SENR6419-03

September 1999

Disassembly and
Assembly
G3500 Engines
4WD1-Up (Engine)
5JD1-Up (Engine)
8LD1-Up (Engine)
9TG1-Up (Engine)
2TJ1-Up (Engine)
7NJ1-Up (Engine)
4EK1-Up (Engine)
6JW1-Up (Engine)
8PW1-Up (Engine)
9AW1-Up (Engine)
 i01097883

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. For a list of the most
current publication form numbers available, see the Service Manual Contents Microfiche, REG1139F.

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.
 3
Table of Contents

Table of Contents Water Pump - Install ............................................. 80

Thermostatic Valve - Remove ............................... 81
Thermostatic Valve - Disassemble ........................ 81
Thermostatic Valve - Assemble ............................ 82
Disassembly and Assembly Section Thermostatic Valve - Install ................................... 82
Auxiliary Water Pump - Remove .......................... 83
Air Starting Motor - Remove ................................... 5
Auxiliary Water Pump - Disassemble ................... 84
Air Starting Motor - Disassemble ........................... 6
Auxiliary Water Pump - Assemble ....................... 86
Air Starting Motor - Assemble .............................. 11
Auxiliary Water Pump - Install .............................. 89
Air Starting Motor - Install ..................................... 18
Engine Oil Cooler - Remove ................................. 90
Electric Starting Motor - Remove and Install ....... 19
Engine Oil Cooler - Disassemble ......................... 91
Service Meter - Remove and Install ..................... 20
Engine Oil Cooler - Assemble .............................. 93
Gas Pressure Regulator Solenoid - Remove and
Engine Oil Cooler - Install ..................................... 94
Install .................................................................. 21
Engine Oil Pump - Remove .................................. 95
Gas Pressure Regulator - Remove ....................... 22
Engine Oil Pump - Disassemble ........................... 96
Gas Pressure Regulator - Remove (High
Engine Oil Pump - Assemble ................................ 98
Pressure) ............................................................ 22
Engine Oil Pump - Install ...................................... 99
Gas Pressure Regulator - Remove (Low
Engine Oil Filter Housing - Remove .................... 100
Pressure) ............................................................ 23
Engine Oil Filter Housing - Disassemble ........... 101
Gas Pressure Regulator - Disassemble .............. 23
Engine Oil Filter Housing - Assemble ................ 104
Gas Pressure Regulator - Assemble ................... 24
Engine Oil Filter Housing - Install ....................... 106
Gas Pressure Regulator - Install ........................... 26
Engine Oil and Water Pump Drive - Remove ...... 107
Gas Pressure Regulator - Install (Low Pressure) .. 26
Engine Oil and Water Pump Drive -
Gas Pressure Regulator - Install (High Pressure) .. 27
Disassemble ..................................................... 107
Fuel Control Actuator - Remove and Install .......... 27
Engine Oil and Water Pump Drive - Assemble ... 108
Fuel Control Actuator - Remove and Install .......... 29
Engine Oil and Water Pump Drive - Install ......... 109
Fuel Control Valve - Remove and Install ............... 30
Engine Oil Pan - Remove .................................. 110
Fuel Control Valve - Remove and Install ............... 31
Engine Oil Pan - Disassemble ............................ 111
Electronic Sensor - Remove and Install ................ 32
Engine Oil Pan - Assemble ................................. 112
Carburetor - Remove (Low Pressure) ................... 33
Engine Oil Pan - Install ...................................... 113
Carburetor - Remove (High Pressure) .................. 34
Crankcase Breather - Remove and Install ......... 114
Carburetor - Remove (Low Pressure) ................... 35
Valve Cover and Spark Plug - Remove and
Carburetor - Disassemble (High Pressure) ........... 35
Install ................................................................. 114
Carburetor - Disassemble (High Pressure) ........... 36
Rocker Shaft and Push Rod - Remove ............... 116
Carburetor - Assemble (High Pressure) ................ 37
Rocker Shaft - Disassemble .............................. 117
Carburetor - Assemble (High Pressure) ................ 38
Rocker Shaft - Assemble ................................... 118
Carburetor - Install (Low Pressure) ....................... 39
Rocker Shaft and Push Rod - Install ................... 119
Carburetor - Install (Low Pressure) ....................... 40
Cylinder Head - Remove ..................................... 120
Carburetor - Install (High Pressure) ...................... 40
Cylinder Head - Disassemble ............................ 121
Air Cleaner - Remove and Install .......................... 41
Cylinder Head - Assemble ................................. 124
Turbocharger - Remove ........................................ 41
Cylinder Head - Install ........................................ 127
Turbocharger - Remove ........................................ 43
Spacer Plate - Remove and Install ..................... 128
Turbocharger - Disassemble ................................ 44
Accessory Drive (Front) - Remove ...................... 131
Turbocharger - Assemble ..................................... 47
Accessory Drive (Front) - Disassemble .............. 131
Turbocharger - Install ............................................ 51
Accessory Drive (Front) - Assemble ................... 132
Turbocharger - Install ............................................ 52
Accessory Drive (Front) - Install .......................... 134
Aftercooler - Remove and Install .......................... 53
Drive Housing (Front) - Remove and Install ........ 134
Aftercooler - Remove and Install .......................... 58
Vibration Damper - Remove and Install ............. 138
Air Inlet Manifold - Remove and Install ................ 59
Crankshaft Front Seal and Wear Sleeve - Remove
Exhaust Elbow - Remove and Install ................... 61
........................................................................... 139
Exhaust Elbow - Remove and Install ................... 62
Crankshaft Front Seal and Wear Sleeve - Install
Exhaust Bypass Valve - Remove and Install ....... 64
........................................................................... 140
Exhaust Manifold - Remove (Dry) ......................... 65
Flywheel - Remove and Install ........................... 142
Exhaust Manifold - Remove (Water Cooled) ......... 66
Crankshaft Rear Seal and Wear Sleeve - Remove
Exhaust Manifold - Install (Water Cooled) ............ 68
........................................................................... 143
Exhaust Manifold - Install (Dry) ............................. 69
Crankshaft Rear Seal and Wear Sleeve - Install
Water Temperature Regulators - Remove ............ 71
........................................................................... 144
Water Temperature Regulators - Install ................ 73
Flywheel Housing - Remove ............................... 146
Water Pump - Remove ......................................... 75
Flywheel Housing - Install ................................... 148
Water Pump - Disassemble ................................. 76
Engine Oil Sequence Valves - Remove and Install
Water Pump - Assemble ...................................... 78
........................................................................... 150
4
Table of Contents

Gear Group (Rear) - Remove ............................. 152

Gear Group (Rear) - Install ................................. 154
Piston Cooling Jets - Remove and Install ........... 155
Bearing Clearance - Check ................................. 156
Connecting Rod Bearings - Remove and Install
........................................................................... 157
Crankshaft Main Bearings - Remove .................. 159
Crankshaft Main Bearings - Install ...................... 161
Piston and Connecting Rods - Remove ............. 163
Piston and Connecting Rods - Install ................. 165
Cylinder Liner - Remove ..................................... 166
Cylinder Liner - Install ......................................... 167
Camshaft - Remove ............................................ 169
Camshaft - Install ................................................ 172
Camshaft Bearings - Remove ............................. 176
Camshaft Bearings - Install ................................. 177
Crankshaft - Remove .......................................... 178
Crankshaft - Install .............................................. 180

Index Section
Index ................................................................... 183
 5
Disassembly and Assembly Section

Disassembly and Assembly

Section
i01130023

Air Starting Motor - Remove

SMCS Code: 1451-011

Removal Procedure
NOTICE
Keep all parts clean from contaminants. g00597643
Illustration 2

Contaminants may cause rapid wear and shortened

5. Disconnect hose (5).
component life.
6. Attach a suitable hoist to the air starting
Note: Several different air starting motors are motor. The weight of the air starting motor is
available for use. The starting motors can have approximately 48 kg (106 lb).
different configurations for the air lines. Examples
of removing two different air starting motors are 7. Remove three bolts (7). Remove air starting
described below. motor (6). Remove the gasket from the joint
between the cover of the air starting motor and
Removal of an Air Starting Motor Without the flywheel housing.
the Air Lines Attached
Removal of an Air Starting Motor With
1. Turn OFF the supply of pressurized air. Purge the Air Lines Attached
the pressurized air from the air lines and the
starting motor. 1. Turn OFF the supply of pressurized air. Purge
the pressurized air from the air lines and the
starting motor.

g00615939
Illustration 3

2. Disconnect electrical connector (1).

g00597642 3. Disconnect the air supply line from elbow (2).

Illustration 1

2. Disconnect hoses (1).

3. Remove four bolts (2).

4. Remove U-bolt (3) and air lines (4).

6
Disassembly and Assembly Section

Note: Several different air starting motors are

available for use. An example of disassembling a
typical air starting motor is described below.

Note: Before you disassemble the starting motor,

obtain a complete set of these parts: gaskets,
O-ring seals, seals, and vanes.

g00615940
Illustration 4

4. Attach a suitable hoist to the air starting

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

5. Remove three bolts (3). Remove air starting

motor (4). Remove the gasket from the joint Illustration 5
g00597693
between the cover of the air starting motor and
the flywheel housing. 1. Remove elbow (1) and bracket (2) from motor
housing (3).
i01130369

Air Starting Motor -

Disassemble
SMCS Code: 1451-015

Disassembly Procedure
Table 1
Required Tools
Tool Part Part Description Qty
Number
g00597694
A 1P-1854 1 Illustration 6
Retaining Ring Pliers
B - Plate 1 2. To ensure correct assembly, mark the position of
50.8 mm (2 inches) wide motor housing (3) in relation to gear case (6).
Remove bolts (4). Remove gear case (6) and
102 mm (4 inches) long drive housing (5) as a unit.
6 mm (0.25 inches) thick
C 1p-1857 Retaining Ring Pliers 1

Start By:

a. Remove the air starting motor.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.
 7
Disassembly and Assembly Section

5. Remove O-ring seal (13) from drive housing (5).

g00597696
Illustration 7
g00597701
Illustration 10
3. Use Tool (A) to remove ring (8) from drive gear
(7).

The drive shaft, the piston, and the drive gear are
under a spring force. Slowly release the spring
force before you remove these components.

6. Place Tool (B) between drive gear (7) and piston

(14). Use a press to compress the return spring.
Remove the ring that holds the drive shaft and
the piston in drive housing (5).

g00597697
Illustration 8

Note: Bolt (9) has right hand threads.

4. Remove bolt (9) and washer (10). Remove pinion

(11), the sleeve, and the spring.

To ensure correct assembly, mark the position

of drive housing (5) in relation to gear case (6).
Remove bolts (12) and drive housing (5) from
gear case (6). Illustration 11 g00597709

7. Slowly release the press in order to remove the

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

g00597698
Illustration 9
8
Disassembly and Assembly Section

g00597711 g00597714
Illustration 12 Illustration 15

8. Loosen the bolt for the drive gear with a 5/16 11. Remove ring (20) from piston (14). Remove the
inch hex wrench until the bolt moves freely. piston from drive shaft (17).
Remove drive shaft (17) and piston (14) from
drive gear (7) as a unit.

g00597715
Illustration 16

g00597712
Illustration 13 12. Remove O-ring seal (22) and seal (21) from
piston (14).
9. Remove bulkhead (18) from piston (14).

g00597716
Illustration 17
g00597713
Illustration 14
13. Remove the following parts from drive shaft (17):
10. Remove O-ring seals (19) from bulkhead (18). ring (31), cup (30), spring (29), driven clutch
jaw (28), driving clutch jaw (27), bearing (26),
washer (25), lockwasher (24), and bolt (23).
 9
Disassembly and Assembly Section

g00597717 g00597723
Illustration 18 Illustration 21

Note: A new ring is always required for assembly 17. Remove seal (38) from drive housing (5).
when ring (32) is removed.

14. Remove ring (32) and bearing (33) from drive

shaft (17).

g00597724
Illustration 22

18. To ensure correct assembly, mark the position

of cover (39) in relation to motor housing (3).
g00597719
Illustration 19 Remove cover (39) and remove the O-ring seal
from motor housing (3).
15. Use Tool (C) to remove ring (35). Remove
bearing (34) from gear case (6).

g00597725
Illustration 23

g00597722
Illustration 20 19. Remove bolt (41) and rotor pinion (40) from the
rotor in the motor housing.
16. Remove spring seat (36) and bearing (37) from
drive housing (5).
10
Disassembly and Assembly Section

g00597726 g00597729
Illustration 24 Illustration 27

20. Loosen bolt (43) and remove nut (42). Remove 23. Remove rotor (48) from motor housing (3).
bearing (44) from rear end plate (45).

g00597730
Illustration 28
g00597727
Illustration 25
24. Use a press to remove bearing (49) and front
21. Remove O-ring seal (46) and rear end plate (45). end plate (50) from rotor (48) as a unit.

g00597728 g00597731
Illustration 26 Illustration 29

22. Remove vanes (47) from rotor (48). 25. Remove bearing (49) from front end plate (50).
 11
Disassembly and Assembly Section

i01130984

Air Starting Motor - Assemble

SMCS Code: 1451-016

Assembly Procedure
Table 2
Required Tools
Tool Part Part Description Qty
Number
A 1P-1854 Retaining Ring Pliers 1
g00597732
Illustration 30 B - Plate 2

26. Remove washers (51) from front end plate (50). 51 mm (2 inches) wide
102 mm (4 inches) long
6 mm (0.25 inch) thick
C 1p-1857 Retaining Ring Pliers 1
D - Tube 1
57 mm (2.25 inch)
diameter
6 mm (0.25 inch) thick
wall
203 mm (8 inches) long
E 1P-0510 Driver Group 1

g00597734
Illustration 31
NOTICE
Keep all parts clean from contaminants.
27. Remove O-ring seals (52) from rotor cylinder
(53). Contaminants may cause rapid wear and shortened
component life.

Note: Several different air starting motors are

available for use. An example of assembling a
typical air starting motor is provided below.

Note: Thoroughly clean all of the parts. Use a

2S-3230 Grease Cartridge in order to apply grease
to all of the bearings and to the drive assembly.
Before assembly, coat all of the other parts with an
SAE 10 grade of oil.

g00597735
Illustration 32

28. Remove rotor cylinder (53) from motor housing

(3). Remove the two O-ring seals from the rotor
cylinder.
12
Disassembly and Assembly Section

g00598178 g00598222
Illustration 33 Illustration 36

1. Install O-ring seals (54) on rotor cylinder (53). 4. Install O-ring seal (46) over the shaft of the rotor.
Install the rotor cylinder in motor housing (3).
Orient pin (55) of the rotor cylinder with slot (56)
in the motor housing.

g00598197
Illustration 37

5. Install bearing (44) over the shaft of the rotor.

g00598181
Illustration 34 The bearing will fit into the rear end plate.

2. Install O-ring seal (52) onto rotor cylinder (53).

g00598200
Illustration 38

g00598221
Illustration 35 6. Install rotor clamp nut (42) on the shaft of the
rotor. Orient the shoulder of the nut toward the
3. Install rear end plate (45) on the shaft of rotor bearing.
(48).
 13
Disassembly and Assembly Section

g00598201 g00598223
Illustration 39 Illustration 42

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

g00598420
Illustration 43

11. Install washers (51) over the shaft of the rotor

g00598207
Illustration 40 onto the front end plate.

8. Install rotor (48) into motor housing (3). Align pin

(57) into the slot of the rear end plate.

g00598225
Illustration 44

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

g00598208
Illustration 41

9. Install vanes (47) into the rotor.

14
Disassembly and Assembly Section

g00598445 g00598232
Illustration 45 Illustration 48

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

g00598227 g00598234
Illustration 46 Illustration 49

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

g00598230 g00598241
Illustration 47 Illustration 50

15. Install O-ring seal (60) onto the rotor bearing 18. Install these parts into drive shaft (17): bolt
that is on the rear end plate. Install cover (39) (23), lockwasher (24), washer (25), bearing (26),
onto motor housing (3). driving clutch jaw (27), driven clutch jaw (28),
spring (29), and cup (30). Install ring (31).
 15
Disassembly and Assembly Section

g00598242 g00598261
Illustration 51 Illustration 54

19. Use Tool (E) in order to install the seal into piston 22. Install bulkhead (18) onto piston (14).
(14). Ensure that the lip of the seal is oriented
toward the outside of the piston. Install O-ring
seal (22).

g00598263
Illustration 55

23. Install drive gear (7) onto drive shaft (17). Use
g00598244
Illustration 52 an Allen wrench in order to tighten the bolt of the
drive gear to 77 N·m (57 lb ft).
20. Install piston (14) onto the drive shaft (17). Install
ring (20) onto the piston.

g00598264
Illustration 56

g00598246
Illustration 53 24. Use Tool (E) in order to install the seal into drive
housing (5). Ensure that the lip of the seal is
21. Install O-ring seals (19) onto bulkhead (18). oriented toward the outside of the housing.
16
Disassembly and Assembly Section

g00598267 g00598270
Illustration 57 Illustration 60

25. Install bearing (37) into the drive housing. 28. Install the drive gear, the piston, and the drive
shaft onto the return spring as a unit.

Install ring (15) over the piston. Place Tool (B)

between the drive gear and the piston. Use a
press in order to compress the return spring.
Install ring (15) into the groove of the drive
housing. Slowly release the press. Remove Tool
(B).

g00598268
Illustration 58

26. Install spring seat (36) into the drive housing.

g00598272
Illustration 61

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

g00598269
Illustration 59

27. Install return spring (16) onto the spring seat

inside the drive housing.
 17
Disassembly and Assembly Section

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

pinion spring (62), spring sleeve (61), drive
pinion (11), bolt (9), and the washer. Tighten the
bolt to 110 N·m (80 lb ft).

g00598274
Illustration 62

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

sure that the shaft on the end of the drive gear is
correctly engaged with the bearing in the gear Illustration 65 g00598278
case. Tighten the bolts to a torque of 36 N·m
(27 lb ft). 33. Install gear case (6) and drive housing (5) onto
cover (3) as a unit. Tighten bolts (4) evenly to a
torque of 80 N·m (60 lb ft).

g00598276
Illustration 63

31. Use Tool (A) to install ring (8). Illustration 66 g00597693

34. Install the gasket, elbow (1), and bracket (2) on

motor housing (3).

Verify the Operation of the Air Starting

Motor
Use the following procedure to verify that the air
starting motor is operating correctly:

1. Turn the drive pinion by hand in the direction of

the rotation of the starting motor. The drive clutch
must operate smoothly with a clicking sound.
g00598277 2. Turn the drive pinion in the opposite direction of
Illustration 64
the rotation of the starting motor. The drive pinion
Note: Bolt (9) has left hand threads. must turn by hand.
18
Disassembly and Assembly Section

3. Apply 345 kPa (50 psi) of air pressure in the inlet Installation of an Air Starting Motor
of the drive housing. The drive pinion must move Without the Air Lines Attached
away from the drive housing and air must come
out of the outlet of the drive housing.

4. Plug the outlet of the drive housing. Apply

1034 kPa (150 psi) in the inlet of the drive
housing. Ensure that no air is leaking. Measure
the dimension from the face of the drive
pinion to the mounting face of the drive
housing. The dimension must be 73 ± 2 mm
(2.874 ± 0.08 inch). Remove the air pressure.
Measure the dimension again. The dimension
must be 44.5 ± 2 mm (1.75 ± 0.08 inch).

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

of the drive housing. The starting motor must
g00597643
run smoothly. Illustration 67

End By: 1. Attach a suitable hoist to starting motor (6).

The starting motor weighs approximately 48 kg
a. Install the air starting motor. (106 lb).

2. Install a new gasket for the joint between the

i01130365
cover of the starting motor and the flywheel
Air Starting Motor - Install housing. Lift the starting motor onto the mounting
position. Install three bolts (7).
SMCS Code: 1451-012
3. Connect hose (5).
Installation Procedure
NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

Note: Several different air starting motors are

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

g00597642
Illustration 68

4. Install air lines (4) and U-bolt (3).

5. Install four bolts (2).

6. Attach hoses (1).

 19
Disassembly and Assembly Section

Installation of an Air Starting Motor With i01128256

the Air Lines Attached Electric Starting Motor -
Remove and Install
SMCS Code: 1453-010

Removal Procedure

Disconnect batteries before performance of any

service work.

Note: Before disconnecting the wires and electrical

Illustration 69 g00615940 cables, mark the items for the proper connections
in order to ensure correct assembly.
1. Attach a suitable hoist to starting motor (4). The
weight of the starting motor with the air lines is
approximately 86 kg (190 lb).

2. Install a new gasket for the joint between the

cover of the starting motor and the flywheel
housing. Lift the starting motor onto the mounting
position. Install three bolts (3).

g00597378
Illustration 71

1. Disconnect the wires and electrical cables from

solenoid (1) and starting motor (2).

If the engine has two starting motors, disconnect

the wires between the two solenoids and starting
motors.
g00615939
Illustration 70
2. Attach a suitable hoist to the starting motor.
3. Connect the air supply line to elbow (1). The starting motor weighs approximately 30 kg
(66 lb).
4. Connect electrical connector (2).
3. Remove three bolts (3). Remove the starting
motor. Remove the gasket from the joint between
the starting motor and the flywheel housing.

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

2. Attach a suitable hoist to the starting motor.

The starting motor weighs approximately 30 kg
(66 lb).
20
Disassembly and Assembly Section

3. Remove the two nuts and the two electrical

connectors from the bracket. Remove the bracket
and service meter (3) from panel (2).

g00597378
Illustration 72

3. Place the gasket in the cover for the starting

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

4. Connect the wires and electrical cables to

solenoid (1) and starting motor (2).

If the engine has two starting motors, connect g00598072

the wires between the two solenoids and starting Illustration 74
motors.
4. Remove the clip and disconnect connector (4).
Loosen locknut (5) and remove sensor (6).
i01130781

Service Meter - Remove and Installation Procedure

Install
SMCS Code: 7451-010

Removal Procedure

g00598071
Illustration 73 g00598072
Illustration 75

1. Loosen two screws (1) on the cover of panel (2).

Open the cover in order to gain access to the
back of service meter (3).

2. Place an identification mark on all of the wires for

the installation procedure.
 21
Disassembly and Assembly Section

g00598071 g00597626
Illustration 76 Illustration 77

1. Install the bracket, the two nuts, and service 1. Turn off the gas supply.
meter (3) in panel (2).
2. Disconnect the electrical line from solenoid (1).
2. Install sensor (6) until the sensor touches the
tooth of the flywheel ring gear. Turn the sensor 3. Remove solenoid (1) from gas pressure regulator
in the counterclockwise direction for 1/2 turn. (2).
Tighten the locknut to a torque of 45 ± 7 N·m
(33 ± 5 lb ft). The clearance of the sensor and Installation Procedure
the flywheel ring gear should be 0.69 ± 0.14 mm
(0.027 ± 0.006 inch).
NOTICE
3. Install connector (4) and install the clip. Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

i01130333 component life.
Gas Pressure Regulator
Solenoid - Remove and Install
SMCS Code: 1270-010
S/N: 4WD1-Up
S/N: 5JD1-Up
S/N: 8LD1-Up
S/N: 9TG1-Up
S/N: 7NJ1-Up
S/N: 4EK1-Up g00597626
Illustration 78
Typical example
Removal Procedure
1. Install solenoid (1) on gas pressure regulator (2).
NOTICE
Keep all parts clean from contaminants. 2. Connect the electrical line to solenoid (1).
Contaminants may cause rapid wear and shortened 3. Turn on the gas supply.
component life.
22
Disassembly and Assembly Section

i01192937 i01130395

Gas Pressure Regulator - Gas Pressure Regulator -

Remove Remove
SMCS Code: 1270-011 (High Pressure)
S/N: 2TJ1-Up SMCS Code: 1270-011

Removal Procedure Removal Procedure

NOTICE Start By:
Keep all parts clean from contaminants.
a. Remove the gas pressure regulator solenoid.
Contaminants may cause rapid wear and shortened
component life. NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

1. Turn off the gas supply.

g00638261
Illustration 79

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

Note: The plate on the fuel inlet is for shipping

purposes only. A gas line will be connected to the
gas regulator. Illustration 80 g00597689

2. Disconnect line (2) and line (5) from gas pressure 2. Disconnect tube (1) from the fitting on gas
regulator (5). pressure regulator (4).
3. Remove the nuts and bolts (1) from gas pressure 3. Remove clamps (3) from the joint.
regulator (5).
4. Remove five bolts (2) and gas pressure regulator
4. Remove gas pressure regulator (4) from the (4).
engine.
 23
Disassembly and Assembly Section

i01130388
NOTICE
Gas Pressure Regulator - Keep all parts clean from contaminants.
Remove
Contaminants may cause rapid wear and shortened
(Low Pressure) component life.
SMCS Code: 1270-011

Removal Procedure
Start By:

a. Remove the gas pressure regulator solenoid.

1. Turn off the gas supply.

g00597827
Illustration 82
Typical example

1. Remove the bolts and fitting (1).

g00600648
Illustration 81
Typical example

2. Disconnect gas supply line (3).

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

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

and remove gas pressure regulator (2). Illustration 83 g00597828

Typical example
i01130525
2. Remove O-ring seal (2) and orifice (3).
Gas Pressure Regulator -
Disassemble
SMCS Code: 1270-015

Disassembly Procedure
Start By:

a. Remove the gas pressure regulator.

24
Disassembly and Assembly Section

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

gasket and the pusher post from diaphragm (15).

g00597832
Illustration 84
Typical example
g00597839
Illustration 87
3. Remove the bolts that hold the gas pressure Typical example
regulator together.
7. Remove cap (16) and the gasket from cover
4. Remove cover assembly (4), seat (5), spring (6), assembly (4).
seat (7), and diaphragm (8) from housing (9).

g00597840
Illustration 88
g00597833
Illustration 85
Typical example
Typical example
8. Remove screw (17).
5. Remove the two screws, the pin, lever (10), stem
assembly (11), and holder (12).
i01130594

Gas Pressure Regulator -

Assemble
SMCS Code: 1270-016

Assembly Procedure
NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.
g00597835
Illustration 86
Typical example
 25
Disassembly and Assembly Section

g00597840 g00597833
Illustration 89 Illustration 92
Typical example Typical example

1. Install screw (17). 4. Install holder (12), stem assembly (11), lever
(10), the pin, and the two screws.

g00597839
Illustration 90
g00597832
Typical example Illustration 93
Typical example
2. Install the gasket and cap (16) in cover assembly
(4). 5. Install diaphragm (8), seat (7), spring (6), seat
(5), and cover assembly (4) in housing (9).

g00597835
Illustration 91
g00597828
Typical example Illustration 94
Typical example
3. Install the pusher post, the head gasket, two
heads (14), and bolt (13) in diaphragm (15). 6. Install orifice (3) and O-ring seal (2).
26
Disassembly and Assembly Section

2. Install bolts (1) and the nuts in gas pressure

regulator (4).

3. Connect line (2) and line (5) on gas pressure

regulator (5).

4. Connect the gas line to fuel inlet (3).

i01130393

Gas Pressure Regulator -

Install
(Low Pressure)
g00597827
Illustration 95
Typical example
SMCS Code: 1270-012

7. Install fitting (1) and the bolts. Installation Procedure

End By:

a. Install the gas pressure regulator.

i01192993

Gas Pressure Regulator -

Install
SMCS Code: 1270-012
S/N: 2TJ1-Up
g00600648
Installation Procedure Illustration 97
Typical example
NOTICE
Keep all parts clean from contaminants. 1. Install gas pressure regulator (2) with two bolts
(1) on the mounting bracket.
Contaminants may cause rapid wear and shortened
component life. 2. Install two bolts (4) that hold the gas line to gas
pressure regulator (2).

3. Connect gas supply line (1).

4. Turn on the gas supply.

End By:

a. Install the gas pressure regulator solenoid.

g00638261
Illustration 96

1. Position gas pressure regulator (4) on the engine.

 27
Disassembly and Assembly Section

i01130412 i01104449

Gas Pressure Regulator - Fuel Control Actuator - Remove

Install and Install
(High Pressure) SMCS Code: 1909-010-AQ
SMCS Code: 1270-012 S/N: 2TJ1-Up

Installation Procedure Removal Procedure

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.

g00597689 g00581770
Illustration 98 Illustration 99

1. Install gas pressure regulator (4) and five bolts 1. Remove four bolts (1) and the nuts that connect
(2). elbow (2) of the engine throttle control to the
aftercooler.
2. Install clamps (3) on the joint.
2. Remove four bolts (4) and the nuts that hold
3. Connect tube (1) to the fitting on gas pressure elbow (2) to the engine throttle control.
regulator (4).
3. Remove elbow (2).
4. Turn on the gas supply.
4. Disconnect the wiring harness from plug (3).
End By:

a. Install the gas pressure regulator solenoid.

g00581761
Illustration 100
28
Disassembly and Assembly Section

5. Remove four bolts (6) that hold engine throttle

control (5) to the adapter.

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

engine throttle control (5) to the fuel control
actuator.

7. Remove engine throttle control (5).

g00581761
Illustration 103

2. Position engine throttle control (5) on the adapter.

Ensure that the shaft of engine throttle control (5)
is installed in the coupling.

3. Tighten setscrew (7) in order to hold the shaft of

engine throttle control (5) to fuel control actuator
Illustration 101 g00581764 (8).

8. Remove four bolts (9) that hold fuel control 4. Install four bolts (6) that hold engine throttle
actuator (8) on the mounting plate. control (5) to the adapter.

Installation Procedure
NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

g00581770
Illustration 104

5. Connect the wiring harness to plug (3).

6. Install four bolts (4) and the nuts that hold elbow
(2) to the engine throttle control.

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

elbow (2) of the engine throttle control to the
Illustration 102 g00581764 aftercooler.

1. Position fuel control actuator (8) on the mounting

plate and install four bolts (9) with the nuts.
 29
Disassembly and Assembly Section

i01130211 Installation Procedure

Fuel Control Actuator - Remove
and Install
SMCS Code: 1909-010-AQ
S/N: 4WD1-Up
S/N: 5JD1-Up
S/N: 8LD1-Up
S/N: 9TG1-Up
S/N: 7NJ1-Up
S/N: 4EK1-Up g00597502
Illustration 106
Typical example
S/N: 6JW1-Up
S/N: 8PW1-Up 1. Position fuel control actuator (5) on the engine
and install four nuts (2).
S/N: 9AW1-Up
2. Install linkage (3) on fuel control actuator (5) and
Removal Procedure install nut (4).

3. Connect wiring harness (1) to fuel control

actuator (5).

g00597502
Illustration 105
Typical example

1. Disconnect wiring harness (1) from fuel control

actuator (5).

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

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

actuator (5) from the engine.
30
Disassembly and Assembly Section

g00597521
Illustration 107
Typical example

4. Open the fuel control actuator completely. Adjust

the linkage to an angle of 26 ± 2 degrees.
Ensure that there is an equal amount of slack on
each end of the linkage.

i01130314

Fuel Control Valve - Remove

and Install
SMCS Code: 1909-010
S/N: 2TJ1-Up
g00597612
Illustration 108
Removal Procedure
2. Disconnect tube (2).
NOTICE
Keep all parts clean from contaminants. 3. Remove clip (5) and disconnect tube (7).
Contaminants may cause rapid wear and shortened 4. Remove bolts (1), the nuts, and the spacers.
component life.
5. Remove gas regulator (6) and the gasket.
1. Turn off the gas supply.
Note: The plate that is on the end of the gas
regulator is for shipping purposes. The customer
will remove the plate.

6. Remove fuel line (3) and fuel control valve (4).

 31
Disassembly and Assembly Section

Installation Procedure i01130746

NOTICE
Fuel Control Valve - Remove
Keep all parts clean from contaminants. and Install
Contaminants may cause rapid wear and shortened SMCS Code: 1909-010
component life.
S/N: 4WD1-Up

1. Apply 5P-3413 Pipe Sealant to all pipe threads S/N: 5JD1-Up

prior to assembly.
S/N: 8LD1-Up
S/N: 9TG1-Up
S/N: 7NJ1-Up
S/N: 4EK1-Up
S/N: 6JW1-Up
S/N: 8PW1-Up
S/N: 9AW1-Up

Removal Procedure
g00597612 1. Turn off the gas supply.
Illustration 109

2. Install fuel control valve (4) and fuel line (3).

3. Install the gasket and gas regulator (6). Install

bolts (1), the spacers, and the nuts.

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

5. Install tube (2).

6. Turn on the gas supply.

g00598031
Illustration 110

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

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

fuel control valve (2).
32
Disassembly and Assembly Section

g00598035
Illustration 111

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

5. Remove fuel control valve (2).

Installation Procedure Illustration 113 g00598031

1. Inspect the condition of the O-ring seal on the 3. Connect linkage (3) to fuel control valve (2) and
bottom of the fuel control valve. Replace the install bolt (4).
O-ring seal, if necessary.
4. Install two clamps (1) on the fuel supply line.

5. Turn on the gas supply.

i01130144

Electronic Sensor - Remove

and Install
SMCS Code: 1904-010

Removal Procedure
g00598035
Illustration 112

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

and four bolts (5).

g00597454
Illustration 114

1. Disconnect wire assembly (2). Remove

transducer module (1).
 33
Disassembly and Assembly Section

2. Install two washers and bolts (5).

3. Connect wire assembly (4).

g00597462
Illustration 115

2. Cut tie straps (3).

g00597462
Illustration 118

4. Install new tie straps (3).

g00597464
Illustration 116

3. Disconnect wire assembly (4).

g00597454
Illustration 119
4. Remove two bolts and washers (5).
5. Install transducer module (1) and connect wire
5. Remove control group (6). assembly (2).

Installation Procedure i01129770

Carburetor - Remove
(Low Pressure)
SMCS Code: 1266-011
S/N: 2TJ1-Up

Removal Procedure
Start By:

a. Remove the air cleaner.

g00597464
Illustration 117

1. Install control group (6).

34
Disassembly and Assembly Section

i01129131
NOTICE
Keep all parts clean from contaminants.
Carburetor - Remove
(High Pressure)
Contaminants may cause rapid wear and shortened
component life. SMCS Code: 1266-011
S/N: 4WD1-Up
1. Turn off the gas supply.
S/N: 5JD1-Up
S/N: 8LD1-Up
S/N: 9TG1-Up
S/N: 7NJ1-Up
S/N: 4EK1-Up
S/N: 6JW1-Up
S/N: 8PW1-Up
S/N: 9AW1-Up

Illustration 120 g00597142 Removal Procedure

2. Loosen clamp (1). NOTICE
Keep all parts clean from contaminants.
3. Disconnect tube (2).
Contaminants may cause rapid wear and shortened
4. Remove nuts (4) and the bolts from carburetor component life.
(3).

5. Remove four nuts (5) from the gas line. Remove

carburetor (3).

g00597082
Illustration 121
Typical example

1. Turn off the gas supply.

2. Disconnect tube (2) and control rod (4) from

carburetor (3).

3. Remove clamp (5).

4. Remove four bolts (1) and the gasket.

5. Remove carburetor (3) and the gasket.

 35
Disassembly and Assembly Section

i01129219 6. Remove the washers and the nuts that hold

carburetor (1) to the support bracket.
Carburetor - Remove
(Low Pressure) 7. Loosen clamp (4).

SMCS Code: 1266-011 8. Remove carburetor (1).

S/N: 4WD1-Up
i01129893
S/N: 5JD1-Up
Carburetor - Disassemble
S/N: 8LD1-Up
(High Pressure)
S/N: 9TG1-Up
SMCS Code: 1266-015
S/N: 7NJ1-Up
S/N: 4WD1-Up
S/N: 4EK1-Up
S/N: 5JD1-Up
S/N: 6JW1-Up
S/N: 9TG1-Up
S/N: 8PW1-Up
S/N: 7NJ1-Up
S/N: 9AW1-Up
S/N: 6JW1-Up
Removal Procedure S/N: 9AW1-Up

NOTICE Disassembly Procedure

Keep all parts clean from contaminants.
Start By:
Contaminants may cause rapid wear and shortened
component life. a. Remove the carburetor.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

g00597138
Illustration 122
Typical example

1. Turn off the gas supply.

2. Loosen clamp (7). Remove the bolts and air

cleaner (8). Illustration 123 g00597237

Typical example
3. Disconnect tube (5).
1. Remove adapter (1) and the gasket from base
4. Disconnect tube (6). (2).
5. Loosen clamp (2) and remove boot (3).
36
Disassembly and Assembly Section

6. Loosen the set screw and remove stop assembly

(9). Remove shaft (11).

g00597238
Illustration 124
Typical example
g00597280
Illustration 127
2. Remove the screws, cover (5), spring (4), and Typical example
air valve assembly (3).
7. Remove the screws and mixer housing (12).

8. Remove the bolts, and base (13) from throttle

assembly (14).

i01130088

Carburetor - Disassemble
(High Pressure)
SMCS Code: 1266-015
S/N: 8LD1-Up

Illustration 125 g00597239 S/N: 4EK1-Up

Typical example S/N: 8PW1-Up
3. Remove four screws (6) and diaphragm (7).
Disassembly Procedure
Start By:

a. Remove the carburetor.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

g00597284
Illustration 126
Typical example

4. Remove the screws and disc (10) from shaft (11).

5. Loosen the bolt and remove lever (8).

 37
Disassembly and Assembly Section

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

(12).

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

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

12. Repeat Steps 1 through 11 for the second

carburetor.

i01130064

Carburetor - Assemble
(High Pressure)
g00597403
Illustration 128 SMCS Code: 1266-016
Typical example
S/N: 4WD1-Up
1. Remove adapter (1) and the gasket from throttle
S/N: 5JD1-Up
assembly (2).
S/N: 9TG1-Up
S/N: 7NJ1-Up
S/N: 6JW1-Up
S/N: 9AW1-Up

Assembly Procedure
NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

g00597405 component life.
Illustration 129
Typical example

2. Remove screws (10) that hold mixer housing (3)

to throttle assembly (2).

3. Separate mixer housing (3) and throttle assembly

(2).

4. Remove washer (6), jet (5), and O-ring seal (4)

from throttle assembly (2).

5. Remove the screw and valve (7) from mixer

housing (3).

6. Remove O-ring seal (8). g00597280

Illustration 130
7. Remove the two screws and piston (9) from Typical example
mixer housing (3).
1. Place base (13) on throttle assembly (14) and
8. Remove screws (18) and cover (17) from mixer install the bolts.
housing (3).
2. Install body (12) on base (13).
9. Remove spring (16) and air valve assembly (12)
from mixer housing (3).
38
Disassembly and Assembly Section

7. Install air valve assembly (3), spring (4), cover

(5), and the screws.

g00597284
Illustration 131
Typical example
g00597237
Illustration 134
3. Install shaft (11). Install stop assembly (9) and Typical example
tighten the set screw.
8. Install the gasket and adapter (1) on base (2).
4. Install lever (8) and tighten the bolt.
End By:
5. Install disc (10) on shaft (11).
a. Install the carburetor.

i01130107

Carburetor - Assemble
(High Pressure)
SMCS Code: 1266-016
S/N: 8LD1-Up
S/N: 4EK1-Up
S/N: 8PW1-Up
g00597239
Illustration 132
Typical example Assembly Procedure
6. Install diaphragm (7) and four screws (6). NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

1. Inspect the condition of the gaskets and the

O-ring seals. Replace the gaskets and the O-ring
seals, if necessary.

g00597238
Illustration 133
Typical example
 39
Disassembly and Assembly Section

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

assembly (2).

End By:

a. Install the carburetor.

i01129831

Carburetor - Install
(Low Pressure)
SMCS Code: 1266-012
g00597405 S/N: 2TJ1-Up
Illustration 135
Typical example
Installation Procedure
2. Install shaft (13), diaphragm (14), plate (15), and
the screws in air valve assembly (12).
NOTICE
Keep all parts clean from contaminants.
3. Install O-ring seal (11) in air valve assembly (12).
Contaminants may cause rapid wear and shortened
4. Install air valve assembly (12) and spring (16) in
component life.
mixer housing (3).

5. Install cover (17) and screws (18) on mixer

housing (3).

6. Install piston (9) and the screws in mixer housing

(3).

7. Install O-ring seal (8).

8. Install valve (7) and the screw in mixer housing

(3).

9. Install O-ring seal (4), jet (5), and washer (6) in

throttle assembly (2).
g00597142
10. Assemble mixer housing (3) and throttle Illustration 137
assembly (2).
1. Position carburetor (3) on the gas line and install
four nuts (5).

2. Install the bolts and nuts (4) that hold carburetor

(3) to the adapter.

3. Tighten clamp (1).

4. Connect tube (2).

End By:

a. Install the air cleaner.

g00597403
Illustration 136
Typical example
40
Disassembly and Assembly Section

i01129818 6. Install the air cleaner (8) with the bolts. Tighten
clamp (7).
Carburetor - Install
(Low Pressure) 7. Turn on the gas supply.

SMCS Code: 1266-012 i01129804

S/N: 4WD1-Up Carburetor - Install

S/N: 5JD1-Up (High Pressure)
S/N: 8LD1-Up
SMCS Code: 1266-012
S/N: 9TG1-Up
S/N: 4WD1-Up
S/N: 7NJ1-Up
S/N: 5JD1-Up
S/N: 4EK1-Up
S/N: 8LD1-Up
S/N: 6JW1-Up
S/N: 9TG1-Up
S/N: 8PW1-Up
S/N: 7NJ1-Up
S/N: 9AW1-Up
S/N: 4EK1-Up

Installation Procedure S/N: 6JW1-Up

S/N: 8PW1-Up
NOTICE
Keep all parts clean from contaminants. S/N: 9AW1-Up

Contaminants may cause rapid wear and shortened Installation Procedure

component life.
NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

g00597138
Illustration 138
Typical example

1. Install carburetor (1).

2. Tighten clamp (4). g00597082

Illustration 139

3. Install the washers and the nuts that hold Typical example
carburetor (1) on the support bracket.
1. Position the gasket and carburetor (3) on the
4. Slide the boot on carburetor (1) and tighten engine.
clamp (2).
2. Install the gasket and four bolts (1).
5. Connect tubes (5) and (6).
3. Install clamp (5).
 41
Disassembly and Assembly Section

4. Connect tube (2) and control rod (4) to carburetor Installation Procedure
(3).
Table 4
5. Adjust the linkage on control rod (4). Refer to Required Tools
the Testing and Adjusting Module for the correct
procedure. Part
Tool Part Description Qty
Number
6. Turn on the gas supply. A 138-7573 Link Bracket 1

i01134294

Air Cleaner - Remove and

Install
SMCS Code: 1051-010
S/N: 2TJ1-Up

Removal Procedure
Table 3
Required Tools
Part
Tool Part Description Qty
Number
A 138-7573 Link Bracket 1

g00597144
Illustration 141

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

order to hold air cleaner (2) in position.

2. Install five bolts (3).

3. Tighten clamp (1) on the boot.

i01101124

Turbocharger - Remove
SMCS Code: 1052-011
S/N: 2TJ1-Up

Removal Procedure
g00597144
Illustration 140
Start By:
1. Install Tool (A) and attach a suitable lifting device
a. Remove the exhaust elbow.
to air cleaner (2).

2. Loosen clamp (1) from the boot. NOTICE

Keep all parts clean from contaminants.
3. Remove five bolts (3) and remove air cleaner
(2). The air cleaner weighs approximately 32 kg Contaminants may cause rapid wear and shortened
(70 lb). component life.
42
Disassembly and Assembly Section

5. Disconnect water line (5).

NOTICE
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. g00579890
Illustration 144
View below the turbocharger

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

g00579878
Illustration 142

1. Remove two bolts (2) from the oil supply line on

top of turbocharger (4). Remove the oil line and
the gasket. g00601109
Illustration 145
2. Disconnect water line (1).
7. Attach a suitable lifting device to turbocharger
3. Loosen two hose clamps (3). (4).

8. Remove four mounting bolts (9) from

turbocharger (4).

9. Remove turbocharger (4) and the gasket. Use a

pry bar on outlet (10) from turbocharger (4) to
the aftercooler, if necessary.

g00579887
Illustration 143

4. Remove two bolts (6) from the oil drain tube on

the bottom of turbocharger (4). Remove the oil
drain tube and the gasket.
 43
Disassembly and Assembly Section

i01123265

Turbocharger - Remove
SMCS Code: 1052-011
S/N: 4WD1-Up
S/N: 5JD1-Up
S/N: 8LD1-Up
S/N: 9TG1-Up
S/N: 7NJ1-Up
S/N: 4EK1-Up g00593736
Illustration 146
S/N: 6JW1-Up
1. Remove two bolts (1) from each end of oil drain
S/N: 8PW1-Up tube (3). Remove oil drain tube (3).
S/N: 9AW1-Up 2. Remove tube (4).

Removal Procedure 3. Remove four bolts (2).

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

NOTICE
Care must be taken to ensure that fluids are 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. g00593777
Illustration 147
Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and supplies 4. Remove two bolts (7) from the oil supply line.
suitable to collect and contain fluids on Caterpillar Remove the oil supply line and the gasket from
products. the turbocharger.

Dispose of all fluids according to local regulations and 5. Remove air inlet tube (5) and tube (6).
mandates.
6. Remove four nuts (8).
44
Disassembly and Assembly Section

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

g00593781
Illustration 148

7. Attach a suitable lifting device to turbocharger

(10) and remove turbocharger (10) from the
engine. The weight of the turbocharger is
approximately 38 kg (84 lb).
g00593902
Illustration 149
i01123440
Typical example
Turbocharger - Disassemble 1. Place the turbocharger on Tool (A). Mark the
SMCS Code: 1052-015 turbocharger housings for the proper alignment
during assembly.
S/N: 4WD1-Up
2. Loosen clamp (2). Remove compressor housing
S/N: 5JD1-Up (1) and clamp (2).
S/N: 8LD1-Up
S/N: 9TG1-Up
S/N: 7NJ1-Up
S/N: 4EK1-Up
S/N: 6JW1-Up
S/N: 8PW1-Up
S/N: 9AW1-Up

Disassembly Procedure
g00593906
Table 5 Illustration 150
Typical example
Required Tools
Part 3. Loosen clamp (5) and remove cartridge
Tool Part Description Qty
Number assembly (3) from turbine housing (4).
Turbocharger Fixture
A 9S-6363 1
Group
B 9S-6343 Fixture Assembly 1
C 1P-1853 Retaining Ring Pliers 1

Start By:

a. Remove the turbocharger.

 45
Disassembly and Assembly Section

g00593907 g00593915
Illustration 151 Illustration 153
Typical example Typical example

NOTICE 6. Remove seal ring (8) and shroud (9) from turbine
Do Not place a side force on the shaft when the nut is shaft (7).
removed or tightened. The shaft will bend and cause
damage to the turbocharger.

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

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

g00593918
Illustration 154
Typical example

g00593908
Illustration 152
Typical example

5. Use a suitable press to push the turbine shaft

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

g00593920
Illustration 155
Typical example

7. Bend the tabs of the locks away from bolts (10)

and remove bolts (10).

Note: Examine the position of the oil holes in the

backplate assembly and the cartridge housing for
the assembly procedure.
46
Disassembly and Assembly Section

8. Remove backplate assembly (11).

9. Remove spacer (12) from backplate assembly

(11).

g00593962
Illustration 159
Typical example

Note: Place an identification mark on the bearings if

g00593922
Illustration 156 the bearings are reusable.
Typical example
13. Remove bearing (17) and the washer from the
10. Remove seal rings (13) from spacer (12). cartridge housing.

g00593923 g00593963
Illustration 157 Illustration 160
Typical example Typical example

11. Remove thrust collar (14) and seal ring (15). 14. Use Tool (C) to remove snap rings (18) and (19).

g00593925 g00593965
Illustration 158 Illustration 161
Typical example Typical example

12. Remove thrust bearing (16). 15. Remove bearing (20) and washer (21).
 47
Disassembly and Assembly Section

i01123732

Turbocharger - Assemble
SMCS Code: 1052-016
S/N: 4WD1-Up
S/N: 5JD1-Up
S/N: 8LD1-Up
S/N: 9TG1-Up
S/N: 7NJ1-Up

g00593966 S/N: 4EK1-Up

Illustration 162
Typical example S/N: 6JW1-Up

16. Use Tool (C) to remove the lower snap ring from S/N: 8PW1-Up
the cartridge housing. S/N: 9AW1-Up

Assembly Procedure
Table 6
Required Tools
Part
Tool Part Description Qty
Number
Turbocharger Fixture
A 9S-6363 1
Group
B 9S-6343 Fixture Assembly 1
C 1P-1853 Retaining Ring Pliers 1
D 8T-5096 Dial Indicator 1

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

Illustration 163
g00593901 component life.

Note: This procedure is a typical disassembly 1. Ensure that all of the oil passages in the
procedure for a turbocharger. Cartridge Assembly turbocharger cartridge housing, the backplate
(3) is secured to compressor housing (1) and assembly, and the bearing are clean.
turbine housing (4) with clamp (2) and clamp
(5). All turbochargers will have the same basic 2. Place clean engine oil on all of the parts for the
components. cartridge during the assembly procedure.

Note: Ensure that the round edge of the outside

diameter of the snap rings is toward the bearing
during installation.
48
Disassembly and Assembly Section

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

cartridge housing until washer (23) makes
contact with snap ring (18).

g00594129
Illustration 164
Typical example

3. Use Tool (C) to install snap ring (22) in the g00594134

Illustration 167
turbine end of the cartridge housing. Typical example

4. Install washer (21) and bearing (20). Use Tool 7. Install thrust bearing (16) on the dowels in the
(C) to install snap ring (19). cartridge housing. Ensure that the grooves in
bearing (16) are toward the outside.

g00594131
Illustration 165
Typical example g00594620
Illustration 168
Typical example
5. Use Tool (C) to install snap ring (18).
8. Install seal ring (15) in the groove of the cartridge
housing.

g00594133
Illustration 166
Typical example
g00594621
Illustration 169
Typical example
 49
Disassembly and Assembly Section

9. Install thrust collar (14) on the thrust bearing with 12. Align oil passage (24) in the cartridge housing
the counterbore upward. with oil passage (25) in backplate assembly (11).

13. Install backplate assembly (11) on the cartridge

housing. Ensure that the spacer fits correctly in
the counterbore of the thrust collar.

g00594622
Illustration 170
Typical example

10. Install seal rings (13) on spacer (12). The gaps g00594644
in the rings should be 180 degrees away from Illustration 173
each other. Typical example

14. Install the locks and the bolts on backplate

assembly (11). Tighten the bolts to a torque of
10 ± 1 N·m (7 ± 1 lb ft).

g00594623
Illustration 171
Typical example

11. Install spacer (12) in backplate assembly (11). g00594647

Illustration 174
Typical example

15. Install turbine shaft (7) in Tool (B). Place

6V-2055 Grease in the groove for seal ring (8).
Ensure that the grease fills half of the groove.
This creates a carbon dam under the seal ring.

16. Install seal ring (8) and shroud (9).

g00594642
Illustration 172
Typical example
50
Disassembly and Assembly Section

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

19. Place clean engine oil on the threads of the

turbine shaft and on the face of the compressor
wheel that is under the nut. Tighten the nut to
a torque of 17 N·m (13 lb ft). Loosen the nut
and tighten the nut again to a torque of 4 N·m
(35 lb in). Turn the nut for an additional 120
degrees (1/3 turn).
g00594650
Illustration 175 20. Remove the nut. Apply 4C-9500 Quick Cure
Typical example Primer to the threads of the turbine shaft.

17. Install the cartridge housing on the turbine shaft. 21. Place 4C-9507 Retaining Compound on the
Hold the spacer in position. Ensure that the seal threads of the turbine shaft. Install the nut and
ring on the turbine is correctly placed in the tighten the nut to a torque of 4 N·m (35 lb in).
cartridge housing. Turn the nut for an additional 120 degrees (1/3
turn).

g00594652
Illustration 176
g00594677
Typical example Illustration 178
Typical example
18. Install compressor wheel (6).
22. Place the cartridge in a vise. Install Tool (D)
and check the end play of the shaft. The end
play must not be more than 0.165 ± 0.085 mm
(0.0065 ± 0.0033 inch).

g00594673
Illustration 177
Typical example
 51
Disassembly and Assembly Section

i01103839

Turbocharger - Install
SMCS Code: 1052-012
S/N: 2TJ1-Up

Installation Procedure
NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

g00594680 component life.
Illustration 179
Typical example
1. Inspect the condition of the gaskets and the
23. Install turbine housing (4) on Tool (A). Install the O-ring seals. Replace the seals and the gaskets,
cartridge and clamp (5) in turbine housing (4). if necessary.
Ensure that the marks on the housing and the
cartridge are aligned.

24. Install clamp (5). Tighten the clamp to a torque

of 14 ± 1 N·m (10± 1 lb ft). Lightly tap the clamp
with a soft hammer. Tighten the clamp to the
same torque again.

g00601109
Illustration 181

2. Attach a suitable lifting device to the turbocharger

and position the turbocharger on the exhaust
manifold.

3. Position outlet (10) on the aftercooler and install

g00594683 four mounting bolts (9) on the turbocharger.
Illustration 180
Typical example

25. Install clamp (2) and compressor housing (1)

on the cartridge. Install clamp (2). Tighten the
clamp to a torque of 14 ± 1 N·m (10± 1 lb ft).
Lightly tap the clamp with a soft hammer. Tighten
the clamp to the same torque again.

End By:

a. Install the turbocharger.

g00579890
Illustration 182
52
Disassembly and Assembly Section

4. Install two bolts (8) that fasten the oil drain tube i01123430
to the cylinder block.
Turbocharger - Install
5. Install clip (7) on the oil drain tube.
SMCS Code: 1052-012
S/N: 4WD1-Up
S/N: 5JD1-Up
S/N: 8LD1-Up
S/N: 9TG1-Up
S/N: 7NJ1-Up
S/N: 4EK1-Up
S/N: 6JW1-Up
S/N: 8PW1-Up
g00579887
Illustration 183 S/N: 9AW1-Up
6. Connect water line (5).
Installation Procedure
7. Install the gasket and two bolts (6) that connect
the oil drain tube to turbocharger (4). NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

1. Inspect the condition of the gaskets. Replace the

gaskets, if necessary.

g00579878
Illustration 184

8. Tighten two hose clamps (3).

9. Connect water line (1).

10. Install the gasket and two bolts (2) that connect
the oil supply line to the top of turbocharger (4). g00593781
Illustration 185
End By:
2. Attach a suitable lifting device (11) to
a. Install the exhaust elbow. turbocharger (10).
 53
Disassembly and Assembly Section

i01102037

Aftercooler - Remove and

Install
SMCS Code: 1063-010
S/N: 2TJ1-Up

Removal Procedure
Table 7
Required Tools

g00593777 Part
Illustration 186 Tool Part Description Qty
Number
3. Apply 5P-3931 Anti-Seize Compound to the A 138-7573 Link Bracket 2
studs on the exhaust manifold. Install four nuts
(8). Tighten the nuts to a torque of 54 ± 5 N·m
(40 ± 4 lb ft). NOTICE
Keep all parts clean from contaminants.
4. Connect air inlet tube (5) and tube (6).
Contaminants may cause rapid wear and shortened
5. Position the oil supply line and the gasket on component life.
the turbocharger. Install two bolts (7) in the oil
supply line. NOTICE
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.
g00593736
Illustration 187

6. Install four bolts (2).

7. Connect tube (4).

8.

g00580321
Illustration 188

1. Disconnect line (1) that runs to the exhaust

bypass for the turbocharger.
54
Disassembly and Assembly Section

2. Remove four bolts (2) and the nuts on the air

inlet from the turbocharger.

g00580361
Illustration 189
View from the top of the engine

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

outlet pipe (4) of the aftercooler. g00580433
Illustration 191

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

(8).

8. Remove outlet pipe (4) and inlet pipe (8) from

the aftercooler. Plug all openings immediately.

g00580403
Illustration 190

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

outlet pipe (4) to the aftercooler.

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

inlet pipe (8) to the aftercooler. g00580439
Illustration 192

6. Disconnect fitting (7). 9. Remove four bolts (10) and the nuts that attach
the elbow of the engine throttle control to the
aftercooler.
 55
Disassembly and Assembly Section

g00580793 g00597710
Illustration 193 Illustration 195

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

16. Use the following steps if the mounting plate for

the aftercooler must be removed.

a. Remove the fuel control actuator from the

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

g00580797
Illustration 194
The exhaust heat shields are removed for the photos only.

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

to the mounting plate. There are four bolts on the
rear of the aftercooler and four bolts that are on
the front of the aftercooler.

12. Lift the aftercooler off the engine.

Note: Ensure that the oil lines and the water lines for
the turbocharger are not damaged.

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

the aftercooler. Remove the gasket that is on the g00580834
Illustration 196
air outlet of the aftercooler.
View from the top of the engine
14. Remove bolts (12) that hold the water outlet on
the aftercooler in order to clean the aftercooler. b. Remove four bolts (15) and the spacers from
the base of the mounting plate. There are two
bolts that are on the front of the mounting
plate and two bolts that are on the rear of the
mounting plate.

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

d. Remove the mounting plate.

56
Disassembly and Assembly Section

Installation Procedure
Table 8
Required Tools
Part
Tool Part Description Qty
Number
A 138-7573 Link Bracket 2

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.
g00580793
Illustration 198

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

g00580797
Illustration 199
The exhaust heat shields are removed for photos only.

4. Install eight bolts (11) that hold the aftercooler to

the mounting plate. There are four bolts on the
rear of the aftercooler and four bolts on the front
g00580834 of the aftercooler.
Illustration 197
View from the top of the engine

a. Position the mounting plate on the engine.

Install two bolts (14) and the nuts.

b. Install spacers and four bolts (15) in the base

of the mounting plate.

c. Install the fuel control actuator on the

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

g00580439
Illustration 200
 57
Disassembly and Assembly Section

5. Install four bolts (10) and the nuts that attach

the elbow of the engine throttle control to the
aftercooler.

g00580361
Illustration 203
View from the top of the engine

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

g00580433
Illustration 201

6. Install inlet pipe (8) and outlet pipe (4) on the

aftercooler.

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

g00580321
Illustration 204

12. Install four bolts (2) and the nuts on the air inlet
from the turbocharger.

13. Connect line (1) that runs to the exhaust bypass

for the turbocharger.

14. Fill the cooling system to the correct level with

coolant. Refer to the Operation and Maintenance
Illustration 202
g00580403 Manual for the correct procedure.

8. Connect fitting (7) on the line that runs from the

water manifold to the turbocharger.

9. Install the bracket and two bolts (6) that hold

inlet pipe (8) to the aftercooler.

10. Install the bracket and two bolts (5) that hold
outlet pipe (4) to the aftercooler.
58
Disassembly and Assembly Section

i01128127

Aftercooler - Remove and

Install
SMCS Code: 1063-010
S/N: 4WD1-Up
S/N: 5JD1-Up
S/N: 8LD1-Up
S/N: 9TG1-Up
S/N: 7NJ1-Up g00596707
Illustration 205
S/N: 4EK1-Up
2. Install Tool (A) and attach a suitable lifting device
S/N: 6JW1-Up to the aftercooler.
S/N: 8PW1-Up
3. Remove eight bolts (1). Remove eight bolts (2),
S/N: 9AW1-Up retainers (3), two tubes (4) and the O-ring seals.

4. Disconnect tube (5) from the aftercooler housing.

Removal Procedure Remove eight bolts (6).
Table 9
Required Tools
Part
Tool Part Description Qty
Number
A 138-7573 Link Bracket 2

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

g00596708
NOTICE Illustration 206
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test- 5. Remove six bolts (7).
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open- 6. Remove the aftercooler from the engine. The
ing any compartment or disassembling any compo- aftercooler weighs approximately 114 kg (250 lb).
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.

1. Drain the coolant from the cooling system into a

suitable container for storage or disposal.
 59
Disassembly and Assembly Section

g00596709 g00596708
Illustration 207 Illustration 209

7. Remove plate (9) and core assembly (8), if 4. Install six bolts (7).
necessary.

Installation Procedure
Table 10
Required Tools
Part
Tool Part Description Qty
Number
A 138-7573 Link Bracket 2

NOTICE
Keep all parts clean from contaminants.
g00596707
Illustration 210
Contaminants may cause rapid wear and shortened
component life.
5. Install eight bolts (6) and connect tube (5).

1. Inspect the condition of the O-ring seals. Replace 6. Place clean engine oil on the O-ring seals and
the gaskets and the seals, if necessary. connect two tubes (4).

7. Install retainers (3) and eight bolts (2). Install

eight bolts (1).

8. Fill the cooling system to the correct level with

coolant. Refer to the Operation and Maintenance
Manual for the correct procedure.

i01134281

Air Inlet Manifold - Remove

and Install
SMCS Code: 1058-010
g00596709
Illustration 208

2. Install core assembly (8) and plate (9), if

Removal Procedure
necessary. Start By:
3. Use a suitable lifting device and Tool (A) to a. Remove the aftercooler.
position the aftercooler on the engine.
60
Disassembly and Assembly Section

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

g00638707
Illustration 211

1. Remove four bolts (1) from the cylinder head and

four bolts (2) from the air inlet manifold (5).

2. Remove air inlet elbow (3) from the engine.

3. Repeat the steps for the remaining air inlet

elbows.

4. Remove bolts (4) from the cover on air inlet

manifold (5).

Installation Procedure
NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.
 61
Disassembly and Assembly Section

g00638707
Illustration 212

1. Install the cover on air inlet manifold (5).

2. Install bolts (4).

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

4. Install four bolts (2) in air inlet manifold (5) and

install four bolts (1) in the cylinder head.

End By:

a. Install the aftercooler.

i01128746
g00597041
Illustration 213
Exhaust Elbow - Remove and
Install 1. Remove exhaust heat shield (1) from the exhaust
elbow.
SMCS Code: 1060-010
S/N: 2TJ1-Up

Removal Procedure
NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.
62
Disassembly and Assembly Section

g00597043 g00597041
Illustration 214 Illustration 216

2. Remove the nuts and bolts (4). 4. Install exhaust heat shield (1) on the exhaust
elbow.
3. Remove two nuts (3) and the bolts.
i01128403
4. Remove exhaust elbow (2).
Exhaust Elbow - Remove and
Installation Procedure Install
NOTICE SMCS Code: 1060-010
Keep all parts clean from contaminants.
S/N: 4WD1-Up
Contaminants may cause rapid wear and shortened
component life. S/N: 5JD1-Up
S/N: 8LD1-Up
S/N: 9TG1-Up
S/N: 7NJ1-Up
S/N: 4EK1-Up
S/N: 6JW1-Up
S/N: 8PW1-Up
S/N: 9AW1-Up

Removal Procedure
g00597043 Table 11
Illustration 215
Required Tools
1. Position exhaust elbow (2) on the engine.
Part
Tool Part Description Qty
Number
2. Install two bolts (3) and the nuts.
A 138-7573 Link Brackets 2
3. Install bolts (4) and the nuts.
NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.
 63
Disassembly and Assembly Section

g00596957 g00596963
Illustration 217 Illustration 220

1. Disconnect tube (2) from the exhaust elbow. 7. Install Tool (A) and attach a suitable lifting device
to exhaust elbow (8). Remove exhaust elbow (8)
2. Remove four bolts (3) and eight bolts (1). and the gaskets from the engine. The exhaust
elbow weighs approximately 36 kg (80 lb).

Installation Procedure
Table 12
Required Tools
Part
Tool Part Description Qty
Number
A 138-7573 Link Brackets 2

NOTICE
Keep all parts clean from contaminants.
g00596959
Illustration 218
Contaminants may cause rapid wear and shortened
component life.
3. Disconnect tube (4) from the exhaust bypass.

4. Remove tube (6) from the exhaust elbow.

5. Remove four bolts (6).

g00596963
Illustration 221

1. Install Tool (A) on exhaust elbow (8) and attach

a suitable lifting device. Position the gasket and
Illustration 219 g00596961 exhaust elbow (8) on the engine.

6. Disconnect tube (7) from the exhaust elbow and

the exhaust bypass.
64
Disassembly and Assembly Section

g00596959 g00596948
Illustration 222 Illustration 224

2. Install four bolts (3) and four bolts (5). 1. Disconnect tube (1) from the exhaust bypass.
Remove tube (2).

g00596957
Illustration 223
g00596950
Illustration 225
3. Install eight bolts (2). Ensure that the gaskets
between the adapters and the exhaust elbow 2. Disconnect tubes (3) and (5).
are positioned correctly.
3. Remove four bolts (4), the exhaust bypass, and
4. Connect tubes (2), (4), (6), and (7) to exhaust the gasket.
elbow (8).
Installation Procedure
i01128325
NOTICE
Exhaust Bypass Valve - Keep all parts clean from contaminants.
Remove and Install
Contaminants may cause rapid wear and shortened
SMCS Code: 1057-010 component life.

Removal Procedure
NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.
 65
Disassembly and Assembly Section

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

1. Cut the wires that hold the exhaust heat shield in

place and remove the exhaust heat shield.

g00596950
Illustration 226

1. Install the gasket and the exhaust bypass with

four bolts (4).

g00585318
Illustration 228
G3508 COSA Engines

2. Remove four bolts (2) and the nuts from each

side of exhaust adapter (3).

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

exhaust bellows (3) to the exhaust adapter.
g00596948
Illustration 227 4. Remove exhaust adapter (3) and the two metal
gaskets.
2. Connect tubes (1), (3), and (5).

3. Install tube (2).

i01109743

Exhaust Manifold - Remove

(Dry)
SMCS Code: 1059-011

Removal Procedure
Start By:
g00585604
Illustration 229
a. Remove the exhaust elbow. G3508 COSA Engines

b. Remove the turbocharger. 5. Remove four nuts (4) and the bolts in order to
remove the remaining sections of the exhaust
c. Remove the exhaust bypass valve. manifold.

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

are not damaged by any tools.
66
Disassembly and Assembly Section

6. Use the following steps if only one of the sections i01128163

of the exhaust manifold must be removed on all
G3500 Engines. Exhaust Manifold - Remove
(Water Cooled)
SMCS Code: 1059-011
S/N: 4WD1-Up
S/N: 5JD1-Up
S/N: 8LD1-Up
S/N: 9TG1-Up
S/N: 7NJ1-Up
S/N: 4EK1-Up
S/N: 6JW1-Up
S/N: 8PW1-Up
S/N: 9AW1-Up

Removal Procedure
g00585641
Illustration 230
Typical example
Start By:

a. Remove eight bolts (6) and the nuts that hold a. Remove the turbochargers.
each section of the exhaust manifold together.
b. Remove the aftercooler.
b. Remove four bolts (7) and the washers that
hold the exhaust manifold to the cylinder NOTICE
head. Keep all parts clean from contaminants.

c. Remove exhaust manifold section (5) and the Contaminants may cause rapid wear and shortened
metal gasket between each of the sections. component life.
Also remove the gasket that is on the cylinder
head. 1. Turn off the gas supply.
d. Repeat these steps for each section of the
exhaust manifold that must be removed.

g00596844
Illustration 231

2. Disconnect tube (1) from fitting on the gas

pressure regulator.

3. Remove clamp (2) from the joint.

 67
Disassembly and Assembly Section

9. Remove the bolts that hold the manifold for the

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

g00596753
Illustration 232

4. Disconnect tube (1) from the carburetor.

g00596757
Illustration 235
5. Remove clamp (3).
10. Remove bolts (7) that hold the exhaust manifold
6. Remove tubes (1) and (4). to the water temperature regulator housing.

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

exhaust manifold.

g00596755
Illustration 233

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

to the cylinder head. g00596758
Illustration 236

g00596756 g00596759
Illustration 234 Illustration 237

8. Remove tubes (6) from the exhaust manifold to 12. Attach a suitable lifting device to the exhaust
the exhaust bypass. manifold and remove bolts (9) that hold the
exhaust manifold to the mounting bracket.
68
Disassembly and Assembly Section

13. Remove the exhaust manifold. The exhaust

manifold weighs approximately 287 kg (632 lb).

i01128240

Exhaust Manifold - Install

(Water Cooled)
SMCS Code: 1059-012
S/N: 4WD1-Up
S/N: 5JD1-Up
S/N: 8LD1-Up g00596758
Illustration 239
S/N: 9TG1-Up
S/N: 7NJ1-Up
S/N: 4EK1-Up
S/N: 6JW1-Up
S/N: 8PW1-Up
S/N: 9AW1-Up

Installation Procedure
NOTICE
Keep all parts clean from contaminants. Illustration 240
g00596757

Contaminants may cause rapid wear and shortened 2. Install bolts (7), (8), and (9).
component life.

g00596755
Illustration 241
g00596759
Illustration 238
3. Install bolts (5).
1. Use a suitable lifting device to position the
exhaust manifold on the engine. Ensure that the
gaskets are in the proper position.
 69
Disassembly and Assembly Section

b. Install the turbochargers.

i01110463

Exhaust Manifold - Install

(Dry)
SMCS Code: 1059-012

Installation Procedure
NOTICE
Keep all parts clean from contaminants.
g00596756
Illustration 242
Contaminants may cause rapid wear and shortened
4. Install tube (6). component life.

1. Use the following steps to install one section of

the exhaust manifold for all G3500 Engines.

g00596753
Illustration 243

5. Install tubes (1) and (4). Install clamp (3).

g00585641
Illustration 245
Typical example

a. Inspect the condition of the metal gaskets.

Replace the gaskets, if necessary.

b. Install the metal gaskets on the cylinder head

g00596844 and between each section of the exhaust
Illustration 244
manifold.
6. Install clamp (2) and connect tube (1) to the gas
pressure regulator.

7. Turn on the gas supply.

End By:

a. Install the aftercooler.

70
Disassembly and Assembly Section

3. Install four bolts (4) and the nuts. Tighten the

bolts to a torque of 47 ± 5 N·m (35 ± 4 lb ft).

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

are not damaged with any tools.

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

(35 ± 4 lb ft).

g00638469
Illustration 246

c. Ensure that the exhaust manifold is installed

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

d. Position the exhaust manifold on the engine. Illustration 248 g00585318

Install four bolts (7) that hold the exhaust G3508 COSA Engines
manifold to the engine.
5. Install the metal gaskets and position exhaust
e. Install four bolts (6) that hold each section adapter (3) on the engine.
of the exhaust manifold together. Tighten the
bolts to a torque of 47 ± 5 N·m (35 ± 4 lb ft). 6. Install four bolts (2) and the nuts that hold
exhaust adapter (3) to the mounting plate.
Note: Ensure that bellows (5) of the exhaust manifold
are not damaged with any tools. 7. Install four bolts (1) and the nuts on the exhaust
manifold.
f. Tighten the bolts again to a torque of
47 ± 5 N·m (35 ± 4 lb ft). 8. Use the same torque procedure that is given
above.
g. Repeat these steps for each section of the
exhaust manifold that must be installed.

g00585604
Illustration 247
G3508 COSA Engines

2. Install the metal gaskets and position each

section of the exhaust manifold on the engine.
 71
Disassembly and Assembly Section

g00586100
Illustration 249
Wiring diagram for the exhaust heat shield that is on G3508 Engines with dual turbochargers

9. Install the long sections of the exhaust heat

shield and wire the heat shield together. NOTICE
Keep all parts clean from contaminants.
End By:
Contaminants may cause rapid wear and shortened
a. Install the exhaust bypass valve. component life.
b. Install the turbocharger.
NOTICE
c. Install the exhaust elbow. 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
i01197972
collect the fluid with suitable containers before open-
Water Temperature Regulators ing any compartment or disassembling any compo-
nent containing fluids.
- Remove
Refer to Special Publication, NENG2500, “Caterpillar
SMCS Code: 1355-011 Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
Removal Procedure products.

Table 13 Dispose of all fluids according to local regulations and

mandates.
Required Tools
Part 1. Drain the coolant from the cooling system into a
Tool Part Description Qty
Number
suitable container for storage or disposal.
A 138-7573 Link Bracket 2
72
Disassembly and Assembly Section

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

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

g00593658
Illustration 252
Typical example

8. Install Tool (A) and attach a suitable lifting device.

9. Remove eight bolts (11) and water temperature

regulator housing (12) from water manifold (10).
The weight of the water temperature regulator
g00593651
housing is approximately 59 kg (130 lb).
Illustration 250
Typical example 10. Remove the two O-ring seals from the radiator.

2. Remove the bolts from retainers (1) and (6). 11. Remove the bolts and housing (13).

3. Remove the bolts from support bracket (4).

4. Remove tube (5) and the O-ring seals.

5. Remove the four bolts from elbow (2). Remove

elbow (2) and the gasket.

6. Disconnect the line and the wiring harness from

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

g00593660
Illustration 253
Typical example

12. Remove four water temperature regulators (14).

g00593655
Illustration 251
Typical example
 73
Disassembly and Assembly Section

g00593662 g00593662
Illustration 254 Illustration 255
Typical example Typical example

13. Remove valve assembly (15) and seals (16), if 1. Install valve assembly (15). Ensure that the valve
necessary. is flush with the surface of the housing.

2. Use Tool (B) to install seals (16), if necessary.

i01197999
Ensure that the lip of the seal is toward the inside
Water Temperature Regulators of the housing.

- Install
SMCS Code: 1355-012

Installation Procedure
Table 14
Required Tools
Part
Tool Part Description Qty
Number
A 138-7573 Link Bracket 2
B 1P-0510 Driver Group 1
g00593660
Illustration 256
Typical example
NOTICE
Keep all parts clean from contaminants.
NOTICE
Contaminants may cause rapid wear and shortened If the water temperature regulator is installed incor-
component life. rectly, it will cause the engine to overheat.

3. Install four water temperature regulators (14) with

the spring upward.
74
Disassembly and Assembly Section

g00593658
Illustration 257
Typical example

4. Use Tool (A) and a suitable lifting device to

position water temperature regulator housing (12)
on the engine. Install the bolts and housing (12).

5. Install the two O-ring seals in the water

temperature regulator housing (12).

6. Install eight bolts (11) that hold water temperature

regulator housing (12) on water manifold (10).
g00593651
Illustration 259
Typical example

8. Install a new gasket and elbow (2).

9. Install tube (5) with retainers (1) and (6).

10. Install support bracket (5) and the bolts.

11. Install pressure sensor (3). Connect the line and

the wiring harness to pressure sensor (3).

12. Fill the cooling with coolant to the correct level.

g00593655
Refer to the Operation and Maintenance Manual
Illustration 258 for the correct procedure.
Typical example

7. Install mounting straps (7) and (9). Install plate

(8) on the engine oil filter housing.
 75
Disassembly and Assembly Section

i01121212

Water Pump - Remove

SMCS Code: 1361-011
S/N: 4WD1-Up
S/N: 5JD1-Up
S/N: 8LD1-Up
S/N: 9TG1-Up
S/N: 7NJ1-Up
S/N: 4EK1-Up
S/N: 6JW1-Up
S/N: 8PW1-Up
S/N: 9AW1-Up

Removal Procedure
NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

g00592484
component life. Illustration 260

2. Remove bolts (5) and the retainer from the water

NOTICE pump.
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test- 3. Remove the bolts and retainer (2) from elbow (1).
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open- 4. Remove the bolt from support bracket (4).
ing any compartment or disassembling any compo- Remove tube assembly (3).
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.

1. Drain the coolant from the cooling system into a

suitable container for storage or disposal.

g00592487
Illustration 261

5. Attach a suitable lifting device to the water pump.

Remove bolts (6), bolts (7), and water pump (8).
The weight of the water pump is approximately
38 kg (85 lb).
76
Disassembly and Assembly Section

Handling the Water Pump i01121280

Water Pump - Disassemble

NOTICE
Radial movement of the pump drive shaft can allow the SMCS Code: 1361-015
shaft to contact the ceramic seals in the water pump.
This can damage the ceramic seals. Damage to the S/N: 4WD1-Up
seals will cause leaks and failure of the pump. Do not
cause radial movement of the pump drive shaft. S/N: 5JD1-Up
S/N: 8LD1-Up
S/N: 9TG1-Up
S/N: 7NJ1-Up
S/N: 4EK1-Up
S/N: 6JW1-Up
S/N: 8PW1-Up
S/N: 9AW1-Up

Disassembly Procedure
g00616674 Table 15
Illustration 262
Section view of the water pump Required Tools
(1) Ceramic seals Part
(2) Pump drive shaft Tool Part Description Qty
Number
Use the following guidelines for handling the water 5F-7465 Puller 1
pump: 3L-5085 Bolt 2

• Do not cause radial movement of the pump drive 4B-5270 Hard Washer 2
shaft. Never use any tool that will cause radial A
4B-5271 Hard Washer 2
movement of the shaft.
4B-5273 Hard Washer 2
• Never place the water pump on a surface so the 1P-0458 Drive Plate 1
shaft rests on the surface.

• Never handle the water pump by the shaft. Start By:

a. Remove the water pump.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.
 77
Disassembly and Assembly Section

g00592559 g00592567
Illustration 263 Illustration 266

1. Remove elbow (1) and the O-ring seal from 5. Loosen nut (8) from impeller (7). Use Tool (A) to
housing (2). loosen impeller (7). Remove Tool (A), nut (8), the
washer, and impeller (7) from housing (2).

g00592562
Illustration 264
g00592581
Illustration 267
2. Remove O-ring seal (5) from the rear of housing
(2). 6. Remove spring (10).

3. Remove washer (4) that holds shaft assembly 7. Use a soft hammer to push shaft assembly
(3) in housing (2). (3) out of seal assembly (9) and housing (2).
Remove seal assembly (9).

g00592565
Illustration 265
g00592583
Illustration 268
4. Remove cover (6) and the O-ring from housing
(2). 8. Remove ceramic seal (11) and the rubber ring
from housing (2).
78
Disassembly and Assembly Section

g00592586 g00592637
Illustration 269 Illustration 270

9. Remove seal (12) from the rear of housing (2). 1. Replace two filters (1) and plug (2), if necessary.

2. Use Tool (A) to install the seal in the housing.

i01121350
Ensure that the lip of the seal is toward the
Water Pump - Assemble outside. Place clean engine oil on the seal.

SMCS Code: 1361-016

S/N: 4WD1-Up
S/N: 5JD1-Up
S/N: 8LD1-Up
S/N: 9TG1-Up
S/N: 7NJ1-Up
S/N: 4EK1-Up
S/N: 6JW1-Up
g00592638
S/N: 8PW1-Up Illustration 271

S/N: 9AW1-Up 3. Install shaft assembly (3) in housing (6). Install

washer (4) and the bolts. Install O-ring seal (5)
on the rear of housing (6).
Assembly Procedure
Table 16
Required Tools
Part
Tool Part Description Qty
Number
A 1P-0510 Driver Group 1

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.
g00592639
Illustration 272
 79
Disassembly and Assembly Section

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

4. Install ceramic seal (7) in the rubber ring. Use

hand pressure and the tool that is supplied with
the seal group to install the seal.

g00592646
Illustration 275

8. Install the washer and nut (11) on impeller (10).

Tighten the nut to a torque of 200 ± 25 N·m
(150 ± 18 lb ft).

g00592640
Illustration 273

5. Remove the spring from seal assembly (8). Use

hand pressure and the tool that is supplied with
the seal group to install the seal. The face of the
seal should make light contact with the shaft.

g00592647
Illustration 276

9. Ensure that the studs for cover (12) are tight in

the housing.

10. Place clean engine oil on O-ring seal (15) and

install the seal on cover (12).

11. Install the nuts on the studs. Tighten the nuts to

a torque of 27 ± 4 N·m (20 ± 3 lb ft).

g00592644
Illustration 274

6. Install spring (9).

7. Install impeller (10).

g00592650
Illustration 277
80
Disassembly and Assembly Section

12. Place clean engine oil on the O-ring seal and 1. Ensure that the gasket for the water line adapter
install the seal in elbow (1). Install elbow (1) on and the O-ring seal on the pump are in the
housing (6). correct position. Place clean engine oil on the
O-ring seal.
13. Place clean engine oil on the O-ring seal and
install the seal on the rear of housing (6). 2. Fasten a hoist to water pump (8) and install
water pump (8). Ensure that the splines on water
End By: pump (8) are correctly positioned. Install bolts
(6) and (7).
a. Install the water pump.

i01121249

Water Pump - Install

SMCS Code: 1361-012
S/N: 4WD1-Up
S/N: 5JD1-Up
S/N: 8LD1-Up
S/N: 9TG1-Up
S/N: 7NJ1-Up
S/N: 4EK1-Up
S/N: 6JW1-Up
S/N: 8PW1-Up
S/N: 9AW1-Up

Installation Procedure
NOTICE
Keep all parts clean from contaminants. Illustration 279
g00592484

Contaminants may cause rapid wear and shortened 3. Place clean engine oil on the O-ring seals on
component life. tube assembly (3). Install tube assembly (3).

4. Install support bracket (4) and the bolt.

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

6. Install bolts (5) and the retainer.

7. Fill the cooling system with coolant to the correct

level. Refer to the Operation and Maintenance
Manual for the correct procedure.

g00592487
Illustration 278
 81
Disassembly and Assembly Section

i01122852 i01122879

Thermostatic Valve - Remove Thermostatic Valve -

SMCS Code: 1355-011
Disassemble
SMCS Code: 1355-015
Removal Procedure
Disassembly Procedure
NOTICE
Keep all parts clean from contaminants. Start By:
Contaminants may cause rapid wear and shortened a. Remove the thermostatic valve.
component life.
NOTICE
1. Disconnect the supply line to the auxiliary water Keep all parts clean from contaminants.
pump. Plug all openings immediately.
Contaminants may cause rapid wear and shortened
component life.

g00593573
Illustration 280
Typical example
g00593619
Illustration 282
2. Remove two clamps (1).
1. Remove two tubes (1). Remove plug (6).
3. Remove three bolts (2). Remove thermostatic
valve (4) and bracket (3). 2. Remove remaining bolt (7), upper housing (2),
O-ring seal (3), thermostat (4), and lower housing
(5).

g00593574
Illustration 281

4. Remove three bolts (5) and separate thermostatic Illustration 283 g00593623
valve (4) from bracket (3).
3. Remove retaining screw (9) and seal (8), if
necessary.
82
Disassembly and Assembly Section

4. Remove bolt (11) and plate (10), if necessary. End By:

a. Install the thermostatic valve.

i01122947

Thermostatic Valve - Assemble i01122865

SMCS Code: 1355-016 Thermostatic Valve - Install

SMCS Code: 1355-012
Assembly Procedure
NOTICE
Installation Procedure
Keep all parts clean from contaminants.
NOTICE
Contaminants may cause rapid wear and shortened Keep all parts clean from contaminants.
component life.
Contaminants may cause rapid wear and shortened
component life.

g00593623
Illustration 284
g00593574
1. Install plate (10) and bolt (11), if necessary. Illustration 286

2. Install seal (8) and retaining screw (9), if 1. Position bracket (3) on thermostatic valve (4)
necessary. and install three bolts (5).

g00593619 g00593573
Illustration 285 Illustration 287

3. Assemble lower housing (5), thermostat (4), 2. Position thermostatic valve (4) and bracket (3)
O-ring seal (3), upper housing (2), and bolt (7). on the engine and install three bolts (2).

4. Install plug (6) and two tubes (1). 3. Install two clamps (1).

4. Connect the supply line to the auxiliary water

pump.
 83
Disassembly and Assembly Section

i01120889

Auxiliary Water Pump -

Remove
SMCS Code: 1371-011
S/N: 4WD1-Up
S/N: 5JD1-Up
S/N: 8LD1-Up
S/N: 9TG1-Up
S/N: 7NJ1-Up g00592158
Illustration 288
S/N: 4EK1-Up
2. Remove two clamps (1).
S/N: 6JW1-Up
S/N: 8PW1-Up 3. Remove four bolts (2) and four bolts (3).

S/N: 9AW1-Up

Removal Procedure
Table 17
Required Tools
Part
Tool Part Description Qty
Number
A 138-7573 Link Bracket 2

NOTICE
Keep all parts clean from contaminants. g00592165
Illustration 289

Contaminants may cause rapid wear and shortened

4. Remove the bolts that hold wiring clip (6) to the
component life.
engine oil pan.

NOTICE 5. Remove six bolts (5) and bolt (7).

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.
g00592166
Illustration 290
1. Drain the coolant from the cooling system into a
suitable container for storage or disposal. 6. Remove bolts (8) and cover (9).
84
Disassembly and Assembly Section

i01121062

Auxiliary Water Pump -

Disassemble
SMCS Code: 1371-015
S/N: 4WD1-Up
S/N: 5JD1-Up
S/N: 8LD1-Up
S/N: 9TG1-Up

g00592169
S/N: 7NJ1-Up
Illustration 291
S/N: 4EK1-Up
7. Remove bolts (11) and adapter (10).
S/N: 6JW1-Up
S/N: 8PW1-Up
S/N: 9AW1-Up

Disassembly Procedure
Table 18
Required Tools
Part
Tool Part Description Qty
Number
5F-7465 Puller 1

g00592170 3L-5085 Bolt 2

Illustration 292
A 9M-1974 Hard Washer 2
8. Remove the bearing from adapter (10), if 5P-8245 Hard Washer 2
necessary.
1P-0458 Drive Plate 1

Start By:

a. Remove the auxiliary water pump.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

g00592172
Illustration 293

9. Install Tool (A) and attach a suitable lifting device

to the auxiliary water pump. Pull the pump and
the drive gear out of the front housing.

10. Remove the auxiliary water pump. The weight of

the pump is approximately 39 kg (86 lb).
 85
Disassembly and Assembly Section

NOTICE
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 g00592356

Illustration 296
mandates.

g00592357
Illustration 297
g00592354
Illustration 294
4. Remove bolt (6) that holds impeller (7) on the
1. Remove O-ring seals (3) and (4). shaft.

2. Remove the bolts and gear (2) from shaft (1). 5. Use Tool (A) to remove impeller (7) from the shaft.

g00592355 g00592367
Illustration 295 Illustration 298

3. Remove the bolts and adapter (5) from the 6. Remove spring (9) from carbon seal assembly
housing. Remove the O-ring seal from adapter (10). Remove carbon seal assembly (10) from
(5). shaft (8).
86
Disassembly and Assembly Section

g00592368 g00592372
Illustration 299 Illustration 302

7. Remove the bolts that hold retaining washers 11. Remove bearing (15).
(12) on the housing. Remove shaft (1) and
washers (12).
i01121105

Auxiliary Water Pump -

Assemble
SMCS Code: 1371-016
S/N: 4WD1-Up
S/N: 5JD1-Up
S/N: 8LD1-Up
S/N: 9TG1-Up
S/N: 7NJ1-Up
g00592370
Illustration 300
S/N: 4EK1-Up
8. Remove the bolts that hold the shims and S/N: 6JW1-Up
retaining washers (13) on the housing. Remove
shaft (8), the shims, and washers (13). S/N: 8PW1-Up

9. Remove the rubber ring and ceramic seal (11) S/N: 9AW1-Up
from the housing. Refer to Illustration 298.
Assembly Procedure
Table 19
Required Tools
Part
Tool Part Description Qty
Number
A 1P-0510 Driver Group 1

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.
g00592371
Illustration 301

10. Remove lip type seal (14) from the housing.

 87
Disassembly and Assembly Section

3. Install shaft (2), retaining washers (3), the shims,

and the bolts that hold shaft (2) in the housing.

g00592393
Illustration 303

1. Ensure that the oil hole in the bearing is aligned Illustration 306 g00592397
with the oil passage in housing (1). Use Tool
(A) and a suitable press to install the bearing in 4. Place clean engine oil on the bearing in the
housing (1). The bearing must be 1.5 ± 0.5 mm housing. Install shaft (4) and retaining washers
(0.06 ± 0.02 inch) below the surface of the (5) on shaft (2). Install retaining washers (5) and
housing. The diameter of the bearing must be the bolts on the housing.
75.000 ± 0.055 mm (2.9527 ± 0.0022 inch) after
installation.
NOTICE
Clean water is the only lubricant that is permitted for
assembly. DO NOT damage or touch the wear sur-
faces of the carbon ring or the ceramic ring. Install the
ceramic ring with the smoothest face of the ring toward
the carbon seal.

g00592394
Illustration 304

2. Use Tool (A) to install the lip type seal in housing

(1). Ensure that the lip of the seal is toward the
bearing. Place clean engine oil on the seal.
g00592401
Illustration 307

5. Install ceramic seal ring (6) in the rubber seal.

Place clean water on the rubber seal and
ceramic seal ring (6) for lubrication. Use hand
pressure and the tool that is supplied with the
seal group to install the seal.

g00592396
Illustration 305
88
Disassembly and Assembly Section

g00592403 g00592431
Illustration 308 Illustration 311

6. Remove the spring from carbon seal assembly 9. Install O-ring seal (11) around adapter (10).
(7). Place clean water on the inside diameter Place clean engine oil on the seal.
of the seal assembly for lubrication. Use hand
pressure and the tool that is supplied with the 10. Position adapter (10) in the housing and install
seal group in order to install seal assembly (7). the bolts.
The face of the seal should make light contact
with the shaft.

g00592434
Illustration 312

g00592428
Illustration 309 11. Place gear (12) on shaft (4) and install the bolts.

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

g00592437
Illustration 313

g00592429
Illustration 310 12. Install O-ring seals (13) and (14) in the housing.
Place clean engine oil on the seals.
8. Install impeller (9) on the shaft. Install the washer
and the bolt. Tighten the bolt to a torque of
38 ± 4 N·m (28 ± 3 lb ft).
 89
Disassembly and Assembly Section

End By:

a. Install the auxiliary water pump.

i01120977

Auxiliary Water Pump - Install

SMCS Code: 1371-012
S/N: 4WD1-Up
S/N: 5JD1-Up
S/N: 8LD1-Up
g00592172
Illustration 314
S/N: 9TG1-Up
S/N: 7NJ1-Up 2. Use Tool (A) and a suitable lifting device to align
the auxiliary water pump in the front housing.
S/N: 4EK1-Up
S/N: 6JW1-Up
S/N: 8PW1-Up
S/N: 9AW1-Up

Installation Procedure
Table 20
Required Tools
Part
Tool Part Description Qty
Number
A 138-7573 Link Bracket 2 g00592165
Illustration 315
B 1P-0510 Driver Group 1
3. Install the bolt that holds wiring clip (6) to the
engine oil pan.
NOTICE
Keep all parts clean from contaminants. 4. Install six bolts (5) and bolt (7).

Contaminants may cause rapid wear and shortened

component life.

1. Install the O-ring seal on the auxiliary water

pump. Place clean engine oil on the seal.

g00592287
Illustration 316
90
Disassembly and Assembly Section

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

with the oil passage in adapter (10). Use Tool
(B) and a suitable press to install the bearing in
adapter (10). The bearing must be 1.5 ± 0.5 mm
(0.06 ± 0.02 inch) below the surface of the
adapter. The bearing should have a diameter of
75.000 ± 0.055 mm (2.9527 ± 0.0022 inch) after
installation.

g00592158
Illustration 319

9. Position the inlet elbow and install four bolts (3).

10. Position the outlet elbow and install four bolts (2).

11. Install two clamps (1).

g00592170 12. Fill the cooling system with coolant to the correct
Illustration 317
level. Refer to the Operation and Maintenance
6. Install O-ring seal (12) in adapter (10). Place Manual for the correct procedure.
clean engine oil on the O-ring seal.
i01119364
7. Install adapter (12) in the front housing.
Engine Oil Cooler - Remove
SMCS Code: 1378-011

Removal Procedure
NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

NOTICE
g00592166 Care must be taken to ensure that fluids are contained
Illustration 318
during performance of inspection, maintenance, test-
8. Install the O-ring seal in cover (9) and place ing, adjusting and repair of the product. Be prepared to
clean engine oil on the seal. Install cover (9) collect the fluid with suitable containers before open-
with bolts (8). 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.

1. Drain the coolant from the cooling system into a

suitable container for storage or disposal.
 91
Disassembly and Assembly Section

2. Drain the engine oil from the oil cooler into a

suitable container for storage or disposal.

g00591631
Illustration 322

Illustration 320 g00591628 7. Disconnect wiring harness (12) for the detonation
sensor.
3. Remove the bolts and retainers (3) from both
ends of tube (2). 8. Attach a suitable lifting device to the engine oil
cooler. Remove two bolts (8) and two bolts (11).
4. Remove the bolt and clamp (1).
9. Remove engine oil cooler (10) from tube (9)
5. Disconnect flange (5) and tube (4) from the and remove tube (2). The weight of the engine
adapter for the water line. oil cooler is approximately 45 kg (100 lb) on
G3508 Engines. The weight of the engine oil
cooler is approximately 65 kg (145 lb) on G3512
Engines. The weight of the engine oil cooler is
approximately 78 kg (171 lb) on G3516 Engines.

i01119536

Engine Oil Cooler -

Disassemble
SMCS Code: 1378-015

Disassembly Procedure
g00591629
Illustration 321 Start By:
6. Remove the bolts in elbow (6) and tube (7). a. Remove the engine oil cooler.
Remove the unit from the engine oil cooler
bonnet.
NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.
92
Disassembly and Assembly Section

NOTICE
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 g00591722

Illustration 325
mandates.
4. Remove the bolts and elbow (5) from the engine
oil cooler bypass. Remove the O-ring seals from
elbow (5).

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

Remove the O-ring seals from tube (7).

g00591718
Illustration 323

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

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

2. Remove tube (2) and the O-ring seals from

elbow (1). Illustration 326 g00591723

6. Remove two bolts (9), cover (10), spring (11),

bypass valve (12) and O-ring seals (13) from
elbow (5).

7. Remove the bolts and cover (14). Remove the

O-ring seal from the elbow of the engine oil
cooler bypass.

g00591720
Illustration 324

3. Place an identification mark on bonnet (3) and

engine oil cooler core (4) for the assembly
procedure. Remove bonnet (3) from engine oil
cooler core (4).
 93
Disassembly and Assembly Section

g00591724 g00591724
Illustration 327 Illustration 329

8. Place an identification mark on bonnet (6) and 2. Install the O-ring seal and cover (16), if
engine oil cooler core (4) for the assembly necessary.
procedure. Remove bonnet (6).
3. Install the O-ring seal and drain plug (15), if
9. Remove drain plug (15) and the O-ring seal, if necessary.
necessary.
4. Install the gasket and bonnet (6) on engine oil
10. Remove cover (16) and the O-ring seal, if cooler core (4). Install the bolts.
necessary.

i01119811

Engine Oil Cooler - Assemble

SMCS Code: 1378-016

Assembly Procedure
NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened g00591723

Illustration 330
component life.
5. Install the O-ring seal on elbow (5) of the engine
oil cooler bypass and place clean engine oil on
the O-ring seal.

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

(5). Install O-ring seal (13) and place clean
engine oil on the O-ring seal. Install cover (10)
and two bolts (9).

g00591822
Illustration 328

1. Ensure that the tubes in engine oil cooler core

(4) are clean.
94
Disassembly and Assembly Section

11. Install the O-ring seal on elbow (1) and place

clean engine oil on the O-ring seal. Install elbow
(1), tube (2), and the bolts on the engine oil
cooler core.

End By:

a. Install the engine oil cooler.

i01119499

Engine Oil Cooler - Install

SMCS Code: 1378-012
g00591722
Illustration 331
Installation Procedure
7. Install the O-ring seal on elbow (5) and install
elbow (5) on the engine oil cooler with the bolts. NOTICE
Keep all parts clean from contaminants.
8. Install the O-ring seals on tube (7) and place
clean engine oil on the O-ring seals. Install tube Contaminants may cause rapid wear and shortened
(7) and flange (8) on bonnet (6). component life.

g00591720
Illustration 332
g00591631
Illustration 334
9. Install the gasket, bonnet (3), and the bolts.
1. Ensure that the O-ring seals are in position on
tubes (2) and (9). Place clean engine oil on the
seals.

2. Attach a suitable lifting device to engine oil

cooler (10) and install tube (2).

3. Install engine oil cooler (10) on tube (9). Ensure

that tube (2) is in the correct position in the
adapter of the engine oil filter housing.

4. Install two bolts (8).

5. Install two bolts (11) and remove the lifting

device.
g00591718
Illustration 333

10. Install the O-ring seals on both ends of tube (2).

Place clean engine oil on the O-ring seals. Install
tube (2) in elbow (1).
 95
Disassembly and Assembly Section

i01119816

Engine Oil Pump - Remove

SMCS Code: 1304-011

Removal Procedure
Table 21
Required Tools
Part
Tool Part Description Qty
Number
A 138-7573 Link Bracket 2
g00591629
Illustration 335
NOTICE
6. Place clean engine oil on the O-ring seal on the Keep all parts clean from contaminants.
end of tube (7). Install elbow (6) and tube (7)
in the engine oil cooler bonnet. Ensure that the Contaminants may cause rapid wear and shortened
gasket is in place and install the bolts. component life.

NOTICE
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.
g00591628
Illustration 336 Dispose of all fluids according to local regulations and
mandates.
7. Install the gasket and the bolts that hold flange
(5) and tube (4).
1. Drain the coolant from the cooling system into a
8. Install clamp (1) and the bolts that hold tube (2) container for storage or disposal.
on the engine.

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

of tube (2).

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

g00591830
Illustration 337

2. Remove bolts (1), (2), and (4). Remove adapter

(3).
96
Disassembly and Assembly Section

i01120287

Engine Oil Pump - Disassemble

SMCS Code: 1304-015

Disassembly Procedure
Table 22
Required Tools
Part
Tool Part Description Qty
Number
A 1P-0510 Driver Group 1
g00591831
Illustration 338
Start By:
3. Remove four bolts (8). Remove elbow (5) and
tube (6). a. Remove the engine oil pump.

4. Remove the flange and tube (7) from the engine

NOTICE
oil cooler bonnet.
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

NOTICE
Care must be taken to ensure that fluids are 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

Illustration 339 g00591832 Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
5. Install Tool (A) and attach a suitable lifting device products.
to engine oil pump (9).
Dispose of all fluids according to local regulations and
6. Remove bolts (10) and (11). Disconnect wiring mandates.
clip (12).

7. Remove engine oil pump (9). The weight of the

engine oil pump is approximately 39 kg (86 lb).

g00591928
Illustration 340
 97
Disassembly and Assembly Section

g00591930 g00591936
Illustration 341 Illustration 343

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

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

Spring force will be released when covers are re-

moved.

Be prepared to hold spring loaded covers as the

bolts are loosened.

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

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

g00591962
Illustration 344

4. Use Tool (A) to remove bearings (8) from cover

assembly (7).

g00591932
Illustration 342

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

the engine oil pump.

g00591963
Illustration 345

5. Remove shaft assemblies (10) from engine oil

pump (9).
98
Disassembly and Assembly Section

g00591964 g00592092
Illustration 346 Illustration 348

6. Inspect gears (11) for wear and for defects. 1. Align bearings (1) in the body of the engine oil
pump. The bearing joints should be 45 ± 15
degrees from the centerline of the bearing bores.

2. Use Tool (A) to install bearing (1). The bearings

must be 1.5 ± 0.5 mm (0.06 ± 0.02 inch) below
the gear bore. The diameter of the bearings must
be 31.811 ± 0.013 mm (1.2524 ± 0.0005 inch)
after installation.

g00591965
Illustration 347

7. Use Tool (A) to remove bearings (12) from engine

oil pump (9).

i01120701

Engine Oil Pump - Assemble Illustration 349 g00617511

SMCS Code: 1304-016 3. Replace gears (2) and the shaft assemblies, if
necessary.
Assembly Procedure
Table 23
Required Tools
Part
Tool Part Description Qty
Number
A 1P-0510 Driver Group 1

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.
g00592099
Illustration 350
 99
Disassembly and Assembly Section

4. Install shaft assemblies (3) and (4) in the engine 8. Ensure that the two pins in cover assembly
oil pump. (9) are installed at a distance of 6.0 ± 1.0 mm
(0.24 ± 0.04 inch) above the surface of the cover.

g00592101
Illustration 351
g00591930
Illustration 354
5. Ensure that dowels (5) and (8) are installed in
cover assembly (6) at a distance of 6.0 ± 0.5 mm 9. Place clean engine oil on valve spool (13). Install
(0.24 ± 0.02 inch) above the surface of the cover. spring (12), gasket (11), cover (10), and the
bolts.
6. Use Tool (A) to install bearings (7) in cover
assembly (6) with the bearing joints in the correct Note: Refer to the Specifications Module, “Engine
position. Oil Pump” for more information.

End By:

a. Install the engine oil pump.

i01120209

Engine Oil Pump - Install

SMCS Code: 1304-012

Installation Procedure
Table 24
g00592110
Illustration 352 Required Tools

7. Position cover assembly (6) and install the bolts. Part

Tool Part Description Qty
Number
A 138-7573 Link Bracket 2

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

g00592103
Illustration 353
100
Disassembly and Assembly Section

g00591832 g00591830
Illustration 355 Illustration 357

1. Place clean engine oil on the O-rings. Install Tool 5. Install the gaskets and adapter (3) with bolts (1),
(A) and attach a suitable lifting device to engine (2), and (4).
oil pump (9).
Note: Refer to the Specifications Module, “Engine
2. Ensure that the splines on the shaft of engine oil Oil Pump” for more information.
pump (9) are correctly engaged with the splines
of the engine oil pump drive gear. Install bolts 6. Fill the cooling system to the correct level with
(10) and (11). coolant. Refer to the Operation and Maintenance
Manual for the correct procedure.

i01119032

Engine Oil Filter Housing -

Remove
SMCS Code: 1306-011

Installation Procedure
Table 25
Required Tools
g00591831
Illustration 356 Part
Tool Part Description Qty
Number
3. Place clean engine oil on the O-ring seals and
install tube (6) in elbow (5). Install elbow (5) on A 138-7573 Link Bracket 2
tube (6) with the bolts.
NOTICE
4. Place clean engine oil on the O-ring seals and Keep all parts clean from contaminants.
install tube (7) with the flange on the bonnet.
Contaminants may cause rapid wear and shortened
component life.

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

the seals, if necessary.
 101
Disassembly and Assembly Section

g00590989 g00590926
Illustration 358 Illustration 360

2. Install Tool (A) and position the engine oil filter 10. Install adapter (1) and three bolts (2).
housing on the engine.
i01119071
3. Install bolts (10) that hold the engine oil filter
housing to the engine. Engine Oil Filter Housing -
Disassemble
SMCS Code: 1306-015

Disassembly Procedure
Start By:

a. Remove the engine oil filter housing.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
g00590984
Illustration 359 ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
4. Install bolts (9). ing any compartment or disassembling any compo-
nent containing fluids.
5. Remove Tool (A) and install two bolts (3).
Refer to Special Publication, NENG2500, “Caterpillar
6. Install pressure sensor (7) and the mounting Tools and Shop Products Guide” for tools and supplies
plate with bolts (6). suitable to collect and contain fluids on Caterpillar
products.
7. Connect wiring harness (8).
Dispose of all fluids according to local regulations and
8. Connect line (5) to pressure sensor (7). mandates.

9. Install bolt (4) in the clip.

102
Disassembly and Assembly Section

g00591497 g00591500
Illustration 361 Illustration 363

3. Remove three engine oil filter elements (5).

Personal injury can result from parts and/or cov-

ers under spring pressure.

Spring force will be released when covers are re-

moved.

Be prepared to hold spring loaded covers as the

bolts are loosened.

1. Remove the three bolts and cover (1).

g00591502
Illustration 364

4. Remove O-ring seals (7).

5. Remove the three bolts and bypass valve

housing (6). The weight of the housing is
approximately 43 kg (95 lb).

g00591498
Illustration 362

2. Remove retainer (2), spring (3), and O-ring seal

(4) from cover (1).

g00591504
Illustration 365

6. Remove adapter (8). Remove O-ring seal (9)

from the adapter.
 103
Disassembly and Assembly Section

Personal injury can result from parts and/or cov-

ers under spring pressure.

Spring force will be released when covers are re-

moved.

Be prepared to hold spring loaded covers as the

bolts are loosened.

9. Remove bolts (14) and (16). Also remove covers

(15) and (17).
g00591541
Illustration 366

7. Remove O-ring seal (11) and pins (10), if

necessary.

g00591546
Illustration 369

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

g00591544 11. Remove spring (19) and bypass valve (18).

Illustration 367

8. Remove three nuts (12) and bolts from support

(13).

g00591547
Illustration 370

12. Remove three bolts (22), cover (23), and the

g00591545 three O-ring seals from the housing.
Illustration 368
13. Remove O-ring seal (25) and pin (24), if
necessary.
104
Disassembly and Assembly Section

i01119344

Engine Oil Filter Housing -

Assemble
SMCS Code: 1306-016

Installation Procedure
NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life. g00591545
Illustration 373

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

(16).

g00591547
Illustration 371

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

Install cover (23) and three bolts (22). Illustration 374 g00591544

2. Install O-ring seal (25). 7. Install support (13), the three bolts and three nuts
(12). Tighten the nuts to a torque of 55 ± 7 N·m
3. Install pin (24), if necessary. The pin must be (41 ± 5 lb ft).
6.50 ± 1.00 mm (0.256 ± 0.040 inch) above the
surface of the housing.

g00591541
Illustration 375
g00591546
Illustration 372 8. Install O-ring seal (11).
4. Install bypass valve (18) and spring (19).

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

 105
Disassembly and Assembly Section

9. Install new pins (10) in the bypass valve housing, 13. Install three new engine oil filter elements (5).
if necessary. The pins must be 6.50 ± 1.00 mm
(0.256 ± 0.040 inch) above the surface of the
housing.

g00591498
Illustration 379

14. Install O-ring seal (4), spring (3), and retainer

g00591504
Illustration 376 (2) on cover (1).

10. Install adapter (8). Install O-ring seal (9) on

adapter (8) and lubricate the seal with clean
engine oil.

g00591497
Illustration 380

15. Install cover (1) and the three bolts.

g00591502
Illustration 377 End By:

11. Install bypass valve housing (6). Tighten the a. Install the engine oil filter housing.
three bolts to a torque of 55 ± 7 N·m (41 ± 5 lb ft).

12. Install O-ring seals (7).

g00591500
Illustration 378
106
Disassembly and Assembly Section

i01119302

Engine Oil Filter Housing -

Install
SMCS Code: 1306-012

Installation Procedure
Table 26
Required Tools
Part
Tool Part Description Qty
Number
A 138-7573 Link Bracket 2

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened g00590984

component life. Illustration 382

4. Install bolts (9).

1. Inspect the condition of the O-ring seals. Replace
the seals, if necessary. 5. Remove Tool (A) and install two bolts (3).

6. Install pressure sensor (7) and the mounting

plate with bolts (6).

7. Connect wiring harness (8).

8. Connect line (5) to pressure sensor (7).

9. Install bolt (4) in the clip.

g00590989
Illustration 381

2. Install Tool (A) and position the engine oil filter

housing on the engine.

3. Install bolts (10) that hold the engine oil filter

housing to the engine.

g00590926
Illustration 383

10. Install adapter (1) and three bolts (2).

 107
Disassembly and Assembly Section

i01118960

Engine Oil and Water Pump

Drive - Remove
SMCS Code: 1313-011

Removal Procedure
Start By:

a. Remove the engine oil pump.

b. Remove the water pump.

g00590550
Illustration 385
NOTICE Typical example
Keep all parts clean from contaminants.
2. Remove bolts (4) and front adapter assembly (3).
Contaminants may cause rapid wear and shortened
component life. i01117596

Engine Oil and Water Pump

NOTICE
Care must be taken to ensure that fluids are contained Drive - Disassemble
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to SMCS Code: 1313-015
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo- Disassembly Procedure
nent containing fluids.
Table 27
Refer to Special Publication, NENG2500, “Caterpillar
Required Tools
Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar Part
Tool Part Description Qty
products. Number
A 1P-0520 Driver Group 1
Dispose of all fluids according to local regulations and
mandates.
Start By:

a. Remove the oil and water pump drive.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

g00590549
Illustration 384
Typical example

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

108
Disassembly and Assembly Section

5. Remove bolts (9) from shaft assembly (1).

Remove gears (8) and (10) from shaft assembly
(1).

g00590605
Illustration 386

1. Remove O-ring seal (4).

g00590613
Illustration 389
2. Remove the bolts and washers (2). Remove rear
adapter assembly (3) from shaft assembly (1). 6. Remove O-ring seal (13) from front adapter
assembly (12).

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

bearing (11) from front adapter assembly (12).

i01117378

Engine Oil and Water Pump

Drive - Assemble
SMCS Code: 1313-016

Disassembly Procedure
g00590608
Illustration 387
Table 28

3. Remove O-ring seals (6) and (7) from rear Required Tools
adapter assembly (3). Part
Tool Part Description Qty
Number
4. Use Tool (A) and a suitable press to remove
bearing (5). A 1P-0520 Driver Group 1

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

g00590612
Illustration 388
 109
Disassembly and Assembly Section

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

oil hole in the bearing with the oil hole that is in
rear adapter assembly (3). Use Tool (A) and a
suitable press to install bearing (5).

6. Ensure that bearing (5) does not extend above

the surface of rear adapter assembly (3).
Machine the bearing, if necessary. The bore
in the bearing must be 75.00 ± 0.06 mm
(2.953 ± 0.002 inch) after installation.

7. Install O-ring seals (6) and (7) on rear adapter

assembly (3).

g00590613
Illustration 390

1. Lower the temperature of bearing (11). Use Tool

(A) and a suitable press to install bearing (11)
in front adapter assembly (12). Machine the
bearing, if necessary. The bore in the bearing
must be 75.00 ± 0.06 mm (2.953 ± 0.002 inch)
after installation.

2. Install O-ring seal (13).

g00590605
Illustration 393

8. Install rear adapter assembly (3) on shaft

assembly (1).

9. Install washers (2) and the bolts.

10. Install O-ring seal (4) on rear adapter assembly

(3).

End By:
g00590612
Illustration 391 a. Install the oil and water pump drive.
3. Install gears (8) and (10) on shaft assembly (1).
i01118961
4. Install bolts (9).
Engine Oil and Water Pump
Drive - Install
SMCS Code: 1313-012

Installation Procedure
NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

g00590608
Illustration 392
110
Disassembly and Assembly Section

1. Ensure that the O-ring seals are installed in the i01115255

grooves of the adapter assemblies. Also apply
clean engine oil to the seals. Engine Oil Pan - Remove
SMCS Code: 1302-011

Removal Procedure
NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

NOTICE
Care must be taken to ensure that fluids are contained
g00590550 during performance of inspection, maintenance, test-
Illustration 394 ing, adjusting and repair of the product. Be prepared to
Typical example collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
2. Install front adapter assembly (3) and bolts (4). 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.

1. Drain the oil from the engine into a suitable

container for storage or disposal.

g00590549
Illustration 395
Typical example

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

End By:

a. Install the water pump.

b. Install the engine oil pump.

g00590117
Illustration 396

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

engine oil pump to the engine oil pan.
 111
Disassembly and Assembly Section

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

g00590118
Illustration 397
Typical example

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

engine.

4. Lift the engine off the engine oil pan. The engines g00590183
have the following weights: Illustration 398
Typical example
• G3508 Engines weigh approximately 4300 kg
(9500 lb). 1. Remove covers (1) and (2). Also remove the
O-ring seals.
• G3512 Engines weigh approximately 5443 kg
(12000 lb).

• G3516 Engines weigh approximately 6447 kg

(14200 lb).

5. The engine oil pans have the following weights:

• G3508 engine oil pan weighs approximately

295 kg (650 lb).

• G3512 engine oil pan weighs approximately

364 kg (800 lb).

• G3516 engine oil pan weighs approximately g00590204

393 kg (865 lb). Illustration 399

2. Remove screen assembly (3).

i01115569

Engine Oil Pan - Disassemble

SMCS Code: 1302-015

Disassembly Procedure
Start By:

a. Remove the engine oil pan.

g00590205
Illustration 400
112
Disassembly and Assembly Section

3. Remove the bolts and the engine oil level gauge

(4).

g00590209
Illustration 403
Typical example
g00590206
Illustration 401
Typical example 1. Install tube assembly (7) and the O-ring seals.

4. Remove the bolts that hold bell (5) on the engine 2. Install housing (6) with the bolts.
oil pan. Remove bell (5) from the tube assembly.
3. Insert tube assembly (7) into housing (6).

g00590209
Illustration 402
g00590206
Illustration 404
Typical example
Typical example
5. Pull tube assembly (7) from housing (6).
4. Position bell (5) on tube assembly (7). Install the
6. Remove the bolts and housing (6). bolts that hold bell (5) on the engine oil pan.

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

i01117060

Engine Oil Pan - Assemble

SMCS Code: 1302-016

Assembly Procedure
NOTICE
Keep all parts clean from contaminants.
g00590205
Illustration 405
Contaminants may cause rapid wear and shortened
component life. 5. Install engine oil level gauge (4) and the bolts.
 113
Disassembly and Assembly Section

2. Install four 3/8-16 NC guide bolts in the engine

oil pan and install the gasket.

g00590204
Illustration 406

6. Install screen assembly (3). Illustration 408 g00590118

Typical example

3. Install engine oil pan (2) and install bolts (3).

g00590183
Illustration 407
Typical example

7. Install the O-ring seals on covers (1) and (2). Illustration 409
g00590117
Install covers (1) and (2).
4. Install bolts (1) that hold the adapter of the
End By: engine oil pump to the engine oil pan.
a. Install the engine oil pan. Note: Refer to the Specifications Module, “Engine
Oil Pan” for more information.
i01115289
5. Fill the engine to the correct level with
Engine Oil Pan - Install clean engine oil. Refer to the Operation and
Maintenance Manual for the correct procedure.
SMCS Code: 1302-012

Installation Procedure
NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

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

adapter of the engine oil pump and place clean
engine oil on the O-ring seal.
114
Disassembly and Assembly Section

i01112071 Installation Procedure

Crankcase Breather - Remove NOTICE
and Install Keep all parts clean from contaminants.

SMCS Code: 1317-010 Contaminants may cause rapid wear and shortened
component life.
Removal Procedure
NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

NOTICE
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.
g00587344
Illustration 411
Dispose of all fluids according to local regulations and
mandates. 1. Install the gasket and crankcase breather (1).

2. Install four bolts (2).

i01111761

Valve Cover and Spark Plug -

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

Removal Procedure
NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

g00587344
Illustration 410

1. Remove four bolts (2).

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

 115
Disassembly and Assembly Section

NOTICE
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 g00587206

Illustration 414
mandates.
4. Remove O-ring seal (5) from transformer (4).

5. Remove the spark plug from the cylinder head.

6. Repeat the steps for the remaining valve covers

and the spark plugs.

Installation Procedure
NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.
g00587197
Illustration 412

1. Remove bolts (2), valve cover (1), and the seal. 1. Inspect the condition of the seals and the
gaskets. Replace the seals and the gaskets, if
necessary.

2. Install the spark plug in the cylinder head.

Tighten the spark plug to a torque of 68 ± 4 N·m
(50 ± 3 lb ft).

g00587202
Illustration 413

2. Disconnect electrical connector (3) from

transformer (4).

Note: Some engines have a hold-down that must be g00587206

removed from the transformer. Illustration 415

3. Lift transformer (4) out of the cylinder head. 3. Install new O-ring seal (5) on transformer (5).
116
Disassembly and Assembly Section

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

NOTICE
Care must be taken to ensure that fluids are 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-
g00587202 nent containing fluids.
Illustration 416
Refer to Special Publication, NENG2500, “Caterpillar
4. Set transformer (4) in the cylinder head. Push Tools and Shop Products Guide” for tools and supplies
down slightly in order to seat transformer (4). suitable to collect and contain fluids on Caterpillar
products.
5. Connect wiring harness (3) to transformer (4).
Dispose of all fluids according to local regulations and
mandates.

g00587197
Illustration 417

6. Install the seal and valve cover (1) on the g00587020

Illustration 418
cylinder head.

7. Install bolts (2). 1. Remove bolts (1) and remove rocker shaft (2)
from the valve cover base.

i01118964

Rocker Shaft and Push Rod -

Remove
SMCS Code: 1102-011; 1208-011

Removal Procedure
Start By:

a. Remove the valve cover and the spark plug.

g00587021
Illustration 419

Note: Place an identification mark on each push rod

in order to identify the proper location in the engine.
 117
Disassembly and Assembly Section

2. Remove push rods (4) from the valve lifters.

3. Remove valve bridges (3).

i01111599

Rocker Shaft - Disassemble

SMCS Code: 1102-015

Disassembly Procedure
Table 29
Required Tools g00587082
Illustration 420
Part
Tool Part Description Qty
Number 1. Slide rocker shaft (1) out of rocker arms (3) and
A 1P-0510 Driver Group 1 spacer (2).

2. Remove dowel (4), if necessary.

Start By:

a. Remove the rocker shaft assembly and the push

rods.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to g00587083
Illustration 421
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo- 3. Remove adjustment screw (5) and the nut from
nent containing fluids. rocker arm (3).

Refer to Special Publication, NENG2500, “Caterpillar 4. Use a hammer and a punch to remove socket
Tools and Shop Products Guide” for tools and supplies (6) from rocker arm (3).
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

mandates.

g00587085
Illustration 422
118
Disassembly and Assembly Section

5. Remove the O-ring that holds button (7) in socket

(6).

6. Remove button (7).

g00587087
Illustration 424

1. Align the oil hole in bearing (8) with the oil

passage in rocker arm (3).
g00587087
Illustration 423
2. Use Tool (A) to install bearing (8) in rocker
7. Use Tool (A) to remove bearing (8) from rocker arm (3). The bore of bearing (8) must be
arm (3). 37.140 ± 0.015 mm (1.4622 ± 0.0006 inch) after
assembly.
8. Repeat the steps for the other rocker arm.

i01111696

Rocker Shaft - Assemble

SMCS Code: 1102-016

Assembly Procedure
Table 30
Required Tools
Part
Tool Part Description Qty g00587141
Number Illustration 425
A 1P-0510 Driver Group 1
3. Align the scribe mark on socket (6) with the mark
on rocker arm (3) and install socket (6).
NOTICE
Keep all parts clean from contaminants. 4. Install button (7) and O-ring (9) in socket (6).

Contaminants may cause rapid wear and shortened

component life.

g00587083
Illustration 426
 119
Disassembly and Assembly Section

5. Install adjustment screw (5) and the nut on

rocker arm (3).

6. Repeat the steps for the second rocker arm.

g00587021
Illustration 428

1. Loosen the adjustment screws on valve bridges

(3).
g00587082
Illustration 427
2. Place clean engine oil on the dowels for valve
7. If dowel (4) was removed from rocker shaft bridges (3), on the inside diameter of the valve
(1), install a new dowel. The new dowel must bridges, and on the top buffer of the valve
be 6.00 mm (0.236 inch) above the surface of bridges.
rocker shaft (1).
3. Install valve bridges (3) on the dowels.
8. Place clean engine oil on bearing (8) and rocker
shaft (1). 4. While valve bridges (3) are pushed straight down
with a force of 5 to 45 N (1 to 10 lb), turn the
9. Install rocker arms (3) and spacer (2) on rocker adjustment screw until the screw makes contact
shaft (1). with the valve stem. Turn the adjustment screw
for an additional 20 or 30 degrees. This will align
End By: the valve bridge straight on the dowel. This also
compensates for the slack in the threads of the
a. Install the rocker shaft assembly and the push adjustment screw.
rods.
5. Hold the adjustment screw in position and tighten
the nut on the adjustment screw to a torque of
i01118966 30 ± 4 N·m (22 ± 3 lb ft).
Rocker Shaft and Push Rod - 6. Apply 8T-2998 Lubricant to the ends of push
Install rods (4).

SMCS Code: 1102-012; 1208-012 NOTICE

Ensure that the crankshaft and the camshafts are in
Installation Procedure time with each other. Also ensure that the adjustment
screws in the rocker arms are loosened completely
NOTICE before the bolts on the rocker shaft are tightened or
Keep all parts clean from contaminants. damage to the valves and the pistons may occur.

Contaminants may cause rapid wear and shortened 7. Install push rods (4) in the valve lifters.
component life.
120
Disassembly and Assembly Section

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

NOTICE
Care must be taken to ensure that fluids are 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-
g00587020 nent containing fluids.
Illustration 429
Refer to Special Publication, NENG2500, “Caterpillar
8. Install rocker shaft (2) on the valve cover base. Tools and Shop Products Guide” for tools and supplies
Ensure that the rocker arms and the push rods suitable to collect and contain fluids on Caterpillar
are aligned. products.
9. Install bolts (1). Tighten the bolts to a torque of Dispose of all fluids according to local regulations and
109 ± 14 N·m (80 ± 10 lb ft). mandates.
10. Set the valve lash on the intake valve to a
clearance of 0.51 mm (0.020 inch). Set the valve Note: Repeat the procedure for each cylinder head.
lash on the exhaust valve to a clearance of
1.02 mm (0.040 inch). 1. Drain the coolant from the cooling system into a
suitable container for storage or disposal.
11. Refer to the Testing and Adjusting Module,
“Valve Clearance Setting” for more information.

End By:

a. Install the spark plug and the valve cover.

i01109397

Cylinder Head - Remove

SMCS Code: 1100-011

Removal Procedure g00585022

Illustration 430
Table 31 Typical example
Required Tools
2. Remove bolts (3) from valve cover base (2).
Part
Tool Part Description Qty
Number 3. Remove valve cover base (3) from cylinder head
A 6V-2156 Link Bracket 2 (1).

Start By:

a. Remove the rocker shaft assemblies and the

push rods.
 121
Disassembly and Assembly Section

g00585024 g00585028
Illustration 431 Illustration 433
Typical example Typical example

4. Remove four bolts (6) from air inlet elbow (5). 12. Remove cylinder head gasket (13).

5. Remove four bolts (4) from exhaust elbow (7). 13. Remove the spacer plate gasket and the spacer
plate. Refer to Disassembly and Assembly,
“Spacer Plate - Remove and Install” for the
correct procedure.

i01130853

Cylinder Head - Disassemble

SMCS Code: 1100-015

Disassembly Procedure
Start By:
g00585027 a. Remove the cylinder head.
Illustration 432
Typical example
Inlet and Exhaust Valves
6. Disconnect exhaust temperature sensor (9).
Table 32
7. Remove two bolts (10) from tube (8) that runs Required Tools
from the water manifold to cylinder head (1).
There are also two bolts on the top of tube (8). Part
Tool Part Description Qty
Number
8. Install Tool (A) on cylinder head (1). Use the A 5S-1330 Valve Spring Compressor 1
holes for the bolts that hold the valve cover base.
B 8S-2263 Spring Tester 1
9. Fasten a suitable lifting device to cylinder head
(1). NOTICE
Keep all parts clean from contaminants.
10. Remove eight bolts (11) and two bolts (12) from
cylinder head (1). Contaminants may cause rapid wear and shortened
component life.
11. Remove cylinder head (1) from the engine.
Cylinder head (1) weighs 47 kg (105 lb).
122
Disassembly and Assembly Section

g00598108 g00598111
Illustration 434 Illustration 436

1. Use Tool (A) to compress valve spring (1). 5. Check the valve spring force with Tool (B). Refer
to the Specifications Module for the correct
2. Remove retainer lock (2). spring force values.

3. Remove Tool (A). Remove the valve rotator and 6. Repeat Steps 1 through 5 for the remaining
spring (1). valves.

Valve Train Bridge Dowels

Table 33
Required Tools
Part
Tool Part Description Qty
Number
5P-0944 Dowel Puller Group 1
A
5P-0942 Dowel Extractor 1

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

g00618922
Illustration 435

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

spring (4), and seal (6).

Note: Place an identification mark on the valves for

the assembly procedure.

g00598150
Illustration 437

1. Use Tool (A) to remove bridge dowel (1) from

the cylinder head.
 123
Disassembly and Assembly Section

Inlet and Exhaust Valve Seat Inserts

Table 34
Required Tools
Part
Tool Part Description Qty
Number
166-7441 Valve Seat Extractor 1
A
165-5647 Valve Seat Extractor 1

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened Illustration 439 g00598158
component life.
1. Use Tool (A) and a hammer to remove the valve
guides from the cylinder head.

Valve Lifters

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

Note: The valve lifters may also be removed with the

cylinder head on the engine. Remove the camshaft
and use the following steps in order to remove the
g00598156
Illustration 438 valve lifters with the cylinder head on the engine.

1. Use Tool (A) to remove the valve seat inserts

from the cylinder head.

2. Thoroughly clean the valve seat bores.

Inlet and Exhaust Valve Guides

Table 35
Required Tools
Part
Tool Part Description Qty
Number
7M-3975 Valve Guide Driver 1
A
5P-1729 Valve Guide Bushing 1 g00586578
Illustration 440

1. Pull valve lifter (1) out of the cylinder head.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.
124
Disassembly and Assembly Section

g00586579 g00586578
Illustration 441 Illustration 443

2. Remove guide spring (2) from the valve lifter. 2. Place valve lifter (1) in a container of clean
engine oil prior to installation.
i01131013
3. Install valve lifter (1) in the cylinder head.
Cylinder Head - Assemble Note: Refer to the Specifications Module, “Valve
SMCS Code: 1100-016 Rocker Arms, Lifters, and Bridges” for additional
information.

Assembly Procedure Inlet and Exhaust Valve Guides

Valve Lifters Table 36
Required Tools
NOTICE
Keep all parts clean from contaminants. Part
Tool Part Description Qty
Number
Contaminants may cause rapid wear and shortened A 5P-1729 Valve Guide Bushing 1
component life.
NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

g00586579
Illustration 442

1. Install guide spring (2) in the valve lifter.

g00598228
Illustration 444

1. Place clean engine oil on the outside of the valve

guides prior to installation.
 125
Disassembly and Assembly Section

2. Use Tool (A) to install the valve guides. The

valve guide should extend 26.00 ± 0.50 mm
(1.0236 ± 0.0197 inch) above the surface of the
cylinder head.

Inlet and Exhaust Valve Seat Inserts

Table 37
Required Tools
Part
Tool Part Description Qty
Number
A 166-7441 Valve Seat Extractor Tool 1

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.
g00598233
Illustration 446

2. The orientation of the valve seat inserts is shown

in Illustration 446.

Valve Train Bridge Dowels

Table 38
Required Tools
Part
Tool Part Description Qty
Number
A 6V-4009 Dowel Driver 1
g00598231
Illustration 445
NOTICE
1. Cool the valve seat inserts (1). Install valve seat Keep all parts clean from contaminants.
inserts with Tool (A).
Contaminants may cause rapid wear and shortened
component life.
126
Disassembly and Assembly Section

1. Place clean engine oil on the valves (4) and

install valves (4) in the cylinder head.

2. Install seal (2), the inner spring, outer spring (1),

and valve rotator (3) on the valve stem and the
valve guide.

g00598238
Illustration 447 g00598237 Illustration 449

1. Use Tool (A) to install bridge dowels (1). The 3. Compress the valve spring with Tool (A) and
bridge dowels must extend 66.5 ± 0.5 mm install retainer lock (6).
(2.62 ± 0.02 inch) above the surface of the
cylinder head.

Inlet and Exhaust Valves If the valve locks are not positioned correctly, the
locks can be expelled when the spring pressure is
Table 39 released.
Required Tools
To help prevent personal injury, stay away from the
Part front of the valve retainer and springs. Ensure that
Tool Part Description Qty
Number the valve locks are positioned correctly.
A 5S-1330 Valve Spring Compressor 1
4. Remove Tool (A) and lightly tap the top of the
NOTICE valves with a hammer. This will ensure that the
Keep all parts clean from contaminants. retainer locks are in the proper position.

Contaminants may cause rapid wear and shortened 5. Repeat Steps 1 through 4 for the remaining
component life. valves.

End By:

a. Install the cylinder head.

g00598243
Illustration 448
 127
Disassembly and Assembly Section

i01109430

Cylinder Head - Install

SMCS Code: 1100-012

Installation Procedure
Table 40
Required Tools
Part
Tool Part Description Qty
Number
A 6V-2156 Link Bracket 2
g00585054
Illustration 451
NOTICE
Keep all parts clean from contaminants. NOTICE
The plug at location (A) MUST be installed on engines
Contaminants may cause rapid wear and shortened that are equipped with a dry exhaust manifold. RE-
component life. MOVE the plug on engines that are equipped with a
water cooled exhaust manifold.
Note: Repeat the procedure for each cylinder head.
4. Install Tool (A) and attach a suitable lifting device
1. Clean the surface of the cylinder head and the to the cylinder head. Position the cylinder head
surface of the spacer plate. A new spacer plate on the spacer plate.
gasket must be installed when the cylinder head
is removed.

2. Install the spacer plate gasket and the spacer

plate. Refer to Disassembly and Assembly,
“Spacer Plate - Remove and Install” for the
correct procedure.

g00585027
Illustration 452
Typical example

5. Install eight bolts (11) and two bolts (12) in the

cylinder head.

g00585028
Illustration 450
Typical example

3. Install cylinder head gasket (13).

128
Disassembly and Assembly Section

9. Install four bolts (4) on exhaust elbow (7).

10. Install four bolts (6) on air inlet elbow (5).

g00585055
Illustration 453

6. Use the following procedure to tighten the

cylinder head bolts. Illustration 455
g00585022

Typical example
a. Apply 5P-3931 Anti-Seize Compound to the
threads of the cylinder head bolts. 11. Position valve cover base (2) on cylinder head
(1).
b. Tighten bolt (1) through bolt (8) in a numerical
sequence to a torque of 30 ± 5 N·m 12. Install bolts (3) in valve cover base (2).
(22 ± 4 lb ft).
13. Fill the cooling system to the correct level with
c. Tighten bolt (1) through bolt (8) again coolant. Refer to the Operation and Maintenance
in a numerical sequence to a torque of Manual for the correct filling procedure.
270 ± 35 N·m (200 ± 26 lb ft).
End By:
d. Tighten bolt (1) through bolt (8) again
in a numerical sequence to a torque of a. Install the rocker shaft assemblies and the push
450 ± 20 N·m (330 ± 15 lb ft). rods.
e. Tighten bolt (9) and bolt (10) to a torque of
55 ± 10 N·m (40 ± 7 lb ft). i01105974

7. Install two bolts (10) in tube (8) that runs from the Spacer Plate - Remove and
water manifold to the cylinder head. Also install
the two bolts on the top of tube (8).
Install
SMCS Code: 1221-010
8. Connect exhaust temperature sensor (9).
Removal Procedure
Start By:

a. Remove the cylinder head assembly.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

g00585024
Illustration 454
Typical example
 129
Disassembly and Assembly Section

NOTICE
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 g00583157

Illustration 458
mandates.
Typical example

3. Remove gasket (6) from the dowels.

g00583155
Illustration 456
Typical example
g00583158
Illustration 459
1. Remove gasket (4), seals (1), seals (2), and Typical example
O-ring seal (3) from the spacer plate.
4. Remove the O-ring seal from dowel (7).

Installation Procedure
NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

1. Ensure that the spacer plate and the surface of

the cylinder block are clean.
g00583156
Illustration 457
Typical example

2. Remove spacer plate (5) from the dowels in the

cylinder block.
130
Disassembly and Assembly Section

g00583158 g00583156
Illustration 460 Illustration 462
Typical example Typical example

2. Install the O-ring seal on dowel (7). 4. Install spacer plate (5) on the dowels.

g00583157 g00583155
Illustration 461 Illustration 463
Typical example Typical example

NOTICE 5. Install new seals (1) and (2) in spacer plate (5).
Ensure that the surface of the spacer plate gasket and
the surface of the cylinder block are clean. Do not use 6. Install new O-ring seal (3) on the dowel.
a gasket adhesive on these surfaces.
7. Check the cylinder liner projection. Refer to
Disassembly and Assembly, “Cylinder Liner -
3. Install a new gasket (6) on the dowels in the Install” for the correct procedure.
cylinder block.
8. Install new gasket (4) on top of spacer plate (5).

End By:

a. Install the cylinder head assembly.

 131
Disassembly and Assembly Section

i01112466 4. Remove the bolts and remove front adapter

assembly (3), the drive gear, and the shaft as
Accessory Drive (Front) - one unit.
Remove
i01112635
SMCS Code: 1207-011
Accessory Drive (Front) -
Removal Procedure Disassemble
NOTICE SMCS Code: 1207-015
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

Disassembly Procedure
component life. Table 41
Required Tools
Part
Tool Part Description Qty
Number
A 1P-0520 Driver Group 1

Start By:

a. Remove the accessory drive (front).

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

g00587600
Illustration 464 component life.
Typical example

1. Remove the bolts and rear cover (2) with the

O-ring seals.

2. Remove the bolts and use two 1/2-13 NC Forcing

Screws to remove rear adapter assembly (1).

g00587704
Illustration 466

1. Remove O-ring seals (2) and (3) from front

adapter assembly (1).

g00587601
Illustration 465
Typical example

3. Remove the front cover.

132
Disassembly and Assembly Section

6. Remove shaft (6) from front adapter assembly

(10).

g00587707
Illustration 467

2. Remove seal (4) from rear adapter assembly (1). Illustration 470 g00587770

3. Use Tool (A) and a suitable press to remove 7. Remove O-ring seals (12) and (13) from front
bearing (5) from rear adapter assembly (1). adapter assembly (10).

8. Use Tool (A) and a suitable press to remove

bearing (11) from front adapter assembly (10).

i01112769

Accessory Drive (Front) -

Assemble
SMCS Code: 1207-016

Assembly Procedure
g00587709 Table 42
Illustration 468
Required Tools
4. Remove bolts (7) and gear (8) from shaft (6). Part
Tool Part Description Qty
Number
A 1P-0520 Driver Group 1

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

g00587711
Illustration 469

5. Remove bolts (9) and the retaining washer.

Note: Later models have two retaining washers.

 133
Disassembly and Assembly Section

g00587828 g00587844
Illustration 471 Illustration 473

1. Align the oil hole in the bearing and the oil 5. Position gear (4) on shaft (3) and install the bolts.
hole in front adapter assembly (1). Use Tool
(A) and a suitable press to install the bearing
in front adapter assembly (1). The bore of
the bearing must be 75.00 ± 0.055 mm
(2.9527 ± 0.0022 inch) after installation.

2. Install the two O-ring seals in front adapter

assembly (1).

g00587850
Illustration 474

6. Align the oil hole in the bearing and the

oil hole in rear adapter assembly (5). Use
Tool (A) and a suitable press to install the
bearing in rear adapter assembly (5). The bore
of the bearing must be 75.00 ± 0.055 mm
(2.9527 ± 0.0022 inch) after installation.
g00587830
Illustration 472
7. Use Tool (A) to install the seal in rear adapter
3. Place clean engine oil on the bearing and install assembly (5). Ensure that the lip of the seal is
shaft (3). toward the bearing.

4. Install retaining washer (2).

Note: Later models have two retaining washers.

g00587855
Illustration 475
134
Disassembly and Assembly Section

8. Install O-ring seals (6) and (7) in rear adapter

assembly (5). Place clean engine oil on the
O-ring seals.

End By:

a. Install the accessory drive (front).

i01112537

Accessory Drive (Front) -

Install
SMCS Code: 1207-012 g00587600
Illustration 477
Typical example
Installation Procedure
4. Place clean engine oil on the O-rings on adapter
NOTICE assembly (1) and on the bearing in rear adapter
Keep all parts clean from contaminants. assembly (1).
Contaminants may cause rapid wear and shortened 5. Ensure that the O-ring seal is installed in rear
component life. cover (2).

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

rear cover (2) and install the bolts.

i01134287

Drive Housing (Front) - Remove

and Install
SMCS Code: 1151-010

Removal Procedure
Table 43
g00587657
Illustration 476
Required Tools
Typical example
Part
Tool Part Description Qty
1. Place clean engine oil on the O-ring seals for Number
front adapter assembly (3). 1P-0074 Slide Hammer Puller 1
A
Note: Ensure that the teeth of the accessory gear 8B-7557 Adapter 1
are correctly engaged with the teeth of the lower B 1P-0520 Driver Group 1
accessory drive gear.
C 138-7573 Link Bracket 2
2. Install the shaft, the drive gear, and adapter
assembly (3) in the front housing. Install the bolts. Start By:
3. Install the front cover. a. Remove the oil filter housing.

b. Remove the crankshaft front seal and the wear

sleeve.

c. Remove accessory drive (front).

d. Remove the engine oil and water pump drive.

 135
Disassembly and Assembly Section

e. Remove the auxiliary water pump.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

g00598966
Illustration 480
Typical example

4. Remove four tubes (4).

5. Remove elbow (5) and tube (3).

g00598961
Illustration 478
Typical example

1. Remove clamps (1).

g00598967
Illustration 481
Typical example

6. Remove cover (6) and the O-ring seal.

g00598964
Illustration 479
Typical example

2. Attach a suitable lifting device to mounting

bracket (2) with a 1/2-13 forged eyebolt.

3. Remove the ten bolts and mounting bracket (2)

from the engine. The mounting bracket weighs
approximately 69 kg (152 lb).

g00598970
Illustration 482
Typical example

7. Remove the bolts from the end of shaft (8). Use

Tool (A) to remove shaft (8) and idler gear (7)
from both sides of the engine.
136
Disassembly and Assembly Section

8. Use Tool (B) and a suitable press to remove the Installation Procedure
bearing from idler gear (7).
Table 44
Required Tools
Part
Tool Part Description Qty
Number
A 1P-0520 Driver Group 1
B 138-7573 Link Bracket 2

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.
g00598971
Illustration 483
Typical example

9. Remove two washers (9) from the front drive

housing.

10. Remove all of the bolts that hold the engine oil
pan to the engine. Install 3/8-16 NC guide bolts
in both sides of the engine oil pan. Attach a
suitable lifting device to the engine and lift the
engine off the engine oil pan 12 mm (0.5 inch).
Install two 50 mm wide x 100 mm long x 6mm
thick (2 inch x 4 inch x 1/4 inch) plates between
the engine and the engine oil pan. Rest the
engine on the plates. g00599039
Illustration 485
Typical example

1. Install the front drive housing gasket on the

cylinder block. Install two 5/8-11 NC guide bolts
in the cylinder block.

2. Install Tool (B) and attach a suitable lifting device

to front drive housing (10). Position front drive
housing (10) on the guide bolts.

3. Install the bolts in front drive housing (10) and

tighten the bolts evenly. Cut the excess gasket at
the face of the cylinder block.
g00598973 4. Attach a suitable lifting device to the engine
Illustration 484
Typical example and lift the engine enough to remove the two
plates between the engine and the engine oil
11. Install Tool (C) and attach a suitable lifting pan. Install all of the bolts that hold the engine
device to front drive housing (10). Remove front oil pan to the engine.
drive housing (10) and the gasket. The front drive
housing weighs approximately 209 kg (460 lb). 5. Inspect the condition of the gasket on the engine
oil pan. Replace the gasket, if necessary. Install
all of the bolts in the engine oil pan.
 137
Disassembly and Assembly Section

g00598971 g00598967
Illustration 486 Illustration 488
Typical example Typical example

6. Install two washers (9) in front drive housing (10). 9. Place clean engine oil and the O-ring seals and
install cover (6).

g00598970
Illustration 487
g00598966
Typical example Illustration 489
Typical example
7. Use Tool (A) to install the bearing in idler
gear (7). The bearing must have a diameter 10. Lubricate the O-ring seals on tube (3) with
of 90.00 ± 0.06 mm (3.543 ± 0.002 inch) after glycerin. Install tube (3) and elbow (5).
installation.
11. Install four tubes (4).
8. Place clean engine oil on the O-ring seal of shaft
(8). Install idler gear (7) and shaft (8) on both
sides of the engine.

g00598964
Illustration 490
Typical example
138
Disassembly and Assembly Section

12. Use a 1/2-13 forged eyebolt and a suitable

lifting device to install mounting bracket (2) on
the front drive housing. Install the ten bolts.

g00589930
Illustration 492

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

g00598961
Illustration 491
Typical example

13. Install four clamps (1).

End By:

a. Install the auxiliary water pump.

b. Install the engine oil and water pump drive.

c. Install the accessory drive (front).

d. Install the crankshaft front seal and the wear

sleeve. g00589939
Illustration 493

e. Install the engine oil filter housing.

2. Remove two bolts (5).

i01115046 3. Install two 1"-14 NF x 11" (280 mm) guide bolts

(3).
Vibration Damper - Remove
and Install 4. Install Tool (A) and attach a suitable lifting device.

SMCS Code: 1205-010 5. Remove the remaining bolts (5).

6. Remove vibration damper (4). The damper

Removal Procedure weighs approximately 91 kg (200 lb).
Table 45 7. Remove bolts (6) and remove the adapter from
Required Tools vibration damper (2), if necessary. The adapter
weighs approximately 34 kg (75 lb).
Part
Tool Part Description Qty
Number
A 138-7573 Link Bracket 2
Installation Procedure
Table 46
NOTICE Required Tools
Keep all parts clean from contaminants.
Part
Tool Part Description Qty
Number
Contaminants may cause rapid wear and shortened
component life. A 138-7573 Link Bracket 2
 139
Disassembly and Assembly Section

7. Install guard (2) and eight bolts (1). Tighten the

NOTICE bolts to a torque of 15 ± 3 N·m (11 ± 2 lb ft).
Keep all parts clean from contaminants.
i01113358
Contaminants may cause rapid wear and shortened
component life. Crankshaft Front Seal and
Wear Sleeve - Remove
1. If the adapter was removed, install the adapter
with bolts (6). Tighten the bolts to a torque SMCS Code: 1160-011; 7558-011
100 ± 15 N·m (75 ± 10 lb ft).
Removal Procedure
Table 47
Required Tools
Part
Tool Part Description Qty
Number
A 5P-7409 Sleeve Distorter 1
B 6V-3143 Distorter Adapter 1

Start By:

a. Remove the vibration damper.

g00589939
Illustration 494
NOTICE
2. Install Tool (A) and attach a suitable lifting device. Keep all parts clean from contaminants.
3. Apply 4C-5593 Anti-Seize Compound to the Contaminants may cause rapid wear and shortened
threads of the bolts. component life.
4. Position vibration damper (4) on the engine and
install four bolts (5). NOTICE
Care must be taken to ensure that fluids are contained
5. Remove the two guide bolts (3). during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
6. Install two remaining bolts (5). Tighten the bolts collect the fluid with suitable containers before open-
to a torque of 1125 ± 100 N·m (830 ± 75 lb ft). ing any compartment or disassembling any compo-
nent containing fluids.
Note: Refer to the Specifications Module, “Vibration
Damper” for more information. 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.

NOTICE
Every time that the crankshaft seal is removed from
the wear sleeve, a new wear sleeve and crankshaft
seal must be installed.

g00589930
Illustration 495
140
Disassembly and Assembly Section

5. Install Tool (A) between Tool (B) and wear sleeve

(5). Turn Tool (A) until the edge of the tool makes
a flat crease in wear sleeve (5). Repeat this
procedure several times until the wear sleeve
can be removed by hand.

i01113463

Crankshaft Front Seal and

Wear Sleeve - Install
SMCS Code: 1160-012; 7558-012

Illustration 496 g00588494 Installation Procedure

Table 48
1. Remove four bolts (1) from adapter (2) and install
two 5/16-18 NC forcing screws in adapter (2). Required Tools
Part
2. Use forcing screws to remove adapter (2). Tool Part Description Qty
Number
A 6V-4002 Forcing Bracket 2
B 6V-4001 Forcing Ring 1
C 1D-4716 Full Nut 4
6V-4003 Locator 1
D
2N-5006 Bolt 2

- Guide Bolts (5/16 -18 NC

E 4
x 4 in (101.6mm) long)
F 6V-4977 Installer 1
G 9S-8858 Nut 1

g00588495
Illustration 497 NOTICE
Keep all parts clean from contaminants.
3. Remove O-ring seal (4) and crankshaft seal (3)
from adapter (2). Contaminants may cause rapid wear and shortened
component life.

NOTICE
Every time that the crankshaft seal is removed from
the wear sleeve, a new wear sleeve and crankshaft
seal must be installed.

g00588497
Illustration 498

4. Install Tool (B) in the adapter bore.

 141
Disassembly and Assembly Section

g00588333 g00588568
Illustration 499 Illustration 500

1. Install adapter (3) on Tool (A). 8. Install Tool (D) on the end of the crankshaft.

NOTICE 9. Install Tool (E) in the drive housing. Place

If the crankshaft seal and the wear sleeve come apart adapter (3) on Tool (E) and (D). Ensure that the
during installation, the crankshaft seal and the wear wear sleeve makes contact with the end of the
sleeve must be replaced. crankshaft.

Note: The front crankshaft seal and the wear sleeve

can not be interchanged with the rear crankshaft
seal and the wear sleeve.

NOTICE
Do not place engine oil on the crankshaft seal for in-
stallation. Lubrication of the crankshaft seal can give
a false indication of leakage at a later time.

2. Place crankshaft seal (2) and wear sleeve (1)

on adapter (3). Ensure that the lip of the seal
is facing upward.
g00588569
Illustration 501
3. Install the O-ring seal on adapter (3).
10. Install Tool (B) over the outside diameter of Tool
4. Install Tool (B) on the studs of Tool (A). Install (F) until Tool (B) is against the shoulder of Tool
Tool (C) and tighten evenly until the seal is (F).
against the bottom of the adapter bore.
11. Install Tool (B) and (F) on Tool (E).
5. Remove Tools (C), (B), and (A) from adapter (3).
12. Apply 1P-0808 Multipurpose Grease on the
6. Clean the outer surface of the crankshaft with face of Tool (G). Install Tool (G) on Tool (D).
4C-9500 Quick Cure Primer. Tighten Tool (G) until the wear sleeve and the
adapter are in the correct position.
7. Place clean engine oil on the O-ring seal and
install the seal on adapter (3). Apply 4C-9507 13. Remove the tools from the engine.
Retaining Compound to the outside diameter of
the crankshaft and to the inside diameter of the
wear sleeve.
142
Disassembly and Assembly Section

NOTICE
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.

g00588570 Dispose of all fluids according to local regulations and

Illustration 502
mandates.
14. Install bolts (4) in adapter (3).

Note: Refer to the Specifications Module,

“Crankshaft Wear Sleeves And Seals” for more
information.

End By:

a. Install the vibration damper.

i01114804

Flywheel - Remove and Install

SMCS Code: 1156-010 Illustration 503
g00589791

Removal Procedure 1. Install Tool (A) on flywheel (1) and attach a

suitable lifting device.
Table 49
Required Tools 2. Remove two bolts (2) and install two 1-14 NF
guide bolts.
Part
Tool Part Description Qty
Number 3. Remove remaining bolts (2).
A 138-7573 Link Bracket 2
4. Remove flywheel (1). The flywheel weighs
approximately 167 kg (370 lb).
NOTICE
Keep all parts clean from contaminants. Installation Procedure
Contaminants may cause rapid wear and shortened Table 50
component life.
Required Tools
Part
Tool Part Description Qty
Number
A 138-7573 Link Bracket 2

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.
 143
Disassembly and Assembly Section

1. Inspect the condition of the flywheel gear. i01112849

Replace the gear, if necessary.
Crankshaft Rear Seal and Wear
a. Remove the damaged ring from the flywheel. Sleeve - Remove
b. Heat the new ring gear to a maximum SMCS Code: 1161-011; 7558-011
temperature of 316 C (600 F).

c. Install the gear on the flywheel with the Removal Procedure

chamfer of the gear teeth toward the engine.
Table 51
Required Tools
Part
Tool Part Description Qty
Number
A 5P-7409 Sleeve Distorter 1
B 6v-3143 Distorter Adapter 1
C 1U-7600 Slide Hammer Puller 1

Start By:

a. Remove the flywheel.

g00589791 NOTICE
Illustration 504
Keep all parts clean from contaminants.
2. Install two 1-11 NC guide bolts in the end of the
crankshaft. Contaminants may cause rapid wear and shortened
component life.
Note: Ensure that the mark on the flywheel is aligned
with the mark on the crankshaft.
NOTICE
3. Install Tool (A) and a suitable lifting device on Care must be taken to ensure that fluids are contained
flywheel (1). during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
4. Place clean engine oil on the threads of the bolts collect the fluid with suitable containers before open-
and install ten bolts (2). ing any compartment or disassembling any compo-
nent containing fluids.
5. Remove Tool (A) and the guide bolts in order
to install remaining two bolts (2). Tighten all Refer to Special Publication, NENG2500, “Caterpillar
of the bolts to a torque of 1150 ± 60 N·m Tools and Shop Products Guide” for tools and supplies
(850 ± 44 lb ft). suitable to collect and contain fluids on Caterpillar
products.
Note: Refer to the Specifications Module, “Flywheel”
for more information. Dispose of all fluids according to local regulations and
mandates.

NOTICE
Every time that the crankshaft seal is removed from
the wear sleeve, a new wear sleeve and crankshaft
seal must be installed.
144
Disassembly and Assembly Section

4. Install Tool (A) between Tool (B) and wear sleeve

(4). Turn Tool (A) until the edge of the tool
creates a flat crease in wear sleeve (4). Perform
this step several times until wear sleeve (4) can
be removed by hand.

i01113220

Crankshaft Rear Seal and Wear

Sleeve - Install
SMCS Code: 1161-012; 7558-012

Illustration 505 g00588053 Installation Procedure

Table 52
1. Remove the bolts from adapter (1). Install two
5/16-18 NC Forcing Screws in order to remove Required Tools
adapter (1). Part
Tool Part Description Qty
Number
Note: Use Tool (C) to remove the lip seal on engines
that do not have an adapter. A 6V-4002 Forcing Bracket 2
B 6V-4001 Forcing Ring 1
C 1D-4716 Full Nut 4
6V-4003 Locator 1
D
2N-5006 Bolt 2

- Guide Bolts (5/16 -18 NC

E 4
x 4 in (101.6mm) long)
F 6V-4977 Installer 1
G 9S-8858 Nut 1
H 8T-3099 Installation 1

Illustration 506 g00588054 NOTICE

Keep all parts clean from contaminants.
2. Remove O-ring seal (3) and crankshaft seal (2)
from adapter (1). Contaminants may cause rapid wear and shortened
component life.

NOTICE
Every time that the crankshaft seal is removed from
the wear sleeve, a new wear sleeve and crankshaft
seal must be installed.

g00588055
Illustration 507

3. Install Tool (B) in the adapter bore.

 145
Disassembly and Assembly Section

g00588333 g00588337
Illustration 508 Illustration 509

1. Install adapter (3) on Tool (A). 8. Install Tool (D) on the end of the crankshaft.

NOTICE 9. Install Tool (E) in the drive housing. Place

If the crankshaft seal and the wear sleeve come apart adapter (3) on Tool (E) and (D). Ensure that the
during installation, the crankshaft seal and the wear wear sleeve makes contact with the end of the
sleeve must be replaced. crankshaft.

Note: The front crankshaft seal and the wear sleeve

can not be interchanged with the rear crankshaft
seal and the wear sleeve.

2. Place crankshaft seal (2) and wear sleeve (1)

on adapter (3). Ensure that the lip of the seal
is facing upward.

3. Install the O-ring seal on adapter (3).

4. Install Tool (B) on the studs of Tool (A). Install

Tool (C) and tighten evenly until the seal is
against the bottom of the adapter bore. g00588348
Illustration 510
5. Remove Tools (C), (B), and (A) from adapter (3).
10. Install Tool (B) over the outside diameter of Tool
(F) until Tool (B) is against the shoulder of Tool
NOTICE (F).
Do not place engine oil on the crankshaft seal for in-
stallation. Lubrication of the crankshaft seal can give 11. Install Tool (B) and (F) on Tool (E).
a false indication of leakage at a later time.
12. Apply 1P-0808 Multipurpose Grease on the
6. Clean the outer surface of the crankshaft with face of Tool (G). Install Tool (G) on Tool (D).
4C-9500 Quick Cure Primer. Tighten Tool (G) until the wear sleeve and the
adapter are in the correct position.
7. Place clean engine oil on the O-ring seal and
install the seal on adapter (3). Apply 4C-9507 13. Remove the tools from the engine.
Retaining Compound to the outside diameter of
the crankshaft and to the inside diameter of the Note: Use Tool (H) in place of Tools (B) and (F) if
wear sleeve. the engine does not have an adapter.
146
Disassembly and Assembly Section

Note: Refer to the Testing and Adjusting Module,

“Installation/Removal Of The Speed/Timing Sensor”
for the correct procedure.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
Illustration 511 g00588350 ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
14. Install bolts (4) in adapter (3). ing any compartment or disassembling any compo-
nent containing fluids.
Note: Refer to the Specifications Module,
“Crankshaft Wear Sleeves And Seals” for more Refer to Special Publication, NENG2500, “Caterpillar
information. Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
End By: products.

a. Install the flywheel. Dispose of all fluids according to local regulations and
mandates.

i01113541

Flywheel Housing - Remove

SMCS Code: 1157-011

Removal Procedure
Table 53
Required Tools
Part
Tool Part Description Qty
Number
9U-6600 Hand Hydraulic Pump 1 g00588653
Illustration 512
8B-7548 Push-Puller Tool Group 1 Typical example
A 8B-7559 Adapter 2
1. Remove camshaft covers (1) and the gaskets
1P-0820 Hydraulic Puller 1 from flywheel housing (2).
5H-1504 Hard Washer 3
B 138-7573 Link Bracket 2

Start By:

a. Remove the starting motors.

b. Remove the oil pan.

c. Remove the crankshaft rear seal and the wear

sleeve.

d. Remove the speed/timing sensor.

 147
Disassembly and Assembly Section

NOTICE
Do not apply more than 51675 kPa (7500 psi) pressure
to the hydraulic puller. The adapters are rated at 6
1/2 tons each and the hydraulic puller is rated at 17
tons at 68900 kPa (10000 psi). If too much pressure
is applied, the gear may be damaged.

5. Install Tool (A) on camshaft drive gear (3).

Apply 51675 kPa (7500 psi) to the puller. Use a
hammer to tap the head of the puller screw on
Tool (A). This will break camshaft drive gear (3)
free from the camshaft.
g00588654
Illustration 513 6. Repeat the procedure for the remaining camshaft
drive gear.
2. Remove the bolt and timing pin (3).
7. Place blocks under the engine. The engines
have the following weights.

a. G3508 Engines weigh approximately 4300 kg

(9500 lb).

b. G3512 Engines weigh approximately 5443 kg

(12000 lb).

c. G3516 Engines weigh approximately 6447 kg

(14200 lb).

8. Install Tool (B) on the top of flywheel housing (2)

and attach a suitable lifting device.
g00588655
Illustration 514

3. Remove the bolt and plate (5) from camshaft

drive gear (4).

g00588658
Illustration 516
Typical example

9. Remove all bolts from flywheel housing (2).

g00588656
Illustration 515
Note: Dowel pins are used for the alignment of the
flywheel housing on the engine block. Removal of
4. Place the three washers of Tool (A) behind plate the dowel pins may help free the flywheel housing
(5) and install the bolt and plate (5). from the engine block.

10. Remove flywheel housing (2) from the engine.

The weight of the flywheel is approximately
210 kg (460 lb).
148
Disassembly and Assembly Section

i01113885

Flywheel Housing - Install

SMCS Code: 1157-012

Installation Procedure
Table 54
Required Tools
Part
Tool Part Description Qty
Number
A 138-7573 Link Bracket 2

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

1. Clean the mating surface of the flywheel housing

and the engine block with 4C-9500 Quick Cure
Primer. Place 6V-6640 RTV Silicone Sealant on
the mating surfaces also.

g00588653
Illustration 517
Typical example

2. Use Tool (A) and a suitable lifting device to

position flywheel housing (2) on the engine.

3. If the dowel pins were removed from flywheel

housing (2), install the dowel pins and ensure
that the dowel pins are properly seated.
 149
Disassembly and Assembly Section

g00589053
Illustration 518
(U) 6M-9613 Bolt (228.6 mm (9.00 inch)) (W) 1D-4566 Bolt (88.9 mm (3.50 inch)) (Y) 9S-1374 Bolt (203.2 mm (8.00 inch))
(V) 0S-1595 Bolt (31.8 mm (1.25 inch)) (X) 8S-9089 Bolt (114.3 mm (4.50 inch)) (Z) 1D-4590 Bolt (120.7 mm (4.75 inch))

4. Install the bolts for flywheel housing (2). Refer

to Illustration 518 for the proper locations of the
bolts. Tighten the 1/2-NC bolts to a torque of
100 ± 14 N·m (75 ± 10 lb ft). Tighten the 5/8-NC
bolts to a torque of 200 ± 25 N·m (150 ± 20 lb ft).

5. Remove Tool (A).

6. Place the camshaft timing pins in position and

place the timing bolt in the flywheel with the
No. 1 piston at the top center position on the
compression stroke.

g00588655
Illustration 519

7. Install camshaft drive gear (4).

8. Install plate (5) and the bolt.

150
Disassembly and Assembly Section

g00588654 g00588653
Illustration 520 Illustration 521
Typical example
9. Install timing ring (3) on the camshaft drive gear
and on the locating dowel. 13. Install camshaft covers (1) on the flywheel
housing.
10. Install the washer and the bolt for timing ring (3).
End By:
11. Use the following steps to seat camshaft drive
gears (4) onto the ends of the camshafts. a. Install the speed/timing sensor.
a. Tighten the bolt for timing ring (3) to a torque b. Install the crankshaft rear seal and the wear
of 360 ± 70 N·m (265 ± 52 lb ft). sleeve.
b. Use a soft hammer to hit the head of the bolt c. Install the engine oil pan.
for timing ring (3). This will help seat camshaft
drive gear (4) on the camshaft. d. Install the starting motors.
c. Tighten the bolt for timing ring (3) again to a
torque of 360 ± 70 N·m (265 ± 52 lb ft). i01115110

d. Place an index mark on the bolt for timing Engine Oil Sequence Valves -
ring (3). Remove and Install
e. Repeat these steps until the bolt for timing SMCS Code: 1332-010
ring (3) does not move after tightening the
bolt. The marks should stay aligned.
Removal Procedure
Note: Refer to the Disassembly and Assembly,
“Camshafts - Install” for more information. Start By:

12. Remove the timing pins from the camshafts and a. Remove the front drive housing.
the flywheel.
b. Remove the flywheel housing.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.
 151
Disassembly and Assembly Section

NOTICE
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 g00589988

Illustration 524
mandates.
Typical example

3. Remove the idler gear and the shaft. Remove

cover (4) on the rear of the cylinder block.

g00589986
Illustration 522

1. Remove cover (1) from the front of the cylinder

block. Illustration 525 g00589989

Typical example

4. Remove plunger assembly (5) and spring (6)

from the rear of the cylinder block.

Installation Procedure
NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

g00589987
Illustration 523

2. Remove plunger assembly (2) and spring (3)

from the front of the cylinder block.
152
Disassembly and Assembly Section

5. Install spring (3) and plunger assembly (2) on

the front of the cylinder block.

g00589989
Illustration 526
Typical example
g00589986
Illustration 529
1. Place clean engine oil on spring (6) and plunger
assembly (5). 6. Install cover (1) on the front of the cylinder block.

2. Install spring (6) and plunger assembly (5). End By:

a. Install the flywheel housing.

b. install the front drive housing.

i01112300

Gear Group (Rear) - Remove

SMCS Code: 1206-011; 1212-011

Removal Procedure
Table 55
g00589988
Illustration 527 Required Tools
Typical example
Part
Tool Part Description Qty
Number
3. Install cover (4) on the rear of the cylinder block.
Install the idler gear and the shaft. A 1P-0520 Driver Group 1

Start By:

a. Remove the flywheel housing.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

g00589987
Illustration 528

4. Place clean engine oil on spring (3) and plunger

assembly (2).
 153
Disassembly and Assembly Section

NOTICE
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 g00587521

Illustration 532
mandates.
4. Remove the bolts, the washers, and camshaft
idler gears (4).

g00587517
Illustration 530

1. Remove plate (1) and gear (2). Illustration 533 g00587523

5. Remove washers (6) and shafts (5) from

camshaft idler gears (4).

6. Use Tool (A) and a suitable press to remove

bearings from camshaft idler gears (4).

g00587518
Illustration 531

2. Use Tool (A) and a suitable press to remove

bearing (3) from gear (2).

3. Use Tool (A) and a suitable press to separate

the two gears. Illustration 534 g00587524

7. Remove the four bolts from shaft (7) and remove

shaft (7).
154
Disassembly and Assembly Section

g00587526 g00587524
Illustration 535 Illustration 537

8. Remove the bolts and gear (8) from the end of 2. Install shaft (7) and the four bolts.
the crankshaft.

i01112418

Gear Group (Rear) - Install

SMCS Code: 1206-012; 1212-012

Installation Procedure
Table 56
Required Tools
Part
Tool Part Description Qty
Number g00587523
Illustration 538
A 1P-0520 Driver Group 1
3. Use Tool (A) and a suitable press to install the
bearings in camshaft idler gears (4). The bore
NOTICE of the bearing must be 75.060 ± 0.010 mm
Keep all parts clean from contaminants. (2.9551 ± 0.0004 inch) after installation.
Contaminants may cause rapid wear and shortened 4. Place clean engine oil on the bearings and install
component life. shafts (5) with washers (6) on camshaft idler
gears (4).

g00587526
Illustration 536
g00587521
Illustration 539
1. Install crankshaft gear (8) and the bolts.
5. Install camshaft idler gears (4) and the bolts.
 155
Disassembly and Assembly Section

i01105864

Piston Cooling Jets - Remove

and Install
SMCS Code: 1331-010

Removal Procedure
NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

g00587518
component life.
Illustration 540

6. Use Tool (A) and a suitable press to install bearing NOTICE

(3) on gear (2). The bore of the bearing must Care must be taken to ensure that fluids are contained
be 75.060 ± 0.010 mm (2.9551 ± 0.0004 inch) during performance of inspection, maintenance, test-
after installation. ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
7. Heat the large gear to a maximum temperature ing any compartment or disassembling any compo-
of 400 C (752 F). Install the large gear on the nent containing fluids.
small gear.
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.

1. Remove the cylinder block cover from the side

of the engine.

g00587517
Illustration 541

8. Place clean engine oil on gear (2) and install

gear (2) on the engine.

9. Install plate (1) and the bolts.

End By:

a. Install the flywheel housing.

g00583062
Illustration 542

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

156
Disassembly and Assembly Section

g00583236 g00583062
Illustration 543 Illustration 545

3. Remove piston cooling jet (3) from the inside of 2. Install retainer (2) and two bolts (1).
the engine.
3. Install the cylinder block cover on the side of
the engine.
Installation Procedure
NOTICE i01190340
Keep all parts clean from contaminants.
Bearing Clearance - Check
Contaminants may cause rapid wear and shortened
component life. SMCS Code: 1203-535; 1219-535

Measurement Procedure
Table 57
Required Tools
Part
Tool Number Part Description Qty
A - Plastigage -

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

Illustration 544 g00583236 component life.

1. Position piston cooling jet (3) in the engine block. Note: Caterpillar does not recommend the checking
Ensure that the oil holes in the end of the jet are of the actual bearing clearances particularly on
facing toward the piston. 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.
 157
Disassembly and Assembly Section

Note: The measurements should be within 3. Carefully remove the cap, but do not remove
specifications and the correct bearings should Tool (A). Measure the width of Tool (A) while Tool
be used. If the crankshaft journals and the bores (A) is in the bearing cap or on the crankshaft
for the block and the rods were measured during journal. Refer to Illustration 546.
disassembly, no further checks are necessary.
However, if the technician still wants to measure 4. Remove all of Tool (A) before you install the
the bearing clearances, Tool (A) is an acceptable bearing cap.
method. Tool (A) is less accurate on journals with
small diameters if clearances are less than 0.10 mm Note: When Tool (A) is used, the readings can
(0.004 inch). sometimes be unclear. For example, all parts of
Tool (A) are not the same width. Measure the major
NOTICE width in order to ensure that the parts are within
Lead wire, shim stock or a dial bore gauge can dam- the specification range. Refer to the Specifications
age the bearing surfaces. Manual, “Connecting Rod Bearing Journal” and
Specifications Manual, “Main Bearing Journal” for
the correct clearances.
The technician must be very careful to use Tool (A)
correctly. The following points must be remembered:
i01105033

• Ensure that the backs of the bearings and the

bores are clean and dry.
Connecting Rod Bearings -
Remove and Install
• Ensure that the bearing locking tabs are properly
seated in the tab grooves. SMCS Code: 1219-010

• The crankshaft must be free of oil at the contact Removal Procedure

points of Tool (A).
Table 58
1. Put a piece of Tool (A) on the crown of the
Required Tools
bearing that is in the cap.
Part
Tool Part Description Qty
Note: Do not allow Tool (A) to extend over the edge Number
of the bearing.
A 9S-9082 Engine Turning Tool 1
2. Use the correct torque-turn specifications in
order to install the bearing cap. Do not use an Start By:
impact wrench. Be careful not to dislodge the
bearing when the cap is installed. a. Remove the piston cooling jets.

Note: Do not turn the crankshaft when Tool (A) is NOTICE

installed. Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

g00473227
Illustration 546
Typical example
158
Disassembly and Assembly Section

NOTICE
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 g00582298

Illustration 548
mandates.
Typical example

1. Use Tool (A) to turn the flywheel in order to 4. Remove lower half (3) of the connecting rod
access the connecting rod cap that will be bearing from connecting rod cap (2).
removed.
Installation Procedure
NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

1. Check the clearance of the bearings. Refer to

Disassembly and Assembly, “Bearing Clearance
- Check” for the correct procedure.

2. Place clean engine oil on the connecting rod

Illustration 547 g00582297 bearings.
Typical example

2. Remove bolts (1) and connecting rod bearing

cap (2) from the crankshaft.

3. Push the connecting rod away from the

crankshaft and remove the upper half of the
connecting rod bearing.

g00582298
Illustration 549
Typical example

3. Install lower half (3) of the connecting rod

bearing in connecting rod cap (2).

4. Install the upper half of the connecting rod

bearing in the connecting rod.

5. Position the connecting rod on the crankshaft.

 159
Disassembly and Assembly Section

Note: Bolts (4) and (5) are installed on the same side
as the locating pin. The locating pin must extend a
distance of 4.0 ± 0.5 mm (0.16 ± 0.02 inch) from
the connecting rod cap.

9. Tighten the bolts in the sequence that is

shown above. Tighten the bolts to a torque of
90 ± 5 N·m (65 ± 4 lb ft).

10. Tighten the bolts again to a torque of 90 ± 5 N·m

(65 ± 4 lb ft).

11. Turn the bolts for an additional 90 ± 5 degrees

(1/4 turn).
g00582299
Illustration 550 End By:
Typical example
a. Install the piston cooling jets.
6. Position connecting rod cap (2) on the
connecting rod. Ensure that the number on the
side of connecting rod cap (2) corresponds to i01098813
the number that is on the connecting rod.
Crankshaft Main Bearings -
7. Apply 6v-4876 Lubricant to the bolts. Remove
SMCS Code: 1203-011

Removal Procedure
Table 59
Required Tools
Part
Tool Part Description Qty
Number
A 9S-9082 Engine Turning Tool 1
B 2P-5517 Bearing Tool 1

Illustration 551 g00582297 Start By:

Typical example
a. Remove the piston cooling jets.
8. Install bolts (1) in connecting rod cap (2).
NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

g00582300
Illustration 552
Tightening sequence
160
Disassembly and Assembly Section

NOTICE
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 g00577797

Illustration 555
mandates.
5. Remove thrust plates (4) from each side of the
center main bearing.

g00577793
Illustration 553

1. Use Tool (A) to turn the engine and align Illustration 556 g00577798
counterweights (2) for removal of the main
bearing caps.
NOTICE
If the crankshaft is turned in the wrong direction, the
2. Counterweights (2) can be removed, if necessary.
tab of the main bearing will be pushed between the
crankshaft and the cylinder block. This may damage
3. Remove the four bolts and main bearing caps
both the crankshaft and the cylinder block.
(1) from the crankshaft.

6. Install Tool (B) in the oil hole of the crankshaft

journal and remove upper main bearing halves
(5) by turning the crankshaft.

Note: The center main bearing does not have an

oil hole. Place a soft piece of material that will not
damage the crankshaft journal against the end
of the bearing. Ensure that the material is on the
opposite side of the tab. Tap the bearing until the
tab is free from the cylinder block. Remove the
upper half of the center main bearing.

g00577796
Illustration 554

4. Remove lower bearing halves (3) from main

bearing caps (1).
 161
Disassembly and Assembly Section

i01099002

Crankshaft Main Bearings -

Install
SMCS Code: 1203-012

Installation Procedure
Table 60
Required Tools
Part
Tool Part Description Qty
Number
g00577894
A 9S-9082 Engine Turning Tool 1 Illustration 558

B 2P-5518 Bearing Tool 1 4. Place clean engine oil on thrust plates (1) and
C 8S-2328 Dial Indicator 1 install thrust plates (1) on each side of center
main bearing (2).

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

NOTICE
Ensure that the upper halves and the lower halves of
the main bearings are installed with the tabs fitting into
the notch in the cylinder block and the notch in the
main bearing cap.

1. Place clean engine oil on the main bearings. g00577895

Illustration 559
2. Check the clearance of the bearings. Refer to
Disassembly and Assembly, “Bearing Clearance 5. Ensure that main bearing caps (3) are clean and
- Check” for the correct procedure. install the lower half of main bearing (4) in main
bearing caps (3).

g00577798
Illustration 557 g00577550
Illustration 560
3. Install Tool (B) in the oil hole of the crankshaft Tightening sequence
journal. Place the upper half of the main bearing
on the crankshaft. Use Tool (A) to turn the engine
and push the upper half of the main bearing into
position with Tool (B).
162
Disassembly and Assembly Section

Note: The main bearing caps must be installed with d. Loosen the bolts in all of the counterweights.
the word “FRONT” and the part number toward the
front of the engine. Each main bearing cap has e. Tighten the bolts in all of the counterweights
a number on the bottom surface and each main to a torque of 70 ± 5 N·m (50 ± 4 lb ft).
bearing must be installed in the corresponding
position in the cylinder block. f. Tighten the bolts in all of the counterweights
for an additional 120 ± 5 degrees (1/3 turn).
6. Lubricate the bolts with clean engine oil prior
to assembly. 12. The following procedure is for the installation
of the counterweights in G3512 and G3516
7. Place the main bearing caps into position and Engines.
install the bolts. Tighten the bolts in the numerical
sequence that is shown above to a torque of a. Ensure that the dowels are in the correct
190 ± 14 N·m (140 ± 10 lb ft). position and install the counterweights on the
crankshaft.
8. Turn the bolts for an additional 180 ± 5 degrees.
b. Apply 6V-4876 Lubricant to the threads of
9. Check the end play of the crankshaft with the bolt, to the shank of the bolt, and to the
Tool (C). The end play must not exceed seat of the bolt prior to assembly.
0.40 ± 0.23 mm (0.0157 ± 0.0091 inch).
c. Tighten the bolts in all of the counterweights
to a torque of 70 ± 5 N·m (50 ± 4 lb ft).

d. Tighten the bolts in all of the counterweights

for an additional 120 ± 5 degrees (1/3 turn).

Note: Refer to the Specifications Module for more

information on the crankshaft.

End By:

a. Install the piston cooling jets.

g00577897
Illustration 561

NOTICE
Each counterweight is numbered and must be in-
stalled in the same position as the corresponding
number on the crankshaft mounting pad in order to
prevent damage to the crankshaft.

10. Install counterweights (9) and use the correct

tightening procedure below.

11. The following procedure is for the installation of

the counterweights in G3508 Engines.

a. Ensure that the dowels are in the correct

position and install the counterweights on the
crankshaft.

b. Apply 6V-4876 Lubricant to the threads of

the bolt, to the shank of the bolt, and to the
seat of the bolt prior to assembly.

c. Tighten the bolts in all of the counterweight to

a torque of 200 ± 5 N·m (150 ± 4 lb ft).
 163
Disassembly and Assembly Section

i01105197
NOTICE
Piston and Connecting Rods - Care must be taken to ensure that fluids are contained
Remove during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
SMCS Code: 1225-011 collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Removal Procedure
Table 61 Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and supplies
Required Tools suitable to collect and contain fluids on Caterpillar
Part products.
Tool Part Description Qty
Number
Dispose of all fluids according to local regulations and
A 9S-9082 Engine Turning Tool 1 mandates.
B 1P-1861 Retaining Ring Pliers 1
C 6V-4020 Piston Ring Expander 1 1. Use Tool (A) to turn the engine in order to access
the bolts in the connecting rod cap.
5P-8639 Hydraulic Press 1
5P-9725 Hydraulic Cylinder 1 2. Mark the cylinder number on each connecting
rod and the corresponding connecting rod cap.
8F-0024 Hose Assembly 1
1P-2375 Connecting Coupler 1 Note: The front of the engine is opposite the flywheel
end. The No. 1 cylinder is at the front of the engine
1P-2376 Connecting Coupler 1 on the right side. The No. 2 cylinder is on the left
D side.
5P-8649 Adapter 1
6V-3043 Spacer 1
6V-3042 Adapter 1
2D-2825 Hydraulic Pump 1
5P-8640 Bar Clamp 1

Start By:

a. Remove the spacer plate.

b. Remove the piston cooling jets.

NOTICE Illustration 562 g00582418

Keep all parts clean from contaminants.
Typical example
Contaminants may cause rapid wear and shortened
component life. 3. Remove bolts (1) and connecting rod cap (2)
from the connecting rod.

4. Remove the bearings from connecting rod cap

(2) and the connecting rod.
164
Disassembly and Assembly Section

g00582419 g00582421
Illustration 563 Illustration 565
Typical example Typical example

5. Push piston (3) out of the cylinder head until the 10. Use Tool (C) to remove piston rings (6) from
piston rings are completely out of the cylinder piston (3).
liner.
11. Clean the piston ring grooves with an acceptable
6. Remove the piston and connecting rod assembly. ring groove tool. Refer to Guideline For Reusable
Parts, SEBF8059-01, “Procedure To Clean And
Inspect 3500 Series Engine Pistons” for the
correct procedure for cleaning the pistons.

12. Heat connecting rod (2) in an oven to a

temperature of 218 ± 40C (425 ± 75F).

Note: Do not use a direct flame in order to heat the

connecting rod.

g00582420
Illustration 564
Typical example

7. Use Tool (B) to remove the retaining rings that

hold piston pin (4).

8. Remove piston pin (4).

9. Remove piston (3) from connecting rod (5). g00582422

Illustration 566

13. Place 6V-3043 Spacer (14) in the base plate of

Tool (D). Place the connecting rod on the base
plate.

14. Place the piston pin bearing in the center of the

port assembly on Tool (D). Install pin (9) in the
center of the bore for the piston pin.

15. Install 5P-8649 Adapter (12). Align the hole in

the adapter with the hole that is in the base plate
of Tool (D).
 165
Disassembly and Assembly Section

16. Install bar clamp (13) and clamp pin (10).

Note: The old bearing is pushed out while the new

bearing is installed.

17. Position 6V-3042 Adapter (11) with the tapered

side facing downward. The piston pin bearing
joint must be aligned with the hole in adapter
(12) and the hole in the base plate of Tool (D).

18. Place pusher (7) on adapter (11).

19. Use Tool (D) to push new piston pin bearing (8)
into the connecting rod until adapter (11) makes
contact with the connecting rod. g00582421
Illustration 567
20. Remove the connecting rod and the old piston Typical example
pin bearing from Tool (D).
1. Use Tool (C) to install piston rings (6) on piston
21. Measure the diameter of the bore after the (3).
piston pin bearing is removed. The bore
should have a diameter of 70.380 ± 0.010 mm 2. The ends of the oil control piston ring should be
(2.7709 ± 0.0004 inch). 180 degrees away from the oil ring end gap. The
white colored section of the oil ring spring should
22. Refer to Special Instruction, SMHS7295-02, “Use also be visible at the oil ring end gap.
Of Piston Pin Bearing Removal And Installation
Tools” for more information. 3. Install the intermediate ring with the side that
is marked “UP” toward the top of the piston.
Position the intermediate ring with the green strip
i01105718 on the right side of the end gap.
Piston and Connecting Rods 4. Install the top piston ring with the red strip on the
- Install right side of the end gap.

SMCS Code: 1225-012 5. The piston ring end gaps must be approximately
120 degrees away from each other after
installation.
Installation Procedure
Table 62
Required Tools
Part
Tool Part Description Qty
Number
A 9S-9082 Engine Turning Tool 1
B 1P-1861 Retaining Ring Pliers 1
C 6V-4020 Piston Ring Expander 1
D 1U-7616 Piston Ring Compressor 1

NOTICE
g00582420
Keep all parts clean from contaminants. Illustration 568
Typical example
Contaminants may cause rapid wear and shortened
component life. 6. Place clean engine oil on piston pin (4), the
piston pin bearing, and the bore in piston pin (4).

7. Position connecting rod (5) in piston (3) and

install piston pin (4).
166
Disassembly and Assembly Section

8. Use Tool (B) to install the snap rings that hold 13. Install the lower half of the connecting rod
piston pin (4). bearing in connecting rod cap (2). Ensure that
the tab on the back of the bearing is in the
9. Check the clearance of the bearings. Refer to bearing tab groove on connecting rod cap (2).
Disassembly and Assembly, “Bearing Clearance
- Check” for the correct procedure. 14. Place clean engine oil on the upper half and on
the lower half of the connecting rod bearing.
10. Install the upper half of the connecting rod
bearing in connecting rod (5). Ensure that the 15. Apply 6V-4876 Lubricant to the threads of the
tab on the back of the bearing is in the bearing bolts and the threads in connecting rod caps (2).
tab groove on connecting rod (5).
16. Position connecting rod cap (2) on the
connecting rod and install bolts (1) in connecting
rod cap (2).

17. Refer to Disassembly and Assembly,

“Connecting Rod Bearings - Remove and Install”
for the correct tightening procedure of the bolts
in the connecting rod cap.

18. Check the side clearance that is between two of

the connecting rods that are on the same journal.
The clearance must be 0.850 ± 0.232 mm
(0.0335 ± 0.0091 inch).

End By:
g00582933
Illustration 569
Typical example a. Install the piston cooling jets.

11. Place clean engine oil on the piston rings and b. Install the spacer plate.
the cylinder liner bore. Use Tool (D) to compress
the piston rings.
i01099846

12. Install the piston and connecting rod assembly Cylinder Liner - Remove
in the engine.
SMCS Code: 1216-011
NOTICE
Ensure that the piston and connecting rod assembly is Removal Procedure
installed in the engine with the chamfer of the connect-
ing rod bore adjacent to the crank pin thrust surface. Table 63
The opposite side should also thrust against the mat-
Required Tools
ing rod on the crank pin.
Part
Tool Part Description Qty
Number
A 5P-8665 Cylinder Liner Puller 1
B 6V-4133 Wedge Bracket 1

Start By:

a. Remove the pistons and the connecting rod

assemblies.

NOTICE
Keep all parts clean from contaminants.

g00582418 Contaminants may cause rapid wear and shortened

Illustration 570 component life.
Typical example
 167
Disassembly and Assembly Section

4. Remove seals (1) and filler band (2) from the

NOTICE cylinder liner.
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
i01100240
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open- Cylinder Liner - Install
ing any compartment or disassembling any compo-
nent containing fluids. SMCS Code: 1216-012
Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and supplies Installation Procedure
suitable to collect and contain fluids on Caterpillar
Table 64
products.
Required Tools
Dispose of all fluids according to local regulations and Part
mandates. Tool Part Description Qty
Number
1U-9895 Crossblock 1
3H-0465 Push Puller Plate 2
A 8F-6123 Bolt 2
0S-1575 Bolt 4
- Washer (3/4 inch Copper) 4
Liner Projection Tool
B 8T-0455 1
Group
C 2P-8260 Cylinder Liner Installer 1

NOTICE
g00578729 Keep all parts clean from contaminants.
Illustration 571
Typical example Contaminants may cause rapid wear and shortened
component life.
1. Drain the coolant from the cooling system into a
suitable container for storage or disposal.
1. Install the spacer plate gasket and the spacer
2. Place a cover on the crankshaft journals in order plate. Refer to Disassembly and Assembly,
to shield the journals from dirt and coolant. “Spacer Plate - Remove and Install”.

3. Install Tool (A) and (B) in order to remove the Note: Ensure that all surfaces are clean and dry
cylinder liner. when the spacer plate gasket is installed.

2. Clean the cylinder liner and the cylinder bore in

the cylinder block.

3. Position the cylinder liner in the cylinder bore

without the seals or the filler band.

g00578731
Illustration 572
Typical example
168
Disassembly and Assembly Section

d. Check the liner projection with Tool (B) at four

locations on the cylinder liner. The cylinder
liner projection must be 0.129 ± 0.070 mm
(0.0051 ± 0.0028 inch). A distance of 0.05 mm
(0.002 inch) must be the maximum difference
between the measurements.

Note: If the cylinder liner is turned in the cylinder

block, there will be a difference in the liner
projection.

g00578873
Illustration 573
Typical example

4. Use the following steps to check the cylinder g00578874

Illustration 574
liner projection:
5. If the liner projection is not 0.129 ± 0.070 mm
a. Install four bolts (4) and the washers from Tool
(0.0051 ± 0.0028 inch), check the thickness of
(A). Tighten the bolts evenly in four steps.
the following items:
Step 1 ................................... 14 N·m (10 lb ft)
(5) Spacer plate .................. 12.313 ± 0.025 mm
(0.4848 ± 0.0010 inch)
Step 2 ................................... 35 N·m (25 lb ft)
(6) Spacer plate gasket ........ 0.208 ± 0.025 mm
Step 3 ................................... 70 N·m (50 lb ft)
(0.0082 ± 0.0010 inch)
Step 4 ................................... 95 N·m (70 lb ft)
(7) Cylinder liner flange .......... 12.65 ± 0.02 mm
(0.498 ± 0.001 inch)
b. Install crossbar (2), plates (3), and bolts (1)
from Tool (A). Ensure that crossbar (2) is in
6. Place an alignment mark on the cylinder liner
position at the center of the cylinder liner. Also
and the cylinder block in order to install the
ensure that the surface of the cylinder liner is
cylinder liner in the same position.
clean. Tighten bolts (1) evenly in four steps.
7. Remove Tool (A), Tool (B), and the spacer plate.
Step 1 ....................................... 7 N·m (5 lb ft)
Also remove the cylinder liner.
Step 2 ................................... 20 N·m (15 lb ft)

Step 3 ................................... 35 N·m (25 lb ft)

Step 4 ................................... 70 N·m (50 lb ft)

c. Check the distance from the bottom of

crossblock (2) to the top of the spacer plate.
The distance at both ends of the crossbar
must be equal.
 169
Disassembly and Assembly Section

i01099504

Camshaft - Remove
SMCS Code: 1210-011

Removal Procedure
Table 65
Required Tools
Part
Tool Part Description Qty
Number
A 9S-9082 Engine Turning Tool 1
g00578875
Illustration 575 1P-0820 Hydraulic Puller 1
Typical example
8B-7548 Push-Puller Tool Group 1
8. Apply liquid soap to seals (5), the grooves of the B 8B-7559 Adapter 2
cylinder liner, and the cylinder block.
5H-1504 Hard Washer 3
9. Install seals (5) on the cylinder liner. 9U-6600 Hand Hydraulic Pump 1
8T-3168 Pilot Assembly 2
10. Dip the filler band (6) in clean engine oil. C
Immediately install filler band (6) in the groove 4J-7945 Bolt 2
that is under the cylinder liner flange.
D 8T-3167 Guide Assembly 1
E 8T-3169 Crank Assembly 1

Start By:

a. Remove the rocker shaft assemblies and the

push rods.

b. Remove the speed/timing sensor. Refer

to Electronic Troubleshooting Module,
SENR6413-03, “Control Sensors”.

NOTICE
Keep all parts clean from contaminants.
g00578876
Illustration 576
Typical example Contaminants may cause rapid wear and shortened
component life.
11. Install the cylinder liner immediately after filler
band (6) is installed on the cylinder liner. Ensure
that the marks that are on the cylinder liner and NOTICE
the cylinder block are aligned. Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
12. Use Tool (C) to press the cylinder liner into the ing, adjusting and repair of the product. Be prepared to
cylinder block. collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
End By: nent containing fluids.

a. Install the pistons and the connecting rod Refer to Special Publication, NENG2500, “Caterpillar
assemblies. 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.
170
Disassembly and Assembly Section

g00579084 g00579117
Illustration 577 Illustration 580

1. Remove access covers (1) from each side of the 3. Remove the bolts and cover (3) from the left side
engine. of the front housing.

g00579086 g00579119
Illustration 578 Illustration 581

4. Disconnect the two control rods for the carburetor

from lever (4), if equipped.

5. Remove the bolts from cover (5). Remove cover

(5) and lever (4) from the front housing as one
unit.

g00579090
Illustration 579

2. Push valve lifters (2) away from the camshaft.

Hold valve lifters (2) in position with an O-ring
seal.

g00579569
Illustration 582

6. If the engine is not equipped with a carburetor,

disconnect electrical plug (X) and remove bolts
from cover (5).
 171
Disassembly and Assembly Section

NOTICE
Do not apply more than 51675 kPa (7500 psi) pressure
to the hydraulic puller. The adapters are rated at 6
1/2 tons each and the hydraulic puller is rated at 17
tons at 68900 kPa (10000 psi). If too much pressure
is applied, the gear may be damaged.

10. Install Tool (B) on camshaft drive gear (8). Apply

51675 kPa (7500 psi) to the puller and hit the
screw on the puller with a hammer until camshaft
drive gear (8) is free from the camshaft. Remove
Tool (B) and camshaft drive gear (8).
g00579522
Illustration 583

7. Remove cover (6) for the camshaft drive gears

from the flywheel housing.

g00579144
Illustration 586

11. Remove bolts (9) and thrust washers (10) that

fasten the camshaft to the right side of the
engine block.
g00579141
Illustration 584

8. Remove the bolt and plate (7) that fastens

camshaft drive gear (8) to the camshaft.

g00579145
Illustration 587

12. Remove timing ring (11) from the camshaft on

the left side of the engine.
g00579142
Illustration 585
13. Repeat Steps 7 through 11 for the camshaft
9. Place the three washers from Tool (B) behind drive gear on the left side of the engine.
plate (7) and install the bolt.
172
Disassembly and Assembly Section

g00579148 g00579149
Illustration 588 Illustration 589
Typical example
b. Remove bolts (14). Separate the camshafts
14. Install Tool (C) on each end of the camshaft. and remove spacer (15).

Note: Tool (D) can be installed on the flywheel 19. Remove the dowel from the front of the camshaft,
housing in order to remove the camshaft from the if necessary.
rear. Tool (D) can also be installed on the front
housing in order to remove the camshaft from the 20. Repeat Steps 14 through 19 for the second
front of the engine. camshaft.

15. Install Tool (D) on the flywheel housing. i01099567

16. Install Tool (E) on the end of Tool (C). Camshaft - Install
Note: The camshafts for G3508 Engines are in SMCS Code: 1210-012
one piece. The camshafts for G3512 and G3516
Engines are in two pieces.
Installation Procedure
17. The following step is for G3508 Engines.
Table 66

a. Rotate the camshaft with Tool (E). Pull the Required Tools
camshaft out of the engine until a suitable Part
lifting device can be attached. Remove the Tool Part Description Qty
Number
camshaft from the engine. The camshaft has
a weight of 42 kg (93 lb). A 8T-3167 Guide Assembly 1
8T-3168 Pilot Assembly 2
18. The following steps are for G3512 and G3516 B
Engines. 4J-7945 Bolt 2
C 8T-3169 Crank Assembly 1
a. Rotate the camshaft with Tool (E). Pull the
camshaft out of the engine until a suitable D 9S-9082 Engine Turning Tool 1
lifting device can be attached. Remove front
camshaft (12) and rear camshaft (13) as a
unit. The camshaft for a G3512 Engines has a NOTICE
weight of 63 kg (139 lb). The camshaft for a Keep all parts clean from contaminants.
G3516 Engines has a weight of 82 kg (181 lb).
Contaminants may cause rapid wear and shortened
component life.
 173
Disassembly and Assembly Section

g00579257 g00579260
Illustration 590 Illustration 592
Typical example Typical example

1. The following steps are for the installation of g. If the dowel was removed from the front half
a camshaft in the G3512 Engines and G3516 of camshaft (12), install the dowel. The dowel
Engines. The camshaft is in two pieces. should be 22.0 ± 0.5 mm (0.87 ± 0.02 inch)
from the surface of the camshaft.
a. Install Tool (A) on the flywheel housing. Do not
tighten the bolts on Tool (A). Note: Ensure that the camshafts are installed
according to the marks on the ends of the
b. Install Tool (B) on the end of the front half of camshafts.
the crankshaft.
h. Fasten a hoist to the rear half of camshaft
c. Ensure that the camshaft and the camshaft (13). Install spacer (15) and the rear half of
bearings are clean. Place clean engine oil on camshaft (13) onto the front half of camshaft
the lobes and the journals of the camshaft. (12). Install bolts (14) and tighten to a torque
Also place clean engine oil on the camshaft of 55 ± 7 N·m (41 ± 5 lb ft).
bearings.
i. Install Tool (B) and Tool (C) on the end of
d. Position the front half of camshaft (12) in the camshaft (13).
engine until Tool (B) is in the first camshaft
bearing. j. Rotate camshaft (13) and insert the camshaft
into the engine.
e. Rotate camshaft (12) and tighten the bolts
for Tool (A). k. Remove all tools. Repeat Steps 1.a through
1.j for the camshaft on the opposite side of
f. Rotate camshaft (12) and insert camshaft (12) the engine. Go to Step 3.
until camshaft (12) is slightly protruding from
Tool (A). 2. The following steps are for the installation of a
camshaft in the G3508 Engines. The camshaft is
in one piece.

a. Install Tool (A) on the flywheel housing. Do not

tighten the bolts on Tool (A).

b. Install Tool (B) on the ends of the camshaft.

c. Ensure that the camshaft and the camshaft

bearings are clean. Place clean engine oil on
the lobes and the journals of the camshaft.
Also place clean engine oil on the camshaft
bearings.

Note: Ensure that the camshafts are installed

g00579259
Illustration 591 according to the marks on the ends of the
Typical example camshafts.
174
Disassembly and Assembly Section

d. Fasten a hoist to the camshaft. Insert the 5. Turn the camshaft until timing pin (16) can be
camshaft in the engine until tool (B) is in the installed through the cylinder block and into
first camshaft bearing. groove (17) that is in the camshaft.

e. Install Tool (C). Rotate the camshaft and 6. Repeat Steps 4 and 5 for the camshaft on the
tighten the bolts on Tool (A). opposite side of the engine.

f. Rotate the camshaft and insert the camshaft

into the engine.

g. Repeat Steps 2.a through 2.f for the camshaft

on the opposite side of the engine. Go to
Step 3.

g00579262
Illustration 595

7. Remove bolts (19), cover (18), and plug (20).

g00579144
Illustration 593

3. Install thrust washers (10) and bolts (9) that

fasten the camshaft to the engine.

g00579263
Illustration 596

8. Install one bolt (19) into the flywheel housing

through the hole for plug (20). Use Tool (D)
and a ratchet to turn the flywheel until bolt (19)
can be installed through the hole and into the
flywheel. This will position the No. 1 cylinder at
the top center. Refer to the Testing and Adjusting
g00579261
Illustration 594 Module for more information.

NOTICE
If the camshaft is out of time more than 18 degrees
(approximately 1/2 of the timing pin is out of the
groove), the valves can make contact with the pis-
tons. This will cause damage to the engine. Refer to
Testing and Adjusting, “Camshaft Timing” for more
information.

4. Remove timing pin (16) from the storage position

on the side of the engine.
 175
Disassembly and Assembly Section

a. Tighten the bolt for timing ring (11) to a torque

of 360 ± 70 N·m (265 ± 52 lb ft).

b. Use a soft hammer to hit the head of the

bolt for timing ring (11). This will help seat
camshaft drive gear (8) on the camshaft.

c. Tighten the bolt for timing ring (11) again to a

torque of 360 ± 70 N·m (265 ± 52 lb ft).

d. Place an index mark on the bolt for timing

ring (11).

e. Repeat Steps 12.b and 12.c until the bolt for

g00579264
timing ring (11) does not move after tightening
Illustration 597 the bolt. The marks should stay aligned.
9. Place camshaft drive gears (8) into position on f. Repeat Steps 12.a through 12.e in order to
both of the camshafts. seat camshaft drive gear (8) on the opposite
side of the engine.

13. Remove timing pins (16) from the camshafts.

Install timing pins (16) in the original locations.

g00579145
Illustration 598

10. Install timing ring (11) and the bolt on the

camshaft that is on the left side of the engine.
g00579119
Illustration 600

14. Install cover (5) and lever (4) on the front

housing.

15. Connect the two control rods for the carburetor

to lever (4), if equipped.

g00579141
Illustration 599

11. Install plate (7) and the bolt on the camshaft that
is on the right side of the engine.

12. Use the following steps to seat camshaft drive

gears (8) onto the ends of the camshafts.
g00579569
Illustration 601
176
Disassembly and Assembly Section

16. If the engine is not equipped with a carburetor,

install cover (5) with the bolts and connect
electrical plug (X).

g00579084
Illustration 604

20. Install access covers (1) on the side of the

Illustration 602 g00579522 engine.

17. Install cover (6) with the bolts on the flywheel End By:
housing.
a. Install the speed/timing sensor. Refer to Electronic
18. Remove bolt (19) from the flywheel. Install plug Troubleshooting Module, SENR6413-03, “Control
(20) in the timing hole. Remove Tool (D) and Sensors”.
install cover (18) with bolts (19) on the flywheel
housing. b. Install the rocker shaft assemblies and the push
rods.

i01100561

Camshaft Bearings - Remove

SMCS Code: 1211-011

Removal Procedure
Table 67
Required Tools
Part
Tool Part Description Qty
g00579090
Number
Illustration 603
Camshaft Bearing Tool
A 6V-4077 1
19. Remove the O-ring seals from valve lifters (2). Group
Push valve lifters (2) against the camshaft. Camshaft Bearing Tool
B 8S-2241 1
Group
C 5P-5247 Hydraulic Puller 1

Start By:

a. Remove the camshafts.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.
 177
Disassembly and Assembly Section

d. Use the extensions to obtain the correct

NOTICE length for Tool (A).
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test- e. Install the puller plate on the bolt and the
ing, adjusting and repair of the product. Be prepared to flywheel housing or the front housing.
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo- Note: Tool (B) can be used to remove the camshaft
nent containing fluids. bearings when the flywheel housing and the front
housing have been removed.
Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and supplies 2. Install Tool (C) on Tool (A) and pull the bearing
suitable to collect and contain fluids on Caterpillar from the cylinder block.
products.
Note: An 8H-0684 Ratchet Wrench can be used in
Dispose of all fluids according to local regulations and place of Tool (C), if necessary.
mandates.
i01100563

Camshaft Bearings - Install

SMCS Code: 1211-012

Installation Procedure
Table 68
Required Tool
Part
Tool Part Description Qty
Number
Camshaft Bearing Tool
A 6V-4077 1
g00578295 Group
Illustration 605
Typical example Camshaft Bearing Tool
B 8S-2241 1
Group
C 5P-5247 Hydraulic Puller 1

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

g00578306
Illustration 606
Typical example

1. Use the following steps to install Tool (A).

a. Install the pilot group in the camshaft bearing.

b. Place the backup plate in position and ensure

that the bearing is between the two parts.
g00578338
Illustration 607
c. Install the bolt that holds Tool (A) together.
Typical example
178
Disassembly and Assembly Section

1. Install camshaft bearing (1) on Tool (A). i01098283

Note: Tool (B) can be used to install the camshaft Crankshaft - Remove
bearings when the flywheel housing and the front
housing have been removed. SMCS Code: 1202-011

Note: The camshaft bearing joint must be on the Removal Procedure

horizontal centerline of the bore. The upper oil
hole must be 20 ± 5 degrees above the horizontal Table 69
centerline of the bore. The lower oil hole of the Required Tools
camshaft bearing should be 20 ± 5 degrees below
the horizontal centerline of the bore. The camshaft Part
Tool Part Description Qty
bearing joints on the right side of the engine must Number
face the inside of the cylinder block. The camshaft A 4C-9832 Engine Roll-Over Stand 1
bearing joints on the left side of the engine must
face the outside of the cylinder block.
Start By:
2. Position camshaft bearing (1) and Tool (A) in the
bore. a. Remove the rocker shaft assemblies and the
push rods.

b. Remove the front housing.

c. Remove the balancer gear from the rear gear

group.

d. Remove the piston cooling jets.

NOTICE
The rocker shaft assemblies and the push rods must
be removed to ensure that the inlet and exhaust valves
are not open. If the valves are open the face of the
inlet and exhaust valves could be damaged when the
g00578349 pistons are pushed into the cylinder, away from the
Illustration 608
crankshaft.
3. Install Tool (C) on Tool (A) and pull camshaft
bearing (1) into the bore. NOTICE
Keep all parts clean from contaminants.
Note: An 8H-0684 Ratchet Wrench can be used
in place of Tool (C). Contaminants may cause rapid wear and shortened
component life.
4. Check the bore of camshaft bearing (1) after
installation. The bore must be 86.00 ± 0.06 mm
(3.385 ± 0.002 inch). NOTICE
Care must be taken to ensure that fluids are contained
End By: during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
a. Install the camshafts. 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.
 179
Disassembly and Assembly Section

1. Use Tool (A) to turn the engine in a horizontal

position. The engine can also be supported with
blocks. The engines have the following weights:

• G3508 Engines weigh approximately 4300 kg

(9500 lb).

• G3512 Engines weigh approximately 5443 kg

(12000 lb).

• G3516 Engines weigh approximately 6447 kg

(14200 lb).

Note: It is not necessary to remove the

counterweights from the crankshaft, if the piston g00577388
and connecting rod assemblies have been removed Illustration 611
from the engine.
4. Remove the center main bearing cap and two
thrust plates (3) from each side of the center
main bearing.

g00577386
Illustration 609

2. Place identification marks on counterweights (1). g00577389

Remove counterweights (1) from the engine. Illustration 612
Typical example

5. Use two of the bolts from the flywheel and install

one bolt in each end of the crankshaft.

6. Attach a suitable lifting device to the crankshaft.

Remove remaining main bearing caps (5) and
remove crankshaft (6) from the engine. The
crankshafts have the following weights:

• The crankshaft for the G3508 Engines weighs

approximately 367 kg (807 lb).

• The crankshaft for the G3512 Engines weighs

approximately 549 kg (1201 lb).
g00577387
Illustration 610
• The crankshaft for the G3516 Engines weighs
Note: Ensure that the journals of the crankshaft are approximately 762 kg (1602 lb).
not scratched by the connecting rods.
7. Remove the upper halves of the main bearings
3. Remove connecting rod bearing caps (2) and also remove the upper halves of the
and push the connecting rods away from the connecting rod bearings.
crankshaft.
180
Disassembly and Assembly Section

1. If crankshaft gears (1) were removed, install the

gears on crankshaft (2).

2. Check the clearance of the bearings. Refer to

Disassembly and Assembly, “Bearing Clearance
- Check” for the correct procedure.

g00577390
Illustration 613

8. If necessary, remove bolts (7) and crankshaft

gear (6) from each end of the crankshaft.

i01098514 g00577547
Illustration 615
Crankshaft - Install
Note: Place clean engine oil on the main bearings
SMCS Code: 1202-012 and on the connecting rod bearings prior to
installation.
Installation Procedure Note: The upper halves of the main bearings have
Table 70
an oil hole in the center.

Required Tools 3. Install the upper halves of main bearings (3) in

Part the cylinder block.
Tool Part Description Qty
Number
4. Install the upper halves of connecting rod
A 4C-9832 Engine Roll-Over Stand 1 bearings (4) in the connecting rod assemblies.
B 8S-2328 Dial Indicator 1

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

g00577548
Illustration 616
Typical example

Note: Ensure that the word “FRONT” that is on the

end of the crankshaft is toward the front of the
engine.

5. Attach a suitable lifting device to crankshaft (2)

Illustration 614
g00577546 and position the crankshaft in the cylinder block.
 181
Disassembly and Assembly Section

g00577550 g00577579
Illustration 617 Illustration 619
Tightening sequence
10. Position the connecting rods on the journals of
Note: The main bearing caps must be installed with the crankshaft.
the word “FRONT” and the part number toward the
front of the engine. Each main bearing cap has Note: The number that is on the side of the
a number on the bottom surface and each main connecting rod caps must be installed next to the
bearing must be installed in the corresponding corresponding number that is on the side of the
position in the cylinder block. connecting rod.

6. Place 6V-4876 Lubricant on the bolts for the

main bearing caps.

7. Place clean engine oil on thrust plates (9). Install

thrust plates (9) on each side of the center main
bearing.

g00577581
Illustration 620
Tightening sequence

11. Place 6V-4876 Lubricant on the bolts for the

connecting rod caps.

12. Place connecting rod caps (10) and install the

g00577577
Illustration 618 bolts. Tighten the bolts with the following steps:

8. Place the main bearing caps into position and a. Tighten bolts (11) and (12) to a torque of
install the bolts. Tighten the bolts in the numerical 90 ± 5 N·m (65 ± 4 lb ft).
sequence that is shown above to a torque of
190 ± 14 N·m (140 ± 10 lb ft). Tighten the bolts b. Tighten bolts (13) and (14) to a torque of
again for an additional 180 ± 5 degrees. 90 ± 5 N·m (65 ± 4 lb ft).

9. Check the end play with Tool (B). The end c. Tighten bolts (11) and (12) again to a torque
play must not exceed 0.40 ± 0.23 mm of 90 ± 5 N·m (65 ± 4 lb ft).
(0.0157 ± 0.0091 inch).
d. Tighten bolts (13) and (14) again to a torque
of 90 ± 5 N·m (65 ± 4 lb ft).
182
Disassembly and Assembly Section

e. Tighten each bolt for an additional 90 ± 5 a. Ensure that the dowels are in the correct
degrees (1/4 turn). An impact wrench may position and install the counterweights on the
be used. crankshaft.

13. Place the remaining connecting rod caps in b. Apply 6V-4876 Lubricant to the threads of
position and tighten the bolts with the same the bolt, to the shank of the bolt, and to the
procedure that is in Steps 12.a through 12.e. seat of the bolt prior to assembly.

c. Tighten the bolts in all of the counterweights

to a torque of 70 ± 5 N·m (50 ± 4 lb ft).

d. Tighten the bolts in all of the counterweights

for an additional 120 ± 5 degrees (1/3 turn).

Note: Refer to the Specifications Module for more

information on the crankshaft.

End By:

a. Install the piston cooling jets.

b. Install the balancer gear on the rear gear group.

g00577584
Illustration 621
c. Install the front housing.
NOTICE
Each counterweight is numbered and must be in- d. Install the rocker shaft assemblies and the push
stalled in the same position as the corresponding rods.
number on the crankshaft mounting pad in order to
prevent damage to the crankshaft.

14. Install counterweights (15) and use the correct

tightening procedure below.

15. The following procedure is for the installation

of the counterweights in G3508 Engines.

a. Ensure that the dowels are in the correct

position and install the counterweights on the
crankshaft.

b. Apply 6V-4876 Lubricant to the threads of

the bolt, to the shank of the bolt, and to the
seat of the bolt prior to assembly.

c. Tighten the bolts in all of the counterweight to

a torque of 200 ± 5 N·m (150 ± 4 lb ft).

d. Loosen the bolts in all of the counterweights.

e. Tighten the bolts in all of the counterweights

to a torque of 70 ± 5 N·m (50 ± 4 lb ft).

f. Tighten the bolts in all of the counterweights

for an additional 120 ± 5 degrees (1/3 turn).

16. The following procedure is for the installation

of the counterweights in G3512 and G3516
Engines.
 183
Index Section

Index
A Carburetor - Install (High Pressure)....................... 40
Installation Procedure ........................................ 40
Accessory Drive (Front) - Assemble.................... 132 Carburetor - Install (Low Pressure) ................. 39–40
Assembly Procedure........................................ 132 Installation Procedure .................................. 39–40
Accessory Drive (Front) - Disassemble ............... 131 Carburetor - Remove (High Pressure)................... 34
Disassembly Procedure ................................... 131 Removal Procedure ........................................... 34
Accessory Drive (Front) - Install .......................... 134 Carburetor - Remove (Low Pressure).............. 33, 35
Installation Procedure ...................................... 134 Removal Procedure ..................................... 33, 35
Accessory Drive (Front) - Remove ...................... 131 Connecting Rod Bearings - Remove and Install.. 157
Removal Procedure ......................................... 131 Installation Procedure ...................................... 158
Aftercooler - Remove and Install ..................... 53, 58 Removal Procedure ......................................... 157
Installation Procedure .................................. 56, 59 Crankcase Breather - Remove and Install........... 114
Removal Procedure ..................................... 53, 58 Installation Procedure ...................................... 114
Air Cleaner - Remove and Install........................... 41 Removal Procedure ......................................... 114
Installation Procedure ........................................ 41 Crankshaft - Install............................................... 180
Removal Procedure ........................................... 41 Installation Procedure ...................................... 180
Air Inlet Manifold - Remove and Install .................. 59 Crankshaft - Remove........................................... 178
Installation Procedure ........................................ 60 Removal Procedure ......................................... 178
Removal Procedure ........................................... 59 Crankshaft Front Seal and Wear Sleeve - Install.. 140
Air Starting Motor - Assemble ............................... 11 Installation Procedure ...................................... 140
Assembly Procedure.......................................... 11 Crankshaft Front Seal and Wear Sleeve -
Air Starting Motor - Disassemble............................. 6 Remove ............................................................. 139
Disassembly Procedure ....................................... 6 Removal Procedure ......................................... 139
Air Starting Motor - Install...................................... 18 Crankshaft Main Bearings - Install....................... 161
Installation Procedure ........................................ 18 Installation Procedure ...................................... 161
Air Starting Motor - Remove .................................... 5 Crankshaft Main Bearings - Remove................... 159
Removal Procedure ............................................. 5 Removal Procedure ......................................... 159
Auxiliary Water Pump - Assemble ......................... 86 Crankshaft Rear Seal and Wear Sleeve - Install.. 144
Assembly Procedure.......................................... 86 Installation Procedure ...................................... 144
Auxiliary Water Pump - Disassemble .................... 84 Crankshaft Rear Seal and Wear Sleeve -
Disassembly Procedure ..................................... 84 Remove ............................................................. 143
Auxiliary Water Pump - Install ............................... 89 Removal Procedure ......................................... 143
Installation Procedure ........................................ 89 Cylinder Head - Assemble................................... 124
Auxiliary Water Pump - Remove............................ 83 Assembly Procedure........................................ 124
Removal Procedure ........................................... 83 Cylinder Head - Disassemble .............................. 121
Disassembly Procedure ................................... 121
Cylinder Head - Install ......................................... 127
B Installation Procedure ...................................... 127
Cylinder Head - Remove ..................................... 120
Bearing Clearance - Check ................................. 156 Removal Procedure ......................................... 120
Measurement Procedure ................................. 156 Cylinder Liner - Install.......................................... 167
Installation Procedure ...................................... 167
Cylinder Liner - Remove ...................................... 166
C Removal Procedure ......................................... 166

Camshaft - Install................................................. 172

Installation Procedure ...................................... 172 D
Camshaft - Remove............................................. 169
Removal Procedure ......................................... 169 Disassembly and Assembly Section........................ 5
Camshaft Bearings - Install ................................. 177 Drive Housing (Front) - Remove and Install ........ 134
Installation Procedure ...................................... 177 Installation Procedure ...................................... 136
Camshaft Bearings - Remove ............................. 176 Removal Procedure ......................................... 134
Removal Procedure ......................................... 176
Carburetor - Assemble (High Pressure) .......... 37–38
Assembly Procedure.................................... 37–38
Carburetor - Disassemble (High Pressure) ..... 35–36
Disassembly Procedure ............................... 35–36
184
Index Section

E Exhaust Manifold - Install (Water Cooled) ............. 68

Installation Procedure ........................................ 68
Electric Starting Motor - Remove and Install ......... 19 Exhaust Manifold - Remove (Dry) ......................... 65
Installation Procedure ........................................ 19 Removal Procedure ........................................... 65
Removal Procedure ........................................... 19 Exhaust Manifold - Remove (Water Cooled) ......... 66
Electronic Sensor - Remove and Install ................ 32 Removal Procedure ........................................... 66
Installation Procedure ........................................ 33
Removal Procedure ........................................... 32
Engine Oil and Water Pump Drive - Assemble.... 108 F
Disassembly Procedure ................................... 108
Engine Oil and Water Pump Drive - Flywheel - Remove and Install ............................ 142
Disassemble ...................................................... 107 Installation Procedure ...................................... 142
Disassembly Procedure ................................... 107 Removal Procedure ......................................... 142
Engine Oil and Water Pump Drive - Install .......... 109 Flywheel Housing - Install.................................... 148
Installation Procedure ...................................... 109 Installation Procedure ...................................... 148
Engine Oil and Water Pump Drive - Remove ...... 107 Flywheel Housing - Remove................................ 146
Removal Procedure ......................................... 107 Removal Procedure ......................................... 146
Engine Oil Cooler - Assemble ............................... 93 Fuel Control Actuator - Remove and Install..... 27, 29
Assembly Procedure.......................................... 93 Installation Procedure .................................. 28–29
Engine Oil Cooler - Disassemble........................... 91 Removal Procedure ..................................... 27, 29
Disassembly Procedure ..................................... 91 Fuel Control Valve - Remove and Install ......... 30–31
Engine Oil Cooler - Install...................................... 94 Installation Procedure .................................. 31–32
Installation Procedure ........................................ 94 Removal Procedure ..................................... 30–31
Engine Oil Cooler - Remove.................................. 90
Removal Procedure ........................................... 90
Engine Oil Filter Housing - Assemble.................. 104 G
Installation Procedure ...................................... 104
Engine Oil Filter Housing - Disassemble ............. 101 Gas Pressure Regulator - Assemble ..................... 24
Disassembly Procedure ................................... 101 Assembly Procedure.......................................... 24
Engine Oil Filter Housing - Install ........................ 106 Gas Pressure Regulator - Disassemble ................ 23
Installation Procedure ...................................... 106 Disassembly Procedure ..................................... 23
Engine Oil Filter Housing - Remove .................... 100 Gas Pressure Regulator - Install ........................... 26
Installation Procedure ...................................... 100 Installation Procedure ........................................ 26
Engine Oil Pan - Assemble.................................. 112 Gas Pressure Regulator - Install (High Pressure).. 27
Assembly Procedure........................................ 112 Installation Procedure ........................................ 27
Engine Oil Pan - Disassemble ............................. 111 Gas Pressure Regulator - Install (Low Pressure) .. 26
Disassembly Procedure ................................... 111 Installation Procedure ........................................ 26
Engine Oil Pan - Install ........................................ 113 Gas Pressure Regulator - Remove ....................... 22
Installation Procedure ...................................... 113 Removal Procedure ........................................... 22
Engine Oil Pan - Remove .................................... 110 Gas Pressure Regulator - Remove (High
Removal Procedure ......................................... 110 Pressure) ............................................................. 22
Engine Oil Pump - Assemble................................. 98 Removal Procedure ........................................... 22
Assembly Procedure.......................................... 98 Gas Pressure Regulator - Remove (Low
Engine Oil Pump - Disassemble............................ 96 Pressure) ............................................................. 23
Disassembly Procedure ..................................... 96 Removal Procedure ........................................... 23
Engine Oil Pump - Install ....................................... 99 Gas Pressure Regulator Solenoid - Remove and
Installation Procedure ........................................ 99 Install ................................................................... 21
Engine Oil Pump - Remove ................................... 95 Installation Procedure ........................................ 21
Removal Procedure ........................................... 95 Removal Procedure ........................................... 21
Engine Oil Sequence Valves - Remove and Gear Group (Rear) - Install.................................. 154
Install ................................................................. 150 Installation Procedure ...................................... 154
Installation Procedure ...................................... 151 Gear Group (Rear) - Remove .............................. 152
Removal Procedure ......................................... 150 Removal Procedure ......................................... 152
Exhaust Bypass Valve - Remove and Install ......... 64
Installation Procedure ........................................ 64
Removal Procedure ........................................... 64 I
Exhaust Elbow - Remove and Install ............... 61–62
Installation Procedure .................................. 62–63 Important Safety Information ................................... 2
Removal Procedure ..................................... 61–62
Exhaust Manifold - Install (Dry) ............................. 69
Installation Procedure ........................................ 69
 185
Index Section

P Vibration Damper - Remove and Install............... 138

Installation Procedure ...................................... 138
Piston and Connecting Rods - Install .................. 165 Removal Procedure ......................................... 138
Installation Procedure ...................................... 165
Piston and Connecting Rods - Remove .............. 163
Removal Procedure ......................................... 163 W
Piston Cooling Jets - Remove and Install ............ 155
Installation Procedure ...................................... 156 Water Pump - Assemble........................................ 78
Removal Procedure ......................................... 155 Assembly Procedure.......................................... 78
Water Pump - Disassemble ................................... 76
Disassembly Procedure ..................................... 76
R Water Pump - Install .............................................. 80
Installation Procedure ........................................ 80
Rocker Shaft - Assemble ..................................... 118 Water Pump - Remove .......................................... 75
Assembly Procedure........................................ 118 Removal Procedure ........................................... 75
Rocker Shaft - Disassemble ................................ 117 Water Temperature Regulators - Install ................. 73
Disassembly Procedure ................................... 117 Installation Procedure ........................................ 73
Rocker Shaft and Push Rod - Install ................... 119 Water Temperature Regulators - Remove ............. 71
Installation Procedure ...................................... 119 Removal Procedure ........................................... 71
Rocker Shaft and Push Rod - Remove................ 116
Removal Procedure ......................................... 116

Service Meter - Remove and Install ...................... 20

Installation Procedure ........................................ 20
Removal Procedure ........................................... 20
Spacer Plate - Remove and Install ...................... 128
Installation Procedure ...................................... 129
Removal Procedure ......................................... 128

Table of Contents..................................................... 3
Thermostatic Valve - Assemble ............................. 82
Assembly Procedure.......................................... 82
Thermostatic Valve - Disassemble ........................ 81
Disassembly Procedure ..................................... 81
Thermostatic Valve - Install ................................... 82
Installation Procedure ........................................ 82
Thermostatic Valve - Remove................................ 81
Removal Procedure ........................................... 81
Turbocharger - Assemble ...................................... 47
Assembly Procedure.......................................... 47
Turbocharger - Disassemble.................................. 44
Disassembly Procedure ..................................... 44
Turbocharger - Install....................................... 51–52
Installation Procedure .................................. 51–52
Turbocharger - Remove ................................... 41, 43
Removal Procedure ..................................... 41, 43

Valve Cover and Spark Plug - Remove and

Install ................................................................. 114
Installation Procedure ...................................... 115
Removal Procedure ......................................... 114
186
Index Section
 187
Index Section
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