G3408C and G3412C Engines Caterpillar

Installation Procedure

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Illustration 1	g01424064

1. Install pin (5) in crankshaft (7) .

   Maximum protrusion of pin (5) from the face of crankshaft (7) ... 6.4 ± 0.5 mm (0.25 ± 0.02 inch)

2. Install dowel (6) in crankshaft (7) .

   The protrusion of dowel (6) from crankshaft (7) face. ... 4.1 ± 0.5 mm (0.16 ± 0.02 inch)

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Illustration 2	g01424067

3. Raise the temperature of crankshaft gear (2) to a maximum temperature of 232 °C (450 °F). Install gear (2) on the crankshaft with groove (3) in alignment with the dowel.

   Note: Gear (2) must be installed on the crankshaft with the "V"timing mark toward the outside.

4. Clean the block and the upper main bearings.

   Note: Install the main bearings dry when clearance checks are made. Put clean engine oil on the upper main bearings and journals of the crankshaft.

5. Install the upper bearings in the cylinder block. Ensure that the tab in each bearing is in alignment with the notch in the cylinder block.

6. Install one of the flywheel bolts in each end of the crankshaft. Fasten a hoist to the crankshaft and place the crankshaft into position in the block. The weight of the crankshaft is approximately 180 kg (400 lb).

7. Install the crankshaft with the "V"mark on the crankshaft gear in alignment with the "V"mark on the idler gear.

8. Put Tooling (D) on the bolts. Install No. 1 and No. 7 main bearing caps with bolts finger tight. Ensure that the arrows on the caps are pointing toward the front of the engine.

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Illustration 3	g01424070

9. Install thrust plates (4) for the No. 4 upper main bearing. Install the thrust plates with the side that has identification "BLOCK SIDE"toward the cylinder block.

10. Put Tooling (E) on the bolts. Install No. 1 through No. 7 main bearing caps (1) with the bolts finger tight. Ensure that the arrows on the caps are pointing toward the front of the engine.

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NOTICE
Do not use an impact wrench to tighten the bolts the additional 120 degrees.

11. Tighten the bolts for the main bearing caps (1) , as follows:

    1. Tighten the bolts on the tab end of the caps first to a torque of 260 ± 14 N·m (190 ± 10 lb ft).

    2. Tighten the bolts on the other end of the caps to a torque of 258 ± 14 N·m (190 ± 10 lb ft).

    3. Put a mark across the head of the bolt and cap. Tighten the bolts opposite the tab end for an additional 120 degrees.

    4. Tighten tab end bolts an additional 120 degrees.

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Illustration 4	g00791107

12. Check the end play of the crankshaft with Tooling (C) . Ensure that the dial indicator is against a machined surface. End play with new thrust plates must be 0.13 ± 0.50 mm (0.005 ± 0.020 inch).

End By:

1. Install pistons and the connecting rods. Refer to Disassembly and Assembly, "Pistons and Connecting Rods - Install".
2. Install the piston cooling jets. Refer to Disassembly and Assembly, "Piston Cooling Jets - Remove and Install".
3. Install the timing gear cover. Refer to Disassembly and Assembly, "Timing Gear Cover - Remove and Install".
4. Install the flywheel housing. Refer to Disassembly and Assembly, "Flywheel Housing - Install".