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Diésel San Pedro Cat C7 Armado PDF
Diésel San Pedro Cat C7 Armado PDF
August 2008
Disassembly and
Assembly
C7 On-Highway Engine
YPG1-Up (Engine)
NPH1-Up (Engine)
KAL1-Up (Engine)
LBM1-Up (Engine)
SAP1-Up (Engine)
C7T1-Up (Engine)
WAX1-Up (Engine)
SAFETY.CAT.COM
i01658146
Disassembly and Assembly 2. Remove fuel priming pump (1) and the gasket.
Removal Procedure
NOTICE
Care must be taken to ensure that fluids are contained Illustration 2
g00987651
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to 1. Position the gasket and fuel priming pump (1) on
collect the fluid with suitable containers before open- the fuel filter base.
ing any compartment or disassembling any compo-
nent containing fluids. 2. Install bolts (2). Tighten bolts (2) to a torque of
25 ± 6 N·m (18 ± 4 lb ft).
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar i01921666
products.
Fuel Filter Base - Remove and
Dispose of all fluids according to local regulations and Install
mandates.
SMCS Code: 1262-010
Removal Procedure
g00987651
Illustration 1
Installation Procedure
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
g00987754
Illustration 4
i02226208
g00987754
Removal Procedure
Illustration 3
Table 1
1. Disconnect tube assembly (1) and tube assembly
Required Tools
(3).
Part
2. Remove bolts (2). Tool Number Part Description Qty
A 218-8171 Bolt 1
3. Remove fuel filter base (4).
Start By:
NOTICE
Keep all parts clean from contaminants.
g01123057
Illustration 5
3. Remove tie bolt (1) that is located in the top left 1. Position fuel transfer pump (2) on the unit injector
corner of the pump first. hydraulic pump. Be sure to align the drive tang of
the fuel transfer pump to the drive slot in the end
4. Replace tie bolt (1) with Tooling (A). of the pump shaft.
Note: Tooling (A) has an undersized bolt head. 2. Install tie bolts (4). Tighten the bolts to a snug fit.
Tooling (A) will prevent the body of the unit injector
hydraulic pump from separating during service. 3. Remove Tooling (A) that is located in the upper left
hole and install remaining tie bolt (1) to a snug fit.
5. Tighten Tooling (A) to a torque of 10 N·m (89 lb in).
4. Install bolts (3) for fuel transfer pump (2). Tighten
6. Start with tie bolt (4) in the lower left corner the bolts to a snug fit.
and remove the remainder of the bolts from fuel
transfer pump (2).
RENR7458-09 7
Disassembly and Assembly Section
5. Start in the lower left corner of the unit injector 2. Remove socket head bolts (1) from unit injector
hydraulic pump and tighten tie bolts (4) to a torque (2).
of 28 ± 2 N·m (21 ± 1 lb ft) in a crisscross pattern.
Torque the bolts again.
End By:
i02325874
Removal Procedure
Table 3
g01161909
Illustration 8
Required Tools
Part 3. Use Tooling (A) and Tooling (B) to remove unit
Tool Number Part Description Qty injector (2) from the cylinder head.
A 152-1057 Fuel Injector Installer As 1
Note: Do not use a wire brush on the tip of the unit
B 274-9198 Leg 2 injector. Damage to the unit injector will occur.
Start By:
NOTICE
Keep all parts clean from contaminants.
g01123753
Illustration 9
NOTICE
Keep all parts clean from contaminants.
6. Lubricate the O-ring seals and the backup rings 9. Install socket head bolt (1) on the exhaust side of
on the unit injector with clean engine oil before the bracket. Tighten the exhaust side of socket
installation. head bolt (1) until the bolt is seated. Tighten the
inlet side of socket head bolt (1) to a torque of
Note: Proper installation of the unit injector is very 12 ± 1 N·m (9 ± 1 lb ft).
important. Damage to the upper high pressure seals
can cause excessive oil leakage under the valve 10. Connect harness assembly (3).
cover. This may cause the engine not to start due
to a low actuation pressure. Damage to the lower End By:
high pressure seals may allow high pressure oil to
leak into the fuel supply passage. This will result in a. Install the valve mechanism cover. Refer to
excessive oil consumption. Disassembly and Assembly, “Valve Mechanism
Cover - Remove and Install”.
Note: Do not hit or strike the unit injector during
installation.
i02300862
Start By:
NOTICE
Keep all parts clean from contaminants.
g01123847
Illustration 13
g01618682
Illustration 15
g01123850
Illustration 14
2. Apply Tooling (G) to bores prior to installation.
4. Use Tooling (B) to remove the unit injector sleeve.
3. Apply a thin coating of Tooling (E) around the
outer circumference of unit injector sleeve (1) at
i03145071 Area (C).
Unit Injector Sleeve - Install 4. Use Tooling (D) and a hammer to position the unit
injector sleeve in the cylinder head.
SMCS Code: 1713-012
Note: Allow Tooling (E) to cure for two hours at 21 °C
Installation Procedure (70 °F) before filling the engine with fuel or coolant.
Longer curing time is required for lower temperatures.
Table 6
5. Fill the cooling system. Refer to Operation and
Required Tools
Maintenance Manual, “Cooling System Coolant
Part - Change”.
Tool Number Part Description Qty
End By:
D 221-9777 Sleeve Installer 1
E 4C-9506 Retaining Compound 1 a. Install the unit injectors. Refer to Disassembly and
Assembly, “Unit Injector - Install”.
F 4C-5552 Large Bore Brush 1
G 6V-6640 Sealant 1
RENR7458-09 11
Disassembly and Assembly Section
Removal Procedure
Table 7
Required Tools
Part
Tool Number Part Description Qty
A 192-5092 Removal Tool 1
g01127845
Illustration 17
NOTICE
Keep all parts clean from contaminants. 4. Remove bolts (7). Remove unit injector hydraulic
pump (1).
Contaminants may cause rapid wear and shortened
component life.
i02227969
g01127845
Illustration 18
g01127843
Illustration 16
1. Position unit injector hydraulic pump (1) in the
front housing.
1. Disconnect tube assembly (4), tube assembly (5),
and tube assembly (6). 2. Install bolts (7).
2. Use Tooling (A) in order to disconnect hose
assembly (3).
12 RENR7458-09
Disassembly and Assembly Section
Installation Procedure
Table 8
Required Tools
Part
Tool Number Part Description Qty
A 5P-3975 Rubber Lubricant 1
g01127843
Illustration 19
i02228143
g01124071
Modulating Valve - Remove Illustration 21
and Install Note: Make sure that nut (3) is loose prior to
installation.
SMCS Code: 3139-010
2. Install valve assembly (1) and solenoid assembly
(2). Tighten the valve assembly to a torque of
Removal Procedure 50 ± 5 N·m (37 ± 4 lb ft).
i02236344
Turbocharger - Remove
SMCS Code: 1052-011
Illustration 20
g01124071 Removal Procedure
1. Disconnect the harness assembly from solenoid NOTICE
assembly (2). Keep all parts clean from contaminants.
2. Loosen nut (3) in order to allow solenoid assembly Contaminants may cause rapid wear and shortened
(2) to rotate around valve assembly (1) during the component life.
removal procedure.
NOTICE NOTICE
Care must be taken to ensure that fluids are contained Keep all parts clean from contaminants.
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to Contaminants may cause rapid wear and shortened
collect the fluid with suitable containers before open- component life.
ing any compartment or disassembling any compo-
nent containing fluids.
1. Apply Tooling (A) on the threads of the mounting
Refer to Special Publication, NENG2500, “Caterpillar studs for the turbocharger.
Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
g01031231
Illustration 23
i02228177
Turbocharger - Install
SMCS Code: 1052-012
Installation Procedure
Table 9
Required Tools
Part
Tool Number Part Description Qty
A 5P-3931 Anti-Seize Compound 1
14 RENR7458-09
Disassembly and Assembly Section
i02228217
Removal Procedure
g01124147
Illustration 25
Installation Procedure
Table 10
Required Tools
Part
Tool Number Part Description Qty
g00617739
Illustration 26
A 2P-2333 High Temperature Sealer 1
B 5P-3931 Anti-Seize Compound 1 4. Tighten Bolt (1) through Bolt (12) in a numerical
sequence.
NOTICE Tighten bolts to the following torque. .... 4 ± 1 N·m
Excessive use of sealant can cause damage to com- (35 ± 9 lb in)
ponents.
5. Tighten Bolt (1) through Bolt (12) in a numerical
To avoid component damage use only the amount of sequence.
sealant necessary for the application.
RENR7458-09 15
Disassembly and Assembly Section
i02228257
Removal Procedure
g01124203
Illustration 28
Disconnect batteries before performance of any
service work.
1. Position solenoid (1) on the engine.
1. Disconnect the battery. Refer to Operation and 2. Connect harness assemblies (2) and harness
Maintenance Manual, “Battery or Battery Cable assemblies (3).
- Disconnect”.
3. Connect the battery. Refer to Operation and
Maintenance Manual, “Battery or Battery Cable
- Disconnect”.
i02228289
Removal Procedure
Table 11
Required Tools
Part
Tool Number Part Description Qty
A 5S-1330 Valve Spring Compressor 1
g01124203
Illustration 27
Start By:
2. Disconnect harness assemblies (2) and harness
assemblies (3). a. Remove the cylinder head assembly. Refer to
Disassembly and Assembly, “Cylinder Head -
3. Remove solenoid (1). Remove”.
NOTICE
Keep all parts clean from contaminants.
g01127720 g01127720
Illustration 29 Illustration 30
The valve spring keepers can be thrown from Improper assembly of parts that are spring loaded
the valve when the valve spring compressor is can cause bodily injury.
released. Ensure that the valve spring keepers
are properly installed on the valve stem. To help To prevent possible injury, follow the established
prevent personal injury, keep away from the front assembly procedure and wear protective equip-
of the valve spring keepers and valve springs ment.
during the installation of the valves.
1. Lubricate valve (2) with clean engine oil. Install
Note: The following components of the exhaust valve (2) in the cylinder head assembly. Install
valves are different from the components of the inlet new valve seal (1) against the valve guide.
valves: spring retainer (5), valve spring (4), and valve
(2). 2. Place the following items on the valve stem:
washer (3), valve spring (4), and spring retainer
1. Use Tooling (A) to compress valve spring (4). (5).
Remove retainer locks (6).
Note: A small amount of grease can be used to hold
2. Remove Tooling (A). Remove spring retainer (5), the retainer locks in position during installation.
valve spring (4), and washer (3).
3. Use Tooling (A) to compress valve spring (4).
3. Remove valve seal (1) and valve (2). Install retainer locks (6).
End By:
Installation Procedure
Table 12 a. Install the cylinder head assembly. Refer to
Disassembly and Assembly, “Cylinder Head -
Required Tools Install”.
Part
Tool Number Part Description Qty
A 5S-1330 Valve Spring Compressor 1
NOTICE
Keep all parts clean from contaminants.
NOTICE
Keep all parts clean from contaminants.
g01124397
Illustration 32
Start By:
End By:
g01124436
Illustration 33
i02519791
Removal Procedure
Table 17
Required Tools
Part
Tool Number Part Description Qty
g01261010
A 185-3630 Strap Wrench Assembly 1 Illustration 36
i02229026
Disassembly Procedure
Start By:
g01261004
a. Remove the engine oil filter base and the oil
Illustration 35 cooler. Refer to Disassembly and Assembly,
“Engine Oil Filter Base and Oil Cooler - Remove”.
2. Remove nuts (1). Remove bracket (2) and the
hose assembly. Use Tooling (A) and remove oil
filter (3). NOTICE
Keep all parts clean from contaminants.
g01124604 g01124604
Illustration 38 Illustration 39
Personal injury can result from being struck by Improper assembly of parts that are spring loaded
parts propelled by a released spring force. can cause bodily injury.
Make sure to wear all necessary protective equip- To prevent possible injury, follow the established
ment. assembly procedure and wear protective equip-
ment.
Follow the recommended procedure and use all
recommended tooling to release the spring force.
(1) Oil cooler bypass valve
(1) Oil cooler bypass valve (2) Oil filter bypass valve
a. Install the engine oil filter base and the oil cooler.
i02229174
Refer to Disassembly and Assembly, “Engine Oil
Engine Oil Filter Base - Filter Base and Oil Cooler - Install”.
Assemble i02519800
g01261018
Illustration 40
g01261020
Illustration 42
g01261019
Illustration 41
g01261022
Illustration 43
4. Install oil filter (3) with Tooling (A). Install the hose
assembly and bracket (2). Install nuts (1).
i02229240 i02229280
NOTICE
Keep all parts clean from contaminants.
g00987795
Illustration 44
g01127673 g01127673
Illustration 46 Illustration 47
i02229316
End By:
i02229347
NOTICE
Engine Oil Pump - Install Keep all parts clean from contaminants.
SMCS Code: 1304-012 Contaminants may cause rapid wear and shortened
component life.
Installation Procedure
NOTICE NOTICE
Keep all parts clean from contaminants. Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
Contaminants may cause rapid wear and shortened ing, adjusting and repair of the product. Be prepared to
component life. collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
g00987795
Illustration 49
a. Install the engine oil pan. Refer to Disassembly 2. Remove bolts (1). Remove support bracket (2).
and Assembly, “Engine Oil Pan - Remove and
Install”. 3. Disconnect hose (3).
Removal Procedure
Start By:
i02229484 i02229489
g01124833
Illustration 51
2. Remove gasket (4). 1. Use Tooling (A) and a suitable press to install
pulley (9) on shaft assembly (8).
3. Use Tooling (A) and a suitable press to remove
shaft assembly (8) from impeller (5) and housing 2. Use Tooling (B) and a suitable press to install seal
(7). assembly (6) in housing (7).
4. Use Tooling (A) and a suitable press to remove 3. Use Tooling (A) and a suitable press to install
seal assembly (6) from housing (7). shaft assembly (8) into housing (7). Install the
shaft assembly until the bearing is flush with the
5. Use Tooling (A) and a suitable press to remove housing.
pulley (9) from shaft assembly (8).
4. Use Tooling (A) and a suitable press to install
impeller (5) on shaft assembly (8). Install the
impeller until the distance between the impeller
and the machined surface of the water pump is
0.75 ± 0.25 mm (0.030 ± 0.010 inch).
26 RENR7458-09
Disassembly and Assembly Section
6. Position cover (3) and install bolts (2). Install new Water Temperature Regulator -
O-ring seals (1). Remove and Install
End By: SMCS Code: 1355-010
a. Install the water pump. Refer to Disassembly and
Assembly, “Water Pump - Install”. Removal Procedure
NOTICE
i02229490
Keep all parts clean from contaminants.
Water Pump - Install Contaminants may cause rapid wear and shortened
SMCS Code: 1361-012 component life.
g01124776
Illustration 53
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
g01125043
Illustration 56
1. Position the water temperature regulators in water 3. Remove flywheel (2) from Tooling (B).
temperature regulator housing (3).
4. Replace ring gear (3), if necessary. Use a hammer
2. Install a gasket and pipe (2) on water temperature and a punch in order to remove the flywheel ring
regulator housing (3). gear.
NOTICE
Keep all parts clean from contaminants.
g01125043
Illustration 57
7. Check the flywheel runout. Refer to Testing and Crankshaft Rear Seal - Install
Adjusting, “Flywheel - Inspect”.
SMCS Code: 1161-012
i02230478
Installation Procedure
Crankshaft Rear Seal - Remove Table 26
SMCS Code: 1161-011 Required Tools
Part
Removal Procedure Tool Number Part Description Qty
Required Tools
NOTICE
Part
Tool Number Part Description Qty
Keep all parts clean from contaminants.
A 1U-8145 Drill Bit 1 Contaminants may cause rapid wear and shortened
B 1U-7600 Slide Hammer Puller 1
component life.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
g01125095
Illustration 59
End By:
g00987190
i02230508 Illustration 60
Flywheel Housing - Remove 1. Fasten Tooling (A) and a suitable lifting device
and Install to flywheel housing (1). The weight of flywheel
housing (1) is approximately 25 kg (55 lb).
SMCS Code: 1157-010
2. Remove bolts (2) and bolt (3). Remove bolts (4).
Removal Procedure 3. Remove bolts (5) that fasten the engine oil pan to
flywheel housing (1). Remove flywheel housing
Table 27
(1).
Required Tools
Part Installation Procedure
Tool Number Part Description Qty
Table 28
A 138-7573 Link Bracket 2
Required Tools
Start By: Part
Tool Number Part Description Qty
a. Remove the flywheel. Refer to Disassembly and A 138-7573 Link Bracket 2
Assembly, “Flywheel - Remove”.
B 1U-8846 Sealant -
30 RENR7458-09
Disassembly and Assembly Section
NOTICE
Keep all parts clean from contaminants.
g00991061
Illustration 62
End By:
i02230536
Removal Procedure
1. Remove the belts.
RENR7458-09 31
Disassembly and Assembly Section
Removal Procedure
Table 29
Required Tools
Part
Tool Number Part Description Qty
A 1U-7600 Slide Hammer Puller 1
B 1U-8145 Drill Bit 1
Start By:
g00991061
Illustration 65
3. Install the belts. 1. Use Tooling (B) and carefully drill three evenly
spaced holes in crankshaft front seal (1).
i02230558 i02230581
g00991101
Illustration 68
g00989228
Illustration 67
1. Remove bolts (2), (3), and (4). Remove front cover
Note: The crankshaft seal is designed to be installed (1) and the gasket from the front housing.
dry.
i02230634
1. Use Tooling (C) to install crankshaft front seal (1).
Front Cover - Install
End By:
SMCS Code: 1166-012
a. Install the vibration damper and the pulley. Refer
to Disassembly and Assembly, “Vibration Damper Installation Procedure
and Pulley - Remove and Install”.
NOTICE
Keep all parts clean from contaminants.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
g00991101
Illustration 69
End By:
i02230639
g01125215 g01125215
Illustration 71 Illustration 72
2. Remove bolts (3) and (5). Remove front housing 1. Clean the joint face on front housing (4) with
(4). Tooling (A).
g00989343
Illustration 73
End By: 3. Remove bolt (7) and idler shaft (3) from the
cylinder block. Remove thrust plate (5).
a. Install the air compressor. Refer to Disassembly
and Assembly, “Air Compressor - Remove and 4. Use Tooling (A) and a suitable press to remove
Install”. bearing (6) from camshaft idler gear (2).
Start By:
NOTICE Illustration 75
g01125304
Keep all parts clean from contaminants.
1. Use Tooling (A) and a suitable press to install
Contaminants may cause rapid wear and shortened bearing (6) in camshaft idler gear (2). Install the
component life. bearing until the bearing is 1.080 ± 0.250 mm
(0.0425 ± 0.0098 inch) below the front face of
camshaft idler gear (2).
Illustration 74
g01125301 End By:
1. Remove bolts (4) and retaining plate (1). a. Install the front housing. Refer to Disassembly and
Assembly, “Housing (Front) - Install”.
2. Remove camshaft idler gear (2).
36 RENR7458-09
Disassembly and Assembly Section
i02230894
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
i02231006
Illustration 76
g01125461 Removal Procedure
1. Remove bolts (1). Start By:
2. Remove valve mechanism cover (2). a. Remove the valve mechanism cover. Refer to
Disassembly and Assembly, “Valve Mechanism
Cover - Remove and Install”.
Installation Procedure
NOTICE
NOTICE Keep all parts clean from contaminants.
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
Contaminants may cause rapid wear and shortened component life.
component life.
g01125461
Illustration 77
g01125477
Illustration 79
RENR7458-09 37
Disassembly and Assembly Section
3. Remove bolts (2) and valve mechanism cover Rocker Shaft and Pushrod -
base (3) from the cylinder head. Remove
Installation Procedure SMCS Code: 1102-011; 1208-011
Removal Procedure
Start By:
NOTICE
Keep all parts clean from contaminants.
g01127431
Illustration 81
Contaminants may cause rapid wear and shortened 1. Lubricate all of the components of the rocker shaft
component life. with clean engine oil.
g01155738
Illustration 85
g01155738
Illustration 84
RENR7458-09 39
Disassembly and Assembly Section
a. Install the rocker shaft. Refer to Disassembly and 1. Apply Tooling (A) to both ends of pushrods (6).
Assembly, “Rocker Shaft and Pushrod - Install”.
2. Lubricate pushrods (6) with clean engine oil.
i02231166
Install pushrods (6) and inlet valve bridges (5).
Installation Procedure
Table 34
Required Tools
Part
Tool Number Part Description Qty
A 8T-2998 Lubricant 1
NOTICE
Keep all parts clean from contaminants.
End By:
i02231291
Removal Procedure
g01125661
Start By: Illustration 88
a. Remove the valve mechanism cover base. Refer 1. Disconnect harness assembly (1), harness
to Disassembly and Assembly, “Valve Mechanism assembly (2), harness assembly (3), and harness
Cover Base - Remove and Install”. assembly (4).
b. Remove the rocker shaft and pushrods. Refer to 2. Remove tube assembly (7).
Disassembly and Assembly, “Rocker Shaft And
Pushrod - Remove”. 3. Disconnect hose (6).
c. Remove the unit injectors. Refer to Disassembly 4. Disconnect harness assembly (5).
and Assembly, “Unit Injector - Remove”.
NOTICE
Keep all parts clean from contaminants.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
i02231335
Installation Procedure
Table 35
Required Tools
Part
Tool Number Part Description Qty
A 6V-4876 Lubricant 1
B 4C-5590 Anti-Seize Compound 1
NOTICE
Keep all parts clean from contaminants.
g01125672
Contaminants may cause rapid wear and shortened
Illustration 90 component life.
6. Disconnect tube assembly (10) and tube assembly
(12) from turbocharger (11). 1. Install a new cylinder head gasket.
7. Attach a suitable lifting device to the cylinder head. Note: To avoid damage to the cylinder head gasket,
The weight of the cylinder head is approximately use guide bolts of an appropriate size to install the
175 kg (385 lb). cylinder head.
g01125676
Illustration 91
g01125720
Illustration 93
End By:
i02231540
Removal Procedure
Start By:
Installation Procedure
Table 36
Required Tools
Part
Tool Number Part Description Qty
A 9S-3263 Thread Lock Compound 1 g01125745
Illustration 100
2. Install lifter arms (4) on lifter shaft (5). f. Install the fuel filter base. Refer to Disassembly
and Assembly, “Fuel Filter Base - Remove and
3. Position lifter shaft (5) over the dowels on the side Install”.
cover. Ensure that the oil holes in the lifter shaft
are facing the side cover. Apply Tooling (A) on the
threads of bolts (3) that hold lifter shaft (5) to the
side cover. Install bolts (3). Tighten bolts (3) to a
torque of 13 ± 3 N·m (10 ± 2 lb ft). Tighten the two
center bolts. Then tighten the end bolts.
i02231590
Camshaft - Remove
SMCS Code: 1210-011
Removal Procedure
Table 37
Required Tools
Part
Tool Number Part Description Qty
136-4632 Timing Pin 1
A
139-7063 Timing Pin Adapter 1
B FT-2730 Puller 12
Start By:
NOTICE
Keep all parts clean from contaminants.
Camshaft - Install
SMCS Code: 1210-012
Contaminants may cause rapid wear and shortened
component life.
Installation Procedure
1. Use Tooling (B) to reposition the valve lifters out
of the way. NOTICE
Keep all parts clean from contaminants.
2. Ensure that the No. 1 cylinder is at the top
center compression stroke. Refer to Testing and Contaminants may cause rapid wear and shortened
Adjusting, “Finding Top Center Position for No. 1 component life.
Piston”. Install Tooling (A) in the flywheel.
i02235225
Removal Procedure
Start By:
g01125899
Illustration 102
g00987675 g00989974
Illustration 104 Illustration 105
2. Align key (3) in the camshaft with the groove 1. Use Tooling (A) to remove camshaft bearing (1)
(keyway) in the camshaft gear. from the front of the cylinder block. Remove the
remaining camshaft bearings (2) from the cylinder
3. Install camshaft gear (1) on the end of camshaft block.
(2).
End By:
Installation Procedure
Table 39
a. Install the camshaft. Refer to Disassembly and
Assembly, “Camshaft - Install”. Required Tools
Part
Tool Number Part Description Qty
i02232381
Camshaft Bearing Tool
Camshaft Bearings - Remove A 8S-2241
Group
1
and Install
NOTICE
SMCS Code: 1211-010 Keep all parts clean from contaminants.
Start By:
NOTICE
Keep all parts clean from contaminants. Illustration 106
g00990062
Contaminants may cause rapid wear and shortened 1. Use Tooling (A) to install all of the camshaft
component life. bearings (2) except for the front camshaft bearing.
Locate the oil hole in each bearing so that oil
Note: Note the oil hole orientation in each camshaft hole (3) is located at the top of the bore. Refer to
bearing prior to removal for assembly purposes. Specifications for more information.
48 RENR7458-09
Disassembly and Assembly Section
g00989938
Illustration 107
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
i02232665
Removal Procedure
Start By:
g00987883 NOTICE
Illustration 109
Keep all parts clean from contaminants.
g00987444
Illustration 111
g00987889 1. Remove bolt (2) and piston cooling jet (1) from
Illustration 110
each cylinder.
Note: Do not put liquid gasket material on the oil pan
gasket or on the gasket surface of engine oil pan (1). Installation Procedure
1. Position a new gasket and engine oil pan (1) on NOTICE
the cylinder block. Keep all parts clean from contaminants.
2. Install bolts (2). Tighten Bolts (X) to a torque of Contaminants may cause rapid wear and shortened
31 ± 3 N·m (23 ± 2 lb ft). component life.
g00987444
Illustration 112
Removal Procedure
Start By:
i02232839 i02233056
NOTICE
Keep all parts clean from contaminants.
g01126141
Illustration 118
Illustration 117
g01126306 e. Position piston rings (4) so the gaps are 120
degrees from each other.
1. Use Tooling (C) to remove the old bearing and
install the new bearing (6) at the same time. The 3. Check the clearance between the ends of piston
adapter of Tooling (C) should make full contact rings (4). Refer to Specifications, “Piston And
with the surfaces of connecting rod (3). Rings”.
Note: Orient the bearing joint within 12 ± 5 degrees 4. Position piston (1) on connecting rod (3). Apply
of either Location (X). clean engine oil to piston pin (5) and install the
piston pin. Use Tooling (B) to install retaining ring
(2). Make sure that the retaining rings are fully
NOTICE seated in the grooves of the piston assembly.
The connecting rod must be heated for the installation
of the piston pin bearing. Do not use a torch. End By:
a. Raise the temperature of connecting rod (3) a. Install the pistons and the connecting rods. Refer
along Length (Y). to Disassembly and Assembly, “Pistons and
Connecting Rods - Install”.
(Y) Maximum Length for heating the
connecting rod .. 75 ± 5 mm (3.0 ± 0.2 inch)
Installation Procedure
Table 42
Required Tools
Part
Tool Number Part Description Qty
A 173-5529 Piston Ring Compressor 1
B 4C-5593 Anti-Seize Compound 1
g01126089
NOTICE Illustration 120
Keep all parts clean from contaminants.
g01126088
Illustration 121
g00954373
Illustration 119
5. Before connecting rod (3) comes in contact with
2. Position the piston rings so that the end gaps the crankshaft, install the upper half of connecting
are located 120 degrees from each other. Install rod bearing (4). Ensure that the bearing tab
Tooling (A) in order to compress the piston rings. engages with the slot in connecting rod (3).
Note: Install the piston and connecting rod so that 6. Apply clean engine oil to the surface of the upper
the forging number on the connecting rod points half of connecting rod bearing (4). Use a soft
toward the flywheel end of the engine. faced hammer in order to tap the piston into the
cylinder bore while you guide connecting rod (3)
3. With the number one crankshaft throw at the onto the crankshaft.
bottom center, install the piston and connecting
rod in the engine. Ensure that the proper piston 7. Place the lower half of connecting rod bearing (4)
and connecting rod are in the corresponding in corresponding connecting rod cap (2). Ensure
cylinder with the bearing retainer notch toward the that the bearing tab engages with the groove in
right side of the engine. connecting rod cap (2).
54 RENR7458-09
Disassembly and Assembly Section
i02304516
Removal Procedure
Table 43
Required Tools
Part
Tool Number Part Description Qty
g01126410
Illustration 123 A 2P-5518 Main Bearing Tool 1
End By:
g00988316
Illustration 124
i02307306
Installation Procedure
Table 44
Required Tools
Part
Tool Number Part Description Qty
A 2P-5518 Main Bearing Tool 1
B 8T-5096 Dial Indicator Group 1
NOTICE
Keep all parts clean from contaminants.
g00988318
Illustration 125
Contaminants may cause rapid wear and shortened
NOTICE component life.
If the crankshaft is turned in the wrong direction, the
tab of the crankshaft main bearing will be pushed be- Note: Install the crankshaft main bearings dry
tween the crankshaft and the cylinder block. this can when clearance checks are performed. Refer to
cause damage to either or both the crankshaft and the Disassembly and Assembly, “Bearing Clearance -
cylinder block. Check”. Apply clean engine oil on the crankshaft
main bearings for final assembly.
3. Use the following steps in order to remove the
upper half of crankshaft main bearings: Note: Ensure that the tabs on the back side of the
crankshaft main bearings fit in the grooves of the
crankshaft main bearing caps and the cylinder block.
a. Turn the crankshaft until Tooling (A) can
be installed in the crankshaft journal. Install
Tooling (A).
g00988318
Illustration 126
i02236686
Crankshaft - Remove
SMCS Code: 1202-011
Removal Procedure
Start By:
NOTICE
Crankshaft main bearing caps should be installed with
the part number toward the right side of the engine.
Crankshaft main bearing caps are to be identified by
stamped numbers 1 through 7 located on the bottom
surface. The thrust plate is used on the number 6
crankshaft main bearing only.
End By: 1. Remove bolts (2) and main bearing caps (3).
a. Install the engine oil pump. Refer to Disassembly 2. Attach a suitable lifting device to each end of
and Assembly, “Engine Oil Pump - Install”. crankshaft (1). The weight of crankshaft (1) is
approximately 62 kg (137 lb). Carefully remove
crankshaft (1) from the cylinder block.
i02236693
Crankshaft - Install
SMCS Code: 1202-012
Installation Procedure
Table 45
Required Tools
Part
Tool Number Part Description Qty
A 8T-5096 Dial Indicator Group 1
NOTICE
Keep all parts clean from contaminants.
Note: When the bolts for the rear main bearing cap
are tightened, slide the main bearing cap as far
forward as possible until the cap is against the bolts.
Hold the main bearing cap in this position and tighten
the bolts.
End By:
i02307746
Start By:
NOTICE
Keep all parts clean from contaminants.
g00988783
Illustration 131
60 RENR7458-09
Disassembly and Assembly Section
Bearing Clearance - Check • Ensure that the backs of the bearings and the
bores are clean and dry.
SMCS Code: 1203-535; 1219-535
• Ensure that the bearing locking tabs are properly
seated in the tab grooves.
Measurement Procedure
• The crankshaft must be free of oil at the contact
Table 47 points of Tooling (A).
Required Tools
1. Put a piece of Tooling (A) on the crown of the
Part
bearing that is in the cap.
Tool Number Part Description Qty
198-9142 Plastic Gauge (Green) Note: Do not allow Tooling (A) to extend over the
0.025 to 0.076 mm 1 edge of the bearing.
(0.001 to 0.003 inch)
198-9143 Plastic Gauge (Red) 2. Use the correct torque-turn specifications in order
0.051 to 0.152 mm 1 to install the bearing cap. Do not use an impact
(0.002 to 0.006 inch) wrench. Be careful not to dislodge the bearing
A when the cap is installed.
198-9144 Plastic Gauge (Blue)
0.102 to 0.229 mm 1
Note: Do not turn the crankshaft when Tooling (A)
(0.004 to 0.009 inch)
is installed.
198-9145 Plastic Gauge (Yellow)
0.230 to 0.510 mm 1 3. Carefully remove the cap, but do not remove
(0.009 to 0.020 inch) Tooling (A). Measure the width of Tooling (A)
while Tooling (A) is in the bearing cap or on the
Note: Plastic gauge may not be necessary when the crankshaft journal. Refer to Illustration 132.
engine is in the chassis.
NOTICE
Keep all parts clean from contaminants.
g01128083
Illustration 133
4. Remove all of Tooling (A) before you install the Coolant Temperature Sensor -
bearing cap. Remove and Install
Note: When Tooling (A) is used, the readings can SMCS Code: 1906-010
sometimes be unclear. For example, all parts of
Tooling (A) are not the same width. Measure the NOTICE
major width in order to ensure that the parts are Care must be taken to ensure that fluids are contained
within the specification range. Refer to Specifications during performance of inspection, maintenance, test-
Manual, “Connecting Rod Bearing Journal” and ing, adjusting and repair of the product. Be prepared to
Specifications Manual, “Main Bearing Journal” for the collect the fluid with suitable containers before open-
correct clearances. ing any compartment or disassembling any compo-
nent containing fluids.
i02236791
Refer to Special Publication, NENG2500, “Caterpillar
Atmospheric Pressure Sensor Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
- Remove and Install products.
SMCS Code: 1923-010
Dispose of all fluids according to local regulations and
mandates.
NOTICE
Keep all parts clean from contaminants.
g01128268
Illustration 134
i02236802 i02236851
NOTICE NOTICE
Care must be taken to ensure that fluids are contained Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test- during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open- collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo- ing any compartment or disassembling any compo-
nent containing fluids. nent containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and supplies Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar suitable to collect and contain fluids on Caterpillar
products. products.
Dispose of all fluids according to local regulations and Dispose of all fluids according to local regulations and
mandates. mandates.
g01128091 g01128104
Illustration 135 Illustration 136
(1) Engine oil pressure sensor ................ 10 ± 2 N·m (1) Injection actuation pressure sensor ... 20 ± 2 N·m
(90 ± 18 lb in) (15 ± 1.5 lb ft)
i02237012
Speed/Timing Sensor -
Remove and Install
SMCS Code: 1907-010; 1912-010
NOTICE
Keep all parts clean from contaminants.
g01128114 g01128200
Illustration 137 Illustration 138
Note: The speed/timing sensors must be replaced (1) Boost pressure sensor ....................... 10 ± 2 N·m
as a pair. (90 ± 18 lb in)
g01128213
Illustration 139
64 RENR7458-09
Disassembly and Assembly Section
(1) Inlet air temperature sensor ............... 20 ± 5 N·m Two-Piece Fan Drive Mounting (If
(15 ± 4 lb ft) Equipped)
i02237494
Removal Procedure
Start By:
g01128365
Illustration 141
Installation Procedure
One-Piece Fan Drive Mounting (If
Equipped)
g01128363
Illustration 140
g01128363
Illustration 142
RENR7458-09 65
Disassembly and Assembly Section
g01128321
Illustration 144
i02528409
End By:
g01128834
Illustration 145
66 RENR7458-09
Disassembly and Assembly Section
Installation Procedure
g01063153
Illustration 147
i02276552
Removal Procedure
i02237659
Removal Procedure
Table 48 g00992674
Illustration 149
Required Tools
Part
Tool Number Part Description Qty
A 138-7573 Link Bracket 1
NOTICE
Keep all parts clean from contaminants.
NOTICE g00992677
Illustration 150
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to 2. Disconnect hose assembly (1), hose assembly
collect the fluid with suitable containers before open- (3), hose assembly (6), and hose (2).
ing any compartment or disassembling any compo-
nent containing fluids. 3. Remove bolts (7).
i02237680
Removal Procedure
Table 50
Required Tools
Part
Tool Number Part Description Qty
g00992674
Illustration 151 A 132-5451 Holding Fixture 1
Start By:
g00992677
Illustration 152
RENR7458-09 69
Disassembly and Assembly Section
g01128545 g01148907
Illustration 153 Illustration 154
1. Install Tooling (A) on air compressor drive gear (1). 1. Install air compressor drive gear (1) on the air
compressor.
2. Remove nut (2).
2. Install Tooling (A) on air compressor drive gear (1).
3. Remove air compressor drive gear (1).
3. Install nut (2).
i02294313
Tapered Shaft on Bendix Air Compressor
Air Compressor Drive Gear -
1. Tighten nut (2) to a torque of 160 ± 15 N·m
Install (118 ± 11 lb ft).
(Two Cylinder)
2. Tap the gear axially with a soft faced hammer in
SMCS Code: 1803-012-GE order to seat the gear onto the tapered crankshaft.
i02967460
Installation Procedure
Table 52
Required Tools
Part
Tool Number Part Description Qty
A 132-5451 Holding Fixture 1
g01128545
Illustration 155
End By:
Index
A Crankshaft Gear - Remove and Install .................. 59
Installation Procedure ........................................ 59
Air Compressor - Remove and Install.................... 67 Removal Procedure ........................................... 59
Installation Procedure ........................................ 68 Crankshaft Main Bearings - Install......................... 56
Removal Procedure ........................................... 67 Installation Procedure ........................................ 56
Air Compressor Drive Gear - Install....................... 70 Crankshaft Main Bearings - Remove..................... 55
Installation Procedure ........................................ 70 Removal Procedure ........................................... 55
Air Compressor Drive Gear - Install (Two Crankshaft Rear Seal - Install................................ 28
Cylinder) .............................................................. 69 Installation Procedure ........................................ 28
Installation Procedure ........................................ 69 Crankshaft Rear Seal - Remove............................ 28
Air Compressor Drive Gear - Remove................... 68 Removal Procedure ........................................... 28
Removal Procedure ........................................... 68 Cylinder Head - Install ........................................... 41
Air Inlet Heater Solenoid - Remove and Install...... 15 Installation Procedure ........................................ 41
Installation Procedure ........................................ 15 Cylinder Head - Remove ....................................... 40
Removal Procedure ........................................... 15 Removal Procedure ........................................... 40
Alternator - Remove and Install ............................. 65
Installation Procedure ........................................ 66
Removal Procedure ........................................... 65 D
Atmospheric Pressure Sensor - Remove and
Install ................................................................... 61 Disassembly and Assembly Section........................ 4
B E
Bearing Clearance - Check ................................... 60 Electric Starting Motor - Remove and Install ......... 66
Measurement Procedure ................................... 60 Installation Procedure ........................................ 66
Boost Pressure Sensor - Remove and Install........ 63 Removal Procedure ........................................... 66
Engine Control Module - Remove and Install ........ 65
Engine Oil Filter Base - Assemble......................... 20
C Assembly Procedure.......................................... 20
Engine Oil Filter Base - Disassemble .................... 19
Camshaft - Install................................................... 45 Disassembly Procedure ..................................... 19
Installation Procedure ........................................ 45 Engine Oil Filter Base and Oil Cooler - Install ....... 20
Camshaft - Remove............................................... 45 Installation Procedure ........................................ 20
Removal Procedure ........................................... 45 Engine Oil Filter Base and Oil Cooler - Remove ... 19
Camshaft Bearings - Remove and Install .............. 47 Removal Procedure ........................................... 19
Installation Procedure ........................................ 47 Engine Oil Pan - Remove and Install..................... 48
Removal Procedure ........................................... 47 Installation Procedure ........................................ 48
Camshaft Gear - Remove and Install .................... 46 Removal Procedure ........................................... 48
Installation Procedure ........................................ 46 Engine Oil Pressure Sensor - Remove and Install.. 62
Removal Procedure ........................................... 46 Engine Oil Pump - Assemble................................. 23
Camshaft Idler Gear - Remove and Install ............ 35 Assembly Procedure.......................................... 23
Installation Procedure ........................................ 35 Engine Oil Pump - Disassemble............................ 22
Removal Procedure ........................................... 35 Disassembly Procedure ..................................... 22
Connecting Rod Bearings - Install ......................... 54 Engine Oil Pump - Install ....................................... 24
Installation Procedure ........................................ 54 Installation Procedure ........................................ 24
Connecting Rod Bearings - Remove ..................... 54 Engine Oil Pump - Remove ................................... 22
Removal Procedure ........................................... 54 Removal Procedure ........................................... 22
Coolant Temperature Sensor - Remove and Exhaust Manifold - Remove and Install ................. 14
Install ................................................................... 61 Installation Procedure ........................................ 14
Crankshaft - Install................................................. 58 Removal Procedure ........................................... 14
Installation Procedure ........................................ 58
Crankshaft - Remove............................................. 57
Removal Procedure ........................................... 57 F
Crankshaft Front Seal - Install ............................... 32
Installation Procedure ........................................ 32 Fan Drive Mounting Group - Remove and Install .. 64
Crankshaft Front Seal - Remove ........................... 31 Installation Procedure ........................................ 64
Removal Procedure ........................................... 31 Removal Procedure ........................................... 64
Flywheel - Install.................................................... 27
Installation Procedure ........................................ 27
72 RENR7458-09
Index Section
Flywheel - Remove................................................ 27 P
Removal Procedure ........................................... 27
Flywheel Housing - Remove and Install ................ 29 Piston Cooling Jets - Remove and Install.............. 49
Installation Procedure ........................................ 29 Installation Procedure ........................................ 49
Removal Procedure ........................................... 29 Removal Procedure ........................................... 49
Front Cover - Install ............................................... 32 Pistons and Connecting Rods - Assemble ............ 51
Installation Procedure ........................................ 32 Assembly Procedure.......................................... 51
Front Cover - Remove ........................................... 32 Pistons and Connecting Rods - Disassemble ....... 51
Removal Procedure ........................................... 32 Disassembly Procedure ..................................... 51
Fuel Filter Base - Remove and Install ..................... 4 Pistons and Connecting Rods - Install................... 53
Installation Procedure .......................................... 5 Installation Procedure ........................................ 53
Removal Procedure ............................................. 4 Pistons and Connecting Rods - Remove............... 50
Fuel Priming Pump - Remove and Install ................ 4 Removal Procedure ........................................... 50
Installation Procedure .......................................... 4
Removal Procedure ............................................. 4
Fuel Transfer Pump - Install .................................... 6 R
Installation Procedure .......................................... 6
Fuel Transfer Pump - Remove ................................ 5 Rocker Shaft - Assemble....................................... 38
Removal Procedure ............................................. 5 Assembly Procedure.......................................... 38
Rocker Shaft - Disassemble .................................. 38
Disassembly Procedure ..................................... 38
H Rocker Shaft and Pushrod - Install........................ 39
Installation Procedure ........................................ 39
Housing (Front) - Install ......................................... 34 Rocker Shaft and Pushrod - Remove.................... 37
Installation Procedure ........................................ 34 Removal Procedure ........................................... 37
Housing (Front) - Remove ..................................... 33
Removal Procedure ........................................... 33
S
M
V
Modulating Valve - Remove and Install ................. 12
Installation Procedure ........................................ 12 Valve Mechanism Cover - Remove and Install...... 36
Removal Procedure ........................................... 12 Installation Procedure ........................................ 36
Removal Procedure ........................................... 36
RENR7458-09 73
Index Section