling (E) for both the injectors.
Note: Do not turn Tooling (A) all the way. This will lead to an inaccurate synchronization.
9. When the engine is viewed from the flywheel end, rotate Tooling (A) in a clockwise direction
through the entire range of motion. The readings on Tooling (E) should change as the position of
Tooling (A) is changed. Take a note of the values and of the difference in the values.
10. If the values are within a tolerance of 0.05 mm (0.0020 inch), no adjustment is required. If an
adjustment is required, install Tooling (F) on the locknut at the base of the unit injector.

175
11. Loosen the locknut with the outer rod (6) and adjust the injector with the inner rod (7). Tighten the
locknut when the adjustment is complete.
12. Repeat Step 8 through Step 11. Illustration 4 shows two unit injectors that have been properly
synchronized.
13. Once the first two injectors have been synchronized, synchronize the remaining injectors by
following the previous procedure. Remove Tooling (B) from the No. 2 cylinder and move to the No.
3 cylinder. Do not move Tooling (B) from the No. 1 cylinder. Always synchronize the injectors with
the first injector. The first injector is the reference point for all the injectors.
14. Once all the injectors have been synchronized, remove all the tooling from the engine. Install bolts
(1) that attach the air intake housing. Replace the valve cover and tighten the bolts that attach the
valve cover. Refer to Specifications, "Valve Mechanism Cover" for instructions.

176
Air Inlet and Exhaust System - Inspect

There will be a reduction in the performance of the engine if there is a restriction in the air inlet system
or the exhaust system.
Table 1
Tools Needed
Refer to Special Instruction, SEHS8907, "Using the 1U-5470 Engine Pressure Group " for the
instructions that are needed to use the 1U-5470 Engine Pressure Group .
1. Inspect the engine air cleaner inlet and ducting in order to ensure that the passageway is not blocked
or collapsed.
2. Inspect the engine air cleaner element. Replace a dirty engine air cleaner element with a clean engine
air cleaner element.
3. Check for dirt on the clean side of the engine air cleaner element. If dirt is observed, contaminants
are flowing past the engine air cleaner element and/or the seal for the engine air cleaner element.
Hot engine components can cause injury from burns. Before

performing maintenance on the engine, allow the engine and the
components to cool.
Making contact with a running engine can cause burns from hot parts
and can cause injury from rotating parts.
When working on an engine that is running, avoid contact with hot
parts and rotating parts.
4. Use the differential pressure gauge of the 1U-5470 Engine Pressure Test Group in order to measure
the restriction of the air inlet system.

177
, (1) Turbocharger (2) Air inlet piping (3) Test location (4) Air cleaner
a. Connect the vacuum port of the differential pressure gauge to test location (3). The test location
can be located anywhere along air inlet piping (2) after engine air cleaner (4) but before
turbocharger (1) .
b. Leave the pressure port of the differential pressure gauge open to the atmosphere.
c. Start the engine. Run the engine in the no-load condition at high idle.
d. Record the value and compare the result to the appropriate values that follow.
The air flow through a used engine air cleaner may have a restriction. The air flow through a plugged
engine air cleaner will be restricted to some magnitude. In either case, the restriction must not be more
than the following amount:
Maximum restriction ... 6.2 kPa (25 inch of H2O)
Exhaust Restriction
Back pressure is the difference in the pressure between the exhaust at the outlet elbow and the
atmospheric air.
Table 2
Tools Needed
Refer to Special Instruction, SEHS8907, "Using the 1U-5470 Engine Pressure Group " for the
instructions that are needed to use the 1U-5470 Engine Pressure Group.

178

components to cool.
Use the differential pressure gauge of the 1U-5470 Engine Pressure Group in order to measure back
pressure from the exhaust. Use the following procedure in order to measure back pressure from the
exhaust:
, (1) Turbocharger (5) Muffler (6) Test location (7) Exhaust piping
1. Connect the pressure port of the differential pressure gauge to test location (6). The test location can
be located anywhere along exhaust piping (7) after turbocharger (1) but before the muffler (5) .
2. Leave the vacuum port of the differential pressure gauge open to the atmosphere.
3. Start the engine. Run the engine in the no-load condition at high idle.
4. Record the value and compare the result to the value that follows.
Maximum back pressure from the exhaust must not be more than the following amount:
Standard Exhaust ... 6.7 kPa (27 inch of H2O)
Water Cooled Exhaust ... 10 kPa (40 inch of H2O)

179
Turbocharger - Inspect
Disconnect batteries before performance of any service work.

components to cool.
Personal injury can result from rotating and moving parts.

Stay clear of all rotating and moving parts.
Never attempt adjustments while the machine is moving or the engine is
running unless otherwise specified.
The machine must be parked on a level surface and the engine stopped.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.
Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop
Products Guide" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.
Before you begin inspection of the turbocharger, be sure that the inlet air restriction is within the
specifications for your engine. Be sure that the exhaust system restriction is within the specifications
for your engine. Refer to Systems Operation/Testing and Adjusting, "Air Inlet and Exhaust System -
Inspect".
The condition of the turbocharger will have definite effects on engine performance. Use the following
inspections and procedures to determine the condition of the turbocharger.
¡ Inspection of the Compressor and the Compressor Housing
¡ Inspection of the Turbine Wheel and the Turbine Housing
¡ Inspection of the Wastegate

180

Remove air piping from the compressor inlet.
1. Inspect the compressor wheel for damage from a foreign object. If there is damage, determine the
source of the foreign object. As required, clean the inlet system and repair the intake system. Replace
the turbocharger. If there is no damage, go to Step 3.
2. Clean the compressor wheel and clean the compressor housing if you find buildup of foreign
material. If there is no buildup of foreign material, go to Step 3.
3. Turn the rotating assembly by hand. While you turn the assembly, push the assembly sideways. The
assembly should turn freely. The compressor wheel should not rub the compressor housing. Replace
the turbocharger if the compressor wheel rubs the compressor wheel housing. If there is no rubbing
or scraping, go to Step 4.
4. Inspect the compressor and the compressor wheel housing for oil leakage. An oil leak from the
compressor may deposit oil in the aftercooler. Drain and clean the aftercooler if you find oil in the
aftercooler.
a. Check the oil level in the crankcase. If the oil level is too high, adjust the oil level.
b. Inspect the air cleaner element for restriction. If restriction is found, correct the problem.
c. Inspect the engine crankcase breather. Clean the engine crankcase breather or replace the engine
crankcase breather if the engine crankcase breather is plugged.
d. Remove the turbocharger oil drain line. Inspect the drain opening. Inspect the oil drain line.
Inspect the area between the bearings of the rotating assembly shaft. Look for oil sludge. Inspect
the oil drain hole for oil sludge. Inspect the oil drain line for oil sludge in the drain line. If
necessary, clean the rotating assembly shaft. If necessary, clean the oil drain hole. If necessary,
clean the oil drain line.
e. If Steps 4.a through 4.d did not reveal the source of the oil leakage, the turbocharger has internal
damage. Replace the turbocharger.

Remove the air piping from the turbine outlet casing.
1. Inspect the turbine for damage by a foreign object. If there is damage, determine the source of the
foreign object. Replace the turbocharger. If there is no damage, go to Step 2.
2. Inspect the turbine wheel for buildup of carbon and other foreign material. Inspect the turbine
housing for buildup of carbon and foreign material. Clean the turbine wheel and clean the turbine
housing if you find buildup of carbon or foreign material. If there is no buildup of carbon or foreign
material, go to Step 3.
3. Turn the rotating assembly by hand. While you turn the assembly, push the assembly sideways. The
assembly should turn freely. The turbine wheel should not rub the turbine wheel housing. Replace
the turbocharger if the turbine wheel rubs the turbine wheel housing. If there is no rubbing or
scraping, go to Step 4.
4. Inspect the turbine and the turbine wheel housing for oil leakage. Inspect the turbine and the turbine
wheel housing for oil coking. Some oil coking may be cleaned. Heavy oil coking may require
replacement of the turbocharger. If the oil is coming from the turbocharger center housing go to Step
4.a. Otherwise go to "Inspection of the Wastegate".
a. Remove the turbocharger oil drain line. Inspect the drain opening. Inspect the area between the
bearings of the rotating assembly shaft. Look for oil sludge. Inspect the oil drain hole for oil
sludge. Inspect the oil drain line for oil sludge. If necessary, clean the rotating assembly shaft. If
necessary, clean the drain opening. If necessary, clean the drain line.
b. If crankcase pressure is high, or if the oil drain is restricted, pressure in the center housing may be
greater than the pressure of the turbine housing. Oil flow may be forced in the wrong direction and
the oil may not drain. Check the crankcase pressure and correct any problems.
c. If the oil drain line is damaged, replace the oil drain line.
d. Check the routing of the oil drain line. Eliminate any sharp restrictive bends. Make sure that the oil
drain line is not too close to the engine exhaust manifold.
e. If Steps 4.a through 4.d did not reveal the source of the oil leakage, the turbocharger has internal
damage. Replace the turbocharger.

181

The wastegate controls the amount of exhaust gas that is allowed to bypass the turbine side of the
turbocharger. This valve then controls the rpm of the turbocharger.
, (1) Actuating rod (2) Canister (3) Line
When the engine operates in conditions of low boost (lug), a spring presses against a diaphragm in
canister (2). The actuating rod (1) will move and the wastegate will close. Then, the turbocharger can
operate at maximum performance.
When the boost pressure increases against the diaphragm in the canister (2), the wastegate will open.
The rpm of the turbocharger becomes limited. The rpm limitation occurs because a portion of the
exhaust gases bypass the turbine wheel of the turbocharger.
The following levels of boost pressure indicate a problem with the wastegate:
¡ too high at full load conditions
¡ too low at all lug conditions
Note: The housing assembly for the wastegate is preset at the factory and no adjustments can be made.
NOTICE
If the high idle rpm or the engine rating is higher than given in the
Technical Marketing Information (TMI) for the height above sea level
at which the engine is operated, there can be damage to engine or to
turbocharger parts. Damage will result when increased heat and/or
friction due to the higher engine output goes beyond the engine cooling
and lubrication system's abilities.
To check the operation of the wastegate valve, remove line (3) and slowly apply 200 kPa (29 psi) of air
to canister (2). DO NOT EXCEED 200 kPa (29 psi). The actuating lever should move more than 0.50
mm (0.020 inch) when the external supply of air is connected to line (3). If the actuating lever does not
move at least 0.50 mm (0.020 inch), replace the entire turbocharger or replace the housing assembly for
the turbine. The housing assembly or the turbine includes the wastegate.
The boost pressure controls the maximum rpm of the turbocharger, because the boost pressure controls
the position of the wastegate. The following factors also affect the maximum rpm of the turbocharger:
¡ the engine rating
¡ the horsepower demand on the engine
¡ the high idle rpm
¡ the height above sea level for engine operation
¡ inlet air restriction
¡ exhaust system restriction

182
Inlet Manifold Pressure - Test
The efficiency of an engine can be checked by making a comparison of the pressure in the inlet
manifold with the information given in the TMI (Technical Marketing Information). The information is
also listed on the Fuel Setting And Related Information Microfiche. This test is used when there is a
decrease of horsepower from the engine, yet there is no real sign of a problem with the engine.
The correct pressure for the inlet manifold is listed in the TMI (Technical Marketing Information). The
correct pressure is also on the Fuel Setting And Related Information Microfiche. Development of this
information is performed under the following conditions:
¡ 99 kPa (29.7 in Hg) dry barometric pressure
¡ 29 °C (85 °F) outside air temperature
¡ 35 API rated fuel
On a turbocharged, aftercooled engine, a change in the fuel rating will change the horsepower. A
change in the fuel rating will change the inlet manifold pressure. If the fuel is rated above 35 API, the
inlet manifold pressure can be less than the pressure given in the TMI (Technical Marketing
Information). The pressure will also be less than the pressure that is listed on the Fuel Setting And
Related Information Microfiche. If the fuel is rated below 35 API, the inlet manifold pressure can be
more than the pressure listed in the TMI (Technical Marketing Information). The pressure will also be
more than the pressure that is listed on the Fuel Setting And Related Information Microfiche.
Note: Ensure that the air inlet and the exhaust are not restricted when you are checking the inlet
manifold pressure.
Pressure test location on inlet manifold, (1) Plug
Table 1
Tools Needed
1U-5470 Engine Pressure Test Group 1
8J-7844 Adapter Fitting 1
3K-0360 O-Ring Seal 1
4M-5317 Reducing Bushing 1

183
1U-5470 Engine Pressure Test Group
Refer to Special Instruction, SEHS8907, "Using the 1U-5470 Engine Pressure Test Group " for the
instructions that are needed to use the 1U-5470 Engine Pressure Test Group .
Use the following procedure in order to measure the inlet manifold pressure:
1. Remove plug (1) from the inlet manifold.
2. Connect the following Tools to the inlet manifold at the pressure test location: 8J-7844 Adapter
Fitting, 3K-0360 O-Ring Seal, 4M-5317 Reducing Bushing and 1U-5470 Engine Pressure Test
Group .
3. Record the value.
4. Compare the value that was recorded in Step 3 to the pressure that is given in the TMI (Technical
Marketing Information). The correct pressure is also given in the Fuel Setting And Related
Information Microfiche.

184
Exhaust Temperature - Test

Table 1
Required Tools
Part Number Part Name Qty
164-3310 Infrared Thermometer 1
When the engine runs at low idle, the temperature of an exhaust manifold port can indicate the
condition of a fuel injection nozzle.
A low temperature indicates that no fuel is flowing to the cylinder. An inoperative fuel injection nozzle
or a problem with the fuel injection pump could cause this low temperature.
A very high temperature can indicate that too much fuel is flowing to the cylinder. A malfunctioning
fuel injection nozzle could cause this very high temperature.
Use the 164-3310 Infrared Thermometer to check exhaust temperature. The manual that comes with the
164-3310 Infrared Thermometer contains the complete operating and maintenance instructions.

185
Engine Crankcase Pressure (Blowby) - Test

Table 1
Tools Needed
285-0910 Multi-Tool Gp 1
285-0900 Blowby Tool Group 1
NETG5044 Software license 1
Damaged pistons or rings can cause too much pressure in the crankcase. This condition will cause the
engine to run rough. There will be more than the normal amount of fumes (blowby) rising from the
crankcase breather. The breather can then become restricted in a very short time, causing oil leakage at
gaskets and seals that would not normally have leakage. Blowby can also be caused by worn valve
guides or by a failed turbocharger seal.
285-0910 Multi-Tool Gp
The 285-0910 Multi-Tool Gp is used to check the amount of blowby.

186
Compression - Test
An engine that runs roughly can have a leak at the valves. An engine that runs roughly can also have
valves that need an adjustment. Remove the head and inspect the valves and valve seats. This is
necessary to find those small defects that would not normally cause problems. Repairs of these
problems are normally performed when you are reconditioning the engine.

187
Engine Valve Lash - Inspect/Adjust
To prevent possible injury, do not use the starter to turn the flywheel.
Hot engine components can cause burns. Allow additional time for the
engine to cool before measuring valve clearance.
Note: Valve lash is measured between the rocker arm and the valve. All measurements and adjustments
must be made with the engine stopped and the valves FULLY CLOSED.
Valve Lash Check

An adjustment is NOT NECESSARY if the measurement of the valve lash is in the acceptable range in
Table 1.
Table 1
Valve Lash Check (Stopped Engine)
Inlet 0.30 to 0.46 mm (0.012 to 0.018 inch)
Exhaust 0.56 to 0.72 mm (0.022 to 0.028 inch)
If the measurement is not within this range, an adjustment is necessary. Refer to "Valve Lash
Adjustment" for the proper procedure.

Table 2
Valve Lash Setting (Stopped Engine)
Inlet 0.38 mm (0.015 inch)
Exhaust 0.64 mm (0.025 inch)

188
Use the following procedure to adjust the valve lash:
Valve Adjustment (Typical Example), (1) Valve (2) Rocker arm (3) Adjustment locknut (4) Adjustment screw
1. Put the No. 1 piston at the top center position on the compression stroke. Refer to Testing and
Adjusting, "Finding Top Center Position for No. 1 Piston".
2. With the No. 1 piston at the top center position of the compression stroke, an adjustment can be
made to the valves. Refer to Testing and Adjusting, "Gear Group (Front) - Time" for the information
that is required in order to adjust the valves.
Note: Before any actual adjustment is made, lightly tap the rocker arm at the top of the adjustment
screw with a soft mallet. This will ensure that the lifter roller seats against the camshaft's base circle.
3. Loosen adjustment locknut (3) .
4. If there is not enough clearance in order to insert the feeler gauge between rocker arm (2) and valve
(1), turn adjustment screw (4) counterclockwise in order to increase the clearance.
5. Place the appropriate feeler gauge between rocker arm (2) and the valve (1). Then, turn the
adjustment screw in a clockwise direction. Slide the feeler gauge between the rocker arm and the
valve. Continue turning the adjustment screw until a slight drag is felt on the feeler gauge. Remove
the feeler gauge.
6. Tighten adjustment locknut (3) to a torque of 25 ± 7 N·m (18± 5 lb ft). Do not allow the adjustment
screw to turn while you are tightening the adjustment locknut. Recheck the valve lash after
tightening the adjustment locknut.
7. Remove the timing bolt and turn the flywheel by 360 degrees in the direction of engine rotation. This
will put the No. 6 piston at the top center position on the compression stroke. Install the timing bolt
in the flywheel.
8. Adjust the valve lash on the remaining valves. Refer to Testing and Adjusting, "Gear Group (Front) -
Time" for the information that is required in order to adjust the valves.
9. Repeat Step 3 through Step 6 for these valve adjustments.
10. Remove the timing bolt from the flywheel after all adjustments to the valve lash have been made.
Reinstall the timing cover.
Refer to Testing and Adjusting, "Unit Injector - Adjust".

189
Engine Oil Pressure - Test

Work carefully around an engine that is running. Engine parts that are
hot, or parts that are moving, can cause personal injury.
NOTICE
NOTICE
containing fluids.
Table 1
Tools Needed
1U-5470 Engine Pressure Test Group 1
1U-5470 Engine Pressure Test Group
The 1U-5470 Engine Pressure Test Group measures the oil pressure in the system. This engine tool
group can read the oil pressure inside the oil gallery.
190
Note: Refer to Special Instruction, SEHS8907, "Using the 1U-5470 Engine Pressure Test Group " for
more information.
Oil Pressure Test Location, (1) Oil gallery plug
1. Remove oil gallery plug (1) from the side of the cylinder block.
2. Install the following Tools into the port in the left side of the engine: 1U-5470 Engine Pressure Test
Group, 8J-7844 Adapter Fitting, 3K-0360 O-Ring Seal and 4M-5317 Reducing Bushing .
3. Start the engine. Run the engine with SAE 10W40 oil. Refer to Operation and Maintenance Manual,
"Engine Oil" for the recommendations of engine oil.
4. Record the value of the engine oil pressure when the engine is at operating temperature and operating
under full load.
The minimum engine oil pressure should be approximately 250 kPa (36 psi). Minimum engine oil
pressure at low idle rpm (750 to 850 rpm) should be approximately 100 kPa (15 psi). Maximum
engine oil pressure should be approximately 600 kPa (88 psi) when the engine is at operating
temperature and operating under full load condition.
5. Compare the recorded engine oil pressure with the oil pressure indicators on the instrument panel.
6. An engine oil pressure indicator that has a defect or an engine oil pressure sensor that has a defect
can give a false indication of a low oil pressure or a high oil pressure. If there is a notable difference
between the engine oil pressure readings make necessary repairs.
7. If you have determined that the engine oil pressure is low, then go to "Reasons For Low Engine Oil
Pressure".
8. If you have determined that the engine oil pressure is high, refer to "Reason for High Engine Oil
Pressure".
NOTICE
NOTICE
containing fluids.

191
Check the engine oil level in the crankcase. The oil level can possibly be too far below the oil pump
supply tube. This will cause the oil pump not to have the ability to supply enough lubrication to the
engine components. If the engine oil level is low add engine oil in order to obtain the correct engine oil
level. Refer to Operation and Maintenance Manual, "Engine Oil" for the recommendations of engine
oil.
Check the following problems that may occur to the engine oil pump.
1. Air leakage in the supply side of the oil pump will also cause cavitation and loss of oil pressure.
Check the supply side of the oil pump and make necessary repairs. For information on the repair of
the engine oil pump, refer to Disassembly and Assembly, "Engine Oil Pump - Remove".
2. Oil pump gears that have too much wear will cause a reduction in oil pressure. Repair the engine oil
pump. For information on the repair of the engine oil pump, refer to Disassembly and Assembly,
"Engine Oil Pump - Remove".
The inlet screen of the oil pickup tube for the engine oil pump can have a restriction. This restriction
will cause cavitation and a loss of engine oil pressure. Check the inlet screen on the oil pickup tube and
remove any material that may be restricting engine oil flow. Low engine oil pressure may also be the
result of the oil pickup tube that is drawing in air. Check the joints of the oil pickup tube for cracks or a
damaged O-ring seal. Remove the engine oil pan in order to gain access to the oil pickup tube and the
oil screen. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove and Install" for more
information.
Engine oil that is contaminated with fuel or coolant will cause low engine oil pressure. High engine oil
level in the crankcase can be an indication of contamination. Determine the reason for contamination of
the engine oil and make the necessary repairs. Replace the engine oil with the approved grade of engine
oil. Refer to Operation and Maintenance Manual, "Engine Oil" for the recommendations of engine oil.
NOTICE
Caterpillar oil filters are built to Caterpillar specifications. Use of an
oil filter not recommended by Caterpillar could result in severe engine
damage to the engine bearings, crankshaft, etc., as a result of the larger
waste particles from unfiltered oil entering the engine lubricating
system. Only use oil filters recommended by Caterpillar.
If the engine oil bypass valves are held in the open position, a reduction in the oil pressure can be the
result. This may be due to debris in the engine oil. If the engine oil bypass valves are stuck in the open
position, remove each engine oil bypass valve and clean each bypass valve in order to correct this
problem. You must also clean each bypass valve bore. Install new engine oil filters. New engine oil
filters will prevent more debris from causing this problem. For information on the repair of the engine
oil bypass valves, refer to Disassembly and Assembly, "Engine Oil Filter Base - Disassemble".
An oil line or an oil passage that is open, broken, or disconnected will cause low engine oil pressure.
192
An open lubrication system could be caused by a piston cooling jet that is missing or damaged.
Determine the reason for an open lubrication system of the engine and make the necessary repairs.
Piston Cooling Jets
The piston cooling jets direct engine oil toward the bottom of the piston in order to cool the piston. This
also provides lubrication for the piston pin. Breakage, a restriction or incorrect installation of the piston
cooling jets will cause seizure of the piston.
Excessive clearance at engine bearings will cause low engine oil pressure. Check the engine
components that have excessive bearing clearance and make the necessary repairs.
NOTICE
NOTICE
containing fluids.
Engine oil pressure will be high if the engine oil bypass valves become stuck in the closed position and
the engine oil flow is restricted. Foreign matter in the engine oil system could be the cause for the
restriction of the oil flow and the movement of the engine oil bypass valves. If the engine oil bypass
valves are stuck in the closed position, remove each bypass valve and clean each bypass valve in order
to correct this problem. You must also clean each bypass valve bore. Install new engine oil filters. New
engine oil filters will prevent more debris from causing this problem. For information on the repair of
the engine oil filter bypass valve, refer to Disassembly and Assembly, "Engine Oil Filter Base -
Disassemble".
NOTICE
Caterpillar oil filters are built to Caterpillar specifications. Use of an
oil filter not recommended by Caterpillar could result in severe engine
damage to the engine bearings, crankshaft, etc., as a result of the larger
waste particles from unfiltered oil entering the engine lubricating
system. Only use oil filters recommended by Caterpillar.

193
Excessive Bearing Wear - Inspect
When some components of the engine show bearing wear in a short time, the cause can be a restriction
in an oil passage.
An engine oil pressure indicator may show that there is enough oil pressure, but a component is worn
due to a lack of lubrication. In such a case, look at the passage for the oil supply to the component. A
restriction in an oil supply passage will not allow enough lubrication to reach a component. This will
result in early wear.

194
Excessive Engine Oil Consumption - Inspect

Check for leakage at the seals at each end of the crankshaft. Look for leakage at the oil pan gasket and
all lubrication system connections. Look for any oil that may be leaking from the crankcase breather.
This can be caused by combustion gas leakage around the pistons. A dirty crankcase breather will
cause high pressure in the crankcase. A dirty crankcase breather will cause the gaskets and the seals to
leak.

Oil leakage into the combustion area of the cylinders can be the cause of blue smoke. There are four
possible ways for oil leakage into the combustion area of the cylinders:
¡ Oil leakage between worn valve guides and valve stems
¡ Worn components or damaged components (pistons, piston rings, or dirty oil return holes)
¡ Incorrect installation of the compression ring and/or the intermediate ring
¡ Oil leakage past the seal rings in the impeller end of the turbocharger shaft
Excessive oil consumption can also be the result if oil with the wrong viscosity is used. Oil with a thin
viscosity can be caused by fuel leakage into the crankcase or by increased engine temperature.

195
Increased Engine Oil Temperature - Inspect
When the engine is at operating temperature and you are using SAE 10W30 oil, the maximum oil
temperature is 115 °C (239 °F). This is the temperature of the oil after passing through the oil cooler.
Look for a restriction in the oil passages of the oil cooler. The oil temperature may be higher than
normal when the engine is operating. In such a case, the oil cooler may have a restriction. A restriction
in the oil cooler will not cause low oil pressure in the engine.
Determine if the oil cooler bypass valve is held in the open position. This condition will allow the oil to
pass through the valve instead of the oil cooler. The oil temperature will increase.

196
Cooling System - Check - Overheating
Above normal coolant temperatures can be caused by many conditions. Use the following procedure to
determine the cause of above normal coolant temperatures:
Personal injury can result from escaping fluid under pressure.

If a pressure indication is shown on the indicator, push the release valve
in order to relieve pressure before removing any hose from the radiator.
1. Check the coolant level in the cooling system. Refer to Operation and Maintenance Manual,
"Cooling System Coolant Level - Check". If the coolant level is too low, air will get into the cooling
system. Air in the cooling system will cause a reduction in coolant flow and bubbles in the coolant.
Air bubbles will keep coolant away from the engine parts, which will prevent the transfer of heat to
the coolant. Low coolant level is caused by leaks or incorrectly filling the radiator.
2. Check the mixture of antifreeze and water. The mixture should be approximately 50 percent water
and 50 percent antifreeze with 3 to 6 percent coolant conditioner. Refer to Operation and
Maintenance Manual, "General Coolant Information". If the coolant mixture is incorrect, drain the
system. Put the correct mixture of water, antifreeze and coolant conditioner in the cooling system.
3. Check for air in the cooling system. Air can enter the cooling system in different ways. The most
common causes of air in the cooling system are not filling the cooling system correctly and
combustion gas leakage into the cooling system. Combustion gas can get into the system through
inside cracks, a damaged cylinder head, or a damaged cylinder head gasket. Air in the cooling
system causes a reduction in coolant flow and bubbles in the coolant. Air bubbles keep coolant away
from the engine parts, which prevents the transfer of heat to the coolant.
4. Check the water temperature gauge. A water temperature gauge which does not work correctly will
not show the correct temperature. Refer to Testing and Adjusting, "Cooling System - Inspect".
5. Check the sending unit. In some conditions, the temperature sensor in the engine sends signals to a
sending unit. The sending unit converts these signals to an electrical impulse which is used by a
mounted gauge. If the sending unit malfunctions, the gauge can show an incorrect reading. Also if
the electric wire breaks or if the electric wire shorts out, the gauge can show an incorrect reading.
6. Check the radiator.
a. Check the radiator for a restriction to coolant flow. Check the radiator for debris, dirt, or deposits
on the inside of the radiator core. Debris, dirt, or deposits will restrict the flow of coolant through
the radiator.
b. Check for debris or damage between the fins of the radiator core. Debris between the fins of the
radiator core restricts air flow through the radiator core. Refer to Testing and Adjusting, "Cooling
System - Inspect".
7. Check the filler cap. A pressure drop in the radiator can cause the boiling point to be lower. This can
cause the cooling system to boil. Refer to Testing and Adjusting, "Cooling System - Test".
8. Check the fan and/or the fan shroud.
a. The fan must be large enough to send air through most of the area of the radiator core. Ensure that
the size of the fan and the position of the fan are according to the OEM specifications.
b. The fan shroud must be the proper size and the fan shroud must be positioned correctly. Ensure
that the size of the fan shroud and the position of the fan shroud are according to the OEM
specifications.
9. Check for loose drive belts.
a. A loose fan drive belt will cause a reduction in the air flow across the radiator. Check the fan drive
belt for proper belt tension. Adjust the tension of the fan drive belt, if necessary. Refer to
Operation and Maintenance Manual, "Belt - Inspect".
b. A loose water pump drive belt will cause a reduction in coolant flow through the radiator. Check
the water pump drive belt for proper belt tension. Adjust the water pump drive belt's tension, if

197
necessary. Refer to Operation and Maintenance Manual, "Belt - Inspect".
10. Check the cooling system hoses and clamps. Damaged hoses with leaks can normally be seen. Hoses
that have no visual leaks can soften during operation. The soft areas of the hose can become kinked
or crushed during operation. These areas of the hose can cause a restriction in the coolant flow.
Hoses become soft and/or get cracks after a period of time. The inside of a hose can deteriorate, and
the loose particles of the hose can cause a restriction of the coolant flow. Refer to Operation and
Maintenance Manual, "Hoses and Clamps - Inspect/Replace".
11. Check for a restriction in the air inlet system. A restriction of the air that is coming into the engine
can cause high cylinder temperatures. High cylinder temperatures require higher than normal
temperatures in the cooling system. Refer to Testing and Adjusting, "Air Inlet and Exhaust System -
Inspect".
a. If the measured restriction is higher than the maximum permissible restriction, remove the foreign
material from the engine air cleaner element or install a new engine air cleaner element. Refer to
Operation and Maintenance Manual, "Engine Air Cleaner Element - Clean/Replace".
b. Repeat the check for a restriction in the air inlet system.
c. If the measured restriction is still higher than the maximum permissible restriction, check the air
inlet piping for a restriction.
12. Check for a restriction in the exhaust system. A restriction of the air that is coming out of the engine
can cause high cylinder temperatures.
a. Make a visual inspection of the exhaust system. Check for damage to exhaust piping or for a
damaged muffler. If no damage is found, check the exhaust system for a restriction. Refer to
Testing and Adjusting, "Air Inlet and Exhaust System - Inspect".
b. If the measured restriction is higher than the maximum permissible restriction, there is a restriction
in the exhaust system. Repair the exhaust system, as required.
13. Check the water temperature regulator. A water temperature regulator that does not open, or a water
temperature regulator that only opens part of the way can cause overheating. Refer to Testing and
Adjusting, "Water Temperature Regulator - Test".
14. Check the water pump. A water pump with a damaged impeller does not pump enough coolant for
correct engine cooling. Remove the water pump and check for damage to the impeller. Refer to
Testing and Adjusting, "Water Pump - Test".
15. Check the air flow through the engine compartment. The air flow through the radiator comes out of
the engine compartment. Ensure that the filters, air conditioner, and similar items are not installed in
a way that prevents the free flow of air through the engine compartment.
16. Consider high outside temperatures. When outside temperatures are too high for the rating of the
cooling system, there is not enough of a temperature difference between the outside air and coolant
temperatures.
17. Consider high altitude operation. The cooling capacity of the cooling system goes down as the
engine is operated at higher altitudes. A pressurized cooling system that is large enough to keep the
coolant from boiling must be used.

198
Cooling System - Inspect
Cooling systems that are not regularly inspected are the cause for increased engine temperatures. Make
a visual inspection of the cooling system before any tests are performed.

1. Check the coolant level in the cooling system. Refer to Operation and Maintenance Manual,
"Cooling System Coolant Level - Check".
2. Check the quality of the coolant. The coolant should have the following properties:
n Color that is similar to new coolant
n Odor that is similar to new coolant
n Free from dirt and debris
If the coolant does not have these properties, drain the system and flush the system. Refill the
cooling system with the correct mixture of water, antifreeze, and coolant conditioner. Refer to the
Operation and Maintenance Manual for your engine in order to obtain coolant recommendations.
3. Look for leaks in the system.
Note: A small amount of coolant leakage across the surface of the water pump seals is normal. This
leakage is required in order to provide lubrication for this type of seal. A hole is provided in the
water pump housing in order to allow this coolant/seal lubricant to drain from the pump housing.
Intermittent leakage of small amounts of coolant from this hole is not an indication of water pump
seal failure.
4. Ensure that the air flow through the radiator does not have a restriction. Look for bent core fins
between the folded cores of the radiator. Also, look for debris between the folded cores of the
radiator.
5. Inspect the drive belts for the fan.
6. Check for damage to the fan blades.
7. Look for air or combustion gas in the cooling system.
8. Inspect the filler cap, and check the surface that seals the filler cap. This surface must be clean.

199
Cooling System - Test
This engine has a pressure type cooling system. A pressure type cooling system has two advantages.
The cooling system can be operated in a safe manner at a temperature higher than the normal boiling
point (steam) of water.
This type of system prevents cavitation in the water pump. Cavitation is the forming of low pressure
bubbles in liquids that are caused by mechanical forces. The formation of an air pocket or a steam
pocket in this type of cooling system is difficult.
Boiling point of water
Remember that temperature and pressure work together. When a diagnosis is made of a cooling system
problem, temperature and pressure must be checked. Cooling system pressure will have an effect on the
cooling system temperature. For an example, refer to Illustration 1. This will show the effect of
pressure on the boiling point (steam) of water. This will also show the effect of height above sea level.
Personal injury can result from hot coolant, steam and alkali.
At operating temperature, engine coolant is hot and under pressure.
The radiator and all lines to heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.
Remove filler cap slowly to relieve pressure only when engine is stopped
and radiator cap is cool enough to touch with your bare hand.
Cooling System Conditioner contains alkali. Avoid contact with skin
and eyes.
The coolant level must be to the correct level in order to check the coolant system. The engine must be
cold and the engine must not be running.
After the engine is cool, loosen the pressure cap in order to relieve the pressure out of the cooling
system. Then remove the pressure cap.
The level of the coolant should not be more than 13 mm (0.5 inch) from the bottom of the filler pipe. If
the cooling system is equipped with a sight glass, the coolant should be to the proper level in the sight
glass.

Table 1
Required Tools

200

4C-6500 Digital Thermometer 1
8T-2700 Blowby/Air Flow Indicator 1
9S-8140 Pressurizing Pump 1
9U-7400 Multitach Tool Group 1
4C-4500 Digital Thermometer
The 4C-6500 Digital Thermometer is used in the diagnosis of overheating conditions and in the
diagnosis of overcooling conditions. This group can be used to check temperatures in several different
parts of the cooling system. Refer to Operating Manual, NEHS0554, " 4C-6500 Digital Thermometer
Group" for the testing procedure.
8T-2700 Blowby/Air Flow Indicator
The 8T-2700 Blowby/Air Flow Indicator is used to check the air flow through the radiator core. Refer
to Special Instruction, SEHS8712, "Using the 8T-2700 Blowby/Air Flow Indicator " for the test
procedure for checking blowby.

201
9U-7400 Multitach
The 9U-7400 Multitach Tool Group is used to check the fan speed. Refer to Operating Manual,
NEHS0605, " 9U-7400 Multitach Tool Group " for the testing procedure.
9S-8140 Pressurizing Pump
The 9S-8140 Pressurizing Pump is used to test the filler caps. This pressurizing pump is also used to
pressure test the cooling system for leaks.
1U-7297 Coolant/Battery Tester or 1U-7298 Coolant/Battery Tester
Check the coolant frequently in cold weather for the proper glycol concentration. Use either the 1U-
7297 Coolant/Battery Tester or the 1U-7298 Coolant/Battery Tester in order to ensure adequate freeze
protection. The testers are identical except for the temperature scale. The testers give immediate,
accurate readings. The testers can be used for antifreeze/coolants that contain ethylene or propylene
glycol.

Adding pure antifreeze as a makeup solution for the cooling system top-off is an unacceptable practice.
Adding pure antifreeze increases the concentration of antifreeze in the cooling system. This increases
the concentration of the dissolved solids and the undissolved chemical inhibitors in the cooling system.

202
Add the antifreeze and water mixture to the same freeze protection as your cooling system. The
following chart assists in determining the concentration of antifreeze to use. Refer to Operation and
Maintenance Manual, "General Coolant Information".
Table 2
Antifreeze Concentrations
Temperature Concentration
Protection to
30% antifreeze and 70% water
-15 °C (5 °F)
Protection to
-23 °C (-10 °F)
Protection to
-37 °C (-34 °F)
Protection to
-51 °C (-60 °F)

Table 3
Required Tools
One cause for a pressure loss in the cooling system can be a damaged seal on the radiator filler cap.
Typical schematic of filler cap, (1) Sealing surface of both filler cap and radiator
and eyes.
To check for the amount of pressure that opens the filler cap, use the following procedure:
1. After the engine cools, carefully loosen the filler cap. Slowly release the pressure from the cooling
system. Then, remove the filler cap.
Carefully inspect the filler cap. Look for any damage to the seals and to the sealing surface. Inspect
the following components for any foreign substances:
n Filler cap

203
n Seal
n Surface for seal
Remove any deposits that are found on these items, and remove any material that is found on these
items.
2. Install the filler cap on the 9S-8140 Pressurizing Pump .
3. Look at the gauge for the exact pressure that opens the filler cap.
4. Compare the gauge's reading with the opening pressure that is listed on the filler cap.
5. If the filler cap is damaged, replace the filler cap.

Table 4
Required Tools
Use the following procedure in order to check the cooling system for leaks:
and eyes.
1. After the engine is cool, loosen the filler cap slowly and allow pressure out of the cooling system.
Then remove the filler cap from the radiator.
2. Ensure that the coolant level is above the top of the radiator core.
3. Install the 9S-8140 Pressurizing Pump onto the radiator.
4. Take the pressure reading on the gauge to 20 kPa (3 psi) more than the pressure on the filler cap.
5. Check the radiator for leakage on the outside.
6. Check all connection points for leakage, and check the hoses for leakage.
The cooling system does not have leakage only if the following conditions exist:
¡ You do NOT observe any outside leakage.
¡ The reading remains steady after five minutes.
The inside of the cooling system has leakage only if the following conditions exist:
¡ The reading on the gauge goes down.
¡ You do NOT observe any outside leakage.
Make any repairs, as required.

Table 5
Required Tools
4C-6500 Digital Thermometer 1
or

204
2F-7112 Thermometer 1
or
5P-2720 Probe Adapter 1
164-2192 Probe Adapter Gp 1

Check the accuracy of the water temperature indicator or water temperature sensor if you find either of
the following conditions:
¡ The engine runs at a temperature that is too hot, but a normal temperature is indicated. A loss of
coolant is found.
¡ The engine runs at a normal temperature, but a hot temperature is indicated. No loss of coolant is
found.
Location Of The Test Port
Remove the plug (1) from housing (2). Install one of the following thermometers in the open port:
¡ The 4C-6500 Digital Thermometer
¡ The 2F-7112 Thermometer
A temperature indicator of known accuracy can also be used to make this check.
Start the engine. Run the engine until the temperature reaches the desired range according to the test
thermometer. If necessary, place a cover over part of the radiator in order to cause a restriction of the
air flow. The reading on the water temperature indicator should agree with the test thermometer within
the tolerance range of the water temperature indicator.

205
Water Temperature Regulator - Test

1. Remove the water temperature regulator from the engine.

2. Heat water in a pan until the temperature of the water is equal to the fully open temperature of the
water temperature regulator. Refer to Specifications, "Water Temperature Regulator" for the fully
open temperature of the water temperature regulator. Stir the water in the pan. This will distribute the
temperature throughout the pan.
3. Hang the water temperature regulator in the pan of water. The water temperature regulator must be
below the surface of the water. The water temperature regulator must be away from the sides and the
bottom of the pan.
4. Keep the water at the correct temperature for ten minutes.
5. After ten minutes, remove the water temperature regulator. Immediately measure the opening of the
water temperature regulator. Refer to Specifications, "Water Temperature Regulator" for the
minimum opening distance of the water temperature regulator at the fully open temperature.
If the distance is less than the amount listed in the manual, replace the water temperature regulator.

206
Water Pump - Test

Table 1
Required Tools
Part Number Description Quantity
6V-7775 Air Pressure Gauge 1
5P-2725 Probe Seal Adapter 1
164-2192 Probe Adapter Gp (1) 1
5P- 4487 Adapter 1
1J-9671 O-Ring Seal 1
5P-2720 Probe Adapter 1
164-2192 Probe Adapter Gp (2) 1
(1) If port (1) is used, two tools are required. See the Illustration 1 below.
(2) If port (2) is used, two tools are required. See the Illustration 1 below.
Pressure test ports for the water pump, (1) Pump outlet pressure (alternate heater supply) (2) Alternate pump outlet
pressure (engine diagnosis) (3) 2 Ports for the water pump inlet (heater return line)
The pressure rise is the difference between inlet pressure and outlet pressure. The pressure rise
indicates if the water pump operates correctly. Port (1) and Port (2) represent the water pump outlet
pressure. Port (3) represents the water pump inlet pressure.
To measure the pressure rise, compare inlet pressure with outlet pressure. Calculate the difference
between the pressure of the inlet port and the outlet ports. The pressure rise must add up to a minimum
of 80 kPa (12 psi) under both of the following conditions:
¡ The engine is at operating temperature.
¡ The engine operates at full load condition.

207
Piston Ring Groove - Inspect
The pistons of the engine have a keystone design ring groove. The piston rings are a keystone ring. The
3114 Engine and the 3116 Engine requires the 4C-8164 Piston Ring Groove Gauge in order to check
the top ring groove in the piston. Refer to the instruction card for correct use of the 4C-8164 Piston
Ring Groove Gauge. The 3126 Engine requires the 186-0137 Piston Ring Groove Gauge Gp in order to
check the top ring groove in the piston. Refer to the instruction card for correct use of the 186-0137
Piston Ring Groove Gauge Gp .
Refer to Guideline For Reusable Parts And Salvage Operations, SEBF8049, "Pistons" for more
information.

208
Connecting Rod Bearings - Inspect
The connecting rod bearings fit tightly in the bore in the rod. If the bearing joints are fretted, check the
bore size. This can be an indication of wear because of a loose fit.
Connecting rod bearings are available with 0.25 mm (0.010 inch) and 0.50 mm (0.020 inch) smaller
inside diameter than the original size bearings. These bearings are for crankshafts that have been
ground.

209
Main Bearings - Inspect
Main bearings are available with 0.25 mm (0.010 inch) and a 0.50 mm (0.020 inch) smaller inside
diameter than the original size bearings. These bearings are for crankshafts that have been ground.
Main bearings are also available with a larger outside diameter than the original size bearings. These
bearings are used for the cylinder blocks with the main bearing bore that is made larger than the bore's
original size. The size that is available has a 0.50 mm (0.020 inch) outside diameter that is larger than
the original size bearings.
Refer to Special Instruction, SMHS7606, "Use of 1P-4000 Line Boring Tool Group " for the
instructions that are needed to use the 1P-4000 Line Boring Tool Group . The 1P-4000 Line Boring
Tool Group is used in order to check the alignment of the main bearing bores. The 1P-3537 Dial Bore
Gauge Group can be used to check the size of the bore. Refer to Instruction Manual, GMG00981, " 1P-
3537 Dial Bore Gauge Group " for the instructions that are needed to use the 1P-3537 Dial Bore Gauge
Group .

210
Cylinder Block - Inspect

Table 1
Required Tools
1P-3537 Dial Bore Gauge Group 1
1P-3537 Dial Bore Gauge Group
If the main bearing caps are installed without bearings, the bore in the block for the main bearings can
be checked. Tighten the nuts on the bearing caps to the torque that is given in Specifications, "Cylinder
Block". Alignment error in the bores must not be more than 0.08 mm (0.003 inch).
The 1P-3537 Dial Bore Gauge Group can be used to check the size of the bore.

211
Flywheel - Inspect
Table 1
Required Tools
Part Number Description Qty
8T-5096 Dial Indicator Gp 1
Checking face runout of the flywheel
1. Refer to Illustration 1 and install the dial indicator. Always put a force on the crankshaft in the same
direction before the dial indicator is read. This will remove any crankshaft end clearance.
2. Set the dial indicator to read 0.0 mm (0.00 inch).
3. Turn the flywheel at intervals of 90 degrees and read the dial indicator. Refer to Testing and
Adjusting, "Finding Top Center Position for No. 1 Piston".
4. Take the measurements at all four points. The difference between the lower measurements and the
higher measurements that are performed at all four points must not be more than 0.13 mm (0.005
inch), which is the maximum permissible face runout (axial eccentricity) of the flywheel.
Checking bore runout of flywheel, (1) 7H-1945 Holding Rod (2) 7H-1645 Holding Rod (3) 7H-1940 Universal
Attachment (4) 7H-1942 Dial Indicator

212
1. Install 7H-1942 Dial Indicator (4) . Make an adjustment of 7H-1940 Universal Attachment (3) so the
dial indicator makes contact on the flywheel.
2. Set the dial indicator to read 0.0 mm (0.00 inch).
3. Turn the flywheel at intervals of 90 degrees and read the dial indicator.
4. Take the measurements at all four points. The difference between the lower measurements and the
higher measurements that are performed at all four points must not be more than 0.15 mm (0.006
inch), which is the maximum permissible bore runout (radial eccentricity) of the flywheel.
Flywheel clutch pilot bearing bore
5. To find the runout (eccentricity) of the pilot bearing bore, use the preceding procedure.
6. The runout (eccentricity) of the bore for the pilot bearing in the flywheel must not exceed 0.13 mm
(0.005 inch).

213
Flywheel Housing - Inspect

Table 1
Tools Needed
8T-5096 Dial Indicator Gp 1
8T-5096 Dial Indicator
If you use any other method except the method that is given here, always remember that the bearing
clearance must be removed in order to receive the correct measurements.
1. Fasten a dial indicator to the flywheel so the anvil of the dial indicator will contact the face of the
flywheel housing.
2. Put a force on the crankshaft toward the rear before the dial indicator is read at each point.
Checking face runout of the flywheel housing
3. Turn the flywheel while the dial indicator is set at 0.0 mm (0.00 inch) at location (A). Read the dial
indicator at locations (B), (C) and (D) .
4. The difference between the lower measurements and the higher measurements that are performed at
all four points must not be more than 0.30 mm (0.012 inch), which is the maximum permissible face
runout (axial eccentricity) of the flywheel housing.

214
8T-5096 Dial Indicator
1. Fasten a dial indicator to the flywheel so the anvil of the dial indicator will contact the bore of the
flywheel housing.
Checking bore runout of the flywheel housing
2. While the dial indicator is in the position at location (C) adjust the dial indicator to 0.0 mm (0.00
inch). Push the crankshaft upward against the top of the bearing. Refer to Illustration 5. Write the
measurement for bearing clearance on line 1 in column (C) .
Note: Write the measurements for the dial indicator with the correct notations. This notation is
necessary for making the calculations in the chart correctly.
3. Divide the measurement from Step 2 by two. Write this number on line 1 in columns (B) and (D) .
4. Turn the flywheel in order to put the dial indicator at position (A). Adjust the dial indicator to 0.0
mm (0.00 inch).
5. Turn the flywheel counterclockwise in order to put the dial indicator at position (B). Write the
measurements in the chart.
6. Turn the flywheel counterclockwise in order to put the dial indicator at position (C). Write the
measurement in the chart.
7. Turn the flywheel counterclockwise in order to put the dial indicator at position (D). Write the
measurement in the chart.
8. Add the lines together in each column.
9. Subtract the smaller number from the larger number in column B and column D. Place this number
on line III. The result is the horizontal eccentricity (out of round). Line III in column C is the vertical
eccentricity.
215
Graph for total eccentricity, (1) Total vertical eccentricity (2) Total horizontal eccentricity (3) Acceptable value (4)
Unacceptable value
10. Find the intersection of the eccentricity lines (vertical and horizontal) in Illustration 6.
11. If the point of the intersection is in the ACCEPTABLE range, the bore is in alignment. If the point of
intersection is in the NOT ACCEPTABLE range, the flywheel housing must be changed.

216
Vibration Damper - Check

Vibration damper and pulley, (1) Adapter (2) Rubber (3) Damper assembly (4) Bolt (5) Crankshaft pulley
The vibration damper is installed on the front of crankshaft. The space in the damper assembly (3) is
filled with rubber (2) . The vibration damper limits the torsional vibration.
Replace the damper if any of the following conditions exist:
¡ The damper is dented or cracked.
¡ The paint on the damper is discolored from heat.
¡ There is a large amount of gear train wear that is not caused by lack of oil.
¡ Analysis of the oil has revealed that the front main bearing is badly worn.
¡ The engine has had a failure because of a broken crankshaft.
Viscous vibration damper, (6) Pulley (7) Weight (8) Case
Damage to the vibration damper or failure of the vibration damper will increase vibrations. This will
result in damage to the crankshaft.
Replace the damper if any of the following conditions exist:
¡ The damper is dented, cracked, or fluid is leaking from the damper.

217
¡ The paint on the damper is discolored from excessive heat.
¡ The damper is bent.
¡ The bolt holes are worn or there is a loose fit for the bolts.
¡ The engine has had a crankshaft failure due to torsional forces.
NOTICE
Inspect the viscous vibration damper for signs of leaking and for signs
of damage to the case. Either of these conditions can cause the weight
to contact the case. This contact can affect damper operation.

218
Battery - Test
Most of the tests of the electrical system can be done on the engine. The wiring insulation must be in
good condition. The wire and cable connections must be clean, and both components must be tight.
Never disconnect any charging unit circuit or battery circuit cable from
the battery when the charging unit is operated. A spark can cause an
explosion from the flammable vapor mixture of hydrogen and oxygen
that is released from the electrolyte through the battery outlets. Injury
to personnel can be the result.
The battery circuit is an electrical load on the charging unit. The load is variable because of the
condition of the charge in the battery.
NOTICE
The charging unit will be damaged if the connections between the
battery and the charging unit are broken while the battery is being
charged. Damage occurs because the load from the battery is lost and
because there is an increase in charging voltage. High voltage will
damage the charging unit, the regulator, and other electrical
components.
177-2330 Battery Analyzer

219
4C-4911 Battery Load Tester
Use the 4C-4911 Battery Load Tester or the 177-2330 Battery Analyzer in order to test a battery that
does not maintain a charge when the battery is active. The 4C-4911 Battery Load Tester and the 177-
2330 Battery Analyzer are portable units. The 4C-4911 Battery Load Tester or the 177-2330 Battery
Analyzer can be used under field conditions and under high temperatures. The tester can be used to
load test all 6, 8, and 12 Volt batteries. This tester has two heavy-duty load cables that can easily be
fastened to the battery terminals. A load adjustment knob is located on the top of the tester. The load
adjustment knob permits the current that is being drawn from the battery to be adjusted to a maximum
of 1000 amperes. The tester is cooled by an internal fan that is automatically activated when a load is
applied.
The tester has a built-in LCD. The LCD is a digital voltmeter. The LCD is a digital meter that will also
display the amperage. The digital voltmeter accurately measures the battery voltage at the battery
through wires for tracing. These wires are buried inside the load cables. The digital meter, that displays
the amperage, accurately displays the current that is being drawn from the battery which is being tested.
Note: Refer to Operating Manual, SEHS9249, "Use of 4C-4911 Battery Load Tester for 6, 8, and 12
Volt Lead Acid Batteries" for detailed instruction on the use of the 4C-4911 Battery Load Tester .
Refer to Operating Manual, NEHS0764, "Using the 177-2330 Battery Analyzer " for detailed
instruction on the use of the 177-2330 Battery Analyzer . See Special Instruction, SEHS7633, "Battery
Test Procedure" for the correct procedures to use when the battery is tested . This publication also
contains the specifications to use when the battery is tested.

220
Charging System - Test
The condition of charge in the battery at each regular inspection will show if the charging system is
operating correctly. An adjustment is necessary when the battery is constantly in a low condition of
charge or a large amount of water is needed. A large amount of water would be more than one ounce of
water per cell per week or per every 100 service hours.
When it is possible, make a test of the charging unit and voltage regulator on the engine, and use wiring
and components that are a permanent part of the system. Off-engine testing or bench testing will give a
test of the charging unit and voltage regulator operation. This testing will give an indication of needed
repair. After repairs are made, perform a test in order to prove that the units have been repaired to the
original condition of operation.

Table 1
Required Tools
Part Number Description Qty
8T-0900 Ammeter 1
6V-7070 Digital Multimeter 1
8T-0900 Ammeter
8T-0900 Ammeter
The 8T-0900 Ammeter is completely portable. This ammeter is a self-contained instrument that
measures electrical currents without breaking the circuit and without disturbing the conductor's
insulation.
The ammeter contains a digital display that is used to monitor current directly within a range between 1
ampere and 1200 amperes. If an optional 6V-6014 Cable is connected between this ammeter and a
digital multimeter, current readings can be viewed directly from the display of the multimeter. This can
be accomplished under only one condition:
¡ the readings are less than 1 ammeter.
A lever opens the ammeter's jaws over a conductor. The conductor's diameter can not be larger than 19
mm (0.75 inch).
The spring loaded jaws close around the conductor for measuring the current. A trigger switch controls
the ammeter. The trigger switch can be locked into the ON position or into the OFF position.
After the trigger has been working and the trigger is turned to the OFF position, the reading appears in
the digital display for five seconds. This accurately measures currents in areas with a limited access.
221
For example, these areas include areas that are beyond the operator's sight. For DC operation, an
ammeter contains a zero control, and batteries inside the handle supply the power.
Note: Refer to Special Instruction, SEHS8420 for more information about using the 8T-0900
Ammeter.
The 6V-7070 Digital Multimeter is a hand-held service tool with a digital display, that is completely
portable. This multimeter is built with extra protection against damage in field applications. The
multimeter is equipped with 7 functions and 29 ranges. The 6V-7070 Digital Multimeter has an instant
ohms indicator. This indicator permits checking continuity for a fast inspection of the circuits. The
multimeter can also be used for troubleshooting capacitors that have small values.
Note: Refer to Special Instruction, SEHS7734 for complete information for the use of the 6V-7070
Digital Multimeter .
The charging rate of the alternator should be checked when an alternator is charging the battery too
much. The charging rate of the alternator should be checked when an alternator is not charging the
battery enough. Refer to the Specifications Module, SENR3582 in order to find all testing
specifications for the alternators and regulators.No adjustment can be made in order to change the rate
of charge on the 24 V alternator regulators. If the rate of charge is not correct, a replacement of the
regulator is necessary.See Special Instruction, REHS0354, "Charging System Troubleshooting" for the
correct procedures to use to test the charging system. This publication also contains the specifications
to use when you test the charging system.

222
Tools For Tightening The Alternator Pulley Nut, (1) 8T-9293 Torque Wrench (2) 8S-1588 Adapter (1/2 inch female to 3/8
inch male) (3) 2P-8267 Socket Assembly (4) 8H-8517 Combination Wrench (1-1/8 inch) (5) 8T-5314 Socket
Tighten the nut that holds the pulley with the tools shown. Refer to the Specifications module for the
torque.

223
Electric Starting System - Test
Most of the tests of the electrical system can be done on the engine. The wiring insulation must be in
good condition. The wire and cable connections must be clean, and both components must be tight. The
battery must be fully charged. If the on-engine test shows a defect in a component, remove the
component for more testing.
The starting system consists of the following components:
¡ Keyswitch
¡ Starting motor solenoid
¡ Starting motor
Table 1
Tools Needed
237-5130
or Digital Multimeter 1
146-4080
237-5130 Digital Multimeter or the 146-4080 Digital Multimeter
The 237-5130 Digital Multimeter Gp and the 146-4080 Digital Multimeter Gp are portable hand-held
service tools with a digital display. These multimeters are built with extra protection against damage in
field applications. Both multimeters are equipped with 7 functions and 29 ranges. The 237-5130 Digital
Multimeter Gp and the 146-4080 Digital Multimeter Gp have an instant ohms indicator. This indicator
permits checking continuity for a fast inspection of the circuits. These multimeters can also be used for
troubleshooting capacitors that have small values.
Note: Refer to Special Instruction, SEHS7734 for complete information for the use of the 237-5130
Digital Multimeter . Refer to Operation Manual, NEHS0678 for complete information for the use of the
146-4080 Digital Multimeter .
Use the multimeter in the DCV range to find starting system components which do not function.
Move the start control switch in order to activate the starting solenoids. The starting solenoid's
operation can be heard as the pinions of the starting motors are engaged with the ring gear on the
engine flywheel.
If a solenoid for a starting motor will not operate, it is possible that the current from the battery did not
reach the solenoid. Fasten one lead of the multimeter to the terminal connection for the battery cable on
the solenoid. Touch the other lead to a good ground. A zero reading indicates that there is a broken
circuit from the battery. More testing is necessary when there is a voltage reading on the multimeter.
The solenoid operation also closes the electric circuit to the motor. Connect one lead of the multimeter
to the terminal connection of the solenoid that is fastened to the motor. Touch the other lead to a good
ground. Activate the starting solenoid and look at the multimeter. A reading of the battery voltage
shows that the problem is in the motor. The motor must be removed for further testing. A zero reading
on the multimeter shows that the solenoid contacts do not close. This is an indication of the need for
224
repair to the solenoid or an adjustment to be made to the pinion clearance for the starting motor.
Perform a test. Fasten one multimeter lead to the terminal connection for the small wire at the solenoid
and fasten the other lead to the ground. Look at the multimeter and activate the starting solenoid. A
voltage reading shows that the problem is in the solenoid. A zero reading indicates that the problem is
in the start switch or the wires for the start switch.
Fasten one multimeter lead to the start switch at the terminal connection for the wire from the battery.
Fasten the other lead to a good ground. A zero reading indicates a broken circuit from the battery.
Make a check of the circuit breaker and wiring. If there is a voltage reading, the problem is in the start
switch or in the wires for the start switch.
Starting motors that operate too slowly can have an overload because of too much friction in the engine
that is being started. Slow operation of the starting motors can also be caused by a short circuit, loose
connections and/or dirt in the motors.

225
Pinion Clearance - Adjust

When the solenoid is installed, make an adjustment of the pinion clearance. The adjustment can be
made with the starting motor removed.
Connection for checking pinion clearance
Typical example, (1) Connector to the motor (2) Switch terminal (3) Ground terminal
1. Install the solenoid without connector (1) from the MOTOR connections (terminal) on the solenoid
to the motor.
2. Connect a battery, that has the same voltage as the solenoid, to the "SW" terminal (2) .
3. Connect the other side of the battery to connector (3) .
4. For a moment, connect a wire from the solenoid connection (terminal), which is marked "MOTOR",
to the ground connection (terminal). The pinion will shift to the crank position and the pinion will
stay there until the battery is disconnected.
Typical example, (4) Shaft nut (5) Pinion (6) Pinion clearance
5. Push the pinion toward the end with the commutator in order to remove free movement.
6. Pinion clearance (6) must be 1.02 ± 0.76 mm (0.04 ± 0.03 inch).
7. In order to adjust the pinion clearance, remove the plug and turn the shaft nut (4) .
8. After the adjustment is completed, install the plug over the nut (4) and install the connector (1)
between the MOTOR terminal on the solenoid and the starter motor.

226
SENR3611-18
INDEX
Fuel Filter Base - Remove and Install INDEX 226
232
Removal Procedure
Fuel Filter Base - Remove and Install 234
Removal Procedure
Fuel Priming Pump and Primary Fuel Filter - Remove and Install 236
Removal Procedure
Fuel Transfer Pump - Remove 239
Removal Procedure
Fuel Transfer Pump - Install 241
Fuel Shutoff Solenoid - Remove and Install 243
Removal Procedure
Governor - Remove 245
Removal Procedure
Governor - Install 248
Fuel Injection Control Linkage - Remove 251
Removal Procedure
Fuel Injection Control Linkage - Install 253
Unit Injector - Remove 256
Removal Procedure
Unit Injector - Install 258
Unit Injector Sleeve - Remove 260
Removal Procedure
Unit Injector Sleeve - Install 261
Turbocharger - Remove 262
Removal Procedure
Turbocharger - Install 263
Exhaust Manifold - Remove and Install 264
Removal Procedure
Inlet Manifold - Remove 266
SENR3611-18
227
Removal Procedure
Inlet Manifold - Install 267
Inlet and Exhaust Valves - Remove and Install 268
Removal Procedure
Inlet and Exhaust Valve Guides - Remove and Install 271
Removal Procedure
Inlet and Exhaust Valve Seat Inserts - Remove and Install 273
Removal Procedure
Engine Oil Filter Base - Remove 276
Removal Procedure
Engine Oil Filter Base - Disassemble 277
Engine Oil Filter Base - Assemble 278
Assembly Procedure
Engine Oil Filter Base - Install 279
Engine Oil Filter Bypass Valve - Remove and Install 280
Removal Procedure
Engine Oil Cooler Bypass Valve - Remove and Install 282
Removal Procedure
Engine Oil Cooler - Remove 284
Removal Procedure
Engine Oil Cooler - Install 285
Engine Oil Pump - Remove 286
Removal Procedure
Engine Oil Pump - Disassemble 287
Engine Oil Pump - Assemble 289
Assembly Procedure
Engine Oil Pump - Install 291
Water Pump - Remove 292
Removal procedure
Water Pump - Disassemble 294
Water Pump - Assemble 296
Assembly Procedure
Water Pump - Install 298
SENR3611-18
228
Water Temperature Regulator Housing - Remove and Install 299
Removal Procedure
Water Temperature Regulator - Remove and Install 301
Removal Procedure
Aftercooler - Remove 302
Removal Procedure
Aftercooler - Install 304
Engine Lifting Bracket - Remove and Install 306
Removal Procedure
Flywheel - Remove 307
Removal Procedure
Flywheel - Install 308
Crankshaft Rear Seal - Remove 309
Removal Procedure
Crankshaft Rear Seal - Install 310
Crankshaft Wear Sleeve (Rear) - Remove - If Equipped 311
Removal Procedure
Crankshaft Wear Sleeve (Rear) - Install 312
Crankshaft Rear Seal Carrier - Remove and Install 313
Removal Procedure
Flywheel Housing - Remove and Install 315
Removal Procedure
Vibration Damper and Pulley - Remove and Install 317
Removal Procedure
Crankshaft Front Seal - Remove 319
Removal Procedure
Crankshaft Front Seal - Install 320
Front Cover - Remove 321
Removal Procedure
Front Cover - Install 322
Gear Group (Front) - Remove 323
Removal Procedure
Gear Group (Front) - Install 324
SENR3611-18
229
Housing (Front) - Remove 327
Removal Procedure
Housing (Front) - Install 328
Crankcase Breather - Remove and Install 330
Removal Procedure
Valve Mechanism Cover - Remove and Install 331
Removal Procedure
Rocker Shaft and Pushrod - Remove 333
Removal Procedure
Rocker Shaft - Disassemble 334
Rocker Shaft - Assemble 336
Assembly Procedure
Rocker Shaft and Pushrod - Install 337
Cylinder Head - Remove 338
Removal Procedure
Cylinder Head - Install 340
Lifter Group - Remove and Install 342
Removal Procedure
Camshaft - Remove 344
Removal Procedure
Camshaft - Install 345
Camshaft Gear - Remove and Install 347
Removal Procedure
Camshaft Bearings - Remove and Install 348
Removal Procedure
Engine Oil Pan - Remove and Install 350
Removal Procedure
Engine Balancer Shaft - Remove and Install 352
Removal Procedure
Piston Cooling Jets - Remove and Install 354
Removal Procedure
Pistons and Connecting Rods - Remove 356
Removal Procedure
SENR3611-18
230
Pistons and Connecting Rods - Disassemble 358
Pistons and Connecting Rods - Assemble 359
Assembly Procedure
Pistons and Connecting Rods - Install 362
Crankshaft Main Bearings - Remove 365
Removal Procedure
Crankshaft Main Bearings - Install 367
Crankshaft - Remove 369
Removal Procedure
Crankshaft - Install 371
Crankshaft Gear - Remove and Install 374
Removal Procedure
Bearing Clearance - Check 376
Engine Oil Pressure Sensor - Remove and Install 378
Removal Procedure
Ether Atomizer - Remove and Install 380
Removal Procedure
Belt Tensioner - Remove and Install 381
Removal Procedure
Belt Tightener - Remove 382
Removal Procedure
Belt Tightener - Install 383
Alternator - Remove and Install 384
Removal Procedure
Electric Starting Motor - Remove and Install 386
Removal Procedure
Air Compressor - Remove and Install 388
Removal Procedure
Air Compressor Drive Gear - Remove and Install 390
Removal Procedure
SENR3611-18
231
SENR3611-18
232
001 Disassembly and Assembly
Fuel Filter Base - Remove and Install

Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 185-3630 Strap Wrench As 1
Start By:
A. Remove the crankcase breather. Refer to Disassembly and Assembly, "Crankcase Breather - Remove
and Install".
NOTICE
NOTICE
containing fluids.
Typical example
1. Use Tooling (A) to remove fuel filter (5) .
2. Disconnect tube assemblies (1) and (2) from fuel filter base (4) .
3. Remove bolts (3) from fuel filter base (4) .
4. Remove fuel filter base (4) and the gasket from the engine.
001 : Disassembly and Assembly

233
5. Remove fuel pressure relief valve (7) from fuel filter base (4), if necessary.
Table 2
Required Tools
NOTICE
Typical example
1. Install fuel pressure relief valve (7) on fuel filter base (4) .
2. Inspect the condition of the gasket. Replace the gasket, if necessary.
3. Position the gasket and fuel filter base (4) on the engine.
4. Install bolts (3) that secure fuel filter base (4) on the engine.
5. Connect tube assemblies (1) and (2) to fuel filter base (4) .
6. Use Tooling (A) to install fuel filter (5) .
7. Install O-ring seal (6) on fuel filter base (4) .
End By: Install the crankcase breather. Refer to Disassembly and Assembly, "Crankcase Breather -
Remove and Install".

234
Fuel Filter Base - Remove and Install

Removal Procedure
Table 1
Required Tools
Start By:
A. Remove the crankcase breather. Refer to Disassembly and Assembly, "Crankcase Breather - Remove
and Install".
NOTICE
NOTICE
containing fluids.
Typical example
1. Use Tooling (A) to remove fuel filter (5) .
2. Disconnect tube assemblies (1) and (2) from fuel filter base (4) .
3. Remove bolts (3) from fuel filter base (4) .
4. Remove fuel filter base (4) and the gasket from the engine.

235
5. Remove fuel pressure relief valve (7) from fuel filter base (4), if necessary.
Table 2
Required Tools
NOTICE
Typical example
1. Install fuel pressure relief valve (7) on fuel filter base (4) .
2. Inspect the condition of the gasket. Replace the gasket, if necessary.
3. Position the gasket and fuel filter base (4) on the engine.
4. Install bolts (3) that secure fuel filter base (4) on the engine.
5. Connect tube assemblies (1) and (2) to fuel filter base (4) .
6. Use Tooling (A) to install fuel filter (5) .
7. Install O-ring seal (6) on fuel filter base (4) .
End By: Install the crankcase breather. Refer to Disassembly and Assembly, "Crankcase Breather -

236
Fuel Priming Pump and Primary Fuel Filter - Remove and

Install
Removal Procedure
NOTICE
NOTICE
containing fluids.

1. Disconnect tube assembly (2) from primary fuel filter base (1) .
2. Remove bolts (4) from the fuel priming pump (3) .
3. Remove fuel priming pump (3) from the primary fuel filter base.

237

4. Remove bolt (5) from the primary fuel filter base.
5. Remove filter element (6) and housing (7) from the primary fuel filter base.
6. Remove bolts (8) from the primary fuel filter base (1) .
7. Remove primary fuel filter base (1) from the engine.
NOTICE
1. Install bolts (8) that secure primary fuel filter base (1) to the engine.
2. Install filter element (6) and housing (7) to the primary filter base with bolt (5) .

238

3. Install bolts (4) that secure fuel priming pump (3) to the primary fuel filter base.
4. Connect tube assembly (2) to primary fuel filter base (1) .

239
Fuel Transfer Pump - Remove

Removal Procedure
Note: The governor and the fuel transfer pump have been removed from the engine for photographic
purposes only. This procedure may be done with the governor on the engine.
Personal injury can result from parts and/or covers under spring
pressure.
Spring force will be released when covers are removed.
Be prepared to hold spring loaded covers as the bolts are loosened.
1. Hold cover (1) in place and remove bolts (2) in order to release the spring beneath cover (1). Remove
cover (1) .

2. Remove fitting (3) and the check valve from cover (1). Remove the filter screen (if equipped) from
fitting (3) .
3. Remove spring (4) and piston (5) .
4. Remove upper O-ring seal (6) .

240

5. Remove sleeve assembly (7). Inspect the face of lifter (8) for excessive wear. Inspect the surface of
the camshaft that is inside of the governor for excessive wear or damage.
6. Remove lower O-ring seal (9) .
7. Remove fitting (10) and the check valve.
Note: For information on reusability of the components in the fuel transfer pump, refer to Guideline
For Reusable Parts And Salvage Operations, SEBF8434, "3100 Governor Inspection and General
Information for Mechanical Governor Groups Used in 3114, 3116, and 3126 Engines Equipped with
Mechanical Unit Injectors (MUI)".

241
Fuel Transfer Pump - Install

Table 1
Required Tools
A 8T-2998 Lubricant 1
NOTICE
Note: For information on reusability of the components in the fuel transfer pump, refer to Guideline

1. Lubricate fitting (10) and the bore with clean engine oil. Install the check valve and fitting (10) .
2. Inspect the condition of the O-ring seal. Replace the O-ring seal, if necessary. Install lower O-ring
seal (9) .
3. Apply Tooling (A) on the face of lifter (8). Install sleeve assembly (7). Ensure that the flat on the
sleeve aligns with the flat in the bore of the housing.

4. Lubricate piston (5) with clean engine oil. Install piston (5) and spring (4) .
5. Lubricate fitting (3) and the bore for the check valve with clean engine oil. Install the check valve
with the sealing face toward the fitting.
6. Install the O-ring seal and fitting (3) .

242
Improper assembly of parts that are spring loaded can cause bodily
injury.
To prevent possible injury, follow the established assembly procedure
and wear protective equipment.
7. Place cover (1) over spring (4). Install bolts (2) in order to compress spring (4) .

243
Fuel Shutoff Solenoid - Remove and Install

Removal Procedure
Table 1
Required Tools
A 9U-5120 Spanner Wrench (1) 1
(1) This tool is part of the 128-8822 Fuel System and Governor Tool Group .
NOTICE
NOTICE
containing fluids.
1. Disconnect the harness assembly (2) from fuel shutoff solenoid (1) .
2. Use Tooling (A) to remove the fuel shutoff solenoid from the governor.
3. Remove the O-ring seal from the shutoff solenoid .

244
Table 2
Required Tools
A 9U-5120 Spanner Wrench (1) 1
NOTICE
NOTICE
containing fluids.
1. Inspect the O-ring seal on the fuel shutoff solenoid. If the O-ring seal is worn or damaged, use new
parts for replacement.
2. Install the O-ring seal on the fuel shutoff solenoid.
3. Install the fuel shutoff solenoid in the governor. Use Tooling (A) and a suitable torque wrench to
tighten the fuel shutoff solenoid to the following torque 30 ± 5 N·m (22 ± 4 lb ft).
4. Connect the harness assembly to the fuel shutoff solenoid.

245
Governor - Remove
Removal Procedure
Table 1
Required Tools
A 136-4149 Governor Pliers (1) 1
Start By:
A. Remove the fuel shutoff solenoid. Refer to Disassembly and Assembly, "Fuel Shutoff Solenoid -
NOTICE
containing fluids.

1. Disconnect the governor control cable.
2. Remove oil tube assembly (1). Remove tube assembly (2) and tube assembly for fuel ratio control
(3), if equipped. Plug and cap all connections.
3. Remove clip (4) .

246
4. Use Tooling (A) to slide tube assembly (5) into the cylinder head.
5. Remove the clip and use Tooling (A) to remove the clevis pin (6) .
Note: Clevis pin (6) must stay with the governor in order to be adjusted.

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

8. Remove O-ring seal (3) on the governor.
9. Remove the O-ring seal and tube assembly (5) from the cylinder head.

247

10. Remove O-ring seal (2) on the tube assembly (5) .
11. Remove O-ring seal (1) from the cylinder head.
Note: For more information on the governor, refer to Service Manual, SENR6454, "3114, 3116, &
3126 Engine Governors". The Service Manual, SENR6454 requires the use of a 1U-7326 Governor
Calibration Bench. For information on reusability of components in the governor, refer to Guideline

248
Governor - Install
Table 1
Required Tools
128-8827 Pin (1) 1
B
1U-7523 Pin Pilot (1) 1
(1) This tool is part of the 128-8822 Governor Tool Group .
NOTICE
Note: For more information on the governor, refer to Service Manual, SENR6454, "3114, 3116, &
3126 Engine Governors". The Service Manual, SENR6454 requires the use of a 1U-7326 Governor
Calibration Bench. For information on reusability of components in the governor, refer to Guideline

1. Apply lubricant to the new O-ring seal (1). Install new O-ring seal (1) in the cylinder head.
2. Apply lubricant to the new O-ring seal (2). Install new O-ring seal (2) on the tube assembly (5) .

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

249
4. Apply lubricant to the new O-ring seal (3). Install new O-ring seal (3) on the governor.

5. Place the governor in position on the engine.
6. Install the washers and bolts (7) that hold the governor in place.

7. Install clevis pin (6) in Tooling (B) .
8. Use Tooling (B) to install clevis pin (6) and the clip.
9. Check the fuel setting adjustment. Refer to Testing and Adjusting, SENR5118.
10. Use Tooling (A) to slide tube assembly (5) into the governor.
11. Install clip (4) .

250
12. Install oil tube assembly (1). Install tube assembly (2) and tube assembly for fuel ratio control (3), if
equipped. Plug and cap all connections.
13. Install the governor control cable.
End By: Install the fuel shutoff solenoid. Refer to Disassembly and Assembly, "Fuel Shutoff Solenoid
- Remove and Install".

251
Fuel Injection Control Linkage - Remove

Removal Procedure
Table 1
Required Tools
A 136-4149 Governor Pliers 1
Start By:
A. Remove the rocker shaft and the pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and
Pushrod - Remove".
NOTICE
1. Remove clip (4). Clip (4) is located between the governor and the cylinder head.
2. Use Tooling (A) to slide tube assembly (5) into the cylinder head.

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

252
4. Remove bolts (1) and remove fuel injection control linkage (2). Control lever (3) connects the fuel
injection control linkage (2) to the governor.
Note: For information on the inspection procedure for control lever (3), refer to Special Instruction,
REHS0601, "Inspection and Modification of the 102-7459 Fuel Injection Control Linkage and the
4P-9048 Fuel Injection Control Linkage".

253
Fuel Injection Control Linkage - Install

Table 1
Required Tools
128-8827 Pin (1) 1
B
1U-7523 Pin Pilot (1) 1
C 1U-6675 Spring Compressor (1) 6
D 128-8822 Fuel System and Governor Tool Gp 1
(1) This tool is part of the 128-8822 Governor Tool Group .
Note: For information on the inspection procedure for control lever (3), refer to Special Instruction,
REHS0601, "Inspection and Modification of the 102-7459 Fuel Injection Control Linkage and the
4P-9048 Fuel Injection Control Linkage".
1. Loosen setscrews (4) on each bracket.
2. Install fuel control linkage (2) and install bolts (1). Use the following sequence in order to tighten the
bolts.
3. Tighten bracket (A) and (D) to a torque of 12 ± 3 N·m (106 ± 27 lb in).
4. Tighten brackets (B) and (C) to a torque of 12 ± 3 N·m (106 ± 27 lb in).
5. Position brackets (B) and (C) in order to allow free rotation of the fuel control rod.
6. Use a 2.5 mm (0.10 inch) wrench to tighten setscrews (4). Tighten the setscrews to a torque of 3.5 ±
0.2 N·m (31 ± 2 lb in). Do not overtighten the setscrews. Ensure that the control rod rotates freely.
7. The control rod should rotate freely when a force of 4.4 N (1 lb) or less is applied to control lever
(3) .

254
8. Rotate the unit injectors in order to engage the injector rack bar (5) with the fuel injection control
linkage (2) .
Note: If the unit injectors are not installed, refer to the Disassembly and Assembly, "Unit Injector -
Install".
9. Install Tooling (C) on the unit injectors and compress the springs.
Note: For the procedure to install Tooling (C), refer to Tool Operating Manual, NEHS0610, "Using
the 128-8822 Tool Group on 3114, 3116, and 3126 Engines with Mechanical Unit Injectors (MUI)".
10. Install clevis pin (6) in Tooling (B). Clevis pin (6) attaches the control lever (3) to the governor.
11. Use Tooling (B) to install clevis pin (6) and the clip.
12. Use Tooling (D) to set the unit injector synchronization.
Note: For the procedure to use Tooling (D), refer to Tool Operating Manual, NEHS0610, "Using the
128-8822 Tool Group on 3114, 3116, and 3126 Engines with Mechanical Unit Injectors (MUI)".
13. Remove Tooling (C) from the unit injectors.
14. Use Tooling (A) to slide tube assembly (5) into the governor.

255
15. Install clip (4) .
End By: Install the rocker arm assemblies and the pushrods. Refer to Disassembly and Assembly,
"Rocker Shaft and Pushrod - Install".

256
Unit Injector - Remove

Removal Procedure
Table 1
Required Tools
A 5P-0302 Bar 1
Start By:
Pushrod - Remove".
NOTICE
NOTICE
containing fluids.
Refer to Special Publication, NENG2500, "Caterpillar Dealer Service
Tool Catalog" for tools and supplies suitable to collect and contain
Note: For determining the ability to reuse a unit injector, refer to Special Instruction, SEHS9787, "Test
Procedure For Caterpillar 3114, 3116 And 3126 Mechanical Unit Injectors".
1. Remove fuel injector hold-down bolt (1) .

257
Note: Do not pry on the injector hold-down bracket. Damage to the unit injector could occur. The
unit injector has a notch on the opposite side of the rack. This notch is used for prying the unit
injector loose. Some fuel injector racks move freely when the spring is not compressed. Do not move
the fuel injector rack without compressing the fuel injector spring slightly. Damage may occur to the
unit injector.
2. Use Tooling (A) to loosen the unit injector. Rotate the unit injector in order to disengage injector
rack bar (3) from fuel injection control linkage (2) .
3. Remove the unit injector. Ensure that two O-ring seals are on the unit injector.

258
Unit Injector - Install

Table 1
Required Tools
B 4C-5553 Injector Seat Cleaning Brush 1
C 173-1530 Injector Seating Tool 1
D 143-2099 Unit Injector Tool Group (Sleeve Replacement) 1
NOTICE
Note: For determining the ability to reuse a unit injector, refer to Special Instruction, SEHS9787, "Test
Procedure For Caterpillar 3114, 3116 And 3126 Mechanical Unit Injectors".
1. Inspect the unit injector sleeve for pitting and for carbon tracking. Used unit injector sleeves do not
need to be reamed unless the seated area is pitted or eroded. If the seated area has excessive carbon
deposits, the used unit injector sleeves need to be reamed. Refer to Tool Operating Manual,
NEHS0675, "Using the 143-2099 Sleeve Replacement Tool Group on 3114, 3116, and 3126
Engines". Use Tooling (D) to ream injector sleeves.
2. Inspect the condition of the O-ring seals on the unit injector. Replace the seals, if necessary.
3. Lubricate the O-ring seals with clean engine oil.
4. Position the unit injector in the cylinder head and rotate the unit injector in order to engage injector
rack bar (3) with fuel injection control linkage (2) . Push down on the unit injector and ensure that
the unit injector is properly seated in the cylinder head.
Note: Do not use fuel injector hold-down bolt (1) to pull the unit injector into the cylinder head.
5. Install a new fuel injector hold-down bolt (1) in the hold-down bracket for the unit injector. Tighten
fuel injector hold-down bolt (1) to a torque of 12 ± 3 N·m (106 ± 27 lb in).
Note: Do not overtighten fuel injector hold-down bolt (1) . Excessive torque may cause damage to
the unit injector and the unit injector may seize.
6. Refer to the Tool Operating Manual, NEHS0738, "Using the 173-1530 Injector Seating Tool Group

259
on 3114, 3116, and 3126 MUI or 3126 HEUI 2-Valve Engines" for the remaining steps on installing
the unit injector.
End By:
a. Install the rocker shaft and the pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and
Pushrod - Install".
b. Synchronize the unit injectors. Refer to Testing and Adjusting, "Unit Injector Synchronization -
Adjust".

260
Unit Injector Sleeve - Remove

Removal Procedure
Table 1
Required Tools
A 143-2099 Unit Injector Tool Group 1
Start By:
A. Remove the unit injector. Refer to Disassembly and Assembly, "Unit Injector - Remove".
NOTICE
NOTICE
containing fluids.
1. Use Tooling (A) to remove unit injector sleeve (1) from the cylinder head. Refer to Tool Operating
Manual, NEHS0675, "Using the 143-2099 Sleeve Replacement Tool Group on 3114, 3116, and 3126
Engines" for the correct procedure.

261
Unit Injector Sleeve - Install

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

262
Turbocharger - Remove
Removal Procedure
NOTICE
NOTICE
containing fluids.
Note: For information on the reusability of components of the turbocharger, refer to Guideline For
Reusable Parts And Salvage Operations, SEBF8018, "Turbochargers". For information on the salvage
of components of the turbocharger, refer to Guideline For Reusable Parts And Salvage Operations,
SEBF8071, "Procedures to Salvage Turbocharger Components".
1. Disconnect oil supply tube assembly (5) from turbocharger (6) .
2. Remove bolts (1) and disconnect oil drain tube assembly (2) from turbocharger (6) .
3. Remove bolts (3) .
4. Remove locknuts (4) .
5. Remove turbocharger (6) and the gasket from the exhaust manifold.
Note: Place index marks on the turbocharger cartridge and the housing.
6. Remove the end housing from the cartridge.
Note: The wastegate is part of the turbine housing and the wastegate is preset at the factory. The
wastegate is nonserviceable.

263
Turbocharger - Install
Table 1
Required Tools
A 5P-3931 Anti-Seize Compound 1
NOTICE
Note: For information on the reusability of components of the turbocharger, refer to Guideline For
Reusable Parts And Salvage Operations, SEBF8018, "Turbochargers". For information on the
salvage of components of the turbocharger, refer to Guideline For Reusable Parts And Salvage
Operations, SEBF8071, "Procedures to Salvage Turbocharger Components".
1. Inspect the turbocharger gasket for wear or damage. If the turbocharger gasket is worn or damaged,
use a new part for replacement.
2. Apply Tooling (A) on the threads of the mounting studs for the turbocharger.
3. Position the turbocharger gasket and turbocharger (6) on the exhaust manifold. Install nuts (4) and
tighten nuts (4) to a torque of 54 ± 5 N·m (40 ± 4 lb ft).
4. Inspect the gaskets for oil supply tube assembly (5) and oil drain tube assembly (2). If the gaskets are
worn or damaged, use a new part for replacement.
5. Position oil drain tube assembly (2) and the gasket on turbocharger (6). Install bolts (1) on the
turbocharger and install bolts (3) on the cylinder block.
6. Install the gasket for oil supply tube assembly (5) and connect oil supply tube assembly (5) to
turbocharger (6) .

264
Exhaust Manifold - Remove and Install

Removal Procedure
Start By:
A. Remove the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Remove".
Typical example
1. Remove bolts (1), exhaust manifold (2), locks and the gaskets from the cylinder head assembly.
2. If the engine is equipped with a three-piece exhaust manifold, disassemble exhaust manifold (2) into
three pieces.
3. Remove mounting studs (3) from exhaust manifold (2), if necessary.
Table 1
Required Tools
A 5P-3931 Anti-Seize Compound 1
B 2P-2333 High Temperature Sealer 1
Typical example
1. Apply Tooling (A) to the threads of mounting studs (3) .
2. Install mounting studs (3). Tighten mounting studs (3) to a torque of 35 ± 5 N·m (26 ± 4 lb ft).
3. If the engine is equipped with a three-piece exhaust manifold, apply a thin coat of Tooling (B) to the
male ends of exhaust manifold (2). Coat the inside of the female ends of exhaust manifold (2) with
clean engine oil. Assemble exhaust manifold (2) and remove the excess sealant from the joints.
4. Install new exhaust manifold gaskets.

265
5. Apply Tooling (A) to the threads of bolts (1). Position the gaskets and exhaust manifold (2) on the
cylinder head assembly. Install locks and bolts (1) .

Typical example of a three-piece exhaust manifold Exhaust manifold for a Four cylinder engine

Water cooled exhaust manifold Typical example of locking tabs
6. Tighten bolts (1) in a numerical sequence to a torque of 4 ± 1 N·m (35 ± 9 lb in).
7. Tighten bolts (1) in a numerical sequence to a torque of 45 ± 5 N·m (33 ± 4 lb ft).
8. Bend the locking tabs (4) over the flat of each bolt head.
End By: Install the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Install".

266
Inlet Manifold - Remove

Removal Procedure
Start By:
A. Remove the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover
NOTICE
NOTICE
containing fluids.
1. Disconnect air inlet piping from the turbocharger to the aftercooler, if necessary.
2. Remove bolts (1) and disconnect air inlet heater solenoid (3) .
3. Remove air inlet elbows (2) from air inlet manifold (5) .
4. Remove bolts (4) from air inlet manifold (5) .
5. Remove air inlet manifold (5) and the gasket.

267
Inlet Manifold - Install

NOTICE
NOTICE
containing fluids.

1. Install a new gasket (6) on the cylinder head.
2. Position the air inlet manifold (5) on the engine.
3. Install bolts (4). Tighten the bolts to a torque of 28 ± 7 N·m (21 ± 5 lb ft).
4. Install air inlet elbows (2) on air inlet manifold (5) .
5. Install bolts (1) and connect air inlet heater solenoid (3) .
End By: Install the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism
Cover - Remove and Install".

268
Inlet and Exhaust Valves - Remove and Install

Removal Procedure
Table 1
Required Tools
A 5S-1330 Valve Spring Compressor 1
Start By:
A. Remove the cylinder head assembly. Refer to Disassembly and Assembly, "Cylinder Head -
Remove".
NOTICE
Note: For information on the reusability of the inlet valves, the exhaust valves and the springs, refer to
Guideline For Reusable Parts And Salvage Operations, SEBF8002, "Valves, Valve Springs, Valve
Rotators, and Locks", Guideline For Reusable Parts And Salvage Operations, SEBF8034, "Valve and
Valve Spring Specifications", and Guideline For Reusable Parts And Salvage Operations, SEBF8162,
"Specifications to Measure and Salvage Cylinder Head Assemblies and Related Components".
Note: The following components of the exhaust valves are different from the components of the inlet
valves: spring retainer (2), valve spring (3) and valve (5).
1. Use Tooling (A) to compress valve spring (3). Remove retainer lock (1) .
2. Remove Tooling (A) .
3. Remove spring retainer (2). Remove valve spring (3) .
4. Remove valve seal (4) and valve (5) .
5. Repeat Steps 1 through 4 in order to remove the remaining inlet valves and exhaust valves.

269
Table 2
Required Tools
A 5S-1330 Valve Spring Compressor 1
NOTICE
Note: For information on the reusability of the inlet valves, the exhaust valves and the springs, refer to
Guideline For Reusable Parts And Salvage Operations, SEBF8002, "Valves, Valve Springs, Valve
Rotators, and Locks", Guideline For Reusable Parts And Salvage Operations, SEBF8034, "Valve and
Valve Spring Specifications", and Guideline For Reusable Parts And Salvage Operations, SEBF8162,
"Specifications to Measure and Salvage Cylinder Head Assemblies and Related Components".
1. Lubricate valve (5) with clean engine oil. Install valve (5) in the cylinder head assembly. Install new
valve seal (4) against the valve guide.
2. Place the following items on the valve stem: valve spring (3) and spring retainer (2) .
The valve keepers can be thrown from the valve when the valve spring
compressor is released. Ensure that the valve keepers are properly
installed on the valve stem. To help prevent personal injury, keep away
from the front of the valve keepers and valve springs during the
installation of the valves.
Note: A small amount of grease can be used to hold retainer locks (1) in position during installation.

270
3. Use Tooling (A) to compress valve spring (3). Install retainer lock (1) .
4. Repeat Steps 1 through 3 in order to install the remaining inlet valves and exhaust valves.
End By: Install the cylinder head assembly. Refer to Disassembly and Assembly, "Cylinder Head -
Install".

271
Inlet and Exhaust Valve Guides - Remove and Install

Removal Procedure
Table 1
Required Tools
A 1U-7793 Valve Guide Driver (1) 1
(1) Part of 1U-6685 Valve Guide Tool Kit
Start By:
A. Remove the inlet and exhaust valves. Refer to Disassembly and Assembly, "Inlet and Exhaust
Valves - Remove and Install".
NOTICE
Note: For information on the reusability of the valve guides, refer to Guideline For Reusable Parts And
Salvage Operations, SEBF8218, "Specifications for Cylinder Head Asseblies 3114, 3116, and 3126
Engines" and Guideline For Reusable Parts And Salvage Operations, SEBF8162, "Procedure to
Measure and Salvage Cylinder Head Assemblies and Related Components".
Typical example
1. Use Tooling (A) to remove the inlet valve guides from the cylinder head assembly. Use Tooling (A)
to remove the exhaust valve guides from the cylinder head assembly.

272
Table 2
Required Tools
A 1U-7793 Valve Guide Driver (1) 1
B 1U-7792 Guide Collar (1) 1
C 9U-6895 Valve Guide Driver 1
D 149-4008 Guide Collar 1
(1) Part of 1U-6685 Valve Guide Tool Kit
NOTICE
Note: For information on the reusability of the valve guides, refer to Guideline For Reusable Parts And
Salvage Operations, SEBF8218, "Specifications for Cylinder Head Assemblies 3114, 3116, and 3126
Engines" and Guideline For Reusable Parts And Salvage Operations, SEBF8162, "Procedure to

Typical example Typical example
1. Position inlet valve guide (1) and tap on the top of inlet valve guide (1). This is done in order to start
inlet valve guide (1) into the cylinder head assembly.
2. Use Tooling (A) and Tooling (B) to install inlet valve guide (1). Install inlet valve guides (1) until
tooling (B) contacts the cylinder head.
3. Position exhaust valve guide (2) and tap on the top of exhaust valve guide (2). This is done in order
to start the exhaust valve guide into the cylinder head assembly.
Note: Some of the early engines have inlet valves and exhaust valves that are identical in size. Use
the same specifications and the same tools for both valves. Proceed to Step 4 if the valves are not the
same size.
4. Use Tooling (C) and Tooling (D) to install exhaust valve guide (2). Install inlet valve guides (2) until
tooling (D) contacts the cylinder head.
End By: Install the inlet and exhaust valves. Refer to Disassembly and Assembly, "Inlet and Exhaust

273
Inlet and Exhaust Valve Seat Inserts - Remove and Install

Removal Procedure
Table 1
Required Tools
A (1) 6V-4194 Valve Seat Extractor 1
B (1) 165-5647 Valve Seat Extractor 1
C (1) 6V-4804 Handle 1
D (1) 6V-4192 Threaded Shaft 1
E (1) 6V-4199 Lifting Bracket 1
(1) Part of the 166-7441 Valve Seat Extractor Tool
Start By:
A. Remove the inlet and exhaust valves. Refer to Disassembly and Assembly, "Inlet and Exhaust
NOTICE
Note: For information on the reusability of the valve seats, refer to Guideline For Reusable Parts And
Engines".
Note: Replace Tooling (A) with Tooling (B) for the removal of the inlet valve seat insert.
1. Install Tooling (A) in the exhaust valve seat insert.
2. Install Tooling (C) and Tooling (D) in Tooling (A). Hand tighten Tooling (D). Tooling (A) will
expand below the edge of valve seat insert (1) .

274
3. Install Tooling (E) on the cylinder head under Tooling (C). Hold Tooling (D) while you turn Tooling
(C). Remove valve seat insert (1) .
Table 2
Required Tools
F 1U-6685 Guide and Insert Tool Group 1
NOTICE
Note: For information on the reusability of the valve seats, refer to Guideline For Reusable Parts And
Engines".
1. Cool the valve seat inserts for easier installation.
2. Turn Tooling (F) upside-down and use Tooling (F) and a press to install the valve seat inserts in the
cylinder head assembly.
3. After the valve seat inserts are installed, grind the inserts to the final specification. Refer to Guideline
275
for Reusable Parts and Salvage Operation, SEBF8218, "Specifications for Cylinder Head Assemblies
3114, 3116, and 3126 Engines" for the specifications.
End By: Install the inlet valves and exhaust valves. Refer to Disassembly and Assembly, "Inlet and
Exhaust Valves - Remove and Install".

276
Engine Oil Filter Base - Remove

Removal Procedure
Table 1
Required Tools
A 185-3630 Strap Wrench 1
Start By:
A. Remove the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Remove".
NOTICE
NOTICE
containing fluids.
1. Use Tooling (A) to remove engine oil filter (3) .
2. Disconnect the tube assembly for the turbocharger inlet (1) from the engine oil filter base (4) .
3. Remove bolts (2) and the washers that hold engine oil filter base (4) to the cylinder block.
4. Remove engine oil filter base (4) and the gasket.

277
Engine Oil Filter Base - Disassemble

Start By:
A. Remove the engine oil filter base. Refer to Disassembly and Assembly, "Engine Oil Filter Base -
Remove".
Personal injury can result from being struck by parts propelled by a

released spring force.
Make sure to wear all necessary protective equipment.
Follow the recommended procedure and use all recommended tooling to
release the spring force.
1. Remove plugs (1) and (3) from oil filter base (2) .
2. Remove springs (4) and valves (6). Remove O-ring seals (5) from plugs (1) and (3). Inspect the parts
for wear or damage. If the parts are worn or damaged, use new parts for replacement.

278
Engine Oil Filter Base - Assemble

Assembly Procedure

1. Install O-ring seals (5) onto plugs (1) and (3). Install valves (6) and springs (4) .
injury.
2. Install plugs (1) and (3) onto oil filter base (2) .
End By: Install the engine oil filter base. Refer to Disassembly and Assembly, "Engine Oil Filter Base
- Install".

279
Engine Oil Filter Base - Install

NOTICE
1. Position the gasket and engine oil filter base (4) on the cylinder block.
2. Install the washers and bolts (2) that hold engine oil filter base (4) to the cylinder block. Tighten the
bolts according to the following procedure:
a. Tighten Bolt (1) through Bolt (15) in a numerical sequence to a torque of 15 N·m (11 lb ft).
b. Tighten Bolt (1) through Bolt (15) in a numerical sequence to a torque of 28 N·m (21 lb ft).
3. Apply lubricant to new O-ring seal (5) . Install O-ring seal (5) in the fitting on the engine oil filter
base.
4. Connect tube assembly (1) to engine oil filter base (4) .
Note: Never install an oil filter with a wrench. Follow the instructions on the oil filter.
5. Put a coat of fresh oil on the O-ring seal for the engine oil filter. Install engine oil filter (3) on engine
oil filter base (4) by hand.
6. After the O-ring seal contacts engine oil filter base (4) , turn engine oil filter (3) for 3/4 of a turn.
End By: Install the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Install".

280
Engine Oil Filter Bypass Valve - Remove and Install

Removal Procedure
NOTICE
NOTICE
containing fluids.

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

281
NOTICE
injury.
1. Inspect the condition of the O-ring seal. Replace the seal, if necessary.
2. Install bypass valve (3) and valve spring (2) in the engine oil filter base.
3. Install plug (1) in the engine oil filter base.

282
Engine Oil Cooler Bypass Valve - Remove and Install

Removal Procedure
NOTICE
NOTICE
containing fluids.

1. Remove plug (1) and the O-ring seal from the engine oil cooler.
2. Remove valve spring (2) and bypass valve (3) from the engine oil cooler.
NOTICE
283
injury.
1. Inspect the condition of the O-ring seal. Replace the seal, if necessary.
2. Install bypass valve (3) and valve spring (2) in the engine oil cooler.
3. Install plug (1) in the engine oil cooler.

284
Engine Oil Cooler - Remove

Removal Procedure
Start By:
A. Remove the engine oil filter base. Refer to Disassembly and Assembly, "Engine Oil Filter Base -
Remove".
NOTICE
NOTICE
containing fluids.
Note: For information on the reusability of the engine oil cooler, refer to Guideline For Reusable Parts
And Salvage Operations, SEBF8077, "Engine Oil Coolers".

1. Remove engine oil cooler (1) and the gasket.
2. Remove O-ring seals (2) .

285
Engine Oil Cooler - Install

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

1. Install new O-ring seals (2) .
2. Install new gasket (3) on the engine oil cooler (1) .
Note: Installation can be simplified by the use of guide bolts.

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

286
Engine Oil Pump - Remove

Removal Procedure
Start By:
A. Remove the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove and
Install".
NOTICE
NOTICE
containing fluids.
Note: For information on the reusability of the engine oil pump, refer to Guideline For Reusable Parts
And Salvage Operations, SEBF8167, "Reconditioning Procedures 3114 and 3116 Engines".
1. Remove bolts (1) and bolt (2) .
2. Remove engine oil pump (3) .
3. Remove the O-ring seal that is located between the cylinder block and the outlet elbow.

287
Engine Oil Pump - Disassemble

Table 1
Required Tools
A 1P-0510 Driver Gp 1
B 1P-2320 Combination Puller 1
Start By:
A. Remove the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump - Remove".
NOTICE
NOTICE
containing fluids.

1. Remove the bolts from tube assembly for the pickup of oil (2), and the gasket from the engine oil
pump. Remove the bolt and outlet elbow (1) from the engine oil pump.
2. Remove bolt (3), washer (4), and idler gear (5) from the engine oil pump.

288

3. Use Tooling (A) and a suitable press in order to remove the bearing from idler gear (5) .
4. Remove shaft (6) of engine oil pump from oil pump body assembly (7) .
5. Use Tooling (B) to remove drive gear (8) .
6. Remove bolts (10). Separate oil pump body (9) from oil pump body assembly (7) .
NOTICE
Before removing the drive shaft from the pump housing, be sure that
no burrs exist on the drive shaft. If the drive shaft has burrs on it, the
bores in the pump housing may be scratched.
7. Remove shaft assembly (11) and shaft assembly (12) from oil pump body (9) .
Personal injury can result from parts and/or covers under spring
pressure.
Spring force will be released when covers are removed.
Be prepared to hold spring loaded covers as the bolts are loosened.
8. Remove the following items from oil pump body assembly (7) : the bolt and the washer, spring (14)
and oil pressure relief plunger (13)
289
Engine Oil Pump - Assemble

Assembly Procedure
Table 1
Required Tools
NOTICE
1. Ensure that all of the parts of the engine oil pump are thoroughly clean prior to assembly.
Note: Lubricate all internal parts of the engine oil pump with clean engine oil.
injury.
2. Install oil pressure relief plunger (13) and spring (14) in oil pump body assembly (7). Install the
washer and the bolt.

290

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

6. Press drive gear (8) on shaft assembly (11) until drive gear (8) is flush with the end of shaft assembly
(11) .
7. Install oil pump shaft (6). Install the bearing in idler gear (5) with Tooling (A). Install the bearing so
the distance between the hub bolt face of idler gear (5) and the bearing is 0.75 ± 0.25 mm (0.030 ±
0.010 inch).
8. Install idler gear (5) on oil pump shaft (6). Install washer (4) and bolt (3). Tighten bolt (3) to 70 ± 15
N·m (52 ± 11 lb ft).
9. Check the condition of the gasket that is used in tube assembly for the pickup of oil (2). If the gasket
is damaged, replace the gasket. Install the gasket and tube assembly for the pickup of oil (2) .
10. Check the condition of the O-ring seal that is used in outlet elbow (1). If the O-ring seal is damaged,
replace the O-ring seal. Install the O-ring seal and outlet elbow (1) .
End By: Install the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump - Install".

291
Engine Oil Pump - Install

NOTICE
Note: Ensure that the mounting surfaces for the engine oil pump are thoroughly clean.
1. Install the O-ring seal. Position engine oil pump (3) on the cylinder block.
2. Install bolts (1) and bolt (2) .
End By: Install the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove
and Install".

292
Water Pump - Remove

Removal procedure
NOTICE
NOTICE
containing fluids.
Remove cooling system pressure cap slowly to relieve pressure only
when engine is stopped and cooling system pressure cap is cool enough
to touch with your bare hand.
Do not attempt to tighten hose connections when the coolant is hot, the
hose can come off causing burns.
Cooling System Coolant Additive contains alkali. Avoid contact with
skin and eyes.
1. Drain the coolant from the cooling system into a suitable container for storage or for disposal.
2. Use hole (4) to remove tension from the V-belt.
3. Loosen bolts (3) and (6) on idler pulley assembly (7) .

293
Note: For information on the reusability of idler pulley assembly (7), refer to Guideline For Reusable
Parts And Salvage Operations, SEBF8046, "Cast Iron and Steel Pulleys".
4. Remove water pump V-belt (5) .
5. Loosen hose clamps (1). Disconnect the hose assembly between the water pump and the water
temperature regulator housing.
6. Remove bolts (2) that hold the water pump to the front of the engine. Carefully remove the water
pump and two O-ring seals from the front of the engine.

294
Water Pump - Disassemble

Table 1
Required Tools
A 1P-0510 Driver Group 1
B 1P-0520 Driver Group 1
Start By:
A. Remove the water pump. Refer to Disassembly and Assembly, "Water Pump - Remove".
NOTICE
containing fluids.

1. Remove O-ring seals (1) from the rear cover of the water pump. Remove bolts (2) and the washers.
Remove the rear cover and the gasket.
2. Position the water pump in a press. Use spacer plates to level the water pump.
3. Push the shaft and pulley (3) out of impeller (4) with a suitable drive plate from Tooling (A) and a
press. Remove the impeller.
Note: For information on the reusability of pulley (3), refer to Guideline For Reusable Parts And
Salvage Operations, SEBF8046, "Cast Iron and Steel Pulleys".
Note: The new 7E-0321 Pump Impeller, 153-9123 Impeller and a 109-5324 Impeller can be
removed with a bolt. Insert a bolt 0.75inch into the thread insert of the impeller. Turn the bolt inward
toward the shaft. Twist and pull the impeller out of the pump.

295
Note: Do not allow the shaft and the pulley to fall to the floor when the shaft and the pulley are
removed.
4. Continue to push the shaft and pulley (3) out of seal (5) and the water pump housing.
5. Remove seal (5) from the water pump housing with the handle from Tooling (B) and a press.
6. Remove the shaft and the bearing from pulley (3) with a press.

296
Water Pump - Assemble

Assembly Procedure
Table 1
Required Tools
C 5P-9722 Seal Driver 1
NOTICE

1. Install the shaft and the bearing into pulley (3) with a press. Install the shaft until the shaft is flush
with the end of pulley (3) .
2. Press the shaft, the bearing, and pulley (3) as a unit into the water pump housing. The distance
between the front of pulley (3) and the machined surface of the water pump housing must be 103.8 ±
0.3 mm (4.09 ± 0.01 inch).
Note: For information on the reusability of pulley (3), refer to Guideline For Reusable Parts And
Salvage Operations, SEBF8046, "Cast Iron and Steel Pulleys".
3. Install seal (5) in the water pump housing with Tooling (C) .

297
4. Install impeller (4) on the shaft of the water pump with a press. Install the impeller until the distance
between the impeller and the machined surface of the water pump is 0.75 ± 0.25 mm (0.030 ± 0.010
inch).
5. Install a new gasket between the rear cover of the water pump and the water pump housing. Position
the gasket and the cover on the water pump housing. Install bolts (2) and the washers.
6. Install new O-ring seals (1) in the rear cover.
End By: Install the water pump. Refer to Disassembly and Assembly, "Water Pump - Install".

298
Water Pump - Install

NOTICE
NOTICE
containing fluids.
1. Install new O-ring seals in the cover of the water pump. Position the water pump on the front of the
engine. Install bolts (2) .
2. Connect the hose assembly between the water pump and the water temperature regulator housing.
Tighten hose clamps (1) that hold the hose in position.
3. Position V-belt (5) on the idler pulley assembly (7) .
Note: For information on the reusability of idler pulley assembly (7), refer to Guideline For Reusable
4. Adjust the tension on the water pump V-belt (5) .
5. Use hole (4) to apply tension to the V-belt. Refer to Specifications, "Belt Tensioner Chart" for the
correct tension on the belt.
6. Fill the cooling system to the correct level. Refer to the Operation and Maintenance Manual, "Refill
Capacities" topic for the correct fluid and the correct filling procedure.

299
Water Temperature Regulator Housing - Remove and Install

Removal Procedure
NOTICE
NOTICE
containing fluids.
1. Drain the coolant from the cooling system into a suitable container for storage or disposal.
2. Loosen clamp (3) .
4. Remove water temperature regulator housing (1) and the gasket from the cylinder head.
NOTICE

300
1. Install a new gasket and water temperature regulator housing (1) on the cylinder head.
2. Install bolts (2) .
3. Tighten clamp (3) .
4. Fill the cooling system with coolant to the correct level. Refer to the Operation and Maintenance
Manual for the correct procedure.

301
Water Temperature Regulator - Remove and Install

Removal Procedure
NOTICE
Typical Example
3. Remove pipe assembly for the water outlet (2) and remove the gasket from the water temperature
regulator housing.
4. Remove water temperature regulator (3) from the water temperature regulator housing.
NOTICE

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

302
Aftercooler - Remove
Removal Procedure
Table 1
Required Tools
A 8T-0292 Bolt 2
NOTICE
NOTICE
containing fluids.
At operating temperature, the engine coolant is hot and under pressure.

Steam can cause personal injury.
Check the coolant level only after the engine has been stopped and the
fill cap is cool enough to touch with your bare hand.
Remove the fill cap slowly to relieve pressure.
Cooling system conditioner contains alkali. Avoid contact with the skin
and eyes to prevent personal injury.
Note: Put identification marks on all hose assemblies, on all wires, and on all tube assemblies for
installation purposes. Plug all hose assemblies and tube assemblies. This helps to prevent fluid loss and
this helps to keep contaminants from entering the system.

303

2. Remove bolts (2). Remove exhaust elbow (1) and exhaust pipe assembly (3) .
3. Loosen clamp (4) .
4. Disconnect coupling (5) .
5. Loosen clamps (6) and (7) .
6. Remove two top bolts (8) and install Tooling (A). Remove remaining bolts (8). Remove aftercooler
(10) .
7. Remove gasket (9) from aftercooler (10) .

304
Aftercooler - Install
Table 1
Required Tools
A 4C-9502 Gasket Sealant 1
B 5P-3931 Anti-Seize Compound 1
NOTICE
Note: Use a new gasket in order to install the aftercooler.
Note: Apply Tooling (A) to the threads of the bottom bolts before installation.
1. Install gasket (9) on the engine. Install aftercooler (10). Install bolts (8) .
2. Tighten clamp (6) and tighten clamp (7) .
3. Tighten clamp (4).
4. Connect coupling (5) .

305
Note: Apply Tooling (B) to the threads of the exhaust elbow bolts.
5. Install exhaust elbow (1) and exhaust pipe (3). Install bolts (2) .
6. Fill the cooling system. Refer to Operation and Maintenance Manual, SEBU7098, "Cooling System
Level - Check" for the correct procedure.

306
Engine Lifting Bracket - Remove and Install

Removal Procedure

1. Remove bolts (2) and the washers.
2. Remove engine lifting bracket (1) from the front of the engine.
4. Remove engine lifting bracket (3) from the rear of the engine.

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

307
Flywheel - Remove
Removal Procedure
Table 1
Required Tools
A 138-7573 Link Bracket 2
B - Guide Bolt (M16 x 2 by 4 inch) 1
Note: For information on the reusability of the flywheel on 3116 engines, refer to Guideline For
Reusable Parts And Salvage Operations, SEBF8207, "Flywheel Specifications for 3116 Engines".
1. Support the engine with blocks or a suitable lifting device.
2. Install Tooling (A) on the flywheel. Fasten a suitable lifting device to the flywheel.
3. Remove top bolt (1) and the washers. Install Tooling (B). Remove remaining bolts (1) and the
washers.
4. Remove flywheel (2) from Tooling (B). The weight of flywheel (2) is approximately 23 kg (50 lb).
5. Inspect the flywheel ring gear. Replace the ring gear, if necessary. Place the flywheel on a wood
block. Use a hammer and a punch in order to remove the flywheel ring gear.

308
Flywheel - Install
Table 1
Required Tools
B - Guide Bolt (M16 x 2 by 4 inch) 1
C 9S-3263 Thread Lock Compound 1
Note: For information on the reusability of the flywheel on 3116 engines, refer to Guideline For
Reusable Parts And Salvage Operations, SEBF8207, "Flywheel Specifications for 3116 Engines".
Note: Drill and tap the new flywheel ring gear if the outer bolt holes of the flywheel are used. Use
the flywheel as a template and drill twelve holes to a diameter of 8.2 mm (0.32 inch). Thread the
holes with a tap.
1. Raise the temperature of the flywheel ring gear to a maximum temperature of 204 °C (400 °F). Do
not use a torch to heat the flywheel ring gear. Install the flywheel ring gear on the flywheel. Position
the flywheel ring gear with the part number toward the crankshaft. Allow the flywheel ring gear to
cool. Use a soft hammer in order to seat the flywheel ring gear against the shoulder of the flywheel.
2. Install Tooling (A) on flywheel (2). Fasten a suitable lifting device to flywheel (2) .
3. Place flywheel (2) in the original position on Tooling (B). Align the arrows on flywheel (2) and the
crankshaft.
4. Apply Tooling (C) to the threads of bolts (1) .
5. Install bolts (1) and the washers. Remove Tooling (B) and install remaining bolt (1) and the washer.
Tighten the bolts evenly to a torque of 120 ± 20 N·m (90 ± 15 lb ft).
6. Check the flywheel runout. Refer to Testing and Adjusting, "Basic Block" for the correct procedure.

309
Crankshaft Rear Seal - Remove

Removal Procedure
Table 1
Required Tools
A 1U-8145 Drill Bit 1
B 1U-7600 Slide Hammer Puller Gp 1
C 4C-4869 Distorter Ring 1
D 5P-7312 Seal Distorter 1
Start By:
A. Remove the flywheel. Refer to Disassembly and Assembly, "Flywheel - Remove".
NOTICE
1. Use Tooling (A) to drill three evenly spaced holes in the crankshaft rear seal.
2. Carefully remove crankshaft rear seal (1) by alternating the position of Tooling (B) from hole to
hole. This will allow crankshaft rear seal (1) to be removed evenly without damage to the rear flange
surface of the crankshaft.
Note: New engines from the factory do not have a wear sleeve. Engines with seals that have been
replaced will be equipped with a wear sleeve. If the crankshaft of the engine is equipped with a wear
sleeve, refer to Disassembly and Assembly, "Crankshaft Wear Sleeve (Rear) - Remove" in order to
remove the wear sleeve.
3. Use Tooling (C) and Tooling (D) to remove the wear sleeve (if equipped).

310
Crankshaft Rear Seal - Install

Table 1
Required Tools
E 1U-7598 Seal Installer Gp 1
NOTICE
Note: Replacement rear seals are supplied with a wear sleeve. This wear sleeve must be installed with
the rear seal. New engines from the factory do not have a wear sleeve. Do not install the rear seal if any
of the following conditions exist:
¡ The crankshaft rear seal has been separated from the wear sleeve.
¡ The rear seal group appears to be damaged.
¡ The crankshaft rear seal has been lubricated. The seal is designed to be installed dry.
1. Ensure that the rear of the crankshaft is thoroughly clean and dry prior to the installation of the
crankshaft rear seal.
Typical example
2. Use Tooling (E) to install crankshaft rear seal (1) .
End By: Install the flywheel. Refer to Disassembly and Assembly, "Flywheel - Install".

311
Crankshaft Wear Sleeve (Rear) - Remove - If Equipped

Removal Procedure
Table 1
Required Tools
A 4C-4869 Distorter Ring 1
B 5P-7312 Seal Distorter 1
Start By:
A. Remove the crankshaft rear seal. Refer to Disassembly and Assembly, "Crankshaft Rear Seal -
Remove".
NOTICE
Note: Wear sleeves are not installed at the factory. The wear sleeve is included with the replacement
rear seal.
1. Install Tooling (A) in the bore of the crankshaft rear sleeve.
2. Install Tooling (B) between Tooling (A) and the crankshaft wear sleeve. Turn Tooling (B) until the
edge of Tooling (B) makes a crease in the crankshaft wear sleeve. Make a crease in the crankshaft
wear sleeve at two other locations around the crankshaft wear sleeve until the crankshaft wear sleeve
is loose.
3. Remove Tooling (B), Tooling (A), and the crankshaft wear sleeve from the end of the crankshaft.

312
Crankshaft Wear Sleeve (Rear) - Install

Table 1
Required Tools
C (1) 132-8772 Seal Locator 1
D (1) 1U-7596 Bolt 2
E (1) 1U-7597 Sleeve Ring 1
F (1) 1U-7594 Seal Installer 1
G (1) 9S-8858 Nut 1
(1) Part of the 1U-7598 Seal Installer
NOTICE
1. Ensure that the rear of the crankshaft is thoroughly clean and dry prior to the installation of the
crankshaft rear seal.
Typical example
2. Fasten Tooling (C) to the rear of the crankshaft with Tooling (D). Hand tighten Tooling (D) .
3. Position the crankshaft rear seal and crankshaft rear sleeve (1) on Tooling (C). Position Tooling (E)
on Tooling (C) .
4. Position Tooling (F) over Tooling (C) and Tooling (E). Install Tooling (G). Tighten Tooling (G) in
order to install the crankshaft rear seal and the crankshaft wear sleeve.
5. Remove Tooling (G), Tooling (F), and Tooling (E). Turn over Tooling (E). Install Tooling (E),
Tooling (F), and Tooling (G). Tighten Tooling (G) in order to complete the installation of the
crankshaft rear seal and the crankshaft wear sleeve.
6. Remove Tooling (G) and Tooling (F). Check Tooling (E) and Tooling (C). The faces of Tooling (E)
and Tooling (C) will be flush if the crankshaft rear seal and the crankshaft wear sleeve are properly
installed. Refer to the Specifications module for more information.
7. Remove Tooling (E), Tool (E), and Tooling (C) .

313
Crankshaft Rear Seal Carrier - Remove and Install

Removal Procedure
Start By:
A. Remove the flywheel housing. Refer to Disassembly and Assembly, "Flywheel Housing - Remove
and Install".
NOTICE
2. Remove rear seal carrier (2) .
Table 1
Required Tools
A 138-8440 Component Cleaner
B 169-5464 Quick Cure Primer
C 1U-8846 Gasket Sealant
D 9S-3263 Thread Lock Compound
NOTICE

314
1. Clean the joint face of rear seal carrier (2) and the cylinder block with Tooling (A) .
2. Apply Tooling (B) to the joint face of rear seal carrier (2). Allow the primer to air dry for three to
five minutes.
Note: Tooling (C) is used on the joint face of rear seal carrier (2). Do not allow the sealant to get into
the oil passage in the mounting face of the cylinder block.
3. Apply Tooling (C) to the joint face of rear seal carrier (2). Spread the sealant uniformly. Rear seal
carrier (2) must be installed within ten minutes of application of the sealant.
4. Position rear seal carrier (2) on the dowels in the rear of the cylinder block.
5. Apply Tooling (D) on the threads of bolts (1). Install bolts (1) that hold rear seal carrier (2) to the
cylinder block.
End By: Install the flywheel housing. Refer to Disassembly and Assembly, "Flywheel Housing -

315
Flywheel Housing - Remove and Install

Removal Procedure
Table 1
Required Tools
Start By:
A. Remove the flywheel. Refer to Disassembly and Assembly, "Flywheel - Remove".
NOTICE
NOTICE
containing fluids.
1. Fasten Tooling (A) and a suitable lifting device to flywheel housing (1) .
2. Remove bolts (2) and bolt (3) that fastens the flywheel housing to the cylinder block.
3. Remove bolts (4). Remove flywheel housing (1). The weight of flywheel housing (1) is
approximately 25 kg (55 lb).

316
Table 2
Required Tools
B 1U-8846 Gasket Sealant 1
NOTICE
1. Apply Tooling (B) to the entire mounting face of the flywheel housing prior to installation.
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 flywheel housing (1) on the cylinder block.
Install bolts (4) .
3. Install bolts (2) and bolt (3) .

317
Vibration Damper and Pulley - Remove and Install

Removal Procedure
NOTICE
NOTICE
containing fluids.

1. Remove bolts (2), crankshaft vibration damper (3), and spacers from the crankshaft pulley.
Note: For information on the reusability of the vibration damper on 3114 and 3116 engines, refer to
Guideline For Reusable Parts And Salvage Operations, SEBF8220, "Specifications for Damper
Inspection 3114 and 3116 Engines".
2. Loosen the tension on water pump drive belt (1). Remove the belt from the crankshaft pulley.
4. Remove crankshaft pulley (5) .
Note: For information on the reusability of the crankshaft pulley, refer to Guideline For Reusable
NOTICE

318

1. Position crankshaft pulley (5) on the crankshaft. Install bolts (4) and tighten the bolts to a torque of
160 ± 30 N·m (118 ± 22 lb ft).
Note: For information on the reusability of the crankshaft pulley, refer to Guideline For Reusable
2. Install water pump drive belt (1) .
Note: Check the alignment marks on the rubber vibration dampers for proper alignment. The rubber
vibration damper should be replaced if the rubber vibration damper is out of alignment. Refer to
Specifications, "Vibration Damper".
3. Install spacers and crankshaft vibration damper (3). Tighten bolts (2) to a torque of 55 ± 10 N·m (40
± 7 lb ft).
Note: For information on the reusability of the vibration damper on 3114 and 3116 engines, refer to
Guideline For Reusable Parts And Salvage Operations, SEBF8220, "Specifications for Damper
Inspection 3114 and 3116 Engines".
4. Adjust the tension of water pump drive belt (1). Refer to the Specifications Module, "Belt Tension
Chart". Also, refer to the Operation and Maintenance Manual, "Belt - Inspect".

319
Crankshaft Front Seal - Remove

Removal Procedure
Table 1
Required Tools
A 1U-7600 Slide Hammer Puller 1
B 1U-8145 Drill Bit 1
Start By:
A. Remove the vibration damper and the pulley. Refer to Disassembly and Assembly, "Vibration
Damper and Pulley - Remove and Install".
NOTICE
1. Use Tooling (B) and carefully drill three evenly spaced holes in crankshaft front seal (1) .
2. Alternate between the drilled holes and use Tooling (A) to remove crankshaft front seal (1) .

320
Crankshaft Front Seal - Install

Table 1
Required Tools
C 1U-7430 Front Seal Installer 1
NOTICE
1. Use Tooling (C) to install crankshaft front seal (1) .
Note: The crankshaft seal is designed to be installed dry.
End By: Install the vibration damper and the pulley. Refer to Disassembly and Assembly, "Vibration
Damper and Pulley - Remove and Install".

321
Front Cover - Remove

Removal Procedure
Note: It is not necessary to remove the vibration damper and the crankshaft pulley in order to
remove the front cover.
1. Remove bolts (1) from front cover (2) .
2. Remove front cover (2) and the gasket from the front of the engine.

322
Front Cover - Install

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

323
Gear Group (Front) - Remove

Removal Procedure
Table 1
Required Tools
Start By:
A. Remove the crankshaft vibration damper. Refer to Disassembly and Assembly, "Vibration Damper
and Pulley - Remove and Install".
B. Remove the crankshaft front seal. Refer to Disassembly and Assembly, "Crankshaft Front Seal -
Remove".
C. Remove the camshaft. Refer to Disassembly and Assembly, "Camshaft - Remove".
D. Remove the front housing. Refer to Disassembly and Assembly, "Housing (Front) - Remove".
Note: For information on reusability of the camshaft idler gear, refer to Guideline For Reusable Parts
And Salvage Operations, SEBF8045, "Timing Gears for All Engines".
1. Place the engine at the Top Center position. The timing marks should be in line with the crankshaft
gear.

2. Identify the type of idler gear on the engine. Remove bolts (1) that hold the idler gear to the block.
Remove plate (7) .
3. Identify the location of timing marks (4) and (5) on the camshaft idler gear. Identify the location of
timing mark (6) on the crankshaft drive gear.
4. Remove idler shaft (3) and camshaft idler gear (2). Separate idler gear (2) from idler shaft (3) and
remove the sleeve bearing from the camshaft idler gear.
5. Use Tooling (A) and a press to remove the bearing.

324
Gear Group (Front) - Install

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

325
Type 2
1. Use Tooling (A) and a suitable press and install the sleeve bearing in the camshaft idler gear.
2. Install plate (4) on the back of idler shaft (3). Position idler gear assembly on the cylinder block.
Install bolts that hold the idler gear to the engine block. Tighten the bolts to a torque of 70 ± 15 N·m
(51 ± 11 lb ft).
4. Align the timing marks on camshaft idler gear (2) with the timing marks on the crankshaft drive gear.

326
Type 3
1. Position idler shaft (3) on the cylinder block. Install the shortest bolt in the recessed hole in idler
shaft (3). This bolt will hold the shaft in position on the cylinder block.
3. Align the timing marks on idler gear (2) with the timing marks on the camshaft drive gear.
4. Position plate (4) over the gear and install the remaining bolts (1). Tighten bolts (1) to a torque of 70
± 15 N·m (51 ± 11 lb ft).
End By:
a. Install the front housing. Refer to Disassembly and Assembly, "Housing (Front) - Install".
b. Install the camshaft. Refer to Disassembly and Assembly, "Camshaft - Install".
c. Install the crankshaft front seal. Refer to Disassembly and Assembly, "Crankshaft Front Seal -
Install".
d. Install the crankshaft vibration damper and pulley. Refer to Disassembly and Assembly, "Vibration
Damper and Pulley -Remove and Install".

327
Housing (Front) - Remove

Removal Procedure
Start By:
A. Remove the crankshaft vibration damper. Refer to Disassembly and Assembly, "Vibration Damper
and Pulley - Remove and Install".
B. Remove the crankshaft front seal. Refer to Disassembly and Assembly, "Crankshaft Front Seal -
Remove".
C. Remove the camshaft. Refer to Disassembly and Assembly, "Camshaft - Remove".
NOTICE
containing fluids.
1. Remove any external components, if equipped.

2. Support the front of the engine.
3. Remove bolts (2) and remove front engine support.
4. Remove bolts (1) and belt tightener (3) .
5. Remove bolts (5) that fasten front housing (4) to the cylinder block and to the engine oil pan.
Remove front housing (4). Clean the sealant from front housing (4) and the cylinder block.

328
Housing (Front) - Install

Table 1
Required Tools
Tools Part Number Part Description Qty
A 138-8440 Component Cleaner 1
B 169-5464 Quick Cure Primer 1
C 1U-8846 Gasket Sealant 1
1. Clean the joint face on front housing (4) with Tooling (A) .
2. Apply Tooling (B) to the joint face. Allow the primer to dry for at least three to five minutes.
Note: Do not allow Tooling (C) to seal the main oil passage on front housing (4) .
3. Apply Tooling (C) to the joint face. Spread the sealant uniformly. The front housing must be
installed within ten minutes of applying the sealant.
4. Position the front housing on the cylinder block.
5. Install bolts (5) that fasten the front housing to the cylinder block and the engine oil pan.
6. Position belt tightener (3) and install bolts (1) .
7. Position the front engine support and install bolts (2) .
8. Install any external components, if equipped.
End By:
329
a. Install the camshaft. Refer to Disassembly and Assembly, "Camshaft - Install".
b. Install the crankshaft front seal. Refer to Disassembly and Assembly, "Crankshaft Front Seal -
Install".
c. Install the crankshaft vibration damper. Refer to Disassembly and Assembly, "Vibration Damper and
Pulley - Remove and Install".

330
Crankcase Breather - Remove and Install

Removal Procedure
1. Remove bolt (4) and the clip from the engine block.
2. Loosen clamp (2) and remove the hose from crankcase breather (3) .
3. Remove bolt (1) and remove crankcase breather (3) from the fuel filter base.
1. Inspect the filter in crankcase breather (3). Replace the filter, if necessary.
2. Position crankcase breather (3) on the fuel filter base and install bolt (1). Tighten the bolt to a torque
of 7 ± 2 N·m (62 ± 18 lb in).
3. Install the hose on crankcase breather (3) and tighten clamp (2) .
4. Install the clip and bolt (4) on the hose.

331
Valve Mechanism Cover - Remove and Install

Removal Procedure
Table 1
Required Tools
A 138-8440 Component Cleaner 1
NOTICE
1. Remove engine oil filler cap (if equipped).
2. Remove bolts (1) and washers (2) from valve mechanism cover (3) .
3. Remove valve mechanism cover (3) and gasket (4) .
4. Clean valve mechanism cover (3) with Tooling (A) .
Table 2
Required Tools
B 154-8874 Adhesive Kit 1
NOTICE

332
Tightening sequence for the engine valve covers, (A) Rear
Note: For later valve cover gaskets which have a rubber bead on one side, no adhesive is required.
The gasket is designed to be installed dry.
1. Apply adhesive to valve mechanism cover (3) with Tooling (B) .
2. Install new gasket (4) and valve mechanism cover (3) .
3. Install washers (2) and bolts (1) .
(B) Front
4. Tighten the bolts in sequence to a torque of 12 ± 3 N·m (106 ± 27 lb in).
5. Install engine oil filler cap (if equipped).

333
Rocker Shaft and Pushrod - Remove

Removal Procedure
Start By:
A. Remove the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover
NOTICE
Note: For information on reusability of components of the rocker shaft, refer to Guideline For Reusable
Parts And Salvage Operations, SEBF8267, "Rocker Arms and Rocker Arm Shafts for 3114 and 3116
Engines".
1. Loosen all rocker arm adjustment screws (3) .
2. Remove bolts (1) from the rocker shaft assembly (2) .
3. Remove rocker shaft assembly (2) from the cylinder head.
4. Repeat the procedure for each rocker shaft assembly.
5. Remove the pushrods.

334
Rocker Shaft - Disassemble

Table 1
Required Tools
A 6V-0083 Emery Polishing Paper 1
Start By:
Pushrod - Remove".
NOTICE
Engines".
1. Remove support bracket (1) from rocker shaft assembly (4) .
2. Remove valve rocker arms (2) and unit injector rocker arm (3) from rocker shaft assembly (4) .
Note: Do not force the rocker arms from the rocker shaft assembly. If necessary, use a piece of
Tooling (A) to lightly buff the surface of the shaft to aid in removal .
3. Check the adjustment screws on valve rocker arms (2) and unit injector rocker arm (3) for damage.
4. Inspect rocker shaft assembly (4) for scratches and cracks.

335
5. Inspect bearing (5) on unit injector rocker arm (3). The bore in the rocker arm is 24.808 ± 0.20 mm
(0.9767 ± 0.0079 inch). Refer to Specification, "Valve Rocker Arm and Lifters". Replace the
bearing, if necessary.
6. Ensure that button (6) on unit injector rocker arm (3) is not damaged. Also ensure that the retaining
ring for button (6) is in place.

336
Rocker Shaft - Assemble

Assembly Procedure
NOTICE
Engines".

1. Install button (6) and the retaining ring, if necessary.
2. Place clean engine oil on a new bearing (5) prior to installation.
3. Ensure that the oil hole in bearing (5) is aligned with the oil hole in the rocker arm. Hone the bearing,
if necessary. Refer to the Specifications Module for the correct dimensions.
4. Lubricate rocker shaft assembly (4) with clean engine oil.
5. Install valve rocker arms (2) and unit injector rocker arm (3) on rocker shaft assembly (4) .
6. Install support bracket (1) on rocker shaft assembly (4) .
End By: Install the rocker shaft and the pushrods. Refer to Disassembly and Assembly, "Rocker Shaft
and Pushrod - Install".

337
Rocker Shaft and Pushrod - Install

Table 1
Required Tools
A 146-2597 Pushrod Holder 1
NOTICE
Engines".
1. Install the pushrods in the engine. The base of the pushrod should be in the seat of the pushrod lifter.
2. Install Tooling (A) .
3. Position rocker shaft assembly (2) in the engine. Line up the pushrods with the rocker arms.
4. Install bolts (1) in rocker shaft assembly (2) . Tighten the bolts to a torque of 28 ± 7 N·m (21 ± 5 lb
ft).
5. Remove Tooling (A) from the pushrods.
6. Adjust the valve lash on all of the adjustment screws. Refer to Testing and Adjusting, "Engine Valve
Lash - Inspect/Adjust".
7. Repeat the procedure for the remaining rocker shaft assemblies.
End By: Install the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism
Cover - Remove and Install".

338
Cylinder Head - Remove

Removal Procedure
Start By:
A. Remove the fuel filter base. Refer to Disassembly and Assembly, "Fuel Filter Base - Remove and
Install".
B. Remove the governor. Refer to Disassembly and Assembly, "Governor - Remove".
C. Remove the fuel control linkage. Refer to Disassembly and Assembly, "Fuel Injection Control
Linkage - Remove".
D. Remove the unit injectors. Refer to Disassembly and Assembly, "Unit Injector - Remove".
E. Remove the water temperature regulator housing. Refer to Disassembly and Assembly, "Water
Temperature Regulator Housing - Remove and Install".
F. Remove the inlet manifold. Refer to Disassembly and Assembly, "Inlet Manifold - Remove".
G. Remove the exhaust manifold. Refer to Disassembly and Assembly, "Exhaust Manifold - Remove
and Install".
NOTICE
NOTICE
containing fluids.
Note: For information on the reusability of the cylinder head, refer to Guideline For Reusable Parts
And Salvage Operations, SEBF8218, "Specifications for Cylinder Head Assemblies 3114, 3116, and
3126 Engines" and Guideline For Reusable Parts And Salvage Operations, SEBF8162, "Procedure to

339
Typical example
1. Attach a suitable lifting device to the cylinder head.
2. Remove bolts (1) and (2) that hold the cylinder head to the cylinder block. Carefully remove the
cylinder head from the cylinder block. The cylinder head for the 3116 engine weighs approximately
85 kg (187 lb).
3. Remove cylinder head gasket (3) .

340
Cylinder Head - Install

Table 1
Required Tools
A 6V-4876 Lubricant 1
NOTICE
Note: For information on the reusability of the cylinder head, refer to Guideline For Reusable Parts
And Salvage Operations, SEBF8218, "Specifications for Cylinder Head Assemblies 3114, 3116, and
3126 Engines" and Guideline For Reusable Parts And Salvage Operations, SEBF8162, "Procedure to
1. Thoroughly clean the mating surfaces of the cylinder head and the cylinder block.

Typical example Typical example
2. Install a new cylinder head gasket (3) .
Note: For information on the cylinder head gasket for 3116 engines, refer to Special Instruction,
SEHS9395, "3116 Cylinder Head Gasket Usage".
Note: To avoid damage to the cylinder head gasket, use guide bolts of an appropriate size to install
the cylinder head.
3. Attach a suitable lifting device to the cylinder head. Position the cylinder head assembly onto the
dowels in the cylinder block. Lower the cylinder head onto the cylinder block.

341

3114 Cylinder head
4. Inspect the condition of cylinder head bolts (1) and (2). For information on the reusability of the
bolts, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8301, "Inspection and
Reuse of Critical Fasteners Used in All Engines". Replace cylinder head bolts (1) and (2), if
necessary.
5. Lubricate cylinder head bolts (1) and (2) and both sides of the washers with Tooling (A). Install
cylinder head bolts (1) and (2). Follow Step 6 for the correct tightening procedure.
6. Tighten the cylinder head bolts according to the following procedure:
7. Tighten bolt (1) through bolt (14) in a numerical sequence to a torque of 150 ± 15 N·m (110 ± 11 lb
ft).
8. Tighten bolt (1) through bolt (14) again in a numerical sequence to a torque of 435 ± 20 N·m (320 ±
15 lb ft).
9. Tighten bolt (1) through bolt (14) again in a numerical sequence to a torque of 435 ± 20 N·m (320 ±
15 lb ft).
10. Tighten bolt (15) through bolt (20) in a numerical sequence to a torque of 55 ± 7 N·m (41 ± 5 lb ft).
End By:
a. Install the exhaust manifold. Refer to Disassembly and Assembly, "Exhaust Manifold - Remove and
Install".
b. Install the inlet manifold. Refer to Disassembly and Assembly, "Inlet Manifold - Install".
c. Install the water temperature regulator housing. Refer to Disassembly and Assembly, "Water
Temperature Regulator Housing- Remove and Install".
d. Install the unit injectors. Refer to Disassembly and Assembly, "Unit Injector - Install".
e. Install the fuel control linkage. Refer to Disassembly and Assembly, "Fuel Injection Control Linkage
- Install".
f. Install the governor. Refer to Disassembly and Assembly, "Governor - Install".
g. Install the fuel filter base. Refer to Disassembly and Assembly, "Fuel Filter Base - Remove and
Install".

342
Lifter Group - Remove and Install

Removal Procedure
Start By:
Pushrod - Remove".
NOTICE
NOTICE
containing fluids.
Note: For information on reusability of components of the lifter group, refer to Guideline For Reusable
Parts And Salvage Operations, SEBF8264, "Camshaft Roller Followers Used in 3114 and 3116
Engines" and Guideline For Reusable Parts And Salvage Operations, SEBF8067, "Slipper Followers
and Camshaft Roller Followers".

1. Remove bolts (1) from cover (2) .
2. Carefully remove cover (2) and the gasket.
Note: It may be necessary to remove the governor in order to remove the cover at the front of the
engine.
3. Remove bolts (4), lifter shaft (5), and lifters (3) from cover (2) .

343
NOTICE
Note: For information on reusability of components of the lifter group, refer to Guideline For Reusable
Parts And Salvage Operations, SEBF8264, "Camshaft Roller Followers Used in 3114 and 3116
Engines" and Guideline For Reusable Parts And Salvage Operations, SEBF8067, "Slipper Followers
and Camshaft Roller Followers".

1. Position lifters (3) and lifter shaft (5) on cover (2). Install bolts (4) .
2. Position the gasket and cover (2) on the engine.
3. Install bolts (1) in cover (2) .
End By: Install the rocker shaft and the pushrods. Refer to Disassembly and Assembly, "Rocker Shaft
and Pushrod - Install".

344
Camshaft - Remove
Removal Procedure
Start By:
A. Remove the governor. Refer to Disassembly and Assembly, "Governor - Remove".
B. Remove the side covers. Refer to Disassembly and Assembly, "Lifter Group - Remove and Install".
C. Remove the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove".
NOTICE
NOTICE
containing fluids.
Note: For information on reusability of the camshaft, refer to Guideline For Reusable Parts And
Salvage Operations, SEBF8097, "Camshaft Measurement", Guideline For Reusable Parts And Salvage
Operations, SEBF8146, "Visual Inspection of Camshafts", and Guideline For Reusable Parts And
Salvage Operations, SEBF8251, "Specifications for Measurement of Camshafts in 3114/3116
Engines". For information on reusability of the camshaft gear, refer to Guideline For Reusable Parts
Note: The air compressor was removed in order to accommodate the engine repair stand.
Note: It is not necessary to remove the cylinder head for removal of the camshaft.
1. Turn the crankshaft to top center compression stroke for the No. 1 piston. Install the timing bolt in
the flywheel. This is for timing during installation.
Typical example
2. Ensure that timing mark (1) on the camshaft gear is aligned with timing mark (2) on the idler gear.
3. Remove bolts (4) and camshaft retainer plate (6) .
4. Remove camshaft gear (5) and camshaft (3) from the cylinder block.
345
Camshaft - Install
NOTICE
Note: For information on reusability of the camshaft, refer to Guideline For Reusable Parts And
Salvage Operations, SEBF8097, "Camshaft Measurement", Guideline For Reusable Parts And Salvage
Operations, SEBF8146, "Visual Inspection of Camshafts", and Guideline For Reusable Parts And
Salvage Operations, SEBF8251, "Specifications for Measurement of Camshafts in 3114/3116
Engines". For information on reusability of the camshaft gear, refer to Guideline For Reusable Parts
1. Lubricate the camshaft and the camshaft bearings with clean engine oil.
2. Carefully install camshaft (3) and camshaft gear (5) in the engine.
NOTICE
When installing the camshaft, make sure the number one cylinder is at
top center of the compression stroke with the timing bolt installed in
the flywheel. The camshaft timing is very important. The timing mark
on the camshaft drive gear must line up with the timing mark on the
idler gear. Refer to the Specifications Manual for more information.
Typical example

346
3. Ensure that timing mark (1) on the camshaft gear is aligned with timing mark (2) on the idler gear.
4. Install camshaft retainer plate (6) and bolts (4) .
End By:
a. Install the front cover. Refer to Disassembly and Assembly, "Front Cover - Install".
b. Install the side cover. Refer to Disassembly and Assembly, "Lifter Group - Remove and Install".
c. Install the governor. Refer to Disassembly and Assembly, "Governor - Install".

347
Camshaft Gear - Remove and Install

Removal Procedure
Start By:
A. Remove the camshaft. Refer to Disassembly and Assembly, "Camshaft - Remove".
Note: For information on reusability of the camshaft gear, refer to Guideline For Reusable Parts And
Salvage Operations, SEBF8045, "Timing Gears for All Engines".
1. Wrap the camshaft with a protective covering in order to prevent damage to the camshaft.
NOTICE
Do not allow the camshaft to fall to the floor when pressing it from the
drive gear. Also make sure that the camshaft lobes do not catch on the
press plates.
2. Place the camshaft and camshaft gear (1) in a suitable press. Press the camshaft from camshaft gear
(1) .
1. Heat the camshaft gear to a maximum temperature of 315 °C (600 °F).
2. Align the key in the camshaft with the groove (keyway) in the camshaft gear.
3. Install the camshaft gear on the end of the camshaft.
End By: Install the camshaft. Refer to Disassembly and Assembly, "Camshaft - Install".
348
Camshaft Bearings - Remove and Install

Removal Procedure
Table 1
Required Tools
A 8S-2241 Camshaft Bearing Tool Group 1
Start By:
A. Remove the camshaft. Refer to Disassembly and Assembly, "Camshaft - Remove".
NOTICE
NOTICE
containing fluids.
Note: Note the oil hole orientation in each camshaft bearing prior to removal for assembly purposes.
1. Use Tooling (A) to remove the camshaft bearings from the cylinder block.
Table 2
Required Tools
A 8S-2241 Camshaft Bearing Tool Group 1
NOTICE

349

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

350
Engine Oil Pan - Remove and Install

Removal Procedure
NOTICE
NOTICE
containing fluids.
Note: Drain engine oil into a suitable container for disposal.

1. Remove bolts (1) and the washers that hold engine oil pan (2) to the cylinder block.
2. Remove engine oil pan (2) and the gasket. Use a rubber mallet to tap lightly on engine oil pan (2) if it
is necessary.
Note: Do not pry on the engine oil pan.
1. Clean the mating surfaces of the engine oil pan and the cylinder block.
Note: Do not put liquid gasket material on the oil pan gasket or on the gasket surface of the engine
oil pan.
2. Put the gasket and the engine oil pan (2) in position on the cylinder block. Install bolts (1) and
washers.

351
Typical drawing (6 cylinder engine)
3. Tighten four bolts (3). Start with bolt (4) and tighten the remaining bolts in a counterclockwise
sequence.
4. Tighten bolts to a torque of 31 ± 3 N·m (23 ± 2 lb ft).
5. Fill the crankcase with engine oil to the proper level. Refer to Operation and Maintenance Manual,
"Refill Capacities".

352
Engine Balancer Shaft - Remove and Install

Removal Procedure
Start By:
A. Remove the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove and
Install".
NOTICE
NOTICE
containing fluids.
Note: The Balancer shafts are used on the 3114 Engines.
314 engine
1. Remove oil tube assembly (1) .
2. Remove bolts (2) and the washers that hold the balancer group in position.
3. Remove the balancer group and the engine oil pump as a unit.

353
NOTICE
1. Turn the engine in the counterclockwise direction and place the number one piston at the top center
(TC) of the compression stroke. Install the timing bolt in the flywheel housing.
2. Align the timing marks on the balancer gears (3) with oil holes (4) in the engine oil pump. Position
the balancer group in the cylinder block. Install the washers and bolts (2) .
3. Check the condition of the O-ring seals in oil tube assembly (1). Replace the O-ring seal, if
necessary.
4. Remove the timing bolt from the flywheel housing.
End By: Install the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove
and Install".

354
Piston Cooling Jets - Remove and Install

Removal Procedure
Start By:
A. Remove the engine balancer shaft on the 3114 engines only. Refer to Disassembly and Assembly,
"Engine Balancer Shaft - Remove and Install".
B. Remove the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump - Remove".
NOTICE
containing fluids.
1. Remove bolt (1) and piston cooling jet (2) .
2. Remove the remainder of the piston cooling jets.

355
NOTICE
Ensure that the piston cooling jet is seated properly prior to tightening
the bolt.
1. Position piston cooling jet (2) in the cylinder block.

2. Ensure that the piston cooling jet is seated properly and install bolt (1) that holds the piston cooling
jet in position.
NOTICE
Hold piston cooling jet in position when the mounting bolt is tightened.
If the cooling tube is not held in position, the cooling tube may bend or
the cooling tube may break.
3. Install the remainder of the piston cooling jets.
End By:
a. Install the engine balancer shaft on the 3114 engine. Refer to Disassembly and Assembly, " Engine
Balancer Shaft - Remove and Install".
b. Install the oil pump. Refer to Disassembly and Assembly, " Engine Oil Pump - Install".

356
Pistons and Connecting Rods - Remove

Removal Procedure
Start By:
A. Remove the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Remove".
C. Remove the piston cooling jets. Refer to Disassembly and Assembly, "Piston Cooling Jets - Remove
and Install".
NOTICE
Note: For information on reusability of the pistons, refer to the following list.
¡ Guideline For Reusable Parts And Salvage Operations, SEBF8049, "Pistons"
¡ Guideline For Reusable Parts And Salvage Operations, SEBF8228, "Procedure to Clean and
Inspect One and Two-Piece Pistons in 3114/3116 Engines"
¡ Guideline For Reusable Parts And Salvage Operations, SEBF8290, "Visual Inspection of Two-
Piece Pistons"
Note: For information on reusability of the connecting rods, refer to the following list.
¡ Guideline For Reusable Parts And Salvage Operations, SEBF8206, "Specifications for
Connecting Rods on 3116 Engines"
¡ Guideline For Reusable Parts And Salvage Operations, SEBF8063, "Visual Inspection of
Connecting Rods"
¡ Guideline For Reusable Parts And Salvage Operations, SEBF8064, "Salvage of Non-Serrated
Connecting Rods"
Note: For information on reusability of the piston pins, refer to the following list.
¡ Guideline For Reusable Parts And Salvage Operations, SEBF8051, "Piston Pins and Retaining
Rings"
¡ Guideline For Reusable Parts And Salvage Operations, SEBF8303, "Procedure to Inspect Piston
Pins"
Note: For information on reusability of the rod eye bushing, refer to the following list.
¡ Guideline For Reusable Parts And Salvage Operations, SEBF8242, "Verification of Connecting
Rod Eye Bushing Retention Using 5P-8639 Connecting Rod Bushing Press Group"
¡ Guideline For Reusable Parts And Salvage Operations, SEBF8274, "Using Rod Eye Bushing
Installation and Removal Tools"
Note: For information on reusability of the cylinder block and salvage procedures, refer to the
following list.
¡ Guideline For Reusable Parts And Salvage Operations, SEBF8192, "Specifications and Salvage
for Cylinder Blocks on 3114, 3116, 3126 Engines"
¡ Guideline For Reusable Parts And Salvage Operations, SEBF8261, "Installing a 7C-6208
Cylinder Sleeve in 3114, 3116 Engines and a 107-7604 Cylinder Sleeve in 3126 Engines"
¡ Special Instruction, GMG00981, "Using 1P-3537 Dial Bore Gauge Group to Check Cylinder
Bore Size"
¡ Special Instruction, SMHS7606, " Use of 1P-4000 Line Boring Tool Group"

357
¡ Special Instruction, SEHS8841, " Using the Ironstitch Procedure for Casting Salvage"
¡ Special Instruction, SEHS8919, "Salvage Weld Procedure for Cast Iron Cylinder Blocks"
¡ Guideline For Reusable Parts And Salvage Operations, SEBF8076, "Specifications to Salvage
Cylinder Block Contact Surfaces"
¡ Special Instruction, SEHS8869, "Cylinder Block Salvage Procedure Using Belzona Ceramic R
Metal"

1. Inspect the connecting rod and connecting rod cap (2) for the proper identification mark. The
connecting rod and connecting rod cap (2) should have an etched number on the side that is toward
the right side of the engine. The number should match the cylinder number. Mark the connecting rod
and connecting rod cap (2), if necessary.
2. Remove connecting rod cap nuts (1), bolts (5), and connecting rod cap (2) .
3. Remove the lower half of bearing (4) from connecting rod cap (2) .
NOTICE
Install short pieces of rubber hose over both connecting rod bolts in
order to protect the crankshaft from the threaded portion of the
connecting rod bolts.
4. Push the piston and connecting rod away from the crankshaft. Remove the upper half of connecting
rod bearing (4) from connecting rod (3) .
5. Remove the piston and connecting rod (3) from the cylinder block.
6. Repeat Steps 1 through 5 for the remaining pistons and connecting rods.

358
Pistons and Connecting Rods - Disassemble

Table 1
Required Tools
A 1U-6683 Ring Expander 1
B 1P-1861 Retaining Ring Pliers 1
Start By:
A. Remove the pistons and the connecting rods. Refer to Disassembly and Assembly, "Pistons and
Connecting Rods - Remove".
NOTICE

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

359
Pistons and Connecting Rods - Assemble

Assembly Procedure
Table 1
Required Tools
A 1U-6683 Ring Expander 1
B 1P-1861 Retaining Ring Pliers 1
NOTICE
NOTICE
Verify correct assembly of the pistons and the connecting rods. Ensure
that the etched numbers on the rod and the rod cap are in the correct
positions. The etched number on the rod and the rod cap correspond to
the cylinder in which it should be installed.
¡ Guideline For Reusable Parts And Salvage Operations, SEBF8228, "Procedure to Clean and
Inspect One and Two-Piece Pistons in 3114/3116 Engines"
Piece Pistons"
¡ Tool Operating Manual, NEHS0775, "Using the 186-0137 Pston Ring Gauge on Steel Crown,
Two-Piece Pistons used in 3126 Engines"
¡ Guideline For Reusable Parts And Salvage Operations, SEBF8206, "Specificatios for
ConnectingRods on 3116 Engines"
Connecting Rods"
Connecting Rods"
Rings"
Pins"

360
1. Check the clearance between the ends of piston rings (5). Refer to the Specifications Manual,
"Pistons and Rings".
Note: The oil ring must be installed over the spring with the end gap 180 degrees from the oil ring
spring joint.
2. Install the oil control piston ring with Tooling (A). The ends of the spring should be rotated 180
degrees from the ring end gap.
3. Install the intermediate piston ring with the side marked "UP-2" toward the top of the piston. Use
Tooling (A) in order to install the ring.
4. Install the top piston ring with the side marked "UP-1" toward the top of the piston. Use Tooling (A)
in order to install the ring.
One piece piston
5. Replace rod bearing (6) by pressing a new bearing into the connecting rod. Refer to Special
Instruction, SEHS7295 for the correct tooling and the correct installation procedure.

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

361
worn or damaged. Bearing (9) is nonserviceable.
7. Position piston (1) on connecting rod (3). Coat piston pin (4) with clean engine oil and install piston
pin (4) .

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

362
Pistons and Connecting Rods - Install

Table 1
Required Tools
187-1462 Piston Ring Compressor (1) 1
A (2)
173-5529 Piston Ring Compressor 1
B 4C-5593 Anti-Seize Compound 1
(1) Used for 3114 and 3116 Engines
(2) Used for 3126 Engines
NOTICE
Piece Pistons"
¡ Tool Operating Manual, NEHS0775, "Using the 186-0190 Piston Ring Gauge on Steel Crown,
Two-Piece Pistons used in 3126 and 3126B Engines"
Connecting Rods"
Connecting Rods"
Rings"
Pins"

363

1. Install the bolts (5) and the upper half of connecting rod bearing (4) . Ensure that the bearing tab
engages with the slot in connecting rod (3) .
2. Install the lower half of connecting rod bearing (4) . Ensure that the bearing tab engages with the slot
in connecting rod cap (2) .
3. Place clean engine oil on the following items: the pistons, the piston rings, the cylinder bore, the
upper half of the connecting rod bearing and the lower half of the connecting rod bearing.
NOTICE
Install short pieces of rubber hose over both connecting rod bolts in
order to protect the crankshaft from the threaded portion of the
connecting rod bolts.

4. Install short pieces of rubber hose (6) over both connecting rod bolts.
Note: Each piston ring end gap must be positioned 120 degrees from each other.
5. Install Tooling (A) in order to compress the piston rings.
6. With the number one crankshaft throw at the bottom center, install the piston and connecting rod in
the engine. Ensure that the proper piston and connecting rod are in the corresponding cylinder with
the bearing retainer notch toward the right side of the engine.
Note: The etched number on the connecting rod must be on the right side of the engine in the
corresponding cylinder.
7. Line up the piston and the connecting rod with the crankshaft. Use a soft hammer and tap the piston
into the cylinder bore until Tooling (A) comes off of the piston.
8. Use a soft hammer in order to tap the piston into the cylinder bore while you guide the connecting
rod onto the crankshaft.
9. Remove the hoses that were installed in Step 4 from the connecting rod bolts.

364

10. Install connecting rod bearing cap (2) on the connecting rod (3) . Ensure that the number on
connecting rod bearing cap (2) matches the number on the connecting rod (3) . Ensure that the
numbers are on the same side.
11. Lubricate connecting rod cap bolts with Tooling (B) .
NOTICE
Loose connecting rod nuts can result in the separation of the rod cap
and result in major engine damage.
Note: Later connecting rods will have bolts in place of the bolts and nuts.
12. Install connecting rod cap nuts (1) . Tighten nuts (1) to the torque that is specified in Table 2.
Table 2
Torque Specifications
Machined Connecting Tighten nuts (1) to a torque of 54 ± 7 N·m (40 ± 5 lb ft) plus an
Rods additional 60 ± 5 degrees.
Fractured Connecting Tighten nuts (1) to a torque of
Rods 70 ± 5 N·m (52 ± 4 lb ft) plus an additional 120 ± 5 degrees.
13. Repeat Steps 1 through 12 for the remaining pistons and connecting rods.
End By:
a. Install the piston cooling jets. Refer to Disassembly and Assembly, "Piston Cooling Jets - Remove
and Install".
b. Install the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump - Install".
c. Install the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Install".

365
Crankshaft Main Bearings - Remove

Removal Procedure
Table 1
Required Tools
A 2P-5518 Bearing Tool 1
Start By:
A. Remove the engine balancer shaft on 3114 engines. Refer to Disassembly and Assembly, "Engine
NOTICE

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) .
NOTICE
If the crankshaft is turned in the wrong direction, the tab of the
crankshaft main bearing will be pushed between the crankshaft and
the cylinder block. this can cause damage to either or both the
crankshaft and the cylinder block.
Note: Some crankshaft main bearing journals do not have an oil hole. Place a thin piece of soft
material that will not damage the journal against the end of the bearing. Ensure that the material is on
the opposite side of the bearing tab. Hit the bearing with the soft material until the bearing tab is free
from the bearing tab groove in the cylinder block.
3. Use the following steps in order to remove the upper half of crankshaft main bearings:
a. Turn the crankshaft until Tooling (A) can be installed in the crankshaft journal. Install Tooling
(A) .
b. Turn the crankshaft in order to remove the upper half of the crankshaft main bearing. In order to
get the tab out first, the crankshaft must be turned in the correct direction.

366
c. Check the condition of the crankshaft main bearings. Refer to the Guideline For Reusable Parts
And Salvage Operations, SEBF8009, "Main and Connecting Rod Bearings" and Special
Publication, SEBD0531, "Engine Bearings and Crankshafts".

367
Crankshaft Main Bearings - Install

Table 1
Required Tools
A 2P-5518 Bearing Tool 1
B 8T-5096 Dial Indicator Group 1
NOTICE
Note: For information on the reusability of the crankshaft main bearings, refer to the Guideline For
Reusable Parts And Salvage Operations, SEBF8009, "Main and Connecting Rod Bearings".
Note: Place clean engine oil on the crankshaft main bearings prior to assembly. Ensure that the tabs on
the back side of the crankshaft main bearings fit in the grooves of the crankshaft main bearing caps and
the cylinder block.

1. Use Tooling (A) and install the upper halves of the crankshaft main bearings in the cylinder block.
Do not put oil on the back of the crankshaft main bearing.
2. Install the lower halves of the crankshaft main bearings in crankshaft main bearing caps (2). Do not
put oil on the back of the crankshaft main bearing.

Six cylinder engine with oil grooves in the cylinder Six cylinder engine with no oil grooves in the cylinder
block block

368
NOTICE
Crankshaft main bearing caps should be installed with the part
number toward the right side of the engine. Crankshaft main bearing
caps are to be identified by stamped numbers 1 through 7 located on
the bottom surface. The thrust plate is used on the number 6
crankshaft main bearing only.
3. Oil grooves are machined in the saddles of the cylinder blocks of all 3114 engines and earlier 3116
engines. No oil grooves are machined in the saddles of the cylinder block on later 3116 engines and
all 3126 engines.
4. Install the bearing caps with the sequence number to the right. A six cylinder engine has an order of
1 through 7 (front to rear). A four cylinder engine has an order of 1 through 5 (front to rear). Place
crankshaft main bearing caps (2) in position on the cylinder block. Place clean engine oil or
Molylube on the bolt threads and the washer face. Install bolts (1) .
5. Tighten bolts (1) to a torque of 54 ± 7 N·m (40 ± 5 lb ft). Tighten each bolt (1) for an additional 90 ±
5 degrees (1/4 turn).
6. Check the end play of the crankshaft with Tooling (B). The end play must be 0.07 mm (0.003 inch)
to 0.32 mm (0.013 inch).
End By:
a. Install the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump - Install".
b. Install the engine balancer shaft on 3114 engines. Refer to Disassembly and Assembly, "Engine

369
Crankshaft - Remove
Removal Procedure
Start By:
A. Remove the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Remove".
B. Remove the crankshaft seal carrier. Refer to Disassembly and Assembly, "Crankshaft Rear Seal
Carrier - Remove and Install".
C. Remove the front gear group. Refer to Disassembly and Assembly, "Gear Group (Front) - Remove".
D. Remove the piston and the connecting rods. Refer to Disassembly and Assembly, "Piston and
Connecting Rods-Remove".
NOTICE
NOTICE
containing fluids.
Note: For information on reusability of the crankshaft, refer to the following list.
¡ Guideline For Reusable Parts And Salvage Operations, SEBF8041, "Crankshaft Measurement"
¡ Guideline For Reusable Parts And Salvage Operations, SEBF8054, "Procedure to Measure and
Straighten Bent Crankshafts"
¡ Guideline For Reusable Parts And Salvage Operations, SEBF8094, "Procedure to Grind
Crankshafts"
Crankshafts"
¡ Guideline For Reusable Parts And Salvage Operations, SEBF8039, "Inspection of Crankshafts
for Cracks"
¡ Guideline For Reusable Parts And Salvage Operations, SEBF8042, "Procedure to Polish
Crankshafts"
Note: For information on reusability of the crankshaft main bearings, refer to Guideline For Reusable
Parts And Salvage Operations, SEBF8009, "Main and Connecting Rod Bearings".
following list.
for Cylinder Blocks on 3114, 3116, and 3126 Engines"

370
Metal"
Bore Size"
Note: The weight of the crankshaft for the 3114 Engine is 37 kg (82 lb). The weight of the
crankshaft for 3116 and 3126 Engines is 62 kg (137 lb).
1. Use a suitable lifting device. Remove bolts (2), the washers and main bearing caps (3). Carefully
remove crankshaft (1) from the cylinder block.
2. Remove upper main bearing (4) from the cylinder block.
3. Remove the main bearings from the main bearing caps.

371
Crankshaft - Install
Table 1
Required Tools
A 8T-5096 Dial Indicator Group 1
NOTICE
NOTICE
Ensure that the crankshaft main bearing tabs engage with the grooves
in the block and the crankshaft main bearing cap.
Note: For information on reusability of the crankshaft, refer to the following list.
¡ Guideline For Reusable Parts And Salvage Operations, SEBF8041, "Crankshaft Measurement"
¡ Guideline For Reusable Parts And Salvage Operations, SEBF8054, "Procedure to Measure and
Straighten Bent Crankshafts"
¡ Guideline For Reusable Parts And Salvage Operations, SEBF8094, "Procedure to Grind
Crankshafts"
Crankshafts"
¡ Guideline For Reusable Parts And Salvage Operations, SEBF8039, "Inspection of Crankshafts
for Cracks"
¡ Guideline For Reusable Parts And Salvage Operations, SEBF8042, "Procedure to Polish
Crankshafts"
following list.
for Cylinder Blocks on 3114, 3116, and 3126 Engines"
Metal"
Bore Size"
1. Check the condition of the crankshaft main bearings. Refer to the Guideline For Reusable Parts And
Salvage Operations, SEBF8009, "Main and Connecting Rod Bearings" and Special Publication,
SEBD0531, "Engine Bearings and Crankshafts".

372
Note: The number four main bearing in 3114 Engines is the thrust bearing. The number six main
bearing in the six cylinder engines is the thrust bearing.
2. Clean the bearing surfaces in the cylinder block for the main bearings.
Typical example
3. Install the upper main bearings (4) in the cylinder block. Ensure that the tab on the back side of the
bearing engages with the groove in the cylinder block. Apply clean engine oil on the upper main
bearing. Do not put engine oil on the back side of the bearing surfaces.
4. Put clean engine oil on the journals of the crankshaft bearing. Fasten lifting straps and a hoist to
crankshaft (1). Carefully install the crankshaft in the cylinder block.
5. Clean the bearing surface of the main bearing caps.
Typical example
6. Install the lower main bearings (5) in the crankshaft main bearing caps (3). Ensure that the tab on the
back side of the bearing engages with the groove in the main bearing cap. Apply clean engine oil on
the lower main bearing. Do not put engine oil on the back side of the bearing surfaces.
7. Install crankshaft main bearing caps with the part numbers toward the right hand side of the cylinder
block. Ensure that crankshaft main bearing caps have numbers 1 through 7. The numbers should start
at the front of the engine. Place clean engine oil or Molylube on the bolt threads and the washers.
Note: When the bolts for the rear main bearing cap are tightened, slide the main bearing cap as far
forward as possible until the cap is against the bolts. Hold the main bearing cap in this position and
tighten the bolts.
8. Install bolts (2) and the washers for main bearing caps (3). Tighten bolts (2) to a torque of 54 ± 7
N·m (40 ± 5 lb ft).
9. Turn bolts (2) for an additional 90 ± 5 degrees (1/4 turn).

373
Typical example
10. Check the end play of crankshaft (1) with Tooling (A). The end play must be 0.07 mm (0.003 inch)
to 0.32 mm (0.013 inch).
End By:
a. Install the pistons and connecting rods. Refer to Disassembly and Assembly, "Pistons and
Connecting Rods - Install".
b. Install the front gear group. Refer to Disassembly and Assembly, "Gear Group (Front) - Install".
c. Install the crankshaft seal carrier. Refer to Disassembly and Assembly, "Crankshaft Rear Seal
Carrier- Remove and Install".
d. Install the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Install".

374
Crankshaft Gear - Remove and Install

Removal Procedure
Start By:
A. Remove the front gear group. Refer to Disassembly and Assembly, "Gear Group (Front) - Remove".
NOTICE
1. Place alignment marks on the crankshaft gear and on the crankshaft. The alignment marks will
ensure that the camshaft gear is aligned properly during installation.
2. Heat crankshaft gear (1). Remove crankshaft gear (1) from crankshaft (2) .

375
NOTICE
1. Heat crankshaft gear (1) to a maximum temperature of 204 °C (400 °F) for no longer than 1 hour for
installation.
2. Align the timing marks on the crankshaft and on crankshaft gear (1). Install crankshaft gear (1) on
crankshaft (2) .
Note: Ensure that crankshaft gear (1) is flush against the shoulder of crankshaft. If the gear is not
flush damage to the gear may occur.
End By: Install the front gear group. Refer to Disassembly and Assembly, "Gear Group (Front) -
Install".

376
Bearing Clearance - Check

Table 1
Required Tools
Plastic Gauge (Green)
198-9142 0.025 to 0.076 mm 1
(0.001 to 0.003 inch)
Plastic Gauge (Red)
198-9143 0.051 to 0.152 mm 1
(0.002 to 0.006 inch)
A
Plastic Gauge (Blue)
198-9144 0.102 to 0.229 mm 1
(0.004 to 0.009 inch)
Plastic Gauge (Yellow)
198-9145 0.230 to 0.510 mm 1
(0.009 to 0.020 inch)
Note: Plastic gauge may not be necessary when the engine is in the chassis.
NOTICE
Note: Caterpillar does not recommend the checking of the actual bearing clearances particularly on
small engines. This is because of the possibility of obtaining inaccurate results and the possibility of
damaging the bearing or the journal surfaces. Each Caterpillar engine bearing is quality checked for
specific wall thickness.
Note: The measurements should be within specifications and the correct bearings should be used. If the
crankshaft journals and the bores for the block and the rods were measured during disassembly, no
further checks are necessary. However, if the technician still wants to measure the bearing clearances,
Tooling (A) is an acceptable method. Tooling (A) is less accurate on journals with small diameters if
clearances are less than 0.10 mm (0.004 inch).
NOTICE
Lead wire, shim stock or a dial bore gauge can damage the bearing
surfaces.
The technician must be very careful to use Tooling (A) correctly. The following points must be
remembered:
¡ Ensure that the backs of the bearings and the bores are clean and dry.
¡ Ensure that the bearing locking tabs are properly seated in the tab grooves.
¡ The crankshaft must be free of oil at the contact points of Tooling (A) .
1. Put a piece of Tooling (A) on the crown of the bearing that is in the cap.
Note: Do not allow Tooling (A) to extend over the edge of the bearing.
2. Use the correct torque-turn specifications in order to install the bearing cap. Do not use an impact
377
wrench. Be careful not to dislodge the bearing when the cap is installed.
Note: Do not turn the crankshaft when Tooling (A) is installed.
3. Carefully remove the cap, but do not remove Tooling (A) . Measure the width of Tooling (A) while
Tooling (A) is in the bearing cap or on the crankshaft journal. Refer to Illustration 1.
Typical Example
4. Remove all of Tooling (A) before you install the bearing cap.
Note: When Tooling (A) is used, the readings can sometimes be unclear. For example, all parts of
Tooling (A) are not the same width. Measure the major width in order to ensure that the parts are
within the specification range. Refer to Specifications Manual, "Connecting Rod Bearing Journal"
and Specifications Manual, "Main Bearing Journal" for the correct clearances.

378
Engine Oil Pressure Sensor - Remove and Install

Removal Procedure
NOTICE
containing fluids.
At operating temperature, the engine coolant is hot and under pressure.

Steam can cause personal injury.
Check the coolant level only after the engine has been stopped and the
filler cap is cool enough to touch with the bare hand.
Remove the filler cap slowly to relieve pressure.
Cooling system conditioner contains alkali. Avoid contact with skin and
eyes to prevent personal injury.
Note: Put identification on all hose assemblies, wires, and tube assemblies for installation purposes.
Install a cap or plug on all hose assemblies and tube assemblies in order to prevent foreign material
from entering the system.
Note: Drain all fluids into a suitable container for storage or disposal.

1. Disconnect harness assembly (2) at the clip.
2. Remove oil pressure sensor (1) and O-ring seal (3) .

379

1. Install a new O-ring seal (3) on oil pressure sensor (1). Install oil pressure sensor (1) .
2. Connect harness assembly (2) at the clip.
Note: Refer to the Operation and Maintenance Manual for all fluid capacities and the proper filling
procedures.

380
Ether Atomizer - Remove and Install

Removal Procedure
NOTICE
1. Remove ether atomizer (1) from the top of the air inlet manifold.
Note: Install the ether atomizer so that the direction of the spray is parallel to the air inlet heater, If
equipped. The ether atomizer has an indicator in order to show the direction of the spray.
Note: The ether atomizer has two ports that are separated by 180 degrees. The two ports must be
aimed parallel to the length of the block.
1. Install ether atomizer (1). The minimum torque for the ether atomizer is 2.8 N·m (25 lb in).

381
Belt Tensioner - Remove and Install

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

382
Belt Tightener - Remove

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

383
Belt Tightener - Install

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

384
Alternator - Remove and Install

Removal Procedure
Table 1
Required Tools
A 168-0383 Circuit Breaker Bar 1
Typical Example
Note: Release the tension on the belt at the belt tightener, if the engine is not equipped with a belt
tensioner.
1. Use Tooling (A) to release the tension on belt tensioner (5) .
2. Remove drive belt (4) from the drive pulley on alternator (3) .
3. Place an index mark on the wires of harness assembly (1) that are connected to the alternator.
Disconnect harness assembly (1) from the alternator.
5. Remove alternator (3) from the mounting bracket.
Table 2
Required Tools
A 168-0383 Circuit Breaker Bar 1
Typical example

385
1. Position alternator (3) on the mounting bracket. Install bolts (2) .
2. Use Tooling (A) to install drive belt (4) on the drive pulley of the alternator.
Note: Adjust the tension on the drive belt if the engine is not equipped with a belt tensioner. Refer to
the Operation and Maintenance Manual for the correct adjusting procedure.
3. Connect harness assembly (1) to the alternator. Use the index marks to correctly connect the harness
assembly. Tighten the mounting bolt for the ground wire to a torque of 6.2 ± 0.6 N·m (54 ± 5 lb in).
Tighten the mounting bolt for the battery wire to a torque of 11.3 ± 2.3 N·m (100 ± 20 lb in).

386
Electric Starting Motor - Remove and Install

Removal Procedure
Personal injury can result from failure to disconnect the battery.

First, disconnect the negative battery cable. Then, disconnect the
positive battery cable.
A positive power lead can cause sparks if the battery is not
disconnected. Sparks can possibly result in battery explosion or fire.
1. Place an index mark on all of the harness assemblies. Disconnect the harness assemblies from
electric starting motor (1) .
2. Fasten a suitable lifting device to electric starting motor (1). The weight of electric starting motor (1)
is approximately 35 kg (77 lb).
4. Remove electric starting motor (1) and the gasket from the flywheel housing.

387
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".

388
Air Compressor - Remove and Install

Removal Procedure
Do not disconnect the air lines until the air pressure in the system is at
zero. If hose is disconnected under pressure it can cause personal
injury.
NOTICE
NOTICE
containing fluids.
1. Remove the air pressure from the air tank and drain the coolant from the cooling system.
Typical example
2. Disconnect hose assemblies (1), (2) and (9) from the air compressor. Remove tube assembly (4) from
the air compressor.
3. Remove bolt (5) and the washer. Remove clamp (7) from tube assembly for the breather. Move the
tube assembly for the breather aside.
4. Remove bolts (3) and the washers that hold the air compressor to the timing gear housing.
5. Remove bolts (6) and remove air compressor (8) and the gasket from the engine.

389
Table 1
Required Tools
A 4C-4030 Thread Lock Compound 1
NOTICE
Note: Check the condition of the gaskets and O-ring seals. If gaskets or O-ring seals are damaged, use
new parts for replacement.
Typical example
1. Use bolts (3) and the washers to install air compressor (8). Apply Tooling (A) to the threads of bolts
(6). Torque bolts (6) to 160 ± 30 N·m (118 ± 22 lb ft).
2. Install clamp (7) for the tube assembly for the breather with bolt (5) and the washer.
3. Install tube assembly (4) and connect hose assemblies (9), (2) and (1) to air compressor (8) .

390
Air Compressor Drive Gear - Remove and Install

Removal Procedure
Table 1
Required Tools
A 132-5451 Holding Fixture 1
Start By:
A. Remove the air compressor. Refer to Disassembly and Assembly, "Air Compressor - Remove and
Install".
NOTICE
1. Install Tooling (A) on drive gear (2) .
2. Remove nut (1) and drive gear (2) .
Table 2
Required Tools
A 132-5451 Holding Fixture 1
NOTICE

391
1. Position drive gear (2) on the air compressor.
2. Install Tooling (A) on drive gear (2) .
3. Install nut (1). Tighten the nut to a torque of 170 ± 15 N·m (125 ± 10 lb ft).
End By: Install the air compressor. Refer to Disassembly and Assembly, "Air Compressor - Remove
and Install".

It 28 Engine

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SENR3611-18

3114, 3116 and 3126 Engines for built machines

Fuel System - Inspect 34 153

Bore ... 105.0 mm (4.13 inch)

Type of combustion ... Direct Injection

Bore ... 105.0 mm (4.13 inch)

Type of combustion ... Direct Injection

Bore ... 110.0 mm (4.33 inch)

Type of combustion ... Direct Injection

Fuel Transfer Pump

Fuel Filter Lines

Fuel Filter Base

Fuel Filter (Primary)

Fuel Filter and Water Separator

Ether Starting Aid

Fuel Injection Control Linkage

Unit Injector Mechanism

Valve Rocker Arms and Lifters

Type 2 ( 3114 and 3116 Engines)

Type 3 ( 3126 Engines)

Valve Mechanism Cover

Cylinder Head Valves

Valve Seat Standard Standard Smaller ID Smaller ID

Exhaust Spring Standard Longer Longer Standard

Type 1 Cylinder Head

Type 3 Cylinder Head

Type 4 Cylinder Head

Turbine Housing And Compressor Housing Bolted To

Turbine Housing And Compressor Housing Clamped To

Water Cooled Turbocharger

(1) Air inlet (2) Bolt

(7) Specific camshaft lobe lift

Engine Oil Filter Base

Remote Mounted Base

Engine Oil Pump

Engine Oil Pressure

Water Temperature Regulator

4W-4011 Water Temperature Regulator

Cylinder Block Cover Group

Tighten bolts (1 through 8) in a numerical sequence.

Main Bearing 6 0.50 mm (0.020

Illustration 1 g00594167 Illustration 2 g00291470

(1) Carrier housing and flywheel housing (2) Rear seal

Vibration Damper and Pulley

Connecting Rod Bearing Journal

Main Bearing Journal

Piston and Rings

(2) Top ring

3114 and 3116 Engines

(3) Intermediate ring

3114 and 3116 Engines

Oil Control Ring

(4) Oil control ring

3114 and 3116 Engines

(5) Piston pin

Two-Piece Articulated Piston

(3) The top ring has the mark "UP-1".

3114 and 3116 Engines

(4) The intermediate ring has the mark "UP-2".

Tapered Intermediate Ring

Rectangular Intermediate Ring

Oil Control Ring

3114 and 3116 Engines