CATERPILLAR RENR9716-02

September 2008

Disassembly and
Assembly
C27 and C32 G enerator Sets Engines
DWB1-Up (Generator Set)
SXC1-Up (Generator Set)
MED1-Up (Power Module)
W DR1-Up (Generator Set)

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.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal W ord” such as
“DANGER”, “W ARNING” or “CAUTION”. The Safety Alert “W ARNING” label is shown below.

A WARNING

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. If a tool,
procedure, work method or operating technique that is not specifically recommended by Caterpillar
is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that
the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Caterpillar dealers have the most current information available.

A WARNING
When replacement parts are required for this
product Caterpillar recommends using Caterpil­
lar replacement parts or parts with equivalent
specifications including, but not limited to, phys­
ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema­

ture failures, product damage, personal injury or
death.
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 and Assembly 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) - R e m o ve .......................................... 60
Fuel Filter Base - Remove ...................................... 10
Housing (Rear) - In s ta ll.............................................. 60
Fuel Filter Base - Install .......................................... 10
Valve Mechanism Cover - Remove and In s ta ll 62
Fuel Filter and W ater Separator - Remove and
Valve Mechanism Cover Base - Remove and
In s ta ll............................................................................ 11
In s ta ll......................................................................... 62
Fuel Transfer Pump - R e m o ve ................................ 12
Rocker Arm and Shaft - R e m o ve ..............................63
Fuel Transfer Pump - In s ta ll..................................... 12
Rocker Arm - D isassem ble........................................64
Electronic Unit Injector - R e m o v e ........................... 13
Rocker Arm - A s se m b le ............................................. 64
Electronic Unit In je cto r-In sta ll ............................... 14
Rocker Arm and Shaft - In s ta ll.................................. 65
Electronic Unit Injector Sleeve - R e m o v e 15
Cylinder Head - Remove ........................................... 66
Electronic Unit Injector Sleeve - Install .................. 16
Cylinder Head - Install ................................................68
Turbocharger - R e m o v e ........................................... 17
Camshaft - R e m o ve .................................................... 71
Turbocharger - Disassemble .................................. 17
Camshaft - In s ta ll.........................................................73
Turbocharger - Assemble ....................................... 18
Camshaft Bearings - R e m o ve ................................... 76
Turbocharger - In s ta ll................................................ 18
Camshaft Bearings - In s ta ll........................................76
Exhaust Manifold - Remove and Install ................ 19
Engine Oil Pan - Remove and Install .................... 78
Inlet and Exhaust Valve Springs - Remove and
Cylinder Liner - R e m o v e .......................................... 79
In s ta ll........................................................................... 20
Cylinder Liner - In s ta ll.................................................79
Inlet and Exhaust Valves - Remove and Install .... 22
Piston Cooling Jets - Remove and In s ta ll 80
Inlet and Exhaust Valve Guides - Remove and
Pistons and Connecting Rods - R e m o ve .......... 81
In s ta ll......................................................................... 23
Pistons and Connecting Rods - D isassem ble 82
Inlet and Exhaust Valve Seat Inserts - Remove and
Pistons and Connecting Rods - Assemble ....... 82
In s ta ll......................................................................... 24
Pistons and Connecting Rods - In s ta ll................. 83
Engine Oil Filter Base - Remove ..............................25
Connecting Rod Bearings - Remove ....................... 84
Engine Oil Filter Base - Disassemble ...................... 26
Connecting Rod Bearings - In s ta ll............................85
Engine Oil Filter Base - A s s e m b le ............................26
Crankshaft Main Bearings - R e m o ve ..................... 86
Engine Oil Filter Base - Install .................................. 27
Crankshaft Main Bearings - In s ta ll............................87
Engine Oil Cooler - R e m o v e ......................................27
Crankshaft - R e m o ve ..................................................88
Engine Oil Cooler - In s ta ll.......................................... 28
Crankshaft - In s ta ll...................................................... 90
Engine Oil Pump - R e m o v e .......................................28
Bearing Clearance - C h e c k ........................................92
Engine Oil Pump - D isa sse m b le...............................29
Atmospheric Pressure Sensor - Remove and
Engine Oil Pump - A s s e m b le .................................... 29
In s ta ll......................................................................... 93
Engine Oil Pump - Install ......................................... 30
Camshaft Position Sensor - Remove and Install .. 93
W ater Pump - Remove ............................................ 31
Crankshaft Position Sensor- Remove and In s ta ll.. 94
W ater Pump - Disassemble .................................... 31
Coolant Temperature Sensor - Remove and
W ater Pump - Assemble ......................................... 32
In s ta ll......................................................................... 95
W ater Pump - Install ................................................. 33
Engine Oil Pressure Sensor - Remove and Install
W ater Temperature Regulator Housing - Remove and
..................................................................................... 96
Install ........................................................................ 33
Fuel Pressure Sensor - Remove and In s ta ll 97
Cooling System Package (Radiator, Aftercooler, Fuel
Fuel Temperature Sensor - Remove and Install ... 97
Cooler) - R e m o ve .................................................... 35
Turbocharger Outlet Pressure Sensor - Remove and
Cooling System Package (Radiator, Aftercooler, Fuel
In s ta ll......................................................................... 98
Cooler) - In s ta ll......................................................... 36
Inlet A ir Temperature Sensor - Remove and
A fte rco ole r-R em ove ............................................... 38
In s ta ll......................................................................... 99
A fte rco o le r-In sta ll ..................................................... 40
Belt Guard - Remove and In sta ll..............................99
Radiator Core - Remove ........................................... 42
Fan Guard - Remove and Install ........................ 100
Radiator Core - Install ................................................44
Fan - Remove and Install... ..................................... 101
Engine Support (Front) - Remove and In s ta ll.........45
Fan Drive - Remove and Install ........................... 102
Gear Group (Rear) - R e m o v e ................................... 46
Electronic Control Module - Remove and Install ..1 0 3
Gear Group (Rear) - In s ta ll........................................48
Alternator - Remove and Install ........................... 104
Flywheel - Remove and Install ................................. 49
Electric Starting M o to r-R e m o ve and Install .... 105
Crankshaft Rear Seal - R e m o v e ............................. 50
Crankshaft Rear Seal - In s ta ll................................. 50
Flywheel Housing - Remove and Install .............. 51 Index Section
Index 106
4 RENR9716-02
Disassembly and Assembly Section

Disassembly and Assembly

Section
i02747487

Engine - Remove
SMCS Code: 1000-011

Removal Procedure
Table 1

Required Tools
Illu stra tio n 2 g 0 l2 9 H 6 0
Part
Tool Number Part Description Qty 2. Disconnect harness assembly (6).
A 1 3 8 -7 5 7 3 Link Bracket 2

B 2 3 8 -9 5 8 6 Engine Turning Tool 1

C 1U-9 2 0 0 Lever Puller Hoist 1

D 189-041 1 Shackle As 2

E 6 V -6 1 4 6 Load Leveling Beam 1

S ta rt By:

a. Remove the cooling package. Refer to

Disassembly and Assembly, “Cooling System
Package (Radiator, Aftercooler, Fuel Cooler) -
Remove”.
g01291161
Illu stra tio n 3

3. Disconnect hose assemblies (7), (8), and (9).

g01291159
Illu s tra tio n 1

1. Disconnect hose assembly (1). Disconnect cable

assembly (2). Disconnect harness assemblies Illu stra tio n 4
g01291162
(3). Disconnect cable assembly (4). Disconnect
harness assemblies (5). 4. Disconnect clamp (10).
RENR9716-02 5
Disassembly and Assembly Section

7. Disconnect clamp (15).

Illu stra tio n 8 g01291225

8. Remove bolts (16). Remove guard (17).

g01291179
Illu s tra tio n 5

5. Remove bolts (11). Remove bolts (12). Repeat for

the opposite side. Disconnect tube assembly (13).
Repeat for the opposite side.

Illu stra tio n 9 g 0 l2 9 l2 2 7

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

g01291183
Illu s tra tio n 6

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

onto exhaust elbow (14). The weight of exhaust
elbow (14) is approximately 34 kg (75 lb). Remove
exhaust elbow (14).

g01291228
Illu stra tio n 10

10 . Disconnect hose (20).

g01291186
Illu s tra tio n 7
6 RENR9716-02
Disassembly and Assembly Section

Illu s tra tio n 11 901291232 Illu stra tio n 14 g 0 l2 9 l2 4 6

13. Attach Tooling (D) onto engine (24). Attach Tooling

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

Illu s tra tio n 12 g 0 l2 9 l2 4 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). Illu stra tio n 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
Illu s tra tio n 13 g0l376223
Part
12 . Use Tooling (C) in order to support generator Tool Number Part Description Qty
rotor (23). A 1 3 8 -7 5 7 3 Link Bracket 2

B 2 3 8 -9 5 8 6 Engine Turning Tool 1

C 1 U -9 2 0 0 Lever Puller Hoist 1

D 1 8 9 -0 4 1 1 Shackle As 2

E 6 V -6 1 4 6 Load Leveling Beam 1

RENR9716-02 7
Disassembly and Assembly Section

g01291246 g01291232
Illu s tra tio n 16 Illu stra tio n 19

1. Attach Tooling (D) onto engine (24). Attach Tooling 3. Install bolts (21). Use Tooling (B) in order 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
Illu stra tio n 20

g01291247
Illu s tra tio n 17 4. Remove Tooling (C).

2. Install mounting bolts (25).

g01291228
Illu stra tio n 21

g01291243
Illu s tra tio n 18 5. Connect hose (20).
8 RENR9716-02
Disassembly and Assembly Section

g01291227 g01291183
Illu s tra tio n 22 Illu stra tio n 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).

Illu s tra tio n 23 g 0 l2 9 l2 2 5

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

Illu stra tio n 2 6 g01291179

10. Connect tube assembly (13). Install bolts (12).

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

Illu s tra tio n 2 4 g 0 l2 9 H 8 6

8. Connect clamp (15).

g01291162
Illu stra tio n 27
RENR9716-02 9
Disassembly and Assembly Section

11 . Connect clamp (10). End By:

a. Install the cooling package. R eferto Disassembly

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

i02580978

Fuel Priming Pump - Remove

and Install
SMCS Code: 1258-010

Removal Procedure
Illu s tra tio n 28 g01291161
NOTICE
12 . Connect hose assemblies (7), (8), and (9). 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.

R eferto Special Publication, NENG2500, “Caterpillar

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

Dispose of all fluids according to local regulations and

mandates.

g01291160 NOTICE
Illu s tra tio n 29
Keep all parts clean from contaminants.
13 . Connect harness assembly (6). Contaminants may cause rapid w ear and shortened
component life.

g01291159
Illu s tra tio n 30

g01292755
14 . Connect harness assemblies (5). Connect cable Illu stra tio n 31

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

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

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

Illu s tra tio n 32 g01292755

1. Position the gasket and fuel priming pump (2) on

the fuel filter base.

2. Install bolts (1).

Illu stra tio n 3 3 g01292764
i02580993
2. Use Tooling (A) to remove fuel filter (6) from fuel
Fuel Filter Base - Remove filter base (5).

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

Removal Procedure 4. Disconnect hose assembly (1) and hose assembly

(2).
Table 3

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

Part
Tool Number Part Description Qty i02581008

A 1 8 5 -3 6 3 0 Strap Wrench 1 Fuel Filter Base - Install

SMCS Code: 1262-012
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, 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 w ear and shortened
Refer to Special Publication, NENG2500, “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.
RENR9716-02 11
Disassembly and Assembly Section

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

R eferto 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.

Illu s tra tio n 3 4 g0l292764

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

bolts (3).

2. Connect hose assembly (1) and hose assembly

(2).

3. Connect harness assemblies (4).

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

5. Turn the fuel supply to the ON position. Illu stra tio n 3 5 gO l292832

i02581074
2. Use Tooling (A) to remove the fuel filter and water
separator (5) from base assembly (4).
Fuel Filter and Water Separator
3. Disconnect hose assemblies (2) and (3).
- Remove and Install
4. Remove bolts (1) and base assembly (4).
SMCS Code: 1261-010; 1263-010

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

Tool Part Number Part Description Qty Contaminants may cause rapid w ear and shortened
component life.
A 1 8 5 -3 6 3 0 Strap Wrench 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

Illu s tra tio n 36 g0l292832

1. Position base assembly (4) on the cylinder block

and install bolts (1).

2 . Connect hose assemblies (2) and (3).

Illu stra tio n 3 7 gOH43748
3. Install a new fuel filter and w ater separator (5) on
base assembly (4).
2 . Disconnect hose assemblies (3).
4 . Turn the fuel supply to the ON position.
3 . Remove bolts (2).

i02285574 4 . Remove fuel transfer 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
Keep all parts clean from contaminants.
ing any compartment or disassembling any compo­
nent containing fluids.
Contaminants may cause rapid w ear and shortened
component life.
R e fe rto Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” fortools 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. Turn the fuel supply to the “OFF” position.

RENR9716-02 13
Disassembly and Assembly Section

1. Disconnect harness assembly (1).

2. Remove bridge assemblies (3).

Illu s tra tio n 38 gOH43748 NOTICE

If the injector hold down bolt is loose during the re­
1. Install the O-ring seal on fuel transfer 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 transfer pump (1) on the engine.

3. Remove bolt (4), spacer (5), and clamp (6).
Install bolts (2).
4. Place an identification mark on electronic unit
3. Connect hose assemblies (3).
injectors (2) for installation purposes. Each
electronic unit injector must be reinstalled in the
4. Turn the fuel supply to the “ON” position. original location in the cylinder head.

i02208070

Electronic Unit Injector -

Remove
SMCS C ode: 1290-011

Removal Procedure
Table 5

Required Tools

Tool Part Number Part Description Qty

A 5 F -4 7 6 4 Pry Bar 1

5. Use Tooling (A) to pry beneath the base and free

S ta rt By: electronic unit injector (2).

a. Remove the rocker arms and the rocker arm shaft. 6. Remove electronic unit injector (2) from the
Refer to Disassembly and Assembly, “Rocker Arm cylinder 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 C ode: 1290-012

Installation Procedure
Table 6

Required Tools

Tool Part Number Part Description Qty

B 8 T -2 9 9 8 Lubricant 1

1U -57 1 8 Vacuum Pump 1

1 6 9 -7 3 7 2 Fluid Sampling Bottle 1

C
Tube
4 C -4 0 5 7 1
7.9 mm (0.31 inch) OD

D 4 C -5 5 5 2 Large Bore Brush 1

E 4 C -6 7 7 4 Vacuum Gun Kit 1

Surface Reconditioning
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 remove 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
alphanumeric code that is supplied with the data
2. Use Tooling (D) to clean the carbon deposit from 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 o f the codes are located on the 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 Tooling (F) to clean the carbon from the seat • ECM Summary 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 Electronic Service Tool. If the component life.
new electronic injector code is not entered, the char­
acteristics of the previous electronic unit injector is as­
sumed. 1. Drain the coolant from the cooling system into a
suitable container for storage or disposal. Refer
If it is not possible to immediately reprogram the elec­ to Operation and Maintenance Manual, “Cooling
tronic injector code into the personality module soft­ System Coolant - Change”.
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 electronic unit injector (2) in the cylinder

head.

7. Install spacer (5), clamp (6), and bolt (4). Tighten

the bolt to a torque of 55 ± 10 N m (41 ± 7 lb ft).

8. Install bridge assemblies (3).

9 . Connect harness assembly (1). Tighten the nuts

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

End By: 2. Install Tooling (A) in electronic unit injector sleeve

( 1).
a. Install the rocker arms and the rocker arm shaft.
Refer to Disassembly and Assembly, “Rocker Arm 3. Tighten the nut on Tooling (A) until the electronic
and Shaft - Install”. unit injector sleeve is pulled free of the cylinder
head.
i02300212

Electronic Unit Injector Sleeve 1

- Remove
SMCS Code: 1713-011

Removal Procedure
Table 7

Required Tools

Part
Tool Number Part Description Qty
g01073635
Illu stra tio n 4 4
A 9U -6891 Injector Tool Group 1
4. Remove 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
Electronic Unit Injector Sleeve injector sleeve only.
- Install
4. Lubricate O-ring seals (2) with clean engine oil.
SMCS C ode: 1713-012

Installation Procedure
Table 8

Required Tools

Tool Part Number Part Description Qty

A 9U -6891 Injector Tool Group 1

9 U -6 8 6 2 Tapered Brush 1

9 U -6 8 6 3 Small Bore Brush 1

B 9 U -7 2 4 4 End Brush 1

9 U -7 2 3 7 Brush Extension 1

4 C -5 5 5 2 Large Bore Brush 1

5. Install electronic unit injector sleeve (1) on Tooling
C 4 C -9 5 0 7 Retaining Compound 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 (B) to clean the bore in the cylinder "RING" when the electronic unit injector sleeve is fully
head for the electronic unit injector sleeve. seated in the bore of the cylinder head.

NOTICE 6. Remove Tooling (A). Remove excess Tooling (C).

Ensure that the electronic unit injector sleeve and the
cylinder head bore are completely free o f oil, dirt, and 7. Fill the cooling system with coolant. Refer to
sealant debris. Operation and Maintenance Manual, “Cooling
System Coolant - Change”.

End By:

a. Install the electronic unit injectors. R e fe rto

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

2. Install new 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 ”.
RENR9716-02 17
Disassembly and Assembly Section

i02287744

Turbocharger - 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.

R e fe rto Special Publication, NENG2500, “Caterpillar 2 . Remove tube assembly (2).

Tools and Shop Products Guide” fortools and supplies
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 lifting device to turbocharger (5).
mandates. The weight of turbocharger (5) is approximately
45 kg (100 lb).
NOTICE
Keep all parts clean from contaminants. 5 . Remove nuts (3). Remove turbocharger (5) and
the gasket.
Contaminants may cause rapid wear and shortened
component life. i02287870

1. Drain the coolant from the cooling system into a

Turbocharger - Disassemble
suitable container for storage or disposal. Refer
SMCS Code: 1052-015
to Operation and Maintenance Manual, “Cooling
System Coolant - Change”.
Disassembly Procedure
Start By:

a. Remove the turbocharger. R eferto Disassembly

and Assembly, “Turbocharger - Remove”.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

g01145002
Illu s tra tio n 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 clamp (2) to a torque

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

3. Tighten the nuts on 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 diam eter of the band clamp.
Tighten the nuts again to a torque of 14 ± 1 N m
Illu s tra tio n 49 gOH45263
(10 ± 1 lb ft).

1. Loosen V-band clamp (2) and V-band clamp (4). 4 . Ensure that the impeller spins freely.

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

turbocharger cartridge (3).
a. Install the turbocharger. R eferto Disassembly and
3. Separate turbine housing (5) from turbocharger Assembly, “Turbocharger - Install”.
cartridge (3).

i02288273
i02451256

Turbocharger - Assemble Turbocharger - Install

SMCS Code: 1052-012
SMCS Code: 1052-016

Installation Procedure
Assembly Procedure
Table 9

NOTICE Required Tools

Keep all parts clean from contaminants.
Tool Part Number Part Description Qty
Contaminants may cause rapid wear and shortened A 5 P -3931 Anti-Seize Compound 1
component life.

NOTICE
NOTICE Keep all parts clean from contaminants.
The compressor housing must remain straight with
the turbocharger cartridge during disassembly 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
Illu s tra tio n 50
RENR9716-02 19
Disassembly and Assembly Section

1. Position the gasket on the exhaust manifold. 2 . Remove locknuts (6) from exhaust manifold (7).

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

3. Attach a suitable lifting device to turbocharger (5). 4 . Remove exhaust manifold (7) and gaskets (1)
The weight o f turbocharger (5) is approximately from the cylinder head.
45 kg (100 lb). Position turbocharger (5) on the
exhaust manifold. 5 . If necessary, remove clamps (4) and expansion
joints (5).
4. Install nuts (3) and tighten to a torque of 55 ± 9 N m
(41 ± 7 lb ft).
Installation Procedure
5 . Connect tube assemblies (1) and tube assembly Table 10
(4).
Required Tools
6. Install tube assembly (2). Tool Part Number Part Description Qty

7. Fill the cooling system. Refer to Operation and A 5 P -3931 Anti-Seize Compound -
Maintenance Manual, “Cooling System Coolant B 1 6 5 -4 6 3 8 Guide 3
- Change”.

i02617122

Exhaust Manifold - Remove

and Install
SMCS Code: 1059-010

Removal Procedure
Start By:

a. Remove the turbocharger. Refer to Disassembly

and Assembly, “Turbocharger - Remove”.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

1. Remove the shield 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

Tool Part Number Part Description Qty

A 9U -7241 Valve Spring Compressor 1

Illu s tra tio n 55 g00566l45
B 8 S -2 2 6 3 Spring Tester 1
1. If necessary, install expansion 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 . Apply Tooling (A) to the studs prior to assembly. If Disassembly and Assembly, “Electronic Unit
necessary, install the studs and tighten to a torque Injector - Remove”.
o f 35 ± 5 N m (26 ± 4 lb ft).

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

the cylinder head. Keep all parts clean from contaminants.

4 . Install spacers (2) and (3) on exhaust manifold (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 o fth e 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) on exhaust manifold (7).
Tighten locknuts (6) in a numerical sequence to a 1. Position the No. 1 piston at the top center of
torque o f 20 ± 3 N m (15 ± 2 lb ft). Tighten locknuts the compression stroke. Refer to Testing and
(6) again in a numerical sequence to a torque of Adjusting, “Finding Top Center Position for No. 1
38 ± 5 N m (28 ± 4 lb ft). Piston”.

6. Install the shield assemblies on the exhaust

manifolds.

End By:

a. Install the turbocharger. R eferto Disassembly and

Assembly, “Turbocharger - Install”.

V
g01073852
Illu stra tio n 56
RENR9716-02 21
Disassembly and Assembly Section

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid w ear and shortened

component life.

1. Lubricate the valve stems with clean engine oil.

A WARNING
Personal injury can result from being struck by
parts propelled by a released spring force.

Make sure to w ear all necessary protective equip­

ment.

Follow the recommended procedure and use all

recommended tooling to release the spring force. ^ WARNING
Improper assembly of parts that are spring loaded
2. Install Tooling (A) in the electronic unit injector
can cause bodily injury.
sleeve. Secure Tooling (A) with unit injector clamp
( 1). To prevent possible injury, follow the established
assembly procedure and w ear protective equip­
3. Tighten the full nut until valve spring keepers (3)
ment.
are loose on valve (2).

4. Remove valve spring keepers (3) from the valve. 2. Ensure that washer (7) is installed on the valve
guide.
5. Carefully remove Tooling (A).
3. Install inner valve spring (5) and outer valve spring
6. Remove valve rotator (4). (6) on valve (2).

7. Remove outer valve spring (6) and inner valve 4. Install valve rotator (4) on valve (2).
spring (5) from the valve.

8. Remove washer (7) from the valve guide. A WARNING

9. Use Tooling (B) to check the valve springs (spring The valve spring keepers can be thrown from
force). R efe rto Specifications, “Cylinder Head the valve when the valve spring com pressor is
Valves” for additional information on the valve released. Ensure that the valve spring keepers
springs. are properly installed on the valve stem. To help
prevent personal injury, keep away from the front
of the valve spring keepers and valve springs
Installation Procedure during the installation of the valves.

Table 12
5. Use Tooling (A) to compress inner valve spring
Required Tools
(5) and outer valve spring (6). Install valve spring
Tool Part Number Part Description Qty keepers (3) on valve (2). Remove unit injector
clamp (1) and Tooling (A).
A 9U -7241 Valve Spring Compressor 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 and Exhaust Valves -

Remove and Install
SMCS Code: 1105-010

Removal Procedure
Table 13

Required Tools

Tool Part Number Part Description Qty

Valve Spring
A 5 S -1 3 3 0 1
Compressor

B 8 S -2 2 6 3 Spring Tester 1

Start By:

a. Remove the cylinder head. Refer to Disassembly

and Assembly, “Cylinder Head - Remove”.

NOTICE
A WARNING
Keep all parts clean from contaminants. Personal injury can result from being struck by
parts propelled by a released spring force.
Contaminants may cause rapid wear and shortened
component life. Make sure to wear all necessary protective equip­
ment.

Follow the recommended procedure and use all

recommended tooling to release the spring force.

1. Install Tooling (A) and compress the valve springs.

Remove valve spring keepers (2) from valve (1).

2. Carefully remove Tooling (A) from valve (1).

3. Remove valve rotator (3).

4. Remove outer valve spring (5) and inner valve

spring (4) from valve (1).

5. Remove washer (6) and valve (1) from the valve

guide.

6. Use Tooling (B) to check the valve springs (spring

force). Refer to Specifications, “Cylinder Head
Valves” for additional information on the valve
springs.

7. Inspect the valves. Refer to Specifications,

“Cylinder Head Valves” for additional information
on the inlet and exhaust valves.
RENR9716-02 23
Disassembly and Assembly Section

Installation Procedure 3. Install inner valve spring (4) and outer valve spring
(5) on valve (1).
Table 14

Required Tools 4. Install valve rotator (3) on valve (1).

Tool Part Number Part Description Qty 5. Use Tooling (A) to compress inner valve spring
Valve Spring (4) and outer valve spring (5). 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 w ear and shortened the valve when the valve spring com pressor 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 small amount of grease can be used to hold of the valve spring keepers and valve springs
the retainer locks in position during installation. during the installation o fth e valves.

1. Lubricate the valves with clean engine oil. Install

the valves in the cylinder head. 6. Carefully remove Tooling (A).

End By:

a. Install the cylinder head. Refer to Disassembly

and Assembly, “Cylinder Head - Install”.

i02109151

Inlet and Exhaust Valve Guides

- Remove and Install
SMCS Code: 1104-010

Removal Procedure
Table 15

Required Tools

Tool Part Num ber Part Description Qty

Ad) 9 U -6 8 9 5 Valve Guide Driver 1

0) P art o f 9 U - 7 5 3 0 E n g in e Tool G ro up

Start By:

a. Remove the inlet and exhaust valves. Refer to

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

NOTICE
A WARNING Keep all parts clean from contaminants.
Improper assembly of parts that are spring loaded
Contaminants may cause rapid w ear and shortened
can cause bodily injury.
component life.
To prevent possible injury, follow the established
assem bly procedure and w ear protective equip­
ment.

2. Install washer (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 top of valve guide from cylinder head

surface .... 35.00 ± 0.50 mm (1.378 ± 0.020 inch)

Note: For more information, referto Specifications,

“Cylinder Head Valves”.

3. Install valve stem seal (1) on the valve guide.

End By:

a. Install the inlet and exhaust valves. R eferto

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

1. Remove valve stem seal (1) from valve guide (2).

i02288478
2. Use Tooling (A) and a hammer 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

Tool Part Number Part Description Qty Table 17

AO) 9U -6 8 9 5 Valve Guide Driver 1 Required Tools

BO) 9 U -6 8 9 4 Guide Collar 1 Part
0) P art o f 9 U - 7 5 3 0 E n g in e Tool G ro up Tool Number Part Description Qty

Valve Seat Extractor Tool 1

A 1 6 6 -7 4 4 1
NOTICE Group
Keep all parts clean from contaminants.
Start By:
Contaminants may cause rapid wear and shortened
component life. a. Remove the inlet and exhaust valves. Refer to
Disassembly and Assembly, “Inlet and Exhaust
Valves - Remove and Install”.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

1. Lubricate the bores for the valve guides with clean

engine oil.

2. Install valve guide (2) in the cylinder head with

Tooling (A) and Tooling (B).

g01145463
Illu stra tio n 63
RENR9716-02 25
Disassembly and Assembly Section

1. Use Tooling (A) to remove valve seat insert (1) i02438648

from the cylinder head.
Engine Oil Filter Base -
2. Clean the bores in the cylinder 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 Number Part Description Qty Tool Number Part Description Qty
Valve Seat Driver 1 A 1 8 5 -3 6 3 0 Strap Wrench As 1
9 U -6 8 9 8
BO) (Exhaust)

9 U -6 8 9 7 Valve Seat Driver (Inlet) 1

NOTICE
0) P art o f 9 U - 7 5 3 0 E n g in e Tool G ro up Keep all parts clean from contaminants.

NOTICE Contaminants may cause rapid wear and shortened

Keep all parts clean from contaminants. component life.

Contaminants may cause rapid wear and shortened

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

Refer to Special Publication, NENG2500, “Caterpillar

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

Dispose of all fluids according to local regulations and

mandates.

1. Drain the engine oil into a suitable container

for storage or disposal. Refer to Operation and
1. Lower the temperature of new valve seat insert Maintenance Manual, “Engine Oil and Filter -
( 1).
Change”.

2. Use Tooling (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 excessive valve stem projection indicates that the
valve seat insert is not seated or material was not
cleaned from the bottom of the counterbore.

End By:

a. Install the inlet and exhaust valves. Refer to

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

2 . Use Tooling (A) in order to remove engine oil 3 . Remove springs (3) and plungers (2) from oil filter
filters (6). base assembly (1).

3. Remove bolts (1), (2), (4), and (5).

i02127824

4 . Remove engine oil filter base (3). Engine Oil Filter Base -
Assemble
i02127750

SMCS Code: 1306-016

Engine Oil Filter Base -
Disassemble Assembly Procedure
SMCS Code: 1306-015
NOTICE
Keep all parts clean from contaminants.
Disassembly Procedure
Contaminants may cause rapid w ear and shortened
Start By:
component life.
a. Remove the engine oil filter base. R e fe rto
Disassembly and Assembly, “Engine Oil Filter
Base - Remove”.

1. Remove the O-ring seals.

A WARNING
Improper assembly of parts that are spring loaded
can cause bodily injury.

A WARNING To prevent possible injury, follow the established

assembly procedure and wear protective equip­
Personal injury can result from being struck by ment.
parts propelled by a released spring force.
1. Install plungers (2) and springs (3) in oil filter base
Make sure to w ear all necessary protective equip­
assembly (1).
ment.
2 . Install cover (4).
Follow the recommended procedure and use all
recommended tooling to release the spring force.
3 . Install the O-ring seals.

2 . Remove cover (4).

RENR9716-02 27
Disassembly and Assembly Section

End By: i02438849

a. Install the engine oil filter base. Refer to Engine Oil Cooler - Remove
Disassembly and Assembly, “Engine Oil Filter
Base - Install”. SMCS Code: 1378-011

i02438813
Removal Procedure
Engine Oil Filter Base - Install Start By:

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 Number Part Description Qty component life.

A 1 8 5 -3 6 3 0 Strap Wrench As 1
NOTICE
Care must be taken to ensure that fluids are contained
NOTICE during performance of inspection, maintenance, test­
Keep all parts clean from contaminants. ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open­
Contaminants may cause rapid wear and shortened ing any compartment or disassembling any compo­
component life. nent containing fluids.

R eferto Special Publication, NENG2500, “Caterpillar

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

Dispose of all fluids according to local regulations and

mandates.

1. Drain the coolant from the cooling system into a

suitable container for storage or 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), and (5).

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

4 . Refill the engine with engine oil. R eferto Operation

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

2 . Remove tube assembly (2).

3 . Remove bonnet (1) and the gasket.

28 RENR9716-02
Disassembly and Assembly Section

4. Remove engine oil cooler (3). i02439263

5. Remove the O-ring seals from engine oil cooler 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 must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test­
Contaminants may cause rapid wear and shortened ing, adjusting and repair of the product. Be prepared to
component life. collect the fluid with suitable containers before open­
ing any compartment or disassembling any compo­
nent containing fluids.

Refer to Special Publication, NENG2500, “Caterpillar

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 seals on engine oil cooler (3).

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

or glycerin.

3. Install engine oil cooler (3).

4. Install the gasket and bonnet (1).

5. Install tube assembly (2).

1. Remove tube assemblies (3) from engine oil pump
6. Refill the cooling system with coolant. Refer to (2).
Operation and Maintenance Manual, “Cooling
System Coolant - Change”. 2. Remove bolts (1) and engine oil pump (2).

End By:

a. Install the engine oil filter base. Refer to

Disassembly and Assembly, “Engine Oil Filter
Base - Install”.
RENR9716-02 29
Disassembly and Assembly Section

i02439652 3. Remove bolts (4) and separate cover assembly

(3) from body assembly (1).
Engine Oil Pump - Disassemble
4. Use Tooling (A) and a suitable press in order to
SMCS Code: 1304-015 remove the bearings from cover assembly (3).

Disassembly Procedure 5. Remove shaft assemblies (2).

Table 21 6. Remove bolts (12) and retainer (11).

Required Tools
7. Remove spring (10), plunger ring (9), and plunger
Part (8).
Tool Number Part Description Qty

A 1 P -0 5 1 0 Driver Group 1 8. Use Tooling (A) and a suitable press in order to

remove the bearings from body assembly (1).
B 1P -2 3 2 0 Puller Assembly 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”.
Assembly Procedure
NOTICE
Keep all parts clean from contaminants. Table 22

Required Tools
Contaminants may cause rapid wear and shortened
component life. Part
Tool Number Part Description Qty

A 1P -0 5 1 0 Driver Group 1

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid w ear and shortened

component life.

A WARNING
Personal injury can result from being struck by
parts propelled by a released spring force.

Make sure to w ear all necessary protective equip­

ment.

Follow the recommended procedure and use all

recommended tooling to release the spring force.

1. Remove bolt (7) and washer (6).

2. Use Tooling (B) to remove drive gear (5) from

body assembly (1). Remove the key from the
pump shaft.
30 RENR9716-02
Disassembly and Assembly Section

5 . Use Tooling (A) to install the bearings 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
Angle (Y). Angle (Y) is 30 ± 15 degrees from the
center line of the bearing bores, and toward the
outlet passage. The outlet passage has a cavity
between the bearing bores.

6. Install cover assembly (3) on body assembly (1).

Install bolts (4).

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

gear (5). Install washer (6) and bolt (7). Tighten
bolt (7) to a torque of 55 ± 10 N m (41 ± 7 lb ft).
Illu s tra tio n 7 4 g 0 l2 l9 0 4 5

End By:
3
a. Install the engine oil pump. R eferto 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 w ear and shortened

component life.
Improper assembly of parts that are spring loaded
can cause bodily injury.

To prevent possible injury, follow the established

assem bly procedure and w ear protective equip­
ment.

1. Use Tooling (A) to install the bearings 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
Angle (X). Angle (X) is 30 ± 1 5 degrees from the
center line of the bearing bores and toward the
outlet passage in the engine oil pump.

2 . Install plunger (8), plunger ring (9), and spring

( 10 ).
1. Position engine oil pump (2) and install bolts (1).
3 . Install retainer (11) and bolts (12).
2 . Install tube assemblies (3) on engine oil pump (2).
4 . Install shaft assemblies (2).
End By:

a. Install the engine oil pan. R eferto Disassembly

and Assembly, “Engine Oil Pan - Remove and
Install”.
RENR9716-02 31
Disassembly and Assembly Section

i02440626

Water Pump - Remove

SMCS C ode: 1361-011

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

Refer to Special Publication, NENG2500, “Caterpillar

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

Dispose of all fluids according to local regulations and

mandates.
4. Remove bolts (6) and nuts (5).

NOTICE 5. Remove water pump (4).

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened i02451192

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

Required Tools

Part
Tool Number Part Description Qty

8 S -2 2 6 4 Puller Group 1

Bolt
4 B -3 9 0 3 5/16 - 18 NC by 4 2
A inch

1P -0 4 5 6 Plate 1

4 B -4 2 7 7 W asher 2

B 1P -0 5 1 0 Driver Group 1

S ta rt By:

a. Remove the water pump. Refer to Disassembly

and Assembly, “Water Pump - Remove”.

Illu s tra tio n 77 g 0 l2 l9 2 7 4 NOTICE

Keep all parts clean from contaminants.
2. Remove bolts (1) and bolts (2).
Contaminants may cause rapid wear and shortened
3. Remove cover (3). component life.
32 RENR9716-02
Disassembly and Assembly Section

Note: The w ater pump seal can be replaced without i02394663

removing the water pump from the engine.
Water Pump - Assemble
Note: An intermittent leakage of a small amount of
coolant from the hole in the w ater pump housing is SMCS Code: 1361-016
not an indication o f a w ater pump seal failure. This
is required to provide lubrication for the seal. Do not Assembly Procedure
replace the w ater pump seal unless a large amount
o f leakage or a constant flow of coolant is draining Table 2 4
from the w ater pump housing. Required Tools

Part
Tool Number Part Description Qty

B 1P -0 5 1 0 Driver Group 1

C 7 N -7 8 4 3 Seal Installation Tool 1

D 6V -1541 Quick Cure Primer 1

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

1. Remove adapter (15).

2 . Remove bolt (9) and w asher (8).

3. Use Tooling (A) to remove impeller (5) from shaft

10
( ).

4. Remove bolt (7), washer (6), and gear (4) from

shaft (10).

5 . Remove bolts (11) and retainer (13).

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

7. Use a suitable press to remove shaft (10) and

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 assembly
2 . Apply Tooling (D) to shaft (10). Use a suitable
(1) from shaft (10).
press to install bearing assembly (1) on shaft (10).
9 . Remove seal assembly (12) from housing (3).
3 . Install shaft (10) and bearing assembly (1) in
housing (3).
10. Use Tooling (B) to remove lip seal (2) from the
housing.
4 . Install O-ring seal (14) on housing (3).

5 . Install retainer (13) and bolts (11).

6. Position gear (4) on shaft (10). Install washer (6)

and bolt (7).
RENR9716-02 33
Disassembly and Assembly Section

7. Use Tooling (C) to install seal assembly (12) onto

shaft (10) until the stationary cup is fully seated
into housing (3).

8. Install impeller (5) on shaft (10). Install washer

(8) and bolt (9). Tighten bolt (9) to a torque of
39 ± 3 N m (29 ± 2 lb ft).

9 . Install adapter (15).

End By:

a. Install the water pump. R eferto Disassembly and

Assembly, “W ater Pump - Install”.

i02440675

Water Pump - Install

SMCS Code: 1361-012

Illu stra tio n 8 2 g 0 l2 l9 2 7 4

Installation Procedure
3. Position cover (3) on the water pump.
NOTICE
Keep all parts clean from contaminants. 4. Install bolts (2) and bolts (1).

Contaminants may cause rapid wear and shortened 5. Fill the cooling system. Refer 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 the coolant from the cooling system into a
suitable container for storage or disposal until the
coolant is below the level of the water temperature
regulator housing. Refer to Operation and
Maintenance Manual, “Cooling System Coolant
- Change”.

Illu s tra tio n 81 g 0 l2 l9 2 7 5

1. Position w ater pump (4) in the front housing.

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

34 RENR9716-02
Disassembly and Assembly Section

2. Disconnect hose assembly (1) and elbow (3). 2. Install water temperature regulators (7) and O-ring
seals (6) in water temperature regulator housing
3. Remove bolts (2) and bolts (4). Remove water (5).
temperature regulator housing (5).

3. Position water temperature regulator housing (5)

4. Remove O-ring seals (6) and w ater temperature on the engine. Install bolts (4) and bolts (2).
regulators (7) from water temperature regulator
housing (5). 4. Connect elbow (3) and hose assembly (1).

5. If necessary, remove the lip seals. 5. Fill the cooling system. Refer to Operation and
Maintenance Manual, “Cooling System Coolant
- Change”.
Installation Procedure
Table 25

Required Tools

Part
Tool Number Part Description Qty

A 2 2 1 -8 6 4 7 Seal Installer Gp 1

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

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

RENR9716-02 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 Qty Illu stra tio n 8 8 g 0 l2 9 0 9 l5
Number

A 1 8 9 -0 4 1 0 Shackle As 2 3. Disconnect bottom aftercooler tube (2).

S ta rt By:

a. Remove the fan. R e fe rto Disassembly and

Assembly, “Fan - Remove and Install”.

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.

R e fe rto Special Publication, NENG2500, “Caterpillar Illu stra tio n 8 9 g 0 l2 9 0 9 l6

Tools and Shop Products Guide” fortools and supplies
suitable to collect and contain fluids on Caterpillar 4. Disconnect top radiator hose (3).
products.

Dispose of all fluids according to local regulations and

mandates.

1. Drain the coolant from the cooling system into

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

Illu stra tio n 9 0 g 0 l2 9 0 9 l7

5. Disconnect top aftercooler tube (4).

Illu s tra tio n 87 g0l290908

2. Remove clamp (1). Repeat for the opposite side.

36 RENR9716-02
Disassembly and Assembly Section

g01290930 g01290940
Illu s tra tio n 91 Illu stra tio n 9 4

6. Disconnect bottom radiator hose (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).

Illu s tra tio n 92 g0l290934

Illu stra tio n 9 5 gO l290941
7 . Disconnect hose assembly (8) from fuel cooler (7).
10. Remove bolts (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
Illu s tra tio n 93 g0l290939 Table 27

Required Tools
8. Disconnect hose assembly (9) from fuel cooler (7).
Part Number Part Description

1 8 9 -0 4 1 0 Shackle As
RENR9716-02 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, NENG2500, “Caterpillar

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

Dispose of all fluids according to local regulations and Illu stra tio n 9 8 gO l290939
mandates.
3. Connect hose assembly (9) onto fuel cooler (7).

Illu s tra tio n 96 g0l290940

Illu stra tio n 9 9 gO l290934

1. Attach Tooling (A) and a suitable lifting device
onto cooling package (10). The weight of cooling 4. Connect hose assembly (8) onto fuel cooler (7).
package (10) is approximately 544 kg (1200 lb).

g01290930
Illu stra tio n 100
g01290941
Illu s tra tio n 97

5. Connect bottom aftercooler tube (6). Connect

2. Install cooling package (10). Install bolts (11). bottom radiator hose (5).
Repeat for the opposite side.
38 RENR9716-02
Disassembly and Assembly Section

Illu s tra tio n 101 g 0 l2 9 0 9 l7 Illu stra tio n 104 gOl 290908

6. Connect top aftercooler tube (4). 9. Install clamp (1). Repeat for the opposite 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

Assembly, “Fan - Remove and Install”.

i02584900

Aftercooler - Remove
SMCS Code: 1063-011
Illu s tra tio n 102 g 0 l2 9 0 9 l6

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

Table 28

Required Tools

Tool Part Number Part Description Qty

A 1 8 9 -0 4 1 0 Shackle As 2

Start By:

a. Remove the fan. R e fe rto Disassembly and

Assembly, “Fan - Remove and Install”.

Illu s tra tio n 103 g 0 l2 9 0 9 l5

8. Connect bottom aftercooler tube (2).

RENR9716-02 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.

R e fe rto Special Publication, NENG2500, “Caterpillar

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

Dispose of all fluids according to local regulations and g01290916

Illu stra tio n 107
mandates.
4. Disconnect top radiator hose (3).
1. Drain the coolant from the cooling system into
a suitable container for storage or for disposal.
Refer to Operation and Maintenance Manual,
“Cooling System Coolant (ELC) - Change” .

Illu stra tio n 108 g 0 l2 9 0 9 l7

5. Disconnect top aftercooler tube (4).

Illu s tra tio n 105 g0l290908

2. Remove clamp (1). Repeat for the opposite side.

Illu stra tio n 109 gOl 290930

6. Disconnect bottom radiator hose (5). Disconnect

bottom aftercooler tube (6).
Illu s tra tio n 106 g 0 l2 9 0 9 l5

3. Disconnect bottom aftercooler tube (2).

40 RENR9716-02
Disassembly and Assembly Section

Illu s tra tio n 110 g0l290934 g01294232

Illu stra tio n 113

7 . Disconnect hose assembly (8) from fuel cooler (7). 10 . Attach Tooling (A) and a suitable lifting device
onto aftercooler (12). The weight of aftercooler
(12) is approximately 227 kg (500 lb).

g01290939
Illu s tra tio n 111

g01294234
8. Disconnect hose assembly (9) from fuel cooler (7). Illu stra tio n 114

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

(15) from aftercooler (12).

12. Repeat Step 9 through Step 11 for the opposite

side.

13. Remove aftercooler (12).

i02585968

Aftercooler - Install
SMCS Code: 1063-012
go1294215
Illu s tra tio n 112
Installation Procedure
9. Remove bolts (10). Remove bolt (11).
Table 29

Required Tools

Part
Tool Part Number Qty
Description

A 1 8 9 -0 4 1 0 Shackle As 2
RENR9716-02 41
Disassembly and Assembly Section

g01294232 Illu stra tio n 118 gOl 290939

Illu s tra tio n 115

1. Attach Tooling (A) and a suitable lifting device onto 5. Connect hose assembly (9) onto fuel cooler (7).
aftercooler (12). The weight o f aftercooler (12) is
approximately 227 kg (500 lb). Install aftercooler
(12).

g01290934
Illu stra tio n 119

6. Connect hose assembly (8) onto fuel cooler (7).

g01294234
Illu s tra tio n 116

2. Install bolts (14) and bolts (15) into aftercooler

(12). Install bolt (13).

g01290930
Illu stra tio n 120

7. Connect bottom aftercooler tube (6). Connect

bottom radiator hose (5).
Illu s tra tio n 117 g 0 l2 9 4 2 l5

3. Install bolt (11). Install bolts (10).

4. Repeat Step 2 and Step 3 for the opposite side.

42 RENR9716-02
Disassembly and Assembly Section

Illu s tra tio n 121 g 0 l2 9 0 9 l7 Illu stra tio 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

Assembly, “Fan - Remove and Install”.

i02581106

Radiator Core - Remove

SMCS Code: 1353-011; 1353-011-KO
Illu s tra tio n 122 g 0 l2 9 0 9 l6

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

Table 30

Required Tools

Part
Tool Part Description Qty
Number

A 1 3 8 -7 5 7 5 Link Bracket 2

Start By:

a. Remove the aftercooler. Refer to Disassembly

and Assembly, “Aftercooler - Remove”.

Illu s tra tio n 123 g 0 l2 9 0 9 l5

10 . Connect bottom aftercooler tube (2).

RENR9716-02 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.

R e fe rto Special Publication, NENG2500, “Caterpillar

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

Dispose of all fluids according to local regulations and Illu stra tio n 127 gOl 294577
mandates.
3. Remove the upper and the lower braces (3).

Illu s tra tio n 125 g0 l2 9 2 9 H

Illu stra tio n 128 gOl 294578

1. Remove the upper and the lower radiator guards
( 1). 4. Remove bolts (4) and remove bolts (5).

Illu s tra tio n 126 g 0 l2 9 2 9 l2

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

radiator top tank (2). The weight of the radiator is
approximately 227 kg (500 lb).

g01294579
Illu stra tio n 129

5. Remove bolts (6).

44 RENR9716-02
Disassembly and Assembly Section

g01292912
Illu stra tio n 132

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

radiator top tank (2). The weight o fth e radiator is
approximately 227 kg (500 lb).

go1294580
Illu s tra tio n 130

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

support (9).

7. Repeat Steps 4 through 6 for the opposite side.

g01294602
Illu stra tio n 133

2. Install radiator (10). Install bolts (11). Repeat for

the opposite side.

g01294602
Illu s tra tio n 131

8. Remove bolts (11). 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 Part Description Qty
Number Illu stra tio n 134 gOl 294580
A 1 3 8 -7 5 7 5 Link Bracket 2
3. Install support (9). Install bolts (8). Install bolts (7).
RENR9716-02 45
Disassembly and Assembly Section

g01292911
Illu stra tio n 138

8. Install the upper and the lower radiator guards (1).

End By:

a. Install the aftercooler. Refer to Disassembly and

Illu s tra tio n 135 g0l294579
Assembly, “Aftercooler - Install”.
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 Disassembly and Assembly, “Vibration
Damper and Pulley - Remove and Install”.
Illu s tra tio n 136 g0l294578
1. Support the front of the engine.
5. Install bolts (4) and bolts (5).

6. Repeat Steps 3 through 5 for the opposite side.

g01221659
Illu stra tio n 139

2. Remove bolts (1).

Illu s tra tio n 137 g0l294577
3. Remove engine support (2).
7. Install the upper and the lower braces (3).
46 RENR9716-02
Disassembly and Assembly Section

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

Illu stra tio n 142 g 0 l2 2 l6 6 3

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

End By: 2 . Install bolts (3).

a. Install the vibration damper and the pulley. Refer End By:
to Disassembly and Assembly, “Vibration Damper
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 dam per and the pulley. Gear Group (Rear) - Remove
Refer to Disassembly and Assembly, “Vibration
Damper and Pulley - Remove and Install”. SMCS Code: 1206-011; 1212-011

1 . Support the front of the engine.

Removal Procedure
Table 32

Required Tools

Part
Tool Number Part Description Qty

A 1 P -0 5 1 0 Driver Group 1

Start By:

a. Remove the flywheel housing. Refer to

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

Illu s tra tio n 141 g 0 l2 2 l6 6 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).
RENR9716-02 47
Disassembly and Assembly Section

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

NOTICE the bearing from gear assembly (6).
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test­ 5. Remove bolts (2), gear assembly (1), and shaft
ing, adjusting and repair o f the product. Be prepared to assembly (3).
collect the fluid with suitable containers before open­
ing any compartment or disassembling any compo­ 6. Use Tooling (A) and a suitable press to remove
nent containing fluids. the bearing from gear assembly (1).

Refer to Special Publication, NENG2500, “Caterpillar 7. Remove gear assembly (12).

Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar 8. Remove bolts (5) 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. Remove bolts (16) and shaft assembly (17).

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

assemblies (15).

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

plates. Remove the O-ring seals.

1 . Remove bolts (10), thrust plate (11), and gear

assembly (9).

2 . Use Tooling (A) and a suitable press to remove

the bearing from gear assembly (9).

3. Remove bolts (8), gear assembly (6), and shaft

assembly (7).
48 RENR9716-02
Disassembly and Assembly Section

i02442469

Gear Group (Rear) - Install

SMCS C ode: 1206-012; 1212-012

Installation Procedure
Table 33

Required Tools

Part
Tool Number Part Description Qty

A 1 P -0 5 1 0 Driver Group 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.

Illu stra tio n 147 gO H 5l468

4. Refer to Testing and Adjusting, “Rear 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 assemblies (4) and install bolts (5).

1. Install the O-ring seals and the sealing plates on
the cylinder head. 6. Install gear assembly (12).

2. Install adapter assemblies (15), thrust plates (14), 7. Use Tooling (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 assembly (17) and install bolts (16).
RENR9716-02 49
Disassembly and Assembly Section

8. Install shaft assembly (3), gear assembly (1), and

bolts (2).

9 . Use Tooling (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: Align the Timing Mark on gear assembly (9)

with the Timing Mark on gear assembly (12).

12 . Install gear assembly (9), thrust plate (11), and 1. Remove two bolts (1). Install Tooling (A) in the
bolts (10). crankshaft.

13. Tighten the bolts on gear assemblies (4) to a 2. Remove remaining bolts (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 flywheel (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 hammer 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 Number Part Description Qty

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

Table 3 4 B 6 V -4 8 7 6 Lubricant -
Required Tools

Part
Tool Number Part Description Qty

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

g01220437
Illu s tra tio n 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 of the teeth upward. The chamfered
side of the gear teeth will be facing toward the starting
motor when the flywheel is installed.

1. Raise the temperature o f ring gear (3). Install ring

gear (3) on flywheel (2).
1 . Use Tooling (A) o ra punch and hammer in order
2 . Install Tooling (A) in the crankshaft. 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 Tooling (A) to remove crankshaft rear seal (1)
(285 lb). Position flywheel (2) on the crankshaft. and crankshaft wear sleeve (2).

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

i02442921

5 . Install bolts (1). Remove Tooling (A). Install Crankshaft Rear Seal - Install
remaining bolts (1).
SMCS Code: 1161-012
6. Tighten bolts (1) to a torque of 100 ± 5 N m
(75 ± 4 lb ft). Turn the bolts for an additional 180 ±
5 degrees. Installation Procedure
Table 37
7 . Check the flywheel runout. Refer to Testing and
Adjusting, “Flywheel - Inspect”. Required Tools

Part
Tool Number Part Description Qty
i02442878
2 4 9 -2 9 3 7 0 ) Seal Locator As 1
Crankshaft Rear Seal - Remove
5 P - 731 00) Bolt 3
SMCS Code: 1161-011
9 S - 88580) Nut (Seal Installer) 1

6V - 6 1 43 d) Seal Installer 1
Removal Procedure B
5P -1 733(2) Seal Locator As 1
Table 36
5 P - 7309(2) Bolt 3
Required Tools
9 S - 8858(2) Nut (Seal Installer) 1
Part
Tool Number Part Description Qty 6 V -6142(2) Seal Installer 1

A 1U -7 60 0 Slide Hammer Puller 1 0) Large c ra n k s h a ft g e a r

(2) S m all cra n k s h a ft g e a r

Start By:

a. Remove the flywheel. Refer to Disassembly and

Assembly, “Flywheel - Remove and Install”.
RENR9716-02 51
Disassembly and Assembly Section

b. Remove the electric starting motor. Refer to

NOTICE Disassembly and Assembly, “Electric 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 diam eter of the crankshaft.

Note: Install the crankshaft rear seal with the arrow

that shows the direction of crankshaft rotation toward
the rear of the engine.

2. Use Tooling (B) to install crankshaft w ear sleeve

(2) and crankshaft rear seal (1) as a unit.

End By:

a. Install the flywheel. Refer to Disassembly and

Assembly, “Flywheel - Remove and Install”.

i02752908

Flywheel Housing - Remove 1. Disconnect hose assemblies (1) from flywheel

housing (2).
and Install
2. Disconnect fuel filter base (5) from flywheel
SMCS Code: 1157-010 housing (2). Reposition fuel filter base (5) and the
hose assemblies.
Removal Procedure
3. Remove two bolts (4) and install 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 Number Part Description Qty

A 1 3 8 -7 5 7 4 Link Bracket 2 5. Remove remaining bolts (4), bolts (6), and bolts
(3). Remove flywheel housing (2) and the gasket
Guide Stud from the rear housing.
B - 2
1 /2 - 1 3 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 Number Part Description Qty

A 1 3 8 -7 5 7 4 Link Bracket 2

Guide Stud
B - 2
1 /2 - 1 3 NC by 7 inch

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

1. Install Tooling (B) in the cylinder 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. Remove Tooling (B) and install remaining bolts (4).

5 . Tighten the bolts, as follows:

a. In a numerical sequence, tighten Bolt 1 through

Bolt 2 to a torque of 55 ± 10 N m (41 ± 7 lb ft).

b. In a numerical sequence, tighten Bolt 3

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

c. In a numerical sequence, tighten Bolt 11

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

6. Reposition fuel filter base (5) and the hose

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

7 . Connect hose assemblies (1) to flywheel housing

(2).
RENR9716-02 53
Disassembly and Assembly Section

End By:

a. Install the electric starting motor. Refer to

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

b. Install the crankshaft rear seal. Refer to

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

i02443805

Vibration Damper and Pulley -

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

Removal Procedure 2. Remove two bolts (2) and install Tooling (A).
Table 40
3. Remove remaining bolts (2) and pulley (3).
Required Tools
4. Slide vibration damper (4) along Tooling (A).
Part
Tool Num ber Part Description Qty
5. Attach a suitable lifting device onto vibration
Guide Stud damper (4). The weight of vibration damper (4)
A - 2
1 /2 - 1 3 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 Number Part Description Qty

Guide Stud
A - 2
1 /2 - 1 3 NC by 5 inch

g01221078
Illu stra tio n 159
54 RENR9716-02
Disassembly and Assembly Section

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

Illu stra tio n 161 g 0 l2 2 l2 7 2

1. Install Tooling (A) in the adapter. 1. Remove bolts (1) and adapter (2).

2 . Attach a suitable lifting device onto vibration

damper (4). The weight o f vibration dam per (4)
is approximately 34 kg (75 lb). Position vibration
damper (4) on the adapter.

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

4 . Remove Tooling (A). Install remaining bolts (2).

Tighten bolts (2) to a torque o f 135 ± 20 N m
(100 ± 15 lb ft).

5 . Install V-belt (1) on the engine.

i02444403
Illu stra tio n 162 g 0 l2 2 l2 7 6

Crankshaft Front Seal -

2 . Use Tooling (A) or a punch and hammer in order
Remove to puncture three or more holes in crankshaft front
seal (4).
SMCS Code: 1160-011
3 . Use Tooling (A) to remove crankshaft front seal
Removal Procedure (4).

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

hammer in order to puncture three or more holes
Required Tools
in crankshaft wear sleeve (3). Use Tooling (A) to
Part remove crankshaft wear sleeve (3).
Tool Number Part Description Qty

A 1U -7 6 0 0 Slide Hammer Puller 1

Start By:

a. Remove the crankshaft vibration dam per 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 Number Part Description Qty

5 P -1 7 3 3 Seal Locator 1

5 P -1 7 3 7 Bolt 3
B
9 S -8 8 5 8 Nut (Seal Installer) 1 3. Install adapter (2) and bolts (1).
6 V -6 1 4 2 Seal Installer 1
End By:

NOTICE a. Install the crankshaft vibration damper and pulley.

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

1. Clean the outside diam eter of the crankshaft. Gear Group (Front) - Remove
SMCS Code: 1206-011

Removal Procedure
Start By:

a. Remove the front housing. Refer 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 (B) to install crankshaft front seal (4)

and crankshaft wear sleeve (3) as a unit.

Note: Install the crankshaft front seal with the arrow

that shows the direction of crankshaft rotation toward
the front of the engine.
56 RENR9716-02
Disassembly and Assembly Section

1. Apply 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
torque of 55 ± 10 N m (41 ± 7 lb ft).

1. Remove bolts (5) and gear assembly (4).

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

assembly (1).

3. Remove bolts (6) and shaft (7). 2 . Position gear assembly (1) on the shaft. Install
plate (2) and bolts (3).

i02691256
3 . Install gear assembly (4) and bolts (5).
Gear Group (Front) - Install End By:
SMCS Code: 1206-012
a. Install the front housing. R eferto Disassembly and
Assembly, “Housing (Front) - Install”.
Installation Procedure
NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.
RENR9716-02 57
Disassembly and Assembly Section

i02445219

Housing (Front) - Remove

SMCS Code: 1151-011

Removal Procedure
Start By:

a. Remove the w ater temperature regulator housing.

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

b. Remove the water pump. Refer to Disassembly

and Assembly, “Water Pump - Remove”.

c. Remove the crankshaft front seal. Refer to

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

d. Remove the front engine support. Refer to

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

e. Remove the alternator. Refer to Disassembly and 2. Remove covers (1).

Assembly, “Alternator - Remove and Install”.
3. Remove alternator bracket (3) from front housing
f. Remove the crankshaft position sensor. Refer to (4).
Disassembly and Assembly, “Crankshaft 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, maintenance, test­
ing, adjusting and repair o f the product. Be prepared to
collect the fluid with suitable containers before open­
ing any compartment or disassembling any compo­
nent containing fluids.

Illu stra tio n 170 g 0 l2 2 l9 4 l

Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar 4. Remove bolts (5) and dampers (6).
products.

Dispose o f 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 4 4

Required Tools

Part
Tool Number Part Description Qty

A 4 C -9 6 1 2 Silicone Sealant 1
Illu s tra tio n 171 901221953

NOTICE
5. Disconnect bracket (7) and elbows (8). Keep all parts clean from contaminants.

Contaminants may cause rapid w ear and shortened

component life.

6. Remove adapters (9).

7. Attach a suitable lifting device to front housing (4).

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

9. Remove front housing (4) and the gasket. 2. Attach a suitable lifting 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 (11).

4. Trim the gasket between the front housing and the

cylinder block even with the bottom of the front
housing.

5. Install adapters (9).

RENR9716-02 59
Disassembly and Assembly Section

Illu s tra tio n 174 g 0 l2 2 l9 5 3

6. Connect elbows (8) and bracket (7).

Illu stra tio n 177 g 0 l2 2 l8 9 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. Install the camshaft position sensor. R eferto

Illu s tra tio n 175
g01221941 Disassembly and Assembly, “Camshaft Position
Sensor - Remove and Install”.

b. Install the crankshaft position sensor. R eferto

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

c. Install the alternator. R eferto Disassembly and

Assembly, “Alternator - Remove and Install”.

d. Install the front engine support. R e fe rto

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

e. Install the crankshaft front seal. Refer to

Disassembly and Assembly, “Crankshaft Front
Illu s tra tio n 176 g O H 5 l4 4 l Seal - Install”.

7. Install dampers (6) and bolts (5). f. Install the water pump. Refer to Disassembly and
Assembly, “Water Pump - Install”.
8. Tighten the bolts to a torque of 240 ± 40 N m
(177 ± 30 lb ft). Tighten the bolts in the following g. Install the water temperature regulator housing.
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 reargeargroup. R eferto Disassembly

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

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid w ear and shortened

component life.

1. Remove the bolts that hold the engine oil pan to

the rear housing.

2 . Disconnect hose assembly (1).

3 . Remove bolts (2).

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

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

5 . Remove bolts (3).

6. Remove rear housing (4) and the gasket.

i02291566

Housing (Rear) - Install

SMCS Code: 1157-012

Installation Procedure
Table 45

Required Tools

Part
Tool Number Part Description Qty

A 4 C -9 6 1 2 Silicone Sealant 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. Apply Tooling (A) to the bottom of the rear housing

at the junction of the cylinder block and the 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 gasket on rear housing (4).

4 . Position rear housing (4) on the cylinder block.

Install bolts (3). Tighten bolts (3) in a numerical
sequence to a torque of 55 ± 10 N m (41 ± 7 lb ft).
g01147138
Illu s tra tio n 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

Illu stra tio n 183 gOH4794l

1. Remove bolts (1) and valve mechanism covers

(2).

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

7. Connect hose assembly (1). Contaminants may cause rapid wear and shortened
component life.
8. Install the bolts that hold the engine oil pan to the
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 re a rg ea rg ro u p. R e ferto Disassembly

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

i02293132

Valve Mechanism Cover -

Illu stra tio n 184 gOH4794l
Remove and Install
1. Position valve mechanism covers (2) on 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”.
RENR9716-02 63
Disassembly and Assembly Section

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

3 4 5

Illu stra tio n 186 gOH47965

1. Install the seal on valve mechanism cover base

(3).

3 4 5 2 . Position valve mechanism cover base (3) on the

cylinder head and install bolts (4).
Illu s tra tio n 185 gOH47965

3. Position harness assemblies (5) on the electronic

1. Remove tube assemblies (1). unit injectors. Tighten the cap nuts to a torque of
1.70 ± 0 .2 5 N m (15 ± 2 lb in).
2. Disconnect harness assemblies (5) and harness
assembly (2). 4. Connect harness assembly (2).

3. Remove bolts (4). 5 . Install tube assemblies (1).

4. Remove valve mechanism cover base (3) and the End By:
seal from the cylinder 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 Number Part Description Qty

A 1 2 4 -2 9 4 6 Lifting Bracket 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. Remove valve rocker arms (11) and electronic unit

injector rocker arm (3) from rocker shaft assembly
(4).

2. Remove jam nut (7) from adjustment screw (8).

3. Remove adjustment screw (8) from valve rocker

arms (11).

4. Remove button (10) from adjustment screw (8).

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

5. Remove jam nut (2) from unit injector adjustment

screw (1).
3 4

Illu s tra tio n 187 g0H48045

6. Remove unit injector adjustment screw (1) from
electronic unit injector rocker arm (3).
1. Remove bolts (2).
7. Remove button (6) from unit injector adjustment
screw (1). Remove O-ring seal (5) from the unit
2. Use Tooling (A) to remove rocker arm shaft
injector adjustment screw.
assembly (4), valve rocker arms (3), and electronic
unit injector rocker arms (1) as a unit.
i02451120

i02451112 Rocker Arm - Assemble

Rocker Arm - Disassemble SMCS Code: 1123-016
SMCS Code: 1123-015
Assembly Procedure
Disassembly Procedure
NOTICE
Start By: Keep all parts clean from contaminants.

a. Remove the rocker arms and the rocker shaft. Contaminants may cause rapid wear and shortened
Refer to Disassembly and Assembly, “Rocker 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

Rocker Arm and Shaft - Install

SMCS Code: 1102-012

Installation Procedure
Table 47

Required Tools

Part
Tool Number Part Description Qty

A 1 2 4 -2 9 4 6 Lifting Bracket 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) in button (10).

2. Use a soft hammer to seat button (10) on

adjustment screw (8).

3. Install adjustment screw (8) in valve rocker arms

(11). Install jam nut (7) on the adjustment screw.

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

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

injector adjustment screw (1).

6. Install unit injector adjustment screw (1) in

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

7. Lubricate rocker shaft assembly (4) with clean

engine oil.

8. Install valve rocker arms (11) and electronic unit

3 4
injector rocker arm (3) on rocker shaft assembly
(4). g01148045
Illu stra tio n 190

End By:

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

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

g01325993
Illu stra tio n 191
66 RENR9716-02
Disassembly and Assembly Section

1. Position rocker arm shaft assembly (4), valve

rocker arms (3), and electronic unit injector rocker NOTICE
arms (1) as a unit with Tooling (A) on the cylinder Care must be taken to ensure that fluids are contained
head. during performance of inspection, maintenance, test­
ing, adjusting and repair of the product. Be prepared to
2. Install bolts (2) and tighten to a torque of collect the fluid with suitable containers before open­
50 ± 5 N m (37 ± 4 lb ft) 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.
R eferto Special Publication, NENG2500, “Caterpillar
3. Adjust the valve lash for the inlet valves and the Dealer Service Tool Catalog” for tools and supplies
exhaust valves. R eferto Testing and Adjusting, suitable to collect and contain fluids on Caterpillar
“Engine Valve Lash - Inspect/Adjust”. products.

4. Adjust the electronic unit injectors. R eferto Testing 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
Cylinder Head - Remove 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 during installation, interference can
occur between the pistons and the valves, resulting in
Removal Procedure damage to the engine.

Table 48
1. Drain the coolant from the cooling system into a
Required Tools suitable container for storage or disposal. Refer
Part to Operation and Maintenance Manual, “Cooling
Tool Number Part Description Qty System Coolant - Change”.

A 1 3 8 -7 5 7 3 Link Bracket 3

B 1U-9 2 0 0 Lever Puller Hoist 1

Start By:

a. Remove the electronic unit injectors. Refer to

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

b. Remove the valve mechanism cover base. Refer

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

c. Remove the fuel transfer pump. Refer to

Disassembly and Assembly, “Fuel Transfer Pump
- Remove”. 2 . Remove cover (1).
RENR9716-02 67
Disassembly and Assembly Section

3. Remove bolts (2) and gear (3). 6. Remove elbow (8). Disconnect hose assembly (9).

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

assembly (6).

g01148489
Illu stra tio n 197

7. Remove elbow (11) and cover (10).

8. Disconnect harness assembly (12) and harness

assembly (13).

9. Remove bracket (14).

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

Remove the O-ring seals.

g01148492
Illu stra tio n 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 of cylinder head (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. Remove bolts (17). Remove sealing plate (18) Installation Procedure
and adapter assembly (19).
Table 49

Required Tools

Tool Part Number Part Description Qty

A 1 3 8 -7 5 7 3 Link Bracket 3

B 1U -9 2 0 0 Lever Puller Hoist 1

C 4 C -5 5 9 3 Anti-Seize Compound 1

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.
g01148522
Illu s tra tio n 20 0

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
Illu stra tio n 202

g01148568
Illu s tra tio n 201
RENR9716-02 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
Illu s tra tio n 2 0 3

1. Install the gaskets, O-ring seals, and the spacer

plate on the engine.

2 . 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 of cylinder head (25) is approximately
365 kg (800 lb).

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

the cylinder block.

Note: Apply Tooling (C) to the bolt threads and

both sides o f the washers. Tighten the bolts in the
following step sequence:
Illu stra tio n 2 0 4 gOH48522

4. Install bolts (26) and bolts (27) according to the

following procedure. 5. Connect tube assembly (23) and install tube
assembly (24).
a. In a numerical sequence, tighten Bolt (1)
through Bolt (26) to a torque of 270 ± 15 N m 6. Install bracket (20).
(199 ± 11 lb ft).
7. Connect clip assembly (22). Install tube
b. In a numerical sequence, tighten Bolt (1) assemblies (21).
through Bolt (26) to a torque of 450 ± 15 N m
(332 ± 11 lb ft).

c. In a numerical sequence, again tighten Bolt (1)

through Bolt (26) to a torque of 450 ± 15 N m
(332 ± 11 lb ft).

d. In a numerical sequence, tighten Bolt (27)

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

g01148516
Illu stra tio n 205
70 RENR9716-02
Disassembly and Assembly Section

8. Install adapter assembly (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
Illu s tra tio n 20 6

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

Illu s tra tio n 2 0 7 g O H 5 l4 4 l

9. Install dam per (16) and bolts (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 adapter assembly (6), thrust plate (5), and

bolts (4).
g01148489
Illu s tra tio n 20 8
RENR9716-02 71
Disassembly and Assembly Section

End By:

a. Install the fuel transfer pump. R eferto Disassembly

and Assembly, “Fuel Transfer Pump - Install”.

b. Install the valve mechanism cover base. R eferto

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

c. Install the electronic unit injectors. R e fe rto

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

i02446397

Camshaft - Remove
SMCS Code: 1210-011

Removal Procedure
Table 50

Required Tools

Tool Part Number Part Description Qty

A 1 7 7 -8 0 0 1 Pilot Sleeve 2

B 2 4 9 -2 9 3 6 Adapter 1

2 7 4 -7 9 3 2 0 )
Illu s tra tio n 2 1 3 gO H 5l468
C or Guide 1
274-7933(2)

17. Install gear (3) and bolts (2). 0) F ro n t R em oval

(2) R e a r R em o val

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 shafts.
R eferto 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 during installation, interference 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 the cooling system into a

suitable container for storage or disposal. Refer
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. Remove cover (1).

g01160256
Illu stra tio n 219

6. Remove elbow (9) and cover (8).

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

g01160259
Illu stra tio n 220

7. Remove bolts (10) and damper (11).

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

assembly (6).
RENR9716-02 73
Disassembly and Assembly Section

Note: Rotate the camshaft during removal. This will

prevent the camshaft from binding in the camshaft
bearings.

i02446568

Camshaft - Install
SMCS Code: 1210-012

Installation Procedure
Table 51

Required Tools

Part
8. Remove bolts (12). Remove sealing plate (13) and Tool Num ber Part Description Qty
adapter assembly (14). A 1 7 7 -8 0 0 1 Pilot Sleeve 2

9. B 2 4 9 -2 9 3 6 Adapter 1

2 7 4 -7 9 3 2 0 )
C or Guide 1
15 274-7933(2)

D 8 T -2 9 9 8 Lubricant 1
0) F ro n t R em oval
(2) R e a r R em o val

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

Illu s tra tio n 2 2 2 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 during installation, interference 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 camshaft and camshaft bearings
are thoroughly clean. Lubricate the camshaft
Note: Avoid lifting the camshaft. The camshaft should lobes with a 50/50 mixture of Tooling (D) and clean
rest on Tooling (A) and Tooling (B). Lifting of 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 slide 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 of the camshaft is approximately
35 kg (77 lb).
74 RENR9716-02
Disassembly and Assembly Section

15

g01160265 g01160259
Illu s tra tio n 22 3 Illu stra tio n 225

2. Install Tooling (A) and Tooling (B) on the rear 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 technicians to install the camshaft. 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
Illu stra tio n 22 6 g O H 5 l4 4 l
camshaft is approximately 35 kg (77 lb).

Note: Rotate the camshaft during installation. This 7 . Install dam per (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 . Remove Tooling (A) and Tooling (B) from the sequence: 1 ,4 ,2 , 5, 3 ,6 ,1 , 4.
camshaft.

g01160256
Illu stra tio n 227

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

6. Install adapter assembly (14) and sealing plate
(13). Install bolts (12).
RENR9716-02 75
Disassembly and Assembly Section

Illu stra tio n 231 gO H 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
Arms and Shaft - Install”.

g01222230
Illu s tra tio n 23 0
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 camshaft bearings from the cylinder
head.
SMCS Code: 1211-011
4. Use Tooling (A) to remove camshaft bearing (1)
Removal Procedure from the cylinder head.

Table 52 5. Remove Tooling (B) from Tooling (A) and remove

Required Tools
the camshaft bearing.

Tool Part Number Part Description Qty

i02451063
Camshaft Bearing Tool
A 8S -2241 1
Group Camshaft Bearings - Install
9 U -7 2 2 2 Camshaft Bearing Pilot 1
SMCS Code: 1211-012
B Taperlock Stud
8M -8778 1
1 /2 - 1 3 by 1 9/16 inch
Installation Procedure
C 9 U -7 2 1 0 Puller Plate 1
Table 53

Start By: Required Tools

Tool Part Number Part Description Qty

a. Remove the camshaft. R efe rto Disassembly and
Assembly, “Camshaft - Remove”. Camshaft Bearing Tool
A 8S -2 2 4 1 1
Group

NOTICE 9 U -7 2 2 2 Camshaft Bearing Pilot 1

Keep all parts clean from contaminants. B Taperlock Stud
8M -8778 1
1/2 -1 3 by 1 9/16 inch
Contaminants may cause rapid wear and shortened
component life. C 9 U -7 2 1 0 Puller Plate 1

D 9 U -7 2 2 3 Alignm ent Bushing 1

9 U -7 2 1 3 Backup Plate 1
E Bolt
OS-1621 1
1/2 - 1 3 by 1 inch

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.

Illu s tra tio n 2 3 3 gOH59745

1. Remove the No. 7 camshaft bearing (rear). Work

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

2. Install the small end of Tooling (B) in camshaft

bearing (1).

3. Position Tooling (C) over Tooling (A). Install

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

g01159754
Illu stra tio n 23 4
RENR9716-02 77
Disassembly and Assembly Section

1. Install the No. 7 camshaft 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) over Tooling (A). Install

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

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

Install Tooling (E) on Tooling (B).

Note: Refer to Specifications, “Cylinder Head” for

appropriate information for the orientation of the
camshaft bearings in the cylinder head.

d. Use Tooling (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. 1 camshaft bearing (front), as
face of the camshaft bore, the camshaft bearing is follows:
properly installed.
a. Insert the large end o f Tooling (B) into the No.
1 camshaft bore. Assemble Tooling (A) 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, “Cylinder Head” for

appropriate information for the location and the
orientation of the camshaft bearings in the cylinder
head.

Note: Tooling (F) is used to seat the No. 1 camshaft

bearing to the correct depth in the camshaft bore.

c. Use Tooling (A) in order to pull the No. 1

2. Install the No. 6 through No. 2 camshaft bearings, camshaft bearing into the No. 1 camshaft bore.
as follows: When the chamfer of Tooling (E) contacts
the face of the camshaft bore, the camshaft
a. Insert the large end of Tooling (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 diam eter of any installed camshaft Assembly, “Camshaft - Install”.
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, “Cylinder Head” for

appropriate information for the location and the
orientation of the camshaft bearings in the cylinder
head.

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

bearing (1) into the camshaft bore.
78 RENR9716-02
Disassembly and Assembly Section

i02447352 2. Remove tube assemblies (1) from engine oil pan

(3).
Engine Oil Pan - Remove and
Install 3. Use Tooling (A) to support engine oil pan (3). The
weight of engine oil pan (3) is approximately 25 kg
SMCS C ode: 1302-010 (55 lb).

4. Remove bolts (2). Remove engine oil pan (3) and

Removal Procedure the gasket.
Table 5 4

Required Tools
Installation Procedure
Part Table 55
Tool Number Part Description Qty Required Tools
A 1U -7 5 0 5 Hydraulic Jack 1 Part
Tool Num ber Part Description Qty

NOTICE A 1U -7 5 0 5 Hydraulic Jack 1

Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test­
ing, adjusting and repair o f the product. 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
nent containing fluids. Contaminants may cause rapid wear and shortened
component life.
R e fe rto 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 w ear and shortened

component life.

1. Drain the engine oil into a suitable container

for storage or disposal. R efe rto Operation and
Maintenance Manual, “Engine Oil and F ilte r- 1. Use Tooling (A) to support engine oil pan (3). The
Change”. weight of engine oil pan (3) is approximately 25 kg
(55 lb).

2. Position the gasket and engine oil pan (3) on 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 assemblies (1) on engine oil pan (3).

4. Fill the engine with engine oil to the correct level.

R e fe rto Operation and Maintenance Manual,
“Engine Oil and Filter - Change”.

g01222524
Illu s tra tio n 23 7
RENR9716-02 79
Disassembly and Assembly Section

i02294951

Cylinder Liner - Remove

SMCS Code: 1216-011

Removal Procedure
Table 56

Required Tools

Tool Part Number Part Description Qty

A 5 P -86650) Cylinder Liner Puller Gp 1

0) T h e 6 V - 9 4 4 8 C y lin d e r P ack P u lle r is an o p tio n a l Tool fo r
re m o v in g th e c y lin d e r liner.

Start By:

a. Remove the pistons and connecting rods. Refer

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

NOTICE 1. Use Tooling (A) to remove cylinder liner (1).

Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test­ 2. Remove liner seals (3) and filler band (2) from
ing, adjusting and repair o f the product. 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

R e fe rto Special Publication, NENG2500, “Caterpillar Cylinder Liner - Install

Tools and Shop Products Guide” fortools and supplies
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 Tool Part Number Part Description Qty
Keep all parts clean from contaminants.
B 2 P -8 2 6 0 Cylinder Liner Installer 1
Contaminants may cause rapid wear and shortened C 5 P -3 9 7 5 Rubber Lubricant 1
component life.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

1. Check the cylinder liner projection. R e fe rto

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 cylinder liner (1).

3. Apply Tooling (C) on the cylinder 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 crankshaft in order to
moment. Install the filler band on the cylinder liner gain access to the piston cooling jet.
immediately.
2. Remove bolt (1) and piston cooling jet (2).
5. Use Tooling (B) to install cylinder 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 Tool Number Part Description
Qty
Connecting Rods - Install”.
A 9 S -9 0 8 2 Engine Turning 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
Qty
Tool Number Part Description

A 9 S -9 0 8 2 Engine Turning Tool 1

RENR9716-02 81
Disassembly and Assembly Section

1. Use Tooling (A) to rotate the crankshaft in order to 1. Use Tooling (A) to rotate the crankshaft until the
gain access to the piston cooling jet. piston is at the bottom center.

2 . Position piston cooling jet (2) in the cylinder block. 2 . Remove the carbon ridge from the 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).
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. R eferto Disassembly etched number on the side. The number should
and Assembly, “Engine Oil Pump - Install”. match the cylinder number. Mark 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. Remove bolts (1) and connecting rod bearing cap
SMCS Code: 1225-011 (2).

Removal Procedure
Table 60

Required Tools

Tool Part Number Part Description Qty

A 9 S -9 0 8 2 Engine Turning Tool 1

Start By:

a. Remove the cylinder head. R eferto Disassembly

and Assembly, “Cylinder Head - Remove”.

b. Remove the piston cooling jets. Refer to

Disassembly and Assembly, “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. Remove upper connecting rod bearing (8) from

connecting rod (6).
Pistons and Connecting Rods
- Disassemble 3. Use Tooling (A) to remove pin retainers (5) from
piston body assembly (4).
SMCS Code: 1225-015
4. Remove connecting rod pin (7) and connecting
rod (6) from the piston body assembly.
Disassembly Procedure
5. Use Tooling (B) to remove 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 Number Part Description Qty i02447828

A 6 V -6 1 9 2 Pliers 1
Pistons and Connecting Rods
B 7 B -7 9 7 4 Piston Ring Expander Gp 1
- Assemble
Start By: SMCS Code: 1225-016

a. Remove the pistons and connecting rods. Refer

to Disassembly and Assembly, “Pistons and
Assembly Procedure
Connecting Rods - Remove”. Table 62

Note: Mark the components o f each piston and Required Tools

connecting rod assembly. The components must be Part
reinstalled in the original location. Do not interchange Tool Number Part Description Qty
components.
A 6 V -6 1 9 2 Pliers 1

NOTICE B 7 B -7 9 7 4 Piston Ring Expander 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. Remove lower connecting rod bearing (9) from

connecting rod bearing cap (10).
RENR9716-02 83
Disassembly and Assembly Section

Note: Ensure that the bearing locking tab is located

in the notch of the connecting rod bearing cap.

10. Ensure that the dowels are installed 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 the oil control piston ring in Required Tools
the oil ring groove in the piston body assembly.
Part
Tool Part Description Qty
2 . Position oil control piston ring (3) over the spring. Number
Position the oil control piston ring so that the gap A 9 S -9 0 8 2 Engine Turning Tool 1
is 180 degrees from the joint in the spring. Install
the oil control piston ring on the piston with Tooling B 2 0 0 -3 9 1 4 Piston Ring Compressor 1
(B). C 8 T -3 0 5 2 Degree Wheel 1

3. Use Tooling (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.
Note: Install the connecting rod bearings dry
5. Position top piston ring (1), intermediate piston
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. Apply clean engine oil to the cylinder liner 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) in

connecting rod (6).

Note: Ensure that the bearing locking tab is located

in the notch of the connecting rod.

9 . Install lower connecting rod bearing (9) in

connecting rod bearing cap (10).
84 RENR9716-02
Disassembly and Assembly Section

Note: Ensure that the number on the side of the

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

8. Lubricate the threads of bolts (1) with clean engine

oil. Install the bolts.

9 . Tighten bolts (1), as follows:

a. Tighten Bolt (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 Tooling (A) to rotate the crankshaft 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 piston (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).

4. Install the upper 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 connecting rod onto the crankshaft journal. the crankshaft turns freely.

6. Install the lower connecting rod bearing in the End By:

connecting rod bearing cap.
a. Install the piston cooling jets. R eferto Disassembly
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. Install the cylinder head. R eferto Disassembly
and Assembly, “Cylinder Head - Install”.

i02295567

Connecting Rod Bearings -

Remove
SMCS Code: 1219-011

Removal Procedure
Table 6 4

Required Tools

Part
7. Position connecting rod bearing cap (2) on the Tool Number Part Description Qty
connecting rod.
A 9 S -9 0 8 2 Engine Turning Tool 1
RENR9716-02 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 Number Part Description Qty

A 9 S -9 0 8 2 Engine Turning Tool 1

B 8 T -3 0 5 2 Degree Wheel 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. R eferto
Disassembly and Assembly, “Bearing Clearance -
1. Use Tooling (A) to rotate the crankshaft 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 connecting rod cap

for the proper identification mark. The connecting
rod and the connecting rod cap should have an
etched number on the side. The number should
match the cylinder number. Mark the connecting
rod and the connecting rod cap, if necessary.

Note: Do not stamp the connecting rod assembly.

Stamping or punching the connecting rod assembly
could cause the connecting rod to fracture.

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

(2) from the connecting rod.

4. Remove the lower half of the connecting rod

bearing from the connecting rod bearing cap.
1. Use Tooling (A) to rotate the crankshaft until the
5. Push the connecting 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 lower half connecting 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 connecting rod bearing in

the connecting rod.

Note: Ensure that the bearing locking tab is located

in the notch o f the connecting rod.
86 RENR9716-02
Disassembly and Assembly Section

4. Pull the connecting rod onto the crankshaft. i02296017

Crankshaft Main Bearings -

Remove
SMCS Code: 1203-011

Removal Procedure
Table 66

Required Tools

Part
Tool Num ber Part Description Qty

A 2 P -5 5 1 8 Bearing Tool 1

Start By:
5 . Position connecting rod bearing cap (2) on the
connecting rod. a. Remove the engine oil pump. Refer to
Disassembly and Assembly, “Engine Oil Pump
Note: Ensure that the number on the side of the - Remove”.
connecting rod bearing cap is on the same side as
the number on the connecting rod. The bearing tabs
NOTICE
of the connecting rod bearing cap and the connecting
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) with clean engine
oil. Install the bolts.
1. Check the main bearing caps for identification of
7 . Tighten bolts (1), as follows: the location and check the direction of the main
bearing caps in relation to the cylinder block. The
a. Tighten Bolt (A) and Bolt (C) to a torque 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 ± 4 N m (52 ± 3 lb 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. Remove bolts (1) and bolts (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: Remove No. 1 and No. 7 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 Disassembly

and Assembly, “Engine Oil Pump - Install”.
RENR9716-02 87
Disassembly and Assembly Section

Note: Install the main bearings dry when clearance

checks are performed. R e fe rto Disassembly and
Assembly, “Bearing Clearance - Check”. Apply clean
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 upper halves of the main bearings have
the oil groove and the oil hole.

3. Install Tooling (A) in the oil hole of the crankshaft.

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 upper main bearing (4) on the
crankshaft. crankshaft. Insert the end of the upper main
bearing that does not have the tab into the cylinder
4. Remove the thrust plates from each side of the block. Install Tooling (A) in the oil hole of the
No. 4 main bearing. crankshaft. Carefully rotate the crankshaft in order
to push the upper main bearing into the cylinder
5. Remove the lower 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 thrust plates on each side of the No. 4
main bearing.
Installation Procedure
Note: Install the thrust plates with the words “Block
Table 67 Side” toward the cylinder block.
Required Tools
3. Install the lower halves of the crankshaft main
Tool Part Number Part Description Qty bearings in the main bearing caps.
A 2 P -5 5 1 8 Bearing Tool 1
Note: Ensure that the main bearings are installed so
B 8 T -5 0 9 6 Dial Indicator 1 that bearing tabs fit into the notch in the main bearing
C 8 T -3 0 5 2 Degree Wheel 1
caps.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid w ear 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 Tooling (B) to check the crankshaft end 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:
Illu s tra tio n 2 5 5 gOH49987

a. Install the engine oil pump. R eferto 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 toward the front o f the cylinder block. Crankshaft - Remove
5. Lubricate the threads of bolts (1) and 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 bearing
caps, as follows: Table 68

Required Tools
a. Tighten Bolt (A) to a torque o f 258 ± 14 N m
(190 ± 10 lb ft). Part
Tool Number Part Description Qty
Note: Bolt (A) is on the bearing tab side of the main A 1 3 8 -7 5 7 4 Link Bracket 2
bearing cap.
1 H -3 1 10 Bearing Puller 1
b. Tighten Bolt (B) to a torque o f 258 ± 14 N m 8 B -7 5 6 0 Step Plate 1
(190 ± 10 lb ft).
9 U -6 6 0 0 Hand Hydraulic Pump 1
Note: Bolt (B) is on the opposite side of the bearing 1 H -3108 Push-Puller Leg 2
tab of the main bearing cap.
1 H -3 1 0 7 Bearing Puller 1
B
c. Tighten Bolt (B) for an additional 120 ± 5 3 H -0 4 6 8 Puller Plate 5
degrees (2 flats).
3 H -0 4 6 5 Push-Puller Plate 2
Note: If Tooling (C) is not used, place an index mark 1P -0 8 2 0 Hydraulic Puller 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 Forcing Screw 1
degrees (2 flats).
5 P -0 9 4 4 Dowel Puller Group 1
C
Note: If Tooling (C) is not used, place an index mark 5 P -0 9 3 9 Dowel Extractor 1
on the bolt and the main bearing cap.

e. Tighten Bolt (D) to a torque of 80 ± 10 N m Start By:

(59 ± 7 lb ft).
a. Remove the front housing. R eferto Disassembly
Note: Bolt (D) is on the opposite side of the bearing and Assembly, “Housing (Front) - Remove”.
tab of the main bearing cap.
b. Remove the rear housing. R eferto 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. Remove the piston cooling jets. Refer to 6. Remove crankshaft (6) from the cylinder block.
Disassembly and Assembly, “Piston Cooling Jets
- Remove and Install”. 7. Remove the thrust plates from each side o f the
No. 4 main bearing.
NOTICE
Keep all parts clean from contaminants. 8. Remove the lower 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. Check the main bearing caps for identification 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. Check the connecting rod and the connecting rod

bearing caps for identification and the location in
the cylinder block.

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

from crankshaft (6).

3. Remove bolts (1). Remove connecting rod bearing

caps (2).

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

and dowel (9) from crankshaft (6).

4. Remove bolts (3) and bolts (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 upper halves of the main bearings have
the oil groove and the oil hole.
SMCS C ode: 1202-012

Installation Procedure
Table 69

Required Tools

Part
Tool Number Part Description Qty

A 1 3 8 -7 5 7 4 Link Bracket 2

D 8 T -5 0 9 6 Dial Indicator 1

E 8 T -3 0 5 2 Degree Wheel 1

NOTICE
Keep all parts clean from contaminants.
5 . Install Tooling (A) and a suitable 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 crankshaft (6) with Timing Mark “V ” on 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: Install the thrust plates with the words “Block

Side” toward the cylinder block.

8. Install the lower halves of the crankshaft 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) in the crankshaft.
9 . Position main bearing caps (4) on the crankshaft.
Protrusion of dowel (8) from the crankshaft
f a c e ........................................... 8.4 mm (0.33 inch) Note: Ensure that the numbers on the main bearing
caps match the numbers on the cylinder block. Also
2. Install dowel (9) in the crankshaft. 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 ± 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 gear (7) on the crankshaft with
11. Tighten bolts (3) and bolts (5) for the main bearing
the keyway in alignment with dowel (9). Timing
Mark “V” o f the gear should face away from caps, as follows:
crankshaft (6).
a. Tighten Bolt (A) to a torque of 258 ± 14 N m
Note: Install the main bearings dry when clearance (190 ± 10 lb ft).
checks are performed. R e fe rto Disassembly and
Note: Bolt (A) is on the bearing tab side of the main
Assembly, “Bearing Clearance - Check”. Apply clean
engine oil on the main bearings for final assembly. bearing cap.

4. Install the upper halves of the main bearings in b. Tighten Bolt (B) to a torque of 258 ± 14 N m
the cylinder block. (190 ± 10 lb ft).
RENR9716-02 91
Disassembly and Assembly Section

Note: Bolt (B) is on the opposite side of the bearing Note: Ensure that the number on the side of the
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 connecting 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. Tighten Bolt (D) to a torque of 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 Bolt (B) and Bolt (D) for an additional 60 ±
tab of the main bearing cap. 5 degrees (1/6 turn).

f. Tighten Bolt (C) to a torque of 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 of the main d. Tighten Bolt (A) and Bolt (C) again to a torque
bearing cap. of 70 ± 4 N m (52 ± 3 lb ft).

g. Rotate the crankshaft in order 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 Tooling (D) to check the crankshaft end 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 crankshaft in order 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. R eferto Disassembly
when clearance checks are performed. R e ferto 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. Install the rear housing. R eferto Disassembly and
Assembly, “Housing (Rear) - Install”.

c. Install the front housing. R eferto Disassembly and

Assembly, “Housing (Front) - Install”.

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 that the backs o f the bearings and the
SMCS C ode: 1203-535; 1219-535 bores are clean and dry.

Measurement Procedure • Ensure that the bearing locking tabs are properly
seated in the tab grooves.
Table 70
• The crankshaft must be free o f oil at the contact
Required Tools
points of Tooling (A).
Part
Tool Number Part Description Qty 1. Put a piece of Tooling (A) on the crown of the
1 9 8 -9 1 4 2 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.
1 9 8 -9 1 4 3 Plastic Gauge (Red)
0.051 to 0.152 mm 1
2. Use the correct torque-turn specifications in order
(0.002 to 0.006 inch)
A to install the bearing cap. Do not use an impact
1 9 8 -9 1 4 4 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)

1 9 8 -9 1 4 5 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. Carefully remove the cap, but do not remove
Tooling (A). Measure the width of Tooling (A)
Note: Plastic gauge may not be necessary when the 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

o f the actual bearing clearances particularly on
small engines. This is because of the possibility of
obtaining inaccurate results and the possibility of
damaging the bearing or the journal surfaces. Each
Caterpillar engine bearing is quality checked for
specific wall thickness.

Note: The measurements should be within

specifications and the correct bearings should
be used. If the crankshaft journals and the bores
for the block and the rods were measured during
disassembly, no further checks are necessary.
However, if the technician still wants to measure the T yp ica l E xam ple
bearing clearances, Tooling (A) is an acceptable
method. Tooling (A) is less accurate on journals with 4. Remove all of Tooling (A) before you install the
small diameters if clearances are less than 0.10 mm bearing cap.
(0.004 inch).

NOTICE
Lead wire, shim stock or a dial bore gauge can dam­
age the bearing surfaces.
RENR9716-02 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. R eferto Specifications
Manual, “Connecting Rod Bearing Journal” and
Specifications Manual, “Main Bearing Journal” for the
correct clearances.

i02449735

Atmospheric Pressure Sensor

- Remove and Install
SMCS Code: 1923-010

1. Install a new O-ring seal on atmospheric pressure

Removal Procedure sensor (1).

NOTICE 2. Install atmospheric pressure sensor (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).
component life.

i02297743

Camshaft Position Sensor -

Remove and Install
SMCS Code: 1912-010

Removal Procedure
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test­
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open­
ing any compartment or disassembling any compo­
nent containing fluids.
1. Disconnect harness assembly (2).
R eferto Special Publication, NENG2500, “Caterpillar
2. Remove atmospheric pressure sensor (1) from Tools and Shop Products Guide” fortools and supplies
the adapter on the cylinder block. suitable to collect and contain fluids on Caterpillar
products.
3. Remove the O-ring 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 must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test­
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open­
ing any compartment or disassembling any compo­
nent containing fluids.
1 . Disconnect harness assembly (3).
R eferto Special Publication, NENG2500, “Caterpillar
2. Remove bolt (1) and camshaft position sensor (2). Tools and Shop Products Guide” fortools and supplies
suitable to collect and contain fluids on Caterpillar
3 . Remove the O-ring seal from camshaft position products.
sensor (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 camshaft position 1 . Disconnect harness assembly (1).
sensor (2). Lubricate the O-ring seal with clean
engine oil. 2 . Remove bolt (3) and crankshaft position sensor
(2).
2 . Position camshaft position sensor (2) in the front
housing and install bolt (1). Tighten bolt (1) to a 3 . Remove the O-ring seal from crankshaft position
torque of 28 ± 7 N m (21 ± 5 lb ft). sensor (2).

3 . Connect harness assembly (3).

RENR9716-02 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 coolant from the cooling system to a
level below the coolant temperature sensor into a
suitable container for storage or disposal. Refer
to Operation and Maintenance Manual, “Cooling
System Coolant - Change”.

1. Install a new O-ring seal on crankshaft position

sensor (2). Lubricate the O-ring seal with clean
engine oil.

2. Install crankshaft position sensor (2) in the front

housing. Install bolt (3). Tighten bolt (3) to a torque 2. Disconnect harness assembly (1).
o f 28 ± 7 N m (21 ± 5 lb ft).
3. Remove coolant temperature sensor (2).
3. Connect harness assembly (1).
4. Remove the O-ring seal from coolant temperature
sensor (2).
i02449857

Coolant Temperature Sensor - Installation Procedure

Remove and Install
NOTICE
SMCS C ode: 1906-010 Keep all parts clean from contaminants.

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, maintenance, test­
ing, adjusting and repair o f the product. Be prepared to
collect the fluid with suitable containers before open­
ing any compartment or disassembling any compo­
nent containing fluids.

Refer to Special Publication, NENG2500, “Caterpillar

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

Dispose o f all fluids according to local regulations and

mandates.
96 RENR9716-02
Disassembly and Assembly Section

1. Install a new O-ring seal on coolant temperature 2 . Remove engine oil pressure sensor (1) from the
sensor (2). adapter on the cylinder block.

2 . Install coolant temperature sensor (2) and tighten 3. Remove the O-ring seal from engine oil pressure
to a torque o f 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 C ode: 1924-010

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

R e fe rto Special Publication, NENG2500, “Caterpillar

1. Install a new O-ring seal on engine oil pressure
Tools and Shop Products Guide” fortools and supplies sensor (1).
suitable to collect and contain fluids on Caterpillar
products.
2 . Install engine oil pressure sensor (1) and tighten
to a torque o f 10 ± 2 N m (89 ± 18 lb in).
Dispose of all fluids according to local regulations and
mandates. 3. Connect harness assembly (2).

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

1 . Disconnect harness assembly (2).

RENR9716-02 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 w ear 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.

R e fe rto Special Publication, NENG2500, “Caterpillar

Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Illu stra tio n 27 5 g01292812
Dispose of all fluids according to local regulations and
mandates.
1. Install a new O-ring seal on fuel pressure sensor
(2).
NOTICE
Keep all parts clean from contaminants. 2. Install fuel pressure sensor (2). Tighten fuel
pressure sensor (2) to a torque o f 10 ± 2 N m
Contaminants may cause rapid wear and shortened (90 ± 18 lb in).
component life.
3. Connect harness assembly (1).
1. Turn the fuel supply valve to the OFF position. 4. Turn the fuel supply valve to the ON position.

i0 2 5 8 1 061

Fuel Temperature Sensor -

Remove and Install
SMCS Code: 1922-010

Removal Procedure
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test­
Illu s tra tio n 2 7 4 g 0 i2 9 2 8 i2 ing, adjusting and repair ofthe product. Be prepared to
collect the fluid with suitable containers before open­
2. Disconnect harness assembly (1). ing any compartment or disassembling any compo­
nent containing fluids.
3. Remove fuel pressure sensor (2) from the fuel
filter base. R eferto Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies
4. Remove the O-ring seal from fuel pressure sensor suitable to collect and contain fluids on Caterpillar
(2). products.

Dispose of all fluids according to local regulations and

mandates.
98 RENR9716-02
Disassembly and Assembly Section

2. Install fuel temperature sensor (2). Tighten fuel

NOTICE temperature sensor (2) to a torque o f 20 ± 5 N m
Keep all parts clean from contaminants. (15 ± 4 lb ft).

Contaminants may cause rapid wear and shortened 3. Connect harness assembly (1).
component life.
4. Turn the fuel supply valve to the ON position.

1. Turn the fuel supply 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 w ear and shortened

component life.
Illu s tra tio n 27 6 g0l292826

2. Disconnect harness assembly (1).

3. Remove fuel temperature sensor (2) from the fuel

filter base.

4. Remove the O-ring seal from fuel temperature

sensor (2).

Installation Procedure
NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid w ear and shortened

component life.
1. Disconnect harness assembly (1).

2. Remove turbocharger outlet pressure sensor (2)

from the inlet manifold.

3. Remove the O-ring seal from turbocharger outlet

pressure sensor (2).

Installation Procedure
NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid w ear and shortened

component life.
Illu s tra tio n 27 7 g0l292826

1. Install a new O-ring seal on fuel temperature

sensor (2).
RENR9716-02 99
Disassembly and Assembly Section

3. Remove the O-ring seal from inlet air temperature

sensor (2).

Installation Procedure
NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid w ear and shortened

component life.

1 .2

1. Install a new O-ring seal on turbocharger outlet

pressure sensor (2).

2. Install turbocharger outlet pressure sensor (2) and

tighten to a torque o f 10 ± 2 N m (90 ± 18 lb in).

3. Connect harness assembly (1).

i02449945
Illu stra tio n 281 gO l223082
Inlet Air Temperature Sensor -
1. Install a new O-ring seal on inlet air temperature
Remove and Install sensor (2).
SMCS Code: 1921-010 2. Install inlet air temperature sensor (2) and tighten
to a torque o f 20 ± 5 N m (15± 4 lb ft).
Removal Procedure
3. Connect harness assembly (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).

2. Remove inlet air temperature sensor (2) from the Illu stra tio n 28 2 gO l289708
inlet manifold.
100 RENR9716-02
Disassembly and Assembly Section

1. Remove bolts (1). Repeat for the opposite side. i02 755046
Remove bottom belt guard (2).
Fan Guard - Remove and Install
SMCS Code: 1360-010

Removal Procedure

Illu s tra tio n 28 3 g0l289709

2. Remove bolt (3). Repeat for the opposite side.

Remove upper belt guard (4).

Illu stra tio n 28 6 gO l289778

Installation Procedure
1. Remove bolts (1). Remove lower fan guard (2).

Illu s tra tio n 2 8 4 g0l289709

Illu stra tio n 28 7 gO l379587

1. Install upper belt guard (4). Install bolt (3). Repeat
for the opposite side.
2. Remove bolts (3). Remove upper fan guard (4).

Installation Procedure

Illu s tra tio n 28 5 g0l289708

2. Install lower belt guard (2). Install bolts (1). Repeat

for the opposite side. Illu stra tio n 28 8 gO l379587

1. Install upper fan guard (4). Install bolts (3).

RENR9716-02 101
Disassembly and Assembly Section

Illu s tra tio n 28 9 g0l289778

2. Install lower fan guard (2). Install bolts (1).

i02755088

Fan - Remove and Install Illu stra tio n 291

g01289733

SMCS Code: 1356-010 2. Remove bolts (2). Remove fan (1).

Removal Procedure Installation Procedure

Table 71 Table 72

Required Tools Required Tools

Part Part
Tool Number Part Description Qty Tool Number Part Description Qty
A 1 4 0 -7 7 4 2 Sleeve 1 A 1 4 0 -7 7 4 2 Sleeve 1

S ta rt By:

a. Remove the fan guard. R eferto Disassembly and

Assembly, “Fan Guard - Remove and Install”.

•
p

H f t \
S S ^ W ill

[I9 J K !
h i /'1

g01289730
Illu s tra tio n 290

g01289733
Illu stra tio n 292
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
Illu s tra tio n 293

2. Remove Tooling (A) and the suitable lifting device

from fan (1).

End By:
Illu stra tio n 2 9 4 gO l289585
a. Install the fan guard. Refer to Disassembly and
Assembly, “Fan Guard - Remove and Install”.
2. Loosen bolts (1). Loosen locknut (2).

i02574047

Fan Drive - Remove and Install

SMCS Code: 1359-010; 1386-010

Removal Procedure
S ta rt By:

a. Remove the fan. Refer to Disassembly and

Assembly, “Fan - Remove and Install”.

b. Remove the belt guard. Refer to Disassembly and

Assembly, “Belt Guard - Remove and Install”.

1. Remove the belts. Refer to Operation

and Maintenance Manual, “Belts -
Inspect/Adjust/Replace".

g01289589
Illu stra tio n 295

3. Attach a suitable lifting device onto fan drive (3).

The weight of fan drive (3) is approximately 45 kg
(100 lb). Remove bolts (1). Remove fan drive (3).
RENR9716-02 103
Disassembly and Assembly Section

Installation Procedure b. Install the fan. R e fe rto Disassembly and

Assembly, “Fan - Remove and Install”.

i02417465

Electronic Control Module -

Remove and Install
SMCS Code: 1901-010

Removal Procedure
1. Turn the battery disconnect switch to the “OFF”
position.

2. Disconnect the negative battery terminal at the

battery.

Illu s tra tio n 2 9 6 g01289589

1. Attach a suitable lifting device onto fan drive (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). Disconnect the

harness assembly from electronic control module
(5).

4. Disconnect hose assemblies (2) and (4).

5. Remove bolts (6). Remove electronic control

Illu s tra tio n 2 9 7 g01289585 module (5) and ground strap (3).

2. Install the belts. Refer to Operation 6. Remove washers (7) and isolation mounts (8)
and Maintenance Manual, “Belts - from electronic control module (5).
Inspect/Adjust/Replace”.

3. Tighten bolts (1). Tighten locknut (2).

End By:

a. Install the belt guard. R eferto Disassembly and

Assembly, “Belt Guard - Remove and Install”.
104 RENR9716-02
Disassembly and Assembly Section

Installation Procedure

2. Remove V-belt (1) from alternator (3).

3. Disconnect the harness assemblies from

alternator (3).

4. Remove bolt (2) and bolt (4).

5. Remove alternator (3) from the mounting group.

1. Position isolation mounts (8) on electronic control
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. Connect hose assemblies (4) and (2).

3. Connect the harness assembly to electronic

control module (5). Tighten alien head screw (1)
to a torque of 6 ± 1 N m (53 ± 9 lb in).

4. Connect the negative battery terminal at the

battery.

5. Turn the battery disconnect switch to the “ON”

position.

i02450170

Alternator - Remove and Install 1. Position alternator (3) on the mounting group.

SMCS C ode: 1405-010 2. Install bolt (4) and bolt (2).

Removal Procedure 3. Connect the harness assemblies to alternator (3).

R eferto Specifications, “Alternator and Regulator”.
1. Turn the battery disconnect switch to the OFF
position. 4. Install V-belt (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 disconnect switch to the ON

position.
RENR9716-02 105
Disassembly and Assembly Section

i02419387 Installation Procedure

Electric Starting Motor -
Remove and Install
SMCS Code: 1453-010

Removal Procedure

^ WARNING
Personal injury can result from failure to discon­
nect the battery.

First, disconnect the negative battery cable. Then,

disconnect the positive battery cable.

A positive power lead can cause sparks if the bat­

tery is not disconnected. Sparks can possibly re­
sult in battery explosion or fire.

Illu stra tio n 30 3 g01208927

1. Turn the battery disconnect switch to the “OFF”
position.
1. Fasten a suitable lifting device to electric starting
motor (1). The weight of electric starting motor (1)
is approximately 37 kg (80 lb).

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

in the flywheel housing. Install bolts (2).

3. Connect the harness assemblies to electric

starting motor (1). R eferto Specifications, “Electric
Starting Motor”.

4. Turn the battery disconnect switch to the “ON”

position.

Illu s tra tio n 30 2 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 electric starting

motor (1). The weight of electric starting motor (1)
is approximately 37 kg (80 lb).

4. Remove bolts (2).

5. Remove electric starting motor (1) and the gasket

from the flywheel housing.
106 RENR9716-02
Index Section

Index
A Crankshaft Main Bearings - Install.............................87
Installation Procedure............................................. 87
Aftercooler - Install....................................................... 40 Crankshaft Main Bearings - Remove...................... 86
Installation P rocedure............................................. 40 Removal Procedure.................................................86
A fte rc o o le r-R e m o v e ................................................. 38 Crankshaft Position Sensor - Remove and Install.. 94
Removal P rocedure............................................... 38 Installation Procedure............................................. 95
Alternator - Remove and Install............................. 104 Removal P rocedure.................................................94
Installation P rocedure......................................... 104 Crankshaft Rear Seal - Install.....................................50
Removal P rocedure............................................. 104 Installation Procedure............................................. 50
Atm ospheric Pressure Sensor - Remove and Crankshaft Rear Seal - Remove................................ 50
In s ta ll......................................................................... 93 Removal Procedure.................................................50
Installation P rocedure........................................... 93 Cylinder Head - In sta ll.................................................68
Removal P rocedure............................................... 93 Installation Procedure............................................. 68
Cylinder Head - R em ove............................................ 66
Removal Procedure.................................................66
B Cylinder Liner - Install..................................................79
Installation Procedure............................................. 79
Bearing Clearance - C h e c k ...................................... 92 Cylinder Liner - Rem ove........................................... 79
Measurement P roce du re ...................................... 92 Removal P rocedure.................................................79
Belt Guard - Remove and In s ta ll............................. 99
Installation P rocedure......................................... 100
Removal P rocedure............................................... 99 D

Disassembly and Assembly Section............................4

C

Camshaft - Install........................................................ 73 E
Installation P rocedure........................................... 73
Camshaft - Rem ove................................................... 71 Electric Starting Motor - Remove and In stall 105
Removal P rocedure............................................... 71 Installation Procedure......................................... 105
Camshaft Bearings - In s ta ll...................................... 76 Removal P rocedure............................................ 105
Installation P rocedure........................................... 76 Electronic Control Module - Remove and Install.. 103
Camshaft Bearings - R e m o ve................................. 76 Installation Procedure......................................... 104
Removal P rocedure............................................... 76 Removal P rocedure............................................ 103
Camshaft Position Sensor - Remove and Install... 93 Electronic Unit Injector - Install................................ 14
Installation P rocedure........................................... 94 Installation Procedure........................................... 14
Removal P rocedure............................................... 93 Electronic Unit Injector - R em ove............................ 13
Connecting Rod Bearings - Install.......................... 85 Removal Procedure............................................... 13
Installation P rocedure........................................... 85 Electronic Unit Injector Sleeve - Install................... 16
Connecting Rod Bearings - R em ove........................ 84 Installation Procedure........................................... 16
Removal P rocedure............................................... 84 Electronic Unit Injector Sleeve - R em ove.............. 15
Coolant Temperature Sensor - Remove and Removal Procedure............................................... 15
In s ta ll......................................................................... 95 Engine - Install................................................................ 6
Installation P rocedure........................................... 95 Installation Procedure................................................6
Removal P rocedure............................................... 95 Engine - Rem ove............................................................4
Cooling System Package (Radiator, Aftercooler, Fuel Removal Procedure................................................... 4
Cooler) - In s ta ll......................................................... 36 Engine Oil Cooler - Install........................................... 28
Installation P rocedure........................................... 36 Installation Procedure............................................. 28
Cooling System Package (Radiator, Aftercooler, Fuel Engine Oil Cooler - Rem ove.......................................27
Cooler) - R e m o ve .................................................... 35 Removal Procedure.................................................27
Removal P rocedure............................................... 35 Engine Oil Filter Base - A ssem ble.............................26
Crankshaft - Install..................................................... 90 Assembly Procedure................................................26
Installation P rocedure........................................... 90 Engine Oil Filter Base - D isassem ble....................... 26
Crankshaft - Rem ove................................................. 88 Disassembly Procedure.......................................... 26
Removal P rocedure............................................... 88 Engine Oil Filter Base - In sta ll................................... 27
Crankshaft Front Seal - Install................................. 55 Installation Procedure............................................. 27
Installation P rocedure........................................... 55 Engine Oil Filter Base - R em ove............................... 25
Crankshaft Front Seal - R em ove............................. 54 Removal Procedure.................................................25
Removal P rocedure............................................... 54
RENR9716-02 107
Index Section

Engine Oil Pan - Remove and Install...................... 78 G

Installation P rocedure........................................... 78
Removal P rocedure............................................... 78 Gear Group (Front) - In sta ll........................................56
Engine Oil Pressure S ensor- Remove and Install.. 96 Installation Procedure............................................. 56
Installation P rocedure........................................... 96 Gear Group (Front) - R em ove................................... 55
Removal P rocedure............................................... 96 Removal P rocedure.................................................55
Engine Oil Pump - Assem ble......................................29 Gear Group (Rear) - Install......................................... 48
Assembly Procedure................................................29 Installation Procedure............................................. 48
Engine Oil Pump - Disassem ble................................ 29 Gear Group (Rear) - Rem ove.................................... 46
Disassembly P rocedure.......................................... 29 Removal P rocedure.................................................46
Engine Oil Pump - Install.......................................... 30
Installation P rocedure........................................... 30
Engine Oil Pump - R em ove........................................28 H
Removal P rocedure.................................................28
Engine Support (Front) - Remove and Install 45 Housing (Front) - Install...............................................58
Installation Procedure (Type 1 )..............................46 Installation Procedure............................................. 58
Installation Procedure (Type 2 ) ..............................46 Housing (Front) - R em ove.......................................... 57
Removal Procedure (Type 1 )................................. 45 Removal P rocedure.................................................57
Removal Procedure (Type 2 ) ................................. 46 Housing (Rear) - Install................................................60
Exhaust Manifold - Remove and Install.................. 19 Installation Procedure............................................. 60
Installation P rocedure........................................... 19 Housing (Rear) - Rem ove........................................... 60
Removal P rocedure............................................... 19 Removal P rocedure.................................................60

F I

Fan - Remove and In s ta ll....................................... 101 Important Safety Inform ation........................................2

Installation P rocedure......................................... 101 Inlet A ir Temperature Sensor - Remove and
Removal P rocedure............................................. 101 In s ta ll......................................................................... 99
Fan Drive - Remove and Install............................. 102 Installation Procedure............................................. 99
Installation P rocedure......................................... 103 Removal P rocedure.................................................99
Removal P rocedure............................................. 102 Inlet and Exhaust Valve Guides - Remove and
Fan Guard - Remove and In s ta ll........................... 100 In s ta ll......................................................................... 23
Installation P rocedure......................................... 100 Installation Procedure............................................. 24
Removal P rocedure............................................. 100 Removal P rocedure.................................................23
Flywheel - Remove and In s ta ll.................................. 49 Inlet and Exhaust Valve Seat Inserts - Remove and
Installation P rocedure............................................. 49 In s ta ll......................................................................... 24
Removal P rocedure.................................................49 Installation Procedure............................................. 25
Flywheel Housing - Remove and In sta ll................. 51 Removal Procedure.................................................24
Installation P rocedure........................................... 52 Inlet and Exhaust Valve Springs - Remove and
Removal P rocedure............................................... 51 In s ta ll........................................................................... 20
Fuel Filter and W ater Separator - Remove and Installation Procedure............................................. 21
In s ta ll............................................................................ 11 Removal P rocedure.................................................20
Installation P rocedure.............................................. 11 Inlet and Exhaust Valves - Remove and In sta ll 22
Removal P rocedure................................................. 11 Installation Procedure............................................. 23
Fuel Filter Base - Install............................................ 10 Removal P rocedure.................................................22
Installation P rocedure........................................... 10
Fuel Filter Base - R em ove........................................ 10
Removal P rocedure............................................... 10 P
Fuel Pressure Sensor - Remove and Install 97
Installation P rocedure........................................... 97 Piston Cooling Jets - Remove and Install.............. 80
Removal P rocedure............................................... 97 Installation Procedure............................................. 80
Fuel Priming Pump - Remove and Install................. 9 Removal P rocedure.................................................80
Installation P rocedure........................................... 10 Pistons and Connecting Rods - A ssem ble 82
Removal P rocedure................................................... 9 Assembly Procedure................................................82
Fuel Temperature Sensor - Remove and Install.... 97 Pistons and Connecting Rods - D isassem ble 82
Installation P rocedure........................................... 98 Disassembly Procedure.......................................... 82
Removal P rocedure............................................... 97 Pistons and Connecting Rods - Install...................... 83
Fuel Transfer Pump - In s ta ll..................................... 12 Installation Procedure............................................. 83
Installation P rocedure........................................... 12 Pistons and Connecting Rods - Rem ove................ 81
Fuel Transfer Pump - R e m o ve ................................ 12 Removal Procedure.................................................81
Removal P rocedure............................................... 12
R Water Temperature Regulator Housing - Remove and
In s ta ll......................................................................... 33
Radiator Core - Install..................................................44 Installation Procedure............................................. 34
Installation P rocedure............................................. 44 Removal P rocedure.................................................33
Radiator Core - Rem ove............................................. 42
Removal Procedure.................................................42
Rocker Arm - Assem ble.............................................. 64
Assembly Procedure................................................64
Rocker Arm - D isassem ble.........................................64
Disassembly P rocedure.......................................... 64
Rocker Arm and Shaft - Install................................... 65
Installation P rocedure............................................. 65
Rocker Arm and Shaft - Rem ove...............................63
Removal P rocedure.................................................63

Table of Contents............................................................3
Turbocharger - A ssem ble......................................... 18
Assembly Procedure.............................................. 18
Turbocharger - D isassem ble.................................... 17
Disassembly P rocedure........................................ 17
Turbocharger - In s ta ll................................................ 18
Installation P rocedure........................................... 18
Turbocharger - R e m o v e ........................................... 17
Removal Procedure............................................... 17
Turbocharger Outlet Pressure Sensor - Remove and
In s ta ll......................................................................... 98
Installation P rocedure........................................... 98
Removal Procedure............................................... 98

Valve Mechanism Cover - Remove and Install 62

Installation P rocedure............................................. 62
Removal Procedure.................................................62
Valve Mechanism Cover Base - Remove and
In s ta ll......................................................................... 62
Installation P rocedure............................................. 63
Removal Procedure.................................................62
Vibration Damper and Pulley - Remove and
In s ta ll......................................................................... 53
Installation P rocedure........................................... 53
Removal Procedure............................................... 53

Water Pump - A ssem ble........................................... 32

Assembly Procedure.............................................. 32
Water Pump - D isassem ble...................................... 31
Disassembly P rocedure........................................ 31
Water Pump - Install.................................................. 33
Installation P rocedure........................................... 33
Water Pump - R em ove.............................................. 31
Removal Procedure............................................... 31

From the library of Barrington Diesel Club

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