August 2002
Disassembly and
Assembly
C-10 and C-12 Truck Engines
1YN1-Up (Engine)
2PN1-Up (Engine)
i01658146
Summary of Revisions
SMCS Code: 1000
Information Changes
The following table summarizes the major changes
in this manual:
Table 1
Titles Description of Change
Revision 05
“Fuel Filter Base - Remove” Tooling (A)
“Fuel Filter Base - Install” Tooling (A)
“Electronic Unit Injector Sleeve - Remove” Tooling (A)
“Inlet and Exhaust Valve Guides - Remove and Install” Tooling (A)
“Inlet and Exhaust Valve Seat Inserts - Remove and Install” Tooling (A)
“Engine Oil Filter Base - Remove” Tooling (A)
“Engine Oil Filter Base - Install” Tooling (A)
“Water Pump - Assemble” Tooling (D)
Procedure
“Water Pump - Disassemble” Tooling (C)
“Crankshaft Gear - Remove and Install” Procedure
“Cylinder Head - Remove” Tooling (A)
“Cylinder Head - Install” Tooling (A)
i01468998
NOTICE
Fuel Priming Pump - Remove Care must be taken to ensure that fluids are contained
and Install during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
SMCS Code: 1258-010 collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Removal Procedure
Refer to Special Publication, NENG2500, “Caterpillar
NOTICE Tools and Shop Products Guide” for tools and supplies
Keep all parts clean from contaminants. suitable to collect and contain fluids on Caterpillar
products.
Contaminants may cause rapid wear and shortened
component life. Dispose of all fluids according to local regulations and
mandates.
5
Disassembly and Assembly Section
i01015037
Removal Procedure
Table 2
Required Tools
Part
Tool Part Description Qty
Number
g00511626
Illustration 1 A 2P-8250 Strap Wrench Assembly 1
Typical example
g00511626
Illustration 2
Typical example
g00520760
Illustration 4
Typical example
g00520760
Illustration 5
2. Use Tool (A) to remove fuel filter (6). Typical example
3. Disconnect the sensor connector from fuel 4. Install the two O-rings on fuel filter base (5).
temperature sensor (2).
5. Install fuel filter base (5) on the fuel manifold with
4. Remove fuel temperature sensor (2). two bolts (4) and the washers.
5. Disconnect hose assembly (3). Plug all openings 6. Connect hose assembly (3).
immediately.
7. Install fuel temperature sensor (2). Connect the
6. Remove two bolts (4) and the washers. sensor connector to fuel temperature sensor (2).
7. Remove fuel filter base (5) and the two O-ring 8. Use Tool (A) in order to install new fuel filter (6).
seals. Follow the instructions on the fuel filter.
8. Remove the fuel filter mounting stud from the fuel
filter base, if necessary.
Installation Procedure
Table 3
Required Tools
Part
Tool Part Description Qty
Number
A 2P-8250 Strap Wrench Assembly 1
NOTICE g00519561
Keep all parts clean from contaminants. Illustration 6
Contaminants may cause rapid wear and shortened 9. Install plug (1).
component life.
i00999915 i01770561
Contaminants may cause rapid wear and shortened Contaminants may cause rapid wear and shortened
component life. component life.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the machine. Be prepared
to collect the fluid with suitable containers before
opening any compartment or disassembling any
component containing fluids.
3. Remove fuel transfer pump (1) and the gasket. Removal Procedure
Start By:
NOTICE
Keep all parts clean from contaminants.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids. g00846262
Illustration 10
Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and supplies 4. Remove six O-ring seals (4).
suitable to collect and contain fluids on Caterpillar
products. 5. Remove plugs (5) and the O-ring seals, if
necessary.
Dispose of all fluids according to local regulations and
mandates. i01633987
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
g00846262
Illustration 11
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
End By:
i01770576
g00511865
Illustration 13
Electronic Unit Injector -
Remove 1. Remove plug (1) from the fuel manifold.
SMCS Code: 1290-011 2. Drain the fuel from the cylinder head assembly
into a suitable container for storage or disposal.
Removal Procedure
Table 4
Required Tools
Part
Tool Part Description Qty
Number
A 5F-4764 Pry Bar 1
Start By:
g00764868
Illustration 15
i01770633
NOTICE
Keep all parts clean from contaminants.
g00511927
Illustration 17
g00511936
Illustration 20
End By:
g00529729
Illustration 19
(12) Electronic injector code
NOTICE
When a fuel injector group is serviced, the new fuel
injector group’s electronic injector code must be pro-
grammed into the engine’s personality module soft-
ware by using the calibration menu on the Electronic
Service Tool. If the new fuel injector group’s electronic
code is not entered, the previous fuel injector group’s
characteristics are assumed.
i01770685
Removal Procedure
Table 6
Required Tools
Part
Tool Part Description Qty
Number
g00512002
221-9778 Puller Stud 1 Illustration 22
128-7889 Bridge Puller 1 2. Install the following parts from Tooling (A) over
A(1) 9U-6877 Thrust Bearing 1 the stud: bridge puller, thrust bearing, hard
washer, and nut. See Step 1.
5P-8247 Hard Washer 1
4K-0367 Nut 1 3. Tighten the nut until the unit injector sleeve is
pulled free of the cylinder head assembly.
(1) The tools that are listed in the chart are part of the 9U-6891
Injector Tool Group.
4. Remove Tooling (A) from the unit injector sleeve.
Start By:
5. Repeat Steps 1 through 4 in order to remove the
remaining unit injector sleeves.
a. Remove the electronic unit injectors. Refer to
Disassembly and Assembly, “Electronic Unit
Injector - Remove”. i01770693
NOTICE
Electronic Unit Injector Sleeve
Keep all parts clean from contaminants. - Install
Contaminants may cause rapid wear and shortened SMCS Code: 1713-012
component life.
Installation Procedure
Table 7
Required Tools
Part
Tool Part Description Qty
Number
A 4C-5552 Large Bore Brush 1
9U-7237 Brush Extension 1
B
9U-7244 End Brush 1
C 9U-7258 Driver Cap 1
Illustration 21
g00512128 NOTICE
Keep all parts clean from contaminants.
Typical example
Contaminants may cause rapid wear and shortened
1. Install the puller stud from Tooling (A) into the component life.
unit injector sleeve.
13
Disassembly and Assembly Section
End By:
i01469974
Turbocharger - Remove
SMCS Code: 1052-011
Removal Procedure
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
g00766939
Illustration 25
Typical Example
g00512116
Illustration 24
g00521930 g00521930
Illustration 26 Illustration 27
Typical example Typical example
Turbocharger - Install 2. Place clean engine oil in the oil supply port of
the turbocharger prior to installation. The oil will
SMCS Code: 1052-012 provide lubrication during starting and protection
during storage.
Installation Procedure 3. Apply 5P-3931 Anti-Seize Compound to the
turbocharger mounting studs on the exhaust
1. Inspect the condition of the gasket between the manifold.
turbocharger and the exhaust manifold and the
O-ring seals. Replace the O-ring seals and the 4. Install turbocharger (1) and gasket (10) on the
gaskets, if necessary. exhaust manifold. Install four nuts (11). Tighten
the nuts to a torque of 70 N·m (52 lb ft).
6. Install oil drain tube (6) with two bolts (5) and
the washers.
i01465377
Typical example
Start By:
4. Position the gaskets with the tabs in the upward
a. Remove the turbocharger. Refer to Disassembly
position. Install exhaust manifold (2).
and Assembly, “Turbocharger - Remove”.
5. Apply 5P-3931 Anti-Seize Compound to
locknuts (1). Install locknuts (1) with the washers
and spacers. Tighten the locknuts to a torque of
55 ± 10 N·m (41 ± 7 lb ft).
End By:
3. Remove the studs that hold the exhaust manifold Removal Procedure
to the cylinder head assembly.
NOTICE
4. Remove studs (3) from the exhaust manifold, if
Keep all parts clean from contaminants.
necessary.
Contaminants may cause rapid wear and shortened
Installation Procedure component life.
NOTICE
Keep all parts clean from contaminants.
g00526804
Illustration 36
g00526802
Illustration 34 7. Remove valve rotators (4).
3. Install the remainder of Tooling (A). 8. Remove the inlet valve springs and the exhaust
valve springs (5) from each valve.
g00526803
Illustration 35
g00526805
Illustration 37
Installation Procedure
Table 9
Required Tools
Part
Tool Part Description Qty
Number
A 4C-6726 Valve Spring Compressor 1
NOTICE
Keep all parts clean from contaminants.
g00526804
Illustration 39
Tool
Part
Part Description Qty
Installation Procedure
Number
Table 11
Valve Spring
A 5S-1330 1 Required Tools
Compressor
Part
Tool Part Description Qty
Start By: Number
Valve Spring
a. Remove the cylinder head. Refer to Disassembly A 5S-1330 1
Compressor
and Assembly, “Cylinder Head - Remove”.
NOTICE
Keep all parts clean from contaminants.
g00513273
Illustration 41
Make sure to wear all necessary protective equip- 1. Lubricate the inlet valve (7) and the exhaust
ment. valve (8) with clean engine oil. Install the inlet
valves and exhaust valves in the cylinder head
Follow the recommended procedure and use all assembly.
recommended tooling to release the spring force.
Table 12
Required Tools
Part
Tool Part Description Qty
Number
Valve Guide and Seat Tool
A 9U-6460 1
Group
Start By:
NOTICE
Keep all parts clean from contaminants.
Start By:
NOTICE
Keep all parts clean from contaminants.
g00513641
Illustration 45
g00513519 Typical example
Illustration 44
End By:
Part
Tool Part Description Qty
Number
Valve Guide and Seat Tool
A 9U-6460 1
Group
22
Disassembly and Assembly Section
i01234011
NOTICE
Keep all parts clean from contaminants. Engine Centrifugal Oil Filter -
Remove and Install
Contaminants may cause rapid wear and shortened
component life. SMCS Code: 1328-010
Removal Procedure
Table 16
Required Tools
Part
Tool Part Description Qty
Number
A 1P-1857 Retaining Ring Pliers 1
NOTICE
Keep all parts clean from contaminants.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
End By:
g00512749
Illustration 49
g00512845
Illustration 53
Illustration 50
g00512750 6. Remove seal (10) from the body of the filter
assembly (1).
3. Remove filter rotor assembly (4) from filter cover
assembly (3).
g00512756
Illustration 54
Illustration 51
g00512752 7. Remove filter adapter assembly (11) from the
oil filter base.
4. Use Tool (A) to remove retaining ring (5) from
filter cover assembly (3).
g00512755
Illustration 55
Installation Procedure
Table 17
Required Tools
Part
Tool Part Description Qty
Number
A 1P-1857 Retaining Ring Pliers 1
NOTICE
Keep all parts clean from contaminants.
1. Inspect the condition of the O-ring seals. Replace 4. Install O-ring seal (8) on filter cover bolt (9).
the seals, if necessary.
g00512752
Illustration 59
g00512755
Illustration 56
5. Install filter cover bolt (9) in filter cover (6) with
2. Install O-ring seal (12) onto filter adapter retaining ring (5).
assembly (11).
6. Install seal (7) on filter cover (6).
g00512756
Illustration 57
g00512750
Illustration 60
3. Place the filter adapter assembly (11) on the oil
filter base. Tighten the adapter to a torque of 7. Place filter rotor assembly (4) on filter cover
47 ± 7 N·m (35 ± 5 lb ft). assembly (3).
25
Disassembly and Assembly Section
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
i01770753
SMCS Code: 1306-011 1. Remove oil filter assembly (1) with Tooling (A).
Removal Procedure
Table 18
Required Tools
Tool Part Number Part Description Qty
Strap Wrench
A 185-3630 1
Assembly
NOTICE
Keep all parts clean from contaminants.
Note: Bolts (6) that hold the oil filter base assembly
to the cylinder block are marked. This is done for
installation purposes.
i01465384
Disassembly Procedure
Start By:
g00513077
Illustration 66
Typical example
1. Remove three O-ring seals (1) from the oil filter 6. Remove the following items from oil filter base
base. (8): cover (13), O-ring seal (14), spring (11), and
oil pump bypass valve (9).
27
Disassembly and Assembly Section
g00513080 g00513080
Illustration 67 Illustration 68
Typical example Typical example
7. Remove the following items from oil filter base 3. Install relief valve plunger (15) and spring (16)
(8): plug (18), O-ring seal (17), spring (16), and into oil filter base (8).
relief valve plunger (15).
4. Place O-ring seal (17) on plug (18) and install
8. Remove the stud that holds the oil filter to the oil the plug in oil filter base (8).
filter base, if necessary.
i01582272
Assembly Procedure
NOTICE
Keep all parts clean from contaminants.
g00764944
Illustration 69
Contaminants may cause rapid wear and shortened
component life. 5. Install the following items in oil filter base (8): oil
pump bypass valve (9), spring (11), and O-ring
seal (14).
1. Inspect the condition of the O-ring seals. Replace
the seals, if necessary.
6. Install cover (13) and the two bolts with washers
that hold the cover in place.
2. Install the stud that holds the oil filter to the
oil filter base. Tighten the stud to a torque of
7. Install O-ring seal (10) and valve (12) in oil filter
68 ± 7 N·m (50 ± 5 lb ft).
base (8).
i01770797
Installation Procedure
Table 19
Required Tools
Part
Tool Part Description Qty
Number
A 185-3630 Strap Wrench Assembly 1
g00764949
Illustration 70
NOTICE
9. Install the following items in oil filter base (8): Keep all parts clean from contaminants.
retainer (3), retainer spring (4), seat of the relief
valve spring (5), and spacer (7). Contaminants may cause rapid wear and shortened
component life.
10. Install bolt (6).
g00513002
Illustration 71
12. Install three O-ring seals (1) in the oil filter base
assembly.
g00512861
Illustration 72
End By:
2. Install the O-ring seals in oil filter base assembly
a. Install the engine oil filter base. Refer to (4). Position the oil filter base assembly on the
Disassembly and Assembly, “Engine Oil Filter cylinder block. Apply 9S-3263 Thread Lock
Base - Install”. Compound to bolts (6) that are marked.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
i01463799
Removal Procedure
Remove cooling system pressure cap slowly to 3. Remove elbow (1) of the engine oil cooler and
relieve pressure only when engine is stopped and the O-ring seals.
cooling system pressure cap is cool enough to
touch with your bare hand. 4. Remove two bolts (3) from the core of engine
oil cooler (4).
Do not attempt to tighten hose connections when
the coolant is hot, the hose can come off causing
burns.
NOTICE
Keep all parts clean from contaminants.
g00513711
Illustration 75
Typical example
30
Disassembly and Assembly Section
6. Remove two bolts (6) and the washers. Engine Oil Cooler - Install
7. Remove engine oil cooler (4) and the two O-ring SMCS Code: 1378-012
seals from the oil filter base.
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
g00513712
Illustration 76
Typical example
g00513712
Illustration 78
Typical example
g00513713
Illustration 77
Typical example
g00513711
Illustration 79
Typical example
31
Disassembly and Assembly Section
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the machine. Be prepared
to collect the fluid with suitable containers before
opening any compartment or disassembling any
component containing fluids.
i01000454
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
i01770805
Disassembly Procedure
Table 20
Required Tools
Part
Tool Part Description Qty
Number
5F-7344 Block-Puller 1
g00512335
A 7S-7786 Puller Leg 1 Illustration 83
5F-7345 Screw 1 1. Remove elbow (1) from the engine oil pump.
Start By: 2. Remove the two O-ring seals from the elbow of
the engine oil pump.
a. Remove the engine oil pump. Refer to
Disassembly and Assembly, “Engine Oil Pump - 3. Remove bolts (2).
Remove ”.
4. Remove cover (3) from the pump housing.
NOTICE
Keep all parts clean from contaminants.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
g00512369
Refer to Special Publication, NENG2500, “Caterpillar Illustration 84
Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar 5. Remove O-ring seal (4) and idler gear (5) from
products. the cover.
Dispose of all fluids according to local regulations and 6. Use Tooling (A) to remove gear (6) from drive
mandates. shaft (7).
NOTICE
Before removing the drive shaft from the pump hous-
ing, be sure that no burrs exist on the drive shaft. If
the drive shaft has burrs on it, the bores in the pump
housing may be scratched.
i01770816
Assembly Procedure
NOTICE
Keep all parts clean from contaminants.
NOTICE
The pump must rotate freely by hand after assembly.
End By:
i01000464
g00512304
Illustration 87
34
Disassembly and Assembly Section
NOTICE
Keep all parts clean from contaminants.
4. Install two bolts (3) that hold the elbow of oil NOTICE
pump (4) to the cylinder block. Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
5. Install two bolts (2) and the washers that hold the ing, adjusting and repair of the product. Be prepared to
tube to the elbow of the oil pump. collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
i01463822
a. Remove the alternator. Refer to Disassembly and 1. Drain the coolant from the system into a suitable
Assembly , “Alternator - Remove and Install”. container for storage or disposal.
i01770979
Disassembly Procedure
Table 21
Required Tools
Tool Part Description Qty
Number
A 5F-7344 Puller 1
g00513750 Block(1)
Illustration 89
5F-7345 Screw(1) 1
2. Remove two bolts (4) and the washers from tube
7S-7789 Bumper(1) 2
assembly (5).
B 1P-1861 Retaining 1
3. Cut plastic tie (3) from tube assembly (5). Ring Pliers
C 8B-7554 Puller 1
4. Loosen hose clamp (2) and remove hose (1). Group
(1) Part of 8B-7554 Bearing Cup Puller
5. Remove bolt (8) and the washer.
6. Remove dipstick tube (6) with the O-ring seal. Start By:
7. Remove two bolts (9) and the washers from the a. Remove the water pump. Refer to Disassembly
alternator bracket. and Assembly, “Water Pump - Remove”. The
information is in this manual.
NOTICE
Keep all parts clean from contaminants.
g00513753
Illustration 90
g00718982
Illustration 93
g00824994
Illustration 91
(3) Cover bolts
(4) Hex washer
(5) Bolt
(6) Bearing
(7) Gear
(8) Retaining ring
(9) Impeller
(10) Shaft
(11) Water seal
(12) Oil seal
(13) Water pump housing
g00718996
Illustration 94
g00718976
Illustration 92
g00719029 g00916133
Illustration 96 Illustration 99
g00719007 g00719348
Illustration 97 Illustration 100
5. Use Tooling (A) to remove gear (7). 8. Use a hydraulic press and remove shaft
assembly (10).
g00830165
Illustration 98
g00719377
Illustration 101
6. Use Tooling (B) to remove retaining ring (8).
Remove inner bearing (6). 9. Remove water seal (11).
38
Disassembly and Assembly Section
g00719396
Illustration 102
i01771127
NOTICE
Keep all parts clean from contaminants.
g00912795 g00824983
Illustration 105 Illustration 108
3. Install bearing (6) into water pump housing (13). 7. Use a hydraulic press to install impeller (9) onto
the shaft assembly. The impeller should be flush
4. Use Tooling (E) to install retaining ring (8). with the top of the shaft assembly.
g00912794 g00719552
Illustration 106 Illustration 109
g00913308
Illustration 110
Dimension “A” is 29.3 mm (1.15 inch).
g00912821
Illustration 107 8. Use a hydraulic press to install gear (7). Install
the gear to a height of 29.3 mm (1.15 inch). Use
6. Use a hydraulic press with Tooling (B) to install Tooling (C) to measure dimension “A”.
water seal (11) onto shaft assembly (10). Install
the water seal with the part number upward.
Ensure that the water seal is flush against the
pump housing. Do not lubricate the seal.
40
Disassembly and Assembly Section
g00824987 g00718976
Illustration 111 Illustration 114
9. Install bearing (6). Ensure that the bearing is 12. Install a new gasket and water pump elbow (1).
flush with the gear. Install a new gasket and elbow (2).
End By:
i01463891
Installation Procedure
g00718996
Illustration 112
NOTICE
10. Install hex washer (4) and hex socket head bolt Keep all parts clean from contaminants.
(5).
Contaminants may cause rapid wear and shortened
component life.
g00718982
Illustration 113
g00513750
Illustration 115
41
Disassembly and Assembly Section
i01771159
Removal Procedure
g00513801
Illustration 117
Typical example
g00513806
Illustration 120
Installation Procedure
Table 23
Illustration 118
g00513802 Required Tools
Typical example Part
Tool Part Description Qty
Number
5. Remove gasket (5).
A 1P-0510 Driver Group 1
NOTICE
Keep all parts clean from contaminants.
g00513803
Illustration 119
43
Disassembly and Assembly Section
g00513801
Illustration 121
Typical example
g00513806
Illustration 123
g00513803
Illustration 124
i01005442
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
g00515793
Illustration 127
The air inlet manifold has been removed for photo purposes.
6. Inspect the flywheel ring gear. Replace the ring 3. Place the flywheel in the original position on
gear, if necessary. Place the flywheel on a wood the crankshaft. Align the arrows on the flywheel
block. Use a hammer and a punch in order to and the crankshaft. Slide the flywheel over the
remove the ring gear. guide studs.
Removal Procedure
Always wear protective gloves when handling Start By:
parts that have been heated.
a. Remove the flywheel. Refer to Disassembly and
Assembly, “Flywheel - Remove”.
1. Heat the ring gear to a maximum temperature of
315 C (599 F). Position the ring gear with the
part number toward the crankshaft. Install the NOTICE
ring gear on the flywheel. Allow the ring gear to Care must be taken to ensure that fluids are contained
cool. Use a soft hammer in order to seat the ring during performance of inspection, maintenance, test-
gear against the shoulder of the flywheel. ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
g00513879
Illustration 130
g00514081 g00514082
Illustration 131 Illustration 133
g00514082 g00514081
Illustration 132 Illustration 134
1. Remove six nuts (1) and three bolts (2). 2. Clean the seal surface of the crankshaft.
Lubricate O-ring seal (4) with clean engine oil.
2. Use a screwdriver to remove crankshaft rear seal Position O-ring seal (4) on the back of crankshaft
(3). rear seal (3).
3. Remove O-ring seal (4). The O-ring seal is 3. Position the crankshaft rear seal (3) on the
located behind the crankshaft rear seal (3). crankshaft and the studs. Push crankshaft rear
seal (3) in place. This will dislodge the shipping
sleeve.
i01602316
Crankshaft Rear Seal - Install 4. Install the six nuts (1) and the washers.
Removal Procedure
Table 26
Required Tools
Part
Tool Part Description Qty
Number
A 5F-4764 Pry Bar 1
Start By:
g00521969
a. Remove the flywheel housing. Refer to Illustration 137
Disassembly and Assembly, “Flywheel Housing
- Remove and Install”. 1. Place a new gasket over dowels (3).
g00521945 g00521970
Illustration 135 Illustration 138
g00521945
Illustration 139
Removal Procedure
Start By:
g00514036
Illustration 140
g00514036 g00520761
Illustration 143 Illustration 144
3. Position flywheel housing (2) on the rear of the 1. Install Tooling (A) in the crankshaft.
cylinder block. Install twelve bolts (1) and the
washers. 2. Remove bolts (1) and crankshaft seal (2).
End By: 3. Remove bolts (3), cover (4), and the gasket.
Inspect the condition of the gasket. Replace the
a. Install the crankshaft rear seal. Refer to gasket, if necessary.
Disassembly and Assembly, “Crankshaft Rear
Seal - Install” .
i01771286
Table 27
4. Remove crankshaft gear (5) from the crankshaft.
Required Tools Remove the O-ring seal from crankshaft gear (5).
Part
Tool Number Part Description Qty 5. Remove Tooling (A).
A 8T-0514 Guide Bolt 2
6. Remove bolts (6) that fasten shaft (7) to the
B 1P-0520 Driver Group 1 flywheel housing.
Start By:
NOTICE
Keep all parts clean from contaminants.
g00520763 g00765120
Illustration 146 Illustration 149
7. Use a pry bar in order to remove shaft (7) and 10. Remove O-ring seal (15) and lip type seal (13)
gear assembly (8). from carrier assembly (11).
g00520764
Illustration 147
g00520766 g00520770
Illustration 148 Illustration 151
9. Remove bolts (10) that fasten carrier assembly 12. Remove bolts (16), cover assembly (17), and
(11) to the flywheel housing. Install two bolts thrust washer (18). Replace the O-ring seal.
(10) opposite each other at location (12). Use
these bolts as forcing screws in order to remove 13. Inspect the condition of thrust washer (18).
carrier assembly (11). Replace thrust washer (18), if necessary.
14. Inspect the condition of the dowels for thrust 18. Remove thrust washer (24) from the flywheel
washer (18) in cover assembly (17). Remove the housing.
dowels if replacement is necessary.
19. Inspect the condition of thrust washer (24).
Replace thrust washer (24), if necessary.
g00520771 i01771332
Illustration 152
15. Remove bolts (19) and thrust plate (20) from the
Rear Power Take-Off (RPTO) -
output shaft. Install
SMCS Code: 1165-012-RE
Installation Procedure
Table 28
Required Tools
Part
Tool Number Part Description Qty
A 8T-0514 Guide Bolt 2
B 1P-0520 Driver Group 1
g00907516 NOTICE
Illustration 153
Keep all parts clean from contaminants.
16. Remove hex socket head bolts (21) that fasten
gear (23) to output shaft (22). Contaminants may cause rapid wear and shortened
component life.
17. Remove output shaft (22) from gear (23).
Remove gear (23) from the flywheel housing.
g00520774
Illustration 155
g00520774
Illustration 154
53
Disassembly and Assembly Section
g00520772
Illustration 158
g00520770
g00520773 Illustration 160
Illustration 157
54
Disassembly and Assembly Section
10. Install O-ring seal (15) and lip type seal (13) in
the carrier assembly. Lubricate lip type seal (13)
lightly with the lubricant that is being sealed.
g00520764
Illustration 164
g00520767
Illustration 162
g00520765
Illustration 165
g00520768
Illustration 163
i01464063
Removal Procedure
1. Relieve the tension on the belt tensioner and
remove the drive belts.
g00520762
Illustration 166
g00514208
Illustration 168
g00520761
Illustration 167
16. Hold cover (4) and the gasket in position on the g00514209
flywheel housing and install bolts (3). Illustration 169
17. Install crankshaft seal (2) and bolts (1). 5. Separate pulley (3) and adapter (4) from vibration
damper (2).
18. Remove Tooling (A) from the crankshaft.
End By:
Removal Procedure
Start By:
g00514250
Illustration 172
g00514211
Illustration 171
1. Remove nuts (2) and the washers.
1. Place adapter (4) and pulley (3) on vibration 2. Remove crankshaft front seal (1).
damper (2). Install eight bolts (5). Tighten the
bolts to a torque of 55 ± 10 N·m (41 ± 7 lb ft).
i01464078
2. Install bolts (1) and the washers. Tighten all
bolts evenly to a torque of 240 ± 40 N·m Crankshaft Front Seal - Install
(175 ± 30 lb ft).
SMCS Code: 1160-012
3. Install the drive belt and apply the correct
tension. Installation Procedure
NOTICE
Keep all parts clean from contaminants.
End By:
g00514870
i01464100 Illustration 174
Typical example
Front Cover - Remove
1. Remove studs (1) with the nuts and the seal
SMCS Code: 1166-011 washers.
NOTICE g00514872
Illustration 175
Keep all parts clean from contaminants.
Typical example
Contaminants may cause rapid wear and shortened
component life. 5. Remove housing cover gasket (4).
58
Disassembly and Assembly Section
i01533820
Removal Procedure
g00514872
Illustration 176
Table 29
Typical example
Required Tools
2. Install housing cover gasket (4). Part
Tool Number Part Description Qty
A 6V-8214 Bolt 4
Start By:
e. Remove the camshaft position sensor. Refer to Note: Align the timing marks on the idler gear with
Disassembly and Assembly, “ Camshaft Position the marks on the crankshaft gear and the camshaft
Sensor - Remove and Install”. gear before removal.
NOTICE
Keep all parts clean from contaminants.
g00522192
NOTICE Illustration 179
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test- 2. Remove the following items from the front
ing, adjusting and repair of the product. Be prepared to housing: bolt (1), shaft (2), gear (3), and the
collect the fluid with suitable containers before open- bearing.
ing any compartment or disassembling any compo-
nent containing fluids. 3. Next, remove the following items from the front
housing: bolt (4), shaft (5), gear (6), and the
Refer to Special Publication, NENG2500, “Caterpillar bearing.
Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar Note: During installation, it is possible to install the
products. accessory drive incorrectly. Before removal, mark
accessory drive (8) for correct orientation.
Dispose of all fluids according to local regulations and
mandates. 4. Remove bolts (7) and accessory drive (8).
i01533832
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
g00523036
Illustration 181
61
Disassembly and Assembly Section
i01464328 i01667069
C-10 8YS1-Up -
1. Remove thirteen bolts (1) and the washers. C-12 2KS1-69602 2KS69603-Up
C-12 CPD1-304 CPD305-Up
2. Remove front housing (2) and the gasket.
C-12 CPN1-323 CPN324-Up
C-12 9SM1-862 9SM863-Up
Type 1
g00856344
Illustration 185
40 mm (1.57 inch) bolt length
Remanufactured Engines
g00856491
Illustration 184
204-0712 Bolt
g00838007 g00514286
Illustration 187 Illustration 188
Depth of counterbore (Z) requires engines to use the 40 mm Typical example
(1.57 inch) Bolt.
1. Apply a bead of 8T-9022 Silicone Gasket to the
Remanufactured engines require special attention lower edges (5) of the cylinder block.
in order to use the correct bolt. The counterbore
in the engine block must be measured in order
to determine the bolts that will be used. If your
engine block has a counterbore (Y) of 5 mm
(0.20 inch), refer to “Type 1”. If your engine block
has a counterbore (Z) of 15 mm (0.60 inch), refer
to “Type 2”.
Table 31
Dimension Counterbore Bolt Part
Depth Number
Y 5 mm (0.20 inch) 204-0712
Type 1
Z 15 mm 40 mm
(0.60 inch) (1.57 inch) Bolt g00514307
Illustration 189
Type 2
Typical example
Note: The face of the housing and the face of the 2. Install gasket (3). Apply a bead of 8T-9022
block must be clean prior to installation. Silicone Gasket to lower edges (4) of gasket (3).
NOTICE
Do not use fingers or towels in order to remove the
excess 8T-9022 Silicone Gasket. The use of fingers
or towels will not leave a flat sealing surface. A leak
may develop.
g00514280
Illustration 190
3.
64
Disassembly and Assembly Section
g00521981
Illustration 192
g00521983 g00522020
Illustration 193 Illustration 195
2. Use Tooling (A) to remove two bearings (2) from 1. Lower the temperature of gear and shaft (1).
gear and shaft (1).
g00521986
Illustration 194
i01771920
i01004798
Removal Procedure
g00522024 NOTICE
Illustration 197
Keep all parts clean from contaminants.
5. Install gear and shaft (1) with bearings (2) into
accessory drive housing (3). Contaminants may cause rapid wear and shortened
component life.
End By:
g00515001
Illustration 198
Typical example
Note: Spacer (5) is used on engines that are Valve Mechanism Cover Base -
equipped with a compression brake. Remove and Install
4. Remove the following items from the cylinder SMCS Code: 1120-010
head: valve cover (2), spacer (5), and seals (4).
Removal Procedure
Installation Procedure
Start By:
NOTICE
Keep all parts clean from contaminants. a. Remove the valve mechanism covers. Refer to
Disassembly and Assembly, “Valve Mechanism
Contaminants may cause rapid wear and shortened Cover - Remove and Install”.
component life.
NOTICE
1. Cut seals (4) to the correct length for the valve Keep all parts clean from contaminants.
cover and spacer. Apply 3S-6252 Sealant to
each joint surface after installation. Contaminants may cause rapid wear and shortened
component life.
2. Place the following items on the valve cover
base: seals (4), spacer (5), and valve cover (2).
NOTICE
Care must be taken to ensure that fluids are contained
3. Place clip (3) on the valve cover.
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
g00280493
Illustration 200
g00668535
Illustration 201
g00515303 g00668535
Illustration 202 Illustration 204
3. Remove isolators (7) and isolator sleeves (8). 5. Connect wiring harness (2) and the clips.
4. Remove valve cover base (5) and base gasket 6. Connect the hose to the side of the valve cover
(9). base and tighten clamp (1).
End By:
Installation Procedure
a. Install the valve mechanism covers. Refer to
NOTICE Disassembly and Assembly, “Valve Mechanism
Keep all parts clean from contaminants. Cover - Remove and Install”.
Contaminants may cause rapid wear and shortened
component life. i01464340
Removal Procedure
Start By:
NOTICE
Keep all parts clean from contaminants.
g00515303
Illustration 203
Contaminants may cause rapid wear and shortened
1. Install base gasket (9) and valve cover base (5) component life.
on the cylinder head.
Start By:
NOTICE
Care must be taken to ensure that fluids are contained a. Remove the compression brake. Refer to
during performance of inspection, maintenance, test- Disassembly and Assembly, “Compression
ing, adjusting and repair of the product. Be prepared to Brake - Remove”.
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo- NOTICE
nent containing fluids. Keep all parts clean from contaminants.
Refer to Special Publication, NENG2500, “Caterpillar Contaminants may cause rapid wear and shortened
Tools and Shop Products Guide” for tools and supplies component life.
suitable to collect and contain fluids on Caterpillar
products.
NOTICE
Dispose of all fluids according to local regulations and Care must be taken to ensure that fluids are contained
mandates. during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
g00521562
Illustration 205
i01465421
Compression Brake -
Disassemble Illustration 206 g00523471
Disassembly Procedure
Table 34
Required Tools
Part
Tool Number Part Description Qty
A 1P-1858 Retaining Ring Pliers 1
B 1P-1854 Retaining Ring Pliers 1
C 134-2837 Piston Compressor 1
g00523472
Illustration 207
70
Disassembly and Assembly Section
g00524781
Illustration 210
g00523476
Illustration 208
g00523481
Illustration 211
NOTICE
g00524780
Do not disassemble or tamper with the solenoid valve.
Illustration 209 Engine damage could result.
g00523482 g00523484
Illustration 212 Illustration 214
Typical example
10. Loosen slave piston adjustment screw (13) until
8. Remove three O-ring seals (11) from solenoid the slave piston is fully retracted.
valve (10). Discard the O-ring seals.
g00524785
Illustration 215
g00523483
Illustration 213
NOTICE
Do not diassemble or tamper with slave piston adjust-
ing screw. Engine damage could result.
g00524782 g00524784
Illustration 217 Illustration 219
Remove slave pistons carefully. The slave pistons Remove master pistons carefully. The master pis-
are under spring pressure. Remove with care to ton is under spring pressure. Remove with care to
avoid personal injury. avoid personal injury.
11. Place Tool (C) over slave piston adjustment 14. Apply downward pressure to retaining washer
screw (13). Turn the handle on Tool (C) until (19) with a punch of suitable size. Remove
spring retainer (14) is depressed approximately retaining ring (18) with Tool (B).
1.0 mm (.04 inch) in order to relieve the pressure
from retaining ring (15). 15. Slowly release the pressure from retaining
washer (19) until the spring pressure ceases.
12. Remove retaining ring (15) with Tool (A). Slowly Remove retaining washer (19), two springs (20),
back out the handle on Tool (C) until the spring and master piston (21).
pressure ceases. Remove Tool (C).
Note: Repeat Steps 14 and 15 for the remaining
13. Remove spring retainer (14), springs (16), and master piston.
slave piston (17).
i01533855
Note: Repeat Steps 9 through 13 for the remaining
slave piston. Compression Brake -
Assemble
SMCS Code: 1119-016
Assembly Procedure
Table 35
Required Tools
Part
Tool Number Part Description Qty
A 1P-1858 Retaining Ring Pliers 1
B 1P-1854 Retaining Ring Pliers 1
g00524783
Illustration 218
C 134-2837 Piston Compressor 1
73
Disassembly and Assembly Section
NOTICE
Keep all parts clean from contaminants.
g00524783
Illustration 222
g00523650
Illustration 220
g00524782
Illustration 223
g00524784
Illustration 221
g00523486
Illustration 224
74
Disassembly and Assembly Section
g00523483
Illustration 227
g00523472
Illustration 232
g00524781
Illustration 230
g00523471
Illustration 233
g00524780
Illustration 231
76
Disassembly and Assembly Section
End By: b. Adjust the slave piston lash. Refer to the Testing
and Adjusting, “Compression Brake” topic for
a. Install the compression brake. Refer to the correct procedure.
Disassembly and Assembly, “Compression
Brake - Install”. c. Install the valve mechanism covers.
i01018713 i01464346
NOTICE
Keep all parts clean from contaminants.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
g00521562
Illustration 234 nent containing fluids.
1. Position compression brake housing (4) on the Refer to Special Publication, NENG2500, “Caterpillar
two studs. Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
2. Install two nuts (1) and tighten to a torque of products.
80 ± 15 N·m (60 ± 11 lb ft).
Dispose of all fluids according to local regulations and
3. Install bolt (3) and tighten to a torque of mandates.
55 ± 10 N·m (41 ± 7 lb ft).
NOTICE
Keep all parts clean from contaminants.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
g00524203
nent containing fluids.
Illustration 235
Typical example Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and supplies
1. Put identification marks on each rocker arm in suitable to collect and contain fluids on Caterpillar
order to identify the proper location in the engine products.
for installation.
Dispose of all fluids according to local regulations and
2. Remove bolt (1) and stud (3). mandates.
g00524205
Illustration 236
i01248751
i01249012 3. Align the bolt holes of the rocker shaft with the
bolt holes in the stand. Then slide the rocker
Rocker Shaft - Assemble shaft (5) into the stand.
SMCS Code: 1102-016
i01464353
g00524205
Illustration 239
g00665676
Illustration 238
2. Install the valve rocker arm (1) and (3) with the
unit injector rocker arm (2) in the stand (4) by the Illustration 240 g00524203
order of the identification marks.
79
Disassembly and Assembly Section
i01771996
Removal Procedure
Table 36
Required Tools
Part
Tool Part Description Qty
Number
g00517348
Illustration 241
A 185-3630 Strap Wrench Assembly 1
1. Remove bolt (1). Remove clip (2).
Start By:
2. Disconnect sensors from engine wiring harness
a. Remove the base for the valve mechanism cover. (3).
Refer to Disassembly and Assembly, “Valve
Mechanism Cover Base - Remove and Install”. 3. Remove the sensors.
NOTICE
Keep all parts clean from contaminants.
g00517351
Illustration 242
g00517354
Illustration 243
Typical example
g00517359
6. Use Tooling (A) in order to remove fuel filter Illustration 246
(8). Disconnect hose (9). Plug all openings
immediately. 11. Remove head bolts (17).
7. Loosen bolt (11). Disconnect wiring harness (10). 12. Remove water outlet manifold gaskets (18) from
cylinder head (19).
g00517355
Illustration 244
g00517361
Typical example Illustration 247
8. Disconnect sensor connector (13) and clips (12). 13. Attach a suitable lifting device to cylinder
Remove clip (14) and the bolt. head (19). Remove cylinder head (19) from the
cylinder block. The weight of cylinder head (19)
is 135 kg (300 lb).
g00517356
Illustration 245
Typical example
81
Disassembly and Assembly Section
i01792874
Installation Procedure
Table 37
Required Tools
Part
Tool Number Part Description Qty
A 185-3630 Strap Wrench Assembly 1
g00810396
B 1U-5686(1) 21/32 inch Drill Bit 1 Illustration 248
Cylinder Head Gasket
C 4C-9732(1) M16x2.0-D7 Plug Tap 1
(29) Straight Edge
9U-5604 M16x2.0 32mm Heli-Coil 1
D
Insert(2)
E 8T-2799(1) Heli-Coil Installation Tool 1
F 8T-3096 Plug Tap 1
G 6V-4876 Lubricant 1
(1) Part of 4C-8367 Thread Repair Kit
(2) This is a special length.
NOTICE
Keep all parts clean from contaminants.
6. Inspect the cylinder head and the cylinder block 8. Install the correct cylinder head gasket (26) and
for flatness. Refer to Guideline for Reusable new O-ring seals (27) on the cylinder block.
Parts and Salvage Operations, SEBF8162, Inspect the condition of the remaining gaskets.
“Procedure to Measure and Salvage Cylinder Replace the gaskets, if necessary.
Head Assemblies and Related Components”.
82
Disassembly and Assembly Section
g00525534
Illustration 251
g00517501
Illustration 252
Note: Engines that are equipped with a compression 13. Tighten the cylinder head bolts according to the
brake will have three head bolt studs. Install the following procedure:
head bolt studs in positions (2), (8), and (10).
Tighten the head bolt studs in sequence with the
cylinder head bolts.
83
Disassembly and Assembly Section
g00676967
Illustration 255
g00525468
Illustration 253
20. Install fuel filter (10) with Tool (A). Follow the
instructions on the fuel filter.
84
Disassembly and Assembly Section
Removal Procedure
Start By:
NOTICE
Keep all parts clean from contaminants.
24. Install tube assembly (5) with the O-ring seals, NOTICE
two bolts (6), and the washers. Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
25. Install tube assembly (3) with the O-ring seal, ing, adjusting and repair of the product. Be prepared to
two bolts (4), and the washers. Install the clip collect the fluid with suitable containers before open-
and the bolt to tube assembly (5) and (3). ing any compartment or disassembling any compo-
nent containing fluids.
g00524436
Illustration 258
a. Install the rocker shaft and the pushrods. Refer 1. Remove bolts (1) and lifter assembly (2). The
to Disassembly and Assembly, “Rocker Shaft lifter assembly can be removed in two sections.
and Pushrods - Install”.
g00515668 g00515670
Illustration 260 Illustration 262
Typical example
2. Remove the following items from the right end of
lifter shaft (5): bracket assembly (6), valve lifters 1. Install the spring pin and dowel (10) in bracket
(8), and unit injector lifter (9). (7).
3. Remove the following items from the middle of
lifter shaft (5): valve lifters (8) and unit injector
lifter (9).
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
NOTICE
Keep all parts clean from contaminants.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
g00515645
nent containing fluids.
Illustration 264
Refer to Special Publication, NENG2500, “Caterpillar
Note: Immerse the entire lifter assembly in clean Tools and Shop Products Guide” for tools and supplies
engine oil prior to installation on the engine. suitable to collect and contain fluids on Caterpillar
products.
6. Place the lifter assembly (2) on the engine and
install bolts (1). Tighten the bolts to a torque of Dispose of all fluids according to local regulations and
30 ± 3 N·m (22 ± 2 lb ft). mandates.
End By:
1. Turn the crankshaft to top center compression
a. Install the cylinder head. Refer to Disassembly stroke for the No. 1 piston. Install the timing
and Assembly, “Cylinder Head - Remove”. bolt in the flywheel. This is for timing during
installation.
Removal Procedure
Table 38
Required Tools
Part
Tool Number Part Description Qty
A 131-1525 Camshaft Pilot 1
Start By:
a. Remove the rocker shaft and the pushrods. Refer Illustration 265 g00529917
to Disassembly and Assembly, “Rocker Shaft
and Pushrod - Remove”. Note: It is not necessary to remove the cylinder
head for removal of the camshaft.
b. Remove the front cover. Refer to Disassembly
and Assembly, “Front Cover - Remove”. 3. Wire the valve lifters away from the camshaft.
See Illustration 265.
c. Remove the camshaft position sensor. Refer to
Disassembly and Assembly, “Camshaft Position
Sensor - Remove and Install”.
87
Disassembly and Assembly Section
g00516004 g00516006
Illustration 266 Illustration 268
Typical example
4. Remove thrust pin (1).
1. Install Tooling (A).
NOTICE
When installing the camshaft, make sure the num-
Illustration 267 g00765230 ber one cylinder is at top center of the compression
stroke with the timing bolt installed in the flywheel. The
5. Install Tooling (A) into camshaft (2). camshaft timing is very important. The timing mark
on the camshaft drive gear must line up with the tim-
Note: Lubricate Tooling (A) for easier removal of the ing mark on the idler gear. Refer to the Specifications
camshaft. Lubrication also prevents damaging the Manual for more information.
camshaft lobes and the camshaft bearings.
i01772108
Camshaft - Install
SMCS Code: 1210-012
Installation Procedure
Table 39
Required Tools
Part
Tool Number Part Description Qty
A 131-1525 Camshaft Pilot 1
g00813917
Illustration 269
88
Disassembly and Assembly Section
g00522082
Illustration 271
NOTICE
g00813405
Illustration 270 Do not allow the camshaft to fall to the floor when
(1) Thrust Pin pressing it from the drive gear. Also make sure that
(2) Camshaft the camshaft lobes do not catch on the press plates.
i01465422
End By:
NOTICE
a. Install the camshaft. Refer to Disassembly and Care must be taken to ensure that fluids are contained
Assembly, “Camshaft - Install”. during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
i01533953
ing any compartment or disassembling any compo-
Camshaft Bearings - Remove nent containing fluids.
Start By:
Note: All of the tools that are listed above are used
with the 8S-2241 Camshaft Bearing Tool Group.
NOTICE
Keep all parts clean from contaminants.
i01533955
NOTICE
Camshaft Bearings - Install Location of the camshaft bearing lubrication holes is
critical. Position the clinch butt joint up for all seven
SMCS Code: 1211-012
camshaft bearings. The No. 1 camshaft bearing oil
hole is located 115 degrees counter clockwise from
Installation Procedure top center to align with the oil supply passage in the
block. Camshaft bearings No. 2 through No. 7 are in-
Table 41 stalled with the oil hole 45 degrees clockwise from
Required Tools top center. All are viewed from the front of the en-
gine. Camshaft bearings 1,2,3,4,5, and 6 are the same
Part width. Camshaft bearing No. 7 has a smaller width.
Tool Part Description Qty
Number Refer to the Specifications Manual for more informa-
129-6671 Reaction Sleeve 1 tion.
129-6672 Puller Plate 1
End By:
129-6673 Bearing Pilot 1
A
129-6674 Backup Plate 1 a. Install the camshaft. Refer to Disassembly and
Assembly, “Camshaft - Install”.
6F-7032 Bolt 1
1P-5542 Taper Lock Stud 1 b. Install the lifter group. Refer to Disassembly and
Assembly, “Lifter Group - Remove and Install”.
Note: All of the tools that are listed above are used
with the 8S-2241 Camshaft Bearing Tool Group. i01183159
NOTICE
Keep all parts clean from contaminants.
5. Remove pipe plug (3) and drain plug (4) with the
NOTICE O-ring seal, if necessary.
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test- Installation Procedure
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
NOTICE
ing any compartment or disassembling any compo-
Keep all parts clean from contaminants.
nent containing fluids.
Contaminants may cause rapid wear and shortened
Refer to Special Publication, NENG2500, “Caterpillar
component life.
Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products. 1. Inspect the condition of the gasket. Replace the
gasket, if necessary.
Dispose of all fluids according to local regulations and
mandates. 2. Clean the mating surface of the engine oil pan
and the cylinder block.
1. Drain the engine oil into a suitable container for
storage or disposal. Note: Apply 8T-9022 Silicone Gasket to the right
and the left edges of the cylinder block prior to
installation.
g00516290
Illustration 276
Typical example Illustration 278 g00516292
Typical example
2. Remove six bolts (2) and the washers. Remove
sound suppression cover (1), if equipped.
3. Place the gasket and engine oil pan (6) on the
cylinder block.
g00516292
Illustration 277
Typical example
g00516290
Illustration 280
Typical example
a. Clean the bolt hole and dry the bolt hole. i01772112
b. Clean the oil pan bolt and dry the oil pan bolt. Cylinder Liner - Remove
c. Apply 4C-4030 Thread Lock Compound or SMCS Code: 1216-011
9S-3263 Thread Lock Compound to the
threads of the bolt. Removal Procedure
d. Install the oil pan bolt and tighten the bolt to a Table 42
torque of 55 ± 10 N·m (40 ± 7 lb ft).
Required Tools
5. Wipe off excess 8T-9022 Silicone Gasket from Tool Part Number Part Description Qty
all gasket joints. Use a flat, straight tool in order
1U-9593(1) Cylinder Pack Puller 1
to remove the sealant.
129-6675(2) Cylinder Pack Puller 1
6. Apply 9S-3263 Thread Lock Compound to pipe A
1U-9897 Bridge Group 1
plug (3). Install pipe plug (3). Tighten the plug to
a torque of 80 ± 11 N·m (60 ± 8 lb ft). 1U-6319 Socket 1
(1) The 1U-9593 Cylinder Pack Puller is for use on C-10 Engines.
7. Install drain plug (4) and the O-ring seal. Tighten (2) The 129-6675 Cylinder Pack Puller is for use on C-12 Engines.
the plug to a torque of 70 ± 15 N·m (50 ± 11 lb ft).
Start By:
NOTICE NOTICE
Keep all parts clean from contaminants. When removing the cylinder liner, watch the rod, and
prevent it from catching on the bore in the cylinder
Contaminants may cause rapid wear and shortened block as it comes out.
component life.
3. Install Tooling (A) and remove cylinder liner (5),
NOTICE piston assembly and connecting rod.
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test- 4. Remove Tooling (A) from the cylinder liner.
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
g00516413
Illustration 283
i01772116
g00474523
Illustration 281 Installation Procedure
1. Remove connecting rod cap bolts (2) from each Table 43
connecting rod. Remove connecting rod caps Required Tools
(4).
Part
Tool Part Description 1
2. Tap connecting rod (3) away from the crankshaft Number
with a soft hammer. Remove the top half of Cylinder Liner Installation
connecting rod bearing (1). A 2P-8260 1
Group
NOTICE
Keep all parts clean from contaminants.
g00516411
Illustration 282
94
Disassembly and Assembly Section
NOTICE
Keep all parts clean from contaminants.
g00474523
Illustration 285
95
Disassembly and Assembly Section
Removal Procedure
Start By:
NOTICE
g00516600
Keep all parts clean from contaminants.
Illustration 286
Contaminants may cause rapid wear and shortened
1. Remove bolt (1) and piston cooling jet (2) from component life.
each cylinder.
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
g00516602
Illustration 288
g00516600
Illustration 287
96
Disassembly and Assembly Section
g00516756
Illustration 290
i01772139
NOTICE
Keep all parts clean from contaminants.
NOTICE
Do not use a hard surfaced tool to install plug. Do not
strike or impact plug during installation. If the plug is
dropped, replace the plug with another new plug.
g00765257 g00516756
Illustration 294 Illustration 296
End By:
g00516777
Illustration 295 a. Install the pistons and the connecting rods.
Refer to Disassembly and Assembly, “Piston and
1. Place piston crown (2) in piston skirt (4). Place Connecting Rods - Install”.
the piston assembly on connecting rod (5). Put
clean engine oil on piston pin (7) and install the
pin. Install new plug (3). i01734968
2. Check the clearance between the ends of the Pistons and Connecting Rods
piston rings. See the Specifications Manual, - Install
“Pistons and Rings” topic.
SMCS Code: 1225-012
Note: The oil ring must be installed over the spring
with the end gap 180 degrees from the oil ring
spring joint. Installation Procedure
Table 46
3. Install the oil control piston ring. The ends of the
spring should be rotated 180 degrees from the Required Tools
ring end gap. The white colored portion of the Tool Part Number Part Description Qty
spring must be visible at the ring end gap.
161-4163(1)
Piston Ring
A or 1
Compressor
161-4164(2)
(1) Use with C-10 Engines
(2) Use with C-12 Engines
99
Disassembly and Assembly Section
NOTICE
Keep all parts clean from contaminants.
g00516604
Illustration 298
9. Install connecting rod cap bolts (2). Tighten the 1. Inspect the connecting rod and connecting
bolts to a torque of 130 ± 7 N·m (95 ± 5 lb ft). rod cap (2) for the proper identification mark.
The connecting rod and connecting rod cap
10. Place an index mark on each bolt head. Tighten (2) should have an etched number on the side
each bolt for an additional 60 ± 5 degrees (1/6 that is toward the right side of the engine. The
turn). number should match the cylinder number. The
bearing retainer notch should also be on the right
11. Repeat Steps 1 through 10 for the remaining side. Mark the connecting rod and connecting
pistons and connecting rods. rod cap (2), if necessary.
12. Install piston cooling jets (1) and the bolts. 2. Remove connecting rod cap bolts (1) and
Tighten the bolts to a torque of 35 ± 3 N·m connecting rod cap (2).
(26 ± 2 lb ft).
3. Remove the lower half of the connecting rod
End By: bearing from connecting rod cap (2).
i01464812
NOTICE i01735295
Keep all parts clean from contaminants.
Connecting Rod Bearings -
Contaminants may cause rapid wear and shortened Install
component life.
SMCS Code: 1219-012
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
g00522734
Illustration 300
101
Disassembly and Assembly Section
End By:
i01772186
3. Position connecting rod (3) and connecting rod A 2P-5518 Bearing Tool 1
bearing (4) on the crankshaft.
Start By:
NOTICE
Keep all parts clean from contaminants.
g00522734
Illustration 303
8. Place an index mark on each bolt head. Tighten 2. Remove the lower half of the crankshaft main
each bolt for an additional 60 ± 5 degrees (1/6 bearing from crankshaft main bearing cap (2).
turn).
102
Disassembly and Assembly Section
i01772200
Installation Procedure
NOTICE
If the crankshaft is turned in the wrong direction, the Table 48
tab of the crankshaft main bearing will be pushed be- Required Tools
tween the crankshaft and the cylinder block. this can
cause damage to either or both the crankshaft and the Part
Tool Part Description Qty
cylinder block. Number
A 2P-5518 Bearing Tool 1
B 8T-5096 Dial Indicator Group 1
NOTICE
Keep all parts clean from contaminants.
NOTICE
Ensure that the crankshaft main bearings are installed
in the correct locations. Two different part numbers are
used in quantities of three and four. The part number
Illustration 306
g00516919 having the quantity of four is to be installed on crank-
shaft main bearings 2, 3, 5, and 6. The part number
3. Use the following steps in order to remove the having the quantity of three is to be installed on crank-
upper half of crankshaft main bearings (3): shaft bearing 1, 4, and 7. The thrust plate is to be in-
stalled on the center crankshaft main bearing only.
a. Turn the crankshaft until Tooling (A) can be
installed in the crankshaft journal. Install
Tooling (A).
NOTICE
Crankshaft main bearing caps should be installed with
the part number toward the right side of the engine.
Crankshaft main bearing caps are to be identified by
stamped numbers 1 through 7 located on the bottom
surface. The thrust plate is used on the number 6
crankshaft main bearing only.
g00516919
Illustration 308
g00517003
Illustration 310
1. Use Tooling (A) and install the new upper halves
of crankshaft main bearings (3) in the cylinder 5. Check the end play of the crankshaft with Tool
block. This half of the bearing has an oil hole. Do (B). The end play must be 0.10 mm (0.004 inch)
not put oil on the back of the crankshaft main to 0.50 mm (0.020 inch).
bearing.
Note: The crankshaft end play is controlled by
crankshaft thrust bearings (4). Thrust bearings (4)
are located at the center of the crankshaft.
End By:
g00516918
Illustration 309
104
Disassembly and Assembly Section
i01465195
Crankshaft - Remove
SMCS Code: 1202-011
Removal Procedure
Start By:
NOTICE i01465227
Keep all parts clean from contaminants.
Crankshaft - Install
Contaminants may cause rapid wear and shortened
SMCS Code: 1202-012
component life.
Installation Procedure
Table 49
Required Tools
Part
Tool Part Description Qty
Number
A 8T-5096 Dial Indicator Group 1
NOTICE
Keep all parts clean from contaminants.
Note: Crankshaft main bearing caps (2) are marked 1. Place the upper halves of the crankshaft main
with the numbers 1 through 7. Crankshaft main bearings in the cylinder block. Place the lower
bearing caps (2) that are not marked should be halves of the crankshaft main bearings in
marked with the corresponding cylinder number on crankshaft main bearing caps.
the side that is toward the right side of the engine.
105
Disassembly and Assembly Section
g00517116
Illustration 313
2. Fasten suitable lifting device (4) to the crankshaft Illustration 316 g00517182
and place the crankshaft in the cylinder block.
6. Check the end play of the crankshaft with Tool
(A). The end play must be 0.10 mm (.004 inch)
to 0.50 mm (.020 inch).
End By:
i01772213
Removal Procedure
Table 50
Required Tools
g00517115
Illustration 315
Part
Tool Part Description Qty
Number
4. Install crankshaft main bearing caps (2) with
the part numbers toward the right hand side of A 1U-6400 Three Jaw Puller 1
the cylinder block. Ensure that crankshaft main
bearing caps (2) have numbers 1 through 7. The Start By:
numbers should start at the front of the engine.
Place clean engine oil or Molylube on the bolt a. Remove the crankshaft. Refer to Disassembly
threads and the washers. Install bolts (1). Tighten and Assembly, “Crankshaft - Remove”.
the bolts to a torque of 95 ± 5 N·m (70 ± 4 lb ft).
106
Disassembly and Assembly Section
g00912338
Illustration 317
2. Remove drive pin (3). 4. Use Tooling (A) to seat crankshaft gear (2)
against shoulder (5) of crankshaft (1).
Installation Procedure
5. Use Tooling (B) to ensure that crankshaft gear (2)
Table 51 is seated against shoulder (5) on crankshaft (1).
Required Tools
Note: Check the crankshaft gear in three places
Tool
Part
Part Description Qty
with Tooling (B).
Number
A 6V-2098 Press Sleeve 1 End By:
g00909842
Illustration 318
NOTICE
Keep all parts clean from contaminants.
i01014165
Removal Procedure
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the machine. Be prepared
to collect the fluid with suitable containers before
opening any compartment or disassembling any
component containing fluids.
Removal Procedure
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the machine. Be prepared
to collect the fluid with suitable containers before
opening any compartment or disassembling any g00518479
component containing fluids. Illustration 324
Refer to Special Publication, NENG2500, “Caterpillar 1. Install engine oil pressure sensor (3).
Tools and Shop Products Guide”, for tools and sup-
plies suitable to collect and contain fluids in Caterpillar 2. Connect engine oil pressure sensor connector
machines. (1) and install new tie wrap (2).
Removal Procedure
g00518479
Illustration 323
g00518484 g00518485
Illustration 326 Illustration 328
4. Remove O-ring seal (5) from speed/timing sensor Note: Ensure that the top of a gear tooth is visible
(4). through the speed/timing sensor opening in the front
housing prior to installation. See Illustration 328.
5. Extend slip head (6) for the installation procedure.
Installation Procedure
1. Inspect the condition of the O-ring seal. Replace
the seal, if necessary.
NOTICE
The No. 1 piston must be at either top center of
the compression stroke or top center of the exhaust
stroke. After sensor installation the electronic timing
must be recalibrated.
g00518484
Illustration 327
i01582984
Removal Procedure
g00519256
Illustration 332
g00519256
Illustration 331
g00519259
2. Remove bolt (4) and the washer. Illustration 333
Installation Procedure
1. Inspect the condition of the belt tightener and
the drive belt. Replace the tightener and the belt,
if necessary.
112
Disassembly and Assembly Section
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Dispose of all fluids according to local regulations and Contaminants may cause rapid wear and shortened
mandates. component life.
g00522333 g00522336
Illustration 334 Illustration 336
1. Disconnect hose (2) and hose (4) from the 1. Position ECM (10) on the cylinder block.
Engine Control Module ECM.
2. Install the following items: four spacers, eight
2. Plug all openings immediately. rubber mounts (11), four washers (9), strap (7),
and four bolts (8).
3. Loosen allen head screw (3) until engine wiring
harness (1) can be disconnected.
g00522333 g00519357
Illustration 337 Illustration 338
Typical example
3. Connect engine wiring harness (1) and tighten
allen head screw (3) to the following torque 3. Remove bolt (1) and the washer.
2.25 ± 0.25 N·m (20 ± 2 lb in).
4. Remove nut (2) with the washer and bolt (3) from
4. Connect machine wiring harness (6) and tighten mounting bracket (4).
allen head screw (5).
5. Remove the alternator.
5. Connect hose (2) and hose (4) to ECM (10).
i01591987
Removal Procedure
First, disconnect the negative battery cable. Then, 1. Place the alternator on mounting bracket (4).
disconnect the positive battery cable. Install bolt (3) with the washer and nut (2). Hand
tighten nut (2).
A positive power lead can cause sparks if the bat-
tery is not disconnected. Sparks can possibly re- 2. Install bolt (1) and the washer. Do not tighten.
sult in battery explosion or fire.
3. Install the drive belt on the drive pulley of the
1. Remove the drive belt from the drive pulley on alternator.
the alternator.
4. Adjust the tension on the drive belt. Refer to
2. Place an index mark on all of the electrical wires the Operation and Maintenance Manual for the
that are connected to the alternator. Disconnect correct adjusting procedure.
the electrical wires from the alternator.
5. Tighten bolt (1).
i01748192
Removal Procedure
A positive power lead can cause sparks if the bat- 2. Install the gasket on the electric starting motor
tery is not disconnected. Sparks can possibly re- (2).
sult in battery explosion or fire.
3. Fasten a suitable lifting device to the electric
starting motor.
i01024767
1. Inspect the condition of the gasket. Replace the 1. Remove two bolts (1) with the nuts and the
gasket, if necessary. washers.
NOTICE
Keep all parts clean from contaminants.
b. Install two bolts (2) and the washers. Finger Refer to Special Publication, NENG2500, “Caterpillar
tighten the bolts. Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
NOTICE products.
Ensure that there is no gap between the air condition-
er compressor support bracket and the engine front Dispose of all fluids according to local regulations and
housing. Ensure that there is no gap between the air mandates.
conditioner support bracket and the cylinder head.
Reposition the air conditioner compressor support 1. Remove the air pressure from the air tank and
bracket in order to eliminate the gap. drain the coolant from the cooling system.
Installation Procedure
Table 54
Required Tools
Tool Part Part Description Qty
Number
A 138-7573 Link Bracket 1
NOTICE
Keep all parts clean from contaminants.
2. Remove bolt (6). Disconnect fittings (3) and 1. Inspect the condition of the gasket. Replace the
remove tube assembly (5). gasket, if necessary.
g00511528
Illustration 346
7. Remove bolts (7). 5. Install bolts (8). Tighten bolts (8) to a torque of
55 ± 10 N·m (41 ± 7 lb ft). Remove Tooling (A).
8. Use a suitable lifting device. Apply tension to the
lifting device and remove bolts (8). Remove air 6. Connect hose assembly (9) to the air compressor.
compressor (4) and the gasket from the engine.
117
Disassembly and Assembly Section
g00511527 g00524786
Illustration 347 Illustration 348
Typical example
7. Install tube assembly (5) and connect fittings (3).
1. Mount air compressor (1) in a bench vise.
8. Install bolt (6).
2. Install Tooling (A) on air compressor (1), as
9. Connect hose assembly (2). shown.
10. Connect hose assembly (1). 3. Remove nut (2).
11. Fill the cooling system with coolant to the correct 4. Remove Tooling (A) and air compressor drive
level. Refer to the Operation and Maintenance gear (3).
Manual for the correct filling procedure.
i01768768
i01772534
Air Compressor Drive Gear -
Air Compressor Drive Gear - Install
Remove
SMCS Code: 1803-012-GE
SMCS Code: 1803-011-GE
Installation Procedure
Removal Procedure
Table 56
Table 55
Required Tools
Required Tools
Part
Part Tool Number Part Description Qty
Tool Number Part Description Qty
Holding Fixture (Air
Holding Fixture (Air A 132-5451 1
A 132-5451 1 Compressor Drive Gear)
Compressor Drive Gear)
NOTICE
Start By: Keep all parts clean from contaminants.
a. Remove the air compressor. Refer to Disassembly Contaminants may cause rapid wear and shortened
and Assembly, “Air Compressor - Remove and component life.
Install”.
NOTICE
Keep all parts clean from contaminants.
g00524786
Illustration 349
Typical example
End By:
Index
A Coolant Temperature Sensor - Remove and
Install ................................................................. 108
Accessory Drive - Assemble.................................. 65 Installation Procedure ...................................... 108
Assembly Procedure.......................................... 65 Removal Procedure ......................................... 108
Accessory Drive - Disassemble............................. 64 Crankshaft - Install............................................... 104
Disassembly Procedure ..................................... 64 Installation Procedure ...................................... 104
Accessory Drive - Install........................................ 66 Crankshaft - Remove........................................... 104
Installation Procedure ........................................ 66 Removal Procedure ......................................... 104
Accessory Drive - Remove .................................... 64 Crankshaft Front Seal - Install ............................... 56
Removal Procedure ........................................... 64 Installation Procedure ........................................ 56
Air Compressor - Remove and Install.................. 115 Crankshaft Front Seal - Remove ........................... 56
Installation Procedure ...................................... 116 Removal Procedure ........................................... 56
Removal Procedure ......................................... 115 Crankshaft Gear - Remove and Install ................ 105
Air Compressor Drive Gear - Install..................... 117 Installation Procedure ...................................... 106
Installation Procedure ...................................... 117 Removal Procedure ......................................... 105
Air Compressor Drive Gear - Remove................. 117 Crankshaft Main Bearings - Install....................... 102
Removal Procedure ......................................... 117 Installation Procedure ...................................... 102
Air Conditioner Support Bracket - Remove and Crankshaft Main Bearings - Remove................... 101
Install ................................................................. 114 Removal Procedure ......................................... 101
Installation Procedure ...................................... 115 Crankshaft Rear Seal - Install................................ 47
Removal Procedure ......................................... 114 Installation Procedure ........................................ 47
Alternator - Remove and Install ........................... 113 Crankshaft Rear Seal - Remove............................ 46
Installation Procedure ...................................... 113 Removal Procedure ........................................... 46
Removal Procedure ......................................... 113 Crankshaft Rear Seal Carrier - Remove and
Install ................................................................... 48
Installation Procedure ........................................ 48
B Removal Procedure ........................................... 48
Cylinder Head - Install ........................................... 81
Bearing Clearance - Check ................................. 107 Installation Procedure ........................................ 81
Measurement Procedure ................................. 107 Cylinder Head - Remove ....................................... 79
Belt Tensioner - Remove and Install .................... 111 Removal Procedure ........................................... 79
Installation Procedure ...................................... 111 Cylinder Liner - Install............................................ 93
Removal Procedure ......................................... 111 Installation Procedure ........................................ 93
Cylinder Liner - Remove ........................................ 92
Removal Procedure ........................................... 92
C
Camshaft - Install................................................... 87 D
Installation Procedure ........................................ 87
Camshaft - Remove............................................... 86 Disassembly and Assembly Section........................ 4
Removal Procedure ........................................... 86
Camshaft Bearings - Install ................................... 90
Installation Procedure ........................................ 90 E
Camshaft Bearings - Remove ............................... 89
Removal Procedure ........................................... 89 Electric Starting Motor - Remove and Install ....... 114
Camshaft Gear - Remove and Install .................... 88 Installation Procedure ...................................... 114
Installation Procedure ........................................ 88 Removal Procedure ......................................... 114
Removal Procedure ........................................... 88 Electronic Unit Injector - Install .............................. 10
Compression Brake - Assemble ............................ 72 Installation Procedure ........................................ 10
Assembly Procedure.......................................... 72 Electronic Unit Injector - Remove ............................ 9
Compression Brake - Disassemble ....................... 69 Removal Procedure ............................................. 9
Disassembly Procedure ..................................... 69 Electronic Unit Injector Sleeve - Install .................. 12
Compression Brake - Install .................................. 76 Installation Procedure ........................................ 12
Installation Procedure ........................................ 76 Electronic Unit Injector Sleeve - Remove .............. 12
Compression Brake - Remove............................... 68 Removal Procedure ........................................... 12
Removal Procedure ........................................... 68 Engine Centrifugal Oil Filter - Remove and Install.. 22
Connecting Rod Bearings - Install ....................... 100 Installation Procedure ........................................ 24
Installation Procedure ...................................... 100 Removal Procedure ........................................... 22
Connecting Rod Bearings - Remove ................... 100
Removal Procedure ......................................... 100
120
Index Section
Engine Control Module - Remove and Install ...... 112 Fuel Transfer Pump - Remove ................................. 7
Installation Procedure ...................................... 112 Removal Procedure ............................................. 7
Removal Procedure ......................................... 112
Engine Oil Cooler - Install...................................... 30
Installation Procedure ........................................ 30 G
Engine Oil Cooler - Remove .................................. 29
Removal Procedure ........................................... 29 Gear Group (Front) - Install ................................... 59
Engine Oil Filter Base - Assemble......................... 27 Installation Procedure ........................................ 59
Assembly Procedure.......................................... 27 Gear Group (Front) - Remove ............................... 58
Engine Oil Filter Base - Disassemble .................... 26 Removal Procedure ........................................... 58
Disassembly Procedure ..................................... 26
Engine Oil Filter Base - Install ............................... 28
Installation Procedure ........................................ 28 H
Engine Oil Filter Base - Remove ........................... 25
Removal Procedure ........................................... 25 Housing (Front) - Install ......................................... 61
Engine Oil Pan - Remove and Install ..................... 90 Installation Procedure ........................................ 61
Installation Procedure ........................................ 91 Housing (Front) - Remove ..................................... 61
Removal Procedure ........................................... 90 Removal Procedure ........................................... 61
Engine Oil Pressure Sensor - Remove and
Install ................................................................. 109
Installation Procedure ...................................... 109 I
Removal Procedure ......................................... 109
Engine Oil Pump - Assemble................................. 33 Important Safety Information ................................... 2
Assembly Procedure.......................................... 33 Inlet and Exhaust Valve Guides - Remove and
Engine Oil Pump - Disassemble............................ 32 Install ................................................................... 20
Disassembly Procedure ..................................... 32 Installation Procedure ........................................ 20
Engine Oil Pump - Install ....................................... 33 Removal Procedure ........................................... 20
Installation Procedure ........................................ 33 Inlet and Exhaust Valve Seat Inserts - Remove and
Engine Oil Pump - Remove ................................... 31 Install ................................................................... 21
Removal Procedure ........................................... 31 Installation Procedure ........................................ 21
Exhaust Manifold - Remove and Install ................. 15 Removal Procedure ........................................... 21
Installation Procedure ........................................ 15 Inlet and Exhaust Valve Springs - Remove and
Removal Procedure ........................................... 15 Install ................................................................... 16
Installation Procedure ........................................ 18
Removal Procedure ........................................... 16
F Inlet and Exhaust Valves - Remove and Install ..... 19
Installation Procedure ........................................ 19
Flywheel - Install.................................................... 46 Removal Procedure ........................................... 19
Installation Procedure ........................................ 46 Inlet Manifold - Install............................................. 16
Flywheel - Remove................................................ 45 Installation Procedure ........................................ 16
Removal Procedure ........................................... 45 Inlet Manifold - Remove......................................... 15
Flywheel Housing - Remove and Install ................ 49 Removal Procedure ........................................... 15
Installation Procedure ........................................ 49
Removal Procedure ........................................... 49
Front Cover - Install ............................................... 58 L
Installation Procedure ........................................ 58
Front Cover - Remove ........................................... 57 Lifter Group - Remove and Install.......................... 84
Removal Procedure ........................................... 57 Installation Procedure ........................................ 85
Fuel Filter Base - Remove and Install ..................... 5 Removal Procedure ........................................... 84
Installation Procedure .......................................... 6
Removal Procedure ............................................. 5
Fuel Manifold - Install .............................................. 8 P
Installation Procedure .......................................... 8
Fuel Manifold - Remove........................................... 7 Piston Cooling Jets - Remove and Install .............. 94
Removal Procedure ............................................. 7 Installation Procedure ........................................ 95
Fuel Priming Pump - Remove and Install ................ 4 Removal Procedure ........................................... 94
Installation Procedure .......................................... 5 Pistons and Connecting Rods - Assemble ............ 97
Removal Procedure ............................................. 4 Assembly Procedure.......................................... 97
Fuel Transfer Pump - Install..................................... 7 Pistons and Connecting Rods - Disassemble ....... 96
Installation Procedure .......................................... 7 Disassembly Procedure ..................................... 96
121
Index Section
Table of Contents..................................................... 3
Turbocharger - Install............................................. 14
Installation Procedure ........................................ 14
Turbocharger - Remove ......................................... 13
Removal Procedure ........................................... 13