Disassembly and Assembly: C27 and C32 Generator Sets Engines

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 identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
The meaning of this safety alert symbol is as follows:

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

product Caterpillar recommends using Caterpil-
lar replacement parts or parts with equivalent
specifications including, but not limited to, phys-
ical dimensions, type, strength and material.
Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
RENR9716-02 3
Table of Contents
Table of Contents Vibration Damper and Pulley - Remove and Install

............................................................................. 53
Crankshaft Front Seal - Remove .......................... 54
Crankshaft Front Seal - Install .............................. 55
Disassembly and Assembly Section Gear Group (Front) - Remove .............................. 55
Gear Group (Front) - Install .................................. 56
Engine - Remove ................................................... 4
Housing (Front) - Remove .................................... 57
Engine - Install ....................................................... 6
Housing (Front) - Install ........................................ 58
Fuel Priming Pump - Remove and Install .............. 9
Housing (Rear) - Remove ..................................... 60
Fuel Filter Base - Remove ................................... 10
Housing (Rear) - Install ......................................... 60
Fuel Filter Base - Install ....................................... 10
Valve Mechanism Cover - Remove and Install ..... 62
Fuel Filter and Water Separator - Remove and
Valve Mechanism Cover Base - Remove and
Install .................................................................... 11
Install ................................................................... 62
Fuel Transfer Pump - Remove .............................. 12
Rocker Arm and Shaft - Remove .......................... 63
Fuel Transfer Pump - Install .................................. 12
Rocker Arm - Disassemble ................................... 64
Electronic Unit Injector - Remove ......................... 13
Rocker Arm - Assemble ........................................ 64
Electronic Unit Injector - Install ............................. 14
Rocker Arm and Shaft - Install .............................. 65
Electronic Unit Injector Sleeve - Remove ............. 15
Cylinder Head - Remove ...................................... 66
Electronic Unit Injector Sleeve - Install ................. 16
Cylinder Head - Install .......................................... 68
Turbocharger - Remove ........................................ 17
Camshaft - Remove .............................................. 71
Turbocharger - Disassemble ................................ 17
Camshaft - Install .................................................. 73
Turbocharger - Assemble .................................... 18
Camshaft Bearings - Remove ............................... 76
Turbocharger - Install ............................................ 18
Camshaft Bearings - Install ................................... 76
Exhaust Manifold - Remove and Install ............... 19
Engine Oil Pan - Remove and Install ................... 78
Inlet and Exhaust Valve Springs - Remove and
Cylinder Liner - Remove ....................................... 79
Install ................................................................... 20
Cylinder Liner - Install ........................................... 79
Inlet and Exhaust Valves - Remove and Install .... 22
Piston Cooling Jets - Remove and Install ............. 80
Inlet and Exhaust Valve Guides - Remove and
Pistons and Connecting Rods - Remove .............. 81
Install ................................................................... 23
Pistons and Connecting Rods - Disassemble ....... 82
Inlet and Exhaust Valve Seat Inserts - Remove and
Pistons and Connecting Rods - Assemble ........... 82
Install ................................................................... 24
Pistons and Connecting Rods - Install .................. 83
Engine Oil Filter Base - Remove .......................... 25
Connecting Rod Bearings - Remove .................... 84
Engine Oil Filter Base - Disassemble ................... 26
Connecting Rod Bearings - Install ........................ 85
Engine Oil Filter Base - Assemble ........................ 26
Crankshaft Main Bearings - Remove .................... 86
Engine Oil Filter Base - Install .............................. 27
Crankshaft Main Bearings - Install ........................ 87
Engine Oil Cooler - Remove ................................. 27
Crankshaft - Remove ............................................ 88
Engine Oil Cooler - Install ..................................... 28
Crankshaft - Install ................................................ 90
Engine Oil Pump - Remove .................................. 28
Bearing Clearance - Check ................................... 92
Engine Oil Pump - Disassemble ........................... 29
Atmospheric Pressure Sensor - Remove and
Engine Oil Pump - Assemble ................................ 29
Install ................................................................... 93
Engine Oil Pump - Install ...................................... 30
Camshaft Position Sensor - Remove and Install .. 93
Water Pump - Remove ......................................... 31
Crankshaft Position Sensor - Remove and Install .. 94
Water Pump - Disassemble ................................. 31
Coolant Temperature Sensor - Remove and
Water Pump - Assemble ...................................... 32
Install ................................................................... 95
Water Pump - Install ............................................. 33
Engine Oil Pressure Sensor - Remove and Install
Water Temperature Regulator Housing - Remove and
............................................................................. 96
Install .................................................................. 33
Fuel Pressure Sensor - Remove and Install ......... 97
Cooling System Package (Radiator, Aftercooler, Fuel
Fuel Temperature Sensor - Remove and Install ... 97
Cooler) - Remove ................................................ 35
Turbocharger Outlet Pressure Sensor - Remove and
Cooling System Package (Radiator, Aftercooler, Fuel
Install ................................................................... 98
Cooler) - Install .................................................... 36
Inlet Air Temperature Sensor - Remove and
Aftercooler - Remove ........................................... 38
Install ................................................................... 99
Aftercooler - Install ............................................... 40
Belt Guard - Remove and Install ........................... 99
Radiator Core - Remove ...................................... 42
Fan Guard - Remove and Install ........................ 100
Radiator Core - Install .......................................... 44
Fan - Remove and Install ................................... 101
Engine Support (Front) - Remove and Install ....... 45
Fan Drive - Remove and Install ......................... 102
Gear Group (Rear) - Remove ............................... 46
Electronic Control Module - Remove and Install .. 103
Gear Group (Rear) - Install ................................... 48
Alternator - Remove and Install ......................... 104
Flywheel - Remove and Install ............................. 49
Electric Starting Motor - Remove and Install ..... 105
Crankshaft Rear Seal - Remove ........................... 50
Crankshaft Rear Seal - Install ............................... 50
Flywheel Housing - Remove and Install .............. 51 Index Section
Index ................................................................... 106
4 RENR9716-02
Disassembly and Assembly Section
Disassembly and Assembly

Section
i02747487
Engine - Remove
SMCS Code: 1000-011
Removal Procedure
Table 1
Required Tools g01291160
Illustration 2
Part
Tool Number Part Description Qty 2. Disconnect harness assembly (6).
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”.
g01291161
Illustration 3
3. Disconnect hose assemblies (7), (8), and (9).
g01291159
Illustration 1
1. Disconnect hose assembly (1). Disconnect cable

assembly (2). Disconnect harness assemblies Illustration 4
g01291162
(3). Disconnect cable assembly (4). Disconnect
harness assemblies (5). 4. Disconnect clamp (10).
RENR9716-02 5
7. Disconnect clamp (15).
g01291225
Illustration 8
8. Remove bolts (16). Remove guard (17).
g01291179
Illustration 5
5. Remove bolts (11). Remove bolts (12). Repeat for

the opposite side. Disconnect tube assembly (13).
Repeat for the opposite side.
g01291227
Illustration 9
9. Remove bolts (18). Remove guard (19).
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).
g01291228
Illustration 10
10. Disconnect hose (20).
g01291186
Illustration 7
6 RENR9716-02
g01291232 g01291246
Illustration 11 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).
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). Illustration 15
g01291247
14. Remove mounting bolts (25). Remove engine

(24) from the generator.
i02747534
Engine - Install
SMCS Code: 1000-012
Installation Procedure
Table 2
g01376223
Required Tools
Illustration 13
Part
12. Use Tooling (C) in order to support generator Tool Number Part Description Qty
rotor (23). 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
RENR9716-02 7
g01291246 g01291232
1. Attach Tooling (D) onto engine (24). Attach Tooling 3. Install bolts (21). Use Tooling (B) in order to rotate
(E) and a suitable lifting device onto Tooling the engine. Install bolts (22).
(D). The weight of engine (24) is approximately
3527 kg (7775 lb). Install engine (24).
g01291245
Illustration 20
g01291247
Illustration 17 4. Remove Tooling (C).
2. Install mounting bolts (25).
g01291228
Illustration 21
g01291243
Illustration 18 5. Connect hose (20).
8 RENR9716-02
g01291227 g01291183
6. Install guard (19). Install bolts (18). 9. Attach Tooling (A) and a suitable lifting device
onto exhaust elbow (14). The weight of exhaust
elbow (14) is approximately 34 kg (75 lb). Install
exhaust elbow (14).
g01291225
Illustration 23
7. Install guard (17). Install bolts (16).
g01291179
Illustration 26
10. Connect tube assembly (13). Install bolts (12).

Repeat for the opposite side. Install bolts (11).
g01291186
Illustration 24
8. Connect clamp (15).
g01291162
Illustration 27
RENR9716-02 9
11. Connect clamp (10). 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
g01291161
Illustration 28
NOTICE
12. Connect hose assemblies (7), (8), and (9). Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar

Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and

mandates.
g01291160 NOTICE
Illustration 29
Keep all parts clean from contaminants.
13. Connect harness assembly (6). Contaminants may cause rapid wear and shortened
component life.
g01291159
Illustration 30
g01292755
14. Connect harness assemblies (5). Connect cable Illustration 31
assembly (4). Connect harness assemblies (3).
Connect cable assembly (2). Connect hose 1. Remove bolts (1).
assembly (1).
2. Remove fuel priming pump (2) and the gasket.
10 RENR9716-02
Installation Procedure 1. Turn the fuel supply to the OFF position.
g01292755
Illustration 32
1. Position the gasket and fuel priming pump (2) on

the fuel filter base.
2. Install bolts (1).

g01292764
Illustration 33
i02580993
2. Use Tooling (A) to remove fuel filter (6) from fuel
Fuel Filter Base - Remove filter base (5).
SMCS Code: 1262-011 3. Disconnect harness assemblies (4).
Removal Procedure 4. Disconnect hose assembly (1) and hose assembly

(2).
Table 3
Required Tools 5. Remove bolts (3) and fuel filter base (5).
Part
Tool Number Part Description Qty i02581008
A 185-3630 Strap Wrench 1 Fuel Filter Base - Install

SMCS Code: 1262-012
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test- Installation Procedure
collect the fluid with suitable containers before open- NOTICE
ing any compartment or disassembling any compo- Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
Refer to Special Publication, NENG2500, “Caterpillar component life.
Dealer Service Tool Catalog” for tools and supplies
products.

mandates.
NOTICE

component life.
RENR9716-02 11
NOTICE

products.

mandates.
1. Turn the fuel supply to the OFF position.
g01292764
Illustration 34
1. Position fuel filter base (5) on the engine. Install

bolts (3).
2. Connect hose assembly (1) and hose assembly

(2).
3. Connect harness assemblies (4).
4. Install fuel filter (6) on fuel filter base (5).
5. Turn the fuel supply to the ON position. Illustration 35

g01292832
i02581074
2. Use Tooling (A) to remove the fuel filter and water
separator (5) from base assembly (4).
Fuel Filter and Water Separator
3. Disconnect hose assemblies (2) and (3).
- Remove and Install
4. Remove bolts (1) and base assembly (4).
SMCS Code: 1261-010; 1263-010
Removal Procedure Installation Procedure

Table 4 NOTICE
Required Tools
Tool Part Number Part Description Qty Contaminants may cause rapid wear and shortened
component life.
A 185-3630 Strap Wrench As 1
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).

g01143748
Illustration 37
3. Install a new fuel filter and water separator (5) on
base assembly (4).
2. Disconnect hose assemblies (3).
4. Turn the fuel supply to the ON position.
3. Remove bolts (2).
i02285574 4. Remove fuel transfer pump (1) and the O-ring

seal.
Fuel Transfer Pump - Remove
SMCS Code: 1256-011 i02287501
Fuel Transfer Pump - Install

Removal Procedure
SMCS Code: 1256-012
NOTICE
Care must be taken to ensure that fluids are contained Installation Procedure
NOTICE
component life.
products.

mandates.
NOTICE

component life.
1. Turn the fuel supply to the “OFF” position.

RENR9716-02 13
g01114892
Illustration 39
1. Disconnect harness assembly (1).
2. Remove bridge assemblies (3).
Illustration 38
g01143748 NOTICE
If the injector hold down bolt is loose during the re-
1. Install the O-ring seal on fuel transfer pump (1). moval procedure, inspect the injector bore for wear
Lubricate the O-ring seal with clean engine oil. and debris. Replace the clamp and spacer.
2. Position fuel transfer pump (1) on the engine. 3. Remove bolt (4), spacer (5), and clamp (6).
Install bolts (2).
4. Place an identification mark on electronic unit
3. Connect hose assemblies (3). injectors (2) for installation purposes. Each
electronic unit injector must be reinstalled in the
4. Turn the fuel supply to the “ON” position. original location in the cylinder head.
i02208070
Electronic Unit Injector -

Remove
SMCS Code: 1290-011
Removal Procedure
Table 5
Required Tools
Tool Part Number Part Description Qty
g01073439
A 5F-4764 Pry Bar 1 Illustration 40
5. Use Tooling (A) to pry beneath the base and free

Start By: electronic unit injector (2).
a. Remove the rocker arms and the rocker arm shaft. 6. Remove electronic unit injector (2) from the
Refer to Disassembly and Assembly, “Rocker Arm cylinder head.
and Shaft - Remove”.
NOTICE

component life.
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
g01114892
Illustration 41
169-7372 Fluid Sampling Bottle 1
C
Tube
4C-4057 1
7.9 mm (0.31 inch) OD
D 4C-5552 Large Bore Brush 1
E 4C-6774 Vacuum Gun Kit 1
Surface Reconditioning
F 8T-7765 1
Pad
NOTICE

component life. g01135876
Illustration 42
1. Use Tooling (C) to remove the fuel and oil from 5. When you install a new injector the E-Trim
the cylinder. Evacuate as much fuel and oil as value must be programmed into the engine
possible from the cylinder before installing the control module. The injector confirmation code
electronic unit injector. Several evacuations may may need to be programmed into the engine
be necessary. control module. E-Trim Value (X) is a twelve digit
alphanumeric code that is supplied with the data
2. Use Tooling (D) to clean the carbon deposit from sheet that comes with the new injectors. Injector
the inside of the electronic unit injector sleeve. Confirmation Code (Y) is a four digit numeric
Tooling (E) is available to clean loose material code. Both of the codes are located on the top of
from the bore of the electronic unit injector sleeve electronic unit injector (2). Use the following menu
and the cylinder. to program the E-Trim value.
3. Use Tooling (F) to clean the carbon from the seat • ECM Summary Screen
area that is inside of the electronic unit injector
sleeve. • Service Menu
4. Install the O-ring seals on the electronic unit • Calibration
injector. Lubricate the top two O-ring seals with a
50/50 mixture of clean engine oil and Tooling (B). • Injector Code Calibration
RENR9716-02 15
NOTICE NOTICE
When an electronic unit injector is replaced, the new Keep all parts clean from contaminants.
electronic injector code must be programmed into the
engine’s personality module software by using the cal- Contaminants may cause rapid wear and shortened
ibration menu on the Electronic Service Tool. If the component life.
new electronic injector code is not entered, the char-
acteristics of the previous electronic unit injector is as-
sumed. 1. Drain the coolant from the cooling system into a
suitable container for storage or disposal. Refer
If it is not possible to immediately reprogram the elec- to Operation and Maintenance Manual, “Cooling
tronic injector code into the personality module soft- System Coolant - Change”.
ware, the engine will not be severely harmed. The new
electronic injector code should be reprogrammed as
quickly as possible in order to optimize engine perfor-
mance.
6. Position electronic unit injector (2) in the cylinder

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

the bolt to a torque of 55 ± 10 N·m (41 ± 7 lb ft).
8. Install bridge assemblies (3).
9. Connect harness assembly (1). Tighten the nuts

to a torque of 2.5 ± 0.25 N·m (22 ± 2 lb in). g01043124
Illustration 43
End By: 2. Install Tooling (A) in electronic unit injector sleeve

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

- Remove
SMCS Code: 1713-011
Removal Procedure
Table 7
Required Tools
Part
Tool Number Part Description Qty
g01073635
Illustration 44
A 9U-6891 Injector Tool Group 1
4. Remove O-ring seals (2) and O-ring seal (3) from
Start By: electronic unit injector sleeve (1).
a. Remove the electronic unit injectors. Refer to

Disassembly and Assembly, “Electronic Unit
Injector - Remove”.
16 RENR9716-02
i02287628 Note: Do not apply Tooling (C) to the cylinder head

surfaces. Apply Tooling (C) on the electronic unit
Electronic Unit Injector Sleeve injector sleeve only.
- Install
4. Lubricate O-ring seals (2) with clean engine oil.
SMCS 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
B 9U-7244 End Brush 1
g01099549
9U-7237 Brush Extension 1 Illustration 46
4C-5552 Large Bore Brush 1

5. Install electronic unit injector sleeve (1) on Tooling
C 4C-9507 Retaining Compound 1 (A). Position the electronic unit injector sleeve in
the cylinder head. Use care not to damage the
O-ring seals on the electronic unit injector sleeve.
NOTICE Use Tooling (A) and a hammer to install the
Keep all parts clean from contaminants. electronic unit injector sleeve in the cylinder head.
component life. NOTICE
Ensure that the electronic unit injector sleeve is
properly seated in the cylinder head. The Tooling will
1. Use Tooling (B) to clean the bore in the cylinder "RING" when the electronic unit injector sleeve is fully
head for the electronic unit injector sleeve. seated in the bore of the cylinder head.
NOTICE 6. Remove Tooling (A). Remove excess Tooling (C).

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

Injector - Install”.
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”.
RENR9716-02 17
i02287744
Turbocharger - Remove
SMCS Code: 1052-011
Removal Procedure
NOTICE
nent containing fluids. Illustration 48
g01148173
Refer to Special Publication, NENG2500, “Caterpillar 2. Remove tube assembly (2).

suitable to collect and contain fluids on Caterpillar 3. Disconnect tube assemblies (1) and tube
products. assembly (4).
Dispose of all fluids according to local regulations and 4. Attach a suitable lifting device to turbocharger (5).
mandates. The weight of turbocharger (5) is approximately
45 kg (100 lb).
NOTICE
Keep all parts clean from contaminants. 5. Remove nuts (3). Remove turbocharger (5) and
the gasket.
component life. i02287870
1. Drain the coolant from the cooling system into a

Turbocharger - Disassemble
suitable container for storage or disposal. Refer SMCS Code: 1052-015
to Operation and Maintenance Manual, “Cooling
Disassembly Procedure
Start By:
a. Remove the turbocharger. Refer to Disassembly

and Assembly, “Turbocharger - Remove”.
NOTICE

component life.
g01145002
Illustration 47
18 RENR9716-02
1. Position compressor housing (1) and turbine

housing (5) on turbocharger cartridge (3).
Note: Ensure that the mating surfaces are flush.
2. Tighten the nuts on V-band clamp (2) to a torque

of 14 ± 1 N·m (10 ± 1 lb ft). Use a soft hammer to
lightly hit around the diameter of the band clamp.
Tighten the nuts again to a torque of 14 ± 1 N·m
(10 ± 1 lb ft).
3. Tighten the nuts on V-band clamp (4) to a torque

of 14 ± 1 N·m (10 ± 1 lb ft). Use a soft hammer to
lightly hit around the diameter of the band clamp.
g01145263
Tighten the nuts again to a torque of 14 ± 1 N·m
Illustration 49 (10 ± 1 lb ft).
1. Loosen V-band clamp (2) and V-band clamp (4). 4. Ensure that the impeller spins freely.
2. Separate compressor housing (1) from End By:
turbocharger cartridge (3).
a. Install the turbocharger. Refer to Disassembly and
3. Separate turbine housing (5) from turbocharger Assembly, “Turbocharger - Install”.
cartridge (3).
i02288273
i02451256
Turbocharger - Assemble Turbocharger - Install

SMCS Code: 1052-012
SMCS Code: 1052-016
Assembly Procedure
Table 9
NOTICE Required Tools
Contaminants may cause rapid wear and shortened A 5P-3931 Anti-Seize Compound 1
component life.
NOTICE
NOTICE Keep all parts clean from contaminants.
The compressor housing must remain straight with
the turbocharger cartridge during disassembly and as- Contaminants may cause rapid wear and shortened
sembly. Tilting may cause damage to the tips of the component life.
compressor wheel and the compressor shaft.
g01148173
Illustration 51
g01145263
Illustration 50
RENR9716-02 19
g01145002 g01218139
1. Position the gasket on the exhaust manifold. 2. Remove locknuts (6) from exhaust manifold (7).
2. Apply Tooling (A) to the threads of the exhaust 3. Remove spacers (2) and (3) from exhaust
manifold studs. manifold (7).
3. Attach a suitable lifting device to turbocharger (5). 4. Remove exhaust manifold (7) and gaskets (1)
The weight of turbocharger (5) is approximately from the cylinder head.
45 kg (100 lb). Position turbocharger (5) on the
exhaust manifold. 5. If necessary, remove clamps (4) and expansion
joints (5).
4. Install nuts (3) and tighten to a torque of 55 ± 9 N·m
(41 ± 7 lb ft). Installation Procedure
5. Connect tube assemblies (1) and tube assembly Table 10
(4).
Required Tools
6. Install tube assembly (2). Tool Part Number Part Description Qty
7. Fill the cooling system. Refer to Operation and A 5P-3931 Anti-Seize Compound -
Maintenance Manual, “Cooling System Coolant B 165-4638 Guide 3
- Change”.
i02617122
Exhaust Manifold - Remove

and Install
SMCS Code: 1059-010
Removal Procedure
Start By:
a. Remove the turbocharger. Refer to Disassembly

g01218139
and Assembly, “Turbocharger - Remove”. Illustration 54
NOTICE

component life.
1. Remove the shield assemblies from the exhaust

manifolds.
20 RENR9716-02
i02300073
Inlet and Exhaust Valve

Springs - Remove and Install
SMCS Code: 1108-010
Removal Procedure
Table 11
Required Tools
g00566145
A 9U-7241 Valve Spring Compressor 1
Illustration 55
B 8S-2263 Spring Tester 1
1. If necessary, install expansion joints (5) and
clamps (4). Tighten the clamps to a torque of Start By:
8.5 ± 1.0 N·m (75 ± 9 lb in).
2. Apply Tooling (A) to the studs prior to assembly. If Disassembly and Assembly, “Electronic Unit
necessary, install the studs and tighten to a torque Injector - Remove”.
of 35 ± 5 N·m (26 ± 4 lb ft).
3. Position gaskets (1) and exhaust manifold (7) on NOTICE

the cylinder head. Keep all parts clean from contaminants.
4. Install spacers (2) and (3) on exhaust manifold (7). Contaminants may cause rapid wear and shortened
component life.
Note: Use Tooling (B) in at least one oversize hole
per manifold section in order to align the exhaust Note: Place the piston at the top of the compression
manifolds. Do not remove Tooling (B) until removal stroke (TC). Remove the valve springs for that
is required to tighten the locknuts. cylinder. If the valves fall into the cylinder liner, then
the cylinder head must be removed.
5. Install locknuts (6) on exhaust manifold (7).
Tighten locknuts (6) in a numerical sequence to a 1. Position the No. 1 piston at the top center of
torque of 20 ± 3 N·m (15 ± 2 lb ft). Tighten locknuts the compression stroke. Refer to Testing and
(6) again in a numerical sequence to a torque of Adjusting, “Finding Top Center Position for No. 1
38 ± 5 N·m (28 ± 4 lb ft). Piston”.
6. Install the shield assemblies on the exhaust
manifolds.
End By:
a. Install the turbocharger. Refer to Disassembly and

Assembly, “Turbocharger - Install”.
g01073852
Illustration 56
RENR9716-02 21
NOTICE

component life.
1. Lubricate the valve stems with clean engine oil.
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. g01043625
Illustration 58
Follow the recommended procedure and use all
recommended tooling to release the spring force.
Improper assembly of parts that are spring loaded

2. Install Tooling (A) in the electronic unit injector
can cause bodily injury.
sleeve. Secure Tooling (A) with unit injector clamp
(1).
To prevent possible injury, follow the established
assembly procedure and wear protective equip-
3. Tighten the full nut until valve spring keepers (3)
ment.
are loose on valve (2).
4. Remove valve spring keepers (3) from the valve. 2. Ensure that washer (7) is installed on the valve
guide.
5. Carefully remove Tooling (A).
3. Install inner valve spring (5) and outer valve spring
6. Remove valve rotator (4). (6) on valve (2).
7. Remove outer valve spring (6) and inner valve 4. Install valve rotator (4) on valve (2).
spring (5) from the valve.
8. Remove washer (7) from the valve guide.
9. Use Tooling (B) to check the valve springs (spring The valve spring keepers can be thrown from
force). Refer to Specifications, “Cylinder Head the valve when the valve spring compressor is
Valves” for additional information on the valve released. Ensure that the valve spring keepers
springs. are properly installed on the valve stem. To help
prevent personal injury, keep away from the front
of the valve spring keepers and valve springs
Installation Procedure during the installation of the valves.
Table 12
5. Use Tooling (A) to compress inner valve spring
Required Tools
(5) and outer valve spring (6). Install valve spring
Tool Part Number Part Description Qty keepers (3) on valve (2). Remove unit injector
clamp (1) and Tooling (A).
A 9U-7241 Valve Spring Compressor 1
22 RENR9716-02
End By:
a. Install the electronic unit injectors. Refer to

i02642655
Inlet and Exhaust Valves -

Remove and Install
SMCS Code: 1105-010
Removal Procedure
Table 13
Required Tools
Valve Spring
A 5S-1330 1
Compressor
B 8S-2263 Spring Tester 1
Start By:
a. Remove the cylinder head. Refer to Disassembly Illustration 59

g01015263
and Assembly, “Cylinder Head - Remove”.
NOTICE
Keep all parts clean from contaminants. Personal injury can result from being struck by
component life. Make sure to wear all necessary protective equip-
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 Specifications, “Cylinder Head
Valves” for additional information on the valve
springs.
7. Inspect the valves. Refer to Specifications,

“Cylinder Head Valves” for additional information
on the inlet and exhaust valves.
RENR9716-02 23
Installation Procedure 3. Install inner valve spring (4) and outer valve spring
(5) on valve (1).
Table 14
Required Tools 4. Install valve rotator (3) on valve (1).
Tool Part Number Part Description Qty 5. Use Tooling (A) to compress inner valve spring
Valve Spring (4) and outer valve spring (5). Install valve spring
A 5S-1330 1 keepers (2) on valve (1).
Compressor
NOTICE
The valve spring keepers can be thrown from
Contaminants may cause rapid wear and shortened the valve when the valve spring compressor is
component life. released. Ensure that the valve spring keepers
are properly installed on the valve stem. To help
prevent personal injury, keep away from the front
Note: A small amount of grease can be used to hold of the valve spring keepers and valve springs
the retainer locks in position during installation. during the installation of the valves.
1. Lubricate the valves with clean engine oil. Install

the valves in the cylinder head. 6. Carefully remove Tooling (A).
End By:
a. Install the cylinder head. Refer to Disassembly

and Assembly, “Cylinder Head - Install”.
i02109151
Inlet and Exhaust Valve Guides

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
Illustration 60
g01015263 Valves - Remove and Install”.
NOTICE
component life.
ment.
2. Install washer (6) on the valve guide.

24 RENR9716-02
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 Specifications,

“Cylinder Head Valves”.
3. Install valve stem seal (1) on the valve guide.
End By:
a. Install the inlet and exhaust valves. Refer to

g01073841
Illustration 61 Valves - Remove and Install”.
1. Remove valve stem seal (1) from valve guide (2).
i02288478
2. Use Tooling (A) and a hammer to remove the
valve guide from the cylinder head. Inlet and Exhaust Valve Seat
Inserts - Remove and Install
SMCS Code: 1103-010
Table 16
Required Tools Removal Procedure
Tool Part Number Part Description Qty Table 17
A(1) 9U-6895 Valve Guide Driver 1 Required Tools
B(1) 9U-6894 Guide Collar 1 Part
(1) Part of 9U-7530 Engine Tool Group Tool Number Part Description Qty
Valve Seat Extractor Tool 1
A 166-7441
NOTICE Group
Start By:
component life. a. Remove the inlet and exhaust valves. Refer to
Valves - Remove and Install”.
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).
g01145463
Illustration 63
RENR9716-02 25
1. Use Tooling (A) to remove valve seat insert (1) i02438648

from the cylinder head.
Engine Oil Filter Base -
2. Clean the bores in the cylinder head for the valve Remove
seat inserts. Remove any rough areas from the
bores. SMCS Code: 1306-011
Installation Procedure Removal Procedure

Table 18 Table 19
Required Tools Required Tools
Part Part
Tool Number Part Description Qty Tool Number Part Description Qty
Valve Seat Driver 1 A 185-3630 Strap Wrench As 1
9U-6898
B(1) (Exhaust)
9U-6897 Valve Seat Driver (Inlet) 1
NOTICE
(1) Part of 9U-7530 Engine Tool Group Keep all parts clean from contaminants.
NOTICE Contaminants may cause rapid wear and shortened

Keep all parts clean from contaminants. component life.

component life. NOTICE

products.

mandates.
Illustration 64
g01079028 1. Drain the engine oil into a suitable container
for storage or disposal. Refer to Operation and
1. Lower the temperature of new valve seat insert Maintenance Manual, “Engine Oil and Filter -
(1). Change”.
2. Use Tooling (B) to install the new valve seat insert

in the cylinder head.
Note: Do not machine the prefinished valve seat

inserts in order to correct the valve stem projection.
An excessive valve stem projection indicates that the
valve seat insert is not seated or material was not
cleaned from the bottom of the counterbore.
End By:
a. Install the inlet and exhaust valves. Refer to

Valves - Remove and Install”. g01218560
Illustration 65
26 RENR9716-02
2. Use Tooling (A) in order to remove engine oil 3. Remove springs (3) and plungers (2) from oil filter
filters (6). base assembly (1).
3. Remove bolts (1), (2), (4), and (5).

i02127824
4. Remove engine oil filter base (3). Engine Oil Filter Base -
Assemble
i02127750
Engine Oil Filter Base - SMCS Code: 1306-016
Disassemble Assembly Procedure

SMCS Code: 1306-015
NOTICE
Start By:
component life.
a. Remove the engine oil filter base. Refer to
Disassembly and Assembly, “Engine Oil Filter
Base - Remove”.
1. Remove the O-ring seals.
g01083088
Illustration 67
g01083088
Illustration 66 can cause bodily injury.

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

RENR9716-02 27
End By: i02438849
a. Install the engine oil filter base. Refer to Engine Oil Cooler - Remove
Base - Install”. SMCS Code: 1378-011
i02438813
Removal Procedure
Engine Oil Filter Base - Install Start By:
SMCS Code: 1306-012 a. Remove the engine oil filter base. Refer to
Base - Remove”.
Table 20 NOTICE
Required Tools
Part Contaminants may cause rapid wear and shortened
Tool Number Part Description Qty component life.
A 185-3630 Strap Wrench As 1
NOTICE
NOTICE during performance of inspection, maintenance, test-
Keep all parts clean from contaminants. ing, adjusting and repair of the product. Be prepared to
Contaminants may cause rapid wear and shortened ing any compartment or disassembling any compo-
component life. nent containing fluids.

products.

mandates.

g01218560
Illustration 68
1. Position engine oil filter base (3) on the engine

oil cooler.
2. Install bolts (1), (2), (4), and (5).
3. Use Tooling (A) to install engine oil filters (6).
4. Refill the engine with engine oil. Refer to Operation

and Maintenance Manual, “Engine Oil and Filter
- Change”.
g01218689
Illustration 69
2. Remove tube assembly (2).
3. Remove bonnet (1) and the gasket.

28 RENR9716-02
4. Remove engine oil cooler (3). i02439263
5. Remove the O-ring seals from engine oil cooler Engine Oil Pump - Remove
(3).
SMCS Code: 1304-011
i02438914
Removal Procedure
Engine Oil Cooler - Install
Start By:
SMCS Code: 1378-012
a. Remove the engine oil pan. Refer to Disassembly
and Assembly, “Engine Oil Pan - Remove and
Installation Procedure Install”.
NOTICE NOTICE
Keep all parts clean from contaminants. Care must be taken to ensure that fluids are contained
Contaminants may cause rapid wear and shortened ing, adjusting and repair of the product. Be prepared to
component life. collect the fluid with suitable containers before open-

products.

mandates.
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).

g01218847
Illustration 71
5. Install tube assembly (2).
1. Remove tube assemblies (3) from engine oil pump
6. Refill the cooling system with coolant. Refer to (2).
Operation and Maintenance Manual, “Cooling
System Coolant - Change”. 2. Remove bolts (1) and engine oil pump (2).
End By:
a. Install the engine oil filter base. Refer to

Base - Install”.
RENR9716-02 29
i02439652 3. Remove bolts (4) and separate cover assembly

(3) from body assembly (1).
Engine Oil Pump - Disassemble
4. Use Tooling (A) and a suitable press in order to
SMCS Code: 1304-015 remove the bearings from cover assembly (3).
Disassembly Procedure 5. Remove shaft assemblies (2).
Table 21 6. Remove bolts (12) and retainer (11).

Required Tools
7. Remove spring (10), plunger ring (9), and plunger
Part (8).
A 1P-0510 Driver Group 1 8. Use Tooling (A) and a suitable press in order to
remove the bearings from body assembly (1).
B 1P-2320 Puller Assembly 1
i02439997
Start By:
Engine Oil Pump - Assemble
a. Remove the engine oil pump. Refer to
Disassembly and Assembly, “Engine Oil Pump SMCS Code: 1304-016
- Remove”.
Assembly Procedure
NOTICE
Keep all parts clean from contaminants. Table 22
Required Tools
component life. Part
A 1P-0510 Driver Group 1
NOTICE

component life.
g01218982
Illustration 72
Personal injury can result from being struck by

Make sure to wear all necessary protective equip-

ment. g01218982
Illustration 73
1. Remove bolt (7) and washer (6).
2. Use Tooling (B) to remove drive gear (5) from

body assembly (1). Remove the key from the
pump shaft.
30 RENR9716-02
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
g01219045
bolt (7) to a torque of 55 ± 10 N·m (41 ± 7 lb ft).
Illustration 74
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
Illustration 75
g01219048 NOTICE

component life.

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.
g01218847
2. Install plunger (8), plunger ring (9), and spring Illustration 76
(10).
1. Position engine oil pump (2) and install bolts (1).
3. Install retainer (11) and bolts (12).
2. Install tube assemblies (3) on engine oil pump (2).
4. Install shaft assemblies (2).
End By:
a. Install the engine oil pan. 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.
g01219275
Dispose of all fluids according to local regulations and Illustration 78
mandates.
4. Remove bolts (6) and nuts (5).
NOTICE 5. Remove water pump (4).

Contaminants may cause rapid wear and shortened i02451192

component life.
Water Pump - Disassemble
1. Drain the coolant from the cooling system into a SMCS Code: 1361-015
to Operation and Maintenance Manual, “Cooling Disassembly Procedure
Table 23
Required Tools
Part
8S-2264 Puller Group 1
Bolt
4B-3903 5/16 - 18 NC by 4 2
A inch
1P-0456 Plate 1
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”.
Illustration 77
g01219274 NOTICE
2. Remove bolts (1) and bolts (2).
3. Remove cover (3). component life.
32 RENR9716-02
Note: The water pump seal can be replaced without i02394663

removing the water pump from the engine.
Water Pump - Assemble
Note: An intermittent leakage of a small amount of
coolant from the hole in the water pump housing is SMCS Code: 1361-016
not an indication of a water pump seal failure. This
is required to provide lubrication for the seal. Do not Assembly Procedure
replace the water pump seal unless a large amount
of leakage or a constant flow of coolant is draining Table 24
from the water pump housing. Required Tools
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 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). Illustration 80

g01195730
7. Use a suitable press to remove shaft (10) and 1. Use Tooling (B) to install lip seal (2) into the
bearing assembly (1) from housing (3). housing.
8. Use a suitable press to remove bearing assembly 2. Apply Tooling (D) to shaft (10). Use a suitable
(1) from shaft (10). press to install bearing assembly (1) on shaft (10).
9. Remove seal assembly (12) from housing (3). 3. Install shaft (10) and bearing assembly (1) in
housing (3).
10. Use Tooling (B) to remove lip seal (2) from the
housing. 4. Install O-ring seal (14) on housing (3).
5. Install retainer (13) and bolts (11).
6. Position gear (4) on shaft (10). Install washer (6)

and bolt (7).
RENR9716-02 33
7. Use Tooling (C) to install seal assembly (12) onto

shaft (10) until the stationary cup is fully seated
into housing (3).
8. Install impeller (5) on shaft (10). Install washer

(8) and bolt (9). Tighten bolt (9) to a torque of
39 ± 3 N·m (29 ± 2 lb ft).
9. Install adapter (15).
End By:
a. Install the water pump. Refer to Disassembly and

Assembly, “Water Pump - Install”.
i02440675
Water Pump - Install

SMCS Code: 1361-012
g01219274
Illustration 82
3. Position cover (3) on the water pump.
NOTICE
Keep all parts clean from contaminants. 4. Install bolts (2) and bolts (1).
Contaminants may cause rapid wear and shortened 5. Fill the cooling system. Refer to Operation and
component life. Maintenance Manual, “Cooling System Coolant
- Change”.
i02440754
Water Temperature Regulator

Housing - Remove and Install
SMCS Code: 1393-010
Removal Procedure
suitable container for storage or disposal until the
coolant is below the level of the water temperature
regulator housing. Refer to Operation and
Maintenance Manual, “Cooling System Coolant
- Change”.
g01219275
Illustration 81
1. Position water pump (4) in the front housing.
2. Install nuts (5) and bolts (6).

34 RENR9716-02
g01219336 g01223744
2. Disconnect hose assembly (1) and elbow (3). 2. Install water temperature regulators (7) and O-ring
seals (6) in water temperature regulator housing
3. Remove bolts (2) and bolts (4). Remove water (5).
temperature regulator housing (5).
g01219336
Illustration 86
g01223744
Illustration 84
3. Position water temperature regulator housing (5)
4. Remove O-ring seals (6) and water temperature on the engine. Install bolts (4) and bolts (2).
regulators (7) from water temperature regulator
housing (5). 4. Connect elbow (3) and hose assembly (1).
5. If necessary, remove the lip seals. 5. Fill the cooling system. Refer to Operation and
- Change”.
Table 25
Required Tools
Part
A 221-8647 Seal Installer Gp 1
NOTICE

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

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
Part
Tool Part Description Qty Illustration 88
g01290915
Number
A 189-0410 Shackle As 2 3. Disconnect bottom aftercooler tube (2).
Start By:
a. Remove the fan. Refer to Disassembly and

Assembly, “Fan - Remove and Install”.
NOTICE
Refer to Special Publication, NENG2500, “Caterpillar Illustration 89

g01290916
suitable to collect and contain fluids on Caterpillar 4. Disconnect top radiator hose (3).
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”.
g01290917
Illustration 90
5. Disconnect top aftercooler tube (4).
g01290908
Illustration 87
2. Remove clamp (1). Repeat for the opposite side.

36 RENR9716-02
g01290930 g01290940
6. Disconnect bottom radiator hose (5). Disconnect 9. Attach Tooling (A) and a suitable lifting device
bottom aftercooler tube (6). onto cooling package (10). The weight of cooling
package (10) is approximately 544 kg (1200 lb).
g01290934
Illustration 92
g01290941
Illustration 95
7. Disconnect hose assembly (8) from fuel cooler (7).
10. Remove bolts (11). Repeat for the opposite side.
Remove cooling package (10).
i02576308
Cooling System Package

(Radiator, Aftercooler, Fuel
Cooler) - Install
SMCS Code: 1063-012; 1353-012; 1712-012
g01290939 Table 27
Illustration 93
Required Tools
8. Disconnect hose assembly (9) from fuel cooler (7).
A 189-0410 Shackle As 2
RENR9716-02 37
NOTICE

products.
Dispose of all fluids according to local regulations and g01290939

Illustration 98
mandates.
3. Connect hose assembly (9) onto fuel cooler (7).
g01290940
Illustration 96
g01290934
Illustration 99
onto cooling package (10). The weight of cooling 4. Connect hose assembly (8) onto fuel cooler (7).
package (10) is approximately 544 kg (1200 lb).
g01290930
g01290941
Illustration 100
Illustration 97
5. Connect bottom aftercooler tube (6). Connect
2. Install cooling package (10). Install bolts (11). bottom radiator hose (5).
Repeat for the opposite side.
38 RENR9716-02
g01290917 g01290908
6. Connect top aftercooler tube (4). 9. Install clamp (1). Repeat for the opposite side.
10. Fill the cooling system with coolant. Refer to

System Coolant (ELC) - Change”.
End By:
a. Install the fan. Refer to Disassembly and

i02584900
Aftercooler - Remove
g01290916 SMCS Code: 1063-011
Illustration 102
7. Connect top radiator hose (3). Removal Procedure

Table 28
Required Tools
Start By:

g01290915
Illustration 103
8. Connect bottom aftercooler tube (2).

RENR9716-02 39
NOTICE

products.

Illustration 107
mandates.
4. Disconnect top radiator hose (3).
1. Drain the coolant from the cooling system into
a suitable container for storage or for disposal.
“Cooling System Coolant (ELC) - Change”.
g01290917
Illustration 108
5. Disconnect top aftercooler tube (4).

g01290908
Illustration 105
2. Remove clamp (1). Repeat for the opposite side.
g01290930
Illustration 109
6. Disconnect bottom radiator hose (5). Disconnect

bottom aftercooler tube (6).
g01290915
Illustration 106
3. Disconnect bottom aftercooler tube (2).

40 RENR9716-02
g01290934 g01294232
7. Disconnect hose assembly (8) from fuel cooler (7). 10. Attach Tooling (A) and a suitable lifting device
onto aftercooler (12). The weight of aftercooler
(12) is approximately 227 kg (500 lb).
g01290939
Illustration 111
g01294234
8. Disconnect hose assembly (9) from fuel cooler (7). 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
g01294215
Illustration 112
9. Remove bolts (10). Remove bolt (11).
Table 29
Required Tools
Part
Tool Part Number Qty
Description
RENR9716-02 41
g01294232 g01290939
1. Attach Tooling (A) and a suitable lifting device onto 5. Connect hose assembly (9) onto fuel cooler (7).
aftercooler (12). The weight of aftercooler (12) is
approximately 227 kg (500 lb). Install aftercooler
(12).
g01290934
Illustration 119
6. Connect hose assembly (8) onto fuel cooler (7).

g01294234
Illustration 116
2. Install bolts (14) and bolts (15) into aftercooler

(12). Install bolt (13).
g01290930
Illustration 120
7. Connect bottom aftercooler tube (6). Connect

bottom radiator hose (5).
g01294215
Illustration 117
3. Install bolt (11). Install bolts (10).
4. Repeat Step 2 and Step 3 for the opposite side.

42 RENR9716-02
g01290917 g01290908
8. Connect top aftercooler tube (4). 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

g01290916 SMCS Code: 1353-011; 1353-011-KO
Illustration 122
9. Connect top radiator hose (3). Removal Procedure

Table 30
Required Tools
Part
Tool Part Description Qty
Number
Start By:
a. Remove the aftercooler. Refer to Disassembly

and Assembly, “Aftercooler - Remove”.
g01290915
Illustration 123
10. Connect bottom aftercooler tube (2).

RENR9716-02 43
NOTICE

products.

Illustration 127
mandates.
3. Remove the upper and the lower braces (3).
g01292911
Illustration 125
g01294578
Illustration 128
1. Remove the upper and the lower radiator guards
(1). 4. Remove bolts (4) and remove bolts (5).
g01292912
Illustration 126
2. Attach Tooling (A) and a suitable lifting device onto

radiator top tank (2). The weight of the radiator is
approximately 227 kg (500 lb).
g01294579
Illustration 129

44 RENR9716-02
g01292912
Illustration 132
1. Attach Tooling (A) and a suitable lifting device onto

radiator top tank (2). The weight of the radiator is
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 133
2. Install radiator (10). Install bolts (11). Repeat for

the opposite side.
g01294602
Illustration 131
8. Remove bolts (11). Repeat for the opposite side.

Remove radiator (10).
i02585957
Radiator Core - Install

SMCS Code: 1353-012-KO; 1353-012
Table 31
Required Tools
Part
Number g01294580
Illustration 134
3. Install support (9). Install bolts (8). Install bolts (7).
RENR9716-02 45
g01292911
Illustration 138
8. Install the upper and the lower radiator guards (1).
End By:
g01294579 a. Install the aftercooler. Refer to Disassembly and

Illustration 135
Assembly, “Aftercooler - Install”.
4. Install bolts (6).
i02444868
Engine Support (Front) -

Remove and Install
SMCS Code: 1154-010-FR
Removal Procedure (Type 1)

Start By:
a. Remove the vibration damper and the pulley.

Refer to Disassembly and Assembly, “Vibration
Damper and Pulley - Remove and Install”.
g01294578
Illustration 136
1. Support the front of the engine.
5. Install bolts (4) and bolts (5).
6. Repeat Steps 3 through 5 for the opposite side.
g01221659
Illustration 139

g01294577
Illustration 137
3. Remove engine support (2).
7. Install the upper and the lower braces (3).
46 RENR9716-02
Installation Procedure (Type 1) Installation Procedure (Type 2)
g01221659 g01221663
1. Position engine support (2) on the engine. 1. Use a suitable lifting device to position engine
support (4) on the engine. The weight of engine
2. Install bolts (1). support (4) is approximately 35 kg (77 lb).
End By: 2. Install bolts (3).
a. Install the vibration damper and the pulley. Refer End By:
to Disassembly and Assembly, “Vibration Damper
and Pulley - Remove and Install”. a. Install the vibration damper and the pulley. Refer
to Disassembly and Assembly, “Vibration Damper
and Pulley - Remove and Install”.
Removal Procedure (Type 2)
Start By: i02440962
a. Remove the vibration damper and the pulley. Gear Group (Rear) - Remove
Refer to Disassembly and Assembly, “Vibration
Damper and Pulley - Remove and Install”. SMCS Code: 1206-011; 1212-011
1. Support the front of the engine. Removal Procedure

Table 32
Required Tools
Part
Start By:
a. Remove the flywheel housing. Refer to

Disassembly and Assembly, “Flywheel Housing
- Remove and Install”.
g01221663
Illustration 141
3. Use a suitable lifting device to remove engine

support (4). The weight of engine support (4) is
RENR9716-02 47
4. Use Tooling (A) and a suitable press to remove

NOTICE the bearing from gear assembly (6).
during performance of inspection, maintenance, test- 5. Remove bolts (2), gear assembly (1), and shaft
ing, adjusting and repair of the product. Be prepared to assembly (3).
ing any compartment or disassembling any compo- 6. Use Tooling (A) and a suitable press to remove
nent containing fluids. the bearing from gear assembly (1).
Refer to Special Publication, NENG2500, “Caterpillar 7. Remove gear assembly (12).

suitable to collect and contain fluids on Caterpillar 8. Remove bolts (5) and gear assemblies (4).
products.

mandates.
NOTICE

component life.
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.
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).
48 RENR9716-02
i02442469
Gear Group (Rear) - Install

SMCS Code: 1206-012; 1212-012
Table 33
Required Tools
Part
NOTICE

component life.
Note: Apply clean engine oil to the bearings and the

shaft assemblies prior to installation on the engine.
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.
g01219500
Illustration 145
5. Position gear assemblies (4) and install bolts (5).
1. Install the O-ring seals and the sealing plates on
the cylinder head. 6. Install gear assembly (12).
2. Install adapter assemblies (15), thrust plates (14), 7. Use Tooling (A) and a suitable press to install the
and bolts (13). bearing in gear assembly (1). Install the bearing to
a depth of 2.6 ± 0.5 mm (0.10 ± 0.02 inch).
3. Position shaft assembly (17) and install bolts (16).
RENR9716-02 49
8. Install shaft assembly (3), gear assembly (1), and

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

bearing in gear assembly (6). Install the bearing to
a depth of 2.6 ± 0.5 mm (0.10 ± 0.02 inch).
10. Install shaft assembly (7), gear assembly (6), and

bolts (8).
11. Use Tooling (A) and a suitable press to install the

bearing in gear assembly (9). Install the bearing to
a depth of 2.5 ± 0.5 mm (0.10 ± 0.02 inch).
Note: Align the Timing Mark on gear assembly (9) g01220438

with the Timing Mark on gear assembly (12). Illustration 149
12. Install gear assembly (9), thrust plate (11), and 1. Remove two bolts (1). Install Tooling (A) in the
bolts (10). crankshaft.
13. Tighten the bolts on gear assemblies (4) to a 2. Remove remaining bolts (1). Slide flywheel (2)
torque of 240 ± 40 N·m (177 ± 30 lb ft). Tighten away from the engine on Tooling (A).
the bolts in the following sequence: 1, 4, 2, 5, 3,
6, 1, 4. 3. Attach a suitable lifting device to flywheel (2). The
weight of flywheel (2) is approximately 130 kg
End By: (285 lb). Remove flywheel (2).
a. Install the flywheel housing. Refer to Disassembly 4. If necessary, use a hammer and a punch in order
and Assembly, “Flywheel Housing - Remove and to remove ring gear (3) from flywheel (2).
Install”.
i02752668
Table 35
Flywheel - Remove and Install Required Tools
Part
SMCS Code: 1156-010 Tool Number Part Description Qty
Guide Stud
Removal Procedure A -
5/8 - 18 UNF by 11 inch
2
Table 34 B 6V-4876 Lubricant -

Required Tools
Part
- Guide Stud
A 2
5/8 - 18 UNF by 11 inch
g01220438
Illustration 150
g01220437
Illustration 148
50 RENR9716-02
NOTICE

component life.
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 flywheel is installed.
g01220531
1. Raise the temperature of ring gear (3). Install ring Illustration 152
gear (3) on flywheel (2).
1. Use Tooling (A) or a punch and hammer in order
2. Install Tooling (A) in the crankshaft. to puncture three or more holes in crankshaft rear
seal (1).
3. Attach a suitable lifting device to flywheel (2). The
weight of flywheel (2) is approximately 130 kg 2. Use Tooling (A) to remove crankshaft rear seal (1)
(285 lb). Position flywheel (2) on the crankshaft. and crankshaft wear sleeve (2).
4. Apply Tooling (B) to the threads of bolts (1).

i02442921
5. Install bolts (1). Remove Tooling (A). Install Crankshaft Rear Seal - Install
remaining bolts (1).
SMCS Code: 1161-012
6. Tighten bolts (1) to a torque of 100 ± 5 N·m
(75 ± 4 lb ft). Turn the bolts for an additional 180 ±
5 degrees. Installation Procedure
Table 37
7. Check the flywheel runout. Refer to Testing and
Adjusting, “Flywheel - Inspect”. Required Tools
Part
i02442878
249-2937(1) Seal Locator As 1
Crankshaft Rear Seal - Remove
5P-7310(1) Bolt 3
SMCS Code: 1161-011 9S-8858(1) Nut (Seal Installer) 1
6V-6143(1) Seal Installer 1
Removal Procedure B
5P-1733(2) Seal Locator As 1
Table 36
5P-7309(2) Bolt 3
Required Tools
9S-8858(2) Nut (Seal Installer) 1
Part
Tool Number Part Description Qty 6V-6142(2) Seal Installer 1
(1) Large crankshaft gear
A 1U-7600 Slide Hammer Puller 1
(2) Small crankshaft gear
Start By:
a. Remove the flywheel. Refer to Disassembly and

Assembly, “Flywheel - Remove and Install”.
RENR9716-02 51
b. Remove the electric starting motor. Refer to

NOTICE Disassembly and Assembly, “Electric Starting
Keep all parts clean from contaminants. Motor - Remove and Install”.
Contaminants may cause rapid wear and shortened NOTICE

component life. Keep all parts clean from contaminants.

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 flywheel. Refer to Disassembly and

Assembly, “Flywheel - Remove and Install”.
g01220951
Illustration 154
i02752908
Flywheel Housing - Remove 1. Disconnect hose assemblies (1) from flywheel

housing (2).
and Install
2. Disconnect fuel filter base (5) from flywheel
SMCS Code: 1157-010 housing (2). Reposition fuel filter base (5) and the
hose assemblies.
Removal Procedure
3. Remove two bolts (4) and install Tooling (B).
Table 38
Required Tools 4. Attach Tooling (A) and a suitable lifting device
to flywheel housing (2). The weight of flywheel
Part housing (2) is approximately 110 kg (245 lb).
A 138-7574 Link Bracket 2 5. Remove remaining bolts (4), bolts (6), and bolts
(3). Remove flywheel housing (2) and the gasket
- Guide Stud from the rear housing.
B 2
1/2 - 13 NC by 7 inch
Start By:
a. Remove the crankshaft rear seal. Refer to

Disassembly and Assembly, “Crankshaft Rear
Seal - Remove”.
52 RENR9716-02
Table 39
Required Tools
Part
- Guide Stud
B 2
1/2 - 13 NC by 7 inch
NOTICE

component life.
g01221009
Illustration 156
1. Install Tooling (B) in the cylinder block.

to flywheel housing (2). The weight of flywheel
housing (2) is approximately 110 kg (245 lb).
3. Position the gasket and flywheel housing (2) on

the rear housing. Install bolts (3), bolts (6), and
bolts (4).
4. Remove Tooling (B) and install remaining bolts (4).
5. Tighten the bolts, as follows:
a. In a numerical sequence, tighten Bolt 1 through

Bolt 2 to a torque of 55 ± 10 N·m (41 ± 7 lb ft).
g01220951
Illustration 155
b. In a numerical sequence, tighten Bolt 3
through Bolt 10 to a torque of 135 ± 20 N·m
(100 ± 15 lb ft).
c. In a numerical sequence, tighten Bolt 11

through Bolt 36 to a torque of 47 ± 9 N·m
(35 ± 7 lb ft).
6. Reposition fuel filter base (5) and the hose

assemblies. Connect fuel filter base (5) to flywheel
housing (2).
7. Connect hose assemblies (1) to flywheel housing

(2).
RENR9716-02 53
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 g01221078
Illustration 158
SMCS Code: 1205-010
1. Remove V-belt (1) from the engine.
Removal Procedure 2. Remove two bolts (2) and install Tooling (A).
Table 40
3. Remove remaining bolts (2) and pulley (3).
Required Tools
Part 4. Slide vibration damper (4) along Tooling (A).
5. Attach a suitable lifting device onto vibration
- Guide Stud damper (4). The weight of vibration damper (4)
A 2
1/2 - 13 NC by 5 inch is approximately 34 kg (75 lb). Remove vibration
damper (4) from the adapter.
Table 41
Required Tools
Part
- Guide Stud
A 2
1/2 - 13 NC by 5 inch
g01221066
Illustration 157
g01221078
Illustration 159
54 RENR9716-02
NOTICE

component life.
g01221066 g01221272
1. Install Tooling (A) in the adapter. 1. Remove bolts (1) and adapter (2).
2. Attach a suitable lifting device onto vibration
damper (4). The weight 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 N·m
(100 ± 15 lb ft).
5. Install V-belt (1) on the engine.
i02444403 g01221276
Illustration 162
Crankshaft Front Seal -
2. Use Tooling (A) or a punch and hammer in order
Remove to puncture three or more holes in crankshaft front
seal (4).
SMCS Code: 1160-011
3. Use Tooling (A) to remove crankshaft front seal
Removal Procedure (4).
Table 42 4. If necessary, use Tooling (A) or a punch and

Required Tools
hammer in order to puncture three or more holes
in crankshaft wear sleeve (3). Use Tooling (A) to
Part remove crankshaft wear sleeve (3).
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”.
RENR9716-02 55
i02444556
Crankshaft Front Seal - Install

SMCS Code: 1160-012
Table 43
Required Tools
Part
5P-1733 Seal Locator 1
g01221272
5P-1737 Bolt 3 Illustration 164
B
9S-8858 Nut (Seal Installer) 1 3. Install adapter (2) and bolts (1).
6V-6142 Seal Installer 1
End By:
NOTICE a. Install the crankshaft vibration damper and pulley.

Keep all parts clean from contaminants. Refer to Disassembly and Assembly, “Vibration
Damper and Pulley - Remove and Install”.
component life.
i02292422
1. Clean the outside diameter of the crankshaft. Gear Group (Front) - Remove
SMCS Code: 1206-011
Removal Procedure
Start By:
a. Remove the front housing. Refer to Disassembly

and Assembly, “Housing (Front) - Remove”.
NOTICE

g01221389
Illustration 163 component life.
2. Use Tooling (B) to install crankshaft front seal (4)

and crankshaft wear sleeve (3) as a unit.
Note: Install the crankshaft front seal with the arrow

that shows the direction of crankshaft rotation toward
the front of the engine.
56 RENR9716-02
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 N·m (41 ± 7 lb ft).
g01147593
Illustration 165
1. Remove bolts (5) and gear assembly (4).
2. Remove bolts (3) and plate (2). Remove gear

assembly (1).
g01147620 g01147593
3. Remove bolts (6) and shaft (7). 2. Position gear assembly (1) on the shaft. Install
plate (2) and bolts (3).
i02691256
3. Install gear assembly (4) and bolts (5).
Gear Group (Front) - Install End By:
SMCS Code: 1206-012
a. Install the front housing. Refer to Disassembly and
Assembly, “Housing (Front) - Install”.
NOTICE

component life.
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”.
g01221893
Illustration 169
d. Remove the front engine support. Refer to
Disassembly and Assembly, “Engine Support 1. Disconnect hose assemblies (2) from front
(Front) - Remove and Install”. housing (4).
e. Remove the alternator. Refer to Disassembly and 2. Remove covers (1).

Assembly, “Alternator - Remove and Install”.
3. Remove alternator bracket (3) from front housing
f. Remove the crankshaft position sensor. Refer to (4).
Disassembly and Assembly, “Crankshaft Position
Sensor - Remove and Install”.
g. Remove the camshaft position sensor. Refer to

Disassembly and Assembly, “Camshaft Position
NOTICE
g01221941
Refer to Special Publication, NENG2500, “Caterpillar Illustration 170
suitable to collect and contain fluids on Caterpillar 4. Remove bolts (5) and dampers (6).
products.

mandates.
NOTICE

component life.
58 RENR9716-02
i02445708
Housing (Front) - Install

SMCS Code: 1151-012
Table 44
Required Tools
Part
A 4C-9612 Silicone Sealant 1
g01221953
Illustration 171
NOTICE
5. Disconnect bracket (7) and elbows (8). Keep all parts clean from contaminants.

component life.
g01221955
Illustration 172
6. Remove adapters (9).

g01221955
7. Attach a suitable lifting device to front housing (4). Illustration 173
The weight of front housing (4) is approximately
70 kg (155 lb). 1. Apply Tooling (A) to the bottom of front housing
(4) at the junction of the cylinder block and the
8. Remove bolts (10) and bolts (11). engine oil pan.
9. Remove front housing (4) and the gasket. 2. Attach a suitable lifting device to front housing (4).
The weight of front housing (4) is approximately
70 kg (155 lb). Position the gasket and front
housing (4) on the dowel pins on the cylinder
block.
3. Install bolts (10) and bolts (11).
4. Trim the gasket between the front housing and the

cylinder block even with the bottom of the front
housing.
5. Install adapters (9).

RENR9716-02 59
g01221953
Illustration 174
6. Connect elbows (8) and bracket (7).
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

Illustration 175
g01221941 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
Illustration 176
g01151441 Seal - Install”.
7. Install dampers (6) and bolts (5). f. Install the water pump. Refer to Disassembly and
Assembly, “Water Pump - Install”.
8. Tighten the bolts to a torque of 240 ± 40 N·m
(177 ± 30 lb ft). Tighten the bolts in the following g. Install the water temperature regulator housing.
sequence: 1, 4, 2, 5, 3, 6, 1, 4. Refer to Disassembly and Assembly, “Water
Temperature Regulator Housing - Remove and
Install”.
60 RENR9716-02
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.
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
g01147132
Illustration 178
Housing (Rear) - Install
SMCS Code: 1157-012
Table 45
Required Tools
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.
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 N·m (41 ± 7 lb ft).
g01147138
Illustration 180
5. Trim the gasket between the rear housing and the
cylinder block even with the bottom of the rear
housing.
62 RENR9716-02
g01147941
Illustration 183
1. Remove bolts (1) and valve mechanism covers

(2).
g01147132
Illustration 182
NOTICE
6. Install bolts (2). Keep all parts clean from contaminants.
7. Connect hose assembly (1). Contaminants may cause rapid wear and shortened
component life.
8. Install the bolts that hold the engine oil pan to the
rear housing.
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 - g01147941

Remove and Install Illustration 184
1. Position valve mechanism covers (2) on the valve

SMCS Code: 1107-010
mechanism cover base. Install bolts (1).
Removal Procedure
i02293148
NOTICE Valve Mechanism Cover Base -

Remove and Install
component life. SMCS Code: 1120-010
Removal Procedure
Start By:
a. Remove the valve mechanism cover. Refer to

Disassembly and Assembly, “Valve Mechanism
Cover - Remove and Install”.
RENR9716-02 63
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).
g01147965
Illustration 185
3. Position harness assemblies (5) on the electronic
1. Remove tube assemblies (1). unit injectors. Tighten the cap nuts to a torque of
1.70 ± 0.25 N·m (15 ± 2 lb in).
2. Disconnect harness assemblies (5) and harness
assembly (2). 4. Connect harness assembly (2).
3. Remove bolts (4). 5. Install tube assemblies (1).

4. Remove valve mechanism cover base (3) and the End By:
seal from the cylinder head.
a. Install the valve mechanism cover. Refer to
Installation Procedure Disassembly and Assembly, “Valve Mechanism
NOTICE
Keep all parts clean from contaminants. i02293245
Contaminants may cause rapid wear and shortened Rocker Arm and Shaft -
component life. Remove
SMCS Code: 1102-011
Removal Procedure
Table 46
Required Tools
Part
A 124-2946 Lifting Bracket 1
64 RENR9716-02
Start By:
a. Remove the valve mechanism cover. Refer to

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).
Illustration 187
g01148045 6. Remove unit injector adjustment screw (1) from
electronic unit injector rocker arm (3).
7. Remove button (6) from unit injector adjustment
2. Use Tooling (A) to remove rocker arm shaft screw (1). Remove O-ring seal (5) from the unit
assembly (4), valve rocker arms (3), and electronic injector adjustment screw.
unit injector rocker arms (1) as a unit.
i02451120
i02451112 Rocker Arm - Assemble

Rocker Arm - Disassemble SMCS Code: 1123-016
SMCS Code: 1123-015
Assembly Procedure
NOTICE
Start By: Keep all parts clean from contaminants.
a. Remove the rocker arms and the rocker shaft. Contaminants may cause rapid wear and shortened
Refer to Disassembly and Assembly, “Rocker Arm component life.
NOTICE

component life.
RENR9716-02 65
i03203773
Rocker Arm and Shaft - Install

SMCS Code: 1102-012
Table 47
Required Tools
Part
A 124-2946 Lifting Bracket 1
g01047557
Illustration 189
NOTICE
Note: Do not reuse the O-ring seal on the adjustment Keep all parts clean from contaminants.
screw if the button is removed from the adjustment
screw. Contaminants may cause rapid wear and shortened
component life.
1. Install O-ring seal (9) in button (10).
2. Use a soft hammer to seat button (10) on

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

(11). Install jam nut (7) on the adjustment screw.
4. Install O-ring seal (5) in button (6).
5. Use a soft hammer to seat button (6) on unit

injector adjustment screw (1).
6. Install unit injector adjustment screw (1) in

electronic unit injector rocker arm (3). Install jam
nut (2) on the unit injector adjustment screw.
7. Lubricate rocker shaft assembly (4) with clean

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

injector rocker arm (3) on rocker shaft assembly
(4). Illustration 190
g01148045
End By:
a. Install the rocker arms and the rocker shaft. Refer

to Disassembly and Assembly, “Rocker Arm and
Shaft - Install”.
g01325993
Illustration 191
66 RENR9716-02
1. Position rocker arm shaft assembly (4), valve

rocker arms (3), and electronic unit injector rocker NOTICE
arms (1) as a unit with Tooling (A) on the cylinder Care must be taken to ensure that fluids are contained
head. during performance of inspection, maintenance, test-
2. Install bolts (2) and tighten to a torque of collect the fluid with suitable containers before open-
50 ± 5 N·m (37 ± 4 lb ft) plus 45 ± 5 degree turn. ing any compartment or disassembling any compo-
Tighten the bolts in the following sequence: 2, 3, nent containing fluids.
4, 1.
3. Adjust the valve lash for the inlet valves and the Dealer Service Tool Catalog” for tools and supplies
exhaust valves. Refer to Testing and Adjusting, suitable to collect and contain fluids on Caterpillar
“Engine Valve Lash - Inspect/Adjust”. products.
4. Adjust the electronic unit injectors. Refer to Testing Dispose of all fluids according to local regulations and
and Adjusting, “Electronic Unit Injector - Adjust”. mandates.
End By:
NOTICE
a. Install the valve mechanism cover. Refer to Keep all parts clean from contaminants.
Cover - Remove and Install”. Contaminants may cause rapid wear and shortened
component life.
i02446003
NOTICE
Cylinder Head - Remove Do not turn the crankshaft or the camshaft while the
camshaft gear is removed. If the rear gear group is
SMCS Code: 1100-011 not correctly timed during installation, interference can
occur between the pistons and the valves, resulting in
Removal Procedure damage to the engine.
Table 48
Required Tools suitable container for storage or disposal. Refer
Part to Operation and Maintenance Manual, “Cooling
Tool Number Part Description Qty System Coolant - Change”.
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 Illustration 192

g01222228
Disassembly and Assembly, “Fuel Transfer Pump
- Remove”. 2. Remove cover (1).
RENR9716-02 67
g01222230 g01148246
3. Remove bolts (2) and gear (3). 6. Remove elbow (8). Disconnect hose assembly (9).
g01222233
Illustration 194
4. Remove bolts (4), thrust plate (5), and adapter

assembly (6).
g01148489
Illustration 197
7. Remove elbow (11) and cover (10).
8. Disconnect harness assembly (12) and harness

assembly (13).
9. Remove bracket (14).
g01222234
Illustration 195
5. Use bolt (4) in order to remove sealing plate (7).

Remove the O-ring seals.
g01148492
Illustration 198
68 RENR9716-02
10. Remove bolts (15) and damper (16). 15. Attach Tooling (A) and a suitable lifting device to
cylinder head (25). Attach Tooling (B) to the side
of cylinder head (25) that is near the turbocharger.
The weight of cylinder head (25) is approximately
365 kg (800 lb).
16. Remove bolts (26) and bolts (27).
17. Remove cylinder head (25). Remove the gaskets,

O-ring seals, and the spacer plate.
i02446286
Cylinder Head - Install

g01148516 SMCS Code: 1100-012
Illustration 199
11. Remove bolts (17). Remove sealing plate (18) Installation Procedure
and adapter assembly (19).
Table 49
Required Tools
B 1U-9200 Lever Puller Hoist 1
C 4c-5593 Anti-Seize Compound 1
NOTICE

component life.
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 202
g01148568
Illustration 201
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: g01148522
Illustration 204
4. Install bolts (26) and bolts (27) according to the
following procedure. 5. Connect tube assembly (23) and install tube
assembly (24).
a. In a numerical sequence, tighten Bolt (1)
through Bolt (26) to a torque of 270 ± 15 N·m 6. Install bracket (20).
(199 ± 11 lb ft).
7. Connect clip assembly (22). Install tube
b. In a numerical sequence, tighten Bolt (1) assemblies (21).
through Bolt (26) to a torque of 450 ± 15 N·m
(332 ± 11 lb ft).
c. In a numerical sequence, again tighten Bolt (1)

(332 ± 11 lb ft).
d. In a numerical sequence, tighten Bolt (27)

(33 ± 5 lb ft).
g01148516
Illustration 205
70 RENR9716-02
8. Install adapter assembly (19) and sealing plate 11. Install bracket (14).
(18). Install bolts (17).
12. Connect harness assembly (13) and harness
assembly (12).
13. Install cover (10) and elbow (11).
g01148492
Illustration 206
g01148246
Illustration 209
14. Connect hose assembly (9). Install elbow (8).
g01151441
Illustration 207
9. Install damper (16) and bolts (15).

(177 ± 30 lb ft). Tighten the bolts in the following
sequence: 1, 4, 2, 5, 3, 6, 1, 4. Illustration 210
g01222314
15. Install new O-ring seals and sealing plate (7).
g01222233
Illustration 211
16. Install adapter assembly (6), thrust plate (5), and

bolts (4).
g01148489
Illustration 208
RENR9716-02 71
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

i02446397
g01222230
Illustration 212
Camshaft - Remove
SMCS Code: 1210-011
Removal Procedure
Table 50
Required Tools
A 177-8001 Pilot Sleeve 2
B 249-2936 Adapter 1
274-7932(1)
g01151468 C or Guide 1
Illustration 213
274-7933(2)
(1) Front Removal
17. Install gear (3) and bolts (2).
(2) Rear Removal
(177 ± 30 lb ft). Tighten the bolts in the following Start By:
sequence: 1, 4, 2, 5, 3, 6, 1, 4.
a. Remove the rocker arms and the rocker shafts.
Refer to Disassembly and Assembly, “Rocker Arm
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
Illustration 214
g01222228 occur between the pistons and the valves, resulting in
damage to the engine.
20. Fill the cooling system. Refer to Operation and NOTICE

Maintenance Manual, “Cooling System Coolant Care must be used when removing or installing the
- Change”. camshaft. Do not damage the finshed surfaces of the
camshaft or the camshaft bearings.
72 RENR9716-02

g01222234
Illustration 218
5. Use bolt (4) in order to remove sealing plate (7).

Remove the O-ring seals.
g01222228
Illustration 215
2. Remove cover (1).
g01160256
Illustration 219
6. Remove elbow (9) and cover (8).

g01222230
Illustration 216
3. Remove bolts (2) and gear (3).
g01160259
Illustration 220
7. Remove bolts (10) and damper (11).

g01222233
Illustration 217
4. Remove bolts (4), thrust plate (5), and adapter

assembly (6).
RENR9716-02 73
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
g01160261 Required Tools

Illustration 221
Part
8. Remove bolts (12). Remove sealing plate (13) and Tool Number Part Description Qty
adapter assembly (14). A 177-8001 Pilot Sleeve 2
9. B 249-2936 Adapter 1
274-7932(1)
C or Guide 1
274-7933(2)
D 8T-2998 Lubricant 1
(1) Front Removal
(2) Rear Removal
NOTICE

component life.
g01160265
Illustration 222 NOTICE
Do not turn the crankshaft or the camshaft while the
10. Install Tooling (A) and Tooling (B) on the rear of camshaft gear is removed. If the rear gear group is
camshaft (15). Install Tooling (A) on the front of not correctly timed during installation, interference can
camshaft (15). occur between the pistons and the valves, resulting in
damage to the engine.
11. Install Tooling (C) on the front housing or the
rear housing. Tooling (C) is used to support the
camshaft. NOTICE
Care must be used when removing or installing the
Note: It is necessary to install Tooling (A) and Tooling camshaft. Do not damage the finshed surfaces of the
(B) on the camshaft. Tooling (A) and Tooling (B) will camshaft or the camshaft bearings.
support the camshaft as the camshaft is moved out
of the cylinder head and into Tooling (C). Align the
camshaft with the bore of Tooling (C). 1. Ensure that the camshaft and camshaft bearings
are thoroughly clean. Lubricate the camshaft
Note: Avoid lifting the camshaft. The camshaft should lobes with a 50/50 mixture of Tooling (D) and clean
rest on Tooling (A) and Tooling (B). Lifting of the engine oil. Apply a thin coat of clean engine oil on
camshaft can cause misalignment as the camshaft the camshaft bearings.
is removed, resulting in damage to the camshaft
bearings.
12. Carefully slide the camshaft out of the cylinder

head for removal. Use two technicians to remove
the camshaft. Keep the camshaft level while the
camshaft is being removed from the cylinder
head. The weight of the camshaft is approximately
35 kg (77 lb).
74 RENR9716-02
g01160265 g01160259
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 g01151441
camshaft is approximately 35 kg (77 lb). Illustration 226
Note: Rotate the camshaft during installation. This 7. Install damper (11) and bolts (10).
will prevent the camshaft from binding in the camshaft
bearings. 8. Tighten the bolts to a torque of 240 ± 40 N·m
5. Remove Tooling (A) and Tooling (B) from the sequence: 1, 4, 2, 5, 3, 6, 1, 4.
camshaft.
g01160256
Illustration 227
g01160261
Illustration 224
9. Install cover (8) and elbow (9).
6. Install adapter assembly (14) and sealing plate
(13). Install bolts (12).
RENR9716-02 75
g01222314 g01151468
10. Install new O-ring seals and sealing plate (7). 12. Install gear (3) and bolts (2).

sequence: 1, 4, 2, 5, 3, 6, 1, 4.
g01222233
Illustration 229
11. Install adapter assembly (6), thrust plate (5), and

bolts (4).
g01222228
Illustration 232
15. Fill the cooling system. Refer to Operation and

- Change”.
End By:
a. Install the rocker arms and the rocker shafts.

Refer to Disassembly and Assembly, “Rocker
Arms and Shaft - Install”.
g01222230
Illustration 230
76 RENR9716-02
i02451045 Note: Tooling (C) is installed on the outside of the

cylinder head. Tooling (C) is required in order to
Camshaft Bearings - Remove remove all the camshaft bearings from the cylinder
head.
SMCS Code: 1211-011
4. Use Tooling (A) to remove camshaft bearing (1)
Removal Procedure from the cylinder head.
Table 52 5. Remove Tooling (B) from Tooling (A) and remove

Required Tools the camshaft bearing.

i02451063
Camshaft Bearing Tool
A 8S-2241
Group
1
Camshaft Bearings - Install
9U-7222 Camshaft Bearing Pilot 1
SMCS Code: 1211-012
B Taperlock Stud
8M-8778 1
1/2 - 13 by 1 9/16 inch
C 9U-7210 Puller Plate 1
Table 53
Start By: Required Tools

a. Remove the camshaft. Refer to Disassembly and
Assembly, “Camshaft - Remove”. Camshaft Bearing Tool
A 8S-2241 1
Group
NOTICE 9U-7222 Camshaft Bearing Pilot 1

Keep all parts clean from contaminants. B Taperlock Stud
8M-8778 1
1/2 - 13 by 1 9/16 inch
component life. C 9U-7210 Puller Plate 1
D 9U-7223 Alignment Bushing 1
9U-7213 Backup Plate 1
E Bolt
0S-1621 1
1/2 - 13 by 1 inch
F 9U-7214 Spacer Plate 1
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).
g01159754
Illustration 234
RENR9716-02 77
1. Install the No. 7 camshaft bearing (rear), as Note: When the chamfer of Tooling (E) contacts the
follows: face of the camshaft bore, the camshaft bearing is
properly installed.
a. Insert the large end of Tooling (B) into the No.
7 camshaft bore.
b. Position Tooling (C) over Tooling (A). Install

Tooling (A) through the cylinder head on
Tooling (B).
c. Position camshaft bearing (1) on Tooling (B).

Install Tooling (E) on Tooling (B).
Note: Refer to Specifications, “Cylinder Head” for

appropriate information for the orientation of the
camshaft bearings in the cylinder head.
d. Use Tooling (A) in order to pull camshaft

g01159758
bearing (1) into the camshaft bore. Illustration 236
Note: When the chamfer of Tooling (E) contacts the 3. Install the No. 1 camshaft bearing (front), as
face of the camshaft bore, the camshaft bearing is follows:
properly installed.
a. Insert the large end 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.
g01159756
Illustration 235
c. Use Tooling (A) in order to pull the No. 1
2. Install the No. 6 through No. 2 camshaft bearings, camshaft bearing into the No. 1 camshaft bore.
as follows: When the chamfer of Tooling (E) contacts
the face of the camshaft bore, the camshaft
a. Insert the large end of Tooling (B) into the bearing is properly installed.
camshaft bore.
End By:
Note: Use Tooling (D) to align Tooling (A) and Tooling
(B) with the camshaft bearing bores. Install Tooling a. Install the camshaft. Refer to Disassembly and
(D) in the inside diameter of any installed camshaft Assembly, “Camshaft - Install”.
bearing between Tooling (A) and Tooling (B).
b. Install Tooling (A) on Tooling (B). Position

camshaft bearing (1) on Tooling (B). Install
Tooling (E) on Tooling (B).

appropriate information for the location and the
orientation of the camshaft bearings in the cylinder
head.
c. Use Tooling (A) in order to pull camshaft

bearing (1) into the camshaft bore.
78 RENR9716-02
i02447352 2. Remove tube assemblies (1) from engine oil pan

(3).
Engine Oil Pan - Remove and
Install 3. Use Tooling (A) to support engine oil pan (3). The
weight of engine oil pan (3) is approximately 25 kg
SMCS Code: 1302-010 (55 lb).
4. Remove bolts (2). Remove engine oil pan (3) and

Removal Procedure the gasket.
Table 54
Required Tools
Part Table 55
Tool Number Part Description Qty Required Tools
A 1U-7505 Hydraulic Jack 1 Part
NOTICE A 1U-7505 Hydraulic Jack 1
ing, adjusting and repair of the product. Be prepared to NOTICE
collect the fluid with suitable containers before open- Keep all parts clean from contaminants.
nent containing fluids. Contaminants may cause rapid wear and shortened
component life.
products.

mandates.
NOTICE

component life.
g01222524
1. Drain the engine oil into a suitable container Illustration 238
for storage or disposal. Refer to Operation and
Maintenance Manual, “Engine Oil and Filter - 1. Use Tooling (A) to support engine oil pan (3). The
Change”. weight of engine oil pan (3) is approximately 25 kg
(55 lb).
2. Position the gasket and engine oil pan (3) on the

engine. Install bolts (2).
Note: If the oil drain plugs were removed, install the

oil drain plugs. Tighten the oil drain plugs to a torque
of 80 ± 10 N·m (59 ± 7 lb ft).
3. Install tube assemblies (1) on engine oil pan (3).
4. Fill the engine with engine oil to the correct level.

“Engine Oil and Filter - Change”.
g01222524
Illustration 237
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”. g01149417
Illustration 239
NOTICE 1. Use Tooling (A) to remove cylinder liner (1).

during performance of inspection, maintenance, test- 2. Remove liner seals (3) and filler band (2) from
ing, adjusting and repair of the product. Be prepared to cylinder liner (1).
nent containing fluids. i02294960
Refer to Special Publication, NENG2500, “Caterpillar Cylinder Liner - Install

suitable to collect and contain fluids on Caterpillar SMCS Code: 1216-012
products.
mandates. Table 57
Required Tools
NOTICE Tool Part Number Part Description Qty
B 2P-8260 Cylinder Liner Installer 1
Contaminants may cause rapid wear and shortened C 5P-3975 Rubber Lubricant 1
component life.
NOTICE

component life.
1. Check the cylinder liner projection. Refer to

Testing and Adjusting, “Cylinder Liner Projection
- Inspect”.
80 RENR9716-02
Start By:
a. Remove the engine oil pump. Refer to

Disassembly and Assembly, “Engine Oil Pump
- Remove”.
NOTICE

component life.
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). Illustration 241
g01149484
4. Dip filler band (2) in clean engine oil for a 1. Use Tooling (A) to rotate the crankshaft in order to
moment. Install the filler band on the cylinder liner gain access to the piston cooling jet.
immediately.
2. Remove bolt (1) and piston cooling jet (2).
5. Use Tooling (B) to install cylinder liner (1) in the
cylinder block. Ensure that any marks in relation
to the cylinder liner projection are in alignment. Installation Procedure
Table 59
End By:
Required Tools
a. Install the pistons and connecting rods. Refer
Part
to Disassembly and Assembly, “Pistons and Tool Number Part Description
Qty
Connecting Rods - Install”.
A 9S-9082 Engine Turning Tool 1
i02295020
NOTICE
Piston Cooling Jets - Remove Keep all parts clean from contaminants.
and Install Contaminants may cause rapid wear and shortened
SMCS Code: 1331-010 component life.
Removal Procedure
Table 58
Required Tools
Part
Qty
Tool Number Part Description
RENR9716-02 81
g01149484 g01149594
1. Use Tooling (A) to rotate the crankshaft in order to 1. Use Tooling (A) to rotate the crankshaft until the
gain access to the piston cooling jet. piston is at the bottom center.
2. Position piston cooling jet (2) in the cylinder block. 2. Remove the carbon ridge from the top inside
Install bolt (1). Tighten the bolt to a torque of surface of the cylinder liner.
25 ± 6 N·m (18 ± 4 lb ft).
3. Inspect the connecting rod and connecting rod cap
End By: for the proper identification mark. The connecting
rod and the connecting rod cap should have an
a. Install the engine oil pump. Refer to Disassembly etched number on the side. The number should
and Assembly, “Engine Oil Pump - Install”. match the cylinder number. Mark the connecting
rod and the connecting rod cap, if necessary.
i02295112
Note: Do not stamp the connecting rod assembly.
Pistons and Connecting Rods Stamping or punching the connecting rod assembly
could cause the connecting rod to fracture.
- Remove
4. Remove bolts (1) and connecting rod bearing cap
SMCS Code: 1225-011 (2).
Removal Procedure
Table 60
Required Tools
Start By:
a. Remove the cylinder head. Refer to Disassembly

and Assembly, “Cylinder Head - Remove”.
g01149595
b. Remove the piston cooling jets. Refer to Illustration 244
Disassembly and Assembly, “Piston Cooling Jets
- Remove and Install”. 5. Remove piston (3) and the connecting rod from
the cylinder liner.
NOTICE

component life.
82 RENR9716-02
i02447789 2. Remove upper connecting rod bearing (8) from

connecting rod (6).
Pistons and Connecting Rods
- Disassemble 3. Use Tooling (A) to remove pin retainers (5) from
piston body assembly (4).
SMCS Code: 1225-015
4. Remove connecting rod pin (7) and connecting
rod (6) from the piston body assembly.
5. Use Tooling (B) to remove top piston ring (1),
Table 61
intermediate piston ring (2), and oil control piston
Required Tools ring (3) from the piston body assembly.
Part
Tool Number Part Description Qty i02447828
6V-6192
A Pliers 1
7B-7974
B Piston Ring Expander Gp 1
- Assemble
Start By: SMCS Code: 1225-016
a. Remove the pistons and connecting rods. Refer

to Disassembly and Assembly, “Pistons and Assembly Procedure
Connecting Rods - Remove”. Table 62
Note: Mark the components of each piston and Required Tools

connecting rod assembly. The components must be Part
reinstalled in the original location. Do not interchange Tool Number Part Description Qty
components.
A 6V-6192 Pliers 1
NOTICE B 7B-7974 Piston Ring Expander Gp 1

Note: Prior to removal from the engine, the pistons
Contaminants may cause rapid wear and shortened and connecting rod assemblies were marked.
component life. The components must be reassembled together.
The components must be installed in the original
location in the engine. Do not interchange any of the
components.
NOTICE

component life.
g01222629
Illustration 245
1. Remove lower connecting rod bearing (9) from

connecting rod bearing cap (10).
RENR9716-02 83
Note: Ensure that the bearing locking tab is located

in the notch of the connecting rod bearing cap.
10. Ensure that the dowels are installed in the

connecting rod bearing cap.
End By:
a. Install the pistons and connecting rods. Refer

to Disassembly and Assembly, “Pistons and
Connecting Rods - Install”.
i02630922

- Install
SMCS Code: 1225-012
g01222629
Illustration 246
Table 63
1. Position the spring for the oil control piston ring in Required Tools
the oil ring groove in the piston body assembly.
Part
2. Position oil control piston ring (3) over the spring. Number
Position the oil control piston ring so that the gap A 9S-9082 Engine Turning Tool 1
is 180 degrees from the joint in the spring. Install
the oil control piston ring on the piston with Tooling B 200-3914 Piston Ring Compressor 1
(B). C 8T-3052 Degree Wheel 1
3. Use Tooling (B) to install intermediate piston ring

(2) with the side that has the identification “UP-2” NOTICE
toward the top of the piston. Keep all parts clean from contaminants.
4. Use Tooling (B) to install top piston ring (1) with Contaminants may cause rapid wear and shortened
the side that has the identification “UP-1” toward component life.
the top of the piston.
Note: Install the connecting rod bearings dry
5. Position top piston ring (1), intermediate piston
when clearance checks are performed. Refer to
ring (2), and oil control piston ring (3) so the gaps
Disassembly and Assembly, “Bearing Clearance -
are 120 degrees from each other.
Check”. Apply clean engine oil on the connecting rod
bearings for final assembly.
6. Check the clearance between the ends of top
piston ring (1), intermediate piston ring (2), and
1. Apply clean engine oil to the cylinder liner bore, to
oil control piston ring (3). Refer to Specifications,
the piston rings, and to the outer surface of the
“Pistons And Rings”.
piston.
7. Position piston body assembly (4) on connecting
Note: Ensure that the connecting rod and pistons are
rod (6). Apply clean engine oil to connecting rod
installed in the correct cylinder.
pin (7) and install the connecting rod pin. Install
pin retainers (5) with Tooling (A).
8. Install upper connecting rod bearing (8) in

connecting rod (6).

in the notch of the connecting rod.
9. Install lower connecting rod bearing (9) in

connecting rod bearing cap (10).
84 RENR9716-02
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 N·m (52 ± 3 lb ft).
g01149650
Illustration 247 b. Tighten Bolt (B) and Bolt (D) to a torque of
70 ± 4 N·m (52 ± 3 lb ft).
2. Use Tooling (A) to rotate the crankshaft until the
connecting rod journal is at the bottom center. c. Turn Bolt (B) and Bolt (D) for an additional 60 ±
5 degrees (1/6 turn).
3. Use Tooling (B) to install piston (3) and the
connecting rod in the cylinder liner. Note: If Tooling (C) is not used, place an index mark
on each bolt.
Note: Install the connecting rod so that the bearing
tab is located on the opposite side of the piston d. Tighten Bolt (A) and Bolt (C) again to a torque
cooling jet. of 70 ± 4 N·m (52 ± 3 lb ft).
4. Install the upper connecting rod bearing in the e. Turn Bolt (A) and Bolt (C) for an additional 60 ±
connecting rod. 5 degrees (1/6 turn).
Note: Ensure that the connecting rod bearing is Note: If Tooling (C) is not used, place an index mark
installed so that the bearing tab fits into the notch in on each bolt.
the connecting rod.
f. Rotate the crankshaft in order to ensure that
5. Pull the connecting rod onto the crankshaft journal. the crankshaft turns freely.
6. Install the lower connecting rod bearing in the End By:
connecting rod bearing cap.
a. Install the piston cooling jets. Refer to Disassembly
Note: Ensure that the connecting rod bearing is and Assembly, “Piston Cooling Jets - Remove
installed so that the bearing tab fits into the notch in and Install”.
the connecting rod.
b. Install the cylinder head. Refer to Disassembly
and Assembly, “Cylinder Head - Install”.
i02295567
Connecting Rod Bearings -

Remove
SMCS Code: 1219-011
Removal Procedure
Table 64
g01149651 Required Tools
Illustration 248
Part
7. Position connecting rod bearing cap (2) on the Tool Number Part Description Qty
connecting rod.
RENR9716-02 85
Start By: i02295910
a. Remove the engine oil pump. Refer to Connecting Rod Bearings -

Disassembly and Assembly, “Engine Oil Pump Install
- Remove”.
SMCS Code: 1219-012
NOTICE
Contaminants may cause rapid wear and shortened Table 65
component life.
Required Tools
Part
B 8T-3052 Degree Wheel 1
NOTICE

component life.
Note: Install the connecting rod bearings dry

g01149594
Illustration 249 when clearance checks are performed. Refer to
Disassembly and Assembly, “Bearing Clearance -
1. Use Tooling (A) to rotate the crankshaft until the Check”. Apply clean engine oil on the connecting rod
connecting rod is at the bottom center. bearings for final assembly.
2. Inspect the connecting rod and connecting rod cap

for the proper identification mark. The connecting
rod and the connecting rod cap should have an
etched number on the side. The number should
match the cylinder number. Mark the connecting
rod and the connecting rod cap, if necessary.
Note: Do not stamp the connecting rod assembly.

Stamping or punching the connecting rod assembly
could cause the connecting rod to fracture.
3. Remove bolts (1) and connecting rod bearing cap

(2) from the connecting rod.
g00998730
4. Remove the lower half of the connecting rod Illustration 250
bearing from the connecting rod bearing cap.
1. Use Tooling (A) to rotate the crankshaft until the
5. Push the connecting rod away from the crankshaft. connecting rod journal is at the bottom center.
Remove the upper half of the connecting rod
bearing from the connecting rod. 2. Install a new lower half connecting rod bearing (3)
in connecting rod bearing cap (2).
Note: Ensure that bearing locking tab (4) is located

in the notch of the connecting rod bearing cap.
3. Install a new upper half connecting rod bearing in

the connecting rod.

in the notch of the connecting rod.
86 RENR9716-02
4. Pull the connecting rod onto the crankshaft. i02296017
Crankshaft Main Bearings -

Remove
SMCS Code: 1203-011
Removal Procedure
Table 66
Required Tools
Part
A 2P-5518 Bearing Tool 1
g01149651
Illustration 251
Start By:
5. Position connecting rod bearing cap (2) on the
connecting rod. a. Remove the engine oil pump. Refer to
Disassembly and Assembly, “Engine Oil Pump
Note: Ensure that the number on the side of the - Remove”.
connecting rod bearing cap is on the same side as
NOTICE
of the connecting rod bearing cap and the connecting
rod are located on the side opposite of the piston
cooling jet.
component life.
6. Lubricate the threads of bolts (1) with clean engine
oil. Install the bolts.
1. Check the main bearing caps for identification of
7. Tighten bolts (1), as follows: the location and check the direction of the main
bearing caps in relation to the cylinder block. The
a. Tighten Bolt (A) and Bolt (C) to a torque of main bearing caps must be installed in the original
70 ± 4 N·m (52 ± 3 lb ft). location and the original direction.
b. Tighten Bolt (B) and Bolt (D) to a torque of

70 ± 4 N·m (52 ± 3 lb ft).
c. Turn Bolt (B) and Bolt (D) for an additional 60 ±

5 degrees (1/6 turn).
Note: If Tooling (B) is not used, place an index mark

on each bolt.
d. Tighten Bolt (A) and Bolt (C) again to a torque

of 70 ± 4 N·m (52 ± 3 lb ft).
e. Tighten Bolt (A) and Bolt (C) for an additional

60 ± 5 degrees (1/6 turn).
g01149949
Illustration 252
Note: If Tooling (B) is not used, place an index mark
on each bolt. 2. Remove bolts (1) and bolts (3) from No. 2 through
No. 6 main bearing caps (2).
f. Rotate the crankshaft in order to ensure that
the crankshaft turns freely. Note: Remove No. 1 and No. 7 main bearing caps
(2) after No. 2 through No. 6 main bearing caps have
End By: been installed.

and Assembly, “Engine Oil Pump - Install”.
RENR9716-02 87
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 final assembly.
Note: Ensure that the main bearings are installed

so that bearing tabs fit into the notch in the cylinder
block. The upper halves of the main bearings have
the oil groove and the oil hole.
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 Illustration 254
g01149952
and the bearing area of the cylinder block. This can
result in damage to the cylinder block and/or the 1. Position new upper main bearing (4) on the
crankshaft. crankshaft. Insert the end of the upper main
bearing that does not have the tab into the cylinder
4. Remove the thrust plates from each side of the block. Install Tooling (A) in the oil hole of the
No. 4 main bearing. crankshaft. Carefully rotate the crankshaft in order
to push the upper main bearing into the cylinder
5. Remove the lower halves of the main bearings block.
from the main bearing caps.
Note: Push the upper main bearing from the side of
i02296049
the bearing tab with Tooling (A). If the crankshaft is
turned in the wrong direction, the tab on the bearing
Crankshaft Main Bearings - will be pushed between the crankshaft and the
bearing area of the cylinder block. This can result in
Install damage to the cylinder block and/or the crankshaft.
SMCS Code: 1203-012 2. Install the thrust plates on each side of the No. 4
main bearing.
Note: Install the thrust plates with the words “Block
Table 67 Side” toward the cylinder block.
Required Tools
3. Install the lower halves of the crankshaft main
Tool Part Number Part Description Qty bearings in the main bearing caps.
A 2P-5518 Bearing Tool 1
Note: Ensure that the main bearings are installed so
B 8T-5096 Dial Indicator 1 that bearing tabs fit into the notch in the main bearing
C 8T-3052 Degree Wheel 1 caps.
NOTICE

component life.
88 RENR9716-02
Note: Bolt (C) is on the bearing tab side of the main

bearing cap.
g. Rotate the crankshaft in order to ensure that

the crankshaft turns freely.
7. Use Tooling (B) to check the crankshaft end play.

Ensure that Tooling (B) is against a machined
surface. The end play is controlled by the thrust
plates of No. 4 main bearing (center).
Crankshaft end play (new thrust

plates) ...... 0.10 to 0.60 mm (0.004 to 0.024 inch)
g01149987
End By:
Illustration 255
4. Position main bearing caps (2) on the crankshaft. and Assembly, “Engine Oil Pump - Install”.
Note: Ensure that the numbers on the main bearing
caps match the numbers on the cylinder block. Also i02296738
ensure that the “FRONT” on the main bearing cap is
installed toward the front of the cylinder block. Crankshaft - Remove
5. Lubricate the threads of bolts (1) and bolts (3) with SMCS Code: 1202-011
clean engine oil. Install the bolts.
Removal Procedure
6. Tighten bolts (1) and bolts (3) for the main bearing
caps, as follows: Table 68
Required Tools
a. Tighten Bolt (A) to a torque of 258 ± 14 N·m
(190 ± 10 lb ft). Part
Note: Bolt (A) is on the bearing tab side of the main A 138-7574 Link Bracket 2
bearing cap.
1H-3110 Bearing Puller 1
b. Tighten Bolt (B) to a torque of 258 ± 14 N·m 8B-7560 Step Plate 1
(190 ± 10 lb ft).
9U-6600 Hand Hydraulic Pump 1
Note: Bolt (B) is on the opposite side of the bearing 1H-3108 Push-Puller Leg 2
tab of the main bearing cap.
1H-3107 Bearing Puller 1
B
c. Tighten Bolt (B) for an additional 120 ± 5 3H-0468 Puller Plate 5
degrees (2 flats).
3H-0465 Push-Puller Plate 2
Note: If Tooling (C) is not used, place an index mark 1P-0820 Hydraulic Puller 1
on the bolt and the main bearing cap.
5B-0637 Nut 1
d. Tighten Bolt (A) for an additional 120 ± 5 8S-6586 Forcing Screw 1
degrees (2 flats).
5P-0944 Dowel Puller Group 1
C
Note: If Tooling (C) is not used, place an index mark 5P-0939 Dowel Extractor 1
on the bolt and the main bearing cap.
e. Tighten Bolt (D) to a torque of 80 ± 10 N·m Start By:

(59 ± 7 lb ft).
a. Remove the front housing. Refer to Disassembly
Note: Bolt (D) is on the opposite side of the bearing and Assembly, “Housing (Front) - Remove”.
tab of the main bearing cap.
b. Remove the rear housing. Refer to Disassembly
f. Tighten Bolt (C) to a torque of 80 ± 10 N·m and Assembly, “Housing (Rear) - Remove”.
(59 ± 7 lb ft).
RENR9716-02 89
c. Remove the piston cooling jets. Refer to 6. Remove crankshaft (6) from the cylinder block.
Disassembly and Assembly, “Piston Cooling Jets
- Remove and Install”. 7. Remove the thrust plates from each side of the
No. 4 main bearing.
NOTICE
Keep all parts clean from contaminants. 8. Remove the lower main bearings from main
bearing caps (4). Remove the upper main
Contaminants may cause rapid wear and shortened bearings from the cylinder block.
component life.
1. Check the main bearing caps for identification for

the location and the direction in the cylinder block.
The identification marks on the main bearing caps
must be installed in the same direction prior to
removal.
2. Check the connecting rod and the connecting rod

bearing caps for identification and the location in
the cylinder block.
g01150282
Illustration 258
9. Use Tooling (B) to remove crankshaft gear (7)

from crankshaft (6).
g01150281
Illustration 256
3. Remove bolts (1). Remove connecting rod bearing

caps (2).
g01150284
Illustration 259
10. If necessary, use Tooling (C) to remove dowel (8)

and dowel (9) from crankshaft (6).
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).
90 RENR9716-02
i02296800 Note: Ensure that the main bearings are installed so

that the bearing tabs fit into the notch in the cylinder
Crankshaft - Install block. The upper halves of the main bearings have
the oil groove and the oil hole.
SMCS Code: 1202-012
Table 69
Required Tools
Part
D 8T-5096 Dial Indicator 1
E 8T-3052 Degree Wheel 1
g01150344
NOTICE Illustration 261
5. Install Tooling (A) and a suitable lifting device
Contaminants may cause rapid wear and shortened on each end of crankshaft (6). The weight of
component life. crankshaft (6) is approximately 188 kg (415 lb).
6. Install crankshaft (6) with Timing Mark “V” on the

crankshaft gear in alignment with Timing Mark “V”
on the cluster gear.
7. Install the thrust plates on each side of the No. 4

main bearing.
Note: Install the thrust plates with the words “Block

Side” toward the cylinder block.
8. Install the lower halves of the crankshaft main

bearings in the main bearing caps.
Note: Ensure that the main bearings are installed

Illustration 260
g01150312 so that the bearing tabs fit into the notch in the main
bearing cap.
1. Install dowel (8) in the crankshaft.
9. Position main bearing caps (4) on the crankshaft.
Protrusion of dowel (8) from the crankshaft
face ........................................ 8.4 mm (0.33 inch) Note: Ensure that the numbers on the main bearing
caps match the numbers on the cylinder block. Also
2. Install dowel (9) in the crankshaft. ensure that the “FRONT” on the main bearing cap is
installed toward the front of the cylinder block.
Protrusion of dowel (9) from the crankshaft
............................ 4.1 ± 0.5 mm (0.16 ± 0.02 inch) 10. Lubricate the threads of bolts (3) and bolts (5)
with clean engine oil. Install the bolts.
3. Install crankshaft gear (7) on the crankshaft with
the keyway in alignment with dowel (9). Timing 11. Tighten bolts (3) and bolts (5) for the main bearing
Mark “V” of the gear should face away from caps, as follows:
crankshaft (6).
a. Tighten Bolt (A) to a torque of 258 ± 14 N·m
Note: Install the main bearings dry when clearance (190 ± 10 lb ft).
checks are performed. Refer to Disassembly and
Assembly, “Bearing Clearance - Check”. Apply clean Note: Bolt (A) is on the bearing tab side of the main
engine oil on the main bearings for final assembly. bearing cap.
4. Install the upper halves of the main bearings in b. Tighten Bolt (B) to a torque of 258 ± 14 N·m
the cylinder block. (190 ± 10 lb ft).
RENR9716-02 91
Note: Bolt (B) is on the opposite side of the bearing Note: Ensure that the number on the side of the
tab of the main bearing cap. connecting rod bearing cap is on the same side as
c. Tighten Bolt (B) for an additional 120 ± 5 of the connecting rod bearing cap and the connecting
degrees (2 flats). rod are located on the side opposite of the piston
cooling jet.
Note: If Tooling (E) is not used, place an index mark
on the bolt and the main bearing cap. 14. Lubricate the threads of bolts (1) with clean
engine oil. Install the bolts.
d. Tighten Bolt (A) for an additional 120 ± 5
degrees (2 flats). 15. Tighten bolts (1), as follows:
Note: If Tooling (E) is not used, place an index mark a. Tighten Bolt (A) and Bolt (C) to a torque of
on the bolt and the main bearing cap. 70 ± 4 N·m (52 ± 3 lb ft).
e. Tighten Bolt (D) to a torque of 80 ± 10 N·m b. Tighten Bolt (B) and Bolt (D) to a torque of
(59 ± 7 lb ft). 70 ± 4 N·m (52 ± 3 lb ft).
Note: Bolt (D) is on the opposite side of the bearing c. Turn Bolt (B) and Bolt (D) for an additional 60 ±
tab of the main bearing cap. 5 degrees (1/6 turn).
f. Tighten Bolt (C) to a torque of 80 ± 10 N·m Note: If Tooling (E) is not used, place an index mark
(59 ± 7 lb ft). on each bolt and connecting rod cap.
Note: Bolt (C) is on the bearing tab side of the main d. Tighten Bolt (A) and Bolt (C) again to a torque
bearing cap. of 70 ± 4 N·m (52 ± 3 lb ft).
g. Rotate the crankshaft in order to ensure that e. Turn Bolt (A) and Bolt (C) for an additional 60 ±
the crankshaft turns freely. 5 degrees (1/6 turn).
12. Use Tooling (D) to check the crankshaft end play. Note: If Tooling (E) is not used, place an index mark
Ensure that Tooling (D) is against a machined on each bolt and connecting rod cap.
surface. The end play is controlled by the thrust
plates of No. 4 main bearing (center). f. Rotate the crankshaft in order to ensure that
the crankshaft turns freely.
Crankshaft end play (new thrust
plates) ...... 0.10 to 0.60 mm (0.004 to 0.024 inch) End By:
Note: Install the connecting rod bearings dry a. Install the piston cooling jets. Refer to Disassembly
when clearance checks are performed. Refer to and Assembly, “Piston Cooling Jets - Remove
Disassembly and Assembly, “Bearing Clearance - and Install”.
Check”. Apply clean engine oil on the connecting rod
bearings for final assembly. b. Install the rear housing. Refer to Disassembly and
Assembly, “Housing (Rear) - Install”.
c. Install the front housing. Refer to Disassembly and

Assembly, “Housing (Front) - Install”.
g01150364
Illustration 262
13. Position the connecting rod against the

crankshaft. Install connecting rod bearing cap (2)
on the connecting rod.
92 RENR9716-02
i02717761 The technician must be very careful to use Tooling (A)

correctly. The following points must be remembered:
Bearing Clearance - Check
• Ensure that the backs of the bearings and the
SMCS Code: 1203-535; 1219-535 bores are clean and dry.
Measurement Procedure • Ensure that the bearing locking tabs are properly
seated in the tab grooves.
Table 70
Required Tools • The crankshaft must be free of oil at the contact
points of Tooling (A).
Part
Tool Number Part Description Qty 1. Put a piece of Tooling (A) on the crown of the
198-9142 Plastic Gauge (Green) bearing that is in the cap.
0.025 to 0.076 mm 1
(0.001 to 0.003 inch) Note: Do not allow Tooling (A) to extend over the
edge of the bearing.
198-9143 Plastic Gauge (Red)
0.051 to 0.152 mm 1
2. Use the correct torque-turn specifications in order
(0.002 to 0.006 inch)
A to install the bearing cap. Do not use an impact
198-9144 Plastic Gauge (Blue) wrench. Be careful not to dislodge the bearing
0.102 to 0.229 mm 1 when the cap is installed.
(0.004 to 0.009 inch)
198-9145 Plastic Gauge (Yellow) Note: Do not turn the crankshaft when Tooling (A)
0.230 to 0.510 mm 1 is installed.
(0.009 to 0.020 inch)
3. Carefully remove the cap, but do not remove
Tooling (A). Measure the width of Tooling (A)
Note: Plastic gauge may not be necessary when the while Tooling (A) is in the bearing cap or on the
engine is in the chassis. crankshaft journal. Refer to Illustration 263.
NOTICE

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
specific wall thickness.
Note: The measurements should be within

specifications and the correct bearings should
be used. If the crankshaft journals and the bores
for the block and the rods were measured during
g01152855
disassembly, no further checks are necessary. Illustration 263
However, if the technician still wants to measure the Typical Example
bearing clearances, Tooling (A) is an acceptable
method. Tooling (A) is less accurate on journals with 4. Remove all of Tooling (A) before you install the
small diameters if clearances are less than 0.10 mm bearing cap.
(0.004 inch).
NOTICE
Lead wire, shim stock or a dial bore gauge can dam-
age the bearing surfaces.
RENR9716-02 93
Note: When Tooling (A) is used, the readings can

sometimes be unclear. For example, all parts of
Tooling (A) are not the same width. Measure the
major width in order to ensure that the parts are
within the specification range. Refer to Specifications
Manual, “Connecting Rod Bearing Journal” and
Specifications Manual, “Main Bearing Journal” for the
correct clearances.
i02449735
Atmospheric Pressure Sensor

g01222887
SMCS Code: 1923-010 Illustration 265
1. Install a new O-ring seal on atmospheric pressure

Removal Procedure sensor (1).
NOTICE 2. Install atmospheric pressure sensor (1) and

Keep all parts clean from contaminants. tighten to a torque of 10 ± 2 N·m (90 ± 18 lb in).
Contaminants may cause rapid wear and shortened 3. Connect harness assembly (2).
component life.
i02297743
Camshaft Position Sensor -

Remove and Install
SMCS Code: 1912-010
Removal Procedure
NOTICE
g01222887 collect the fluid with suitable containers before open-
Illustration 264
2. Remove atmospheric pressure sensor (1) from Tools and Shop Products Guide” for tools and supplies
the adapter on the cylinder block. suitable to collect and contain fluids on Caterpillar
products.
3. Remove the O-ring seal from atmospheric
pressure sensor (1). Dispose of all fluids according to local regulations and
mandates.
NOTICE
Contaminants may cause rapid wear and shortened component life.
component life.
94 RENR9716-02
i02297803
Crankshaft Position Sensor -

Remove and Install
SMCS Code: 1912-010
Removal Procedure
NOTICE
g01150693
Illustration 266 ing any compartment or disassembling any compo-
2. Remove bolt (1) and camshaft position sensor (2). Tools and Shop Products Guide” for tools and supplies
3. Remove the O-ring seal from camshaft position products.
sensor (2).
Installation Procedure mandates.
NOTICE NOTICE
Keep all parts clean from contaminants. Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened Contaminants may cause rapid wear and shortened
component life. component life.
g01150693 g01150731
1. Install a new O-ring seal on camshaft position 1. Disconnect harness assembly (1).
sensor (2). Lubricate the O-ring seal with clean
engine oil. 2. Remove bolt (3) and crankshaft position sensor
(2).
2. Position camshaft position sensor (2) in the front
housing and install bolt (1). Tighten bolt (1) to a 3. Remove the O-ring seal from crankshaft position
torque of 28 ± 7 N·m (21 ± 5 lb ft). sensor (2).
3. Connect harness assembly (3).
RENR9716-02 95
NOTICE
Contaminants may cause rapid wear and shortened component life.
component life.
1. Drain the coolant from the cooling system to a
level below the coolant temperature sensor into a
g01150731
Illustration 269
1. Install a new O-ring seal on crankshaft position

sensor (2). Lubricate the O-ring seal with clean
engine oil.
g01222981
Illustration 270
2. Install crankshaft position sensor (2) in the front
housing. Install bolt (3). Tighten bolt (3) to a torque 2. Disconnect harness assembly (1).
of 28 ± 7 N·m (21 ± 5 lb ft).
3. Remove coolant temperature sensor (2).
4. Remove the O-ring seal from coolant temperature
sensor (2).
i02449857
Coolant Temperature Sensor - Installation Procedure

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

Removal Procedure component life.
NOTICE

products.

mandates. g01222981
Illustration 271
96 RENR9716-02
1. Install a new O-ring seal on coolant temperature 2. Remove engine oil pressure sensor (1) from the
sensor (2). adapter on the cylinder block.
2. Install coolant temperature sensor (2) and tighten 3. Remove the O-ring seal from engine oil pressure
to a torque of 20 ± 5 N·m (15 ± 4 lb ft). sensor (1).

Operation and Maintenance Manual, “Cooling NOTICE
System Coolant - Change”. Keep all parts clean from contaminants.

i02298137 component life.
Engine Oil Pressure Sensor -
Remove and Install
SMCS Code: 1924-010
Removal Procedure
NOTICE
nent containing fluids. Illustration 273
g01150948
Refer to Special Publication, NENG2500, “Caterpillar 1. Install a new O-ring seal on engine oil pressure
Tools and Shop Products Guide” for tools and supplies sensor (1).
products. 2. Install engine oil pressure sensor (1) and tighten
to a torque of 10 ± 2 N·m (89 ± 18 lb in).
mandates. 3. Connect harness assembly (2).
NOTICE

component life.
g01150948
Illustration 272

RENR9716-02 97
i02581037 Installation Procedure

Fuel Pressure Sensor - NOTICE
Remove and Install Keep all parts clean from contaminants.
SMCS Code: 7414-010 Contaminants may cause rapid wear and shortened
component life.
Removal Procedure
NOTICE

products.
g01292812
Illustration 275
mandates.
1. Install a new O-ring seal on fuel pressure sensor
(2).
NOTICE
Keep all parts clean from contaminants. 2. Install fuel pressure sensor (2). Tighten fuel
pressure sensor (2) to a torque of 10 ± 2 N·m
Contaminants may cause rapid wear and shortened (90 ± 18 lb in).
component life.
1. Turn the fuel supply valve to the OFF position. 4. Turn the fuel supply valve to the ON position.
i02581061
Fuel Temperature Sensor -

Remove and Install
SMCS Code: 1922-010
Removal Procedure
NOTICE
g01292812
Illustration 274 ing, adjusting and repair of the product. Be prepared to
2. Disconnect harness assembly (1). ing any compartment or disassembling any compo-
3. Remove fuel pressure sensor (2) from the fuel
filter base. Refer to Special Publication, NENG2500, “Caterpillar
4. Remove the O-ring seal from fuel pressure sensor suitable to collect and contain fluids on Caterpillar
(2). products.

mandates.
98 RENR9716-02
2. Install fuel temperature sensor (2). Tighten fuel

NOTICE temperature sensor (2) to a torque of 20 ± 5 N·m
Keep all parts clean from contaminants. (15 ± 4 lb ft).
Contaminants may cause rapid wear and shortened 3. Connect harness assembly (1).
component life.
4. Turn the fuel supply valve to the ON position.
1. Turn the fuel supply valve to the OFF position.
i02449930
Turbocharger Outlet Pressure

Sensor - Remove and Install
SMCS Code: 1917-010
Removal Procedure
NOTICE

component life.
g01292826
Illustration 276
3. Remove fuel temperature sensor (2) from the fuel

filter base.
4. Remove the O-ring seal from fuel temperature

sensor (2).
NOTICE
g01223056
Illustration 278
component life.
2. Remove turbocharger outlet pressure sensor (2)

from the inlet manifold.
3. Remove the O-ring seal from turbocharger outlet

pressure sensor (2).
NOTICE

component life.
g01292826
Illustration 277
1. Install a new O-ring seal on fuel temperature

sensor (2).
RENR9716-02 99
3. Remove the O-ring seal from inlet air temperature

sensor (2).
NOTICE

component life.
g01223056
Illustration 279
1. Install a new O-ring seal on turbocharger outlet

pressure sensor (2).
2. Install turbocharger outlet pressure sensor (2) and

tighten to a torque of 10 ± 2 N·m (90 ± 18 lb in).
i02449945
g01223082
Illustration 281
Inlet Air Temperature Sensor -
1. Install a new O-ring seal on inlet air temperature
Remove and Install sensor (2).
SMCS Code: 1921-010 2. Install inlet air temperature sensor (2) and tighten
to a torque of 20 ± 5 N·m (15± 4 lb ft).
Removal Procedure
NOTICE
Keep all parts clean from contaminants. i02574366
Contaminants may cause rapid wear and shortened Belt Guard - Remove and
component life.
Install
SMCS Code: 1357-010-GD
Removal Procedure
g01223082
Illustration 280
2. Remove inlet air temperature sensor (2) from the g01289708

Illustration 282
inlet manifold.
100 RENR9716-02
1. Remove bolts (1). Repeat for the opposite side. i02755046

Remove bottom belt guard (2).
Fan Guard - Remove and Install
SMCS Code: 1360-010
Removal Procedure
g01289709
Illustration 283
2. Remove bolt (3). Repeat for the opposite side.

Remove upper belt guard (4).
g01289778
Installation Procedure Illustration 286
1. Remove bolts (1). Remove lower fan guard (2).
g01289709
Illustration 284
g01379587
1. Install upper belt guard (4). Install bolt (3). Repeat Illustration 287
for the opposite side.
2. Remove bolts (3). Remove upper fan guard (4).
g01289708
Illustration 285
2. Install lower belt guard (2). Install bolts (1). Repeat

for the opposite side. 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 Illustration 291

g01289733
SMCS Code: 1356-010 2. Remove bolts (2). Remove fan (1).
Removal Procedure Installation Procedure

Table 71 Table 72
Required Tools Required Tools
Part Part
Tool Number Part Description Qty Tool Number Part Description Qty
A 140-7742 Sleeve 1 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
g01289733
1. Attach Tooling (A) and a suitable lifting device Illustration 292
onto fan (1). The weight of fan (1) is approximately
45 kg (100 lb). 1. Attach Tooling (A) and a suitable lifting device
onto fan (1). The weight of fan (1) is approximately
45 kg (100 lb). Install fan (1). Install bolts (2).
102 RENR9716-02
g01289730
Illustration 293
2. Remove Tooling (A) and the suitable lifting device

from fan (1).
End By:
g01289585
Illustration 294
a. Install the fan guard. Refer to Disassembly and
Assembly, “Fan Guard - Remove and Install”.
2. Loosen bolts (1). Loosen locknut (2).
i02574047
Fan Drive - Remove and Install

SMCS Code: 1359-010; 1386-010
Removal Procedure
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”.
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
Installation Procedure 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.
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).
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

g01289585
Illustration 297 module (5) and ground strap (3).
2. Install the belts. Refer to Operation 6. Remove washers (7) and isolation mounts (8)
and Maintenance Manual, “Belts - from electronic control module (5).
3. Tighten bolts (1). Tighten locknut (2).
End By:
a. Install the belt guard. Refer to Disassembly and

Assembly, “Belt Guard - Remove and Install”.
104 RENR9716-02
g01223195
Illustration 300
2. Remove V-belt (1) from alternator (3).
3. Disconnect the harness assemblies from

alternator (3).
g01208278 4. Remove bolt (2) and bolt (4).

Illustration 299
5. Remove alternator (3) from the mounting group.
1. Position isolation mounts (8) on electronic control
module (5). Position the spacers, washers (7),
ground strap (3), and electronic control module (5) Installation Procedure
on the support assemblies. Install bolts (6).
2. Connect hose assemblies (4) and (2).
3. Connect the harness assembly to electronic

control module (5). Tighten allen head screw (1)
to a torque of 6 ± 1 N·m (53 ± 9 lb in).
4. Connect the negative battery terminal at the

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

position.
g01223195
i02450170 Illustration 301
Alternator - Remove and Install 1. Position alternator (3) on the mounting group.
SMCS Code: 1405-010 2. Install bolt (4) and bolt (2).
Removal Procedure 3. Connect the harness assemblies to alternator (3).

Refer to Specifications, “Alternator and Regulator”.
1. Turn the battery disconnect switch to the OFF
position. 4. Install V-belt (1) on alternator (3).
5. Adjust the tension on the V-belt. Refer to

Operation and Maintenance Manual, “Belt -
6. Turn the battery disconnect switch to the ON

position.
RENR9716-02 105
i02419387 Installation Procedure

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 fire.
g01208927
Illustration 303
1. Turn the battery disconnect switch to the “OFF”
position.
1. Fasten a suitable lifting device to electric starting
motor (1). The weight of electric starting motor (1)
is approximately 37 kg (80 lb).
2. Position the gasket and electric starting motor (1)

in the flywheel housing. Install bolts (2).
3. Connect the harness assemblies to electric

starting motor (1). Refer to Specifications, “Electric
Starting Motor”.
4. Turn the battery disconnect switch to the “ON”

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 flywheel housing.
106 RENR9716-02
Index Section
Index
A Crankshaft Main Bearings - Install......................... 87
Installation Procedure ........................................ 87
Aftercooler - Install................................................. 40 Crankshaft Main Bearings - Remove..................... 86
Installation Procedure ........................................ 40 Removal Procedure ........................................... 86
Aftercooler - Remove............................................. 38 Crankshaft Position Sensor - Remove and Install.. 94
Removal Procedure ........................................... 38 Installation Procedure ........................................ 95
Alternator - Remove and Install ........................... 104 Removal Procedure ........................................... 94
Installation Procedure ...................................... 104 Crankshaft Rear Seal - Install................................ 50
Removal Procedure ......................................... 104 Installation Procedure ........................................ 50
Atmospheric Pressure Sensor - Remove and Crankshaft Rear Seal - Remove............................ 50
Install ................................................................... 93 Removal Procedure ........................................... 50
Installation Procedure ........................................ 93 Cylinder Head - Install ........................................... 68
Cylinder Head - Remove ....................................... 66
Removal Procedure ........................................... 66
B Cylinder Liner - Install............................................ 79
Bearing Clearance - Check ................................... 92 Cylinder Liner - Remove........................................ 79
Measurement Procedure ................................... 92 Removal Procedure ........................................... 79
Belt Guard - Remove and Install ........................... 99
Installation Procedure ...................................... 100
Removal Procedure ........................................... 99 D
Disassembly and Assembly Section........................ 4

C
Camshaft - Install................................................... 73 E
Camshaft - Remove............................................... 71 Electric Starting Motor - Remove and Install ....... 105
Removal Procedure ........................................... 71 Installation Procedure ...................................... 105
Camshaft Bearings - Install ................................... 76 Removal Procedure ......................................... 105
Installation Procedure ........................................ 76 Electronic Control Module - Remove and Install.. 103
Camshaft Bearings - Remove ............................... 76 Installation Procedure ...................................... 104
Removal Procedure ........................................... 76 Removal Procedure ......................................... 103
Camshaft Position Sensor - Remove and Install ... 93 Electronic Unit Injector - Install .............................. 14
Installation Procedure ........................................ 94 Installation Procedure ........................................ 14
Removal Procedure ........................................... 93 Electronic Unit Injector - Remove .......................... 13
Connecting Rod Bearings - Install ......................... 85 Removal Procedure ........................................... 13
Installation Procedure ........................................ 85 Electronic Unit Injector Sleeve - Install .................. 16
Connecting Rod Bearings - Remove ..................... 84 Installation Procedure ........................................ 16
Removal Procedure ........................................... 84 Electronic Unit Injector Sleeve - Remove .............. 15
Coolant Temperature Sensor - Remove and Removal Procedure ........................................... 15
Install ................................................................... 95 Engine - Install......................................................... 6
Installation Procedure ........................................ 95 Installation Procedure .......................................... 6
Removal Procedure ........................................... 95 Engine - Remove..................................................... 4
Cooling System Package (Radiator, Aftercooler, Fuel Removal Procedure ............................................. 4
Cooler) - Install .................................................... 36 Engine Oil Cooler - Install...................................... 28
Installation Procedure ........................................ 36 Installation Procedure ........................................ 28
Cooling System Package (Radiator, Aftercooler, Fuel Engine Oil Cooler - Remove.................................. 27
Cooler) - Remove ................................................ 35 Removal Procedure ........................................... 27
Removal Procedure ........................................... 35 Engine Oil Filter Base - Assemble......................... 26
Crankshaft - Install................................................. 90 Assembly Procedure.......................................... 26
Installation Procedure ........................................ 90 Engine Oil Filter Base - Disassemble .................... 26
Crankshaft - Remove............................................. 88 Disassembly Procedure ..................................... 26
Removal Procedure ........................................... 88 Engine Oil Filter Base - Install ............................... 27
Crankshaft Front Seal - Install ............................... 55 Installation Procedure ........................................ 27
Installation Procedure ........................................ 55 Engine Oil Filter Base - Remove ........................... 25
Crankshaft Front Seal - Remove ........................... 54 Removal Procedure ........................................... 25
RENR9716-02 107
Index Section
Engine Oil Pan - Remove and Install..................... 78 G

Removal Procedure ........................................... 78 Gear Group (Front) - Install ................................... 56
Engine Oil Pressure Sensor - Remove and Install.. 96 Installation Procedure ........................................ 56
Installation Procedure ........................................ 96 Gear Group (Front) - Remove ............................... 55
Removal Procedure ........................................... 96 Removal Procedure ........................................... 55
Engine Oil Pump - Assemble................................. 29 Gear Group (Rear) - Install.................................... 48
Assembly Procedure.......................................... 29 Installation Procedure ........................................ 48
Engine Oil Pump - Disassemble............................ 29 Gear Group (Rear) - Remove................................ 46
Disassembly Procedure ..................................... 29 Removal Procedure ........................................... 46
Engine Oil Pump - Install ....................................... 30
Engine Oil Pump - Remove ................................... 28 H
Engine Support (Front) - Remove and Install ........ 45 Housing (Front) - Install ......................................... 58
Installation Procedure (Type 1) .......................... 46 Installation Procedure ........................................ 58
Installation Procedure (Type 2) .......................... 46 Housing (Front) - Remove ..................................... 57
Removal Procedure (Type 1) ............................. 45 Removal Procedure ........................................... 57
Removal Procedure (Type 2) ............................. 46 Housing (Rear) - Install.......................................... 60
Exhaust Manifold - Remove and Install ................. 19 Installation Procedure ........................................ 60
Installation Procedure ........................................ 19 Housing (Rear) - Remove...................................... 60
Removal Procedure ........................................... 19 Removal Procedure ........................................... 60
F I
Fan - Remove and Install .................................... 101 Important Safety Information ................................... 2
Installation Procedure ...................................... 101 Inlet Air Temperature Sensor - Remove and
Removal Procedure ......................................... 101 Install ................................................................... 99
Fan Drive - Remove and Install ........................... 102 Installation Procedure ........................................ 99
Installation Procedure ...................................... 103 Removal Procedure ........................................... 99
Removal Procedure ......................................... 102 Inlet and Exhaust Valve Guides - Remove and
Fan Guard - Remove and Install ......................... 100 Install ................................................................... 23
Installation Procedure ...................................... 100 Installation Procedure ........................................ 24
Removal Procedure ......................................... 100 Removal Procedure ........................................... 23
Flywheel - Remove and Install .............................. 49 Inlet and Exhaust Valve Seat Inserts - Remove and
Installation Procedure ........................................ 49 Install ................................................................... 24
Flywheel Housing - Remove and Install ................ 51 Removal Procedure ........................................... 24
Installation Procedure ........................................ 52 Inlet and Exhaust Valve Springs - Remove and
Removal Procedure ........................................... 51 Install ................................................................... 20
Fuel Filter and Water Separator - Remove and Installation Procedure ........................................ 21
Install .................................................................... 11 Removal Procedure ........................................... 20
Installation Procedure ......................................... 11 Inlet and Exhaust Valves - Remove and Install ..... 22
Removal Procedure ............................................ 11 Installation Procedure ........................................ 23
Fuel Filter Base - Install......................................... 10 Removal Procedure ........................................... 22
Fuel Filter Base - Remove..................................... 10
Removal Procedure ........................................... 10 P
Fuel Pressure Sensor - Remove and Install.......... 97
Installation Procedure ........................................ 97 Piston Cooling Jets - Remove and Install.............. 80
Fuel Priming Pump - Remove and Install ................ 9 Removal Procedure ........................................... 80
Installation Procedure ........................................ 10 Pistons and Connecting Rods - Assemble ............ 82
Removal Procedure ............................................. 9 Assembly Procedure.......................................... 82
Fuel Temperature Sensor - Remove and Install .... 97 Pistons and Connecting Rods - Disassemble ....... 82
Installation Procedure ........................................ 98 Disassembly Procedure ..................................... 82
Removal Procedure ........................................... 97 Pistons and Connecting Rods - Install................... 83
Fuel Transfer Pump - Install .................................. 12 Installation Procedure ........................................ 83
Installation Procedure ........................................ 12 Pistons and Connecting Rods - Remove............... 81
Fuel Transfer Pump - Remove .............................. 12 Removal Procedure ........................................... 81
R Water Temperature Regulator Housing - Remove and
Install ................................................................... 33
Radiator Core - Install............................................ 44 Installation Procedure ........................................ 34
Installation Procedure ........................................ 44 Removal Procedure ........................................... 33
Radiator Core - Remove........................................ 42
Rocker Arm - Assemble......................................... 64
Assembly Procedure.......................................... 64
Rocker Arm - Disassemble.................................... 64
Disassembly Procedure ..................................... 64
Rocker Arm and Shaft - Install............................... 65
Rocker Arm and Shaft - Remove........................... 63
Table of Contents..................................................... 3
Turbocharger - Assemble ...................................... 18
Turbocharger - Disassemble ................................. 17
Turbocharger - Install ............................................ 18
Turbocharger - Remove ........................................ 17
Turbocharger Outlet Pressure Sensor - Remove and
Install ................................................................... 98
Valve Mechanism Cover - Remove and Install...... 62

Valve Mechanism Cover Base - Remove and
Install ................................................................... 62
Vibration Damper and Pulley - Remove and
Install ................................................................... 53
Water Pump - Assemble........................................ 32

Water Pump - Disassemble ................................... 31
Water Pump - Install .............................................. 33
Water Pump - Remove .......................................... 31
©2008 Caterpillar Cat, Caterpillar, their respective logos, “Caterpillar Yellow” and the Power edge Printed in U.S.A.
All Rights Reserved trade dress, as well as corporate and product identity used herein, are trademarks
of Caterpillar and may not be used without permission.

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What are the main components discussed in the manual?

What are the main components discussed in the manual?

What safety precautions are emphasized?

What safety precautions are emphasized?

RENR9716-02

Important Safety Information

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Failure to heed this warning can lead to prema-

Table of Contents Vibration Damper and Pulley - Remove and Install

Disassembly and Assembly

a. Remove the cooling package. Refer to

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

1. Disconnect hose assembly (1). Disconnect cable

7. Disconnect clamp (15).

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

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

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

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

10. Disconnect hose (20).

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

11. Install Tooling (B). Use Tooling (B) in order to

14. Remove mounting bolts (25). Remove engine

2. Install mounting bolts (25).

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

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

8. Connect clamp (15).

11. Connect clamp (10). End By:

a. Install the cooling package. Refer to Disassembly

Fuel Priming Pump - Remove

Refer to Special Publication, NENG2500, “Caterpillar

Dispose of all fluids according to local regulations and

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

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

2. Install bolts (1).

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

A 185-3630 Strap Wrench 1 Fuel Filter Base - Install

Dispose of all fluids according to local regulations and

Contaminants may cause rapid wear and shortened

Refer to Special Publication, NENG2500, “Caterpillar

Dispose of all fluids according to local regulations and

1. Turn the fuel supply to the OFF position.

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

2. Connect hose assembly (1) and hose assembly

3. Connect harness assemblies (4).

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

5. Turn the fuel supply to the ON position. Illustration 35

Removal Procedure Installation Procedure

Contaminants may cause rapid wear and shortened

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

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

i02285574 4. Remove fuel transfer pump (1) and the O-ring

Fuel Transfer Pump - Install

Dispose of all fluids according to local regulations and

Contaminants may cause rapid wear and shortened

1. Turn the fuel supply to the “OFF” position.

1. Disconnect harness assembly (1).

2. Remove bridge assemblies (3).

Electronic Unit Injector -