Installation of 0R2875 Remanufactured 3208 Truck Engine (Natural Aspiration){1000} Caterpillar

Introduction

This instruction contains adaptability and installation information for the Remanufactured engine given in the chart that follows.

Do not perform any procedure, outlined in this publication, or order any parts until you read and understand the information contained within.

Reference: FUEL SETTING INFORMATION LIBRARY and/or the FUEL SETTING AND RELATED INFORMATION microfiche, form SBFY1113.

Exchange of Parts

If the size of the work area permits, it will be beneficial to position the old engine and the new Remanufactured engine in a position where they are side-by-side. This will help when comparing the appearance and configuration of external parts, to determine what parts may need to be exchanged.

The Remanufactured engine is built to the engine arrangement given in the previous charts. No modification or parts exchange is necessary if the part number of the Remanufactured Engine Arrangement is the same as the original engine arrangement it is replacing.

Some modification or parts exchange may be necessary when the Remanufactured Engine Arrangement part number is different than the original engine arrangement part number.

Use the reference literature indicated when it is necessary to exchange parts between the original engine and the Remanufactured engine.

Although some parts on the Remanufactured engine may be different from those on the original engine, an exchange may not be necessary, depending upon the specific application.

In some instances, it may be more advantageous to make minor modifications to the truck frame or engine mounting rails, rather than exchanging components between the Remanufactured engine and the original engine.

Before installation of the Remanufactured engine, make sure the transmission mounting group, flywheel housing, flywheel, and vibration damper/crankshaft pulley are compatible with your application.

Each Remanufactured engine is rated at a specific horsepower (kW) at a specific rpm. The recommended Remanufactured engine that is to be installed will not necessarily have the same exact horsepower (kW) and rpm rating as the original engine that it is replacing. The horsepower (kW) and rpm setting of the recommended Remanufactured engine can, however, be adjusted to the same horsepower (kW) and rpm as the original engine.

NOTE: Always refer to the FUEL SETTING INFORMATION LIBRARY and/or the FUEL SETTING AND RELATED INFORMATION microfiche, form SBFY1113, before making any changes to the fuel setting.

For maximum life of the Caterpillar Remanufactured engine, during the installation procedure be sure to check/inspect the following items for condition and/or adaptability in the specific application.

Sound Suppression

If the original engine has sound suppression material on the valve covers, oil pan and/or cylinder block, it is sometimes necessary, by law, to install sound suppression material on a replacement engine.

It may be necessary to clean the valve covers of the old engine and exchange them with the valve covers on the Remanufactured engine.

Sound suppression that is on the old cylinder block and oil pan can possibly be removed and installed on the Remanufactured engine.

Air Compressor

Since the air compressor uses engine oil for lubrication, be sure it is clean inside. Foreign material from a failure of the former engine can decrease engine life. A worn air compressor can also be the source of "oil consumption", by pumping oil into the engine air intake, or the vehicle air tanks.

Air Cleaner

Install a new filter element in the air cleaner. Install all hoses and clamps as necessary. Check all piping and connections for leaks and make corrections as necessary.

Radiator

Make sure the radiator is clean inside and out. Install new hoses and clamps. Check for leaks. If the engine is equipped with a viscous fan clutch, check fan speed to be sure of correct operation.

Exchange those connections, such as inlet and/or outlet elbows, shunt line, etc., that are needed to connect the new engine to the vehicle cooling system.

Water Separator

Some Remanufactured engines do not have a factory installed water separator, however, it is a Caterpillar recommendation that a water separator be installed. Either transfer the water separator from the original engine, or, install a new water separator group on the Remanufactured engine.

If the water separator from the original engine is transferred to the Remanufactured engine, be sure to install a new water filter element.

Oil Pan

Compare the oil pan configuration on the Remanufactured engine with that of the original engine. If they are different, it will be necessary to change the oil pan on the Remanufactured engine to match the original engine.

When the oil pan is changed, it may be necessary to change the oil pump suction bell to fit the oil pan sump location. Always make sure the engine has the correct weight and type of oil in the oil pan sump before engine startup.

The oil level gauge and/or guide may also need to be changed and/or recalibrated for a particular application. In some applications when the oil level gauge and guide are exchanged, it may be necessary to change the guide assembly.

If it is necessary to change the location of the gauge and guide or guide assembly, be sure to plug the open hole that remains.

Fuel System

Check the horsepower (kW) and rpm setting given on the engine information plate of the recommended Remanufactured engine. Compare this information with the same settings of the original engine. If the settings are different, it is possible that some fuel system adjustment will be necessary.

Use the reference numbers given to obtain the necessary information about governor springs, torque control groups, etc., from the Parts Book, Service Manual, the FUEL SETTING INFORMATION LIBRARY and/or the FUEL SETTING AND RELATED INFORMATION microfiche, form SBFY1113. It may be necessary to change some of these parts, or the settings, for a specific engine application.

It may also be necessary to exchange the fuel filter mounting group from one engine to the other. If this is done, be sure to install a new fuel filter element.

NOTE: Whenever an engine is reset to new specifications, always install a new 4W5140 Plate on top of the original engine information plate, located on the valve cover. Stamp the new information on the new information plate. Refer to March 5, 1984 Service Magazine, the April 7, 1984 Engine News and the April 4, 1984 Truck Engine News.

Flywheel

Remove, clean and inspect the flywheel of the original engine. If the original flywheel cannot be used again, refer to the specific Parts Book to find the part number of the flywheel needed.

Install the flywheel on the Remanufactured engine and tighten the bolts to the correct torque. Refer to the Service Manual for the torque specification.

Governor (Accelerator) Control

Remove the needed governor (accelerator) control linkage from the original engine and install it on the Remanufactured engine. Adjust as necessary; see the Service Manual for procedure.

Engine Lifting Brackets

Check the lifting brackets on both engines. In some applications, for either clearance or installation purposes, it may be necessary to exchange either the front or the rear lifting bracket, while in other applications it will be necessary to exchange both lifting brackets.

In some instances, even though the lifting brackets look different, it may not be necessary to make an exchange.

Crankshaft Pulley and Damper

If it is necessary to exchange the crankshaft pulley and/or damper, refer to the Service Manual for bolt torque specifications.

Miscellaneous

Remove any other components that are needed, such as starter motor, alternator and/or alternator mounting group, tachometer drive, water pump pulley, auxiliary drive pulley groups, belt tightener, etc., from the original engine for cleaning, inspection and/or installation on the Remanufactured engine.

Be sure to check the transmission mounting group to make sure it is adaptable to the replacement engine. Make any changes that are necessary to get a good installation.

If parts from the original engine are not in a condition that permits them to be used again, either recondition them or refer to the Parts Book for the part number of new parts.

Procedures to Follow Before Return Shipment of Original (Old) Engine to the Factory

* Remove the drain plugs. Make sure that all coolant is removed from the engine. Do not install the plugs back in the engine.

* Put the plugs in a package and use a piece of wire or similar material to fasten the package to the engine.

* All parts removed from the new engine must be installed on the original (old) engine before it is returned to the factory.