G3508J, G3516J, and G3520J Engines Caterpillar

Installation Procedure

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Illustration 1	g00913137

1. Install crankshaft gear (8) and the bolts.
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   Illustration 2	g00913136

2. Install shaft (7) and the bolts. The torque for the bolts is 140 ± 10 N·m (105 ± 5 lb ft).
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   Illustration 3	g01051669

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   Illustration 4	g01068502
   (4) Camshaft Idler Gear. (9) Bearing. (E) 81.060 ± 0.010 mm (3.1913 ± 0.0004 inch). (F) 1.00 ± 0.25 mm (0.040 ± 0.010 inch).

3. Use Tooling (A) and a suitable press to install the bearings in camshaft idler gears (4). Install bearing (9) into gear (4) to Depth (F), as shown.

4. Machine the inside diameter of bearing (9) to Dimension (E), as shown.

   Note: The surface finish of Bore (E) must be 0.8 micrometers. Pitch Diameter (H) must be concentric with a total indicator reading of 0.12 mm (0.005 inch). Surface (G) of gear (4) must be square with Bore (E) within 0.05 mm (0.002 inch).

5. Place clean engine oil on the bearings and install shafts (5) with washers (6) on camshaft idler gears (4).
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   Illustration 5	g00913054

6. Install camshaft idler gears (4) and the bolts.
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   Illustration 6	g01068516
   (2) Cluster Idler Gear. (3) Bearing. (A) 75.060 ± 0.010 mm (2.9551 ± 0.0004 inch). (B) 1.5 ± 0.5 mm (0.06 ± 0.02 inch).

7. Use Tooling (A) and a suitable press to install bearing (3) in gear (2). Install bearing (3) to Depth (B), as shown.

8. Replace the gear assembly.
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   Illustration 7	g01056631

   Note: When you install the rear cluster gear assembly to the crank gear, there are no timing marks on the G3516 engines.

9. Put clean engine oil on the bearing and install the gear assembly on the shaft. Make sure that the marks on the gear assembly and the crankshaft are in alignment with the rotation of the engine, as shown.
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   Illustration 8	g00913045

10. Place clean engine oil on gear (2) and install gear (2) on the engine.

11. Install plate (1) and the bolts.

End By:

1. Install the flywheel housing.