C7.1 Marine Engine Caterpillar

Removal Procedure

Start By:

1. If the engine is equipped with a fan, remove the fan.

2. Remove the crankshaft pulley.

3. Remove the engine oil pan plate.

4. Remove the water pump.

5. Remove the timing gears.

6. Remove the fuel injection pump.

7. Remove the auxiliary water pump.

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Illustration 1	g02198874

1. Cut cable strap (2) from wiring harness assembly.

2. Remove bolts (3) that secure bypass tube (1) to front housing (4).

3. Remove bypass tube (1) from the cylinder head. Remove O-ring (5) and O-ring (6) from bypass tube (1).
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   Illustration 2	g02198875

4. Remove bolts (7), bolts (8) and bolts (9) from front housing (4).

   Note: The bolts are three different lengths. Note the positions of the different bolts.

5. Remove front housing (4) from the cylinder block.

6. Remove gasket (10).
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   Illustration 3	g02198876

7. Remove thrust washer (11) from the cylinder block.

Installation Procedure

1. Ensure that the front housing is clean and free from damage. If necessary, replace the front housing.

   If necessary, install blanking plugs to a new front housing. Use Tooling (A) in order to seal all D-plugs.

2. Clean all the gasket surfaces of the cylinder block.
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   Illustration 4	g02198913

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   Illustration 5	g02198914

3. Inspect dowel (12) and dowel (13) for damage. If necessary, replace the dowels in the cylinder block.

4. Install thrust washer (11) into the recess in the cylinder block. Refer to Disassembly and Assembly, "Camshaft - Install" for more information.

5. Install Tooling (B) to the cylinder block. Refer to Illustration 5.

6. Align a new gasket (10) with Tooling (B). Install the gasket to the cylinder block.

   Note: Ensure that two circular Tabs (X) on the gasket are engaged in two Holes (Y) in the cylinder block. Ensure that dowel (12) in the cylinder block is engaged on the gasket.

7. Install Tooling (C) to the cylinder block.

8. Install the front housing over Tooling (B) and Tooling (C) onto the cylinder block.
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   Illustration 6	g02198915
   (7) M8 by 20 mm (8) M8 by 35 mm (9) M8 by 25 mm

9. Install new bolts (9) to front housing (4) hand tight.

10. Remove Tooling (B).

11. Loosely install bolts (7) and bolts (8) finger tight. Refer to Illustration 6 for the correct position of the bolts.
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    Illustration 7	g01998054

12. Tighten bolts (7), bolts (8) and bolts (9) in the sequence that is shown in Illustration 7 to a torque of 28 N·m (248 lb in).

13. Remove Tooling (C) from the cylinder block.
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    Illustration 8	g02198874

14. Install new O-ring seal (5) and O-ring seal (6) to bypass tube (1). Use Tooling (D) in order to lubricate the O-ring seals.

15. Install bypass tube (1) to the cylinder head. Install bolts (3). Tighten the bolts to a torque of 9 N·m (80 lb in)

16. Install a new cable strap (2) to the wiring harness assembly.

End By:

1. Install the fuel injection pump

2. Install the timing gears.

3. Install the engine oil pan plate.

4. Install the crankshaft pulley

5. Install the water pump.

6. If the engine is equipped with a fan, install the fan.

7. Install the auxiliary water pump.