Required Tools | |||
Tool | Part Number | Part Description | Qty |
A(1) | 9U-6198 | Crankshaft Turning Tool | 1 |
A(2) | 9U-7336 | Housing | 1 |
5P-7305 | Engine Turning Tool | 1 | |
B | 230-6284 | Timing Pin (Camshaft) | 1 |
C | 364-9107 | Fuel Injection Pump Timing Pin | 1 |
D | 136-4632 | Timing Pin (Crankshaft) | 1 |
268-1966 | Adapter | 1 | |
E | 9U-7324 | Indicator Bracket | 1 |
7H-1942 | Dial Indicator | 1 | |
3S-3268 | Indicator Contact Point | 1 | |
7H-1940 | Universal Attachment | 1 |
(1) | The Crankshaft Turning Tool is used on the front pulley. |
(2) | This Tool is used in the aperture for the electric starting motor. |
Start By:
- Remove the front cover.
- Remove the valve mechanism cover.
NOTICE |
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Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
NOTICE |
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Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products. Dispose of all fluids according to local regulations and mandates. |
Note: Either Tooling (A) can be used. Use the Tooling that is most suitable. Care must be taken to ensure that the fuel injection pump timing is not lost during the removal of the front gear group. Carefully follow the procedure to remove the gear group.
- Remove plug (2) from the cylinder block. Remove O-ring seal (1) from the plug.
- Use Tooling (A) 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.
- Install Tooling (D) through Hole (W) to lock the crankshaft.
- Remove Tooling (D).
- Use Tooling (A) to rotate the crankshaft in a clockwise direction and position the crankshaft at 60 degrees after top dead center.
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Illustration 2 g01992077 - Use Tooling (E) to loosen threaded inserts (4) on all rocker arms (3). Unscrew threaded inserts (4) on all rocker arms (3) until all valves are fully closed. Ensure that guides (5) for the pushrods are left in position on threaded inserts (4).
Note: Ensure that ALL threaded inserts are fully unscrewed.
- Use Tooling (A) 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.
- Install Tooling (D) through Hole (W) to lock the crankshaft. Refer to Illustration 1.
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Illustration 3 g01992075 - Install Tooling (B) through Hole (X) in camshaft gear (6) into the front housing. Use Tooling (B) to lock the camshaft in the correct position. Refer to System Operation, Testing and Adjusting, "Finding Top Center Position for No.1 Piston" for the correct procedure.
- Install Tooling (D) into Hole (W) in the cylinder block. Use Tooling (D) 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.
Note: Do not use excessive force to install Tooling (D). Do not use Tooling (D) to hold the crankshaft during repairs.
- Use Tooling (C) 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 4 g01992078 - Mark gear (6), gear (7), gear (8) and gear (9) in order to show alignment. Refer to Illustration 4.
Note: Identification will ensure that the gears can be installed in the original alignment.
- Remove Tooling (B), Tooling (C), and Tooling (D).
- Remove camshaft gear (6). Refer to Disassembly and Assembly, "Camshaft Gear - Remove and Install" for the correct procedure.
- Remove idler gear (7). Refer to Disassembly and Assembly, "Idler Gear - Remove and Install" for the correct procedure.
Illustration 1 | g01992076 |
Note: The fuel injection pump must remain locked until the procedure instructs you to unlock the fuel injection pump.
- 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 5 g02085993 - If necessary, install Tooling (D) into Hole (W) in the cylinder block. Use Tooling (D) 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.
Note: Do not use excessive force to install Tooling (D). Do not use Tooling (D) to hold the crankshaft during repairs.
- Ensure that all of the components of the front gear group are clean and free from wear and damage. If necessary, replace any components that are worn or damaged.
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Illustration 6 g01992079 - Install camshaft gear (6). Loosely install bolt (11) and washer (10) for the camshaft gear. Refer to Disassembly and Assembly, "Camshaft Gear - Remove and Install" for the correct procedure.
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Illustration 7 g01993593 - Install Tooling (B) through Hole (X) in camshaft gear (6) into the front housing.
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Illustration 8 g01993576 Show/hide tableIllustration 9 g01992078 Alignment of timing marks - Install idler gear (7). Ensure that the timing marks on gear (6), gear (7), gear (8) and gear (9) are in alignment. Refer to Disassembly and Assembly, "Idler Gear - Remove and Install". Check the end play of the idler gear. Refer to Specifications, "Gear Group (Front)" and refer to Disassembly and Assembly, "Idler Gear - Remove and Install" for the correct procedure.
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Illustration 10 g02086016 - Ensure that the fuel injection pump is locked in the correct position. Refer to Disassembly and Assembly, "Fuel Injection Pump - Install" for the correct procedure.
- Remove Tooling (B) and Tooling (C).
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Illustration 11 g02353396 - When a 8.8 Graded bolt (11) is installed. Tighten the bolt to a torque of
95 N·m (70 lb ft) .When a 10.9 Graded bolt (11) is installed. Tighten the bolt to a torque of
120 N·m (89 lb ft) . - Check the end play of the camshaft gear. Refer to Specifications, "Camshaft" for more information.
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Illustration 12 g02086053 - Use Tooling (E) to measure the backlash for gear (6), gear (7), gear (8) and gear (9). Refer to Specifications, "Gear Group (Front)" for more information.
- Lubricate each gear with clean lubricating engine oil.
- If necessary, use Tooling (A) 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. If necessary, use Tooling (D) in order to lock the crankshaft so that number one piston is at top dead center on the compression stroke.
- Remove Tooling (D).
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NOTICE Failure to ensure that the crankshaft is positioned at 60 degrees after top dead center will result in interference between the pistons and the valves. Interference between the pistons and the valves will result in damage to the engine.
- Use Tooling (A) to rotate the crankshaft in a clockwise direction and position the crankshaft at 60 degrees after top dead center.
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Illustration 13 g01992077 - Ensure that guides (5) for the pushrods are correctly positioned on threaded inserts (4). Tighten the threaded inserts to a torque of
30 N·m (22 lb ft) .Note: When the threaded insert is tightened, the threaded insert must be seated correctly into the cup for the pushrod.
Show/hide tableIllustration 14 g01992076 - Install a new O-ring seal (1) to plug (2). Install the plug into Hole (W) in the cylinder block. Tighten plug (2) to a torque of
21 N·m (186 lb in) . - The engine should not be operated for a period 30 minutes after the threaded inserts on all the rocker arms have been tightened. This period will allow the force from the valve springs to purge off excessive engine oil from the hydraulic lifters.
End By:
- Install the front cover.
- Install the valve mechanism cover.