RENR9716-02

C A T E R P IL L A R September 2008

Disassembly and
Assembly
Assembly
C27 and C32 Generator Sets Engines
DWB1-Up (Generator Set)
SXC1-Up (Generator Set)
SXC1-Up
MED1-Up (Power Module)
WDR1-Up (Generato r Se
Set)
t)

From the library of Barrington Diesel Club

 i01658146

Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills and tools to perform these functions properly.
I mproper operat ion, lubric at ion, maint enanc e or repair of this
this produc t c an 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
read and unders t ood t he operat ion, lubric at ion, maint enanc e and repair inf ormat ion.
Safety preca utions and warning s are provided in this manua l and on the product. If these hazard warnin gs
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
“DAN GER” , “WARN ING” or “CAUTION ”. The Safety Alert “WARNING ” label is shown belbelow.
ow.

A WAR NING

The meaning of this safety alert symbol is as follows:

A t te n ti o n ! B ec o m e A le r t! Yo u r Safe
Sa fe ty is In vo lv ed .
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warn ing s in this pu blication and on the pro duct are, therefore, not all inclusiv e. IIff a tool,
proc edure, work met hod or operat ing t ec hnique t hat is not s pec if ic ally rec ommended by Cat erpillar erpillar
is us ed, y ou mus t s at is f y y ours elf t hat it is s a
aff e f or y ou and f o r ot hers . Y
You
ou s hou ld als o ens ure t hat
the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair proc edures t hat y ou c hoos e.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Caterpillar dealers have the m ost current information availabl
available.
e.

A WAR NING
When replacement parts are required for this
produc t Cat erpillar rec ommends us ing Cat erpil
lar replacement parts or parts with equivalent
s pec if ic at ions
ions inc luding, but not limit e
ed
d t o, phy s 
ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema

ture failures, product damage, personal injury or
death.
RENR9716-02 3
Table of Contents

Table of Contents Vibration Damper and Pulley - Remove and Install

..................................................................................... 53
Crankshaft Front Seal - Remove .............................. 54
Crankshaft Front Seal - Install .................................. 55
Disassembly
Disassembly and Assembly Section
Section
Gear Group (Front) - Remove .................................. 55
Gear Group (Front) - Install ....................................... 56
Engine - Remove .......................................................... 4
Housing (Front) - Remove ....................................... 57
Engine - Install .............................................................. 6
Housing (Front) - Install ............................................. 58
Fuel Priming Pump - Remove and Install .............. 9
Housing (Rear) - Remove .......................................... 60
Fuel Filter Base - Remove ...................................... 10
Fuel Filter Base - Install .......................................... 10 Housing (Rear) - Install .............................................. 60
Valve Mechanism Cover - Remove and In s ta ll
Valve 62
Fuel Filter and Water Separator - Remove and
Valve Mechanism Cover Base - Remove and
Install ............................................................................ 11
Install ......................................................................... 62
Fuell Transf
Fue Transfer er Pump - Rem ove ................................ 12
Rocker Arm and Shaft Shaft - Rem ov e .............................. 63
Fuel Transfer Pump - Install ..................................... 12
Rockerr Arm - D isassem ble ........................................ 64
Rocke
Electronic
Elect ronic Unit
Unit Inject
Injector or - R em ov e ........................... 13
Rockerr Arm - Ass em ble ............................................. 64
Rocke
Electronic
Elect ronic Unit
Unit Inje ctor-In stall ............................... 14
Rocker Arm and Shaft - Install .................................. 65
Electronic
Elect ronic Unit Injector
Injector SleevSleeve e - R em ov e 15
Cylinder Head - Remove ........................................... 66
Electronic Unit Injector Sleeve - Install .................. 16
C yli
ylind
nd er Head - Insta ll .....................
................................
......................
................68
.....68
Turbocharg
Turbo charger er - Rem ove ........................................... 17
Camshaft
Camsha ft - Rem ove .................................................... 71
Turbocharger - Disassemble .................................. 17
Camshaft - Install ......................................................... 73
Turbocharger - Assemble ....................................... 18
Camshaft Bearings - Remove ................................... 76
Turbocharger - Ins tall ................................................ 18
Camshaft Bearings - Install ........................................ 76
Exhaust Manifold - Remove and Install ................ 19
Engine Oil Pan - Remove and Install .................... 78
Inlet and Exhaust Valve Springs - Remove and
Cylinder Liner - Re m ov e .......................................... 79
...........................................................................
Install
Inlet and Exha ust Valves - Remove and Install .. .... 20
.. 22 Cylinder Liner - In sta ll ................................................. 79
Piston
Pist on Cooling Jets - Remove and In s ta ll 80
Inlet and Exhaust Valve Guides - Remove and
Pistons and Connecting Rods - R em ov e .......... 81
Install ......................................................................... 23
Pistons and Connecting Rods - Dis as sem ble 82
Inlet and Exhaust Valve Seat Inserts - Remove and
Pistons and Connecting Rods - Assemb le ....... 82
Install ......................................................................... 24
Pistons and Connecting Rods - In st all ................. 83
Engine Oil Filter Base - Remove .............................. 25
Connecting Rod Bearings - Remove ....................... 84
Engine Oil Filter Base - Disassemble ...................... 26
Connecting Rod Bearings - Install ............................ 85
Engine Oil Filter Base - Assemble ............................ 26
Crankshaftt Ma
Crankshaf Main in Bearings
Bearings - Re m ov e ..................... 86
Engine Oil Filter Base - Install .................................. 27
Crankshaft Main Bearings - Install ............................ 87
Engin e Oil Co ole r - R e m o v e .... ........
........
........
........
........
........
........
........
......27
..27
Crankshaf
Crank shaftt - Re mo ve .................................................. 88
Engine
Engi ne Oil Cooler - In sta ll .......................................... 28
Crankshaft - Install ...................................................... 90
Engine
Engi ne Oi
Oill Pump - Re m ov e ....................................... 28
Bearing
Bear ing Clearance
Clearance - Ch ec k ........................................ 92
Engine
Engi ne Oi
Oill Pump - Disass em ble ............................... 29
At mo sp he ric Pre ss ure Se ns or - Re mo ve and
Engine
Engi ne Oi
Oill Pump - As se m ble .................................... 29
Install ......................................................................... 93
Engine Oil Pump - Install ......................................... 30
Cam shaft Position Sens or - Remove and Install .. 93
............................................
Water
W ate r Pump
Pump -- Remove
Disas sem ble .... ........
........
........
........
........
........
........
........ 31
.... 31 Crankshaft PositionPosition Sen sor- R emove and and In sta ll. ll... 94
Coolant Temperature Sensor - Remove and
Water Pump - Assemble ......................................... 32
Install ......................................................................... 95
Water Pump - Install ................................................. 33
Engine Oil Pressure Sensor - Remove and Install
Wa ter T Temperatur
emperature e Regulator Housing - Remove and
..................................................................................... 96
Install ........................................................................ 33
Fuell Pressure Sensor - Remove and In s ta ll
Fue 97
Cooling System Package (Radiator, Aftercooler, Fuel
Fuel Temperature S ens or - Remove and Install .. .... 97
Cooler) - Remove .................................................... 35
Turbocharge r Outlet Pressure Sensor - Remove and
Cooling System Package (Radiator, Aftercooler, Fuel
Install ......................................................................... 98
Cooler) - Install ......................................................... 36
Inlet Air Temperature Sensor - Remove and
A fte rc o o le r- R e m o v e ............................................... 38
Install ......................................................................... 99
A fte rc o o le r- In s ta ll ..................................................... 40
Belt Guard - Remove and and Ins tall .............................. 99
Radiator Core - Remove ........................................... 42
Fan Guard - Remov e and Install ........................ 100
R ad iat or Core
Co re - Inst all ..........
.....................
......................
......................
................44
.....44
Fan - Remove and Install .. .... ..................................... 10 101
1
Engine Support (Front) - Remove and Install ......... 45
Fan Drive - Remove and Install ........................... 102
Gear Group
Group (Re (Rear)
ar) - Re m ov e ................................... 46
Electronic ControlControl Module - Remove and and Install
Install ..1 0 3
........................................
Gear Group
Flywheel (Rear) -and
(Rear)
- Remove Ins Install
ta ll ................................. 48
49 Alt er na to
torr - Re mo ve and Insta ll ........................... 104
Electric Starting Motor-Remove and Install .... 105
Crankshaft Rear Seal - Remove ............................. 50
Crankshaft Rear Seal - Install ................................. 50
Flywheel Housing - Remove and Install .............. 51 Index Section

In d e x 106
4 RENR9716-02
Disassembly and Assembly Section

Disassembly and As sembly

Disassembly
Section
i02747487

Engine - Remove
SMCS Code: 1000-011

Removal Procedure
Table 1

Required Tools
Illustrati
Illustration
on 2 g0l29H 60
Part
Tool N u m b er Par t D es c r i p t i o n Qty 2. Disconnect harness assembly (6)
(6)..
A 1 3 8 -7 5 7 3 Lin k Bra cke t 2

B 238-9586 E n g in e T u rn in g Tool 1

C 1U - 9 2 0 0 L e v e r P u ll e r H o is t 1

D 1 8 9 -0 4 1 1 S h a c k le A s 2

E 6V-6146 L oa d L e v e lin g B e a m 1

Start By:

a. Remove tthe
he cooling package. Refer to
Disassembly and Assembly, “Cooling System
Package (Radiator, Aftercooler, Fuel Cooler) -
Remove”.
g01291161
Illustration 3

3. Disco nnect hose assem blies (7), (8),

(8), and
and (9).

g01291159
Illustration 1

1. Discon nect hose assem bly (1). Disco nnect cable

assembly (2). Disconnect harness assemblies Illustration 4
g01291162
(3). Disconnect cable assembly (4). Disconnect
harness assem blies (5).
(5). 4. Disco nnect clamp (10).
R E N R 9 7 1 6 -0 2 5
Disassembly and Assembly Section

7. D isconne ct clamp (15).

Illustra tion 8 g01291225

g01291225

8. Remov e bolts ((16).

16). Remove guard (17).

g01291179
Illustration 5

5. Remove bolts (11

(11).
). Remove bolts (12)
(12).. Repeat for
the opposite side. Disconnect tube assembly (13).
Repeat for the opposite side.

Illustrati
Illustration
on 9 g0l29l22 7

9. Remov e bolts (18). Remove guard (19).

(19).

Illustration 6 g01291183

6. Attach Tooling (A) and

and a suitable lifting
lifting device
onto exhaust elbow (14). The weight of exhaust
elbow (14) is approximately 34 kg (75 lb). Remove
exhaust elbow (14
(14).
).

g01291228
Illustration 10

10 . Disconnect hose (20).

g01291186
Illustration 7
6 RENR9716-02
Disassembly and Assembly Section

Illustration 11 9012912
901291232
32 Illustration 14 g0 l29l24 6

13. Attach Tooling

Tooling (D) o nto engine (24). Attach Tooling
(E) and a suitable lifting device onto Tooling
(D). The weight of engine (24) is approximately
3527 kg (7775 lb).

Illustration
Illustration 12 g0l29l24 3

11 . Install Tooling (B). Use Tooling (B) in order to

rotate the engine. Rotate the engine in order to
gain access to bolts (22). Remove bolts (22).
Remove bolts (21). Illustra tion 15 901291247

14 . Remove mounting bolts (25). Remove engine

(24) from the generator.

i02 747534

Engine - Install
SMCS Code: 1000-012

Installation Procedure
Table 2

Required Tools
Illustration 13 g0l376223
Part
12 . Use Tooling (C) in order to support generator Tool N u m b er Par t D es c r i p t i o n Qt y
rotor (23). A 1 3 8 -7 5 7 3 Lin k Bra cke t 2

B 2 3 8 -9 5 8 6 E n g in e T u rn in g Tool 1

C 1 U -9 2 0 0 L e v e r P u ll e r H o is t 1

D 189-0411 S h a c k le A s 2

E 6V-6146 L oa d L e v e lin g B e a m 1
R E N R 9 7 1 6 -0 2 7
Disassembly and Assembly Section

g01291246 g01291232
Illustration 16 Illustration 19

1. Attach Tooling (D) onto engine (24). Attach Tooling 3. Install bolts (21). Use Tooling (B)
(B) in ord er to rotate
(E) and a suitable lifting device onto Tooling the engine. Install bolts (22).
(D). The weight of engine (24) is approximately
3527 kg (7775 lb). Install engine (24).

g01291245
Illustration 20

g01291247
Illustration 17 4. Remov e Tooling (C)
(C)..

2. Install mounting bolts (2

(25).
5).

g01291228
Illustration 21

g01291243
Illustration 18 5. Connect hose (20).
8 RENR9716-02
Disassembly and Assembly Section

g01291227 g01291183
Illustration 22 Illustration 25

6. Install guard (19). Install bolts (18). 9. Attach Tooling (A) and a suitable lifting device
onto exhaust elbow (14). The weight of exhaust
elbow (14) is approximately 34 kg (75 lb). Install
exhaust elbow (14).
(14).

Illustration
Illustration 23 g0l29l22 5

7. Install guard (17). Install bolts (16).

Illustra tion 26 g01291179

g01291179

10. Conn ect tube

tube ass embly (13). Install bolts
bolts (12).
(12).
Repeat for the opposite side. Install bolts (11).

Illustration
Illustration 24 g0l29H 86

8. C onne ct clamp (15).

g01291162
Illustration 27
R E N R 9 7 1 6 -0 2 9
Disassembly and Assembly Section

11 . Connect clamp (10). End By:

a. Install the cooling package. Referto Disassembly

and Assembly, “Cooling System Package
(Radiator, Aftercooler, Fuel Cooler) - Install”.

i02580978

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

Removal Procedure
Illus tratio n 28 g012911
g01291161
61
NOTICE
12 . Connect hose assemblies (7), (8), and (9). Care m ust be taken to ensure tha t fl
fluids
uids are contained
during performance of inspect
inspection,
ion, maintenance, test
ing, adjusting and repair ofthe product. Be prepared to
collect the fluid with suitable containers before open
ing any compartment or disassembling any compo
nent containing fluids.

Referto Special Publication, NENG2500, “Caterpillar

Tools and Shop Products Guide” fortoo ls and supplies
Tools
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

mandates.

g01291160 NOTICE
Illustration 29
Keep all parts clean from contaminants.

13 . Connect harness assembly (6).

Contaminants may cause rapid wear and shortened
component life.

g01291159
Illustration 30

g01292755
14 . Connect harness assemblies (5). Connect cable Illustration 31

assembly (4). Connect harness assemblies (3).

Connect cable assembly (2). Connect hose 1. Remove bolts (1).
assembly (1).
2 . Remov e ffuel
uel priming pump (2) and the gasket.
10 RENR9716-02
Disassembly and Assembly Section

Installation Procedure 1. Turn the fuel supply to the OFF position.

Illustration 32 g012927
g01292755
55

1. Position tthe
he gas ket and ffuel
uel priming pum p (2) o
on
n
the fuel filter base.

2. Install bolts (1).

Illustration 33 g012927
g01292764
64
i02580993

Fuel Filter Base - Remove 2. filter

Use Tooli
Tooling
baseng (A) to remove fuel filter (6) from fuel
(5).

SMCS Code: 1262-011 3. Disconnect harness assemblies (4

(4).
).

Removal Procedure 4. Disconnect hose assembly (1

(1)) and hose assembly
(2).
Table 3

Required Tools 5. Remov e bolts (3) and fuel filter base (5)
(5)..

Part
Tool N u m b er Par t D e s c r i p t i o n Qt y i02581008

A 185-3630 S tr a p W r e n c h 1 Fuel Filter Base - Install

SMCS Code: 1262-012
NOTICE

Care must
during be taken to
performance of ensure that fluids
inspection, are contained
maintenance, test Installation Procedure
ing, adjusting and repair ofthe product. Be prepared to
collect the fluid with suitable containers before open NOTICE
ing any compartment or disassembling any compo Keep all parts clean from contaminants.
nent containing fluids.
Contaminants may cause rapid wear and shortened
Refer to Special Publication,
Publication, N ENG2500, “Caterpillar component life.
Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

mandates.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.
R E N R 9 7 1 6 -0 2 11
Disassembly and Assembly Section

NOTICE
Care m ust be taken to ensure tha t fl fluids
uids are contained
during performance of inspect
inspection,
ion, maintenance, test
ing
ing,, adjusting and re pair of the produc t. Be prepared to
collect the fluid with suitable containers before open
ing any compartment or disassembling any compo
nent containing fluids.

Referto 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. Turn the fuel supply to the OFF position.

Illustration 34 g0l292764

1. Position fuel filter base (5) on the engine. Install

bolts (3).

2. Conn ect hose asse mbly (1) and hose assem bly
(2).

3. Connect harness assemblies (4)

(4)..

4. Install fuel
fuel filter (6) on fuel fil
filter
ter base (5).
(5).

5. Turn the ffuel

uel supply to the ON position. Illustration 35 gOl292832
gOl292832

i02581074
2. Use Tool
Tooling
ing (A) to remove the fuel filter
filter and water
separa tor (5)
(5) from base a ssembly (4
(4).
).
Fuel Filter and
Fuel and Water Separato r
3. Disco nnec t hose assem blies (2)
(2) and (3)
(3)..
- Remove and Install
SMCS Code: 1261-010; 1263-010 4. Remov e bolts ((1)
1) and
and base assem bly (4
(4).
).

Installation Procedure
Removal Procedure
Table 4 NOTICE
Keep all parts clean from contaminants.
Required Tools

To o l Par t N u m b e r P a r t D es c r i p t i o n Qt y Contaminants may cause rapid wear and shortened

component life.
A 1 8 5 -3 6 3 0 Strap Wr en ch As 1

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.
12 RENR9716-02
Disassembly and Assembly Section

Illustration 36 g0l292832

1. Position base assem bly (4) on the cylinde r block

and install bolts (1).

2 . Conn ect hose assemblies (2) a

and
nd (3
(3).
).
Illustration 37 gOH43748
gOH43748
3. Install a new fuel filter an
and
d wa ter separ ator (5) on
base assembly (4).
2 . Disconnect hose assembli
assemblies
es (3).
(3).

4 . Turn the ffuel

uel supply to the ON position. 3 . Remove bolts (2).

i02285574 4 . Remov e fuel tran sfer pump (1) and the O-ring
seal.
Fuel Transfer Pump - Remove
SMCS Code: 1256-011 i02287501

Fuel Transfer Pump - Install

Removal Procedure
SMCS Code: 1256-012
NOTICE
Care must be taken to ensure that fluids are contained Installation Procedure
during performance of inspection, maintenance, test
ing, adjusting and repair ofthe product. Be prepared to
NOTICE
collect the fluid with suitable containers before open
ing any compartment or disassembling any compo Keep all parts clean from contaminants.
nent containing fluids.
Contaminants may cause rapid wear and shortened
component life.
Referto Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” fortoo ls and supplies
Tools
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

mandates.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

1. Turn the
the fuel supp ly to the “OFF” positi
position.
on.
RENR9716-02 13
Disassembly and Assembly Section

1. D isconn ect harness asse mbly (1

(1).
).

2. Remov e bridge assem blies (3

(3).
).

Illustration 38 gOH43748
gOH43748 NOTICE
If the injector hold down bolt is loose during the re
1. Install the O-ring seal on fuel ttrans
rans fer pump (1). moval procedure, inspect the injector bore for wear
Lubricate the O-ring seal with clean engine oil. and debris. Replace the clamp and spacer.

2. Position fuel tran sfer pump (1) on the engine.

3. Remov e bolt (4
(4),
), spac er (5),
(5), and clamp (6).
(6).
Install bolts (2).
4. Place an identifi
identification
cation mark on electronic unit
3. Co nnec t hose asse mblies (3)
(3)..
injectors (2) for installation purposes. Each
electronic unit injector must be reinstalled in the
4. Turn the ffuel
uel supply to the “ON” position.
original location in the cylinder head.

i02208070

Electronic Unit Injector -

Remove
SMCS Code: 1290-011

Removal Procedure
Table 5

Required Tools

To o l Par t N u m b er Par t D es c r i p t i o n Qt y

A 5F-4764 P ry B a r 1

5. Use Tooli
Tooling
ng (A) to pry beneath the base and free
Start By: electronic unit injector (2).

a. Remove the rocker arms and

and tthe
he rocker arm shaft
shaft.. 6. Remo ve elec tronic unit injector (2)
(2) from the
Refer to Disassem bly and Assembly, “R ocker Arm
Arm cylinder head.
head.
and Shaft - Remove”.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.
14 RENR9716-02
Disassembly and Assembly Section

i03143340

Electronic Unit Injector - Install

SMCS Code: 1290-012

Installation Procedure
Table 6

Required Tools

To o l Par t N u m b e r Par t D es c r i p t i o n Qty

B 8 T -2 9 9 8 L u b r ic a n t 1

1 U -5 7 1 8 V ac u um Pum p 1

1 6 9 -7 3 7 2 F lu id S a m p lin g B o ttle 1
C
Tube
4C-4057 1
7.9 mm (0.31 inch) OD

D 4 C -5 5 5 2 L a r g e B o r e B ru s h 1

E 4C-6774 V a c u u m G u n Kit 1

Surface Reconditi
Reconditioning
oning
F 8 T -7 7 6 5 1
Pad

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

1. Use Tooling (C) to remo ve the fuel and oil from 5. When you install a new injector the E-Trim
the cylinder. Evacuate as much fuel and oil as value must be programmed into the engine
possible from the cylinder before installing the control module. The injector confirmation code
electronic unit injector. Several evacuations may may need to be programmed into the engine
be necessary. control module. E-Trim Value (X) is a twelve digit
alphanum eric code that is supplied with the data
2. Use Tooli
Tooling
ng (D) to clean the carbon depo sit ffrom
rom sheet that comes with the new injectors. Injector
the inside of the electronic unit injector sleeve. Confirmation Code (Y) is a four digit numeric

Tooling (E) is available to clean loose material code. Both of the code s are located on thethe top of
from the bore of the electronic unit injector sleeve electronic unit injector (2). Use the following menu
and the cylinder. to program the E-Trim value.

3. Use Tooli
Tooling
ng (F) to clean the carbon from the seat • ECM Summ ary Screen
area that is inside of the electronic unit injector
sleeve. • Service Menu

4. Install the O-ring seals on the electronic unit • Calibration

injector. Lubricate the top two O-ring seals with a
50/50 mixture of clean engine oil and Tooling (B). • Injector Code Calibration
RENR9716-02 15
Disassembly and Assembly Section

NOTICE NOTICE
When an electronic unit injector is replaced, the new Keep all parts clean from contaminants.
electronic injector code must be programmed into the
engine’s personality module software by using the cal Contaminants may cause rapid wear and shortened
ibration menu on the Elec tronic Service Tool. If the component life.
new electronic injector code is not entered, the char
acteristics of the previous electronic unit injector is as
1. Drain tthe
he coo lant from
from the cooling system into a
sumed.
suitable container for storage o r disposal.
disposal. Refer
to Operation and Maintenance Manual, “Cooling
If it is not possible to immediately reprogram the elec
System Coolant - Change”.
tronic injector code into the personality module soft
ware, the engine will not be severely harmed. The new
electronic injector code should be reprogrammed as
quickly as possible in order to optimize engine perfor
mance.

6. Position electron ic unit injecto r ((2)

2) iin
n the cylind er
head.

7. Install spa cer (5), clamp (6), and bolt ((4).

4). Tight
Tighten
en
the bolt to a torqu e o f 55 ± 10 N m (41 ± 7 lb fft).
t).

8. Install bridge assemb lies (3)

(3)..

9 . Conn ect harness asse mbly (1). Tighten the nunuts

ts
to a torque of 2.5 ± 0.25 N m (22 ± 2 lb in).

End By: 2. Install Tooling (A) in electro nic unit injector sleeve
( 1).
a. Install the rocker arms and the rocker arm shaft.
Refer to Disassem bly and Assembly, “R ocker Arm
Arm 3. Tighten the nut on Too
Tooling
ling (A) until the elec tronic
and Shaft - Install”. unit injector sleeve is pulled free of the cylinder
head.
i02300212

Electro nic Unit Injector Sle

Electro Sleeve
eve 1

- Remove
SMCS Code: 1713-011

Removal Procedure
Table 7

Required Tools

Part
Tool N u m b er Par t D e s c r i p t i o n Qt y
g01073635
Illustration 44
A 9U-6891 In j e c to r Tool G ro u p 1
4. Remo ve O-ring seals (2) and O-ring seal (3) from
Start By: electronic unit injector sleeve (1).

a. Remove the electronic unit injectors. Refer to

Disassembly and Assembly, “Electronic Unit
Injector - Remove”.
16 RENR9716-02
Disassembly and Assembly Section

i02287628 Note: Do not apply Tooling (C) to the cylinder head

surfaces. Apply Tooling (C) on the electronic unit
Electro nic Unit Injector Sle
Electro Sleeve
eve injector sleeve only.
- Install
4. Lubricate O-ring seals (2) with clean engine oil
oil..
SMCS Code: 1713-012

Installation Procedure
Table 8

Required Tools

To o l Par t N u m b e r Par t Des c r i p t i o n Qt y

A 9U -6 89 1 Inj ec tor Tool Gro up 1

9 U -6 8 6 2 T a p e re d B rus h 1

9 U -6 8 6 3 S m a l l B o r e B ru s h 1

B 9 U -7 2 4 4 E nd B ru s h 1

9 U -7 2 3 7 B r u s h E x te n s i o n 1

4 C -5 5 5 2 L a r g e B o re B r u s h 1
5. Install electronic unit injector sleeve (1) on
on Tooling
Tooling
C 4 C -9 5 0 7 R e t a i n in g C o m p o u n d 1 (A). Position the electronic unit injector sleeve in
the cylinder head. Use care not to damage the
O-ring seals on the electronic unit injector sleeve.
NOTICE Use Tooling (A) and a hammer to install the
Keep all parts clean from contaminants. electronic unit injector sleeve in the cylinder head.

Contaminants may cause rapid wear and shortened

component life. NOTICE
Ensure that the electronic unit injector sleeve is
properly seated in the cylinder head. The Tooling will
1. Use Tooling
Tooling (B
(B)) to clean the bore in the cylinde r "RING" when the electronic unit injector sleeve is ffully
ully
head for the electronic unit injector sleeve. seated in the bore of the cylinder head.

NOTICE 6. Remo ve Tooling (A). Remov e excess To

Tooling
oling (C).
(C).
Ensure that the electronic unit injector sleeve and the
cylinder head bore are completely free of oil, dirt, and 7. Fil
Filll tthe
he cooling s ystem with coo lant. R efer to
sealant debris. Operation and Maintenance Manual, “Cooling
System Coolant - Change”.

End By:

a. Install the electronic unit

unit injectors. Re fer to
Disassembly and Assembly, “Electronic Unit
Injector - Install”.

2. Install new O-ring

O-ring seals (2) and O-ring seal (3) on
electronic unit injector sleeve (1).

3. Apply Tooling (C) to the contact surface of

electronic unit injector sleeve (1) on the surface
that is Marked “X”.
R E N R 9 7 1 6 -0 2 17
Disassembly and Assembly Section

i02287744

Turboc harger - Re
Remove
SMCS Code: 1052-011

Removal Procedure

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

Referto Special Publication, NENG2500, “Caterpillar 2 . Remove tube assembly ((2)

2)..
Tools and Shop Products G uide” fortools and suppli
Tools supplies
es
suitable to collect and contain fluids on Caterpillar 3. Disconnect tube assemblies (1) and tube
products. assembly (4).

Dispose of all fluids according to local regulations and 4 . Attach a suitable lifti
lifting
ng device to turbo cha rge r ((5)
5)..
mandates. The weight o f turbocha rger (5) is approximately
45 kg (100 lb).
NOTICE
5 . Remov e nuts (3). Remov e turbo cha rger (5) and
Keep all parts clean from contaminants.
the gasket.
Contaminants may cause rapid wear and shortened
component life. i02287870

1. Drain the
the coola nt from the cooling system into a
Turbo charger - Disassemble
Disassemble
suitable container for storage or disposal. R efer
SMCS Code: 1052-015
to Operation and Maintenance Manual, “Cooling
System Coolant - Change”.
Disassembly Procedure
Start By:

a. Remove the turbocharger. Referto Disassembly

and Assembly, “Turbocharger - Remove”.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

g01145002
Illustration 47
18 RENR9716-02
Disassembly and Assembly Section

1 . Position compressor housing (1) and turbine

housing (5) on turbocharger cartridge (3).
1 2 3 4 5

Note: Ensure that the mating surfaces are flush.

2 . Tighten the nuts on V-band c lamp (2) toto a torque

of 14 ± 1 N m (10 ± 1 lb ft). Use a soft hammer to
lightly hit around the diameter of the band clamp.
Tighten the nuts again to a torque of 14 ± 1 N m
(10 ± 1 lb ftft).
).

3. Tighten the nuts onon V-band clamp (4) to a torque

of 14 ± 1 N m (10 ± 1 lb ft). Use a soft hammer to
lightly hit around the diameter of the band clamp.
Tighten the nuts again to a torque of 14 ± 1 N m
Illustration 49 gOH45263
gOH45263
(10 ± 1 lb ftft).
).

1. Loosen V-band clam p (2

(2)) and V-band clam p (4
(4).
). 4 . Ensure that the impeller spins freely.

2. Separate compressor housing (1) from End By:

turbocharg er cartridge (3)
(3)..
a. Install
Install the turbocharger. R efe rto Disassemb ly and
and
3. Separate turbi
turbine
ne housing (5) from tturboch
urboch arger Asse
As se mb ly, “Turb
“Tu rb oc ha rg er - Ins tal
tall”.
l”.
cartridge (3).

i02288273
i02451256
Turbocharger - Install
Turbocharger - Ass emble
SMCS Code: 1052-012
SMCS Code: 1052-016

Installation Procedure
A s s em b l y Pr o c ed u r e
Table 9

NOTICE Required Tools

Keep all parts clean from contaminants.
To o l P ar t N u m b er P ar t D e s c r i p t i o n Qt y

Contaminants may cause rapid wear and shortened A 5 P -3 93 1 An ti- Se ize Co mp oun d 1
component life.

NOTICE
NOTICE Keep all parts clean from contaminants.
The compressor housing must remain straight with
the turbocharger cartridge during
during disassem bly and as Contaminants may cause rapid wear and shortened
sembly. Tilting may cause damage to the tips of the component life.
compressor wheel and the compressor shaft.

1 2 3 4 5

g01145263
Illustration 50
R E N R 9 7 1 6 -0 2 19
Disassembly and Assembly Section

1. Position tthe
he gaske t on the exhau st manifold. 2 . Remo ve locknuts (6) from exhaus t manifold (7).
(7).

2 . Apply Tooli
Tooling
ng (A) to the threads o f the exhaust 3 . Remov e spacers (2) and (3) from exhaust
manifold studs. manifold (7).

3. Attach a suitable lifting device to turboc harg er (5

(5).
). 4 . Remov e exhaus t manifold
manifold (7) and gaskets (1)
The weight of turbocharger (5) is approximately from the c ylinder head.
45 kg (100 lb). Position turbocharger (5) on the
exhaust manifold. 5 . If necessary, remov e clamps (4) and expansion
jo
joint
int s (5).
4. Install nuts (3) and tighten to a torq
torq ue o f 55 ± 9 N m
(41 ± 7 lb ft).
Installation Procedure
5 . Connect ttube
ube assemb lies (1
(1)) and tube assembly Table 10
(4).
Required Tools
6. Install tube ass embly (2). To o l P ar t N u m b er P a r t D es c r i p t i o n Qt y

7. Fill the cooling system. Refer to Operation and A 5P-3931 An ti-S eiz e Co mp ou nd -
Maintenance Manual, “Cooling System Coolant B 165-4638 G u id e 3
- Change”.

i02617122

Exhaust Manifold - Remove

and Install
SMCS Code: 1059-010

Removal Procedure
Start By:

a. Remove the turbocharger. Re fer to Disassem bly

and Assembly, “Turbocharger - Remove”.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

1. Remove the shi

shield
eld assemblies from the exhaust
manifolds.
20 RENR9716-02
Disassembly and Assembly Section

i02300073

Inlet and Exhaust Valve

Springs - Remove and Install

<E> <3> <D <D <D ©

SMCS Code: 1108-010

Removal Procedure
<D <D © © Table 11

Required Tools

To o l Par t N u m b er P a r t D es c r i p t i o n Qt y

A 9U-7241 V a lv e Sp
Sp ri n g Co
Co m
mpp rre
essor 1
Illustration 55 g00566l45
B 8 S -2 2 6 3 Spring Tester 1
1. If necessary, install expan sion joints (5) and
clamps (4). Tighten the clamps to a torque of Start By:
8.5 ±1.0 N m (75 ± 9 lb in).
a. Remove the electronic unit injectors. Refer to
2 . App ly Tool
Tooling
ing (A) tto
o the studs prior to assembly. If Disassembly and Assembly, “Electronic Unit
necessary, install the studs and tighten to a torque Injector - Remove”.
of 35 ± 5 N m (26 ± 4 lb ft)ft)..

3. Position gaskets (1) and exhaust manifold (7) on NOTICE

Keep all parts clean from contaminants.
the cylinde r head
head..

4 . Install space rs (2) a

and
nd (3) o
on
n exhaus t manifold (7)
(7).. Contaminants may cause rapid wear and shortened
component life.
Note: Use Tooling (B) in at least one oversize hole
per manifold section in order to align the exhaust Note: Place the piston at the top ofthe compression
manifolds. Do not remove Tooling (B) until removal stroke (TC). Remove the valve springs for that
is required to tighten the locknuts. cylinder. If the valves fall into the cylinder liner, then
the cylinder head must be removed.
5. Install locknuts (6
(6)) on exhaus t manifold (7)
(7)..
Tighten locknuts (6) in a numerical sequence to a 1. Pos ition the No. 1 pist piston
on at tthe
he top center of
torque of 20 ± 3 N m (15 ± 2 lb fft).
t). Tighten lockn uts the compression stroke. Refer to Testing and
(6) again in a numerical sequence to a torque of Ad jus tin
ting,
g, “F inding forr No. 1
indi ng Top Ce nte r Pos ition fo
38 ± 5 N m (28 ± 4 lb ft). Piston”.

6. Install the shield assem blies on the exhaus t

manifolds.

End By:

a. Install
Install the tur
turbocharger.
bocharger. R eferto Disassembly and
Asse
As se mb ly, “Tu rb oc ha rger
rg er - Ins tal
tall”
l” .

V
g01073852
Illustration 56
R E N R 9 7 1 6 -0 2 21
Disassembly and Assembly Section

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

1. Lubricate the valve stems with clean engine oil.

A WAR NING
Pers onal injury c an res ult f rom being s t ruc k by
parts propelled by a released spring force.

Make sure to wear all necessary protective equip

ment.

Follow t he rec ommended proc edure and us e all

rec ommended t o oling t o relea
releas
s e t he s pring f orc e. ^ WAR NI
NI NG
I mproper as s embly of part s t hat are
are s pring loade
loaded
d
2. Install Tooli
Tooling
ng (A) in the elec tronic unit injector
can cause bodily injury.
sleeve. Secure Tooling (A) with unit injector clamp
( 1). To prevent possible injury, follow the established
as s embly proc edure and wear prot ec t iv e equip
3. Tighten the full nut unt
until
il valve spring k eepers (3)
ment.
are loose on valve (2).

4. Remove va lve spring keepers (3) from tthe

he valve. 2. Ensure that wash er (7) iis
s installed on the valve
guide.
5. Care fully remove Too
Tooling
ling (A
(A).
).
3. Install inner valve spring (5) and
and oute r valve spring
6. Remove valve rota tor (4).
(4). (6) on valve (2).

7. Remove o uter valve spring (6

(6)) and inner valve 4. Install valve rota tor (4) on valve (2).
spring (5) from the valve.

8. Remove wa she r ((7)

7) from the valve guide. A WAR NING
The valve spring keepers can be thrown from
9. Use Tooli
Tooling
ng (B) to check the valve springs (spring
t he v alv e when t he v alv e s pring c ompres s or is
force). Referto Specifications, “Cylinder Head
Valves” for additional information on the valve released. Ensure that the valve spring keepers
are properly installed on the valve stem. To help
springs.
prevent personal injury, keep away from the front
of the valve spring keepers and valve springs
Installation Procedure during t he ins t allat
allat ion of t he v alv
alv es .

Table 12
5. Use Tooling
Tooling (A) to compre ss inne r valve spring
Required Tools
(5) and outer valve spring (6). Install valve spring
To o l P ar t N u m b e r P a r t D es c r i p t i o n Qt y keepers (3) on valve (2). Remove unit injector
clamp (1) and Tooling (A).
A 9U-7241 Va lv e S p ri n g C o
om
m pr
pr e s s o r 1
22 RENR9716-02
Disassembly and Assembly Section

End By:

a. Install the electronic unit injectors. Refer to

Disassembly and Assembly, “Electronic Unit
Injector - Install”.

i02642655

Inlet
Removeand and
Exhaust
InstallValves -
SMCS Code: 1105-010

Removal Procedure
Table 13

Required Tools

To o l Par t N u m b er P ar t D e s c r i p t i o n Qt y

Valve Spring
A 5S-1330 1
Compressor

B 8 S -2 2 6 3 S p r i n g T e s te r 1

Start By:

a. Remove the cylinder head. Re fer to Disassem bly

and Assembly, “Cylinder Head - Remove”.

NOTICE
A WAR NING
Keep all parts clean from contaminants. Pers onal injury c an res ult f rom being s t ruc k by
parts propelled by a released spring force.
Contaminants may cause rapid wear and shortened
component life. Make sure to wear a
all
ll necessar y pro tective equip 
ment.

Follow t he rec ommended proc edure and us e all

rec ommended t ooling t o releas
releas e t he s pring f orc e.

1. Install Tooling
Tooling (A) and compres s the valve springs.
Remove valve spring keepers (2) from valve (1).

2. Carefu lly remove Tooling (A)

(A) from valve (1
(1).
).

3. Remove valve rota tor (3)

(3)..

4. Remove o uter valve spring (5

(5)) and inner valve
spring (4) from valve (1).

5. Remove wa she r (6
(6)) and valve (1) from the valve
guide.

6. Use Tool
Tooling
ing (B) to check the valve springs (spring
force). Refer to Specifications, “Cylinder Head
Valves” for additional information on the valve
springs.

7. Inspect tthe
he valves. R efer to Specifications,
“Cylinder Head Valves” for additional information
on the inlet and exhaust valves.
R E N R 9 7 1 6 -0 2 23
Disassembly and Assembly Section

Installation Procedure 3. Install inner valve spring (4) and

and oute r valve spring
(5) on valve (1).
(1).
Table 14

Required Tools 4. Install valve rota tor (3) on valve (1).

To o l Par t N u m b er P ar t D e s c r i p t i o n Qt y 5. Use Tool

Tooling
ing (A) to compre ss inn er valve spring
spring
Valve Spring (4) and outer valve spring (5). Install
Install valve spring
A 5 S -1 3 3 0 1 keepers (2) on valve (1).
Compressor

NOTICE WARNING
Keep all parts clean from contaminants.
The valve spring keepers can be thrown from
Contaminants may cause rapid wear and shortened t he v alv e when t he v alv e s pring c ompres s or is
component life. released. Ensure that the valve spring keepers
are properly installed on the valve stem. To help
prevent personal injury, keep away from the front
Note: A sm all am ou nt o f gre as e can be used to hold of the valve spring keepers and valve springs
the retainer locks in position during installation. during t he ins t allat ion of t he v alv es .

1. Lubricate the valves with clclean

ean engine oil
oil.. Install
the valves in the cylinder head. 6. Carefully remove Tooling
Tooling ((A).
A).

End By:

a. Install
Install the
the c ylinder head. R efer to
to Disassembly
and Assembly, “Cylinder Head - Install”.

i02109151

Inlet and Ex haus t Va

Valv
lv e Guid
Guid es
- Remove and Install
SMCS Code: 1104-010

Removal Procedure
Table 15

Required Tools

To o l P ar t N u m b e r P ar t D es c r i p t i o n Qt y
Ad) 9U-6895 V alv e G u id e D r i v e r 1
0 ) P a r t o f 9 U - 7 5 3 0 E n g i n e T o ol
ol G r o up
up

Start By:

a. Remove the inlet and exhaust valves. Refer to

Disassembly and Assembly, “Inlet and Exhaust
Valves - Remove and Install”.

NOTICE
A WAR NING Keep all parts clean from contaminants.

I mproper as s embly of part s t hat are s pring loade

loaded
d
Contaminants may cause rapid wear and shortened
can cause bodily injury.
component life.

To prevent possible injury, follow the established

as s embly proc edure and wear prot ec t iv e equip
ment.

2. Install wa she r (6) on the valve guide.

24 RENR9716-02
Disassembly and Assembly Section

Note: Tooling (B) must be used in order to install the

valve guide to the correct height.

Height to
to top of valve guide from cylinder head
surface .... 35.00 ± 0.50 mm (1.378 ± 0.020 inch)

Note: For more information,

information, re ferto Specifications,
Specifications,
“Cylinder Head Valves”.

3. Install valve stem seal (1) on the

the valve guide.

End By:

a. Install the inlet and exhaust valves. Referto

Disassembly and Assembly, “Inlet and Exhaust
Valves - Remove and Install”.

1. Remov e valve stem seal (1

(1)) from
from valve guide (2).
i02288478
2. Use Tool
Tooling
ing (A) and a ham mer to remove the
valve guide from the cylinder head. Inlet and Exhaust Valve Seat
Inserts - Remove and Install
Installation Procedure
SMCS Code: 1103-010
Table 16

Required Tools Removal Procedure

To o l P ar t N u m b e r P ar t D e s c r i p t i o n Qt y Table 17

A
AO
O) 9U-6895 Valve Guide Driver 1 Required Tools
BO) 9U-6894 G u i d e C o ll a r 1 Part
0) Part of 9U-7 53 0 Engine To
oo
ol Group Tool N u m b er Par t Des c r i p t i o n Qt y

Valve Seat Extractor Tool 1

A 166-7441
NOTICE Group
Keep all parts clean from contaminants.
Start By:
Contaminants may cause rapid wear and shortened
component life. a. Remove the inle
inlett and exhau st valves. Refer to
Disassembly and Assembly, “Inlet and Exhaust
Valves - Remove and Install”.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

1. Lubricate the bores for tthe

he valve guides with clean
engine oil.

2. Install valve guide (2) in the cylin der head with

Tooling (A) and Tooling (B).

g01145463
Illustration 63
R E N R 9 7 1 6 -0 2 25
Disassembly and Assembly Section

1. Use Tooli
Tooling
ng (A) tto
o rem ove valve sea t insert (1) i02438648
from the cylinder head.
Engine Oil Filter Base -
2. Clean the bores in the cylind er head for the valve Remove
seat inserts. Remove any rough areas from the
bores. SMCS Code: 1306-011

Installation Procedure Removal Procedure

Table 18 Table 19
Required Tools Required Tools
Part Part
Tool N u m b er Par t Des c r i p t i o n Qt y Tool N u m b er Par t Des c r i p t i o n Qty
Valve Seat Driver 1 A 1 8 5 -3 6 3 0 Strap Wrench As 1
9U-6898
BO) (Exhaust)

9 U --6
6897 V a lv e S e a t D ri v e r (In le t) 1
NOTICE
0) Part of 9U-7 53 0 Engine To
oo
ol Group Keep all parts clean from contaminants.

NOTICE Contaminants may cause rapid wear and shortened

Keep all parts clean from contaminants. component life.

Contaminants may cause rapid wear and shortened

component life. NOTICE
Care m ust be taken to ensu re that fluids
fluids are con tained
during performance of inspection, maintenance, test
ing
ing,, adjus ting and repa ir of the produc t. Be prepared to
collect the fluid with suitable containers before open
ing any compartment or disassembling any compo
nent containing fluids.

Refer to
to Special Publicat
Publication,
ion, NEN G2500, “Caterpill
“Caterpillar
ar
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 tthe
he engine oil into
into a suitable co ntainer
for storage or disposal. Refer to
to Op eration and
1. Lower the ttemperature
emperature of new valve seat insert Maintenance Manual, “Engine Oil and Filter -
Change”.
( 1).

2. Use Too
Tooling
ling (B
(B)) to install the new valve seat insert
in the cylinder head.

Note: Do not machine the prefinished valve seat

inserts in order to correct the valve stem projection.
An ex ce
cess
ssive
ive valve
va lve ste m projec
pro jec tion ind ica
icates
tes that
th at the
valve seat insert is not seated or material was not
cleaned from the botto
bottom
m o f the counterbore.

End By:

a. Install the inlet and exhaust valves. Refer to

Disassembly and Assembly, “Inlet and Exhaust
Valves - Remove and Install”.
26 RENR9716-02
Disassembly and Assembly Section

2 . Use Tool
Tooling
ing (A) in order tto
o remo ve engine oil 3 . Remove springs (3) and plungers (2) from oil filter
filters (6). base assembly (1).

3. Rem ove bolts (1), (2), (4

(4),
), and (5
(5).
).
i02127824

4 . Remove eng ine oil filter base (3)

(3)..
Engine Oil Filter Base -
A s s em b l e
i02127750

SMCS Code: 1306-016

Engine Oil Filter Base -
Disassemble A s s em b l y Pr o c ed u r e
SMCS Code: 1306-015
NOTICE
Keep all parts clean from contaminants.
Disassembly Procedure
Contaminants may cause rapid wear and shortened
Start By:
component life.
a. Remove the engine oil filter base. Referto
Disassembly and Assembly, “Engine Oil Filter
Base - Remove”.

1. Remove the O-ring seals.

A WAR NING
I mproper as s embly of part s t hat are
are s pring loade
loaded
d
can cause bodily injury.

A WAR NING To prevent possible injury, follow the established

as s embly proc edure and wear prot ec t iv e equip
Pers onal injury c an res ult f rom being s t ruc k by ment.
parts propelled by a released spring force.
1. Install plungers (2) and springs (3) in o
oil
il filter base
Make sure to wear all necessary protective equip
assembly (1).
ment.
2 . Install cove r (4)
(4)..
Follow t he rec ommended proc edure and us e all
rec ommended t o oling t o rele
releas
as e tthe
he s pring f orc e.
3 . Install the O-ring seals.

2 . Remove cover (4).

R E N R 9 7 1 6 -0 2 27
Disassembly and Assembly Section

End By: i02438849

a. Install the engine oil filter base. Refer to Engine Oil Coo ler - Re
Remo
mo ve
Disassembly and Assembly, “Engine Oil Filter
Base - Install”. SMCS Code: 1378-011

i02438813
Removal Procedure
Start By:
Engine Oil Filter Base - Install
SMCS Code: 1306-012 a. Remove the engine oil filter base. Refer to
Disassembly and Assembly, “Engine Oil Filter
Base - Remove”.
Installation Procedure
Table 20 NOTICE
Keep all parts clean from contaminants.
Required Tools

Part Contaminants may cause rapid wear and shortened

Tool N u m b er P ar t D es c r i p t i o n Qt y component life.

A 1 8 5 -3 6 3 0 Strap Wrench As 1
NOTICE
Care m ust be taken to ensu re that fluids
fluids are con tained
NOTICE
during performance of inspection, maintenance, test
Keep all parts clean from contaminants.
ing
ing,, adjus
collect theting andwith
fluid re pair of the containers
suitable produc t. Bebefore
prepared to
open
Contaminants may cause rapid wear and shortened ing any compartment or disassembling any compo
component life. nent containing fluids.

Referto 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 tthe
he coo lant from
from the cooling system into a
suitable container for storage o r disposal.
disposal. Refer
to Operation and Maintenance Manual, “Cooling
System Coolant - Change”.

1. Position engine oil filter base (3) on the engine

oil cooler.

2 . Install bolts (1), (2), (4

(4),
), and (5).

3. Use Tooling (A) to install engin e oil filters (6).

4 . Refill the engine with engine o

oil.
il. Refe rto Operation
and Maintenance Manual, “Engine Oil and Filter
- Change”.

2 . Remove tube assembly ((2)

2)..

3 . Remov e bonnet (1) and the gasket.

28 RENR9716-02
Disassembly and Assembly Section

4. Remov e engine oil coole r (3).

(3). i02439263

5. Remov e the
the O-ring seals from engine o
oil
il coo ler Engine Oil Pump - Remove
(3).
SMCS Code: 1304-011

i02438914
Removal Procedure
Engine Oil Cooler - Install
Start By:
SMCS Code: 1378-012
a. Remove the engine oil pan. Refer to Disassembly
and Assembly, “Engine Oil Pan - Remove and
Installation Procedure Install”.

NOTICE NOTICE
Keep all parts clean from contaminants. Care m ust be taken to ensu re that fluids
fluids are con tained
during performance of inspection, maintenance, test
Contaminants may cause rapid wear and shortened ing
ing,, adjus ting and re pair of the produc t. Be prepared to
component life. collect the fluid with suitable containers before open
ing any compartment or disassembling any compo
nent containing fluids.

Refer to
to Special Publicat
Publication,
ion, NEN G2500, “Caterpill
“Caterpillar
ar
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. Install the O-ring se als on engine oil coole r (3).

(3).

2. Lubricate the O-ring seals with clean engine oil

or glycerin.

3. Install engine oil coole r (3

(3).
).

4. Install the gaske t and

and bonn et (1
(1).
).

5. Install tube asse mbly (2)

(2)..
1. Remov e ttube
ube asse mblies (3) from engine oil pump
6. Refill the cooling sys tem with coolant. R efer to (2).
Operation and Maintenance Manual, “Cooling
System Coolant - Change”. 2. Remov e bolts (1) and engine oil pump (2).
(2).

End By:

a. Install the engine oil filter base. Refer to

Disassembly and Assembly, “Engine Oil Filter
Base - Install”.
R E N R 9 7 1 6 -0 2 29
Disassembly and Assembly Section

i02439652 3. Remov e bolts (4) and sepa rate cove r assem bly
(3) from body assem bly (1)
(1)..
Engine Oil
Oil Pump - Disass embl e
4. Use Tool
Tooling
ing (A) and a suitable press in order to
SMCS Code: 1304-015 remove the bearings from co ver assembly (3(3).
).

Disassembly Procedure 5. Remove shaft assemblies (2).

Table 21 6. Remove bolts (12) and retaine r ((11

11).
).
Required Tools
7. Remov e spring (10), plunger ri
ring
ng (9)
(9),, and plunger
Part (8).
Tool N u m b er Par t D e s c r i p t i o n Qt y

A 1P-0510 D r iv e r G r o u p 1 8. Use Tooli

Tooling
ng (A) and a suitable p ress in order to
to
remove the bearings from body assembly (1 (1).
).
B 1P - 2 3 2 0 P u ll e r A s s e m b l y 1

i02439997
Start By:
Engine Oil Pump - Assemble
a. Remove the engine oil pump. Refer to
Disassembly and Assembly, “Engine Oil Pump SMCS Code: 1304-016
- Remove”.

A s s em b l y Pr o c ed u r e
NOTICE
Keep all parts clean from contaminants. Table 22

Required Tools
Contaminants may cause rapid wear and shortened
component life. Part
Tool Nu m b er Par t D es c r i p t i o n Qt y

A 1P -0 5 1 0 Dr ive r Gro up 1

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

A WAR NING
Pers onal injury c an res ult f rom being s t ruc k by
parts propelled by a released spring force.

Make sure to wear all necessary protective equip

ment.

Follow t he rec ommended proc edure and us e all

rec ommended t o oling t o rele
releas
as e tthe
he s pring f orc e.

1. Remove b olt ((7)

7) and wa she r (6).
(6).

2. Use Tooli
Tooling
ng (B) tto
o remov e drive ge ar (5
(5)) from
body assembly (1). Remove the key from the
pump shaft.
30 RENR9716-02
Disassembly and Assembly Section

5 . Use Tool
Tooling
ing (A) to install the b earings in cover
assembly (3) until the bearings are even with
the outside surface of cover assembly (3). Install
the bearings so the junctions in the bearings are
An gle (Y). An gle (Y) is 30 ± 15 de gre es fro
from
m the
cen ter line of the bearing bores, and toward the
outlet passage. The outlet passage has a cavity
between the bearing bores.

6. Install cover assem bly (3) on body assem bly (1).

(1).
Install bolts (4).

7. Install the key into the pump shaft. Install drive

gear (5). Install washer (6) and bolt (7). Tighten
bol
boltt (7) to a tor qu e o f 5
55
5 ± 10 N m (41
(41 ± 7 lb fft).
t).
Illustration
Illustration 74 g0l2l904 5

End By:
3
a. Install the engine oil pump. Referto Disassembly
and Assembly, “Engine Oil Pump - Install”.

i02440080

Engine Oil Pump - Install

SMCS Code: 1304-012

Installation Procedure

NOTICE
Keep all parts clean from contaminants.

WARNING Contaminants may cause rapid wear and shortened

component life.
I mproper as s embly of part s t hat are s pring loaded
can cause bodily injury.

To prevent possible injury, follow the established

as s embly proc edure and wear prot ec t iv e equip
ment.

1. Use Tooli
Tooling
ng (A) to inst
install
all the b earings in body
assembly (1) until the bearings are even with
the outside surface of body assembly (1). Install
the bearings so the junctions in the bearings are
An gle (X). Angle
An gle (X) is 3
300 ± 1 5 de gre es from the
center line of the bearing bores and toward the
outlet passage in the engine oil pump.

2 . Install plunger (8)

(8),, plung er ri
ring
ng (9), a
and
nd spring
( 10 ).
1. Positio n engine oil pump (2) and install bolts (1).
3 . Install retain er ((11)
11) and bolts (12).
2 . Install tube ass emb lies (3) o
on
n engine oil pump (2).
4 . Install shaft assemb lies (2
(2).
).
End By:

a. Install the engine oil pan. Referto Disassembly

and Assembly, “Engine Oil Pan - Remove and
Install”.
R E N R 9 7 1 6 -0 2 31
Disassembly and Assembly Section

i02440626

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 re pair of the produc t. 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,

Publication, N ENG2500, “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.
4. Rem ove bolts (6) and nuts (5).
(5).

NOTICE 5. Remove water pump (4

(4).
).
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened i02451192

component life.
Water Pump - Disassemble
1. Drain the coola nt ffrom
rom the cooling system into a SMCS Code: 1361-015
suitable container for storage or disposal. R efer
to Operation and Maintenance Manual, “Cooling
System Coolant - Change”.
Disassembly Procedure
Table 23

Required Tools

Part
Tool N u m b er P ar t D es c r i p t i o n Qty

8 S -2 2 6 4 P u ll e r G r o u p 1

Bolt
4B-3903 5/16 - 18 NC by 4 2
A inch

1P - 0 4 5 6 P la t e 1

4B-4277 W ashe r 2

B 1P - 0 5 1 0 D ri v e r G ro u p 1

Start By:

a. Remove the
the wate r pump. Refer to Di
Disassembly
sassembly
and Assembly, “Water Pump - Remove”.

Illustration
Illustration 77 g0l2l927 4 NOTICE
Keep all parts clean from contaminants.
2. Rem ove bolts (1) and bolts (2
(2).
).
Contaminants may cause rapid wear and shortened
3. R emove cove r (3)
(3).. component life.
32 RENR9716-02
Disassembly and Assembly Section

Note: The wate r pump seal can be replaced without i02394663

removing the wate r pump from the engine.
Waterr Pump - As semb le
Wate
Note: An inte rm itte nt leaka
lea kage
ge of a sm all am ou nt of
coolant from the hole in the water pump housing is SMCS Code: 1361-016
not an indication of a water pump seal failure. This
is required to provide lubrication for the seal. Do not A s s em b l y Pr o c ed u r e
replace the
the w ater pump seal unless a large amount
of leakage o r a constant flow o f coolant is drai
draining
ning Table 24
from the water pump housing.
Required Tools

Part
Tool N u m b er P a r t D es c r i p t i o n Qt y

B 1P-0510 D r iv e r G r o u p 1

C 7N-7843 S e a l In s ta ll a tio n Tool 1

D 6V-1541 Q u i c k C u r e P r im e r 1

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

1. R emove adap ter (15)

(15)..

2 . Remo ve bolt ((9)

9) and wa sh er (8
(8).
).

3. Use Tooli
Tooling
ng (A) tto
o remov e im peller (5) from shaft
( 10).

4. Remov e bolt (7)

(7),, wash er (6)
(6),, and gear (4) from
shaft (10).

5 . Remo ve bolts (11

(11)) and retainer (13
(13).
).

6. Remov e O-ring seal (14) from housing (3).

7. Use a suitable press to remove sh aft (10) an

and
d
1. Use Tooling (B) to install lip seal (2) into the
bearing assembly (1) from housing (3).
housing.

8. Use a suitable press to remove bearing assem bly

2 . Apply Tooling (D) to shaft (10). Use a suitable
(1) from shaft (10
(10).
).
press to install bearing assembly (1) on shaft (10).

9 . Remo ve seal asse mbly (12) from housing (3)

(3)..
3 . Install shaft (10) and bearing asse mbly (1) in
housing (3).
10. Use Tooling (B) to remove lip seal (2) from the
housing. 4 . Install O-ring seal (14) on
on housing (3).

5 . Install retainer (13) an

and
d bolts (11).
(11).

6. Position gea r ((4)

4) on
on shaft (10). Install wa she r ((6)
6)
and bolt (7).
R E N R 9 7 1 6 -0 2 33
Disassembly and Assembly Section

7. Use Tooli
Tooling
ng (C) to iinstall
nstall seal assem bly (12) onto
shaft (10) until the stationary cup is fully seated
into housing (3).

8. Install iimpe
mpe ller ((5)
5) o
on
n shaft (10). Instal
Installl wa she r
(8) and bolt (9). Tighten bolt (9) to a torque of
39 ± 3 N m (29 ± 2 lb ft).

9 . Install ada pter (1

(15).
5).

End By:

a. Install the water pump. Referto Disassembly and

Asse
As se mb ly, “W at er Pump
Pu mp - Ins tall”
tal l” .

i02440675

Water Pump - Install

SMCS Code: 1361-012

Illustrati
Illustration
on 82 g0l2l927 4
Installation Procedure
3. Position cove r ((3)
3) on
on the wa ter pump.

NOTICE
Keep all parts clean from contaminants. 4. Install bolts (2) and bolts (1).
(1).

Contaminants may cause rapid wear and shortened 5. Fil

Filll the cooling system . Re fer to Operation and
component life. Maintenance Manual, “Cooling System Coolant
- Change”.

i02440754

Water Temperature Regulator

Housing - Remove and Install
SMCS Code: 1393-010

Removal Procedure
1. Drain tthe
he coo lant from the cooling system into
into a
suitable con tainer for storage or disposal until the
the
coolant is below the level of tthe
he wa ter temperature
regulator housing. Refer to Operation and
Maintenance Manual, “Cooling System Coolant
- Change”.

Illustration 81 g0l2 l927 5

1. Position wate r pump (4) in the front housing.

2. Install nuts (5) and bolts (6).

34 RENR9716-02
Disassembly and Assembly Section

2. Discon nect hose assem bly (1) and elbow (3

(3).
). 2. Install wa ter temp erature re gulators (7) and O-ring
seals (6
(6)) in water temperature regulator housing
housing
3. Remov e bolts (2
(2)) and bolts (4). Remove water (5).
temperature regulator housing (5).

3. Position wa ter temp erature r egula tor housing (5)

4. Remove O-ring seals (6) a and
nd water temperature
temperature on the engine. Install bolts (4) and bolts (2).
regulators (7) from water temperature regulator
housing (5). 4. Con nect elbow (3
(3)) and hose asse mbly (1).

5. If necessary, remov e the lip seals. 5. Fil

Filll the cooling system . Re fer to Operation and
Maintenance Manual, “Cooling System Coolant
- Change”.
Installation Procedure
Table 25

Required Tools

Part
Tool N u m b er Par t Des c r i p t i o n Qt y

A 221-8647 S e a l I n s t a l le r G p 1

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

1. If neces sary, use Tooling (A) to install the lip seals .

R E N R 9 7 1 6 -0 2 35
Disassembly and Assembly Section

i02576096

Cooling System Package

(Radiator, Aftercooler, Fuel
Cooler) - Remove
SMCS Code: 1063-011; 1353-011; 1712-011

Removal Procedure
Table 26

Required Tools

Part
Tool Part Description Qt y Illustrati
Illustration
on 88 g0l290 9l5
Number

A 189-0410 S h a c k le A s 2 3. Disco nnect bottom aftercoole r tube (2).

(2).

Start By:

a. Remove tthehe fan

fan.. R efe rto D isassembly a and
nd
Asse
As se mb ly, “Fa n - Re
Remo
moveve and Ins tall”
tall ” .

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

Referto Special Publication, NENG2500, “Caterpillar Illustrati

Illustration
on 89 g0l290 9l6
Tools and Shop Products Guide” fortools and suppli
Tools supplies
es
suitable to collect and contain fluids on Caterpillar 4. Disco nnect top radia tor hose (3).
(3).
products.

Dispose of all fluids according to local regulations and

mandates.

1. Drain tthe
he coo lant ffrom
rom the cooling system into
a suitable con tainer for storage or for disposal.
Refer to Operation and Maintenance Manual,
“Cooling System Coolant (ELC) - Change”.

Illustrati
Illustration
on 90 g0l290 9l7

5. Disconnect top aftercooler tube (4).

Illustration 87 g0l290908

2. Remove cla mp (1). Repeat for the oppos ite si

side.
de.
36 RENR9716-02
Disassembly and Assembly Section

g01290930 g01290940
Illustration 91 Illustration 94

6. Discon nect bottom radiator hose (5

(5).
). Disconnect 9. Attach Tooling (A) and a suitable lifting device
bottom aftercooler tube (6). onto cooling package (10). The weight of cooling
package (10) is approximately 544 kg (1200 lb).

Illustration 92 g0l290934
Illustration 95 gOl2909
gOl290941
41
7 . Disconnect hose a ssembly (8) from fue
fuell co oler (7)
(7)..
10. Remov e bolts (11).
(11). Repeat for the opposite side.
Remove cooling package (10).

i02576308

Cooling System Package

(Radiator, Aftercooler, Fuel
Cooler) - Install
SMCS Code: 1063-012; 1353-012; 1712-012

Installation Procedure
Illustration 93 g0l290939 Table 27

Required Tools
8. Discon nect hose assem bly (9) from fuel coo ler (7
(7).
).
Par t N u
ummbe
err Par t D e
es
s c ri
ri pt
p t io
io n

189-0410 Shackle As
R E N R 9 7 1 6 -0 2 37
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 ofthe 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,

Publication, NE NG2500, “Caterpillar
Tools
Tool s and Shop Products Guide” fortools and suppli
supplies
es
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

Illustration 98 gOl290939
gOl290939
mandates.
3. Conn ect hose asse mbly (9) onto fuel coole r (7)
(7)..

Illustration 96 g0l290940

Illustration 99 gOl290934
gOl290934
1. Attach Tooling (A) and
and a suitable lifting
lifting device
onto cooling package (10). The weight of cooling 4. Conn ect hose asse mbly (8)
(8) onto
onto fuel coo ler (7)
(7)..
package (10) is approximately 544 kg (1200 lb).

g01290930
Illustration 100
g01290941
Illustration 97

5. Connect bottom aftercooler ttube

ube (6
(6).
). Connect
2. Install cooling pack age (10). Install bolts (1
(11).
1). bottom radiator hose (5).
Repeat for the opposite side.
38 RENR9716-02
Disassembly and Assembly Section

Illustration 10
101
1 g0l2 909 l7 Illustr atio n 104 gOl 290908
290908

6. Connect top aftercooler tube (4). 9. Install clamp (1)

(1).. Re peat for the oppo site side.

10. Fill the cooling system with coolant. Refer to

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

End By:

a. Install the fan. Refer to Disassembly and

As se
semb
mb ly, “Fa n - Re mo
move
ve and Ins tall
tall”” .

i02584900

A f t er c o o l er - Rem o v e
SMCS Code: 1063-011
Illustration
Illustration 102 g0l290 9l6

7. Conn ect top radiato r hose ((3).

3). Removal Procedure
Table 28

Required Tools

To o l Par t N u m b er Par t D e s c r i p t i o n Qt y

A 1 8 9 -0 4 1 0 Sh ack le As 2

Start By:

a. Remove the fan. Referto Disassembly and

As se
semb
mb ly, “Fa n - Re mo
move
ve and Ins tall
tall”” .

Illustration
Illustration 103 g0l290 9l5

8. Conn ect bottom afterco oler tube ((2).

2).
R E N R 9 7 1 6 -0 2 39
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 ofthe product. Be prepared to
collect the fluid with suitable containers before open
ing any compartment or disassembling any compo
nent containing fluids.

Referto Special Publication, NENG2500, “Caterpillar

Tools and Shop Products Guide” fortools and suppli
Tools supplies
es
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and g01290916

Illustration 107
mandates.
4. Disco nnect top radia tor hose (3).
(3).
1. Drain the
the coola nt from the cooling system into
a suitable con tainer for storage or for disposal.
Refer to Operation and Maintenance Manual,
“Cooling System Coolant (ELC) - Change”.

Illustration
Illustration 108 g0l290 9l7

5. Disconnect top aftercooler tube (4).

Illustration 105 g0l290908

2. Remove clam p (1
(1).
). Repeat for the opposite side.

Illustr atio n 109 gOl 290930

290930

6. Disco nnect bottom radiator hose (5).

(5). Disconnec t
bottom aftercooler tube (6).
Illustration
Illustration 106 g0l290 9l5

3. Discon nect bottom aftercoole r tube (2

(2).
).
40 RENR9716-02
Disassembly and Assembly Section

Illustration 110 g0l290934 g01294232

Illustration 113

7 . Disconnect hose assembly (8)

(8) from fuel coo ler (7)
(7).. 10 . Att ac h Tooling (A) and a s uit ab le lifting de
devic
vice
e
onto aftercooler (12). The weight of aftercooler
(12)) is approximately 227 kg (500
(12 (500 lb).
lb).

g01290939
Illustration 111

g01294234
8. Disconnect hose assembly (9) from ffuel
uel cooler (7).
(7). Illustration 114

11 . Remove bolt (13). Remove bolts (14) and bolts

(15)) from aftercooler
(15 aftercooler ((12
12).
).

12. Repe at Step 9 throug h Step 11

11 for the oppos ite
side.

13.
13. Remove aftercooler ((12)
12)..

i02585968

A f t er c o o l er - Ins
In s t all
SMCS Code: 1063-012
go1294215
Illustration 112
Installation Procedure
9. Remove bolt
bolts
s (10
(10).
). Remove bol
boltt ((11
11).
).
Table 29

Required Tools

To o l P ar t N u m b er Part Qt y
Description

A 189-0410 S h a c k le A s 2
R E N R 9 7 1 6 -0 2 41
Disassembly and Assembly Section

g01294232 Illustra tion 118 gOl 290939

Illustration 115

1. Attach Tooling (A) aand

nd a suitable lifting
lifting device onto 5. Conn ect hose assem bly (9)
(9) onto fuel cooler (7).
(7).
aftercooler (12). The weight of aftercooler (12) is
approximately 227 kg (500 lb). Install aftercooler
(12).

g01290934
Illustration 119

6. Conn ect hose assem bly (8) onto fuel coo ler ((7).
7).
g01294234
Illustration 116

2. Install bolts (14) and bolts (15) into afte rco ole r
(12). Install bolt (13).

g01290930
Illustration 120

7. Connect bottom aftercooler ttube

ube (6
(6).
). Connect
bottom radiator hose (5).
Illustration
Illustration 117 g0l294 2l5

3. Install bolt (11).

(11). Install bolts (10).

4. Repe at Step 2 and Step 3 for tthe

he oppo site side.
42 RENR9716-02
Disassembly and Assembly Section

Illustration 12
121
1 g0l2 909 l7 Illustr atio n 124 gOl 290908

8. Connect top aftercooler tube (4). 11 . Install clamp (1). Repeat for the opposite side.

12. Fill the cooling system with coolant. Refer to

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

End By:

a. Install the fan. Refer to Disassembly and

As se
semb
mb ly, “Fa n - Re mo
move
ve and Ins tall
tall”” .

i02581106

Radiator Core - Remo

Remo ve
SMCS Code: 1353-011; 1353-011-KO
Illustration
Illustration 122 g0l290 9l6

9 . Connect top radiator hose (3). Removal Procedure

Table 30

Required Tools

Part
Tool Part Description Qt y
Number
A 1 3 8 -7 5 7 5 Link Bracket 2

Start By:

a. Remove the aftercooler.

aftercooler. Refer to Disassembly
and Assembly, “Aftercooler - Remove”.

Illustration
Illustration 123 g0l2909 l5

10 . Connect bottom aftercooler tube (2)

(2)..
R E N R 9 7 1 6 -0 2 43
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 ofthe product. Be prepared to
collect the fluid with suitable containers before open
ing any compartment or disassembling any compo
nent containing fluids.

Referto Special Publication, NENG2500, “Caterpillar

Tools
Tool s and Shop Products Guide” fortools and suppli
supplies
es
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

Illustr atio n 127 gOl 294577
294577
mandates.
3. Remov e tthe
he up per and the lowe r braces (3).
(3).

Illustration
Illustration 125 g0l2929H

Illustr atio n 128 gOl 294578

294578
1. Remove the upper and tthe
he lower radiator guar
guards
ds
( 1). 4. Remove bolts (4
(4)) and remove bolts (5).
(5).

Illustration
Illustration 126 g0l292 9l2

2. Attach Tooling (A) and

and a suitable lifting device onto
radiator top tank (2). The weight of the radiator is
approximately 227 kg (500 lb).

g01294579
Illustration 129

5. Remov e bolts (6)

(6)..
44 RENR9716-02
Disassembly and Assembly Section

g01292912
Illustration 132

1. Attac h Tooling (A) and a suita ble lifting dev ice onto
radiator top tank (2). The weight o fthe radiator is is
approximately 227 kg (500 lb).

go1294580
Illustration 130

6. Remove bolts (7). Remove bolts (8). Remove

support (9).

7. Repeat Steps 4 tthrough

hrough 6 for the opposite si
side.
de.

g01294602
Illustration 133

2. Install radiator (10).

(10). Install bolts
bolts (11).
(11). Repeat for
the opposite side.

g01294602
Illustration 131

8. Remove bolts (1
(11).
1). Repeat for the opposite side.
Remove radiator (10).

i02585957

Radiator Core - Install

SMCS Code: 1353-012-KO; 1353-012

Installation Procedure
Table 31

Required Tools

Part
Tool P ar t D e s c r i p t i o n Qty
Number Illustr atio n 134 gOl 294580

A 1 3 8 -7 5 7 5 Link Bracket 2
 3. Install supp ort (9).
(9). Install bolts (8).
(8). Install bolts (7).

RENR9716-02 45
Disassembly and Assembly Section

g01292911
Illustration 138

8. Install the upper and the lower radiator guard s (1).

(1).

End By :

a. Install the aftercooler. Refer to Disassembly and

Illustration 135 g0l294579
As se
semb
mb ly, “Af te rc oo le r - Ins tal
tall”
l” .

4. Install bolts (6).

i02444868

Engine Support (Front) -

Remove and Install
SMCS Code: 1154-010-FR

Removal Procedure (Type 1)

Start By :

a. Remove the vibration damper and the pulley.

Refer to
to Disassembly and Assembly, “Vibration
“Vibration
Damper and Pulley - Remove and Install”.
Install”.
Illustration 136 g0l294578

1. Supp ort the front of the engine.

5. Install bolts (4) and bolts (5).

6. Repe at Steps 3 through 5 for the opposite side.

g01221659
Illustration 139

2. Remov e bolts (1)

(1)..
Illustration 137 g0l294577
3. Remov e engine supp ort (2).
(2).
7. Install the upper a
and
nd the lower braces ((3).
3).
46 RENR9716-02
Disassembly and Assembly Section

Installation Procedure (Type 1) Installation Procedure (Type 2)

Illustration
Illustration 142 g0l22l66 3

1. Position engine sup port (2) on the engine. 1. Use a suitable lifti
lifting
ng device to position engine
support (4) on the engine. The weight of engine
2. Install bolts (1
(1).
). support (4) is approximately 35 kg (77 lb).

End By: 2 . Install bolts ((3).

3).

a. to
Install the vibration
Disassembly and damper and“Vibration
Assembly, the pulley.Damper
Refer End By:
and Pulley - Remove and Install”. a. Install the vibration damper and the pulley. Refer
to Disassembly and Assembly, “Vibration Damper
and Pulley - Remove and Install”.
Removal Procedure (Type 2)
Start By: i02440962

a. Remove the vibration damper and the pulley. Gear Group (Rear) - Remove
Refer to Disassembly and Assembly, “Vibr
“Vibration
ation
Dampe r an
and
d Pulley - Remove and Install
Install”.
”. SMCS Code: 1206-011; 1212-011

1 . Support the front o f the engine.

Removal Procedure
Table 32

Required Tools
Part
Tool Nu m b er P a r t D es c r i p t i o n Qt y

A 1 P -0 5 1 0 Dr ive r Gro up 1

Start By:

a. Remove the flywheel housing. Refer to

Disassembly and Assembly, “Flywheel Housing
- Remove and Install”.

Illustration 141 g0l2 2l66 3

2 . Remove bolts (3).

3 . Use a suitable lifting device to remove engine

support (4). The weight of engine support (4) is
approximately 35 kg (77 lb).
R E N R 9 7 1 6 -0 2 47
Disassembly and Assembly Section

4 . Use Tool
Tooling
ing (A) and a suitable pres s to remove
NOTICE the bearing from ge ar assembly (6(6).
).
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test 5. Remov e bolts (2
(2),
), gea r asse mbly (1), and shaft
ing, adjusting and re pair of the produc t. Be prepared to assembly (3).
collect the fluid with suitable containers before open
ing any compartment or disassembling any compo 6. Use Tooli
Tooling
ng (A) and a suitable press to remove
nent containing fluids. the bearing from ge ar assembly (1
(1).
).

Refer to Special Publication,

Publication, N ENG2500, “Caterpillar 7. Remove gear assembly (12
(12).
).
Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar 8. Remov e bolts ((5)
5) and
and gear assemblies (4).
products.

Dispose of all fluids according to local regulations and

mandates.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

9. Remov e bolts (1
(16)
6) and
and shaft assembly (17).

10. Remove bolts (13), thrust plates (14), and adapter

assemblies (15).
(15).

11 . Use bolt (13) in order to remove the sealing

plates. Remove the O-ring seals.

1 . Remo ve bolts (10), thrus t plat

plate
e (11)
(11),, and gear
assembly (9).

2 . Use Tooli
Tooling
ng (A) and a suitable press to remove
the bearing from ge ar assembly (9).
(9).

3. Remov e bolts (8
(8),
), gear assemb ly (6)
(6),, and shaft
assembly (7).
48 RENR9716-02
Disassembly and Assembly Section

i02442469

Gear Group (Rear) - Install

SMCS Code: 1206-012; 1212-012

Installation Procedure

Table 33
Required Tools

Part
Tool N u m b er Par t D es c r i p t i o n Qt y

A 1P-0510 D r iv e r G r o u p 1

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

Note: Apply clean engine oil to the bearings and the

shaft assemblies prior to installation on the engine.

Illustration 147 gOH5 l468

4. Refer tto
o Testing
Testing and Adjus ting, “R ear Gear Group
- Time” for additional information.

Note: Align the Timing Marks on gear assemblies (4)

with the Timing Marks on the rear housing and align
the dowels on gear assemblies (4) with the adapter
assemblies.

5. Position gear assem blies (4) and

and install bolts (5).
(5).
1. Install the O-ring seals and the sealing plates on
the cylinde r head
head.. 6. Install gea r assem bly (12).
(12).

2. Install ada pter assemb lies (15), thrus t plates ((14),

14), 7. Use Tooli
Tooling
ng (A) and a suitable press to install the
and bolts (13). bearing in gear assembly (1). Install the bearing to
a depth of 2.6 ± 0.5 mm (0.10 ± 0.02 inch).
3. Position shaft assemb ly (17
(17)) and install bol
bolts
ts (16)
(16)..
RENR9716-02 49
Disassembly and Assembly Section

8. Install shaft assem bly (3), gea r asse mbly (1), and
bolts (2).

9 . Use Tooli
Tooling
ng (A) and a suitable press to install the
bearing in gear assembly (6). Install the bearing to
a depth of 2.6 ± 0.5 mm (0.10 ± 0.02 inch).

10. Install shaft assembly (7), gear assembly (6), and

bolts (8).
11 . Use Tooling (A) and a suitable press to install the
bearing in gear assembly (9). Install the bearing to
a depth of 2.5 ± 0.5 mm (0.10 ± 0.02 inch).

Note: Ali gn the Tim ing Ma rk on ge ar as se mb ly (9)

with the Timing Mark on gear assembly (12).

12 . Install gear ass embly (9), thrust plate (11), and

Install 1. Rem ove two bolts (1). Ins tall Tooling (A) in the
bolts (10). crankshaft.

13. Tighten the bolts on gear assemblies (4) to a 2. Remo ve remaining bolts (1).
(1). Slide flywheel (2)
torque of 240 ± 40 N m (177 ± 30 lb ft). Tighten away from the engine on Tooling (A).
the bolts in the following sequence: 1, 4, 2, 5, 3,
6, 1, 4. 3. Attach a suitable lifting device to flywhee l (2). The
weight of flywheel (2) is approximately 130 kg
End By: (285 lb). Remove flywheel (2).

a. Install the flywheel housing. Refer to Disassembly 4. If necessary, use a hamm er and
and a punch in order
and Assembly, “Flywheel Housing - Remove and to remove ring gear (3) from flywheel (2).
Install”.
Installation Procedure
i02752668
Table 35

Flywheel - Remove and Install Required Tools

Part
SMCS Code: 1156-010
Tool N u m b er P ar t D e s c r i p t i o n Qty

Guide Stud
Removal Procedure A -
5 /8 -1 8 UNF by 11
11 inch
inch
2

Table 34 B 6 V -4 8 7 6 L u b ri c a n t -
Required Tools

Part
Tool N u m b er Pa r t D es c r i p t i o n Qt y

Guide Stud
A - 2
5 /8 -1 8 UNF by 11 inch
inch
 g01220437
Illustration 148

50 RENR9716-02
Disassembly and Assembly Section

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

Note: Ring gear (3) must be installed with the

chamfered side o f the teeth
teeth upward. The chamfered
side of the gear teeth will be facing toward the starting
motor when the flywheel is installed.

1. Raise the tempera ture o f ring gear (3). Install ri

ring
ng
gear (3) on flywheel (2).
1 . Use Tooling
Tooling (A)
(A) o ra punch and hammer in order
2 . Install Tooling (A) iin
n the crank sha ft. to puncture three or more holes in crankshaft rear
seal (1).
3 . Attach a suitable lifting device to flywheel (2). The
weight of flywheel (2) is approximately 130 kg 2 . Use Tooli
Tooling
ng (A) to remove cra nksh aft rear seal (1)
(285 lb). Position flywheel (2) on the crankshaft. and cranksh aft wear sleeve (2
(2).
).

4 . App ly Tool
Tooling
ing (B) to the threads of bolts (1
(1).
).
i02442921

5 . Install bolts (1
(1).
). Remo ve Tooling (A). Install Crankshaft Rear Seal - Install
remaining bolts (1).
SMCS Code: 1161-012
6. Tighten bolts (1) to a torq ue o f 100 ± 5 N m
(75 ±4 lb ft). Turn the bolts for an additional 180 ±
5 degrees. Installation Procedure
Table 37
7 . Che ck tthe
he flywheel runout. R efer to Test
Testing
ing and
Ad jus tin
ting,
g, “F
“Flyw
lyw hee l - Ins pect”
pe ct” . Required Tools

Part
Tool N u m b er Par t D es c r i p t i o n Qt y
i02442878
2 4 9 -2 9 3 7 0 ) S e a l L o c a to r A s 1
Cran k sh aft Rear Seal
Seal - Remo
Remo ve
5 P - 731 00) B o lt 3
SMCS Code: 1161-011
9 S - 8 85 80) N u t ( S e a l In s t a l l e r ) 1

6V - 61 43 d) S e a l I n s t a ll e r 1
Removal Procedure B
5P -1 733(2) S e a l L o c a to r A s 1
Table 36
5 P -730
-7309(
9(2)
2) B o lt 3
Required Tools
9 S -8858(
-8858(2)
2) N u t ( S e a l In s t a l l e r ) 1
Part
Tool Nu m b er Par t D es c r i p t i o n Qty 6V-6142(2) S e a l I n s t a ll e r 1

A 1U -7 6 0 0 Sli de Ha mm er Pu ller 1 0) Large crank shaft gear

(2) Small crankshaft gear

Start By:

a. Remove the flywheel. R efer to Disasse mbly and

 Asse
As se mb ly, “F lyw he
heel
el - Re mo
move
ve and Ins tall”
tall ” .

R E N R 9 7 1 6 -0 2 51
Disassembly and Assembly Section

b. Remove the electric starting motor. Refer to

NOTICE Disassembly and Assembly, “Electric Starting
Starting
Keep all parts clean from contaminants. Motor - Remove and Install”.

Contaminants may cause rapid wear and shortened NOTICE

component life. Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

1. Clean the outside diameter of the crankshaft.

Note: Install the crankshaft rear seal with the arrow

that shows the d irecti
irection
on of crankshaft rotati
rotation
on toward
the re ar of the engine.

2. Use Tool
Tooling
ing (B) to install cranks haft wear sleeve
(2) and cranksh aft rear seal (1) as a unit
unit..

End By:

a. Install the flywheel. Refer to Disassembly and

Asse
As se mb ly, “F lyw he
heel
el - Re mo
move
ve and Ins tall”
tall ” .

i02752908

1. Disconnect hose assem blies (1) from

from flywheel
Flywheel
and InstallHousing - Remove
housing (2).

2. Disco nnec t fuel filter

filter base (5) from flywheel
SMCS Code: 1157-010 housing (2). Reposition fuel filter base (5) and the
hose assemblies.
Removal Procedure
3. Remov e two bolts (4) and install Tooling
Tooling (B).
Table 38
4. Attach Tooling (A) and a suitable lifting device
Required Tools
to flywheel housing (2). The weight of flywheel
Part housing (2) is approximately 110 kg (245 lb).
Tool N u m b er Par t D es c r i p t i o n Qt y

A 138-7574 L in k B r a c k e t 2 5. Remov e remaining bolts (4),

(4), bolts (6), and bolts
(3). Remove flywheel housing (2) and the gasket
Guide Stud from the rea r housing.
housing.
B - 2
1/2-13 NC by 7 inch

Start By:

a. Remove the crankshaft rear seal. Refer to

Disassembly and Assembly, “Crankshaft Rear
 Seal - Remove”.

52 RENR9716-02
Disassembly and Assembly Section

Installation Procedure
Table 39

Required Tools

Part
Tool Nu m b er P ar t D e s c r i p t i o n Qty

A 1 3 8 -7 5 7 4 Lin k Bra cke t 2

Guide Stud
B - 2
1/2-13 NC by 7 inch

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

1. Install Tooling (B) iin

n the cy lind er block.

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

to flywheel housing (2). The weight of flywheel
housing (2) is approximately 110 kg (245 lb).

3. Position the gasket and flywheel housing (2) on

the rear housing. Install bolts (3), bolts (6), and
bolts (4).

4. Remov e Tool
Tooling
ing (B) and
and install remaining bolts (4).
5 . Tighten the bolts, as follows:

a. In a numerical sequence , tighten Bolt 1 through

Bolt 2 to a torq ue of 55 ± 10 N m (4
(41
1 ± 7 lb
lb ft).
ft).

b. In a numerical sequence, tighten Bolt 3

through Bolt 10 to a torque of 135 ± 20 N m
(100 ± 15 lb ft).

c. In a num eric al seque nce , tigh ten B olt 1

11
1
through Bolt 36 to a torque of 47 ± 9 N m
(35 ± 7 lb ft).

6. Repos ition fuel filter base (5)

(5) and the hose

assemblies.
housing (2). Connect fuel filter base (5) to flywheel

7 . Con nect hose assemblies (1) to flywhee l housing

(2).
R E N R 9 7 1 6 -0 2 53
Disassembly and Assembly Section

End By:

a. Install the ele ctric starting motor. Refer tto

o
Disassembly and Assembly, “Electric St Starting
arting
Motor - Remove and Install”.

b. Install the cran ksha ft rear seal. Re fer to

Disassembly and Assembly, “Crankshaft Rear

Seal - Install”.

i02443805

Vibration Damper and Pulley -

Remove and Install
SMCS Code: 1205-010
1. Remov e V-belt (1) from the engine.

Removal Procedure 2. Remov e two bolts (2) and install Tooling

Tooling (A).
Table 40
3. Remov e remaining bolts (2) an
and
d pulley (3).
(3).
Required Tools
4. Slide vibration dam per (4)
(4) along
along Tooling
Tooling (A
(A).
).
Part

Tool Nu m b er P ar t D e s c r i p t i o n Qt y 5. Attach a suitable lifting device onto vibration

Guide Stud damper (4). The weight of vibration damper (4)
A - 2
1/2-13 NC by 5 inch is approximately 34 kg (75 lb). Remove vibration
damper (4) from the adapter.

Installation Procedure
Table 41

Required Tools

Part
Tool N u m b er Par t Des c r i p t i o n Qt y

Guide Stud
A - 2
1/2-13 NC by 5 inch

g01221078
Illustration 159
54 RENR9716-02
Disassembly and Assembly Section

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

Illustration 16
161
1 g0l22 l272

1. Install Tooling (A) iin

n the adapter. 1. Remov e bolts (1) and adap ter (2).
(2).

2 . Attach a suitable lifting device onto vibration

damper (4). The weight of vibration damper (4)
is approximately 34 kg (75 lb). Position vibration
damper (4) on the adapter.

3 . Install pulley (3) and bolts (2).

4 . Remo ve Tooli
Tooling
ng (A). Instal
Installl remaining bolts (2).
Tighten bolts (2) to a torque of 135 ± 20 N m
(100 ± 15 lb ft).

5 . Install V-be lt (1
(1)) on tthe
he engine.

i02444403
Illustration
Illustration 162 g0l22l27 6

Crankshaft Front Seal - 2 . Use Tool

Tooling
ing (A) or a punch and ham mer in orde r
Remove to puncture three or more holes in crankshaft front
seal (4).
SMCS Code: 1160-011
3 . Use Tool
Tooling
ing (A) to remove cra nksh aft front seal
Removal Procedure (4).

Table 42 4 . If necessary, use Tooling (A) or a punch and

hamm er in order tto
o puncture three or more holes
Required Tools
in crankshaft wear sleeve (3). Use Tooling (A) to
Part remove cranksh aft wear sleeve (3).
Tool N u m b er P a r t D es c r i p t i o n Qt y

A 1U -7 6 0 0 Sli de Ha mm er Pu lle r 1

Start By:

a. Remove the crankshaft vibration damper and

pulley. Refer to Disassembly and Assembly,
“Vibration Damper and Pulley - Remove and
Install”.
RENR9716-02 55
Disassembly and Assembly Section

i02444556

Crankshaft Front Seal - Install

SMCS Code: 1160-012

Installation Procedure

Table 43
Required Tools

Part
Tool N u m b er P ar t D es c r i p t i o n Qty

5 P -1 7 3 3 S e a l L o c a to r 1

5 P -1 7 3 7 B o lt 3
B
9 S -8 8 5 8 N u t ( S e a l In s t a l l e r ) 1
3. Install ada pter (2)
(2) and bolts (1)
(1)..
6 V -6 1 4 2 S e a l In s t a l l e r 1
End By:

NOTICE a. Install the crankshaft vibration damper and pulley.

Keep all parts clean from contaminants. Refer to
to Disassembly and Assembly, “Vibration
“Vibration
Damper and Pulley - Remove and Install”.
Install”.
Contaminants may cause rapid wear and shortened
component life.
i02292422

1. Clean the outside diameter of the crankshaft. Gearr Group (Fron

Gea (Fron t) - Remo
Remo ve
SMCS Code: 1206-011

Removal Procedure
Start By:

a. Remove the front housing. R efer to Disassembly

and Assembly, “Housing (Front) - Remove”.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened
component life.

2. Use Tooling
Tooling (B) tto
o install cranks haft front seal (4)
and crankshaft wear sleeve (3) as a unit.

Note: Install the crankshaft front seal with the arrow

that shows the directi
direction
on of crankshaft rotati
rotation
on toward
the front o f the
the engin
engine.
e.
56 RENR9716-02
Disassembly and Assembly Section

1. App ly clean engine oil to shaft (7), the bearing

bore, and the thrust faces prior to installation.
Install shaft (7) and bolts (6). Tighten bolts (6) to a
to
torqu
rqu e o f 55 ± 10 N m (41
(41 ± 7 lb ft).

1. Remov e bolts (5
(5)) and gear assembly (4).

2 . Remo ve bolts (3
(3)) and plat
plate
e (2)
(2).. Remo ve gear
assembly (1).

3. Remov e bolt
bolts
s (6)
(6) and shaft ((7).
7). 2 . Position gea r asse mbly (1) on the shaft. Install
plate (2) and bolts (3).

i02691256
3 . Install ge ar assemb ly (4)
(4) and bolts (5).
(5).
Gear Group (Front) - Install End By:
SMCS Code: 1206-012
a. Install the front housing. R eferto Disassembly and
Install
As se mb ly, “H ou
ousin
sing
g (Fro nt) - Ins tall
tall”” .
Installation Procedure

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.
R E N R 9 7 1 6 -0 2 57
Disassembly and Assembly Section

i02445219

Housing (Front) - Remove

SMCS Code: 1151-011

Removal Procedure

Start By:

a. Remove the wate r temperature regu lator h

housing
ousing..
Refer to Disassembly and Assembly, “Water
Temperature Regulator Housing - Remove and
Install”.

b. Remove the water pum

pump.
p. Refer tto
o Disassemb ly
and Assembly, “Water Pump - Remove”.

c. Remove the cranks haft front seal. Refer tto

o
Disassembly and Assembly, “Crankshaft Front
Seal - Remove”.

d. Remove the front engine support. Refer tto

o
Disassembly and Assembly, “Engine Support 1 . Disconnect hose assemblies (2) ffrom
rom front
(Front) - Remove and Install”. housing (4).

e. Remo ve the alternator. Refer to Disasse mbly and 2. R emove covers (1).
Asse
As se mb ly, “Alt er na tor
to r - Re mo ve and Ins tall”
tal l” .
3. Remo ve alterna tor bracket (3)
(3) from
from front housing
f. Remov e the cranksh aft position sensor. Refer to (4).
Disassembly and Assembly, “Crankshaft Position
Position
Sensor - Remove and Install”.

g. Remove the camshaft position sensor. Refer to

Disassembly and Assembly, “Camshaft Position
Sensor - Remove and Install”.

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection,
inspection, maintenance, test
ing
ing,, adjus ting and re pair of the produc t. Be prepared to
collect the fluid with suitable containers before open
ing any compartment or disassembling any compo
nent containing fluids.

Illustration
Illustration 170 g0 l22l9 4l
Refer to
to Special Publicat
Publication,
ion, NENG 2500, “C aterpillar
Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar 4. Remov e bolts (5
(5)) and damp ers (6).
products.

Dispose of all fluids according to local regulations and

mandates.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.
58 RENR9716-02
Disassembly and Assembly Section

i02445708

Housing (Front) - Install

SMCS Code: 1151-012

Installation Procedure

Table 44
Required Tools

Part
Tool N u m b er Par t D e s c r i p t i o n Qt y

A 4 C -9 6 1 2 S il ic o n e S e a la n t 1
Illus tratio n 171 901221953
901221953

NOTICE
5. Discon nect bracke t (7) and elbows (8
(8).
). Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

6. Remove adapters (9).

7. Attach a suitable lift

lifting
ing device to front housing (4).
The weight of front housing (4) is approximately
70 kg (155 lb). 1. Apply Tooling (A(A)) tto
o tthe
he bottom o f front housing
(4) at the junction of the cylinder block and the
8. Remove bolts (10) and bolts (11
(11).
). engine oil pan.

9. Remove front housing (4)

(4) and the gasket. 2. Attach a suitable lift
lifting
ing device to front housing (4).
The weight of front housing (4) is approximately
70 kg (155 lb). Position the gasket and front
housing (4) on the dowel pins on the cylinder
block.

3. Install bolts (10) and bolts (1

(11).
1).

4. Trim the gaske t between the front housing and the

cylinder block even with the bottom
bottom o f the front
housing.

5. Install adapters (9).

R E N R 9 7 1 6 -0 2 59
Disassembly and Assembly Section

Illustration
Illustration 174 g0l22l95 3

6. Conn ect elbows (8) a

and
nd bracket (7).

Illustration
Illustration 177 g0l22l89 3

9. Install alternator bracket (3) on front housing (4).

10. Install covers (1).

11. Connect hose assemblies (2) to front housing (4).

End By:

a. Inst
Install
all the camshaft position
position sensor.
sensor. R efe rto
Illustration 175
g01221941 Disassembly and Assembly, “Camshaft Position
Sensor - Remove and Install”.

b. Inst
Install
all the crankshaft position
position sensor.
sensor. R efe rto
Disassembly and Assembly, “Crankshaft Positio
Position
n
Sensor - Remove and Install”.

c. Install
Install the alternato
alternator.
r. R efe rto Disassembly and
As se
semb
mb ly, “Alt er na to r - Re mo
move
ve and Ins tall
tall”” .

d. Install the front engine support. Referto

Disassembly and Assembly, “Engine Support
(Front) - Remove and Install”.

e. Install the cra nksh aft front seal. R efer to

Disassembly and Assembly, “Crankshaft Front
Illustration
Illustration 176 gOH 5l44l Seal - Install”.

7. Install dam pers (6) and bolts (5)

(5).. f. Install
Install the
the wa ter pump. R efer toto Disassembly and
As se
semb
mb ly, “W ate r Pum p - Ins tal
tall”
l” .
8. Tighten the bolts to a torque o f 240 ± 40 N m
(177 ± 30 lb ft). Tighten the bolts in the following g. Inst
Install
all the
the wate r temperature
temperature regulator housi
housing.
ng.
sequence: 1, 4, 2, 5, 3, 6, 1, 4. Refer to Disassembly and Assembly, “Water
Temperature Regulator Housing - Remove and
Install”.
60 RENR9716-02
Disassembly and Assembly Section

i02290579

Housing (Rear) - Remove

SMCS Code: 1157-011

Removal Procedure

Start By:

a. Remove the reargearg roup. Referto Disassembly

and Assembly, “Gear Group (Rear) - Remove”.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

1. Remov e the bolts that hold the engine oil pan to

the rear housing.

2 . Disconnect hose assembly (1).

(1).

3 . Remove bolts (2).

4 . Attach a suitable lift

lifting
ing device to rear housing (4).
The weight of rear housing (4) is approximately
84 kg (185 lb).

5 . Remove bolts (3).

6. Remo ve rear housing (4

(4)) and the gasket.

i02291566

Housing (Rear) - Install

SMCS Code: 1157-012

Installation Procedure
Table 45

Required Tools

Part
Tool N u m b er Par t Des c r i p t i o n Qt y

A 4 C -9 6 1 2 Sili co ne Se ala nt 1
RENR9716-02 61
Disassembly and Assembly Section

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

1. at
Apply Tooling of
the junction
the (A)tthe
to the
he bottom
c ylinder o f the
block andrear
the housing
engine
oil pan.

2 . Attach a suitable lifting device to rear housing (4).

The weight of rear housing (4) is approximately
84 kg (185 lb).

3. Position the gask et on rear housing (4).

4 . Position rear housing (4) on the cylinde r block.

block.
Install bolts (3). Tighten bolts (3) in a numerical
seq uen ce to a torqu e o f 55 ± 10 N m (41
(41 ± 7 lb ft).
g01147138
Illustration 180

5 . Trim the gasket between the rear housing and the

cylinder block even with the bottom of the rear
housing.
62 RENR9716-02
Disassembly and Assembly Section

1 2

Illustration 183 gOH4794l

1. Remov e bolts
bolts (1) and valve mechanism covers
(2).

Installation Procedure

NOTICE
6. Install bolts (2).
(2). Keep all parts clean from contaminants.

7. C onne ct hose asse mbly (1)

(1).. Contaminants may cause rapid wear and shortened
component life.
8. Install the bolts that hold the eng ine oil pan to tthe
he
rear housing.
1 2
9 . Tighten all the bolts that hold the engine oil pan
evenly in order to raise the engine oil pan into
position.

End By:

a. Install the reargeargroup. Referto Disassembly

and Assembly, “Gear Group (Rear) - Install”.

i02293132

Valve Mechanism Cover -

Illustration 184 gOH4794l
Remove and Install
1. Position valve mecha nism covers (2)
(2) o
on
n the valve
SMCS Code: 1107-010
mechanism cover base. Install bolts (1).

Removal Procedure
i02293148

NOTICE Valve Mechanism Cover Base -

Keep all parts clean from contaminants.
Remove and Install
Contaminants may cause rapid wear and shortened
component life. SMCS Code: 1120-010

Removal Procedure
Start By:

a. Remove the valve mechanism cover. Refer to

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

R E N R 9 7 1 6 -0 2 63
Disassembly and Assembly Section

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

3 4 5

Illustration 186 gOH47965

gOH47965

1. Install the seal o

on
n valve mecha nism co ver base
(3).

3 4 5 2 . Position valve mech anism cov er base ((3)

3) on
on tthe
he
cylinder head and install bolts (4).
Illustration 185 gOH47965
gOH47965

3. Position harness asse mblies (5) on the electronic

1. Remov e tube assem blies (1
(1).
). unit injectors. Tighten the cap nuts to a torque of
1.70 ±0.25 N m (15 ±2 lb in).
2. D isconn ect harness assem blies (5
(5)) and harness
assembly (2). 4. Connect harness assembly (2).

3. Remov e bolts ((4).

4). 5 . Install tube assemb lies (1).

4. Remove valve mechanism co ver base (3

(3)) and tthe
he End By:
seal from the cy linder head
head..
a. Install the valve mechanism cover. Refer to
Installation Procedure Disassembly and Assembly, “Valve Mechanism
Cover - Remove and Install”.
NOTICE
Keep all parts clean from contaminants. i02293245

Contaminants may cause rapid wear and shortened Rocker Arm and Shaft -
component life.
Remove
SMCS Code: 1102-011

Removal Procedure
Table 46

Required Tools

Part
Tool Nu m b er P ar t D es c r i p t i o n Qt y

A 1 2 4 -2 9 4 6 Liftin g Bra cke t 1

64 RENR9716-02
Disassembly and Assembly Section

Start By:

a. Remove the valve mechanism cover. Refer to

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

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

1 2

1. Remov e valve rocke r arms (11) and electronic unit

injector rocker arm (3) from rocker sha ft assembly
(4).

2. Remov e jam nut (7) from adjustm ent screw (8)

(8)..

3. Remove adjustment screw (8) from val

valve
ve rocker
arms (11).

4. Remov e button (10) from adjustm ent screw (8)

(8)..
Remove O-ring seal (9) from the adjustment
screw.

5. Remov e jam nut (2)

(2) from unit injector adjus tment
screw (1).
3 4

Illustration 187 g0H48045

6. Remov e unit injecto r adjustm ent screw (1) from
electronic unit injector rocker arm (3).
1. Remov e bolts ((2).
2).
7. Remo ve button (6) from unit injector adjustment
screw (1). Remove O-ring seal (5) from the unit
2. Use Tool
Tooling
ing (A) tto
o remove rocke r arm shaft
injector adjustment screw.
screw.
assembly (4), valve rocker arms (3), and electronic
unit injector rocker arms (1) as a unit.
i02451120

i02451112 Rocker Arm - As semb le

Rock er Arm - Disassemble SMCS Code: 1123-016
SMCS Code: 1123-015
A s s em b l y Pr o c ed u r e
Disassembly Procedure
NOTICE
Start By: Keep all parts clean from contaminants.

a. Remove the rocker arms and the rocker shaf

shaft.
t. Contaminants may cause rapid wear and shortened
Refer to Disassem bly and Assembly, “R ocker Arm
Arm component life.
and Shaft - Remove”.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.
RENR9716-02 65
Disassembly and Assembly Section

i03203773

Rock er Arm and Shaft - Insta

Install
ll
SMCS Code: 1102-012

Installation Procedure
Table 47
Required Tools

Part
Tool N u m b er P a r t D es c r i p t i o n Qt y

A 124-2946 L i fti n g B r a c k e t 1

NOTICE
Note: Do not reuse the O-ring seal on the adjustment Keep all parts clean from contaminants.
screw if the button is removed from the adjustment
screw. Contaminants may cause rapid wear and shortened
component life.
1. Install O-ring seal (9) iin
n button (10).

2. Use a soft ha mm er to seat button (10) on

adjustment screw (8
(8).
).
3. Install adjus tment screw (8) in valve roc ker arms
(11). Install jam nut (7) on the adjustment screw.

4. Install O-ring seal (5) in button (6).

5. Use a soft hamme r to seat button (6) on unit

injector adjustment screw (1).
(1).

6. Install unit injector adjustm ent screw (1) in

electronic unit injector rocker arm (3). Install jam
nut (2) on the unit injector adjustment screw.

7. Lubricate roc ker sha ft assem bly (4) with clean

engine oil.

8. Install valve roc ker arms (11

(11)) and electronic unit
3 4
injector rocker arm (3) on rocker shaft assembly
(4). g01148045
Illustration 190

End By:

a. Install the rocker arms and the rocker shaft. Refer

to Disassembly and Assembly, “Rocker Arm and
Shaft - Install”.

g01325993
Illustration 191
66 RENR9716-02
Disassembly and Assembly Section

1. Position rock er arm shaft asse mbly (4), valve

rocker arms (3), and electronic unit injector rocker NOTICE
arms (1) as a unit with Tooling (A) on the cylinder Care m ust be taken to ensu re that fluids
fluids are con tained
head. during performance of inspecti
inspection,
on, maintenance, test
ing
ing,, adjus ting and repa ir of the produc t. Be prepared to
2. Install bolts (2
(2)) and tighten to a torque of collect the fluid with suitable containers before open
50 ± 5 N m (37 ±4 lb fft) t) plus 45 ± 5 degree turn. ing any compartment or disassembling any compo
Tighten the bolts in the following sequence: 2, 3, nent containing fluids.
4, 1.
Referto Special Publication, NENG2500, “Caterpillar
3. Adjus t the valve lash for the inlet valves and the Dealer Service Tool Catalog” for tools and supplies
exhaust valves. Referto Testing and Adjusting, suitable to collect and contain fluids on Caterpillar
“Engine Valve Lash - Inspect/Adjust”. products.

4. Adjus t the electron ic unit injectors. Re fert o Test

Testing
ing Dispose of all fluids according to local regulations and
and Adjusting, “Electronic Unit Injector - Adjust”. mandates.

End By:
NOTICE
a. Install the valve mechanism cover. Refer to Keep all parts clean from contaminants.
Disassembly and Assembly, “Valve Mechanism
Cover - Remove and Install”. Contaminants may cause rapid wear and shortened
component life.

i02446003
NOTICE
Cyl ind er He
Hea
ad - Remo
Remo ve Do not turn the crankshaft or the camshaft while the
camshaft gear is removed. If the rear gear group is
SMCS Code: 1100-011 not correctly timed
timed during installation, interferenc e can
occur between the pistons and the valves, resulting in
Removal Procedure damage to the engine.

Table 48
1. Drain tthe
he coo lant from
from the cooling system into a
Required Tools suitable container for storage o r disposal.
disposal. Refer
Part to Operation and Maintenance Manual, “Cooling
Tool N u m b er Par t Des c r i p t i o n Qt y System Coolant - Change”.

A 138-7573 L in k B r a c k e t 3

B 1U - 9 2 0 0 L e v e r P u l le r H o is t 1

Start By:

a. Remo ve tthe
he elec tronic unit injectors. Refer to
Disassembly and Assembly, “Electronic Unit
Injector - Remove”.

b. Remove the val

valve
ve mechanism cov er ba
base.
se. Refer
to Disassembly and Assembly, “Valve Mechanism
Cover Base - Remove and Install”.

c. Remove the fuel ttransfer

ransfer pump. R efer to
Disassembly and Assembly, “Fuel Transfer Pump
- Remove”. 2 . Remove cover (1).
R E N R 9 7 1 6 -0 2 67
Disassembly and Assembly Section

3. R
Ree m ov e b olts (2) and g e a r (3). 6. R
Ree m o v e e lb o w (8). D is c o n n e c t hose a s s e m b ly (9).

4. Remov e bolts ((4),

4), thrust plate (5),
(5), a
and
nd adapte r
assembly (6).

g01148489
Illustration 197

7. Remov e elbow (11)

(11) and cover (10).

8. Disconnect harness assembly (12) an

and
d harness
assembly (13).

9. R emove brack et (14).

5. Use bolt (4
(4)) in orde r to remove sealing plate (7).
(7).
Remove the O-ring seals.
 g01148492
Illustration 198

68 RENR9716-02
Disassembly and Assembly Section

10. Remove bolts (15) and damper (16). 15. Attach Tooling (A) and a suitable lifting device to
cylinder head (25). Attach Tooling (B) to the side
of cylinder head (25) that is near the turbocharger.
The weight o f cylinder hea
headd (25)
(25) is approximately
365 kg (800 lb).

16. Remove bolts (26) and bolts (27).

17. Remove cylinder head (25). Remove the gaskets,

O-ring seals, and the spacer plate.

i02446286

Cylinder Head - Install

SMCS Code: 1100-012

11. Remo ve bolts ((17).

17). Remove sealing plate (1
(18)
8) Installation Procedure
and adapter assembly (19).
Table 49

Required Tools

To o l Par t N u m b er P ar t D e s c r i p t i o n Qty

A 1 3 8 -7 5 7 3 Lin k Bra cke t 3

B 1U-9200 L e v e r P u ll e r H o is t 1

C 4C-5593 An ti- Se ize Co mp oun d 1

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.
g01148522
Illustration 200

12. Disconnect clip assembly (22) from the cylinder

head. Remove tube assemblies (21).

13. Remove bracket (20).

14. Disconnect tube assembly (23) and remove tube
assembly (24).

g01148568
Illustration 202

g01148568
Illustration 201
R E N R 9 7 1 6 -0 2 69
Disassembly and Assembly Section

38_ 36_ 34 32 ._30_ 28_ 27 _ 3J_ 33_ 35 37 39

o o o o o o o o o o O o O

0 0 0 0 0 0 !i

0 0 0 0 0 0 h
i 0 0 0 0 0 (26) I

g01148791
Illustration
Illustration 20 3

1. Install the gaskets, O-ring seals, and the space r

plate on the engine.

2 . Attach Tooling (A) and a suitable lifting

lifting device to
cylinder head (25). Attach Tooling (B) to the side
of cylinder head (25) that is near the turbocharger.
The weight o f cyli
cylinder
nder head (25
(25)) is approximately
365 kg (800 lb).

3. Position cylind er head (25) on the dowel pins in

the cy linder block
block..

Note: Ap ply Tooli

Tooling
ng (C) to the bolt thr ea ds and
both sides o f the wash ers. T ighten the bolts in the
following step sequence:
Illustration 204 gOH48522
gOH48522

4. Install bolts
bolts (26) and bolts (27) according to the
following procedure. 5. Con nect tube asse mbly (23) and install
install tube
assembly (24).
a. In a numerical sequen ce, tighten Bo lt ((1)
1)
through Bolt (26) to a torque of 270 ± 15 N m 6. Install bracket (20
(20).
).
(19 9 ± 1
11
1 lb ft).
7. Connect clip assembly (22). Install tube
b. In a numerical sequ ence, tighten Bolt (1
(1)) assemblies (21).
(21).
through Bolt (26) to a torque of 450 ± 15 N m
(33 2 ± 1
11
1 lb ft).

c. In a numerical sequenc e, again tighten Bolt (1

(1))
through Bolt (26) to a torque of 450 ± 15 N m
(33 2 ± 1
11
1 lb ft).

d. In a numerical sequen ce, tighten Bolt (27)

through Bolt (39) to a torque of 45 ± 7 N m
(33 ± 5 lb ft).
 g01148516
Illustration 205

70 RENR9716-02
Disassembly and Assembly Section

8. Install adap ter asse mbly (19) and sealing plate 11 . Install bracket (14).
(18). Install bolts (17).
12 . Connect harness assembly (13) and harness
assembly (12).

13 . Install cover (10) and elbow (11).

g01148492
Illustration 206

14 . Connect hose assembly (9). Install elbow (8).

Illustration
Illustration 207 gOH 5l44l

9. Install dam per (16) and bolt

bolts
s (15).

10. Tighten the bolts to a torque of 240 ± 40 N m

(177 ± 30 lb ft). Tighten the bolts in the following
sequence: 1, 4, 2, 5, 3, 6, 1, 4.

15 . Install new O-ring seals and sealing plate (7).

16. Install adap ter asse mbly (6), thrus t plate (5),
(5), and
bolts (4).
 g01148489
Illustration 208

R E N R 9 7 1 6 -0 2 71
Disassembly and Assembly Section

End By:

a. Inst
Install
all the fuel
fuel transfer pump.
pump. R eferto Disassembly
and Assembly, “Fuel Transfer Pump - Install”.

b. Install
Install the valve mechanism cover base.
base. R efer to
Disassembly and Assembly, “Valve Mechanism
Cover Base - Remove and Install”.

c. Inst
Install
all the electronic unit
unit injectors.
injectors. Re ferto
Disassembly and Assembly, “Electronic Unit
Injector - Install”.

i02446397

Camshaft - Remove
SMCS Code: 1210-011

Removal Procedure
Table 50

Required Tools

To o l Par t N u m b er P ar t D es c r i p t i o n Qt y

A 177-8001 P ilo t S le e v e 2

B 249-2936 Ad ap te r 1

274-79320)
C or G uide 1
Illustration
Illustration 213 gOH5l468
274-7933(2)

17. Install gear (3) and bolts (2). 0) Front Removal

(2)
(2) Re ar Remova l

18. Tighten the bolts to a torque of 240 ± 40 N m

(177 ± 30 lb ft). Tighten the bolts in the following Start By:
sequence: 1, 4, 2, 5, 3, 6, 1, 4.
a. Remove the rocker arms and the rocker shaft
shafts.
s.
Referto Disassembly and Assembly, “Rocker Arm
and Shaft - Remove”.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

NOTICE
Do not turn the crankshaft or the camshaft while the
camshaft gear is removed. If the rear gear group is
not correctly timed
timed during installation, interferenc e can
occur between the pistons and the valves, resulting in
damage to the engine.
19. Install cover (1).

20. Fill the cooling system. Refer to Operation and NOTICE

Maintenance Manual, “Cooling System Coolant Care must be used when removing or installing the
- Change”. camshaft. Do not damage the finshed surfaces of the
camshaft or the camshaft bearings.
72 RENR9716-02
Disassembly and Assembly Section

1. Drain the coolant from tthe

he cooling sy stem into a
suitable container for storage or disposal. R efer
to Operation and Maintenance Manual, “Cooling
System Coolant - Change”.

5 . Use bolt (4) in order to remove sealing plate (7).

Remove the O-ring seals.

2. Remov e cover ((1).

1).

g01160256
Illustration 219

6. Remov e elbow (9) and cove r ((8).

8).

3 . Remove bolts (2) and gear (3).

g01160259
Illustration 220

7. Remov e bolts (10) and damp er (11)

(11)..

4 . Remove bolts (4), thrust plate (5), and adapter

assembly (6).
R E N R 9 7 1 6 -0 2 73
Disassembly and Assembly Section

Note: Rotate the camshaft during removal. This will

prevent the
the camshaft from bindi
binding
ng in the camsh aft
bearings.

i02446568

Camshaft - Install
SMCS Code: 1210-012

Installation Procedure
Table 51

Required Tools

Part
8. Remov e bolts ((12).
12). Remove sealing plate (13) an
and
d Tool Nu m b er Par t D e s c r i p t i o n Qt y
adapter assembly (14). A 177-8001 P il o t S le e v e 2

9. B 2 4 9 -2 9 3 6 A d a p te r 1

274-79320)
C or Guide 1
15 274-7933(2)

D 8 T -2 9 9 8 L u b r ic a n t 1
0) Front Removal
(2)
(2) Re ar Remova l

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

Illustration
Illustration 222 g0H60265
NOTICE
Do not turn the crankshaft or the camshaft while the
10. Install Tooling (A) and Tooling (B) on the rear of camshaft gear is removed. If the rear gear group is
camshaft (15). Install Tooling (A) on the front of not correctly timed
timed during installation, interferenc e can
camshaft (15).
occur between the pistons and the valves, resulting in
damage to the engine.
11 . Install Tooling (C) on the front housing or the
rear housing. Tooling (C) is used to support the
camshaft. NOTICE
Care must be used when removing or installing the
Note: It is necessary to install Tooling (A) and Tooling camshaft. Do not damage the finshed surfaces o f the
(B) on the camshaft. Tooling (A) and Tooling (B) will camshaft or the camshaft bearings.
support the camshaft as the camshaft is moved out
of the cylinder head and into Tooling (C). Align the
camshaft with the bore of Tooling (C). 1. Ensure that the camsh aft and camshaft bearings
are thoroughly clean. Lubricate the camshaft
Note: Avoid
Av oid lifting the cam sha ft. The ca ms ha ft sh ould
oul d lobes with a 50/50 mixture of Tooling (D) and clean
rest on Tooling (A) and Tooling (B). Lifting o f the engine oil. Apply a thin coat of clean engine oil on
camshaft can cause misalignment as the camshaft the camshaft bearings.
is removed, resulting in damage to the camshaft
bearings.

12. Carefully sl
slide
ide the camshaft out of the cylinder
head for removal. Use two technicians to remove
the camshaft. Keep the camshaft level while the
 camshaft is being removed from the cylinder
head. The weight o f the cam shaft is approximately
35 kg (77 lb).

74 RENR9716-02
Disassembly and Assembly Section

15

g01160265 g01160259
Illustration 223 Illustration 225

2. Install Tooling (A) and Tooling (B) on the re ar of

camshaft (15). Install Tooling (A) on the front of
camshaft (15).

3 . Install Tooling (C) on the front housing or the

rear housing. Tooling (C) is used to support the
camshaft.

4 . Use two technicia ns to inst

install
all the camsh aft. Use
Tooling (C) to assist in aligning the camshaft
with the camshaft bearings. Carefully slide
the camshaft into the cylinder head. Keep the
camshaft level while the camshaft is being
installed in the cylinder head. The weight of the
Illustration
Illustration 226 gOH 5l44l
camshaft is approximately 35 kg (77 lb).

Note: Rotate the camshaft during installation. This 7 . Install da mp er (11)

(11) and bolts (10).
will prevent the camshaft from binding in the camshaft
bearings. 8. Tighten the bolts to a torque of 240 ± 40 N m
(177 ± 30 lb ft). Tighten the bolts in the following
5 . Remo ve Tooling (A
(A)) and Tooli
Tooling
ng (B) from the sequence: 1,4,2, 5, 3,6,1, 4.
camshaft.

g01160256
Illustration 227

9 . Install cover (8) and elbow (9).

6. Install ada pter assemb ly (14) and sealing plate
(13). Install bolts (12).
R E N R 9 7 1 6 -0 2 75
Disassembly and Assembly Section

Illustration 231 gOH 5l468

10. Install new O-ring seals and sealing plate (7). 12. Install gear (3) and bolts (2).

13. Tighten the bolts to a torque of 240 ± 40 N m

(177 ± 30 lb ft). Tighten the bolts in the following
sequence: 1,4,2, 5, 3,6,1, 4.

11 . Install adapter assembly (6), thrust plate (5), and

bolts (4).

14. Install cover (1).

15. Fill the cooling system. Refer to Operation and

Maintenance Manual, “Cooling System Coolant
- Change”.

End By:

a. Install the rocker arms and the rocker shafts.

Refer to Disassembly and Assembly, “Rocker
Arm s and Shaft
Sh aft - Ins tall ” .

g01222230
Illustration 230
76 RENR9716-02
Disassembly and Assembly Section

i02451045 Note: Tooling (C) is installed on the outside of the

cylinder head. Tooling (C) is required in order to
Camshaft Bearings - Remove remove all the
the cam shaft bearings from the cylinder
head.
SMCS Code: 1211-011
4. Use Tooli
Tooling
ng (A) to remove ca msh aft bearing (1)
Removal Procedure from the c ylinder head.

Table 52 5. Remov e Tool

Tooling
ing (B) from Tooling
Tooling (A) and remove
the camshaft bearing.
Required Tools

To o l Par t N u m b er Par t Des c r i p t i o n Qt y

i02451063
Camshaft Bearing Tool
A 8S -2 24 1 1
Group Camshaft Bearings - Install
9 U -7 2 2 2 C a m s h a ft B e a rin g P ilo t 1
SMCS Code: 1211-012
B Taperlock Stud
8M-8778 1
1/2 -1 3 by 1 9/
9/16
16 iinc
nch
h
Installation Procedure
C 9U-7210 P u l l e r P l a te 1
Table 53

Start By: Required Tools

To o l Par t N u m b er P a r t D es c r i p t i o n Qty
a. Remove the camshaft. Referto Disassembly and
Asse
As se mb ly, “C am sh aft - Re m ov e” . A 8 S -2 2 4 1 Camshaft Bearing Tool 1
Group

NOTICE 9U-7222 C a m s h a f t B e a r in g P ilo t 1

Keep all parts clean from contaminants. B Taperlock Stud
8M-8778 1
1/
1/2
2 -13 by 1 9/1
9/16
6 inch
inch
Contaminants may cause rapid wear and shortened
component life. C 9U-7210 Puller Plate 1

D 9 U -7 2 2 3 A li g n m e n t B u s h in g 1

9 U -7 2 1 3 B a c k u p Pla te 1
E Bolt
OS-1621 1
1/
1/2
2 -1 3 by 1 in
inch
ch

F 9 U -7 2 1 4 Spacer Plate 1

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

Illustration 233 gOH59745

gOH59745

1. Remov e the No. 7 cam shaft bearing (rear). Work

from the rear of tthe
he engine to the front of the
engine.

2. Install the small end o f Tooling (B) iin

n camsha ft
bearing (1).

3. Positio n Tooling (C) ov er Tooling (A). Install

Tooling (A) through the cylinder head on Tooling
(B).

g01159754
 Illustration 234

R E N R 9 7 1 6 -0 2 77
Disassembly and Assembly Section

1. Install the No. 7 camsha ft bearing (rear), as Note: When the chamfer of Tooling (E) contacts the
follows: face of the camshaft bore, the camshaft bearing is
properly installed.
a. Insert the large end of Tooling (B) into the No.
7 camshaft bore.

b. Position Tooling (C) ove r Tooling (A). Install

Tooling (A) through the cylinder head on
Tooling (B).

c. Position cams haft bearing (1) on Tooling (B

(B).
).
Install Tooling (E) on Tooling (B).

Note: Refer to Specifications,

Specifications, “Cylinder Head” for
appropriate informat
information
ion for the orientati
orientation
on of tthe
he
camshaft bearings in the cylinder head.

d. Use Tooling (A(A)) in order to pull camshaft

bearing (1) into the camshaft bore.

Note: When the chamfer of Tooling (E) contacts the 3. Install the No.
No. 1 cams haft bearing (front), as
face o f the cam shaft bore, the cams haft bearing is follows:
properly installed.
a. Insert tthe
he large end o f Tooling (B) into the No.
1 camshaft bore. Assemb le Tool
Tooling
ing (A) and
and
Tooling (D) on Tooling (B).

b. Position camshaft bearing (1) on Tooling (B).

Install Tooling (E) and Tooling (F) on Tooling
(B).

Note: Refer to Specifications,

Specifications, “C ylinder Head ” for
appropriate information for the location and the
orientation
orientation of tthe
he camshaft bearings in the cylinder
head.

Note: Tooling (F)

(F) is used to seat the No. 1 cams haft
bearing to the correct depth in the camshaft bore.

c. Use Tooling (A) in orde r to pull the

the No. 1
2. Install the No. 6 throug h No. 2 cams haft bearings, camshaft bearing into the No. 1 camshaft bore
bore..
as follows: When the chamfer of Tooling (E) contacts
the face of the camshaft bore, the camshaft
a. Insert the large end o f Tooli
Tooling
ng (B) into the bearing is properly installed.
camshaft bore.
End By:
Note: Use Tooling (D) to align Tooling (A) and Tooling
(B) with the camshaft bearing bores. Install Tooling a. Install the camshaft. Refer to Disassembly and
(D) in the inside diameter of any installed camshaft As se mb ly, “C am sh aft - Ins tal
tall”
l” .
bearing between Tooling (A) and Tooling (B).

b. Install Tooling (A) on Tooling (B). Position

camshaft bearing (1) on Tooling (B). Install
Tooling (E) on Tooling (B).

Note: Refer to Specifications,

Specifications, “Cylinder Head” for
appropriate information for the location and the
orientation
orientation of tthe
he c amshaft bearings in the cylinder
head.

c. Use Tooling (A
(A)) in order to pull camshaft
 bearing (1) into the camshaft bore.

78 RENR9716-02
Disassembly and Assembly Section

i02447352 2. Remov e ttube

ube as semb lies (1) from engine oil pan
pan
(3).
Engine Oil Pan - Remove and
Install 3. Use Tooling (A) to suppo rt engine oil pan (3). The
weight of engine oil pan (3) is approximately 25 kg
SMCS Code: 1302-010 (55 lb).

4. Remov e bolts (2)

(2).. Remov e engine oil pan (3
(3)) and

Removal Procedure the gasket.

Table 54

Required Tools
Installation Procedure
Part Table 55
Tool Nu m b er Par t Des c r i p t i o n Qty Required Tools
A 1U -7 5 0 5 Hy dra uli c Ja ck 1 Part
Tool N u m b er Par t Des c r i p t i o n Qty

NOTICE A 1U -7 5 0 5 Hy dra uli c Ja ck 1

Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test
ing, adjusting and re pair of the produc t. Be prepared to NOTICE
collect the fluid with suitable containers before open Keep all parts clean from contaminants.
ing any compartment or disassembling any compo
Contaminants may cause rapid wear and shortened
nent containing fluids. component life.
Referto Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

mandates.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

1. Drain the engine oil int

into
o a suitable co ntainer
for storage or disposal. Referto Operation and
Maintenance Manual, “Engine Oil and Filter- 1. Use Tooling (A) to suppo rt engine oil pan (3). The
Change”. weight of engine oil pan (3) is approximately 25 kg
(55 lb).

2. Position the gaske t and engine oil pan (3)

(3) on the
the
engine. Install bolts (2).

Note: If the oil drain plugs were removed, install the

oil drain plugs. Tighten the oil drain plugs to a torque
of 80 ± 10 N m (59 ± 7 lb ft).

3. Install tube ass emb lies (1) o

on
n engine oil pan (3).
(3).

4. Fil
Filll tthe
he en gine with eng ine oil to the
the correct level.
Referto Operation and Maintenance Manual,
“Engine Oil and Filter - Change ”.

g01222524
Illustration 237
R E N R 9 7 1 6 -0 2 79
Disassembly and Assembly Section

i02294951

Cylin der L iner - Re

Remove
move
SMCS Code: 1216-011

Removal Procedure
Table 56

Required Tools

To o l P ar t N u m b er P ar t D e s c r i p t i o n Qt y

A 5 P -8 66 50 ) Cy lin de r Lin er Pu lle r Gp 1

0) Th e 6V -9 44 8 C ylinder Pack Puller is an optional

optional Tool for
removing the cylinder liner.

Start By:

a. Remove the pistons and connecting rods. Refer

to Disassembly and Assembly, “Pistons and
Connecting Rods - Remove”.

NOTICE 1. Use Tooli

Tooling
ng (A) to remove c ylinde r li
liner
ner (1).
(1).
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test 2. Remov e liner seals (3) and fil
filler
ler band (2) from
from
ing, adjusting and re pair of the produc t. Be prepared to cylinder liner (1).
collect the fluid with suitable containers before open
ing any compartment or disassembling any compo
nent containing fluids. i02294960

Referto Special Publication, NENG2500, “Caterpillar Cylinder Liner - Install

Tools
Tool s and Shop Products G uide” fortools and suppli
supplies
es
suitable to collect and contain fluids on Caterpillar SMCS Code: 1216-012
products.
Installation Procedure
Dispose of all fluids according to local regulations and
mandates. Table 57

Required Tools

NOTICE To o l Par t N u m b er P ar t D e s c r i p t i o n Qt y
Keep all parts clean from contaminants.
B 2P-8260 C y li n d e r L i n e r I n s t a ll e r 1
Contaminants may cause rapid wear and shortened C 5 P -3 9 7 5 R u b b e r L u b r ic a n t 1
component life.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

1. Check tthe
he cylinder liner projection.
projection. Re ferto
Testing and Adjusting, “Cylinder Liner Projection
- Inspect”.
80 RENR9716-02
Disassembly and Assembly Section

Start By:

a. Remove the engine oil pump. Refer to

Disassembly and Assembly, “Engine Oil Pump
- Remove”.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

2. Install liner seals (3) on cylinde r liner ((1).

1).

3. Apply Tooling (C) on the cylin der block liner bore

surfaces and liner seals (3).

4. Dip filler band (2) in clean engine oil for a 1. Use Tooling (A) to rotate the crank shaft in orde r to
moment. Install the filler band on the cylinder liner gain access to the piston cooling jet.
immediately.
2. Remov e bolt (1
(1)) and piston cooling jet (2).
5. Use Tooling (B) to install cyli nd er liner (1) in the
cylinder block. Ensure that any marks in relation
to the cylinder liner projection are in alignment. Installation Procedure
Table 59
End By:
Required Tools
a. Install the pistons and connecting rods. Refer
Part
to Disassembly and Assembly, “Pistons and Qt y
Connecting Rods - Install”. Tool N u m b er P a r t D es c r i p t i o n
A 9 S -9 0 8 2 En gin e Tur nin g Tool 1

i02295020
NOTICE
Piston Cooling Jets - Remove Keep all parts clean from contaminants.
and Install Contaminants may cause rapid wear and shortened
SMCS Code: 1331-010 component life.

Removal Procedure
Table 58

Required Tools

Part
Tool N u m b er P ar t D e s c r i p t i o n Qt y

A 9S-9082 E n g in e T u rn in g Tool 1
R E N R 9 7 1 6 -0 2 81
Disassembly and Assembly Section

1. Use Tooli
Tooling
ng (A) to rotate the crank sha ft iin
n order to 1. Use Tooling (A(A)) to rotate the
the cran ksha ft until the
gain access to the piston cooling jet. piston is at the bottom center.

2 . Position piston cooling jet (2) in the cylin der block. 2 . Remove the carbon ridge from tthe
he top inside
Install bolt (1). Tighten the bolt to a torque of surface of the cylinder liner.
25 ± 6 N m (18 ± 4 lb ft ft).
).
3. Inspect the connecting rod and connecting rod cap

End By: for the proper identification mark. The connecting

rod and the connecting rod cap should have an
a. Install the engine oil pump. Referto Disassembly etched number on the side. The number should
and Assembly, “Engine Oil Pump - Install”. match the cylinder number. M ark the connecting
rod and the connecting rod cap, if necessary.

i02295112
Note: Do not stamp the connecting rod assembly.
Pistons and Connecting Rods Stamping or punching the connecting rod assembly
could cause the connecting rod to fracture.
- Remove
4. Remov e bolts ((1)
1) and
and connecting rod bearing cap
SMCS Code: 1225-011 (2).

Removal Procedure
Table 60

Required Tools

To o l Par t N u m b er Par t Des c r i p t i o n Qty

A 9 S -9 0 8 2 En gine Tu rni ng Tool 1

Start By:

a. Remove the cylinder head

head.. Re ferto Disassem bly
and Assembly, “Cylinder Head - Remove”.

b. Remove the piston cooling jets. Refer to

Disassembly and Assembly, “Piston
“Piston Cooling Jets
- Remove and Install”. 5 . Remove piston (3) and the connecting rod from
the cylinder liner.
NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.
82 RENR9716-02
Disassembly and Assembly Section

i02447789 2. Remov e uppe r conne cting rod bearing (8

(8)) from
connecting rod (6).
Pistons and Connecting Rods
- Disassemble 3. Use Tooling (A) to remov e pin retainers (5) from
piston body assembly (4).
SMCS Code: 1225-015
4. Remov e connecting rod pin ((7)
7) and connecting
rod (6) from the piston body assembly.

Disassembly Procedure 5. Use Tooling (B) to remov e top piston ring (1),
Table 61
intermediate piston ring (2), and oil control piston
Required Tools ring (3) from the piston body assembly.
Part
Tool N u m b er Par t D es c r i p t i o n Qty i02447828

A 6 V -6 1 9 2 Plie rs 1
Pistons and Connecting Rods
B 7 B -7 9 7 4 P is to n R in g E x p a n d e r G p 1
- Assemble
Start By: SMCS Code: 1225-016

a. Remove the pistons and connecting rods. Refer

to Disassembly and Assembly, “Pistons and
A s s em b l y Pr o c ed u r e
Connecting Rods - Remove”. Table 62

Note: Mark the components of each piston and Required Tools

connecting rod assembly. The components must be Part
reinstalled in the original location. Do not interchange Tool N u m b er P a r t D es c r i p t i o n Qty
components.
A 6V-6192 P lie rs 1

NOTICE B 7B-7974 P isto n Ri

Rin g Ex
E x p a n d e r Gp 1
Keep all parts clean from contaminants.
Note: Prior to removal from the engine, the pistons
Contaminants may cause rapid wear and shortened and connecting rod assemblies were marked.
component life. The components must be reassembled together.
The components must be installed in the original
location in the engine. Do not interchange any of the
components.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

1. Remo ve lower connec ting rod bearing (9) from

 connecting rod bearing cap (10).

R E N R 9 7 1 6 -0 2 83
Disassembly and Assembly Section

Note: Ensure that the bearing locking tab is located

in the notch o f the con necting rod bearing cap.

10. Ensure that the dowels are iinstalled

nstalled in the
connecting rod bearing cap.

End By:

a. Install the pistons and connecting rods. Refer

to Disassembly and Assembly, “Pistons and
Connecting Rods - Install”.

i02630922

Pistons and Connecting Rods

- Install
SMCS Code: 1225-012

Installation Procedure
Table 63
1. Position the spring for tthe
he oil control piston ring in
the oil ring groove in the piston body assembly. Required Tools
Part
Tool P a r t D es c r i p t i o n Qty
2 . Position oil control piston ring (3
(3)) ove r the spring. Number
Position the oil control piston ring so that the gap A 9 S -9 0 8 2 En gin e Tu rnin g Tool 1
is 180 degrees from the joint in the spring. Install
the oil control piston ring on the piston with Tooli
Tooling
ng B 200-3914 P isto n Rin g C o m pr
pr e s s o r 1
(B). C 8 T -3 0 5 2 D e g re e W h e e l 1

3. Use Tooli
Tooling
ng (B) to install intermediate piston ring
(2) with the side that has the identification “UP-2” NOTICE
toward the top of the piston. Keep all parts clean from contaminants.

4. Use Tooling (B) to install top piston ring (1) with Contaminants may cause rapid wear and shortened
the side that has the identification “UP-1” toward component life.
the top of the piston.

5. Position top piston ring

ring (1), intermediate piston Note: Install the connecting rod bearings dry
when clearance checks are performed. Refer to
ring (2), and oil control piston ring (3) so the gaps
Disassembly and Assembly, “Bearing Clearance -
are 120 degrees from each other.
Check”. Apply clean engine oil on the connecting rod
bearings for final assembly.
6. Check the clearance between the ends of top
piston ring (1), intermediate piston ring (2), and
1. App ly clean engine oil to the cylind er liner bore,
bore, to
oil control piston ring (3). Refer to Specifications,
the piston rings, and to the outer surface of the
“Pistons And Rings”.
piston.
7. Position piston body assembly (4) on connecting
Note: Ensure that the connecting rod and pistons are
rod (6). Apply clean engine oil to connecting rod
installed in the correct cylinder.
pin (7) and install the connecting rod pin. Install
pin retainers (5) with Tooling (A).

8. Install upper connecting rod bearing (8) iin

n
connecting rod (6).

Note: Ensure that the bearing locking tab is located

in the notch of the connecting rod.
9 . Install lower conne cting rod bearing (9) iin
n
connecting rod bearing cap (10).

84 RENR9716-02
Disassembly and Assembly Section

Note: Ensure that the num ber on the side of tthe

he
3 B connecting rod bearing cap is on the same side as
the number on the connecting rod. The bearing tabs
of the connec ting rod bearing cap and the connecting
rod are located on the side opposite of the piston
cooling jet.

8. Lubricate the tthrea

hrea ds of bolts (1)
(1) with
with clean engine
oil. Install the bolts.

9 . Tighten bolts (1), as follows:

a. Tighten Bo lt (A
(A)) and Bolt (C) to a torque of
70 ± 4 N m (52 ± 3 lb ft).

b. Tighten Bolt (B) and Bolt (D) to a torque of

70 ± 4 N m (52 ± 3 lb ft).
2. Use Tooli
Tooling
ng (A) to rotate the cra nksh aft until the
connecting rod journal is at the bottom center. c. Turn Bolt (B) and Bolt (D) for an additional 60 ±
5 degrees (1/6 turn).
3. Use Tooling (B) to install pis ton (3) and the
connecting rod in the cylinder liner. Note: If Tooling (C) is not used, place an index mark
on each bolt.
Note: Install the connecting rod so that the bearing
tab is located on the opposite side of the piston d. Tighten Bolt (A) and Bolt (C) again to a torque
cooling jet. of 70 ±4 N m (52 ±3 lb ft ft).
).

4. Install the up per connecting rod bearing in the e. Turn Bolt (A) and Bolt (C) for an additional 60 ±
connecting rod. 5 degrees (1/6 turn).

Note: Ensure that the connecting rod bearing is Note: If Tooling (C) is not used, place an index mark
installed so that the bearing tab fits into the notch in on each bolt.
the connecting rod.
f. Rotate the crankshaft in order to ensure that
5. Pull the connec ting rod onto the crank shaft journa l. the crankshaft turns freely.

6. Install the low er connecting rod bearing in tthe

he End By:
connecting rod bearing cap.
a. Install
Install the piston cooling jets. Re ferto Dis assem bly
Note: Ensure that the connecting rod bearing is and Assembly, “Piston Cooling Jets - Remove
installed so that the bearing tab fits into the notch in and Install”.
the connecting rod.
b. Inst
Install
all the cylinder head. Re ferto Disassembly
and Assembly, “Cy linder Head - Install”.

i02295567

Connecting Rod Bearings -

Remove
SMCS Code: 1219-011

Removal Procedure
Table 64

Required Tools

Part
7. Position connec ting rod bearing cap (2) on the Tool N u m b er Par t Des c r i p t i o n Qt y
 connecting rod.
A 9 S -9 0 8 2 En gin e Tur nin g Tool 1

R E N R 9 7 1 6 -0 2 85
Disassembly and Assembly Section

Start By: i02295910

a. Remove the engine oil pump. Refer to Connecting Rod Bearings -

Disassembly and Assembly, “Engine Oil Pump Install
- Remove”.
SMCS Code: 1219-012
NOTICE
Keep all parts clean from contaminants.
Installation Procedure
Contaminants may cause rapid wear and shortened Table 65
component life.
Required Tools

Part
Tool N u m b er Par t Des c r i p t i o n Qty

A 9 S -9 0 8 2 Eng ine Tu rnin g Tool 1

B 8 T -3 0 5 2 D e g re e W h e e l 1

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

Note: Install the connecting rod bearings dry

when clearance checks are performed. Referto
Disassembly and Assembly, “Bearing Clearance -
1. Use Tooli
Tooling
ng (A) to rotate the cra nksh aft until the Check”. Apply clean engine oil on the connecting rod
connecting rod is at the bottom center. bearings for final assembly.

2. Inspect the connecting rod and connec ting rod cap

for the prope r identif
identificati
ication
on mark. The connecting
rod and the connecting rod cap should have an
etched nu mber on tthehe side. The number should
match the cylinder number. Mark the connecting
rod and the connecting rod cap, if necessary.

Note: Do not stamp the connecting rod assembly.

Stamping or punching the connecting rod assembly

could cause the connecting rod to fracture.

3. Remov e bolts ((1)

1) and connecting rod bearing cap
(2) from the connecting rod.

4. Remove the lower ha lf of the connecting rod

bearing from the connecting rod bearing cap.
1. Use Tooling (A
(A)) to rotate the
the cran ksha ft until the
5. Push the connec ting rod away from the crankshaft. connecting rod journal is at the bottom center.
Remove the upper half of the connecting rod
bearing from the connecting rod. 2. Install a new lowe
lowe r half connec ting rod bearing (3)
in connecting rod bearing cap (2).

Note: Ensure that bearing locking tab (4) is located

in the notch of the connecting rod bearing cap.

3. Install a new upper half connec ting rod bearing in

the connecting rod.

Note: Ensure that the bearing locking tab is located

 Note: Ensure that the bearing locking tab is located
in the notch of the connecting rod.

86 RENR9716-02
Disassembly and Assembly Section

4. Pull the connec ting rod onto the crankshaft. i02296017

Crankshaft Main Bearings -

Remove
SMCS Code: 1203-011

Removal Procedure
Table 66

Required Tools

Part
Tool Nu m b er Par t Des c r i p t i o n Qt y

A 2 P -5 5 1 8 Bea ring Tool 1

Start By:
5 . Position connecting rod bearing cap ((2)
2) on the
connecting rod. a. Remove the engine oil pump. Refer to
Disassembly and Assembly, “Engine Oil Pump
Note: Ensure that the
the number on the side of tthe
he - Remove”.
connecting rod bearing cap is on the same side as
the number on the connecting rod. The bearing tabs
of the conne cting rod bearing cap and tthe
he conn ecting NOTICE
Keep all parts clean from contaminants.
rod are located on the side opposite of the piston
cooling jet.
Contaminants may cause rapid wear and shortened
component life.
6. Lubricate the threads of bolts ((1)
1) with clean engine
oil. Install the bolts.
1. Che ck the main bearing caps for identification of
7 . Tighten bo lts (1), as follows : the location and check the direction of the main
bearing caps in relation to the cylinder block. The
a. Tighten B olt (A) and Bolt (C) to a torq ue of main bearing caps must be installed in the original
70 ± 4 N m (52 ± 3 lb ft). location and the original direction.

b. Tighten Bolt (B) and Bolt (D) to a torque of

70 ± 4 N m (52 ± 3 lb ft).

c. Turn Bolt (B) and Bolt (D) for an additional 60 ±

5 degrees (1/6 turn).

Note: If Tooling (B) is not used, place an index mark

on each bolt.

d. Tighten Bolt (A) and Bolt (C) again to a torque

of 70
70 ± 4 N m (52 ±3 lb ft
ft).
).

e. Tighten Bolt (A) and Bolt (C) for an additional

60 ± 5 degrees (1/6 turn).

Note: If Tooling (B) is not used, place an index mark

on each bolt. 2. Remo ve bolts (1) and bolts (3)
(3) from No. 2 through
No. 6 main bearing caps (2).
f. Rotate the crankshaft in order to ensure that
the crankshaft turns freely. Note: Remo ve No. 1 and No. 7 main
main bearing caps
(2) after No. 2 through No. 6 main bearing caps have
End By: been installed.

a. Install the engine oil pump. Refer to Disassem bly

 and Assembly, “Engine Oil Pump - Install”.

R E N R 9 7 1 6 -0 2 87
Disassembly and Assembly Section

Note: Install the main bearings dry when clearance

checks are performed. Referto Disassembly and
As
Asse
se mb ly, “B ear
earing
ing Cle ar
aran
an ce - Ch ec k” . App ly clea n
engine oil on the main bearings for final assembly.

Note: Ensure that the main bearings are installed

so that bearing tabs fit into the notch in the cylinder
block. The uppe r halves of the main bearings have
the oil groove and the oil hole.

3. Install Tooling (A) in

in the oil hole of the cra nks haft.
Carefully rotate the crankshaft in order to remove
upper main bearing (4) from the cylinder block.

Note: Push the upper main bearing from the opposite

side of the bearing tab with Tooling (A). If the
crankshaft is turned in the wrong direction, the tab on
the bearing will be pushed between the crankshaft
and the bearing area of the cylinder block. This can
result in damage to the cylinder block and/or the 1. Position new u pper main bearing (4) o on
n the
crankshaft. crankshaft. Insert the end of the upper main
bearing that does not have the tab into the cylinder
4. Remov e the thrus t plates ffrom
rom each side of the block. Install Tooling (A) in the oil hole o f the
No. 4 main bearing. crankshaft. Carefully rotate the crankshaft in order
to push the upper main bearing into the cylinder
5. Remov e the
the low er halves of the main bearings block.
from the main bearing caps.
Note: Push the upper main bearing from the side of
the bearing tab with Tooling (A). If the crankshaft is
i02296049
turned in the wrong direction, the tab on the bearing
Crankshaft Main Bearings - will be pushed between the crankshaft and the
bearing area of the cylinder block. This can result in
Install damage to the cylinder block and/or the crankshaft.

SMCS Code: 1203-012 2. Install the thrus t plates on each side o f the No. 4
main bearing.
Installation Procedure
Note: Insta
Install
ll the thrust plates with the words “Block
Table 67 Side” toward the cylinder block.
Required Tools
3. Install the low er halves of the crank shaft main
To o l Par t N u m b er Par t Des c r i p t i o n Qt y bearings in the main bearing caps.
A 2 P -5 5 1 8 Bea ring Tool 1
Note: Ensure that the main bearings are installed so
B 8 T -5 0 9 6 D ia l I n d ic a to r 1 that bearing tabs fit into the notch in the main bearing
C 8 T -3 0 5 2 D e g re e W h e e l 1
caps.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.
88 RENR9716-02
Disassembly and Assembly Section

Note: Bolt (C) is on the bearing tab side of the main

bearing cap.

g. Rotate the crankshaft in order to ensure that

the crankshaft turns freely.

7. Use Tool
Tooling
ing (B) to check the cranksha ft end play.
play.
Ensure that Tooling (B) is against a machined
surface. The end play is controlled by the thrust
plates of No. 4 main bearing (center).

Crankshaft end play (new thrust

plates) ....... 0.10 to 0.60 mm (0.004 to 0.024 inch)

End By:
Illustration 255 gOH49987
gOH49987

a. Install the engine oil pump. Referto Disassembly

4 . Position main bearing caps (2) on the crankshaft. and Assembly, “Engine Oil Pump - Install”.

Note: Ensure that the numbers on the main bearing

caps match the numbers on the cylinder block. Also i02296738
ensure that the “FRONT” on the main bearing cap is
installed
installed toward the front o f the c ylinder block. Crankshaft - Remove

5. Lubricate the threads o f bol

bolts
ts (1) an
and
d bolts (3) with SMCS Code: 1202-011
clean engine oil. Install the bolts.
Removal Procedure
6. Tighten bolts (1) and bolts (3) for the main bearin g
caps, as follows: Table 68

Required Tools
a. Tighten Bolt (A) to a torq ue o f 258 ± 14 N m
(190 ± 10 lb ft). Part
Tool Nu m b er Par t Des c r i p t i o n Qty
Note: Bolt (A) is on the bearing tab side of the main A 138-7574 L in k B r a c k e t 2
bearing cap.
1H-3110 B e a r in g P u lle r 1
b. Tighten Bolt (B) to a torque of 258 ± 14 N m 8B-7560 Step Plate 1
(190 ± 10 lb ft).
9 U -6 6 0 0 H a n d H y d r a u li c P u m p 1
Note: Bolt (B) is on the opposite side of the bearing 1 H -3 1 0 8 P u s h -P u ll e r Leg 2
tab of the main bearing cap. 1H-3107 B e a r in g P u lle r 1
B
c. Tighten Bolt (B) for a
an
n additional 120 ± 5 3H-0468 Puller Plate 5
degrees (2 flats).
3 H -0 4 6 5 P u s h -P u ll e r P la te 2
Note: If Tooling (C) is not used, place an index mark 1P-0820 H y d r a u li c P u l le r 1
on the bolt and the main bearing cap.
5 B -0 6 3 7 Nut 1
d. Tighten Bolt (A) for an additional 120 ± 5 8 S -6 5 8 6 F o r c in g S c r e w 1
degrees (2 flats).
5P-0944 D o w e l P u ll e r G r o u p 1
C
Note: If Tooling (C) is not used, place an index mark 5P-0939 D o w e l E x tra c to r 1
on the bolt and the main bearing cap.

e. Tighten Bolt (D) to a torq ue o f 80 ± 10 N m Start By:

(59 ± 7 lb ft).
a. and
Remove the front
Assembly, housing.
“Housing Re ferto
(Front) Disassembly
- Remove”.
Note: Bolt (D) is on the opposite side of the bearing
tab of the main bearing cap.
b. Remove the rear housing. Referto Disassembly
 f. Tighten Bolt (C) to a torque of 80 ± 10 N m and Assembly, Housing (Rear) Remove .
(59 ± 7 lb ft).

RENR9716-02 89
Disassembly and Assembly Section

c. Remo ve the pist

piston
on cooling jets. Refer to 6. Remov e crank shaft (6) from the
the cylind er block.
block.
Disassembly and Assem bly, “Piston Cooling Jets
- Remove and Install”. 7. Remov e the thrus t plates ffrom
rom each side o f the
No. 4 main bearing.
NOTICE
Keep all parts clean from contaminants. 8. Remov e the lowe r main bearings from main
bearing caps (4). Remove the upper main
Contaminants may cause rapid wear and shortened bearings from the cylinder block.
component life.

1. Che ck the main bearing caps for identifi

identification
cation for
the location and the direction in the cylinder block.
The identification marks on the main bearing caps
must be installed in the same direction prior to
removal.

2. Che ck the connecting rod and tthe

he connecting rod
bearing caps for identification and the location in
the cy linder block
block..

9. Use Tooling (B) to remove crankshaft gear (7)

from crankshaft (6).

3. Remo ve bolts (1)

(1).. Remove connecting rod bearing
caps (2).

10. If necessary, use Tooling (C) to remove dow el (8)

and dowel (9) from crankshaft (6).

4. Remo ve bolts (3
(3)) and bolts ((5).
5). Remove main
bearing caps (4).

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

 on each end of crankshaft (6). The weight of
crankshaft (6) is approximately 188 kg (415 lb).

90 RENR9716-02
Disassembly and Assembly Section

i02296800 Note: Ensure that the main bearings are installed so

that the bearing tabs fit into the notch in the cylinder
Crankshaft - Install block. The uppe r halves of the main bearings have
the oil groove and the oil hole.
SMCS Code: 1202-012

Installation Procedure
Table 69

Required Tools

Part
Tool N u m b er Par t Des c r i p t i o n Qty

A 1 3 8 -7 5 7 4 Lin k Bra cke t 2

D 8 T -5 0 9 6 Dia l In d i c a t o r 1

E 8T-3052 D e gre e W he e l 1

NOTICE
Keep all parts clean from contaminants.
5 . Install Tooling (A) and a suita ble lifting device
Contaminants may cause rapid wear and shortened on each end of crankshaft (6). The weight of
component life. crankshaft (6) is approximately 188 kg (415 lb).

6. Install cranksh aft (6) with Timing M ark “V” o

on
n the
crankshaft gear in alignment with Timing Mark “V”
on the cluster gear.

7. Install the thrust plates on each side of the No. 4

main bearing.

Note: Insta
Install
ll the thrust plates with the words “Block
Side” toward the cylinder block.

8. Install the low er halves of the crank shaft main

bearings in the main bearing caps.

Note: Ensure that the main bearings are installed

so that the bearing tabs fit into the notch in the main
bearing cap.
1. Install dowel (8) iin
n the crank shaft.
9 . Position main bearing caps (4) on the crankshaft.
Protrusion of dowel (8) from the crankshaft
Note: Ensure that the numbers on the main bearing
f a c e ........................................... 8.4 mm (0.33 inch)
caps match the numbers on the cylinder block. Also
2. Install dowel (9) iin
n the crank shaft. ensure that the “FRONT” on the main bearing cap is
installed toward the front of the cylinder block.
Protrusion of dowel (9) from the crankshaft
.............................. 4.1
4.1 ± 0.5 mm (0.16 ± 0.02 inch) 10. Lubricate the threads of bolts (3) and bolts (5)
with clean engine oil. Install the bolts.
3. Install crankshaft gea r ((7)
7) on the cran ksha ft with
11. Tighten bolts (3) and bolts (5) for the main bearing
the keyway in alignment with dowel (9). Timing
caps, as follows:
Mark “V” of the gear should face away from
crankshaft (6).
a. Tighte n Bo lt (A) to a torque of 258 ± 14 N m
Note: Install the main bearings dry when clearance (190 ± 10 lb ft).
checks are performed. Referto Disassembly and
Note: Bolt (A) is on the bearing tab side of the main
As se mb ly, “B ear ing Cle ara nc e - Ch ec k” . App ly clea n
bearing cap.
engine oil on the main bearings for final assembly.

b. Tighten Bolt (B) to a torque of 258 ± 14 N m

4. Install the up per halves of the main bea rings in
(190 ± 10 lb ft).
the cy linder block
block..

R E N R 9 7 1 6 -0 2 91
Disassembly and Assembly Section

Note: Bolt (B) is on the opposite side of the bearing Note: Ensure that the num ber on the side of tthe
he
tab of the main bearing cap. connecting rod bearing cap is on the same side as
the number on the connecting rod. The bearing tabs
c. Tighten Bolt (B) for an additional 120 ± 5 of the connec ting rod bearing cap and the connecting
degrees (2 flats). rod are located on the side opposite of the piston
cooling jet.
Note: If Tooling (E) is not used, place an index mark
on the bolt and the main bearing cap. 14. Lubricate the threads of bolts (1) with clean
engine oil. Install the bolts.
d. Tighten Bolt (A) for an additional 120 ± 5
degrees (2 flats). 15. Tighten bolts (1), as follows:

Note: If Tooling (E) is not used, place an index mark a. Tighten Bolt (A) and Bolt (C) to a torque of
on the bolt and the main bearing cap. 70 ± 4 N m (52 ± 3 lb ft).

e. Tighte n Bo lt (D) to a torq ue o f 80 ± 10 N m b. Tighten Bolt (B) and Bolt (D) to a torque of
(59 ± 7 lb ft). 70 ± 4 N m (52 ± 3 lb ft).

Note: Bolt (D) is on the opposite side of the bearing c. Turn Bo lt (B

(B)) and Bolt (D) for an addition al 60 ±
tab of the main bearing cap. 5 degrees (1/6 turn).

f. Tighte n Bolt (C) to a torq ue o f 80 ± 10 N m Note: If Tooling (E) is not used, place an index mark
(59 ± 7 lb ft). on each bolt and connecting rod cap.

Note: Bolt (C) is on the bearing tab side o f the main d. Tighten Bolt (A) and Bolt (C) again to a torque
bearing cap. of 70 ±4 N m (52 ±3 lb ft ft).
).

g. Rotate the cranks haft in orde r to ensure that e. Turn Bolt (A) and Bolt (C) for an additional 60 ±
the crankshaft turns freely. 5 degrees (1/6 turn).

12. Use Tooli

Tooling
ng (D) to chec k the cran ksha ft e
end
nd play
play.. Note: If Tooling (E) is not used, place an index mark
Ensure that Tooling (D) is against a machined on each bolt and connecting rod cap.
surface. The end play is controlled by the thrust
plates of No. 4 main bearing (center). f. Rotate the cranks haft in
in orde r to ensure that
the crankshaft turns freely.
Crankshaft end play (new thrust
plates) ..... 0.10 to 0.60 mm (0.004 to 0.024 inch) End By:

Note: Install the connecting rod bearings dry a. Install the piston cooling jets. Re ferto Dis assem bly
when clearance checks are performed. Referto and Assembly, “Piston Cooling Jets - Remove
Disassembly and Assembly, “Bearing Clearance - and Install”.
Check”. Apply clean engine oil on the connecting rod
bearings for final assembly. b. Inst
Install
all the rear housing.
housing. R efe rto Disassembly and
Asse
As se mb ly, “H
“Hous
ous ing (Re ar) - Ins tal
tall”
l” .

c. Install
Install the front housing.
housing. Re ferto D isassembly and
and
Asse
As se mb ly, “H ous ing (Fro nt) - Ins tall
tall”” .
13. Position the connecting rod against the
crankshaft. Install connecting rod bearing cap (2)
on the connecting rod.

92 RENR9716-02
Disassembly and Assembly Section

i02717761 The technician must be very careful to use Tooling (A)

correctly. The following points must be remembered:
Bearing Clearance - Check
• Ensure tthat
hat the backs of the bearings and the
the
SMCS Code: 1203-535; 1219-535 bores are clean and dry.

Measurem
Measurem ent Procedure • Ensure that the bearing locking tabs are properly
seated in the tab grooves.
Table 70
• The crank shaft mus t bbe
e free of oil
oil at the contact
Required Tools
points of Tooling (A).
Part
Tool N u m b er Par t D es c r i p t i o n Qt y 1. Put a piece of Tooli
Tooling
ng (A) on the
the crown of the
198-9142 Plastic Gauge (Green) bearing that is in the cap.
0.025 to 0.076 mm 1
(0.001 to 0.003 inch) Note: Do not allow Tooling (A) to extend over the
edge of the bearing.
198-9143 Plastic Gauge (Red)
0.051 to 0.152 mm 1
2. Use the correct torque-tu rn specifica tions in order
(0.002 to 0.006 inch)
A to install the bearing cap. Do not use an impact
198-9144 Plastic Gauge (Blue) wrench. Be careful not to dislodge the bearing
0.102 to 0.229 mm 1 when the cap is installed.
(0.004 to 0.009 inch)

198-9145 Plastic Gauge (Yellow) Note: Do not turn the crankshaft when Tooling (A)
0.230 to 0.510 mm 1 is installed.
(0.009 to 0.020 inch)
3. Care fully remove the cap, but do not remove
Tooling (A). Measure the width of Tooling (A)
Note: Plastic gauge may not be necessary when tthe
he
while Tooling (A) is in the bearing cap or on the
engine is in the chassis.
crankshaft journal. Refer to Illustration 263.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

Note: Caterpillar does not recommend the checking

of the actual bearing c learanc es pa rticularly on
small engines. T his is because o f the poss ibility of
obtaining inaccurate results and the possibility of
damaging the bearing or tthe
he journal surfaces. Each
Caterpillar engine bearing is quality checked for
specific wall thickness.

Note: The measurements should be within

specifications and the correct bearings should
be used. If the crankshaft journals and the bores
for the block and the rods were measured during
disassembly, no further checks are necessary.
However, if the technician still wants to measure the Typical Example
bearing clearances, Tooling (A) is an acceptable
method. Tooling (A) is less accurate on journals with 4. Remov e all of Tooling (A) before you install
install tthe
he
small diameters if c
clearances
learances are less tthan
han 0.10 mm bearing cap.
(0.004 inch).

NOTICE
Lead wire, shim stock or a dial bore gauge can dam
age the bearing surfaces.
R E N R 9 7 1 6 -0 2 93
Disassembly and Assembly Section

Note: When Tooling (A) is used, the readings can

sometimes be unclear. For example, all parts of
Tooling (A) are not the same width. Measure the
major width in order to ensure that the parts are
within the specification range. Referto Specifications
Manual, “Connecting Rod Bearing Journal” and
Specifications Manual, “Main Bearing Journal” for tthe
he
correct clearan
clearances.
ces.

i02449735

A t m o s p h er i c Pr es s u r e Sen
Se n s o r
- Remove and Install
SMCS Code: 1923-010

1. Install a new O-ring seal on

on atmosp heric pressure
Removal Procedure sensor (1).

NOTICE 2. Install atmos phe ric pressure sens or (1)

(1) and
Keep all parts clean from contaminants. tighten to a torque of 10 ± 2 N m (90 ± 18 lb in).

Contaminants may cause rapid wear and shortened 3. Connect harness assembly (2)
(2)..
component life.
i02297743

Camshaft Position Sensor -

Remove and Install
SMCS Code: 1912-010

Removal Procedure

NOTICE
Care m ust be taken to ensu re that fluids
fluids are con tained
during performance of inspection, maintenance, test
ing
ing,, adjus ting and repa ir of the produc t. Be prepared to

collect
ing anythe fluid with suitable
compartment containers before
or disassembling open
any compo
nent containing fluids.
1. Disconnect harness assembly (2)
(2)..
Referto Special Publication, NENG2500, “Caterpillar
2. Remove atmo spheric pressure sensor (1
(1)) fro
from
m Tools and Shop Products Guide” fortoo ls and supplies
Tools
the adapter on the cylinder block. suitable to collect and contain fluids on Caterpillar
products.
3. Remove the O-rin
O-ring
g seal from atmospheric
pressure sensor (1). Dispose of all fluids according to local regulations and
mandates.
Installation Procedure
NOTICE
NOTICE Keep all parts clean from contaminants.
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
Contaminants may cause rapid wear and shortened component life.
component life.
94 RENR9716-02
Disassembly and Assembly Section

i02297803

Crankshaft Position Sensor -

Remove and Install
SMCS Code: 1912-010

Removal Procedure
NOTICE
Care m ust be taken to ensu re that fluids
fluids are con tained
during performance of inspection, maintenance, test
ing
ing,, adjus ting and re pair of the produc t. Be prepared to
collect the fluid with suitable containers before open
ing any compartment or disassembling any compo
nent containing fluids.
1 . Disconnect harness assembly ((3)
3)..
Referto Special Publication, NENG2500, “Caterpillar
2. Remov e bolt (1) and camsha ft posi
position
tion senso r ((2).
2). Tools
Tool s and Shop Products Guide” fortoo ls and supplies
suitable to collect and contain fluids on Caterpillar
3 . Remove the O-ring seal from camshaft positi
position
on products.
senso r (2)
(2)..
Dispose of all fluids according to local regulations and
Installation Procedure mandates.

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

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

1. Install a new O-ring seal on camsha ft position

position 1 . Disconnect harness assembly (1)
(1)..
sensor (2). Lubricate the O-ring seal with clean
engine oil. 2 . Remov e bolt (3) and cranksh aft position sensor
(2).
2 . Position cams haft position sen sor (2) iin
n the front
housing and install bolt (1). Tighten bolt (1) to a 3 . Remo ve tthe
he O-ring seal from cranks haft position
position
torq ue of 28 ± 7 N m ((21
21 ± 5 lb ft
ft).
). sensor (2).

3 . Connect harness assembly (3

(3).
).
R E N R 9 7 1 6 -0 2 95
Disassembly and Assembly Section

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

1. Drain the
the coolan t from the cooling system to a
level below the coolant temperature senso r int
into
oa
suitable container for storage o r disposal.
disposal. Refer
to Operation and Maintenance Manual, “Cooling
System Coolant - Change”.

1. Install a new O-ring seal on cran ksha ft posit

position
ion
sensor (2). Lubricate the O-ring seal with clean
engine oil.

2. Install crank shaft position sens or (2)(2) in the front

housing. Instal
Installl bolt (3). Tighten bolt (3) to a torque 2. Disconnect harness assembly (1)
(1)..
o f 28 ± 7 N m (21 ± 5 lb ft).
3. Remove coolant ttemperature
emperature sen sor (2).
(2).
3. Connect harness assembly (1).
4. Remove the O-ring seal ffrom
rom coolant ttemperature
emperature
sensor (2).
i02449857

Coolant Temperature
Temperature Sens
Sens or - Installation Procedure
Remove and Install
NOTICE
Keep all parts clean from contaminants.
SMCS Code: 1906-010

Contaminants may cause rapid wear and shortened

Removal Procedure component life.

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection,
inspection, maintenance, test
ing
ing,, adjus ting and re pair of the produc t. Be prepared to
collect the fluid with suitable containers before open
ing any compartment or disassembling any compo
nent containing fluids.

Refer to
to Special Publicat
Publication,
ion, NENG 2500, “C aterpillar
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.

96 RENR9716-02
Disassembly and Assembly Section

1. Install a new O-ring seal on coolant tempe rature 2 . Remov e engine oil pressure se nso r (1) from the
the
sensor (2). adapter on the cylinder block.

2 . Inst
Install
all coolant temperature sen sor (2) anand
d tight
tighten
en 3. Remov e tthe
he O-ring seal from engine oil pressure
to a torque of 20 ± 5 N m (15 ± 4 lb ft). sensor (1).

3. Connect harness assembly (1).

Installation Procedure
4 . Fill the cooling system with coolant. Refer to
Operation and Maintenance Manual, “Cooling NOTICE
System Coolant - Change”. Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

i02298137 component life.

Engine Oil Pressure Sensor -

Remove and Install
SMCS Code: 1924-010

Removal Procedure

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

Referto Special Publication, NENG2500, “Caterpillar

1. Install a new O-ring seal on engine oil pressure
Tools
Tool s and Shop Products G uide” fortools and suppli
supplies
es
sensor (1).
suitable to collect and contain fluids on Caterpillar
products.
2 . Install engine oil pressure sen sor (1) and
and tighten
to a torque of 10 ± 2 N m (89 ± 18 lb in).
Dispose of all fluids according to local regulations and
mandates. 3. Connect harness assembly (2)
(2)..

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.
1 . Disconnect harness assembly (2).

R E N R 9 7 1 6 -0 2 97
Disassembly and Assembly Section

i02581037 Installation Procedure

Fuel Pressure Sensor - NOTICE
Remove and Install Keep all parts clean from contaminants.

SMCS Code: 7414-010 Contaminants may cause rapid wear and shortened
component life.

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

Referto Special Publication, NENG2500, “Caterpillar

Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Illustration 275 g01
g012928
292812
12
Dispose of all fluids according to local regulations and
mandates.
1. Install a new O-ring seal on fuel
fuel pressu re senso r
(2).
NOTICE
Keep all parts clean from contaminants. 2. Install ffuel
uel pressu re sens or (2).
(2). Tighten fuel
pressure sensor (2) to a torque of 10 ± 2 N m
Contaminants may cause rapid wear and shortened (90 ± 18 lb in).
component life.
3. Co nnec t harness asse mbly (1).
(1).

1. Turn the ffuel

uel supp ly valve to the OFF position.
4. Turn the fuel supply valve to the ON p osition.

i0 2 5 8 1 0 6 1

Fuel Temperature Sensor -

Remove and Install
SMCS Code: 1922-010

Removal Procedure

NOTICE
Care m ust be taken to ensure tha t fl
fluids
uids are contained
during performance of inspect
inspection,
ion, maintenance, test
Illustration
Illustration 274 g0i2928 i2 ing, adjusting and repair ofthe product. Be prepared to
collect the fluid with suitable containers before open
2. Disconnect harness assembly (1)
(1).. ing any compartment or disassembling any compo
nent containing fluids.
3. Remove fuel pres sure sen sor (2) from the fuel
filter base. Referto Special Publication, NENG2500, “Caterpillar

4. Remove the O-ring seal from fuel pressure sensor Dealer Service
suitable Tooland
to collect Catalog”
containforfluids
tools on
andCaterpillar
supplies
(2). products.
 Dispose of all fluids according to local regulations and
mandates.

98 RENR9716-02
Disassembly and Assembly Section

2. Install fuel temp eratu re sens or (2).

(2). Tighten
Tighten fuel
NOTICE temperature sensor (2) to a torque of 20 ± 5 N m
Keep all parts clean from contaminants. (15 ±4 lb ftft).
).

Contaminants may cause rapid wear and shortened 3. Connect harness assembly (1).
component life.
4. Turn the fuel supply valve to the ON p osition.

1. Turn the ffuel

uel supp ly valve to the OFF position.
i02449930

Turbocharger Outlet Pressure

Sensor - Remove and Install
SMCS Code: 1917-010

Removal Procedure

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.
Illustration 276 g0l292826

2. Disconnect harness assembly (1)

(1)..

3. Remove fuel temperature sensor (2) ffrom

rom the fue
fuell
filter base.

4. Remove the O-ring seal from fuel tempe rature

senso r (2)
(2)..

Installation Procedure

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.
1. Disconnect harness assembly (1
(1).
).

2. Remove turbocharg er outoutlet

let pressure sensor (2
(2))
from the inlet manifold.

3. Remove the O-ring seal from turbocharge r outlet

outlet
pressure sen sor (2).

Installation Procedure

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.
Illustration 277 g0l292826

1. Install a new O-ring seal on fuel temp erature

 senso r (2)
(2)..

R E N R 9 7 1 6 -0 2 99
Disassembly and Assembly Section

3. Remove the O-ring seal from inlet air tempe rature

sens or (2).
(2).

Installation Procedure

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

1 .2

1. Install a new O-ring seal on turbo cha rger outlet

pressure sens or (2)
(2)..

2. Install turbo cha rge r outlet pressure senso r ((2)

2) an
and
d
tighten to a torque of 10 ± 2 N m (90 ± 18 lb in).

3. Connect harness assembly (1)

(1)..

i02449945
Illustr atio n 281 gOl223082

Inlet Air Te
Temperature
mperature Sensor -
1. Install a new O-ring seal on
on inlet air tempe rature
Remove and Install sens or (2).
(2).

SMCS Code: 1921-010

2. Install inl
inlet
et air temp erature se nso r ((2)
2) and tighten
to a torque of 20 ± 5 N m (15± 4 lb ft).
Removal Procedure
3. Co nnec t harness asse mbly (1).
(1).
NOTICE
Keep all parts clean from contaminants. i02574366

Contaminants may cause rapid wear and shortened Belt Guard - Remove and
component life.
Install
SMCS Code: 1357-010-GD

Removal Procedure

1. Disconnect harness assembly (1)

(1)..
2. Remove inlet air temp erature se nso r ((2)
2) from the
Illustration 282 gOl289708
gOl289708
inlet manifold.

100 RENR9716-02
Disassembly and Assembly Section

1. Remove bolts (1).

(1). Repeat for the opposite si
side.
de. i02 755046
Remove bottom belt guard (2).
Fan Guard - Remove and Install
SMCS Code: 1360-010

Removal Procedure

Illustration 283 g0l289709

2. Remove bo lt (3). Repeat for the opposite side.

Remove upper belt guard (4).

Illustration 286 gOl289778

gOl289778
Installation Procedure
1. Remov e bolts (1)
(1).. Remove lo wer fan
fan guard (2).

Illustration 284 g0l289709

Illustration 287 gOl379587

gOl379587
1. Install upper belt guard (4). Install bolt (3). Repeat
for the opposite side.
2. Remov e bolts ((3).
3). Remove upp er fan guard (4).
(4).

Installation Procedure

Illustration 285 g0l289708

2. Install lower belt guard (2)
(2).. Install bolts ((1).
1). Repeat
for the opposite side. Illustration 288 gOl379587
gOl379587

1. Install upp er fan guard (4). Install bolts (3).

R E N R 9 7 1 6 -0 2 101
Disassembly and Assembly Section

Illustration 289 g0l289778

2. Install low er fan guard (2). Install bolts (1).

i02755088

Fan - Remove and Install Illustration 291

g01289733

SMCS Code: 1356-010

2. Remov e bolts (2
(2).
). Remove fan (1).
(1).
Removal Procedure Installation Procedure
Table 71 Table 72

Required Tools Required Tools

Part Part
Tool N u m b er Par t D es c r i p t i o n Qt y Tool N u m b er Par t D e s c r i p t i o n Qty
A 140-7742 S le e v e 1 A 140-7742 S le e v e 1

Start By:

a. Remove the ffanan guard. Refe rto Disassem bly a and

nd
Asse
As se mb ly, “Fan Guard
Gu ard - Re mo ve and Ins tall”
tal l” .

H f
p

\
t S S ^ W ill

[I9JK!
hi/'1

g01289730
Illustration 290

Illustration 292 g01289733

1. Attach Tooling (A) and a suitable lifting device
onto fan (1). The weight of fan (1) is approximately
45 kg (100 lb). 1. Attach Tooling (A) and a suitable lifting device
 onto fan (1). The weight of fan (1) is approximately
45 kg (100 lb). Install fan (1). Install bolts (2).

102 RENR9716-02
Disassembly and Assembly Section

g01289730
Illustration 293

2. Remove Tooling (A)

(A) and the suitable lliftin
ifting
g device
from fan (1).

End By:
Illustration 294 gOl289585
gOl289585
a. Install the fan guard. Refe r to Disasse mbly and
Asse
As se mb ly, “Fan Guard
Gu ard - Re mo ve and Ins tall”
tal l” .
2. Loosen bolts (1)
(1).. Loosen lock nut (2).
(2).
i02574047

Fan Drive - Remove and Install

SMCS Code: 1359-010; 1386-010

Removal Procedure
Start By:

a. Remove the fan. Refer to Disas semb ly a and

nd
Asse
As se mb ly, “Fa n - Re
Remo
move
ve and Ins tall”
tall ” .

b. Remove the belt guard. Refer tto

o Disassem bly and
Asse
As se mb ly, “B elt Guard
Gu ard - Re mo ve and Ins tall”
tal l” .

1. Remove the belts. Refer to Operation

and Maintenance Manual, “Belts -
Inspect/Adjust/Replace".

g01289589
Illustration 295

3. Attach a suitable lifting device onto fan drive (3

(3).
).
The weight of fan drive (3) is approximately 45 kg
(100 lb). Remove bolts (1). Remove fan drive (3).
R E N R 9 7 1 6 -0 2 103
Disassembly and Assembly Section

Installation Procedure b. Inst

Install
all the fan. R efe rto D isassembly and and
As se mb ly, “Fa n - Re mo
move
ve and Ins tall
tall”” .

i02417465

Electronic Control Module -

Remove and Install
SMCS Code: 1901-010

Removal Procedure
1. Turn the battery disco nne ct switch tto
o the “OFF”
position.

2. Disco nnec t the negative battery termina l at the

battery.

Illustration 296 g012895

g01289589
89

1. Attach a suitable lifting device o nto fan dridrive

ve (3).
The weight of fan drive (3) is approximately 45 kg
(100 lb). Install fan drive (3). Install bolts (1).

3. Loosen alien head screw (1)

(1).. Disc onnect the
the
harness assembly from electronic control module
module
(5).

4. Disco nnec t hose assem blies (2) and (4).

(4).

5. Remov e bolts (6). Remo ve electron ic control

Illustration 297 g012895
g01289585
85 module (5) and ground strap (3).

2. Install the belts. R efer tto

o Opera tion 6. Remo ve washers (7) and isolation mounts (8)
and Maintenance Manual, “Belts - from electronic control module (5).
Inspect/Adjust/Replace”.

3. Tighten bolts (1). Tighten lock nut (2

(2).
).

End By:
a. Install
Install the belt guard. Re ferto Disassembly and
Asse
As se mb ly, “B elt Guard
Gu ard - Re move
mo ve and Ins tall”
tal l” .

104 RENR9716-02
Disassembly and Assembly Section

Installation Procedure

2. Remov e V-belt (1) from alterna tor (3).

(3).

3. Disconnect the harness assemblies from

alternator (3).

4. Remo ve bolt (2
(2)) and bolt (4).
(4).

1. Position isolation mounts (8) o

on
n electron ic cont
control
rol 5. Remov e alternato r ((3)
3) from the
the mounting group.
module (5). Position the spacers, washers (7),
ground strap (3), and electronic control module (5) Installation Procedure
on the support assemblies. Install bolts (6).

2. Conn ect hose assemb lies (4

(4)) and (2
(2).
).

3. Connect the harness assembly to electr

electronic
onic
control module (5). Tighten alien head screw (1)
to a torque o f 6 ± 1 N m (53 ± 9 lb in
in).
).

4. Con nect the negative battery terminal at the

battery.

5. Turn the battery disco nnec t switch to tthe

he “O N”

position.

i02450170

A l t er n at o r - Rem
R em o v e and
an d Ins
In s t al
alll 1. Position alterna tor (3)
(3) on the moun ting group.

SMCS Code: 1405-010 2. Install bolt (4) and bolt (2).

Removal Procedure 3. Connect the harness a ssemblies to alternator (3

(3).
).
Referto Specifications, “Alternator and Regulator”.
1. Turn the battery disco nne ct switch to the OFF
position. 4. Install V-be lt (1
(1)) on alternator (3).

5. Adjust the tension on the V-belt. Refer to

Operation and Maintenance Manual, “Belt -
Inspect/Adjust/Replace”.

6. Turn the battery disconn ect switch to the

the ON
position.
R E N R 9 7 1 6 -0 2 105
Disassembly and Assembly Section

i02419387 Installation Procedure

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

Removal Procedure
^ WAR NI
NI NG
Pe
Pers
rs onal injury c an res ult f rom f ailure t o dis c o n
nect the batte
battery.
ry.

First, discon nect the negative b attery cable. Then,

disconnect the positive battery cable.

A p o s it iv e p o w er lead
le ad ca n c au s e s p ar k s if th e b at 
t ery is not dis c onnec t ed. Spark s c an pos s ibly re
sult in battery explosion or fire.

Illustration 303 g012089

g01208927
27
1. Turn the battery disco nne ct switch to the “OFF”
position. 1. Fasten a suitable lifting device to elec tric starting
starting
motor (1). The weight of electric starting motor (1)
is approximately 37 kg (80 lb).

2. Position tthe
he gask et and electric starting mo tor (1
(1))
in the flywheel housing. Install bolts (2).

3. Connect the harness ass emblies to electelectric

ric
starting
starting motor (1).
(1). R eferto Specifications,
Specifications, “Electric
Starting Motor”.

4. Turn the battery disco nne ct switch to the “ON”

position.

Illustration 302 g0l208927

2. Place an index mark on all of the harness

assemblies. Disconnect the harness assemblies
from electric starting motor (1).

3. Fasten a suitable lifting device to elec tric starting

motor (1). The weight of electric starting motor (1)
is approximately 37 kg (80 lb).

4. Remove bolts (2).

5. Remove ele ctric starti

starting
ng m otor ((1)
1) and the gasket
 from the flywheel housing.

106 RENR9716-02
Index Section

Index

A Crankshaft Main Bearings - Install ............................. 87

Installation Procedure ............................................. 87
lerr - Ins tal l ....................................................... 40
Af te rc oo le Crankshaft Main Bearings - Remove ...................... 86
Installation Procedure ............................................. 40 Removal Procedure ................................................. 86
.................................................
A ftRemoval
e rc o o le r-Procedure
R e m o v e ............................................... 38 38 Cran ksha ft Position
Installation Senso
Procedure r - Remove and Install.. 94
............................................. 95
Alte
Al tern
rn at or - Re mo ve and In s ta ll ............................. 104 Removal Procedure ................................................. 94
Installation Procedure ......................................... 104 Crankshaft Rear Seal - Install ..................................... 50
Removal Procedure ............................................. 104 Installation Procedure ............................................. 50
Atm os ph er ic Pre ss ssure
ure Se ns or - Re mov e and Crankshaft Rear Seal - Remove ................................ 50
Install ......................................................................... 93 Removal Procedure ................................................. 50
Installation Procedure ........................................... 93 Cylinder Head - Install ................................................. 68
Removal Procedure ............................................... 93 Installation Procedure ............................................. 68
Cylinder Head - Remove ............................................ 66
Removal Procedure ................................................. 66
B Cylinder Liner - Install .................................................. 79
Installation Procedure ............................................. 79
Bearing Clearance - Check ...................................... 92 Cylinder Liner
Liner - Remov e ........................................... 79
Measurement Procedure ...................................... 92 Removal Procedure ................................................. 79
Belt Guard - Remove and Install ............................. 99
.........................................
Installation
Removal Procedure
Procedure ............................................... 100
99 D

Disassembly and Assembly Section ............................ 4

C

Camsh aft - Install........................................................ 73 E

Installation Procedure ........................................... 73
Camshaft - Remove ................................................... 71 Electric Starting
Starting Motor - Remove and Ins tall 105
105
Removal Procedure ............................................... 71 Installation Procedure ......................................... 105
Camshaft Bearings - Install ...................................... 76 Removal Procedure ............................................ 105
Installation Procedure ........................................... 76 Electron ic Control Mod ule - Remo ve and Install. Install... 103
Camshaft Beari
Bearings
ngs - Rem ove ................................. 76 Installation Procedure ......................................... 104
Removal Procedure ............................................... 76 Removal Procedure ............................................ 103
Cam shaft Position Sensor - Remo ve and Install... 93 Electronic Unit Injector
Injector - Insta ll ................................ 14
Installation Procedure ........................................... 94 Installation Procedure ........................................... 14
............................................... ............................
Removal Procedure
Connecting Rod Bearings - Install .......................... 85 93 Electronic
RemovalUnit Injector...............................................
Procedure - Remove 13
13
Installation Procedure ........................................... 85 Electronic Unit Injector
Injector Sleeve - Ins tall ................... 16
Connecting Rod Bearings- Bearings - Remove ........................ 84 Installation Procedure ........................................... 16
Removal Procedure ............................................... 84 Electronic Unit Injector Sleeve - Remove .............. 15
Coolant Temperature Sensor - Remove and Removal Procedure ............................................... 15
Install ......................................................................... 95 Engine - Install ................................................................ 6
Installation Procedure ........................................... 95 Installation Procedure ................................................ 6
Removal Procedure ............................................... 95 Engine - Remove ............................................................ 4
Cooling System Package (Radiator, Aftercooler, Fuel Removal Procedure ................................................... 4
Cooler) - Install ......................................................... 36 Engine Oil Cooler - Install ........................................... 28
Installation Procedure ........................................... 36 Installation Procedure ............................................. 28
Cooling System Package (Radiator, Aftercooler, Fuel Engine Oil Cooler - Remove ....................................... 27
Cooler) - Remove .................................................... 35 Removal Procedure ................................................. 27
Removal Procedure ............................................... 35 Engine Oil Filter
Filter Base - As sem ble ............................. 26
Crankshaft - Install ..................................................... 90 As se m bly Pr oc ed ur e ................................................ 26

Installation Procedure ........................................... 90 Engine Oil Filter Base - Disassemble ....................... 26

Crankshaft - Rem ove .................................................
Crankshaft 88 Disassembly Procedure .......................................... 26
Removal Procedure ............................................... 88 Engine Oil Filter
Filter Base - In sta ll ................................... 27
Crankshaft Front Seal - Install ................................. 55 Installation Procedure ............................................. 27
 Installation Procedure ........................................... 55 Engine Oil Filter Base - Remove ............................... 25
Crankshaft Front Seal - Remove ............................. 54 Removal Procedure ................................................. 25
Removal Procedure ............................................... 54

R E N R 9 7 1 6 -0 2 107
Index Section

Engine Oil Pan - Remove and Install ...................... 78 G

Installation Procedure ........................................... 78
Removal Procedure ............................................... 78 Gear Group (Front) - Install ........................................ 56
Engine Oil
Oil Pressure Sens or- R emove and Inst Install.
all... 96 Installation Procedure ............................................. 56
Installation Procedure ........................................... 96 Gear Group (Front) - Remove ................................... 55
Removal Procedure ............................................... 96 Removal Procedure ................................................. 55
Engin e Oil Pum p - A ss em ble .... ........
........
........
........
........
........
........
........
......29
..29 Gear Group (Rear) - Install ......................................... 48
As se m bly Pr oc ed ur e ................................................ 29 Installation Procedure ............................................. 48
Engine Oil Pump - Disassemble ................................ 29 Gear Group (Rear) - Remove .................................... 46
Disassembly
Disassembl y Proc edure .......................................... 29 Removal Procedure ................................................. 46
Engine Oil Pump - Install .......................................... 30
Installation Procedure ........................................... 30
Engine Oil Pump - Remove ........................................ 28 H
Removal Procedure ................................................. 28
Engine Support (Front
(Front)) - Remove and Insta ll 45 Housing (Front) - Install ............................................... 58
Installation Procedure (Type 1) .............................. 46 Installation Procedure ............................................. 58
Installation Procedure (Type 2 ) .............................. 46 Housing (Front) - Remove .......................................... 57
Removal Procedure (Type 1) ................................. 45 Removal Procedure ................................................. 57
Removal Procedure (Type 2 ) ................................. 46 Housing (Rear) - Install ................................................ 60
Exhaust Manifold - Remove and Install .................. 19 Installation Procedure ............................................. 60
Installation Procedure ........................................... 19 Housing (Rear) - Remove ........................................... 60
Removal Procedure ............................................... 19 Removal Procedure ................................................. 60

F I

Fan - Remove and Install ....................................... 101 101 Important Safety Information ........................................ 2
Installation Procedure ......................................... 101 101 Inlet Air Temperature Sensor - Remove and
Removal Procedure ............................................. 101 101 Install ......................................................................... 99
Fan Drive - Remove and Install ............................. 102 Installation Procedure ............................................. 99
Installation Procedure ......................................... 103 Removal Procedure ................................................. 99
Removal Procedure ............................................. 102 Inlet and Exhaust Valve Guides - Remove and
Fan Guard - Remove and Install ........................... 100 Install ......................................................................... 23
Installation Procedure ......................................... 100 Installation Procedure ............................................. 24
Removal Procedure ............................................. 100 Removal Procedure ................................................. 23
Flywheel - Remove and Install .................................. 49 Inlet and Exhaust Valve Seat Inserts - Remove and
Installation Procedure ............................................. 49 Install ......................................................................... 24
Removal Procedure ................................................. 49 Installation Procedure ............................................. 25
Flywheel Housing - Remove and Install ................. 51 Removal Procedure ................................................. 24
Installation Procedure ........................................... 52 Inlet and Exhaust Valve Springs - Remove and
Removal Procedure ............................................... 51 Install ........................................................................... 20
Fuel Filter and Water Separator - Remove and Installation Procedure ............................................. 21
Install ............................................................................ 11 Removal Procedure ................................................. 20
Installation Procedure .............................................. 11 Inl
Inlet
et and Exhaust Valves - Remove and Ins tall 22
Removal Procedure ................................................. 11 Installation Procedure ............................................. 23
Fuel Filter Base - Install ............................................ 10 Removal Procedure ................................................. 22
Installation Procedure ........................................... 10
Fuel Filter Base - Remove ........................................ 10
Removal Procedure ............................................... 10 P
Fuel Pressure Sensor - Remove and Install 97
Installation Procedure ........................................... 97 Piston Cooling Jets - Remove and Install .............. 80
Removal Procedure ............................................... 97 Installation Procedure ............................................. 80
Fuel Priming Pump - Remove and Install ................. 9 Removal Procedure ................................................. 80
Installation Procedure ........................................... 10 Pistons and Connecting Rods - As se m ble 82
Removal Procedure ................................................... 9 As se m bly Pr oc ed ur e ................................................ 82
Fuel Tempera ture Sens or - Remove and Install.... 97 Pistons and Connecting Rods - Dis as sem ble 82
Installation Procedure ........................................... 98 Disassembly Procedure .......................................... 82
Removal Procedure ............................................... 97 Pistons and Connecting Rods - Install ...................... 83
Fuel Transfer Pump - Install ..................................... 12 Installation Procedure ............................................. 83
 Installation Procedure ........................................... 12 Pistons and Connecting Rods - Remove ................ 81
Fuel Transf
Fuel Transfer
er Pump - Rem ove ................................ 12 Removal Procedure ................................................. 81
Removal Procedure ............................................... 12

R Water Temperature Regulator Housing - Remove and

Install ......................................................................... 33
Radiator Core - Install .................................................. 44 Installation Procedure ............................................. 34
Installation Procedure ............................................. 44 Removal Procedure ................................................. 33
Radiator Core - Remove ............................................. 42
Removal Procedure ................................................. 42
Rocker Arm - Asse mble .............................................. 64
As se mb ly Pr oc ed ur e ................................................ 64
Rocker Arm - Disasse mble ......................................... 64
Disassembly
Disassembl y Proc edure .......................................... 64
Rocke r Arm and Sh aft - Install................................... 65
Installation Procedure ............................................. 65
Rocker Arm and Shaft - Remove ............................... 63
Removal Procedure ................................................. 63

Table of Con tents ............................................................ 3

Table
Turbocharger - Assem ble ......................................... 18
As se m bly Pr oc ed ur e...................
e..............................
......................
................
..... 18
Tu rbo ch arg er - D is as se m bl e...........
e...............
........
........
........
........
........
...... 17
Disassembly
Disassembl y Proc edure ........................................ 17
Turbocharger - Ins tall ................................................ 18
Installation Procedure ........................................... 18
Turbocharg
Turbo charger er - Rem ove ........................................... 17
Removal Procedure ............................................... 17
Turbocharger Outlet Pressure Sen sor - Remove and
Install ......................................................................... 98
Installation Procedure ........................................... 98
Removal Procedure ............................................... 98

Valve Mechanism Cover - Remove and Install

Valve 62
Installation Procedure ............................................. 62
Removal Procedure ................................................. 62
Valve Mechanism Cover Base - Remove and
Install ......................................................................... 62
Installation Procedure ............................................. 63
Removal Procedure ................................................. 62
Vibration Damper and Pulley - Remove and
Install ......................................................................... 53
Installation Procedure ........................................... 53
Removal Procedure ............................................... 53

Water Pump
Pump - Assem ble ........................................... 32
As se mb ly Pr oc ed ur e...................
e..............................
......................
................
..... 32
Water Pump
Pump - D isassemble ...................................... 31
Disassembly
Disasse mbly Proced ure ........................................ 31
Water Pump - Install .................................................. 33
Installation Procedure ........................................... 33
Water Pump
Pump - Remo ve .............................................. 31
Removal Procedure ............................................... 31