Professional Documents
Culture Documents
March 2006
Disassembly and
Assembly
3500B High Displacement Engines for
Caterpillar Built Machines
8WM1-Up (Engine)
i01658146
RENR9717-02
Table of Contents
Disassembly and Assembly Section
Air Starting Motor - Remove ................................... 5
Air Starting Motor - Disassemble ........................... 6
Air Starting Motor - Assemble ............................... 11
Air Starting Motor - Install ..................................... 17
Electric Starting Motor - Remove and Install ....... 18
Alternator - Remove and Install ........................... 19
Electronic Control Module (Engine) - Remove and
Install ................................................................... 20
Fuel Transfer Pump - Remove .............................. 21
Fuel Transfer Pump - Disassemble ..................... 21
Fuel Transfer Pump - Assemble .......................... 23
Fuel Transfer Pump - Install .................................. 25
Turbocharger - Remove ........................................ 25
Turbocharger - Disassemble ................................ 27
Turbocharger - Assemble .................................... 28
Turbocharger - Install ............................................ 29
Aftercooler - Remove and Install ......................... 30
Air Inlet Manifold - Remove and Install ................ 34
Exhaust Manifold - Remove and Install ............... 35
Water Temperature Regulators - Remove ............ 37
Water Temperature Regulators - Install ................ 38
Water Pump - Remove ......................................... 39
Water Pump - Disassemble ................................. 40
Water Pump - Assemble ...................................... 42
Water Pump - Install ............................................. 44
Auxiliary Water Pump - Remove .......................... 45
Auxiliary Water Pump - Disassemble ................... 46
Auxiliary Water Pump - Assemble ....................... 47
Auxiliary Water Pump - Install .............................. 49
Engine Oil Cooler - Remove ................................. 50
Engine Oil Cooler - Install ..................................... 52
Engine Oil Cooler Bypass Valve - Remove and Install
............................................................................. 53
Transmission Oil Cooler - Remove and Install ..... 55
Engine Oil Pump - Remove .................................. 56
Engine Oil Pump - Disassemble ........................... 58
Engine Oil Pump - Assemble ................................ 59
Engine Oil Pump - Install ...................................... 61
Engine Oil Filter Base - Remove .......................... 62
Engine Oil Filter Base - Disassemble ................... 63
Engine Oil Filter Base - Assemble ........................ 64
Engine Oil Filter Base - Install .............................. 65
Engine Oil and Water Pump Drive - Remove ....... 66
Engine Oil and Water Pump Drive - Disassemble .. 67
Engine Oil and Water Pump Drive - Assemble ..... 68
Engine Oil and Water Pump Drive - Install ........... 69
Engine Oil Pan - Remove .................................... 70
Engine Oil Pan - Disassemble .............................. 71
Engine Oil Pan - Assemble ................................... 72
Engine Oil Pan - Install ........................................ 73
Engine Oil Scavenge Pump - Remove ................. 74
Engine Oil Scavenge Pump - Disassemble .......... 75
Engine Oil Scavenge Pump - Assemble ............... 76
Engine Oil Scavenge Pump - Install ..................... 78
Valve Cover - Remove and Install ........................ 79
Rocker Shaft and Push Rods - Remove .............. 80
Rocker Shaft - Disassemble ................................ 80
3
Table of Contents
4
Table of Contents
Index Section
Index ................................................................... 173
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5
Disassembly and Assembly Section
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Illustration 2
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Illustration 3
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6
Disassembly and Assembly Section
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Illustration 4
Illustration 5
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i02493499
Disassembly Procedure
Illustration 6
Table 1
Required Tools
Tool
Part Number
1P-1854
1P-1857
Part Description
Qty
Plate
51.0 by 102.0 by 6.0 mm
(2.00 by 4.00 by 0.25
inches)
g00925012
Start By:
a. Remove the air starting motor gp. Refer to
Disassembly and Assembly, Air Starting Motor Remove.
NOTICE
Keep all parts clean from contaminants.
Illustration 7
g00925015
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7
Disassembly and Assembly Section
Illustration 10
Illustration 8
g01142879
g00925059
Personal injury can result from parts and/or covers under spring pressure.
Spring force will be released when covers are removed.
Be prepared to hold spring loaded covers as the
bolts are loosened.
The drive shaft, the piston, and the drive gear are
under a spring force. Slowly release the spring
force before you remove these components.
6. Place Tooling (B) between drive gear (7) and
piston (14). Use a suitable press to compress
the return spring. Remove retaining ring (15)
that holds the drive shaft and the piston in drive
housing (5).
Illustration 11
g00925068
Illustration 9
g00925061
8
Disassembly and Assembly Section
Illustration 12
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g00925083
8. Loosen the bolt for the drive gear with a 5/16 inch
hex wrench until the bolt moves freely. Remove
drive shaft (17) and piston (14) from drive gear
(7) as a unit.
Illustration 15
11. Remove O-ring seal (22) and lip seal (21) from
piston (14).
Illustration 16
Illustration 13
g00925095
g01052459
g01143104
Personal injury can result from parts and/or covers under spring pressure.
Spring force will be released when covers are removed.
Be prepared to hold spring loaded covers as the
bolts are loosened.
12. Remove retaining ring (31), cup (30), spring (29),
driven clutch jaw (28), driving clutch jaw (27),
bearing (26), washer (25), lockwasher (24), and
bolt (23) from drive shaft (17).
Illustration 14
g00925092
RENR9717-02
Illustration 17
9
Disassembly and Assembly Section
g00925104
Illustration 20
g00925110
Illustration 21
Illustration 18
g00925105
Illustration 19
g00925107
g00925114
Illustration 22
g00925116
18. Remove bolt (41) and rotor pinion (40) from the
rotor in the motor housing.
10
Disassembly and Assembly Section
Illustration 23
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g00925149
19. Loosen bolt (43) and remove rotor clamp nut (42).
Remove bearing (44) from rear end plate (45).
Illustration 24
g00925151
20. Remove O-ring seal (46) and rear end plate (45).
Illustration 25
g00925152
Illustration 26
g00925156
Illustration 27
g00925157
Illustration 28
g00925210
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11
Disassembly and Assembly Section
i02270736
Assembly Procedure
Table 2
Required Tools
Illustration 29
g00925216
Tool
Part Number
1P-1854
1P-1857
E
F
Part Description
Qty
Plate
51.0 x 102.0 x 6.0 mm
(2.00 x 4.00 x 0.25 inch)
Tube
57.0 x 203.0 x 6.0 mm
(2.25 x 8.00 x 0.25 inch)
1P-0510
Driver Gp
2S-3230
Bearing Lubricant
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Illustration 30
g01142915
Illustration 31
g00925323
12
Disassembly and Assembly Section
Illustration 32
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Illustration 33
Illustration 35
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g00925356
Illustration 34
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Illustration 37
g01142988
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13
Disassembly and Assembly Section
10. Install front end plate (50) onto the rotor. Align
small hole (58) of front end plate onto rotor pin
(59).
Illustration 41
Illustration 38
g00925361
g00925384
Illustration 39
Illustration 42
g00925390
Illustration 43
g00925391
g00925366
g00925116
14
Disassembly and Assembly Section
Illustration 44
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Illustration 46
g00925419
18. Install piston (14) onto the drive shaft (17). Install
retaining ring (20) onto the piston.
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.
16. Install retaining ring (31). Install bolt (23),
lockwasher (24), and washer (25) into drive shaft
(17). Apply Tooling (F) to bearing (26) and install
bearing (26) into the drive shaft. Install bolt (23),
lockwasher (24), and washer (25) into drive shaft
(17). Apply Tooling (F) to bearing (26) and install
the bearing into the drive shaft. Install driving
clutch jaw (27), driven clutch jaw (28), spring (29),
and cup (30) into the drive shaft. Install retaining
ring (31). Thoroughly lubricate the drive assembly
with SAE 10W oil.
Illustration 45
g01143059
17. Use Tooling (E) to install lip seal (21) into piston
(14). Install O-ring seal (22).
Illustration 47
g01143104
Illustration 48
g01143117
20. Install drive gear (7) onto drive shaft (17). Use
a 5/16 inch hex wrench to tighten the bolt of the
drive gear to 77 Nm (57 lb ft).
RENR9717-02
15
Disassembly and Assembly Section
Illustration 49
g01143120
21. Use Tooling (E) to install lip seal (38) into drive
housing (5).
Illustration 50
g01143123
Illustration 51
25. Install the drive gear, the piston, and the drive
shaft onto the return spring as a unit.
Illustration 52
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g00925068
Illustration 53
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16
Disassembly and Assembly Section
RENR9717-02
Illustration 54
g00925470
Illustration 57
g00925012
30. Install gear case (6) and drive housing (5) onto
motor housing (3). Install bolts (4) and tighten
evenly to a torque of 80 Nm (60 lb ft).
Illustration 55
g01143454
Illustration 58
Illustration 56
g01143442
g00925011
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17
Disassembly and Assembly Section
g00597643
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Note: Several different air starting motors are
available for use. The air starting motors can have
different configurations for the air lines. Examples of
installing two different air starting motors are provided
below.
Illustration 60
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18
Disassembly and Assembly Section
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Removal Procedure
Illustration 61
g01049697
Illustration 63
g00597378
g01049692
Installation Procedure
1. Inspect the gasket for the joint between the
electric starting motor and the flywheel housing.
Obtain a new gasket, if necessary.
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Illustration 64
19
Disassembly and Assembly Section
g00597378
Illustration 66
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Removal Procedure
g00599024
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Illustration 67
Illustration 65
g00599021
g00599024
20
Disassembly and Assembly Section
Illustration 68
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Illustration 69
g01213557
Installation Procedure
Removal Procedure
Note: If the ECM is being replaced, download the
personality module before you remove the ECM.
Refer to Troubleshooting, Replacing the ECM.
1. Turn the keyswitch to the OFF position.
Illustration 70
g01213557
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21
Disassembly and Assembly Section
Illustration 71
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
g01054098
i02055539
Disassembly Procedure
Start By:
a. Remove the fuel transfer pump. Refer to
Disassembly and Assembly, Fuel Transfer Pump
- Remove.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Note: Cleanliness is an important factor. Before
you begin the disassembly procedure, the exterior
of the components should be thoroughly cleaned.
This will help to prevent dirt from entering the
internal mechanism. Precision components can
be damaged by contaminants or by dirt. Perform
disassembly procedures on a clean work surface.
Keep components covered and protected at all times.
22
Disassembly and Assembly Section
Illustration 72
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Illustration 73
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Illustration 74
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Illustration 75
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g00918555
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23
Disassembly and Assembly Section
i02044203
Assembly Procedure
Table 3
Required Tools
Illustration 77
Tool
Part
Number
1P-0510
Part Description
Qty
1
Driver Group
g00918557
Illustration 78
g00918558
Illustration 80
g01049857
Illustration 79
g00918559
8. Remove outer lip seal (17) and inner lip seal (18)
from bracket (16).
If the bearings in bracket (16) are damaged,
the bracket must be replaced. The bearings are
nonserviceable.
Illustration 81
g01049858
24
Disassembly and Assembly Section
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Illustration 82
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Illustration 85
Illustration 86
Illustration 83
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Illustration 84
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Illustration 87
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25
Disassembly and Assembly Section
i02055376
Installation Procedure
Illustration 88
g00918545
Illustration 90
g01054098
Turbocharger - Remove
SMCS Code: 1052-011
Removal Procedure
Note: Put identification marks on all hoses, on
all hose assemblies, on all wires, and on all tube
assemblies for installation purposes. Plug all
hose assemblies and all tube assemblies. This
helps to prevent fluid loss, and this helps to keep
contaminants from entering the system.
Illustration 89
g00918544
10. Coat O-ring seal (1) with clean engine oil. Install
the O-ring seal. Install drive coupling (2) onto the
drive shaft.
End By:
a. Install the fuel transfer pump. Refer to Disassembly
and Assembly, Fuel Transfer Pump - 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
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.
26
Disassembly and Assembly Section
RENR9717-02
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Illustration 94
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Illustration 91
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Illustration 95
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Illustration 92
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Illustration 96
Illustration 93
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Illustration 97
27
Disassembly and Assembly Section
g01054745
Illustration 98
g01054902
Illustration 99
g01054903
i02431148
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.
28
Disassembly and Assembly Section
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i02431715
Turbocharger - Assemble
SMCS Code: 1052-016
Assembly Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Different turbochargers are available for use with
3500B Engines. For instructions and torques for
your specific turbocharger, see the Specifications,
Turbocharger topic. The following procedure
describes the assembly of a typical turbocharger.
Note: Obtain new seals for assembly. Thoroughly
clean all of the parts. Unless other instructions are
provided, coat the parts of the cartridge with clean
engine oil.
Illustration 101
g01054902
Illustration 100
g01054903
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29
Disassembly and Assembly Section
i02428906
Turbocharger - Install
Installation Procedure
Illustration 105
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g01213750
Illustration 106
Illustration 103
g01054745
g01054733
Illustration 107
Illustration 104
g01213749
g01054729
30
Disassembly and Assembly Section
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g01054724
Illustration 108
Illustration 110
g01052362
i02428937
Removal Procedure
Table 4
Required Tools
Tool
Part Number
138-7573
Part Description
Link Bracket
Qty
2
Illustration 111
g01052363
Illustration 109
g01052361
Illustration 112
g01052364
RENR9717-02
Illustration 113
31
Disassembly and Assembly Section
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Illustration 116
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Illustration 114
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Illustration 115
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Illustration 117
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Illustration 118
g01052368
32
Disassembly and Assembly Section
RENR9717-02
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Illustration 119
Illustration 122
g01052368
g00918303
Illustration 120
Installation Procedure
Illustration 123
g00918287
Table 5
Required Tools
Tool
Part Number
138-7573
Part Description
Link Bracket
Qty
Illustration 124
Illustration 121
g00918303
g01052367
RENR9717-02
33
Disassembly and Assembly Section
Illustration 128
Illustration 125
g00918205
g01052364
Illustration 129
Illustration 126
g00918169
Illustration 127
g00918166
g01052363
Illustration 130
g01052362
34
Disassembly and Assembly Section
RENR9717-02
Illustration 131
g01052361
g00598890
Removal Procedure
Start By:
a. Remove the aftercooler. Refer to Disassembly
and Assembly, Aftercooler - Remove and Install.
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Illustration 132
Illustration 133
g00598884
Illustration 134
g00598890
RENR9717-02
35
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.
Note: Put identification marks on all hoses, on
all hose assemblies, on all wires, and on all tube
assemblies for installation purposes. Plug all
hose assemblies and all tube assemblies. This
helps to prevent fluid loss, and this helps to keep
contaminants from entering the system.
Illustration 135
g00598884
Illustration 136
g00915389
Removal Procedure
Start By:
a. Remove the aftercooler. Refer to Disassembly
and Assembly, Aftercooler - Remove and Install.
Illustration 137
g00915391
36
Disassembly and Assembly Section
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Illustration 141
Illustration 138
g01213959
Installation Procedure
Illustration 142
Illustration 139
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g00915412
g00915416
Illustration 143
Illustration 140
g00915418
g00915418
RENR9717-02
Illustration 144
37
Disassembly and Assembly Section
g00915412
g00915389
Illustration 147
g01213959
Removal Procedure
Table 6
Required Tools
Part
Number
138-7573
Part Description
Link Bracket
Qty
2
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Illustration 146
g00915391
38
Disassembly and Assembly Section
RENR9717-02
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 into a suitable container for
storage or disposal. Refer to Operation and
Maintenance Manual, Capacities - Refill.
Illustration 148
g00890783
g00890807
Illustration 150
g01215550
Illustration 151
Installation Procedure
Table 7
Illustration 149
Required Tools
g00890799
Tool
Part
Number
138-7573
Link Bracket
221-8647
Driver
Part Description
Qty
RENR9717-02
Illustration 152
39
Disassembly and Assembly Section
g01215557
Illustration 155
g00890799
Illustration 153
g01215550
Illustration 156
g00890783
i02053499
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Illustration 154
g00890807
40
Disassembly and Assembly Section
RENR9717-02
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 disposal.
g01053079
Illustration 159
g01053081
Illustration 160
Illustration 157
g01053075
Disassembly Procedure
Table 8
Required Tools
Tool
Illustration 158
g01053077
Part
Number
Part Description
Qty
5F-7465
Puller
8S-4728
Bolt
4B-5270
Washer
4B-5271
Washer
4B-5273
Washer
1P-0458
Drive Plate
RENR9717-02
41
Disassembly and Assembly Section
Start By:
a. Remove the water pump. Refer to Disassembly
and Assembly, Water Pump - Remove.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Illustration 163
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Illustration 161
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Illustration 164
g00920965
Illustration 162
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g00920967
42
Disassembly and Assembly Section
RENR9717-02
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
g00920997
Illustration 166
Illustration 168
g01050556
g01050480
Illustration 167
Assembly Procedure
Table 9
Required Tools
Tool
Part
Number
1P-0510
Part Description
Driver Group
g01053320
Qty
1
RENR9717-02
Illustration 170
43
Disassembly and Assembly Section
g00920997
NOTICE
Clean water is the only lubricant that is permitted for
assembly. DO NOT damage or touch the wear surfaces of the carbon ring or the ceramic ring. Install the
ceramic ring with the smoothest face of the ring toward
the carbon seal.
Illustration 172
g01050569
Illustration 173
g00920965
Illustration 171
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Illustration 174
g01050574
9. Ensure that the studs for cover (6) are tight in the
housing.
10. Place clean engine oil on O-ring seal (15) and
install the O-ring seal on cover (6).
44
Disassembly and Assembly Section
RENR9717-02
Illustration 175
g00920954
Illustration 177
g01053079
Illustration 178
Installation Procedure
g01053077
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Illustration 179
g01053075
Illustration 176
g01053081
RENR9717-02
45
Disassembly and Assembly Section
Removal Procedure
Table 10
Illustration 180
g00916981
Required Tools
Tool
Part Number
138-7573
Link Bracket
187-2718
Filter Wrench
Assembly
2P-9697
Plug
6J-7366
Flared Cap
5P-2909
Plug
8S-4951
Cap
ZZ
Part Description
Qty
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 181
g00916983
Illustration 182
g00916986
46
Disassembly and Assembly Section
Illustration 183
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Illustration 184
g01050610
Illustration 186
g01052312
g01050612
Illustration 187
Disassembly Procedure
Illustration 185
g00916995
Table 11
Required Tools
Part Number
Part Description
Qty
5F-7465
Puller
5P-8244
Washer
8S-4730
Bolt
RENR9717-02
Illustration 188
47
Disassembly and Assembly Section
g00917152
g00917211
Illustration 190
g00917233
Illustration 191
Illustration 189
g00917158
Assembly Procedure
Table 12
Required Tools
Tool
Part
Number
1P-0510
Driver Gp
7N-8268
Installation Tool
Part Description
Qty
48
Disassembly and Assembly Section
Illustration 192
RENR9717-02
g01050689
Illustration 195
Illustration 196
Illustration 193
g00917233
g00917211
g00917364
Illustration 197
Illustration 194
g01050692
g01050694
RENR9717-02
49
Disassembly and Assembly Section
i02046914
Installation Procedure
Table 13
Required Tools
Tool
Part Number
Part Description
Qty
138-7573
Link Bracket
187-2718
Illustration 200
g00916995
Illustration 198
g01050612
Illustration 201
g01052312
Illustration 199
g01050610
g00916990
50
Disassembly and Assembly Section
RENR9717-02
i02429699
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Illustration 203
g00916986
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 204
g00916983
Illustration 206
Illustration 205
g00916981
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RENR9717-02
Illustration 207
51
Disassembly and Assembly Section
g00915174
Illustration 208
Illustration 210
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Illustration 211
g00915012
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Illustration 212
Illustration 209
g00915021
g00916150
52
Disassembly and Assembly Section
RENR9717-02
i02429716
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Illustration 215
g00915021
Illustration 213
g00916150
Illustration 216
g00915012
Illustration 214
g00915024
Illustration 217
g00914993
RENR9717-02
53
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.
Illustration 218
g00915174
Illustration 220
Illustration 219
g00892677
g00915172
i02433907
Removal Procedure
Start By:
a. Remove the engine oil cooler. Refer to
Disassembly and Assembly, Engine Oil Cooler Remove.
Illustration 221
g00892681
54
Disassembly and Assembly Section
RENR9717-02
Illustration 222
g00892694
Illustration 224
g00892677
Installation Procedure
Illustration 225
Illustration 223
g00892681
g00892694
RENR9717-02
55
Disassembly and Assembly Section
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.
g00917854
g01052355
Installation Procedure
Illustration 226
g01052354
g01052355
56
Disassembly and Assembly Section
RENR9717-02
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.
g00917854
Illustration 230
g01052354
Illustration 231
Illustration 232
Removal Procedure
Table 14
Required Tools
Part Number
138-7573
Tool
g01052034
Part Description
Link Bracket
Qty
1
Start By:
a. Remove the fuel transfer pump. Refer to
Disassembly and Assembly, Fuel Transfer Pump
- Remove.
RENR9717-02
Illustration 233
57
Disassembly and Assembly Section
g01052037
Illustration 234
g00916836
g01052039
Illustration 235
Illustration 236
g01052041
Illustration 237
g00916838
Illustration 238
g01052043
12. Remove bolts (16) and slide the oil pump away
from the drive. Remove oil pump (17). The weight
of oil pump (17) is approximately 45 kg (100 lb).
58
Disassembly and Assembly Section
RENR9717-02
i02413353
Personal injury can result from parts and/or covers under spring pressure.
Disassembly Procedure
Table 15
Required Tools
Tool
Part
Number
1P-0510
Part Description
Driver Group
Qty
1
Start By:
a. Remove the engine oil pump. Refer to
Disassembly and Assembly, Engine Oil Pump Remove.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Illustration 241
g00921232
Illustration 239
g00921216
Illustration 240
g00921219
g00921234
RENR9717-02
59
Disassembly and Assembly Section
i02046966
Assembly Procedure
Table 16
Required Tools
Illustration 243
Tool
Part
Number
1P-0510
Part Description
Driver Group
Qty
1
g01050749
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Illustration 244
g00921264
Illustration 246
g01050759
g01052070
60
Disassembly and Assembly Section
Illustration 247
RENR9717-02
g00921264
Illustration 248
Illustration 250
g00921232
g01050761
Illustration 251
g00921219
Illustration 249
g00921234
RENR9717-02
61
Disassembly and Assembly Section
g00921216
Illustration 252
Illustration 254
g00916838
End By:
a. Install the engine oil pump. Refer to Disassembly
and Assembly, Engine Oil Pump - Install.
i02411353
Installation Procedure
Illustration 255
Table 17
Required Tools
Tool
Part
Number
Part Description
Qty
138-7573
Link Bracket
Illustration 256
Illustration 253
g00916836
g01052043
g01052041
62
Disassembly and Assembly Section
RENR9717-02
Illustration 257
g01052039
Removal Procedure
Table 18
Required Tools
Illustration 258
g01052037
Tool
Part
Number
138-7573
Link Bracket
187-2718
Part Description
Qty
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 259
g01052034
Illustration 260
g00891250
RENR9717-02
63
Disassembly and Assembly Section
Illustration 264
Illustration 261
g00891476
g00891255
Illustration 265
Illustration 262
g00891466
g00891483
Disassembly Procedure
Start By:
Illustration 263
g00891470
64
Disassembly and Assembly Section
Illustration 266
RENR9717-02
g00892312
Illustration 268
g00892355
Assembly Procedure
Illustration 267
g00892328
Illustration 269
g00892355
RENR9717-02
65
Disassembly and Assembly Section
i02431993
Installation Procedure
Table 19
Required Tools
Illustration 270
g00892328
Tool
Part
Number
138-7573
Link Bracket
187-2718
Part Description
Qty
Illustration 272
g00891483
Illustration 271
g00892312
Illustration 273
g00891476
66
Disassembly and Assembly Section
Illustration 274
RENR9717-02
g00891470
Illustration 277
g00891250
Removal Procedure
Start By:
Illustration 275
g00891466
Illustration 276
g00891255
RENR9717-02
67
Disassembly and Assembly Section
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
g00921410
Illustration 278
Illustration 280
g01052078
g00921411
Illustration 279
Illustration 281
Disassembly Procedure
Table 20
Required Tools
Tool
Part
Number
1P-0520
Part Description
Driver Group
Qty
1
Start By:
a. Remove the engine oil and water pump drive.
Refer to Disassembly and Assembly, Engine Oil
and Water Pump Drive - Remove.
68
Disassembly and Assembly Section
RENR9717-02
g00921574
Illustration 282
Illustration 284
g00921575
Illustration 283
Assembly Procedure
Table 21
Required Tools
Tool
Part
Number
1P-0520
Part Description
Driver Group
g00921574
Qty
1
RENR9717-02
69
Disassembly and Assembly Section
i02047064
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Illustration 286
g00921559
Illustration 288
g00921411
Illustration 287
g01052078
Illustration 289
g00921410
70
Disassembly and Assembly Section
RENR9717-02
i02047077
Removal 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.
Illustration 291
g00921656
Illustration 292
g00604419
Improper lift rigging can allow unit to tumble causing injury and damage.
Note: If improper equipment is used to lift the engine,
injury and damage can occur. Use cables or chains
that are properly rated for the weight. Use a spreader
bar and attach the cables or chains according to the
information that is on the lifting film for the engine.
Illustration 290
g00921655
RENR9717-02
71
Disassembly and Assembly Section
i02047084
Disassembly Procedure
Start By:
a. Remove the engine oil pan. Refer to Disassembly
and Assembly, Engine Oil Pan - Remove.
Illustration 293
g00604420
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
g00590183
Illustration 294
g00604494
Illustration 296
g00921661
72
Disassembly and Assembly Section
RENR9717-02
i02047087
Assembly Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Illustration 297
g00921665
Illustration 300
g00921673
g00921672
Illustration 299
g00921673
Illustration 301
g00921672
RENR9717-02
73
Disassembly and Assembly Section
i02047093
Installation Procedure
Table 22
Required Tools
Illustration 302
g00921665
Tool
Part
Number
7M-7260
Part Description
Qty
Liquid Gasket
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Illustration 303
g00921661
Illustration 305
g00604494
Illustration 304
g00590183
Improper lift rigging can allow unit to tumble causing injury and damage.
Note: If improper equipment is used to lift the engine,
injury and damage can occur. Use cables or chains
that are properly rated for the weight. Use a spreader
bar and attach the cables or chains according to the
information that is on the lifting film for the engine.
74
Disassembly and Assembly Section
Illustration 306
RENR9717-02
g00604420
Illustration 308
g00604418
5. Install bolts (2) that hold the engine and the oil
pan together.
4. Lift the engine. Place the engine onto the oil pan
or place the oil pan in position under the engine.
Remove Tooling (B) from the oil pan.
Illustration 309
g00604417
6. Install bolts (1) that hold the connector for the oil
pump to the oil pan.
7. Fill the engine crankcase with oil. Refer to the
Operation and Maintenance Manual, Capacities
(Refill) for the oil capacity.
i02412217
g00604419
Removal Procedure
Start By:
a. Remove the engine oil pan. Refer to Disassembly
and Assembly, Engine Oil Pan - Remove.
RENR9717-02
75
Disassembly and Assembly Section
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
g01205699
Illustration 312
Illustration 310
g01205685
i02412825
Disassembly Procedure
Table 23
Required Tools
Tool
A
Illustration 311
Part Description
Qty
1P-2321
Combination Puller
9S-9155
Spacer
g01205694
Part
Number
Start By:
a. Remove the engine oil scavenge pump. Refer
to Disassembly and Assembly, Engine Oil
Scavenge Pump - Remove.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
76
Disassembly and Assembly Section
Illustration 313
RENR9717-02
g01205956
g01205955
Illustration 315
g01205958
Illustration 316
Illustration 314
g00923147
Assembly Procedure
Table 24
Required Tools
Tool
Part
Number
1P-0510
Part Description
Driver Group
Qty
1
RENR9717-02
77
Disassembly and Assembly Section
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Illustration 317
g01205958
Illustration 320
g01205955
Illustration 318
g00604752
Illustration 321
g01206056
Illustration 319
g01206054
78
Disassembly and Assembly Section
RENR9717-02
i02412658
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Illustration 322
g01206142
Illustration 324
Illustration 323
g01206144
g01205699
g01205694
RENR9717-02
Illustration 326
79
Disassembly and Assembly Section
g01205685
Illustration 328
g00923171
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
i02413993
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Illustration 329
g00605124
Illustration 327
g01052600
80
Disassembly and Assembly Section
RENR9717-02
Illustration 330
g01052600
g00636958
Illustration 332
Removal Procedure
Start By:
i02047273
Disassembly Procedure
Table 25
Required Tools
Tool
Part
Number
1P-0510
Part Description
Driver Group
Qty
1
Start By:
a. Remove the rocker shaft assemblies. Refer to
Disassembly and Assembly, Rocker Shaft and
Push Rods - Remove.
Illustration 331
g00605234
RENR9717-02
81
Disassembly and Assembly Section
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Assembly Procedure
Table 26
Required Tools
Illustration 333
g00605478
Tool
Part
Number
1P-0510
Part Description
Qty
Driver Group
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Perform Steps 1 through 4 for each rocker arm.
Illustration 334
g00605479
Illustration 336
g01050986
Note: Make sure that the bore of the rocker arm and
the sleeve bearing are thoroughly clean.
Illustration 335
g00636969
82
Disassembly and Assembly Section
RENR9717-02
i02047291
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Illustration 337
g01050990
Illustration 339
g01051014
Illustration 338
g00605478
RENR9717-02
83
Disassembly and Assembly Section
End By:
a. Install the valve covers. Refer to Disassembly and
Assembly, Valve Cover - Remove and Install.
i02415328
Removal Procedure
Table 27
Required Tools
Tool
Part
Number
5F-4764
Part Description
Pry Bar
Qty
1
Start By:
Illustration 340
g01051017
NOTICE
If the rocker shaft is not positioned correctly, the oil
supply to the sleeve bearings in the rocker arm will be
shut off. This will cause seizure of the bearings and
severe damage to the engine.
Illustration 341
g00903832
84
Disassembly and Assembly Section
RENR9717-02
g00903932
Illustration 342
Installation Procedure
Table 28
Required Tools
Illustration 343
Tool
Part
Number
9U-6862
Tapered Brush
4C-5027
Tap Wrench
4C-6774
1P-0808
Multipurpose Grease
1U-5512
or
8T-7765
Abrasive Material
or
Surface Reconditioning
Pad
Part Description
Qty
g01051051
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
NOTICE
Remove all carbon deposits from the angled surface
at the bottom of the cylinder head bore for the fuel
injection pump. Failure to clean this area may prevent the fuel injection pump from seating properly. This
could result in failure of the fuel injection pump due to
leakage of exhaust gas into the fuel passage.
Illustration 344
g01051052
RENR9717-02
85
Disassembly and Assembly Section
Removal Procedure
i02414981
Table 29
Required Tools
Tool
Part
Number
138-7573
Part Description
Link Bracket
Qty
2
Start By:
a. Remove the valve cover base. Refer to
Disassembly and Assembly, Valve Cover Base
- Remove and Install.
NOTICE
Keep all parts clean from contaminants.
Illustration 345
g01052571
86
Disassembly and Assembly Section
Illustration 346
RENR9717-02
g01053854
Illustration 347
Illustration 349
g01053859
Illustration 350
Illustration 348
g01053975
g01053860
g01053977
Illustration 351
g01053978
RENR9717-02
87
Disassembly and Assembly Section
g01053983
Illustration 352
Illustration 353
g00905560
Disassembly Procedure
Start By:
a. Remove the cylinder head. Refer to Disassembly
and Assembly, Cylinder Head - Remove.
Required Tools
Tool
Part
Number
Part Description
Qty
5S-1330
8S-2263
Spring Tester
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Illustration 354
g00618922
88
Disassembly and Assembly Section
RENR9717-02
Table 31
Required Tools
Part
Number
Bridge Dowels
Tool
NOTICE
Keep all parts clean from contaminants.
Part Description
Qty
5P-0944
5P-0942
Dowel Extractor
NOTICE
Keep all parts clean from contaminants.
Required Tools
Tool
Part
Number
Part Description
Qty
7M-3975
5P-1729
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
1. Use Tooling (E) and a hammer to remove the
valve guides from the cylinder head.
Valve Lifters
NOTICE
Keep all parts clean from contaminants.
g01051069
Illustration 355
Required Tools
Tool
Part
Number
166-7441
Part Description
Valve Seat Extractor Tool
Qty
1
RENR9717-02
89
Disassembly and Assembly Section
i02415471
Assembly Procedure
Valve Lifters
NOTICE
Keep all parts clean from contaminants.
Illustration 356
g01051072
Illustration 357
g01051073
Illustration 358
g01051073
Illustration 359
g01051072
90
Disassembly and Assembly Section
RENR9717-02
Bridge Dowels
Table 36
Required Tools
Required Tools
Tool
E
Part
Number
Part Description
Qty
7M-3975
5P-1729
Tool
Part
Number
6V-4009
Part Description
Dowel Driver
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.
Note: Use new valve guides for assembly.
1. Coat the outside of the valve guides with clean
engine oil prior to installation.
2. Use Tooling (E) to install the valve guides.
The valve guide must extend 26.0 0.50 mm
(1.02 0.02 inch) above the surface of the cylinder
head.
g01051069
Illustration 360
Table 35
Required Tools
Tool
Part
Number
Part Description
Qty
166-7441
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Note: Use new inserts for assembly.
1. Cool the valve seat inserts. Install the valve seat
inserts with Tooling (D).
Required Tools
Tool
Part
Number
5S-1330
Part Description
Valve Spring Compressor
Qty
1
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
RENR9717-02
91
Disassembly and Assembly Section
i02415073
Installation Procedure
Table 38
Required Tools
Tool
Part
Number
138-7573
Part Description
Link Bracket
Qty
2
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Illustration 361
g00618922
Illustration 362
g01053983
Illustration 363
g01053978
92
Disassembly and Assembly Section
RENR9717-02
NOTICE
Ensure that the surface of the spacer plate gasket and
the surface of the cylinder block are clean. Do not use
a gasket adhesive on these surfaces.
3. Install a new gasket (13) on the dowels in the
cylinder block.
Illustration 366
g00618255
NOTICE
The plug for Location (C) MUST be installed in the
cylinder head.
Illustration 364
g01053977
Illustration 367
Illustration 365
g01053975
g01053935
RENR9717-02
Illustration 368
93
Disassembly and Assembly Section
g00585055
g01053958
Illustration 370
11. Coat the threads of the bolts with clean engine oil.
End By:
a. Install the valve cover base. Refer to Disassembly
and Assembly, Valve Cover Base - Remove and
Install.
i02414673
Removal Procedure
Table 39
Required Tools
Tool
Part
Number
Part Description
Guide Bolts
1/2 in x 13 NC
Qty
2
NOTICE
Keep all parts clean from contaminants.
Illustration 369
g01053859
94
Disassembly and Assembly Section
RENR9717-02
i02507146
Disassembly Procedure
Table 40
Required Tools
Illustration 371
g01054400
Tool
Part
Number
1P-0520
Part Description
Qty
Driver Group
Start By:
Illustration 372
g00906510
Illustration 373
g00906726
RENR9717-02
Illustration 374
95
Disassembly and Assembly Section
g01255143
g01255150
Illustration 377
Assembly Procedure
Table 41
Required Tools
Illustration 375
g01255146
Tool
Part
Number
1P-0520
Part Description
Driver Group
Qty
1
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Illustration 376
g01255149
g01255150
96
Disassembly and Assembly Section
RENR9717-02
1. Align the oil hole in the bearing and the oil hole in
front adapter assembly (9). Use Tooling (A) and
a suitable press to install bearing (11) into front
adapter assembly (9). The bore of the bearing
must be 75.0 0.055 mm (2.95 0.0020 inch)
after installation.
2. Install O-ring seals (12) and (13) into front adapter
assembly (9).
Illustration 381
g01255143
6. Align the oil hole in the bearing and the oil hole in
rear adapter assembly (1). Use Tooling (A) and
a suitable press to install bearing (5) into rear
adapter assembly (1). The bore of the bearing
must be 75.0 0.055 mm (2.95 0.0020 inch)
after installation.
Illustration 379
g01255149
Illustration 382
g00906726
g01255146
End By:
a. Install the accessory drive (front). Refer to
Disassembly and Assembly, Accessory Drive
(Front) - Install.
RENR9717-02
97
Disassembly and Assembly Section
i02049692
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Removal Procedure
Start By:
a. Remove the fuel injectors. Refer to Disassembly
and Assembly, Fuel Injector - Remove.
Illustration 383
g00906510
Illustration 384
Illustration 385
Installation Procedure
g01054400
g01052887
Illustration 386
g01052887
98
Disassembly and Assembly Section
RENR9717-02
Removal Procedure
g00907030
Table 42
Required Tools
Part
Number
Tool
Part Description
Qty
1P-0074
8B-7557
Threaded Adapter
138-7573
Link Bracket
1P-0520
Driver Group
Guide Bolt
3/816 NC
Start By:
a. Remove the oil filter base. Refer to Disassembly
and Assembly, Engine Oil Filter Base - Remove.
b. Remove the crankshaft front seal and the wear
sleeve. Refer to Disassembly and Assembly,
Crankshaft Front Seal and Wear Sleeve Remove.
Illustration 388
g00907040
Illustration 389
g00907098
RENR9717-02
99
Disassembly and Assembly Section
Illustration 391
g00907145
Illustration 390
g00907145
Installation Procedure
Table 43
Required Tools
Tool
Part
Number
138-7573
Link Bracket
1P-0520
Driver Group
Guide Bolt
3/816 NC
Part Description
Qty
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
1. Install the gasket for the front drive housing onto
the cylinder block. Install Tooling (D) into the
cylinder block.
Illustration 392
g00907120
100
Disassembly and Assembly Section
RENR9717-02
Removal Procedure
Illustration 393
g00907040
Table 44
Required Tools
7. Coat the bore for the O-ring seal of shaft (2) with
clean engine oil. Install the O-ring seal onto shaft
(2).
8. Place shaft (2) into position in the front drive
housing. Install the bolts for shaft (2).
Tool
Part
Number
Guide Bolts
3/8 - 16 NC by 4 inch
Guide Bolts
1/2 - 13 NC by 4 inch
138-7575
Link Bracket
1U-9393
Part Description
Qty
Illustration 394
g00907030
Illustration 395
g01207380
RENR9717-02
Illustration 396
101
Disassembly and Assembly Section
g00916223
Illustration 397
Illustration 399
g00916284
g01054420
Illustration 400
g00916292
Illustration 401
g00916297
g00916274
102
Disassembly and Assembly Section
Illustration 402
RENR9717-02
g00916389
g01207444
Illustration 404
Installation Procedure
Table 45
Required Tools
Illustration 403
g00916309
Tool
Part
Number
Guide Bolts
3/8 - 16 NC by 4 inch
Guide Bolts
1/2 - 13 NC by 4 inch
138-7575
Link Bracket
1U-9393
Part Description
Qty
Illustration 405
g01207444
RENR9717-02
103
Disassembly and Assembly Section
Illustration 406
g00916297
Illustration 409
g00916292
g00916309
Illustration 407
Illustration 408
g00916389
Illustration 410
g00916284
104
Disassembly and Assembly Section
RENR9717-02
Illustration 411
g00916274
g01207380
Illustration 414
Removal Procedure
Table 46
Required Tools
Illustration 412
g01054420
8. Install key (5) and hub (6). Tighten set screw (4)
in hub (6).
Tool
Part
Number
1U-7600
6V-3143
Distorter Adapter
5P-7409
Sleeve Distorter
Part Description
Qty
Start By:
a. Remove the vibration damper. Refer to
Disassembly and Assembly, Vibration Damper
- Remove and Install.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Illustration 413
g01051456
NOTICE
Every time that the crankshaft seal is removed from
the wear sleeve, a new wear sleeve and crankshaft
seal must be installed.
RENR9717-02
105
Disassembly and Assembly Section
i02415670
Installation Procedure
Table 47
Required Tools
Tool
Illustration 415
g00659180
Part Description
Qty
6V-4003
Seal Locator As
2N-5006
Bolt
8T-3099
Seal Installer
9S-8858
Nut
169-5464
4C-9507
Retaining Compound
1P-0808
Multipurpose Grease
Part
Number
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Illustration 416
g00659181
NOTICE
Every time that the crankshaft seal is removed from
the wear sleeve, a new wear sleeve and crankshaft
seal must be installed.
106
Disassembly and Assembly Section
RENR9717-02
Illustration 419
g01207499
g01005029
Illustration 418
g01207497
Illustration 420
g01051474
RENR9717-02
107
Disassembly and Assembly Section
g01005047
Illustration 421
g00911678
Illustration 422
End By:
i02415754
Removal Procedure
Installation Procedure
Table 48
Required Tools
Tool
Part Number
138-7573
2D-1201
Part Description
Table 49
Qty
Required Tools
Link Bracket
Tool
Part Number
Guide Bolts
1 - 14 NF by 8 inch
138-7573
Eyebolts
Part Description
Qty
Link Bracket
Guide Bolts
1 - 14 NF by 8 inch
NOTICE
Keep all parts clean from contaminants.
NOTICE
Keep all parts clean from contaminants.
108
Disassembly and Assembly Section
RENR9717-02
i02415885
Removal Procedure
Table 50
Required Tools
Illustration 423
g00911678
Tool
Part
Number
1U-7600
6V-3143
Distorter Adapter
5P-7409
Sleeve Distorter
Part Description
Qty
Start By:
a. Remove the flywheel. Refer to Disassembly and
Assembly, Flywheel - Remove and Install.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
NOTICE
Every time that the crankshaft seal is removed from
the wear sleeve, a new wear sleeve and crankshaft
seal must be installed.
Illustration 424
g00659239
RENR9717-02
109
Disassembly and Assembly Section
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
NOTICE
Every time that the crankshaft seal is removed from
the wear sleeve, a new wear sleeve and crankshaft
seal must be installed.
g00659240
Illustration 425
Illustration 426
g01005029
g01005030
Installation Procedure
Table 51
Required Tools
Tool
Part
Number
Part Description
Qty
6V-4003
Seal Locator As
2N-5006
Bolt
8T-3099
Seal Installer
9S-8858
Nut
169-5464
Illustration 427
4C-9507
Retaining Compound
1P-0808
Multipurpose Grease
110
Disassembly and Assembly Section
RENR9717-02
g01005035
Illustration 430
g01207617
4. Place rear seal (1) and the wear sleeve (2) onto
Tooling (D).
Removal Procedure
Table 52
Required Tools
Part
Number
Tool
Part Description
Qty
8B-7548
8B-7559
Adapter
8H-0684
Ratchet Wrench
8B-7561
Step Plate
138-7573
Link Bracket
169-5464
Start By:
a. Remove the starting motors. Refer to Disassembly
and Assembly, Air Starting Motor - Remove or
Disassembly and Assembly, Electric Starting
Motor - Remove and Install.
Illustration 429
g01051474
RENR9717-02
111
Disassembly and Assembly Section
Illustration 432
Installation Procedure
Table 53
Required Tools
Illustration 431
g00912881
Tool
Part
Number
138-7573
185-3984(1)
or
4C-5300
(1)
Part Description
Qty
Link Bracket
Guide Bolts
5/8 - 11 NC by 8 inch
Gasket Sealant
EAME
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
112
Disassembly and Assembly Section
RENR9717-02
Illustration 433
g01259519
Illustration 434
g00912883
RENR9717-02
113
Disassembly and Assembly Section
g01259521
Illustration 435
(A) 1/2 - NC
(B) 1/2 - NC
(C) 1/2 - NC
(D) 1/2 - NC
(E) 1/2 - NC
(F) 5/8 - NC
114
Disassembly and Assembly Section
RENR9717-02
g01259551
Illustration 436
(G) 1/2 - NC
(H) 1/2 - NC
(I) 1/2 - NC
(J) 5/8 - NC
(K) 5/8 - NC
(L) 5/8 - NC
Illustration 437
g01226902
RENR9717-02
115
Disassembly and Assembly Section
Removal Procedure
Start By:
a. Remove the front drive housing. Refer to
Disassembly and Assembly, Front Drive Housing
- Remove and Install.
b. Remove the flywheel housing. Refer to
Disassembly and Assembly, Flywheel Housing Remove.
NOTICE
Keep all parts clean from contaminants.
g00912963
Personal injury can result from parts and/or covers under spring pressure.
Spring force will be released when covers are removed.
Be prepared to hold spring loaded covers as the
bolts are loosened.
1. Remove cover (1) from the front of the cylinder
block.
116
Disassembly and Assembly Section
RENR9717-02
Illustration 441
Illustration 439
g00912966
g00912969
Personal injury can result from parts and/or covers under spring pressure.
Spring force will be released when covers are removed.
Be prepared to hold spring loaded covers as the
bolts are loosened.
3. Remove the idler gear and the shaft. Remove
cover (4) on the rear of the cylinder block.
Illustration 442
g00912966
g00912969
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
RENR9717-02
117
Disassembly and Assembly Section
Start By:
a. Remove the flywheel housing. Refer to
Disassembly and Assembly, Flywheel Housing Remove.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
g00912963
Illustration 443
Removal Procedure
Table 54
Required Tools
Tool
Part
Number
1P-0520
Part Description
Driver Group
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
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.
Note: The following Step is for a 3508 Engine.
118
Disassembly and Assembly Section
RENR9717-02
g01056631
Illustration 444
Illustration 447
Illustration 445
g00913045
Illustration 446
g00913049
g00913054
Illustration 448
g01051669
RENR9717-02
119
Disassembly and Assembly Section
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
g00913136
Illustration 449
Illustration 451
g00913137
Illustration 450
Illustration 452
g00913137
g00913136
2. Install shaft (7) and the bolts. The torque for the
bolts is 140 10 Nm (105 5 lb ft).
i02147058
Installation Procedure
Table 55
Required Tools
Tool
Part
Number
1P-0520
Part Description
Driver Gp
Qty
1
Illustration 453
g01051669
120
Disassembly and Assembly Section
Illustration 454
RENR9717-02
g01068502
Illustration 456
g01068516
Illustration 455
g00913054
RENR9717-02
121
Disassembly and Assembly Section
g01056631
Illustration 457
i02087195
Removal Procedure
Start By:
a. Remove the engine oil pump, if necessary. Refer
to Disassembly and Assembly, Engine Oil Pump
- Remove.
NOTICE
Keep all parts clean from contaminants.
Illustration 458
g00913045
10. Place clean engine oil on gear (2) and install gear
(2) on the engine.
11. Install plate (1) and the bolts.
End By:
a. Install the flywheel housing. Refer to Disassembly
and Assembly, Flywheel Housing - Install.
122
Disassembly and Assembly Section
RENR9717-02
Illustration 459
g00913178
Illustration 461
g00913185
Illustration 460
g00913185
Illustration 462
g00913178
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
RENR9717-02
123
Disassembly and Assembly Section
i01793772
Measurement Procedure
Table 56
Required Tools
Tool
Part
Number
Part Description
Qty
198-9142
Plastic Gauge
198-9143
Plastic Gauge
198-9144
Plastic Gauge
198-9145
Plastic Gauge
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Note: Caterpillar does not recommend the checking
of the actual bearing clearances particularly on
small engines. This is because of the possibility of
obtaining inaccurate results and the possibility of
damaging the bearing or the journal surfaces. Each
Caterpillar engine bearing is quality checked for
specific wall thickness.
Illustration 463
g00473227
Typical Example
124
Disassembly and Assembly Section
RENR9717-02
Removal Procedure
i02140851
Table 57
Required Tools
Tool
Part
Number
5R-7425
(1)
Part Description
Qty
Barring Gp(1)
Start By:
a. Remove the piston cooling jets. Refer to
Disassembly and Assembly, Piston Cooling Jets
- Remove and Install.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
1. Use Tooling (A) to turn the flywheel in order
to access the connecting rod cap that will be
removed.
g01064420
Illustration 465
Installation Procedure
Table 58
Required Tools
Tool
Part
Number
6V-4876
Part Description
Qty
Lubricant
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
1. Check the clearance of the bearings. Refer to
Disassembly and Assembly, Bearing Clearance Check for the correct procedure.
Illustration 464
g01064418
RENR9717-02
Illustration 466
125
Disassembly and Assembly Section
g01064420
Illustration 468
g01064455
Illustration 467
g01064418
126
Disassembly and Assembly Section
RENR9717-02
i02040853
Removal Procedure
Table 59
Required Tools
Tool
Part
Number
9S-9082
Illustration 470
9U-5023
2P-5517
3. Use Tooling (B) and loosen the bolts for the main
bearing cap.
230-5843(1)
or
236-6688(2)
(1)
(2)
Part Description
Qty
g00930580
Start By:
a. Remove the oil pump. Refer to Disassembly and
Assembly, Engine Oil Pump - Remove.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Illustration 469
Illustration 471
g00930589
g00930577
Illustration 472
g00930593
RENR9717-02
127
Disassembly and Assembly Section
i01987340
Installation Procedure
Table 60
Required Tools
Illustration 473
Tool
Part
Number
9S-9082
9U-5023
2P-5517
230-5843(1)
or
236-6688(2)
9S-7351
Torque Wrench
6V-4876
Lubricant
g00930603
Part Description
Qty
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
1. Measure the clearances of the main bearings.
Refer to Disassembly and Assembly, Bearing
Clearance - Check.
NOTICE
Ensure that the upper halves and the lower halves of
the main bearings are installed with the tabs fitting into
the notch in the cylinder block and the notch in the
main bearing cap.
Illustration 474
g00930606
128
Disassembly and Assembly Section
RENR9717-02
Illustration 477
g00930745
g00930606
Illustration 476
Illustration 478
g00930580
Illustration 479
g01049012
g00930593
RENR9717-02
129
Disassembly and Assembly Section
i02418035
Removal Procedure
Table 61
Required Tools
Illustration 480
Tool
Part Number
5R-7425
Barring Gp(1)
1P-1861
6V-4020
5P-8639
Hydraulic Press
8F-0024
Hose Assembly
1P-2375
Quick Connect
Coupler
1P-2376
Quick Connect
Coupler
1U-5230
5P-8649
Adapter
6V-3043
Spacer
6V-3042
Adapter
g00930577
(1)
Part Description
Qty
Start By:
a. Remove the cylinder head. Refer to Disassembly
and Assembly, Cylinder Head - Remove.
b. Remove the piston cooling jets. Refer to
Disassembly and Assembly, Piston Cooling Jets
- Remove and Install.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Note: The front end of the engine is the end that is
opposite of the flywheel. The number one cylinder is
the right front cylinder and the number two cylinder
is the front left cylinder.
1. Remove the cover from the front right side of the
flywheel housing. Use Tooling (A) to rotate the
flywheel until all four bolts in the connecting rod
cap can be removed.
2. Mark the cylinder number on each connecting rod
and on the corresponding connecting rod cap.
130
Disassembly and Assembly Section
Illustration 481
RENR9717-02
g00913801
Illustration 483
g00913818
Illustration 482
g01051820
Illustration 484
g01208346
RENR9717-02
131
Disassembly and Assembly Section
Illustration 485
g01004841
i02418583
Installation Procedure
Table 62
Required Tools
Tool
Part
Number
5R-7425
Barring Gp(1)
1P-1861
6V-4020
1U-7616
6V-4876
Lubricant
(1)
Part Description
Qty
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Illustration 486
g01006026
132
Disassembly and Assembly Section
RENR9717-02
Illustration 487
g01051820
Illustration 490
g01006030
g01004842
Illustration 489
Chamfer on one side of the connecting rod bore
g00613051
RENR9717-02
133
Disassembly and Assembly Section
Start By:
a. Remove the pistons and the connecting rod
assemblies. Refer to Disassembly and Assembly,
Pistons and Connecting Rods - Remove.
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.
g01006031
Illustration 491
(12) Side of the connecting rod with the chamfer
(13) Location pin
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
1. Drain the coolant from the cooling system and
the engine block into a suitable container for
storage or for disposal. Refer to Operation and
Maintenance Manual, Cooling System Coolant
- Change.
2. Place covers over the crankshaft journals in order
to shield the journals from dirt and coolant.
3. Use Tooling (A) in order to remove the cylinder
liner.
End By:
a. Install the piston cooling jets. Refer to Disassembly
and Assembly, Piston Cooling Jets - Remove
and Install.
b. Install the cylinder head. Refer to Disassembly
and Assembly, Cylinder Head - Install.
i02141166
Removal Procedure
Illustration 492
g01004731
Table 63
Required Tools
Tool
Part
Number
5P-8665
Part Description
Cylinder Liner Puller
Qty
1
134
Disassembly and Assembly Section
RENR9717-02
i02418752
Installation Procedure
Table 64
Required Tools
Tool
Part
Number
Part Description
Qty
1U-9895
Crossblock
3H-0465
Push-Puller Plate
8F-6123
Bolt
0S-1575
Bolt
3B-1925
Washer
8T-0455
2P-8260
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Illustration 493
g01208517
Illustration 494
g00578874
RENR9717-02
135
Disassembly and Assembly Section
g01051464
Illustration 496
Camshaft - Remove
Illustration 495
g01004731
Removal Procedure
Table 65
Required Tools
Tool
Part
Number
238-9586
1P-0820
Hydraulic Puller
8B-7548
8B-7559
Adapter
5H-1504
Hard Washer
9U-6600
125-0200
Camshaft Pilot As
125-0201
Camshaft Guide As
8T-3169
Crank Assembly
Part Description
Qty
136
Disassembly and Assembly Section
RENR9717-02
Start By:
a. Remove the valve cover base. Refer to
Disassembly and Assembly, Valve Cover Base
- Remove and Install.
b. Remove the speed/timing sensor. Refer to the
Service Manual, Electronic Troubleshooting
module.
c. Remove the electronic control module. Refer to
Disassembly and Assembly, Electronic Control
Module (ECM) and Personality Module (PM) Remove and Install.
Illustration 499
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Illustration 500
Illustration 497
g01007161
g01053356
g01053366
Illustration 501
Illustration 498
g00914348
g01053357
RENR9717-02
Illustration 502
137
Disassembly and Assembly Section
g00914453
Illustration 504
g00914454
NOTICE
Do not apply more than 51675 kPa (7500 psi) pressure to the hydraulic puller. The adapters are rated at
6 1/2 tons each and the hydraulic puller is rated at 17
tons at 68900 kPa (10000 psi). If too much pressure
is applied, the gear may be damaged.
8. Install Tooling (B) on camshaft drive gear (8).
Apply 51675 kPa (7500 psi) to Tooling (B). Strike
the screw on Tooling (B) with a hammer until
camshaft drive gear (8) is free from the camshaft.
Remove Tooling (B) and camshaft drive gear (8).
Illustration 505
g00914462
g00613686
138
Disassembly and Assembly Section
RENR9717-02
Start By:
NOTICE
Keep all parts clean from contaminants.
g00579149
Illustration 506
Illustration 507
g01208871
i02419334
Removal Procedure
Table 66
Required Tools
Tool
Part
Number
6V-4077
8S-2241
5P-5247
Hydraulic Puller
8H-0684
Ratchet Wrench
Part Description
Qty
RENR9717-02
139
Disassembly and Assembly Section
g01208875
Illustration 508
Installation Procedure
Table 67
Required Tool
Tool
Part
Number
6V-4077
8S-2241
5P-5247
Hydraulic Puller
8H-0684
Ratchet Wrench
Part Description
Qty
Illustration 509
g00578338
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Illustration 510
g01208939
140
Disassembly and Assembly Section
RENR9717-02
End By:
a. Install the camshafts. Refer to Disassembly and
Assembly, Camshaft - Install.
i02458929
Camshaft - Install
Installation Procedure
Table 68
Required Tools
Tool
Part
Number
238-9586
125-0200
Camshaft Pilot As
125-0201
Camshaft Guide As
8T-3169
Crank As
Part Description
Qty
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
1. The following steps are for the installation of
a camshaft in the 3512B Engines and 3516B
Engines. The camshaft is in two pieces.
Note: Ensure that the camshafts are assembled and
installed according to the marks on the ends of the
camshafts.
Illustration 511
Illustration 512
g00914670
Illustration 513
g00914462
g01053512
RENR9717-02
141
Disassembly and Assembly Section
Illustration 514
g00914691
Illustration 515
g00914693
142
Disassembly and Assembly Section
RENR9717-02
Illustration 516
g00914707
Illustration 519
g00914728
Illustration 517
g01053668
Illustration 520
g01053357
Illustration 518
g00914726
RENR9717-02
143
Disassembly and Assembly Section
Illustration 523
g01053668
Illustration 524
g00914707
Illustration 521
g01053666
Illustration 525
Illustration 522
g01053366
g00914348
144
Disassembly and Assembly Section
RENR9717-02
i02421036
Crankshaft - Remove
SMCS Code: 1202-011
Removal Procedure
Table 69
Required Tools
Illustration 526
g01053356
Tool
Part
Number
Part Description
4C-9832
138-7576
Link Bracket
Qty
Start By:
a. Remove the rocker shaft assemblies and the
pushrods. Refer to Disassembly and Assembly,
Rocker Shaft and Push Rods - Remove.
b. Remove the front housing. Refer to Disassembly
and Assembly, Front Drive Housing - Remove
and Install.
c. Remove the balancer gear from the rear gear
group. Refer to Disassembly and Assembly, Gear
Group (Rear) - Remove.
Illustration 527
g01007161
RENR9717-02
145
Disassembly and Assembly Section
g00914800
Illustration 528
g00914774
Illustration 531
g00930694
g00914776
146
Disassembly and Assembly Section
RENR9717-02
g00914805
Illustration 532
Illustration 533
g01049072
i02421041
Crankshaft - Install
SMCS Code: 1202-012
Installation Procedure
Table 70
Required Tools
Tool
Part
Number
Part Description
4C-9832
138-7576
Link Bracket
6V-4876
Lubricant
8T-5096
Dial Indicator Gp
Qty
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Illustration 534
g01049073
RENR9717-02
147
Disassembly and Assembly Section
Illustration 535
g00930694
Illustration 537
g01049103
Illustration 536
g01049012
148
Disassembly and Assembly Section
RENR9717-02
NOTICE
Each counterweight is numbered and must be installed in the same position as the corresponding
number on the crankshaft mounting pad in order to
prevent damage to the crankshaft.
Illustration 538
g01049104
Illustration 540
g01049106
g01049105
RENR9717-02
149
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.
End By:
a. Install the piston cooling jets. Refer to Disassembly
and Assembly, Piston Cooling Jets - Remove
and Install.
b. Install the flywheel housing. Refer to Disassembly
and Assembly, Flywheel Housing - Install.
Removal Procedure
Note: Put identification marks on all hoses, on
all hose assemblies, on all wires, and on all tube
assemblies for installation purposes. Plug all
hose assemblies and all tube assemblies. This
helps to prevent fluid loss, and this helps to keep
contaminants from entering the system.
Illustration 541
g00917715
150
Disassembly and Assembly Section
RENR9717-02
Illustration 542
g01209052
Illustration 545
g01209052
2. Install clamps (4) and (5) and install bolts (6) into
the bottom of air compressor (3).
3. Connect hose assembly (7).
Illustration 543
g01209060
Installation Procedure
Illustration 546
g00917715
Illustration 544
g01209060
RENR9717-02
151
Disassembly and Assembly Section
i02419895
Removal Procedure
Illustration 547
g00899413
Illustration 548
g01209223
Use a certified recovery and recycling cart to properly remove the refrigerant from the air conditioning system.
1. Recover the air conditioner refrigerant from
the air conditioner system. Refer to Service
Manual, SENR5664, Air Conditioning and
Heating Systems with R-134a Refrigerant for
the procedure. Refer to Special Publication,
NEDG5065, Air Conditioning Tools for the tools.
2. Disconnect the hose assemblies (not shown).
Illustration 549
g01209226
152
Disassembly and Assembly Section
RENR9717-02
Installation Procedure
Illustration 550
g01209226
Removal Procedure
g01209223
Illustration 552
g00899413
RENR9717-02
153
Disassembly and Assembly Section
Installation Procedure
1. Verify that all components of the engine oil level
gauge are clean and free of foreign material prior
to installation.
Illustration 553
g01056033
1. Lift cover (2) and remove oil level gauge (1) from
tube assembly (3).
Illustration 556
g00573473
Illustration 554
g00573452
g00573452
Illustration 555
g00573473
154
Disassembly and Assembly Section
Illustration 558
RENR9717-02
g01056033
4. Lift cover (2) and install oil level gauge (1) to tube
assembly (3).
i02423433
Illustration 559
g00922262
Installation Procedure
Removal Procedure
Note: Put identification marks on all hoses, on
all hose assemblies, on all wires, and on all tube
assemblies for installation purposes. Plug all
hose assemblies and all tube assemblies. This
helps to prevent fluid loss, and this helps to keep
contaminants from entering the system.
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 valve to the OFF position.
Illustration 560
g00922262
RENR9717-02
155
Disassembly and Assembly Section
i02421334
Removal Procedure
Table 71
Required Tools
Tool
Part
Number
Part
Description
Qty
180-3034
Repair
Stand Set
Guide Bolts
1/2 - 13 NC
by 8 inch
Start By:
a. Remove the vibration damper. Refer to
Disassembly and Assembly, Vibration Damper
- Remove and Install.
g00916552
Illustration 563
Installation Procedure
Table 72
Required Tools
Illustration 561
Tool
Part
Number
Part
Description
Qty
180-3034
Repair
Stand Set
Guide Bolts
1/2 - 13 NC
by 8 inch
g00916548
Illustration 564
g00916552
Illustration 562
g01210000
156
Disassembly and Assembly Section
RENR9717-02
g01210000
Illustration 565
Illustration 567
g00555775
Illustration 566
Required Tools
Part
Number
1U-7094
Part Description
Breaker Bar
g00555777
Tool
Illustration 568
Qty
1
RENR9717-02
Illustration 569
157
Disassembly and Assembly Section
g00555784
Illustration 571
g01056037
Disassembly Procedure
Start By:
Illustration 570
g01056036
Illustration 572
g00555790
158
Disassembly and Assembly Section
Illustration 573
RENR9717-02
g00555791
Illustration 574
g00555792
Illustration 575
Illustration 576
g01056049
Illustration 577
g01056051
g00555793
Illustration 578
g01056054
RENR9717-02
159
Disassembly and Assembly Section
g01056055
Illustration 579
Illustration 581
g01056056
Illustration 580
Assembly Procedure
Table 74
Required Tools
Tool
Part
Number
1P-0500
Driver Group
1P-0808
Multipurpose Grease
Part Description
g01056055
Qty
160
Disassembly and Assembly Section
Illustration 583
RENR9717-02
g01056109
Illustration 586
g01056051
Illustration 584
g01056054
Illustration 587
g01056049
8. Install idler pulley (8), the bearing and the lip seal
onto tightener arm (7) as a unit.
Illustration 585
g01056109
Illustration 588
g00555793
RENR9717-02
161
Disassembly and Assembly Section
i02050576
Installation Procedure
Table 75
Required Tools
Illustration 589
g00555792
Illustration 590
Part Number
1U-7094
Breaker Bar
9U-7370
1P-0808
Multipurpose Grease
g00555791
Illustration 592
Illustration 591
Tool
Part Description
Qty
g01056037
g00555790
12. Install cover (2) and the gasket to the idler pulley
with bolts (1) and the washers.
End By:
a. Install the belt tightener. Refer to Disassembly and
Assembly, Belt Tightener - Install.
Illustration 593
g01056036
162
Disassembly and Assembly Section
RENR9717-02
Illustration 596
Illustration 594
g00555784
Removal Procedure
Start By:
a. Remove the radiator. Refer to Disassembly and
Assembly, Radiator - Remove.
Illustration 595
g00555777
RENR9717-02
163
Disassembly and Assembly Section
Illustration 597
g00585927
Illustration 600
g00585940
Disassembly Procedure
Start By:
Illustration 598
g00585932
Illustration 601
Illustration 599
g00585953
g01211375
164
Disassembly and Assembly Section
RENR9717-02
Illustration 602
g01052047
Illustration 605
g01211389
Illustration 603
g01211377
Illustration 606
Illustration 607
Illustration 604
g01211385
g01211393
g01211431
RENR9717-02
Illustration 608
165
Disassembly and Assembly Section
g01211480
g01211490
Illustration 611
Assembly Procedure
Table 76
Required Tools
Illustration 609
Tool
Part
Number
1P-0510
g01211483
Illustration 612
Illustration 610
g01211485
Part Description
Driver Group
Qty
1
g01211490
166
Disassembly and Assembly Section
Illustration 613
RENR9717-02
g01211485
Illustration 616
g01212125
Illustration 614
g01211987
g01211393
Illustration 615
g01212121
RENR9717-02
Illustration 618
167
Disassembly and Assembly Section
g01211389
Illustration 619
g01211385
Illustration 621
g01052047
Illustration 622
g01211375
Installation Procedure
Illustration 620
g01211377
168
Disassembly and Assembly Section
RENR9717-02
Illustration 623
g00585940
g00590422
Illustration 624
g00586954
Illustration 626
g00585953
RENR9717-02
169
Disassembly and Assembly Section
i02422429
Removal Procedure
Illustration 627
g00585932
Illustration 629
g00564833
Illustration 628
g00585927
g00564834
End By:
a. Install the radiator. Refer to Disassembly and
Assembly, Radiator - Remove.
Illustration 631
g00564835
170
Disassembly and Assembly Section
RENR9717-02
Illustration 635
Illustration 632
g01051993
g01210391
Installation Procedure
1. Check all of the O-ring seals and the components
of the rear accessory drive for wear or damage.
Replace the components of the rear accessory
drive if it is necessary.
2. Lubricate the O-ring seals with clean engine oil
prior to installation.
Illustration 633
g01051995
Illustration 636
Illustration 634
g01210391
g00564839
RENR9717-02
171
Disassembly and Assembly Section
Illustration 640
Illustration 637
g00564839
Illustration 641
Illustration 638
g01051993
g00564835
g00564834
Illustration 642
g00564833
g01052002
172
Disassembly and Assembly Section
11. Install yoke (2) to the shaft with locknut (1) and
the washers. Tighten the locknut to the correct
torque. Refer to Specifications, Accessory Drive
(Lower Left Hand).
RENR9717-02
RENR9717-02
173
Index Section
Index
A
B
Bearing Clearance - Check .................................
Measurement Procedure .................................
Belt Tightener - Assemble ...................................
Assembly Procedure........................................
Belt Tightener - Disassemble ..............................
Disassembly Procedure ...................................
Belt Tightener - Install..........................................
Installation Procedure ......................................
Belt Tightener - Remove......................................
Removal Procedure .........................................
123
123
159
159
157
157
161
161
156
156
E
Electric Starting Motor - Remove and Install ......... 18
Installation Procedure ........................................ 18
Removal Procedure ........................................... 18
Electronic Control Module (Engine) - Remove and
Install ................................................................... 20
Installation Procedure ........................................ 20
Removal Procedure ........................................... 20
174
Index Section
RENR9717-02
121
122
121
131
131
RENR9717-02
175
Index Section
81
81
80
80
82
82
80
80
T
Table of Contents..................................................... 3
Transmission Oil Cooler - Remove and Install ...... 55
Installation Procedure ........................................ 55
Removal Procedure ........................................... 55
Turbocharger - Assemble ...................................... 28
Assembly Procedure.......................................... 28
Turbocharger - Disassemble ................................. 27
Disassembly Procedure ..................................... 27
Turbocharger - Install ............................................ 29
Installation Procedure ........................................ 29
Turbocharger - Remove ........................................ 25
Removal Procedure ........................................... 25
V
Valve Cover - Remove and Install ......................... 79
Installation Procedure ........................................ 79
Removal Procedure ........................................... 79
Valve Mechanism Cover Base - Remove and
Install ................................................................... 97
Installation Procedure ........................................ 97
Removal Procedure ........................................... 97
Vibration Damper - Remove and Install............... 100
Installation Procedure ...................................... 102
Removal Procedure ......................................... 100
W
Water Pump - Assemble........................................
Assembly Procedure..........................................
Water Pump - Disassemble ...................................
Disassembly Procedure .....................................
Water Pump - Install ..............................................
Installation Procedure ........................................
Water Pump - Remove ..........................................
Removal Procedure ...........................................
Water Temperature Regulators - Install .................
Installation Procedure ........................................
Water Temperature Regulators - Remove.............
Removal Procedure ...........................................
42
42
40
40
44
44
39
39
38
38
37
37
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All Rights Reserved
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