G3508J, G3516J, and G3520J Engines Caterpillar

Installation Procedure

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Illustration 1	g01226804
Typical example

1. The following steps are for the installation of a camshaft in the G3512Engines , G3516Engines , and G3520Engines. The camshaft is in two pieces.

   1. Install Tooling (D) on the flywheel housing. Do not tighten the bolts on Tooling (D).

   2. Install Tooling (C) on the end of the front half of the crankshaft.

   3. Ensure that the camshaft and the camshaft bearings are clean. Place clean engine oil on the lobes and the journals of the camshaft. Also place clean engine oil on the camshaft bearings.

   4. Attach a suitable lifting device to the front half of camshaft (12). The camshaft for G3508 Engines has a weight of approximately 42 kg (93 lb). The camshaft for G3512 Engines has a weight of approximately 63 kg (140 lb). The camshaft for G3516 Engines has a weight of approximately 82 kg (185 lb). The camshaft for G3520 Engines has a weight of approximately 100 kg (220 lb). Position the front half of camshaft (12) in the engine until Tooling (C) is in the first camshaft bearing.

   5. Rotate camshaft (12) and tighten the bolts for Tooling (D).

   6. Rotate camshaft (12) and insert camshaft (12) until camshaft (12) is slightly protruding from Tooling (D).
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      Illustration 2	g00579259
      Typical example

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      Illustration 3	g00579148
      Typical example

   7. If the dowel was removed from the front half of camshaft (12), install the dowel. The dowel should be 22.0 ± 0.5 mm (0.87 ± 0.02 inch) from the surface of the camshaft.

      Note: Ensure that the camshafts are installed according to the marks on the ends of the camshafts.

   8. Attach a suitable lifting device to the rear half of camshaft (13). Install spacer (15) and the rear half of camshaft (13) onto the front half of camshaft (12). Install bolts (14) and tighten to a torque of 55 ± 7 N·m (41 ± 5 lb ft).

   9. Install Tooling (C) and Tooling (E) on the end of camshaft (13).

   10. Rotate camshaft (13) and insert the camshaft into the engine.

   11. Remove all Tooling. Repeat Steps 1.a through 1.j for the camshaft on the opposite side of the engine. Go to Step 3.

2. The following steps are for the installation of a camshaft in the G3508 Engines. The camshaft is in one piece.

   1. Install Tooling (D) on the flywheel housing. Do not tighten the bolts on Tooling (D).

   2. Install Tooling (C) on the ends of the camshaft.

   3. Ensure that the camshaft and the camshaft bearings are clean. Place clean engine oil on the lobes and the journals of the camshaft. Also place clean engine oil on the camshaft bearings.

      Note: Ensure that the camshafts are installed according to the marks on the ends of the camshafts.

   4. Attach a suitable lifting device to the camshaft. The weight of the camshaft is approximately 42 kg (93 lb). Insert the camshaft in the engine until Tooling (C) is in the first camshaft bearing.

   5. Install Tooling (E). Rotate the camshaft and tighten the bolts on Tooling (D).

   6. Rotate the camshaft and insert the camshaft into the engine.

   7. Repeat Steps 2.a through 2.f for the camshaft on the opposite side of the engine. Go to Step 3.
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   Illustration 4	g00579144

3. Install thrust washers (10) and bolts (9) that fasten the camshaft to the engine.
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   Illustration 5	g00579261

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   NOTICE
   If the camshaft is out of time more than 18 degrees (approximately 1/2 of the timing pin is out of the groove), the valves can make contact with the pistons. This will cause damage to the engine. Refer to Testing and Adjusting, "Camshaft Timing" for more information.

4. Remove timing pin (16) from the storage position on the side of the engine.

5. Turn the camshaft until timing pin (16) can be installed through the cylinder block and into groove (17) that is in the camshaft.

6. Repeat Steps 4 and 5 for the camshaft on the opposite side of the engine.
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   Illustration 6	g00579262

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   Illustration 7	g01226865

7. Remove bolts (19), cover (18), and plug (20).

8. Install one bolt (19) into the flywheel housing through the hole for plug (20). Use Tooling (A) and a ratchet to turn the flywheel until bolt (19) can be installed through the hole and into the flywheel. Doing so will position the No. 1 cylinder at the top center. Refer to the Testing and Adjusting Module for more information.
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   Illustration 8	g00579264

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   Illustration 9	g00579145

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   Illustration 10	g00579141

9. Use the following procedure to install camshaft drive gears (8).

   1. Clean the taper of the camshaft and the tapered bore of the camshaft gear with a lint free cloth saturated with solvent to remove oil. Clean the parts again with a lint free alcohol wipe to remove any residue. The alcohol wipe will be dirty after cleaning the parts. Clean the parts again with a lint free alcohol wipe until no residue is left on the alcohol wipe.

      Note: The camshaft and the tapered bore of the camshaft gear must be clean, dry, and free of residue before assembly.

   2. Ensure that the camshaft timing pins and the timing pin for the flywheel are installed.

   3. Place camshaft drive gears (8) in position. Remove the backlash by rotating the gears in the opposite direction of camshaft rotation.

      Note: For "Standard Rotation" engines, turn the camshaft drive gears COUNTERCLOCKWISE. For "Reverse Rotation" engines, turn the camshaft drive gears CLOCKWISE.

   4. Install the bolt and plate (7).

   5. Install the bolt and timing ring (11). Ensure that the hole in the timing ring is properly seated on the locating pin.

   6. Tighten the bolt to a torque of 360 N·m (265 lb ft).

   7. Place a Mark on the bolt.

   8. Place a driver against the retaining plate of the camshaft gear. Strike the driver solidly with a hammer 3 to 4 times.

   9. Tighten the bolt again to a torque of 360 N·m (265 lb ft).

   10. Repeat Steps 9.h and 9.i until the Mark has turned at least 90 degrees.

10. Remove the timing pins from the camshafts. Install the timing pins in the original locations.
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    Illustration 11	g00579522

11. Install cover (6) with the bolts on the flywheel housing.
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    Illustration 12	g01281296

12. Install the bolts in cover (5) and connect harness assembly (X).
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    Illustration 13	g01281295

13. Install the bolts and cover (3) on the front housing.

14. Install the bolts and cover (4) on the front housing.
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    Illustration 14	g00579262

15. Remove bolt (19) from the flywheel. Install plug (20) in the timing hole. Remove Tooling (A) and install cover (18) with bolts (19) on the flywheel housing.
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    Illustration 15	g00579090

16. Remove the O-ring seals from valve lifters (2). Push valve lifters (2) against the camshaft.
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    Illustration 16	g00579084

17. Install access covers (1) on each side of the engine.

18. Install the engine speed/timing sensor. Refer to Testing and Adjusting, "Engine Speed/Timing Sensor".

End By:

1. Install the rocker shaft assemblies and the pushrods.