G3500 Engines Caterpillar

Installation Procedure

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Illustration 1	g00582421
Typical example

1. Use Tool (C) to install piston rings (6) on piston (3).

2. The ends of the oil control piston ring should be 180 degrees away from the oil ring end gap. The white-colored section of the oil ring spring should also be visible at the oil ring end gap.

3. Install the intermediate ring with the side that is marked "UP" toward the top of the piston. Position the intermediate ring with the green strip on the right side of the end gap.

4. Install the top piston ring with the red strip on the right side of the end gap.

5. The piston ring end gaps must be approximately 120 degrees away from each other after installation.
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   Illustration 2	g00582420
   Typical example

6. Place clean engine oil on piston pin (4), the piston pin bearing, and the bore in piston pin (4).

7. Position connecting rod (5) in piston (3) and install piston pin (4).

8. Use Tool (B) to install the snap rings that hold piston pin (4).

9. Check the clearance of the bearings. Refer to Disassembly and Assembly, "Bearing Clearance - Check" for the correct procedure.

10. Install the upper half of the connecting rod bearing in connecting rod (5). Ensure that the tab on the back of the bearing is in the bearing tab groove on connecting rod (5).
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    Illustration 3	g00582933
    Typical example

11. Place clean engine oil on the piston rings and the cylinder liner bore. Use Tool (D) to compress the piston rings.

12. Install the piston and connecting rod assembly in the engine.
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    NOTICE
    Ensure that the piston and connecting rod assembly is installed in the engine with the chamfer of the connecting rod bore adjacent to the crank pin thrust surface. The opposite side should also thrust against the mating rod on the crank pin.

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    Illustration 4	g00582418
    Typical example

13. Install the lower half of the connecting rod bearing in connecting rod cap (2). Ensure that the tab on the back of the bearing is in the bearing tab groove on connecting rod cap (2).

14. Place clean engine oil on the upper half and on the lower half of the connecting rod bearing.

15. Apply Bel-Ray Molylube 67700 to the threads of the bolts and the threads in connecting rod caps (2). Refer to the following link for ordering purpose.

    www.belray.com

16. Position connecting rod cap (2) on the connecting rod and install bolts (1) in connecting rod cap (2).

17. Refer to Disassembly and Assembly, "Connecting Rod Bearings - Remove and Install" for the correct tightening procedure of the bolts in the connecting rod cap.

18. Check the side clearance that is between two of the connecting rods that are on the same journal. The clearance must be 0.850 ± 0.232 mm (0.0335 ± 0.0091 inch).

End By:

a. Install the piston cooling jets.

b. Install the spacer plate.