3054C Industrial Engine D&A.

RENR2433-04 (en-us)
June 2021
Disassembly and Assembly

3054C Industrial Engine
334 1-UP (Engine)
330 1-UP (Engine)
ZAS 1-UP (Engine)
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i07966018
Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards, including human factors
that can affect safety. This person should also have the necessary training, skills and tools to perform these
functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could
result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you verify
that you are authorized to perform this work, and have read and understood the operation,
lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
A non-exhaustive list of operations that may cause product damage are identified by “NOTICE” labels on
the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. You must not
use this product in any manner different from that considered by this manual without first
satisfying yourself that you have considered all safety rules and precautions applicable to the
operation of the product in the location of use, including site-specific rules and precautions
applicable to the worksite. If a tool, procedure, work method or operating technique that is not
specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you
and for others. You should also ensure that you are authorized to perform this work, and that the
product will not be damaged or become unsafe by the operation, lubrication, maintenance or repair
procedures that you intend to use.
The information, specifications, and illustrations in this publication are on the basis of information that was
available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Cat dealers have the most current information available.
NOTICE
When replacement parts are required for this product Caterpillar recommends using original Cater-
pillar® replacement parts.
Other parts may not meet certain original equipment specifications.
When replacement parts are installed, the machine owner/user should ensure that the machine re-
mains in compliance with all applicable requirements.
In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
RENR2433-04 3
Table of Contents
Table of Contents Lifter Group - Remove and Install .........................67

Camshaft - Remove and Install ............................68
Camshaft Gear - Remove and Install ...................68
Disassembly and Assembly Section Camshaft Bearings - Remove and Install ..............69
Engine Oil Pan - Remove and Install ....................71
Fuel Priming Pump and Fuel Filter Base - Remove Balancer Group - Remove (If Equipped)................72
and Install ..........................................................4 Balancer Group - Install (If Equipped) ...................74
Fuel Injection Lines - Remove and Install ...............5 Piston Cooling Jets - Remove and Install ..............75
Fuel Injection Nozzles - Remove ...........................6 Pistons and Connecting Rods - Remove ...............76
Fuel Injection Nozzles - Install ...............................7 Pistons and Connecting Rods - Disassemble ........77
Fuel Injection Pump - Remove (Bosch EVPE) .........7 Pistons and Connecting Rods - Assemble.............78
Fuel Injection Pump - Remove (Delphi DP210) ........9 Pistons and Connecting Rods - Install...................79
Fuel Injection Pump - Install (Bosch EVPE) ........... 11 Connecting Rod Bearings - Remove .....................81
Fuel Injection Pump - Install (Delphi DP210)..........13 Connecting Rod Bearings - Install.........................82
Turbocharger - Remove.......................................14 Crankshaft Main Bearings - Remove.....................83
Turbocharger - Install ..........................................16 Crankshaft Main Bearings - Install ........................84
Exhaust Manifold - Remove and Install ................17 Crankshaft - Remove...........................................86
Inlet and Exhaust Valve Springs - Remove and Crankshaft - Install ..............................................87
Install ...............................................................18 Crankshaft Gear - Remove and Install ..................90
Inlet and Exhaust Valves - Remove and Install.......20 Bearing Clearance - Check ..................................91
Inlet and Exhaust Valve Guides - Remove and Coolant Temperature Sensor - Remove and Install 92
Install ...............................................................23 Engine Oil Pressure Sensor - Remove and Install .93
Inlet and Exhaust Valve Seat Inserts - Remove and Glow Plugs - Remove and Install .........................94
Install ...............................................................24 V-Belts - Remove and Install ................................95
Engine Oil Filter Base - Remove and Install ..........25 Fan - Remove and Install ....................................96
Engine Oil Cooler - Remove.................................27 Fan Drive - Remove and Install ............................97
Engine Oil Cooler - Install ....................................28 Alternator - Remove ............................................98
Engine Oil Relief Valve - Remove and Install (Engine Alternator - Install ................................................98
with Balancer Group) .........................................29 Electric Starting Motor - Remove and Install .........99
Engine Oil Relief Valve - Remove and Install (Engine Air Compressor - Remove and Install ................. 100
without Balancer Group) ....................................30 Air Compressor Idler Gear - Remove and Install .. 102
Engine Oil Pump - Remove (Engines Without a
Balancer) ..........................................................31 Index Section
Engine Oil Pump - Install (Engines Without a
Balancer) ..........................................................32 Index................................................................ 104
Water Pump - Remove and Install ........................33
Water Temperature Regulator - Remove and
Install ...............................................................34
Flywheel - Remove..............................................36
Flywheel - Install .................................................36
Crankshaft Rear Seal - Remove ...........................37
Crankshaft Rear Seal - Install...............................38
Crankshaft Wear Sleeve (Rear) - Remove ............39
Crankshaft Wear Sleeve (Rear) - Install ................40
Flywheel Housing - Remove and Install ................41
Crankshaft Pulley - Remove and Install ................42
Crankshaft Front Seal - Remove ..........................43
Crankshaft Front Seal - Install ..............................44
Front Cover - Remove and Install .........................45
Idler Gear - Remove and Install (Delphi DP210 Fuel
Injection Pump) .................................................46
Idler Gear - Remove and Install (Bosch EPVE Fuel
Injection Pump) .................................................49
Housing (Front) - Remove....................................52
Housing (Front) - Install .......................................54
Accessory Drive - Remove and Install ..................56
Crankcase Breather - Remove and Install ............58
Valve Mechanism Cover - Remove and Install .......59
Rocker Shaft and Pushrod - Remove ....................60
Rocker Shaft - Disassemble ................................61
Rocker Shaft - Assemble ....................................61
Rocker Shaft and Pushrod - Install........................62
Cylinder Head - Remove......................................63
Cylinder Head - Install .........................................65
4 RENR2433-04
Disassembly and Assembly Section
Disassembly and NOTICE

Care must be taken to ensure that fluids are con-
Assembly Section tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
i02289796 ers before opening any compartment or disassem-
bling any component containing fluids.
Fuel Priming Pump and Fuel Refer to Special Publication, NENG2500, “Dealer
Filter Base - Remove and Service Tool Catalog” for tools and supplies suitable
to collect and contain fluids on Cat products.
Install
Dispose of all fluids according to local regulations
SMCS Code: 1258-010; 1260-010; 1261-010-SE; and mandates.
1262-010
Removal Procedure
Table 1
Required Tools(1)
Tool Part Number Part Description Qty
9U-7069 Cap 3
ZZ
9U-7067 Cap 3
(1) SERVICE DATA: TOOLING (ZZ) WILL NOT BE IDENTIFIED
IN PHOTOGRAPHS IN THE REMOVAL OR THE INSTALLA-
TION. THIS TOOLING IS SHOWN IN ORDER TO ASSIST
THE EXPERIENCED SERVICEMAN.
Start By:
a. Remove the assembly of the filter case and the Illustration 1 g00952432
fuel filter element. Refer to this Disassembly Typical example
and Assembly Manual, “Fuel Filter Base -
Remove and Install”. 1. Disconnect the tube assembly (5). Disconnect the
tube assembly (6). Install dust covers onto the
Note: Put identification marks on all fuel hose
connectors for the fuel priming pump.
assemblies and on all tube assemblies for installation
purposes. After being disconnected, plug all fuel 2. Disconnect the fuel return line from the connector
hose assemblies and plug all tube assemblies. This (3). Install a dust cover to the connector (3).
helps prevent fluid loss, and this helps to keep
contaminants from entering the system. 3. Disconnect the harness assembly from the
connector (2).
NOTICE 4. Support the fuel priming pump. Remove the three
Keep all parts clean from contaminants.
setscrews (1) and discard the rubber washers.
Contaminants may cause rapid wear and shortened Remove the fuel priming pump (4).
component life.
Installation Procedure
NOTICE
Contaminants may cause rapid wear and shortened
component life.
RENR2433-04 5
NOTICE
component life.
NOTICE
tained during performance of inspection, mainte-
ers before opening any compartment or disassem-
Refer to Special Publication, NENG2500, “Dealer
Illustration 2 g00952432 Service Tool Catalog” for tools and supplies suitable
Typical example to collect and contain fluids on Cat products.
1. Clean the external surfaces of the fuel priming
and mandates.
pump (4). Position the fuel priming pump (4) and
install the setscrews (1) and new rubber washers.
2. Remove the dust covers from the fuel priming
pump. Remove the plugs from the tube
assemblies. Connect the tube assembly (5).
Connect the tube assembly (6).
3. Connect the fuel return line to the connector (3).
4. Connect the harness assembly to the connector
(2).
5. Remove the air from the fuel system. Refer to the
Operations and Maintenance Manual, “Fuel
System - Prime”.
i01924034
Illustration 3 g01001306
Fuel Injection Lines - Remove

1. Remove bolts (1). Remove cover (2) from the
and Install cylinder head.
SMCS Code: 1252-010
Removal Procedure
Table 2
Required Tools
9U-7067 Cap 4
ZZ
9U-7069 Cap 4
Note: SERVICE DATA: TOOLING (ZZ) WILL NOT

BE IDENTIFIED IN PHOTOGRAPHS IN THE
REMOVAL OR THE INSTALLATION. THIS
TOOLING IS SHOWN IN ORDER TO ASSIST THE Illustration 4 g01001381
EXPERIENCED SERVICEMAN.
2. Disconnect fuel injection lines (3) at fuel injection
nozzles (4).
6 RENR2433-04
3. Disconnect fuel injection lines (3) at fuel injection

pump (5).
4. Remove the fuel injection lines.
NOTICE
component life.
4. Position cover (2) on the cylinder head. Install bolts

(1). Tighten the bolts to a torque of 9 N·m
(80 lb in).
i01878115
Fuel Injection Nozzles -

Remove
SMCS Code: 1254-011
Removal Procedure
1. Connect fuel injection lines (3) at fuel injection
nozzles (4). Tighten the nut to 30 N·m (22 lb ft). Start By:
2. Connect the fuel injection lines at fuel injection a. Remove the fuel injection lines. Refer to
pump (5). Tighten the nut to 30 N·m (22 lb ft). Disassembly and Assembly, “Fuel Injection
Lines - Remove and Install”.
3. Remove the air from the fuel system. Refer to
Operations and Maintenance Manual, “Fuel NOTICE
System - Prime”. Keep all parts clean from contaminants.
component life.
NOTICE
Service Tool Catalog” for tools and supplies suitable
and mandates.
RENR2433-04 7
Illustration 7 g00975056 Illustration 8 g00975210
1. Remove hose (2) from fuel injection nozzle (1). 1. Lubricate seat washer (6) with clean engine oil.
Install the seat washer in the cylinder head.
2. Remove bolt (3). Remove clamp (4) from the fuel
injection nozzle. Note: If the original seat washer is reused, the
projection of the fuel injection nozzle will be incorrect.
3. Remove the fuel injection nozzle from the cylinder
head. Remove O-ring seal (5) from the fuel 2. Install O-ring seal (5) on fuel injection nozzle (1).
injection nozzle. Install the fuel injection nozzle in the cylinder
4. Remove seat washer (6) from the cylinder head. head.
Note: If the original seat washer is not removed, the Note: Alignment Pin (X) must be located opposite
projection of the fuel injection nozzle will be incorrect clamp (4).
when a new seat washer is installed.
3. Position clamp (4) on the fuel injection nozzle.
i01878202 Install bolt (3). Tighten the bolt to a torque of
27 N·m (20 lb ft).
Fuel Injection Nozzles - Install 4. Install hose (2) to the fuel injection nozzle.
SMCS Code: 1254-012 End By:
a. Install the fuel injection lines. Refer to
Installation Procedure Disassembly and Assembly, “Fuel Injection
NOTICE
Keep all parts clean from contaminants. i01913153

component life. Fuel Injection Pump - Remove
(Bosch EVPE)
SMCS Code: 1251-011
Removal Procedure
Table 3
Required Tools
Tool Part Number Part Name Qty
A 230-6284 Timing Pin (Camshaft) 1
B 230-6283 Timing Pin (Crankshaft) 1
(continued)
8 RENR2433-04
(Table 3, contd)
C 9U-6198 Crankshaft Turning Tool 1
D 1P-2320 Combination Puller 1
9U-7069 Cap 2
ZZ
9U-7067 Cap 2
Start By:
a. Remove the fuel injection lines. Refer to
Disassembly and Assembly, “Fuel Injection
b. Remove the crankshaft pulley. Refer to
Disassembly and Assembly, “Crankshaft
Pulley - Remove and Install”.
c. Remove the front cover. Refer to Disassembly
and Assembly, “Front Cover - Remove and
Install”.
d. Remove the air compressor, if equipped. Refer
to Disassembly and Assembly, “Air Illustration 9 g00996409
Compressor - Remove and Install”.
2. Disconnect tube assembly (1) from the fuel
Note: SERVICE DATA: TOOLING (ZZ) WILL NOT injection pump. Disconnect tube assembly (2) from
BE IDENTIFIED IN PHOTOGRAPHS IN THE the fuel injection pump.
TOOLING IS SHOWN IN ORDER TO ASSIST THE 3. Disconnect the wiring harness assembly from cold
EXPERIENCED SERVICEMAN. start advance unit (3). Disconnect the wiring
harness assembly from engine shutoff solenoid
NOTICE (4).
component life.
1. Use Tooling (C) to ensure that the No. 1 cylinder is

at the top center compression stroke. Refer to
Testing and Adjusting, “Finding Top Center
Position for No. 1 Piston”.
Note: Install Tooling (A) through the camshaft gear.
Install Tooling (B) into the crankshaft web.
4. Loosen bolt (6). Move spacer (5) in order to allow

bolt (6) to tighten against the shaft of the fuel
injection pump. Rotate the fuel injection pump
gear in a counterclockwise direction in order to
remove the backlash. Tighten bolt (6) to a torque
of 31 N·m (23 lb ft).
Note: Bolt (6) must be tightened in order to prevent
the shaft of the fuel injection pump from rotating.
RENR2433-04 9
10. Remove the fuel injection pump from the front

housing. Remove O-ring seal (9) from the fuel
injection pump.
i02075261
Fuel Injection Pump - Remove

(Delphi DP210)
SMCS Code: 1251-011
Removal Procedure
Table 4
Illustration 11 g00996413 Required Tools

5. Remove nut (7) and the washer from the shaft of
the fuel injection pump. A 230-6284 Timing Pin (Camshaft) 1
6. Install Tooling (D) and remove fuel injection pump B 230-6283 Timing Pin (Crankshaft) 1
gear (8). B 230-6283 Timing Pin ( Crankshaft) 1
Note: Do Not pry the fuel injection pump gear from C 9U-6198 Crankshaft Turning Tool 1
the shaft of the fuel injection pump.
9U-7067 Cap 2
ZZ
9U-7069 Cap 2
Start By:
a. Remove the fuel injection lines. Refer to
Install”.
d. Remove the air compressor, if equipped. Refer
to Disassembly and Assembly, “Air
Compressor - Remove and Install”.
Note: SERVICE DATA: TOOLING (ZZ) WILL NOT
Illustration 12 g00996474 BE IDENTIFIED IN PHOTOGRAPHS IN THE
7. Remove nut (13). Remove bolt (11). TOOLING IS SHOWN IN ORDER TO ASSIST THE
EXPERIENCED SERVICEMAN.
8. If necessary, remove the bolt and bracket (10) from
the cylinder block. NOTICE
9. Remove bolts (12) in order to remove the fuel
injection pump. Contaminants may cause rapid wear and shortened
component life.
10 RENR2433-04

Install Tooling (B) into the crankshaft web.
6. Remove nut (8) and the washer from the shaft of

the fuel injection pump.
7. Install Tooling (D) and remove fuel injection pump
gear (9).
Illustration 13 g00956204 Note: Do Not pry the fuel injection pump gear from
NOTICE
The locking bolt must not be loosened under any cir-
cumstances while the pump is off the engine. If the
shaft is moved, dynamic timing of the pump will be
lost. Reestablishing timing must be done by an au-
thorized Delphi dealer, and is not a warrantable
expense.
2. Loosen bolt (5). Move spacer (6) in order to allow

remove the backlash. Tighten bolt (5) to a torque
of 17 N·m (13 lb ft).
Note: Bolt (5) must be tightened in order to prevent Illustration 15 g00956267
8. Remove nut (14). Remove bolt (12).
3. Disconnect fuel return line (1). Disconnect tube
assembly (4) from the fuel injection pump. 9. If necessary, remove bolt (15) and bracket (11)
from the cylinder block.
4. Disconnect harness assembly (2). Disconnect fuel
line (3). 10. Remove bolts (13) in order to remove the fuel
injection pump.
5. Disconnect the harness assembly from timing
advance solenoid (7).
RENR2433-04 11
11. Remove the fuel injection pump from the front

housing. Remove O-ring seal (10) from the fuel
injection pump.
i01913195
Fuel Injection Pump - Install

(Bosch EVPE)
SMCS Code: 1251-012
Table 5
Required Tools
C 9U-6198 Crankshaft Turning Tool 1 Illustration 16 g00996474
2. Install O-ring seal (9) on the fuel injection pump.

NOTICE Position the fuel injection pump on the front
housing. Install bolts (12). Tighten the bolts to a
Contaminants may cause rapid wear and shortened torque of 25 N·m (18 lb ft).
component life.
3. If necessary, install the bolt and bracket (10) on the
cylinder block. Tighten the bolt to a torque of
1. Use Tooling (C) to ensure that the No. 1 cylinder is 44 N·m (32 lb ft).
Testing and Adjusting, “Fuel Injection Timing - 4. Install bolt (11) and nut (13).
Check”.
Note: Ensure that the mating surfaces of the fuel
Note: Install Tooling (A) through the camshaft gear. injection pump gear and the shaft of the fuel injection
Install Tooling (B) through the crankshaft web. pump are clean. Lubricate the threads of the shaft for
the fuel injection pump. The nut must turn freely until
contact is made with the fuel injection pump gear.
12 RENR2433-04
5. Position fuel injection pump gear (8) on the shaft of 9. Loosen bolt (6). Move spacer (5) in order to
the fuel injection pump. Install the washer and nut prevent bolt (6) from tightening against the shaft of
(7). Rotate the fuel injection pump gear in a the fuel injection pump. Tighten bolt (6) to a torque
counterclockwise direction in order to remove the of 12 N·m (106 lb in).
backlash. Tighten nut (7) to a torque of 24 N·m
(17 lb ft). Note: Spacer (5) must be installed and bolt (6) must
be tightened in order to prevent the bolt from
contacting the shaft of the fuel injection pump.
10. Tighten nut (7) to a torque of 88 N·m (65 lb ft).

11. Remove Tooling (A) and Tooling (B).
6. Connect the wiring harness assembly to engine

shutoff solenoid (4).
7. Connect the wiring harness assembly to cold start
advance unit (3).
8. Connect tube assembly (2) to the fuel injection
pump. Connect tube assembly (1) to the fuel
injection pump.
RENR2433-04 13
End By:
a. Install the front cover. Refer to Disassembly
Install”.
b. Install the crankshaft pulley. Refer to
c. Install the fuel injection lines. Refer to
d. Install the air compressor, if equipped. Refer to
Disassembly and Assembly, “Air Compressor -
Remove and Install”.
i05570925
2. Use Tooling (D) in order to lubricate O-ring seal
Fuel Injection Pump - Install (10). Install a new O-ring seal (10) onto the fuel
injection pump.
(Delphi DP210)
3. Install new washers to bolts (13).
SMCS Code: 1251-012
4. Align the holes in the fuel injection pump with the
holes in the front housing. Install the fuel injection
Installation Procedure pump to the housing.
Table 6
Required Tools Note: The fuel injection pump should be supported
by hand until the bolts are installed.
5. Install bolts (13). Tighten bolts (13) to a torque of
22 N·m (16 lb ft).
6. Position support bracket (11) onto the cylinder
C 9U-6198 Crankshaft Turning Tool 1 block. Install bolt (15) finger tight.
D 1U-6396 O-Ring Assembly Compound 1 7. Install bolt (12) and nut (14) finger tight.
8. Tighten bolt (12) and nut (14) to a torque of 22 N·m
NOTICE (16 lb ft). Tighten bolt (15) to a torque of 44 N·m
Keep all parts clean from contaminants. (32 lb ft).
Contaminants may cause rapid wear and shortened Note: Ensure that the fuel injection pump is not
component life. stressed as the bolts for the bracket are tightened.

Testing and Adjusting, “Fuel Injection Timing -
Check”.

Install Tooling (B) through the crankshaft web.
14 RENR2433-04
Note: Spacer (6) must be correctly positioned and

bolt (5) must be tightened in order to prevent the bolt
from contacting the shaft of the fuel injection pump.

injection pump gear and the shaft of the fuel injection
pump are clean. Lubricate the threads of the shaft for Illustration 24 g00992965
contact is made with the fuel injection pump gear. 14. Tighten nut (8) to a torque of 88 N·m (65 lb ft).
9. Position fuel injection pump gear (9) on the shaft of 15. Remove Tooling (A) and Tooling (B).
the fuel injection pump. Install the washer and nut End By:
(8). Rotate the fuel injection pump gear in a
counterclockwise direction in order to remove the a. Install the front cover. Refer to Disassembly
backlash. Tighten nut (8) to a torque of 24 N·m and Assembly, “Front Cover - Remove and
Install”.
(17 lb ft).
c. Install the fuel injection lines. Refer to
d. Install the air compressor, if equipped. Refer to
i02291815
Turbocharger - Remove
SMCS Code: 1052-011
10. Connect the harness assembly to timing advance Removal Procedure

solenoid (7).
NOTICE
11. Connect harness assembly (2). Connect fuel line Keep all parts clean from contaminants.
(3).
12. Connect fuel return line (1). Connect tube component life.
assembly (4) to the fuel injection pump.
13. Loosen bolt (5). Move spacer (6) in order to
prevent bolt (5) from tightening against the shaft of
the fuel injection pump. Tighten bolt (5) to a torque
of 12 N·m (106 lb in).
RENR2433-04 15
NOTICE
and mandates.
1. Thoroughly clean the outer surfaces of the

turbocharger (1).
2. Loosen the hose clamps and remove the air inlet
hose at the turbocharger compressor housing.
Note: The exhaust elbow is an option.
3. Remove the exhaust pipe from the turbocharger
outlet or remove the exhaust pipe from the 9. Remove the banjo bolt (10). Remove the oil supply
exhaust elbow, if equipped. Refer to the OEM tube assembly (12) and the washers (11) from the
provided information for the correct procedure in turbocharger. Discard the washers (11). If
order to remove the exhaust pipe. necessary, remove the oil supply tube assembly
(12) from the cylinder block and discard the
washers.
10. Remove the setscrews (17). Remove the oil drain
tube assembly (18) from the turbocharger.
Remove the gasket (16) and discard the gasket. If
necessary, remove the oil drain tube assembly
from the cylinder block and discard the gasket.
11. If necessary, remove the studs (8) from the
turbocharger housing.
12. Remove the nuts (15). Remove the turbocharger
(7). Remove the gasket (9). Discard the gasket (9).
If necessary, remove the studs (14) from the
exhaust manifold.
Note: Do not use the actuator rod of wastegate (13)
4. Remove the setscrews (5) from the exhaust elbow to lift the turbocharger.
(3), if equipped.
5. Remove the setscrews (6) and remove the bracket
(4) from the cylinder block.
6. If equipped, remove the exhaust elbow (3) from the
exhaust adapter (1).
7. Remove the nuts (2) and remove the exhaust
adapter (1) from the turbocharger.
8. Place a suitable container below the turbocharger
(1) in order to collect any spillage of oil.
16 RENR2433-04
13. Plug the oil supply and the oil drain ports of the Note: Do not use any sealant on the gasket.
turbocharger. Install covers on the manifold ports.
4. Position the turbocharger (7) on the exhaust
i02291816 manifold.
5. Apply Tooling (A) to the threads of studs (14).
Turbocharger - Install Install the nuts (15). Tighten the nuts to a torque of
47 N·m (35 lb ft).
SMCS Code: 1052-012
6. Lubricate the bearing housing with clean engine
Installation Procedure oil.
Table 7 7. Inspect the oil hose assemblies (12 and 18). If
Required Tools necessary, replace the hose assemblies.
Tool Part Number Part Description Qty Note: The top flange of the oil drain tube assembly
A 5P-3931 Anti-Seize Compound - (18) is secured to the turbocharger with 6 mm
setscrews (17). The bottom flange of the oil drain
tube assembly (18) is secured to the cylinder block
NOTICE with 8 mm setscrews.
8. Position a new gasket (16) and the oil drain tube
Contaminants may cause rapid wear and shortened assembly (18) on the bottom of the turbocharger.
component life. Install the setscrews (17). Tighten the setscrews to
a torque of 9 N·m (80 lb in).
1. Remove all of the plastic plugs from all of the ports 9. If necessary, install a new gasket and the oil drain
of the turbocharger. Clean the mating surfaces of tube assembly (18) to the cylinder block. Tighten
the exhaust manifold and the turbocharger. Clean the setscrews to a torque of 22 N·m (16 lb ft).
the mating surfaces of turbocharger and the oil
supply tube assembly and the oil drain tube 10. Position new washers (11) and the oil supply
assembly. tube assembly (12) on the turbocharger. Install the
banjo bolt (10). Tighten the banjo bolt to a torque
2. Ensure that the turbocharger inlet and outlet ports of 22 N·m (16 lb ft).
are clean and free from restrictions. The
turbocharger shaft must rotate freely. Note: Ensure that the oil supply tube assembly (12)
does not come into contact with any other component
when the assembly is installed onto the engine.
11. If necessary, install new washers and the oil

supply tube assembly (12) to the cylinder block.
Tighten the banjo bolt to a torque of 22 N·m
(16 lb ft).
12. If necessary, install the studs (8) in the
turbocharger housing.
3. If necessary, install the studs (14) in the exhaust

manifold. Install gasket (9) over the studs.
RENR2433-04 17
18. Position the exhaust pipe on the exhaust elbow

or onto the exhaust adapter (1). Refer to the OEM
information for the correct procedure in order to
install the exhaust pipe.
i02291817
Exhaust Manifold - Remove

and Install
SMCS Code: 1059-010
Removal Procedure
Illustration 28 g00975635 Start By:
a. Remove the turbocharger. Refer to
13. Position the exhaust adapter (1) on the studs (8). Disassembly and Assembly, “Turbocharger -
Install the nuts (2). Do not tighten the nuts at this Remove”.
time.
Note: The exhaust elbow is an option for this engine.
14. If equipped, install the exhaust elbow (3) onto the

exhaust adapter (1). Position the bracket (4) on
the cylinder block and install the setscrews (6).
15. Install the setscrews (5) in order to secure the
exhaust elbow (3) to the bracket (4).
16. Tighten the three nuts (2) finger tight. Tighten the
nuts in the same sequence to a torque of 25 N·m
(18 lb ft).
17. Ensure that there is no restriction in the inlet
hose. Position the air inlet hose on the
turbocharger compressor housing. Install the hose
clamps. Tighten the clamps to a torque of 5 N·m
1. Remove the setscrews (1) in reverse numerical
(44 lb in).
order. Refer to Illustration 29 . This will help
Note: The air inlet hose has a reflective heat shield prevent distortion of the exhaust manifold.
that partially covers the hose. The reflective heat
2. Remove the exhaust manifold from the cylinder
shield must be installed toward the engine. The
reflective heat shield must be kept clean and free head and the exhaust manifold gasket. Discard
from dust, oil or paint. the exhaust manifold gasket.
Note: Use a solution of water and 5 % soap to install Installation Procedure

a new air inlet hose. Do not use oil or grease. Table 8
Required Tools
Guide Bolt
A - 2
(M10 X 1.5 by 100 mm)
Note: Improper installation of the exhaust manifold

can result in a cracked exhaust manifold. The
setscrews that secure the exhaust manifold must be
tightened in the correct sequence and to the correct
torque.
18 RENR2433-04
Start By:
a. Remove the rocker shaft assembly. Refer to
Disassembly and Assembly, “Rocker Shaft and
Pushrod - Remove”.
NOTICE
component life.
Note: The following procedure should be adopted in

order to remove the valve springs when the cylinder
head is still installed onto the cylinder block. Refer to
Illustration 30 g00951297 Disassembly and Assembly Manual, “Inlet and
Exhaust Valves - Remove and Install” for the correct
1. Install Tooling (A) in the cylinder head in Hole (X). procedure that should be used to remove the valve
springs from a cylinder head that has been removed
Note: Do not use any sealant on the exhaust from the cylinder block.
manifold gaskets.
Note: Before you begin the removal of the valve
2. Position a new exhaust manifold gasket on the springs, refer to Specifications, “Cylinder Head
Tooling (A) in the cylinder head. Position the Valves” for appropriate information on the valve
exhaust manifold on the Tooling (A). Install the springs.
setscrews (1) finger tight in order to secure the
1. Ensure that the piston is at the top center position
exhaust manifold to the cylinder head.
before the valve keepers are removed from the
3. Remove the Tooling (A). Install the remaining valve. Failure to ensure that the piston is at top
setscrews (1) and tighten the setscrews evenly to dead center may allow the valve to drop into the
a torque of 33 N·m (24 lb ft). Tighten the cylinder block. Use the following procedure in
setscrews in the sequence that is shown in order to find the top center position for the piston.
Illustration 30 .
NOTICE
End By: Do not turn the crankshaft while the valve springs are
removed.
a. Install the turbocharger. Refer to Disassembly
and Assembly, “Turbocharger - Install”.
i02291819
Inlet and Exhaust Valve

Springs - Remove and Install
SMCS Code: 1108-010
Removal Procedure
Table 9
Required Tools
A 9U-6195 Valve Spring Compressor 1
B 9U-6198 Crankshaft Turning Tool 1

RENR2433-04 19
NOTICE
Do not turn the crankshaft while the valve springs are
removed.
Table 10
Required Tools
B 9U-6198 Crankshaft Turning Tool 1
NOTICE
Personal injury can result from being struck by component life.
parts propelled by a released spring force.
Make sure to wear all necessary protective
equipment.
Follow the recommended procedure and use
all recommended tooling to release the spring
force.
a. Install the Tooling (A).
NOTICE
Ensure that the valve spring is compressed squarely
or damage to the valve stem may occur.
b. Compress the valve spring in order to open the

valve. Do not compress the valve spring
sufficiently so that the valve keepers (1) could Illustration 32 g00937233
be removed from the recess in the valve stem.
c. Turn the crankshaft until the piston touches the
valve.
Improper assembly of parts that are spring
d. Continue to turn the crankshaft until the valve loaded can cause bodily injury.
stem is at the highest point. The piston is now at
the top center position. Release the pressure of To prevent possible injury, follow the established
assembly procedure and wear protective
the Tooling (A) when the piston is at the top
equipment.
center position.
2. Use Tooling (A) in order to compress valve spring 1. Place the new valve spring into position.
(3). Remove valve keepers (1). 2. Install the valve spring retainer (2).
3. Carefully release the pressure on the Tooling (A).
Remove the valve spring retainer (2) and the valve NOTICE
spring (3). or damage to the valve stem may occur.
Note: If you are replacing all of the valve springs, the
procedure can be done on two cylinders at the same 3. Install the Tooling (A). Compress the valve spring
time. The procedure can be done on cylinder 1 and (3).
cylinder 4, and on cylinder 2 and cylinder 3.
4. Install valve keepers (1).
20 RENR2433-04
5. Carefully release the pressure on the Tooling (A).

Remove the Tooling (A). Rotate the crankshaft by
approximately 45 degrees in order to lower the
piston. Strike the top of the valves with a soft
hammer in order to ensure that the valve keepers
are properly installed.
Note: If you are replacing all of the valve springs the

procedure can be done on two cylinders at the same
time. The procedure can be done on cylinder 1 and
cylinder 4, and on cylinder 2 and cylinder 3.
End By:
a. Install the rocker shaft assembly. Refer to
Disassembly and Assembly, “Rocker Shaft and
Pushrod - Install”.
i02291880
Inlet and Exhaust Valves -

Remove and Install Illustration 33 g01015306
Typical example
SMCS Code: 1105-010
1. Clean the bottom face of the cylinder head. Use a
Removal Procedure dial indicator to check the depth of the valves
Table 11 below the face of the cylinder head before the
Required Tools valve springs are removed. Refer to the illustration
33 and refer toSpecifications, “Cylinder Head
Valves” for the correct dimensions.
2. Place an index mark on the heads of the inlet
valves and the exhaust valves for installation
Start By: purposes.
a. Remove the cylinder head assembly. Refer to
Disassembly and Assembly, “Cylinder Head -
Remove”.
Note: Ensure that the machined face of the cylinder
head is kept on a clean, soft surface in order to
prevent damage to the machined surface.
NOTICE
component life.
RENR2433-04 21
6. Remove the valve spring retainer (2).

7. Remove the valve spring (3).
8. Remove the valve stem seal (4) for the inlet valve
or the exhaust valve.
9. Remove the inlet valve (5) or the exhaust valve (6).
10. Repeat Step 3 to Step 9 for each inlet valve (7)
and for each exhaust valve (8).
Table 12
Required Tools
Illustration 34 g00936484 Tool Part Number Part Description Qty
NOTICE
component life.
NOTICE
or damage to the valve stem may occur.
3. Use the Tooling (A) to compress spring (3).

4. Remove the valve keeper (1). Illustration 36 g00953724
1. Carefully clean the bottom face of the cylinder

head. Ensure that there is no debris in the inlet
The valve spring keepers can be thrown from the and exhaust ports. Also ensure that there is no
valve when the valve spring compressor is re- debris in the coolant passages and in lubrication
leased. Ensure that the valve spring keepers are passages. Inspect the cylinder head. Refer to the
properly installed on the valve stem. To help pre- Testing and Adjusting Manual, “Cylinder Head
vent personal injury, keep away from the front of
the valve spring keepers and valve springs dur- Inspect” for further information.
ing the installation of the valves.
5. Carefully release the pressure on the Tooling (A)

and remove the Tooling (A).
22 RENR2433-04
2. Inspect all of the valve seats for wear and for

damage. Refer to the Specifications Manual,
“Cylinder Head Valves” for further information.
Also refer to this Disassembly and Assembly
Manual, “Inlet and Exhaust Valve Seat Inserts -
Remove and Install” and refer to Testing and
Adjusting Manual, “Valve Depth - Inspect ” for
further information. Replace any worn parts.
3. Inspect all of the valve guides for wear and for
damage. Refer to the Specifications Manual,
“Cylinder Head Valves” for further information.
Also refer to this Disassembly and Assembly
Manual, “Inlet and Exhaust Valve Guides -
Remove and Install” and refer to Testing and Illustration 37 g00936484
Adjusting Manual, “Valve Guide - Inspect” for
further information. Replace any worn parts.
4. Inspect the valves if the valves are not
replacement parts. Refer to the Specifications The valve spring keepers can be thrown from the
Manual, “Cylinder Head Valves” for further valve when the valve spring compressor is re-
information. leased. Ensure that the valve spring keepers are
properly installed on the valve stem. To help pre-
5. Lubricate the stem of the inlet valve (5) and the vent personal injury, keep away from the front of
stem of the exhaust valve (6) with clean engine oil. the valve spring keepers and valve springs dur-
ing the installation of the valves.
6. Install inlet valve (5) and exhaust valve (6) in the
respective positions.
NOTICE
7. Carefully turn over the cylinder head and ensure Ensure that the valve spring is compressed squarely
that all of the valves remain in place. Place the or damage to the valve stem may occur.
machined surface of the cylinder head onto a
clean, soft surface.
12. Use the Tooling (A) to compress the valve spring
Note: The valve guide must be clean and dry before (3).
installing the valve stem seal. 13. Install the valve keeper (1).
8. Install a new valve stem seal (4) for the inlet valve 14. Carefully release the pressure on Tooling (A) and
or the exhaust valve on the valve guide. remove Tooling (A). Strike the top of the valves
9. Inspect the valve springs (3) for wear and for the with a soft hammer in order to ensure that the
correct installed length. Refer to the Specifications valve keepers are properly installed.
Manual, “Cylinder Head Valves ” for further 15. Repeat Step 5 to Step 14 for all of the valves.
information on the correct installed length of the
valve springs (5). Replace any worn parts. 16. Use a dial indicator to check the depth of the new
valves below the face of the cylinder head. Refer
10. Install the valve spring (3). to Specifications, “Cylinder Head Valves” for more
11. Install the valve spring retainer (2). information on inlet valves and exhaust valves. If
the depth of the new valves is below the correct
depth, the valve seat inserts must be replaced.
Refer to Disassembly and Assembly, “Inlet and
Exhaust Valve Seat Inserts - Remove and Install”.
RENR2433-04 23
End By: 3. Remove the valve seat inserts. Refer to

Disassembly and Assembly, “Inlet and Exhaust
a. Install the cylinder head assembly. Refer to Valve Seat Inserts - Remove and Install”.
Install”.
i02292376
Table 14
Required Tools
Inlet and Exhaust Valve Guides Tool Part Number Part Description Qty
- Remove and Install A 157-3722 Valve Guide Driver 1
SMCS Code: 1104-010 B 9U-6220 Stop Collar 1
C 157-3720 Valve Seat Cutter 1

Removal Procedure
Table 13
Required Tools NOTICE
A 157-3722 Valve Guide Driver 1 component life.
Start By:
a. Remove the inlet valves and the exhaust valves.
Exhaust Valves - Remove and Install”.
NOTICE
component life.
Typical example
1. Clean the parent bores in the cylinder head for all

of the appropriate valve guides (4).
2. Put the valve guide in position. Carefully tap the
valve guide in order to start the installation. Use
Tooling (A) and Tooling (B) to seat the valve guide
in the cylinder head.
3. Check the protrusion of the valve guides. The
valve guides should protrude 12.35 to 12.65 mm
Typical example (0.4862 to 0.4980 inch) above the valve spring
recess.
1. Use Tooling (A) in order to remove the valve
guides from the cylinder head. 4. Repeat the procedure to install the remaining valve
guides.
2. Repeat the procedure for the remaining valve
guides. 5. Install the valve seat inserts. Refer to Disassembly
and Assembly, “Inlet and Exhaust Valve Seat
Note: When new valve guides are installed, new Inserts - Remove and Install”.
valves and new valve seat inserts must be installed.
24 RENR2433-04
Note: After installing the valve guides and valve seat

inserts, the valve guides must be reamed and the
valve seat inserts must be cut to the finished
diameter. The valve guides and valve seat inserts are
cut and reamed in one operation. This procedure
ensures the concentricity of the valve seat to the
valve guide in order to create a good seal. Refer to
Specifications, “Cylinder Head Valves” for the
finished diameter of the valve guides and valve seat
inserts.
6. Position Tooling (C) into the valve guide. Carefully

turn the handle in a clockwise direction and
gradually move the reamer into the valve guide
until the valve guide is reamed to the finished size.
7. Continue to turn the handle in a clockwise direction
in order to cut the valve seat insert. Remove the
minimum amount of material in order to ensure a
good valve seat. Keep the valve seat as narrow as
possible.
8. Remove Tooling (C). Clean the debris from the Illustration 40 g00937142
valve guide and the valve seat. Typical example
End By:
1. Use the Tooling (A) in order to remove valve seat
a. Install the inlet valves and the exhaust valves. inserts from the cylinder head.
Exhaust Valves - Remove and Install”. 2. Repeat the procedure for the remaining valve seat
inserts.
i02292377
Note: When new valve seat inserts are installed, new
valves and new valve guides must be installed.
Inlet and Exhaust Valve Seat
Inserts - Remove and Install 3. Remove the valve guides. Install partially finished
valve guides. Refer to Disassembly and Assembly,
SMCS Code: 1103-010 “Inlet and Exhaust Valve Guides - Remove and
Install”.
Removal Procedure
Table 15
Table 16
Required Tools
Required Tools
166-7441 Valve Seat Extractor 1
A 157-3716 Valve Seat Driver (Exhaust) 1
9S-3095 Puller Handle 1 B
157-3717 Valve Seat Driver (Inlet) 1
Start By: C 157-3720 Valve Seat Cutter 1
a. Remove the inlet valves and the exhaust valves.

Exhaust Valves - Remove and Install”. NOTICE
NOTICE Contaminants may cause rapid wear and shortened
Keep all parts clean from contaminants. component life.
component life. Note: The inserts for the inlet valves are a larger
diameter than the exhaust valve inserts.
RENR2433-04 25
1. Use the partially finished bore of the valve guide as 5. After installing the valve guides and valve seat
a pilot bore in order to machine a recess for a new inserts, the valve guides must be reamed and the
valve seat. Refer to the Specifications Manual, valve seat inserts must be cut to the finished
“Cylinder Head Valves” for the required diameter. The valve guides and valve seat inserts
dimensions of the recess for the valve seat. are cut and reamed in one operation. This
Remove all debris from the cylinder head ports procedure ensures the concentricity of the valve
and passages. seat to the valve guide in order to create a good
seal. Refer to Specifications, “Cylinder Head
Note: If the cylinder head has been previously Valves” for the finished diameter of the valve
ground then the bottom face of valve seat must be
guides and valve seat inserts.
ground in order to ensure that the valve seat will be
installed correctly into the cylinder head. A 30 degree 6. Position the Tooling (C) into the valve guide.
chamfer must be machined to the outer edge of the Carefully turn the handle in a clockwise direction
valve seat after the back face of the valve insert has and gradually move the reamer into the valve
been ground to the correct dimensions. The 30 guide until the valve guide is reamed to the
degree chamfer must be within the tolerance of
finished size.
0.91 mm (0.036 inch) to 1.3 mm (0.051 inch). Also,
the chamfer must be inclined to the vertical face of 7. Continue to turn the handle in a clockwise direction
the valve insert. in order to cut the valve seat insert. Remove the
minimum amount of material in order to ensure a
2. Repeat the Step 1 for all of the appropriate valve
good valve seat. Keep the valve seat as narrow as
seats. possible.
Note: Do not apply any lubricant before the new 8. Remove Tooling (C). Clean the debris from the
valve seat insert is installed into the cylinder head. valve guide and the valve seat.
9. Repeat Step 6 to Step 8 in order to cut all of the
appropriate valve seats.
End By:
a. Install the inlet valves and the exhaust valves.
Exhaust Valves - Remove and Install”.
i02292381
Engine Oil Filter Base -

Remove and Install
SMCS Code: 1306-010
Typical example Removal Procedure
Table 17
3. Put the valve seat insert in position. Carefully tap Required Tools
the valve seat insert in order to start the
installation. Use the Tooling (B) to seat the valve Tool Part Number Part Description Qty
seat insert in the cylinder head. A 185-3630 Strap Wrench As 1
4. Repeat the procedure for the remaining valve seat
inserts.
NOTICE
Note: Refer to the Specifications Module for more Keep all parts clean from contaminants.
information on the valve seat inserts.
component life.
26 RENR2433-04
NOTICE
and mandates.
1. Remove all dirt, oil, and grease from the engine oil
filter assembly and from the drain plug of the
engine oil pan. Place a suitable container beneath
the drain plug of the engine oil pan.
2. Operate the engine until the engine is warm. Stop
the engine.
3. Remove the oil drain plug and the O-ring from the
engine oil pan. Drain the engine oil into the 5. Remove the engine oil filter (6) with the Tooling
container for storage or disposal. (A).
6. Remove the setscrews (4).
7. Remove the engine oil filter base (3) from the
cylinder block. Remove the gasket (2). Discard the
gasket (2).
8. If necessary, remove the adapter (7) from the
engine oil filter base. Remove the O-ring seal and
plug (6) from the engine oil filter base. If equipped,
remove the oil sampling valve.
Table 18
Required Tools
Tool Part Number Part Description
B 9S-3263 Thread Lock Compound
NOTICE
component life.
4. Remove the oil pressure sensor (1). Refer to
Disassembly and Assembly manual, “Engine Oil
Pressure Sensor Remove and Install”.
RENR2433-04 27
7. Clean the mating surface of the oil filter base (3) to

the oil filter element (6).
8. Lubricate the top of the O-ring on the oil filter
element (6) with clean engine lubricating oil. Spin
the new oil filter element (6) onto the adapter (7).
Tighten the oil filter element (6) by hand. Do not
use a strap wrench to tighten the oil filter element
(6).
9. Inspect the O-ring for the drain plug for the engine
oil pan. If necessary, replace the O-ring. Install the
O-ring onto the drain plug for the engine oil pan
and install the drain plug into the engine oil pan.
Tighten the drain plug to the correct torque. Refer
to this Disassembly and Assembly Manual,
“Engine Oil Pan - Remove and Install” for the
correct torque. Remove the containers beneath
the engine oil pan and beneath the oil filter
housing.
10. Fill the lubrication system with engine oil. Refer
to Operation and Maintenance Manual, “Refill
1. Clean the oil passages within the oil filter base (3). Capacities” for the lubrication system capacity of
Clean the mating surfaces of the cylinder block the engine.
and the engine oil filter base (3).
i02293092
2. Inspect the adapter (7) if the adapter was removed
from the oil filter base (3). Apply the Tooling (B) to Engine Oil Cooler - Remove
the thread of the adapter. Install the adapter (7)
into the oil filter base (3). Tighten the adapter to a SMCS Code: 1378-011
torque of 28 N·m (20.6 lb ft).
3. Inspect the O-ring for the plug (5) if the plug was
Removal Procedure
removed from the oil filter base (3). If necessary,
NOTICE
replace the O-ring. Install the O-ring and the plug Keep all parts clean from contaminants.
(5) into the oil filter base (3). Tighten the plug (5) to
a torque of 12 N·m (8.8 lb ft). If equipped, install Contaminants may cause rapid wear and shortened
the oil sampling valve. Tighten the oil sampling component life.
valve to a torque of 12 N·m (8.8 lb ft).
Note: New setscrews (4) have sealant on the first NOTICE
13 mm (0.5 inch) of the threads. In order to reuse the Care must be taken to ensure that fluids are con-
old setscrews (4), clean the old sealant from the nance, testing, adjusting, and repair of the product.
setscrews and apply Tooling (B) to the setscrews. Be prepared to collect the fluid with suitable contain-
Note: Do not use sealants on the gasket (2). bling any component containing fluids.
4. Position a new gasket (2) and the engine oil filter Refer to Special Publication, NENG2500, “Dealer
base (3) on the cylinder block. Install the Service Tool Catalog” for tools and supplies suitable
setscrews (4) in order to secure the engine oil filter to collect and contain fluids on Cat products.
base (3).
5. Evenly tighten the setscrews (4) to a torque of and mandates.
22 N·m (16.2 lb ft).
6. Install the oil pressure sensor. Refer to
Disassembly and Assembly manual, “Engine Oil
Pressure Sensor - Remove and Install”.
28 RENR2433-04
1. Drain the coolant from the engine oil cooler into a

suitable container. Drain the engine oil from the
engine oil cooler into a suitable container. Refer to
Operation and Maintenance Manual for the
procedure on draining the engine coolant and the
engine oil.
Note: Refer to Operation and Maintenance Manual,

“Refill Capacities” for the coolant capacity and the
engine oil capacity of the engine.
2. Position the engine oil cooler (2) and new seals (5)
on the housing for the engine oil cooler. Install the
setscrews (7) in order to secure the engine oil
cooler to the housing.
Note: Do not use sealants on the gasket (1).
3. Position the housing for the engine oil cooler (3)

and a new gasket (1) on the cylinder block. Install
Illustration 45 g00952614 the setscrews (4) and the setscrews (6) in order to
secure the housing for the engine oil cooler to the
2. Remove the setscrews (6). Remove the setscrews cylinder block.
(4).
4. Tighten all of the setscrews (4, 6 and 7) to the
Note: Do not remove the setscrews (7) at this time. correct torque. Refer to the Torque specifications
Manual, “Standard Torques for Metric Fasteners”
3. Remove the housing for the engine oil cooler (3) for further information.
4. Remove the setscrews (7). Remove the engine oil “Refill Capacities” for the cooling system capacity
cooler (2) and the seals (5) from the housing for and the lubrication system capacity of the engine.
the engine oil cooler (3). Discard the seals (5).
5. Remove the gasket (1) from the housing for the
engine oil cooler and the cylinder block. Discard
the gasket (1).
i02293093
Engine Oil Cooler - Install

SMCS Code: 1378-012
NOTICE
component life.
1. Clean the mating surfaces of the housing for the

engine oil cooler and the cylinder block.
RENR2433-04 29
5. Fill the cooling system with coolant. Fill the Installation Procedure
lubrication system with engine oil.
NOTICE
i01888684
Engine Oil Relief Valve - component life.
Remove and Install
(Engine with Balancer Group) 1. Clean the spring and the plunger of the engine oil
relief valve. Lubricate the spring and the plunger
SMCS Code: 1315-010 with clean engine oil.
Removal Procedure
Start By:
a. Remove the engine oil pan. Refer to
Disassembly and Assembly, “Engine Oil Pan -
NOTICE
component life.

loaded can cause bodily injury.
To prevent possible injury, follow the established
equipment.
2. Install plunger (4) and spring (3) in balancer group

(1).
3. Install plug (2). Tighten the plug to a torque of
22 N·m (16 lb ft).
Personal injury can result from being struck by

equipment.
Follow the recommended procedure and use all
recommended tooling to release the spring force.
1. Remove plug (2). Remove spring (3) and plunger

(4) from balancer group (1).
2. Check the spring and the plunger for wear or for
other damage. The plunger (4) must slide easily in
the balancer group.
30 RENR2433-04
End By: 2. Check the spring and the plunger for wear or for
other damage. The plunger (4) must slide easily in
a. Install the engine oil pan. Refer to Disassembly the engine oil pump assembly.
and Assembly, “Engine Oil Pan - Remove and
Install”.
i02317428
NOTICE
Engine Oil Relief Valve -
Remove and Install component life.
(Engine without Balancer Group)
1. Clean the spring and the plunger of the engine oil
SMCS Code: 1315-010
relief valve. Lubricate the spring and the plunger
with clean engine oil.
Removal Procedure
Start By:
NOTICE
component life.

equipment.
2. Install plunger (4) and spring (3) in engine oil pump

Illustration 49 g00959674 assembly (1).
3. Install plug (2). Tighten the plug to a torque of
22 N·m (16 lb ft).

equipment.
1. Remove plug (2). Remove spring (3) and plunger

(4) from engine oil pump assembly (1).
RENR2433-04 31
End By:
a. Install the engine oil pan. Refer to Disassembly
Install”.
i02293101
Engine Oil Pump - Remove

(Engines Without a Balancer)
SMCS Code: 1304-011
Removal Procedure
Start By: Illustration 51 g01147907
a. Remove the oil pan. Refer to Disassembly and 1. Remove the setscrews (3) and the suction pipe (4).
Assembly, “Engine Oil Pan - Remove and
Install”. 2. Remove the setscrews (1). Remove the assembly
of the engine oil pump (2) from the cylinder block.
Note: This procedure is for the removal of the engine
oil pump on engines that are not equipped with a
balancer. Refer to this Disassembly and Assembly
Manual, “Balancer Group - Remove” for information
on the removal of the engine oil pump on engines
that are equipped with a balancer.
NOTICE equipment.
Contaminants may cause rapid wear and shortened recommended tooling to release the spring force.
component life.
3. If necessary, remove the pressure relief valve (5)
from the assembly of the engine oil pump (4).
NOTICE Refer to this Disassembly and Assembly Manual,
Care must be taken to ensure that fluids are con- “Engine Oil Relief Valve - Remove and Install”.
and mandates.
4. Remove the setscrews (8). Remove engine oil

pump (9).
32 RENR2433-04
5. If necessary, remove the setscrews and remove

the front cover assembly from the engine oil pump
(7) in order to inspect the components within the
engine oil pump.
i02293102
Engine Oil Pump - Install

(Engines Without a Balancer)
SMCS Code: 1304-012
Note: This procedure is for the installation of the Illustration 53 g00956778
engine oil pump on engines that are not equipped
with a balancer. Refer to this Disassembly and 3. Install the engine oil pump (9) into the assembly of
Assembly Manual, “Balancer Group - Install” for the engine oil pump (2). Install the setscrews (8).
information on the installation of the engine oil pump Tighten the setscrews to a torque of 9 N·m
on engines that are equipped with a balancer. (80 lb in).
4. Fill engine oil pump (9) with clean engine oil.
NOTICE
Keep all parts clean from contaminants. 5. Position the assembly of the engine oil pump (2)
Contaminants may cause rapid wear and shortened against the cylinder block. Ensure that dowel pin
component life. (10) and hollow dowel (11) are correctly located in
the cylinder block.
6. Install the setscrews (1). Tighten the setscrews to
NOTICE
If any of the parts on the engine oil pump are worn or a torque of 44 N·m (32 lb ft).
damaged, the entire pump must be replaced. 7. Check the backlash between the idler gear of the
oil pump and the crankshaft gear. Refer to the
1. Clean all of the internal components of the oil Specifications Manual, “Gear Group - Front” for
pump if the front cover of the oil pump was further information.
previously removed in order to inspect the internal
components. Check the internal components for
wear and for other damage. Check the clearance
between the outer rotor of the oil pump and the oil
pump body. Check the clearance between the
outer rotor and the inner rotor. Check the end play
movement of the rotor. Refer to the Systems
Operation/Testing and Adjusting Manual, “Engine
Oil Pump - Inspect”. Replace the engine oil pump
if any of the components are worn or damaged.
2. Lubricate the inner rotor and the outer rotor of the
engine oil pump with clean engine lubricating oil.
Install the front cover of the engine oil pump onto
the body of the oil pump. Install the setscrews and
tighten the setscrews in order to secure the front
cover to the body.
RENR2433-04 33
NOTICE
and mandates.
Illustration 54 g01147909 1. Drain the coolant from the cooling system into a
suitable container for storage or disposal.
“Refill Capacities” for the coolant capacity of the
Improper assembly of parts that are spring engine.
2. Loosen the clamps and remove the hose from the
assembly procedure and wear protective water pump inlet.
equipment.
8. If the pressure relief valve (5) was removed, install

the pressure relief valve. Refer to this
Disassembly and Assembly Manual, “Engine Oil
Relief Valve - Remove and Install” for further
information.
9. Position the suction pipe (4) and install the
setscrews (3).
End By:
a. Install the oil pan. Refer to Disassembly and
Assembly, “Engine Oil Pan - Remove and
Install”.
i02293115
3. Remove the setscrews (3) that fasten the water
Water Pump - Remove and pump (4) to the front housing (1).
Install 4. If necessary, tap the water pump with a soft
hammer in order to loosen the water pump.
SMCS Code: 1361-012; 1361-011
5. Remove water pump (4). Remove the gasket (2)
Removal Procedure from the front housing and the water pump.
Discard the gasket (2).
Start By:
a. Remove the fan. Refer to Disassembly and
Assembly, “Fan - Remove and Install”. Table 19
Required Tools
NOTICE
Keep all parts clean from contaminants. Tool Part Number Part Description Qty
A 9S-3263 Thread Lock -

component life. Guide Bolt
B - 2
(M8 X 1.25 by 70 mm)
34 RENR2433-04
6. Install the setscrews (3) that fasten the water pump

NOTICE
Keep all parts clean from contaminants. to the front housing. Do not tighten the setscrews
at this time.
component life. 7. Remove Tooling (B) and install the remaining
setscrews in order to secure the water pump to the
front housing.
1. Inspect the drive gear for the water pump for wear
or other damage. If necessary, replace the drive Note: Tighten the setscrews evenly in order to pull
gear. the water pump into the front housing.
2. Clean the joint faces of the water pump and the 8. Tighten the setscrews (3) to a torque of 22 N·m
front housing. (16 lb ft). Tighten the setscrews in the sequence
that is shown in Illustration 57 .
Note: Do not use sealant on the gasket for the water
pump. 9. Install the hose to the water pump inlet. Tighten the
hose clamps.
10. Fill the cooling system with coolant. Refer to
Operation and Maintenance, “Refill Capacities” for
the cooling system capacity.
End By:
a. Install the fan. Refer to Disassembly and
Assembly, “Fan - Remove and Install”.
i02293128
Water Temperature Regulator -

Remove and Install
Illustration 56 g00952716 SMCS Code: 1355-010
3. Install Tooling (B) in the front housing (1). Removal Procedure

4. Install a new gasket (2) on the front housing.
NOTICE
component life.
NOTICE
5. Install the water pump (4) on the front housing. and mandates.
Note: New setscrews have sealant on the first
13 mm (0.5 inch) of the threads. In order to reuse the 1. Drain the coolant from the cooling system to a
old setscrews, clean the old sealant from the level below the water temperature regulator into a
setscrews and apply Tooling (A) to the setscrews. suitable container for storage or disposal.
RENR2433-04 35
2. Loosen the hose clamp from the upper radiator

hose and remove the upper radiator hose from the
water temperature regulator housing.
2. Position the water temperature regulator (3) in the

water temperature regulator housing. Squeeze the
retainers (A) and rotate the water temperature
regulator in order to secure the water temperature
3. Remove the setscrews (2) that hold the water
regulator to the water temperature regulator
temperature regulator housing (1) in position on
housing.
the cylinder head. Remove the water temperature
regulator housing. Remove the O-ring seal from Note: The retainers (A) must be inserted behind the
the water temperature regulator housing. Discard tabs of the water temperature regulator housing in
the O-ring. order to secure the water temperature regulator
during engine operation.
4. Squeeze the retainers (A) and rotate the water
temperature regulator in order to release the water 3. Install a new O-ring seal on the water temperature
temperature regulator from the tabs of the water regulator housing (1). Lubricate the O-ring seal
temperature regulator housing. with red rubber grease. Position the water
5. Refer to Systems Operation, Testing and temperature regulator housing on the cylinder
Adjusting, “Water Temperature Regulator - Test” head.
for the correct procedure on testing the water 4. Install the setscrews (2) that fasten water
temperature regulator. temperature regulator housing (1) to the cylinder
head.
5. Install the upper radiator hose and tighten the hose
NOTICE clamps. Refer to the Torque Specifications Manual
Keep all parts clean from contaminants. for the correct torque.
component life.
1. Clean the water temperature regulator housing.

36 RENR2433-04
6. Fill the cooling system to the proper level. Refer to 2. Remove the remaining setscrews (1) that secure
the Operation and Maintenance Manual, “Refill flywheel (2) to the crankshaft.
Capacities” for further information.
3. Remove the flywheel (2) from the engine.
i02293555
Flywheel - Remove
SMCS Code: 1156-011
Removal Procedure
Table 20
Required Tools
Part
Tool Number Part Description Qty
- Guide Bolt (1/2 inch - 20 NF by 4 2
A
inch)
B 138-7575 Link Bracket 1
4. Check the condition of the ring gear (4). Remove

NOTICE the ring gear (4) if the ring gear is worn or
Keep all parts clean from contaminants. damaged.
Contaminants may cause rapid wear and shortened Note: Identify the orientation of the ring gear (4) on
component life. the flywheel (2) and the position of the chamfer on
the teeth for the correct positioning when the new
ring gear is installed.
5. Place the flywheel (2) and the ring gear (4) on a

suitable support. Use a hammer and a chisel in
order to remove the ring gear (4) from the flywheel
(2).
i07030444
Flywheel - Install
SMCS Code: 1156-012
Table 21
Required Tools
Guide Bolt
A - 2
(1/2 inch - 20 NF by 4 inch)
Illustration 60 g01148312 B 138-7575 Link Bracket 1

Typical example
1. Remove the two setscrews and install the Tooling NOTICE

(A) as guides.
Note: The weight of the flywheel (2) is approximately component life.
54 kg (119 lb). Install the Tooling (B) in order to
support the flywheel (2) before the remainder of the
setscrews (1) are removed.
RENR2433-04 37
1. Thoroughly clean the flywheel housing. Inspect the

crankshaft rear seal for leaks. If there are any oil
leaks, refer to this Disassembly and Assembly
Manual, “Crankshaft Rear Seal - Remove” for the
correct procedure.
4. Install the Tooling (A) on the crankshaft. Install the

Tooling (B) and a suitable lifting device on flywheel
Always wear protective gloves when handling (2) and position the flywheel in the flywheel
parts that have been heated.
housing. The weight of the flywheel is
approximately 54 kg (119 lb).
Note: If ring gear (3) has been removed from
5. Install bolts (1) to flywheel (2).
flywheel (2). Identify the orientation of ring gear (3) on
the flywheel for the correct positioning when the new 6. Remove Tooling (A). Install the remaining bolts (1)
ring gear is installed. that secure flywheel (2) to the crankshaft. Tighten
the bolts (1) to a torque of 140 N·m (103 lb ft).
2. Heat the ring gear to 250 °C (480 °F) in an oven to
install the ring gear onto the flywheel. Ensure that 7. Check the alignment of flywheel (2) with the
the orientation of the ring gear is correct and crankshaft. Refer to Testing and Adjusting,
quickly install the ring gear onto the flywheel. “Flywheel - Inspect” for the correct procedure.
Note: Do not use a torch to heat the ring gear. i02293665
3. Clean flywheel (2) and ring gear (3) when the ring
gear has cooled.
Crankshaft Rear Seal -
Remove
SMCS Code: 1161-011
Removal Procedure
Start By:
a. Remove the flywheel. Refer to Disassembly
and Assembly, “Flywheel - Remove”.
NOTICE
component life.
38 RENR2433-04
Note: The following procedure assumes that the

NOTICE
Care must be taken to ensure that fluids are con- crankshaft rear seal is a replacement assembly.
nance, testing, adjusting, and repair of the product. Note: The crankshaft rear seal is lubricated. There is
Be prepared to collect the fluid with suitable contain- no need to lubricate the seal or the crankshaft flange
ers before opening any compartment or disassem- before installation.
Note: An installation sleeve (2) is supplied with the
Refer to Special Publication, NENG2500, “Dealer new housing assembly. The installation sleeve must
Service Tool Catalog” for tools and supplies suitable be in place when housing assembly is installed on
to collect and contain fluids on Cat products. the crankshaft flange in order to prevent damage to
the crankshaft rear seal during assembly.
and mandates.
NOTICE
component life.
1. Ensure that the crankshaft flange (1) is clean, dry

and free from rough metal edges. Ensure that the
face of the cylinder block and the bridge in the
crankcase are clean and dry.
Note: The crankshaft rear seal is nonserviceable. If

the crankshaft rear seal is removed, the complete
housing assembly must be replaced.
1. Remove the setscrews (1) from the housing

assembly (2).
2. Remove the housing assembly (2) from the
cylinder block. Discard the housing assembly (2).
2. Remove the packaging from the new assembly of
i02293676
the crankshaft rear seal (3). Ensure that the plastic
sleeve (2) is squarely installed within the seal of
Crankshaft Rear Seal - Install the assembly of the crankshaft rear seal (3). The
SMCS Code: 1161-012 plastic sleeve (2) is included in order to protect the
lip of the seal as the lip is pushed over the
crankshaft flange (1).
Table 22
Required Tools
A FT-2806 Alignment Tool 1
Note: The crankshaft rear seal and the housing for

the crankshaft rear seal are manufactured as a one-
piece assembly. The assembly of the crankshaft rear
seal uses ten setscrews in order to fasten the
assembly to the cylinder block.
RENR2433-04 39
Typical example
3. Place the assembly of the crankshaft rear seal (3)

over the crankshaft flange (1) and engage the
plastic sleeve (2) onto the crankshaft flange.
4. Ensure that the plastic sleeve (2) is engaged onto
the crankshaft flange (1). Push the assembly of
8. Tighten the setscrews (1) in numerical order to a
the crankshaft rear seal (3) evenly and push the
torque of 22 N·m (16 lb ft). Do not tighten the
assembly smoothly onto the crankshaft flange (1)
setscrews (X) at this time.
until the assembly is against the cylinder block.
During this process, the plastic sleeve (2) will be 9. Remove the Tooling (A). Tighten the setscrews (X)
forced out of the assembly of the crankshaft rear to a torque of 22 N·m (16 lb ft).
seal (3). Discard the plastic sleeve (2). End By:
5. Rotate the assembly of the crankshaft rear seal (3)
a. Install the flywheel. Refer to Disassembly and
in order to align the setscrew holes in the Assembly, “Flywheel - Install”.
assembly with the setscrew holes in the rear face
of the cylinder block. i05322247
6. Install the setscrews (5) in order to position
housing assembly (3) to the cylinder block. Do Not Crankshaft Wear Sleeve (Rear)
tighten the bolts. - Remove
7. Place the Tooling (A) over housing assembly (2).
SMCS Code: 1161-011-ZV
This will center the housing assembly onto the
crankshaft flange (3).
Removal Procedure
Table 23
Required Tools
242-9955 Puller 1
A
- Spacer 1
40 RENR2433-04
Start By: (Table 24, contd)

5P-8247 Hard Washer 1
a. Remove the crankshaft rear seal. Refer to
Disassembly and Assembly, “Crankshaft Rear B 438-3245 Oil Seal Locator 1
Seal - Remove and Install” for the correct
procedure. 9U-6172 Bolt 2
NOTICE
Keep all parts clean from contaminants. NOTICE
component life. Contaminants may cause rapid wear and shortened
component life.
Note: Wear sleeves are used to reclaim worn seal

surfaces or damaged seal surfaces. Wear sleeves Note: Wear sleeves are used to reclaim worn seal
are not original equipment. The wear sleeve is surfaces or damaged seal surfaces. Wear sleeves
supplied with a crankshaft rear seal that has a larger are not original equipment. The wear sleeve is
internal diameter than a standard crankshaft rear supplied with a crankshaft rear seal that has a larger
seal. A standard crankshaft rear seal cannot be used internal diameter than a standard crankshaft rear
if a wear sleeve is installed. seal. A standard crankshaft rear seal cannot be used
if a wear sleeve is installed.
1. Ensure that the crankshaft is thoroughly clean and

dry. Remove any areas of raised damage.
2. Lubricate the inner surface of the crankshaft wear
sleeve with clean engine oil.
Typical example
1. Use Tooling (A) in order to remove crankshaft wear

sleeve (1) from crankshaft (2).
i05764187
Sectional view of the crankshaft, the wear sleeve,
Crankshaft Wear Sleeve (Rear) and the installation tool
- Install 3. Use Tooling (A) and Tooling (B) to install the

crankshaft wear sleeve, as follows:
SMCS Code: 1161-012-ZV
a. Align Tooling (B) with the dowels in crankshaft
Installation Procedure (2) and install Tooling (B) to the crankshaft.
Ensure the correct orientation.
Table 24
Required Tools Note: Verify that Tooling (A) will slide freely over
Tooling (B).
438-3244 Oil Seal Installer 1 b. Carefully slide crankshaft wear sleeve (1) over
A Tooling (B) until the crankshaft wear sleeve
8T-0375 Bolt 1
contacts the rear of crankshaft (2).
c. Assemble Tooling (A) to Tooling (B) and install
(continued) the bolt and the washer. Ensure that the face of
RENR2433-04 41
Tooling (A) with the deep counterbore is toward 1. The weight of the flywheel housing (3) is
crankshaft wear sleeve (1). approximately 39 kg (85 lb). Use suitable lifting
equipment to support the flywheel housing (3)
d. Tighten the bolt until Tooling (A) bottoms out on
while the setscrews (1) are being removed and
Tooling (B) in order to pull crankshaft wear
while the flywheel housing is being removed.
sleeve (1) onto crankshaft (2).
e. Remove Tooling (A) and Tooling (B).
End By:
a. Install the new crankshaft rear seal that was
supplied with the crankshaft wear sleeve.
i02294250
Flywheel Housing - Remove

and Install
SMCS Code: 1157-010
Removal Procedure Illustration 70 g00977367

Table 25
Required Tools 2. Remove the setscrews (1) from the top of the
flywheel housing (3).
Part Part Description Qty
Tool
Number 3. Attach the Tooling (A) and a suitable lifting device
138-7575 Link Bracket 2
to the flywheel housing (3).
A
4. Remove the setscrews (2) that attach the flywheel
Start By: housing (3) to the cylinder block.
a. Remove the electric starting motor. Refer to 5. Remove the flywheel housing (3). If necessary, tap
Disassembly and Assembly, “Electric Starting the flywheel housing with a soft faced hammer in
Motor - Remove and Install”. order to separate the flywheel housing from the
cylinder block.
b. Remove the flywheel. Refer to Disassembly
and Assembly, “Flywheel - Remove”. Installation Procedure
Table 26
NOTICE
Keep all parts clean from contaminants. Required Tools
Contaminants may cause rapid wear and shortened Part Part Description Qty
Tool
component life. Number
A 138-7575 Link Bracket 2
NOTICE
tained during performance of inspection, mainte- NOTICE
nance, testing, adjusting, and repair of the product. Keep all parts clean from contaminants.
Be prepared to collect the fluid with suitable contain- Contaminants may cause rapid wear and shortened
ers before opening any compartment or disassem- component life.
Refer to Special Publication, NENG2500, “Dealer 1. Clean the rear face of the cylinder block and the
to collect and contain fluids on Cat products. mating surface of the flywheel housing (3).

and mandates.
42 RENR2433-04
End By:
a. Install the flywheel. Refer to Disassembly and
Assembly, “Flywheel - Install”.
b. Install the electric starting motor. Refer to
Disassembly and Assembly, “Electric Starting
Motor - Remove and Install”.
i02294252
Crankshaft Pulley - Remove

and Install
SMCS Code: 1205-010
Removal Procedure
2. If a felt seal (5) is installed, replace the felt seal.
Inspect the dowels (4) in the cylinder block that Start By:
align the flywheel housing (3). Replace the a. Remove the V-Belts. Refer to Disassembly and
dowels, if necessary. Assembly, “V-Belts - Remove and Install”.
3. The weight of the flywheel housing (3) is
NOTICE
approximately 39 kg (85 lb). Use the Tooling (A) Keep all parts clean from contaminants.
and a suitable lifting device to position the flywheel
housing (3) on the dowels (4) that are on the Contaminants may cause rapid wear and shortened
cylinder block. component life.
4. Install the setscrews (1) that attach the flywheel

housing (3) to the cylinder block.
5. Install the setscrews (2) that attach the flywheel
Tighten the setscrews (1) and the setscrews (2) to

the following torque:
M10 “8.8” . . . . . . . . . . . . . . . . . . 44 N·m ((33 lb ft))
M10 “10.9” . . . . . . . . . . . . . . . . 63 N·m ((46 lb ft))
M12 “8.8” . . . . . . . . . . . . . . . . . . 75 N·m ((55 lb ft))
M12 “10.9” . . . . . . . . . . . . . . . 115 N·m ((85 lb ft))

6. Remove Tooling (A) and the lifting device from the Illustration 72 g00952102
flywheel housing.
1. Remove the setscrews (1). Remove the thrust
7. Check the alignment of the flywheel housing with block (2).
the cylinder block. Refer to Testing and Adjusting,
“Flywheel Housing - Inspect”. 2. Remove the pulley (3) from the crankshaft (4).
RENR2433-04 43
Installation Procedure End By:

a. Install the V-Belts. Refer to Disassembly and
Assembly, “V-Belts - Remove and Install”.
i02294258
Crankshaft Front Seal -

Remove
SMCS Code: 1160-011
Removal Procedure
Start By:
a. Remove the crankshaft pulley. Refer to
Illustration 73 g00952102 Disassembly and Assembly, “Crankshaft
1. Clean the pulley (3) and clean the thrust block (2).
Inspect the pulley (3) and the thrust block (2) for NOTICE
wear and for damage. If necessary, replace any Keep all parts clean from contaminants.
damaged component. Inspect the area on the
pulley (3) that is normally in contact with the component life.
crankshaft front seal. If there is excessive wear
then a wear sleeve can be installed. Refer to this
Disassembly and Assembly Manual, “Crankshaft NOTICE
Wear Sleeve (Front) - Remove and Crankshaft Care must be taken to ensure that fluids are con-
Wear Sleeve (Rear) - Install” for further details. tained during performance of inspection, mainte-
2. Position the pulley (3) onto the crankshaft (4). Be prepared to collect the fluid with suitable contain-
3. Lubricate the threads and the shoulder of the bling any component containing fluids.
setscrews (1). Position the thrust block and install
the setscrews (1). Tighten the setscrews evenly to Refer to Special Publication, NENG2500, “Dealer
a final torque of 115 N·m (85 lb ft).
and mandates.
Note: Do not remove the crankshaft front seal at this

time if the housing (front) will also be removed. It is
easier to remove the crankshaft front seal when the
housing (front) has been removed from the engine.
Refer to this Disassembly and Assembly Manual,
“Housing (Front) - Remove”.
44 RENR2433-04
Note: This procedure assumes that the housing

(front) is still on the engine. Do not follow this
procedure if the housing (front) has been removed
from the engine. Refer to this Disassembly and
Assembly Manual, “Housing (Front) - Install” if the
housing (front) has been removed from the engine.
1. Clean the oil seal housing (8) and inspect the oil
seal housing for damage. If necessary, replace the
housing (front). Refer to this Disassembly and
Assembly Manual, “Housing (Front) - Remove and
Housing (Front) - Install”.
2. Check the face on the pulley that contacts the
crankshaft front seal for wear. If necessary, repair
Illustration 74 g01020672 the crankshaft pulley. Refer to this Disassembly
and Assembly Manual, “Crankshaft Wear Sleeve
1. Use a suitable puller (1) with three legs and install (Front) - Remove and Crankshaft Wear Sleeve
the legs under the crankshaft front seal (2). Lock (Front) - Install” for further details.
the legs into position.
Note: A sleeve (5) is attached to the new crankshaft
2. Install a suitable adapter (3) between the front seal (6). Do not remove the sleeve (5) at this
crankshaft (4) and the puller (1). time. Discard the new crankshaft front seal (6) if the
sleeve (5) is not installed on the new crankshaft front
NOTICE seal.
Ensure that the main lip is used in order to remove
the crankshaft front seal. Do not damage the edge of
the housing for the crankshaft front seal.
3. Use the puller (1) in order to remove the crankshaft

front seal (2). Discard the crankshaft front seal (2).
NOTICE
Ensure that the main lip is used in order to remove
the crankshaft front seal. Do not damage the edge of
the housing for the crankshaft front seal.
i02294259
Crankshaft Front Seal - Install Illustration 75 g01148784

SMCS Code: 1160-012 The Tooling (A) includes items 1, 2, 3, 4, 7 and 9.
Installation Procedure 3. Install the fastener plate (7) onto the front of the
crankshaft. Install the nut (1) and the pressure
Table 27
plate (2) onto the threaded bar (3).
Required Tools
Note: Do not lubricate the crankshaft front seal (6).
Do not lubricate the oil seal housing (8).
A 9U-6210 Front Seal Installer 1
NOTICE
Ensure that the lip of the crankshaft front seal that is
NOTICE spring loaded is facing toward the inside of the front
Keep all parts clean from contaminants. housing and that it is square with the bore of the
housing for the crankshaft front seal.
component life.
4. Align the assembly of the sleeve (5) and the
crankshaft front seal (6) to the front of the oil seal
housing (8).
RENR2433-04 45
5. Install the adapter (4) onto the sleeve (5).

6. Install the pressure plate (2) onto the adapter (4)
and tighten the threaded bar (3) onto the fastener
plate (7). Check the alignment of the assembly
and the crankshaft front seal (6) to the oil seal
housing (8).
7. Insert a suitable rod through the hole (9) in the
threaded bar (3) in order to prevent the threaded
rod from turning as the nut (1) is tightened. Tighten
the nut (1) in order to push the crankshaft front
seal (6) into the oil seal housing (8). Continue to
tighten the nut (1) until contact is made with the
bottom face of the oil seal housing (8).
8. Turn the sleeve (5) counterclockwise and pull the
sleeve at the same time in order to remove the 1. Remove the setscrews (3) and the setscrews (4).
sleeve from the oil seal housing (8). Remove the Remove the setscrew (5) from the front cover (1).
adapter (7).
2. Remove the front cover from the front housing.
9. Immediately install the crankshaft pulley. Refer to
this Disassembly and Assembly Manual, 3. Remove the gasket (2) from the front cover and
“Crankshaft Pulley - Remove and Install”. the front housing. Discard the gasket.
i02294796
Table 28
Front Cover - Remove and Required Tools
Install Tool Part Number Part Description Qty
SMCS Code: 1166-010 Guide Bolt

A - 2
(M8 x 1.25 x 70mm)
Removal Procedure
1. Clean all surfaces of the front housing and clean
Start By:
the front cover thoroughly.
a. Remove the water pump. Refer to Disassembly
and Assembly, “Water Pump - Remove and Note: Do not use sealant on the gasket for the front
Install”. cover.
Note: It is not necessary to remove the fan, the

crankshaft pulley or the alternator in order to remove
the front cover. The fan, the crankshaft pulley and the
alternator have been removed for illustration
purposes.
2. Position the gasket (2) on the front cover (1).
Note: The gasket is located by three locating dowels

at Location (X) on the front cover.
46 RENR2433-04
3. Install the Tooling (A) in the front housing at

NOTICE
Location (Z). Care must be taken to ensure that fluids are con-
4. Position the front cover (1) and the gasket (2) on nance, testing, adjusting, and repair of the product.
the front housing. Install the setscrews (3) in Be prepared to collect the fluid with suitable contain-
Location (Y). Install the setscrews (4) and the ers before opening any compartment or disassem-
setscrew (5). Tighten the setscrews to a torque of bling any component containing fluids.
22 N·m (16 lb ft).
End By: Service Tool Catalog” for tools and supplies suitable
a. Install the water pump. Refer to Disassembly
and Assembly, “Water Pump - Remove and Dispose of all fluids according to local regulations
Install”. and mandates.
i01875845
1. Use Tooling (A) to ensure that the No. 1 cylinder is
Idler Gear - Remove and Install at the top center compression stroke. Refer to
(Delphi DP210 Fuel Injection Position for No. 1 Piston”.
Pump) Note: Install Tooling (B) through the camshaft gear.
Install Tooling (C) into the crankshaft web.
SMCS Code: 1206
NOTICE
Removal Procedure The valve timing and the fuel injection pump timing
Table 29 will be lost if the crankshaft is rotated when the idler
gear is removed.
Required Tools
A 9U-6198 Crankshaft Turning Tool 1
B 230-6284 Timing Pin (Camshaft) 1
C 230-6283 Timing Pin (Crankshaft) 1
E 1P-0510 Driver Group 1
Start By:
b. Remove the front cover. Refer to Disassembly Illustration 78 g00992803
Install”. 2. Loosen bolt (1). Move spacer (2) in order to allow
NOTICE injection pump. Rotate and hold the fuel injection
Keep all parts clean from contaminants. pump gear in a counterclockwise direction in order
Contaminants may cause rapid wear and shortened to remove the backlash. Tighten bolt (1) to a
component life. torque of 17 N·m (13 lb ft).
Note: Bolt (1) must be tightened in order to prevent
RENR2433-04 47
NOTICE
component life.

Note: Install Tooling (B) through the camshaft gear.
Illustration 79 g00992812 NOTICE

The valve timing and the fuel injection pump timing
3. Remove nut (3) and the washer from the shaft of will be lost if the crankshaft is rotated when the idler
gear is removed.
4. Install Tooling (D) and remove fuel injection pump
gear (4).
Note: Do Not pry the fuel injection pump gear from
5. Remove bolts (7) and retaining plate (6).
2. Position idler gear hub (9) and install bolts (7) in

order to locate the idler gear hub. Tighten the bolts
in order to seat the idler gear hub.
Note: The Lubrication Hole (X) of the idler gear hub

Illustration 80 g00992822 must be positioned at the top of the idler gear hub.
6. Remove idler gear (5) and idler gear hub (9). 3. Use a suitable press and Tooling (E) to install
bushings (8) on each side of idler gear (5).
7. Use Tooling (E) and remove bushings (8) from
each side of the idler gear. 4. Remove bolts (7) from the idler gear hub. Install
idler gear (5) on idler gear hub (9).
Table 30
Note: When you install the idler gear, ensure that the
marked teeth are facing toward the front.
5. Install retainer plate (6) and bolts (7). Tighten the
bolts to a torque of 44 N·m (32 lb ft).

48 RENR2433-04
6. Check the end play for the idler gear. The end play Note: Ensure that the mating surfaces of the fuel
for the idler gear is 0.10 to 0.20 mm injection pump gear and the shaft of the fuel injection
(0.004 to 0.008 inch). pump are clean. Lubricate the threads of the shaft for
9. Position fuel injection pump gear (4) on the shaft of

the fuel injection pump. Rotate the fuel injection
pump gear in a counterclockwise direction in order
to remove the backlash. Install the washer and nut
(3). Tighten the nut to a torque of 24 N·m (17 lb ft).
7. Check the backlash between the idler gear and the

camshaft gear. The backlash for the gears is
0.052 to 0.107 mm (0.0020 to 0.0042 inch).
8. Check the backlash between the idler gear and the
crankshaft gear. The backlash for the gears is
0.064 to 0.124 mm (0.0025 to 0.0049 inch). Illustration 85 g00992803
10. Loosen bolt (1). Move spacer (2) in order to

the fuel injection pump. Tighten bolt (1) to a torque
of 12 N·m (106 lb in).
Note: Spacer (2) must be correctly positioned and
bolt (1) must be tightened in order to prevent the bolt
RENR2433-04 49
Start By:
b. Remove the front cover. Refer to Disassembly
Install”.
NOTICE
component life.
NOTICE
11. Tighten nut (3) to a torque of 88 N·m (65 lb ft). Care must be taken to ensure that fluids are con-
12. Remove Tooling (B) and Tooling (C). nance, testing, adjusting, and repair of the product.
End By: ers before opening any compartment or disassem-
and Assembly, “Front Cover - Remove and Refer to Special Publication, NENG2500, “Dealer
Install”. Service Tool Catalog” for tools and supplies suitable
Disassembly and Assembly, “Crankshaft Dispose of all fluids according to local regulations
Pulley - Remove and Install”. and mandates.
i01915654
Idler Gear - Remove and Install at the top center compression stroke. Refer to
(Bosch EPVE Fuel Injection Position for No. 1 Piston”.
Pump) Note: Install Tooling (B) through the camshaft gear.
SMCS Code: 1206
NOTICE
Removal Procedure The valve timing and the fuel injection pump timing
Table 31 will be lost if the crankshaft is rotated when the idler
gear is removed.
Required Tools

50 RENR2433-04
2. Loosen bolt (2). Remove spacer (1) in order to 6. Remove idler gear (5) and idler gear hub (9).
allow bolt (2) to tighten against the shaft of the fuel
7. Use Tooling (E) and remove bushings (8) from
each side of the idler gear.
remove the backlash. Tighten bolt (2) to a torque Installation Procedure
of 31 N·m (23 lb ft).
Table 32
Note: Bolt (1) must be tightened in order to prevent A 9U-6198 Crankshaft Turning Tool 1
NOTICE
component life.

Note: Install Tooling (B) through the camshaft gear.
3. Remove nut (3) and the washer from the shaft of Install Tooling (C) into the crankshaft web.
4. Install Tooling (D) and remove fuel injection pump NOTICE
The valve timing and the fuel injection pump timing
gear (4). will be lost if the crankshaft is rotated when the idler
gear is removed.
Note: Do Not pry the fuel injection pump gear from
5. Remove bolts (7) and retaining plate (6).

RENR2433-04 51
2. Position idler gear hub (9) and install bolts (7) in 7. Check the backlash between the idler gear and the
order to locate the idler gear hub. Tighten the bolts camshaft gear. The backlash for the gears is
in order to seat the idler gear hub. 0.052 to 0.107 mm (0.0020 to 0.0042 inch).
Note: The Lubrication Hole (X) of the idler gear hub 8. Check the backlash between the idler gear and the
must be positioned at the top of the idler gear hub. crankshaft gear. The backlash for the gears is
0.064 to 0.124 mm (0.0025 to 0.0049 inch).
3. Use a suitable press and Tooling (E) to install
bushings (8) on each side of idler gear (5).
4. Remove bolts (7) from the idler gear hub. Install
idler gear (5) on idler gear hub (9).
Note: When you install the idler gear, ensure that the
marked teeth are facing toward the front.
5. Install retainer plate (6) and bolts (7). Tighten the

bolts to a torque of 44 N·m (32 lb ft).

injection pump gear and the shaft of the fuel injection
pump are clean. Lubricate the threads of the shaft for
9. Position fuel injection pump gear (4) on the shaft of

the fuel injection pump. Rotate the fuel injection
pump gear in a counterclockwise direction in order
to remove the backlash. Install the washer and nut
6. Check the end play for the idler gear. The end play (3). Tighten the nut to a torque of 24 N·m (17 lb ft).
for the idler gear is 0.10 to 0.20 mm
(0.004 to 0.008 inch).
52 RENR2433-04
End By:
Install”.
i05324845
Housing (Front) - Remove

SMCS Code: 1151-011
Removal Procedure
10. Loosen bolt (1). Move spacer (2) in order to Start By:
the fuel injection pump. Tighten bolt (1) to a torque a. Remove the alternator. Refer to Disassembly
and Assembly, “Alternator - Remove”.
of 12 N·m (106 lb in).
Note: Spacer (2) must be correctly positioned and Disassembly and Assembly, “Crankshaft
bolt (1) must be tightened in order to prevent the bolt Pulley - Remove and Install”.
Install”.
d. Remove the engine oil pan. Refer to
e. Remove the idler gear. Refer to Disassembly
and Assembly, “Idler Gear - Remove and
Install”.
f. Remove the camshaft gear. Refer to
Disassembly and Assembly, “Camshaft Gear -
g. Remove the air compressor, if equipped. Refer
to Disassembly and Assembly, “Air
Illustration 95 g00992883 Compressor - Remove and Install”.
11. Tighten nut (3) to a torque of 88 N·m (65 lb ft). NOTICE

12. Remove Tooling (B) and Tooling (C).
component life.
RENR2433-04 53
2. Remove bolts (4) that fasten fuel injection pump

NOTICE
Care must be taken to ensure that fluids are con- (3) to the front housing.
and mandates.
3. Remove bolts (7) and bolts (9) that fasten the front
4. Remove front housing (5). Remove gasket (8) from
the cylinder block and the front housing.
5. Remove gasket (6) from the back side of the front
housing.
6. Remove the O-ring seal from the fuel injection
pump housing.
Typical example
1. Remove bolts (1). Remove bypass tube (2) from

the cylinder head. Remove the O-ring seals from
the bypass tube.
Typical Example
54 RENR2433-04
7. Remove thrust washer (10) from camshaft (11). 2. Ensure that thrust washer (10) is aligned with
hollow dowel (12). Install the thrust washer on
i05324846 camshaft (11).
3. Install a new O-ring seal on the fuel injection pump
Housing (Front) - Install housing.
SMCS Code: 1151-012
Table 33
Guide Bolt
A - 2
(M8 X 1.25 by 70 mm)
B 5P-3975 Rubber Lubricant -
NOTICE
component life. Illustration 101 g00995387
4. Install Tooling (A) in the cylinder block in Hole (Y).

1. Clean all mating surfaces thoroughly.
5. Position gasket (8) on Tooling (A). Install gasket
(6) on the back side of front housing (5).
6. Position front housing (5) on the cylinder block.
Install bolts (7) and bolts (9). Remove Tooling (A)
and install the remaining bolts in order to secure
the front housing to the cylinder block. Tighten
bolts (7) and bolts (9) finger tight at this time.
RENR2433-04 55
7. Align the front housing and the cylinder block.

Note: Ensure that the bottom of the front cover is
aligned with the bottom of the cylinder block before
the bolts are tightened. The alignment of the bottom
face of the front cover and the bottom of the cylinder
block must not exceed 0.00 ± 0.05 mm Typical example
(0.000 ± 0.002 inch).
10. Install new O-ring seals on bypass tube (2). Apply
8. Tighten bolts (7) and bolts (9) to a torque of Tooling (B) to the O-ring seals. Install the bypass
22 N·m (16 lb ft). tube in the cylinder head. Install bolts (1).

Typical Example
9. Install bolts (4) that fasten fuel injection pump (3)

to the front housing. Tighten the bolts to a torque
of 25 N·m (18 lb ft).
56 RENR2433-04
End By:
a. Install the camshaft gear. Refer to Disassembly
and Assembly, “Camshaft Gear - Remove and
Install”.
b. Install the idler gear. Refer to Disassembly and
Assembly, “Idler Gear - Remove and Install”.
c. Install the engine oil pan. Refer to Disassembly
Install”.
d. Install the front cover. Refer to Disassembly
Install”.
e. Install the crankshaft pulley. Refer to
f. Install the alternator. Refer to Disassembly and
Assembly, “Alternator - Install”.
g. Install the air compressor, if equipped. Refer to Illustration 105 g00948832
1. Remove the front cover (7). Refer to this
i02295086
Disassembly and Assembly Manual, “Front Cover
- Remove and Install”.
Accessory Drive - Remove and 2. Remove the Allen head screws (2) and (9).
Install Remove the accessory drive assembly (8) from
the rear face of the front housing (11).
SMCS Code: 1207-010
3. Remove circlip (6) from housing (8).
Removal Procedure 4. Use the Tooling (A) in order to remove the
Table 34 bearings (3) and (4) from the gear and the
housing.
Required Tools
5. Remove the O-ring (12) from the front housing (8)
and discard the O-ring.
8H-0663 Bearing Puller Gp 1
5F-7345 Screw 1
Table 35
A 126-7183 Crossblock 1
Required Tools
126-7181 Sliding Plate 1
126-7177 Puller Leg 2
B 7M-7456 Bearing Mount Compound 1
NOTICE
Keep all parts clean from contaminants. NOTICE
component life. Contaminants may cause rapid wear and shortened
component life.
RENR2433-04 57
6. Lubricate the O-ring seal with red rubber grease

and install the housing in front housing (11). Install
Allen head screws (2) and (9) to secure housing
(8) in the front housing.

Typical Example
7. Check the backlash between the idler gear and

1. Inspect the condition of the teeth and the splines of
gear (5). The backlash for the gears is
the gear (5), the bearings (3 and 4), the circlip (6),
0.11 to 0.17 mm (0.004 to 0.007 inch).
and the groove for the circlip in the front housing
(8) for wear and for damage. Replace any worn
component or any damaged component.
2. Apply a small continuous bead of the Tooling (B) to
the outer surface of the bearing (4). Support the
front face of the housing (8). Position the bearing
in the housing. Use a suitable adapter on the outer
race of the bearing and press the bearing into the
housing (8) until the bearing is against the front
face of the recess. Remove any excess bearing
mount compound.
the inner surface of the bearing (4). Support the
bearing (4). Position the small hub of the gear (5)
toward the bearing and press the gear (5) into the
bearing until the shoulder of the gear is against the
bearing. Remove any excess bearing mount
compound.
the inner surface and the outer surface of the
bearing (3). Support the bearing (4). Use a
suitable adapter on the outer race of the bearing
(3) and press the bearing into the housing and
onto the shoulder of the gear. Remove any excess
bearing mount compound.
5. Install the circlip (6) into the groove in the front
housing (8). Install a new O-ring seal (12) on
housing (8).
58 RENR2433-04
8. Install the front cover (7) on the front housing. 5. Remove the diaphragm (4) and the cap (6).
Refer to this Disassembly and Assembly Manual, Remove the spring (7).
“Front Cover - Remove and Install”.
i02295089
Crankcase Breather - Remove

and Install
SMCS Code: 1317-010
Removal Procedure

Illustration 108 g01149576 equipment.
1. Loosen the clamp (9) and remove the hose (10) 1. Install the spring (7), the cap (6), and the
from the connector (12). diaphragm (4).
2. Remove the setscrews (8) and remove the 2. Install the plate (3). Install the screws (2).
connector (12) from the cylinder head. Remove
3. Install the cover (1) on the valve mechanism cover.
the gasket (13). Remove the O-ring seal (11) from
the connector. Discard the gasket (13) and the O- 4. Install a new O-ring seal (11) on the connector
ring seal (11). (12). Install a new gasket (13) on the connector
(12). Position the connector in the valve
3. Remove the cover (1) from the valve mechanism
mechanism cover.
cover (5).
5. Install the setscrews (8). Tighten the setscrews to
a torque of 9 N·m (80 lb in).
Personal injury can result from parts and/or cov-

ers under spring pressure.
Spring force will be released when covers are
removed.
Be prepared to hold spring loaded covers as the
bolts are loosened.
4. Remove the screws (2). Remove the plate (3).

RENR2433-04 59
6. Install the hose (10) on the connector (12). Tighten

the clamp (9) to a torque of 5 N·m (44 lb in).
i02295100
Valve Mechanism Cover -

Remove and Install
SMCS Code: 1107-010
Removal Procedure
Start By:
a. Remove the heat shields, if equipped.
b. Remove the cover for the fuel injection nozzles.
Refer to this Disassembly and Assembly 1. Remove the breather tube (3) from the valve
Manual, “Fuel Injection Nozzle Cover - Remove mechanism cover (1). Refer to this Disassembly
and Install”. and Assembly Manual, “Crankcase Breather -
NOTICE
Keep all parts clean from contaminants. 2. Remove the fasteners (2). Remove valve
mechanism cover (1). Remove the gasket from the
component life. cylinder head and discard the gasket.
NOTICE
and mandates.
1. Thoroughly clean the valve mechanism cover (1).

Ensure that the groove for the gasket for the valve
mechanism cover (1) is clean and dry. Ensure that
the mating face on the cylinder head is clean and
dry.
2. If the valve mechanism cover (1) is equipped with
an oil filler cap, check the condition of the O-ring
for the oil filler cap. If necessary, replace the O-
ring.
3. Check the condition of the fasteners (2). Replace
the fasteners (2), if necessary.
4. Install the gasket and valve mechanism cover (1)
on the cylinder head.
60 RENR2433-04
Start By:
a. Remove the valve mechanism cover. Refer to
Disassembly and Assembly, “Valve
Mechanism Cover - Remove and Install”.
NOTICE
component life.
5. Install the fasteners (2). Tighten the fasteners in

the sequence that is shown in Illustration 112 to a
torque of 9 N·m (80 lb in).
6. Connect breather tube (3) to the valve mechanism
cover. Refer to this Disassembly and Assembly
Manual, “Crankcase Breather - Remove and
Install”.
End By:
a. Install the cover for the fuel injection nozzles.
Refer to this Disassembly and Assembly
Manual, “Fuel Injection Nozzle Cover - Remove
and Install”.
b. If equipped, ensure that the heat shields are
clean and free from dust, oil, and paint. Install
the heat shields.
i02296699
Rocker Shaft and Pushrod - Illustration 114 g00960224
Remove 1. If the rocker shaft will not be disassembled, install

the Tooling (A) around the rocker arms (4) in order
SMCS Code: 1102-011; 1208-011 to slightly compress the springs (5). The rocker
arms must be held away from the machined faces
Removal Procedure of the cylinder head (2) during installation.
Table 36
2. Remove the Torx screws (1) from the rocker shaft
Required Tools (3).
Tool Part Number Part Description Qty 3. Remove the rocker shaft assembly from the
A 6K-0806 Cable Strap 3 cylinder head.
RENR2433-04 61
4. Remove the pushrods (6) from the cylinder head. 2. Place an identification mark on each of the
Place an identification mark on each of the components for installation. Ensure that you note
pushrods for installation. the component's relationship to the machined flat
(6).
i02298103
3. Remove the rocker arm assembly (3) for the inlet
valve from the rocker shaft (7). Remove the rocker
Rocker Shaft - Disassemble arm assembly (4) for the exhaust valve from the
SMCS Code: 1102-015 rocker shaft (7).
4. Remove the spring (5) from the rocker shaft
Disassembly Procedure assembly.
Table 37 5. Repeat Step 3 and Step 4 in order to completely
Required Tools disassemble the rocker shaft assembly.
i02298104
A 1P-1855 Retaining Ring Pliers 1
Rocker Shaft - Assemble
Start By:
SMCS Code: 1102-016
a. Remove the rocker shaft assembly. Refer to
Disassembly and Assembly, “Rocker Shaft and Assembly Procedure
Pushrod - Remove”.
Table 38
Required Tools

parts propelled by a released spring force. A 1P-1855 Retaining Ring Pliers 1

equipment.

Typical example
1. Clean all of the components and inspect all of the

Illustration 115 g01150908 components. Inspect the grooves for the circlips
(1) and ensure that all of the oil holes in the rocker
1. Remove the retaining ring (1) and remove the shaft (7) and in the rocker arms (3 and 4) are not
washer (2) from both ends of the rocker shaft plugged before you begin the assembly
assembly. procedure. If necessary, replace any worn
components and any damaged components.
Note: The rocker shaft (7) is not symmetrical as there
is a machined flat (6) toward one end of the shaft.
62 RENR2433-04
2. Check the clearance between the rocker shaft (7)

and the bushing of every rocker arm (3 and 4).
Refer to the Specifications Manual, “Rocker Shaft”
or further information. If necessary, replace any
worn components.
3. Lubricate all of the components with clean engine
oil before assembly.
Note: Ensure that the machined flat (6) on the rocker
shaft (7) is facing upward.
4. Install a circlip (1) onto the end of the rocker shaft

(7) that is closest to the machined flat (6). Install a
washer (2) onto the rocker shaft (7).
5. Install the rocker arm assembly (3) for the inlet
valve onto the rocker shaft (7). Install the rocker
arm assembly (4) for the exhaust valve onto the
rocker shaft (7).
6. Install the spring (5) onto the rocker shaft (7).
7. Repeat Step 5 and Step 6 in order to assemble the
rocker shaft assembly.

equipment. Illustration 118 g00960345
8. Install the remaining washer (2) and the remaining 1. Apply clean engine lubricating oil to both ends of
circlip (1) onto the rocker shaft (7). the pushrods (6). Install the pushrods (6).
i02298106 Note: Ensure that the pushrods are installed in the

original location and that the pushrods are seated in
Rocker Shaft and Pushrod - the valve lifters correctly.
Install 2. If the rocker shaft was disassembled, install the
Tooling (A) around the rocker arms (4) in order to
SMCS Code: 1102-012; 1208-012 slightly compress spring (5). The rocker arms must
be held away from the machined face of the
Installation Procedure cylinder head (2) during reassembly.
Table 39
3. Loosen the nut (8) and the adjustment screw (7)
Required Tools on each rocker arm. This will help prevent a bent
Tool Part Number Part Description Qty valve or a bent pushrod during the installation of
the rocker shaft.
A 6K-0806 Cable Strap 3
4. Position the rocker shaft assembly on the cylinder
head.
NOTICE
Keep all parts clean from contaminants. Note: The rocker shaft (3) of the rocker shaft
assembly is not symmetrical. The rocker shaft (3) has
Contaminants may cause rapid wear and shortened a machined flat at the front end of the shaft. Ensure
component life. that the machined flat is toward the top and toward
the front end of the engine.
RENR2433-04 63
5. Install the Torx screws (1) in the rocker shaft (3). End By:
Note: The longest Torx screw must be installed at the a. Install the valve mechanism cover. Refer to
front of the cylinder head in the hole (X). Disassembly and Assembly, “Valve
Mechanism Cover - Remove and Install”.
6. Ensure that the adjustment screws (7) are properly
seated in the ends of the pushrods (6). i02298184
7. Alternately tighten the Torx screws (1). Start from Cylinder Head - Remove
the center and work toward the outside. Tighten
the Torx screws (1) to a torque of 35 N·m SMCS Code: 1100-011
(26 lb ft).
8. Cut and remove the Tooling (A) from the rocker Removal Procedure
shaft assembly. Start By:
9. Adjust the inlet valve lash to 0.20 mm (0.008 inch) a. Drain the coolant from the engine oil cooler
and adjust the exhaust valve lash to 0.45 mm into a suitable container for storage or
(0.018 inch). Refer to Testing and Adjusting, disposal. Drain the engine oil from the engine
“Engine Valve Lash - Inspect/Adjust” for more oil cooler into a suitable container. Refer to
Operation and Maintenance Manual for the
information on adjusting the valve lash. procedure on draining the engine coolant and
the engine oil.
b. Remove the hose from the air filter to the
integral air inlet. Refer to the OEM information
for further details.
c. Remove the fuel priming pump. Refer to this
Disassembly and Assembly Manual, “Fuel
Priming Pump and Fuel Filter Base - Remove
and Install”.
d. Remove the pipe for the boost control.
e. Remove the fuel injectors. Refer to this
Injection Nozzles - Remove”.
f. Remove the exhaust manifold. Refer to
Disassembly and Assembly, “Exhaust
Manifold - Remove and Install”.
g. Remove the rocker shaft assembly and the
pushrods. Refer to Disassembly and Assembly,
“Rocker Shaft and Pushrod - Remove”.
h. Remove the glow plugs. Refer to this
Disassembly and Assembly Manual, “Glow
Plugs - Remove and Install”.
NOTICE
component life.
64 RENR2433-04
NOTICE
and mandates.
Note: Refer to Operation and Maintenance Manual, Illustration 120 g00954953

“Refill Capacities” for the coolant capacity and the
engine oil capacity of the engine. 4. Remove the setscrews (6). Remove the bypass
tube (7) from the cylinder head. Remove the O-
ring seals from the bypass tube. Discard the O-
ring seals.
1. Remove the setscrew (1) and the fuel line from the
cylinder head. Illustration 121 g00951484
2. Disconnect the harness assembly (4) from the 5. Gradually loosen the setscrews (8) in reverse
coolant temperature sensor. numerical order. Refer to Illustration 121 . This will
3. Disconnect tube assembly (5) from the cylinder help prevent distortion of the cylinder head.
head. 6. Remove the setscrews (8) from the cylinder head
(9).
7. Use a suitable lifting device and carefully lift the
cylinder head off the cylinder block. The weight of
the cylinder head is approximately 57 kg (126 lb).
Note: Take care not to damage the machined

surfaces of the cylinder head (9) during removal.
Note: Do not use a lever to separate the cylinder

head from the cylinder block.
NOTICE
Place the cylinder head on a surface that will not
scratch the face of the cylinder head.
RENR2433-04 65
8. Remove the cylinder head gasket. Discard the Note: Do not use any sealant or compound on the
cylinder head gasket. cylinder head gasket.
Note: Note the location of the dowels on the cylinder 2. Install the Tooling (A) in the cylinder block.
block.
3. Use a suitable lifting device to install the cylinder
i02298802
head. The weight of the cylinder head is
approximately 57 kg (126 lb).
Cylinder Head - Install Note: Ensure that the cylinder head is positioned on
dowels (10). Take care not to damage the machined
SMCS Code: 1100-012
surfaces of the cylinder head during installation.
Installation Procedure 4. Remove the Tooling (A).

Table 40
Required Tools
A 9U-6238 Guide Bolt 2
B 8T-3052 Degree Wheel 1
C - Red Rubber Grease -
NOTICE
component life.
Note: Thoroughly clean the top of the cylinder block
and the bottom of the cylinder head. Ensure that 5. Clean the threads of the setscrews that secure the
there is no debris in the cylinder bores, the coolant cylinder head. Inspect the threads of the
passages, and the lubricant passages. setscrews that secure the cylinder head.
Note: Thoroughly clean the hole in the cylinder head Note: Do not use the setscrews if there is any visual
for the gas that is ventilated from the crankcase. reduction in the diameter of the threads (Y) that has
Ensure that the hole is not restricted by debris and/or not been engaged with the cylinder block. Use a
oil deposits. straight edge to check the bolts.
6. Apply clean engine oil to the threads and the

shoulder of the setscrews that secure the cylinder
head before installation.
1. Install the cylinder head gasket on the dowels (10)

on top of the cylinder block.
66 RENR2433-04
b. Turn the long setscrews (1, 3, and 4) for an

additional 270 degrees.
7. Install the setscrews (8) in cylinder head (9).

Note: The short setscrews are installed in holes that
are marked 2, 5, 6, 7, 8, 9, and 10. 12. Install new O-ring seals on the bypass tube (7).
Apply Tooling (C) to the O-ring seals. Install the
Note: The long setscrews are installed in holes that bypass tube in the cylinder head. Install the
are marked 1, 3, and 4. setscrews (6).
8. Tighten the setscrews in numerical order to a
torque of 50 N·m (37 lb ft). Refer to Illustration
124 .
9. Tighten the setscrews in numerical order to a
torque of 100 N·m (74 lb ft). Refer to Illustration
124 .
13. Connect the tube assembly (5) to the cylinder

head.
14. Connect the harness assembly (4) to the coolant
temperature sensor.
Illustration 125 g01151296 15. Install bolt (1) and the fuel line to the cylinder
head.
10. Use the Tooling (B) to achieve the correct final
16. Fill the cooling system with coolant. Fill the
torque.
lubrication system with engine oil.
Note: If the Tooling (B) is not available, place an
index mark on each setscrew. Note: Refer to Operation and Maintenance Manual,
“Refill Capacities” for the cooling system capacity
11. Tighten the setscrews in numerical order. Refer to and the lubrication system capacity of the engine.
Illustration 124 .
a. Turn the short setscrews (2, 5, 6, 7, 8, 9, and
10) for an additional 225 degrees.
RENR2433-04 67
End By:
a. Install the glow plugs. Refer to Disassembly
and Assembly Manual, “Glow Plugs - Remove
and Install”.
b. Install the rocker shaft and the pushrods. Refer
to Disassembly and Assembly, “Rocker Shaft
and Pushrod - Install”.
c. Install the exhaust manifold. Refer to
Disassembly and Assembly, “Exhaust
Manifold - Remove and Install”.
d. Install the fuel injection Nozzles. Refer to
Injection Nozzles - Install”.
e. Install the pipe for the boost control.
f. Install the fuel priming pump. Refer to 1. Use Tooling (A) to remove lifters (1).
Priming Pump and Fuel Filter Base - Remove Note: Place an identification mark on the lifters for
and Install”. installation purposes.
g. Install the hose from the integral air inlet to the Installation Procedure
air filter. Refer to the OEM information for
further details. Table 42
Required Tools
h. Refill the engine with coolant and engine oil.
Refer to the Operation and Maintenance Tool Part Number Part Description Qty
Manual for the correct procedure, the
quantities, the coolant specification, and the A 1U-7262 Telescoping Magnet 1
specification for the engine oil.
i02333592 NOTICE
Lifter Group - Remove and Contaminants may cause rapid wear and shortened
Install component life.
SMCS Code: 1209-010

1. Lubricate the lifters with clean oil before installing
the lifters in the cylinder block.
Removal Procedure
Table 41
Required Tools
A 1U-7262 Telescoping Magnet 1
Start By:
a. Remove the camshaft. Refer to Disassembly
and Assembly, “Camshaft - Remove and
Install”.
NOTICE
component life.
2. Use Tooling (A) to install lifters (1).
68 RENR2433-04
Note: Ensure that the lifters are installed in the Installation Procedure
original location and that the lifters are seated
correctly. NOTICE
End By:
a. Install the camshaft. Refer to Disassembly and component life.
Assembly, “Camshaft - Remove and Install”.
i02299051 Note: Ensure that the camshaft is clean. Lubricate

the camshaft with clean engine oil prior to installation.
Camshaft - Remove and Install
NOTICE
SMCS Code: 1210-010 Do not damage the lobes or the bearings when the
camshaft is removed or installed.
Removal Procedure
Start By: 1. Carefully install camshaft (3) in the cylinder block.
End By:
a. Remove the rocker shaft assembly and the
pushrods. Refer to Disassembly and Assembly, a. Install the front housing. Refer to Disassembly
“Rocker Shaft and Pushrod - Remove”. and Assembly, “Housing (Front) - Install”.
b. Remove the front housing. Refer to b. Install the rocker shaft and the pushrods. Refer
Disassembly and Assembly, “Housing (Front) - to Disassembly and Assembly, “Rocker Shaft
Remove”. and Pushrod - Install”.
NOTICE i02299077
Contaminants may cause rapid wear and shortened Camshaft Gear - Remove and
component life. Install
1. Turn the engine upside-down so the valve lifters SMCS Code: 1210-010-GE
are held in a position away from the camshaft.
Removal Procedure
Table 43
Required Tools
Start By:
b. Remove the front cover. Refer to Disassembly
Install”.
c. Remove the idler gear. Refer to Disassembly
NOTICE
Do not damage the lobes or the bearings when the and Assembly, “Idler Gear - Remove and
camshaft is removed or installed. Install”.
NOTICE
2. Carefully remove camshaft (3) from the cylinder Keep all parts clean from contaminants.
block.
component life.
RENR2433-04 69
Note: Ensure that the key is installed on the

camshaft. When you install the camshaft gear,
ensure that the marked teeth are facing toward the
front. If necessary, tap the gear with a soft hammer in
order to seat the key in the keyway. Make sure that
the Tooling (A) goes into the hole in the front housing.
5. Install the setscrew (1) and the washer on the

camshaft gear (2). Tighten the setscrew to a
torque of 95 N·m (70 lb ft).
6. Remove the Tooling (A) from the camshaft gear.
Remove the Tooling (B) from the crankshaft web.
End By:
Illustration 131 g01001848 a. Install the idler gear. Refer to Disassembly and
Assembly, “Idler Gear - Remove and Install”.
1. Remove the setscrew (1) and the washer from the
b. Install the front cover. Refer to Disassembly
camshaft gear (2). and Assembly, “Front Cover - Remove and
2. Remove the camshaft gear from the camshaft. Install”.
Note: Do not lose the key from the camshaft gear. c. Install the fan. Refer to Disassembly and
Installation Procedure i02299758
NOTICE Camshaft Bearings - Remove

and Install
component life. SMCS Code: 1211-010
1. Make sure that the No. 1 cylinder is at the top Removal Procedure
center compression stroke. Refer to Testing and Table 44
Adjusting, “Finding Top Center Position for No. 1
Required Tools
Piston”.
Part
2. Inspect the camshaft gear and the key for wear or Tool Number Part Description Qty
damage.
8S-2241 Camshaft Bearing Tool Group 1
3. Install the Tooling (A) through the camshaft gear. A
8H-0684 Ratchet Wrench 1
Install the Tooling (B) into the crankshaft web.
Start By:
a. Remove the camshaft. Refer to Disassembly
and Assembly, “Camshaft - Remove and
Install”.
NOTICE
component life.
4. Install the camshaft gear (2) on the camshaft.

70 RENR2433-04
1. Use the Tooling (A) in order to remove the 1. Use the Tooling (A) in order to install the camshaft
camshaft bearing (1) from the cylinder block. bearing (1) into the bore in the cylinder block.
Installation Procedure Note: Align the oil hole in camshaft bearing (1) with
Table 45
the oil hole in the bore in the cylinder block.
Required Tools Note: The camshaft bearing must be inserted until

the front edge of the bearing is flush with the face of
Part the recess in the cylinder block.
Tool Number Part Description Qty
8S-2241 Camshaft Bearing Tool Group 1
A
8H-0684 Ratchet Wrench 1
NOTICE
component life.
RENR2433-04 71
End By: 2. Operate the engine until the engine is warm. Stop
the engine.
a. Install the camshaft. Refer to Disassembly and
Assembly, “Camshaft - Remove and Install”. 3. Remove the oil drain plug (6) and the O-ring seal.
Drain the engine oil into a suitable container for
i05003149 storage or disposal.
Engine Oil Pan - Remove and Note: Refer to the Operation and Maintenance
Manual, “Refill Capacities” for information on the
Install capacity of the lubrication system.
SMCS Code: 1302-010 Note: Ensure that the engine oil pan is fully
supported before the oil pan is removed. Particular
Removal Procedure care must be taken with the cast iron version of the
engine oil sump as this version is heavy.
NOTICE
Keep all parts clean from contaminants. 4. Remove the setscrews (3) and the setscrews (4)
from the engine oil pan (5).
component life. 5. Remove the engine oil pan (5) and remove the
gasket (1) from the cylinder block. Discard the
gasket (1).
NOTICE
Care must be taken to ensure that fluids are con- 6. If necessary, remove the nut (2), the seal, and the
tained during performance of inspection, mainte- tube assembly from the engine oil pan.
Be prepared to collect the fluid with suitable contain- 7. Clean the engine oil pan (5) with a suitable
ers before opening any compartment or disassem- cleaning fluid. Ensure that all of the cleaning fluid
bling any component containing fluids. is removed.
Refer to Special Publication, NENG2500, “Dealer Installation Procedure
Table 46
Required Tools
and mandates. Part
Tool Part Description Qty
Number
Guide Bolt
A - 4
(M8 x 1.25 x 70 mm)
B - Loctite 5900 -
C - Loctite 243 -
NOTICE
component life.
1. Clean the flange face of the engine oil pan (5) and
the flange face of the cylinder block.
1. Remove all dirt, oil, and grease from the exterior

surfaces of the oil pan (5).
72 RENR2433-04
5. Position a new gasket (1) and the engine oil pan

(5) on the cylinder block. Install the setscrews (3
and 4) in order to secure the engine oil pan to the
cylinder block. Tighten the setscrews finger tight.
6. Remove the Tooling (A) and install the remaining
setscrews (3 an 4). Tighten the setscrews (3) in
Hole (Y) to a torque of 22 N·m (16 lb ft).
7. Tighten the remaining setscrews (3 and 4) to a
8. Inspect the O-ring for the drain plug (6). Replace
the O-ring if it is necessary. Install the O-ring seal
and drain plug (6). Tighten the drain plug to a
9. If necessary, install the seal and the tube assembly
2. When the gasket for the oil pan is removed, in the engine oil pan. Tighten the nut (2) to a
damage may occur to the existing seal in the torque of 18 N·m (13 lb ft).
groove of the bridge. If the seal is damaged, apply
a sufficient amount of Tooling (B) in order to fill the 10. Fill the engine oil pan to the correct level that is
groove. The groove must be completely filled. indicated on the engine oil level gauge.
3. Apply Tooling (B) to the joint between the cylinder Note: Refer to the Operation and Maintenance
block and the front housing. Manual, “Refill Capacities” for the lubrication system
capacity of the engine.
i02323221
Balancer Group - Remove

(If Equipped)
SMCS Code: 1220-011
Removal Procedure
Table 47
Required Tools
C 231-8849 Timing Pin (Balancer) 1
D 1P-0510 Driver Group 1
Illustration 139 g00956479 E 1P-2320 Combination Puller 1
4. Install Tooling (A) in the cylinder block in Hole (X).
Note: New setscrews have sealant on the first

13 mm (0.5 inch) of the threads. In order to reuse the
old setscrews, clean the old sealant from the bolts
and apply Tooling (C) to the setscrews.
Note: Ensure that the engine oil pan is properly
supported while the engine oil pan (5) is installed
onto the cylinder block.
RENR2433-04 73
Start By: Note: The weight of the balancer group is

approximately 25 kg (55 lb). Take care when the
a. Remove the engine oil pan. Refer to balancer group is lifted or when the balancer group is
Disassembly and Assembly, “Engine Oil Pan - lowered. If the engine is not inverted, support the
Remove and Install”. balancer group before removing the setscrews.
b. Remove the engine oil relief valve. Refer to
Disassembly and Assembly, “Engine Oil Relief 3. Remove the setscrews (5) and then remove the
Valve - Remove and Install (Engine with balancer group.
Balancer Group)”.
NOTICE
component life.
NOTICE
and mandates.
1. Ensure that the No. 1 cylinder is at the top center
compression stroke. Refer to Testing and 4. Remove the setscrew (8) and the shaft (9).
Adjusting, “Finding Top Center Position for No. 1 Remove the idler gear (10) and the thrust washer
Piston”. (12). Use Tooling (D) to remove the bearing (11)
from the idler gear (10).
Install Tooling (B) into the crankshaft web. 5. Remove the nut (13). Use Tooling (E) to remove
the gear (14) from the shaft.
6. Remove the setscrews (15). Remove the cover
(16).
7. Remove the rotor assembly (17).
2. Install the Tooling (C) into the balancer. Ensure

that the Tooling (C) is fully located in the drive
shaft.
74 RENR2433-04
8. If necessary, remove the dowel (7) and the hollow

dowel (6).
i02300675
Balancer Group - Install

(If Equipped)
SMCS Code: 1220-012
Table 48
Required Tools
C 231-8849 Timing Pin (Balancer) 1
D 1P-0510 Driver Group 1 Illustration 142 g00978986
Guide Bolt
E - 1 3. Install the rotor assembly (17). Check the
(M10 x 1.5 x 100 mm)
clearance between the outer rotor and the body.
F 9S-3263 Thread Lock Compound 1 Check the clearance between the inner rotor and
the outer rotor. Check the end play for the rotor
assembly. Refer to Specifications, “Engine Oil
NOTICE Pump”.
4. Lubricate the rotor assembly with clean engine oil.
Contaminants may cause rapid wear and shortened Install the cover (16). Install the setscrews (15).
component life.
Tighten the setscrews to a torque of 28 N·m
(21 lb ft).
1. Clean all of the components and inspect all of the
5. Ensure that the threads of the shaft are clean and
components that were removed previously.
dry. Position the oil pump gear (14) on the shaft.
Replace any component that is worn or damaged.
Install the nut (13). Tighten the nut to a torque of
2. Clean the mating surfaces of the cylinder block 95 N·m (70 lb ft).
and the balancer.
6. Use Tooling (D) and install a new bearing (11) in
the idler gear (10).
7. Lubricate the bearing (11) with clean engine oil.
Install the shaft (9) in the idler gear (10).
8. Position the idler gear (10) and the thrust washer
(12) on the balancer group. Ensure that the
threads of the setscrew (8) are clean and dry.
Apply Tooling (F) to the threads of the setscrew
and install the setscrew (8). Tighten the setscrew
to a torque of 26 N·m (19 lb ft).
9. Check the end play for the idler gear. Refer to
Specifications, “Engine Oil Pump”.
10. Check the backlash between the gear for the
engine oil pump and the idler gear. Refer to
Specifications, “Engine Oil Pump”.
RENR2433-04 75
11. Ensure that the dowel (7) and the hollow dowel 17. Remove the Tooling (E) and install the remaining
(6) are installed in the balancer (1). setscrews (5). Tighten the setscrews to a torque of
54 N·m (40 lb ft).
12. Make sure that the No. 1 cylinder is at the top
center compression stroke. Refer to Testing and 18. Remove the Tooling (A) from the camshaft gear.
Adjusting, “Finding Top Center Position for No. 1 Remove the Tooling (B) from the crankshaft web.
Piston”.
19. Remove the Tooling (C). Rotate the crankshaft in
Note: Install Tooling (A) through the camshaft gear. order to ensure that the balancer group turns
Install Tooling (B) into the crankshaft web. freely.
End By:
a. Install the engine oil relief valve. Refer
toDisassembly and Assembly, “Engine Oil
Relief Valve - Remove and Install (Engine with
Balancer Group)”.
b. Install the engine oil pan. Refer to Disassembly
Install”.
i02300831
Piston Cooling Jets - Remove

and Install
Illustration 143 g01152041 SMCS Code: 1331-010
13. Install the Tooling (E) in the cylinder block.
Removal Procedure
Start By:
NOTICE
component life.
14. Install the Tooling (C). Ensure that the Tooling (C)
is fully located in the drive shaft.
15. Carefully position the balancer group (1) onto the
Tooling (E). Ensure that the teeth of the idler gear
and the crankshaft gear are aligned.
Note: The balancer weights must be pointing away

16. Install two setscrews (5) in the center of the Illustration 145 g01152129
balancer group. Tighten the setscrews to a torque
of 54 N·m (40 lb ft). 1. Remove the setscrew (1). Remove the piston
cooling jet assembly (2) from the cylinder block.
76 RENR2433-04
Note: The engine crankshaft may be rotated in order End By:

to access all of the piston cooling jet assemblies.
a. Install the engine oil pan. Refer to Disassembly
Note: Ensure that the ball moves freely within the and Assembly, “Engine Oil Pan - Remove and
valve assembly of the piston cooling jet. Check that Install”.
the tube of the piston cooling jet assembly is not
damaged. i02301207
Installation Procedure Pistons and Connecting Rods

- Remove
NOTICE
Keep all parts clean from contaminants. SMCS Code: 1225-011
component life. Removal Procedure
Table 49
Required Tools
Part
Number
A 8S-2269 Ridge Reamer 1
Start By:
a. Remove the cylinder head. Refer to
Remove”.
b. Remove the engine oil pan. Refer to
c. Remove the engine oil pump. Refer to
1. Install piston cooling jet assembly (2) to the Disassembly and Assembly, “Engine Oil Pump
- Remove”.
cylinder block. Install the setscrew (1). Tighten the
setscrew (1) to a torque of 9 N·m (80 lb in). d. Remove the piston cooling jets. Refer to
Disassembly and Assembly, “Piston Cooling
Note: Ensure that piston cooling jet assembly (2) is Jets - Remove and Install”.
properly located on the cylinder block. Refer to the
Specifications Manual, “Piston Cooling Jet” for the NOTICE
correct procedure for the alignment of the piston Keep all parts clean from contaminants.
cooling jet.
component life.
1. Use Tooling (A) in order to remove the carbon

ridge from the top inside surface of the cylinder
liners.
2. Rotate the crankshaft until the pistons that are
being removed are at the bottom center position.
RENR2433-04 77
7. Repeat Steps 2 through 6 in order to remove the

remaining pistons and connecting rods.
i01880507
Pistons and Connecting Rods

- Disassemble
SMCS Code: 1225-015
Disassembly Procedure
Table 50
Required Tools
3. Remove the setscrews (1). A 1U-6683 Ring Expander 1
Note: Do not reuse the setscrews (1). Use new B 1P-1857 Retaining Ring Pliers 1
setscrews in order to secure the connecting rod cap C 1P-0510 Driver Group 1
for reassembly.
4. Remove the connecting rod cap (2) and the Start By:
connecting rod bearing.
a. Remove the pistons and the connecting rods.
Note: Inspect the connecting rod and connecting rod Refer to Disassembly and Assembly, “Piston
cap for the proper identification mark. The connecting and Connecting Rods - Remove”.
rod and the connecting rod cap should have an
etched number on the side. The number should NOTICE
match the cylinder number. Mark the connecting rod Keep all parts clean from contaminants.
and the connecting rod cap, if necessary. Contaminants may cause rapid wear and shortened
component life.
Note: Do not stamp the connecting rod assembly.
Stamping or punching the connecting rod assembly
could cause the connecting rod to fracture.
5. Put a temporary identification mark on the top of

the piston in order to indicate the cylinder number
that is shown on the connecting rod. Put the
temporary mark on the same side as the mark that
is on the connecting rods in order to ensure
correct assembly of the piston and the connecting
rod.
Note: Do not etch the top surface of the piston. Do
not allow scratches or stamped markings in the top
surface of the piston.
6. Push the pistons and the connecting rods through

the top of the cylinder block. Illustration 148 g00970499
1. Remove the lower connecting rod bearing from the

connecting rod cap. Remove the upper connecting
rod bearing from the connecting rod.
Note: The forged marks (X) must be installed toward
the front of the engine.
78 RENR2433-04
NOTICE
Installation of the piston pin bushing must be carried
out by personnel with the correct training. Also spe-
cial machinery is required.
Note: A new piston pin bushing is in a shape of a

wedge. For further information on installation of the
piston pin bushing, refer to your authorized
Caterpillar dealer or your Caterpillar distributor for
assistance.
1. Refer to Testing and Adjusting, “Connecting Rod -

Inspect” for the correct height grade for the
fractured split connecting rod.
2. Use Tooling (A) in order to remove compression

rings (1) and (2), and oil control ring (3) from piston
(6).
3. Use Tooling (B) in order to remove retaining rings
(8) that hold the piston pin in position.
4. Remove piston pin (7) from the piston.
Note: If the piston pin cannot be removed by hand,
heat the piston to a temperature of 45 ± 5 °C
(113 ± 9 °F). Do not use a torch to heat the piston.
5. Use Tooling (C) and a suitable press in order to

remove bushing (4) from connecting rod (5). Illustration 150 g01000785
6. Repeat Steps 1 through 5 in order to disassemble Alignment of the shell

the remaining pistons and connecting rods.
2. The bearing shells for the connecting rod and the
i07489015 connecting rod cap must be aligned by a tool
before the bearing shells are installed. Refer to
Pistons and Connecting Rods illustration 150 . Check the alignment of the
bearing shells and remove the alignment tool from
- Assemble the assembly. The bearing shell must be an equal
SMCS Code: 1225-016 distance from each end. Refer to illustration 151 .
Assembly Procedure
Table 51
Required Tools
A 1P-1857 Retaining Ring Pliers 1
B 1U-6683 Ring Expander 1
NOTICE
component life. Illustration 151 g01001160
Aligned shell
RENR2433-04 79
3. Align the mark (1) on the connecting rod to the

boss cutout (2) of the piston. Also check that the
arrow (3) that is marked on top of the piston is
aligned. Install the piston pin into the piston and
through the connecting rod.
Note: If the piston pin cannot be installed by hand,

use hot water to heat the piston to a temperature of
45° ± 5°C (113° ± 9°F).
b. Install the intermediate piston ring (8) with the

tapered face into the second groove on the
piston. The stamp “TOP” must be toward the
top of the piston.
Note: Intermediate piston rings that are new have

an orange mark which must be on the left of the
piston ring gap when the piston ring is installed.
c. Install the top piston ring (9) with the barrel face
Align the connecting rod to the piston. and the molybdenum insert into the top groove
on the piston. The top piston ring has a
4. Use the Tooling (A) to install the circlips (4) that keystone ring. The stamp “TOP” must be
hold the piston pin in position. toward the top of the piston.
5. Use the Tooling (B) to install the piston rings on the
Note: Top piston rings that are new have a green
piston with the following steps.
mark which must be on the left of the ring gap
when the ring is installed.
d. Position the piston ring gaps at 120 degrees

away from each other.
End By:
a. Install the pistons and the connecting rods.
Refer to Disassembly and Assembly, “Pistons
and Connecting Rods - Install”.
i05830375
Pistons and Connecting Rods

- Install
SMCS Code: 1225-012
a. Install the spring (6) for the oil control piston
ring (7) in the groove (4) that is lowest on the Installation Procedure
piston. The latch pin (5) must be located inside
Table 52
the ends of the spring. Locate the oil control
ring (7) over the internal spring (6). Required Tools
Note: Ensure that the latch pin is 180 degrees from
the oil control ring gap. A 1U-6684 Piston Ring Compressor 1
B 8T-3052 Degree Wheel 1

80 RENR2433-04
9. Install new setscrews (1) in the connecting rod.

NOTICE
Note: Do not reuse the old setscrews in order to
Contaminants may cause rapid wear and shortened secure the connecting rod cap.
component life.
10. Tighten the setscrews evenly to a torque of
18 N·m (13 lb ft).
1. Thoroughly clean all of the components.
2. Lubricate the piston and the cylinder bore with 70 N·m (52 lb ft).
clean engine oil.
12. Use the Tooling (B) to achieve the correct final
Note: The piston and connecting rod are matched to torque.
a specific cylinder. Ensure that the connecting rod
and pistons are installed in the correct cylinder. Note: If the Tooling (B) is not used, place an index
mark on each setscrew.
3. Rotate the crankshaft until the connecting rod
journal is at the bottom center. Lubricate the 13. Turn the setscrews for an additional 120 degrees.
connecting rod journal with clean engine oil. 14. Rotate the crankshaft in order to ensure that
4. Lubricate the upper connecting rod bearing with there is no binding.
clean engine oil. 15. Repeat Steps 2 through 14 in order to install the
5. Install the Tooling (A) on the piston. remaining pistons and connecting rods.
Note: Ensure that the Tooling (A) is installed correctly 16. Refer to Testing and Adjusting, “Piston Height -
and that the piston can easily slide from the tool. Inspect” for the correct procedure on checking the
height of the piston above the cylinder block.
Note: The arrow that is on the top of the piston must
be toward the front of the engine.
6. Push the piston and the connecting rod assembly

into the cylinder bore and onto the connecting rod
journal.
7. Lubricate the lower connecting rod bearing with
clean engine oil.
Note: The connecting rod is a forging. The

connecting rod has been hydraulically split in order to
separate the connecting rod cap and the connecting
rod. This process provides accurately matched
surfaces. Do not mix the connecting rod cap and the
connecting rod.
8. Install the connecting rod cap (2).

RENR2433-04 81
End By:
a. Install the piston cooling jets. Refer to
Disassembly and Assembly, “Piston Cooling
Jets - Remove and Install”.
b. Install the engine oil pump. Refer to
Disassembly and Assembly, “Engine Oil Pump
- Install”.
c. Install the engine oil pan. Refer to Disassembly
Install”.
d. Install the cylinder head. Refer to Disassembly
and Assembly, “Cylinder Head - Install”.
i02301286 Illustration 156 g00970465
Connecting Rod Bearings -

Remove
SMCS Code: 1219-011
Removal Procedure
Start By:
b. Remove the engine oil pump. Refer to
- Remove”. Illustration 157 g00974873
NOTICE 2. Inspect the connecting rod (5) and connecting rod

cap (2) for the proper identification mark. The
Contaminants may cause rapid wear and shortened connecting rod and the connecting rod cap should
component life. have an etched Number (Y) on the side. The
number should match the cylinder number. Mark
1. In order to remove the connecting rod caps, rotate the connecting rod and the connecting rod cap, if
the crankshaft in a clockwise direction until the necessary.
piston is at the bottom center position. 3. Remove the setscrews (1) from the connecting rod
(5). Remove the connecting rod cap (2). Remove
the lower connecting rod bearing (3) from the
connecting rod cap.
Note: Do not reuse the setscrews (1). Use new
setscrews in order to secure the connecting rod cap
for reassembly.
4. Carefully push the connecting rod into the cylinder

bore. Remove the upper connecting rod bearing
(4) from the connecting rod.
Note: Do not allow the connecting rod to contact the
piston cooling jet.
82 RENR2433-04
5. Repeat Steps 1 through 4 for the remaining 4. Install the lower connecting rod bearing (3) in the
connecting rod bearings. connecting rod cap (2). The lower connecting rod
bearing must be centered in the connecting rod
i05830319 cap. Lubricate the bearing face with clean engine
oil.
Connecting Rod Bearings -
Note: The connecting rod is a forging. The
Install connecting rod has been hydraulically split in order to
separate the connecting rod cap and the connecting
SMCS Code: 1219-012 rod. This process provides accurately matched
surfaces. Do Not mix the connecting rod cap and the
Installation Procedure connecting rod.
Table 53
Note: Ensure that the etched number on connecting
Required Tools rod bearing cap (2) matches the etched number on
the connecting rod (5). Ensure that the numbers (Y)
are on the same side.
A 8T-3052 Degree Wheel 1
NOTICE
component life.
5. Install the connecting rod cap (2).

6. Install new setscrews (1) in the connecting rod.
Note: Do not reuse the old setscrews in order to
secure the connecting rod cap.
Illustration 158 g00974873 7. Tighten the setscrews evenly to a torque of 18 N·m

(13 lb ft).
1. Install the upper connecting rod bearing (4) in the
connecting rod. The upper connecting rod bearing 8. Tighten the setscrews evenly to a torque of 70 N·m
must be centered in the connecting rod. Lubricate (52 lb ft).
the bearing face with clean engine oil. 9. Use the Tooling (A) to achieve the correct final
2. Pull the connecting rod into position against the torque.
crankshaft. Note: If the Tooling (A) is not used, place an index
mark on each setscrew.
Note: Do not allow the connecting rod to contact the
piston cooling jet. 10. Turn the setscrews for an additional 120 degrees.
3. Clean the connecting rod cap (2) and the lower 11. Rotate the crankshaft in order to ensure that
connecting rod bearing (3). Lubricate the bearing there is no binding.
face with clean engine oil.
12. Repeat Steps 1 through 11 for the remaining
connecting rod bearings.
RENR2433-04 83
End By:
a. Install the engine oil pump. Refer to
- Install”.
b. Install the engine oil pan. Refer to Disassembly
Install”.
i01882385
Crankshaft Main Bearings -

Remove
SMCS Code: 1203-011 Illustration 161 g00934803
Removal Procedure 3. Remove lower main bearing (3) from main bearing
Start By: cap (2). Keep the respective main bearing and the
main bearing cap together for proper installation.
a. Remove the engine oil pump. Refer to
- Remove”.
NOTICE
component life.
Note: Remove the following components from the

engine in order to remove the rear main bearing with
the crankshaft in position: flywheel, flywheel housing,
rear oil seal housing and bridge assembly.
1. Make sure that the main bearing caps are marked

for the location and direction for installation. The
main bearings and the main bearing caps must be 4. Push upper main bearing (4) from the opposite
installed in the same location. side of the bearing tab with a suitable tool.
Carefully rotate the crankshaft while you push on
the bearing. Remove upper main bearing (4) from
the cylinder block. Keep the upper bearing halves
together in order to ensure proper installation.
5. Repeat Step 2 through Step 4 for the remaining
main bearings.
2. Remove bolts (1) and main bearing cap (2).

84 RENR2433-04
NOTICE
component life.
Note: The upper bearing for the No. 1 crankshaft

journal has a lubricating oil slot. The remaining upper
bearings have an oil hole for lubrication. All new
upper bearings will have the slot for lubrication.
6. Remove the lower half of thrust washer (5) from

the center main bearing cap.
1. Clean upper main bearing (4) and lubricate the

bearing surface with clean engine oil.
Note: Ensure that the upper halves of the main
bearings are installed so that the bearing tabs fit into
the notch in the cylinder block.
NOTICE
7. Remove the upper half of thrust washer (6) from Only the upper half of the main bearing has lubrica-
each side of the center main bearing in the tion holes. Make sure the upper half of the main bear-
cylinder block with a suitable tool. Carefully rotate ing is installed correctly in the cylinder block to
ensure proper lubrication.
the crankshaft while you push on the thrust
washer (6). If necessary, move the crankshaft to
the front or to the rear in order to loosen a tight 2. Slide upper main bearing (4) into position between
thrust washer. the crankshaft journal and the cylinder block.
i01882386
Crankshaft Main Bearings -

Install
SMCS Code: 1203-012
Table 54
Required Tools
Part
Number
A 8H-8581 Feeler Gauge 1

RENR2433-04 85
3. Clean main bearing cap (2) and lower main 6. Install the lower half of thrust washer (5) on each
bearing (3). Lubricate the bearing surface of lower side of the center main bearing cap. The grooves
main bearing (3) with clean engine oil. on the thrust washer must be located against the
crankshaft.
Note: Ensure that the lower halves of the main
bearings are installed so that the bearing tabs fit into
the notch in the main bearing caps.
4. Install lower main bearing (3) in main bearing cap

(2).
7. Install main bearing caps (2). Lubricate the

threads of bolts (1) with clean engine oil.
8. Install bolts (1). Tighten bolts (1) to a torque of
Illustration 167 g00947861 245 N·m (181 lb ft).
5. Install the upper half of thrust washer (6) on each 9. Rotate the crankshaft in order to ensure that the
side of the center main bearing in the cylinder crankshaft turns freely.
block. The grooves on the thrust washer must be 10. Repeat Steps 1 through 9 for the remaining main
located against the crankshaft. If necessary, move bearings.
the crankshaft to the front or to the rear in order to
install the thrust washer.
86 RENR2433-04
End By:
- Install”.
i01882243
Crankshaft - Remove
SMCS Code: 1202-011
Removal Procedure
Start By:
Illustration 170 g00975012 a. Remove the engine oil pump. Refer to
11. Check the crankshaft end play. Use a prybar to - Remove”.
move the crankshaft toward the front of the
b. Remove the front housing. Refer to
engine. Use Tooling (A) to measure the end play Disassembly and Assembly, “Housing (Front) -
between rear thrust washer (5) and the crankshaft. Remove”.
The maximum permissible crankshaft end play is
0.51 mm (0.020 inch). c. Remove the flywheel housing. Refer to
Disassembly and Assembly, “Flywheel
Note: If the crankshaft was not removed for the rear Housing - Remove and Install”.
main bearing removal, the following components
must be installed: bridge assembly, rear oil seal d. Remove the housing for the crankshaft rear
seal. Refer to Disassembly and Assembly,
housing, flywheel housing and flywheel. “Crankshaft Rear Seal - Remove”.
NOTICE
component life.
1. Remove socket head bolts (1) from the bridge.

2. Remove bridge (2) from the cylinder block.
Note: Make sure that the main bearing caps and the
connecting rod caps are marked for the location and
direction for installation.
3. Remove main bearing cap bolts (3).

RENR2433-04 87
4. Remove main bearing caps (4) from the cylinder

block. Remove the bearings from the main bearing
caps. Keep the main bearings with the respective
main bearing cap.
5. Remove bolts (5) from the connecting rods.
Note: Do Not reuse bolts (5). Use new bolts in order
to secure the connecting rod cap for reassembly.
6. Remove connecting rod bearing caps (6) from the

connecting rods. Remove the bearings from the
connecting rod bearing caps. Keep the connecting
rod bearings with the respective connecting rod
bearing cap.
NOTICE
Do not allow the connecting rods to strike the piston 10. Remove lower main bearings (8) from main
cooling jets. Damage or misalignment may occur.
bearing caps (4). Remove the lower thrust
washers from the center main bearing cap. Keep
7. Push the piston assemblies into the cylinder bores. the lower main bearings with the respective main
bearing cap.
8. Attach lifting straps and a suitable lifting device to
the crankshaft. Lift the crankshaft out of the
i05819083
cylinder block. The weight of the crankshaft is
approximately 32 kg (70 lb). Do not scratch any of
the finished surfaces on the crankshaft.
Crankshaft - Install
SMCS Code: 1202-012
Table 55
Required Tools
A - Loctite 5900 -
B 8H-8581 Feeler Gauge 1
C 8T-3052 Degree Wheel 1
NOTICE
9. Remove the upper main bearings (7). Remove the component life.
upper thrust washers from the center main bearing
block. Keep the upper main bearings with the
respective main bearing caps. Note: The upper bearing for the No. 1 crankshaft
journal has a lubricating oil slot. The remaining upper
bearings have an oil hole for lubrication. All new
upper bearings will have the slot for lubrication.
1. If necessary, install the pistons and connecting

rods. Refer to Disassembly and Assembly Manual,
“Pistons and Connecting Rods - Install”.
2. Remove the setscrews (5) from the connecting
rods and then remove the connecting rod caps (6)
from the connecting rods. Discard the setscrews
(5).
88 RENR2433-04
3. Ensure that all of the lubrication passages are 8. Ensure that the locating dowels (10) for the main
clean and free of debris. bearing caps (4) are in the correct position in the
main bearing caps or in the cylinder block.

4. Install upper main bearings (8). The bearing tabs
for the upper main bearings must be located in the 9. Clean the lower half of the thrust washers (7) and
correct position in the cylinder block. Lubricate lubricate the lower half of thrust washers . Place
upper main bearings (8) with clean engine oil. the lower half of the thrust washers (7) in both
sides of the center main bearing cap (4). The
5. Clean the upper half of the thrust washers and
grooves on the thrust washer must be located
lubricate the upper half of thrust washers. Place
against the crankshaft.
the upper half of the thrust washer in both sides in
the recess in the cylinder block of the center main
bearing. The grooves on the thrust washer must
be located against the crankshaft.
6. Ensure that the main bearing journals and the
connecting rod bearing journals of the crankshaft
are clean. Attach lifting straps and a suitable lifting
device in order to position the crankshaft in the
cylinder block. The weight of the crankshaft is
approximately 32 kg (70 lb). Do not scratch any of
the finished surfaces on the crankshaft.
10. Install the main bearing caps (4) in the position

that was marked during the removal process. All of
the bearing tabs for the main bearings should be
on the same side. Install the main bearing cap
bolts (3). Tighten the bolts to a torque of
245 ± 20 N·m (180 ± 14 lb ft).
11. Ensure that the upper connecting rod bearings
are centered in the connecting rod. Install the
lower connecting rod bearings in the connecting
rod cap. Lubricate the bearing faces with clean
engine oil.
7. Clean the lower main bearings. Install the lower
main bearings (9) in the main bearing caps (4) with Note: Do not reuse the old setscrews (5) in order to
the bearing tabs in the correct position. Lubricate secure the connecting rod cap (6).
the lower main bearing caps with clean engine oil.
RENR2433-04 89
Note: Ensure that the etched number on the

connecting rod bearing cap matches the etched
number on the connecting rod . Ensure that the
etched numbers are on the same side.
12. Install the connecting rod caps (6). Install new

setscrews (5) in the connecting rod. Tighten the
setscrews evenly to a torque of 18 N·m (13 lb ft).
70 N·m (52 lb ft).
14. Use Tooling (C) to achieve the correct final
torque.
Note: If Tooling (C) is not used, place an index mark
on each bolt. Illustration 178 g00975426
15. Turn the setscrews for an additional 120 degrees.

16. Rotate the crankshaft in order to ensure that
there is no binding.
17. Clean the bridge and the face of the cylinder

block. Apply a thin bead of Tooling (A) on the
corners of the seat for the bridge. Also apply
Tooling (A) around the thread holes in the seat for
the bridge. Use the following steps when you
apply Tooling (A) to the cylinder block and the
bridge.
a. Apply a 3.0 mm (0.12 inch) bead of Tooling (A)
along the corner of the top recess in the
cylinder block.
Note: The maximum protrusion for the bridge (2)
from the outside of the cylinder block is 0.075 mm
(0.0029 inch).
b. Install the bridge (2) and the rubber seals, if

equipped. The rubber seals will sit higher than
the bridge when the seals are correctly
installed. Use a straight edge to line up the
bridge with the face of the cylinder block.
Tighten the socket head screws (1) to a torque
of 16 N·m (12 lb ft). Tighten the socket head
screws evenly.
90 RENR2433-04
c. When the bridge is positioned and the socket End By:

head screws have been tightened, inject
Tooling (A) in the groove that is at each end of a. If necessary, install the cylinder head. Refer to
Disassembly and Assembly Manual, “Cylinder
the bridge. The groove must be completely Head - Install”.
filled.
b. Install the rocker shaft and pushrods. Refer to
d. When the gasket for the oil pan is removed, Disassembly and Assembly Manual, “Rocker
damage may occur to the existing seal in the Shaft and Pushrod - Install”.
grooves of the bridge. If the seal is damaged,
c. Install the housing for the crankshaft rear seal.
apply a sufficient amount of Tooling (A) in order
Refer to Disassembly and Assembly,
to fill the grooves. “Crankshaft Rear Seal - Install”.
d. Install the flywheel housing. Refer to
Disassembly and Assembly, “Flywheel
Housing - Remove and Install”.
e. Install the front housing. Refer to Disassembly
and Assembly, “Housing (Front) - Install”.
f. If the engine is not equipped with a balancer
group, install the engine oil pump. Refer to
- Install”.
g. If the engine is equipped with a balancer group,
install the balancer group. Refer to
Disassembly and Assembly, “Balancer Group -
Install”.
i02305687
18. Check the crankshaft end play. Use a prybar to
move the crankshaft toward the front of the Crankshaft Gear - Remove and
engine. Use Tooling (B) to measure the end play Install
between the rear thrust washer and the
crankshaft. The maximum permissible crankshaft SMCS Code: 1204-010-GE
end play is 0.51 mm (0.020 inch).
Removal Procedure
NOTICE Table 56
If the crankshaft has been reground or if the crank-
shaft has been replaced, the height of the piston Required Tools
above the cylinder block must be inspected. It is nec-
essary to remove the cylinder head in order to inspect Tool Part Number Part Description Qty
the height of the piston above the cylinder block. 8H-0663 Bearing Puller Gp 1
A
126-7175 Push-Puller 1
19. Check the height of the piston above the top face
of the cylinder block. Refer to Testing and
Adjusting, “Piston Height - Inspect”. Start By:
a. Remove the front housing. Refer to
Disassembly and Assembly, “Housing (Front) -
Remove”.
b. Remove the engine oil pump. Refer to
- Remove”.
NOTICE
component life.
RENR2433-04 91
End By:
- Install”.
b. Install the front housing. Refer to Disassembly
and Assembly, “Housing (Front) - Install”.
i05977048
Bearing Clearance - Check

SMCS Code: 1203-535; 1219-535
Measurement Procedure
Table 57
Required Tools
Plastic Gauge (Green)

198-9142 0.025 to 0.076 mm 1
(0.001 to 0.003 inch)
Plastic Gauge (Red)

198-9143 0.051 to 0.152 mm 1
(0.002 to 0.006 inch)
A
Plastic Gauge (Blue)
Illustration 181 g01157947 198-9144 0.102 to 0.229 mm 1
(0.004 to 0.009 inch)
1. Use the Tooling (A) to remove the crankshaft gear Plastic Gauge (Yellow)
(1) from the crankshaft (3). Refer to illustration 181 198-9145 0.230 to 0.510 mm 1
. (0.009 to 0.020 inch)
2. Remove the key (2) from the crankshaft.

Note: Plastic gauge may not be necessary when the
Installation Procedure engine is in the chassis.
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.
1. Heat the crankshaft gear in an oven to 200 °C Note: Cat does not recommend the checking of the
(392 °F). actual bearing clearances particularly on small
2. Install the key (2) in the crankshaft (3). Install the engines. This is because of the possibility of
crankshaft gear (1). obtaining inaccurate results and the possibility of
damaging the bearing or the journal surfaces. Each
Note: The shoulder of the crankshaft gear must be Cat engine bearing is quality checked for specific wall
installed toward the front of the crankshaft. thickness.
92 RENR2433-04
Note: The measurements should be within

specifications and the correct bearings should be
used. If the crankshaft journals and the bores for the
block and the rods were measured during
disassembly, no further checks are necessary.
However, if the technician still wants to measure the
bearing clearances, Tooling (A) is an acceptable
method. Tooling (A) is less accurate on journals with
small diameters if clearances are less than 0.10 mm
(0.004 inch).
NOTICE
Lead wire, shim stock or a dial bore gauge can dam-
age the bearing surfaces.
The technician must be very careful to use Tooling

(A) correctly. The following points must be
remembered:
• Ensure that the backs of the bearings and the

bores are clean and dry. Illustration 182 g01152855
Typical Example
• Ensure that the bearing locking tabs are properly
seated in the tab grooves.
4. Remove all of Tooling (A) before you install the
• The crankshaft must be free of oil at the contact bearing cap.
points of Tooling (A).
Note: When Tooling (A) is used, the readings can
1. Put a piece of Tooling (A) on the crown of the sometimes be unclear. For example, all parts of
bearing that is in the cap. Tooling (A) are not the same width. Measure the
major width in order to ensure that the parts are
Note: Do not allow Tooling (A) to extend over the within the specification range. Refer to Specifications
edge of the bearing. Manual, “Connecting Rod Bearing Journal” and
Specifications Manual, “Main Bearing Journal” for the
2. Use the correct torque-turn specifications in order correct clearances.
to install the bearing cap. Do not use an impact
wrench. Be careful not to dislodge the bearing i02306203
when the cap is installed.

Coolant Temperature Sensor -
Note: Do not turn the crankshaft when Tooling (A) is
installed.
Remove and Install
SMCS Code: 1906-010
3. Carefully remove the cap, but do not remove
Tooling (A). Measure the width of Tooling (A) while
Tooling (A) is in the bearing cap or on the Removal Procedure
crankshaft journal. Refer to Illustration 182 .
NOTICE
component life.
RENR2433-04 93
NOTICE
and mandates.
1. Drain the coolant from the cooling system to a Illustration 184 g00975971
level below the coolant temperature sensor into a
suitable container for storage or disposal. 1. Install a new O-ring seal on the coolant
temperature sensor. Lubricate the O-ring seal with
clean engine oil.
2. Install the coolant temperature sensor (2) in the
cylinder head. Tighten the coolant temperature
sensor to a torque of 20 N·m (15 lb ft).
3. Connect the harness assembly (1).
4. Fill the cooling system to the correct level. Refer to
Operation and Maintenance, “Refill Capacities” for
the cooling system capacity.
i01923855
Engine Oil Pressure Sensor -

Remove and Install
2. Disconnect the harness assembly (1).
SMCS Code: 1924-010
3. Remove the coolant temperature sensor (2) from
the cylinder head. Removal Procedure
4. Remove the O-ring seal from the coolant
NOTICE
temperature sensor. Keep all parts clean from contaminants.
Installation Procedure Contaminants may cause rapid wear and shortened
component life.
NOTICE
NOTICE
Contaminants may cause rapid wear and shortened Care must be taken to ensure that fluids are con-
component life. tained during performance of inspection, mainte-
and mandates.
94 RENR2433-04
4. Fill the engine oil pan to the correct level that is

indicated on the engine oil level gauge.
i02306266
Glow Plugs - Remove and

Install
SMCS Code: 1412-010
Removal Procedure
NOTICE
1. Disconnect harness assembly (1). component life.
2. Remove engine oil pressure sensor (2).

1. Turn the disconnect switch to the OFF position.
3. Remove the O-ring seal from the engine oil
2. Remove the fuel injection nozzle cover. Refer to
pressure sensor.
Installation Procedure Injection Nozzle Cover - Remove and Install”.
3. Remove the fuel injection lines. Refer to this
NOTICE Disassembly and Assembly Manual, “Fuel
Injection Lines - Remove”.
component life.
4. Disconnect the harness assembly from the

Illustration 186 g00976014 connector (4) on the bus bar (1).
1. Install a new O-ring seal on the engine oil pressure 5. Loosen the nuts (2) that secure the bus bar (1) to
sensor. Lubricate the O-ring seal with clean engine the glow plugs (3).
oil. 6. Remove the bus bar (1) from the glow plugs (3).
2. Install engine oil pressure sensor (2). Tighten the 7. Remove the glow plug (3) from the cylinder head.
engine oil pressure sensor to a torque of 10 N·m
(89 lb in).
3. Connect harness assembly (1).
RENR2433-04 95
Installation Procedure 7. Turn the disconnect switch to the ON position.
NOTICE i02308847
Contaminants may cause rapid wear and shortened V-Belts - Remove and Install
component life.
SMCS Code: 1357-010
Removal Procedure

1. Clean the threads of the glow plug (3).
Typical example
2. Install the glow plug (3) in the cylinder head.
Tighten the glow plug to a torque of 18 N·m 1. If necessary, remove the setscrews (6) that fasten
(13 lb ft). the fan guard (3) to the fan shroud. Remove the
3. Position the bus bar (1) on the glow plugs (3). fan guard (3).
Tighten nuts (2) on the glow plugs to a torque of 2. Loosen the nut (1), the clamping screw (4), and the
2 N·m (17 lb in). setscrew (7). Slide the alternator (2) toward the
4. Connect the harness assembly to the connector engine.
(4) on the bus bar (1). Note: If the nut (1) is loose on the setscrew, remove
5. Install the fuel injection lines. Refer to Disassembly the nut and discard the nut.
and Assembly Manual, “Fuel Injection Lines -
3. Maneuver the V-belts (5) around the fan and
Install”.
remove the V-belts.
6. Install the fuel injection nozzle cover. Refer to
Disassembly and Assembly Manual, “Fuel Note: Never replace one V-belt. Always replace sets
of V-belts, if equipped.
Injection Nozzle Cover - Remove and Install”.
96 RENR2433-04
Installation Procedure 5. If the fan guard was previously removed, put the
fan guard (3) in position on the fan shroud. Install
the setscrews (6) that fasten the fan guard to the
fan shroud.
i02308856
Fan - Remove and Install

SMCS Code: 1356-010
Removal Procedure
Start By:
a. Remove the V-Belts. Refer to Disassembly and
Assembly, “V-Belts - Remove and Install”.
Typical example
1. Install the V-belts (5) behind the fan and on the

correct pulleys.
2. Adjust the tension on the V-belts (5) by moving the
alternator (2) away from the engine. After the
correct belt tension is set, tighten the clamping
screw (4) to a torque of 78 N·m (58 lb ft). Refer to
Testing and Adjusting, “V-Belt - Test” for the
correct tension of the V-belts.
Note: If the V-belt cannot be checked with a gauge,
press on the V-belt at the center of the longest free
length in order to check the deflection. Under a
moderate amount of pressure, the V-belt should have Illustration 191 g00542576
a deflection of 10.0 mm (0.40 inch).
1. Remove the setscrews (1).
3. Tighten the setscrew (7) to a torque of 22 N·m
(16 lb ft). 2. Remove the fan (2).
4. If necessary, install a new nut (1). Tighten the nut 3. If equipped, remove the extension (3).
4. Remove the fan pulley (4).

RENR2433-04 97
Installation Procedure End By:

1. Inspect the condition of the fan pulley (4) and the a. Install the V-Belts. Refer to Disassembly and
fan (2). If necessary, replace the fan pulley or the Assembly, “V-Belts - Remove and Install”.
fan.
i02308860
Fan Drive - Remove and Install

SMCS Code: 1359-010; 1386-010
Removal Procedure
Start By:
2. Install the fan pulley (4).
1. Remove the setscrews (1) from the fan drive (2).

2. Remove the fan drive (2).
3. If equipped, install the extension (3).

4. Install the fan (2).
5. Install the setscrews (1). Tighten the setscrews (1)
1. Position the fan drive (2) on the front face of the

cylinder block with the shaft toward the bottom of
the mounting flange.
98 RENR2433-04
2. Install the setscrews (1). Tighten the setscrews to 8. If necessary, remove the nut (3) and the alternator
a torque of 44 N·m (32 lb ft). pulley from the alternator.
End By:
i02309551
a. Install the fan. Refer to Disassembly and
Assembly, “Fan - Remove and Install”. Alternator - Install
i02308906 SMCS Code: 1405-012
Alternator - Remove Installation Procedure

SMCS Code: 1405-011 Note: If the alternator pulley was removed, install the
alternator pulley and the nut (3). Tighten the nut to a
Removal Procedure torque of 80 ± 10 N·m (59 ± 7 lb ft).
1. Turn the battery disconnect switch to the OFF

position.

Typical Example
1. Put the alternator (2) in position on the engine.
Typical Example
2. Install the nut and the setscrew (1). Tighten the nut
2. Place an index mark on all of the harness finger tight.
assemblies that are connected to the alternator. 3. Install the clamp screw (8) through the adjustment
3. Disconnect the harness assemblies (4), (6), and bracket and into the alternator. Do not tighten the
(7) from the alternator. clamp screw (8) at this time.
4. Disconnect the ground harness assembly (5) from 4. Install the V-belts on the alternator pulley. Adjust
the alternator. the tension on the V-belts by moving the alternator
(2) away from the engine. Tighten the clamp screw
5. Loosen the nut and the setscrew (1). (8) after the correct tension is made. Refer to
6. Remove the clamp screw (8) and slide the Testing and Adjusting, “V-Belt - Test” for the
alternator (2) toward the engine. Remove the V- correct tension of the V-belts.
belts from the alternator pulley.
Note: If the V-belt cannot be checked with a gauge,
7. Remove the setscrew (1) from the alternator press on the V-belt at the center of the longest free
bracket. Remove the alternator (2) from the length in order to check the deflection. Under a
engine. moderate amount of pressure, the V-belt should have
a deflection of 10 mm (0.40 inch).
5. Tighten the nut and the setscrew (1).

6. Connect the harness assemblies (4), (6), and (7) to
the alternator.
7. Connect the ground harness assembly (5) to the
alternator.
RENR2433-04 99
8. Turn the battery disconnect switch to the ON

position.
i02309785
Electric Starting Motor -

Remove and Install
SMCS Code: 1453-010
Removal Procedure
Note: The procedure for removal of the 12 volt
electric starting motor and the 24 volt electric starting
motor is identical. Refer to illustration 199 or 200 .
1. Turn the battery disconnect switch to the OFF

position.
2. Place an identification mark on all of the harness
assemblies that are connected to the starting
motor.
3. Disconnect the harness assemblies (1), (2) and (3)
from the starting motor.
4. Remove the nuts (4) from the studs.
5. Remove the starting motor (4) from the flywheel
housing.
12 Volt Starting Motor Note: The procedure for installation of the 12 volt
electric starting motor and the 24 volt electric starting
motor is identical. Refer to illustration 201 or 202 .
100 RENR2433-04
4. Turn the battery disconnect switch to the ON

position.
i02311044
Air Compressor - Remove and

Install
SMCS Code: 1803-010
Removal Procedure
Do not disconnect the air lines until the air pres-

sure in the system is at zero. If hose is discon-
nected under pressure it can cause personal
injury.
NOTICE
Illustration 201 g01157125 Keep all parts clean from contaminants.
12 Volt Starting Motor
component life.
NOTICE
and mandates.
1. Remove the air pressure from the air tank and

drain the coolant from the cooling system.
1. Install the starting motor (4) on the flywheel

housing.
2. Install the nuts (4) on the studs. Tighten the nuts to
a torque of 44 N·m (32 lb ft).
3. Connect the harness assemblies (1), (2), and (3) to
the electric starting motor.
RENR2433-04 101
NOTICE
component life.
NOTICE
2. Disconnect the air lines from the air compressor. Service Tool Catalog” for tools and supplies suitable
Disconnect the coolant hose (1) and the coolant to collect and contain fluids on Cat products.
hose (2) from the air compressor.
3. Disconnect the oil supply tube assembly (3) from and mandates.
the air compressor. If necessary, remove the
adapter for the oil supply tube assembly from the
air compressor.
4. Remove the setscrews (4). Remove the setscrew
(5). Remove the bracket (6) that supports the air
compressor.
1. If necessary, position the air compressor drive

gear (9) on the air compressor crankshaft. Install
the nut (8). Tighten the nut to a torque of 120 N·m
(89 lb ft).
2. Remove the setscrews (14) and remove the cover
5. Remove the nut (7) from the front side of the front (12) from the mounting bracket.
housing. Remove the nut (11). Carefully remove 3. Install a new O-ring seal (10) on the air
the air compressor from the front housing. compressor. Lubricate the O-ring seal with clean
Remove the O-ring seal (10) from the air engine oil. Align the mounting studs with the air
compressor. Discard the O-ring seal. compressor and the front housing. Slide the air
6. If necessary, remove the nut (8) from the air compressor into the front housing. Rotate the
compressor crankshaft. Remove the air crankshaft of the air compressor in a clockwise
compressor drive gear (9). direction in order to align the air compressor drive
gear and the idler gear for the air compressor.
Carefully push the air compressor against the front
housing.
102 RENR2433-04
4. Install a new O-ring seal (13) and the cover (12) on Start By:
the air compressor. Install the setscrews (14).
a. Remove the front cover. Refer to Disassembly
5. Install the nut (11) and the nut (7) in order to and Assembly, “Front Cover - Remove”.
secure the air compressor to the front housing.
1. Ensure that the No. 1 cylinder is at the top center
Tighten the nuts to a torque of 75 N·m (55 lb ft).
compression stroke. Refer to Testing and
Adjusting, “Finding Top Center Position for No. 1
Piston”.
Note: The air compressor must be timed with the
engine in order to minimize engine vibration.
Note: Do not rotate the crankshaft or the air
compressor if the idler gear for the air compressor is
removed.
6. Position the bracket (6) and install the two

setscrews (4) in order to secure the bracket to the
air compressor. Tighten the setscrews to a torque
of 22 N·m (16 lb ft). Install the setscrew (5) in
order to secure the bracket to the cylinder block.
Tighten the setscrew to a torque of 44 N·m
(32 lb ft).
7. If necessary, install the adapter for the oil supply
tube assembly to the air compressor. Tighten the 2. Remove the setscrews (8). Remove the retaining
adapter to a torque of 22 N·m (16 lb ft). Connect plate (7).
the oil supply tube assembly (3) to the air
compressor. Tighten the nut to a torque of 9 N·m 3. Remove the idler gear for the air compressor (6)
(80 lb in). and the bearing (9) from the idler gear hub (4).
Remove O-ring seal (3) from the idler gear hub.
8. Connect the coolant hose (1) and the coolant hose Discard the O-ring seal.
(2) to the air compressor. Connect the air lines to
the air compressor. 4. Remove the setscrews (1). Remove the idler gear
hub (4).
9. Fill the cooling system with coolant to the correct
level. Refer to the Operation and Maintenance 5. Remove the setscrews that secure the bracket (2)
Manual for the correct filling procedure. to the front housing (5).
i02311046
Table 59
Air Compressor Idler Gear - Required Tools
Remove and Install Tool Part Number Part Description Qty
SMCS Code: 1803-010-GE A 9U-6198 Crankshaft Turning Tool 1
Removal Procedure 1. Ensure that the No. 1 cylinder is at the top center
Table 58 compression stroke. Refer to Testing and
Required Tools Adjusting, “Finding Top Center Position for No. 1
Piston”.

RENR2433-04 103
Note: The air compressor must be timed with the 6. Check the backlash between the idler gear for the
engine in order to minimize engine vibration. air compressor and the idler gear. The backlash
for the gears is 0.072 to 0.122 mm
Note: Do not rotate the crankshaft or the air
(0.0028 to 0.0048 inch).
compressor if the idler gear for the air compressor is
removed. 7. Check the backlash between the idler gear for the
air compressor and the air compressor gear. The
backlash for the gears is 0.072 to 0.127 mm
(0.0028 to 0.0050 inch).
End By:
and Assembly, “Front Cover - Install”.
2. Position the bracket (2). Install the setscrews in

order to secure the bracket to the front housing.
Tighten the setscrews to a torque of 35 N·m
(26 lb ft).
3. Install a new O-ring seal (3) on the idler gear hub
(4). Lubricate the O-ring seal with clean engine oil.
Position the idler gear hub and install setscrews
(1). Tighten the setscrews to a torque of 60 N·m
(44 lb ft).
4. Lubricate the shaft of the idler gear hub with clean
engine oil. Install the bearing (9). Lubricate the
bore of the idler gear for the air compressor (6)
with clean engine oil. Install the idler gear for the
air compressor.
5. Position retaining plate (7) and install bolts (8).
Tighten the bolts to a torque of 22 N·m (16 lb ft).

Typical Example
104 RENR2433-04
Index Section
Index
A Crankshaft Rear Seal - Install...............................38
Installation Procedure ......................................38
Accessory Drive - Remove and Install...................56 Crankshaft Rear Seal - Remove ...........................37
Installation Procedure ......................................56 Removal Procedure .........................................37
Removal Procedure .........................................56 Crankshaft Wear Sleeve (Rear) - Install ................40
Air Compressor - Remove and Install.................. 100 Installation Procedure ......................................40
Removal Procedure ....................................... 100 Crankshaft Wear Sleeve (Rear) - Remove ............39
Air Compressor Idler Gear - Remove and Install .. 102 Removal Procedure .........................................39
Installation Procedure .................................... 102 Cylinder Head - Install .........................................65
Removal Procedure ....................................... 102 Installation Procedure ......................................65
Alternator - Install ................................................98 Cylinder Head - Remove......................................63
Alternator - Remove ............................................98
Removal Procedure .........................................98
D
B Disassembly and Assembly Section .......................4
Balancer Group - Install (If Equipped) ...................74
Installation Procedure ......................................74 E
Balancer Group - Remove (If Equipped)................72
Removal Procedure .........................................72 Electric Starting Motor - Remove and Install ..........99
Bearing Clearance - Check ..................................91 Installation Procedure ......................................99
Measurement Procedure ..................................91 Removal Procedure .........................................99
Engine Oil Cooler - Install ....................................28
C Engine Oil Cooler - Remove.................................27
Camshaft - Remove and Install ............................68 Engine Oil Filter Base - Remove and Install...........25
Installation Procedure ......................................68 Installation Procedure ......................................26
Removal Procedure .........................................68 Removal Procedure .........................................25
Camshaft Bearings - Remove and Install ..............69 Engine Oil Pan - Remove and Install.....................71
Camshaft Gear - Remove and Install ....................68 Engine Oil Pressure Sensor - Remove and
Installation Procedure ......................................69 Install ...............................................................93
Removal Procedure .........................................68 Installation Procedure ......................................94
Connecting Rod Bearings - Install.........................82 Removal Procedure .........................................93
Installation Procedure ......................................82 Engine Oil Pump - Install (Engines Without a
Connecting Rod Bearings - Remove .....................81 Balancer) ..........................................................32
Removal Procedure .........................................81 Installation Procedure ......................................32
Coolant Temperature Sensor - Remove and Engine Oil Pump - Remove (Engines Without a
Install ...............................................................92 Balancer) ..........................................................31
Removal Procedure .........................................92 Engine Oil Relief Valve - Remove and Install
Crankcase Breather - Remove and Install .............58 (Engine with Balancer Group).............................29
Crankshaft - Install ..............................................87 Engine Oil Relief Valve - Remove and Install
Installation Procedure ......................................87 (Engine without Balancer Group) ........................30
Crankshaft - Remove...........................................86 Installation Procedure ......................................30
Crankshaft Front Seal - Install ..............................44 Exhaust Manifold - Remove and Install .................17
Crankshaft Front Seal - Remove ..........................43 Removal Procedure .........................................17
Crankshaft Gear - Remove and Install ..................90
Installation Procedure ......................................91 F
Crankshaft Main Bearings - Install ........................84 Fan - Remove and Install .....................................96
Crankshaft Main Bearings - Remove.....................83 Removal Procedure .........................................96
Removal Procedure .........................................83 Fan Drive - Remove and Install ............................97
Crankshaft Pulley - Remove and Install.................42 Installation Procedure ......................................97
Removal Procedure .........................................42 Flywheel - Install .................................................36
RENR2433-04 105
Index Section

Flywheel - Remove..............................................36 Removal Procedure .........................................20
Flywheel Housing - Remove and Install.................41
Installation Procedure ......................................41 L
Removal Procedure .........................................41 Lifter Group - Remove and Install .........................67
Front Cover - Remove and Install .........................45 Installation Procedure ......................................67
Fuel Injection Lines - Remove and Install ................5
Installation Procedure ........................................6 P
Removal Procedure ...........................................5
Fuel Injection Nozzles - Install ................................7 Piston Cooling Jets - Remove and Install ..............75
Installation Procedure ........................................7 Installation Procedure ......................................76
Fuel Injection Nozzles - Remove ............................6 Removal Procedure .........................................75
Removal Procedure ...........................................6 Pistons and Connecting Rods - Assemble.............78
Fuel Injection Pump - Install (Bosch EVPE) .......... 11 Assembly Procedure ........................................78
Installation Procedure ...................................... 11 Pistons and Connecting Rods - Disassemble ........77
Fuel Injection Pump - Install (Delphi DP210).........13 Disassembly Procedure ...................................77
Installation Procedure ......................................13 Pistons and Connecting Rods - Install...................79
Fuel Injection Pump - Remove (Bosch EVPE).........7 Installation Procedure ......................................79
Removal Procedure ...........................................7 Pistons and Connecting Rods - Remove ...............76
Fuel Injection Pump - Remove (Delphi DP210) .......9 Removal Procedure .........................................76
Removal Procedure ...........................................9
Fuel Priming Pump and Fuel Filter Base -
Remove and Install ..............................................4 R
Installation Procedure ........................................4 Rocker Shaft - Assemble .....................................61
Removal Procedure ...........................................4 Assembly Procedure ........................................61
Rocker Shaft - Disassemble .................................61
Disassembly Procedure ...................................61
G Rocker Shaft and Pushrod - Install........................62
Glow Plugs - Remove and Install ..........................94 Installation Procedure ......................................62
Installation Procedure ......................................95 Rocker Shaft and Pushrod - Remove ....................60
H T
Housing (Front) - Install .......................................54 Table of Contents ..................................................3
Installation Procedure ......................................54 Turbocharger - Install ..........................................16
Housing (Front) - Remove....................................52 Installation Procedure ......................................16
Removal Procedure .........................................52 Turbocharger - Remove.......................................14
I
V
Idler Gear - Remove and Install (Bosch EPVE
Fuel Injection Pump)..........................................49 V-Belts - Remove and Install ................................95
Idler Gear - Remove and Install (Delphi DP210 Valve Mechanism Cover - Remove and Install .......59
Fuel Injection Pump)..........................................46 Installation Procedure ......................................59
Important Safety Information ..................................2
Inlet and Exhaust Valve Guides - Remove and W
Install ...............................................................23 Water Pump - Remove and Install ........................33
Inlet and Exhaust Valve Seat Inserts - Remove Water Temperature Regulator - Remove and
and Install .........................................................24 Install ...............................................................34
Inlet and Exhaust Valve Springs - Remove and
Install ...............................................................18
Inlet and Exhaust Valves - Remove and Install.......20
RENR2433 CAT, CATERPILLAR, LET’S DO THE WORK, their respective
©2021 Caterpillar logos, “Caterpillar Corporate Yellow”, the “Power Edge” and Cat
All Rights Reserved “Modern Hex” trade dress as well as corporate and product identity
used herein, are trademarks of Caterpillar and may not be used
without permission.
106 June 2021

3054C Industrial Engine D&amp;A.

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Disassembly and Assembly

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Table of Contents Lifter Group - Remove and Install .........................67

Disassembly and NOTICE

Tool Part Number Part Description Qty

Fuel Injection Lines - Remove

Tool Part Number Part Description Qty

Note: SERVICE DATA: TOOLING (ZZ) WILL NOT

3. Disconnect fuel injection lines (3) at fuel injection

4. Position cover (2) on the cylinder head. Install bolts

Fuel Injection Nozzles -

Illustration 7 g00975056 Illustration 8 g00975210

Contaminants may cause rapid wear and shortened

Tool Part Number Part Name Qty

A 230-6284 Timing Pin (Camshaft) 1

B 230-6283 Timing Pin (Crankshaft) 1

D 1P-2320 Combination Puller 1

1. Use Tooling (C) to ensure that the No. 1 cylinder is

4. Loosen bolt (6). Move spacer (5) in order to allow

10. Remove the fuel injection pump from the front

Fuel Injection Pump - Remove

Illustration 11 g00996413 Required Tools

Tool Part Number Part Name Qty

1. Use Tooling (C) to ensure that the No. 1 cylinder is

6. Remove nut (8) and the washer from the shaft of

2. Loosen bolt (5). Move spacer (6) in order to allow

11. Remove the fuel injection pump from the front

Fuel Injection Pump - Install

Tool Part Number Part Name Qty

A 230-6284 Timing Pin (Camshaft) 1

B 230-6283 Timing Pin (Crankshaft) 1

C 9U-6198 Crankshaft Turning Tool 1 Illustration 16 g00996474

2. Install O-ring seal (9) on the fuel injection pump.

Illustration 17 g00996413 Illustration 19 g00996410

10. Tighten nut (7) to a torque of 88 N·m (65 lb ft).

6. Connect the wiring harness assembly to engine

1. Use Tooling (C) to ensure that the No. 1 cylinder is

Note: Install Tooling (A) through the camshaft gear.

Note: Spacer (6) must be correctly positioned and

Note: Ensure that the mating surfaces of the fuel

10. Connect the harness assembly to timing advance Removal Procedure

1. Thoroughly clean the outer surfaces of the

11. If necessary, install new washers and the oil

3. If necessary, install the studs (14) in the exhaust

18. Position the exhaust pipe on the exhaust elbow

Exhaust Manifold - Remove

Note: The exhaust elbow is an option for this engine.

14. If equipped, install the exhaust elbow (3) onto the

Note: Use a solution of water and 5 % soap to install Installation Procedure

Tool Part Number Part Description Qty

Note: Improper installation of the exhaust manifold

Note: The following procedure should be adopted in

Inlet and Exhaust Valve

Tool Part Number Part Description Qty

A 9U-6195 Valve Spring Compressor 1

B 9U-6198 Crankshaft Turning Tool 1

Tool Part Number Part Description Qty

A 9U-6195 Valve Spring Compressor 1

B 9U-6198 Crankshaft Turning Tool 1

a. Install the Tooling (A).

b. Compress the valve spring in order to open the

3054C Industrial Engine D&A.

3054C Industrial Engine D&A.