Usage:
preparatory steps:
a) remove cylinder head assemblies
b) remove engine oil cooler (right bank only)
c) remove water pump (right rear bank only)
d) remove starters (left bank only)
1. To remove pistons on right bank only, remove the engine oil cooler oil inlet elbow (1). Remove engine right side inspection covers (2).
2. To remove pistons on left bank only, remove the prelube pump oil inlet line retaining bolts. Remove pump oil outlet line clamp retaining bolt. Disconnect pump oil outlet line (4). Disconnect wiring harness. Mark wiring for identification when installing.
3. Attach a hoist to pump motor, and remove the mounting bolts (3). Remove prelube pump and motor assembly-weight 105 lbs. (48 kg).
4. On Industrial engines only, remove the fumes disposal tube.
5. Disconnect oil sensing line (6) from turbocharger lubrication manifold. Remove the prelube motor mounting plate. Remove wiring harness (5) and mounting plates retaining bolts, and lay harness and plates aside. Remove the remaining inspection cover mounting bolts. Remove the engine left side inspection covers.
6. Remove the carbon ridge from top of cylinder liners.
7. Rotate the crankshaft clockwise (as viewed from front of engine) until connecting rod caps (7) are in removal position shown.
| NOTICE |
|---|
Be sure all timing pins and bolt have been removed from their respective timing slots before attempting to rotate crankshaft. Do not rotate crankshaft if the right rear cylinder head is removed and the right front camshaft housing is installed and/or if the left front cylinder head is removed and the left rear camshaft housing is installed. Damage to pistons and valve mechanism can result. |
6. Remove the connecting rod cap retaining bolts and connecting rod bearing cap.
NOTE: Remove the No. 1,3,5,7,9,11,13, and 15 connecting rod caps through right side of cylinder block. Remove the No. 2,4,6,8,10,12,14 and 16 connecting rod caps through left side of cylinder block.
9. Push the piston and connecting rod upward until the piston rings clear the cylinder liner. Remove the piston and connecting rod assembly.
10. Remove the upper half of bearing from connecting rod. Remove the lower half of bearing from cap. Keep the connecting rod bearing cap with its respective connecting rod and piston.
11. Repeat Steps 6 through 10 for the remaining pistons on that bank.
Install Pistons
1. Rotate the crankshaft clockwise (as viewed from front of engine) to position crankshaft bearing journal of piston being installed.
| NOTICE |
|---|
Be sure all timing pins and bolts have been removed from their respective timing slots before attempting to rotate crankshaft. Do not rotate crankshaft if the right rear cylinder head is removed and the right front camshaft housing is installed and/or if the left front cylinder head is removed and the left rear camshaft housing is installed. Damage to pistons and valve mechanism can result. |
2. Install the new connecting rod bearing in cap and in connecting rod. Lubricate the crankshaft bearing journal, bore of cylinder liner, piston, rings and connecting rod bearings with clean SAE 30 engine oil.
NOTE: Engines 61P1 - 61P570 and 62P1 - 62P317 have connecting rods with bearings that have tabs on them so they will not turn in the bore of the connecting rod and cap.
Engines 61P571-UP and 62P318-UP have connecting rods with bearings that use dowels in the connecting rod and cap to keep them from turning in the rod and cap. The connecting rods are marked even and odd. The connecting rods marked even are installed on the left side of the engine and the connecting rods marked odd are installed on the right side of the engine (as viewed from the flywheel end of the engine). The wide faces (1) and (2) of the connecting rods must be toward the shoulders of the crankshaft as shown.
The connecting rods marked even and odd may be used in earlier engines if the piston cooling tubes have been changed. See the topic, PISTON COOLING TUBES.
3. Using Compressor (A), install the piston and connecting rod in cylinder liner so that "V" mark on piston is aligned with "V" mark on block. Guide the lower end of connecting rod over the crankshaft journal to prevent damage to crankshaft.
4. Coat the threads of connecting rod bearing cap retaining bolts with 9M3710 Anti-Seize Compound. Install the connecting rod bearing cap so that number is adjacent to and corresponds to number on connecting rod. Install the retaining bolts. Using torque wrench (B), tighten both retaining bolts initially to 90 ± 5 lb. ft. (12,4 ± 0,7 mkg). Mark the head of each bolt and the connecting rod cap. Tighten each bolt an additional 120° from mark after initial tightening.
5. Repeat above Steps for each remaining piston.
6. Install the engine right side inspection covers. Install the oil cooler oil inlet elbow.
7. Install the engine left side inspection covers. Install wiring harness and mounting plates. Install the prelube motor mounting plate. Connect oil sensing line to turbocharger lubrication manifold. Install the fumes disposal tube.
8. Attach a hoist to the prelube pump motor. Position motor on engine and install mounting bolts. Connect motor wiring harness. Connect prelube pump oil outlet line, and install clamp retaining bolt. Install pump oil inlet line retaining bolts.
9. Fill engine crankcase to specified oil level.
concluding steps:
a) install cylinder head assembly
b) install starters (left bank only)
c) install engine oil cooler (right bank only)
d) install water pump (right rear bank only)