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Disassembly and Assembly c15 c16 c18
Disassembly and Assembly c15 c16 c18
July 2008
Disassembly and
Assembly
C-15, C-16 and C-18 Truck Engines
W1A1-Up (Engine)
CJP1-Up (Engine)
MDP1-Up (Engine)
MEP1-Up (Engine)
6NZ1-Up (Engine)
7CZ1-Up (Engine)
9NZ1-Up (Engine)
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iO '1658 '146
Index Section
Index ................................................................... 140
RENR2306-09 5
Disassembly and Assembly Section
and Install
SMCS Code: 1258-010
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
NOTICE
g01002542
Care must be taken to ensure that fluids are contained Illustration 2
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to 1. Ensure that gasket (5) is in position for the fuel
collect the fluid with suitable containers before open- priming pump.
ing any compartment or disassembling any compo-
nent containing fluids. 2. Put fuel priming pump (3) in position on fuel filter
base (2). Install bolt (1) and bolt (4).
Refer to Special Publication, NENG2500, "Caterpillar
Tools and Shop Products Guide" for tools and supplies
i01988510
suitable to collect and contain fluids on Caterpillar
products. Fuel Filter Base - Remove
Dispose of all fluids according to local regulations and SMCS Code: 1262-011
mandates.
Removal Procedure
2
Table 1
Required Tools
Part
Tool Part Description Qty
Number
A 185-3630 Strap Wrench 1
9U-7072 Tapered Cap/Plug 3
II
9U-7070 Tapered CaplPlug 3
5
Note: SERVICE DATA: TOOLING (ZZ) WILL
g01002542 NOT BE IDENTIFIED IN PHOTOGRAPHS IN
Illustration 1
THE REMOVAL OR THE INSTALLATION. THIS
TOOLING IS SHOWN IN ORDER TO ASSIST THE
1. Remove bolt (1) and bolt (4). Remove fuel priming EXPERIENCED SERVICEMAN.
pump (3) from fuel filter base (2).
/-- NOTICE
2. Remove gasket (5) for the fuel priming pump and
the fuel filter base. Keep all parts clean from contaminants.
101805883
NOTICE
Care must be taken to ensure that fluids are contained Fuel Filter Base - Disassemble
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to SMCS Code: 1262-015
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo- Disassembly Procedure
nent containing fluids.
Start By:
Refer to Special Publication, NENG2500, "Caterpillar
Tools and Shop Products Guide" for tools and supplies a. Remove the fuel filter base. Refer to Disassembly
suitable to collect and contain fluids on Caterpillar and Assembly, "Fuel Filter Base - Remove".
products.
NOTICE
Dispose of all fluids according to local regulations and Keep all parts clean from contaminants.
mandates.
Contaminants may cause rapid wear and shortened
1. Turn the fuel supply to the "OFF" position. component life.
g01002631 g00628020
Illustration 3 Illustration 4
2. Disconnect harness assembly (2) from the fuel 1. Remove check valve (1) from the fuel filter base.
temperature sensor.
g00628032
Illustration 5
..
~ ,
3. Remove bypass valve (3) from the fuel filter base. 1. Install O-ring seals (2) on check valve (1).
Illustration 7 900626092
4. Remove O-ring seals (4) from bypass valve (3). Illustration 9 900626092
Fuel Filter Base - Assemble 4. Install bypass valve (3) in the fuel filter base.
NOTICE
i01926166
Keep all parts clean from contaminants.
Fuel Filter Base - Install
Contaminants may cause rapid wear and shortened
component life. SMCS Code: 1262-012
Note: Check the condition of the O-ring seals. If the Installation Procedure
O-ring seals are worn or damaged use new parts for
replacement.
NOTICE
Keep all parts clean from contaminants.
NOTICE
3
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-
901002631
nent containing fluids.
Illustration 10
Refer to Special Publication, NENG2500, "Caterpillar
1. Install fuel filter base (4) with bolts (1). Tools and Shop Products Guide" for tools and supplies
suitable to collect and contain fluids on Caterpillar
2. Install fuel filter (7) on fuel filter base (4). Follow products.
the direction on the fuel filter for the correct
installation procedure. Dispose of all fluids according to local regulations and
mandates.
3. Connect tube assembly (5) to the fuel filter base.
i01926198
Required Tools
Part Part Description Qty
Tool Number
9U-7072 Tapered Cap/Plug 2
ZZ
9U-7072 Tapered Cap/Plug 2
NOTICE
Keep all parts clean from contaminants.
3
Illustration 13 g01002713
Illustration 15 g01026993
901002540
NOTICE
Illustration 14 Do not reuse the injector hold down bolts. New injector
hold down bolts must be used.
2. Put fuel transfer pump (1) in position. Install bolts
(2).
NOTICE
3. Connect fuel lines (3) and (4). If the injector hold down bolt is loose during the re-
moval procedure, inspect the injector bore for wear
and debris. Replace the clamp and spacer.
Illustration 16 900996395
901054374
2
Illustration 18 .. """"",'.
8. Inspect electronic unit injector seat (8) and
electronic unit injector bore (9).
i02555344
Installation Procedure
Illustration 17 901039929
Table 4
7. Remove O-ring seals (7) from electronic unit Required Tools
injector (2).
Part
Tool Number Part Description Qty
B 9U-6862 Tapered Brush 1
C 9U-6863 Small Bore Brush 1
-
D 9U-7237 Brush Extension 1
E 8T-299B Lubricant 1
NOTICE
Keep all parts clean from contaminants.
J
Illustration 21 golo19373
NOTICE
When a fuel injector group is serviced, the new fuel
injector group's electronic injector code must be pro-
grammed into the engine's personality module soft-
Illustration 19 gol054374 ware by using the calibration menu on the Electronic
Service Tool. If the new fuel injector group's electronic
1. Use Tooling (8) and Tooling (D) in order to clean code is not entered, the previous fuel injector group's
electronic unit injector seat (8). characteristics are assumed.
2. Use Tooling (C) and Tooling (D) in order to clean If it is not possible to immediately reprogram the elec-
electronic unit injector bore (9). tronic injector code of the injector into the personal-
ity module software, the engine will not be severely
harmed. The new electronic injector code should be
reprogrammed as quickly as possible in order to opti-
2 mize engine performance.
3
Illustration 20 go 1039929
NOTICE
Do not reuse O-ring seals. New O-ring seals must be 4
used.
Illustration 22 go1026993
12 RENR2306-09
Disassembly and Assembly Section
5. Install electronic unit injector (2) into the original 102733293 '
location in the cylinder head.
Electronic Unit Injector Sleeve
6. Install clamp (6) and spacer (5). - Remove
NOTICE SMCS Code: 1713-011
Do not reuse the injector hold down bolts. New injector
hold down bolts must be used. Removal Procedure
Table 5
NOTICE --
If the injector hold down bolt is loose during the re- Required Tools
moval procedure, inspect the injector bore for wear Part
and debris. Replace the clamp and spacer. Tool Number Part Description Qty
128-7889 Bridge Puller 1
7. Install bolt (4). Tighten bolt (4) according to the
following procedure. 221-9778 Puller Stud 1
A(I) 9U-6877 Thrust Bearing 1
a. Tighten the bolt for the electronic unit injector
to 50 ± 10 N'm (37 ± 7 Ib ft). 5P-8247 Hard Washer 1
4K-0367 Nut 1
b. Loosen the bolt until you can turn the bolt by
(1) Part of the 9U - 6891 Injector Tool Group
hand.
Start By:
c. Tighten the bolt for the electronic unit injector
again to 50 ± 10 N'm (37 ± 7 Ib ft).
a. Remove the electronic unit injectors. Refer to
Disassembly and Assembly, "Electronic Unit
8. Install bridge assemblies (3) in the respective
Injector - Remove".
locations.
NOTICE
Before starting installation ensure that the unit injector
sleeve and the cylinder head bore for the unit injector
sleeve are completely free of oil, dirt, and sealant de-
bris.
2
2
g00948616
Illustration 24
B 9U-7244 End Brush 1 6. Position Tooling (C) and unit injector sleeve (1) in
9U-7237 Brush Extension 1 the cylinder head. Use care not to damage the
O-ring seals on the unit injector sleeve.
4C-5552 Large Bore Brush 1
C(l) 221-9778 Puller Stud 1 NOTICE
Ensure that the unit injector sleeve is properly seat-
0(1) 9U-7258 Driver Cap 1
ed in the cylinder head. The tool and the unit injector
E 4C-9507 Retaining Compound - sleeve will"RING" when the unit injector sleeve is fully
(1) Part of the 9U-6891 Injector Tool Group seated in the bore in the cylinder head.
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.
End By:
i01153a8a 1. Remove the bolts and tube assembly (1) from the
turbocharger. Remove the two bolls that fasten
Turbocharger - Remove tube assembly (2) to the turbocharger. Check the
condition of the seals on tube assembly (1) and
SMCS Code: 1052-011 (2). Use new parts for replacement if the gaskets
are worn or damaged.
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
g00612675
Illustration 28
Turbocharger - Assemble
Disassembly Procedure
SMCS Code: 1052-016
NOTICE
Keep all parts clean from contaminants. Assembly Procedure
Contaminants may cause rapid wear and shortened
component life. NOTICE
Keep all parts clean from contaminants.
NOTICE
Compressor housing must go straight on the tur-
bocharger assembly without tilting. Tilting may cause
compressor blade to tip, or the compressor shaft can
be damaged.
5
g00513698
Illustration 29
g00513698 g00555701
Illustration 32 Illustration 33
5. Install wastegate (1) . 1. Loosen the nuts on V-band clamps (2) enough to
allow compressor housing (1) and turbine housing
(4) to rotate.
101154088
Turbocharger - Install
SMCS Code: 1052-012
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
900612892
NOTICE Illustration 34
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test- 2. Use 5P - 3931 Anti-Seize Compound on the
ing, adjusting and repair of the product. Be prepared to manifold bolts.
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo- 3. Position gasket (5) and turbine housing (4) on the
nent containing fluids. exhaust manifold . Install the manifold bolts. Do
not tighten bolts completely.
Refer to Special Publication, NENG2500, "Caterpillar
Tools and Shop Products Guide" for tools and supplies 4. Tighten the nut on V-band clamp (2) for turbine
suitable to collect and contain fluids on Caterpillar housing (4) to a torque of 14 ± 3 N 'm (10 ± 2 Ib ft).
products.
5. Tighten manifold bolts (5) to a torque of 55 ± 5 N'm
Dispose of all fluids according to local regulations and (41 ± 4 Ib ft) .
mandates.
6. Position compressor housing (1) so the air outlet
is zero degrees from top vertical.
g006 12952
IlIuslration 35
Exhaust Manifold - Remove 2. Remove sleeve assemblies (4) from the cylinder
head .
and Install
SMCS Code: 1059-010 Installation Procedure
Table 7
Removal Procedure
Required Tools
Start By: Tool Part Part Description Qty
Number
a. Remove the turbocharger. Refer to Disassembly
and Assembly, "Turbocharger - Remove", A 5P-3931 Anti-Seize 1
Compound
b. Remove the water temperature regulator. Refer to B 2P-2333 High Temperature 1
Disassembly and Assembly, "Water Temperature Sealer
Regulator - Remove and Install",
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.
Illustration 36 g00619289
Typical ex ample
18 RENR2306-09
Disassembly and Assembly Section
11 3 7 1 9 5
~ 4 12 2 8 6 10
900632595 900498448
Illustration 38 Illustration 40
Typical example Tightening sequence for the exhaust manifold
1. Apply Tooling (A) to studs (1). If the studs were 5. Tighten the nuts for the exhaust manifold in a
removed from the cylinder head, install the studs numeric sequence to a torque of 38 ± 5 N'm
in the cylinder head. Tighten the studs to a torque (28 ± 4 Ib ft).
of 35 ± 5 N'm (26 ± 4 Ib tt).
6. Install exhaust manifold shield (3). Apply Tooling
2. Install sleeve assemblies (4) in the cylinder head. (A) to the nuts for the exhaust manifold shield .
Tighten the nuts for the shield to a torque of
........ 25 ± 7 N'm (18 ± 5 Ib ft) .
~ -- '- -:- ' ..
End By:
900619289
Illustration 39
Typical example
i02340873
Removal Procedure
Table 8
Required Tools
Part
Tool Number Part Description Qty
901003311
1U-8826 Thrust Bearing 1 Illustration 42
9U-7242
9U-7548
Compressor Plate
Compressor Base
1
1
,. ' '. . A WARNING ' .
A(I )
2J -3506 Full Nut 1 Personal injury can result from being struck by
parts propelled by a released spring force_
5P-8248 Hard Washer I 1
Make sure to wear all necessary protective equip-
OL-1143 Bolt 1
ment.
B 8S-2263 Spring Tester 1
(I) Part of the 9U - 7241 Valve Spring Compressor Follow the recommended procedure and use all
recommended tooling to release the spring force.
Start By:
2. Secure Tooling (A) with unit injector clamp (1) .
a. Remove the electronic unit injectors. Refer to
Disassembly and Assembly, "Electronic Unit 3. Tighten the full nut until valve spring retainers (3)
Injector - Remove". are loose on valve (2) .
Illustration 41 901003285
20 RENR2306-09
Disassembly and Assembly Section
Installation Procedure 5. Secure Tooling (A) with unit injector clamp (1). '"
Use Tooling (A) to compress the valve springs.
Table 9 Install valve spring retainers (3) on each valve (2) ,
Required Tools
Part '," .';\\','~"
j '. .),',
"" ,,,,'A WARNING
"
'
' v ). . . ,~,
' "\ :. ~":'
,'!1 '~. i' ,
, . .'
Tool Number Part Description Qty
The valve spring keepers can be thrown from
1U-8826 Thrust Bearing 1
the valve when the valve spring compressor is
9U-7242 Compressor Plate 1 released. Ensure that the valve spring keepers
are properly installed on the valve stem. To help
9U-7548 Compressor Base 1
A(l) prevent personal injury, keep away from the front
2J -3506 Full Nut 1 of the valve spring keepers and valve springs
during the installation of the valves.
5P-8248 Hard Washer 1
OL-1143 Bolt 1
6. Carefully remove Tooling (A). Strike the top of
(1) Part of the 9U - 7241 Valve Spring Compressor the valve wi til a soft faced Ilammer in order to
ensure tllat valve spring retainers (3) are properly
NOTICE installed ,
Keep all parts clean from contaminants.
End By:
Contaminants may cause rapid wear and shortened
component life. a. Install the electronic unit injectors. Refer to
Disassembly and Assembly. "Electronic Unit
Injector - Install".
1. Lubricate the valve stems with clean engine oil.
i02341194
Removal Procedure
Table 10
-
Required Tools
Part
Illustration 43
901003311
Tool Number Part Description I Qty
A 58-1330 Valve Spring Compressor 1
Installation Procedu re
Ta ble 11
Required Tools
Part
Tool Number
I Part Description Qty
A 58·1330 I Valve Spring Compressor 1
NOTICE
Keep all parts clean from contaminants.
2 3 4 5 6
Illustrati on 44 g0104228 1
AWARNIN~ ' .
Personal injury can result from being st ruck by
parts propelled by a released spring force.
6. Use Tooling (8) to check the valve springs (spring To prevent possible injury, follow the established
force) . Refer to Specifications, "Cylinder Head assembly procedure and wear protective equip-
Valves". ment.
7. Inspect the inlet valves and the exhaust valves.
Refer to Specifications, "Cylinder Head Valves". 2. Ensure that washer (6) is installed on the valve
guide.
22 RENR2306-09
Disassembly and Assembly Section
Inlet and Exhaust Valve Guides (1) Part of 9U - 7530 Engine Tool Group
Table 12
Required Tools
Part
Tool Number Part Description Qty
A(I) 9U-6895 Valve Guide Driver 1
B
(1) Part or 9U -7530 Engine Tool Group
Start By: 1
Required Tools
t"""'" Removal Procedure 1---,----···--···--···
Part
Table 14
Tool Number Part Description
1---1·----1----._·
Required Tools Valve Seat Driver
9U-6898
8(1) (Exhaust)
Part
Tool Number Part Description Qty 9U - 6897 Valve Seat Driver (Inlet) 1
_. - - ----
1_ _ _ ' -_ _ _ _ ..•..___... _ _ ..
a. Remove the inlet and exhaust valves. Refer to Contaminants may cause rapid wear and shortened
Disassembly and Assembly, "Inlet and Exhaust component life.
Valves - Remove and Install n •
NOTICE
Keep all parts clean from contaminants.
Illustration 49 g01042315
End By:
Illustration 50 900516322
i02110~ 58
Table 16 Part
Tool Number Part Description Qty
Required Tools
A 5P-7414 Seal Pick 1
Part
Tool Number Part Description Qty 8(1) 9U-6890 Seal Installer 1
BE
(1) Part 01 the 9U - 7226 Seal Installer
9U-6890 Seal Installer 1
C(I) 9U-7216 Valve Seal Pin 1
NOTICE
( 1) Part 01 the 9U· 7226 Seal Installer Keep all parts clean from contaminants.
NOTICE
Keep all parts clean from contaminants.
i0193316 1
Removal Procedure
Table 18
Required Tools
Part
Tool Number Part Description Qty
90051 6323
IlIuslralion 52 A 185-3630 Strap Wrench As 1
4. Insert Tooling (C) through Tooling (B) and the new Refer to Special Publication , NENG2500, "Caterpillar
valve seal. Tools and Shop Products Guide" for tools and supplies
suitable to collect and contain fluids on Caterpillar
5. Position Tooling (C) in the valve guide bore. products.
6. Use Tooling (B) to push valve seal (2) in position Dispose of all fluids according to local regulations and
on valve guide (3) . mandates.
End By:
Illustration 53 900611747
1. Remove plug (1) and drain the oil from the engine
oil filter base into a suitable container for storage
or disposal.
i01924925 ,A
Disassembly Procedure
NOTICE
Keep all parts clean from contaminants.
~2
g01018410
Illustration 55
VIEW A-A
g01001860
Illustration 56
RENR2306-09 27
Disassembly and Assembly Section
Make sure to wear all necessary protective equip- To prevent poss ible 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. Install plunger (3).
1. Remove plugs (2) that hold the valves in engine 2. Install spring (4) .
oil filter base (1).
3. Install plugs (2) that hold the valves in engine oil
2. Remove spring (4). filter base (1) . Tighten plugs (2) to a torque of
100 ± 15 N'm (74 ± 11 Ib ft) .
3. Remove plunger (3).
i01 959647
iO 1989932
Engine Oi l Filter Base - Install
Engine Oil Filter Base -
Assemble SMCS Code: 1306-012
1 2
At-. 3 4 5
~~v- _ ~2
~J J
VIEW A-A Illustra tio n 58 9 01 016325
Illustration 57 901001660 1. Install bolts (7) that hold elbows (8) to the eng ine
oil filter base.
28 RENR2306-09
Disassembly and Assembly Section
i01933191
Removal Procedure
Start By:
900611747
Illustration 60
SMCS Code : 1378-015 1. Separate oil cooler bonnet (1) and elbow (3) from
oil cooler (2) .
Disassembly Procedure
Start By:
NOTICE
Keep all parts clean from contaminants.
IlIuslration 64 900619807
g00619745 900619616
Illustration 65 Illustration 67
4. Clean tubes (7) for the oil cooler core with a 2. Put O-ring seal (4) in position on oil cooler bonnet
3.81 mm (0.150 inch) rod . (1). Put clean engine oil on O-ring seal (4).
i01163135
Assembly Procedure
NOTICE
Keep all parts clean from contaminants.
Note: Before assembly, check the condition of the 3. Align oil cooler bonnet (1) with oil cooler (2).
gaskets and the O-ring seals. If the gaskets or the Lubricate the bore of oil cooler (2) with clean
O-ring seals are worn or damaged, use new parts engine oil. Install oil cooler bonnet (1) into the oil
for replacement. cooler.
End By:
900619807
Illustration 66
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.
g006 ·19340
Illustration 69
Refer to Special Publication, NENG2500, "Caterpillar
Typical example Tools and Shop Products Guide" for tools and supplies
suitable to collect and contain fluids on Caterpillar
1. Use two technicians to put oil cooler (33), oil products.
cooler bonnet (1) and oil cooler bonnet (5) for
the oil cooler into position on the engine as an Dispose of all fluids according to local regulations and
assembly. The weight of the oil cooler assembly is mandates.
approximately 24 kg (53 Ib).
3. Install bolts (4) that hold oil cooler bonnet (5) for
the oil cooler to the water pump.
End By:
Illustration 70 g01001 9 11
i0211 0543 A
Disassembly Procedure
2
Table 19
Required Tools
Part
Tool Number Part Description Qty
A 1P-2321 Combination Puller 1
B 1P-0510 Driver Group 1
a. Remove the engine oil pump . Refer to 1. Remove the bolt that holds drive gear (1) to the
Disassembly and Assembly , "Engine Oil Pump shaft of body assembly (2).
- Remove".
2. Use Tooling (A) in order to remove drive gear (1)
NOTICE from the shaft. Remove the key from the shaft.
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.
Dispose of all fluids according to local regulations and Personal injury can result from parts and/or cov-
mandates. ers under spring pressure.
i02110556
' .. AWARNING
Engine Oil Pump - Assemble Improper assembly of parts that are spring loaded
can cause bodily injury.
SMCS Code: 1304-016
To prevent possible injury, follow the established
assembly procedure and wear protective equip-
Assembly Procedure ment.
Table 20
Required Tools
3. Lubricate the bearings and idler gear and drive
gear (3) with clean engine oil. Install the idler gear
Part and drive gear in body assembly (2).
Tool Number Part Description Qty
B 1P-0510 Driver Group 1 4. Install cover (4). Install bolts (5) in order to secure
the cover to body assembly (2) .
IlIuslralion 73 90 1017356
a. Install the engine oil pump. Refer to Disassembly Water Pump - Remove
and Assembly, "Engine Oil Pump - Install".
SMCS Code: 1361-011
i01984303
Removal Procedure
Engine Oil Pump - Install
Start By:
SMCS Code: 1304-012
a. Remove the belt tensioner. Refer to Disassembly
and Assembly, "Belt Tensioner - Remove and
Installation Procedure Install".
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.
End By:
i02331 283
Disassembly Procedure
Table 2t
Required Tools
Part
Tool Number Part Description Qty
--
8S-226 4 Puller Group 1
g00625778
Illustration 77 48-3903 Bolt 2
A -. -
1P-0456 Plate 1
1. Identify the location of the hose clamps for
installation purposes. Loosen hose clamps (1). 48-4277 Washer 2
Slide the hose assembly from the cover (3).
B 9S-9152 Bearing Puller Gp 1
2. Remove bolts (2) and cover (3) .
Start By:
3. Remove the O-ring seal from cover (3) .
a. Remove the water pump. Refer to Disassembly
and Assembly . "Water Pump - Remove".
NOTICE
Keep all parts clean from contaminants .
Illustration 78 900625816
i02331352 "
2
Water Pump - Assemble
SMCS Code: 1361-016
Assembly Procedure
9
Table 22
Required Tools
11
Part
Tool Number Part Description Qty
C 1P-0510 Driver Group 1
D 138-9299 Oil Seal Tool 1
E 139-0088 Seal Tool 1
F 4C-9500 Quick Cure Primer 1
NOTICE
Keep all parts clean from contaminants.
g01163722
Illustration 80
gOl163722
Illustration 81
2. Use Tooling (C) to install a new oil seal (5) in Note: Check the condition of the gaskets and the
housing (4) . Install the seal with the part number O-ring seals. If the gaskets or the O-ring seals are
on the metal face of the seal toward the housing . worn or damaged , use new parts for rep lacement.
Ensure that the oil seal is flush with the front edge
of the counterbore of the housing . Do not lubricate
the oil seal.
6. Install the gear and shaft assembly into housing Illustra tion 8 2 g00499380
(4) . Use care not to damage the oil seal. Install
bolts (14) that hold bearing retainer (8) to the 1. Install O-ring seal (6) on the water pump.
housing .
End By:
i01 933227
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.
i01156288
900494763 900494820
Illustration 87 IIluslration 90
5. Remove gasket (5) from manifold (4) for the water 9. Remove two lip seals (9) from water temperature
temperature regulators. regulator housing (2).
Installation Procedure
Table 23
Required Tools
Part
Tool Number Part Description Qty
A 1P-0510 Driver Group 1
NOTICE
Keep all parts clean from contaminants.
IIluslration 91 900494820
g00494803 g00494763
IlIuslration 92 Illustration 94
g00615062
Illustration 95
Typical example
900494766
8. Fill the cooling system to the correct coolant level.
Illustration 93 Refer to Operation and Maintenance Manual,
"Refill Capacities" in the Maintenance Section .
4. Put water temperature regulator housing (2) in
position on manifold (4) for the water temperature
regulator. Install four bolts (6) and tighten the bolts
to a torque of 50 ± 10 N'm (37 ± 71b ft) .
RENR2306-09 41
Disassembly and Assembly Section
i01164962 i02110602
Required Tools
Part
Tool Number Part Description Qty
.-
A 138-7573 Lifting Bracket 2
B FT2712 Guide Stud 2
-
NOTICE
Keep all parts clean from contaminants.
Installation Procedure
g0104 24 14
Illustration 98
Typical example
g01042415
Illustration 99
i02016230
A 138-7573 Lifting Bracket 2 5. Install bolts (1). Remove Tooling (8). Install bolts
B FT2712 Guide Stud 2 (1) in place of Tooling (8).
g01042415
Illustration 100
RENR2306-09 43
Disassembly and Assembly Section
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.
End By:
i02735902
NOTICE NOTICE
The front and rear seals and wear sleeves have differ- Keep all parts clean from contaminants.
ent spiral grooves in the seal. Because of this type of
design, the front seal group for an engine is different Contaminants may cause rapid wear and shortened
from the rear seal group. If a seal group is installed on component life.
the wrong end of the engine, oil can actually be taken
out of the engine instead of moving oil back into the
engine.
Note: Install the seal with the arrow that shows the
direction of crankshaft rotation toward the rear of
the engine.
RENR2306-09 45
Disassembly and Assembly Section
g01009 222
Illustration 107
Installation Procedure
Illustration 105 g00623745
Table 29
1. Remove bolts (1) that fasten the eng ine oil pan Required Tools
to flywheel housing (2) . Part
Tool Number Part Description Qty
2. Install Tooling (A) and a suitable lifting device on
flywheel housing (2). A 13B-7574 Link Bracket 2
B BT -9022 Silicone Gasket 1
NOTICE
Keep all parts clean from contaminants.
901009222
Illustration 108 .
g01009218
Illustration 109
RENR2306-09 47
Disassembly and Assembly Section
i02530824
NOTICE
Vibration Damper and Pulley - Keep all parts clean from contaminants.
Remove and Install
Contaminants may cause rapid wear and shortened
SMCS Code: 1205-010 component life.
- Guide Bolt
A 2
5/8 - 18 NF by 7 inch
NOTICE
Keep all parts clean from contaminants.
901077686
Illustration 112
a. Remove the vibration damper and the pulley. Crankshaft Front Seal - Install
Refer to Disassembly and Assembly, "Vibration
Damper and Pulley - Remove and Install". SMCS Code: 1160-012
NOTICE
Keep all parts clean from contaminants.
g01042474
Illustration 113
g01042507' ~
Illustration 114 "
Note: Install the crankshaft front seal with the arrow 2. Remove front cover (2).
that shows the direction of crankshaft rotation toward
the front of the engine.
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 flu id with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
900611 393 Dispose of all fluids according to local regula tions and
IlIuslration 118
mandates .
2. Install front cover (2) , button head screws (1) and
nuts (3). Note: Be sure to mark the orientation of each of the
gears for installation purposes.
3. Tighten button head screws (3) to a torque of
13 ± 3 N'm (10 ± 21b ft) .
End By:
i02025735
901010064
Removal Procedure Illustration 119
Start By:
NOTICE
Keep all parts clean from contaminants.
900576209
Contaminants may cause rapid wear and shortened Illustration 120
component life.
2. Remove seal assembly (3) and adapter (4).
RENR2306-09 51
Disassembly and Assembly Section
900576240 g00576203
Illustration 121 Illustration 124
3. Remove O-ring seals (5) and (6) from seal 6. Remove bolts (12), plate (13), and idler gear (11).
assembly (3).
9. Check the condition of bearing (15) in cluster gear Illustration 129 g00618962
(16). If bearing (15) is worn or damaged, lise
a new part for replacement. Use Tooling (A) to 14. Remove gasket (25) from the cylinder block.
replace bearing (15) in cluster gear (16).
i02169466
Installation Procedure
Table 35
Required Tools
Part
Tool Part Description
Number
Thread Lock
I Qty
B 98-3263 1
Compound
C 8T-2998 Lubricant 1
NOTICE
Keep all parts clean from contaminants.
9005 76208
Illustration 128
Contaminants may calise rapid wear and shortened
Note: Shaft assemblies (19) and (20) must be component life.
removed in order to remove plate (23).
1. Install a new gasket (25) on tile cylinder block. 5. Apply Tooling (8) to bolts (22). Install shaft (21) .
Tighten bolts (22) to a torque of 55 ± 10 N·m
(41 ± 7 Ib ft) in sequence. (1 , 3 , 4, 5, 2, 1, 2, 3,
4, 5, 1)
g0 1010048
Illustration 133
g005762 08
Illustration 131
End By:
i01933482
Removal Procedure
g00576240 Start By:
Illustration 137
b. Remove the vibration damper and the pulley. Note: The air compressor has been removed for
Refer to Disassembly and Assembly, "Vibration photo purposes.
Damper and Pulley - Remove and Install".
1. Remove bolts (1) that fasten the bracket to the
c. Remove the engine oil pan. Refer to Disassembly housing.
and Assembly, "Engine Oil Pan - 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- Illustration 140
g00624215
ing any compartment or disassembling any compo-
nent containing fluids . 2. Remove bolts (2) .
Refer to Special Publication, NENG2500, "Caterpillar
Tools and Shop Products Guide" for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
NOTICE
Do not turn the crankshaft or the camshaft while the
camshaft gear is removed . If the front gear group is
not correctly timed during installation, interference can
occur between the pistons and the valves, resulting in
damage to the engine. g00624350
Illustration 141
900624568
Illustration 142
Typical exa mple
900624732
Illustration 145
Typical example
900624658
Illustration 143
Typical example
900624827
Illustration 146
90062468 1 Typical example
Illustration 144
8. Remove gasket (13) from front plate (12) .
6. Remove bolts (11) from the housing.
RENR2306-09 57
Disassembly and Assembly Section
i01933501
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
NOTICE
Do not turn the crankshaft or the camshaft while the
camshaft gear is removed . If the front gear group is
not correctly timed during installation, interference can
occur between the pistons and the valves, resulting in
damage to the engine.
g00624732
Illustration 148
Typical example
Typical example
Typical example
900624658
Illustration 150
Typical example
900624215
Illustration 153
Typical example
900624568
Illustration 151
Typical example
End By:
d. Install the fan drive. Refer to Disassembly and 3. Remove the O-ring seal from the accessory drive
Assembly, "Fan Drive - Install". group.
Disassembly Procedure
i01933551
Table 36
Accessory Drive - Remove Required Tools
~
SMCS Code: 1207-011 Part
Tool Number Part Description
Removal Procedure A 2P - B312 Retaining Ring Pliers 1
B BH-0663 Bearing Puller Gp 1
NOTICE
Keep all parts clean from contaminants.
Start By:
Contaminants may cause rapid wear and shortened
component life. a. Remove the accessory drive. Refer to
Disassembly and Assembly, "Accessory Drive -
Remove" .
NOTICE
Care must be taken to ensure that fluids are contained NOTICE
during performance of inspection, maintenance, test- Keep all parts clean from contaminants.
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open- Contaminants may cause rapid wear and shortened
ing any compartment or disassembling any compo- component life.
nent containing fluids.
i01933884 ,
Assembly Procedure
Table 37
Required Tools
Part
Tool Number Part Description Qty
A 2P-8312 Retaining Ring Pliers 1
900620408
Illustration 156
NOTICE
1. Remove bolts (1) that fasten plate (3) to adapter Keep all parts clean from contaminants.
(2). Remove O-ring seal (4) from adapter (2) .
Remove the gear from the adapter (2). Contaminants may cause rapid wear and shortened
component life.
g00620611
Illustration 157
900620817
Illustration 159
Illustration 158
900620866
Illustration 160
i01 994409
5. Put clean engine oil on the O-ring seal (7). Install Contaminants may cause rapid wear and shortened
O-ring seal (7) in adapter (8) . component life.
End By:
i01933894
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
04 o1 50
06
2
o
900579295
Illustration 165
NOTICE
Keep all parts clean from contaminants.
g01033224
Illustration 164
RENR2306-09 63
Disassembly and Assembly Section
g01028794 g01028794
Illustration 166 Illustration 167
Contaminants may cause rapid wear and shortened 1. Position valve cover base (2) on the cylinder head
component life. and install bolts (4). Tighten bolts (4) to a torque of
18 ± 3 N'm (13 ± 21b ft) in the numerical sequence
that is shown in Illustration 168.
Note: Before assembly, check the condition of the
seal. If the seal is worn or damaged, use a new part
for replacement. 2. Connect harness assembly (1).
End By:
Required Tools
NOTICE Part
Care must be taken to ensure that fluids are contained Tool Number Part Description Qty
during performance of inspection, maintenance, test- A 134-2837 Piston Compressor 1
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- Start By:
nent containing fluids.
a. Remove the compression brake. Refer to
Refer to Special Publication, NENG2500, "Caterpillar Disassembly and Assembly, "Compression Brake
Tools and Shop Products Guide" for tools and supplies - Remove ".
suitable to collect and contain fluids on Caterpillar
products. NOTICE
Keep all parts clean from contaminants.
Dispose of all fluids according to local regulations and
mandates. Contaminants may cause rapid wear and shortened
component life.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids .
A WARNING
Personal injury can result from parts and/or cov-
ers under spring pressure.
Typical example
NOTICE
Do not diassemble or tamper with slave piston adjust-
ing screw. Engine damage could result.
g00512594
IlIuslration 173
Typical example
o 0
9. Place Tooling (A) over slave piston adjusting
screw (7) .
o o 15 _ ....... ..
o
_~
0
16
o 17
18
----""~. ,
9----
----@
19 -------0
901009791
Illustration 175
Typical ex ample
Required Tools
o 0
I
Part
.
Tool Number Part Description Qty
o
A 134-2837 Piston Compressor 1
9 - - -......;=1
e
NOTICE 10 - _~
Keep all parts clean from contaminants. @3
o o
15 ---
16 _~
17 _ _ ~
18 ____
@
19 ----0
Illustration 176 901009791
10. Put control valve cover (3) in position and install "
allen head screw (4).
901009783
Illustration 179
Typical example
900512487
Illustration 181
6. Inspect slave piston adjustment screw (7). The Typical ex am ple
plunger should protrude from the bottom of slave
piston adjusting screw (7) . Approximately 53 N 11 . Use new seals (2). Coat the seals with clean
(12 Ib) of force is required to move the plunger. engine oil. Install the upper seal and the center
Ensure that the spring retaining pin for the plunger seal on the solenoid body. Install the lower seal in
is seated . the bottom of the bore for the solenoid valve in the
compression brake housing .
7. Install slave piston adjusting screw (7) and slave
piston adjustment screw locknut (8). Do not tighten 12. Ensure that seals (2) are seated properly.
the assembly at this time. Carefully install solenoid valve (1) in the
compression brake housing. Tighten the solenoid /'
Note: Refer to Testing and Adjusting, "Slave Piston valve to a torque of 12.4 N' m (110 Ib in). Be careful
Lash - Adjust" for more information on the adjustment not to twist the seals during installation .
of the slave piston lash .
End By:
i01 9944 19
Illustration 180
901 009776 Installation Procedure
Typical example
NOTICE
8. Push a wire through the hole in the base of control Keep all parts clean from contaminants .
valve (5) in order to ensure that the check ball
is free. The check ball should unseat with slight Contaminants may cause rapid wear and shortened
pressure on the wire. If the check ball is stuck, component life .
replace the control valve.
End By:
i02346853
Illustration 182
Removal Procedure
Tabl e 40
Note: The installation procedure is identical for all
three compression brake housings. Required Tools
Part
1. Install the stud for nut (3) if the stud was removed. Tool Number Part Description Qty
Tighten the stud to a torque of 88 N 'm (65 Ib ft) .
A 124 - 2946 Lifting Bracket 1
Note: Some of the early 340, 340A, and 340B
compression brakes utilized two mounting studs that Start By:
are located in the front of the brake housing .
a. Remove the valve mechanism cover. Refer to
2. Place compression brake housing (5) over the Disassembly and Assembly, "Valve Mechan ism
stUd . Cover - Remove and Install".
3. Install bolts (1), bolts (2), and the washers. Install b. Remove the compression brake, if equipped . Refer
nut (2) . to Disassembly and Assembly, "Compression
Brake - Remove" .
4. Use the following procedure in order to tighten the
compression brake:
NOTICE
Keep all parts clean from contaminants.
Note: If your application has two mounting studs, use
a crisscross pattern in order to torque the mounting
Contaminants may cause rapid wear and shortened
stud nuts and the center bolts .
component life.
a. Tighten center bolts (2) to a torque of 54 N'm
(40 Ib ft).
i01985468 ,A
Disassembly Procedure
Start By:
Illustration 184
900517462 NOTICE
Keep all parts clean from contaminants.
900517457
Illustralion 185
Assembly Procedure a. Install the rocker arms and the rocker shaft. Refer
to Disassembly and Assembly. "Rocker Arm and
Shaft - Install".
NOTICE
Keep all parts clean from contaminants.
i02110799
Contaminants may cause rapid wear and shortened
component life. Rocker Arm and Shaft - Install
SMCS Code: 1102-012
Installation Procedure
Table 41
Required Tools
Part
Tool Number Part Description Qty
A 124-2946 Lifting Bracket 1
NOTICE
Keep all parts clean from contaminants.
Illustration 187 901028860
Contaminants may cause rapid wear and shortened
Note: Do not reuse the O-ring seals on the rocker component life.
arm adjustment screws if the buttons Ilave been
removed from the adjustment screws.
. .. A WARNING
1. Install the O-ring seals in button (6) and button (4).
Valve rocker arms and unit injector rocker arms
2. Install the O-ring seals and the buttons on the can move on the shaft after the bolts have been
valve rocker arms, as follows : removed. The shaft should be kept level when re-
moved from the cylinder head. To avoid possible
a. Support valve rocker arm (7) in a vise with soft personal injury, keep fingers clear of the valve
jaws. rocker arms and the unit injector rocker arms
when lifting the assembly from the cylinder head.
b. Position the O-ring seal and button (6) on the
round end of adjustment screw (5).
i02489840
Removal Procedure
Start By:
g00517462
Illustration 189 a. Remove the water temperature regulator. Refer to
Disassembly and Assembly, "Water Temperature
Regulator - Remove and Install".
NOTICE
Keep all parts clean from contaminants.
900517442
Illustration 190
Contaminants may cause rapid wear and shortened
1. Install rocker shaft (3), valve rocker arms (1), and component life.
unit injector rocker arms (4) as a unit with Tooling
(A).
NOTICE
Note: Install rocker shaft (3) with the flat side facing Care must be taken to ensure that fluids are contained
upward. during performance of inspection, maintenance, test-
ing, adjusting and repairofthe product. Be prepared to
Note: If the engine is equipped with a compression collect tile fluid with suitable containers before open -
ing any compartment or disassembling any compo-
brake, skip Step 2.
nent containing fluids.
2. Install bolts (2). Tighten bolts (2) to a torque of
109 ± 15 N'm (80 ± 11 Ib ft). Refer to Special Publication, NENG2500, "Caterpillar
Dealer Service Tool Catalog" for tools and supplies
3. Repeat Steps 1 and 2 for the remainder of the suitable to collect and contain fluids on Caterpillar
rocker arm assemblies. products.
3. Remove O-ring seals (5) and (6) from seal 7. Remove the bolt and support clip (13) for the
assembly (3) . harness assembly.
74 RENR2306-09
Disassembly and Assembly Section
8. Disconnect the harness assembly from sensor 12. Carefully remove cylinder head (8) . The weight of ,A
(14), sensor (15), and ground stud (16). the cylinder head is approximately 235 kg (518 Ib).
g00580810 g00580833
Illustration 197 Illustration 200
9. Remove bolts (18) and spacers (17) that fasten 13. Remove cylinder head gasket (21) .
bracket (19) to the cylinder head.
900632047
Illustration 201
g00580811
Illustration 198
14. Remove O-ring seal (22) and water seals (23) .
10. Remove cylinder head bolts (20). Remove seal (24) .
g00580812
Illustration 199
,-
... / ' I
,I
g00632049 g00632049
IIluslralion 203 IIluslralio n 204
17. Remove O-ring seal (26) . 1. Apply a thin film of clean engine oil to O-ring seal
(26) . Install O-ring seal (26) .
Note: If the cylinder head was removed from the
cylinder block as a result of a failed head gasket,
refer to Special Instruction, SEHS9564, "3400
Cylinder Head Joint Repair Procedure" for additional
information .
i024901 06
Installation Procedure
Table 42 g00632048
IlIuslralion 205
Required Tools
I - 2. Install a new spacer plate gasket (25).
Tool Part Part Description Qty
Number
I 3. Install the spacer plate on the engine .
I A 6V -4876 Lubricant 1
l B 8T - 2998 Lubricant 1
~
9S -3263 Thread Lock 1
Compound
NOTICE
Keep all parts clean from contaminants.
900513934
Illustration 209
RENR2306-09
77
Disassembly and Assembly Section
900580810
Illustration 210
g00580805
Illustration 213
i02110601 ,
Camshaft - Remove
SMCS Code: 1210-011
Removal Procedure
Table 43
Required Tools
Part
Tool Number Part Description Qty
A 9U-7257 Cradle 1
900576639
Illustration 215 B 9U-7256 Guide 1
16. Install O-ring seals (5) and (6) in seal assembly C 9U - 7225 Camshaft Pilot 2
(3). Lubricate seal (6) with Tooling (B) . D 9U - 7240 Camshaft Hook 2
a. Install the camshaft gear. Refer to Disassembly Contaminants may cause rapid wear and shortened
and Assembly , "Camshaft Gear - Remove and component life.
Install".
NOTICE
Care must be used when removing the camshaft to
not damage the highly finshed surfaces of both the
camshaft and camshaft bearings
901028806
IlIuslration 216
NOTICE
Do not turn the crankshaft or the camshaft while the
camshaft gear is removed. If the front gear group is
not correctly timed during installation, interference can 900509797
Illustration 219
occur between the pistons and the valves, resulting in
damage to the engine.
900581441
Illustration 220
901074729 g00581445
Illustration 222 Illustration 224
7. Position camshaft (8) into the bore of Tooling (8). c. Keep the camshaft level while the camshaft is
Tighten the bolts that hold Tooling (8) to the front being removed from the cylinder head. The
housing . weight of the camshaft is approximately 39 kg
(86 Ib).
Required Tools
Part
Tool Number Part Description Qty
E(1) 177-8001 Sleeve 1
F 177 -8002 Adapter 1
G 6L-4697 Bolts 3
(1) Part of 177 - 8003 Engine Tool Group
900581444
Illustration 223
Start By:
Note: Avoid lifting camshaft (8) with Tooling (D). The
camshaft should rest on Tooling (A) . Lifting of the a. Remove the camshaft gear. Refer to Disassembly
camshaft can cause misalignment as the camshaft and Assembly, "Camshaft Gear - Remove and
is removed, resulting in damage to the camshaft Install".
bearings.
b. Remove the rocker arms and the rocker shafts.
Refer to Disassembly and Assembly, "Rocker Arm
and Shaft - 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 disassembl ing any compo-
nent containing fluids. 900576209
Illustration 226
Refer to Special Publication, NENG2500, "Caterpillar
Tools and Shop Products Guide" for tools and supplies 2. Remove seal assembly (3) and adapter (4).
suitable to collect and contain fluids on Caterpillar
products.
9005 76240
Illustration 227
90 '1028806
Illustralion 225
NOTICE
Do not turn the crankshaft or the camshaft wllile the
camshaft gear is removed . If the front gear group is
not correctly timed during installation , interference can
occur between the pistons and the valves, resulting in
damage to the engine.
NOTICE
Care must be used when removing tile camshaft to
not damage tile highly finshed surfaces of both the
camshaft and camshaft bearings
82 RENR2306-09
Disassembly and Assembly Section
Note: Carefully align Tooling (F) with the end of the 8. To remove the camshaft from the front of the
camshaft. If the adapter and the camshaft are not engine, install Tooling (E) on the rear of the
aligned, the camshaft may not be removed. The camshaft.
adapter and camshaft bearing will interfere.
9. Carefully slide the camshaft to the front of the
5. To remove the camshaft from the rear of the engine for removal. Use two technicians to remove
engine, install Tooling (F) on the front of the the camshaft. Keep the camshaft level while the
camshaft with Tooling (G) . camshaft is being removed from the cyl inder
head . The weight of the camshaft is approximately
6. Install Tooling (E) . 39 kg (86 Ib).
i02963221
Camshaft - Install
SMCS Code: 1210-012
Installation Procedure
Ta bl e 45
Required Tools
Part
Tool Number Part Description Qty
g01043577
Illustra tion 230 A 9U - 7257 Cradle 1
B 9U - 7256 Guide 1
7. Carefully slide the camshaft to the rear of the
engine for removal. Use two technicia ns to remove C 9U - 7225 Camshaft Pilot 2
the camshaft. Keep the camshaft level wh ile the
0 9U - 724 0 Camshaft Hook 2
camshaft is being removed from the cylinder
head . The weight of the camshaft is approximately H 9U - 7243 Alignment Sleeve 1
39 kg (86 Ib) .
J 98-3263 Thread Lock Compound 1
K 8T - 2998 Lubricant 1
NOTICE
Keep all parts clean from contaminants.
1. Ensure that the camshaft and camshaft bearings 4. Use Tooling (H) to align Tooling (8) with the
are thoroughly clean. Lubricate the camshaft camshaft bearings. Tighten the bolts that hold
lobes with a 50/50 mixture of Tooling (K) and clean Tooling (8) to front housing (7). Remove Tooling
engine oil. Apply a thin coat of clean engine oil on (H).
the camshaft bearings.
Note: Tooling (H) should move freely from the bore
of Tooling (8).
g00509797
IIluslralion 232
g00581445
1II11slraiion 235
g00581441
Illustration 233
g005614 43 g0057G639
IlIuslralion 237 Illustration 239
Note: Tooling (C) must be removed before the 10. Install O-ring seals (5) and (6) in seal assembly
camshaft can be completely installed in the cylinder (3) . Lubricate seal (6) with Tooling (K) .
head.
11. Install seal assembly (3) . Position adapter (4) .
7. Remove the lifting device. Rotate the camshaft Ensure that the dowel in adapter (4) engages the
during installation. Use care not to allow the end hole in the camshaft.
of the camshaft and Tooling (C) to drop. Use
Tooling (D) to assist in aligning camshaft (8) with 12. Position thrust plate (1) . Apply Tooling (J) to bolts
the camshaft bearings. (2). Hold thrust plate (1) in position and install bolts
(2). Evenly tighten bolts (2) until seal assembly (3)
8. Remove Tooling (C) and finish installing camshaft and O-ring seal (5) are seated against the cylinder
(8) in the bore. head.
9. Remove Tooling (A) and Tooling (B). Note: Be careful in order to ensure that O-ring seal
(5) stays in the groove in seal assembly (3).
End By:
Part
Tool Number Part Description Qty
E(1) 177-8001 Sleeve 1
G 6L-4697 Bolts 3
J 9S-3263 Thread Lock Compound 1
K 8T-2998 Lubricant 1
11) Part of 177 - 8003 Engine Tool Group
RENR2306-09 85
Disassembly and Assembly Section
901043575
Illustration 242
6. Install Tooling (F) on the end of the camshaft. 10. Install O-ring seals (5) and (6) in seal assembly
(3). Lubricate seal (6) with Tooling (K).
86 RENR2306-09
Disassembly and Assembly Section
End By:
NOTICE
Keep all parts clean from contaminants.
900579965
Illustration 245
RENR2306-09 87
Disassembly and Assembly Section
g00579966 g00593987
Illustration 247 Illustration 249
2. Align the hole in the back of camshaft gear (1) End By:
with the dowel in the adapter. Install camshaft
gear (1) over Tooling (A) . a. Install the fron t cover. Refer to Disassembly and
Assembly , "Front Cover - Install".
g00579965
tllustration 248
Removal Procedure
Table 49
Required Tools
f---
Part
Tool Number Part Description Qty
Camshaft Bearing Tool
88-2241 Group
1
88-8290 Nut 1
88-8291 Threaded Shaft 1 901034895
All) Illustration 251
88-8287 Thrust Bearing Assembly 1
88-8288 Cone 1 2. Remove the No. 7 camshaft bearing (rear). Work
from the rear of the engine to the front of the
88-8292 Extension (Short) 2 engine.
-
88-8293 Extension (Long) 1
3. Install the small end of Tooling (8) in the camshaft
9U-7222 Camshaft Bearing Pilot 1 bearing.
B Taperlock Stud (1/2 inch - 1
8M-8778 13 UNC by 1 9/16 inch) 4. Position Tooling (D) on Tooling (A). Install Tooling
(A) on Tooling (8).
C 9U-7223 Alignment Bushing 1
D 9U-7210 Puller Plate 1 Note: Tooling (D) is installed on the outside of the
cylinder head. Tooling (0) is required in order to
(1) Part of the 8S· 2241 Camshaft Bearing Tool Group
remove the No. 7 camshaft bearing from the cylinder
head.
Start By:
5. Use Tooling (A) to remove camshaft bearing (3)
a. Remove the camshaft. Refer to Disassembly and from the cylinder head.
Assembly, "Camshaft - Remove".
6. Remove Tooling (8) from Tooling (A) and remove
NOTICE the camshaft bearing.
Keep all parts clean from contaminants.
7. Repeat Step 3 through Step 6 in order to remove
Contaminants may cause rapid wear and shortened the remaining camshaft bearings. Work from the
component life. rear of the engine to the front of the engine.
i01995166
Installation Procedure
Table 50
Required Tools
Part
Tool Number Part Description Qty
Camshaft Bearing Tool
88-2241 1
Group Illustration 252
gO 1034920
88-8290 Nut 1
1. Install the NO.7 camshaft bearing (rear), as
88-8291 Threaded Shaft 1 follows:
A(l)
88-8287 Thrust Bearing Assembly 1
a. Insert the large end of Tooling (8) into the No.
88-8288 Cone 1 7 camshaft bore. Position camshaft bearing (3)
88-8292 Extension (Short) 2 on Tooling (8).
1-
88-8293 Extension (Long) 1 b. Position Tooling (D) on Tooling (A). Install
9U-7222 Camshaft Bearing Pilot 1 Tooling (A) in Tooling (8).
B Taperlock Stud (1/2 inch - 1
8M-8778 c. Position camshaft bearing (3) on Tooling (8).
13 UNC by 1 9/16 inch)
Install Tooling (E) on Tooling (8).
C 9U-7223 Alignment Bushing 1
Note: Refer to Specifications, "Cylinder Head" for
D 9U-7210 Puller Plate 1
appropriate information for the orientation of the
9U-7213 Backup Plate 1 camshaft bearings in the cylinder head.
E Bolt (1/2 inch - 13 UNC by
08-1621 1 d. Use Tooling (A) in order to pull camshaft
.1 inch)
bearing (3) into the camshaft bore.
F 9U-7214 Spacer Plate 1
(1) Part of the 8S - 2241 Camshaft Bearing Tool Group Note: When the chamfer of Tooling (E) contacts the
face of the camshaft bore, the camshaft bearing is
properly installed.
NOTICE
Keep all parts clean from contaminants. e. Remove Tooling (E) from Tooling (8). Remove
Tooling (A) from Tooling (8). Remove Tooling
Contaminants may cause rapid wear and shortened (8) from the cylinder head.
component life.
3
Note: Ensure that the inside of the cylinder head
is clean. Inspect the camshaft bore for metal burrs.
Put a thin film of clean engine oil on the inside of
the camshaft bearing bores and on each camshaft
bearing prior to installation.
c~
Illustration 253 g01034921
a. Insert the large end of Tooling (8) into the Note: Refer to Specifications, "Cylinder Head" for
camshaft bore. appropriate information for the location and the ~
orientation of the camshaft bearings in the cylinder
Note: Use Tooling (C) to align Tooling (A) and Tooling head.
(8) with the camshaft bearing bores. Install Tooling
(C) in the inside diameter of any installed camshaft Note: Tooling (F) is used to seat the No.1 camshaft
bearing between Tooling (A) and Tooling (8). bearing to the correct depth in the camshaft bore.
b. Install Tooling (A) in Tooling (8). Position c. Use Tooling (A) in order to pull the No. 1
camshaft bearing (3) on Tooling (8). Install camshaft bearing into the No. 1 camshaft bore.
Tooling (E) on Tooling (8). When the chamfer of Tooling (E) contacts
the face of the camshaft bore, the camshaft
Note: Refer to Specifications, "Cylinder Head" for bearing is properly installed.
appropriate information for the location and the
orientation of the camshaft bearings in the cylinder d. Remove Tooling (E) and Tooling (F) from
head. Tooling (8). Remove Tooling (A) from Tooling
(8).
c. Use Tooling (A) in order to pull camshaft
bearing (3) into the camshaft bore. e. Remove Tooling (8) and Tooling (C) from the
cylinder head.
Note: When the chamfer of Tooling (E) contacts the
face of the camshaft bore, the camshaft bearing is
properly installed.
Illustration 255
901005315
End By:
iOl1710 24
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
NOTICE 4. Remove seal (3) for oil pan from the cylinder block.
Care must be taken to ensure that fluids are contained
during performance of inspection , maintenance, test- Installation Procedure
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- NOTICE
nent containing fluids. Keep all parts clean from contaminants.
Refer to Special Publication, NENG2500, "Caterpillar Contaminants may cause rapid wear and shortened
Tools and Shop Products Guide" for tools and supplies component life.
suitable to collect and contain fluids on Ca terpillar
products.
1. Drain the oil from the engine oil pan into a suitable
container for storage or disposal. 90062521 6
Illustralion 258
--- ..
Required Tools
102000204 Part
Tool Number Part Description Qty
Cylinder Liner - Remove
B 2p·8260 Cylinder Liner Installer 1
SMCS Code: 1216-011 5P-3975 Rubber Lubricant 1
C
Removal Procedure
NOTICE
Table 51 Keep all parts clean from contaminants.
Required Tools
Contaminants may cause rapid wear and shortened
Part component life.
Tool Part Description Qty
Number
A 5P-8665(1) Cylinder Liner Puller Gp 1 1. Check the cylinder liner projection. Refer to
'---
(1) The 6V· 9448 Cylinder Pack Puller is an optional Tool for Testing and Adjusting, "Cylinder Liner Projection
removing the cylinder liner. - Inspect".
Start By:
a. Remove the pistons and connecting rods. Refer
to Disassembly and Assembly, "Pistons and
Connecting Rods - Remove".
NOTICE
Keep all parts clean from contaminants.
g01004993
Illustration 261
g01005579
Illustration 260
B
2
g01005003 g01004705
Illustration 262 Illustration 263
5. Use Tooling (8) to install cylinder liner (1) in the 1. Use Tooling (A) to rotate the crankshaft in order to
cylinder block. Ensure that any marks in relation gain access to the piston cooling jet.
to the cylinder liner projection are in alignment.
2. Remove bolt (1) and piston cooling jet (2).
Note: Refer to Special Instruction, SEHS9564 for
more information about cylinder liner installation. Installation Procedure
End By: Table 54
Required Tools
a. Install the pistons and connecting rods. Refer
to Disassembly and Assembly, "Pistons and
Connecting Rods - Install". --:;- ~~:d;
A 98 - 9082
-
Part Descrlpllon
Engine Turning Tool
-" .
Qty
1
i02347015
Removal Procedure
Table 53 2
--- - - - - - ,
Required Tools
---'--'---'
Part
Tool Number Part Descripti
A 98-9082 Engine Turning Too
--
Start By:
End By:
i02736757
NOTICE
Keep all parts clean from contaminants.
NOTICE
Care must be taken to ensure that fluids are contained Illustration 266 90050622 9
during performance of inspection , maintenance, test-
ing, adjusting and repair of the product. Be prepared to 4. Remove piston (2) and the connecting rod from
collect the fluid with suitable containers before open - tile cylinder liner.
ing any compartment or disassembling any compo-
nent containing flu ids. 5. Repeat Steps 1 through 4 in order to remove the
remainder of the pistons and connecting rods.
Refer to Special Publication, NENG2500, "Caterpillar
Dealer Service Tool Catalog" for tools and supplies
suitable to collect and contain fluids on Caterpillar
products .
Disassembly Procedure
Table 55
Required Tools
Part
Tool Number Part Description Qty
1P -1861 (1)
A or Retaining Ring Pliers 1
139-9039(2)
7M-3978(3)
or 6----~
8 Ring Expander 1
149-7179(4)
(1) Use wilh one-piece piston
(2) Use with two-piece piston Illustration 267 g01033568
(3) Use with C-15 Engines
(4) Use with C-16 Engines
1. Remove bearings (5) from connecting rod (4) and
connecting rod cap (6).
Start By:
2. Use Tooling (A) to remove retaining ring (2).
a. Remove the pistons and connecting rods. Refer
to Disassembly and Assembly I "Pistons and
3. Remove pin (3) and separate piston (1) from
Connecting Rods - Remove" for the procedure.
connecting rod (4).
Note: Mark the components of each piston and
4. Use Tooling (B) to remove the piston rings from
connecting rod assembly. The components must be
piston (1).
reinstalled in the original location. Do not interchange
components.
NOTICE
Keep all parts clean from contaminants.
Assembly Procedure
Table 56
Required Tools
Part
Tool Number Part Description Qty
1P -1861 (1)
A or Retaining Ring Pliers 1
139 - 9039(2)
7M-3978(3)
B or Ring Expander 1
149-7179(4)
Hydraulic Press
5P-8639 (Connecting Rod Bearing)
1
901033611
5P-8651 Spacer 1
Illustration 268
5P-8649 Adapter 1
1. Remove bearings (16) from connecting rod (12) 8P-8650 Bushing Adapter 1
and connecting rod cap (17). Remove dowel (18)
from connecting rod cap (17). 9U-6600 Hydraulic Pump 1
(1) Use with one-piece piston
2. Use Tooling (A) to remove retaining ring (14). (2) Use with two-piece piston
(3) Use with C-15 Engines
3. Remove pin (15) and connecting rod (12) from (4) Use with C-16 Engines
the piston.
Note: Prior to removal from the engine, the pistons
4. Use Tooling (8) to remove piston rings (7), (8), and connecting rod assemblies were marked.
and (9) from the piston. The components must be reassembled together.
The components must be installed in the original
5. Separate piston crown (11) from piston skirt (13). location in the engine. Do not interchange any of the
components.
Note: Piston pin bearing (10) will be pushed out
of connecting rod (12) during installation of the NOTICE
new bearing. Refer to Disassembly and Assembly, Keep all parts clean from contaminants.
"Pistons and Connecting Rods - Assemble" for the
procedure. Contaminants may cause rapid wear and shortened
component life.
RENR2306-09 97
Disassembly and Assembly Section
2 3
6----~
901033568
IIIUSlration 269
x 12
901033643
IIluslration 271
b. Use Tooling (C) to remove the old bearing and 7. Use Tooling (8) to install top piston ring (7) with
install the new bearing at the same time. The the side that has the identification "UP-1" toward
adapter of Tooling (C) should make full contact the top of the piston.
with the surfaces of the connecting rod.
S. Position piston rings (7), (8), and (9) so the gaps
Note: Orient the bearing joint within ± 5 degrees of are 120 degrees from each other.
either Location (X).
9. Position piston crown (11) on piston skirt (13).
c. Allow the connecting rod and the bearing to
cool to room temperature. Note: Ensure that piston pin bearing (10) is in the
correct position in connecting rod (12).
2. Use a pin boring machine to machine the bore of
the piston pin bearing to the correct diameter. 10. Position the piston on connecting rod (12). Apply
clean engine oil to piston pin (15) and install the
Diameter of piston pin bore ... 55.035 ± 0.008 mm piston pin. Install retainer rings (14) with Tooling
(2.1667 ± 0.0003 inch) (A). Make sure that the retainer rings are fully
seated in the grooves of the piston.
End By:
i02736821
Installation Procedure
Table 57
i0 1934239
Removal Procedure
Start By:
End By:
3. Remove bolts (1) and the connecting rod bearing 2. Install a new upper half connecting rod bearing in
cap from the connecting rod . Remove the lower the connecting rod .
half of the connecting rod bearing from the
connecting rod bearing cap. 3. Pull the connecting rod onto the crankshaft.
i01974969
Note: Install the connecting rod bearings dry when 7. Repeat Steps 1 through 6 in order to install the
clearance checks are performed . Apply clean engine remainder of the connecting rod bearings.
oil on the connecting rod bearings for final assembly.
End By:
1. Install a new lower half connecting rocl bearing (3)
in connecting rod bearing cap (2) . a. Install the engine oil pump. Refer to Disassembly
and Assembly, "Engine Oil Pump - Install".
RENR2306-09 101
Disassembly and Assembly Section
i018 104 21
Removal Procedure
Table 59
Required Tools
Part
Tool Part Description Qty
Number
900503084
I A 2P-5518 Bearing Tool 1 Illustration 278
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.
900503174
Refer to Special Publication, NENG2500, "Caterpillar Illustration 279
Tools and Shop Products Guide" for tools and supplies
suitable to collect and contain fluids on Caterpillar Note: If the crankshaft is turned in the wrong
products. direction, the tab on the bearing will be pushed
between the crankshaft and the bearing area of
Dispose of all fluids according to local regulations and the cylinder block. This can result in damage to
mandates. the cylinder block and/or the crankshaft. Turn the
crankshaft so that the bearing tab is rotated out of
1. Check the main bearing caps for identification of the crankshaft.
the location and check the direction of the main
bearing caps in relation to the cylinder block. The 3. Remove the upper halves of the main bearings by
main bearing caps must be installed in the original putting Tooling (A) in oil hole (2) in the crankshaft.
location and the original direction. Turn the crankshaft in the direction which will
remove the upper halves of the main bearings.
NOTICE
Keep all parts clean from contaminants .
g00503 174
Illustration 280
Note: Install the thrust plates for the No.4 main i02345057
bearing with the words "Block Side" toward the
cylinder block. Crankshaft - Remove
5. Tighten the bolts for the main bearing caps, as SMCS Code: 1202-011
follows:
Removal Procedure
a. Tighten the bolt first on the bearing tab
side of the main bearing cap to a torque of Table 61
260 ± 14 N·m (190 ± 10 Ib ft). Required Tools
b. Tighten the bolt opposite the bearing tab side Part
to a torque of 260 ± 14 N·m (190 ± 10 Ib ft). Tool Number Part Description Qty
1H-3110 Bearing Puller 1
c. Put a mark on each bolt and on each main
bearing cap. 88-7560 Slep Plate 1
9U-6600 Hand Hydraulic Pump 1
d. Tighten the bolt opposite the bearing tab side
for an additional 120 ± 5 degrees (2 flats). 1H-3108 Push-Puller Leg 2
1H-3107 Bearing Puller 1
e. Tighten the bolt on the bearing tab side for an A
additional 120 ± 5 degrees (2 flats). 3H-0468 Puller Plate 5
3H-0465 Push-Puller Plate 2
6. Use Tooling (B) to check the crankshaft end play.
Ensure that Tooling (B) is against a machined 1P-0820 Hydraulic Puller 1
surface. The end play is controlled by the thrust 58-0637 Nut 1
plates of No.4 main bearing (center).
88-6586 Forcing Screw 1
Crankshaft end play (new thrust 5P-0944 Dowel Puller Group 1
plates) ...... 0.15 to 0.55 mm (0.006 to 0.022 inch) B
5P-0939 Dowel Extractor 1
Maximum permissible crankshaft end play (used
thrust plates) ...................... 0.89 mm (0.035 inch) Start By:
NOTICE
Keep all parts clean from contaminants.
g01029696
gO 1029696 Illustration 286
Illustration 284
3. Remove the connecting rod caps. 1. Install pin (5) in the crankshaft.
NOTICE
Keep all parts clean from contaminants.
NOTICE
Lead wire, shim stock or a dial bore gauge can dam-
age the bearing surfaces.
106 RENR2306-09
Disassembly and Assembly Section
The technician must be very careful to use Tooling (A) Note: When Tooling (A) is used, the readings can
correctly. The following points must be remembered: sometimes be unclear. For example, all parts of ~
Tooling (A) are not the same width. Measure the
• Ensure that the backs of the bearings and the major width in order to ensure that the parts are
bores are clean and dry. within the specification range. Refer to Specifications
Manual, "Connecting Rod Bearing Journal" and
• Ensure that the bearing locking tabs are properly Specifications Manual, "Main Bearing Journal" for the
seated in the tab grooves. correct clearances.
NOTICE
Keep all parts clean from contaminants.
A
Contaminants may cause rapid wear and shortened
component life.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
g00523078 901039699
IlIuslration 289 Illustration 291
1. Disconnect hose assembly (1) from the fitting in 5. Install a suitable lifting device to the top of the
the BrakeSaver housing. BrakeSaver housing.
8 5F-7345 Screw
I 1
1P-0490 Drive Plate I 1
Start By:
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 tile product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids . 900523331
Illustration 293
Refer to Special Publication, NENG2500, "Caterpillar
Tools and Shop Products Guide" for tools and supplies 3. Put alignment marks on stator (3) and BrakeSaver
suitable to collect and contain fluids on Caterpillar housing (4) for assembly purposes. Remove bolts
products. (5) and tile stator.
900523 34 2
IIluslration 294
9005 23236
Illustration 292
g00523350
Illustration 295
6. Remove O-ring seal (11) and the six smaller 10. Remove spiral ring (15). Rotate the 8rakeSaver,
O-ring seals from the oil holes on the 8rakeSaver and remove sleeve assembly (17) . Remove the lip
housing . seal and O-ring seal (16) from the sleeve.
8. Remove seal ring (10) from both sides of the rotor. BrakeSaver - Assemble
SMCS Code: 1155-016
Assembly Procedure
Table 65
Required Tools
Part
Tool Number Part Description Qty
NOTICE
Keep all parts clean from contaminants.
Illustration 298 900523368 1. Inspect the O-ring seals. If the O-ring seals are
worn or damaged, use new parts for replacement.
Put clean engine oil on the O-ring seals.
110 RENR2306-09
Disassembly and Assembly Section
10. Install O-ring seal (7) and lip seal (8) on sleeve
assembly (9). Install sleeve assembly (9) in the
stator. Make an alignment of the notch in the
sleeve with the dowel in the stator.
g00523342 g0 1070733
Illustration 305 Illustration 307
11. Rotate the stator and install spiral ring (6) that b. Install Tooling (E) with Tooling (G).
holds the sleeve in the stator.
g01 070735
Illustration 308
g0052333 1
Illustration 306
c. Rotate the BrakeSaver housing and install
12. Put stator (3) in the correct location on BrakeSaver Tooling (C) and Tooling (D) on the rotor.
housing (4). Ensure that the oil holes in the stator
and in the BrakeSaver housing are in alignment. d. The wear sleeve and the seal are installed as
a unit on Tooling (C) .
13. Install bolts (5) that hold the stator to the
BrakeSaver housing. Tighten the bolts to a torque Note: Once the seal and the wear sleeve are
of 55 ± 7 N·m (41 ± 5 Ib ft) . separated, these components cannot be used again .
e. Put Tooling (F) in position on the locator. 19. Install Tooling (A) on the rotor and the BrakeSaver
housing .
f. Put clean engine oil on the face of Tooling (H).
Install Tooling (H) on the locator.
End By:
Part
Tool Part Description Qty
Number
5P-8718 Rotor Support 1
A
08-1594 Bolt 4
B - Guide Bolts (5/8 -18 NF) 2
NOTICE
Keep all parts clean from contaminants.
901039744
Illustration 313
i011 69133
Removal Procedure
Start By:
NOTICE
Keep all parts clean from contaminants.
g00523583
Illustration 318
Contaminants may cause rapid wear and shortened Typical example
component life.
3. Remove baffle assembly (4) and the a-ring seal
from the oil pan.
Installation Procedure
NOTICE
Keep all parts clean from contaminants .
g00523580
Illustration 316 Note: Check condition of the a-rings. If the a-rings
Typical example are worn or damaged, use new parts for replacement.
1. Disconnect oil line (1) from the left side of the 1. Ensure that the oil pan is free of oil and gasket
engine oil pan . material.
RENR2306-09 115
Disassembly and Assembly Section
Typical example
4. Install the O-ring seal and the baffle assembly (4) i019959 13
in the oil pan .
BrakeSaver Engine Oil Pump -
Remove
SMCS Code: 1155-011
Removal Procedure
Start By:
i02111000
NOTICE
Keep all parts clean from contaminants.
BrakeSaver Engine Oil Pump
- Disassemble
Contaminants may cause rapid wear and shortened
component life. SMCS Code: 1155-015
Disassembly Procedure
Table 67
Required Tools
Part
Tool Number Part Description Qty
A 1P-2322 Puller Assembly 1
B 1P-0510 Driver Group 1
Start By:
90052299G
a. Remove the oil pump. Refer to Disassembly
Illustration 322
and Assembly, "BrakeSaver Engine Oil Pump -
Remove" .
1. Remove suction bell (3) from the oil pump.
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.
A WARNING
Personal injury can result from parts and/or cov-
ers under spring pressure.
g01033606
Illustration 328
BEAniNG JUNCTION
g01033766
Illustration 331
g01033809
Illustration 329
RENR2306-09 119
Disassembly and Assembly Section
i01995999
Installation Procedure
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repairofthe product. Be prepared to
901033768
collect the fluid with suitable containers before open-
Illustration 332 ing any compartment or disassembling any compo-
nent containing fluids.
A WARNING .' .
Refer to Special Publication, NENG2500, "Caterpillar
Improper assembly of parts that are spring loaded Tools and Shop Products Guide" for tools and supplies
can cause bodily injury. suitable to collect and contain fluids on Caterpillar
products.
To prevent possible injury, follow the established
assembly procedure and wear protective equip- Dispose of all fluids according to local regulations and
ment. mandates.
6. Install pump body (2) and bolts (3). Install bypass NOTICE
valve (4), spring (5), and retainer (6) . Keep all parts clean from contaminants.
7. Install the key on the shaft. Contaminants may cause rapid wear and shortened
component life.
g0052341 4
Illustration 333
901 040833
Illustration 334
NOTICE
The oil pump must turn freely after it is assembled . 1. Install engine oil pump (5) on the engine.
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.
5. Install tube assembly (2) on the engine block. Do not disconnect any air lines until the air pres-
Install BrakeSaver tube assembly (1) on the sure is zero.
engine block.
a. Install the BrakeSaver engine oil pan . Refer to 2. Drain the oil from the oil pan .
Disassembly and Assembly, "BrakeSaver Engine
Oil Pan - Remove and Install".
i01996122
Removal Procedure
NOTICE
Keep all parts clean from contaminants . Illustration 336 900524237
Contaminants may cause rapid wear and shortened 3. Remove short bolts (1) and longer bolts (3)
component life. from manifold (2) and the BrakeSaver housing .
Remove manifold (2). Remove the O-ring seals
from the manifold.
RENR2306-09 121
Disassembly and Assembly Section
4. Remove oil temperature sensing unit (4) from the 8. Remove bolts (12) and BrakeSaver control valve
BrakeSaver control valve. (11) from the oil pan . The weight of the BrakeSaver
control valve is approximately 22 kg (50 Ib).
5. Disconnect air tube assembly (5) and hose
assembly (6) from the BrakeSaver control valve . 9. Remove elbow assembly (13) from the BrakeSaver
control valve . Remove the O-ring seals.
i01996154
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 tile fluid wi til suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids .
'A WARNING . ,
The covers hold springs under compression. To
prevent possible injury from flying parts, hold cov-
ers when the bolts are removed.
i0211 1017
~JI/I!IIIJJIJIIJ)JJ
",," cb '
, ......
. ~ BrakeSaver Control Valve
Assemble
SMCS Code: 1159-016
g00524484 g00524416
IIluslration 344 Illustration 346
A WARNING
Improper assembly of parts that are spring loaded
can cause bodily injury.
i01996159
2. Align the hole in plate (13) with the pin in valve
spool (8). Install plate (13) with bolt (11) .
BrakeSaver Control Valve -
3. Install sleeves (5) and the O-ring seals in the Install
BrakeSaver control valve.
SMCS Code: 1159-012
4. Position spring (7), stop (10), spring (6), and slug
(9) in valve spool (8) .
Installation Procedure
5. Install valve spool (8) into the valve body. As the Table 69
valve spool (8) is installed, ensure that the edge of
the diapllragm makes contact all the way around Required Tools
with the groove in the valve body. The valve spool Part
(8) must extend 38 .1 mm (1 .50 inch) from the Tool Number Part Description Qty
_ ._-
valve body. Push the valve spool approximately
6.4 to 12.7 mm (0 .25 to 0.50 inch) farther into Thread Lock
A 98-3263 Compound 1
the valve body until a curved depression is
caused between tile valve spool and the valve
body. Ensure that there are no wrinkles in the NOTICE
diaphragm . Keep all parts clean from contaminants .
g00524237
Illustration 349
g00524248
Illustration 350
g00524244
Illustration 348
g00524245
Illustration 351
i01931524
Contaminants may cause rapid wear and shortened 3. Connect harness assembly (1).
component life.
i01930700
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
i01930969
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
2 3
901004514 g01004661
Illustration 355 Illustration 356
1. Install a new O-ring seal on the camshaft position 1. Disconnect harness assembly (1).
sensor.
2. Remove bolt (2) that fastens crankshaft position
2. Position camshaft position sensor (2) in the sensor (3) to the front housing. Remove the
housing and install bolt (3). crankshaft position sensor.
3. Connect harness assembly (1). 3. Remove the O-ring seal from the crankshaft
position sensor.
RENR2306-09 127
Disassembly and Assembly Section
Installation 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.
HI
mandates .
i01930445
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.
;01930569
IIluslralion 360 g01004482
Engine Oil Pressure Sensor -
Remove and Install 1. Disconnect harness assembly (1).
SMCS Code: 1924-010 2. Remove engine oil pressure sensor (2) from the
adapter on the cylinder block.
Removal Procedure 3. Remove the O-ring seal from the engine oil
pressure sensor.
NOTICE
Keep all parts clean from contaminants.
Installation Procedure
Contaminants may cause rapid wear and shortened
component life. NOTICE
Keep all parts clean from contaminants.
g01004482 g01004847
Illustration 361 Illustration 362
1. Install a new O-ring seal on the engine oil pressure 1. Disconnect harness assembly (1).
sensor.
2. Remove fuel temperature sensor (2) from the fuel
2. Install engine oil pressure sensor (2). Tighten filter base.
the engine oil pressure sensor to a torque of
10 ± 2 N·m (89 ± 18 Ib in). 3. Remove the O-ring seal from the fuel temperature
sensor.
3. Connect harness assembly (1).
Installation Procedure
i01931558
NOTICE
~ Fuel Temperature Sensor - Keep all parts clean from contaminants.
Remove and Install
Contaminants may cause rapid wear and shortened
SMCS Code: 1922-010 component life.
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
2
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- g01004847
Illustration 363
ing any compartment or disassembling any compo-
nent containing fluids.
1. Install a new O-ring seal on the fuel temperature
Refer to Special Publication, NENG2500, "Caterpillar sensor.
Tools and Shop Products Guide" for tools and supplies
suitable to collect and contain fluids on Caterpillar 2. Install fuel temperature sensor (2). Tighten the
products. fuel temperature sensor to a torque of 20 ± 5 N·m
(15 ± 4 Ib ft).
Dispose of all fluids according to local regulations and
mandates. 3. Connect harness assembly (1) .
130 RENR2306-09
Disassembly and Assembly Section
i01930516
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
i01931690
NOTICE
Keep all parts clean from contaminants.
g01004963 ----..
Illustration 366
Installation Procedure 2
NOTICE
Keep all parts clean from contaminants.
"'\\--~---2
g01001164
Illustration 368
Installation Procedures
901004963
Illustration 367
i01923796
Removal Procedure
g01001164
Illustration 369
1. Remove the serpentine belt. Refer to Operation
and Maintenance Manual, "Belts - Inspect".
1. Position belt tensioner (1) on the front cover.
i0198841 5
NOTICE
Fan Drive - Remove Keep all parts clean from contaminants .
SMCS Code: 1359-011
Contaminants may caLise rapid wear and shortened
component life .
Removal Procedure
NOTICE 1 2 5 6
Keep all parts clean from contaminants.
7
Contaminants may cause rapid wear and shortened
component life.
8
:=1~: ; .
,I I - ,
1. . -=~
~.... I
Illustration 371
-' CIJr- 9 10 11
90 1029 786
1. Loosen bolts (2) and nuts (3) . Remove bolt (1) , 4. Remove pulley (5) from shaft assembly (1) .
and remove fan drive belts (5) .
5. Remove bearing (9) and spacer (6) from pulley
2. Remove the nuts and the bolts that hold the fan (5) . Remove spacer (2), lip seal (3), and bearing
drive . Remove fan drive (4) . (4) from pulley (5) .
Required Tools
a. Remove the fan drive . Refer to Disassembly and
Part
Assembly, "Fan Drive - Remove ".
Tool Number Part Description Qty
A 1P - 0510 Driver Group 1
i01988436
NOTICE
Keep all parts clean from contaminants.
Fan Drive - Install
SMCS Code: 1359-012
Contaminants may cause rapid wear and shortened
component life.
Installation Procedure
1 2 NOTICE
Keep all parts clean from contaminants.
7
Contaminants may cause rapid wear and shortened
8
component life.
:j1~ ~·\ - I
f . -=~
. ~I
~IP- 9 10 11
901029786
Illustration 372
3. Install spacer (2) so the end with the taper is Illustration 373
901029819
toward the inside of pulley (5) .
1. Position fan drive (4) on the front housing .
4. Install spacer (6) and bearing (9) in the front of
pulley (5). 2. Install bolts (2) and nuts (3) loosely.
5. Position O-ring seal (7) on the front of pulley (5) . 3. Install bolt (1) .
Install the pulley on shaft assembly (1).
Note: Install belts (5) as a set only.
6. Install retainer (10) and bolts (11) . Tighten bolts
(11) to a torque of 25 ± 6 N·m (18 ± 4 Ib ft) . 4. Install the fan drive belts and adjust the belt
tension . Refer to Specifications, "Belt Tension
7. Install the fan adapter on pulley (5). Tighten bolts Chart" .
(8) to a torque of 47 ± 9 N·m (35 ± 7 Ib ft) .
5. Tighten bolt (2) and nuts (3) that hold the fan drive
8. Fill the fan drive with Tooling (B) . in position .
End By:
SMCS Code: 1901-010 Contaminants may cause rapid wear and shortened
component life,
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
900625434
Illustration 376
900625429
3. Install clamp (5) in position .
Illustration 374
g00625429
Illustration 377
Removal Procedure
I
i A WARNING
Accidental engine starting can cause injury or
death to personnel working on the equipment.
iO 193439 1
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
2
Contaminants may cause rapid wear and shortened
component life.
90104 271 4
Illustration 378
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.
.' : A WARNING ' '. 4. Remove coolant line (4) from the air compressor.
Do not disconnect the air lines llntil the air pres- 5. Remove nuts (5) that hold the air compressor to
sure in the system is at zero. If hose is disconnect- the accessory drive.
ed under pressure it can cause personal injury.
6. Remove the air compressor from the engine.
1. Loosen the purge valves , and release the air
pressure in the air tank.
Typical ex ample
2. Disconnect coolant supply line (1) and air supply Installation Procedure
line (2) from the air compressor.
NOTICE
3. Disconnect oil supply line (3) from the air Keep all parts clean from contaminants.
compressor.
Contaminants may cause rapid wear and shortened
component life.
RENR2306-09 137
Disassembly and Assembly Section
NOTICE
To prevent water from collecting and freezing in the air
compressor lines, ensure that the air compressor lines
are sloping downward and away from the air compres-
sor.
i02237680
Required Tools
Part
Tool Number Part Description Qty
A 132-5451 Holding Fixture 1
Start By:
g00620840
Illustration 384
Typical example
5. Connect coolant supply line (1) to the air 3. Remove air compressor drive gear (1).
compressor.
138 RENR2306-09
Disassembly and Assembly Section
Table 72
Wabco 250 Air Compressor
Required Tools
Part 1. Tighten nut (2) to a torque of 150 ± 5 N'm
Tool Number Part Description Qty (111 ± 4 Ib tt).
A 132-5451 Holding Fixture 1 2. Place an index mark on the nut and rotate nut (2)
for an additional turn of 60 ± 5 degrees.
Note: Caterpillar may use air compressors that have
a tapered shaft or a straight shaft. The torque for the End By:
nut on the air compressor crankshaft is different for
each type of crankshaft. a. Install the air compressor. Refer to Disassembly
and Assembly I "Air Compressor - Remove and
Note: Identify the manufacturer of the air compressor Install".
for your particular application.
i02967460
Installation Procedure
Table 73
Required Tools
Part
Tool Number Part Description Qty
A 132-5451 Holding Fixture 1
gOl148907
Illustration 387
gOl128545
Illustration 388
End By:
Index
A BrakeSaver Engine Oil Pump - Disassemble ....... 116
Disassembly Procedure .................................... 116
Accessory Drive - Assemble .................................. 60 BrakeSaver Engine Oil Pump -Install .................. 119
Assembly Procedure .......................................... 60 Installation Procedure ....................................... 119
Accessory Drive - Disassemble ............................. 59 BrakeSaver Engine Oil Pump - Remove .............. 115
Disassembly Procedure ..................................... 59 Removal Procedure .......................................... 115
Accessory Drive -Install ........................................ 61
Installation Procedure ........................................ 61
Accessory Drive - Remove .................................... 59 c
Removal Procedure ........................................... 59
Air Compressor - Remove and Install... ............... 135 Camshaft -InstalL .................................................. 82
Installation Procedure ...................................... 136 Alternative Installation Procedure ...................... 84
Removal Procedure ......................................... 135 Installation Procedure ........................................ 82
Air Compressor Drive Gear - InstalL .................... 138 Camshaft - Remove ............................................... 78
Installation Procedure...................................... 138 Alternative Removal Procedure ......................... 80
Air Compressor Drive Gear - Install (Two Removal Procedure ........................................... 78
Cylinder) ............................................................ 138 Camshaft Bearings - Install ................................... 89
Installation Procedure ...................................... 138 Installation Procedure ........................................ 89
Air Compressor Drive Gear - Remove ................. 137 Camshaft Bearings - Remove ............................... 88
Removal Procedure ......................................... 137 Removal Procedure ........................................... 88
Atmospheric Pressure Sensor - Remove and Camshaft Gear - Remove and Install .................... 86
Install ................................................................. 125 Installation Procedure ........................................ 86
Installation Procedure ...................................... 125 Removal Procedure ........................................... 86
Removal Procedure ......................................... 125 Camshaft Position Sensor - Remove and Install.. 125
Installation Procedure ...................................... 126
Removal Procedure......................................... 125
B Compression Brake - Assemble (If Equipped) ...... 67
Assembly Procedure .......................................... 67
Bearing Clearance - Check................................. 105 CompreSSion Brake - Disassemble (If Equipped) .. 64
Measurement Procedure ................................. 105 Disassembly Procedure ..................................... 64
Belt Tensioner - Remove and Install .................... 131 CompreSSion Brake -Install (If Equipped) ............. 68
Installation Procedures .................................... 131 Installation Procedure ........................................ 68
Removal Procedure.......... ............................... 131 Compression Brake - Remove (If Equipped) ......... 64
Boost Pressure Sensor - Remove and Install.. .... 130 Removal Procedure ........................................... 64
Installation Procedure ...................................... 130 Connecting Rod Bearings -Instal!... .................... 100
Removal Procedure.................................... ..... 130 Installation Procedure ...................................... 100
BrakeSaver - Assemble....................................... 109 Connecting Rod Bearings - Remove ..................... 99
Assembly Procedure........................................ 109 Removal Procedure ........................................... 99
BrakeSaver - Disassemble .................................. 107 Coolant Temperature Sensor - Remove and
Disassembly Procedure................................... 107 Install ................................................................. 127
BrakeSaver - Install .............................................. 113 Installation Procedure ...................................... 127
Installation Procedure ....................................... 113 Removal Procedure......................................... 127
BrakeSaver - Remove......................................... 106 Crankshaft - Install... ............................................ 104
Removal Procedure ......................................... 106 Installation Procedure ...................................... 104
BrakeSaver Control Valve - Assemble................ 122 Crankshaft - Remove........................................... 103
Assembly Procedure ........................................ 122 Removal Procedure ......................................... 103
BrakeSaver Control Valve - Disassemble ............ 121 Crankshaft Front Seal - Install ............................... 48
Disassembly Procedure ................................... 121 Installation Procedure ........................................ 48
BrakeSaver Control Valve - InstalL ...................... 123 Crankshaft Front Seal - Remove ........................... 47
Installation Procedure ...................................... 123 Removal Procedure ........................................... 47
BrakeSaver Control Valve - Remove................... 120 Crankshaft Main Bearings - Install ....................... 102
Removal Procedure ......................................... 120 Installation Procedure ...................................... 102
BrakeSaver Engine Oil Pan - Remove and Crankshaft Main Bearings - Remove ................... 101
Install .................................................................. 114 Removal Procedure ......................................... 101
Installation Procedure ....................................... 114 Crankshaft Position Sensor - Remove and
Removal Procedure .......................................... 114 Install ................................................................. 126
BrakeSaver Engine Oil Pump - Assemble ............ 117 Installation Procedure ...................................... 127
Assembly Procedure ......................................... 117 Removal Procedure......................................... 126
RENR2306-09 141
Index Section
Crankshaft Rear Seal - Install .................... '" ......... 43 Engine Oil Pump - Install. ...................................... 34
Installation Procedure ........................................ 43 Installation Procedure ........................................ 34
Crankshaft Rear Seal - Remove ............................ 43 Engine Oil Pump - Remove ................................... 31
Removal Procedure ........................................... 43 Removal Procedure ........................................... 31
Cylinder Head - Install ........................................... 75 Engine Support (Front) - Remove and Install ........ 41
Installation Procedure ........................................ 75 Installation Procedure ........................................ 41
Cylinder Head - Remove ....................................... 72 Removal Procedure ........................................... 41
Removal Procedure ........................................... 72 Exhaust Manifold - Remove and Install ................. 17
Cylinder Liner - Instal!. ........................................... 92 Installation Procedure ........................................ 17
Installation Procedure ........................................ 92 Removal Procedure........................................... 17
Cylinder Liner - Remove ........................................ 92
Removal Procedure ........................................... 92
F
H T