Caterpillar C27-C32.pdf
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(2) 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: 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. 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. 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 the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose. 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. Caterpillar dealers have the most current information available.. When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength and material. Failure to heed this warning can lead to premature failures, product damage, personal injury or death..
(3) RENR9716-02. Table of Contents Disassembly and Assembly Section Engine - Remove ................................................... 4 Engine - Install ....................................................... 6 Fuel Priming Pump - Remove and Install .............. 9 Fuel Filter Base - Remove ................................... 10 Fuel Filter Base - Install ....................................... 10 Fuel Filter and Water Separator - Remove and Install .................................................................... 11 Fuel Transfer Pump - Remove .............................. 12 Fuel Transfer Pump - Install .................................. 12 Electronic Unit Injector - Remove ......................... 13 Electronic Unit Injector - Install ............................. 14 Electronic Unit Injector Sleeve - Remove ............. 15 Electronic Unit Injector Sleeve - Install ................. 16 Turbocharger - Remove ........................................ 17 Turbocharger - Disassemble ................................ 17 Turbocharger - Assemble .................................... 18 Turbocharger - Install ............................................ 18 Exhaust Manifold - Remove and Install ............... 19 Inlet and Exhaust Valve Springs - Remove and Install ................................................................... 20 Inlet and Exhaust Valves - Remove and Install .... 22 Inlet and Exhaust Valve Guides - Remove and Install ................................................................... 23 Inlet and Exhaust Valve Seat Inserts - Remove and Install ................................................................... 24 Engine Oil Filter Base - Remove .......................... 25 Engine Oil Filter Base - Disassemble ................... 26 Engine Oil Filter Base - Assemble ........................ 26 Engine Oil Filter Base - Install .............................. 27 Engine Oil Cooler - Remove ................................. 27 Engine Oil Cooler - Install ..................................... 28 Engine Oil Pump - Remove .................................. 28 Engine Oil Pump - Disassemble ........................... 29 Engine Oil Pump - Assemble ................................ 29 Engine Oil Pump - Install ...................................... 30 Water Pump - Remove ......................................... 31 Water Pump - Disassemble ................................. 31 Water Pump - Assemble ...................................... 32 Water Pump - Install ............................................. 33 Water Temperature Regulator Housing - Remove and Install .................................................................. 33 Cooling System Package (Radiator, Aftercooler, Fuel Cooler) - Remove ................................................ 35 Cooling System Package (Radiator, Aftercooler, Fuel Cooler) - Install .................................................... 36 Aftercooler - Remove ........................................... 38 Aftercooler - Install ............................................... 40 Radiator Core - Remove ...................................... 42 Radiator Core - Install .......................................... 44 Engine Support (Front) - Remove and Install ....... 45 Gear Group (Rear) - Remove ............................... 46 Gear Group (Rear) - Install ................................... 48 Flywheel - Remove and Install ............................. 49 Crankshaft Rear Seal - Remove ........................... 50 Crankshaft Rear Seal - Install ............................... 50 Flywheel Housing - Remove and Install .............. 51. 3 Table of Contents. Vibration Damper and Pulley - Remove and Install ............................................................................. 53 Crankshaft Front Seal - Remove .......................... 54 Crankshaft Front Seal - Install .............................. 55 Gear Group (Front) - Remove .............................. 55 Gear Group (Front) - Install .................................. 56 Housing (Front) - Remove .................................... 57 Housing (Front) - Install ........................................ 58 Housing (Rear) - Remove ..................................... 60 Housing (Rear) - Install ......................................... 60 Valve Mechanism Cover - Remove and Install ..... 62 Valve Mechanism Cover Base - Remove and Install ................................................................... 62 Rocker Arm and Shaft - Remove .......................... 63 Rocker Arm - Disassemble ................................... 64 Rocker Arm - Assemble ........................................ 64 Rocker Arm and Shaft - Install .............................. 65 Cylinder Head - Remove ...................................... 66 Cylinder Head - Install .......................................... 68 Camshaft - Remove .............................................. 71 Camshaft - Install .................................................. 73 Camshaft Bearings - Remove ............................... 76 Camshaft Bearings - Install ................................... 76 Engine Oil Pan - Remove and Install ................... 78 Cylinder Liner - Remove ....................................... 79 Cylinder Liner - Install ........................................... 79 Piston Cooling Jets - Remove and Install ............. 80 Pistons and Connecting Rods - Remove .............. 81 Pistons and Connecting Rods - Disassemble ....... 82 Pistons and Connecting Rods - Assemble ........... 82 Pistons and Connecting Rods - Install .................. 83 Connecting Rod Bearings - Remove .................... 84 Connecting Rod Bearings - Install ........................ 85 Crankshaft Main Bearings - Remove .................... 86 Crankshaft Main Bearings - Install ........................ 87 Crankshaft - Remove ............................................ 88 Crankshaft - Install ................................................ 90 Bearing Clearance - Check ................................... 92 Atmospheric Pressure Sensor - Remove and Install ................................................................... 93 Camshaft Position Sensor - Remove and Install .. 93 Crankshaft Position Sensor - Remove and Install .. 94 Coolant Temperature Sensor - Remove and Install ................................................................... 95 Engine Oil Pressure Sensor - Remove and Install ............................................................................. 96 Fuel Pressure Sensor - Remove and Install ......... 97 Fuel Temperature Sensor - Remove and Install ... 97 Turbocharger Outlet Pressure Sensor - Remove and Install ................................................................... 98 Inlet Air Temperature Sensor - Remove and Install ................................................................... 99 Belt Guard - Remove and Install ........................... 99 Fan Guard - Remove and Install ........................ 100 Fan - Remove and Install ................................... 101 Fan Drive - Remove and Install ......................... 102 Electronic Control Module - Remove and Install .. 103 Alternator - Remove and Install ......................... 104 Electric Starting Motor - Remove and Install ..... 105. Index Section Index ................................................................... 106.
(4) 4 Disassembly and Assembly Section. RENR9716-02. Disassembly and Assembly Section i02747487. Engine - Remove SMCS Code: 1000-011. Removal Procedure Table 1. Required Tools. Illustration 2. Tool. Part Number. A. 138-7573. Link Bracket. 2. B. 238-9586. Engine Turning Tool. 1. C. 1U-9200. Lever Puller Hoist. 1. D. 189-0411. Shackle As. 2. E. 6V-6146. Load Leveling Beam. 1. Part Description. Qty. g01291160. 2. Disconnect harness assembly (6).. Start By: a. Remove the cooling package. Refer to Disassembly and Assembly, “Cooling System Package (Radiator, Aftercooler, Fuel Cooler) Remove”. Illustration 3. g01291161. 3. Disconnect hose assemblies (7), (8), and (9).. Illustration 1. g01291159. 1. Disconnect hose assembly (1). Disconnect cable assembly (2). Disconnect harness assemblies (3). Disconnect cable assembly (4). Disconnect harness assemblies (5).. Illustration 4. 4. Disconnect clamp (10).. g01291162.
(5) RENR9716-02. 5 Disassembly and Assembly Section. 7. Disconnect clamp (15).. Illustration 8. g01291225. 8. Remove bolts (16). Remove guard (17).. Illustration 5. g01291179. 5. Remove bolts (11). Remove bolts (12). Repeat for the opposite side. Disconnect tube assembly (13). Repeat for the opposite side.. Illustration 9. g01291227. 9. Remove bolts (18). Remove guard (19).. Illustration 6. g01291183. 6. Attach Tooling (A) and a suitable lifting device onto exhaust elbow (14). The weight of exhaust elbow (14) is approximately 34 kg (75 lb). Remove exhaust elbow (14).. Illustration 10. 10. Disconnect hose (20).. Illustration 7. g01291186. g01291228.
(6) 6 Disassembly and Assembly Section. Illustration 11. RENR9716-02. g01291232. g01291246. Illustration 14. 13. Attach Tooling (D) onto engine (24). Attach Tooling (E) and a suitable lifting device onto Tooling (D). The weight of engine (24) is approximately 3527 kg (7775 lb).. Illustration 12. g01291243. 11. Install Tooling (B). Use Tooling (B) in order to rotate the engine. Rotate the engine in order to gain access to bolts (22). Remove bolts (22). Remove bolts (21).. g01291247. Illustration 15. 14. Remove mounting bolts (25). Remove engine (24) from the generator. i02747534. Engine - Install SMCS Code: 1000-012. Installation Procedure Table 2 Illustration 13. Required Tools. g01376223. 12. Use Tooling (C) in order to support generator rotor (23).. Tool. Part Number. A. 138-7573. Link Bracket. 2. B. 238-9586. Engine Turning Tool. 1. C. 1U-9200. Lever Puller Hoist. 1. D. 189-0411. Shackle As. 2. E. 6V-6146. Load Leveling Beam. 1. Part Description. Qty.
(7) RENR9716-02. Illustration 16. 7 Disassembly and Assembly Section. g01291246. 1. Attach Tooling (D) onto engine (24). Attach Tooling (E) and a suitable lifting device onto Tooling (D). The weight of engine (24) is approximately 3527 kg (7775 lb). Install engine (24).. Illustration 19. 3. Install bolts (21). Use Tooling (B) in order to rotate the engine. Install bolts (22).. Illustration 20 Illustration 17. g01291247. g01291232. g01291245. 4. Remove Tooling (C).. 2. Install mounting bolts (25).. Illustration 21 Illustration 18. g01291243. 5. Connect hose (20).. g01291228.
(8) 8 Disassembly and Assembly Section. Illustration 22. RENR9716-02. g01291227. 6. Install guard (19). Install bolts (18).. Illustration 23. Illustration 25. g01291183. 9. Attach Tooling (A) and a suitable lifting device onto exhaust elbow (14). The weight of exhaust elbow (14) is approximately 34 kg (75 lb). Install exhaust elbow (14).. g01291225. 7. Install guard (17). Install bolts (16).. Illustration 26. g01291179. 10. Connect tube assembly (13). Install bolts (12). Repeat for the opposite side. Install bolts (11).. Illustration 24. g01291186. 8. Connect clamp (15).. Illustration 27. g01291162.
(9) RENR9716-02. 9 Disassembly and Assembly Section. End By:. 11. Connect clamp (10).. a. Install the cooling package. Refer to Disassembly and Assembly, “Cooling System Package (Radiator, Aftercooler, Fuel Cooler) - Install”. i02580978. Fuel Priming Pump - Remove and Install SMCS Code: 1258-010. Removal Procedure Illustration 28. g01291161. 12. Connect hose assemblies (7), (8), and (9).. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component 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.. Illustration 29. g01291160. 13. Connect harness assembly (6).. Illustration 30. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.. g01291159. 14. Connect harness assemblies (5). Connect cable assembly (4). Connect harness assemblies (3). Connect cable assembly (2). Connect hose assembly (1).. Illustration 31. g01292755. 1. Remove bolts (1). 2. Remove fuel priming pump (2) and the gasket..
(10) 10 Disassembly and Assembly Section. RENR9716-02. Installation Procedure. 1. Turn the fuel supply to the OFF position.. g01292755. Illustration 32. 1. Position the gasket and fuel priming pump (2) on the fuel filter base. 2. Install bolts (1). Illustration 33. g01292764. i02580993. Fuel Filter Base - Remove. 2. Use Tooling (A) to remove fuel filter (6) from fuel filter base (5).. SMCS Code: 1262-011. 3. Disconnect harness assemblies (4).. Removal Procedure. 4. Disconnect hose assembly (1) and hose assembly (2).. Table 3. 5. Remove bolts (3) and fuel filter base (5).. Required Tools Tool. Part Number. A. 185-3630. Part Description Strap Wrench. Qty 1. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.. i02581008. Fuel Filter Base - Install SMCS Code: 1262-012. Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life..
(11) RENR9716-02. 11 Disassembly and Assembly Section. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. 1. Turn the fuel supply to the OFF position.. g01292764. Illustration 34. 1. Position fuel filter base (5) on the engine. Install bolts (3). 2. Connect hose assembly (1) and hose assembly (2). 3. Connect harness assemblies (4). 4. Install fuel filter (6) on fuel filter base (5). 5. Turn the fuel supply to the ON position.. Illustration 35 i02581074. Fuel Filter and Water Separator - Remove and Install. NOTICE Keep all parts clean from contaminants.. Table 4. Required Tools. A. 185-3630. Part Description Strap Wrench As. 3. Disconnect hose assemblies (2) and (3).. Installation Procedure. Removal Procedure. Part Number. 2. Use Tooling (A) to remove the fuel filter and water separator (5) from base assembly (4).. 4. Remove bolts (1) and base assembly (4).. SMCS Code: 1261-010; 1263-010. Tool. g01292832. Qty 1. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.. Contaminants may cause rapid wear and shortened component life..
(12) 12 Disassembly and Assembly Section. Illustration 36. RENR9716-02. g01292832. 1. Position base assembly (4) on the cylinder block and install bolts (1). 2. Connect hose assemblies (2) and (3). 3. Install a new fuel filter and water separator (5) on base assembly (4). 4. Turn the fuel supply to the ON position.. Illustration 37. 2. Disconnect hose assemblies (3). 3. Remove bolts (2).. i02285574. Fuel Transfer Pump - Remove. 4. Remove fuel transfer pump (1) and the O-ring seal.. SMCS Code: 1256-011. Removal Procedure NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component 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. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Turn the fuel supply to the “OFF” position.. g01143748. i02287501. Fuel Transfer Pump - Install SMCS Code: 1256-012. Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life..
(13) RENR9716-02. 13 Disassembly and Assembly Section. Illustration 39. g01114892. 1. Disconnect harness assembly (1). 2. Remove bridge assemblies (3). g01143748. Illustration 38. 1. Install the O-ring seal on fuel transfer pump (1). Lubricate the O-ring seal with clean engine oil. 2. Position fuel transfer pump (1) on the engine. Install bolts (2).. NOTICE If the injector hold down bolt is loose during the removal procedure, inspect the injector bore for wear and debris. Replace the clamp and spacer. 3. Remove bolt (4), spacer (5), and clamp (6). 4. Place an identification mark on electronic unit injectors (2) for installation purposes. Each electronic unit injector must be reinstalled in the original location in the cylinder head.. 3. Connect hose assemblies (3). 4. Turn the fuel supply to the “ON” position. i02208070. Electronic Unit Injector Remove SMCS Code: 1290-011. Removal Procedure Table 5. Required Tools Tool. Part Number. A. 5F-4764. Part Description Pry Bar. Qty 1. Illustration 40. g01073439. Start By:. 5. Use Tooling (A) to pry beneath the base and free electronic unit injector (2).. a. Remove the rocker arms and the rocker arm shaft. Refer to Disassembly and Assembly, “Rocker Arm and Shaft - Remove”.. 6. Remove electronic unit injector (2) from the cylinder head.. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life..
(14) 14 Disassembly and Assembly Section. RENR9716-02. i03143340. Electronic Unit Injector - Install SMCS Code: 1290-012. Installation Procedure Table 6. Required Tools Tool. Part Number. B. 8T-2998. Lubricant. 1. 1U-5718. Vacuum Pump. 1. 169-7372. Fluid Sampling Bottle. 1. 4C-4057. Tube 7.9 mm (0.31 inch) OD. 1. D. 4C-5552. Large Bore Brush. 1. E. 4C-6774. Vacuum Gun Kit. 1. F. 8T-7765. Surface Reconditioning Pad. 1. C. Part Description. Qty. Illustration 41. g01114892. Illustration 42. g01135876. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Use Tooling (C) to remove the fuel and oil from the cylinder. Evacuate as much fuel and oil as possible from the cylinder before installing the electronic unit injector. Several evacuations may be necessary. 2. Use Tooling (D) to clean the carbon deposit from the inside of the electronic unit injector sleeve. Tooling (E) is available to clean loose material from the bore of the electronic unit injector sleeve and the cylinder.. 5. When you install a new injector the E-Trim value must be programmed into the engine control module. The injector confirmation code may need to be programmed into the engine control module. E-Trim Value (X) is a twelve digit alphanumeric code that is supplied with the data sheet that comes with the new injectors. Injector Confirmation Code (Y) is a four digit numeric code. Both of the codes are located on the top of electronic unit injector (2). Use the following menu to program the E-Trim value.. 3. Use Tooling (F) to clean the carbon from the seat area that is inside of the electronic unit injector sleeve.. • ECM Summary Screen. 4. Install the O-ring seals on the electronic unit injector. Lubricate the top two O-ring seals with a 50/50 mixture of clean engine oil and Tooling (B).. • Calibration. • Service Menu. • Injector Code Calibration.
(15) RENR9716-02. 15 Disassembly and Assembly Section. NOTICE When an electronic unit injector is replaced, the new electronic injector code must be programmed into the engine’s personality module software by using the calibration menu on the Electronic Service Tool. If the new electronic injector code is not entered, the characteristics of the previous electronic unit injector is assumed. If it is not possible to immediately reprogram the electronic injector code into the personality module software, the engine will not be severely harmed. The new electronic injector code should be reprogrammed as quickly as possible in order to optimize engine performance.. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Drain the coolant from the cooling system into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Change”.. 6. Position electronic unit injector (2) in the cylinder head. 7. Install spacer (5), clamp (6), and bolt (4). Tighten the bolt to a torque of 55 ± 10 N·m (41 ± 7 lb ft). 8. Install bridge assemblies (3). 9. Connect harness assembly (1). Tighten the nuts to a torque of 2.5 ± 0.25 N·m (22 ± 2 lb in). End By: a. Install the rocker arms and the rocker arm shaft. Refer to Disassembly and Assembly, “Rocker Arm and Shaft - Install”.. Illustration 43. g01043124. 2. Install Tooling (A) in electronic unit injector sleeve (1). 3. Tighten the nut on Tooling (A) until the electronic unit injector sleeve is pulled free of the cylinder head.. i02300212. Electronic Unit Injector Sleeve - Remove SMCS Code: 1713-011. Removal Procedure Table 7. Required Tools Tool. Part Number. A. 9U-6891. Part Description. Qty. Injector Tool Group. Start By: a. Remove the electronic unit injectors. Refer to Disassembly and Assembly, “Electronic Unit Injector - Remove”.. 1. Illustration 44. g01073635. 4. Remove O-ring seals (2) and O-ring seal (3) from electronic unit injector sleeve (1)..
(16) 16 Disassembly and Assembly Section. RENR9716-02. i02287628. Electronic Unit Injector Sleeve - Install. Note: Do not apply Tooling (C) to the cylinder head surfaces. Apply Tooling (C) on the electronic unit injector sleeve only. 4. Lubricate O-ring seals (2) with clean engine oil.. SMCS Code: 1713-012. Installation Procedure Table 8. Required Tools Tool. Part Number. A. 9U-6891. Injector Tool Group. 1. 9U-6862. Tapered Brush. 1. 9U-6863. Small Bore Brush. 1. 9U-7244. End Brush. 1. 9U-7237. Brush Extension. 1. 4C-5552. Large Bore Brush. 1. 4C-9507. Retaining Compound. 1. B. C. Part Description. Qty. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Use Tooling (B) to clean the bore in the cylinder head for the electronic unit injector sleeve. NOTICE Ensure that the electronic unit injector sleeve and the cylinder head bore are completely free of oil, dirt, and sealant debris.. Illustration 46. g01099549. 5. Install electronic unit injector sleeve (1) on Tooling (A). Position the electronic unit injector sleeve in the cylinder head. Use care not to damage the O-ring seals on the electronic unit injector sleeve. Use Tooling (A) and a hammer to install the electronic unit injector sleeve in the cylinder head. NOTICE Ensure that the electronic unit injector sleeve is properly seated in the cylinder head. The Tooling will "RING" when the electronic unit injector sleeve is fully seated in the bore of the cylinder head. 6. Remove Tooling (A). Remove excess Tooling (C). 7. Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Change”. End By: a. Install the electronic unit injectors. Refer to Disassembly and Assembly, “Electronic Unit Injector - Install”.. Illustration 45. g01043165. 2. Install new O-ring seals (2) and O-ring seal (3) on electronic unit injector sleeve (1). 3. Apply Tooling (C) to the contact surface of electronic unit injector sleeve (1) on the surface that is Marked “X”..
(17) RENR9716-02. 17 Disassembly and Assembly Section. i02287744. Turbocharger - Remove SMCS Code: 1052-011. Removal Procedure NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.. Illustration 48. g01148173. Refer to Special Publication, NENG2500, “Caterpillar Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar products.. 2. Remove tube assembly (2).. Dispose of all fluids according to local regulations and mandates.. 4. Attach a suitable lifting device to turbocharger (5). The weight of turbocharger (5) is approximately 45 kg (100 lb).. NOTICE Keep all parts clean from contaminants.. 3. Disconnect tube assemblies (1) and tube assembly (4).. 5. Remove nuts (3). Remove turbocharger (5) and the gasket.. Contaminants may cause rapid wear and shortened component life. 1. Drain the coolant from the cooling system into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Change”.. i02287870. Turbocharger - Disassemble SMCS Code: 1052-015. Disassembly Procedure Start By: a. Remove the turbocharger. Refer to Disassembly and Assembly, “Turbocharger - Remove”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.. Illustration 47. g01145002.
(18) 18 Disassembly and Assembly Section. RENR9716-02. 1. Position compressor housing (1) and turbine housing (5) on turbocharger cartridge (3). Note: Ensure that the mating surfaces are flush. 2. Tighten the nuts on V-band clamp (2) to a torque of 14 ± 1 N·m (10 ± 1 lb ft). Use a soft hammer to lightly hit around the diameter of the band clamp. Tighten the nuts again to a torque of 14 ± 1 N·m (10 ± 1 lb ft).. Illustration 49. g01145263. 3. Tighten the nuts on V-band clamp (4) to a torque of 14 ± 1 N·m (10 ± 1 lb ft). Use a soft hammer to lightly hit around the diameter of the band clamp. Tighten the nuts again to a torque of 14 ± 1 N·m (10 ± 1 lb ft).. 1. Loosen V-band clamp (2) and V-band clamp (4).. 4. Ensure that the impeller spins freely.. 2. Separate compressor housing (1) from turbocharger cartridge (3).. End By:. 3. Separate turbine housing (5) from turbocharger cartridge (3). i02451256. Turbocharger - Assemble. a. Install the turbocharger. Refer to Disassembly and Assembly, “Turbocharger - Install”. i02288273. Turbocharger - Install SMCS Code: 1052-012. SMCS Code: 1052-016. Installation Procedure. Assembly Procedure. Table 9. NOTICE Keep all parts clean from contaminants.. Required Tools. Contaminants may cause rapid wear and shortened component life. NOTICE The compressor housing must remain straight with the turbocharger cartridge during disassembly and assembly. Tilting may cause damage to the tips of the compressor wheel and the compressor shaft.. Illustration 50. g01145263. Tool. Part Number. A. 5P-3931. Part Description Anti-Seize Compound. Qty 1. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.. Illustration 51. g01148173.
(19) RENR9716-02. Illustration 52. 19 Disassembly and Assembly Section. g01145002. g01218139. Illustration 53. 1. Position the gasket on the exhaust manifold.. 2. Remove locknuts (6) from exhaust manifold (7).. 2. Apply Tooling (A) to the threads of the exhaust manifold studs.. 3. Remove spacers (2) and (3) from exhaust manifold (7).. 3. Attach a suitable lifting device to turbocharger (5). The weight of turbocharger (5) is approximately 45 kg (100 lb). Position turbocharger (5) on the exhaust manifold.. 4. Remove exhaust manifold (7) and gaskets (1) from the cylinder head.. 4. Install nuts (3) and tighten to a torque of 55 ± 9 N·m (41 ± 7 lb ft). 5. Connect tube assemblies (1) and tube assembly (4). 6. Install tube assembly (2). 7. Fill the cooling system. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Change”.. 5. If necessary, remove clamps (4) and expansion joints (5).. Installation Procedure Table 10. Required Tools Tool. Part Number. Part Description. Qty. A. 5P-3931. Anti-Seize Compound. -. B. 165-4638. Guide. 3. i02617122. Exhaust Manifold - Remove and Install SMCS Code: 1059-010. Removal Procedure Start By: a. Remove the turbocharger. Refer to Disassembly and Assembly, “Turbocharger - Remove”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Remove the shield assemblies from the exhaust manifolds.. Illustration 54. g01218139.
(20) 20 Disassembly and Assembly Section. RENR9716-02. i02300073. Inlet and Exhaust Valve Springs - Remove and Install SMCS Code: 1108-010. Removal Procedure Table 11. Required Tools. Illustration 55. g00566145. 1. If necessary, install expansion joints (5) and clamps (4). Tighten the clamps to a torque of 8.5 ± 1.0 N·m (75 ± 9 lb in). 2. Apply Tooling (A) to the studs prior to assembly. If necessary, install the studs and tighten to a torque of 35 ± 5 N·m (26 ± 4 lb ft).. Tool. Part Number. Part Description. Qty. A. 9U-7241. Valve Spring Compressor. 1. B. 8S-2263. Spring Tester. 1. Start By: a. Remove the electronic unit injectors. Refer to Disassembly and Assembly, “Electronic Unit Injector - Remove”.. 3. Position gaskets (1) and exhaust manifold (7) on the cylinder head.. NOTICE Keep all parts clean from contaminants.. 4. Install spacers (2) and (3) on exhaust manifold (7).. Contaminants may cause rapid wear and shortened component life.. Note: Use Tooling (B) in at least one oversize hole per manifold section in order to align the exhaust manifolds. Do not remove Tooling (B) until removal is required to tighten the locknuts. 5. Install locknuts (6) on exhaust manifold (7). Tighten locknuts (6) in a numerical sequence to a torque of 20 ± 3 N·m (15 ± 2 lb ft). Tighten locknuts (6) again in a numerical sequence to a torque of 38 ± 5 N·m (28 ± 4 lb ft).. Note: Place the piston at the top of the compression stroke (TC). Remove the valve springs for that cylinder. If the valves fall into the cylinder liner, then the cylinder head must be removed. 1. Position the No. 1 piston at the top center of the compression stroke. Refer to Testing and Adjusting, “Finding Top Center Position for No. 1 Piston”.. 6. Install the shield assemblies on the exhaust manifolds. End By: a. Install the turbocharger. Refer to Disassembly and Assembly, “Turbocharger - Install”.. Illustration 56. g01073852.
(21) RENR9716-02. 21 Disassembly and Assembly Section. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Lubricate the valve stems with clean engine oil.. g01043625. Illustration 57. Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment.. Illustration 58. g01043625. Follow the recommended procedure and use all recommended tooling to release the spring force. 2. Install Tooling (A) in the electronic unit injector sleeve. Secure Tooling (A) with unit injector clamp (1). 3. Tighten the full nut until valve spring keepers (3) are loose on valve (2). 4. Remove valve spring keepers (3) from the valve. 5. Carefully remove Tooling (A).. Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment. 2. Ensure that washer (7) is installed on the valve guide. 3. Install inner valve spring (5) and outer valve spring (6) on valve (2).. 6. Remove valve rotator (4). 7. Remove outer valve spring (6) and inner valve spring (5) from the valve.. 4. Install valve rotator (4) on valve (2).. 8. Remove washer (7) from the valve guide. 9. Use Tooling (B) to check the valve springs (spring force). Refer to Specifications, “Cylinder Head Valves” for additional information on the valve springs.. Installation Procedure Table 12. Required Tools Tool. Part Number. Part Description. Qty. A. 9U-7241. Valve Spring Compressor. 1. The valve spring keepers can be thrown from the valve when the valve spring compressor is released. Ensure that the valve spring keepers are properly installed on the valve stem. To help prevent personal injury, keep away from the front of the valve spring keepers and valve springs during the installation of the valves. 5. Use Tooling (A) to compress inner valve spring (5) and outer valve spring (6). Install valve spring keepers (3) on valve (2). Remove unit injector clamp (1) and Tooling (A)..
(22) 22 Disassembly and Assembly Section. RENR9716-02. End By: a. Install the electronic unit injectors. Refer to Disassembly and Assembly, “Electronic Unit Injector - Install”. i02642655. Inlet and Exhaust Valves Remove and Install SMCS Code: 1105-010. Removal Procedure Table 13. Required Tools Tool. Part Number. Part Description. Qty. A. 5S-1330. Valve Spring Compressor. 1. B. 8S-2263. Spring Tester. 1. Start By: a. Remove the cylinder head. Refer to Disassembly and Assembly, “Cylinder Head - Remove”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.. Illustration 59. g01015263. Personal injury can result from being struck by 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. 1. Install Tooling (A) and compress the valve springs. Remove valve spring keepers (2) from valve (1). 2. Carefully remove Tooling (A) from valve (1). 3. Remove valve rotator (3). 4. Remove outer valve spring (5) and inner valve spring (4) from valve (1). 5. Remove washer (6) and valve (1) from the valve guide. 6. Use Tooling (B) to check the valve springs (spring force). Refer to Specifications, “Cylinder Head Valves” for additional information on the valve springs. 7. Inspect the valves. Refer to Specifications, “Cylinder Head Valves” for additional information on the inlet and exhaust valves..
(23) RENR9716-02. 23 Disassembly and Assembly Section. Installation Procedure. 3. Install inner valve spring (4) and outer valve spring (5) on valve (1).. Table 14. 4. Install valve rotator (3) on valve (1).. Required Tools Tool A. Part Number 5S-1330. Part Description Valve Spring Compressor. Qty 1. NOTICE Keep all parts clean from contaminants.. 5. Use Tooling (A) to compress inner valve spring (4) and outer valve spring (5). Install valve spring keepers (2) on valve (1).. Note: A small amount of grease can be used to hold the retainer locks in position during installation.. The valve spring keepers can be thrown from the valve when the valve spring compressor is released. Ensure that the valve spring keepers are properly installed on the valve stem. To help prevent personal injury, keep away from the front of the valve spring keepers and valve springs during the installation of the valves.. 1. Lubricate the valves with clean engine oil. Install the valves in the cylinder head.. 6. Carefully remove Tooling (A).. Contaminants may cause rapid wear and shortened component life.. End By: a. Install the cylinder head. Refer to Disassembly and Assembly, “Cylinder Head - Install”. i02109151. Inlet and Exhaust Valve Guides - Remove and Install SMCS Code: 1104-010. Removal Procedure Table 15. Required Tools Tool. Part Number. A(1). 9U-6895. (1). Part Description Valve Guide Driver. Qty 1. Part of 9U-7530 Engine Tool Group. Start By:. Illustration 60. g01015263. a. Remove the inlet and exhaust valves. Refer to Disassembly and Assembly, “Inlet and Exhaust Valves - Remove and Install”. NOTICE Keep all parts clean from contaminants.. Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment. 2. Install washer (6) on the valve guide.. Contaminants may cause rapid wear and shortened component life..
(24) 24 Disassembly and Assembly Section. RENR9716-02. Note: Tooling (B) must be used in order to install the valve guide to the correct height. Height to top of valve guide from cylinder head surface ..... 35.00 ± 0.50 mm (1.378 ± 0.020 inch) Note: For more information, refer to Specifications, “Cylinder Head Valves”. 3. Install valve stem seal (1) on the valve guide. End By:. g01073841. Illustration 61. a. Install the inlet and exhaust valves. Refer to Disassembly and Assembly, “Inlet and Exhaust Valves - Remove and Install”.. 1. Remove valve stem seal (1) from valve guide (2). i02288478. 2. Use Tooling (A) and a hammer to remove the valve guide from the cylinder head.. Inlet and Exhaust Valve Seat Inserts - Remove and Install. Installation Procedure. SMCS Code: 1103-010. Table 16. Removal Procedure. Required Tools Tool. Part Number. A(1). 9U-6895. Valve Guide Driver. 1. B(1). 9U-6894. Guide Collar. 1. (1). Part Description. Qty. Part of 9U-7530 Engine Tool Group. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.. Table 17. Required Tools Tool. Part Number. A. 166-7441. Part Description. Qty. Valve Seat Extractor Tool Group. 1. Start By: a. Remove the inlet and exhaust valves. Refer to Disassembly and Assembly, “Inlet and Exhaust Valves - Remove and Install”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.. Illustration 62. g01073842. 1. Lubricate the bores for the valve guides with clean engine oil. 2. Install valve guide (2) in the cylinder head with Tooling (A) and Tooling (B). Illustration 63. g01145463.
(25) RENR9716-02. 25 Disassembly and Assembly Section. 1. Use Tooling (A) to remove valve seat insert (1) from the cylinder head. 2. Clean the bores in the cylinder head for the valve seat inserts. Remove any rough areas from the bores.. i02438648. Engine Oil Filter Base Remove SMCS Code: 1306-011. Installation Procedure. Removal Procedure. Table 18. Table 19. Required Tools Tool B(1) (1). Part Number. Required Tools Qty. Tool. Part Number. 9U-6898. Valve Seat Driver (Exhaust). 1. A. 185-3630. 9U-6897. Valve Seat Driver (Inlet). 1. Part Description. Part of 9U-7530 Engine Tool Group. Part Description Strap Wrench As. Qty 1. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.. Illustration 64. g01079028. 1. Lower the temperature of new valve seat insert (1).. 1. Drain the engine oil into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, “Engine Oil and Filter Change”.. 2. Use Tooling (B) to install the new valve seat insert in the cylinder head. Note: Do not machine the prefinished valve seat inserts in order to correct the valve stem projection. An excessive valve stem projection indicates that the valve seat insert is not seated or material was not cleaned from the bottom of the counterbore. End By: a. Install the inlet and exhaust valves. Refer to Disassembly and Assembly, “Inlet and Exhaust Valves - Remove and Install”.. Illustration 65. g01218560.
(26) 26 Disassembly and Assembly Section. RENR9716-02. 2. Use Tooling (A) in order to remove engine oil filters (6).. 3. Remove springs (3) and plungers (2) from oil filter base assembly (1).. 3. Remove bolts (1), (2), (4), and (5).. i02127824. 4. Remove engine oil filter base (3). i02127750. Engine Oil Filter Base Disassemble. Engine Oil Filter Base Assemble SMCS Code: 1306-016. Assembly Procedure. SMCS Code: 1306-015. NOTICE Keep all parts clean from contaminants.. Disassembly Procedure. Contaminants may cause rapid wear and shortened component life.. Start By: a. Remove the engine oil filter base. Refer to Disassembly and Assembly, “Engine Oil Filter Base - Remove”. 1. Remove the O-ring seals.. Illustration 67. Illustration 66. g01083088. Personal injury can result from being struck by 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. 2. Remove cover (4).. g01083088. Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment. 1. Install plungers (2) and springs (3) in oil filter base assembly (1). 2. Install cover (4). 3. Install the O-ring seals..
(27) RENR9716-02. 27 Disassembly and Assembly Section. End By:. i02438849. a. Install the engine oil filter base. Refer to Disassembly and Assembly, “Engine Oil Filter Base - Install”. i02438813. Engine Oil Cooler - Remove SMCS Code: 1378-011. Removal Procedure. Engine Oil Filter Base - Install. Start By:. SMCS Code: 1306-012. a. Remove the engine oil filter base. Refer to Disassembly and Assembly, “Engine Oil Filter Base - Remove”.. Installation Procedure. NOTICE Keep all parts clean from contaminants.. Table 20. Required Tools Tool. Part Number. A. 185-3630. Part Description. Qty. Contaminants may cause rapid wear and shortened component life.. 1. Strap Wrench As. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. 1. Drain the coolant from the cooling system into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Change”.. Illustration 68. g01218560. 1. Position engine oil filter base (3) on the engine oil cooler. 2. Install bolts (1), (2), (4), and (5). 3. Use Tooling (A) to install engine oil filters (6). 4. Refill the engine with engine oil. Refer to Operation and Maintenance Manual, “Engine Oil and Filter - Change”. Illustration 69. 2. Remove tube assembly (2). 3. Remove bonnet (1) and the gasket.. g01218689.
(28) 28 Disassembly and Assembly Section. RENR9716-02. 4. Remove engine oil cooler (3).. i02439263. 5. Remove the O-ring seals from engine oil cooler (3). i02438914. Engine Oil Cooler - Install. Engine Oil Pump - Remove SMCS Code: 1304-011. Removal Procedure Start By:. SMCS Code: 1378-012. a. Remove the engine oil pan. Refer to Disassembly and Assembly, “Engine Oil Pan - Remove and Install”.. Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.. Illustration 70. g01218689. 1. Install the O-ring seals on engine oil cooler (3). 2. Lubricate the O-ring seals with clean engine oil or glycerin. 3. Install engine oil cooler (3). 4. Install the gasket and bonnet (1). 5. Install tube assembly (2). 6. Refill the cooling system with coolant. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Change”. End By: a. Install the engine oil filter base. Refer to Disassembly and Assembly, “Engine Oil Filter Base - Install”.. Illustration 71. g01218847. 1. Remove tube assemblies (3) from engine oil pump (2). 2. Remove bolts (1) and engine oil pump (2)..
(29) RENR9716-02. 29 Disassembly and Assembly Section. i02439652. Engine Oil Pump - Disassemble. 3. Remove bolts (4) and separate cover assembly (3) from body assembly (1).. SMCS Code: 1304-015. 4. Use Tooling (A) and a suitable press in order to remove the bearings from cover assembly (3).. Disassembly Procedure. 5. Remove shaft assemblies (2).. Table 21. 6. Remove bolts (12) and retainer (11). Required Tools. Tool. Part Number. A. 1P-0510. Driver Group. 1. B. 1P-2320. Puller Assembly. 1. Part Description. Qty. 7. Remove spring (10), plunger ring (9), and plunger (8). 8. Use Tooling (A) and a suitable press in order to remove the bearings from body assembly (1). i02439997. Start By: a. Remove the engine oil pump. Refer to Disassembly and Assembly, “Engine Oil Pump - Remove”.. Engine Oil Pump - Assemble SMCS Code: 1304-016. Assembly Procedure. NOTICE Keep all parts clean from contaminants.. Table 22. Required Tools. Contaminants may cause rapid wear and shortened component life. Tool. Part Number. A. 1P-0510. Part Description Driver Group. Qty 1. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.. Illustration 72. g01218982. Personal injury can result from being struck by 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. 1. Remove bolt (7) and washer (6). 2. Use Tooling (B) to remove drive gear (5) from body assembly (1). Remove the key from the pump shaft.. Illustration 73. g01218982.
(30) 30 Disassembly and Assembly Section. RENR9716-02. 5. Use Tooling (A) to install the bearings in cover assembly (3) until the bearings are even with the outside surface of cover assembly (3). Install the bearings so the junctions in the bearings are Angle (Y). Angle (Y) is 30 ± 15 degrees from the center line of the bearing bores, and toward the outlet passage. The outlet passage has a cavity between the bearing bores. 6. Install cover assembly (3) on body assembly (1). Install bolts (4).. Illustration 74. g01219045. 7. Install the key into the pump shaft. Install drive gear (5). Install washer (6) and bolt (7). Tighten bolt (7) to a torque of 55 ± 10 N·m (41 ± 7 lb ft). End By: a. Install the engine oil pump. Refer to Disassembly and Assembly, “Engine Oil Pump - Install”. i02440080. Engine Oil Pump - Install SMCS Code: 1304-012. Installation Procedure Illustration 75. g01219048. Improper assembly of parts that are spring loaded can cause bodily injury.. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.. To prevent possible injury, follow the established assembly procedure and wear protective equipment. 1. Use Tooling (A) to install the bearings in body assembly (1) until the bearings are even with the outside surface of body assembly (1). Install the bearings so the junctions in the bearings are Angle (X). Angle (X) is 30 ± 15 degrees from the center line of the bearing bores and toward the outlet passage in the engine oil pump. 2. Install plunger (8), plunger ring (9), and spring (10). 3. Install retainer (11) and bolts (12). 4. Install shaft assemblies (2).. Illustration 76. g01218847. 1. Position engine oil pump (2) and install bolts (1). 2. Install tube assemblies (3) on engine oil pump (2). End By: a. Install the engine oil pan. Refer to Disassembly and Assembly, “Engine Oil Pan - Remove and Install”..
(31) RENR9716-02. 31 Disassembly and Assembly Section. i02440626. Water Pump - Remove SMCS Code: 1361-011. Removal Procedure NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. g01219275. Dispose of all fluids according to local regulations and mandates.. Illustration 78. NOTICE Keep all parts clean from contaminants.. 5. Remove water pump (4).. Contaminants may cause rapid wear and shortened component life. 1. Drain the coolant from the cooling system into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Change”.. 4. Remove bolts (6) and nuts (5).. i02451192. Water Pump - Disassemble SMCS Code: 1361-015. Disassembly Procedure Table 23. Required Tools Part Number. Tool. A. B. Part Description. Qty. 8S-2264. Puller Group. 1. 4B-3903. Bolt 5/16 - 18 NC by 4 inch. 2. 1P-0456. Plate. 1. 4B-4277. Washer. 2. 1P-0510. Driver Group. 1. Start By: a. Remove the water pump. Refer to Disassembly and Assembly, “Water Pump - Remove”. Illustration 77. 2. Remove bolts (1) and bolts (2). 3. Remove cover (3).. g01219274. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life..
(32) 32 Disassembly and Assembly Section. RENR9716-02. Note: The water pump seal can be replaced without removing the water pump from the engine. Note: An intermittent leakage of a small amount of coolant from the hole in the water pump housing is not an indication of a water pump seal failure. This is required to provide lubrication for the seal. Do not replace the water pump seal unless a large amount of leakage or a constant flow of coolant is draining from the water pump housing.. i02394663. Water Pump - Assemble SMCS Code: 1361-016. Assembly Procedure Table 24. Required Tools Tool. Part Number. Part Description. Qty. B. 1P-0510. Driver Group. 1. C. 7N-7843. Seal Installation Tool. 1. D. 6V-1541. Quick Cure Primer. 1. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.. Illustration 79. g01195730. 1. Remove adapter (15). 2. Remove bolt (9) and washer (8). 3. Use Tooling (A) to remove impeller (5) from shaft (10). 4. Remove bolt (7), washer (6), and gear (4) from shaft (10). 5. Remove bolts (11) and retainer (13). 6. Remove O-ring seal (14) from housing (3).. Illustration 80. g01195730. 7. Use a suitable press to remove shaft (10) and bearing assembly (1) from housing (3).. 1. Use Tooling (B) to install lip seal (2) into the housing.. 8. Use a suitable press to remove bearing assembly (1) from shaft (10).. 2. Apply Tooling (D) to shaft (10). Use a suitable press to install bearing assembly (1) on shaft (10).. 9. Remove seal assembly (12) from housing (3).. 3. Install shaft (10) and bearing assembly (1) in housing (3).. 10. Use Tooling (B) to remove lip seal (2) from the housing.. 4. Install O-ring seal (14) on housing (3). 5. Install retainer (13) and bolts (11). 6. Position gear (4) on shaft (10). Install washer (6) and bolt (7)..
(33) RENR9716-02. 33 Disassembly and Assembly Section. 7. Use Tooling (C) to install seal assembly (12) onto shaft (10) until the stationary cup is fully seated into housing (3). 8. Install impeller (5) on shaft (10). Install washer (8) and bolt (9). Tighten bolt (9) to a torque of 39 ± 3 N·m (29 ± 2 lb ft). 9. Install adapter (15). End By: a. Install the water pump. Refer to Disassembly and Assembly, “Water Pump - Install”. i02440675. Water Pump - Install SMCS Code: 1361-012 Illustration 82. Installation Procedure. g01219274. 3. Position cover (3) on the water pump.. NOTICE Keep all parts clean from contaminants.. 4. Install bolts (2) and bolts (1).. Contaminants may cause rapid wear and shortened component life.. 5. Fill the cooling system. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Change”. i02440754. Water Temperature Regulator Housing - Remove and Install SMCS Code: 1393-010. Removal Procedure 1. Drain the coolant from the cooling system into a suitable container for storage or disposal until the coolant is below the level of the water temperature regulator housing. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Change”.. Illustration 81. g01219275. 1. Position water pump (4) in the front housing. 2. Install nuts (5) and bolts (6)..
(34) 34 Disassembly and Assembly Section. RENR9716-02. g01219336. Illustration 83. 2. Disconnect hose assembly (1) and elbow (3). 3. Remove bolts (2) and bolts (4). Remove water temperature regulator housing (5).. g01223744. Illustration 84. 4. Remove O-ring seals (6) and water temperature regulators (7) from water temperature regulator housing (5). 5. If necessary, remove the lip seals.. Table 25. Required Tools Part Number. A. 221-8647. Part Description Seal Installer Gp. g01223744. 2. Install water temperature regulators (7) and O-ring seals (6) in water temperature regulator housing (5).. Illustration 86. g01219336. 3. Position water temperature regulator housing (5) on the engine. Install bolts (4) and bolts (2). 4. Connect elbow (3) and hose assembly (1). 5. Fill the cooling system. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Change”.. Installation Procedure. Tool. Illustration 85. Qty 1. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. If necessary, use Tooling (A) to install the lip seals..
(35) RENR9716-02. 35 Disassembly and Assembly Section. i02576096. Cooling System Package (Radiator, Aftercooler, Fuel Cooler) - Remove SMCS Code: 1063-011; 1353-011; 1712-011. Removal Procedure Table 26. Required Tools Tool. Part Number. A. 189-0410. Part Description. Qty. Shackle As. 2. Illustration 88. g01290915. 3. Disconnect bottom aftercooler tube (2).. Start By: a. Remove the fan. Refer to Disassembly and Assembly, “Fan - Remove and Install”. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component 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.. Illustration 89. g01290916. 4. Disconnect top radiator hose (3).. Dispose of all fluids according to local regulations and mandates. 1. Drain the coolant from the cooling system into a suitable container for storage or for disposal. Refer to Operation and Maintenance Manual, “Cooling System Coolant (ELC) - Change”.. Illustration 90. 5. Disconnect top aftercooler tube (4).. Illustration 87. g01290908. 2. Remove clamp (1). Repeat for the opposite side.. g01290917.
(36) 36 Disassembly and Assembly Section. Illustration 91. RENR9716-02. g01290930. 6. Disconnect bottom radiator hose (5). Disconnect bottom aftercooler tube (6).. Illustration 92. g01290940. Illustration 94. 9. Attach Tooling (A) and a suitable lifting device onto cooling package (10). The weight of cooling package (10) is approximately 544 kg (1200 lb).. g01290934 g01290941. Illustration 95. 7. Disconnect hose assembly (8) from fuel cooler (7).. 10. Remove bolts (11). Repeat for the opposite side. Remove cooling package (10). i02576308. Cooling System Package (Radiator, Aftercooler, Fuel Cooler) - Install SMCS Code: 1063-012; 1353-012; 1712-012. Installation Procedure Illustration 93. g01290939. 8. Disconnect hose assembly (9) from fuel cooler (7).. Table 27. Required Tools Tool. Part Number. A. 189-0410. Part Description Shackle As. Qty 2.
(37) RENR9716-02. 37 Disassembly and Assembly Section. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component 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.. Illustration 98. g01290939. 3. Connect hose assembly (9) onto fuel cooler (7).. Illustration 96. g01290940. 1. Attach Tooling (A) and a suitable lifting device onto cooling package (10). The weight of cooling package (10) is approximately 544 kg (1200 lb).. Illustration 97. g01290941. 2. Install cooling package (10). Install bolts (11). Repeat for the opposite side.. Illustration 99. g01290934. 4. Connect hose assembly (8) onto fuel cooler (7).. Illustration 100. g01290930. 5. Connect bottom aftercooler tube (6). Connect bottom radiator hose (5)..
(38) 38 Disassembly and Assembly Section. Illustration 101. RENR9716-02. g01290917. 6. Connect top aftercooler tube (4).. g01290908. Illustration 104. 9. Install clamp (1). Repeat for the opposite side. 10. Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, “Cooling System Coolant (ELC) - Change”. End By: a. Install the fan. Refer to Disassembly and Assembly, “Fan - Remove and Install”. i02584900. Aftercooler - Remove Illustration 102. g01290916. SMCS Code: 1063-011. Removal Procedure. 7. Connect top radiator hose (3).. Table 28. Required Tools Tool. Part Number. A. 189-0410. Part Description. Qty. Shackle As. Start By: a. Remove the fan. Refer to Disassembly and Assembly, “Fan - Remove and Install”.. Illustration 103. 8. Connect bottom aftercooler tube (2).. g01290915. 2.
(39) RENR9716-02. 39 Disassembly and Assembly Section. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component 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. 1. Drain the coolant from the cooling system into a suitable container for storage or for disposal. Refer to Operation and Maintenance Manual, “Cooling System Coolant (ELC) - Change”.. Illustration 107. g01290916. 4. Disconnect top radiator hose (3).. Illustration 108. g01290917. 5. Disconnect top aftercooler tube (4). Illustration 105. g01290908. 2. Remove clamp (1). Repeat for the opposite side.. Illustration 109. Illustration 106. 3. Disconnect bottom aftercooler tube (2).. g01290915. g01290930. 6. Disconnect bottom radiator hose (5). Disconnect bottom aftercooler tube (6)..
(40) 40 Disassembly and Assembly Section. Illustration 110. RENR9716-02. g01290934. 7. Disconnect hose assembly (8) from fuel cooler (7).. Illustration 111. g01294232. Illustration 113. 10. Attach Tooling (A) and a suitable lifting device onto aftercooler (12). The weight of aftercooler (12) is approximately 227 kg (500 lb).. g01290939. 8. Disconnect hose assembly (9) from fuel cooler (7).. g01294234. Illustration 114. 11. Remove bolt (13). Remove bolts (14) and bolts (15) from aftercooler (12). 12. Repeat Step 9 through Step 11 for the opposite side. 13. Remove aftercooler (12). i02585968. Aftercooler - Install SMCS Code: 1063-012 Illustration 112. 9. Remove bolts (10). Remove bolt (11).. g01294215. Installation Procedure Table 29. Required Tools Tool. Part Number. A. 189-0410. Part Description Shackle As. Qty 2.
(41) RENR9716-02. Illustration 115. 41 Disassembly and Assembly Section. g01294232. 1. Attach Tooling (A) and a suitable lifting device onto aftercooler (12). The weight of aftercooler (12) is approximately 227 kg (500 lb). Install aftercooler (12).. Illustration 118. 5. Connect hose assembly (9) onto fuel cooler (7).. Illustration 119. Illustration 116. g01294234. g01290939. g01290934. 6. Connect hose assembly (8) onto fuel cooler (7).. 2. Install bolts (14) and bolts (15) into aftercooler (12). Install bolt (13).. Illustration 120. Illustration 117. g01294215. 3. Install bolt (11). Install bolts (10). 4. Repeat Step 2 and Step 3 for the opposite side.. g01290930. 7. Connect bottom aftercooler tube (6). Connect bottom radiator hose (5)..
(42) 42 Disassembly and Assembly Section. Illustration 121. RENR9716-02. g01290917. 8. Connect top aftercooler tube (4).. g01290908. Illustration 124. 11. Install clamp (1). Repeat for the opposite side. 12. Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, “Cooling System Coolant (ELC) - Change”. End By: a. Install the fan. Refer to Disassembly and Assembly, “Fan - Remove and Install”. i02581106. Radiator Core - Remove Illustration 122. g01290916. SMCS Code: 1353-011; 1353-011-KO. Removal Procedure. 9. Connect top radiator hose (3).. Table 30. Required Tools Tool. Part Number. A. 138-7575. Part Description Link Bracket. Qty 2. Start By: a. Remove the aftercooler. Refer to Disassembly and Assembly, “Aftercooler - Remove”.. Illustration 123. 10. Connect bottom aftercooler tube (2).. g01290915.
(43) RENR9716-02. 43 Disassembly and Assembly Section. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component 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.. Illustration 127. g01294577. 3. Remove the upper and the lower braces (3).. Illustration 125. g01292911. 1. Remove the upper and the lower radiator guards (1).. Illustration 126. Illustration 128. g01294578. 4. Remove bolts (4) and remove bolts (5).. g01292912. 2. Attach Tooling (A) and a suitable lifting device onto radiator top tank (2). The weight of the radiator is approximately 227 kg (500 lb). Illustration 129. 5. Remove bolts (6).. g01294579.
(44) 44 Disassembly and Assembly Section. RENR9716-02. Illustration 132. g01292912. 1. Attach Tooling (A) and a suitable lifting device onto radiator top tank (2). The weight of the radiator is approximately 227 kg (500 lb). g01294580. Illustration 130. 6. Remove bolts (7). Remove bolts (8). Remove support (9). 7. Repeat Steps 4 through 6 for the opposite side.. Illustration 133. g01294602. 2. Install radiator (10). Install bolts (11). Repeat for the opposite side.. g01294602. Illustration 131. 8. Remove bolts (11). Repeat for the opposite side. Remove radiator (10). i02585957. Radiator Core - Install SMCS Code: 1353-012-KO; 1353-012. Installation Procedure Table 31. Required Tools Tool. Part Number. A. 138-7575. Part Description. Qty Illustration 134. Link Bracket. 2. g01294580. 3. Install support (9). Install bolts (8). Install bolts (7)..
(45) RENR9716-02. 45 Disassembly and Assembly Section. Illustration 138. g01292911. 8. Install the upper and the lower radiator guards (1). End By: Illustration 135. g01294579. a. Install the aftercooler. Refer to Disassembly and Assembly, “Aftercooler - Install”.. 4. Install bolts (6). i02444868. Engine Support (Front) Remove and Install SMCS Code: 1154-010-FR. Removal Procedure (Type 1) Start By: a. Remove the vibration damper and the pulley. Refer to Disassembly and Assembly, “Vibration Damper and Pulley - Remove and Install”. Illustration 136. g01294578. 1. Support the front of the engine.. 5. Install bolts (4) and bolts (5). 6. Repeat Steps 3 through 5 for the opposite side.. Illustration 139. 2. Remove bolts (1). Illustration 137. 7. Install the upper and the lower braces (3).. g01294577. 3. Remove engine support (2).. g01221659.
(46) 46 Disassembly and Assembly Section. RENR9716-02. Installation Procedure (Type 1). Illustration 140. g01221659. 1. Position engine support (2) on the engine.. Installation Procedure (Type 2). g01221663. Illustration 142. 2. Install bolts (1).. 1. Use a suitable lifting device to position engine support (4) on the engine. The weight of engine support (4) is approximately 35 kg (77 lb).. End By:. 2. Install bolts (3).. a. Install the vibration damper and the pulley. Refer to Disassembly and Assembly, “Vibration Damper and Pulley - Remove and Install”.. End By:. Removal Procedure (Type 2). a. Install the vibration damper and the pulley. Refer to Disassembly and Assembly, “Vibration Damper and Pulley - Remove and Install”.. Start By:. i02440962. a. Remove the vibration damper and the pulley. Refer to Disassembly and Assembly, “Vibration Damper and Pulley - Remove and Install”. 1. Support the front of the engine.. Gear Group (Rear) - Remove SMCS Code: 1206-011; 1212-011. Removal Procedure Table 32. Required Tools Tool. Part Number. A. 1P-0510. Part Description Driver Group. Qty 1. Start By: a. Remove the flywheel housing. Refer to Disassembly and Assembly, “Flywheel Housing - Remove and Install”. Illustration 141. g01221663. 2. Remove bolts (3). 3. Use a suitable lifting device to remove engine support (4). The weight of engine support (4) is approximately 35 kg (77 lb)..
(47) RENR9716-02. 47 Disassembly and Assembly Section. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products.. 4. Use Tooling (A) and a suitable press to remove the bearing from gear assembly (6). 5. Remove bolts (2), gear assembly (1), and shaft assembly (3). 6. Use Tooling (A) and a suitable press to remove the bearing from gear assembly (1). 7. Remove gear assembly (12). 8. Remove bolts (5) and gear assemblies (4).. Dispose of all fluids according to local regulations and mandates. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.. Illustration 144. g01219500. 9. Remove bolts (16) and shaft assembly (17). 10. Remove bolts (13), thrust plates (14), and adapter assemblies (15). 11. Use bolt (13) in order to remove the sealing plates. Remove the O-ring seals.. Illustration 143. g01219485. 1. Remove bolts (10), thrust plate (11), and gear assembly (9). 2. Use Tooling (A) and a suitable press to remove the bearing from gear assembly (9). 3. Remove bolts (8), gear assembly (6), and shaft assembly (7)..
(48) 48 Disassembly and Assembly Section. RENR9716-02. i02442469. Gear Group (Rear) - Install SMCS Code: 1206-012; 1212-012. Installation Procedure Table 33. Required Tools Tool. Part Number. A. 1P-0510. Part Description Driver Group. Qty 1. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Note: Apply clean engine oil to the bearings and the shaft assemblies prior to installation on the engine.. Illustration 146. g01220275. Illustration 147. g01151468. 4. Refer to Testing and Adjusting, “Rear Gear Group - Time” for additional information.. Illustration 145. g01219500. Note: Align the Timing Marks on gear assemblies (4) with the Timing Marks on the rear housing and align the dowels on gear assemblies (4) with the adapter assemblies. 5. Position gear assemblies (4) and install bolts (5).. 1. Install the O-ring seals and the sealing plates on the cylinder head.. 6. Install gear assembly (12).. 2. Install adapter assemblies (15), thrust plates (14), and bolts (13).. 7. Use Tooling (A) and a suitable press to install the bearing in gear assembly (1). Install the bearing to a depth of 2.6 ± 0.5 mm (0.10 ± 0.02 inch).. 3. Position shaft assembly (17) and install bolts (16)..
(49) RENR9716-02. 49 Disassembly and Assembly Section. 8. Install shaft assembly (3), gear assembly (1), and bolts (2). 9. Use Tooling (A) and a suitable press to install the bearing in gear assembly (6). Install the bearing to a depth of 2.6 ± 0.5 mm (0.10 ± 0.02 inch). 10. Install shaft assembly (7), gear assembly (6), and bolts (8). 11. Use Tooling (A) and a suitable press to install the bearing in gear assembly (9). Install the bearing to a depth of 2.5 ± 0.5 mm (0.10 ± 0.02 inch). Note: Align the Timing Mark on gear assembly (9) with the Timing Mark on gear assembly (12).. Illustration 149. 12. Install gear assembly (9), thrust plate (11), and bolts (10).. 1. Remove two bolts (1). Install Tooling (A) in the crankshaft.. 13. Tighten the bolts on gear assemblies (4) to a torque of 240 ± 40 N·m (177 ± 30 lb ft). Tighten the bolts in the following sequence: 1, 4, 2, 5, 3, 6, 1, 4.. 2. Remove remaining bolts (1). Slide flywheel (2) away from the engine on Tooling (A).. End By: a. Install the flywheel housing. Refer to Disassembly and Assembly, “Flywheel Housing - Remove and Install”. i02752668. Flywheel - Remove and Install. g01220438. 3. Attach a suitable lifting device to flywheel (2). The weight of flywheel (2) is approximately 130 kg (285 lb). Remove flywheel (2). 4. If necessary, use a hammer and a punch in order to remove ring gear (3) from flywheel (2).. Installation Procedure Table 35. Required Tools Tool. Part Number. Removal Procedure. A. -. Table 34. B. 6V-4876. SMCS Code: 1156-010. Part Description. Qty. Guide Stud 5/8 - 18 UNF by 11 inch. 2. Lubricant. -. Required Tools Tool. Part Number. A. -. Part Description Guide Stud 5/8 - 18 UNF by 11 inch. Qty 2. Illustration 150. Illustration 148. g01220437. g01220438.
(50) 50 Disassembly and Assembly Section. RENR9716-02. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.. g01220437. Illustration 151. Note: Ring gear (3) must be installed with the chamfered side of the teeth upward. The chamfered side of the gear teeth will be facing toward the starting motor when the flywheel is installed. 1. Raise the temperature of ring gear (3). Install ring gear (3) on flywheel (2).. g01220531. Illustration 152. 2. Install Tooling (A) in the crankshaft.. 1. Use Tooling (A) or a punch and hammer in order to puncture three or more holes in crankshaft rear seal (1).. 3. Attach a suitable lifting device to flywheel (2). The weight of flywheel (2) is approximately 130 kg (285 lb). Position flywheel (2) on the crankshaft.. 2. Use Tooling (A) to remove crankshaft rear seal (1) and crankshaft wear sleeve (2).. 4. Apply Tooling (B) to the threads of bolts (1).. i02442921. Crankshaft Rear Seal - Install. 5. Install bolts (1). Remove Tooling (A). Install remaining bolts (1). 6. Tighten bolts (1) to a torque of 100 ± 5 N·m (75 ± 4 lb ft). Turn the bolts for an additional 180 ± 5 degrees. 7. Check the flywheel runout. Refer to Testing and Adjusting, “Flywheel - Inspect”. i02442878. SMCS Code: 1161-012. Installation Procedure Table 37. Required Tools Tool. Crankshaft Rear Seal - Remove SMCS Code: 1161-011. Removal Procedure. B. Table 36. Required Tools Tool. Part Number. A. 1U-7600. Part Description Slide Hammer Puller. Qty 1. Start By: a. Remove the flywheel. Refer to Disassembly and Assembly, “Flywheel - Remove and Install”.. (1) (2). Part Number. Part Description. Qty. 249-2937(1). Seal Locator As. 1. 5P-7310(1). Bolt. 3. 9S-8858(1). Nut (Seal Installer). 1. 6V-6143(1). Seal Installer. 1. 5P-1733(2). Seal Locator As. 1. 5P-7309(2). Bolt. 3. 9S-8858(2). Nut (Seal Installer). 1. 6V-6142(2). Seal Installer. 1. Large crankshaft gear Small crankshaft gear.
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