KENR6052 79

Disassembly and Assembly Section

i03474986 i02403294

Rocker Shaft and Push Rods - Rocker Shaft - Disassemble

Remove SMCS Code: 1102-015
SMCS Code: 1102-011
Disassembly Procedure
Removal Procedure Table 39

Start By: Required Tools

Tool Part Number Part Description Qty
a. Remove the valve cover. Refer to Disassembly
and Assembly, “Valve Cover - Remove and A 1P-1863 Retaining Ring Pliers 1
Install”. B 1P-0510 Driver Gp 1

Start By:

a. Remove the rocker shaft. Refer to Disassembly

and Assembly, “Rocker Shaft and Push Rod -
Remove”.

g01815113
Illustration 274

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

(2).

g01200255
Illustration 276

1. Use Tooling (A) in order to remove retaining ring

(1) and the washer.

g01815116
Illustration 275

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

g01200257
Illustration 277

Note: Note the orientation of the rocker arms for

assembly purposes.

2. Remove rocker arms (2) and shaft (4) from rocker

arm pedestal (3).
80 KENR6052
Disassembly and Assembly Section

g01200259 g01200260
Illustration 278 Illustration 280

3. Use Tooling (B) and remove bushing (5) from 1. Install adjusting screw (7) and nut (6).
rocker arm (2).

g01200259
Illustration 281
g01200260
Illustration 279
2. Use Tooling (B) and install bushing (5) into rocker
4. Remove nut (6). Remove adjusting screw (7). arm (2). Make sure that the oil holes in bushing
(5) are aligned with the oil holes in rocker arm (2).
The oil holes must be aligned in the exact position.
i02403357

Rocker Shaft - Assemble

SMCS Code: 1102-016

Assembly Procedure
Table 40
Required Tools
Tool Part Number Part Description Qty
A 1P-1863 Retaining Ring Pliers 1
B 1P-0510 Driver Gp 1
g01200257
Illustration 282

3. Install rocker arms (2) and shaft (4) onto pedestal

(3).
KENR6052 81
Disassembly and Assembly Section

g01200255 g01815113
Illustration 283 Illustration 285

4. Install the washer. Use Tooling (A) in order to 2. Position rocker shaft assembly (2) in the dowel
install retaining ring (1). holes. Install bolts (1). Tighten bolts (1) to a torque
of 200 ± 30 N·m (147 ± 22 lb ft).
End By:
3. Adjust the valve lash. Refer to Testing and
a. Install the rocker shaft. Refer to Disassembly and Adjusting, “Engine Valve Lash - Inspect/Adjust”.
Assembly, “Rocker Shaft and Push Rod - Install”.
End By:
i03475064
a. Install the valve cover. Refer to Disassembly and
Rocker Shaft and Push Rods Assembly, “Valve Cover - Remove and Install”.

- Install
i02408869

SMCS Code: 1102-012 Valve Lifter - Remove

Installation Procedure SMCS Code: 1209-011

Removal Procedure
Table 41
Required Tools
Tool Part Number Part Description Qty
A 3E-3879 Eyebolt 1

Start By:

a. Remove the rocker shaft and pushrods. Refer to

Disassembly and Assembly, “Rocker Shaft and
g01815116 Pushrods - Remove”.
Illustration 284
b. Remove the exhaust manifolds. Refer to
1. Lubricate bridges (4) and the pockets with clean Disassembly and Assembly, “Exhaust Manifold
engine oil. Install bridges (4). Lubricate pushrods - Remove and Install”.
(3) with clean engine oil. Install pushrods (3). Seat
pushrods (3) in the lifter cups.
NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.
82 KENR6052
Disassembly and Assembly Section

g01203661 g01204408
Illustration 286 Illustration 288

1. Attach Tooling (A) and a suitable lifting device 1. Remove bolts (1). Remove shaft assembly (2)
onto valve lifter (1). Remove bolts (2). Remove from housing (3).
valve lifter (1).

g01204412
Illustration 289
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Illustration 287
2. Remove levers (4) from shaft (5). Remove thrust
2. Remove integral seal (3). washer (6) from shaft (5).

3. Repeat Steps 1 and 2 for the remaining valve

i02410168
lifters.
Valve Lifter - Assemble
i02410099
SMCS Code: 1209-016
Valve Lifter - Disassemble
SMCS Code: 1209-015
Installation Procedure
NOTICE
Disassembly Procedure Keep all parts clean from contaminants.
Start By: Contaminants may cause rapid wear and shortened
component life.
a. Remove the valve lifter. Refer to Disassembly and
Assembly, “Valve Lifter - Remove”.
KENR6052 83
Disassembly and Assembly Section

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

g01204412
Illustration 290

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

levers (4) onto shaft (5).

g01204525
Illustration 292

1. Install integral seal (3).

g01204408
Illustration 291

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

Install bolts (1). Tighten bolts (1) to a torque of
55 ± 10 N·m (41 ± 7 lb ft).
g01203661
End By: Illustration 293

a. Install the valve lifter. Refer to Disassembly and 2. Attach Tooling (A) and a suitable lifting device
Assembly, “Valve Lifter - Install”. onto valve lifter (1). Position valve lifter (1) onto
the engine. Install bolts (2). Tighten bolts (2) to a
torque of 55 ± 10 N·m (41 ± 7 lb ft).
i02409468
3. Repeat Steps 1 and 2 for the remaining valve
Valve Lifter - Install lifters.
SMCS Code: 1209-012
End By:

Installation Procedure a. Install the exhaust manifolds. Refer to

Disassembly and Assembly, “Exhaust Manifold
Table 42 - Remove and Install”.
Required Tools
b. Install the rocker shaft and pushrods. Refer to
Tool Part Number Part Description Qty Disassembly and Assembly, “Rocker Shaft and
A 3E-3879 Eyebolt 1 Pushrods - Install”.
KENR6052 127
Disassembly and Assembly Section

Note: Match the tabs on the ODD and EVEN i02648188

connecting rod caps with the connecting rods.
Camshaft - Remove
7. Install connecting rod cap (2). Apply Tooling (G)
under the head bolts (1) and to the threads of SMCS Code: 1210-011
bolts (1). Install bolts (1).
Removal Procedure
8. Use Tooling (A) to rotate the ywheel in order
to access the connecting rod cap that will be Table 83
installed. Required Tools
Tool Part Number Part Description Qty
A 282-9962 Guide 2
B 255-2820 Camshaft Pilot 2
C 8T-3169 Crank As 1

Illustration 441
g01431693 Start By:

9. Use the following procedure to tighten bolts (3): a. Remove the camshaft followers. Refer to
Disassembly and Assembly, “Camshaft Followers
a. Tighten bolts (1) and (2) to a torque of - Remove”.
105 ± 5 N·m (77 ± 4 lb ft).
NOTICE
b. Tighten bolts (3) and (4) to a torque of Care must be taken to ensure that uids are contained
105 ± 5 N·m (77 ± 4 lb ft). during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
c. Tighten bolts (5) and (6) to a torque of collect the uid with suitable containers before open-
105 ± 5 N·m (77 ± 4 lb ft). ing any compartment or disassembling any compo-
nent containing uids.
d. Repeat Steps 9.a through 9.c.
Refer to Special Publication, NENG2500, “Caterpillar
e. Turn bolts (3) and (4) for an additional 90 ± 5 Dealer Service Tool Catalog” for tools and supplies
degrees. suitable to collect and contain uids on Caterpillar
products.
f. Turn bolts (5) and (6) for an additional 90 ± 5
degrees. Dispose of all uids according to local regulations and
mandates.
g. Turn bolts (1) and (2) for an additional 90 ± 5
degrees. 1. Drain the coolant from the cooling system into a
suitable container for storage or disposal. Refer
10. Fill the engine with oil. Refer to Operation and to Operation and Maintenance Manual, “Cooling
Maintenance Manual, “Engine Oil and Filter - System Coolant - Change”.
Change”.

End By:

a. Install the piston cooling jet. Refer to Disassembly

and Assembly, “Piston Cooling Jet - Remove and
Install”.

b. Install the cylinder head. Refer to Disassembly

and Assembly, “Cylinder Head - Install”.

g01837093
Illustration 442
128 KENR6052
Disassembly and Assembly Section

2. Disconnect harness assemblies (3). Remove bolts 7. Remove bolts (19). Remove elbow (18).
(4). Remove cover (5). Remove bolts (2). Remove
lifting bracket (1). 8. Remove bolts (14). Remove cover (17).

3. Remove bolts (6). Remove cover (7).

g01228274
Illustration 446
Typical Example
g01228235
Illustration 443

4. Remove bolts (8). Remove bolt (9). Remove

spacer (10). Remove cam gear (11).

g01228276
Illustration 447
Typical Example

g01228236 9. Apply a thin coat of oil to Tooling (A) and Tooling

Illustration 444 (B). Install Tooling (A) and leave the bolts loose.
Install Tooling (B). Tighten the bolts for Tooling
5. Remove bolts (12) and the washers. Remove (A). Install Tooling (C). Use Tooling (C) in order to
retainer (13). rotate the camshaft. Rotate the camshaft in order
to remove the camshaft.

Note: The camshaft can be removed from either end

of the engine.

g01837094
Illustration 445

6. Disconnect harness assembly (15). Disconnect

tube assembly (16).
KENR6052 129
Disassembly and Assembly Section

g01203149
Illustration 449
205

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

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

g01329080
Illustration 448

10. Remove camshaft (20) halfway from the engine.

Use a suitable lifting device in order to support
camshaft (20). The weight of camshaft (20)
is approximately 95 kg (210 lb). Remove the
remaining portion of camshaft (20).

i03092004

Camshaft Bearings - Remove

SMCS Code: 1211-011
g01203308
Illustration 450
Removal Procedure
2. Install Tooling (B). Remove camshaft bearing (1).
Start By:
Hydraulic Removal
a. Remove the camshaft. Refer to Disassembly and
Assembly, “Camshaft - Remove”. Table 85
Required Tools
Manual Removal Tool Part Number Part Description Qty
Table 84 125-2739 Bearing Pilot 1
Required Tools A 125-2740 Back Up Plate 1
Tool Part Number Part Description Qty 125-2741 Bearing Sleeve 1
125-2739 Bearing Pilot 1 6V-4013 Screw 1
A 125-2740 Back Up Plate 1 6V-4010 Puller Plate 1
125-2741 Bearing Sleeve 1 B 8M-8778 Taperlock Stud 1
6V-4013 Screw 1 2J-3506 Full Nut 1
6V-4010 Puller Plate 1 5P-8248 Hard Washer 1
B 8M-8778 Taperlock Stud 1 5P-5247 Hydraulic Puller 1
2J-3506 Full Nut 1 Electric Hydraulic
3S-6224 1
5P-8248 Hard Washer 1 C Pump Gp (115 V)
Electric Hydraulic
8S-8033 1
Pump Gp (230 V)