Caterpillar c32 acert мануал

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• RENR9716-02September 2008

  Disassembly andAssemblyC27 and C32 Generator Sets EnginesDWB1-Up
  (Generator Set)SXC1-Up (Generator Set)MED1-Up (Power Module)WDR1-Up
  (Generator Set)

  SAFETY.CAT.COM

• i01658146

  Important Safety InformationMost accidents that involve product
  operation, maintenance and repair are caused by failure to
  observebasic safety rules or precautions. An accident can often be
  avoided by recognizing potentially hazardoussituations before an
  accident occurs. A person must be alert to potential hazards. This
  person should alsohave the necessary training, skills and tools to
  perform these functions properly.

  Improper operation, lubrication, maintenance or repair of this
  product can be dangerous andcould result in injury or death.Do not
  operate or perform any lubrication, maintenance or repair on this
  product, until you haveread 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 warningsare 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 asDANGER, 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 pictoriallypresented.

  Operations that may cause product damage are identified by
  NOTICE labels on the product and inthis 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 Caterpillaris used, you must satisfy
  yourself that it is safe for you and for others. You should also
  ensure thatthe product will not be damaged or be made unsafe by the
  operation, lubrication, maintenance orrepair procedures that you
  choose.The information, specifications, and illustrations in this
  publication are on the basis of information thatwas 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 canaffect the
  service that is given to the product. Obtain the complete and most
  current information before youstart any job. Caterpillar dealers
  have the most current information available.

  When replacement parts are required for thisproduct Caterpillar
  recommends using Caterpil-lar replacement parts or parts with
  equivalentspecifications 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 ordeath.

• RENR9716-02 3Table of Contents

  Table of Contents

  Disassembly and Assembly Section

  Engine — Remove
  …………………………………………… 4Engine —
  Install ……………………………………………….
  6Fuel Priming Pump — Remove and Install ………….. 9Fuel Filter
  Base — Remove …………………………….. 10Fuel Filter
  Base — Install ………………………………… 10Fuel
  Filter and Water Separator — Remove andInstall
  …………………………………………………………..
  11Fuel Transfer Pump — Remove ………………………… 12Fuel
  Transfer Pump — Install …………………………….
  12Electronic Unit Injector — Remove …………………….
  13Electronic Unit Injector — Install ………………………..
  14Electronic Unit Injector Sleeve — Remove ………….
  15Electronic Unit Injector Sleeve — Install ……………..
  16Turbocharger — Remove ………………………………….
  17Turbocharger — Disassemble …………………………..
  17Turbocharger — Assemble ………………………………
  18Turbocharger — Install
  …………………………………….. 18Exhaust Manifold —
  Remove and Install …………… 19Inlet and Exhaust Valve
  Springs — Remove andInstall
  ………………………………………………………….
  20Inlet and Exhaust Valves — Remove and Install …. 22Inlet and
  Exhaust Valve Guides — Remove andInstall
  ………………………………………………………….
  23Inlet and Exhaust Valve Seat Inserts — Remove andInstall
  ………………………………………………………….
  24Engine Oil Filter Base — Remove ……………………..
  25Engine Oil Filter Base — Disassemble ………………. 26Engine
  Oil Filter Base — Assemble …………………… 26Engine Oil
  Filter Base — Install ………………………… 27Engine Oil
  Cooler — Remove …………………………… 27Engine Oil
  Cooler — Install ………………………………. 28Engine Oil
  Pump — Remove ……………………………. 28Engine Oil Pump
  — Disassemble ……………………… 29Engine Oil Pump —
  Assemble ………………………….. 29Engine Oil Pump —
  Install ……………………………….. 30Water Pump —
  Remove ………………………………….. 31Water Pump —
  Disassemble …………………………… 31Water Pump —
  Assemble ……………………………….. 32Water Pump —
  Install ……………………………………… 33Water
  Temperature Regulator Housing — Remove andInstall
  …………………………………………………………
  33Cooling System Package (Radiator, Aftercooler, FuelCooler) —
  Remove ………………………………………… 35Cooling
  System Package (Radiator, Aftercooler, FuelCooler) — Install
  ……………………………………………. 36Aftercooler
  — Remove ……………………………………. 38Aftercooler
  — Install ………………………………………..
  40Radiator Core — Remove ………………………………..
  42Radiator Core — Install
  …………………………………… 44Engine Support (Front)
  — Remove and Install ……. 45Gear Group (Rear) — Remove
  …………………………. 46Gear Group (Rear) — Install
  …………………………….. 48Flywheel — Remove and Install
  ……………………….. 49Crankshaft Rear Seal — Remove
  ……………………… 50Crankshaft Rear Seal — Install
  …………………………. 50Flywheel Housing — Remove and
  Install ………….. 51

  Vibration Damper and Pulley — Remove and
  Install…………………………………………………………………..
  53Crankshaft Front Seal — Remove ……………………..
  54Crankshaft Front Seal — Install …………………………
  55Gear Group (Front) — Remove ………………………… 55Gear
  Group (Front) — Install …………………………….
  56Housing (Front) — Remove ………………………………
  57Housing (Front) — Install
  …………………………………. 58Housing (Rear) — Remove
  ………………………………. 60Housing (Rear) — Install
  ………………………………….. 60Valve Mechanism Cover —
  Remove and Install ….. 62Valve Mechanism Cover Base — Remove
  andInstall
  ………………………………………………………….
  62Rocker Arm and Shaft — Remove …………………….. 63Rocker
  Arm — Disassemble …………………………….. 64Rocker Arm
  — Assemble …………………………………. 64Rocker Arm
  and Shaft — Install ………………………… 65Cylinder Head
  — Remove ……………………………….. 66Cylinder Head —
  Install …………………………………… 68Camshaft —
  Remove ………………………………………. 71Camshaft —
  Install …………………………………………..
  73Camshaft Bearings — Remove ………………………….
  76Camshaft Bearings — Install ……………………………..
  76Engine Oil Pan — Remove and Install ……………….
  78Cylinder Liner — Remove …………………………………
  79Cylinder Liner — Install
  ……………………………………. 79Piston Cooling Jets —
  Remove and Install …………. 80Pistons and Connecting Rods —
  Remove ………….. 81Pistons and Connecting Rods — Disassemble
  ……. 82Pistons and Connecting Rods — Assemble ………..
  82Pistons and Connecting Rods — Install ………………
  83Connecting Rod Bearings — Remove ………………..
  84Connecting Rod Bearings — Install ……………………
  85Crankshaft Main Bearings — Remove ………………..
  86Crankshaft Main Bearings — Install ……………………
  87Crankshaft — Remove ……………………………………..
  88Crankshaft — Install
  ………………………………………… 90Bearing
  Clearance — Check …………………………….. 92Atmospheric
  Pressure Sensor — Remove andInstall
  ………………………………………………………….
  93Camshaft Position Sensor — Remove and Install .. 93Crankshaft
  Position Sensor — Remove and Install .. 94Coolant Temperature
  Sensor — Remove andInstall
  ………………………………………………………….
  95Engine Oil Pressure Sensor — Remove and
  Install…………………………………………………………………..
  96Fuel Pressure Sensor — Remove and Install ……… 97Fuel
  Temperature Sensor — Remove and Install … 97Turbocharger Outlet
  Pressure Sensor — Remove andInstall
  ………………………………………………………….
  98Inlet Air Temperature Sensor — Remove andInstall
  ………………………………………………………….
  99Belt Guard — Remove and Install ……………………… 99Fan
  Guard — Remove and Install …………………… 100Fan — Remove
  and Install …………………………….. 101Fan Drive —
  Remove and Install ……………………. 102Electronic Control
  Module — Remove and Install .. 103Alternator — Remove and Install
  ……………………. 104Electric Starting Motor — Remove and
  Install ….. 105

  Index Section

  Index
  ………………………………………………………….
  106

• 4 RENR9716-02Disassembly and Assembly Section

  Disassembly and AssemblySection

  i02747487

  Engine — RemoveSMCS Code: 1000-011

  Removal ProcedureTable 1

  Required Tools

  ToolPart

  Number Part Description Qty

  A 138-7573 Link Bracket 2

  B 238-9586 Engine Turning Tool 1

  C 1U-9200 Lever Puller Hoist 1

  D 189-0411 Shackle As 2

  E 6V-6146 Load Leveling Beam 1

  Start By:

  a. Remove the cooling package. Refer toDisassembly and Assembly,
  Cooling SystemPackage (Radiator, Aftercooler, Fuel Cooler)
  -Remove.

  g01291159Illustration 1

  1. Disconnect hose assembly (1). Disconnect cableassembly (2).
  Disconnect harness assemblies(3). Disconnect cable assembly (4).
  Disconnectharness assemblies (5).

  g01291160Illustration 2

  2. Disconnect harness assembly (6).

  g01291161Illustration 3

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

  g01291162Illustration 4

  4. Disconnect clamp (10).

• RENR9716-02 5Disassembly and Assembly Section

  g01291179Illustration 5

  5. Remove bolts (11). Remove bolts (12). Repeat forthe opposite
  side. Disconnect tube assembly (13).Repeat for the opposite
  side.

  g01291183Illustration 6

  6. Attach Tooling (A) and a suitable lifting deviceonto exhaust
  elbow (14). The weight of exhaustelbow (14) is approximately 34 kg
  (75 lb). Removeexhaust elbow (14).

  g01291186Illustration 7

  7. Disconnect clamp (15).

  g01291225Illustration 8

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

  g01291227Illustration 9

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

  g01291228Illustration 10

  10.Disconnect hose (20).

• 6 RENR9716-02Disassembly and Assembly Section

  g01291232Illustration 11

  g01291243Illustration 12

  11. Install Tooling (B). Use Tooling (B) in order torotate the
  engine. Rotate the engine in order togain access to bolts (22).
  Remove bolts (22).Remove bolts (21).

  g01376223Illustration 13

  12.Use Tooling (C) in order to support generatorrotor (23).

  g01291246Illustration 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 approximately3527 kg (7775 lb).

  g01291247Illustration 15

  14.Remove mounting bolts (25). Remove engine(24) from the
  generator.

  i02747534

  Engine — InstallSMCS Code: 1000-012

  Installation ProcedureTable 2

  Required Tools

  ToolPart

  Number Part Description Qty

  A 138-7573 Link Bracket 2

  B 238-9586 Engine Turning Tool 1

  C 1U-9200 Lever Puller Hoist 1

  D 189-0411 Shackle As 2

  E 6V-6146 Load Leveling Beam 1

• RENR9716-02 7Disassembly and Assembly Section

  g01291246Illustration 16

  1. Attach Tooling (D) onto engine (24). Attach Tooling(E) and a
  suitable lifting device onto Tooling(D). The weight of engine (24)
  is approximately3527 kg (7775 lb). Install engine (24).

  g01291247Illustration 17

  2. Install mounting bolts (25).

  g01291243Illustration 18

  g01291232Illustration 19

  3. Install bolts (21). Use Tooling (B) in order to rotatethe
  engine. Install bolts (22).

  g01291245Illustration 20

  4. Remove Tooling (C).

  g01291228Illustration 21

  5. Connect hose (20).

• 8 RENR9716-02Disassembly and Assembly Section

  g01291227Illustration 22

  6. Install guard (19). Install bolts (18).

  g01291225Illustration 23

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

  g01291186Illustration 24

  8. Connect clamp (15).

  g01291183Illustration 25

  9. Attach Tooling (A) and a suitable lifting deviceonto exhaust
  elbow (14). The weight of exhaustelbow (14) is approximately 34 kg
  (75 lb). Installexhaust elbow (14).

  g01291179Illustration 26

  10.Connect tube assembly (13). Install bolts (12).Repeat for the
  opposite side. Install bolts (11).

  g01291162Illustration 27

• RENR9716-02 9Disassembly and Assembly Section

  11.Connect clamp (10).

  g01291161Illustration 28

  12.Connect hose assemblies (7), (8), and (9).

  g01291160Illustration 29

  13.Connect harness assembly (6).

  g01291159Illustration 30

  14.Connect harness assemblies (5). Connect cableassembly (4).
  Connect harness assemblies (3).Connect cable assembly (2). Connect
  hoseassembly (1).

  End By:

  a. Install the cooling package. Refer to Disassemblyand
  Assembly, Cooling System Package(Radiator, Aftercooler, Fuel
  Cooler) — Install.

  i02580978

  Fuel Priming Pump — Removeand InstallSMCS Code: 1258-010

  Removal Procedure

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

  Refer to Special Publication, NENG2500, CaterpillarTools and
  Shop Products Guide for tools and suppliessuitable to collect and
  contain fluids on Caterpillarproducts.

  Dispose of all fluids according to local regulations
  andmandates.

  NOTICEKeep all parts clean from contaminants.

  Contaminants may cause rapid wear and shortenedcomponent
  life.

  g01292755Illustration 31

  1. Remove bolts (1).

  2. Remove fuel priming pump (2) and the gasket.

• 10 RENR9716-02Disassembly and Assembly Section

  Installation Procedure

  g01292755Illustration 32

  1. Position the gasket and fuel priming pump (2) onthe fuel
  filter base.

  2. Install bolts (1).

  i02580993

  Fuel Filter Base — RemoveSMCS Code: 1262-011

  Removal ProcedureTable 3

  Required Tools

  ToolPart

  Number Part Description Qty

  A 185-3630 Strap Wrench 1

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

  Refer to Special Publication, NENG2500, CaterpillarDealer
  Service Tool Catalog for tools and suppliessuitable to collect and
  contain fluids on Caterpillarproducts.

  Dispose of all fluids according to local regulations
  andmandates.

  NOTICEKeep all parts clean from contaminants.

  Contaminants may cause rapid wear and shortenedcomponent
  life.

  1. Turn the fuel supply to the OFF position.

  g01292764Illustration 33

  2. Use Tooling (A) to remove fuel filter (6) from fuelfilter
  base (5).

  3. Disconnect harness assemblies (4).

  4. Disconnect hose assembly (1) and hose assembly(2).

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

  i02581008

  Fuel Filter Base — InstallSMCS Code: 1262-012

  Installation Procedure

  NOTICEKeep all parts clean from contaminants.

  Contaminants may cause rapid wear and shortenedcomponent
  life.

• RENR9716-02 11Disassembly and Assembly Section

  g01292764Illustration 34

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

  i02581074

  Fuel Filter and Water Separator- Remove and InstallSMCS Code:
  1261-010; 1263-010

  Removal ProcedureTable 4

  Required Tools

  Tool Part Number Part Description Qty

  A 185-3630 Strap Wrench As 1

  NOTICEKeep all parts clean from contaminants.

  Contaminants may cause rapid wear and shortenedcomponent
  life.

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

  Refer to Special Publication, NENG2500, CaterpillarDealer
  Service Tool Catalog for tools and suppliessuitable to collect and
  contain fluids on Caterpillarproducts.

  Dispose of all fluids according to local regulations
  andmandates.

  1. Turn the fuel supply to the OFF position.

  g01292832Illustration 35

  2. Use Tooling (A) to remove the fuel filter and waterseparator
  (5) from base assembly (4).

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

  4. Remove bolts (1) and base assembly (4).

  Installation Procedure

  NOTICEKeep all parts clean from contaminants.

  Contaminants may cause rapid wear and shortenedcomponent
  life.

• 12 RENR9716-02Disassembly and Assembly Section

  g01292832Illustration 36

  1. Position base assembly (4) on the cylinder blockand install
  bolts (1).

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

  3. Install a new fuel filter and water separator (5) onbase
  assembly (4).

  4. Turn the fuel supply to the ON position.

  i02285574

  Fuel Transfer Pump — RemoveSMCS Code: 1256-011

  Removal Procedure

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

  Refer to Special Publication, NENG2500, CaterpillarTools and
  Shop Products Guide for tools and suppliessuitable to collect and
  contain fluids on Caterpillarproducts.

  Dispose of all fluids according to local regulations
  andmandates.

  NOTICEKeep all parts clean from contaminants.

  Contaminants may cause rapid wear and shortenedcomponent
  life.

  1. Turn the fuel supply to the OFF position.

  g01143748Illustration 37

  2. Disconnect hose assemblies (3).

  3. Remove bolts (2).

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

  i02287501

  Fuel Transfer Pump — InstallSMCS Code: 1256-012

  Installation Procedure

  NOTICEKeep all parts clean from contaminants.

  Contaminants may cause rapid wear and shortenedcomponent
  life.

• RENR9716-02 13Disassembly and Assembly Section

  g01143748Illustration 38

  1. Install the O-ring seal on fuel transfer pump (1).Lubricate
  the O-ring seal with clean engine oil.

  2. Position fuel transfer pump (1) on the engine.Install bolts
  (2).

  3. Connect hose assemblies (3).

  4. Turn the fuel supply to the ON position.

  i02208070

  Electronic Unit Injector -RemoveSMCS Code: 1290-011

  Removal ProcedureTable 5

  Required Tools

  Tool Part Number Part Description Qty

  A 5F-4764 Pry Bar 1

  Start By:

  a. Remove the rocker arms and the rocker arm shaft.Refer to
  Disassembly and Assembly, Rocker Armand Shaft — Remove.

  NOTICEKeep all parts clean from contaminants.

  Contaminants may cause rapid wear and shortenedcomponent
  life.

  g01114892Illustration 39

  1. Disconnect harness assembly (1).

  2. Remove bridge assemblies (3).

  NOTICEIf the injector hold down bolt is loose during the
  re-moval procedure, inspect the injector bore for wearand debris.
  Replace the clamp and spacer.

  3. Remove bolt (4), spacer (5), and clamp (6).

  4. Place an identification mark on electronic unitinjectors (2)
  for installation purposes. Eachelectronic unit injector must be
  reinstalled in theoriginal location in the cylinder head.

  g01073439Illustration 40

  5. Use Tooling (A) to pry beneath the base and freeelectronic
  unit injector (2).

  6. Remove electronic unit injector (2) from thecylinder
  head.

• 14 RENR9716-02Disassembly and Assembly Section

  i03143340

  Electronic Unit Injector — InstallSMCS Code: 1290-012

  Installation ProcedureTable 6

  Required Tools

  Tool Part Number Part Description Qty

  B 8T-2998 Lubricant 1

  1U-5718 Vacuum Pump 1

  169-7372 Fluid Sampling Bottle 1C

  4C-4057 Tube7.9 mm (0.31 inch) OD 1

  D 4C-5552 Large Bore Brush 1

  E 4C-6774 Vacuum Gun Kit 1

  F 8T-7765 Surface ReconditioningPad 1

  NOTICEKeep all parts clean from contaminants.

  Contaminants may cause rapid wear and shortenedcomponent
  life.

  1. Use Tooling (C) to remove the fuel and oil fromthe cylinder.
  Evacuate as much fuel and oil aspossible from the cylinder before
  installing theelectronic unit injector. Several evacuations maybe
  necessary.

  2. Use Tooling (D) to clean the carbon deposit fromthe inside of
  the electronic unit injector sleeve.Tooling (E) is available to
  clean loose materialfrom the bore of the electronic unit injector
  sleeveand the cylinder.

  3. Use Tooling (F) to clean the carbon from the seatarea that is
  inside of the electronic unit injectorsleeve.

  4. Install the O-ring seals on the electronic unitinjector.
  Lubricate the top two O-ring seals with a50/50 mixture of clean
  engine oil and Tooling (B).

  g01114892Illustration 41

  g01135876Illustration 42

  5. When you install a new injector the E-Trimvalue must be
  programmed into the enginecontrol module. The injector confirmation
  codemay need to be programmed into the enginecontrol module. E-Trim
  Value (X) is a twelve digitalphanumeric code that is supplied with
  the datasheet that comes with the new injectors.
  InjectorConfirmation Code (Y) is a four digit numericcode. Both of
  the codes are located on the top ofelectronic unit injector (2).
  Use the following menuto program the E-Trim value.

  ECM Summary Screen

  Service Menu

  Calibration

  Injector Code Calibration

• RENR9716-02 15Disassembly and Assembly Section

  NOTICEWhen an electronic unit injector is replaced, the
  newelectronic injector code must be programmed into theengines
  personality module software by using the cal-ibration menu on the
  Electronic Service Tool. If thenew electronic injector code is not
  entered, the char-acteristics of the previous electronic unit
  injector is as-sumed.

  If it is not possible to immediately reprogram the elec-tronic
  injector code into the personality module soft-ware, the engine
  will not be severely harmed. The newelectronic injector code should
  be reprogrammed asquickly as possible in order to optimize engine
  perfor-mance.

  6. Position electronic unit injector (2) in the
  cylinderhead.

  7. Install spacer (5), clamp (6), and bolt (4). Tightenthe bolt
  to a torque of 55 10 Nm (41 7 lb ft).

  8. Install bridge assemblies (3).

  9. Connect harness assembly (1). Tighten the nutsto a torque of
  2.5 0.25 Nm (22 2 lb in).

  End By:

  a. Install the rocker arms and the rocker arm shaft.Refer to
  Disassembly and Assembly, Rocker Armand Shaft — Install.

  i02300212

  Electronic Unit Injector Sleeve- RemoveSMCS Code: 1713-011

  Removal ProcedureTable 7

  Required Tools

  ToolPart

  Number Part Description Qty

  A 9U-6891 Injector Tool Group 1

  Start By:

  a. Remove the electronic unit injectors. Refer toDisassembly and
  Assembly, Electronic UnitInjector — Remove.

  NOTICEKeep all parts clean from contaminants.

  Contaminants may cause rapid wear and shortenedcomponent
  life.

  1. Drain the coolant from the cooling system into asuitable
  container for storage or disposal. Referto Operation and
  Maintenance Manual, CoolingSystem Coolant — Change.

  g01043124Illustration 43

  2. Install Tooling (A) in electronic unit injector
  sleeve(1).

  3. Tighten the nut on Tooling (A) until the electronicunit
  injector sleeve is pulled free of the cylinderhead.

  g01073635Illustration 44

  4. Remove O-ring seals (2) and O-ring seal (3) fromelectronic
  unit injector sleeve (1).

• 16 RENR9716-02Disassembly and Assembly Section

  i02287628

  Electronic Unit Injector Sleeve- InstallSMCS Code: 1713-012

  Installation ProcedureTable 8

  Required Tools

  Tool Part Number Part Description Qty

  A 9U-6891 Injector Tool Group 1

  9U-6862 Tapered Brush 1

  9U-6863 Small Bore Brush 1

  9U-7244 End Brush 1

  9U-7237 Brush Extension 1

  B

  4C-5552 Large Bore Brush 1

  C 4C-9507 Retaining Compound 1

  NOTICEKeep all parts clean from contaminants.

  Contaminants may cause rapid wear and shortenedcomponent
  life.

  1. Use Tooling (B) to clean the bore in the cylinderhead for the
  electronic unit injector sleeve.

  NOTICEEnsure that the electronic unit injector sleeve and
  thecylinder head bore are completely free of oil, dirt, andsealant
  debris.

  g01043165Illustration 45

  2. Install new O-ring seals (2) and O-ring seal (3) onelectronic
  unit injector sleeve (1).

  3. Apply Tooling (C) to the contact surface ofelectronic unit
  injector sleeve (1) on the surfacethat is Marked X.

  Note: Do not apply Tooling (C) to the cylinder headsurfaces.
  Apply Tooling (C) on the electronic unitinjector sleeve only.

  4. Lubricate O-ring seals (2) with clean engine oil.

  g01099549Illustration 46

  5. Install electronic unit injector sleeve (1) on Tooling(A).
  Position the electronic unit injector sleeve inthe cylinder head.
  Use care not to damage theO-ring seals on the electronic unit
  injector sleeve.Use Tooling (A) and a hammer to install
  theelectronic unit injector sleeve in the cylinder head.

  NOTICEEnsure that the electronic unit injector sleeve isproperly
  seated in the cylinder head. The Tooling will»RING» when the
  electronic unit injector sleeve is fullyseated in the bore of the
  cylinder head.

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

  7. Fill the cooling system with coolant. Refer toOperation and
  Maintenance Manual, CoolingSystem Coolant — Change.

  End By:

  a. Install the electronic unit injectors. Refer toDisassembly
  and Assembly, Electronic UnitInjector — Install.

• RENR9716-02 17Disassembly and Assembly Section

  i02287744

  Turbocharger — RemoveSMCS Code: 1052-011

  Removal Procedure

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

  Refer to Special Publication, NENG2500, CaterpillarTools and
  Shop Products Guide for tools and suppliessuitable to collect and
  contain fluids on Caterpillarproducts.

  Dispose of all fluids according to local regulations
  andmandates.

  NOTICEKeep all parts clean from contaminants.

  Contaminants may cause rapid wear and shortenedcomponent
  life.

  1. Drain the coolant from the cooling system into asuitable
  container for storage or disposal. Referto Operation and
  Maintenance Manual, CoolingSystem Coolant — Change.

  g01145002Illustration 47

  g01148173Illustration 48

  2. Remove tube assembly (2).

  3. Disconnect tube assemblies (1) and tubeassembly (4).

  4. Attach a suitable lifting device to turbocharger (5).The
  weight of turbocharger (5) is approximately45 kg (100 lb).

  5. Remove nuts (3). Remove turbocharger (5) andthe gasket.

  i02287870

  Turbocharger — DisassembleSMCS Code: 1052-015

  Disassembly ProcedureStart By:

  a. Remove the turbocharger. Refer to Disassemblyand Assembly,
  Turbocharger — Remove.

  NOTICEKeep all parts clean from contaminants.

  Contaminants may cause rapid wear and shortenedcomponent
  life.

• 18 RENR9716-02Disassembly and Assembly Section

  g01145263Illustration 49

  1. Loosen V-band clamp (2) and V-band clamp (4).

  2. Separate compressor housing (1) fromturbocharger cartridge
  (3).

  3. Separate turbine housing (5) from turbochargercartridge
  (3).

  i02451256

  Turbocharger — AssembleSMCS Code: 1052-016

  Assembly Procedure

  NOTICEKeep all parts clean from contaminants.

  Contaminants may cause rapid wear and shortenedcomponent
  life.

  NOTICEThe compressor housing must remain straight withthe
  turbocharger cartridge during disassembly and as-sembly. Tilting
  may cause damage to the tips of thecompressor wheel and the
  compressor shaft.

  g01145263Illustration 50

  1. Position compressor housing (1) and turbinehousing (5) on
  turbocharger cartridge (3).

  Note: Ensure that the mating surfaces are flush.

  2. Tighten the nuts on V-band clamp (2) to a torqueof 14 1 Nm
  (10 1 lb ft). Use a soft hammer tolightly hit around the diameter
  of the band clamp.Tighten the nuts again to a torque of 14 1 Nm(10
  1 lb ft).

  3. Tighten the nuts on V-band clamp (4) to a torqueof 14 1 Nm
  (10 1 lb ft). Use a soft hammer tolightly hit around the diameter
  of the band clamp.Tighten the nuts again to a torque of 14 1 Nm(10
  1 lb ft).

  4. Ensure that the impeller spins freely.

  End By:

  a. Install the turbocharger. Refer to Disassembly andAssembly,
  Turbocharger — Install.

  i02288273

  Turbocharger — InstallSMCS Code: 1052-012

  Installation ProcedureTable 9

  Required Tools

  Tool Part Number Part Description Qty

  A 5P-3931 Anti-Seize Compound 1

  NOTICEKeep all parts clean from contaminants.

  Contaminants may cause rapid wear and shortenedcomponent
  life.

  g01148173Illustration 51

• RENR9716-02 19Disassembly and Assembly Section

  g01145002Illustration 52

  1. Position the gasket on the exhaust manifold.

  2. Apply Tooling (A) to the threads of the exhaustmanifold
  studs.

  3. Attach a suitable lifting device to turbocharger (5).The
  weight of turbocharger (5) is approximately45 kg (100 lb). Position
  turbocharger (5) on theexhaust manifold.

  4. Install nuts (3) and tighten to a torque of 55 9 Nm(41 7 lb
  ft).

  5. Connect tube assemblies (1) and tube assembly(4).

  6. Install tube assembly (2).

  7. Fill the cooling system. Refer to Operation andMaintenance
  Manual, Cooling System Coolant- Change.

  i02617122

  Exhaust Manifold — Removeand InstallSMCS Code: 1059-010

  Removal ProcedureStart By:

  a. Remove the turbocharger. Refer to Disassemblyand Assembly,
  Turbocharger — Remove.

  NOTICEKeep all parts clean from contaminants.

  Contaminants may cause rapid wear and shortenedcomponent
  life.

  1. Remove the shield assemblies from the exhaustmanifolds.

  g01218139Illustration 53

  2. Remove locknuts (6) from exhaust manifold (7).

  3. Remove spacers (2) and (3) from exhaustmanifold (7).

  4. Remove exhaust manifold (7) and gaskets (1)from the cylinder
  head.

  5. If necessary, remove clamps (4) and expansionjoints (5).

  Installation ProcedureTable 10

  Required Tools

  Tool Part Number Part Description Qty

  A 5P-3931 Anti-Seize Compound —

  B 165-4638 Guide 3

  g01218139Illustration 54

• 20 RENR9716-02Disassembly and Assembly Section

  g00566145Illustration 55

  1. If necessary, install expansion joints (5) andclamps (4).
  Tighten the clamps to a torque of8.5 1.0 Nm (75 9 lb in).

  2. Apply Tooling (A) to the studs prior to assembly.
  Ifnecessary, install the studs and tighten to a torqueof 35 5 Nm
  (26 4 lb ft).

  3. Position gaskets (1) and exhaust manifold (7) onthe cylinder
  head.

  4. Install spacers (2) and (3) on exhaust manifold (7).

  Note: Use Tooling (B) in at least one oversize holeper manifold
  section in order to align the exhaustmanifolds. Do not remove
  Tooling (B) until removalis required to tighten the locknuts.

  5. Install locknuts (6) on exhaust manifold (7).Tighten locknuts
  (6) in a numerical sequence to atorque of 20 3 Nm (15 2 lb ft).
  Tighten locknuts(6) again in a numerical sequence to a torque of38
  5 Nm (28 4 lb ft).

  6. Install the shield assemblies on the exhaustmanifolds.

  End By:

  a. Install the turbocharger. Refer to Disassembly andAssembly,
  Turbocharger — Install.

  i02300073

  Inlet and Exhaust ValveSprings — Remove and InstallSMCS Code:
  1108-010

  Removal ProcedureTable 11

  Required Tools

  Tool Part Number Part Description Qty

  A 9U-7241 Valve Spring Compressor 1

  B 8S-2263 Spring Tester 1

  Start By:

  a. Remove the electronic unit injectors. Refer toDisassembly and
  Assembly, Electronic UnitInjector — Remove.

  NOTICEKeep all parts clean from contaminants.

  Contaminants may cause rapid wear and shortenedcomponent
  life.

  Note: Place the piston at the top of the compressionstroke (TC).
  Remove the valve springs for thatcylinder. If the valves fall into
  the cylinder liner, thenthe cylinder head must be removed.

  1. Position the No. 1 piston at the top center ofthe compression
  stroke. Refer to Testing andAdjusting, Finding Top Center Position
  for No. 1Piston.

  g01073852Illustration 56

• RENR9716-02 21Disassembly and Assembly Section

  g01043625Illustration 57

  Personal injury can result from being struck byparts propelled
  by a released spring force.

  Make sure to wear all necessary protective equip-ment.

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

  2. Install Tooling (A) in the electronic unit injectorsleeve.
  Secure Tooling (A) with unit injector clamp(1).

  3. Tighten the full nut until valve spring keepers (3)are loose
  on valve (2).

  4. Remove valve spring keepers (3) from the valve.

  5. Carefully remove Tooling (A).

  6. Remove valve rotator (4).

  7. Remove outer valve spring (6) and inner valvespring (5) from
  the valve.

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

  9. Use Tooling (B) to check the valve springs (springforce).
  Refer to Specifications, Cylinder HeadValves for additional
  information on the valvesprings.

  Installation ProcedureTable 12

  Required Tools

  Tool Part Number Part Description Qty

  A 9U-7241 Valve Spring Compressor 1

  NOTICEKeep all parts clean from contaminants.

  Contaminants may cause rapid wear and shortenedcomponent
  life.

  1. Lubricate the valve stems with clean engine oil.

  g01043625Illustration 58

  Improper assembly of parts that are spring loadedcan cause
  bodily injury.

  To prevent possible injury, follow the establishedassembly
  procedure and wear protective equip-ment.

  2. Ensure that washer (7) is installed on the valveguide.

  3. Install inner valve spring (5) and outer valve spring(6) on
  valve (2).

  4. Install valve rotator (4) on valve (2).

  The valve spring keepers can be thrown fromthe valve when the
  valve spring compressor isreleased. Ensure that the valve spring
  keepersare properly installed on the valve stem. To helpprevent
  personal injury, keep away from the frontof the valve spring
  keepers and valve springsduring the installation of the valves.

  5. Use Tooling (A) to compress inner valve spring(5) and outer
  valve spring (6). Install valve springkeepers (3) on valve (2).
  Remove unit injectorclamp (1) and Tooling (A).

• 22 RENR9716-02Disassembly and Assembly Section

  End By:

  a. Install the electronic unit injectors. Refer toDisassembly
  and Assembly, Electronic UnitInjector — Install.

  i02642655

  Inlet and Exhaust Valves -Remove and InstallSMCS Code:
  1105-010

  Removal ProcedureTable 13

  Required Tools

  Tool Part Number Part Description Qty

  A 5S-1330 Valve SpringCompressor 1

  B 8S-2263 Spring Tester 1

  Start By:

  a. Remove the cylinder head. Refer to Disassemblyand Assembly,
  Cylinder Head — Remove.

  NOTICEKeep all parts clean from contaminants.

  Contaminants may cause rapid wear and shortenedcomponent
  life.

  g01015263Illustration 59

  Personal injury can result from being struck byparts propelled
  by a released spring force.

  Make sure to wear all necessary protective equip-ment.

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

  1. Install Tooling (A) and compress the valve springs.Remove
  valve spring keepers (2) from valve (1).

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

  3. Remove valve rotator (3).

  4. Remove outer valve spring (5) and inner valvespring (4) from
  valve (1).

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

  6. Use Tooling (B) to check the valve springs (springforce).
  Refer to Specifications, Cylinder HeadValves for additional
  information on the valvesprings.

  7. Inspect the valves. Refer to Specifications,Cylinder Head
  Valves for additional informationon the inlet and exhaust
  valves.

• RENR9716-02 23Disassembly and Assembly Section

  Installation ProcedureTable 14

  Required Tools

  Tool Part Number Part Description Qty

  A 5S-1330 Valve SpringCompressor 1

  NOTICEKeep all parts clean from contaminants.

  Contaminants may cause rapid wear and shortenedcomponent
  life.

  Note: A small amount of grease can be used to holdthe retainer
  locks in position during installation.

  1. Lubricate the valves with clean engine oil. Installthe valves
  in the cylinder head.

  g01015263Illustration 60

  Improper assembly of parts that are spring loadedcan cause
  bodily injury.

  To prevent possible injury, follow the establishedassembly
  procedure and wear protective equip-ment.

  2. Install washer (6) on the valve guide.

  3. Install inner valve spring (4) and outer valve spring(5) on
  valve (1).

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

  5. Use Tooling (A) to compress inner valve spring(4) and outer
  valve spring (5). Install valve springkeepers (2) on valve (1).

  The valve spring keepers can be thrown fromthe valve when the
  valve spring compressor isreleased. Ensure that the valve spring
  keepersare properly installed on the valve stem. To helpprevent
  personal injury, keep away from the frontof the valve spring
  keepers and valve springsduring the installation of the valves.

  6. Carefully remove Tooling (A).

  End By:

  a. Install the cylinder head. Refer to Disassemblyand Assembly,
  Cylinder Head — Install.

  i02109151

  Inlet and Exhaust Valve Guides- Remove and InstallSMCS Code:
  1104-010

  Removal ProcedureTable 15

  Required Tools

  Tool Part Number Part Description Qty

  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 toDisassembly and
  Assembly, Inlet and ExhaustValves — Remove and Install.

  NOTICEKeep all parts clean from contaminants.

  Contaminants may cause rapid wear and shortenedcomponent
  life.

• 24 RENR9716-02Disassembly and Assembly Section

  g01073841Illustration 61

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

  2. Use Tooling (A) and a hammer to remove thevalve guide from
  the cylinder head.

  Installation ProcedureTable 16

  Required Tools

  Tool Part Number Part Description Qty

  A(1) 9U-6895 Valve Guide Driver 1

  B(1) 9U-6894 Guide Collar 1(1) Part of 9U-7530 Engine Tool
  Group

  NOTICEKeep all parts clean from contaminants.

  Contaminants may cause rapid wear and shortenedcomponent
  life.

  g01073842Illustration 62

  1. Lubricate the bores for the valve guides with cleanengine
  oil.

  2. Install valve guide (2) in the cylinder head withTooling (A)
  and Tooling (B).

  Note: Tooling (B) must be used in order to install thevalve
  guide to the correct height.

  Height to top of valve guide from cylinder headsurface …..
  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 toDisassembly and
  Assembly, Inlet and ExhaustValves — Remove and Install.

  i02288478

  Inlet and Exhaust Valve SeatInserts — Remove and InstallSMCS
  Code: 1103-010

  Removal ProcedureTable 17

  Required Tools

  ToolPart

  Number Part Description Qty

  A 166-7441 Valve Seat Extractor ToolGroup1

  Start By:

  a. Remove the inlet and exhaust valves. Refer toDisassembly and
  Assembly, Inlet and ExhaustValves — Remove and Install.

  NOTICEKeep all parts clean from contaminants.

  Contaminants may cause rapid wear and shortenedcomponent
  life.

  g01145463Illustration 63

• RENR9716-02 25Disassembly and Assembly Section

  1. Use Tooling (A) to remove valve seat insert (1)from the
  cylinder head.

  2. Clean the bores in the cylinder head for the valveseat
  inserts. Remove any rough areas from thebores.

  Installation ProcedureTable 18

  Required Tools

  ToolPart

  Number Part Description Qty

  9U-6898 Valve Seat Driver(Exhaust)1

  B(1)

  9U-6897 Valve Seat Driver (Inlet) 1(1) Part of 9U-7530 Engine
  Tool Group

  NOTICEKeep all parts clean from contaminants.

  Contaminants may cause rapid wear and shortenedcomponent
  life.

  g01079028Illustration 64

  1. Lower the temperature of new valve seat insert(1).

  2. Use Tooling (B) to install the new valve seat insertin the
  cylinder head.

  Note: Do not machine the prefinished valve seatinserts in order
  to correct the valve stem projection.An excessive valve stem
  projection indicates that thevalve seat insert is not seated or
  material was notcleaned from the bottom of the counterbore.

  End By:

  a. Install the inlet and exhaust valves. Refer toDisassembly and
  Assembly, Inlet and ExhaustValves — Remove and Install.

  i02438648

  Engine Oil Filter Base -RemoveSMCS Code: 1306-011

  Removal ProcedureTable 19

  Required Tools

  ToolPart

  Number Part Description Qty

  A 185-3630 Strap Wrench As 1

  NOTICEKeep all parts clean from contaminants.

  Contaminants may cause rapid wear and shortenedcomponent
  life.

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

  Refer to Special Publication, NENG2500, CaterpillarDealer
  Service Tool Catalog for tools and suppliessuitable to collect and
  contain fluids on Caterpillarproducts.

  Dispose of all fluids according to local regulations
  andmandates.

  1. Drain the engine oil into a suitable containerfor storage or
  disposal. Refer to Operation andMaintenance Manual, Engine Oil and
  Filter -Change.

  g01218560Illustration 65

• 26 RENR9716-02Disassembly and Assembly Section

  2. Use Tooling (A) in order to remove engine oilfilters (6).

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

  4. Remove engine oil filter base (3).

  i02127750

  Engine Oil Filter Base -DisassembleSMCS Code: 1306-015

  Disassembly ProcedureStart By:

  a. Remove the engine oil filter base. Refer toDisassembly and
  Assembly, Engine Oil FilterBase — Remove.

  1. Remove the O-ring seals.

  g01083088Illustration 66

  Personal injury can result from being struck byparts propelled
  by a released spring force.

  Make sure to wear all necessary protective equip-ment.

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

  2. Remove cover (4).

  3. Remove springs (3) and plungers (2) from oil filterbase
  assembly (1).

  i02127824

  Engine Oil Filter Base -AssembleSMCS Code: 1306-016

  Assembly Procedure

  NOTICEKeep all parts clean from contaminants.

  Contaminants may cause rapid wear and shortenedcomponent
  life.

  g01083088Illustration 67

  Improper assembly of parts that are spring loadedcan cause
  bodily injury.

  To prevent possible injury, follow the establishedassembly
  procedure and wear protective equip-ment.

  1. Install plungers (2) and springs (3) in oil filter
  baseassembly (1).

  2. Install cover (4).

  3. Install the O-ring seals.

• RENR9716-02 27Disassembly and Assembly Section

  End By:

  a. Install the engine oil filter base. Refer toDisassembly and
  Assembly, Engine Oil FilterBase — Install.

  i02438813

  Engine Oil Filter Base — InstallSMCS Code: 1306-012

  Installation ProcedureTable 20

  Required Tools

  ToolPart

  Number Part Description Qty

  A 185-3630 Strap Wrench As 1

  NOTICEKeep all parts clean from contaminants.

  Contaminants may cause rapid wear and shortenedcomponent
  life.

  g01218560Illustration 68

  1. Position engine oil filter base (3) on the engineoil
  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 Operationand
  Maintenance Manual, Engine Oil and Filter- Change.

  i02438849

  Engine Oil Cooler — RemoveSMCS Code: 1378-011

  Removal ProcedureStart By:

  a. Remove the engine oil filter base. Refer toDisassembly and
  Assembly, Engine Oil FilterBase — Remove.

  NOTICEKeep all parts clean from contaminants.

  Contaminants may cause rapid wear and shortenedcomponent
  life.

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

  Refer to Special Publication, NENG2500, CaterpillarDealer
  Service Tool Catalog for tools and suppliessuitable to collect and
  contain fluids on Caterpillarproducts.

  Dispose of all fluids according to local regulations
  andmandates.

  1. Drain the coolant from the cooling system into asuitable
  container for storage or disposal. Referto Operation and
  Maintenance Manual, CoolingSystem Coolant — Change.

  g01218689Illustration 69

  2. Remove tube assembly (2).

  3. Remove bonnet (1) and the gasket.

• 28 RENR9716-02Disassembly and Assembly Section

  4. Remove engine oil cooler (3).

  5. Remove the O-ring seals from engine oil cooler(3).

  i02438914

  Engine Oil Cooler — InstallSMCS Code: 1378-012

  Installation Procedure

  NOTICEKeep all parts clean from contaminants.

  Contaminants may cause rapid wear and shortenedcomponent
  life.

  g01218689Illustration 70

  1. Install the O-ring seals on engine oil cooler (3).

  2. Lubricate the O-ring seals with clean engine oilor
  glycerin.

  3. Install engine oil cooler (3).

  4. Install the gasket and bonnet (1).

  5. Install tube assembly (2).

  6. Refill the cooling system with coolant. Refer toOperation and
  Maintenance Manual, CoolingSystem Coolant — Change.

  End By:

  a. Install the engine oil filter base. Refer toDisassembly and
  Assembly, Engine Oil FilterBase — Install.

  i02439263

  Engine Oil Pump — RemoveSMCS Code: 1304-011

  Removal ProcedureStart By:

  a. Remove the engine oil pan. Refer to Disassemblyand Assembly,
  Engine Oil Pan — Remove andInstall.

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

  Refer to Special Publication, NENG2500, CaterpillarDealer
  Service Tool Catalog for tools and suppliessuitable to collect and
  contain fluids on Caterpillarproducts.

  Dispose of all fluids according to local regulations
  andmandates.

  g01218847Illustration 71

  1. Remove tube assemblies (3) from engine oil pump(2).

  2. Remove bolts (1) and engine oil pump (2).

• RENR9716-02 29Disassembly and Assembly Section

  i02439652

  Engine Oil Pump — DisassembleSMCS Code: 1304-015

  Disassembly ProcedureTable 21

  Required Tools

  ToolPart

  Number Part Description Qty

  A 1P-0510 Driver Group 1

  B 1P-2320 Puller Assembly 1

  Start By:

  a. Remove the engine oil pump. Refer toDisassembly and Assembly,
  Engine Oil Pump- Remove.

  NOTICEKeep all parts clean from contaminants.

  Contaminants may cause rapid wear and shortenedcomponent
  life.

  g01218982Illustration 72

  Personal injury can result from being struck byparts propelled
  by a released spring force.

  Make sure to wear all necessary protective equip-ment.

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

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

  2. Use Tooling (B) to remove drive gear (5) frombody assembly
  (1). Remove the key from thepump shaft.

  3. Remove bolts (4) and separate cover assembly(3) from body
  assembly (1).

  4. Use Tooling (A) and a suitable press in order toremove the
  bearings from cover assembly (3).

  5. Remove shaft assemblies (2).

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

  7. Remove spring (10), plunger ring (9), and plunger(8).

  8. Use Tooling (A) and a suitable press in order toremove the
  bearings from body assembly (1).

  i02439997

  Engine Oil Pump — AssembleSMCS Code: 1304-016

  Assembly ProcedureTable 22

  Required Tools

  ToolPart

  Number Part Description Qty

  A 1P-0510 Driver Group 1

  NOTICEKeep all parts clean from contaminants.

  Contaminants may cause rapid wear and shortenedcomponent
  life.

  g01218982Illustration 73

• 30 RENR9716-02Disassembly and Assembly Section

  g01219045Illustration 74

  g01219048Illustration 75

  Improper assembly of parts that are spring loadedcan cause
  bodily injury.

  To prevent possible injury, follow the establishedassembly
  procedure and wear protective equip-ment.

  1. Use Tooling (A) to install the bearings in bodyassembly (1)
  until the bearings are even withthe outside surface of body
  assembly (1). Installthe bearings so the junctions in the bearings
  areAngle (X). Angle (X) is 30 15 degrees from thecenter line of the
  bearing bores and toward theoutlet passage in the engine oil
  pump.

  2. Install plunger (8), plunger ring (9), and spring(10).

  3. Install retainer (11) and bolts (12).

  4. Install shaft assemblies (2).

  5. Use Tooling (A) to install the bearings in coverassembly (3)
  until the bearings are even withthe outside surface of cover
  assembly (3). Installthe bearings so the junctions in the bearings
  areAngle (Y). Angle (Y) is 30 15 degrees from thecenter line of the
  bearing bores, and toward theoutlet passage. The outlet passage has
  a cavitybetween the bearing bores.

  6. Install cover assembly (3) on body assembly (1).Install bolts
  (4).

  7. Install the key into the pump shaft. Install drivegear (5).
  Install washer (6) and bolt (7). Tightenbolt (7) to a torque of 55
  10 Nm (41 7 lb ft).

  End By:

  a. Install the engine oil pump. Refer to Disassemblyand
  Assembly, Engine Oil Pump — Install.

  i02440080

  Engine Oil Pump — InstallSMCS Code: 1304-012

  Installation Procedure

  NOTICEKeep all parts clean from contaminants.

  Contaminants may cause rapid wear and shortenedcomponent
  life.

  g01218847Illustration 76

  1. Position engine oil pump (2) and install bolts (1).

  2. Install tube assemblies (3) on engine oil pump (2).

  End By:

  a. Install the engine oil pan. Refer to Disassemblyand Assembly,
  Engine Oil Pan — Remove andInstall.

• RENR9716-02 31Disassembly and Assembly Section

  i02440626

  Water Pump — RemoveSMCS Code: 1361-011

  Removal Procedure

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

  Refer to Special Publication, NENG2500, CaterpillarDealer
  Service Tool Catalog for tools and suppliessuitable to collect and
  contain fluids on Caterpillarproducts.

  Dispose of all fluids according to local regulations
  andmandates.

  NOTICEKeep all parts clean from contaminants.

  Contaminants may cause rapid wear and shortenedcomponent
  life.

  1. Drain the coolant from the cooling system into asuitable
  container for storage or disposal. Referto Operation and
  Maintenance Manual, CoolingSystem Coolant — Change.

  g01219274Illustration 77

  2. Remove bolts (1) and bolts (2).

  3. Remove cover (3).

  g01219275Illustration 78

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

  5. Remove water pump (4).

  i02451192

  Water Pump — DisassembleSMCS Code: 1361-015

  Disassembly ProcedureTable 23

  Required Tools

  ToolPart

  Number Part Description Qty

  8S-2264 Puller Group 1

  4B-3903Bolt5/16 — 18 NC by 4inch

  2

  1P-0456 Plate 1

  A

  4B-4277 Washer 2

  B 1P-0510 Driver Group 1

  Start By:

  a. Remove the water pump. Refer to Disassemblyand Assembly,
  Water Pump — Remove.

  NOTICEKeep all parts clean from contaminants.

  Contaminants may cause rapid wear and shortenedcomponent
  life.

• 32 RENR9716-02Disassembly and Assembly Section

  Note: The water pump seal can be replaced withoutremoving the
  water pump from the engine.

  Note: An intermittent leakage of a small amount ofcoolant from
  the hole in the water pump housing isnot an indication of a water
  pump seal failure. Thisis required to provide lubrication for the
  seal. Do notreplace the water pump seal unless a large amountof
  leakage or a constant flow of coolant is drainingfrom the water
  pump housing.

  g01195730Illustration 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) fromshaft (10).

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

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

  7. Use a suitable press to remove shaft (10) andbearing assembly
  (1) from housing (3).

  8. Use a suitable press to remove bearing assembly(1) from shaft
  (10).

  9. Remove seal assembly (12) from housing (3).

  10.Use Tooling (B) to remove lip seal (2) from thehousing.

  i02394663

  Water Pump — AssembleSMCS Code: 1361-016

  Assembly ProcedureTable 24

  Required Tools

  ToolPart

  Number Part Description Qty

  B 1P-0510 Driver Group 1

  C 7N-7843 Seal Installation Tool 1

  D 6V-1541 Quick Cure Primer 1

  NOTICEKeep all parts clean from contaminants.

  Contaminants may cause rapid wear and shortenedcomponent
  life.

  g01195730Illustration 80

  1. Use Tooling (B) to install lip seal (2) into thehousing.

  2. Apply Tooling (D) to shaft (10). Use a suitablepress to
  install bearing assembly (1) on shaft (10).

  3. Install shaft (10) and bearing assembly (1) inhousing
  (3).

  4. Install O-ring seal (14) on housing (3).

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

  6. Position gear (4) on shaft (10). Install washer (6)and bolt
  (7).

• RENR9716-02 33Disassembly and Assembly Section

  7. Use Tooling (C) to install seal assembly (12) ontoshaft (10)
  until the stationary cup is fully seatedinto housing (3).

  8. Install impeller (5) on shaft (10). Install washer(8) and
  bolt (9). Tighten bolt (9) to a torque of39 3 Nm (29 2 lb ft).

  9. Install adapter (15).

  End By:

  a. Install the water pump. Refer to Disassembly andAssembly,
  Water Pump — Install.

  i02440675

  Water Pump — InstallSMCS Code: 1361-012

  Installation Procedure

  NOTICEKeep all parts clean from contaminants.

  Contaminants may cause rapid wear and shortenedcomponent
  life.

  g01219275Illustration 81

  1. Position water pump (4) in the front housing.

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

  g01219274Illustration 82

  3. Position cover (3) on the water pump.

  4. Install bolts (2) and bolts (1).

  5. Fill the cooling system. Refer to Operation andMaintenance
  Manual, Cooling System Coolant- Change.

  i02440754

  Water Temperature RegulatorHousing — Remove and InstallSMCS
  Code: 1393-010

  Removal Procedure1. Drain the coolant from the cooling system
  into asuitable container for storage or disposal until thecoolant
  is below the level of the water temperatureregulator housing. Refer
  to Operation andMaintenance Manual, Cooling System Coolant-
  Change.

• 34 RENR9716-02Disassembly and Assembly Section

  g01219336Illustration 83

  2. Disconnect hose assembly (1) and elbow (3).

  3. Remove bolts (2) and bolts (4). Remove watertemperature
  regulator housing (5).

  g01223744Illustration 84

  4. Remove O-ring seals (6) and water temperatureregulators (7)
  from water temperature regulatorhousing (5).

  5. If necessary, remove the lip seals.

  Installation ProcedureTable 25

  Required Tools

  ToolPart

  Number Part Description Qty

  A 221-8647 Seal Installer Gp 1

  NOTICEKeep all parts clean from contaminants.

  Contaminants may cause rapid wear and shortenedcomponent
  life.

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

  g01223744Illustration 85

  2. Install water temperature regulators (7) and O-ringseals (6)
  in water temperature regulator housing(5).

  g01219336Illustration 86

  3. Position water temperature regulator housing (5)on the
  engine. Install bolts (4) and bolts (2).

  4. Connect elbow (3) and hose assembly (1).

  5. Fill the cooling system. Refer to Operation andMaintenance
  Manual, Cooling System Coolant- Change.

• RENR9716-02 35Disassembly and Assembly Section

  i02576096

  Cooling System Package(Radiator, Aftercooler, FuelCooler) —
  RemoveSMCS Code: 1063-011; 1353-011; 1712-011

  Removal ProcedureTable 26

  Required Tools

  Tool PartNumber Part Description Qty

  A 189-0410 Shackle As 2

  Start By:

  a. Remove the fan. Refer to Disassembly andAssembly, Fan —
  Remove and Install.

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

  Refer to Special Publication, NENG2500, CaterpillarTools and
  Shop Products Guide for tools and suppliessuitable to collect and
  contain fluids on Caterpillarproducts.

  Dispose of all fluids according to local regulations
  andmandates.

  1. Drain the coolant from the cooling system intoa suitable
  container for storage or for disposal.Refer to Operation and
  Maintenance Manual,Cooling System Coolant (ELC) — Change.

  g01290908Illustration 87

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

  g01290915Illustration 88

  3. Disconnect bottom aftercooler tube (2).

  g01290916Illustration 89

  4. Disconnect top radiator hose (3).

  g01290917Illustration 90

  5. Disconnect top aftercooler tube (4).

• 36 RENR9716-02Disassembly and Assembly Section

  g01290930Illustration 91

  6. Disconnect bottom radiator hose (5). Disconnectbottom
  aftercooler tube (6).

  g01290934Illustration 92

  7. Disconnect hose assembly (8) from fuel cooler (7).

  g01290939Illustration 93

  8. Disconnect hose assembly (9) from fuel cooler (7).

  g01290940Illustration 94

  9. Attach Tooling (A) and a suitable lifting deviceonto cooling
  package (10). The weight of coolingpackage (10) is approximately
  544 kg (1200 lb).

  g01290941Illustration 95

  10.Remove bolts (11). Repeat for the opposite side.Remove
  cooling package (10).

  i02576308

  Cooling System Package(Radiator, Aftercooler, FuelCooler) —
  InstallSMCS Code: 1063-012; 1353-012; 1712-012

  Installation ProcedureTable 27

  Required Tools

  Tool Part Number Part Description Qty

  A 189-0410 Shackle As 2

• RENR9716-02 37Disassembly and Assembly Section

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

  Refer to Special Publication, NENG2500, CaterpillarTools and
  Shop Products Guide for tools and suppliessuitable to collect and
  contain fluids on Caterpillarproducts.

  Dispose of all fluids according to local regulations
  andmandates.

  g01290940Illustration 96

  1. Attach Tooling (A) and a suitable lifting deviceonto cooling
  package (10). The weight of coolingpackage (10) is approximately
  544 kg (1200 lb).

  g01290941Illustration 97

  2. Install cooling package (10). Install bolts (11).Repeat for
  the opposite side.

  g01290939Illustration 98

  3. Connect hose assembly (9) onto fuel cooler (7).

  g01290934Illustration 99

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

  g01290930Illustration 100

  5. Connect bottom aftercooler tube (6). Connectbottom radiator
  hose (5).

• 38 RENR9716-02Disassembly and Assembly Section

  g01290917Illustration 101

  6. Connect top aftercooler tube (4).

  g01290916Illustration 102

  7. Connect top radiator hose (3).

  g01290915Illustration 103

  8. Connect bottom aftercooler tube (2).

  g01290908Illustration 104

  9. Install clamp (1). Repeat for the opposite side.

  10. Fill the cooling system with coolant. Refer toOperation and
  Maintenance Manual, CoolingSystem Coolant (ELC) — Change.

  End By:

  a. Install the fan. Refer to Disassembly andAssembly, Fan —
  Remove and Install.

  i02584900

  Aftercooler — RemoveSMCS Code: 1063-011

  Removal ProcedureTable 28

  Required Tools

  Tool Part Number Part Description Qty

  A 189-0410 Shackle As 2

  Start By:

  a. Remove the fan. Refer to Disassembly andAssembly, Fan —
  Remove and Install.

• RENR9716-02 39Disassembly and Assembly Section

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

  Refer to Special Publication, NENG2500, CaterpillarTools and
  Shop Products Guide for tools and suppliessuitable to collect and
  contain fluids on Caterpillarproducts.

  Dispose of all fluids according to local regulations
  andmandates.

  1. Drain the coolant from the cooling system intoa suitable
  container for storage or for disposal.Refer to Operation and
  Maintenance Manual,Cooling System Coolant (ELC) — Change.

  g01290908Illustration 105

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

  g01290915Illustration 106

  3. Disconnect bottom aftercooler tube (2).

  g01290916Illustration 107

  4. Disconnect top radiator hose (3).

  g01290917Illustration 108

  5. Disconnect top aftercooler tube (4).

  g01290930Illustration 109

  6. Disconnect bottom radiator hose (5). Disconnectbottom
  aftercooler tube (6).

• 40 RENR9716-02Disassembly and Assembly Section

  g01290934Illustration 110

  7. Disconnect hose assembly (8) from fuel cooler (7).

  g01290939Illustration 111

  8. Disconnect hose assembly (9) from fuel cooler (7).

  g01294215Illustration 112

  9. Remove bolts (10). Remove bolt (11).

  g01294232Illustration 113

  10.Attach Tooling (A) and a suitable lifting deviceonto
  aftercooler (12). The weight of aftercooler(12) is approximately
  227 kg (500 lb).

  g01294234Illustration 114

  11.Remove bolt (13). Remove bolts (14) and bolts(15) from
  aftercooler (12).

  12.Repeat Step 9 through Step 11 for the oppositeside.

  13.Remove aftercooler (12).

  i02585968

  Aftercooler — InstallSMCS Code: 1063-012

  Installation ProcedureTable 29

  Required Tools

  Tool Part Number PartDescription Qty

  A 189-0410 Shackle As 2

• RENR9716-02 41Disassembly and Assembly Section

  g01294232Illustration 115

  1. Attach Tooling (A) and a suitable lifting device
  ontoaftercooler (12). The weight of aftercooler (12)
  isapproximately 227 kg (500 lb). Install aftercooler(12).

  g01294234Illustration 116

  2. Install bolts (14) and bolts (15) into aftercooler(12).
  Install bolt (13).

  g01294215Illustration 117

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

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

  g01290939Illustration 118

  5. Connect hose assembly (9) onto fuel cooler (7).

  g01290934Illustration 119

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

  g01290930Illustration 120

  7. Connect bottom aftercooler tube (6). Connectbottom radiator
  hose (5).

• 42 RENR9716-02Disassembly and Assembly Section

  g01290917Illustration 121

  8. Connect top aftercooler tube (4).

  g01290916Illustration 122

  9. Connect top radiator hose (3).

  g01290915Illustration 123

  10.Connect bottom aftercooler tube (2).

  g01290908Illustration 124

  11. Install clamp (1). Repeat for the opposite side.

  12. Fill the cooling system with coolant. Refer toOperation and
  Maintenance Manual, CoolingSystem Coolant (ELC) — Change.

  End By:

  a. Install the fan. Refer to Disassembly andAssembly, Fan —
  Remove and Install.

  i02581106

  Radiator Core — RemoveSMCS Code: 1353-011; 1353-011-KO

  Removal ProcedureTable 30

  Required Tools

  Tool PartNumber Part Description Qty

  A 138-7575 Link Bracket 2

  Start By:

  a. Remove the aftercooler. Refer to Disassemblyand Assembly,
  Aftercooler — Remove.

• RENR9716-02 43Disassembly and Assembly Section

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

  Refer to Special Publication, NENG2500, CaterpillarTools and
  Shop Products Guide for tools and suppliessuitable to collect and
  contain fluids on Caterpillarproducts.

  Dispose of all fluids according to local regulations
  andmandates.

  g01292911Illustration 125

  1. Remove the upper and the lower radiator guards(1).

  g01292912Illustration 126

  2. Attach Tooling (A) and a suitable lifting device ontoradiator
  top tank (2). The weight of the radiator isapproximately 227 kg
  (500 lb).

  g01294577Illustration 127

  3. Remove the upper and the lower braces (3).

  g01294578Illustration 128

  4. Remove bolts (4) and remove bolts (5).

  g01294579Illustration 129

  5. Remove bolts (6).

• 44 RENR9716-02Disassembly and Assembly Section

  g01294580Illustration 130

  6. Remove bolts (7). Remove bolts (8). Removesupport (9).

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

  g01294602Illustration 131

  8. Remove bolts (11). Repeat for the opposite side.Remove
  radiator (10).

  i02585957

  Radiator Core — InstallSMCS Code: 1353-012-KO; 1353-012

  Installation ProcedureTable 31

  Required Tools

  Tool PartNumber Part Description Qty

  A 138-7575 Link Bracket 2

  g01292912Illustration 132

  1. Attach Tooling (A) and a suitable lifting device ontoradiator
  top tank (2). The weight of the radiator isapproximately 227 kg
  (500 lb).

  g01294602Illustration 133

  2. Install radiator (10). Install bolts (11). Repeat forthe
  opposite side.

  g01294580Illustration 134

  3. Install support (9). Install bolts (8). Install bolts
  (7).

• RENR9716-02 45Disassembly and Assembly Section

  g01294579Illustration 135

  4. Install bolts (6).

  g01294578Illustration 136

  5. Install bolts (4) and bolts (5).

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

  g01294577Illustration 137

  7. Install the upper and the lower braces (3).

  g01292911Illustration 138

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

  End By:

  a. Install the aftercooler. Refer to Disassembly andAssembly,
  Aftercooler — Install.

  i02444868

  Engine Support (Front) -Remove and InstallSMCS Code:
  1154-010-FR

  Removal Procedure (Type 1)Start By:

  a. Remove the vibration damper and the pulley.Refer to
  Disassembly and Assembly, VibrationDamper and Pulley — Remove and
  Install.

  1. Support the front of the engine.

  g01221659Illustration 139

  2. Remove bolts (1).

  3. Remove engine support (2).

• 46 RENR9716-02Disassembly and Assembly Section

  Installation Procedure (Type 1)

  g01221659Illustration 140

  1. Position engine support (2) on the engine.

  2. Install bolts (1).

  End By:

  a. Install the vibration damper and the pulley. Referto
  Disassembly and Assembly, Vibration Damperand Pulley — Remove and
  Install.

  Removal Procedure (Type 2)Start By:

  a. Remove the vibration damper and the pulley.Refer to
  Disassembly and Assembly, VibrationDamper and Pulley — Remove and
  Install.

  1. Support the front of the engine.

  g01221663Illustration 141

  2. Remove bolts (3).

  3. Use a suitable lifting device to remove enginesupport (4).
  The weight of engine support (4) isapproximately 35 kg (77 lb).

  Installation Procedure (Type 2)

  g01221663Illustration 142

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

  2. Install bolts (3).

  End By:

  a. Install the vibration damper and the pulley. Referto
  Disassembly and Assembly, Vibration Damperand Pulley — Remove and
  Install.

  i02440962

  Gear Group (Rear) — RemoveSMCS Code: 1206-011; 1212-011

  Removal ProcedureTable 32

  Required Tools

  ToolPart

  Number Part Description Qty

  A 1P-0510 Driver Group 1

  Start By:

  a. Remove the flywheel housing. Refer toDisassembly and
  Assembly, Flywheel Housing- Remove and Install.

• RENR9716-02 47Disassembly and Assembly Section

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

  Refer to Special Publication, NENG2500, CaterpillarDealer
  Service Tool Catalog for tools and suppliessuitable to collect and
  contain fluids on Caterpillarproducts.

  Dispose of all fluids according to local regulations
  andmandates.

  NOTICEKeep all parts clean from contaminants.

  Contaminants may cause rapid wear and shortenedcomponent
  life.

  g01219485Illustration 143

  1. Remove bolts (10), thrust plate (11), and gearassembly
  (9).

  2. Use Tooling (A) and a suitable press to removethe bearing
  from gear assembly (9).

  3. Remove bolts (8), gear assembly (6), and shaftassembly
  (7).

  4. Use Tooling (A) and a suitable press to removethe bearing
  from gear assembly (6).

  5. Remove bolts (2), gear assembly (1), and shaftassembly
  (3).

  6. Use Tooling (A) and a suitable press to removethe bearing
  from gear assembly (1).

  7. Remove gear assembly (12).

  8. Remove bolts (5) and gear assemblies (4).

  g01219500Illustration 144

  9. Remove bolts (16) and shaft assembly (17).

  10.Remove bolts (13), thrust plates (14), and adapterassemblies
  (15).

  11.Use bolt (13) in order to remove the sealingplates. Remove
  the O-ring seals.

• 48 RENR9716-02Disassembly and Assembly Section

  i02442469

  Gear Group (Rear) — InstallSMCS Code: 1206-012; 1212-012

  Installation ProcedureTable 33

  Required Tools

  ToolPart

  Number Part Description Qty

  A 1P-0510 Driver Group 1

  NOTICEKeep all parts clean from contaminants.

  Contaminants may cause rapid wear and shortenedcomponent
  life.

  Note: Apply clean engine oil to the bearings and theshaft
  assemblies prior to installation on the engine.

  g01219500Illustration 145

  1. Install the O-ring seals and the sealing plates onthe
  cylinder head.

  2. Install adapter assemblies (15), thrust plates (14),and bolts
  (13).

  3. Position shaft assembly (17) and install bolts (16).

  g01220275Illustration 146

  g01151468Illustration 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 alignthe dowels on gear
  assemblies (4) with the adapterassemblies.

  5. Position gear assemblies (4) and install bolts (5).

  6. Install gear assembly (12).

  7. Use Tooling (A) and a suitable press to install thebearing in
  gear assembly (1). Install the bearing toa depth of 2.6 0.5 mm
  (0.10 0.02 inch).

• RENR9716-02 49Disassembly and Assembly Section

  8. Install shaft assembly (3), gear assembly (1), andbolts
  (2).

  9. Use Tooling (A) and a suitable press to install thebearing in
  gear assembly (6). Install the bearing toa depth of 2.6 0.5 mm
  (0.10 0.02 inch).

  10. Install shaft assembly (7), gear assembly (6), andbolts
  (8).

  11.Use Tooling (A) and a suitable press to install thebearing in
  gear assembly (9). Install the bearing toa depth of 2.5 0.5 mm
  (0.10 0.02 inch).

  Note: Align the Timing Mark on gear assembly (9)with the Timing
  Mark on gear assembly (12).

  12. Install gear assembly (9), thrust plate (11), andbolts
  (10).

  13. Tighten the bolts on gear assemblies (4) to atorque of 240
  40 Nm (177 30 lb ft). Tightenthe bolts in the following sequence:
  1, 4, 2, 5, 3,6, 1, 4.

  End By:

  a. Install the flywheel housing. Refer to Disassemblyand
  Assembly, Flywheel Housing — Remove andInstall.

  i02752668

  Flywheel — Remove and InstallSMCS Code: 1156-010

  Removal ProcedureTable 34

  Required Tools

  ToolPart

  Number Part Description Qty

  A — Guide Stud5/8 — 18 UNF by 11 inch 2

  g01220437Illustration 148

  g01220438Illustration 149

  1. Remove two bolts (1). Install Tooling (A) in
  thecrankshaft.

  2. Remove remaining bolts (1). Slide flywheel (2)away from the
  engine on Tooling (A).

  3. Attach a suitable lifting device to flywheel (2). Theweight
  of flywheel (2) is approximately 130 kg(285 lb). Remove flywheel
  (2).

  4. If necessary, use a hammer and a punch in orderto remove ring
  gear (3) from flywheel (2).

  Installation ProcedureTable 35

  Required Tools

  ToolPart

  Number Part Description Qty

  A — Guide Stud5/8 — 18 UNF by 11 inch 2

  B 6V-4876 Lubricant —

  g01220438Illustration 150

• 50 RENR9716-02Disassembly and Assembly Section

  g01220437Illustration 151

  Note: Ring gear (3) must be installed with thechamfered side of
  the teeth upward. The chamferedside of the gear teeth will be
  facing toward the startingmotor when the flywheel is installed.

  1. Raise the temperature of ring gear (3). Install ringgear (3)
  on flywheel (2).

  2. Install Tooling (A) in the crankshaft.

  3. Attach a suitable lifting device to flywheel (2). Theweight
  of flywheel (2) is approximately 130 kg(285 lb). Position flywheel
  (2) on the crankshaft.

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

  5. Install bolts (1). Remove Tooling (A). Installremaining bolts
  (1).

  6. Tighten bolts (1) to a torque of 100 5 Nm(75 4 lb ft). Turn
  the bolts for an additional 180 5 degrees.

  7. Check the flywheel runout. Refer to Testing andAdjusting,
  Flywheel — Inspect.

  i02442878

  Crankshaft Rear Seal — RemoveSMCS Code: 1161-011

  Removal ProcedureTable 36

  Required Tools

  ToolPart

  Number Part Description Qty

  A 1U-7600 Slide Hammer Puller 1

  Start By:

  a. Remove the flywheel. Refer to Disassembly andAssembly,
  Flywheel — Remove and Install.

  NOTICEKeep all parts clean from contaminants.

  Contaminants may cause rapid wear and shortenedcomponent
  life.

  g01220531Illustration 152

  1. Use Tooling (A) or a punch and hammer in orderto puncture
  three or more holes in crankshaft rearseal (1).

  2. Use Tooling (A) to remove crankshaft rear seal (1)and
  crankshaft wear sleeve (2).

  i02442921

  Crankshaft Rear Seal — InstallSMCS Code: 1161-012

  Installation ProcedureTable 37

  Required Tools

  ToolPart

  Number Part Description Qty

  249-2937(1) Seal Locator As 1

  5P-7310(1) Bolt 3

  9S-8858(1) Nut (Seal Installer) 1

  6V-6143(1) Seal Installer 1

  5P-1733(2) Seal Locator As 1

  5P-7309(2) Bolt 3

  9S-8858(2) Nut (Seal Installer) 1

  B

  6V-6142(2) Seal Installer 1(1) Large crankshaft gear(2) Small
  crankshaft gear

• RENR9716-02 51Disassembly and Assembly Section

  NOTICEKeep all parts clean from contaminants.

  Contaminants may cause rapid wear and shortenedcomponent
  life.

  g01220558Illustration 153

  1. Clean the outside diameter of the crankshaft.

  Note: Install the crankshaft rear seal with the arrowthat shows
  the direction of crankshaft rotation towardthe 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 andAssembly,
  Flywheel — Remove and Install.

  i02752908

  Flywheel Housing — Removeand InstallSMCS Code: 1157-010

  Removal ProcedureTable 38

  Required Tools

  ToolPart

  Number Part Description Qty

  A 138-7574 Link Bracket 2

  B — Guide Stud1/2 — 13 NC by 7 inch 2

  Start By:

  a. Remove the crankshaft rear seal. Refer toDisassembly and
  Assembly, Crankshaft RearSeal — Remove.

  b. Remove the electric starting motor. Refer toDisassembly and
  Assembly, Electric StartingMotor — Remove and Install.

  NOTICEKeep all parts clean from contaminants.

  Contaminants may cause rapid wear and shortenedcomponent
  life.

  g01220951Illustration 154

  1. Disconnect hose assemblies (1) from flywheelhousing (2).

  2. Disconnect fuel filter base (5) from flywheelhousing (2).
  Reposition fuel filter base (5) and thehose assemblies.

  3. Remove two bolts (4) and install Tooling (B).

  4. Attach Tooling (A) and a suitable lifting deviceto flywheel
  housing (2). The weight of flywheelhousing (2) is approximately 110
  kg (245 lb).

  5. Remove remaining bolts (4), bolts (6), and bolts(3). Remove
  flywheel housing (2) and the gasketfrom the rear housing.

• 52 RENR9716-02Disassembly and Assembly Section

  Installation ProcedureTable 39

  Required Tools

  ToolPart

  Number Part Description Qty

  A 138-7574 Link Bracket 2

  B — Guide Stud1/2 — 13 NC by 7 inch 2

  NOTICEKeep all parts clean from contaminants.

  Contaminants may cause rapid wear and shortenedcomponent
  life.

  g01220951Illustration 155

  g01221009Illustration 156

  1. Install Tooling (B) in the cylinder block.

  2. Attach Tooling (A) and a suitable lifting deviceto flywheel
  housing (2). The weight of flywheelhousing (2) is approximately 110
  kg (245 lb).

  3. Position the gasket and flywheel housing (2) onthe rear
  housing. Install bolts (3), bolts (6), andbolts (4).

  4. Remove Tooling (B) and install remaining bolts (4).

  5. Tighten the bolts, as follows:

  a. In a numerical sequence, tighten Bolt 1 throughBolt 2 to a
  torque of 55 10 Nm (41 7 lb ft).

  b. In a numerical sequence, tighten Bolt 3through Bolt 10 to a
  torque of 135 20 Nm(100 15 lb ft).

  c. In a numerical sequence, tighten Bolt 11through Bolt 36 to a
  torque of 47 9 Nm(35 7 lb ft).

  6. Reposition fuel filter base (5) and the hoseassemblies.
  Connect fuel filter base (5) to flywheelhousing (2).

  7. Connect hose assemblies (1) to flywheel housing(2).

• RENR9716-02 53Disassembly and Assembly Section

  End By:

  a. Install the electric starting motor. Refer toDisassembly and
  Assembly, Electric StartingMotor — Remove and Install.

  b. Install the crankshaft rear seal. Refer toDisassembly and
  Assembly, Crankshaft RearSeal — Install.

  i02443805

  Vibration Damper and Pulley -Remove and InstallSMCS Code:
  1205-010

  Removal ProcedureTable 40

  Required Tools

  ToolPart

  Number Part Description Qty

  A — Guide Stud1/2 — 13 NC by 5 inch 2

  g01221066Illustration 157

  g01221078Illustration 158

  1. Remove V-belt (1) from the engine.

  2. Remove two bolts (2) and install Tooling (A).

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

  4. Slide vibration damper (4) along Tooling (A).

  5. Attach a suitable lifting device onto vibrationdamper (4).
  The weight of vibration damper (4)is approximately 34 kg (75 lb).
  Remove vibrationdamper (4) from the adapter.

  Installation ProcedureTable 41

  Required Tools

  ToolPart

  Number Part Description Qty

  A — Guide Stud1/2 — 13 NC by 5 inch 2

  g01221078Illustration 159

• 54 RENR9716-02Disassembly and Assembly Section

  g01221066Illustration 160

  1. Install Tooling (A) in the adapter.

  2. Attach a suitable lifting device onto vibrationdamper (4).
  The weight of vibration damper (4)is approximately 34 kg (75 lb).
  Position vibrationdamper (4) on the adapter.

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

  4. Remove Tooling (A). Install remaining bolts (2).Tighten bolts
  (2) to a torque of 135 20 Nm(100 15 lb ft).

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

  i02444403

  Crankshaft Front Seal -RemoveSMCS Code: 1160-011

  Removal ProcedureTable 42

  Required Tools

  ToolPart

  Number Part Description Qty

  A 1U-7600 Slide Hammer Puller 1

  Start By:

  a. Remove the crankshaft vibration damper andpulley. Refer to
  Disassembly and Assembly,Vibration Damper and Pulley — Remove
  andInstall.

  NOTICEKeep all parts clean from contaminants.

  Contaminants may cause rapid wear and shortenedcomponent
  life.

  g01221272Illustration 161

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

  g01221276Illustration 162

  2. Use Tooling (A) or a punch and hammer in orderto puncture
  three or more holes in crankshaft frontseal (4).

  3. Use Tooling (A) to remove crankshaft front seal(4).

  4. If necessary, use Tooling (A) or a punch andhammer in order
  to puncture three or more holesin crankshaft wear sleeve (3). Use
  Tooling (A) toremove crankshaft wear sleeve (3).

• RENR9716-02 55Disassembly and Assembly Section

  i02444556

  Crankshaft Front Seal — InstallSMCS Code: 1160-012

  Installation ProcedureTable 43

  Required Tools

  ToolPart

  Number Part Description Qty

  5P-1733 Seal Locator 1

  5P-1737 Bolt 3

  9S-8858 Nut (Seal Installer) 1B

  6V-6142 Seal Installer 1

  NOTICEKeep all parts clean from contaminants.

  Contaminants may cause rapid wear and shortenedcomponent
  life.

  1. Clean the outside diameter of the crankshaft.

  g01221389Illustration 163

  2. Use Tooling (B) to install crankshaft front seal (4)and
  crankshaft wear sleeve (3) as a unit.

  Note: Install the crankshaft front seal with the arrowthat shows
  the direction of crankshaft rotation towardthe front of the
  engine.

  g01221272Illustration 164

  3. Install adapter (2) and bolts (1).

  End By:

  a. Install the crankshaft vibration damper and pulley.Refer to
  Disassembly and Assembly, VibrationDamper and Pulley — Remove and
  Install.

  i02292422

  Gear Group (Front) — RemoveSMCS Code: 1206-011

  Removal ProcedureStart By:

  a. Remove the front housing. Refer to Disassemblyand Assembly,
  Housing (Front) — Remove.

  NOTICEKeep all parts clean from contaminants.

  Contaminants may cause rapid wear and shortenedcomponent
  life.

• 56 RENR9716-02Disassembly and Assembly Section

  g01147593Illustration 165

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

  2. Remove bolts (3) and plate (2). Remove gearassembly (1).

  g01147620Illustration 166

  3. Remove bolts (6) and shaft (7).

  i02691256

  Gear Group (Front) — InstallSMCS Code: 1206-012

  Installation Procedure

  NOTICEKeep all parts clean from contaminants.

  Contaminants may cause rapid wear and shortenedcomponent
  life.

  g01147620Illustration 167

  1. Apply clean engine oil to shaft (7), the bearingbore, and the
  thrust faces prior to installation.Install shaft (7) and bolts (6).
  Tighten bolts (6) to atorque of 55 10 Nm (41 7 lb ft).

  g01147593Illustration 168

  2. Position gear assembly (1) on the shaft. Installplate (2) and
  bolts (3).

  3. Install gear assembly (4) and bolts (5).

  End By:

  a. Install the front housing. Refer to Disassembly andAssembly,
  Housing (Front) — Install.

• RENR9716-02 57Disassembly and Assembly Section

  i02445219

  Housing (Front) — RemoveSMCS Code: 1151-011

  Removal ProcedureStart By:

  a. Remove the water temperature regulator housing.Refer to
  Disassembly and Assembly, WaterTemperature Regulator Housing —
  Remove andInstall.

  b. Remove the water pump. Refer to Disassemblyand Assembly,
  Water Pump — Remove.

  c. Remove the crankshaft front seal. Refer toDisassembly and
  Assembly, Crankshaft FrontSeal — Remove.

  d. Remove the front engine support. Refer toDisassembly and
  Assembly, Engine Support(Front) — Remove and Install.

  e. Remove the alternator. Refer to Disassembly andAssembly,
  Alternator — Remove and Install.

  f. Remove the crankshaft position sensor. Refer toDisassembly
  and Assembly, Crankshaft PositionSensor — Remove and Install.

  g. Remove the camshaft position sensor. Refer toDisassembly and
  Assembly, Camshaft PositionSensor — Remove and Install.

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

  Refer to Special Publication, NENG2500, CaterpillarDealer
  Service Tool Catalog for tools and suppliessuitable to collect and
  contain fluids on Caterpillarproducts

Catalog excerpts