Bomba de combustible - quitar e instalar SMCS - 1258-010 Procedimiento de Remocin AV S!

Se debe tener cuidado "ara #aranti$ar que los %luidos se encuentran durante la e&ecucin de la ins"eccin' mantenimiento' "rueba' a&uste ( re"aracin del "roducto) *st+ "re"arado "ara reco#er el l,quido con contenedores adecuados antes de abrir cualquier com"artimento o desmonta&e de cualquier com"onente que conten#a l,quidos) Re%i+rase a la "ublicacin es"ecial' -*-.2500' /Cater"illar 0erramientas .u,a de Productos ( tiendas/ "ara las 1erramientas ( suministros adecuados "ara reco#er ( contener los %luidos de los "roductos Cater"illar) 2es13#ase de todos los %luidos de acuerdo con las re#ulaciones locales ( los mandatos) AV S! Manten#a todas las "artes lim"ias de contaminantes) Contaminantes "ueden "ro4ocar un r3"ido des#aste ( acorta la 4ida de los com"onentes) Ver ima#en

lustracin 1 #00505675

8uite el "erno ban&o 91: ( arandelas 92: 9no se muestra: de la bomba de combustible' a %in de eliminar la l,nea de salida de combustible 97:) -ota; Ca" todas las aberturas o el enc1u%e de inmediato todas las aberturas a %in de e4itar la contaminacin del sistema de combustible) A%lo&e la abra$adera de la man#uera 96:' a %in de eliminar la l,nea de suministro de combustible 95:) -ota; Ca" todas las aberturas o el enc1u%e de inmediato todas las aberturas a %in de e4itar la contaminacin del sistema de combustible)

Ver) ima#e

Illustration 2 g00606441 Remove nuts (6) that secure the fuel priming pump to the fuel injection pump. Note: uel !ill "rain from the fuel priming pump "uring removal. #ollect the fuel in a suita$le container for storage or for "isposal. Remove fuel priming pump (%) an" the &'ring (() (not sho!n). Note: #ap all openings or plug all openings imme"iatel) in or"er to prevent contamination of the fuel s)stem. Installation *roce"ure +er imagen

Illustration , g00606441 Note: #hec- the &'ring (() (not sho!n) for !ear or "amage. Replace a !orn &'ring or a "amage" &'ring !ith a ne! replacement part. *lace the &'ring (() (not sho!n) an" place the fuel priming pump (%) in position on the fuel injection pump. Install nuts (6) that secure the fuel priming pump to the fuel injection pump. +er imagen

Illustration 4 g006064,6 #onnect fuel suppl) line (.) an" hose clamp (4) to the fuel priming pump. /ighten the hose clamps. Note: #hec- the !ashers (2) (not sho!n) for !ear or "amage. Replace a !orn !asher or a "amage" !asher !ith a ne! replacement part. 0ecure the fuel outlet line (,) an" the !ashers (2) (not sho!n) to the fuel priming pump !ith $anjo $olt (1) . /ighten $anjo $olt (1) to a tor1ue of 20 to 2. N2m (1. to 1( l$ ft).

Fuel Filter Base - Remove and Install SMCS - 1262-010

Table 1 Required Tools Tool A Part Number 185-3630 Part Description Strap Wrench Assembly Qty 1

N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. N&/I#3 #are must $e ta-en to ensure that flui"s are containe" "uring performance of inspection5 maintenance5 testing5 a"justing an" repair of the pro"uct. 6e prepare" to collect the flui" !ith suita$le containers $efore opening an) compartment or "isassem$ling an) component containing flui"s. Refer to 0pecial *u$lication5 N3N72.005 8#aterpillar /ools an" 0hop *ro"ucts 7ui"e8 for tools an" supplies suita$le to collect an" contain flui"s on #aterpillar pro"ucts. 9ispose of all flui"s accor"ing to local regulations an" man"ates. +er imagen

Illustration 1 g00(1,12% :se /ool (;) to remove fuel filter (,) from fuel filter $ase (2) . Note: It is not necessar) to remove the fuel filter in or"er to remove the fuel filter $ase. Remove $anjo $olts (1) an" copper !ashers in or"er to "isconnect the fuel lines (4) from the fuel filter $ase (2). Note: #ap all openings or plug all openings imme"iatel) in or"er to prevent contamination of the fuel s)stem. +er imagen

'''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' Illustration 2 g00(1,14%

Remove t!o $olts (.) an" the !ashers that secure the fuel filter $ase (2) to the air inlet manifol". Remove the fuel filter $ase (2) from the fuel filter $rac-et. Installation *roce"ure N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. +er imagen

Illustration , g00(1,14%

*lace the fuel filter $ase (2) in position on the fuel filter $rac-et. Install the !ashers an" t!o $olts (.) that secure the fuel filter $ase tothe fuel filter $rac-et. +er imagen

Illustration 4 g00(1,12%

Install the $anjo $olts (1) an" install ne! copper !ashers in or"er to connect the fuel lines (4) to the fuel filter $ase (2) . If the fuel filter !as remove"5 install the fuel filter (,) to the fuel filter $ase (2). /ighten the fuel filter $) han" accor"ing to the instructions that are sho!n on the fuel filter. 9o not overtighten the fuel filter. uel Injection <ines ' Remove an" Install 0=#0 ' 12.2'010

Removal Procedure Start By: Remove the fuel filter $ase. Refer to 9isassem$l) an" ;ssem$l)5 8 uel ilter 6ase ' Remove an" Install8. N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. N&/I#3 #are must $e ta-en to ensure that flui"s are containe" "uring performance of inspection5 maintenance5 testing5 a"justing an" repair of the pro"uct. 6e prepare" to collect the flui" !ith suita$le containers $efore opening an) compartment or "isassem$ling an) component containing flui"s. Refer to 0pecial *u$lication5 N3N72.005 8#aterpillar /ools an" 0hop *ro"ucts 7ui"e8 for tools an" supplies suita$le to collect an" contain flui"s on #aterpillar pro"ucts. 9ispose of all flui"s accor"ing to local regulations an" man"ates. +er imagen

'''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' Illustration 1 g00606,01 /he ,066 3ngine is sho!n.

Remove the $olts (1)5 the !ashers5 an" the clamps (2)5 !hich secure the fuel lines to the inlet manifol" (,) . '''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' +er imagen

'''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' Illustration 2 g00606,10

9isconnect the fuel injection lines (4) from the fuel injection no>>les (.) . Note: #ap all openings or plug all openings imme"iatel) in or"er to prevent contamination of the fuel s)stem. '''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' +er imagen

'''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' Illustration , g00606,14 uel injection pump for a ,066 3ngine

9isconnect the en" of the fuel injection lines (4) from the fuel injection pump (6) . Note: #ap all openings or plug all openings imme"iatel) in or"er to prevent contamination of the fuel s)stem. Remove the fuel injection lines (4) from the engine. '''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' +er imagen

'''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' Illustration 4 g00606,1%

<oosen the acorn nuts (%)5 !hich secure the fuel return line to the fuel injection no>>les. Remove one $olt (() an" the !asher from the clamp that secures the fuel return line to the inta-e manifol". Note: /he clamp !ill remain !ith the fuel return line5 !hen the fuel return line is remove" from the engine. 9isconnect fitting (?). Remove fuel return line (10) from the engine. Note: #ap all openings or plug all openings imme"iatel) in or"er to prevent contamination of the fuel s)stem. Installation *roce"ure ''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''

N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. +er imagen

'''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' Illustration . g00606,1%

*lace the fuel return line (10) in position on the engine. #onnect fitting (?) of the fuel return line to the fuel injection pump. Install the !asher an" $olt (() through the clamp in or"er to secure the fuel return line to the inlet manifol". Install the fuel return line (10) to the fuel injection no>>les. 0ecure the fuel return line to the fuel injection no>>le !ith acorn nuts (%) . '''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' +er imagen

'''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' Illustration 6 g00606,?? uel injection pump for a ,066 3ngine

*lace the fuel injection lines (4) on the engine. #onnect the fuel injection lines (4) to the fuel injection pump (6) . #onnect the fuel injection lines (4) to the fuel injection no>>les (.) .

Note: /he fuel lines (4) shoul" $e connecte" at the fuel injection no>>le (.) an" at the fuel injection pump (6) $efore tightening the nuts for the fuel injection line. /ighten the nuts for the fuel injection line to a tor1ue of 2. N2m (1( l$ ft). '''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' +er imagen

'''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' Illustration % g00606,01 uel lines for a ,066 3ngine

Install the clamps (2)5 the !ashers5 an" the $olts (1)5 !hich secure the fuel lines to the inlet manifol" (,) . 3n" 6): Install the fuel filter $ase. Refer to 9isassem$l) an" ;ssem$l)5 8 uel ilter 6ase ' Remove an" Install8.

Fuel Injection o!!les - Remove SMCS - 12"#-011

Table 1 Required Tools Tool A B Part Number 1U-7600 !U-6"78 Part Description Slide Hammer P ller Adapter Qty 1 1

0tart 6): Remove the fuel injection lines. Refer to 9isassem$l) an" ;ssem$l)5 8 uel Injection <ines ' Remove an" Install8. N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. +er imagen

Illustration 1 g006.2,1? Remove $olt (1) an" the !asher that secures the clamp (2) to the c)lin"er hea" assem$l). Remove the clamp (2) that secures the fuel injection no>>le (,) in position in the c)lin"er hea" assem$l). Note: *ut caps or plugs on all openings imme"iatel) in or"er to prevent contamination in the fuel s)stem. Note: =ar- the clamp for later installation. Install /ool (6) (not sho!n) to the fuel injection no>>le. Note: /ool (6) is installe" at the connection (4) for the fuel injection lines. #onnect /ool (;) (not sho!n) to /ool (6) in or"er to carefull) remove fuel injection no>>le (,) . Note: ;lign the centerline of /ool (;) !ith the e@ten"e" centerline of fuel injection no>>le (,). /his proce"ure !ill help prevent "istortion of the fuel injection no>>le !hich can cause the fuel injection no>>le to $en" or $rea-. Remove the seat !asher from the fuel injection no>>le.

Fuel Injection o!!les - Install SMCS - 12"#-012 Installation *roce"ure N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. +er imagen

'''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' Illustration 1 g006.2,1?

Install a ne! seat !asher (.) . Install fuel injection no>>le (,). Install clamp (2)5 the !asher5 an" $olt (1) that secures the fuel injection no>>le to the c)lin"er hea" assem$l). /ighten $olt (1)5 that secures the fuel injection no>>le5 to a tor1ue of 22 N2m (16 l$ ft). 3n" 6): Install the fuel injection lines. Refer to 9isassem$l) an" ;ssem$l)5 8 uel Injection <ines ' Remove an" Install8. Fuel S$uto%% Solenoid - Remove and Install SMCS - 12"&-010 Removal *roce"ure +er imagen

Illustration 1 g0061(?,(

9isconnect t!o !ire lea"s (1). =ar- the !ires for later installation. 9isconnect actuator lever (2) from the governor lever. Remove t!o $olts (,) an" !ashers that secure the fuel shutoff solenoi" to the $rac-et. Remove shutoff solenoi" (4) from the $rac-et. Installation *roce"ure +er imagen

Illustration 2 g0061(?,(

*lace the shutoff solenoi" (4) in position on the $rac-et. Install the t!o !ashers an" $olts (,) that secure the fuel shutoff solenoi" to the $rac-et. #onnect actuator lever (2) to the governor lever. #onnect t!o !ire lea"s (1) to the fuel shutoff solenoi". 3nsure that the !ires are properl) connecte".

Fuel Injection Pum' - Remove SMCS - 12"1-011 (a)le 1

Required Tools Tool A B Part Number !U-61"# !U-61"8 Part Description Uni$ersal %etric S&c'et Set Uni$ersal %etric S&c'et (1) Qty 1 1

0tart 6): Remove the fuel injection lines. Refer to 9isassem$l) an" ;ssem$l)5 8 uel Injection <ines ' Remove an" Install8. N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. N&/I#3

#are must $e ta-en to ensure that flui"s are containe" "uring performance of inspection5 maintenance5 testing5 a"justing an" repair of the pro"uct. 6e prepare" to collect the flui" !ith suita$le containers $efore opening an) compartment or "isassem$ling an) component containing flui"s. Refer to 0pecial *u$lication5 N3N72.005 8#aterpillar /ools an" 0hop *ro"ucts 7ui"e8 for tools an" supplies suita$le to collect an" contain flui"s on #aterpillar pro"ucts. 9ispose of all flui"s accor"ing to local regulations an" man"ates. 3nsure that the engine is the top center position on num$er one piston. Refer to /esting an" ;"justing5 8 in"ing #enter *osition for No. 1 *iston8. +er imagen

Illustration 1 g00(1,442

Remove $olts (1) an" !ashers that secure the cover (2) to the engine front housing. Remove the access cover. Note the timing mar-s on the fuel injection pump "rive gear an" the i"ler gear for later installation. +er imagen

'''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' Illustration 2 g00(1,4,0

0cri$e a line across the front plate (,) an" the mounting flange for the fuel injection pump (4). /his ensures proper alignment for the installation of fuel injection pump (() .

<oosen fitting (.) for oil line (6) . Remove oil line (6) from nipple (%) (not sho!n). Note: *ut caps or plugs on all openings imme"iatel) in or"er to prevent contamination. :se a lifting sling an" a hoist in or"er to secure the fuel injection pump. /he !eight of the fuel injection pump is 1, -g (2? l$). Note: :se /ool (6) to remove the $olts an" the !ashers that mount the fuel injection pump (() . Remove $olt (?) an" the !asher from the c)lin"er $loc-. Remove four $olts (10) an" the !ashers that secure the fuel injection pump to the front housing. '''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' +er imagen

'''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' Illustration , g00(1,.?,

Remove the fuel injection pump ((). /he gear an" the mounting flange !ill remain !ith the fuel injection pump. Note: /he fuel injection pump must $e mounte" to the engine in or"er to loosen the nut for the "rive gear. Note: 9o not rotate the engine after the fuel injection pump is remove". 3nsure that the ol" gas-et material is remove" from all mating surfaces of the pump mounting flange an" the face of the fuel injection pump flange. Fuel Injection Pum' - Install SMCS - 12"1-012

Table 1 Required Tools Tool A B Part number !U-61"# !U-61"8 Part Description Uni$ersal %etric S&c'et Set Uni$ersal %etric S&c'et (1) Qty 1 1

( 1 ) Part &* the Uni$ersal %etric S&c'et Set

N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. Note: If the nut for the fuel injection pump "rive gear is remove"5 )ou must tighten the nut for the fuel injection pump "rive gear to (( A . N2m (6. A 4 l$ ft). +er imagen

Illustration 1 g00(1,4,0 :se a lifting sling an" a hoist in or"er to secure the fuel injection pump ((). /he !eight of the fuel injection pump is 1, -g (2? l$). Install a ne! gas-et an" install fuel injection pump (() . 3nsure that the engine is in the top center position on No. 1 piston. Refer to /esting an" ;"justing5 8 in"ing /op #enter *osition for No. 1 *iston8. 3nsure that the mar- on the front plate (,) an" the mar- on the fuel injection pump flange (4) are aligne". Refer to /esting an" ;"justing5 8 uel Injection /iming'#hec-8 for more information on fuel injection pump timing. Note: :se /ool (6) to install the $olts an" !ashers that secure the fuel injection pump to the c)lin"er $loc-. Install the !ashers an" $olts (?) that secure the fuel injection pump to the engine c)lin"er $loc-. Remove the sling from the fuel injection pump. #onnect oil line (6) to nipple (%) (not sho!n). /ighten fitting (.) for oil line (6) .

(ur)oc$ar*er - Remove SMCS - 10"2-011 Removal *roce"ure N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. N&/I#3 #are must $e ta-en to ensure that flui"s are containe" "uring performance of inspection5 maintenance5 testing5 a"justing an" repair of the pro"uct. 6e prepare" to collect the flui" !ith suita$le containers $efore opening an) compartment or "isassem$ling an) component containing flui"s. Refer to 0pecial *u$lication5 N3N72.005 8#aterpillar /ools an" 0hop *ro"ucts 7ui"e8 for tools an" supplies suita$le to collect an" contain flui"s on #aterpillar pro"ucts. 9ispose of all flui"s accor"ing to local regulations an" man"ates. +er imagen

Illustration 1 g0060(1,6

<oosen the hose clamp (1) on hose (2) . Remove hose (2) from the tur$ocharger (,) . +er imagen

'''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' Illustration 2 g00(12(46 9isconnect oil suppl) line (4) from the c)lin"er $loc-. <oosen t!o clamps (.) on hose (%) . 0li"e hose (%) off fitting (() onto oil return line (6) . +er imagen

Illustration , g0060(1%% Remove eight nuts (?) from the stu"s on the e@haust manifol". Note: /he four stu"s have t!o nuts for a total of eight nuts. Remove tur$ocharger (,)5 oil suppl) line (4)5 an" oil return line (6) as an unit. Remove metal gas-et (10) (not sho!n). #hec- the gas-et for !ear or "amage. Replace the gas-et5 if necessar). /ur$ocharger ' 9isassem$le 0=#0 ' 10.2'01.

9isassem$l) *roce"ure 0tart 6): Remove the tur$ocharger. Refer to 9isassem$l) an" ;ssem$l)5 8/ur$ocharger ' Remove8. '''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. ''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''

'''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' N&/I#3

#are must $e ta-en to ensure that flui"s are containe" "uring performance of inspection5 maintenance5 testing5 a"justing an" repair of the pro"uct. 6e prepare" to collect the flui" !ith suita$le containers $efore opening an) compartment or "isassem$ling an) component containing flui"s. Refer to 0pecial *u$lication5 N3N72.005 8#aterpillar /ools an" 0hop *ro"ucts 7ui"e8 for tools an" supplies suita$le to collect an" contain flui"s on #aterpillar pro"ucts. 9ispose of all flui"s accor"ing to local regulations an" man"ates.

*lace an in"e@ mar- on all of the components. /he mar-s !ill help to align the components "uring the assem$l) proce"ure. +er imagen

Illustration 1 g0060(212

Remove t!o $olts (1) from the oil return line. Remove $olt (2) from the oil suppl) line. Remove oil return line (,) from the cartri"ge. Remove oil suppl) line (4) from the cartri"ge. +er imagen

Illustration 2 g0060(210

Remove gas-et (.) from the cartri"ge. Remove gas-et (6) from the tur$ine housing. +er imagen

Illustration , g0060(,42

Remove the $olt an" nut (%) from clamp ((). Remove clamp (() that secures the tur$ine housing (?) to the cartri"ge (10) . 0eparate tur$ine housing (?) from the cartri"ge (10) . +er imagen

'''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' Illustration 4 g0060(41. +er imagen

Illustration . g0060(4.2 Remove snap ring (11) from compressor housing (12) . 0eparate compressor housing (12) from the cartri"ge (10) . +lectric Startin* Motor - Remove and Install SMCS - 1#",-010 Removal *roce"ure 9isconnect $atteries $efore performance of an) service !or-. N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. *ut i"entification mar-s on the !ires for the electric starting motor. 9isconnect the !ires from the terminals of the electric starting motor. +er imagen

Illustration 1 g0060.,44

Remove t!o $olts (1) an" the !ashers that secure electric starting motor (4) to the fl)!heel housing. Remove electric starting motor (4) from the fl)!heel housing. Note: #hec- the con"ition of the &'ring (2) (not sho!n). If the &'ring is "amage"5 use a ne! part for replacement . Installation *roce"ure

'''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. +er imagen

'''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' Illustration 2 g0060.,44 Note: ;ppl) gl)cerine to the &'ring $efore installation of the starter. *ut the &'ring (2) (not sho!n) an" electric starting motor (4) in position on the fl)!heel housing. Install t!o $olts (1) that secure electric starting motor (4) to the fl)!heel housing. #onnect the !ires to the terminals (,) of electric starting motor (4) . Note: /ighten starter terminals (,) to a tor1ue of 11 A 1 N2m (( A 1 l$ ft). -lternator - Remove and Install SMCS - 1#0"-010 Removal *roce"ure 0tart 6): Remove the +'$elts. Refer to 9isassem$l) an" ;ssem$l)5 8+'6elts ' Remove an" Install8. 9isconnect $atteries $efore performance of an) service !or-. N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. +er imagen

Illustration 1 g00604446 +er imagen

Illustration 2 g0060444?

*ut i"entification mar-s on the !ires for the alternator. 9isconnect !ires (1) from the alternator. Remove $olt (6) an" the !asher from alternator (4) . Remove $olt (%) an" the !asher from the c)lin"er $loc-. Remove the $elt tensioner (.) from the engine. Remove $olt (2) an" the !asher from the alternator support. Remove $olt (,) (not sho!n) an" the !asher from the alternator support. Remove alternator (4) from the engine. Installation *roce"ure N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. +er imagen

Illustration , g00604446 +er imagen

Illustration 4 g0060444?

*ut alternator (4) in position. Install $olt (2) an" the !asher into the alternator support. Install $olt (,) an" the !asher into the alternator support. /he $olts are installe" finger tight into the alternator. Note: If the alternator pulle) (() is remove"5 tighten the alternator pulle) nut (?) to a tor1ue of 14% A 1. N2m (10(.. A 10.. l$ ft). *lace the $elt tensioner (.) in position on the engine. Install $olt (%) an" the !asher into the c)lin"er $loc- in or"er to secure the $elt tensioner. Install $olt (6) an" the !asher into the alternator. Reconnect !ires (1) to the alternator. 3n" 6): Install the +'$elts. Refer to 9isassem$l) an" ;ssem$l)5 8+'6elts ' Remove an" Install8.

.-Belts - Remove and Install SMCS - 1,"/-010 Removal *roce"ure N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. +er imagen

Illustration 1 g00(1.0.1 <oosen $olts (2) an" (.) on alternator (4) . <oosen $olt (,) on the alternator $rac-et (1) . *ush alternator (4) to!ar" the engine an" remove t!o +'$elts (6) from the engine. Installation *roce"ure N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. +er imagen

Illustration 2 g00(1.0.1

#hec- the con"ition of +'$elts (6). If the +'$elts are !orn or "amage"5 use ne! +'$elts for replacement. Note: ;l!a)s replace the +'$elts in sets of t!o. Install t!o +'$elts (6). =ove alternator (4) a!a) from the engine an" tighten $olt (,) in or"er to appl) tension to +' $elts (6). /ighten $olts (2) an" (.) on alternator (4). Reference: Refer to the 0pecifications =o"ule5 86elt /ension #hart8 for the correct tension of the +'$elts. +n*ine 0il Pressure S1itc$ - Remove and Install SMCS - 1&2# Removal *roce"ure N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. N&/I#3 #are must $e ta-en to ensure that flui"s are containe" "uring performance of inspection5 maintenance5 testing5 a"justing an" repair of the pro"uct. 6e prepare" to collect the flui" !ith suita$le containers $efore opening an) compartment or "isassem$ling an) component containing flui"s. Refer to 0pecial *u$lication5 N3N72.005 8#aterpillar /ools an" 0hop *ro"ucts 7ui"e8 for tools an" supplies suita$le to collect an" contain flui"s on #aterpillar pro"ucts. 9ispose of all flui"s accor"ing to local regulations an" man"ates.

Note: 9isconnect all electrical connections to the engine oil pressure s!itch $efore procee"ing. =ar- all connections for later installation. '''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' +er imagen

Illustration 1 g00(1.016 Remove engine oil pressure s!itch (1) from the c)lin"er $loc-. Installation *roce"ure

N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. +er imagen

Illustration 2 g00(1.016 Install engine oil pressure s!itch (1) in the c)lin"er $loc-. /ighten engine oil pressure s!itch (1) to a tor1ue of % to 12 N2m (62 to 106 l$ in). Note: Reconnect all electrical connections to the engine oil pressure s!itch $efore )ou operate the engine. Coolant (em'erature S1itc$ - Remove and Install SMCS - 1&06-010 Removal *roce"ure *ersonal injur) can result from hot coolant5 steam an" al-ali. ;t operating temperature5 engine coolant is hot an" un"er pressure. /he ra"iator an" all lines to heaters or the engine contain hot coolant or steam. ;n) contact can cause severe $urns. Remove cooling s)stem pressure cap slo!l) to relieve pressure onl) !hen engine is stoppe" an" cooling s)stem pressure cap is cool enough to touch !ith )our $are han". 9o not attempt to tighten hose connections !hen the coolant is hot5 the hose can come off causing $urns. #ooling 0)stem #oolant ;""itive contains al-ali. ;voi" contact !ith s-in an" e)es. N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. #are must $e ta-en to ensure that flui"s are containe" "uring performance of inspection5 maintenance5 testing5 a"justing an" repair of the pro"uct. 6e prepare" to collect the flui" !ith suita$le containers $efore opening an) compartment or "isassem$ling an) component containing flui"s. Refer to 0pecial *u$lication5 N3N72.005 8#aterpillar /ools an" 0hop *ro"ucts 7ui"e8 for tools an" supplies suita$le to collect an" contain flui"s on #aterpillar pro"ucts. 9ispose of all flui"s accor"ing to local regulations an" man"ates.

9rain the level of coolant from the ra"iator $elo! the coolant temperature s!itch. 9rain the coolant into a suita$le container for storage or "isposal. 9isconnect the electrical connection to the coolant temperature s!itch. +er imagen

Illustration 1 g00(14?(2 Remove coolant temperature s!itch (1) from the el$o!. Installation *roce"ure N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. ;ppl) a thin coat of .*',41, *ipe 0ealant to coolant temperature s!itch (1) . +er imagen

Illustration 2 g00(14?(2

Install coolant temperature s!itch (1). /ighten coolant temperature s!itch (1) to a tor1ue of % to 12 N2m (62 to 106 l$ in).

Reconnect the electrical connection to the coolant temperature s!itch. ill the cooling s)stem !ith coolant to the correct level. Refer to the &peration an" =aintenance =anual5 8Refill #apacities8 topic for more information.

Bearin* Clearance - C$ec2

SMCS - 1"03-535+ 1"1!-535

Measurement Procedure
Table 1 Required Tools Tool A Part Number Part Description Plastic ,a -e (.ell&/) 00"30 t& 00510 mm (0000! t& 000"0 inch) Qty

1!8-!1#5

Note: Plastic -a -e may n&t be necessary /hen the en-ine is in the chassis0

N T!C"
#eep all parts clean $rom contaminants% Contaminants may cause rapid &ear and s'ortened component li$e%

Note: 1aterpillar d&es n&t rec&mmend the chec'in- &* the act al bearin- clearances partic larly &n small en-ines0 This is beca se &* the p&ssibility &* &btainin- inacc rate res lts and the p&ssibility &* dama-in- the bearin- &r the 2& rnal s r*aces0 3ach 1aterpillar en-ine bearin- is 4 ality chec'ed *&r speci*ic /all thic'ness0 Note: The meas rements sh& ld be /ithin speci*icati&ns and the c&rrect bearin-s sh& ld be sed0 5* the cran'sha*t 2& rnals and the b&res *&r the bl&c' and the r&ds /ere meas red d rin- disassembly6 n& * rther chec's are necessary0 H&/e$er6 i* the technician still /ants t& meas re the bearin- clearances6 T&&lin- (A) is an acceptable meth&d0 T&&lin- (A) is less acc rate &n 2& rnals /ith small diameters i* clearances are less than 0010 mm (0000# inch)0

N T!C"
(ead &ire) s'im stoc* or a dial bore +au+e can dama+e t'e bearin+ sur$aces%

The technician m st be $ery care* l t& se T&&lin- (A) c&rrectly0 The *&ll&/in- p&ints m st be remembered7

3ns re that the bac's &* the bearin-s and the b&res are clean and dry0 3ns re that the bearin- l&c'in- tabs are pr&perly seated in the tab -r&&$es0 The cran'sha*t m st be *ree &* &il at the c&ntact p&ints &* T&&lin- (A) 0

10 P t a piece &* T&&lin- (A) &n the cr&/n &* the bearin- that is in the cap0 Note: 8& n&t all&/ T&&lin- (A) t& e9tend &$er the ed-e &* the bearin-0 10 Use the c&rrect t&r4 e-t rn speci*icati&ns in &rder t& install the bearin- cap0 8& n&t se an impact /rench0 :e care* l n&t t& disl&d-e the bearin- /hen the cap is installed0 Note: 8& n&t t rn the cran'sha*t /hen T&&lin- (A) is installed0 10 1are* lly rem&$e the cap6 b t d& n&t rem&$e T&&lin- (A) 0 %eas re the /idth &* T&&lin- (A) /hile T&&lin- (A) is in the bearin- cap &r &n the cran'sha*t 2& rnal0 ;e*er t& 5ll strati&n 10

5ll strati&n 1

-0115"855

Typical 39ample

10 ;em&$e all &* T&&lin- (A) be*&re y& install the bearin- cap0 Note: When T&&lin- (A) is sed6 the readin-s can s&metimes be nclear0 <&r e9ample6 all parts &* T&&lin- (A) are n&t the same /idth0 %eas re the ma2&r /idth in &rder t& ens re that the parts are /ithin the speci*icati&n ran-e0 ;e*er t& Speci*icati&ns %an al6 =1&nnectin- ;&d :earin- >& rnal= and Speci*icati&ns %an al6 =%ain :earin- >& rnal= *&r the c&rrect clearances0
Cran2s$a%t 3ear - Remove and Install

SMCS - 1"0#-010-,3

Remo,al Procedure
Table 1 Required Tools Tool A Start By: A0 ;em&$e the cran'sha*t0 ;e*er t& 8isassembly and Assembly6 =1ran'sha*t - ;em&$e=0 Part Number 8:-7551 Part Description :earin- P ller Qty 1

:se /ool (;) to remove cran-shaft gear (1) from cran-shaft (2) . Note: 9o not remove the gear $) tapping !ith a hammer. Note: 6e careful not to "amage the finishe" surfaces on the cran-shaft. #hec- the -e) on the cran-shaft. If the -e) is "amage"5 use a ne! part for replacement. Installation *roce"ure N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. ;l!a)s !ear protective gloves !hen han"ling parts that have $een heate". :se an oven an" heat the cran-shaft gear to a temperature of a$out 100 B# (212 B ). /he cran-shaft gear is heate" in or"er to ease installation of the cran-shaft gear. Cear e)e protection in or"er to prevent possi$le personal injur) !hile performing the follo!ing steps. Note: 6e careful not to "amage the finishe" surfaces on the cran-shaft. Install the cran-shaft gear on the en" of the cran-shaft. 3nsure that the -e) in the cran-shaft is aligne" !ith the -e)!a) in the gear. /ap lightl) !ith a copper hammer until the cran-shaft gear is seate". 3nsure that the cran-shaft gear is seate" against the shoul"er on the cran-shaft. Note: 3nsure that the timing mar-s of the cran-shaft gear are on the front. 3n" 6): Install the cran-shaft. Refer to 9isassem$l) an" ;ssem$l)5 8#ran-shaft ' Install Cran2s$a%t - Install SMCS - 1202-012

Table 1 Required Tools Tool A B Part Number 6?-!1"0 8T-50!6 Part Description S&c'et (1) 8ial 5ndicat&r Qty 1 1

N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. +er imagen

Illustration 1 g006046(%

If the thrust !ashers !ere remove"5 then install a thrust !asher (11) on the rear face of the cran-shaft !ith the oil groove to!ar" the outsi"e. *lace the upper halves of cran-shaft main $earings (10) in the c)lin"er $loc-. *lace the lo!er halves of the cran-shaft main $earings in cran-shaft main $earing caps. Install the $earings !ith the main $earing ta$s in the correct position. <u$ricate the $earings !ith clean engine oil. '''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' +er imagen

''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''

Illustration 2 g00604.(4

<u$ricate the cran-shaft journals !ith clean engine oil. asten a suita$le lifting "evice an" straps to cran-shaft (?). /he !eight of the cran-shaft for the ,064 engine is (4 -g (1(. l$). /he !eight of the cran-shaft for the ,066 engine is ?? -g (220 l$). *osition cran-shaft (?) onto the upper halves of the cran-shaft main $earings. Note: 6e careful not to "amage the finishe" surfaces on the cran-shaft. '''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' +er imagen

'''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' Illustration , g00604.(2

Install main $earings into main $earing caps ((). Install the $earings !ith the main $earing ta$s in the correct position. <u$ricate the $earings !ith clean engine oil. *lace the thrust !ashers on the rear main $earing cap. Install the rear main $earing cap an" t!o seals on the rear journal of the c)lin"er $loc-. Install cran-shaft main $earing caps ((). *ut clean engine oil on the threa"s of the main $earing cap $olts. Install main $earing cap $olts (%). /ighten the $olts evenl) to a tor1ue of 1,% A . N2m (101 A 4 l$ ft). Note: 3nsure that the cran-shaft main $earing caps are installe" in the original locations. #ut off the e@cess length on the t!o seals on the rear journal of the c)lin"er $loc-. '''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' +er imagen

Illustration 4 g00604%.,

#hec- the en" pla) of the cran-shaft !ith /ool (6). /he en" pla) must $e 0.100 to 0.264 mm (0.00,? to 0.0104 inch). Refer to the /esting an" ;"justing =o"ule5 86asic 6loc-8 for more information on cran-shaft en" pla). +er imagen

Illustration . g00604..2

;ppl) a light coat of clean engine oil to the connecting ro" $earing surfaces an" to the connecting ro" journals. Install the connecting ro"s onto the connecting ro" journals. Install the lo!er half of the connecting $earings into the correspon"ing connecting ro" caps an" install connecting ro" caps (6) . Note: ;lign the ta$s on the $ac- of the connecting ro" $earings !ith the ta$ grooves in the connecting ro" caps. Install the pistons an" connecting ro"s. Refer to 9isassem$l) an" ;ssem$l)5 8*istons an" #onnecting Ro"s ' Install8. '''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' +er imagen

Illustration 6 g00604.4?

#hec- for free cran-shaft rotation $) rotating the cran-shaft for t!o complete revolutions. :se /ool (;) on cran-shaft pulle) nut (4) in or"er to rotate the cran-shaft. +er imagen

Illustration % g006046,% Install &'ring seal (,) on oil suppl) tu$e (2) . +er imagen

Illustration ( g0060462%

*osition oil suppl) tu$e (2). Install t!o $olts (1) in or"er to secure the oil suppl) tu$e to the c)lin"er $loc-. 3n" 6): Install the engine oil pan. Refer to 9isassem$l) an" ;ssem$l)5 83ngine &il *an ' Remove an" Install8. Install the fl)!heel housing. Refer to 9isassem$l) an" ;ssem$l)5 8 l)!heel Dousing ' Remove an" Install8. Install the front housing. Refer to 9isassem$l) an" ;ssem$l)5 8Dousing ( ront) ' Install8. Install the cran-shaft rear seal5 if the cran-shaft !ear sleeve !as remove". Refer to 9isassem$l) an" ;ssem$l)5 8#ran-shaft Rear 0eal ' Install8. Cran2s$a%t - Remove SMCS - 1202-011 (a)le 1

Required Tools

Tool A

Part Number 6?-!1"0

Part Description S&c'et (1)

Qty 1

( 1 ) T&&l (A) is a #6 mm s&c'et0

0tart 6): Remove Remove Remove Remove the the the the front housing. Refer to 9isassem$l) an" ;ssem$l)5 8Dousing ( ront) ' Remove8. cran-shaft rear seal. Refer to 9isassem$l) an" ;ssem$l)5 8#ran-shaft Rear 0eal ' Remove8. fl)!heel housing. Refer to 9isassem$l) an" ;ssem$l)5 8 l)!heel Dousing ' Remove an" Install8. engine oil pan. Refer to 9isassem$l) an" ;ssem$l)5 83ngine &il *an ' Remove an" Install8.

N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. +er imagen

Illustration 1 g0060462% Remove t!o $olts (1) from oil suppl) tu$e (2). Remove oil suppl) tu$e (2) from the engine c)lin"er $loc-. +er imagen

Illustration 2 g006046,% #hec- con"ition of the &'ring seal (,) on the oil suppl) tu$e (2). If the &'ring is "amage"5 use a ne! part for replacement. +er imagen

Illustration , g00604.4?

Install nut (4) an" the !asher onto the cran-shaft. :se /ool (;) to turn the cran-shaft. +er imagen

Illustration 4 g00604..2

Remove nuts an" $olts (.) that secure connecting ro" caps (6) to the connecting ro"s. Remove connecting ro" caps (6) from the connecting ro"s. Note: 6e careful not to "amage the $earings. =ar- each connecting ro" cap an" the $earing in or"er to ensure installation in the original location. #arefull) push the connecting ro"s an" the pistons into the top of $ores. +er imagen

'''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' Illustration . g00604.(2

Remove $olts (%) that secure cran-shaft main $earing caps (() in position in the engine c)lin"er $loc-. Remove cran-shaft main $earing caps (() from the engine. Note: 6e careful not to "amage the $earings. =ar- each cran-shaft main $earing cap an" the $earing in or"er to ensure installation in the original location. '''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' +er imagen

'''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' Illustration 6 g00604.(4

asten a suita$le lifting "evice an" straps to cran-shaft (?). Remove the cran-shaft. /he !eight of the cran-shaft for the ,064 engine is (4 -g (1(. l$). /he !eight of the cran-shaft for the ,066 engine is ?? -g (220 l$). Note: 6e careful not to "amage the finishe" surfaces on the cran-shaft. '''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' +er imagen

'''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' Illustration % g006046(%

Remove the upper halves of cran-shaft main $earings (10). If necessar)5 remove thrust !ashers (11) . '''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' +er imagen

'''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' Illustration ( g00604.??

If necessar)5 use a hammer an" a chisel to remove the !ear sleeve (12) for the cran-shaft rear seal. Dol" the chisel at right angles to the surface of the !ear sleeve. /ap the !ear sleeve in three places. Eou can remove the !ear sleeve once the tension is release". Note: Chen )ou are removing the !ear sleeve5 ta-e e@treme care not to "amage the cran-shaft. Note: /a-e e@treme care not to "amage the !ear sleeve5 if it is not necessar) to remove the !ear sleeve. Cran2s$a%t Main Bearin*s - Install SMCS - 120,-012 Installation *roce"ure N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. +er imagen

Illustration 1 g006024%0 Install the upper halves of the cran-shaft main $earings (1) in the main $earing housing of the c)lin"er $loc-. Note: 3nsure that the main $earing ta$ fits in the ta$ groove of the $earing housing of the c)lin"er $loc-. Install thrust !ashers (2) into the c)lin"er $loc- an" the rear main cap. Note: Install the thrust !ashers !ith the oil grooves to!ar" the outsi"e. +er imagen

Illustration 2 g006026%( Install the lo!er halves of the cran-shaft main $earings (4) into the cran-shaft main $earing caps (,) . Note: 3nsure that the main $earing ta$ fits in the ta$ groove of the cran-shaft main $earing cap. 3n" 6): Install the cran-shaft. Refer to 9isassem$l) an" ;ssem$l)5 8#ran-shaft ' Install8.

Cran2s$a%t Main Bearin*s - Remove SMCS - 120,-011

Removal *roce"ure 0tart 6): Remove the cran-shaft. Refer to 9isassem$l) an" ;ssem$l)5 8#ran-shaft ' Remove8. N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. '''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' +er imagen

Illustration 1 g006024%0 Remove the main $earings (1) (upper shell) from the main $earing housing of the engine c)lin"er $loc-. /he ,066 3ngine has seven main $earings !hile the ,064 3ngine has five main $earings. Remove thrust !ashers (2) from the c)lin"er $loc- an" from the rear main cap. +er imagen

Illustration 2 g006026%( Remove the lo!er halves of the cran-shaft main $earings (4) from the main $earing cap (,) . Note: 6e careful not to "amage the $earings. =ar- each main $earing in or"er to ensure installation in the original location. Note: #hec- the con"ition of the cran-shaft main $earings. Refer to the 7ui"eline or Reusa$le *arts5 036 (00?5 8=ain an" #onnecting Ro" 6earings8 or refer to the 0pecial *u$lication5 03690.,15 83ngine 6earings an" #ran-shafts8. Note: Refer to the 0pecifications =o"ule5 8=ain 6earing Fournal8 for more information on cran-shaft main $earings an" the main $earing journals. Connectin* Rod Bearin*s - Install SMCS - 121&-012

Table 1

Required Tools Tool A Part Number 6?-!1"0 Part Description S&c'et (1) Qty 1

N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. N&/I#3 Chen the connecting ro" caps are installe"5 ensure that the i"entification mar-s are aligne". Note: Refer to 0pecifications5 8#onnecting Ro" 6earing Fournal8 for information on $earing clearance chec-s. '''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' +er imagen

Illustration 1 g00.(6406 #lean the $earing surface of connecting ro" (.) an" connecting ro" cap (2). 3nsure that the num$er on connecting ro" cap (2) matches the num$er on connecting ro" (.) . #lean upper connecting ro" $earing (4) an" lu$ricate the $earing face !ith clean engine oil. #lean lo!er connecting ro" $earing (,) an" lu$ricate the $earing face !ith clean engine oil. Note: ;lign the ta$s on the $ac- of the connecting ro" $earings !ith the ta$ grooves in the connecting ro". :se /ool (;) to rotate the cran-shaft until t!o of the connecting ro" journals are at the $ottom center. Install upper connecting ro" $earing (4) in connecting ro" (.) . *ull connecting ro" (.) into position against the cran-shaft. Install lo!er connecting ro" $earing (,) in connecting ro" cap (2) .

*ut clean engine oil on the connecting ro" $olts. +er imagen

Illustration 2 g00.,4?,%

Install t!o nuts (1) on connecting ro" cap (2). /ighten the connecting ro" nuts to a tor1ue of 10, A . N2m (%6 A 4 l$ ft). Repeat 0teps 1 through ( for the installation of the remaining connecting ro" $earings. 3n" 6): Install the oil suppl) tu$e. Refer to 9isassem$l) an" ;ssem$l)5 8#ran-shaft ' Install8. Install the engine oil pan. Refer to 9isassem$l) an" ;ssem$l)5 83ngine &il *an ' Remove an" Install8.

Connectin* Rod Bearin*s - Remove SMCS - 121&-011 0tart 6): Remove the engine oil pan. Refer to 9isassem$l) an" ;ssem$l)5 83ngine &il *an ' Remove an" Install8. Remove the oil suppl) tu$e. Refer to 9isassem$l) an" ;ssem$l)5 8#ran-shaft ' Remove8. /a$le 1

Required Tools Tool A

N&/I#3

Part Number 6?-!1"0

Part Description S&c'et (1)

Qty 1

4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. +er imagen

Illustration 1 g00.,4?,%

:se /ool (;) to rotate the cran-shaft until t!o of the pistons are at the $ottom center. Remove connecting ro" nuts (1) from the connecting ro". Remove connecting ro" cap (2) for one connecting ro". Remove the lo!er half of the connecting ro" $earing from connecting ro" cap (2) . Remove the upper half of the connecting ro" $earing from the connecting ro". *ush the connecting ro" a!a) from the cran-shaft5 if necessar). Note: :se tape or ru$$er tu$ing on connecting ro" $olts to protect the cran-shaft journals. /he sharp e"ges of the connecting ro" $olts coul" "amage the cran-shaft journals. Note: 3nsure that i"entification mar-s are on the connecting ro"5 the connecting ro" cap an" the connecting ro" $earing. /he i"entification mar-s must $e on the $earing ta$ si"e for installation purposes. Repeat 0teps 1 through , for the remaining connecting ro" $earings.

+4$aust Mani%old - Remove and Install SMCS - 10"&-010 Removal *roce"ure 0tart 6): Remove the tur$ocharger. Refer to 9isassem$l) an" ;ssem$l)5 8/ur$ocharger ' Remove8. N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. +er imagen

Illustration 1 g0060.4.4

Remove the nuts (1) an" !ashers that secure the e@haust manifol" to the c)lin"er hea" assem$l). /he ,066 3ngine has t!elve nuts an" !ashers !hile the ,064 3ngine has eight nuts an" !ashers. Remove e@haust manifol" (2) from the c)lin"er hea" assem$l). Remove e@haust manifol" gas-et (,) that is locate" $et!een e@haust manifol" (2) an" the c)lin"er hea" assem$l). Note: /he ,066 3ngine has t!o e@haust manifol" gas-ets5 !hile the ,064 3ngine has one e@haust manifol" gas-et. Installation *roce"ure N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. +er imagen

Illustration 2 g0060.4.4 Install e@haust manifol" gas-et (,) $et!een e@haust manifol" (2) an" the c)lin"er hea" assem$l). Note: /he ,066 3ngine has t!o e@haust manifol" gas-ets5 !hile the ,064 3ngine has one e@haust manifol" gas-et. *lace e@haust manifol" (2) in position on the c)lin"er hea".

Install the nuts (1) an" the !ashers that secure the e@haust manifol" to the c)lin"er hea" assem$l). /he ,066 3ngine has t!elve nuts an" !ashers !hile the ,064 3ngine has eight nuts an" !ashers. /ighten e@haust manifol" nuts (1) to a tor1ue of 1( A 4 N2m (1, A , l$ ft). 3n" 6): Install the tur$ocharger. Refer to 9isassem$l) an" ;ssem$l)5 8/ur$ocharger ' Install8. -ir Inlet 5eater - Remove and Install SMCS - 10&0-010 Removal *roce"ure N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. +er imagen

Illustration 1 g0061114% <oosen hose clamp (1) that secures air inlet hose (2) to air inlet el$o! (4) . 9isconnect air inlet hose (2) from air inlet el$o! (4) . Remove four $olts (,) an" !ashers that secure the follo!ing items to the air inlet manifol": air inlet el$o! (4)5 gas-et (.)5 air inlet heater (6) an" gas-et (%) . +er imagen

Illustration 2 g0061116. Remove the follo!ing items from the air inlet manifol": air inlet el$o! (4)5 gas-et (.)5 air inlet heater (6) an" gas-et (%) . Note: #hec- the con"ition of the gas-ets that are use" $et!een the el$o! an" the air inlet heater. #hec- the gas-ets $et!een the air inlet heater an" the air inlet manifol". If the gas-ets are "amage" in an) !a)5 replace the gas-ets. Installation *roce"ure N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. +er imagen

Illustration , g0061116. Note: #hec- con"ition of the gas-ets for the air inlet el$o! an" the air inlet heater. If the gas-ets are "amage"5 use a ne! part for replacement. /he !ire mesh gas-et (%) is installe" $et!een the air inlet manifol" an" the air inlet heater. *lace the follo!ing items in position on the air inlet manifol": gas-et (%)5 the air inlet heater (6)5 gas-et (.) an" the air inlet el$o! (4) . '''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' +er imagen

'''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' Illustration 4 g0061114%

Install four $olts (,) that secure the follo!ing items to the air inlet manifol": gas-et (%)5 the air inlet heater (6)5 gas-et (.) an" the air inlet el$o! (4) /ighten $olts (,) to a tor1ue of 2( A % N2m (21 A . l$ ft). #onnect air inlet hose (2) to air inlet el$o! (4) . /ighten hose clamp (1) that secures the air inlet hose to the air inlet el$o!. Inlet Mani%old - Remove SMCS - 10"6-011 Removal *roce"ure 0tart 6): Remove fuel filter $ase. Refer to 9isassem$l) an" ;ssem$l)5 8 uel ilter 6ase ' Remove an" Install8. Remove fuel injection lines. Refer to 9isassem$l) an" ;ssem$l)5 8 uel Injection <ines ' Remove an" Install8. Remove the air inlet heater. Refer to 9isassem$l) an" ;ssem$l)5 8;ir Inlet Deater ' Remove an" Install8. N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. +er imagen

Illustration 1 g00604,.2 <oosen clamp (1) on hose assem$l) (,) . Remove t!o $olts (2) that secure the hose assem$l) to the engine. 0li"e the hose assem$l) (,) from the retaining ring (4) . Remove the $olts an" !ashers (.) that secure the air inlet manifol" to the c)lin"er hea"s. /he ,066 3ngine has eleven $olts an" !ashers !hile the ,064 3ngine has eight $olts an" !ashers. Note: &ne $olt has previousl) $een remove" in or"er to remove the fuel return line. Remove one $olt (6) an" the !asher that secures the lifting $rac-et (%) to the c)lin"er $loc-. Remove inlet manifol" (() an" remove the lifting $rac-et (%) . Remove gas-ets (?) (not sho!n). #hec- the gas-ets for !ear or "amage. Replace the gas-ets5 if the gas-et is !orn or "amage". Note: /he ,064 3ngine has one gas-et5 !hile the ,066 3ngine has t!o gas-ets

Inlet Mani%old - Remove SMCS - 10"6-011

Removal *roce"ure 0tart 6): Remove fuel filter $ase. Refer to 9isassem$l) an" ;ssem$l)5 8 uel ilter 6ase ' Remove an" Install8. Remove fuel injection lines. Refer to 9isassem$l) an" ;ssem$l)5 8 uel Injection <ines ' Remove an" Install8. Remove the air inlet heater. Refer to 9isassem$l) an" ;ssem$l)5 8;ir Inlet Deater ' Remove an" Install8. N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. +er imagen

Illustration 1 g00604,.2 <oosen clamp (1) on hose assem$l) (,) . Remove t!o $olts (2) that secure the hose assem$l) to the engine.

0li"e the hose assem$l) (,) from the retaining ring (4) . Remove the $olts an" !ashers (.) that secure the air inlet manifol" to the c)lin"er hea"s. /he ,066 3ngine has eleven $olts an" !ashers !hile the ,064 3ngine has eight $olts an" !ashers. Note: &ne $olt has previousl) $een remove" in or"er to remove the fuel return line. Remove one $olt (6) an" the !asher that secures the lifting $rac-et (%) to the c)lin"er $loc-. Remove inlet manifol" (() an" remove the lifting $rac-et (%) . Remove gas-ets (?) (not sho!n). #hec- the gas-ets for !ear or "amage. Replace the gas-ets5 if the gas-et is !orn or "amage". Note: /he ,064 3ngine has one gas-et5 !hile the ,066 3ngine has t!o gas-ets. Inlet Mani%old - Install SMCS - 10"6-012

Installation *roce"ure N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. +er imagen

Illustration 1 g00604,.2 Note: #hec- con"ition of the inlet manifol" gas-et. If the gas-et is "amage"5 use a ne! part for replacement. *lace the follo!ing items in position on the engine: gas-et (?) (not sho!n)5 air inlet manifol" (() an" lifting $rac-et (%) . Install the !asher an" one $olt (6) onto lifting $rac-et (%) . Install the !ashers an" $olts (.) that secure the inlet manifol" to the c)lin"er hea". /he ,066 3ngine has eleven !ashers an" $olts !hile the ,064 3ngine has eight !ashers an" $olts. 0li"e the hose assem$l) (,) through the retaining ring (4) .

Install !ashers an" t!o $olts (2) that secure the hose assem$l) to the engine. /ighten the hose clamps (1) on the hose assem$l) (,) . 3n" 6): Install the air inlet heater. Refer to 9isassem$l) an" ;ssem$l)5 8;ir Inlet Deater ' Remove an" Install8. Install the fuel injection lines. Refer to 9isassem$l) an" ;ssem$l)5 8 uel Injection <ines ' Remove an" Install8. Install the fuel filter $ase. Refer to 9isassem$l) an" ;ssem$l)5 8 uel ilter 6ase ' Remove an" Install8.

Inlet and +4$aust .alve S'rin*s - Remove and Install SMCS - 1106-010 /a$le 1

Required Tools Tool A B C D

0tart 6): Remove the roc-er shaft assem$l) an" the pushro"s. Refer to 9isassem$l) an" ;ssem$l)5 8Roc-er 0haft an" *ushro" ' Remove8. Remove the fuel injection no>>les. Refer to 9isassem$l) an" ;ssem$l)5 8 uel Injection No>>les ' Remove8. N&/I#3 #are must $e ta-en to ensure that flui"s are containe" "uring performance of inspection5 maintenance5 testing5 a"justing an" repair of the pro"uct. 6e prepare" to collect the flui" !ith suita$le containers $efore opening an) compartment or "isassem$ling an) component containing flui"s. Refer to 0pecial *u$lication5 N3N72.005 8#aterpillar /ools an" 0hop *ro"ucts 7ui"e8 for tools an" supplies suita$le to collect an" contain flui"s on #aterpillar pro"ucts. 9ispose of all flui"s accor"ing to local regulations an" man"ates. N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. Note: /he follo!ing proce"ure is for the removal of the inlet valve springs an" the e@haust valve springs !ithout removing the c)lin"er hea". +er imagen

Part Number 5S-13"" !U-61#5 6?-5"18 8S-""63

Part Description ?al$e @eeper 5nstaller Air 1&nnect&r (1) :&lt Sprin- Tester

Qty 1 1 1 1

Illustration 1 g0060??04 Install /ool (6). ;ttach an air hose to /ool (6) in or"er to force air pressure into the c)lin"er. /his !ill hol" the valves in position !hile the inlet an" e@haust valve springs are remove" an" installe". Note: =aintain air pressure in each c)lin"er until $oth of the valve springs are remove" an" installe". :se /ool (#) to compress the valve spring (1) . Note: #ompress the valve spring evenl) in or"er to avoi" "amage to the valve stem. :se the magnetic en" of /ool (;) to remove cap (2) (not sho!n) an" valve -eepers (,) (not sho!n) from the inlet an" e@haust valves. 0lo!l) release the tension on /ool (#) . Remove the retainer an" spring (1) from the c)lin"er hea" assem$l). Note: Repeat 0teps 1 through . in or"er to remove the remaining valve spring of the same c)lin"er. +er imagen

Illustration 2 g00.2.2%1

#hec- the valve spring force !ith /ool (9). Refer to 0pecifications5 8+alve =echanism8 for information on the valve springs. Install the valve springs. Refer to the follo!ing installation proce"ure. *erform 0teps 1 through % for the removal an" installation of the remaining inlet an" e@haust valve springs. Installation *roce"ure

Table " Required Tools Tool A Part Number 5S-13"" Part Description ?al$e @eeper 5nstaller Qty 1

B C

!U-61#5 6?-5"18

Air 1&nnect&r :&lt

1 1

N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life.

+er imagen

Illustration , g0060??04 4eep an air hose connecte" to /ool (6) in or"er to force air pressure into the c)lin"er. /his !ill hol" the valves in position !hile the inlet an" e@haust valve springs are remove" an" installe". *osition valve spring (1) an" the retainer over the valve stem. :se /ool (#) to compress valve spring (1) . Note: #ompress the valve spring evenl) in or"er to avoi" "amage to the valve stem. *lace the valve -eepers (,) (not sho!n) in position on the inlet an" e@haust valves. Note: /ool (;) ma) $e use" to install valve -eepers. /he valve -eepers can $e thro!n from the valve !hen the valve spring compressor is release". 3nsure that the valve -eepers are properl) installe" on the valve stem. /o help prevent personal injur)5 -eep a!a) from the front of the valve -eepers an" valve springs "uring the installation of the valves. Install cap (2) (not sho!n) on the inlet an" e@haust valves an" slo!l) release the tension on /ool (#). /ap the top of valve !ith a soft face" hammer in or"er to ensure that the valve -eepers are properl) installe". Note: Repeat 0teps 1 through . in or"er to install the remaining valve spring of the same c)lin"er. Remove air hose an" /ool (6) . *erform 0teps 1 through 6 for the installation of the remaining inlet an" e@haust valve springs. 3n" 6): Install the fuel injection no>>les. Refer to 9isassem$l) an" ;ssem$l)5 8 uel Injection No>>les ' Install8. Install the roc-er shaft assem$l) an" the pushro"s. Refer to 9isassem$l) an" ;ssem$l)5 8Roc-er 0haft an" *ushro" ' Install8.

Inlet and +4$aust .alves - Remove and Install SMCS - 110"-010 (a)le 1

Required Tools Tool A B C D

0tart 6): Remove the c)lin"er hea". Refer to 9isassem$l) an" ;ssem$l)5 8#)lin"er Dea" ' Remove8. N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. +er imagen

Part Number 8S-66!1 1P-35"7 5S-13"" 8S-""63

Part Description 1ylinder Head ;epair Stand ?al$e Sprin- 1&mpress&r ?al$e @eeper 5nstaller Sprin- Tester

Qty 1 1 1 1

Illustration 1 g0061044?

+er imagen

Illustration 2 g0061046? 0upport c)lin"er hea" assem$l) (1) on /ool (;) . :se tool (6) to compress valve spring (2) . :se the magnetic en" of tool (#) (not sho!n) to remove cap (4) an" valve -eepers (,). 0lo!l) release the pressure on tool (6) an" remove tool (6) . Remove retainer (.) an" remove spring (2) . +er imagen

Illustration , g00.2.2%1

#hec- the valve spring force !ith /ool (9). Refer to 0pecifications5 8+alve =echanism8 for information on the valve springs. Remove e@haust valve (6) an" inlet valve (%) through the $ottom of the c)lin"er hea" assem$l) (1). *ut i"entification mar-s on the valves for installation purposes. *erform the follo!ing proce"ure5 if the valves nee" to $e reface": 0et the machine that !ill reface the valves at an angle of ,0 "egrees.

/he valve has a stellite facing. /his facing !ill $e gone5 if the margin of the valve e@cee"s the service limit. Replace the valve5 if the margin e@cee"s the service limit after refacing. 7rin" the valve seat in or"er to reface the valve seat5 if necessar). Replace the valve seat5 if the !i"th e@cee"s the repair limit as a result of !ear or grin"ing. *erform 0teps 2 through % for the remaining inlet valves an" e@haust valves in the c)lin"er hea" assem$l).

Table " Required Tools Tool A B C Part Number 8S-66!1 1P-35"7 5S-13"" Part Description 1ylinder Head ;epair Stand ?al$e Sprin- 1&mpress&r ?al$e @eeper 5nstaller Qty 1 1 1

N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. +er imagen

Illustration 4 g0061046? +er imagen

Illustration . g0061044? 0upport c)lin"er hea" assem$l) on /ool (;). <u$ricate the inlet an" e@haust valves !ith clean engine oil. Install the inlet an" e@haust valves through the $ottom of the c)lin"er hea". Note: 3nsure that the inlet an" e@haust valves are installe" in the original location in the c)lin"er hea". Install spring (2) an" retainer (.) . :se /ool (6) to compress spring (2). Install valve -eepers (,) an" cap (4) on the valve stem !ith /ool (#) . /he valve -eepers can $e thro!n from the valve !hen the valve spring compressor is release". 3nsure that the valve -eepers are properl) installe" on the valve stem. /o help prevent personal injur)5 -eep a!a) from the front of the valve -eepers an" valve springs "uring the installation of the valves. #arefull) remove /ool (6). /ap the top of e@haust valve (6) or inlet valve (%) !ith a soft face" hammer in or"er to ensure that the valve -eepers are properl) installe". Repeat 0teps 2 through 4 for the installation of the remaining inlet an" e@haust valves. 3n" 6): Install the c)lin"er hea". Refer to 9isassem$l) an" ;ssem$l)5 8#)lin"er Dea" ' Install8. Inlet and +4$aust .alve 3uides - Remove and Install SMCS - 110#-010

Removal *roce"ure /a$le 1

Required Tools Tool A

0tart 6): Remove the inlet an" e@haust valves. Refer to 9isassem$l) an" ;ssem$l)5 8Inlet an" 3@haust +alves ' Remove an" Install8. N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. +er imagen

Part Number #1-6366

Part Description ?al$e , ide 8ri$er

Qty 1

Illustration 1 g00610.12

:se /ool (;) to remove the inlet an" e@haust valve gui"es (2) from the c)lin"er hea" (1) . Repeat 0tep 1 in or"er to remove the remaining inlet an" e@haust valve gui"es. Installation *roce"ure /a$le 2

Required Tools Tool A B Part Number #1-6366 #1-6370 Part Description ?al$e , ide 8ri$er ?al$e , ide 1&llar Qty 1 1

N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. +er imagen

Illustration 2 g0061,442

*ut clean engine oil on the outsi"e "iameter of the valve gui"e. Install valve gui"e (2) !ith /ool (;) an" /ool (6). /he valve gui"e is "riven from the top of the c)lin"er hea". +er imagen

Illustration , g00.0(601 /)pical 3@ample

/he counter$ore in /ool (6) installs the valve gui"e to the correct height. Deight (G) from the top of the valve gui"e to the c)lin"er hea" must $e 1%.00 A 0.,0 mm (0.6?? A 0.012 inch). or more information on the inlet an" e@haust valve gui"es5 refer to 0pecifications5 8+alve =echanism8. Note: In or"er to help prevent "amage to the valve gui"es5 /ool (6) must $e use" "uring installation. +er imagen

Illustration 4 g0061,4%. +ie! (G) sho!s that the contact $et!een the valve an" the valve seat is goo". +ie! (E) sho!s that the contact $et!een the valve an" the valve seat is poor.

*erform the follo!ing proce"ure after the valve gui"e has $een inspecte" or the valve gui"e has $een replace": #hec- the valve face. *ress the valve that is coate" !ith re" lea" against the seat !ithout rotating the valve. ;fter refacing or replacement of the valve or valve seat5 $e sure to lap the valve into the valve seat. Repeat 0teps 1 through , for the remaining inlet an" e@haust valve gui"es. 3n" 6): Install the inlet an" e@haust valves. Refer to 9isassem$l) an" ;ssem$l)5 8Inlet an" 3@haust +alves ' Remove an" Install8. Inlet and +4$aust .alve Seat Inserts - Remove and Install SMCS - 110,-010

Table 1 Required Tools Tool A Part Number 6?-#1!6 Part Description ?al$e Seat 39tract&r (1) Qty 1

( 1 ) This is a c&mp&nent &* the ?al$e Seat 39tract&r T&&l ,r& p0

0tart 6): Remove the inlet an" e@haust valves. Refer to 9isassem$l) an" ;ssem$l)5 8Inlet an" 3@haust +alves ' Remove an" Install8. N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. +er imagen

Illustration 1 g00.24.40 - ,066 cylinder $ead is s$o1n7 :se the valve seat grin"er of /ool (;) in or"er to notch the valve seat. +er imagen

Illustration 2 g00.24.4. ; ,066 c)lin"er hea" is sho!n.

:se the valve seat e@tractor of /ool (;) to remove the inlet an" e@haust valve seats. #lean the valve seat in the c)lin"er hea". Remove an) rough areas from the valve seat in the c)lin"er hea". Repeat 0teps 1 through , for the remaining inlet valve seat inserts an" e@haust valve seat inserts. Installation *roce"ure /a$le 2

Required Tools Tool B C Part Number !U-6176 !U-6177 Part Description ?al$e Seat 8ri$er ?al$e Seat 8ri$er Adapter Qty 1 1

N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. +er imagen

Illustration , g00610%%? - ,066 cylinder $ead is s$o1n7

<o!er the temperature of the ne! inlet valve seat inserts. :se /ool (6) to install the ne! inlet valve seat insert (1) in the c)lin"er hea". Note: /he temperature of the valve seat insert is lo!ere" in or"er to ease the installation of the valve seat insert. +er imagen

; ,066 c)lin"er hea" is sho!n.

<o!er the temperature of the ne! e@haust valve seat inserts. :se /ool (6) an" (#) to install the ne! e@haust valve seat insert (2) in the c)lin"er hea". Note: /he temperature of the valve seat insert is lo!ere" in or"er to ease the installation of the valve seat insert. Repeat 0tep 1 an" 2 for the remaining inlet valve seat inserts an" e@haust valve seat inserts. 3n" 6): Install the inlet an" e@haust valves. Refer to 9isassem$l) an" ;ssem$l)5 8Inlet an" 3@haust +alves ' Remove an" Install8.

Inlet and +4$aust .alve Seals - Remove and Install SMCS - 110#-010-S-

/a$le 1

Required Tools Tool A

0tart 6): Remove the inlet an" e@haust valves. Refer to 9isassem$l) an" ;ssem$l)5 8Inlet an" 3@haust +alves ' Remove an" Install8.

Part Number 5P-17"0

Part Description Seal Pic'

Qty 1

N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. +er imagen

Illustration 1 g00610601 +er imagen

'''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' Illustration 2 g0061060.

:se /ool (;) to remove valve stem seal (1) from the inlet an" e@haust valve gui"e. Illustration 1 sho!s the removal of the valve stem seal5 !hen the valve gui"e (2) is remove" from c)lin"er hea" (4) . Illustration 2 sho!s the removal of the valve stem seal5 !hile the valve gui"e (2) is installe" in c)lin"er hea" (4) . Installation *roce"ure /a$le 2 Re1uire" /ools /ool *art Num$er *art 9escription ; .*'1%20 0eal *ic1 /a$le 2

Ht)

Required Tools

Tool A

Part Number 5P-17"0

Part Description Seal Pic'

Qty 1

N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. Note: 9o not appl) an) oil or sealant to the mating surface of the valve seal that comes into contact !ith the valve gui"e. Chen the valve seal is installe"5 coat the surface of the valve stem !ith engine oil in or"er to ensure initial lu$rication of the seal lip. '''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' +er imagen

'''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' Illustration , g00610601 +er imagen

'''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' Illustration 4 g0061060.

*lace the ne! valve stem seal in position on the valve gui"e. :se /ool (;) to assist in installing the ne! valve stem seal. Illustration , sho!s the installation of the valve stem seal5 !hen the valve gui"e (2) is remove" from the c)lin"er hea" (4) . Illustration 4 sho!s the installation of the valve stem seal5 !hile the valve gui"e (2) is installe" in the c)lin"er hea" (4) . Note: ;fter the valve stem seal is installe" on the valve gui"e5 ensure that the seal is properl) installe" in the groove of the valve gui"e. 3n" 6): Install the inlet an" e@haust valves. Refer to 9isassem$l) an" ;ssem$l)5 8Inlet an" 3@haust +alves ' Remove an" Install8.

Cylinder 5ead - Remove SMCS - 1100-011

Removal Procedure

Table 1 Required Tools Tool A Start By:

Remove the e@haust manifol". Refer to 9isassem$l) an" ;ssem$l)5 83@haust =anifol" ' Remove an" Install8. Remove the roc-er shaft an" pushro"s. Refer to 9isassem$l) an" ;ssem$l)5 8Roc-er 0haft an" *ushro" ' Remove8. Remove the inlet manifol". Refer to 9isassem$l) an" ;ssem$l)5 8Inlet =anifol" ' Remove8. Remove the !ater temperature regulator. Refer to 9isassem$l) an" ;ssem$l)5 8Cater /emperature Regulator' Remove an" Install8. N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. N&/I#3 #are must $e ta-en to ensure that flui"s are containe" "uring performance of inspection5 maintenance5 testing5 a"justing an" repair of the pro"uct. 6e prepare" to collect the flui" !ith suita$le containers $efore opening an) compartment or "isassem$ling an) component containing flui"s. Refer to 0pecial *u$lication5 N3N72.005 8#aterpillar /ools an" 0hop *ro"ucts 7ui"e8 for tools an" supplies suita$le to collect an" contain flui"s on #aterpillar pro"ucts. 9ispose of all flui"s accor"ing to local regulations an" man"ates. Note: /he ,064 3ngine has one c)lin"er hea"5 !hile the ,066 3ngine has t!o c)lin"er hea"s. +er imagen

Part Number 138-7573

Part Description Ain' :rac'et

Qty "

Illustration 1 g00.2%.2% /or1ue se1uence for the c)lin"er hea" $olts ( ,066 3ngine) +er imagen

Illustration 2 g00.2%..6 /or1ue se1uence for the c)lin"er hea" $olts ( ,064 3ngine) +er imagen

Illustration , g00604??, 7ra"uall) remove the c)lin"er hea" $olts (1) from the c)lin"er hea". /he ,066 3ngine has thirteen c)lin"er hea" $olts !hile the ,064 3ngine has seventeen c)lin"er hea" $olts. Remove the $olts in reverse or"er of the tor1ue se1uence. Note: 9o not use a pr) $ar to separate the c)lin"er hea" from the engine $loc-. +er imagen

Illustration 4 g0060.044 /)pical e@ample Install /ooling (;)5 chains an" a suita$le lifting "evice to c)lin"er hea" (2) . Remove the c)lin"er hea" (2) from the c)lin"er $loc-. /he !eight of the c)lin"er hea" assem$l) for the ,066 3ngine is ,2 -g (%0 l$). /he !eight of the c)lin"er hea" assem$l) for the ,064 3ngine is 4. -g (100 l$). Note: *lace the c)lin"er hea" on a surface that !ill not "amage the face of the c)lin"er hea". +er imagen

Illustration . g0060.0%( Note: Chen the gas-et is remove" from the c)lin"er $loc-5 $e careful not to "amage the mounting face of the c)lin"er $loc-. Remove the c)lin"er hea" gas-et (,) from the c)lin"er $loc-. Repeat 0tep 1 through 0tep 4 for the other c)lin"er hea" ( ,066 3ngine). Cylinder 5ead - Install SMCS - 1100-012 Installation Procedure

Table 1 Required Tools Tool A Part Number 138-7573 Part Description Ain' :rac'et Qty "

N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. Note: /he ,064 3ngine has one c)lin"er hea"5 !hile the ,066 3ngine has t!o c)lin"er hea"s. +er imagen

'''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' Illustration 1 g0060.0%(

#lean the surfaces of the c)lin"er hea" an" the c)lin"er $loc- that are in contact !ith each other. 3nsure that the surfaces are clean an" "r). Install a ne!5 "r) c)lin"er hea" gas-et (,) on the c)lin"er $loc-. Note: 9o not use an) sealant or gas-et a"hesive on the c)lin"er hea" gas-et . '''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' +er imagen

'''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' Illustration 2 g0060.044 /)pical e@ample

Install /ooling (;) 5 chains5 an" a suita$le lifting "evice to the c)lin"er hea". Install the c)lin"er hea" in position on the c)lin"er $loc-. /he !eight of the c)lin"er hea" assem$l) for the ,066 3ngine is appro@imatel) ,2 -g (%0 l$). /he !eight of the c)lin"er hea" assem$l) for the ,064 3ngine is appro@imatel) 4. -g (100 l$). Remove /ooling (;) . '''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' +er imagen

'''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' Illustration , g00604??,

*ut clean engine oil on the threa"s of the c)lin"er hea" $olts. Install thirteen c)lin"er hea" $olts (1) into c)lin"er hea" (2) ( ,066 3ngine). Install seventeen c)lin"er hea" $olts (1) into c)lin"er hea" (2) ( ,064 3ngine). +er imagen

Illustration 4 g00.2%..6 /or1ue se1uence for the c)lin"er hea" $olts ( ,064 3ngine) +er imagen

Illustration . g00.2%.2% /or1ue se1uence for the c)lin"er hea" $olts ( ,066 3ngine)

/ighten the c)lin"er hea" $olts in the appropriate numerical se1uence to tor1ue of11( A . N2m ((% A 4 l$ ft). Repeat step ? through step 6 for the other c)lin"er hea" ( ,066 3ngine). ;fter assem$l)5 run the engine to operating temperature. 0top the engine an" allo! the engine to cool. /ighten the c)lin"er hea" $olts again in the appropriate numerical se1uence to a tor1ue of 11( A . N2m ((% A 4 l$ ft). 3n" 6): Install the !ater temperature regulator. Refer to 9isassem$l) an" ;ssem$l)5 8Cater /emperature Regulator ' Remove an" Install8. Install the inlet manifol". Refer to 9isassem$l) an" ;ssem$l)5 8Inlet =anifol" ' Install8. Install the roc-er shaft an" pushro"s. Refer to 9isassem$l) an" ;ssem$l)5 8Roc-er 0haft an" *ushro" ' Install8. Install the e@haust manifol". Refer to 9isassem$l) an" ;ssem$l)5 83@haust =anifol" ' Remove an" Install8.

Pistons and Connectin* Rods - Install

SMCS - 1""5-01"

!nstallation Procedure
Table 1 Required Tools Tool A B Part Number 1U-668# 6?-!1"0 Part Description Pist&n ;in- 1&mpress&r S&c'et (1) Qty 1 1

( 1 ) T&&l (:) is a #6 mm s&c'et0

N&/I#3

4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. Note: Refer to 9isassem$l) an" ;ssem$l)5 8#onnecting Ro" 6earings ' Install8 for the inspection proce"ure of the connecting ro" $earings an" the cran-shaft connecting ro" journals. *ut clean engine oil on the cran-shaft journals an" on the insi"e of the c)lin"er $ores. *ut clean engine oil on the piston rings an" the connecting ro" $earings. :se /ooling (6) to rotate the cran-shaft until the $earing journals are at the $ottom center. /he $earing journals that are at the $ottom center are for the piston installation. +er imagen

Illustration 1 g00.244?2 (;) 3n" gap for No. 1 ring (top compression ring) (6) 3n" gap for No. 2 ring (interme"iate compression ring) (#) 3n" gap for oil control ring (G) #amshaft si"e of engine $loc(E) 0i"e of engine !ith com$ustion cham$er

=ove the piston rings on the pistons until the ring openings are separate" $) appro@imatel) 120 "egrees. +er imagen

Illustration 2 g00.,4?44 *ut the piston in the c)lin"er liner. ;lign the i"entification mar-s on the top of the piston to the camshaft si"e of the c)lin"er $loc-. *ut /ooling (;) in position on the c)lin"er $loc- an" compress the piston rings. ;lign the piston an" connecting ro" !ith the cran-shaft. :se a soft face" hammer to tap the piston into the c)lin"er $ore until /ool (;) comes off the piston. Note: 3nsure that /ooling (;) is installe" correctl) in or"er to allo! the piston an" the connecting ro" to easil) slip into the c)lin"er $loc-. Note: :se tape or ru$$er tu$ing on connecting ro" $olts to protect the cran-shaft journals. /he sharp e"ges of the connecting ro" $olts coul" "amage the surface of the connecting ro" journal. 6efore the connecting ro" contacts the cran-shaft5 install the ro" $earing upper half in the respective connecting ro". =a-e sure that the $earing ta$ properl) engages !ith the slot in the connecting ro". *lace clean engine oil on the surface of the upper half of the connecting ro" $earing. 7ui"e the connecting ro" into position on the cran-shaft. Install the lo!er half of the connecting ro" $earing in the correspon"ingl) mar-e" connecting ro" cap. *ut clean engine oil on the surface of the lo!er half of the connecting ro" $earing an" on the connecting ro" $olts. '''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' +er imagen

Install connecting ro" cap (2) an" connecting ro" nuts (1) . /ighten $oth of the nuts to a tor1ue of 10, A . N2m (%6 A 4 l$ ft). Repeat 0teps 1 through ? for the remain"er of the piston an" connecting ro"s.

3n" 6): Install the oil suppl) tu$e. Refer to 9isassem$l) an" ;ssem$l)5 8#ran-shaft ' Install8. Install the engine oil pan. Refer to 9isassem$l) an" ;ssem$l)5 83ngine &il *an ' Remove an" Install8. Install the c)lin"er hea". Refer to 9isassem$l) an" ;ssem$l)5 8#)lin"er Dea" ' Install8.

Pistons and Connectin* Rods - -ssem)le SMCS - 1""5-016

Assembly Procedure
Table 1 Required Tools Tool A B C Part Number 1P-1857 1U-6683 1P-0510 Part Description ;etainin- ;in- Pliers ;in- 39pander 8ri$er ,r& p Qty 1 1 1

4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. +er imagen

Illustration 1 g00.,.40% *iston an" #onnecting Ro" ;ssem$l) +er imagen

Illustration 2 g00.,.406

If necessar)5 use /ool (#) an" a suita$le press to install piston pin $earing (() into connecting ro" (,) . Note: ;lign the oil holes in the piston pin $earing an" the connecting ro" !hen the piston pin $earing is installe". Note: If the clearance $et!een piston pin (2) an" piston pin $earing (() is over 0.0001 mm (0.000( inch)5 replace the piston pin or the piston pin $earing !ith a ne! part. #lean the piston ring grooves of the use" pistons !ith an accepta$le tool or 4#'(64( #leaner. #lean e@cess car$on from piston (4) . +er imagen

Illustration , g00.,.(02

Install connecting ro" (,) into piston (4). 3nsure that the i"entification mar-s on the connecting ro" are on the same si"e as the mar-s on the top of the piston. <u$ricate piston pin (2) !ith clean engine oil an" install piston pin (2) through the piston an" connecting ro". :se /ool (;) to install t!o retaining rings (1) on the en" of piston pin (2). <ocate the en"s of retaining rings (1) to!ar" the $ottom of piston (4) . Note: 3nsure that the piston pin turns freel) in the piston pin $earing. +er imagen

Illustration 4 g00.,.400 +er imagen

Illustration . g00.,.,?( +er imagen

Illustration 6 g00.?%0(. (G) 3n"s of spring for the oil control piston ring (E) &il ring en" gap

Install the oil control piston ring on the piston !ith /ool (6) . Note: /he en"s of spring (?) of the oil control piston ring shoul" $e assem$le" 1(0 "egrees from the oil ring en" gap. +er imagen

Illustration % g00(,%61( Note: 3ach piston ring (.) shoul" $e installe" !ith the si"e mar-e" 8R or /8 (11) to!ar" the top of the piston. :se /ool (6) to install the interme"iate piston ring onto the piston. :se /ool (6) to install the top piston ring onto the piston. Note: /he gaps in the interme"iate piston ring an" the top piston ring shoul" $e separate" $) 120 "egrees. Note: #hec- the clearance of the piston ring en" gap for all the rings. Refer to 0pecifications5 8*iston an" Rings8. 3n" 6): Install the pistons an" connecting ro"s. Refer to 9isassem$l) an" ;ssem$l)5 8*istons an" #onnecting Ro"s ' Install

Pistons and Connectin* Rods - 8isassem)le SMCS - 1""5-015

Disassembly Procedure
Table 1 Required Tools Tool A B C
0tart 6): Remove the pistons an" connecting ro"s. Refer to 9isassem$l) an" ;ssem$l)5 8*istons an" #onnecting Ro"s ' Remove8. N&/I#3 4eep all parts clean from contaminants.

Part Number 1P-1857 1U-6683 1P-0510

Part Description ;etainin- ;in- Pliers ;in- 39pander 8ri$er ,r& p

Qty 1 1 1

#ontaminants ma) cause rapi" !ear an" shortene" component life. +er imagen

Illustration 1 g00.,.(02 :se /ool (;) to remove t!o retaining rings (1) from piston (4) . Remove piston pin (2) an" connecting ro" (,) from piston (4) . Note: #hec- the con"ition of the follo!ing parts: retaining rings (1)5 piston pin (2) an" piston (4). If these items are !orn or "amage"5 use ne! parts for replacement. +er imagen

Illustration 2 g00.,.(0, +er imagen

Illustration , g00.,.,?( +er imagen

Illustration 4 g00.,.400 Remove piston rings (.) from pistons (4) !ith tool (6) . Note: #hec- the con"ition of the piston rings. If the piston rings are !orn or "amage"5 use ne! parts for replacement. +er imagen

Illustration . g00%%0?2. Remove connecting ro" $earing (6) an" t!o $olts (%) from connecting ro" (,) . Note: #hec- the con"ition of the follo!ing items: connecting ro" $earing (6)5 connecting ro" $olt (%)5 piston pin $ushing (() an" connecting ro" (,). If the items are !orn or "amage"5 use ne! parts for replacement. +er imagen

Illustration 6 g00.,.406

:se /ool (#) an" a suita$le press to remove piston pin $ushing (() from connecting ro" (,) . +er imagen

Illustration % g00662?%? *iston an" #onnecting Ro" ;ssem$l) (1) Retaining rings (2) *iston pin (,) #onnecting ro"

(4) *iston (.) *iston rings (6) #onnecting ro" $earing (%) #onnecting ro" $olts (() *iston pin $ushing

Cylinder 9iner - Install SMCS - 1"16-01"

!nstallation Procedure
Table 1 Required Tools Tool A Part Number 5H-150# Part Description Hard Washer Qty 1

N T!C"
#eep all parts clean $rom contaminants% Contaminants may cause rapid &ear and s'ortened component li$e%

Illustration 1 g0060.2,% (1) orcing 0cre! (2) D)"raulic *uller (,) #)lin"er liner (4) *uller *late (.) Nut (6) #)lin"er $loc(%) *uller *late

:se /ool (;) to install c)lin"er liner (,) . *ress c)lin"er liner (,) into the c)lin"er $loc- (6) !ithin 0., to 0.. mm (0.012 to 0.020 inch) of the top of the c)lin"er $loc-. /hen ma-e the c)lin"er liner (,) flush !ith the top of the c)lin"er $loc-. 6ore the c)lin"er liner an" hone the c)lin"er liner to 102.01% A 0.01% mm (4.02 A 0.000% inch). Refinish the rest of the c)lin"er liners to the same si>e. Note: or more information on the assem$l) specifications for the c)lin"er liner5 refer to 0pecifications =o"ule5 8#)lin"er $loc-8. 3n" 6): Install the cran-shaft. Refer to 9isassem$l) an" ;ssem$l)5 8#ran-shaft ' Install8. Install the pistons an" connecting ro"s. Refer to 9isassem$l) an" ;ssem$l)5 8*iston an" #onnecting Ro"s ' Install8. Install the c)lin"er hea". Refer to 9isassem$l) an" ;ssem$l)5 8#)lin"er Dea" ' Install8.

Cylinder 9iner - Remove SMCS - 1216-011 Removal *roce"ure 0tart 6): Remove the cran-shaft. Refer to 9isassem$l) an" ;ssem$l)5 8#ran-shaft ' Remove8. Remove the pistons an" connecting ro"s. Refer to 9isassem$l) an" ;ssem$l)5 8*istons an" #onnecting Ro"s ' Remove8. N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. Cear e)e protection in or"er to prevent possi$le personal injur) !hile performing the follo!ing steps. Note: 6efore )ou procee" !ith the removal of the c)lin"er liner5 chec- the c)lin"er liners for the follo!ing items: !ear5 "amage an" rusting. Note: If the liner is foun" in goo" con"ition an" the liner !ear is less than the repair limit5 then perform the follo!ing tas-s: replace the piston rings5 an" ream the 8ri"ge8 at the top of the liner. Done the $ore5 if necessar). +er imagen

:se the follo!ing proce"ure in or"er to remove the c)lin"er liners from the engine c)lin"er $loc-. 0et up a $oring machine on the c)lin"er $loc-. ;lign the $oring machine !ith the center of the $ottom of the c)lin"er liner !ith the less !orn area. 6ore the liner until the thic-ness of the liner is 0..0 mm (0.020 inch). +er imagen

Illustration 2 g0060.1,0 +er imagen

Illustration , g00.2??62

6rea- the c)lin"er liner in or"er to remove the remain"er of the c)lin"er liner. 6e careful not to "amage the c)lin"er $loc-.

+n*ine 0il Pan - Remove and Install

SMCS - 130"-010

Remo,al Procedure
-ot oil and components can cause personal in.ury% Do not allo& 'ot oil or components to contact s*in%

N T!C"
#eep all parts clean $rom contaminants% Contaminants may cause rapid &ear and s'ortened component li$e%

N T!C"
Care must be ta*en to ensure t'at $luids are contained durin+ per$ormance o$ inspection) maintenance) testin+) ad.ustin+ and repair o$ t'e product% Be prepared to collect t'e $luid &it' suitable containers

be$ore openin+ any compartment or disassemblin+ any component containin+ $luids% Re$er to Special Publication) N"N/0122) 3Caterpillar Tools and S'op Products /uide3 $or tools and supplies suitable to collect and contain $luids on Caterpillar products% Dispose o$ all $luids accordin+ to local re+ulations and mandates%

Remove oil pan "rain plug (1). 9rain the engine oil into a suita$le container.

10 5nstall &il pan drain pl - (1)0 Ti-hten the &il pan drain pl - t& a t&r4 e &* 3! B 5 CDm ("! B # lb *t)0 10 ;em&$e b&lts (") and /ashers that sec re the &il pan t& the en-ine cylinder bl&c'0 The 3066 3n-ine has 38 b&lts and /ashers /hile the 306# 3n-ine has 30 b&lts and /ashers0 ;em&$e en-ine &il pan (#) and -as'et (3) *r&m the en-ine cylinder bl&c'0 Note: A li4 id -as'et may be *act&ry installed in place &* an &il pan -as'et0

!nstallation procedure
N T!C"
#eep all parts clean $rom contaminants% Contaminants may cause rapid &ear and s'ortened component li$e%

#lean engine oil pan (4) .

Note: 3ns re that the en-ine &il pan and all &* the matin- s r*aces are *ree &* &il and -as'et material0 10 5nstall -as'et (3)6 en-ine &il pan (#)6 b&lts (") and the /ashers0 Ti-hten the b&lts t& a t&r4 e &* "8 B 7 CDm ("1 B 5 lb *t)0 Note: 4T-5200 Silic&ne ,as'et may be sed instead &* -as'et (3)0 :&th c&ntact s r*aces m st be c&mpletely *ree &* &il0 Apply -as'et material &n the cylinder bl&c' &n the inside &* the b&lt h&le pattern in a c&ntin & s bead in &rder t& help pre$ent an &il lea'0 10 <ill the cran'case /ith en-ine &il t& the c&rrect le$el0 ;e*er t& the pr&per Eperati&n and %aintenance %an al *&r the c&rrect en-ine &il and the c&rrect *illin- pr&ced re0
Cams$a%t Bearin*s - Install SMCS - 1211-012

5nstallati&n Pr&ced re Table 1 Required Tools Tool A Part Number 8H-068# Part Description ;atchet Wrench Qty 1

N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. +er imagen

Illustration 1 g00.,,0?.

+er imagen

Illustration 2 g00.,,0?6

:se /ool (;) in or"er to install the camshaft $earings into the c)lin"er $loc-. 3nsure that the oil hole of the camshaft $earings are in alignment !ith the oil ports in the engine $loc-. Note: Refer to the instructions of the (0'2241 #amshaft 6earing /ool 7roup for the proper proce"ure. +er imagen

Illustration , g00612%0% Install plug (1) into the c)lin"er $loc-. :se (/'?01, 0ilicone 0ealant . 3n" 6): Install the camshaft. Refer to 9isassem$l) an" ;ssem$l)5 8#amshaft ' Install8. Install the fl)!heel housing. Refer to 9isassem$l) an" ;ssem$l)5 8 l)!heel Dousing ' Remove an" Install8.

Cams$a%t Bearin*s - Remove SMCS - 1"11-011

Remo,al Procedure
Table 1 Required Tools Tool A
0tart 6): Remove the fl)!heel housing. Refer to 9isassem$l) an" ;ssem$l)5 8 l)!heel Dousing ' Remove an" Install8. Remove the camshaft. Refer to 9isassem$l) an" ;ssem$l)5 8#amshaft ' Remove8. N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. +er imagen

Part Number 8H-068#

Part Description ;atchet Wrench

Qty 1

Illustration 1 g00612%0% Remove plug (1) from the c)lin"er $loc-. +er imagen

Illustration 2 g00.,,0?. +er imagen

Illustration , g00.,,0?6 :se /ool (;) in or"er to remove the camshaft $earings from the c)lin"er $loc-. Note: Refer to the instructions of the (0'2241 #amshaft 6earing /ool 7roup for the proper proce"ure. Cams$a%t 3ear - Remove and Install SMCS - 1210-010-3+ Removal Procedure

Table 1 Required Tools Tool A Part Number !S-!153 Part Description P ller >a/s Qty 3

0tart 6): Remove the camshaft. Refer to 9isassem$l) an" ;ssem$l)5 8#amshaft ' Remove8. '''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' N&/I#3

4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. +er imagen

Illustration 1 g00.?(,1% :se tool (;) to remove camshaft gear (1) from camshaft (,) . Remove thrust plate (2) from camshaft (,) . Note: It is not necessar) to remove the camshaft gear unless the gear (1) or the thrust plate (2) is "amage". Note: #hec- the slot in the camshaft for the !oo"ruff -e) for !ear or "amage. Note: #hec- the thrust plate (2) for !ear or "amage. Installation *roce"ure N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. +er imagen

Illustration 2 g00.?(,1(

Note: 9uring installation5 ensure that camshaft (,) is clean an" lu$ricate all of the components !ith clean engine oil. Install the thrust plate (2) on the camshaft (,) . ;l!a)s !ear protective gloves !hen han"ling parts that have $een heate". Deat camshaft gear (1) in an oven to a temperature of a$out 100 B# (212 B ) an" install camshaft gear (1) onto camshaft (,) . Note: /he camshaft gear is heate" in or"er to ease the installation of the camshaft gear. Note: 3nsure that the timing mar-s of the camshaft gear are on the front. 3n" 6): Install the camshaft. Refer to 9isassem$l) an" ;ssem$l)5 8#amshaft ' Install8. Cams$a%t - Install SMCS - 1210-012

Installation *roce"ure Note: In this installation proce"ure5 the engine nee"s to remain in the upsi"e'"o!n position in or"er to -eep the lifters in position !hile the camshaft is installe". N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. Note: 9uring installation5 ensure that the camshaft is clean an" lu$ricate all of the components !ith clean engine oil. Install the valve lifters. Refer to 9isassem$l) an" ;ssem$l)5 8<ifter 7roup ' Remove an" Install8. +er imagen

Illustration 1 g00.6?,%1 Note: 9uring installation5 ensure that the mar-s on the timing gears are in alignment. ;lign fuel injection "rive gear (;) !ith the 8,,8 mar- !ith the 8,8 mar- on i"ler gear (6). =a-e an alignment of the 828 mar- on camshaft gear (#) !ith the 8228 mar- on i"ler gear (6). ;lign the 818 mar- on cran-shaft gear (9) !ith the 8118 mar- on i"ler gear (6). /he No. 1 c)lin"er is at the top center position !hen these mar-s are in alignment.

#arefull) install the camshaft assem$l) into the original location in the c)lin"er $loc-. Note: #aution must $e use" !hen the camshaft is installe" in or"er to not "amage the camshaft lo$e or the camshaft $earings.

+er imagen

Illustration 2 g00604.21 *osition camshaft gear (2) so that the gearIs slots align from the top to the $ottom. Install t!o $olts (1) an" the !ashers that hol" thrust plate (,). /ighten $olts (1) to a tor1ue of 11 A 2 N2m (( A 1 l$ ft). 3n" 6): Install the oil pan. Refer to 9isassem$l) an" ;ssem$l)5 83ngine &il *an ' Remove an" Install8. Install the roc-er shaft assem$l) an" the pushro"s. Refer to 9isassem$l) an" ;ssem$l)5 8Roc-er 0haft an" *ushro" ' Install8. Install the timing gear cover. Refer to 9isassem$l) an" ;ssem$l)5 8Dousing ( ront) ' Install8.

Cams$a%t - Remove SMCS - 1"10-011

Remo,al Procedure
0tart 6): Remove the front housing. Refer to 9isassem$l) an" ;ssem$l)5 8 Dousing ( ront) ' Remove8. Remove the roc-er shaft assem$l) an" the pushro"s. Refer to 9isassem$l) an" ;ssem$l)5 8Roc-er 0haft an" *ushro" ' Remove8. Remove the oil pan. Refer to 9isassem$l) an" ;ssem$l)5 83ngine &il *an ' Remove an" Install8. Note: In this removal proce"ure5 the engine nee"s to $e place" in the upsi"e'"o!n position. /his !ill allo! the lifters to remain in position after the camshaft is remove". N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. N&/I#3 #are must $e ta-en to ensure that flui"s are containe" "uring performance of inspection5 maintenance5 testing5 a"justing an" repair of the pro"uct. 6e prepare" to collect the flui" !ith suita$le containers $efore opening an) compartment or "isassem$ling an) component containing flui"s. Refer to 0pecial *u$lication5 N3N72.005 8#aterpillar /ools an" 0hop *ro"ucts 7ui"e8 for tools an" supplies suita$le to collect an" contain flui"s on #aterpillar pro"ucts.

9ispose of all flui"s accor"ing to local regulations an" man"ates. +er imagen

Illustration 1 g00.6?,%1 Note: 3nsure that the mar-s on the timing gears are in alignment. ;lign fuel injection "rive gear (;) !ith the 8,,8 mar- !ith the 8,8 mar- on i"ler gear (6). =a-e an alignment of the 828 mar- on camshaft gear (#) !ith the 8228 maron i"ler gear (6). ;lign the 818 mar- on cran-shaft gear (9) !ith the 8118 mar- on i"ler gear (6). /he No. 1 c)lin"er is at the top center position !hen these mar-s are in alignment. Rotate the engine at 1(0 "egrees in or"er to place the engine in the upsi"e'"o!n position. /his !ill ease the removal of the camshaft. +er imagen

Illustration 2 g00604.21 N&/I#3 9o not "amage the lo$es or the $earings !hen the camshaft is remove" or installe". *osition camshaft gear (2) so that the gearIs slots align from the top to the $ottom. Remove t!o $olts (1) an" the !ashers that hol" thrust plate (,) (not sho!n).

#arefull) remove the camshaft5 the thrust plate an" the camshaft gear as an assem$l). Remove the valve lifters. Refer to 9isassem$l) an" ;ssem$l)5 8<ifter 7roup ' Remove an" Install8. 9i%ter 3rou' - Remove and Install SMCS - 120&-010 Removal *roce"ure 0tart 6): Remove the camshaft. Refer to 9isassem$l) an" ;ssem$l)5 8#amshaft ' Remove8. N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. +er imagen

'''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' Illustration 1 g00610(24 +er imagen

Illustration 2 g00.,2061

:se a magnet to remove valve lifter (1) from the engine c)lin"er $loc-5 as sho!n. *ut i"entification mar-s on the valve lifters for installation purposes. Repeat 0tep 1 for the remain"er of the valve lifters. +er imagen

Illustration , g0061,6%. +ie! (G) sho!s a goo" contact pattern. +ie!s (E) an" (J) sho! $a" contact patterns. Note: #hec- the valve lifters for !ear. Note: Refer to 0pecifications5 8#amshaft8 for more information on valve lifters.

Installation *roce"ure N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. +er imagen

Illustration 4 g00.,2061

*ut (/'2??( <u$ricant on valve lifter (1) prior to installation. Install valve lifter (1) in the original location in the engine c)lin"er $loc-. Repeat 0tep 1 for the remain"er of the valve lifters. 3n" 6): Install the camshaft. Refer to 9isassem$l) an" ;ssem$l)5 8#amshaft ' Install8. Roc2er S$a%t and Pus$rod - Install SMCS - 1102-012: 1206-012 Installation *roce"ure N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. +er imagen

Illustration 1 g0060?2(% Install valve caps (%) on the en" of the valve stem. Install pushro"s (.) in the c)lin"er hea" assem$l) (6) . Note: 3nsure that the pushro"s are installe" in the original location. ;lso5 ensure that the pushro"s are seate" in the valve lifters correctl). +er imagen

Illustration 2 g0060?26% *lace the roc-er shaft assem$l) (4) in position on the c)lin"er hea". Install si@ long $olts (,) for the roc-er shaft $rac-et an" tighten the $olts to a tor1ue of 1. A , N2m (11 A 2 l$ ft). Install si@ short $olts (2) an" the !ashers. /ighten the short $olts to a tor1ue of 1. A , N2m (11 A 2 l$ ft). Note: *erform 0teps 1 through . for the other hea" assem$l) on the ,066 3ngine. ;"just the inlet valve lash an" the e@haust valve lash to 0.2. mm (0.010 inch). Refer to /esting an" ;"justing5 8;ir Inlet an" 3@haust 0)stem8 for more information on setting the valve lash. /ighten a"justing scre!s (1) . 3n" 6): Install the valve mechanism cover. Refer to 9isassem$l) an" ;ssem$l)5 8+alve =echanism #over ' Remove an" Install8.

Roc2er S$a%t - -ssem)le SMCS - 1102-016

Table 1 Required Tools Tool A Part Number 1P-0510 Part Description 8ri$er ,r& p Qty 1

N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. +er imagen

Illustration 1 g0060?4?1 +er imagen

Illustration 2 g0060?4?0

:se /ool (;) to install $ushing (%) into roc-er arm (6)5 if the $ushing !as remove". Refer to 0pecifications5 8Roc-er 0haft8 for more information.

+er imagen

Illustration , g0060?4((

Install spacer (4) an" clip (,) onto one en" of shaft assem$l) (.) . 0li"e components onto shaft (.) in the correct or"er. Refer to Illustration 1 in or"er to install the components correctl). /he shaft assem$l) inclu"es the follo!ing components: 6olt (1) &il tu$e (2) #lip (,) 0pacer (4) 0haft assem$l) (.) Roc-er arm (6) 6ushing (%) Roc-er shaft $rac-et (() 0pring (?) Install spacer (4) an" clip (,) onto the other en" of shaft assem$l) (.) . Install $olt (1) an" oil suppl) tu$e (2) into the en" of shaft assem$l) (.) . 3n" 6): Install the roc-er shaft an" pushro"s. Refer to 9isassem$l) an" ;ssem$l)5 8Roc-er 0haft an" *ushro" ' Install8.

Roc2er S$a%t - 8isassem)le

SMCS - 110"-015

Disassembly Procedure
Table 1 Required Tools Tool A Start By:
Remove the roc-er shaft an" pushro"s. Refer to 9isassem$l) an" ;ssem$l)5 8Roc-er 0haft an" *ushro" ' Remove8. 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. =ar- the location an" the position of each component for later assem$l). +er imagen

Part Number 1P-0510

Part Description 8ri$er ,r& p

Qty 1

Illustration 1 g0060?4(( +er imagen

Illustration 2 g0060?4?1

Remove $olt (1) an" oil suppl) tu$e (2) from the en" of shaft assem$l) (.) . Remove clip (,) an" remove spacer (4) from shaft assem$l) (.) . Note: #hec- the spacer for !ear. Replace the spacer5 if necessar). 0li"e components to the left an" off the en" of shaft assem$l) (.) . /he shaft assem$l) inclu"es the follo!ing components: 6olt (1) &il tu$e (2) #lip (,) 0pacer (4) 0haft assem$l) (.) Roc-er arm (6) 6ushing (%) Roc-er shaft $rac-et (() 0pring (?) Remove clip (,) an" remove spacer (4) from the other en" of shaft assem$l) (.) . Note: #hec- the spacer for !ear. Replace the spacer5 if necessar). +er imagen

Illustration , g0060?4?0 Inspect $ushing (%) for !ear or "amage. :se /ool (;) to remove the $ushing from roc-er arm (6)5 if necessar). Refer to 0pecifications5 8Roc-er 0haft8 for more information.

Roc2er S$a%t and Pus$rod - Remove SMCS - 110"-011+ 1"08-011

Remo,al Procedure

0tart 6): Remove the valve mechanism cover. Refer to 9isassem$l) an" ;ssem$l)5 8+alve =echanism #over ' Remove an" Install8. N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. +er imagen

Illustration 1 g0060?26% <oosen a"justing scre!s (1) on each the roc-er arms a$out one rotation. <oosen si@ short $olts (2) an" the !ashers on the roc-er shaft $rac-ets. <oosen si@ long $olts (,) for the roc-er shaft $rac-et. Remove si@ $olts (,) from the roc-er shaft $rac-ets. Remove si@ short $olts (2) an" the !ashers from the roc-er shaft $rac-ets. Remove the roc-er shaft assem$l) (4) from the c)lin"er hea". Note: *erform 0teps 1 through 6 for the other roc-er shaft assem$l) on the ,066 3ngine. Note: #hec- the contact surface of the a"justing scre! (1) for !ear from the pushro"s an" chec- for threa"s that are strippe". +er imagen

Illustration 2 g0060?2(% *ut i"entification mar-s on pushro"s (.) in or"er to i"entif) the location of the pushro"s in the engine. Remove si@ pushro"s (.) from each hea" assem$l) (6) ( ,066 3ngine) or remove eight pushro"s (.) from hea" assem$l) (6) ( ,064 3ngine). Note: #hec- pushro"s for !orn en"s an" chec- for "istortion. If necessar)5 replace an) pushro"s that are !orn or "istorte". Remove valve caps (%) from the valve stem. /his !ill prevent the valve cap from $ecoming lost. Note: #hec- the contact surface of the valve caps for !ear an" chec- for oil passages that are clogge".

.alve Mec$anism Cover - Remove and Install SMCS - 1107-010

Remo,al Procedure
4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. +er imagen

Illustration 1 g00(1424,

<oosen hose clamp (2) an" remove hose (1) from the air inlet manifol" (,) an" the tur$ocharger (%) . <oosen hose clamps (4) an" "isconnect hose (.) from the $reather (6) . Remove $olts (() an" the !ashers from valve mechanism cover (?) . Note: /he ,064 3ngine has four $olts an" !ashers !hile the ,066 3ngine has si@ $olts an" !ashers. 3arlier mo"els of the ,064 an" ,066 3ngines use" acorn nuts an" !ashers in place of $olts. Remove valve mechanism cover (?) . Note: /he ,064 3ngine has one valve mechanism cover !hile the ,066 3ngine has t!o valve mechanism covers. Installation *roce"ure N&/I#3 4eep all parts clean from contaminants.

#ontaminants ma) cause rapi" !ear an" shortene" component life. +er imagen

Illustration 2 g00(1424,

#hec- the con"ition of the gas-et on valve mechanism cover (?). If the gas-et is !orn or "amage"5 use a ne! part for replacement. Install valve mechanism cover (?). Install the !ashers an" $olts (() . Note: /he ,064 3ngine has four $olts an" !ashers !hile the ,066 3ngine has si@ $olts an" !ashers. Note: /he ,064 3ngine has one valve mechanism cover !hile the ,066 3ngine has t!o valve mechanism covers. 3arlier mo"els of the ,064 an" ,066 3ngines use" acorn nuts an" !ashers in place of $olts. /or1ue $olts (() to 1. A , N2m (11 A 2 l$ ft). Install hose (.) onto the $reather (6). /ighten t!o hose clamps (4) that secure the hose. Install hose (1) an" tighten hose clamp (2) that secures the hose to the air inlet manifol" (,) an" to the tur$ocharger (%) .

Cran2case Breat$er - Remove and Install SMCS - 6768-262

Remo,al Procedure
N T!C"
#eep all parts clean $rom contaminants% Contaminants may cause rapid &ear and s'ortened component li$e%

N T!C"

Care must be ta*en to ensure t'at $luids are contained durin+ per$ormance o$ inspection) maintenance) testin+) ad.ustin+ and repair o$ t'e product% Be prepared to collect t'e $luid &it' suitable containers be$ore openin+ any compartment or disassemblin+ any component containin+ $luids% Re$er to Special Publication) N"N/0122) 3Caterpillar Tools and S'op Products /uide3 $or tools and supplies suitable to collect and contain $luids on Caterpillar products% Dispose o$ all $luids accordin+ to local re+ulations and mandates%

<oosen hose clamps (2) on hose (1). Remove the hose from the $reather assem$l) (,) . Remove $reather assem$l) (,) from valve mechanism cover (4) . Installation N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. +er imagen

Illustration 2 g00(14.?? Install ne! $reather assem$l) (,). Install hose (1) on the $reather assem$l) (,) an" tighten the hose clamp (2) .

Front Plate - Install SMCS - 116,-012 Installation *roce"ure N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. +er imagen

Illustration 1 g00611%11

*lace gas-et (,) (not sho!n) in position on the engine. Note: 3nsure that all mating surfaces are clear of ol" gas-ets. *lace front plate (2) in position on the engine. Install one $olt (1) an" the !asher in or"er to secure front plate (2) to the engine. /ighten the $olt to a tor1ue of ,. A . N2m (26 A 4 l$ ft). 3n" 6): Install the fuel injection pump. Refer to 9isassem$l) an" ;ssem$l)5 8 uel Injection *ump ' Install8. Install the camshaft. Refer to 9isassem$l) an" ;ssem$l)5 8#amshaft ' Install8. Install the i"ler gear. Refer to 9isassem$l) an" ;ssem$l)5 87ear 7roup ( ront) ' Install8. Front Plate - Remove SMCS - 116,-011 Removal *roce"ure 0tart 6): Remove the i"ler gear. Refer to 9isassem$l) an" ;ssem$l)5 87ear 7roup ( ront) ' Remove8. Remove the camshaft. Refer to 9isassem$l) an" ;ssem$l)5 8#amshaft ' Remove8. Remove the fuel injection pump. Refer to 9isassem$l) an" ;ssem$l)5 8 uel Injection *ump ' Remove8. N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. +er imagen

Illustration 1 g00611%11 Remove one $olt (1) an" the !asher from the front plate (2) . Remove front plate (2) from the engine. Remove gas-et (,) (not sho!n) from the engine or from the front plate (2) . Note: 3nsure that all mating surfaces are clear of ol" gas-ets. Note: #hec- the c)lin"er $loc- for the follo!ing con"itions: scale $uil"up5 corrosion an" other "amage.

5ousin* ;Front< - Install

SMCS - 1151-01"

!nstallation Procedure
Table 1 Required Tools Tool A Part Number 1P-0510 Part Description 8ri$er ,r& p Qty 1

Illustration 1 g00(,661? ;lignment mar-s for timing gears

#hec- the alignment of the timing gears. Note: 3nsure that the mar-s on the timing gears are in alignment. ;lign the fuel injection "rive gear !ith the 8,,8 mar- !ith the 8,8 mar- on i"ler gear. =a-e an alignment of the 828 mar- on the camshaft gear !ith the 8228 mar- on the i"ler gear. ;lign the 818 mar- on the cran-shaft gear !ith the 8118 mar- on the i"ler gear. /he No. 1 c)lin"er is at the top center position !hen the timing mar-s are in alignment. Note: Chen the mar-s are aligne"5 the piston in No. 1 c)lin"er is at the top center position on the compression stro-e. Note: Refer to 0pecifications5 87ear 7roup ( ront)8 for specifications on the assem$l) of the timing gears. '''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' +er imagen

Illustration 2 g00606022

3nsure that the ol" gas-et material (?) is remove" from the mating surface of front housing (4) an" the timing gear plate. Install a ne! gas-et. If the cran-shaft front seal (10) (not sho!n) !as remove"5 use /ool (;) to install a ne! cran-shaft front seal. '''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' +er imagen

Illustration , g00606002 6efore installation of the front housing5 chec- the gas-et (%) (not sho!n) for the oil pan for "amage. Replace the gas-et5 if necessar). Refer to 9isassem$l) an" ;ssem$l)5 83ngine &il *an ' Remove an" Install8 for replacement of the gas-et for the engine oil pan. :se t!o technicians to install the front housing onto the front plate an" the c)lin"er $loc-. /he !eight of the front housing is 20 -g (4. l$). Install t!o $olts (6) in or"er to fasten front housing (4) onto the c)lin"er $loc- an" the front plate (() . +er imagen

Illustration 4 g0060.?(. Install the !ashers an" si@ $olts (.) (not sho!n) in or"er to secure front housing (4) onto engine oil pan. Install $olts (,) an" !ashers that secure the front housing (4) to the front plate an" the c)lin"er $loc-. +er imagen

Illustration . g0060.?(1

#onnect hose (2) to the front housing. Install the hose clamp (1) in or"er to secure the hose to the front housing. 3n" 6): Install Install Install Install the the the the fuel injection pump. Refer to 9isassem$l) an" ;ssem$l)5 8 uel Injection *ump ' Install8. cran-shaft pulle). Refer to 9isassem$l) an" ;ssem$l)5 8#ran-shaft *ulle) ' Remove an" Install8. !ater pump. Refer to 9isassem$l) an" ;ssem$l)5 8Cater *ump ' Install8. alternator. Refer to 9isassem$l) an" ;ssem$l)5 8;lternator ' Remove an" Install8.

Fly1$eel - Remove
SMCS - 1156-011

Remo,al Procedure
Table 1 Required Tools Tool A B Part Number 138-7575 Part Description Ain' :rac'et <&rcin- scre/s %16 F " Qty 1 "

N T!C"
#eep all parts clean $rom contaminants% Contaminants may cause rapid &ear and s'ortened component li$e%

Remove t!elve $olts (1) an" !ashers from the a"apter (2) . Remove the a"apter (2) from the fl)!heel housing. +er imagen

Illustration 2 g0060.4?%

Remove four soc-et hea" $olts (,) from the inner ring (4) . Remove the inner ring (4) from the fl)!heel. +er imagen

Illustration , g0060..01

Remove si@ $olts (.) that secure fl)!heel (6) to the cran-shaft. #hec- all $olts for strippe" threa"s. Replace the $olts5 if necessar). +er imagen

Illustration 4 g0060..04

Install /ool (;)5 a strap5 an" a suita$le lifting "evice onto the fl)!heel (6). :se /ool (6) in or"er to remove the fl)!heel an" ring gear out of the housing. /he !eight of the fl)!heel is .0 -g (110 l$). *erform the follo!ing proce"ure in or"er to remove the fl)!heel ring gear. +er imagen

' Illustration . g0061,0,( *lace the fl)!heel an" ring gear assem$l) on a suita$le support. Note: #hec- the fl)!heel ring gear for the follo!ing con"itions:crac-s5 "amage" "o!el holes5 !orn ring gear an" "amage" ring gear. Note: I"entif) the orientation of the ol" ring gear on the fl)!heel for proper positioning5 !hen the ne! ring gear is installe". ;l!a)s !ear protective gloves !hen han"ling parts that have $een heate".

Deat ring gear (%) uniforml).

Remove the ring gear (%) $) tapping the ring gear all the !a) aroun" the fl)!heel (6) . Reposition the fl)!heel in or"er to remove the ring gear.

=ater (em'erature Re*ulator - Remove and Install SMCS - 1,""-010

Removal *roce"ure ;t operating temperature5 the engine coolant is hot an" un"er pressure. 0team can cause personal injur). #hec- the coolant level onl) after the engine has $een stoppe" an" the filler cap is cool enough to touch !ith the $are han". Remove the filler cap slo!l) to relieve pressure. #ooling s)stem con"itioner contains al-ali. ;voi" contact !ith s-in an" e)es to prevent personal injur). N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. N&/I#3 #are must $e ta-en to ensure that flui"s are containe" "uring performance of inspection5 maintenance5 testing5 a"justing an" repair of the pro"uct. 6e prepare" to collect the flui" !ith suita$le containers $efore opening an) compartment or "isassem$ling an) component containing flui"s. Refer to 0pecial *u$lication5 N3N72.005 8#aterpillar /ools an" 0hop *ro"ucts 7ui"e8 for tools an" supplies suita$le to collect an" contain flui"s on #aterpillar pro"ucts. 9ispose of all flui"s accor"ing to local regulations an" man"ates. 9rain the coolant level $elo! the !ater temperature regulator. +er imagen

''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''

Illustration 1 g0060?6?,

<oosen hose clamp (1) an" "isconnect hose (2) from cover (4) of the !ater temperature regulator. Remove t!o $olts (,) an" the !ashers from cover (4) of the !ater temperature regulator. 0eparate cover (4) from el$o! (.) . Remove $olts (6). 0eparate el$o! (.) from the !ater outlet manifol". Remove !ater temperature regulator (() (not sho!n) from cover (4) . Remove gas-et (%) (not sho!n) an" gas-et (?) (not sho!n) from the mounting surfaces of cover (4) an" el$o! (.) . :se the follo!ing proce"ure in or"er to test the !ater temperature regulator: *ut the !ater temperature regulator in a tu$ of !ater. Deat the !ater in or"er to test the !ater temperature regulator for thermostatic action. Note: 0tir the !ater in the tu$ in or"er to maintain even temperature "uring the test. Chen the valve of the !ater temperature regulator lifts more than 10 mm (0.4 inch)5 measure the !ater temperature. Note: /he opening temperature for the !ater temperature regulator is %1B A 2B# (160B A ,.6B ). If the valve fails to operate properl)5 replace the !ater temperature regulator. Installation *roce"ure N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. #lean all of the mounting surfaces for the gas-ets an" remove all gas-et material. N&/I#3 If the !ater temperature regulator is installe" incorrectl)5 it !ill cause the engine to overheat. +er imagen

Illustration 2 g0060?6?,

Install !ater temperature regulator (() (not sho!n) into el$o! (.) . Note: Chen the !ater temperature regulator is installe"5 ensure that the hole for the air vent is up. Install gas-et (%) (not sho!n) an" gas-et (?) (not sho!n). Note: #hec- the con"ition of the gas-ets. If the gas-ets are !orn or "amage"5 use (/'?01, 0ilicone 0ealant for replacement. Install the $olts (6) in or"er to secure el$o! (.) to the !ater outlet manifol". Install cover (4) for the !ater regulator housing. Install the !ashers an" t!o $olts (,) in or"er to secure cover (4) of the !ater regulator housing. Reconnect hose (2) an" tighten hose clamp (1) onto cover (4) of the !ater regulator housing. ill the cooling s)stem to the correct level. Refer to the &peration an" =aintenance =anual for the correct flui" an" the correct filling proce"ure.

=ater Pum' - Install SMCS - 1,61-012

Installation *roce"ure N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. +er imagen

Illustration 1 g0060??.0 Replace &'ring (4) (not sho!n) !ith a ne! part. ;ppl) gl)cerine to the &'ring $efore the installation of the !ater pump (,) an" !ater pump pulle) (2) . Install the !ater pump (,) an" !ater pump pulle) (2) as a unit onto the engine. Note: Chen the !ater pump is installe"5 ensure that the grease fitting is up. ;lso5 ensure that the !eep hole is "o!n. Install $olts (1) in or"er to secure !ater pump (,) to the c)lin"er $loc-. ill the cooling s)stem to the correct level. Refer to the appropriate &peration an" =aintenance =anual for the correct flui" an" the correct filling proce"ure. 3n" 6): Install +'$elts. Refer to 9isassem$l) an" ;ssem$l)5 8+'6elts ' Remove an" Install8.

=ater Pum' - -ssem)le

SMCS - 1361-016

Assembly Procedure
Table 1 Required Tools Tool A B Part Number 1P-0510 1P-1861 Part Description 8ri$er ,r& p ;etainin- ;in- Pliers Qty 1 1

Note: Refer to 0pecifications5 8Cater *ump8 for specifications that are re1uire" "uring assem$l). '''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' +er imagen

Illustration 1 g00(1,?4( Install seal (14)5 if the seal !as remove" "uring the "isassem$l) proce"ures. /he follo!ing components are installe" on shaft (?) : Casher (1,) 6earing (12) 0pacer (11) 6earing (10) Note: #hec- t!o $earings (10) an" (12) for correct rotation. +er imagen

Illustration 2 g00610140 :se a press an" /ool (;) to install shaft assem$l) (.) into the !ater pump housing. :se a press an" /ool (;) to install impeller (() onto shaft assem$l) (.) . +er imagen

Illustration , g0061012% :se /ool (6) to install retaining ring (4) into the !ater pump housing. :se a press an" /ool (;) to install flange (,) onto shaft assem$l) (.) . +er imagen

Illustration 4 g0061010( Install !ater pump pulle) (2) onto the flange. Install four $olts (1) in or"er to secure !ater pump pulle) (2) to the flange. 3n" 6): Install the !ater pump. Refer to 9isassem$l) an" ;ssem$l)5 8Cater *ump ' Install8.

+n*ine 0il Pum' - Install

SMCS - 130#-01"

!nstallation Procedure
Table 1 Required Tools Tool A Part Number 1P-0510 Part Description 8ri$er ,r& p Qty 1

:se /ool (;) to install the front oil seal (() (not sho!n). +er imagen

Illustration 2 g0060%?62

<o!er the temperature of the spin"le (10). Install spin"le (10) an" i"ler gear (11) as an assem$l) in the front housing. Note: /he temperature of the spin"le is lo!ere" in or"er to ease the installation of the spin"le in the front housing.

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Illustration , g0060%?..

Install set scre! (?) in the front housing. +er imagen

Illustration 4 g0060%((.

<o!er the temperature of the "rive gear assem$l). Install "rive gear (%) in the front housing. Note: /he temperature of the "rive gear assem$l) is lo!ere" in or"er to ease the installation of the "rive gear assem$l) in the front housing. +er imagen

Illustration . g0060(012 ;l!a)s !ear protective gloves !hen han"ling parts that have $een heate". Deat the oil pump gear up to 1(0 to 220 B# (,.6 to 42( B ). 0upport en" (G) of the shaft (%) ("rive gear). Install oil pump gear (6) onto the shaft. /he en" of the gear (J) shoul" $e flush !ith the en" of the shaft (E) . +er imagen

Illustration 6 g0060%%%0

Install "riven gear (4) into the front housing (slip fit). +er imagen

Illustration % g0060%(26

*lace gas-et (,) an" cover (2) in position on the front housing. Note: 3nsure that the ol" gas-et material is remove" from the mating surfaces. Install the !asher an" $olt (1) that secures the cover to the front housing. /ighten $olt (1) to a tor1ue of ,4 A . N2m (2. A 4 l$ ft). Refer to the 0pecifications =o"ule5 83ngine &il *ump8 for more information on the engine oil pump. 3n" 6): Install the front housing. Refer to 9isassem$l) an" ;ssem$l)5 8 Dousing ( ront) ' Install8.

+n*ine 0il By'ass .alve - Remove and Install

SMCS - 1306-010-:?

Remo,al Procedure
0tart 6): Remove the engine oil pan. Refer to 9isassem$l) an" ;ssem$l)5 83ngine &il *an ' Remove an" Install8. N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. +er imagen

Illustration 1 g0060%6%? +er imagen

Illustration 2 g0060%6(( Remove threa"e" plug (1) for the engine oil $)pass valve from the c)lin"er $loc- (2) . Remove shim (,) from the c)lin"er $loc- (2) . Remove spring (4) from the c)lin"er $loc- (2) . Remove spring seat (.) from the c)lin"er $loc- (2) . Note: #hec- the spring seat (.) an" the valve seat for an a$normal contact pattern. Inspect the spring (4) for !ea-ness or "amage. If necessar)5 replace the engine oil $)pass valve !ith a ne! part. Note: #hec- the c)lin"er $loc- (2) for oil passages that are clogge". Installation *roce"ure N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life.

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Illustration , g0060%6(( +er imagen

Illustration 4 g0060%6%?

Install spring seat (.) (not sho!n) an" spring (4) in the c)lin"er $loc- (2) . Install shim (,) an" threa"e" plug (1) in the c)lin"er $loc- (2) . /ighten the threa"e" plug (1) to a tor1ue of 6? A . N2m (.1 A 4 l$ ft). Note: /est the opening pressure for the engine oil relief valve. /he opening pressure for the relief valve is ?(1 A ?( -*a (142 A 14 psi). =a-e a"justments $) shimming5 if necessar). or information on testing the engine oil relief valve5 refer to /esting an" ;"justing5 8<u$rication 0)stem8. or more information5 refer to 0pecifications5 83ngine &il 6)pass +alve8. 3n" 6): Install the engine oil pan. Refer to 9isassem$l) an" ;ssem$l)5 83ngine &il *an ' Remove an" Install8.

+n*ine 0il Cooler - Install SMCS - 1378-01"

!nstallation Procedure
N&/I#3 4eep all parts clean from contaminants. #ontaminants ma) cause rapi" !ear an" shortene" component life. +er imagen

Illustration 1 g00611,20 Install engine oil cooler (.) an" ne! gas-et (6) (not sho!n). 3nsure that all mating surfaces are clean. Install $olts (4) an" !ashers in or"er to secure the engine oil cooler to the engine c)lin"er $loc-. /he ,066 3ngine has 24 $olts an" !ashers !hile the ,064 3ngine has 16 $olts an" !ashers. +er imagen

Illustration 2 g00611,1? Install oil tu$e assem$l) ("ipstic-) (2) into the c)lin"er $loc-. Note: ;ppl) clean engine oil to the &'ring seal (,) (not sho!n) $efore installation. Install $olt (1) an" the !asher into the c)lin"er hea". 3n" 6): Install the fuel injection pump. Refer to 9isassem$l) an" ;ssem$l)5 8 uel Injection *ump ' Install8.