Disassembly & Assembly0000 PDF

DATERPII.
[AR' RENR9365_10
September 2010
35OOc EngineG
i03991 620
lmportant Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills and tools to perform these functions properly.
lmproper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manualand on the product. lf 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 SafetV Alert "WARNlNG" 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
oresented.
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 rnight 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. lf a tool, procedure, work method or operating technique that is not
specifically recommended by Gaterpillar is used, you must satisfy yourself that it is safe for you
and for others. You should also ensure that the product will not be damaged or 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 Gaterpillar recommends using Gat re-
placement parts or parts with equivalent speci-
fications including, but not limited to, physical
dimensions, type, strength and material.
Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury 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.
RENR9365_10
Table of Contents
Table of Contents Auxitiary Water puAp _ Install ........ ...........

Rem
Engine Oil Cooler _ 81
82
Disassembly and Assembfy Section B3
B4
B5
B6
6l
9,7
BB
B9
91
YZ
^6
93
94
95
95
96
b[:
e......... 39
... . 98
,................ 99
Crankshaft Fronl Seal and Wear 127

Sleevu I inri"f r
Flywheet- nemove anJ in.l"li -.. I zo

Crankshaft Rear Seal and Wear 129
Auxiliary Water pumb _ Assembte Sfeeve Remove
. .. ......... .... t[
_
130
4 RENR9365-'10
Tab e of Contents
Crankshaft Rear Seal and Wear Sleeve - lnstall Engine Speed Sensor - Remove and lnstall .... .. 193
131 Fuel Pressure Sensor - Remove and lnstall ...... 194
Flywheel Housing - Remove 41.) Fuel Pressure Sensor- Remove and Install ....... '195
Flvwheel Housino - Install 134
Engine Oil Sequence Valves - Remove and lnstall lndex Section
136
Gear Group (Rear) - Remove 139 1ndex......... ........ 197
Gear Group (Rear) - Install 139
Piston Cooling Jets - Remove and Install .......,... 140
Bearing Clearance - Check 141
Connecting Rod Bearings - Remove and Install
142
Crankshaft Main Bearings - Remove ..... .....,... , 144
Crankshaft Main Bearings - Install ...................... 145
Pistons and Connecting Rods - Remove ............ 147
Pistons and Connecting Rods - Install ................ 148
Cylinder Liner - Remove ...... 150
Cylinder Liner - lnstall ......... ............. 150
Camshaft - Remove ... 151
Camshaft Bearings - Remove ................ 154
Camshaft Bearings - Install ........ ...,. 154
Camshaft - lnstall .. ....... 155
Crankshaft - Remove ........... 159
Crankshaft - Install .,...... 160
Radiator Group - Remove .,....... ....., 163
Radiator Group - Install ...................... 165
Radiator Core - Remove ................. 167
Radiator Core - Instal ........ ............. 169
Fan Drive - Remove ... ......... 171
Fan Drive - Disassemble .,.......,...,.. 173
Fan Drive - Assemble .... .......,.... . 175
Fan Drive - Install .......... 176
Balancer Group (Front) - Remove and Install (3508C
Engine) .... 178
Coolant Level Sensor - Remove and lnstall .. .... 179
Engine Oil Pressure Sensor - Remove and Install
.................. 180
Enqine Oil Pressure Sensor - Remove and lnstall
181
Turbocharger Inlet Pressure Sensor - Remove and
lnstall..,...... ..... 182
Turbocharger Inlet Pressure Sensor - Remove and
Install... ........ 183
Turbocharger Outlet Pressure Sensor - Remove and
lnstall......... ................. 184
Turbocharger Outlet Pressure Sensor - Remove and
Install......... .................. 185
Coolant Temperature Sensor - Remove and
Install......... .................... 186
Coolant Temperature Sensor - Remove and
Install......... .............,.... 187
Aftercooler Coolant Temperature Sensor - Remove
and Install ...... 188
Aftercooler Coolant Temperature Sensor - Remove
and lnstall ...,..,.........,... 189
Engine Speed/Timing Sensor - Remove and
Install......... .................... 190
Crankcase Pressure Sensor - Remove and
Install......... .................. 191
Atmosoheric Pressure Sensor - Remove and
lnstall ......... .. 192
Atmospheric Pressure Sensor - Remove and
Install........, ...... 193
RENR9365_10
Disassem bly and Assembfy Removal of an Air Starting Motor

Section Without
the Air Tube Assembli"" ittr.-fr"A
1. OFF the suppfJ of pressurized
I-r_rn
the pressurized air trom the air air. purge
i02514309 lines and the air
Air Starting Motor - Remove starting motor.
SMCS Code: 1451_011

S/N: LLA1-Up
S/N: R141-Up
S/N: LLBl-Up
S/N: LLCl-Up
S/N: C8E1-Up
S/N: LLE1-Up
S/N: LLF1-Up
S/N: SBGl-Up
S/N: SBJl-Up
S/N: C8K.t-Up
S/N: SBK1-Up
lllustration
S/N: NAM1-Up 1
901 257888
S/N: SBMl-Up 2. Disconnect hose assemblies (1).
S/N: KENl-Up 3. Remove bolts (2).

S/N: PESl-Up 4. Remove union nut (3) and air tube assemblies
(4).
S/N: R151-Up
S/N: RMSl-Up
S/N: T2X1-Up
S/N: RTX1-Up; R2A1_Up
Removal procedure
Keep al parts crean t Jr?*?ilinants.

9^":l:l1gt!: r"y caLrse rapid wear and shortened
component life.
lllustration 2
900597643
ir starting motors are 5. Disconnect hose assembly (5).

starting motors can have
r the air lines. Examples 6, Attach a suitable lifting device
to air starting
air starting motors are motor (6). The weight-o-f-all starting
approximate! aS kg (106 tb). - "r !rioior
' 'v' 101 is
7. Remove bolts (7). Remove

air starting motor (6).
gasket.fro, fll"
l_?roug.the
cover of the air starting motoiioinl'0"X"""n t .
ano t[eiivwneef
housing.
6 RENR9365-10
Disassembly and Assembly Section
Removal of an Air Starting Motor With i02558 383
the Air Tube Assemblies Attached Air Starting Motor -

1. Turn OFF the supply of pressurized air, Purge Disassemble
the pressurized air from the air lines and the air
starting motor. SMCS Gode: 1451-015
S/N: LLA1-up
S/N: R1A1-Up
S/N: LLBl-Up
S/N: LLCl-Up
S/tl: CBEl-Up
S/N: LLEl-Up
S/N: LLFl-Up
S/N: SBGl-Up
lllustration 3 901 049692 S/N: SBJl-Up

S/N: CBK1-Up
2. Disconnect harness assembly (8).
S/N: SBK1-Up
3. Disconnect the air supply tube from elbow (9).
S/N: NAM'1-Up
S/N: SBMl-Up
S/N: KENl-Up
S/N: PESl-Up
S/N: R1S1-Up
S/N: RMSl-Up
S/N: T2X1-Up
S/N: RTX1-Up; R2A1-Up
lllustration 4 901 049697

Disassembly Procedure
Table 1
4. Attach a suitable lifting device to air starting motor
(11). The weight of air starting motor (11) with Required Tools
the air tube assemblies is approximately 86 kg Tool Part Number Part Description Qtv
(1e0 rb).
A 1P-1854 Retaining Ring Pliers 1
5. Remove bolts (10) and air starting motor (11). Plate

Remove the gasket from the joint between the 51 .0 by 102.0 by 6.0 mm
B 2
cover of air starting motor (11) and the flywheel (2.00 by 4,00 by 0.25
housino. inches)
1P-1857 Retaining Ring Pliers 1
Start By:
a. Remove the air starting
motor. Refer to
Disassembly and Assembly, "Air Starting Motor
- Remove".
RENR9365_10
7
Disassembly and Assembly
Section
Keep al parts crean t Hll?irrinants

9:llll",r,l: rry cause rapid wear and snortened
component life.
Note:.Several different air starting

motors are
available for use. An example
of disassembling a
typicat air starting motor gp'is
oe;il;;l;i"*
lllustration 7
90092501 5
t remove retainins nng (8) rrom

ff"""t;:ilt#'to
lllustration s
9009250 1 1
t (1) and bracket (2) from motor

ilTlr";(:how
@__
lllustration B
900925059
f_"_r:gnll injury can result from parts and/or

ers under spring pressure. cov_
Spring force will be refeased when

moved.
covers are re_
lllustration 6 go092So12 Be.prepared to hold spring loaded

bolts are loosened. covers as the
2. To ensure correct assembly,
mark the position
of motor housinq reltn retaiio;j;'g;;r'""se
Remove bolts (4).'l (6), Note: Bolt (9) has left hand threads.
oriue nousinn rbi sear case (6) and
"13T,?Y," 4. Remove bolt (9) and washer (10).
Remove drive
(11), th'e'sprins ir""u")
Ti:l
spnng. "r,io't#'iinion
embly, mark the position

relation to gear case (6).
d drive housing (5) from'
8 RENR9365-10
7. Slowly release the suitable press in order to

remove the force of return spring ('16). Remove
Tooling (B). Remove retaining ring (15). Remove
the drive gear, piston (14), and the drive shaft
from drive housing (5) as a unit. Remove return
spring (16).
lllustration 9 900925061
5. Remove O-ring seal (13) from drive housing (5).
L Loosen the bolt for the drive gear with a 5/16 inch
hex wrench until the bolt moves freely. Remove
drive shaft (17) and piston (14) from drive gear
(7) as a unit.
The drive shaft, the piston, and the drive gear are
under a sprinE force. Slowly release the spring
force before you remove these components.
6. Place Tooling (B) between drive gear (7) and lllustration 13 s01143104
piston (14). Use a suitable press to compress
the return spring. Remove retaining ring (15) 9. Remove bulkhead (18) from piston (14). Remove
that holds the drive shaft and the oiston in drive O-ring seals (19) from bulkhead (18)
housing (5).
RENR9365_10
o
10. Remove retainino (20) from piston (14)

Remove the pisto-n 1ng
rr.im oii'"" ,i;['i;;;
lllustration 1 7 gooe251o4
lllustration 15
90092S09S t t rin g (32) a nd bearins (33)
tt seal (22) and rip seal (21)'from
J,?33il:ti"(i'il1 " rro m
JS-Tiii.i-rins Note: Note: Do not reuse retaining

ring (32)
lllustration 16
901 0524S9
lllustration 1B 05
900925 1
14. Use Tooting (C) to

rins (35) Remove
bearins (34) rrom,:T:::Ji'J
l:r::^ll,_,liury
ers
can resutt rrorn
under spring pressure.
p-rtilrd/or cov_
-I-
Spring force will be released

when covers are re_
moved.
Be.orepared to hold spring loaded

lllustration 19
900925 1 07
15. Remove spring seat (36)

and bearing (37) from
orrve housing (5).
10 RENR9365-10
900925'110 900925 1 49
lllustration 20 lllustration 23
16. Remove lip seal (38) from drive housing (5). 19. Loosen hex socket head bolt (43) and remove
rotor clamp nut (42). Remove bearing (44) from
rear end plate (45).
o
900925 1 1 4
lllustration 21
f 7.To ensure correct assembly, mark the position lllustration 24 9009251 51
of cover (39) in relation to motor housing (3).

Remove cover (39) and remove the O-ring seal 20. Remove O-ring seal (46) and rear end plate (45).
from motor housing (3).
21. Remove vanes (47) from rotor (48).

18. Remove bolt (41) and rotor pinion (40) from the
rotor in the motor housing. 22. Remove rotor (48) from the motor housing.
RENR9365-10
11
Section
lllustration 26
90092s i 56
lllustration 29
90092521 6
23. Use a suitable oress to
remove bearing (4g) and
front end ptate ('50) rrom roior'fiii5r'""rnit 26. Remove O-ring seals (52)
from rotor cytinder (S3).
lllustration 27 g0092sl S7
lllustration 30
901 14291 5
24, Remove bearing (49) 27. Remove rotor cvlinder (S3)-from

from front end plate (50). motor housing
(3). Remove o_ring (s+i i.r-tt"'rotor"
cylinder. ""at,
il
lllustration 2g
900925210
25. Remove washers (S1)

from front end plate (50).
I
12 RENR9365-10
NOTICE
Air Starting Motor - Assemble Keep all parts clean from contaminants.
SMGS Code: 1451-016 Contaminants may cause rapid wear and shortened
S/N: LLA1-Up component life.
S/N: RIA1-Up
S/N: LLBl-Up
S/N: LLCl-Up
S/N: C8E1-Up
S/N: LLEl-Up
S/l{: LLF1 -Up
S/N: SBG1-Up
S/N: SBJl-Up
S/N: CBK1-Up lllustration 31 900925323
Sll.l: SBK1-Up
1. lnstall O-ring seals (54) on rotor cylinder (53).
S/N: NAMl-Up Install the rotor cylinder in motor housing (3).
Orient pin (55) of the rotor cylinder with slot (56) in
S/N: SBMl-Up the motor housing.
S/N: KENl-Up
S/N: PES'1-Up
S/tl: R1S1-Up
S/N: RMS'1-Up
S/N: T2X1-Up
S/l,l: RTXI -Up, R2A1 -Up
Assembly Procedure
Table 2
Required Tools 90092521 6

lllustration 32
Tool Part Number Part Description atv
2. Install O-ring seals (52) onto rotor cylinder (53).
A 1P-1854 Retaining Ring Pliers 1
Plate
B 5'1.0 by 102.0 by 6.0 mm z
(2.00 by a.00 by 0.25 inch)
.- 1P-1857 Retaining Ring Pliers 1
Tube
D 57 0 by 203 0 by 6.0 mm
(2.25by 8.00 by 0.25 inch)
E 1P-0510 Driver Gp 1
F 25 - 3230 Bearing Lubricant
lllustration 33 s01142958
3. Install rear end plate (45) on the shaft of rotor (48).

RENR9365_10
IJ
Section
4' Instalr o-ring sear (46) over

the shaft of the rotor.
8. Install rotor (48) intg;1o-!or housing
(3). Atign pin
(57) into the slot of rne rear
end plate.
lllustration 34
901 142900
5. Apply Toolinq (F) to bearin g (44).Instatl lllustration 37

901 142988
(4.4.) over tnJsnjrt bearing
plate (45).
.toiia'e)'jno'ffi rear end S. fhgr.ouglly tubricatevanes (47)
"r with SAE 10Woil
6. f nstarr rotor cramp nut-(42) on
and instalt vanes (47) into tfi"
6i;;' "' "
the shaft of the rotor.
l0.lnstall front_end plate.(50) onto
orient the shoutder or irrE' n ui i;;;; ffi
bea rins. smail hote (58) of froniend pt;i"
the rotor. Align
(5e).
o;i;;tor pin
lllustration 35
oo1142961
O 7. Tighten rotor ctamp

l{^(42) in order to obtain a
lllustration 3B
900925361
;!"ff.::?^"j9# 1""9 gP^'-i'ron6i to"ffis incrr)

$""Y::: lp ::: l -"lq I tli i;bi ;; o'Ioioi io u I
11.Instali washers (51) over the
onto the front end plate.
shaft of the rotor
Y:f:y"^ :g :f l.'l :; y:i1 *i"" i"l b"Jb :
ur e a o n oi tli i i i" rtliYEr."
clamp L"l : ? "J,."
L,gl,;. Inut(42). t"r.
rueaslie fr.," J""ijrJ"1;::;l
lllustration 39
900925366
lllustration 36
900925356
14 RENR9365-'10
f 2.Apply Tooling (F)to bearing (49) Use Tooling (E)

and a suitable press to install bearing (49) in the
front end plate.
90092539 1
lllustration 43
f 5.Apply Tooling (F)to bearing (33) Install bearing

lllustration 40 900925 1 1 6 (33) and new retaining ring (32) onto drive shaft
{3.Install rotor pinion (40). Install bolt (41). Tighten !:'J,i"?:il?1'R?"1Blf li,i,Tilxil",iliii,,f ,,,.1
the bolt to a torque of 120 N m (e0 rb ft).
l.{ote: Note: Do not reuse retaining ring (32).
901 052459
lllustration 44
14.Install O-ring seal (60). Install cover (39) onto
motor housing (3)
lmproper assembly of parts that are spring loaded

can cause bodily injury.
To prevent possible injury, follow the established

assernbly procedure and wear protective equip-
ment.
16.Install retaining ring (31). Install bolt (23),

lockwasher (24), and washer (25) into drive shaft
(17). Apply Tooling (F) to bearing (26) and install
bearing (26) into the drive shaft. Install bolt (23),
lockwasher (24), and washer (25) into drive shaft
(17). Apply Tooling (F) to bearing (26) and install
lllustration 42 900925390 the bearing into the drive shaft. Install driving
clutch jaw (27), driven clutch jaw (28), spring (29),
and cup (30) into the drive shaft Install retaining
ring (31). Thoroughly lubricate the drive assembly
with SAE 10W oil.
RENR9365_10
14
bh
-"
-(^ \_/
lllustration 45
901 '143059
lllustration 4B go11 43117
sear (21) into piston

"iYff trJ:11%.-Ttf J::lliii 20.In_stall drive gear (7) onto
drive shaft (.17). Use
a st16 inch h-ex wrench t" iigh[,
drive gear to 7Z N m (52 tb fi).
ih" t"ri
"iin""
lllustration 46
9009254 1 9
lllustration 49 go1143jZ0
drivenshaft (r 7) . Install
".3:1;1L!1ru [#] :i8 lffi 2f ..Use Tooting (E) to install lip
seal (38) into drive
nousing (5).
(t,)
lllustration 47
9011431 04
19. Install O-ring seals lllustration 50

burkhead (iB) onto
(18) Install 90.t143123
513,H11".?'lkhead 22.,Appty Tooting (F) to bearinq (37)

and install the
Deanng into the drive housinq.
23.lnstall spring seat (36) into the

drive houslno.
16 RENR9365-10
@--==-
900925068 900925 1 o5
27" Apply Tooling (F) to bearing (34) and install

bearing (34) into gear case (6). Use Tooling (C) _
lmproper assembly of parts that are spring loaded to inst;ll'loit< ring"las;. O

assembly procedure and wean protective equip-
rnent,
24.Install return spring (16) onto the spring seat

inside drive housing (5).
25.Install the drive gear, the piston, and the drive

shaft onto the return spring as a unit.
Install retaining ring (15) over the piston. Place

Tooling (B) between the drive gear and piston (14).
g0 43454
Use a suitable press to compress return spring lllustration 54
1 1
(16). Install retaining ring (15) into the groove of

the drive housing. Slowly release the press and 28.Install drive housing (5) on gear case (6). Make
remove Tooling (B). sure that the shaft on the end of the drive gear
is correctly engaged with the bearing in the gear
case. Install bolts (12) and tighten to a torque of
36 N m (27 tb ft).
26. Install O-ring seal (13) to drive housing (5).

29. Use Tooling (A) to install retaining ring (B).

RENR9365-10
lllustration S6 901143442
lllustration SB 9009250 1 1
32.Install.the gasket, elbow (1), and

brackei (2) on
motor housirg (3)
assembly of parts tt
I!r-ol"r
can cause bodily injury. "t "r" "pring
toaded
33.After you verify.that the starting motor
operates
property, attach the air lines to
To prevent possible injury, follow the starting ,otor.
the established
assembly procedure and wear pr;i;".tiu"
t_erify the Operation of the Air Starting
ment. equip_
Motor
Note: Bolt (9) has Ieft hand threads.
procedure to verify that the air
Y_:_"_,I_"j:li:wing
srarttng motor is operating correcfly:
30.Instail pinion spring (62), spring
steeve (61), and
drive pinion (11). Install ir,,air,er"1ioy 1. Turn the drive pinion by hand in the direction
an'j oort 1s1. of
Tighten bott (9)'to a torque or rrb
rrti,i'iio lu ttl. the rotationof the starting ,otor'il" drive clutch
musr operate smoothly with a clicking
Note: Bolt (9) has left hand threads. sound.
2. Turn the drive pinion in the opposite direction
the rotation of the.starting mdtbr. fne-jrive of
pinion
must turn by hand.
3. Ap,glV 345 kpa (50 psi) of air pressure

ln the inlet
of the drive frousingj. the Orivb pmio;must
move
away from the drive housing
,rrt
art"
out of the ouflet of the drivihousinq.
"nd "o."
lllustration S7 900925012
" :":lilf,* ?s)1?i,3,:i fl :ilS "

eventy to a torque of 80 N.m (60i,j':trJ;131
t'b ft).
S. Ag,glV 620 kpa (90 psi) of air pressure
in the intet
of the drive housing. fhe stariing rnoto,
smoothly.
,rrtr"rn
End By:
a. Install the air starting motor.

Refer to Disassembly
and Assembly, ,,Air Starting fVfotor _ f
nsiaff,,.
18 RENR9365-10
i02514373 Installation of an Air Starting Motor

Air Starting Motor - Install Without the Air Tube Assemblies
Attached
SMCS Code: 1451-012
S/N: LLA1-Up
S/N: RlAl-Up
S/N: LLB1-Up
S/N: LLC1-Up
S/N: C8E1-Up
S/N: LLEl-Up
S/N: LLF1-Up
S/N: SBG1-Up
lllustration 59
S/N: SBJl-Up
1. Attach a suitable lifting device to air starting
S/N: C8K1-Up motor (6). The weight of air starting motor (6) is
S/N: SBK1-Up approximately 48 kg (106 lb).
S/N: NAMl-Up Install a new gasket for the joint between the cover
of the air starting motor and the flywheel housing.
S/N: SBMl-Up Position the air starting motor and install bolts (7).
S/N: KENl-Up Connect hose assembly (5).
S/N: PES1-Up
S/N: R151-Up
S/N: RMS1-Up
S/N: T2X1-Up
S/N: RTXI-Up; R2A1-Up
I nstallation Proced u re
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened

component life.
Note: Several different air starting motors are

available for use. The air starting motors can have
different configurations for the air lines. Examples of
installing twp different air starting motors are provided lllustration 60 901 257888
below.
4. Install air tube assemblies (4) and union nut (3).
5. Install bolts (2).

6. Connect hose assemblies (1).
RENR9365_10
19
Installation of an Air Starting Motor

With
the Air Tube Assemblies Atticfrlo i024.10981
Electric Starting Motor _

Remove and lnJtalt
SMCS Gode: 1453-010
Removal procedure
Disconnect batteries before pu.form"n""

service work. of any
Note: Before disconnecting the harness

g0 1 049697 assemblies,
mark the items for the. pro rer connections
in order to
ensure correct assemblv.
1. Attach a suitable lifting device to
air starting motor
LJtt In" weisht or aiistartinl'rJitiii'rt
the air tube *ill
assembties is a6 kg
(1e0 tb). "piro*ir"tliy
2. lnstall q ngw gasket for the joint between the
cover of air startinq. m9to1
position 1ti I ano irre itywtreel
housing a-ir;Cirirg ,i,Ji"i
bolts (10). iiil'"nd instatl
lllustration 63
1. Disconnect the harness assemblies

(1) and etectric starting moior"" solenoid
from
fii.--
lf.the engine has two electric starting
motors,
disconnect the harness assemblies
between the
solenoids and electric starting ,otors. '
2. Attach a suitable lifting device to electric

starting
motor (2). The weight of etectric
3. Connect the air supply tube to elbow - siartlnf
-'-''"'= motor (z)
(9). is approximatety 30 kg (66 tbf.
4. Connect harness assembly (g). 3. Remove bolts
motor
5. Turn ON the supply of pressurized 121.nemove- een
air. et6ctric stariin
housing.
Installation procedu re
t. I:ry:, the.gasket for the joint between the
etecrnc startinq motor and the flywheel
Obtain a new lasket, if necessa'm '--' '
housing.
20 RENR9365-10
NOTICE

component life.
1. Disconnect the batteries.
2. Put an index mark on the harness assemblies that

are connected to the prelubrication oil pump.
3. Disconnect the harness assemblies from the

prelubrication oil pump.
2. Attach a suitable lifting device to electric starting

motor (2). The weight of electric stafting motor (2)
is approximately 30 kg (66 lb).
3. Place the gasket in the cover for electric starting

motor (2). Lift the electric starting motor (2) onto
the mounting position. Install bolts (3).
Connect the harness assemblies to solenoid (1)

and electric starting motor (2).
lf the engine has two electric starting motors,

connect the harness assemblies between the
solenoids and electric startinq motors. lllustration 65 901 947358
4. Disconnect hose assembly (3)and hose assembly

(6)from prelubrication oil pump (1).
Prelubrication Oil Pump -
5. Attach a suitable lifting device to prelubrication oil
Remove and Install pump (1). The weight of prelubrication oil pump
(1) is approximately 2a kg (53 lb).
SMCS Code:1319-010
6. Remove bolts (2), bolts (4), bolts (5), and
S/N: FlXl-Up prelubrication oil pump (1).
S/N: F2X1-Up
Installation Procedure
Removal Procedure
NOTICE
NOTICE Keep all parts clean from contaminants.
Care must be taken to ensure that fluids are contained
d uri n g .performance of inspection, maintena nce, test-
ing, adjusting and repair of the product. Be prepared to component life.
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Refer to Special Publication, NENG2500, "Caterpillar

Dealer Service Tool Catalog" for tools and supplies
suitable to collect and contain fluids on Cateroillar
products.
Dispose of all fluids according to local regulations and

mandates.
RENR9365_10
zl
Prelubrication oil pum , -'o"o"o"

r-
Remove and instalt
SMCS Gode: .1319-0i0
S/N: SBGl-Up
S/N: SBJ'l-Uo
S/N: SBK1-Uo
S/N: NAMl-Uo
lllustration 66
901 942358
S/N: SBMl-Uo
1. Attach a surtable lifting device to prelubrication S/N: KENl-Up

pump (1i oil
Ih.: y"lghJ of pretubriiation oii pu-mi S/N: RTXl-Up; R2A1-Up
A (1) is approximatety z+ tb fsa rOl
- z. l-osttton prelubrication oil pump (1)

t and install
Removal Procedure
botts (S), bolts (4), ano ooiis
fil
3. Connect no^=:::"rgry and hose assembty care must be taken,o |n?t'"'
tO)
(3) to pretubrication oit 'prl#p during performance of
ff l
ing, adjusting and repar
4. Connect the narness assemblies to collect the fluid with su
the
prelubrication oil pump. rng any compartment or
5. Connect the batteries.
Refer to Special publication, NENG2500, ,,Caterpillar
products Guide,,
Iogl: ?ng Shop ro, toli=
suitable to collect and contain fiuiOs "no suppties
products. on" Caterpillar
Dispose of all fluids according to local

regularrons and
mandates.
Keep atl parts crean trffil?[rinants

!ôllamina,njl may cause rapid wear and shortened
component life.
1. Disconnect the batteries.

2. Put an index mark on the harness
assemblies that
are connected to the prelubrication
oil pump.
3. Disconnect the harness assemblies
from the
pretubrication oil pump.
22 RENR9365-10
4. Connect the harness assemblies to the

prelubrication oil pump.
5. Connect the batteries.
i02492916
F Alternator - Rernove and Install

I
SMCS Code: 1405-010

S/N: LLA1-Up
S/N: R141-Up
lllustration 67 901 1 30821 S/N: LLBl-Up
4. Disconnect tube assembly (1) and disconnect tube S/N: LLCl-Up

assembly (2) from the prelubrication oil pump. S/N: C8E1-Up
5. Fasten a suitable lifting device to prelubrication oil S/N: LLEl-Up
pump (3). The weight of prelubrication oil pump
(3) is approximately 24 kg (53 lb). S/N: LLFl -Up
S/N: SBGl-Up
6. Remove bolts (4) and remove the prelubrication
oil pump. S/N: SBJl-Up
S/N: CBK1-Up
lnstallation Procedune
S/!S: SBK1-Up
NOTICE
Keep all parts clean from contaminants. S/N: NAMl-Up
S/N: SBMl-Up
component life. S/N: KENl-Up
S/N: PESl-Up
S/N: RlSl-Up
S/N: RMS1-Up
S/N: T2X1-Up
Removal Procedure
901 1 30821
Fersonal injury can result from failure to discon-
lllustration 6B nect the battery.
1. Fasten a suitable lifting device to prelubrication oil First, dlsconnect the negative battery cable. Then,
pump (3). The weight of prelubrication oil pump disconnect the positive battery cable.
(3) is approximately 2a kg (53 lb).
A positive power lead can cause sparks if the bat-
2. Position the prelubrication oil pump and install tery is not disconnected. Sparks can possibly re-
bolts (4). sult in battery explosion or fire.
3. Connect tube assembly (2) and tube assembly (1)
to the prelubrication oil pump. 1. Disconnect the batteries
2. Remove the belt guard.

RENR9365_10
ZJ
1. lf necessary, install the pulley on

alternator
(1f Instail nut (4) anO ti!fiteri to'aloiqr"
110!10Nm(8ir7tb-ft). or
2. Position atternator
(J) gn9 instail bott (b) and bott
(3). Do not tighten tne notts.
3. lnstatt bett (6).
4, Adjust the bett tension tjOhten adjusting nuts

(2) on the adjusting rod31d Ref# to'blZr.tion ,nO
M a n te n a n ce- M a n Lia t,,;
i
e iir" n r]o;'ih r rt"
"
5. Tighten bott (3) and bolt (5).
6. Connect the harness assemblies

on alternator
(1). rishten the nuts.,
Tefgl i; SpJ.irilrt,on.,
"Atternator and Regutator,t r* t Jioiqil u"lr".
7. Install the belt guard.
lllustration 69
9o1246413 8. Connect the batteries,
3. Put an index mark on all of the harness assemblies
that are connected to atternatoiji;. ""'
4. Disconnect the harness assemblies from the
alternator.
5. Loosen adjusting nuts (2).
6. Remove bett (6).
7. Remove bolt (3). Remove bolt (S)

and remove the
alternator.
8. lf necessary, remove nut (4) and

pulley from the alternator. remove the
Installation procedure
lllustration 70
901246413
24 RENR9365-10
i02492929
Alternator Mounting Group -

Remove and Install
SMCS Code: 1405-010-MT
S/N: LLA1-Up
S/N: RIA'1-Up
S/tl: LLBl -Up
S/N: LLCl-Up
S/N: CBEl-Up
901246426
lllustration 71
S/N: LLE'1-Up
S/N: LLFl-Up
'l
" Remove bolts (2) and remove alternator support
(1 ).
S/N: SBGl-Up
2. Remove bolts (3). Remove pulley (4) from the
S/N: SBJl-Up accessory drive.
S/tr!: C8K1-Up 3. Remove lip seal (5) and sleeve (6) from pulley (4)
S/N: SBI(1-Up
lnstallation Frocedure
$/i'l: NAMl-Up
Table 3
S/N: SBMl-Up
Required Tools
S/N: KENl-Up Tool Part Number Part Description Qtv
S/N: PESl-Up 1P-0520 Driver Group 1
S/N: R1S1-Up
NOTICE
S/N: RMS1-Up Keep all parts clean from contaminants.
S/N: T2X'1-Up
S/N: RTX1-Up; R2A1-Up comoonent life.
Removal Procedure
Start By:
a. Remove the alternator. Refer to Disassembly and

Assembly, "Alternator - Remove and Install".
NOTICE

component life.
1. Use Tooling (A)to install sleeve (6) on pulley (4).
2. Use Tooling (A)to install lip seal (5). Apply clean

engine oil to the lip seal. Position the pulley on the
accessory drive and install bolts (3).
3. Position alternatorsupport (1)and install bolts (2).

RENR9365_.10
Disassemb and Assembly Section
End By:
7. If necessary, remove bolts (6)
and bracket (5).
a. Install the alternato.r. Refer
to Disassembly and
Remove th6 gasket.
Assembly, ,,Atternator _ R;r;;;;;inri"rr .
i03630669
Electronic Gontrol Module
(Engine) - Remove and Install
SMCS Gode: 1900_010
S/N: FlXl-Up
S/N: F2X1-Up
Removal procedure
Keep al parts crean rffillffirinants lllustration 74

90 1 948308
Contamina,n,{: r"y cause rapid wear and shortened 1. Install the gasket and bracket (5).
Instail botts (6)
component life.
2. Position electronic control module (4) and install
bolts (3).
Note: tf the etectron,".:l,l:lmodute
(ECM) is being
replaced, download the_personality
you remove the ECM. Refer module before 3. Connect ground strap (7).
"Replacing the ECM,'. to frouOtlshJoting,
4. Connect hose assembly (2) and
hose assembly
(1) to electronic control'm"irf" "
1. Disconnect the negative battery f+].""
terminal at the
battery.
5. Connect the harness. assemblies to the
control module and tighten the etectronic
2. Remove the sensors from allen hJ"o ,"ruws
the bracket. t
to a torque of 6 1 N:m (sa
i;i;) ""
is
3. Loosen the allen heao
screws and disconnect the 6. Install the sensors in the bracket.
narness assemblies from the electronic
module. control
7. the negative battery terminal at
ic_o,llfect
batterv. the
lllustralion 73
901 948308
4. Disconnect hose assembly (1)

and
(2) from electronic control'mo'dri" hose assembly
frii.""
5. Disconnect ground strap (Z).
6. Remove bolts (3) and electronic control

(4) module
26 RENR9365-10
i02723993
EEeetnonie Gontrol ModuEe

{Hngine} - Ren'love and Ineta!fl
SMCS Code: 1900-010
S/[tl: LLAl-Up
S/N: RlAl-Up
S/N: LLBl-Up
S/N: LLCl-Up
$$/F,l: C8E'1-Up
$/N: LLEl-Up
?. Loosen allen head screw (3) and disconnect
S/N: LLFI -Up the harness assemblies from electronic control
S/N: SBGl-Up module (2).
$/Nl: SBJl-Up Disconnect ground strap (6).
S/ttl: CBK1-Up 4. Remove bolts (1). Remove electronic control

module (2).
$/hl: SBK'1-Up
S/N: NAMl-Up 5. lf necessary, remove bolts (4) and bracket (5)
Remove gasket (7).
S/t{: SBMl -Up
S/N: KENl-Up !nstallatiosr Procedure
$/N: PESl-Up
S/N: RlSl-Up
S/N: RMS1-Up
S/f{: T2X1-Up
Removal Frocedune
NOTICE
lllustration 76
comoonent life. '!. Install gasket (7) and bracket (5). Install bolts (4).
Note: lf the electronic control module (ECM) is being 2. Position electronic control module (2) and install
replaced, download the personality module before bolts ('1).
you remove the ECIM. Refer to Troubleshooting,

"Replacing the ECM". 3. Connect ground strap (6) and tighten to a torque
of 2.50 ! 0.25 N'm (22 t 2 lb in).
f " Disconnect the negative battery terminal at the
battery 4. Connect the harness assemblies to the electronic
control module and tighten allen head screw (3) to
a torque of 6 r 1 N.m (53 t 9 lb in).
5. Connect the negative battery terminal at the

batterv.
RENR9365_1 o
27
i019297 1o
Fuel Filter Housing - Remove
Care must be taken ," l'lr?
SMCS Code: 1262_011 during performance of ins
ing, adjusting and repair o
S/N: LLA1-Up
collect the fluid with suita
S/N: R141-Up Ing any compartment or
S/N: LLB1-Up
Refer to Special publication, NENG2500, ,,Caterpillar
S/N: LLCl-Up rogtq gn! shop products culde;i;it"i[lno
suitable to collect and contain suppties
S/N: CBEl-Up luiJs on Caterpillar
products.
S/N: LLE1-Up
Dispose of all fluids according
S/N: LLF1-Up to local regulations and
mandates.
S/N: SBGl-Up
2. Drarn the fuel filter housing into
a suitabte
S/N: SBJl-Up container for storage or foiOispoiaL
S/N: CBK1-Up
S/N: SBK1-Up
S/N: NAMl-Up
S/N: SBMl-Up
S/N: KENl-Up
S/N: PESl-Up
S/N: RMSl-Up
S/N: FlX1-Up
S/N: F2X1-Up
lllustration 77
901 050833
S/N: T2X1-Up
S/N: RTXI-Up; R2A1_Up
O Removaf procedure propeiled by a releasedTo,r"inf,"t,,"rny

ff l""'l*i:i,:?"::l_l"llr_t-f
parts
=p.ing'ilr"..
to wear ail necessary protective
Keep att parts crean r'.H]l:erinants H:l;."r* equip_
Contaminants may cause rapid Follow the recommended procedure

wear and shortened recommended tooling to release and use all
component life, ttre spiing force.
1. Shut OFF the fuelsupply to the 3. Disconnect fuel pressure

engine. sensor (2).
4. Disconnect hose assembly (3).
5. Remove cover (1)

28 RENR9365-10
NOTICE
during performance of inspection, maintenance, test-
ing, adjusting and repairof the product. Be prepared to
collect the fluid with suitable containers before ooen-

Tools and Shop Products Guide" for tools and supplies
products.
g0'1050834 Dispose of all fluids according to local regulations and

lllustration 7B
mandates.
6. Disconnect tube assemblies (6).
f . Shut OFF the fuel supply to the engine.
7 Remove bolts (5).
8. Attach a suitable lifting device onto fuel filter Do not allow dirt to enter the fuel system. Thoroughly
housing (4). The weight of fuel filter housing (4) clean the area around a fuel system component that
is approximately 30 kg (66 lb), Remove fuelfilter will be disconnected. Fit a suitable cover over discon-
housing (4). nected fuel system component.
io2044890
Fuel Filter Housing - Rernove

(Spin-on Filter)
SMCS Code: 1262-011
S/N: R141-Up
S/N: R1S1-Up
Removal Procedure
NOTICE

component life.
lllustration 79 90'1050681
2. Disconnect tube assemblies (1) and tube

assembly (3) from fuel filter housing (2).
3. Remove bolts (4) that are located behind the fuel

filter housing.
4. Remove fuel filter housing (2).

RENR9365_10
ZY
Disassemb and Assemblv Section
io2492451
Fuel Filter Housing - fnstall
SMCS Code: 1262_012
S/N: LLA1-Up
S/N: RlAl-Up
S/N: LLBl-Up
S/N: LLCl-Up
S/N: C8E1-Up
S/N: LLE1-Up
S/N: LLF1-Up dnln(nat/
S/N: SBGl-Up 1. device to fuel filter

S/N: SBJl-Up fuet fitter housing (4)
-of
66 tb). position rueitiitdr
S/N: CBK1-Up otts (S).
S/N: SBK1-Up 2. Connect tube assemblies (6).
S/N: NAM1-Up
S/N: SBMl-Up
S/N: KEN1-Up
S/N: PESl-Up
S/N: RMSl-Up
S/N: FlXl-Up
S/N: F2X1-Up
S/N: T2X1-Up
S/N: RTX1-Up; R2A1_Up lllustration B 1
901 050833
f nstallation procedu re 3. lnstall cover (1).

4. Connect hose assembly (3).
Keep al parts crean t $.?]l?ilinants. 5. Connect fuel pressure sensor (2).
may cause rapid wear and shortened 6. Turn ON the fuel supply to the engine.
^"glU'lq".t9
component life.
7. l-rime the fuel system. Refer to Operation
and
Maintenance M jnuat, "rr"fsvrtJri'r-_
ilr"".
RENR9365-10
io2057 113 i0363239 I

Fuel Filter Housing - lsrstall Fuel Friming Purnp - Remove
(Spin-on Filters) and Install
SMCS Code: 1262-012 SMCS Code: 1258-010
S/N: RlAl-Up S/N: FlXl-Up
S/N: R1S1-Up S/N: F2X1-Up
Fl,emoval Procedure
I nstallation Procedurre NOTICE
NOTICE during performance of inspection, maintenance, test-
Keep all parts clean from contaminants. ing, adjusting and repair of the product. Be prepared to
Contaminants may cause rapid wear and shortened or disassembrins anv comnf
component life. '[n iiJ.ffifl]i3iilft?l

Dealer Seruice Tool Catalog" for tools and supplies
products.

mandates.
NOTICE

comoonent life.
'1. Turn the fuel supply to the OFF position.
901 050681
lllustration B2
1. Position fuelfilter housing (2).
2" Install bolts (4) that are located behind fuel filter
housing (2).
3. Connect tube assemblies (1) and tube assembly

(3).
4. Turn ON the fuel supply to the engine. 9O1948724

lllustration 83
RENR9365_10

ol
2. Install the ball and the spring in

the fuet filter
nousing. Instail the O_ring s"iton
Personal injury can resuft from parts plus
ptu;]1). Instatl
and/or cov_ (1).
ers under spring pressure.
3. Position a new gasket and fuel priming
Spring force will be released when pump (S).
moved.
covers are re_
4. Instail botts (B) and botts (4).
Be.orepared to hold spring loaded 5. Turn the fuel supply to the ON position.
,. I""I:y" botts (_4.) and botts (8). Remove

fuel
pnmrng pump (5) and the gab(et.
a. plug (1). Remove the O_ring

I:ryyS
prug (1). Remove the spring anO
seatfrom
tfre"Oitf from the
fuel filter housing.
o.
Lt:^.:::l?l
nose 9i..ggn!ect hose assembty (6) and
assembly (7). Remove Oolts q3ja,nO
(2). bracket
f nstaflation procedure
NOTICE
Contaminants may cause rapid

wear and shortened
component life.
Illustration 84
901948724
lTtTIgl
can cause"ssembty
of parts flr"rr* toaded
bodily injury. "pi"g
To prevent possibre injury, foilow
the estabrished
procedure inO weai pr"i""ti-""
il"""Tb,t equip_
1. lf necessary, install bracket (2)

and botts (3).
u_onnect hose assembly (7) and hose
(6). assembly
JZ RENR9365-'10
io2242261 1. Turn the fuel supply to the OFF position.

Fue! FriminE Fump - Remove
and lnstall
SMCS Code: 1258-010
S/N: LLA1-Up
S/N: RlAl-Up
S/N: LLB1-Up
S/N: LLCl-Up
S/N: C8E1-Up
S/f,l: LLEl -Up lllustration B5 901 1 301 50
S/N: LLFI-Up
S/N: SBGl-Up
S/N: SBJl-Up Personal injury can result from pafts and/or cov-
S/f{; C8K1-Up
Spring force will be released when covers are re-
S/N: SBK1-Up moved.
S/N: NAM'1-Up Be prepared to hold spring loaded covers as the
S/N: SBM'1-Up bolts are loosened.
S/N: KENl-Up 2. Remove bolts (2).

S/ltl: PES'1-Up
3. Remove bolts (3). Remove fuel priming pump ('1)
S/N: RMSl-Up and the gasket from the fuel filter housing.
S/N: T2X1-Up 4. Remove plug (6). Remove the O-ring seal from
S/N: RTXI-Up, R2A1-Up the plug.
5. Remove spring (5) and ball (a) from the fuelfi

Remova! Frocedure housing.
NOTICE
lnstallation Procedu!"e
ing, adjusting and repair of the product. Be prepared to NOTICE
collect the fluid with suitable containers before open- Keep all parts clean from contaminants.
nent containing fluids. Contaminants may cause rapid wear and shortened
component life.
oroducts.

mandates.
NOTICE
Keep all parts clean from contaminants

component life.
RENR9365_.10

Section
i02203950
Fuel Transfer pump - Remove
SMCS Code: 1256-011
Removal procedure
l^-
IUE
lllustration 86
rng any compartment or
g0'11 301 50
Refer to Speciat pubtication, NENG2S00, ,,Caterpiltar

_To9l: ?nq
Shop products Guide,,fortolis
.l"".Tnlv 9f parts ft,rt.rfrEg suitable to collect and contain ffuiOs anO suppties
lTl.Igl
can cause bodily injury. toaded products. on'Caterpillar
To prevent possible injury, folfow Dispose of all fluids according to

'wear the established local regularlons and
il"""Tu,r
procedure dno pr;i;;;" equip_
mahdates.
1. Position a new gasket and fuelpriming Keep al

pump (1). parts crean r,Hll?l"rinants
2. lnstall bolts (3) and tighten to
1513 Nm(t1 t2tb-ft). -- a- torque'v'Yve of !11!1mina,n,1: rry cause rapid wear and shorrened
component life.
3. Instail botts (2).
1. Turn the fuel shutoff valve to the
OFF position.
o. (4) and spring (5) in rhe fuet
l]:l:!lg"lt
noustno. fitter
5, Instalt I n"* o-rin (6)' Install the

plus in the ruel rir"?;:i!if.plus
O. Turn the fuer suppty to the

I ON position,
lllustration B7
901112959
2. Disconnect tube assembly (3).

Disconnect tube
assembty (4).
3. Remove botts (1).
4. Remove fuel transfer pump (2).

J+ RENR9365-1 0
Fuel Transfer Pump -

D isassenr ble
SMCS Gode: 1256-015
Disassemb!y Procedure
Start By:
a. Remove the fuel transfer pump. Refer to

Disassembly and Assembly, "Fuel Transfer Pump
- Remove".
90111 3096
lllustration B9
NOTICE

component life.
3. Remove bolts (7). Remove head (B) from plate (9).
4. Remove check valve (11) from head (B).

2986
lllustration BB 901 11
5. Remove plate (9). Remove gasket (10). Remove
the O-ring seal from the plate.
Note: lf the bearings in plate (9) are damaged,

Personal injury can result from belng struck by the plate must be replaced. The bearings are
parts propelled by a released spring force. nonserviceable separately,
Make sure to wear all necessary protective equip-

ment.
Follow the recornmended procedure and use all

recommended tooling to release the spring force.
1. Remove drive coupling (1) from the drive shaft.

Remove O-ring seal (2).
2. Remove cap (6), washer (5), spring (4), and

poppet valve (3).
90111 3004
lllustration 91
6. Remove idler gear (12) and drive shaft (13)from

casing (14).
RENR9365_1 0
35
7. Remove casing (14) from bracket (16).

-ri Remove
the O-ring seaifiom,casing
f]+1. n-J"""."ry,
remove terminal Uushings (1S).'
16
g2 1. Tooting (A)_to instail inner tip seal (18)

lllustration go1113o1z 9r: and
jl3 ( 1'6 ) ricate th e
t (17) and inner rip sear (18)
il'Sj ;:,? !lJlT?,1;T:il
Lud
f;[l?v,.:&:,if,,E ="", Note: lf the bearings in bracket (16)

are damageo,
Note: lf the bearinos in bracket (16)are the bracket must bi r, rhe bearings
damageo, are
nonseryrceaotu .up"rjlJaced
the bracket must bi reptaced. The
bearinqs
nonserviceable separaielv. --""Y are'-
4a
tz
i02203993
Fuel Transfer pump _ Assernbie
SMCS Code: 1256-016
Assembly procedure
Table 4
Required Tools
Part Number
lllustration 94
901113004
1P-0510
2. Installterminal bushings (15) in casing
(14). Instatl
the O-ring seal in casiig (t+; Install
NOTICE casing (14)
Keep all parts clean from contaminants. onto bracket (16).
Contaminants may cause rapid wear

and shortened
t g:lfl| (12) and drive shaft (13) into
component life. ?]?!nu"'
lllustration g5 901113073
36 RENR9365-10
Note: lf the bearings in plate (9) are damaged,

the plate must be replaced. The bearings are
nonserviceable separately.
Personal injury can result from parts and/or cov'
4. Install the O-ring seal into the side of the plate that
is opposite of gasket ('10). Install plate (9). Install
gasket ('10). Spring force will be released when covers are re-
moved.
11
Be prepared to hold spring loaded covers as the
bolts are loosened,
8. Install poppet valve (3), spring (4), washer (5),

and cap (6).
9. Install O-ring seal (2).
10.Install drive coupling (1).
End By:
a" lnstall the fuel transfer pump. Refer to Disassembly

901 1 1 2998
lllustration 96 and Assembly, "Fuel Tranfer Pump - Install".
5. Use Tooling (A) to install check valve (11)into

head (8). i02723973
Fue! Tnansfer Fump - lnstalE

SMCS Gode: 1256-012
lnstallation Procedure
NOTICE

component life.
901 1 1 2994
lllustration 97
6" Install head (B) onto plate (9).
1. Position fueltransfer pump (2) and install bolts (1).
2, Connect tube assembly (3). Connect tube

assembly (4).
lllustration 98 901112986 3. Turn the fuel shutoff valve to the "ON" position.
RENR9365_10
3I
4. Remove the air from the fuel system.
Testing and Adjusting, ,,fu;f Refer to 1. Turn the fuel suppty to the OFF position.
sy,s-#: brir",,.
i02858358
Fuef Gooler - Remove and
Install
SMCS Code: 1712_O1O
S/N: SBGl-Up
S/N: SBJl-Up
S/N: SBK1-Up
S/N: NAMl-Up
lllustration 100
901 22889S
S/N: SBMl-Up
S/N: KENl-Up
2. Remove hose assemblies (1).
S/N: PES1-Up
S/N: RMSl-Up
Removal procedure
Start By:
a. Remove the fan drive. Refer

to Disassembly and
Assembly, "Fan Drive _ n"roJ"i.'"""'='
.ooting system components

I:|:.,.]h"
may vary depending on your and weights lllustration 10.1
901 228896
"ir"ng"m"nt.
3' ing
TICE 3).
co
VE
mounting bracket (2) a
Ing any compartment or
,bF:jl9n,,NENG2sOo,,,Caterpi[ar
ol Catalog,, for tools anO sup[iies
and contain ftuids on c.teibiir"i
Dispose of allfluids according

to localregulations and
mandates.
I,l:1,,:i1"g-or
trical componenis
spined onto nffi lllustration j02 go1228eo1
a fire. i;;"1T::
::1Ilg_"ib|e. i1jury,".n
turn""us"
the it",llr,i,iiJn
it",l!r,i,iiJn off when 4. Remove bolts (5) in order to remove
If,*13:',L,^",,1ilry, fuel cooler
:13lp::gJ1,_e.r1!9ii.orwater""p"i.toi'"iJ;ffJ
9l*1rr11 fuet spilts immeOiatetyi
38 RENR9365-10
Installation Procedure End By:
a. Install the fan drive. Refer to Disassembly and

Assembly, "Fan Drive - Install".
i03962570
Turrbochargen - Remove
SnflCS Code: 1052-011
S/N: F1X1-Uo
S/N: F2X1-Up
lllustration 103 so1228eo1 Removal Frocedure

1. Place fuel cooler (3) into position and install bolts NOTICE
(5) Care must be taken to ensure that fluids are containeA.
during performance of inspection, maintenance, tef
ing, adjusting and repairof the product. Be prepared to-

suitable to collect and contain fluids on Caterpillar
products.

mandates.
lllustration 104
g0'1228896 NOTICE
2. Attach a suitable lifting device to mounting bracket
(2) and fuel cooler (3). The dry weight of mounting Contaminants may cause rapid wear and shortened
bracket (2) and fuel cooler (3) is approximately component life.
18 kg (a0 lb). Place mounting bracket (2) and fuel
cooler (3) into position. Install bolts (4).
lllustration 105 901 228895 1. Remove the spring clips on the top and sides of
covers (1) and (2).
3. Install hose assemblies (1).
2. Remove front cover (1).
4. Turn the fuel supply to the ON position.
3. Remove back cover (2).
RENR9365_10
?o
DisassemblV
rbly sfld Assembly q,
and Assemhtr Section
io2479610
Tunbocharger - Rennove
SMCS Code: 1052-011
S/N: LLA1-Up
S/N: LLBl -Ltp
S/N: LLCl -Up
S/N: CBEl-Up
S/N: LLEl -Up
lllustration i07 902160811 S/N: LLF1-Up
4. Remove the bolts and disconnect
adapter (3)
S/N: CBK1-Up
5. Remove the bolts and disconnect elbow S/N: PESl-Up

(6).
Remove the gasket. S/N: RMSi-Up
6. Loosen clamp (4) and clamp (S). S/N: RTXl-Up; R2A1-Up
Rernoval Frocedua.e
care must be taken ," |n?llSirat fruids

are contained
our
intenance, test-
ing, .Be prepared to
co'
rn^ rs before open_
ng any compo-
nen
ubtication,
ot Catalog,,.NENG2500,,Caterpiilar
for tools and supplies
and contain fluids on Caterpittar
lllustration 108
902160812
," Drsconnect hose assembly (S) and

hose assembly
Dispose of all fluids according to
local regulatrons and
mandates.
a
L Attach a suitable lifting device to turbocharger
(7).
The weight of turbocharger (7) i"
30 ks (66 tb).
ufpiox,m"tuty Keep att parts crean uffi]l?[r,r".,.
9. Remove bolts (10).and_disconnect the actapter !11lamina,11: .uy cause rapid wear and shorrened
component
from turbocharger(7). nemoue if,-e life.
O_"riig ,ears.
to.L:T?".: and turbocharser (7) from the 1. Remove the air cleaner
!"tl: (9) Remr
exnaust manifold, ve the gisket.'
40 RENR9365-1 0
i02490504
Turbocha nger - Renmove

SMCS Code: 1052-011
S/N: RlAl-Up
S/N: SBG1-Up
S/N: SBJl-Up
S/N: SBKl-Up
S/N: NAMl-Up
901 11 6759 S/ftt: SBM1-Up

lllustration 109
S/N: KENl-Up
2. Remove tube assembly (1) and tube assembly (2).
S/N: R1S1-Up
3. Remove the water hose assembiies, if necessary.
SIN: T2X1-Up
RemovaI Fnoeedune
NOTICE
Care must be taken to ensure that fluids are containecl
during performance of rnspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to

4. Remove air pipe (3). Remove the O-ring seals products.
from the air pipe.
fr Loosen clamp (7). Slide the clamp onto elbow
coupling (9).
6. Attach a suitable lifting device to turbocharger (B) NOTICE

The weight of turbocharger (8) is approximately Keep all parts clean from contaminants.
40 ks (88 lb).
7" Remove bolts (4) that attach the turbocharger to comoonent life.
exhaust manifold (5). Remove turbocharger (8).
Remove gasket (6). f . Remove the air cleaners
RENR9365_10
41
Disassembly ancj Assembly
Section
Turbochargen - D!sass**bffi'ou'n
(Type 1)
SMCS Code: 1052_01S
S/N: RlAl-Up
S/N: LLCl-Up
S/N: CBE1-Up
S/N: LLEl-Up
fllustration 111 go12443z1 S/N: LLF1-Up
Z. hose assembty (1) and tube S/N: SBGl-Up
assembty
ftlmove S/N: SBJl-Up
3. Remove the water tube assemblies, S/N: C8K1-Up
if necessarv.
S/N: NAMl-Up
S/N: KENl-Up
SiN: PESl-Up
S/N: R151-Up
S/N: F1X1-Up
S/N: F2X1-Up
Disassembly Frocedure
lllustration 112
901244331
Start By;
1. Remove the bolts and elbow (3) Remove the
O-ring seals from the elOow.' '-' a. Remove the turbocharger. Refer
to Disassembly
and Assembly, ,'TurboJhrrg", _
2' n"-m;i;;.
O Loosen clamp (4). sride the clamp
and the beilows
assembly away from turbochargdr
(5).
Keep att parts crean rr#]f:[,"inants
3. Loosen clamp_(6). Remove the hose
from
turbocharger (5).
9^":lTrqr,l: ruy cause rapid wear and snortened
component life.
4. Attach a suitable.lifting device
to turbocharger (S).
The weig ht of tu rbochirg"r.
40 ks (BB i5l'['rpproximatety
tb).
Do not attempt to oi".rf3l.,l3,!
5. Remove the bolts-that attach ,n" turbocharser car_
turbocharger (S) to trid ge asse mb ty. Th e tu r,bgcha
the exhaust manifold. numouu rg;, rtiii#,.sem bty
iurno"hJrgui(sf rsnnot fietd serviced,
and the gasket.
and shoutd"b";;pi".A only as a
"u
4Z RENR9365-'10
NOTICE
Do not attempt to disassemble the turbocharger car-
tridge assembly. The turbocharger cartridge assembly
is not field serviced, and should be replaced only as a
unit.
901 1 1 7601
lllustration 113
'1. Position the turbocharger on a bench. Place

alignment marks on compressor housing (1),
turbocharger cartridge (3), and turbine housing
(5)
9o1117411
2. Loosen the nut on clamp assembly (4). Separate Illustration 1 14
turbine housing (5) from turbocharger cartridge

(3). 1. Position the turbocharger on a bench. Place
alignment marks on compressor housing (6),
3. Loosen the nut on clamp assembly (2). Separate turbocharger cartridge (4), and turbine housirrg
turbocharger cartridge (3) from compressor (1)
housing ('1).
2. Remove bolts (3) and clamp plates (2). Separate
turbine housing (1) from turbocharger cartridge
io2214123 (4). Remove the O-ring seal from the turbocharger
cartridge.
Tur[:ocharger - Disassemble
{Type 2} 3. Remove bolts (5). Separate turbocharger cartridge
(4) from compressor housing (6).
SMGS Code: 1052-015
S/N: LLA1-Uo
S/N: LLBl -Uo
S/N: SBKI-Uo
S/N: SBM'1-Up
S/N: RMSI-Up
S/hl: T2X1-Up
Start By:
a. Remove the turbocharger. Refer to Disassembly

and Assembly, "Turbocharger - Remove".
NOTICE
Contaminants may cause rapid wear and shoftened

comoonent life.
RENR936S-10
4s
i02214561
Turbocharger - Assembfe
(Type 1)
SMCS Code: 1052_016
S/N: RlAl-Up
S/N: LLCl-Up
S/N: C8E1-Up
S/N: LLE1-Up
S/N: LLF1-Up
S/N: SBGl-Up lllustration 115
901 1 1 7601
S/N: SBJl-Up 2. Align the marks ano c

('1) to turbocharger ca
S/N: C8K1-Up
assemb
S/N: NAMl-Up (10r11
a namm
S/N: KEN.1-Up torque o
S/N: PES.1-Up 3. Rotate the turbocharger cartridge
in oroer to
S/N: R1S1-Up ensure that the turbocharger ca,-rtridge
contact the compressor h6using. - r- ooes' not
S/N: FlXl-Up
4.
S/N: F2X1-Up
Assembly procedure
5. Rotate the turbocharger cartridge
in order to
ensure that the turbocharger.uitriJg.
Keep att parts crean r,Hll:[rinants contact the turbine lrousing. Joes not
Contaminants may cause raptd End By:

wear and shortened
component life.
a. Install the turbocha,rger. Refer
to Disassembty ancl
Assembty,,'Turbochirg"r. _ tnriatl'""""'
Compressor housin
bocharger u.."roty tur-
compressor.btade t6 tip,
oe damaged.
o H;
1. Pulan alignment mark on the

new turbocnarger
cartridge in the same location
tu rbocharger cartrioge,
,i tn"
"jo
44 RENR9365-10
i02479697 3. Rotate the turbocharger caftridge in order to

ensure that the turbocharger cartridge does not
Turbochanger - Assesnhle contact the compressor housing.
(Type 2)
4" Align the marks and connect turbine housing (1)
SIUCS Gode: 1052-0'16 onto turbocharger cartridge (4) Installclamp plate
(2) and bolts (3). Tighten bolts (3) to a torque of
S/l\l: LLAl-Up 40!2 N.m(30r1lbft),
S/N: LLBl-Up 5, Rotate the turbocharger cartridge in order to
ensure that the turbocharger cartridge does not
S/N: SBK1-Uo
contact the turbine housino.
S/N: SBMl-Up
End By:
SiN: RMSl-Up
a. Install the turbocharger. Refer to Disassembly and
S/N: T2X1-Up Assembly, "Turbocharger - Install".
SIN: RTX1-Up; R2A1-Up
Assembly Procedure TurbocharEer - !nstall

NOTICE SMGS Code: 1052-012
S/N: F1X1-Up
comoonent life.
S/tl: F2X1-Up
NOTICE
Compressor housing must go straight on the tur- Table 5
bocharger assembly without tilting. Tilting may cause Required Tools
compressor blade to tip, or the compressor shaft can
be damaoed. Tool Part Number Part Description Qtli
A 5P- 393't Anti-Seize Compound
'N. Put an alignment mark on the new turbocharger O-Ring Assembly
cartridge in the same location as the old B 1U-6396
Compound
turbocharger cartridge.
NOTICE
Keep all pafts clean from contaminants. v
component life.
lllustration 116 9o1117 411
2. Install the O-ring seals on cartridge (4). Align the

marks and connect compressor housing (6) to
turbocharger cartridge (4). Install bolts (5) and
tighten to a torque of 40 t 2 N.m (30 t 1 lb ft).
lllustration 1 17 902 1 6081 2
RENR9365_1 0
3i
1. Attach a suitable lifting device to turbocharger
The weight of turbocharger (7) is (7). 9. Install front cover (1).
approximately
30 ks (66 tb).
1O.lnstail sOrjnq,clips on the top and sides
covers !!9
(1) and (2).
of
i02479704
Turbocharger - Install
3. Install the O-ring seats on the adapter. Lubricate SMCS Gode: 1OS2-012
the o-ring sealjwith r""iirg
fBi St"nnect tne
adapter to turbocharser (7) ;riJ S/N: LLA1-Up
ir.l; ii';;trs ( i 0).
4. Connect hose assembly S/N: LLBl-Up
(11) and hose assembly
(B)
S/N: LLC1-Up
S/N: C8E1-Up
S/N: LLE1-Up
S/N: LLF1-Up
S/N: C8K1-Up
S/N: PESl-Up
S/N: RMSl-Up
S/N: RTXI-Up, R2A1_Up
lllustration 118
902160811
Table 6
5. Position,clam.p (5) and ctamp (4).
Tighten the Required Tools
l.q!g on the ctamps to a torque- of
(124 ! 9 tb in). Lighfly
li t
1 N.m
ta1 '-
J'tf," Jiameter of
the ctamps wittr a s-oit, iighj; the nuts
t
again to a torque of 14 1 N.m
trI+'i'b rn inl.
6. install th.e gasket and connect elbow
(6). Apply
(A) to the threads ifr" U"ri=tano
lgolinq.
the instatt
bolts "i
Keep att parts crean t,.HIl?;rinants.
7. Connect adapter (3). Apply Tooting
(A)
threads of the botis ano initail tne"nJlt6. to the
!ô1i_amina.llg r"y cause rapid wear and shortened
component life.
8. Install back cover (2). lllustration 120 901'116799

46 RENR9365-10
Attach a suitable lifting device to turbocharger (8). i0249080 1
The weight of turbocharger (B) is approximately

a0 kg (BB lb). Tunboehargen - InstaIl
,, SMCS Code: 1052^012
Install new gasket (6) between exhaust rnanifold
(5) and turbocharger (B). Position turbocharger (B)
S/f.{: RIA'1-Up
on the exhaust manifold. Apply Tooling (A) to the
threads of bolts (4). Install bolts (4) and tighten to S/N: SBGl-Up
a torque of 54 ! 5 N m (40 lb ft).
$/tl: SBJl-Up
Position clamp (7) over elbow coupling (9) and
the turbocharger. Tighten the nut on the clamp S/N: SBK1-Up
to a torque of 14 t 1 N.m (124 ! I lb in). Lightly
Sl[d: NAM'l-Up
tap around the diameter of the clamp with a soft
hammer. Tighten the nut to a torque of 14 t 1 N.m $/$$: SBM1-Up
(124f9lbin).
$/N: KENl-Up
4" Instali the O-ring seals on air pipes (3). Lubricate
the O-ring seals with Tooling (B). Install air pipes S/N; R1S1-Up
(3)
S/N: T2X1-Up
inetallatEon [snoeed u re
Table 7
Required Tools
Part
Tool Number Part Descriptiorr Qtv
A 5P-3931 Anti-Seize Compound
O-Ring Assembly
B 1U-6396
Compound
lllustration 12'l 9011 16759

NOTICE
5. Install the water lrose assemblies, if necessary. Keep all parts clean from contaminants.
6. lnstalltube assembly (2) and tube assembly (1).
7. Install the air cleaner.
lllustration 122 9o1244331
1. Attach a suitable lifting device to turbocharger (5).

The weight of turbocharger (5) is approximately
40 kg (88 lb). Place the gasket and turbocharger
(5) on the exhaust manifold.
RENR9365-1 0
47
Z. Tooting (A) to the threads of the botts.

lOgty,
Instail the bolts that attach turnocnaigeiqs; i0260411 5
to tt.,"
exhaust manifold.
Air Shutoff - Remove and
3. Position the hose on turbocharger (S).
Tighten
Instaf l
clamp (6).
SMCS Code: 1O7B-O1O
4. Slide the clamp and.the bellows assembly
on S/N: LLA1-Up
turbocharger (S). Tighten cf amp-1+i.--"'-
S/N: RlAl-Up
5. Install the O-ring seals on elbow (3).
Lubrrcate
the,o-rins seats"with i";ii"siB; iiiir]iirno* S/N: LLBl-Up
and the bolts. tsl
S/N: LLCl-Up
S/N: C8E'1-Up
S/N: LLEl-Up
S/N: LLF'|-Up
S/N: SBGl-Up
S/N: SBJ'1-Up
S/N: CBK1-Up
S/N: SBK1-Up
S/N: NAMl-Up
lllustration 123 901244s27
SiN: SBMl-Up
6. Install the water tube assemblies,
if necessary. S/N: KEN'1-Up
7. lnstall tube assembly (2) and hose
assembly (1). S/N: PESl-Up
8. Install the air cleaners. S/N: RMSl-Up
Removal procedure
Keep al parts crean t,jlfll:Arinants
!ô1!-amina.nlg
rry cause rapid wear and shortened
component life.
P_e_rsonaf injury can result from parts

,nd/ol,
ers under spring pressure. "ou_
Spring force will be released when covers
moved.
are re_
Be. prepared to hold spring loaded

covers as the
bolts are loosened.
48 RENR9365-10
5. Remove air shutoff (4) and remove the gasket.
Personal injury or death can occur from not fol- Note: Inspect the lines of the air intake for debris.
lowing the proper procedure or the recommended
tooling. lnstallation Frocedure
To prevent the possibility of injury or death, follow NOTICE
the established procedure using the recommend- Keep all parts clean from contaminants.
ed tooling.
component life.
Before you remove the air intake shutoff, pull the

trip knob on the air intake shutoff or press the
emergency stop button in order to release the
blade latch. lf the blade latch is released after the
air intake shutoff is removed, serious personal
injury can result.
L Manually release the air shutoff. Pull or press in

order to release the knob on the air shutoff. Ensure
that the indicator on the air shutoff points straioht
down to the "OFF" position. lf the aii shutoff didnot
trip, refer to Troubleshooting, "Air Shutoff System".
lnstall a new gasket and air shutoff (4) to the

intake manifold. Install bolts (6) and the washers
and tighten bolts (6) to a torque of 25 x 6 N.m
(1Br4rbft).
2. Reconnect air inlet hose (5). Install bolts (2) to
adapter (3) and tighten bolts (2) to a torque of
25 !6 N.m ('18 i 4lb ft).
3. Reconnect tube assembly (1) to air shutoff (4).
4. Reset the indicator on the air shutoff. Ensure that

lllustration 124 901 30361 I the arrow on the indicator is pointing straight up
to the "OPEN" position.
2. Disconnect tube assembly (1) from air shutoff (4).
5. Test air shutoff (4) for proper operation and refer to
3. Disconnect air inlet hose (5) by loosening bolts (2) Operation And Maintenance Manual. "Air Shutoff'.
from adapter (3) on air shutoff (4).
4. Remove bolts (6) and the washers that mount air

shutoff (4) to the intake manifold.
RENR9365_10
3t
i04045553
Air Shutoff - Remove and
Insta lf
SMCS Gode: 1078-010
S/N: R151-Up
Removal procedure
NOTICE
Contaminants may cause rapid wear

and shortened lllustration 126
component life. 902255535
2. Disconnect harness assemblies (S),

(6), and (7).
3. Disconnect tube assembly (3) from
air shutoff (2)
can resutt from parts and/or cov_
3t:."-11_tliury
ers under spring pressure. 4. Loosen the hose clamp and disconnect nose (4)
Spring force will be released when 5. Remove nuts (1) that mount air shutoff
(2) to the
covers are re_ air cleaner
moved.
Be-prepared to hold spring loaded 6. Remove air shutoff (2) and the gasket.
covers as the
bolts are loosened.
Note: Inspect the lines of the air intake
for debris.
7. Repeat for the other atr shutoff.
l_:-To13.t
injury
or death can occur from not fot_ Installation procedu re
towing the proper procedure or tne
recommended
tooling.
To prevent the possibifity of injury

Keep att parts crean t,jlfll?[rinants
or death, follow
the. esta bt is hed proced u r" u"
ed tooling. ffi 'trr-" ie-Jomme n o _ Contaminants may cause rapid wear
and shortened
component life.
pgfo.re you remove the air intake snutoft, pull the

trip knob on the air..intake sh;i#;;';r"ss
emergency stop button in order io-ieiease the
blade tatch. tf the btade tatch i" tne
air intake shutoff is removed, iirJI"Li after the
serious personal
injury can result.
1. Manually release the al

order to release the kno
that the indicator on th
to the "CLOSED" posr
trip, refer to Troubiesh lllustration.l2T 902255535
1 ffl1i: new gasket and air shutoff (2) on

the air
cteaner. Install nuts (1).
2. Connect hose (4)and tighten the hose ctamo.

3. Connect tube assembly (3) to air shutoff
(2)
6n RENR9365-1 0
4" Connect harness assemblies (7), (6), and (5)
Reset the indicator on the air shutoff. Ens:ure that

the arrow on the indicator is pointing straight to
the "OPEN" oosition.
f!
U. Test air shutoff (2) for proper operation and refer to
Operation and lViaintenance Manual, "Air Shutotf".
Repeat for the other air shutoff.
i03633442
Aftereoo$en - RernCIvs annd

901 949540
EmstalE lllustration 128
S!q'1CS Code: 1063-010 2, Remove bolts (3) and strap (4)
$/i\: FlXl-Up -
S/ld: F2X1-Up
5:T';:iff tg}Sis
(2)
1fl3=3ff 5H,:J il"a"#to
Rernovafl Frroaedune 4. Remove bolts (6), air inlet elbow (5), and the
O-ring seal.
Table B
Required Tools 5" Reoeat for the other side of the aftercooler.
fool Pa/c ldumber Part Desciiption arlt

1 3B - 7573 Link Bracl<et a
NOTICE
ing, adjusting and repairof the product Be prepared to
collect the fluid witlr suitable containers before onen-
ing any compartment or disassembling any compo.
nent containing fluids

suitable to collect and contain fluids on Cateroillar lllustration 129 90194e543
products.
6. Remove bolts (8) and disconnect elbow (9).
Dispose of all fluids according to local regulations and Remove the O-ring seal.
mandates.
7. Disconnect hose assembly ('12). Remove bolts
(10) and disconnect elbow (11). Renrove the
NOTICE O-ring seal.
L Remove bolts (13) and disconnect the flange.
Contaminants may cause rapid wear and shortened Remove the O-ring seals.
comoonent life.
o Remove bolts (14) and disconnect the flange.
'i. Drain the coolant from the cooling system into Remove the O-ring seals.
a suitable container for storage or for disposal
Refer to Ooeration and lVaintenance Manual.
"Cooling System Coolant - Change".
RENR9365-10
R.1
and Assembly Section
NOTICE
Côntaminanlg may cause rapid wear

and shortened
component life.
Note: Be careful not to damage the fins of

the
aftercooler cores.
10. Attach Tooling (A) and a suitable

lifting device to
!h." lop of air i-ntet'cou"ilio).Trr-e'weignt or air
intet cover (16) is approximateiy ss
k; (27 tb).
l1.Remove bolts (1b), air inlet cover (16),
and the
seal.
N-ote: Be careful not to damage the

fins of the
aftercooler core.
lllustration '131
901 949004
12.Aftach a suitable lifting device onto

aftercooler
core (17). The weight -
gore_i_s.qORroximately of
the 3512C aftercooler
3508C
(71 lb). Remove after '\Y
the seal from adapter
13. Remove bolts (18). Remove adapter

(19) and the
seal.
14.Aftach a suitable lifting device onto 3512C

aftercooter
core (20). The weight of
gore is approximately 60
the 3512C aftercooler co
(187 lb). Remove afterco lllustration 132 901238547
the seal from the air inlet manifold.
N-ote: Be careful not to damage the

fins of the
aftercooler core.
I nstallation procedure
Table 9
Required Tools
138-7573
3. Remove the tape that secured the bottom

seal.
4. Install the seal
and adapter (1g) on top of
aftercoolercore(20). '-'--r
cz RENR9365-10
s, Install bolts (18). Hand tighten bolts (18) to the '!3.Install the O-ring seal on elbow (9). Lubricate the
following procedure: O-ring seal with Tooling (B). Connect elbow (9)
and install bolts (8).
Tighten the bolts in the numerical sequence to
a torque of 24 N m (18 lb ft).
U" Tighten the bolts in the numerical sequence to

a torque of 47 N.m (35 lb ft).
fl
IJ, Install the seal on adapter (19).
V. Attach a suitable lifting device onto aftercooler

-l-he
core (17), weight of the 3508C aftercooler
core is approximately 23 kg (51 lb). The weight of
the 3512C aftercooler core is approximately 32 kg
(71 lb). Position aftercooler core ('17) onto adapter
(19). Ensure that the bottom seal is properly
seated,
lllustration 1 34 s0'1e49540
t]. Attach Tooling (A) and a suitable lifting device to
ihe top of air inlei cover (16). The weight of air i4..Install the O-ring seal, air inlet elbow f St, ,nO O
inlet cover (16) is approximately 35 kg (77 lb). bolts (6).
Install the seal and air inlet cover (16).
'15" Installthe O-ring seals on air pipe (2) Lurbricate
Install bolts (15). Hand tighten bolts ('15) to the tlro O-ring scals with Tooling (B). Install air pipe
following procedure: (2). Tighten clamps (1) and install bolt (7).
Tighien the bolts in the nurnerical sequence to f 6. Install strap (4) and bolts (3).
a torque of 24 N.rn (18 lb ft).
'17" Repeat for the other side of the aftercoolei".
b. Tighten the bolts in the numerical sequence to
a torque of 47 N m (35 lb ft) f ti" Fill the cooling system with coolant. Refer to
Operation and Maintenance Manual, Cooling
System Coolant - Change".
g0 949543
lllustration '133 1
'10.Install the O-ring seals on the tube assembly.

Lubricate the O-ring seals with Tooling (B).
Connect the flange and install bolts (14)
'l'1" Install the O-ring seals on the elbow, [-ubricate the

O-ring seals with Tooling (B). Connect the flange
f 2.Install the O-ring seal on elbow (11). Lubricate

the O-ring seal with Tooling (B). Connect elbow
(11) and install bolts (10). Connect hose assembly
(12)
RENR9365_10
53
Section
i02479781
Aftencooler - Remove and
Install
SMGS Code: 1063_010
S/N: LLA1_Up
S/N: LLBl_Up
S/N: LLCl_Uo
S/N: C8E1_Up
S/N: LLEI_Uo
S/N: LLF1_Up lllustration 135
9o123847 1
S/N: CBKI_Uo ,. I:iy:, bolts (1) and the retainers. Remove

prpes (2). Remove the O_ring arr
S/N: pESl_Up
pipes. "u"f.
fifii the air
- S/N: RMSl_Up
3. lf necessary, remove bolts (5) and
SiN: T2X1_Up remove
adapters (4). Renrove the O-rirrg
seals from the
adapters.
S/N: RTXl_Up; R2A1_Uo
4. (A) and a suitabte tifting
Removaf procedure f,litTooting
rne top of air inlet device to
cover (3). fhe weigtt of air inlet
cover (3) is approximateiy'35
kg (7tjbi.
Tabte 10
5. Remove bolts (6). Remove air
inlet cover (3).
Required Tools
Note: Be careful not ro oamage
the fins of the
aftercooler core.
1 38 -7573 Link Bracket
TICE

ublication, NENG2500,,,Caterpillar
ot Catalog,, for tools anO ,upbfie.
and contain ftuids on catuipiirii
Dispose of all fluids according lllustration 136

901238477
to local regulations and
mandates,
6. D_isconnect tube assembly (7)
and tube assemblv
(8). Remove ttre o_ring sbJiJ
from the tube
assqmblies.
Keep al parts crean rr#*:[rinants
7. Attach a suitable lifting device
onto aftercoorer
9^":lT'lgr,!: r"y cause rapid wear and shortened
l^"1?l9l rhe weight.oi the 3508C ar6iloor"r"
component life. rs approximaterv 60 kg (132
"oru
rb). The we-ight orLe
3512C aftercooler core'is appioximlieiy
(1.87 tb). Remove artercoorei'c;;; es tg
intet man ifotd. Re move .u" t" idi;;|, the air
core (9). iioj t'r-#' utur.oo lur
N-ote: Be careful not to damage
the fins of the
aftercooler core.
54 RENR9365-10
I qnetallatlon Fnocedune
Table 11
Required Tools
Tool Part Paft Description Qtv
f{umbel'
A 1 38 - 7573 Link Bracket Z
O-Ring Assembly
B 1U-6395
Oompound
NOTICE
l(eep all parts clean from contanrinants.
lllustration 138 901 23847 1

component life.
Itote: Be careful not to damaqe the fins of the

aftercooler cores. 350BC
3512C
b" Attach Tooling (A) and a sLritable lifting device to

o Zd ri- ql-zd bI+:<or ri- ro-!ie) - the top of air inlet cover (3). The weight of air inlet
LLrJE--rf,- ry ".'h -rFrr{- -T+-
-r{m{- cover (3) is approximately 35 kg (77 lb).
a Position air inlet cover (3) onto the aftercooler
4 Install seal (10) on the bottom of aftercooler core core. Ensure that the seal is seated between air
(9). Temporarily secure the bottom seal with inlet cover (3) and the aftercooler core.
tape. Make sure that the tape can be removed
after the aftercooler core is installed. Do not use 8. Install bolts (6). Hand tighten bolts (6) to the
an adhesive, a silicone lubricant, or any other following procedure:
lubricant for retention of the seal.
a. Tighten the boltsin the numerical sequence to
2. Attach a suitable lifting device onto aftercooler a torque of 24 N'm (18lb ft).
core (9). The weight of the 3508C aftercooler core
is approximately 60 kg (132 lb). The weight of the b. Tighten the bolts in the numerical sequence to
3512C aftercooler core is approximately 85 kg a torque of 47 N'm (35 lb ft).
(187 lb). Position aftercooler core (9) onto the
air inlet manifold Ensure that the bottom seal is 9. Remove the tape that secured the bottom seal,
properly seated
10.Install the O-ring seals on adapters (4), Position
? Install seal (10) on top of the aftercooler core. adapters (4) on the cover and install bolts (5).
s. Install the O-ring seal on tube assembly (B). 11.Install the O-ring seals on air pipes (2). Lubricate
Lubricate the O-ring sealwith Tooling (B). Connect the O-ring seals with Tooling (B). Install air pipes
tube assembly (B) to aftercooler core (9). (2) and install the retainers and bolts (1).
c. Install the O-ring seal on tube assembly (7). 12.Ftll the cooling system with coolant. Refer to
l-ubricate the O-ring sealwith Tooling (B). Connect Operation and Maintenance Manual, "Cooling
tube assembly (7) to aftercooler core (9). System Coolant - Change".
RENR9365_10
Disassembty and Assembly

s".ti3i
i04045450 3. Remove the bolts, elbow (1),
Aftercooter - Remove and and the O_ring seals
Install 4. Remove the bolts. air intet
elbow (3), and the
O-ring seal,
SMCS Code: 1063-010
5. Repeat for all of the air inlet
S/N: R151-Up elbows.
Removal procedure
Table 12
Required Tools
Part Number
138-7573
NOTICE
Care must be taken to
' '-"'v that 'qr fluids
(' rrtrrus are contatned
contained
ou'no performance
during ,.,Frfnrman^^ ;'^.:l:yr"
Ins, adiusrin.r
ing, adjusting, and ':'"t'""''wrr'
ah.r ,^j]ll.L.?tion,
rrralnlenance,
maintenance, test-
test_
|."-'
to collecr rha ,,,,., .:]llrof the product. Be prepared
oi"""Tll:.j"lillT1_ylitiiiii""JJ,it#:.3,"f"?:;: D e Io re
p e n n g a n y co
i
ponent confainina
containing o,,,llnt "
o i disassembling
m p a rtm n t or ar: I"""
"".:' 11,':'^='"
any com_
fluids.
Referto Special publication,

NENG2S00,,,DeaterSer_
:i:l]:"t Catalog" for_toots
colect and contain fluids g*
;roo,ids'suitabte
. to lllustration
on C"t proiil.irl. 14.1
902254854
fluids according to tocat

regutations and t.
R,""ffiffI "lt l,tj:-:,l}otins.(A):,nd a suitabte tiftins device to
| ; i;
h' ;; ;;r'" i c o v e r
il :il?L ; il : L(il). I ?? 1+ ;
?fl'
Keep ar parrs crean 7. Remove bolts (5), air inlet
rr#Il?,="rinants cover (4), and the seal.
8. Remove the bolts, (6)' elbow (7), elbow (B),
cause rapid wear and
:""#fil5iiililttu shortened and the o-rins .""iJbot
lllustration 142
9. Remove the bolts, elbow (9),

and the O_ring seals.
10. lf necessary, remove
tube assembly (10).
lllustration 140 11. Attach Toolino (A)
gO22S479s and a suitable lifting device
coid onto
2. ?ft"r999!q, 1ir1 The weight of a-ftercoorer
Remove the clamps and core (11) is apprdximatety
hose assembty (2). 1s0"ti; i60il,
RENR9365-10
12. Remove bolts (14), aftercooler core (11), and the

seal.
13.lf necessary, remove bolts (13) and tanks (12)

from the ends of aftercooler core (11).
I nstallation Procedure
Table 13
Required Tools
Part
Tool Number Paft Description Qtv
1 38 - 7573 Link Brackel z
B 5P - 3975 Rubber Lubricant
NOTICE

component life.
6. Apply Tooling (B) to the O-ring seals. Install the
O-ring seals, elbow (B), elbow (7), elbow (6), and
the bolts.
7. Attach Tooling (A) and a suitable lifting device to

air inlet cover (4). The weight of air inlet cover (4)
8. Install the seal on the aftercooler core. Position

air inlet cover (4) onto the aftercooler core. Ensure
that the seal is seated between air inlet cover (4)
and the aftercooler core. Install bolts (5).
1. lf necessary, install tanks (12) and bolts (13) on

the ends of aftercooler core (11). Tighten bolts
(13)to a torque of 20 t 5 N.m (15 r 4 lb ft).
2. Install the seal on the air inlet manifold.
3. Attach Tooling (A) and a suitable lifting device onto

aftercooler core (11). The weight of aftercooler
core (11) is approximately 180 kg (400 lb). Position
aftercooler core (11) onto the air inlet manifold.
Ensure that the bottom seal is propedy seated. lllustration 145 902254793
Install bolts (14).
9. Install the O-ring seal, air inlet elbow (3), and the
4. lf necessary, install tube assembly (10). bolts.
5. Apply Tooling (B) to the O-ring seals. Install the 10.Apply Tooling (B) to the O-ring seals. Installthe
O-ring seals, elbow (9), and the bolts. O-ring seals, elbow (1), and the bolts.
ll.lnstall hose assembly (2) and the clamps. Install

the clamps according to the following procedure.
a. Align the clamps with the marks on the hose

assembly.
RENR9365_10
Disassembly and Assembl 57

Section
b. Orient the-oi,
cla
m in im u m 3'5:;: Ji ?lJii-": jr" [,,r??:, t. botts (2) pry etbows (3)
,T:jlu_"
rnlet manifold (1). away from air
c. Tighten the cli tnt to a torque of g
rso i-ie'l;iif t 2Nm 2. Remove bolts (4).
12. Repeat for the otner 3. Attach a suitable ,,fl!g^9gy,g"
air inlet elbows. to air intet manifotd
(1), The weisht of the-3508d
f 3. Fill the coolinq sr irili manifotd is
with coolant Refer to "li
operation ,nd MI::tPI Manual"'coolins 3E?iJTifg,i: r . ml,li!i,%y_i"
svstem Coo ;i:'8;:llnce
4. Remove air inlet r
(1) Remove the o-rins
i0248006S
seals from
Air Inlet Manifold _ Remorre "tb;;;?3i'f"ld
and Instalf Insta lfation procedure
SMCS Code: 10SB_010
Keep ar parts crean r,.H]l:lrinants
S/N: LLAI-Up
O s/N: LLBl-Up
:"Tfil5f,ili"t"u cause rapid wear and
shorrened
S/N: LLCl_Up
S/N: CBEl_Up
S/N: LLEl_Up
S/N: LLF1-Up
S/N: CBK.1_Up
S/N: R'151-Up lllustration 147

901114292
S/N: RMSl_Up '!. Install the O_rino,.seals
on elbows (3). Apply a
S/N: FlXl-Up of !rycerin i; th;;;;"!"1o'"
lg:L:'n"r.t ,nu o_rins
S/N: F2X.l-Up
S/N: RTXl_Up; R2A1_Up manifold
nifold is
Removaf procedure %Ji",
Start By:
3. Position air inlet manifotd
(1) and instail botts (4).
a. Remove the aftercoolur,,R"f"j
and Assembly, ,,Aftercooter to Disassembly 4. Position elbows (3) and
_ install bolts (2).
nemov-e"JnO tnstatt,,.
End By:
Keep ar parrs crean,r#*?lrinants a. lnstall the aftercool:,r:1"I",
to Disassembly and
Hs s e y,,,A
Contaminanlg muy cause
mb I ft e rc oo e r _ n
I
ri,Z n*i in. t" r r,,
rapid wear and snortened " "
component life.
lllustration 146
go1114292
RENR9365-1 0
i02480111
Ain lnlet Mnanifold - Remove

and lnstal[
SMCS Code: 1058-010
$/N: RlAl-Up
S/NI: SBGl-Up
S/il|: SBJl -Up

S/hl: SBK'1-Up
$lt'd: NAMl-Up
S/N: SBMl-Up
S/t{: KENl-Up
S/N: PESl-Up
$/hl: T2X'1-Up
Sif'l: RTXI -Up; R2Al -Up
ffientovaE Froeedure
Table 14
Required Tools lllustration 148 901238645
Part {. Remove the tube assembly that connects to air

Tool Number Part Description Qiv inlet cover (11).
1 38 - 7s73 Link Bracket Z
L. Remove bolts (3)and bolts (10). Remove adapter
(8) and adapter (9) from the air inlet covers.
NOTICE Remove the O-ring seals from the adapters.
Attach Tooling (A) and a suitable lifting device to
Contaminants may cause rapid vuear and shoriened air inlet cover (11). The weight of the 3512C air
component life inlet cover is approximately 25 kg (55 lb). The
weight of the 3516C air inlet cover is approximatqb.
60 kg (132 lb). Remove bolts (12). Remove air !
B{ote: The 3512C Engines have one air inlet cover.
inlet cover (11). Remove the O-ring seal from air
The 3516C Engines have two air inlet covers. The
inlet cover (11).
following procedures describe the removal and
installation of the 3516C air inlet manifold.
air inlet cover (2). The weight of the 3516C air
inlet cover is approximately 30 kg (66 lb). Remove
bolts (1). Remove air inlet cover (2). Remove the
O-ring seal from air inlet cover (2).
5. Remove bolts (4). Pry elbows (5) away from air

inlet manifold (6).
6. Remove bolts (7).
t" Attach a suitable lifting device to air inlet manifold

(6). The weight of the 3512C air inlet manifold is
approximately 65 kg (143 lb). The weight of the
3516C air inlet manifold is approximately 90 kg
(1e8 rb).
RENR9365_.10
Disassembly and Assembly 59

Section
8. Remove air inlet manifold (6)
seals from elbows (5). \-/'
Remove the O-ring
Table 15
Required Tools 6. Attach Tooting (A)an

Intet cover (11). The
1 38 -757 3
Keep ar parts crean r,H]l?ilinants

r (g) and adapter
9:ll,lqry:life.rry
component
cause rapid wear and shortened rin to the bores
;i?ti3i:t;o*'
8. Install the tube assembly
that connects to air inlet
cover (11).
i03634273
Exhaust Elbow - Remove and
Instatl
SMCS Code: .1060_010
S/N: FIX1-Up
S/N: F2X1-Up
Removal procedure
Table 16
Required Tools
Part Description
1 38 -7573
Start By:
lllustration .149
g0 1 238645
a. Remove the turbochargers.
Refer to Dis
1. Instalt the O_rino...û-1." and Assembrv,,,irroo :ha rger _
gn etbows (S). Appty a R"rouu?.tsembly
of ltycerin to tne ooL!-ioi
!g:L"r"rrt tnu o_rins b. Remove the exhaust bypass
valve. Refer to
Disassemblv ano Rssemoty, "Llnlrri"ayprr.
2. Attach a suitable lifting device Valve - Remove and Instali,.
!6-l
rh: weisht of the 3sirciiito irr"i
air inlet
,rilanirotd
manifold
approximatetv 65 kg-(1as rnl is
ine rieis'ht or the
3516c air int6t man'iroro
(1e8 lb).
t "i,prir"i#JiEry
oo r.s
Keep alr parts crean r,H]::[rinants
9glTin".llg r"y cause rapid wear and snortened
3. Position air intet manifotd (6)
and instalt botts (7)
component life.
4. Position elbows (5) and instalt bolts (4).

AN RENR9365-10
NOTICE

comoonent life.
go195oo27
lllustration 150
1. Remove bolts (1) and support (2).
2. Remove bolts (3) and bellows assembly (4),
lllustration 152
1. lf necessary, install adapter (6) and the bolts on

exhaust elbow (8).

exhaust elbow (B). The weight of exhaust elbow
(8) is approximately 27 kg (60 lb).
3. Position exhaust elbow (B) on the support bracket

4. Tighten band clamp (7) and band clamp (5),

Illustration 151 901 950029
3. Loosen band clamp (5) and band clamp (7).

exhaust elbow (8) The weight of exhaust elbow
(B) is approximately 27 kg (60 lb).
5. Remove bolts (9) and exhaust elbow (8),
6. lf necessary, remove the bolts and adapter (6)

from exhaust elbow (B).
go195oo27
Table 17
lllustration 153
Required Tools 5. Install bellows assembly (4) and bolts (3).
Part
Tool Number Part Description atv 6. Install support (2) and bolts (1).
A 1 38 - 7573 Link Bracket 2 End By:
a. Install the exhaust bypass valve.

Refer to
Disassembly and Assembly, "Exhaust Bypass
Valve - Remove and lnstall".
b. Install the turbochargers. Refer to Disassembly

and Assembly, "Turbocharger - Install".
RENR9365_1 o

Section
Exhaust Efbow - Removc i024 90808

t
and #'rXtl""",J'ifl |fi Tô : 'qitabre riftins device to
Install rr i iiIipiJ"ll,liJiu'13,ffi%t:ii-hiust eIbow
SMCS Code: 1060_010 2. Remove bolts (2). Remove

exhaust elbow (1).
S/N: LLA1_Up
f nstaf lation procedu
S/N: LLBl_Up re
Table 19
S/N: LLCl_Up
Required Tools
SiN: C8E.t_Up
Part
Tool Number
S/N: LLEl-Up Part Description
Qti,
138 -75-/3 Link Bracket
S/N: LLF1_Up 2
S/N: CBK1-Up
Keep ar parts crean ,,.H]::[rrnants
S/N: RMSl_Up
s/N: RrXl_Up; R2A1_Up lglaminqll: ,ry cause rapid wear and
o compone rt life shortened
Removal procedure
Table 1B
Required Tools
138-7573
Start By:
a, Remove the turboc

ano ns se ml,;",ir"[::gfft j"-tfi'# Rsa
ss e m biy
lllustration 155
9o1141406
Keep ar parts crean
,#]l?F"rinants
C"Tfil!f,ililt"u shortened
End By:
a. Install the turbochr

an o nsiem6i;:+;1iy,,""f , to Dsas se m bry
[:1":
lllustration 154
9011 41406
62 RENR9365-1 0
4
io24l Attach Tooling (A) and a suitable lifting device to
exhaust elbow (1). The weight of exhaust elbow
Exilaust Elbow - Remove affid (1) is approximately 25 kg (55 lb).
!r'rsta!l ,,
Remove bolts (2). Remove exhaust elbow (1).
SMCS Gode: 1060-010
S/N: R141-Up
lnstal lation Proced u re
fable 21
$/id: SBGl-Up
Required Tools
$/i{: SBJl -Up
Part
S/F{: SBKl-Up Tool l,{umber Part Description Qtv
S/${: NAMl-Up 138 -7573 Link Bracket z
S/N: SBMl-Up
NOTICE
S/N: KENl-Up Keep all parts clean from contaminants,
S/N: R1S1-Up Contaminants may cause rapid wear and shortenf

component life.
S/lil: T2X1-Up
S/h{: RTX1-Up; R2A1-Up
Rermooral Fnocedure
Table 20
Required Tools
Part
Tool Number Part Description Qtv
A 1 3B - 7573 Link Bracket z
Start By:
a. Remove the turbochargers. Refer to Disassembly lllustration 157 901244702
and Assembly, "Turbocharger - Remove"

t. Attach Tooling (A) and a suitable lifting device to _
NOTICE
Keep all parts clean from contaminants. iils ;il;:*
:=J t ;iA" -t?8i fi B:llliT : fr"o
elbow (1) on the exhaust manifold and install bolts
(2)
Contaminants may Gause rapid wear and shortened
component life
End By:
a. Install the turboclrargers. Refer to Disassembly

and Assembly, "Turbocharger - Install".

RENR9365_10
Exhaust Manifotd - i03972070
and Instalf Remove

SMCS Gode: 1059_010
S/N: F1X1_Uo
S/N: F2X1_Up
Removaf procedure
Start By:
". ursassembly
I:^T^"_r_"
the air injet manifold.
Refer to
I
and
Kemove ano tn.trnfsembly, ',Air Inlet Manifold _ 902162818
t' sprins crips rrom the
$:ff|?)the LH side of heat
Keep ar parrs crean
,r#Il?,t"rinants. t
O Contaminants mav [?3;e"the
back hear shietd from
the middte
component life. ' ause rapid wear and snortened
ci
t. the middte heat shietd
$",J;l.v" from the front heat
t procedure on
g used ce the RH side or heat
":lily,X'::gffi :Hil.[:l" on Disca rd xn:.S,"r"bTe
caro
n t8l
a' berows ass-em;i", ?Fr,,
.?"?XTi 0",."0
^:n::011.1 ;#Jr;L:."0 once. Dis_
llluslration 160
902.162839
illfiL':j,1",iii#?F: a_cap instead or

an adapter
assemoties-1ii'#liX'"',[*?J"T:u"toi.t#i"'='
9O2162817 t (3) ror the adapter
hT:;ilj,j:[T;:::Tbries
valve' Disconnect ror
assemntiel'(lj.t"t be'ilows-'
. n e c r m a n
fi :T;,"r: ln".jh f,.],,Kemove
ô: ":n the gasket
fo d ( 1 0 f ro
i I
) m
turuocrrJrle]Ysr' from the
t
fi:lliJ: &ji"-!tJi:l th e,,sectio s
or exh
ove bellows assemblies ust
n a
tne seals. (9) and
8. Remove bolts (5) f

to the cytind"r'n;;!31 attach exhaust manifold (7)
64 RENR9365-1 0
9. Remove exhaust manifold (7) and exhaust 2. Apply Tooling (A) to the threads, the bearing
manifold gasket (6). surfaces, and the inner surface of the bolts for
exhaust manifold (7). Install the seals, bellows
10. Repeat Steps 7 through 9 for the remaining assemblies (9), and bolts (B) on exhaust manifold
exhaust manifolds. (7), Tighten the bolts that are diagonal to each
other to a torque of 55 t 5 N.m (41 t 4 lb ft).
Installation Procedure Tighten the other bolts that are diagonal to each
other to a torque of 55 t 5 N.m (41 t 4 lb ft).
Iable 22
3. Repeat Steps 1 through 2 for the remaining
Required Tools exhaust manifolds.
Part
Tool Number Part Description otv 4. Apply Tooling (A) to the threads, the bearing
surfaces, and the inner surface of the bolts for the
A 5P-3931 Anti-Seize Compound
turbocharger. Install a new gasket and connect
manifold (8) to the turbocharger. Install bolts
NOTICE (11). Tighten the bolts to a torque of 54 t 5 N'm
Keep all parts clean from contaminants. (40r4rbft).
Contaminants may cause rapid wear and shortened 5. Connect bellows assemblies (4). Tighten
component life. "t"rnpf
assemblies (3) for the adapter for the exhaust
bypass valve.
NOTICE
Clamp assemblies MUST only be used once. Discard
all clamp assemblies after use.
NOTICE
Bellows assemblies MUST only be used once. Dis-
card all bellows assemblies after use.
L Apply Tooling (A) to the threads of bolts (5). Place

exhaust manifold gasket (6) and exhaust manifold
(7) in position on the cylinder head. lnstall bolts
(5). Tighten the bolts that are diagonal to each
i
other to a torque of 55 t 5 N.m (41 4 lb ft).
Tighten the other bolts that are diagonal to each
other to a torque of 55 t 5 N.m (41 r 4 lb ft).
6. Install the front heat shield. Slide the middle heat
Note: Ensure that the bellows assembly is in the shield under the front heat shield.
proper orientation during installation. The direction of
flow arrow must point in the correct direction. The 7. Install by slidingthe back heat shield under the
spacing between the ridges of the bellows assembly middle heat shield
should be equal.
8. lnstall the spring clips on LH side of heat shields
(1).
RENR9365_10
Disassembly and 65
Assembly Section
t procedure on
the RH side of heat
5n:5'"rtbTe
End By:
a. tnstall the air inlet r

p3g;,1 lil il
i illi'#;,ffi';, :"_ 3fi ff :"# :,
Eolqust lVtanifofd - i0249 to07
and Install Rernove

SMCS Code: 1059_010
S/N: LLA1_Up lllustration 164
9o111621 o
S/N; LLBl_Up 1. Remove bolts (2) ri
attach exhau.sr manifold
S/N: LLCl_Up
to the ilr;#",A#ar (1)
S/N: CBEl_Up
S/N: LLEl_Up
S/N: LLF1_Up
S/N: C8K1_Up
S/N: pESl_Up
S/N; RMSl_Up
S/N: RTXl_Up; R2A.1_Up
Removaf procedure lllustration 165

901116213
Start By: 350BC exhaust
manifold
Remove the aftercoc 2. Remove bolts (3).

manifold (4), and
and Assemlr; d;,:::, X,:lX gp*;'lfJ[,, necessary. sleeves (S), if
Remove the air inlet 3. Remove bolts (Z).

Remove bracket (10).
R:ffii3':?g ru#i:m,!l:'{, i;',:i [7a n iroro .
Keep ail parts crean NoTlcE

from contaminants.
Contaminants mav
component life. "
c:luse rapid wear
and shortened
5. Remove exhaust n
Remove
,;,:"_ji[",J,"J::,iJ3iil:l,an
manirorJ ;;i;,"J
iiiTt:!ltl
,/. Kemove gaskets exhaust
(6).
jf o,ds
,il,!'li*l,""'";;f
ffi"[HjflX,:.,*1:
ou"o o"i;,-],##
_:, l,
It rh e rtu,^.o Jj,*" u" r
cu
[ [jf"',."'' J;,i[H,9r:fi:
"
","
llil"J ll$rr3,,:;v; : fl
j ?.,".1u
re s d e s c rib e t h e re m o va I
66 RENR9365..10
2. Install sleeve (11) and manifold (13) on the

exhaust rnanifold. Apply Tooling (A)to the threads
of bolts (12). Install bolts (12) and tighten to a
torque of 55 t 5 N'm (41 t 4 lb ft).
lllustration 166 901 I 1 6240
6. Remove bolts (12). Remove sleeve (11) and

manifold (13).
lllustration 168
7. Remove bolts (12). Remove sleeves ('11) and 3508C exhaust manifold
manifolds (14) from the exhaust manifold.
3. Attach a suitable lifting device to exhaust manifold
Emstalfiation Pi'ocednarB (1). The weight of the 3508C exhaust manifold is
approximately 45 kg (100 lb), The weight of the
Table 23 3512C exhaust manifold is approxrmately 68 kg
Required -lbols (150 rb).
Part 4_ Install new exhaust manifold gaskets (9) and

tool ldumber Part Derscription CJty position the exhaust manifold onto the cylinder
5P-3931 Anti-Seize Compound head. Apply Tooling (A) to the threads of bolts
(B). Install bolts (B) and tighten to a torque of
50r5N.m(37t4lbft).
NOTICE
Keep all parts clean from contaminants. Install sleeves (5) and manifold (4) on the exhaust
manifold, if necessary. Apply Tooling (A) to the
Contaminants may cause rapid wear and shortened threads of bolts (3). Install bolts (3) and tighten to
comoonent life. a torque of 55 t 5 N'm (41 t 4 lb ft).
ltlote: l-he following procedures describe the

installation of the 3508C exhaust manifold.
4a
lllustration '169 901116440
6. Install new gasket (6) between exlraust manifold

lllustration 167 901116240 (1) and the turbocharger. Apply Tooling (A) to the
threads of bolts (2). Install bolts (2) and tighten to
'{. Install sleeves (11)and manifolds (14) on the a torque of 54 t 5 N.m (40 lb ft).
exhaust manifold Apply Tooling (A) to the threads
of bolts (12). Install bolis (12) and tighten to a
torque of 55 t 5 N'm (41 t 4 lb ft).
RENR9365_1 0
Disasse and Assembly Section

End By;
a. Install the air inlet manjfolg

Bgl", to"nJrou"
"Air tntet Maniroro'-
Disassembly
il?j,i""torv, uno
O. aftercooler Refer to Disassembly

f^r^,:l^1]l,"
Hssembty,',Aftercooler and
R"r;;;;;Tn.ru,,,,
_
i02491228
Exhaust ll/fanifofd - Remove
and Instal!
SMCS Code: 1059_010
lllustration 170
S/N: R141_Up 901244926
S/N: SBGl_Up t (1), manifotd (2), andsteeves

ftTgJ:|^bolts (3), ir
S/N; SBJl_Up
2. a suitabte
^ S/N: SBK.|-Up i\,"91
(4). The
lifrins
weight of the
- 3
S/N: NAMl_Up
S/N: SBMl_Up
.S/N: KEN,1_Up
3. Remove exhaust n
S/N: RlSl_Up manifold gaskets
(4) and exhaust
,ranifold
S/N: T2X1_Up
S/N: RTX1_Up; R2A1_Up
78
Removaf procedure
Start By:
lilustration 171
901245020
4. Remove bolts (9) Remove sleeves (Z) and

Keep ar parts crean
,Hll?ilinants manifotds (8).
3"",ifil5fti1ilt"u cause rapid wear and

shortened
f nstaf lation Procedure
Jable 24
Required Tools
5P-3931
6B RENR9365-10
End Ey:
NOTICE
Keep all parts clean from contaminants. d. Install the air inlet manifold. Refer to Disassembly
and Assembly, "Air Inlet Manifold - Remove and
Contaminants may cause rapid wear and shortened lnstall".
component life.
b. Install the exhaust elbows. Refer to Disassembly
and Assembly, "Exhaust Elbow - Remove and
Install"
03349600
ffixhaust Bypass Va$vnq* -

Rernove and $rastaBE
Sfr',qG$ Code: 1057-010
S/N: FlXl-Up
S/h{; F2X1-Up
901245020
lllustration 172 Removal Proeedu:re
1. Install sleeves (7) and manifolds (B). Apply Tooling
(A) to the threads of bolts (9) ancl install bolts (9). NOTICE
Tighten bolts (9) in a diagonal manner to a torque Keep all parts clean from contaminarrts.
of 55 t 5 N.m (41 t 4 lb ft).
comoonent life.
NOTICE
ing, adjusting and repair of the product Be prepared to
Refer to Special Publication, NENG2500, "Caterpillat-

Dealer Service Tool Catalog" for tools anO supptif
suitable to collect and coniain fluids on Cateroillai-
901244926
products.
lllustration 173

2. Attach a suitable lifting device to exhaust manifold mandates.
(4). The weight of the 35'12C exhaust manifold is
approximately 55 kg (121 lb). The weight of the
35'16C exhaust manifold is approximately BS kg '1. Drain the coolant from the cooling system to
(187 lb). a level below the exhaust bypass valve into a
suitable container for storage or disposal. Refer
3. Install new exhaust manifold gaskets (6) and to Operation and Maintenance Manual, "Cooling
position exhaust manifold (4) onto the cylinder System Coolant - Change".
head. Apply Tooling (A) to the threads of bolts
(5). Install bolts (5) and tighten to a torque of
50t5N'm(37t4lbft).
4" Install sleeves (3) and manifold (2), if necessary.
Apply Tooling (A) to the threads of bolts ('1). lnstall
bolts (1)and tighten to a torque of 55 t 5 N m
(41 r4rbft).
RENR9365_10
7
7
Ilustration 174
901 360694
lllustration i 75
2. Disconnect hose ass",m9l.y
g0 1 360694
(3), and hose assembty (2) ,'--v

hose assembty
(i)..-7; " 1. lf the studs for
bypass valve (1) are
t instaled, tiqhten_exhaust
ttre stuo,s"ti"l
3sr 5 trt m 1zo t4 tb ft). - -- s iJ,lqru
!v'L or
:;ffii,;';il?.")lgT9!:-I ir(8) ror adapter (7) ror
necessarv'
beltows Distdnnect 2. Appty Tooting (B) to
"ii"ilri5l"init to the mating face o
4. Remove botts (6) new gasket
bvpass u"ru"-tiil,?H.XlgtT Q) ror exhaust exhaust elb
locknuts (5)
5. Remove locknuts,(5),exha,ust
and the gasket from the bypass valve (1),
a. Tighten **o
"*n"r.i5[o'* g5qolgt locknuts
2s t 6 N.m (181q n ftt .".a torque of
.".- to
t studs for exhaust bvpass
ft"ff]ljie varve (1), if
b. Tighten ,nu ,:f?,l,lg jocknuts
25 t 6 N.m (18 r 4 tb" ." a torque of
to ,
ftt.-"',"."
Instaflation procedure
c. Tighten alt four
'-* torque
to a
tloglluts
\v'YL of
Table 25 47 ! g N.m (35
z tb ft).
Required Tools Note: Ensure that thê- rear,lifting
eye is out of the
a dapter ro r tr e'
;3il#jl i* :re eirr allt, iip"., u" ru"
Anti-Seize Compound 3. lf necessary, install,adapter

(Z) for exhaust bypass
varve (1) Instail bolts,qg
Hrgh Temperature Sealer
torque of 55 t 5 N m
riiten ["ii,
"",.. tuf t" ,
1ai t +"iniij
Keep ar parts crean rrHIl:Erinants
Côrtaminan!9
component life.
,ry cause rapid wear and shortened
5. Connect hose assr

(4), hose assembty (3),
and hose ;;ffiUjv
tv RENR9365-10
6. Fill the cooling system with coolant. Refer to J. Disconnect tube assembly (2) from water
Operation and Maintenance Manual, "Cooling temperature regulator housing (6). Remove the
System Coolant - Change". O-ring seal from the tube assembly.
4" Remove tube assembly (3) from the water

io2212884
temperature regulator housing.
Water TenrBeratu!'e Regulators 5. Remove bolts (4). Remove water temperature
- Rernove regulator housing (6). Remove gasket (7).
SMGS Gode: 1355-011 6. lf necessary, remove bolts (B) and remove outlet
elbow (9) from the water temperature regulator
Rennoval Procedure housing. Remove the gasket from the outlet elbow.
NOTICE
during performance of inspection, rnaintenance, test-
ing any compartment or disassembling any compo- 12
Refer to Special Publication, NENG2500, "Caterpillar 13

products.
Dispose of all fluids according to local regulations and lllustration 177 901117084
mandates.
7. Remove water temperature regulator (14).
NOTICE Remove lip seal (15) from water temperature
Keep all parts clean from contaminants. regulator housing (6).
Contaminants may cause rapid wear and shortened 8. Remove bolts (10). Remove cover (11 ) and gasket
comoonent life. (12). Remove vent assembly (1 3) from the water
temperatu re regulator housing.
1" Drain the cooling system until the level of the

coolant is below the water temoerature regulator i02492562
housing.
Wate r Tem peratrr!'e Reg ulatorO
- lnstall
SMCS Code: 1355-012
lnstallation Procedur re
Table 26
Required Tools
Tool Part Number Part Description otv
A 221 -8647 Seal lnstaller Go 1
't u - O-Ring Assembly

B 6395
Compound
901 1 1 7083
lllustration 176
2. Disconnect hose assembly (1) and hose assembly NOTICE

(5) from water temperature regulator housing (6). Keep all parts clean from contaminants.

component life.
RENR9365_10
9. Fill the coolinq with coolant

to the correct tevel.
Refer to OpeEtion and Maintenance
the correct procedure. Manuat for
io2207334
Water Furnp - Remove
SMCS Code: 1361_011
Removal procedure
lllustration 178 NOTICE

901117084 t:.:
1. Install vent assembly ifl: Jj:l::j1111ce or n
I
n
su
*
re th a t
p".tioi,,i u"i
fi u ids a re co n ta in ed
(3) p water temperarure flTi is",p:f_"rma i
ti' ; ;;"; k; i"1\ z1 n a

gy#li*i* :*i: i:
collect the fluiO wittr'sr
.:
r;:l?h
-' 'e vuuur..
[?]
., p,
i3 ;Jiil
prepared to tJe ?,?!
?jB
::?:Fl?i il;il i [3i,.'rf
i
fl " I n q
i"r,, iiJ"
nent
an v
containing
co mn a rrmp
f
fluids:,
T : :,;Iffi
n-
;
lt', 1,:
;;,^1Tta
rs befo re
o pe
* ;"i ffi ,i,,.,ii,3"?i n -
i ne
Fi _
',:;o:?:l[3 1t]l?,fff[Jgf;i;l 1 5) into water

Refer to Special publication,
NENG2500, ,,Caterpillar
NOTICE j ::i J# : :. ::;i : i; ff '3;s51,1:;

lfthe water temperature
regulator is installed
lj*lHt "' H
J,t"J
rectly, rt will cause the incor_
engine to overheat.
Dispose of all fluids accordi "",
rng to local regulations ano
mandates.
3. Install water temperature
regulators (14).
Keep al parrs ctean *ffi1?f"rinants

9^",:g,lq.,l:
component life.
,"y caLrse rapid wear and
shortened
1. Drain the coolant fr

su ita o6 coit"a'il,fli,,j,":;:?is into a
JJ;jem
lllustra tion 1 79
901'1 1 7083
' i"?',lL13,.XX'ff l, l%i',i $;,lTJ,?I(fi

ra tu re
u the gasket and outet erbow

;"";:t'it (e) and instarl
6. Install tube assembly

(3).
T. Connect hose assembly lllustration 180

(1) and hose assembly 9011144s3
2. Remove bolts (1) and the

retarners.
8. j?:lflf Jlg o-lnn ."rl9,n tube_assem bty (2).
llB:'*:J["o,?iilt sealwith r;r""; ftii \istat| ' ffil?J;Jilj:l?'I,1Lff#JH'n'"' e'bow (B)

72 RENR9365-10
5. Remove bolts (4). Remove water pump (5) from

the housing.
Note: Do not handle the water pump by the shaft or Personal injury can result frorn parts and/or cov-
allow the shaft to support the water pump. lmproper ers under spring pressllre.
handling of the shaft can allow the shaft to contact the
ceramic seals in the water pump. This can damage Spring force will be released when covers are re-
the ceramic seals. Damage to the seals will cause moved"
leaks and failure of the water pump.
6. Remove gasket (3)from the water pump. Remove bolts are loosened.
the O-ring seal from the water pump.
4
Remove nuts (2). Remove cover (4) and the
O-ring seal from housing ('1). lf necessary, remove
i02208055
taperlock studs (3) from the housing.
Waten Fump - Dlsassemble
2. Use Tooling (A) to remove impeller (5).
SMCS Code:1361-015
Disassenrbly Procedure
Iable 27
Required Tools
5F - 7465 Puller 1
BS-4728 Bot z
48-5270 Washer a
A
48-5271 Washer z
48-5273 Washer Z lllustration 182 901114919
1P-0458 Drive Plate 1

3. Remove spring (6).
Start By:
a. Remove the water pump. Refer to Disassembly

and Assembly, "Water Pump - Remove".
NOTICE

component life.
4, Remove bolts (8) and thrust washer (9).
5. Use a soft hammer to push shaft (7) out of housing

(1)
6. Remove adapter (10) from the housing. Remove

the O-ring seal from the adapter.
901 1 1 4887
lllustration 181
RENR9365_10
II
11
12
t4
lllustration 184
9011 14s4j
Illustration .185
7. Remove sealassembly (11) 90.111500s
from housing (1). t.
t ring (12) and rubber
)l:"1:"lllq
(
fptto instal tip seal
r/. uo not lubricate housins
fofril3;:,iff sear (13) the sealino ,fj.u) 'nto
v^ 9" Remove ring assemb ly (e

from the housing.
10. Remove lip seal (15)
from the housing.
11. Remove filter (16)
from the housinq.
Water pump _ Assemble

i02701635
SMCS Code: 136.1_0.16
Assembly procedure lllustration 186

90 1114929
Iable 28
2. Install the O_rino seal.on
adapter (10). Install
Required Tools adapter (i0) an"O
a torque'or
1oo r 1o N m rro ini',itnll
1P-0510 3. Instail shaft (Z) into nousing
(1).
4. Position thrust was in the sroove or the
O-Ring Assembly .n"t ini in.i",;";;,?S?Ji)
uompound
Keep ar parts crean rrlf]l?l"rinants

:"Tfili,fliftt"u shortened
74 RENR9365-1 0
lllustration 1BB 901115043


assembly procedure and wear protective equip-
rnent.
Note: Do not handle the water pump by the shaft or

allow the shaft to support the water pump. lmproper
handling of the shaft can allow the shaft to contact the lmproper assembly of parts that are spring loaded
ceramic seals in the water pump. This can damage can cause bodily injury.
the ceramic seals. Damage to the seals will cause
leaks and failure of the water pump. To prevent possible injury, follow the established
5" Install filter (16) into the housing.

6" lnstall ring assembly (\ into the housing. 10. Use a suitable press to install impeller (5) onto
t
shaft (7). Dimension (X) is 31.58 0.44 mm
Note: Use only clean water to lubricate the seals (1 .243 t 0.017 inch).
during assembly.
Note: Dimension (X) is the distance from the top of
7. Position rubber seal (13) and ceramic seal (12) impeller (5)to face of housing (1).
on shaft (7). Use Tooling (C) and hand pressure
to install rubber seal (13) and ceramic seal (12) 11.lf necessary, install taperlock studs (3) in housing
into the housing. (1). Tighten the taperlock studs to a torque of
35t5N.m(26t4|bft).
L Remove spring (6) from seal assembly (11).
Position seal assembly (11) on the shaft Use 12.Install the O-ring seal on cover (4). Lubricate the
Tooling (C) and hand pressure to press seal O-ring seal with Tooling (D). Position cover (4)
assembly (11) on the shaft until the seal faces and install nuts (2). Tighten nuts (2) to a torque of
make light contact. lnstall spring (6) on seal 27!4N'm(20r3|bft).
assembly (11).
End By:
9. Install spring (6) onto the shaft assembly in the
housing. a. Install the water pump. Refer to Disassembly and
Assembly, "Water Pump - Install".
R ENR9365_1 0
75
Section
i02207335
lffater pump - lnstal! i02724036
Auxiliary Water pump _
SMCS Gode: 1361_012
KETNOVE
Insta!lation procedure SMCS Code: 1311_011
Table 29 S/N; LLAl-Up
Required Tools S/N: LLBl-Up
Part Description S/N: LLCl-Up
S/N; CBEl-Up
S/N: LLEl -Up
S/N: LLF.1-Up
Keep ar parts crean -Hll:ilinants
S/N: CBK1-Up
;a:ll,l1,l: r"y cause rapid wear and snorrened
component life. S/N: PES.t-Up
S/N: R'1S1-Up
Note: Do not handle the.water pump
attow the shaft to suoport by the shaft or S/N: RMSl-Up
trandling of the shaft'can ll ille;;;;i'
" tf.re-.fi# i5 ,rpropur
ailow S/N: F1X1-Up
ceramrc seals in the water prrp. the
seats.
inir't""ni.r.gu
"ontact
ll^",g:lp
reaKs and fajlure of_Damage
to the seats wiil cause
the water pump.
S/l.l: F2X1-Up
S/N: T2X1-Up
S/N: RTXl-Up; R2A1_Up
Removal procedure
4
5
Keep ar parts crean t,Hll?ilinants
ruy cause rapid wear
^":lq,lr.ll:
component life. ancJ shorteneci
lllustration 190
9011144s3
' lil:'3ilffi :;'Jilffii;i,ffii"{ lumn (s) Lubricate
t sasket (3) and water pump (5). Install

ffii:t'|il
3. Install botts (Z).
4. Lubricate the O_rir

,?r1
rnirnitJr'.tn"e"":,';i',""1"J.ffi f ,i[i:,nfl
5. lnstail pump inlet elbow (8) and
instail
'"'*" botts (6).
Install the retainers and Ootts "
1i).
t. system. For the proper procedure
llltt_::oling
and coolant to use, see the op"r"lionino
Maintenance Manuar.
lllustration 19.1
9o1141238
76 RENR9365-10
1. Remove the bolts, the retainers, and retaining ring

(2) that fastens tube (1) to the elbow on auxiliary
water pump (B).
z, Remove the bolts, the retainers, and retaining ring

(4) that fastens tube (5) to the thermostatic control
valve group (9).
3. Remove bolts (6) that fasten thermostatic control

valve group (9) to bracket (10).
4. The weight of thermostatic control valve group (9)

is approximately 28 kg (62 lb). Use a suitable lifting
device to remove thermostatic controlvalve group
(9). Remove bolts (3) that fasten thermostatic
control valve group (9)to auxiliary water pump (B).
Remove thermostatic control valve group (9).
Auxiliary water pump (8) must be removed with

the accessory drive shaft and the accessory drive
gear as a unit. The weight of auxiliary water purnp
(B), the accessory drive shaft, and the accessory lllustration 193 9o1141237
ririve gear is approximately 48 kg ('106 lb). Use a
suitable lifting device to remove auxiliary water 7. Remove bolts (14) and thrust rvashers ('i5) tirai
pump (8), the accessory drive shaft, and the secure accessory drive shaft (13) to auxiliary
accessory drive gear. Remove bolts (7) that fasten water pump (8).
auxiliary water pump (B)to the front drive housing.
Remove auxiliary water pump (8), the accessor)/
drive shaft, and the accessory drive gear as a unit.
lllustration 192 901 1 41 236
6^ Remove bolts (11) that fasten accessory drive

gear (12)to accessory drive shaft (13).
RENR9365-10 aa
Disassembly and Assembl Section
i0319320'l
Auxiliary Water Pump -

Disassemble
SMCS Code: 1371-015
S/N: LLA1-Up
S/N: LLB1-Up
S/N: LLCl-Up
S/N: CBEl-Up
\ --.-tt-
S/N: LLEl -Up
S/N: LLF1-Up
S/N: CBK1-Up
S/N: PESl-Up
S/N: RlSl-Up
S/N: RMS'1-Up
1. Remove bolts (1) and remove adapter (2) from
S/N: FlXl-Up housing assembly (3). Remove the O-ring seal
from adapter (2)
S/N: F2X1-Up
S/N: T2X1-Up
S/N; RTXI-Up; R2A1-Up
Table 30
Required Tools
Tool Part Number Paft Description Qtv
1 26 -7 175 Push-Puller Tool Gp 1
start By:
O a. Remove the auxiliary water pump. Refer to
Disassembly and Assembly, "Auxiliary Water
Pump - Remove".
NOTICE
Keep all parts clean from contaminants. lllustration 195 901141330
Contaminants may cause rapid wear and shortened 2. Use Tooling (A) in order to remove impeller (4)
component life.
7R
RENR9365-1 0
lllustration 196 9O1141329 901 I 41 325

lllustration 198
6. Carefully remove the rubber seal and ceramic ring

(B)
Personal injury can result frorn parts and/or cov-
14
Spring force will be released when covers are re-
moved.
Be prepared to hold spring Ioaded covers as the

lrolts are loosened.
3. Remove spring (5). Remove retainer assembly

(6). Remove carbon seal (7). The rubber seal and
ceramic ring (8) will be removed after the shaft
is removed.
7. Remove lip seal (13) from housing assembly (3) O

8- Remove bearing (14) from housing assembly (3)
4. Remove bolts (9), shims (10), and thrustwashers

(11)
5. Remove shaft (12).

RENR9365-10
79
Disassembl Assembly Sectiorr
io2482131
Auxiliary Water pump -

Assemble
SMGS Gode: 137i-016
S/N: LLA1-Up
S/N: LLBl-Up
S/N: LLCl-Up
S/N: C8E1-Up
S/N: LLEl-Up
S/N: LLF1-Up
S/N: CBK1-Up
S/N: PESl-Up
S/N: RlSl-Up
S/N: RMS'1-Up
S/N: FlXl-Up
S/N: F2X1-Up
S/N: T2X1-Up
S/N: RTX'1-Up; R2A1-Up
Assem bly Procedure

Table 31
Required Tools
Tool Pad Number I part Description
---. .-----
--l -
t"-t
B 1P-0510 lDriverGroup t1
I
1P-0520 Driver Group 1
NOTICE

component life.
lllustration 201 90114133t

80 RENR9365-1 0
\r --.---'-l
4. Install shaft (12). Install shims (10), thrust washers 6. Lightly coat shaft (12)with clean engine oil prior to
(11), and bolts (9). installation of impeller (4).
7. Use Tooling (B) and a suitable press to install

5 impeller (4) on shaft (12). Ensure that the surface
o of shaft (12) is flush with the impeller after
installation.
7


ment.
lllustration 205 go1oo9292

5. Assemble spring (5), retainer assembly (6), and
carbon seal (7). Lubricate inside diameter of 8. Lightly lubricate the seal groove in adapter (2)
assembled components (5), (6), and (7). Use with clean engine oil. lnstall the O-ring seal in
Tooling (B) to install the assembled components adapter (2).
until carbon seal (7) makes light contact with
ceramic ring (8). 9. Install adapter (2) in housing assembly (3). Install
bolts (1) and tighten to a torque of 24 t 5 N m
(17r3tbft).
RENR9365-10 B1
End By:
a. Install the auxiliary water pump. Refer to

Pump - Install".
io2482138
Auxiliary Water Pump - Install

SMCS Gode: 1371-012
S/N: LLA1-Up
S/N: LLB1-Up
S/N: LLC1-Up
S/N: CBEl-Up
S/N; LLE1-Up '13
S/N: LLF'1-Up
S/N: CBK1-Up
1. Slide accessory drive shaft (13) on the shaft of
S/N: PESl-Up auxiliary water pump (8). Position thrust washers
('15) on the auxiliary water pump and install bolts
S/N: RlSl-Up
(14).
S/N: RMSl-Up
S/N: F'1X'l-Up
S/N: F2X1-Up
S/N: T2X1-Up
NOTICE

component life.
lllustration 207 901 0091'18
2. Position accessory drive gear (12) on accessory

drive shaft (13). Install bolts (11).
82 RENR9365-10
i02724031
EnErne OiE Goolen - Rermove

SMCS Code: 1378-011
Remova! Froeedure
NOTICE
ing, adjusting and repair of the product. Be prepared tcr

products.

Dispose of all fluids accorcting to tocat regulations
mandates "O
The weiEht of auxiliary water pump (B), the
accessory drive shaft, and the accessory drive
gear is approximately 4B kg (106 lb). Use a NOTICE
suitable lifting device to install the cornponents in Keep all parts clean from contaminants.
tlre front drive housing. Install bolts (7).
4. The weight of thermostatic control valve group component life.
(9) is approximately 28 kg (62 lb). Use a suitabte
lifting device to position thermostatic control valve
group (9). Install bolts (3). Install bolts (6) in order f . Drain the coolant from the cooling system into a
to fasten thermostatic control valve group (g) to
to Operation and Maintenance Manual, "Cooling
bracket (10).
c, lnstall the O-ring seal on tube (1) and install tube
(1) in the elbow on auxiliary water pump (B). Install
retaining ring (2), the retainers, and the bolts to
secure tube (1).
b. Install the O-ring seal on tube (5) and install tube

(5) in thermostatic control valve group (9). lnstall
retaining ring (4), the retainers, and the bolts to
secure tube (5).
2. Remove bolts (2). Remove elbow (3) and tube

assembly (1). Remove the gasket from the elbow.
3. Remove tube assembly (1) from elbow (3).

Remove O-ring seals (4) from the tube.
RENR9365-1 0 83
g 01 1 35604 35749
lllustration 210 lllustration 2'1'1 90 1 1
4. Attach a suitable lifting device to engine oil 1. Remove bolts (7). Remove elbow (6) Remove
cooler (7). The weight of engine oil cooler (7) is gasket (B) from the elbow.
approximately 78 kg (172lb).
2. Remove tube (4)from elbow (6). Remove O-ring
O5 Remove bolts (B) and bolts (9). Remove the clamp
assembly from tube assembly (10).
seals (5) from tube (4).
J" Remove the bolts and cover (9) from elbow (6).
6. Remove tube assembly (10) from the cooler Remove the gasket from the elbow
bypass elbow Remove the O-ring seal and the
retaining ring from the tube assembly. 4. Place an identification mark on oil cooler bonnet
(3) and on engine oil cooler core (1) for assembly
7. Remove bolts (5) and bolts (6). Remove adapter purposes. Remove bolts (10) and rernove oil
(1'1 ) from the engine oil cooler. Remove the gasket cooler bonnet (3) from engine oil cooler core (1).
from the adaoter. Remove gasket (2) from the engine oil cooler core.
9. Remove engine oil cooler (7) from tube (13).

Remove the O-ring seal from the tube. 13
4A
Engine Oil Gooler

Disassemble
SMCS Code:1378-015
Disassembly Procedure lllustration 212 901 1 35795
Start By:
5. Place an identification mark on oil cooler bonnet
a" Remove the engine oil cooler. Refer to (14)and on engine oil cooler core (1)for assembly
Disassembly and Assembly, "Engine Oil Cooler purposes. Remove bolts (13) and remove oil
- Remove". cooler bonnet (14) from engine oil cooler core ('1).
Remove gasket ('16) from the engine oil cooler
core.
NOTICE
Keep all parts clean from contaminants. 6. Remove bolts (11)and elbow (12)from the engine
oil cooler bypass. Remove the O-ring seals from
Contaminants may cause rapid wear and shortened the elbow.
component life.
7. Remove cover (17) and the O-ring seal.
8. lf necessary, remove drain plug (15) and the

O-ring seal.
RENR9365-10
9. Thoroughly clean the tubes in the engine oil cooler

core.

Personal injury can result from parts and/or cov-
ers under spring pressure. Tcrprevent possible injury, follow the establisr"p
Spring force will be released when covers are re- ment.
moved.
Be prepared to hold spring loaded covers as the 2" lnstall bypass valve (20) and spring (19) in elbow
bolts are loosened. ('12). Install O-ring seal (18) and lubricate the
O-ring seal with clean engine oil. Install cover (21)
and bolts (22).
10. Remove bolts (22), cover (21), O-ring seat (18),
spring (19), and bypass valve (20) from elbow
(12).
'12
i02259048
Engine Oil Cooler - Assernble 14
SMCS Code: 1378-016
Assembly Procedune
NOTICE
lllustration 215 901 I 3591 5

component life. 3. Install gasket (16) and oil cooler bonnet (14) on
engine oil cooler core (1) in the orientation that
was noted during the disassembly procedure.
1. Thoroughly clean the tubes in the engine oilcooler Install bolts (13),
core.
4. Install the O-ring seal and cover (17).
5. Install the O-ring seal and drain plug (1b).
6. Install the O-ring seal and elbow (12) on the

engine oil cooler core. Install bolts (1'l).
7. Install the O-ring seal on tube (4). Appty ctean

engine oil on the O-ring seal, Install tube (4) in
elbow (12).
RENR9365-10
85
Disassembly and Assemblv Section
lllustration 216 g0'11 35749

g0 35604
8. Install gasket (2) and oil cooler bonnet (3) on 1. Attach a suitable lifting device to engine oil
engine oil cooler core (1) in the orientation that cooler (7). The weight of engine oil cooler (7) is
was noted during the disassembly procedure. approximately 78 kg (i72 tb).
lnstall bolts (10).
2. Install the O-ring seal on tube (13) Apply clean
9. Install O-ring seat (5) on tube (4). Appty ctean engirre oil to the O-ring seal.
engine oil on the O-ring seal. Install elbow (6) on
iube (4). 3. Position engine oil cooler (7) on tube (13). lnstall
bolts (12).
10. Position gasket (8) and etbow (6) on engine oil
cooter core (1). Install bolts (7). 4. P.osition the gasket and adapter (11) on the engine
oil cooler. Install botts (6) and botts (5).
11. Position the gasket ancJ cover (9) on elbow (6).
Install the bolts. 5" Install the O-ring seal and the retaining ring on
tube assembty (10). Instail tube assembty ftO;.
End By:
6. Install the clamp, bolts (8), and botts (9). Tighten
a. Install the engine oil cooler. Refer to Disassembly
and Assembly, "Engine Oil Cooler - Install,,.
bolts (B)to a torque of 47 ! 9 N.m (35 i 7 h ft).
Tighten bolts (9) to a torque of 47 t 9 N.m
(35r7tbft)
io2255502
Engine Oil Cooler - Install

SMCS Cocle: 1378-012
NOTICE

component life.
7. Install O-ring seals (4) on tube assembly (1). Apply

clean engine oil to the O-ring seals.
8. Install elbow (3) on tube assembly (.i). Install tube

assembly (1) in the adapter. position the gasket
and elbow (3) on the cylinder block and install
bolts (2).
B6 RENR9365-10
9. Fill the cooling system.Refer to Operation and 2. Remove tube assemblies (1) and the brackets.
Maintenance Manual, "Cooling System Coolant
- Change". 3. Remove bolts (2), (4), and (5). Remove adapter
(3), Remove the gaskets from the adapter.
io2724021
Engine Oil Pump - Remove

SMCS Gode: 1304-011
Removal Procedure
Start By:
a. Remove the fuel transfer pump. Refer to

Disassembly and Assembly, "Fuel Transfer Pump
- Remove".
NOTICE lllustration 220 901141973

during performance of inspection, maintenance, test- 4. Remove bolts (6) in order to disconnect elbow
p
ing, adjusting and repair of the product. Be prepared to from engine oil pump (8). Remove the O-ring seal
collect the fluid with suitable containers before open- from the elbow.

products.

mandates.
NOTICE
Contaminants may cause rapid wear and shortened lllustration 221 901141977
component life.
{. Drain the coolant from the cooling system into a

u
lj'fl?l', 3, :+'lXT%ilI;l %|:XLTJ"" il? i,? ?J,,, O
approximately 42 kg (93 lb). Remove bolts (9) in
suitable container for storage or disposal. Refer order to remove engine oil pump (8) from the front
to Operation and Maintenance Manual, "Cooling housing. Remove bolts (10) in order to remove
System Coolant - Change". engine oil pump (8)from adapter (11). Remove
the engine oil pump. Remove the O-ring seal from
adapter (11),
6. Remove the O-ring seal from adapter (11).

Remove the O-ring seal from engine oil pump (8).

RENR9365-10
87
Disa and Assembly Section
i02483493
Engine Oil Pump - Disassemble

Personal injury can result from parts and/or cov_
SMCS Code: 1304-015 ers under spring pressure.
Disassembly Procedure Spring force will be released when covers are re_
moved.
Table 32
Required Tools bolts are loosened.
Tool Part Number Part Description Qtv
1P-0510 Driver Gp 1
1. Remove bolts ('1'1) and relief valve cover (12).
Remove spring (14) and pressure relief spool'(,1S)
B 6V-2166 Bearing Puller Gp 1
Remove gasket (13) from the relief valve cover.
Start By: 2. Remove bolts (1) and pump cover assembly

(2). Remove gasket (3) from the pump cover
a. Remove the engine oil pump. Refer to assembly. lf necessary, remove the dowels from
Disassembly and Assembly,,,Engine oi Pump pump cover assembly (2).
- Remove".
3. Remove bolts ('10) and pump cover assembly (4)
NOTICE from oil pump body assembly (9).
4. Use Tooling (A) to remove sleeve bearings (5)

from pump cover assembly ( ). lf necessary,
remove the hollow dowels from pump cover
assembly (4).
5. Remove idler shaft assemblies (6) and pump drive

ubtication, NENG2500,,,Caterpillar str.aft assembly (7) from
oil purnp body assembly
ol Catalog" for tools and supplies (e)
and contain fluids on Caterpillar
6. Use Tooling (A) or Tooling (B) to remove sleeve
bearings (8) from oil pump body assembly (9)
mandates.
i02483664
Engine Oil Pump - Assemble

xeeo arr parts ui'f"t:::Lmin"nts
I "r"", SMCS Code: 1304-016
component life. Assembly Procedure
Table 33
Required Tools
A 1P-0510 Driver Gp 1
NOTICE

component life.
10 1
lllustration 222 9o11421 57

BB RENR9365-10
A
I. Align the joints of sleeve bearings (B) to 45 t
15 degrees from the centerlines of the bearing
bores in oil pump body assembly (9). Use Tooling
(A) to install sleeve bearings (8) in oil pump
body assembly (9). The sleeve bearings must be
1.5 r 0.5 mm (0.06 ! 0.02 inch) below the gear
bore.
(
I z. Install hollow dowels (16) in pump cover assembly
(
!
(4) at a distance of 6.0 t 0.5 mm (0.24 0.02 inch)
above the face of the pump cover assembly
2 Align the joints of sleeve bearings (5) to 45 t 15
10 11 tz 42 14 15 degrees from the centerlines of the bearing bores
901142157
in pump cover assembly (4). Use Tooling (A) to
lllustration 223
install sleeve bearings (5) in pump cover assembly
(a). The sleeve bearings must be 1.5 t 0 5 mm
(0.06 i 0.02 inch) below the face of the pump
cover assembly.
4. Apply clean engine oil to pump drive shaft

n assembly (7) and to idler shaft assemblies (6). -
Install the pump drive shaft assembly and the idler
shaft assemblies in oil pump body assembly (9).
Position pump cover assembly (4) onto the oil
pump body assembly and install bolts (10).
5. Install the dowels in pump cover assembly (2) at a

distance of 6.0 t I .0 mm (0.24 t 0.04 inch) above
the surface of the cover assembly. Position gasket
lllustration 224 9O1142223 (3) and pump cover assembly (2) on oii pump
k.rody assembly (9). Install bolts ('l).
Note: The engine oil pump must turn freely after

assembly. Turn the engine oil pump by hand.
6. Apply clean engine oil on pressure relief spool

(15), Install pressure relief spool (15) and spring
(14) in the oil pump body assembly. Install gasket
(11)'
valve cover (12)' and bolts
,"ltl;i"""r o
a. Install the engine oil pump. Refer to Disassembly
and Assembly, "Engine Oil Pump - Install".

i0249357 1
Engine Oil Pump - lnstall

lmproper assembly of parts that are spring loaded SMCS Code: 1304-012
NOTICE
ment.

comoonent life.
RENR9365-10
End By:
a. lnstall the fuel transferSump. Refer to Disassembly

and Assembly, "Fuel Transfer pump _ lnstall,.
i02205467
Engine Oil Filter Housing -

Remove
SMCS Code: 1306-011
S/N: LLA1-Up
lllustration 226 9o1142097 S/N: LLBl-Up
1. Install the O-ring seal on adapter (11). Instail the S/N: LLCl-Up
u-nng seat on elbow(7). Install the O_ring sealon
engine oil pump (B). Appty clean engine oil to the S/N: CBEl-Up
O-ring seals. S/N: LLEl-Up
2. the engine oit pump with ctean engine S/N: LLFl-Up
!ybl?3J"
ol. Hefore you install the engine oil pump, miake
sure that the shaft of the pump will turn by hand. S/N: SBGl-Up
3. Attach a suitable lifting device to engine oil S/N: SBJl-Up

engine oil pump (g) is S/N: C8K1-Up
lb). Align the splines of
the splines of the drive S/N: SBKl-Up
pump on the rront S/N: NAMl-Up

n"r.;.tn""=ltl'?:i": "#Yi3?rl:
S/N: SBMl-Up
4. Install botts (10). Instail botts (6).
S/N: KENl-Up
S/N: PESl-Up
S/N: RMSl-Up
S/N: FlXl-Up
S/N: F2X1-Up
S/N: T2X1-Up
Removal Procedure
227
lllustration 227 901141965 Table 34
Required Tools
5. P.osition the. gaskets and adapter (3). Install
botts
(4), (5), and (2). Tool Part Number Part Description Qtl,
A 1 38 - 7573 Link Bracket
6. Install tube assemblies (1) and the brackets. z
7. Fill the cooling system. Refer to Operation Start By:

and
rM€tntenance Manual,,,Cooling System Coolant
- Change". a. Remove the fuel filter housing. Refer to
Disassembly and Assembly, ,,Fuel
Filtei Housing
- Remove".
90 REN R9365-1 0
3" Remove bolts (4) and spacers (5) from tube

NOTICE assembly (3).
during performance of inspection, maintenance, test- 4. Remove bolts (6) and plate (7).

Tools and Shop Products Guide" fortools and supplies
products.
Dispose of all fluids according to local reguiations and

mandates.
11
NOTICE
Keep all parts clean from contaminants. lllustration 230 s01117
Contaminants may cause rapid wear and shortened q
Instali Tooling (A) and a suitable lifting device on
component life. engine oil filter housing (9). l-he weight of engine
oil filter housing (9) is approximately 95 kg (210 lb).
f . Drain the oil from the engine oil filter housing
G. Rernove bolts (8) Remove engine oilfilter housing
into a suitable container. Refer to Operation and
(e)
Maintenance Manual, "Enqine Oil and Filter -
Chanoe".
t. Attach a suitable lifting device on oil filter housing
support (11). The weight of oil filter housing
sr"ipport (11) is approximately 71kg (157 lb)
8" Remove bolts (10). Remove oil filter housing

support ('11).
2. Remove bolts (1) and adapter (2). Remove the

O-ring seal from the adapter.
g0111s75'1
lllustration 229
RENR9365-10
91
Disassembly and Assembly Sectiorr
i02206447
Engine Oil Filter Housing -

Disassemble
SMCS Code: 1306-01b
S/N: LLA'1-Up
S/N: LLBl-Up
S/N: LLCl-Up
S/N: C8E1-Up
S/N: LLE1-Up
S/N: LLFl-Up
S/N: SBGl-Up
o S/N: SBJl-Up
S/N: C8K1-Up
Personal injury can result from parts and/or cov-
S/N: SBK1-Up Spring force will be released when covers are re-
moved.
S/N: NAMl-Up
S/N: SBMl-Up
bolts are loosened.
S/N: KENl-Up
S/N: PESl-Up 1. Remove bolts (1) and cover (7). Remove the
O-ring seal from the cover. lf necessary, remove
S/N: RMS1-Up the dowel from the cover.
S/N: F1X1-Up 2. Remove the engine oil filter elements from filter
housing (2).
S/N: F2X1-Up
S/N: T2X1-Up 3. Remove bolts (8). Remove adapter (3) and filter
housing (2) from housing (11). Remove the O+ing
S/N: RTX'I-Up; R2A1-Up seal from the adapter.
Disassembly Procedure 4. Remove bolts (12). Remove housing support (6)

O from housing (11) Remove the O-ring seals from
the housing. lf necessary, remove the dowels from
Start By:
the housing.
a. Remove the engine oil filter housing. Refer to
Disassembly and Assembly, "Engine Oil Filter
5. Re_move bolts (4) and cover (5). Remove spring
(13) and bypass valve (14) from the housing.
Housing - Remove".
6. Remove bolts (9) and cover (10). Remove the
NOTICE O-ring seal from the cover.

component life.
92 RENR9365-10
i02704053
Engine Oll Filter Ffousing

Assemble
SMCS Code: 1306-016
S/N: LLA1-Up
S/$,1: LLBl-Up
S/N: LLCl-Up
S1ill: CBE'1-Up
S/N: LLEl-Up
901 1 1 3975
lllustration 232
S/N: LLFl-Up
S/N: SBGl-Up
S/N: SBJl-Up
gfiTfr"i$:"Jllf
S/N: CBKl-Up
S/hl: SBK1-Up "t",'"t#:n-thataresprinstoao!
S/N: NAfiil1-Up ment.
S/N: SBMl-Up
f . Install bypass valve (14) and spring (13) in
S/N: KENl-Up housing (11).
S/lrl: PESl-Up Note: The bypass valve must move freely in the bore.
S/N: RMS1-Up
2. Install the O-ring seal on cover (5). Install cover
S/N: F1X1-Up (5) and bolts (4).
S/N: F2X1-Up 3. Installthe O-ring seal on cover (10) Installcover

(10) and bolts (9).
S/N: T2X1-Up
S/N: RTX'I -Up; R2A'l -Up 4. lf necessary, install the dowels in housing
(1'1). The dowels must be 6.50 r 1.00 mm
0'040 inch) above the surrace or the
Assembly Frocedune [133f,J O
NOTICE t. Install the O-ring seals on housing (11). Install
Keep all parts clean from contaminants, housing support (6) on housing (1'1). Install
bolts (12) and tighten to a torque of 55 t 7 N.m
Contaminants may cause rapid wear and shortened (41 r5rbft).
comoonent life.
6. lnstall the O-ring seal on adapter (3). Installfilter
housing (2) and adapter (3) on housing (11 ). Install
bolts (B) and tighten to a torque of 55 7 N'm t
(41 r5rbft).
7" Install new engine oil filter elements in filter
housing (2).
8. lf necessary, install the dowel in cover (7). The

dowel must be 6.50 t 1.00 mm (0.256 t 0.040 inch)
above the surface of the cover.
9. Install the O-ring seal on cover (7). Install cover

(7) and bolts (1).
RENR9365-1 0 93
End By:
a. Install the engine oil filter housing. Refer to

Housing - Install".
io22.o5469
Engine Oil Filter [-lousinE -

Insta ll
SMCS Code: 1306-012
S/N: LLA1-Up
lllustration 233
S/N: LLBl-Up
S/N: LLCl-Up 1. Attach a suitable lifting device on oil filter housirrg
support (11). The weight of oil filter housing
S/N: CBEl-Up support (11) is approximately 71 kg (157 lb).
Position oilfilter housing support (11)and install
S/N: LLE1-Up bolts (10).
S/N: LLF'1-Up
Install Tooling (A) and a suitable lifting device
S/N: SBGl-Up on engine oil filter housing (9). The weight of
engine oil filter housing (9) is approximately 95 kg
S/N: SBJl-Up (210 lb). Position engine oil filter housing (9) and
install bolts (B). Remove Tooling (A).
S/N: CBKl-Up
S/N: SBK'1-Up
S/N: NAM'1-Up
S/N: SBMl-Up
S/N: KENl-Up
S/N: PES'1-Up
S/N: RMSl-Up
S/N: F1X1-Up
S/N: F2X1-Up
S/N: T2X1-Up
S/N: RTX1-Up; R2A1-Up 3. Position plate (7) and install bolts (6)
I nstallation Procedu re 4. Install spacers (5) and bolts (4) to secure tube
assembly (3).
Table 35
Required Tools
rffi;""ripti"" -l-oty
A 1 38 - 7573 Link Bracket a
NOTICE

component life
94 RENR9365-10
NOTICE
ing, adjusting and repair of the product Be prepared to
collect the fluid with suitable containers before onen-
Refer to Special Publication, NENG2500 "Caterpillar

products.
9o1113749 Dispose of all fluids according to local regulations and

lllustration 235
mandates.
5. Instail the O-ring seal on adapter (2). Install tlre
adapter and install bolts (1).
6. Check the oil level. Maintain the oil level at the

"FULL" mark. Refer to Operation and Maintenance
.-o
Manual, "Engine Oil and Filter - Change" for the
correct filling procedure.
End Ey:
a. Install the fuelfilter housing. Refer to Disassembly

and Assembly, "Fuel Filter Housing - Install".
io2485014
Hmgiffie GiH fi$ten Base -

Rermove
SIWGS Gode: 1306-011
S/N: R141-Up
lllustratiou 236 9o1240761
S/N: R1S1-Up
n (B) in order to remove ensine oit
S/N: RTXI-Up; R2A1-Up Hi""rJBing I
Rem<lva! Procedure 2. Remove bolis (3) and bolts (5) at engine oil filter
base (2).
Table 36
? Disconnect the harness assemblies from enoine
Required Tools
oil filter base (2).
Part
lool Number Part Description Qtv 4" Attach Tooling (A) and a suitable lifting device to
A 38 - 7573 Link Bracket
engine oil filter base (2). The weight of engine
1 z
oil filter base (2) is approximately 55 kg (120 lb).
B 187 -2718 Filter Wrench Assemblv 1 Remove bolts (1). Remove engine oil filter base
(2)
RENR9365-10
i02485 1 34
Engine Oil Filter Base - Engine Oil Filter Base -

Disassemble Assemble
SMCS Gode: 1306-015 SMCS Code: 1306-016
S/N: R141-Uo S/N: R141-Up
S/N: R151-Uo S/N: R151-Uo
S/N: RTXI-Up; R2A1-Up S/N: RTXI-Up; R2A1-Up
Disassembly Procedure Assembly Procedure

Start By:
a. Remove the engine oil filter base. Refer to
Base - Remove".
o
SECTION A-A
4
o
SECTION A-A lmproper assembly of parts that are spring loaded
lllustration 237 gO124o8O2 can cause bodily injury.

ment.
Personal injury can result from being struck by
parts propelled by a released spring force.
O 1. Installvalves (6), springs (5), and the gaskets.
ment. 2. Install relief valve covers (4).
Follow the recommended procedure and use all 3. Position plate assembly (2) on engine oil filter
recommended tooling to release the spring force. base (3) and install bolts (1).
End By:
1. Remove bolts ('l) and plate assembly (2) from
engine oilfilter base (3). a. Install the engine oil filter base.
Refer to
2. Remove relief valve covers (4).
Base - lnstall".
3. Remove the gaskets, springs (5), and valves (6)
YO RENR9365-10
io2485147 i0248 531'l
ffisrsine Oil FEEter' tsase - EmstaBH Hnginre OiE Fan - Reffixove

SMCS Code: 1306-012 SMCS Code; 1302-011
S/N: RlAl-Uo
Renioval Frocedure
S/[ql: R1S1-Up
NOTICE
S/il!: RTXI-Up; R2A1-Up
I r"nstaIEatron Proeed alne ing, adjusting and repair of the product. Be prepared to
Table 37 ing any compartment or disassembling any compo-
Required Tools nent containing fluids.
Part Refer to Special Publication, NENG2500, "Caterpillar
Tool ber
N r.rrn Pad Descrlption atl/ Dealer Service Tool Catalog" for tools and supplies
1 38-7573 Link Bracket z suitable to collect and contain flLrids on Cateroillar
products
B 1 87 "2718 Filter Wrench Assembly 1
O
mandates.
NOTICE

component life.
l. Drain the engine oil into a suitable container for

storage or for disposal Refer to Operation and
Maintenance Manual. "Enoine Oil and Filter -
Change".
'1. Attach Tooling (A) and a suitable lifting device to

engine oil filter base (2). The weight of engine
oil filter base (2) is approximately 55 kg (120 lb).
Place engine oil filter base (2) in position and
install bolts (1).
901 1 23595
2, Connect the harness assemblies to engine oil lllustration 240
filter base (2).
2" Remove bolts (1) that hold the connector for the
3. lnstall bolts (3) and bolts (5) at engine oil filter engine oil pump to engine oil pan (2).
base (2).
4. Use Tooling (B) in order to install engine oilfilters

A\
RENR9365-10
:x
lllustration 24'1 901123597
t connect ensine oil pan (2)

[".il""""? i'i:lf'fn"t
i02282781
Engine Oil Pan - Disassemble

SMCS Code: 1302-015
Disassernbly procedure
Start By:
lllustration 242 g0
a. Remove the engine oil pan. Refer to Disassembly
1 1 23599
and Assembly, "Engine Oil pan _ Remove,,.
NOTICE
lmproper lift rigging can allow unit to tumble caus_
rng lnJury and damage.
component life.
4. Attach a suitable lifting device to the engine lifting
:u"t S'BC Ensine is

kg (10000 tb). The weight
is approximately 240 [g
512C Engine is
kg (15000 tb). The weight
is approximately 295 kg
. The weight of the 3S16C Engine is

e,100 ks (20000 tb). rhe weisht
:ppJ?lTqt"ty
ol-rhe engine oil pan is approximately 409 [g
(e00 tb).
5. Lift the engine from the engine oil pan.

9B RENR9365-10
f 0' Remove drain plug (12). Remove the O-ring seal

from the drain plug.
ffir'lgrne GlE Fan - Assenr[:Ee

SMCS Gode: 1302-016
Assesmbly Frocedure
Table 38
Required Tools
A 1P-0808 Multipurpose Grease
lllLrstration 244 9o1142529
'1" Retnove drain plug (7). Remove the O-ring seal

from the drain plug.
2. Remove connector (1) and O-ring seal (2).

3. Remove engine oil level gauge (3) and gasket (4).
4. Remove cover (6) and O-ring seal (5).
5. Remove adapter (11) and O-ring seal (10). lllustration 246 901'142583
6. Remove bolts (8). Remove suction screen {. Install the O-ring seals on tube assembly (17).
assembly (9)from adapter ('11). Apply Tooling (A) to the O-ring seals. Position tube
assembly in the engine oil pan. Install bolts ('19)
and tighten to a torque of 47 x 9 N.m (35 I 7 lb ft)
;i iyi,'$'"f,'[il,:f'?Tffi[3y j;', o
' 47!9N'm(35l7lbft).
iHlSli
3. Installthe O-ring seal on suction tube (15). Apply

Tooling (A) to the O-ring seal. Install suction tube
(15) into oil housing (18). Installclamp (14)and
bolts ('13).
4. Install the O-ring seal on drain plug (12). Install

drain plug (12) and tighten to a torque of
145 I 15 N'm (107 t 11 lb ft).
g 01 1 42583
lllustration 245
7. Remove bolts (13) and clamp (14). Remove

suction tube (15). Remove the O-ring seal from
the suction tube.
8. Remove bolts (16). Remove oil housing (18)from

tube assembly (17).
9. Remove bolts (19). Remove tube assembly (17)

from the engine oil pan. Remove the O-ring seals
from the tube assembly.
RENR9365-1 0
io2724011
Engine Oil Pan - lnstall

SMCS Gode: 1302-012
Installation Procedune
Table 39
Required Tools
Too Part Number Pad Description atv
A BT - 90't 4 Silicone Sealant
B 1 P. OBOB Multipurpose Grease
a Guide Stud
3/8 - 16 by 5 inch
NOTICE
lllustration 247 901 ! 42529

5. Install suction screen assembly (9) on adapter component life.
(11). Install bolts (B)
6. Install O-ring seal (10) and adapter ('1'1) on the

1. Clean the sealing surfaces of the engine oil pan
engine oil pan. and the cylinder block.
7. Install O-ring seal (5) and cover (6) on the engine

oil pan.
B. Install gasket (4) and engine oil level gauge (3)
9. Install O-ring seal (2) and connector ('1).
10.Install the O-ring seal on drain plug (7).

Install drain plug (7) and tighten to a torque of
145 ! 15 N m (107 ! 11 tb ft).
End By:
O
a. Install the engine oil pan. Refer to Disassembly 23600
and Assembly, "Engine Oil pan - Install".

2. Apply Tooling (A) to oil pan gasket (4). Instail the
o1l pan gasket on the engine oil pan. Install Tooling
(C) in the engine oil pan.
3. Apply Tooling (B) to the bore of ftange (7). Instatl

seal (B) inside flange (7). Position the ftange and
install bolts (6). lnstall O-ring seal (5) on the flange.
100 RENR9365-10
901 1 23599 901 1 23595

7. Install bolts (1) that hold the connector for the

engine oil pump to engine oil pan (2).
lmproper lift rigging can allow unit to tumble caus-
ing iniury and darnage.
' ill. g?"",'Sil
i,. : :ffi l" 3 i [
Operation and Maintenance "i3i
",
Manual, "EnEine Oil

,5
: l, L%:"i5,:l,t
4. Attach a suitable lifting device to the engine lifting and Filter - Change".
eyes.
u The weight of the 3508C Engine is i0.1932610
approximately 4535 kg (10000 lb). The weight

of the engine oil pan is approximately 240 kg
Grankcase Breather - Remsve
(530 rb). and Install
" The weight of the 3512C Engine is SMCS Code: 13'17-010
approximately 6800 kg (15000 lb). The weight
(650 rb).
RemovaN Frocedure
. The weight of the 3516C Engine is NOTICE

approximately 9100 kg (20000 lb). The weight Keep all parts clean from contaminants.
(s00 tb) Contaminants may cause rapid wear and shortened
5. Lift the engine. Place the engine onto the engine

oil pan.
23597
1. Loosen clamp (2). Remove the clamp and tube
(3)
6. Install bolts (3). Remove Tooling (C) from engine
oil pan (2) and install remaining bolts (3). 2. Loosen clamps (4). Remove both breathers (1)
as a unit.
RENR9365-10 101
9o1o57824 901 057825

3. Remove O-ring seals (5) from the valve covers. Note: Coat the rubber parts with clean engine oil or
Discard the O-ring seals. petroleum jelly in order to make installation easier.
1. Place clamps (6) over the parts of tee assembly

(7) that will receive breathers (1). Install breathers
(1) into the tee assembly, Tighten the clamps to a
torque of 3.0 t 0.5 N'm (27 ! 4lb in).
901 057825
lllustration 254
4. Remove clamps (6). Remove both breathers (1)

from tee assembly (7).
9o1057824
Inspect the tee assembly for cracks. lf the tee lllustration 256
assembly is cracked, discard the old tee assembly
and obtain a new tee assembly for installation. 2. Coat new O-ring seals (5) with clean engine oil
Place the O-ring seals on the valve covers.
5. Turn the breathers upside-down in order to inspect
the condition of the breather elements.
Clean the breather elements with clearr,

nonflammable solvent. lf the breather elements
remain contaminated after the cleaning, discard
the breathers and obtain new breathers. Do not
attempt to disassemble the breathers.
Allow the breather elements to drv before

installation.
I nstallation Procedu re
NOTICE 901 057823
lllustration 257
3. Place clamps (4) around the parts of the breathers
Contaminants may cause rapid wear and shortened that will be attached to the valve covers. Install
comoonent life. both breathers (1) as a unit. Tighten the clamps.
102 RENR9365-10
4. Place clamp (2) on the part of the tee assembly i02486546

that will receive tube (3). Install the tube. Tighten
the clamp to a torque of 3.0 i 0.5 N'm (27 t4lbin\. Valve Mechanism Cover Base -
Remove and Install
io27ooos3
SMCS Gode: 1120-010
valve Mechanism Gover -
Remove and Install Removal Procedure
SMCS Code: 1107-010 Start By:
Removal Procedure a. Remove the electronic unit injectors. Refer to

Disassembly and Assembly, "Electronic Unit
Injector - Remove".
901 052887
L Remove bolts (1). Remove valve mechanism lllustration 260
cover (2).
1. Remove tube assemblies (1).
2. Remove the seal from the valve mechanism cover,
2. Remove bolts (2) (not shown) and valve
mechanism cover base (3).
Table 40
Thread Lock Compound
1. Installthe seal on the valve mechanism cover.

2. Install valve mechanism cover (2). Install bolts (1)
lllustration 261
RENR9365-10 103
1. Position valve mechanism cover base (3). Apply 3. To remove pushrod (5), it is necessary to remove
Tooling (A) to the threads of bolts (2) (not shown) valve mechanism cover base (6).
and install bolts (2) (not shown).
i0231 5619
2. Install tube assemblies (1).
Rocker Shaft - Disassemble
End By:
SMCS Gode: 1102-015
a. Install the electronic unit injectors.
Refer to
Disassembly and Assembly, "Electronic Unit
Injector - Install". Disassembly Procedure
Table 41
i02315452
Required Tools
Rocker Shaft and Pushrod - Tool Part Number Part Description Qtv
Remove A 1P-0510 Driver Group 1
SMCS Code: 1102-011; 1208-011 Start By:
Removal Procedure a. Remove the rocker shaft assembly. Refer to

Disassembly and Assembly, "Rocker Shaft and
Start By: Pushrod - Remove".
a. Remove the valve mechanism cover. Refer to

Disassembly and Assembly, "Valve Mechanism
Cover - Remove and Install".
NOTICE

comoonent life.
g01 1 20055
lllustration 263
1. Slide shaft (2) out of rocker arm (1). lf necessary,

remove spring pin (3) from the shaft
901 1 1 9693
lllustration 262
1. Remove bolts (1). Remove rocker shaft assembly

(2) from valve mechanism cover base (6). Remove
valve pushrods (4).
Note: Mark the valve pushrods for identiftcation of

location for assembly
901 1 20059
lllustration 264
2. Remove bridge assemblies (3) from the valve
stems. 2. Remove jam nut (4) from adjustment screw (6)
Remove the adjustment screw from rocker arm
Note: Mark the bridge assemblies with identification (1)
of location for assembly.
104 RENR9365-10
3. Remove button (9) from socket (7). Remove

retaining ring (B)from button (9).
4. Use a hammer and a punch to remove socket (7)

from rocker arm (1).
5" Use Tooling (A)to remove sleeve bearing (5)frorn

the rocker arm.
i02706144
Roe ker Shaft - Assemble

SMCS Gode: 1102-016
Assennhly Proceetrure
5. lf spring pin (3) was removed from shaft (2), install
fable 42 a new spring pin. Position the split in spring pin (3)
Required Tools toward the end of shaft (2) and press the spring
pin into the shaft.
Tool Part Number Part Description Qtv O
A 'tP-0510 Driver Group 1
6. Apply clean engine oil to the sieeve bearing of
rocker arm (1) and to shaft (2). Install the rocker
arm on the shaft.
End By:
a. Install the rocker shaft assembly. Refer to

Disassembly and Assembly, "Rocker Shafi and
Pushrod - lnstall".
Rocker Shaft affid PuusllroeE -

lmstall
20089 SF'flCS Code: 1102-012; 1208-Q12
t. The sleeve bearing and the rocker arm have oil lnsta!lation Pnocedure
supply holes. The holes must be aligned when the
sleeve bearing is installed in the rocker arm. Align NOTICE
the joint of the sleeve bearing toward the top of the Keep all parts clean from contaminants
rocker arm. Align the oil hole in the sleeve bearing
with the oil hole in the rocl<er arm. Use Tooling (A) Contaminants may cause rapid wear and shortened
to install sleeve bearing (5) in rocker arm (1). component life.
2" Align the scribe mark on socket (7)with the center
line of rocker arm (1). Press socket (7) fully into
rocker arm (1).
3. Place retaining ring (B) on button (9). Instail button

(9) in socket (7).
4. Install adjustment screw (6) in rocker arm (1).

Installjam nut (4) on the adjustment screw.
105
RENR9365-1 0
g0'1119759
lllustration 267
1. Loosen jam nut (B) and adjustment screw (7).

Loosen jam nut (10) and adjustment screw (9).
901 946786
lllr-rstration 270
Floating valve bridge
(X) Round pocket
(Y) Slotted pocket
(Z) Outside of engine
2. Apply clean engine oil to pushrod (5).
3. Apply clean engine oil to valve pushrods (4), and

the cup of the valve lifters. Install valve pushrods
(4) in the original location.
901131377 4. Valve bridge assemblies for dowel installations

lllustration 268
have an adjustment screw and a jam nut. Use the
following procedure to install this configuration.
11
a. Loosen adjustment screw ('11 ) and jam nut (12)
12 on bridge assemblY (3).
b. Coat these ttems with clean engine oil: the

dowels, the receptacle of the bridge assembly
for the dowels, and the uppermost contact
surface of bridge assemblY (3).
c. Place bridge assembly (3) into position on the

dowel. Apply a downward force of 5 to 45 N
(1 to 10 lb) on the uppermost contact surface of
bridge assembly (3). While you apply the force,
lllustration 269
901158612 turn adjustment screw (11 ) until the adjustment
screw contacts the valve stem.
Valve bridge for dowel installations
d. Turn the adjustment screw for an additional 20

to 30 degrees (1/3 lo 112 of the hex).
e. Hold the adjustment screw in position and

tighten jam nut (12) to a torque of 30 i 4 N m
(22r3lbft).
5. For floating valve bridge assemblies, use the
following procedure.
106 RENR9365-10
a. Apply clean engine oil to the contact surface End By:

of bridge assemblies (3) and the valve stems.
Install bridge assemblies (3) on the valve a. Install the valve mechanism cover, Refer to
stems. Disassembly and Assembly, "Valve Mecharrism
Cover - Remove and lnstall"
h Install the bridge assemblies with the rouno
pocl<et toward the outside of the engine. Refer
to lllustration 270. i02242680
H|eetnomEe Uurlt Enjector -

NOTICE
Ensure that the crankslraft and the camshafts are in Remorre
time with each other. AIso ensure that the adjustment
screws in the rocl<er arms are loosened completely SIitiC$ Code: 1290-011
before the bolts on the rocker shaft are tightened or
damage to the valves and the pistons may occur. Fleemoval Proeedure
Table 43
NOTICE
lf the rocl<er shaft is not positioned correctly, the oil
supply to the sleeve bearings in the rocker arm will be
shut off. l'his will cause seizure of the bearings and
5F -4764 Pry Bar
sevcre damage to the errgine.
Be sure to orient the rocker shaft in the correct nosi- Stant Ey:
tion.
a" Remove the rocker shaft assenrblv. Refer to
6. Place rocker shaft assembly (2) in position Disassembly and Assembly, 'Rocker Shafi: arrd
on
valve mechanism cover base (6). l\Iake sure that Pushrod - Remove".
valve pushrods (4) and pushrod (5) are aligned
with the rocker arms. Install bolts (1). Tighten the NOTICE
bolts to a torque of 215 t 40 N.m (160 I 30 lb ft). Care must be taken to ensure that fluids are contained

prodLrcts.
17
mandates.
lllustration 271 901 1 1 9849 NOTICE

7. Adjust the valve lash according to Testing
and Adjusting, "Valve Lash and Valve Bridge
Adjustment". Hold adjustment screw (7) of the comoonent life.
rocker arm assembly and tighten jam nut (B) to a
torque of 70 t 15 N.m (52 t 11 lb ft).
8. Adjust the electronic unit injector lash according to

Testing and Adjusting, "Fuel Injector Adjustment".
Hold adjustment screw (9) of the rocker arm
assembly and tighten nut (10) to a torque of
120 t 15 N m (89 t 1'l lb ft).
RENR9365-1 0
107
and Assemblv Section
io2242684
Electronic Unit Injector - Install

SMCS Code: 1290-012
Table 44
Required Tools
B 9U - 6862 Tapered Brush I
4C -5027 Tap Wrench
lllustration 272 901130s66 1
D 4C-6774 Vacuum Gun Kit 1

1. Disconnect harness assembly (2) from electronic
unit injector (5). E 1P-OBOB Multipurpose Grease
2. Remove bolt (1) and electronic unit injector ctamp

O NOTICE
3. Remove plug (4) from the cylinder head. Contaminants may cause rapid wear and snortened
component life.
4" Place an identification mark on the electronic unit
injector for installation pLtrposes. Each electronic
unit injector must be reinstalled in the original
location in the cylinder head.
1. Use Tooling (B) to clean the bore for the electronic

unit injector in the cylinder head. Hold Toolinq
lB)with Tooting (C). Rotate Tooting (B) againit
Surface (X) of the bore. Continue cleaning until
Surface (X) is smooth and shiny,
2. Use Tooling (D) to remove the fuel from the

cylinder. Evacuate as much fuel as possible from
lllustration 273 90113056e the cylinder before installing the electronic unit
injector. Several evacuations may be necessary.
5. 9_:"-
Tooling (A) to remove electronic unit injector
(5) from the cylinder head.
6, Remove O-ring seal (6) and O-ring seal (7) from

the electronic unit iniector.
lllustration 275 g0l130615

108 RENR9365-10
3. Install O-ring seal (6) and O-ring seal (7) on the i0248039 1
electronic unit injector.

Cylinder Head - Ren'rove
4" Apply Tooling (E) to the bore of the cylinder head
for the electronic unit injector. SMCS Code: 1100-011
NOTICE R.enroval Procedure

When an electronic unit injector is replaced, the new
Table 45
electronic injector code must be programmed into the
engine's personality module software by using the cal- Required Tools
ibration menu on the Electronic Service Tool. lf the
Part
new electronic injector code is not entered, the char- Tool Number Part Description Qtv
acteristics of the previous electronic unit injector is as-
sumed. A 1 38 - 7573 Link Brackel 2
lf it is not possible to immediately reprogram the elec- Start By:

tronic injector code into the personality module soft-
ware, the engine will not be severely harmed. The new a. Remove tlre valve mechanism cover base. Refer
electronic injector code should be reprogramrned as to Disassembly and Assembly, "Valve Mechanisry
quickly as possible in order to optimize engine perfor- Cover Base - Remove and Install".
mance. O
NOTICE
5. Position electronic unit injector (5) into the originat Care must be taken to ensure that fluids are contained
location in the cylinder head. Center the solenoid ciuring pefformarrce of inspection, maintenance, test-
between the valve springs. Press the electronic ing, adjusting and repair of the product. Be prepared to
unit injector into the cylinder head. Do not strike collect the fluid with suitable containers before ooen-
the electronic unit iniector. ing any compartment or disassembling any compo-

suitable to collect and contain fluids orr Caterpillar
products.

mandates.
NOTICE
lllustration 276
g0 1 1 30566
::::i: :T: ::l J:",Jil1",
component life.
n.
"n "
u*t
6. Install plug (a) in the cylinder head. 1. Drain the coolant from the cooling system into
a suitable container for storage or for disposal.
7. Install electronic unit injector clamp (3) and bolt
Refer to Operation and Maintenance Manual,
(1). Tighten bolt (1) in order to seat electronic unit
injector (5) in the cylinder head, Do not strike the
electronic unit injector. Tighten bolt (1) to a torque
of 65 t 7 N.m (48 r 5lb ft).
B. Connect harness assembly (2). Tighten the

terminal nuts to a torque of 2.5 t 0.25 N'm
(22 ! 2lb in).
End By:
a. Install the rocker shaft assembly. Refer to

Pushrod - lnstall".
RENR9365-10 109
-f
Remove seals (10). Remove seals (11). Remove
O-ring seal (13).
8. Remove spacer plate ('12). Remove gasket (14).

Remove O-ring seal (15)from the dowel.
i02486512
Cylinder Head - lnstall

SMCS Code: 1100-012
6x@).FftA
Table 46
Required Tools
Tool I Part Number Part Description Qtv
I r ee-zszs Link Brackel 2

B | 5P-3931 Anti-Seize Comoound
2. Remove tube (1). Remove the O-ring seal and the NOTICE
integral seal from the tube, Remove bolts (3) from Keep all parts clean from contaminants.
exhaust tube assembly. Remove bolts (4) from
inlet tube assembly. Contaminants may cause rapid wear and shortened
component life.
3. Remove bolts (7). Remove bolts (6),
4. Install Tooling (A) and a suitable lifting device on

cylinder head (8). The weight of cylinder head (B)
5. Remove cylinder head (B), Remove cylinder head

gasket (9).
6. Remove gasket (5) from the inlet tube assembly.

Remove gasket (2) from the exhaust tube
assemblv.
Note: Thoroughly clean the spacer plate and the

bottom surface of the cylinder head and the top of
the cylinder block. A new spacer plate gasket and
a cylinder head gasket must be installed when the
cylinder head is removed.
1. Install O-ring seal ('15) on the dowel. Install gasket

(14).
lllustfation 278 901'1 21095

2. Install spacer plate (12). Install seals ('10) and
seals (11). Install O-ring seal ('13).
110 RENR9365-10
3. Check the cylinder liner projection. Refer to

Testing and Adjusting, "Cylinder Lirrer Projection"
N
-6
6
ox@.71e
go112o7 17
lllustration 280
4. Pipe plug (16) MUST be installed in cylinder head

(8)
5. Apply Tooling (B)to the threads of pipe plug (17).
6. lnstall cylinder head gasket (9) on the spacer

olate.
7- Install Tooling (A) and a suitable lifting device on

cylindcr head (8). The weight of cylinder head (B)
is approximately 47 kg (10a lb).
8. Carefully install cylinder head (8) on the dowel

pins on the cylinder block.
9. Apply clean engine oil to the threads of bolts (6)

and bolts (7). Install the bolts in the cylinder head.
Tighten the cylinder head bolts according to the
following procedure.
a. Tighten Bolt (1)through Bolt (8) rn a numerical

sequence to a torque of 30 t 5 N'm (22 r 4 lb ft).
b. Tighten Bolt (1)through Bolt (8) in a numerical

lllustration 2Bl 901121159 sequence to a torque of 200 t '15 N.m
(148 r 11 lb ft).
c" Tighten Bolt (1)through Bolt (8) in a numerical

sequence to a torque of 200 t 15 N.m
(148t 1 rbft).
d. Tighten Bolt (1)through Bolt (8) in a numerical

sequence for an additional 180 t 5 degrees
(1/2 turn).
RENR9365-10 111
e. Tighten Bolt (9) and Bolt (10)to a torque of

55 t 10 N'm (40 t 7 lb ft).
10.Apply Tooling (B) to the threads of bolts (3).
Position gasket (2) and install bolts (3). Tighten
the bolts to a torque of 50 t 5 N m (37 t 4 lb ft).
11. Position gasket (5) and install bolts (4).
12.Install the O-ring seal and the integral seal on

tube (1). Install tube (1).
13. Fill the cooling system. Refer to Operation and

Maintenance Manual, ''Cooling System Coolant
- Change". 901 1 33502
lllustration 284
End By:
a. lnstall the valve mechanism cover base. Refer to

Disassembly and Assembly, "Valve Mechanism Personal injury can result from being struck by
Cover Base - Remove and Install". parts propelled by a released spring force.

ment.
lnlet and Exhaust Valve Follow the recommended procedure and use all
Springs - Remove and Install recommended tooling to release the spring force'
SMCS Code: 1108-010

2. Install Tooting (A) on valve mechanism cover base
(6)
Removal Procedure
3. Use Tooling (A) to compress inner valve spring (3)
Table 47 and outer valve spring (4). Remove valve spring
Required Tools keepers (1) from the valve.
Part
4. Carefully remove Tooling (A).
Tool Number Part Description otv
A 241 -0124 Valve Spring Compressor 1 5. Remove valve rotator (2), inner valve spring (3),
and outer valve spring (4).
B 4C - 9496 Spring Tester 1
6, Remove washer (5) from the exhaust valve guide.

Start By:
Note: Washers are not installed on the inlet valve
a. Remove the rocker shaft and pushrods. Refer to guide.
Pushrod - Remove". 7. Use Tooling (B) to check the valve springs (spring
force). Refer to Specifications, "Cylinder Head
NOTICE Valves" for additional information on the valve
Keep all parts clean from contaminants. spflngs.
Contaminants may cause rapid wear and shortened lnstallation Procedure

component life.
Table 48
Note: Place the piston at the top of the compression Required Tools
stroke (TC). Remove the valve springs for that Part
cylinder. lf the valves fall into the cylinder liner, then Tool Number Part Description Qtv
the cylinder head must be removed.
A 241 -0124 Valve Spring Compressor I
1. Position the No. I piston at the top center of

the compression stroke. Refer to Testing and
Adjusting, "Finding Top Center Position for No. 1
Piston"
112 RENR9365-10
NOTICE
Keep all parts clean from contaminants,
The valve spring keepers can be thrown fronl
the valve when the valve spring compressor is
Contaminants may cause rapid wear and shoftened
released. Ensure that the valve spring keepers
component life.
are properly installed on the valve stem. To help
prevent personal injury, keep away frorn the front
f . Lubricate the valve stems with clean engine oil of the valve spring keepers and valve springs
during the installation of the valves.
1
z End By:
J
a. Install the rocker shaft and pushrods. Refer to
4 Pushrod - lnstall".
Inlet and Exhaust Valves

FLemove and Install
SMCS Code: 1105-010

Removal Procedure
can cause bodily injury. Table 49
To prevent possible injury, follow the established Required Tools

assembly procedure and wear protective equip- Tool Pad Number Part Description Qtv
rnent"
A 5S-1330 Valve Spring Compressor I
2. Position washer (5), inner valve spring (3), and B 4C - 9496 Spring Tester I
outer valve spring (4) on the exhaust valve guide
Start By:
? Position inner valve spring (3) and outer valve
spring (4) on the inlet valve guide. a. Remove the cylinder head. Refer to Disassemb
and Assembly, "Cylinder Head - Remove".
Note: Washer (5) is not installed on the inlet valve
guides.
NOTICE
4. Position valve rotator (2) on the valve stem.
5. InstallTooling (A) on valve mechanism cover base
component life.
(ol.
6. Use Tooling (A) to compress inner valve spring

(3) and outer valve spring (4). Install valve spring
keepers (1) on the valve. Ensure that the valve
spring keepers are properly installed.
RENR9365-10 113
6. Use Tooling (B) to check the valve springs (spring

force). Refer to Specifications, "Cylinder Head
Valves" for additional informatron on the valve
spnngs.
Table 50
Required Tools
A 5S-1330 Valve Spring Compressor 1
9011 3431 I NOTICE

lllustration 286

component life.
Personal injury can result from being struck by
parts propelled by a released spring force.

ment.
Follow the recommended procedure and use all

recommended tooling to release the spring force.
'1 . Use Tooling (A) to compress inner valve spring (3)

and outer valve spring (4), Remove valve spring
keepers (1).

g0 1 1 34256
3. Remove valve rotator (2), inner valve spring (3) lllustration 288
and outer valve spring (4).
Remove washer (5)from the exhaust valve guide.

Remove inlet valve (6)and exhaust valve (7 ) from can cause bodily injury.
the valve guides.
To prevent possible iniury, follow the established
Note: lf the exhaust valves or the inlet valves will assembly procedure and wear protective equip-
be reused, put identification marks on the exhaust ment.
valves and the inlet valves for installation purposes.
1. Apply clean engine oil to the stem of exhaust

valves (7). Install the exhaust valve into exhaust
valve guide (10).
2. Install washer (5), inner valve spring (3), and outer

valve spring (4) on exhaust valve guide (10).
3. Position valve rotator (2) on the stem of the

exhaust valve.

(3) and outer valve spring (4). Install valve spring
keepers (1) on the exhaust valve.
9011 33465
lllustration 287
114 RENR9365-10
i024s2614
The valve spring keepers can be thrown from

lnlet and Exhaust Valve Guides
the valve when the valve spring compressor is - Flemove and lnstall
are properly installed on the valve stem. To help SMCS Gode: 1104-010
prevent personal injury, keep away from the front
of the valve spring keepers and valve springs Flenroval Procedure
Table 51
5. Carefully remove Tooling (A). Strike the top of the Reguired Tools
valves with a soft faced hammer in order to ensure
that valve spring keepers ('1) are properly installed
on the valve stems. A 7M-3975 Valve Guide Driver 1
6" Apply clean engine oil to the stem of inlet valves

Start By:
(6). lnstall the inlet valve into inlet valve guide.
Note: Ensure that valve stem seal (B) is installed on

a. Remove the inlet valves and the exhaust valves.
inlet valve guide (9).
7. Install inner valve spring (3) and outer valve spring

ffl:i:l ?:ff:;:PJ[ 3l: ffi iH],,',','
n'e" n
O
(4) on inlet valve guide (9). NOTICE
8" Position valve rotator' (2) on the stem of the inlet
valve. Contaminants may cause rapid wear and shortened
component life.
(3) and outervalve spring (4). Installvalve spring
keepers (1) on the inlet valve.
The valve spring keepers can be thrown from

the valve when the valve spring compressor is
are properly installed on the valve stem. To help
prevent personal injury, keep away from the front
of the valve spring keepers and valve springs
33624
10. Carefully remove Tooling (A). Strike the top of lllustration 289 901 1
the valves with a soft faced hammer in order to

ensure that valve spring keepers (1) are properly 1. Remove valve stem seal (3) from inlet valve guide
installed on the valve stems. (2)
End By: Note: The valve stem seal is not installed on exhaust
valve guide (1).
a. Install the cylinder head. Refer to Disassembly
and Assembly, "Cylinder Head - Install". 2. Turn the cylinder head upside-down. Use Tooling
(A) and a hammer to remove the valve guides
from the cylinder head.
RENR9365-'10 115
Disassembly and Asse Section
I nstallation P roced u re End By:
fable 52 a. lnstall the inlet valves and the exhaust valves

Required Tools Refer to Disassembly attd Assembly, "lnlet and
Exhaust Valves - Remove and Install".
ffi"rtD".*ipti"" Totv
7M - 3975 Valve Guide Driver 1 i02707?37
Valve Guide Bushing

lnlet and Exhaust Valve Seat
1
B 5P - 1729
Note: lf you replace the valve guides, you must

lnserts - Remove and Install
reolace the valve seats with new valve seats.
SMCS Code: 1103-0'10
Note: Inspect the valve guides Do not use valve
guides with obvious damage or with excessive wear. Removal Procedure
Check available specifications. Remove valve guides
that are loose or damaged. Replace the valve guides Table 53
with new components, if necessary. Correct any Required Tools
condition tlrat could cause the original damage or
wear. Tool Part Number Part Description Qtv
A 1 66 -7 441 Valve Seat Extractor Tool 1
NOTICE
Keep all parts clean from contaminants. Start By:
Contaminants may cause rapid wear and shortened a, Remove the inlet valves and the exhaust valves.
comoonent life. Refer to Disassembly and Assembly, "lnlet and
Exhaust Valves - Remove and Install".
Note: Use new valve guides for assembly.
Note: For information on the reusability of valve
seats, refer to Guideline For Reusable Parts And
Salvage Operation, SEBF81 55.
NOTICE

component life.
901133624
lllustration 290
1. Coat the outside of the valve guide with clean

engine oil prior to installation,
2. Use Tooling (A) and Tooling (B) to install exhaust

valve guide (1) and inlet valve guide (2) in the
cylinder head.
3. Install new valve stem seal (3) on inlet valve guide 901 1 33493
lllustration 291
tzt.
Note: Valve stem seals are not installed on exhaust 1. Use Tooling (A) to remove valve seat inserts (2)
valve guide (1). from cylinder head (1).
2. Thoroughly clean the valve seat bores in the

cylinder head.
116 RENR9365-1 0
I nstal lation Froeedure

Table 54 Accessory Drive (Front) -
Required Tools Flemove
Tool Part hlumber Part Description otv {Engine 0!! Fqimp and \ffaten
B 1P-0510 Driver Gp 1 Fump)
Note: Do not machine the orefinished valve seat SnnCS Code: 1207-011
inserts in order to correct tlre valve stem projection.
S/tl: LLA1-Up
An excessive valve stem projection indieates that the
valve seat insert is not seated or materialwas not S/N: RlAl-Up
cleaned from the bottom of the counterbore.
S/N: LLBl -Up
Note: lf the valve seats are replaced, you must
replace the valve guides. S/N: LLC1-Up
S/N: C8E1-Up
NOTICE
Keep all parts clean frorn contaminants. S/N: LLEl-Up
S/N: LLF1-Up
conrponent life. S/F{: SBGl-Up
S/N: SBJl-Up
S/N: C8K1-Up
S/l{: SBK1-Up
a-)
S/N: NAMl-Llp
$/N: SBMl-Up
l, !) (@)
c>
,,t
S/N: KENl-Up
S/Nl: PES1-Up
S/N: R1S1-Up
901 1 33494
S/N: RMSl-Up
lllustration 292
S/tl: F1X1-Up
'1. Lower the temperature of valve seat inserts (2).
S/N: F2X1-Up
2. Use Tooling (B) to install valve seat inserts (2) in
cylinder head (1), S/N: RTXI-Up; R2A1-Up
End By: Removal Frocedune

a. Install the inlet valves and the exhaust valves Table 55
Refer to Disassembly and Assembly, "lnlet and Required Tools
Exhaust Valves - Remove and lnstall".
Forcing Screw
2
3/8 - 16 by 1 1/2 inch
Forcing Screw
B I
112 - 13 by 1 1/2 inch
Start By:
a. Remove the auxiliary water pump. Refer to

Disassembly and Assembly, "Auxilary Water
Pump - Remove".
RENR9365-1 0 117
b. Remove the engine oil pump. Refer to i024e3585

Disassembly and Assembly, "Engine Oil Pump
- Remove". Accessory Drive (Front) -
c. Remove the water pump. Refer to Disassembly
Remove
and Assembly, "Water Pump - Remove". SMCS Code: 1207-011
NOTICE Removal Proced ure

Table 56
component life. Required Tools
Part Description
Forcing Screw
112 - 13 by 1 1 /2 inch
Start By:
a. Remove the alternator. Refer to Disassemblv and

b. Remove the electronic control module. Refer to

Disassembly and Assembly,' Electronic Control
Module - Remove and lnstall".
NOTICE
lllustration 293 901132543 Keep all parts clean from contaminants.
1. Remove bolts (2) Contaminants may cause rapid wear and shortened
component life.
2. Use Tooling (A) to remove pump adapter assembly
(1) from front housing (3). Remove the O-ring seal
from the pump adapter assembly.
f . Drain the coolant from the cooling system into
a suitable container for storage or for disposal.
Refer to Operation and Maintenance Manual,
3. Remove bolts (4) g0 1 1 25984

lllustration 295
4. Use Tooling (B) to remove pump adapter assembly
(5) from front housing (3) Remove the O-ring seal
2. Remove adapter (5). Remove the gaskets from
from the pump adapter assembly. the adaoter.
3. Remove bolts (3). Remove alternator pulley (1).
4. Remove bolts (2). Use Tooling (A) to remove

adapter assembly (4) from the front housing,
Remove the O-ring seal from the adapter
assembly.
118 RENR9365-'10
5. Remove the lip seal from adapter assembly (4). i0224ee3e
6. Remove cover (7) from the adapter assembly. Accessory Drive (Front) -
Remove the gasket from the cover. Disassemble
7. Remove bolts (6). (Engine Oil Pump and Waten
Pump)
SMCS Code: 1207-015
S/N: LLA1-Up
S/N: RlAl-Up
S/N: LLBl-Up
S/N: LLCl-Up
S/N: C8E1-Up
S/N: LLE1-Up
lllustralion 296 gO1126268 S/N: LLF1-Up

S/N: SBGl-Up
8. Remove adapter assembly (8), the shaft, and
the drive gear as a unit from the drive housing, S/N: SBJl-Up
Remove the O-ring seal from the adapter
assemblv. S/N: CBKl-Up
S/N: SBK1-Up
S/N: NAMl-Up
S/N: SBMl-Up
S/N: KENl-Up
S/N: PESl-Up
S/N: R1S1-Up
S/N: RMSl-Up
S/N: FlXl-Up
S/N: F2X1-Up
Table 57
Required Tools
A 1P-0520 Driver Group 1
Start By:
a. Remove the accessory drive for the engine oil

pump and the water pump. Refer to Disassembly
and Assembly, "Accessory Drive (Front) -
Remove".
RENR9365-1 0
119
Disassem and Assembly Section
NOTICE
Contaminants may cause rapid wear ancl shortened

component life.
lllustration 299 go1'132971
7. Remove accessory drive gear (g) from pump drive

shaft (7).
lllustration 297 s01132s64
B. lf necessary, remove the socket setscrew from the
1. Remove O-ring seal (3) from pump adapter end of pump drive shaft (7).
assembly (2).
2. Use Tooling (A) and a suitable press to remove

sleeve bearing (1) from pump adapter assembly
(2\.
9, Remove O-ring seal(11)and O-ring seal (12)from

pump adapter assembly (4).
10, Use Tooling (A) and a suitable press to remove

lllustration 298 901132e67
sleeve bearing (10) from pump adapter assembly
(4).
4. Remove thrust washers (6) from pump adapter
i022344s0
assembly (4).
Accessory Drive (Front) -
5. Remove pump adapter assembly (4) from pump Disassernble
drive shaft (7).
SMCS Code: 1207-015
Table 58
Required Tools
Tool Part Number Part Description ary
A 1P-0520 Driver Group 1
120 RENR9365-10
Start By: L Use Tooling (A) and a suitable press to remove

sleeve bearing (14) from adapter assembly (12)
a. Remove the accessory drive (front).Refer to
Disassembly and Assembly, "Accessory Drive 9. lf necessary, remove pipe plug (11).
(Front) - Remove".
i02249940
NOTICE
Keep all parts clean from contaminants. Accessory DrEve (Froffiti -
Contaminants may cause rapid wear and'shortened
,AssembIe
comnonent life. (trngEne Oif, Funmp affid tfi{aten
Fump)
SMCS Gode: 1207-016
S/N: LLA1-Up
S/i{; RlAl-Up
S/N: LLBl-Up
Sih{: LLC'l-Up
$/N: CBEl-Up
S/N: LLEl-Up
S/1tr: LLF'1-Up
lllustration 301 901'126654
S/N: SBG'1-Up
{. Renrove O-ring seal (2) and O-ring seal (4)frorn
adapter assembly (1). S/N; SBJl-Up

S/N: C8K1-Up
sleeve bearing (3). S/N: SBKl-Up
3. lf necessary, remove pipe plug (5). S/N: NAM'i-Up
S/N: SBMl-Up
S/N: KENl-Up
S/N: PESl-Up
S/N: R1S1-Llp
S/N: RMSl-Up
S/N: FlXl-Up
S/N: F2X1-Up
9011 26667
lllustration 302 Assennbiy Froeedure
4. Remove O-ring seal (13) and O-ring seal (6)from Table 59
adapter assembly (12).
Required Tools
5. Remove bolts (10). Remove gear (9) from shaft Tool Part Number Part Description Qtv
(15)
A 1P-0520 Driver Group ,1
6. Remove bolts (B) and thrust washer (7).
"7
Remove shaft (15)from adapter assembly (12)
121
RENR9365-10
Disassemblv and Assembl Section
NOTICE
Contaminants maY calrse rapid wear and shortened

component life.
901 1 33086
lllustration 305
5. Install pump adapter assembly (4) onto putnp

drive shaft (7).
6. Install thrust washer (6) and bolts (5)

9011 33092
lllustration 303 7. Install O-ring seal (12) and O-ring seal (11) on
pump adapter assemblY (4).
1. Align the oil hole in sleeve bearing (10)and the oil
hole in pump adapter assembly (4). Use Tooling
(A) and a suitable press to install sleeve bearing
(10) into pump adapter assembly (4).
Note: The sleeve bearing must not project above the

pump adapter assemblY.
2. Apply clean engine oil to sleeve bearing (10).
901 1 32964
lllustration 306
8, Align the oil hole in sleeve bearing (1)and the oil

hole in pump adapter assembly (2). Use Tooling
(A) and a suitable press to install sleeve bearing
(1) into pump adapter assembly (2).
9. Install O-ring seal (3) on the pump adapter

assembly.
9011 33098
lllustration 304
End By:
3. Position accessory drive gear (9) on pump drive
shaft (7). Install bolts (8). a. Install the accessory drive for the engine oil pump
and the water pump. Refer to Disassembly and
4. lf necessary, install socket setscrew ('13) in the Assembly, "Accessory Drive (Front) - Install".
end of pump drive shaft and tighten to a torque of
6t1N'm(53t9lbin).
122 RENR9365-10
Disassembly and Assembl Section
i02234452
Aecessory Dnlve (Front) -

Asses"nb!e
SMICS Code: 1207-016
Assembly Pnoeedure
Table 60
Flequired Tools
1P-0520 Driver Group
NOTICE 7. Align the oil hole in sleeve bearing (3) and the oil
Keep all parts clean from contaminants. hole in adapter assembly (1). Use Tooling (A) and
a suitable press to install sleeve bearing (3) into
Contaminants may cause rapid wear and shortenecl adapter assembly (1).
comoonent life. O
8. Install O-ring seal (2) and O-ring seal (4) on
adapter assembly (1). Apply clean engine oil on
the O-ring seals.
L Install pipe plug (5) in adapter assembly (1).
End By:
a. Install the accessory drive (front) Refer to

Disassembly and Assembly, "Accessory Drive
(Front) - Install".
1. Align the oil hole in sleeve bearing ('14) and the oil
hole in adapter assembly (12). Use Tooling (A)
and a suitable press to install sleeve bearing (14)
into adapter assembly (12).
2. Install pipe plug (11) in adapter assembty (12).
3. Apply clean engine oil on sleeve bearing (14) and

install shaft (15) in adapter assembty (12).
4. Install thrust washer (7) and bolts (8).
5. Position gear (9) on shaft (15) and instatt bolts

(10).
6. Install O-ring seal (6) and O-ring seal (13) on

adapter assembly (12) Apply clean engine oil on
the O-ring seals.
RENR9365-10
123
io2487020
Accessory Drive (Front) -

Insta ll
(Engine Oil Pump and Water
Pump)
SMCS Code: 1207-012
S/N: LLA1-Up
S/N: RlAl-Up
S/N: LLB1-Up
S/N: LLCl-Up lllustration 309 901'l 32545
SiN: CBEl-Up 1. lnsta.ll the O-ring seal in pump adapter assembly

(5). Apply clean engine oil to the bore in front
S/N: LLEl-Up housing (3) for pump adapter assenrbly (5).
S/N: LLFl-Up
2. Position pump adapter assembly (5) in the front
S/N: SBGl-Up housing and install bolts (4).
S/N: SBJl-Up
S/N: C8K1-Up
S/N: SBKl-Up
S/N: NAMl-Up
S/N: SBMl-Up
S/N: KENl-Up
S/N: PESl-Up
S/N: RlSl-Up
S/N: RMSl-Up lllustration 3'10 901 1 32543
S/N: FlXl-Up 3. lnstall the O-ring seal in pump adapter assembly

S/N: F2X1-Up (1). Apply clean engine oil to the bore in front
housing (3) for pump adapter assembly (.1).
4. Positron pump adapter assembly (1) in the front
Instaf lation Procedure housing and install bolts (2).
End By:
NOTICE
Keep all parts clean from contaminants. a. !h9 w-qter pump. Refer to Disassembly and
Install
Assembly, "Water Pump - Install".
component life. b. Install the engine oil pump. Refer to Disassemblv
and Assembly, "Engine Oil pump - Install',.
c. Install the auxiliary water pump. Refer to

Pump - Install".
124 RENR9365-10
i02493646 2. Install the O-ring seal on adapter assembly (B).

Apply clean engine oil to the O-ring seal. Install
Accessory Drive (Front) - the drive gear, the shaft, and adapter assembly
lnstall (8) as a unit. Make sure that the teeth of the drive
gear are properly aligned with the teeth of the
SMCS Code: 1207-012 drive gear for the oil pump and the water pump.
Table 6'l
Required Tools
B 1P-0520 Driver Gp 1
NOTICE

component life. lllustration 313
4. Install the gasket and cover (7) on the adapter

assembly.
5. Install the O-ring seal on adapter assembly (4).

Apply clean engine oil to the O-ring seal and the
lip seal. Install adapter assembly (4) on the front
housing and install bolts (2).
6. Position alternator pulley ('l) on the auxiliary drive

shaft and install bolts (3).
7. Install the gaskets and adapter (5).

8. Fill the cooling system with coolant. Refer to

1. Use Tooling (B) to install lip seal (9) in adapter Operation and Maintenance Manual, "Coolinq
assembly (4). System Coolant - Change".
"
O
End By:
a" Install the electronic control module. Refer to

Disassembly and Assembly, "Electronic Control
Module - Remove and Install".
b. Install the alternator. Refer to Disassembly and


RENR9365_10
i
i02487128 1. Remove bolts and covers (1). Remove
Housing (Front) _ Remove from front housing - \'/' 'rv"'vvs the
(2).
L' gaskets
SMCS Gode: 1151_011 2. Remove bolts and cover (3).

Remove the O_ring
seal from the cover.
Removal procedure
Table 62
Required Tools
1 38 - 7573
Guide Stud
518 - 11 by 8 inch
Illustration 31S
9011 31 809
Start By:
3, Remove botts (7). Use.Jgolng (A)
to remove shaft
a. Remove the engine oil filter housing. t$:,_iousin s I neirf ie' o_,i L g sea | (8)
Disassembty an-o nsiemniv,' ;;;;',* Refer to ffljr?il 1z
Housing - Remove... 5,, ri,..,.

o. idter gear (5) and
b. Remove the crankshaft front seal I:Toug
the front housino.
thrust washer (9) from
and the wear
steeve. Refer to OisassemOty
'Crankshaft Front Seat;; "iOLJ."rorV u.
Remove',.
iv;;; 6E;" _ Y::.F:!ry,lc)jrg
steeve
a suitabte press to remove
bearing (6) from idteig;;r '" (-sj
c. Remove the accessory drive,
Refer to
Disasse m blv a n d Assemnrv,-,;n"I"'..i",y
(Front) - Remove',. o riu"
d. Remove the enoine oil pump

and water pump
drive. Refer to disassembly
"Accessory Drive (Front) _ and Assembly,
Removei.'-"'
Keep art parts crean rr#]l:Erinants.

:a:ll,lqr,l: r"y cause rapid wear and shortened
component life.
901 1 31 907
7. Remove gasket (11) from the

front housing and
the cylinder block.
llluslration 314 g0 1 246380

126 RENR9365-10
io2487230
l-lousing (Front) - lnstall

SMCS Code: 1151-012
Table 63
Required Tools
B 138-7573 Link Bracket 2
1P-0520 Driver Group 1

lllustration 318 90113195s
Guide Stud
D 2
518 - 11 by 8 inch
5. Use Tooling (C) to install sleeve bearing (6) in
NOTICE
idler gear (5).
6. Install O-ring seal (8) on shaft (a). Apply clean

o-
engine oil to the bore in front housing (2) for the
Contaminants may cause rapid wear and shoftened shaft,
comoonent life.
7. Position thrust washer (9), idler gear (5), and shaft
(4) in the front housing. Install bolts (7).
901 1 31 907
lllustration 317
1. Install gasket (11) on the cylinder block. lnstall
Tooling (D) into the cylinder block. B. Install the O-ring seal in cover (3). Position cover
(3) on front housing (2) and install the bolts.
2. Attach Tooling (B) and attach a suitable lifting
device to front housing (2). The weight of front 9. Position the gaskets and covers (1) on front
housing (2) is approximately 181 kg (400 lb). housing (2) and install the bolts.
Position the front housing onto Tooling (D).
End By:
3. Install bolts (10) that hold front housing (2) to the
cylinder block. Remove Tooling (D) and install a. Install the engine oil pump and water pump drive.
remaining bolts (10). Tighten the bolts evenly. Refer to Disassembly and Assembly, "Accessory
Drive (Front) - Install".
4. Cut any excess gasket (11) from the bottom of the
front housing. b. Install the accessory drive. Refer to Disassembly
and Assembly, "Accessory Drive (Front)- Install".
lnstall the crankshaft front seal and the wear

sleeve. Refer to Disassembly and Assembly,
"Crankshaft Front Seal and Wear Sleeve - Install".
RENR9365-10 127
d. Install the engine oil filter housing. Refer to

Disassembly and Assembly, 'Engine Oil Filter
Housing - Install".
Vibration Damper - Rernove

and Install
SMCS Gode: 1205-010
Removal Procedure
Table 64 901137704
lllustration 321
Required Tools
1. Install Tooling (B) in the crankshaft.
A 138 -7573 Lifting Bracket z 2. Attach Tooling (A) and a suitable lifting device
Guide Stud
to vibration damper (2). The weight of vibration
B z damper (2) is approximately 175 kg (385 lb).
1 - 14 by 10 inch
3. Install the vibration damper on Tooling (B),

Install bolts (1). Remove Tooling (B) and install
remaining bolts (1). Tighten bolts (1) to a torque of
1125 ! 100 N'm (820 r 74 lb ft).
4. Remove Tooling (A). Apply Tooling (C) to the

threads of bolts (3). Install bolts (3) and tighten to
a torque of 55 t 7 N'm (41 r 5 lb ft).
Grankshaft Front Seal and

Wear Sleeve - Remove
SMGS Gode:'1160-011 ; 7558-011
1. Remove two bolts (1) and installTooling (B).
Removal Procedure
2. Remove two bolts (3)and attach Tooling (A) and a
suitable lifting device to vibration damper (2). The Table 66
weight of vibration damper (2) is approximately Required Tools
175 kg (385 lb). Remove remaining bolts (1).
Remove vibration damper (2). Part
Tool Number Part Description otv
4
1U-7600 Slide Hammer Puller
lnstallation Procedure I
6V-31 43
Table 65 B or Distorter Adaoter 1
Required Tools 1U-7325

5P - 7409 Sleeve Distorter I
Tool Part Number Part Description Qtlt
A 1 38 - 7573 Lifting Brackel z
Start By:
Guide Stud
B z
1 - 14 by 10 inch a. Remove the vibration damper. Refer to
a 95 3263
- Thread Lock Compound Disassembly and Assembly, "Vibration Damper
- Remove and lnstall".
128 RENR9365-10
Repeat this procedure several times around wear

NOTICE sleeve (2) until wear sleeve (2) can be removed
Keep all parts clean from contaminants. by hand.

i02262638
component life.
erankshaft Front Seal and
NOTICE Wear Sleeve - Install
Every time that the crankshaft seal is removed from
the wear sleeve, a new wear sleeve and crankshaft SMCS Code: 1160-012', 7 558-012
seal must be installed.
Table 67
Part Number
NOTICE
lllustration 322 9006591 80 Keep all parts clean from contaminants.
t. Drill three evenly spaced holes in crankshaft front Contaminants may cause rapid wear and shortened
component life.
seal (1) and use Tooling (A) to remove crankshaft
front seal (1) from the front housing.
Note: The crankshaft front seal and the wear
sleeve must be replaced at the same time. Once
the crankshaft front seal and the wear sleeve are
separated, these components cannot be used again.
Note: Do not use any type of lubricant during the

installation of the crankshaft front seal and the wear
steeve.
1. Before installation of the crankshaft front .u"' O

and the wear sleeve, inspect the crankshaft for
scratches. Also, inspect the crankshaft for any
distortion on the surface that may lead to an out of
round condition. Use a polishing cloth in order to
90065918'l
remove any imperfections on the crankshaft.
lllustration 323
2, Insert Tooling (B) between the front housing and

wear sleeve (2).
NOTICE
The use of excessive force on the sleeve distorter can
cause the distorter adapter to crack the housing. To
help avoid damage to the engine, do not use exces-
sive force to remove the wear sleeve.
3. lnsert Tooling (C) between Tooling (B) and wear

sleeve (2). Carefully turn Tooling (C) until the edge
of the tool creates a crease in wear sleeve (2).
RENR9365-1 0 129
2. Clean the outside diameter of crankshaft (3) and

the inside diameter of the new wear sleeve (2).
Clean the bore for the crankshaft front seal in front
housing (4).
3. Install Tooling (D) on crankshaft (3).
4. Place crankshaft front seal (1) and wear sleeve

(2) onto Tooling (D).
5. Position Tooling (E) onto Tooling (D). Lubricate

the face of the washer on Tooling (F). Install
Tooling (F) onto Tooling (E). Tighten Tooling (F)
until Tooling (E) contacts Tooling (D).
gol'126776
lllustration 325
6. Remove the tooling from the crankshaft.
7. Check the crankshaft front seal and the wear 1. Attach Tooling (A) and a suitable lifting device
sleeve for the correct installation. to flywheel (1). The weight of flywheel (1) is
approximately 170 kg (375 lb).
O End By:
2. Remove two bolts (2) on each side of the
crankshaft and install Tooling (B).
a. Install the vibration damper. Refer to Disassembly
and Assembly, "Vibration Damper - Remove and
lnstall". 3. Remove remaining bolts (2).
4. Remove flywheel (1).
i02488070
Note: lf necessary, Use a prybar against Tooling (A)
Flywheel - Remove and Install to remove the flywheel from the crankshaft.
SMCS Code: 1'156-010 5. Use a hammer and a punch in order to remove
ring gear (3) from flywheel (1).
Removal Procedure
Table 68
Required Tools Table 69
Tool Part Number Part Description Qtv Required Tools
A 138-7573 Lifting Bracket a Tool Part Number Part Description Qtv
A 1 38 - 7573 Lifting Bracket z

Guide Stud
B 2
1 - 14 by 6 inch Guide Stud
B z
1-14by6inch
Start By:
NOTICE
a. Remove the engine speed sensor. Refer to Keep all parts clean from contaminants.
Disassembly and Assembly, "Engine Speed
Sensor - Remove and Install". Contaminants may cause rapid wear and shortened
comoonent life.
NOTICE
Contaminants may cause raoid wear and shortened

component life.
130 RENR9365-10
i03565063
Crankshaft Rear Seal and Wear

Sleeve - Remove
SMCS Code: 1161-011; 7558-0'11
Rernoval Procedure
Table 70
Illustration 326 901126776

Slide Hammer Puller
L Raise the temperature of new ring gear (3). Instail 6V-3143
the ring gear on flywheel (1). Ensure that the or
chamfer of the gear teeth will be toward the pinion 1U-7325
of the starting motor.
2. Install Tooling (B) in the end of the crankshaft.

Start By:
3. Attach Tooling (A) and a suitable lifting device
to flywheel (1). The weight of flywheel (1) is a. Remove the flywheel. Refer to Disassembly and
approximately 170 kg (375 lb). Assembly, "Flywheel - Remove and lnstall".
4. Lift the flywheel into position onto Tooling (B). NOTICE

Ensure that the mark on the flywheel is aligned Keep all parts clean from contaminants.
with the mark on the crankshaft.
Contaminants may cause rapid wear and shorlened
5. Apply clean engine oil to the threads of bolts (2). component life.
Install bolts (2).
6. Remove Tooling (A) and Tooling (B). Instatl NOTICE

remaining bolts (2). Tighten bolts (2) to a torque of Every time that the crankshaft seal is removed from
t
1150 60 N.m (848 r 44 lb ft). the wear sleeve, a new wear sleeve and crankshaft
seal must be installed.
End By:
a. Install the engine speed sensor. Refer to

Sensor - Remove and Install".
lllustration 327 goo65s239
1. Drill three evenly spaced holes in crankshaft

rear seal (1). Use Tooling (A) in order to remove
crankshaft rear seal (1).
RENR9365-10
131
Note: The crankshaft rear seal and the wear

steeve must be replaced at the same time. Once
the crankshaft rear seal and the wear sleeve are
separated, these components cannot be used again.
fofe,; lo not use any type of lubricant during the

installation of the crankshaft rear seal and th6 wear
sleeve.
2. Insert Tooling (B) between the rear housing and

wear steeve (2).
NOTICE t-
distorter can I
,i1f'J:.J: I
sleeve (2). Carefulty turn Tooting

@) until the edge
of the tool causes a crease in wear sleeve (2). "
Repeat this procedure several times around wear lllustration 329 g0 I 1 s6390
sleeve (2) until wear sleeve (2) can be removed

by hand. 2. Clean the of crankshaft (3) and
the inside ew wear sleeve'(2).
Clean the kshaft rear seal in'
i02262636 flywheel h
Cnankshaft Rear Seal and Wear 3. lnstall Tooling (D) on crankshaft (3).
Sleeve - Install
4. Place crankshaft rear seal (1) and wear sleeve
I Sr"r code: 1161-012;7bsL-012 (2) onto Tooting (D).
I nstallation Proced u re 5. Position To D). Lubricate the

face of the lhstall Tooling
Table 71
(F) onto To ing (F) until
Tooling (E)
Required Tools
Tool Pad Number 6. Remove the tooling from the crankshaft.
Part Description Qtv
6V - 4003 Seal Locator As 1 7. Check the crankshaft rear seal and the wear
D
2N - 5006 Bot sleeve for the correct installation.
z
E BT - 309S Seal Installer End By:
1
F 95 - B85B Nut 4
I
a. Install the flywheel. Refer to Disassembly and
Assembly, "Flywheel - Remove and Instdll,,.
NOTICE

component life.
t51 RENR9365-'10
i02763007
FEywheel I{ousEng - R.esmove

SMCS Gode: 1157-011
Rea"noval Froeedure
fable 72
Required Tools
A 238 - 9586 Camshaft Drive Grouo
BB - 7548 Push-Puller Tool Group 1
lllustration 330 901 I 26909

BB - 7559 Adapter 2
BB - 7561 Step Plate 1 1 Remove rear camshaft covers (1).

B
1P-0820 Hydraulic Puller 1
?. Remove timing pin (2)from the storage Oositiof
5H-1504 Hard Washer
3. Remove timing bolt (5)from the storage positiorr.
9U - 6600 Hand Hvdraulic Pumo 1
Remove cover (3) and plug (4) from the flyrrheel
n 138-7573 Linl< Bracket housing.
Guide Stud
D
5lB - 11 by 6 inch
4. Use Tooling (A) to turn tho flywheel in order to
install timing bolt (5) in the flywheel and timing
E 1 69 - 5464 Quick Cure Prirner pin (2) in both camshafts. Refer to Testing and
Adjusting, "Camshaft Timing". Refer to Testing
and Adjusting, "Finding the Top Center Position
Stant By:
for the No. 1 Piston".
Remove the starting rnotor. Refer to Disassembly
and Assembly, "Air Starting Motor - Remove".
5. Remove the timing bolt from the flywheel
Refer to Disassembly and Assembly, "Electric
Starting Motor - Remove and Install".
6. Remove the crankshaft rear seal and the wear
sleeve. Refer to Disassembly and Assernbly,
h lf the exhaust elbow is attached to the flywlreel "Crankshaft Rear Seal and Wear Sleeve -
Remove".
housing, remove the exhaust elbow and remove
the bracket for the exhaust elbow. Refer to
Disassembly and Assembly, "Exhaust Elbow -
Remove and Install".
c. Remove the engine oil pan. Refer to Disassembly

and Assembly, "Engine Oil Pan - Remove".
d. Remove the engine speed sensor. Refer to

Sensor - Remove and lnstall".
e. Remove the engine speed/timing sensor.

Refer to Disassembly and Assembly, "Engine
Speed/Timirrg Sensor - Remove and Install".
901 1 26908
lllustration 331
NOTICE
Keep all parts clean from contaminants. 7. Remove tube (6).
Contaminants may cause rapid wear and shortened 8. Remove drain tubes (7) for the turbochargers.
component life. Remove the gaskets from the elbows
9 Remove covers (8) and the gasket.

RENR9365-10
133
Disassem and Assembly Section

lllustration 334
il'usrratton 334 901316307
10. Removebolt (9) and plate (10). ptace
the three
washers from Tooling (B) behind plate (10) and
install bott (9) Instati Tooting (B) bn camshaft
drive gear (11). Appty b1675 te'a
lZSOO psi) to
the puller. Strike the screw on the'putter with a
hammer until camshaft drive ge"r
itt) is free
from the camshaft. Remove T6olinj (d) from the
drive gear Remove camdrrb{ drive gear
:lT:l?l
(tt ) rrom the camshaft.
Note: Plate.(10) must be installed in order to keep
gear (11) on the camshaft during the
:^"1t:l_qt 9live
removal procedure. elgt9.(10) must be instailed in order to keep
ltt_ote,
g_agshqft drive gear (14) on the camshaft during the
removal procedure.
lllustration 333 90131630.1

11. Remove bolt (12). Remove ring (13).
13.Ins_tall Tooling (C) and a suitable liftinq
device
on lywheet housing (16). The weight 6f ftywneel
housing (16) is app-roximately ZgSjig
Ord
rOl.
14. Remove two bolts (17) and install Tooting

(D).
Remove the remainjng bolts (17) and-remove
flywheet housing (16)Trom tne citinOer Ltoct<.
15.,|f necessary, remove plugs (15)from the

flywheel
housing.
134 RENR9365-10
Note: Ensure that the rear gear group and the

crankshaft are properly protected during the cleaning
procedure. Ensure that the bolts are cleaned with
a wire brush in order to remove debris or residue.
Ensure that the bores for the bolts in the cylinder
block are tapped again. Ensure that the bores for
the bolts are cleaned in order to remove debris or
residue.
16.After removing flywheel housing (16), clean the

mating surface of the cylinder block and the mating
surface of the flywheel housing with Tooling (E).
lf necessary, use a gasket scraper and a solvent
in order to remove any residual gasket material.
Both mating surfaces must be clean, dry, and free
of any oil before installation.
io2724294
Flywheel l-lousing - lnstall

901 317446
SMGS Code: 1157-012 lllustration 336
2. Apply a 6.0 mm (0.25 inch) bead of Tooling (F)to

lnstallation Procedure the mating surface of the flywheel housing. Refer
Table 73
to lllustration 336.
Required Tools
c 138-7573 Link Bracket z
Guide Stud
D z
518 - 11 by 6 inch
1 85 - 3984(1)
F or Gasket Sealant
4C - 5300
(1) EAME
NOTICE

3. InstallTooling (D) into the cylinder block.
component life.
4. InstallTooling (C) and a suitable lifting device on
NOTICE flywheel housing (16). The weight of flywheel
Do not turn the crankshaft or the camshaft while the housing (16) is approximately 235 kg (5181b).
camshaft gear is removed. lf the front gear group is
not correctly timed during installation, interference can 5. Lift the flywheel housing into position onto Tooling
occur between the pistons and the valves, resulting in (D)
damage to the engine.
6. Install bolts (17) and the hard washers that secure
the flywheel housing to the cylinder block. Remove
Note: Refer to Engine News, 27 March 2006, Tooling (D) and install remaining bolts (17) and
"Sealing and lnstalling the Flywheel Housing" for the hard washers.
more information.
Note: Refer to Parts Manual for the correct positions
1. Ensure that the mating surface of the flywheel for bolts that secure the flywheel housing to the
housing and the engine block are clean. Both cylinder block.
mating surfaces must be clean, dry, and free of
any oil before Tooling (F) is applied.
RENR9365-10
7. Tighten bott _ NC
bolts to a to
5 lb ft)'
Tighten the
270 t 40 N.
8. Tighten.plugs (15) to a torque of 70 + 15 N.m

(50 r 11 tb ft).
9. Install the crankshaftrear seal and the wear

sleeve. Refer to Disassembly anO nislmnty,
"Crankshaft Rear Seat anO Wear-5i"Lu" _
Install,,.
lllustration 340 901 3 I 6354
11. Use the following procedure in order

to install
camshaft drive oear (11)and gear
(1q. "rrin"ridrive
a. Clean the taper of the camshaft and clean
,-/ the
,-9J tapered bore of the camshaft gear with a lint
free cloth that is saturated wit6 i solvent
in
order to remove any excess oil. Clean the parts
again with a lint free alcohol wipe in order
lllustration 338 to
901 1 40296
remov olwipe is dirty
after c eParts.again
witha no residue is
reft on rpe.
Note: lt is critical that the taper of the camshaft
and
the tapered bore of the camihaft g"ar.
Jiy,
and free of residue before assemSly. "re'cfean,
b. Ensure that the camshaft timing pins and

the
timing pin for the flywheet are iisiatteO,
c. Place camshaft drive gear (11) and camshaft

driv - Remove the
bac ars in the opposite
dire
Note: For "standard Rotation" engines, turn
the
g1T:|"1! drive gears cLoCKWtSE. roi. i,R"u"r."
I9r.a.lt-ol engines, turn the camshaft drive gears
COUNTERCLOCKWISE
d. lnstalt bott (9) and ptate (10).
e. Instalt bolt (12) and ring (13). Ensure that

rne note in the ring is properly seated on the
locating pin.
f. Tighten the bott to a torque of 360 N.m

(265 tb ft).
g. Place a mark on the bolt.

tr. a driver against the retaining ptate of
flace, the
camshaft drive gear. Strike the driver with
a
hammer, three iimes or four ti;;;.--
136 RENR9365-10
I
Tighten the bolt again to a torque of 360 N.m b. Install the engine speed sensor. Refer to
(265 rb ft) Disassembly and Assembly, "Engine Speed
Sensor - Remove and lnstall".
t Repeat Steps 11.h and 11.i untilthe mark has
turned at least 90 degrees. c. Install the engine oil pan. Refer to Disassembly
and Assembly, "Engine Oil Pan - lnstall".
d. lf the exhaust elbow was removed, install

the exhaust elbow. Refer to Disassembly and
Assembly, "Exhaust Elbow - Remove and Install".
e. Install tlre starting motors. Refer to Disassembly

and Assembly, "Air Starting Motor - lnstall". Refer
to Disassembly and Assembly, 'Electt'ic Starting
Motor - Remove and Install".
i02488312
Engfrne SnE $equerxce Va$ves .O

lllustration 341
g0 1 1 26909 Res'Y'Bove arlel lrrstmEI
12" Remove tlre timing pin from the carnshafts. Install SIbICS Code; 1332-010
timing pin (2) in the storage position. Install rear
canrshaft covers (1). ERermoval Preeedure
'i3. Remove the timing bolt from the flywheel. Install
$tart Ey:
plug (4) in the timing hole. Install cover (3) arrd
timing bolt (5) in the storage position on the a. Remove the frorrt housing. Refer to Disassembly
flywheel housing. and Assembly, "Housing (Front) - Remove".
b. Remove the flywheel housing. Refer to

Disassembly and Assembly, "Flywheel Housing
- Rernove".
NOTICE
cause rapid wear and shorter!

3Jil:ili,ii,1iu'un
14.Install tube (6).
15.Install the gaskets on the elbows. Install drain

tubes (7) for the turbochargers.
16.Install the gasket and covers (8) on the flywheel

housing.
End By:
lllustratlon 343 901135024
a. Install the engine speed/timing sensor. Refer

to Disassembly and Assembly, "Engine 1" Remove bolts (1) and thrust plate (2). Remove
Speed/Timing Sensor - Remove and Install". balancer gear (3) from the balancer gear shaft
RENR9365_1 0
137
Section
Note: The balancer qear is for
the 3S0BC engine.
3,?1?c Engine a"nd the blr'oc
Il?
nave the balancer gear on E"n!in"".oo not
the front of if..r"-"ngin".
lllustration 346
901 1 35029
lllustralion
901 1 35028
Personal injury
,,uq,y can
rerur result
resutr from
rrom parts and/or cov_
ers under spring pressure,
Personal injury can resutt
from parts and/or cov_ Spring force will be released
ers under spring pressure. when covers are
moved. re_
Spring force will be released
when covers are re- Be prepared to hold spring
moved. loaded covers as the
bolts are toosened.
Be prepared to hold spring
loaded covers as the
bolts are loosened_ 6. Remove bolts (15) and cover (16)
the cylinder block from the rear of
2. Remove bolts (4) and cover (5)
from the front of 7. Remove plunger e
the cylinder btock. (17) and spring (18)
Irom the cytinder;ilt"To'u
3. Remove plunoer artt"tbly (6)
and spring (7) trom
the cylinder blo"k f nstalfation procedure
Keep ar parts crean rrlfll?l"rinants.

o 9^":l:l'lqr,l: rry cause rapid wear and shortened
component life.
10
11
1a
11.
lllustration 34S
901 1 35030
4.
leqovg.botts (12).and thrust ptate (13). Remove
(ta) rrom th"";;;, brifie .yrinoe,
;il:i"'idler sear
u. (8), idter shaft (9), camshaft
*Igy:.botts.
gear (10), and thrust washer idter lllustration 347
iii').--"'"". 901 1 35029
138 RENR9365-10


ment.
t. Apply clean engine oil on spring (18) and plunger

assembly (17).
2. Install spring (18) and plunger assembly (17) in

the cylinder block. 35028
3. Install cover (16) and bolts (15).
!mproper assembty of parts that are spring


assernbly procedure and wear protective equip-
ment.
12
6. Apply clean engine oil on spring (7) and plunger
4a assembly (6).
IJ
7. Install spring (7) and plunger assembly (6) in the

cylinder block.
901 1 35030
lllustration 348
8. Install cover (5) and bolts (4).
4. Apply clean engine oil to the sleeve bearing in
camshaft idler gear ('10) and idler shaft (9). Install
idler shaft (9) in camshaft idler gear (10). Position
camshaft idler gear (10) and thrust washer (11)
and install bolts (B). Tighten bolts (B) to a torque
of 240 t 20 N'm (177 t 15 lb ft).
5, Apply clean engine oil on the sleeve bearing in

cluster idler gear (14) and the cluster gear shaft.
Install cluster idler gear (14) on the cluster gear
shaft. Make sure that the marks on cluster idler
gear (14) and the crankshaft gear are in alignment
with the rotation of the engine. Install thrust plate
(13) and bolts (12).
901 1 35024
lllustration 350
9. Apply clean engine oil on the sleeve bearing in

balancer gear (3) and the balancer gear shaft.
lnstall balancer gear (3) on the balancer gear
shaft. Make sure that the marks on balancer gear
(3) and the crankshaft gear are in alignment with
the rotation of the engine. Install thrust plate (2)
and bolts (1).
Note: The balancer gear is for the 3508C engine.

The 3512C engine and the 3516C Engine do not
have the balancer gear on the front of the engine.
RENR9365_10
'139
Section
End By;
,. (A)and.a suitabte press
" pfi
Y::.IT,ins
sreeve bearing (11) from to remove
I,.'JIJSJIff i[i::i fl "::,fJ li lJ,."ii-", o,u gear
"fr=tuiiO]ui (3).
3. Remove botts (B)
' ['J3li'ff qil;:?ff i$ff':!;:Bliassemb,y and
(1). Remove idier llg.l9T"u" camshaft idier
shaft fZl ,.0 tiirrt"washer gear
(2)
o. Tooting (n)
l1::
steeve bearing 3,n_l3suitabte press ro remove
(6) from .rr.r,Jru"jtli,gear
1t1.
Gear Group (Rear) - 5. Remove bolts (4). Rernove
Rerno;;""' cluster gear.shaft (S).
SMCS Code: 1206_011; 6. Remove bolts (12).
Remove crankshaft
12j2_011 gear (13).
Renloval procedure
lable 74 Gear Gnoup (Rear) _
!nrsta El'"'o'n'o
Reqrrired Tools SMCS Code: 1206_012;
12-12_012
Part Number
Part Description
1P-0520 !nstalfation Frclcedure
Table 75
Start By:
Re lQuirerJ T^^l
a. Remove the flywhr Tool
:l'n"Ul; # ;?#il,]lsr,l.:ft:
Part Number
l'oH o,. i n g A 1P-0520
Nl..lTr^-
rrv
t\Jt: I
Keep all parts clean Keep ar parts crean
from contaminants t.ffill:,:rinants
cause rapicl wear and
:"ffiil!f,ililt"u shortened :"Tfil5flililt"u cause rapid wear and shortened

901 1 18210 g0111Bs4s
t thrust prate (10) Remove 1. Instail crankshaft gear
5;$:li.[? L'";?ffd (13) and botts (12).
140 RENR9365-10
2. Use Tooling (A) and a suitable press to install i02235598

sleeve bearing (6) to a depth of 1.00 * 0.25 mm
(0.039 t 0.010 inch) in camshaft idler gear (1). Piston eooling Jets - Renrove
Use Tooling (A) and a suitable press to install
sleeve bearing (11) to a depth of 1.50 t 0.50 mm
and lnstal!
(0.059 t 0.020 inch) in cluster idler gear (3). SMCS Code: 1331
f{ote: Sleeve bearing (6) and sleeve bearing (1'l)
must be machined to the correct inside diameter. Rermoval Fnoeedure
Refer to Special Instructions, SEH59282, "Machining
of Replacement Sleeve Bearings". Start By:
3. Apply clean engine oil to sleeve bearing (6) and a" Remove the engine oil pump, if necessary. Refer
idler shaft (7). Install idler shaft (7) in camshaft to Disassembly and Assembly, "Engine Oil Pump
idler gear (1). Position camshaft idler gear (1)and - Remove".
thrustwasher (2) and install bolts (8). Tighten bolts
(B) to a torque of 240 r 20 N.m (177 ! 15 lb ft). NOTICE
L Position cluster gear shaft (5) and install bolts

(4). Tighten bolts (4) to a torque ot 140 t '10 N'm
l(eep all parts clean from contaminants.
Contaminants may caLrse rapid wear and shorte n aal

o
(103r7rbft). comoonent life.
901 1 1 8356
lllustration 354
5. Apply clean engine oil on sleeve bearing (1'1) and

1. Remove cylinder block side cover (1).
cluster gear shaft (5). Install cluster idler gear
(3) on the cluster gear shaft. Make sure that the
marks on cluster idler gear (3) and crankshaft
gear (13) are in alignment with the rotation of the
engine. lnstall thrust plate (10) and bolts (9).
End tsy:
a. lnstall the flywheel housing. Refer to Disassembly

and Assembly, "Flywheel Housing - Install".
2. Remove bolts (2) and retainer (3).
3. Remove piston cooling jet (4) from the inside of

the cvlinder block.
RENR9365_1 0
Disassembly and 141

Section
lnstaf lation Procedure
io2717761
NOTICE
Keep all parts clean from Bearing Clearance - G heek
contaminants.
Contaminants mav cause SMCS Code: 1203_535;
1219_S3S
rapid wear and snortened
component life
Measurement procedure
Table 76
Required Tools
Part Description
198-9142
55;!ifstgE l?ff"')
(0.0O,| to 0.003 inch)
'r
98 - 9143
5,'3;i':f;1uffi,,
(0.002 to 0.006 in;h)
198-9144 Plaslic Gauge (BlLre)
lllustration 356 0.102 to 0.229 tnm '
9o1127419 (0.94 to 0.009 inch)
t !::iil_r.piston coollns jet (4) in the cytinder 198-9145
rnsure that the block 5H8ifs!?;11;1,"*)
oil o'f the piston
cooring r"f;;;;i,,?"ln}Jt}f;"Td (0.009 to 0 020 inch)
2. Instail retainer (3) and bolts (2). Note:_Plastic gauge rnay

not be necessary when
engtne is in the chassis. the
Keep al pafts ctean r,"HI?[rinants
cause rapid wear and shortened

S"Tl1l!fillilt"u
lllustration 357
9o1127415
3. lnstall cylinder block side

cover (1). snould be within
End By: rect bearings should
Journals and the oores
r li,:lll,l_?,ensine oit pump, if necessarv Refer
and to
,"n,rt].,,:"to,y
Assemotll, fnlir" o'ii Pump -
NorlcE
Lead wire, shim stocr
dial bore gauge can dam-
age the bearing ,rn;::"
142 RENR9365-10
The technician must be very carefulto use Tooling (A) Note: \l/hen Tooling (A) is used, the readings can
correctly. The following points must be remembered: sometimes be unclear. For example, all parts of
Tooling (A) are not the same width. Measure the
. Ensure that the backs of the bearings and the major width in order to ensure that the parts are
bores are clean and dry. within the specification range. Refer to Specifications
Manual, "Connecting Rod Bearing Journal" and
. Ensure that the bearing locking tabs are properly Specifications Manual, "Main Bearing Journal" for the
seated in the tab grooves. correct clearances.
" The crankshaft must be free of oil at the contact

points of Tooling (A). io2230497
f . Put a piece of Tooling (A) on the crown of the

Connecting Rod Bearings -
bearing that is in the cap. Remove and Install
Note: Do not allow Tooling (A) to extend over the SMCS Gode: 1219-010
edge of the bearing.
R.emoval Procedure
2. Use the correct torque-turn specifications in order
to installthe bearing cap. Do not use an impact Table 77
wrench. Be careful not to dislodge the bearing
Required Tools
when the cap is installed.
Note: Do not turn the crankshaft when Tooling (A)
A 95- 9082 Engine Turning Tool 1
is installed.
3. Carefully remove the cap, but do not remove Start By:

Tooling (A). Measure the width of Tooling (A)
while Tooling (A) is in the bearing cap or on the a. Remove the engine oil pump. Refer to
crankshaft journal. Referto illustration 358. Disassembly and Assembly, "Engine Oil Pump
- Remove".
NOTICE

component life.
1. Use Tooling (A) to turn the flywheel in order

to access the connecting rod cap that will be
removed.
901 1 52855
lllustration 358
Typical Example
4. Remove all of Tooling (A) before you install the

bearing cap.
90091 3801
lllustration 359
RENR9365-10
143
Disassembly and AssemblV Section
g rod and connecting rod

ion mark. The connectino
cap should have an
The number should
malg| the cylinder number. Mark the connecting rod
and the connecting rod cap, if necessary.
2. Remove.bolts (1) and connecting rod cap (2)from

the crankshaft.
fllustration 361 90112441'9
3. Bolt tightening sequence for the connecting rod caps

Push the connecting rod away from the crankshaft.
Remove the upper half of the connectinq rod
bearing.
Note: Be careful not to damage the cylinder liner or

the crankshaft journa l.
4. Remove the lower half of the connecting rod

bearing from connecting rod cap (2).
3.
O Installation procedure
Install the lower half of the connecting rod bearing
on connecting rod cap (2). Ensure that the
connecting rod bearing is installecl so that the
Table 78
bearing tab fits into the notch in the connecting rod
Required Tools cap. Coat the connecting rod bearing with cleln
engine oil.
95 - 9082 Engine Turning Tool 1
Note: The number that is on the side of the
connecting rod caps must be installed next to the
B 6V -4876 Lubricant corresponding number that is on the side of the
connecting rod. Install the chamfered side of the
NOTICE connecting rod cap next to the thrust surface of the
Keep all parts clean from contaminants. crankshaft.
Contaminants may cause rapid wear and shortened 4. Apply Tooling (B) to the threads, the shank, and
component life. the seat of bolts (1).
5. Place connecting rod cap (2) into position. Install

Note: Install the connecting rod bearings dry bolts (1). Use the following procedure to tighten
when clearance checks are performed.-Refer to the bolts:
Disassembly and Assembly, ,,Bearing Clearance _
Check". Apply clean engine oil on thd connecting rod a.
bearings for final assembly. ]iSntgn Bolt (A) and Bott (B) to a torque of
90t5N.m(65r4tbft).
1, Use Tooling (A) to rotate the crankshaft untilthe b.
connecting rod journal is at the bottom center. ]10ht9n Bolt (C) and Bott (D) to a torque of
90t5N.m(65r4tbft).
c. Tigtten _Bolt (C) and Bott (D) again to a torque
of90t5N.m(6bt4tbft).
d. Place an index mark on the bolts and the
connecting rod cap. Tighten each bolt for an
additional 90 r 5 degrees (1/4 turn).
6. Rotate the crankshaft in order to ensure that the

crankshaft turns freelv
End By:
a. Install the
engine oil pump. Refer to Disassembly
and Assembly, "Engine Oil pump - Install',.
lllustration 360 9009 I 3801
144 RENR9365-1 0
i02724262
erankshaft Mlain Bearings -

R.emove
SMCS Code: 1203-011
Rennoval Proeedure
Table 79
Required Tools
Tool Part Number Paft Description Qtv
A 95 - 9082 Engine Turning Tool 1
1 251 96
B 9U - 5023 Main Bearing Wrench 1
(- 2P -5517 Main Bearing Tool 1

3. Use Tooling (B) and loosen bolts (3)for the main
bearing cap. Remove the outer bolts from main
D 236 - 66BB Main Bearing Cap Tool z bearing cap (2).
Staft By:
a. Remove the oil pump. Refer to Disassembly and
Assembly, "Engine Oil Pump - Remove".
NOTICE
Keep all pafts clean from contaminants.

component life.
4. Install Tooling (D) until Tooling (D) bottoms out

in the block. Adjust the nuts on Tooling (D) until
the nuts make contact with main bearing cap (2).
Remove bolts (3) from the main bearing cap.
O
lllustration 362 9O1125228
1. Remove side cover (1) from the cylinder block.
2. Use Tooling (A) to rotate the counterweight on the

crankshaft to the top of the cylinder block.
llluslration 365 9O1125205
5. Loosen the nuts on Tooling (D) evenly in order to

lower main bearing cap (2). Lower main bearing
cap (2) to the end of the bolt on Tooling (D) in
order to gain access to the main bearings,
RENR9365_10
i02488634
Crankshaft Main Bearings _
Install
SMCS Code: 1203_012
I nsta llation procedu re

Table 80
Required Tools
lilustration 366
901125209
e. (A)
!;g_r3otin.s
ort "lg l_oJ?.tg the crankshaft untit the
hote of the crankshart;qurnaiil
main beering..without thi:;rrii"ro* ft,"
o :11:,_"lthe
roorrng (C) and remove"the
7. The following step rs for

tab. Instatl
;il;; ;"";1;s
removing the thrust plates
Main Bearing Cap Tool
rrom the cytinder bto"k.,

on each side of the center
R;;;;;iri"jriirr, prares
8T- 5096 Dial Indicator Gp
n ecessa
,"irllrrirgllt ,ry n"
ry to move th e,.r, n r.i r, Jri ilritho" pry
rn order to remove n.r.
ttre tnrusl-neliing.frJ,
cylinder block. r," Keep an parrs crean -Hll:irrinants,
:"TffiiftTi"t"t shortened
9o1125211
t lower main bearing (4)

from main bearing
5""flU:
lllustration 368
90112521'1
146 RENR9365-10
2. Install the upper main bearing with the side without 7. Coat the underside of the bolt heads and the
the tab into the side of the cylinder block with threads of bolts (3) with clean engine oil. Install
the tab. Use your hand and roll the upper main the inner bolts for the main bearing cap, Remove
bearing into position. Use Tooling (A) and rotate Tooling (D) and install the outer bolts for the main
the crankshaft. Rotate the crankshaft until the oil bearing cap.
hole is positioned in front of the side of the upper
main bearing with the tab.
901 1 39473
lllustration 371
3. Install Tooling (C) and finish rolling the upper main

bearing into position. Make sure that Tooling (C)
does not slide under the upper main bearing.
Ensure that the main bearing is installed so that
the bearing tab fits into the notch in the cylinder
block.
4. Remove Tooling (C).
5. The following step is for installing the thrust

plates on each side of the center main bearing.
Place clean engine oil on the thrust plates. Install 9o1124192
the thrust plates on each side of the center lllustration 372
main bearing. lt may be necessary to move the Bolt tightening sequence for the main bearing caps
crankshaft with a prybar in order to install a new
thrust bearing. Use Tooling (F) to measure the 8. Use Tooling (E) and Tooling (B) and tighten nofJr
end play of the crankshaft. The end play must not (3) in sequence to a torque of 190 t 14 N'm
exceed 0.17 to 0.63 mm (0.007 to 0.025 inch). (140 + 10 rb ft).
9. Place an index mark on the bolts and the main

bearing cap. Tighten the bolts for an additional
1 B0 t 5 degrees (112 turn).
crankshaft turns freelv.
lllusLration 370 901125192
6. Tighten the nuts on Tooling (D) in order to raise

main bearing cap (2) to the cylinder block. The
nuts must be tightened evenly in order for main
bearing cap (2) to fit into the block.
RENR9365-10
lllustration 373
90112522a
lllustration 374
11. Install side covers (1) 90091 3 B0 1
onto the cylinder block.

t. (A)to rotate the crankshaft
End By: !1e_logting
(1) can be removeo. untit botts
t' F:l:l! 11" 9'lprtpi*, to Disassembry and 2. Remove the carbon, rid.ge
surface of the cylinder liner -"' the
nssembly, ,,Engine from r''v top
lvr inside
\lt Hurnp _ Install,,.
3. Inspect the
for the prop
Pistons and connecting rod and the
- Remove R;;r" etched num
match the cylinder nu
rod and the connectin
SMCS Gode: 1225_011
Note: Do not stamp the connecting
rod assembly.
Removal procedure
t rod cap (2)
Table Bl F;s,'^""?3Hill,::qj-"ltg:ling
until the piston
out of the cytinoe/ifl":?t rinss are
5. Remove the pistor t and

the connecting rod from
the cylinder lin"r.
5A-7425
Note: Be careful not to
1P-1861 or the crankshaft journarlqmgge the cylinder tiner
prston and the connecting
ourN"jtne-rlrroJjr or tn"
271 -0498 rod.-
(1)The95-90urfn@
a. Remove the cylinder head.

Refer to Disi
and Assembtyl ';Cy,,no",
Head _ *"rou3l.t"to,n
o oiston cootins jets Refer to
|:-T^"1^"jf1g
ursassemblv and AssemOiV,, ;pirton',dootin
- Remove and Instarr g .Jets
.
Keep ar parts crean rr#ll:ilinants.

lllustration 375
.""Tiilif,t;Lt"u 901051 820
6. Use Tooting (B) to

pin
that hold pistbrf Ings
n (4)
Remove piston
1bj'
148 RENR9365-10
7. Remove the bearings from connecting rod (5) and

the connecting rod cap.
Note: lf necessary, separate the piston skirt from the

piston crown.
1. Use Tooling (C)to installthe piston rings onto tha

piston.
v
lllustration 376 90091 381 I a. For the oil control ring, ensure that the ends of
the spring are 180 degrees from the ring gap.
L Use Tooling (C) to remove piston rings (6) from The white portion of the spring must be visible
piston (3). at the ring gap.
b. Install the intermediate ring with the side

i03899290 marked 'UP-2' toward the top of the piston.
Plstons and Gonnecting Rods c. Installthe top ring with the side marked "UP-1"
= Instal! toward the top of the piston.
SMCS Code: 1225-012 d" After the rings are installed, rotate the rings so
that the gaps are spread apart by 120 degrees.
Orient the oil control ring gap toward the bore
lnstallation Procedure for the piston pin.
Table 82
Required Tools
Tool Paft Number Part Description Qtv
A 5R-7425 Barring Gp (1)
1
B 1P-1861 Retaining Ring Pliers 1
271 -0498 Expander Ring I
Piston Ring Compressor

D 1U-76't6 1
Gp
E 6V - 4876 Lubricanl
(t) The 95- 9082 Engine Turning Tool is allernative tooling.

NOTICE
2. Place the piston crown into the piston skirt.
Use clean engine oil to coat the bore of piston
(3), piston pin (4), and the piston pin bearing in
component life.
connecting rod (5). Position connecting rod (5)
inside piston (3). Insert piston pin (4) through
Note: Install the connecting rod bearings dry piston (3) and the bearing.
when clearance checks are oerformed. Refer to
Disassembly and Assembly, "Bearing Clearance -
Check". Apply clean engine oil on the connecting rod
bearings for finaI assembly.
RENR9365_10
Disassemb .
149
lilustration 379
902142776
llluslration 381
3. Use Tooling (B) to_in_sta,llthe g 009 1 3801
retaining rings. Orient
tne reraining ring gaps
t"*rrJti" '[i
oipiston (3).
4. Apply clean enqine.oilto,the
cylinder liner bore, to
the piston rings] anO to the outer surface
ptston. of the
Note: Ensure that the c_onnecting

tnstalled in the correct v 'rod s"v ppistons are
-- and
cylinder.
lllustralion 382
9021 431 0S
Bolt tightening sequence
for the connecting rod
caps
902142782
u (A) ro 8. lnstall the lower

$Ig:,ins lotgfe the crankshaft untitthe
connecting rod journal
hatf of
on connecting rod cap
is atirre Ooit"o,i'."nt"r.
connecting rod bearing
6. Use Tooring (D) to instail bearing tab fits into the-
the piston in the cyrinder
cap. Coat the connecti
engine oil.
Note: Be careful not
fo,dqmage the cylinder liner or
journar.ourrng
I:.g"lk:laft
ptston and the connecting
the installation of the
rod.
ll:,9t,l".rrn connecting rods are not

tne cylinder position. numbered for
t' itolrl:?li?s.(E) t? the rhreads, the shank, and

tne seat of bolts (1).
150 RENR936s-.10
10. Place connecting rod cap (2) into position. lnstall

bolts (1). Use the following procedure to tighten
the bolts:
a. Tighten Bolt (A) and Bolt (B) to a torque of

90 15N'm(65t4lbft).
b. Tighten Bolt (C) and Bolt (D) to a torque of
90i5N.m(65r4|bft).
c. Tighten Bolt (C)and Bolt (D) again to a torque
of90t5N'm(65r4|bft).
d. Place an index mark on the bolts and the
additional 90 I 5 degrees (1/4 turn). lllustration 383 901120797
f f . Rotate the crankshafi in order to ensure that thc,r

f . Use Tooling (A)to remove cylinder liner (1).
crankshaft turns freelv.
Hnd By:
Install the piston cooling jets. Refer to Disassernbly

and Assembly, "Piston Cooling Jets - Remove
anci lnstall".
b. install the cylinder head. Refer to Disassembiy

and Assernbly, "Cylinder Head - Install",
i02220615
GyBEnden Liner - Fiemove

g0 1 004 993
lllustration 384
Si\qCS Gode: 1216-011
2. Remove O-ring seals (3) and filler bancl (2) from
Removal Fnocedua'e cylinder liner (1).
Table 83
,orru,J
Required Tools
Tool Part Number Pad Description otv
eyBincler l-!ner - Ins'talE
5P - 8665 Cylirrder Liner Puller 1 SMCS Gode: 1216-012
Start By: lnstalNation Fnocedure

a. Remove the pistons and the connecting rod Table B4
assemblies. Refer to Disassembly and Assembly, Required Tools
"Pistons and Connectino Rods - Remove".
Part
Tool Number Part Description Qtv
NOTICE
6 2P - 8260 Cylinder Liner Installer
Contaminants may cause rapid wear and shortened NOTICE

component life. Keep all parts clean from contaminants.

component life.
1. Check the cylinder liner projection. Refer to

Testing and Adjusting, "Cylinder Liner Projection"
R ENR9365_1 0
151
^;---
i02489 1 57
Camshaft - Flemove
SMCS Code: 1Z1O_011
Removat procedure
Table 85
Required Tools
Tool Part Number Part Description
Qtv
1P-0820 Hydraulic puller
1
llluslration 385
g0 1 004993 8B - 7548 Push-Puller Tool Groun 1
8B - 7559 Adapter
A
BB - 7561 Step Plate
1
5H- 1 504 Hard Washer
J
9U - 6600 Hand HydraLrfi" pLrnrp 1
B 25 - 0200
1 Camshaft pilot As
1 25 - 0201 Camshaft Guide As
1
U BT-3169 Crarrk Assembly
1
Start By:
a, Remove the rocker shaft assemblies

pushrods. and the
Refer to Dis::*ri;;il,issemury,
"Rocker Shaft and Husnrod _
Remove,,.
b. lt is necessarv t
module in order
left hand side of
and Assembly,,,Electri
(trngtne)
_ Remove
and Install,,
Keep ar parrs crean trlfl?i"rinants

lllustration 386
90112o,s7 Contaminants may cause rapid
component life. wear and shorteneo
o. j::,t"qting (B) ro press cytinder tiner (1) into the
cytrnder block.
Note:The followino orocedure is
Encl By: camshaft from the ieit tranO
for removlng the
.io"-or tnJun"qin".
a. lnstall the pistons and the connectinq
assemblies. roo
Refe r to OisTsemO-f
/a'nl issem
"pistons and Connecting
RoJ;'Iin;tJ I
oty,
152 RENR9365-10
901122149 go't122151
t. Remove camshaft covers (1). -

F!ruJ: S8J:t,tf; ffiT JisJliHi;3lf fi.:'ti,h'a
housing.
901 1 57699
lllustration 3BB
2. Remove cover (2) from the front housing. lllustration 391 9o1122250
5. Remove bolt (6). Remove ring (7).
3. Push valve lifters (3) away from the camshaft. lllustration 392 901122265
Hold the valve lifters in position with O-ring seals.
6. Place the three washers from Tooling (A) behind
plate (9) and install bolt (6).
RENR9365_10
lllustration 395
901122935
10. Install Tooling (B)

onto both ends of the
camshaft
11.Install Tooling (C)
on the front housing.
instarred on the rywheel

il""rtS,;f,; i,.%!?1"":l l-e
remove
901122324
rear. the camshaft fr6m th;
Do not appry more NorlcE

than srnz5-,kPa
12. Instail Tooling (D)
on the end of Tooling
pressure t (B).
"_,^-o .(rcuu
.(7500 psi)
rated at 6 | ne adapters are Note: The following
Step is for 3S0gC Engines.
rated at 17 -hydraulic puller is
oo
pressure is
is ___,,__, .,,, Psi). lf too much
veiJr may # H,#"L:ir:
Note: The followino Steps

3516C Engines. are for 3S12C and
lllustration 394
901122334
L Remove botts (11) and

thrust washer (10).
9. Remove bolts (12)
from the front housing.
lllustration 396
901122346
154 RENR9365-10
15. Remove bolts (14). Separate the camshafts and c. Installthe bolt that holds Tooling (A) together.
remove spacer (13).
d. Use the extensions to obtain the correct lenoth
16. Remove the dowel from the front of the camshaft. for Tooling (A).
if necessary.
e. Install the puller plate on the bolt and the
flywheel housing or the front housing.
i01 929989
Gamshaft Bearings - Flernove Note: Tooling (B) can be used to remove the
camshaft bearings when the flywheel housing and
SMCS Gode: 1211-011 the front housing have been removed.
Removal Procedure
Table 86
Required Tools
-4077 Camshaft Bearing

A 6V 1
Tool
Camshaft Bearing
B 8S-2241 1
Tool Grouo
5P -5247 Hydraulic Puller 1
D BH - 0684 Ratchet Wrench 1

9009145'12
lllustration 398
Typical example
Start By:
2. InstallTooling (C) on Tooling (A). Pullthe bearing
a. Remove the camshafts. Refer to Disassemblv and from the cylinder block.
Assemblv, "Camshaft - Remove".
lilote: Tooling (D)can be used in place of Tooling (C),
NOTICE if necessary.
i03867082
component life. Gamshaft Bearings - Install
SMCS Code: 1211-012 O
Installation Procedu re
Table 87
Required Tool
Tool Part Number Part Description ary
-4077 Camshaft Bearing

A 6V I
Tool
Camshaft Bearing
B 8S-2241 1
Tool Group
5P -5247 Hydraulic Puller 1
Typical example IJ 8H - 0684 Ratchet Wrench 1
1. Use the following steps to install Tooling (A)

NOTICE
a. Install the pilot group in the camshaft bearing.
b. Place the backup plate in position and ensure
component Iife.
that the bearing is between the two parts.
RENR9365_10
155
and Assembl Section
lllustration 399
900578338
lllustration 401
1. Installcamshaft bearing 900578349
(1) on Tooling (A).
t. j:'l:l (c) on roorins (A) and puil
Note: Tooling (B) can,be_used
to installthe camshaft oeanng]gglilg
(1) into the bore. camshaft
oeanngs when the flv
nousing have been -wheeldhousing and the front Note: Tooling (D) can be
used in ptace of Tooting
(C).
4. After the camshalb_:rT,g
is_instalted, measure
the bore. The bor
(3.6221 0.002 ,n""nt"t be 92'00 t 0'06 mm -
End By:
a. lnstall the camsha[s, Rgfei

to. Disassembty
assembly, ,,Camshaft _ Install,, and
io2485277
Camshaft - Instalt
lllustration 400 SMCS Gode: 1Z1O_012
9021 08639
Rear View
bearins ioints
Instalfation procedure
i:::flil :l ffi T:['J'
dlr, Table 88
camshaft bearins (1) and

ir:r[T rootins (A) in Required Tools
BT-31 69
Keep au parts crean rrffi]l?Erinants

g",iiil5f,Till"t cause rapid wear and
shortened
Note: The followino

"[,irnpr"ced u re is fo r
r
ca msnaiiln iil and side
i nsta ting
of the engine.
I th e
156 RENR9365-1 0
Note: The following Step is for 35f 2C and 3516G 3. Install Tooling (C) on the front housing. Do not
Engines. tighten the bolts on Tooling (C).
Note: Tooling (C) can be installed on the flywheel

housing in order to install the camshaft from the rear
of the engine.
4. lnstall Tooling (B) on the ends of the camshaft.

lnstallTooling (D) on Tooling (B)which is installed
on the front of the camshaft.
5. Ensure that the camshaft and the camshaft

bearings are clean. Place clean engine oil on the
lobes and the journals of the camshaft. Also place
clean engine oil on the camshaft bearings.
6. Rotate the camshaft and insert the camshaft into

the engine. Position the camshaft in the enginel
untilTooling (B) is in the front camshaft bearing]
,|. Attach a suitable lifting device to rear half of the Rotate the camshaft in order to align Tooling (C)-
camshaft. The weight of one-half of the camshaft and the camshaft bores. Tighten the bolts for
for 3516C Engine is approximately 47 kg (104 lb). Tooling (C).
The weight of one-half of the camshaft for 3512C
Engine is approximately 45 kg (99 lb). Install 7" Rotate the camshaft and insert the camshaft into
spacer (13) and the rear half of the camshaft onto the engine. Remove Tooling (D) from Tooling (B).
the front half of the camshaft. Install bolts (14) and Remove Tooling (B) from the camshaft. Remove
tighten to a torque of 55 t 7 N'm (41 t 5 lb ft). Tooling (C) from the front housing.
Note: Ensure that the camshafts are assembled

according to the marks on the ends of the camshafts.
lf the dowel was removed from the front half of
the camshaft, install the dowel. Install the dowel to
120 ! 0.5 mm (0.47 ! 0.02 inch)from the surface
of the camshaft.
Note: The following Step is for 3508G Engines.
2. Attach a suitable lifting device to the camshaft.

The weight of the camshaft for 3508C Engine is
approximately 50 kg (110 lb).
Note: Ensure that the camshaft is installed according

to the marks on the ends of the camshaft. lf the dowel lllustration 404 so1122334
was removed from the front half of the camshaft,

install the dowel. Install the dowel to 12.0 t 0.5 mm B. Install thrust washer (10) and bolts (11).
(0.47 ! 0.02 inch).
9. lnstall bolts (12).
NOTICE
lf the camshaft is out of time more than 1B degrees
(approximately 112 of the timing pin is out of the
groove), the valves can make contact with the pis-
tons. This will cause damage to the engine. Refer to
Testing and Adjusting, "Camshaft Timing" for more
information.

RENR9365_1 0
Disassembly and Assemlrl 157

Section
lllustration 405
901122583
lllustration 407
901.123380
10. Remove timing plate
(15) from tne storage
position under ihe r""i 14. Use the- following procedure
in oroer to install
"iir.r,rft.cover. camshaft drive gear (B).
I f t..frrn the camshaft untit the timing
instared thro_ugh,the .vii,io"i"t]i"cr prn can be a. Clean the
- groove that is_in the
ano into the taOgl of the camshaft ano
tapered bore,of the camshaft ctean the
Adj ustin g,,'cams traft-camshaft.
n"i", to Testing and gear with a lint
ii;;;:i f;'- o re info rmation.
free ctoth that rs satuiatef
ivitill.sotvent in
order to remove an
agaln with a lint fre
rgmove any residue
IO 17 aner cteaning the pz
wttn a lint free alcoh
left on the alcohol wtpe.
Note: lt is critical thatlhe

taper of
the tapered bore of tnecamshaft the camshaft and
and free of residue before ,r; clean, dry,
g;"r. *,"
18
"rrur6lyl'
VIEW A-A b. Ensure that the cams.haft
timing pins and the
timing pin for the ftywheel
19 "r"'iX#rilo
c. place camshaft drive gear (B)
llfustration 406 Remove the backlash -oy
in position.
go112g337
r.oiuiing In"u guarc in
the opposite direction
Ottrft*ove.bolts-(17),rcover (16), "i "rgr"
Lirii",
flywheel housing \ -/' and
s"v
(19).
prus (18) from
Note: For,,Standard
ga m a ft o * j,.,
e tr
g t"rl8,t"rirni3
Hi Fl ; #,".
l,H:
" "
ES,S,,i"f;fr S?aA.,.Xru;_.,,.i},'o"r.luJn"",.. "
d. Instail bott (6) ng (7).
"11 f se.aieOEnsure that the hote
in the ring is froperty
on]f,L
lo."ting pin.
e. Tghten the bolt to a torque
more information. (265 of 360 N.m
tb ft).
f. Place a Mark on the bolt.
g. Place a driver against.the

retaining
plate of the
camshaft gear. i the driver sotidty with a
nammer g to + ti|,l{s"e
h. Tighten the bolt again to a

torque of 360 N.m
(265 tb ft).
,. Steps 14 g,and 14.h untitthe

|.gp_"?,
turned Mark has
at least 90 degrees.
158 RENR9365-1 0
15. Remove the timing pin from the camshaft. Install

the timing pin in the storage position under the
rear camshaft cover.
901 1 57099
lllustration 410
20. Install cover (2) on the front housing.

f 6.lnstall the O-ring seal on engine speed/timing

sensor (5). Extend the sliphead of the speed/timing
sensor to a minimum distance of 4.0 mm (0.16
inch) prior to installation.
{7. Apply Tooling (F) to the threads of engine

speed/timing sensor (5). Install the engine
speed/timing sensor in the flywheel housing and
tighten to a torque of 40 t 5 N.m (30 * 4 lb ft).
18.Install cover (4) on the flywheel housing.
21. Remove the O-ring seals from valve lifters (3).

Push the valve lifters aqainst the camshaft.
19. Remove the timing bolt from the flywheel. Install

plug (18) in the timing hole. Installcover (16) and
bolts (17) on flywheel housing (19).
lllustration 412 90112214s
22.lnstallcamshaft covers (1) on the cylinder block.
End By:
a. Install the electronic control module. Refer to the

Disassembly and Assembly, "Electronic Control
Module (Engine) - Remove and lnstall".
RENR9365-10
b. Install the rocker shaft assemblies and tne

pushrods. Refer to Disassembly and Assembly,
. The weight of the 3512C Enqine is
"Rocker Shaft and pushrod _ tnltitt,;.
. -- approximatety 6800 kg (15000 tb).
. The weight of the 3S16C Enqine is

t02489644
approximatety 9100 kg (20000 tb).
Grankshaft - Remove Note: lt isnot necessary-crankshaft,
to remove the
counterweights from the if the piston and
SMCS Code: 1202-O1i connecting rod assemblies have been removed
from
the engine.
Removal Procedure
Table Bg
Required Tools
Part Number
Engine Rollover Stand
'|
3B - 7576
Start By:
a. Remove the rocker shaft assemblies and the

pushrods. Refer toDisassembly anO
nisemOty,
"Rocker Shaft and pushrod _ nemove,.-
lllustration 413
ilrusrratton 413 901124519
b. Remove the flywheel housing. Refer to

Disassembly and AssemOty, ;ftywneei Housing
2. Place identification marks on counterweights
(2),
- Remove". fem,oye botts (1) and countenveigLt. (iffrorithe
crankshaft.
c. Remove the front housing. Refer to Disassembly
and Assembly, ,,Housing
Note: Do not reuse bolts (1). Use new bolts in
lFront) _ nemove,,. order
to secure the countenryeighito tne crJnf<snaft.
d. Remove the piston cooling jets. Refer to wtl:w Ww a.t **?? vw.ilwdv
Disassembly and Assemniyj,'eiston Cooting -+V*lt?.,:+
.,rets
- Remove and Install,,
Faiture to remove ,n"*r:l[rt.haft assembriesand

push rods can result in damaged valves
when tfre pis_
tons and connectino rods ar6 pushed iway
trom tne
crankshaft.
T9 help avoid damage to the valves, remove

the rocker
shaft assembties a-nd pr.r,
the crankshaft.
,odri"i;;;;;, remove

NOTICE
Note: Number the connecting rod caps and
the
Contaminants may cause rapid wear and connecting rods for installation purposes.
shortened
component life.
t. l?l::"_g:llr.,!01 Remove connectins rod cap
(4) an0 push the connecting rod away from the
1. Use Toofg (A)to turn the engine to a horizontal crankshaft.
position. The engine can be sipported
witn
tooilng 14) or with blocks. Note: Ensure that the journals of the crankshaft
are
not scratched by the connecting rods.
. The weight of the 3S0BC Enqine is
approxrmatety 4535 kg (10000 tb).
160 RENR9365-10
i02489783
Crankshaft - lnstall
SMCS Gode: 1202-012
Table 90
1 38 - 7576
901 1 24538
lllustration 415
4. Attach Tooling (B) to each end of crankshaft (7).

Attach a suitable lifting device to Tooling (B). The
weight of the 3508C crankshaft is approximately
400 kg (880 lb). The weight of the 3512C NOTICE
crankshaft is approximately 600 kg (1325 lb). The Keep all parts clean from contaminants,
weight of the 3516C crankshaft is approximately
800 kg (1765 lb). Contaminants may cause rapid wear and shortened
component life.
b. Remove bolts (5) and main bearing caps (6).
6. Remove thrust plates (8) from each side of the

center main bearing.
t. Remove crankshaft (7) from the cylinder block.
B. Remove the upper halves of the main bearings

from the cylinder block.
L Remove the upper halves of the connecting rod

bearings from the connecting rods.
lllustration 417
f . Install plugs (11) and tighten to a torque of

50t7N'm(37r5|bft).
2. Position crankshaft gear (10) on the crankshaft
10.lf necessary, remove bolts (9) and crankshaft

gear (10) from each end ofthe crankshaft.

RENR9365_10
1^1
Disassemb and Assembty SectiJn
Note: lnstall the main
bearinos
:l::kr, are perform;. R;i;r"; 6. place clean engrn_e oil on thrust plates (g). Install
Hssembly,,'Bearing Cfe"r"nce"_
engine oiton the ,""in g#151"*' (8) on each .ld;;iil;".enter main
Ou"iin!-. fo
3. Install the
ranng (12) in the
cylinder bl main bearing
g in the
t"*i!i#' th
instatteO so is bearing is
the notch
,:1;,i::l[ffifi^ bearing
gffiJ,n",r of the main bearins 8. Coat the underside of

ffi:";i|3 has an oil
l!lq"gr of botts (5) wit
main bearing capj tion
4. lnstall the upper nl,y:,
of connecting rod bearings
1o;
washers. Do-not'tight; O
(13) in the connectTg
,o{.."=9"mbtiet. coat
con nectin g rod bea the
riris with ;l;;;;nni,.,."
",,.
9. Tighten botts (5) i

1et;;4 N;il'#;?X'irH ,o torque or
"
10. Place an index
bearing cap. Tioht
.lf,gn the botts and the main
ror an additionii
180 r s desreei (i; ff.'!:'ts
11. Rotate the crankshaft
in order to ensure that
crankshaft turns freery. the
lllustration 419
go1124s3B
tr._Y^."^_Io?ting
to. m_easure the end ptay
-(D)
rne crankshaft. The
of
o 1i i; do5ii' ib:r:&.,3li5ryi*3i exceed
!?P/'it at .azwpew
lllustration 420
go11z41e2
for the main bearing
caps
Note: Ensure that ther,v91O ,flOfi!f,, lllustration 421
end of the crankshaft that is on the 9o1124522
is toward tne froni't?the
engine.
Illustration 422
go1124419
for the connecting rod
caos
162 RENR9365-10
Note: Install the connecting rod bearings dry

when clearance checks are performed. Refer to
Disassembly and Assembly, "Bearing Clearance -
Check". Apply clean engine oil on the connecting rod
bearings for final assembly.
13.Installthe upper half of the connecting rod bearing

on the connecting rod . Ensure that the connecting
rod bearing is installed so that the bearing tab
fits into the notch in the connecting rod. Coat
the connecting rod bearing with clean engine oil.
Position the connecting rod onto a journal of the
crankshaft.
the lower half of the connecting rod

14" Install
901124519
bearing on connecting rod cap (4). Ensure that lllustration 423
the connecting rod bearing is installed so that the
bearing tab fits into the notch in the connecting rod
cap. Coat the connecting rod bearing with clean
t*,fsrJxJ,"o"J
ig,!"1,'I
the threads' the shank'
"b
engine oil.
Note: Do not reuse bolts (1). Use new bolts in order
Ilste: The number that is on the side of the to secure the counterweight to the crankshaft.
connecting rod caps must be installed next to the
corresponding number that is on the side of tlre 19. Position counterweights (2) in the correct position
connecting rod. Install the chamfered side of the on the crankshaft and install bolts ('1). Tighten the
connecting rod cap next to the thrust surface of the t
bolts evenly to a torque of 70 5 N.m (50 t 4 lb ft).
crankshaft.
20. Place an index mark on the bolts and the
Nlote: Reman connectino rods are not numbered for countenveight. Tighten the bolts for an additional
the cylinder position. !
120 5 degrees (1/3 turn).
f S.Apply Tooling (C) to the threads, the shank, and 2f . Use Tooling (A) in order to turn the engine to a
the seat of bolts (3). vertical position.
'16. Placeconnecting rod cap (4) into position. Install n The weight of the 3508C Engine is
bolts (3). Use the following procedure to tighten approximately 4535 kg (10000 lb).
the bolts:
" The weight of the 3512C Engine is
a. Tighten Bolt (A) and Bolt (B) to a torque of approximately 6800 kg (15000 lb).
90t5N'm(65i4|bft). . The weight of the 3516C Engine is
b. Tighten Bolt (C) and Bolt (D) to a torque of approximately 9100 kg (20000 lb).
90t5N.m(65t4lbft).
End By:
c. Tighten Bolt (C) and Bolt (D) again to a torque
of90t5N.m(65t4|bft). a. Install the piston cooling jets. Refer to Disassembly
and Assembly, "Piston Cooling Jets - Remove
d. Place an index mark on the bolts and the and Install".
additional 90 t 5 degrees (1/4 turn). b. Install the front housing. Refer to Disassembly and
Assembly, "Housing (Front) - Install".
crankshaft turns freelv. c. Install the flywheel housing. Refer to Disassembly
and Assembly, "Flywheel Housing - Install".
NOTICE d. lnstall the rocker shaft assemblies and the

Each counterweight is numbered and must be in- pushrods. Refer to Disassembly and Assembly,
stalled in the same position as the corresponding "Rocker Shaft and Pushrod - lnstall".
number on the crankshaft mounting pad in order to
prevent damage to the crankshaft.
RENR9365_1 0
roJ
_ Disassembly ancl Assembly
Section
i02BsB372
Radlaton Group - Rernove
StlltCs Code: .1
353_01 1
fi,Xo,.Tl
hot I nn .'"ir::.:
ano' uncJer
jy'",
pr**irr*.
rh ;;;H;ff ffi ;fil
S/N: SBGl-Up
Steam can cause personal
S/[tl: SBJl-Up injury.
S/l',1: SBKl_Up jt- cootant levet.o.nty a{,rer ilre engine trirs
Pl::l stoppecl
neen and ilreJift,J*f, i= *rl'eiror.rgh
SiN: NAM.1-Up touch with your !:are hand. to
S/ilI: SBMl-Up Remove the fill eap slowly
to refieve pres_sure.
S/N: KEN'1-Up
Coof ing system conditio"ner
contains alkali. Arroicl
S/IIJ: RMS1-UP with the skin and uv*n t"'ir"iJ,riooruonu,
::lll1"t
Inrury.
I n**ovaf pnocedure e cooling system into a

rage or disposal. Refer
Table 9.1 ance Manuarl ,,Cooling
hange,' or Operatron arrd
otrng System Coolant
f{ote: The coolinqsvllem components ano

may vary depend'ing on youf weights
arrangement.
Note:
tubes hoses, wires, and
on all caps and plugs
loss o er to prevent fiuid
S,
NOTICE
Care must vvbe taken
_. Du'no
, Lqnsil to
r.u-ensure that fluids
are contained
1f,1, 19.,P:flo
nerform.^^^
rm u
I 9e
^,:::yr"
o f. in s-pecfio n, ri""i
aolustin g and repair of'tf,e ntun a n ce, test-
lllustration 424
901225862
-lq,collect the fluid with,s : oiri,,"i"Ro
proouct.
_. _,," y, uvuur. oe
'"-''" vvrr(qrrrtrrs
prepared
Be orepared
^"^^^_^.,to_
ntaine rs IJeIore
2. Disconnect har.ness assemblies
ing any
Inq corhn: rrma n;lt:
a nv compartmeni-
bebre open-
open- (2)
or ll,: -t:
dlsassembling any compo-
nent containino
containing ftrrirrc
fluids 3. Disconnect tube assemblies (1).
, o,i.:jl?1, E N G2 500,,,caterp
iila r
ot Catatog,,l, for tools Jno
and contain ftuids on caterbirtii
"rpbii"l
ftuids accordins to tocat

flt;ff:il|ail resutations and
lllustration 425
901 225865
4. Disconnect tube assembly (3).

164 RENR9365-10
lllustration 426 901225867 lllustration 429 9O1225897
5. Disconnect elbow (4). B. Attach Tooling (A) and a suitable lifting device to-
radiator group (7). The weight of radiator groupJ
-
is approiimaieiy 2050 kg (4500 lb).
-
Illustration 427 901225892
6. Remove guard assemblies (5). lllustration 430 9O1225901
901 225893 lllustration 431 9o1225902

lllustration 428
7. Remove belts (6). 9. Remove bolts (8) and bolts (9)from both sides.
RENR9365_.to
3:
care must be taken ," llr?ll3Fâ*,

trinn narF^.*^
rirro 6F^ ^^h.^:- - ,
rll
during performance -t
^ ^^ of
ing, adjusting and repai
colect the fluid with su
ublication, NENG2S00,,,Caterpillar
ot C,"l1gg,. for. toots ano suppties
ano contain fluids on Cateriiilar
lllustration 432 gO.t2ZSs04 Dispose of all fluids according

to local regulations and
mandates.
10. Move radiator group (7)
away from engine (10).
O nroiator Group - fnstatl

io2858374
SMCS Code: 1353_012

S/N: SBGl_Up
S/N: SBJl_Uo
S/N: SBKI_Up
S/N: NAM.t_Up
S/N: SBMl_Up
lllustration 433
9012258s7
S/N: KENl_Uo
t. and a suitabte tifting devrce
S/N: RMSl_Up 1,1?:l_t:9ling.el
raorator group (7). to
Ttre.weight of r"diati group (7)
rs approximatety 2050 t<g
S/N: RTXl-Up; R2Aj_Up 14SOO tb).
Instaf fation procedure

^
E;r'^ tautc ^^
Jz
-7
I:l:.1J"_:ooting system components and weights

may vary depending on your
"rr"ng"r"ni."
lllustration 434
2. Position radiator group (Z) by

engine (10).
166 RENR9365-10
5. Install guard assemblies (5).
g0'12259o1
lllustration 436
3. lnstall bolts (9) and bolts (8) on both sides. lllustration 439 9o1225867
6. Connect elbow (4)
lllustration 437
4. Install belts (6). lllustration 440
7. Connect tube assembly (3)

RENR9365_10
167
Section
Start By:
a, Remove the fuel cooler. Refer

to Disassembly and
Assem bly,,, Fuel Cooler" _ jn.t"
n"nl*u"""n"i I r,,.
I:l:.,.fn" system components and weights

may "ooting on your
vary depending rirnngur"r.ri.
lllustration 441
9O1225862
B. Connect tube assemblies (1).
L Connect harness assemblies

(2)
lllustration 442
901 232360
t
1,,,,:-"j^t-ooling,(t).and a suitabte tifting device to
l"f:ff""ff'j{]"flifi?ve norts iziiri order to
i0285838.1
Raldlaton Gore - Remove
SMCS Code; 1353_01.1
S/N: SBGl_Up
S/N: SBJl_Up
S/N: SBK.I_Up
S/N: NAM.1-Up
S/N: SBMl_Up
|.rru' KENl-Up
S/N: RMS1_Up lllustration 443 go12324js
S/N; RTXl_Up; R2A1_Up 2. Remove guard assemblies (3)
Removal procedure
Table g3
Required Tools
1 38 - 7573
1 38 - 7575 Link Bracket

Lever Puller Hoist
lllustration 444
9o1232442
168 RENR9365-'10
3. Attach Tooling (B) and a suitable lifting device 6. Attach Tooling (A) and a suitable lifting device to
to support (4). The weight of support (4) is coolant tank assembly (7). The weight of coolant
approximately 91 kg (200 lb). Remove bolts (5) in tank assembly (7) is approximately 91 kg (200 lb).
order to remove support (4). Remove channels (9). Remove bolts (10) and
plates (11). Remove coolant tank assembly (7)
and the gasket.
4. Use Tooling (A), Tooling (B), and Tooling (C) in lllustration 448 901 232450
order to stabilize radiator cores (6).

7. Attach Tooling (A), Tooling (D), and a suitable
5. Remove some of the bolts in order to move
support (8) away from coolant tank assembly (7).
Leave the bolts in the bottom of support (8) in
i'i$:.i:xi?: 8 ir sJ;ii; ffi i?, li"-ui t'JJ
Remove channels (13). Remove bolts ('12) and
i,p
-
order to stabilize radiator cores (6). plates (14).
901232447 lllustration 450 901 232460

lllustration 447
B. Remove radiator core (6)

RENR9365_10

Section
-_
lllustration 451
go12s2S42
lllustration 452
901237S15
9. Repeat Step 3 in order to remove
R-epeat_Steps 7 and g in support (g).
order to rembve radiator
core (15).
O to,Remove ptate assem bty (17).
tt.!ep99!Steps 7 and 8 in order to remove

core (16) and radiator core radiator
(te).-
i02858382
Radiator Core - Instalf
SMCS Code: 1353_012
S/N: SBGl-Up lllustration 453
9O1232542
S/N: SBJl-Up ting (D), and a suitabte

S/N: SBKl-Up eight of
S/N: NAMl-Up l?3',1?
S/N: SBMl-Up
2. Repeat Step 1 in order to install
SiN: KEN't-Up radiator core (1g).
3. Instail plate assembty (17).
S/N: RMSl-Uo
S/N: RTXI-Up; R2A1_Up 4. Repeat Step 1 in order to install
radiator core (15).
t. and.a suitabte lifting device
I nstallation procedure 1,,:.:l_I:gtjlg
to support (a) Lq)
rhe_ralgiglt.gr
approximatetv 91 ks (2 io lrpp"*'idf ,=
tb). FrJJ"
Table 94 position and lnstail inb .lb"port (8) in
"vv vv'"r
oottsl
Required Tools
138-7573
138-7575
I:l:.,.]-L","ooling system components and weights

may vary depending on your
"ir.ng"r";i.-
170 RENR9365-10
9O1232450 901232445
7. Use Tooling (A), Tooling (B), and Tooling (C) in

order to stabilize radiator cores (6).

coolant tank assembly (7). The weight of coolant
tank assembly (7) is approximately 91 kg (200 lb).
i Hlsii il:.Ssi[?l 3tl ;:fr5?l Jilfiffi:ilr?x'.gf

(e)
6. Repeat Step 1 in order to install radiator core (6).

Install plates (14) and bolts (12). Install channels
(1 3).
901 23291 9
lllustration 459
9. Position support (8) near coolant tank assembly

(7). Install the bolts.
RENR9365_1 0
End By:
a, Install the fuel cooler Refer to Disassernbly

Assembty, 'Fuet coorer _ R*;"o;;;;Jinstal,,and
i02858384
Fan ffinlve - p*ennove
Stu'iCs Gc<le: 1 3Sg_01 j
S/FJ: StsG1.Up
S/N: SBJl-Up
lllustration 460
9o1232442
S/N: SBKl-Up
10 Jp) anO a suitabte tifting device S/N: NAMl-Up
The weight of support
i+) is
91 kg (200 tb). ptaie support (4) S/N; SBMl-Up
in
botts (5).
S/N: KENl-Up
5/N: RMSl-Up
S/N: RTXl-Up; R2A1_Up
Rem ovi-,r I p roeeci u l.e

Table 95
Required Tools
Part
Nurnber Part Dc.scription I
Lever Puller fJoist I
lllustration 46.1
9o1232415
I:1.".'.]_,l" :ooting system components and weights
rnay vary depending
11. Install guard assemblies (s) on your arrangement,
lllustration 463
lllustration 462 g0
90122601j
1 232360
,t jll::11:!l1q 1. Disconnect harness assemblies (2).

(41.ary a suitabte tifting device
to
9::,11:r.uTbty (1) ptace-suard ,.="inory , 2. Disconnect tube assemblies (1) and
posttton and install (2i 1r; ' position
r""
bolts tube assemblies out of the wav. -" the
ttz RENR9365-10
lllustration 464 lllustration 467 901226027
3. Remove guard assemblies (3) and plates (4). 6. Remove guard assemblies (7).
lllustration 465 lllustration 468 901226028
4" Remove belts (5) 7. Remove guard assemblies (B)
$. Remove guard assemblies (6) B. Attach Tooling (A) and a suitable lifting device
to fan drive (9). The weight of fan drive (9) is
approximately 295 kg (650 lb). Remove bolts (10).
RENR9365_10
Start By:
a. Remove the fan O!y9

nssembly, ',Fan Drive _[gter to Disassembly and
R"rou"i'-"""',
Note: The coolinq sv1lem
components and weights
may vary dependlng
on your arrangement.
9. Remove fan drive (9)

from radiator group (11)
O rrn Drive - Dlsassembfe io2ss'4oz
Sll/tCS Code: 1359_01S lllustration 471

g0'1228698
S/N: SBGl_Up
t ran assembrv (1)
S/N: SBJl-Up +l':"J"?r"l'l??5."llq 9:yi':.!q
assetbly (1)
zzs r,g i"fjob tb';o" is approximately'
S/N: SBK1-Up
S/N: NAM1-Up
S/N: SBMl-Up
S/N: KENl-Up
S/N: RMSl-Up
S/N: RTXl-Up; R2A,l_Up
Disassembly procedure
Required Toofs lllustration 472

9o1228703
2. Loosen setscrews (3).

Remove bolts (2).
Hydrauric Pump
5,;"u,"
3H - 0469
1A- 1935
1P-051o
lllustration 473
3. Lower fan assembly (1)

from retainer (4).
174 RENR9365-10
lllustration 474 9o1228705 lllustration 477 901228728
4. Use Tooling (A) in order to remove retainer (4). 7. Loosen setscrew (10). Attach a suitable lifting
ffi ''."?,H i,:if 5l % Iis H; fl:',"JfJ

install bolts (9) at Locations (X). Tighten the bolts
in order to remove pulley (B) from the fan shaft.
[:t J i L i't
Remove pulley (B) and key (11).
lllustration 475 9O122a708
5. Remove key (5)from fan shaft (6). Remove fan

assembly (1).
lllustration 476 90122A723
6. Attach a suitable lifting device to fan shaft (6), lllustration 479 901228737
bearings (7), and pulley (8). The weight of fan shaft

(6), bearings (7), and pulley (8) is approximately Note: Mark the location of bearings (7) for assembly.
70 kg (150 lb). Place fan shaft (6), bearings (7),
and pulley (8) on suitable cribbing. 8. Loosen setscrews (12)from bearings (7). Remove
bearings (7) from fan shaft (6).
RENR9365_10
I;
i02858411
Fan Drive - Assemble
SUICS Code: 1359_016
S/N: SBGl-Uo
S/N: SBJl-Up
S/N: SBKl-Uo
S/N: NAMl-Uo
S/N: SBMl-Up
S/N: KENl-Uo
S/N: RMSl-Uo lllustration 481
9o1228735
S/N: RTXI-Up; R2A1_Uo 1. Install bearings (7) on fan shaft (6) Tighten
,
setscrews (12) in bearings ,
(7).
Assembly procedure
I
Table g7
Required Toots
Thread Lock Compound
I:1:.,._t_l","ooling system compone nts and weights

may vary depending on your rrr"ngur";i."
Keep ar parts crean t,H]l:i"rinants. lllustration 482

901228847
r"y cause rapid wear and shortened
^":!q'lltl:
component life. 2. Attach a suitable trfting device
to pulley
weight of pulev {8) is lpprox_"t5lv 'g:j (8). The
kg (20 tb)
key 1ir j ano piirev'iei;*n
lo:i!:.nbotts
lnstail (9).'
ih:in ,n"ft
.. fl,y Too.t11g (B) to setscrew (10).

Tishten
setscrew (10).
lllustration 480
9o12287s7
lllustration 483
9O1228723
1'76 RENR9365-1 0
Eisassembly and Assembly Section
4. Attach a suitable lifting device to fan shaft (6), 7. Install bolts (2). Apply Tooling (B) to setscrews (3)
bearings (7), and pulley (B). The weight of fan shafi Tighten setscrews (3).
(6), bearings (7), and pulley (8) is approximately
. 70 kg (150 lb). Place fan shaft (6), bearings (7), End By:
and pulley (8) in a vertical position.
a. lnstall the fan drive. Refer to Disassemblv and
Assembly, "Fan Drive - Install".
i0285841 9
Fan Dn"E'se - Install

Sl\flCS Code: 1359-012
$/N: SBG1-Up
S/N: SBJl-Up
S/hl: SBK1-Up
gO'1228708 S/N: NAMl-Up

lllustration 484
S/N: SBMl-Up
5. Attach a suitable lifting device to fan assembly (1).
The weight of fan assembly (1) is approximately $/N: KENl-Up
225k9 (500 lb). Installfan assembly (1) on fan
S/N: RMSl-I.JP
shaft (6). Install key (5).
I E"rsta! latlon F roced u re

Table 98
Required Tools
Fart
Tool Number Part Description atv
A 1U-9200 Lever Puller Hoist 1
Note: The cooling system conrponents and weights_

may vary oepending on your arrangement,
901228704
O
lllustration 485
6. lnstall retainer (4). Raise fan assembly (1) to

retainer (4).
g01 226031
lllustration 487
g01228703
lllustration 486
RENR936s_10
lllustration 4BB
901226029
lllustration 491
1. nd a suitable lifting device
9o1226021
5. Install guard assemblies (6)

,-333
(11).
fi';:.n', lf lt ;i,
"
2. lnstail botts (10).
lllustration 492
s01226018
6. Install belts (5)

lllustration 48g
901226028
Install guard assemblies

(g).
lllustration 493
901 2260.1s
7. lnstall plates (4) and guard assembties (3).

lllustration 490
9o1226027
4. lnstall guard assemblies (7)

178 RENR9365-10
35236
Illustration 494 901226011 lllustration 495
g0 1 1
B. Place tube assemblies (1) in position and connect 1. Remove bolts (3) and thrust plate (4).
the tube assemblies.
2. Remove balancer gear (5)from gear srrat (21. O
9. Connect harness assemblies (2).
sleeve bearing (6) from balancer gear (5).
i02487338
Balancer Group (Front) - 4" Remove bolts (1) and gear shaft
of the cylinder block.
(2) fronr the front
Etremove and lnsta!!

(3508C Englne) lnstallation Procedure
SMCS Code: 1220-010 Table 100
Required Tools
S/N: LLCI-Up
S/N: C8E1-Up
A 1 P-0520 Driver Group 1
S/N: LLE1-Up
S/N: CBKI-Up NOTICE
S/l{: FlXl-Up
S/tN: RTXI-Up; R2A1-Up
Contaminants may cause rapid wear anO sfrorterf
comnonent life.
Renroval Procedure
Table 99
Required Tools
A 1P-0520 Driver Group I
Start By:
a. Remove the front housing. Refer to Disassembly
and Assembly, "Housing (Front) - Remove".
NOTICE lllustration 496 901 1 35236

1. Use Tooling (A) and a suitable press to install
Contaminants may cause rapid wear and shortened sleeve bearing (6) in balancer gear (5).
component life.
RENR9365_10
Disassembly 175
clg4!:eruly rsgpn
ve bearing (6lr1ust
be
de diametLr n"r"ii" machined to the
so"Zi"i,i
,,,Machinins or Reptacem;i
3,r",:i:,'"r,
Keep ar parts crean
,,ff]l?ir"rinants
2, Instalt gear shaft (2)_and
bolts (1). Tiohten bolts
(1) to a torque jdnjlr'ri iiol oj,??
cause rapid wear an<j
shortenecJ
3.
"r ,o ,,1 "C"Tiillillilt"u
't" Drain the coolant
fr
r oeiow'ffi ;,i;T, H":"r"",,,ff"
eve r to a
container for storage :ystern
rrrt"o a suitable
gear are in alignnrent o,. OiuouJi'wr
engtne. Install thrust p
End By;
a. lnstalt the front

n"r:,lpr_TRfer
Hssembty, ,'Housing (Front) to Disassembty anct
_ tn.t"ir]*"".
e oglant Levef $ensor - n**u**

and lnstafl
SMC.S Code: 7470_010
S/N: SBGl_Up got13?,110
S/N: SBJ.t_Up 2. Disconnect the hat

assemblv and remove
S/N: SBK1-Up
coorant l;;i
;J;;?ess
S/N: NAMl_Up fnstailation procedure
S/N: SBMi_Up
NOTICE
Keep all parts clean
S/N: KENl_Up from contaminants.
S/ilt: pES.t_Up Contaminants mav cause
component life. rapid wear and shortelred
a:,*,RMs1_Up
vs/N: RTXl_Up; R2A1_Up
Removal procedure
NOTICE
Care must be taken
to fluids are contained
f,u'nq performan^^
f'[i' :fl j 3 sifJ H ^r::::l_jhat ff
?: :*j t?i:l
pJr+d!: ,ilT*li::f
ff ;x?,1,1
collect the ?fl
luiOfi T
": rilu
r ry ':ri,, pruuuc[.
"1
ii:?' H:
Ue ??:;:,j:i5
Orepared to
*ittt-a
;
:
rn g any comoa betore open-

rtmen; 1Y1',:
; ; ; ^lltai19rs
[',
nentliJ, ij [,'r'"?i'l.iiFi_
containing
ffi ;l i I ill,:?.
fluiJs. " " "i
o n,
i""JiJ
",i.tSfr
:f i:H 1':
t r
NENG250 0, " c a te rp i || a r lllustration 498
s21j
; [5fj?.rrl]
J# #:'::ti: fl l?J :"J #.3 i#?sffT f . Instail cootaniluup,__r9!:or-
9011 O
(1) and tighten

torque of 30 5 N.m t tzz
Lrvrrl to a
fljffi,""llalt
fluids accordrng ro tocal
regutations and N-ote: Do not applv
"i'in\t)-
additrbnal sealant to
ot the coolant level the threads
sensor.
2. Connect the harness assemblv.
180 RENR9365-10
3. Fill the cooling system. Refer to Operation and i0?-241445

Maintenance, "Coolant System Coolant - Change"
Engine (}i! FressLlre Serner:r ".
Remove and lnstall

SMCS Code: 1924-010
S/N: LLA1-Up
S/N: RlAl-Up
S/N: LLBl-Up
S/N: LLC1-Up
S/N: C8E1-Up
S/N: LLEl-Up
S/N: LLFl-Up
S/Fl: SBGl-Up
SiN: SBJl-Up
S/N: CBK1-Up
S/N: SBK1-Up
S/N: NAMl-Up
S/N: SBMl-Up
S/N: KEN'I-Up
S/N: PESl-Up
S/N: RMSl-Up
S/N: F1X1-Up
S/N: F2X1-Up
S/N: T2X1-Up
S/N: RTX1-Up; R2A'1-Up
Removal Procedus'e
NOTICE

products.

mandates.
RENR9365_10
,la1
and Assemoty sectiJn
Keep ar parts crean

t q'^11,1 1,rr t" re d e n g n e o
,r#Il?lrrinants i?::1 l, il 1?x,3;'ll( r'l'
I
Hpply clean engin6

i iI
b-ring r-""i'tovr oilto the

:"ffiilinililtrn shortened 2. lnstall filtered
oil pressure sensor (1)
tighten to a torque
"ngî1u,
of .10 r 2 N.m (89 r i8 and
tb in).
3. Connect the harness
assembly.
4. lnstalla new O_r. t^":i'?t unfiltered en.qine
pressure sensor'lq oil
b-fis ;";'towt \t)' Hppty clean engine
oit to itre
5. Instalt unfiltered
pre.ssure sensor (2)
rrghten to a torque
":g1n"ôil and
or ro t , N;i;g:'rB ,b ,n;,
6. Connect the harness
assembly.
lllustration 499 Engine oif pressure

901129710
Remove and tnstail-
su"*n'J'l"'
vvrri
1. Disconnect the h
ri r t
"
i" i . g i ;J"; i
T1"",'.', ffi:Tjjl
a n d re m o ve
SMCS Code: 1924_010
"
2. Remove the O_ri ng seal
from the engine oil S/N: R1S1-Uo
pressure sensor.
3. Disconnect
"e the he
Removat procedure
re mo ve
u n ri rte ie J n sil' :ii ;;..: ff: Tjlfi l
4. Remove the O_rin g seal
from the engine oil
pressure sensor. tffi fl;"',3 :J:::: :,+: lii.fu r, u i d sa re con ta i n e d
ing,
In9, adiustino enr{
adjusting, ra^^;-
;nJi"p"ir.
Instalfation procedure ro coilect the fluid with
opentng any compartmen
ponent containing
fluids.
Keep ar parts crean
,rffill?l"rinants
1z-ontaminants mzly cause rapid wear and
;::" i:xi E:i"lil v
?i :: r n, NENG2s0 0,
ies
D e a re r se r-
component shortened
co rr e c t-a-n o"J#,"# iiJ J: ? ; S:?
su ita b e to
;:!ir
I
life.
Dispose of allfluids
ac)cordtng to local
mandates. regulations and
Keep ar parts crean

rr**:ilinants
shorlened
"#fil5,iili.t"u
lllustration 500
90112s7 jO
182 RENR9365-10
a new O-ring sealon unfiltered engine oil

4" Install
pressure sensor (1). Apply clean engine oil to the
O-ring seal.
5. lnstall unfiltered engine oil pressure sensor (1) and

t
tighten to a torque of 10 t 2 N'm (89 1B lb in).
i02240085
Turbochanger !nlet Pnessure

$ensor - Remove and InstalE
SMGS Gode: 1917-010
1. Disconnect the harness assembly and remove S/N: LLAI-Uo
filtered engine oil pressure sensor (2).
S/N: RlAl-Up
2. Remove the O-ring seal from the engine oil
S/N: LLBl-Uo
pressure sensor.
S/N: LLCl-Up
3. Disconnect the harness assembly and remove
unfiltered engine oil pressure sensor (1). S/N: CBE'1-Up
4. Remove the O-ring seal from the engine oil S/N: LLEI-Uo
pressure sensor.
S/l{: LLFI-Up
fi nstallation Frocedu re S/N: C8K1-Up

S/N: PESl-Up
NOTICE
Keep all parts clean from contaminants. S/N: RMS1-Up

S/N: FlXl-Up
component life. S/N: F2X1-Up
Removal Procedune
NOTICE

component life.
1. Install a new O-ring seal on filtered engine oil

pressure sensor (2). Apply clean engine oil to the
O-ring seal.
2. Install filtered engine oil pressure sensor (2) and

tighten to a torque of '10 t 2 N.m (89 r 1B lb in).
3. Connect the harness assembly.

g0'11 29348
lllustration 503
RENR9365_10
183
Section
1. Disconnect the harness assembly

turbocharger and remove
inlet pressur","ni,jr?i'i'
2. Remove the O_ring seal from the Turbocha-rger I n let press u
turbocharger ;';'0""
inlet pressure sensor. uensor - Remove and Install
I nsta tlation procedure SMCS Code: 1gi7_O1O
Table 101 S/N: RlSl-Up
Required Tools
Removal procedure
Keep att parts crean *ffi]l?i"rinants,

9glU'lq.J9 m"y cause rapid wear and shortened
component life.
Keep ar parts crean rr#]:?i".inants
9^":31'l_qr,t: ruy cause rapid wear and shortened
component life.
llluslration 505
902256654
1. Disconnect the harness assembly

and remove
turbocharger inlet pressrr" ,"n.drlt'i '
lllustration 504 g0 1 1 29348
2. Remove the O_ring seal from
1. Install a new O_ring sealon turbocharger inlet pressure sensor.
the turbocharger
pressure sensor (1). Appty inlet
rooring iAiL tre
O-ring seal.
Instalt turbocharoer inleJ
tighten to a torqJe oi to tO1e99ure
sensor (1) and Table 102
2 N.m (89 r 1e in int.
Keep al parts ctean n#]l?,"rinanrs

9^*lq'lqq: r"y cause rapid wear and shortened
component life.
184 RENR9365-10
i02239883
Turbocharger Outlet Fressure

Senson - Remove and lnstall
SMCS Code: 1917-010
S/N: LLA1-Up
S/N: RlAl-Up
S/N: LLBl-Up
S/N: LLC1-Up
S/N: CBE1-Up
S/N: LLE1-Up
1. Install a new O-ring seal on turbocharger inlet
pressui'e sensor (1). Apply Tooling (A) to the S/N: LLF1-Up
O-ring seal. S/ttl; CBK1-Up
2. Install turbocharger inlet pressure sensor (1) and S/N: PES1-Up
t r
tighten to a torque of 10 2 N.m (89 1B lb in).
S/N: RMSl-Up
S/N: F1X1-Up
S/N: F2X1-Up
Rernova! Procedure
NOTICE

component life.

turbocharger outlet pressure sensor (1).
2. Remove the O-ring seal from the turbocharger

outlet oressure sensor.
RENR9365_10
Instalfation procedure
Keep ar parrs crean r,.ffi]l:l"rinants.
^":lf'lqt!: ,ry cause rapid wear and shortened

component life.
lllustration 509
902256275
1. Disconnect the ha
tu ro oc n aiil ; ;,iE i??::.1?:g?'J"?
? ?I f "' ou.
2. Remove the O_ring_seal from
the turbocharger
outlet pressure senso.
lllustration 508
90112s223
1. Install a new O_ring Installation procedure

seat on turbocharger ouilet
pressure sensor (.1).
2. Install turbocharoer gyt.!"t pressure sensor (1) and

Keep al parts ctean t,"H]1ffi,ninants
tishten to a torqrie or iijl I'N:iii;;:"lu ,o ,n,. ,"y cause rapid wear and
3. Connect the harness 9g$'lq+:
component life. shortened
assemblv.
i04046115
Turbocharger Ouflet pressure
Sensor - R6move and Instaf
i
SMGS Code: 1917_010
jsAt: R1s1-up
Removal procedure
Keep ar parts crean t,Jfll:i"rinants. lllustration S10

902256775
C_oltaminants may cause
rapid wear and shortened 1. Install a new O_ring seal
component life on turbocharger ouilet
pressure sensor (1).
2. Install turbocharoer ouilet pressure

sensor (1) and
ib;
tishren to a torqrie ot
til;i;d;'iu ,o ,nr.
186 RENR9365-10
io27 10195
NOTICE
Coolant Ternperature Senson - Keep all parts clean from contaminants.
Remove and lnstall
SMCS Gode: 1906-010 component life.
S/N: LLA1-Up
1. Drain the coolant from the cooling system to a
S/N: RlAl-Up level below the coolant temperature sensor into a
S/N: LLBl-tjp to Operation and Maintenance Manual, "Cooling
S/N: LLCl-Up System Coolant - Change".
SIN: CBEl-Up
S/N: LLEI-Uo
S/N: LLF1-Up
S/N: SBG1-Up
S/N: SBJ'1-Up
S/N: CBK1-Up
S/N: SBKl-Up
S/N: NAM1-Up
S/N: SBMI-Uo lilustration 511 901 1 29260
S/N: KENl-Up 2. Disconnect the harness assembly and remove

coolant temperature sensor (1).
S/N: PESl-Up
S/N: RMSl-Uo 3. Remove the O-ring seal from the coolant
temperature sensor.
S/hl: FlXl-Up
4. lf necessary, remove the adapter from the water
S/N: F2X1-Up temperature regulator housing, Remove the
S/N: T2X1-Up O-ring seal from the adapter.
S/N: RTX1-Up; R2A1-Up lnstallation Procedure

Removal Procedure NOTICE
NOTICE
Care must be taken to ensure that fluids are contained Contaminants may cause rapid wear and shortened
during performance of inspection, maintenance, test- component life.

products.

mandates.
RENR9365_10

Section
Keep ar parts crean ,,'#r?l?l",.ninants
gTiilIfiililt"t cause rapid wear and

shortened
lllustration S12
901 129266
1. Install a new O_rhg seal.on

the adapter. Install
n t h e w a te r t", p u r"ii
i
I[", S,ffi : ", il,r'e s u a tor.

r
, O-ring seat on coolant

[.^,:t-qfw
sensor (1). temperature
3. Install coolant tem

to a torfilir; 1fii.il?;lT',Ji?,and tishten
u g."vrlg,l, lllustration S.l3
l;l,k^:"_"in
rvrarnrenance Manual, Iefer to operation and 902257027
cooring SyJGri.bootant
- Ghange',. 2. Disconnect the harness
assembly q"u
cootant temperature ', and remove
,"";;;ii;.
3. Remove the O_ring
i04046124 seal from the coolant
Coolant Temperature remperature sensor.
Remove and Instalf
Sensor -
4.
pter from the water
SMCS Code: 1 906-0 g. Remove the
1 0
Rlsl-Up
fsw: f nstallation procedure
Removal procedure
Keep al parts crean tr#liffi,inants
NOTICE
Care must be taken to
that fluids are contained
turf no oerforrn,^^^ ^r:::yr" cause rapid wear and
fl.l:' :%,i:,.f:':ff ff
?^*]l;i.":e#: l; flT?:i"i: :i .?liliXTif;if"t"t shortened
collect tnl nuiO -ri-,, "'rrrc 1.rueuct. ue prepared
lln;lfl,i?,'i,,ylll^,:ill,"i,.,l-"-ii;,j.llil",iJl?S;
to j?ll
opening
openino any Ar.*/ compart;
-" -"'''"rs uurllalners
containers before
ponent containin! ^^mnar_11,suitgble
or disassembling any com-
containinn ,,,,,I."nt
fluids.
Referto Speciat tro,,:?!gl, ,,Deater

vice Toot Catatog,, to1j9o_fs NENG2500, Ser_
corect and contain fluids Ird ,rpptids.suitabte
. to
on cat proiiriis
ftuids according ro tocatregutations

Rt;ffifft"il and
188 RENR9365-10
i027 10224
Aftercooler Coolant
Temperature Sensor - Rernove
and install
SMCS Code: 1906-010
S/N: LLA1-Up
S/N: LLB1-Up
S/N: LLC1-Up
S/N: C8E1-Up
S/N: LLEl-Up
'1. Install a new O-ring seal on the adapter. Install
S/N: LLF1-Up
the adapter in the water temperature regulator
housing. S/N: C8K1-Up
2. Install a new O-ring seal on coolant temperature S/N: PESI-Up
sensor (1).
S/N: RMSl-Up
3. Install coolant temperature sensor (1) and tighten S/hl: FlXl-Up
to a torque of 20 t 5 N.m (15 t 4 lb ft).
S/N: F2X1-Up
S/N: RTX'1-Up; R2A1-Up
5. Fill the cooling system. Refer to Operation and
Maintenance Manual, "Cooling System Coolant R.emoval Procedq.rne
- Change".
NOTICE
Refer to Special Publication, NENG2500, "Caterpitt)i7

products.

mandates.
NOTICE

component life.
1. Drain the coolant from the cooling system to a

level below the aftercooler coolant temperature
sensor into a suitable container for storage or
disposal. Refer to Operation and Maintenance
Manual, "Cooling System Coolant - Change".
RENR9365_10
Disassembty and Assero11,

s""li3i
Aftercoorer coorant 'o4o4o14e
Temperature S"nio. _ Remove

and Install
SMGS Code: .1906_010
S/N: RlSl-Up
Removal procedure
lllustration S15
NOTICE
9o1190042 Care must be taken to
,. perrormance ji' '""' ' rdL llulos
fiuids are contained
tr
ou'nq oerformanô
during
the harness assembty
?j::?1":ct coolant and remove ^r-9llll^l.h.t
rng, adiustin' rn.r ,^l]Lt!.",9tion, maintenance, test-
aftercooler temperature *6n."Ir trl. lln;lfl1?,'i^n;:1f,,:mf i,f g;iil;:i:"J""1?S;l?ll
[ "d.".L,; :,"8'T"?:?:
3. Remove the O_ring seal from
the aftercooler
:",
:P:lIs
jl
:"j
"T containing
ponent ",J
i i*
any gompartmenr it F
"1!1. or dirsassembling any com_
coolant temperature fluids.
sensor.
Referto Speciat oro,i:?|igl,
lnstaf fation procedure vrce Toot Cataloq" NENG2s00, ,,Deater
Ser_
coilect and contaln fluros i* .-rpptiJs.suitable to
":.,:ol:
on Cat products.
Keep ar parts crean ,Hll:F"rinants. Dispose of all fluids ar
:cording to local regulations
mandates. and
:"TfilSiif"t"u shorrened
Keep at parts clean

r#*?Erinants
.C"TiillnTilt"n cause rapid wear and shortened
f . Drain the coolant fr
revel below the afte
sensor into a suitab
orsposal. Refer to O
rvlanual, ,,Cooling Sy
lllustration 516
901130042
1. Installa new O_rir
seal on aftercooler coolant
t"tp"*iri"';;llY
2. Install aftercooler coolant.temperature
and tighten to a torque sensor (1)
or ro I ! rvl#1E0.* re tn int
4. Ftl the coolino svs with coolant' Refer to
operation ,n,i nr;it9t lllustration 517
svstem coor"nf --3i313:?: Manuar' "coolins 902257034
a. the harness assembty

Ôjr^:glnpct coolant
aftercooler and remove
temperature $r.ir.
ir f
3. Remove the O_rinq_seal
from
coolant temperatuie sensor. the aftercoorer
190 RENR9365-1 0
I srstallation Procedure
NOTICE

component life.
901'128361
lllustration 519
1. Disconnect harness assembly (1).

2. Remove engine speed/timing sensor (2) from trJ
flywheel housing. Remove the O-ring seal froin
the engine speed/timing sensor.
go2257034
lllustration 518
I nstal lation P neiced u re
t" Install a new O-ring seal on aftercooler coolant Table 103
temperature sensor (1 ).
Required Tools
z.- Install aftercooler coolant temperatute sensor (1) Tool Part Number Pad Description Qtv
and tighten to a torque of 10 t 2 N.m (89 t 18 lb in).
A 5P - 3931 Anti-Seize Comnound
NOTICE
4. Fill the cooling system with coolant. Refer to
Operation and Maintenance Manual, "Cooling
component life.
io2237506
Engine Speed/Timing Senson -

Rernove and Install
SMCS Coele: 1912-010
Rernoval Procedure
NOTICE

component life.
1. Install the O-ring seal on engine speed/timing

sensor (2). Extend sliphead (3) to a minimum
distance of 4.0 mm (0.16 inch) prior to installation.
2. Apply Tooling (A) to the threads of engine

speed/timing sensor (2). Install the engine
speeditiming sensor in the flywheel housing and
tighten to a torque of 40 t 5 N'm (30 r 4 lb ft).
RENR9365_1 o
3. Connect harness assembty (1).
io2241924
Grankcase Fressure Sensor
Rernove and lnstail -v''
_
SMCS Gode: 1916_010
Remova! procedure
Keep al parts ctean r#]f[rinants

9^":ill'lqtl: ,"y cause rapid wear and snortened lllustration 522
component life 9o1129987
1. Install a new O_ring seal

on the crankcase
pressure sensor (1).
Install crankcase pres
to a torque ;r-di;"r,r:XliffTru tishten
l|,iio
J. Connect the harness
assemblv.
lllustration 521
901129987
and remove
crankcase pi";;;T:nrX', iTblv
2. Remove the O_ring seal from the crankcase
pressure sensor.
Ol nsta llation procedure
Keep ar parts crean rr#]l:lrrinants

9^*il,l:r,f r"y cause rapid wear and shortened
component life.
192 RENR9365-10
i02237707
Atmospheric Pressure $ensor

- Rernove and lnstall
SMCS Gode: 1923-010
S/N: LLA1-Up
S/N: R1A1-Up
S/N: LLBl-Up
S/N: LLC1-Up
S/N: C8E1-Up 1 28579
S/N: LLE1-Up
S/N: LLF1-Up atmospheric pressure sensor (1).
S/N: SBG1-Up
2. Remove the O-ring seal from the atmospheric
S/N: SBJl-Up Dressure sensor.
SIN: C8K1-Uo
lnstallation Procedu re
S/N: SBK1-Up
NOTICE
S/N: NAMI-Uo Keep all parts clean from contaminants.
S/N: SBMl-Up
S/N: KENl-Up component life.
S/trl: PESl-Up
SiN: RMS1-Up
SIN: F1X1-Up
S/N: F2X1-Up
S/N: T2X1-Up
Rernoval Procedure
NOTICE
Keep all parts clean from contaminants. lllustration 524 901 1 28579
Contaminants may cause rapid wear and shortened t. Install a new O-ring seal on atmospheric pressure
component life. sensor (1).
2. Install atmospheric pressure sensor (1) and

tighten to a torque of 10 t 2 N'm (89 r 18 lb in)

RENR9365_10
;3i
Atmospheric pressur" S"nrfr'

- Remove and tnstaii
SMCS Code: 1923_010
S/N: RlSl-Up
Removal procedure
Keep ar parts crean rffill?ilinants

9^":lll,lql!: r"y cause rapid wear and shortened
component life. lllustration 526
902257 1 33
1. Install a new O_ring seat on atmospheric pressufe

sensor (1).
2. lnstall atmospheric pressure

sensor (1) anO
tishten to a torque or rol-z
rrril A, ! i8 tb in).
Engine Speed Sensor _

Kemove and Instalf
lllustration 525 SMCS Gode: 1907_010
902257133
a n o re m o v
Removal procedure
a t m o s p rrliic p;;;:',i,:'.""?::;
t
v e
|t
2. Remove the O_rinr seal
pressure sensor 3
from the atmospheric Keep al parts crean -Hli:Arinants.
9^":ll'lltl: ,ry cause rapid wear and shortened
lnstaffation procedure component life.
O
Keep alr parrs crean -Hll:i"rinants.
:"Tiil!fti1il'n"t
lllustration 527
901 1 28309
1. Disconnect harness assembly

(1).
2. Loosen the locknut and.remove
engine' speed
sensor (2) from the flTwheef
frousin6.'
194 RENR9365-10
lnstallation Procedure i02241907
NOTICE
Fuel Pressure $ensor -
Keep all parts clean from contaminants. Remove and lsxstall
Contaminants may cause rapid v'rear and shortened SMCS Code: 7414-010
component life.
S/N: LLAI-Up
S/N: R'141-Up
S/N: LLBl-Up
S/N: LLCl-Up
S/N: CBEl-Up
S/N: LLE1-Up
S/N: LLF1-Up
S/N: SBGl-Up
S/N: SBJl-Up
g0'1128261
lllustration 528 S/N: C8K1-Up
1. Install engine speed sensor (2) in the flywheel S/N: SBK1-Up

housing. Turn the engine speed sensor until there S/N: NAMl-Up
is contact with the tooth of the ring gear of flywheel
(3). Turn the engine speed sensor for 112 of a turn S/N: SBMl-Up
away from the ring gear. Tighten the locknut to a
t
torque of 25 5 N'm (18 t 4 lb ft). S/N: KENl-Up
2" Connect harness assembly (1). S/N: PES1-Up

S/N: RMSl-Up
S/N: FlXl-Up
S/N: F2X1-Up
S/N: T2X1-Up
Removal Procedure
NOTICE

products.

mandates.
RENR9365_10

."J:l
Keep ar parts crean -ffill?i"rinants
:"Tfil!ftililttu shortened
1. Turn the fuelshr_rtoff valve

to the OFF position.
lllustration 530
go11z9g7s
1. Install a new O_ri

sensor r r r Appri,HfffJ
?li[-iis ffl#::."l,..
2. Install filtered fuel pressure
sensor (1) and tighten
to a rorque of 10 +'2
N ri funi'ji rt ir,l
lllustration 529 3. Connect the harness assembly.
901-l 2s97s
2. Disconnect h the 4. Install a new O_ringseal

fir;;;j i;;i ;;:Jfli:"J,.3i}?T:,u and remove
sensor (2). Apply Tooting
onûnfiltererJ fuer pressure
(n) to ir.le o_iing ."rt.
3. Remove the O_ring seal from 5. fnstall unfiltered fuel.pressure
pressure the filtered fuel sensor (21 ano
sensor, tishten to a torque i0 U'N rn qbii*,fu ro iny
4. "f
Disconnect the hz 6, Connect the harness
u n riite iu J i,; ft1ff :',:'r-."#ill an d re move assembly
7. Turn the fuel shutoff
u' valve to the ,,ON,, positiorr
I:19y" the
pressLlre
o-ring seat from the unfittered
sensor. fuel
Fuef pressure sensor

io4o4'247
Instaf lation procedure
Table 104 Renrove and lnstiii-'
-
SMCS Gode: 7414_01O
S/N: RlSl-Up
O-Ring Assernbly
uompoUnd Removal procedure
Keep ar parrs clean NOTICE

,r#I::[rinants Care must be taken to
that
rrrot flLrids
rrLrrus are cotltained
during
ctu'no performanc"
nerfnrmo^^^ ^,:l:rr" contained
Côrtaminan!! ,"y cause i;"""'" maintenance, test-
rapid wear and shortened n adiustin n )nA "Î]1*!.".9tion,
lne,
component life 3 ; 3 flii,'i^n;
to__colecr th; ?,?,q^,:
fluid :iI "i;i;ilffit.";
il[h
"
r',
"-p
i" i ili : ", ii ri5 ; i?3 l-
:ff ::lT:y9".p",tij.l,rt""?tl3r'._::.ffi
ponent ,i:'j.,f pj"
ng any com_
containing fluids.
Refer to Special publication,

NENG2S00, ,,Dealer Ser-
Catatog" fo1_t3ots
:::iI"_"t
colect and contain g* .ropds.suitabte to
fluids on C"t proil"i"
ftuids according to tocat
R5ffiill"il regutatiorrs and
196 RENR9365-10
NOTICE

component life.
f . Turn the fuel shutoff valve to the OFF position.
lllustration 532 s02257253
t. Install a new O-ring seal on filtered fuel pressure

sensor (2). Apply Tooling (A) to the O-rin1u seat
2. Installfiltered fuel pressure sensor (2) and tighten

f
to a torque of 1012 N'm (Bg t 1B lb in).
3. Counect the harness assembly.

4. Install a new O-ring seal on unfiltered fuel pressure

2. Disconnect the harness assembly and remove sensor (1). Apply Tooling (A) to the O-ring seal.
filtered fuel pressure sensor (2).
5. Install unfiltered fuel pressure sensor (1) and
3. Remove the O-ring seal from the filtered fuel t t
tighten to a torque of 10 2 N.m (89 1B lb in).
DTESSUTC SENSOT.
unfiltered fuel pressure sensor (1). 7. Turn the fuel shutoff valve to the "ON" position.
5. Remove the O-ring sealfrom the unfiltered fuel

oressure sensor.
Table 105
Required Tools
O-Ring Assembly
1U-6396
Compound
NOTICE

component life.
RENR9365_10
46-t
IJI
lndex Section
Auxiliary Water pump _

Remove
Removal procedure.... 75
.
75
127
127
145
r4c
144
144
131
131
xemoval procedure 130

198 RENR9365-10
lndex Section
Cylinder Head - 1nsta1,.......... 109 Engine Oil Pressure Sensor - Remove and
Installation P rocedure 109 Install......... ......... 1BO--1B1
Cylinder Head - Remove 108 Installation Procedure 181-182
Removal Procedure 108 Removal Procedure 180-181
Cylinder Liner - Install.......... '150 Engine Oil Pump - Assentble. ............. 87
nstallation Procedu re
i 150 Assembly Procedure... .................... 87
Cylinder Liner - Remove,..,.. 150 Engine Oil Pump - Disassemble................ ....,... .. 87
Removal Procedure 150 Disassembly Procedure ............,..... 87
Engine Oil Pump - Install ..... . 88
lnstallation Procedure .,.,... BB
U Engine Oil Pump - Remove ... . 86
Removal Procedure . ......, . 86
Disassembiy and Assemlrly Section.. ................... .. 5 Engine Oil Sequence Valves - Remove and
lnstall,......,. ..................... 136
Installation Procedure .... '137
Removal Procedure .... 136
Engine Speed Sensor - flemo'ye and lnstall.., .... 193
Hectric Stafting ltlotor - Renrove and Install,........ 19 lnstallation Procedure ..... ..... ...... l94.
lnstallation Procedure ,...,.............. 19 1O
Removal Procedure .... 19 .,'Ti,#HL:[iffli1fs;;;;;. R;,iiooo"nr
Electronic Control MoCule (Engine) - Remr.rve and Install......... ...............,. 190
Install......... 25'-26 Installation Procedure ................., 190
Installation Procedure 25^2.6 Removal Procedr,rre .......... '190
Removal Procedure 2-5-26 Flxhaust Bypass Valve - Removc and Install........ 6B
Electronic Unit Injector - Install ........ 107 Installation Procedure ...., tig
Installation Procedure .................. 107 Removal Procedure ...................,....68
Lllectronic Unit Injector - Renrove .... 106 f:xfraust Elbow - Remotre and lnstall........ 59, 61-62
Remcval Procedure ... 106 Installation Procedure 60-62
Engine Oil Cooler - Assemble ........... 84 Removal Procedure 59, 61-62
Assembly Procedure... ,.................. 84 Exlraust Manifold - Remove and Instail..... 63. 65. 67
Engine Oil Cooler - Disassemb1e..,........................ B3 Installation Procedure ......... 64,66-67
Disassembly Procedure ................. B3 Removal Procedure 63. 65. 67
Engine Oil Cooler - Install........ .................. 85
lnstallation Procedure .................... 85
Engine Oil Cooler - Remove.... .......... 82 F
Removal Procedure .... B2
Engine Oil Filter Base - Assemb|e......................... 95 Fan Drive - Assemble 75
Assembly Procedure... ................... 95 Assembly Procedure... 75
Engine Oil Filter Base - Disassemb|e.................... 95 Fan Drive - Disassemble ..,............. ,-
Disassembly Procedure ................. 95 Disassembly Procedure
Engine Oil Filter Base - Install .............................. 96 Fan Drive - lnstall 76
Installation Procedure ...... 96 Installation Procedure /o
Engine Oil Filter Base - Rernove ....... 94 Fan Drive - Remove 71
Removal Procedure .... 94 Removal Procedure tl
Engine Oil Filter Housing - Assemble...,..............,. 92 Flywheel - Rernove and Install ......... 129
Assembly Procedure.. .................... 92 Installation Procedure ...............,... '129
Engine Oil Filter Housing - Disassemble............... 91 Removal Procedure ...................... 129
Disassembly Procedure ................. 91 Flywheel Housing - Install... ........,.... 134
Engine Oil Filter Housing - lnstall ....... 93 Installation Procedure ................... 134
Installation Procedure ...... 93 Flywheel Housing - Remove.... ....,.... 132
Engine Oil Filter Housing - Remove...............,...... Bg Removal Procedure .., 132
Removal Procedure .... Bg Fuel Cooler - Remove and Install ...... 37
Engine Oil Pan - Assemble. ............... 98 Installation Procedure .........,...........38
Assembly Procedure... ...,......,...,.,.. 98 Removal Procedure ........... 37
Engine Oil Pan - Disassemb|e............................... 97 Fuel Filter Housing - Install....... .......... 29
Disassembly Procedure ................. 97 lnstallation Procedure .........,..............29
Engine Oil Pan - Install ......... 99 Fuel Filter Housing - Install (Spin-on Filters)......... 30
Installation Procedure ...,................ 99 Installation Procedure ....,.....,.......30
Engine Oil Pan - Remove .................. 96 Fuel Filter Housing - Remove ..... ..... 27
Removal Procedure ....... 96 Removal Procedure .... ................... 27
Fuel Filter Housing - Remove (Spin-on Filter). ... 28
Removal Procedure ................... 28
RENR9365_1 0
1qo
lndex Section
r\crrovar Hrocedure vs " ".................. 33

...
OJ
o?:l,9foyp (Rear) - Instarl

tnstallation procedure 139
^ Group-f
Gear neiill [j;ou;
..
rJv
xemoval procedure..... 139
.
139
liousing (Front) _ Instail

tnstallation procedure tzo
,
Horsing (Front) I nlrouu. tzo
xemoval procedure.. .
tzo
125
I lnstallation procuoi:l . '............. 11s

, .Removal pd;;;:i" . 116
Inlet and Exhaust " - "" "' ...115
%i
Install........ ......
ve springs _ Remove
and
111
111
111
- Remove anO nstafi....
f
ttz
113
112
V
P
- Remove and Install....

102
140
102
141
r_';""
""" '. 102
140 Base _ Remove ano
148 102
148
102
147
102
147 ve and Install.. .... 127
..'....'..' tzt
127

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DATERPII.

lmportant Safety Information

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Failure to heed this warning can lead to prema-

Table of Contents Auxitiary Water puAp _ Install ........ ...........

Crankshaft Fronl Seal and Wear 127

Flywheet- nemove anJ in.l"li -.. I zo

Disassem bly and Assembfy Removal of an Air Starting Motor

SMCS Code: 1451_011

S/N: SBMl-Up 2. Disconnect hose assemblies (1).

S/N: KENl-Up 3. Remove bolts (2).

Keep al parts crean t Jr?*?ilinants.

ir starting motors are 5. Disconnect hose assembly (5).

7. Remove bolts (7). Remove

Removal of an Air Starting Motor With i02558 383

the Air Tube Assemblies Attached Air Starting Motor -

lllustration 3 901 049692 S/N: SBJl-Up

lllustration 4 901 049697

5. Remove bolts (10) and air starting motor (11). Plate

Keep al parts crean t Hll?irrinants

Note:.Several different air starting

t remove retainins nng (8) rrom

t (1) and bracket (2) from motor

f_"_r:gnll injury can result from parts and/or

Spring force will be refeased when

lllustration 6 go092So12 Be.prepared to hold spring loaded

embly, mark the position

7. Slowly release the suitable press in order to

5. Remove O-ring seal (13) from drive housing (5).

10. Remove retainino (20) from piston (14)

JS-Tiii.i-rins Note: Note: Do not reuse retaining

14. Use Tooting (C) to

Spring force will be released

Be.orepared to hold spring loaded

15. Remove spring seat (36)

f 7.To ensure correct assembly, mark the position lllustration 24 9009251 51

of cover (39) in relation to motor housing (3).

21. Remove vanes (47) from rotor (48).

24, Remove bearing (49) 27. Remove rotor cvlinder (S3)-from

25. Remove washers (S1)

Required Tools 90092521 6

F 25 - 3230 Bearing Lubricant

3. Install rear end plate (45) on the shaft of rotor (48).

4' Instalr o-ring sear (46) over

5. Apply Toolinq (F) to bearin g (44).Instatl lllustration 37

O 7. Tighten rotor ctamp

;!"ff.::?^"j9# 1""9 gP^'-i'ron6i to"ffis incrr)

f 2.Apply Tooling (F)to bearing (49) Use Tooling (E)

f 5.Apply Tooling (F)to bearing (33) Install bearing

lmproper assembly of parts that are spring loaded

To prevent possible injury, follow the established

16.Install retaining ring (31). Install bolt (23),

sear (21) into piston

19. Install O-ring seals lllustration 50

513,H11".?'lkhead 22.,Appty Tooting (F) to bearinq (37)

23.lnstall spring seat (36) into the

27" Apply Tooling (F) to bearing (34) and install

To prevent possible injury, follow the established

24.Install return spring (16) onto the spring seat

25.Install the drive gear, the piston, and the drive

Install retaining ring (15) over the piston. Place