2002/03/11 Caterpillar

Machine Engines:

C-9 (S/N: 4ZF)

C-9 (S/N: CLJ)

Reference: The connecting rod cap bolts should not be reused during installation of the connecting rod. Always use new connecting rod cap bolts. This change is shown in the following text. This change will be included in the next revision of this manual.

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Illustration 1	g00872506
(1) Connecting rod (2) Bolt (3) Connecting rod cap (4) Bolt (5) Connecting rod bearing (Lower half) (6) Connecting rod bearing (Upper half) (7) Fractured face of connecting rod

1. Install the upper half of connecting rod bearing (6). Ensure that the bearing tab engages with the slot in connecting rod (1). Place clean engine oil on the surface of the upper half of connecting rod bearing (6) .

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Illustration 2	g00828435

Note: The joint between the connecting rod and the connecting rod cap is produced by fracturing. These connecting rods must be handled with care. New connecting rod assemblies come with the connecting rod cap on the connecting rod. The connecting rod cap is fastened with the connecting rod cap bolts. Use a soft jawed vise in order to hold the connecting rod when loosening the connecting rod cap bolts from a new connecting rod. Use a soft faced hammer and tap the connecting rod cap in order to separate the connecting rod cap from the connecting rod.

2. Place protective cap (B) over the long end of the fractured connecting rod.

3. Place clean engine oil on the pistons, the piston rings, and the cylinder bore.

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Illustration 3	g00634923

Note: Each piston ring end gap must be positioned 120 degrees from each other.

4. Install Tool (A) in order to compress the piston rings.

5. With the crankshaft throw at the bottom center, install the piston and connecting rod in the engine. Ensure that the proper piston and connecting rod are in the corresponding cylinder with the bearing retainer notch toward the right side of the engine.

   Note: The etched number on the connecting rod must be on the right side of the engine in the corresponding cylinder.

6. Line up the piston and the connecting rod with the crankshaft. Use a soft hammer and tap the piston into the cylinder bore until Tool (A) comes off of the piston.

7. Remove protective cap (B) from the long end of the connecting rod.

8. Use a soft hammer in order to tap the piston into the cylinder bore while you guide connecting rod (1) onto the crankshaft.

9. Place the lower half of connecting rod bearing (5) in corresponding connecting rod cap (3). Ensure that the bearing tab engages with the groove in connecting rod cap (3) .

10. Place clean engine oil on the surface of the lower half of connecting rod bearing (5). Install connecting rod bearing cap (3) on the connecting rod (1). Ensure that the number on connecting rod bearing cap (3) matches the number on the connecting rod (1). Ensure that the numbers are on the same side.

Note: Do not reuse the connecting rod cap bolts. Always use new connecting rod cap bolts.

11. Lubricate the new connecting rod cap bolts with 4C-5593 Anti-Seize Compound .

12. Install the new connecting rod cap bolts (2) and (4). Tighten bolts (2) and (4) to a torque of 50 ± 5 N·m (37 ± 3 lb ft).

13. Place an index mark on each connecting rod cap bolt. Tighten each bolt (2) and (4) for an additional 90 ± 5 degrees (1/4 turn).

14. Repeat Steps 1 through 13 for the remaining pistons and connecting rods.

End By:

a. - Install the piston cooling jets. Refer to Disassembly and Assembly, "Piston Cooling Jets - Remove and Install".

b. - Install the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump - Install".

c. - Install the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Install".