G3500 Engines Caterpillar

Piston and Connecting Rods - Remove

Usage:

Removal Procedure

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Table 1
Required Tools
Tool	Part Number	Part Description	Qty
A	9S-9082	Engine Turning Tool	1
B	1P-1861	Retaining Ring Pliers	1
C	6V-4020	Piston Ring Expander	1
D	5P-8639	Hydraulic Press	1
	5P-9725	Hydraulic Cylinder	1
	8F-0024	Hose Assembly	1
	1P-2375	Connecting Coupler	1
	1P-2376	Connecting Coupler	1
	5P-8649	Adapter	1
	6V-3043	Spacer	1
	6V-3042	Adapter	1
	2D-2825	Hydraulic Pump	1
	5P-8640	Bar Clamp	1

Start By:

Remove the spacer plate.
Remove the piston cooling jets.

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NOTICE

Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

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NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, 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, PERJ1017, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat^® products. Dispose of all fluids according to local regulations and mandates.

Use Tool (A) to turn the engine in order to access the bolts in the connecting rod cap.
Mark the cylinder number on each connecting rod and the corresponding connecting rod cap.
Note: The front of the engine is opposite the flywheel end. The No. 1 cylinder is at the front of the engine on the right side. The No. 2 cylinder is on the left side.
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Illustration 1 g00582418

Typical example
Remove bolts (1) and connecting rod cap (2) from the connecting rod.
Remove the bearings from connecting rod cap (2) and the connecting rod.
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Illustration 2 g00582419

Typical example
Push piston (3) out of the cylinder head until the piston rings are completely out of the cylinder liner.
Remove the piston and connecting rod assembly.
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Illustration 3 g00582420

Typical example
Use Tool (B) to remove the retaining rings that hold piston pin (4).
Remove piston pin (4).
Remove piston (3) from connecting rod (5).
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Illustration 4 g00582421

Typical example
Use Tool (C) to remove piston rings (6) from piston (3).
Clean the piston ring grooves with an acceptable ring groove tool. Refer to Guideline For Reusable Parts, SEBF8059-01, "Procedure To Clean And Inspect 3500 Series Engine Pistons" for the correct procedure for cleaning the pistons.
Heat connecting rod (2) in an oven to a temperature of 218° ± 40°C (425° ± 75°F).
Note: Do not use a direct flame in order to heat the connecting rod.
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Illustration 5 g00582422
Place 6V-3043 Spacer (14) in the base plate of Tool (D). Place the connecting rod on the base plate.
Place the piston pin bearing in the center of the port assembly on Tool (D). Install pin (9) in the center of the bore for the piston pin.
Install 5P-8649 Adapter (12). Align the hole in the adapter with the hole that is in the base plate of Tool (D).
Install bar clamp (13) and clamp pin (10).
Note: The old bearing is pushed out while the new bearing is installed.
Position 6V-3042 Adapter (11) with the tapered side facing downward. The piston pin bearing joint must be aligned with the hole in adapter (12) and the hole in the base plate of Tool (D).
Place pusher (7) on adapter (11).
Use Tool (D) to push new piston pin bearing (8) into the connecting rod until adapter (11) makes contact with the connecting rod.
Remove the connecting rod and the old piston pin bearing from Tool (D).
Measure the diameter of the bore after the piston pin bearing is removed. The bore should have a diameter of 70.380 ± 0.010 mm (2.7709 ± 0.0004 inch).
Refer to Special Instruction, SMHS7295-02, "Use Of Piston Pin Bearing Removal And Installation Tools" for more information.