3618 Engine Caterpillar

Removal Procedure

Start By:

1. Remove the cylinder heads. Refer to Disassembly and Assembly, "Cylinder Head - Remove".

Note: Tooling (E) provides all protective covers and plugs for one cylinder. Use these protective covers to maximize protection during maintenance procedures.

Note: If only the connecting rod bearing will be serviced, use Tooling (F). Tooling (F) supports the piston and connecting rod during service of the connecting rod bearing. Tooling (F) enables the connecting rod bearing to be serviced without removal of the piston and connecting rod.

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If more than one piston is to be removed, the crankshaft can turn due to the weight of the remaining pistons. Lock the position of the crankshaft in in order to prevent unexpected movement, personal injury, or component damage.

1. Remove the cylinder block cover for the piston that will be removed.
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   Illustration 1	g00695435

2. Rotate the crankshaft until the bolts of connecting rod cap (1) can be reached through the side of the cylinder block.

3. Loosen the bolts of connecting rod cap (1). Do not remove the bolts at this time.

4. Carefully remove two bolts from opposite ends of connecting rod cap (1). Install Tooling (C) through the bolt holes into the connecting rod. Remove the remaining two bolts. Tap the connecting rod cap with a plastic hammer in order to loosen the connecting rod cap.
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   Illustration 2	g00649648

5. Move the connecting rod cap outward on Tooling (C). Carefully remove the connecting rod cap. Be careful not to scratch the machined surface of the connecting rod cap.

6. Mark the connecting rod cap and the lower half of the connecting rod bearing for identification upon assembly.

7. Remove Tooling (C) from the connecting rod.

8. Rotate the crankshaft in order to raise the journal of the crankshaft to the top center position.

9. Attach Tooling (D) and a suitable lifting device to the top of the piston. If necessary, use a 1/2 - 13 NC tap in order to clean the holes. The weight of the piston and the connecting rod is approximately 160 kg (353 lb).

10. Wrap the connecting rod with a cushion of towels. This will help to prevent damage to the cylinder liner and to the connecting rod when the piston is removed.

11. Slowly remove the piston and connecting rod. Observe the removal of the piston and connecting rod at the top and the bottom. Make sure that there are no points of interference.

12. Remove the top half of the connecting rod bearing from the connecting rod. Mark the connecting rod bearing and the connecting rod for identification upon assembly.

13. Place cardboard or a similar material that will not scratch the components onto a smooth, flat surface. Carefully lower the piston and connecting rod until the components rest upon the surface. Lay the components sideways. Remove Tooling (D) from the top of the piston.
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    Illustration 3	g00700650

14. Lift connecting rod (2) and piston (3). Rest the piston on the crown of the piston.

    Continue to provide support for the connecting rod in order to prevent the rod from falling when the piston pin is removed.

15. Use Tooling (A) to remove pin retainers (4) from piston (3).

16. Carefully remove piston pin (5) from piston (3). The weight of piston pin (5) is approximately 22 kg (50 lb).
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    Illustration 4	g00746918

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    Illustration 5	g00704192

17. Carefully lift connecting rod (2) from piston (3). The weight of connecting rod (2) is approximately 92 kg (203 lb).

18. Use a suitable lifting device to place piston (3) with the piston skirt (bottom) downward. The weight of piston (3) is approximately 46 kg (101 lb).

19. Use Tooling (B) to remove piston rings (6) from piston (3).