RENR9700

December 2004

C18 Engine

Engine Design
Bore 145 mm (5.71 inch)
Stroke 183 mm (7.20 inch)
Number of Cylinders 6
Cylinder Arrangement *In-line
Firing Order (Injection Sequence) 1, 5, 3, 6, 2, 4
Direction of Rotation
Counterclockwise
(Viewed from flywheel end)

Engine Assembly Procedure

Q - Denotes Critical Checkpoints
Sub Assembly Installation Parts Assembly Sub Assembly Sub Assembly Installation Parts Assembly
Sub Assembly
Parts Sequence Procedure Parts Sequence Procedure
Clean oil passages. Pump Fuel Injection Time fuel pump camshaft
Q–1 Q – 24
Block Check liner projection. Governor Assembly with timing pin.
Covers Install fuel injection pump
Position block on engine
Plugs Block 25 housing assembly and fuel
2 stand with accessory drive
Liners Assembly filter.
side up.
Camshaft Install fuel pump drive gear
Bearings Install main bearings to 26
3 and torque.
block and caps.
Cylinder Head Install gasket and spacer
27
4 Oil main bearings. Plate Assembly plate.
Install crankshaft and Install gasket and cylinder
5 28
thrust plates. head.
Crankshaft Crankshaft Install and torque main 29 Install push rods.
Q–6
Gear Assembly bearing caps.
30 Install rocker arm assembly.
Rotate crankshaft and
Q–7 Torque cylinder head and
check end play. Q – 31
rocker arm bolts.
Lubricate cylinder block
Q – 32 Adjust valve lash.
liner bores and rubber
surfaces with 5P-3975 33 Install valve cover, breather.
Connecting rubber lubricant just prior
Rods 8 Front Housing Install front housing.
to inserting liners. Housing 34
Assembly
Rings Piston & Rod Lubricate the rings and
Pistons Assembly bearings with clean engine Install wear sleeve and seal
35
oil. to crankshaft.
Pins
Bearings Install in block with the 36 Install front support.
forging part number on the Install crankshaft damper
Q–9 37
rod pointed toward the and pulley.
flywheel end of the engine.
Install water pump, regulator
Q – 10 Torque rod nuts. Q – 38
and elbows.
Rotate crankshaft and Pump Install exhaust manifold.
Q – 11 Water Pump
recheck end play.
Regulator 39
Flywheel 12 Install flywheel housing. Assembly
Elbows
Housing Check flywheel housing
Flywheel Q – 13 40 Install engine oil cooler.
Covers bore and face runout.
Housing 41 Install oil filter base and filter.
Plugs
Assembly Install wear sleeve and
Seals 14 seal to crankshaft and Install transmission oil
42
Sleeve flywheel housing. cooler.

Q – 15 Install flywheel and torque. 43 Install tube assemblies.

Check flywheel bore and 44 Install air compressor.

Q – 16
face runout. 45 Install fuel lines.
17 Install front timing plate. 46 Install starter motor.
Pump, 18 Install oil pump. 47 Install alternator.
Gears Oil Pump Install miscellaneous covers,
Tube Assembly Assembly 19 Install oil pan. lines, and accessories.
48
Suction Bell Compare completed engine
with illustration.
20 Set engine upright.
Put No. 1 piston at top
21 center. Put timing bolt in
flywheel.
Install camshaft, thrust
Q – 22
washers, gear & torque.
Install idler gear and check
backlash between the
camshaft gear and idler
gear. The backlash
between the two gears
should be taken with idler
Camshaft Camshaft gear assembly held
Gear Assembly stationary. The backlash
measurement should be
0.216 ± 0.114 mm (0.0085
± 0.0045 inch). Note:
Marks on camshaft and
crankshaft gear must be in
alignment.
Install injector hydraulic
23
pump.

©2004 Caterpillar Inc.

All Rights Reserved Printed in U.S.A.
 Crankshaft Cylinder Liners
1. Connecting Rod Journal 97.0 ± 0.020 mm (3.8189 ± 0.0008 inch) Bore in liner (New) 145 ± 0.025 mm (5.71 ± 0.001 inch)
Connecting Rod Journal-to- Liner flange thickness 8.890 ± 0.020 mm (0.3500 ± 0.0008 inch)
0.062 to 0.160 mm (0.0024 to .0063 inch)
Bearing Clearance Spacer plate thickness 8.585 ± 0.025 mm (0.338 ± 0.0010 inch)
Maximum Permissible Clearance between Spacer plate gasket 0.20 ± 0.02 mm
0.20 mm (0.008 inch)
Connecting Rod Journal-to-Bearing thickness (0.008 ± 0.0008 inch)
2. Main Bearing Journal 120.65 ± 0.020 mm (4.75 ± 0.0008 inch) Liner projection 0.025 to 0.152 mm (0.0010 ± 0.0060 inch)
Main Bearing Journal-to- Installation Tool Required
0.091 to 0.186 mm (0.0036 to .0073 inch)
Bearing Clearance
Part No. Description
Maximum Permissible Clearance between 2P-8260 Cylinder Liner Installer
0.25 mm (0.010 inch)
Main Bearing Journal-to-Bearing Note: Apply 5P-3975 Rubber Lubricant on the surfaces of the cylinder
3. Crankshaft End Play 0.11 to 0.57 mm (.0043 to 0.022 inch) liner bore. Apply 5P-3975 Rubber Lubricant on the rubber seals on the
lower part of the cylinder liner. Put the filler band completely in clean
4. Clearance between main bearing cap and cylinder block -0.038 mm
engine oil for a moment. Install filler band in the groove under the liner
(0.0015 inch) Tight to 0.038 mm (0.0015 inch) Loose.
flange without delay. Install the liner in the bore immediately, before the
5. Main bearing cap width 215.900 ± 0.025 mm (8.500 ± 0.001 inch) filler band expands.
6. Width of cylinder block
215.900 ± 0.013 mm (8.500 ± 0.0005 inch)
for main bearing cap
Piston, Rings and Connecting Rods
Installation Tool Recommended
Torque Procedure Part No. Description
Note: Lubricate bolts (1,2, 3, 4) with engine oil before assembly. 5P-3526 Piston Ring Compressor
Connecting Rod Bolts Note: Thoroughly lubricate pin with clean engine oil just before
a. Torque bolts (1, 3) to 70 ± 4 N·m (52 ± 3 lb ft) inserting the pin into the piston and rod assembly.
Note: Thoroughly lubricate piston group 360° on piston skirt and piston
b. Torque bolts (2, 4) to 70 ± 4 N·m (52 ± 3 lb ft)
head with clean engine oil.
c. Mark the head of each bolt. Note: Install top ring with side marked “UP-1” toward top of piston
d. Tighten bolts (2, 4) an additional 60° ± 5° (purple color stripe to the right of ring end gap).
Note: Install intermediate ring with side marked “UP-2” toward top of
e. Retighten bolts (1, 3) to 70 ± 4 N·m (52 ± 3 lb ft)
piston (white color stripes to right of ring end gap).
f. Torque bolts (1, 3) an additional 60° ± 5° Note: Oil ring spring ends to be assembled 180° from ring end gap.
g. Torque piston cooling jet bolt (A) to 55 ± 10 N·m (40 ± 7 lb ft) Green color stripe can be to right or to the left of the ring gap.
Note: After assembling rings on piston, orient ring gaps 120° apart.
Note: Orientation not required for pin retainer.
Note: Piston and rod group is to be assembled with rod bearing tabs
closest to piston cooling jet mounting pads in block. The oil hold in rod
and bearing is opposite rod/cap joint with bearing tabs.

Cylinder Head

Piston Cooling Jets

a. 62.59 ± 0.25 mm (2.464 ± 0.01 inch)
Note: The following bolts are marked “x” and are 216 mm (8.5 in.) long:
b. 41.13 ± 0.25 mm (1.62 ± 0.01 inch)
11, 12, 13, 14, 16, 18, 20, 22, 24 & 26. The rest of the bolts are 194 mm
c. 81.8 ± 0.25 mm (3.22 ± 0.01 inch) (7.6 in.) long.
d. 54 ± 0.25 mm (2.13 ± 0.01 inch) Note: Apply 4C-5593 Anti-seize Compound to the bolt threads and both
sides of washers.
e. 250 mm (9.84 inch) Tighten bolts in the following Step sequence:
Step 1. Tighten bolts 1 thru 26 in a numerical 270 ± 15 N·m
sequence to (200 lb ft ± 11 lb ft)
Step 2. Tighten bolts 1 thru 26 in a numerical 450 ± 15 N·m
sequence to (330 ± 11 lb ft)
Step 3. Retighten bolts 1 thru 26 in a numerical 450 ± 15 N·m
sequence to (330 ± 11 lb ft)

Flywheel Housing

Main Bearing Bolts

Note: Main bearing caps to be assembled with the word “front” toward
the front of the block. 1. Maximum permissible runout (radial 0.30 mm
eccentricity) of the flywheel housing bore. (0.012 inch)
a. Lubricate bolts with engine oil before assembly.
2. Maximum permissible runout (axial 0.38 mm
b. Torque tab end to 258 ± 14 N·m (190 ± 10 lb ft).
eccentricity) of the flywheel housing face. (0.015 inch)
c. Mark each bolt and cap.
d. Torque opposite end from tab 258 ± 14 N·m (190 ± 10 lb ft).
e. Turn the bolt on the opposite end from tab an additional 120° ± 5° Flywheel
f. Turn the bolt on the end with tab an additional 120° ± 5°

Turbocharger
1. Apply 5P-3931 Anti Seize Compound on bolt threads and lock nuts that hold
turbocharger to exhaust manifold.
2. Install turbocharger on exhaust manifold and torque lock nuts to 55 ± 5 N·m
(40 ± 4 lb ft).

1. Maximum permissible runout (radial eccentricity) 0.15 mm

off center of bore (total indicator reading) (0.006 inch)
2. Maximum permissible runout (axial eccentricity) 0.15 mm
of face (total indicator reading) (0.006 inch)
3. Maximum permissible runout (axial eccentricity) 0.013 mm
of center of bore (total indicator reading) (0.005 inch)
4. Lubricate bolt threads with engine oil before assembly.
270 ± 40 N·m
5. Torque for flywheel bolts
(199 ± 30 lb ft)

©2004 Caterpillar Inc.

All Rights Reserved Printed in U.S.A.
Vibration Damper and Pulley Valve Cover

Tighten all bolts in numerical sequence to 18 ± 3 N·m (13 ± 2 lb in)

1) Damper Bolt 3) Damper
2) Pulley 4) Adapter
Tighten damper bolts to 215 ± 40 N·m (158 ± 30 lb ft) Exhaust Manifold

Valve and Injector Mechanisms

35 ± 5 N·m
1. Torque for studs installed in cylinder head
(26 ± 4 lb ft)
2. Put 5P-3931 Anti-Seize Compound on threads of the locknuts.
A) Intake 3. Tighten locknuts holding exhaust manifold to 38 ± 5 N·m
B) Exhaust cylinder head in numerical sequence shown (28 ± 4 lb ft)
C) Flywheel end of engine
D) Right side of engine

Sequence for Installation and Adjustment

Of Valve and Injector Mechanisms
1. Valve lash settings:
Intake 0.38 ± 0.08 (0.0149 ± 0.0031 inch)
Exhaust 0.76 ± 0.08 (0.299 ± 0.0031 inch)
A. Adjust the valve lash setting with engine cold and stopped.
B. After setting valve lash, tighten adjusting screw locknut 30 ± 7
N·m (22 ± 5 lb ft).
C. Recheck valve lash setting.
2. Unit injector adjusting instructions:
A. Turn the unit injector rocker arm screw until unit injector height
from timing seat is 78.0 ± 0.02 (3.07 ± 0.0078 inch).
B. Hold the adjusting screw in this position and tighten the locknut to
100 ± 10 N·m (74 ± 7 lb ft).
3. A static torque of 100 + 50 –10 N·m (74 + 37 – 7 lb ft) is permitted.

Procedure for Setting Valve Lash and Unit Injector

1. Set No. 1 piston at TDC on the compression stroke.
2. Set inlet valves on cylinders 1, 2, and 4.
3. Set exhaust valves on cylinders 1, 3, and 5.
4. Set unit injector on cylinders 3, 5, and 6.
5. Turn crankshaft 360° in direction of engine rotation (No. 6 piston at
TDC of compression stroke).
5. Set inlet valves on cylinders 3, 5, and 6.
6. Set exhaust valves on cylinders 2, 4, and 6.
7. Set unit injector on cylinders 1, 2, and 4.

Front Gear Train

1) Water pump gear 7) Idler gear

2) Cluster gear 8) Fuel transfer pump gear
3) Camshaft gear 9) Timing marks
4) Timing marks 10) Crankshaft gear
5) Adjustable idler gear 11) Oil pump gear
6) Air compressor gear

©2004 Caterpillar Inc.

All Rights Reserved Printed in U.S.A.