G3500 Engines Caterpillar

Installation Procedure

Note: Refer to Engine News, 27, March 2006, "Sealing and Installing the Flywheel Housing" for more information.

1. Ensure that the mating surface 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.
   Show/hide table

   Illustration 1	g01258819

2. Apply a 6.0 mm (0.25 inch) bead of Tooling (D) to the mating surface of the flywheel housing. Refer to Illustration 1.
   Show/hide table

   Illustration 2	g00588658
   Typical example

3. Attach Tooling (B) and a suitable lifting device to the top of flywheel housing (2). The weight of flywheel housing (2) is approximately 210 kg (460 lb).

4. Position flywheel housing (2) on the engine.

5. If the dowel pins were removed from flywheel housing (2), install the dowel pins and ensure that the dowel pins are properly seated.
   Show/hide table

   Illustration 3	g01259294
   (U) 1/2 - NC (V) 1/2 - NC (W) 1/2 - NC (X) 1/2 - NC (Y) 1/2 - NC (Z) 5/8 - NC

6. Install the bolts and the hard washers for flywheel housing (2). Refer to Illustration 3 for the proper locations of the bolts. 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).

7. Remove Tooling (B).

8. Install the crankshaft rear seal and the wear sleeve. Refer to Disassembly and Assembly, "Crankshaft Rear Seal and Wear Sleeve - Install".

9. Place the camshaft timing pins in position and place the timing bolt in the flywheel with the No. 1 piston at the top center position on the compression stroke.
   Show/hide table

   Illustration 4	g00588655

   Show/hide table

   Illustration 5	g00588654

10. Use the following procedure in order to install camshaft drive gears (4).

    1. Clean the taper of the camshaft and clean the tapered bore of the camshaft gear with a lint free cloth that is saturated with a solvent in order to remove any excess oil. Clean the parts again with a lint free alcohol wipe in order to remove any residue. If the alcohol wipe is dirty after cleaning the parts, clean the parts again with a lint free alcohol wipe until no residue is left on the alcohol wipe.

       Note: It is critical that the taper of the camshaft and the tapered bore of the camshaft gear are clean, dry, and free of residue before assembly.

    2. Ensure that the camshaft timing pins and the timing pin for the flywheel are installed.

    3. Place camshaft drive gears (4) in position. Remove the backlash by rotating the gears in the opposite direction of camshaft rotation.

       Note: For "Standard Rotation" engines, turn the camshaft drive gears COUNTERCLOCKWISE. For "Reverse Rotation" engines, turn the camshaft drive gears CLOCKWISE.

    4. Install the bolt and plate (5).

    5. Install the bolt and timing ring (3). Ensure that the hole in the timing ring is properly seated on the locating pin.

    6. Tighten the bolt to a torque of 360 N·m (265 lb ft).

    7. Place a Mark on the bolt.

    8. Place a driver against the retaining plate of the camshaft gear. Strike the driver solidly with a hammer 3 to 4 times.

    9. Tighten the bolt again to a torque of 360 N·m (265 lb ft).

    10. Repeat Steps 10.h and 10.i until the Mark has turned at least 90 degrees.

        Note: Refer to the Disassembly and Assembly, "Camshaft - Install" for more information.

11. Remove the timing pins from the camshafts and the flywheel.
    Show/hide table

    Illustration 6	g00588653
    Typical example

12. Install the gaskets and camshaft covers (1) on flywheel housing (2).

13. Install the engine speed/timing sensor. Refer to Testing and Adjusting, "Engine Speed/Timing Sensor".

End By:

1. Install the rocker shaft and the pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod - Install".

2. Install the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Install".

3. Install the starting motors. Refer to Disassembly and Assembly, "Air Starting Motor - Install" or Disassembly and Assembly, "Electric Starting Motor - Remove and Install".