G3508J, G3516J, and G3520J Engines Caterpillar

Installation Procedure

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Illustration 1	g00577390

1. If crankshaft gears (6) were removed, install crankshaft gears (6) on the crankshaft and install bolts (7).

2. Check the clearance of the bearings. Refer to Disassembly and Assembly, "Bearing Clearance - Check" for the correct procedure.
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   Illustration 2	g01353563

   Note: Place clean engine oil on the main bearings and on the connecting rod bearings prior to installation.

   Note: The upper halves of the main bearings have an oil hole in the center.

3. Install the upper halves of main bearings (8) in the cylinder block.

4. Install the upper halves of connecting rod bearings (9) in the connecting rod assemblies.
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   Illustration 3	g01353615
   Typical example

   Note: Ensure that the word "FRONT" that is on the end of the crankshaft is toward the front of the engine.

5. Attach a suitable lifting device to crankshaft (4) and position the crankshaft in the cylinder block. The crankshaft for the G3508 Engines weighs approximately 405 kg (895 lb). The weight of crankshaft (4) is approximately 762 kg (1680 lb). The crankshaft for the G3520 Engines weighs approximately 910 kg (2010 lb).
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   Illustration 4	g01353620
   Tightening sequence

   Note: The main bearing caps must be installed with the word "FRONT" and the part number toward the front of the engine. Each main bearing cap has a number on the bottom surface and each main bearing must be installed in the corresponding position in the cylinder block.

6. Place Tooling (C) on the bolts for the main bearing caps.
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   Illustration 5	g01353682

7. Place clean engine oil on thrust plates (3). Install thrust plates (3) on each side of the center main bearing.

8. Place main bearing caps (5) into position and install the bolts. Tighten the bolts in the numerical sequence that is shown above to a torque of 190 ± 14 N·m (140 ± 10 lb ft). Tighten the bolts again for an additional 180 ± 5 degrees.

9. Check the end play with Tooling (B). The end play must not exceed 0.40 ± 0.23 mm (0.016 ± 0.009 inch).
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   Illustration 6	g01353696

10. Position the connecting rods on the journals of the crankshaft. Install connecting rod bearing caps (2).

    Note: The number that is on the side of the connecting rod caps must be installed next to the corresponding number that is on the side of the connecting rod.

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    Illustration 7	g01353701
    Tightening sequence

11. Place Tooling (C) on the bolts for the connecting rod caps and install the bolts.

12. Tighten the bolts with the following steps:

    1. Tighten bolts (14) and (15) to a torque of 90 ± 5 N·m (65 ± 4 lb ft).

    2. Tighten bolts (16) and (17) to a torque of 90 ± 5 N·m (65 ± 4 lb ft).

    3. Tighten bolts (14) and (15) again to a torque of 90 ± 5 N·m (65 ± 4 lb ft).

    4. Tighten bolts (16) and (17) again to a torque of 90 ± 5 N·m (65 ± 4 lb ft).

    5. Tighten each bolt for an additional 90 ± 5 degrees (1/4 turn). An impact wrench may be used.

13. Place the remaining connecting rod caps in position and tighten the bolts with the same procedure that is in Steps 12.a through 12.e.
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    Illustration 8	g01353745

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    NOTICE
    Each counterweight is numbered and must be installed in the same position as the corresponding number on the crankshaft mounting pad in order to prevent damage to the crankshaft.

14. Install counterweights (1).

15. The following procedure is for the installation of the counterweights in G3508, G3516, and G3520 Engines .

    1. Ensure that the dowels are in the correct position and install the counterweights on the crankshaft.

    2. Apply Tooling (C) to the threads of the bolt, to the shank of the bolt, and to the seat of the bolt prior to assembly.

    3. Tighten the bolts in all the counterweights to a torque of 70 ± 5 N·m (50 ± 4 lb ft).

    4. Tighten the bolts in all the counterweights for an additional 120 ± 5 degrees (1/3 turn).

16. Use Tooling (A) to rotate the engine back to a vertical position.

Note: Refer to the Specifications Module for more information on the crankshaft.

End By:

1. Install the piston cooling jets.

2. Install the rear gear group.

3. Install the front drive housing.

4. Install the rocker shaft assemblies and the pushrods.