3204 VEHICULAR ENGINE FOR 943 & 953 TRACK-TYPE LOADERS Caterpillar

Timing Gear Cover

Usage:

Remove Timing Gear Cover

START BY:

a. remove crankshaft front pulley

b. remove muffler

c. remove oil pan

1. Disconnect wires (1) from the alternator.

2. Remove four bolts (2), the spacer on the back side, and remove the alternator and brackets (3) as a unit.

3. If the machine has an air conditioner, disconnect wire (4), and remove bolts (5) and (6).

4. Remove bolts (7) and (8), and move the air conditioner compressor and bracket clear of the timing gear cover.

5. Remove bolts (9) that hold the hydraulic pump to the timing gear plate.

6. Remove bolts (10) that hold the elbow to the timing gear cover.

7. Remove bolt (11) that holds the lower water tube to the engine front support.

8. Disconnect governor linkage (12) from the governor. Remove the bolts that hold bracket (13) to the flywheel housing, and move the bracket clear of the flywheel housing.

9. On a 953 machine, remove bolt (14) from the platform support on both sides of the machine.

10. Install tooling (A) on both sides of the flywheel housing. On a 953 machine, install the L1774 Centering Spacers (15) under the screw in tooling (A) as shown. On a 943 machine, the screw in tooling (A) will push directly against the head of the bolt in the platform support. Tooling (A) is used to hold the weight of the engine when the engine front support is removed.

11. Remove bolt (16) and rubber mount (17) from the bottom of the engine front support.

12. Evenly tighten the forcing screws in tooling (A) until there is no weight on engine front support (19).

13. Remove eight bolts (18) and engine front support (19).

14. Remove bolts (20) and plate (21) from the frame.

15. Remove tube (22).

16. Loosen hose clamp (23) between the cylinder head assembly and timing gear cover.

17. Disconnect wires (24) from the water temperature sending unit on the front of the timing gear cover. Move the wires clear of the timing gear cover.

18. Fasten tooling (B) and a hoist to the timing gear cover. Install two 3/8"-16 NC guide bolts in the timing gear cover.

19. Remove the bolts from the front and back of timing gear cover (26). Bolt (25) cannot be completely removed but must be loosened as the timing gear cover is removed. Remove the timing gear cover. Weight is 29 kg (65 lb.).

Install Timing Gear Cover

1. Clean the old gasket from the contact surfaces of the timing gear cover and timing gear plate.

2. Install a new gasket. Cut the gasket even with the bottom face of the cylinder block. Put 5H2471 Gasket Cement on the bottom of the gasket where the gasket makes contact with the gasket for the oil pan.

3. Inspect the condition of water ferrule and seal (2). Make a replacement if needed. Put water ferrule and seal (2) in position with the adjusting screw of hose clamp (1) toward the top and approximately 45° to the right of vertical as seen from the front of the engine. Make sure the seal is installed all the way into the counterbore.

4. Install tooling (B) on the timing gear cover as shown, and fasten a hoist. Install two 3/8"-16 NC guide bolts in the cylinder block. Put timing gear cover (3) in position on the timing gear plate. Be sure the gear on the engine oil pump is engaged with the crankshaft gear as the timing gear cover is installed. Tighten bolt (4) on the back side of the timing gear plate as the cover is installed. Install the remainder of the bolts in the timing gear cover.

5. Connect wires (5) to the temperature sending unit on the timing gear cover.

6. Install bolts (6) that hold the hydraulic pump in place.

7. Tighten hose clamp (1), and install tube (7) between the timing gear cover and cylinder head.

8. Put Plate (8) and the rubber mount in position on the frame, and install the bolts that hold the plate in place.

9. Put engine front support (9) in position on the timing gear cover, and install the bolts that hold it in place. Tighten the 3/8 in. bolts to a torque of 55 ± 7 N·m (41 ± 5 lb.ft.). Tighten the 7/16 in. bolts to a torque of 90 ± 15 N·m (65 ± 11 lb.ft.).

10. Evenly loosen the forcing screws in tooling (A) until there is no weight on tooling (A). Remove tooling (A) from both sides of the flywheel housing.

11. Install rubber mount (10) with the sleeve and bolt through the frame and into the engine front support. Tighten the bolt to a torque of 875 ± 100 N·m (640 ± 75 lb.ft.).

12. Put bracket (12) in position on the flywheel housing, and install the bolts that hold it in place. Tighten the bolts to a torque of 200 ± 25 N·m (150 ± 20 lb.ft.). On a 953 machine, install the two bolts in the platform supports, and tighten them to a torque of 875 ± 100 N·m (640 ± 75 lb.ft.).

13. Connect governor linkage (11) to the governor.

14. Install a new gasket and bolts (13) that hold the elbow to the timing gear cover.

15. Install bolt (14) that holds the lower water tube to the engine front support.

16. Put air conditioner compressor (15) and brackets in position on the timing gear cover, and install the four bolts in the brackets.

17. Install bolts (16) in the brackets for the air conditioner compressor. Connect the wire to the compressor.

18. Put the alternator and bracket (17) in position on the timing gear cover, and install the four bolts that hold the bracket in place. Be sure to install the spacer on the back side of the timing gear plate.