SENR6419-14

March 2015

Disassembly and Assembly

G3500 Engines
E62 1-Up (Generator Set) 6JW 1-Up (Engine)
TJ2 1-Up (Generator Set) 8PW 1-Up (Engine)
WC2 1-Up (Generator Set) 9AW 1-Up (Engine)
WC3 1-Up (Generator Set) E6W 1-Up (Generator Set)
TJ4 1-Up (Generator Set) CPY 1-Up (Generator Set)
TJ6 1-Up (Generator Set) E6Y 1-Up (Generator Set)
WC6 1-Up (Generator Set) CSZ 1-Up (Generator Set)
TJ7 1-Up (Generator Set) E6Z 1-Up (Generator Set)
WC7 1-Up (Generator Set) ZAZ 1-Up (Generator Set)
WC8 1-Up (Generator Set)
E8A 1-Up (Generator Set)
ZBA 1-Up (Generator Set)
CRC 1-Up (Generator Set)
E2C 1-Up (Generator Set)
E8C 1-Up (Generator Set)
4WD 1-Up (Engine)
5JD 1-Up (Engine)
8LD 1-Up (Engine)
E2E 1-Up (Generator Set)
9TG 1-Up (Engine)
CPG 1-Up (Generator Set)
2TJ 1-Up (Engine)
7NJ 1-Up (Engine)
CPJ 1-Up (Generator Set)
4EK 1-Up (Engine)
CRN 1-Up (Generator Set)
E6N 1-Up (Generator Set)
CSP 1-Up (Generator Set)
E6R 1-Up (Generator Set)
CPS 1-Up (Generator Set)

SAFETY.CAT.COM
 i05296198

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, including human factors
that can affect safety. 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 verify
that you are authorized to perform this work, and have read and understood the operation,
lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

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

When replacement parts are required for this

product Caterpillar recommends using Cat re-
placement parts.
Failure to follow this warning may lead to pre-
mature failures, product damage, personal in-
jury or death.

In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
SENR6419 3
Table of Contents

Table of Contents Exhaust Elbow - Remove and Install....... ....... 89

Exhaust Elbow - Remove and Install....... ....... 90
Disassembly and Assembly Section Exhaust Bypass Valve - Remove and Install . . 93
Exhaust Manifold - Remove (Dry).......... ......... 93
Air Starting Motor - Remove ............... .............. 5 Exhaust Manifold - Remove (Water Cooled) . . 95
Air Starting Motor - Disassemble........... ........... 6 Exhaust Manifold - Install (Water Cooled) ... ... 97
Air Starting Motor - Disassemble.......... .......... 12 Exhaust Manifold - Install (Dry)............ ........... 99
Air Starting Motor - Assemble............. ............ 22 Water Temperature Regulators - Remove .. .. 101
Air Starting Motor - Assemble............. ............ 29 Water Temperature Regulators - Install .... .... 103
Air Starting Motor - Install ................ ............... 39 Water Pump - Remove ................. ................ 104
Electric Starting Motor - Remove and Install . . 40 Water Pump - Disassemble............. ............. 106
Service Meter - Remove and Install........ ........ 41 Water Pump - Assemble................ ............... 108
Gas Pressure Regulator Solenoid - Remove and Water Pump - Install ................... ...................112
Install............................... .............................. 42 Thermostatic Valve - Remove............ ............113
Gas Pressure Regulator - Remove ........ ........ 43 Thermostatic Valve - Disassemble ........ ........114
Gas Pressure Regulator - Remove (High Thermostatic Valve - Assemble .......... ...........115
Pressure) ........................... ........................... 44 Thermostatic Valve - Install.............. ..............115
Gas Pressure Regulator - Remove (Low Auxiliary Water Pump - Remove.......... ..........116
Pressure) ........................... ........................... 44 Auxiliary Water Pump - Disassemble ...... ......118
Gas Pressure Regulator - Disassemble ..... .... 45 Auxiliary Water Pump - Assemble ........ ........ 120
Gas Pressure Regulator - Assemble ....... ....... 46 Auxiliary Water Pump - Install............ ........... 123
Gas Pressure Regulator - Install (Low Engine Oil Cooler - Remove............. ............ 126
Pressure) ........................... ........................... 48 Engine Oil Cooler - Disassemble......... ......... 127
Gas Pressure Regulator - Install (High Engine Oil Cooler - Assemble............ ........... 128
Pressure) ........................... ........................... 48 Engine Oil Cooler - Install ............... .............. 130
Fuel Control Actuator - Remove and Install.. .. 48 Engine Oil Pump - Remove ............. ............. 131
Fuel Control Actuator - Remove and Install.. .. 50 Engine Oil Pump - Disassemble.......... ......... 132
Fuel Control Valve - Remove and Install .... .... 52 Engine Oil Pump - Assemble............ ............ 134
Fuel Control Valve - Remove and Install .... .... 53 Engine Oil Pump - Install ............... ............... 136
Electronic Sensor - Remove and Install..... ..... 55 Engine Oil Filter Housing - Remove ....... ...... 137
Carburetor - Remove (Low Pressure)...... ...... 56 Engine Oil Filter Housing - Disassemble ... ... 138
Carburetor - Remove (High Pressure)...... ..... 56 Engine Oil Filter Housing - Assemble...... ..... 140
Carburetor - Remove (Low Pressure)...... ...... 57 Engine Oil Filter Housing - Install ........ ......... 143
Carburetor - Disassemble (High Pressure).. .. 58 Engine Oil and Water Pump Drive - Remove 144
Carburetor - Disassemble (High Pressure).. .. 60 Engine Oil and Water Pump Drive -
Carburetor - Assemble (High Pressure) .... .... 61 Disassemble ........................ ....................... 144
Carburetor - Assemble (High Pressure) .... .... 63 Engine Oil and Water Pump Drive -
Carburetor - Install (Low Pressure)........ ........ 64 Assemble .......................... .......................... 145
Carburetor - Install (Low Pressure)........ ........ 64 Engine Oil and Water Pump Drive - Install .. . 147
Carburetor - Install (High Pressure)........ ....... 65 Engine Oil Pan - Remove ............... .............. 147
Air Cleaner - Remove and Install.......... .......... 66 Engine Oil Pan - Disassemble........... ........... 148
Turbocharger - Remove................. ................. 67 Engine Oil Pan - Assemble.............. ............. 149
Turbocharger - Remove................. ................. 69 Engine Oil Pan - Install ................. ................ 150
Turbocharger - Disassemble ............. ............. 70 Crankcase Breather - Remove and Install.. .. 151
Turbocharger - Assemble ................ ............... 74 Valve Cover and Spark Plug - Remove and
Turbocharger - Install................... ................... 78 Install.............................. ............................. 152
Turbocharger - Install................... ................... 79 Rocker Shaft and Push Rod - Remove..... .... 154
Aftercooler - Remove and Install .......... .......... 81 Rocker Shaft - Disassemble ............. ............ 154
Aftercooler - Remove and Install .......... .......... 86 Rocker Shaft - Assemble............... ............... 155
Air Inlet Manifold - Remove and Install ...... ..... 88 Rocker Shaft and Push Rod - Install....... ...... 156
Cylinder Head - Remove ............... ............... 157
4 SENR6419
Table of Contents

Cylinder Head - Disassemble ............ ........... 159

Cylinder Head - Assemble.............. .............. 161
Cylinder Head - Install ................. ................. 164
Spacer Plate - Remove and Install ........ ....... 166
Accessory Drive (Front) - Remove ........ ....... 168
Accessory Drive (Front) - Disassemble .... .... 169
Accessory Drive (Front) - Assemble....... ...... 170
Accessory Drive (Front) - Install .......... ......... 171
Drive Housing (Front) - Remove and Install .. 172
Vibration Damper - Remove and Install.... .... 175
Crankshaft Front Seal and Wear Sleeve -
Remove ........................... ........................... 177
Crankshaft Front Seal and Wear Sleeve -
Install.............................. ............................. 178
Flywheel - Remove and Install........... ........... 180
Crankshaft Rear Seal and Wear Sleeve -
Remove ........................... ........................... 181
Crankshaft Rear Seal and Wear Sleeve -
Install.............................. ............................. 182
Flywheel Housing - Remove............. ............ 184
Flywheel Housing - Install............... .............. 186
Engine Oil Sequence Valves - Remove and
Install.............................. ............................. 189
Gear Group (Rear) - Remove ............ ........... 191
Gear Group (Rear) - Install .............. ............. 193
Piston Cooling Jets - Remove and Install... .. 196
Bearing Clearance - Check ............. ............. 197
Connecting Rod Bearings - Remove and
Install.............................. ............................. 198
Crankshaft Main Bearings - Remove...... ...... 200
Crankshaft Main Bearings - Install........ ........ 201
Piston and Connecting Rods - Remove ........ 203
Piston and Connecting Rods - Install...... ...... 205
Cylinder Liner - Remove................ ............... 207
Cylinder Liner - Install .................. ................. 208
Camshaft - Remove................... ................... 210
Camshaft - Install..................... ..................... 213
Camshaft Bearings - Remove ........... ........... 218
Camshaft Bearings - Install.............. ............. 219
Crankshaft - Remove.................. .................. 220
Crankshaft - Install.................... .................... 222

Index Section

Index............................... .............................. 226

SENR6419 5
Disassembly and Assembly Section

Disassembly and Assembly

Section
i01929453

Air Starting Motor - Remove

SMCS Code: 1451-011

Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened Illustration 2 g00597643
component life.
5. Disconnect hose assembly (5).
Note: Several different air starting motors are 6. Attach a suitable lifting device onto air starting
available for use. The starting motors can have motor (6). The weight of air starting motor (6) is
different configurations for the air tube assemblies. approximately 48 kg (106 lb).
Examples of removing two different air starting
motors are described below. 7. Remove bolts (7). Remove air starting motor (6).
Remove the gasket from the joint between the
Removal of an Air Starting Motor Without cover of air starting motor (6) and the flywheel
the Air Tube Assemblies Attached housing.

1. Turn off the supply of pressurized air. Purge the Removal of an Air Starting Motor With the
pressurized air from the air tube assemblies and Air Tube Assemblies Attached
the starting motor.
1. Turn off the supply of pressurized air. Purge the
pressurized air from the air tube assemblies and
the starting motor.

Illustration 3 g00615939

2. Disconnect harness assembly (1).

Illustration 1 g00597642
3. Disconnect the tube assembly from elbow (2).
2. Disconnect hose assemblies (1).

3. Remove bolts (2).

4. Remove U-bolt (3) and tube assemblies (4).

6 SENR6419
Disassembly and Assembly Section

Note: Several different air starting motors are

available for use. An example of disassembling a
typical air starting motor is described below.
Note: Before you disassemble the air starting motor,
obtain a complete set of these parts: gaskets, O-ring
seals, seals and vanes.

Illustration 4 g00615940

4. Attach a suitable lifting device onto air starting

motor (4). The weight of air starting motor (4) is
approximately 86 kg (190 lb).

5. Remove bolts (3). Remove air starting motor (4).

Remove the gasket from the joint between the Illustration 5 g00597693
cover of air starting motor (4) and the flywheel
housing. 1. Remove elbow (1) and bracket (2) from motor
housing (3).
i01929516

Air Starting Motor -

Disassemble
SMCS Code: 1451-015

Disassembly Procedure
Table 1
Required Tools

Tool Part Number Part Description Qty

A 1P-1854 Retaining Ring Pliers 1

Plate
50.8 mm (2 inches) x 102 Illustration 6 g00597694
B 1
mm (4 inches) x 6 mm (0.25
inches) 2. To ensure correct assembly, mark the position of
C 1P-1857 Retaining Ring Pliers 1 motor housing (3) in relation to gear case (6).
Remove bolts (4). Remove gear case (6) and drive
housing (5) as a unit.
Start By:
a. Remove the air starting motor. Refer to
Disassembly and Assembly, “Air Starting Motor -
Remove”.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
SENR6419 7
Disassembly and Assembly Section

Illustration 7 g00597696 Illustration 9 g00597698

3. Use Tooling (A) in order to remove ring (8) from 5. Remove O-ring seal (13) from drive housing (5).
drive gear (7).

Illustration 10 g00597701
Illustration 8 g00597697

Note: Bolt (9) has left hand threads.

4. Remove bolt (9) and washer (10). Remove pinion The drive shaft, the piston, and the drive gear are
(11), the sleeve, and the spring. under a spring force. Slowly release the spring
To ensure correct assembly, mark the position of force before you remove these components.
drive housing (5) in relation to gear case (6).
Remove bolts (12) and drive housing (5) from gear 6. Position Tooling (B) between drive gear (7) and
case (6). piston (14). Use a suitable press in order to
compress the return spring. Remove the ring that
holds the drive shaft and the piston in drive
housing (5).
8 SENR6419
Disassembly and Assembly Section

Illustration 11 g00597709 Illustration 13 g00597712

9. Remove bulkhead (18) from piston (14).

Personal injury can result from being struck by

parts propelled by a released spring force.
Make sure to wear all necessary protective
equipment.
Follow the recommended procedure and use all
recommended tooling to release the spring force.

7. Slowly release the press in order to remove the

force of return spring (16). Remove Tooling (B).
Remove ring (15). Remove the drive gear, the
piston, and the drive shaft from drive housing (5)
as a unit. Remove return spring (16).

Illustration 14 g00597713

10. Remove O-ring seals (19) from bulkhead (18).

Illustration 12 g00597711

8. Loosen the bolt (not shown) until the bolt moves

freely. Remove drive shaft (17) and piston (14)
Illustration 15 g00597714
from drive gear (7) as a unit.
11. Remove ring (20) from piston (14). Remove the
piston from drive shaft (17).
SENR6419 9
Disassembly and Assembly Section

Illustration 16 g00597715 Illustration 18 g00597717

12. Remove O-ring seal (22) and seal (21) from Note: A new ring is always required for assembly
piston (14). when ring (32) is removed.
14. Remove ring (32) and bearing (33) from drive
shaft (17).

Illustration 17 g00597716

Illustration 19 g00597719

15. Use Tooling (C) to remove ring (35). Remove

Personal injury can result from being struck by
parts propelled by a released spring force. bearing (34) from gear case (6).

Make sure to wear all necessary protective

equipment.
Follow the recommended procedure and use all
recommended tooling to release the spring force.

13. Remove the following parts from drive shaft (17) :

ring (31), cup (30), spring (29), driven clutch jaw
(28), driving clutch jaw (27), bearing (26), washer
(25), lockwasher (24) and bolt (23).

Illustration 20 g00597722

16. Remove spring seat (36) and bearing (37) from

drive housing (5).
10 SENR6419
Disassembly and Assembly Section

Illustration 21 g00597723 Illustration 24 g00597726

17. Remove seal (38) from drive housing (5). 20. Loosen bolt (43) and remove nut (42). Remove
bearing (44) from rear end plate (45).

Illustration 22 g00597724
Illustration 25 g00597727
18. To ensure correct assembly, mark the position of
cover (39) in relation to motor housing (3). Remove 21. Remove O-ring seal (46) and rear end plate (45).
cover (39) and remove the O-ring seal from motor
housing (3).

Illustration 26 g01054297

Illustration 23 g00597725 22. Remove vanes (47) from rotor (48).

19. Remove bolt (41) and rotor pinion (40) from the
rotor in the motor housing.
SENR6419 11
Disassembly and Assembly Section

Illustration 27 g00597729 Illustration 30 g00597732

23. Remove rotor (48) from motor housing (3). 26. Remove washers (51) from front end plate (50).

Illustration 28 g00597730 Illustration 31 g00597734

24. Use a suitable press in order to remove bearing 27. Remove O-ring seals (52) from rotor cylinder (53).
(49) and front end plate (50) from rotor (48) as a
unit.

Illustration 32 g01005075

Illustration 29 g00597731 28. Remove rotor cylinder (53) from motor housing
(3). Remove O-ring seals (54) from rotor cylinder
25. Remove bearing (49) from front end plate (50). (53).
12 SENR6419
Disassembly and Assembly Section

i02733454
1. Mark all the adjacent parts of the housing for the air
Air Starting Motor - starting motor for assembly purposes.
Disassemble
SMCS Code: 1451-015

S/N: TJ61–Up
S/N: WC61–Up
S/N: WC81–Up
S/N: E8A1–Up
S/N: CRC1–Up
S/N: E2C1–Up
S/N: 5JD1–Up
S/N: 8LD1–Up
Illustration 33 g01170823
S/N: E2E1–Up
2. Remove bolts (1) and remove drive housing (2)
S/N: 7NJ1–Up
from gearbox housing (3).
S/N: 4EK1–Up
S/N: CRN1–Up
S/N: CSP1–Up
S/N: E6R1–Up
S/N: CPS1–Up
S/N: E6W1–Up
S/N: E6Y1–Up

Disassembly Procedure
Table 2
Required Tools

Tool Part Number Part Description Qty

A 1P-1855 Retaining Ring Pliers 1

B 9S-9152 Bearing Puller Gp 1

C 1P-0510 Driver Gp 1

D 1P-1861 Retaining Ring Pliers 1

E 1P-1863 Retaining Ring Pliers 1

F 8B-7551 Bearing Puller Gp 1

G 277-7088 Spanner Socket 1

H 8H-0663 Bearing Puller Gp 1

Start By:
a. Remove the air starting motor. Refer to
Disassembly and Assembly, “Air Starting Motor -
Remove”.
Note: The individual parts of the air starting motor are
nonserviceable. An overhaul kit must be purchased in
order to service the air starting motor.
SENR6419 13
Disassembly and Assembly Section

Illustration 34 g01170843 Illustration 36 g01170867

4. Remove drive assembly (7), spring (8), and washer

(9) from drive housing (2).

Illustration 35 g01171324

Illustration 37 g01171383

Personal injury can result from being struck by

5. Use Tooling (A) and remove retaining ring (10) from
parts propelled by a released spring force.
drive assembly (7).
Make sure to wear all necessary protective
equipment.
Follow the recommended procedure and use all
recommended tooling to release the spring force.

Note: When bolt (4) is removed spring tension will be

released from drive assembly (7).
3. Position drive housing (2) into a suitable press.
Remove bolt (4) and washer (5). Remove pinion
gear (6). Slowly release the suitable press in order
to release the spring tension on drive assembly
(7).

Illustration 38 g01171410

6. Use Tooling (B), Tooling (C), and a suitable press in

order to remove bearing (11) from drive assembly
(7).
14 SENR6419
Disassembly and Assembly Section

Illustration 39 g01171415 Illustration 42 g01171531

7. Remove spacer (12). Remove lip seal (13). 10. Use Tooling (C) and a suitable press in order to
remove bearing (17).

Illustration 40 g01171417
Illustration 43 g01171424
8. Use Tooling (C) and a suitable press in order to
remove spur gear (14) from drive housing (2). 11. Use Tooling (F), Tooling (C), and a suitable press
in order to remove bearing (18) from spur gear
(14).

Illustration 41 g01171422

9. Use Tooling (D) to remove retaining ring (15). Use Illustration 44 g01171533
Tooling (E) to remove retaining ring (16).
12. If necessary, remove bearing (19) from drive
housing (2).
SENR6419 15
Disassembly and Assembly Section

Illustration 45 g01171573 Illustration 47 g01171580

13. Remove bolts (20) and remove gearbox housing 15. Remove allen head bolts (22).
(3).

Illustration 48 g01171591
Illustration 46 g01171575
16. Remove planetary assembly (23). Remove O-ring
14. Remove ring gear (21). seal (24).
16 SENR6419
Disassembly and Assembly Section

Illustration 49 g01171739 Illustration 51 g01171752

17. Bend the tab of lock washer (26) out of slot in 19. Remove lock washer (26). Remove spur gear (27)
spanner nut (25). and the woodruff key.

Illustration 52 g01171762

Personal injury can result from being struck by

parts propelled by a released spring force.
Illustration 50 g01171744
Make sure to wear all necessary protective
18. Position planetary assembly (23) into a soft jawed equipment.
vise. Use Tooling (G) and remove spanner nut Follow the recommended procedure and use all
(25). recommended tooling to release the spring force.

20. Use a suitable press and remove planetary carrier

assembly (29) from bearing housing (28).
SENR6419 17
Disassembly and Assembly Section

Illustration 53 g01171769 Illustration 55 g01171774

21. Use Tooling (D) and remove retaining ring (30) 23. Use Tooling (H) and a suitable press in order to
from bearing housing (28). Remove bearing (31). remove bearing (35) from planetary carrier
assembly (29).

Illustration 54 g01171772
Illustration 56 g01171808
22. Remove spacer (32), washer (33), and spring
washers (34). 24. Use Tooling (A) and remove retaining ring (36).
18 SENR6419
Disassembly and Assembly Section

Illustration 57 g01171812

25. Remove pin (39), thrust washers (37), and

planetary gear (38).

Illustration 59 g01171986

28. Remove allen head bolts (41). Remove housing

(42).

Illustration 58 g01171983

26. Use Tooling (C) and a suitable press in order to

remove bearing (40) from planetary gear (38).

27. Repeat Step 24 through Step 26 for the remaining

planetary gears. Illustration 60 g01171989

29. Remove O-ring seal (43) from housing (42).

SENR6419 19
Disassembly and Assembly Section

Illustration 61 g01171998 Illustration 63 g01172024

30. Remove allen head bolt (44) and the washer. 32. Remove allen head bolts (48) and retainer plate
Remove rotor (45) and the woodruff key. (49).

Illustration 62 g01172022 Illustration 64 g01172168

31. Remove spacer (46). Remove allen head bolts 33. Use a suitable press and remove turbine shaft
(47). (50).
20 SENR6419
Disassembly and Assembly Section

Illustration 65 g01172209

34. Remove spacer (51) and bearing (52) from

turbine shaft (50).

Illustration 66 g01172212

Illustration 67 g01173007

35. Remove housing (53) and O-ring seal (54).

Remove spacer (55), rotor (56), and the woodruff
key (not shown).
SENR6419 21
Disassembly and Assembly Section

Illustration 70 g01172618

38. Use Tooling (C) and remove lip seal (60) from
nozzle (58).

Illustration 68 g01172585

36. Remove allen head bolts (57) and remove nozzle

(58).

Illustration 71 g01172599

39. Remove spacer (61).

Illustration 69 g01172614

37. Remove O-ring seal (59).

22 SENR6419
Disassembly and Assembly Section

(Table 3, contd)
A 1P-1854 Retaining Ring Pliers 1

Plate
50.8 mm (2 inches) x 102 mm
B 2
(4 inches) x 6 mm (0.25
inches)

C 1P-1857 Retaining Ring Pliers 1

Tube
57 mm (2.25 inch) diameter x
D 1
6 mm (0.25 inch) thick wall x
203 mm (8 inches) long

E 1P-0510 Driver Group 1

F 2S-3230 Bearing Lubricant

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
Illustration 72 g01172613 component life.

40. Use Tooling (C) and a suitable press. Press

Note: Thoroughly clean all of the parts. Apply Tooling
through lip seal (62) in order to remove bearing (F) to all of the bearings and the drive assembly.
(63) (not shown). Before assembly, coat all of the other parts with an
SAE 10 grade of oil.

Illustration 73 g01172628

Illustration 74 g01054313
41. Remove wave washer (64). Use Tooling (C) and a
suitable press and remove lip seal (62). Note: Check the O-ring seals for wear or for damage.
If necessary, replace the O-ring seals.
i01929517 1. Install O-ring seals (54) on rotor cylinder (53).
Install rotor cylinder (53) into motor housing (3).
Air Starting Motor - Assemble Orient pin (55) of rotor cylinder (53) with slot (56) in
motor housing (3).
SMCS Code: 1451-016

Assembly Procedure
Table 3
Required Tools

Tool Part Number Part Description Qty

(continued)
SENR6419 23
Disassembly and Assembly Section

Illustration 75 g00598181 Illustration 78 g01054320

2. Install O-ring seal (52) onto rotor cylinder (53). 5. Install bearing (44) over the shaft of rotor (48). The
bearing will fit into the rear end plate.

Illustration 76 g00598221
Illustration 79 g01054321
3. Install rear end plate (45) on the shaft of rotor (48).
6. Install rotor clamp nut (42) on the shaft of rotor (48).
Orient the shoulder of nut (42) toward the bearing.

Illustration 77 g01054318

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

If necessary, replace the O-ring seal.
4. Install O-ring seal (46) over the shaft of rotor (48).
24 SENR6419
Disassembly and Assembly Section

Illustration 80 g00598201
Illustration 83 g01054327
7. Tighten the rotor clamp nut in order to obtain a
clearance of 0.03 to 0.08 mm (0.001 to 0.003 inch) 10. Install front end plate (50) onto rotor (48). Align
between the rear end plate and the rotor. Measure small hole (58) of front end plate (50) onto rotor pin
the clearance with a feeler gauge. Tighten hex (59).
socket head bolt (43) into the rotor clamp nut.
Measure the clearance again.

Illustration 84 g00598420

Illustration 81 g00598207 11. Install washers (51) over the shaft of the rotor
onto the front end plate.
8. Install rotor (48) into motor housing (3). Align pin
(57) into the slot of the rear end plate.

Illustration 85 g00598225

Illustration 82 g01054297 12. Place bearing (49) onto the front end plate.

9. Install vanes (47) into rotor (48).

SENR6419 25
Disassembly and Assembly Section

Illustration 86 g00598445 Illustration 89 g00598232

13. Use Tooling (E) and a suitable press in order to 16. Install bearing (33) and new ring (32) onto drive
complete the installation of bearing (49). shaft (17).

Illustration 87 g00598227 Illustration 90 g00598234

14. Install rotor pinion (40) with the hex head bolt. 17. Use Tooling (D) with a suitable press in order to
Tighten the bolt to a torque of 120 N·m (90 lb ft). complete the installation of the new ring.

Illustration 88 g00598230

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

If necessary, replace the O-ring seal.
15. Install O-ring seal (60) onto the rotor bearing that
is on the rear end plate. Install cover (39) onto
motor housing (3).
26 SENR6419
Disassembly and Assembly Section

Illustration 91 g00598241 Illustration 93 g00598244

20. Install piston (14) onto the drive shaft (17). Install
ring (20) onto the piston.
Improper assembly of parts that are spring loaded
can cause bodily injury.
To prevent possible injury, follow the established
assembly procedure and wear protective
equipment.

18. Install these parts into drive shaft (17) : bolt (23),
lockwasher (24), washer (25), bearing (26), driving
clutch jaw (27), driven clutch jaw (28), spring (29)
and cup (30). Install ring (31).

Illustration 94 g00598246

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

If necessary, replace the O-ring seals.
21. Install O-ring seals (19) onto bulkhead (18).

Illustration 92 g00598242

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

If necessary, replace the O-ring seal.
19. Use Tooling (E) in order to install the seal into
piston (14). Ensure that the lip of the seal is
oriented toward the outside of the piston. Install O-
ring seal (22).

Illustration 95 g00598261

22. Install bulkhead (18) onto piston (14).

SENR6419 27
Disassembly and Assembly Section

Illustration 96 g00598263 Illustration 99 g00598268

23. Install drive gear (7) onto drive shaft (17). Tighten 26. Install spring seat (36) into the drive housing.
the bolt (not shown) of the drive gear to a torque of
77 N·m (57 lb ft).

Illustration 100 g00598269

Illustration 97 g00598264 27. Install return spring (16) onto the spring seat
inside the drive housing.
24. Use Tooling (E) in order to install the seal into
drive housing (5). Ensure that the lip of the seal is
oriented toward the outside of the housing.

Illustration 98 g00598267

25. Install bearing (37) into the drive housing.

28 SENR6419
Disassembly and Assembly Section

Illustration 101 g00598270 Illustration 103 g00598274

30. Install drive housing (5) in gear case (6). Make

sure that the shaft on the end of the drive gear is
Improper assembly of parts that are spring loaded correctly engaged with the bearing in the gear
can cause bodily injury. case. Tighten the bolts to a torque of 36 N·m
(27 lb ft).
To prevent possible injury, follow the established
assembly procedure and wear protective
equipment.

28. Install the drive gear, the piston, and the drive
shaft onto the return spring as a unit.
Install ring (15) over the piston. Place Tooling (B)
between the drive gear and the piston. Use a
suitable press in order to compress the return
spring. Install ring (15) into the groove of the drive
housing. Slowly release the press. Remove
Tooling (B).

Illustration 104 g00598276

31. Use Tooling (A) and install ring (8).

Illustration 102 g00598272

29. Install bearing (34) into gear case (6). Use Tooling
(C) in order to install the ring that retains the
bearing in the gear case.

Illustration 105 g00598277

Note: Bolt (9) has left hand threads.

SENR6419 29
Disassembly and Assembly Section

32. Install these parts on the end of the drive shaft:

pinion spring (62), spring sleeve (61), drive pinion 3. Apply 345 kPa (50 psi) of air pressure in the inlet
(11), bolt (9) and the washer. Tighten bolt (9) to a of the drive housing. The drive pinion must move
torque of 110 N·m (80 lb ft). away from the drive housing and air must come out
of the outlet of the drive housing.

4. Plug the outlet of the drive housing. Apply

1034 kPa (150 psi) in the inlet of the drive
housing. Ensure that no air is leaking. Measure the
dimension from the face of the drive pinion to the
mounting face of the drive housing. The dimension
must be 73.00 ± 2.0 mm (2.874 ± 0.08 inch).
Remove the air pressure. Measure the dimension
again. The dimension must be 44.5 ± 2.0 mm
(1.75 ± 0.08 inch).

5. Apply 620 kPa (90 psi) of air pressure in the inlet

of the drive housing. The starting motor must run
smoothly.
Illustration 106 g00598278
End By:
33. Install gear case (6) and drive housing (5) onto a. Install the air starting motor. Refer to Disassembly
cover (3) as a unit. Tighten bolts (4) evenly to a and Assembly, “Air Starting Motor - Install”.
torque of 80 N·m (60 lb ft).
i02347120

Air Starting Motor - Assemble

SMCS Code: 1451-016

S/N: TJ61–Up
S/N: WC61–Up
S/N: WC81–Up
S/N: E8A1–Up
S/N: CRC1–Up
S/N: E2C1–Up
S/N: 5JD1–Up
Illustration 107 g00597693
S/N: 8LD1–Up
34. Install the gasket, elbow (1), and bracket (2) on
S/N: E2E1–Up
motor housing (3).
S/N: 7NJ1–Up
35. After you verify that the starting motor operates
properly, attach the air lines to the starting motor. S/N: 4EK1–Up
S/N: CRN1–Up
Verify the Operation of the Air Starting
S/N: CSP1–Up
Motor
S/N: E6R1–Up
Use the following procedure to verify that the air
starting motor is operating correctly: S/N: CPS1–Up

1. Turn the drive pinion by hand in the direction of the S/N: E6W1–Up
rotation of the starting motor. The drive clutch must S/N: E6Y1–Up
operate smoothly with a clicking sound.

2. Turn the drive pinion in the opposite direction of the

rotation of the starting motor. The drive pinion must
turn by hand.
30 SENR6419
Disassembly and Assembly Section

Assembly Procedure
Table 4
Required Tools

Tool Part Number Part Description Qty

A 1P-1855 Retaining Ring Pliers 1

C 1P-0510 Driver Gp 1

D 1P-1861 Retaining Ring Pliers 1

E 1P-1863 Retaining Ring Pliers 1

G 277-7088 Spanner Socket 1

J 9S-3263 Thread Lock Compound 1

Note: The individual parts of the air starting motor are

nonserviceable. An overhaul kit must be purchased in
order to service the air starting motor.

Illustration 109 g01172024

2. Position retainer plate (49) and install allen head

bolts (48). Tighten allen head bolts (48) to a torque
of 5.0 N·m (40.0 lb in).

Illustration 108 g01172945

Illustration 110 g01172948
1. Install bearing (52) on turbine shaft (50). Use a
suitable press and install turbine shaft (52) and 3. Install spacer (51) and spacer (61) on turbine shaft
bearing (50) into the housing. (50). Install O-ring seal (59).
SENR6419 31
Disassembly and Assembly Section

Illustration 111 g01172618 Illustration 113 g01173007

4. Use Tooling (C) and install lip seal (60) into nozzle 6. Install the woodruff key and rotor (56). Make sure
(58). that the woodruff key did not push out during
installation of rotor (56). Install spacer (55).

Illustration 114 g01172628

7. Use Tooling (C) and install lip seal (62). Install

wave washer (64).

Illustration 112 g01172585

5. Position nozzle (58). Apply Tooling (J) to the

threads of allen head bolts (57). Install allen head
bolts (57). Tighten allen head bolts (57) to a torque
of 3.0 N·m (30.00 lb in).
32 SENR6419
Disassembly and Assembly Section

Illustration 115 g01173045 Illustration 117 g01172022

8. Use Tooling (C) and a suitable press to install 10. Apply Tooling (J) to the threads of allen head bolts
bearing (63) into housing (53). (47). Install allen head bolts (47). Tighten allen
head bolts (47) to a torque of 3.0 N·m (30.00 lb in).

Illustration 116 g01172212

Illustration 118 g01171998
9. Install O-ring seal (54). Install housing (53).
11. Install the woodruff key and install rotor (45).
Make sure that the woodruff key did not push out
during installation of rotor (45). Install the washer
and allen head bolt (44). Tighten allen head bolt
(44) to a torque of 11.0 N·m (100.00 lb in).
SENR6419 33
Disassembly and Assembly Section

Illustration 119 g01171989 Illustration 121 g01171983

12. Install O-ring seal (43) onto housing (42). 14. Use Tooling (C) and a suitable press to install
bearing (40) into planetary gear (38).

Illustration 122 g01171812

15. Install thrust washers (37), planetary gear (38),

and pin (39) into the planetary carrier.

Illustration 120 g01171986

13. Position housing (42). Apply Tooling (J) to the

threads of allen head bolts (41). Install allen head
bolts (41). Tighten allen head bolts (41) to a torque
of 9.0 N·m (80.00 lb in).
34 SENR6419
Disassembly and Assembly Section

Illustration 123 g01171808 Illustration 125 g01171772

16. Use Tooling (A) and install retaining ring (36). 19. Install spring washers (34), washer (33), and
spacer (32).
17. Repeat Step 14 through Step 16 for the remaining
planetary gears.

Illustration 126 g01171769

Illustration 124 g01173138 20. Install bearing (31). Use Tooling (D) and install
retaining ring (30) into bearing housing (28).
18. Use Tooling (C) and a suitable press to install
bearing (35) onto planetary carrier assembly (29).
SENR6419 35
Disassembly and Assembly Section

Illustration 127 g01173235

Improper assembly of parts that are spring loaded

can cause bodily injury.
Illustration 129 g01171744
To prevent possible injury, follow the established
assembly procedure and wear protective 23. Position planetary assembly (23) into a soft jawed
equipment.
vise. Use Tooling (G) and install spanner nut (25).
Tighten spanner nut (25) to a torque of
21. Install bearing housing (28) onto planetary carrier
122 to 136 N·m (90 to 100 lb ft).
assembly (29). Install the woodruff key and spur
gear (27).

Illustration 130 g01171739

Illustration 128 g01173238

24. Bend the tab of lock washer (26) into the slot in
spanner nut (25).
22. Install lock washer (26).
36 SENR6419
Disassembly and Assembly Section

Illustration 131 g01171591 Illustration 133 g01171575

25. Lubricate planetary assembly (23) with the grease 27. Install ring gear (21).
that is supplied in the overhaul kit. Install planetary
assembly (23). Install O-ring seal (24).

Illustration 134 g01171573

Illustration 132 g01171580 28. Position gearbox housing (3). Install bolts (20).
Tighten bolts (20) to a torque of 13 N·m (113 lb in).
26. Install allen head bolts (22). Tighten allen head
bolts (22) to a torque of 13 N·m (113 lb in).
SENR6419 37
Disassembly and Assembly Section

Illustration 135 g01171533 Illustration 138 g01171422

29. Install bearing (19) into drive housing (2). 32. Use Tooling (E) and install retaining ring (16). Use
Tooling (D) and install retaining ring (15).

Illustration 136 g01173294

Illustration 139 g01173298
30. Use Tooling (C) and a suitable press to install
bearing (18) onto spur gear (14). 33. Use Tooling (C) and a suitable press to install
spur gear (14) into drive housing (2).

Illustration 137 g01171531

Illustration 140 g01171415
31. Use Tooling (C) and a suitable press to install
bearing (17). 34. Use Tooling (C) to install lip seal (13). Install
spacer (12).
38 SENR6419
Disassembly and Assembly Section

Illustration 141 g01173353 Illustration 143 g01170867

35. Use a suitable press and install bearing (11) onto

drive assembly (7).
Improper assembly of parts that are spring loaded
can cause bodily injury.
To prevent possible injury, follow the established
assembly procedure and wear protective
equipment.

38. Install spring (8), washer (9), and drive assembly

(7) into drive housing (2).

Illustration 142 g01171383

36. Use Tooling (A) and install retaining ring (10) onto
drive assembly (7).

37. Lubricate drive assembly (7) with the grease that

is supplied in the overhaul kit.
SENR6419 39
Disassembly and Assembly Section

End By:
a. Install the air starting motor. Refer to Disassembly
and Assembly, “Air Starting Motor - Install”.

i01929504

Air Starting Motor - Install

SMCS Code: 1451-012

Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Illustration 144 g01170823
Contaminants may cause rapid wear and shortened
component life.

Note: Several different air starting motors are

available for use. The starting motors can have
different configurations for the air tube assemblies.
Examples of installing two different air starting motors
are provided below.

Installation of an Air Starting Motor

Without the Air Tube Assemblies
Attached

Illustration 145 g01171324

39. Position drive housing (2) into a suitable press.

Press drive assembly (7) into drive housing (2).
Install pinion gear (6), washer (5), and bolt (4).
Tighten bolt (4) to a torque of 81 N·m (60 lb ft).

Illustration 147 g00597643

1. Attach a suitable lifting device to air starting motor

(6). The weight of air starting motor (6) is
approximately 48 kg (106 lb).

2. Install a new gasket for the joint between the cover

of air starting motor (6) and the flywheel housing.
Illustration 146 g01170843 Position air starting motor (6). Install bolts (7).

40. Position drive housing (2) onto gearbox housing 3. Connect hose assembly (5).
(3). Install bolts (1). Tighten bolts (1) to a torque of
13 N·m (113 lb in).
40 SENR6419
Disassembly and Assembly Section

Illustration 150 g00615939

3. Connect the tube assemblies to elbow (2).

4. Connect harness assembly (1).

Illustration 148 g00597642 i01128256

4. Install tube assemblies (4) and U-bolt (3). Electric Starting Motor -
5. Install bolts (2).
Remove and Install
SMCS Code: 1453-010
6. Connect hose assemblies (1).
Removal Procedure
Installation of an Air Starting Motor With
the Air Tube Assemblies Attached

Disconnect batteries before performance of any

service work.

Note: Before disconnecting the wires and electrical

cables, mark the items for the proper connections in
order to ensure correct assembly.

Illustration 149 g00615940

1. Attach a suitable lifting device to air starting motor

(4). The weight of air starting motor (4) with the air
tube assemblies is approximately 86 kg (190 lb).

2. Install a new gasket for the joint between the cover

of air starting motor (4) and the flywheel housing. Illustration 151 g00597378
Position air starting motor (4). Install bolts (3).
1. Disconnect the wires and electrical cables from
solenoid (1) and starting motor (2).
SENR6419 41
Disassembly and Assembly Section

If the engine has two starting motors, disconnect

the wires between the two solenoids and starting
motors.
2. Attach a suitable hoist to the starting motor. The
starting motor weighs approximately 30 kg (66 lb).

3. Remove three bolts (3). Remove the starting motor.

Remove the gasket from the joint between the
starting motor and the flywheel housing.

Installation Procedure
1. Inspect the gasket for the joint between the starting
motor and the flywheel housing. Obtain a new
gasket, if necessary.
Illustration 153 g01248557

2. Attach a suitable hoist to the starting motor. The

starting motor weighs approximately 30 kg (66 lb).

Illustration 152 g00597378

3. Place the gasket in the cover for the starting motor.

Lift the starting motor onto the mounting position.
Install three bolts (3). Illustration 154 g01248562

4. Connect the wires and electrical cables to solenoid 1. Loosen screws (1) on the cover of panel (3). Open
(1) and starting motor (2). the cover in order to gain access to the back of
service meter (2).
If the engine has two starting motors, connect the
wires between the two solenoids and starting 2. Place an identification mark on all of the harness
motors.
assemblies for the installation procedure.
i02496818 3. Remove the nuts and the harness assemblies from
the bracket. Remove the bracket and service
Service Meter - Remove and meter (2) from panel (3).
Install 4. Remove the clip and disconnect connector (4).
SMCS Code: 7451-010 Loosen locknut (5) and remove sensor (6).

Removal Procedure Installation Procedure

42 SENR6419
Disassembly and Assembly Section

i02496856

Gas Pressure Regulator

Solenoid - Remove and Install
SMCS Code: 1270-010

S/N: E621–Up
S/N: TJ21–Up
S/N: WC21–Up
S/N: WC31–Up
S/N: TJ41–Up
S/N: TJ61–Up
S/N: WC61–Up
S/N: WC81–Up
S/N: E8A1–Up
Illustration 155 g01248562 S/N: ZBA1–Up
S/N: CRC1–Up
S/N: E2C1–Up
S/N: 4WD1–Up
S/N: 5JD1–Up
S/N: 8LD1–Up
S/N: E2E1–Up
S/N: 9TG1–Up
S/N: CPG1–Up
S/N: 7NJ1–Up
S/N: 4EK1–Up
Illustration 156 g01248557
S/N: CRN1–Up
1. Install the bracket, the nuts, and service meter (2) S/N: E6N1–Up
in panel (3).
S/N: CSP1–Up
2. Install sensor (6) until the sensor touches the tooth
of the flywheel ring gear. Turn the sensor in the S/N: E6R1–Up
counterclockwise direction for 1/2 turn. Tighten S/N: CPS1–Up
locknut (5) to a torque of 45 ± 7 N·m (33 ± 5 lb ft).
The clearance of the sensor and the flywheel ring S/N: E6W1–Up
gear should be 0.69 ± 0.14 mm S/N: E6Y1–Up
(0.027 ± 0.006 inch).
S/N: CSZ1–Up
3. Install connector (4) and install the clip. S/N: E6Z1–Up
4. Close the cover and tighten screws (1). S/N: ZAZ1–Up
SENR6419 43
Disassembly and Assembly Section

Removal Procedure 3. Turn ON the gas supply.

NOTICE i01192937
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened Gas Pressure Regulator -
component life. Remove
SMCS Code: 1270-011

S/N: TJ61–Up
S/N: WC61–Up
S/N: E8A1–Up
S/N: CRC1–Up
S/N: E2C1–Up
S/N: E2E1–Up
S/N: 2TJ1–Up
S/N: CRN1–Up
S/N: CSP1–Up
Illustration 157 g01248600
S/N: E6R1–Up
1. Turn OFF the gas supply. S/N: CPS1–Up
2. Disconnect the harness assembly from solenoid S/N: E6W1–Up
(2).
Removal Procedure
3. Remove solenoid (2) from gas pressure regulator
(1). NOTICE
Keep all parts clean from contaminants.
Installation Procedure
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.

Illustration 159 g00638261

1. Disconnect the gas line from fuel inlet (3).

Illustration 158 g01248600 Note: The plate on the fuel inlet is for shipping
purposes only. A gas line will be connected to the gas
1. Install solenoid (2) on gas pressure regulator (1). regulator.

2. Connect the harness assembly to solenoid (2). 2. Disconnect line (2) and line (5) from gas pressure
regulator (5).
44 SENR6419
Disassembly and Assembly Section

S/N: 6JW1–Up
3. Remove the nuts and bolts (1) from gas pressure
S/N: 8PW1–Up
regulator (5).
S/N: 9AW1–Up
4. Remove gas pressure regulator (4) from the
engine. S/N: E6W1–Up
S/N: CPY1–Up
i02558851
S/N: E6Y1–Up
Gas Pressure Regulator - S/N: CSZ1–Up
Remove S/N: E6Z1–Up
(High Pressure) S/N: ZAZ1–Up
SMCS Code: 1270-011
Removal Procedure
S/N: E621–Up
Start By:
S/N: TJ21–Up
a. Remove the gas pressure regulator solenoid. Refer
S/N: WC21–Up to Disassembly and Assembly, “Gas Pressure
Regulator Solenoid - Remove and Install”.
S/N: WC31–Up
S/N: TJ41–Up NOTICE
Keep all parts clean from contaminants.
S/N: TJ61–Up
Contaminants may cause rapid wear and shortened
S/N: WC61–Up component life.
S/N: TJ71–Up
S/N: WC71–Up
S/N: WC81–Up
S/N: E8A1–Up
S/N: ZBA1–Up
S/N: CRC1–Up
S/N: E2C1–Up
S/N: E8C1–Up
S/N: 4WD1–Up
S/N: 5JD1–Up
S/N: 8LD1–Up Illustration 160 g01280862

S/N: E2E1–Up 1. Remove clamps (2) from the joint.

S/N: 9TG1–Up
2. Disconnect tube assembly (1) from the fitting on
S/N: CPG1–Up gas pressure regulator (4).
S/N: 7NJ1–Up 3. Remove bolts (3) and gas pressure regulator (4).
S/N: CPJ1–Up
i01130388
S/N: 4EK1–Up
S/N: CRN1–Up Gas Pressure Regulator -
S/N: E6N1–Up Remove
S/N: CSP1–Up (Low Pressure)
S/N: E6R1–Up
S/N: CPS1–Up
SENR6419 45
Disassembly and Assembly Section

SMCS Code: 1270-011

Removal Procedure
Start By:
a. Remove the gas pressure regulator solenoid.

1. Turn off the gas supply.

Illustration 162 g00597827

Typical example

1. Remove the bolts and fitting (1).

Illustration 161 g00600648

Typical example

2. Disconnect gas supply line (3).

3. Remove two bolts (4) from the gas line that runs to
the engine.

4. Remove two bolts (1) from the mounting bracket

and remove gas pressure regulator (2).
Illustration 163 g00597828
i02496907
Typical example
Gas Pressure Regulator - 2. Remove O-ring seal (2) and orifice (3).
Disassemble
SMCS Code: 1270-015

Disassembly Procedure
Start By:
a. Remove the gas pressure regulator. Refer to
Disassembly and Assembly, “Gas Pressure
Regulator - Remove”.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Illustration 164 g00597832
Typical example

3. Remove the bolts that hold the gas pressure

regulator together.
46 SENR6419
Disassembly and Assembly Section

4. Remove cover assembly (4), seat (5), spring (6), 7. Remove cap (16) and the gasket from cover
seat (7), and diaphragm (8) from housing (9). assembly (4).

Illustration 165 g00597833 Illustration 168 g00597840

Typical example Typical example

5. Remove the screws, the pin, lever (10), stem 8. Remove screw (17).
assembly (11), and holder (12).
i02496945

Gas Pressure Regulator -

Assemble
SMCS Code: 1270-016

Assembly Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Illustration 166 g00597835

Typical example

6. Remove bolt (13), heads (14), the head gasket and

the pusher post from diaphragm (15).

Illustration 169 g00597840

Typical example

1. Install screw (17).

Illustration 167 g00597839

Typical example
SENR6419 47
Disassembly and Assembly Section

Illustration 170 g00597839

Typical example Illustration 173 g00597832
Typical example
2. Install the gasket and cap (16) in cover assembly
(4). 5. Install diaphragm (8), seat (7), spring (6), seat (5),
and cover assembly (4) in housing (9).

6. Install the bolts that hold the gas pressure regulator

together.

Illustration 171 g00597835

Typical example

3. Install the pusher post, the head gasket, heads

(14), and bolt (13) in diaphragm (15). Illustration 174 g00597828
Typical example

7. Install orifice (3) and O-ring seal (2).

Illustration 172 g00597833

Typical example

4. Install holder (12), stem assembly (11), lever (10), Illustration 175 g00597827

the pin, and the screws. Typical example

48 SENR6419
Disassembly and Assembly Section

8. Install fitting (1) and the bolts. SMCS Code: 1270-012

End By:
Installation Procedure
a. Install the gas pressure regulator. Refer to
Disassembly and Assembly, “Gas Pressure NOTICE
Regulator - Install”. Keep all parts clean from contaminants.

i01130393
Contaminants may cause rapid wear and shortened
component life.
Gas Pressure Regulator -
Install
(Low Pressure)
SMCS Code: 1270-012

Installation Procedure

Illustration 177 g01280862

1. Install gas pressure regulator (4) and bolts (3).

2. Connect tube assembly (1) to the fitting on gas

pressure regulator (4).

3. Install clamps (2) on the joint.

Illustration 176 g00600648
Typical example End By:
a. Install the gas pressure regulator solenoid. Refer to
1. Install gas pressure regulator (2) with two bolts (1) Disassembly and Assembly, “Gas Pressure
on the mounting bracket. Regulator Solenoid - Remove and Install”.
2. Install two bolts (4) that hold the gas line to gas
i01104449
pressure regulator (2).

3. Connect gas supply line (1). Fuel Control Actuator -

4. Turn on the gas supply.
Remove and Install
SMCS Code: 1909-010
End By:
a. Install the gas pressure regulator solenoid. S/N: TJ61–Up
S/N: WC61–Up
i02558880
S/N: TJ71–Up
Gas Pressure Regulator - S/N: WC71–Up
Install S/N: E8A1–Up
(High Pressure) S/N: CRC1–Up
S/N: E2C1–Up
S/N: E8C1–Up
S/N: E2E1–Up
S/N: 2TJ1–Up
SENR6419 49
Disassembly and Assembly Section

S/N: CPJ1–Up
S/N: CRN1–Up
S/N: CSP1–Up
S/N: E6R1–Up
S/N: CPS1–Up
S/N: E6W1–Up
S/N: CPY1–Up

Removal Procedure
NOTICE
Keep all parts clean from contaminants. Illustration 179 g00581761

Contaminants may cause rapid wear and shortened

component life. 5. Remove four bolts (6) that hold engine throttle
control (5) to the adapter.

6. Loosen setscrew (7) that holds the shaft of engine

throttle control (5) to the fuel control actuator.

7. Remove engine throttle control (5).

Illustration 178 g00581770

1. Remove four bolts (1) and the nuts that connect

elbow (2) of the engine throttle control to the
aftercooler.
Illustration 180 g00581764
2. Remove four bolts (4) and the nuts that hold elbow
(2) to the engine throttle control. 8. Remove four bolts (9) that hold fuel control actuator
(8) on the mounting plate.
3. Remove elbow (2).
Installation Procedure
4. Disconnect the wiring harness from plug (3).
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
50 SENR6419
Disassembly and Assembly Section

Illustration 181 g00581764 Illustration 183 g00581770

1. Position fuel control actuator (8) on the mounting 5. Connect the wiring harness to plug (3).
plate and install four bolts (9) with the nuts.
6. Install four bolts (4) and the nuts that hold elbow (2)
to the engine throttle control.

7. Install four bolts (1) and the nuts that connect

elbow (2) of the engine throttle control to the
aftercooler.

i01130211

Fuel Control Actuator -

Remove and Install
SMCS Code: 1909-010

S/N: E621–Up
Illustration 182 g00581761 S/N: TJ21–Up
S/N: WC21–Up
2. Position engine throttle control (5) on the adapter.
Ensure that the shaft of engine throttle control (5) S/N: WC31–Up
is installed in the coupling.
S/N: TJ41–Up
3. Tighten setscrew (7) in order to hold the shaft of S/N: TJ61–Up
engine throttle control (5) to fuel control actuator
(8). S/N: WC61–Up
S/N: TJ71–Up
4. Install four bolts (6) that hold engine throttle control
(5) to the adapter. S/N: WC71–Up
S/N: WC81–Up
S/N: E8A1–Up
S/N: ZBA1–Up
S/N: CRC1–Up
S/N: E2C1–Up
S/N: E8C1–Up
S/N: 4WD1–Up
S/N: 5JD1–Up
S/N: 8LD1–Up
SENR6419 51
Disassembly and Assembly Section

S/N: E2E1–Up
S/N: 9TG1–Up
S/N: CPG1–Up
S/N: 7NJ1–Up
S/N: CPJ1–Up
S/N: 4EK1–Up
S/N: CRN1–Up
S/N: E6N1–Up
S/N: CSP1–Up
S/N: E6R1–Up Illustration 185 g00597502
S/N: CPS1–Up Typical example
S/N: 6JW1–Up 1. Position fuel control actuator (5) on the engine and
S/N: 8PW1–Up install four nuts (2).
S/N: 9AW1–Up 2. Install linkage (3) on fuel control actuator (5) and
S/N: E6W1–Up install nut (4).

S/N: CPY1–Up 3. Connect wiring harness (1) to fuel control actuator

(5).
S/N: E6Y1–Up
S/N: CSZ1–Up
S/N: E6Z1–Up
S/N: ZAZ1–Up

Removal Procedure

Illustration 184 g00597502

Typical example

1. Disconnect wiring harness (1) from fuel control

actuator (5).

2. Remove nut (4) and remove linkage (3).

3. Remove four nuts (2). Remove fuel control actuator

(5) from the engine.

Installation Procedure
52 SENR6419
Disassembly and Assembly Section

Illustration 186 g00597521

Typical example

4. Open the fuel control actuator completely. Adjust S/N: CSP1–Up

the linkage to an angle of 26 ± 2 degrees. Ensure
S/N: E6R1–Up
that there is an equal amount of slack on each end
of the linkage. S/N: CPS1–Up
S/N: E6W1–Up
i01130314
S/N: CPY1–Up
Fuel Control Valve - Remove
Removal Procedure
and Install
SMCS Code: 1909-010 NOTICE
Keep all parts clean from contaminants.
S/N: TJ61–Up
Contaminants may cause rapid wear and shortened
S/N: WC61–Up component life.
S/N: TJ71–Up
1. Turn off the gas supply.
S/N: WC71–Up
S/N: E8A1–Up
S/N: CRC1–Up
S/N: E2C1–Up
S/N: E8C1–Up
S/N: E2E1–Up
S/N: 2TJ1–Up
S/N: CPJ1–Up
S/N: CRN1–Up
SENR6419 53
Disassembly and Assembly Section

4. Connect tube (7) and install clip (5).

5. Install tube (2).

6. Turn on the gas supply.

i01130746

Fuel Control Valve - Remove

and Install
SMCS Code: 1909-010

S/N: E621–Up
Illustration 187 g00597612
S/N: TJ21–Up
2. Disconnect tube (2). S/N: WC21–Up
3. Remove clip (5) and disconnect tube (7). S/N: WC31–Up
4. Remove bolts (1), the nuts, and the spacers. S/N: TJ41–Up

5. Remove gas regulator (6) and the gasket. S/N: TJ61–Up

S/N: WC61–Up
Note: The plate that is on the end of the gas regulator
is for shipping purposes. The customer will remove S/N: WC81–Up
the plate.
S/N: E8A1–Up
6. Remove fuel line (3) and fuel control valve (4). S/N: ZBA1–Up
Installation Procedure S/N: CRC1–Up

NOTICE S/N: E2C1–Up

Keep all parts clean from contaminants. S/N: 4WD1–Up
Contaminants may cause rapid wear and shortened S/N: 5JD1–Up
component life.
S/N: 8LD1–Up
1. Apply 5P-3413 Pipe Sealant to all pipe threads S/N: E2E1–Up
prior to assembly. S/N: 9TG1–Up
S/N: CPG1–Up
S/N: 7NJ1–Up
S/N: 4EK1–Up
S/N: CRN1–Up
S/N: E6N1–Up
S/N: CSP1–Up
S/N: E6R1–Up
S/N: CPS1–Up
S/N: 6JW1–Up

Illustration 188 g00597612

S/N: 8PW1–Up
S/N: 9AW1–Up
2. Install fuel control valve (4) and fuel line (3).
S/N: E6W1–Up
3. Install the gasket and gas regulator (6). Install bolts
S/N: E6Y1–Up
(1), the spacers, and the nuts.
54 SENR6419
Disassembly and Assembly Section

S/N: CSZ1–Up 1. Inspect the condition of the O-ring seal on the

bottom of the fuel control valve. Replace the O-ring
S/N: E6Z1–Up
seal, if necessary.
S/N: ZAZ1–Up

Removal Procedure
1. Turn off the gas supply.

Illustration 191 g00598035

2. Install the fuel control valve with two flanges (6)

and four bolts (5).

Illustration 189 g00598031

2. Remove two clamps (1) from the fuel supply line.

3. Remove bolt (4) and disconnect linkage (3) from

fuel control valve (2).

Illustration 192 g00598031

3. Connect linkage (3) to fuel control valve (2) and

install bolt (4).

4. Install two clamps (1) on the fuel supply line.

Illustration 190 g00598035 5. Turn on the gas supply.

4. Remove four bolts (5) and two flanges (6).

5. Remove fuel control valve (2).

Installation Procedure
SENR6419 55
Disassembly and Assembly Section

i01130144

Electronic Sensor - Remove

and Install
SMCS Code: 1904-010

Removal Procedure

Illustration 195 g00597464

3. Disconnect wire assembly (4).

4. Remove two bolts and washers (5).

5. Remove control group (6).

Installation Procedure
Illustration 193 g00597454

1. Disconnect wire assembly (2). Remove transducer

module (1).

Illustration 196 g00597464

1. Install control group (6).

2. Install two washers and bolts (5).

Illustration 194 g00597462
3. Connect wire assembly (4).
2. Cut tie straps (3).
56 SENR6419
Disassembly and Assembly Section

S/N: CPJ1–Up
S/N: CRN1–Up
S/N: CSP1–Up
S/N: E6R1–Up
S/N: CPS1–Up
S/N: E6W1–Up
S/N: CPY1–Up

Removal Procedure
Start By:
Illustration 197 g00597462 a. Remove the air cleaner.

4. Install new tie straps (3). NOTICE

Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

1. Turn off the gas supply.

Illustration 198 g00597454

5. Install transducer module (1) and connect wire

assembly (2).

i01129770
Illustration 199 g00597142

Carburetor - Remove
2. Loosen clamp (1).
(Low Pressure)
SMCS Code: 1266-011 3. Disconnect tube (2).

S/N: TJ61–Up 4. Remove nuts (4) and the bolts from carburetor (3).

S/N: WC61–Up 5. Remove four nuts (5) from the gas line. Remove
carburetor (3).
S/N: TJ71–Up
S/N: WC71–Up i02499592

S/N: E8A1–Up
Carburetor - Remove
S/N: CRC1–Up
(High Pressure)
S/N: E2C1–Up SMCS Code: 1266-011
S/N: E8C1–Up
S/N: E621–Up
S/N: E2E1–Up
S/N: TJ21–Up
S/N: 2TJ1–Up
S/N: WC21–Up
SENR6419 57
Disassembly and Assembly Section

S/N: WC31–Up Removal Procedure

S/N: TJ41–Up
NOTICE
S/N: TJ61–Up Keep all parts clean from contaminants.
S/N: WC61–Up Contaminants may cause rapid wear and shortened
component life.
S/N: TJ71–Up
S/N: WC71–Up
S/N: WC81–Up
S/N: E8A1–Up
S/N: ZBA1–Up
S/N: CRC1–Up
S/N: E2C1–Up
S/N: E8C1–Up
S/N: 4WD1–Up
S/N: 5JD1–Up
S/N: 8LD1–Up
Illustration 200 g00597082
S/N: E2E1–Up Typical example
S/N: 9TG1–Up
1. Turn OFF the gas supply.
S/N: CPG1–Up
2. Disconnect tube (2) and control rod (4) from
S/N: 7NJ1–Up carburetor (3).
S/N: CPJ1–Up
3. Remove clamp (5).
S/N: 4EK1–Up
4. Remove bolts (1) and the gasket.
S/N: CRN1–Up
S/N: E6N1–Up 5. Remove carburetor (3) and the gasket.

S/N: CSP1–Up i01129219

S/N: E6R1–Up
Carburetor - Remove
S/N: CPS1–Up
(Low Pressure)
S/N: 6JW1–Up
SMCS Code: 1266-011
S/N: 8PW1–Up
S/N: E621–Up
S/N: 9AW1–Up
S/N: TJ21–Up
S/N: E6W1–Up
S/N: WC21–Up
S/N: CPY1–Up
S/N: WC31–Up
S/N: E6Y1–Up
S/N: TJ41–Up
S/N: CSZ1–Up
S/N: TJ61–Up
S/N: E6Z1–Up
S/N: WC61–Up
S/N: ZAZ1–Up
S/N: TJ71–Up
S/N: WC71–Up
S/N: WC81–Up
S/N: E8A1–Up
58 SENR6419
Disassembly and Assembly Section

S/N: ZBA1–Up
S/N: CRC1–Up
S/N: E2C1–Up
S/N: E8C1–Up
S/N: 4WD1–Up
S/N: 5JD1–Up
S/N: 8LD1–Up
S/N: E2E1–Up
S/N: 9TG1–Up
S/N: CPG1–Up Illustration 201 g00597138
S/N: 7NJ1–Up Typical example
S/N: CPJ1–Up 1. Turn off the gas supply.
S/N: 4EK1–Up
2. Loosen clamp (7). Remove the bolts and air
S/N: CRN1–Up cleaner (8).
S/N: E6N1–Up 3. Disconnect tube (5).
S/N: CSP1–Up
4. Disconnect tube (6).
S/N: E6R1–Up
5. Loosen clamp (2) and remove boot (3).
S/N: CPS1–Up
S/N: 6JW1–Up 6. Remove the washers and the nuts that hold
carburetor (1) to the support bracket.
S/N: 8PW1–Up
7. Loosen clamp (4).
S/N: 9AW1–Up
S/N: E6W1–Up 8. Remove carburetor (1).

S/N: CPY1–Up i02499629

S/N: E6Y1–Up
Carburetor - Disassemble
S/N: CSZ1–Up
(High Pressure)
S/N: E6Z1–Up
SMCS Code: 1266-015
S/N: ZAZ1–Up
S/N: TJ61–Up
Removal Procedure S/N: WC61–Up
NOTICE S/N: TJ71–Up
Keep all parts clean from contaminants.
S/N: WC71–Up
Contaminants may cause rapid wear and shortened
component life. S/N: E8A1–Up
S/N: CRC1–Up
S/N: E2C1–Up
S/N: E8C1–Up
S/N: 4WD1–Up
S/N: 5JD1–Up
S/N: E2E1–Up
S/N: 9TG1–Up
SENR6419 59
Disassembly and Assembly Section

S/N: 7NJ1–Up
S/N: CPJ1–Up
S/N: CRN1–Up
S/N: CSP1–Up
S/N: E6R1–Up
S/N: CPS1–Up
S/N: 6JW1–Up
S/N: 9AW1–Up
S/N: E6W1–Up
S/N: CPY1–Up Illustration 203 g00597238
Typical example
Disassembly Procedure
Start By:
a. Remove the carburetor. Refer to Disassembly and
Assembly, “Carburetor - Remove”. Personal injury can result from parts and/or cov-
ers under spring pressure.
NOTICE
Keep all parts clean from contaminants. Spring force will be released when covers are
removed.
Contaminants may cause rapid wear and shortened Be prepared to hold spring loaded covers as the
component life. bolts are loosened.

2. Remove the screws, cover (5), spring (4), and air

valve assembly (3).

Illustration 202 g00597237

Typical example
Illustration 204 g00597239
1. Remove adapter (1) and the gasket from base (2).
Typical example

3. Remove screws (6) and diaphragm (7).

60 SENR6419
Disassembly and Assembly Section

S/N: TJ41–Up
S/N: TJ61–Up
S/N: WC61–Up
S/N: TJ71–Up
S/N: WC71–Up
S/N: WC81–Up
S/N: E8A1–Up
S/N: ZBA1–Up
S/N: CRC1–Up

Illustration 205 g00597284

S/N: E2C1–Up
Typical example S/N: E8C1–Up

4. Remove the setscrews and disc (10) from shaft S/N: 8LD1–Up
(11). S/N: E2E1–Up
5. Loosen the bolt and remove lever (8). S/N: CPG1–Up

6. Loosen the set screw and remove stop assembly S/N: CPJ1–Up
(9). Remove shaft (11). S/N: 4EK1–Up
S/N: CRN1–Up
S/N: E6N1–Up
S/N: CSP1–Up
S/N: E6R1–Up
S/N: CPS1–Up
S/N: 8PW1–Up
S/N: E6W1–Up
S/N: CPY1–Up
S/N: E6Y1–Up
S/N: CSZ1–Up
Illustration 206 g00597280
Typical example S/N: E6Z1–Up
S/N: ZAZ1–Up
7. Remove the screws and mixer housing (12).

8. Remove the bolts and base (13) from throttle Disassembly Procedure
assembly (14). Start By:
a. Remove the carburetor.
i01130088

NOTICE
Carburetor - Disassemble Keep all parts clean from contaminants.
(High Pressure) Contaminants may cause rapid wear and shortened
SMCS Code: 1266-015 component life.

S/N: E621–Up
S/N: TJ21–Up
S/N: WC21–Up
S/N: WC31–Up
SENR6419 61
Disassembly and Assembly Section

10. Remove O-ring seal (11) from air valve assembly

(12).

11. Remove the screws, plate (15), diaphragm (14),

and shaft (13) from air valve assembly (12).

12. Repeat Steps 1 through 11 for the second

carburetor.

i02499633

Carburetor - Assemble
(High Pressure)
SMCS Code: 1266-016
Illustration 207 g00597403
Typical example S/N: TJ61–Up

1. Remove adapter (1) and the gasket from throttle S/N: WC61–Up
assembly (2). S/N: TJ71–Up
S/N: WC71–Up
S/N: E8A1–Up
S/N: CRC1–Up
S/N: E2C1–Up
S/N: E8C1–Up
S/N: 4WD1–Up
S/N: 5JD1–Up
S/N: E2E1–Up
S/N: 9TG1–Up

Illustration 208 g00597405

S/N: 7NJ1–Up
Typical example S/N: CPJ1–Up
S/N: CRN1–Up
2. Remove screws (10) that hold mixer housing (3) to
throttle assembly (2). S/N: CSP1–Up

3. Separate mixer housing (3) and throttle assembly S/N: E6R1–Up

(2). S/N: CPS1–Up
4. Remove washer (6), jet (5), and O-ring seal (4) S/N: 6JW1–Up
from throttle assembly (2).
S/N: 9AW1–Up
5. Remove the screw and valve (7) from mixer S/N: E6W1–Up
housing (3).
S/N: CPY1–Up
6. Remove O-ring seal (8).
Assembly Procedure
7. Remove the two screws and piston (9) from mixer
housing (3). NOTICE
Keep all parts clean from contaminants.
8. Remove screws (18) and cover (17) from mixer
housing (3). Contaminants may cause rapid wear and shortened
component life.
9. Remove spring (16) and air valve assembly (12)
from mixer housing (3).
62 SENR6419
Disassembly and Assembly Section

Illustration 209 g00597280 Illustration 211 g00597239

Typical example Typical example

1. Place base (13) on throttle assembly (14) and 6. Install diaphragm (7) and screws (6).
install the bolts.
2. Install the screws and mixer housing (12) on base
(13).

Illustration 212 g00597238

Typical example

Illustration 210 g00597284

Typical example
Improper assembly of parts that are spring loaded
3. Install shaft (11). Install stop assembly (9) and can cause bodily injury.
tighten the set screw. To prevent possible injury, follow the established
assembly procedure and wear protective
4. Install lever (8) and tighten the bolt. equipment.
5. Install disc (10) and the setscrews on shaft (11). 7. Install air valve assembly (3), spring (4), cover (5),
and the screws.
SENR6419 63
Disassembly and Assembly Section

S/N: 4EK1–Up
S/N: CRN1–Up
S/N: E6N1–Up
S/N: CSP1–Up
S/N: E6R1–Up
S/N: CPS1–Up
S/N: 8PW1–Up
S/N: E6W1–Up
S/N: CPY1–Up

Illustration 213 g00597237

S/N: E6Y1–Up
Typical example S/N: CSZ1–Up

8. Install the gasket and adapter (1) on base (2). S/N: E6Z1–Up

End By: S/N: ZAZ1–Up

a. Install the carburetor. Refer to Disassembly and Assembly Procedure

Assembly, “Carburetor - Install”.
NOTICE
i01130107 Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
Carburetor - Assemble component life.
(High Pressure)
SMCS Code: 1266-016 1. Inspect the condition of the gaskets and the O-ring
seals. Replace the gaskets and the O-ring seals, if
S/N: E621–Up necessary.
S/N: TJ21–Up
S/N: WC21–Up
S/N: WC31–Up
S/N: TJ41–Up
S/N: TJ61–Up
S/N: WC61–Up
S/N: TJ71–Up
S/N: WC71–Up
S/N: WC81–Up
S/N: E8A1–Up
Illustration 214 g00597405
S/N: ZBA1–Up Typical example
S/N: CRC1–Up
2. Install shaft (13), diaphragm (14), plate (15), and
S/N: E2C1–Up the screws in air valve assembly (12).
S/N: E8C1–Up
3. Install O-ring seal (11) in air valve assembly (12).
S/N: 8LD1–Up
4. Install air valve assembly (12) and spring (16) in
S/N: E2E1–Up mixer housing (3).
S/N: CPG1–Up
5. Install cover (17) and screws (18) on mixer housing
S/N: CPJ1–Up (3).
64 SENR6419
Disassembly and Assembly Section

6. Install piston (9) and the screws in mixer housing S/N: CRN1–Up
(3).
S/N: CSP1–Up
7. Install O-ring seal (8). S/N: E6R1–Up
8. Install valve (7) and the screw in mixer housing (3). S/N: CPS1–Up

9. Install O-ring seal (4), jet (5), and washer (6) in S/N: E6W1–Up
throttle assembly (2). S/N: CPY1–Up
10. Assemble mixer housing (3) and throttle Installation Procedure
assembly (2).
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Illustration 215 g00597403

Typical example

11. Install the gasket and adapter (1) on throttle

assembly (2).
End By: Illustration 216 g00597142

a. Install the carburetor. 1. Position carburetor (3) on the gas line and install
four nuts (5).
i01129831
2. Install the bolts and nuts (4) that hold carburetor (3)
Carburetor - Install to the adapter.
(Low Pressure) 3. Tighten clamp (1).
SMCS Code: 1266-012
4. Connect tube (2).
S/N: TJ61–Up End By:
S/N: WC61–Up
a. Install the air cleaner.
S/N: TJ71–Up
i01129818
S/N: WC71–Up
S/N: E8A1–Up Carburetor - Install
S/N: CRC1–Up (Low Pressure)
S/N: E2C1–Up SMCS Code: 1266-012

S/N: E8C1–Up S/N: E621–Up

S/N: E2E1–Up S/N: TJ21–Up
S/N: 2TJ1–Up S/N: WC21–Up
S/N: CPJ1–Up S/N: WC31–Up
SENR6419 65
Disassembly and Assembly Section

S/N: TJ41–Up Installation Procedure

S/N: TJ61–Up
NOTICE
S/N: WC61–Up Keep all parts clean from contaminants.
S/N: TJ71–Up Contaminants may cause rapid wear and shortened
component life.
S/N: WC71–Up
S/N: WC81–Up
S/N: E8A1–Up
S/N: ZBA1–Up
S/N: CRC1–Up
S/N: E2C1–Up
S/N: E8C1–Up
S/N: 4WD1–Up
S/N: 5JD1–Up
S/N: 8LD1–Up
S/N: E2E1–Up
Illustration 217 g00597138
S/N: 9TG1–Up Typical example
S/N: CPG1–Up
1. Install carburetor (1).
S/N: 7NJ1–Up
2. Tighten clamp (4).
S/N: CPJ1–Up
S/N: 4EK1–Up 3. Install the washers and the nuts that hold
carburetor (1) on the support bracket.
S/N: CRN1–Up
4. Slide the boot on carburetor (1) and tighten clamp
S/N: E6N1–Up (2).
S/N: CSP1–Up
5. Connect tubes (5) and (6).
S/N: E6R1–Up
6. Install the air cleaner (8) with the bolts. Tighten
S/N: CPS1–Up clamp (7).
S/N: 6JW1–Up
7. Turn on the gas supply.
S/N: 8PW1–Up
S/N: 9AW1–Up i02499669

S/N: E6W1–Up Carburetor - Install

S/N: CPY1–Up (High Pressure)
S/N: E6Y1–Up SMCS Code: 1266-012
S/N: CSZ1–Up S/N: E621–Up
S/N: E6Z1–Up S/N: TJ21–Up
S/N: ZAZ1–Up S/N: WC21–Up
S/N: WC31–Up
S/N: TJ41–Up
S/N: TJ61–Up
S/N: WC61–Up
S/N: TJ71–Up
66 SENR6419
Disassembly and Assembly Section

S/N: WC71–Up
S/N: WC81–Up
S/N: E8A1–Up
S/N: ZBA1–Up
S/N: CRC1–Up
S/N: E2C1–Up
S/N: E8C1–Up
S/N: 4WD1–Up
S/N: 5JD1–Up
S/N: 8LD1–Up Illustration 218 g00597082
S/N: E2E1–Up Typical example
S/N: 9TG1–Up 1. Position the gasket and carburetor (3) on the
S/N: CPG1–Up engine.
S/N: 7NJ1–Up 2. Install the gasket and bolts (1).
S/N: CPJ1–Up 3. Install clamp (5).
S/N: 4EK1–Up
4. Connect tube (2) and control rod (4) to carburetor
S/N: CRN1–Up (3).
S/N: E6N1–Up 5. Adjust the linkage on control rod (4). Refer to
S/N: CSP1–Up Testing and Adjusting for the correct procedure.
S/N: E6R1–Up 6. Turn ON the gas supply.
S/N: CPS1–Up
i01134294
S/N: 6JW1–Up
S/N: 8PW1–Up Air Cleaner - Remove and
S/N: 9AW1–Up Install
S/N: E6W1–Up SMCS Code: 1051-010; 1051-010-HG; 1051-010-
FQ; 1054-010
S/N: CPY1–Up
S/N: TJ61–Up
S/N: E6Y1–Up
S/N: WC61–Up
S/N: CSZ1–Up
S/N: TJ71–Up
S/N: E6Z1–Up
S/N: WC71–Up
S/N: ZAZ1–Up
S/N: E8A1–Up
Installation Procedure S/N: CRC1–Up
NOTICE S/N: E2C1–Up
Keep all parts clean from contaminants.
S/N: E8C1–Up
Contaminants may cause rapid wear and shortened S/N: E2E1–Up
component life.
S/N: 2TJ1–Up
S/N: CPJ1–Up
S/N: CRN1–Up
S/N: CSP1–Up
SENR6419 67
Disassembly and Assembly Section

S/N: E6R1–Up
S/N: CPS1–Up
S/N: E6W1–Up
S/N: CPY1–Up

Removal Procedure
Table 5
Required Tools

Tool Part Number Part Description Qty

A 138-7573 Link Bracket 1

Illustration 220 g00597144

1. Install Tool (A) and use a suitable lifting device in

order to hold air cleaner (2) in position.

2. Install five bolts (3).

3. Tighten clamp (1) on the boot.

i01101124

Turbocharger - Remove
SMCS Code: 1052-011

Illustration 219 g00597144

S/N: TJ61–Up
S/N: WC61–Up
1. Install Tool (A) and attach a suitable lifting device to
air cleaner (2). S/N: TJ71–Up
S/N: WC71–Up
2. Loosen clamp (1) from the boot.
S/N: E8A1–Up
3. Remove five bolts (3) and remove air cleaner (2).
The air cleaner weighs approximately 32 kg (70 lb) S/N: CRC1–Up
. S/N: E2C1–Up
Installation Procedure S/N: E8C1–Up
Table 6 S/N: E2E1–Up
Required Tools
S/N: 2TJ1–Up
Tool Part Number Part Description Qty
S/N: CPJ1–Up
A 138-7573 Link Bracket 1
S/N: CRN1–Up
S/N: CSP1–Up
S/N: E6R1–Up
S/N: CPS1–Up
S/N: E6W1–Up
68 SENR6419
Disassembly and Assembly Section

S/N: CPY1–Up

Removal Procedure
Start By:
a. Remove the exhaust elbow.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

NOTICE
Care must be taken to ensure that fluids are con- Illustration 222 g00579887
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product. Be 4. Remove two bolts (6) from the oil drain tube on the
prepared to collect the fluid with suitable containers bottom of turbocharger (4). Remove the oil drain
before opening any compartment or disassembling tube and the gasket.
any component containing fluids.
5. Disconnect water line (5).
Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and sup-
plies suitable to collect and contain fluids on Caterpil-
lar products.
Dispose of all fluids according to local regulations and
mandates.

Illustration 223 g00579890

View below the turbocharger

6. Remove clip (7) and two bolts (8) from the oil drain
tube that is below turbocharger (4).

Illustration 221 g00579878

1. Remove two bolts (2) from the oil supply line on top
of turbocharger (4). Remove the oil line and the
gasket.

2. Disconnect water line (1).

3. Loosen two hose clamps (3).

Illustration 224 g00601109

7. Attach a suitable lifting device to turbocharger (4).

SENR6419 69
Disassembly and Assembly Section

8. Remove four mounting bolts (9) from turbocharger S/N: 9AW1–Up

(4).
S/N: E6W1–Up
9. Remove turbocharger (4) and the gasket. Use a S/N: CPY1–Up
pry bar on outlet (10) from turbocharger (4) to the
aftercooler, if necessary. S/N: E6Y1–Up
S/N: CSZ1–Up
i02500310
S/N: E6Z1–Up
Turbocharger - Remove S/N: ZAZ1–Up
SMCS Code: 1052-011
Removal Procedure
S/N: E621–Up
NOTICE
S/N: TJ21–Up Keep all parts clean from contaminants.
S/N: WC21–Up Contaminants may cause rapid wear and shortened
S/N: WC31–Up component life.

S/N: TJ41–Up
NOTICE
S/N: TJ61–Up
Care must be taken to ensure that fluids are con-
S/N: WC61–Up tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product. Be
S/N: TJ71–Up prepared to collect the fluid with suitable containers
S/N: WC71–Up before opening any compartment or disassembling
any component containing fluids.
S/N: WC81–Up
Refer to Special Publication, NENG2500, “Caterpillar
S/N: E8A1–Up Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
S/N: ZBA1–Up products.
S/N: CRC1–Up Dispose of all fluids according to local regulations and
S/N: E2C1–Up mandates.

S/N: E8C1–Up
1. Drain the coolant from the cooling system to a level
S/N: 4WD1–Up below the turbochargers into a suitable container
for storage or disposal. Refer to Operation and
S/N: 5JD1–Up
Maintenance Manual, “Cooling System Coolant -
S/N: 8LD1–Up Change”.
S/N: E2E1–Up
S/N: 9TG1–Up
S/N: CPG1–Up
S/N: 7NJ1–Up
S/N: CPJ1–Up
S/N: 4EK1–Up
S/N: CRN1–Up
S/N: E6N1–Up
S/N: CSP1–Up
S/N: E6R1–Up
Illustration 225 g01250347
S/N: CPS1–Up
2. Remove bolts (2) from each end of oil drain tube
S/N: 6JW1–Up
(4). Remove oil drain tube (4).
S/N: 8PW1–Up
70 SENR6419
Disassembly and Assembly Section

3. Remove tube assembly (3). S/N: WC31–Up

4. Remove bolts (1). S/N: TJ41–Up

S/N: TJ61–Up
S/N: WC61–Up
S/N: TJ71–Up
S/N: WC71–Up
S/N: WC81–Up
S/N: E8A1–Up
S/N: ZBA1–Up
S/N: CRC1–Up
S/N: E2C1–Up
S/N: E8C1–Up
Illustration 226 g01250350
S/N: 4WD1–Up
5. Remove bolts (7) from the oil supply line. Remove S/N: 5JD1–Up
the oil supply line and the gasket from the
turbocharger. S/N: 8LD1–Up
S/N: E2E1–Up
6. Remove air inlet tube (5) and tube assembly (6).
S/N: 9TG1–Up
S/N: CPG1–Up
S/N: 7NJ1–Up
S/N: CPJ1–Up
S/N: 4EK1–Up
S/N: CRN1–Up
S/N: E6N1–Up
S/N: CSP1–Up
S/N: E6R1–Up
S/N: CPS1–Up
Illustration 227 g01250354 S/N: 6JW1–Up
7. Attach a suitable lifting device to turbocharger (9). S/N: 8PW1–Up
The weight of turbocharger (9) is approximately S/N: 9AW1–Up
38 kg (84 lb).
S/N: E6W1–Up
8. Remove nuts (8) that attach turbocharger (9) to the
exhaust manifold. Remove turbocharger (9) from S/N: CPY1–Up
the engine. S/N: E6Y1–Up
S/N: CSZ1–Up
i02500385
S/N: E6Z1–Up
Turbocharger - Disassemble S/N: ZAZ1–Up
SMCS Code: 1052-015

S/N: E621–Up
S/N: TJ21–Up
S/N: WC21–Up
SENR6419 71
Disassembly and Assembly Section

Disassembly Procedure
Table 7
Required Tools

Tool Part Number Part Description Qty

A 9S-6363 Holding Fixture 1

B 9S-6343 Fixture Assembly 1

C 1P-1853 Retaining Ring Pliers 1

Start By:
a. Remove the turbocharger. Refer to Disassembly
and Assembly, “Turbocharger - Remove”.
Illustration 229 g00593902

NOTICE Typical example

Keep all parts clean from contaminants.
1. Place the turbocharger on Tooling (A). Mark the
Contaminants may cause rapid wear and shortened turbocharger housings for the proper alignment
component life. during assembly.

2. Loosen clamp (2). Remove compressor housing

(1) and clamp (2).

Illustration 230 g00593906

Typical example

3. Loosen clamp (5) and remove cartridge assembly

Illustration 228 g01250400
(3) from turbine housing (4).
Note: This procedure is a typical disassembly
procedure for a turbocharger. Cartridge assembly (3)
is secured to compressor housing (1) and turbine
housing (4) with clamp (2) and clamp (5). All
turbochargers will have the same basic components.
72 SENR6419
Disassembly and Assembly Section

Illustration 231 g00593907 Illustration 233 g00593915

Typical example Typical example

6. Remove seal ring (8) and shroud (9) from turbine

NOTICE
Do Not place a side force on the shaft when the nut is shaft (7).
removed or tightened. The shaft will bend and cause
damage to the turbocharger.

4. Place the end of the turbine shaft in Tooling (B).

Use a socket with a universal joint to remove the
nut that holds compressor wheel (6).

Illustration 234 g00593920

Typical example

Illustration 232 g00593908

Typical example

5. Use a suitable press to push the turbine shaft out

of compressor wheel (6) and the cartridge housing.
Remove compressor wheel (6).

Illustration 235 g00593918

Typical example

7. Bend the tabs of the locks away from bolts (10) and
remove bolts (10).
SENR6419 73
Disassembly and Assembly Section

Note: Examine the position of the oil holes in the

back plate assembly and the cartridge housing for the
assembly procedure.

8. Remove back plate assembly (11).

9. Remove spacer (12) from back plate assembly

(11).

Illustration 238 g00593925

Typical example

12. Remove thrust bearing (16).

Illustration 236 g00593922

Typical example

10. Remove seal rings (13) from spacer (12).

Illustration 239 g00593962

Typical example

Note: Place an identification mark on the bearings if

the bearings are reusable.
13. Remove bearing (17) and the washer from the
cartridge housing.

Illustration 237 g00593923

Typical example

11. Remove thrust collar (14) and seal ring (15).

Illustration 240 g00593963

Typical example
74 SENR6419
Disassembly and Assembly Section

14. Use Tooling (C) to remove retaining rings (18) and S/N: WC71–Up
(19).
S/N: WC81–Up
S/N: E8A1–Up
S/N: ZBA1–Up
S/N: CRC1–Up
S/N: E2C1–Up
S/N: E8C1–Up
S/N: 4WD1–Up
S/N: 5JD1–Up
S/N: 8LD1–Up
S/N: E2E1–Up
Illustration 241 g00593965 S/N: 9TG1–Up
Typical example S/N: CPG1–Up
15. Remove bearing (20) and washer (21). S/N: 7NJ1–Up
S/N: CPJ1–Up
S/N: 4EK1–Up
S/N: CRN1–Up
S/N: E6N1–Up
S/N: CSP1–Up
S/N: E6R1–Up
S/N: CPS1–Up
S/N: 6JW1–Up
S/N: 8PW1–Up
S/N: 9AW1–Up
Illustration 242 g01257541
Typical example S/N: E6W1–Up
S/N: CPY1–Up
16. Use Tooling (C) to remove the lower retaining ring
(22) from the cartridge housing. S/N: E6Y1–Up
S/N: CSZ1–Up
i04958569
S/N: E6Z1–Up
Turbocharger - Assemble S/N: ZAZ1–Up
SMCS Code: 1052-016
Assembly Procedure
S/N: E621–Up Table 8
S/N: TJ21–Up Required Tools

S/N: WC21–Up Tool Part Number Part Description Qty

S/N: WC31–Up A 9S-6363 Holding Fixture 1

S/N: TJ41–Up B 9S-6343 Fixture Assembly 1

S/N: TJ61–Up C 1P-1853 Retaining Ring Pliers 1

S/N: WC61–Up
(continued)
S/N: TJ71–Up
SENR6419 75
Disassembly and Assembly Section

(Table 8, contd)
D 8T-5096 Dial Indicator 1
E 6V-2055 Grease -

F 4C-9500 Quick Cure Primer -

G 4C-9507 Retaining Compound -

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

1. Ensure that all of the oil passages in the cartridge Illustration 244 g00594131
housing, the back plate assembly, and the bearing Typical example
are clean.
2. Place clean engine oil on all of the parts for the
cartridge assembly during the assembly
procedure.
Note: Ensure that the round edge of the outside
diameter of the snap rings is toward the bearing
during installation.

Illustration 245 g00594133

Typical example

5. Use Tooling (C) to install retaining ring (18).

6. Install washer (23) and bearing (17) in the cartridge

housing until washer (23) makes contact with
retaining ring (18).
Illustration 243 g00594129
Typical example

3. Use Tooling (C) to install lower retaining ring (22) in

the turbine end of the cartridge housing.

4. Install washer (21) and bearing (20). Use Tooling

(C) to install retaining ring (19).

Illustration 246 g00594134

Typical example
76 SENR6419
Disassembly and Assembly Section

7. Install thrust bearing (16) on the dowels in the

cartridge housing. Ensure that the grooves in
thrust bearing (16) are toward the outside.

Illustration 249 g00594622

Typical example

10. Install seal rings (13) on spacer (12). The gaps in

Illustration 247 g00594620 the rings should be 180 degrees away from each
Typical example other.

8. Install seal ring (15) in the groove of the cartridge

housing.

Illustration 250 g00594623

Typical example

Illustration 248 g00594621 11. Install spacer (12) in back plate assembly (11).
Typical example

9. Install thrust collar (14) on the thrust bearing with

the counterbore upward.

Illustration 251 g00594642

Typical example
SENR6419 77
Disassembly and Assembly Section

17. Install the cartridge housing on the turbine shaft.

Hold the spacer in position. Ensure that the seal
ring on the turbine is correctly placed in the
cartridge housing.

Illustration 252 g00594647

Typical example

12. Align oil passage (24) in the cartridge housing

with oil passage (25) in back plate assembly (11).

13. Install back plate assembly (11) on the cartridge Illustration 254 g00594652
housing. Ensure that the spacer fits correctly in the Typical example
counterbore of the thrust collar.
18. Install compressor wheel (6).
14. Install the locks and the bolts on back plate
assembly (11). Tighten the bolts per the torques in
Table 9 .
Table 9
Torque Specs

Bolt Size Torque

1/4-20 10 ± 1 N·m (89 ± 9 lb in)

3/8-16 39 ± 2 N·m (29 ± 1 lb ft)

6mm x 22 11 ± 1 N·m (97 ± 9 lb in)

Illustration 255 g00594673

Typical example

NOTICE
Do Not place a side force on the shaft when the nut is
removed or tightened. The shaft will bend and cause
damage to the turbocharger.

19. Place clean engine oil on the threads of the

turbine shaft and on the face of compressor wheel
(6) that is under the nut. Tighten the nut to a torque
Illustration 253 g00594650
of 16 ± 2 N·m (12 ± 1 lb ft).
Typical example
20. Remove the nut. Apply Tooling (F) to the threads
15. Install turbine shaft (7) in Tooling (B). Apply of the turbine shaft.
Tooling (E) in the groove for seal ring (8). Ensure
that Tooling (E) fills half of the groove. This creates 21. Apply Tooling (G) on the threads of the turbine
a carbon dam under the seal ring. shaft. Install the nut and tighten the nut to a torque
of 4 N·m (35 lb in). Turn the nut for an additional
16. Install seal ring (8) and shroud (9). 120 degrees (1/3 turn).
78 SENR6419
Disassembly and Assembly Section

Illustration 258 g00594683

Illustration 256 g00594677 Typical example
Typical example
25. Install clamp (2) and compressor housing (1) on
22. Place the cartridge assembly in a vise. Install the cartridge assembly. Install clamp (2). Tighten
Tooling (D) and check the end play of the shaft. the clamp to a torque of 14 ± 1 N·m (10 ± 1 lb ft).
The end play must not be more than Lightly tap the clamp with a soft hammer. Tighten
0.165 ± 0.085 mm (0.0065 ± 0.0033 inch). the clamp to the same torque again.
End By:
a. Install the turbocharger. Refer to Disassembly and
Assembly, “Turbocharger - Install”.

i01103839

Turbocharger - Install
SMCS Code: 1052-012

S/N: TJ61–Up
S/N: WC61–Up
S/N: TJ71–Up
Illustration 257 g00594680 S/N: WC71–Up
Typical example
S/N: E8A1–Up
23. Install turbine housing (4) on Tooling (A). Install S/N: CRC1–Up
the cartridge assembly and clamp (5) in turbine
S/N: E2C1–Up
housing (4). Ensure that the marks on the housing
and the cartridge are aligned. S/N: E8C1–Up

24. Install clamp (5). Tighten the clamp to a torque of S/N: E2E1–Up
14 ± 1 N·m (10 ± 1 lb ft). Lightly tap the clamp with S/N: 2TJ1–Up
a soft hammer. Tighten the clamp to the same
torque again. S/N: CPJ1–Up
S/N: CRN1–Up
S/N: CSP1–Up
S/N: E6R1–Up
S/N: CPS1–Up
S/N: E6W1–Up
S/N: CPY1–Up
SENR6419 79
Disassembly and Assembly Section

Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

1. Inspect the condition of the gaskets and the O-ring

seals. Replace the seals and the gaskets, if
necessary.

Illustration 261 g00579887

6. Connect water line (5).

7. Install the gasket and two bolts (6) that connect the
oil drain tube to turbocharger (4).

Illustration 259 g00601109

2. Attach a suitable lifting device to the turbocharger

and position the turbocharger on the exhaust
manifold.
3. Position outlet (10) on the aftercooler and install
four mounting bolts (9) on the turbocharger.

Illustration 262 g00579878

8. Tighten two hose clamps (3).

9. Connect water line (1).

10. Install the gasket and two bolts (2) that connect
the oil supply line to the top of turbocharger (4).
End By:
a. Install the exhaust elbow.

i02500749

Illustration 260 g00579890 Turbocharger - Install

4. Install two bolts (8) that fasten the oil drain tube to SMCS Code: 1052-012
the cylinder block. S/N: E621–Up
5. Install clip (7) on the oil drain tube. S/N: TJ21–Up
S/N: WC21–Up
S/N: WC31–Up
S/N: TJ41–Up
80 SENR6419
Disassembly and Assembly Section

S/N: TJ61–Up
NOTICE
S/N: WC61–Up Keep all parts clean from contaminants.
S/N: TJ71–Up Contaminants may cause rapid wear and shortened
component life.
S/N: WC71–Up
S/N: WC81–Up 1. Inspect the condition of the gaskets. Replace the
S/N: E8A1–Up gaskets, if necessary.

S/N: ZBA1–Up
S/N: CRC1–Up
S/N: E2C1–Up
S/N: E8C1–Up
S/N: 4WD1–Up
S/N: 5JD1–Up
S/N: 8LD1–Up
S/N: E2E1–Up
S/N: 9TG1–Up
S/N: CPG1–Up
Illustration 263 g01250354
S/N: 7NJ1–Up
2. Attach a suitable lifting device to turbocharger (9).
S/N: CPJ1–Up The weight of turbocharger (9) is approximately
S/N: 4EK1–Up 38 kg (84 lb).
S/N: CRN1–Up 3. Apply Tooling (A) to the studs on the exhaust
S/N: E6N1–Up manifold. Install turbocharger (9) and nuts (8) that
attach turbocharger (9) to the exhaust manifold.
S/N: CSP1–Up Tighten nuts (8) to a torque of 54 ± 5 N·m
S/N: E6R1–Up (40 ± 4 lb ft).

S/N: CPS1–Up
S/N: 6JW1–Up
S/N: 8PW1–Up
S/N: 9AW1–Up
S/N: E6W1–Up
S/N: CPY1–Up
S/N: E6Y1–Up
S/N: CSZ1–Up
S/N: E6Z1–Up
S/N: ZAZ1–Up Illustration 264 g01250350

Installation Procedure 4. Install air inlet tube (5) and tube assembly (6).
Table 10
Required Tools
5. Position the oil supply line and the gasket on the
turbocharger. Install bolts (7) in the oil supply line.
Tool Part Number Part Description Qty

A 5P-3931 Anti-Seize Compound -

SENR6419 81
Disassembly and Assembly Section

Removal Procedure
Table 11
Required Tools

Tool Part Number Part Description Qty

A 138-7573 Link Bracket 2

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Illustration 265 g01250347

NOTICE
Care must be taken to ensure that fluids are con-
6. Install bolts (1). tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product. Be
7. Install tube assembly (3). prepared to collect the fluid with suitable containers
before opening any compartment or disassembling
8. Install oil drain tube (4) and bolts (2). any component containing fluids.
9. Fill the cooling system to the correct level with Refer to Special Publication, NENG2500, “Caterpillar
coolant. Refer to Operation and Maintenance Tools and Shop Products Guide” for tools and sup-
Manual, “Cooling System Coolant - Change”. plies suitable to collect and contain fluids on Caterpil-
lar products.
i01102037 Dispose of all fluids according to local regulations and
mandates.
Aftercooler - Remove and
Install
SMCS Code: 1063-010

S/N: TJ61–Up
S/N: WC61–Up
S/N: TJ71–Up
S/N: WC71–Up
S/N: E8A1–Up
S/N: CRC1–Up
S/N: E2C1–Up
S/N: E8C1–Up Illustration 266 g00580321

S/N: E2E1–Up
1. Disconnect line (1) that runs to the exhaust bypass
S/N: 2TJ1–Up for the turbocharger.
S/N: CPJ1–Up
2. Remove four bolts (2) and the nuts on the air inlet
S/N: CRN1–Up from the turbocharger.
S/N: CSP1–Up
S/N: E6R1–Up
S/N: CPS1–Up
S/N: E6W1–Up
S/N: CPY1–Up
82 SENR6419
Disassembly and Assembly Section

Illustration 267 g00580361

View from the top of the engine

3. Remove two bolts (3) and the retainers from outlet

pipe (4) of the aftercooler.

Illustration 269 g00580433

7. Remove bolt (9) and the retainer from inlet pipe (8).

8. Remove outlet pipe (4) and inlet pipe (8) from the
aftercooler. Plug all openings immediately.

Illustration 268 g00580403

4. Remove two bolts (5) from the bracket that holds

outlet pipe (4) to the aftercooler.

5. Remove two bolts (6) from the bracket that holds

inlet pipe (8) to the aftercooler.
Illustration 270 g00580439
6. Disconnect fitting (7).
9. Remove four bolts (10) and the nuts that attach the
elbow of the engine throttle control to the
aftercooler.
SENR6419 83
Disassembly and Assembly Section

Illustration 271 g00580793 Illustration 273 g00597710

10. Install Tool (A) and attach a suitable lifting device 15. Use a suitable sized rod to clean aftercooler core
to the aftercooler. (13), if necessary.

16. Use the following steps if the mounting plate for

the aftercooler must be removed.
a. Remove the fuel control actuator from the
mounting plate. Refer to Disassembly and
Assembly, “Fuel Control Actuator - Remove
and Install” for the correct procedure.

Illustration 272 g00580797

The exhaust heat shields are removed for the photos
only.

11. Remove eight bolts (11) that hold the aftercooler

to the mounting plate. There are four bolts on the
rear of the aftercooler and four bolts that are on the
front of the aftercooler.
12. Lift the aftercooler off the engine.
Note: Ensure that the oil lines and the water lines for
the turbocharger are not damaged.

13. Remove the O-ring seal that is on the air inlet of Illustration 274 g00580834

the aftercooler. Remove the gasket that is on the View from the top of the engine
air outlet of the aftercooler.
b. Remove four bolts (15) and the spacers from
14. Remove bolts (12) that hold the water outlet on the base of the mounting plate. There are two
the aftercooler in order to clean the aftercooler. bolts that are on the front of the mounting plate
and two bolts that are on the rear of the
mounting plate.

c. Remove two nuts (14) and the bolts.

d. Remove the mounting plate.

84 SENR6419
Disassembly and Assembly Section

Installation Procedure
Table 12
Required Tools

Tool Part Number Part Description Qty

A 138-7573 Link Bracket 2

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

1. Inspect the condition of the seals and the gaskets. Illustration 276 g00580793
Replace the seals and the gaskets, if necessary.
3. Install Tool (A) and attach a suitable lifting device to
2. Use the following steps to install the mounting plate the aftercooler. Position the aftercooler on the
for the aftercooler, if necessary: engine.
Note: Ensure that the oil lines and the water lines for
the turbocharger are not damaged.

Illustration 277 g00580797

The exhaust heat shields are removed for photos
Illustration 275 g00580834 only.
View from the top of the engine
4. Install eight bolts (11) that hold the aftercooler to
the mounting plate. There are four bolts on the rear
a. Position the mounting plate on the engine.
of the aftercooler and four bolts on the front of the
Install two bolts (14) and the nuts.
aftercooler.
b. Install spacers and four bolts (15) in the base
of the mounting plate.

c. Install the fuel control actuator on the mounting

plate. Refer to Disassembly and Assembly,
“Fuel Control Actuator - Remove and Install”
for the correct procedure.
SENR6419 85
Disassembly and Assembly Section

Illustration 278 g00580439 Illustration 280 g00580403

5. Install four bolts (10) and the nuts that attach the 8. Connect fitting (7) on the line that runs from the
elbow of the engine throttle control to the water manifold to the turbocharger.
aftercooler.
9. Install the bracket and two bolts (6) that hold inlet
pipe (8) to the aftercooler.

10. Install the bracket and two bolts (5) that hold
outlet pipe (4) to the aftercooler.

Illustration 281 g00580361

Illustration 279 g00580433 View from the top of the engine

6. Install inlet pipe (8) and outlet pipe (4) on the 11. Install the retainers and two bolts (3) for outlet
aftercooler. pipe (4) of the aftercooler.

7. Install the retainer and bolt (9) on inlet pipe (8).

86 SENR6419
Disassembly and Assembly Section

S/N: 8LD1–Up
S/N: E2E1–Up
S/N: 9TG1–Up
S/N: CPG1–Up
S/N: 7NJ1–Up
S/N: CPJ1–Up
S/N: 4EK1–Up
S/N: CRN1–Up
S/N: E6N1–Up

Illustration 282 g00580321

S/N: CSP1–Up
S/N: E6R1–Up
12. Install four bolts (2) and the nuts on the air inlet
from the turbocharger. S/N: CPS1–Up
S/N: 6JW1–Up
13. Connect line (1) that runs to the exhaust bypass
for the turbocharger. S/N: 8PW1–Up

14. Fill the cooling system to the correct level with S/N: 9AW1–Up
coolant. Refer to the Operation and Maintenance S/N: E6W1–Up
Manual for the correct procedure.
S/N: CPY1–Up
i02500875 S/N: E6Y1–Up

Aftercooler - Remove and S/N: CSZ1–Up

Install S/N: E6Z1–Up

SMCS Code: 1063-010 S/N: ZAZ1–Up

S/N: E621–Up Removal Procedure

Table 13
S/N: TJ21–Up
Required Tools
S/N: WC21–Up
Tool Part Number Part Description Qty
S/N: WC31–Up
A 138-7573 Link Bracket 2
S/N: TJ41–Up
S/N: TJ61–Up Start By:
S/N: WC61–Up a. If necessary, remove the fuel control valve. Refer to
Disassembly and Assembly, “Fuel Control Valve -
S/N: TJ71–Up Remove and Install”.
S/N: WC71–Up
NOTICE
S/N: WC81–Up Keep all parts clean from contaminants.
S/N: E8A1–Up Contaminants may cause rapid wear and shortened
component life.
S/N: ZBA1–Up
S/N: CRC1–Up
S/N: E2C1–Up
S/N: E8C1–Up
S/N: 4WD1–Up
S/N: 5JD1–Up
SENR6419 87
Disassembly and Assembly Section

NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product. Be
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling
any component containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
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.
Illustration 284 g01250869
1. Drain the coolant from the cooling system into a
suitable container for storage or disposal. Refer to 5. Remove bolts (8).
Operation and Maintenance Manual, “Cooling
6. Remove aftercooler (1) from the engine.
System Coolant - Change”.

Illustration 285 g01250872

Illustration 283 g01250839

7. Remove plate (10) and core assembly (9), if

2. Attach Tooling (A) and a suitable lifting device to
necessary.
aftercooler (1). The weight of aftercooler (1) is
approximately 114 kg (250 lb). Installation Procedure
3. Remove bolts (2) and disconnect the tube Table 14
assemblies. Remove bolts (3), retainers (4), tubes Required Tools
(7), and the O-ring seals. Qty
Tool Part Number Part Description
4. Disconnect tube assembly (5) from aftercooler (1). A 138-7573 Link Bracket 2
Remove bolts (6).

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

1. Inspect the condition of the O-ring seals. Replace

the gaskets and the seals, if necessary.
88 SENR6419
Disassembly and Assembly Section

6. Place clean engine oil on the O-ring seals and

connect tubes (7).

7. Install retainers (4) and bolts (3). Connect the tube

assemblies and install bolts (2).

8. Fill the cooling system to the correct level with

coolant. Refer to Operation and Maintenance
Manual, “Cooling System Coolant - Change”.
End By:
a. If necessary, install the fuel control valve. Refer to
Disassembly and Assembly, “Fuel Control Valve -
Remove and Install”.
Illustration 286 g01250872
i02501048

2. Install core assembly (9) and plate (10), if

necessary.
Air Inlet Manifold - Remove and
Install
SMCS Code: 1058-010

Removal Procedure
Start By:
a. Remove the aftercooler. Refer to Disassembly and
Assembly, “Aftercooler - Remove and Install”.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Illustration 287 g01250869

Illustration 289 g01250966

Illustration 288 g01250839

1. Remove bolts (1) from the cylinder head and
remove bolts (2) from air inlet manifold (7).
3. Attach Tooling (A) and a suitable lifting device to
aftercooler (1). The weight of aftercooler (1) is 2. Remove air inlet elbows (3) from the engine.
approximately 114 kg (250 lb). Position aftercooler
(1) on the engine. 3. Remove bolts (4) from cover (5) on air inlet
manifold (7).
4. Install bolts (8).
4. If necessary, remove air inlet adapter (6) and cover
5. Install bolts (6) and connect tube assembly (5). (5).
SENR6419 89
Disassembly and Assembly Section

Installation Procedure S/N: CPJ1–Up

S/N: CRN1–Up
NOTICE
Keep all parts clean from contaminants. S/N: CSP1–Up
Contaminants may cause rapid wear and shortened S/N: E6R1–Up
component life.
S/N: CPS1–Up
S/N: E6W1–Up
S/N: CPY1–Up

Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Illustration 290 g01250966

1. If necessary, install cover (5) and air inlet adapter

(6) on air inlet manifold (7).

2. Install bolts (4).

3. Position air inlet elbows (3) on the engine.

4. Install bolts (2) in air inlet manifold (7) and install

bolts (1) in the cylinder head.
End By: Illustration 291 g00597041

a. Install the aftercooler. Refer to Disassembly and

Assembly, “Aftercooler - Remove and Install”. 1. Remove exhaust heat shield (1) from the exhaust
elbow.
i01128746

Exhaust Elbow - Remove and

Install
SMCS Code: 1060-010

S/N: TJ61–Up
S/N: WC61–Up
S/N: TJ71–Up
S/N: WC71–Up
S/N: E8A1–Up
S/N: CRC1–Up Illustration 292 g00597043

S/N: E2C1–Up
2. Remove the nuts and bolts (4).
S/N: E8C1–Up
3. Remove two nuts (3) and the bolts.
S/N: E2E1–Up
4. Remove exhaust elbow (2).
S/N: 2TJ1–Up
90 SENR6419
Disassembly and Assembly Section

Installation Procedure S/N: WC31–Up

S/N: TJ41–Up
NOTICE
Keep all parts clean from contaminants. S/N: TJ61–Up
Contaminants may cause rapid wear and shortened S/N: WC61–Up
component life.
S/N: TJ71–Up
S/N: WC71–Up
S/N: WC81–Up
S/N: E8A1–Up
S/N: ZBA1–Up
S/N: CRC1–Up
S/N: E2C1–Up
S/N: E8C1–Up
S/N: 4WD1–Up
S/N: 5JD1–Up
S/N: 8LD1–Up
Illustration 293 g00597043
S/N: E2E1–Up
1. Position exhaust elbow (2) on the engine.
S/N: 9TG1–Up
2. Install two bolts (3) and the nuts. S/N: CPG1–Up
3. Install bolts (4) and the nuts. S/N: 7NJ1–Up
S/N: CPJ1–Up
S/N: 4EK1–Up
S/N: CRN1–Up
S/N: E6N1–Up
S/N: CSP1–Up
S/N: E6R1–Up
S/N: CPS1–Up
S/N: 6JW1–Up
S/N: 8PW1–Up
S/N: 9AW1–Up
Illustration 294 g00597041
S/N: E6W1–Up
4. Install exhaust heat shield (1) on the exhaust
S/N: CPY1–Up
elbow.
S/N: E6Y1–Up
i02559151
S/N: CSZ1–Up
Exhaust Elbow - Remove and S/N: E6Z1–Up
Install S/N: ZAZ1–Up
SMCS Code: 1060-010

S/N: E621–Up
S/N: TJ21–Up
S/N: WC21–Up
SENR6419 91
Disassembly and Assembly Section

Removal Procedure
Table 15
Required Tools

Tool Part Number Part Description Qty

A 138-7573 Link Bracket 2

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Illustration 296 g01251046

NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte- 4. Disconnect tube assembly (4) from exhaust elbow
nance, testing, adjusting and repair of the product. Be (1).
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling 5. Remove bolts (2) and bolts (3).
any component 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. Turn the engine control switch to the OFF/RESET

position.

2. 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”. Illustration 297 g01251048

6. Disconnect tube assembly (5) from the exhaust

elbow and the exhaust bypass.

Illustration 295 g01282266

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

exhaust elbow (1). The weight of exhaust elbow (1) Illustration 298 g01281057

is approximately 36 kg (80 lb).

7. Disconnect tube assembly (7) and tube assembly
(9) from the exhaust bypass.
92 SENR6419
Disassembly and Assembly Section

8. Remove tube assembly (6) from exhaust elbow (1). 3. Install tube assembly (6) on exhaust elbow (1).

9. Remove bolts (8). 4. Connect tube assembly (9) and tube assembly (7)
to the exhaust bypass.
10. Remove exhaust elbow (1) and the gaskets from
the engine.

Installation Procedure
Table 16
Required Tools

Tool Part Number Part Description Qty

A 138-7573 Link Bracket 2

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Illustration 301 g01251048

5. Connect tube assembly (5) to the exhaust elbow

and the exhaust bypass.

Illustration 299 g01282266

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

exhaust elbow (1). The weight of exhaust elbow (1) Illustration 302 g01251046
is approximately 36 kg (80 lb). Place the gaskets
and exhaust elbow (1) in position. 6. Ensure that the gaskets between the adapters and
the exhaust elbow are positioned correctly. Install
bolts (2) and bolts (3).

7. Connect tube assembly (4) to exhaust elbow (1).

8. Fill the cooling system to the correct level with

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

9. Turn the engine control switch to the AUTO or

START position.

Illustration 300 g01281057

2. Install bolts (8).

SENR6419 93
Disassembly and Assembly Section

i02559262 Installation Procedure

Exhaust Bypass Valve - NOTICE
Keep all parts clean from contaminants.
Remove and Install
SMCS Code: 1057-010 Contaminants may cause rapid wear and shortened
component life.
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Illustration 305 g01281081

1. Install the gasket, exhaust bypass valve (1), and

bolts (4).

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

Illustration 303 g01282236

1. Disconnect tube assembly (2) and clamp (3) from

exhaust bypass valve (1).

Illustration 306 g01282236

3. Connect tube assembly (2) and clamp (3) to

exhaust bypass valve (1).

Illustration 304 g01281081 i01109743

2. Disconnect tube assembly (5) and tube assembly Exhaust Manifold - Remove
(6). (Dry)
3. Remove bolts (4), exhaust bypass valve (1), and
the gasket.
94 SENR6419
Disassembly and Assembly Section

SMCS Code: 1059-011

Removal Procedure
Start By:
a. Remove the exhaust elbow.
b. Remove the turbocharger.
c. Remove the exhaust bypass valve.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life. Illustration 308 g00585604
G3508 COSA Engines
1. Cut the wires that hold the exhaust heat shield in
place and remove the exhaust heat shield. 5. Remove four nuts (4) and the bolts in order to
remove the remaining sections of the exhaust
manifold.

Note: Ensure that bellows (5) of the exhaust manifold

are not damaged by any tools.

6. Use the following steps if only one of the sections

of the exhaust manifold must be removed on all
G3500 Engines.

Illustration 307 g00585318

G3508 COSA Engines

2. Remove four bolts (2) and the nuts from each side
of exhaust adapter (3).

3. Remove eight bolts (1) and the nuts that hold

exhaust bellows (3) to the exhaust adapter.

4. Remove exhaust adapter (3) and the two metal

gaskets.

Illustration 309 g00585641

Typical example

a. Remove eight bolts (6) and the nuts that hold

each section of the exhaust manifold together.

b. Remove four bolts (7) and the washers that

hold the exhaust manifold to the cylinder head.
SENR6419 95
Disassembly and Assembly Section

S/N: 6JW1–Up
c. Remove exhaust manifold section (5) and the
S/N: 8PW1–Up
metal gasket between each of the sections.
Also remove the gasket that is on the cylinder S/N: 9AW1–Up
head.
S/N: E6W1–Up
d. Repeat these steps for each section of the S/N: CPY1–Up
exhaust manifold that must be removed.
S/N: E6Y1–Up
i01128163
S/N: CSZ1–Up
Exhaust Manifold - Remove S/N: E6Z1–Up
(Water Cooled) S/N: ZAZ1–Up
SMCS Code: 1059-011
Removal Procedure
S/N: E621–Up Start By:
S/N: TJ21–Up a. Remove the turbochargers.
S/N: WC21–Up b. Remove the aftercooler.
S/N: WC31–Up
NOTICE
S/N: TJ41–Up Keep all parts clean from contaminants.
S/N: TJ61–Up Contaminants may cause rapid wear and shortened
S/N: WC61–Up component life.

S/N: TJ71–Up
1. Turn off the gas supply.
S/N: WC71–Up
S/N: WC81–Up
S/N: E8A1–Up
S/N: ZBA1–Up
S/N: CRC1–Up
S/N: E2C1–Up
S/N: E8C1–Up
S/N: 4WD1–Up
S/N: 5JD1–Up
S/N: 8LD1–Up
Illustration 310 g00596844
S/N: E2E1–Up
S/N: 9TG1–Up 2. Disconnect tube (1) from fitting on the gas pressure
S/N: CPG1–Up regulator.

S/N: 7NJ1–Up 3. Remove clamp (2) from the joint.

S/N: CPJ1–Up
S/N: 4EK1–Up
S/N: CRN1–Up
S/N: E6N1–Up
S/N: CSP1–Up
S/N: E6R1–Up
S/N: CPS1–Up
96 SENR6419
Disassembly and Assembly Section

9. Remove the bolts that hold the manifold for the

wastegate to the exhaust manifold. The bolts are
below tube (6).

Illustration 311 g00596753

4. Disconnect tube (1) from the carburetor.

5. Remove clamp (3). Illustration 314 g00596757

6. Remove tubes (1) and (4). 10. Remove bolts (7) that hold the exhaust manifold
to the water temperature regulator housing.

11. Remove bolts (8) that hold the adapters to the

exhaust manifold.

Illustration 312 g00596755

7. Remove bolts (5) that hold the exhaust manifold to

the cylinder head.

Illustration 313 g00596756

8. Remove tubes (6) from the exhaust manifold to the

exhaust bypass.
SENR6419 97
Disassembly and Assembly Section

S/N: WC81–Up
S/N: E8A1–Up
S/N: ZBA1–Up
S/N: CRC1–Up
S/N: E2C1–Up
S/N: E8C1–Up
S/N: 4WD1–Up
S/N: 5JD1–Up
S/N: 8LD1–Up

Illustration 315 g00596758

S/N: E2E1–Up
S/N: 9TG1–Up
S/N: CPG1–Up
S/N: 7NJ1–Up
S/N: CPJ1–Up
S/N: 4EK1–Up
S/N: CRN1–Up
S/N: E6N1–Up
S/N: CSP1–Up
S/N: E6R1–Up
S/N: CPS1–Up
Illustration 316 g00596759
S/N: 6JW1–Up
12. Attach a suitable lifting device to the exhaust S/N: 8PW1–Up
manifold and remove bolts (9) that hold the S/N: 9AW1–Up
exhaust manifold to the mounting bracket.
S/N: E6W1–Up
13. Remove the exhaust manifold. The exhaust
manifold weighs approximately 287 kg (632 lb). S/N: CPY1–Up
S/N: E6Y1–Up
i01128240
S/N: CSZ1–Up
Exhaust Manifold - Install S/N: E6Z1–Up
(Water Cooled) S/N: ZAZ1–Up
SMCS Code: 1059-012
Installation Procedure
S/N: E621–Up
NOTICE
S/N: TJ21–Up Keep all parts clean from contaminants.
S/N: WC21–Up Contaminants may cause rapid wear and shortened
S/N: WC31–Up component life.

S/N: TJ41–Up
S/N: TJ61–Up
S/N: WC61–Up
S/N: TJ71–Up
S/N: WC71–Up
98 SENR6419
Disassembly and Assembly Section

Illustration 317 g00596759 Illustration 320 g00596755

1. Use a suitable lifting device to position the exhaust 3. Install bolts (5).
manifold on the engine. Ensure that the gaskets
are in the proper position.

Illustration 321 g00596756

Illustration 318 g00596758 4. Install tube (6).

Illustration 319 g00596757 Illustration 322 g00596753

2. Install bolts (7), (8), and (9). 5. Install tubes (1) and (4). Install clamp (3).
SENR6419 99
Disassembly and Assembly Section

Illustration 323 g00596844

6. Install clamp (2) and connect tube (1) to the gas

pressure regulator.

7. Turn on the gas supply.

Illustration 324 g00585641
End By: Typical example
a. Install the aftercooler.
a. Inspect the condition of the metal gaskets.
b. Install the turbochargers. Replace the gaskets, if necessary.

i01110463 b. Install the metal gaskets on the cylinder head

and between each section of the exhaust
Exhaust Manifold - Install manifold.
(Dry)
SMCS Code: 1059-012

Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

1. Use the following steps to install one section of the

exhaust manifold for all G3500 Engines.
Illustration 325 g00638469

c. Ensure that the exhaust manifold is installed in

the correct direction. The word “FLOW” and
an arrow is stamped on each of the sections.
This arrow should face toward the
turbocharger.

d. Position the exhaust manifold on the engine.

Install four bolts (7) that hold the exhaust
manifold to the engine.

e. Install four bolts (6) that hold each section of

the exhaust manifold together. Tighten the
bolts to a torque of 47 ± 5 N·m (35 ± 4 lb ft).
100 SENR6419
Disassembly and Assembly Section

Note: Ensure that bellows (5) of the exhaust 7. Install four bolts (1) and the nuts on the exhaust
manifold are not damaged with any tools. manifold.

f. Tighten the bolts again to a torque of 8. Use the same torque procedure that is given
47 ± 5 N·m (35 ± 4 lb ft). above.

g. Repeat these steps for each section of the

exhaust manifold that must be installed.

Illustration 326 g00585604

G3508 COSA Engines

2. Install the metal gaskets and position each section

of the exhaust manifold on the engine.

3. Install four bolts (4) and the nuts. Tighten the bolts
to a torque of 47 ± 5 N·m (35 ± 4 lb ft).

Note: Ensure that bellows (5) of the exhaust manifold

are not damaged with any tools.

4. Tighten the bolts again to a torque of 47 ± 5 N·m

(35 ± 4 lb ft).

Illustration 327 g00585318

G3508 COSA Engines

5. Install the metal gaskets and position exhaust

adapter (3) on the engine.

6. Install four bolts (2) and the nuts that hold exhaust
adapter (3) to the mounting plate.
SENR6419 101
Disassembly and Assembly Section

Illustration 328 g00586100

Wiring diagram for the exhaust heat shield that is on G3508 Engines with dual turbochargers

9. Install the long sections of the exhaust heat shield

NOTICE
and wire the heat shield together.
Care must be taken to ensure that fluids are con-
End By: tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product. Be
a. Install the exhaust bypass valve. prepared to collect the fluid with suitable containers
before opening any compartment or disassembling
b. Install the turbocharger. any component containing fluids.
c. Install the exhaust elbow. Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies
i02502522 suitable to collect and contain fluids on Caterpillar
products.
Water Temperature Regulators Dispose of all fluids according to local regulations and
- Remove mandates.
SMCS Code: 1355-011
1. Drain the coolant from the cooling system into a
Removal Procedure suitable container for storage or disposal. Refer to
Table 17 Operation and Maintenance Manual, “Cooling
System Coolant - Change”.
Required Tools

Tool Part Number Part Description Qty

A 138-7573 Link Bracket 2

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
102 SENR6419
Disassembly and Assembly Section

7. Remove mounting straps (7) and (9) that hold the

water temperature regulator housing to the engine
oil filter housing. Remove plate (8) from the engine
oil filter housing.

Illustration 331 g01251850

Typical example

8. Attach Tooling (A) and a suitable lifting device to

water temperature regulator housing (12). The
weight of water temperature regulator housing (12)
is approximately 59 kg (130 lb).
Illustration 329 g01251848
9. Remove bolts (11) and water temperature regulator
Typical example housing (12) from exhaust manifold (13).
2. Remove the bolts from retainers (2) and (6). 10. Remove the O-ring seals from water temperature
regulator housing (12).
3. Remove the bolts from support bracket (4).
11. Remove regulator housing (10) from water
4. Remove tube (5) and the O-ring seals.
temperature regulator housing (12).
5. Remove the bolts from elbow (1). Remove elbow
(1) and the gasket.

6. Disconnect the harness assembly from pressure

sensor (3). Remove the bolts from pressure sensor
(3). Remove pressure sensor (3).

Illustration 332 g01251884

Typical example

12. Remove water temperature regulators (14) from

regulator housing (10).

Illustration 330 g00593655 13. Remove the valve assembly and the seals, if
Typical example necessary.
SENR6419 103
Disassembly and Assembly Section

i02502575

Water Temperature Regulators

- Install
SMCS Code: 1355-012

Installation Procedure
Table 18
Required Tools

Tool Part Number Part Description Qty

A 138-7573 Link Bracket 2

B 1P-0510 Driver Group 1

Illustration 334 g01251850
Typical example
NOTICE
Keep all parts clean from contaminants. 4. Install regulator housing (10) on water temperature
regulator housing (12).
Contaminants may cause rapid wear and shortened
component life. 5. Install the O-ring seals in water temperature
regulator housing (12).
1. Install the valve assembly, if necessary. Ensure 6. Attach Tooling (A) and a suitable lifting device to
that the valve is flush with the surface of the water temperature regulator housing (12). The
housing. weight of water temperature regulator housing (12)
is approximately 59 kg (130 lb). Position water
2. Use Tooling (B) to install the seals, if necessary.
temperature regulator housing (12) on the engine.
Ensure that the lip of the seal is toward the inside
of the housing. 7. Install bolts (11) that attach water temperature
regulator housing (12) to exhaust manifold (13).

Illustration 333 g01251884

Typical example Illustration 335 g00593655
Typical example
NOTICE
If the water temperature regulator is installed incor- 8. Install mounting straps (7) and (9). Install plate (8)
rectly, it will cause the engine to overheat. on the engine oil filter housing.

3. Install water temperature regulators (14) in

regulator housing (10) with the spring upward.
104 SENR6419
Disassembly and Assembly Section

S/N: TJ71–Up
S/N: WC71–Up
S/N: WC81–Up
S/N: E8A1–Up
S/N: ZBA1–Up
S/N: CRC1–Up
S/N: E2C1–Up
S/N: E8C1–Up
S/N: 4WD1–Up
S/N: 5JD1–Up
S/N: 8LD1–Up
S/N: E2E1–Up
S/N: 9TG1–Up
S/N: CPG1–Up
S/N: 7NJ1–Up
S/N: CPJ1–Up
S/N: 4EK1–Up
S/N: CRN1–Up
Illustration 336 g01251848
Typical example S/N: E6N1–Up
S/N: CSP1–Up
9. Install a new gasket, elbow (1), and the bolts.
S/N: E6R1–Up
10. Install the O-ring seals and tube (5). Install
retainers (2) and (6) with the bolts. S/N: CPS1–Up
S/N: 6JW1–Up
11. Install support bracket (4) and the bolts.
S/N: 8PW1–Up
12. Install pressure sensor (3). Connect the harness
assembly to pressure sensor (3). S/N: 9AW1–Up
S/N: E6W1–Up
13. Fill the cooling system to the correct level with
coolant. Refer to Operation and Maintenance S/N: CPY1–Up
Manual, “Cooling System Coolant - Change”.
S/N: E6Y1–Up
i02502604 S/N: CSZ1–Up
S/N: E6Z1–Up
Water Pump - Remove
S/N: ZAZ1–Up
SMCS Code: 1361-011

S/N: E621–Up Removal Procedure

S/N: TJ21–Up NOTICE
Keep all parts clean from contaminants.
S/N: WC21–Up
S/N: WC31–Up Contaminants may cause rapid wear and shortened
component life.
S/N: TJ41–Up
S/N: TJ61–Up
S/N: WC61–Up
SENR6419 105
Disassembly and Assembly Section

NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product. Be
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling
any component containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
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.
Illustration 338 g00592487
1. Drain the coolant from the cooling system into a
suitable container for storage or disposal. Refer to 5. Attach a suitable lifting device to water pump (8).
Operation and Maintenance Manual, “Cooling The weight of water pump (8) is approximately
System Coolant - Change”. 38 kg (85 lb). Remove bolts (6), bolts (7), and
water pump (8).

Handling the Water Pump

NOTICE
Radial movement of the pump drive shaft can allow
the shaft to contact the ceramic seals in the water
pump. This can damage the ceramic seals. Damage
to the seals will cause leaks and failure of the pump.
Do not cause radial movement of the pump drive
shaft.

Illustration 339 g01251962

Illustration 337 g01251960 Section view of the water pump
(9) Ceramic seals
2. Remove bolts (4) and the retainer from the water (10) Pump drive shaft
pump.
Use the following guidelines for handling the water
3. Remove the bolts and retainer (2) from elbow (1). pump:

4. Remove the bolt from support bracket (5). Remove

tube assembly (3).
106 SENR6419
Disassembly and Assembly Section

• Do not cause radial movement of the pump drive S/N: 8PW1–Up

shaft. Never use any Tooling that will cause radial
movement of the shaft. S/N: 9AW1–Up
S/N: E6W1–Up
• Never place the water pump on a surface so the
shaft rests on the surface. S/N: CPY1–Up
• Never handle the water pump by the shaft. S/N: E6Y1–Up
S/N: CSZ1–Up
i05523130
S/N: E6Z1–Up
Water Pump - Disassemble S/N: ZAZ1–Up
SMCS Code: 1361-015
Disassembly Procedure
S/N: E621–Up
Table 19
S/N: TJ21–Up Required Tools

S/N: WC21–Up Tool Part Number Part Description Qty

S/N: WC31–Up A 1P-0510 Driver Gp 1

S/N: TJ41–Up
Start By:
S/N: TJ61–Up
a. Remove the water pump.
S/N: WC61–Up
S/N: TJ71–Up
S/N: WC71–Up
S/N: WC81–Up
S/N: E8A1–Up
S/N: ZBA1–Up
S/N: CRC1–Up
S/N: E2C1–Up
S/N: E8C1–Up
S/N: 4WD1–Up
S/N: 5JD1–Up
S/N: 8LD1–Up
S/N: E2E1–Up
S/N: 9TG1–Up
S/N: CPG1–Up Illustration 340 g03475023

S/N: 7NJ1–Up
1. Remove nuts (1) and the studs from cover
S/N: CPJ1–Up assembly (2). Remove cover assembly (2).
S/N: 4EK1–Up
S/N: CRN1–Up
S/N: E6N1–Up
S/N: CSP1–Up
S/N: E6R1–Up
S/N: CPS1–Up
S/N: 6JW1–Up
SENR6419 107
Disassembly and Assembly Section

Illustration 341 g03475339 Illustration 342 g03418638

2. Remove O-ring seal (3) and O-ring seal (4) from

cover assembly (2).

Illustration 343 g03418645

3. Remove bolts (5) and the washers from thrust

washer (6) and pump housing (7).

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

remove shaft assembly (9) and thrust washer (6)
from impeller (8).
108 SENR6419
Disassembly and Assembly Section

Illustration 344 g03418655 Illustration 346 g03419186

5. Remove rotating seal group (10) and stationary 8. Remove filters (15) from pump housing (7).
seal group (11) from pump housing (7).
Reference: Refer to Reuse and Salvage Guidelines,
6. Remove plug assembly (12). SEBF8418, “Salvage of Water Pumps in 3500 Series
Engines” for reuse and salvage guidelines.

i05523131

Water Pump - Assemble

SMCS Code: 1361-016

S/N: E621–Up
S/N: TJ21–Up
S/N: WC21–Up
S/N: WC31–Up
S/N: TJ41–Up
S/N: TJ61–Up
S/N: WC61–Up
S/N: TJ71–Up
S/N: WC71–Up
Illustration 345 g03418663 S/N: WC81–Up
S/N: E8A1–Up
7. Remove lip seal (13), ring assembly (14), and the
locating pin from pump housing (7). S/N: ZBA1–Up
S/N: CRC1–Up
S/N: E2C1–Up
S/N: E8C1–Up
S/N: 4WD1–Up
S/N: 5JD1–Up
SENR6419 109
Disassembly and Assembly Section

S/N: 8LD1–Up
S/N: E2E1–Up
S/N: 9TG1–Up
S/N: CPG1–Up
S/N: 7NJ1–Up
S/N: CPJ1–Up
S/N: 4EK1–Up
S/N: CRN1–Up
S/N: E6N1–Up
S/N: CSP1–Up
S/N: E6R1–Up
S/N: CPS1–Up
S/N: 6JW1–Up
S/N: 8PW1–Up Illustration 347 g03419186
S/N: 9AW1–Up
1. Replace filters (15) into pump housing (7).
S/N: E6W1–Up
S/N: CPY1–Up
S/N: E6Y1–Up
S/N: CSZ1–Up
S/N: E6Z1–Up
S/N: ZAZ1–Up

Assembly Procedure
Table 20
Required Tools

Tool Part Number Part Description Qty

A 1P-0510 Driver Gp 1

B 7N-8268 Installation Tool 1

C 438-8155 Installation Tool 1

Reference: Refer to Reuse and Salvage Guidelines,

SEBF8418, “Salvage of Water Pumps in 3500 Series Illustration 348 g03418663
Engines” for reuse and salvage guidelines.
2. Install ring (14) and the locating pin.

3. Use Tooling (A) to install lip seal (13) into pump

housing (7).
110 SENR6419
Disassembly and Assembly Section

Illustration 350 g03476061

Illustration 349 g03476081

4. Install shaft assembly (9), thrust washer (6), bolts

(5), and the washers into the pump housing.

Illustration 351 g03476619

5. Use Tooling (B) in order to install stationary seal

group (11) with the ceramic side facing out.
SENR6419 111
Disassembly and Assembly Section

Illustration 352 g03476066 Illustration 354 g03419292

7. Lubricate the shaft assembly with a light coat of

engine oil. Use a suitable press in order to install
impeller (8) into pump housing (7) and onto the
shaft assembly. Install impeller (8) to a depth of
0.0 ± 0.15 mm (0.00000 ± 0.00591 inch) from the
end of the shaft assembly to the outer face of the
impeller.

Illustration 353 g03419283

6. Use Tooling (C) and a suitable press to install

rotating seal group (10). Rotating seal group (10) is
to be installed with installation clips (X) in place
until rotating seal group (10) is fully seated.
Remove installation clips (X).
Note: Do not use hammer to install seal groups as Illustration 355 g03419302
damage to the ceramic faces on the seal groups will
occur. 8. Install plug assembly (12) and the O-ring seal into
pump housing (7).
112 SENR6419
Disassembly and Assembly Section

i05831719

Water Pump - Install

SMCS Code: 1361-012

S/N: E621–Up
S/N: TJ21–Up
S/N: WC21–Up
S/N: WC31–Up
S/N: TJ41–Up
S/N: TJ61–Up
S/N: WC61–Up
S/N: TJ71–Up
S/N: WC71–Up
S/N: WC81–Up
Illustration 356 g03475339 S/N: E8A1–Up

9. Install O-ring seal (4) and O-ring seal (3) onto cover S/N: ZBA1–Up
assembly (2). S/N: CRC1–Up
S/N: E2C1–Up
S/N: E8C1–Up
S/N: 4WD1–Up
S/N: 5JD1–Up
S/N: 8LD1–Up
S/N: E2E1–Up
S/N: 9TG1–Up
S/N: CPG1–Up
S/N: 7NJ1–Up
S/N: CPJ1–Up
S/N: 4EK1–Up
S/N: CRN1–Up
S/N: E6N1–Up

Illustration 357 g03475023

S/N: CSP1–Up
S/N: E6R1–Up
10. Install cover assembly (2), the studs, and nuts (1).
Tighten the studs to a torque of 35 ± 5 N·m S/N: CPS1–Up
(25 ± 3 lb ft). Tighten nuts (1) to a torque of S/N: 6JW1–Up
27 ± 5 N·m (19 ± 3 lb ft).
S/N: 8PW1–Up
End By:
S/N: 9AW1–Up
a. Install the water pump.
S/N: E6W1–Up
S/N: CPY1–Up
S/N: E6Y1–Up
SENR6419 113
Disassembly and Assembly Section

S/N: CSZ1–Up
S/N: E6Z1–Up
S/N: ZAZ1–Up

Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

NOTICE
Water pumps may leak as a result of damaged face
seals. Relative movement between the shaft and the
housing may allow the drive shaft to contact the face
seal in the water pump. If contact occurs, the face
seal will be damaged, and very early hour failures can
result.

1. Refer to Special Instruction, REHS9244 for proper

water pump handling procedures prior to
installation.

Illustration 359 g01251960

4. Lubricate the O-ring seals on tube assembly (3)

with clean unused engine oil. Install tube assembly
(3).

5. Install support bracket (5) and the bolt.

6. Install the bolts and retainer (2) on elbow (1).

7. Install bolts (4) and the retainer.

8. Fill the cooling system to the correct level with

coolant. Refer to Operation and Maintenance
Illustration 358 g00592487
Manual, “Cooling System Coolant - Change”.
2. Ensure that the gasket for the water line adapter
i02502696
and the O-ring seal on the water pump are in the
correct position. Lubricate the O-ring seal with
clean unused engine oil. Thermostatic Valve - Remove
SMCS Code: 1355-011
3. Attach a suitable lifting device to water pump (8).
The weight of water pump (8) is approximately
38 kg (85 lb). Install water pump (8). Ensure that
Removal Procedure
the splines on water pump (8) are correctly NOTICE
positioned. Install bolts (6) and (7). Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
114 SENR6419
Disassembly and Assembly Section

i02502740
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
Thermostatic Valve -
nance, testing, adjusting and repair of the product. Be Disassemble
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling SMCS Code: 1355-015
any component containing fluids.
Disassembly Procedure
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies Start By:
suitable to collect and contain fluids on Caterpillar
products. a. Remove the thermostatic valve. Refer to
Disassembly and Assembly, “Thermostatic Valve -
Dispose of all fluids according to local regulations and Remove”.
mandates.
NOTICE
Keep all parts clean from contaminants.
1. Disconnect the supply line to the auxiliary water
pump. Plug all openings immediately. Contaminants may cause rapid wear and shortened
component life.

Illustration 360 g01252048

Typical example Illustration 362 g00593619

2. Remove clamps (3). 1. Remove tubes (1). Remove plug (6).

3. Remove bolts (1). Remove thermostatic valve (4) 2. Remove remaining bolt (7), upper housing (2), O-
and bracket (2). ring seal (3), thermostat (4), and lower housing (5).

Illustration 361 g01252049

Illustration 363 g01252074

4. Remove bolts (5) and separate thermostatic valve 3. Remove retaining screw (10) and seal (8), if
(4) from bracket (2). necessary.
SENR6419 115
Disassembly and Assembly Section

4. Remove bolt (9) and plate (11), if necessary. End By:

a. Install the thermostatic valve. Refer to Disassembly
i02502765 and Assembly, “Thermostatic Valve - Install”.
Thermostatic Valve - Assemble i02502788
SMCS Code: 1355-016
Thermostatic Valve - Install
Assembly Procedure SMCS Code: 1355-012
NOTICE
Keep all parts clean from contaminants. Installation Procedure
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.

Illustration 364 g01252074

1. Install plate (11) and bolt (9), if necessary.

Illustration 366 g01252049

2. Install seal (8) and retaining screw (10), if

necessary. 1. Position bracket (2) on thermostatic valve (4) and
install bolts (5).

Illustration 365 g00593619

Illustration 367 g01252048

3. Assemble lower housing (5), thermostat (4), O-ring

seal (3), upper housing (2), and bolt (7). 2. Position thermostatic valve (4) and bracket (2) on
the engine and install bolts (1).
4. Install plug (6) and tubes (1).
3. Install clamps (3).
116 SENR6419
Disassembly and Assembly Section

4. Connect the supply line to the auxiliary water S/N: E6W1–Up

pump.
S/N: CPY1–Up

i02502887 S/N: E6Y1–Up

S/N: CSZ1–Up
Auxiliary Water Pump -
S/N: E6Z1–Up
Remove
S/N: ZAZ1–Up
SMCS Code: 1371-011

S/N: E621–Up Removal Procedure

Table 21
S/N: TJ21–Up
Required Tools
S/N: WC21–Up
Tool Part Number Part Description Qty
S/N: WC31–Up
A 138-7573 Link Bracket 2
S/N: TJ41–Up
S/N: TJ61–Up NOTICE
S/N: WC61–Up Keep all parts clean from contaminants.

S/N: TJ71–Up Contaminants may cause rapid wear and shortened

component life.
S/N: WC71–Up
S/N: WC81–Up
NOTICE
S/N: E8A1–Up Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
S/N: ZBA1–Up nance, testing, adjusting and repair of the product. Be
S/N: CRC1–Up prepared to collect the fluid with suitable containers
before opening any compartment or disassembling
S/N: E2C1–Up any component containing fluids.
S/N: E8C1–Up Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies
S/N: 4WD1–Up suitable to collect and contain fluids on Caterpillar
products.
S/N: 5JD1–Up
S/N: 8LD1–Up Dispose of all fluids according to local regulations and
mandates.
S/N: E2E1–Up
S/N: 9TG1–Up 1. Drain the coolant from the cooling system into a
suitable container for storage or disposal. Refer to
S/N: CPG1–Up
Operation and Maintenance Manual, “Cooling
S/N: 7NJ1–Up System Coolant - Change”.
S/N: CPJ1–Up
S/N: 4EK1–Up
S/N: CRN1–Up
S/N: E6N1–Up
S/N: CSP1–Up
S/N: E6R1–Up
S/N: CPS1–Up
S/N: 6JW1–Up
S/N: 8PW1–Up
S/N: 9AW1–Up
SENR6419 117
Disassembly and Assembly Section

Illustration 368 g01252192 Illustration 371 g01252196

2. Remove clamps (1). 7. Remove bolts (10) and adapter (11).

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

Illustration 372 g01252198

Illustration 369 g00592165 8. Remove the bearing from adapter (11), if

necessary.
4. Remove the bolts that hold harness assembly (6)
to the engine oil pan. 9. Remove O-ring seal (12) from adapter (11).

5. Remove bolts (5) and bolt (7) from auxiliary water

pump (4).

Illustration 373 g01252200

10. Attach Tooling (A) and a suitable lifting device to

Illustration 370 g00592166 auxiliary water pump (4). The weight of auxiliary
water pump (4) is approximately 39 kg (86 lb).
6. Remove bolts (8) and cover (9).
118 SENR6419
Disassembly and Assembly Section

11. Pull auxiliary water pump (4) and the drive gear S/N: E6W1–Up
out of the front housing. Remove auxiliary water
S/N: CPY1–Up
pump (4).
S/N: E6Y1–Up
i02503016
S/N: CSZ1–Up
Auxiliary Water Pump - S/N: E6Z1–Up
Disassemble S/N: ZAZ1–Up
SMCS Code: 1361-015
Disassembly Procedure
S/N: E621–Up Table 22

S/N: TJ21–Up Required Tools

S/N: WC21–Up Tool Part Number Part Description Qty

S/N: WC31–Up 5F-7465 Puller 1

4B-3903 Bolt 2
S/N: TJ41–Up
A 9M-1974 Hard Washer 2
S/N: TJ61–Up
5P-8245 Hard Washer 2
S/N: WC61–Up
1P-0458 Drive Plate 1
S/N: TJ71–Up
S/N: WC71–Up Start By:

S/N: WC81–Up a. Remove the auxiliary water pump. Refer to

Disassembly and Assembly, “Auxiliary Water
S/N: E8A1–Up Pump - Remove”.
S/N: ZBA1–Up
NOTICE
S/N: CRC1–Up Keep all parts clean from contaminants.
S/N: E2C1–Up Contaminants may cause rapid wear and shortened
component life.
S/N: E8C1–Up
S/N: 4WD1–Up
NOTICE
S/N: 5JD1–Up Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
S/N: 8LD1–Up nance, testing, adjusting and repair of the product. Be
S/N: E2E1–Up prepared to collect the fluid with suitable containers
before opening any compartment or disassembling
S/N: 9TG1–Up any component containing fluids.
S/N: CPG1–Up Refer to Special Publication, NENG2500, “Caterpillar
S/N: 7NJ1–Up Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
S/N: CPJ1–Up products.

S/N: 4EK1–Up Dispose of all fluids according to local regulations and

mandates.
S/N: CRN1–Up
S/N: E6N1–Up
S/N: CSP1–Up
S/N: E6R1–Up
S/N: CPS1–Up
S/N: 6JW1–Up
S/N: 8PW1–Up
S/N: 9AW1–Up
SENR6419 119
Disassembly and Assembly Section

Illustration 374 g00592354 Illustration 377 g01252415

1. Remove O-ring seals (3) and (4).

2. Remove the bolts and gear (2) from shaft (1).

Personal injury can result from parts and/or cov-
ers under spring pressure.
Spring force will be released when covers are
removed.
Be prepared to hold spring loaded covers as the
bolts are loosened.

5. Remove spring (8) from carbon seal assembly (9).

Remove carbon seal assembly (9) from shaft (7).
Note: The rubber ring and ceramic seal (10) will be
removed in Step 8.

Illustration 375 g00592355

3. Remove the bolts and adapter (5) from the

housing. Remove the O-ring seal from adapter (5).

Illustration 378 g01252418

6. Remove the bolts that hold retaining washers (11)

on the housing. Remove shaft (1) and retaining
washers (11).

Illustration 376 g01252413

4. Use Tooling (A) to remove impeller (6) from the

shaft.
120 SENR6419
Disassembly and Assembly Section

i02733486

Auxiliary Water Pump -

Assemble
SMCS Code: 1361-016

S/N: E621–Up
S/N: TJ21–Up
S/N: WC21–Up
S/N: WC31–Up
S/N: TJ41–Up
Illustration 379 g01252420 S/N: TJ61–Up

7. Remove the bolts that hold the shims and retaining S/N: WC61–Up
washers (12) on the housing. Remove shaft (7), S/N: TJ71–Up
the shims, and retaining washers (12).
S/N: WC71–Up
8. Remove the rubber ring and the ceramic seal from
S/N: WC81–Up
the housing. Refer to Illustration 377 .
S/N: E8A1–Up
S/N: ZBA1–Up
S/N: CRC1–Up
S/N: E2C1–Up
S/N: E8C1–Up
S/N: 4WD1–Up
S/N: 5JD1–Up
S/N: 8LD1–Up
S/N: E2E1–Up
S/N: 9TG1–Up
Illustration 380 g01252423
S/N: CPG1–Up
9. Remove lip seal (13) from the housing. S/N: 7NJ1–Up
S/N: CPJ1–Up
S/N: 4EK1–Up
S/N: CRN1–Up
S/N: E6N1–Up
S/N: CSP1–Up
S/N: E6R1–Up
S/N: CPS1–Up
S/N: 6JW1–Up
S/N: 8PW1–Up
S/N: 9AW1–Up
Illustration 381 g01252424
S/N: E6W1–Up
10. Remove bearing (14). S/N: CPY1–Up
SENR6419 121
Disassembly and Assembly Section

S/N: E6Y1–Up
S/N: CSZ1–Up
S/N: E6Z1–Up
S/N: ZAZ1–Up

Assembly Procedure
Table 23
Required Tools

Tool Part Number Part Description Qty

B 1P-0510 Driver Group 1

Illustration 382 g01252599

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Illustration 383 g01252424

1. Ensure that the oil hole in the bearing is aligned

with the oil passage in housing (15). Use Tooling
(B) and a suitable press to install bearing (14) in
housing (15). Bearing (14) must be 1.5 ± 0.5 mm
(0.06 ± 0.02 inch) below the surface of the
housing. The diameter of bearing (14) must be
75.000 ± 0.055 mm (2.9527 ± 0.0022 inch) after
installation.
122 SENR6419
Disassembly and Assembly Section

NOTICE
Clean water is the only lubricant that is permitted for
assembly. DO NOT damage or touch the wear surfa-
ces of the carbon ring or the ceramic ring. Install the
ceramic ring with the smoothest face of the ring to-
ward the carbon seal.

Illustration 384 g01252620

2. Use Tooling (B) to install lip seal (13) in housing

(15). Ensure that the lip of the seal is toward the
bearing. Place clean engine oil on the lip seal.

Illustration 387 g01252650

5. Install ceramic seal (10) in the rubber ring. Place

clean water on the rubber ring and ceramic seal
(10) for lubrication. Use hand pressure and the
Tooling that is supplied with the seal group to
install the ceramic seal.

Illustration 385 g01252420

3. Install shaft (7), retaining washers (12), the shims,

and the bolts that hold shaft (7) in the housing.

Illustration 388 g01252659

6. Remove the spring from carbon seal assembly (9).

Place clean water on the inside diameter of the
carbon seal assembly for lubrication. Use hand
pressure and the Tooling that is supplied with the
seal group in order to install carbon seal assembly
(9). The face of the seal should make light contact
Illustration 386 g01252622 with the shaft.

4. Place clean engine oil on the bearing in the

housing. Install shaft (1) and retaining washers
(11) on shaft (7). Install retaining washers (11) and
the bolts on the housing.
SENR6419 123
Disassembly and Assembly Section

Illustration 389 g01252660 Illustration 391 g00592355

9. Install the O-ring seal around adapter (5). Place

clean engine oil on the O-ring seal.
Improper assembly of parts that are spring loaded
10. Position adapter (5) on the housing and install the
can cause bodily injury.
bolts.
To prevent possible injury, follow the established
assembly procedure and wear protective
equipment.

7. Install spring (8) on carbon seal assembly (9).

Illustration 392 g00592354

11. Place gear (2) on shaft (1) and install the bolts.

12. Install O-ring seals (3) and (4) on the housing.

Illustration 390 g01252664 Place clean engine oil on the O-ring seals.
End By:
8. Place clean engine oil on the shaft prior to
installation of impeller (6). Install impeller (6) on the a. Install the auxiliary water pump. Refer to
shaft. Use a suitable press to install impeller (6). Disassembly and Assembly, “Auxiliary Water
Install the impeller until the distance between the Pump - Install”.
face of the impeller and the face of the shaft is
0.000 ± 0.076 mm (0.0000 ± 0.0030 inch). i02503697

Auxiliary Water Pump - Install

SMCS Code: 1371-012

S/N: E621–Up
S/N: TJ21–Up
S/N: WC21–Up
S/N: WC31–Up
124 SENR6419
Disassembly and Assembly Section

S/N: TJ41–Up Installation Procedure

Table 24
S/N: TJ61–Up
Required Tools
S/N: WC61–Up
Tool Part Number Part Description Qty
S/N: TJ71–Up
A 138-7573 Link Bracket 2
S/N: WC71–Up
B 1P-0510 Driver Group 1
S/N: WC81–Up
S/N: E8A1–Up
NOTICE
S/N: ZBA1–Up Keep all parts clean from contaminants.
S/N: CRC1–Up Contaminants may cause rapid wear and shortened
component life.
S/N: E2C1–Up
S/N: E8C1–Up 1. Install the O-ring seal on the auxiliary water pump.
S/N: 4WD1–Up Place clean engine oil on the O-ring seal.

S/N: 5JD1–Up
S/N: 8LD1–Up
S/N: E2E1–Up
S/N: 9TG1–Up
S/N: CPG1–Up
S/N: 7NJ1–Up
S/N: CPJ1–Up
S/N: 4EK1–Up
S/N: CRN1–Up
S/N: E6N1–Up Illustration 393 g01252200
S/N: CSP1–Up
2. Attach Tooling (A) and a suitable lifting device to
S/N: E6R1–Up auxiliary water pump (4). The weight of auxiliary
S/N: CPS1–Up water pump (4) is approximately 39 kg (86 lb).
Align auxiliary water pump (4) in the front housing.
S/N: 6JW1–Up
S/N: 8PW1–Up
S/N: 9AW1–Up
S/N: E6W1–Up
S/N: CPY1–Up
S/N: E6Y1–Up
S/N: CSZ1–Up
S/N: E6Z1–Up
S/N: ZAZ1–Up

Illustration 394 g00592165

3. Install the bolt that holds harness assembly (6) to

the engine oil pan.
SENR6419 125
Disassembly and Assembly Section

4. Install bolts (5) and bolt (7) in auxiliary water pump

(4).

Illustration 397 g01252196

7. Install adapter (11) and bolts (10) in the front

Illustration 395 g01252818 housing.

5. Ensure that the oil hole in the bearing is aligned

with the oil passage in adapter (11). Use Tooling
(B) and a suitable press to install the bearing in
adapter (11). The bearing must be 1.5 ± 0.5 mm
(0.06 ± 0.02 inch) below the surface of the adapter.
The bearing should have a diameter of
75.000 ± 0.055 mm (2.9527 ± 0.0022 inch) after
installation.

Illustration 398 g00592166

8. Install the O-ring seal in cover (9) and place clean

engine oil on the O-ring seal. Install cover (9) and
bolts (8).

Illustration 396 g01252198

6. Install O-ring seal (12) on adapter (11). Place clean

engine oil on the O-ring seal.

Illustration 399 g01252192

9. Position the inlet elbow and install bolts (2).

10. Position the outlet elbow and install bolts (3).

126 SENR6419
Disassembly and Assembly Section

11. Install clamps (1). 4. Remove the bolt and clamp (1).

12. Fill the cooling system to the correct level with 5. Disconnect flange (5) and tube (4) from the adapter
coolant. Refer to Operation and Maintenance for the water line.
Manual, “Cooling System Coolant - Change”.

i01119364

Engine Oil Cooler - Remove

SMCS Code: 1378-011

Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Illustration 401 g00591629

NOTICE
Care must be taken to ensure that fluids are con- 6. Remove the bolts in elbow (6) and tube (7).
tained during performance of inspection, mainte- Remove the unit from the engine oil cooler bonnet.
nance, testing, adjusting and repair of the product. Be
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling
any component containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and sup-
plies suitable to collect and contain fluids on Caterpil-
lar 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.

2. Drain the engine oil from the oil cooler into a Illustration 402 g00591631
suitable container for storage or disposal.
7. Disconnect wiring harness (12) for the detonation
sensor.
8. Attach a suitable lifting device to the engine oil
cooler. Remove two bolts (8) and two bolts (11).

9. Remove engine oil cooler (10) from tube (9) and

remove tube (2). The weight of the engine oil
cooler is approximately 45 kg (100 lb) on G3508
Engines. The weight of the engine oil cooler is
approximately 65 kg (145 lb) on G3512 Engines.
The weight of the engine oil cooler is
approximately 78 kg (171 lb) on G3516 Engines.

Illustration 400 g00591628

3. Remove the bolts and retainers (3) from both ends

of tube (2).
SENR6419 127
Disassembly and Assembly Section

i02503929

Engine Oil Cooler -

Disassemble
SMCS Code: 1378-015

Disassembly Procedure
Start By:
a. Remove the engine oil cooler. Refer to
Disassembly and Assembly, “Engine Oil Cooler -
Remove”.
Note: Check the O-ring seals, the gaskets, and the
Illustration 404 g01004559
seals for wear or for damage. Replace the
components, if necessary.
3. Place an identification mark on bonnet (4) and on
NOTICE engine oil cooler core (3) for assembly purposes.
Keep all parts clean from contaminants. Remove bonnet (4) from engine oil cooler core (3).

Contaminants may cause rapid wear and shortened

component life.

Illustration 403 g01004313

1. Remove the bolts from elbow (1). Remove elbow

(1) and tube (2) from the engine oil cooler. Illustration 405 g01004658

2. Remove tube (2) and the O-ring seals from elbow 4. Remove the bolts and elbow (5) from the engine oil
(1). cooler bypass. Remove the O-ring seals from
elbow (5).

5. Remove flange (8) and tube (7) from bonnet (6).

Remove the O-ring seals from tube (7).
128 SENR6419
Disassembly and Assembly Section

9. Remove cover (14) and the O-ring seal, if

necessary.

i02503999

Engine Oil Cooler - Assemble

SMCS Code: 1378-016

Assembly Procedure
Note: Check the O-ring seals, the gaskets, and the
seals for wear or for damage. Replace the
components, if necessary.
Note: Lubricate the O-ring seals with the oil that is
being used.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
Illustration 406 g01004704 component life.

Personal injury can result from parts and/or cov-

ers under spring pressure.
Spring force will be released when covers are
removed.
Be prepared to hold spring loaded covers as the
bolts are loosened.

6. Remove bolts (13), cover (9), O-ring seal (10),

spring (11), and bypass valve (12) from elbow (5).

Illustration 408 g01004839

Note: Make sure that you do not damage the

tubes in engine oil cooler core (3) during the
cleaning.
1. Make sure that the tubes in engine oil cooler core
Illustration 407 g01253217
(3) are clean.

7. Place an identification mark on bonnet (6) and on

engine oil cooler core (3) for assembly purposes.
Remove bonnet (6) and the gasket.

8. Remove drain plug (15) and the O-ring seal, if

necessary.
SENR6419 129
Disassembly and Assembly Section

Illustration 409 g01253217

2. Install the O-ring seal and cover (14), if necessary.

3. Install the O-ring seal and drain plug (15), if

necessary.

4. Install the gasket and bonnet (6) on engine oil

Illustration 411 g01004658
cooler core (3) in the orientation that was noted
during the disassembly procedure. Install the bolts.
6. Install the O-ring seals on tube (7) and lubricate the
O-ring seals with clean engine oil. Install tube (7)
and flange (8) on bonnet (6).

7. Install the O-ring seal on elbow (5) and install

elbow (5) on the engine oil cooler with the bolts.

Illustration 412 g01004559

Illustration 410 g01004704
8. Install the gasket and bonnet (4) on engine oil
cooler core (3) in the location that was marked
during the disassembly procedure. Install the bolts
Improper assembly of parts that are spring loaded in bonnet (4).
can cause bodily injury.
To prevent possible injury, follow the established
assembly procedure and wear protective
equipment.

5. Install bypass valve (12) and spring (11) in elbow

(5). Install O-ring seal (10) and lubricate the O-ring
seal with clean engine oil. Install cover (9) and
bolts (13).
130 SENR6419
Disassembly and Assembly Section

Illustration 413 g01004313 Illustration 414 g00591631

9. Install the O-ring seals on both ends of tube (2). 1. Ensure that the O-ring seals are in position on
Lubricate the O-ring seals with clean engine oil. tubes (2) and (9). Place clean engine oil on the
Install tube (2) in elbow (1). seals.

10. Install the O-ring seal on elbow (1) and lubricate 2. Attach a suitable lifting device to engine oil cooler
the O-ring seal with clean engine oil. Install elbow (10) and install tube (2).
(1) and tube (2) with the bolts on the engine oil
cooler core. 3. Install engine oil cooler (10) on tube (9). Ensure
that tube (2) is in the correct position in the adapter
End By: of the engine oil filter housing.
a. Install the engine oil cooler. Refer to Disassembly 4. Install two bolts (8).
and Assembly, “Engine Oil Cooler - Install”.
5. Install two bolts (11) and remove the lifting device.
i01119499

Engine Oil Cooler - Install

SMCS Code: 1378-012

Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Illustration 415 g00591629

6. Place clean engine oil on the O-ring seal on the

end of tube (7). Install elbow (6) and tube (7) in the
engine oil cooler bonnet. Ensure that the gasket is
in place and install the bolts.
SENR6419 131
Disassembly and Assembly Section

NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product. Be
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling
any component containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
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.
Illustration 416 g00591628
1. Drain the coolant from the cooling system into a
7. Install the gasket and the bolts that hold flange (5) suitable container for storage or disposal. Refer to
and tube (4). Operation and Maintenance Manual, “Cooling
System Coolant - Change”.
8. Install clamp (1) and the bolts that hold tube (2) on
the engine.

9. Install retainers (3) and the bolts on the ends of

tube (2).

10. Check the oil level in the engine. Add engine oil, if
necessary. Fill the coolant system to the correct
level with coolant. Refer to the Operation and
Maintenance Manual for the correct procedure.

i02504072

Engine Oil Pump - Remove

SMCS Code: 1304-011
Illustration 417 g01253311
Removal Procedure
Table 25 2. Remove bolts (2), (3), and (4). Remove adapter
(1).
Required Tools

Tool Part Number Part Description Qty

A 138-7573 Link Bracket 2

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Illustration 418 g01253313

3. Remove bolts (7). Remove elbow (6) and tube (5).

4. Remove the flange and tube (8) from the engine oil
cooler bonnet.
132 SENR6419
Disassembly and Assembly Section

NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product. Be
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling
any component containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
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.
Illustration 419 g00591832

5. Attach Tooling (A) and a suitable lifting device to

engine oil pump (9). The weight of engine oil pump
(9) is approximately 39 kg (86 lb).

6. Remove bolts (10) and (11). Disconnect clip (12).

7. Remove engine oil pump (9).

i02504081

Engine Oil Pump -

Disassemble
SMCS Code: 1304-015
Illustration 420 g00591928

Disassembly Procedure
Table 26
Required Tools

Tool Part Number Part Description Qty

A 1P-0510 Driver Group 1

Start By:
a. Remove the engine oil pump. Refer to
Disassembly and Assembly, “Engine Oil Pump -
Remove”.

NOTICE
Keep all parts clean from contaminants. Illustration 421 g00591930

Contaminants may cause rapid wear and shortened

component life.

Personal injury can result from parts and/or cov-

ers under spring pressure.
Spring force will be released when covers are
removed.
Be prepared to hold spring loaded covers as the
bolts are loosened.
SENR6419 133
Disassembly and Assembly Section

1. Remove bolts (1), cover (2), gasket (3), spring (4),

and valve spool (5) from the engine oil pump.

Illustration 425 g00591963

5. Remove shaft assemblies (10) from engine oil

Illustration 422 g00591932 pump (9).

2. Remove cover assembly (6) and the gasket from

the engine oil pump.

Illustration 426 g00591964

6. Inspect gears (11) for wear and for defects.

Illustration 423 g00591936

3. Remove cover assembly (7) from the engine oil

pump.

Illustration 427 g00591965

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

bearings (12) from engine oil pump (9).
Illustration 424 g00591962

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

bearings (8) from cover assembly (7).
134 SENR6419
Disassembly and Assembly Section

i02504083

Engine Oil Pump - Assemble

SMCS Code: 1304-016

Assembly Procedure
Table 27
Required Tools

Tool Part Number Part Description Qty

A 1P-0510 Driver Group 1

NOTICE Illustration 429 g00591964

Keep all parts clean from contaminants.
3. Replace gears (11) and the shaft assemblies, if
Contaminants may cause rapid wear and shortened
necessary.
component life.

Illustration 430 g00591963

Illustration 428 g01253344
4. Install shaft assemblies (10) in engine oil pump (9).
1. Align bearings (12) in the body of engine oil pump
(9). The bearing joints should be 45 ± 15 degrees
from the centerline of the bearing bores.

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

bearings (12). The bearings must be 1.5 ± 0.5 mm
(0.06 ± 0.02 inch) below the gear bore. The
diameter of the bearings must be
31.811 ± 0.013 mm (1.2524 ± 0.0005 inch) after
installation.
SENR6419 135
Disassembly and Assembly Section

Illustration 431 g01253345 Illustration 433 g01253349

8. Ensure that the pins in cover assembly (6) are

installed at a distance of 6.0 ± 1.0 mm
(0.24 ± 0.04 inch) above the surface of the cover.

9. Install the gasket and cover assembly (6) on the

engine oil pump.

Illustration 432 g00591962

5. Ensure that dowels (13) and (14) are installed in

cover assembly (7) at a distance of 6.0 ± 0.5 mm
(0.24 ± 0.02 inch) above the surface of the cover.

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

bearings (8) in cover assembly (7) with the bearing
joints in the correct position. The bearing joints
should be 45 ± 15 degrees from the centerline of
the bearing bores.

7. Install cover assembly (7) on the engine oil pump.

136 SENR6419
Disassembly and Assembly Section

i02504111

Engine Oil Pump - Install

SMCS Code: 1304-012

Installation Procedure
Table 28
Required Tools

Tool Part Number Part Description Qty

A 138-7573 Link Bracket 2

Illustration 434 g00591930

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Illustration 435 g00591928

Illustration 436 g00591832

Improper assembly of parts that are spring loaded
can cause bodily injury. 1. Place clean engine oil on the O-ring seals. Attach
To prevent possible injury, follow the established Tooling (A) and a suitable lifting device to engine
assembly procedure and wear protective oil pump (9). The weight of engine oil pump (9) is
equipment. approximately 39 kg (86 lb).

10. Place clean engine oil on valve spool (5). Install 2. Ensure that the splines on the shaft of engine oil
spring (4), gasket (3), cover (2), and bolts (1). pump (9) are correctly engaged with the splines of
the engine oil pump drive gear. Install bolts (10)
End By: and (11).
a. Install the engine oil pump. Refer to Disassembly
and Assembly, “Engine Oil Pump - Install”. 3. Connect clip (12).
SENR6419 137
Disassembly and Assembly Section

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Illustration 437 g01253313

4. Place clean engine oil on the O-ring seals and

install tube (5) in elbow (6). Install bolts (7).

5. Place clean engine oil on the O-ring seals and

install tube (8) and the flange on the engine oil
Illustration 439 g00590926
cooler bonnet.
1. Remove bolts (2) and adapter (1).

Illustration 438 g01253311

6. Install the gaskets and adapter (1) with bolts (2),

(3), and (4).

7. Fill the cooling system to the correct level with

coolant. Refer to Operation and Maintenance
Manual, “Cooling System Coolant - Change”.
Illustration 440 g01253416
i02504203
2. Remove clip (3).
Engine Oil Filter Housing - 3. Disconnect tube assembly (6) from pressure
Remove sensor (7).
SMCS Code: 1306-011
4. Disconnect harness assembly (9).
Removal Procedure 5. Remove pressure sensor (7) and the mounting
Table 29 plate with bolts (8).
Required Tools
6. Remove bolts (4).
Tool Part Number Part Description Qty

A 138-7573 Link Bracket 2

138 SENR6419
Disassembly and Assembly Section

7. Attach Tooling (A) and a suitable lifting device to

NOTICE
engine oil filter housing (5). The weight of engine
Care must be taken to ensure that fluids are con-
oil filter housing (5) is approximately 95 kg (210 lb) tained during performance of inspection, mainte-
. nance, testing, adjusting and repair of the product. Be
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling
any component containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
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.

Illustration 441 g01253439

8. Remove bolts (10).

9. Remove engine oil filter housing (5).

10. Inspect the condition of the O-ring seals.

i02504298

Engine Oil Filter Housing -

Disassemble Illustration 442 g00591497

SMCS Code: 1306-015

Disassembly Procedure Personal injury can result from parts and/or cov-
Start By: ers under spring pressure.

a. Remove the engine oil filter housing. Refer to Spring force will be released when covers are
Disassembly and Assembly, “Engine Oil Filter removed.
Housing - Remove”. Be prepared to hold spring loaded covers as the
bolts are loosened.
NOTICE
Keep all parts clean from contaminants. 1. Remove the bolts and cover (1).
Contaminants may cause rapid wear and shortened
component life.
SENR6419 139
Disassembly and Assembly Section

Illustration 443 g00591498 Illustration 446 g00591504

2. Remove retainer (2), spring (3), and O-ring seal (4) 6. Remove adapter (8). Remove O-ring seal (9) from
from cover (1). the adapter.

Illustration 444 g00591500 Illustration 447 g00591541

3. Remove engine oil filter elements (5). 7. Remove O-ring seal (11) and pins (10), if
necessary.

Illustration 445 g00591502

Illustration 448 g00591544
4. Remove O-ring seals (7).
8. Remove nuts (12) and the bolts from support (13).
5. Remove the bolts and bypass valve housing (6).
The weight of bypass valve housing (6) is
approximately 43 kg (95 lb).
140 SENR6419
Disassembly and Assembly Section

Illustration 449 g00591545 Illustration 451 g00591547

12. Remove bolts (22), cover (23), and the O-ring

seals from the housing.
Personal injury can result from parts and/or cov-
13. Remove O-ring seal (25) and pin (24), if
ers under spring pressure.
necessary.
Spring force will be released when covers are
removed. i02505235

Be prepared to hold spring loaded covers as the

bolts are loosened. Engine Oil Filter Housing -
Assemble
9. Remove bolts (14) and (16). Also remove covers
(15) and (17). SMCS Code: 1306-016

Assembly Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Illustration 450 g00591546

10. Remove O-ring seals (20) and (21).

11. Remove spring (19) and bypass valve (18).

Illustration 452 g00591547

1. Install the O-ring seals on the housing. Install cover

(23) and bolts (22).

2. Install O-ring seal (25).

SENR6419 141
Disassembly and Assembly Section

3. Install pin (24), if necessary. The pin must be

6.50 ± 1.00 mm (0.256 ± 0.040 inch) above the
surface of the housing.

Illustration 455 g00591544

7. Install support (13), the bolts, and nuts (12).

Tighten the nuts to a torque of 55 ± 7 N·m
Illustration 453 g00591546 (41 ± 5 lb ft).

4. Install bypass valve (18) and spring (19).

5. Install O-ring seals (20) and (21).

Illustration 456 g00591541

8. Install O-ring seal (11).

Illustration 454 g00591545 9. Install new pins (10) in the bypass valve housing, if
necessary. The pins must be 6.50 ± 1.00 mm
(0.256 ± 0.040 inch) above the surface of the
housing.
Improper assembly of parts that are spring loaded
can cause bodily injury.
To prevent possible injury, follow the established
assembly procedure and wear protective
equipment.

6. Install covers (15) and (17). Install bolts (14) and

(16).
142 SENR6419
Disassembly and Assembly Section

Illustration 457 g00591504 Illustration 459 g00591500

10. Install adapter (8). Install O-ring seal (9) on 13. Install new engine oil filter elements (5).
adapter (8) and lubricate the seal with clean
engine oil.

Illustration 460 g00591498

Illustration 458 g00591502 14. Install O-ring seal (4), spring (3), and retainer (2)
on cover (1).
11. Install bypass valve housing (6). The weight of
bypass valve housing (6) is approximately 43 kg
(95 lb). Tighten the bolts to a torque of 55 ± 7 N·m
(41 ± 5 lb ft).

12. Install O-ring seals (7).

SENR6419 143
Disassembly and Assembly Section

Illustration 461 g00591497 Illustration 462 g01253439

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

engine oil filter housing (5). The weight of engine
Improper assembly of parts that are spring loaded oil filter housing (5) is approximately 95 kg (210 lb)
can cause bodily injury. . Position engine oil filter housing (5) on the
engine.
To prevent possible injury, follow the established
assembly procedure and wear protective 3. Install bolts (10) that hold engine oil filter housing
equipment. (5) to the engine.

15. Install cover (1) and the bolts.

End By:
a. Install the engine oil filter housing. Refer to
Disassembly and Assembly, “Engine Oil Filter
Housing - Install”.

i02505264

Engine Oil Filter Housing -

Install
SMCS Code: 1306-012

Installation Procedure
Table 30
Required Tools

Tool Part Number Part Description Qty

A 138-7573 Link Bracket 2

Illustration 463 g01253416

NOTICE 4. Install bolts (4).

Keep all parts clean from contaminants.
5. Install pressure sensor (7) and the mounting plate
Contaminants may cause rapid wear and shortened with bolts (8).
component life.
6. Connect harness assembly (9).
1. Inspect the condition of the O-ring seals. Replace
7. Connect tube assembly (6) to pressure sensor (7).
the O-ring seals, if necessary.
8. Install clip (3).
144 SENR6419
Disassembly and Assembly Section

Illustration 464 g00590926 Illustration 466 g00590550

Typical example
9. Install adapter (1) and bolts (2).
2. Remove bolts (4) and front adapter assembly (3).
i02505706
i02505747
Engine Oil and Water Pump
Drive - Remove Engine Oil and Water Pump
SMCS Code: 1313-011 Drive - Disassemble
SMCS Code: 1313-015
Removal Procedure
Start By: Disassembly Procedure
Table 31
a. Remove the engine oil pump. Refer to
Disassembly and Assembly, “Engine Oil Pump - Required Tools
Remove”. Part Description Qty
Tool Part Number
b. Remove the water pump. Refer to Disassembly A 1P-0520 Driver Group 1
and Assembly, “Water Pump - Remove”.

NOTICE Start By:

Keep all parts clean from contaminants.
a. Remove the engine oil and water pump drive.
Contaminants may cause rapid wear and shortened Refer to Disassembly and Assembly, “Engine Oil
component life. and Water Pump Drive - Remove”.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Illustration 465 g00590549

Typical example

1. Remove bolts (1) and rear adapter assembly (2).

SENR6419 145
Disassembly and Assembly Section

Illustration 467 g01254535 Illustration 469 g00590612

1. Remove O-ring seal (3). 5. Remove bolts (9) from shaft assembly (1). Remove
gears (8) and (10) from shaft assembly (1).
2. Remove the bolts and washers (2). Remove rear
adapter assembly (4) from shaft assembly (1).

Illustration 470 g00590613

Illustration 468 g01254536 6. Remove O-ring seal (13) from front adapter
assembly (12).
3. Remove O-ring seals (6) and (7) from rear adapter
assembly (4). 7. Use Tooling (A) and a suitable press to remove
bearing (11) from front adapter assembly (12).
4. Use Tooling (A) and a suitable press to remove
bearing (5).
i02505955

Engine Oil and Water Pump

Drive - Assemble
SMCS Code: 1313-016

Assembly Procedure
Table 32
Required Tools

Tool Part Number Part Description Qty

A 1P-0520 Driver Group 1

146 SENR6419
Disassembly and Assembly Section

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Illustration 473 g01254536

5. Lower the temperature of bearing (5). Align the oil

hole in the bearing with the oil hole that is in rear
adapter assembly (4). Use Tooling (A) and a
suitable press to install bearing (5).
Illustration 471 g00590613
6. Ensure that bearing (5) does not extend above the
surface of rear adapter assembly (4). Machine the
1. Lower the temperature of bearing (11). Use Tooling
bearing, if necessary. The bore in the bearing must
(A) and a suitable press to install bearing (11) in
be 75.00 ± 0.06 mm (2.953 ± 0.002 inch) after
front adapter assembly (12). Machine the bearing,
installation.
if necessary. The bore in the bearing must be
75.00 ± 0.06 mm (2.953 ± 0.002 inch) after 7. Install O-ring seals (6) and (7) on rear adapter
installation. assembly (4).
2. Install O-ring seal (13) on front adapter assembly
(12).

Illustration 474 g01254535

8. Install rear adapter assembly (4) on shaft assembly

Illustration 472 g00590612
(1).
3. Install gears (8) and (10) on shaft assembly (1). 9. Install washers (2) and the bolts.
4. Install bolts (9). 10. Install O-ring seal (3) on rear adapter assembly
(4).
End By:
a. Install the engine oil and water pump drive. Refer
to Disassembly and Assembly, “Engine Oil and
Water Pump Drive - Install”.
SENR6419 147
Disassembly and Assembly Section

i02505961 End By:

Engine Oil and Water Pump a. Install the water pump. Refer to Disassembly and
Assembly, “Water Pump - Install”.
Drive - Install
b. Install the engine oil pump. Refer to Disassembly
SMCS Code: 1313-012 and Assembly, “Engine Oil Pump - Install”.

Installation Procedure i02505991

NOTICE Engine Oil Pan - Remove

Keep all parts clean from contaminants.
SMCS Code: 1302-011
Contaminants may cause rapid wear and shortened
component life. Removal Procedure
1. Ensure that the O-ring seals are installed in the NOTICE
grooves of the adapter assemblies. Also apply Keep all parts clean from contaminants.
clean engine oil to the O-ring seals. Contaminants may cause rapid wear and shortened
component life.

NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product. Be
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling
any component containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Illustration 475 g00590550

Dispose of all fluids according to local regulations and
mandates.
Typical example

2. Install front adapter assembly (3) and bolts (4). 1. Drain the engine oil from the engine into a suitable
container for storage or disposal. Refer to
Operation and Maintenance Manual, “Engine Oil -
Change”.

Illustration 476 g00590549

Typical example

3. Install rear adapter assembly (2) and bolts (1). Illustration 477 g00590117

2. Remove bolts (1) that hold the adapter of the

engine oil pump to the engine oil pan.
148 SENR6419
Disassembly and Assembly Section

i01929669

Engine Oil Pan - Disassemble

SMCS Code: 1302-015

Disassembly Procedure
Start By:
a. Remove the engine oil pan. Refer to Disassembly
and Assembly, “Engine Oil Pan - Remove”.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
Illustration 478 g01254661 component life.
Typical example

3. Remove bolts (2) that hold engine oil pan (3) to the
engine.

4. Lift the engine off the engine oil pan. The engines
have the following weights:

• G3508Engines weigh approximately 4300 kg

(9500 lb).

• G3512Engines weigh approximately 5443 kg

(12000 lb).

• G3516Engines weigh approximately 6440 kg

(14200 lb).
Illustration 479 g00590183
5. The engine oil pans have the following weights:
1. Remove cover (1), cover (2), and the O-ring seals.
• G3508 engine oil pan weighs approximately
295 kg (650 lb).

• G3512 engine oil pan weighs approximately

364 kg (800 lb).

• G3516 engine oil pan weighs approximately

393 kg (865 lb).

Illustration 480 g00590204

2. Remove screen assembly (3).

SENR6419 149
Disassembly and Assembly Section

6. Remove housing (6).

7. Remove tube assembly (7) and the O-ring seals.

i01929671

Engine Oil Pan - Assemble

SMCS Code: 1302-016

Assembly Procedure

Illustration 481 g01004297

3. Remove engine oil level gauge (4).

Illustration 484 g00590209

1. Install tube assembly (7) and the O-ring seals.

2. Install housing (6).

3. Install tube assembly (7) into housing (6).

Illustration 482 g00590206

4. Remove bell (5) from the tube assembly.

Illustration 485 g00590206

4. Install bell (5) on the tube assembly.

Illustration 483 g00590209

5. Remove tube assembly (7) from housing (6).

150 SENR6419
Disassembly and Assembly Section

Illustration 488 g00590183

7. Install the O-ring seals on cover (1) and cover (2).

Install cover (1) and cover (2).
End By:

Illustration 486 g01004297 a. Install the engine oil pan. Refer to Disassembly
and Assembly, “Engine Oil Pan - Install”.
5. Install engine oil level gauge (4).
i02506269

Engine Oil Pan - Install

SMCS Code: 1302-012

Installation Procedure
Table 33
Required Tools

Tool Part Number Part Description Qty

Guide Bolt
A - 4
3/8 - 16 NC

Illustration 487 g00590204 NOTICE

Keep all parts clean from contaminants.
6. Install screen assembly (3). Contaminants may cause rapid wear and shortened
component life.

1. Ensure that the O-ring seal is installed on the

adapter of the engine oil pump and place clean
engine oil on the O-ring seal.

2. Install Tooling (A) in the engine oil pan and install

the gasket.
SENR6419 151
Disassembly and Assembly Section

Note: Refer to Specifications, “Engine Oil Pan” for

more information.
7. Fill the engine to the correct level with clean engine
oil. Refer to Operation and Maintenance Manual,
“Engine Oil - Change”.

i01112071

Crankcase Breather - Remove

and Install
SMCS Code: 1317-010

Illustration 489 g01254661 Removal Procedure

Typical example
NOTICE
Keep all parts clean from contaminants.
3. Lift the engine onto the engine oil pan. The engines
have the following weights: Contaminants may cause rapid wear and shortened
component life.
• G3508Engines weigh approximately 4300 kg
(9500 lb).
NOTICE
• G3512Engines weigh approximately 5443 kg Care must be taken to ensure that fluids are con-
(12000 lb). tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product. Be
• G3516Engines weigh approximately 6440 kg prepared to collect the fluid with suitable containers
(14200 lb). before opening any compartment or disassembling
any component containing fluids.
4. The engine oil pans have the following weights:
Refer to Special Publication, NENG2500, “Caterpillar
• G3508 engine oil pan weighs approximately Tools and Shop Products Guide” for tools and sup-
295 kg (650 lb). plies suitable to collect and contain fluids on Caterpil-
lar products.
• G3512 engine oil pan weighs approximately
Dispose of all fluids according to local regulations and
364 kg (800 lb).
mandates.
• G3516 engine oil pan weighs approximately
393 kg (865 lb).

5. Install bolts (2) on engine oil pan (3).

Illustration 490 g00590117

6. Install bolts (1) that hold the adapter of the engine

oil pump to the engine oil pan.
152 SENR6419
Disassembly and Assembly Section

i05844609

Valve Cover and Spark Plug -

Remove and Install
SMCS Code: 1107-010; 1555-010

Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Illustration 491 g00587344

1. Remove four bolts (2).

2. Remove crankcase breather (1) and the gasket.

Installation Procedure
NOTICE
Keep all parts clean from contaminants. Illustration 493 g00587197

Contaminants may cause rapid wear and shortened

component life. 1. Remove bolts (2), valve cover (1), and the seal.

Illustration 494 g01254714

2. Disconnect harness assembly (4) from transformer

(3).

Note: Some engines have a hold-down that must be

removed from the transformer.
Illustration 492 g00587344
3. Lift transformer (3) out of the cylinder head.
1. Install the gasket and crankcase breather (1).

2. Install four bolts (2).

SENR6419 153
Disassembly and Assembly Section

Illustration 495 g01254715 Illustration 497 g01254714

4. Remove O-ring seal (5) from transformer (3). 4. Set transformer (3) in the cylinder head. Push
down slightly in order to seat transformer (3).
5. Remove the spark plug from the cylinder head.
5. Connect harness assembly (4) to transformer (3).
6. Repeat the steps for the remaining valve covers
and the spark plugs.

Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

1. Inspect the condition of the seals and the gaskets.

Replace the seals and the gaskets, if necessary.

2. Install the spark plug in the cylinder head. Tighten

the spark plug to a torque of 50 ± 4 N·m
Illustration 498 g00587197
(37 ± 3 lb ft).
6. Install the seal and valve cover (1) on the cylinder
head.
7. Install bolts (2).

Illustration 496 g01254715

3. Install new O-ring seal (5) on transformer (3).

154 SENR6419
Disassembly and Assembly Section

i02506577 i02506654

Rocker Shaft and Push Rod - Rocker Shaft - Disassemble

Remove SMCS Code: 1102-015
SMCS Code: 1102-011; 1208-011
Disassembly Procedure
Removal Procedure Table 34

Start By: Required Tools

Tool Part Number Part Description Qty

a. Remove the valve cover and the spark plug. Refer
to Disassembly and Assembly, “Valve Cover and A 1P-0510 Driver Group 1
Spark Plug - Remove and Install”.

NOTICE Start By:

Keep all parts clean from contaminants.
a. Remove the rocker shaft assembly and the
Contaminants may cause rapid wear and shortened pushrods. Refer to Disassembly and Assembly,
component life. “Rocker Shaft and Push Rod - Remove”.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Illustration 499 g00587020

1. Remove bolts (1) and remove rocker shaft (2) from

the valve cover base.

Illustration 501 g00587082

1. Slide rocker shaft (1) out of rocker arms (3) and

spacer (2).

2. Remove dowel (4), if necessary.

Illustration 500 g00587021

Note: Place an identification mark on each pushrod in

order to identify the proper location in the engine.
2. Remove pushrods (4) from the valve lifters.

3. Remove valve bridges (3).

SENR6419 155
Disassembly and Assembly Section

Illustration 502 g00587083 Illustration 504 g01257432

3. Remove adjustment screw (5) and the nut from 7. Use Tooling (A) to remove bearing (9) from rocker
rocker arm (3). arm (3).

4. Use a hammer and a punch to remove socket (6) 8. Repeat the steps for the other rocker arm.
from rocker arm (3).
i02506663

Rocker Shaft - Assemble

SMCS Code: 1102-016

Assembly Procedure
Table 35
Required Tools

Tool Part Number Part Description Qty

A 1P-0510 Driver Group 1

NOTICE
Illustration 503 g01257431
Keep all parts clean from contaminants.
5. Remove O-ring seal (8) that holds button (7) in Contaminants may cause rapid wear and shortened
socket (6). component life.

6. Remove button (7).

Illustration 505 g01257432

1. Align the oil hole in bearing (9) with the oil passage
in rocker arm (3).
156 SENR6419
Disassembly and Assembly Section

2. Use Tooling (A) to install bearing (9) in rocker arm

(3). The bore of bearing (9) must be
37.140 ± 0.015 mm (1.4622 ± 0.0006 inch) after
assembly.

Illustration 508 g00587082

7. If dowel (4) was removed from rocker shaft (1),

install a new dowel. The new dowel must be
6.00 mm (0.236 inch) above the surface of rocker
shaft (1). The split in dowel (4) must be oriented
Illustration 506 g01257440 toward the end of rocker shaft (1).

8. Place clean engine oil on the bearings and rocker

shaft (1).

9. Install rocker arms (3) and spacer (2) on rocker

shaft (1).
End By:
a. Install the rocker shaft assembly and the pushrods.
Refer to Disassembly and Assembly, “Rocker
Shaft and Push Rod - Install”.

i02506699

Rocker Shaft and Push Rod -

Illustration 507 g00587083 Install
SMCS Code: 1102-012; 1208-012
3. Align the scribe mark on socket (6) with the mark
on rocker arm (3) and install socket (6).
Installation Procedure
4. Install button (7) and O-ring seal (8) in socket (6). Table 36
Required Tools
5. Install adjustment screw (5) and the nut on rocker
arm (3). Tool Part Number Part Description Qty

A 8T-2998 Lubricant -
6. Repeat the steps for the second rocker arm.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
SENR6419 157
Disassembly and Assembly Section

Illustration 509 g00587021 Illustration 510 g00587020

1. Loosen the adjustment screws on valve bridges 8. Install rocker shaft (2) on the valve cover base.
(3). Ensure that the rocker arms and the pushrods are
aligned.
2. Place clean engine oil on the dowels for valve
bridges (3), on the inside diameter of the valve 9. Install bolts (1). Tighten the bolts to a torque of
bridges, and on the top buffer of the valve bridges. 120 ± 20 N·m (90 ± 15 lb ft).

3. Install valve bridges (3) on the dowels. 10. Set the valve lash on the intake valve to a
clearance of 0.51 mm (0.020 inch). Set the valve
4. While valve bridges (3) are pushed straight down lash on the exhaust valve to a clearance of
with a force of 5 to 45 N (1 to 10 lb), turn the 1.27 mm (0.050 inch).
adjustment screw until the screw makes contact
with the valve stem. Turn the adjustment screw for 11. Refer to Testing and Adjusting, “Valve Lash and
an additional 20 or 30 degrees. This will align the Valve Bridge Adjustment” for more information.
valve bridge straight on the dowel. This also
End By:
compensates for the slack in the threads of the
adjustment screw. a. Install the spark plug and the valve cover. Refer to
Disassembly and Assembly, “Valve Cover and
5. Hold the adjustment screw in position and tighten Spark Plug - Remove and Install”.
the nut on the adjustment screw to a torque of
30 ± 4 N·m (22 ± 3 lb ft). i02506846

6. Apply Tooling (A) to the ends of pushrods (4). Cylinder Head - Remove
SMCS Code: 1100-011
NOTICE
Ensure that the crankshaft and the camshafts are in Removal Procedure
time with each other. Also ensure that the adjustment
Table 37
screws in the rocker arms are loosened completely
before the bolts on the rocker shaft are tightened or Required Tools
damage to the valves and the pistons may occur.
Tool Part Number Part Description Qty

A 138-7573 Link Bracket 2

7. Install pushrods (4) in the valve lifters.

Start By:
a. Remove the rocker shaft assemblies and the
pushrods. Refer to Disassembly and Assembly,
“Rocker Shaft and Push Rod - Remove”.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
158 SENR6419
Disassembly and Assembly Section

NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product. Be
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling
any component containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
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.
Illustration 512 g00585024

Note: Repeat the procedure for each cylinder head. Typical example

1. Drain the coolant from the cooling system into a 4. Remove bolts (6) from air inlet elbow (5).
suitable container for storage or disposal. Refer to
Operation and Maintenance Manual, “Cooling 5. Remove bolts (4) from exhaust elbow (7).
System Coolant - Change”.

Illustration 513 g01254926

Illustration 511 g00585022 Typical example

Typical example
6. Disconnect exhaust temperature sensor (8).
2. Remove bolts (3) from valve cover base (2).
7. Remove bolts (10) from tube (9) that runs from the
3. Remove valve cover base (3) from cylinder head water manifold to cylinder head (1). There are also
(1). bolts on the top of tube (9).

8. Attach Tooling (A) and a suitable lifting device to

cylinder head (1). The weight of cylinder head (1)
is approximately 47 kg (105 lb). Use the holes for
the bolts that hold the valve cover base.
9. Remove bolts (11) and bolts (12) from cylinder
head (1).

10. Remove cylinder head (1) from the engine.

SENR6419 159
Disassembly and Assembly Section

Illustration 514 g00585028 Illustration 515 g00598108

Typical example

11. Remove cylinder head gasket (13).

Personal injury can result from parts and/or cov-
i04326176 ers under spring pressure.

Cylinder Head - Disassemble Spring force will be released when covers are
removed.
SMCS Code: 1100-015
Be prepared to hold spring loaded covers as the
bolts are loosened.
Disassembly Procedure
Start By:
a. Remove the cylinder head.

Inlet and Exhaust Valves

Table 38
Required Tools

Tool Part Number Part Description Qty

A 5S-1330 Valve Spring Compressor 1

B 8S-2263 Spring Tester 1

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Illustration 516 g00618922

1. Use Tooling (A) to compress valve spring (1).

2. Remove retainer lock (2).

3. Remove Tooling (A). Remove the valve rotator and

spring (1).

4. Remove valve rotator (3), outer spring (5), inner

spring (4), and seal (6).
160 SENR6419
Disassembly and Assembly Section

Note: Place an identification mark on valves (7) for Inlet and Exhaust Valve Seat Inserts
the assembly procedure.
Table 40
Required Tools

Tool Part Number Part Description Qty

166-7441 Valve Seat Extractor 1

D
165-5647 Valve Seat Extractor 1

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Illustration 517 g00598111

5. Check the valve spring force with Tooling (B). Refer

to the Specifications Module for the correct spring
force values.
6. Repeat Steps 1 through 5 for the remaining valves.

Valve Train Bridge Dowels

Table 39
Required Tools

Tool Part Number Part Description Qty

Illustration 519 g01354109
5P-0944 Dowel Puller Group 1
C
5P-0942 Dowel Extractor 1 1. Use Tooling (D) to remove the valve seat inserts
from the cylinder head.

NOTICE 2. Thoroughly clean the valve seat bores.

Keep all parts clean from contaminants.
Inlet and Exhaust Valve Guides
Contaminants may cause rapid wear and shortened
component life. Table 41
Required Tools

Tool Part Number Part Description Qty

7M-3975 Valve Guide Driver 1

E
5P-1729 Valve Guide Bushing 1

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Illustration 518 g01051069

1. Use Tooling (C) to remove bridge dowel (8) from

the cylinder head.
SENR6419 161
Disassembly and Assembly Section

Illustration 520 g01354112 Illustration 522 g01051073

1. Use Tooling (E) and a hammer to remove the valve 2. Remove guide spring (10) from the valve lifter.
guides from the cylinder head.
i04326223
Valve Lifters
Cylinder Head - Assemble
NOTICE SMCS Code: 1100-016
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened Assembly Procedure
component life.
Valve Lifters
Note: The valve lifters may also be removed with the
cylinder head on the engine. Remove the camshaft NOTICE
and use the following steps in order to remove the Keep all parts clean from contaminants.
valve lifters with the cylinder head on the engine.
Contaminants may cause rapid wear and shortened
component life.

Illustration 521 g01354290

1. Pull valve lifter (9) out of the cylinder head. Illustration 523 g01051073

1. Install guide spring (10) in the valve lifter.

162 SENR6419
Disassembly and Assembly Section

2. Use Tooling (E) to install the valve guides. The

valve guide should extend 26.00 ± 0.50 mm
(1.024 ± 0.020 inch) above the surface of the
cylinder head.

Inlet and Exhaust Valve Seat Inserts

Table 43
Required Tools

Tool Part Number Part Description Qty

F 1P-0510 Driver Gp 1

Illustration 524 g01354290 NOTICE

Keep all parts clean from contaminants.
2. Place valve lifter (9) in a container of clean engine Contaminants may cause rapid wear and shortened
oil prior to installation. component life.
3. Install valve lifter (9) in the cylinder head.
Note: Refer to the Specifications Module, “Valve
Rocker Arms, Lifters, and Bridges” for additional
information.

Inlet and Exhaust Valve Guides

Table 42
Required Tools

Tool Part Number Part Description Qty

E 5P-1729 Valve Guide Bushing 1

NOTICE
Illustration 526 g01354361
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened 1. Cool valve seat inserts (11). Install valve seat
component life. inserts (11) with Tooling (F).

Illustration 525 g01354132

1. Place clean engine oil on the outside of the valve

guides prior to installation.
SENR6419 163
Disassembly and Assembly Section

Illustration 528 g01051069

1. Use Tooling (G) to install bridge dowels (8). The

bridge dowels must extend 66.5 ± 0.5 mm
(2.62 ± 0.02 inch) above the surface of the cylinder
head.
Illustration 527 g00598233
Inlet and Exhaust Valves
2. The orientation of the valve seat inserts is shown in
Table 45
Illustration 527 .
Required Tools
Valve Train Bridge Dowels Tool Part Number Part Description Qty

Table 44 A 5S-1330 Valve Spring Compressor 1

Required Tools

Tool Part Number Part Description Qty NOTICE

Keep all parts clean from contaminants.
G 6V-4009 Dowel Driver 1
Contaminants may cause rapid wear and shortened
component life.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
164 SENR6419
Disassembly and Assembly Section

End By:
a. Install the cylinder head.

i02506977

Cylinder Head - Install

SMCS Code: 1100-012

Installation Procedure
Table 46
Required Tools

Tool Part Number Part Description Qty

A 138-7573 Link Bracket 2

NOTICE
Keep all parts clean from contaminants.

Illustration 529 g00618922 Contaminants may cause rapid wear and shortened
component life.

Note: Repeat the procedure for each cylinder head.

Personal injury can result from parts and/or cov-
ers under spring pressure. 1. Clean the surface of the cylinder head and the
surface of the spacer plate. A new spacer plate
Spring force will be released when covers are gasket must be installed when the cylinder head is
removed.
removed.
Be prepared to hold spring loaded covers as the
bolts are loosened.

1. Place clean engine oil on valves (7) and install

valves (7) in the cylinder head.

2. Install seal (6), inner spring (4), outer spring (5),

and valve rotator (3) on the valve stem and the
valve guide.

3. Compress the valve spring with Tooling (A) and

install retainer lock (2).

Illustration 530 g00585028

If the valve locks are not positioned correctly, the
locks can be expelled when the spring pressure is Typical example
released.
2. Install cylinder head gasket (13).
To help prevent personal injury, stay away from
the front of the valve retainer and springs. Ensure
that the valve locks are positioned correctly.

4. Remove Tooling (A) and lightly tap the top of the

valves with a hammer. This will ensure that the
retainer locks are in the proper position.

5. Repeat Steps 1 through 4 for the remaining valves.

SENR6419 165
Disassembly and Assembly Section

Illustration 531 g00585054 Illustration 533 g00585055

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

NOTICE
The plug at Location (A) MUST be installed on en- cylinder head (1). The weight of cylinder head (1)
gines that are equipped with a dry exhaust manifold. is approximately 47 kg (105 lb). Position cylinder
REMOVE the plug on engines that are equipped with head (1) on the spacer plate.
a water cooled exhaust manifold.
4. Install bolts (11) and bolts (12) in the cylinder head.

5. Use the following procedure to tighten the cylinder

head bolts.
a. Apply clean engine oil to the threads of the
cylinder head bolts.

b. Tighten Bolt (1) through Bolt (8) in a numerical

sequence to a torque of 30 ± 5 N·m
(22 ± 4 lb ft).

c. Tighten Bolt (1) through Bolt (8) again in a

numerical sequence to a torque of
270 ± 35 N·m (200 ± 26 lb ft).

d. Tighten Bolt (1) through Bolt (8) again in a

Illustration 532 g01254926 numerical sequence to a torque of
Typical example 450 ± 20 N·m (330 ± 15 lb ft).

e. Tighten Bolt (9) and Bolt (10) to a torque of

55 ± 10 N·m (40 ± 7 lb ft).

6. Install bolts (10) in tube (9) that runs from the water
manifold to cylinder head (1). Also install the bolts
on the top of tube (9).

7. Connect exhaust temperature sensor (8).

166 SENR6419
Disassembly and Assembly Section

i02507010

Spacer Plate - Remove and

Install
SMCS Code: 1221-010

Removal Procedure
Start By:
a. Remove the cylinder head assembly. Refer to
Disassembly and Assembly, “Cylinder Head -
Remove”.

Illustration 534 g00585024

NOTICE
Keep all parts clean from contaminants.
Typical example
Contaminants may cause rapid wear and shortened
8. Install bolts (4) on exhaust elbow (7). component life.

9. Install bolts (6) on air inlet elbow (5).

Illustration 536 g01255067

Illustration 535 g00585022 Typical example
Typical example
1. Remove gasket (3), seals (1), seals (2), and O-ring
10. Position valve cover base (2) on cylinder head seal (4) from the spacer plate.
(1).

11. Install bolts (3) in valve cover base (2).

12. Fill the cooling system to the correct level with

coolant. Refer to Operation and Maintenance
Manual, “Cooling System Coolant - Change”.
End By:
a. Install the rocker shaft assemblies and the
pushrods. Refer to Disassembly and Assembly,
“Rocker Shaft and Push Rod - Install”.

Illustration 537 g00583156

Typical example

2. Remove spacer plate (5) from the dowels in the

cylinder block.
SENR6419 167
Disassembly and Assembly Section

Illustration 540 g00583158

Illustration 538 g00583157 Typical example
Typical example
2. Install the O-ring seal on dowel (7).
3. Remove gasket (6) from the dowels.

Illustration 541 g00583157

Illustration 539 g00583158 Typical example
Typical example
NOTICE
4. Remove the O-ring seal from dowel (7). Ensure that the surface of the spacer plate gasket
and the surface of the cylinder block are clean. Do
Installation Procedure not use a gasket adhesive on these surfaces.
NOTICE
Keep all parts clean from contaminants. 3. Install a new gasket (6) on the dowels in the
cylinder block.
Contaminants may cause rapid wear and shortened
component life.

1. Ensure that the spacer plate and the surface of the

cylinder block are clean.
168 SENR6419
Disassembly and Assembly Section

i02507103

Accessory Drive (Front) -

Remove
SMCS Code: 1207-011

Removal Procedure
Table 47
Required Tools

Tool Part Number Part Description Qty

A 5J-0490 Bolt 2

Illustration 542 g00583156

Typical example NOTICE
Keep all parts clean from contaminants.
4. Install spacer plate (5) on the dowels.
Contaminants may cause rapid wear and shortened
component life.

Illustration 543 g01255067

Typical example
Illustration 544 g00587600
5. Install new seals (1) and (2) in the spacer plate. Typical example
6. Install new O-ring seal (4) on the dowel. 1. Remove the bolts and rear cover (2) with the O-ring
seals.
7. Check the cylinder liner projection. Refer to Testing
and Adjusting, “Cylinder Liner Projection”. 2. Remove the bolts and use Tooling (A) to remove
rear adapter assembly (1).
8. Install new gasket (3) on top of the spacer plate.
End By:
a. Install the cylinder head assembly. Refer to
Disassembly and Assembly, “Cylinder Head -
Install”.
SENR6419 169
Disassembly and Assembly Section

Illustration 545 g00587601 Illustration 546 g00906726

Typical example
1. Remove O-ring seals (2) and (3) from rear adapter
3. Remove the front cover. assembly (1).

4. Remove the bolts and remove front adapter

assembly (3), the drive gear, and the shaft as a
unit.

i02507146

Accessory Drive (Front) -

Disassemble
SMCS Code: 1207-015

Disassembly Procedure
Table 48
Required Tools
Illustration 547 g01255143

Tool Part Number Part Description Qty

2. Remove seal (4) from rear adapter assembly (1).
A 1P-0520 Driver Group 1
3. Use Tooling (A) and a suitable press to remove
Start By: bearing (5) from rear adapter assembly (1).

a. Remove the accessory drive (front). Refer to

Disassembly and Assembly, “Accessory Drive
(Front) - Remove”.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Illustration 548 g01255146

4. Remove bolts (7) and gear (8) from shaft (6).

170 SENR6419
Disassembly and Assembly Section

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Illustration 549 g01255149

5. Remove the bolts and retaining washer (10).

Note: Later models have two retaining washers.

6. Remove shaft (6) from front adapter assembly (9).

Illustration 551 g01255150

1. Align the oil hole in the bearing and the oil hole in
front adapter assembly (9). Use Tooling (A) and a
suitable press to install bearing (11) into front
adapter assembly (9). The bore of the bearing
must be 75.0 ± 0.055 mm (2.95 ± 0.0020 inch)
after installation.
2. Install O-ring seals (12) and (13) into front adapter
assembly (9).

Illustration 550 g01255150

7. Remove O-ring seals (12) and (13) from front

adapter assembly (9).

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

bearing (11) from front adapter assembly (9).

i02507201

Accessory Drive (Front) -

Illustration 552 g01255149
Assemble
SMCS Code: 1207-016 3. Place clean engine oil on the bearing and install
shaft (6) in front adapter assembly (9).
Assembly Procedure 4. Install retaining washer (10) and the bolts.
Table 49
Note: Later models have two retaining washers.
Required Tools

Tool Part Number Part Description Qty

A 1P-0520 Driver Group 1

SENR6419 171
Disassembly and Assembly Section

Illustration 553 g01255146 Illustration 555 g00906726

5. Position gear (8) on shaft (6) and install bolts (7). 8. Install O-ring seals (2) and (3) into rear adapter
assembly (1). Place clean engine oil on the O-ring
seals.
End By:
a. Install the accessory drive (front). Refer to
Disassembly and Assembly, “Accessory Drive
(Front) - Install”.

i02507209

Accessory Drive (Front) -

Install
SMCS Code: 1207-012

Illustration 554 g01255143 Installation Procedure

6. Align the oil hole in the bearing and the oil hole in NOTICE
rear adapter assembly (1). Use Tooling (A) and a Keep all parts clean from contaminants.
suitable press to install bearing (5) into rear
adapter assembly (1). The bore of the bearing Contaminants may cause rapid wear and shortened
component life.
must be 75.0 ± 0.055 mm (2.95 ± 0.0020 inch)
after installation.
7. Use Tooling (A) to install seal (4) into rear adapter
assembly (1). Ensure that the lip of the seal is
toward the bearing.

Illustration 556 g00587657

Typical example

1. Place clean engine oil on the O-ring seals for front

adapter assembly (3).
172 SENR6419
Disassembly and Assembly Section

Start By:

Note: Ensure that the teeth of the accessory gear are a. Remove the oil filter housing.
correctly engaged with the teeth of the lower
accessory drive gear. b. Remove the crankshaft front seal and the wear
sleeve.
2. Install the shaft, the drive gear, and front adapter
assembly (3) in the front housing. Install the bolts. c. Remove accessory drive (front).

3. Install the front cover. d. Remove the engine oil and water pump drive.
e. Remove the auxiliary water pump.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Illustration 557 g00587600

Typical example

4. Place clean engine oil on the O-ring seals on rear

adapter assembly (1) and on the bearing in rear
adapter assembly (1).

5. Ensure that the O-ring seal is installed in rear cover

(2). Illustration 558 g00598961
Typical example
6. Place clean engine oil on the O-ring seal. Install
rear cover (2) and install the bolts. 1. Remove clamps (1).

i01134287

Drive Housing (Front) -

Remove and Install
SMCS Code: 1151-010

Removal Procedure
Table 50
Required Tools

Tool Part Number Part Description Qty

1P-0074 Slide Hammer Puller 1

A
8B-7557 Adapter 1 Illustration 559 g00598964

Driver Group
Typical example
B 1P-0520 1

C 138-7573 Link Bracket 2 2. Attach a suitable lifting device to mounting bracket

(2) with a 1/2-13 forged eyebolt.

3. Remove the ten bolts and mounting bracket (2)

from the engine. The mounting bracket weighs
approximately 69 kg (152 lb).
SENR6419 173
Disassembly and Assembly Section

7. Remove the bolts from the end of shaft (8). Use

Tool (A) to remove shaft (8) and idler gear (7) from
both sides of the engine.

8. Use Tool (B) and a suitable press to remove the

bearing from idler gear (7).

Illustration 560 g00598966

Typical example

4. Remove four tubes (4).

5. Remove elbow (5) and tube (3).

Illustration 563 g00598971

Typical example

9. Remove two washers (9) from the front drive

housing.

10. Remove all of the bolts that hold the engine oil
pan to the engine. Install 3/8-16 NC guide bolts in
both sides of the engine oil pan. Attach a suitable
lifting device to the engine and lift the engine off
the engine oil pan 12 mm (0.5 inch). Install two 50
mm wide x 100 mm long x 6mm thick (2 inch x 4
inch x 1/4 inch) plates between the engine and the
engine oil pan. Rest the engine on the plates.
Illustration 561 g00598967
Typical example

6. Remove cover (6) and the O-ring seal.

Illustration 564 g00598973

Typical example

11. Install Tool (C) and attach a suitable lifting device

Illustration 562 g00598970 to front drive housing (10). Remove front drive
Typical example housing (10) and the gasket. The front drive
housing weighs approximately 209 kg (460 lb).
174 SENR6419
Disassembly and Assembly Section

Installation Procedure
Table 51
Required Tools

Tool Part Number Part Description Qty

A 1P-0520 Driver Group 1

B 138-7573 Link Bracket 2

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Illustration 566 g00598971
Typical example

6. Install two washers (9) in front drive housing (10).

Illustration 565 g00599039

Typical example

1. Install the front drive housing gasket on the

Illustration 567 g00598970
cylinder block. Install two 5/8-11 NC guide bolts in
Typical example
the cylinder block.

2. Install Tool (B) and attach a suitable lifting device to 7. Use Tool (A) to install the bearing in idler gear (7).
front drive housing (10). Position front drive The bearing must have a diameter of
housing (10) on the guide bolts. 90.00 ± 0.06 mm (3.543 ± 0.002 inch) after
installation.
3. Install the bolts in front drive housing (10) and
8. Place clean engine oil on the O-ring seal of shaft
tighten the bolts evenly. Cut the excess gasket at
(8). Install idler gear (7) and shaft (8) on both sides
the face of the cylinder block.
of the engine.
4. Attach a suitable lifting device to the engine and lift
the engine enough to remove the two plates
between the engine and the engine oil pan. Install
all of the bolts that hold the engine oil pan to the
engine.

5. Inspect the condition of the gasket on the engine oil

pan. Replace the gasket, if necessary. Install all of
the bolts in the engine oil pan.
SENR6419 175
Disassembly and Assembly Section

12. Use a 1/2-13 forged eyebolt and a suitable lifting

device to install mounting bracket (2) on the front
drive housing. Install the ten bolts.

Illustration 568 g00598967

Typical example

9. Place clean engine oil and the O-ring seals and

install cover (6). Illustration 571 g00598961
Typical example

13. Install four clamps (1).

End By:
a. Install the auxiliary water pump.
b. Install the engine oil and water pump drive.
c. Install the accessory drive (front).
d. Install the crankshaft front seal and the wear
sleeve.
e. Install the engine oil filter housing.

i01115046
Illustration 569 g00598966
Typical example Vibration Damper - Remove
10. Lubricate the O-ring seals on tube (3) with and Install
glycerin. Install tube (3) and elbow (5). SMCS Code: 1205-010
11. Install four tubes (4).
Removal Procedure
Table 52
Required Tools

Tool Part Number Part Description Qty

A 138-7573 Link Bracket 2

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Illustration 570 g00598964

Typical example
176 SENR6419
Disassembly and Assembly Section

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

1. If the adapter was removed, install the adapter with

bolts (6). Tighten the bolts to a torque
100 ± 15 N·m (75 ± 10 lb ft).

Illustration 572 g00589930

1. Remove eight bolts (1) and guard (2).

Illustration 574 g00589939

2. Install Tool (A) and attach a suitable lifting device.

3. Apply 4C-5593 Anti-Seize Compound to the

threads of the bolts.
4. Position vibration damper (4) on the engine and
Illustration 573 g00589939 install four bolts (5).

2. Remove two bolts (5). 5. Remove the two guide bolts (3).

3. Install two 1"-14 NF x 11" (280 mm) guide bolts (3). 6. Install two remaining bolts (5). Tighten the bolts to
a torque of 1125 ± 100 N·m (830 ± 75 lb ft).
4. Install Tool (A) and attach a suitable lifting device.
Note: Refer to the Specifications Module, “Vibration
5. Remove the remaining bolts (5). Damper” for more information.

6. Remove vibration damper (4). The damper weighs

approximately 91 kg (200 lb).

7. Remove bolts (6) and remove the adapter from

vibration damper (2), if necessary. The adapter
weighs approximately 34 kg (75 lb).

Installation Procedure
Table 53
Required Tools

Tool Part Number Part Description Qty

A 138-7573 Link Bracket 2

Illustration 575 g00589930

7. Install guard (2) and eight bolts (1). Tighten the

bolts to a torque of 15 ± 3 N·m (11 ± 2 lb ft).
SENR6419 177
Disassembly and Assembly Section

i03900343

Crankshaft Front Seal and

Wear Sleeve - Remove
SMCS Code: 1160-011; 7558-011

Removal Procedure
Table 54
Required Tools

Tool Part Number Part Description Qty

A 5P-7409 Sleeve Distorter 1

6V-3143
Illustration 576 g00588494
B or Distorter Adapter 1
1U-7325
1. Remove four bolts (1) from adapter (2) and install
two 5/16-18 NC forcing screws in adapter (2).
Start By:
2. Use forcing screws to remove adapter (2).
a. Remove the vibration damper.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product. Be
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling
any component containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar Illustration 577 g00588495
Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar 3. Remove O-ring seal (4) and crankshaft seal (3)
products. from adapter (2).
Dispose of all fluids according to local regulations and
mandates.

NOTICE
Every time that the crankshaft seal is removed from
the wear sleeve, a new wear sleeve and crankshaft
seal must be installed.

Illustration 578 g00588497

4. Install Tooling (B) in the adapter bore.

178 SENR6419
Disassembly and Assembly Section

5. Install Tooling (A) between Tooling (B) and wear

sleeve (5). Turn Tooling (A) until the edge of the
tool makes a flat crease in wear sleeve (5). Repeat
this procedure several times until the wear sleeve
can be removed by hand.

i06064214

Crankshaft Front Seal and

Wear Sleeve - Install
SMCS Code: 1160-012; 7558-012

Installation Procedure For Seals

Illustration 579 g00588333
113-8432 and 113-8433
Table 55 1. Install adapter (3) on Tool (A).
Required Tools

Tool Part Number Part Description Qty NOTICE

A 6V-4002(1) Forcing Bracket 2
If the crankshaft seal and the wear sleeve come apart
during installation, the crankshaft seal and the wear
B 6V-4001 Forcing Ring 1 sleeve must be replaced.
C 1D-4716(2) Full Nut 4

6V-4003(3) Locator 1 Note: The front crankshaft seal and the wear sleeve
D cannot be interchanged with the rear crankshaft seal
2N-5006(4) Bolt 2 and the wear sleeve.
Guide Bolts (5/16 -18 NC x 4 in
E -(5) 4
(101.6mm) Long) NOTICE
Do not place engine oil on the crankshaft seal for in-
F 6V-4977(6) Installer 1
stallation. Lubrication of the crankshaft seal can give
G 9S-8858(7) Nut 1 a false indication of leakage at a later time.
H 8T-3099(8) Installation 1
2. Place crankshaft seal (2) and wear sleeve (1) on
J 447-6264(9) Tool As 1
adapter (3). Ensure that the lip of the seal is facing
(1) For installation of seals 113-8432 and 113-8433
(2)
upward.
For installation of seals 113-8432 and 113-8433
(3) For installation of seals 113-8432 and 113-8433
(4) For installation of seals 113-8432 and 113-8433 3. Install the O-ring seal on adapter (3).
(5) For installation of seals 113-8432 and 113-8433
(6) For installation of seals 113-8432 and 113-8433 4. Install Tool (B) on the studs of Tool (A). Install Tool
(7) For installation of seals 113-8432 and 113-8433
(8)
(C) and tighten evenly until the seal is against the
For installation of seals 113-8432 and 113-8433
(9) For Installation of seals 436-1478 and 436-1479 bottom of the adapter bore.

5. Remove Tools (C), (B), and (A) from adapter (3).

NOTICE
Keep all parts clean from contaminants. 6. Clean the outer surface of the crankshaft with
169-5464 Quick Cure Primer.
Contaminants may cause rapid wear and shortened
component life. 7. Place clean engine oil on the O-ring seal and install
the seal on adapter (3). Apply 4C-9507 Retaining
Compound to the outside diameter of the
NOTICE crankshaft and to the inside diameter of the wear
Every time that the crankshaft seal is removed from
sleeve.
the wear sleeve, a new wear sleeve and crankshaft
seal must be installed.
SENR6419 179
Disassembly and Assembly Section

Illustration 580 g00588568 Illustration 582 g00588570

8. Install Tool (D) on the end of the crankshaft. 14. Install bolts (4) in adapter (3).

9. Install Tool (E) in the drive housing. Place adapter Note: Refer to the Specifications Module, “Crankshaft
(3) on Tool (E) and (D). Ensure that the wear Wear Sleeves And Seals” for more information.
sleeve makes contact with the end of the End By:
crankshaft.
a. Install the vibration damper.

Installation Procedure For Seals

436-1478 and 436-1479
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

NOTICE
Do not place engine oil on the crankshaft seal for in-
stallation. Lubrication of the crankshaft seal can give
a false indication of leakage at a later time.
Illustration 581 g00588569

10. Install Tool (B) over the outside diameter of Tool Note: Ensure that there are no imperfections on the
(F) until Tool (B) is against the shoulder of Tool (F). mating surfaces of the crankshaft, the installation
tooling, or on the sealing surface of the crankshaft.
11. Install Tool (B) and (F) on Tool (E). Surface imperfections can distort the seal during
installation and will cause the seal to malfunction.
12. Apply 1P-0808 Multipurpose Grease on the face
of Tool (G). Install Tool (G) on Tool (D). Tighten
Tool (G) until the wear sleeve and the adapter are
in the correct position.

13. Remove the tools from the engine.

180 SENR6419
Disassembly and Assembly Section

NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product. Be
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling
any component containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and sup-
plies suitable to collect and contain fluids on Caterpil-
lar products.
Dispose of all fluids according to local regulations and
mandates.
Illustration 583 g03795762

1. Using Tooling (J), install front seal (1) as outlined in

the following steps:

a. Install pilot (3) to the crankshaft and install

bolts (4).

b. Position front seal (1) onto pilot (3).

c. Install driver (5) onto the shaft of pilot (3). Mark

driver (5) at the 12 O' CLOCK position. Install
bearing (6) and nut (7).

d. Tighten nut (7) until the base of driver (5)

contacts the skirt of pilot (3). Loosen nut (7)
and rotate driver (5) 90°. Retighten nut (7) until Illustration 584 g00589791
driver (5) contacts the skirt of pilot (3).
1. Install Tool (A) on flywheel (1) and attach a suitable
2. Remove Tooling (J). lifting device.
End By:
2. Remove two bolts (2) and install two 1-14 NF guide
a. Install the vibration damper. bolts.
3. Remove remaining bolts (2).
i01114804
4. Remove flywheel (1). The flywheel weighs
Flywheel - Remove and Install approximately 167 kg (370 lb).
SMCS Code: 1156-010
Installation Procedure
Table 57
Removal Procedure
Table 56 Required Tools

Required Tools Tool Part Number Part Description Qty

Tool Part Number Part Description Qty A 138-7573 Link Bracket 2

A 138-7573 Link Bracket 2

NOTICE
Keep all parts clean from contaminants.
NOTICE
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened
component life.
Contaminants may cause rapid wear and shortened
component life.
1. Inspect the condition of the flywheel gear. Replace
the gear, if necessary.

a. Remove the damaged ring from the flywheel.

SENR6419 181
Disassembly and Assembly Section

Start By:
b. Heat the new ring gear to a maximum
temperature of 316 °C (600 °F). a. Remove the flywheel.

c. Install the gear on the flywheel with the NOTICE

chamfer of the gear teeth toward the engine. Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product. Be
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling
any component containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Illustration 585 g00589791
Dispose of all fluids according to local regulations and
mandates.
2. Install two 1-11 NC guide bolts in the end of the
crankshaft.

Note: Ensure that the mark on the flywheel is aligned NOTICE

with the mark on the crankshaft. Every time that the crankshaft seal is removed from
the wear sleeve, a new wear sleeve and crankshaft
3. Install Tool (A) and a suitable lifting device on seal must be installed.
flywheel (1).

4. Place clean engine oil on the threads of the bolts

and install ten bolts (2).

5. Remove Tool (A) and the guide bolts in order to

install remaining two bolts (2). Tighten all of the
bolts to a torque of 1150 ± 60 N·m (850 ± 44 lb ft).

Note: Refer to the Specifications Module, “Flywheel”

for more information.

i03901109

Crankshaft Rear Seal and Wear

Sleeve - Remove
Illustration 586 g00588053
SMCS Code: 1161-011; 7558-011
1. Remove the bolts from adapter (1). Install two 5/16-
Removal Procedure 18 NC Forcing Screws in order to remove adapter
Table 58 (1).
Required Tools
Note: Use Tooling (C) to remove the lip seal on
Tool Part Number Part Description Qty engines that do not have an adapter.
A 5P-7409 Sleeve Distorter 1
6v-3143
B or Distorter Adapter 1
1U-7325
C 1U-7600 Slide Hammer Puller 1
182 SENR6419
Disassembly and Assembly Section

(Table 59, contd)

A 6V-4002(1) Forcing Bracket 2

B 6V-4001(2) Forcing Ring 1

C 1D-4716(3) Full Nut 4

6V-4003(4) Locator 1
D
2N-5006(5) Bolt 2

Guide Bolts (5/16 -18 NC x 4 in

E -(6) 4
(101.6mm) Long)

F 6V-4977(7) Installer 1

G 9S-8858(8) Nut 1

H 8T-3099(9) Installation 1
Illustration 587 g00588054
J 447-6264(10) Tool As 1
2. Remove O-ring seal (3) and crankshaft seal (2) (1) For installation of seals 113-8432 and 113-8433
from adapter (1). (2) For installation of seals 113-8432 and 113-8433
(3) For installation of seals 113-8432 and 113-8433
(4) For installation of seals 113-8432 and 113-8433
(5) For installation of seals 113-8432 and 113-8433
(6) For installation of seals 113-8432 and 113-8433
(7) For installation of seals 113-8432 and 113-8433
(8) For installation of seals 113-8432 and 113-8433
(9) For installation of seals 113-8432 and 113-8433
(10) For Installation of seals 436-1478 and 436-1479

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

NOTICE
Illustration 588 g00588055 Every time that the crankshaft seal is removed from
the wear sleeve, a new wear sleeve and crankshaft
3. Install Tooling (B) in the adapter bore. seal must be installed.

4. Install Tooling (A) between Tooling (B) and wear

sleeve (4). Turn Tooling (A) until the edge of the
tool creates a flat crease in wear sleeve (4).
Perform this step several times until wear sleeve
(4) can be removed by hand.

i06064117

Crankshaft Rear Seal and Wear

Sleeve - Install
SMCS Code: 1161-012; 7558-012

Installation Procedure For Seals

113-8432 and 113-8433 Illustration 589 g00588333

Table 59
1. Install adapter (3) on Tool (A).
Required Tools

Tool Part Number Part Description Qty

(continued)
SENR6419 183
Disassembly and Assembly Section

NOTICE
If the crankshaft seal and the wear sleeve come apart
during installation, the crankshaft seal and the wear
sleeve must be replaced.

Note: The front crankshaft seal and the wear sleeve

cannot be interchanged with the rear crankshaft seal
and the wear sleeve.
2. Place crankshaft seal (2) and wear sleeve (1) on
adapter (3). Ensure that the lip of the seal is facing
upward.

3. Install the O-ring seal on adapter (3).

Illustration 591 g00588348
4. Install Tool (B) on the studs of Tool (A). Install Tool
(C) and tighten evenly until the seal is against the
bottom of the adapter bore. 10. Install Tool (B) over the outside diameter of Tool
(F) until Tool (B) is against the shoulder of Tool (F).
5. Remove Tools (C), (B), and (A) from adapter (3).
11. Install Tool (B) and (F) on Tool (E).

NOTICE 12. Apply 1P-0808 Multipurpose Grease on the face

Do not place engine oil on the crankshaft seal for in- of Tool (G). Install Tool (G) on Tool (D). Tighten
stallation. Lubrication of the crankshaft seal can give Tool (G) until the wear sleeve and the adapter are
a false indication of leakage at a later time. in the correct position.

13. Remove the tools from the engine.

6. Clean the outer surface of the crankshaft with
4C-9500 Quick Cure Primer. Note: Use Tool (H) in place of Tools (B) and (F) if the
engine does not have an adapter.
7. Place clean engine oil on the O-ring seal and install
the seal on adapter (3). Apply 4C-9507 Retaining
Compound to the outside diameter of the
crankshaft and to the inside diameter of the wear
sleeve.

Illustration 592 g00588350

14. Install bolts (4) in adapter (3).

Note: Refer to the Specifications Module, “Crankshaft

Illustration 590 g00588337 Wear Sleeves And Seals” for more information.
End By:
8. Install Tool (D) on the end of the crankshaft.
a. Install the flywheel.
9. Install Tool (E) in the drive housing. Place adapter
(3) on Tool (E) and (D). Ensure that the wear
sleeve makes contact with the end of the
crankshaft.
184 SENR6419
Disassembly and Assembly Section

Installation Procedure For Seals i02515861

436-1478 and 436-1479 Flywheel Housing - Remove

NOTICE SMCS Code: 1157-011
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened Removal Procedure
component life. Table 60
Required Tools

NOTICE Tool Part Number Part Description Qty

Do not place engine oil on the crankshaft seal for in- Hand Hydraulic Pump
9U-6600 1
stallation. Lubrication of the crankshaft seal can give
a false indication of leakage at a later time. 8B-7548 Push-Puller Tool Group 1

A 8B-7559 Adapter 2
Note: Ensure that there are no imperfections on the 1P-0820 Hydraulic Puller 1
mating surfaces of the crankshaft, the installation
tooling, or on the sealing surface of the crankshaft. 5H-1504 Hard Washer 3
Surface imperfections can distort the seal during B 138-7573 Link Bracket 2
installation and will cause the seal to malfunction.
C 169-5464 Quick Cure Primer -

Start By:
a. Remove the starting motors. Refer to Disassembly
and Assembly, “Air Starting Motor - Remove” or
Disassembly and Assembly, “Electric Starting
Motor - Remove and Install”.
b. Remove the engine oil pan. Refer to Disassembly
and Assembly, “Engine Oil Pan - Remove”.
c. Remove the rocker shaft and the pushrods. Refer
to Disassembly and Assembly, “Rocker Shaft and
Pushrod - Remove”.

NOTICE
Illustration 593 g03795762 Keep all parts clean from contaminants.

1. Using Tooling (J), install front seal (1) as outlined in Contaminants may cause rapid wear and shortened
the following steps: component life.

a. Install pilot (3) to the crankshaft and install

bolts (4). NOTICE
Care must be taken to ensure that fluids are con-
b. Position front seal (1) onto pilot (3). tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product. Be
c. Install driver (5) onto the shaft of pilot (3). Mark prepared to collect the fluid with suitable containers
driver (5) at the 12 O' CLOCK position. Install before opening any compartment or disassembling
bearing (6) and nut (7). any component containing fluids.

d. Tighten nut (7) until the base of driver (5) Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies
contacts the skirt of pilot (3). Loosen nut (7) suitable to collect and contain fluids on Caterpillar
and rotate driver (5) 90°. Retighten nut (7) until products.
driver (5) contacts the skirt of pilot (3).
Dispose of all fluids according to local regulations and
2. Remove Tooling (J). mandates.
End By:
1. Remove the engine speed/timing sensor. Refer to
a. Install the flywheel. Testing and Adjusting, “Engine Speed/Timing
Sensor”.
SENR6419 185
Disassembly and Assembly Section

2. Use the timing pins in order to properly time the

engine. Refer to Testing and Adjusting, “Camshaft
Timing”. Refer to Testing and Adjusting, “Finding
the Top Center Position for the No. 1 Piston”.

Illustration 596 g00588655

6. Remove the bolt and plate (5) from camshaft drive

gear (4).

Illustration 594 g00588653

Typical example

3. Remove camshaft covers (1) and the gaskets from

flywheel housing (2).

4. Remove the crankshaft rear seal and the wear

sleeve. Refer to Disassembly and Assembly,
“Crankshaft Rear Seal and Wear Sleeve -
Remove”.

Illustration 597 g00588656

7. Place the three washers of Tooling (A) behind plate

(5) and install the bolt and plate (5).

NOTICE
Do not apply more than 51675 kPa (7500 psi) pres-
sure to the hydraulic puller. The adapters are rated at
6 1/2 tons each and the hydraulic puller is rated at 17
tons at 68900 kPa (10000 psi). If too much pressure
Illustration 595 g00588654 is applied, the gear may be damaged.

5. Remove the bolt and timing ring (3). 8. Install Tooling (A) on camshaft drive gear (4). Apply
51675 kPa (7500 psi) to the puller. Use a hammer
to tap the head of the puller screw on Tooling (A).
This will break camshaft drive gear (4) free from
the camshaft.
9. Repeat the procedure for the remaining camshaft
drive gear.

10. Place blocks under the engine. The engines have

the following weights.

a. The weight of the G3508 Engines are

approximately 4300 kg (9500 lb).
186 SENR6419
Disassembly and Assembly Section

NOTICE
b. The weight of the G3512 Engines are
Keep all parts clean from contaminants.
approximately 5443 kg (12000 lb).
Contaminants may cause rapid wear and shortened
c. The weight of the G3516 Engines are component life.
approximately 6447 kg (14200 lb).

Note: Refer to Engine News27 March 2006, “Sealing

and Installing the Flywheel Housing” for more
information.
1. Ensure that the mating surface of the flywheel
housing and the engine block are clean. Both
mating surfaces must be clean, dry, and free of any
oil before Tooling (D) is applied.

Illustration 598 g00588658

Typical example

11. Install Tooling (B) and a suitable lifting device on

the top of flywheel housing (2). The weight of
flywheel housing (2) is approximately 210 kg
(460 lb).

12. Remove all bolts from flywheel housing (2).

Note: Dowel pins are used for the alignment of the

flywheel housing on the engine block.

13. Remove flywheel housing (2) from the engine.

14. After removing flywheel housing (2), clean the Illustration 599 g01258819
mating surface of the cylinder block and the mating
surface of the flywheel housing with Tooling (C). If 2. Apply a 6.0 mm (0.25 inch) bead of Tooling (D) to
necessary, use a gasket scraper and a solvent in the mating surface of the flywheel housing. Refer
order to remove any residual gasket material. Both to Illustration 599 .
mating surfaces must be clean, dry, and free of any
oil before installation.

i05003273

Flywheel Housing - Install

SMCS Code: 1157-012

Installation Procedure
Table 61
Required Tools

Tool Part Number Part Description Qty

B 138-7573 Link Bracket 2

Illustration 600 g00588658
D -(1) Loctite 5127 -
Typical example
(1) EAME
SENR6419 187
Disassembly and Assembly Section

3. Attach Tooling (B) and a suitable lifting device to

the top of flywheel housing (2). The weight of
flywheel housing (2) is approximately 210 kg
(460 lb).

4. Position flywheel housing (2) on the engine.

5. If the dowel pins were removed from flywheel

housing (2), install the dowel pins and ensure that
the dowel pins are properly seated.

Illustration 601 g01259294

(U) 1/2 - NC (W) 1/2 - NC (Y) 1/2 - NC

(V) 1/2 - NC (X) 1/2 - NC (Z) 5/8 - NC

6. Install the bolts and the hard washers for flywheel

housing (2). Refer to Illustration 601 for the proper 9. Place the camshaft timing pins in position and
locations of the bolts. Tighten the 1/2 - NC bolts to place the timing bolt in the flywheel with the No. 1
a torque of 135 ± 20 N·m (100 ± 15 lb ft). Tighten piston at the top center position on the
the 5/8 - NC bolts to a torque of 270 ± 40 N·m compression stroke.
(200 ± 30 lb ft).

7. Remove Tooling (B).

8. Install the crankshaft rear seal and the wear

sleeve. Refer to Disassembly and Assembly,
“Crankshaft Rear Seal and Wear Sleeve - Install”.
188 SENR6419
Disassembly and Assembly Section

d. Install the bolt and plate (5).

e. Install the bolt and timing ring (3). Ensure that

the hole in the timing ring is properly seated on
the locating pin.

f. Tighten the bolt to a torque of 360 N·m

(265 lb ft).

g. Place a Mark on the bolt.

h. Place a driver against the retaining plate of the

camshaft gear. Strike the driver solidly with a
hammer 3 to 4 times.
Illustration 602 g00588655
i. Tighten the bolt again to a torque of 360 N·m
(265 lb ft).

j. Repeat Steps 10.h. and 10.i. until the Mark has

turned at least 90 degrees.

Note: Refer to the Disassembly and Assembly,

“Camshaft - Install” for more information.
11. Remove the timing pins from the camshafts and
the flywheel.

Illustration 603 g00588654

10. Use the following procedure in order to install

camshaft drive gears (4).

a. Clean the taper of the camshaft and clean the

tapered bore of the camshaft gear with a lint
free cloth that is saturated with a solvent in
order to remove any excess oil. Clean the
parts again with a lint free alcohol wipe in order
to remove any residue. If the alcohol wipe is Illustration 604 g00588653
dirty after cleaning the parts, clean the parts Typical example
again with a lint free alcohol wipe until no
residue is left on the alcohol wipe. 12. Install the gaskets and camshaft covers (1) on
flywheel housing (2).
Note: It is critical that the taper of the camshaft and
the tapered bore of the camshaft gear are clean, 13. Install the engine speed/timing sensor. Refer to
dry, and free of residue before assembly. Testing and Adjusting, “Engine Speed/Timing
Sensor”.
b. Ensure that the camshaft timing pins and the
timing pin for the flywheel are installed.

c. Place camshaft drive gears (4) in position.

Remove the backlash by rotating the gears in
the opposite direction of camshaft rotation.
Note: For “Standard Rotation” engines, turn the
camshaft drive gears COUNTERCLOCKWISE. For
“Reverse Rotation” engines, turn the camshaft
drive gears CLOCKWISE.
SENR6419 189
Disassembly and Assembly Section

End By:
a. Install the rocker shaft and the pushrods. Refer to
Disassembly and Assembly, “Rocker Shaft and
Pushrod - Install”.
b. Install the engine oil pan. Refer to Disassembly
and Assembly, “Engine Oil Pan - Install”.
c. Install the starting motors. Refer to Disassembly
and Assembly, “Air Starting Motor - Install” or
Disassembly and Assembly, “Electric Starting
Motor - Remove and Install”.

i02928334

Engine Oil Sequence Valves - Illustration 605 g00912963

Remove and Install

SMCS Code: 1332-010
Personal injury can result from parts and/or cov-
Removal Procedure ers under spring pressure.
Start By: Spring force will be released when covers are
a. Remove the front drive housing. Refer to removed.
Disassembly and Assembly, “Front Drive Housing - Be prepared to hold spring loaded covers as the
Remove and Install” or Disassembly and Assembly, bolts are loosened.
“Drive Housing (Front) - Remove and Install”.
b. Remove the flywheel housing. Refer to 1. Remove cover (1) from the front of the cylinder
Disassembly and Assembly, “Flywheel Housing - block.
Remove”.
2. Remove plunger assembly (2) and spring (3) from
NOTICE the front of the cylinder block.
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Illustration 606 g00912966

Personal injury can result from parts and/or cov-

ers under spring pressure.
Spring force will be released when covers are
removed.
Be prepared to hold spring loaded covers as the
bolts are loosened.
190 SENR6419
Disassembly and Assembly Section

3. Remove the idler gear and the shaft. Remove

cover (4) on the rear of the cylinder block.

Illustration 609 g00912966

Illustration 607 g00912969

Improper assembly of parts that are spring loaded

4. Remove plunger assembly (5) and spring (6) from
can cause bodily injury.
the rear of the cylinder block.
To prevent possible injury, follow the established
Installation Procedure assembly procedure and wear protective
equipment.
NOTICE
Keep all parts clean from contaminants. 3. Install cover (4) on the rear of the cylinder block.
Install the idler gear and the shaft.
Contaminants may cause rapid wear and shortened
component life.

Illustration 610 g00912963

Illustration 608 g00912969

1. Place clean engine oil on spring (6) and plunger Improper assembly of parts that are spring loaded
assembly (5). can cause bodily injury.
2. Install spring (6) and plunger assembly (5). To prevent possible injury, follow the established
assembly procedure and wear protective
equipment.

4. Place clean engine oil on spring (3) and plunger

assembly (2).

5. Install spring (3) and plunger assembly (2) on the

front of the cylinder block.

6. Install cover (1) on the front of the cylinder block.

SENR6419 191
Disassembly and Assembly Section

End By:
a. Install the flywheel housing. Refer to Disassembly
and Assembly, “Flywheel Housing - Install”.
b. Install the front drive housing. Refer to
Disassembly and Assembly, “Front Drive Housing -
Remove and Install” or Disassembly and Assembly,
“Drive Housing (Front) - Remove and Install”.

i02062075

Gear Group (Rear) - Remove

SMCS Code: 1212-011

Removal Procedure
Table 62
Required Tools

Tool Part Number Part Description Qty

A 1P-0520 Driver Group 1

Start By:
a. Remove the flywheel housing. Refer to
Disassembly and Assembly, “Flywheel Housing -
Remove”.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product. Be
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling
any component containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and sup-
plies suitable to collect and contain fluids on Caterpil-
lar products.
Dispose of all fluids according to local regulations and
mandates.

Note: The following Step is for a 3508 Engine.

192 SENR6419
Disassembly and Assembly Section

Illustration 611 g01056631

1. The engine must be put in time before the flywheel

housing is removed. This is done in order to make
sure that the rear gear group is in alignment with
the rotation of the engine, as shown.

Illustration 613 g00913049

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

bearing (3) from gear (2).

Illustration 612 g00913045

2. Remove plate (1) and gear (2).

Illustration 614 g00913054

4. Remove the bolts, the washers, and camshaft idler

gears (4).
SENR6419 193
Disassembly and Assembly Section

Illustration 617 g00913137

Illustration 615 g01051669
8. Remove the bolts and crankshaft gear (8) from the
5. Remove washers (6) and shafts (5) from camshaft end of the crankshaft.
idler gears (4).
i04014109
6. Use Tooling (A) and a suitable press to remove
bearings from camshaft idler gears (4). Gear Group (Rear) - Install
SMCS Code: 1212-012

Installation Procedure
Table 63
Required Tools

Tool Part Number Part Description Qty

A 1P-0520 Driver Gp 1

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
Illustration 616 g00913136
component life.

7. Remove the bolts from shaft (7) and remove shaft

(7).

Illustration 618 g00913137

1. Install crankshaft gear (8) and the bolts.

194 SENR6419
Disassembly and Assembly Section

3. Use Tooling (A) and a suitable press to install the

bearings in camshaft idler gears (4). Install bearing
(9) into gear (4) to Depth (F), as shown.

4. Machine the inside diameter of bearing (9) to

Dimension (E), as shown.

Note: The surface finish of Bore (E) must be 0.8

micrometers. Pitch Diameter (H) must be concentric
with a total indicator reading of 0.12 mm (0.005 inch).
Surface (G) of gear (4) must be square with Bore (E)
within 0.05 mm (0.002 inch).

5. Place clean engine oil on the bearings and install

shafts (5) with washers (6) on camshaft idler gears
Illustration 619 g00913136 (4).

2. Install shaft (7) and the bolts. The torque for the
bolts is 140 ± 10 N·m (105 ± 5 lb ft).

Illustration 622 g00913054

6. Install camshaft idler gears (4) and the bolts.

Illustration 620 g01051669

Illustration 623 g01068516

Illustration 621 g01068502 (2) Cluster Idler Gear. (3) Bearing. (A)
(4) Camshaft Idler Gear. (9) Bearing. (E) 75.060 ± 0.010 mm (2.9551 ± 0.0004 inch). (B)
81.060 ± 0.010 mm (3.1913 ± 0.0004 inch). (F) 1.5 ± 0.5 mm (0.06 ± 0.02 inch).
1.00 ± 0.25 mm (0.040 ± 0.010 inch).
SENR6419 195
Disassembly and Assembly Section

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

bearing (3) in gear (2). Install bearing (3) to Depth
(B), as shown.

8. Machine the inside diameter of the bearing to

Dimension (A), as shown.

Note: The surface finish of Bore (A) must be 0.8

micrometers. Pitch Diameter (C) must be concentric
with a total indicator reading of 0.15 mm (0.006 inch).
Surface (D) of gear (2) must be square with Bore (A)
within 0.05 mm (0.002 inch).

Note: The following Step is for 3508 and G3508

Engines.

Illustration 624 g01056631

Note: When you install the rear cluster gear

assembly to the crank gear, there are no timing marks
on the 3512, 3516, G3512 and G3516 engines. On
the 3508 and G3508 engines, the rear cluster gears
have timing marks that must be aligned with the
marks that are on the cluster gears.
9. Put clean engine oil on the bearing and install the
gear assembly on the shaft. Make sure that the
marks on the gear assembly and the crankshaft
are in alignment with the rotation of the engine, as
shown.

Illustration 625 g00913045

10. Place clean engine oil on gear (2) and install gear
(2) on the engine.

11. Install plate (1) and the bolts.

196 SENR6419
Disassembly and Assembly Section

End By:
a. Install the flywheel housing. Refer to Disassembly
and Assembly, “Flywheel Housing - Install”.

i02087195

Piston Cooling Jets - Remove

and Install
SMCS Code: 1331

Removal Procedure
Start By:
Illustration 626 g00913178
a. Remove the engine oil pump, if necessary. 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.

1. Remove the cylinder block cover from the side of

the engine.

Illustration 627 g00913185

2. Remove bolts (1) and retainer (2).

3. Remove piston cooling jet (3) from the inside of the

engine.

Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
SENR6419 197
Disassembly and Assembly Section

(Table 64, contd)

Plastic Gauge (Green)
198-9142 0.025 to 0.076 mm 1
(0.001 to 0.003 inch)

Plastic Gauge (Red)

198-9143 0.051 to 0.152 mm 1
(0.002 to 0.006 inch)
A
Plastic Gauge (Blue)
198-9144 0.102 to 0.229 mm 1
(0.004 to 0.009 inch)

Plastic Gauge (Yellow)

198-9145 0.230 to 0.510 mm 1
(0.009 to 0.020 inch)

Illustration 628 g00913185

Note: Plastic gauge may not be necessary when the
engine is in the chassis.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Note: Cat does not recommend the checking of the

actual bearing clearances particularly on small
engines. This is because of the possibility of
obtaining inaccurate results and the possibility of
damaging the bearing or the journal surfaces. Each
Cat engine bearing is quality checked for specific
wall thickness.
Illustration 629 g00913178
Note: The measurements should be within
1. Position piston cooling jet (3) in the engine block. specifications and the correct bearings should be
Ensure that the oil holes in the end of the jet are used. If the crankshaft journals and the bores for the
facing toward the piston. block and the rods were measured during
disassembly, no further checks are necessary.
2. Install retainer (2) and bolts (1). However, if the technician still wants to measure the
bearing clearances, Tooling (A) is an acceptable
3. Install the cylinder block cover on the side of the method. Tooling (A) is less accurate on journals with
engine. small diameters if clearances are less than 0.10 mm
(0.004 inch).
End By:
a. Install the engine oil pump, if necessary. Refer to NOTICE
Disassembly and Assembly, “Engine Oil Pump - Lead wire, shim stock or a dial bore gauge can dam-
Install”. age the bearing surfaces.

i05977048 The technician must be very careful to use Tooling (A)

correctly. The following points must be remembered:
Bearing Clearance - Check • Ensure that the backs of the bearings and the
SMCS Code: 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 64
Required Tools • The crankshaft must be free of oil at the contact
points of Tooling (A).
Tool Part Number Part Description Qty
1. Put a piece of Tooling (A) on the crown of the
bearing that is in the cap.
(continued)
198 SENR6419
Disassembly and Assembly Section

Note: Do not allow Tooling (A) to extend over the i05326135

edge of the bearing.
Connecting Rod Bearings -
2. Use the correct torque-turn specifications in order
to install the bearing cap. Do not use an impact Remove and Install
wrench. Be careful not to dislodge the bearing SMCS Code: 1219-010
when the cap is installed.
Note: Do not turn the crankshaft when Tooling (A) is
Removal Procedure
installed. Table 65
Required Tools
3. Carefully remove the cap, but do not remove
Tooling (A). Measure the width of Tooling (A) while Tool Part Number Part Description Qty
Tooling (A) is in the bearing cap or on the A 5R-7425 Barring Gp(1) 1
crankshaft journal. Refer to Illustration 630 .
(1) The 9S-9082Engine Turning Tool is alternate tooling.

Start By:
a. Remove the piston cooling jets. Refer to
Disassembly and Assembly, “Piston Cooling Jets -
Remove and Install”.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

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

access the connecting rod cap that will be
removed.

Illustration 630 g01152855

Typical Example

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

bearing cap.

Note: When Tooling (A) is used, the readings can

sometimes be unclear. For example, all parts of
Tooling (A) are not the same width. Measure the
major width in order to ensure that the parts are within
the specification range. Refer to Specifications
Manual, “Connecting Rod Bearing Journal” and
Specifications Manual, “Main Bearing Journal” for the
correct clearances.

Illustration 631 g01064418

Note: 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.
SENR6419 199
Disassembly and Assembly Section

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

the crankshaft.
3. Push the connecting rod away from the crankshaft
and remove the upper half of the connecting rod
bearing.

Illustration 633 g01064420

3. Install lower half (3) of the connecting rod bearing

in connecting rod cap (2). Ensure that the tab on
the back of the bearing is in the bearing tab groove
on the connecting rod cap.
Illustration 632 g01064420
4. Install the upper half of the connecting rod bearing
in the connecting rod. Ensure that the tab on the
4. Remove lower half (3) of the connecting rod back of the bearing is in the bearing tab groove on
bearing from connecting rod cap (2). the connecting rod.
Installation Procedure 5. Position the connecting rod on the crankshaft.
Table 66
Required Tools

Tool Part Number Part Description Qty

B 334-0519 Grease -

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

1. Check the clearance of the bearings. Refer to

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

2. Place clean engine oil on the connecting rod

bearings.

Illustration 634 g01064418

6. Position connecting rod cap (2) onto the

connecting rod. Ensure that the number on the
side of connecting rod cap (2) corresponds to the
number that is on the connecting rod.

7. Apply to the threads, the shank, and the seat of

bolts(1) Tooling (B) and install bolts (1).
200 SENR6419
Disassembly and Assembly Section

Start By:
a. Remove the piston cooling jets.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product. Be
Illustration 635 g02143100 prepared to collect the fluid with suitable containers
(4) Side of the connecting rod with the chamfer before opening any compartment or disassembling
(5) Location pin any component containing fluids.

Note: Paint or mark the bolt heads and the Refer to Special Publication, NENG2500, “Caterpillar
connecting rod in order to ensure the correct angle Tools and Shop Products Guide” for tools and sup-
on the additional 90 degree final turn. plies suitable to collect and contain fluids on Caterpil-
lar products.
a. Tighten Bolts (A) and (B) to 90 ± 5 N·m
(65 ± 4 lb ft). Dispose of all fluids according to local regulations and
mandates.
b. Tighten Bolts (C) and (D) to 90 ± 5 N·m
(65 ± 4 lb ft).

c. Tighten Bolts (C) and (D) again to 90 ± 5 N·m

(65 ± 4 lb ft).

d. Paint or mark the bolt head and the connecting

rod before final torque turn.

e. Tighten all of the bolts for an additional 90 ± 5

degrees (1/4 turn).

8. Check the side clearance that is between two of

the connecting rods that are on the same journal.
The clearance must be 0.85 ± 0.332 mm
(0.034 ± 0.0130 inch).
End By: Illustration 636 g00577793

a. Install the piston cooling jets. Refer to Disassembly 1. Use Tool (A) to turn the engine and align
and Assembly, “Piston Cooling Jets - Remove and counterweights (2) for removal of the main bearing
Install”. caps.

i01098813 2. Counterweights (2) can be removed, if necessary.

Crankshaft Main Bearings - 3. Remove the four bolts and main bearing caps (1)
from the crankshaft.
Remove
SMCS Code: 1203-011

Removal Procedure
Table 67
Required Tools

Tool Part Number Part Description Qty

A 9S-9082 Engine Turning Tool 1

B 2P-5517 Bearing Tool 1

SENR6419 201
Disassembly and Assembly Section

Illustration 637 g00577796 Illustration 639 g00577798

4. Remove lower bearing halves (3) from main

NOTICE
bearing caps (1). If the crankshaft is turned in the wrong direction, the
tab of the main bearing will be pushed between the
crankshaft and the cylinder block. This may damage
both the crankshaft and the cylinder block.

6. Install Tool (B) in the oil hole of the crankshaft

journal and remove upper main bearing halves (5)
by turning the crankshaft.

Note: The center main bearing does not have an oil

hole. Place a soft piece of material that will not
damage the crankshaft journal against the end of the
bearing. Ensure that the material is on the opposite
side of the tab. Tap the bearing until the tab is free
from the cylinder block. Remove the upper half of the
center main bearing.
Illustration 638 g00577797

i01099002
5. Remove thrust plates (4) from each side of the
center main bearing. Crankshaft Main Bearings -
Install
SMCS Code: 1203-012

Installation Procedure
Table 68
Required Tools

Tool Part Number Part Description Qty

A 9S-9082 Engine Turning Tool 1

B 2P-5518 Bearing Tool 1

C 8S-2328 Dial Indicator 1

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
202 SENR6419
Disassembly and Assembly Section

NOTICE
Ensure that the upper halves and the lower halves of
the main bearings are installed with the tabs fitting in-
to the notch in the cylinder block and the notch in the
main bearing cap.

1. Place clean engine oil on the main bearings.

2. Check the clearance of the bearings. Refer to

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

Illustration 642 g00577895

5. Ensure that main bearing caps (3) are clean and

install the lower half of main bearing (4) in main
bearing caps (3).

Illustration 640 g00577798

3. Install Tool (B) in the oil hole of the crankshaft

journal. Place the upper half of the main bearing on
the crankshaft. Use Tool (A) to turn the engine and
push the upper half of the main bearing into
position with Tool (B).
Illustration 643 g00577550
Tightening sequence

Note: The main bearing caps must be installed with

the word “FRONT” and the part number toward the
front of the engine. Each main bearing cap has a
number on the bottom surface and each main bearing
must be installed in the corresponding position in the
cylinder block.
6. Lubricate the bolts with clean engine oil prior to
assembly.

7. Place the main bearing caps into position and

install the bolts. Tighten the bolts in the numerical
sequence that is shown above to a torque of
Illustration 641 g00577894 190 ± 14 N·m (140 ± 10 lb ft).

4. Place clean engine oil on thrust plates (1) and 8. Turn the bolts for an additional 180 ± 5 degrees.
install thrust plates (1) on each side of center main
bearing (2). 9. Check the end play of the crankshaft with Tool (C).
The end play must not exceed 0.40 ± 0.23 mm
(0.0157 ± 0.0091 inch).
SENR6419 203
Disassembly and Assembly Section

d. Tighten the bolts in all of the counterweights

for an additional 120 ± 5 degrees (1/3 turn).
Note: Refer to the Specifications Module for more
information on the crankshaft.

End By:
a. Install the piston cooling jets.

i01105197

Piston and Connecting Rods -

Illustration 644 g00577897
Remove
SMCS Code: 1225-011
NOTICE
Each counterweight is numbered and must be in- Removal Procedure
stalled in the same position as the corresponding Table 69
number on the crankshaft mounting pad in order to
Required Tools
prevent damage to the crankshaft.
Tool Part Number Part Description Qty

10. Install counterweights (9) and use the correct A 9S-9082 Engine Turning Tool 1
tightening procedure below.
B 1P-1861 Retaining Ring Pliers 1
11. The following procedure is for the installation of C 6V-4020 Piston Ring Expander 1
the counterweights in G3508 Engines.
5P-8639 Hydraulic Press 1
a. Ensure that the dowels are in the correct 5P-9725 Hydraulic Cylinder 1
position and install the counterweights on the
crankshaft. 8F-0024 Hose Assembly 1

1P-2375 Connecting Coupler 1

b. Apply 6V-4876Lubricant to the threads of the
bolt, to the shank of the bolt, and to the seat of 1P-2376 Connecting Coupler 1
the bolt prior to assembly. D
5P-8649 Adapter 1
c. Tighten the bolts in all of the counterweight to 6V-3043 Spacer 1
a torque of 200 ± 5 N·m (150 ± 4 lb ft).
6V-3042 Adapter 1
d. Loosen the bolts in all of the counterweights. 2D-2825 Hydraulic Pump 1

e. Tighten the bolts in all of the counterweights to 5P-8640 Bar Clamp 1

a torque of 70 ± 5 N·m (50 ± 4 lb ft).

f. Tighten the bolts in all of the counterweights Start By:

for an additional 120 ± 5 degrees (1/3 turn). a. Remove the spacer plate.
12. The following procedure is for the installation of b. Remove the piston cooling jets.
the counterweights in G3512 and G3516 Engines.
NOTICE
a. Ensure that the dowels are in the correct Keep all parts clean from contaminants.
position and install the counterweights on the
crankshaft. Contaminants may cause rapid wear and shortened
component life.
b. Apply 6V-4876Lubricant to the threads of the
bolt, to the shank of the bolt, and to the seat of
the bolt prior to assembly.

c. Tighten the bolts in all of the counterweights to

a torque of 70 ± 5 N·m (50 ± 4 lb ft).
204 SENR6419
Disassembly and Assembly Section

NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product. Be
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling
any component containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and sup-
plies suitable to collect and contain fluids on Caterpil-
lar products.
Dispose of all fluids according to local regulations and
mandates.
Illustration 646 g00582419
1. Use Tool (A) to turn the engine in order to access Typical example
the bolts in the connecting rod cap.
5. Push piston (3) out of the cylinder head until the
2. Mark the cylinder number on each connecting rod piston rings are completely out of the cylinder liner.
and the corresponding connecting rod cap.
6. Remove the piston and connecting rod assembly.
Note: The front of the engine is opposite the flywheel
end. The No. 1 cylinder is at the front of the engine on
the right side. The No. 2 cylinder is on the left side.

Illustration 647 g00582420

Typical example
Illustration 645 g00582418
7. Use Tool (B) to remove the retaining rings that hold
Typical example piston pin (4).
3. Remove bolts (1) and connecting rod cap (2) from 8. Remove piston pin (4).
the connecting rod.
9. Remove piston (3) from connecting rod (5).
4. Remove the bearings from connecting rod cap (2)
and the connecting rod.
SENR6419 205
Disassembly and Assembly Section

16. Install bar clamp (13) and clamp pin (10).

Note: The old bearing is pushed out while the new

bearing is installed.

17. Position 6V-3042 Adapter(11) with the tapered

side facing downward. The piston pin bearing joint
must be aligned with the hole in adapter (12) and
the hole in the base plate of Tool (D).

18. Place pusher (7) on adapter (11).

19. Use Tool (D) to push new piston pin bearing (8)
into the connecting rod until adapter (11) makes
contact with the connecting rod.
Illustration 648 g00582421
Typical example 20. Remove the connecting rod and the old piston pin
bearing from Tool (D).
10. Use Tool (C) to remove piston rings (6) from
21. Measure the diameter of the bore after the piston
piston (3).
pin bearing is removed. The bore should have a
11. Clean the piston ring grooves with an acceptable diameter of 70.380 ± 0.010 mm
ring groove tool. Refer to Guideline For Reusable (2.7709 ± 0.0004 inch).
Parts, SEBF8059-01, “Procedure To Clean And
22. Refer to Special Instruction, SMHS7295-02, “Use
Inspect 3500 Series Engine Pistons” for the correct
Of Piston Pin Bearing Removal And Installation
procedure for cleaning the pistons.
Tools” for more information.
12. Heat connecting rod (2) in an oven to a
temperature of 218° ± 40°C (425° ± 75°F). i05326104

Note: Do not use a direct flame in order to heat the Piston and Connecting Rods -
connecting rod.
Install
SMCS Code: 1225-012

Installation Procedure
Table 70
Required Tools

Tool Part Number Part Description Qty

A 9S-9082 Engine Turning Tool 1

B 1P-1861 Retaining Ring Pliers 1

C 6V-4020 Piston Ring Expander 1

D 1U-7616 Piston Ring Compressor 1

Illustration 649 g00582422

NOTICE
13. Place 6V-3043 Spacer(14) in the base plate of Keep all parts clean from contaminants.
Tool (D). Place the connecting rod on the base
Contaminants may cause rapid wear and shortened
plate.
component life.
14. Place the piston pin bearing in the center of the
port assembly on Tool (D). Install pin (9) in the
center of the bore for the piston pin.

15. Install 5P-8649 Adapter(12). Align the hole in

the adapter with the hole that is in the base plate of
Tool (D).
206 SENR6419
Disassembly and Assembly Section

8. Use Tool (B) to install the snap rings that hold

piston pin (4).

9. Check the clearance of the bearings. Refer to

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

10. Install the upper half of the connecting rod bearing

in connecting rod (5). Ensure that the tab on the
back of the bearing is in the bearing tab groove on
connecting rod (5).

Illustration 650 g00582421

Typical example

1. Use Tool (C) to install piston rings (6) on piston (3).

2. The ends of the oil control piston ring should be

180 degrees away from the oil ring end gap. The
white-colored section of the oil ring spring should
also be visible at the oil ring end gap.

3. Install the intermediate ring with the side that is

marked “UP” toward the top of the piston. Position
the intermediate ring with the green strip on the Illustration 652 g00582933

right side of the end gap. Typical example

4. Install the top piston ring with the red strip on the 11. Place clean engine oil on the piston rings and the
right side of the end gap. cylinder liner bore. Use Tool (D) to compress the
piston rings.
5. The piston ring end gaps must be approximately
120 degrees away from each other after 12. Install the piston and connecting rod assembly in
installation. the engine.

NOTICE
Ensure that the piston and connecting rod assembly
is installed in the engine with the chamfer of the con-
necting rod bore adjacent to the crank pin thrust sur-
face. The opposite side should also thrust against the
mating rod on the crank pin.

Illustration 651 g00582420

Typical example

6. Place clean engine oil on piston pin (4), the piston

pin bearing, and the bore in piston pin (4).

7. Position connecting rod (5) in piston (3) and install

piston pin (4).
SENR6419 207
Disassembly and Assembly Section

Start By:
a. Remove the pistons and the connecting rod
assemblies.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product. Be
Illustration 653 g00582418
prepared to collect the fluid with suitable containers
Typical example before opening any compartment or disassembling
any component containing fluids.
13. Install the lower half of the connecting rod bearing
in connecting rod cap (2). Ensure that the tab on Refer to Special Publication, NENG2500, “Caterpillar
the back of the bearing is in the bearing tab groove Tools and Shop Products Guide” for tools and sup-
plies suitable to collect and contain fluids on Caterpil-
on connecting rod cap (2). lar products.
14. Place clean engine oil on the upper half and on Dispose of all fluids according to local regulations and
the lower half of the connecting rod bearing. mandates.

15. Apply 334-0519 Grease to the threads of the

bolts and the threads in connecting rod caps (2).

16. Position connecting rod cap (2) on the connecting

rod and install bolts (1) in connecting rod cap (2).

17. Refer to Disassembly and Assembly, “Connecting

Rod Bearings - Remove and Install” for the correct
tightening procedure of the bolts in the connecting
rod cap.

18. Check the side clearance that is between two of

the connecting rods that are on the same journal.
The clearance must be 0.850 ± 0.232 mm
(0.0335 ± 0.0091 inch).
End By: Illustration 654 g00578729
Typical example
a. Install the piston cooling jets.
b. Install the spacer plate. 1. Drain the coolant from the cooling system into a
suitable container for storage or disposal.
i01099846 2. Place a cover on the crankshaft journals in order to
shield the journals from dirt and coolant.
Cylinder Liner - Remove
SMCS Code: 1216-011 3. Install Tool (A) and (B) in order to remove the
cylinder liner.
Removal Procedure
Table 71
Required Tools

Tool Part Number Part Description Qty

A 5P-8665 Cylinder Liner Puller 1

B 6V-4133 Wedge Bracket 1

208 SENR6419
Disassembly and Assembly Section

3. Position the cylinder liner in the cylinder bore

without the seals or the filler band.

Illustration 655 g00578731

Typical example

4. Remove seals (1) and filler band (2) from the

cylinder liner.

i01100240

Cylinder Liner - Install Illustration 656 g00578873

SMCS Code: 1216-012 Typical example

Installation Procedure 4. Use the following steps to check the cylinder liner
Table 72 projection:
Required Tools
a. Install four bolts (4) and the washers from Tool
Tool Part Number Part Description Qty (A). Tighten the bolts evenly in four steps.
1U-9895 Crossblock 1 Step 1..............................................14 N·m (10 lb ft)
3H-0465 Push Puller Plate 2
Step 2..............................................35 N·m (25 lb ft)
A 8F-6123 Bolt 2
0S-1575 Bolt 4 Step 3..............................................70 N·m (50 lb ft)
- Washer (3/4 inch Copper) 4 Step 4..............................................95 N·m (70 lb ft)
B 8T-0455 Liner Projection Tool Group 1
b. Install crossbar (2), plates (3), and bolts (1)
C 2P-8260 Cylinder Liner Installer 1 from Tool (A). Ensure that crossbar (2) is in
position at the center of the cylinder liner. Also
ensure that the surface of the cylinder liner is
NOTICE clean. Tighten bolts (1) evenly in four steps.
Keep all parts clean from contaminants.
Step 1..................................................7 N·m (5 lb ft)
Contaminants may cause rapid wear and shortened
component life. Step 2..............................................20 N·m (15 lb ft)

1. Install the spacer plate gasket and the spacer Step 3..............................................35 N·m (25 lb ft)
plate. Refer to Disassembly and Assembly, Step 4..............................................70 N·m (50 lb ft)
“Spacer Plate - Remove and Install”.
c. Check the distance from the bottom of
Note: Ensure that all surfaces are clean and dry
crossblock (2) to the top of the spacer plate.
when the spacer plate gasket is installed.
The distance at both ends of the crossbar
2. Clean the cylinder liner and the cylinder bore in the must be equal.
cylinder block.
SENR6419 209
Disassembly and Assembly Section

d. Check the liner projection with Tool (B) at four

locations on the cylinder liner. The cylinder
liner projection must be 0.129 ± 0.070 mm
(0.0051 ± 0.0028 inch). A distance of 0.05 mm
(0.002 inch) must be the maximum difference
between the measurements.

Note: If the cylinder liner is turned in the cylinder

block, there will be a difference in the liner
projection.

Illustration 658 g00578875

Typical example

8. Apply liquid soap to seals (5), the grooves of the

cylinder liner, and the cylinder block.

9. Install seals (5) on the cylinder liner.

10. Dip the filler band (6) in clean engine oil.

Immediately install filler band (6) in the groove that
is under the cylinder liner flange.

Illustration 657 g00578874

5. If the liner projection is not 0.129 ± 0.070 mm

(0.0051 ± 0.0028 inch), check the thickness of the
following items:

(5) Spacer plate ............................ 12.313 ± 0.025 mm

(0.4848 ± 0.0010 inch)

(6) Spacer plate gasket................... 0.208 ± 0.025 mm

(0.0082 ± 0.0010 inch)

(7) Cylinder liner flange..................... 12.65 ± 0.02 mm

(0.498 ± 0.001 inch)

6. Place an alignment mark on the cylinder liner and Illustration 659 g00578876
the cylinder block in order to install the cylinder Typical example
liner in the same position.
11. Install the cylinder liner immediately after filler
7. Remove Tool (A), Tool (B), and the spacer plate. band (6) is installed on the cylinder liner. Ensure
Also remove the cylinder liner. that the marks that are on the cylinder liner and the
cylinder block are aligned.

12. Use Tool (C) to press the cylinder liner into the
cylinder block.
End By:
a. Install the pistons and the connecting rod
assemblies.
210 SENR6419
Disassembly and Assembly Section

i02458103

Camshaft - Remove
SMCS Code: 1210-011

Removal Procedure
Table 73
Required Tools

Tool Part Number Part Description Qty

A 238-9586 Camshaft Drive Group 1

1P-0820 Hydraulic Puller 1

8B-7548 Push-Puller Tool Group 1 Illustration 660 g00579084

B 8B-7559 Adapter 2
2. Remove access covers (1) from each side of the
5H-1504 Hard Washer 3 engine.
9U-6600 Hand Hydraulic Pump 1

8T-3168 Pilot Assembly 2

C
4J-7945 Bolt 2

D 8T-3167 Guide Assembly 1

E 8T-3169 Crank Assembly 1

Start By:
a. Remove the rocker shaft assemblies and the
pushrods. Refer to Disassembly and Assembly,
“Rocker Shaft and Push Rod - Remove”.

NOTICE
Keep all parts clean from contaminants.
Illustration 661 g00579086
Contaminants may cause rapid wear and shortened
component life.

NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product. Be
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling
any component containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
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 Illustration 662 g00579090
mandates.
3. Push valve lifters (2) away from the camshaft. Hold
valve lifters (2) in position with the O-ring seal.
1. Remove the engine speed/timing sensor. Refer to
Testing and Adjusting, “Engine Speed/Timing
Sensor”.
SENR6419 211
Disassembly and Assembly Section

Illustration 663 g00579117 Illustration 665 g00579569

4. Remove the bolts and cover (3) from the left side of 7. If the engine is not equipped with a carburetor,
the front housing. disconnect electrical Plug (X) and remove bolts
from cover (5).

Illustration 664 g00579119

Illustration 666 g00579522
5. Disconnect the two control rods for the carburetor
from lever (4), if equipped. 8. Remove cover (6) for the camshaft drive gears
from the flywheel housing.
6. Remove the bolts from cover (5). Remove cover (5)
and lever (4) from the front housing as one unit.

Illustration 667 g00579141

9. Remove the bolt and plate (7) that fastens

camshaft drive gear (8) to the camshaft.
212 SENR6419
Disassembly and Assembly Section

Illustration 668 g00579142 Illustration 670 g00579145

10. Place the three washers from Tooling (B) behind 13. Remove timing ring (11) from the camshaft on the
plate (7) and install the bolt. left side of the engine.

14. Repeat Steps 8 through 12 for the camshaft drive

NOTICE gear on the left side of the engine.
Do not apply more than 51675 kPa (7500 psi) pres-
sure to the hydraulic puller. The adapters are rated at
6 1/2 tons each and the hydraulic puller is rated at 17
tons at 68900 kPa (10000 psi). If too much pressure
is applied, the gear may be damaged.

11. Install Tooling (B) on camshaft drive gear (8).

Apply 51675 kPa (7500 psi) to the puller and hit
the screw on the puller with a hammer until
camshaft drive gear (8) is free from the camshaft.
Remove Tooling (B) and camshaft drive gear (8).

Illustration 671 g00579148

Typical example

15. Install Tooling (C) on each end of the camshaft.

Note: Tooling (D) can be installed on the flywheel
housing in order to remove the camshaft from the
rear. Tooling (D) can also be installed on the front
housing in order to remove the camshaft from the
front of the engine.

16. Install Tooling (D) on the flywheel housing.

Illustration 669 g00579144
17. Install Tooling (E) on the end of Tooling (C).
12. Remove bolts (9) and thrust washers (10) that
fasten the camshaft to the right side of the engine Note: The camshafts for G3508 Engines are in one
block. piece. The camshafts for G3512 and G3516 Engines
are in two pieces.

18. The following step is for G3508 Engines.

SENR6419 213
Disassembly and Assembly Section

(Table 74, contd)

a. Rotate the camshaft with Tooling (E). Pull the 4J-7945 Bolt 2
camshaft out of the engine until a suitable
D 8T-3167 Guide Assembly 1
lifting device can be attached. Remove the
camshaft from the engine. The weight of the E 8T-3169 Crank Assembly 1
camshaft is approximately 42 kg (93 lb).

19. The following steps are for G3512 and G3516 NOTICE
Engines. Keep all parts clean from contaminants.

a. Rotate the camshaft with Tooling (E). Pull the Contaminants may cause rapid wear and shortened
camshaft out of the engine until a suitable component life.
lifting device can be attached. Remove front
camshaft (12) and rear camshaft (13) as a unit.
The camshaft for G3512 Engines has a weight
of approximately 63 kg (139 lb). The camshaft
for G3516 Engines has a weight of
approximately 82 kg (181 lb).

Illustration 673 g01226804

Typical example

1. The following steps are for the installation of a

camshaft in the G3512 Engines and G3516
Illustration 672 g00579149 Engines. The camshaft is in two pieces.

b. Remove bolts (14). Separate the camshafts a. Install Tooling (D) on the flywheel housing. Do
and remove spacer (15). not tighten the bolts on Tooling (D).

20. Remove the dowel from the front of the camshaft, b. Install Tooling (C) on the end of the front half of
if necessary. the crankshaft.

21. Repeat Steps 15 through 20 for the second c. Ensure that the camshaft and the camshaft
camshaft. bearings are clean. Place clean engine oil on
the lobes and the journals of the camshaft.
Also place clean engine oil on the camshaft
i04400132
bearings.
Camshaft - Install d. Attach a suitable lifting device to the front half
SMCS Code: 1210-012 of camshaft (12). The camshaft for G3512
Engines has a weight of approximately 63 kg
Installation Procedure (139 lb). The camshaft for G3516 Engines has
Table 74
a weight of approximately 82 kg (181 lb).
Position the front half of camshaft (12) in the
Required Tools
engine until Tooling (C) is in the first camshaft
Tool Part Number Part Description Qty bearing.
A 238-9586 Camshaft Drive Group 1 e. Rotate camshaft (12) and tighten the bolts for
C 8T-3168 Pilot Assembly 2 Tooling (D).

(continued)
214 SENR6419
Disassembly and Assembly Section

f. Rotate camshaft (12) and insert camshaft (12) k. Remove all Tooling. Repeat Steps 1.a. through
until camshaft (12) is slightly protruding from 1.j. for the camshaft on the opposite side of the
Tooling (D). engine. Go to Step 3.

2. The following steps are for the installation of a

camshaft in the G3508 Engines. The camshaft is in
one piece.

a. Install Tooling (D) on the flywheel housing. Do

not tighten the bolts on Tooling (D).

b. Install Tooling (C) on the ends of the camshaft.

c. Ensure that the camshaft and the camshaft

bearings are clean. Place clean engine oil on
the lobes and the journals of the camshaft.
Also place clean engine oil on the camshaft
bearings.
Illustration 674 g00579259
Note: Ensure that the camshafts are installed
Typical example according to the marks on the ends of the
camshafts.
d. Attach a suitable lifting device to the camshaft.
The weight of the camshaft is approximately
42 kg (93 lb). Insert the camshaft in the engine
until Tooling (C) is in the first camshaft bearing.

e. Install Tooling (E). Rotate the camshaft and

tighten the bolts on Tooling (D).

f. Rotate the camshaft and insert the camshaft

into the engine.

g. Repeat Steps 2.a. through 2.f. for the camshaft

on the opposite side of the engine. Go to Step
3.
Illustration 675 g00579148
Typical example

g. If the dowel was removed from the front half of

camshaft (12), install the dowel. The dowel
should be 22.0 ± 0.5 mm (0.87 ± 0.02 inch)
from the surface of the camshaft.
Note: Ensure that the camshafts are installed
according to the marks on the ends of the
camshafts.
h. Attach a suitable lifting device to the rear half
of camshaft (13). Install spacer (15) and the
rear half of camshaft (13) onto the front half of
camshaft (12). Install bolts (14) and tighten to
a torque of 55 ± 7 N·m (41 ± 5 lb ft). Illustration 676 g00579144

i. Install Tooling (C) and Tooling (E) on the end of

3. Install thrust washers (10) and bolts (9) that fasten
camshaft (13).
the camshaft to the engine.
j. Rotate camshaft (13) and insert the camshaft
into the engine.
SENR6419 215
Disassembly and Assembly Section

Illustration 677 g00579261 Illustration 678 g00579262

NOTICE
If the camshaft is out of time more than 18 degrees
(approximately 1/2 of the timing pin is out of the
groove), the valves can make contact with the pis-
tons. This will cause damage to the engine. Refer to
Testing and Adjusting, “Camshaft Timing” for more
information.

4. Remove timing pin (16) from the storage position

on the side of the engine.

5. Turn the camshaft until timing pin (16) can be

installed through the cylinder block and into groove
(17) that is in the camshaft.
Illustration 679 g01226865
6. Repeat Steps 4 and 5 for the camshaft on the
opposite side of the engine. 7. Remove bolts (19), cover (18), and plug (20).

8. Install one bolt (19) into the flywheel housing

through the hole for plug (20). Use Tooling (A) and
a ratchet to turn the flywheel until bolt (19) can be
installed through the hole and into the flywheel.
Doing so will position the No. 1 cylinder at the top
center. Refer to the Testing and Adjusting Module
for more information.
216 SENR6419
Disassembly and Assembly Section

Note: The taper of the camshaft and the tapered

bore of the camshaft gear must be clean, dry, and
free of residue before assembly.

b. Ensure that the camshaft timing pins and the

timing pin for the flywheel are installed.

c. Place camshaft drive gears (8) in position.

Remove the backlash by rotating the gears in
the opposite direction of camshaft rotation.

Note: For “Standard Rotation” engines, turn the

camshaft drive gears COUNTERCLOCKWISE. For
“Reverse Rotation” engines, turn the camshaft
drive gears CLOCKWISE.
Illustration 680 g00579264
d. Install the bolt and plate (7).

e. Install the bolt and timing ring (11). Ensure that

the hole in the timing ring is properly seated on
the locating pin.

f. Tighten the bolt to a torque of 360 N·m

(265 lb ft).

g. Place a Mark on the bolt.

h. Place a driver against the retaining plate of the

camshaft gear. Strike the driver solidly with a
hammer 3 to 4 times.
i. Tighten the bolt again to a torque of 360 N·m
(265 lb ft).
Illustration 681 g00579145

j. Repeat Steps 9.h. and 9.i. until the Mark has

turned at least 90 degrees.

10. Remove the timing pins from the camshafts.

Install the timing pins in the original locations.

Illustration 682 g00579141

9. Use the following procedure in order to install

camshaft drive gears (8).

a. Clean the taper of the camshaft and the Illustration 683 g00579119
tapered bore of the camshaft gear with a lint
free cloth saturated with solvent to remove oil. 11. Install cover (5) and lever (4) on the front housing.
Clean the parts again with a lint free alcohol
wipe in order to remove any residue. The 12. Connect the two control rods for the carburetor to
alcohol wipe will dirty after cleaning the parts. lever (4), if equipped.
Clean the parts again with a lint free alcohol
wipe until no residue is left on the alcohol wipe.
SENR6419 217
Disassembly and Assembly Section

Illustration 684 g00579569

Illustration 687 g00579117
13. If the engine is not equipped with a carburetor,
install cover (5) with the bolts and connect 16. Install the bolts and cover (3) on the left side of
electrical Plug (X). the front housing.

Illustration 685 g00579522 Illustration 688 g00579090

14. Install cover (6) with the bolts on the flywheel 17. Remove the O-ring seals from valve lifters (2).
housing. Push valve lifters (2) against the camshaft.

Illustration 686 g00579262 Illustration 689 g00579084

15. Remove bolt (19) from the flywheel. Install plug 18. Install access covers (1) on each side of the
(20) in the timing hole. Remove Tooling (A) and engine.
install cover (18) with bolts (19) on the flywheel
housing.
218 SENR6419
Disassembly and Assembly Section

19. Install the engine speed/timing sensor. Refer to

Testing and Adjusting, “Engine Speed/Timing
Sensor”.
End By:
a. Install the rocker shaft assemblies and the
pushrods. Refer to Disassembly and Assembly,
“Rocker Shaft and Push Rod - Install”.

i03725265

Camshaft Bearings - Remove

SMCS Code: 1211-011

Removal Procedure Illustration 690 g00578295

Table 75
Typical example
Required Tools

Tool Part Number Part Description Qty

6V-4077 Camshaft Bearing Tool Group 1

125-2739(1) Bearing Pilot 1

A
125-2740(1) Back Up Plate 1

125-2741(1) Bearing Sleeve 1

B 8S-2241 Camshaft Bearing Tool Group 1

C 5P-5247 Hydraulic Puller 1

D 8H-0684 Ratchet Wrench 1

(1) Alternate Tooling for camshaft bearings with a large diameter

Illustration 691 g00578306

Start By:
Typical example
a. Remove the camshafts.
1. Use the following steps to install Tooling (A).
NOTICE
Keep all parts clean from contaminants. a. Install the pilot group in the camshaft bearing.
Contaminants may cause rapid wear and shortened b. Place the backup plate in position and ensure
component life. that the bearing is between the two parts.

c. Install the bolt that holds Tooling (A) together.

NOTICE
Care must be taken to ensure that fluids are con- d. Use the extensions to obtain the correct length
tained during performance of inspection, mainte- for Tooling (A).
nance, testing, adjusting and repair of the product. Be
prepared to collect the fluid with suitable containers e. Install the puller plate on the bolt and the
before opening any compartment or disassembling flywheel housing or the front housing.
any component containing fluids.
Note: Tooling (B) can be used to remove the
Refer to Special Publication, NENG2500, “Caterpillar camshaft bearings when the flywheel housing and
Dealer Service Tool Catalog” for tools and supplies the front housing have been removed.
suitable to collect and contain fluids on Caterpillar
products. 2. Install Tooling (C) on Tooling (A) and pull the
Dispose of all fluids according to local regulations and bearing from the cylinder block.
mandates.
Note: Tooling (D) can be used in place of Tooling (C),
if necessary.
SENR6419 219
Disassembly and Assembly Section

i03867080

Camshaft Bearings - Install

SMCS Code: 1211-012

Installation Procedure
Table 76
Required Tools

Tool Part Number Part Description Qty

6V-4077 Camshaft Bearing Tool Group 1

125-2739(1) Bearing Pilot 1

A
125-2740(1) Back Up Plate 1 Illustration 693 g02108639

125-2741(1) Bearing Sleeve 1 Rear View

(X) Location of camshaft bearing joints
B 8S-2241 Camshaft Bearing Tool Group 1 (Y) Location of oil holes
C 5P-5247 Hydraulic Puller 1
2. Position camshaft bearing (1) and Tooling (A) in the
D 8H-0684 Ratchet Wrench 1 bore.
(1) Alternate Tooling for camshaft bearings with a large diameter
Note: The camshaft bearing joint must be on the
horizontal centerline of the bore. The upper oil hole
NOTICE must be 20 ± 5 degrees above the horizontal
Keep all parts clean from contaminants. centerline of the bore. The lower oil hole of the
Contaminants may cause rapid wear and shortened camshaft bearing must be 20 ± 5 degrees below the
component life. horizontal centerline of the bore. The camshaft
bearing joints must face the inside of the cylinder
block.

Illustration 692 g00578338

Illustration 694 g00578349
Typical example

1. Install camshaft bearing (1) on Tooling (A). 3. Install Tooling (C) on Tooling (A) and pull the
camshaft bearing into the bore.
Note: Tooling (B) can be used to install the camshaft
bearings when the flywheel housing and the front Note: Tooling (D) can be used in place of Tooling (C).
housing have been removed.
4. Check the bore of the camshaft bearing after
installation. The bore must be 86.00 ± 0.06 mm
(3.385 ± 0.002 inch).
End By:
a. Install the camshafts. Refer to Disassembly and
Assembly, “Camshaft - Install”.
220 SENR6419
Disassembly and Assembly Section

i01098283 S/N: ZAZ1–Up

Crankshaft - Remove Removal Procedure

SMCS Code: 1202-011 Table 77
Required Tools
S/N: E621–Up
Tool Part Number Part Description Qty
S/N: WC21–Up
A 4C-9832 Engine Roll-Over Stand 1
S/N: TJ61–Up
S/N: WC61–Up Start By:
S/N: TJ71–Up a. Remove the rocker shaft assemblies and the push
rods.
S/N: WC71–Up
b. Remove the front housing.
S/N: WC81–Up
c. Remove the balancer gear from the rear gear
S/N: E8A1–Up group.
S/N: ZBA1–Up d. Remove the piston cooling jets.
S/N: CRC1–Up
NOTICE
S/N: E2C1–Up The rocker shaft assemblies and the push rods must
S/N: E8C1–Up be removed to ensure that the inlet and exhaust
valves are not open. If the valves are open the face of
S/N: 4WD1–Up the inlet and exhaust valves could be damaged when
the pistons are pushed into the cylinder, away from
S/N: 5JD1–Up the crankshaft.
S/N: 8LD1–Up
S/N: E2E1–Up NOTICE
Keep all parts clean from contaminants.
S/N: 9TG1–Up
S/N: CPG1–Up Contaminants may cause rapid wear and shortened
component life.
S/N: 2TJ1–Up
S/N: 7NJ1–Up NOTICE
S/N: CPJ1–Up Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
S/N: 4EK1–Up nance, testing, adjusting and repair of the product. Be
prepared to collect the fluid with suitable containers
S/N: CRN1–Up before opening any compartment or disassembling
S/N: E6N1–Up any component containing fluids.

S/N: CSP1–Up Refer to Special Publication, NENG2500, “Caterpillar

Tools and Shop Products Guide” for tools and sup-
S/N: E6R1–Up plies suitable to collect and contain fluids on Caterpil-
lar products.
S/N: CPS1–Up
Dispose of all fluids according to local regulations and
S/N: 6JW1–Up mandates.
S/N: 8PW1–Up
S/N: 9AW1–Up 1. Use Tool (A) to turn the engine in a horizontal
position. The engine can also be supported with
S/N: E6W1–Up blocks. The engines have the following weights:
S/N: CPY1–Up
• G3508Engines weigh approximately 4300 kg
S/N: E6Y1–Up (9500 lb).
S/N: CSZ1–Up • G3512Engines weigh approximately 5443 kg
S/N: E6Z1–Up (12000 lb).
SENR6419 221
Disassembly and Assembly Section

• G3516Engines weigh approximately 6447 kg

(14200 lb).

Note: It is not necessary to remove the

counterweights from the crankshaft, if the piston and
connecting rod assemblies have been removed from
the engine.

Illustration 697 g00577388

4. Remove the center main bearing cap and two

thrust plates (3) from each side of the center main
bearing.

Illustration 695 g00577386

2. Place identification marks on counterweights (1).

Remove counterweights (1) from the engine.

Illustration 698 g00577389

Typical example

5. Use two of the bolts from the flywheel and install

one bolt in each end of the crankshaft.
6. Attach a suitable lifting device to the crankshaft.
Illustration 696 g00577387
Remove remaining main bearing caps (5) and
Note: Ensure that the journals of the crankshaft are remove crankshaft (6) from the engine. The
not scratched by the connecting rods. crankshafts have the following weights:
3. Remove connecting rod bearing caps (2) and push
• The crankshaft for the G3508Engines weighs
the connecting rods away from the crankshaft.
approximately 367 kg (807 lb).

• The crankshaft for the G3512Engines weighs

approximately 549 kg (1201 lb).

• The crankshaft for the G3516Engines weighs

approximately 762 kg (1602 lb).

7. Remove the upper halves of the main bearings and

also remove the upper halves of the connecting
rod bearings.
222 SENR6419
Disassembly and Assembly Section

S/N: E6N1–Up
S/N: CSP1–Up
S/N: E6R1–Up
S/N: CPS1–Up
S/N: 6JW1–Up
S/N: 8PW1–Up
S/N: 9AW1–Up
S/N: E6W1–Up
S/N: CPY1–Up

Illustration 699 g00577390

S/N: E6Y1–Up
S/N: CSZ1–Up
8. If necessary, remove bolts (7) and crankshaft gear
(6) from each end of the crankshaft. S/N: E6Z1–Up
S/N: ZAZ1–Up
i01098514
Installation Procedure
Crankshaft - Install Table 78
SMCS Code: 1202-012 Required Tools

Tool Part Number Part Description Qty

S/N: E621–Up
A 4C-9832 Engine Roll-Over Stand 1
S/N: WC21–Up
B 8S-2328 Dial Indicator 1
S/N: TJ61–Up
S/N: WC61–Up
NOTICE
S/N: TJ71–Up Keep all parts clean from contaminants.
S/N: WC71–Up Contaminants may cause rapid wear and shortened
S/N: WC81–Up component life.

S/N: E8A1–Up
S/N: ZBA1–Up
S/N: CRC1–Up
S/N: E2C1–Up
S/N: E8C1–Up
S/N: 4WD1–Up
S/N: 5JD1–Up
S/N: 8LD1–Up
S/N: E2E1–Up
S/N: 9TG1–Up
Illustration 700 g00577546
S/N: CPG1–Up
S/N: 2TJ1–Up 1. If crankshaft gears (1) were removed, install the
gears on crankshaft (2).
S/N: 7NJ1–Up
S/N: CPJ1–Up 2. Check the clearance of the bearings. Refer to
Disassembly and Assembly, “Bearing Clearance -
S/N: 4EK1–Up Check” for the correct procedure.
S/N: CRN1–Up
SENR6419 223
Disassembly and Assembly Section

Illustration 701 g00577547 Illustration 703 g00577550

Tightening sequence
Note: Place clean engine oil on the main bearings
and on the connecting rod bearings prior to Note: The main bearing caps must be installed with
installation. the word “FRONT” and the part number toward the
front of the engine. Each main bearing cap has a
Note: The upper halves of the main bearings have an number on the bottom surface and each main bearing
oil hole in the center. must be installed in the corresponding position in the
3. Install the upper halves of main bearings (3) in the cylinder block.
cylinder block. 6. Place 6V-4876 Lubricant on the bolts for the main
bearing caps.
4. Install the upper halves of connecting rod bearings
(4) in the connecting rod assemblies. 7. Place clean engine oil on thrust plates (9). Install
thrust plates (9) on each side of the center main
bearing.

Illustration 702 g00577548

Typical example
Illustration 704 g00577577
Note: Ensure that the word “FRONT” that is on the
end of the crankshaft is toward the front of the engine. 8. Place the main bearing caps into position and
5. Attach a suitable lifting device to crankshaft (2) and install the bolts. Tighten the bolts in the numerical
position the crankshaft in the cylinder block. sequence that is shown above to a torque of
190 ± 14 N·m (140 ± 10 lb ft). Tighten the bolts
again for an additional 180 ± 5 degrees.

9. Check the end play with Tool (B). The end play
must not exceed 0.40 ± 0.23 mm
(0.0157 ± 0.0091 inch).
224 SENR6419
Disassembly and Assembly Section

e. Tighten each bolt for an additional 90 ± 5

degrees (1/4 turn). An impact wrench may be
used.
13. Place the remaining connecting rod caps in
position and tighten the bolts with the same
procedure that is in Steps 12.a. through 12.e..

Illustration 705 g00577579

10. Position the connecting rods on the journals of the

crankshaft.

Note: The number that is on the side of the

connecting rod caps must be installed next to the
corresponding number that is on the side of the
connecting rod.
Illustration 707 g00577584

NOTICE
Each counterweight is numbered and must be in-
stalled in the same position as the corresponding
number on the crankshaft mounting pad in order to
prevent damage to the crankshaft.

14. Install counterweights (15) and use the correct

tightening procedure below.

15. The following procedure is for the installation

of the counterweights in G3508 Engines.

a. Ensure that the dowels are in the correct

Illustration 706 g00577581
position and install the counterweights on the
Tightening sequence crankshaft.
11. Place 6V-4876 Lubricant on the bolts for the b. Apply 6V-4876Lubricant to the threads of the
connecting rod caps. bolt, to the shank of the bolt, and to the seat of
the bolt prior to assembly.
12. Place connecting rod caps (10) and install the
bolts. Tighten the bolts with the following steps: c. Tighten the bolts in all of the counterweight to
a torque of 200 ± 5 N·m (150 ± 4 lb ft).
a. Tighten bolts (11) and (12) to a torque of
90 ± 5 N·m (65 ± 4 lb ft). d. Loosen the bolts in all of the counterweights.

b. Tighten bolts (13) and (14) to a torque of e. Tighten the bolts in all of the counterweights to
90 ± 5 N·m (65 ± 4 lb ft). a torque of 70 ± 5 N·m (50 ± 4 lb ft).

c. Tighten bolts (11) and (12) again to a torque of f. Tighten the bolts in all of the counterweights
90 ± 5 N·m (65 ± 4 lb ft). for an additional 120 ± 5 degrees (1/3 turn).

d. Tighten bolts (13) and (14) again to a torque of 16. The following procedure is for the installation
90 ± 5 N·m (65 ± 4 lb ft). of the counterweights in G3512 and G3516
Engines.
SENR6419 225
Disassembly and Assembly Section

a. Ensure that the dowels are in the correct

position and install the counterweights on the
crankshaft.
b. Apply 6V-4876Lubricant to the threads of the
bolt, to the shank of the bolt, and to the seat of
the bolt prior to assembly.

c. Tighten the bolts in all of the counterweights to

a torque of 70 ± 5 N·m (50 ± 4 lb ft).

d. Tighten the bolts in all of the counterweights

for an additional 120 ± 5 degrees (1/3 turn).
Note: Refer to the Specifications Module for more
information on the crankshaft.

End By:
a. Install the piston cooling jets.
b. Install the balancer gear on the rear gear group.
c. Install the front housing.
d. Install the rocker shaft assemblies and the push
rods.
226 SENR6419
Index Section

Index
A Camshaft Bearings - Remove ....................... 218
Removal Procedure ................................... 218
Accessory Drive (Front) - Assemble.............. 170
Carburetor - Assemble (High Pressure) .......... 61
Assembly Procedure.................................. 170
Carburetor - Assemble (High Pressure) .......... 63
Accessory Drive (Front) - Disassemble ......... 169
Carburetor - Assemble (High Pressure)
Disassembly Procedure............................. 169
Assembly Procedure.................................... 61
Accessory Drive (Front) - Install .................... 171
Carburetor - Assemble (High Pressure)
Installation Procedure ................................ 171
Assembly Procedure.................................... 63
Accessory Drive (Front) - Remove ................ 168
Carburetor - Disassemble (High Pressure) ..... 58
Removal Procedure ................................... 168
Carburetor - Disassemble (High Pressure) ..... 60
Aftercooler - Remove and Install ................81, 86
Carburetor - Disassemble (High Pressure)
Installation Procedure .............................84, 87
Disassembly Procedure............................... 59
Removal Procedure ................................81, 86
Carburetor - Disassemble (High Pressure)
Air Cleaner - Remove and Install..................... 66
Disassembly Procedure............................... 60
Installation Procedure .................................. 67
Carburetor - Install (High Pressure)................. 65
Removal Procedure ..................................... 67
Installation Procedure .................................. 66
Air Inlet Manifold - Remove and Install ............ 88
Carburetor - Install (Low Pressure).................. 64
Installation Procedure .................................. 89
Carburetor - Install (Low Pressure).................. 64
Removal Procedure ..................................... 88
Carburetor - Install (Low Pressure)
Air Starting Motor - Assemble.....................22, 29
Installation Procedure .................................. 64
Assembly Procedure...............................22, 30
Carburetor - Install (Low Pressure)
Air Starting Motor - Disassemble..................6, 12
Installation Procedure .................................. 65
Disassembly Procedure............................6, 12
Carburetor - Remove (High Pressure)............. 56
Air Starting Motor - Install ................................ 39
Removal Procedure ..................................... 57
Installation Procedure .................................. 39
Carburetor - Remove (Low Pressure).............. 56
Air Starting Motor - Remove .............................. 5
Carburetor - Remove (Low Pressure).............. 57
Removal Procedure ....................................... 5
Carburetor - Remove (Low Pressure)
Auxiliary Water Pump - Assemble ................. 120
Removal Procedure ..................................... 56
Assembly Procedure.................................. 121
Carburetor - Remove (Low Pressure)
Auxiliary Water Pump - Disassemble .............118
Removal Procedure ..................................... 58
Disassembly Procedure..............................118
Connecting Rod Bearings - Remove and
Auxiliary Water Pump - Install........................ 123
Install............................................................ 198
Installation Procedure ................................ 124
Installation Procedure ................................ 199
Auxiliary Water Pump - Remove.....................116
Removal Procedure ................................... 198
Removal Procedure ....................................116
Crankcase Breather - Remove and Install..... 151
Installation Procedure ................................ 152
B Removal Procedure ................................... 151
Crankshaft - Install......................................... 222
Bearing Clearance - Check ........................... 197
Installation Procedure ................................ 222
Measurement Procedure ........................... 197
Crankshaft - Remove..................................... 220
Removal Procedure ................................... 220
C Crankshaft Front Seal and Wear Sleeve -
Install............................................................ 178
Camshaft - Install........................................... 213 Installation Procedure For Seals 113-8432 and
Installation Procedure ................................ 213 113-8433 .................................................. 178
Camshaft - Remove....................................... 210 Installation Procedure For Seals 436-1478 and
Removal Procedure ................................... 210 436-1479.................................................. 179
Camshaft Bearings - Install............................ 219 Crankshaft Front Seal and Wear Sleeve -
Installation Procedure ................................ 219 Remove ....................................................... 177
SENR6419 227
Index Section

Removal Procedure ................................... 177 Engine Oil and Water Pump Drive -
Crankshaft Main Bearings - Install................. 201 Remove ....................................................... 144
Installation Procedure ................................ 201 Removal Procedure ................................... 144
Crankshaft Main Bearings - Remove............. 200 Engine Oil Cooler - Assemble........................ 128
Removal Procedure ................................... 200 Assembly Procedure.................................. 128
Crankshaft Rear Seal and Wear Sleeve - Engine Oil Cooler - Disassemble................... 127
Install............................................................ 182 Disassembly Procedure............................. 127
Installation Procedure For Seals 113-8432 and Engine Oil Cooler - Install .............................. 130
113-8433 .................................................. 182 Installation Procedure ................................ 130
Installation Procedure For Seals 436-1478 and Engine Oil Cooler - Remove.......................... 126
436-1479.................................................. 184 Removal Procedure ................................... 126
Crankshaft Rear Seal and Wear Sleeve - Engine Oil Filter Housing - Assemble............ 140
Remove ....................................................... 181 Assembly Procedure.................................. 140
Removal Procedure ................................... 181 Engine Oil Filter Housing - Disassemble ....... 138
Cylinder Head - Assemble............................. 161 Disassembly Procedure............................. 138
Assembly Procedure.................................. 161 Engine Oil Filter Housing - Install .................. 143
Cylinder Head - Disassemble ........................ 159 Installation Procedure ................................ 143
Disassembly Procedure............................. 159 Engine Oil Filter Housing - Remove .............. 137
Cylinder Head - Install ................................... 164 Removal Procedure ................................... 137
Installation Procedure ................................ 164 Engine Oil Pan - Assemble............................ 149
Cylinder Head - Remove ............................... 157 Assembly Procedure.................................. 149
Removal Procedure ................................... 157 Engine Oil Pan - Disassemble....................... 148
Cylinder Liner - Install .................................... 208 Disassembly Procedure............................. 148
Installation Procedure ................................ 208 Engine Oil Pan - Install .................................. 150
Cylinder Liner - Remove................................ 207 Installation Procedure ................................ 150
Removal Procedure ................................... 207 Engine Oil Pan - Remove .............................. 147
Removal Procedure ................................... 147
Engine Oil Pump - Assemble......................... 134
D Assembly Procedure.................................. 134
Disassembly and Assembly Section ................. 5 Engine Oil Pump - Disassemble.................... 132
Drive Housing (Front) - Remove and Install .. 172 Disassembly Procedure............................. 132
Installation Procedure ................................ 174 Engine Oil Pump - Install ............................... 136
Removal Procedure ................................... 172 Installation Procedure ................................ 136
Engine Oil Pump - Remove ........................... 131
Removal Procedure ................................... 131
E Engine Oil Sequence Valves - Remove and
Electric Starting Motor - Remove and Install ... 40 Install............................................................ 189
Installation Procedure .................................. 41 Installation Procedure ................................ 190
Removal Procedure ..................................... 40 Removal Procedure ................................... 189
Electronic Sensor - Remove and Install........... 55 Exhaust Bypass Valve - Remove and Install ... 93
Installation Procedure .................................. 55 Installation Procedure .................................. 93
Removal Procedure ..................................... 55 Removal Procedure ..................................... 93
Engine Oil and Water Pump Drive - Exhaust Elbow - Remove and Install......... 89–90
Assemble ..................................................... 145 Installation Procedure .............................90, 92
Assembly Procedure.................................. 145 Removal Procedure ................................89, 91
Engine Oil and Water Pump Drive - Exhaust Manifold - Install (Dry)........................ 99
Disassemble ................................................ 144 Installation Procedure .................................. 99
Disassembly Procedure............................. 144 Exhaust Manifold - Install (Water Cooled) ....... 97
Engine Oil and Water Pump Drive - Install .... 147 Installation Procedure .................................. 97
Installation Procedure ................................ 147 Exhaust Manifold - Remove (Dry).................... 93
Removal Procedure ..................................... 94
228 SENR6419
Index Section

Exhaust Manifold - Remove (Water Cooled) ... 95 I

Removal Procedure ..................................... 95
Important Safety Information ............................. 2

F P
Flywheel - Remove and Install....................... 180
Piston and Connecting Rods - Install............. 205
Installation Procedure ................................ 180
Installation Procedure ................................ 205
Removal Procedure ................................... 180
Piston and Connecting Rods - Remove ........ 203
Flywheel Housing - Install.............................. 186
Removal Procedure ................................... 203
Installation Procedure ................................ 186
Piston Cooling Jets - Remove and Install...... 196
Flywheel Housing - Remove.......................... 184
Installation Procedure ................................ 196
Removal Procedure ................................... 184
Removal Procedure ................................... 196
Fuel Control Actuator - Remove and Install.... 48,
50
Installation Procedure .............................49, 51 R
Removal Procedure ................................49, 51
Rocker Shaft - Assemble............................... 155
Fuel Control Valve - Remove and Install ... 52–53
Assembly Procedure.................................. 155
Installation Procedure ............................ 53–54
Rocker Shaft - Disassemble .......................... 154
Removal Procedure ................................52, 54
Disassembly Procedure............................. 154
Rocker Shaft and Push Rod - Install.............. 156
G Installation Procedure ................................ 156
Rocker Shaft and Push Rod - Remove.......... 154
Gas Pressure Regulator - Assemble ............... 46
Removal Procedure ................................... 154
Assembly Procedure.................................... 46
Gas Pressure Regulator - Disassemble .......... 45
Disassembly Procedure............................... 45 S
Gas Pressure Regulator - Install (High
Service Meter - Remove and Install................. 41
Pressure) ....................................................... 48
Installation Procedure .................................. 41
Installation Procedure .................................. 48
Removal Procedure ..................................... 41
Gas Pressure Regulator - Install (Low
Spacer Plate - Remove and Install ................ 166
Pressure) ....................................................... 48
Installation Procedure ................................ 167
Installation Procedure .................................. 48
Removal Procedure ................................... 166
Gas Pressure Regulator - Remove ................. 43
Removal Procedure ..................................... 43
Gas Pressure Regulator - Remove (High T
Pressure) ....................................................... 44
Removal Procedure ..................................... 44 Table of Contents............................................... 3
Gas Pressure Regulator - Remove (Low Thermostatic Valve - Assemble ......................115
Pressure) ....................................................... 44 Assembly Procedure...................................115
Removal Procedure ..................................... 45 Thermostatic Valve - Disassemble .................114
Gas Pressure Regulator Solenoid - Disassembly Procedure..............................114
Remove and Install ........................................ 42 Thermostatic Valve - Install.............................115
Installation Procedure .................................. 43 Installation Procedure .................................115
Removal Procedure ..................................... 43 Thermostatic Valve - Remove.........................113
Gear Group (Rear) - Install ............................ 193 Removal Procedure ....................................113
Installation Procedure ................................ 193 Turbocharger - Assemble ................................ 74
Gear Group (Rear) - Remove ........................ 191 Assembly Procedure.................................... 74
Removal Procedure ................................... 191 Turbocharger - Disassemble ........................... 70
Disassembly Procedure............................... 71
Turbocharger - Install................................. 78–79
Installation Procedure ............................ 79–80
SENR6419 229
Index Section

Turbocharger - Remove..............................67, 69
Removal Procedure ............................... 68–69

V
Valve Cover and Spark Plug - Remove and
Install............................................................ 152
Installation Procedure ................................ 153
Removal Procedure ................................... 152
Vibration Damper - Remove and Install......... 175
Installation Procedure ................................ 176
Removal Procedure ................................... 175

W
Water Pump - Assemble................................ 108
Assembly Procedure.................................. 109
Water Pump - Disassemble........................... 106
Disassembly Procedure............................. 106
Water Pump - Install .......................................112
Installation Procedure .................................113
Water Pump - Remove .................................. 104
Removal Procedure ................................... 104
Water Temperature Regulators - Install ......... 103
Installation Procedure ................................ 103
Water Temperature Regulators - Remove ..... 101
Removal Procedure ................................... 101
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