3508, 3512 and 3516 Generator Set Engines Caterpillar

Removal Procedure

Start By:

1. Remove the starting motors.

2. Remove the exhaust elbow.

3. Remove the tachometer drive.

1. Use the timing pins in order to properly time the engine. Refer to Testing and Adjusting, "Camshaft Timing". Refer to Testing and Adjusting, "Finding the Top Center Position for the No. 1 Piston".

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

3. Remove the camshaft covers and gaskets.

4. Remove the bolts and plates from the camshafts.
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   Illustration 1	g00912881

5. Use Tooling (A) in order to remove camshaft drive gears (1).
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   Illustration 2	g02025044

6. Remove bracket (2) and bracket (3).

7. Attach Tooling (B) and a suitable lifting device to flywheel housing (4). The weight of flywheel housing (4) is approximately 250 kg (550 lb).

8. Remove bolts (5) and bolts (6). Remove flywheel housing (4) and the gasket.
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   Illustration 3	g02025087

9. Remove O-ring seal (7).

10. After removing the flywheel housing, clean the mating surface of the cylinder block and the mating surface of the flywheel housing with Tooling (C). If necessary, use a gasket scraper and a solvent in order to remove any residual gasket material. Both mating surfaces must be clean, dry, and free of any oil before installation.

Installation Procedure

1. Install flywheel housing (4) in the reverse order of removal.
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   Illustration 4	g01259519

   1. Apply a 6.0 mm (0.25 inch) bead of Tooling (E) to the mating surface of the flywheel housing. Refer to Illustration 4.

   2. Install Tooling (D) in the cylinder block.

      Note: For the correct positions of the bolts, see Illustration 5 or Illustration 6.

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      Illustration 5	g02025183
      (A) 1/2 - NC (B) 1/2 - NC (C) 1/2 - NC (D) 1/2 - NC (E) 1/2 - NC (F) 5/8 - NC

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      Illustration 6	g02025184
      (G) 1/2 - NC (H) 1/2 - NC (I) 1/2 - NC (J) 5/8 - NC (K) 5/8 - NC (L) 5/8 - NC

   3. Tighten the 1/2 - NC bolts to a torque of 135 ± 20 N·m (100 ± 15 lb ft). Tighten the 5/8 - NC bolts to a torque of 270 ± 40 N·m (200 ± 30 lb ft).

   4. Install the camshaft gears.