C175-16 Generator Set Engine Caterpillar

Removal Procedure

Start By:

a. Remove the electronic unit injector.

b. Remove the fuel pump.

c. Remove the engine oil cooler.

d. Remove the engine oil pump.

1. Drain the engine oil into a suitable container for storage or for disposal. Refer to Operation and Maintenance Manual, "Engine Oil and Filter - Change".

2. Drain the coolant from the cooling system into a suitable container for storage or for disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change".

3. If necessary, remove components for access to the side covers. Remove the panel, the starting motor, and the alternator.
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   Illustration 1	g01206105

4. Remove bolts (1). Remove side cover (2).

5. Use Tooling (A) to turn the flywheel to access the connecting rod cap that will be removed.
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   Illustration 2	g03406166

   Note: Inspect and carefully handle the fractured connecting rod and the connecting rod cap for the proper identification mark. The connecting rod and the connecting rod cap should have an etched number on the side. Clean with Tooling (D) if the etching is hard to view. The number should match the cylinder number. Mark the connecting rod and the connecting rod cap, if necessary. Improper handling of the fractured connecting rods and the connecting rod caps can cause misalignment during assembly. The connecting rod caps should be placed on the side to prevent damage.

6. Remove bolts (3) and spacers (4). Remove connecting rod caps (5).
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   Illustration 3	g03406257

   Note: Notice the location of the tabs when the connecting rod bearings are removed from the ODD and EVEN connecting rod caps.

7. Remove the lower half of connecting rod bearing (6) from connecting rod cap (5).
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   Illustration 4	g02049074

8. If necessary, rotate the crankshaft to install Tooling (B).
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   Illustration 5	g02049093

9. Install Tooling (C) to hold the pistons in place.

10. Use the adjusting nut to raise the pistons until the connecting rod is above the crankshaft journal. Remove Tooling (B) that is not against the crankshaft journal. Remove the upper half of the connecting rod bearing.

11. Push the connecting rod into position and remove the rest of Tooling (B). The connecting rod should swing over the crankshaft journal. Check to avoid contact between the connecting rod and the connecting rod journal.

Installation Procedure

1. Clean the connecting rod cap and the connecting rod bearing bore with Tooling (D) and clean lint free rag. Inspect both the connecting rod cap and the connecting rod bearing bore. Check for carbon on the connecting rod cap and the connecting rod bearing bore.

2. Inspect the fractured joints and remove any loose material. Clean the face with a clean paint brush to remove loose material on the fractured areas.

3. Check the clearance of the bearings. Refer to Disassembly and Assembly, "Bearing Clearance - Check" for the correct procedure.

4. Use Tooling (D) and a lint free rag to clean the new bearing. Apply a light film of clean oil to back of bearing surface and a generous amount of oil on the front of each bearing

5. Install the upper half of the connecting rod bearing in the connecting rod. Inspect to ensure that the tab on the back of the bearing is in the bearing tab groove on the connecting rod.

6. Inspect the connecting rod bearing and the crankshaft journal for seating, alignment, and cleanliness. Apply clean engine oil.

7. Push the connecting rod into position over the connecting rod journal and install Tooling (B).

8. Position the connecting rod over the crankshaft. Use Tooling (C) to lower the piston on the crankshaft journal.
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   Illustration 6	g01240845

9. Remove Tooling (B) from the connecting rod.
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   Illustration 7	g03406166

   Note: Match the tabs on the ODD and EVEN connecting rod caps with the connecting rods.

10. Install connecting rod cap (5). Apply Tooling (E) under the connecting rod bolts (3), the rings, and to the threads of the bolts. Install connecting rod bolts (3) and spacers (4).

11. Use Tooling (A) to rotate the flywheel to access the connecting rod cap (5) that will be installed.
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    Illustration 8	g03406088
    The arrow represents the front of the engine block Bolt numbering for 316-0062 Connecting Rod, 316-0063 Connecting Rod, 434-0480 Connecting Rod, and 434-0481 Connecting Rod. Bolt (1) is always identified as the center bolt on the bearing tab side of the connecting rod. (A) Bearing tab side (X) Odd numbered connecting rod (Y) Even numbered connecting rod

    Note: Identify the connecting rod part number to determine which of the following torque procedures to follow.

12. Use the following procedure to tighten the connecting rod bolts for Type 1 connecting rods:
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    Table 3

    Assembly Specification for Type 1 Connecting Rods with 290-2541 Bolts
    Item	Qty	Part	Specification Description
    1	6	290-2541 Bolts	Use the following procedure to tighten the bolts of the connecting rod: Note : Apply Bel-Ray Molylube 67700 to the threads and middle rings of bolt (2) and the contact surface under the bolt head. Refer to the following link for ordering purpose. www.belray.com 1. Install the spacers (2) and the bolts (1). Hand tighten the bolts. Note : Bolt 1 is identified as the middle bolt on the tab side of the bearing on the connecting rod. Tighten this bolt first to seat the bearing into the bore. 2. Tighten bolt 1 and bolt 2 to 105 ± 5 N·m (77 ± 4 lb ft). 3. Tighten bolt 3 and bolt 4 to 105 ± 5 N·m (77 ± 4 lb ft). 4. Tighten bolt 5 and bolt 6 to 105 ± 5 N·m (77 ± 4 lb ft). 5. Again tighten bolt 1 and bolt 2 to 105 ± 5 N·m (77 ± 4 lb ft). 6. Again tighten bolt 3 and bolt 4 to 105 ± 5 N·m (77 ± 4 lb ft). 7. Again tighten bolt 5 and bolt 6 to 105 ± 5 N·m (77 ± 4 lb ft). 8. Turn bolt 3 and bolt 4 to 90 ± 5 degrees. 9. Turn bolt 5 and bolt 6 to 90 ± 5 degrees. 10. Turn bolt 1 and bolt 2 to 90 ± 5 degrees.
    2	2	269-0588 Spacers

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    Table 4

    Assembly Specification for Type 1 Connecting Rods with 428-7386 Bolt As
    Item	Qty	Part	Specification Description
    1	6	428-7386 Bolt As	Use the following procedure to tighten the bolts of the connecting rod: Lubricate each bolt with Bel-Ray Molylube 67700 by fully coating the elastomer rings, threads, and the contact surface under the bolt head. Refer to the following link for ordering purpose. www.belray.com 1. Install all the bolts into the spacers by pushing and rotating the bolt simultaneously. Note: Rotating the bolt while pushing will avoid damage to the bolts. 2. Install the bolts into the connecting rod cap by pushing and rotating the bolt simultaneously. 3. Engage the threads by pushing and slowly rotating the bolt. Do not tap the bolt. All six bolts should have the threads engaged before the joint is drawn together on either side. The order of engaging the threads is bolts 1-2-3-4-5-6. Engaging bolt 1 and 2 first helps center the cap to the connecting rod. Once bolts 1 and 2 threads have engaged install the remaining bolts in order. 4. Tighten bolt 1 and bolt 2 to 105 ± 5 N·m (77 ± 4 lb ft). 5. Tighten bolt 3 and bolt 4 to 105 ± 5 N·m (77 ± 4 lb ft). 6. Tighten bolt 5 and bolt 6 to 105 ± 5 N·m (77 ± 4 lb ft). 7. Again tighten bolt 1 and bolt 2 to 105 ± 5 N·m (77 ± 4 lb ft). 8. Again tighten bolt 3 and bolt 4 to 105 ± 5 N·m (77 ± 4 lb ft). 9. Again tighten bolt 5 and bolt 6 to 105 ± 5 N·m (77 ± 4 lb ft). 10. Turn bolt 3 and bolt 4 an extra 90 ± 5 degrees. 11. Turn bolt 5 and bolt 6 an extra 90 ± 5 degrees. 12.Turn bolt 1 and bolt 2 an extra 90 ± 5 degrees.
    2	2	269-0588 Spacer

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    Illustration 9	g03406077
    The arrow represents the front of the engine block Bolt numbering for 434-0486 Connecting Rod Gp, 434-0487 Connecting Rod Gp, 376-4939 Connecting Rod, 376-4938 Connecting Rod, 417-7902 Connecting Rod, and 417-7903 Connecting Rod. Bolt (1) is always identified as the center bolt on the bearing tab side of the connecting rod. (A) Bearing tab side (X) Odd numbered connecting rod (Y) Even numbered connecting rod

13. Use the following procedure to tighten the connecting rod bolts for Type 2 connecting rods:
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    Table 5

    Assembly Specifications for Type 2 Connecting Rods with 290-2541 Bolts
    Item	Qty	Part	Specification Description
    1	6	290-2541 Bolt	Use the following procedure to tighten the bolts of the connecting rod: Note: Apply Bel-Ray Molylube 67700 to the threads and middle rings of bolt and the contact surface under the bolt head. Refer to the following link for ordering purpose. www.belray.com 1. Install bolts (1) and spacers (2). Hand tighten the bolts. Bolt 1 is identified as the middle bolt on the tab side of the bearing on the connecting rod. Tighten this bolt first to seat the bearing into the bore. 2. Tighten bolt 1 and bolt 2 to 85 ± 5 N·m (63 ± 4 lb ft). 3. Tighten bolt 3 and bolt 4 to 85 ± 5 N·m (63 ± 4 lb ft). 4. Tighten bolt 5 and bolt 6 to 85 ± 5 N·m (63 ± 4 lb ft). 5. Again tighten bolt 1 and bolt 2 to 85 ± 5 N·m (63 ± 4 lb ft). 6. Again tighten bolt 3 and bolt 4 to 85 ± 5 N·m (63 ± 4 lb ft). 7. Again tighten bolt 5 and bolt 6 to 85 ± 5 N·m (63 ± 4 lb ft). 8. Turn bolt 3 and bolt 4 for an extra 90 ± 5 degrees. 9. Turn bolt 5 and bolt 6 for an extra 90 ± 5 degrees. 10. Turn bolt 1 and bolt 2 for an extra 90 ± 5 degrees.
    2	2	366-5649 Spacer

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    Table 6

    Assembly Specifications for Type 2 Connecting Rods with 428-7386 Bolt As
    Item	Qty	Part	Specification Description
    1	6	428-7386 Bolt As	Use the following procedure to tighten the bolts of the connecting rod: Note: Lubricate each bolt with Bel-Ray Molylube 67700 by fully coating the elastomer rings, threads, and the contact surface under the bolt head. Refer to the following link for ordering purpose. www.belray.com 1. Install all the bolts into the spacers by pushing and rotating the bolt simultaneously. Note: Rotating the bolt while pushing will avoid damage to the bolts. 2. Install the bolts into the connecting rod cap by pushing and rotating the bolt simultaneously. 3. Engage the threads by pushing and slowly rotating the bolt. Do not tap the bolt. All six bolts should have the threads engaged before the joint is drawn together on either side. The order of engaging the threads is bolts 1-2-3-4-5-6. Engaging bolt 1 and 2 first helps center the cap to the connecting rod. Once bolts 1 and 2 threads have engaged install the remaining bolts in order. 4. Tighten bolt 1 and bolt 2 to 85 ± 5 N·m (63 ± 4 lb ft). 5. Tighten bolt 3 and bolt 4 to 85 ± 5 N·m (63 ± 4 lb ft). 6. Tighten bolt 5 and bolt 6 to 85 ± 5 N·m (63 ± 4 lb ft). 7. Again tighten bolt 1 and bolt 2 to 85 ± 5 N·m (63 ± 4 lb ft). 8. Again tighten bolt 3 and bolt 4 to 85 ± 5 N·m (63 ± 4 lb ft). 9. Again tighten bolt 5 and bolt 6 to 85 ± 5 N·m (63 ± 4 lb ft). 10. Turn bolt 3 and bolt 4 an extra 90 ± 5 degrees. 11. Turn bolt 5 and bolt 6 an extra 90 ± 5 degrees. 12. Turn bolt 1 and bolt 2 an extra 90 ± 5 degrees.
    2	2	366-5649 Spacers

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    Illustration 10	g02049093

14. Remove Tooling (C).
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    Illustration 11	g01206105

15. Position side cover (2). Install bolts (1).

16. If necessary, install the components for access to the side covers. Install the panel, the starting motor, and the alternator.

End By:

a. Install the engine oil pump.

b. Install the engine oil cooler.

c. Install the fuel pump.

d. Install the electronic unit injector.