C9 Marine Engines and C9 Marine Generator Sets Caterpillar

Installation Procedure

Note: Install the crankshaft main bearings and the connecting rod bearings dry when clearance checks are performed. Refer to Disassembly and Assembly, "Bearing Clearance - Check". Apply clean engine oil on the crankshaft main bearings and the connecting rod bearings for final assembly.

Note: Do not place the fractured faces of the connecting rod cap on any surface. The connecting rod cap must be laid flat on the side in order to prevent damage to the fractured faces of the connecting rod cap.

1. Install the upper halves of the main bearings in the cylinder block. Do not apply oil to the back of the crankshaft main bearing. Ensure that all of the lubrication passages are clean and free of debris.

   Note: Ensure that the crankshaft main bearings are installed so that the bearing tabs fit into the notch in the cylinder block. The upper halves of the crankshaft main bearings have the oil groove and the oil hole.

   Show/hide table

   Illustration 1	g01144484

2. Attach Tooling (A) and a suitable lifting device to crankshaft (5). The weight of crankshaft (5) is approximately 68 kg (150 lb). Install the crankshaft with the timing mark on the crankshaft gear in alignment with the "V" mark on the idler gear.
   Show/hide table

   Illustration 2	g01026881

3. Install thrust plates (6) on each side of the No. 6 main bearing.

   Note: Install the thrust plates with the words "Block Side" toward the cylinder block.

4. Install the lower half of the crankshaft main bearing in the crankshaft main bearing cap. Do not apply oil to the back of the crankshaft main bearing.

   Note: Ensure that the crankshaft main bearing is installed so that the bearing tab fits into the notch in the main bearing cap.

   Show/hide table

   Illustration 3	g01026926

5. Install crankshaft main bearing cap (2) and bolts (1).

6. Check the bearing clearance. Refer to Disassembly and Assembly, "Bearing Clearance - Check".

7. Remove bolts (1) and remove crankshaft main bearing cap (2). Apply a thin coating of clean engine oil on the surface of the lower half of the crankshaft main bearing.

8. Place crankshaft main bearing caps (2) in position on the cylinder block. Apply clean engine oil or Molylube on the bolt threads and the washer face of bolts (1). Install bolts (1).

   Note: Ensure that the numbers on the crankshaft main bearing caps match the numbers on the cylinder block. Also ensure that the part number of the crankshaft main bearing cap is installed on the right side and toward the front of the cylinder block.

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

   1. Tighten Bolt (A) of the crankshaft main bearing cap to a torque of 95 ± 5 N·m (70 ± 4 lb ft).

   2. Tighten Bolt (B) of the crankshaft main bearing cap to a torque of 95 ± 5 N·m (70 ± 4 lb ft).

   3. Tighten Bolt (A) and Bolt (B) for an additional 90 ± 5 degrees (1/4 turn).

      Note: If Tooling (C) is not used, place an index mark on the bolt and the crankshaft main bearing cap.

   4. Rotate the crankshaft in order to ensure that the crankshaft turns freely.

10. Use Tooling (B) to check the crankshaft end play. Ensure that Tooling (B) is against a machined surface. The end play is controlled by the thrust plates of the No. 6 main bearing. The end play must be 0.21 to 0.60 mm (0.008 to 0.024 inch).
    Show/hide table

    Illustration 4	g01145531

11. Line up connecting rod (9) with the crankshaft. Before the connecting rod comes in contact with the crankshaft, remove the protective caps from the end of the connecting rod and install the upper half of connecting rod bearing (8). Ensure that the bearing tab engages with the slot in the connecting rod. Apply clean engine oil to the surface of connecting rod bearing (8). Do not apply oil to the back of the connecting rod bearing.

12. Pull the connecting rod assembly onto the crankshaft.

13. Install the lower half of connecting rod bearing (7) into connecting rod cap (4). Ensure that the bearing tab engages with the slot in the connecting rod cap.

14. Install connecting rod cap (4) and connecting rod bolts (3).

    Note: The "R" on the connecting rod cap must be installed toward the flywheel end of the engine. Ensure that the number on the connecting rod cap matches the number on the connecting rod, and that the numbers are on the same side.

15. Check the bearing clearance. Refer to Disassembly and Assembly, "Bearing Clearance - Check".

16. Remove connecting rod bolts (3) and connecting rod cap (4). Apply a thin coating of clean engine oil on the surface of connecting rod bearing (7). Do not apply oil to the back of the connecting rod bearing.

    Note: Do not place the fractured faces of the connecting rod cap on any surface. The connecting rod cap must be laid flat on the side in order to prevent damage to the fractured faces of the connecting rod cap.

17. Install connecting rod cap (4) and connecting rod bolts (3).

    Note: Do not apply oil to the back of the connecting rod bearing.

    Show/hide table

    Illustration 5	g01026901

18. Tighten connecting rod bolts (3) to a torque of 50 ± 5 N·m (37 ± 3 lb ft).

19. Tighten connecting rod bolts (3) for an additional 90 ± 5 degrees (1/4 turn).

    Note: If Tooling (C) is not used, place an index mark on the bolt and the connecting rod cap.

20. Rotate the crankshaft in order to ensure that the crankshaft turns freely.

End By:

1. Install the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump - Install".

2. Install the flywheel housing. Refer to Disassembly and Assembly, "Flywheel Housing - Install".

3. Install the front housing. Refer to Disassembly and Assembly, "Housing (Front) - Install".