Renr9716 02 01 All

RENR9716-02
September 2008
Disassembly and
Assembly
C27 and C32 Generator Sets Engines
DWB1-Up (Generator Set)
SXC1-Up (Generator Set)
MED1-Up (Power Module)
WDR1-Up (Generator Set)
SAFETY.CAT.COM
i01658146
Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identied 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.
Operations that may cause product damage are identied by NOTICE labels on the product and in
this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. If a tool,
procedure, work method or operating technique that is not specically recommended by Caterpillar
is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that
the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Caterpillar dealers have the most current information available.
When replacement parts are required for this
product Caterpillar recommends using Caterpil-
lar replacement parts or parts with equivalent
specications including, but not limited to, phys-
ical dimensions, type, strength and material.
Failure to heed this warning can lead to prema-
ture failures, product damage, personal injury or
death.
RENR9716-02 3
Table of Contents
Table of Contents
Disassembly and Assembly Section
Engine - Remove ................................................... 4
Engine - Install ....................................................... 6
Fuel Priming Pump - Remove and Install .............. 9
Fuel Filter Base - Remove ................................... 10
Fuel Filter Base - Install ....................................... 10
Fuel Filter and Water Separator - Remove and
Install .................................................................... 11
Fuel Transfer Pump - Remove .............................. 12
Fuel Transfer Pump - Install .................................. 12
Electronic Unit Injector - Remove ......................... 13
Electronic Unit Injector - Install ............................. 14
Electronic Unit Injector Sleeve - Remove ............. 15
Electronic Unit Injector Sleeve - Install ................. 16
Turbocharger - Remove ........................................ 17
Turbocharger - Disassemble ................................ 17
Turbocharger - Assemble .................................... 18
Turbocharger - Install ............................................ 18
Exhaust Manifold - Remove and Install ............... 19
Inlet and Exhaust Valve Springs - Remove and
Install ................................................................... 20
Inlet and Exhaust Valves - Remove and Install .... 22
Inlet and Exhaust Valve Guides - Remove and
Install ................................................................... 23
Inlet and Exhaust Valve Seat Inserts - Remove and
Install ................................................................... 24
Engine Oil Filter Base - Remove .......................... 25
Engine Oil Filter Base - Disassemble ................... 26
Engine Oil Filter Base - Assemble ........................ 26
Engine Oil Filter Base - Install .............................. 27
Engine Oil Cooler - Remove ................................. 27
Engine Oil Cooler - Install ..................................... 28
Engine Oil Pump - Remove .................................. 28
Engine Oil Pump - Disassemble ........................... 29
Engine Oil Pump - Assemble ................................ 29
Engine Oil Pump - Install ...................................... 30
Water Pump - Remove ......................................... 31
Water Pump - Disassemble ................................. 31
Water Pump - Assemble ...................................... 32
Water Pump - Install ............................................. 33
Water Temperature Regulator Housing - Remove and
Install .................................................................. 33
Cooling System Package (Radiator, Aftercooler, Fuel
Cooler) - Remove ................................................ 35
Cooler) - Install .................................................... 36
Aftercooler - Remove ........................................... 38
Aftercooler - Install ............................................... 40
Radiator Core - Remove ...................................... 42
Radiator Core - Install .......................................... 44
Engine Support (Front) - Remove and Install ....... 45
Gear Group (Rear) - Remove ............................... 46
Gear Group (Rear) - Install ................................... 48
Flywheel - Remove and Install ............................. 49
Crankshaft Rear Seal - Remove ........................... 50
Crankshaft Rear Seal - Install ............................... 50
Flywheel Housing - Remove and Install .............. 51
Vibration Damper and Pulley - Remove and Install
............................................................................. 53
Crankshaft Front Seal - Remove .......................... 54
Crankshaft Front Seal - Install .............................. 55
Gear Group (Front) - Remove .............................. 55
Gear Group (Front) - Install .................................. 56
Housing (Front) - Remove .................................... 57
Housing (Front) - Install ........................................ 58
Housing (Rear) - Remove ..................................... 60
Housing (Rear) - Install ......................................... 60
Valve Mechanism Cover - Remove and Install ..... 62
Valve Mechanism Cover Base - Remove and
Install ................................................................... 62
Rocker Arm and Shaft - Remove .......................... 63
Rocker Arm - Disassemble ................................... 64
Rocker Arm - Assemble ........................................ 64
Rocker Arm and Shaft - Install .............................. 65
Cylinder Head - Remove ...................................... 66
Cylinder Head - Install .......................................... 68
Camshaft - Remove .............................................. 71
Camshaft - Install .................................................. 73
Camshaft Bearings - Remove ............................... 76
Camshaft Bearings - Install ................................... 76
Engine Oil Pan - Remove and Install ................... 78
Cylinder Liner - Remove ....................................... 79
Cylinder Liner - Install ........................................... 79
Piston Cooling Jets - Remove and Install ............. 80
Pistons and Connecting Rods - Remove .............. 81
Pistons and Connecting Rods - Disassemble ....... 82
Pistons and Connecting Rods - Assemble ........... 82
Pistons and Connecting Rods - Install .................. 83
Connecting Rod Bearings - Remove .................... 84
Connecting Rod Bearings - Install ........................ 85
Crankshaft Main Bearings - Remove .................... 86
Crankshaft Main Bearings - Install ........................ 87
Crankshaft - Remove ............................................ 88
Crankshaft - Install ................................................ 90
Bearing Clearance - Check ................................... 92
Atmospheric Pressure Sensor - Remove and
Install ................................................................... 93
Camshaft Position Sensor - Remove and Install .. 93
Crankshaft Position Sensor - Remove and Install .. 94
Coolant Temperature Sensor - Remove and
Install ................................................................... 95
Engine Oil Pressure Sensor - Remove and Install
............................................................................. 96
Fuel Pressure Sensor - Remove and Install ......... 97
Fuel Temperature Sensor - Remove and Install ... 97
Turbocharger Outlet Pressure Sensor - Remove and
Install ................................................................... 98
Inlet Air Temperature Sensor - Remove and
Install ................................................................... 99
Belt Guard - Remove and Install ........................... 99
Fan Guard - Remove and Install ........................ 100
Fan - Remove and Install ................................... 101
Fan Drive - Remove and Install ......................... 102
Electronic Control Module - Remove and Install .. 103
Alternator - Remove and Install ......................... 104
Electric Starting Motor - Remove and Install ..... 105
Index Section
Index ................................................................... 106
4 RENR9716-02
Disassembly and Assembly
Section
i02747487
Engine - Remove
SMCS Code: 1000-011
Removal Procedure
Table 1
Required Tools
Tool
Part
Number Part Description Qty
A 138-7573 Link Bracket 2
B 238-9586 Engine Turning Tool 1
C 1U-9200 Lever Puller Hoist 1
D 189-0411 Shackle As 2
E 6V-6146 Load Leveling Beam 1
Start By:
a. Remove the cooling package. Refer to
Disassembly and Assembly, Cooling System
Package (Radiator, Aftercooler, Fuel Cooler) -
Remove.
g01291159
Illustration 1
1. Disconnect hose assembly (1). Disconnect cable
assembly (2). Disconnect harness assemblies
(3). Disconnect cable assembly (4). Disconnect
harness assemblies (5).
g01291160
Illustration 2
2. Disconnect harness assembly (6).
g01291161
Illustration 3
3. Disconnect hose assemblies (7), (8), and (9).
g01291162
Illustration 4
4. Disconnect clamp (10).
RENR9716-02 5
g01291179
Illustration 5
5. Remove bolts (11). Remove bolts (12). Repeat for
the opposite side. Disconnect tube assembly (13).
Repeat for the opposite side.
g01291183
Illustration 6
6. Attach Tooling (A) and a suitable lifting device
onto exhaust elbow (14). The weight of exhaust
elbow (14) is approximately 34 kg (75 lb). Remove
exhaust elbow (14).
g01291186
Illustration 7
7. Disconnect clamp (15).
g01291225
Illustration 8
8. Remove bolts (16). Remove guard (17).
g01291227
Illustration 9
9. Remove bolts (18). Remove guard (19).
g01291228
Illustration 10
10. Disconnect hose (20).
6 RENR9716-02
g01291232
Illustration 11
g01291243
Illustration 12
11. Install Tooling (B). Use Tooling (B) in order to
rotate the engine. Rotate the engine in order to
gain access to bolts (22). Remove bolts (22).
Remove bolts (21).
g01376223
Illustration 13
12. Use Tooling (C) in order to support generator
rotor (23).
g01291246
Illustration 14
13. Attach Tooling (D) onto engine (24). Attach Tooling
(E) and a suitable lifting device onto Tooling
(D). The weight of engine (24) is approximately
3527 kg (7775 lb).
g01291247
Illustration 15
14. Remove mounting bolts (25). Remove engine
(24) from the generator.
i02747534
Engine - Install
SMCS Code: 1000-012
Installation Procedure
Table 2
Required Tools
Tool
Part
B 238-9586 Engine Turning Tool 1
C 1U-9200 Lever Puller Hoist 1
D 189-0411 Shackle As 2
E 6V-6146 Load Leveling Beam 1
RENR9716-02 7
g01291246
Illustration 16
1. Attach Tooling (D) onto engine (24). Attach Tooling
(E) and a suitable lifting device onto Tooling
(D). The weight of engine (24) is approximately
3527 kg (7775 lb). Install engine (24).
g01291247
Illustration 17
2. Install mounting bolts (25).
g01291243
Illustration 18
g01291232
Illustration 19
3. Install bolts (21). Use Tooling (B) in order to rotate
the engine. Install bolts (22).
g01291245
Illustration 20
4. Remove Tooling (C).
g01291228
Illustration 21
5. Connect hose (20).
8 RENR9716-02
g01291227
Illustration 22
6. Install guard (19). Install bolts (18).
g01291225
Illustration 23
7. Install guard (17). Install bolts (16).
g01291186
Illustration 24
8. Connect clamp (15).
g01291183
Illustration 25
onto exhaust elbow (14). The weight of exhaust
elbow (14) is approximately 34 kg (75 lb). Install
exhaust elbow (14).
g01291179
Illustration 26
10. Connect tube assembly (13). Install bolts (12).
Repeat for the opposite side. Install bolts (11).
g01291162
Illustration 27
RENR9716-02 9
11. Connect clamp (10).
g01291161
Illustration 28
12. Connect hose assemblies (7), (8), and (9).
g01291160
Illustration 29
13. Connect harness assembly (6).
g01291159
Illustration 30
14. Connect harness assemblies (5). Connect cable
assembly (4). Connect harness assemblies (3).
Connect cable assembly (2). Connect hose
assembly (1).
End By:
a. Install the cooling package. Refer to Disassembly
and Assembly, Cooling System Package
(Radiator, Aftercooler, Fuel Cooler) - Install.
i02580978
Fuel Priming Pump - Remove
and Install
SMCS Code: 1258-010
Removal Procedure
NOTICE
Care must be taken to ensure that uids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the uid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing uids.
Refer to Special Publication, NENG2500, Caterpillar
Tools and Shop Products Guide for tools and supplies
suitable to collect and contain uids on Caterpillar
products.
Dispose of all uids according to local regulations and
mandates.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
g01292755
Illustration 31
1. Remove bolts (1).
2. Remove fuel priming pump (2) and the gasket.
10 RENR9716-02
g01292755
Illustration 32
1. Position the gasket and fuel priming pump (2) on
the fuel lter base.
2. Install bolts (1).
i02580993
Fuel Filter Base - Remove
SMCS Code: 1262-011
Removal Procedure
Table 3
Required Tools
Tool
Part
A 185-3630 Strap Wrench 1
NOTICE
Dealer Service Tool Catalog for tools and supplies
products.
mandates.
NOTICE
component life.
1. Turn the fuel supply to the OFF position.
g01292764
Illustration 33
2. Use Tooling (A) to remove fuel lter (6) from fuel
lter base (5).
3. Disconnect harness assemblies (4).
4. Disconnect hose assembly (1) and hose assembly
(2).
5. Remove bolts (3) and fuel lter base (5).
i02581008
Fuel Filter Base - Install
SMCS Code: 1262-012
NOTICE
component life.
RENR9716-02 11
g01292764
Illustration 34
1. Position fuel lter base (5) on the engine. Install
bolts (3).
2. Connect hose assembly (1) and hose assembly
(2).
3. Connect harness assemblies (4).
4. Install fuel lter (6) on fuel lter base (5).
5. Turn the fuel supply to the ON position.
i02581074
Fuel Filter and Water Separator
- Remove and Install
SMCS Code: 1261-010; 1263-010
Removal Procedure
Table 4
Required Tools
Tool Part Number Part Description Qty
A 185-3630 Strap Wrench As 1
NOTICE
component life.
NOTICE
products.
mandates.
g01292832
Illustration 35
2. Use Tooling (A) to remove the fuel lter and water
separator (5) from base assembly (4).
3. Disconnect hose assemblies (2) and (3).
4. Remove bolts (1) and base assembly (4).
NOTICE
component life.
12 RENR9716-02
g01292832
Illustration 36
1. Position base assembly (4) on the cylinder block
and install bolts (1).
2. Connect hose assemblies (2) and (3).
3. Install a new fuel lter and water separator (5) on
base assembly (4).
i02285574
Fuel Transfer Pump - Remove
SMCS Code: 1256-011
Removal Procedure
NOTICE
products.
mandates.
NOTICE
component life.
g01143748
Illustration 37
2. Disconnect hose assemblies (3).
4. Remove fuel transfer pump (1) and the O-ring
seal.
i02287501
Fuel Transfer Pump - Install
SMCS Code: 1256-012
NOTICE
component life.
RENR9716-02 13
g01143748
Illustration 38
1. Install the O-ring seal on fuel transfer pump (1).
Lubricate the O-ring seal with clean engine oil.
2. Position fuel transfer pump (1) on the engine.
Install bolts (2).
3. Connect hose assemblies (3).
i02208070
Electronic Unit Injector -
Remove
SMCS Code: 1290-011
Removal Procedure
Table 5
Required Tools
A 5F-4764 Pry Bar 1
Start By:
a. Remove the rocker arms and the rocker arm shaft.
Refer to Disassembly and Assembly, Rocker Arm
and Shaft - Remove.
NOTICE
component life.
g01114892
Illustration 39
2. Remove bridge assemblies (3).
NOTICE
If the injector hold down bolt is loose during the re-
moval procedure, inspect the injector bore for wear
and debris. Replace the clamp and spacer.
3. Remove bolt (4), spacer (5), and clamp (6).
4. Place an identication mark on electronic unit
injectors (2) for installation purposes. Each
electronic unit injector must be reinstalled in the
original location in the cylinder head.
g01073439
Illustration 40
5. Use Tooling (A) to pry beneath the base and free
electronic unit injector (2).
6. Remove electronic unit injector (2) from the
cylinder head.
14 RENR9716-02
i03143340
Electronic Unit Injector - Install
SMCS Code: 1290-012
Table 6
Required Tools
B 8T-2998 Lubricant 1
1U-5718 Vacuum Pump 1
169-7372 Fluid Sampling Bottle 1
C
4C-4057
Tube
7.9 mm (0.31 inch) OD
1
D 4C-5552 Large Bore Brush 1
E 4C-6774 Vacuum Gun Kit 1
F 8T-7765
Surface Reconditioning
Pad
1
NOTICE
component life.
1. Use Tooling (C) to remove the fuel and oil from
the cylinder. Evacuate as much fuel and oil as
possible from the cylinder before installing the
electronic unit injector. Several evacuations may
be necessary.
2. Use Tooling (D) to clean the carbon deposit from
the inside of the electronic unit injector sleeve.
Tooling (E) is available to clean loose material
from the bore of the electronic unit injector sleeve
and the cylinder.
3. Use Tooling (F) to clean the carbon from the seat
area that is inside of the electronic unit injector
sleeve.
4. Install the O-ring seals on the electronic unit
injector. Lubricate the top two O-ring seals with a
50/50 mixture of clean engine oil and Tooling (B).
g01114892
Illustration 41
g01135876
Illustration 42
5. When you install a new injector the E-Trim
value must be programmed into the engine
control module. The injector conrmation code
may need to be programmed into the engine
control module. E-Trim Value (X) is a twelve digit
alphanumeric code that is supplied with the data
sheet that comes with the new injectors. Injector
Conrmation Code (Y) is a four digit numeric
code. Both of the codes are located on the top of
electronic unit injector (2). Use the following menu
to program the E-Trim value.
ECM Summary Screen
Service Menu
Calibration
Injector Code Calibration

RENR9716-02 15
NOTICE
When an electronic unit injector is replaced, the new
electronic injector code must be programmed into the
engines personality module software by using the cal-
ibration menu on the Electronic Service Tool. If the
new electronic injector code is not entered, the char-
acteristics of the previous electronic unit injector is as-
sumed.
If it is not possible to immediately reprogram the elec-
tronic injector code into the personality module soft-
ware, the engine will not be severely harmed. The new
electronic injector code should be reprogrammed as
quickly as possible in order to optimize engine perfor-
mance.
6. Position electronic unit injector (2) in the cylinder
head.
7. Install spacer (5), clamp (6), and bolt (4). Tighten
the bolt to a torque of 55 10 Nm (41 7 lb ft).
8. Install bridge assemblies (3).
9. Connect harness assembly (1). Tighten the nuts
to a torque of 2.5 0.25 Nm (22 2 lb in).
End By:
a. Install the rocker arms and the rocker arm shaft.
and Shaft - Install.
i02300212
Electronic Unit Injector Sleeve
- Remove
SMCS Code: 1713-011
Removal Procedure
Table 7
Required Tools
Tool
Part
A 9U-6891 Injector Tool Group 1
Start By:
a. Remove the electronic unit injectors. Refer to
Disassembly and Assembly, Electronic Unit
Injector - Remove.
NOTICE
component life.
1. Drain the coolant from the cooling system into a
suitable container for storage or disposal. Refer
to Operation and Maintenance Manual, Cooling
System Coolant - Change.
g01043124
Illustration 43
2. Install Tooling (A) in electronic unit injector sleeve
(1).
3. Tighten the nut on Tooling (A) until the electronic
unit injector sleeve is pulled free of the cylinder
head.
g01073635
Illustration 44
4. Remove O-ring seals (2) and O-ring seal (3) from
electronic unit injector sleeve (1).
16 RENR9716-02
i02287628
Electronic Unit Injector Sleeve
- Install
SMCS Code: 1713-012
Table 8
Required Tools
A 9U-6891 Injector Tool Group 1
9U-6862 Tapered Brush 1
9U-6863 Small Bore Brush 1
9U-7244 End Brush 1
9U-7237 Brush Extension 1
B
4C-5552 Large Bore Brush 1
C 4C-9507 Retaining Compound 1
NOTICE
component life.
1. Use Tooling (B) to clean the bore in the cylinder
head for the electronic unit injector sleeve.
NOTICE
Ensure that the electronic unit injector sleeve and the
cylinder head bore are completely free of oil, dirt, and
sealant debris.
g01043165
Illustration 45
2. Install new O-ring seals (2) and O-ring seal (3) on
electronic unit injector sleeve (1).
3. Apply Tooling (C) to the contact surface of
electronic unit injector sleeve (1) on the surface
that is Marked X.
Note: Do not apply Tooling (C) to the cylinder head
surfaces. Apply Tooling (C) on the electronic unit
injector sleeve only.
4. Lubricate O-ring seals (2) with clean engine oil.
g01099549
Illustration 46
5. Install electronic unit injector sleeve (1) on Tooling
(A). Position the electronic unit injector sleeve in
the cylinder head. Use care not to damage the
O-ring seals on the electronic unit injector sleeve.
Use Tooling (A) and a hammer to install the
electronic unit injector sleeve in the cylinder head.
NOTICE
Ensure that the electronic unit injector sleeve is
properly seated in the cylinder head. The Tooling will
"RING" when the electronic unit injector sleeve is fully
seated in the bore of the cylinder head.
6. Remove Tooling (A). Remove excess Tooling (C).
7. Fill the cooling system with coolant. Refer to
Operation and Maintenance Manual, Cooling
End By:
a. Install the electronic unit injectors. Refer to
Injector - Install.
RENR9716-02 17
i02287744
Turbocharger - Remove
SMCS Code: 1052-011
Removal Procedure
NOTICE
products.
mandates.
NOTICE
component life.
g01145002
Illustration 47
g01148173
Illustration 48
2. Remove tube assembly (2).
3. Disconnect tube assemblies (1) and tube
assembly (4).
4. Attach a suitable lifting device to turbocharger (5).
The weight of turbocharger (5) is approximately
45 kg (100 lb).
5. Remove nuts (3). Remove turbocharger (5) and
the gasket.
i02287870
Turbocharger - Disassemble
SMCS Code: 1052-015
Disassembly Procedure
Start By:
a. Remove the turbocharger. Refer to Disassembly
and Assembly, Turbocharger - Remove.
NOTICE
component life.
18 RENR9716-02
g01145263
Illustration 49
1. Loosen V-band clamp (2) and V-band clamp (4).
2. Separate compressor housing (1) from
turbocharger cartridge (3).
3. Separate turbine housing (5) from turbocharger
cartridge (3).
i02451256
Turbocharger - Assemble
SMCS Code: 1052-016
Assembly Procedure
NOTICE
component life.
NOTICE
The compressor housing must remain straight with
the turbocharger cartridge during disassembly and as-
sembly. Tilting may cause damage to the tips of the
compressor wheel and the compressor shaft.
g01145263
Illustration 50
1. Position compressor housing (1) and turbine
housing (5) on turbocharger cartridge (3).
Note: Ensure that the mating surfaces are ush.
2. Tighten the nuts on V-band clamp (2) to a torque
of 14 1 Nm (10 1 lb ft). Use a soft hammer to
lightly hit around the diameter of the band clamp.
Tighten the nuts again to a torque of 14 1 Nm
(10 1 lb ft).
3. Tighten the nuts on V-band clamp (4) to a torque
of 14 1 Nm (10 1 lb ft). Use a soft hammer to
lightly hit around the diameter of the band clamp.
Tighten the nuts again to a torque of 14 1 Nm
(10 1 lb ft).
4. Ensure that the impeller spins freely.
End By:
a. Install the turbocharger. Refer to Disassembly and
Assembly, Turbocharger - Install.
i02288273
Turbocharger - Install
SMCS Code: 1052-012
Table 9
Required Tools
A 5P-3931 Anti-Seize Compound 1
NOTICE
component life.
g01148173
Illustration 51
RENR9716-02 19
g01145002
Illustration 52
1. Position the gasket on the exhaust manifold.
2. Apply Tooling (A) to the threads of the exhaust
manifold studs.
3. Attach a suitable lifting device to turbocharger (5).
The weight of turbocharger (5) is approximately
45 kg (100 lb). Position turbocharger (5) on the
exhaust manifold.
4. Install nuts (3) and tighten to a torque of 55 9 Nm
(41 7 lb ft).
5. Connect tube assemblies (1) and tube assembly
(4).
6. Install tube assembly (2).
7. Fill the cooling system. Refer to Operation and
Maintenance Manual, Cooling System Coolant
- Change.
i02617122
Exhaust Manifold - Remove
and Install
SMCS Code: 1059-010
Removal Procedure
Start By:
a. Remove the turbocharger. Refer to Disassembly
and Assembly, Turbocharger - Remove.
NOTICE
component life.
1. Remove the shield assemblies from the exhaust
manifolds.
g01218139
Illustration 53
2. Remove locknuts (6) from exhaust manifold (7).
3. Remove spacers (2) and (3) from exhaust
manifold (7).
4. Remove exhaust manifold (7) and gaskets (1)
from the cylinder head.
5. If necessary, remove clamps (4) and expansion
joints (5).
Table 10
Required Tools
A 5P-3931 Anti-Seize Compound -
B 165-4638 Guide 3
g01218139
Illustration 54
20 RENR9716-02
g00566145
Illustration 55
1. If necessary, install expansion joints (5) and
clamps (4). Tighten the clamps to a torque of
8.5 1.0 Nm (75 9 lb in).
2. Apply Tooling (A) to the studs prior to assembly. If
necessary, install the studs and tighten to a torque
of 35 5 Nm (26 4 lb ft).
3. Position gaskets (1) and exhaust manifold (7) on
the cylinder head.
4. Install spacers (2) and (3) on exhaust manifold (7).
Note: Use Tooling (B) in at least one oversize hole
per manifold section in order to align the exhaust
manifolds. Do not remove Tooling (B) until removal
is required to tighten the locknuts.
5. Install locknuts (6) on exhaust manifold (7).
Tighten locknuts (6) in a numerical sequence to a
torque of 20 3 Nm (15 2 lb ft). Tighten locknuts
(6) again in a numerical sequence to a torque of
38 5 Nm (28 4 lb ft).
6. Install the shield assemblies on the exhaust
manifolds.
End By:
a. Install the turbocharger. Refer to Disassembly and
Assembly, Turbocharger - Install.
i02300073
Inlet and Exhaust Valve
Springs - Remove and Install
SMCS Code: 1108-010
Removal Procedure
Table 11
Required Tools
A 9U-7241 Valve Spring Compressor 1
B 8S-2263 Spring Tester 1
Start By:
Injector - Remove.
NOTICE
component life.
Note: Place the piston at the top of the compression
stroke (TC). Remove the valve springs for that
cylinder. If the valves fall into the cylinder liner, then
the cylinder head must be removed.
1. Position the No. 1 piston at the top center of
the compression stroke. Refer to Testing and
Adjusting, Finding Top Center Position for No. 1
Piston.
g01073852
Illustration 56
RENR9716-02 21
g01043625
Illustration 57
Personal injury can result from being struck by
parts propelled by a released spring force.
Make sure to wear all necessary protective equip-
ment.
Follow the recommended procedure and use all
recommended tooling to release the spring force.
2. Install Tooling (A) in the electronic unit injector
sleeve. Secure Tooling (A) with unit injector clamp
(1).
3. Tighten the full nut until valve spring keepers (3)
are loose on valve (2).
4. Remove valve spring keepers (3) from the valve.
5. Carefully remove Tooling (A).
6. Remove valve rotator (4).
7. Remove outer valve spring (6) and inner valve
spring (5) from the valve.
8. Remove washer (7) from the valve guide.
9. Use Tooling (B) to check the valve springs (spring
force). Refer to Specications, Cylinder Head
Valves for additional information on the valve
springs.
Table 12
Required Tools
A 9U-7241 Valve Spring Compressor 1
NOTICE
component life.
1. Lubricate the valve stems with clean engine oil.
g01043625
Illustration 58
Improper assembly of parts that are spring loaded
can cause bodily injury.
To prevent possible injury, follow the established
assembly procedure and wear protective equip-
ment.
2. Ensure that washer (7) is installed on the valve
guide.
3. Install inner valve spring (5) and outer valve spring
(6) on valve (2).
4. Install valve rotator (4) on valve (2).
The valve spring keepers can be thrown from
the valve when the valve spring compressor is
released. Ensure that the valve spring keepers
are properly installed on the valve stem. To help
prevent personal injury, keep away from the front
of the valve spring keepers and valve springs
during the installation of the valves.
5. Use Tooling (A) to compress inner valve spring
(5) and outer valve spring (6). Install valve spring
keepers (3) on valve (2). Remove unit injector
clamp (1) and Tooling (A).
22 RENR9716-02
End By:
a. Install the electronic unit injectors. Refer to
Injector - Install.
i02642655
Inlet and Exhaust Valves -
Remove and Install
SMCS Code: 1105-010
Removal Procedure
Table 13
Required Tools
A 5S-1330
Valve Spring
Compressor
1
B 8S-2263 Spring Tester 1
Start By:
a. Remove the cylinder head. Refer to Disassembly
and Assembly, Cylinder Head - Remove.
NOTICE
component life.
g01015263
Illustration 59
ment.
1. Install Tooling (A) and compress the valve springs.
Remove valve spring keepers (2) from valve (1).
2. Carefully remove Tooling (A) from valve (1).
3. Remove valve rotator (3).
4. Remove outer valve spring (5) and inner valve
spring (4) from valve (1).
5. Remove washer (6) and valve (1) from the valve
guide.
6. Use Tooling (B) to check the valve springs (spring
force). Refer to Specications, Cylinder Head
Valves for additional information on the valve
springs.
7. Inspect the valves. Refer to Specications,
Cylinder Head Valves for additional information
on the inlet and exhaust valves.
RENR9716-02 23
Table 14
Required Tools
A 5S-1330
Valve Spring
Compressor
1
NOTICE
component life.
Note: A small amount of grease can be used to hold
the retainer locks in position during installation.
1. Lubricate the valves with clean engine oil. Install
the valves in the cylinder head.
g01015263
Illustration 60
ment.
2. Install washer (6) on the valve guide.
3. Install inner valve spring (4) and outer valve spring
(5) on valve (1).
4. Install valve rotator (3) on valve (1).
5. Use Tooling (A) to compress inner valve spring
(4) and outer valve spring (5). Install valve spring
keepers (2) on valve (1).
The valve spring keepers can be thrown from
the valve when the valve spring compressor is
released. Ensure that the valve spring keepers
are properly installed on the valve stem. To help
prevent personal injury, keep away from the front
of the valve spring keepers and valve springs
during the installation of the valves.
6. Carefully remove Tooling (A).
End By:
a. Install the cylinder head. Refer to Disassembly
and Assembly, Cylinder Head - Install.
i02109151
Inlet and Exhaust Valve Guides
SMCS Code: 1104-010
Removal Procedure
Table 15
Required Tools
A
(1)
9U-6895 Valve Guide Driver 1
(1)
Part of 9U-7530 Engine Tool Group
Start By:
a. Remove the inlet and exhaust valves. Refer to
Disassembly and Assembly, Inlet and Exhaust
Valves - Remove and Install.
NOTICE
component life.
24 RENR9716-02
g01073841
Illustration 61
1. Remove valve stem seal (1) from valve guide (2).
2. Use Tooling (A) and a hammer to remove the
valve guide from the cylinder head.
Table 16
Required Tools
A
(1)
9U-6895 Valve Guide Driver 1
B
(1)
9U-6894 Guide Collar 1
(1)
NOTICE
component life.
g01073842
Illustration 62
1. Lubricate the bores for the valve guides with clean
engine oil.
2. Install valve guide (2) in the cylinder head with
Tooling (A) and Tooling (B).
Note: Tooling (B) must be used in order to install the
valve guide to the correct height.
Height to top of valve guide from cylinder head
surface ..... 35.00 0.50 mm (1.378 0.020 inch)
Note: For more information, refer to Specications,
Cylinder Head Valves.
3. Install valve stem seal (1) on the valve guide.
End By:
a. Install the inlet and exhaust valves. Refer to
i02288478
Inlet and Exhaust Valve Seat
Inserts - Remove and Install
SMCS Code: 1103-010
Removal Procedure
Table 17
Required Tools
Tool
Part
A 166-7441
Valve Seat Extractor Tool
Group
1
Start By:
a. Remove the inlet and exhaust valves. Refer to
NOTICE
component life.
g01145463
Illustration 63
RENR9716-02 25
1. Use Tooling (A) to remove valve seat insert (1)
2. Clean the bores in the cylinder head for the valve
seat inserts. Remove any rough areas from the
bores.
Table 18
Required Tools
Tool
Part
9U-6898
Valve Seat Driver
(Exhaust)
1
B
(1)
9U-6897 Valve Seat Driver (Inlet) 1
(1)
NOTICE
component life.
g01079028
Illustration 64
1. Lower the temperature of new valve seat insert
(1).
2. Use Tooling (B) to install the new valve seat insert
in the cylinder head.
Note: Do not machine the prenished valve seat
inserts in order to correct the valve stem projection.
An excessive valve stem projection indicates that the
valve seat insert is not seated or material was not
cleaned from the bottom of the counterbore.
End By:
a. Install the inlet and exhaust valves. Refer to
i02438648
Engine Oil Filter Base -
Remove
SMCS Code: 1306-011
Removal Procedure
Table 19
Required Tools
Tool
Part
NOTICE
component life.
NOTICE
products.
mandates.
1. Drain the engine oil into a suitable container
for storage or disposal. Refer to Operation and
Maintenance Manual, Engine Oil and Filter -
Change.
g01218560
Illustration 65
26 RENR9716-02
2. Use Tooling (A) in order to remove engine oil
lters (6).
3. Remove bolts (1), (2), (4), and (5).
4. Remove engine oil lter base (3).
i02127750
Disassemble
SMCS Code: 1306-015
Start By:
a. Remove the engine oil lter base. Refer to
Disassembly and Assembly, Engine Oil Filter
Base - Remove.
1. Remove the O-ring seals.
g01083088
Illustration 66
ment.
2. Remove cover (4).
3. Remove springs (3) and plungers (2) from oil lter
base assembly (1).
i02127824
Assemble
SMCS Code: 1306-016
Assembly Procedure
NOTICE
component life.
g01083088
Illustration 67
ment.
1. Install plungers (2) and springs (3) in oil lter base
assembly (1).
2. Install cover (4).
3. Install the O-ring seals.
RENR9716-02 27
End By:
a. Install the engine oil lter base. Refer to
Base - Install.
i02438813
Engine Oil Filter Base - Install
SMCS Code: 1306-012
Table 20
Required Tools
Tool
Part
NOTICE
component life.
g01218560
Illustration 68
1. Position engine oil lter base (3) on the engine
oil cooler.
2. Install bolts (1), (2), (4), and (5).
3. Use Tooling (A) to install engine oil lters (6).
4. Rell the engine with engine oil. Refer to Operation
and Maintenance Manual, Engine Oil and Filter
- Change.
i02438849
Engine Oil Cooler - Remove
SMCS Code: 1378-011
Removal Procedure
Start By:
a. Remove the engine oil lter base. Refer to
Base - Remove.
NOTICE
component life.
NOTICE
products.
mandates.
g01218689
Illustration 69
2. Remove tube assembly (2).
3. Remove bonnet (1) and the gasket.
28 RENR9716-02
4. Remove engine oil cooler (3).
5. Remove the O-ring seals from engine oil cooler
(3).
i02438914
Engine Oil Cooler - Install
SMCS Code: 1378-012
NOTICE
component life.
g01218689
Illustration 70
1. Install the O-ring seals on engine oil cooler (3).
2. Lubricate the O-ring seals with clean engine oil
or glycerin.
3. Install engine oil cooler (3).
4. Install the gasket and bonnet (1).
5. Install tube assembly (2).
6. Rell the cooling system with coolant. Refer to
End By:
a. Install the engine oil lter base. Refer to
Base - Install.
i02439263
Engine Oil Pump - Remove
SMCS Code: 1304-011
Removal Procedure
Start By:
a. Remove the engine oil pan. Refer to Disassembly
and Assembly, Engine Oil Pan - Remove and
Install.
NOTICE
products.
mandates.
g01218847
Illustration 71
1. Remove tube assemblies (3) from engine oil pump
(2).
2. Remove bolts (1) and engine oil pump (2).
RENR9716-02 29
i02439652
Engine Oil Pump - Disassemble
SMCS Code: 1304-015
Table 21
Required Tools
Tool
Part
A 1P-0510 Driver Group 1
B 1P-2320 Puller Assembly 1
Start By:
a. Remove the engine oil pump. Refer to
Disassembly and Assembly, Engine Oil Pump
- Remove.
NOTICE
component life.
g01218982
Illustration 72
ment.
1. Remove bolt (7) and washer (6).
2. Use Tooling (B) to remove drive gear (5) from
body assembly (1). Remove the key from the
pump shaft.
3. Remove bolts (4) and separate cover assembly
(3) from body assembly (1).
4. Use Tooling (A) and a suitable press in order to
remove the bearings from cover assembly (3).
5. Remove shaft assemblies (2).
6. Remove bolts (12) and retainer (11).
7. Remove spring (10), plunger ring (9), and plunger
(8).
8. Use Tooling (A) and a suitable press in order to
remove the bearings from body assembly (1).
i02439997
Engine Oil Pump - Assemble
SMCS Code: 1304-016
Assembly Procedure
Table 22
Required Tools
Tool
Part
NOTICE
component life.
g01218982
Illustration 73
30 RENR9716-02
g01219045
Illustration 74
g01219048
Illustration 75
ment.
1. Use Tooling (A) to install the bearings in body
assembly (1) until the bearings are even with
the outside surface of body assembly (1). Install
the bearings so the junctions in the bearings are
Angle (X). Angle (X) is 30 15 degrees from the
center line of the bearing bores and toward the
outlet passage in the engine oil pump.
2. Install plunger (8), plunger ring (9), and spring
(10).
3. Install retainer (11) and bolts (12).
4. Install shaft assemblies (2).
5. Use Tooling (A) to install the bearings in cover
assembly (3) until the bearings are even with
the outside surface of cover assembly (3). Install
the bearings so the junctions in the bearings are
Angle (Y). Angle (Y) is 30 15 degrees from the
center line of the bearing bores, and toward the
outlet passage. The outlet passage has a cavity
between the bearing bores.
6. Install cover assembly (3) on body assembly (1).
Install bolts (4).
7. Install the key into the pump shaft. Install drive
gear (5). Install washer (6) and bolt (7). Tighten
bolt (7) to a torque of 55 10 Nm (41 7 lb ft).
End By:
a. Install the engine oil pump. Refer to Disassembly
and Assembly, Engine Oil Pump - Install.
i02440080
Engine Oil Pump - Install
SMCS Code: 1304-012
NOTICE
component life.
g01218847
Illustration 76
1. Position engine oil pump (2) and install bolts (1).
2. Install tube assemblies (3) on engine oil pump (2).
End By:
a. Install the engine oil pan. Refer to Disassembly
and Assembly, Engine Oil Pan - Remove and
Install.
RENR9716-02 31
i02440626
Water Pump - Remove
SMCS Code: 1361-011
Removal Procedure
NOTICE
products.
mandates.
NOTICE
component life.
g01219274
Illustration 77
2. Remove bolts (1) and bolts (2).
g01219275
Illustration 78
4. Remove bolts (6) and nuts (5).
5. Remove water pump (4).
i02451192
Water Pump - Disassemble
SMCS Code: 1361-015
Table 23
Required Tools
Tool
Part
8S-2264 Puller Group 1
4B-3903
Bolt
5/16 - 18 NC by 4
inch
2
1P-0456 Plate 1
A
4B-4277 Washer 2
B 1P-0510 Driver Group 1
Start By:
a. Remove the water pump. Refer to Disassembly
and Assembly, Water Pump - Remove.
NOTICE
component life.
32 RENR9716-02
Note: The water pump seal can be replaced without
removing the water pump from the engine.
Note: An intermittent leakage of a small amount of
coolant from the hole in the water pump housing is
not an indication of a water pump seal failure. This
is required to provide lubrication for the seal. Do not
replace the water pump seal unless a large amount
of leakage or a constant ow of coolant is draining
from the water pump housing.
g01195730
Illustration 79
1. Remove adapter (15).
2. Remove bolt (9) and washer (8).
3. Use Tooling (A) to remove impeller (5) from shaft
(10).
4. Remove bolt (7), washer (6), and gear (4) from
shaft (10).
5. Remove bolts (11) and retainer (13).
6. Remove O-ring seal (14) from housing (3).
7. Use a suitable press to remove shaft (10) and
bearing assembly (1) from housing (3).
8. Use a suitable press to remove bearing assembly
(1) from shaft (10).
9. Remove seal assembly (12) from housing (3).
10. Use Tooling (B) to remove lip seal (2) from the
housing.
i02394663
Water Pump - Assemble
SMCS Code: 1361-016
Assembly Procedure
Table 24
Required Tools
Tool
Part
B 1P-0510 Driver Group 1
C 7N-7843 Seal Installation Tool 1
D 6V-1541 Quick Cure Primer 1
NOTICE
component life.
g01195730
Illustration 80
1. Use Tooling (B) to install lip seal (2) into the
housing.
2. Apply Tooling (D) to shaft (10). Use a suitable
press to install bearing assembly (1) on shaft (10).
3. Install shaft (10) and bearing assembly (1) in
housing (3).
4. Install O-ring seal (14) on housing (3).
5. Install retainer (13) and bolts (11).
6. Position gear (4) on shaft (10). Install washer (6)
and bolt (7).
RENR9716-02 33
7. Use Tooling (C) to install seal assembly (12) onto
shaft (10) until the stationary cup is fully seated
into housing (3).
8. Install impeller (5) on shaft (10). Install washer
(8) and bolt (9). Tighten bolt (9) to a torque of
39 3 Nm (29 2 lb ft).
9. Install adapter (15).
End By:
a. Install the water pump. Refer to Disassembly and
Assembly, Water Pump - Install.
i02440675
Water Pump - Install
SMCS Code: 1361-012
NOTICE
component life.
g01219275
Illustration 81
1. Position water pump (4) in the front housing.
2. Install nuts (5) and bolts (6).
g01219274
Illustration 82
3. Position cover (3) on the water pump.
4. Install bolts (2) and bolts (1).
- Change.
i02440754
Water Temperature Regulator
Housing - Remove and Install
SMCS Code: 1393-010
Removal Procedure
suitable container for storage or disposal until the
coolant is below the level of the water temperature
regulator housing. Refer to Operation and
- Change.
34 RENR9716-02
g01219336
Illustration 83
2. Disconnect hose assembly (1) and elbow (3).
3. Remove bolts (2) and bolts (4). Remove water
temperature regulator housing (5).
g01223744
Illustration 84
4. Remove O-ring seals (6) and water temperature
regulators (7) from water temperature regulator
housing (5).
5. If necessary, remove the lip seals.
Table 25
Required Tools
Tool
Part
A 221-8647 Seal Installer Gp 1
NOTICE
component life.
1. If necessary, use Tooling (A) to install the lip seals.
g01223744
Illustration 85
2. Install water temperature regulators (7) and O-ring
seals (6) in water temperature regulator housing
(5).
g01219336
Illustration 86
3. Position water temperature regulator housing (5)
on the engine. Install bolts (4) and bolts (2).
4. Connect elbow (3) and hose assembly (1).
- Change.
RENR9716-02 35
i02576096
Cooling System Package
(Radiator, Aftercooler, Fuel
Cooler) - Remove
SMCS Code: 1063-011; 1353-011; 1712-011
Removal Procedure
Table 26
Required Tools
Tool
Part
Number
Part Description Qty
A 189-0410 Shackle As 2
Start By:
a. Remove the fan. Refer to Disassembly and
Assembly, Fan - Remove and Install.
NOTICE
products.
mandates.
1. Drain the coolant from the cooling system into
a suitable container for storage or for disposal.
Refer to Operation and Maintenance Manual,
Cooling System Coolant (ELC) - Change.
g01290908
Illustration 87
2. Remove clamp (1). Repeat for the opposite side.
g01290915
Illustration 88
3. Disconnect bottom aftercooler tube (2).
g01290916
Illustration 89
4. Disconnect top radiator hose (3).
g01290917
Illustration 90
5. Disconnect top aftercooler tube (4).
36 RENR9716-02
g01290930
Illustration 91
6. Disconnect bottom radiator hose (5). Disconnect
bottom aftercooler tube (6).
g01290934
Illustration 92
7. Disconnect hose assembly (8) from fuel cooler (7).
g01290939
Illustration 93
g01290940
Illustration 94
onto cooling package (10). The weight of cooling
package (10) is approximately 544 kg (1200 lb).
g01290941
Illustration 95
10. Remove bolts (11). Repeat for the opposite side.
Remove cooling package (10).
i02576308
Cooling System Package
(Radiator, Aftercooler, Fuel
Cooler) - Install
SMCS Code: 1063-012; 1353-012; 1712-012
Table 27
Required Tools
RENR9716-02 37
NOTICE
products.
mandates.
g01290940
Illustration 96
onto cooling package (10). The weight of cooling
package (10) is approximately 544 kg (1200 lb).
g01290941
Illustration 97
2. Install cooling package (10). Install bolts (11).
Repeat for the opposite side.
g01290939
Illustration 98
3. Connect hose assembly (9) onto fuel cooler (7).
g01290934
Illustration 99
g01290930
Illustration 100
5. Connect bottom aftercooler tube (6). Connect
bottom radiator hose (5).
38 RENR9716-02
g01290917
Illustration 101
6. Connect top aftercooler tube (4).
g01290916
Illustration 102
7. Connect top radiator hose (3).
g01290915
Illustration 103
8. Connect bottom aftercooler tube (2).
g01290908
Illustration 104
9. Install clamp (1). Repeat for the opposite side.
System Coolant (ELC) - Change.
End By:
a. Install the fan. Refer to Disassembly and
i02584900
Aftercooler - Remove
SMCS Code: 1063-011
Removal Procedure
Table 28
Required Tools
Start By:
RENR9716-02 39
NOTICE
products.
mandates.
1. Drain the coolant from the cooling system into
a suitable container for storage or for disposal.
Cooling System Coolant (ELC) - Change.
g01290908
Illustration 105
2. Remove clamp (1). Repeat for the opposite side.
g01290915
Illustration 106
3. Disconnect bottom aftercooler tube (2).
g01290916
Illustration 107
4. Disconnect top radiator hose (3).
g01290917
Illustration 108
5. Disconnect top aftercooler tube (4).
g01290930
Illustration 109
6. Disconnect bottom radiator hose (5). Disconnect
bottom aftercooler tube (6).
40 RENR9716-02
g01290934
Illustration 110
g01290939
Illustration 111
g01294215
Illustration 112
9. Remove bolts (10). Remove bolt (11).
g01294232
Illustration 113
onto aftercooler (12). The weight of aftercooler
(12) is approximately 227 kg (500 lb).
g01294234
Illustration 114
11. Remove bolt (13). Remove bolts (14) and bolts
(15) from aftercooler (12).
12. Repeat Step 9 through Step 11 for the opposite
side.
13. Remove aftercooler (12).
i02585968
Aftercooler - Install
SMCS Code: 1063-012
Table 29
Required Tools
Tool Part Number
Part
Description
Qty
RENR9716-02 41
g01294232
Illustration 115
1. Attach Tooling (A) and a suitable lifting device onto
aftercooler (12). The weight of aftercooler (12) is
approximately 227 kg (500 lb). Install aftercooler
(12).
g01294234
Illustration 116
2. Install bolts (14) and bolts (15) into aftercooler
(12). Install bolt (13).
g01294215
Illustration 117
3. Install bolt (11). Install bolts (10).
4. Repeat Step 2 and Step 3 for the opposite side.
g01290939
Illustration 118
g01290934
Illustration 119
g01290930
Illustration 120
7. Connect bottom aftercooler tube (6). Connect
bottom radiator hose (5).
42 RENR9716-02
g01290917
Illustration 121
8. Connect top aftercooler tube (4).
g01290916
Illustration 122
9. Connect top radiator hose (3).
g01290915
Illustration 123
10. Connect bottom aftercooler tube (2).
g01290908
Illustration 124
11. Install clamp (1). Repeat for the opposite side.
System Coolant (ELC) - Change.
End By:
a. Install the fan. Refer to Disassembly and
i02581106
Radiator Core - Remove
SMCS Code: 1353-011; 1353-011-KO
Removal Procedure
Table 30
Required Tools
Tool
Part
Number
Start By:
a. Remove the aftercooler. Refer to Disassembly
and Assembly, Aftercooler - Remove.
RENR9716-02 43
NOTICE
products.
mandates.
g01292911
Illustration 125
1. Remove the upper and the lower radiator guards
(1).
g01292912
Illustration 126
radiator top tank (2). The weight of the radiator is
approximately 227 kg (500 lb).
g01294577
Illustration 127
3. Remove the upper and the lower braces (3).
g01294578
Illustration 128
4. Remove bolts (4) and remove bolts (5).
g01294579
Illustration 129
44 RENR9716-02
g01294580
Illustration 130
6. Remove bolts (7). Remove bolts (8). Remove
support (9).
7. Repeat Steps 4 through 6 for the opposite side.
g01294602
Illustration 131
Remove radiator (10).
i02585957
Radiator Core - Install
SMCS Code: 1353-012-KO; 1353-012
Table 31
Required Tools
Tool
Part
Number
g01292912
Illustration 132
radiator top tank (2). The weight of the radiator is
g01294602
Illustration 133
2. Install radiator (10). Install bolts (11). Repeat for
the opposite side.
g01294580
Illustration 134
3. Install support (9). Install bolts (8). Install bolts (7).
RENR9716-02 45
g01294579
Illustration 135
g01294578
Illustration 136
6. Repeat Steps 3 through 5 for the opposite side.
g01294577
Illustration 137
7. Install the upper and the lower braces (3).
g01292911
Illustration 138
8. Install the upper and the lower radiator guards (1).
End By:
a. Install the aftercooler. Refer to Disassembly and
Assembly, Aftercooler - Install.
i02444868
Engine Support (Front) -
Remove and Install
SMCS Code: 1154-010-FR
Removal Procedure (Type 1)
Start By:
a. Remove the vibration damper and the pulley.
Refer to Disassembly and Assembly, Vibration
Damper and Pulley - Remove and Install.
1. Support the front of the engine.
g01221659
Illustration 139
3. Remove engine support (2).
46 RENR9716-02
Installation Procedure (Type 1)
g01221659
Illustration 140
1. Position engine support (2) on the engine.
End By:
a. Install the vibration damper and the pulley. Refer
to Disassembly and Assembly, Vibration Damper
and Pulley - Remove and Install.
Removal Procedure (Type 2)
Start By:
a. Remove the vibration damper and the pulley.
1. Support the front of the engine.
g01221663
Illustration 141
3. Use a suitable lifting device to remove engine
support (4). The weight of engine support (4) is
Installation Procedure (Type 2)
g01221663
Illustration 142
1. Use a suitable lifting device to position engine
support (4) on the engine. The weight of engine
support (4) is approximately 35 kg (77 lb).
End By:
a. Install the vibration damper and the pulley. Refer
to Disassembly and Assembly, Vibration Damper
and Pulley - Remove and Install.
i02440962
Gear Group (Rear) - Remove
SMCS Code: 1206-011; 1212-011
Removal Procedure
Table 32
Required Tools
Tool
Part
Start By:
a. Remove the ywheel housing. Refer to
Disassembly and Assembly, Flywheel Housing
- Remove and Install.
RENR9716-02 47
NOTICE
products.
mandates.
NOTICE
component life.
g01219485
Illustration 143
1. Remove bolts (10), thrust plate (11), and gear
assembly (9).
2. Use Tooling (A) and a suitable press to remove
the bearing from gear assembly (9).
3. Remove bolts (8), gear assembly (6), and shaft
assembly (7).
5. Remove bolts (2), gear assembly (1), and shaft
assembly (3).
7. Remove gear assembly (12).
8. Remove bolts (5) and gear assemblies (4).
g01219500
Illustration 144
9. Remove bolts (16) and shaft assembly (17).
10. Remove bolts (13), thrust plates (14), and adapter
assemblies (15).
11. Use bolt (13) in order to remove the sealing
plates. Remove the O-ring seals.
48 RENR9716-02
i02442469
Gear Group (Rear) - Install
SMCS Code: 1206-012; 1212-012
Table 33
Required Tools
Tool
Part
NOTICE
component life.
Note: Apply clean engine oil to the bearings and the
shaft assemblies prior to installation on the engine.
g01219500
Illustration 145
1. Install the O-ring seals and the sealing plates on
the cylinder head.
2. Install adapter assemblies (15), thrust plates (14),
and bolts (13).
3. Position shaft assembly (17) and install bolts (16).
g01220275
Illustration 146
g01151468
Illustration 147
4. Refer to Testing and Adjusting, Rear Gear Group
- Time for additional information.
Note: Align the Timing Marks on gear assemblies (4)
with the Timing Marks on the rear housing and align
the dowels on gear assemblies (4) with the adapter
assemblies.
5. Position gear assemblies (4) and install bolts (5).
6. Install gear assembly (12).
7. Use Tooling (A) and a suitable press to install the
bearing in gear assembly (1). Install the bearing to
a depth of 2.6 0.5 mm (0.10 0.02 inch).
RENR9716-02 49
8. Install shaft assembly (3), gear assembly (1), and
bolts (2).
a depth of 2.6 0.5 mm (0.10 0.02 inch).
10. Install shaft assembly (7), gear assembly (6), and
bolts (8).
a depth of 2.5 0.5 mm (0.10 0.02 inch).
Note: Align the Timing Mark on gear assembly (9)
with the Timing Mark on gear assembly (12).
12. Install gear assembly (9), thrust plate (11), and
bolts (10).
13. Tighten the bolts on gear assemblies (4) to a
torque of 240 40 Nm (177 30 lb ft). Tighten
the bolts in the following sequence: 1, 4, 2, 5, 3,
6, 1, 4.
End By:
a. Install the ywheel housing. Refer to Disassembly
and Assembly, Flywheel Housing - Remove and
Install.
i02752668
Flywheel - Remove and Install
SMCS Code: 1156-010
Removal Procedure
Table 34
Required Tools
Tool
Part
A -
Guide Stud
5/8 - 18 UNF by 11 inch
2
g01220437
Illustration 148
g01220438
Illustration 149
1. Remove two bolts (1). Install Tooling (A) in the
crankshaft.
2. Remove remaining bolts (1). Slide ywheel (2)
away from the engine on Tooling (A).
3. Attach a suitable lifting device to ywheel (2). The
weight of ywheel (2) is approximately 130 kg
(285 lb). Remove ywheel (2).
4. If necessary, use a hammer and a punch in order
to remove ring gear (3) from ywheel (2).
Table 35
Required Tools
Tool
Part
A -
Guide Stud
5/8 - 18 UNF by 11 inch
2
B 6V-4876 Lubricant -
g01220438
Illustration 150
50 RENR9716-02
g01220437
Illustration 151
Note: Ring gear (3) must be installed with the
chamfered side of the teeth upward. The chamfered
side of the gear teeth will be facing toward the starting
motor when the ywheel is installed.
1. Raise the temperature of ring gear (3). Install ring
gear (3) on ywheel (2).
2. Install Tooling (A) in the crankshaft.
3. Attach a suitable lifting device to ywheel (2). The
weight of ywheel (2) is approximately 130 kg
(285 lb). Position ywheel (2) on the crankshaft.
4. Apply Tooling (B) to the threads of bolts (1).
5. Install bolts (1). Remove Tooling (A). Install
remaining bolts (1).
6. Tighten bolts (1) to a torque of 100 5 Nm
(75 4 lb ft). Turn the bolts for an additional 180
5 degrees.
7. Check the ywheel runout. Refer to Testing and
Adjusting, Flywheel - Inspect.
i02442878
Crankshaft Rear Seal - Remove
SMCS Code: 1161-011
Removal Procedure
Table 36
Required Tools
Tool
Part
A 1U-7600 Slide Hammer Puller 1
Start By:
a. Remove the ywheel. Refer to Disassembly and
Assembly, Flywheel - Remove and Install.
NOTICE
component life.
g01220531
Illustration 152
1. Use Tooling (A) or a punch and hammer in order
to puncture three or more holes in crankshaft rear
seal (1).
2. Use Tooling (A) to remove crankshaft rear seal (1)
and crankshaft wear sleeve (2).
i02442921
Crankshaft Rear Seal - Install
SMCS Code: 1161-012
Table 37
Required Tools
Tool
Part
249-2937
(1)
Seal Locator As 1
5P-7310
(1)
Bolt 3
9S-8858
(1)
Nut (Seal Installer) 1
6V-6143
(1)
Seal Installer 1
5P-1733
(2)
Seal Locator As 1
5P-7309
(2)
Bolt 3
9S-8858
(2)
Nut (Seal Installer) 1
B
6V-6142
(2)
Seal Installer 1
(1)
Large crankshaft gear
(2)
Small crankshaft gear
RENR9716-02 51
NOTICE
component life.
g01220558
Illustration 153
1. Clean the outside diameter of the crankshaft.
Note: Install the crankshaft rear seal with the arrow
that shows the direction of crankshaft rotation toward
the rear of the engine.
2. Use Tooling (B) to install crankshaft wear sleeve
(2) and crankshaft rear seal (1) as a unit.
End By:
a. Install the ywheel. Refer to Disassembly and
Assembly, Flywheel - Remove and Install.
i02752908
Flywheel Housing - Remove
and Install
SMCS Code: 1157-010
Removal Procedure
Table 38
Required Tools
Tool
Part
B -
Guide Stud
1/2 - 13 NC by 7 inch
2
Start By:
a. Remove the crankshaft rear seal. Refer to
Disassembly and Assembly, Crankshaft Rear
Seal - Remove.
b. Remove the electric starting motor. Refer to
Disassembly and Assembly, Electric Starting
Motor - Remove and Install.
NOTICE
component life.
g01220951
Illustration 154
1. Disconnect hose assemblies (1) from ywheel
housing (2).
2. Disconnect fuel lter base (5) from ywheel
housing (2). Reposition fuel lter base (5) and the
hose assemblies.
3. Remove two bolts (4) and install Tooling (B).
to ywheel housing (2). The weight of ywheel
housing (2) is approximately 110 kg (245 lb).
5. Remove remaining bolts (4), bolts (6), and bolts
(3). Remove ywheel housing (2) and the gasket
from the rear housing.
52 RENR9716-02
Table 39
Required Tools
Tool
Part
B -
Guide Stud
1/2 - 13 NC by 7 inch
2
NOTICE
component life.
g01220951
Illustration 155
g01221009
Illustration 156
1. Install Tooling (B) in the cylinder block.
to ywheel housing (2). The weight of ywheel
housing (2) is approximately 110 kg (245 lb).
3. Position the gasket and ywheel housing (2) on
the rear housing. Install bolts (3), bolts (6), and
bolts (4).
4. Remove Tooling (B) and install remaining bolts (4).
5. Tighten the bolts, as follows:
a. In a numerical sequence, tighten Bolt 1 through
Bolt 2 to a torque of 55 10 Nm (41 7 lb ft).
b. In a numerical sequence, tighten Bolt 3
through Bolt 10 to a torque of 135 20 Nm
(100 15 lb ft).
c. In a numerical sequence, tighten Bolt 11
through Bolt 36 to a torque of 47 9 Nm
(35 7 lb ft).
6. Reposition fuel lter base (5) and the hose
assemblies. Connect fuel lter base (5) to ywheel
housing (2).
7. Connect hose assemblies (1) to ywheel housing
(2).
RENR9716-02 53
End By:
a. Install the electric starting motor. Refer to
Disassembly and Assembly, Electric Starting
Motor - Remove and Install.
b. Install the crankshaft rear seal. Refer to
Disassembly and Assembly, Crankshaft Rear
Seal - Install.
i02443805
Vibration Damper and Pulley -
Remove and Install
SMCS Code: 1205-010
Removal Procedure
Table 40
Required Tools
Tool
Part
A -
Guide Stud
1/2 - 13 NC by 5 inch
2
g01221066
Illustration 157
g01221078
Illustration 158
1. Remove V-belt (1) from the engine.
2. Remove two bolts (2) and install Tooling (A).
3. Remove remaining bolts (2) and pulley (3).
4. Slide vibration damper (4) along Tooling (A).
5. Attach a suitable lifting device onto vibration
damper (4). The weight of vibration damper (4)
is approximately 34 kg (75 lb). Remove vibration
damper (4) from the adapter.
Table 41
Required Tools
Tool
Part
A -
Guide Stud
1/2 - 13 NC by 5 inch
2
g01221078
Illustration 159
54 RENR9716-02
g01221066
Illustration 160
1. Install Tooling (A) in the adapter.
2. Attach a suitable lifting device onto vibration
damper (4). The weight of vibration damper (4)
is approximately 34 kg (75 lb). Position vibration
damper (4) on the adapter.
3. Install pulley (3) and bolts (2).
4. Remove Tooling (A). Install remaining bolts (2).
Tighten bolts (2) to a torque of 135 20 Nm
(100 15 lb ft).
5. Install V-belt (1) on the engine.
i02444403
Crankshaft Front Seal -
Remove
SMCS Code: 1160-011
Removal Procedure
Table 42
Required Tools
Tool
Part
A 1U-7600 Slide Hammer Puller 1
Start By:
a. Remove the crankshaft vibration damper and
pulley. Refer to Disassembly and Assembly,
Vibration Damper and Pulley - Remove and
Install.
NOTICE
component life.
g01221272
Illustration 161
1. Remove bolts (1) and adapter (2).
g01221276
Illustration 162
2. Use Tooling (A) or a punch and hammer in order
to puncture three or more holes in crankshaft front
seal (4).
3. Use Tooling (A) to remove crankshaft front seal
(4).
4. If necessary, use Tooling (A) or a punch and
hammer in order to puncture three or more holes
in crankshaft wear sleeve (3). Use Tooling (A) to
remove crankshaft wear sleeve (3).
RENR9716-02 55
i02444556
Crankshaft Front Seal - Install
SMCS Code: 1160-012
Table 43
Required Tools
Tool
Part
5P-1733 Seal Locator 1
5P-1737 Bolt 3
9S-8858 Nut (Seal Installer) 1
B
6V-6142 Seal Installer 1
NOTICE
component life.
1. Clean the outside diameter of the crankshaft.
g01221389
Illustration 163
2. Use Tooling (B) to install crankshaft front seal (4)
and crankshaft wear sleeve (3) as a unit.
Note: Install the crankshaft front seal with the arrow
that shows the direction of crankshaft rotation toward
the front of the engine.
g01221272
Illustration 164
3. Install adapter (2) and bolts (1).
End By:
a. Install the crankshaft vibration damper and pulley.
i02292422
Gear Group (Front) - Remove
SMCS Code: 1206-011
Removal Procedure
Start By:
a. Remove the front housing. Refer to Disassembly
and Assembly, Housing (Front) - Remove.
NOTICE
component life.
56 RENR9716-02
g01147593
Illustration 165
1. Remove bolts (5) and gear assembly (4).
2. Remove bolts (3) and plate (2). Remove gear
assembly (1).
g01147620
Illustration 166
3. Remove bolts (6) and shaft (7).
i02691256
Gear Group (Front) - Install
SMCS Code: 1206-012
NOTICE
component life.
g01147620
Illustration 167
1. Apply clean engine oil to shaft (7), the bearing
bore, and the thrust faces prior to installation.
Install shaft (7) and bolts (6). Tighten bolts (6) to a
torque of 55 10 Nm (41 7 lb ft).
g01147593
Illustration 168
2. Position gear assembly (1) on the shaft. Install
plate (2) and bolts (3).
3. Install gear assembly (4) and bolts (5).
End By:
a. Install the front housing. Refer to Disassembly and
Assembly, Housing (Front) - Install.
RENR9716-02 57
i02445219
Housing (Front) - Remove
SMCS Code: 1151-011
Removal Procedure
Start By:
a. Remove the water temperature regulator housing.
Refer to Disassembly and Assembly, Water
Temperature Regulator Housing - Remove and
Install.
b. Remove the water pump. Refer to Disassembly
and Assembly, Water Pump - Remove.
c. Remove the crankshaft front seal. Refer to
Disassembly and Assembly, Crankshaft Front
Seal - Remove.
d. Remove the front engine support. Refer to
Disassembly and Assembly, Engine Support
(Front) - Remove and Install.
e. Remove the alternator. Refer to Disassembly and
Assembly, Alternator - Remove and Install.
f. Remove the crankshaft position sensor. Refer to
Disassembly and Assembly, Crankshaft Position
Sensor - Remove and Install.
g. Remove the camshaft position sensor. Refer to
Disassembly and Assembly, Camshaft Position
NOTICE
products.
mandates.
NOTICE
component life.
g01221893
Illustration 169
1. Disconnect hose assemblies (2) from front
housing (4).
2. Remove covers (1).
3. Remove alternator bracket (3) from front housing
(4).
g01221941
Illustration 170
4. Remove bolts (5) and dampers (6).
58 RENR9716-02
g01221953
Illustration 171
5. Disconnect bracket (7) and elbows (8).
g01221955
Illustration 172
6. Remove adapters (9).
7. Attach a suitable lifting device to front housing (4).
The weight of front housing (4) is approximately
70 kg (155 lb).
9. Remove front housing (4) and the gasket.
i02445708
Housing (Front) - Install
SMCS Code: 1151-012
Table 44
Required Tools
Tool
Part
A 4C-9612 Silicone Sealant 1
NOTICE
component life.
g01221955
Illustration 173
1. Apply Tooling (A) to the bottom of front housing
(4) at the junction of the cylinder block and the
engine oil pan.
2. Attach a suitable lifting device to front housing (4).
The weight of front housing (4) is approximately
70 kg (155 lb). Position the gasket and front
housing (4) on the dowel pins on the cylinder
block.
4. Trim the gasket between the front housing and the
cylinder block even with the bottom of the front
housing.
5. Install adapters (9).
RENR9716-02 59
g01221953
Illustration 174
6. Connect elbows (8) and bracket (7).
g01221941
Illustration 175
g01151441
Illustration 176
7. Install dampers (6) and bolts (5).
8. Tighten the bolts to a torque of 240 40 Nm
(177 30 lb ft). Tighten the bolts in the following
sequence: 1, 4, 2, 5, 3, 6, 1, 4.
g01221893
Illustration 177
9. Install alternator bracket (3) on front housing (4).
10. Install covers (1).
11. Connect hose assemblies (2) to front housing (4).
End By:
a. Install the camshaft position sensor. Refer to
Disassembly and Assembly, Camshaft Position
b. Install the crankshaft position sensor. Refer to
Disassembly and Assembly, Crankshaft Position
c. Install the alternator. Refer to Disassembly and
Assembly, Alternator - Remove and Install.
d. Install the front engine support. Refer to
Disassembly and Assembly, Engine Support
(Front) - Remove and Install.
e. Install the crankshaft front seal. Refer to
Disassembly and Assembly, Crankshaft Front
Seal - Install.
f. Install the water pump. Refer to Disassembly and
Assembly, Water Pump - Install.
g. Install the water temperature regulator housing.
Refer to Disassembly and Assembly, Water
Temperature Regulator Housing - Remove and
Install.
60 RENR9716-02
i02290579
Housing (Rear) - Remove
SMCS Code: 1157-011
Removal Procedure
Start By:
a. Remove the rear gear group. Refer to Disassembly
and Assembly, Gear Group (Rear) - Remove.
NOTICE
component life.
1. Remove the bolts that hold the engine oil pan to
the rear housing.
g01147132
Illustration 178
g01147138
Illustration 179
2. Disconnect hose assembly (1).
4. Attach a suitable lifting device to rear housing (4).
The weight of rear housing (4) is approximately
84 kg (185 lb).
6. Remove rear housing (4) and the gasket.
i02291566
Housing (Rear) - Install
SMCS Code: 1157-012
Table 45
Required Tools
Tool
Part
A 4C-9612 Silicone Sealant 1
RENR9716-02 61
NOTICE
component life.
1. Apply Tooling (A) to the bottom of the rear housing
at the junction of the cylinder block and the engine
oil pan.
g01147138
Illustration 180
g01147149
Illustration 181
2. Attach a suitable lifting device to rear housing (4).
The weight of rear housing (4) is approximately
84 kg (185 lb).
3. Position the gasket on rear housing (4).
4. Position rear housing (4) on the cylinder block.
Install bolts (3). Tighten bolts (3) in a numerical
sequence to a torque of 55 10 Nm (41 7 lb ft).
5. Trim the gasket between the rear housing and the
cylinder block even with the bottom of the rear
housing.
62 RENR9716-02
g01147132
Illustration 182
7. Connect hose assembly (1).
8. Install the bolts that hold the engine oil pan to the
rear housing.
9. Tighten all the bolts that hold the engine oil pan
evenly in order to raise the engine oil pan into
position.
End By:
a. Install the rear gear group. Refer to Disassembly
and Assembly, Gear Group (Rear) - Install.
i02293132
Valve Mechanism Cover -
Remove and Install
SMCS Code: 1107-010
Removal Procedure
NOTICE
component life.
g01147941
Illustration 183
1. Remove bolts (1) and valve mechanism covers
(2).
NOTICE
component life.
g01147941
Illustration 184
1. Position valve mechanism covers (2) on the valve
mechanism cover base. Install bolts (1).
i02293148
Valve Mechanism Cover Base -
Remove and Install
SMCS Code: 1120-010
Removal Procedure
Start By:
a. Remove the valve mechanism cover. Refer to
Disassembly and Assembly, Valve Mechanism
Cover - Remove and Install.
RENR9716-02 63
NOTICE
component life.
g01147965
Illustration 185
1. Remove tube assemblies (1).
2. Disconnect harness assemblies (5) and harness
assembly (2).
4. Remove valve mechanism cover base (3) and the
seal from the cylinder head.
NOTICE
component life.
g01147965
Illustration 186
1. Install the seal on valve mechanism cover base
(3).
2. Position valve mechanism cover base (3) on the
cylinder head and install bolts (4).
3. Position harness assemblies (5) on the electronic
unit injectors. Tighten the cap nuts to a torque of
1.70 0.25 Nm (15 2 lb in).
5. Install tube assemblies (1).
End By:
a. Install the valve mechanism cover. Refer to
i02293245
Rocker Arm and Shaft -
Remove
SMCS Code: 1102-011
Removal Procedure
Table 46
Required Tools
Tool
Part
A 124-2946 Lifting Bracket 1
64 RENR9716-02
Start By:
a. Remove the valve mechanism cover. Refer to
NOTICE
component life.
g01148045
Illustration 187
2. Use Tooling (A) to remove rocker arm shaft
assembly (4), valve rocker arms (3), and electronic
unit injector rocker arms (1) as a unit.
i02451112
Rocker Arm - Disassemble
SMCS Code: 1123-015
Start By:
a. Remove the rocker arms and the rocker shaft.
and Shaft - Remove.
NOTICE
component life.
g01047557
Illustration 188
1. Remove valve rocker arms (11) and electronic unit
injector rocker arm (3) from rocker shaft assembly
(4).
2. Remove jam nut (7) from adjustment screw (8).
3. Remove adjustment screw (8) from valve rocker
arms (11).
4. Remove button (10) from adjustment screw (8).
Remove O-ring seal (9) from the adjustment
screw.
5. Remove jam nut (2) from unit injector adjustment
screw (1).
6. Remove unit injector adjustment screw (1) from
electronic unit injector rocker arm (3).
7. Remove button (6) from unit injector adjustment
screw (1). Remove O-ring seal (5) from the unit
injector adjustment screw.
i02451120
Rocker Arm - Assemble
SMCS Code: 1123-016
Assembly Procedure
NOTICE
component life.
RENR9716-02 65
g01047557
Illustration 189
Note: Do not reuse the O-ring seal on the adjustment
screw if the button is removed from the adjustment
screw.
1. Install O-ring seal (9) in button (10).
2. Use a soft hammer to seat button (10) on
adjustment screw (8).
3. Install adjustment screw (8) in valve rocker arms
(11). Install jam nut (7) on the adjustment screw.
4. Install O-ring seal (5) in button (6).
5. Use a soft hammer to seat button (6) on unit
injector adjustment screw (1).
6. Install unit injector adjustment screw (1) in
electronic unit injector rocker arm (3). Install jam
nut (2) on the unit injector adjustment screw.
7. Lubricate rocker shaft assembly (4) with clean
engine oil.
8. Install valve rocker arms (11) and electronic unit
injector rocker arm (3) on rocker shaft assembly
(4).
End By:
a. Install the rocker arms and the rocker shaft. Refer
to Disassembly and Assembly, Rocker Arm and
Shaft - Install.
i03203773
Rocker Arm and Shaft - Install
SMCS Code: 1102-012
Table 47
Required Tools
Tool
Part
A 124-2946 Lifting Bracket 1
NOTICE
component life.
g01148045
Illustration 190
g01325993
Illustration 191
66 RENR9716-02
1. Position rocker arm shaft assembly (4), valve
rocker arms (3), and electronic unit injector rocker
arms (1) as a unit with Tooling (A) on the cylinder
head.
2. Install bolts (2) and tighten to a torque of
50 5 Nm (37 4 lb ft) plus 45 5 degree turn.
Tighten the bolts in the following sequence: 2, 3,
4, 1.
3. Adjust the valve lash for the inlet valves and the
exhaust valves. Refer to Testing and Adjusting,
Engine Valve Lash - Inspect/Adjust.
4. Adjust the electronic unit injectors. Refer to Testing
and Adjusting, Electronic Unit Injector - Adjust.
End By:
a. Install the valve mechanism cover. Refer to
i02446003
Cylinder Head - Remove
SMCS Code: 1100-011
Removal Procedure
Table 48
Required Tools
Tool
Part
B 1U-9200 Lever Puller Hoist 1
Start By:
Injector - Remove.
b. Remove the valve mechanism cover base. Refer
to Disassembly and Assembly, Valve Mechanism
Cover Base - Remove and Install.
c. Remove the fuel transfer pump. Refer to
Disassembly and Assembly, Fuel Transfer Pump
- Remove.
NOTICE
products.
mandates.
NOTICE
component life.
NOTICE
Do not turn the crankshaft or the camshaft while the
camshaft gear is removed. If the rear gear group is
not correctly timed during installation, interference can
occur between the pistons and the valves, resulting in
damage to the engine.
g01222228
Illustration 192
RENR9716-02 67
g01222230
Illustration 193
3. Remove bolts (2) and gear (3).
g01222233
Illustration 194
4. Remove bolts (4), thrust plate (5), and adapter
assembly (6).
g01222234
Illustration 195
5. Use bolt (4) in order to remove sealing plate (7).
Remove the O-ring seals.
g01148246
Illustration 196
6. Remove elbow (8). Disconnect hose assembly (9).
g01148489
Illustration 197
7. Remove elbow (11) and cover (10).
8. Disconnect harness assembly (12) and harness
assembly (13).
9. Remove bracket (14).
g01148492
Illustration 198
68 RENR9716-02
10. Remove bolts (15) and damper (16).
g01148516
Illustration 199
11. Remove bolts (17). Remove sealing plate (18)
and adapter assembly (19).
g01148522
Illustration 200
12. Disconnect clip assembly (22) from the cylinder
head. Remove tube assemblies (21).
13. Remove bracket (20).
14. Disconnect tube assembly (23) and remove tube
assembly (24).
g01148568
Illustration 201
15. Attach Tooling (A) and a suitable lifting device to
cylinder head (25). Attach Tooling (B) to the side
of cylinder head (25) that is near the turbocharger.
The weight of cylinder head (25) is approximately
365 kg (800 lb).
17. Remove cylinder head (25). Remove the gaskets,
O-ring seals, and the spacer plate.
i02446286
Cylinder Head - Install
SMCS Code: 1100-012
Table 49
Required Tools
B 1U-9200 Lever Puller Hoist 1
C 4c-5593 Anti-Seize Compound 1
NOTICE
component life.
g01148568
Illustration 202
RENR9716-02 69
g01148791
Illustration 203
1. Install the gaskets, O-ring seals, and the spacer
plate on the engine.
2. Attach Tooling (A) and a suitable lifting device to
cylinder head (25). Attach Tooling (B) to the side
of cylinder head (25) that is near the turbocharger.
The weight of cylinder head (25) is approximately
365 kg (800 lb).
3. Position cylinder head (25) on the dowel pins in
the cylinder block.
Note: Apply Tooling (C) to the bolt threads and
both sides of the washers. Tighten the bolts in the
following step sequence:
4. Install bolts (26) and bolts (27) according to the
following procedure.
a. In a numerical sequence, tighten Bolt (1)
through Bolt (26) to a torque of 270 15 Nm
(199 11 lb ft).
b. In a numerical sequence, tighten Bolt (1)
(332 11 lb ft).
c. In a numerical sequence, again tighten Bolt (1)
(332 11 lb ft).
d. In a numerical sequence, tighten Bolt (27)
(33 5 lb ft).
g01148522
Illustration 204
5. Connect tube assembly (23) and install tube
assembly (24).
6. Install bracket (20).
7. Connect clip assembly (22). Install tube
assemblies (21).
g01148516
Illustration 205
70 RENR9716-02
8. Install adapter assembly (19) and sealing plate
(18). Install bolts (17).
g01148492
Illustration 206
g01151441
Illustration 207
9. Install damper (16) and bolts (15).
sequence: 1, 4, 2, 5, 3, 6, 1, 4.
g01148489
Illustration 208
11. Install bracket (14).
12. Connect harness assembly (13) and harness
assembly (12).
13. Install cover (10) and elbow (11).
g01148246
Illustration 209
14. Connect hose assembly (9). Install elbow (8).
g01222314
Illustration 210
15. Install new O-ring seals and sealing plate (7).
g01222233
Illustration 211
16. Install adapter assembly (6), thrust plate (5), and
bolts (4).
RENR9716-02 71
g01222230
Illustration 212
g01151468
Illustration 213
17. Install gear (3) and bolts (2).
sequence: 1, 4, 2, 5, 3, 6, 1, 4.
g01222228
Illustration 214
- Change.
End By:
a. Install the fuel transfer pump. Refer to Disassembly
and Assembly, Fuel Transfer Pump - Install.
b. Install the valve mechanism cover base. Refer to
Cover Base - Remove and Install.
c. Install the electronic unit injectors. Refer to
Injector - Install.
i02446397
Camshaft - Remove
SMCS Code: 1210-011
Removal Procedure
Table 50
Required Tools
A 177-8001 Pilot Sleeve 2
B 249-2936 Adapter 1
C
274-7932
(1)
or
274-7933
(2)
Guide 1
(1)
Front Removal
(2)
Rear Removal
Start By:
a. Remove the rocker arms and the rocker shafts.
and Shaft - Remove.
NOTICE
component life.
NOTICE
NOTICE
Care must be used when removing or installing the
camshaft. Do not damage the nshed surfaces of the
camshaft or the camshaft bearings.
72 RENR9716-02
g01222228
Illustration 215
g01222230
Illustration 216
3. Remove bolts (2) and gear (3).
g01222233
Illustration 217
4. Remove bolts (4), thrust plate (5), and adapter
assembly (6).
g01222234
Illustration 218
5. Use bolt (4) in order to remove sealing plate (7).
Remove the O-ring seals.
g01160256
Illustration 219
6. Remove elbow (9) and cover (8).
g01160259
Illustration 220
7. Remove bolts (10) and damper (11).
RENR9716-02 73
g01160261
Illustration 221
8. Remove bolts (12). Remove sealing plate (13) and
adapter assembly (14).
9.
g01160265
Illustration 222
10. Install Tooling (A) and Tooling (B) on the rear of
camshaft (15). Install Tooling (A) on the front of
camshaft (15).
11. Install Tooling (C) on the front housing or the
rear housing. Tooling (C) is used to support the
camshaft.
Note: It is necessary to install Tooling (A) and Tooling
(B) on the camshaft. Tooling (A) and Tooling (B) will
support the camshaft as the camshaft is moved out
of the cylinder head and into Tooling (C). Align the
camshaft with the bore of Tooling (C).
Note: Avoid lifting the camshaft. The camshaft should
rest on Tooling (A) and Tooling (B). Lifting of the
camshaft can cause misalignment as the camshaft
is removed, resulting in damage to the camshaft
bearings.
12. Carefully slide the camshaft out of the cylinder
head for removal. Use two technicians to remove
the camshaft. Keep the camshaft level while the
camshaft is being removed from the cylinder
head. The weight of the camshaft is approximately
35 kg (77 lb).
Note: Rotate the camshaft during removal. This will
prevent the camshaft from binding in the camshaft
bearings.
i02446568
Camshaft - Install
SMCS Code: 1210-012
Table 51
Required Tools
Tool
Part
A 177-8001 Pilot Sleeve 2
B 249-2936 Adapter 1
C
274-7932
(1)
or
274-7933
(2)
Guide 1
D 8T-2998 Lubricant 1
(1)
Front Removal
(2)
Rear Removal
NOTICE
component life.
NOTICE
NOTICE
Care must be used when removing or installing the
camshaft. Do not damage the nshed surfaces of the
camshaft or the camshaft bearings.
1. Ensure that the camshaft and camshaft bearings
are thoroughly clean. Lubricate the camshaft
lobes with a 50/50 mixture of Tooling (D) and clean
engine oil. Apply a thin coat of clean engine oil on
the camshaft bearings.
74 RENR9716-02
g01160265
Illustration 223
2. Install Tooling (A) and Tooling (B) on the rear of
camshaft (15). Install Tooling (A) on the front of
camshaft (15).
3. Install Tooling (C) on the front housing or the
rear housing. Tooling (C) is used to support the
camshaft.
4. Use two technicians to install the camshaft. Use
Tooling (C) to assist in aligning the camshaft
with the camshaft bearings. Carefully slide
the camshaft into the cylinder head. Keep the
camshaft level while the camshaft is being
installed in the cylinder head. The weight of the
camshaft is approximately 35 kg (77 lb).
Note: Rotate the camshaft during installation. This
will prevent the camshaft from binding in the camshaft
bearings.
5. Remove Tooling (A) and Tooling (B) from the
camshaft.
g01160261
Illustration 224
6. Install adapter assembly (14) and sealing plate
(13). Install bolts (12).
g01160259
Illustration 225
g01151441
Illustration 226
7. Install damper (11) and bolts (10).
sequence: 1, 4, 2, 5, 3, 6, 1, 4.
g01160256
Illustration 227
9. Install cover (8) and elbow (9).
RENR9716-02 75
g01222314
Illustration 228
10. Install new O-ring seals and sealing plate (7).
g01222233
Illustration 229
11. Install adapter assembly (6), thrust plate (5), and
bolts (4).
g01222230
Illustration 230
g01151468
Illustration 231
12. Install gear (3) and bolts (2).
sequence: 1, 4, 2, 5, 3, 6, 1, 4.
g01222228
Illustration 232
- Change.
End By:
a. Install the rocker arms and the rocker shafts.
Refer to Disassembly and Assembly, Rocker
Arms and Shaft - Install.
76 RENR9716-02
i02451045
Camshaft Bearings - Remove
SMCS Code: 1211-011
Removal Procedure
Table 52
Required Tools
A 8S-2241
Camshaft Bearing Tool
Group
1
9U-7222 Camshaft Bearing Pilot 1
B
8M-8778
Taperlock Stud
1/2 - 13 by 1 9/16 inch
1
C 9U-7210 Puller Plate 1
Start By:
a. Remove the camshaft. Refer to Disassembly and
Assembly, Camshaft - Remove.
NOTICE
component life.
g01159745
Illustration 233
1. Remove the No. 7 camshaft bearing (rear). Work
from the rear of the engine to the front of the
engine.
2. Install the small end of Tooling (B) in camshaft
bearing (1).
3. Position Tooling (C) over Tooling (A). Install
Tooling (A) through the cylinder head on Tooling
(B).
Note: Tooling (C) is installed on the outside of the
cylinder head. Tooling (C) is required in order to
remove all the camshaft bearings from the cylinder
head.
4. Use Tooling (A) to remove camshaft bearing (1)
5. Remove Tooling (B) from Tooling (A) and remove
the camshaft bearing.
i02451063
Camshaft Bearings - Install
SMCS Code: 1211-012
Table 53
Required Tools
A 8S-2241
Camshaft Bearing Tool
Group
1
9U-7222 Camshaft Bearing Pilot 1
B
8M-8778
Taperlock Stud
1/2 - 13 by 1 9/16 inch
1
C 9U-7210 Puller Plate 1
D 9U-7223 Alignment Bushing 1
9U-7213 Backup Plate 1
E
0S-1621
Bolt
1/2 - 13 by 1 inch
1
F 9U-7214 Spacer Plate 1
NOTICE
component life.
g01159754
Illustration 234
RENR9716-02 77
1. Install the No. 7 camshaft bearing (rear), as
follows:
a. Insert the large end of Tooling (B) into the No.
7 camshaft bore.
b. Position Tooling (C) over Tooling (A). Install
Tooling (A) through the cylinder head on
Tooling (B).
c. Position camshaft bearing (1) on Tooling (B).
Install Tooling (E) on Tooling (B).
Note: Refer to Specications, Cylinder Head for
appropriate information for the orientation of the
camshaft bearings in the cylinder head.
d. Use Tooling (A) in order to pull camshaft
bearing (1) into the camshaft bore.
Note: When the chamfer of Tooling (E) contacts the
face of the camshaft bore, the camshaft bearing is
properly installed.
g01159756
Illustration 235
2. Install the No. 6 through No. 2 camshaft bearings,
as follows:
a. Insert the large end of Tooling (B) into the
camshaft bore.
Note: Use Tooling (D) to align Tooling (A) and Tooling
(B) with the camshaft bearing bores. Install Tooling
(D) in the inside diameter of any installed camshaft
bearing between Tooling (A) and Tooling (B).
b. Install Tooling (A) on Tooling (B). Position
camshaft bearing (1) on Tooling (B). Install
Tooling (E) on Tooling (B).
appropriate information for the location and the
orientation of the camshaft bearings in the cylinder
head.
c. Use Tooling (A) in order to pull camshaft
bearing (1) into the camshaft bore.
Note: When the chamfer of Tooling (E) contacts the
face of the camshaft bore, the camshaft bearing is
properly installed.
g01159758
Illustration 236
3. Install the No. 1 camshaft bearing (front), as
follows:
a. Insert the large end of Tooling (B) into the No.
1 camshaft bore. Assemble Tooling (A) and
Tooling (D) on Tooling (B).
b. Position camshaft bearing (1) on Tooling (B).
Install Tooling (E) and Tooling (F) on Tooling
(B).
appropriate information for the location and the
orientation of the camshaft bearings in the cylinder
head.
Note: Tooling (F) is used to seat the No. 1 camshaft
bearing to the correct depth in the camshaft bore.
c. Use Tooling (A) in order to pull the No. 1
camshaft bearing into the No. 1 camshaft bore.
When the chamfer of Tooling (E) contacts
the face of the camshaft bore, the camshaft
bearing is properly installed.
End By:
a. Install the camshaft. Refer to Disassembly and
Assembly, Camshaft - Install.
78 RENR9716-02
i02447352
Engine Oil Pan - Remove and
Install
SMCS Code: 1302-010
Removal Procedure
Table 54
Required Tools
Tool
Part
A 1U-7505 Hydraulic Jack 1
NOTICE
products.
mandates.
NOTICE
component life.
1. Drain the engine oil into a suitable container
for storage or disposal. Refer to Operation and
Maintenance Manual, Engine Oil and Filter -
Change.
g01222524
Illustration 237
2. Remove tube assemblies (1) from engine oil pan
(3).
3. Use Tooling (A) to support engine oil pan (3). The
weight of engine oil pan (3) is approximately 25 kg
(55 lb).
4. Remove bolts (2). Remove engine oil pan (3) and
the gasket.
Table 55
Required Tools
Tool
Part
A 1U-7505 Hydraulic Jack 1
NOTICE
component life.
g01222524
Illustration 238
1. Use Tooling (A) to support engine oil pan (3). The
weight of engine oil pan (3) is approximately 25 kg
(55 lb).
2. Position the gasket and engine oil pan (3) on the
engine. Install bolts (2).
Note: If the oil drain plugs were removed, install the
oil drain plugs. Tighten the oil drain plugs to a torque
of 80 10 Nm (59 7 lb ft).
3. Install tube assemblies (1) on engine oil pan (3).
4. Fill the engine with engine oil to the correct level.
Engine Oil and Filter - Change.
RENR9716-02 79
i02294951
Cylinder Liner - Remove
SMCS Code: 1216-011
Removal Procedure
Table 56
Required Tools
A 5P-8665
(1)
Cylinder Liner Puller Gp 1
(1)
The 6V-9448 Cylinder Pack Puller is an optional Tool for
removing the cylinder liner.
Start By:
a. Remove the pistons and connecting rods. Refer
to Disassembly and Assembly, Pistons and
Connecting Rods - Remove.
NOTICE
products.
mandates.
NOTICE
component life.
g01149417
Illustration 239
1. Use Tooling (A) to remove cylinder liner (1).
2. Remove liner seals (3) and ller band (2) from
cylinder liner (1).
i02294960
Cylinder Liner - Install
SMCS Code: 1216-012
Table 57
Required Tools
B 2P-8260 Cylinder Liner Installer 1
C 5P-3975 Rubber Lubricant 1
NOTICE
component life.
1. Check the cylinder liner projection. Refer to
Testing and Adjusting, Cylinder Liner Projection
- Inspect.
80 RENR9716-02
g01149469
Illustration 240
2. Install liner seals (3) on cylinder liner (1).
3. Apply Tooling (C) on the cylinder block liner bore
surfaces and liner seals (3).
4. Dip ller band (2) in clean engine oil for a
moment. Install the ller band on the cylinder liner
immediately.
5. Use Tooling (B) to install cylinder liner (1) in the
cylinder block. Ensure that any marks in relation
to the cylinder liner projection are in alignment.
End By:
a. Install the pistons and connecting rods. Refer
Connecting Rods - Install.
i02295020
Piston Cooling Jets - Remove
and Install
SMCS Code: 1331-010
Removal Procedure
Table 58
Required Tools
Tool
Part
Number Part Description
Qty
A 9S-9082 Engine Turning Tool 1
Start By:
- Remove.
NOTICE
component life.
g01149484
Illustration 241
1. Use Tooling (A) to rotate the crankshaft in order to
gain access to the piston cooling jet.
2. Remove bolt (1) and piston cooling jet (2).
Table 59
Required Tools
Tool
Part
Number Part Description
Qty
NOTICE
component life.
RENR9716-02 81
g01149484
Illustration 242
1. Use Tooling (A) to rotate the crankshaft in order to
gain access to the piston cooling jet.
2. Position piston cooling jet (2) in the cylinder block.
Install bolt (1). Tighten the bolt to a torque of
25 6 Nm (18 4 lb ft).
End By:
i02295112
Pistons and Connecting Rods
- Remove
SMCS Code: 1225-011
Removal Procedure
Table 60
Required Tools
Start By:
a. Remove the cylinder head. Refer to Disassembly
and Assembly, Cylinder Head - Remove.
b. Remove the piston cooling jets. Refer to
Disassembly and Assembly, Piston Cooling Jets
NOTICE
component life.
g01149594
Illustration 243
1. Use Tooling (A) to rotate the crankshaft until the
piston is at the bottom center.
2. Remove the carbon ridge from the top inside
surface of the cylinder liner.
3. Inspect the connecting rod and connecting rod cap
for the proper identication mark. The connecting
rod and the connecting rod cap should have an
etched number on the side. The number should
match the cylinder number. Mark the connecting
rod and the connecting rod cap, if necessary.
Note: Do not stamp the connecting rod assembly.
Stamping or punching the connecting rod assembly
could cause the connecting rod to fracture.
4. Remove bolts (1) and connecting rod bearing cap
(2).
g01149595
Illustration 244
5. Remove piston (3) and the connecting rod from
the cylinder liner.
82 RENR9716-02
i02447789
- Disassemble
SMCS Code: 1225-015
Table 61
Required Tools
Tool
Part
A 6V-6192 Pliers 1
B 7B-7974 Piston Ring Expander Gp 1
Start By:
a. Remove the pistons and connecting rods. Refer
Connecting Rods - Remove.
Note: Mark the components of each piston and
connecting rod assembly. The components must be
reinstalled in the original location. Do not interchange
components.
NOTICE
component life.
g01222629
Illustration 245
1. Remove lower connecting rod bearing (9) from
connecting rod bearing cap (10).
2. Remove upper connecting rod bearing (8) from
connecting rod (6).
3. Use Tooling (A) to remove pin retainers (5) from
piston body assembly (4).
4. Remove connecting rod pin (7) and connecting
rod (6) from the piston body assembly.
5. Use Tooling (B) to remove top piston ring (1),
intermediate piston ring (2), and oil control piston
ring (3) from the piston body assembly.
i02447828
- Assemble
SMCS Code: 1225-016
Assembly Procedure
Table 62
Required Tools
Tool
Part
A 6V-6192 Pliers 1
B 7B-7974 Piston Ring Expander Gp 1
Note: Prior to removal from the engine, the pistons
and connecting rod assemblies were marked.
The components must be reassembled together.
The components must be installed in the original
location in the engine. Do not interchange any of the
components.
NOTICE
component life.
RENR9716-02 83
g01222629
Illustration 246
1. Position the spring for the oil control piston ring in
the oil ring groove in the piston body assembly.
2. Position oil control piston ring (3) over the spring.
Position the oil control piston ring so that the gap
is 180 degrees from the joint in the spring. Install
the oil control piston ring on the piston with Tooling
(B).
3. Use Tooling (B) to install intermediate piston ring
(2) with the side that has the identication UP-2
toward the top of the piston.
4. Use Tooling (B) to install top piston ring (1) with
the side that has the identication UP-1 toward
the top of the piston.
5. Position top piston ring (1), intermediate piston
ring (2), and oil control piston ring (3) so the gaps
are 120 degrees from each other.
6. Check the clearance between the ends of top
piston ring (1), intermediate piston ring (2), and
oil control piston ring (3). Refer to Specications,
Pistons And Rings.
7. Position piston body assembly (4) on connecting
rod (6). Apply clean engine oil to connecting rod
pin (7) and install the connecting rod pin. Install
pin retainers (5) with Tooling (A).
8. Install upper connecting rod bearing (8) in
connecting rod (6).
Note: Ensure that the bearing locking tab is located
in the notch of the connecting rod.
9. Install lower connecting rod bearing (9) in
connecting rod bearing cap (10).
in the notch of the connecting rod bearing cap.
10. Ensure that the dowels are installed in the
connecting rod bearing cap.
End By:
a. Install the pistons and connecting rods. Refer
Connecting Rods - Install.
i02630922
- Install
SMCS Code: 1225-012
Table 63
Required Tools
Tool
Part
Number
B 200-3914 Piston Ring Compressor 1
C 8T-3052 Degree Wheel 1
NOTICE
component life.
Note: Install the connecting rod bearings dry
when clearance checks are performed. Refer to
Disassembly and Assembly, Bearing Clearance -
Check. Apply clean engine oil on the connecting rod
bearings for nal assembly.
1. Apply clean engine oil to the cylinder liner bore, to
the piston rings, and to the outer surface of the
piston.
Note: Ensure that the connecting rod and pistons are
installed in the correct cylinder.
84 RENR9716-02
g01149650
Illustration 247
connecting rod journal is at the bottom center.
3. Use Tooling (B) to install piston (3) and the
connecting rod in the cylinder liner.
Note: Install the connecting rod so that the bearing
tab is located on the opposite side of the piston
cooling jet.
4. Install the upper connecting rod bearing in the
connecting rod.
Note: Ensure that the connecting rod bearing is
installed so that the bearing tab ts into the notch in
the connecting rod.
5. Pull the connecting rod onto the crankshaft journal.
6. Install the lower connecting rod bearing in the
connecting rod bearing cap.
Note: Ensure that the connecting rod bearing is
installed so that the bearing tab ts into the notch in
the connecting rod.
g01149651
Illustration 248
7. Position connecting rod bearing cap (2) on the
connecting rod.
Note: Ensure that the number on the side of the
connecting rod bearing cap is on the same side as
the number on the connecting rod. The bearing tabs
of the connecting rod bearing cap and the connecting
rod are located on the side opposite of the piston
cooling jet.
8. Lubricate the threads of bolts (1) with clean engine
oil. Install the bolts.
9. Tighten bolts (1), as follows:
a. Tighten Bolt (A) and Bolt (C) to a torque of
70 4 Nm (52 3 lb ft).
b. Tighten Bolt (B) and Bolt (D) to a torque of
70 4 Nm (52 3 lb ft).
c. Turn Bolt (B) and Bolt (D) for an additional 60
5 degrees (1/6 turn).
Note: If Tooling (C) is not used, place an index mark
on each bolt.
d. Tighten Bolt (A) and Bolt (C) again to a torque
of 70 4 Nm (52 3 lb ft).
e. Turn Bolt (A) and Bolt (C) for an additional 60
on each bolt.
f. Rotate the crankshaft in order to ensure that
the crankshaft turns freely.
End By:
a. Install the piston cooling jets. Refer to Disassembly
and Assembly, Piston Cooling Jets - Remove
and Install.
b. Install the cylinder head. Refer to Disassembly
and Assembly, Cylinder Head - Install.
i02295567
Connecting Rod Bearings -
Remove
SMCS Code: 1219-011
Removal Procedure
Table 64
Required Tools
Tool
Part
RENR9716-02 85
Start By:
- Remove.
NOTICE
component life.
g01149594
Illustration 249
connecting rod is at the bottom center.
2. Inspect the connecting rod and connecting rod cap
for the proper identication mark. The connecting
rod and the connecting rod cap should have an
etched number on the side. The number should
match the cylinder number. Mark the connecting
rod and the connecting rod cap, if necessary.
Note: Do not stamp the connecting rod assembly.
Stamping or punching the connecting rod assembly
could cause the connecting rod to fracture.
3. Remove bolts (1) and connecting rod bearing cap
(2) from the connecting rod.
4. Remove the lower half of the connecting rod
bearing from the connecting rod bearing cap.
5. Push the connecting rod away from the crankshaft.
Remove the upper half of the connecting rod
bearing from the connecting rod.
i02295910
Connecting Rod Bearings -
Install
SMCS Code: 1219-012
Table 65
Required Tools
Tool
Part
B 8T-3052 Degree Wheel 1
NOTICE
component life.
g00998730
Illustration 250
connecting rod journal is at the bottom center.
2. Install a new lower half connecting rod bearing (3)
in connecting rod bearing cap (2).
Note: Ensure that bearing locking tab (4) is located
in the notch of the connecting rod bearing cap.
3. Install a new upper half connecting rod bearing in
the connecting rod.
in the notch of the connecting rod.
86 RENR9716-02
4. Pull the connecting rod onto the crankshaft.
g01149651
Illustration 251
5. Position connecting rod bearing cap (2) on the
connecting rod.
cooling jet.
6. Lubricate the threads of bolts (1) with clean engine
oil. Install the bolts.
70 4 Nm (52 3 lb ft).
70 4 Nm (52 3 lb ft).
Note: If Tooling (B) is not used, place an index mark
on each bolt.
of 70 4 Nm (52 3 lb ft).
e. Tighten Bolt (A) and Bolt (C) for an additional
60 5 degrees (1/6 turn).
Note: If Tooling (B) is not used, place an index mark
on each bolt.
End By:
i02296017
Crankshaft Main Bearings -
Remove
SMCS Code: 1203-011
Removal Procedure
Table 66
Required Tools
Tool
Part
A 2P-5518 Bearing Tool 1
Start By:
- Remove.
NOTICE
component life.
1. Check the main bearing caps for identication of
the location and check the direction of the main
bearing caps in relation to the cylinder block. The
main bearing caps must be installed in the original
location and the original direction.
g01149949
Illustration 252
2. Remove bolts (1) and bolts (3) from No. 2 through
No. 6 main bearing caps (2).
Note: Remove No. 1 and No. 7 main bearing caps
(2) after No. 2 through No. 6 main bearing caps have
been installed.
RENR9716-02 87
g01149952
Illustration 253
3. Install Tooling (A) in the oil hole of the crankshaft.
Carefully rotate the crankshaft in order to remove
upper main bearing (4) from the cylinder block.
Note: Push the upper main bearing from the opposite
side of the bearing tab with Tooling (A). If the
crankshaft is turned in the wrong direction, the tab on
the bearing will be pushed between the crankshaft
and the bearing area of the cylinder block. This can
result in damage to the cylinder block and/or the
crankshaft.
4. Remove the thrust plates from each side of the
No. 4 main bearing.
5. Remove the lower halves of the main bearings
from the main bearing caps.
i02296049
Crankshaft Main Bearings -
Install
SMCS Code: 1203-012
Table 67
Required Tools
A 2P-5518 Bearing Tool 1
B 8T-5096 Dial Indicator 1
C 8T-3052 Degree Wheel 1
NOTICE
component life.
Note: Install the main bearings dry when clearance
checks are performed. Refer to Disassembly and
Assembly, Bearing Clearance - Check. Apply clean
engine oil on the main bearings for nal assembly.
Note: Ensure that the main bearings are installed
so that bearing tabs t into the notch in the cylinder
block. The upper halves of the main bearings have
the oil groove and the oil hole.
g01149952
Illustration 254
1. Position new upper main bearing (4) on the
crankshaft. Insert the end of the upper main
bearing that does not have the tab into the cylinder
block. Install Tooling (A) in the oil hole of the
crankshaft. Carefully rotate the crankshaft in order
to push the upper main bearing into the cylinder
block.
Note: Push the upper main bearing from the side of
the bearing tab with Tooling (A). If the crankshaft is
turned in the wrong direction, the tab on the bearing
will be pushed between the crankshaft and the
bearing area of the cylinder block. This can result in
damage to the cylinder block and/or the crankshaft.
2. Install the thrust plates on each side of the No. 4
main bearing.
Note: Install the thrust plates with the words Block
Side toward the cylinder block.
3. Install the lower halves of the crankshaft main
bearings in the main bearing caps.
Note: Ensure that the main bearings are installed so
that bearing tabs t into the notch in the main bearing
caps.
88 RENR9716-02
g01149987
Illustration 255
4. Position main bearing caps (2) on the crankshaft.
Note: Ensure that the numbers on the main bearing
caps match the numbers on the cylinder block. Also
ensure that the FRONT on the main bearing cap is
installed toward the front of the cylinder block.
5. Lubricate the threads of bolts (1) and bolts (3) with
clean engine oil. Install the bolts.
6. Tighten bolts (1) and bolts (3) for the main bearing
caps, as follows:
a. Tighten Bolt (A) to a torque of 258 14 Nm
(190 10 lb ft).
Note: Bolt (A) is on the bearing tab side of the main
bearing cap.
b. Tighten Bolt (B) to a torque of 258 14 Nm
(190 10 lb ft).
Note: Bolt (B) is on the opposite side of the bearing
tab of the main bearing cap.
c. Tighten Bolt (B) for an additional 120 5
degrees (2 ats).
on the bolt and the main bearing cap.
d. Tighten Bolt (A) for an additional 120 5
degrees (2 ats).
e. Tighten Bolt (D) to a torque of 80 10 Nm
(59 7 lb ft).
Note: Bolt (D) is on the opposite side of the bearing
f. Tighten Bolt (C) to a torque of 80 10 Nm
(59 7 lb ft).
Note: Bolt (C) is on the bearing tab side of the main
bearing cap.
g. Rotate the crankshaft in order to ensure that
7. Use Tooling (B) to check the crankshaft end play.
Ensure that Tooling (B) is against a machined
surface. The end play is controlled by the thrust
plates of No. 4 main bearing (center).
Crankshaft end play (new thrust
plates) ...... 0.10 to 0.60 mm (0.004 to 0.024 inch)
End By:
i02296738
Crankshaft - Remove
SMCS Code: 1202-011
Removal Procedure
Table 68
Required Tools
Tool
Part
1H-3110 Bearing Puller 1
8B-7560 Step Plate 1
9U-6600 Hand Hydraulic Pump 1
1H-3108 Push-Puller Leg 2
1H-3107 Bearing Puller 1
3H-0468 Puller Plate 5
3H-0465 Push-Puller Plate 2
1P-0820 Hydraulic Puller 1
5B-0637 Nut 1
B
8S-6586 Forcing Screw 1
5P-0944 Dowel Puller Group 1
C
5P-0939 Dowel Extractor 1
Start By:
a. Remove the front housing. Refer to Disassembly
and Assembly, Housing (Front) - Remove.
b. Remove the rear housing. Refer to Disassembly
and Assembly, Housing (Rear) - Remove.
RENR9716-02 89
c. Remove the piston cooling jets. Refer to
Disassembly and Assembly, Piston Cooling Jets
NOTICE
component life.
1. Check the main bearing caps for identication for
the location and the direction in the cylinder block.
The identication marks on the main bearing caps
must be installed in the same direction prior to
removal.
2. Check the connecting rod and the connecting rod
bearing caps for identication and the location in
the cylinder block.
g01150281
Illustration 256
3. Remove bolts (1). Remove connecting rod bearing
caps (2).
g01150289
Illustration 257
4. Remove bolts (3) and bolts (5). Remove main
bearing caps (4).
5. Install Tooling (A) and a suitable lifting device
on each end of crankshaft (6). The weight of
crankshaft (6) is approximately 188 kg (415 lb).
6. Remove crankshaft (6) from the cylinder block.
7. Remove the thrust plates from each side of the
No. 4 main bearing.
8. Remove the lower main bearings from main
bearing caps (4). Remove the upper main
bearings from the cylinder block.
g01150282
Illustration 258
9. Use Tooling (B) to remove crankshaft gear (7)
from crankshaft (6).
g01150284
Illustration 259
10. If necessary, use Tooling (C) to remove dowel (8)
and dowel (9) from crankshaft (6).
90 RENR9716-02
i02296800
Crankshaft - Install
SMCS Code: 1202-012
Table 69
Required Tools
Tool
Part
D 8T-5096 Dial Indicator 1
E 8T-3052 Degree Wheel 1
NOTICE
component life.
g01150312
Illustration 260
1. Install dowel (8) in the crankshaft.
Protrusion of dowel (8) from the crankshaft
face ........................................ 8.4 mm (0.33 inch)
2. Install dowel (9) in the crankshaft.
Protrusion of dowel (9) from the crankshaft
............................ 4.1 0.5 mm (0.16 0.02 inch)
3. Install crankshaft gear (7) on the crankshaft with
the keyway in alignment with dowel (9). Timing
Mark V of the gear should face away from
crankshaft (6).
Note: Install the main bearings dry when clearance
checks are performed. Refer to Disassembly and
Assembly, Bearing Clearance - Check. Apply clean
engine oil on the main bearings for nal assembly.
4. Install the upper halves of the main bearings in
the cylinder block.
Note: Ensure that the main bearings are installed so
that the bearing tabs t into the notch in the cylinder
block. The upper halves of the main bearings have
the oil groove and the oil hole.
g01150344
Illustration 261
5. Install Tooling (A) and a suitable lifting device
on each end of crankshaft (6). The weight of
crankshaft (6) is approximately 188 kg (415 lb).
6. Install crankshaft (6) with Timing Mark V on the
crankshaft gear in alignment with Timing Mark V
on the cluster gear.
7. Install the thrust plates on each side of the No. 4
main bearing.
Note: Install the thrust plates with the words Block
Side toward the cylinder block.
8. Install the lower halves of the crankshaft main
bearings in the main bearing caps.
Note: Ensure that the main bearings are installed
so that the bearing tabs t into the notch in the main
bearing cap.
9. Position main bearing caps (4) on the crankshaft.
Note: Ensure that the numbers on the main bearing
caps match the numbers on the cylinder block. Also
ensure that the FRONT on the main bearing cap is
installed toward the front of the cylinder block.
10. Lubricate the threads of bolts (3) and bolts (5)
with clean engine oil. Install the bolts.
11. Tighten bolts (3) and bolts (5) for the main bearing
caps, as follows:
a. Tighten Bolt (A) to a torque of 258 14 Nm
(190 10 lb ft).
Note: Bolt (A) is on the bearing tab side of the main
bearing cap.
b. Tighten Bolt (B) to a torque of 258 14 Nm
(190 10 lb ft).
RENR9716-02 91
Note: Bolt (B) is on the opposite side of the bearing
c. Tighten Bolt (B) for an additional 120 5
degrees (2 ats).
Note: If Tooling (E) is not used, place an index mark
d. Tighten Bolt (A) for an additional 120 5
degrees (2 ats).
e. Tighten Bolt (D) to a torque of 80 10 Nm
(59 7 lb ft).
Note: Bolt (D) is on the opposite side of the bearing
f. Tighten Bolt (C) to a torque of 80 10 Nm
(59 7 lb ft).
Note: Bolt (C) is on the bearing tab side of the main
bearing cap.
g. Rotate the crankshaft in order to ensure that
12. Use Tooling (D) to check the crankshaft end play.
Ensure that Tooling (D) is against a machined
surface. The end play is controlled by the thrust
plates of No. 4 main bearing (center).
Crankshaft end play (new thrust
plates) ...... 0.10 to 0.60 mm (0.004 to 0.024 inch)
g01150364
Illustration 262
13. Position the connecting rod against the
crankshaft. Install connecting rod bearing cap (2)
on the connecting rod.
cooling jet.
14. Lubricate the threads of bolts (1) with clean
engine oil. Install the bolts.
70 4 Nm (52 3 lb ft).
70 4 Nm (52 3 lb ft).
on each bolt and connecting rod cap.
of 70 4 Nm (52 3 lb ft).
e. Turn Bolt (A) and Bolt (C) for an additional 60
on each bolt and connecting rod cap.
End By:
a. Install the piston cooling jets. Refer to Disassembly
and Assembly, Piston Cooling Jets - Remove
and Install.
b. Install the rear housing. Refer to Disassembly and
Assembly, Housing (Rear) - Install.
c. Install the front housing. Refer to Disassembly and
Assembly, Housing (Front) - Install.
92 RENR9716-02
i02717761
Bearing Clearance - Check
SMCS Code: 1203-535; 1219-535
Measurement Procedure
Table 70
Required Tools
Tool
Part
198-9142 Plastic Gauge (Green)
0.025 to 0.076 mm
(0.001 to 0.003 inch)
1
198-9143 Plastic Gauge (Red)
0.051 to 0.152 mm
(0.002 to 0.006 inch)
1
198-9144 Plastic Gauge (Blue)
0.102 to 0.229 mm
(0.004 to 0.009 inch)
1
A
198-9145 Plastic Gauge (Yellow)
0.230 to 0.510 mm
(0.009 to 0.020 inch)
1
Note: Plastic gauge may not be necessary when the
engine is in the chassis.
NOTICE
component life.
Note: Caterpillar 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
Caterpillar engine bearing is quality checked for
specic wall thickness.
Note: The measurements should be within
specications and the correct bearings should
be used. If the crankshaft journals and the bores
for the block and the rods were measured during
disassembly, no further checks are necessary.
However, if the technician still wants to measure the
bearing clearances, Tooling (A) is an acceptable
method. Tooling (A) is less accurate on journals with
small diameters if clearances are less than 0.10 mm
(0.004 inch).
NOTICE
Lead wire, shim stock or a dial bore gauge can dam-
age the bearing surfaces.
The technician must be very careful to use Tooling (A)
correctly. The following points must be remembered:
Ensure that the backs of the bearings and the

bores are clean and dry.
Ensure that the bearing locking tabs are properly

seated in the tab grooves.
The crankshaft must be free of oil at the contact

points of Tooling (A).
1. Put a piece of Tooling (A) on the crown of the
bearing that is in the cap.
Note: Do not allow Tooling (A) to extend over the
edge of the bearing.
2. Use the correct torque-turn specications in order
to install the bearing cap. Do not use an impact
wrench. Be careful not to dislodge the bearing
when the cap is installed.
Note: Do not turn the crankshaft when Tooling (A)
is installed.
3. Carefully remove the cap, but do not remove
Tooling (A). Measure the width of Tooling (A)
while Tooling (A) is in the bearing cap or on the
crankshaft journal. Refer to Illustration 263.
g01152855
Illustration 263
Typical Example
4. Remove all of Tooling (A) before you install the
bearing cap.
RENR9716-02 93
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 specication range. Refer to Specications
Manual, Connecting Rod Bearing Journal and
Specications Manual, Main Bearing Journal for the
correct clearances.
i02449735
Atmospheric Pressure Sensor
SMCS Code: 1923-010
Removal Procedure
NOTICE
component life.
g01222887
Illustration 264
2. Remove atmospheric pressure sensor (1) from
the adapter on the cylinder block.
3. Remove the O-ring seal from atmospheric
pressure sensor (1).
NOTICE
component life.
g01222887
Illustration 265
1. Install a new O-ring seal on atmospheric pressure
sensor (1).
2. Install atmospheric pressure sensor (1) and
tighten to a torque of 10 2 Nm (90 18 lb in).
i02297743
Camshaft Position Sensor -
Remove and Install
SMCS Code: 1912-010
Removal Procedure
NOTICE
products.
mandates.
NOTICE
component life.
94 RENR9716-02
g01150693
Illustration 266
2. Remove bolt (1) and camshaft position sensor (2).
3. Remove the O-ring seal from camshaft position
sensor (2).
NOTICE
component life.
g01150693
Illustration 267
1. Install a new O-ring seal on camshaft position
sensor (2). Lubricate the O-ring seal with clean
engine oil.
2. Position camshaft position sensor (2) in the front
housing and install bolt (1). Tighten bolt (1) to a
torque of 28 7 Nm (21 5 lb ft).
i02297803
Crankshaft Position Sensor -
Remove and Install
SMCS Code: 1912-010
Removal Procedure
NOTICE
products.
mandates.
NOTICE
component life.
g01150731
Illustration 268
2. Remove bolt (3) and crankshaft position sensor
(2).
3. Remove the O-ring seal from crankshaft position
sensor (2).
RENR9716-02 95
NOTICE
component life.
g01150731
Illustration 269
1. Install a new O-ring seal on crankshaft position
sensor (2). Lubricate the O-ring seal with clean
engine oil.
2. Install crankshaft position sensor (2) in the front
housing. Install bolt (3). Tighten bolt (3) to a torque
of 28 7 Nm (21 5 lb ft).
i02449857
Coolant Temperature Sensor -
Remove and Install
SMCS Code: 1906-010
Removal Procedure
NOTICE
products.
mandates.
NOTICE
component life.
1. Drain the coolant from the cooling system to a
level below the coolant temperature sensor into a
g01222981
Illustration 270
3. Remove coolant temperature sensor (2).
4. Remove the O-ring seal from coolant temperature
sensor (2).
NOTICE
component life.
g01222981
Illustration 271
96 RENR9716-02
1. Install a new O-ring seal on coolant temperature
sensor (2).
2. Install coolant temperature sensor (2) and tighten
to a torque of 20 5 Nm (15 4 lb ft).
i02298137
Engine Oil Pressure Sensor -
Remove and Install
SMCS Code: 1924-010
Removal Procedure
NOTICE
products.
mandates.
NOTICE
component life.
g01150948
Illustration 272
2. Remove engine oil pressure sensor (1) from the
adapter on the cylinder block.
3. Remove the O-ring seal from engine oil pressure
sensor (1).
NOTICE
component life.
g01150948
Illustration 273
1. Install a new O-ring seal on engine oil pressure
sensor (1).
2. Install engine oil pressure sensor (1) and tighten
to a torque of 10 2 Nm (89 18 lb in).
RENR9716-02 97
i02581037
Fuel Pressure Sensor -
Remove and Install
SMCS Code: 7414-010
Removal Procedure
NOTICE
products.
mandates.
NOTICE
component life.
1. Turn the fuel supply valve to the OFF position.
g01292812
Illustration 274
3. Remove fuel pressure sensor (2) from the fuel
lter base.
4. Remove the O-ring seal from fuel pressure sensor
(2).
NOTICE
component life.
g01292812
Illustration 275
1. Install a new O-ring seal on fuel pressure sensor
(2).
2. Install fuel pressure sensor (2). Tighten fuel
pressure sensor (2) to a torque of 10 2 Nm
(90 18 lb in).
4. Turn the fuel supply valve to the ON position.
i02581061
Fuel Temperature Sensor -
Remove and Install
SMCS Code: 1922-010
Removal Procedure
NOTICE
products.
mandates.
98 RENR9716-02
NOTICE
component life.
1. Turn the fuel supply valve to the OFF position.
g01292826
Illustration 276
3. Remove fuel temperature sensor (2) from the fuel
lter base.
4. Remove the O-ring seal from fuel temperature
sensor (2).
NOTICE
component life.
g01292826
Illustration 277
1. Install a new O-ring seal on fuel temperature
sensor (2).
2. Install fuel temperature sensor (2). Tighten fuel
temperature sensor (2) to a torque of 20 5 Nm
(15 4 lb ft).
4. Turn the fuel supply valve to the ON position.
i02449930
Turbocharger Outlet Pressure
Sensor - Remove and Install
SMCS Code: 1917-010
Removal Procedure
NOTICE
component life.
g01223056
Illustration 278
2. Remove turbocharger outlet pressure sensor (2)
from the inlet manifold.
3. Remove the O-ring seal from turbocharger outlet
NOTICE
component life.
RENR9716-02 99
g01223056
Illustration 279
1. Install a new O-ring seal on turbocharger outlet
2. Install turbocharger outlet pressure sensor (2) and
tighten to a torque of 10 2 Nm (90 18 lb in).
i02449945
Inlet Air Temperature Sensor -
Remove and Install
SMCS Code: 1921-010
Removal Procedure
NOTICE
component life.
g01223082
Illustration 280
2. Remove inlet air temperature sensor (2) from the
inlet manifold.
3. Remove the O-ring seal from inlet air temperature
sensor (2).
NOTICE
component life.
g01223082
Illustration 281
1. Install a new O-ring seal on inlet air temperature
sensor (2).
2. Install inlet air temperature sensor (2) and tighten
to a torque of 20 5 Nm (15 4 lb ft).
i02574366
Belt Guard - Remove and
Install
SMCS Code: 1357-010-GD
Removal Procedure
g01289708
Illustration 282
100 RENR9716-02
Remove bottom belt guard (2).
g01289709
Illustration 283
2. Remove bolt (3). Repeat for the opposite side.
Remove upper belt guard (4).
g01289709
Illustration 284
1. Install upper belt guard (4). Install bolt (3). Repeat
for the opposite side.
g01289708
Illustration 285
2. Install lower belt guard (2). Install bolts (1). Repeat
for the opposite side.
i02755046
Fan Guard - Remove and Install
SMCS Code: 1360-010
Removal Procedure
g01289778
Illustration 286
1. Remove bolts (1). Remove lower fan guard (2).
g01379587
Illustration 287
2. Remove bolts (3). Remove upper fan guard (4).
g01379587
Illustration 288
1. Install upper fan guard (4). Install bolts (3).
RENR9716-02 101
g01289778
Illustration 289
2. Install lower fan guard (2). Install bolts (1).
i02755088
Fan - Remove and Install
SMCS Code: 1356-010
Removal Procedure
Table 71
Required Tools
Tool
Part
A 140-7742 Sleeve 1
Start By:
a. Remove the fan guard. Refer to Disassembly and
Assembly, Fan Guard - Remove and Install.
g01289730
Illustration 290
onto fan (1). The weight of fan (1) is approximately
45 kg (100 lb).
g01289733
Illustration 291
2. Remove bolts (2). Remove fan (1).
Table 72
Required Tools
Tool
Part
A 140-7742 Sleeve 1
g01289733
Illustration 292
onto fan (1). The weight of fan (1) is approximately
45 kg (100 lb). Install fan (1). Install bolts (2).
102 RENR9716-02
g01289730
Illustration 293
2. Remove Tooling (A) and the suitable lifting device
from fan (1).
End By:
a. Install the fan guard. Refer to Disassembly and
Assembly, Fan Guard - Remove and Install.
i02574047
Fan Drive - Remove and Install
SMCS Code: 1359-010; 1386-010
Removal Procedure
Start By:
b. Remove the belt guard. Refer to Disassembly and
Assembly, Belt Guard - Remove and Install.
1. Remove the belts. Refer to Operation
and Maintenance Manual, Belts -
Inspect/Adjust/Replace.
g01289585
Illustration 294
2. Loosen bolts (1). Loosen locknut (2).
g01289589
Illustration 295
3. Attach a suitable lifting device onto fan drive (3).
The weight of fan drive (3) is approximately 45 kg
(100 lb). Remove bolts (1). Remove fan drive (3).
RENR9716-02 103
g01289589
Illustration 296
1. Attach a suitable lifting device onto fan drive (3).
The weight of fan drive (3) is approximately 45 kg
(100 lb). Install fan drive (3). Install bolts (1).
g01289585
Illustration 297
2. Install the belts. Refer to Operation
and Maintenance Manual, Belts -
3. Tighten bolts (1). Tighten locknut (2).
End By:
a. Install the belt guard. Refer to Disassembly and
Assembly, Belt Guard - Remove and Install.
b. Install the fan. Refer to Disassembly and
i02417465
Electronic Control Module -
Remove and Install
SMCS Code: 1901-010
Removal Procedure
1. Turn the battery disconnect switch to the OFF
position.
2. Disconnect the negative battery terminal at the
battery.
g01208278
Illustration 298
3. Loosen allen head screw (1). Disconnect the
harness assembly from electronic control module
(5).
4. Disconnect hose assemblies (2) and (4).
5. Remove bolts (6). Remove electronic control
module (5) and ground strap (3).
6. Remove washers (7) and isolation mounts (8)
from electronic control module (5).
104 RENR9716-02
g01208278
Illustration 299
1. Position isolation mounts (8) on electronic control
module (5). Position the spacers, washers (7),
ground strap (3), and electronic control module (5)
on the support assemblies. Install bolts (6).
2. Connect hose assemblies (4) and (2).
3. Connect the harness assembly to electronic
control module (5). Tighten allen head screw (1)
to a torque of 6 1 Nm (53 9 lb in).
4. Connect the negative battery terminal at the
battery.
5. Turn the battery disconnect switch to the ON
position.
i02450170
Alternator - Remove and Install
SMCS Code: 1405-010
Removal Procedure
position.
g01223195
Illustration 300
2. Remove V-belt (1) from alternator (3).
3. Disconnect the harness assemblies from
alternator (3).
4. Remove bolt (2) and bolt (4).
5. Remove alternator (3) from the mounting group.
g01223195
Illustration 301
1. Position alternator (3) on the mounting group.
2. Install bolt (4) and bolt (2).
3. Connect the harness assemblies to alternator (3).
Refer to Specications, Alternator and Regulator.
4. Install V-belt (1) on alternator (3).
5. Adjust the tension on the V-belt. Refer to
Operation and Maintenance Manual, Belt -
position.
RENR9716-02 105
i02419387
Electric Starting Motor -
Remove and Install
SMCS Code: 1453-010
Removal Procedure
Personal injury can result from failure to discon-
nect the battery.
First, disconnect the negative battery cable. Then,
disconnect the positive battery cable.
A positive power lead can cause sparks if the bat-
tery is not disconnected. Sparks can possibly re-
sult in battery explosion or re.
position.
g01208927
Illustration 302
2. Place an index mark on all of the harness
assemblies. Disconnect the harness assemblies
from electric starting motor (1).
3. Fasten a suitable lifting device to electric starting
motor (1). The weight of electric starting motor (1)
is approximately 37 kg (80 lb).
5. Remove electric starting motor (1) and the gasket
from the ywheel housing.
g01208927
Illustration 303
1. Fasten a suitable lifting device to electric starting
motor (1). The weight of electric starting motor (1)
is approximately 37 kg (80 lb).
2. Position the gasket and electric starting motor (1)
in the ywheel housing. Install bolts (2).
3. Connect the harness assemblies to electric
starting motor (1). Refer to Specications, Electric
Starting Motor.
position.
106 RENR9716-02
Index Section
Index
A
Aftercooler - Install................................................. 40
Installation Procedure ........................................ 40
Aftercooler - Remove............................................. 38
Removal Procedure........................................... 38
Alternator - Remove and Install ........................... 104
Installation Procedure ...................................... 104
Removal Procedure......................................... 104
Atmospheric Pressure Sensor - Remove and
Install ................................................................... 93
B
Bearing Clearance - Check ................................... 92
Measurement Procedure ................................... 92
Belt Guard - Remove and Install ........................... 99
C
Camshaft - Install................................................... 73
Camshaft - Remove............................................... 71
Camshaft Bearings - Install ................................... 76
Camshaft Bearings - Remove ............................... 76
Camshaft Position Sensor - Remove and Install ... 93
Connecting Rod Bearings - Install ......................... 85
Connecting Rod Bearings - Remove..................... 84
Coolant Temperature Sensor - Remove and
Install ................................................................... 95
Cooler) - Install .................................................... 36
Cooler) - Remove ................................................ 35
Crankshaft - Install................................................. 90
Crankshaft - Remove............................................. 88
Removal Procedure ........................................... 88
Crankshaft Front Seal - Install ............................... 55
Crankshaft Front Seal - Remove........................... 54
Crankshaft Main Bearings - Install......................... 87
Installation Procedure........................................ 87
Crankshaft Main Bearings - Remove..................... 86
Crankshaft Position Sensor - Remove and Install .. 94
Crankshaft Rear Seal - Install................................ 50
Crankshaft Rear Seal - Remove............................ 50
Cylinder Head - Install ........................................... 68
Cylinder Head - Remove....................................... 66
Cylinder Liner - Install ............................................ 79
Cylinder Liner - Remove........................................ 79
D
Disassembly and Assembly Section........................ 4
E
Electric Starting Motor - Remove and Install ....... 105
Installation Procedure...................................... 105
Removal Procedure ......................................... 105
Electronic Control Module - Remove and Install .. 103
Installation Procedure...................................... 104
Electronic Unit Injector - Install .............................. 14
Electronic Unit Injector - Remove.......................... 13
Electronic Unit Injector Sleeve - Install .................. 16
Electronic Unit Injector Sleeve - Remove.............. 15
Engine - Install ......................................................... 6
Installation Procedure.......................................... 6
Engine - Remove..................................................... 4
Removal Procedure ............................................. 4
Engine Oil Cooler - Install ...................................... 28
Engine Oil Cooler - Remove.................................. 27
Engine Oil Filter Base - Assemble......................... 26
Assembly Procedure.......................................... 26
Engine Oil Filter Base - Disassemble.................... 26
Disassembly Procedure..................................... 26
Engine Oil Filter Base - Install ............................... 27
Engine Oil Filter Base - Remove........................... 25
RENR9716-02 107
Index Section
Engine Oil Pan - Remove and Install..................... 78
Engine Oil Pressure Sensor - Remove and Install .. 96
Engine Oil Pump - Assemble................................. 29
Engine Oil Pump - Disassemble............................ 29
Engine Oil Pump - Install ....................................... 30
Engine Oil Pump - Remove................................... 28
Engine Support (Front) - Remove and Install ........ 45
Installation Procedure (Type 1) .......................... 46
Installation Procedure (Type 2) .......................... 46
Removal Procedure (Type 1) ............................. 45
Removal Procedure (Type 2) ............................. 46
Exhaust Manifold - Remove and Install ................. 19
F
Fan - Remove and Install .................................... 101
Fan Drive - Remove and Install ........................... 102
Fan Guard - Remove and Install ......................... 100
Flywheel - Remove and Install .............................. 49
Flywheel Housing - Remove and Install ................ 51
Fuel Filter and Water Separator - Remove and
Install .................................................................... 11
Installation Procedure ......................................... 11
Removal Procedure............................................ 11
Fuel Filter Base - Install ......................................... 10
Fuel Filter Base - Remove..................................... 10
Fuel Pressure Sensor - Remove and Install .......... 97
Fuel Priming Pump - Remove and Install ................ 9
Removal Procedure............................................. 9
Fuel Temperature Sensor - Remove and Install .... 97
Fuel Transfer Pump - Install .................................. 12
Fuel Transfer Pump - Remove .............................. 12
G
Gear Group (Front) - Install ................................... 56
Gear Group (Front) - Remove ............................... 55
Gear Group (Rear) - Install .................................... 48
Gear Group (Rear) - Remove................................ 46
H
Housing (Front) - Install ......................................... 58
Housing (Front) - Remove..................................... 57
Housing (Rear) - Install.......................................... 60
Housing (Rear) - Remove...................................... 60
I
Important Safety Information................................... 2
Inlet Air Temperature Sensor - Remove and
Install ................................................................... 99
Inlet and Exhaust Valve Guides - Remove and
Install ................................................................... 23
Inlet and Exhaust Valve Seat Inserts - Remove and
Install ................................................................... 24
Inlet and Exhaust Valve Springs - Remove and
Install ................................................................... 20
Inlet and Exhaust Valves - Remove and Install ..... 22
P
Piston Cooling Jets - Remove and Install .............. 80
Pistons and Connecting Rods - Assemble ............ 82
Pistons and Connecting Rods - Disassemble ....... 82
Pistons and Connecting Rods - Install................... 83
Pistons and Connecting Rods - Remove............... 81
R
Radiator Core - Install............................................ 44
Radiator Core - Remove........................................ 42
Rocker Arm - Assemble......................................... 64
Rocker Arm - Disassemble.................................... 64
Rocker Arm and Shaft - Install............................... 65
Rocker Arm and Shaft - Remove........................... 63
T
Table of Contents..................................................... 3
Turbocharger - Assemble...................................... 18
Turbocharger - Disassemble ................................. 17
Turbocharger - Install ............................................ 18
Turbocharger - Remove ........................................ 17
Turbocharger Outlet Pressure Sensor - Remove and
Install ................................................................... 98
V
Valve Mechanism Cover - Remove and Install ...... 62
Valve Mechanism Cover Base - Remove and
Install ................................................................... 62
Vibration Damper and Pulley - Remove and
Install ................................................................... 53
W
Water Pump - Assemble........................................ 32
Water Pump - Disassemble................................... 31
Water Pump - Install .............................................. 33
Water Pump - Remove.......................................... 31
Water Temperature Regulator Housing - Remove and
Install ................................................................... 33
2008 Caterpillar
All Rights Reserved
Cat, Caterpillar, their respective logos, Caterpillar Yellow and the Power edge
trade dress, as well as corporate and product identity used herein, are trademarks
of Caterpillar and may not be used without permission.
Printed in U.S.A.

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ECM Summary Screen

Injector Code Calibration

Ensure that the backs of the bearings and the

Ensure that the bearing locking tabs are properly

The crankshaft must be free of oil at the contact

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