C6.6 Industrial Engine Caterpillar

Removal Procedure

Start By:

1. Remove the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install" for the correct removal procedure.

2. Remove the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove and Install" for the correct removal procedure.

Note: Either Tooling (A) can be used. Use the Tooling that is most suitable to the application.

1. Use Tooling (A) in order to rotate the crankshaft so that number one piston is at top dead center on the compression stroke. Refer to System Operation, Testing and Adjusting, "Finding Top Center Position for No.1 Piston" for the correct procedure.
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   Illustration 1	g02009113

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   Illustration 2	g02009114

2. Install Tooling (C) through Hole (X) in camshaft gear (1) into the front housing. Use Tooling (C) in order to lock the camshaft in the correct position.

3. Remove plug (3) from the cylinder block. Remove O-ring seal (2) from the plug.

4. Install Tooling (E) into Hole (Y) in the cylinder block. Use Tooling (E) in order to lock the crankshaft in the correct position.

   Note: Do not use excessive force to install Tooling (E). Do not use Tooling (E) to hold the crankshaft during repairs.

5. Use Tooling (D) in order to lock the fuel injection pump gear in the correct position. Refer to Disassembly and Assembly, "Fuel Injection Pump - Remove" for the correct procedure.
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   Illustration 3	g02009115

6. Use Tooling (B) in order to loosen threaded inserts (4) on all rocker arms (5). Unscrew threaded inserts (4) on all rocker arms (5) until all valves are fully closed.

   Note: Ensure that all threaded inserts are fully unscrewed.

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   Illustration 4	g02009116
   Alignment of timing marks

7. Mark gear (1), gear (6), gear (7) and gear (8) in order to show alignment. Refer to Illustration 4.

   Note: Identification will ensure that the gears can be installed in the original alignment.

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   Illustration 5	g02009117

8. Remove Tooling (C), Tooling (D), and Tooling (E).

9. Remove bolt (10) and washer (9) from camshaft gear (1)

10. Remove camshaft gear (1) from the camshaft.

    Note: If the camshaft gear is a tight fit on the nose of the camshaft, use a prybar in order to remove the camshaft gear.

11. If necessary, remove the key from the nose of the camshaft.

Installation Procedure

1. Ensure that number one piston is at top dead center on the compression stroke. Refer to System Operation, Testing and Adjusting, "Finding Top Center for No. 1 Piston" for the correct procedure.
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   Illustration 6	g02009353

2. Ensure that Tooling (E) is installed in Hole (Y) in the cylinder block. Use Tooling (E) in order to lock the crankshaft in the correct position. Refer to System Operation, Testing and Adjusting, "Finding Top Center Position for No.1 Piston" for the correct procedure.

3. Use Tooling (D) in order to lock the fuel injection pump gear in the correct position. Refer to Disassembly and Assembly, "Fuel Injection Pump - Install" for the correct procedure.

4. Ensure that the camshaft gear and the key are clean and free from wear and damage.

5. If necessary, install the key into the nose of the camshaft.

   Note: Ensure that the key is squarely seated.

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   Illustration 7	g02009113

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   Illustration 8	g02009116
   Alignment of timing marks

6. Align the keyway in camshaft gear (1) with the key in the camshaft. Install the camshaft gear onto the camshaft. Ensure that the timing marks on gear (1), gear (6), gear (7) and gear (8) are in alignment. Refer to Illustration 8.
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   Illustration 9	g02009117

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   Illustration 10	g02009114

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   Illustration 11	g02352635

7. Install Tooling (C) through Hole (X) in the camshaft gear into the front housing.

8. Install washer (9) and bolt (10) to camshaft gear (1).

   When an 8.8 Graded bolt is installed, tighten bolt (10) to a torque of 95 N·m (70 lb ft).

   When an 10.9 Graded bolt is installed, tighten bolt (10) to a torque of 120 N·m (89 lb ft).

9. Remove Tooling (E), Tooling (D), and Tooling (C).

10. Install a new O-ring seal (2) to plug (3). Install the plug into Hole (Y) in the cylinder block. Refer to Illustration 10. Tighten plug (3) to a torque of 21 N·m (186 lb in).

11. Use Tooling (F) in order to measure the backlash for gear (1), gear (6), gear (7) and gear (8), refer to Illustration 8. Refer to Specifications, "Gear Group (Front)" for further information.

12. Use Tooling (F) in order to measure the end play of camshaft gear (1). Refer to Specifications, "Camshaft" for further information.

13. Lubricate the teeth of the gears with clean engine oil.
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    Illustration 12	g02009115

14. Use Tooling (B) in order to tighten threaded inserts (4) on all rocker arms (5). Tighten the threaded inserts to a torque of 30 N·m (266 lb in).

    Note: When the threaded insert is tightened, the threaded insert must be seated correctly into the cup for the pushrod.

End By:

1. Install the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove and Install" for the correct procedure.

2. Install the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install" for the correct procedure.