Usage:
Start By:
a. remove exhaust elbow
b. remove crankshaft rear seal and wear sleeve
c. remove flywheel
1. Remove the starter from the flywheel housing.
2. Remove the covers and gaskets from the flywheel housing.
Typical Example
3. Remove the bolts and the plates from the camshafts. Use tooling (A) to remove camshaft drive gears (1).
Typical Example
4. Drain the oil from the oil pan.
5. Remove all of the bolts that hold the oil pan to the engine. Install 3/8" -16 NC guide bolts in each side of the oil pan. Fasten a hoist to the engine and lift the engine approximately 12 mm (0.5 in) off the oil pan. Put two 50 mm wide x 100 mm long x 6 mm thick (2 in wide x 4 in long x 1/4 in thick) plates in position between the cylinder block and the oil pan on each side of the engine. Lower the engine on the plates and remove the hoist. The weight of the 3508 engine is approximately 4445 kg (9800 lb). The weight of the 3512 engine is approximately 5902 kg (13,000 lb). The weight of the 3516 Engine is approximately 7718 kg (17,000 lb).
6. Use tooling (B) to fasten a hoist to the flywheel housing. Remove the bolts and remove flywheel housing (2) from the engine. The weight of the flywheel housing is 251 kg (552 lb).
6A. After removing flywheel housing (2), clean the mating surface of the cylinder block and the mating surface of the flywheel housing with tooling (C). If necessary use a gasket scraper and a solvent in order to remove any residual gasket material. Both mating surfaces must be clean, dry, and free of any oil before installation.
7. Remove the gasket and O-ring seal (3) from the engine block.
NOTE: The following steps are for installation of the flywheel housing.
8. Install O-ring seal (3) on the engine block and put clean engine oil on it.
NOTE: Refer to Engine News, 27 March 2006, "Sealing and Installing the Flywheel Housing" for more information.
9. Ensure that the mating surfaces of the flywheel housing and the engine block are clean. Both mating surfaces must be clean, dry, and free of any oil before tooling (D) is applied.
9A. Apply a 6.0 mm (0.25 in) bead of tooling (D) to the mating surface of the flywheel housing.
NOTE: See the topic, Flywheel Housing in the 3500 Generator Set Engines Specifications Manual, Form No. SENR3878, for proper bolt locations and torques.
10. Install two 5/8" -11 NC guide bolts in the rear of the cylinder block. Use tooling (B) to fasten a hoist to the flywheel housing. Put the flywheel housing in position on the guide bolts. Install the bolts to hold the flywheel housing in position. Remove the guide bolts and install the remainder of the bolts.
11. Tighten the 1/2 - NC bolts to a torque of 135 ± 20 N·m (100 ± 15 lb ft). Tighten the 5/8 - NC bolts to a torque of 270 ± 40 N·m (200 ± 30 lb ft).
12. Fasten a hoist to the engine and lift the engine enough to remove the plates between the cylinder block and the oil pan. If the oil pan gasket is damaged, the engine will have to be removed from the oil pan to make a replacement of the gasket. Lower the engine on the oil pan and remove the guide bolts from the oil pan. Install all of the bolts that hold the oil pan to the engine.
13. Install camshaft drive gears (1), the plates, and the bolts. See the topic, Install Camshaft for proper tightening procedures.
14. Install the flywheel housing covers and gaskets.
15. Install the starter.
16. Fill the engine with oil to the correct level. See the Operation and Maintenance Manual for the correct levels.
End By:
a. install crankshaft rear seal and wear sleeve
b. install exhaust elbow