3608 Engine Caterpillar

Installation Procedure

Note: Use 8T-0447 Dial Calipers to measure the dimensions in the following procedure.

Note: Refer to Disassembly and Assembly, "General Information (Reference Material)" for more information. Refer to page 7 for torque values.

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Illustration 1	g03374611

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

Note: Ensure that the shanks of connecting rod bolts (3) are free of debris and oil prior to installation.

1. If a new heat shrink tube needs to be installed, follow Step 1.a through Step 1.d.

   1. Clean the shank of connecting rod bolt (3) free of debris and oil.

   2. Slide the new heat shrink tube (10) onto connecting rod bolt (3). Install the new heat shrink tube (10) to Dimension (Y). Dimension (Y) is 1.50 mm (0.059 inch).

   3. Use a suitable heat gun or use a suitable oven to shrink the heat shrink tube (10) onto connecting rod bolt (3). If a suitable oven is used, heat the connecting rod bolt (3) and heat shrink tube (10) at a temperature of 135° ± 14° C (275° ± 57°F) for 10 minutes.

   4. After installing the new heat shrink tube (10) onto connecting rod bolt (3), allow connecting rod bolt (3) to cool. Ensure that heat shrink tube (10) does not have any bumps or wrinkles. Ensure that the heat shrink tube (10) does not move under light finger pressure.
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   Illustration 2	g03376355

   Note: Ensure that piston (4) is clean and meets reuse guidelines.

2. Use an inside micrometer to measure the inside diameter of the bore of the piston pin bearing. Refer to Specifications, "Connecting Rod".

3. Use an inside micrometer to measure the inside diameter of the connecting rod bearing. Make the measurement through the center line of the connecting rod. Refer to Specifications, "Connecting Rod".

4. Before the piston rings are installed on the piston, check the end gap on each piston ring. Refer to Specifications, "Piston and Rings".
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   NOTICE
   Do not install the piston rings without the use of the piston ring expander. Piston ring breakage and piston damage may result if the piston ring expander is not used.

5. Use Tooling (D) to install the piston rings on piston (4).

6. The piston ring gaps should be separated by 120 degrees. Install the piston rings in the following manner:

   1. Install the piston ring expander on the piston. The ends of the oil ring spring should be installed 180 degrees from the oil ring end gap. The white portion of the oil ring spring must be visible at the ring end gap.

   2. If installing a fourth piston ring, the third piston ring must be installed with Mark "UP-3" upward.

   3. The second piston ring must be installed with Mark "UP-2" upward.

   4. The top ring must be installed with Mark "UP-1" upward.

7. After the piston rings have been installed, measure the side clearance between the piston rings and the piston grooves. Refer to Specifications, "Piston and Rings".

8. Locate Mark (4a) on the top of piston (4). Draw an alignment mark on the side of the piston.

   Note: Mark (4a) is a mill dot on the top of piston (4).

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   Illustration 3	g03374939

9. Attach a suitable lifting device to connecting rod (7). The weight of connecting rod (7) is approximately 54 kg (120 lb). Install the upper half of connecting rod bearing (8) in connecting rod (7). Ensure that the tabs of the upper half of connecting rod bearing (8) are engaged with the slots in connecting rod (7).

10. Install Tooling (A) onto the connecting rod bolts. Tooling (A) will hold the upper half of connecting rod bearing (8) in position. Apply clean engine oil to the face of the upper half of connecting rod bearing (8).

11. Position connecting rod (7) in a VERTICAL position on a suitable surface. Hold the connecting rod (7) to prevent the connecting rod from falling. Remove the suitable lifting device from connecting rod (7).
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    Illustration 4	g03374721

12. Attach Tooling (B) and a suitable lifting device to piston (4). The weight of piston (4) is approximately 36 kg (80 lb). Align Mark (4a) with the tab side of the connecting rod (7). Carefully lower piston (4) onto connecting rod (7).

13. Apply clean engine oil to piston pin (6). Use Tooling (G) to install piston pin (6). Install piston pin (6).

14. Remove Tooling (G).

    Note: Install retaining rings (5) with the word "OUT" away from piston (4).

15. Use Tooling (C) to install retaining rings (5). Ensure that retaining rings (5) are seated properly in the piston grooves.

16. Use the suitable lifting device and Tooling (B) to support piston (4) and connecting rod (7). The combined weight of piston (4) and connecting rod (7) is approximately 125 kg (275 lb).

    Note: The piston ring gaps must not be aligned after installation. The piston ring gaps should be separated by 120 degrees.

17. Apply clean engine oil on the piston rings. Install Tooling (H) on piston (4).

18. Remove the protective cover from the cylinder liner and Tooling (E) from the journal of the crankshaft. Apply clean engine oil to the journal of the crankshaft.

19. Use the suitable lifting device and Tooling (B) to install piston (4) and connecting rod (7). Position piston (4) and connecting rod (7) over the proper cylinder liner.

20. The crankshaft must be rotated until the connecting rod bearing journal is at theTOP CENTER position.

    Note: Ensure that Mark (4a) on piston (4) and the mark on the cylinder block are aligned.

21. Ensure that the notch on piston (4) and the piston cooling jet will be in alignment.
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    NOTICE
    Do not use excessive force in order to move the piston into the cylinder liner. Piston ring breakage may occur.

22. Carefully lower piston (4) and connecting rod (7) in the cylinder liner. The weight of piston (4) and connecting rod (7) will allow the piston rings to move away from Tooling (H) and to be installed into the cylinder liner.

23. If piston (4) will not move into the cylinder liner, remove piston (4) and connecting rod (7). Inspect piston (4) and the piston rings.

24. Ensure that connecting rod (7) is in alignment with the crankshaft. Lower piston (4) and connecting rod (7) until connecting rod (7) and the upper half of the connecting rod bearing is seated on the crankshaft.

25. Remove Tooling (A) from the connecting rod bolts.
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    Illustration 5	g03374990

26. Install the lower half of connecting rod bearing (9) in connecting rod cap (1). Ensure that the tabs of the lower half of connecting rod bearing (9) are engaged with the slots in connecting rod cap (1).

27. Apply clean engine oil on the face of the lower half of the connecting rod bearing (9).
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    Illustration 6	g03374720

28. Position Tooling (F) across the opposite access cover under connecting rod cap (1).

29. Ensure that the numbers on the connecting rod and connecting rod cap (1) are identical. Ensure that the numbers are aligned. Place connecting rod cap (1) in position under connecting rod bolts (3). The weight of connecting rod cap (1) is approximately 16 kg (35 lb).

    Note: Use Tooling (K) to lubricate the threads of connecting rod bolts (3), the threads of nuts (2), and the seating face of nuts (2).

    Note: This torque procedure was developed with Tooling (K). The use of any other lubricant may result in an incorrect torque value and in subsequent failure of the connecting rod bolt.

    Note: Nuts (2) are a one time use. Do not reuse nuts (2).

30. Raise Tooling (F). Carefully guide connecting rod cap (1) on connecting rod bolts (3). Install new nuts (2) on connecting rod bolts (3) to secure connecting rod cap (1).

31. Remove Tooling (F).
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    Illustration 7	g03375398

32. Use the following Steps to tighten nuts (2):

    Note: Nut (1) and Nut (2) are on the same side of the connecting rod as the raised bosses and the tab slots for the connecting rod bearing.

    1. Turn all four nuts by hand until the nuts contact the face of the cap. No resistance should be felt that would indicate thread damage or debris in the joint. Threading the nuts by hand will provide an opportunity to identify problems with the threads. If the nuts and/or bolts cannot be threaded by hand, the nuts and/or bolts must be replaced. Do not use an impact wrench to install the nuts up to the face of the cap.

    2. Tighten Nut (1), Nut (4), Nut (2), and Nut (3) to a torque of 105 ± 15 N·m (75 ± 10 lb ft).

    3. Tighten Nut (1) to a torque of 340 ± 15 N·m (251 ± 11 lb ft).

    4. Tighten Nut (4) to a torque of 340 ± 15 N·m (251 ± 11 lb ft).

    5. Tighten Nut (2) to a torque of 340 ± 15 N·m (251 ± 11 lb ft).

    6. Tighten Nut (3) to a torque of 340 ± 15 N·m (251 ± 11 lb ft).

    7. Without loosening the nut, tighten Nut (2) again to a torque of 340 ± 15 N·m (251 ± 11 lb ft).

    8. Without loosening the nut, tighten Nut (3) again to a torque of 340 ± 15 N·m (251 ± 11 lb ft).

    9. Without loosening the nut, tighten Nut (1) again to a torque of 340 ± 15 N·m (251 ± 11 lb ft).

    10. Without loosening the nut, tighten Nut (4) again to a torque of 340 ± 15 N·m (251 ± 11 lb ft).

    11. Tighten Nut (1) an additional 180 ± 5 degrees.

    12. Tighten Nut (4) an additional 180 ± 5 degrees.

    13. Tighten Nut (2) an additional 180 ± 5 degrees.

    14. Tighten Nut (3) an additional 180 ± 5 degrees.

33. Use Tooling (J) to check the side clearance between the connecting rod and the crankshaft. Place a pry bar between the crankshaft and the connecting rod. For side clearance information refer to Specifications Manual, "Connecting Rod".

34. If the clearance is not within the range that is given in Step 33, remove the connecting rod cap. Ensure that the connecting rod cap is on the correct connecting rod. Check for damage.

35. Install the cylinder liner sleeve. Ensure that the cylinder liner sleeve is clean prior to installation.

36. Install the crankcase covers on the cylinder block.

End By:

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

2. Install the cylinder heads. Refer to Disassembly and Assembly, "Cylinder Head - Install".