C9 Disassembly Assembly

RENR8633-02
January 2013
Disassembly and Assembly

C9 Petroleum Engines
P9L 1-Up (Engine)
KLW 1-Up (Engine)
P7Z 1-Up (Engine)
SAFETY.CAT.COM
i05086812
Important Safety Information

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

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

product Caterpillar recommends using Cat re-
placement parts 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.
RENR8633 3
Table of Contents
Table of Contents Aftercooler - Install..................... ..................... 54

Flywheel - Remove and Install............ ............ 55
Disassembly and Assembly Section Crankshaft Rear Seal - Remove........... .......... 56
Crankshaft Rear Seal - Install............. ............ 57
Fuel Priming Pump - Remove and Install ..... .... 5 Flywheel Housing - Remove and Install ..... .... 57
Fuel Filter Base - Remove and Install........ ....... 6 Vibration Damper and Pulley - Remove and
Electronic Unit Injector - Remove ........... .......... 8 Install............................... .............................. 58
Electronic Unit Injector - Install ............. ............ 9 Crankshaft Front Seal - Remove .......... .......... 59
Electronic Unit Injector Sleeve - Remove .... ....11 Crankshaft Front Seal - Install ............ ............ 60
Electronic Unit Injector Sleeve - Install ...... ..... 12 Front Cover - Remove and Install.......... ......... 60
Unit Injector Hydraulic Pump - Remove..... ..... 12 Gear Group (Front) - Remove ............ ............ 61
Unit Injector Hydraulic Pump - Install....... ....... 13 Gear Group (Front) - Install............... .............. 62
Turbocharger - Remove................. ................. 14 Housing (Front) - Remove ............... ............... 63
Turbocharger - Remove................. ................. 15 Housing (Front) - Install ................. ................. 64
Turbocharger - Install................... ................... 15 Crankcase Breather - Remove and Install... ... 65
Turbocharger - Install................... ................... 16 Cylinder Block Cover - Remove and Install .. .. 66
Air Lines - Remove and Install............ ............ 17 Valve Mechanism Cover - Remove and Install 67
Exhaust Manifold - Remove and Install ..... ..... 18 Valve Mechanism Cover Base - Remove and
Exhaust Manifold - Remove and Install ..... ..... 19 Install............................... .............................. 68
Air Inlet Heater - Remove ................ ............... 20 Rocker Arm and Shaft - Remove.......... .......... 69
Air Inlet Heater - Install .................. ................. 21 Rocker Arm - Disassemble............... .............. 70
Inlet and Exhaust Valve Springs - Remove and Rocker Arm - Assemble................. ................. 70
Install............................... .............................. 22 Rocker Arm and Shaft - Install............ ............ 71
Inlet and Exhaust Valves - Remove and Install 24 Cylinder Head - Remove ................ ................ 72
Inlet and Exhaust Valve Guides - Remove and Cylinder Head - Install .................. .................. 73
Install............................... .............................. 25 Lifter Group - Remove and Install.......... ......... 75
Inlet and Exhaust Valve Seat Inserts - Remove Camshaft - Remove.................... .................... 76
and Install........................... ........................... 26 Camshaft - Install...................... ...................... 77
Engine Oil Filter Base and Oil Cooler - Camshaft Gear - Remove and Install ....... ...... 78
Remove ............................ ............................ 27 Camshaft Bearings - Remove ............ ............ 78
Engine Oil Filter Base and Oil Cooler - Install. 28 Camshaft Bearings - Install............... .............. 79
Engine Oil Pump - Remove .............. .............. 29 Engine Oil Pan - Remove and Install....... ....... 80
Engine Oil Pump - Disassemble........... .......... 31 Cylinder Liner - Remove ................. ................ 82
Engine Oil Pump - Assemble............. ............. 32 Cylinder Liner - Install ................... .................. 82
Engine Oil Pump - Install ................ ................ 33 Piston Cooling Jets - Remove and Install.... ... 83
Water Pump - Remove .................. ................. 34 Pistons and Connecting Rods - Remove.... .... 83
Water Pump - Disassemble.............. .............. 35 Pistons and Connecting Rods - Disassemble 84
Water Pump - Assemble................. ................ 35 Pistons and Connecting Rods - Assemble ... .. 85
Water Pump - Install .................... ................... 36 Pistons and Connecting Rods - Install...... ...... 86
Water Temperature Regulator - Remove and Connecting Rod Bearings - Remove ....... ....... 88
Install............................... .............................. 37 Connecting Rod Bearings - Install ......... ......... 88
Water Temperature Regulator - Remove and Crankshaft Main Bearings - Remove....... ....... 89
Install............................... .............................. 39 Crankshaft Main Bearings - Install......... ......... 90
Auxiliary Water Pump - Remove........... .......... 41 Crankshaft - Remove................... ................... 91
Auxiliary Water Pump - Disassemble ....... ...... 42 Crankshaft - Install..................... ..................... 91
Auxiliary Water Pump - Disassemble (Type 2) 43 Bearing Clearance - Check .............. .............. 92
Auxiliary Water Pump - Assemble ......... ......... 47 Atmospheric Pressure Sensor - Remove and
Auxiliary Water Pump - Assemble (Type 2) .. . 49 Install............................... .............................. 93
Auxiliary Water Pump - Install............. ............ 53 Atmospheric Pressure Sensor - Remove and
Aftercooler - Remove................... ................... 53 Install............................... .............................. 94
4 RENR8633
Table of Contents
Coolant Temperature Sensor - Remove and

Install............................... .............................. 95
Install............................... .............................. 96
Engine Oil Pressure Sensor - Remove and
Install............................... .............................. 97
Engine Oil Pressure Sensor - Remove and
Install............................... .............................. 98
Fuel Pressure Sensor - Remove and Install.. . 99
Fuel Pressure Sensor - Remove and Install. 100
Injection Actuation Pressure Sensor - Remove
and Install.......................... .......................... 101
Injection Actuation Pressure Sensor - Remove
and Install.......................... .......................... 102
Speed/Timing Sensor - Remove and Install . 103
Speed/Timing Sensor - Remove and Install . 105
Turbocharger Outlet Pressure Sensor - Remove
and Install.......................... .......................... 106
Turbocharger Outlet Pressure Sensor - Remove
and Install.......................... .......................... 107
Inlet Air Temperature Sensor - Remove and
Install.............................. ............................. 108
Inlet Air Temperature Sensor - Remove and
Install.............................. ............................. 109
Fan Drive Mounting Group - Remove and
Install.............................. ..............................110
Fan Drive - Remove.................... ...................110
Fan Drive - Disassemble ............... ................ 111
Fan Drive - Assemble .................. ..................112
Fan Drive - Install...................... .....................113
Pump Drive - Remove ................. ..................114
Pump Drive - Install ................... ....................114
Electronic Control Module - Remove and
Install.............................. ..............................115
Alternator - Remove and Install .......... ...........116
Electric Starting Motor - Remove and Install .117
Air Compressor - Remove and Install...... ......118
Index Section
Index............................... .............................. 121

RENR8633 5
Disassembly and Assembly Section
Disassembly and Assembly

Section
i02538070
Fuel Priming Pump - Remove

and Install
SMCS Code: 1258-010
Removal Procedure
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product. Be
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling
any component containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
Illustration 1 g01270491
NOTICE 1. Remove bolts (3) and the washers.

Keep all parts clean from contaminants.
2. Remove fuel priming pump (2) and the gasket from
Contaminants may cause rapid wear and shortened fuel filter base (1).
component life.
Installation Procedure
NOTICE
Contaminants may cause rapid wear and shortened
component life.
6 RENR8633
NOTICE
products.
mandates.
1. Position the gasket and fuel priming pump (2) on

fuel filter base (1).
2. Install bolts (3) and the washers.
3. Purge the air from the fuel system.
i02538087
Fuel Filter Base - Remove and

Install
SMCS Code: 1262-010
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 185-3630 Strap Wrench Assembly 1
NOTICE
component life.
RENR8633 7
Illustration 3 g01167050 Illustration 5 g01270505
1. Use Tooling (A) to remove fuel filter (2). 1. Position fuel filter base (1) on the bracket. Install
bolts (6) and the washers.
2. Disconnect hose assemblies (4) and (5) from fuel
filter base (1). Immediately cap all openings or plug 2. Connect hose assemblies (4) and (5) to fuel filter
all openings in order to prevent contamination. base (1).
3. Disconnect fuel sensor (3) from fuel filter base (1). 3. Connect fuel sensor (3) to the fuel filter base.
4. Remove bolts (6) and the washers from fuel filter 4. Install fuel filter (2). Refer to the Operation and
base (1). Remove fuel filter base (1) from the Maintenance Manual, “Fuel System Secondary
bracket. Filter - Replace” topic for more information.
Installation Procedure 5. Prime the fuel system. Refer to the Operation and
Maintenance Manual, “Fuel System - Prime” topic
for more information.
8 RENR8633
i04893121
Electronic Unit Injector -

Remove
SMCS Code: 1290-011
Removal Procedure
Table 2
Required Tools
Fuel Injector Installer and

A 367-3070 2
Removal Tooling
Start By:
Remove the valve mechanism cover. Refer to
Disassembly and Assembly, “Valve
Mechanism Cover - Remove and Install”.
NOTICE
Care must be taken to ensure that fluids are con- 2. Use a small flat head screwdriver to disconnect
tained during performance of inspection, mainte- harness assembly (2) from electronic unit injector
nance, testing, adjusting, and repair of the product.
(1).
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
3. Remove socket head bolts (3).
bling any component containing fluids.
Refer to Special Publication, NENG2500, “Dealer
Service Tool Catalog” for tools and supplies suitable
to collect and contain fluids on Cat products.
mandates.
NOTICE
component life.
1. Remove the plug at the rear of the cylinder head.

Allow the engine oil to drain from the hole in the Illustration 8 g03031916
cylinder head before the electronic unit injector is

removed. 4. Use Tooling (A) to remove electronic unit injector
(1) from the cylinder head.
Note: Do not use a wire brush on the tip of the

electronic unit injector. Damage to the electronic unit
injector will occur.
RENR8633 9
(Table 3, contd)
J 4C-6161 Tube Brush 1
K 9U-6862 Tapered Brush 1
L 4C-6774 Vacuum Gun Kit 1
M 4C-5027 Tap Wrench 1
NOTICE
component life.
1. Evacuate as much fuel and oil as possible from the

cylinder head before installing the electronic unit
injector. Several evacuations may be necessary.
Use Tooling (G) to remove the fuel and oil from the
cylinder head.
Note: Tooling (L) is available to clean loose material

from the sleeve bore and the cylinder.
2. Inspect the electronic unit injector sleeve for

damage and carbon deposits.
3. Clean the carbon from the sleeve, the sleeve bore,

Illustration 9 g01137291 and the end of the electronic unit injector, if the
electronic unit injector is being reused. Clean the
5. Remove O-ring seals (6), (7), and (8) from carbon from the seat area that is inside of the
electronic unit injector (1). Remove backup rings cylinder head. A fine grade of Scotch Brite
(4), (5), and (9) from electronic unit injector (1). material is preferred. Use Tooling (H) to clean the
bore of the electronic unit injector tip. Use the
i04892357 Surface Reconditioning Pad in order to clean the
carbon in the cylinder head. Use Tooling (J) in
Electronic Unit Injector - Install order to remove the carbon from the surface of the
SMCS Code: 1290-012 sleeve.
Note: Using power tools in order to rotate the material

Installation Procedure should not be necessary. The carbon in the sleeve is
Table 3 more removable than the carbon at locations that are
exposed to higher temperatures.
Required Tools
Tool Part Number Part Description Qty The following procedure is the preferred method of
cleaning the sleeve bore.
A 367-3070 Fuel Injector Installer As 2
Place a 38 mm (1.5 inch) square piece of Scotch
E 149-2955 Seal Protector 1 Brite material on the end of Tooling (K). Twist
F 149-2956 Seal Installer 1 Tooling (K) with Tooling (M) against the lower
surface of the sleeve bore.
1U-5718 Vacuum Pump 1
The surface should be cleaned until the surface is
169-7372 Bottle Assembly 1 smooth and shiny. The entire sleeve bore should
be cleaned in order to remove any loose carbon
G Clear Plastic Tubing particles.
4C-4057 1
7.92 mm (0.312 inch) OD
Clear Plastic Tubing Note: Tooling (J) is available to clean loose material
4C-4055
6.35 mm (0.250 inch) OD
1 from the sleeve bore and the cylinder.
H 9U-5470 Reamer 1
(continued)
10 RENR8633
8. Lubricate the O-ring seals and the backup rings on

NOTICE
electronic unit injector (1) with clean engine oil
The correct procedures and tooling specifications
must always be used. Failure to follow any of the pro- before installation.
cedures may result in damage, malfunction, or possi-
ble engine failure. Note: Proper installation of the electronic unit injector
is important. Damage to the upper high-pressure
seals can cause excessive oil leakage under the
Note: New seals should be installed after each valve cover. This may cause the engine not to start
removal of the electronic unit injector from the engine. due to a low actuation pressure. Damage to the lower
To order O-ring seals for the electronic unit injector, high-pressure seals may allow high-pressure oil to
refer to the Parts Manual. leak into the fuel supply passage. This will result in
excessive oil consumption.
NOTICE
The O-ring seals and the backup rings must be in- Note: Do not hit or strike the electronic unit injector
stalled in the correct orientation. Damaged seals will during installation. Do not use a wire brush to clean
result in excessive oil consumption or excessive leak- the tip of the electronic unit injector. Damage to the
age under the valve cover. Use care to prevent nicks electronic unit injector will occur.
or damage to the seals. 9. When you install a new electronic unit injector the
E-Trim value must be programmed into the
Electronic Control Module. The E-Trim value is a
six digit alphanumeric code that is supplied with
the data sheet that comes with the new electronic
unit injectors. Use the following menu to program
the E-Trim value.
• ECM Summary Screen
• Service Menu
• Calibration
• Injector Code Calibration
4. Lubricate O-ring seals (6), (7), and (8) and the 10. Use Tooling (A) to install electronic unit injector (1)
sleeve bore of the electronic unit injector sparingly in the cylinder head.
with clean engine oil.
5. Use Tooling (E) and Tooling (F) to install the

backup rings (4) and (5) first. Install O-ring seal (6).
6. Use Tooling (E) and Tooling (F) to install backup

ring (9). Install O-ring seal (8).
7. Install O-ring seal (7).

RENR8633 11
Start By:
Remove the electronic unit injectors. Refer to
Disassembly and Assembly, “Electronic Unit
Injector - Remove”.
NOTICE
products.
mandates.
Illustration 12 g01148880 NOTICE

11. Install socket head bolt (3) on the exhaust side of
the bracket. Tighten the exhaust side of socket Contaminants may cause rapid wear and shortened
head bolt (3) until the bolt is seated. Tighten the component life.
inlet side of socket head bolt (3) to a torque of
12 ± 1 N·m (106 ± 9 lb in) . 1. Position Tooling (C) at the bottom of the electronic
unit injector sleeve. This will prevent debris from
12. Connect harness assembly (2) to electronic unit entering the cylinder during the removal of the
injector (1). electronic unit injector sleeve.
13. Install the plug at the rear of the cylinder head. 2. Coat the plug tap in Tooling (A) with clean grease.
End By: Use Tooling (A) to cut threads into electronic unit
injector sleeve (1).
Install the valve mechanism cover. Refer to
i02878003
Electronic Unit Injector Sleeve

- Remove
SMCS Code: 1713-011
Removal Procedure
Table 4
Required Tools
1P-3042 Plug Tap 1

A
221-0052 Guide Sleeve 1
9U-6858 Bridge Plate 1

B
9U-6891 Injector Tool Group 1
C 221-9803 Rubber Stopper 1
D 4C-6774 Vacuum Gun Kit 1 3. Install Tooling (B) in electronic unit injector sleeve
(1).
12 RENR8633
3. Apply a thin coating of Tooling (G) around the outer

4. Use Tooling (B) to remove the electronic unit circumference of electronic unit injector sleeve (1)
injector sleeve. at Area (X).
5. Remove Tooling (B) and Tooling (C) from electronic 4. Place electronic unit injector sleeve (1) on Tooling
unit injector sleeve (1). (E).
Note: Do not reuse the electronic unit injector sleeve. 5. Position the electronic unit injector sleeve in the
cylinder head. Use a hammer and Tooling (E) to
6. Use Tooling (D) to remove any debris from the bore install the electronic unit injector sleeve in the
for the electronic unit injector sleeve. cylinder head.
i02878055 Note: Allow Tooling (G) to cure for two hours at 21 °C

(70 °F) before filling the engine with fuel or coolant.
Electronic Unit Injector Sleeve Longer curing time is required for lower temperatures.
- Install End By:

SMCS Code: 1713-012 Install the electronic unit injectors. Refer to
Installation Procedure Injector - Install”.
Table 5
Required Tools i01991043
Tool Part Number Part Description Qty Unit Injector Hydraulic Pump -
E 221-9777 Sleeve Installer 1 Remove
F 4C-5552 Large Bore Brush 1 SMCS Code: 1714-011
G 4C-9507 Retaining Compound -
Removal Procedure
NOTICE NOTICE
Keep all parts clean from contaminants. Care must be taken to ensure that fluids are con-
Contaminants may cause rapid wear and shortened nance, testing, adjusting and repair of the product. Be
component life. prepared to collect the fluid with suitable containers
1. Use Tooling (F) to clean the bore for the electronic any component containing fluids.
unit injector sleeve. Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and sup-
plies suitable to collect and contain fluids on Caterpil-
lar products.
mandates.
NOTICE
component life.
2. Install new O-ring seals (2) on the new electronic

unit injector sleeve (1). Lubricate the O-ring seals
with clean engine oil.
RENR8633 13
1. Remove tube assembly (3) and tube assembly (6). 5. Remove O-ring seal (8) from unit injector hydraulic
pump (1).
2. Remove tube assembly (4) and tube assembly (5).
i04941691
3. Disconnect harness assembly (2) from unit injector
hydraulic pump (1).
Unit Injector Hydraulic Pump -
Install
SMCS Code: 1714-012
Table 6
Required Tools
Loctite 243 Threadlocker Med.

A 9S-3263 or -(1) -
Strength
(1) EAME
NOTICE
4. Support unit injector hydraulic pump (1) by hand Contaminants may cause rapid wear and shortened
and remove bolts (7) through the front housing. component life.
Remove the unit injector hydraulic pump.
14 RENR8633
5. Prime the fuel system. Refer to Operation and

Maintenance Manual, “Fuel System - Prime”.
i02538337
Turbocharger - Remove
SMCS Code: 1052-011
S/N: KLW1–Up
S/N: P7Z1–Up
Removal Procedure
1. Install O-ring seal (8) onto unit injector hydraulic Contaminants may cause rapid wear and shortened
pump (1). component life.
NOTICE
products.
mandates.
2. Position unit injector hydraulic pump (1) and install

bolts (7) through the front housing.
3. Apply Tooling (A) to the threads of tube assemblies

(3), (6), (4), and (5) and install the tube assemblies. Illustration 21 g01270689
4. Connect harness assembly (2).

1. Disconnect hose assembly (2).
RENR8633 15
2. Remove bolts (5) and tube assembly (4).
3. Attach a suitable lifting device onto turbocharger

(1). The weight of turbocharger (1) is
approximately 27 kg (60 lb). Remove nuts (3).
Remove turbocharger (1) and the gasket.
i02898089
Turbocharger - Remove
SMCS Code: 1052-011
S/N: P9L1–Up
S/N: P7Z1–Up
Removal Procedure
NOTICE
Contaminants may cause rapid wear and shortened Illustration 22 g01443159
component life.
2. Loosen hose clamp (2) and disconnect hose (3).
NOTICE 3. Remove tube assembly (1).

tained during performance of inspection, mainte- 4. Remove the bolts and hose assembly (7).
prepared to collect the fluid with suitable containers 5. Disconnect hose assembly (6).
any component containing fluids. 6. Disconnect the bolts and tube assembly (8).
Refer to Special Publication, NENG2500, “Caterpillar 7. Attach a suitable lifting device onto turbocharger
Dealer Service Tool Catalog” for tools and supplies (4). The weight of turbocharger (4) is
suitable to collect and contain fluids on Caterpillar approximately 23 kg (50 lb). Remove nuts (5).
products. Remove turbocharger (4) and the gasket.
mandates. 8. If necessary, remove the studs for the
turbocharger.
1. Drain the coolant from the cooling system to a level

i04000980
below the turbocharger into a suitable container for
storage or disposal. Refer to Operation and Turbocharger - Install
Maintenance Manual, “Cooling System Coolant -
Change”. SMCS Code: 1052-012
S/N: P9L1–Up
S/N: P7Z1–Up
Table 7
Required Tools
A 5P-3931 Anti-Seize Compound -

16 RENR8633
i04000979
NOTICE
Turbocharger - Install
Contaminants may cause rapid wear and shortened SMCS Code: 1052-012
component life.
S/N: KLW1–Up
1. If necessary, install the studs for the turbocharger. S/N: P7Z1–Up
Tighten the studs to a torque of 35 ± 5 N·m
(26 ± 4 lb ft). Installation Procedure
Table 8
Required Tools
A 5P-3931 Anti-Seize Compound -
NOTICE
component life.
1. Apply Tooling (A) to the turbocharger mounting

studs on the exhaust manifold.
2. Attach a suitable lifting device to turbocharger (4).

The weight of turbocharger (4) is approximately
23 kg (50 lb). Position the gasket and
turbocharger (4) on the exhaust manifold.
Note: Discard the nuts after use. Use new nuts for
installation.
3. Apply Tooling (A) to the threads of nuts (5). Install
nuts (5). Tighten nuts (5) to a torque of 54 ± 5 N·m
(40 ± 4 lb ft).
4. Position tube assembly (8) and install the bolts.
5. Connect hose assembly (6). Illustration 24 g01270689
6. Position hose assembly (7) and install the bolts. 2. Attach a suitable lifting device to turbocharger (1).
The weight of turbocharger (1) is approximately
7. Install tube assembly (1).
27 kg (60 lb). Position the gasket and
8. Connect hose (3) and tighten hose clamp (2). turbocharger (1) on the exhaust manifold.
9. Fill the cooling system with coolant. Refer to

Operation and Maintenance Manual, “Cooling installation.
System Coolant - Change”. 3. Install nuts (3). Tighten nuts (3) to a torque of
54 ± 5 N·m (40 ± 4 lb ft).
4. Position tube assembly (4) and install bolts (5).

RENR8633 17
5. Connect hose assembly (2). Table 9
Required Tools
i02900541
Part
Part Description Qty
Air Lines - Remove and Install Tool Number
A 5P-3975 Rubber Lubricant -
SMCS Code: 1071-010
S/N: P9L1–Up
NOTICE
S/N: P7Z1–Up Keep all parts clean from contaminants.
Removal Procedure component life.
NOTICE
component life.
1. Install the bracket assembly and nuts (4), if

necessary.
Illustration 25 g01444013 2. Install the O-ring seals on tube assembly (8). Apply
Tooling (A) to the O-ring seals.
1. Remove bolts (10) and retainers (9).
3. Install hose (7) on tube (3) and tube assembly (8).
2. Loosen hose clamps (1). Slide hose (2) onto tube Tighten hose clamps (6).
(3).
4. Install the air lines group, clips (5), and the bolts.
3. Remove the bolts, clips (5), and the air lines group.
5. Slide hose (2) into position. Tighten hose clamps
4. Loosen hose clamps (6). Remove hose (7) from (1).
tube (3) and tube assembly (8).
6. Install retainers (9) and bolts (10).
5. Remove the O-ring seals from tube assembly (8).
6. Remove nuts (4) and the bracket assembly, if

necessary.
18 RENR8633
i04000972 Installation Procedure

Exhaust Manifold - Remove NOTICE
and Install
SMCS Code: 1059-010 Contaminants may cause rapid wear and shortened
component life.
S/N: KLW1–Up
S/N: P7Z1–Up
Removal Procedure
Start By:
Remove the turbocharger. Refer to Disassembly
and Assembly, “Turbocharger - Remove”.
NOTICE
component life.
Typical Example
1. Check the condition of studs (1). Replace studs (1),

if necessary.
Typical Example
1. Remove nuts (2), the washers, and the spacers

from studs (1).
2. Remove the exhaust manifold assembly and the

gaskets from the cylinder head assembly.
3. Disassemble the exhaust manifold assembly into

three pieces (3), (4), and (5).
Typical Example
installation.
RENR8633 19
2. Install the new gaskets with the tabs upward.

Assemble three pieces (3), (4), and (5) into the
exhaust manifold assembly. Position the gaskets
and the exhaust manifold assembly on the cylinder
head assembly. Install the spacers, the washers,
and nuts (2).
3. Tighten nuts (2) to a torque of 55 ± 10 N·m

(41 ± 7 lb ft).
End By:
Install the turbocharger. Refer to Disassembly
and Assembly, “Turbocharger - Install”.
i02898234
Exhaust Manifold - Remove

and Install
SMCS Code: 1059-010
S/N: P9L1–Up
S/N: P7Z1–Up 2. Disconnect hose assembly (1) and hose
assemblies (4) from exhaust manifold (2).
Removal Procedure
Table 10 3. Remove hose assembly (5), hose assembly (6),
hose assembly (7), and hose assembly (8) from
Required Tools
the engine.
4. Install Tooling (A) and a suitable lifting device on
A 138-7573 Link Bracket 1
exhaust manifold (2). The weight of exhaust
manifold (2) is approximately 30 kg (66 lb).
Start By:
5. Remove bolts (3) and remove exhaust manifold (2)
Remove the turbocharger. Refer to Disassembly from the cylinder head.
and Assembly, “Turbocharger - Remove”.
6. Remove the exhaust manifold gasket from the
NOTICE cylinder head.
component life. Table 11
Required Tools
1. Drain the coolant from the cooling system into a Tool Part Number Part Description Qty
suitable container for storage or disposal. Refer to
Operation and Maintenance Manual, “Cooling
System Coolant - Change”. Guide Stud
B - 2
(M10 x 1.50 x 200 mm)
NOTICE
component life.
20 RENR8633
3. Install Tooling (A) and a suitable lifting device on

exhaust manifold (2). The weight of exhaust
manifold (2) is approximately 30 kg (66 lb).
4. Install exhaust manifold (2) on Tooling (B). Install

bolts (3). Tighten the bolts finger tight. Remove
Tooling (A) and Tooling (B) and install remaining
bolts (3). Tighten the bolts by using the following
procedure:
Note: The bolts that are Marked “X” are 200 mm
(7.9 inch) long. The rest of the bolts are 170 mm
(6.7 inch) long.
a. Tighten Bolt (1) through Bolt (16) in a

numerical sequence. Tighten the bolts to a
torque of 4 ± 1 N·m (35 ± 9 lb in).
b. Tighten Bolt (1) through Bolt (16) in a

numerical sequence to a torque of 55 ± 5 N·m
Illustration 31 g01443509 (41 ± 4 lb ft).
c. Tighten Bolt (1) through Bolt (16) again in a

numerical sequence to a torque of 55 ± 5 N·m
(41 ± 4 lb ft).
5. Install hose assembly (8), hose assembly (7), hose

assembly (6), and hose assembly (5) on the
engine.
6. Connect hose assemblies (4) and hose assembly

(1) to exhaust manifold (2).
7. Fill the cooling system with coolant. Refer to

System Coolant - Change”.
End By:
Install the turbocharger. Refer to Disassembly
and Assembly, “Turbocharger - Install”.
i02878379
Illustration 32 g01443332 Air Inlet Heater - Remove

SMCS Code: 1090-011
S/N: KLW1–Up
S/N: P7Z1–Up
Removal Procedure
NOTICE
1. Install Tooling (B) in the cylinder head. Install component life.
Tooling (B) at Locations (Y).
2. Install the exhaust manifold gasket on Tooling (B) 1. Turn the disconnect switch to the OFF position.
and the cylinder head.
RENR8633 21
i02908772
Air Inlet Heater - Install

SMCS Code: 1090-012
S/N: KLW1–Up
S/N: P7Z1–Up
Table 12
Required Tools
A 4C-9500 Quick Cure Primer 1

B 8C-8422 Sealant 1
NOTICE
component life.
2. Disconnect cable assembly (2).
3. Disconnect harness assembly (1).
4. Remove nut (4) and disconnect ground strap (3).
5. Remove bolts (5) and remove air inlet elbow (6).
1. Clean the face of air inlet heater (7) with cleaning

solvent. Apply Tooling (A) to the face of air inlet
heater (7). Allow Tooling (A) to dry for 3 to 5
minutes. Apply Tooling (B) to the joint face and
spread uniformly. Air inlet heater (7) must be
6. Remove air inlet heater (7). installed and tightened within 10 minutes.
22 RENR8633
Start By:
Remove the rocker arm and shaft. Refer to
Disassembly and Assembly, “Rocker Arm and
Shaft - Remove”.
Remove the electronic unit injector. Refer to
NOTICE
component life.
Note: The following procedure is for the removal of

the inlet valve springs and the exhaust valve springs
without removing the cylinder head. This procedure
can be performed on only one cylinder at a time. This
will prevent the inlet valves and the exhaust valves
from falling into the cylinder.
1. Rotate the crankshaft in order to bring the piston to
2. Position air inlet elbow (6). Install bolts (5). the top center position in the cylinder.
3. Connect ground strap (3) and install nut (4).
5. Connect cable assembly (2).
6. Turn the disconnect switch to the ON position.
i02878461
Inlet and Exhaust Valve

Springs - Remove and Install
SMCS Code: 1108-010
Removal Procedure
Table 13
Required Tools
A 176-5487 Valve Spring Compressor 1 Illustration 38 g01167733
Personal injury can result from being struck by

parts propelled by a released spring force.
Make sure to wear all necessary protective
equipment.
Follow the recommended procedure and use all
recommended tooling to release the spring force.
2. Use Tooling (A) in order to compress the inlet valve

springs and the exhaust valve springs.
RENR8633 23
3. Remove retainer locks (2).
4. Remove Tooling (A).
5. Remove spring retainer (3).
6. Remove inner valve spring (4) and outer valve

spring (5) from each valve (1). Remove the valve
spring seats from the cylinder head.
7. Install the inlet valve springs and the exhaust valve

springs before you rotate the crankshaft.
Table 14
Required Tools
A 176-5487 Valve Spring Compressor 1
NOTICE Illustration 39 g01167733

component life.
Improper assembly of parts that are spring loaded
can cause bodily injury.
1. Install the valve spring seats for the inlet valve
springs and the exhaust valve springs. To prevent possible injury, follow the established
assembly procedure and wear protective
equipment.
2. Install inner valve spring (4) and outer valve spring

(5) on each valve (1).
3. Install spring retainer (3).
4. Use Tooling (A) in order to compress the inlet valve

springs and the exhaust valve springs.
5. Install retainer locks (2).

End By:
Install the electronic unit injector. Refer to
Injector - Install”.
Install the rocker arm and shaft. Refer to
Shaft - Install”.
24 RENR8633
i02550198
Inlet and Exhaust Valves -

Remove and Install
SMCS Code: 1105-010
Removal Procedure
Table 15
Required Tools
A 5S-1330 Valve Spring Compressor 1
Start By:
Remove the cylinder head. Refer to Disassembly
and Assembly, “Cylinder Head - Remove”.
NOTICE
Keep all parts clean from contaminants. Illustration 40 g01137560

component life.

parts propelled by a released spring force.
The valve spring keepers can be thrown from the equipment.
valve when the valve spring compressor is re-
leased. Ensure that the valve spring keepers are Follow the recommended procedure and use all
properly installed on the valve stem. To help pre- recommended tooling to release the spring force.
vent personal injury, keep away from the front of
the valve spring keepers and valve springs during 1. Use Tooling (A) to compress valve springs (3).
the installation of the valves. Remove retainer locks (1).
2. Remove Tooling (A). Remove spring retainer (2)

and valve springs (3).
3. Remove valve stem seal (4), spring seat washer

(5), and valves (6).
Table 16
Required Tools
A 5S-1330 Valve Spring Compressor 1
NOTICE
component life.
RENR8633 25
i05165105
Inlet and Exhaust Valve Guides

- Remove and Install
SMCS Code: 1104-010
Removal Procedure
Table 17
Required Tools
9U-6895
A or Valve Guide Driver 1
4C-6366(1)
(1) If necessary, use Tooling on inlet valve guides.
Start By:
Remove the inlet and exhaust valves. Refer to
Disassembly and Assembly, “Inlet and Exhaust
Illustration 41 g01137560 Valves - Remove and Install”.
NOTICE
Improper assembly of parts that are spring loaded Contaminants may cause rapid wear and shortened
can cause bodily injury. component life.
To prevent possible injury, follow the established
equipment.
1. Lubricate valves (6) with clean engine oil. Install

valves (6) in the cylinder head assembly. Install
new valve stem seal (4) against the valve guide.
2. Install spring seat washer (5), valve springs (3),

and spring retainer (2).
The valve spring keepers can be thrown from the

valve when the valve spring compressor is re-
leased. Ensure that the valve spring keepers are Illustration 42 g01137612
properly installed on the valve stem. To help pre-
vent personal injury, keep away from the front of 1. Use Tooling (A) to remove the inlet valve guides
the valve spring keepers and valve springs during and exhaust valve guides from the cylinder head
the installation of the valves. assembly.
Note: A small amount of grease can be used to hold Installation Procedure

the valve keepers in position during installation. Table 18
3. Use Tooling (A) to compress valve springs (3). Required Tools
Install retainer locks (1).
End By:
9U-6895
Install the cylinder head. Refer to Disassembly A or Valve Guide Driver 1
and Assembly, “Cylinder Head - Install”. 4C-6366(1)
(continued)
26 RENR8633
(Table 18, contd) i04420274
B 173-5524 Guide Collar 1

C 342-6109 Guide Collar 1
Inlet and Exhaust Valve Seat
(1) If necessary, use Tooling on inlet valve guides.
Inserts - Remove and Install
SMCS Code: 1103-010
NOTICE
Keep all parts clean from contaminants. Removal Procedure
Table 19
component life. Required Tools
A 9S-3095 Puller Handle 1

6V-4194(1) Valve Seat Extractor 1
B
1U-9167(2) Valve Seat Extractor 1
(1) For use with Exhaust Valve Seat
(2) For use with Intake Valve Seat
Start By:
Remove inlet and exhaust valves. Refer to
Valves - Remove and Install”.
1. Position the inlet valve guide and exhaust valve

guide in the cylinder head. Tap on the top of the
valve guides in order to start the inlet valve guides
and exhaust valve guides into the cylinder head
assembly.
2. Use Tooling (A) and Tooling (B) to install the

Exhaust valve guide. Use Tooling (A) and Tooling
(C) to install the Intake valve guide. Install the
valve guides until the protrusion is Distance (X).
Distance (X) is 12.0 ± 0.5 mm (0.47 ± 0.02 inch) Illustration 44 g01137634
above the cylinder head assembly.
1. Use Tooling (A) and Tooling (B) to remove valve
End By:
seat inserts (1).
Install the inlet and exhaust valves. Refer to
Disassembly and Assembly, “Inlet and Exhaust Installation Procedure
Valves - Remove and Install”. Table 20
Required Tools
4C-6372(1) Valve Seat Driver 1

C
364-4009(2) Valve Seat Driver 1
(1) For use with Exhaust Valve Seat
(2) For use with Intake Valve Seat
RENR8633 27
NOTICE NOTICE
Keep all parts clean from contaminants. Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened Contaminants may cause rapid wear and shortened
component life. component life.
NOTICE
products.
mandates.
1. Drain the coolant from the cooling system into a

suitable container for storage or for disposal. Refer
to Operation and Maintenance Manual, “Cooling
System Coolant - Change”.
Note: Do not machine the prefinished valve seat

inserts in order to correct the valve stem projection.
An excessive valve stem projection indicates that the
valve seat insert is not seated or material was not
cleaned from the bottom of the counterbore.
1. Lower the temperature of new valve seat inserts
(1). Use Tooling (C) to install valve seat inserts (1)
into the cylinder head.
End By:
Install the inlet and exhaust valves. Refer to
Valves - Remove and Install”.
i02539716
Engine Oil Filter Base and Oil

Cooler - Remove
SMCS Code: 1306-011; 1378-012 Illustration 46 g01171123
2. Use Tooling (A) to remove engine oil filter (1).

Removal Procedure
Table 21
Required Tools
A 185-3630 Strap Wrench Assembly 1

28 RENR8633
i02879382
Engine Oil Filter Base and Oil

Cooler - Install
SMCS Code: 1306-012; 1378-012
NOTICE
component life.
3. Disconnect hose assembly (2). Remove bolts (4).

Remove engine oil filter base (3) and the oil seal.
1. Install the gasket and engine oil cooler (5).
4. Remove engine oil cooler (5) and the gasket.

RENR8633 29
3. Install engine oil filter (1).
4. Fill the engine with coolant to the correct level.

Refer to Operation and Maintenance Manual,
“Cooling System Coolant - Change”.
i02879910
Engine Oil Pump - Remove

SMCS Code: 1304-011
Removal Procedure
Table 22
Required Tools
A 1P-0510 Driver Gp 1
Start By:
Remove the engine oil pan. Refer to Disassembly
2. Apply clean engine oil to the oil seal. Install the oil and Assembly, “Engine Oil Pan - Remove and
Install”.
seal in engine oil filter base (3). Position engine oil
filter base (3) over the engine oil cooler. Install NOTICE
bolts (4). Tighten the bolts in a numerical Keep all parts clean from contaminants.
sequence. Tighten the bolts again in a numerical
sequence. Connect hose assembly (2). Contaminants may cause rapid wear and shortened
component life.
30 RENR8633
NOTICE
products.
mandates.
5. Remove bolts (7), outlet elbow (8), and the O-ring

seal.
6. Remove bolts (5). Remove oil pickup tube (6) and
the gasket.
1. Remove bolts (4).
2. Remove bolt (3).
3. Remove bolts (2) and remove engine oil pump (1).
4. Remove the O-ring seal that is located between the

cylinder block and the outlet elbow.
7. Remove bolt (12) and the washer. Remove idler

gear (11). Use Tooling (A) in order to remove
bearing (10) from idler gear (11). Remove shaft (9)
from engine oil pump (1).
RENR8633 31
i02879644
Engine Oil Pump -

Disassemble
SMCS Code: 1304-015
Disassembly Procedure
Table 23
Required Tools
A 1P-2320 Combination Puller 1
Start By:
1. Use Tooling (A) to remove drive gear (1) from oil
Remove the engine oil pump. Refer to
Disassembly and Assembly, “Engine Oil Pump pump body assembly (2).
- Remove”.
NOTICE
component life.
NOTICE
products.
mandates. Illustration 57 g01433241
2. Remove bolts (5). Separate oil pump body (4) from

oil pump body assembly (2).
NOTICE
Before removing the drive shaft from the pump hous-
ing, be sure that no burrs exist on the drive shaft. If
the drive shaft has burrs on it, the bores in the pump
housing may be scratched.
3. Remove shaft assembly (3) and shaft assembly (6)

from oil pump body assembly (2).
32 RENR8633
Personal injury can result from parts and/or cov- Improper assembly of parts that are spring loaded
ers under spring pressure. can cause bodily injury.
Spring force will be released when covers are To prevent possible injury, follow the established
removed. assembly procedure and wear protective
equipment.
Be prepared to hold spring loaded covers as the
bolts are loosened.
2. Install oil pressure relief plunger (7) and spring (8)
in oil pump body assembly (2). Install oil plug (9).
4. Remove the following items from oil pump body
assembly (2): oil plug (9), spring (8) and oil
pressure relief plunger (7).
i02879747
Engine Oil Pump - Assemble

SMCS Code: 1304-016
Assembly Procedure
NOTICE
component life.
1. Ensure that all of the parts of the engine oil pump

are thoroughly clean prior to assembly.
Note: Lubricate all internal parts of the engine oil
pump with clean engine oil. Illustration 60 g01433241
3. Install shaft assembly (6) in oil pump body

assembly (2).
RENR8633 33
4. Install shaft assembly (3) in oil pump body (4).
5. Position oil pump body (4) on oil pump body

assembly (2) and install bolts (5).
6. Use a suitable press in order to install drive gear
(1) on the shaft assembly of oil pump body
1. Install shaft (9) onto engine oil pump (1). Use
assembly (2) until drive gear (1) is flush with the
Tooling (A) and a suitable press in order to install
end of the shaft assembly.
bearing (10) into idler gear (11). Install the bearing
End By: so the distance between the hub bolt face of idler
gear (11) and the bearing is 0.75 ± 0.25 mm
Install the engine oil pump. Refer to Disassembly
and Assembly, “Engine Oil Pump - Install”. (0.030 ± 0.010 inch). Position idler gear (11) on
shaft (9). Install the washer and bolt (12).
i02879939
Engine Oil Pump - Install

SMCS Code: 1304-012
Table 24
Required Tools
NOTICE
component life.
2. Inspect the condition of the gasket. Replace the

gasket, if necessary. Position the gasket and oil
pickup tube (6). Install bolts (5).
3. Inspect the condition of the O-ring seal. Replace

the O-ring seal, if necessary. Position the O-ring
seal and outlet elbow (8). Install bolts (7).
34 RENR8633
i02879976
Water Pump - Remove

SMCS Code: 1361-011
Removal Procedure
Start By:
Remove the alternator, if necessary. Refer to
Disassembly and Assembly, “Altenator -
Remove and Install”.
Personal injury can result from hot coolant, steam

and alkali.
At operating temperature, engine coolant is hot
and under pressure. The radiator and all lines to
heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.
Illustration 64 g01172390 Remove cooling system pressure cap slowly to

relieve pressure only when engine is stopped and
Note: Ensure that the mounting surfaces for the cooling system pressure cap is cool enough to
touch with your bare hand.
engine oil pump are thoroughly clean.
4. Inspect the condition of the O-ring seal. Replace Do not attempt to tighten hose connections when
the O-ring seal, if necessary. Install the O-ring seal the coolant is hot, the hose can come off causing
that is located between the cylinder block and the burns.
outlet elbow. Position engine oil pump (1) on the Cooling System Coolant Additive contains alkali.
cylinder block. Avoid contact with skin and eyes.
5. Install bolts (2).
NOTICE
6. Install bolt (3).
End By: prepared to collect the fluid with suitable containers
Install the engine oil pan. Refer to Disassembly any component containing fluids.
and Assembly, “Engine Oil Pan - Remove and
Install”. Refer to Special Publication, NENG2500, “Caterpillar
products.
mandates.

System Coolant (ELC) - Change”.
2. Remove the belt. Refer to Operation and

Maintenance Manual, “Belts - Inspect/Replace”.
RENR8633 35
3. Loosen hose clamps (1). 1. Remove O-ring seals (1) and (2).
4. Disconnect hose (2). 2. Remove bolts (3). Remove rear cover (4) and
gasket (5).
5. Remove bolts (4), elbow assembly (5), and the
gasket. 3. Use Tooling (A) and a suitable press in order to
remove impeller (6) from shaft assembly (9).
7. Remove water pump (3). Note: Do not allow the shaft assembly to fall when
the shaft assembly is removed.
i02880103
4. Use Tooling (A) and a suitable press in order to
remove shaft assembly (9) from water pump
Water Pump - Disassemble housing (8).
SMCS Code: 1361-015 5. Use Tooling (A) to remove seal (7) from water
pump housing (8).
Table 25 i04553969
Required Tools
Water Pump - Assemble
SMCS Code: 1361-016
Assembly Procedure
Start By: Table 26
Remove the water pump. Refer to Disassembly Required Tools

and Assembly, “Water Pump - Remove”. Part Description Qty
Tool Part Number
B 183-4028 Seal Driver 1

36 RENR8633
i02880170
NOTICE
Water Pump - Install
Contaminants may cause rapid wear and shortened SMCS Code: 1361-012
component life.
NOTICE
component life.

install shaft assembly (9) in water pump housing
(8). After installation, the bearing on shaft
assembly (9) should be flush with the face of water
pump housing (8).
2. Use Tooling (B) to install seal (7) over shaft
assembly (9) and into water pump housing (8). 1. Position water pump (3) on the engine block. Install
bolts (6).
install impeller (6) onto shaft assembly (9). Install 2. Install the gasket, elbow assembly (5), and bolts
impeller (6) until the distance between impeller (6) (4).
and the machined surface of water pump housing
(8) is 0.75 ± 0.25 mm (0.030 ± 0.010 inch). 3. Connect hose (2).
4. Position gasket (5) and rear cover (4) on water 4. Tighten hose clamps (1) to a torque of 7 ± 1 N·m
pump housing (8). Install bolts (3). (62 ± 9 lb in).
5. Install the belt. Refer to Operation and

Note: Check the O-ring seals for wear or for damage. Maintenance Manual, “Belts - Inspect/Replace”.
If necessary, replace the O-ring seals.
5. Install O-ring seals (1) and (2). 6. Fill the cooling system with coolant. Refer to
End By: Operation and Maintenance Manual, “Cooling
Install the water pump. Refer to Disassembly and
Assembly, “Water Pump - Install”.
RENR8633 37
i02540514
Water Temperature Regulator -

Remove and Install
SMCS Code: 1355-010
S/N: KLW1–Up
S/N: P7Z1–Up
Removal Procedure

and alkali.
Remove cooling system pressure cap slowly to
cooling system pressure cap is cool enough to 2. Remove bolts (1) from water temperature regulator
touch with your bare hand. housing (2).
Do not attempt to tighten hose connections when
the coolant is hot, the hose can come off causing
burns.
Cooling System Coolant Additive contains alkali.
Avoid contact with skin and eyes.
NOTICE
component life.
NOTICE
Refer to Special Publication, NENG2500, “Caterpillar Illustration 70 g01173071
suitable to collect and contain fluids on Caterpillar 3. Remove water temperature regulator housing (2).
products. Remove gasket (3). Remove water temperature
regulators (4).
mandates.

38 RENR8633
4. Remove seal (5) from water temperature regulator 2. Use Tooling (A) and install seal (5) into water
housing (2). temperature regulator housing (2).
Table 27
Required Tools
A 221-8647 Seal Installer 1
NOTICE
component life.
1. Clean the mating surfaces of the water

temperature regulator housings.
RENR8633 39
i02880244
Water Temperature Regulator -

Remove and Install
SMCS Code: 1355-010
S/N: P9L1–Up
S/N: P7Z1–Up
Removal Procedure

and alkali.
Remove cooling system pressure cap slowly to
cooling system pressure cap is cool enough to
touch with your bare hand.
Do not attempt to tighten hose connections when
the coolant is hot, the hose can come off causing
burns.
Cooling System Coolant Additive contains alkali.
Avoid contact with skin and eyes.
NOTICE
component life.
NOTICE
3. Install water temperature regulators (4). Install a
new gasket (3). Refer to Special Publication, NENG2500, “Caterpillar
4. Position water temperature regulator housing (2). suitable to collect and contain fluids on Caterpillar
Install bolts (1). products.
5. Fill the cooling system with coolant. Refer to Dispose of all fluids according to local regulations and
mandates.
System Coolant (ELC) - Change” and Operation
and Maintenance Manual, “Capacities (Refill)”. 1. Drain the coolant from the cooling system into a
40 RENR8633
4. Remove seal (5) from water temperature regulator

housing (2).
Illustration 75 g01433672 Table 28
Required Tools
2. Remove bolts (1) from water temperature regulator
housing (2).
A 221-8647 Seal Installer 1
NOTICE
component life.
1. Clean the mating surfaces of the water

temperature regulator housing.
3. Remove water temperature regulator housing (2).

Remove gasket (3). Remove water temperature
regulators (4).
2. Use Tooling (A) and install seal (5) into water

temperature regulator housing (2).
RENR8633 41
i01995668
Auxiliary Water Pump -

Remove
SMCS Code: 1371-011
S/N: P9L1–Up
S/N: P7Z1–Up
Removal Procedure
NOTICE
Illustration 79 g01433673 Tools and Shop Products Guide” for tools and sup-
plies suitable to collect and contain fluids on Caterpil-
lar products.
mandates.
NOTICE
component life.
3. Install water temperature regulators (4). Install a

new gasket (3).
4. Position water temperature regulator housing (2). Illustration 81 g01032968

Install bolts (1).
1. Disconnect hose (2) and hose (4) from auxiliary
5. Fill the cooling system with coolant. Refer to water pump (3).
System Coolant (ELC) - Change”. 2. Remove bolts (1).
3. Remove auxiliary water pump (3) from the front

housing.
4. Remove the integral seal from the face of the

auxiliary water pump.
42 RENR8633
i02880484

Disassemble
SMCS Code: 1371-015
S/N: P9L1–Up
S/N: P7Z1–Up
Table 29
Required Tools
A 1P-1855 Retaining Ring Pliers 1
B 1P-1861 Retaining Ring Pliers 1
C 1P-0510 Driver Group 1
D 1U-6400 Three Jaw Puller 1 Illustration 82 g01032983
E 9S-9152 Bearing Puller Gp 1

1. Remove integral seal (9), if necessary.
F 8S-6470 Forcing Screw 1
2. Remove bolts (1) and remove elbow (2). Remove
Start By: O-ring seal (3) from the elbow.
Remove the auxiliary water pump. Refer to 3. Remove bolts (10) and remove elbow (12).
Disassembly and Assembly, “Auxiliary Water Remove O-ring seal (11) from the elbow.
Pump - Remove”.
4. Remove nut (5) and washer (4). Use Tooling (D) to
NOTICE remove gear (8).
5. Remove bolts (7) and remove cover (6).
component life.
Note: Your specific auxiliary water pump may vary.

Refer to Parts Information for more information.
6. Remove O-ring seal (22) from housing (15).

RENR8633 43
7. Remove bolt (16). Remove the O-ring seal from the

bolt.
8. Use Tooling (F) to remove impeller (21) from shaft
(19).
9. Remove cam (17) from the housing.
10. Remove stainless key (18) from the shaft.
11. Remove bolts (14) and remove adapter (13) from

housing (15).
12. Use Tooling (C) and a suitable press to remove

pump seal (20) from the adapter.
17. Use Tooling (C) and a suitable press to remove

pump seal assembly (27) from the housing.
Illustration 84 g01039021 18. Use Tooling (A) to remove retaining ring (28).
Remove washer (29) from shaft (19).
13. Use Tooling (B) to remove retaining ring (23) from
housing (15). 19. Use Tooling (A) to remove retaining ring (34).
Remove washer (33) from shaft (19).
14. Use Tooling (A) to remove retaining ring (26) from
shaft (19). 20. Use Tooling (E) and a suitable press to remove
ball bearing (30), spacer (32), and ball bearing (31)
15. Remove washer (25) and plate assembly (24). from shaft (19).
16. Use a suitable press to remove shaft (19) out of
i04161770
the water pump housing. Press on shaft (19) from
the impeller end of the water pump housing.
Disassemble
(Type 2)
SMCS Code: 1371-015
S/N: P9L1–Up
S/N: P7Z1–Up
44 RENR8633
Disassembly Procedure 4. Remove nut (5) and washer (4). Use Tooling (D) to
Table 30
remove gear (8).
Required Tools 5. Remove bolts (7). Remove cover (6) and the O-ring
Tool Part Number Part Description Qty seal (not shown).
D 1U-6400 Three Jaw Puller 1
E 9S-9152 Bearing Puller Gp 1
F 8S-6470 Forcing Screw 1
Start By:
Remove the auxiliary water pump. Refer to
Disassembly and Assembly, “Auxiliary Water
Pump - Remove”.
NOTICE
Keep all parts clean from contaminants. 6. Remove bolt (13) and remove the O-ring seal.
component life.

7. Use Tooling (F) in order to remove impeller (14).
1. Remove integral seal (9), if necessary.
2. Remove bolts (1) and remove elbow (2). Remove

O-ring seal (3) from the elbow.
3. Remove bolts (10) and remove elbow (12).
Remove O-ring seal (11) from the elbow.
8. Remove cam (15) from the housing.
RENR8633 45
9. Remove key (16) from the shaft. 12. Use Tooling (B) in order to remove retaining ring
(20).
10. Remove bolts (17) and remove adapter (18) from
the housing. 13. Remove plate assembly (21).
11. Use Tooling (C) and a suitable press in order to 14. Use Tooling (C) and a suitable press in order to
remove pump seal (19) from the adapter. remove shaft (22) from water pump housing (23).
46 RENR8633
Cutaway view of the pump housing showing the
removal of the pump seal assembly.
15. Use Tooling (C) and a suitable press in order to

remove pump seal assembly (24) from the
housing.
16. Use Tooling (E) or Tooling (C) in order to remove 18. Use Tooling (E) and a suitable press in order to
ball bearing (25) from shaft (22). Bearing (25) remove ball bearing (28) from shaft (22) toward the
should be removed from the gear end of the shaft. gear end.
17. Use Tooling (A) in order to remove retaining ring

(26). Remove spacer (27) and slinger (29) from the
shaft (22).
RENR8633 47
i02880898

Assemble
SMCS Code: 1371-016
S/N: P9L1–Up
S/N: P7Z1–Up
Assembly Procedure
Table 31
Required Tools
G 323-3526 Seal Installer Tool 1 Illustration 100 g01039556
H 1U-6396 O-Ring Assembly Compound -

4. Use a suitable press to install shaft (19) in housing
(15).
NOTICE
Keep all parts clean from contaminants. 5. Use Tooling (B) to install retaining ring (23) in the
housing.
component life.

1. Use Tooling (A) to install retaining ring (34) on shaft
(19). Install washer (33) on the shaft. 6. Use Tooling (G) to install pump seal assembly (27).
2. Raise the temperature of the ball bearings. Install 7. Install plate assembly (24) in housing (15). Ensure
ball bearing (31), spacer (32), and ball bearing (30) that locator pin (35) is aligned with the slot in the
on shaft (19). housing.
3. Install washer (29) on shaft (19). Use Tooling (A) to 8. Install washer (25) on pump shaft (19). Use Tooling
install retaining ring (28) on the shaft. (A) to install retaining ring (26) on the shaft.
48 RENR8633
9. Position cam (17) in housing (15) and install the O- 12. Install adapter (13) over shaft (19) on housing
ring seal and bolt (16). (15). Install bolts (14).
10. Install stainless key (18) and impeller (21) on 13. Lubricate O-ring seal (22) with Tooling (H). Install
shaft (19). the O-ring seal on the housing.
11. Use Tooling (C) and a suitable press to install 14. Position cover (6) on housing (15) and install the
pump seal (20) in adapter (13). washers and bolts (7).
15. Position gear (8) on the shaft. Install washer (4)

and nut (5). Tighten the nut to a torque of
63 ± 7 N·m (47 ± 5 lb ft).
16. Install integral seal (9), if necessary.

RENR8633 49
(Table 32, contd)

G - LOCTITE 262 -
H 1U-6396 O-Ring Assembly Compound -
NOTICE
component life.

17. Lubricate O-ring seal (11) with Tooling (H). Install

the O-ring seal in elbow (12). Position the elbow on
housing (15) and install bolts (10). Tighten the
bolts to a torque of 15 ± 3 N·m (11± 2 lb ft).

the housing and install bolts (1). Tighten the bolts
to a torque of 15 ± 3 N·m (11± 2 lb ft).
End By:
Install the auxiliary water pump. Refer to
Disassembly and Assembly, “Auxiliary Water
Pump - Install”.
i04162513

Assemble
(Type 2)
SMCS Code: 1371-016
S/N: P9L1–Up
S/N: P7Z1–Up
Assembly Procedure
Table 32
Required Tools
(continued)
50 RENR8633
1. Raise the temperature of the ball bearings. Install

ball bearing (28) and spacer (27) slightly past the
retaining ring groove that accepts retaining ring
(26).
2. Use Tooling (A) in order to install retaining ring (26)

on shaft (22). Press bearing (28) and spacer (27)
against retaining ring (26).
3. Install bearing (25) onto shaft (22) and press the

bearing against retaining ring (26). Slide slinger
(29) onto the impeller side of shaft (22).
5. Use Tooling (B) to install retaining ring (20) into the

housing.
4. Use a suitable press to install shaft (22) in housing

(23).
RENR8633 51

The illustration is a cutaway view of the pump
housing on a shop press showing the pump seal 8. Use Tooling (C) and a suitable press to install
assembly. pump seal (19) into the adapter.
Note: The Water Seal Tooling is a one time use tool

that is supplied in the water seal assembly kit.
6. Use the Water Seal Tooling (not shown) to press
the spring loaded mechanical seal (24b), with the
black seal face toward the impeller, into the
housing. Pilot the seal seat (24a) onto shaft (22)
with the seat face toward the face on the
mechanical seal (24b). Use the Water Seal Tooling
(not shown) to press the seal seat along the shaft
and against the mechanical seal (24a) until the
Water Seal Tooling presses against the shoulder of
the mechanical seal (24b). The tool compresses
the water seal (24a) and (24b) to the proper seal
spring height.
9. Install adapter (18) over the shaft.
10. Apply Tooling (G) to the threads of bolts (17).

Tighten bolts (17) to a torque of 24 ± 7 N·m
(212 ± 62 lb in).
7. Install plate assembly (21) into the housing. Ensure

that the locator pin is aligned with the slot in the
housing.
11. Install key (16) onto the shaft.

52 RENR8633
15. Position cover (6) and the O-Ring Seal onto the
housing. Install the washers and bolts (7). Tighten
bolts (7) to a torque of 9 ± 2 N·m (80 ± 18 lb in).
16. Position gear (8) on the shaft. Install washer (4)

and nut (5). Tighten the nut to a torque of
63 ± 7 N·m (47 ± 5 lb ft).
17. Install integral seal (9), if necessary.
12. Position cam (15) into the housing.
13. Install the O-ring seal onto bolt (13). Install bolt
(13) and tighten to a torque of 9 ± 2 N·m
(80 ± 18 lb in).

14. Install the impeller (14) onto the shaft. the O-ring seal in elbow (2). Position the elbow on
RENR8633 53
End By: Removal Procedure

Table 33
Install the auxiliary water pump. Refer to
Disassembly and Assembly, “Auxiliary Water Required Tools
Pump - Install”.
i02880922 Guide Stud

A - 2
(M10 x 1.50 x 60 mm)
Auxiliary Water Pump - Install Guide Stud
B - 2
(M8 x 1.25 x 90 mm)
SMCS Code: 1371-012
S/N: P9L1–Up
NOTICE
S/N: P7Z1–Up Keep all parts clean from contaminants.
Installation Procedure Contaminants may cause rapid wear and shortened

component life.
NOTICE
component life.

1. Install the integral seal on the face of auxiliary
water pump (3).
1. Remove the hose from adapter (6). Remove bolts
2. Position auxiliary water pump (3) in the front (7) and adapter (6) from cover (1).
housing. Install bolts (1).
2. Remove bolts (8) and tube assembly (9) from cover
3. Connect hose (2) to the auxiliary water pump. (1).
4. Connect hose (4) to the auxiliary water pump. 3. Remove bolts (4) and adapter (5) from the base
assembly.
i02896897 4. Attach a suitable lifting device to core assembly (3)
at Location (X). The weight of core assembly (3) is
Aftercooler - Remove approximately 35 kg (77 lb).
SMCS Code: 1063-011
5. Remove two bolts (2). Install Tooling (A) into the
S/N: P9L1–Up base assembly.
S/N: P7Z1–Up 6. Remove remaining bolts (2).
7. Remove cover (1). Remove the gasket from cover

(1).
54 RENR8633
8. Remove core assembly (3). (Table 34, contd)

Guide Stud
9. Remove Tooling (A) from the base assembly. B -
(M8 x 1.25 x 90 mm)
2
Remove the gasket from the base assembly.
C 4C-9500 Quick Cure Primer -
D 1U-8846 Gasket Sealant -
NOTICE
component life.
1. Thoroughly clean the mating surfaces of the

cylinder head and the base assembly.
10. Disconnect the harness assembly from sensor

assembly (10).
11. Remove two bolts (11). Install Tooling (B) into the
cylinder head.
12. Remove remaining bolts (11) and bolts (13).
13. Remove base assembly (12). The weight of base

assembly (12) is approximately 23 kg (50 lb).
14. Remove Tooling (B) from the cylinder head.
2. Install Tooling (B) in the cylinder head at Location
i02897897
(Z).
Aftercooler - Install 3. Apply Tooling (C) to base assembly (12).
SMCS Code: 1063-012
4. Allow Tooling (C) to dry for three to five minutes.
S/N: P9L1–Up
5. Apply Tooling (D) to base assembly (12) and install
S/N: P7Z1–Up base assembly (12) on Tooling (B).
Installation Procedure Note: The base assembly must be installed within ten
Table 34
minutes of applying Tooling (D).
Required Tools 6. Position base assembly (12) on Tooling (B). The
Tool Part Number Part Description Qty weight of base assembly (12) is approximately
23 kg (50 lb).
Guide Stud
A - 2
(M10 x 1.50 x 60 mm) 7. Install bolts (11) and bolts (13) finger tight.
8. Remove Tooling (B) and install remaining bolts

(continued) (11). Tighten bolts (11) and bolts (13).
RENR8633 55
9. Connect the harness assembly to sensor assembly i02881237

(10).
Flywheel - Remove and Install
10. Install Tooling (A) in base assembly (12) at
SMCS Code: 1156-010
Location (Y). Install the gasket on Tooling (A).
Removal Procedure
Table 35
Required Tools
Guide Bolt
A - 1
M16 x 2 by 200 mm
11. Attach a suitable lifting device to core assembly

(3) at Location (X) and install the core assembly on
the base assembly and Tooling (A). The weight of
core assembly (3) is approximately 35 kg (77 lb).
12. Install the gasket on core assembly (3). Position

cover (1) onto Tooling (A).
14. Remove Tooling (A). Install remaining bolts (2).
15. Install adapter (5) and bolts (4) in the base

assembly.
16. Install tube assembly (9) and bolts (8) in cover (1).
17. Install adapter (6) and bolts (7) in cover (1). Install
the hose onto adapter (6).

56 RENR8633
1. Remove one bolt (1). Install Tooling (A). Remove

remaining bolts (1).
2. Attach a suitable lifting device to flywheel (2). The

weight of flywheel (2) is approximately 60 kg
(132 lb). Remove flywheel (2).
3. Inspect the ring gear. Replace the ring gear, if

necessary. Place the flywheel on a wood block.
Use a hammer and a punch in order to remove the
ring gear.
Table 36
Required Tools
Guide Bolt
A - 1
M16 x 2 by 200 mm
1. Raise the temperature of the ring gear. Install the Illustration 128 g01173265
ring gear on the flywheel. Position the ring gear
with the part number toward the crankshaft. Allow 3. Position flywheel (2) on the engine. Align the
the ring gear to cool. Use a soft hammer in order to arrows on the flywheel and the crankshaft. Install
seat the ring gear against the shoulder of the bolts (1). Remove Tooling (A) and install the
flywheel. remaining bolt. Tighten the bolts evenly to a torque
of 300 ± 40 N·m (221 ± 30 lb ft).
4. Check the flywheel runout. Refer to Testing and

Adjusting, “Flywheel - Inspect”.
i02540744
Crankshaft Rear Seal - Remove

SMCS Code: 1161-011
Removal Procedure
Start By:
Remove the flywheel. Refer to Disassembly and
Assembly, “Flywheel - Remove and Install”.
NOTICE
component life.
2. Install Tooling (A) in the crankshaft. Attach a

suitable lifting device to flywheel (2). The weight of
flywheel (2) is approximately 60 kg (132 lb).
Note: Use new bolts for installation.

RENR8633 57
1. Remove bolts (2). 1. Lubricate the O-ring seal with clean engine oil.
Position the O-ring seal on the back of crankshaft
2. Remove crankshaft rear seal (1) from the rear seal (1).
crankshaft.
2. Position crankshaft rear seal (1) and the shipping
i02540835 sleeve over the crankshaft. Push crankshaft rear
seal (1) in place. This will dislodge the shipping
Crankshaft Rear Seal - Install sleeve.
SMCS Code: 1161-012 3. Install bolts (2). Tighten the bolts to a torque of
12 ± 3 N·m (106 ± 27 lb in).
Installation Procedure End By:
NOTICE Install the flywheel. Refer to Disassembly and
Keep all parts clean from contaminants. Assembly, “Flywheel - Remove and Install”.
component life. i02881528
Flywheel Housing - Remove

Note: Leave the shipping sleeve in place in order to
install the crankshaft rear seal. The crankshaft rear and Install
seal must be installed dry. SMCS Code: 1157-010
Removal Procedure
Table 37
Required Tools

Guide Bolts
B - 2
M12 x 1.75 by 120 mm
58 RENR8633
Start By:
Remove the crankshaft rear seal. Refer to
Disassembly and Assembly, “Crankshaft Rear
Seal - Remove”.
Remove the electric starting motor, if necessary.
Refer to Disassembly and Assembly, “Electric
Starting Motor - Remove and Install”.
2. Install Tooling (B) in the cylinder block.
3. Attach Tooling (A) and a suitable lifting device to

flywheel housing (1). The weight of flywheel
housing (1) is approximately 55 kg (121 lb).
Position flywheel housing (1) on Tooling (B).
Illustration 131 g01434695 4. Install bolts (2). Remove Tooling (B) and install
remaining bolts (2).
1. Remove two bolts (2). Install Tooling (B) in the
cylinder block. 5. Install bolts (3) (not shown) that fasten the engine
oil pan to flywheel housing (1).
flywheel housing (1). The weight of flywheel End By:
housing (1) is approximately 55 kg (121 lb). Install the electric starting motor, if necessary.
Refer to Disassembly and Assembly, “Electric
3. Remove remaining bolts (2). Starting Motor - Remove and Install”.
4. Remove bolts (3) (not shown) that fasten the Install the crankshaft rear seal. Refer to
engine oil pan to flywheel housing (1). Remove Disassembly and Assembly, “Crankshaft Rear
flywheel housing (1). Seal - Install”.
Installation Procedure i02540969

Table 38
Required Tools
Vibration Damper and Pulley -
Remove and Install
SMCS Code: 1205-010
Guide Bolts
B -
M12 x 1.75 by 120 mm
2 Removal Procedure
C 1U-8846 Gasket Sealant 1 1. Remove the belt. Refer to Operation and
1. Apply Tooling (C) to the entire mounting surface of
the flywheel housing prior to installation. The
flywheel housing must be installed within 10
minutes of application.
RENR8633 59
i02549880
Crankshaft Front Seal -

Remove
SMCS Code: 1160-011
Removal Procedure
Table 39
Required Tools
A 1U-7600 Slide Hammer Puller 1

B 1U-8145 Drill Bit 1
Start By:
Remove the vibration damper and the pulley.
Refer to Disassembly and Assembly,
“Vibration Damper and Pulley - Remove and
Illustration 133 g01151434 Install”.
2. Remove bolts (2) from crankshaft vibration damper

(1). Remove crankshaft vibration damper (1) from
the crankshaft pulley.
3. Remove bolts (3). Remove crankshaft pulley (4).
1. Use Tooling (B) to carefully drill three evenly

spaced holes in crankshaft front seal (1).
2. Alternate between the drilled holes and use Tooling

(A) to remove crankshaft front seal (1).
1. Position crankshaft pulley (4) on the crankshaft.

Install bolts (3).
2. Position crankshaft vibration damper (1) on

crankshaft pulley (4). Install bolts (2).

60 RENR8633
i02550042 i02882225
Crankshaft Front Seal - Install Front Cover - Remove and

SMCS Code: 1160-012 Install
SMCS Code: 1166-010
Table 40 Removal Procedure
Required Tools
Start By:
Remove the vibration damper and the pulley.
C 1U-7430 Front Seal Installer 1 Refer to Disassembly and Assembly,
“Vibration Damper and Pulley - Remove and
Install”.
NOTICE
Remove the fan drive, if necessary. Refer to
Disassembly and Assembly, “Fan Drive -
Contaminants may cause rapid wear and shortened Remove”.
component life. Remove the unit injector hydraulic pump. Refer to
Disassembly and Assembly, “Unit Injector
Hydraulic Pump - Remove”.
NOTICE
products.
mandates.
Note: The crankshaft front seal is designed to be

installed dry.
1. Use Tooling (C) and install crankshaft front seal (1).
End By:
Install the vibration damper and the pulley. Refer
to Disassembly and Assembly, “Vibration
Damper and Pulley - Remove and Install”.
RENR8633 61
1. Support the attachment for the accessory drive and 1. Position the gasket and front cover (3) on the
remove bolts (2). engine.
2. Remove bolts (1). Remove front cover (3) and the 2. Install bolts (1).
gasket.
3. Install bolts (2). Remove the support from the
Installation Procedure attachment for the accessory drive.
End By:
NOTICE
Keep all parts clean from contaminants. Install the unit injector hydraulic pump. Refer to
Contaminants may cause rapid wear and shortened Hydraulic Pump - Install”.
component life.
Install the fan drive, if necessary. Refer to
Note: The rear face of the front cover and the front Install”.
face of the front housing must be clean.
Install the vibration damper and the pulley. Refer
to Disassembly and Assembly, “Vibration
Damper and Pulley - Remove and Install”.
i02882866
Gear Group (Front) - Remove

SMCS Code: 1206-011
Removal Procedure
Table 41
Required Tools
62 RENR8633
Start By:
7. Check the condition of the bearing in idler gear
Remove the front housing. Refer to Disassembly assembly (10). If the bearing is worn or damaged,
and Assembly, “Housing (Front) - Remove”.
replace the idler gear assembly.
NOTICE
Keep all parts clean from contaminants. i02883096

component life.
Gear Group (Front) - Install
SMCS Code: 1206-012
1. Set the No. 1 piston to top center on the
compression stroke. Refer to Testing and
Table 42
Adjusting, “Finding Top Center Position for No. 1
Piston”. Required Tools
NOTICE
component life.
2. Mark the orientation of each of the gears for

installation purposes.
3. Remove bolts (4), bolt (6), and retaining plate (7).
4. Remove idler gear assembly (3), idler shaft (2), and

thrust plate (1) from the cylinder block.
5. Use Tooling (A) to remove bearing (5) from idler

gear assembly (3).
Note: Removal of the engine oil pan may be
Note: Removal of the engine oil pan may be necessary in order to install the idler gear assembly
necessary in order to remove the idler gear assembly for the engine oil pump.
for the engine oil pump. 1. Install idler gear assembly (10) and retaining plate
6. Remove bolt (8), retaining plate (9), and idler gear (9) on the engine oil pump. Install bolt (8).
assembly (10).
RENR8633 63
2. Check the end play for the idler gear assembly. i02883368
The end play for the idler gear assembly is
0.05 to 0.35 mm (0.002 to 0.014 inch). Housing (Front) - Remove
SMCS Code: 1151-011
3. Use Tooling (A) to install bearing (5) in idler gear
assembly (3).
Removal Procedure
4. Align the timing marks on idler gear assembly with Start By:
the holes on the camshaft gear and the crankshaft
gear. Install thrust plate (1), idler shaft (2), idler Remove the fan drive, if necessary. Refer to
gear assembly (3), and retaining plate (7) on the Disassembly and Assembly, “Fan Drive -
cylinder block. Install bolts (4) and bolt (6). Tighten Remove”.
the bolts to a torque of 70 ± 15 N·m (52 ± 11 lb ft). Remove the fuel filter base. Refer to Disassembly
and Assembly, “Fuel Filter Base - Remove and
5. Calibrate the speed/timing sensor. Refer to Install”.
Troubleshooting, “Engine Speed/Timing Sensor -
Calibrate” for the calibration procedure. Remove the unit injector hydraulic pump. Refer to
End By: Hydraulic Pump - Remove”.
Install the front housing. Refer to Disassembly Remove the auxiliary water pump, if necessary.
and Assembly, “Housing (Front) - Install”. Refer to Disassembly and Assembly, “Auxiliary
Water Pump - Remove”.
Remove the air compressor, if necessary. Refer to
Disassembly and Assembly, “Air Compressor -
Remove the crankshaft front seal. Refer to
Disassembly and Assembly, “Crankshaft Front
Seal - Remove”.
Remove the camshaft. Refer to Disassembly and
Assembly, “Camshaft - Remove”.
NOTICE
products.
mandates.
64 RENR8633
(Table 43, contd)

A 138-8440 Component Cleaner 1
B 4C-9500 Quick Cure Primer 1

C 1U-8846 Gasket Sealant 1
NOTICE
component life.
1. Disconnect harness assemblies (1) and (2).
1. Clean the joint face on front housing (4) with

Tooling (A).
Illustration 142 g01151892 2. Apply Tooling (B) to the joint face.

Note: Do not allow Tooling (C) to seal the main oil
3. Remove bolts (3). passage on front housing (4).
3. Apply Tooling (C) to the joint face. Spread the
4. Remove front housing (4). sealant uniformly. Front housing (4) must be
installed within ten minutes of applying the sealant.
i02883411
4. Position front housing (4) on the cylinder block.
Housing (Front) - Install 5. Install bolts (3).
SMCS Code: 1151-012
Table 43
Required Tools
(continued)
RENR8633 65
NOTICE
products.
mandates.
7. Connect harness assemblies (1) and (2).

End By:
Install the camshaft. Refer to Disassembly and
Assembly, “Camshaft - Install”.
Install the crankshaft front seal. Refer to
Disassembly and Assembly, “Crankshaft Front
Seal - Install”.
Install the air compressor, if necessary. Refer to
Disassembly and Assembly, “Air Compressor -
Install the auxiliary water pump, if necessary.
Refer to Disassembly and Assembly, “Auxiliary
Water Pump - Install”.
Install the unit injector hydraulic pump. Refer to
Hydraulic Pump - Install”.
Install the fuel filter base. Refer to Disassembly
Install”.
1. Remove bolt (2) and the washer from breather
Install the fan drive, if necessary. Refer to assembly (1).
Install”. 2. Loosen hose clamp (3) and hose clamp (5).
Remove hose assembly (4).
i02883484
3. Remove breather assembly (1) and the O-ring
Crankcase Breather - Remove seal.
and Install 4. Remove the bolts and fumes disposal group (6), if
SMCS Code: 1317-010 necessary.
Removal Procedure Installation Procedure

NOTICE
NOTICE
66 RENR8633
i02883660
Cylinder Block Cover - Remove

and Install
SMCS Code: 1201-010-CH
Removal Procedure
Start By:
Remove the electronic control module. Refer to
Disassembly and Assembly, “Electronic
Control Module - Remove and Install”.
NOTICE
1. Install fumes disposal group (6) and the bolts, if Dealer Service Tool Catalog” for tools and supplies
necessary. products.
2. Check the condition of the O-ring seal. Replace the Dispose of all fluids according to local regulations and
O-ring seal if the O-ring seal is damaged. mandates.
3. Install the O-ring seal and breather assembly (1).
4. Install bolt (2) and the washer. Tighten bolt (2) to a

torque of 15 ± 3 N·m (11 ± 2 lb ft).
5. Install hose assembly (4). Tighten hose clamp (5)

and hose clamp (3).
1. Loosen hose clamp (1) and disconnect hose

assembly (2).
2. Disconnect tube assembly (3).
3. Disconnect hose assembly (7).

RENR8633 67
5. Remove bolts (4). Remove cylinder block cover (5).

Remove the O-ring seals and the gasket from the b. Tighten the bolts again in a numerical
cylinder block. sequence.
Installation Procedure 3. Connect harness assembly (6).
4. Connect hose assembly (7).
5. Connect tube assembly (3).
6. Connect hose assembly (2) and tighten hose

clamp (1).
End By:
Install the electronic control module. Refer to
Disassembly and Assembly, “Electronic
Control Module - Remove and Install”.
i02580032
Valve Mechanism Cover -

Remove and Install
SMCS Code: 1107-010
Removal Procedure
component life.
Illustration 149 g01435572 1. Remove bolts (1).
Note: Check the condition of the O-ring seals and the 2. Remove valve mechanism cover (2) and seal (3).
gasket. Replace the O-ring seals and the gasket, if
necessary. Installation Procedure
1. Install the O-ring seals and the gasket on the Table 44
cylinder block. Position cylinder block cover (5). Required Tools
2. Install bolts (4). Tighten bolts (4) by using the Tool Part Number Part Description Qty
following procedure: A 4C-9612 Silicone Sealant 1
a. Tighten the bolts in a numerical sequence.

68 RENR8633
i02409213
NOTICE
Valve Mechanism Cover Base -
component life.
Remove and Install
SMCS Code: 1120-010
Removal Procedure
Start By:
NOTICE
component life.
1. Position seal (3) in valve mechanism cover (2).

Apply Tooling (A) to both sides of the seal joint.
Position valve mechanism cover (2) and seal (3)
on the valve cover base.
1. Disconnect sensor (4) and harness assembly (6)
2. Install bolts (1). Tighten bolts (1) in a numerical from valve cover base (5).
sequence to a torque of 20 ± 3 N·m (15 ± 2 lb ft).
2. Remove bolt (1) and the clip that holds the harness
assembly.
3. Disconnect harness assemblies (3).
4. Remove bolts (2), the washers, and the springs.
5. Remove valve cover base (5) and the seal.

RENR8633 69
Installation Procedure 5. Connect harness assembly (6) to valve cover base

(5). Tighten the bolts to a torque of 6 ± 1 N·m
NOTICE (53 ± 9 lb in).
6. Connect sensor (4) to valve cover base (5).
component life. End By:
i02884496
Rocker Arm and Shaft -

Remove
SMCS Code: 1102-011
Removal Procedure
Start By:
NOTICE
component life.
1. Place identification marks on each of the rocker

arms in order to identify the proper location for
installation.
1. Position the seal and valve cover base (5) on the

cylinder head.
2. Install the springs, the washers, and bolts (2).

Tighten bolts (2) in a numerical sequence.
3. Connect harness assemblies (3).
4. Install the clip and bolt (1) that holds the harness
assembly.
2. Loosen nuts (3) and rocker arm adjustment screws
(2).
70 RENR8633
3. Remove bolts (1) and rocker shaft (4).

2. Remove stand (6), inlet rocker arm (5), spring (4),
4. Remove the pushrods and the valve bridges. and exhaust rocker arm (3) from rocker shaft (1).
i02544763 i02544772
Rocker Arm - Disassemble Rocker Arm - Assemble

SMCS Code: 1123-015 SMCS Code: 1123-016
Disassembly Procedure Assembly Procedure

Start By:
NOTICE
Remove the rocker arm and shaft. Refer to Keep all parts clean from contaminants.
Shaft - Remove”. Contaminants may cause rapid wear and shortened
component life.
NOTICE
1. Lubricate all components of the rocker arm shaft
Contaminants may cause rapid wear and shortened with clean engine oil.
component life.
Note: Place an identification mark on each of the

components of the rocker shaft for installation
purposes.
Improper assembly of parts that are spring loaded

Illustration 157 g01160012 can cause bodily injury.
To prevent possible injury, follow the established
equipment.
parts propelled by a released spring force. 2. Install exhaust rocker arm (3), spring (4), inlet
rocker arm (5), and stand (6) on rocker shaft (1).
equipment. 3. Install plug (2) into rocker shaft (1).
Follow the recommended procedure and use all
recommended tooling to release the spring force.
1. Remove plug (2) from rocker shaft (1).

RENR8633 71
End By:
Shaft - Install”.
i02884290
Rocker Arm and Shaft - Install

SMCS Code: 1102-012
Table 45
Required Tools
A 8T-2998 Lubricant 1
NOTICE
Keep all parts clean from contaminants. Illustration 159 g00953116

component life.
1. Apply Tooling (A) to both ends of the pushrods.
2. Lubricate the pushrods with clean engine oil. Install

the pushrods and the valve bridges.
3. Position rocker shaft (4) on the cylinder head.

Install bolts (1). Tighten the bolts in a numerical
sequence.
4. Apply Tooling (A) to each of the bottom faces of the

rocker arms.
5. Position rocker arm adjustment screws (2) and
tighten nuts (3). Adjust the valve lash of the rocker
arms. Refer to Testing and Adjusting, “Engine
Valve Lash - Inspect/Adjust”.
End By:
72 RENR8633
i02884464
Cylinder Head - Remove

SMCS Code: 1100-011
Removal Procedure
Start By:
Remove the valve mechanism cover base. Refer
to Disassembly and Assembly, “Valve
Mechanism Cover Base - Remove and Install”.
Remove the rocker arm and shaft. Refer to
Shaft - Remove”.
Remove the electronic unit injectors. Refer to
Disassembly and Assembly, “Electronic Unit 1. Disconnect coolant temperature sensor (1).
2. Disconnect inlet air temperature sensor (3).
Remove the exhaust manifold. Refer to
Disassembly and Assembly, “Exhaust Manifold
- Remove and Install”. 3. Disconnect inlet air pressure sensor (2).
Remove the aftercooler. Refer to Disassembly 4. Disconnect fuel return tube assembly (4).
and Assembly, “Aftercooler - Remove”.
Remove the fuel filter base. Refer to Disassembly
Install”.
Remove the fan drive. Refer to Disassembly and
Assembly, “Fan Drive - Remove”.
NOTICE
suitable to collect and contain fluids on Caterpillar 5. Disconnect injection actuation pressure sensor (6).
products.
mandates.
7. Disconnect harness assembly (7) and harness
assembly (8).
NOTICE
component life.
RENR8633 73
8. Remove tube assembly (9) from cylinder head 11. Remove plug assemblies (13) and plug
(10). assemblies (14) from the cylinder head. Remove
the O-ring seal from the plug assemblies.
12. Remove pipe plugs (15) from the cylinder head.
13. If necessary, remove cup plugs (12) from the

cylinder head.
i02884958
Cylinder Head - Install

SMCS Code: 1100-012
Table 46
Illustration 164 g01140918 Required Tools

9. Remove cylinder head bolts (11). Attach a suitable
lifting device to cylinder head (10). The weight of A 6V-6640 Sealant -
cylinder head (10) is approximately 100 kg Guide Stud
B - 2
(220 lb). Remove the cylinder head from the (M16 x 2.0 x 200 mm)
cylinder block.
C 8T-3052 Degree Wheel 1
10. Remove the cylinder head gasket assembly from
the cylinder block.
NOTICE
component life.
74 RENR8633
9. Tighten the cylinder head bolts according to the

following procedure:
a. In a numerical sequence, tighten Bolts 1

through 26 to a torque of 130 ± 15 N·m
(96 ± 11 lb ft).
1. Apply Tooling (A) to cup plugs (12). Install the cup
b. In a numerical sequence, tighten Bolts 1
plugs in the cylinder head.
through 26 again to a torque of 130 ± 15 N·m
2. Install pipe plugs (15) in the cylinder head. (96 ± 11 lb ft).
3. Install the O-rings on plug assemblies (13) and c. In a numerical sequence, tighten Bolts 1
plug assemblies (14). Install the plug assemblies in through 26 for an additional 90 ± 5 degrees (1/
the cylinder head. 4 turn).
4. Thoroughly clean the mating surfaces of the Note: If Tooling (C) is not used, place an index
mark on the bolt and the cylinder head.
cylinder head and the cylinder block.
d. Completely loosen Bolts 1 through 26.
5. Install Tooling (B) in the cylinder block.
e. In a numerical sequence, tighten Bolts 1
6. Install a new cylinder head gasket assembly on the
cylinder block.
(96 ± 11 lb ft).
f. In a numerical sequence, tighten Bolts 1

through 26 again to a torque of 130 ± 15 N·m
(96 ± 11 lb ft).
g. In a numerical sequence, tighten Bolts 1

through 26 for an additional 90 ± 5 degrees (1/
4 turn).
Note: If Tooling (C) is not used, place an index
mark on the bolt and the cylinder head.
h. In a numerical sequence, tighten Bolts 27

(21 ± 5 lb ft).
7. Attach a suitable lifting device to cylinder head

(10). The weight of cylinder head (10) is
approximately 100 kg (220 lb). Position the
cylinder head on Tooling (B).
8. Apply clean engine oil to the threads of cylinder

head bolts (11) and under the bolt head. Install
cylinder head bolts (11). Remove Tooling (B).
Install the remaining cylinder head bolts.
RENR8633 75
16. Connect inlet air temperature sensor (3).
17. Connect coolant temperature sensor (1).

End By:
Install the fan drive. Refer to Disassembly and
Assembly, “Fan Drive - Install”.
Install the fuel filter base. Refer to Disassembly
Install”.
Install the aftercooler. Refer to Disassembly and
Assembly, “Aftercooler - Install”.
Illustration 169 g01027265 Install the exhaust manifold. Refer to
Disassembly and Assembly, “Exhaust Manifold
10. Install tube assembly (9) to cylinder head (10). - Remove and Install”.
Install the electronic unit injectors. Refer to
Injector - Install”.
Shaft - Install”.
Install the valve mechanism cover base. Refer to
Mechanism Cover Base - Remove and Install”.
i02281186
Lifter Group - Remove and

Install
SMCS Code: 1209-010
11. Connect harness assembly (7) and harness
assembly (8). Removal Procedure
Start By:
Remove the cylinder head. Refer to Disassembly
13. Connect injection actuation pressure sensor (6). and Assembly, “Cylinder Head - Remove”.
NOTICE
component life.
14. Connect fuel return tube assembly (4).
15. Connect inlet air pressure sensor (2).

76 RENR8633
End By:
Install the cylinder head. Refer to Disassembly
and Assembly, “Cylinder Head- Install”.
i02545092
Camshaft - Remove
SMCS Code: 1210-011
Removal Procedure
Table 48
Required Tools
Illustration 172 g01141708 Tool Part Number Part Description Qty
A FT-2730 Hook 12
1. Remove valve lifter (1) from the cylinder block.
2. Put identification marks on the valve lifter for Start By:

installation purposes.
Remove the rocker arm and the shaft. Refer to
Installation Procedure Disassembly and Assembly, “Rocker Arm and
Shaft - Remove”.
Table 47
Required Tools
Remove the front cover. Refer to Disassembly
and Assembly, “Front Cover - Remove and
Tool Part Number Part Description Qty Install”.
A 8T-2998 Lubricant -
NOTICE
NOTICE Contaminants may cause rapid wear and shortened
Keep all parts clean from contaminants. component life.
component life. 1. Use Tooling (A) to reposition the valve lifters out of
the way of the camshaft.
2. Set the No. 1 piston to top center on the

compression stroke. Refer to Testing and
Piston”.
1. Lubricate the camshaft lobe and the valve lifter

bore with a 50/50 mixture of Tooling (A) and clean
engine oil.
2. Install valve lifter (1) in the original location in the
cylinder block. 3. Ensure that the timing marks on camshaft gear (1)
and idler gear (2) are aligned.
RENR8633 77
4. Remove bolts (3) and thrust plate (4) from the

cylinder block.

Do not damage the lobes or the bearings when the
camshaft is removed or installed.
NOTICE
Do not damage the lobes or the bearings when the
camshaft is removed or installed. Note: During the installation of the camshaft, rotate
the camshaft in both directions in order to prevent
5. Remove camshaft (5) from the cylinder block. binding in the camshaft bearing bores.
1. Lubricate the camshaft lobes and the valve lifter
bore with a 50/50 mixture of Tooling (B) and clean
i02885302
engine oil. Apply clean engine oil on the camshaft
Camshaft - Install bearing journals. Carefully install camshaft (5) in
the cylinder block.
SMCS Code: 1210-012
Table 49
Required Tools
A FT-2730 Hook 12
B 8T-2998 Lubricant -
NOTICE
component life. Illustration 177 g01032348
NOTICE
When installing the camshaft, make sure the number
one cylinder is at top center of the compression stroke
with the timing bolt installed in the flywheel. The cam-
shaft timing is very important. The timing mark on the
camshaft drive gear must line up with the timing mark
on the idler gear. Refer to the Specifications Manual
for more information.
2. Ensure that the timing marks on camshaft gear (1)

and idler gear (2) are aligned.
78 RENR8633
3. Install thrust plate (4) and bolts (3). 2. Use a suitable press to remove the camshaft from
camshaft gear (1).
4. The maximum permissible end play for a worn
camshaft is 0.46 mm (0.018 inch). The maximum Installation Procedure
permissible end play for a new camshaft is
0.13 ± 0.08 mm (0.005 ± 0.003 inch). Note: The temperature of the camshaft gear must not
exceed 177 °C (350 °F) during installation.
5. Use Tooling (A) to position the valve lifters in the
1. Raise the temperature of the camshaft gear up to a
cylinder block.
temperature of 177 °C (350 °F).
6. Calibrate the speed/timing sensor. Refer to
2. Align the key in the camshaft with the groove
Troubleshooting, “Engine Speed/Timing Sensor -
(keyway) in the camshaft gear.
Calibrate”.
End By: 3. Install the camshaft gear on the end of the
camshaft.
Install the front cover. Refer to Disassembly and
Assembly, “Front Cover - Remove and Install”. End By:
Install the rocker arm and the shaft. Refer to Install the camshaft. Refer to Disassembly and
Disassembly and Assembly, “Rocker Arm and Assembly, “Camshaft - Install”.
Shaft - Install”.
i02545687
i02408922
Camshaft Bearings - Remove
Camshaft Gear - Remove and SMCS Code: 1211-011
Install
SMCS Code: 1210-010-GE Removal Procedure
Table 50
Removal Procedure Required Tools
Start By: Tool Part Number Part Description Qty
Remove the camshaft. Refer to Disassembly and A 8S-2241 Camshaft Bearing Tool Group 1
1. Wrap the camshaft with a protective covering in Start By:

order to prevent damage to the camshaft. Remove the camshaft. Refer to Disassembly and
Remove the flywheel housing. Refer to
Disassembly and Assembly, “Flywheel
Housing- Remove and Install”.
Note: Note the oil hole orientation in each camshaft
bearing prior to removal for assembly purposes.
NOTICE
component life.
NOTICE
Do not allow the camshaft to fall to the floor when
pressing it from the drive gear. Also make sure that
the camshaft lobes do not catch on the press plates.
RENR8633 79
NOTICE
products.
mandates.
1. Refer to Illustration 180 for the locations of the

bearings.
(1) Installation Dimension (A) for bearing (1)

............................. 816.5 ± 0.8 mm (32.15 ± 0.03 inch)
(2) Installation Dimension (B) for bearing (2)

............................. 536.5 ± 0.8 mm (21.12 ± 0.03 inch)
(3) Installation Dimension (C) for bearing (3)

..............................294.5 ± 0.8 mm (11.59 ± 0.03 inch)
(4) Installation Dimension (D) for bearing (4)

........................... 0.50 ± 0.25 mm (0.020 ± 0.010 inch)
1. Use Tooling (A) to remove the camshaft bearings

from the cylinder block.
i02545718
Camshaft Bearings - Install

SMCS Code: 1211-012
Table 51
Required Tools
A 8S-2241 Camshaft Bearing Tool Group 1
NOTICE
component life.
NOTICE
Camshaft bearings must be installed into their correct
position. Failure to do so will result in engine damage.
80 RENR8633
2. Use Tooling (A) to install bearings (1), (2), and (3) 3. Install front bearing (4). Carefully locate oil hole (8)
that are behind the front bearing. Install the at the oil gallery. Orient joint (7), as shown.
bearings to the proper depths. Refer to Illustration
End By:
180 and refer to Step 1. Orient the bearings so
that oil holes (5) are located at the tops of the Install the flywheel housing. Refer to Disassembly
bores and joints (6) are positioned, as shown. and Assembly, “Flywheel Housing - Remove
and Install”.
Install the camshaft. Refer to Disassembly and
Assembly, “Camshaft - Install”.
i02885733
Engine Oil Pan - Remove and

Install
SMCS Code: 1302-010
Removal Procedure
Hot oil and components can cause personal

injury.
Do not allow hot oil or components to contact
skin.
RENR8633 81
NOTICE
component life.
NOTICE
products.
mandates.
1. Drain the engine oil into a suitable container for

storage or disposal. Refer to Operation and
Maintenance Manual, “Engine Oil - Change”.

(A) Front
(B) Left
(C) Rear
(D) Right
1. Clean the mating surface of engine oil pan (1) and

the cylinder block. Apply Tooling (A) to four areas
on the sealing surface of the engine oil pan at the
mating surfaces of the front housing, the flywheel
Illustration 183 g01436507 housing, and the engine oil pan. The areas are
Marked Location (Y).
2. Remove bolts (2). Remove engine oil pan (1) and
the gasket. 2. Place a new gasket and engine oil pan (1) on the
cylinder block.
Table 52 3. Tighten four Oil Pan Bolts (X).
Required Tools 4. Start with Bolt (Z) and tighten all remaining bolts (2)
Tool Part Number Part Description Qty in a counterclockwise sequence.
A 230-6352 Silicone Sealant 1 5. Tighten bolts (2) to a torque of 31 ± 3 N·m
(23 ± 2 lb ft).
NOTICE 6. Start again with Bolt (Z) and tighten all remaining
Keep all parts clean from contaminants. bolts in a counterclockwise sequence.
Contaminants may cause rapid wear and shortened 7. Tighten bolts (2) again to a torque of 31 ± 3 N·m
component life.
(23 ± 2 lb ft).
82 RENR8633
8. Fill the engine with oil to the correct level. Refer to i02274286
Operation and Maintenance Manual, “Engine Oil -
Change”. Cylinder Liner - Install
SMCS Code: 1216-012
i02549523
Cylinder Liner - Remove Table 54
SMCS Code: 1216-011 Required Tools
Part Description Qty

Removal Procedure Tool Part Number
Table 53 B 2P-8260 Cylinder Liner Installer 1

Required Tools C 5P-3975 Rubber Lubricant 1
173-5527(1) Cylinder Pack Puller 1 NOTICE

A Keep all parts clean from contaminants.
1U-9897(1) Bridge 1
(1) 5P-8665Cylinder Liner Puller Gp is an optional Tool for remov- Contaminants may cause rapid wear and shortened
ing the cylinder liner. component life.
Start By:
1. Check the cylinder liner projection. Refer to Testing
Remove the pistons and connecting rods. Refer and Adjusting, “Cylinder Liner Projection - Inspect”.
to Disassembly and Assembly, “Pistons and
Connecting Rods - Remove”.
NOTICE
component life.
2. Apply Tooling (C) to new seal (2). Install new seal

(2) in the machined groove on cylinder liner (1).
3. Lubricate the lower portion of cylinder liner (1) with

clean engine oil. Ensure that the corresponding
crankshaft throw is at the bottom center. Use
Illustration 186 g01138987 Tooling (B) to install cylinder liner (1).
End By:
1. Use Tooling (A) to remove cylinder liners (1).
Install the pistons and connecting rods. Refer to
2. Remove the seals from cylinder liners (1). Disassembly and Assembly, “Pistons and
Connecting Rods - Install”.
RENR8633 83
i03433580
NOTICE
Piston Cooling Jets - Remove
and Install Contaminants may cause rapid wear and shortened
component life.
SMCS Code: 1331-010
Removal Procedure
Table 55
Required Tools
A 9S-9082 Engine Turning Tool 1
Start By:
Remove the engine oil pan. Refer to Disassembly
Install”.
NOTICE Illustration 189 g01144041

Contaminants may cause rapid wear and shortened 1. Use Tooling (A) to rotate the crankshaft in order to
component life. gain access to the piston cooling jet.
Note: Engine damage may occur if the piston cooling

jet is not installed properly. Install the piston cooling
jet by hand.
2. Position piston cooling jet (2) in the cylinder block.
Ensure that piston cooling jet (2) is flush with the
cylinder block. Install bolt (1). Tighten bolt (1) to a
torque of 28 ± 7 N·m (21 ± 5 lb ft).
End By:
Install the engine oil pan. Refer to Disassembly
Install”.
i02886266

Pistons and Connecting Rods -
1. Use Tooling (A) to rotate the crankshaft in order to Remove
gain access to the piston cooling jet. SMCS Code: 1225-011
2. Remove bolt (1) and remove piston cooling jet (2).
Removal Procedure
Installation Procedure Table 57
Table 56 Required Tools
Required Tools Part Description Qty
Tool Part Number
Tool Part Number Part Description Qty A 9S-9082 Engine Turning Tool 1
84 RENR8633
Start By:
Remove the cylinder head. Refer to Disassembly Note: This engine has fractured connecting rods.
and Assembly, “Cylinder Head - Remove”. Fractured connecting rods must be handled with
care. Use a soft faced hammer in order to tap the
Remove the engine oil pump. Refer to connecting rod cap, if necessary.
Disassembly and Assembly, “Engine Oil Pump
- Remove”. 3. Loosen connecting rod cap bolts (2). Remove
connecting rod cap bolts (2) and connecting rod
Remove the piston cooling jets. Refer to cap (1).
Disassembly and Assembly, “Piston Cooling
Jets - Remove and Install”. 4. Remove the lower half of connecting rod bearing
(5) from connecting rod cap (1).
NOTICE
Keep all parts clean from contaminants. 5. Push the piston and connecting rod (3) away from
the crankshaft. Remove the upper half of
component life. connecting rod bearing (4) from connecting rod (3).
6. Remove the piston and connecting rod (3) from the

cylinder liner.
i02549610

Disassemble
SMCS Code: 1225-015
Table 58
Required Tools

A 4C-3601 Piston Ring Expander 1
Start By:
Remove the pistons and connecting rods. Refer
to Disassembly and Assembly, “Pistons and
Connecting Rods - Remove”.
NOTICE
component life.
1. Use Tooling (A) to turn the crankshaft until two of

the connecting rod caps are at the bottom center.
2. Inspect connecting rod (3) and connecting rod cap

(1) for the proper identification mark. Connecting
rod (3) and connecting rod cap (1) should have an
etched number on the side that is toward the
camshaft. The number should match the cylinder
number. Mark connecting rod (3) and connecting
rod cap (1), if necessary.
RENR8633 85
NOTICE
The connecting rod must be heated for the installation
of the piston pin bearing. Do not use a torch.

5. Raise the temperature of connecting rod (1) along
Length (X). The maximum distance of Length (X) is
83.0 mm (3.27 inch). Length (X) should raise the
temperature from 175° to 260°C (347 to 500°F) in
order to assemble bearing.
6. Remove old bearing (8) and install new bearing (8)

at the same time.
7. The bearing joint must be within 5 degrees of one
of the locations that are indicated by the arrows.
i02546083

Assemble
SMCS Code: 1225-016
Assembly Procedure
Table 59
Illustration 193 g01139074 Required Tools

Note: This engine has fractured connecting rods.
Fractured connecting rods must be handled with A 4C-3601 Piston Ring Expander 1
care. When possible, the connecting rod assembly
should be kept bolted together in order to protect the
fractured surface when the connecting rod is out of
the engine.
NOTICE
1. Use Tooling (B) in order to remove retaining rings
(3) from piston skirt (2).
2. Remove piston pin (4) and separate piston skirt (2) component life.
and piston crown (6) from connecting rod (1).
3. Inspect bearings (7) in the piston crown (6).
4. Use Tooling (A) to remove piston rings (5).

86 RENR8633
1. Check the clearance between the ends of piston

NOTICE
rings (5). Refer to Specifications, “Piston and
Verify correct assembly of the pistons and the con-
necting rods. Ensure that the etched numbers on the Rings”.
rod and the rod cap are in the correct positions. The
etched number on the rod and the rod cap correspond 2. Install the oil control piston ring with Tooling (A).
to the cylinder in which it should be installed. The ends of the spring should be rotated 180
degrees from the ring end gap.
3. Install the intermediate piston ring with the side

marked “UP-2” toward the top of the piston. Use
Tooling (A) to install the ring.
4. Install the top piston ring with the side marked

“UP-1” toward the top of the piston. Use Tooling
(A) to install the ring.
5. Inspect bearings (7) in piston crown (6). The piston

crown must be replaced if the piston crown is worn
or damaged.
6. Position piston skirt (2) and piston crown (6) on

connecting rod (1). Apply clean engine oil to pin (4)
and install pin (4). Use Tooling (B) to install
retaining rings (3). Ensure that retaining rings (3)
are in the grooves of piston skirt (2).
End By:
Install the pistons and connecting rods. Refer to
Disassembly and Assembly, “Pistons and
Illustration 195 g01139074 Connecting Rods - Install”.
i03120985

Install
SMCS Code: 1225-012
Table 60
Required Tools
B - Plastic Cap 2
C 173-5528 Piston Ring Compressor 1
NOTICE
Note: This engine has fractured connecting rods. component life.
Fractured connecting rods must be handled with
care. Hold the connecting rod in a soft jawed vise.
Then assemble the piston pin to the connecting rod,
the piston skirt, and the piston crown.
RENR8633 87
NOTICE
The joint between the connecting rod and the con-
necting rod cap is produced by fracturing. The con-
necting rod assembly must be handled with care in
order to avoid damage to the mating surfaces. The
connecting rod assembly must be replaced if any
damage occurs to the mating surfaces. New connect-
ing rod assemblies come with the connecting rod
caps bolted on the connecting rod.
Use only a soft jawed vise to hold the connecting rod
assembly when removing the connecting rod cap
bolts. Use only a soft faced hammer to tap the con-
necting rod cap when separating the connecting rod
cap from the connecting rod.
Failure to use a soft jawed vise and a soft faced ham-
mer may result in damage to the connecting rod
assembly. 4. With the crankshaft throw at the bottom center,
install the piston and connecting rod (3) in the
engine. Ensure that the proper piston and
1. Apply clean engine oil to the pistons, the piston connecting rod are in the corresponding cylinder
rings, and the cylinder bore. with the identification mark on the connecting rod
on the side that is toward the camshaft.
Note: The forged part number on the connecting rod

must be installed toward the flywheel end of the
engine.
5. Line up the piston and connecting rod (3) with the

crankshaft. Use a soft faced hammer and tap the
piston into the cylinder bore until Tooling (C)
comes off of the piston.
6. Before connecting rod (3) comes in contact with

the crankshaft, remove Tooling (B) and install the
upper half of connecting rod bearing (4). Ensure
that the bearing tab engages with the slot in
connecting rod (3).
Typical Example 7. Apply clean engine oil to the surface of the upper
half of connecting rod bearing (4). Use a soft faced
2. Place Tooling (B) over both fractured ends of the hammer in order to tap the piston into the cylinder
connecting rod. bore while you guide connecting rod (3) onto the
3. Position the piston rings so that the end gaps are crankshaft.
located 120 degrees from each other. Use Tooling 8. Place the lower half of connecting rod bearing (5)
(C) to compress the piston rings. in corresponding connecting rod cap (1). Ensure
that the bearing tab engages with the groove in
connecting rod cap (1).
9. Apply clean engine oil to the surface of the lower

half of connecting rod bearing (5). Install
connecting rod cap (1) on connecting rod (3).
Ensure that the number on connecting rod cap (1)
matches the number on connecting rod (3). Ensure
that the numbers are on the same side.
10. Install NEW connecting rod cap bolts (2). Tighten
NEW connecting rod cap bolts (2) to a torque of
50 ± 5 N·m (37 ± 3 lb ft).
88 RENR8633
11. Place an index mark on each connecting rod cap 1. Use Tooling (A) to turn the crankshaft until the
bolt. Tighten each connecting rod cap bolt (2) for connecting rod bearing caps are accessible.
an additional 90 ± 5 degrees (1/4 turn).
2. Check connecting rod (3) and connecting rod caps
12. Use Tooling (A) to rotate the crankshaft in order to (1) for identification and for the location.
ensure that the crankshaft turns freely.
3. Remove connecting rod cap bolts (2) and
End By: connecting rod cap (1) from connecting rod (3).
Install the piston cooling jets. Refer to Remove the lower half of connecting rod bearing
Disassembly and Assembly, “Piston Cooling (5) from connecting rod cap (1).
Jets - Remove and Install”.
Note: This engine has fractured connecting rods.
Install the engine oil pump. Refer to Disassembly Fractured connecting rods must be handled with
and Assembly, “Engine Oil Pump - Install”. care. Use a soft faced hammer in order to tap the
connecting rod cap, if necessary.
Install the cylinder head. Refer to Disassembly
and Assembly, “Cylinder Head - Install”. Note: Do not place the fractured faces of the
connecting rod cap on any surface. The connecting
i02886516 rod cap must be laid flat on the side in order to
prevent damage to the fractured faces of the
Connecting Rod Bearings - connecting rod cap.
Remove 4. Push connecting rod (3) away from the crankshaft.
SMCS Code: 1219-011 Remove the upper half of connecting rod bearing
(4) from connecting rod (3).
Removal Procedure Note: Do not damage the fractured faces of the
Table 61 connecting rod. Place a suitable protective cap on the
Required Tools ends of the connecting rod in order to prevent
damage to the fractured faces of the connecting rod.
A 9S-9082 Engine Turning Tool 1 i02886537
Start By:
Connecting Rod Bearings -
Install
Disassembly and Assembly, “Engine Oil Pump SMCS Code: 1219-012
- Remove”.
NOTICE
Table 62
Required Tools
component life. Tool Part Number Part Description Qty
NOTICE
component life.

RENR8633 89
Note: Ensure that the number on the connecting rod

NOTICE cap matches the number on the connecting rod.
The joint between the connecting rod and the con-
Make sure that both of the numbers are located on
necting rod cap is produced by fracturing. The con-
the same side.
necting rod assembly must be handled with care in
5. Install connecting rod cap (1) and connecting rod
order to avoid damage to the mating surfaces. The
connecting rod assembly must be replaced if any cap bolts (2).
damage occurs to the mating surfaces. New connect-
ing rod assemblies come with the connecting rod 6. Check the bearing clearance. Refer to
caps bolted on the connecting rod. Disassembly and Assembly, “Bearing Clearance -
Check”.
Use only a soft faced hammer to tap the connecting
rod cap when separating the connecting rod cap from 7. Tighten connecting rod cap bolts (2) to a torque of
the connecting rod. 50 ± 5 N·m (37 ± 3 lb ft).
Failure to use a soft faced hammer may result in dam- 8. Place an index mark on each connecting rod cap
age to the fractured surfaces of the connecting rod bolt (2). Tighten each bolt for an additional 90 ± 5
assembly. degrees (1/4 turn).
1. Use Tooling (A) to turn the crankshaft until the 9. Use Tooling (A) to rotate the crankshaft in order to
connecting rod bearing cap is accessible. ensure that the crankshaft turns freely.
End By:
and Assembly, “Engine Oil Pump - Install”.
i02304108
Crankshaft Main Bearings -

Remove
SMCS Code: 1203-011
Removal Procedure
Table 63
Required Tools
Note: Install the connecting rod bearings dry when
A 2P-5518 Bearing Tool 1
clearance checks are performed. Apply clean engine
oil to the connecting rod bearings for final assembly.
2. Remove the protective caps from the end of the Start By:
connecting rod and install the upper half of
connecting rod bearing (4). Ensure that the bearing Remove the engine oil pump. Refer to
tab engages with the slot in connecting rod (3). - Remove”.
3. Pull the piston and connecting rod assembly onto
NOTICE
the crankshaft.
4. Install the lower half of connecting rod bearing (5)
into connecting rod cap (1). Ensure that the component life.
bearing tab engages with the slot in connecting rod
cap (1).
Note: Do not place the fractured faces of the

connecting rod cap on any surface. The connecting
rod cap must be laid flat on the side in order to
prevent damage to the fractured faces of the
connecting rod cap.
90 RENR8633
Note: Place clean engine oil on the crankshaft main

bearings prior to assembly. Ensure that the tabs on
the back side of the crankshaft main bearings fit in the
grooves of the crankshaft main bearing caps and the
cylinder block.
1. Remove bolts (1) and crankshaft main bearing cap

(2).
2. Remove the lower half of the crankshaft main

bearing from crankshaft main bearing cap (2). Illustration 202 g01153704
1. Use Tooling (A) and install the upper halves of the

NOTICE crankshaft main bearings in the cylinder block. Do
If the crankshaft is turned in the wrong direction, the not put oil on the back of the crankshaft main
tab of the crankshaft main bearing will be pushed be- bearing.
tween the crankshaft and the cylinder block. this can
cause damage to either or both the crankshaft and 2. Install the lower halves of the crankshaft main
the cylinder block. bearings in crankshaft main bearing caps (2). Do
not put oil on the back of the crankshaft main
3. Install Tooling (A) in the crankshaft journal. bearing.
4. Turn the crankshaft in order to remove the upper

half of the crankshaft main bearing. NOTICE
Crankshaft main bearing caps should be installed
with the part number toward the front of the engine.
i02408967 Crankshaft main bearing caps are to be identified by
stamped numbers 1 through 7 that are located on the
Crankshaft Main Bearings - bottom surface of the bearing cap. The thrust plate is
Install used on the number 6 main bearing.
SMCS Code: 1203-012

3. Place crankshaft main bearing caps (2) in position
on the cylinder block. Place clean engine oil or
Installation Procedure Molylube on the bolt threads and the washer face.
Table 64
Install bolts (1).
Required Tools
4. Tighten each bolt (1) to a torque of 95 ± 5 N·m
(70 ± 4 lb ft). Tighten each bolt (1) for an additional
A 2P-5518 Bearing Tool 1 90 ± 5 degrees (1/4 turn).
B 8T-5096 Dial Indicator Group 1 5. Check the end play of the crankshaft with Tooling
(B). The end play must be 0.21 - 0.60 mm
(0.008 - 0.024 inch).
NOTICE
Keep all parts clean from contaminants. End By:
Contaminants may cause rapid wear and shortened Install the engine oil pump. Refer to Disassembly
component life. and Assembly, “Engine Oil Pump - Install”.
RENR8633 91
i02274621
3. Remove the thrust plates from the cylinder block.
Crankshaft - Remove
SMCS Code: 1202-011
Removal Procedure
Table 65
Required Tools
Start By:
Remove the front housing. Refer to Disassembly
and Assembly, “Housing (Front) - Remove”.
Remove the flywheel housing. Refer to
Disassembly and Assembly, “Flywheel
Housing - Remove and Install”.
- Remove”.
NOTICE
Keep all parts clean from contaminants. 4. Fasten Tooling (A) and a suitable lifting device to
crankshaft (3). The weight of crankshaft (3) is
Contaminants may cause rapid wear and shortened approximately 79 kg (175 lb).
component life.
5. Remove crankshaft (3).
1. Ensure that the No. 1 cylinder is at the top center
compression stroke. Refer to Testing and i02274650

Piston”. Crankshaft - Install
SMCS Code: 1202-012
Table 66
Required Tools
NOTICE
component life.
NOTICE
Ensure that the crankshaft main bearing tabs engage
with the grooves in the block and the crankshaft main
bearing cap.
2. Remove connecting rod caps (1) and crankshaft

main bearing caps (2).
92 RENR8633
a. Tighten each bolt to a torque of 50 ± 5 N·m

(37 ± 3 lb ft).
b. Place an index mark on each bolt. Tighten

each bolt for an additional 90 ± 5 degrees (1/4
turn).
5. Tighten the bolts for crankshaft main bearing caps

(2) by using the following procedure:
a. Tighten each bolt to a torque of 95 ± 5 N·m

(70 ± 4 lb ft).
b. Place an index mark on each bolt. Tighten

each bolt for an additional 90 ± 5 degrees (1/4
turn).
End By:
and Assembly, “Engine Oil Pump - Install”.
Install the flywheel housing. Refer to Disassembly
and Assembly, “Flywheel Housing - Remove
1. Fasten Tooling (A) and a suitable lifting device to and Install”.
crankshaft (3). The weight of crankshaft (3) is
approximately 79 kg (175 lb). Align the timing Install the front housing. Refer to Disassembly
marks and position crankshaft (3) in the cylinder and Assembly, “Housing (Front) - Install”.
block.
i02717761
2. Apply clean engine oil to the thrust plates and
install the thrust plates in the cylinder block. Bearing Clearance - Check
SMCS Code: 1203-535; 1219-535
Measurement Procedure
Table 67
Required Tools
Part
Tool Number Part Description Qty
198-9142 Plastic Gauge (Green)
0.025 to 0.076 mm 1
(0.001 to 0.003 inch)
198-9143 Plastic Gauge (Red)

0.051 to 0.152 mm 1
(0.002 to 0.006 inch)
A
198-9144 Plastic Gauge (Blue)
0.102 to 0.229 mm 1
(0.004 to 0.009 inch)
198-9145 Plastic Gauge (Yellow)

0.230 to 0.510 mm 1
(0.009 to 0.020 inch)
3. Install connecting rod caps (1) and crankshaft main Note: Plastic gauge may not be necessary when the
bearing caps (2). engine is in the chassis.
4. Tighten the bolts for connecting rod caps (1) by

using the following procedure:
RENR8633 93
NOTICE
component life.
Note: Caterpillar does not recommend the checking

of the actual bearing clearances particularly on small
engines. This is because of the possibility of
obtaining inaccurate results and the possibility of
damaging the bearing or the journal surfaces. Each
Caterpillar engine bearing is quality checked for
specific wall thickness.
Note: The measurements should be within
specifications and the correct bearings should be
used. If the crankshaft journals and the bores for the
block and the rods were measured during
disassembly, no further checks are necessary.
However, if the technician still wants to measure the Illustration 207 g01152855
bearing clearances, Tooling (A) is an acceptable Typical Example
method. Tooling (A) is less accurate on journals with
small diameters if clearances are less than 0.10 mm 4. Remove all of Tooling (A) before you install the
(0.004 inch). bearing cap.
NOTICE Note: When Tooling (A) is used, the readings can

Lead wire, shim stock or a dial bore gauge can dam- sometimes be unclear. For example, all parts of
age the bearing surfaces. Tooling (A) are not the same width. Measure the
major width in order to ensure that the parts are within
the specification range. Refer to Specifications
The technician must be very careful to use Tooling (A) Manual, “Connecting Rod Bearing Journal” and
correctly. The following points must be remembered: Specifications Manual, “Main Bearing Journal” for the
• Ensure that the backs of the bearings and the correct clearances.
bores are clean and dry.
i02887760
• Ensure that the bearing locking tabs are properly
seated in the tab grooves. Atmospheric Pressure Sensor
• The crankshaft must be free of oil at the contact - Remove and Install
points of Tooling (A). SMCS Code: 1923-010
1. Put a piece of Tooling (A) on the crown of the S/N: P9L1–Up
bearing that is in the cap.
S/N: P7Z1–Up
Note: Do not allow Tooling (A) to extend over the
edge of the bearing. Removal Procedure
2. Use the correct torque-turn specifications in order NOTICE
to install the bearing cap. Do not use an impact Keep all parts clean from contaminants.
wrench. Be careful not to dislodge the bearing
when the cap is installed. Contaminants may cause rapid wear and shortened
component life.
Note: Do not turn the crankshaft when Tooling (A) is
installed.
3. Carefully remove the cap, but do not remove
Tooling (A). Measure the width of Tooling (A) while
Tooling (A) is in the bearing cap or on the
crankshaft journal. Refer to Illustration 207 .
94 RENR8633
1. Disconnect harness assembly (1) from Note: Check the O-ring seal for wear or for damage.
atmospheric pressure sensor (2). If necessary, replace the O-ring seal.
1. Install the O-ring seal onto atmospheric pressure
2. Remove atmospheric pressure sensor (2) and the sensor (2).
O-ring seal.
2. Install atmospheric pressure sensor (2) and the O-
Installation Procedure ring seal. Tighten atmospheric pressure sensor (2)
to a torque of 10 ± 2 N·m (88 ± 18 lb in).
NOTICE
Keep all parts clean from contaminants. 3. Connect harness assembly (1) to atmospheric
pressure sensor (2).
component life.
i02547038
Atmospheric Pressure Sensor

- Remove and Install
SMCS Code: 1923-010
S/N: KLW1–Up
S/N: P7Z1–Up
Removal Procedure
NOTICE
component life.
RENR8633 95
1. Disconnect harness assembly (1) from Note: Check the O-ring seal for wear or for damage.
atmospheric pressure sensor (2). If necessary, replace the O-ring seal.
1. Install the O-ring seal onto atmospheric pressure
2. Remove atmospheric pressure sensor (2) and the sensor (2).
O-ring seal.
2. Install atmospheric pressure sensor (2) and the O-
Installation Procedure ring seal. Tighten atmospheric pressure sensor (2)
to a torque of 10 ± 2 N·m (88 ± 18 lb in).
NOTICE
Keep all parts clean from contaminants. 3. Connect harness assembly (1) to atmospheric
component life.
i02353549
Coolant Temperature Sensor -

Remove and Install
SMCS Code: 1906-010
S/N: KLW1–Up
S/N: P7Z1–Up
Removal Procedure
96 RENR8633
NOTICE
products.
mandates.
1. Drain the coolant into a suitable container for

storage or for disposal. Drain the coolant to a level
that is below the coolant temperature sensor. Refer
to Operation and maintenance Manual, “Cooling
Note: Check the O-ring seal for wear or for damage.

If necessary, replace the O-ring seal.
1. Install the O-ring seal onto coolant temperature
sensor (2).
2. Install coolant temperature sensor (2) into the

engine. Tighten coolant temperature sensor (2) to
a torque of 20 ± 5 N·m (15 ± 4 lb ft).
3. Connect harness assembly (1) onto coolant

temperature sensor (2).
4. Fill the cooling system. Refer to Operation and

maintenance Manual, “Cooling System Coolant
(ELC) - Change”.
i02887781
Coolant Temperature Sensor -

Illustration 212 g01175490 Remove and Install
SMCS Code: 1906-010
2. Disconnect harness assembly (1) from coolant
temperature sensor (2). S/N: P9L1–Up
3. Remove coolant temperature sensor (2) from the S/N: P7Z1–Up

engine.
Removal Procedure
RENR8633 97
NOTICE
products.
mandates.
1. Drain the coolant into a suitable container for

storage or for disposal. Drain the coolant to a level
that is below the coolant temperature sensor. Refer
to Operation and maintenance Manual, “Cooling

1. Install the O-ring seal onto coolant temperature
sensor (2).
2. Install coolant temperature sensor (2) into the

engine. Tighten coolant temperature sensor (2) to
a torque of 20 ± 3 N·m (15 ± 2 lb ft).
3. Connect harness assembly (1) onto coolant

4. Fill the cooling system. Refer to Operation and

maintenance Manual, “Cooling System Coolant
(ELC) - Change”.
i02547060
Engine Oil Pressure Sensor -

SMCS Code: 1924-010
2. Disconnect harness assembly (1) from coolant
temperature sensor (2). S/N: KLW1–Up
3. Remove coolant temperature sensor (2) from the S/N: P7Z1–Up

engine.
Removal Procedure
NOTICE
component life.
98 RENR8633
NOTICE
products.
mandates.

1. Install the O-ring seal on engine oil pressure
sensor (2).
2. Install engine oil pressure sensor (2). Tighten

engine oil pressure sensor (2) to a torque of
10 ± 2 N·m (88 ± 18 lb in).
3. Connect harness assembly (1) onto engine oil

i02887824

Engine Oil Pressure Sensor -
1. Disconnect harness assembly (1) from engine oil Remove and Install
pressure sensor (2). SMCS Code: 1924-010
2. Remove engine oil pressure sensor (2) and the O- S/N: P9L1–Up
ring seal.
S/N: P7Z1–Up
Removal Procedure
NOTICE NOTICE
RENR8633 99
NOTICE
products.
mandates.

1. Install the O-ring seal on engine oil pressure
sensor (2).
2. Install engine oil pressure sensor (2). Tighten

engine oil pressure sensor (2) to a torque of
10 ± 2 N·m (88 ± 18 lb in).
3. Connect harness assembly (1) onto engine oil

i02887933

Fuel Pressure Sensor -
1. Disconnect harness assembly (1) from engine oil Remove and Install
pressure sensor (2). SMCS Code: 7414-010
2. Remove engine oil pressure sensor (2) and the O- S/N: P9L1–Up
ring seal.
S/N: P7Z1–Up
NOTICE
component life.
100 RENR8633

NOTICE NOTICE
Care must be taken to ensure that fluids are con- Keep all parts clean from contaminants.
nance, testing, adjusting and repair of the product. Be Contaminants may cause rapid wear and shortened
prepared to collect the fluid with suitable containers component life.
products.
mandates.
NOTICE
component life.

1. Install a new O-ring seal on fuel pressure sensor
(2).
2. Install fuel pressure sensor (2) and tighten to a

torque of 10 ± 2 N·m (89 ± 18 lb in).
i02353671
Fuel Pressure Sensor -

SMCS Code: 7414-010
S/N: KLW1–Up
2. Remove fuel pressure sensor (2) from the fuel filter
base. S/N: P7Z1–Up
3. Remove the O-ring seal from fuel pressure sensor

(2).
RENR8633 101

NOTICE NOTICE
Care must be taken to ensure that fluids are con- Keep all parts clean from contaminants.
nance, testing, adjusting and repair of the product. Be Contaminants may cause rapid wear and shortened
prepared to collect the fluid with suitable containers component life.
products.
mandates.
NOTICE
component life.

1. Install a new O-ring seal on fuel pressure sensor
(2).
2. Install fuel pressure sensor (2) and tighten to a

torque of 10 ± 2 N·m (89 ± 18 lb in).
i02888006
Injection Actuation Pressure

Illustration 222 g01175571 Sensor - Remove and Install
SMCS Code: 1925-010
S/N: P9L1–Up
2. Remove fuel pressure sensor (2) from the fuel filter
base. S/N: P7Z1–Up
3. Remove the O-ring seal from fuel pressure sensor Removal Procedure
(2).
NOTICE
component life.
102 RENR8633
NOTICE
products.
mandates.

1. Install the O-ring seal on injection actuation
2. Install injection actuation pressure sensor (2).

Tighten injection actuation pressure sensor (2) to a
torque of 20 ± 2 N·m (15 ± 1 lb ft).
i02353707

Injection Actuation Pressure
Sensor - Remove and Install
1. Disconnect harness assembly (1). SMCS Code: 1925-010
2. Remove injection actuation pressure sensor (2). S/N: KLW1–Up
3. Remove the O-ring from injection actuation S/N: P7Z1–Up
Removal Procedure
NOTICE
NOTICE Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
component life.
RENR8633 103
NOTICE
products.
mandates.

1. Install the O-ring seal on injection actuation
2. Install injection actuation pressure sensor (2).

Tighten injection actuation pressure sensor (2) to a
torque of 20 ± 2 N·m (15 ± 1 lb ft).
i02888045

Speed/Timing Sensor -
Remove and Install
1. Disconnect harness assembly (1). SMCS Code: 1907-010; 1912-010
2. Remove injection actuation pressure sensor (2). S/N: P9L1–Up
3. Remove the O-ring from injection actuation S/N: P7Z1–Up
Removal Procedure
NOTICE
component life.
104 RENR8633
NOTICE
component life.
1. Disconnect harness assemblies (2) from speed/

timing sensors (1).
Note: Check the O-ring seals for wear or for damage.

1. Apply Tooling (A) to the O-ring seals prior to
installation. Install speed/timing sensors (1).
2. Position bracket (5) and install bolt (3) and washer

(4). Tighten bolt (3) to a torque of 28 ± 7 N·m
(21 ± 5 lb ft).
2. Remove bolt (3), washer (4), and bracket (5).

Remove speed/timing sensors (1). Remove the O-
ring seals from speed/timing sensors (1).
Table 68
Required Tools
A 5P-3975 Rubber Lubricant 1

RENR8633 105
3. Connect harness assemblies (2) onto speed/timing 1. Disconnect harness assemblies (2) from speed/
sensors (1). timing sensors (1).
i02354157
Speed/Timing Sensor -
Remove and Install
SMCS Code: 1907-010; 1912-010
S/N: KLW1–Up
S/N: P7Z1–Up
Removal Procedure
2. Remove bolt (3), washer (4), and bracket (5).

Remove speed/timing sensors (1). Remove the O-
ring seals from speed/timing sensors (1).
Table 69
Required Tools
A 5P-3975 Rubber Lubricant 1

106 RENR8633
NOTICE
component life.
3. Connect harness assemblies (2) onto speed/timing

sensors (1).
i02888118

Turbocharger Outlet Pressure
Note: Check the O-ring seals for wear or for damage.
1. Apply Tooling (A) to the O-ring seals prior to SMCS Code: 1917-010
installation. Install speed/timing sensors (1).
S/N: P9L1–Up
2. Position bracket (5) and install bolt (3) and washer S/N: P7Z1–Up
(4). Tighten bolt (3) to a torque of 28 ± 7 N·m
(21 ± 5 lb ft). Removal Procedure
NOTICE
component life.
NOTICE
products.
mandates.
RENR8633 107
2. Install turbocharger outlet pressure sensor (2).

Tighten turbocharger outlet pressure sensor (2) to
a torque of 10 ± 2 N·m (88 ± 18 lb in).
3. Connect harness assembly (1) to turbocharger

outlet pressure sensor (2).
i02547010
Turbocharger Outlet Pressure

SMCS Code: 1917-010
S/N: KLW1–Up
S/N: P7Z1–Up
Removal Procedure
NOTICE
Illustration 236 g01437751 Keep all parts clean from contaminants.
1. Disconnect harness assembly (1) from component life.
turbocharger outlet pressure sensor (2).
2. Remove turbocharger outlet pressure sensor (2)

NOTICE
and the O-ring seal. Care must be taken to ensure that fluids are con-
Installation Procedure nance, testing, adjusting and repair of the product. Be
products.
mandates.
Note: Check the O-ring seal for wear or damage. If

necessary, replace the O-ring seal.
1. Install the O-ring seal on turbocharger outlet
108 RENR8633
2. Install turbocharger outlet pressure sensor (2).

Tighten turbocharger outlet pressure sensor (2) to
a torque of 10 ± 2 N·m (88 ± 18 lb in).
3. Connect harness assembly (1) to turbocharger

outlet pressure sensor (2).
i02888135
Inlet Air Temperature Sensor -

Remove and Install
SMCS Code: 1921-010
S/N: P9L1–Up
S/N: P7Z1–Up
Removal Procedure
NOTICE
Illustration 238 g01175712 Keep all parts clean from contaminants.
1. Disconnect harness assembly (1) from component life.
turbocharger outlet pressure sensor (2).
2. Remove turbocharger outlet pressure sensor (2)

and the O-ring seal.
1. Disconnect harness assembly (1) from inlet air

Illustration 239 g01175712 2. Remove inlet air temperature sensor (2). Remove
the O-ring seal from inlet air temperature sensor
Note: Check the O-ring seal for wear or damage. If
(2).
necessary, replace the O-ring seal.
1. Install the O-ring seal on turbocharger outlet Installation Procedure
RENR8633 109
Note: Check the O-ring seal for wear or for damage. 1. Disconnect harness assembly (1) from inlet air
If necessary, replace the O-ring seal. temperature sensor (2).
1. Install the O-ring seal onto inlet air temperature
sensor (2). 2. Remove inlet air temperature sensor (2). Remove
the O-ring seal from inlet air temperature sensor
2. Install inlet air temperature sensor (2). Tighten inlet (2).
air temperature sensor (2) to a torque of
20 ± 3 N·m (15 ± 2 lb ft). Installation Procedure
3. Connect harness assembly (1) onto inlet air
i02547027
Inlet Air Temperature Sensor -

Remove and Install
SMCS Code: 1921-010
S/N: KLW1–Up
S/N: P7Z1–Up
Removal Procedure
NOTICE
component life.

1. Install the O-ring seal onto inlet air temperature
sensor (2).
110 RENR8633
2. Install inlet air temperature sensor (2). Tighten inlet

air temperature sensor (2) to a torque of
20 ± 5 N·m (15 ± 4 lb ft).
3. Connect harness assembly (1) onto inlet air

i02888365
Fan Drive Mounting Group -

Remove and Install
SMCS Code: 1359-010
S/N: P9L1–Up
S/N: P7Z1–Up
Removal Procedure
1. Position fan drive mounting group (1) on the

engine.
i02354656
Fan Drive - Remove

SMCS Code: 1359-011
S/N: KLW1–Up
S/N: P7Z1–Up
Removal Procedure
2. Remove fan drive mounting group (1).
RENR8633 111
Table 70
Required Tools
Start By:
Remove the fan drive. Refer to Disassembly and
Assembly, “Fan Drive - Remove”.
NOTICE
component life.
2. Remove bolts (1) and remove pulley (2).
1. Remove bolts (2) and washers (3).
2. Remove shaft assembly (4) from fan drive bracket

(1).
3. Remove bolts (3) and remove fan drive (4).
i02547150
Fan Drive - Disassemble

SMCS Code: 1359-015
S/N: KLW1–Up
S/N: P7Z1–Up
112 RENR8633
Assembly Procedure
Table 71
Required Tools
B 8T-1807 Bearing Lubricant 1
NOTICE
component life.
3. Remove bolts (5) and plate (6) from shaft (9).
4. Position shaft assembly into a suitable press. If

necessary, use Tooling (A) or a suitable press and
remove shaft (9) from retainer (8) and bearing (7).
i02547173
Fan Drive - Assemble

SMCS Code: 1359-016
S/N: KLW1–Up
S/N: P7Z1–Up
RENR8633 113
4. Install shaft assembly (4), bolts (2), and washers

(3) into fan drive bracket (1). Tighten bolts (2) to a
torque of 28 ± 7 N·m (21 ± 5 lb ft).
End By:
Install the fan drive. Refer to Disassembly and
Assembly, “Fan Drive - Install”.
i02547382
Fan Drive - Install

SMCS Code: 1359-012
S/N: KLW1–Up
S/N: P7Z1–Up
Note: Cool the shaft before pressing bearing onto the

shaft.
1. Apply Tooling (B) to the outside of shaft (9).
2. Use Tooling (A) and a suitable press. Position

bearing (7) and press into retainer (8) and onto
shaft (9).
3. Install bolts (5) and plate (6) into shaft (9). Tighten
bolts (5) to a torque of 28 ± 7 N·m (21 ± 5 lb ft).
114 RENR8633
i02548204
Pump Drive - Remove

SMCS Code: 3108-011
Removal Procedure
Table 72
Required Tools
1. Position fan drive (4) and install bolts (3). Tighten

1. Remove bolts (10), cover (6), and gasket (5) from

adapter assembly (9). Remove bolts (4), adapter
assembly (9), and O-ring seal (8). Remove gear
assembly (7) from adapter assembly (9). Use
Tooling (A) to remove bearing (3). Remove bearing
(2) from flywheel housing (1).
2. Repeat this same procedure to remove accessory

pump drive (11).

i02888589
2. Position pulley (2) and install bolts (1). Tighten

Pump Drive - Install
SMCS Code: 3108-012
Maintenance Manual, “Belts - Inspect/Replace”. Installation Procedure
Table 73
Required Tools
RENR8633 115

(Y) 2.5 ± 0.5 mm (0.10 ± 0.02 inch)
3. Install gear assembly (7). Install O-ring seal (8).
1. Use Tooling (A) to install bearing (2) to the depth of Install adapter assembly (9) in flywheel housing
Dimension (Y) in flywheel housing (1). (1). Install bolts (4).
4. Install gasket (5). Install cover (6). Install bolts (10).
5. Repeat the same procedure to install accessory

pump drive (11).
i02888640
Electronic Control Module -

Remove and Install
SMCS Code: 1901-010
Removal Procedure
Start By:
Remove the fumes disposal group, if necessary.
“Crankcase Breather - Remove and Install”.

(W) 3.5 ± 0.5 mm (0.14 ± 0.02 inch)
(X) 15 ± 5 degrees
2. Orient bearing (3) to Dimension (X). Use Tooling

(A) to install bearing (3) into adapter assembly (9).
Install bearing (3) to Dimension (W).
116 RENR8633
3. Connect harness assemblies (1). Tighten allen

head screws (5) to a torque of 6 ± 1 N·m
(53 ± 9 lb in).
End By:
Install the fumes disposal group, if necessary.
“Crankcase Breather - Remove and Install”.
i02548664
Alternator - Remove and Install

SMCS Code: 1405-010
Removal Procedure
Personal injury can result from failure to discon-

nect the battery.
1. Loosen allen head screws (5) until harness First, disconnect the negative battery cable. Then,
assemblies (1) can be disconnected. Disconnect disconnect the positive battery cable.
harness assemblies (1).
A positive power lead can cause sparks if the bat-
tery is not disconnected. Sparks can possibly re-
2. Disconnect hose assemblies (3). sult in battery explosion or fire.
3. Remove bolts (2), the washers, and the spacers.
Remove electronic control module (4). 1. Disconnect the batteries.
Installation Procedure 2. Place identification marks on all of the harness

assemblies and disconnect the harness
assemblies.
1. Position electronic control module (4) onto the

cylinder block. Install bolts (2), the washers, and
the spacers.
2. Connect hose assemblies (3).

RENR8633 117
4. Connect the harness assembly to alternator (2)

and install the bolt. Refer to Specifications,
“Alternator and Regulator” for the proper torque for
your alternator.
5. Connect the harness assembly to alternator (2)

and install the nut. Refer to Specifications,
“Alternator and Regulator” for the proper torque for
your alternator.
6. Connect the batteries.
i03904991
Electric Starting Motor -

Remove and Install
SMCS Code: 1453-010
Removal Procedure
4. Remove bolts (1) and alternator (2).

Personal injury can result from failure to discon-
Installation Procedure nect the battery.
First, disconnect the negative battery cable. Then,
disconnect the positive battery cable.
A positive power lead can cause sparks if the bat-
tery is not disconnected. Sparks can possibly re-
sult in battery explosion or fire.
1. If necessary, install the pulley on alternator (2). 1. Disconnect cable strap (1).
Install the nut. Refer to Specifications, “Alternator
and Regulator” for the proper torque for your 2. Place an index mark on all of the harness
alternator. assemblies. Disconnect the harness assemblies
from electric starting motor (2).
2. Position alternator (2) on the alternator mounting
bracket. Install bolts (1). 3. Fasten a suitable lifting device to electric starting
motor (4). The weight of electric starting motor (4)
is approximately 35 kg (77 lb).
118 RENR8633
5. Remove electric starting motor (4) and the gasket

from the flywheel housing.
1. Install electric starting motor (4) in reverse order.
i02889233
Air Compressor - Remove and

Install
SMCS Code: 1803-010
Removal Procedure
Table 74
Required Tools

2. Disconnect hose assembly (1) and hose assembly

(3) from the air compressor.
Do not disconnect the air lines until the air pres-
sure in the system is at zero. If hose is discon- 3. Disconnect hose assembly (2) and hose assembly
nected under pressure it can cause personal
(4) from the air compressor.
injury.
the air compressor. The weight of the air
NOTICE
compressor is approximately 23 kg (51 lb).
Contaminants may cause rapid wear and shortened 5. Remove the mounting bracket for the air
component life. compressor by using the following procedure:
NOTICE
products.
mandates.
1. Remove the air pressure from the air tank and

drain the coolant from the cooling system.
a. Remove bolts (5) that fasten the mounting

bracket to the air compressor.
RENR8633 119
b. Remove bolts (6) that fasten the mounting

bracket to the cylinder block. Remove the
mounting bracket for the air compressor.
1. Install Tooling (A) and a suitable lifting device to the

air compressor. The weight of the air compressor
is approximately 23 kg (51 lb).
2. Inspect the condition of the integral seal. Replace
6. Remove bolts (7), air compressor (8), and the the integral seal, if necessary. Install the integral
integral seal from the timing gear housing. seal between air compressor (8) and the timing
gear housing.
Table 75 3. Position air compressor (8) in the front housing.
Ensure that the drive gear engages correctly with
Required Tools
the gear in the front housing.
4. Apply Tooling (B) to the threads of bolts (7). Install
bolts (7). Tighten bolts (7) to a torque of
B 9S-3263 Thread Lock Compound 1 100 ± 20 N·m (75 ± 15 lb ft).
5. Install the mounting bracket for the air compressor

NOTICE by using the following procedure:
component life.
120 RENR8633

a. Position the bracket for the air compressor and

6. Connect hose assembly (4) to the air compressor.
install bolts (5) and bolts (6) finger tight.
Connect the clip that holds hose assembly (4) to
NOTICE the air compressor, if necessary. Tighten the bolt
A loose compressor bracket can lead to a broken that holds the clip for the oil hose assembly to a
front cover and can cause damage to the front gear torque of 28 ± 7 N·m (21 ± 5 lb ft).
train of the engine.
7. Connect hose assembly (1) and hose assembly (3)
to the air compressor.
b. Tighten bolts (5) to a torque of 60 ± 12 N·m
(44 ± 9 lb ft). Tighten bolts (6) to a torque of 8. Connect hose assembly (2) to the air compressor.
60 ± 12 N·m (44 ± 9 lb ft). Remove the
suitable lifting device and Tooling (A). 9. Fill the cooling system with coolant to the correct
level. Refer to the Operation and Maintenance
Manual for the correct filling procedure.
RENR8633 121
Index Section
Index
A Installation Procedure .................................. 79
Camshaft Bearings - Remove ......................... 78
Aftercooler - Install........................................... 54
Removal Procedure ..................................... 78
Installation Procedure .................................. 54
Camshaft Gear - Remove and Install .............. 78
Aftercooler - Remove....................................... 53
Air Compressor - Remove and Install.............118
Connecting Rod Bearings - Install ................... 88
Installation Procedure .................................119
Removal Procedure ....................................118
Connecting Rod Bearings - Remove ............... 88
Air Inlet Heater - Install .................................... 21
Air Inlet Heater - Remove ................................ 20
Install........................................................ 95–96
Installation Procedure ............................ 96–97
Air Lines - Remove and Install......................... 17
Removal Procedure ............................... 95–96
Crankcase Breather - Remove and Install....... 65
Alternator - Remove and Install ......................116
Crankshaft - Install........................................... 91
Atmospheric Pressure Sensor - Remove
Crankshaft - Remove....................................... 91
and Install................................................. 93–94
Crankshaft Front Seal - Install ......................... 60
Auxiliary Water Pump - Assemble ................... 47
Crankshaft Front Seal - Remove ..................... 59
Assembly Procedure.................................... 47
Auxiliary Water Pump - Assemble (Type 2) ..... 49
Crankshaft Main Bearings - Install................... 90
Auxiliary Water Pump - Disassemble .............. 42
Crankshaft Main Bearings - Remove............... 89
Disassembly Procedure............................... 42
Auxiliary Water Pump - Disassemble (Type
Crankshaft Rear Seal - Install.......................... 57
2).................................................................... 43
Crankshaft Rear Seal - Remove...................... 56
Auxiliary Water Pump - Install.......................... 53
Cylinder Block Cover - Remove and Install ..... 66
Auxiliary Water Pump - Remove...................... 41
Cylinder Head - Install ..................................... 73
B Installation Procedure .................................. 73
Cylinder Head - Remove ................................. 72
Bearing Clearance - Check ............................. 92
Measurement Procedure ............................. 92
Cylinder Liner - Install ...................................... 82
C Cylinder Liner - Remove .................................. 82
Camshaft - Install............................................. 77
Camshaft - Remove......................................... 76 D
Disassembly and Assembly Section ................. 5
Camshaft Bearings - Install.............................. 79
122 RENR8633
Index Section
E Fan Drive Mounting Group - Remove and

Install.............................................................110
Electric Starting Motor - Remove and Install ..117
Flywheel - Remove and Install......................... 55
Electronic Control Module - Remove and
Install.............................................................115
Flywheel Housing - Remove and Install .......... 57
Electronic Unit Injector - Install .......................... 9
Installation Procedure .................................... 9
Front Cover - Remove and Install.................... 60
Electronic Unit Injector - Remove ...................... 8
Removal Procedure ....................................... 8
Electronic Unit Injector Sleeve - Install ............ 12
Fuel Filter Base - Remove and Install................ 6
Electronic Unit Injector Sleeve - Remove .........11
Removal Procedure ......................................11
Fuel Pressure Sensor - Remove and Install.. 99–
Engine Oil Filter Base and Oil Cooler - Install.. 28
100
Installation Procedure ........................ 100–101
Engine Oil Filter Base and Oil Cooler -
Removal Procedure ........................... 100–101
Remove ......................................................... 27
Fuel Priming Pump - Remove and Install .......... 5
Engine Oil Pan - Remove and Install............... 80
Engine Oil Pressure Sensor - Remove and G
Install........................................................ 97–98
Installation Procedure ............................ 98–99 Gear Group (Front) - Install.............................. 62
Removal Procedure ............................... 97–98 Installation Procedure .................................. 62
Engine Oil Pump - Assemble........................... 32 Gear Group (Front) - Remove ......................... 61
Assembly Procedure.................................... 32 Removal Procedure ..................................... 61
Engine Oil Pump - Disassemble...................... 31
Disassembly Procedure............................... 31 H
Engine Oil Pump - Install ................................. 33
Installation Procedure .................................. 33 Housing (Front) - Install ................................... 64
Engine Oil Pump - Remove ............................. 29 Installation Procedure .................................. 64
Removal Procedure ..................................... 29 Housing (Front) - Remove ............................... 63
Exhaust Manifold - Remove and Install ..... 18–19 Removal Procedure ..................................... 63
Removal Procedure ............................... 18–19 I
Important Safety Information ............................. 2
F Injection Actuation Pressure Sensor -
Fan Drive - Assemble .....................................112 Remove and Install .............................. 101–102
Assembly Procedure...................................112 Installation Procedure ........................ 102–103
Fan Drive - Disassemble ................................111 Removal Procedure ........................... 101–102
Disassembly Procedure.............................. 111 Inlet Air Temperature Sensor - Remove and
Fan Drive - Install............................................113 Install.................................................... 108–109
Installation Procedure .................................113 Installation Procedure ........................ 108–109
Fan Drive - Remove........................................110 Removal Procedure ........................... 108–109
Removal Procedure ....................................110 Inlet and Exhaust Valve Guides - Remove
and Install....................................................... 25
RENR8633 123
Index Section
Installation Procedure .................................. 25 S

Speed/Timing Sensor - Remove and Install
Inlet and Exhaust Valve Seat Inserts -
............................................................. 103, 105
Remove and Install ........................................ 26
Installation Procedure ........................ 104–105
Removal Procedure ........................... 103, 105
Inlet and Exhaust Valve Springs - Remove
and Install....................................................... 22 T
Table of Contents............................................... 3
Turbocharger - Install................................. 15–16
Inlet and Exhaust Valves - Remove and
Install.............................................................. 24
Turbocharger - Remove............................. 14–15
Turbocharger Outlet Pressure Sensor -
Remove and Install .............................. 106–107
L Installation Procedure ........................ 107–108
Removal Procedure ........................... 106–107
Lifter Group - Remove and Install.................... 75
Removal Procedure ..................................... 75 U
Unit Injector Hydraulic Pump - Install............... 13
P Installation Procedure .................................. 13
Unit Injector Hydraulic Pump - Remove........... 12
Piston Cooling Jets - Remove and Install........ 83
Pistons and Connecting Rods - Assemble ...... 85 V
Valve Mechanism Cover - Remove and
Install.............................................................. 67
Disassemble .................................................. 84
Pistons and Connecting Rods - Install............. 86
Valve Mechanism Cover Base - Remove
and Install....................................................... 68
Pistons and Connecting Rods - Remove......... 83
Pump Drive - Install ........................................114
Vibration Damper and Pulley - Remove and
Install.............................................................. 58
Pump Drive - Remove ....................................114
R
W
Rocker Arm - Assemble................................... 70
Water Pump - Assemble.................................. 35
Rocker Arm - Disassemble.............................. 70
Water Pump - Disassemble............................. 35
Rocker Arm and Shaft - Install......................... 71
Water Pump - Install ........................................ 36
Rocker Arm and Shaft - Remove..................... 69
Water Pump - Remove .................................... 34
124 RENR8633
Index Section
Water Temperature Regulator - Remove

and Install..................................................37, 39
Installation Procedure .............................38, 40
Removal Procedure ................................37, 39
©2013 Caterpillar CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow”, and the POWER EDGE trade
All Rights Reserved dress as well as corporate and product identity used herein, are trademarks of Caterpillar and
may not be used without permission.

C9 Disassembly Assembly

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C9 Disassembly Assembly

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RENR8633-02

Disassembly and Assembly

Important Safety Information

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Table of Contents Aftercooler - Install..................... ..................... 54

Coolant Temperature Sensor - Remove and

Index............................... .............................. 121

Disassembly and Assembly

Fuel Priming Pump - Remove

NOTICE 1. Remove bolts (3) and the washers.

1. Position the gasket and fuel priming pump (2) on

2. Install bolts (3) and the washers.

3. Purge the air from the fuel system.

Fuel Filter Base - Remove and

Tool Part Number Part Description Qty

A 185-3630 Strap Wrench Assembly 1

Illustration 3 g01167050 Illustration 5 g01270505

Illustration 4 g01270505 Illustration 6 g01270530

Electronic Unit Injector -

Tool Part Number Part Description Qty

Fuel Injector Installer and

1. Remove the plug at the rear of the cylinder head.

cylinder head before the electronic unit injector is

Note: Do not use a wire brush on the tip of the

K 9U-6862 Tapered Brush 1

L 4C-6774 Vacuum Gun Kit 1

M 4C-5027 Tap Wrench 1

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

Note: Tooling (L) is available to clean loose material

2. Inspect the electronic unit injector sleeve for

3. Clean the carbon from the sleeve, the sleeve bore,

Note: Using power tools in order to rotate the material

8. Lubricate the O-ring seals and the backup rings on

• ECM Summary Screen

• Injector Code Calibration

5. Use Tooling (E) and Tooling (F) to install the

6. Use Tooling (E) and Tooling (F) to install backup

7. Install O-ring seal (7).

Illustration 12 g01148880 NOTICE

Electronic Unit Injector Sleeve

Tool Part Number Part Description Qty

1P-3042 Plug Tap 1

9U-6858 Bridge Plate 1

3. Apply a thin coating of Tooling (G) around the outer

i02878055 Note: Allow Tooling (G) to cure for two hours at 21 °C

- Install End By:

2. Install new O-ring seals (2) on the new electronic

Illustration 15 g01031336 Illustration 17 g01031329

Tool Part Number Part Description Qty

Loctite 243 Threadlocker Med.

5. Prime the fuel system. Refer to Operation and

2. Position unit injector hydraulic pump (1) and install

3. Apply Tooling (A) to the threads of tube assemblies

4. Connect harness assembly (2).

2. Remove bolts (5) and tube assembly (4).

3. Attach a suitable lifting device onto turbocharger

NOTICE 3. Remove tube assembly (1).

1. Drain the coolant from the cooling system to a level

Tool Part Number Part Description Qty

A 5P-3931 Anti-Seize Compound -

Tool Part Number Part Description Qty

A 5P-3931 Anti-Seize Compound -

1. Apply Tooling (A) to the turbocharger mounting