CATERPILLAR’ or Disassemlaly Assemioly 3054 Engine For 416B, 426B, 428B, 436B and 438B Backhoe Loaders 416B: 8SG1-UP 426B: 5YJ1-UP 6KL1-UP 428B: 7EJ1-UP 436B: 6MJ1-UP 438B: 3KK1-UPImportant Safety Information Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can of en 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, skils and tools to perform thase 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 wamings are provided in this manual and on the product. i these hazard ‘warnings are not heeded, bodily injury or death coulé ocour to you or other persons. ‘The hazards are identified by the “Safely Alert Symbol” and followed by a "Signal Word! such as ‘WARNING’ as 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 waming, explaining the hazard, can be either written or pictorially presented. Operations that may cause product damage are ideniied by NOTICE labels on the product and in this publication, Caterpilar cannot anticipate every possible circumstance that might involve a potential hazard, The ‘wamings in this publication and on the product are therefore not all inclusive. Ifa tool, procedure, work method or operating technique not specifically recommended by Caterpillar is used, you must satisty ‘yourse!f that itis safe for you and others. You should also ensure that the product will nat be damaged ‘or made unsafe by the operation, lubrication, mainterance or repair procedures you choose. The information, specifications, and illustrations inthis publication are on the basis of information avaliable at the time it was written. The specifications, torques, pressures, measurements, adjustments ilustrations, and other iteris can change at any time. These changes can affect the service given to the product, Obtain the complete and most current information betore starting any job. Caterpillar dealers have the most current information available, For alist of the most current publication form numbers available, see the Service Manual Contents Microfiche, REG1 139F.Index Alternator Alternator Bracket Alternator V-Belt/V-Belts Camshaft Assembly & Tappets Gamshatt Bushing Camshaft Gear Gold Start Heater ‘Connecting Food Bearings Crankshatt Crankshaft Bearings (Upper Shels) Grankshat Front Oi Seal Grankshaft Gear (On Engine) Crankshaft Gear Crankshaft Main Bearing (Without Crankshait Removal) Crankshaft Pulley Grankshalt Rear Oi Seal Crankshaft Thrust Washers Cylinder Block Cylinder Head Cylinder Head, Disassemble & Assembie Cylinder Liners Dipstick Assembly Engine Rear Supports Engine, Torque Converter And Transmission Engine, Torque Converter And Transmission, Separation & Connection Exhaust Manifold Fan Fan Drive Housing Fan Drive Housing, Disassemble & Assemble Flywheel & Ring Gear Flywheel Housing Flywheel Ring Gear Front Engine Support Fuol Filter Fuel injection Lines Fuel injection Nozzle, Disassemble & Assemble Fuo! Injection Nozzies Fue! injection Pump Fuel injection Pump Gear Fuel Pump Fuel Pump, Disassemble & Assemble Idler Gear & Hub Idler Gear Shaft For Oi Pump Inlet Manifold Liting Brackets Muffler Assembly Muffler Support 3054 Engine Oil Fiter Base & Cooler, Disassemble & Assemble Oil Fitter Element il Filter, Oi Filer Base & Cooler Oil Pan Oil Pump Oil Strainer & Suction Pipe Piston & Connecting Rod Assembly Piston & Connecting Rods, Disassemble & Assemble Piston Cooling Jets Precleaner Radiator (Out Of Chassis) Radiator, Oil Cooler And Condenser (in Chassis) Radiator, Oil Cooler And Condenser, Separation & Connection Relief Valve Relief Valve, Disassemble & Assemble Rooker Shaft Assembly & Push Rods Rocker Shaft Assembly, Disassemble & Assemble Starter Starting Aid Thermostat Thermostat Housing Timing Gear Case Assembly Timing Gear Case Cover Turbocharger Turbocharger, Disassemble & Assemble Valve Cover Valve Springs (Head On) Water Pump Water Pump, Disassemble & Assemble Water Separator Water Separator, Disassemble & Assemble 48, 47 a7 48 49 59 51 54 50 55, 55 9 " 60. 60 56 87 58 59 6 6 62 64 65 66 or 67 68 6 73 3 Disconnect batteries before performance of any rvice work. IndexDisassembly & Assembly Engine, Torque Converter And Transmission Remove & Install Engine, Torque Converter And Transmission 1004-010 Tools Needed TA] $SHi01 Sing Assen Start By. 3. Disconnect wiring harnesses that goes to the engine at connectors (4). 1. remove counterweight* b. remove hydraulic tank* cc. remove radiator “Operations are located in the Vehicle Systems, Disassembly and Assembly section. NOTE: Before any removals of any components, put identification on all lines, hoses, wiring harnesses and tubes for installation purposes 4, Disconnect shuttle linkage (5), and then move it to one side, 5. Remove throttle linkage (6). 6. Remove the two transmission mounting bots (7). 1, Remove the floor plates above the transmission. 2. Disconnect wiring harness (2). Loosen bolt (3) and. then remove the shift lever (1) 7. Remove four bolts (8) to disconnect the driveshalt between the transmission and rear axle, 3054 Engine 4 Disassembly & Assembly8. Remove muffler (9) and air cleaner (10) from engine a) 9. Disconnect hose (12) that goes to the water pump. 10. Disconnect all wiring (13) to the starter. 11. Remove air conditioning compressor (14) and ‘mounting bracket (15). 3054 Engine 12. Disconnect two fuel lines (16) and one hose (17). 13. Fasten tool (A) and a hoist to the engine. Remove two front mounting bolts (18) NOTE: Make a final check to be sure that all removals and disconnections have been made from the engine, torque converter and transmission, 14, Remove engine, torque converter and transmission (11) as a unit from the machine Weight of the unit is 550 Kg (1200 Ibs.).NOTE: The following steps are for the installation of the engine, torque converter and transmission as a unit 19. Install mounting bracket (18) and air conditioning ‘compressor (14), 15. Install engine, torque converter and transmission (11) in the machine as a unit, 20. Connect ail wiring (13) to the starter. 21. Connect hose (12) that goes to the water pump. 16. install two front mounting bolts (18), 17. Remove tool (A) from the unit. 22, Install the air cleaner (10) and mutter (9) on the engine, 48. Connect two fuel ines (16) and one hose (17). 3054 Engine 6 Disassembly & Assembly23, Connect the drivochatt botwoon tho transmission and the rear axle and install four bolts (8). 24, Install the two transmission mounting bolts (7) 25, Install throttle linkage (6). 26. Connect shuttle linkage (5) 27. Connect wiring harnesses that goes to the engine at connectors (4) 28. Inctall shift over (1) and then tighten bolt (3). 29. Connect wiring harness (2). End By: a. install radiator b. install hydraulic tank” ¢. install counterweight” ‘Operations located in the Machine Systems, Disassembly and Assembly section, Separation & Connection Of Engine, Torque Converter And Transmission 1004-029 start By a. remove engine, torque converter and transmission 4. Disconnect wiring harness (1) from the transmission and then move the wiring harness to one side and ‘out of the way. 3054 Engine Disassembly & Assembly66. Fasten a hoist to the transmission and torque cconverter as shown, 7. Remove bolts (6) and separate the transmission (7) and torque converter from the engine (8). NOTE: The following steps are for the connection of the engine, torque converter and transmission 2. Drain the fluid from tne transmission. Remove the fill tube (2). 3. Disconnect the two hoses (3). 8. Put transmission (7) and torque converter in position Cn the engine (8) and install bolts (6). Remove the hoist from the transmission and torque converter. Remove jack stand (5) from the oll pan, 4. Remove access cover from the torque convertor housing. Remove the bolts (4) that hold the flex plate to the fywheel. Insert a screwdriver between the flex plate and toraue converte to hold the torque converter in place. 10. Withdraw the screwdriver from between the ‘ex plate and torque converter. 11. Install the bolts (4) that hold the flex pate to the flywheel 5. Install a jack stand (6) under the oil pan to support the engine when the transmission is removed. 3054 Engine 8 Disassembly & Assembly12. Connect two hoses (3). Install ill tube (2). 1, Fill the transmission with fluid to the correct level See the MAINTENANCE MANUAL. 14. Connect wiring harness (1) to the transmission. End By: €. install engine, torque converter and transmission Radiator, Oil Cooler and Condenser Remove & Install Radiator, Oil Cooler And Condenser 1353-010 Tools Needed ‘BVET56 Link Bracket 2 Start By: a. remove hydraulic tank 1. Open the petcock (1) to drain the coolant from the system, 2. Disconnect three lines (2) from under the oil cooler. 3. Disconnect top and bottom radiator hoses (3) 4, Remove fan guard (4) 3054 Engine Disassembly & Assembly10. install radiator, oil cooler and condenser (7) as a unit in the machine. 11. Install the bolts (6) in the radiator mounting brackets. 12, Remove tooling (A) from the radiator group. 6. Fasten tooling (A) and a hoist to the radiator group, 7. Remove bolts (6) from the radiator mounting ean brackets. 8. Remove radiator, oil cooler and condenser (7) as a unit from the machine. 9. Weight of the unit is 68 Kg (150 Ibs.) NOTE: The following steps are for the installation of the radiator, oil cooler and condenser. 14. Install fan guard (4), 15. Connect the bottom and top radiator hoses (3) to the radiator. 3054 Engine 10 Disassembly & Assembly16. Connect thvee lines (2) that goes under the oil 2, Remove bolts (4) [hidden] and separate oil cooler cooler. (3) from the radiator (5). 17. Close the petcock (1) and then fil the cooling NOTE: The following steps are for the connection of system with coolant to the correct level. See the the radiator, oil cooler and condenser. Operation & Maintenance Manual End By: eG a. install hydraulic tank Separation & Connection Of Radiator, Oil Cooler And Condenser 1353-029 Tools Needed a VETE6_ Link Bracket 2 Start By ae lator, oil cooler and cond & remove ractstor, OF cooler anc condenser 3. Make a connection of the oil cooler (3) and radiator (6) with the bolts (4), 1. Remove four bolts (1) and condenser (2) from the ail cooler (3). 4, Install the condenser (2) on the oil cooler (8) with four bolts (1). End By a. install radiator, oil cooler and condenser 3054 Engine n Disassembly & AssemblyAlternator Remove & Install Alternator 1405-010 NOTE: Disconnect all electrical connections to the alternator before proceeding. Mark or identity for later installation 1. Loosen two Eolts (1). 3, Slide alternator (3) towards the engine. Loosen bolt (2) 4. Disconnect alternator V-belt (4) 5. Remove three bolts (1) and (2) previously loosened. 6. Remove alternator (3) NOTE: If the alternator pulley was removed, tighten the alternator nut to a torque of 45 to 55 Nem (33 to 40 Ib ft) NOTE: When installing the alternator, make sure the alternator pulley s aligned to the crankshaft pulley to within 2.4 mm (3/32 inch), NOTE: For installation of the alternator, reverse the removal steps, NOTE: Refer to the topic, "Remove & Install Alternator \V-Belt/V-Belts’, for information on tightening the V- belt/V-belts tension. Alternator V-Belt/V-Belts Remove & Install Alternator V-Belt/V-Belts 1405-BE-010 t 4 1. Remove fan guards (1). 2. Loosen three alternator bolts (2). Slide alternator (3) towards the engine 3. Maneuver the V-belt or V-belts (4) around the fan inside the radiator shroud. 4, Remove the V-belt or V-belts. Check for wear or damage. NOTE: If equipped, always replace the two alternator V-belts when one is to be replaced, NOTE: For installation of the alternator Vibelt or V- bolts, reverse the removal steps. NOTE: Refer to Specifications Manual SENR5S41 for information on the V-belt tension. NOTE: Ifthe V-belt is not to be checked by a gauge, press down on the V-belt with the thumb at the center Of the longest free length and check the cetlection. With moderate thumb pressure, 45 N (10 Ib), the etlection is 10 mm (3/8 inch). When checking V- belts, always use the tighter of the two V-belts fo adjust tension 3054 Engine 12 Disassembly & AssemblyAlternator Bracket Remove & Install Alternator Bracket 1405-BK-010 Start By a. remove alternator 2. Remove thrust washer (1). Note the location of the hollow dowel marked (X) for later installation. 1. Remove three bolts (1). 2. Remove alternator bracket (2). NOTE: For instalation of the alternator bracket, ican reverse the removal steps d End By: 3. Carefully remove camshatt (2). a. install alternator NOTICE Do not nick or scratch any of the finished surfaces on Camshaft Assembly & Tappets ‘the camshaft. Remove & Install Camshaft Assembly & Tappets 1210-010 Start By €. remove timing case cover b. remove rocker shaft and push rods ¢. remove the fuel pump 4. remove the oil pump NOTE: When installing make sure all components are Clean and are lubricated with clean engine oll 1, Rotate the engine 180° (oan side up) so the tappets. ‘4. Remove eight or twelve tappets (3). will remain in position after the camshaft is removed. 3054 Engine 13 Disassembly & AssemblyNOTE: For installation of the camshaft assembly and tappets, reverse the removal steps. End By 2. install he ol pump ». install the fuel pump ¢. instal rocker shaft and push rods d. instal timing case cover Camshaft Bushing Remove & Install Camshaft Bushing 1211-010 "Tools Needed a aszeei ‘Bearing Puler 1 Start By: a. remove camshaft 1. Install Tool (A). Remove camshatt bushing (1) NOTE: Tool (A) is used to both remove and install camshaft bushing. Refer to instructions on 852241 Tool Group for procedure. NOTE: For installation of the camshaft bushing, reverse the removal step. End By: a. install camshaft Camshaft Gear Remove & Install Camshaft Gear 1288-010 Tools Needed TA UST Pale Goar 1 54712 Bot (Used inuncion With TUSETH 1 P0510 Puller Group 1 Start By: a. remove fan b. remove water pump ¢. remove crankshaft pulley 4. remove timing gear case cover NOTE: Turn the crankshaft until the marks on the crankshaft gear, the camshaft gear and the fuel pump gear are in mesh with the ider gear. NOTE: The idler gear marks may not be in mesh with the other three gears due to the different speed of rotation of the idler gear. 3054 Engine 14 Disassembly & Assembly1, Remove bolt (1) and the washer on camshaft gear (2). When installing, tighten the bolt to a torque of 78 Nem (88 Ib ft), 2. Use Too! (A) to remove the camshaft gear. Check the camshaft gear for wear or damage. Replace it necessary. If a new camshaft gear is used, check the backlash, NOTE: Be sure not to lose the key from the camshaft when removing the camshaft gear NOTE: When instaling the camshaft gear, install the gear with the marked teeth towards the front with the keyway correctly aligned with the key. f necessary, hit the gear with a soft hammer to engage the key into the ‘camshaft gear keyway. ‘3. Remove the idler gear it necessary to align the gear teeth properly NOTE: When installing the idler gear, make sure the marked teeth are in correct mesh. If the camshaft has to be turned and a valve hits a piston, remove the rocker assembly, NOTE: For installation of the camshaft gear, reverse the removal steps. NOTE: If a new camshatt gear is installed, check the backlash of the camshaft gear. The backlash is 0.08 ‘mm (0.003 inch) minimum. End By: a. install timing gear case cover b. install crankshaft pulley ©. install water pump 4. instal fan Crankshaft Remove & Install Crankshaft 1202-010 Start By 2. remove fuel injection pump b, remove flywheel housing €. remove rear oil seal housing d. remove oll pump 4. Remove two socket head bolts (1) 2. Remove bridge (2) 3054 Engine 15 Disassembly & Assembly3. Remove ten or fourteen bolts (3) 4, Remove five or seven bearing caps (4). NOTE: Mark or identity fo later installation. 5. Remove the lower half bearings and the upper and lower thrust washers, NOTE: Keep the bearings with thelr respective caps 6. Remove eight or twelve nuts (6) 7. Remove four or six connecting rod caps (6) NOTE: Mark or identity for later installation, 8, Remove the bearings from rod caps (6) Nott ‘eep the bearings with their respective caps. 9. Remove eight or twelve connecting rod bolts (7). 10. Carefully push the pistons into their bores, 11. Attach straps and a suitable lifting device to crankshaft (8). 42. Carefully ft the crankshaft out of the engine block. The weight of the crankshatt is 29 kg (65 Ib). Do not nick or scratch any of the finished surfaces on the crankshaft, 13. Remove the upper haif bearing and piace with the relevant lower half bearing for installation. NOTE: The following steps are for the installation of the crankshaft 14. Make sure that all the lubricating passages are clean and free of debris, 15. Clean the main bearing housings. 16. Clean the upper half bearings. 17. Position the bearings with the location tabs correctly positioned into the recesses, Lubricate the bearings with clean engine oil. 18. Make sure the main journals of the crankshaft are clean. 19. Position the crankshaft into position on the upper half bearings. 20. Clean and lubricate the upper half thrust washers and slide them into position onto the recesses on both sides of the bearing housing, NOTICE Be sure the slotted sides of the thrust washers are towards the crankshaft. 21. Clean the bearing caps and the lower half bearings. 22. Install the bearings to the caps with the location tabs correctly positioned into the recesses. Lubricate the bearings with clean engine oil 16 Disassembly & Assembly23. Clean and lubricate the lower half thrust washers and slide them into position on both sides of the bearing cap for the center main bearing, 24. Check that the location thimbles for the main bearing caps are positioned correctly in the caps or in the oylinder block. Install the bearing caps in their correct position (as shown by the position ‘number stamped on the top of the cap) with the location tabs of the bearing on the same side. In this position the serial numbers stamped on the bearing caps will be in line. The serial number stamped on the bearing caps must be the same umber stamped on the bottom face of the cylinder block. 26. Install the bolts to the main bearing caps. Tighten them gradually and evenly to a torque of 265 Nem. (196 Ib ft). 26. Clean the bridge piece and the location areas for the bridge piece in the cylinder block. Apply a thin strip of 8T9013 Red RTV Silicone in the corners, and around the thread holes of the bridge piece seat in the cylinder block. Install the bridge piece and the rubber seals (f equipped), The rubber seals (if equipped) will be a litle higher than the bridge piece when they are installed correctly, NOTE: Use a straight edge to be sure the that the bridge piece is inline with the rear face of the cylinder block. Tighten the bridge piece cap screws, NOTE: A bridge piece has been introduced which uses 819013 Red RTV Silicone instead of the rubber seal in the groove at each end of the bridge piece. The {groove at each end of the new bridge piece is cast and is off center. The procedure to install the new bridge piece is the same as for the earlier bridge piece except {or the following instructions, NOTE: Apply 3.0 mm (1/8 inch) bead of 8T9013 Red RTV Silicone along the comer in the top of the recess in the cylinder block for the bridge piece. When the bridge piece is in position and the cap screws have been tightened, inject 8T9013 Red ATV Silicone inio the groove at each end ofthe bridge piece until the groove is completely filed. NOTE: When the pan gasket is removed, damage can ‘occur to the 8T9013 Red RTV Silicone seal in the ‘grooves of the bridge piece. If the seal is damaged, apply sufficient 8T9013 Red RTV Silicone to completely fill the grooves. Most of the latest engines hhave setscrews instead of studs to fasten the pan to the bridge piece. The threads of the setscrews have a sealant applied by the manufacturer. When the selsorews are used again, be sure that the threads of the cap sorews and the bridge piece are clean and 983263 Thread Lock is applied to the threads of the selscrews. These instructions would also apply to studs. 27. Install the connecting rod caps. Turn the ‘crankshaft two complete revolutions to check for {ree movement 28. install the lubricating oil pump, the lubricating oll suction pipe and strainer, the delivery pipe and the relief valve, End By: a. install oil pump b. install rear oll seal housing ¢. install flywheel housing 4. install fuel injection pump Crankshaft Bearings (Upper Shells) Remove & Install Crankshaft Bearings (Upper Shells) 1203-TE-010 Start By: a. remove crankshaft 1. Remove five or seven crankshalt bearings (1) 2. It necessary, remove two thrust bearings (2) NOTE: For instalation of the crankshaft bearings (upper bearings), reverse the removal steps End By: a. install crankshaft 3054 Engine Disassembly & AssemblyCrankshaft Gear (On Engine) Remove & Install Crankshaft Gear (On Engine) 1204-010 Start By: a. remove fan . remove water pump . remove crankshaft pulley 4d. remove timing gear case cover NOTE: Turn the crankshaft until the marks on the crankshaft gear, the camshaft gear and the fuel pump {gear are in mesh with the idler gear. NOTE: The idler gear marks may not be in mesh with the other three gears due to the different speed of rotation of the idler gear. 1. Remove the idler gear. NOTE: Refer to the topic, ‘Remove & Install idler Gear’ for additional information. 2. Slide the crankshaft gear off the crankshaft. fit does not come off easly, the removal of the crankshaft is necessary if the gear is to be replaced. NOTE: If the old gear slides off easily and the new ‘one will not slide on the crankshaft, heat the gear to not more than 180° C (226° F). NOTICE Do not use flame on the gear for removal of the gear. NOTE: When installing, make sure the timing marks of the crankshalt gear are to the front. Install the idler gear. NOTE: For installation of the crankshaft gear, reverse the removal steps, End By: a. install timing gear case cover b. instal crankshaft pulley install water pump 2 install fan Crankshaft Gear Remove & Install Crankshaft Gear 1204-010 Start By: a. remove crankshaft 1. Use a suitable puller to remove the crankshaft gear. Hone is not available and the crankshaft gear is 10 bbe replaced, heat crankshaft gear (1) with a torch Use eye protection, personal injury could occur. 2. I necessary, use a hammer and brass punch to remove crankshaft gear (1) from crankshaft (2), NOTE: The following steps are for the installation of the crankshaft gear. 3. Heat the crankshaft gear in an oven to 180° C (356° F), 4, Place the crankshaft gear in its original position on the crankshaft with the timing marks to the front End By: a. install crankshaft 3054 Engine 18 Disassembly & AssemblyCrankshaft Main Bearing (Without Crankshaft Removal) Remove & Install Crankshaft Main Bearing (Without Crankshaft Removal) 1203-010 ‘Tools Needed a ‘BU6282 Torque Adapter Start By. ‘a. remove suction pipe and strainer, delivery pipe and the relief valve NOTE: If the rear main bearing is to be removed without the crankshaft removal, the flywheel, the flywhee! housing, the rear ol seal and the bridge piece will have to be removed, NOTE: The front main bearing can only be removed it a torque wrench is available to remove the front main bearing bolts. if torque wrench and Too! (A) is available, then the front main bearing can be removed together with the ol pump. 1. Remove all other necessary components to access the main bearing to be removed. 2. Remove the two bolts 3. Remove the main bearing cap, 4. Remove the lower bearing half trom the cap. NOTE: Keep the lower bearing half with the main bearing cap 5. With a suitable soft tool, push the upper half bbearing from the side opposite to the location tab to remove the bearing tab from its recess in the bearing housing. Carefully rotate the crankshaft to release the bearing from the housing, NOTICE Keep the bearing halves in their correct positions. NOTE: The following steps are for the installation of the main bearing, 6. Clean the upper half bearing, 7, Lubricate the bearing surface with clean engine oi NOTICE Only the upper half bearing has lubrication holes that must be positioned correctly to the cylinder block side. 8. Install the plain end of the upper bearing between the crankshaft journal and the bearing housing that has the location tab. 9. Side the upper bearing into the housing unt the tab in the bearing isin the correct position in the recess of the housing 10. Clean the lower half bearing 11. Lubricate the bearing surface with clean engine cil 12. Install the tab of the lower bearing haif into the recess of the bearing cap, NOTICE Make sure the components are correctly positioned to the cylinder block or the bearing cap. 13. Install the bearing cap to the cylinder block with both location tabs on the same side. 14. Lubricate the threads of the bolts with clean engine oil 15. Install two bolts. Tighten the two bolts gradually and evenly to a torque of 265 N-m (196 Ib ft), 16. Rotate the crankshaft to make sure the crankshaft turns easily. 17. Check the crankshaft end play if the thrust washers were removed. Refer to the topic, * Crankshaft Thrust Washers" 18. install any components that were removed to gain access to the main bearing, End By: 4. install suction pipe and strainer, delivery pipe and the relief valve 3054 Engine 19 Disassembly & AssemblyCrankshaft Pulley Remove & Install Crankshaft Pulley 1205-010 Star By a. remove radiator b. remove alternator V-belts Photo does not show radiator removed. 41. Loosen three bolts (1). 2. Push alternator (2) towards the engine. 8, Remove V-belt (3) from crankshatt pulley (4) 4. Remove three bolts (6). When installing, lubricate the bolts with clean engine oil. Tighten the three bolts gradually and evenly to a torque of 115 Nem. (85 Ib tt), 5. Remove washer (6) 6. Remove crankshaft pulley (4). NOTE: For installation of the crankshaft pulley, reverse the removal steps. End By: a. install alternator V-belt b. install radiator Crankshaft Front Oil Seal Remove & Install Crankshaft Front Oil Seal 1160-010 ‘Tools Nooded x ‘90620 _ Front Seal installer Group 1 Start By: a. remove crankshatt pulley (C55241P1 1. Remove seal (1) with a suitable pry bar. NOTICE Make sure the main lip is used to remove the crank- shaft front oil seal. Do not damage the edge of the oil seal housing NOTE: The following steps are for the installation of the crankshaft front ol seal 2. Clean the oil seal housing and inspect for any damage to the oil seal housing 3. Lubricate the cil seal with clean engine oil 4. Position the new oil seal to the oil seat housing. 3054 Engine 20 Disassembly & AssemblyNOTICE Make sure the spring loaded lip of the oil seal is facing ‘towards the inside of the timing case cover and is, square to the bore of the seal housing. 5. Use Tool (A) to install the new crankshatt front oil seal 6. Apply clean engine oil to the crankshaft pulley area that will be in contact with the new oil seal End By: a. install crankshaft pulley Crankshaft Rear Oil Seal Remove & Install Crankshaft Rear Oil Seal 1161-010 Tools Needed a ‘96205 _ Rear Seal Installer Group, 1 ‘96202 Plate (Part Of Rear Seal 7 Installer Group 908205) ‘806203 Installer (Part Of Rear Seal 1 Installer Group 906205) ‘9U6204 Seal Guide (Part 1 Rear Seal 1 Installer Group 906205) 41P0510__ Puller Group D Start By: a. remove flywheel b. remove flywheel housing 41, Remove ten bolts (1). When instaling, tighten the ten bolts to 22 Nem (16 Ib ft) 2. Remove two socket head bolts (2). When installing MB bolts, tighten the two bolts to 18 Nem (13 Ib {), When instaling M6 bolts, tighten the two bolts to 13 Nem (10 Ib ft), 8. Remove the rear oil seal, the gasket and housing (3) from the cylinder block dowels. Check the rear oi! seal for wear or damage. Replace if necessary. Replace the gasket with a new gasket. NOTE: The following steps are for the installation of the rear oil seal 4, Clean the faces of all the mating parts. 3054 Engine at Disassembly & Assembly5. Use Tool (A) and a suitable press to install the new rear oll seal When installing, lubricate the components with clean engine oii, Install Too! (A) onto the crankshaft flange. 7. Place the new gasket to the cylinder block dowels. 8. Position housing (3) and the new oil seal over Too! (A), Locate the housing on the two cylinder block dowels 9. Remove tool (A) 10. Install ten bolts (1) 11. Install two socket head bolts (2) 42, Tighten the ton bolts to 22 Nem (16 Ib ft), 13, Tighten the two bolts to 18 Nem (13 Ib ft). End By: a. install flywheel housing b. install flywheel Crankshaft Thrust Washers Remove & Install Crankshaft Thrust Washers 1232-010 NOTE: The axial moverent of the crankshaft is controlled by two haf thrust washers positioned on both sides of the center main bearing, The end play of the crankshaft can te checked by either inserting a {eeler gauge betwee? the thrust washer and the crankshaft or by placing an indicator on the end of the crankshaft on either end to check the movement. If the end play is more than 0.51 mm (0.020 inch), oversize thrust washers can be added to either or both sides of the center bearing to reduce the end play. The oversize thrust washers are 0.19 mm (0.0075 inch). Start By: a. remove lubricating oil strainer and suction pipe 1. Remove two bolts 2. Remove the center main bearing cap and lower half thrust washers. '3. Press down on the upper half thrust washers to remove them from their recesses with a suitable tool ‘made of soft material so the crankshaft will nt be damaged NOTE: if necessary, the crankshaft may have to be ‘moved to the front oF to the rear to allow the removal of the thrust washers, NOTE: The folowing steps are forthe installation of the thrust washer. 4. Lubricate the thrust washers with clean engine oil 5. Slide the upper half thrust washers in the recesses of the cylinder block, NOTE: Make sure the sides of the thrust washers that have the grooves are towards the crankshaft. 6. Position the lower half thrust washers to the center ‘main bearing cap with the location tabs in their proper location, NOTE: Make sure that al the thrust washers are properly located, 7. Position the lower bearing correctly in the center ‘main bearing cap. Position the center main cap with the location tabs to the same side. 9. Install two nuts. Tighten the two nuts gradually and evenly to the torque of 265 Nem (196 Ib ft). 3054 Engine Disassembly & Assembly10. Recheck the crankshalt end play. Cylinder Head or 1 el herein eben euston pos Remove & Install Cynder a a8 : a ; Cylinder Block ase aa ea te Remove & Install Cylinder Star By Block 1201-010 'b. remove fuel injection nozzles a. remove timing case . remove inlet manifold ». remove oylinder liners d. remove exhaust manifold €. remove flywheel housing @. remove thermostat housing 4. remove crankshaft f. remove rocker shaft and push rods @. remove piston cooling jets f. remove camshaft bushing 1. Remove all the plugs from the old cylinder block, When installing, apply 983263 Thread Lock to the plugs. 2. Check the cylinder block for wear or damage. Replace if necessary. Clean the oil and water passages. NOTICE Do not machine the top face of the oylinder block. It ‘would affect the liner flange depth and the piston height above the top face of the cylinder block. 1. Remove evenly and gradually twenty-two head bolts (1) in reverse of the sequence illustrated in (c53860P1 End By: NOTE: Lubricate the threacs and the thrust faces of install camshaft bushi ae the bolts with engine oll before assembly. ©. install piston cooling jots NOTE: When installing cylinder head, to tighten the . install crankshaft bolts evenly and gradually in number sequence to 110 Nem (80 ff Ib). Repeat this process once again of d. install flywhee! housing tightening the bolts evenly and gradually in number sequence to 110 Nem (80 Ib ft). €. install cylinder liners. NOTE: Then, use Tool (A) tghten all bolts and nuts in f. install timing case number sequence as follows: ‘a. Short bolts (s) 150° turther (2.5 flats) b. Medium length bolts (m) 180° further (3.0 flats) ¢. Long bolts (L) 210” further (3.5 flats) 3054 Engine 23 Disassembly & Assembly2. Attach chains and a suitable lifting device to cylinder head (2) as shown. Lift the cylinder head straight up and off the engine block. The weight of the cylinder head is 41 kg (90 Ib. NOTICE Donot use a pry bar to separate the cylinder head from the cylinder block. NOTICE Place the cylinder head on a surface that will not dam- age the cylinder head face. NOTE: Refer to Specification Manual SENRS541, for additional information on tightening the cylinder head bolts to correct torque. NOTE: Refer to Systems Operation Testing & ‘Adjusting Manual SENR5542 for topic ‘Cylinder Compression’ for cylinder head check using Tool Group 906274. End By a. install rocker shaft and push rods b. install thermostat housing 6. install exhaust manifold 4. instal inet manifold ° install fuel injection nozzies install muffler support Disassemble & Assemble Cylinder Head 1100-017 Tools Needed AOGDGG (S601 Repair Stand 2 ‘SSO132 Valve Seat Compressor 7 {906396 Valve Seat Extractor 1 38, Remove yiinder head gasket (3) NOTE: Do not use any sealant or gasket compound Con the cylinder head gasket. When installing the cylinder head gasket be sure the gasket is stamped FRONT TOP" for correct installation. NOTE: When installing the gasket and the cylinder head, place Too! (B) in positions 15 and 20 as numbered on C53860P 1 NOTE: For installation of the cylinder head, reverse the removal steps. (906597 Valve Seat Extractor 1 (9$3095 Handle Assembly 1 U8169 Guide Driver i (906220 _ Stop Collar f ‘USTES Valve Seat Driver 1 (take 45°) 9US184 Valve Seat Driver 1 (Exhaust 45°) 9U6185 Valve Seat Driver 1 (take 30") Start By: a. remove cylinder head NOTE: Before beginning Disassembly & Assembly of the cylinder head, reer to Systems Operation & Testing & Adjusting Module, SENR5542 forthe procedure, “Valve Depth Chek” and other pertinent information on the cylinder head 3054 Engine Disassembly & Assembly7 oO 41. Mark or icentty the valve location on the bottom of 6. Remove valve (4) out of the bottom of the cylinder the cylinder head ifthe valves are to be used again, hhead as shown, 2. Place cylinder head on Tool (A) as shown. 3. Use Too! (8) to compress the valve spring, NOTICE Be sure the valve springs are compressed squarely so the valve stem is not damaged. 4. Remove two coll (1). Slowly release pressure on Too! (B). Remove Tool (8). 5. Remove spring cap (2). Remove valve springs (3). 7. Remove valve seal (5) and seat washer (6). 3054 Engine 25 Disassembly & Assemblymee! OME 8. Turn cylinder head over and reposition Tool (A). 9. Install Tool (C) as shown. Remove valve seat (7). NOTE: While expanding Too! (C), rotate the tool ‘enough to clean the carbon deposits from under the valve seats to create a good grip on the valve seat. 2 10. install Tool (0) as shown. Remove valve guide (8) (not snowny, NOTE: The following steps are for the assembly of the cylinder head, 11. Use Too! (F) to install valve seat (7) 12. Turn cylinder head over and reposition on Too! (A). 13, Install valve guide (8) with Tool (O) and Too! (E) as shown, NOTE: Clean out the cylinder head bore that the guide will be positioned in, Lubricate the guide with clean, engine oil NOTE: Install the valve guide with the smaller diameter {or the later installation of the valve seal facing the top of the cylinder head. NOTE: The exhaust valve guide has a counterbore at the bottom and is sight longer than the inlet valve guide. NOTE: Refer to Specifications Module SENRS541 for more information on the valve guides, 14. Install seat washer (6) and valve seal (5). 3054 Engine Disassembly & AssemblyCylinder Liners Remove & Install Cylinder Liners 1222-010 Tools Needed TAia60_ Balt 709805 Grose Block 253507 _ Nut (1-8 Thread) ‘SF7347 Jam Nut | 5H1504 Washer '5P8245 Washer 15. Install valve (4) from bottom of cylinder head as 6v2189 Forcing Screw shown. ‘BHO684 Ratchet wore he va with ine ol bt ‘908234 Puller Pate : Lubricate the valve with clean engine oil before ‘906235 _Puler Plate inserting into the cylinder head guide, ‘906281 Leg Tool List For Manual Cylinder Liners Removal. allele =l-l-le> "Tools Needed TAid60_ Bot 305119 Jam Nat "10820 Hyeraulic Puller Group ‘F747 Head SH1504 Washer P8245 Washor v2183__ Forcing Screw {6V2184 Forcing Screw Extension ‘906234 Puler Pate (906235 Puler Pate 16. Install valve springs (3) and spring cap (2). 906281 Leg ee EEEPEEEEb> Tool List For Removal Of Cylinder Liners With Hydraulic Pump. Start By: a. remove cylinder head b. remove piston and connecting rod assembly Cc. remove piston cooling jet 17. Use Too! (B) to compress the valve springs. 18. instal two collets (1). Slowiy release pressure on Tool (B). Remove Too! (B). End By: a. install oylinder head 3054 Engine 27NOTE: Before proceeding with the removal of the cylinder liners, check the liners for wear or damage. Check each liner inner diameter at the top, middle and lower section of the liner at two places 180° of each ‘other. The maximum permissible wear without installing a new liner is 0.25 mm (0.010 inch). NOTE: An engine can have a high rate of oil consumption with litle wear if the surface of the liner is glazed NOTE: Glaze can be removed from the cylinder liners by honing the bore of the cylinder liner. 4. Tur the crankshaft to give access to the cylinder liner. Protect the crankshaft pin. G . Install Tool (B) as shown, 7. Press cylinder liner (2) into the cylinder block to within .80 mm (2.0 inch) of installation. Apply 6V1541 Quick Cure Primer to the exposed area of the cylinder liner. Apply 983265 High Strength Retaining Compound to the exposed area of the cylinder liner. Use Tool (B) to complete the installation of the cylinder liner into the cylinder block bore. Wipe off any of the excess compound formed from the installation of the cylinder liner. The cylinder liner is a press ft of + 0.03 mm (+ 0.001 inch) NOTICE Use Too Group BTOHSS to check ta the cnr ner 2. Install Too (A) as sh is between 0.10 mm (0.004 inch) above to 0.10 mm Ista Tool (A) as shown (0.004 inch) below the top face of the cylinder block. 3. Remove cyinde ner (1) NOTE: The following steps are forthe instalation of the cylinder liner. NOTICE After a new cylinder liner is installed the following 4. Clean the cylinder block bore with 8T9O11 steps are advised: ‘Component Cleaner before beginning instalation of cylinder ner. 5. Apply clean engine oil to cylinder block bore a. Do not operate the engine at ful load. EXCEPT for the top 60 mm (2.0 inch). ea poet an ieee eae aciaa ©. Do not allow the engine to run at ow idle speed for an extended time End By. install piston cooing jet ». install piston and rod assembly ¢. install cylinder head 3054 Engine 28Dipstick Assembly Exhaust Manifold Remove & Install Dipstick Remove & Install Exhaust Assembly 1326-010 Manifold 1059-010 Start By: f. remove turbocharger and heat shield (if equipped) 4. Loosen nut (1). 2. Pull dipstick assembly (2) out of the ol pan 4. Remove four nuts (1). When installing, tighten the plated nuts to a torque of 44 Nem (32 Ib ft). When instaling, tighten the non plated nuts to a torque of 50 Nem (37 Ib ft), 2. Remove exhaust manifold (2) and gaskets. Use new =H gaskets when installing the exhaust manifol. NOTE: For installation of the exhaust manifold reverse the removal steps. End By: a. instal turbocharger and heat shield (if equipped) (9) Gauge. (2) Tube Assenbiy. 5) Seal 3. Dipstick assembly upon removal NOTE: For installation of the dipstick assembly, reverse the removal sieps. 3054 Engine 29 Disassembly & AssemblyFan Remove & Install Fan 1356-010 Start By a. remove radiator Fan Drive Housing Remove & Install Fan Drive Housing 1359-HG-010 Start By: a. remove fan 1. Remove four bolts (1). When instaling fan, tighten the bolts to a torque of 44 Nem (33 Ib ft). 2. Remove fan (2). 3. Remove extension (3) (not shown) 4, tf necessary, remove the fan pulley. NOTE: For installation of the fan, reverse the removal steps. Endy: a. install radiator 1. Remove four bolts (1). Wren installing, tighten the four bolts to a torque of 44 Nem (33 Ib ft). 2. Remove fan drive housing (2). NOTE: For installation of the fan drive housing, reverse the removal steps. End By: a. install fan 3054 Engine Disassembly & AssemblyDisassemble & Assemble Fan Drive Flywheel Housin« Housing 1359-017 ad 9 Start By: Remove & Install Flywheel Housing 1157-010 a. remove fan drive housing ‘Tools Needed {V2T56 Unk Brackets 2 Start By: a. remove starter b. remove flywheel and ring gear 1. Set the engine on a tlat level surface and support the engine forward of the flywheel housing 1. Use a suitable puller to remove the hub from the drive shaft 2. Remove the retaining ring which holds the bearing in position. 3. Press on the rear of the bearing with a suitable ‘adapter. Press the bearing and the shaft assembly ‘out through the front of the bearing housing NOTICE Do not apply force to the shaft, NOTE: For assembly of the fan drive housing, reverse the assembly steps. End By: a. install fan drive housing Remove five of six bolts (1). Refer to the note for ‘lywhee! housing torque specificatons. '3. Remove two bolts (2) on top of flywheel housing (3) Refer to the note for flywheel housing torque specifications. 3054 Engine 3 Disassembly & Assembly4, Attach Tool (A) and support the flywheel housing Remove remaining bolt (1). 5. Hit the flywheel housing with a soft hammer to remove the flywheel housing from its doweled location. Move flywheel housing (3) away from the engine. The weight ofthe flywheel housing is 32 kg (70 tb). NOTE: Make sure that the rear face of the cylinder block and the faces of the housing are clean and are not damaged. Make sure the dowels are not damaged If equipped with a felt seal to the rear flange of the il pan, replace this felt seal during the installation procedure. NOTE: Refer to the Specifications Manual SENR5S41 for additional information on the flywheel housing installation NOTE: Torque for the flywheel housing is as follows: ‘a. Cast ion flywheel housing to cylinder block 44 Nem (83 Ib ft), Thread size M10, b. Stamped 8.8 75 Nem 55 Ib ft). Thread size une, ©. Stamped 10.9 115 Nem (85 Ib ft), Thread size M2. 4. Aluminum flywheel housing to cylinder block 70 Nem (52 Ib ft). Thread size M10. NOTE: For installation of the flywheel housing, reverse the removal steps. End By: a. instal flywheel and ring gear b. install starter Flywheel & Ring Gear Remove & Install Flywheel & Gear 1156-010 Tosi Needed x FOR ng 7 1. Install Tool (A) and a suitable lifting device as shown to flywheel and ring gear (1) oo 2. Remove four bolts (3) and bearing housing (4), NOTE: The housing has to be removed to allow clearance for the removal of the flywheel and ring gear bolts, 3. Remove six bolts (2) and washers. When installing the six bolts, tighten the bolts to a torque of 105, Nem (77 Ib tt) 4, Remove flywheel and ring gear (1). The weight of the flywheel and ring gear is 63 kg (120 Ib). NOTE: Refer to the Specifications Manual SENRSS41 for additional information on the flywheel and ring gear installation, 3054 Engine Disassembly & Assembly