3608 Engine Caterpillar

Removal Procedure

Start By:

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

2. Remove the piston cooling jets. Refer to Disassembly and Assembly, "Piston Cooling Jets - Remove and Install".

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Personal injury or death can occur from not following the proper procedure or the recommended tooling. To prevent the possibility of injury or death, follow the established procedure using the recommended tooling.

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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.

Note: Refer to Disassembly and Assembly, "General Information (Reference Material)" for more information.

1. Remove the crankcase covers from the cylinder block.

2. Clean the carbon ridge from the top of the cylinder liner.

3. Remove the cylinder liner sleeve. Ensure that the cylinder liner sleeve is clean prior to installation.
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   Illustration 1	g03374720

   Note: Use the barring group in order to turn the crankshaft until nuts (2) that hold connecting rod cap (1) can be reached. Be sure that these nuts can be reached after the piston moves upward. Refer to Systems Operation, "Manual Barring Group".

4. Turn the crankshaft until nuts (2) that hold connecting rod cap (1) can be reached. Loosen nuts (2) that hold connecting rod cap (1). Do not remove nuts (2) at this time. Turn the crankshaft until the piston is at the TOP CENTER position.

5. Position Tooling (F) under connecting rod cap (1). Tooling (F) will span the engine to the openings of the inspection covers on the opposite side. The weight of connecting rod cap (1) is approximately 16 kg (35 lb).

6. Raise Tooling (F) to support connecting rod cap (1). Perform this procedure on the far side of the engine from connecting rod cap (1).

7. While you support connecting rod cap (1), carefully remove nuts (2). Tap connecting rod cap (1) with a suitable plastic hammer to loosen connecting rod cap (1) from connecting rod bolts (3). Discard nuts (2).

8. Carefully lower Tooling (F) and connecting rod cap (1). Remove connecting rod cap (1). Be sure to identify the lower half of the connecting rod bearing with each connecting rod cap.

9. Install Tooling (A) onto bolts (3) for the connecting rod. Tooling (A) will hold the upper half of the connecting rod bearing in position.
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   Illustration 2	g03374721

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   Personal injury or death can occur from not following the proper procedure or the recommended tooling. To prevent the possibility of injury or death, follow the established procedure using the recommended tooling.

10. Attach Tooling (B) to the top of piston (4). If necessary, use Tooling (L) to clean the threads of the holes.

11. Attach a suitable lifting device to Tooling (B). The combined weight of piston (4) and connecting rod (7) is approximately 125 kg (275 lb).

    Note: Observe the removal of piston (4) and connecting rod (7) at the top and at the bottom. Be sure that there are no points of interference.

12. Remove piston (4) and connecting rod (7) from the engine.

13. Position Tooling (E) on the connecting rod bearing journal.

14. Use the suitable lifting device and Tooling (B) to position piston (4) and connecting rod (7) in a VERTICAL position onto a suitable surface. Use two people to separate piston (4) and connecting rod (7). Use Tooling (C) to remove retaining rings (3). Use Tooling (G) to remove piston pin (6). Hold connecting rod (7) in a VERTICAL position to prevent the connecting rod from falling. Use the suitable lifting device and Tooling (B) to remove piston (4) from connecting rod (7). The weight of connecting rod (7) is approximately 54 kg (120 lb). The weight of piston (4) is approximately 36 kg (80 lb).

15. Position piston (4) onto a suitable surface. Remove the suitable lifting device and Tooling (B).
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    Illustration 3	g03374939

    Note: Do not scratch the machined surface for the connecting rod cap.

16. Attach a suitable lifting device to connecting rod (7). Remove Tooling (A) and the connecting rod bolts.

17. Remove the upper half of connecting rod bearing (8) from connecting rod (7). If necessary, put identification marks on connecting rod bearing (8) so that connecting rod bearing (8) can be installed in the same location.

18. Position connecting rod (7) onto a suitable surface.
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    Illustration 4	g03374990

19. Remove the lower half of connecting rod bearing (9) from connecting rod cap (1). If necessary, put identification marks on connecting rod bearing (9) so that connecting rod bearing (9) can be installed in the same location.
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    Illustration 5	g03374542

20. Use Tooling (D) to remove the piston rings from piston (4).

21. Clean and inspect piston (4) for damage. Check the piston ring grooves for damage. Refer to Specifications, "Piston and Rings" for the width of the piston ring groove.
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    Illustration 6	g03375026

22. Inspect connecting rod bolt (3) at each service of the connecting rod bearings. Ensure that connecting rod bolt (3) meets the following guidelines for reusable parts.

    • There should be no fretting on the shank of connecting rod bolt (3).

    • There should be no fretting on the knurled area of connecting rod bolt (3).

    • Connecting rod bolt (3) should not be longer than Dimension (X). Dimension (X) is 329 mm (12.9 inch).

    • Ensure that heat shrink tube (10) is firmly in place and does not move under light finger pressure.

    • Ensure that the surface of heat shrink tube (10) is smooth.

    • Ensure that the heat shrink tube (10) is not extended into the fillet that is under the connecting rod bolt head.

    • Connecting rod bolt (3) has not been torqued to tension more than five times.

23. If connecting rod bolt (3) is reusable and heat shrink tube (10) is not, carefully cut heat shrink tube (10) from connecting rod bolt (3).

    Note: Ensure that there is no damage to the shank of connecting rod bolt (3) after the removal of heat shrink tube (10).