Renr9214 18 00 All - MANUALS SERVICE MODULES

RENR9214-18
February 2015
Disassembly and Assembly

C11 and C13 Engines for Caterpillar
Built Machines
TXE 1-Up (Engine)
TXF 1-Up (Engine)
MHX 1-Up (Engine)
RSX 1-Up (Engine)
TXX 1-Up (Engine)
SAFETY.CAT.COM
i05296198
Important Safety Information

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

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
A non-exhaustive list of operations that may cause product damage are identified by “NOTICE” labels on
the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. You must not
use this product in any manner different from that considered by this manual without first satisfying
yourself that you have considered all safety rules and precautions applicable to the operation of the
product in the location of use, including site-specific rules and precautions applicable to the
worksite. If a tool, procedure, work method or operating technique that is not specifically
recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others.
You should also ensure that you are authorized to perform this work, and that the product will not be
damaged or become unsafe by the operation, lubrication, maintenance or repair procedures that
you intend to use.
The information, specifications, and illustrations in this publication are on the basis of information that was
available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Cat dealers have the most current information available.
When replacement parts are required for this

product Caterpillar recommends using Cat re-
placement parts.
Failure to follow this warning may lead to pre-
mature failures, product damage, personal in-
jury or death.
In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
RENR9214 3
Table of Contents
Table of Contents Front Cover - Remove .................. .................. 35

Front Cover - Install .................... .................... 36
Disassembly and Assembly Section Gear Group (Front) - Remove ............ ............ 37
Gear Group (Front) - Install............... .............. 37
Fuel Filter Base - Remove and Install........ ....... 5 Housing (Front) - Remove ............... ............... 38
Fuel Transfer Pump - Remove............. ............. 5 Housing (Front) - Install ................. ................. 38
Fuel Transfer Pump - Install............... ............... 6 Accessory Drive - Remove ............... .............. 39
Electronic Unit Injector - Remove ........... .......... 6 Accessory Drive - Install ................. ................ 39
Electronic Unit Injector - Install ............. ............ 7 Valve Mechanism Cover - Remove and Install 39
Electronic Unit Injector Sleeve - Remove ..... .... 8 Valve Mechanism Cover Base - Remove and
Electronic Unit Injector Sleeve - Install ...... ..... 10 Install............................... .............................. 40
Turbocharger - Remove................. ................. 12 Valve Actuator (Variable) - Remove and Install 41
Turbocharger - Install................... ................... 12 Rocker Shaft and Pushrod - Remove....... ...... 42
Exhaust Manifold - Remove and Install ..... ..... 13 Rocker Shaft - Disassemble .............. ............. 42
Inlet Manifold - Remove................. ................. 14 Rocker Shaft - Assemble................ ................ 42
Inlet Manifold - Install................... ................... 14 Rocker Shaft and Pushrod - Install......... ........ 43
Inlet and Exhaust Valve Springs - Remove and Cylinder Head - Remove ................ ................ 43
Install............................... .............................. 14 Cylinder Head - Install .................. .................. 45
Inlet and Exhaust Valves - Remove and Install 16 Lifter Group - Remove and Install.......... ......... 47
Inlet and Exhaust Valve Guides - Remove and Camshaft - Remove.................... .................... 48
Install............................... .............................. 17 Camshaft - Install...................... ...................... 49
Inlet and Exhaust Valve Seat Inserts - Remove Camshaft Gear - Remove and Install ....... ...... 50
and Install........................... ........................... 18 Camshaft Bearings - Remove ............ ............ 50
Engine Oil Filter Base - Remove .......... .......... 19 Camshaft Bearings - Install............... .............. 51
Engine Oil Filter Base - Remove .......... .......... 19 Engine Oil Pan - Remove and Install....... ....... 52
Engine Oil Filter Base - Disassemble ....... ...... 20 Cylinder Liner - Remove ................. ................ 53
Engine Oil Filter Base - Assemble......... ......... 21 Cylinder Liner - Install ................... .................. 54
Engine Oil Filter Base - Install ............ ............ 21 Piston Cooling Jets - Remove and Install.... ... 54
Engine Oil Filter Base - Install ............ ............ 21 Pistons and Connecting Rods - Remove.... .... 55
Engine Oil Cooler - Remove.............. ............. 22 Pistons and Connecting Rods - Disassemble 56
Engine Oil Cooler - Install ................ ............... 22 Pistons and Connecting Rods - Assemble ... .. 57
Engine Oil Pump - Remove .............. .............. 23 Pistons and Connecting Rods - Install...... ...... 58
Engine Oil Pump - Disassemble........... .......... 23 Crankshaft Main Bearings - Remove....... ....... 59
Engine Oil Pump - Assemble............. ............. 24 Crankshaft Main Bearings - Install......... ......... 60
Engine Oil Pump - Install ................ ................ 25 Crankshaft - Remove................... ................... 61
Water Pump - Remove .................. ................. 25 Crankshaft - Install..................... ..................... 62
Water Pump - Disassemble.............. .............. 26 Crankshaft Gear - Remove and Install ...... ..... 63
Water Pump - Assemble................. ................ 26 Bearing Clearance - Check .............. .............. 64
Water Pump - Install .................... ................... 27 Atmospheric Pressure Sensor - Remove and
Water Temperature Regulator - Remove and Install............................... .............................. 65
Install............................... .............................. 28 Camshaft Position Sensor - Remove and
Flywheel - Remove..................... .................... 29 Install............................... .............................. 65
Flywheel - Install....................... ...................... 30 Crankshaft Position Sensor - Remove and
Crankshaft Rear Seal - Remove........... .......... 31 Install............................... .............................. 66
Crankshaft Rear Seal - Install............. ............ 31 Coolant Temperature Sensor - Remove and
Flywheel Housing - Remove and Install ..... .... 32 Install............................... .............................. 66
Vibration Damper and Pulley - Remove and Engine Oil Pressure Sensor - Remove and
Install............................... .............................. 33 Install............................... .............................. 66
Crankshaft Front Seal - Remove .......... .......... 34 Fuel Temperature Sensor - Remove and
Crankshaft Front Seal - Install ............ ............ 34 Install............................... .............................. 67
Boost Pressure Sensor - Remove and Install. 67
4 RENR9214
Table of Contents
Inlet Air Temperature Sensor - Remove and

Install............................... .............................. 68
Fan Drive Mounting Group - Remove and
Install............................... .............................. 68
Engine Control Module - Remove and Install . 70
Alternator - Remove and Install ........... ........... 70
Electric Starting Motor - Remove and Install . . 71
Index Section
Index................................ ............................... 74
Accidental machine starting can cause injury or

death to personnel working on the machine.
To avoid accidental machine starting, turn the
battery disconnect switch to the OFF position
and remove the key. If the machine is not
equipped with a battery disconnect switch,
disconnect the battery cables from the battery
and tape the battery clamps.
Place a do not operate tag at the battery
disconnect switch location to inform personnel
that the machine is being worked on.
RENR9214 5
Disassembly and Assembly Section
Disassembly and Assembly 4. Remove fuel filter base (5).
Section Installation Procedure

i02249881 NOTICE
Keep all parts clean from contaminants.
Fuel Filter Base - Remove and Contaminants may cause rapid wear and shortened
Install component life.
SMCS Code: 1262-010
S/N: BJ6; TXE1–Up

S/N: D3S; TXF1–Up
S/N: BWR; RSX1–Up
S/N: LCT; TXX1–Up
Removal Procedure
NOTICE
Contaminants may cause rapid wear and shortened
component life.
Illustration 2 g01132492
1. Position fuel filter base (5) on the engine.
2. Install bolts (4).
3. Connect hose assemblies (1) and (6).
4. Connect harness assemblies (2) and (3).
i02247172
Fuel Transfer Pump - Remove

SMCS Code: 1256-011
Illustration 1 g01132492 Removal Procedure

1. Disconnect harness assemblies (2) and (3).
2. Disconnect hose assemblies (1) and (6).
3. Remove bolts (4).

6 RENR9214
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, 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 sup-
plies suitable to collect and contain fluids on Caterpil-
lar products.
Dispose of all fluids according to local regulations and
mandates.
1. Position fuel transfer pump (4).
3. Connect tube assemblies (2).
4. Connect hose assembly (1).
i02258461
Electronic Unit Injector -

Remove
SMCS Code: 1290-011
Removal Procedure
1. Disconnect hose assembly (1).
Table 1
2. Disconnect tube assemblies (2). Required Tools
Tool Part Number Part Description Qty

A 5F-4764 Pry Bar 1
4. Remove fuel transfer pump (4).
Start By:
i02247178
a. Remove the rocker shafts. Refer to Disassembly
Fuel Transfer Pump - Install and Assembly, “Rocker Shaft and Pushrod -
Remove”.
SMCS Code: 1256-012
Installation Procedure
RENR9214 7
1. Disconnect harness assembly (1) from electronic

unit injector (2).
2. Remove bolt (3).

3. Position Tooling (A) under unit injector clamp (4) in
order to remove electronic unit injector (2).
2. Use Tooling (B) to clean injector seating (5).
i03781931 3. Use Tooling (C) to clean tip bore (6).
Electronic Unit Injector - Install Note: Do not reuse seals. Use new seals for
installation.
SMCS Code: 1290-012
4. Lubricate the bore lightly with a 50/50 mix of clean
Installation Procedure engine oil and Tooling (D).
Table 2
Required Tools
9U-6862 Tapered Brush 1

B
9U-7237 Brush Extension 1
9U-6863 Small Bore Brush 1
C
D 8T-2998 Lubricant 1
1U-5718 Vacuum Pump 1
E 169-7372 Fluid Sampling Bottle 1
4C-4057 Tube 1
NOTICE
component life.
1. Evacuate as much fuel and oil as possible from the

cylinder head before installing the injector. Several
evacuations may be necessary. Use Tooling (E) to
remove the fuel and oil from the cylinder head.
8 RENR9214
NOTICE
When an electronic unit injector is replaced, the new
electronic injector code must be programmed into the
engine's personality module software by using the
calibration menu on the Electronic Service Tool. If the
new electronic injector code is not entered, the char-
acteristics of the previous electronic unit injector is
assumed.
If it is not possible to immediately reprogram the elec-
tronic injector code into the personality module soft-
ware, the engine will not be severely harmed. The
new electronic injector code should be reprogrammed
as quickly as possible in order to optimize engine
performance.
6. Install electronic unit injector (2) and unit injector

clamp (4).
Note: Use new bolt (3).

7. Install bolt (3).
8. Connect harness assembly (1) to electronic unit

injector (2). Tighten harness assembly (1) to a
torque of 2.50 ± 0.25 N·m (22 ± 2 lb in).
End By:
a. Install the rocker shafts. Refer to Disassembly and
Assembly, “Rocker Shaft and Pushrod - Install”.
i02370015
5. When you install a new injector the E-Trim value Electronic Unit Injector Sleeve
must be programmed into the engine control - Remove
module. The injector confirmation code may need
SMCS Code: 1713-011
to be programmed into the engine control module.
E-Trim Value (X) is a twelve digit alphanumeric
code that is supplied with the data sheet that Removal Procedure
comes with the new injectors. Injector Confirmation
Code (Y) is a four digit numeric code. Both of the Type 1
codes are located on the top of electronic unit
Table 3
injector (2). Use the following menu to program the
E-Trim value. Required Tools

• ECM Summary Screen
A 9U-6891 Injector Tool Group 1
• Service Menu
• Calibration
• Injector Code Calibration

RENR9214 9
4. Tighten the nut until electronic unit injector sleeve

NOTICE
(1) is pulled free of the cylinder head assembly.
nance, testing, adjusting and repair of the product. Be Type 2
before opening any compartment or disassembling Table 4
any component containing fluids. Required Tools
Refer to Special Publication, NENG2500, “Caterpillar Part Part Description Qty
Tool
Dealer Service Tool Catalog” for tools and supplies Number
suitable to collect and contain fluids on Caterpillar
221-9778 Puller Stud 1
products.
128-7889 Bridge Puller 1
mandates. A(1) 9U-6877 Thrust Bearing 1
5P-8247 Hard Washer 1
NOTICE 4K-0367 Nut 1

Keep all parts clean from contaminants. (1) The tools that are listed in the chart are part of the 9U-6891In-
jector Tool Group.
component life.
1. Remove the electronic unit injector. Refer to
Disassembly and Assembly, “Electronic Unit
1. Remove the electronic unit injectors. Refer to Injector - Remove”.
Injector - Remove”. 2. Drain the coolant from the cooling system into a
suitable container for storage or for disposal. Refer
2. Drain the coolant from the cooling system into a to Operation and Maintenance Manual, “Capacities
suitable container for storage or for disposal. Refer (Refill)” for the capacity of the cooling system.
to Operation and Maintenance Manual, “Capacities Refer to the Operation and Maintenance Manual,
(Refill)” for the capacity of the cooling system. “Cooling System Coolant (DEAC) - Change” or
Refer to the Operation and Maintenance Manual, Operation and Maintenance Manual, “Cooling
“Cooling System Coolant (DEAC) - Change” or System Extended Life Coolant - Change”.
Operation and Maintenance Manual, “Cooling
System Extended Life Coolant - Change”.
Illustration 9 g01016237 3. Install the puller stud from Tooling (A) into unit
injector sleeve (1).
3. Install Tooling (A) into electronic unit injector sleeve
(1).
10 RENR9214
4. Install the following parts from Tooling (A) over the

stud: bridge puller, thrust bearing, hard washer and
nut.
5. Tighten the nut until unit injector sleeve (1) is pulled
free of the cylinder head assembly.
i02370001
Electronic Unit Injector Sleeve

- Install
SMCS Code: 1713-012
Type 1
Table 5
Required Tools
Part Description Qty Illustration 11 g01131579

Tool Part Number
B 4C-5552 Large Bore Brush 1 1. Use Tooling (B) to clean the electronic unit injector
9U-7237 Brush Extension 1 bore.
C
9U-7244 End Brush 1 2. Use Tooling (C) to clean the electronic unit injector
D 9U-7258 Driver Cap 1
seat.
E 4C-9507 Retaining Compound 1 3. Apply Tooling (E) to upper land (2) and lower land
(3) on the electronic unit injector sleeve.
NOTICE
Dealer Service Tool Catalog” for tools and supplies
products.
mandates.
NOTICE
component life.
4. Position electronic unit injector sleeve (1) in the

cylinder head assembly. Use Tooling (D) and a
hammer to seat the sleeve.
5. Install the electronic unit injectors. Refer to
Injector - Install”.
RENR9214 11
Note: Do not apply Tooling (E) to the cylinder head

6. Fill the cooling system with coolant. Refer to surfaces. Apply Tooling (E) on the electronic unit
Operation and Maintenance Manual, “Capacities injector sleeve only.
(Refill)” for the cooling system capacity. Refer to 3. Apply Tooling (E) to the contact surface of
Operation and Maintenance Manual, “Cooling electronic unit injector sleeve (1) on the surface
System Coolant (DEAC) - Change” or Operation that is marked “X” .
and Maintenance Manual, “Cooling System
4. Lubricate O-ring seals (2) with clean engine oil.
Extended Life Coolant - Change” for the proper
filling procedure.
Type 2
Table 6
Required Tools
9U-6862 Tapered Brush 1
9U-6863 Small Bore Brush 1

B 9U-7244 End Brush 1
4C-5552 Large Bore Brush 1

C(1) 221-9778 Puller Stud 1
D(1) 9U-7258 Driver Cap 1

5. Install Tooling (C) into the threads of electronic unit
injector sleeve (1).
E 4C-9507 Retaining Compound -
(1) Part of the 9U-6891Injector Tool Group 6. Position Tooling (C) and the electronic unit injector
sleeve in the cylinder head. Use care not to
damage the O-ring seal on the electronic unit
1. Use Tooling (B) to clean the bore in the cylinder
injector sleeve.
head for the electronic unit injector sleeve.
7. Use Tooling (D) and a hammer to install electronic
NOTICE unit injector sleeve (1) in the cylinder head.
Ensure that the electronic unit injector sleeve and the
cylinder head bore are completely free of oil, dirt, and
NOTICE
sealant debris.
Ensure that the electronic unit injector sleeve is prop-
erly seated in the cylinder head. The Tooling will
"RING" when the electronic unit injector sleeve is fully
seated in the bore of the cylinder head.
8. Remove Tooling (D) and Tooling (C). Use a clean

towel and remove excess Tooling (E).
9. Install the electronic unit injector. Refer to

10. Fill the cooling system with coolant. Refer to

Operation and Maintenance Manual, “Capacities
(Refill)” for the cooling system capacity. Refer to
Operation and Maintenance Manual, “Cooling
Illustration 13 g01120522 System Coolant (DEAC) - Change” or Operation
and Maintenance Manual, “Cooling System
2. Install new O-ring seals (2) on electronic unit Extended Life Coolant - Change” for the proper
injector sleeve (1). filling procedure.
12 RENR9214
i02247321 i04001168
Turbocharger - Remove Turbocharger - Install

SMCS Code: 1052-011 SMCS Code: 1052-012
Removal Procedure Installation Procedure

Table 7
NOTICE
Required Tools
component life. A 5P-3931 Anti-Seize Compound -
NOTICE NOTICE
Care must be taken to ensure that fluids are con- Keep all parts clean from contaminants.
nance, testing, adjusting and repair of the product. Be Contaminants may cause rapid wear and shortened
prepared to collect the fluid with suitable containers component life.
lar products.
mandates.
1. Drain the coolant system. Refer to Operation and

Maintenance Manual, “Refill Capacities and
Recommendations”.
1. Apply Tooling (A) to the turbocharger mounting

studs on the exhaust manifold.
2. Position the gasket and turbocharger (2) on the
engine.
Note: Discard the nuts after use. Use new nuts for
installation.
3. Install nuts (1).
4. Connect tube assembly (5).

5. Connect hose assemblies (3), (4), and (6).

2. Disconnect hose assemblies (3), (4), and (6).
6. Fill the coolant system. Refer to Operation and
3. Disconnect tube assembly (5). Maintenance Manual, “Refill Capacities and
Recommendations”.
1. Remove nuts (1).
2. Remove turbocharger (2) and the gasket.

RENR9214 13
i04001170 6. Remove nuts (1), the washers, and the spacers.
Exhaust Manifold - Remove 7. Remove exhaust manifold (4) and the

turbocharger.
and Install
SMCS Code: 1059-010 Installation Procedure
Table 8
Removal Procedure Required Tools

NOTICE
Keep all parts clean from contaminants. A 5P-3931 Anti-Seize Compound -

component life.
NOTICE
NOTICE Contaminants may cause rapid wear and shortened
Care must be taken to ensure that fluids are con- component life.
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Refer to Special Publication, NENG2500, “Dealer
Service Tool Catalog” for tools and supplies suitable
to collect and contain fluids on Cat products.
mandates.

Recommendations”.
1. Attach a suitable lifting device to exhaust manifold

(4) and the turbocharger. The weight of exhaust
manifold (4) and the turbocharger is approximately
41 kg (90 lb). Position exhaust manifold (4) and
the turbocharger on the engine.
2. If the taperlock studs were removed from the

cylinder head, install the taperlock studs in the
cylinder head and tighten to a torque of 35 ± 5 N·m
(26 ± 4 lb ft).
Note: Discard the nuts after use. Use new nuts for
Illustration 17 g01131639 installation.
3. Apply Tooling (A) to nuts (1). Install nuts (1), the
2. Disconnect hose assemblies (2), (3), and (6). washers, and the spacers.
3. Disconnect tube assembly (5). 4. Install oil filler tube (7).
4. Attach a suitable lifting device to exhaust manifold 5. Connect tube assembly (5).
(4) and the turbocharger. The weight of exhaust
manifold (4) and the turbocharger is approximately 6. Connect hose assemblies (2), (3), and (6).
41 kg (90 lb).
5. Remove oil filler tube (7).

14 RENR9214

Recommendations”.
i02540834
Inlet Manifold - Remove

SMCS Code: 1058-011
Removal Procedure
1. Install the gasket, inlet manifold (4), and bolts (1).
2. Connect sensor (2) and sensor (3).
i02247521
Inlet and Exhaust Valve

Springs - Remove and Install
SMCS Code: 1108-010
1. Disconnect sensor (2) and sensor (3). Removal Procedure

Table 9
2. Remove bolts (1), inlet manifold (4), and the Required Tools
gasket.
i02540831 Valve Spring Compression

A 235-0518 1
Group
Inlet Manifold - Install
SMCS Code: 1058-012 Start By:
a. Remove the electronic unit injectors. Refer to
Installation Procedure Disassembly and Assembly, “Electronic Unit
Injector - Remove”.
NOTICE
component life.
Note: The following procedure is for the removal of

the inlet valve springs and the exhaust valve springs
without removing the cylinder head. This procedure
can be performed on only one cylinder at a time. This
will prevent the inlet valves and the exhaust valves
from falling into the cylinder.
RENR9214 15
1. Rotate the crankshaft in order to bring the piston to Table 10
the top center position in the cylinder. Required Tools
Valve Spring Compression

A 235-0518 1
Group
NOTICE
component life.
Personal injury can result from being struck by

parts propelled by a released spring force.
Make sure to wear all necessary protective
equipment.
Follow the recommended procedure and use all
recommended tooling to release the spring force.
2. Install Tooling (A) on the cylinder head.
3. Remove retainer locks (1).
4. Remove Tooling (A). Personal injury can result from being struck by
5. Remove valve rotators (2).
Make sure to wear all necessary protective
6. Remove valve springs (3) and valve springs (4) equipment.
from each valve. Follow the recommended procedure and use all
7. Remove bases (5) from the cylinder head.
Note: Install the valve springs before you rotate the 1. Install bases (5) for the valve springs.
crankshaft.
2. Install valve springs (4) and valve springs (3).
3. Install valve rotators (2).

16 RENR9214
4. Install Tooling (A).
5. Install retainer locks (1).
6. Remove Tooling (A).

End By:
a. Install the electronic unit injectors. Refer to
i02247841
Inlet and Exhaust Valves -

Remove and Install
SMCS Code: 1105-010
Removal Procedure
Table 11
Required Tools
A 5S-1330 Valve Spring Compressor 1
Start By:
a. Remove the cylinder head. Refer to Disassembly
and Assembly, “Cylinder Head - Remove”.
NOTICE
Keep all parts clean from contaminants. Personal injury can result from being struck by
component life. Make sure to wear all necessary protective
equipment.
Follow the recommended procedure and use all
1. Use Tooling (A) to remove retainer locks (1).
2. Remove valve rotators (2).
3. Remove valve springs (3) and valve springs (4).
4. Remove base (5).
5. Remove valves (6) from the cylinder head.
6. Remove valve seals (7).
Table 12
Required Tools
A 5S-1330 Valve Spring Compressor 1

RENR9214 17
i04496931
Inlet and Exhaust Valve Guides

- Remove and Install
SMCS Code: 1104-010
Removal Procedure
Table 13
Required Tools
A 1U-9169 Valve Guide Driver 1
Start By:
a. Remove the inlet valves and exhaust valves. Refer
to Disassembly and Assembly, “Inlet and Exhaust
Valves - Remove and Install”.
NOTICE
component life.
The valve keepers can be thrown from the valve

when the valve spring compressor is released.
Ensure that the valve keepers are properly in-
stalled on the valve stem. To help prevent person-
al injury, keep away from the front of the valve
keepers and valve springs during the installation
of the valves.
Note: A small amount of grease can be used to hold

the retainer locks in position during installation. Illustration 25 g01015291
1. Lubricate valves (6) with clean engine oil. Install
the valves in the cylinder head assembly. 1. Use Tooling (A) to remove the valve guides from
the cylinder head assembly.
2. Install valve seals (7).
3. Install base (5). Table 14
4. Install valve springs (3) and valve springs (4). Required Tools

5. Install valve rotators (2).
124-9057 Guide Collar 1
6. Use Tooling (A) to install retainer locks (1). B
9U-6895 Valve Guide Driver 1
End By:
a. Install the cylinder head. Refer to Disassembly and
Assembly, “Cylinder Head - Install”.
18 RENR9214
Start By:
NOTICE
Keep all parts clean from contaminants. a. Remove the inlet and exhaust valves. Refer to
Disassembly and Assembly, “Inlet and Exhaust
Contaminants may cause rapid wear and shortened Valves - Remove and Install”.
component life.
NOTICE
component life.
1. Use Tooling (A) to remove valve seat inserts (1).
1. Use Tooling (B) to install valve guides (1). Install
the valve guides until Length (X) is 20.0 ± 0.5 mm
Table 16
(0.79 ± 0.02 inch) above the cylinder head
assembly. Required Tools
End By: Tool Part Number Part Description Qty
1U-9170 Valve Seat Driver(1) 1

a. Install the inlet valves and exhaust valves. Refer to B
Disassembly and Assembly, “Inlet and Exhaust 9U-6898 Valve Seat Driver(2) 1
(1) INLET
(2) EXHAUST
i04526310
Inlet and Exhaust Valve Seat NOTICE

Inserts - Remove and Install
SMCS Code: 1103-010 component life.
Removal Procedure
Table 15
Required Tools
A 166-7441 Valve Seat Extractor Tool 1

RENR9214 19
NOTICE
lar products.
mandates.
Note: Do not machine the prefinished valve seat

inserts in order to correct the valve stem projection.
An excessive valve stem projection indicates that the
valve seat insert is not seated or material was not
cleaned from the bottom of the counterbore.
1. Lower the temperature of new valve seat inserts
(1).
2. Use Tooling (B) to install the new valve seat inserts

in the cylinder head assembly.
End By:
a. Install the inlet and exhaust valves. Refer to
Disassembly and Assembly, “Inlet and Exhaust
i02247933
Engine Oil Filter Base -

Remove
SMCS Code: 1306-011
1. Disconnect hose assemblies (2), (5), and (6).
Removal Procedure
2. Remove bolts (1) and (4).
NOTICE
Keep all parts clean from contaminants. 3. Remove oil filter base (3) and the gasket.
Contaminants may cause rapid wear and shortened i02285414

component life.
Remove
SMCS Code: 1306-011
Removal Procedure
Table 17
Required Tools
A 185-3630 Strap Wrench As 1

20 RENR9214
i01942432
NOTICE
component life.
Disassemble
SMCS Code: 1306-015
NOTICE Disassembly Procedure

lar products.
mandates.
Personal injury can result from parts and/or cov-

ers 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) High Pressure Relief Valve

(2) Pump Bypass Valve
1. Use Tooling (A) to remove oil filter (4) from engine
oil filter base (3). (3) Oil Filter Bypass Valve
(4) Oil Cooler Bypass Valve
3. Remove bolts (1) and bolts (5) (not shown).
4. Remove engine oil filter base (3) and the gasket.

RENR9214 21
i01942433 i02285615
Engine Oil Filter Base - Engine Oil Filter Base - Install

Assemble SMCS Code: 1306-012
SMCS Code: 1306-016
Assembly Procedure NOTICE
component life.
Improper assembly of parts that are spring loaded

can cause bodily injury. Illustration 33 g01143629
To prevent possible injury, follow the established 1. Position the gasket and engine oil filter base (3) on
assembly procedure and wear protective the engine.
equipment.
2. Install bolts (1) and bolts (5) (not shown).
(1) High Pressure Relief Valve
(2) Pump Bypass Valve
4. Install oil filter (4) on engine oil filter base (3).
(3) Oil Filter Bypass Valve
i02248041
(4) Oil Cooler Bypass Valve
Engine Oil Filter Base - Install
SMCS Code: 1306-012
NOTICE
component life.
22 RENR9214

Recommendations”.
3. Disconnect hose (4).

1. Position oil filter base (3) and the gasket on the
engine. 4. Attach a suitable lifting device to engine oil cooler
(3). The weight of engine oil cooler (3) is
2. Install bolts (1) and (4).
approximately 23 kg (50 lb).
3. Connect hose assemblies (2), (5), and (6).
5. Remove bolts (5) and (6).
i02248045 6. Remove bonnet (1).
Engine Oil Cooler - Remove 7. Remove engine oil cooler (3).

SMCS Code: 1378-011
i02248059
Removal Procedure Engine Oil Cooler - Install

NOTICE SMCS Code: 1378-012
component life.
NOTICE
NOTICE Contaminants may cause rapid wear and shortened
Care must be taken to ensure that fluids are con- component life.
lar products.
mandates.
RENR9214 23
NOTICE
component life.
1. Attach a suitable lifting device to engine oil cooler

(3). The weight of engine oil cooler (3) is
2. Position engine oil cooler (3) on the engine.
3. Install bonnet (1).
4. Install bolts (5) and (6).
5. Connect hose (4).

7. Fill the coolant system. Refer to Operation and 1. Disconnect tube assembly (1) and tube assembly
Maintenance Manual, “Refill Capacities and (2).
Recommendations”.
i02290926 3. Remove bolts (4).
Engine Oil Pump - Remove 4. Remove engine oil pump (3).

SMCS Code: 1304-011
i02248248
Removal Procedure Engine Oil Pump -

NOTICE Disassemble
SMCS Code: 1304-015
prepared to collect the fluid with suitable containers Disassembly Procedure
before opening any compartment or disassembling Table 18
Required Tools
Tools and Shop Products Guide” for tools and sup- Tool Part Number Part Description Qty
plies suitable to collect and contain fluids on Caterpil- 5F-7344 Puller Block 1
lar products.
A 7S-7786 Puller Leg 1
mandates. 5F-7345 Screw 1
24 RENR9214
Start By:
a. Remove the engine oil pump. Refer to
Disassembly and Assembly, “Engine Oil Pump -
Remove”.
1. Remove elbow (1) from cover (2).
3. Remove cover (2) from engine oil pump (4).
4. Use Tooling (A) in order to remove gear (7).
5. Remove shaft assembly (5) and shaft assembly (8)

from engine oil pump (4).
6. Remove oil seal (6).
1. Install shaft assembly (5) and shaft assembly (8)
i02248255 into engine oil pump (4).
Engine Oil Pump - Assemble 2. Install oil seal (6).

SMCS Code: 1304-016 3. Install cover (2) onto engine oil pump (4).
Assembly Procedure 4. Install bolts (3).
5. Raise the temperature of gear (7).

RENR9214 25
6. Install gear (7). Dimension (X) is 29.40 ± 0.50 mm

NOTICE
(1.158 ± 0.020 inch).
7. Install elbow (1) onto cover (2).
End By: prepared to collect the fluid with suitable containers
a. Install the engine oil pump. Refer to Disassembly any component containing fluids.
and Assembly, “Engine Oil Pump - Install”.
i02290931
lar products.
Engine Oil Pump - Install
SMCS Code: 1304-012 Dispose of all fluids according to local regulations and
mandates.
Recommendations”.
1. Position engine oil pump (3).

4. Connect tube assembly (1) and tube assembly (2).
4. Remove housing (3).
i02248284
5. Remove bracket (4).
Water Pump - Remove 6. Remove tube assembly (5).
SMCS Code: 1361-011
Removal Procedure
NOTICE
component life.
26 RENR9214
Illustration 45 g01132005 Illustration 46 g01132114
7. Remove tube assembly (6). 1. Remove elbow assembly (1).
8. Remove belt tensioner (7). 2. Remove cover (3) from housing assembly (7).
Remove O-ring seal (2) and O-ring seal (4).
3. Hold hex washer (14). Remove hex socket head
10. Remove water pump (9). bolt (15).
i03418322 4. Remove bearing (13).
Water Pump - Disassemble 5. Use Tooling (C) in order to remove gear (12).
SMCS Code: 1361-015 6. Use Tooling (B) in order to remove retaining ring
(11). Remove inner bearing (10).
Disassembly Procedure 7. Use Tooling (A) in order to remove impeller (5).
Table 19
Required Tools 8. Use a suitable press to remove shaft assembly (9)
from housing assembly (7).
Puller Gp
9. Remove water seal (6).
A 5F-7465 1
B 1P-1861 Retaining Ring Pliers 1 10. Remove oil seal (8).

C 1P-2320 Combination Puller 1
i05563196
Start By: Water Pump - Assemble

a. Remove the water pump. Refer to Disassembly SMCS Code: 1361-016
and Assembly, “Water Pump - Remove”.
NOTICE
Assembly Procedure
Keep all parts clean from contaminants. Table 20
Required Tools
component life. Tool Part Number Part Description Qty
(continued)
RENR9214 27
(Table 20, contd) 2. Use Tooling (D) in order to install oil seal (8). Install
B 1P-1861 Retaining Ring Pliers 1 the oil seal with the part number toward the
housing assembly. Ensure that the oil seal is flush
D 138-9299 Seal Guide 1
with the housing assembly. Do not lubricate the oil
E 139-0088 Seal Installer 1 seal.
F 169-5464 Quick Cure Primer - 3. Install inner bearing (10) onto shaft assembly (9).
4. Install shaft assembly (9) into housing assembly

NOTICE (7).
5. Use Tooling (B) in order to install retaining ring (11).
component life.
6. Use Tooling (E) and a suitable press in order to
install water seal (6) onto shaft assembly (9).
Install the water seal with the part number
UPWARD. Ensure that the water seal is flush
against the housing assembly. Do not lubricate the
seal.
7. Use a suitable press in order to install impeller (5)
onto shaft assembly (9). The top of impeller (5)
should be installed to Depth (X) below the surface
of the housing assembly. Depth (X) is
8.40 ± 0.25 mm (0.331 ± 0.010 inch).
8. Use a suitable press in order to install gear (12).
9. Install bearing (13). Ensure that the bearing is flush

with the gear.
10. Install hex washer (14) and hex socket head bolt
(15).
11. Install O-ring seal (2) and O-ring seal (4) in cover
(3). Install cover (3) on housing assembly (7).
12. Install elbow assembly (1).
End By:
a. Install the water pump. Refer to Disassembly and
Assembly, “Water Pump - Install”.
i02248713
Water Pump - Install

SMCS Code: 1361-012
1. Use Tooling (F) in order to clean shaft assembly (9)

and the counterbore in housing assembly (7).
28 RENR9214

Recommendations”.
i02248748
Water Temperature Regulator -

Remove and Install
SMCS Code: 1355-010
Removal Procedure
NOTICE
component life.
NOTICE
1. Position water pump (9). Care must be taken to ensure that fluids are con-
2. Install bolts (8). nance, testing, adjusting and repair of the product. Be
3. Install belt tensioner (7). before opening any compartment or disassembling
4. Install tube assembly (6).
lar products.
mandates.

Recommendations”.
5. Install tube assembly (5).
6. Install bracket (4).
7. Install housing (3).

RENR9214 29
2. Disconnect hose assembly (1). 1. Install the water temperature regulator.
3. Remove bolts (2). 2. Install housing (3).
4. Remove housing (3). 3. Install bolts (2).
5. Remove the water temperature regulator. 4. Connect hose assembly (1).
Installation Procedure 5. Fill the coolant system. Refer to Operation and

NOTICE Recommendations”.
i02249234
component life.
Flywheel - Remove
SMCS Code: 1156-011
Removal Procedure
Table 21
Required Tools
A 138-7574 Link Bracket 1

B FT2712 Guide Stud 1
30 RENR9214
1. Raise the temperature of the ring gear. Position the

ring gear with the part number toward the
crankshaft. Install the ring gear on the flywheel.
Allow the ring gear to cool. Use a soft hammer in
order to seat the ring gear against the shoulder of
the flywheel.
1. Attach Tooling (A) and a suitable lifting device to

flywheel (2). The weight of flywheel (2) is
2. Remove top bolt (1). Install Tooling (B).

3. Remove remaining bolts (1).
4. Remove flywheel (2).
flywheel (2). The weight of flywheel (2) is
5. Use a hammer and a punch in order to remove the approximately 79 kg (175 lb).
ring gear.
3. Position flywheel (2) on Tooling (B).
i02249247 4. Install bolts (1). Remove Tooling (B). Install

remaining bolt (1). Tighten the bolts evenly to a
Flywheel - Install torque of 300 ± 40 N·m (221 ± 30 lb ft).
SMCS Code: 1156-012
5. Check the flywheel runout. Refer to Testing and
Adjusting, “Flywheel - Inspect” for the correct
Installation Procedure procedure.
Table 22
Required Tools

B FT2712 Guide Stud 1
Always wear protective gloves when handling

parts that have been heated.
RENR9214 31
i06010889 Note: Refer to Reuse and Salvage Guidelines,

SEBF9217, “Specifications for Crankshafts C7, C9,
Crankshaft Rear Seal - Remove C-9, C10, C11, C12, C-12, C13, C-13, C15, C-15,
C18, C-18, C27, C30, and C32 Engines” or the
SMCS Code: 1161-011 correct specifications of the crankshaft.
Removal Procedure i06010890

Start By:
Crankshaft Rear Seal - Install
a. Remove the flywheel. Refer to Disassembly and
Assembly, “Flywheel - Remove”. SMCS Code: 1161-012
NOTICE Installation Procedure

Care must be taken to ensure that fluids are con- Table 23
Required Tools
Be prepared to collect the fluid with suitable contain- Tool Part Number Part Description Qty
bling any component containing fluids. A - Loctite 7649 Primer N -
Loctite 620 Retaining
Refer to Special Publication, NENG2500, “Dealer B -
Compound
-
Service Tool Catalog” for tools and supplies suitable
to collect and contain fluids on Cat products. C 147-2675 Wear Sleeve Installer 1

mandates. NOTICE
component life.
2. Remove crankshaft rear seal (2).

Note: Refer to Reuse and Salvage Guidelines,
SEBF8039, “Crankshaft Visual Inspection and
Magnetic Particle Inspection” for the correct
inspection procedure of the crankshaft seal surface.
32 RENR9214
b. Use Tooling (A) to clean the outside diameter

of the crankshaft and the inside diameter of the
crankshaft wear sleeve.
c. Apply Tooling (B) to the outside diameter of the
crankshaft and the inside diameter of the
crankshaft wear sleeve.
d. Use Tooling (C) to install the crankshaft wear
sleeve.
Note: Leave the shipping sleeve in place to install the

crankshaft rear seal. The crankshaft rear seal must
be installed dry.
Note: If the seal group, O-ring seal, and the shipping
sleeve are separated, these components should not
be used.
2. Lubricate the O-ring seal with clean engine oil that
is on the back of the crankshaft rear seal (1).
3. Position crankshaft rear seal (1) and the shipping
sleeve over the crankshaft. Push crankshaft rear
seal (1) in place to dislodge the shipping sleeve.
Note: Do not remove the shipping sleeve until bolts
(2) are installed.
4. Install new bolts (2) hand tight. Then, tighten bolts

(2) in numerical sequence, shown in Illustration 57
. Tighten bolts (2) to a torque of 12 ± 3 N·m
(106 ± 27 lb in).
End By:
a. Install the flywheel. Refer to Disassembly and
Assembly, “Flywheel - Install”.
Illustration 57 g03698745 i02249340

Numerical tightening sequence for bolts (2).
Flywheel Housing - Remove
Note: If required, install a crankshaft wear sleeve at
engine overhaul. For more information please refer to and Install
the following Reuse and Salvage Guidelines. Refer to SMCS Code: 1157-010
Reuse and Salvage Guidelines, SEBF9217,
“Specifications for Crankshafts C7, C9, C-9, C10,
C11, C12, C-12, C13, C-13, C15, C-15, C18, C-18, Removal Procedure
C27, C30, and C32 Engines” or the correct Start By:
specifications of the crankshaft. Refer to Reuse and
Salvage Guidelines, SEBF8039, “Crankshaft Visual a. Remove the electric starting motor. Refer to
Inspection and Magnetic Particle Inspection” for the Disassembly and Assembly, “Electric Starting
correct inspection procedure of the crankshaft seal Motor - Remove and Install”.
surface. b. Remove the flywheel. Refer to Disassembly and
1. If a crankshaft wear sleeve is necessary, refer to Assembly, “Flywheel - Remove”.
Step 1.a. through Step 1.d. to install the crankshaft
wear sleeve. If a crankshaft wear sleeve is not 1. Support the engine.
necessary, refer to Step 2.
a. Clean and polish the crankshaft of

imperfections.
RENR9214 33
End By:
a. Install the flywheel. Refer to Disassembly and
Assembly, “Flywheel - Install”.
b. Install the electric starting motor. Refer to
Disassembly and Assembly, “Electric Starting
Motor - Remove and Install”.
i02249982
Vibration Damper and Pulley -

Remove and Install
SMCS Code: 1205-010
Removal Procedure
2. Attach a suitable lifting device to flywheel housing
(2). The weight of flywheel housing (2) is
3. Remove bolts (1) and flywheel housing (2).
Table 24
Required Tools
A 1U-8846 Gasket Sealant 1
1. Apply Tooling (A) to the face of the cylinder block.
1. Remove belt (1).
2. Attach a suitable lifting device to crankshaft

2. Attach a suitable lifting device to flywheel housing
vibration damper and pulley (3). The weight of
(2). The weight of flywheel housing (2) is
crankshaft vibration damper and pulley (3) is
approximately 62 kg (137 lb). Position flywheel
approximately 27 kg (60 lb). Remove bolts (2).
housing (2) on the rear of the cylinder block.
3. Remove crankshaft vibration damper and pulley
(3).
34 RENR9214
1. Remove nuts (1).
2. Remove crankshaft front seal (2).
i05028942
Crankshaft Front Seal - Install

SMCS Code: 1160-012
NOTICE
1. Attach a suitable lifting device to crankshaft Keep all parts clean from contaminants.
vibration damper and pulley (3). The weight of
crankshaft vibration damper and pulley (3) is Contaminants may cause rapid wear and shortened
approximately 27 kg (60 lb). Position crankshaft component life.
vibration damper and pulley (3) on the engine.
Note: Leave the shipping sleeve in place in order to
install the crankshaft front seal. The crankshaft front
seal must be installed dry.
3. Install belt (1).
i02250084
Crankshaft Front Seal -

Remove
SMCS Code: 1160-011
Removal Procedure
Start By:
a. Remove the crankshaft vibration damper and
pulley. Refer to Disassembly and Assembly,
“Vibration Damper and Pulley - Remove and
Install”.
NOTICE
component life.
RENR9214 35
i02580162
Front Cover - Remove

SMCS Code: 1166-011
Removal Procedure
Start By:
a. Remove the fuel transfer pump. Refer to
Disassembly and Assembly, “Fuel Transfer Pump -
Remove”.
b. Remove the fan drive mounting group. Refer to
Disassembly and Assembly, “Fan Drive Mounting
Group - Remove and Install”.
c. Remove the crankshaft front seal. Refer to
Disassembly and Assembly, “Crankshaft Front
Seal - Remove”.
NOTICE
component life.
NOTICE
1. Position crankshaft front seal (2) on the crankshaft Refer to Special Publication, NENG2500, “Caterpillar
to dislodge the shipping sleeve. Dealer Service Tool Catalog” for tools and supplies
2. Install nuts (1). Tighten nuts (1) in a numerical products.
sequence.
mandates.
36 RENR9214
1. Remove bolts (1). Note: The rear face of cover (3) and the front face of
the housing must be clean.
2. Remove bolt (4). 1. Inspect the condition of the gasket. Replace the
gasket, if necessary.
3. Remove studs (2).
2. Position the gasket and cover (3) on the front
4. Remove cover (3) and the gasket. housing.
i02580172 3. Install studs (2).
Front Cover - Install Note: Bolt (4) is a through bolt. Apply Tooling (A) to
SMCS Code: 1166-012 the threads prior to installation.
4. Install bolt (4).
Installation Procedure 5. Install bolts (1).
Table 25
End By:
Required Tools
Tool Part Number Part Description Qty a. Install the crankshaft front seal. Refer to
Disassembly and Assembly, “Crankshaft Front
A 9S-3263 Thread Lock Compound - Seal - Install”.
b. Install the fan drive mounting group. Refer to
Disassembly and Assembly, “Fan Drive Mounting
NOTICE Group - Remove and Install”.
c. Install the fuel transfer pump. Refer to Disassembly
Contaminants may cause rapid wear and shortened and Assembly, “Fuel Transfer Pump - Install”.
component life.
RENR9214 37
i03384190 i01950583
Gear Group (Front) - Remove Gear Group (Front) - Install


Start By:
NOTICE
a. Remove the front cover. Refer to Disassembly and Keep all parts clean from contaminants.
Assembly, “Front Cover - Remove”.
component life.
NOTICE
component life.
Note: Align the timing marks on the idler gear with the
marks on the crankshaft gear and the camshaft gear
before removal.
1. Install the following items in the front housing: gear

(4), the bearing and shaft (5) and bolt (6).
2. Install the following items in the front housing: gear

(1), the bearing and shaft (2) and bolt (3).
Illustration 67 g01014874 Note: Make sure that the timing marks on the gears
are in alignment.
1. Remove the following items from the front housing: End By:
bolt (3), the bearing and shaft (2) and gear (1).
a. Install the front cover. Refer to Disassembly and
2. Remove the following items from the front housing: Assembly, “Front Cover - Install”.
bolt (6), the bearing and shaft (5) and gear (4).
38 RENR9214
i02250160 i02250365
Housing (Front) - Remove Housing (Front) - Install


Start By:
a. Remove the engine oil pump. Refer to
Disassembly and Assembly, “Engine Oil Pump -
Remove”.
b. Remove the water pump. Refer to Disassembly
and Assembly, “Water Pump - Remove”.
c. Remove the camshaft. Refer to Disassembly and
Assembly, “Camshaft - Remove”.
d. Remove the front gear group. Refer to
Disassembly and Assembly, “Gear Group (Front) -
Remove”.
e. Remove the crankshaft position sensor. Refer to
Disassembly and Assembly, “Crankshaft Position
Sensor - Remove and Install”.
1. Position front housing (3) on the engine.
3. Tighten the oil pan bolts.
4. Install front engine mount (4).
5. Connect sensor (1).

End By:
a. Install the crankshaft position sensor. Refer to
Disassembly and Assembly, “Crankshaft Position
b. Install the front gear group. Refer to Disassembly
Illustration 69 g01132684 and Assembly, “Gear Group (Front) - Install”.
1. Disconnect sensor (1). c. Install the camshaft. Refer to Disassembly and

Assembly, “Camshaft - Install”.
2. Support the engine. d. Install the water pump. Refer to Disassembly and
Assembly, “Water Pump - Install”.
3. Remove front engine mount (4).
e. Install the engine oil pump. Refer to Disassembly
4. Loosen the oil pan bolts in order to allow the front and Assembly, “Engine Oil Pump - Install”.
of the oil pan to drop.
6. Remove front housing (3).

RENR9214 39
i02250527
Accessory Drive - Remove

SMCS Code: 1207-011
Removal Procedure
Table 26
Required Tools
8H-0663 Bearing Puller Gp 1

A
8B-7551 Bearing Puller Gp 1
1. Raise the temperature of the bearing.
2. Lower the temperature of gear (3).
3. Install the bearing into gear (3).
4. Install gear (3), cover (2), and bolts (1).
i02932823
Valve Mechanism Cover -

Remove and Install
SMCS Code: 1107-010
1. Remove bolts (1), cover (2), and gear (3).

Removal Procedure
Note: Put identification marks on all hoses, on all
2. Use Tooling (A) and a suitable press in order to hose assemblies, on all wires, and on all tube
remove the bearings from gear (3). assemblies for installation purposes. Plug all hose
assemblies and all tube assemblies. This helps to
i01943324 prevent fluid loss, and this helps to keep
contaminants from entering the system.
Accessory Drive - Install Note: Cleanliness is an important factor. Before you
SMCS Code: 1207-012 begin the removal procedure, the exterior of the
components should be thoroughly cleaned. This will
Installation Procedure help to prevent dirt from entering the internal
mechanism.
40 RENR9214
1. Remove bolts (2), the washers, and isolator 1. Position isolator seal (4) and valve mechanism
assembly (3). cover (1).
2. Remove valve mechanism cover (1) and isolation 2. Install isolation assembly (3), the washers, and
seal (4). bolts (2).
Installation Procedure i03390484
Note: Cleanliness is an important factor. Before

assembly, thoroughly clean all parts in cleaning fluid. Valve Mechanism Cover Base -
Allow the parts to air dry. Do not use wiping cloths or Remove and Install
rags to dry parts. Lint may be deposited on the parts
which may cause trouble. Inspect all parts. If any SMCS Code: 1120-010
parts are worn or damaged, use new parts for
replacement. Dirt and other contaminants can Removal Procedure
damage the precision component. Perform assembly
procedures on a clean work surface. Keep Start By:
components covered and protected at all times. a. Remove the valve mechanism cover. Refer to
Disassembly and Assembly, “Valve Mechanism
Note: Check the isolator seal for wear or for damage. Cover - Remove and Install”.
Replace the components, if necessary.
RENR9214 41
i05563189
Valve Actuator (Variable) -

Remove and Install
SMCS Code: 1105-010
Removal Procedure
Start By:
a. Remove the valve cover. Refer to Disassembly and
Assembly, “Valve Mechanism Cover - Remove and
Install”.
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
1. Disconnect harness assemblies (2) and harness assemblies and all tube assemblies. This helps to
assembly (4). prevent fluid loss, and helps to keep contaminants
from entering the system.
2. Disconnect hose (5).
Note: Cleanliness is an important factor. Before you
3. Remove bolts (3). begin the removal procedure, the exterior of the
components should be cleaned thoroughly. This will
4. Remove valve mechanism cover base (1). help to prevent dirt from entering the internal
mechanism.
1. Disconnect harness assemblies (3). Remove bolts

1. Position valve mechanism cover base (1) on the (1) and nuts (2). Remove valve actuator (4).
engine.
Note: Cleanliness is an important factor. Before
3. Connect hose (5). assembly, thoroughly clean all parts in cleaning fluid.
Allow the parts to air dry. Do not use wiping cloths or
4. Connect harness assemblies (2) and harness rags to dry parts. Lint may be deposited on the parts
assembly (4). which may cause trouble. Inspect all parts. If any
End By: parts are worn or damaged, use new parts for
replacement. Dirt and other contaminants can
a. Install the valve mechanism cover. Refer to damage the precision component. Perform assembly
Disassembly and Assembly, “Valve Mechanism procedures on a clean work surface. Keep
Cover - Remove and Install”. components covered and protected at all times.
Note: Check the O-ring seals, the gaskets, and the

seals for wear or for damage. Replace the
components, if necessary.
42 RENR9214
i02251334
Rocker Shaft - Disassemble

SMCS Code: 1102-015
Disassembly Procedure
Table 27
Required Tools
A 1P-0510 Driver Gp 1
Start By:
Illustration 78 g01265475 a. Remove the rocker shaft. Refer to Disassembly
and Assembly, “Rocker Shaft and Pushrod -
1. Position valve actuator (4). Install bolts (1) and nuts Remove”.
(2). Tighten bolts (1) to a torque of 100 ± 20 N·m
(74 ± 15 lb ft). Connect harness assemblies (3).
2. Adjust the valve actuators. Refer to Testing and

Adjusting, “Compression Brake Lash- Adjust” for
the proper procedure.
End By:
a. Install the valve cover. Refer to Disassembly and
Assembly, “Valve Mechanism Cover - Remove and
Install”.
i02540277
Rocker Shaft and Pushrod -

Remove
SMCS Code: 1102-011; 1208-011 Note: Place an identification mark on all components
for assembly purposes.
Removal Procedure Note: Stand (5) has an offset hole.
1. Remove stands (1).
2. Remove rocker arms (2), rocker arms (3), rocker

arms (4), and stand (5) from shaft (6).
3. Use Tooling (A) to remove the bushings from the

rocker arms.
i04398594
Rocker Shaft - Assemble

SMCS Code: 1102-016
Assembly Procedure
Illustration 79 g01271795 Table 28
Required Tools
1. Remove the valve cover.
A 1P-0510 Driver Gp 1
3. Remove rocker arm shaft (2) and pushrods (3).
RENR9214 43
1. Use Tooling (A) to install the bushings for the

rocker arms. For correct bearing dimensions, refer
to Specifications, “Electronic Unit Injector Rocker
Arm” and Specifications, “Valve Mechanism”.
1. Position pushrods (3) and rocker arm shaft (2).
3. Adjust the engine valve lash. Refer to Testing and
Adjusting, “Engine Valve Lash - Inspect/Adjust”.
2. Install stand (5), rocker arms (4), rocker arms (3),
4. Install the valve cover.
and rocker arms (2) onto shaft (6).
i02250725
Note: Stand (5) has an offset hole.
Note: Tighten the nuts on rocker arms (4), rocker

Cylinder Head - Remove
arms (3), and rocker arms (2) to 6 ± 3 N·m SMCS Code: 1100-011
(53 ± 27 lb in). The free running torque of the screws
must not exceed 0.4 N·m (3.5 lb in). Removal Procedure
3. Install stands (1).
Start By:
End By:
a. Remove the valve mechanism cover base. Refer to
a. Install the rocker shaft. Refer to Disassembly and Disassembly and Assembly, “Valve Mechanism
Assembly, “Rocker Shaft and Pushrod - Install”. Cover Base - Remove and Install”.
b. Remove the electronic unit injectors. Refer to
i02540278 Disassembly and Assembly, “Electronic Unit
Injector - Remove”.
Rocker Shaft and Pushrod -
Install NOTICE
SMCS Code: 1102-012; 1208-012
component life.
44 RENR9214
NOTICE
lar products.
mandates.

Recommendations”.
7. Disconnect harness assembly (8).
2. Disconnect hose assemblies (1) and (6).
3. Disconnect harness assemblies (3) and (5) (not

shown).
4. Remove oil level gauge tube (2). Illustration 85 g01132970
5. Remove the bracket assembly and fuel filter base

8. Disconnect hose assemblies (11), (12), (13), and
(4).
(16).
9. Disconnect tube assembly (15).
10. Remove the cover for water regulator housing

(14).
11. Attach a suitable lifting device to cylinder head

(10). The weight of cylinder head (10) is
approximately 227 kg (500 lb). Remove bolts (9).
RENR9214 45
12. Remove cylinder head (10).
i05848128
Cylinder Head - Install

SMCS Code: 1100-012
Table 29
Required Tools
A 4C-5593 Anti-Seize Compound -
NOTICE
component life.
1. Thoroughly clean the mating surfaces of the

cylinder head and the cylinder block.
2. Install the correct cylinder head gasket on the

cylinder block.
46 RENR9214
3. Attach a suitable lifting device to cylinder head

(10). The weight of cylinder head (10) is f. Tighten Bolt (1) through Bolt (26) again in a
approximately 227 kg (500 lb). Position cylinder numerical sequence to a torque of
head (10) on the engine block. 170 ± 10 N·m (125 ± 7 lb ft).
4. Lubricate the bolt threads, the underside of the bolt g. Place a mark on Bolt (1) through Bolt (26).
heads, and the washers on Bolt (1) through Bolt Rotate Bolt (1) through Bolt (26) in a numerical
(26) with Tooling (A) prior to assembly. sequence for an additional 120 ± 5 degrees (1/
3 turn).
5. Install bolts (9). Refer to Step 6 for the correct
tightening procedure. h. Tighten Bolt (27) through Bolt (34) in a
numerical sequence to a torque of
Note: Refer to Reuse and Salvage Guideline, 55 ± 10 N·m (41 ± 7 lb ft).
SEBF8301, “Inspection and Reuse of Critical
Fasteners Used in All Engines” for reuse criteria of 7. Install the cover for water regulator housing (14).
cylinder head bolts.
8. Connect tube assembly (15).
6. Tighten the cylinder head bolts according to the
following procedure: 9. Connect hose assemblies (11), (12), (13), and (16).
a. Tighten Bolt (1) through Bolt (26) in a
170 ± 10 N·m (125 ± 7 lb ft).
b. Tighten Bolt (1) through Bolt (26) again in a

170 ± 10 N·m (125 ± 7 lb ft).
c. Place a mark on Bolt (1) through Bolt (26).

Rotate Bolt (1) through Bolt (26) in a numerical
sequence for an additional 120 ± 5 degrees (1/
3 turn).
d. Loosen Bolt (1) through Bolt (26) until the

washers are loose under the bolt heads.
e. Tighten Bolt (1) through Bolt (26) in a
170 ± 10 N·m (125 ± 7 lb ft).
RENR9214 47

Recommendations”.
End By:
a. Install the electronic unit injectors. Refer to
b. Install the valve mechanism cover base. Refer to
Disassembly and Assembly, “Valve Mechanism
Cover Base - Remove and Install”.
i02273888
Lifter Group - Remove and

Install
SMCS Code: 1209-010
Removal Procedure
Start By:
10. Connect harness assembly (8). a. Remove the cylinder head. Refer to Disassembly
and Assembly, “Cylinder Head - Remove”.
2. Remove lifter group (2).
12. Install the bracket assembly and fuel filter base

(4).
13. Install oil level gauge tube (2).
14. Connect harness assemblies (3) and (5) (not

shown).
15. Connect hose assemblies (1) and (6).

48 RENR9214
2. Ensure that the timing marks on the following gears

are aligned: the camshaft drive gear, the idler gear
and the crankshaft gear.
3. Wire the valve lifters away from the camshaft.
1. Position lifter group (2) on the engine.

End By:
a. Install the cylinder head. Refer to Disassembly and

Assembly, “Cylinder Head - Install”. 4. Remove bolts (1).
i02250956
Camshaft - Remove
SMCS Code: 1210-011
Removal Procedure
Table 30
Required Tools

201-4211 Camshaft Pilot 1
A
Start By:
5. Install Tooling (A) on the rear of the camshaft.
a. Remove the rocker shaft and the pushrods. Refer
to Disassembly and Assembly, “Rocker Shaft and
Pushrod - Remove”.
b. Remove the front cover. Refer to Disassembly and
Assembly, “Front Cover - Remove”.
c. Remove the camshaft position sensor. Refer to
Disassembly and Assembly, “Camshaft Position
NOTICE
component life.
1. Turn the crankshaft to top center compression Illustration 94 g01144336
stroke for the No. 1 piston.

Note: Lubricate Tooling (A) with clean oil.
6. Carefully remove camshaft (2) from the engine.
RENR9214 49
i02251403
Camshaft - Install
SMCS Code: 1210-012
Table 31
Required Tools

A
3. Ensure that timing marks (3) on the idler gear are

aligned with the timing marks on the crankshaft
gear and the camshaft drive gear.
1. Install Tooling (A).

Note: Apply clean engine oil to the lobes and journals
of camshaft (2) and Tooling (A).
Note: During installation of camshaft (2), rotate the

camshaft in both directions in order to prevent binding
in the camshaft bearing bores.
2. Carefully install camshaft (2) in the engine.
NOTICE
When installing the camshaft, make sure the number 4. Install bolts (1).
one cylinder is at top center of the compression stroke
5. Remove the wires that were used to hold the valve
with the timing bolt installed in the flywheel. The cam-
shaft timing is very important. The timing mark on the lifters.
camshaft drive gear must line up with the timing mark End By:
on the idler gear. Refer to the Specifications Manual
for more information. a. Install the camshaft position sensor. Refer to
Disassembly and Assembly, “Camshaft Position
b. Install the front cover. Refer to Disassembly and
Assembly, “Front Cover - Install”.
c. Install the rocker shaft and the pushrods. Refer to
Disassembly and Assembly, “Rocker Shaft and
Pushrod - Install”.
50 RENR9214
i02259928
Camshaft Gear - Remove and

Install
SMCS Code: 1210-010-GE
Removal Procedure
Start By:
a. Remove the camshaft. Refer to Disassembly and
1. Wrap the camshaft with a protective covering in

order to prevent damage to the camshaft. Illustration 99 g00522082
1. Install woodruff key (2) in camshaft (3).
2. Raise the temperature of drive gear (1).
3. Install drive gear (1) on the end of camshaft (3).

End By:
a. Install the camshaft. Refer to Disassembly and
Assembly, “Camshaft - Install”.
i04263097
Camshaft Bearings - Remove

SMCS Code: 1211-011
Removal Procedure
NOTICE
Table 32
Do not allow the camshaft to fall to the floor when
pressing it from the drive gear. Also make sure that Required Tools
the camshaft lobes do not catch on the press plates. Part Description Qty
Tool Part Number
8S-2241 Camshaft Bearing Tool Group 1

2. Use a suitable press to remove drive gear (1) from
camshaft (3). 201-4214 Receiving Sleeve 1
201-4213 Puller Plate 1

3. Remove woodruff key (2).
201-4209 Bearing Pilot 1
Installation Procedure 201-4208 Backup Plate 1
A 6F-7032 Bolt 1
8M-8778 Taperlock Stud 1
Extension
8S-8292(1) Short 2
Extension
8S-8293(1) Long 1
B 185-3989 Thread Lubricant 1

(1) Part of 8S-2241Camshaft Bearing Tool Group.
RENR9214 51
Start By: (Table 33, contd)

Extension
a. Remove the lifter group. Refer to Disassembly and 8S-8293(1) Long 1
Assembly, “Lifter Group - Remove and Install”.
b. Remove the camshaft. Refer to Disassembly and (1) Part of 8S-2241Camshaft Bearing Tool Group.
NOTICE
NOTICE
Contaminants may cause rapid wear and shortened component life.
component life.

1. Position new camshaft bearing (1) in Tooling (A)

1. Install Tooling (A). Apply Tooling (B) on the threads.
and install the bearing from the rear to the front of
2. Remove camshaft bearings (1). the engine.
i04263109
Camshaft Bearings - Install

SMCS Code: 1211-012
Table 33
Required Tools
8S-2241 Camshaft Bearing Tool Group 1
201-4214 Receiving Sleeve 1

201-4213 Puller Plate 1
201-4209 Bearing Pilot 1 2. The camshaft bearings are installed with Tooling
A 201-4208 Backup Plate 1
(A). Measure the depth of the camshaft bearings
from the front face of the cylinder block to the
6F-7032 Bolt 1 following distances:
8M-8778 Taperlock Stud 1
a. Dimension (A) is 36.50 mm (1.437 inch).
Extension
8S-8292(1) Short 2 b. Dimension (B) is 192.50 mm (7.579 inch).
c. Dimension (C) is 348.50 mm (13.720 inch).

(continued)
52 RENR9214
NOTICE
d. Dimension (D) is 504.50 mm (19.862 inch).
e. Dimension (E) is 660.50 mm (26.004 inch).
f. Dimension (F) is 816.50 mm (32.146 inch). Be prepared to collect the fluid with suitable contain-
g. Dimension (G) is 972.50 mm (38.287 inch). bling any component containing fluids.
Refer to Special Publication, NENG2500, “Dealer
NOTICE Service Tool Catalog” for tools and supplies suitable
Camshaft bearings must be installed into their correct to collect and contain fluids on Cat products.
position. Failure to do so will result in engine damage.
mandates.
1. Drain the oil into a suitable container. Refer to

Operation and Maintenance Manual, “Refill
Capacities and Recommendations”.
(2) Bearing joint

(3) Oil hole
(H) Bearing oil hole is located at a 45 degree angle
from vertical. All seven bearings have the same Illustration 104 g02466033
angle.
2. Remove bolts (1), washers (2), fastener
End By: assemblies (3) and remove oil pan (4).
a. Install the camshaft. Refer to Disassembly and
Assembly, “Camshaft - Install”. Installation Procedure
b. Install the lifter group. Refer to Disassembly and
Assembly, “Lifter Group - Remove and Install”.
i04970490
Engine Oil Pan - Remove and

Install
SMCS Code: 1302-010
Removal Procedure
Table 34
Required Tools
Part
Tool Part Number Description Qty
Note: Ensure that the oil pan and mating surfaces are
A - Loctite 596 - clean and free of oil.
RENR9214 53
1. Apply Tooling (A) at four locations marked (A). 3. Position oil pan (4), washers (2), and bolts (1) into
Tooling (A) should be applied in 4 ± 1 mm place.
(0.16 ± 0.04 inch) diameter beads.
4. Tighten bolts (1) in the above sequence.
Note: All joints using Tooling (A) must be assembled
within ten minutes of the application. 5. Fill the engine with oil. Refer to Operation and
Recommendations”.
i02251662
Cylinder Liner - Remove

SMCS Code: 1216-011
Removal Procedure
Table 35
Required Tools
Tool Part Number Description Qty
A 5P-8665 Cylinder Liner Puller Gp 1

1U-9593(2) Cylinder Pack Puller 1
2. Install fastener assemblies (3) and the gasket (not 129-6675(3) Cylinder Pack Puller 1
shown) onto oil pan (4). B(1)
1U-9897 Bridge 1
1U-6319 Socket 1
(1) Tooling (B) is used to remove pistons and cylinder liners
together.
(2) The 1U-9593Cylinder Pack Puller is for use on C11 Engines.
(3) The 129-6675Cylinder Pack Puller is for use on C13 Engines.
Start By:
a. Remove the pistons and the connecting rods.
Refer to Disassembly and Assembly, “Pistons and
Connecting Rods - Remove”.
1. Use Tooling (A) to remove cylinder liner (1).
2. Remove the O-ring seals from cylinder liner (1).

Torque Sequence
54 RENR9214
i02251694 i02251702
Cylinder Liner - Install Piston Cooling Jets - Remove

SMCS Code: 1216-012 and Install
SMCS Code: 1331-010
Table 36 Removal Procedure
Required Tools
Start By:
a. Remove the engine oil pan. Refer to Disassembly
C 2P-8260 Cylinder Liner Installer 1 and Assembly, “Engine Oil Pan - Remove and
Install”.
D 5P-3975 Rubber Lubricant 1
NOTICE
Special care must be taken not to bend the piston
cooling jets because the piston cooling jets are preci-
sion aligned with a coolant passage in the pistons.
There is only one position for each cooling jet. The
notch in the bottom of the piston allows clearance for
the piston cooling jet when the piston is at bottom
dead center.
1. Install the O-ring seals on cylinder liner (1).
2. Apply Tooling (D) on the O-ring seals.
Note: Refer to Testing and Adjusting, “Cylinder Liner

Projection” for more information.
Note: If you are installing a cylinder pack, ensure that
the corresponding crankshaft throw is at BOTTOM
center. 1. Remove bolt (1) and piston cooling jet (2).
3. Use Tooling (C) to install cylinder liner (1).
End By:
NOTICE
a. Install the pistons and the connecting rods. Refer Special care must be taken not to bend the piston
to Disassembly and Assembly, “Pistons and
Connecting Rods - Install”. cooling jets because the piston cooling jets are preci-
sion aligned with a coolant passage in the pistons.
There is only one position for each cooling jet. The
notch in the bottom of the piston allows clearance for
the piston cooling jet when the piston is at bottom
dead center.
RENR9214 55
1. Position piston cooling jet (2) and install bolt (1).

Tighten bolt (1) to a torque of 35 ± 3 N·m
(26 ± 2 lb ft).
End By:
a. Install the engine oil pan. Refer to Disassembly
and Assembly, “Engine Oil Pan - Remove and 1. Place an identification mark on connecting rod (1)
Install”. and connecting rod cap (3). The number should
match the cylinder number. The bearing retainer
i02630813 notch should be on the right side.
Pistons and Connecting Rods - 2. Remove connecting rod cap bolts (4) and
Remove connecting rod cap (3). Remove the lower half of
connecting rod bearing (2) from connecting rod
SMCS Code: 1225-011 cap (3).
Removal Procedure 3. Push the piston and connecting rod (1) away from
the crankshaft. Remove the upper half of
Start By: connecting rod bearing (2).
a. Remove the cylinder head. Refer to Disassembly
and Assembly, “Cylinder Head - Remove”. Note: Careful handling is required for fractured
b. Remove the piston cooling jets. Refer to connecting rods. Fractured faces for the connecting
Disassembly and Assembly, “Piston Cooling Jets - rod and connecting rod cap should not be placed on
Remove and Install”. any surface. The connecting rod and the connecting
rod cap should be placed on the sides in order to
NOTICE prevent damage. When possible, the connecting rod
Keep all parts clean from contaminants. and the connecting rod cap should be bolted together
in order to prevent damage.
Contaminants may cause rapid wear and shortened 4. Remove the piston and connecting rod (1) from the
component life. cylinder block.
56 RENR9214
i02631078
Pistons and Connecting Rods -

Disassemble
SMCS Code: 1225-015
Disassembly Procedure
Table 37
Required Tools
A 4C-3601 Piston Ring Expander 1
5P-8639 Hydraulic Press 1 Illustration 114 g01319591
8F-0024 Hose Assembly 1
1P-2375 Connecting Coupler 1
1P-2376 Connecting Coupler 1

B
5P-9725 Hydraulic Cylinder 1
5P-8651 Spacer 1
5P-8649 Adapter 1
5P-8650 Adapter 1
Start By:
a. Remove the pistons and the connecting rods.
Refer to Disassembly and Assembly, “Pistons and
Connecting Rods - Remove”. Illustration 115 g01142147
NOTICE 1. Use Tooling (A) in order to remove piston rings (1)

Keep all parts clean from contaminants. from piston (2).
Contaminants may cause rapid wear and shortened 2. Remove retaining ring (3).
component life.
Note: Careful handling is required for fractured

connecting rods. Fractured faces for the connecting
rod and connecting rod cap should not be placed on
any surface. The connecting rod and the connecting
prevent damage. When possible, the connecting rod
and the connecting rod cap should be bolted together
3. Remove piston pin (6) and piston (2) from
connecting rod (5).
NOTICE
The connecting rod must be heated for the installation
of the piston pin bearing. Do not use a torch.
4. Raise the temperature of connecting rod (5) in the

indicated Area (X). The maximum distance of Area
(X) is 85.0 mm (3.35 inch).
RENR9214 57
5. Use Tooling (B) in order to remove old bearing (4)

and install new bearing (4) at the same time. Refer
to Specifications, “Connecting Rod”.
i02641059

Assemble
SMCS Code: 1225-016
Assembly Procedure
Table 38
Required Tools Illustration 116 g01319591

Note: Ensure that new bearing (4) is installed prior to
A 4C-3601 Piston Ring Expander 1 assembly of the piston.
4C-8165(1) Note: Careful handling is required for fractured
C or Piston Ring Groove Gauge 1 connecting rods. Fractured faces for the connecting
208-7630(2)
(1) Use with C11 Engines only any surface. The connecting rod and the connecting
(2) Use with C13 Engines only rod cap should be placed on the sides in order to
NOTICE and the connecting rod cap should be bolted together
Keep all parts clean from contaminants. in order to prevent damage.
1. Place piston (2) on connecting rod (5). Apply clean
Contaminants may cause rapid wear and shortened engine oil to piston pin (6) and install the piston
component life. pin.
2. Install retaining rings (3).

NOTICE
Verify correct assembly of the pistons and the con- 3. Check the clearance between the ends of piston
necting rods. Ensure that the etched numbers on the rings (1). Refer to Specifications, “Piston and
rod and the rod cap are in the correct positions. The Rings”.
etched number on the rod and the rod cap correspond
to the cylinder in which it should be installed.
Note: The oil ring must be installed over the spring
with the end gap 180 degrees from the oil ring spring
Note: The word “FRONT” may be stamped on the joint.
pistons in some engines. Ensure that the word 4. Install the oil control piston ring. The ends of the
“FRONT” is toward the front of the engine when the spring should be rotated 180 degrees from the ring
piston is installed. The etched number on the end gap.
connecting rod must be on the right side of the engine
in the corresponding cylinder. Ensure that the piston 5. Install the intermediate piston ring with the side
and the etched number are correctly positioned. marked “UP-2” toward the top of the piston. Use
Tooling (A) in order to install the ring.
Note: Inspect condition of all piston ring grooves. Use
Tooling (C) to verify diameter of top ring groove. Refer 6. Install the top piston ring with the side marked
to Tool Operating Manual, NEHS0840 for additional “UP-1” toward the top of the piston. Use Tooling
information. (A) in order to install the ring.
7. After installation, all three of the piston rings should

be placed 120 degrees away from each other.
End By:
a. Install the pistons and the connecting rods. Refer
to Disassembly and Assembly, “Pistons and
Connecting Rods - Install”.
58 RENR9214
i03121102

Install
SMCS Code: 1225-012
Table 39
Required Tools
161-4163(1)
A or Piston Ring Compressor Gp 1
161-4164(2)
B 4C-5590 Anti-Seize Compound 1

(1) 125mm bore
(2) 130mm bore
NOTICE Illustration 118 g01319419

Contaminants may cause rapid wear and shortened 3. With the number one crankshaft throw at the
component life. bottom center, install the piston and connecting rod
(1) in the engine. Ensure that the proper piston and
connecting rod are in the corresponding cylinder
1. Apply clean engine oil on the following items: the
with the bearing retainer notch toward the right
piston, the piston rings and the cylinder bore.
side of the engine.
Note: The word “FRONT” may be stamped on the
crown of the pistons in some engines. Ensure that the
word “FRONT” is toward the front of the engine
when the piston is installed. The etched number on
the connecting rod must be on the right side of the
engine in the corresponding cylinder.
in order to prevent damage. 4. Line up the piston and connecting rod with the
crankshaft. Use a soft hammer and tap the piston
into the cylinder bore until Tooling (A) comes off of
the piston.
5. Before the connecting rod comes in contact with

the crankshaft, install the upper half of connecting
rod bearing (2). Ensure that the bearing tab
engages with the slot in the connecting rod.
6. Apply clean engine oil to the surface of the upper

half of connecting rod bearing (2). Use a soft
hammer in order to tap the piston into the cylinder
bore while you guide the connecting rod onto the
crankshaft.
Illustration 117 g01011856 7. Place the lower half of connecting rod bearing (2)
in corresponding connecting rod cap (3). Ensure
2. Use Tooling (A) in order to compress the piston that the bearing tab engages with the groove in
rings. connecting rod cap (3).
RENR9214 59
8. Apply clean engine oil to the surface of the lower

half of connecting rod bearing (2). Install
connecting rod cap (3) on the connecting rod.
Ensure that the number on connecting rod cap (3)
matches the number on connecting rod (1). Ensure
that the numbers are on the same side.
9. Apply Tooling (B) to connecting rod cap bolts (4).
Install connecting rod cap bolts (4). Tighten the
connecting rod cap bolts to a torque of
130 ± 7 N·m (95 ± 5 lb ft).
10. Place an index mark on each bolt head. Tighten

each bolt for an additional 60 ± 5 degrees (1/6
turn).
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 Illustration 119 g01011713
Assembly, “Cylinder Head - Install”.
1. Remove crankshaft main bearing cap (1).
i03420460
Note: Remove No. 1 and No. 7 crankshaft main
Crankshaft Main Bearings - bearing caps (1) after No. 2 through No. 6 crankshaft
main bearing caps have been installed.
Remove
SMCS Code: 1203-011 2. Remove the lower half of crankshaft main bearing
(2) from crankshaft main bearing cap (1).
Removal Procedure
Table 40
Required Tools
A 2P-5518 Bearing Tool 1
Start By:
and Assembly, “Engine Oil Pan - Remove and
Install”.
NOTICE
Keep all parts clean from contaminants. Illustration 120 g01147837

component life. NOTICE
If the crankshaft is turned in the wrong direction, the
tab of the crankshaft main bearing will be pushed be-
tween the crankshaft and the cylinder block. this can
cause damage to either or both the crankshaft and
the cylinder block.
3. Install Tooling (A) into the crankshaft journal.

60 RENR9214
4. Turn the crankshaft in order to remove the upper

half of crankshaft main bearing (2). In order to get
the tab out first, the crankshaft must be turned in
the correct direction.
5. Check the condition of the crankshaft main
bearings. Refer to the Guideline For Reusable
Parts, SEBF8009, “Main and Connecting Rod
Bearings”.
6. Remove thrust plate (3).
i05511719
Crankshaft Main Bearings - Illustration 121 g01147837

Install
Note: The crankshaft end play is controlled by thrust
SMCS Code: 1203-012 plate (3). Thrust plate (3) is located at the center of
the crankshaft.
Installation Procedure 1. Install thrust plate (3).
Table 41
2. Use Tooling (A) to install the new upper halves of
Required Tools
crankshaft main bearings (2) in the cylinder block.
Tool Part Number Part Description Qty This half of the bearing has an oil hole.
A 2P-5518 Bearing Tool 1
B 8T-5096 Dial Indicator Group 1
NOTICE
component life.
Note: Apply clean engine oil to the crankshaft main

bearings prior to assembly. Do not apply oil to the
back of the crankshaft main bearing. Check the tabs
on the back side of the crankshaft main bearings fit in
the grooves of the crankshaft main bearing caps and
the cylinder block.
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 num-
ber having the quantity of four is to be installed on Illustration 122 g01011713
crankshaft main bearings 2, 3, 5, and 6. The part
number having the quantity of three is to be installed 3. Install the new lower halves of crankshaft main
on crankshaft bearing 1, 4, and 7. The thrust plate is bearings (2) in crankshaft main bearing caps (1).
to be installed on the center crankshaft main bearing Do not apply oil to the back of the crankshaft main
only. bearing.
Note: Crankshaft main bearing caps (1) should be

installed with the part number toward the right side of
the engine. The numerical sequence is identified by
stamped numbers 1 through 7 that are located on the
bottom surface. The thrust plate is used on the
number 4 crankshaft main bearing only.
RENR9214 61
4. Position crankshaft main bearing caps (1) with the

part numbers toward the right hand side of the
cylinder block. Position crankshaft main bearing
caps (1) in a numerical sequence.
5. Apply clean “SAE 30W” oil or molybdenum

grease to the bolt threads and the washers. Install
the bolts. Tighten the bolts to a torque of
150 ± 5 N·m (110 ± 5 lb ft). Place an index mark
on each bolt head. Turn the bolts for an additional
60 ± 5 degrees.
6. Check the end play of the crankshaft with Tooling

(B). The end play must be 0.10 to 0.50 mm
(0.004 to 0.020 inch).
End By:
a. Install the engine oil pan. Refer to Disassembly
Install”.
i02631461

Crankshaft - Remove connecting rods. Fractured faces for the connecting
SMCS Code: 1202-011 rod and connecting rod cap should not be placed on
Removal Procedure prevent damage. When possible, the connecting rod
Table 42 and the connecting rod cap should be bolted together
Required Tools in order to prevent damage.
Tool Part Number Part Description Qty Note: Place an identification mark on all connecting
A 138-7574 Link Bracket 2 rod caps (2). Connecting rod caps (2) should be
marked with the corresponding cylinder number.
1. Remove connecting rod caps (2) and connecting
Start By: rod bearings (1).
and Assembly, “Engine Oil Pan - Remove and Note: Crankshaft main bearing caps (4) are marked
Install”. with the numbers 1 through 7. Crankshaft main
b. Remove the front housing. Refer to Disassembly bearing caps (4) that are not marked should be
and Assembly, “Housing (Front) - Remove”. marked with the corresponding cylinder number on
the side that is toward the right side of the engine.
c. Remove the flywheel housing. Refer to 2. Remove crankshaft main bearing caps (4) and the
Disassembly and Assembly, “Flywheel Housing - lower half of crankshaft main bearings (5).
Remove and Install”.
3. Remove crankshaft thrust bearings (3).
NOTICE
Keep all parts clean from contaminants. 4. Attach Tooling (A) and a suitable lifting device to
crankshaft (6). The weight of crankshaft (6) is
component life. approximately 129 kg (285 lb).
5. Remove crankshaft (6) and the upper half of the

crankshaft main bearings.
62 RENR9214
i02919523
Crankshaft - Install
SMCS Code: 1202-012
Table 43
Required Tools
B 8T-5096 Dial Indicator Group 1
C 4C-5590 Anti-Seize Compound -
NOTICE
component life. Illustration 124 g01013519

NOTICE crankshaft (6). The weight of crankshaft (6) is
Ensure that the crankshaft main bearing tabs engage approximately 129 kg (285 lb). Position the upper
with the grooves in the block and the crankshaft main half of the crankshaft main bearings and
bearing cap. crankshaft (6) in the cylinder block.
3. Install crankshaft thrust bearings (3).

1. Place the upper halves of the crankshaft main
bearings in the cylinder block. Place the lower 4. Install the lower half of crankshaft main bearings
halves of the crankshaft main bearings in (5).
crankshaft main bearing caps.
Note: Crankshaft main bearing caps (4) should be
installed with the part number toward the right side of
the engine. The numerical sequence is identified by
stamped numbers 1 through 7 that are located on the
bottom surface. The thrust plate is used on the
number 4 crankshaft main bearing only.
5. Position crankshaft main bearing caps (4) with the
part numbers toward the right hand side of the
cylinder block. Position crankshaft main bearing
caps (4) in a numerical sequence.
Note: Use new bolts for the installation of bearing

caps (4).
6. Apply clean “SAE 30W” oil or molybdenum
grease to the bolt threads and the washers. Install
the bolts. Tighten the bolts to a torque of
150 ± 5 N·m (110 ± 5 lb ft). Place an index mark
on each bolt head. Turn the bolts for an additional
60 ± 5 degrees (1/6 turn).
7. Check the end play of the crankshaft with Tooling

(B). The end play must be 0.10 to 0.50 mm
(0.004 to 0.020 inch).
RENR9214 63

8. Install connecting rod bearings (1) and connecting
rod caps (2).
9. Apply Tooling (C) to the connecting rod cap bolts.

Install the connecting rod cap bolts. Tighten the
connecting rod cap bolts to a torque of
130 ± 7 N·m (95 ± 5 lb ft).
10. Place an index mark on each bolt head. Tighten
each bolt for an additional 60 ± 5 degrees (1/6 1. Use Tooling (A) to remove crankshaft gear (2) from
turn). crankshaft (1).
End By: 2. Remove drive pin (3).
a. Install the flywheel housing. Refer to Disassembly
and Assembly, “Flywheel Housing - Remove and
Install”. Table 45
Required Tools
b. Install the front housing. Refer to Disassembly and
Assembly, “Housing (Front) - Install”. Tool Part Number Part Description Qty
c. Install the engine oil pan. Refer to Disassembly B 6V-2098 Press Sleeve 1
C 8H-8581 Gauge 1
Install”.
i02253161
Crankshaft Gear - Remove and

Install
SMCS Code: 1204-010-GE
Removal Procedure
Table 44
Required Tools
1P-2326 Forcing Screw 1
1P-2325 Head 1 Illustration 126 g01134649

A 3H-0462 Bolt 6
1. Install drive pin (3).
8H-0709 Strap 6
5F-7373 Jaw 3
Always wear protective gloves when handling

parts that have been heated.
2. Raise the temperature of crankshaft gear (2).
3. Install crankshaft gear (2) on the end of crankshaft

(1). Ensure that slot (4) in crankshaft gear (2) is
aligned with drive pin (3).
64 RENR9214
Note: Cat 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
Cat engine bearing is quality checked for specific
wall thickness.
Note: The measurements should be within
specifications and the correct bearings should be
used. If the crankshaft journals and the bores for the
block and the rods were measured during
disassembly, no further checks are necessary.
However, if the technician still wants to measure the
bearing clearances, Tooling (A) is an acceptable
method. Tooling (A) is less accurate on journals with
small diameters if clearances are less than 0.10 mm
4. Use Tooling (B) to seat crankshaft gear (2) against (0.004 inch).
shoulder (5) of crankshaft (1).
NOTICE
5. Use Tooling (C) to ensure that crankshaft gear (2) Lead wire, shim stock or a dial bore gauge can dam-
is seated against shoulder (5) on crankshaft (1). age the bearing surfaces.
Note: Check the crankshaft gear in three places with The technician must be very careful to use Tooling (A)
Tooling (C). correctly. The following points must be remembered:
i05977048 • Ensure that the backs of the bearings and the

bores are clean and dry.
Bearing Clearance - Check • Ensure that the bearing locking tabs are properly
SMCS Code: 1203-535; 1219-535 seated in the tab grooves.
• The crankshaft must be free of oil at the contact
Measurement Procedure points of Tooling (A).
Table 46
Required Tools 1. Put a piece of Tooling (A) on the crown of the
bearing that is in the cap.
Note: Do not allow Tooling (A) to extend over the
Plastic Gauge (Green)
198-9142 0.025 to 0.076 mm
edge of the bearing.
1
(0.001 to 0.003 inch)
2. Use the correct torque-turn specifications in order
Plastic Gauge (Red) to install the bearing cap. Do not use an impact
198-9143 0.051 to 0.152 mm 1 wrench. Be careful not to dislodge the bearing
(0.002 to 0.006 inch)
A when the cap is installed.
Plastic Gauge (Blue)
198-9144 0.102 to 0.229 mm 1 Note: Do not turn the crankshaft when Tooling (A) is
(0.004 to 0.009 inch) installed.
Plastic Gauge (Yellow) 3. Carefully remove the cap, but do not remove
198-9145 0.230 to 0.510 mm 1 Tooling (A). Measure the width of Tooling (A) while
(0.009 to 0.020 inch)
Tooling (A) is in the bearing cap or on the
crankshaft journal. Refer to Illustration 128 .
Note: Plastic gauge may not be necessary when the
engine is in the chassis.
NOTICE
component life.
RENR9214 65
(1) Atmospheric pressure sensor ...............10 ± 2 N·m

(88 ± 18 lb in)
Illustration 128 g01152855 Note: Atmospheric pressure sensor (1) is to be
Typical Example installed at an angle of 40+/-15 degrees from vertical.
4. Remove all of Tooling (A) before you install the i02253326

bearing cap.
Note: When Tooling (A) is used, the readings can

Camshaft Position Sensor -
sometimes be unclear. For example, all parts of Remove and Install
Tooling (A) are not the same width. Measure the
SMCS Code: 1912-010
major width in order to ensure that the parts are within
the specification range. Refer to Specifications
Manual, “Connecting Rod Bearing Journal” and NOTICE
Specifications Manual, “Main Bearing Journal” for the Keep all parts clean from contaminants.
correct clearances.
component life.
i05196645
Atmospheric Pressure Sensor

- Remove and Install
SMCS Code: 1923-010
NOTICE
component life.
(1) Camshaft position sensor......................28 ± 7 N·m

(21 ± 5 lb ft)
66 RENR9214
i02253629
NOTICE
Crankshaft Position Sensor - tained during performance of inspection, mainte-
Remove and Install nance, testing, adjusting and repair of the product. Be
SMCS Code: 1912-010 before opening any compartment or disassembling
NOTICE
Keep all parts clean from contaminants. Refer to Special Publication, NENG2500, “Caterpillar
Contaminants may cause rapid wear and shortened plies suitable to collect and contain fluids on Caterpil-
component life. lar products.
mandates.
Note: Drain the coolant level until the coolant is

below the sensor.
(1) Crankshaft position sensor....................28 ± 7 N·m

(21 ± 5 lb ft)
i02253756
(1) Coolant temperature sensor..................20 ± 5 N·m
Coolant Temperature Sensor - (15 ± 4 lb ft)
Remove and Install
i02253371
SMCS Code: 1906-010
Engine Oil Pressure Sensor -
NOTICE
Keep all parts clean from contaminants. Remove and Install
SMCS Code: 1924-010
component life.
NOTICE
component life.
RENR9214 67
NOTICE NOTICE
Care must be taken to ensure that fluids are con- Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte- tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product. Be nance, testing, adjusting and repair of the product. Be
prepared to collect the fluid with suitable containers prepared to collect the fluid with suitable containers
before opening any compartment or disassembling before opening any compartment or disassembling
any component containing fluids. any component containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and sup- Tools and Shop Products Guide” for tools and sup-
plies suitable to collect and contain fluids on Caterpil- plies suitable to collect and contain fluids on Caterpil-
lar products. lar products.
Dispose of all fluids according to local regulations and Dispose of all fluids according to local regulations and
mandates. mandates.
(1) Engine oil pressure sensor....................10 ± 2 N·m (1) Fuel temperature sensor .......................20 ± 5 N·m
(88 ± 18 lb in) (15 ± 4 lb ft)
i02253213 i02253255
Fuel Temperature Sensor - Boost Pressure Sensor -

Remove and Install Remove and Install
NOTICE NOTICE
Keep all parts clean from contaminants. Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened Contaminants may cause rapid wear and shortened
component life. component life.
68 RENR9214
i02253795
Fan Drive Mounting Group -

Remove and Install
SMCS Code: 1359-010
Removal Procedure
Personal injury can result from contact with

refrigerant.
Contact with refrigerant can cause frost bite. Keep
face and hands away to help prevent injury.
(1) Boost pressure sensor ..........................10 ± 2 N·m
(88 ± 18 lb in) Protective goggles must always be worn when re-
frigerant lines are opened, even if the gauges indi-
cate the system is empty of refrigerant.
i02253275
Always use precaution when a fitting is removed.
Inlet Air Temperature Sensor - Slowly loosen the fitting. If the system is still
under pressure, release it slowly in a well venti-
Remove and Install lated area.
SMCS Code: 1921-010 Personal injury or death can result from inhaling
refrigerant through a lit cigarette.
NOTICE
Keep all parts clean from contaminants. Inhaling air conditioner refrigerant gas through a
lit cigarette or other smoking method or inhaling
Contaminants may cause rapid wear and shortened fumes released from a flame contacting air condi-
component life. tioner refrigerant gas, can cause bodily harm or
death.
Do not smoke when servicing air conditioners or
wherever refrigerant gas may be present.
Use a certified recovery and recycling cart to
properly remove the refrigerant from the air condi-
tioning system.
1. Recover the air conditioner refrigerant.
2. Disconnect the hose assemblies from the air

conditioner compressor.
3. Disconnect the harness assemblies from the

alternator.
(1) Inlet air temperature sensor ..................20 ± 5 N·m

(15 ± 4 lb ft)
RENR9214 69
4. Remove bolts (1). 1. Install the idler pulley assemblies if the idler pulley
assemblies were removed. Tighten the bolts for
the idler pulley assemblies to a torque of
50 ± 5 N·m (37 ± 4 lb ft).
2. Attach a suitable lifting device to fan drive

mounting group (4). The weight of fan drive
mounting group (4) is approximately 45 kg (100 lb)
. Position fan drive mounting group (4) on the
engine.
3. Install bolts (3) and nuts (5).
5. Remove belt (2).
6. Attach a suitable lifting device to fan drive

mounting group (4). The weight of fan drive
mounting group (4) is approximately 45 kg (100 lb)
.
7. Remove bolts (3) and nuts (5).
8. Remove fan drive mounting group (4).
70 RENR9214
i02283850
Engine Control Module -

Remove and Install
SMCS Code: 1901-010

5. Install bolts (1). (1) Harness assembly..............6 ± 1 N·m (53 ± 9 lb in)

6. Connect the harness assemblies to the alternator.
i02254179
7. Connect the hose assemblies to the air conditioner
compressor. Alternator - Remove and Install
SMCS Code: 1405-010
Removal Procedure
Personal injury can result from contact with
refrigerant.
Contact with refrigerant can cause frost bite. Keep Personal injury can result from failure to discon-
face and hands away to help prevent injury.
nect the battery.
Protective goggles must always be worn when re-
frigerant lines are opened, even if the gauges indi- First, disconnect the negative battery cable. Then,
disconnect the positive battery cable.
cate the system is empty of refrigerant.
A positive power lead can cause sparks if the bat-
Always use precaution when a fitting is removed.
tery is not disconnected. Sparks can possibly re-
Slowly loosen the fitting. If the system is still sult in battery explosion or fire.
under pressure, release it slowly in a well venti-
lated area.
Personal injury or death can result from inhaling 1. Disconnect the batteries.
refrigerant through a lit cigarette. 2. Place identification marks on all of the harness
Inhaling air conditioner refrigerant gas through a assemblies and disconnect the harness
lit cigarette or other smoking method or inhaling assemblies.
fumes released from a flame contacting air condi-
tioner refrigerant gas, can cause bodily harm or
death.
Do not smoke when servicing air conditioners or
wherever refrigerant gas may be present.
Use a certified recovery and recycling cart to
properly remove the refrigerant from the air condi-
tioning system.
8. Recharge the air conditioner refrigerant.

RENR9214 71
4. Connect the harness assembly to alternator (3)

and install the bolt. Tighten the bolt to a torque of
4.4 ± 1.0 N·m (39 ± 9 lb in).
5. Connect the harness assembly to alternator (3)

and install the nut. Tighten the nut to a torque of
18 ± 2 N·m (13 ± 2 lb ft).
6. Connect the batteries.
i02254232
Electric Starting Motor -

Remove and Install
SMCS Code: 1453-010
Removal Procedure

Accidental engine starting can cause injury or
death to personnel working on the equipment.
3. Remove belt (1).
To avoid accidental engine starting, disconnect
4. Remove bolts (2) and alternator (3). the battery cable from the negative (−) battery ter-
minal. Completely tape all metal surfaces of the
Installation Procedure disconnected battery cable end in order to pre-
vent contact with other metal surfaces which
could activate the engine electrical system.
Place a Do Not Operate tag at the Start/Stop
switch location to inform personnel that the
equipment is being worked on.
1. Disconnect the batteries.

2. Place identification marks on all of the harness
assemblies that are connected to the electric
starting motor and the solenoid.
1. If necessary, install the pulley on alternator (3).

Install the nut and tighten the nut to a torque of
127 ± 10 N·m (94 ± 7 lb ft).
2. Position alternator (3) on the alternator mounting

bracket. Install bolts (2).

72 RENR9214
3. Disconnect the harness assemblies from solenoid

(1).
4. Fasten a suitable lifting device to electric starting

motor (2). The weight of electric starting motor (2)
is approximately 26 kg (57 lb).
5. Remove bolts (3). Remove electric starting motor

(2) and gasket (4).
1. Fasten a suitable lifting device to electric starting

motor (2). The weight of electric starting motor (2)
is approximately 26 kg (57 lb).
2. Position gasket (4) and electric starting motor (2)

on the flywheel housing. Install bolts (3).
3. Position the harness assembly on solenoid (1) and

install nut (5). Tighten the nut to a torque of
31 ± 4 N·m (23 ± 3 lb ft).

2.25 ± 0.25 N·m (20 ± 2 lb in).

2.25 ± 0.25 N·m (20 ± 2 lb in).
RENR9214 73
6. If necessary, install the connector and install nut (9)

and bolt (8). Tighten the nut to a torque of
31 ± 4 N·m (23 ± 3 lb ft). Tighten the bolt to a
torque of 8 ± 3 N·m (71 ± 27 lb in).
7. Connect the batteries.

74 RENR9214
Index Section
Index
A Removal Procedure ..................................... 59
Crankshaft Position Sensor - Remove and
Accessory Drive - Install .................................. 39
Install.............................................................. 66
Installation Procedure .................................. 39
Crankshaft Rear Seal - Install.......................... 31
Accessory Drive - Remove .............................. 39
Removal Procedure ..................................... 39
Crankshaft Rear Seal - Remove...................... 31
Alternator - Remove and Install ....................... 70
Cylinder Head - Install ..................................... 45
Atmospheric Pressure Sensor - Remove
Cylinder Head - Remove ................................. 43
and Install....................................................... 65
Cylinder Liner - Install ...................................... 54
B Installation Procedure .................................. 54
Cylinder Liner - Remove .................................. 53
Bearing Clearance - Check ............................. 64
Measurement Procedure ............................. 64
Boost Pressure Sensor - Remove and Install.. 67
D
C Disassembly and Assembly Section ................. 5
Camshaft - Install............................................. 49
Installation Procedure .................................. 49 E
Camshaft - Remove......................................... 48
Electric Starting Motor - Remove and Install ... 71
Camshaft Bearings - Install.............................. 51
Electronic Unit Injector - Install .......................... 7
Camshaft Bearings - Remove ......................... 50
Installation Procedure .................................... 7
Electronic Unit Injector - Remove ...................... 6
Camshaft Gear - Remove and Install .............. 50
Removal Procedure ....................................... 6
Electronic Unit Injector Sleeve - Install ............ 10
Camshaft Position Sensor - Remove and
Electronic Unit Injector Sleeve - Remove .......... 8
Install.............................................................. 65
Removal Procedure ....................................... 8
Coolant Temperature Sensor - Remove and
Engine Control Module - Remove and Install .. 70
Install.............................................................. 66
Engine Oil Cooler - Install ................................ 22
Crankshaft - Install........................................... 62
Engine Oil Cooler - Remove ............................ 22
Crankshaft - Remove....................................... 61
Engine Oil Filter Base - Assemble ................... 21
Crankshaft Front Seal - Install ......................... 34
Assembly Procedure.................................... 21
Engine Oil Filter Base - Disassemble .............. 20
Crankshaft Front Seal - Remove ..................... 34
Disassembly Procedure............................... 20
Engine Oil Filter Base - Install ......................... 21
Crankshaft Gear - Remove and Install ............ 63
Engine Oil Filter Base - Remove ..................... 19
Crankshaft Main Bearings - Install................... 60
Engine Oil Pan - Remove and Install............... 52
Crankshaft Main Bearings - Remove............... 59
RENR9214 75
Index Section
Engine Oil Pressure Sensor - Remove and Installation Procedure .................................. 38

Install.............................................................. 66 Housing (Front) - Remove ............................... 38
Engine Oil Pump - Assemble........................... 24 Removal Procedure ..................................... 38
Engine Oil Pump - Disassemble...................... 23
Disassembly Procedure............................... 23 I
Engine Oil Pump - Install ................................. 25 Important Safety Information ............................. 2
Installation Procedure .................................. 25 Inlet Air Temperature Sensor - Remove and
Engine Oil Pump - Remove ............................. 23 Install.............................................................. 68
Removal Procedure ..................................... 23 Inlet and Exhaust Valve Guides - Remove
Exhaust Manifold - Remove and Install ........... 13 and Install....................................................... 17
Installation Procedure .................................. 13 Installation Procedure .................................. 17
Removal Procedure ..................................... 13 Removal Procedure ..................................... 17
Inlet and Exhaust Valve Seat Inserts -
Remove and Install ........................................ 18
F Installation Procedure .................................. 18
Fan Drive Mounting Group - Remove and Removal Procedure ..................................... 18
Install.............................................................. 68 Inlet and Exhaust Valve Springs - Remove
Installation Procedure .................................. 69 and Install....................................................... 14
Removal Procedure ..................................... 68 Installation Procedure .................................. 15
Flywheel - Install.............................................. 30 Removal Procedure ..................................... 14
Installation Procedure .................................. 30 Inlet and Exhaust Valves - Remove and
Flywheel - Remove.......................................... 29 Install.............................................................. 16
Flywheel Housing - Remove and Install .......... 32 Removal Procedure ..................................... 16
Installation Procedure .................................. 33 Inlet Manifold - Install....................................... 14
Front Cover - Install ......................................... 36 Inlet Manifold - Remove................................... 14
Installation Procedure .................................. 36 Removal Procedure ..................................... 14
Front Cover - Remove ..................................... 35
Fuel Filter Base - Remove and Install................ 5 L
Installation Procedure .................................... 5 Lifter Group - Remove and Install.................... 47
Removal Procedure ....................................... 5 Installation Procedure .................................. 47
Fuel Temperature Sensor - Remove and Removal Procedure ..................................... 47
Install.............................................................. 67
Fuel Transfer Pump - Install............................... 6
Installation Procedure .................................... 6 P
Fuel Transfer Pump - Remove........................... 5 Piston Cooling Jets - Remove and Install........ 54
Removal Procedure ....................................... 5 Installation Procedure .................................. 54
Pistons and Connecting Rods - Assemble ...... 57
G
Gear Group (Front) - Install.............................. 37 Pistons and Connecting Rods -
Installation Procedure .................................. 37 Disassemble .................................................. 56
Gear Group (Front) - Remove ......................... 37 Disassembly Procedure............................... 56
Removal Procedure ..................................... 37 Pistons and Connecting Rods - Install............. 58
Pistons and Connecting Rods - Remove......... 55
H Removal Procedure ..................................... 55
Housing (Front) - Install ................................... 38
76 RENR9214
Index Section
R
Rocker Shaft - Assemble................................. 42
Rocker Shaft - Disassemble ............................ 42
Rocker Shaft and Pushrod - Install.................. 43
Rocker Shaft and Pushrod - Remove.............. 42
T
Table of Contents............................................... 3
Turbocharger - Install....................................... 12
Turbocharger - Remove................................... 12
V
Valve Actuator (Variable) - Remove and
Install.............................................................. 41
Valve Mechanism Cover - Remove and
Install.............................................................. 39
Valve Mechanism Cover Base - Remove
and Install....................................................... 40
Vibration Damper and Pulley - Remove and
Install.............................................................. 33
W
Water Pump - Assemble.................................. 26
Water Pump - Disassemble............................. 26
Water Pump - Install ........................................ 27
Water Pump - Remove .................................... 25
Water Temperature Regulator - Remove
and Install....................................................... 28
©2015 Caterpillar CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow”, and the POWER EDGE trade
All Rights Reserved dress as well as corporate and product identity used herein, are trademarks of Caterpillar and
may not be used without permission.

Renr9214 18 00 All - MANUALS SERVICE MODULES

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RENR9214-18

Disassembly and Assembly

Important Safety Information

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Table of Contents Front Cover - Remove .................. .................. 35

Inlet Air Temperature Sensor - Remove and

Accidental machine starting can cause injury or

Disassembly and Assembly 4. Remove fuel filter base (5).

Section Installation Procedure

S/N: BJ6; TXE1–Up

1. Position fuel filter base (5) on the engine.

2. Install bolts (4).

3. Connect hose assemblies (1) and (6).

4. Connect harness assemblies (2) and (3).

Fuel Transfer Pump - Remove

Illustration 1 g01132492 Removal Procedure

2. Disconnect hose assemblies (1) and (6).

3. Remove bolts (4).

1. Position fuel transfer pump (4).

2. Install bolts (3).

3. Connect tube assemblies (2).

4. Connect hose assembly (1).

Electronic Unit Injector -

Tool Part Number Part Description Qty

1. Disconnect harness assembly (1) from electronic

2. Remove bolt (3).

i03781931 3. Use Tooling (C) to clean tip bore (6).

Tool Part Number Part Description Qty

9U-6862 Tapered Brush 1

1U-5718 Vacuum Pump 1

E 169-7372 Fluid Sampling Bottle 1

1. Evacuate as much fuel and oil as possible from the

6. Install electronic unit injector (2) and unit injector

Note: Use new bolt (3).

8. Connect harness assembly (1) to electronic unit

Tool Part Number Part Description Qty

• Injector Code Calibration

4. Tighten the nut until electronic unit injector sleeve

5P-8247 Hard Washer 1

NOTICE 4K-0367 Nut 1

4. Install the following parts from Tooling (A) over the

Electronic Unit Injector Sleeve

Part Description Qty Illustration 11 g01131579

4. Position electronic unit injector sleeve (1) in the

Note: Do not apply Tooling (E) to the cylinder head

Tool Part Number Part Description Qty

9U-6862 Tapered Brush 1

9U-6863 Small Bore Brush 1

4C-5552 Large Bore Brush 1

D(1) 9U-7258 Driver Cap 1

8. Remove Tooling (D) and Tooling (C). Use a clean

9. Install the electronic unit injector. Refer to

10. Fill the cooling system with coolant. Refer to

Turbocharger - Remove Turbocharger - Install

Removal Procedure Installation Procedure

1. Drain the coolant system. Refer to Operation and

1. Apply Tooling (A) to the turbocharger mounting

4. Connect tube assembly (5).

5. Connect hose assemblies (3), (4), and (6).

2. Remove turbocharger (2) and the gasket.

i04001170 6. Remove nuts (1), the washers, and the spacers.

Exhaust Manifold - Remove 7. Remove exhaust manifold (4) and the