C7.1 Marine Engine Caterpillar

Removal Procedure

Start By:

1. Remove the front cover.

2. Remove the valve mechanism cover.

Note: Care must be taken to ensure that the fuel injection pump timing is not lost during the removal of the idler gear. Carefully follow the procedure to remove the fuel pump gear.

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Illustration 1	g01994555

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Illustration 2	g01994553
Typical Example

1. 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.

2. Remove plug (2) from the cylinder block and remove O-ring seal (1) from the plug.

3. Ensure that Tooling (C) is installed in Hole (Y) in the cylinder block. Use Tooling (C) to lock the crankshaft in the correct position.

4. Ensure that Tooling (B) is installed into Hole (X) in camshaft gear (3). Use Tooling (B) to lock the camshaft in the correct position.

   Note: Ensure that the gears are marked to show alignment. Refer to Illustration 2.

5. Use Tooling (A) 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	g01994556
   Typical Example

6. Loosen threaded inserts (5) on all rocker arms (6). Unscrew threaded inserts (5) on all rocker arms (6) until all valves are fully closed.

   Note: Failure to ensure that ALL threaded inserts are fully unscrewed can result in contact between the valves and pistons.

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   Illustration 4	g01994576
   Typical Example

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   Illustration 5	g01994557
   Typical Example

7. Mark plate (8) to show orientation.

   Note: Identification will ensure that the plate can be installed in the original orientation.

8. Remove bolts (7).

9. Remove plate (8).

10. Remove the assembly of idler gear (4).

11. Remove hub (9) from the recess in the front housing.

Installation Procedure

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Illustration 6	g01996476

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Illustration 7	g01996475

1. Ensure that Tooling (C) is installed in Hole (Y) in the cylinder block. Use Tooling (C) 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.

2. Ensure that Tooling (B) is installed into Hole (X) in camshaft gear (3).

3. Use Tooling (A) 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 8	g01996477

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   Illustration 9	g02196594

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   Illustration 10	g01996576

4. Lubricate hub (9) with clean engine oil. Install hub (9) into the recess in the front housing. Ensure that oil Hole (Z) is position as shown in the Illustration 9.

5. Install idler gear (4) onto hub (9). Ensure that the timing marks are toward the front of the idler gear.

6. Align the timing mark on idler gear (4) with the timing mark on camshaft gear (3), fuel injection pump gear (10) and crankshaft gear (11). Refer to the Illustration 10. Install the assembly of idler gear (4) to hub (9).

7. Lubricate plate (8) with clean engine oil. Align the holes in plate (8) with the holes in hub (9). Install the plate in the original orientation.

   Note: Ensure that the identification mark TOP is upward.

8. Install bolts (7). Tighten the bolts to a torque of 44 N·m (32 lb ft).

9. Remove Tooling (A), Tooling (B), and Tooling (C).

   Note: Ensure that timing marks are aligned, before removing the Tooling (A), Tooling (B) and Tooling (C).

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   Illustration 11	g01996554

10. Position a new O-ring seal (1) onto plug (2). Install the plug to the cylinder block and tighten the plug to a torque of 21 N·m (186 lb in).

11. Use Tooling (D) to check the end play for the idler gear. Refer to Specifications, "Gear Group (Front)" for more information.

12. Use Tooling (D) to check the backlash between the idler gear and the camshaft gear. Refer to Specifications, "Gear Group (Front)" for more information.

13. Use Tooling (D) to check the backlash between the idler gear and the crankshaft gear. Refer to Specifications, "Gear Group (Front)" for more information.

14. Use Tooling (D) to check the backlash between the idler gear and the fuel injection pump gear. Refer to Specifications, "Gear Group (Front)" for more information.

15. Lightly lubricate all of the gears with clean engine oil.
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    Illustration 12	g01994556
    Typical Example

16. 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.

17. 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:

1. Install the front cover.

2. Install the valve mechanism cover.