3412C GENERATOR SET ENGINE Caterpillar

Flywheel Housing

Usage:

Remove Flywheel Housing

Start By:

a. remove crankshaft rear seal and wear sleeve

1. Remove two bolts (1) that hold bracket assembly (2) in position on the flywheel housing.

2. Remove the bolt that holds clip (3) in position on the cover for the oil filter bypass valve. Remove four bolts (4), and move bracket assembly (2) away from the flywheel housing.

3. Remove the bolt that holds brace (5) to the aftercooler. Remove the bolt that holds brace (6) to the flywheel housing. Loosen clamp (7).

4. Fasten tool (A) and a hoist to the top of the air cleaner housing.

5. Remove four bolts (9) that hold air cleaner support (8) against the flywheel. Remove the air cleaner housing and support. The weight of the air cleaner housing and support is approximately 23 kg (50 lb).

6. Disconnect oil line (11) from the cylinder block.

7. On engines with hot manifolds, remove the nuts and bolts that hold clips (16) to shield (17). Remove the two bolts that hold oil line (11) to the top of the turbocharger. Remove oil line (11).

8. Remove the two bolts that hold oil line (18) to the bottom of the turbocharger.

9. Remove shield (25) and clamp (26) from the exhaust manifold.

10. On the other side of the engine, remove clamp (27) and support (28).

11. Fasten two straps and a hoist to turbocharger (29) as shown. Remove the four nuts that hold the manifold and turbocharger to plate (30). Remove turbocharger (29) and the manifold from the engine as a unit. The weight of the turbocharger and manifold is approximately 72 kg (158 lb).

12. Remove plate (30) and adapter (31) from the flywheel housing.

13. Remove the bolts that hold the oil pan to the flywheel housing. Loosen the rest of the bolts that hold the oil pan in position.

14. Install tooling (B) and a hoist to the flywheel housing, as shown.

15. Use tooling (B) and a hoist to lift the end of the engine enough so a 1/2" hardened washer (32) can be installed on each side of the engine between the oil pan and the cylinder block.

16. Remove the blocks from under the flywheel housing. Put a block under the oil pan to give support to the rear of the engine. Lower the rear of the engine down on to the block.

Typical Example

17. Remove two covers (33) from the flywheel housing.

18. Remove the bolts that hold flywheel housing (34) in place. Remove flywheel housing (34). The weight of the flywheel housing is approximately 84 kg (186 lb).

Install Flywheel Housing

1. Install two 1/2" - 13 NC × 4" long guide bolts in the cylinder block. Make sure gasket (2) is in position.

NOTE: The cylinder block, both sides of gasket (2), and the surface of the flywheel housing that makes contact with the gasket must not have any oil, fuel, water, or gasket adhesive on them when the flywheel housing is installed on the engine.

2. Install flywheel housing (1) on the engine. The weight of the flywheel housing is approximately 84 kg (186 lb).

Torque Sequence

3. Install the bolts that hold the flywheel housing in place.

4. Use the following procedure to tighten the bolts:

a. Tighten bolts 1 through 8 in number sequence to 136 ± 14 N·m (100 ± 10 lb ft).

b. Tighten bolts 9 through 20 in number sequence to 54 ± 7 N·m (40 ± 5 lb ft).

c. Again, tighten bolts 1 through 8 in number sequence to 136 ± 14 N·m (100 ± 10 lb ft).

d. Again, tighten bolts 9 through 21 in number sequence to 54 ± 7 Nm (40 ±5 lb ft).

NOTE: If a new gasket is installed, cut the ends of the gasket so the gasket's edge is even with the bottom of the cylinder block.

Typical Example

5. Install the gaskets and covers (3) on the flywheel housing.

6. Use tooling (A) and a hoist to lift the flywheel housing and engine enough so that the washers between the oil pan and the cylinder block can be removed.

7. Remove the block from under the oil pan. Put blocks under the flywheel housing for support. Lower the engine down on to the blocks.

8. Tighten bolts (5) that hold oil pan (4) to the cylinder block. Install the six bolts that hold the oil pan to the flywheel housing.

9. Install plate (6) and adapter (7).

10. Install turbocharger and manifold (8) as a unit on the plate. The weight of the turbocharger and manifold is approximately 72 kg (158 lb).

11. Put 5P3931 Anti-Seize Compound on the threads of the studs that hold the turbocharger and manifold to plate (6). Install the four nuts that hold it in place. Tighten the nuts to a torque of 30 ± 5 N·m (22 ± 4 lb ft).

12. On engines with hot exhaust manifolds, install clamp (16). Install the clamp so that the angle formed by the bolt on the clamp and a vertical line [angle (X)] is 15 ± 10 degrees.

13. Install shield (17).

14. Install clamp (18) on the other side of the engine. Install the clamp so that the angle formed by a horizontal line and the bolt on the clamp, or angle (Y), is 45 ± 10 degrees.

15. Install support (19).

16. Make sure the gasket is in position between elbow (20) and the aftercooler. Install the bolts that hold elbow (20) to the aftercooler.

17. Make sure the gasket is in position between oil line (23) and the bottom of the turbocharger. Connect oil line (23) to the bottom of the turbocharger.

18. Make sure the gasket is in position between oil line (24) and the top of the turbocharger. Install oil line (24).

19. Install the two nuts and bolts that hold clips (27) on oil line (24) in position against shield (28).

20. Connect the end of oil line (24) to the cylinder block, as shown.

21. Install tooling (B) to the top of air cleaner housing (29). Put air cleaner housing (29) and support (30) in position against the flywheel housing. Install four bolts (31) that hold this housing in place. Make sure the four washers are in position between support (30) and the flywheel housing.

22. Install the bolt that holds brace (32) in position on the aftercooler. Install the bolt that holds brace (34) in position on the flywheel housing.

23. Tighten clamp (33) that holds the hose in position on the turbocharger.