XQC1200 and XQC1600 Power Modules Caterpillar

Removal Procedure

Start By:

1. Remove the generator.

2. Remove the valve cover base.

3. Remove the speed/timing sensor.

4. Remove the electronic control module.

5. Remove the turbochargers.

6. Remove the engine mounted breaker box.

7. Remove the fuel priming pump.

1. Set the engine at Top Dead Center on the No. 1 piston. Refer to Testing and Adjusting, "Finding the Top Dead Center Position for the No. 1 Piston" for the correct procedure.
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   Illustration 1	g03710968

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   Illustration 2	g03710974

2. Remove bolts (1) and covers (2) from both sides of the engine. Remove seal (3) from covers (2).
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   Illustration 3	g00914348

3. Remove covers (4) from both sides of the front housing.
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   Illustration 4	g01053356

4. Pull valve lifters (5) away from the camshaft. Hold valve lifters (5) in position with O-ring seals.
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   Illustration 5	g03710997

5. Remove covers (6) for the camshaft drive gears from the flywheel housing.
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   Illustration 6	g03711000

6. Remove the bolt and plate (7) that fastens camshaft drive gear (8) to the camshaft.
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   Illustration 7	g03711010

7. Place the three washers from Tooling (B) behind plate (7) and install the bolt.
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   NOTICE
   Do not apply more than 51675 kPa (7500 psi) pressure to the hydraulic puller. The adapters are rated at 6 1/2 tons each and the hydraulic puller is rated at 17 tons at 68900 kPa (10000 psi). If too much pressure is applied, the gear may be damaged.

8. Install Tooling (B) on camshaft drive gear (8). Apply 51675 kPa (7500 psi) to Tooling (B). Strike the screw on Tooling (B) with a hammer until camshaft drive gear (8) is free from the camshaft. Remove Tooling (B) and camshaft drive gear (8).
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   Illustration 8	g03711027

9. Remove bolts (9) and thrust washers (10) that fasten the camshaft to the engine block.

10. Perform Steps 5 through 9 for the camshaft on the other side of the engine.
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    Illustration 9	g03711031

11. Remove timing ring (11) from the camshaft.
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    Illustration 10	g03711038

12. Install Tooling (C) on each end of the camshaft.

    Note: Tooling (D) can be installed on the flywheel housing in order to remove the camshaft from the rear. Tooling (D) can also be installed on the front housing in order to remove the camshaft from the front of the engine.

13. Install Tooling (D) on the flywheel housing.

14. Install Tooling (E) on the end of Tooling (C).

    Note: The weight of the camshaft is approximately 82 kg (181 lb).

15. Rotate the camshaft with Tooling (E). Pull the camshaft out of the engine until a suitable lifting device can be attached. Remove front camshaft (12) and rear camshaft (13) as a unit.
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    Illustration 11	g03711050

16. Remove bolts (14). Separate the camshafts and remove spacer (15).

17. Remove the dowel from the front of the camshaft, if necessary.

18. Repeat Steps 11 through 17 for the other camshaft.