G3516B and G3520B Generator Set Engines Caterpillar

Removal Procedure

Start By:

1. Remove the engine oil filter housing.

2. Remove the crankshaft front seal and the wear sleeve.

3. Remove accessory drive (front).

4. Remove the engine oil and water pump drive.

5. Remove the auxiliary water pump.

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Illustration 1	g00598961
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1. Remove four clamps (1).
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2. Attach Tooling (C) and a suitable lifting device to mounting bracket (2).

3. Remove the ten bolts and mounting bracket (2) from the engine. The weight of mounting bracket (2) is approximately 69 kg (152 lb).
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4. Remove four tubes (4).

5. Remove elbow (5) and tube (3).
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6. Remove cover (6) and the O-ring seal.
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7. Remove the bolts from the end of shaft (8). Use Tooling (A) to remove shaft (8) and idler gear (7) from both sides of the engine.

8. Use Tooling (B) and a suitable press to remove the bearing from idler gear (7).
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9. Remove two washers (9) from the front drive housing.

10. Remove all the bolts that hold the engine oil pan to the engine. Install Tooling (D) in both sides of the engine oil pan. Attach a suitable lifting device to the engine and lift the engine off the engine oil pan 12 mm (0.5 inch). Install two 50 mm wide x 100 mm long x 6mm thick (2 inch x 4 inch x 1/4 inch) plates between the engine and the engine oil pan. Rest the engine on the plates.
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    Illustration 7	g00598973
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11. Install Tooling (C) and attach a suitable lifting device to front drive housing (10). Remove front drive housing (10) and the gasket. The weight of front drive housing (10) is approximately 209 kg (460 lb).

Installation Procedure

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1. Install the front drive housing gasket on the cylinder block. Install Tooling (E) in the cylinder block.

2. Install Tooling (C) and attach a suitable lifting device to front drive housing (10). The weight of front drive housing (10) is approximately 209 kg (460 lb). Position front drive housing (10) on the guide bolts.

3. Install the bolts in front drive housing (10) and tighten the bolts evenly. Cut the excess gasket at the face of the cylinder block.

4. Attach a suitable lifting device to the engine and lift the engine enough to remove the two plates between the engine and the engine oil pan. Install all the bolts that hold the engine oil pan to the engine.

5. Inspect the condition of the gasket on the engine oil pan. Replace the gasket, if necessary. Install all the bolts in the engine oil pan.
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   Illustration 9	g00598971
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6. Install two washers (9) in the front drive housing.
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   Illustration 10	g00598970
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7. Use Tooling (B) to install the bearing in idler gear (7). The bearing must have a diameter of 90.00 ± 0.06 mm (3.543 ± 0.002 inch) after installation.

8. Place clean engine oil on the O-ring seal of shaft (8). Install idler gear (7) and shaft (8) on both sides of the engine.
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9. Place clean engine oil and the O-ring seals and install cover (6).
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10. Lubricate the O-ring seals on tube (3) with glycerin. Install tube (3) and elbow (5).

11. Install four tubes (4).
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12. Use Tooling (C) and a suitable lifting device to install mounting bracket (2) on the front drive housing. The weight of mounting bracket (2) is approximately 69 kg (152 lb). Install the ten bolts.
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    Illustration 14	g00598961
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13. Install four clamps (1).

End By:

1. Install the auxiliary water pump.

2. Install the engine oil and water pump drive.

3. Install the accessory drive (front).

4. Install the crankshaft front seal and the wear sleeve.

5. Install the engine oil filter housing.