G3508J, G3516J, and G3520J Engines Caterpillar

Removal Procedure

Start By:

1. Remove the engine oil filter housing.

2. Remove the crankshaft front seal and the wear sleeve.

3. Remove accessory drive (front).

4. Remove the engine oil and water pump drive.

5. Remove the auxiliary water pump.

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Illustration 1	g01255428

1. Remove the clips from front drive housing (3).

2. Attach Tooling (C) and a suitable lifting device to mounting bracket (1). The weight of mounting bracket (1) is approximately 70 kg (154 lb).

3. Remove bolts (2) and mounting bracket (1).
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   Illustration 2	g01255435

4. Remove elbow (5) and tube (4).

5. Remove cover (6) and the O-ring seal from front drive housing (3).

6. Remove the bolts from the end of shaft (8). Use Tooling (A) to remove shaft (8) and idler gear (7) from both sides of the engine.

7. Use Tooling (B) and a suitable press to remove the bearing from idler gear (7).
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   Illustration 3	g01255488

8. Remove washers (10) from front drive housing (3).

9. Attach Tooling (C) and a suitable lifting device to front drive housing (3). The weight of front drive housing (3) is approximately 200 kg (450 lb).

10. Remove the bolts that hold the engine oil pan to front drive housing (3). Remove bolts (9), front drive housing (3), and the front drive housing gasket.

Installation Procedure

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Illustration 4	g01255488

1. Install the front drive housing gasket on the cylinder block. Install Tooling (D) in the cylinder block.

2. Attach Tooling (C) and a suitable lifting device to front drive housing (3). The weight of front drive housing (3) is approximately 200 kg (450 lb). Position front drive housing (3) on Tooling (D).

3. Install bolts (9) in front drive housing (3) and tighten the bolts evenly. Cut the excess front drive housing gasket at the face of the cylinder block. Apply sealant to the cut corners of the gasket.

4. Inspect the condition of the gasket on the engine oil pan. Replace the gasket, if necessary. Install the bolts that attach the engine oil pan to front drive housing (3).

5. Install washers (10) in front drive housing (3).
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   Illustration 5	g01255435

6. Use Tooling (B) to install the bearing in idler gear (7). The bearing must have a diameter of 105.97 ± 0.01 mm (4.172 ± 0.001 inch) after installation.

7. Place clean engine oil on the O-ring seal of shaft (8). Install idler gear (7) and shaft (8) on both sides of the engine.

8. Place clean engine oil on the O-ring seal and install cover (6) on front drive housing (3).

9. Lubricate the O-ring seals on tube (4) with glycerin. Install tube (4) and elbow (5).
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   Illustration 6	g01255428

10. Attach Tooling (C) and a suitable lifting device to mounting bracket (1). The weight of mounting bracket (1) is approximately 70 kg (154 lb). Install mounting bracket (1) on front drive housing (3). Install bolts (2).

11. Install the clips on front drive housing (3).

End By:

1. Install the auxiliary water pump.

2. Install the engine oil and water pump drive.

3. Install the accessory drive (front).

4. Install the crankshaft front seal and the wear sleeve.

5. Install the engine oil filter housing.