G3500 Engines Caterpillar

Removal Procedure

Start By:

1. Remove the rocker shaft assemblies and the pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Push Rod - Remove".

1. Remove the engine speed/timing sensor. Refer to Testing and Adjusting, "Engine Speed/Timing Sensor".
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   Illustration 1	g00579084

2. Remove access covers (1) from each side of the engine.
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   Illustration 2	g00579086

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   Illustration 3	g00579090

3. Push valve lifters (2) away from the camshaft. Hold valve lifters (2) in position with the O-ring seal.
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   Illustration 4	g00579117

4. Remove the bolts and cover (3) from the left side of the front housing.
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   Illustration 5	g00579119

5. Disconnect the two control rods for the carburetor from lever (4), if equipped.

6. Remove the bolts from cover (5). Remove cover (5) and lever (4) from the front housing as one unit.
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   Illustration 6	g00579569

7. If the engine is not equipped with a carburetor, disconnect electrical Plug (X) and remove bolts from cover (5).
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   Illustration 7	g00579522

8. Remove cover (6) for the camshaft drive gears from the flywheel housing.
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   Illustration 8	g00579141

9. Remove the bolt and plate (7) that fastens camshaft drive gear (8) to the camshaft.
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   Illustration 9	g00579142

10. Place the three washers from Tooling (B) behind plate (7) and install the bolt.
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    NOTICE
    Do not apply more than 51675 kPa (7500 psi) pressure to the hydraulic puller. The adapters are rated at 6 1/2 tons each and the hydraulic puller is rated at 17 tons at 68900 kPa (10000 psi). If too much pressure is applied, the gear may be damaged.

11. Install Tooling (B) on camshaft drive gear (8). Apply 51675 kPa (7500 psi) to the puller and hit the screw on the puller with a hammer until camshaft drive gear (8) is free from the camshaft. Remove Tooling (B) and camshaft drive gear (8).
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    Illustration 10	g00579144

12. Remove bolts (9) and thrust washers (10) that fasten the camshaft to the right side of the engine block.
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    Illustration 11	g00579145

13. Remove timing ring (11) from the camshaft on the left side of the engine.

14. Repeat Steps 8 through 12 for the camshaft drive gear on the left side of the engine.
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    Illustration 12	g00579148
    Typical example

15. Install Tooling (C) on each end of the camshaft.

    Note: Tooling (D) can be installed on the flywheel housing in order to remove the camshaft from the rear. Tooling (D) can also be installed on the front housing in order to remove the camshaft from the front of the engine.

16. Install Tooling (D) on the flywheel housing.

17. Install Tooling (E) on the end of Tooling (C).

    Note: The camshafts for G3508 Engines are in one piece. The camshafts for G3512 and G3516 Engines are in two pieces.

18. The following step is for G3508 Engines.

    1. Rotate the camshaft with Tooling (E). Pull the camshaft out of the engine until a suitable lifting device can be attached. Remove the camshaft from the engine. The weight of the camshaft is approximately 42 kg (93 lb).

19. The following steps are for G3512 and G3516 Engines.

    1. Rotate the camshaft with Tooling (E). Pull the camshaft out of the engine until a suitable lifting device can be attached. Remove front camshaft (12) and rear camshaft (13) as a unit. The camshaft for G3512 Engines has a weight of approximately 63 kg (139 lb). The camshaft for G3516 Engines has a weight of approximately 82 kg (181 lb).
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       Illustration 13	g00579149

    2. Remove bolts (14). Separate the camshafts and remove spacer (15).

20. Remove the dowel from the front of the camshaft, if necessary.

21. Repeat Steps 15 through 20 for the second camshaft.