KENR6415-01

April 2012

Disassembly and
Assembly
C175-16 Petroleum Engine
P6L1-Up (Engine)

SAFETY.CAT.COM
 i03991620

Important Safety Information

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

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
A non-exhaustive list of operations that may cause product damage are identified by “NOTICE” labels
on the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. You must
not use this product in any manner different from that considered by this manual without first
satisfying yourself that you have considered all safety rules and precautions applicable to the
operation of the product in the location of use, including site-specific rules and precautions
applicable to the worksite. If a tool, procedure, work method or operating technique that is not
specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you
and for others. You should also ensure that the product will not be damaged or become unsafe by
the operation, lubrication, maintenance or repair procedures that you intend to use.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Cat dealers have the most current information available.

When replacement parts are required for this

product Caterpillar recommends using Cat re-
placement parts or parts with equivalent speci-
fications including, but not limited to, physical
dimensions, type, strength and material.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.

In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
KENR6415-01 3
Table of Contents

Table of Contents Engine Oil Pan - Remove .................................... 59

Engine Oil Pan - Disassemble .............................. 60
Engine Oil Pan - Assemble ................................... 61
Engine Oil Pan - Install ........................................ 62
Disassembly and Assembly Section Crankcase Breather - Remove and Install ........... 64
Valve Cover - Remove and Install ........................ 64
Prelubrication Oil Pump - Remove and Install ....... 4
Rocker Shaft and Push Rods - Remove .............. 65
Electronic Control Module (Engine) - Remove and
Rocker Shaft - Disassemble ................................ 65
Install ..................................................................... 4
Rocker Shaft - Assemble ..................................... 66
Fuel Filter Housing - Remove ................................. 5
Rocker Shaft and Push Rods - Install .................. 66
Fuel Filter Housing - Install ..................................... 6
Valve Lifter - Remove ........................................... 67
Fuel Priming Pump - Remove and Install .............. 7
Valve Lifter - Disassemble .................................... 68
Fuel Transfer Pump - Remove ................................ 7
Valve Lifter - Assemble ......................................... 68
Fuel Transfer Pump - Install .................................... 8
Valve Lifter - Install ............................................... 69
High Pressure Fuel Rails - Remove and Install ...... 8
Electronic Unit Injector - Remove ......................... 70
Flow Limiter - Remove and Install ........................ 12
Electronic Unit Injector - Install ............................. 71
Fuel Control Valve - Remove and Install
Electronic Unit Injector Sleeve - Remove ............. 73
(Secondary) ........................................................ 14
Electronic Unit Injector Sleeve - Install ................. 73
Fuel Control Valve - Remove and Install
Cylinder Head - Remove ...................................... 74
(Primary) ............................................................. 16
Cylinder Head - Install .......................................... 75
Fuel Pump (High Pressure) - Remove and Install .. 17
Inlet and Exhaust Valve Springs - Remove and
Air Cleaner - Remove and Install .......................... 18
Install ................................................................... 76
Exhaust Shield - Remove and Install .................... 19
Inlet and Exhaust Valves - Remove and Install .... 77
Turbocharger - Remove ........................................ 21
Inlet and Exhaust Valve Guides - Remove and
Turbocharger - Install ............................................ 23
Install ................................................................... 79
Air Shutoff - Remove and Install ........................... 24
Inlet Valve Seals - Remove and Install ................. 79
Aftercooler - Remove and Install ......................... 25
Front Drive Housing - Remove and Install ........... 80
Air Inlet Manifold - Remove and Install ................ 26
Vibration Damper - Remove and Install ............... 81
Exhaust Elbow - Remove and Install ................... 27
Crankshaft Front Seal - Remove .......................... 82
Exhaust Manifold - Remove and Install ............... 27
Crankshaft Front Seal - Install .............................. 83
Water Temperature Control Valve - Remove (Jacket
Flywheel - Remove and Install ............................. 83
Water (JW)) ......................................................... 29
Crankshaft Rear Seal - Remove ........................... 84
Water Temperature Control Valve - Remove
Crankshaft Rear Seal - Install ............................... 85
(Separate Circuit Aftercooler (SCAC)) ................ 29
Flywheel Housing - Remove ................................. 85
Water Temperature Control Valve - Install (Separate
Flywheel Housing - Install ..................................... 87
Circuit Aftercooler (SCAC)) ................................. 30
Idler Gears (Front) - Remove and Install .............. 89
Water Temperature Control Valve - Install (Jacket
Gear Group (Rear) - Remove ............................... 90
Water (JW)) ......................................................... 30
Gear Group (Rear) - Install ................................... 90
Water Pump - Remove ......................................... 31
Piston Cooling Jets - Remove and Install ............. 91
Water Pump - Disassemble ................................. 31
Bearing Clearance - Check ................................... 92
Water Pump - Assemble ...................................... 33
Connecting Rod Bearings - Remove and Install .. 93
Water Pump - Install ............................................. 36
Crankshaft Main Bearings - Remove .................... 97
Fuel and Auxiliary Water Pump Drive - Remove and
Crankshaft Main Bearings - Install ........................ 99
Install ................................................................... 37
Pistons, Liners, and Connecting Rods -
Auxiliary Water Pump - Remove .......................... 38
Remove ............................................................. 101
Auxiliary Water Pump - Disassemble ................... 39
Pistons and Connecting Rods - Disassemble ..... 103
Auxiliary Water Pump - Assemble ....................... 40
Pistons and Connecting Rods - Assemble ......... 104
Auxiliary Water Pump - Install .............................. 42
Pistons, Liners, and Connecting Rods - Install ... 106
Engine Oil Cooler - Remove ................................. 43
Camshaft - Remove ............................................ 107
Engine Oil Cooler - Disassemble ......................... 44
Camshaft Bearings - Remove ............................. 109
Engine Oil Cooler - Assemble .............................. 44
Camshaft Bearings - Install .................................. 111
Engine Oil Cooler - Install ..................................... 45
Camshaft - Install ................................................. 113
Engine Oil Pump - Remove .................................. 46
Crankshaft - Remove ........................................... 115
Engine Oil Pump - Disassemble ........................... 49
Crankshaft - Install ............................................... 117
Engine Oil Pump - Assemble ................................ 50
Engine Oil Pump - Install ...................................... 51
Engine Oil Filter Housing - Remove ..................... 53 Index Section
Engine Oil Filter Housing - Install ......................... 54
Engine Oil and Water Pump Drive - Remove ....... 55 Index ................................................................... 120
Engine Oil and Water Pump Drive - Disassemble .. 56
Engine Oil and Water Pump Drive - Assemble ..... 56
Engine Oil and Water Pump Drive - Install ........... 57
Engine Oil Screen - Remove and Install .............. 58
4 KENR6415-01
Disassembly and Assembly Section

Disassembly and Assembly Installation Procedure

Section 1. Install prelubrication pump (1) in the reverse order
of removal.
i03702789
i04170055
Prelubrication Oil Pump -
Remove and Install Electronic Control Module
(Engine) - Remove and Install
SMCS Code: 1319-010
SMCS Code: 1900-010
Removal Procedure
Removal Procedure
NOTICE
Care must be taken to ensure that fluids are contained 1. Disconnect the power supply to the engine.
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.

Refer to Special Publication, NENG2500, “Caterpillar

Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

mandates.

g01993335
Illustration 2

2. Remove bolts (1) from both sides of box (3).

Remove cover (2).

g01993035
Illustration 1

1. Disconnect hose assemblies (2) and (3) from

prelubrication pump (1).

2. Disconnect harness assembly (4). Remove

the nuts, washers (9), and bolts (8). Remove
prelubrication pump (1). The weight of
prelubrication pump (1) is approximately 21 kg
(45 lb). Remove the nuts, bolts (5), and washers
(9). Remove bracket (10).
KENR6415-01 5
Disassembly and Assembly Section

i04195343

Fuel Filter Housing - Remove

SMCS Code: 1262-011

Removal Procedure
Start By:

a. Remove the electronic control module.

b. Remove the temperature control valve.

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting, and repair of the product. Be prepared
to collect the fluid with suitable containers before
opening any compartment or disassembling any com-
g01993336 ponent containing fluids.
Illustration 3
Refer to Special Publication, NENG2500, “Dealer Ser-
3. Disconnect harness assemblies (6) and (7). vice Tool Catalog” for tools and supplies suitable to
Remove bolts (4). Remove electronic control collect and contain fluids on Cat products.
module (5).
Dispose of all fluids according to local regulations and
4. Disconnect harness assemblies (10) and (11). mandates.
Remove bolts (8). Remove electronic control
module (9).
1. Turn the fuel supply to the OFF position.
5. Attach a suitable lifting device. Remove the nuts
and washers, and mounting support, and the box.

Installation Procedure
1. Attach a suitable lifting device. Position the
mounting support and the box. Install the washers
and the nuts.

2. Install electronic control modules (9) and (5) in

reverse order of the removal.

a. Tighten the connectors for harness assemblies

(10) and (11) to a torque of 6 ± 1 N·m
(53 ± 9 lb in). Illustration 4
g02384956

b. Tighten the connectors for harness assemblies 2. Disconnect tube assemblies (2) and (3) from fuel
(6) and (7) to a torque of 6 ± 1 N·m (53 ± 9 lb in). filter housing (1).
c. Connect the power supply to the engine.
6 KENR6415-01
Disassembly and Assembly Section

1. Attach a suitable lifting device in order to position

fuel filter housing (1) to the support assembly.
Install the washers and nuts (7).

g02384957
Illustration 5

3. Remove tube assemblies (4) and (5). Remove

bolts (6) from the fuel filter housing. Attach a Illustration 8
g02384957
suitable lifting device to the fuel filter housing.
2. Install bolts (6). Connect tube assemblies (4) and
(5).

g02384958
Illustration 6

4. Remove the washers and nuts (7). Remove fuel Illustration 9

g02384956
filter housing (1).
3. Connect tube assemblies (3) and (2) to fuel filter
i04225351
housing (1).

Fuel Filter Housing - Install 4. Turn the fuel supply to the ON position.

SMCS Code: 1262-012 End By:

a. Install the temperature control valve.

Installation Procedure
b. Install the electronic control module.

g02384958
Illustration 7
KENR6415-01 7
Disassembly and Assembly Section

i03705446 1. Install fuel priming pump (5) in the reverse order

of removal.
Fuel Priming Pump - Remove
and Install a. Turn the fuel supply to the ON position.

SMCS Code: 1258-010 i04280471

Removal Procedure Fuel Transfer Pump - Remove

SMCS Code: 1256-011
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test- Removal Procedure
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open- NOTICE
ing any compartment or disassembling any compo- Care must be taken to ensure that fluids are contained
nent containing fluids. during performance of inspection, maintenance, test-
ing, adjusting, and repair of the product. Be prepared
Refer to Special Publication, NENG2500, “Caterpillar to collect the fluid with suitable containers before
Dealer Service Tool Catalog” for tools and supplies opening any compartment or disassembling any com-
suitable to collect and contain fluids on Caterpillar ponent containing fluids.
products.
Refer to Special Publication, NENG2500, “Dealer Ser-
Dispose of all fluids according to local regulations and vice Tool Catalog” for tools and supplies suitable to
mandates. collect and contain fluids on Cat products.

Dispose of all fluids according to local regulations and

NOTICE
mandates.
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened NOTICE

component life. Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

1. Turn the fuel supply to the OFF position.
component life.

1. Turn the fuel supply to the OFF position.

g01994834
Illustration 10

2. Disconnect hose assemblies (1) and (3).

Disconnect harness assembly (4). Remove bolts g02447596
Illustration 11
(2). Remove fuel priming pump (5).
2. Disconnect hose assemblies (3) and (4).
Installation Procedure Disconnect tube assembly (1) and (2). Disconnect
fittings (5) and (6).
NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.
8 KENR6415-01
Disassembly and Assembly Section

2. Connect fittings (5) and (6). Connect tube

assembly (1) and (2). Connect hose assemblies
(4) and (3).

3. Turn the fuel supply to the ON position.

i04032192

High Pressure Fuel Rails -

Remove and Install
SMCS Code: 1274

Illustration 12
g02447598 Removal Procedure
Table 1
3. Remove bolts (7). Remove fuel transfer pump (8).
Required Tools

i04280734 Part
Tool Part Description Qty
Number
Fuel Transfer Pump - Install 339-9354 Fuel LineCap Kit 1
A
SMCS Code: 1256-012 265-2256 Wipers 1

Installation Procedure Start By:

a. Remove the air inlet manifold.

b. Remove the flow limiters.

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

Refer to Special Publication, NENG2500, “Dealer Ser-

g02447598 vice Tool Catalog” for tools and supplies suitable to
Illustration 13
collect and contain fluids on Cat products.
1. Install fuel transfer pump (8). Install bolts (7). Dispose of all fluids according to local regulations and
mandates.

Do not open the high pressure fuel system without

allowing the fuel system to purge. After the engine
has shut down, allow the fuel system to purge for
ten minutes. This operating fuel system contains
high pressure. Exposure to high pressure fuel can
result in personal injury.

Note: Use Tooling (A) to cap tube assemblies,

fittings, ports, and any opening in the fuel system in
Illustration 14
g02447596 order to prevent contamination.
KENR6415-01 9
Disassembly and Assembly Section

Note: Do not remove all the quills in order to maintain Note: Cap tube assemblies, fittings, ports, and
the alignment of the rail. Maintain at least two quills any opening in the fuel system in order to prevent
attached to the rail at all times. If necessary, replace contamination.
with new quill.
2. Disconnect tube assembly (3) and remove the
bolts on tube assembly (2). Remove bolts (5).
Disconnect tube assembly (4). Remove tube
assembly (2) and the O-ring seals. Remove bolts
(6).

Note: If necessary, secondary fuel filter lines may

need removed in order to remove tube assembly (2).

Note: Replace with new bolts (5)

g01285837
Illustration 15

1. Remove bolt (1) and the clamp from tube

assembly (2).

g01285008
Illustration 18

g01822393
Illustration 16

g01822394
Illustration 19

3. Remove bolts (9). Remove bolts (10) and bolts

(11). Repeat for the opposite side.

Note: Replace with new bolts (9)

4. Remove tube assembly (7). Remove tube

assembly (8) and the O-ring seal.

g01443406
Illustration 17

g01822395
Illustration 20
10 KENR6415-01
Disassembly and Assembly Section

5. Attach a suitable lifting device onto fuel rail (13).

The weight of fuel rail (13) is approximately 60 kg
(131 lb). Remove bolts (12). Remove fuel rail (13).

6. Place the high-pressure fuel rail on a clean

surface. Support the rail so the weight is not resting
on the quills. All openings should be capped or
plugged in order to prevent contamination.

7. Repeat Step 5 for the opposite side.

Installation Procedure
Table 2
Required Tools
Part
Tool Part Description Qty
Number
339-9354 Fuel LineCap Kit 1
A
265-2256 Wipers 1

Note: When Tooling (A) is removed be careful to

prevent contamination.

g01822395
Illustration 21

1. Attach a suitable lifting device onto fuel rail (13).

The weight of fuel rail (13) is approximately 60 kg
(131 lb). Install fuel rail (13). Install bolts (12).

g01443632
Illustration 22

2. Tighten bolts (12) in the sequence that is shown

in Illustration 22. Tighten bolts (12) to a torque of
100 ± 20 N·m (74 ± 15 lb ft).
KENR6415-01 11
Disassembly and Assembly Section

g01822394
Illustration 23

g01443406
Illustration 25

g01285008
Illustration 24

3. Install the new O-ring seals. Lubricate the ends of

tube assembly (8) and the O-ring seals with clean
engine oil. Install new bolts (9) and the washers.
Evenly hand tighten new bolts (9) in order to
assemble tube assembly (8) and the O-ring seals. g01822393
Illustration 26
To prevent cutting or damage of the O-ring seal.
Install tube assembly (7). Install bolts (10) and
Note: If necessary, secondary fuel filter lines may
(11) hand tight. Evenly tighten new bolts (9) to a
torque of 20 N·m (15 lb ft). need installed after tube assembly (2) has been
installed. Do not attempt to push the flanges past
O-ring seals by hand in order to prevent cutting or
Note: New bolts (9) do not rotate more than 90
degrees at a time. damage.

6. Install the new O-ring seals into the pump outlet,

4. Evenly tighten new bolts (9) to a torque of 40 N·m
(30 lb ft). the inlet, and the junction block. Lubricate O-ring
seals and the end of tube assemblies (2) and
(4) with clean engine oil. Install new bolts (5)
Note: New bolts (9) do not rotate more than 45
degrees at a time. and washers. Evenly hand tighten new bolts (5)
in order to engage tube assemblies (2) and (4)
with the O-ring seals. To prevent or damage of
5. Tighten bolts (10) and (11) to a torque of
40 ± 10 N·m (30 ± 7 lb ft). the O-ring seal. Position bolts (6) and tighten
by hand. Evenly hand tighten bolts (5). Evenly
tighten bolts (6) to a torque of 20 N·m (15 lb ft).
Evenly tighten new bolts (5) to a torque of 20 N·m
(15 lb ft). Evenly tighten bolts (6) to a final torque
of 55 ± 10 N·m (41 ± 7 lb ft). Evenly tighten bolts
(5) to a final torque of 40± 10 N·m (30± 7 lb ft).

Note: The bolts in tube assembly (2) do not rotate

more than 90 degrees at a time.
12 KENR6415-01
Disassembly and Assembly Section

7. Evenly tighten the bolts in tube assembly (2) to a

torque of 40 N·m (30 lb ft). NOTICE
Care must be taken to ensure that fluids are contained
Note: The bolts in tube assembly (2) do not rotate during performance of inspection, maintenance, test-
more than 45 degrees at a time. ing, adjusting, and repair of the product. Be prepared
to collect the fluid with suitable containers before
opening any compartment or disassembling any com-
ponent containing fluids.

Refer to Special Publication, NENG2500, “Dealer Ser-

vice Tool Catalog” for tools and supplies suitable to
collect and contain fluids on Cat products.

Dispose of all fluids according to local regulations and

mandates.

NOTICE
Keep all parts clean from contaminants.

Illustration 27
g01285837 Contaminants may cause rapid wear and shortened
component life.
8. Install the bracket, the clamp, and bolt (1) onto
tube assembly (2). Use the bracket to adjust the
position of the clamp and bolt (1) for alignment to
tube assembly (2).
Do not open the high pressure fuel system without
9. Repeat this process on the opposite side. allowing the fuel system to purge. After the engine
has shut down, allow the fuel system to purge for
End By: ten minutes. This operating fuel system contains
high pressure. Exposure to high pressure fuel can
a. Install the flow limiters. result in personal injury.

b. Install the air inlet manifold. Note: Use Tooling (B) to cap tube assemblies,
fittings, ports, and any opening in the fuel system in
i04172609 order to prevent contamination.

Flow Limiter - Remove and Note: Do not remove all the quills in order to maintain
Install the alignment of the rail. Remove one at a time and
replace before the removal of the next. If necessary,
replace with new quill.
SMCS Code: 1715-010

Removal Procedure
Start By:

a. Remove the high-pressure fuel rail.

Table 3
Required Tools
Part
Tool Part Description Qty
Number
A 6V-6195 Interlocking Joint Pliers 1
339-9352 Inj. Sys Cap Kit 1 Illustration 28
g02087086
B
265-2256 Wipers 1
1. Remove bolt (3) and the washer. Remove tube
assembly (1). Disconnect harness assembly (2).
KENR6415-01 13
Disassembly and Assembly Section

Installation Procedure
Table 4
Required Tools
Part
Tool Part Description Qty
Number
A 6V-6195 Interlocking Joint Pliers 1
339-9352 Inj. Sys Cap Kit 1
B
265-2256 Wipers 1

Note: When Tooling (B) is removed be careful to

prevent contamination.

g02087089
Illustration 29

2. Apply clean engine oil to area (X). Repeat for the

opposite collar. Remove bolts (4) and bolts (6).
Remove tube assembly (5).

Note: Replace with new bolts (4) and (6)

g02087090
Illustration 31

1. Apply clean engine oil to the sealing face of the

flow limiter and the fuel rail.

Note: Use a clean plastic squirt bottle to apply clean

engine oil. Do not apply clean engine oil by hand.

2. Use Tooling (A) to install flow limiter (7) into the

fuel rail.

Note: Clean Tooling (A) before using in order to avoid

contamination in the fuel system.
g02087090
Illustration 30

3. Use Tooling (A) to remove flow limiter (7) from the

fuel rail.

Note: Apply protective caps to flow limiter (7 ) in

order to prevent contamination. Clean Tooling (A)
before using in order to avoid contamination in the
fuel system.
14 KENR6415-01
Disassembly and Assembly Section

g02087086
Illustration 34

4. Connect harness assembly (2). Replace the

O-ring seals on both ends of tube assembly (1).
Install tube assembly (1). Install the washer and
bolt (3).
g02087089
Illustration 32
End By:

a. Install the high-pressure fuel rail.

i04228072

Fuel Control Valve - Remove

and Install
(Secondary)
SMCS Code: 1715-010

Removal Procedure
g01285695
Illustration 33
NOTICE
3. Apply clean engine oil to area (X). Repeat for Care must be taken to ensure that fluids are contained
the opposite collar. Apply clean engine oil to the during performance of inspection, maintenance, test-
ends of tube assembly (5). Replace external ing, adjusting, and repair of the product. Be prepared
O-ring seals on tube assembly (5) and lubricate to collect the fluid with suitable containers before
the O-ring seals on the tube assembly with clean opening any compartment or disassembling any com-
engine oil. Install tube assembly (5). Install new ponent containing fluids.
bolts (4) and new bolts (6) hand tight. Evenly
tighten new bolts (4) to a torque of 20 N·m Refer to Special Publication, NENG2500, “Dealer Ser-
(15 lb ft). Evenly tighten new bolts (6) to a torque vice Tool Catalog” for tools and supplies suitable to
of 20 N·m (15 lb ft). Evenly tighten new bolts (4) to collect and contain fluids on Cat products.
a torque of 40 N·m (30 lb ft). Evenly tighten new
bolts (6) to a torque of 40 N·m (30 lb ft). Dispose of all fluids according to local regulations and
mandates.

Do not open the high pressure fuel system without

allowing the fuel system to purge. After the engine
has shut down, allow the fuel system to purge for
ten minutes. This operating fuel system contains
high pressure. Exposure to high pressure fuel can
result in personal injury.
KENR6415-01 15
Disassembly and Assembly Section

1. Lubricate O-ring seals (3), (4), and (5) with Tooling

(A).

g02201493
Illustration 35

1. Remove bolts (2). Remove fuel control valve (1). Illustration 38

g02201493

g01347728
Illustration 36

2. Check O-ring seals (3), (4), and (5) on fuel control

valve (1).

Installation Procedure
g01347742
Illustration 39
Table 5
Required Tools 2. Position fuel control valve (1). Install bolts (2).
Tighten bolts (2) in the sequence that is shown
Tool Part Number Part Description Qty
in Illustration 39. Tighten bolts (2) to a torque of
A 5N-5561 Silicone Lubricant 1 6 N·m (53 lb in). Tighten bolts (2) in the sequence
that is shown in Illustration 39. Tighten bolts (2) to
a torque of 12 N·m (106 lb in).

g01347728
Illustration 37
16 KENR6415-01
Disassembly and Assembly Section

i04227910

Fuel Control Valve - Remove

and Install
(Primary)
SMCS Code: 1715-010

Removal Procedure
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting, and repair of the product. Be prepared Illustration 41
g01347728
to collect the fluid with suitable containers before
opening any compartment or disassembling any com- 2. Check O-ring seals (3), (4), and (5) on fuel control
ponent containing fluids. valve (1).

Refer to Special Publication, NENG2500, “Dealer Ser-

vice Tool Catalog” for tools and supplies suitable to Installation Procedure
collect and contain fluids on Cat products. Table 6

Dispose of all fluids according to local regulations and Required Tools

mandates. Tool Part Number Part Description Qty
A 5N-5561 Silicone Lubricant 1

Do not open the high pressure fuel system without

allowing the fuel system to purge. After the engine
has shut down, allow the fuel system to purge for
ten minutes. This operating fuel system contains
high pressure. Exposure to high pressure fuel can
result in personal injury.

g01347728
Illustration 42

1. Lubricate O-ring seals (3), (4), and (5) with Tooling

(A).

g01347715
Illustration 40

1. Use a mirror to remove bolts (2). Remove fuel

control valve (1).

g01347715
Illustration 43
KENR6415-01 17
Disassembly and Assembly Section

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

Refer to Special Publication, NENG2500, “Caterpillar

Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

mandates.

NOTICE
Keep all parts clean from contaminants.

Illustration 44
g01347742 Contaminants may cause rapid wear and shortened
component life.
2. Position fuel control valve (1). Install bolts (2).
Tighten bolts (2) in the sequence that is shown
in Illustration 44. Tighten bolts (2) to a torque of
6 N·m (53 lb in). Tighten bolts (2) in the sequence
that is shown in Illustration 44. Tighten bolts (2) to Do not open the high pressure fuel system without
a torque of 12 N·m (106 lb in). allowing the fuel system to purge. After the engine
has shut down, allow the fuel system to purge for
ten minutes. This operating fuel system contains
i03706751 high pressure. Exposure to high pressure fuel can
result in personal injury.
Fuel Pump (High Pressure) -
Remove and Install Note: Use Tooling (B) to cap tube assemblies,
fittings, ports, and any openings on the fuel system
SMCS Code: 1288-010 in order to prevent contamination.

Removal Procedure
Table 7
Required Tools
Tool Part Number Part Description Qty
138-7575 Link Bracket 2
A(1) 6V-3668 12 MM Bolt 2
5P-8245 Washer 2
339-9353 High Press. Cap Kit 1
B
265-2256 Wipers 1
C 246-8191 16 MM Socket 1
Multipurpose
D 1P-0808 1
Grease
(1) Use one to remove the fuel pump from the EPG engine.

Start By: g02125567

Illustration 45
a. Remove the fuel transfer pump.
18 KENR6415-01
Disassembly and Assembly Section

1. Remove tube assemblies (1), (2), and (7). Remove b. Install bolts (12) hand tight. Install bolts (8)
hose assembly (4). Disconnect harness assembly hand tight. Use Tooling (C) and evenly tighten
(5). bolts (12) to a torque of 20 N·m (15 lb ft). Use
Tooling (C) and evenly tighten bolts (8) to a
2. Disconnect harness assembly (3) from fuel pump torque of 20 N·m (15 lb ft).
(6).
Note: Do not rotate bolts (12) and (8) more than 90
degrees at a time.

c. Evenly tighten bolts (12) to a torque of 40 N·m

(30 lb ft). Evenly tighten bolts (8) to a torque of
40 N·m (30 lb ft).

Note: Do not rotate bolts (12) and (8) more than 45

degrees at a time.

End By:

a. Install the fuel transfer pump.

i04174652

Air Cleaner - Remove and

Install
SMCS Code: 1051-010
g02125652
Illustration 46
Removal Procedure
Note: When the fuel lines are removed, use clean
engine oil to lubricate the outside diameter of tube
assembly (11) in area (X). Use Tooling (C) in order
to remove bolts (8) and (12). If the procedure is not
followed, contamination and fuel leaks may occur.

3. Remove bolt (10), the washer, and the nut.

Remove clamp assembly (9). Remove bolts (8)
and (12). Remove tube assembly (11) and the
O-ring seals.

4. Use Tooling (A) and attach a suitable lifting device

onto fuel pump (6). The weight of fuel pump (6) is
approximately 102 kg (225 lb). Remove bolts (13).
Lower fuel pump (6) to the ground. g02365096
Illustration 47
Note: The lifting device should not come into contact
with the fuel shutoff valve. This will result in damage 1. Release clamps (1). Remove covers (2) from
to the component. air cleaner housing (4). Disconnect harness
assemblies (3). Repeat the process on the other
air cleaner housing (4).
Installation Procedure
1. Install fuel pump (6) in the reverse order of the
removal.

Note: When Tooling (B) is removed be careful to

prevent contamination.

a. Lubricate the O-ring seals with clean engine

oil. Lubricate the ends of tube assembly (11)
with Tooling (D).
KENR6415-01 19
Disassembly and Assembly Section

i04877833

Exhaust Shield - Remove and

Install
SMCS Code: 1067-010

Removal Procedure
Note: For safety reasons, wear gloves when
removing exhaust shield components.

g02110529
Illustration 48

2. Remove air cleaner elements (6). Loosen clamps

(5).

g02918256
Illustration 50

1. Remove six bolts (1) and hood assembly (2).

g02365325
Illustration 49

3. Remove bolts (7), the washers, and the nuts on

each side of air cleaner housing (4). Remove air
cleaner housing (4). Illustration 51
g02940916

Installation Procedure 2. Remove bolts (3), then remove guard assemblies

(4). Repeat for the other side of the engine.
1. Install air cleaner housing (4) in the reverse order
of removal.
20 KENR6415-01
Disassembly and Assembly Section

g02916499 g02909957
Illustration 52 Illustration 55

3. Remove four bolts (5) and hood assembly (6). 6. Remove bolts (12), disconnect harness assembly
(13), and remove bolts (14).

g02918116
Illustration 53
g02910780
Illustration 56
4. Remove bolts (7) and hood assembly (8).
7. Remove four bolts (15) and remove cover (16) by
sliding upwards.

g02908596
Illustration 54

g02910836
5. Remove cover assemblies (9). Remove LH side Illustration 57
shield (10) and then RH side shield (11).
8. Remove bolts (18) and remove cover assembly
(17).

9. Repeat Steps 6 through 8 for the opposite side.

KENR6415-01 21
Disassembly and Assembly Section

g02911357 g02913159
Illustration 58 Illustration 61

13. Remove cover assembly (26). Remove bolt (28)

and remove cover assembly (27).

g02911796
Illustration 59

10. Remove bolts (19) and bolts (20).

g02916190
Illustration 62

14. Remove two bolts (29) and cover assembly (30).

15. Repeat Step 14 for the opposite side.

Installation Procedure
1. Install exhaust shield group in the reverse order
of removal.

i04175930

g02912918
Turbocharger - Remove
Illustration 60
SMCS Code: 1052-011
11. Remove four bolts (21), bolt (22), and then
remove cover assembly (23).
Removal Procedure
12. Remove 14 bolts (24) and cover assembly (25). Table 8
Required Tools
Tool Part Number Part Description Qty
A 138-7573 Link Bracket 1
22 KENR6415-01
Disassembly and Assembly Section

Start By:

a. Remove the air cleaners.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

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

Refer to Special Publication, NENG2500, “Dealer Ser-

vice Tool Catalog” for tools and supplies suitable to
collect and contain fluids on Cat products. Illustration 64
g02367198

Dispose of all fluids according to local regulations and 2. Disconnect fitting (14). Disconnect fitting (13).
mandates. Remove tube assemblies (7) and (12) together.

3. Attach Tooling (A) and a suitable lifting device onto

turbocharger (9). The weight of turbocharger (9)
is approximately 125 kg (275 lb).

4. Disconnect clamps (10), (11), and (15).

5. Remove bolts (8). Remove turbochargers (9).

g02366696
Illustration 63

Note: For safety reasons wear gloves when removing

the exhaust shield components.

1. Remove half moon shields (1). Remove LH side

shield (2) and then RH side shield (6). Remove
slanted shield (4). Remove two front vertical
shields (3). Remove rear vertical shields (5).

g02367201
Illustration 65

6. Remove screen assembly (16) from turbocharger

support (18) and inspect. Remove O-ring seal
(17).
KENR6415-01 23
Disassembly and Assembly Section

i04177554

Turbocharger - Install
SMCS Code: 1052-012

Installation Procedure
Table 9
Required Tools
Tool Part Number Part Description Qty
A 138-7573 Link Bracket 1

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.
g02367198
Illustration 67
NOTICE
Care must be taken to ensure that fluids are contained 2. Attach Tooling (A) and a suitable lifting device
during performance of inspection, maintenance, test- onto turbocharger (9). The weight of turbocharger
ing, adjusting, and repair of the product. Be prepared (9) is approximately 125 kg (275 lb). Position
to collect the fluid with suitable containers before turbocharger (9). Install bolts (8).
opening any compartment or disassembling any com-
ponent containing fluids. 3. Tighten clamps (11), (15), and (10).
Refer to Special Publication, NENG2500, “Dealer Ser- 4. Position tube assemblies (7) and (12)together.
vice Tool Catalog” for tools and supplies suitable to Connect fittings (14) and (13) to turbocharger (9).
collect and contain fluids on Cat products.

Dispose of all fluids according to local regulations and

mandates.

g02366696
Illustration 68

5. Install rear vertical shields (5). Install two front

vertical shields (3). Install slanted shield (4). Install
RH side shield (6) and then LH side shield (2).
Install half moon shields (1).

End By:

a. Install the air cleaners.

g02367201
Illustration 66

1. Install clean screen assembly (16) into

turbocharger support (18). Install new O-ring seal
(17).
24 KENR6415-01
Disassembly and Assembly Section

i04228189

Air Shutoff - Remove and

Install
SMCS Code: 1078-010

Removal Procedure
NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

Personal injury can result from parts and/or cov-

ers under spring pressure.
g02405236
Illustration 69
Spring force will be released when covers are re-
moved. 2. Disconnect harness assemblies (3).
Be prepared to hold spring loaded covers as the 3. Attach a suitable lifting device to elbow (2).
bolts are loosened. Remove bolts (1) and the washers. Remove bolts
(8) and (7). Remove elbow (2).

4. Disconnect tube assembly (5) from air shutoff (6).

Personal injury or death can occur from not fol- 5. Disconnect harness assembly (4). Remove clamp
lowing the proper procedure or the recommended assembly (9) to the intake manifold.
tooling.
6. Remove air shutoff (6) and the gasket.
To prevent the possibility of injury or death, follow
the established procedure using the recommend- Note: Inspect the lines of the air intake for debris.
ed tooling.
7. Repeat this procedure on the opposite side of the
engine.

Before you remove the air intake shutoff, pull the Installation Procedure
trip knob on the air intake shutoff or press the
emergency stop button in order to release the NOTICE
blade latch. If the blade latch is released after the Keep all parts clean from contaminants.
air intake shutoff is removed, serious personal
injury can result. Contaminants may cause rapid wear and shortened
component life.
1. Manually release the air shutoff. Pull or press in
order to release the knob on the air shutoff. Ensure 1. Install air shutoff (6) in the reverse order of
that the indicator on the air shutoff points straight removal.
down to the “OFF” position. If the air shutoff did not
trip, refer to Troubleshooting, “Air Shutoff System”. 2. Install bolts (8) and the washers and tighten bolts
(8) to a torque of 100 ± 20 N·m (74 ± 15 lb ft).

3. Reset the indicator on the air shutoff. Ensure that

the arrow on the indicator is pointing straight up
to the “OPEN” position.

4. Test air shutoff (6) for proper operation and refer to

Operation and Maintenance Manual, “Air Shutoff”.
KENR6415-01 25
Disassembly and Assembly Section

i04045583

Aftercooler - Remove and

Install
SMCS Code: 1063-010

Removal Procedure
Table 10
Required Tools
Tool Part Number Part Description Qty
A 138-7575 Link Bracket 2
B 138-7573 Link Bracket 2
C 1U-9200 Lever Puller Hoist 1
Guide Bolt
D - M10 by 1.5 by 2
100 mm
g02111599
Illustration 71
E 8T-9022 Silicone Gasket
3. Attach Tooling (A) and Tooling (B) onto aftercooler
Start By: (8). Attach a suitable lifting device onto Tooling
(A). Attach Tooling (C) onto Tooling (B).
a. Remove the exhaust elbow.
4. Remove bolts (11). Repeat for the opposite side.
The weight of aftercooler (8) is approximately
377 kg (829 lb). Use Tooling (C) in order to lift
the rear of aftercooler (8). Remove aftercooler (8)
from the engine.

5. Attach Tooling (B) and a suitable lifting device

onto housing (10). The weight of housing (10) is
approximately 37 kg (81 lb). Remove bolts (9).
Remove housing (10) and the gasket.

g02228633
Illustration 70

1. Remove bolts (5). Remove bolts (3) and the

washers. Remove elbow (4), the connector, and
elbow (6). Remove bolt (1) and disconnect tube
assembly (7). Loosen clamps (2).

2. Repeat Step 1 for the opposite side.

g02111600
Illustration 72

6. Remove two bolts (12). Install Tooling (D).

Remove remaining bolts (12).
26 KENR6415-01
Disassembly and Assembly Section

7. Slide cover (13) outward on Tooling (D). Attach

Tooling (B) and a suitable lifting device onto cover
(13). The weight of cover (13) is approximately
20 kg (44 lb). Remove cover (13) and the gasket.

8. Repeat Steps 6 and 7 for the opposite side.

9. Attach a suitable lifting device onto cover (15).

The weight of cover (15) is approximately 75 kg
(166 lb). Remove bolts (14). Remove cover (15)
and the gasket.

Installation Procedure
1. Install aftercooler (8) in the reverse order of
removal.

Note: When elbow (4), the connector, and elbow (6)

are connected, ensure that there is 1mm spacing
between each of the elbows and the connector.
g02019315
Note: When elbow (4), the connector, and elbow Illustration 73
(6) is installed. Ensure that there is 3mm clearance
between the elbows and the tubes coming out of the 1. Remove bolts (2) from cover (1) for the harness
aftercooler. The clearance between the elbows and assembly. Position cover (1) for the harness
the tubes coming out of the aftercooler are in order assembly out of the way. Ensure support for the
to prevent rubbing. harness in order to prevent damage.

End By:

a. Install the exhaust elbow.

i04229149

Air Inlet Manifold - Remove

and Install
SMCS Code: 1058-010

Removal Procedure
g01242582
Illustration 74
Start By:
2. Attach a suitable lifting device onto air inlet
a. Remove the air shutoff. manifold (6). The weight of air inlet manifold (6) is
approximately 48 kg (105 lb). Remove bolt (3).
Remove bolts (4) and bolts (5).

3. Remove air inlet manifold (6).

4. Repeat the procedure on the opposite side.

Installation Procedure
1. Install air inlet manifold (6) in the reverse order
of removal.

Note: When elbow (9), the connector, and elbow (10)

are connected, ensure that there is 1mm spacing
between each of the elbows and the connector.
KENR6415-01 27
Disassembly and Assembly Section

Note: When air inlet manifold (6) is installed.

Ensure that there is 3mm clearance between air
inlet manifold (6) and the tubes coming out of the
aftercooler. The clearance between air inlet manifold
(6) and the tubes coming out of the aftercooler are in
order to prevent rubbing.

End By:

a. Install the air shutoff.

i04229209

Exhaust Elbow - Remove and

Install Illustration 76
g02405941

SMCS Code: 1060-010 2. Attach Tooling (A) and a suitable lifting device
onto exhaust elbow (3) and support assembly (7).
The weight of exhaust elbow (3) is approximately
Removal Procedure 44 kg (98 lb). The weight of support assembly (7)
is approximately 69 kg (152 lb). Loosen clamps
Table 11
(4). Remove bolts (6). Remove exhaust elbow (3)
Required Tools and support assembly (7).
Tool Part Number Part Description Qty
A 138-7573 Link Bracket 2
Installation Procedure
1. Install exhaust elbow (3) in the reverse order of
removal.

i04230038

Exhaust Manifold - Remove

and Install
SMCS Code: 1059-010

Removal Procedure
Table 12
g02405777
Illustration 75 Required Tools
Part
Note: When removing heat shield components be Tool Part Description Qty
Number
aware of sharp edges.
A 304-9575 Bellows Tool Assembly 1
1. Remove heat shield (3) in two parts. Attach a B 304-9576 Bellows Feeler gauge 1
suitable lifting device to “LH” side of heat shield
(1) and remove the bolts and heat shield (1).
Attach a suitable lifting device to “RH” side of heat Start By:
shield (2) and remove the bolts and heat shield
(2). Remove the bolts and lower heat shield. a. Remove the air cleaners.

NOTICE
Clamp assemblies MUST only be used once. Discard
all clamp assemblies after use.

NOTICE
Bellows assemblies MUST only be used once. Dis-
card all bellows assemblies after use.
28 KENR6415-01
Disassembly and Assembly Section

g02406662
Illustration 77

Note: When removing exhaust shield (1) be aware

of sharp edges.

1. Unlatch exhaust shields (1) and remove the four

sections. g02110436
Illustration 79

4. Remove bolts (6) and the washers from exhaust

manifolds (3). Loosen bolts (5).

5. Repeat Steps 1 through 4 for the opposite side.

Installation Procedure
1. Install exhaust manifold (3) in the reverse order
of removal.

End By:

g02110434
a. Install the air cleaners.
Illustration 78

2. Loosen clamps (4) and clamps (2).

3. Attach a suitable lifting device onto exhaust

manifolds (3). The weight of exhaust manifolds (3)
is approximately 132 kg (290 lb).
KENR6415-01 29
Disassembly and Assembly Section

i04232050 4. Remove bolts (2), the washers, and the nuts.

Disconnect temperature control valve (3) from the
Water Temperature Control elbow and remove the O-ring seal. Remove bolts
Valve - Remove (1), the washers, and the O-ring seal. Remove
temperature control valve (3).
(Jacket Water (JW))
SMCS Code: 1355-011 i04232412

Water Temperature Control

Removal Procedure
Valve - Remove
NOTICE (Separate Circuit Aftercooler
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
(SCAC))
ing, adjusting, and repair of the product. Be prepared
SMCS Code: 1355-011
to collect the fluid with suitable containers before
opening any compartment or disassembling any com-
ponent containing fluids. Removal Procedure
Refer to Special Publication, NENG2500, “Dealer Ser- NOTICE
vice Tool Catalog” for tools and supplies suitable to Care must be taken to ensure that fluids are contained
collect and contain fluids on Cat products. during performance of inspection, maintenance, test-
ing, adjusting, and repair of the product. Be prepared
Dispose of all fluids according to local regulations and to collect the fluid with suitable containers before
mandates. opening any compartment or disassembling any com-
ponent containing fluids.
1. Drain the coolant from the cooling system into
a suitable container for storage or for disposal. Refer to Special Publication, NENG2500, “Dealer Ser-
Refer to Operation and Maintenance Manual, vice Tool Catalog” for tools and supplies suitable to
“Cooling System Coolant - Change”. collect and contain fluids on Cat products.

Dispose of all fluids according to local regulations and

mandates.

1. Drain the coolant from the cooling system into

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

g02407740
Illustration 80
g02408079
Illustration 81
2. Disconnect harness assemblies (4) in order to
remove temperature control valve (3).
2. Disconnect harness assemblies (2) in order to
3. Attach a suitable lifting device in order to remove remove temperature control valve (1).
temperature control valve (3). The weight of
temperature control valve (3) is approximately
40 kg (88 lb). Remove bolts (5), the washers, and
the nuts. Disconnect elbow (6) and remove the
O-ring seal.
30 KENR6415-01
Disassembly and Assembly Section

3. Attach a suitable lifting device in order to remove i04232350

temperature control valve (1). The weight of
temperature control valve (1) is approximately Water Temperature Control
36 kg (80 lb). Remove bolts (3), the washers, the Valve - Install
elbow, and the O-ring seal. Remove bolts (5) and
the washers. (Jacket Water (JW))
4. Remove bolts (6) and the washers. Remove bolts SMCS Code: 1355-012
(4) and the washers. Remove temperature control
valve (1). Installation Procedure
i04232530

Water Temperature Control

Valve - Install
(Separate Circuit Aftercooler
(SCAC))
SMCS Code: 1355-012

Installation Procedure

g02407740
Illustration 83

1. Attach a suitable lifting device onto temperature

control valve (3). The weight of temperature
control valve (3) is approximately 40 kg (88 lb).
Install a new O-ring seal and position temperature
g02408079 control valve (3). Install the washers and bolts (1).
Illustration 82
Install a new O-ring seal into the elbow. Position
the elbow. Install the washers, the nuts, and bolts
1. Attach a suitable lifting device onto temperature (2).
control valve (1). The weight of temperature
control valve (1) is approximately 36 kg (80 lb). 2. Install a new O-ring seal and position the elbow
Install a new O-ring seal and position temperature (6). Install the washers, the nuts, and bolts (5).
control valve (1). Install the washers and bolts (4).
Install the washers and bolts (6). 3. Connect harness assemblies (4).
2. Install the washers and bolts (5). Install a new 4. Fill the cooling system with coolant. Refer to
O-ring seal and position the elbow. Install the Operation and Maintenance Manual, “Cooling
washers and bolts (3). System Coolant - Change”.
3. Connect harness assemblies (2).

4. Fill the cooling system with coolant. Refer to

Operation and Maintenance Manual, “Cooling
System Coolant - Change”.
KENR6415-01 31
Disassembly and Assembly Section

i04232934

Water Pump - Remove

SMCS Code: 1361-011

Removal Procedure
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting, and repair of the product. Be prepared
to collect the fluid with suitable containers before
opening any compartment or disassembling any com-
ponent containing fluids. Illustration 85
g01201281

Refer to Special Publication, NENG2500, “Dealer Ser- 4. Attach a suitable lifting device onto water pump
vice Tool Catalog” for tools and supplies suitable to (9). The weight of water pump (9) is approximately
collect and contain fluids on Cat products. 35 kg (76 lb). Disconnect hose assembly (8).
Remove nuts (7) and remove water pump (7).
Dispose of all fluids according to local regulations and
mandates.
i03855700

1. Drain the coolant from the cooling system into Water Pump - Disassemble
a suitable container for storage or for disposal.
Refer to Operation and Maintenance Manual, SMCS Code: 1361-015
“Cooling System Coolant - Change”.
Disassembly Procedure
Table 13
Required Tools

Part
Tool Part Description Qty
Number

A 1P-0510 Driver Gp 1
B - 1 inch by 4 inch steel plate 2
C 248-3311 Holding Fixture 1
D 248-3310 Spanner Wrench 1
E 8H-0663 Bearing Puller Gp 1

Start By:

a. Remove the water pump.

Illustration 84
g02020859 NOTICE
Keep all parts clean from contaminants.
2. Remove bolts (1). Remove bolts (4). Remove
elbow (3) from tube assembly (2). Remove the Contaminants may cause rapid wear and shortened
O-ring seal from elbow (3). component life.

3. Remove bolts (5). Disconnect elbow (6). Remove

the O-ring seal.
32 KENR6415-01
Disassembly and Assembly Section

g01036014 g01035285
Illustration 86 Illustration 88

1. Remove plug (1) and plug (2) from bearing 4. Install Tooling (B) under impeller (9). Use a
housing (3). Remove plug (6) from housing (5). suitable press and Tooling (A) to remove the
Remove the O-ring seals from the plugs. impeller.

2. Remove water pump filter (4) from bearing Note: Do not allow bearing housing (3) to fall to the
housing (3). floor when the impeller is removed from the pump
shaft.

g01035264
Illustration 87
g01035309
Illustration 89
3. Remove bolts (7) and washers. Remove bearing
housing (3) from housing (5). Remove O-ring seal 5. Remove socket head bolts (10). Remove retainer
(8) from bearing housing (3). (11) and pump shaft (12) from bearing housing (3).

Note: Spring (14) and ceramic seal (13) will be

removed from the shaft assembly when the pump
shaft is removed from the bearing housing.
KENR6415-01 33
Disassembly and Assembly Section

g01035437
Illustration 92

8. Remove ceramic seal (18) and lip seal (19) from

bearing housing (3).

i04823128
g01035407
Illustration 90
Water Pump - Assemble
6. Install pump shaft (12) in Tooling (C). Loosen set
screws (15). Use Tooling (D) to remove bearing SMCS Code: 1361-016
locknut (16) from the pump shaft.
Assembly Procedure
Note: The splined end of the pump shaft is marked
in order to indicate either RH threads or LH threads Table 14
on the pump shaft.
Required Tools

Part
Tool Part Description Qty
Number

A 1P-0510 Driver Gp 1
C 248-3311 Holding Fixture 1
D 248-3310 Spanner Wrench 1
E 8H-0663 Bearing Puller Gp 1
F O-Ring Assembly -
1U-6396
Compound
G
7N-8268 Installation Tool 1

H 8H-8581 Feeler Gauge 1

NOTICE
Keep all parts clean from contaminants.

Illustration 91
g01035429 Contaminants may cause rapid wear and shortened
component life.
7. Use Tooling (E) to remove bearing assembly (17)
from pump shaft (12).
34 KENR6415-01
Disassembly and Assembly Section

Note: The torque wrench must be 90 degrees to

Tooling (D).

6. Install set screws (15) and tighten to a torque of

8 ± 1 N·m (70.8 ± 8.9 lb in).

g01035690
Illustration 95
g01040290
Illustration 93
Note: Do not damage the wear surfaces of the
1. Use Tooling (E) and a suitable press to install carbon ring or the ceramic ring. Do not touch the
bearing assembly (17) on pump shaft (12). wear surfaces of the carbon ring or the ceramic ring.
Install the ceramic ring with the smoothest face of the
2. Install bearing cone (23) on the pump shaft. ring toward the carbon seal.

3. Install spacer (22) and bearing cups (21) on the 7. Apply Tooling (F) to the outside diameter of
pump shaft. ceramic seal (18). Use Tooling (G) and hand
pressure to install ceramic seal (18) in bearing
4. Install bearing cone (20) on the pump shaft. housing (3).

g01035699
Illustration 96

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

seal (19) in bearing housing (3). Ensure that the
lip is toward the outside.

Note: Install the lip seal dry. Install the lip seal within
g01035607
Illustration 94 two minutes of removal from the shipping sleeve.

5. The splined end of the pump shaft is marked in

order to indicate either RH threads or LH threads
on pump shaft (12). Install bearing locknut (16).
Use Tooling (D) on the bearing locknut. Tighten
the bearing locknut to a torque of 300 ± 30 N·m
(221 ± 22 lb ft).
KENR6415-01 35
Disassembly and Assembly Section

11. Apply Tooling (F) to the inside diameter of ceramic

seal (13). Use hand pressure and the tool that is
supplied with the water pump seal group to install
the ceramic seal. The face of ceramic seal (13)
should make light contact with ceramic seal (18).

12. Install spring (14).

13. Lubricate pump shaft (12) on bearing housing (3)

with clean engine oil. Position impeller (9) on the
pump shaft.

g01035809
Illustration 97

9. Lubricate pump shaft (12) with clean engine oil.

Install the pump shaft in bearing housing (3). Install
retainer (11). Install socket head bolts (10) and
tighten to a torque of 12 ± 3 N·m (106 ± 27 lb in).

g01035846
Illustration 99

14. Place bearing housing (3) on impeller (9). Use

a suitable press and press pump shaft (12) into
the impeller. Install the impeller so the dimension
between the impeller and the pump shaft is
0.000 ± 0.076 mm (0.0000 ± 0.0030 inch).

g01035829
Illustration 98

Note: Do not damage the wear surfaces of the

carbon ring or the ceramic ring. Do not touch the
wear surfaces of the carbon ring or the ceramic ring.
Install the ceramic ring with the smoothest face of the
ring toward the carbon seal.

10. Remove spring (14) from ceramic seal (13).

g01035264
Illustration 100
36 KENR6415-01
Disassembly and Assembly Section

15. Install O-ring seal (8) on bearing housing (3). 22. Install water pump filter (4) in bearing housing (3).
Lubricate the O-ring seal with clean engine oil.
End By:
16. Position bearing housing (3) in housing (5). Install
washers and bolts (7) finger tight. a. Install the water pump.

i04233095

Water Pump - Install

SMCS Code: 1361-012

Installation Procedure

g01036084
Illustration 101

17. Tighten the bolts in a numerical sequence to a

torque of 50 ± 9 N·m (35 ± 7 lb ft).

18. Use Tooling (H) and measure the gap between

the impeller and the pump housing. The minimum
gap between the impeller and the pump housing
is 0.20 mm (0.008 inch). g01201281
Illustration 103

1. Attach a suitable lifting device onto water pump

(9). The weight of water pump (9) is approximately
35 kg (76 lb). Position water pump (9) onto
the engine and install nuts (7). Connect hose
assembly (8).

g01036014
Illustration 102

19. Install the O-ring seal on plug (6). Install the plug
in housing (5). Tighten the plug to a torque of
177 ± 7 N·m (131 ± 6 lb ft).

20. Install the O-ring seal on plug (2). Install the plug g02020859
Illustration 104
in bearing housing (3). Tighten the plug to a torque
of 8 ± 1 N·m (6 ± 1 lb ft).
2. Position the O-ring seal and elbow (6). Install bolts
21. Install the O-ring seal on plug (1). Install the plug (5).
in bearing housing (3). Tighten the plug to a torque
of 17 ± 1 N·m (151 ± 9 lb in).
KENR6415-01 37
Disassembly and Assembly Section

3. Position the O-ring seal onto elbow (3). Install

elbow (3) into tube assembly (2). Install bolts (4).
Install bolts (1).

4. Fill the cooling system with coolant. Refer to

Operation and Maintenance Manual, “Cooling
System Coolant - Change”.

i03809320

Fuel and Auxiliary Water Pump

Drive - Remove and Install
SMCS Code: 1288-010; 1371-010-DRV g01213648
Illustration 106

Removal Procedure 2. Remove O-ring seals (3) from housing (1).

Table 15
Required Tools
Tool Part Number Part Description Qty
A 138-7575 Link Bracket 1
B 1P-0520 Driver Gp 1

Start By:

a. Remove the fuel pump.

b. Remove the auxiliary water pump.

g01213659
Illustration 107

3. Use Tooling (B) and a suitable press in order to

remove bearing (4) from housing (1).

g02145874
Illustration 105

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

onto housing (1). The weight of housing (1) is
approximately 23 kg (50 lb). Remove bolts (2).
Remove housing (1). g02145875
Illustration 108

4. Remove fuel and auxiliary water pump drive gear

(5).
38 KENR6415-01
Disassembly and Assembly Section

i03742553

Auxiliary Water Pump -

Remove
SMCS Code: 1371-011

Removal Procedure
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
g01215057
collect the fluid with suitable containers before open-
Illustration 109 ing any compartment or disassembling any compo-
nent containing fluids.
5. Remove bolts (6). Remove adapter (7).
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

mandates.

1. Drain the coolant from the cooling system into

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

g01215060
Illustration 110

6. Remove O-ring seals (8) and (9).

g01215061
Illustration 111
g02021493
Illustration 112
7. Use Tooling (B) and a suitable press in order to
remove bearing (10) from adapter (7). 2. Disconnect harness assemblies (4). Remove
clamp assembly (1). Remove bolt (2) and remove
Installation Procedure the clamp. Remove bolts (6). Remove tube
assembly (3). If necessary, remove hose assembly
1. Install the fuel and auxiliary water pump drive in (5).
the reverse order of removal.
KENR6415-01 39
Disassembly and Assembly Section

g02021673 g01204934
Illustration 113 Illustration 114

3. Remove bolts (9) and elbow (10). 1. Remove nuts (1). Remove cover (2) from water
pump (3).
4. Attach a suitable lifting device onto auxiliary water
pump (7). The weight of auxiliary water pump (7)
is approximately 27 kg (60 lb). Remove bolts (8).
Remove auxiliary water pump (7).

i03856273

Auxiliary Water Pump -

Disassemble
SMCS Code: 1371-015

Disassembly Procedure
g01204935
Table 16 Illustration 115

Required Tools 2. Remove O-ring seal (4) from cover (2).

Tool Part Number Part Description Qty
1U-9895 Crossblock 1
1P-0820 Hydraulic Puller 1
126-7181 Sliding Plate 2
3H-0465 Push-Puller Plate 6
2S-4680 Stud 2
A Electric Hydraulic
3S-6224 1
Pump Gp
2L-4523 Bolt 2
5P-8244 Hard Washer 2
6B-6682 Full Nut 2
2J-3506 Full Nut 2

Start By:

a. Remove the auxiliary water pump.

g01207677
Illustration 116
40 KENR6415-01
Disassembly and Assembly Section

Personal injury can result from being struck by

parts propelled by a released spring force.

Make sure to wear all necessary protective equip-

ment.

Follow the recommended procedure and use all

recommended tooling to release the spring force.

3. Use Tooling (A) in order to remove impeller (5).

g01207698
Illustration 119

6. Remove seal (10) and ring assembly (11).

g01207678
Illustration 117

4. Remove spring (6).

g01207700
Illustration 120

7. Turn over water pump (3). Remove the rubber

seal and the ceramic ring of seal group (12).

i03856500

Auxiliary Water Pump -

Assemble
SMCS Code: 1371-016

Illustration 118
g01207696
Assembly Procedure
5. Turn over water pump (3). Remove bolts (8). Table 17
Remove shaft (7) and thrust washer (9). When Required Tools
you remove shaft (7) the seal ring will be free from
shaft (7). Tool Part Number Part Description Qty
B 1P-0510 Driver Gp 1
C 207-1601 Rubber Lubricant 1
D 7N-8268 Installation Tool 1
KENR6415-01 41
Disassembly and Assembly Section

g01207698 g01207755
Illustration 121 Illustration 124

1. Do not lubricate the sealing lip of seal (10). Install 3. Turn over water pump (3). Use water or Tooling
ring assembly (11). Use Tooling (B) to install seal (C) to aid assembly. Use Tooling (D) and hand
(10). pressure to seat the ceramic ring and the rubber
seal of seal group (12) into water pump (3).
Remove the spring from the seal ring. Use Tooling
(D) and hand pressure to press the seal ring of
seal group (12) on the shaft until the seal faces
make contact.

g01207696
Illustration 122

2. Install shaft (7) with thrust washer (9) into water

pump (3). Install bolts (8).
g01207678
Illustration 125

4. Install spring (6).

g01207752
Illustration 123

g01207798
Illustration 126
42 KENR6415-01
Disassembly and Assembly Section

i03742780

Auxiliary Water Pump - Install

Improper assembly of parts that are spring loaded
can cause bodily injury. SMCS Code: 1371-012
To prevent possible injury, follow the established
assembly procedure and wear protective equip- Installation Procedure
ment.

5. Lubricate shaft (7) with clean engine oil. Use

Tooling (B) and a suitable press in order to install
impeller (5) onto shaft (7). Install impeller (5) until
impeller (5) is flush with shaft (7).

g02021673
Illustration 129

1. Attach a suitable lifting device onto auxiliary water

pump (7). The weight of auxiliary water pump (7)
is approximately 27 kg (60 lb). Position auxiliary
water pump (7). Install bolts (8).
g01204935 2. Position elbow (10) and install bolts (9).
Illustration 127

Note: Check the O-ring seal for wear or for damage.

If necessary, replace the O-ring seal.

6. Install O-ring seal (4) onto cover (2).

g01204934
Illustration 128
g02021493
Illustration 130
7. Install cover (2) onto water pump (3). Install nuts
(1).
3. If necessary, install hose assembly (5). Install tube
assembly (3). Install bolts (6). Position the clamp
End By:
and install bolt (2). Install clamp assembly (1).
Connect harness assembly (4).
a. Install the auxiliary water pump.
4. Fill the cooling system with coolant. Refer to
Operation and Maintenance Manual, “Cooling
System Coolant - Change”.
KENR6415-01 43
Disassembly and Assembly Section

i03743534

Engine Oil Cooler - Remove

SMCS Code: 1378-011

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

Refer to Special Publication, NENG2500, “Caterpillar

Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
g02022246
Dispose of all fluids according to local regulations and Illustration 132
mandates.
3. Remove bolts (8). Disconnect tube assembly (7).
Remove bolts (6). Disconnect tube assembly (5).
1. Drain the coolant from the engine into a suitable
container for storage or for disposal. Refer to
Operation and Maintenance Manual, “Cooling
System Coolant - Change”.

g02022250
Illustration 133

4. Remove bolts (12). Disconnect tube assembly

g02022243 (11). Remove bolts (10). Disconnect tube
Illustration 131
assembly (9).
2. Attach a suitable lifting device onto engine oil
cooler (1). The weight of engine oil cooler (1) is
approximately 150 kg (330 lb). Remove bolt (3)
in order to disconnect clamp (4). Check coupling
(2) for leaks.

Note: Never tighten the bolts in coupling (2) in order

to stop the leak. Drain the tube assembly and loosen
the bolts on coupling (2). Do not remove coupling (2)
but pry in order to disengage the teeth in coupling
(2). Remove coupling (2) from the joint.

g02022251
Illustration 134
44 KENR6415-01
Disassembly and Assembly Section

5. Remove bolts (13) from engine oil cooler (1).

Repeat for the opposite side.

g02022463
Illustration 137

Illustration 135
g02022259 2. Remove bolts (9). Remove elbow (10) and the
O-ring seals. Repeat for the opposite side.
6. Lower engine oil cooler (1) to the ground.

i03743905

Engine Oil Cooler -

Disassemble
SMCS Code: 1378-015

Disassembly Procedure
Start By:

a. Remove the engine oil cooler. Illustration 138

g02022465

Note: Note the orientation of the elbow for assembly 3. Remove bolts (11). Remove bonnet (12) and the
purposes. gaskets. Repeat for the opposite side.

i03743955

Engine Oil Cooler - Assemble

SMCS Code: 1378-016

Assembly Procedure

g02022459
Illustration 136

1. Remove plug (8) and O-ring seal (7). Remove

spring (6) and bypass valve (5). Remove bolts (2).
Remove elbow (1) and the O-ring seals. Remove
bolts (3), elbow (4), and the O-ring seals.

g02022465
Illustration 139
KENR6415-01 45
Disassembly and Assembly Section

1. Position the gaskets and bonnet (12). Install bolts i03743969

(11).
Engine Oil Cooler - Install
SMCS Code: 1378-012

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

g02022463 Refer to Special Publication, NENG2500, “Caterpillar

Illustration 140
Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
2. Position the O-ring seals and elbow (10). Install
products.
bolts (9).
Dispose of all fluids according to local regulations and
mandates.

g02022459
Illustration 141

3. Position the O-ring seals and elbow (4). Install g02022259

bolts (3). Position the O-ring seals and elbow (1). Illustration 142
Install bolts (2). Install bypass valve (5) and spring
(6). Install O-ring seal (7) and plug (8). 1. Attach a suitable lifting device onto engine oil
cooler (1). The weight of engine oil cooler (1) is
End By: approximately 150 kg (330 lb).

a. Install the engine oil cooler.

g02022251
Illustration 143

2. Position engine oil cooler (1). Install bolts (13).

Repeat for the opposite side.
46 KENR6415-01
Disassembly and Assembly Section

4. Clean the joint and the sealing lip on coupling

(2). The tubes are a distance of 20 mm (1.0 inch)
from each other. Center coupling (2) over the gap.
Lubricate the bolts and tighten the bolts evenly
between the bolts. Tighten the bolts to a torque of
20 ± 1 N·m (177 ± 9 lb in). Never tighten the bolts
in coupling (2) a second time.

5. Position clamps (4) and install bolt (3). Remove

the suitable lifting device from engine oil cooler (1).

6. Fill the cooling system with coolant. Refer to

Operation and maintenance Manual, “Cooling
System Coolant - Change”.
g02022250
Illustration 144
i04233129

Engine Oil Pump - Remove

SMCS Code: 1304-011

Removal Procedure
Table 18
Required Tools
Tool Part Number Part Description Qty
A 138-7575 Link Bracket 2

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting, and repair of the product. Be prepared
to collect the fluid with suitable containers before
opening any compartment or disassembling any com-
Illustration 145
g02022246 ponent containing fluids.

3. Connect tube assembly (9). Install bolts (10). Refer to Special Publication, NENG2500, “Dealer Ser-
Connect tube assembly (11). Install bolts (12). vice Tool Catalog” for tools and supplies suitable to
Connect tube assembly (7). Install bolts (8). collect and contain fluids on Cat products.
Connect tube assembly (5). Install bolts (6).
Dispose of all fluids according to local regulations and
mandates.

g02022243
Illustration 146

g02146707
Illustration 147
KENR6415-01 47
Disassembly and Assembly Section

1. Remove bolts (2) from cover (1) for the harness 4. Attach a suitable lifting device onto regulator
assembly. Position cover (1) for the harness assembly (11). The weight of regulator assembly
assembly out of the way. (11) is approximately 34 kg (75 lb). Remove bolts
(12). Remove regulator assembly (11).

g02146716
Illustration 148
g01242497
Illustration 151
2. Remove bolts (3). Remove bolt (5). Remove
the end section of air inlet manifold (4) and the 5. Remove bolts (13).
gaskets.
Note: Remove bolts (14), elbow (15), and the
flange assembly after the engine oil pump has been
removed.

g02146717
Illustration 149

3. Remove hose assembly (6). Remove bolts (7) and

g02146719
disconnect tube assembly (8). Remove bolts (9) Illustration 152
and disconnect tube assembly (10).
6. Attach Tooling (A) and a suitable lifting device
onto engine oil pump (17). The weight of engine
oil pump (17) is approximately 67 kg (147 lb).
Remove bolts (16). Lower engine oil pump (17)
from the engine.

g02146893
Illustration 150
48 KENR6415-01
Disassembly and Assembly Section

g01558135 g01287406
Illustration 153 Illustration 155

9. Remove spring (24), retainer (23), shims (22), and

stem (21) for the maximum pressure relief valve
Personal injury can result from parts and/or cov- from regulator assembly (11). Remove spring (28),
ers under spring pressure. retainer (27), shims (26), and stem (25) for the
regulator valve from regulator assembly (11).
Spring force will be released when covers are re-
moved.

Be prepared to hold spring loaded covers as the

bolts are loosened.

7. Remove bolts (18) and washers. Remove cover

(19) from regulator assembly (11).

g01287407
Illustration 156

g01558136
Illustration 154

8. Remove O-ring seals (20).

g01287417
Illustration 157

10. Remove bolts (29). Remove housing (30).

Remove bolts (31). Remove tube (32). Remove
O-ring seal (33). Remove O-ring seals (34).
KENR6415-01 49
Disassembly and Assembly Section

i03854892

Engine Oil Pump - Disassemble

SMCS Code: 1304-015

Disassembly Procedure
Start By:

a. Remove the engine oil pump.

g01199947
Illustration 160

3. Remove bushings (4) from cover (2).

g01199893
Illustration 158

1. Remove bolts (1) and the washers. Remove cover

(2).

g01199949
Illustration 161

4. Remove gears (5) and shafts (6) from oil pump

housing (7).

g01199895
Illustration 159

2. Remove O-ring seal (3) from cover (2).

g01199952
Illustration 162

5. Remove bushings (8) from oil pump housing (7).

50 KENR6415-01
Disassembly and Assembly Section

g01199954 g01199954
Illustration 163 Illustration 165

6. Remove O-ring seals (9) and (10). 2. Install O-ring seals (9) and (10) into oil pump
housing (7).
i03854902

Engine Oil Pump - Assemble

SMCS Code: 1304-016

Assembly Procedure
Table 19
Required Tools
Tool Part Number Part Description Qty
A 1P-0510 Driver Gp 1
g01199949
Illustration 166

3. Install shafts (6) and gears (5) into oil pump

housing (7).

g01200020
Illustration 164

1. Use Tooling (A) and a suitable press in order to

install bushings (8) into oil pump housing (7).
g01200032
Illustration 167

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

install bushings (4) into cover (2).
KENR6415-01 51
Disassembly and Assembly Section

g01199895 g01287417
Illustration 168 Illustration 170

5. Install O-ring seal (3) into cover (2).

g01287407
Illustration 171

Illustration 169
g01199893 1. Install O-ring seals (34). Install O-ring seal (33).
Install tube (32). Install bolts (29). Install housing
6. Position cover (2). Install the washers and bolts (30). Install bolts (29).
(1).

End By:

a. Install the engine oil pump.

i04233170

Engine Oil Pump - Install

SMCS Code: 1304-012

Installation Procedure
Table 20 g01287406
Illustration 172
Required Tools
2. Install stem (25), shims (26), retainer (27), and
Tool Part Number Part Description Qty spring (28) for the regulator valve into regulator
A 138-7575 Link Bracket 2 assembly (11). Install stem (21), shims (22),
retainer (23), and spring (24) for the maximum
pressure relief valve into regulator assembly (11).
52 KENR6415-01
Disassembly and Assembly Section

g01558136 g01242497
Illustration 173 Illustration 176

3. Install O-ring seals (20). 5. Install the flange assembly and elbow (15). Install
bolts (14).

6. Attach Tooling (A) and a suitable lifting device

onto engine oil pump (17). The weight of engine
oil pump (17) is approximately 67 kg (147 lb).
Position engine oil pump (17) onto the engine.
Install bolts (16).

7. Install bolts (13).

g01558135
Illustration 174

Improper assembly of parts that are spring loaded

can cause bodily injury.

To prevent possible injury, follow the established

assembly procedure and wear protective equip- g02146893
Illustration 177
ment.
8. Attach a suitable lifting device onto manifold (11).
4. Install cover (19) onto regulator assembly (11). The weight of manifold (11) is approximately 34 kg
Install the washers and bolts (18). (75 lb). Position manifold (11) on the engine oil
pump. Install bolts (12).

g02146719
Illustration 175
KENR6415-01 53
Disassembly and Assembly Section

i04233649

Engine Oil Filter Housing -

Remove
SMCS Code: 1306-011

Removal Procedure
Table 21
Required Tools
Tool Part Number Part Description Qty

g02146717
A 138-7573 Link Bracket 3
Illustration 178

9. Connect tube assembly (10). Install bolts (9). Start By:

Connect tube assembly (8). Install bolts (7). Install
hose assembly (6). a. Remove the electronic control module.

b. Remove the temperature control valve.

c. Remove the fuel filter housing.

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

Refer to Special Publication, NENG2500, “Dealer Ser-

g02146716
vice Tool Catalog” for tools and supplies suitable to
Illustration 179 collect and contain fluids on Cat products.
10. Install the gaskets and the end section of air inlet Dispose of all fluids according to local regulations and
manifold (4). Install bolts (3). Install bolt (5). mandates.

1. Drain the oil from the engine oil filter housing into
a suitable container for storage or for disposal.

g02146707
Illustration 180

11. Position cover (1) for the harness assembly onto

the air inlet manifold. Install bolts (2).
54 KENR6415-01
Disassembly and Assembly Section

i04237189

Engine Oil Filter Housing -

Install
SMCS Code: 1306-012

Installation Procedure
Table 22
Required Tools
Part
Tool Part Number Qty
Description
A 138-7573 Link Bracket 3

g02408998
Illustration 181

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

onto engine oil filter housing (1). The weight
of engine oil filter housing (1) is approximately
164 kg (362 lb). Remove bolts (2), elbows (3), and
tube assemblies (5) and (6). Remove bolts (4).

g02408999
Illustration 183

1. Attach Tooling (A) and a suitable lifting device onto

engine oil filter housing (1). The weight of engine
oil filter housing (1) is approximately 164 kg
(362 lb). Position support assembly (11) and install
bolts (7). Position engine oil filter housing (1) onto
support assembly (8). Install bolts (11). Connect
tube assemblies (9) and (10).

g02408999
Illustration 182

3. Disconnect tube assembly (9) and (10). Remove

bolts (11) and engine oil filter housing (1). Remove
bolts (7) and remove support assembly (8).
KENR6415-01 55
Disassembly and Assembly Section

g01200542
Illustration 185

1. Remove bolts (1). Remove cover (2).

g02408998
Illustration 184

2. Install bolts (4) in engine oil filter housing (1).

Position tube assembly (6) and elbow (3) and
install bolts (2). Position tube assembly (5) and
elbow (3) and install bolts (2).

3. Check the engine oil level. Refer to Operation and

Maintenance Manual, “Engine Oil Level - Check”.

End By:
g02411257
Illustration 186
a. Install the fuel filter housing.
2. Remove engine oil and water pump drive (3).
b. Install the temperature control valve.

c. Install the electronic control module.

i04237370

Engine Oil and Water Pump

Drive - Remove
SMCS Code: 1313-011

Removal Procedure
Table 23
g02411258
Required Tools Illustration 187

Tool Part Number Part Description Qty 3. Remove O-ring seals (4 ) and (5).
A 1P-0520 Driver Gp 1

Start By:

a. Remove the engine oil pump.

56 KENR6415-01
Disassembly and Assembly Section

g02411259 g01200684
Illustration 188 Illustration 190

4. Use Tooling (A) and a suitable press in order to 2. Remove spacer (2), gear (3), and pump drive
remove bearing (6) from cover (2). shaft (4).

i03814530 i03814536

Engine Oil and Water Pump Engine Oil and Water Pump
Drive - Disassemble Drive - Assemble
SMCS Code: 1313-015 SMCS Code: 1313-016

Disassembly Procedure Assembly Procedure

Start By:

a. Remove the engine oil and water pump drive.

g01200684
Illustration 191

1. Position pump drive shaft (4), gear (3), and spacer

(2).
g01200678
Illustration 189

1. Remove bolts (1).

KENR6415-01 57
Disassembly and Assembly Section

g01200678 g02411258
Illustration 192 Illustration 194

2. Install bolts (1). Note: Check the O-ring seals for wear or for damage.
If necessary, replace the O-ring seals.
End By:
2. Install O-ring seals (5) and (4).
a. Install the engine oil and water pump drive.

i04237909

Engine Oil and Water Pump

Drive - Install
SMCS Code: 1313-012

Installation Procedure

g02411257
Illustration 195

3. Install engine oil and water pump drive (3).

g02411259
Illustration 193

1. Use Tooling (A) and a suitable press in order to

install bearing (6) into cover (2).

g01200542
Illustration 196

4. Position cover (2). Install bolts (1).

End By:

a. Install the engine oil pump.

58 KENR6415-01
Disassembly and Assembly Section

i03747922

Engine Oil Screen - Remove

and Install
SMCS Code: 1308-010-Z3

Removal Procedure
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open- g01201320
ing any compartment or disassembling any compo- Illustration 198
nent containing fluids.
3. Remove O-ring seal (3) from cover (2).
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

mandates.

1. Drain the engine oil into a suitable container for

storage or for disposal. Refer to Operation and
Maintenance Manual, “Engine Oil and Filter -
Change”.

g02023130
Illustration 199

4. Remove oil screen (4).

Installation Procedure
1. Install oil screen (4) in the reverse order of
removal.

Note: Check the O-ring seal for wear or for damage.

If necessary, replace the O-ring seal.

Illustration 197
g02023127 2. Fill the engine with oil.

2. Remove bolts (1). Remove cover (2).

KENR6415-01 59
Disassembly and Assembly Section

i04242651

Engine Oil Pan - Remove

SMCS Code: 1302-011

Removal Procedure
Table 24
Required Tools

Tool Part Number Part Description Qty

1U-7498 Support Stand As 4
A
1U-7501 Extension Tube 4
B 138-7573 Link Bracket 3
C 323-1146 Engine Lifting 1
Device

g02416356
Start By: Illustration 200

a. Remove the engine oil pump. 4. Remove bolts (3). Remove the flange and adapter
(4). Disconnect harness assemblies (1), (2), and
1. Turn the battery disconnect switch to the OFF (5).
position.

2. Turn the fuel supply valve to the OFF position.

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

Refer to Special Publication, NENG2500, “Dealer Ser-

vice Tool Catalog” for tools and supplies suitable to
collect and contain fluids on Cat products. Illustration 201
g02028643

Dispose of all fluids according to local regulations and 5. Disconnect hose assemblies (6) and (7).
mandates.

3. Drain the oil from the engine into a suitable

container for storage or for disposal. Refer to
Operation and Maintenance Manual, “Engine Oil
and Filter - Change”.

g02028650
Illustration 202

6. Disconnect harness assemblies (10), (11), and

(8). Remove hose assembly (9).
60 KENR6415-01
Disassembly and Assembly Section

Note: Ensure that all water, fuel, exhaust, and

electrical connections have been removed.

g02028701
Illustration 203

Note: Removal of portions of the heat shield required

before attaching Tooling (C).
g02415416
Illustration 205
7. Attach Tooling (C) onto the engine. The weight of
the engine is approximately 11818 kg (26054 lb).
9. Position the engine on Tooling (A).
Remove bolts (12) on all sides of engine oil pan
(13).

g02029066
Illustration 206
g02029024
Illustration 204
10. Attach Tooling (B) and a suitable lifting device
onto engine oil pan (13). The weight of engine
8. Raise the engine from engine oil pan (13) and
oil pan (13) is approximately 958 kg (2108 lb).
remove gasket (14).
Apply slight lifting tension on engine oil pan (13).
Reach through the holes in platform (15) in order
to remove bolts (16). Remove engine oil pan (13)
from platform (15).

i03765116

Engine Oil Pan - Disassemble

SMCS Code: 1302-015

Disassembly Procedure
Start By:

a. Remove the engine oil screen.

b. Remove the engine oil pan.

KENR6415-01 61
Disassembly and Assembly Section

i03765251

Engine Oil Pan - Assemble

SMCS Code: 1302-016

Assembly Procedure

g02029239
Illustration 207

1. Remove bolts (3) and the washers. Remove elbow

(2) and the O-ring seal. Remove tube assembly
(4) and the O-ring seals from engine oil pan (1).

g02029240
Illustration 209

1. Position engine oil screen housing (7). Install the

new O-ring seals. Install the washers and bolts
(8), (5), and (6).

g02029240
Illustration 208

2. Remove bolts (5), (6), and (8), and the washers.

Remove the O-ring seals. Remove engine oil
screen housing (7).

g02029239
Illustration 210

2. Install the new O-ring seals. Position tube

assembly (4) in the engine oil pan (1). Install the
new O-ring seal in elbow (2). Install the washers
and bolts (3).
62 KENR6415-01
Disassembly and Assembly Section

End By:

a. Install the engine oil pan.

b. Install the engine oil screen.

i04246753

Engine Oil Pan - Install

SMCS Code: 1302-012

Installation Procedure
Table 25
Required Tools

Tool Part Number Part Description Qty

1U-7498 Support Stand As 4
A Illustration 212
g02415416
1U-7501 Extension Tube 4
B 138-7573 Link Bracket 3 2. Attach Tooling (C) onto the engine. The weight of
C 323-1146 Engine Lifting 1
the engine is approximately 11818 kg (26054 lb).
Device Remove the engine from Tooling (A).

g02029024
g02029066 Illustration 213
Illustration 211
Note: Install portions of the heat shield after Tooling
1. Attach Tooling (B) and a suitable lifting device (C) has been removed.
onto engine oil pan (13). The weight of engine
oil pan (13) is approximately 958 kg (2108 lb). 3. Position gasket (14). Lower the engine onto
Position engine oil pan (13) onto platform (15). engine oil pan (13). Remove Tooling (C).
Reach through the holes in platform (15) in order
to install bolts (16).
KENR6415-01 63
Disassembly and Assembly Section

g02028701
Illustration 214

4. Install bolts (12) on all sides of engine oil pan (13).

g02416356
Illustration 217

7. Connect harness assemblies (5), (2), and (1).

Install the flange and adapter (4). Install bolts (3).

Note: Ensure that all water, fuel, exhaust, and

electrical connections have been installed.

8. Fill the engine with oil. Refer to Operation and

Maintenance Manual, “Engine Oil and Filter -
Change”.
g02028650
Illustration 215
9. Turn the fuel supply valve to the ON position.
5. Connect harness assemblies (8), (10), and (11).
Connect hose assembly (9). 10. Turn the battery disconnect switch to the ON
position.

End By:

a. Install the engine oil pump.

g02028643
Illustration 216

6. Connect hose assemblies (6) and (7).

64 KENR6415-01
Disassembly and Assembly Section

i03765455 i03766229

Crankcase Breather - Remove Valve Cover - Remove and

and Install Install
SMCS Code: 1317-010 SMCS Code: 1107-010

Removal Procedure Removal Procedure

g02086550
Illustration 219

1. Remove the heat shield.

2. Remove five bolts (1) and the washers. Remove

valve cover (2).
g02110813
Illustration 218

1. Cut the cable straps and loosen hose clamp (3).

Disconnect hose (4). Remove bolts (2) and the
clamps. Remove crankcase breather (1) and the
O-ring seal. Repeat for the opposite side.

Installation Procedure
1. Install crankcase breathers (1) in the reverse
order of removal.

g02086547
Illustration 220

3. Remove seal (3) from valve cover (2).

4. Repeat Steps 1 and 3 for the remaining valve

covers.

Installation Procedure
1. Install valve cover (2) in the reverse order of
removal.

2. Tighten bolts (1) to a torque of 28 ± 7 N·m

(21 ± 5 lb ft).
KENR6415-01 65
Disassembly and Assembly Section

i03816686 i03816849

Rocker Shaft and Push Rods - Rocker Shaft - Disassemble

Remove SMCS Code: 1102-015
SMCS Code: 1102-011
Disassembly Procedure
Removal Procedure Table 26

Start By: Required Tools

Tool Part Number Part Description Qty
a. Remove the valve cover.
A 1P-0510 Driver Gp 1

Start By:

a. Remove the rocker shaft.

g02091239
Illustration 221

1. Remove bolts (1). Remove rocker shaft assembly

(2).
g01846479
Illustration 223

1. Note the orientation of rocker arm assembly (1)

for assembly purposes.

Note:

g02091240
Illustration 222

2. Remove pushrods (3). Remove bridges (4).

g01846480
Illustration 224
66 KENR6415-01
Disassembly and Assembly Section

2. Remove rocker arms (2), and (8), and shaft (5)

from support assembly (7).

3. Remove rocker arms (2) and (8) from shaft (5).

4. Use Tooling (A) and remove bushing (6) from

rocker arm (2) and (8).

5. Remove nut (3) and adjusting screw (4).

i03816853

Rocker Shaft - Assemble

SMCS Code: 1102-016 Illustration 226
g01846479

Assembly Procedure 4. Ensure that rocker arm assembly (1) is correctly

oriented in order to prevent damage.
Table 27
Required Tools End By:

Tool Part Number Part Description Qty a. Install the rocker shaft.
A 1P-0510 Driver Gp 1
i04247549

Rocker Shaft and Push Rods

- Install
SMCS Code: 1102-012

Installation Procedure

g01846480
Illustration 225

g02091240
1. Install adjusting screw (4) and nut (3). Illustration 227

2. Use Tooling (A) and install bushing (6) into rocker

arm (2) and (8). Make sure that the oil holes in
bushing (6) are aligned with the oil holes in rocker
arm (2) and (8). The oil holes must be aligned in
the exact position.

3. Install rocker arms (2) and (8) on shaft (5).

Position rocker arms (2), and (8), and shaft (5)
onto support assembly (7).
KENR6415-01 67
Disassembly and Assembly Section

i03907012

Valve Lifter - Remove

SMCS Code: 1209-011

Removal Procedure
Table 28
Required Tools
Tool Part Number Part Description Qty
A 3E-3879 Eyebolt 1

g01949432
Illustration 228 Start By:

1. Lubricate bridges (4) and the pockets with clean a. Remove the rocker shaft and pushrods.
engine oil. Install bridges (4) on the cylinder head.
Position the round pocket toward the outside of b. Remove the exhaust manifolds.
the engine. Lubricate pushrods (3) with clean
engine oil. Install pushrods (3). Seat pushrods (3) NOTICE
in the lifter cups. Keep all parts clean from contaminants.
Note: Ensure that the pushrods are seated in the Contaminants may cause rapid wear and shortened
bores. Use a flashlight in order to ensure that the component life.
pushrods are in the lifter cups.

g02091239
Illustration 229

2. Position rocker shaft assembly (2) in the dowel

holes. Install bolts (1). Tighten bolts (1) to a torque
of 200 ± 30 N·m (147 ± 22 lb ft).

3. Adjust the valve lash. Refer to Testing and Illustration 230

g02036313
Adjusting, “Engine Valve Lash - Inspect/Adjust”.

End By:

a. Install the valve cover.

68 KENR6415-01
Disassembly and Assembly Section

g02036314 g01204408
Illustration 231 Illustration 233

1. Remove bolts (2) and the washers. Remove 1. Remove bolts (1). Remove shaft assembly (2)
manifold shield (1). from housing (3).

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

onto valve lifter (3). Remove bolts (4). Remove
valve lifter (3).

g01204412
Illustration 234

2. Remove levers (4) from shaft (5). Remove thrust

washer (6) from shaft (5).
g02036315
Illustration 232

i03907013
3. Remove integral seal (5).

4. Repeat Steps 1 and 3 for the manifold shields and

Valve Lifter - Assemble
the remaining valve lifters. SMCS Code: 1209-016

i03809270 Installation Procedure

Valve Lifter - Disassemble NOTICE
SMCS Code: 1209-015 Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

Disassembly Procedure component life.
Start By:

a. Remove the valve lifter.

KENR6415-01 69
Disassembly and Assembly Section

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

g01204412
Illustration 235

1. Install thrust washer (6) onto shaft (5). Install

levers (4) onto shaft (5).

Note: The lever rollers need to face inward when

assembling on the shaft.
g02036315
Illustration 237

1. Install integral seal (5).

g01204408
Illustration 236

2. Install shaft assembly (2) into housing (3).

g02036314
Install bolts (1). Tighten bolts (1) to a torque of Illustration 238
105 ± 20 N·m (77 ± 15 lb ft).

End By:

a. Install the valve lifter.

i03809111

Valve Lifter - Install

SMCS Code: 1209-012

Installation Procedure
Table 29
Required Tools
Tool Part Number Part Description Qty
A 3E-3879 Eyebolt 1

g02036313
Illustration 239
70 KENR6415-01
Disassembly and Assembly Section

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

onto valve lifter (3). Position valve lifter (3) onto
the engine. Install bolts (4). Tighten bolts (4) to a
Do not open the high pressure fuel system without
torque of 55 ± 10 N·m (41 ± 7 lb ft).
allowing the fuel system to purge. After the engine
has shut down, allow the fuel system to purge for
3. Position manifold shield (1) and install the washers
ten minutes. This operating fuel system contains
and bolts (2).
high pressure. Exposure to high pressure fuel can
result in personal injury.
4. Repeat Steps 1 and 3 for the manifold shield and
the remaining valve lifters.
Note: Use Tooling (B) to cap tube assemblies,
End By: fittings, ports, and any openings in the fuel system in
order to prevent contamination.
a. Install the exhaust manifolds.
Note: Do not remove all the quills in order to maintain
b. Install the rocker shaft and pushrods. the alignment of the rail. Remove one at a time and
replace before the removal of the next. If necessary,
replace with new quill.
i04031483

Electronic Unit Injector -

Remove
SMCS Code: 1290-011

Removal Procedure
Table 30
Required Tools
Tool Part Part Description Qty
Number
A 5F-4764 Prybar 1 g02087086
Illustration 240
339-9352 Inj. Sys Cap Kit 1
B 1. Remove bolt (3) and the washer. Remove tube
265-2256 Wipers 1
assembly (1). Disconnect harness assembly (2).

Start By:

a. Remove the valve cover.

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

Refer to Special Publication, NENG2500, “Dealer Ser-

vice Tool Catalog” for tools and supplies suitable to
collect and contain fluids on Cat products.

Dispose of all fluids according to local regulations and

mandates.

NOTICE g02087690
Illustration 241
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened 2. Apply clean engine oil to Area (X). Repeat for the
component life. opposite collar. Remove bolts (4) and bolts (6).
Remove tube assembly (5).
KENR6415-01 71
Disassembly and Assembly Section

Note: Replace with new bolts (4) and (6). i04401492

Electronic Unit Injector - Install

SMCS Code: 1290-012

Installation Procedure
Table 31
Required Tools
Tool Part Number Part Description Qty
339-9352 Inj. Sys Cap Kit 1
B
265-2256 Wipers 1

g02087670 C 312-3204 Brush 1

Illustration 242

3. Disconnect harness assembly (7) from electric Note: When Tooling (B) is removed be careful to
unit injector (8). Remove bolt (9) and the washer. prevent contamination.

4. Place an identification mark on electronic unit NOTICE

injector (8) for installation purposes. Each Keep all parts clean from contaminants.
electronic unit injector must be reinstalled in the
original location. Use Tooling (A) to pry electronic Contaminants may cause rapid wear and shortened
unit injector (8) out by the retaining collar. component life.

g01410032
Illustration 243
g01410032
Illustration 244
5. Check O-ring seals (10) and (11) on electronic
unit injector (8). 1. If necessary, install new O-ring seals (10) and
(11) onto electronic unit injector (8). Apply clean
engine oil to O-ring seals (10) and (11).
72 KENR6415-01
Disassembly and Assembly Section

g02087670 g01285695
Illustration 245 Illustration 247

2. Check the cleanliness of the sealing surface for 5. Apply clean engine oil to Area (X). Repeat for the
the unit injector in the cylinder head. If necessary, opposite collar. Apply clean engine oil to the ends
use Tooling (C) to clean the sealing cone on the of tube assembly (5). Install tube assembly (5).
unit injector. Install new bolts (4) and new bolts (6) hand tight.
Evenly tighten new bolts (4) to a torque of 20 N·m
3. Install electronic unit injector (8). Tighten bolt (9) (15 lb ft). Evenly tighten new bolts (6) to a torque
to a torque of 30 - 50 N·m (22 - 38 lb ft). of 20 N·m (15 lb ft).

4. Remove bolt (9). Hand tighten bolt (9) and the Note: Do not rotate new bolts (4) and (6) more than
washer. Tighten bolt (9) to a torque of 10 N·m 90 degrees at a time.
(7.5 lb ft). Connect harness assembly (7) onto
electronic unit injector (8). 6. Tighten the injector bolt to a torque of 100 ± 2 N·m
(74± 1 lb ft). Evenly tighten new bolts (4) to a
torque of 40 N·m (30 lb ft). Evenly tighten new
bolts (6) to a torque of 40 N·m (30 lb ft).

Note: Do not rotate new bolts (4) and (6) more than
45 degrees at a time.

g02087086
g02087690 Illustration 248
Illustration 246

7. Connect harness assembly (2). Replace the

O-ring seals on both ends of tube assembly (1).
Install tube assembly (1). Install the washer and
bolt (3).

End By:

a. Install the valve cover.

KENR6415-01 73
Disassembly and Assembly Section

i04462817 2. Install Tooling (A) into the electronic unit injector

sleeve.
Electronic Unit Injector Sleeve
- Remove 3. Remove the electronic unit injector sleeve.

SMCS Code: 1713-011 i04463824

Removal Procedure Electronic Unit Injector Sleeve

Table 32
- Install
Required Tools SMCS Code: 1713-012
Tool Part Number Part Description Qty
Inj. Sleeve Shaft
Installation Procedure
A 333-0759 1
As. - 1/2 Drive Table 33
Required Tools
Start By:
Tool Part Number Part Description Qty
a. Remove the electronic unit injector. A 333-0759 Injector Sleeve Shaft 1

b. Remove the rocker shaft and pushrods. Antiseize Thread

B 5P-3931 1
Compound

NOTICE
Care must be taken to ensure that fluids are contained 1. Thoroughly clean the bore in the cylinder for the
during performance of inspection, maintenance, test- electronic unit injector sleeve.
ing, adjusting, and repair of the product. Be prepared
to collect the fluid with suitable containers before
opening any compartment or disassembling any com-
ponent containing fluids.

Refer to Special Publication, NENG2500, “Dealer Ser-

vice Tool Catalog” for tools and supplies suitable to
collect and contain fluids on Cat products.

Dispose of all fluids according to local regulations and

mandates.

1. Drain the coolant from the cooling system into

a suitable container for storage or for disposal.
Operation and Maintenance Manual, “Cooling Illustration 250
g02643976
System Coolant - Change”.

g01850908
Illustration 251
g01850908
Illustration 249
2. Install new O-ring seals (1) on electronic unit
Note: The electronic unit injector sleeve is a threaded injector sleeve (2). Apply clean engine oil on
joint. O-ring seals (1). Apply a light coat of Tooling (B)
to Area (X) and install.
74 KENR6415-01
Disassembly and Assembly Section

3. Install Tooling (A) into electronic unit injector

sleeve (2). Hand tighten electronic unit injector NOTICE
sleeve (2) until electronic unit injector sleeve (2) Keep all parts clean from contaminants.
is seated in the cylinder head. Tighten electronic
unit injector sleeve (2) to a torque of 120 ± 10 N·m Contaminants may cause rapid wear and shortened
(89 ± 7 lb ft). component life.

4. Remove Tooling (A) from electronic unit injector

sleeve (2). Note: Use Tooling (B) to prevent contamination.
Cleanliness is an important factor. Before you
5. Fill the cooling system with coolant. Refer to begin the disassembly procedure, thoroughly clean
Operation and Maintenance Manual, “Cooling the exterior of the components. To prevents dirt
System Coolant - Change”. from entering the internal mechanism. Precision
components can be damaged by contaminants
End By: or by dirt. Perform disassembly procedures on a
clean work surface. Keep components covered and
a. Install the rocker shaft and pushrods. protected at all times.

b. Install the electronic unit injector. 1. Drain the coolant from the cooling system into
a suitable container for storage or for disposal.
Refer to Operation and Maintenance Manual,
i04247709 “Cooling System Coolant - Change”.
Cylinder Head - Remove
SMCS Code: 1100-011

Removal Procedure
Table 34
Required Tools
Tool Part Number Part Description Qty
A 138-7573 Link Bracket 2
339-9352 Inj. Sys Cap Kit 1
B
265-2256 Wipers 1 g02419599
Illustration 252

Start By: 2. Remove bolts (2). Remove heat shield (1).

Remove the bolts and disconnect the exhaust
a. Remove the rocker shaft and pushrods. manifold. Remove bolts (5). Disconnect inlet
manifold (6).
b. Remove the electronic unit injector.
Note: Exercise care in removing the cylinder head
NOTICE and the gasket in order to avoid contamination of oil
Care must be taken to ensure that fluids are contained supply holes in the cylinder block.
during performance of inspection, maintenance, test-
ing, adjusting, and repair of the product. Be prepared 3. Attach Tooling (A) and a suitable lifting device
to collect the fluid with suitable containers before onto cylinder head (3). Cylinder head (3) weighs
opening any compartment or disassembling any com- approximately 68 kg (150 lb). Remove bolts (4).
ponent containing fluids. Remove cylinder head (3) from the engine.

Refer to Special Publication, NENG2500, “Dealer Ser- Note: The positioning dowels need to remain in the
vice Tool Catalog” for tools and supplies suitable to cylinder block. Remove the dowels if the dowels
collect and contain fluids on Cat products. remain in the cylinder head. Install the new dowels in
the cylinder block before installing the cylinder head.
Dispose of all fluids according to local regulations and
mandates.
KENR6415-01 75
Disassembly and Assembly Section

g02419617 g02419617
Illustration 253 Illustration 254

4. Remove Integral seal (7) from the cylinder block. 1. Inspect fire ring (8) for damage and install new,
Remove fire ring (8). if necessary. Install fire ring (8). Install a new
Integral seal (7) onto the cylinder block.
i04248117

Cylinder Head - Install

SMCS Code: 1100-012

Installation Procedure
Table 35
Required Tools
Part
Tool Part Description Qty
Number
A 138-7573 Link Bracket 2
g02419897
Illustration 255
339-9352 Inj. Sys Cap Kit 1
B
265-2256 Wipers 1 2. Attach Tooling (A) and a suitable lifting device
onto cylinder head (3). Cylinder head (3) weighs
Multipurpose
C 1P-0808
Grease
1 approximately 68 kg (150 lb). Position cylinder
head (3) onto the cylinder block. Lubricate the
D 312-2840 Socket 1 threads of bolts (4) with oil. Install bolts (4).

Note: When Tooling (B) is removed be careful to

prevent contamination. Cleanliness is an important
factor. Before assembly, thoroughly clean all parts
in cleaning fluid. Allow the parts to air dry. Do not
use wiping cloths or rags to dry parts. Lint may be
deposited on the parts which may cause trouble.
Inspect all parts. If any parts are worn or damaged,
use new parts for replacement. Dirt and other
contaminants can damage the precision component.
Perform assembly procedures on a clean work
surface. Keep components covered and protected
at all times.
76 KENR6415-01
Disassembly and Assembly Section

i03766652

Inlet and Exhaust Valve

Springs - Remove and Install
SMCS Code: 1108-010

Removal Procedure
Table 36
Required Tools
Tool Part Number Part Description Qty
Valve Spring
A 333-0758 1
Compressor

Start By:

a. Remove the cylinder head.

g02090575
Illustration 256
NOTICE
Keep all parts clean from contaminants.
3. Hand tighten bolts (4) in the numerical sequence
to a maximum torque of 15 N·m (11 lb ft). Use
Contaminants may cause rapid wear and shortened
Tooling (D) to tighten bolts (4) in the numerical
component life.
sequence to a torque of 100 ± 10 N·m (75 ± 7 lb ft).
Tighten bolts (4) again in the numerical sequence
to a torque of 250 ± 15 N·m (185 ± 11 lb ft).
Tighten bolts (4) in the numerical sequence for an
additional 180 ± 5 degrees.

g01206603
Illustration 258

g02419899
Illustration 257

4. Position inlet manifold (6). Install bolts (5). Position

the exhaust manifold and install the bolts. Position
heat shield (1) and install bolts (2).

5. Fill the cooling system with coolant. Refer to

Operation and Maintenance Manual, “Cooling
System Coolant - Change”.

End By:
g01207146
a. Install the rocker shaft and pushrods. Illustration 259

b. Install the electronic unit injector.

KENR6415-01 77
Disassembly and Assembly Section

Installation Procedure
Personal injury can result from being struck by
parts propelled by a released spring force.
Improper assembly of parts that are spring loaded
Make sure to wear all necessary protective equip- can cause bodily injury.
ment.
To prevent possible injury, follow the established
Follow the recommended procedure and use all assembly procedure and wear protective equip-
recommended tooling to release the spring force. ment.

1. Install Tooling (A) into the hole for the electronic 1. Install valve springs (2) in the reverse order of
unit injector. Refer to Illustration 259. removal.

i03766673

Inlet and Exhaust Valves -

Remove and Install
SMCS Code: 1105-010

Removal Procedure
Table 37
Required Tools
Tool Part Number Part Description Qty
g01851274
Illustration 260
Valve Spring
A 333-0758 1
Compressor
2. Install the plate of Tooling (A) onto the valve
springs. Refer to Illustration 260. Install the nut
onto the stud. Tighten the nut in order to compress Start By:
valve springs (2). Remove retainer locks (1).
a. Remove the electronic unit injector. Refer to
Disassembly and Assembly, “Electronic Unit
Injector - Remove”.

b. Remove the cylinder head. Refer to Disassembly

and Assembly, “Cylinder Head - Remove”.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

g01298522
Illustration 261

3. Remove Tooling (A). Remove rotocoil (3), outer

spring (4), and inner spring (5).

4. Repeat Steps 1 through 3 for the remaining valve

springs.
78 KENR6415-01
Disassembly and Assembly Section

2. Install the plate of Tooling (A) onto the valve

springs. Refer to Illustration 264. Install the nut
onto the stud. Tighten the nut in order to compress
valve springs (2). Remove retainer locks (1).

g01206603
Illustration 262

g01206605
Illustration 265

3. Remove Tooling (A). Remove rotocoil (3), outer

spring (4), inner spring (5), valve seal (6), retainer
(7), and valve (8).
g01207146
Illustration 263

1. Install Tooling (A) into the hole for the electronic

Installation Procedure
unit injector. Refer to Illustration 263.

Improper assembly of parts that are spring loaded

can cause bodily injury.

To prevent possible injury, follow the established

assembly procedure and wear protective equip-
ment.

1. Install inlet and exhaust valves (8) in the reverse

order of removal.

End By:

g01851274 a. Install the cylinder head. Refer to Disassembly

Illustration 264
and Assembly, “Cylinder Head - Install”.

b. Install the electronic unit injector. Refer to

Disassembly and Assembly, “Electronic Unit
Personal injury can result from being struck by Injector - Install”.
parts propelled by a released spring force.

Make sure to wear all necessary protective equip-

ment.

Follow the recommended procedure and use all

recommended tooling to release the spring force.
KENR6415-01 79
Disassembly and Assembly Section

i03767157 i03767189

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

Removal Procedure Removal Procedure

Table 38 Table 39
Required Tools Required Tools
Tool Part Number Part Description Qty Tool Part Number Part Description Qty
A 283-0052 Valve guide driver 1 Valve Spring
A 333-0758 1
Compressor
B 284-1503 Collar 1

Start By:
Start By:
a. Remove the cylinder head.
a. Remove the inlet and exhaust valves.

NOTICE NOTICE
Keep all parts clean from contaminants. Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened Contaminants may cause rapid wear and shortened
component life. component life.

g01206603
g01206606 Illustration 267
Illustration 266

1. Turn over the cylinder head. Use Tooling (A) and a

suitable hammer in order to remove valve guides
(1) from the cylinder head.

Installation Procedure
1. Install valve guides (1) in the reverse order of
removal. Valve guide must extend 42.0 ± 0.50 mm
(1.65 ± 0.020 inch) above the surface of the
cylinder head.

g01207146
Illustration 268

1. Install Tooling (A) into the hole for the electronic

unit injector. Refer to Illustration 268.
80 KENR6415-01
Disassembly and Assembly Section

Installation Procedure

Improper assembly of parts that are spring loaded

can cause bodily injury.

To prevent possible injury, follow the established

assembly procedure and wear protective equip-
ment.

1. Install a new valve seal (6) in the reverse order

of removal.
g01851274
Illustration 269
i04280976

Front Drive Housing - Remove

Personal injury can result from being struck by and Install
parts propelled by a released spring force.
SMCS Code: 1151-010
Make sure to wear all necessary protective equip-
ment. Removal Procedure
Follow the recommended procedure and use all Table 40
recommended tooling to release the spring force.
Required Tools
Tool Part Number Part Description Qty
2. Install the plate of Tooling (A) onto the valve
springs. Refer to Illustration 269. Install the nut A 138-7574 Link Bracket 2
onto the stud. Tighten the nut in order to compress
valve springs (2). Remove retainer locks (1). B 1U-8846 Gasket Sealant 1

Start By:

a. Remove the fuel filter housing.

b. Remove the breather group.

c. Remove the engine oil filter housing.

d. Remove the idler gears.

e. Remove the crankshaft front seal.

g01298551
Illustration 270

3. Remove Tooling (A). Remove rotocoil (3), outer

spring (4), and inner spring (5). Remove valve
seal (6).

4. Repeat Steps 1 through 3 for the remaining valve

seals.
KENR6415-01 81
Disassembly and Assembly Section

g02448559
Illustration 273

3. Remove O-ring seals (14) and (15).

Installation Procedure
Illustration 271
g02448217 1. Install front drive housing (1) in the reverse order
of removal.
1. Remove clamp assembly (4) and disconnect tube
assembly (9). Disconnect clamp assemblies (6), Note: Check the O-ring seals for wear or for damage.
(7), and remove elbow (5). Remove bolts (2) and If necessary, replace the O-ring seals.
elbow (3). Remove covers (8) from front drive
housing (1).
i04248869

Vibration Damper - Remove

and Install
SMCS Code: 1205-010

Removal Procedure
Table 41
Required Tools
Tool Part Number Part Description Qty
Guide Bolt
A 323-4712 2
M24 by 500 mm

1. Remove the damper guard.

g02448220
Illustration 272

2. Remove bolts (12) and elbow (13). Remove bolts

(10). Attach Tooling (A) and a suitable lifting
device onto front drive housing (1). The weight
of front drive housing (1) is approximately 363 kg
(800 lb). Remove bolts (11). Remove front drive
housing (1).
82 KENR6415-01
Disassembly and Assembly Section

Installation Procedure
1. Install vibration damper (1) in the reverse order
of removal. Tighten bolts (1) to a torque of
700 ± 50 N·m (516 ± 37 lb ft).

i02416922

Crankshaft Front Seal -

Remove
SMCS Code: 1160-011

Removal Procedure
Table 42
Required Tools
Tool Part Number Part Description Qty

g02420542 A 1U-5593 Drill Bit 1

Illustration 274
Slide Hammer
B 1U-7600 1
2. Remove two bolts (2) from vibration damper (1). Puller Gp

Start By:

a. Remove the vibration damper. Refer to

Disassembly and Assembly, “Vibration Damper
- Remove and Install ”.

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

in the crankshaft front seal.

g02420543
Illustration 275

3. Install Tooling (A). Remove remaining bolts (2). g01208062

Illustration 276

4. Slide spacer (3) and vibration damper (1) on

2. Use Tooling (B) in order to remove the outer half
Tooling (A).
of crankshaft front seal (1).
5. Attach a suitable lifting device onto vibration
3. Use Tooling (A) to drill three evenly spaced holes
damper (1). The weight of vibration damper (1) is
in the crankshaft front seal.
approximately 148 kg (326 lb). Slide spacer (3)
and vibration damper (1) to the end of Tooling (A).
Remove spacer (3) and vibration damper (1).
KENR6415-01 83
Disassembly and Assembly Section

End By:

a. Install the vibration damper.

i04249430

Flywheel - Remove and Install

SMCS Code: 1156-010

Removal Procedure
Table 44

g01208063 Required Tools

Illustration 277
Tool Part Number Part Description Qty
4. Use Tooling (B) in order to remove the inner half Guide Bolt
of crankshaft front seal (1). A - M24 by 2 by 200 2
mm
i04131291 B 138-7575 Link Bracket 3

Crankshaft Front Seal - Install C 189-0408 Shackle As 1

D 1U-9200 Lever Puller Hoist 1
SMCS Code: 1160-012

Installation Procedure
Table 43
Required Tools
Tool Part Number Part Description Qty
250-4587 Installer 1
250-4586 Locator 1
C
322-2078 Bolt 2
9S-8858 Nut 1

g02032640
Illustration 279

1. Remove two bolts (3) from coupler (2). Install

Tooling (A).

2. Install Tooling (B). The weight of coupler (2) is

approximately 96 kg (212 lb). Remove remaining
Illustration 278
g01208138 bolts (3). Remove bolts (1). Slide coupler (2) on
Tooling (A). Remove coupler (2).
1. Use Tooling (C) to install crankshaft front seal (1).

Note: Position the locator and install the bolts to

hold in position. Install the seal over the locator and
position installer. Install nut and turn until the nut
stops. Inspect and remove tooling.
84 KENR6415-01
Disassembly and Assembly Section

4. Install Tooling (B), Tooling (C), and Tooling (D) in

order to support the weight of flywheel (5). The
weight of flywheel (5) is approximately 177 kg
(390 lb). Remove remaining bolts (4). Remove
spacer (6). Slide flywheel (5) on Tooling (A).
Remove flywheel (5).

Installation Procedure
1. Install flywheel (5) in the reverse order of removal.

1. Inspect the condition of the ring gear. Use the

following procedure in order to replace the ring
gear, if necessary.
g02032713
Illustration 280
a. Remove the damaged ring gear from the
flywheel.

b. Raise the temperature of the new ring gear.

c. Install the ring gear on the flywheel. Ensure

that the chamfer of the gear teeth will be toward
the pinion of the starting motor.

2. Tighten new bolts (4) to a torque of 550 ± 50 N·m

(406 ± 37 lb ft). Tighten bolts (4) for an additional
85 to 95 degrees.

3. Tighten new bolts (3) to a torque of 350 ± 40 N·m

(258 ± 30 lb ft).
g02032733
Illustration 281

i03816550
3. Remove two bolts (4) from flywheel (5). Install
Tooling (A). Crankshaft Rear Seal - Remove
SMCS Code: 1161-011

Removal Procedure
Table 45
Required Tools
Tool Part Number Part Description Qty
A 1U-5593 Drill Bit 1
Slide Hammer
B 1U-7600 1
Puller Gp

Start By:

a. Remove the flywheel.

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

in the crankshaft rear seal.
g02032754
Illustration 282
KENR6415-01 85
Disassembly and Assembly Section

g01200319 g01200381
Illustration 283 Illustration 285

2. Use Tooling (B) in order to remove the outer half 1. Use Tooling (C) to install crankshaft rear seal (1).
of rear crankshaft seal (1).
Note: Position the locator and install the bolts to
3. Use Tooling (A) to drill three evenly spaced holes hold in position. Install the seal over the locator and
in the crankshaft rear seal. position the installer. Install the nut and turn until the
nut stops. Inspect and remove tooling.

End By:

a. Install the flywheel.

i04266693

Flywheel Housing - Remove

SMCS Code: 1157-011

Removal Procedure
g01200322 Table 47
Illustration 284
Required Tools
4. Use Tooling (B) in order to remove the inner half
of rear crankshaft seal (1). Part
Tool Part Number Qty
Description
A 138-7575 Link Bracket 2
i04131434

Crankshaft Rear Seal - Install Start By:

SMCS Code: 1161-012 a. Remove the flywheel.

Installation Procedure b. Remove the crankshaft rear seal.

Table 46 c. Remove the exhaust elbow.

Required Tools
d. Remove the turbochargers.
Tool Part Number Part Description Qty
250-4587 Installer 1 e. Remove the aftercooler.

250-4586 Locator 1 f. Remove the starters.

C
322-2078 Bolt 2
g. Remove the air shutoffs.
9S-8858 Nut 1
1. Remove sections of the heat shield as required to
gain access to components.
86 KENR6415-01
Disassembly and Assembly Section

g02436139
Illustration 288

6. Remove bolts (15). Remove cam gear (16).

g02436118
Illustration 286

2. Disconnect harness assemblies (10). Remove

tube assemblies (7) and (9).

3. Remove bolts (6). Remove bracket (8). Remove

the bolts (2) and turbocharger mounts (1). Remove
elbows (3) and (4). Remove lifting eye (5).

g02437259
Illustration 289

7. Disconnect harness assembly (18). Remove three

bolts (17) and bolt (20). Remove cover (19) and
the gasket seal.

g02436136
Illustration 287

4. Rotate the engine so that the number one piston

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

5. Remove bolts (11). Remove cover (12). Remove

bolts (13). Remove cover (14). Illustration 290
g01220569

8. Disconnect harness assembly (23). Remove bolt

(21). Remove crankshaft position sensor (22).
KENR6415-01 87
Disassembly and Assembly Section

g01220583 g02437857
Illustration 291 Illustration 293

9. Attach Tooling (A) and a suitable lifting device 1. Attach Tooling (A) and a suitable lifting device
onto flywheel housing (24). The weight of flywheel onto flywheel housing (24). The weight of flywheel
housing (24) is approximately 726 kg (1600 lb). housing (24) is approximately 726 kg (1600 lb).
Apply slight lifting tension on flywheel housing Apply Tooling (B) to the mating surface of flywheel
(24). housing (24). Position flywheel housing (24).
Install bolts (26).
10. Remove bolts (25) that connect the oil pan to
flywheel housing (24).

g01220583
Illustration 294

g02437857
Illustration 292 2. Install bolts (25) that connect the oil pan to
flywheel housing (24).
11. Remove bolts (26). Remove flywheel housing
(24).

i04268567

Flywheel Housing - Install

SMCS Code: 1157-012

Installation Procedure
Table 48
Required Tools
Part g01220569
Tool Part Description Qty Illustration 295
Number
A 138-7575 Link Bracket 2 3. Install crankshaft position sensor (22). Install bolt
(21). Connect harness assembly (23).
B 1U-8846 Gasket Sealant 1
88 KENR6415-01
Disassembly and Assembly Section

g02437259
Illustration 296

4. Install the gasket seal and cover (19). Install

three bolts (17) and bolt (20). Connect harness
assembly (18).

g02436118
Illustration 299

8. Install lift eye (5). Install elbows (3)and (4).

Position turbocharger mounts (1). Install bolts (2).
Install bracket (8)and bolts (6).

9. Install tube assemblies (7) and (9). Connect

harness assemblies (10).

10. Install sections of the heat shield removed to gain

access to components.

End By:
g02436139
Illustration 297
a. Install the air shutoffs.
5. Rotate the engine so that the number one piston
is at top dead center on the compression stroke. b. Install the starters.
Refer to Testing and Adjusting, “Finding Top
Center Position for No. 1 Piston”. c. Install the aftercooler.

6. Install cam gear (16). Install bolts (15). d. Install the turbocharger.

e. Install the exhaust elbow.

f. Install the crankshaft rear seal.

g. Install the flywheel.

g02436136
Illustration 298

7. Install cover (14). Install bolts (13). Install cover

(12). Install bolts (11).
KENR6415-01 89
Disassembly and Assembly Section

i04268932

Idler Gears (Front) - Remove

and Install
SMCS Code: 1206-010

Removal Procedure
Table 49
Required Tools
Tool Part Number Part Description Qty
A 1P-0520 Driver Gp 1

Start By:

a. Remove the engine oil and water pump drive.

b. Remove the fuel and auxiliary water pump drive.

g02438517
Illustration 301
c. Remove the vibration damper.

g01229252
Illustration 302

2. Support idler gear (7). Remove pin (8). Remove

idler shafts (6). Lower idler gear (7) to the bottom
of the front drive housing. Remove idler gear (7)
from the back side of the front drive housing.

g02034146
Illustration 300

1. Remove bolts (1). Remove cover (2). Remove

bolts (3). Remove cover (4). Remove bolts (5)
from idler shafts (6). Remove the two idler gear
bolts located in the rear of each shaft.

g02438519
Illustration 303

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

remove bearing (9) from gear (7).
90 KENR6415-01
Disassembly and Assembly Section

4. Repeat Steps 2 through 3 for the opposite side.

Installation Procedure
1. Install idler gear (7) in the reverse order of
removal.

i03816577

Gear Group (Rear) - Remove

SMCS Code: 1206-011; 1212-011

Removal Procedure Illustration 306

g01209641

Start By: 3. Remove bolts (5). Remove shaft assembly (6).

a. Remove the flywheel housing.

g01209643
Illustration 307
g01209637
Illustration 304
4. Remove bolts (7). Remove gear (8) from the
crankshaft.
1. Remove bolts (1). Remove plate (2). Remove
gear (3).
i03816636

Gear Group (Rear) - Install

SMCS Code: 1206-012; 1212-012

Installation Procedure
Table 50
Required Tools
Tool Part Number Part Description Qty
A 1P-0520 Driver Gp 1

g01209639
Illustration 305

2. Remove bearing (4).

KENR6415-01 91
Disassembly and Assembly Section

g01209643 g01209637
Illustration 308 Illustration 311

1. Install gear (8) onto the crankshaft. Install bolts (7). 4. Install gear (3). Install plate (2). Install bolts (1).

End By:

a. Install the flywheel housing.

i04300330

Piston Cooling Jets - Remove

and Install
SMCS Code: 1331

Removal Procedure
g01209641
Illustration 309
1. Turn the battery disconnect switch to the OFF
position.
2. Install shaft assembly (6). Install bolts (5).
2. If necessary, remove components for access to
the side covers.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

g01209639
Illustration 310

3. Use Tooling (A) to install bearing (4).

92 KENR6415-01
Disassembly and Assembly Section

i02717761

Bearing Clearance - Check

SMCS Code: 1203-535; 1219-535

Measurement Procedure
Table 51
Required Tools
Part
Tool Number Part Description Qty
198-9142 Plastic Gauge (Green)
0.025 to 0.076 mm 1
(0.001 to 0.003 inch)
198-9143 Plastic Gauge (Red)
0.051 to 0.152 mm 1
(0.002 to 0.006 inch)
A
198-9144 Plastic Gauge (Blue)
Illustration 312
g02034335 0.102 to 0.229 mm 1
(0.004 to 0.009 inch)
3. Remove bolts (1). Remove side cover (2). 198-9145 Plastic Gauge (Yellow)
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
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

Note: Caterpillar does not recommend the checking

g02400820 of the actual bearing clearances particularly on
Illustration 313
small engines. This is because of the possibility of
obtaining inaccurate results and the possibility of
Note: Rotate engine to gain access to the piston damaging the bearing or the journal surfaces. Each
cooling jet. Caterpillar engine bearing is quality checked for
specific wall thickness.
4. Remove bolts (3). Remove piston cooling jet (4).
Mark the location of dowel (5). Note: The measurements should be within
specifications and the correct bearings should
5. Repeat Steps 3 and 4 for the remaining piston be used. If the crankshaft journals and the bores
cooling jets. for the block and the rods were measured during
disassembly, no further checks are necessary.
Installation Procedure However, if the technician still wants to measure the
bearing clearances, Tooling (A) is an acceptable
Note: Point dowel (5) toward the connecting rod as method. Tooling (A) is less accurate on journals with
shown. If, dowel (5) is pointed toward the crankshaft small diameters if clearances are less than 0.10 mm
main will cause improper spray. (0.004 inch).

1. Install piston cooling jet (4) in the reverse order NOTICE

of removal. Lead wire, shim stock or a dial bore gauge can dam-
age the bearing surfaces.
KENR6415-01 93
Disassembly and Assembly Section

The technician must be very careful to use Tooling (A) Note: When Tooling (A) is used, the readings can
correctly. The following points must be remembered: sometimes be unclear. For example, all parts of
Tooling (A) are not the same width. Measure the
• Ensure that the backs of the bearings and the major width in order to ensure that the parts are
bores are clean and dry. within the specification range. Refer to Specifications
Manual, “Connecting Rod Bearing Journal” and
• Ensure that the bearing locking tabs are properly Specifications Manual, “Main Bearing Journal” for the
seated in the tab grooves. correct clearances.

• The crankshaft must be free of oil at the contact i04411267

points of Tooling (A).

1. Put a piece of Tooling (A) on the crown of the

Connecting Rod Bearings -
bearing that is in the cap. Remove and Install
Note: Do not allow Tooling (A) to extend over the SMCS Code: 1219-010
edge of the bearing.
Removal Procedure
2. Use the correct torque-turn specifications in order
to install the bearing cap. Do not use an impact Table 52
wrench. Be careful not to dislodge the bearing
Required Tools
when the cap is installed.
Part
Tool Part Number Qty
Note: Do not turn the crankshaft when Tooling (A) Description
is installed.
Engine Turning
279-3473 1
Tool
3. Carefully remove the cap, but do not remove A
Tooling (A). Measure the width of Tooling (A) Air Power
329-3831(1) 1
while Tooling (A) is in the bearing cap or on the Turning Tool
crankshaft journal. Refer to Illustration 314. 274-5875 Rod Guide 2
B
339-6503 Bolts 2
C 369-4008 Piston Support 1
(1) Optional

Start By:

a. Remove the valve cover.

b. Remove the electronic unit injector.

1. Drain the engine oil into a suitable container for

storage or for disposal.

2. Drain the coolant from the cooling system into a

suitable container for storage or for disposal.

3. If necessary, remove components for access to

g01152855
the side covers.
Illustration 314
Typical Example

4. Remove all of Tooling (A) before you install the

bearing cap.
94 KENR6415-01
Disassembly and Assembly Section

g02052496
Illustration 315

4. Remove bolts (1). Remove side cover (2).

5. Use Tooling (A) to turn the flywheel in order

to access the connecting rod cap that will be
removed. g02076133
Illustration 317

Note: Notice the location of the tabs when the

connecting rod bearings are removed from the ODD
and EVEN connecting rod caps.

7. Remove the lower half of connecting rod bearing

(5) from connecting rod cap (4).

g01431477
Illustration 316
g02052477
Illustration 318
Note: Inspect and carefully handle the fractured
connecting rod and the connecting rod cap for the 8. Install Tooling (B).
proper identification mark. The connecting rod and
the connecting rod cap should have an etched
number on the side. The number should match the
cylinder number. Mark the connecting rod and the
connecting rod cap, if necessary. Improper handling
of the fractured connecting rods and the connecting
rod caps can cause misalignment during assembly.
The connecting rod caps should be placed on the
side in order to prevent damage.

6. Remove bolts (3) and the spacer. Remove

connecting rod caps (4).
KENR6415-01 95
Disassembly and Assembly Section

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

1. Clean the connecting rod cap and the connecting

rod bearing bore. Inspect both the connecting rod
cap and the connecting rod bearing bore.

2. Inspect the fractured joints and remove any loose

material. Do not use a cloth material to remove
loose material on the fractured areas.

3. Check the clearance of the bearings. Refer to

Disassembly and Assembly, “Bearing Clearance -
Check” for the correct procedure.

4. Place clean engine oil on the connecting rod

g02052476 bearings.
Illustration 319

5. Install the upper half of the connecting rod bearing

9. Install Tooling (C) in order to hold the piston in
in the connecting rod. Inspect in order to ensure
place.
that the tab on the back of the bearing is in the
bearing tab groove on the connecting rod.
10. Use the adjusting nut to raise the piston until
the connecting rod is above the crankshaft
6. Inspect the fractured joints. Inspect the connecting
journal. Remove Tooling (B) that is not against the
rod bearing and the crankshaft journal for
crankshaft journal. Remove the upper half of the
cleanliness and apply clean engine oil.
connecting rod bearing.
7. Push the connecting rod into position over the
11. Push the connecting rod into position and remove
connecting rod journal and install Tooling (B).
the rest of Tooling (B). The connecting rod should
swing over the crankshaft journal. Check in order
8. Position the connecting rod over the crankshaft.
to avoid contact between the connecting rod and
Use Tooling (C) to lower the piston on the
the connecting rod journal.
crankshaft journal.

Installation Procedure
Table 53
Required Tools
Part
Tool Part Description Qty
Number
Engine Turning
279-3473 1
Tool
A
Air Power Turning
329-3831(1) 1
Tool
274-5875 Rod Guide 2
B
339-6503 Bolts 2 g02052477
Illustration 320
C 369-4008 Piston Support 1
9. Remove Tooling (B).
Molybdenum
D 6V-4876 1
Paste
(1) Optional
96 KENR6415-01
Disassembly and Assembly Section

11. Position connecting rod cap (4) onto the

connecting rod. Ensure that the number on the
side of connecting rod cap (4) corresponds to the
number that is on the connecting rod.

12. Determine the position of the bearing tab ODD or

EVEN. Designate the center bolt on the bearing
tab side as the bolt 1 for the tightening procedure.

13. Clean the bolts and inspect the bolts for thread
damage. If necessary, use new bolts.

14. Apply Tooling (D) under the heads and to the

threads of bolts (3). Install the spacer and bolts (3)
finger tight. Do not use air gun to run down the
bolts.

g02076133
Illustration 321

Note: Notice the location of the tabs on the ODD

and EVEN connecting rod caps before installing
the connecting rod bearings. Install the tab of the
connecting rod bearing in the slot of the connecting
rod cap or the connecting rod first. The joint of the
connecting rod bearing and the connecting rod
cap or the connecting rod should be aligned. Push
the opposite side of the connecting rod bearing
simultaneously away from the joint into the bore.

10. Install the lower half of connecting rod bearing

(5) in connecting rod cap (4). Inspect in order to
ensure that the tab on the back of the bearing is in
the bearing tab groove on connecting rod cap (4).
g02052476
Illustration 323

15. Remove Tooling (C).

16. Use Tooling (A) to rotate the flywheel in order

to access the connecting rod cap that will be
installed.

g01431693
Illustration 324

17. Use the following procedure to tighten bolts (3):

a. Tighten bolts (1) and (2) to a torque of

105 ± 5 N·m (77 ± 4 lb ft).
g01431477
Illustration 322
b. Tighten bolts (3) and (4) to a torque of
105 ± 5 N·m (77 ± 4 lb ft).
KENR6415-01 97
Disassembly and Assembly Section

c. Tighten bolts (5) and (6) to a torque of i04382812

105 ± 5 N·m (77 ± 4 lb ft).
Crankshaft Main Bearings -
d. Repeat Steps 17.a through 17.c. Remove
e. Turn bolts (3) and (4) for an additional 90 ± 5 SMCS Code: 1203-011
degrees.

f. Turn bolts (5) and (6) for an additional 90 ± 5 Removal Procedure

degrees.
Table 54

g. Turn bolts (1) and (2) for an additional 90 ± 5 Required Tools

degrees.
Tool Part Number Part Description Qty
Note: Paint bolt heads in order to ensure the correct A 253-3272 Cylinder 2
angle on the additional turns. The bolt heads are
B 178-9312 Hose As 2
separated by 30 degrees.
Distribution
C 253-3276 1
Coupler
Electric Hydraulic
227-6724 1
Pump Gp (120 V)
Electric Hydraulic
227-8834 1
D(1)(3) Pump Gp (240 V)
191-5347 Hydraulic Pump Gp 1
Manual Hydraulic
156-7167 1
Pump
Engine Turning
279-3473 1
Tool
E
Air Power Turning
329-3831(2) 1
g02052496 Tool
Illustration 325
F 369-4007 Bearing Driver 1
18. Position side cover (2). Install bolts (1).
- Guide Stud (M20 -
G 2
2.5 by 250 MM)
19. If necessary, install the components for access
(1) Use any of the pumps that are listed in Tooling (D) for this
to the side covers.
procedure.
(3) The latest pumps and hoses require (22000 psi) capacity.
End By: (2) Optional

a. Install the electronic unit injector. Start By:

b. Install the valve cover. a. Remove the starting motors.

b. Remove the fuel pump.

c. Remove the engine oil pump.

d. Remove the engine oil cooler.

e. Remove the fuel and auxiliary water pump drive.

1. If necessary, remove components for access to

the side covers.
98 KENR6415-01
Disassembly and Assembly Section

4. Install Tooling (A) onto the studs for the crankshaft

main bearing cap. Tighten the threaded collar of
Tooling (A). Loosen the threaded collar of Tooling
(A) by 1 1/2 turns. Attach Tooling (B) onto Tooling
(A). Attach Tooling (B) onto Tooling (C). Attach
Tooling (C) onto Tooling (D). Apply approximately
135 MPa (19580 psi) of pressure to Tooling (A).
Use the drive on Tooling (A) in order to loosen the
nuts for the crankshaft main bearings. Turn on the
drive Tooling (A) by approximately three turns.
Release the pressure on Tooling (A). Remove
Tooling (A).

g02052496
Illustration 326

g02104108
Illustration 329

5. Remove crankshaft main bearing nuts (4).

g02104105 Remove plate (5). Remove Tooling (G).
Illustration 327

2. Remove bolts (1) and remove side cover (2).

Repeat for the remaining side covers on both
sides of the engine.

3. Remove bolt (3) from each side of the engine and

install Tooling (G).

g01212288
Illustration 330

6. Slide down crankshaft main bearing cap (6) on the

studs. Remove crankshaft main bearing (7) from
crankshaft main bearing cap (6).

7. Install Tooling (F) in order to remove the upper

g01212105 crankshaft main bearing. If necessary, use Tooling
Illustration 328
(E) in order to rotate the crankshaft and remove
the upper crankshaft main bearing.
KENR6415-01 99
Disassembly and Assembly Section

i04382817 1. Lubricate main bearing studs (8) with clean engine

oil. Use Tooling (H) and a suitable torque wrench
Crankshaft Main Bearings - in order to check the torque on main bearing studs
Install (8). Tighten main bearing studs (8) to a torque of
100 ± 20 N·m (74 ± 15 lb ft).
SMCS Code: 1203-012
Note: Be sure that the back of the main bearing is
clean and free from oil.
Installation Procedure
2. Lightly lubricate the upper crankshaft main bearing
Table 55
with clean engine oil. If necessary, use Tooling (E)
Required Tools in order to rotate the crankshaft and remove main
bearing. Use Tooling (F) and install the upper
Tool Part Number Part Description Qty
crankshaft main bearing into the cylinder block.
A 253-3272 Cylinder 2
B 178-9312 Hose As 2
Distribution
C 253-3276 1
Coupler
Electric Hydraulic
227-6724 1
Pump Gp (120 V)
Electric Hydraulic
227-8834 1
D(1)(3) Pump Gp (240 V)
191-5347 Hydraulic Pump Gp 1
Manual Hydraulic
156-7167 1
Pump
Engine Turning
279-3473 1 g01212288
Tool Illustration 332
E
Air Power Turning
329-3831(2) 1 3. Lightly lubricate crankshaft main bearing (7) with
Tool
clean engine oil. Install crankshaft main bearing
F 369-4007 Bearing Driver 1 (7) into crankshaft main bearing cap (6). Lift
crankshaft main bearing cap (6) into position.
Guide Stud
G - M20-2.5 by 250 2
MM
H 284-5266 Spanner Wrench 1
(1) Use any of the pumps that are listed in Tooling (D) for this
procedure.
(3) The latest pumps and hoses require (22000 psi)capacity.
(2) Optional

g02104105
Illustration 333

4. Lubricate bolts (3) with clean engine oil. Remove

Tooling (G). Install bolts (3) finger tight.

g02104118
Illustration 331
100 KENR6415-01
Disassembly and Assembly Section

7. Install Tooling (A) onto the studs for the crankshaft

main bearing cap. Tighten the threaded collar
of Tooling (A). Attach Tooling (B) onto Tooling
(A). Attach Tooling (C) onto Tooling (D). Apply
approximately 135 MPa (19580 psi) of pressure to
Tooling (B). Use the drive on Tooling (A) in order to
tighten the nuts for the crankshaft main bearings.
Release the pressure on Tooling (A). Reapply
approximately 135 MPa (19580 psi) of pressure
to Tooling (A). Recheck nuts (3) for tightness.
Remove Tooling (A).

g02104108
Illustration 334

5. Lubricate the main bearing studs with clean

engine oil. Install plate (5). Install nuts (4) for the
crankshaft main bearings finger tight.

g02104105
Illustration 337

8. Start at the front of the engine and tighten bolts

(3) on the left side of the cylinder block to a torque
of 100 ± 20 N·m (74 ± 15 lb ft).

g02104105
Illustration 335

6. Start at the front of the engine and tighten bolts (3)

on the right side of the cylinder block to a torque
of 100 ± 20 N·m (74 ± 15 lb ft).

g02104105
Illustration 338

9. Start at the front of the engine and tighten bolts (3)

on the right side of the cylinder block to a torque
of 530 ± 70 N·m (391 ± 52 lb ft).

10. Start at the front of the engine and tighten bolts

(5) on the left side of the cylinder block to a torque
g01212105
of 530 ± 70 N·m (391 ± 52 lb ft).
Illustration 336

Note: Show 14 to 15 threads or 28 to 30 mm of

protrusion of the stud above the nut before tension
is applied. Show 16 to 17 threads or 32 to 34 mm of
protrusion of the stud above the nut after tension is
applied.
KENR6415-01 101
Disassembly and Assembly Section

Start By:

a. Remove the cylinder head.

b. Remove the piston cooling jet.

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

Illustration 339
g02052496 Refer to Special Publication, NENG2500, “Dealer Ser-
vice Tool Catalog” for tools and supplies suitable to
11. Install side cover (2). Install bolts (1). Repeat for collect and contain fluids on Cat products.
the remaining side covers on both sides of the
engine. Dispose of all fluids according to local regulations and
mandates.
12. If necessary, install components for access to the
side covers. 1. Drain the engine oil into a suitable container for
storage or for disposal. Refer to Operation and
End By: Maintenance Manual, “Engine Oil and Filter -
Change”.
a. Install the fuel and auxiliary water pump drive.

b. Install the engine oil cooler.

c. Install the engine oil pump.

d. Install the fuel pump.

e. Install the starting motors.

i04411272

Pistons, Liners, and

Connecting Rods - Remove
SMCS Code: 1216-011; 1225-011

Removal Procedure
Table 56
g01831951
Required Tools Illustration 340

Part
Tool Part Description Qty Note: Inspect the connecting rod and connecting rod
Number
cap for the proper identification mark. The connecting
279-3473 Engine Turning Tool 1 rod and the connecting rod cap should have an
A etched number on the side. The number should
329-3831(1) Air Power Turning Tool 1
match the cylinder number. Mark the connecting rod
274-5875 Guide 2 and the connecting rod cap, if necessary. Careful
B handling is required for fractured connecting rods.
339-6503 Bolt 2
The connecting rod and the rod cap should be placed
C 8T-2686 Puller Group 1 on the sides in order to prevent damage. When
D 328-5926 Spacer 2 possible, the connecting rod and the rod cap should
be bolted together in order to prevent damage.
E 322-3564 Cylinder Puller 1
(1) Optional
102 KENR6415-01
Disassembly and Assembly Section

2. Use Tooling (A) to rotate the flywheel in order

to access the connecting rod cap that will be
removed.

3. Remove bolts (1) and connecting rod cap (2).

Position the crankshaft so that the piston is at the
bottom dead center. Inspect the connecting rod
bearing for wear or for damage.

g02439096
Illustration 343
g01240845
Illustration 341 7. Install Tooling (D). Remove Tooling (C).
4. Install Tooling (B) onto the connecting rod. Note: Do not remove the cylinder pack with Tooling
(C).

g01240763
Illustration 342
g01765495
Illustration 344
5. Install Tooling (C). Hold the bolt of Tooling (C) and
turn the nut. Turn the nut until the nut is tight. 8. Install Tooling (E) onto the piston liner. Rotate
the engine in order to position the piston to the
6. Rotate the engine in order to position the cylinder top. Attach Tooling (E) to the piston. Attach a
pack to the proper height and install Tooling (D). suitable lifting device onto Tooling (E). The weight
of the piston, the liner, and the connecting rod is
approximately 50 kg (110 lb). Remove Tooling (D).
KENR6415-01 103
Disassembly and Assembly Section

g01765496 g01520323
Illustration 345 Illustration 346

9. Remove cylinder pack (3) from the cylinder block. 1. Attach Tooling (A) and a suitable lifting device onto
connecting rod (1). The weight of connecting rod
(1) and the piston is approximately 23 kg (50 lb).
i03851373
Remove connecting rod (1) and the piston from
Pistons and Connecting Rods liner (2).

- Disassemble
SMCS Code: 1225-015

Disassembly Procedure
Table 57
Required Tools
Part
Tool Part Description Qty
Number
A 138-7575 Link Bracket 2
Retaining Ring
B 1P-1861 1
Pliers
C 271-0504 Ring Expander 1

Start By:

a. Remove the pistons, liners, and connecting rods. g01229379

Illustration 347

2. Remove O-ring seals (3) from liner (2).

104 KENR6415-01
Disassembly and Assembly Section

i03851389

Pistons and Connecting Rods

- Assemble
SMCS Code: 1225-016

Assembly Procedure
Table 58
Required Tools
Tool Part Number Part Description Qty

g01229403
A 138-7575 Link Bracket 2
Illustration 348
Retaining Ring
B 1P-1861 1
3. Use Tooling (B) in order to remove retaining ring Pliers
(4). Remove wrist pin (5) and remove connecting C 271-0504 Ring Expander 1
rod (1) from piston (6).
D 255-8897 Ring Compressor 1
Ring Groove Gage -
327-8644 1
Top
Ring Groove Gage -
E 327-8645 1
Second
Ring Groove Gage
327-8646 1
- Oil

g01229404
Illustration 349

4. Use Tooling (C) and remove piston rings (7) from

piston (6).

g01229404
Illustration 350

1. Use Tooling (E) for the ring grooves. Use Tooling

(C) and install piston rings (7) onto piston (6).
Install the top ring with the side that is marked
UP 1 toward the top of the piston. Install the
intermediate ring with the side that is marked UP
2 toward the top of the piston. The oil ring spring
ends must be assembled 180 degrees from the
ring end gap. After the rings have been installed,
rotate the rings so that the end gaps are located
120 degrees from each other. Oil ring end gap
must be in the pin bore plane.
KENR6415-01 105
Disassembly and Assembly Section

4. Coat piston (6) and the piston rings with clean

engine oil. Install Tooling (D) onto piston (6).
Tighten Tooling (D) in order to compress the piston
rings.

g01229403
Illustration 351

2. Coat connecting rod (1) and wrist pin (5) with

clean engine oil. Install connecting rod (1) into
piston (6). Install wrist pin (5) into piston (6) and Illustration 354
g01240872
connecting rod (1). Use Tooling (B) in order to
install retaining ring (4). Position retaining ring (4) 5. Coat the inside of liner (2) with clean engine oil.
with the opening toward the bottom of the piston. Attach Tooling (A) and a suitable lifting device onto
the connecting rod. The weight of the connecting
rod and the piston assembly is approximately
23 kg (50 lb). Install the connecting rod and the
piston assembly into the bottom side of liner (2).

g01229379
Illustration 352

3. Install O-ring seals (3) onto liner (2).

g01520432
Illustration 355

6. Remove Tooling (D) from liner (2).

Note: Do not permit the piston to go past the top

dead center position. If the piston goes past the top
dead center position, the piston rings will lock into the
cuff ring bore.

End By:

a. Install the pistons, liners, and connecting rods.

g01240871
Illustration 353
106 KENR6415-01
Disassembly and Assembly Section

i04411276 1. Rotate the engine in order to position the

crankshaft at the bottom.
Pistons, Liners, and
Connecting Rods - Install 2. Attach a suitable lifting device onto Tooling
(E). The weight of the piston, the liner, and the
SMCS Code: 1216-012; 1225-012 connecting rod is approximately 50 kg (110 lb).
Install Tooling (B) onto the connecting rod. Coat
the liner bore of the cylinder block and the O-ring
Installation Procedure seals on the outside of the cylinder liner with liquid
soap. Install cylinder pack (3) into the cylinder
Table 59
block.
Required Tools
Part
Note: Inspect the connecting rod bearing for wear
Tool Part Description Qty or for damage. If necessary, replace the connecting
Number
rod bearing. Refer to Disassembly and Assembly,
279-3473 Engine Turning Tool 1 “Connecting Rod Bearings - Remove and Install” for
A Air Power Turning the proper procedure. Position the connecting rod so
329-3831(1) 1 that the chamfer is toward the crankshaft. Install the
Tool
piston, the liner, and the connecting rod as a unit.
274-5875 Guide 2
B
339-6503 Bolt 2
E 322-3564 Puller Group 1
288-9169 Installation Bracket 1
F
2P8260 Liner Installer 1
G 4C-5593 Thread Lubricant 1
(1) Optional

Note: Ensure that the top O-ring seal for the liner is at
least 20 °C (68 °F) before installation of liners into the
cylinder block. Assembly with a cold seal may result
in damage to the O-ring seal or to the installation tool.
g01765495
Illustration 357

3. Remove Tooling (E).

g01945551
Illustration 358

4. Install Tooling (F). Use Tooling (F) in order to seat

Illustration 356
g01765496 the liner into the cylinder block. Position the cuff
ring bore to 5 ± 1 mm (0.1969 ± 0.0394 inch)
Note: Ensure that the piston is at top dead center above the top of the cylinder liner in order to hold
when you install the rod in order to prevent on the fire ring.
interference with the counterweights. Refer to Testing
and Adjusting , “Finding Top Center Position for No. 1
Piston”.
KENR6415-01 107
Disassembly and Assembly Section

a. Tighten bolts (1) and (2) to a torque of

105 ± 5 N·m (77 ± 4 lb ft).

b. Tighten bolts (3) and (4) to a torque of

105 ± 5 N·m (77 ± 4 lb ft).

c. Tighten bolts (5) and (6) to a torque of

105 ± 5 N·m (77 ± 4 lb ft).

d. Repeat Steps 8.a through 8.c.

e. Turn bolts (3) and (4) for an additional 90 ± 5

degrees.

g01240845
f. Turn bolts (5) and (6) for an additional 90 ± 5
Illustration 359 degrees.
5. Remove Tooling (B) from the connecting rod. g. Turn bolts (1) and (2) for an additional 90 ± 5
degrees.

9. Fill the engine with oil. Refer to Operation and

Maintenance Manual, “Engine Oil and Filter -
Change”.

End By:

a. Install the piston cooling jet.

b. Install the cylinder head.

i04271273

Camshaft - Remove
SMCS Code: 1210-011

Removal Procedure
g01831951 Table 60
Illustration 360
Required Tools
Note: Match the tabs on the ODD and EVEN Tool Part Number Part Description Qty
connecting rod caps with the connecting rods.
A 282-9962 Guide 2
6. Install connecting rod cap (2). Apply Tooling (G) B 255-2820 Camshaft Pilot 2
under the head bolts (1) and to the threads of
bolts (1). Install bolts (1). C 8T-3169 Crank As 1

7. Use Tooling (A) to rotate the flywheel in order Start By:

to access the connecting rod cap that will be
installed. a. Remove the oil filter housing.

b. Remove the valve lifter.

c. Remove the aftercooler.

g01431693
Illustration 361

8. Use the following procedure to tighten bolts (3):

108 KENR6415-01
Disassembly and Assembly Section

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

Refer to Special Publication, NENG2500, “Dealer Ser-

vice Tool Catalog” for tools and supplies suitable to
collect and contain fluids on Cat products.

Dispose of all fluids according to local regulations and

mandates. g02440957
Illustration 363

1. Drain the coolant from the cooling system. Refer 7. Remove bolts (8). Remove cover (9). Remove
to Operation and Maintenance Manual, “Cooling bolts (10). Remove cover (11).
System Coolant - Change”.
8. Disconnect tube assembly (12). Remove tube
2. Turn the fuel supply to the OFF position. assemblies (13) and (14).

3. Remove sections of the heat shield to gain access

to the components.

g02441223
Illustration 364

9. Remove bolts (15). Remove bolt (16). Remove

g02440956
Illustration 362 spacer (17). Remove cam gear (18).

Note: The camshaft can be removed from either end

of the engine.

4. Rotate the engine so that the number one piston

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

5. Remove elbows (1) and (2). Remove bolts (5) and

lifting mount (3).

6. Remove bolts (6) and remove shield (4).

Disconnect harness assemblies (7).
g02441225
Illustration 365

10. Remove bolts (19) and the washers. Remove

retainer (20).
KENR6415-01 109
Disassembly and Assembly Section

g02441227 g01228276
Illustration 366 Illustration 369
Typical Example
11. Disconnect tube assembly (21) and (22). Remove
bolts (24). Remove housing (23). 13. Apply a thin coat of oil to Tooling (A) and Tooling
(B). Install Tooling (A) and leave the bolts loose.
Install Tooling (B). Tighten the bolts for Tooling
(A). Install Tooling (C). Use Tooling (C) in order to
rotate the camshaft. Rotate the camshaft in order
to remove the camshaft.

Note: The camshaft can be removed from either end

of the engine.

g02441229
Illustration 367

12. Remove bolts (25). Remove cover (26).

g02441230
Illustration 370

14. Remove camshaft (27) halfway from the engine.

Use a suitable lifting device in order to support
camshaft (27). The weight of camshaft (27)
is approximately 95 kg (210 lb). Remove the
remaining portion of camshaft (27).

i04411279
g01228274
Illustration 368
Typical Example
Camshaft Bearings - Remove
SMCS Code: 1211-011

Removal Procedure
Start By:

a. Remove the camshaft.

110 KENR6415-01
Disassembly and Assembly Section

Manual Removal Hydraulic Removal

Table 61 Table 62
Required Tools Required Tools
Tool Part Number Part Description Qty Tool Part Number Part Description Qty
125-2739 Bearing Pilot 1 125-2739 Bearing Pilot 1
A 125-2740 Backup Plate 1 A 125-2740 Backup Plate 1
125-2741 Bearing Sleeve 1 125-2741 Bearing Sleeve 1
6V-4013 Screw 1 6V-4013 Screw 1
6V-4010 Puller Plate 1 6V-4010 Puller Plate 1
B 8M-8778 Taperlock Stud 1 B 8M-8778 Taperlock Stud 1
2J-3506 Full Nut 1 2J-3506 Full Nut 1
5P-8248 Hard Washer 1 5P-8248 Hard Washer 1
316-1493 Hydraulic Puller 1
Electric Hydraulic
350-7768 1
C Pump Gp (115 V)
Electric Hydraulic
350-7769 1
Pump Gp (230 V)

g01203149
Illustration 371
205

1. Install the sleeve of Tooling (A) into camshaft

bearing (1). Install the remainder of Tooling (A).
g01203149
Illustration 373

1. Install the sleeve of Tooling (A) into camshaft

bearing (1). Install the remainder of Tooling (A).

g01203308
Illustration 372

2. Install Tooling (B). Remove camshaft bearing (1).

g01203225
Illustration 374

2. Install Tooling (B) and Tooling (C). Remove

camshaft bearing (1).
KENR6415-01 111
Disassembly and Assembly Section

i04411282

Camshaft Bearings - Install

SMCS Code: 1211-012

Installation Procedure
Manual Procedure
Table 63
Required Tools
Tool Part Number Part Description Qty
g01203523
125-2739 Bearing Pilot 1 Illustration 376

A 125-2740 Backup Plate 1

125-2741 Bearing Sleeve 1
6V-4013 Screw 1
6V-4010 Puller Plate 1
B 8M-8778 Taperlock Stud 1
2J-3506 Full Nut 1
5P-8248 Hard Washer 1

NOTICE
Keep all parts clean from contaminants.
g01204034
Illustration 377
Contaminants may cause rapid wear and shortened
component life.
Note: The camshaft bearing joint must be in the 2
O'clock or the 10 O'clock position. The oil hole must
be located on the centerline of the bore.

2. Position Tooling (A) and camshaft bearing (1) into

the bearing bore. Make sure that the groove in the
back of camshaft bearing (1) is aligned with oil
hole (2) in the cylinder block. Install Tooling (B).
Install camshaft bearing (1).

g01203522
Illustration 375

1. Install camshaft bearing (1) onto Tooling (A).

112 KENR6415-01
Disassembly and Assembly Section

Hydraulic Procedure
Table 64
Required Tools
Tool Part Number Part Description Qty
125-2739 Bearing Pilot 1
A 125-2740 Backup Plate 1
125-2741 Bearing Sleeve 1
6V-4013 Screw 1
6V-4010 Puller Plate 1
B 8M-8778 Taperlock Stud 1
g01203527
Illustration 379
2J-3506 Full Nut 1
5P-8248 Hard Washer 1
316-1493 Hydraulic Puller 1
Electric Hydraulic
350-7768 1
Pump Gp (115 V)
C
Electric Hydraulic
350-7769 1
Pump Gp (230 V)
8S-8292 Extension 1

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened Illustration 380

g01204034
component life.
Note: The camshaft bearing joint must be in the 2
O'clock or the 10 O'clock position. The oil hole must
be located on the centerline of the bore.

2. Position Tooling (A) and camshaft bearing (1) into

the bearing bore. Make sure that the groove in the
back of camshaft bearing (1) is aligned with oil
hole (2) in the cylinder block. Install Tooling (B)
and Tooling (C). Install camshaft bearing (1).

End By:

a. Install the camshaft.

g01203522
Illustration 378

1. Install camshaft bearing (1) onto Tooling (A).

KENR6415-01 113
Disassembly and Assembly Section

i04272254 a. Install Tooling (B) into the engine until Tooling

(B) is through the second camshaft bearing.
Camshaft - Install
b. Slide Tooling (A) over Tooling (B).
SMCS Code: 1210-012
c. Tighten the bolts for Tooling (A).
Installation Procedure
d. Remove Tooling (B).
Table 65
Required Tools
Tool Part Number Part Description Qty
A 282-9962 Guide 2
B 255-2820 Camshaft Pilot 2
C 8T-3169 Crank As 1

g02441230
Illustration 383

2. Attach a suitable lifting device to the middle of

camshaft (27). The weight of camshaft (27) is
approximately 95 kg (210 lb). Install camshaft
(27) halfway into the engine. Remove the suitable
lifting device. Install camshaft (27). Use Tooling
(C) in order to rotate camshaft (27). Rotate
g01228274
camshaft (27) in order to install camshaft (27).
Illustration 381
Typical Example

g02441229
Illustration 384

g01228276
Illustration 382 3. Install cover (25). Install bolts (26).
Typical Example

Note: The camshaft can be installed from either end

of the engine.

1. Apply a thin coat of oil to Tooling (A) and Tooling

(B). Install Tooling (B) into the ends of the
camshaft. Install Tooling (C).

Note: If, Tooling (A) was removed use the following

Steps in order to install Tooling (A).
114 KENR6415-01
Disassembly and Assembly Section

g02441227 g02440957
Illustration 385 Illustration 388

4. Install housing (23). Install bolts (24). Connect 7. Install tube assemblies (13) and (14). Connect
tube assembly (21) and (22). tube assembly (12).

8. Install cover (11). Install bolts (10). Install cover

(9). Install bolts (8).

g02441225
Illustration 386

5. Install retainer (20). Install the washers and bolts

g02440956
(19). Illustration 389

9. Connect harness assemblies (7). Install shield (4).

Install bolts (6).

10. Install lifting mount (3). Install bolts (5). Install

elbows (1) and (2).

11. Install sections of the heat shield removed to gain

access to the components.

12. Fill the cooling system with coolant. Refer to

Operation and Maintenance Manual, “Cooling
System Coolant - Change”.

13. turn the fuel supply to the ON position.

g02441223
Illustration 387
End By:
6. Rotate the engine so that the number one piston
is at top dead center on the compression stroke. a. Install the aftercooler.
Refer to Testing and Adjusting, “Finding Top
Center Position for No. 1 Piston”. Install cam gear b. Install the valve lifter.
(18). Install spacer (17). Install bolt (16). Install
bolts (15). c. Install the oil filter housing.
KENR6415-01 115
Disassembly and Assembly Section

i03852510

Crankshaft - Remove
SMCS Code: 1202-011

Removal Procedure
Table 66
Required Tools
Tool Part Number Part Description Qty
4C-9832 Engine Rollover Stand 1
A 284-8777 Adapter Plate (Rear) 1
284-8766 Adapter Plate (Front) 1
B 253-3272 Cylinder 2
C 178-9312 Hose As 2
D 253-3276 Distribution Coupler 1
g01224384
Electric Hydraulic Illustration 390
227-6724 1
Pump Gp (120 V)
2. Install Tooling (B) onto the studs for the crankshaft
Electric Hydraulic main bearing cap. Tighten threaded collar (1) of
227-8834 1
E(1)(2) Pump Gp (240 V)
Tooling (B). Loosen threaded collar (1) of Tooling
191-5347 Hydraulic Pump Gp 1 (B) by 1 1/2 turns. Attach Tooling (C) onto Tooling
(B). Attach Tooling (C) onto Tooling (D). Attach
Manual Hydraulic
156-7167 1 Tooling (D) onto Tooling (E). Apply approximately
Pump
135 MPa (19580 psi) of pressure to Tooling (B).
F 284-5266 Spanner Wrench 1 Use drive (2) on Tooling (B) in order to loosen the
(1) Use any of the pumps that are listed in Tooling (D) for this nuts for the crankshaft main bearings. Turn drive
procedure. (2) on Tooling (B) by approximately three turns.
(2) The latest pumps and hoses require (22000 psi) capacity. Release the pressure on Tooling (B). Remove
Tooling (B). Repeat for the remaining main bearing
Start By: caps.

a. Remove rocker arm shaft assemblies.

b. Remove the engine oil pan.

c. Remove the front housing.

d. Remove the flywheel housing.

e. Remove the engine oil cooler.

1. Use Tooling (A) in order to rotate the engine to

approximately 120 degrees.

g01432170
Illustration 391

3. Remove nuts (3) for the crankshaft main bearings.

Remove plate (4). Remove bolts (5) from each
side of the engine.
116 KENR6415-01
Disassembly and Assembly Section

Note: Match the tabs on the ODD and EVEN

connecting rod caps with the connecting rod.

g01224401
Illustration 394

Note: If the counterweights are installed on

the crankshaft, the weight of the crankshaft is
Illustration 392
g01432171 approximately 1043 kg (2300 lb).

4. Remove main bearing cap (6) and lower main 7. Attach a suitable lifting device onto crankshaft (12).
bearing (7). The weight of crankshaft (12) is approximately
748 kg (1650 lb). Remove crankshaft (12).
5. Use Tooling (A) in order to rotate the engine to
approximately 180 degrees so that the crankshaft
is on top.

g01224408
Illustration 395

8. Remove upper main bearings (16) from cylinder

block (14). Remove thrust bearing (15) from
cylinder block (14).

g01432172
Illustration 393

6. Number counterweights (13) for assembly

purposes. Remove bolts (11). Remove
counterweights (13). The weight of counterweights
(13) is approximately 18 kg (40 lb). Number the
rod caps and the connecting rods for assembly
purposes. Remove bolts (8). Remove rod caps
(9). Lay rod caps (9) on the side in order to
prevent damage. Position pistons (10) away from
crankshaft (12). g01224414
Illustration 396
KENR6415-01 117
Disassembly and Assembly Section

9. Install Tooling (F) onto main bearing stud (17).

Use a suitable ratchet and Tooling (F) in order to
remove main bearing stud (17).

i03852590

Crankshaft - Install
SMCS Code: 1202-012

Installation Procedure
Table 67
Required Tools g01224408
Illustration 398
Tool Part Number Part Description Qty
4C-9832 Engine Rollover Stand 1 2. Install thrust bearing (15) into the rear of cylinder
block (14). Lightly lubricate upper main bearings
A 284-8777 Adapter Plate (Rear) 1 (16) and the upper connecting rod bearings with
284-8766 Adapter Plate (Front) 1 clean engine oil. Install upper main bearings (16)
into cylinder block (14).
B 253-3272 Cylinder 2
C 178-9312 Hose As 2
D 253-3276 Distribution Coupler 1
Electric Hydraulic
227-6724 1
Pump Gp (120 V)
Electric Hydraulic
227-8834 1
E(1)(2) Pump Gp (240 V)
191-5347 Hydraulic Pump Gp 1
Manual Hydraulic
156-7167 1
Pump
F 284-5266 Spanner Wrench 1
(1) Use any of the pumps that are listed in Tooling (D) for this g01224401
Illustration 399
procedure.
(2) The latest pumps and hoses require (22000 psi) capacity.
3. Attach a suitable lifting device onto crankshaft (12).
The weight of crankshaft (12) is approximately
748 kg (1650 lb). Install crankshaft (12).

4. Use Tooling (A) to rotate the engine slightly above

the horizontal position.

g01224414
Illustration 397

1. Lubricate main bearing studs (17) with clean

engine oil. Install main bearing stud (17). Use
Tooling (F) and a suitable torque wrench in order
to tighten main bearing stud (17). Tighten main
bearing stud (17) to a torque of 100 ± 20 N·m
(74 ± 15 lb ft).
118 KENR6415-01
Disassembly and Assembly Section

g01432463 g01432454
Illustration 400 Illustration 402

Note: Match the tabs on the ODD and EVEN 7. Install counterweights (13). The weight of
connecting rod caps with the connecting rod. counterweights (13) is approximately 18 kg (40 lb).
Lubricate the threads, the shank, the washer, and
5. Position pistons (10) toward crankshaft (12). the seat of bolts (11) with Tooling (E). Install bolts
Lubricate the bearings for rod caps (9) with clean (11). Tighten bolts (11) to a torque of 220 ± 20 N·m
engine oil. Install rod caps (9). Apply Tooling (E) (162 ± 15 lb ft). Turn bolts (11) and additional 90 ±
under the bolt heads (8) and to the bolt threads 5 degrees.
(3). Install bolts (8) finger tight.

g01431693
Illustration 401

6. Use the following procedure to tighten bolts (8):

a. Tighten bolts (1) and (2) to a torque of

105 ± 5 N·m (77 ± 4 lb ft).

b. Tighten bolts (3) and (4) to a torque of

105 ± 5 N·m (77 ± 4 lb ft).

c. Tighten bolts (5) and (6) to a torque of

105 ± 5 N·m (77 ± 4 lb ft).
g01432171
Illustration 403
d. Repeat Steps 6.a through 6.c.
8. Lubricate lower main bearing (7) with clean engine
e. Turn bolts (3) and (4) for an additional 90 ± 5 oil. Install lower main bearing (7) into main bearing
degrees. cap (6). Install main bearing cap (6).

f. Turn bolts (5) and (6) for an additional 90 ± 5

degrees.

g. Turn bolts (1) and (2) for an additional 90 ± 5

degrees.
KENR6415-01 119
Disassembly and Assembly Section

11. Install Tooling (B) onto the studs for the crankshaft
main bearing cap. Tighten threaded collar (1)
of Tooling (B). Attach Tooling (C) onto Tooling
(B). Attach Tooling (C) onto Tooling (D). Attach
Tooling (D) onto Tooling (E). Apply approximately
135 MPa (19580 psi) of pressure to Tooling (B).
Use drive (2) on Tooling (B) in order to tighten the
nuts for the crankshaft main bearings. Release the
pressure on Tooling (B). Reapply approximately
135 MPa (19580 psi) of pressure to Tooling (B).
Recheck nuts (2) for tightness. Remove Tooling
(B).

g01432170
Illustration 404

9. Lubricate the main bearing studs with clean

engine oil. Install plate (4). Install nuts (3) for the
crankshaft main bearings finger tight. Lubricate
bolts (5) with clean engine oil. Install bolts (5) g01225172
finger tight. Illustration 406

10. Start at the front of the engine and tighten bolts 12. Start at the front of the engine and tighten bolts
(5) on the right side of the cylinder block to a (5) on the left side of the cylinder block to a torque
torque of 100 ± 20 N·m (74 ± 15 lb ft). of 100 ± 20 N·m (74 ± 15 lb ft).

13. Start at the front of the engine and tighten bolts

(5) on the right side of the cylinder block to a
torque of 530 ± 70 N·m (391 ± 52 lb ft).

14. Start at the front of the engine and tighten bolts

(5) on the left side of the cylinder block to a torque
of 530 ± 70 N·m (391 ± 52 lb ft).

End By:

a. Install the engine oil cooler.

b. Install the flywheel housing.

c. Install the front housing.

d. Install the engine oil pan.

e. Install rocker arm shaft assemblies.

g01224384
Illustration 405
120 KENR6415-01
Index Section

Index
A Crankshaft Rear Seal - Remove............................ 84
Removal Procedure ........................................... 84
Aftercooler - Remove and Install ........................... 25 Cylinder Head - Install ........................................... 75
Installation Procedure ........................................ 26 Installation Procedure ........................................ 75
Removal Procedure ........................................... 25 Cylinder Head - Remove ....................................... 74
Air Cleaner - Remove and Install........................... 18 Removal Procedure ........................................... 74
Installation Procedure ........................................ 19
Removal Procedure ........................................... 18
Air Inlet Manifold - Remove and Install.................. 26 D
Installation Procedure ........................................ 26
Removal Procedure ........................................... 26 Disassembly and Assembly Section........................ 4
Air Shutoff - Remove and Install............................ 24
Installation Procedure ........................................ 24
Removal Procedure ........................................... 24 E
Auxiliary Water Pump - Assemble ......................... 40
Assembly Procedure.......................................... 40 Electronic Control Module (Engine) - Remove and
Auxiliary Water Pump - Disassemble .................... 39 Install ..................................................................... 4
Disassembly Procedure ..................................... 39 Installation Procedure .......................................... 5
Auxiliary Water Pump - Install ............................... 42 Removal Procedure ............................................. 4
Installation Procedure ........................................ 42 Electronic Unit Injector - Install .............................. 71
Auxiliary Water Pump - Remove ........................... 38 Installation Procedure ........................................ 71
Removal Procedure ........................................... 38 Electronic Unit Injector - Remove .......................... 70
Removal Procedure ........................................... 70
Electronic Unit Injector Sleeve - Install .................. 73
B Installation Procedure ........................................ 73
Electronic Unit Injector Sleeve - Remove .............. 73
Bearing Clearance - Check ................................... 92 Removal Procedure ........................................... 73
Measurement Procedure ................................... 92 Engine Oil and Water Pump Drive - Assemble...... 56
Assembly Procedure.......................................... 56
Engine Oil and Water Pump Drive - Disassemble.. 56
C Disassembly Procedure ..................................... 56
Engine Oil and Water Pump Drive - Install ............ 57
Camshaft - Install.................................................. 113 Installation Procedure ........................................ 57
Installation Procedure ....................................... 113 Engine Oil and Water Pump Drive - Remove ........ 55
Camshaft - Remove............................................. 107 Removal Procedure ........................................... 55
Removal Procedure ......................................... 107 Engine Oil Cooler - Assemble ............................... 44
Camshaft Bearings - Install .................................. 111 Assembly Procedure.......................................... 44
Installation Procedure ....................................... 111 Engine Oil Cooler - Disassemble........................... 44
Camshaft Bearings - Remove ............................. 109 Disassembly Procedure ..................................... 44
Removal Procedure ......................................... 109 Engine Oil Cooler - Install...................................... 45
Connecting Rod Bearings - Remove and Install.... 93 Installation Procedure ........................................ 45
Installation Procedure ........................................ 95 Engine Oil Cooler - Remove.................................. 43
Removal Procedure ........................................... 93 Removal Procedure ........................................... 43
Crankcase Breather - Remove and Install............. 64 Engine Oil Filter Housing - Install .......................... 54
Installation Procedure ........................................ 64 Installation Procedure ........................................ 54
Removal Procedure ........................................... 64 Engine Oil Filter Housing - Remove ...................... 53
Crankshaft - Install................................................ 117 Removal Procedure ........................................... 53
Installation Procedure ....................................... 117 Engine Oil Pan - Assemble.................................... 61
Crankshaft - Remove............................................ 115 Assembly Procedure.......................................... 61
Removal Procedure .......................................... 115 Engine Oil Pan - Disassemble............................... 60
Crankshaft Front Seal - Install ............................... 83 Disassembly Procedure ..................................... 60
Installation Procedure ........................................ 83 Engine Oil Pan - Install .......................................... 62
Crankshaft Front Seal - Remove ........................... 82 Installation Procedure ........................................ 62
Removal Procedure ........................................... 82 Engine Oil Pan - Remove ...................................... 59
Crankshaft Main Bearings - Install......................... 99 Removal Procedure ........................................... 59
Installation Procedure ........................................ 99 Engine Oil Pump - Assemble................................. 50
Crankshaft Main Bearings - Remove..................... 97 Assembly Procedure.......................................... 50
Removal Procedure ........................................... 97 Engine Oil Pump - Disassemble............................ 49
Crankshaft Rear Seal - Install................................ 85 Disassembly Procedure ..................................... 49
Installation Procedure ........................................ 85
KENR6415-01 121
Index Section

Engine Oil Pump - Install ....................................... 51 G

Installation Procedure ........................................ 51
Engine Oil Pump - Remove ................................... 46 Gear Group (Rear) - Install.................................... 90
Removal Procedure ........................................... 46 Installation Procedure ........................................ 90
Engine Oil Screen - Remove and Install................ 58 Gear Group (Rear) - Remove................................ 90
Installation Procedure ........................................ 58 Removal Procedure ........................................... 90
Removal Procedure ........................................... 58
Exhaust Elbow - Remove and Install..................... 27
Installation Procedure ........................................ 27 H
Removal Procedure ........................................... 27
Exhaust Manifold - Remove and Install ................. 27 High Pressure Fuel Rails - Remove and Install....... 8
Installation Procedure ........................................ 28 Installation Procedure ........................................ 10
Removal Procedure ........................................... 27 Removal Procedure ............................................. 8
Exhaust Shield - Remove and Install..................... 19
Installation Procedure ........................................ 21
Removal Procedure ........................................... 19 I

Idler Gears (Front) - Remove and Install ............... 89

F Installation Procedure ........................................ 90
Removal Procedure ........................................... 89
Flow Limiter - Remove and Install ......................... 12 Important Safety Information ................................... 2
Installation Procedure ........................................ 13 Inlet and Exhaust Valve Guides - Remove and
Removal Procedure ........................................... 12 Install ................................................................... 79
Flywheel - Remove and Install .............................. 83 Installation Procedure ........................................ 79
Installation Procedure ........................................ 84 Removal Procedure ........................................... 79
Removal Procedure ........................................... 83 Inlet and Exhaust Valve Springs - Remove and
Flywheel Housing - Install...................................... 87 Install ................................................................... 76
Installation Procedure ........................................ 87 Installation Procedure ........................................ 77
Flywheel Housing - Remove.................................. 85 Removal Procedure ........................................... 76
Removal Procedure ........................................... 85 Inlet and Exhaust Valves - Remove and Install ..... 77
Front Drive Housing - Remove and Install............. 80 Installation Procedure ........................................ 78
Installation Procedure ........................................ 81 Removal Procedure ........................................... 77
Removal Procedure ........................................... 80 Inlet Valve Seals - Remove and Install .................. 79
Fuel and Auxiliary Water Pump Drive - Remove and Installation Procedure ........................................ 80
Install ................................................................... 37 Removal Procedure ........................................... 79
Installation Procedure ........................................ 38
Removal Procedure ........................................... 37
Fuel Control Valve - Remove and Install P
(Primary) .............................................................. 16
Installation Procedure ........................................ 16 Piston Cooling Jets - Remove and Install.............. 91
Removal Procedure ........................................... 16 Installation Procedure ........................................ 92
Fuel Control Valve - Remove and Install Removal Procedure ........................................... 91
(Secondary) ......................................................... 14 Pistons and Connecting Rods - Assemble .......... 104
Installation Procedure ........................................ 15 Assembly Procedure........................................ 104
Removal Procedure ........................................... 14 Pistons and Connecting Rods - Disassemble ..... 103
Fuel Filter Housing - Install...................................... 6 Disassembly Procedure ................................... 103
Installation Procedure .......................................... 6 Pistons, Liners, and Connecting Rods - Install.... 106
Fuel Filter Housing - Remove.................................. 5 Installation Procedure ...................................... 106
Removal Procedure ............................................. 5 Pistons, Liners, and Connecting Rods -
Fuel Priming Pump - Remove and Install ................ 7 Remove ............................................................. 101
Installation Procedure .......................................... 7 Removal Procedure ......................................... 101
Removal Procedure ............................................. 7 Prelubrication Oil Pump - Remove and Install......... 4
Fuel Pump (High Pressure) - Remove and Install.. 17 Installation Procedure .......................................... 4
Installation Procedure ........................................ 18 Removal Procedure ............................................. 4
Removal Procedure ........................................... 17
Fuel Transfer Pump - Install .................................... 8
Installation Procedure .......................................... 8 R
Fuel Transfer Pump - Remove ................................ 7
Removal Procedure ............................................. 7 Rocker Shaft - Assemble....................................... 66
Assembly Procedure.......................................... 66
Rocker Shaft - Disassemble .................................. 65
Disassembly Procedure ..................................... 65
122 KENR6415-01
Index Section

Rocker Shaft and Push Rods - Install.................... 66

Installation Procedure ........................................ 66
Rocker Shaft and Push Rods - Remove................ 65
Removal Procedure ........................................... 65

Table of Contents..................................................... 3
Turbocharger - Install ............................................ 23
Installation Procedure ........................................ 23
Turbocharger - Remove ........................................ 21
Removal Procedure ........................................... 21

Valve Cover - Remove and Install ......................... 64

Installation Procedure ........................................ 64
Removal Procedure ........................................... 64
Valve Lifter - Assemble.......................................... 68
Installation Procedure ........................................ 68
Valve Lifter - Disassemble ..................................... 68
Disassembly Procedure ..................................... 68
Valve Lifter - Install ................................................ 69
Installation Procedure ........................................ 69
Valve Lifter - Remove ............................................ 67
Removal Procedure ........................................... 67
Vibration Damper - Remove and Install................. 81
Installation Procedure ........................................ 82
Removal Procedure ........................................... 81

Water Pump - Assemble........................................ 33

Assembly Procedure.......................................... 33
Water Pump - Disassemble ................................... 31
Disassembly Procedure ..................................... 31
Water Pump - Install .............................................. 36
Installation Procedure ........................................ 36
Water Pump - Remove .......................................... 31
Removal Procedure ........................................... 31
Water Temperature Control Valve - Install (Jacket
Water (JW)) ......................................................... 30
Installation Procedure ........................................ 30
Water Temperature Control Valve - Install (Separate
Circuit Aftercooler (SCAC)).................................. 30
Installation Procedure ........................................ 30
Water Temperature Control Valve - Remove (Jacket
Water (JW)) ......................................................... 29
Removal Procedure ........................................... 29
Water Temperature Control Valve - Remove
(Separate Circuit Aftercooler (SCAC))................. 29
Removal Procedure ........................................... 29
KENR6415-01 123
Index Section
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