RENR7458-09

August 2008

Disassembly and
Assembly m
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C7 On-Highway Engine
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YPG1-Up (Engine)
NPH1-Up (Engine)
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KAL1-Up (Engine)
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LBM1-Up (Engine)
SAP1-Up (Engine)
C7T1-Up (Engine)
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WAX1-Up (Engine)
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SAFETY.CAT.COM
 i01658146

Important Safety Information

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

The meaning of this safety alert symbol is as follows:

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Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
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presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.
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Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. If a tool,
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procedure, work method or operating technique that is not specifically recommended by Caterpillar
is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that
the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
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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
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affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Caterpillar dealers have the most current information available.
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When replacement parts are required for this

product Caterpillar recommends using Caterpil-
lar replacement parts or parts with equivalent
specifications including, but not limited to, phys-
ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
RENR7458-09 3
Table of Contents

Table of Contents Lifter Group - Remove and Install ......................... 43

Camshaft - Remove .............................................. 45
Camshaft - Install .................................................. 45
Camshaft Gear - Remove and Install .................. 46
Disassembly and Assembly Section Camshaft Bearings - Remove and Install ............ 47
Engine Oil Pan - Remove and Install ................... 48
Fuel Priming Pump - Remove and Install .............. 4
Piston Cooling Jets - Remove and Install ............. 49
Fuel Filter Base - Remove and Install .................... 4
Pistons and Connecting Rods - Remove .............. 50
Fuel Transfer Pump - Remove ................................ 5
Pistons and Connecting Rods - Disassemble ....... 51
Fuel Transfer Pump - Install .................................... 6
Pistons and Connecting Rods - Assemble ........... 51
Unit Injector - Remove ............................................ 7
Pistons and Connecting Rods - Install .................. 53
Unit Injector - Install ................................................ 8
Connecting Rod Bearings - Remove .................... 54
Unit Injector Sleeve - Remove ................................ 9
Connecting Rod Bearings - Install ........................ 54
Unit Injector Sleeve - Install .................................. 10
Crankshaft Main Bearings - Remove .................... 55
Unit Injector Hydraulic Pump - Remove ................. 11
Crankshaft Main Bearings - Install ........................ 56
Unit Injector Hydraulic Pump - Install ..................... 11
Crankshaft - Remove ............................................ 57
Modulating Valve - Remove and Install ................ 12
Crankshaft - Install ................................................ 58
Turbocharger - Remove ........................................ 12
Crankshaft Gear - Remove and Install ................ 59
Turbocharger - Install ............................................ 13
Bearing Clearance - Check ................................... 60

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Exhaust Manifold - Remove and Install ............... 14
Atmospheric Pressure Sensor - Remove and
Air Inlet Heater Solenoid - Remove and Install .... 15
Install ................................................................... 61
Inlet and Exhaust Valves - Remove and Install .... 15
Coolant Temperature Sensor - Remove and
Inlet and Exhaust Valve Guides - Remove and
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Install ................................................................... 61
Install ................................................................... 17
Engine Oil Pressure Sensor - Remove and Install
Inlet and Exhaust Valve Seat Inserts - Remove and
............................................................................. 62
Install ................................................................... 18
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Injection Actuation Pressure Sensor - Remove and
Engine Oil Filter Base and Oil Cooler - Remove .. 19
Install ................................................................... 62
Engine Oil Filter Base - Disassemble ................... 19
Speed/Timing Sensor - Remove and Install ........ 62
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Engine Oil Filter Base - Assemble ........................ 20

Boost Pressure Sensor - Remove and Install ....... 63
Engine Oil Filter Base and Oil Cooler - Install ..... 20
Inlet Air Temperature Sensor - Remove and
Engine Oil Pump - Remove .................................. 22
Install ................................................................... 63
Engine Oil Pump - Disassemble ........................... 22
Fan Drive Mounting Group - Remove and Install .. 64
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Engine Oil Pump - Assemble ................................ 23

Engine Control Module - Remove and Install ....... 65
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Engine Oil Pump - Install ...................................... 24

Alternator - Remove and Install ........................... 65
Water Pump - Remove ......................................... 24
Electric Starting Motor - Remove and Install ....... 66
Water Pump - Disassemble ................................. 25
Air Compressor - Remove and Install .................. 67
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Water Pump - Assemble ...................................... 25

Air Compressor Drive Gear - Remove .................. 68
Water Pump - Install ............................................. 26
Air Compressor Drive Gear - Install (Two
Water Temperature Regulator - Remove and Install
Cylinder) .............................................................. 69
............................................................................. 26
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Air Compressor Drive Gear - Install ...................... 70

Flywheel - Remove ............................................... 27
Flywheel - Install ................................................... 27
Crankshaft Rear Seal - Remove ........................... 28 Index Section
Crankshaft Rear Seal - Install ............................... 28
Flywheel Housing - Remove and Install .............. 29 Index ..................................................................... 71
Vibration Damper and Pulley - Remove and Install
............................................................................. 30
Crankshaft Front Seal - Remove .......................... 31
Crankshaft Front Seal - Install .............................. 32
Front Cover - Remove .......................................... 32
Front Cover - Install .............................................. 32
Housing (Front) - Remove .................................... 33
Housing (Front) - Install ........................................ 34
Camshaft Idler Gear - Remove and Install ........... 35
Valve Mechanism Cover - Remove and Install ..... 36
Valve Mechanism Cover Base - Remove and
Install ................................................................... 36
Rocker Shaft and Pushrod - Remove ................... 37
Rocker Shaft - Disassemble ................................ 38
Rocker Shaft - Assemble ..................................... 38
Rocker Shaft and Pushrod - Install ....................... 39
Cylinder Head - Remove ...................................... 40
Cylinder Head - Install .......................................... 41
4 RENR7458-09
Disassembly and Assembly Section

Disassembly and Assembly 2. Remove fuel priming pump (1) and the gasket.

Section Installation Procedure

i02581591

Fuel Priming Pump - Remove

and Install
SMCS Code: 1258-010

Removal Procedure

Fuel leaked or spilled onto hot surfaces or elec-

trical components can cause a fire. To help pre-

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vent possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.
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NOTICE
Care must be taken to ensure that fluids are contained g00987651
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Illustration 2
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to 1. Position the gasket and fuel priming pump (1) on
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collect the fluid with suitable containers before open- the fuel filter base.
ing any compartment or disassembling any compo-
nent containing fluids. 2. Install bolts (2). Tighten bolts (2) to a torque of
25 ± 6 N·m (18 ± 4 lb ft).
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Refer to Special Publication, NENG2500, “Caterpillar

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Dealer Service Tool Catalog” for tools and supplies

suitable to collect and contain fluids on Caterpillar i01921666
products.
Fuel Filter Base - Remove and
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Dispose of all fluids according to local regulations and Install

mandates.
SMCS Code: 1262-010
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Removal Procedure

Fuel leaked or spilled onto hot surfaces or elec-

trical components can cause a fire. To help pre-
vent possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.

g00987651
Illustration 1

1. Remove bolts (2).

RENR7458-09 5
Disassembly and Assembly Section

Installation Procedure
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.

Refer to Special Publication, NENG2500, “Caterpillar

Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

mandates.

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g00987754
Illustration 4

1. Position fuel filter base (4) on the engine.

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2. Install bolts (2).

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3. Connect tube assembly (1) and tube assembly (3).

i02226208
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Fuel Transfer Pump - Remove

SMCS Code: 1256-011
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g00987754
Removal Procedure
Illustration 3
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Table 1
1. Disconnect tube assembly (1) and tube assembly
Required Tools
(3).
Part
2. Remove bolts (2). Tool Number Part Description Qty
A 218-8171 Bolt 1
3. Remove fuel filter base (4).

Start By:

a. Remove the unit injector hydraulic pump. Refer

to Disassembly and Assembly, “Unit Injector
Hydraulic Pump - Remove”.

Note: Tooling (A) is required for replacement of the

fuel transfer pump.
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