KENR6055-14 (en-us)

December 2019

Disassembly and Assembly

3508C, 3512C, 3516C Marine Engines
JTS 1-UP (Engine) PXW 1-UP (Engine) TTW 1-UP (Engine)
SLM 1-UP (Engine) SB2 1-UP (Engine) TT4 1-UP (Engine)
TTA 1-UP (Engine) PXC 1-UP (Engine) TTX 1-UP (Engine)
TTB 1-UP (Engine) BM2 1-UP (Engine) TT5 1-UP (Engine)
TTC 1-UP (Engine) PXE 1-UP (Engine) TTY 1-UP (Engine)
TTD 1-UP (Engine) MB3 1-UP (Engine) TT6 1-UP (Engine)
TTE 1-UP (Engine) PXF 1-UP (Engine) TTZ 1-UP (Engine)
TTF 1-UP (Engine) MNW 1-UP (Engine) TT7 1-UP (Engine)
TTG 1-UP (Engine) PXG 1-UP (Engine) MA2 1-UP (Generator Set)
TTH 1-UP (Engine) RL2 1-UP (Engine) MA3 1-UP (Generator Set)
TTJ 1-UP (Engine) PXZ 1-UP (Engine) T25 1-UP (Generator Set)
E3W 1-UP (Engine) ML2 1-UP (Engine) MA5 1-UP (Generator Set)
E3X 1-UP (Engine) PXD 1-UP (Engine)
E3Y 1-UP (Engine) ML3 1-UP (Engine)
E3Z 1-UP (Engine) PXH 1-UP (Engine)
PAF 1-UP (Engine) FLW 1-UP (Engine)
MXN 1-UP (Engine) PXJ 1-UP (Engine)
2A2 1-UP (Engine) BG3 1-UP (Engine)
MXP 1-UP (Engine) DPB 1-UP (Engine)
DE2 1-UP (Engine) BG2 1-UP (Engine)
MXT 1-UP (Engine) DPC 1-UP (Engine)
FT6 1-UP (Engine) EWJ 1-UP (Engine)
PXA 1-UP (Engine) DPD 1-UP (Engine)
MB4 1-UP (Engine) BS2 1-UP (Engine)
PXB 1-UP (Engine) TTM 1-UP (Engine)
PR2 1-UP (Engine) TT2 1-UP (Engine)
PXX 1-UP (Engine) TTP 1-UP (Engine)
MB2 1-UP (Engine) TT3 1-UP (Engine)

PUBLICATIONS.CAT.COM
 i07966018

Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards, including human factors
that can affect safety. This person should also have the necessary training, skills and tools to perform these
functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could
result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you verify
that you are authorized to perform this work, and have read and understood the operation,
lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
A non-exhaustive list of operations that may cause product damage are identified by “NOTICE” labels on
the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. You must not
use this product in any manner different from that considered by this manual without first
satisfying yourself that you have considered all safety rules and precautions applicable to the
operation of the product in the location of use, including site-specific rules and precautions
applicable to the worksite. If a tool, procedure, work method or operating technique that is not
specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you
and for others. You should also ensure that you are authorized to perform this work, and that the
product will not be damaged or become unsafe by the operation, lubrication, maintenance or repair
procedures that you intend to use.
The information, specifications, and illustrations in this publication are on the basis of information that was
available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Cat dealers have the most current information available.

NOTICE
When replacement parts are required for this product Caterpillar recommends using original Cater-
pillar® replacement parts.
Other parts may not meet certain original equipment specifications.
When replacement parts are installed, the machine owner/user should ensure that the machine re-
mains in compliance with all applicable requirements.

In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
KENR6055-14 3
Table of Contents

Table of Contents Electronic Unit Injector - Remove..........................87

Electronic Unit Injector - Install .............................88
Cylinder Head - Remove......................................89
Disassembly and Assembly Section Cylinder Head - Install .........................................90
Inlet and Exhaust Valve Springs - Remove and
Air Regulator - Remove and Install (Air Starting) ......5 Install ...............................................................94
Electric Starting Motor - Remove and Install ...........7 Inlet and Exhaust Valves - Remove and Install.......96
Alternator - Remove and Install .............................8 Inlet and Exhaust Valve Guides - Remove and
Alternator Mounting Group - Remove and Install......9 Install ...............................................................98
Electronic Control Module (Engine) - Remove and Inlet and Exhaust Valve Seat Inserts - Remove and
Install ...............................................................10 Install ...............................................................99
Fuel Filter Housing - Remove ............................... 11 Accessory Drive (Front) - Remove (Engine Oil Pump
Fuel Filter Housing - Install...................................12 and Water Pump) ............................................ 100
Fuel Priming Pump - Remove and Install ..............13 Accessory Drive (Front) - Remove ...................... 101
Fuel Transfer Pump - Remove..............................14 Accessory Drive (Front) - Disassemble ............... 102
Fuel Transfer Pump - Disassemble ......................14 Accessory Drive (Front) - Disassemble (Engine Oil
Fuel Transfer Pump - Assemble ..........................16 Pump and Water Pump)................................... 103
Fuel Transfer Pump - Install .................................18 Accessory Drive (Front) - Assemble.................... 104
Turbocharger - Remove.......................................18 Accessory Drive (Front) - Assemble (Engine Oil
Turbocharger - Install ..........................................20 Pump and Water Pump)................................... 105
Aftercooler - Remove and Install ..........................21 Accessory Drive (Front) - Install (Engine Oil Pump
Air Inlet Manifold - Remove and Install .................24 and Water Pump) ............................................ 106
Exhaust Elbow - Remove and Install ....................25 Accessory Drive (Front) - Install.......................... 107
Exhaust Manifold - Remove and Install ................26 Housing (Front) - Remove.................................. 108
Exhaust Manifold - Remove and Install ................28 Housing (Front) - Install ..................................... 109
Exhaust Bypass Valve - Remove and Install .........31 Vibration Damper - Remove and Install .............. 110
Water Temperature Regulators - Remove .............33 Crankshaft Front Seal and Wear Sleeve -
Water Temperature Regulators - Install .................34 Remove ......................................................... 111
Water Pump - Remove ........................................35 Crankshaft Front Seal and Wear Sleeve - Install . 112
Water Pump - Disassemble .................................36 Flywheel - Remove and Install ........................... 113
Water Pump - Assemble .....................................39 Crankshaft Rear Seal and Wear Sleeve -
Water Pump - Install ............................................42 Remove ......................................................... 115
Auxiliary Water Pump - Remove ..........................43 Crankshaft Rear Seal and Wear Sleeve - Install .. 116
Auxiliary Water Pump - Disassemble (Auxiliary Pump Flywheel Housing - Remove .............................. 117
(Type 1)) ...........................................................44 Flywheel Housing - Install .................................. 119
Auxiliary Water Pump - Disassemble ...................50 Engine Oil Sequence Valves - Remove and
Auxiliary Water Pump - Assemble ........................51 Install ............................................................. 122
Auxiliary Water Pump - Assemble (Auxiliary Pump Gear Group (Rear) - Remove ............................. 125
(Type 1)) ...........................................................52 Gear Group (Rear) - Install................................. 127
Auxiliary Water Pump - Install ..............................61 Piston Cooling Jets - Remove and Install ............ 130
Engine Oil Cooler - Remove.................................62 Bearing Clearance - Check ................................ 131
Engine Oil Cooler - Disassemble .........................63 Connecting Rod Bearings - Remove and Install .. 132
Engine Oil Cooler - Assemble ..............................64 Crankshaft Main Bearings - Remove................... 134
Engine Oil Cooler - Install ....................................65 Crankshaft Main Bearings - Install ...................... 136
Engine Oil Pump - Remove ..................................66 Pistons and Connecting Rods - Remove ............. 138
Engine Oil Pump - Disassemble ...........................67 Pistons and Connecting Rods - Install................. 140
Engine Oil Pump - Assemble................................68 Cylinder Liner - Remove .................................... 142
Engine Oil Pump - Install......................................69 Cylinder Liner - Install ........................................ 143
Engine Oil Filter Housing - Remove ......................70 Camshaft - Remove .......................................... 145
Engine Oil Filter Housing - Disassemble ...............71 Camshaft Bearings - Remove ............................ 147
Engine Oil Filter Housing - Assemble ...................72 Camshaft Bearings - Install ................................ 148
Engine Oil Filter Housing - Install..........................73 Camshaft - Install .............................................. 149
Engine Oil Pan - Remove ....................................74 Crankshaft - Remove......................................... 153
Engine Oil Pan - Disassemble ..............................75 Crankshaft - Install ............................................ 155
Engine Oil Pan - Assemble ..................................76 Heat Exchanger - Disassemble .......................... 158
Engine Oil Pan - Install .......................................78 Heat Exchanger - Assemble............................... 160
Crankcase Breather - Remove and Install ............79 Heat Exchanger - Assemble............................... 167
Fumes Filter - Remove and Install ........................81 Balancer Group (Front) - Remove and Install (3508C
Valve Mechanism Cover - Remove and Install .......82 Engine)........................................................... 174
Valve Mechanism Cover Base - Remove and Engine Oil Pressure Sensor - Remove and
Install ...............................................................82 Install ............................................................. 176
Rocker Shaft and Pushrod - Remove ....................83 Turbocharger Inlet Pressure Sensor - Remove and
Rocker Shaft - Disassemble ................................84 Install ............................................................. 176
Rocker Shaft - Assemble ....................................85 Turbocharger Outlet Pressure Sensor - Remove and
Rocker Shaft and Push Rods - Install ...................85 Install ............................................................. 177
4 KENR6055-14
Table of Contents

Coolant Temperature Sensor - Remove and

Install ............................................................. 178
Aftercooler Coolant Temperature Sensor - Remove
and Install ....................................................... 179
Engine Speed/Timing Sensor - Remove and
Install ............................................................. 180
Crankcase Pressure Sensor - Remove and Install180
Atmospheric Pressure Sensor - Remove and
Install ............................................................. 181
Engine Speed Sensor - Remove and Install ........ 182
Fuel Pressure Sensor - Remove and Install......... 183

Index Section
Index................................................................ 184
KENR6055-14 5
Disassembly and Assembly Section

Disassembly and S/N: DPD1–Up

Assembly Section S/N: PXD1–Up

S/N: TTD1–Up
i07696998 S/N: PXE1–Up
S/N: TTE1–Up
Air Regulator - Remove and
Install S/N: PXF1–Up

(Air Starting) S/N: TTF1–Up

S/N: PXG1–Up
SMCS Code: 4474-010; 5503
S/N: TTG1–Up
S/N: 2A21–Up
S/N: PXH1–Up
S/N: BG21–Up
S/N: TTH1–Up
S/N: BM21–Up
S/N: EWJ1–Up
S/N: BS21–Up
S/N: PXJ1–Up
S/N: DE21–Up
S/N: TTJ1–Up
S/N: MB21–Up
S/N: SLM1–Up
S/N: ML21–Up
S/N: TTM1–Up
S/N: PR21–Up
S/N: MXN1–Up
S/N: RL21–Up
S/N: MXP1–Up
S/N: SB21–Up
S/N: TTP1–Up
S/N: TT21–Up
S/N: JTS1–Up
S/N: BG31–Up
S/N: MXT1–Up
S/N: MB31–Up
S/N: E3W1–Up
S/N: ML31–Up
S/N: FLW1–Up
S/N: TT31–Up
S/N: MNW1–Up
S/N: MB41–Up
S/N: PXW1–Up
S/N: TT41–Up
S/N: TTW1–Up
S/N: TT51–Up
S/N: E3X1–Up
S/N: FT61–Up
S/N: PXX1–Up
S/N: TT61–Up
S/N: TTX1–Up
S/N: TT71–Up
S/N: E3Y1–Up
S/N: PXA1–Up
S/N: TTY1–Up
S/N: TTA1–Up
S/N: E3Z1–Up
S/N: DPB1–Up
S/N: PXZ1–Up
S/N: PXB1–Up
S/N: TTZ1–Up
S/N: TTB1–Up
S/N: DPC1–Up
S/N: PXC1–Up
S/N: TTC1–Up
6 KENR6055-14
Disassembly and Assembly Section

Removal Procedure

Illustration 1 g06219069
(1) Pressure Regulator
(2) Y-Strainer
(3) Air Tank
(4) Pressure Relief Valve
(5) Air starter
Illustration 3 g06219073
(6) Manual Shut-Off Valve

1. Remove air pressure regulator (1).

Illustration 4 g06219076

Illustration 2 g06219072

2. Remove 10 bolts screws (7) and dome (8). Improper assembly of parts that are spring
loaded can cause bodily injury.
To prevent possible injury, follow the established
assembly procedure and wear protective
equipment.

3. Remove diaphragm assembly (9) and the O-ring

seals.
4. Remove valve cap (11) and the O-ring seal.
5. Remove spring (15), retaining ring (14), Washer
(13), O-ring seal (12), and valve (10).
KENR6055-14 7
Disassembly and Assembly Section

e. Tighten screws (7) to a torque of 10 to 11 N·m

(90 to 100 lb in).

i05202344

Electric Starting Motor -

Remove and Install
SMCS Code: 1453-010

Removal Procedure

Illustration 5 g06219080 Disconnect batteries before performance of any

service work.

1. Turn the battery disconnect switch to the OFF

Improper assembly of parts that are spring position.
loaded can cause bodily injury.
To prevent possible injury, follow the established
assembly procedure and wear protective
equipment.

6. Release the spring load to by turning adjusting

knob (21) in counter clockwise.
7. Remove nylon dome (20) by turning counter
clockwise.
8. Remove diaphragm assembly (19) and the O-ring
seals. Inspect diaphragm assembly (19) visually
for damages. If required, replace with new.
9. Remove valve seat (18) by turning counter
Illustration 6 g01351045
clockwise.
10. Remove spring (16) and valve (17). Note: Before disconnecting the harness assemblies,
mark the items for the proper connections in order to
11. If the regulator cannot be repaired by cleaning ensure correct assembly.
with soap and water, the parts should be replaced.
2. Disconnect the harness assemblies from solenoid
Installation Procedure (1) and electric starting motor (2).
1. Install air pressure regulator (1) in the reverse If the engine has two electric starting motors,
order of removal. disconnect the harness assemblies between the
a. All the O-ring seals and seals are correctly solenoids and electric starting motors.
located. Lubricate O-ring seals and siding 3. Attach a suitable lifting device to electric starting
surfaces with Tooling (A) or equivalent. motor (2). The weight of electric starting motor (2)
b. Tighten vale seat to a torque of 1.1 to 2.3 N·m is approximately 35 kg (77 lb).
(10.0 to 20.0 lb in). 4. Remove bolts (3). Remove electric starting motor
c. Tighten nylon dome (20) to a torque of (2). Remove the gasket from the joint between
22 to 24 N·m (190 ± 210 lb in). electric starting motor (2) and the flywheel
housing.
d. Tighten valve cap (11) to a torque of
68 to 81 N·m (50 to 60 lb ft).
8 KENR6055-14
Disassembly and Assembly Section

Installation Procedure 2. Remove the belt guard.

1. Inspect the gasket for the joint between the electric
starting motor and the flywheel housing. Obtain a
new gasket, if necessary.

Illustration 7 g01351045

2. Attach a suitable lifting device to electric starting

Illustration 8 g01246413
motor (2). The weight of electric starting motor (2)
is approximately 35 kg (77 lb).
3. Put an index mark on all of the harness assemblies
3. Place the gasket in position for electric starting that are connected to alternator (1).
motor (2). Lift electric starting motor (2) onto the
4. Disconnect the harness assemblies from the
mounting position. Install bolts (3).
alternator.
4. Connect the harness assemblies to solenoid (1)
5. Loosen adjusting nuts (2).
and electric starting motor (2).
6. Remove belt (6).
If the engine has two electric starting motors,
connect the harness assemblies between the 7. Remove bolt (3). Remove bolt (5) and remove the
solenoids and electric starting motors. alternator.
5. Turn the battery disconnect switch to the ON 8. If necessary, remove nut (4) and remove the pulley
position. from the alternator.

i02492916

Alternator - Remove and Install

SMCS Code: 1405-010

Removal Procedure

Personal injury can result from failure to discon-

nect the battery.
First, disconnect the negative battery cable.
Then, disconnect the positive battery cable.
A positive power lead can cause sparks if the bat-
tery is not disconnected. Sparks can possibly re-
sult in battery explosion or fire.

1. Disconnect the batteries.

KENR6055-14 9
Disassembly and Assembly Section

Installation Procedure 8. Connect the batteries.

i02492929

Alternator Mounting Group -

Remove and Install
SMCS Code: 1405-010-MT

Removal Procedure
Start By:
a. Remove the alternator. Refer to Disassembly
and Assembly, “Alternator - Remove and
Install”.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Illustration 9 g01246413

1. If necessary, install the pulley on alternator (1).

Install nut (4) and tighten to a torque of
110 ± 10 N·m (81 ± 7 lb ft).
2. Position alternator (1) and install bolt (5) and bolt
(3). Do not tighten the bolts.
3. Install belt (6).
4. Adjust the belt tension and tighten adjusting nuts
(2) on the adjusting rod. Refer to Operation and
Maintenance Manual, “Belt Tension Chart”.
5. Tighten bolt (3) and bolt (5).
Illustration 10 g01246426
6. Connect the harness assemblies on alternator (1).
Tighten the nuts. Refer to Specifications,
1. Remove bolts (2) and remove alternator support
“Alternator and Regulator” for the torque values.
(1).
7. Install the belt guard.
2. Remove bolts (3). Remove pulley (4) from the
accessory drive.
3. Remove lip seal (5) and sleeve (6) from pulley (4).

Installation Procedure
Table 1
Required Tools

Tool Part Number Part Description Qty

A 1P-0520 Driver Group 1

10 KENR6055-14
Disassembly and Assembly Section

S/N: TTC1–Up
NOTICE
Keep all parts clean from contaminants. S/N: DPD1–Up
Contaminants may cause rapid wear and shortened S/N: PXD1–Up
component life.
S/N: TTD1–Up
S/N: PXE1–Up
S/N: TTE1–Up
S/N: PAF1–Up
S/N: PXF1–Up
S/N: TTF1–Up
S/N: PXG1–Up
S/N: TTG1–Up
S/N: PXH1–Up
S/N: TTH1–Up
S/N: PXJ1–Up
Illustration 11 g01246426
S/N: TTJ1–Up
1. Use Tooling (A) to install sleeve (6) on pulley (4).
S/N: SLM1–Up
2. Use Tooling (A) to install lip seal (5). Apply clean
S/N: MXN1–Up
engine oil to the lip seal. Position the pulley on the
accessory drive and install bolts (3). S/N: MXP1–Up
3. Position alternator support (1) and install bolts (2). S/N: JTS1–Up
End By: S/N: MXT1–Up
a. Install the alternator. Refer to Disassembly and S/N: E3W1–Up
Assembly, “Alternator - Remove and Install”.
S/N: FLW1–Up
i02723993 S/N: PXW1–Up

Electronic Control Module S/N: TTW1–Up

(Engine) - Remove and Install S/N: E3X1–Up

S/N: PXX1–Up
SMCS Code: 1900-010
S/N: E3Y1–Up
S/N: ML21–Up
S/N: TTY1–Up
S/N: BG31–Up
S/N: E3Z1–Up
S/N: ML31–Up
S/N: PXZ1–Up
S/N: T251–Up
S/N: TTZ1–Up
S/N: PXA1–Up
S/N: TTA1–Up Removal Procedure
S/N: DPB1–Up NOTICE
Keep all parts clean from contaminants.
S/N: PXB1–Up
Contaminants may cause rapid wear and shortened
S/N: TTB1–Up component life.
S/N: DPC1–Up
S/N: PXC1–Up
KENR6055-14 11
Disassembly and Assembly Section

Note: If the electronic control module (ECM) is being 4. Connect the harness assemblies to the electronic
replaced, download the personality module before control module and tighten allen head screw (3) to
you remove the ECM. Refer to Troubleshooting, a torque of 6 ± 1 N·m (53 ± 9 lb in).
“Replacing the ECM”.
5. Connect the negative battery terminal at the
1. Disconnect the negative battery terminal at the battery.
battery.
i02046946

Fuel Filter Housing - Remove

SMCS Code: 1262-011

Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

1. Shut OFF the fuel supply to the engine.

Illustration 12 g01118581
NOTICE
2. Loosen allen head screw (3) and disconnect the Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
harness assemblies from electronic control nance, testing, adjusting, and repair of the product.
module (2). Be prepared to collect the fluid with suitable contain-
3. Disconnect ground strap (6). ers before opening any compartment or disassem-
bling any component containing fluids.
4. Remove bolts (1). Remove electronic control
module (2). Refer to Special Publication, PERJ1017, “Dealer
Service Tool Catalog” for tools and supplies suitable
5. If necessary, remove bolts (4) and bracket (5). to collect and contain fluids on Cat ® products.
Remove gasket (7).
Dispose of all fluids according to local regulations
and mandates.
Installation Procedure
2. Drain the fuel filter housing into a suitable
container for storage or for disposal.

Illustration 13 g01118581

1. Install gasket (7) and bracket (5). Install bolts (4).

2. Position electronic control module (2) and install
bolts (1).
3. Connect ground strap (6) and tighten to a torque of
2.50 ± 0.25 N·m (22 ± 2 lb in).
12 KENR6055-14
Disassembly and Assembly Section

8. Attach a suitable lifting device onto fuel filter

housing (4). The weight of fuel filter housing (4) is
approximately 30 kg (66 lb). Remove fuel filter
housing (4).

i02724002

Fuel Filter Housing - Install

SMCS Code: 1262-012

Installation Procedure
NOTICE
Illustration 14 g01050833
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Personal injury can result from being struck by

parts propelled by a released spring force.
Make sure to wear all necessary protective
equipment.
Follow the recommended procedure and use all
recommended tooling to release the spring force.

3. Disconnect fuel pressure sensor (2).

4. Disconnect hose assembly (3).
5. Remove cover (1).

Illustration 16 g01050834

1. Attach a suitable lifting device to fuel filter housing

(4). The weight of fuel filter housing (4) is
approximately 30 kg (66 lb). Position fuel filter
housing (4) and install bolts (5).
2. Connect tube assemblies (6).

Illustration 15 g01050834

6. Disconnect tube assemblies (6).

7. Remove bolts (5).
KENR6055-14 13
Disassembly and Assembly Section

Illustration 17 g01050833 Illustration 18 g01130150

3. Install cover (1).

4. Connect hose assembly (3).
Personal injury can result from parts and/or cov-
5. Connect fuel pressure sensor (2). ers under spring pressure.
6. Turn ON the fuel supply to the engine. Spring force will be released when covers are
removed.
7. Remove the air from the fuel system. Refer to
Testing and Adjusting, “Fuel System - Prime”. Be prepared to hold spring loaded covers as the
bolts are loosened.
i05207251
2. Remove bolts (2).
Fuel Priming Pump - Remove 3. Remove bolts (3). Remove fuel priming pump (1)
and Install and the gasket from the fuel filter housing.

SMCS Code: 1258-010 4. Remove plug (6). Remove the O-ring seal from the
plug.
Removal Procedure 5. Remove spring (5) and ball (4) from the fuel filter
housing.
NOTICE
Care must be taken to ensure that fluids are con- Installation Procedure
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain- NOTICE
Keep all parts clean from contaminants.
ers before opening any compartment or disassem-
bling any component containing fluids. Contaminants may cause rapid wear and shortened
component life.
Refer to Special Publication, PERJ1017, “Dealer
Service Tool Catalog” for tools and supplies suitable
to collect and contain fluids on Cat ® products.
Dispose of all fluids according to local regulations
and mandates.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

1. Turn the fuel supply to the OFF position.

14 KENR6055-14
Disassembly and Assembly Section

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

1. Turn the fuel shutoff valve to the OFF position.

Illustration 19 g01130150

Improper assembly of parts that are spring

loaded can cause bodily injury.
To prevent possible injury, follow the established
assembly procedure and wear protective Illustration 20 g01112959
equipment.
2. Disconnect tube assembly (3). Disconnect tube
1. Position a new gasket and fuel priming pump (1). assembly (4).
2. Install bolts (3) and tighten to a torque of 3. Remove bolts (1).
15 ± 3 N·m (11 ± 2 lb ft).
4. Remove fuel transfer pump (2).
3. Install bolts (2).
4. Install ball (4) and spring (5) in the fuel filter i05207411
housing.
Fuel Transfer Pump -
5. Install a new O-ring seal on plug (6). Install the
plug in the fuel filter housing. Disassemble
6. Turn the fuel supply to the ON position. SMCS Code: 1256-015

i05207304 Disassembly Procedure

Fuel Transfer Pump - Remove Start By:
a. Remove the fuel transfer pump. Refer to
SMCS Code: 1256-011 Disassembly and Assembly, “Fuel Transfer
Pump - Remove”.
Removal Procedure
NOTICE
NOTICE Keep all parts clean from contaminants.
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte- Contaminants may cause rapid wear and shortened
nance, testing, adjusting, and repair of the product. component life.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Refer to Special Publication, PERJ1017, “Dealer
Service Tool Catalog” for tools and supplies suitable
to collect and contain fluids on Cat ® products.
Dispose of all fluids according to local regulations
and mandates.
KENR6055-14 15
Disassembly and Assembly Section

Illustration 21 g01112986 Illustration 22 g01113096

Personal injury can result from being struck by

parts propelled by a released spring force.
Make sure to wear all necessary protective
equipment.
Follow the recommended procedure and use all
recommended tooling to release the spring force.

1. Remove drive coupling (1) from the drive shaft.

Remove O-ring seal (2).
2. Remove cap (6), washer (5), spring (4), and
poppet valve (3).
Illustration 23 g01112998

3. Remove bolts (7). Remove head (8) from plate (9).

4. Remove check valve (11) from head (8).
5. Remove plate (9). Remove gasket (10). Remove
the O-ring seal from the plate.
Note: If the bearings in plate (9) are damaged, the
plate must be replaced. The bearings are
nonserviceable separately.
16 KENR6055-14
Disassembly and Assembly Section

Note: If the bearings in bracket (16) are damaged,

the bracket must be replaced. The bearings are
nonserviceable separately.

i05207417

Fuel Transfer Pump -

Assemble
SMCS Code: 1256-016

Assembly Procedure
Table 2

Illustration 24 g01113004 Required Tools

Tool Part Number Part Description Qty

6. Remove idler gear (12) and drive shaft (13) from
casing (14). A 1P-0510 Driver Group 1

7. Remove casing (14) from bracket (16). Remove

the O-ring seal from casing (14). If necessary, NOTICE
remove terminal bushings (15). Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Illustration 25 g01113012

8. Remove outer lip seal (17) and inner lip seal (18)
from bracket (16). Illustration 26 g01113012

1. Use Tooling (A) to install inner lip seal (18) and

outer lip seal (17) into bracket (16). Lubricate the
lip seals with clean engine oil.

Note: If the bearings in bracket (16) are damaged,

the bracket must be replaced. The bearings are
nonserviceable separately.
KENR6055-14 17
Disassembly and Assembly Section

Illustration 27 g01113004 Illustration 29 g01112998

2. Install terminal bushings (15) in casing (14). Install 5. Use Tooling (A) to install check valve (11) into
the O-ring seal in casing (14). Install casing (14) head (8).
onto bracket (16).
3. Install idler gear (12) and drive shaft (13) into
casing (14).

Illustration 30 g01112994

6. Install head (8) onto plate (9).

Illustration 28 g01113073 7. Install bolts (7).

Note: If the bearings in plate (9) are damaged, the

plate must be replaced. The bearings are
nonserviceable separately.

4. Install the O-ring seal into the side of the plate that
is opposite of gasket (10). Install plate (9). Install
gasket (10).
18 KENR6055-14
Disassembly and Assembly Section

Illustration 31 g01112986 Illustration 32 g01112959

1. Position fuel transfer pump (2) and install bolts (1).

2. Connect tube assembly (3). Connect tube
Personal injury can result from parts and/or cov- assembly (4).
ers under spring pressure.
3. Turn the fuel shutoff valve to the “ON” position.
Spring force will be released when covers are
removed. 4. Remove the air from the fuel system. Refer to
Operation and Maintenance Manual, “Fuel System
Be prepared to hold spring loaded covers as the
bolts are loosened. - Prime”.

i05207602
8. Install poppet valve (3), spring (4), washer (5), and
cap (6).
Turbocharger - Remove
9. Install O-ring seal (2).
SMCS Code: 1052-011
10. Install drive coupling (1).
End By: S/N: ML21–Up
S/N: BG31–Up
a. Install the fuel transfer pump. Refer to
Disassembly and Assembly, “Fuel Transfer S/N: ML31–Up
Pump - Install”.
S/N: T251–Up
i05207585
S/N: PXA1–Up
Fuel Transfer Pump - Install S/N: TTA1–Up

SMCS Code: 1256-012 S/N: DPB1–Up

S/N: PXB1–Up
Installation Procedure S/N: TTB1–Up
NOTICE S/N: DPC1–Up
Keep all parts clean from contaminants.
S/N: PXC1–Up
Contaminants may cause rapid wear and shortened
component life. S/N: TTC1–Up
S/N: DPD1–Up
S/N: PXD1–Up
S/N: TTD1–Up
S/N: PXE1–Up
S/N: TTE1–Up
KENR6055-14 19
Disassembly and Assembly Section

S/N: PAF1–Up
NOTICE
S/N: PXF1–Up Keep all parts clean from contaminants.

S/N: TTF1–Up Contaminants may cause rapid wear and shortened

component life.
S/N: PXG1–Up
S/N: TTG1–Up
NOTICE
S/N: PXH1–Up Clamp assemblies MUST only be used once. Discard
all clamp assemblies after use.
S/N: TTH1–Up
S/N: PXJ1–Up
NOTICE
S/N: TTJ1–Up Bellows assemblies MUST only be used once. Dis-
card all bellows assemblies after use.
S/N: SLM1–Up
S/N: MXN1–Up 1. Drain the coolant from the cooling system to a
level below the turbochargers into a suitable
S/N: MXP1–Up
container for storage or disposal. Refer to
S/N: JTS1–Up Operation and Maintenance Manual, “Cooling
System Coolant - Change”.
S/N: MXT1–Up
2. Remove the air cleaner.
S/N: E3W1–Up
S/N: FLW1–Up
S/N: PXW1–Up
S/N: TTW1–Up
S/N: E3X1–Up
S/N: PXX1–Up
S/N: E3Y1–Up
S/N: TTY1–Up
S/N: E3Z1–Up
S/N: PXZ1–Up
S/N: TTZ1–Up Illustration 33 g01351417

Removal Procedure 3. Loosen clamp assemblies (1) and clamp

assemblies (2). Remove the bellows assemblies,
NOTICE clamp assemblies (1), and clamp assemblies (2)
Care must be taken to ensure that fluids are con- from turbocharger (3). Discard the bellows
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product. assemblies, clamp assemblies (1), and clamp
Be prepared to collect the fluid with suitable contain- assemblies (2).
ers before opening any compartment or disassem-
bling any component containing fluids.
Refer to Special Publication, PERJ1017, “Dealer
Service Tool Catalog” for tools and supplies suitable
to collect and contain fluids on Cat ® products.
Dispose of all fluids according to local regulations
and mandates.
20 KENR6055-14
Disassembly and Assembly Section

NOTICE
Bellows assemblies MUST only be used once. Dis-
card all bellows assemblies after use.

Illustration 34 g01351521

4. Loosen clamp assembly (7). Remove bolts (11).

Remove bellows assembly (10) and clamp
assembly (7) from turbocharger (3). Discard
Illustration 35 g01351521
bellows assembly (10) and clamp assembly (7).
5. Disconnect tube assembly (6), tube assembly (8), 1. Attach a suitable lifting device to turbocharger (3).
and tube (9). Remove tube assembly (4). The weight of turbocharger (3) is approximately
135 kg (300 lb).
6. Attach a suitable lifting device to turbocharger (3).
The weight of turbocharger (3) is approximately 2. Position turbocharger (3) on the mounting bracket.
135 kg (300 lb). Apply Tooling (A) to the threads of bolts (5). Install
bolts (5). Do not tighten bolts (5) at this time.
7. Remove bolts (5) and turbocharger (3).
Note: Ensure that the spacers are located between
i07867108 the flange and the bolt head. Do not position the
spacers between the flange and nut.
Turbocharger - Install
3. Install tube assembly (4). Connect tube (9), tube
SMCS Code: 1052-012 assembly (8), and tube assembly (6).

Installation Procedure Note: Ensure that the bellows assembly is in the

proper orientation during installation. The spacing
Table 3 between the ridges of the bellows assembly should
Required Tools be equal.
Tool Part Number Part Description Qty 4. Apply Tooling (A) to the threads, the bearing
Loctite C5-A Anti Seize surfaces, and the inner surface of clamp assembly
A - -
Lubricant (7). Install new bellows assembly (10), bolts (11),
and new clamp assembly (7). Tighten clamp
assembly (7) to a torque of 10 ± 1 N·m
NOTICE (90 ± 9 lb in). Lightly tap around the diameter of
Keep all parts clean from contaminants.
the clamp assembly with a soft hammer. Tighten
Contaminants may cause rapid wear and shortened clamp assembly (7) to a torque of 10 ± 1 N·m
component life. (90 ± 9 lb in).

NOTICE
Clamp assemblies MUST only be used once. Discard
all clamp assemblies after use.
KENR6055-14 21
Disassembly and Assembly Section

NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Refer to Special Publication, PERJ1017, “Dealer
Service Tool Catalog” for tools and supplies suitable
to collect and contain fluids on Cat ® products.
Dispose of all fluids according to local regulations
and mandates.

Illustration 36 g01351417 NOTICE

Keep all parts clean from contaminants.
Note: Ensure that the bellows assembly is in the
proper orientation during installation. The direction of Contaminants may cause rapid wear and shortened
flow arrow must point in the correct direction. The component life.
spacing between the ridges of the bellows assembly
should be equal.
NOTICE
5. Apply Tooling (A) to the threads, the bearing Clamp assemblies MUST only be used once. Discard
surfaces, and the inner surface of clamp all clamp assemblies after use.
assemblies (2) and clamp assemblies (1). Install
new bellows assemblies, new clamp assemblies
NOTICE
(2), and new clamp assemblies (1) on Bellows assemblies MUST only be used once. Dis-
turbocharger (3). Tighten clamp assemblies (2) card all bellows assemblies after use.
and clamp assemblies (1) to a torque of
7.5 ± 1.0 N·m (65 ± 9 lb in). Lightly tap around the
diameter of the clamp assemblies with a soft Note: The 3508C and 3512C Engines have one
aftercooler. The 3516C Engines have two
hammer. Tighten clamp assemblies (2) and clamp
aftercoolers. The following procedures describe the
assemblies (1) to a torque of 7.5 ± 1.0 N·m removal and installation of the 3516C aftercooler.
(65 ± 9 lb in).
6. Tighten bolts (5) in a crisscross pattern. 1. Drain the coolant from the cooling system into a
suitable container for storage or for disposal.
7. Install the air cleaner.
8. Fill the cooling system with coolant. Refer to
Operation and Maintenance Manual, “Cooling
System Coolant - Change”.

i07549372

Aftercooler - Remove and

Install
SMCS Code: 1063-010

Removal Procedure
Table 4
Illustration 37 g01353326
Required Tools

Tool Part Number Part Description Qty 2. Loosen clamp assemblies (5). Remove the bellows
assembly and clamp assemblies (5). Discard the
A 138-7573 Link Bracket 2
bellows assembly and clamp assemblies (5).
22 KENR6055-14
Disassembly and Assembly Section

3. Remove bolts (1) and bolts (4). Remove air inlet Note: Be careful not to damage the fins of the
elbow (2) and air pipe (3). Remove the O-ring aftercooler core.
seals from air inlet elbow (2) and air pipe (3).
Note: The weight of the 3508C aftercooler core is
approximately 58 kg (130 lb). The weight of the
3512C aftercooler core is approximately 84 kg
(185 lb).

12. Attach a suitable lifting device onto aftercooler

core (18). The weight of aftercooler core (18) is
approximately 58 kg (130 lb). Remove aftercooler
core (18) from the air inlet manifold. Remove the
seals from aftercooler core (18).

Note: Be careful not to damage the fins of the

aftercooler core.

Installation Procedure
Table 5
Illustration 38 g01353355
Required Tools
4. Remove tube assembly (8). Tool Part Number Part Description Qty
5. Remove bolts (9) and bolts (12). Remove adapter A 138-7573 Link Bracket 2
(10) and adapter (11) from the air inlet covers.
O-Ring Assembly
Remove the O-ring seals from the adapters. B 1U-6395
Compound
-

6. Install Tooling (A) into the top of air inlet cover (7). C 5P-3931 Anti-Seize Compound -
7. Attach a suitable lifting device onto Tooling (A).
The weight of air inlet cover (7) is approximately
28 kg (62 lb). Remove bolts (6). Remove air inlet NOTICE
Keep all parts clean from contaminants.
cover (7).
Contaminants may cause rapid wear and shortened
Note: Be careful not to damage the fins of the component life.
aftercooler core.
Note: The weight of the 3508C air inlet cover is
approximately 28 kg (62 lb). The weight of the NOTICE
Clamp assemblies MUST only be used once. Discard
3512C air inlet cover is approximately 35 kg (77 lb). all clamp assemblies after use.
8. Install Tooling (A) into the top of air inlet cover (13).
9. Attach a suitable lifting device onto Tooling (A). NOTICE
The weight of air inlet cover (13) is approximately Bellows assemblies MUST only be used once. Dis-
card all bellows assemblies after use.
28 kg (62 lb). Remove bolts (14). Remove air inlet
cover (13).
Note: Be careful not to damage the fins of the
Note: Be careful not to damage the fins of the aftercooler cores.
aftercooler core.
Note: Some clamp assemblies may need to be
loosened to remove the connectors.

10. Remove connector (16) and connector (17) from

the aftercooler cores. Remove the O-ring seals
from the connectors.
11. Attach a suitable lifting device onto aftercooler
core (15). The weight of aftercooler core (15) is
approximately 58 kg (130 lb). Remove aftercooler
core (15) from the air inlet manifold. Remove the
seals from aftercooler core (15).
KENR6055-14 23
Disassembly and Assembly Section

4. Attach a suitable lifting device onto aftercooler

core (15). The weight of aftercooler core (15) is
approximately 58 kg (130 lb). Position aftercooler
core (15) onto the air inlet manifold. Ensure that
the bottom seal is properly seated.
5. Install the O-ring seals on connector (17) and
connector (16). Apply Tooling (B) to the O-ring
seals. Install connector (17) and connector (16).
6. Install the seal on top of aftercooler core (18).
7. Install Tooling (A) into the top of air inlet cover (13).
8. Attach a suitable lifting device onto Tooling (A).
The weight of air inlet cover (13) is approximately
Illustration 39 g01353355 28 kg (62 lb). Position air inlet cover (13) onto the
aftercooler core. Ensure that the seal is seated
between air inlet cover (13) and the aftercooler
core.
Note: The weight of the 3508C air inlet cover is
approximately 28 kg (62 lb). The weight of the
3512C air inlet cover is approximately 35 kg (77 lb).

9. Install the seal on top of aftercooler core (15).

10. Install Tooling (A) into the top of air inlet cover (7).
11. Attach a suitable lifting device onto Tooling (A).
The weight of air inlet cover (7) is approximately
28 kg (62 lb). Position air inlet cover (7) onto the
aftercooler core. Ensure that the seal is seated
between air inlet cover (7) and the aftercooler
core.
12. Install bolts (14) and bolts (6). Hand tighten bolts
(14) and bolts (6) according to the following
procedure:
a. Tighten the bolts in the numerical sequence to
Illustration 40 g01353596
a torque of 24 N·m (18 lb ft).
1. Install the seal on the bottom of aftercooler core b. Tighten the bolts in the numerical sequence to
(18). Apply a light amount of glycerin to the bore a torque of 47 N·m (35 lb ft).
for the seal.
13. Install the O-ring seals on adapter (11) and
2. Attach a suitable lifting device onto aftercooler adapter (10). Apply Tooling (B) to the O-ring seals.
core (18). The weight of aftercooler core (18) is Install adapter (11), adapter (10), bolts (12), and
approximately 58 kg (130 lb). Position aftercooler bolts (9).
core (18) onto the air inlet manifold. Ensure that
the bottom seal is properly seated. 14. Install tube assembly (8).

Note: The weight of the 3508C aftercooler core is

approximately 58 kg (130 lb). The weight of the
3512C aftercooler core is approximately 84 kg
(185 lb).

3. Install the seal on the bottom of aftercooler core

(15). Apply a light amount of glycerin to the bore
for the seal.
24 KENR6055-14
Disassembly and Assembly Section

S/N: PXA1–Up
S/N: TTA1–Up
S/N: DPB1–Up
S/N: PXB1–Up
S/N: TTB1–Up
S/N: DPC1–Up
S/N: PXC1–Up
S/N: TTC1–Up
S/N: DPD1–Up

Illustration 41 g01353326
S/N: PXD1–Up
S/N: TTD1–Up
15. Install the O-ring seals on air pipe (3) and air inlet
elbow (2). Apply Tooling (B) to the O-ring seals. S/N: PXE1–Up
Install air pipe (3) and air inlet elbow (2). Install S/N: TTE1–Up
bolts (4) and bolts (1).
S/N: PAF1–Up
Note: Ensure that the bellows assembly is in the
proper orientation during installation. The direction of S/N: PXF1–Up
flow arrow must point in the correct direction. The S/N: TTF1–Up
spacing between the ridges of the bellows assembly
should be equal. S/N: PXG1–Up

16. Apply Tooling (C) to the threads, the bearing S/N: TTG1–Up
surfaces, and the inner surface of clamp S/N: PXH1–Up
assemblies (5). Install a new bellows assembly
and new clamp assemblies (5). Tighten clamp S/N: TTH1–Up
assemblies (5) to a torque of 7.5 ± 1.0 N·m S/N: PXJ1–Up
(65 ± 9 lb in). Lightly tap around the diameter of
the clamp assemblies with a soft hammer. Tighten S/N: TTJ1–Up
clamp assemblies (5) to a torque of 7.5 ± 1.0 N·m S/N: SLM1–Up
(65 ± 9 lb in).
S/N: TTM1–Up
17. Fill the cooling system with coolant. Refer to the
Operation and Maintenance Manual, “Cooling S/N: MXN1–Up
System Coolant - Change”. S/N: MXP1–Up

i02698735
S/N: TTP1–Up
S/N: JTS1–Up
Air Inlet Manifold - Remove
S/N: MXT1–Up
and Install
S/N: E3W1–Up
SMCS Code: 1058-010
S/N: FLW1–Up
S/N: 2A21–Up S/N: PXW1–Up
S/N: BS21–Up S/N: TTW1–Up
S/N: ML21–Up S/N: E3X1–Up
S/N: BG31–Up S/N: PXX1–Up
S/N: ML31–Up S/N: TTX1–Up
S/N: T251–Up S/N: E3Y1–Up
S/N: FT61–Up S/N: TTY1–Up
KENR6055-14 25
Disassembly and Assembly Section

S/N: E3Z1–Up
S/N: PXZ1–Up
S/N: TTZ1–Up

Removal Procedure
Start By:
a. Remove the aftercooler. Refer to Disassembly Illustration 43 g01114292
and Assembly, “Aftercooler - Remove and
Install”. 1. Install the O-ring seals on elbows (3). Apply a light
amount of glycerin to the bores for the O-ring
NOTICE seals.
Keep all parts clean from contaminants.
2. Attach a suitable lifting device to air inlet manifold
Contaminants may cause rapid wear and shortened (1). The weight of the 3508C air inlet manifold is
component life.
approximately 40 kg (88 lb). The weight of the
3512C air inlet manifold is approximately 65 kg
(145 lb). The weight of the 3516C air inlet manifold
is approximately 90 kg (200 lb).
3. Position air inlet manifold (1) and install bolts (4).
4. Position elbows (3) and install bolts (2).
End By:
a. Install the aftercooler. Refer to Disassembly
Illustration 42 g01114292 and Assembly, “Aftercooler - Remove and
Install”.
1. Remove bolts (2). Pry elbows (3) away from air
inlet manifold (1). i02698838

2. Remove bolts (4). Exhaust Elbow - Remove and

3. Attach a suitable lifting device to air inlet manifold Install
(1). The weight of the 3508C air inlet manifold is
approximately 40 kg (88 lb). The weight of the SMCS Code: 1060-010
3512C air inlet manifold is approximately 65 kg
(145 lb). The weight of the 3516C air inlet manifold Removal Procedure
is approximately 90 kg (200 lb). Table 6
4. Remove air inlet manifold (1). Remove the O-ring Required Tools
seals from elbows (3).
Tool Part Number Part Description Qty
Installation Procedure A 138-7573 Link Bracket 2

NOTICE
Keep all parts clean from contaminants. Start By:

Contaminants may cause rapid wear and shortened a. Remove the turbochargers. Refer to
component life. Disassembly and Assembly, “Turbocharger -
Remove”.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

1. If necessary, loosen the clamp assemblies for the

exhaust bypass valve. Disconnect the bellows
assemblies.
26 KENR6055-14
Disassembly and Assembly Section

Illustration 44 g01353778 Illustration 45 g01353778

2. Attach Tooling (A) and a suitable lifting device to 1. Attach Tooling (A) and a suitable lifting device to
exhaust elbow (1). The weight of exhaust elbow exhaust elbow (1). The weight of exhaust elbow
(1) is approximately 45 kg (100 lb). (1) is approximately 45 kg (100 lb). Position
exhaust elbow (1) on the support bracket and
3. Remove bolts (2). Remove exhaust elbow (1).
install bolts (2).
Installation Procedure 2. If necessary, apply Tooling (B) to the threads, the
Table 7 bearing surfaces, and the inner surface of the
Required Tools clamp assemblies for the exhaust bypass valve.
Connect the bellows assemblies for the exhaust
Tool Part Number Part Description Qty
bypass valve. Tighten the clamp assemblies to a
A 138-7573 Link Bracket 2 torque of 25 ± 6 N·m (18 ± 4 lb ft).
B 5P-3931 Anti-Seize Compound - End By:
a. Install the turbochargers. Refer to Disassembly
NOTICE and Assembly, “Turbocharger - Install”.
Keep all parts clean from contaminants.
i06749820
Contaminants may cause rapid wear and shortened
component life. Exhaust Manifold - Remove
and Install
SMCS Code: 1059-010

S/N: TTH1–Up
S/N: TTJ1–Up

Removal Procedure
Start By:
a. Remove air inlet manifold.

Note: The following clamps and bellows are one-time

use components. Discard the components after
removal and install new components.
KENR6055-14 27
Disassembly and Assembly Section

Note: Note the orientation of clamps (8) and (11). If

installed incorrectly, the clamps will damage the heat
shields.

4. Loosen clamps (11) and (8). Remove bolts (13)

and any spacers.
5. Remove exhaust manifold (12). Remove bellows
(9) and (10) and the gaskets. Remove gasket (14)
from exhaust manifold (12).

Note: The only gasket for bellows (10) will be located

on the exhaust manifold side of the bellows. Note the
orientation of bellows (10) for installation. The air flow
direction is from the exhaust manifold to the
turbocharger.

6. Repeat Step 4 and Step 5 for the other side.

Note: Some engine arrangements are equipped with

a cap in place of adapter (7) for the exhaust bypass
valve. If so, the following step can be ignored.
Illustration 46 g02790637
7. Remove bolts (6) and adapter (7). Remove the
Engine was not illustrated for photographic purposes. gasket from adapter (7).
Note: Note the orientation of clamps (2). If installed Installation Procedure
incorrectly, the clamps will damage the heat shields.
Note: The following clamps and bellows are one-time
1. Loosen clamps (2). Remove bolts (4) and any use components. Discard the components after
spacers. removal and install new components.
2. Remove exhaust manifold (3) and remove bellows
(1) and the gaskets. Remove gasket (5) from
exhaust manifold (3).
3. Repeat Step 1 and Step 2 for the next four exhaust
manifolds. Repeat for the other side.

Illustration 48 g02790688
Engine was not illustrated for photographic purposes.

Note: Some engine arrangements are equipped with

a cap in place of adapter (7) for the exhaust bypass
valve. If so, the following step can be ignored.
Illustration 47 g02790688
Engine was not illustrated for photographic purposes.
28 KENR6055-14
Disassembly and Assembly Section

1. Position adapter (7) and install bolts (6). Tighten Note: Ensure that the gaskets for bellows (1) are
bolts (6) to a torque of 55 ± 5 N·m (41 ± 4 lb ft). seated correctly with the tabs properly positioned. If
the gaskets slide out of position, check that section of
Note: Clamps (11) and (8) are to be orientated the exhaust manifold for damage and replace if there
horizontally with the threaded rods pointing outward is damage.
from the engine. Note the orientation noted when
removed. 7. Seat gasket (5) onto exhaust manifold (4).

Note: Ensure that the gaskets for bellows (9) and 8. Position exhaust manifold (4). Install the spacers
(10) are seated correctly with the tabs properly and bolts (4). Tighten to a torque of 55 ± 5 N·m
positioned. If the gaskets slide out of position, check (41 ± 4 lb ft). Retighten to a torque of 55 ± 5 N·m
that section of the exhaust manifold for damage and (41 ± 4 lb ft).
replace if there is damage.
9. Check the final position of clamps (2). Tighten
2. Install the gaskets for bellows (9) and (10) and clamps (2) to a torque of 12 N·m (106 lb in).
install bellows (9) and (10). Position clamps (11)
10. Repeats Step 7 through Step 9 for the remaining
and (8) horizontally. exhaust manifolds. Repeat for the other side.
Note: Note the orientation of bellows (10) with the 11. Refer to the following checks after installation:
direction of air flow.
a. Confirm that all the clamps are orientated
3. Seat gasket (14) onto exhaust manifold (12). horizontally and the rods pointing outwards
Install exhaust manifold (12). from the engine.
4. Install the spacers and bolts (13). Tighten to a b. Confirm that each clamp has a uniform gap. If
torque of 55 ± 5 N·m (41 ± 4 lb ft). Retighten to a not, ensure that the gasket for each joint is
torque of 55 ± 5 N·m (41 ± 4 lb ft). seated correctly.
5. Check the final position of clamps (8) and (11). c. Check that the bellows are aligned correctly.
Tighten clamps (11) to a torque of 7.5 ± 1 N·m
(66.38 ± 8.85 lb in). Tighten clamps (8) to a torque 12. Use the above procedures to correct any issues
that are found in the above checks.
of 17 ± 2 N·m (150.5 ± 17.7 lb in).
End By:
6. Repeat Step 2 through Step 5 for the other side.
a. Install the air inlet manifold. Refer to
Disassembly and Assembly, “Air Inlet Manifold
- Remove and Install”.

i07105839

Exhaust Manifold - Remove

and Install
SMCS Code: 1059-010

S/N: 2A21–Up
S/N: BG21–Up
S/N: BM21–Up
S/N: BS21–Up
S/N: DE21–Up
S/N: MA21–Up
S/N: MB21–Up
Illustration 49 g02790637
S/N: ML21–Up
Engine was not illustrated for photographic purposes.
S/N: PR21–Up
Note: Clamps (2) are to be orientated horizontally
with the threaded rods pointing outward from the S/N: RL21–Up
engine. Note the orientation noted when removed. S/N: SB21–Up
KENR6055-14 29
Disassembly and Assembly Section

S/N: TT21–Up S/N: MXP1–Up

S/N: BG31–Up S/N: TTP1–Up
S/N: MA31–Up S/N: JTS1–Up
S/N: MB31–Up S/N: MXT1–Up
S/N: ML31–Up S/N: E3W1–Up
S/N: TT31–Up S/N: FLW1–Up
S/N: MB41–Up S/N: MNW1–Up
S/N: TT41–Up S/N: PXW1–Up
S/N: MA51–Up S/N: TTW1–Up
S/N: T251–Up S/N: E3X1–Up
S/N: TT51–Up S/N: PXX1–Up
S/N: FT61–Up S/N: TTX1–Up
S/N: TT61–Up S/N: E3Y1–Up
S/N: TT71–Up S/N: TTY1–Up
S/N: PXA1–Up S/N: E3Z1–Up
S/N: TTA1–Up S/N: PXZ1–Up
S/N: DPB1–Up S/N: TTZ1–Up
S/N: PXB1–Up
Removal Procedure
S/N: TTB1–Up Start By:
S/N: DPC1–Up
a. Remove air inlet manifold.
S/N: PXC1–Up
Note: The following clamps and bellows are one-time
S/N: TTC1–Up use components. Discard the components after
removal and install new components.
S/N: DPD1–Up
S/N: PXD1–Up
S/N: TTD1–Up
S/N: PXE1–Up
S/N: TTE1–Up
S/N: PAF1–Up
S/N: PXF1–Up
S/N: TTF1–Up
S/N: PXG1–Up
S/N: TTG1–Up
S/N: PXH1–Up
S/N: EWJ1–Up
S/N: PXJ1–Up
S/N: SLM1–Up
S/N: TTM1–Up Illustration 50 g02790637

S/N: MXN1–Up Engine was not illustrated for photographic purposes.

30 KENR6055-14
Disassembly and Assembly Section

Note: Note the orientation of clamps (2). If installed Installation Procedure

incorrectly, the clamps will damage the heat shields.
Note: The following clamps and bellows are one-time
1. Loosen clamps (2). Remove bolts (4) and any use components. Discard the components after
spacers. removal and install new components.
2. Remove exhaust manifold (3) and remove bellows
(1) and the gaskets. Remove gasket (5) from
exhaust manifold (3).
3. Repeat Step 1 and Step 2 for the next four exhaust
manifolds. Repeat for the other side.

Illustration 52 g02790688
Engine was not illustrated for photographic purposes.

Note: Some engine arrangements are equipped with

a cap in place of adapter (7) for the exhaust bypass
valve. If so, the following step can be ignored.
Illustration 51 g02790688
1. Position adapter (7) and install bolts (6). Tighten
Engine was not illustrated for photographic purposes.
bolts (6) to a torque of 55 ± 5 N·m (41 ± 4 lb ft).
Note: Note the orientation of clamps (8) and (11). If Note: Clamps (11) and (8) are to be orientated
installed incorrectly, the clamps will damage the heat horizontally with the threaded rods pointing outward
shields. from the engine. Note the orientation when removed.
4. Loosen clamps (11) and (8). Remove bolts (13) Note: Ensure that the gaskets for bellows (9) and
and any spacers. (10) are seated correctly with the tabs properly
5. Remove exhaust manifold (12). Remove bellows positioned. If the gaskets slide out of position, check
that section of the exhaust manifold for damage and
(9), (10) and the gaskets. Remove gasket (14)
replace if there is damage.
from exhaust manifold (12).
2. Install the gaskets for bellows (9), (10) and install
Note: The only gasket for bellows (10) will be on the
bellows (9) and (10). Position clamps (11) and (8)
exhaust manifold side of the bellows. Note the
orientation of bellows (10) for installation. The air flow horizontally.
direction is from the exhaust manifold to the
Note: Note the orientation of bellows (10) with the
turbocharger.
direction of air flow.
6. Repeat Step 4 and Step 5 for the other side.
3. Seat gasket (14) onto exhaust manifold (12).
Note: Some engine arrangements are equipped with Install exhaust manifold (12).
a cap in place of adapter (7) for the exhaust bypass 4. Install the spacers and bolts (13). Tighten to a
valve. If so, the following step can be ignored.
torque of 55 ± 5 N·m (41 ± 4 lb ft). Retighten to a
7. Remove bolts (6) and adapter (7). Remove the torque of 55 ± 5 N·m (41 ± 4 lb ft).
gasket from adapter (7).
KENR6055-14 31
Disassembly and Assembly Section

5. Check the final position of clamps (8) and (11). b. Confirm that each clamp has a uniform gap. If
Tighten clamps (11) to a torque of 7.5 ± 1 N·m not, ensure that the gasket for each joint is
(66.38 ± 8.85 lb in). Tighten clamps (8) to a torque seated correctly.
of 17 ± 2 N·m (150.5 ± 17.7 lb in).
c. Check that the bellows are aligned correctly.
6. Repeat Step 2 through Step 5 for the other side.
13. Use the above procedures to correct any issues
that are found in the above checks.
End By:
a. Install the air inlet manifold. Refer to
Disassembly and Assembly, “Air Inlet Manifold
- Remove and Install”.

i07593110

Exhaust Bypass Valve -

Remove and Install
SMCS Code: 1057-010

S/N: ML21–Up
S/N: BG31–Up
S/N: ML31–Up
S/N: T251–Up
S/N: PXA1–Up
Illustration 53 g02790637
Engine was not illustrated for photographic purposes. S/N: DPB1–Up
S/N: PXB1–Up
Note: Clamps (2) are to be orientated horizontally
with the threaded rods pointing outward from the S/N: DPC1–Up
engine. Note the orientation when removed.
S/N: PXC1–Up
Note: Ensure that the gaskets for bellows (1) are
seated correctly with the tabs properly positioned. If S/N: DPD1–Up
the gaskets slide out of position, check that section of S/N: PXD1–Up
the exhaust manifold for damage and replace if there
is damage. S/N: PXE1–Up

7. Seat gasket (5) onto exhaust manifold (4). S/N: PAF1–Up

8. Install the gaskets for bellows (1) and install S/N: PXF1–Up
bellows (1). Position clamps (2) horizontally. S/N: PXG1–Up
9. Position exhaust manifold (4). Install the spacers S/N: PXH1–Up
and bolts (4). Tighten to a torque of 55 ± 5 N·m
(41 ± 4 lb ft). Retighten to a torque of 55 ± 5 N·m S/N: PXJ1–Up
(41 ± 4 lb ft). S/N: TTJ1–Up
10. Check the final position of clamps (2). Tighten S/N: MXN1–Up
clamps (2) to a torque of 12 N·m (106 lb in).
S/N: MXP1–Up
11. Repeats Step 7 through Step 10 for the remaining
exhaust manifolds. Repeat for the other side. S/N: MXT1–Up

12. Refer to the following checks after installation: S/N: FLW1–Up

a. Confirm that all the clamps are orientated S/N: PXW1–Up

horizontally and the rods pointing outwards S/N: TTW1–Up
from the engine.
S/N: PXX1–Up
32 KENR6055-14
Disassembly and Assembly Section

S/N: TTY1–Up 3. Loosen clamp assemblies (8) for adapter (7) for
exhaust bypass valve (1), if necessary. Disconnect
S/N: PXZ1–Up
bellows assemblies (9).
S/N: TTZ1–Up
4. Remove bolts (6) and adapter (7) for exhaust
bypass valve (1), if necessary.
Removal Procedure
5. Remove locknuts (5), exhaust bypass valve (1),
NOTICE and the gasket from the exhaust elbow.
Keep all parts clean from contaminants.
6. Remove the studs for exhaust bypass valve (1), if
Contaminants may cause rapid wear and shortened necessary.
component life.
Installation Procedure
Table 8
NOTICE
Care must be taken to ensure that fluids are con- Required Tools
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product. Part
Be prepared to collect the fluid with suitable contain- Tool Number Part Description Qty
ers before opening any compartment or disassem- A - Loctite C5A Copper Anti-Seize -
bling any component containing fluids.
B - Loctite 2000° Putty -
Refer to Special Publication, PERJ1017, “Dealer
Service Tool Catalog” for tools and supplies suitable
to collect and contain fluids on Cat ® products.
NOTICE
Dispose of all fluids according to local regulations Keep all parts clean from contaminants.
and mandates. Contaminants may cause rapid wear and shortened
component life.
1. Drain the coolant from the cooling system to a
level below the exhaust bypass valve into a
suitable container for storage or disposal. Refer to
Operation and Maintenance Manual, “Cooling
System Coolant - Change”.

Illustration 55 g01360694

1. If the studs for exhaust bypass valve (1) are

installed, tighten the studs to a torque of
Illustration 54 g01360694
35 ± 5 N·m (26 ± 4 lb ft).

2. Disconnect hose assembly (2), hose assembly (3),

and hose assembly (4).
KENR6055-14 33
Disassembly and Assembly Section

2. Apply Tooling (B) to the threads of the studs and to 6. Fill the cooling system with coolant. Refer to
the mating face of the locknuts. Position the new Operation and Maintenance Manual, “Cooling
gasket and exhaust bypass valve (1) on the System Coolant - Change”.
exhaust elbow. Install new locknuts (5). Tighten
locknuts (5) according to the following procedure. i06808307

a. Tighten two diagonal locknuts to a torque of

25 ± 6 N·m (18 ± 4 lb ft).
Water Temperature Regulators
b. Tighten the remaining locknuts to a torque of
- Remove
25 ± 6 N·m (18 ± 4 lb ft). SMCS Code: 1355-011
c. Tighten all four locknuts to a torque of
47 ± 9 N·m (35 ± 7 lb ft). Removal Procedure
Note: Ensure that the rear lifting eye is out of the way NOTICE
when the adapter for the exhaust bypass valve is Care must be taken to ensure that fluids are con-
installed. tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
3. If necessary, install adapter (7) for exhaust bypass Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
valve (1). Install bolts (6). Tighten bolts (6) to a bling any component containing fluids.
torque of 55 ± 5 N·m (41 ± 4 lb ft).
Refer to Special Publication, PERJ1017, “Dealer
4. If necessary, apply Tooling (A) to the threads, the Service Tool Catalog” for tools and supplies suitable
bearing surfaces, and the inner surface of clamp to collect and contain fluids on Cat ® products.
assemblies (8) for adapter (7) for exhaust bypass
valve (1). Connect bellows assemblies (9) and Dispose of all fluids according to local regulations
install clamp assemblies (8). Tighten clamp and mandates.
assemblies (8) to a torque of 25 ± 6 N·m
(18 ± 4 lb ft). Lightly tap around the diameter of the
NOTICE
clamp assemblies with a soft hammer. Tighten Keep all parts clean from contaminants.
clamp assemblies (8) to a torque of 25 ± 6 N·m
(18 ± 4 lb ft). Contaminants may cause rapid wear and shortened
component life.
5. Connect hose assembly (4), hose assembly (3),
and hose assembly (2).
1. Drain the cooling system until the level of the
coolant is below the water temperature regulator
housing.

Illustration 56 g06123162

2. Disconnect hose assembly (1) and hose assembly

(5) from water temperature regulator housing (6).
34 KENR6055-14
Disassembly and Assembly Section

3. Disconnect tube assembly (2) from water

temperature regulator housing (6). Remove the O-
ring seal from the tube assembly.
4. Remove tube assembly (3) from the water
temperature regulator housing.
5. Remove bolts (4). Remove water temperature
regulator housing (6).
6. If necessary, remove bolts (7) and remove outlet
elbow (8) from the water temperature regulator
housing. Remove the gasket from the outlet elbow.

Illustration 58 g06123166

8. Remove vent valve (12) from the water

temperature regulator housing.

i07580626

Water Temperature Regulators

- Install
SMCS Code: 1355-012

Illustration 57 g06123164 Installation Procedure

Table 9
7. Remove water temperature regulator (12) and
Required Tools
gasket (9). Remove lip seal (10) from water
temperature regulator housing (6). Tool Part Number Part Description Qty

A 221-8647 Seal Installer Gp 1

B 369-9450 Grease -

C FT-3578 Driver As 1
D 1S-0258 Plastic Hammer As 1

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
KENR6055-14 35
Disassembly and Assembly Section

Illustration 59 g06123166 Illustration 61 g06123162

1. Use Tooling (C) and (D) to install vent valve (12) 5. Position water temperature regulator housing (6)
and install bolts (4).
6. Position the gasket and outlet elbow (8) and install
bolts (7).
7. Install tube assembly (3).
8. Connect hose assembly (1) and hose assembly
(5).
9. Install the O-ring seal on tube assembly (2).
lubricate the O-ring seal with Tooling (B). Install
tube assembly (2).
10. Fill the cooling with coolant to the correct level.
Refer to Operation and Maintenance Manual,
Cooling System Coolant - Change for the correct
Illustration 60 g06123164 procedure.

2. Install vent assembly (13) in water temperature i02699744

regulator housing (6). Position gasket (12) and
cover (11). Install bolts (10). Water Pump - Remove
3. Use Tooling (A) to install lip seal (15) into water SMCS Code: 1361-011
temperature regulator housing (6).

NOTICE Removal Procedure

If the water temperature regulator is installed incor-
rectly, it will cause the engine to overheat. NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
4. Install water temperature regulators (14). nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Refer to Special Publication, PERJ1017, “Dealer
Service Tool Catalog” for tools and supplies suitable
to collect and contain fluids on Cat ® products.
Dispose of all fluids according to local regulations
and mandates.
36 KENR6055-14
Disassembly and Assembly Section

5. Remove gasket (2) from the water pump. Remove

NOTICE
Keep all parts clean from contaminants. the O-ring seal from the water pump.

Contaminants may cause rapid wear and shortened i06831535

component life.
Water Pump - Disassemble
1. Drain the coolant from the cooling system into a
SMCS Code: 1361-015
suitable container for storage or disposal. Refer to
Operation and Maintenance Manual, “Cooling
System Coolant - Change”. Disassembly Procedure
Table 10
Required Tools

Tool Part Number Part Description Qty

1U-9895 Crossblock 1

1P-0820 Hydraulic Puller 1

126-7181 Sliding Plate 2

3H-0465 Push-Puller Plate 6

2S-4680 Stud 2
A Electric Hydraulic
3S-6224 1
Pump Gp

2L-4523 Bolt 2
Illustration 62 g01354173 5P-8244 Hard Washer 2

2. Remove bolts (4). Remove pump inlet elbow (5) 6B-6682 Full Nut 2
from the tube and water pump (3). Remove seal 2J-3506 Full Nut 2
(7). B 521-4900 Puller As. 1
3. Remove bolts (6).
4. Remove bolts (1). Remove water pump (3) from
the housing.

Note: Do not handle the water pump by the shaft or

allow the shaft to support the water pump. Improper
handling of the shaft can allow the shaft to contact
the ceramic seals in the water pump. This can
damage the ceramic seals. Damage to the seals will
cause leaks and failure of the water pump.
KENR6055-14 37
Disassembly and Assembly Section

Start By:
a. Remove the water pump.

Illustration 65 g06133692

Illustration 63 g03475023
Personal injury can result from being struck by
1. Remove nuts (1) and the studs from cover parts propelled by a released spring force.
assembly (2). Remove cover assembly (2).
Make sure to wear all necessary protective
equipment.
Follow the recommended procedure and use all
recommended tooling to release the spring force.

3. Use Tooling (A) to remove impeller (5).

Illustration 64 g03475339

2. Remove O-ring seal (3) and O-ring seal (4) from

cover assembly (2).
38 KENR6055-14
Disassembly and Assembly Section

Illustration 66 g06133697 Illustration 68 g06133752

4. Use Tooling (B) to remove the rotating seal group 6. Remove stationary seal group (11).
(6).
7. Remove plug assembly (12) from pump housing
(10).

Illustration 67 g06133750

Illustration 69 g06133753
5. Remove bolts (7) and the washers from thrust
washer (8) from pump housing (9).
8. Remove lip seal (13), ring assembly (14), and the
locating pin from pump housing (10).
KENR6055-14 39
Disassembly and Assembly Section

Illustration 70 g06133754 Illustration 71 g06133754

9. Remove filters (15) from pump housing (10). 1. Install filters (15) into pump housing (10).
Reference: Refer to Reuse and Salvage Guidelines,
SEBF8418, “Salvage of Water Pumps in 3500 Series
Engines” for reuse and salvage guidelines.

i06831536

Water Pump - Assemble

SMCS Code: 1361-016

Assembly Procedure
Table 11
Required Tools

Tool Part Number Part Description Qty

C 1P-0510 Driver Gp 1

D 7N-8268 Installation Tool 1

E 438-8155 Installation Tool 1

Illustration 72 g06133753
Reference: Refer to Reuse and Salvage Guidelines,
SEBF8418, “Salvage of Water Pumps in 3500 Series
Engines” for reuse and salvage guidelines. 2. Install ring (14) and the locating pin.
3. Use Tooling (C) to install lip seal (13) into pump
housing (10).
40 KENR6055-14
Disassembly and Assembly Section

Illustration 74 g06133755

Illustration 73 g06133750

4. Install shaft assembly (8), thrust washer (9), bolts

(7), and the washers into pump housing (10).

Illustration 75 g03476619

5. Use Tooling (D) to install stationary seal group (11)

with the ceramic side facing out.
KENR6055-14 41
Disassembly and Assembly Section

Illustration 76 g06133756 Illustration 78 g06133758

7. Lubricate the shaft assembly with a light coat of

engine oil. Use a suitable press to install impeller
(5) into pump housing (10) and onto the shaft
assembly. Install impeller (5) to a depth of
0.0 ± 0.15 mm (0.00000 ± 0.00591 inch) from the
end of the shaft assembly to the outer face of the
impeller.
Note: Support the shaft assembly to prevent damage
to the thrust washer.

Illustration 77 g06133757

6. Use Tooling (E) and a suitable press to install

rotating seal group (6). Rotating seal group (6) is
to be installed with installation clips (X) in place
until rotating seal group (6) is fully seated.
Remove installation clips (X).
Note: Do not use hammer to install seal groups as
damage to the ceramic faces on the seal groups will
occur.
Illustration 79 g06133759

8. Install plug assembly (12) and the O-ring seal into

pump housing (10).
42 KENR6055-14
Disassembly and Assembly Section

End By:
a. Install the water pump.

i05831770

Water Pump - Install

SMCS Code: 1361-012

Installation Procedure
Table 12
Required Tools

Tool Part Number Part Description Qty

O-Ring Assembly
A 1U-6396 -
Compound

NOTICE
Keep all parts clean from contaminants.
Illustration 80 g03475339
Contaminants may cause rapid wear and shortened
9. Install O-ring seal (4) and O-ring seal (3) onto component life.
cover assembly (2).
NOTICE
Water pumps may leak as a result of damaged face
seals. Relative movement between the shaft and the
housing may allow the drive shaft to contact the face
seal in the water pump. If contact occurs, the face
seal will be damaged, and very early hour failures
can result.

1. Refer to Special Instruction , REHS9244 for proper

water pump handling procedures prior to
installation.

Illustration 81 g03475023

10. Install cover assembly (2), the studs, and nuts

(1). Tighten the studs to a torque of 35 ± 5 N·m
(25 ± 3 lb ft). Tighten nuts (1) to a torque of
27 ± 5 N·m (19 ± 3 lb ft). Illustration 82 g01354173

2. Install the O-ring seal on water pump (3). Lubricate

the O-ring seal with Tooling (A).
3. Place gasket (2) and use a suitable lifting device to
install water pump (3) into position. Install bolts (1).
KENR6055-14 43
Disassembly and Assembly Section

4. Install bolts (6). 3. Remove bolts (6) that fasten thermostatic control
valve group (9) to bracket (10).
5. Lubricate the O-ring seal on the tube with Tooling
(A). Install the O-ring seal on the tube, if 4. The weight of thermostatic control valve group (9)
necessary. is approximately 28 kg (62 lb). Use a suitable
lifting device to remove thermostatic control valve
6. Install seal (7) and pump inlet elbow (5) on water
group (9). Remove bolts (3) that fasten
pump (3). Install bolts (4).
thermostatic control valve group (9) to auxiliary
7. Fill the cooling system. Refer to Operation and water pump (8). Remove thermostatic control
Maintenance Manual, “Cooling System Coolant - valve group (9).
Change”.
5. Auxiliary water pump (8) must be removed with the
accessory drive shaft and the accessory drive
i02724036
gear as a unit. The weight of auxiliary water pump
(8), the accessory drive shaft, and the accessory
Auxiliary Water Pump - drive gear is approximately 48 kg (106 lb). Use a
Remove suitable lifting device to remove auxiliary water
pump (8), the accessory drive shaft, and the
SMCS Code: 1371-011 accessory drive gear. Remove bolts (7) that fasten
auxiliary water pump (8) to the front drive housing.
Removal Procedure Remove auxiliary water pump (8), the accessory
drive shaft, and the accessory drive gear as a unit.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Illustration 84 g01141236

6. Remove bolts (11) that fasten accessory drive gear

(12) to accessory drive shaft (13).

Illustration 83 g01141238

1. Remove the bolts, the retainers, and retaining ring

(2) that fastens tube (1) to the elbow on auxiliary
water pump (8).
2. Remove the bolts, the retainers, and retaining ring
(4) that fastens tube (5) to the thermostatic control
valve group (9).
44 KENR6055-14
Disassembly and Assembly Section

Start By:
a. Remove the auxiliary water pump. Refer to
Disassembly and Assembly, “Auxiliary Water
Pump - Remove”.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Disassemble the Check Valve

Note: If the hose assembly is leaking, the entire hose
assembly must be replaced.

Illustration 85 g01141237

7. Remove bolts (14) and thrust washers (15) that

secure accessory drive shaft (13) to auxiliary
water pump (8).

i03351722

Auxiliary Water Pump -

Disassemble
Illustration 86 g01056041
(Auxiliary Pump (Type 1))
1. Remove hose assembly (1) from the body of check
SMCS Code: 1371-015 valve (2).
S/N: TTH1–Up

Disassembly Procedure
Table 13
Required Tools

Tool Part Number Part Description Qty

Combination Puller (Two Jaw

A 1P-2320 1
or Three Jaw)

B 193-8094 Spline Socket 1

C 193-8100 Socket (Impeller Nut) 1

D 1P-0510 Driver Gp 1

E 136-1452 Retaining Ring Pliers As 1

F 152-7159 Socket As (Water Pump Shaft) 1

G 1U-7600 Slide Hammer Puller Gp 1

H 1P-0074 Slide Hammer Puller Gp 1

J - M10 x 125 Forcing Bolts 2

K - M8 x 1.25 Bolts 2
KENR6055-14 45
Disassembly and Assembly Section

Illustration 89 g01055766

2. Remove O-ring seal (8) from cover (7).

Illustration 87 g00714974

Personal injury can result from parts and/or cov-

ers under spring pressure.
Spring force will be released when covers are
removed.
Be prepared to hold spring loaded covers as the
bolts are loosened.
Illustration 90 g01055768
2. Use Tooling (E) in order to remove retainer (3)
from the body of check valve (2).
3. Remove port plate (9).
3. Remove spring (4) and disc (5) from the body of
check valve (2).

Disassemble the Pump

Illustration 91 g01055769

4. Remove nut (10) and the washer.

Illustration 88 g01055763

1. Remove bolts (6) in order to remove cover (7).

46 KENR6055-14
Disassembly and Assembly Section

Illustration 92 g01055770 Illustration 95 g01055781

5. Use Tooling (A) in order to remove impeller (11). 8. Remove O-ring seal (16) from body (13).

Illustration 93 g01055773 Illustration 96 g01055783

6. Remove bolts (12) from body (13). 9. Remove ring (14) and port plate (15) from body
(13).
Note: Ring (14) and port plate (15) will remain inside
when the body is removed.

Illustration 97 g01055786

Illustration 94 g01055775 10. Remove key (17) and shim (18) from shaft (19).

7. Use Tooling (J) in order to remove body (13).

KENR6055-14 47
Disassembly and Assembly Section

Illustration 98 g01055789 Illustration 101 g01055793

11. Bend the tabs of lockwasher (20) away from the 14. Place body (23) in the downward position.
flats of locknut (21). Remove bolts and washers (24) that attach
bearing housing (25) to the body.

Illustration 99 g00705829
Illustration 102 g01055795
12. Hold the driven end of the shaft with Tooling (B).
Use Tooling (C) in order to loosen the locknut. 15. Use Tooling (K) in order to force bearing housing
(25) from body (23).
Remove the locknut and the lockwasher from the
shaft. Use a new lockwasher upon assembly.

Illustration 100 g01055791

13. Use Tooling (A) in order to remove impeller (22).

48 KENR6055-14
Disassembly and Assembly Section

Illustration 103 g01055796 Illustration 106 g01055802

18. Use an allen wrench to loosen the screws that

hold ring (29) to shaft (19). Remove the ring.

Illustration 104 g01055798

16. Use Tooling (D) and a suitable press in order to

Illustration 107 g01055803
remove the stationary segment of ceramic seal
(26) from body (23).
19. Remove O-ring seal (30) from shaft (19).

Illustration 105 g01055799

Illustration 108 g01055804

17. Remove ring (27) and the rotating segment of

20. Place bearing housing (25) in a vise with the
ceramic seal (28) from shaft (19).
driven end of the shaft in the upward position. Use
Tooling (E) in order to remove retaining ring (31).
KENR6055-14 49
Disassembly and Assembly Section

NOTICE
Do not allow the shaft to fall when the shaft is re-
moved from the bearing housing.

Illustration 111 g01055815

23. Place shaft (19) and bearing (33) in a suitable

press. Orient the driven end of the shaft in the
upward position. Press the shaft out of the
Illustration 109 g01055806
bearing.
21. Place bearing housing (25) and shaft (19) in a
suitable press. Orient the impeller end of the shaft
in the upward position. Press the shaft out of the
bearing housing.

Illustration 112 g01055814

24. Remove collar (34) from bearing housing (25).

Illustration 110 g01055810

22. Place the shaft in a vise. Orient the driven end of

the shaft in the upward position. Use Tooling (F) in
order to remove nut (32) (not shown) from the
shaft.

Illustration 113 g01055816

25. Use Tooling (G) in order to remove oil seal (35)

from bearing housing (25).
50 KENR6055-14
Disassembly and Assembly Section

(Table 14, contd)

126-7176 Forcing Screw
or or
1
8S-5133 Plug
8S-6470 Screw
126-7182 Nut 1
1F-6296 Bolt 2

126-7181 Sliding Plate 2

Start By:
a. Remove the auxiliary water pump. Refer to
Disassembly and Assembly, “Auxiliary Water
Pump - Remove”.
Illustration 114 g01055817

NOTICE
26. Use Tooling (E) in order to remove retaining ring Keep all parts clean from contaminants.
(36) from bearing housing (25).
Contaminants may cause rapid wear and shortened
27. Remove bearing (37) from bearing housing (25). component life.

Illustration 115 g01055821

Illustration 116 g01355107
28. Use Tooling (H) in order to remove bearing race
(38) from bearing housing (25). 1. Remove bolts (5) and flange (4) from housing
assembly (2). Remove O-ring seal (3) from flange
i04404264 (4). Remove O-ring seal (1) from housing
assembly (2).
Auxiliary Water Pump -
Disassemble
SMCS Code: 1371-015

Disassembly Procedure
Table 14
Required Tools

Tool Part Number Part Description Qty

A 126-7183 Crossblock 1

(continued)
KENR6055-14 51
Disassembly and Assembly Section

9. Remove bearing (14) from housing assembly (2).

i02702393

Auxiliary Water Pump -

Assemble
SMCS Code: 1371-016

Assembly Procedure
Table 15
Required Tools

Tool Part Number Part Description Qty

B 1P-0510 Driver Group 1

NOTICE
Keep all parts clean from contaminants.
Illustration 117 g01355134 Contaminants may cause rapid wear and shortened
component life.

Personal injury can result from parts and/or cov-

ers under spring pressure.
Spring force will be released when covers are
removed.
Be prepared to hold spring loaded covers as the
bolts are loosened.

2. Remove bolts (6) and adapter (7) from housing

assembly (2). Remove O-ring seal (8) from
adapter (7).
3. Remove bolt (15). Use Tooling (A) in order to
remove impeller (9).
4. Remove the spring, the retainer assembly, and the
carbon seal from seal assembly (16). The rubber
seal and the ceramic ring will be removed after the
shaft assembly is removed.
5. Remove bolts (11) and thrust washer (10).
Illustration 118 g01355134
6. Remove shaft assembly (12).
7. Carefully remove the rubber seal and the ceramic
ring from seal assembly (16).
8. Remove lip seal (13) from housing assembly (2). Improper assembly of parts that are spring
loaded can cause bodily injury.
To prevent possible injury, follow the established
assembly procedure and wear protective
equipment.

1. Use Tooling (B) in order to install lip seal (13) in

housing assembly (2). Make sure that the lip seal
is correctly oriented during installation.
52 KENR6055-14
Disassembly and Assembly Section

2. Use Tooling (B) in order to install bearing (14) in 10. Install flange (4) on housing assembly (2). Install
housing assembly (2). Make sure that the oil hole bolts (5).
in bearing (14) is aligned with the oil passage in
11. Lightly lubricate O-ring seal (1) with clean engine
housing assembly (2). Bearing (14) must be
oil. Install O-ring seal (1) on housing assembly (2).
installed to a depth of 0 to 0.25 mm
(0 to 0.010 inch). After assembly, the inner End By:
diameter of bearing (14) must be
a. Install the auxiliary water pump. Refer to
54.122 ± 0.025 mm (2.1308 ± 0.0010 inch). Disassembly and Assembly, “Auxiliary Water
3. Lubricate the rubber seal with water. Use Tooling Pump - Install”.
(B) to seat the rubber seal and the ceramic ring in
housing assembly (2). Use only hand pressure i03455280

with Tooling (B). The polished face of the ceramic

ring must face upward. Auxiliary Water Pump -
4. Install shaft assembly (12). Install thrust washer
Assemble
(10) and bolts (11). (Auxiliary Pump (Type 1))
5. Assemble the spring, the retainer assembly, and SMCS Code: 1371-016
the carbon seal for seal assembly (16). Lubricate
the inside diameter of the assembled components. S/N: TTH1–Up
Use Tooling (B) to install the assembled
components until the carbon seal for seal Assembly Procedure
assembly (16) makes light contact with the Table 16
ceramic ring.
Required Tools
6. Lightly coat shaft assembly (12) with clean engine
Tool Part Number Part Description Qty
oil prior to installation of impeller (9).
B 193-8094 Spline Socket 1
7. Use Tooling (B) and a suitable press to install
impeller (9) on shaft assembly (12). Ensure that C 193-8100 Socket 1
the surface of shaft assembly (12) is flush with E 136-1452 Retaining Ring Pliers As 1
impeller (9) after installation. Install bolt (15) and
tighten to a torque of 38 ± 4 N·m (28 ± 3 lb ft). F 152-7159 Socket As 1

L 1P-0520 Driver Gp 1
8. Lightly lubricate the seal groove in adapter (7) with
clean engine oil. Install O-ring seal (8) in adapter M 5P-4197 Spacer 1
(7). Install adapter (7) on housing assembly (2).
N 4C-4030 Thread Lock Compound 1
Install bolts (6).
P 4C-4032 Bearing Mount Compound 1

Q 9S-3263 Thread Lock Compound 1

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Illustration 119 g01355107

9. Lightly lubricate the seal groove in flange (4) with

clean engine oil. Install O-ring seal (3) in flange
(4).
KENR6055-14 53
Disassembly and Assembly Section

Assemble the Check Valve Assemble the Pump

Illustration 122 g01056378

1. Place shaft (19) and bearing (33) in a suitable

press. Make sure that the serial number on the
bearing is toward the driven end of the shaft. Insert
the driven end of the shaft into the bearing. Press
Illustration 120 g00714974 the shaft into the bearing until the shoulder of the
shaft contacts the bearing.
1. Install disc (5) and spring (4) into the body of check
valve (2).
2. Use Tooling (E) in order to install retainer (3) into
the body of check valve (2). After the retainer is
installed, strike the retainer in order to ensure that
the retainer is properly seated.

Illustration 123 g01056379

Note: Thoroughly clean the threads of shaft (19) and

nut (32) with solvent before assembly.

Illustration 121 g01056041

3. Install hose assembly (1) to the body of check

valve (2).
54 KENR6055-14
Disassembly and Assembly Section

Illustration 124 g01055810 Illustration 127 g01056417

2. Secure the shaft in a vise with the driven end of the

shaft in the upward position. Apply Tooling (N) to
the threads of the shaft. Orient the tapered end of
nut (32) (not shown) toward the bearing. Use
Tooling (F) in order to tighten the nut to a torque of
140 ± 10 N·m (103 ± 7 lb ft).

Illustration 128 g01056418

4. Place shaft (19) into bearing housing (25) with the

driven end of the shaft in the upward position. Use
a suitable press and Tooling (M) in order to install
the shaft into the bearing housing.
Illustration 125 g01056412

Illustration 126 g01056415

3. Use a suitable press and Tooling (L) in order to

install bearing race (38) into bearing housing (25).
KENR6055-14 55
Disassembly and Assembly Section

Illustration 131 g01056429

8. Lubricate the inner diameter (lip) of oil seal (35)

with clean engine oil.

Illustration 129 g01055804

5. Place bearing housing (25) into a vise with the

driven end of the shaft in the upward position. Use
Tooling (E) in order to install retaining ring (31) into
the bearing housing. After the retaining ring is
installed, strike the ring with a punch in order to
ensure that the ring is properly seated.

Illustration 132 g01056434

9. Lubricate the outer diameter of oil seal (35) with a

solution of water and five percent soap. Install the
oil seal into bearing housing (25).

Illustration 130 g01055817

6. Place bearing housing (25) into a vise with the

impeller end of the shaft in the upward position.
Place bearing (37) into position with the serial
number in the upward position. Use a hammer and
a brass driver to install the bearing into the bearing
housing.
Alternatively, use a suitable press with an
appropriate sleeve to press the bearing into the Illustration 133 g01056485
housing.
10. Thoroughly clean shaft (19) and collar (34) with
7. Use Tooling (E) in order to install retaining ring (36) solvent. Apply Tooling (P) to the shaft for 15 mm
into bearing housing (25). Make sure that the side (0.6 inch) from the shoulder of the shaft at the
of the retaining ring with the bevel is upward. After bearing diameter. Install the collar onto the shaft.
the retaining ring is installed, strike the ring with a Rotate the collar for 180 degrees in both
punch in order to ensure that the ring is properly directions. Allow the compound to cure for 30
seated. minutes.
56 KENR6055-14
Disassembly and Assembly Section

Illustration 134 g01055803 Illustration 136 g01056491

11. Install O-ring seal (30) on shaft (19) and install 13. Orient the inside of body (23) to the upward
the O-ring seal over the collar. position. Lubricate the stationary segment of
ceramic seal (26) with a solution of water and five
percent soap. Place the marked side of the
segment in the downward position. Use hand
pressure to install the segment into body (23).
After the seal is installed, wipe the surface dry.

Illustration 135 g01055802

12. Install ring (29) on shaft (19) and install the ring
over the O-ring seal. Make sure that the side of the
ring with the step is oriented toward the O-ring
seal. Maintain approximately 490 ± 45 N Illustration 137 g01055793
(110 ± 10 lb) of pressure on ring (29) and use an
allen wrench to tighten the screws to a torque of 14. Place body (23) on blocks. Orient the inside of
0.9 ± 0.1 N·m (7.97 ± 0.10 lb in). After the screws the body to the downward position. Place bearing
are tightened, use a small center punch to peen housing (25) onto the body. Attach the bearing
the threads in the ring. housing to the body with bolts and washers (24).
Tighten the bolts to a torque of 22 ± 4 N·m
Note: Carefully inspect the surface of the ceramic (16 ± 3 lb ft).
seal. If the surface is cracked or scratched, discard
the seal and obtain a new seal for installation. Ensure Note: Carefully inspect the surface of the ceramic
that the faces of the seal are clean. seal. If the surface is cracked or scratched, discard
the seal and obtain a new seal for installation. Ensure
that the faces of the seal are clean.
KENR6055-14 57
Disassembly and Assembly Section

Illustration 138 g01055799 Illustration 140 g01056529

15. Place the body with the inside of the body in the 18. Press impeller (22) onto the shaft.
upward position. Lubricate the rotating segment of
ceramic seal (28) with a solution of water and five
percent soap. Orient the side of the segment with
the spring to the upward position. Use hand
pressure to install the rotating segment of ceramic
seal (28) over shaft (19).
16. Install ring (27) onto shaft (19). If the key was
removed from the shaft, install the key.

Illustration 141 g01056531

19. Thoroughly clean the threads of the shaft and

locknut (21) with solvent. Install lockwasher (20)
onto the shaft. Coat the threads of the shaft with
Tooling (Q). Install locknut (21) onto the shaft.

Illustration 139 g01056519

17. Place bearing housing (25) onto a suitable press.

Orient the driven end of shaft (19) in the downward
position. Use a jack and/or blocking in order to
help prevent damage to the shaft when the
impeller is installed.
58 KENR6055-14
Disassembly and Assembly Section

Illustration 142 g00705829 Illustration 144 g01055783

20. Hold the driven end of the shaft with Tooling (B).
Tighten the locknut with Tooling (C). Tighten the
locknut to a torque of 271 ± 15 N·m
(200 ± 10 lb ft).

Illustration 145 g01056549

22. Lubricate port plate (15) with a solution of water

and five percent soap. Install port plate (15) and
ring (14) into body (13). Make sure that the lug on
Illustration 143 g01055789
the port plate fits into the slot in the body.
21. Bend the edges of lockwasher (20) against the
flats of locknut (21).
KENR6055-14 59
Disassembly and Assembly Section

Illustration 146 g01055781 Illustration 148 g01056558

23. Make sure that O-ring seal (16) is in good 25. Determine the thickness of the shims for the
condition. Coat the O-ring seal with a solution of impeller.
water and five percent soap in order to make
The shims will be used in order to obtain a
installation easier. Install the O-ring seal onto body
clearance of 0.10 to 0.15 mm
(13).
(0.004 to 0.006 inch) on each side of the impeller.
Place a straight edge on the face of the port plate
(15) across the opening for shaft (19). Use a feeler
gauge to measure Dimension (X) between the
shoulder of the shaft and the face of the port plate.
The correct thickness of the shims is Dimension
(X) plus the specification of the clearance. Table
17 is an example of the calculation.
Table 17
Example of the Calculation for Determining the Thickness of
the Shims
Dimension Clearance Thickness of the
(X) Specification Shims

Illustration 147 g01056553 0.56 mm 0.125 mm 0.685 mm

+ =
(0.022 inch) (0.005 inch) (0.0270 inch)
24. Install body (13). Install washers and bolts (12) in
body (13). Tighten the bolts to a torque of In the example, the proper thickness for the shims
22 ± 4 N·m (16 ± 3 lb ft). is 0.685 mm (0.0269 inch).
60 KENR6055-14
Disassembly and Assembly Section

Illustration 149 g01055786 Illustration 151 g01055769

26. Install shim (18) and key (17) onto shaft (19). 28. Thoroughly clean the threads of the shaft and nut
(10) with solvent. Coat the threads of the shaft with
Tooling (Q). Install the washer and nut (10) onto
the shaft. Tighten the nut to a torque of 70 ± 5 N·m
(52 ± 4 lb ft).

Illustration 150 g01056577

27. Fit the keyway of impeller (11) onto the key of

shaft (19). Install the impeller onto the shaft. If you
use a suitable press in order to install the impeller, Illustration 152 g01056579
be sure to support the shaft with a jack and/or
blocks. 29. Lubricate port plate (9) with a solution of water
and five percent soap. Install port plate (9). Note
the position of the lug on the port plate.
KENR6055-14 61
Disassembly and Assembly Section

End By:
a. Install the auxiliary water pump. Refer to
Disassembly and Assembly, “Auxiliary Water
Pump - Install”.

i05838306

Auxiliary Water Pump - Install

SMCS Code: 1371-012

Installation Procedure
NOTICE
Illustration 153 g01055766 Keep all parts clean from contaminants.

30. Ensure that O-ring seal (8) is in good condition. Contaminants may cause rapid wear and shortened
component life.
Install the O-ring seal onto cover (7). Install the
cover. Fit the slot of the cover over the lug on the
port plate. NOTICE
Water pumps may leak as a result of damaged face
seals. Relative movement between the shaft and the
housing may allow the drive shaft to contact the face
seal in the water pump. If contact occurs, the face
seal will be damaged, and very early hour failures
can result.

Note: Do not lift the auxiliary water pump by the

shaft. Do not bump the shaft when installing the
auxiliary water pump onto the engine.

Illustration 154 g01055763

31. Thoroughly clean the threads of bolts (6) with

solvent. Coat the threads of bolts (6) with Tooling
(Q). Install the bolts in cover (7). Tighten the bolts
to a torque of 5 ± 1 N·m (4 ± 1 lb ft).

Illustration 155 g01009132

1. Slide accessory drive shaft (13) on the shaft of

auxiliary water pump (8). Position thrust washers
(15) on the auxiliary water pump and install bolts
(14).
62 KENR6055-14
Disassembly and Assembly Section

4. The weight of thermostatic control valve group (9)

is approximately 28 kg (62 lb). Use a suitable
lifting device to position thermostatic control valve
group (9). Install bolts (3). Install bolts (6) in order
to fasten thermostatic control valve group (9) to
bracket (10).
5. Install the O-ring seal on tube (1) and install tube
(1) in the elbow on auxiliary water pump (8). Install
retaining ring (2), the retainers, and the bolts to
secure tube (1).
6. Install the O-ring seal on tube (5) and install tube
(5) in thermostatic control valve group (9). Install
retaining ring (4), the retainers, and the bolts to
secure tube (5).

i02724031

Engine Oil Cooler - Remove

Illustration 156 g01009118 SMCS Code: 1378-011

2. Position accessory drive gear (12) on accessory Removal Procedure

drive shaft (13). Install bolts (11).
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Refer to Special Publication, PERJ1017, “Dealer
Service Tool Catalog” for tools and supplies suitable
to collect and contain fluids on Cat ® products.
Dispose of all fluids according to local regulations
and mandates.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

1. Drain the coolant from the cooling system into a

Illustration 157 g01009100 suitable container for storage or disposal. Refer to
Operation and Maintenance Manual, “Cooling
3. The weight of auxiliary water pump (8), the System Coolant - Change”.
accessory drive shaft, and the accessory drive
gear is approximately 48 kg (106 lb). Use a
suitable lifting device to install the components in
the front drive housing. Install bolts (7).
KENR6055-14 63
Disassembly and Assembly Section

9. Remove engine oil cooler (7) from tube (13).

Remove the O-ring seal from the tube.

i02259012

Engine Oil Cooler -

Disassemble
SMCS Code: 1378-015

Disassembly Procedure
Start By:
a. Remove the engine oil cooler. Refer to
Illustration 158 g01135600 Disassembly and Assembly, “Engine Oil
Cooler - Remove”.
2. Remove bolts (2). Remove elbow (3) and tube
assembly (1). Remove the gasket from the elbow. NOTICE
Keep all parts clean from contaminants.
3. Remove tube assembly (1) from elbow (3).
Remove O-ring seals (4) from the tube. Contaminants may cause rapid wear and shortened
component life.

Illustration 159 g01135604

4. Attach a suitable lifting device to engine oil cooler Illustration 160 g01135749
(7). The weight of engine oil cooler (7) is
approximately 78 kg (172 lb). 1. Remove bolts (7). Remove elbow (6). Remove
gasket (8) from the elbow.
5. Remove bolts (8) and bolts (9). Remove the clamp
assembly from tube assembly (10). 2. Remove tube (4) from elbow (6). Remove O-ring
seals (5) from tube (4).
6. Remove tube assembly (10) from the cooler
bypass elbow. Remove the O-ring seal and the 3. Remove the bolts and cover (9) from elbow (6).
retaining ring from the tube assembly. Remove the gasket from the elbow.

7. Remove bolts (5) and bolts (6). Remove adapter 4. Place an identification mark on oil cooler bonnet
(11) from the engine oil cooler. Remove the gasket (3) and on engine oil cooler core (1) for assembly
from the adapter. purposes. Remove bolts (10) and remove oil
cooler bonnet (3) from engine oil cooler core (1).
8. Remove bolts (12). Remove gasket (2) from the engine oil cooler core.
64 KENR6055-14
Disassembly and Assembly Section

Illustration 161 g01135795 Illustration 162 g01135796

5. Place an identification mark on oil cooler bonnet

(14) and on engine oil cooler core (1) for assembly
purposes. Remove bolts (13) and remove oil Personal injury can result from parts and/or cov-
cooler bonnet (14) from engine oil cooler core (1). ers under spring pressure.
Remove gasket (16) from the engine oil cooler
core. Spring force will be released when covers are
removed.
6. Remove bolts (11) and elbow (12) from the engine
Be prepared to hold spring loaded covers as the
oil cooler bypass. Remove the O-ring seals from bolts are loosened.
the elbow.
7. Remove cover (17) and the O-ring seal. 10. Remove bolts (22), cover (21), O-ring seal (18),
spring (19), and bypass valve (20) from elbow
8. If necessary, remove drain plug (15) and the O-ring (12).
seal.
9. Thoroughly clean the tubes in the engine oil cooler i02259048

core.
Engine Oil Cooler - Assemble
SMCS Code: 1378-016

Assembly Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

1. Thoroughly clean the tubes in the engine oil cooler

core.
KENR6055-14 65
Disassembly and Assembly Section

7. Install the O-ring seal on tube (4). Apply clean

engine oil on the O-ring seal. Install tube (4) in
elbow (12).

Illustration 163 g01135796

Illustration 165 g01135749

Improper assembly of parts that are spring
loaded can cause bodily injury.
8. Install gasket (2) and oil cooler bonnet (3) on
To prevent possible injury, follow the established engine oil cooler core (1) in the orientation that
assembly procedure and wear protective was noted during the disassembly procedure.
equipment. Install bolts (10).

2. Install bypass valve (20) and spring (19) in elbow 9. Install O-ring seal (5) on tube (4). Apply clean
(12). Install O-ring seal (18) and lubricate the O- engine oil on the O-ring seal. Install elbow (6) on
ring seal with clean engine oil. Install cover (21) tube (4).
and bolts (22). 10. Position gasket (8) and elbow (6) on engine oil
cooler core (1). Install bolts (7).
11. Position the gasket and cover (9) on elbow (6).
Install the bolts.
End By:
a. Install the engine oil cooler. Refer to
Disassembly and Assembly, “Engine Oil
Cooler - Install”.

i02255502

Engine Oil Cooler - Install

SMCS Code: 1378-012
Illustration 164 g01135915
Installation Procedure
3. Install gasket (16) and oil cooler bonnet (14) on
engine oil cooler core (1) in the orientation that NOTICE
was noted during the disassembly procedure. Keep all parts clean from contaminants.
Install bolts (13). Contaminants may cause rapid wear and shortened
4. Install the O-ring seal and cover (17). component life.

5. Install the O-ring seal and drain plug (15).

6. Install the O-ring seal and elbow (12) on the
engine oil cooler core. Install bolts (11).
66 KENR6055-14
Disassembly and Assembly Section

9. Fill the cooling system. Refer to Operation and

Maintenance Manual, “Cooling System Coolant -
Change”.

i02724021

Engine Oil Pump - Remove

SMCS Code: 1304-011

Removal Procedure
Start By:
a. Remove the fuel transfer pump. Refer to
Illustration 166 g01135604 Disassembly and Assembly, “Fuel Transfer
Pump - Remove”.
1. Attach a suitable lifting device to engine oil cooler
(7). The weight of engine oil cooler (7) is NOTICE
Care must be taken to ensure that fluids are con-
approximately 78 kg (172 lb). tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
2. Install the O-ring seal on tube (13). Apply clean
Be prepared to collect the fluid with suitable contain-
engine oil to the O-ring seal. ers before opening any compartment or disassem-
3. Position engine oil cooler (7) on tube (13). Install bling any component containing fluids.
bolts (12). Refer to Special Publication, PERJ1017, “Dealer
4. Position the gasket and adapter (11) on the engine Service Tool Catalog” for tools and supplies suitable
to collect and contain fluids on Cat ® products.
oil cooler. Install bolts (6) and bolts (5).
5. Install the O-ring seal and the retaining ring on Dispose of all fluids according to local regulations
and mandates.
tube assembly (10). Install tube assembly (10).
6. Install the clamp, bolts (8), and bolts (9). Tighten
bolts (8) to a torque of 47 ± 9 N·m (35 ± 7 lb ft). NOTICE
Keep all parts clean from contaminants.
Tighten bolts (9) to a torque of 47 ± 9 N·m
(35 ± 7 lb ft). Contaminants may cause rapid wear and shortened
component life.

1. Drain the coolant from the cooling system into a

suitable container for storage or disposal. Refer to
Operation and Maintenance Manual, “Cooling
System Coolant - Change”.

Illustration 167 g01135600

7. Install O-ring seals (4) on tube assembly (1). Apply

clean engine oil to the O-ring seals.
8. Install elbow (3) on tube assembly (1). Install tube
assembly (1) in the adapter. Position the gasket
and elbow (3) on the cylinder block and install
bolts (2).
KENR6055-14 67
Disassembly and Assembly Section

Illustration 168 g01141965 Illustration 170 g01141977

2. Remove tube assemblies (1) and the brackets. 5. Attach a suitable lifting device to engine oil pump
(8). The weight of engine oil pump (8) is
3. Remove bolts (2), (4), and (5). Remove adapter
approximately 42 kg (93 lb). Remove bolts (9) in
(3). Remove the gaskets from the adapter.
order to remove engine oil pump (8) from the front
housing. Remove bolts (10) in order to remove
engine oil pump (8) from adapter (11). Remove the
engine oil pump. Remove the O-ring seal from
adapter (11).
6. Remove the O-ring seal from adapter (11).
Remove the O-ring seal from engine oil pump (8).

i02483493

Engine Oil Pump -

Disassemble
SMCS Code: 1304-015
Illustration 169 g01141973
Disassembly Procedure
4. Remove bolts (6) in order to disconnect elbow (7) Table 18
from engine oil pump (8). Remove the O-ring seal
Required Tools
from the elbow.
Tool Part Number Part Description Qty

A 1P-0510 Driver Gp 1

B 6V-2166 Bearing Puller Gp 1

68 KENR6055-14
Disassembly and Assembly Section

Start By: 2. Remove bolts (1) and pump cover assembly (2).
Remove gasket (3) from the pump cover
a. Remove the engine oil pump. Refer to assembly. If necessary, remove the dowels from
Disassembly and Assembly, “Engine Oil Pump
- Remove”. pump cover assembly (2).
3. Remove bolts (10) and pump cover assembly (4)
NOTICE from oil pump body assembly (9).
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte- 4. Use Tooling (A) to remove sleeve bearings (5)
nance, testing, adjusting, and repair of the product. from pump cover assembly (4). If necessary,
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem- remove the hollow dowels from pump cover
bling any component containing fluids. assembly (4).

Refer to Special Publication, PERJ1017, “Dealer 5. Remove idler shaft assemblies (6) and pump drive
Service Tool Catalog” for tools and supplies suitable shaft assembly (7) from oil pump body assembly
to collect and contain fluids on Cat ® products. (9).
Dispose of all fluids according to local regulations 6. Use Tooling (A) or Tooling (B) to remove sleeve
and mandates. bearings (8) from oil pump body assembly (9).

i02483664
NOTICE
Keep all parts clean from contaminants. Engine Oil Pump - Assemble
Contaminants may cause rapid wear and shortened
component life. SMCS Code: 1304-016

Assembly Procedure
Table 19
Required Tools

Tool Part Number Part Description Qty

A 1P-0510 Driver Gp 1

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Illustration 171 g01142157

Personal injury can result from parts and/or cov-

ers under spring pressure.
Spring force will be released when covers are
removed.
Be prepared to hold spring loaded covers as the
bolts are loosened.

1. Remove bolts (11) and relief valve cover (12).

Remove spring (14) and pressure relief spool (15).
Remove gasket (13) from the relief valve cover.
KENR6055-14 69
Disassembly and Assembly Section

1. Align the joints of sleeve bearings (8) to 45 ± 15

degrees from the centerlines of the bearing bores
in oil pump body assembly (9). Use Tooling (A) to
install sleeve bearings (8) in oil pump body
assembly (9). The sleeve bearings must be
1.5 ± 0.5 mm (0.06 ± 0.02 inch) below the gear
bore.
2. Install hollow dowels (16) in pump cover assembly
(4) at a distance of 6.0 ± 0.5 mm
(0.24 ± 0.02 inch) above the face of the pump
cover assembly.
3. Align the joints of sleeve bearings (5) to 45 ± 15
degrees from the centerlines of the bearing bores
Illustration 172 g01142157 in pump cover assembly (4). Use Tooling (A) to
install sleeve bearings (5) in pump cover assembly
(4). The sleeve bearings must be 1.5 ± 0.5 mm
(0.06 ± 0.02 inch) below the face of the pump
cover assembly.
4. Apply clean engine oil to pump drive shaft
assembly (7) and to idler shaft assemblies (6).
Install the pump drive shaft assembly and the idler
shaft assemblies in oil pump body assembly (9).
Position pump cover assembly (4) onto the oil
pump body assembly and install bolts (10).
5. Install the dowels in pump cover assembly (2) at a
distance of 6.0 ± 1.0 mm (0.24 ± 0.04 inch) above
the surface of the cover assembly. Position gasket
(3) and pump cover assembly (2) on oil pump
Illustration 173 g01142223
body assembly (9). Install bolts (1).

Note: The engine oil pump must turn freely after

assembly. Turn the engine oil pump by hand.

6. Apply clean engine oil on pressure relief spool

(15). Install pressure relief spool (15) and spring
(14) in the oil pump body assembly. Install gasket
(13), relief valve cover (12), and bolts (11).
End By:
a. Install the engine oil pump. Refer to
Disassembly and Assembly, “Engine Oil Pump
- Install”.

i02493571

Illustration 174 g01142224

Engine Oil Pump - Install
SMCS Code: 1304-012

Improper assembly of parts that are spring Installation Procedure

loaded can cause bodily injury.
To prevent possible injury, follow the established NOTICE
assembly procedure and wear protective Keep all parts clean from contaminants.
equipment. Contaminants may cause rapid wear and shortened
component life.
70 KENR6055-14
Disassembly and Assembly Section

End By:
a. Install the fuel transfer pump. Refer to
Disassembly and Assembly, “Fuel Transfer
Pump - Install”.

i06715370

Engine Oil Filter Housing -

Remove
SMCS Code: 1306-011

Removal Procedure
Illustration 175 g01142067 Table 20
Required Tools
1. Install the O-ring seal on adapter (11). Install the
Tool Part Number Part Description Qty
O-ring seal on elbow (7). Install the O-ring seal on
engine oil pump (8). Apply clean engine oil to the A 138-7573 Link Bracket 2
O-ring seals.
2. Lubricate the engine oil pump with clean engine Start By:
oil. Before you install the engine oil pump, make a. Remove the fuel filter housing. Refer to
sure that the shaft of the pump will turn by hand. Disassembly and Assembly, “Fuel Filter
3. Attach a suitable lifting device to engine oil pump Housing - Remove”.
(8). The weight of engine oil pump (8) is
NOTICE
approximately 42 kg (93 lb). Align the splines of Care must be taken to ensure that fluids are con-
the engine oil pump with the splines of the drive for tained during performance of inspection, mainte-
the engine oil pump. Position the engine oil pump nance, testing, adjusting, and repair of the product.
on the front housing and install bolts (9). Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
4. Install bolts (10). Install bolts (6). bling any component containing fluids.
Refer to Special Publication, PERJ1017, “Dealer
Service Tool Catalog” for tools and supplies suitable
to collect and contain fluids on Cat ® products.
Dispose of all fluids according to local regulations
and mandates.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

1. Drain the oil from the engine oil filter housing into a
Illustration 176 g01141965 suitable container. Refer to Operation and
Maintenance Manual, “Engine Oil and Filter -
5. Position the gaskets and adapter (3). Install bolts Change”.
(4), (5), and (2).
2. Disconnect the oil pressure sensors.
6. Install tube assemblies (1) and the brackets.
7. Fill the cooling system. Refer to Operation and
Maintenance Manual, “Cooling System Coolant -
Change”.
KENR6055-14 71
Disassembly and Assembly Section

Illustration 177 g01113749 Illustration 179 g01113831

3. Remove bolts (1) and adapter (2). Remove the O- 6. Install Tooling (A) and a suitable lifting device on
ring seal from the adapter. engine oil filter housing (9). The weight of engine
oil filter housing (9) is approximately 35 kg (77 lb).
7. Remove bolts (8). Remove engine oil filter housing
(9).
8. Attach a suitable lifting device on oil filter housing
support (11). The weight of oil filter housing
support (11) is approximately 70 kg (155 lb).
9. Remove bolts (10). Remove oil filter housing
support (11).

i02206447

Engine Oil Filter Housing -

Illustration 178 g01113751
Disassemble
SMCS Code: 1306-015
4. Remove bolts (4) and spacers (5) from tube
assembly (3).
Disassembly Procedure
5. Remove bolts (6) and plate (7). Start By:
a. Remove the engine oil filter housing. Refer to
Disassembly and Assembly, “Engine Oil Filter
Housing - Remove”.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
72 KENR6055-14
Disassembly and Assembly Section

6. Remove bolts (9) and cover (10). Remove the O-

ring seal from the cover.

i02704053

Engine Oil Filter Housing -

Assemble
SMCS Code: 1306-016

Assembly Procedure
NOTICE
Keep all parts clean from contaminants.
Illustration 180 g01113975
Contaminants may cause rapid wear and shortened
component life.

Personal injury can result from parts and/or cov-

ers under spring pressure.
Spring force will be released when covers are
removed.
Be prepared to hold spring loaded covers as the
bolts are loosened.

1. Remove bolts (1) and cover (7). Remove the O-

ring seal from the cover. If necessary, remove the
dowel from the cover.
2. Remove the engine oil filter elements from filter
housing (2).
3. Remove bolts (8). Remove adapter (3) and filter Illustration 181 g01113975
housing (2) from housing (11). Remove the O-ring
seal from the adapter.
4. Remove bolts (12). Remove housing support (6)
from housing (11). Remove the O-ring seals from Improper assembly of parts that are spring
loaded can cause bodily injury.
the housing. If necessary, remove the dowels from
the housing. To prevent possible injury, follow the established
assembly procedure and wear protective
5. Remove bolts (4) and cover (5). Remove spring equipment.
(13) and bypass valve (14) from the housing.
1. Install bypass valve (14) and spring (13) in housing
(11).
Note: The bypass valve must move freely in the
bore.

2. Install the O-ring seal on cover (5). Install cover (5)

and bolts (4).
3. Install the O-ring seal on cover (10). Install cover
(10) and bolts (9).
4. If necessary, install the dowels in housing (11). The
dowels must be 6.50 ± 1.00 mm
(0.256 ± 0.040 inch) above the surface of the
housing.
KENR6055-14 73
Disassembly and Assembly Section

5. Install the O-ring seals on housing (11). Install

housing support (6) on housing (11). Install bolts
(12) and tighten to a torque of 55 ± 7 N·m
(41 ± 5 lb ft).
6. Install the O-ring seal on adapter (3). Install filter
housing (2) and adapter (3) on housing (11). Install
bolts (8) and tighten to a torque of 55 ± 7 N·m
(41 ± 5 lb ft).
7. Install new engine oil filter elements in filter
housing (2).
8. If necessary, install the dowel in cover (7). The
dowel must be 6.50 ± 1.00 mm
(0.256 ± 0.040 inch) above the surface of the Illustration 182 g01113831
cover.
9. Install the O-ring seal on cover (7). Install cover (7) 1. Attach a suitable lifting device on oil filter housing
and bolts (1). support (11). The weight of oil filter housing
support (11) is approximately 70 kg (155 lb).
End By: Position oil filter housing support (11) and install
a. Install the engine oil filter housing. Refer to bolts (10).
Disassembly and Assembly, “Engine Oil Filter 2. Install Tooling (A) and a suitable lifting device on
Housing - Install”.
engine oil filter housing (9). The weight of engine
oil filter housing (9) is approximately 35 kg (77 lb).
i06715388
Position engine oil filter housing (9) and install
Engine Oil Filter Housing - bolts (8). Remove Tooling (A).

Install
SMCS Code: 1306-012

Installation Procedure
Table 21
Required Tools

Tool Part Number Part Description Qty

A 138-7573 Link Bracket 2

NOTICE
Keep all parts clean from contaminants.
Illustration 183 g01113751
Contaminants may cause rapid wear and shortened
component life. 3. Position plate (7) and install bolts (6).
4. Install spacers (5) and bolts (4) to secure tube
assembly (3).
74 KENR6055-14
Disassembly and Assembly Section

1. Drain the engine oil into a suitable container for

storage or for disposal. Refer to Operation and
Maintenance Manual, “Engine Oil and Filter -
Change”.

Illustration 184 g01113749

5. Install the O-ring seal on adapter (2). Install the

adapter and install bolts (1).
6. Disconnect the oil pressure sensors. Illustration 185 g01123595

7. Check the oil level. Maintain the oil level at the

2. Remove bolts (1) that hold the connector for the
“FULL” mark. Refer to Operation and Maintenance
engine oil pump to engine oil pan (2).
Manual, “Engine Oil and Filter - Change” for the
correct filling procedure.
End By:
a. Install the fuel filter housing. Refer to
Disassembly and Assembly, “Fuel Filter
Housing - Install”.

i02485311

Engine Oil Pan - Remove

SMCS Code: 1302-011

Removal Procedure
Illustration 186 g01123597
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte- 3. Remove bolts (3) that connect engine oil pan (2) to
nance, testing, adjusting, and repair of the product. the cylinder block.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Refer to Special Publication, PERJ1017, “Dealer
Service Tool Catalog” for tools and supplies suitable
to collect and contain fluids on Cat ® products.
Dispose of all fluids according to local regulations
and mandates.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
KENR6055-14 75
Disassembly and Assembly Section

Illustration 187 g01123599 Illustration 188 g01123600

6. Remove oil pan gasket (4) from the engine oil pan.
Remove O-ring seal (5). Remove bolts (6).
Improper lift rigging can allow unit to tumble Remove flange (7) from the engine oil pan.
causing injury and damage. Remove seal (8) from the flange.

4. Attach a suitable lifting device to the engine lifting i02282781

eyes.
Engine Oil Pan - Disassemble
• The weight of the 3508C Engine is
approximately 4535 kg (10000 lb). The weight SMCS Code: 1302-015
of the engine oil pan is approximately 240 kg
(530 lb). Disassembly Procedure
• The weight of the 3512C Engine is Start By:
approximately 6800 kg (15000 lb). The weight
a. Remove the engine oil pan. Refer to
of the engine oil pan is approximately 295 kg Disassembly and Assembly, “Engine Oil Pan -
(650 lb). Remove”.
• The weight of the 3516C Engine is NOTICE
approximately 9100 kg (20000 lb). The weight Keep all parts clean from contaminants.
of the engine oil pan is approximately 409 kg
(900 lb). Contaminants may cause rapid wear and shortened
component life.
5. Lift the engine from the engine oil pan.
76 KENR6055-14
Disassembly and Assembly Section

9. Remove bolts (19). Remove tube assembly (17)

from the engine oil pan. Remove the O-ring seals
from the tube assembly.
10. Remove drain plug (12). Remove the O-ring seal
from the drain plug.

i02282777

Engine Oil Pan - Assemble

SMCS Code: 1302-016

S/N: ML21–Up
S/N: BG31–Up
S/N: ML31–Up
S/N: T251–Up
S/N: PXA1–Up
S/N: TTA1–Up
Illustration 189 g01142529
S/N: DPB1–Up
1. Remove drain plug (7). Remove the O-ring seal
from the drain plug. S/N: PXB1–Up

2. Remove connector (1) and O-ring seal (2). S/N: TTB1–Up

3. Remove engine oil level gauge (3) and gasket (4). S/N: DPC1–Up

4. Remove cover (6) and O-ring seal (5). S/N: PXC1–Up

5. Remove adapter (11) and O-ring seal (10). S/N: TTC1–Up

6. Remove bolts (8). Remove suction screen S/N: DPD1–Up

assembly (9) from adapter (11). S/N: PXD1–Up
S/N: TTD1–Up
S/N: PXE1–Up
S/N: TTE1–Up
S/N: PAF1–Up
S/N: PXF1–Up
S/N: TTF1–Up
S/N: PXG1–Up
S/N: TTG1–Up
S/N: PXH1–Up

Illustration 190 g01142583 S/N: TTH1–Up

S/N: PXJ1–Up
7. Remove bolts (13) and clamp (14). Remove
suction tube (15). Remove the O-ring seal from S/N: TTJ1–Up
the suction tube. S/N: SLM1–Up
8. Remove bolts (16). Remove oil housing (18) from S/N: MXN1–Up
tube assembly (17).
S/N: MXP1–Up
S/N: JTS1–Up
KENR6055-14 77
Disassembly and Assembly Section

S/N: MXT1–Up 4. Install the O-ring seal on drain plug (12). Install
drain plug (12) and tighten to a torque of
S/N: E3W1–Up
145 ± 15 N·m (107 ± 11 lb ft).
S/N: FLW1–Up
S/N: PXW1–Up
S/N: TTW1–Up
S/N: E3X1–Up
S/N: PXX1–Up
S/N: E3Y1–Up
S/N: TTY1–Up
S/N: E3Z1–Up
S/N: PXZ1–Up
S/N: TTZ1–Up

Assembly Procedure
Table 22
Required Tools

Tool Part Number Part Description Qty

Illustration 192 g01142529
A 1P-0808 Multipurpose Grease -

5. Install suction screen assembly (9) on adapter

(11). Install bolts (8).
6. Install O-ring seal (10) and adapter (11) on the
engine oil pan.
7. Install O-ring seal (5) and cover (6) on the engine
oil pan.
8. Install gasket (4) and engine oil level gauge (3).
9. Install O-ring seal (2) and connector (1).
10. Install the O-ring seal on drain plug (7). Install
drain plug (7) and tighten to a torque of
145 ± 15 N·m (107 ± 11 lb ft).

Illustration 191 g01142583

1. Install the O-ring seals on tube assembly (17).

Apply Tooling (A) to the O-ring seals. Position tube
assembly in the engine oil pan. Install bolts (19)
and tighten to a torque of 47 ± 9 N·m (35 ± 7 lb ft).
2. Install oil housing (18) on tube assembly (17).
Install bolts (16) and tighten to a torque of
47 ± 9 N·m (35 ± 7 lb ft).
3. Install the O-ring seal on suction tube (15). Apply
Tooling (A) to the O-ring seal. Install suction tube
(15) into oil housing (18). Install clamp (14) and
bolts (13).
78 KENR6055-14
Disassembly and Assembly Section

End By:
a. Install the engine oil pan. Refer to Disassembly
and Assembly, “Engine Oil Pan - Install”.

i04999779

Engine Oil Pan - Install

SMCS Code: 1302-012

Installation Procedure
Table 23
Required Tools

Part Description Qty Illustration 194 g01123599

Tool Part Number
A - Loctite 595 -

B 1P-0808 Multipurpose Grease -

Guide Stud
Improper lift rigging can allow unit to tumble
C -
3/8 - 16 by 5 inch
4 causing injury and damage.

4. Attach a suitable lifting device to the engine lifting

NOTICE eyes.
Keep all parts clean from contaminants.
• The weight of the 3508C Engine is
Contaminants may cause rapid wear and shortened approximately 4535 kg (10000 lb). The weight
component life. of the engine oil pan is approximately 240 kg
(530 lb).
1. Clean the sealing surfaces of the engine oil pan
• The weight of the 3512C Engine is
and the cylinder block.
approximately 6800 kg (15000 lb). The weight
of the engine oil pan is approximately 295 kg
(650 lb).

• The weight of the 3516C Engine is

approximately 9100 kg (20000 lb). The weight
of the engine oil pan is approximately 409 kg
(900 lb).

5. Lift the engine. Place the engine onto the engine

oil pan.

Illustration 193 g01123600

2. Apply Tooling (A) to oil pan gasket (4). Install the

oil pan gasket on the engine oil pan. Install Tooling
(C) in the engine oil pan.
3. Apply Tooling (B) to the bore of flange (7). Install
seal (8) inside flange (7). Position the flange and
install bolts (6). Install O-ring seal (5) on the
flange.
KENR6055-14 79
Disassembly and Assembly Section

Illustration 195 g01123597 Illustration 197 g01057823

6. Install bolts (3). Remove Tooling (C) from engine 1. Loosen clamp (2). Remove the clamp and tube (3).
oil pan (2) and install remaining bolts (3).
2. Loosen clamps (4). Remove both breathers (1) as
a unit.

Illustration 196 g01123595

Illustration 198 g01057824

7. Install bolts (1) that hold the connector for the
engine oil pump to engine oil pan (2).
3. Remove O-ring seals (5) from the valve covers.
8. Fill the engine oil pan to the correct level that is Discard the O-ring seals.
indicated on the engine oil level gauge. Refer to
Operation and Maintenance Manual, “Engine Oil
and Filter - Change”.

i01932610

Crankcase Breather - Remove

and Install
SMCS Code: 1317-010

Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Illustration 199 g01057825
Contaminants may cause rapid wear and shortened
component life. 4. Remove clamps (6). Remove both breathers (1)
from tee assembly (7).
80 KENR6055-14
Disassembly and Assembly Section

Inspect the tee assembly for cracks. If the tee

assembly is cracked, discard the old tee assembly
and obtain a new tee assembly for installation.
5. Turn the breathers upside-down in order to inspect
the condition of the breather elements.
Clean the breather elements with clean,
nonflammable solvent. If the breather elements
remain contaminated after the cleaning, discard
the breathers and obtain new breathers. Do not
attempt to disassemble the breathers.
Allow the breather elements to dry before
installation.

Installation Procedure Illustration 201 g01057824

NOTICE 2. Coat new O-ring seals (5) with clean engine oil.
Keep all parts clean from contaminants. Place the O-ring seals on the valve covers.

Contaminants may cause rapid wear and shortened

component life.

Illustration 202 g01057823

3. Place clamps (4) around the parts of the breathers

that will be attached to the valve covers. Install
Illustration 200 g01057825
both breathers (1) as a unit. Tighten the clamps.
Note: Coat the rubber parts with clean engine oil or
petroleum jelly in order to make installation easier.

1. Place clamps (6) over the parts of tee assembly (7)

that will receive breathers (1). Install breathers (1)
into the tee assembly. Tighten the clamps to a
torque of 3.0 ± 0.5 N·m (27 ± 4 lb in).
KENR6055-14 81
Disassembly and Assembly Section

4. Place clamp (2) on the part of the tee assembly 5. Remove bolts (7). Remove fumes disposal group
that will receive tube (3). Install the tube. Tighten (4).
the clamp to a torque of 3.0 ± 0.5 N·m
(27 ± 4 lb in). Installation Procedure
i02704963 NOTICE
Keep all parts clean from contaminants.
Fumes Filter - Remove and Contaminants may cause rapid wear and shortened
Install component life.

SMCS Code: 1317-010

Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem- Illustration 204 g01357042
bling any component containing fluids.
1. Position fumes disposal group (4) on the engine
Refer to Special Publication, PERJ1017, “Dealer and install bolts (7).
Service Tool Catalog” for tools and supplies suitable
to collect and contain fluids on Cat ® products. 2. Apply a light coat of glycerin to the O-ring seal and
install connector (5).
Dispose of all fluids according to local regulations
and mandates. 3. Connect the hose and install clamp (6). Tighten
clamp (6) to a torque of 3.0 ± 0.5 N·m
(27 ± 4 lb in).
4. Apply a light coat of glycerin to the O-ring seal and
install stem assembly (1).

Illustration 203 g01357042

1. Loosen clamp (3) and disconnect hose (2).

2. Remove stem assembly (1), if necessary.
3. Loosen clamp (6) and disconnect the hose.
4. Remove connector (5), if necessary.
82 KENR6055-14
Disassembly and Assembly Section

5. Connect hose (2) and install clamp (3). Tighten 2. Install valve mechanism cover (2). Install bolts (1).
clamp (3) to a torque of 3.0 ± 0.5 N·m
(27 ± 4 lb in). i06703315

i02706053 Valve Mechanism Cover Base -

Valve Mechanism Cover - Remove and Install
Remove and Install SMCS Code: 1120-010

SMCS Code: 1107-010 Removal Procedure

Start By:
Removal Procedure
a. Remove the electronic unit injectors. Refer to
Disassembly and Assembly, “Electronic Unit
Injector - Remove”.

Illustration 205 g01119199

1. Remove bolts (1). Remove valve mechanism Illustration 207 g01052887

cover (2).
1. Remove tube assemblies (1).
2. Remove the seal from the valve mechanism cover.
2. Remove bolts (2) (not shown) and valve
Installation Procedure mechanism cover base (3).

Installation Procedure
Table 24
Required Tools

Tool Part Number Part Description Qty

A Loctite 243 -

Illustration 206 g01119199

1. Install the seal on the valve mechanism cover.

KENR6055-14 83
Disassembly and Assembly Section

S/N: TTE1–Up
S/N: PAF1–Up
S/N: PXF1–Up
S/N: TTF1–Up
S/N: PXG1–Up
S/N: TTG1–Up
S/N: PXH1–Up
S/N: TTH1–Up
S/N: PXJ1–Up

Illustration 208 g01052887

S/N: TTJ1–Up
S/N: SLM1–Up
1. Position valve mechanism cover base (3). Apply
Tooling (A) to the threads of bolts (2) (not shown) S/N: MXN1–Up
and install bolts (2) (not shown). S/N: MXP1–Up
2. Install tube assemblies (1). S/N: JTS1–Up
End By: S/N: MXT1–Up
a. Install the electronic unit injectors. Refer to S/N: E3W1–Up
Disassembly and Assembly, “Electronic Unit
Injector - Install”. S/N: FLW1–Up
S/N: PXW1–Up
i02315452
S/N: TTW1–Up
Rocker Shaft and Pushrod - S/N: E3X1–Up
Remove S/N: PXX1–Up
SMCS Code: 1102-011; 1208-011 S/N: E3Y1–Up
S/N: ML21–Up S/N: TTY1–Up
S/N: BG31–Up S/N: E3Z1–Up
S/N: ML31–Up S/N: PXZ1–Up
S/N: T251–Up S/N: TTZ1–Up
S/N: PXA1–Up
Removal Procedure
S/N: TTA1–Up
Start By:
S/N: DPB1–Up
a. Remove the valve mechanism cover. Refer to
S/N: PXB1–Up Disassembly and Assembly, “Valve
Mechanism Cover - Remove and Install”.
S/N: TTB1–Up
S/N: DPC1–Up NOTICE
Keep all parts clean from contaminants.
S/N: PXC1–Up
Contaminants may cause rapid wear and shortened
S/N: TTC1–Up component life.

S/N: DPD1–Up
S/N: PXD1–Up
S/N: TTD1–Up
S/N: PXE1–Up
84 KENR6055-14
Disassembly and Assembly Section

Start By:
a. Remove the rocker shaft assembly. Refer to
Disassembly and Assembly, “Rocker Shaft and
Pushrod - Remove”.

Illustration 209 g01119693

1. Remove bolts (1). Remove rocker shaft assembly

(2) from valve mechanism cover base (6). Remove
valve pushrods (4).
Illustration 210 g01120055
Note: Mark the valve pushrods for identification of
location for assembly. 1. Slide shaft (2) out of rocker arm (1). If necessary,
remove spring pin (3) from the shaft.
2. Remove bridge assemblies (3) from the valve
stems.

Note: Mark the bridge assemblies with identification

of location for assembly.

3. To remove pushrod (5), it is necessary to remove

valve mechanism cover base (6).

i02315619

Rocker Shaft - Disassemble

SMCS Code: 1102-015

Disassembly Procedure
Illustration 211 g01120059
Table 25
Required Tools 2. Remove jam nut (4) from adjustment screw (6).
Remove the adjustment screw from rocker arm
Tool Part Number Part Description Qty
(1).
A 1P-0510 Driver Group 1
3. Remove button (9) from socket (7). Remove
retaining ring (8) from button (9).
4. Use a hammer and a punch to remove socket (7)
from rocker arm (1).
KENR6055-14 85
Disassembly and Assembly Section

5. Use Tooling (A) to remove sleeve bearing (5) from

the rocker arm.

i02706144

Rocker Shaft - Assemble

SMCS Code: 1102-016

Assembly Procedure
Table 26
Required Tools

Tool Part Number Part Description Qty

Illustration 213 g01120055
A 1P-0510 Driver Group 1

5. If spring pin (3) was removed from shaft (2), install

a new spring pin. Position the split in spring pin (3)
toward the end of shaft (2) and press the spring
pin into the shaft.
6. Apply clean engine oil to the sleeve bearing of
rocker arm (1) and to shaft (2). Install the rocker
arm on the shaft.
End By:
a. Install the rocker shaft assembly. Refer to
Disassembly and Assembly, “Rocker Shaft and
Pushrod - Install”.

i07085947

Illustration 212 g01120089 Rocker Shaft and Push Rods -

1. The sleeve bearing and the rocker arm have oil Install
supply holes. The holes must be aligned when the
SMCS Code: 1102-012
sleeve bearing is installed in the rocker arm. Align
the joint of the sleeve bearing toward the top of the
rocker arm. Align the oil hole in the sleeve bearing Installation Procedure
with the oil hole in the rocker arm. Use Tooling (A)
to install sleeve bearing (5) in rocker arm (1). NOTICE
Keep all parts clean from contaminants.
2. Align the scribe mark on socket (7) with the center
Contaminants may cause rapid wear and shortened
line of rocker arm (1). Press socket (7) fully into component life.
rocker arm (1).
3. Place retaining ring (8) on button (9). Install button
(9) in socket (7).
4. Install adjustment screw (6) in rocker arm (1).
Install jam nut (4) on the adjustment screw.
86 KENR6055-14
Disassembly and Assembly Section

Illustration 214 g01119759

1. Loosen jam nut (8) and adjustment screw (7).

Loosen jam nut (10) and adjustment screw (9).

Illustration 217 g01946786

Floating valve bridge
(X) Round pocket
(Y) Slotted pocket
(Z) Outside of engine

2. Apply clean engine oil to pushrod (5).

3. Apply clean engine oil to valve pushrods (4), and
the cup of the valve lifters. Install valve pushrods
(4) in the original location.
4. Valve bridge assemblies for dowel installations
have an adjustment screw and a jam nut. Use the
Illustration 215 g01131377
following procedure to install this configuration.
a. Loosen adjustment screw (11) and jam nut (12)
on bridge assembly (3).
b. Coat these items with clean engine oil: the
dowels, the receptacle of the bridge assembly
for the dowels and the uppermost contact
surface of bridge assembly (3).
c. Place bridge assembly (3) into position on the
dowel. Apply a downward force of 5 to 45 N
(1 to 10 lb) on the uppermost contact surface of
bridge assembly (3). While you apply the force,
turn adjustment screw (11) until the adjustment
screw contacts the valve stem.
d. Turn the adjustment screw for an additional 20
Illustration 216 g01158612
to 30 degrees (1/3 to 1/2 of the hex).
Valve bridge for dowel installations
e. Hold the adjustment screw in position and
tighten jam nut (12) to a torque of 30 ± 4 N·m
(22 ± 3 lb ft).
5. For floating valve bridge assemblies, use the
following procedure.
KENR6055-14 87
Disassembly and Assembly Section

a. Apply clean engine oil to the contact surface of 8. Adjust the electronic unit injector lash according to
bridge assemblies (3) and the valve stems. Testing and Adjusting, “Fuel Injector Adjustment”.
Install bridge assemblies (3) on the valve Hold adjustment screw (9) of the rocker arm
stems. assembly and tighten nut (10). If nut (10) is 5/8
inch thread, tighten to a torque of 120 ± 15 N·m
b. Install the bridge assemblies with the round
(89 ± 11 lb ft). If nut (10) is 1/2 inch thread, tighten
pocket toward the outside of the engine. Refer
to a torque of 70 ± 15 N·m (52 ± 11lb ft).
to Illustration 217 .
End By:
NOTICE
Ensure that the crankshaft and the camshafts are in a. Install the valve mechanism cover.
time with each other. Also ensure that the adjustment
screws in the rocker arms are loosened completely i02242680
before the bolts on the rocker shaft are tightened or
damage to the valves and the pistons may occur. Electronic Unit Injector -
Remove
NOTICE
If the rocker shaft is not positioned correctly, the oil SMCS Code: 1290-011
supply to the sleeve bearings in the rocker arm will
be shut off. This will cause seizure of the bearings Removal Procedure
and severe damage to the engine.
Table 27
Be sure to orient the rocker shaft in the correct Required Tools
position.
Tool Part Number Part Description Qty

6. Place rocker shaft assembly (2) in position on A 5F-4764 Pry Bar 1

valve mechanism cover base (6). Make sure that
valve pushrods (4) and pushrod (5) are aligned Start By:
with the rocker arms. Install bolts (1). Tighten the
bolts evenly to a torque of 215 ± 40 N·m a. Remove the rocker shaft assembly. Refer to
(160 ± 30 lb ft). Disassembly and Assembly, “Rocker Shaft and
Pushrod - Remove”.
Note: The rocker shaft dowel must be located on the
left-hand side of the rocker shaft when installed. NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Refer to Special Publication, PERJ1017, “Dealer
Service Tool Catalog” for tools and supplies suitable
to collect and contain fluids on Cat ® products.
Dispose of all fluids according to local regulations
and mandates.

NOTICE
Keep all parts clean from contaminants.
Illustration 218 g01119849
Contaminants may cause rapid wear and shortened
component life.
7. Adjust the valve lash according to Testing and
Adjusting, “Valve Lash and Valve Bridge
Adjustment”. Hold adjustment screw (7) of the
rocker arm assembly and tighten jam nut (8) to a
torque of 70 ± 15 N·m (52 ± 11 lb ft).
88 KENR6055-14
Disassembly and Assembly Section

7. Remove all fuel / liquid from the cylinder.

WARNING! Turning over (cranking) an engine with
an injector removed could result in personal injury
or death from fluids escaping through the injector
bore at high velocity.

i06601862

Electronic Unit Injector - Install

SMCS Code: 1290-012

Installation Procedure
Table 28
Illustration 219 g01130566
Required Tools

1. Disconnect harness assembly (2) from electronic Tool Part Number Part Description Qty
unit injector (5). B 9U-6862 Tapered Brush 1
2. Remove bolt (1) and electronic unit injector clamp C 4C-5027 Tap Wrench 1
(3).
D 4C-6774 Vacuum Gun Kit 1
3. Remove plug (4) from the cylinder head.
E 452-6011 Multipurpose Grease -
4. Place an identification mark on the electronic unit
injector for installation purposes. Each electronic
unit injector must be reinstalled in the original NOTICE
location in the cylinder head. Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Illustration 221 g01130613

1. Use Tooling (B) to clean the bore for the electronic

Illustration 220 g01130569 unit injector in the cylinder head. Hold Tooling (B)
with Tooling (C). Rotate Tooling (B) against
5. Use Tooling (A) to remove electronic unit injector Surface (X) of the bore. Continue cleaning until
(5) from the cylinder head. Surface (X) is smooth and shiny.
6. Remove O-ring seal (6) and O-ring seal (7) from 2. Use Tooling (D) to remove the fuel from the
the electronic unit injector. cylinder. Evacuate as much fuel as possible from
the cylinder before installing the electronic unit
injector. Several evacuations may be necessary.
KENR6055-14 89
Disassembly and Assembly Section

Illustration 222 g01130615 Illustration 223 g01130566

3. Install O-ring seal (6) and O-ring seal (7) on the 6. Install plug (4) in the cylinder head.
electronic unit injector.
7. Install electronic unit injector clamp (3) and bolt (1).
4. Apply Tooling (E) to the bore of the cylinder head Tighten bolt (1) in order to seat electronic unit
for the electronic unit injector. injector (5) in the cylinder head. Do not strike the
electronic unit injector. Tighten bolt (1) to a torque
NOTICE of 65 ± 7 N·m (48 ± 5 lb ft).
When an electronic unit injector is replaced, the new
electronic injector code must be programmed into the 8. Connect harness assembly (2). Tighten the
engine's personality module software by using the terminal nuts to a torque of 2.5 ± 0.25 N·m
calibration menu on the Electronic Service Tool. If the (22 ± 2 lb in).
new electronic injector code is not entered, the char-
acteristics of the previous electronic unit injector is End By:
assumed.
a. Install the rocker shaft assembly. Refer to
If it is not possible to immediately reprogram the elec- Disassembly and Assembly, “Rocker Shaft and
tronic injector code into the personality module soft- Pushrod - Install”.
ware, the engine will not be severely harmed. The
new electronic injector code should be reprog- i02486391
rammed as quickly as possible in order to optimize
engine performance.
Cylinder Head - Remove
5. Position electronic unit injector (5) into the original SMCS Code: 1100-011
location in the cylinder head. Center the solenoid
between the valve springs. Press the electronic Removal Procedure
unit injector into the cylinder head. Do not strike Table 29
the electronic unit injector.
Required Tools

Tool Part Number Part Description Qty

A 138-7573 Link Bracket 2

90 KENR6055-14
Disassembly and Assembly Section

Start By: 4. Install Tooling (A) and a suitable lifting device on

cylinder head (8). The weight of cylinder head (8)
a. Remove the valve mechanism cover base. is approximately 47 kg (104 lb).
Refer to Disassembly and Assembly, “Valve
Mechanism Cover Base - Remove and Install”. 5. Remove cylinder head (8). Remove cylinder head
gasket (9).
NOTICE
Care must be taken to ensure that fluids are con- 6. Remove gasket (5) from the inlet tube assembly.
tained during performance of inspection, mainte- Remove gasket (2) from the exhaust tube
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain- assembly.
ers before opening any compartment or disassem-
bling any component containing fluids.
Refer to Special Publication, PERJ1017, “Dealer
Service Tool Catalog” for tools and supplies suitable
to collect and contain fluids on Cat ® products.
Dispose of all fluids according to local regulations
and mandates.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

1. Drain the coolant from the cooling system into a

suitable container for storage or for disposal. Refer
to Operation and Maintenance Manual, “Cooling
System Coolant - Change”.

Illustration 225 g01121095

7. Remove seals (10). Remove seals (11). Remove

O-ring seal (13).
8. Remove spacer plate (12). Remove gasket (14).
Remove O-ring seal (15) from the dowel.

i07511232

Cylinder Head - Install

SMCS Code: 1100-012

Installation Procedure
Table 30
Required Tools

Tool Part Number Part Description Qty

A 439-3938 Link Bracket 2

Illustration 224 g01120972

2. Remove tube (1). Remove the O-ring seal and the NOTICE
integral seal from the tube. Remove bolts (3) from Keep all parts clean from contaminants.
exhaust tube assembly. Remove bolts (4) from Contaminants may cause rapid wear and shortened
inlet tube assembly. component life.
3. Remove bolts (7). Remove bolts (6).
KENR6055-14 91
Disassembly and Assembly Section

1. Ensure that the spacer plate and the surface of the

cylinder block are clean.

Illustration 228 g01053977

4. Install spacer plate (12) on the dowels.

Illustration 226 g01053983
5. Check the cylinder liner projection. Refer to Testing
2. Install the O-ring seal on dowel (14). and Adjusting, “Cylinder Liner Projection” for the
correct procedure.

Illustration 227 g01053978

Illustration 229 g01053975

NOTICE
Ensure that the surface of the spacer plate gasket 6. Install new seals (9) and (10) in the spacer plate.
and the surface of the cylinder block are clean. Do
not use a gasket adhesive on these surfaces. 7. Install a new O-ring seal (11) on the dowel.
8. Ensure that the bottom of the cylinder head
3. Install a new gasket (13) on the dowels in the assembly is thoroughly clean.
cylinder block.
92 KENR6055-14
Disassembly and Assembly Section

Illustration 230 g00618255

NOTICE
The plug for Location (C) MUST be installed in the
cylinder head.

Illustration 232 g06344184

9. Install Tooling (A) into the threaded holes for the
valve cover base in the cylinder head. Attach a
suitable lifting device to Tooling (A). 11. Tightening sequence with 362-8264 Cylinder
Head Gasket (MLS) and 519-7297 Spacer
Plate (Iron).

Note: Refer to Illustration 232 for the correct

tightening sequence.

a. Coat the threads of the bolts with clean engine

oil.
b. Tighten bolt (1) through bolt (8) to a torque of
30 ± 5 N·m (22 ± 4 lb ft).
c. Tighten bolt (1) through bolt (8) to a torque of
145 ± 15 N·m (107 ± 11 lb ft).
d. Tighten bolt (1) through bolt (8) to a torque of
145 ± 15 N·m (107 ± 11 lb ft).
Illustration 231 g01053935
e. Turn bolt (1) through bolt (8) an angle of 180 ± 5
Note: The weight of cylinder head assembly (7) is degrees.
approximately 47 kg (104 lb). f. Tighten bolts (9) and (10) to a torque of
55 ± 10 N·m (40 ± 7 lb ft).
10. Install a new head gasket (8). Lift cylinder head
assembly (7) into position on the cylinder block.
Install bolts (6) and (1) according to the
instructions in Step 11, Step 12, or Step 13.
Note: Only 216 mm (8.5 inch) bolts (6) can be used
for the following torque procedures.
Note: Refer to Specifications, “Cylinder Head”.
KENR6055-14 93
Disassembly and Assembly Section

Illustration 233 g06344184 Illustration 234 g06344229

12. Tightening sequence with 362-8264 Cylinder 13. Tightening sequence with 110-6991 Cylinder
Head Gasket (MLS) and 110-6994 Spacer Head Gasket (Cellulose) and 110-6994
Plate (Aluminum) or 362-9677 Spacer Plate Spacer Plate (Aluminum) or 362-9677 Spacer
(Aluminum). Plate (Aluminum).

Note: Refer to Illustration 233 for the correct Note: The cellulose head gasket cannot be used with
tightening sequence. an iron spacer plate.

a. Coat the threads of the bolts with clean engine Note: Refer to Illustration 234 for the correct
oil. tightening sequence.
b. Tighten bolt (1) through bolt (8) to a torque of a. Tighten bolt (1) through bolt (8) to a torque of
30 ± 5 N·m (22 ± 4 lb ft). 30 ± 5 N·m (22 ± 4 lb ft).
c. Tighten bolt (1) through bolt (8) to a torque of b. Tighten bolt (1) through bolt (8) to a torque of
100 ± 15 N·m (75 ± 11 lb ft). 200 ± 15 N·m (148 ± 11 lb ft).
d. Tighten bolt (1) through bolt (8) to a torque of c. Tighten bolt (1) through bolt (8) again to a
450 ± 15 N·m (332 ± 11 lb ft). torque of 200 ± 15 N·m (148 ± 11 lb ft).
e. Loosen bolt (1) through bolt (8) an angle of 90 d. Turn bolt (1) through bolt (8) to an angle of 180
degrees. degrees.
f. Tighten bolt (1) through bolt (8) to a torque of e. Tighten bolt (9) and bolt (10) to a torque of
490 ± 15 N·m (361 ± 11 lb ft). 55 ± 10 N·m (41 ± 7 lb ft).
g. Tighten bolt (9) and bolt (10) to a torque of 14. Remove Tooling (A) from the cylinder head.
55 ± 10 N·m (40 ± 7 lb ft).
94 KENR6055-14
Disassembly and Assembly Section

End By:
a. Install the valve cover base.

i02486600

Inlet and Exhaust Valve

Springs - Remove and Install
SMCS Code: 1108-010

Removal Procedure
Table 31
Required Tools
Illustration 235 g01053859
Tool Part Number Part Description Qty
15. Install four bolts (4) (not shown) on exhaust tube A 241-0124 Valve Spring Compressor 1
assembly and install four bolts (5) (not shown) on
inlet tube assembly. B 4C-9496 Spring Tester 1

Start By:
a. Remove the rocker shaft and pushrods. Refer
to Disassembly and Assembly, “Rocker Shaft
and Pushrod - Remove”.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Note: Place the piston at the top of the compression

stroke (TC). Remove the valve springs for that
Illustration 236 g01053958
cylinder. If the valves fall into the cylinder liner, then
the cylinder head must be removed.
16. Position tube (3). Install bolts (2). 1. Position the No. 1 piston at the top center of the
17. Fill the cooling system. Refer to Operation and compression stroke. Refer to Testing and
Maintenance Manual, “Cooling System Coolant - Adjusting, “Finding Top Center Position for No. 1
Change”. Piston”.
KENR6055-14 95
Disassembly and Assembly Section

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

1. Lubricate the valve stems with clean engine oil.

Illustration 237 g01133502

Personal injury can result from being struck by

parts propelled by a released spring force.
Make sure to wear all necessary protective
equipment. Illustration 238 g01133502

Follow the recommended procedure and use all

recommended tooling to release the spring force.

2. Install Tooling (A) on valve mechanism cover base Improper assembly of parts that are spring
(6). loaded can cause bodily injury.

3. Use Tooling (A) to compress inner valve spring (3) To prevent possible injury, follow the established
and outer valve spring (4). Remove valve spring assembly procedure and wear protective
keepers (1) from the valve. equipment.

4. Carefully remove Tooling (A). 2. Position washer (5), inner valve spring (3), and
outer valve spring (4) on the exhaust valve guide.
5. Remove valve rotator (2), inner valve spring (3),
and outer valve spring (4). 3. Position inner valve spring (3) and outer valve
spring (4) on the inlet valve guide.
6. Remove washer (5) from the exhaust valve guide.
Note: Washer (5) is not installed on the inlet valve
Note: Washers are not installed on the inlet valve
guides.
guide.
4. Position valve rotator (2) on the valve stem.
7. Use Tooling (B) to check the valve springs (spring
force). Refer to Specifications, “Cylinder Head 5. Install Tooling (A) on valve mechanism cover base
Valves” for additional information on the valve (6).
springs.
6. Use Tooling (A) to compress inner valve spring (3)
Installation Procedure and outer valve spring (4). Install valve spring
Table 32
keepers (1) on the valve. Ensure that the valve
spring keepers are properly installed.
Required Tools

Tool Part Number Part Description Qty

A 241-0124 Valve Spring Compressor 1

96 KENR6055-14
Disassembly and Assembly Section

The valve spring keepers can be thrown from the

valve when the valve spring compressor is re-
leased. Ensure that the valve spring keepers are
properly installed on the valve stem. To help pre-
vent personal injury, keep away from the front of
the valve spring keepers and valve springs dur-
ing the installation of the valves.

7. Carefully remove Tooling (A).

End By:
a. Install the rocker shaft and pushrods. Refer to
Disassembly and Assembly, “Rocker Shaft and
Pushrod - Install”. Illustration 239 g01134319

i02492601

Inlet and Exhaust Valves - Personal injury can result from being struck by
Remove and Install parts propelled by a released spring force.
Make sure to wear all necessary protective
SMCS Code: 1105-010 equipment.

Removal Procedure Follow the recommended procedure and use all

recommended tooling to release the spring force.
Table 33
Required Tools 1. Use Tooling (A) to compress inner valve spring (3)
Tool Part Number Part Description Qty and outer valve spring (4). Remove valve spring
keepers (1).
A 5S-1330 Valve Spring Compressor 1
2. Carefully remove Tooling (A).
B 4C-9496 Spring Tester 1
3. Remove valve rotator (2), inner valve spring (3)
and outer valve spring (4).
Start By:
4. Remove washer (5) from the exhaust valve guide.
a. Remove the cylinder head. Refer to
Disassembly and Assembly, “Cylinder Head - 5. Remove inlet valve (6) and exhaust valve (7 ) from
Remove”. the valve guides.

NOTICE Note: If the exhaust valves or the inlet valves will be

Keep all parts clean from contaminants. reused, put identification marks on the exhaust
valves and the inlet valves for installation purposes.
Contaminants may cause rapid wear and shortened
component life.
KENR6055-14 97
Disassembly and Assembly Section

Illustration 240 g01133465 Illustration 241 g01134256

6. Use Tooling (B) to check the valve springs (spring

force). Refer to Specifications, “Cylinder Head
Valves” for additional information on the valve Improper assembly of parts that are spring
springs. loaded can cause bodily injury.

Installation Procedure To prevent possible injury, follow the established

assembly procedure and wear protective
Table 34
equipment.
Required Tools

Part Description Qty

1. Apply clean engine oil to the stem of exhaust
Tool Part Number
valves (7). Install the exhaust valve into exhaust
A 5S-1330 Valve Spring Compressor 1 valve guide (10).
2. Install washer (5), inner valve spring (3), and outer
NOTICE valve spring (4) on exhaust valve guide (10).
Keep all parts clean from contaminants.
3. Position valve rotator (2) on the stem of the
Contaminants may cause rapid wear and shortened exhaust valve.
component life.
4. Use Tooling (A) to compress inner valve spring (3)
and outer valve spring (4). Install valve spring
keepers (1) on the exhaust valve.

The valve spring keepers can be thrown from the

valve when the valve spring compressor is re-
leased. Ensure that the valve spring keepers are
properly installed on the valve stem. To help pre-
vent personal injury, keep away from the front of
the valve spring keepers and valve springs dur-
ing the installation of the valves.

5. Carefully remove Tooling (A). Strike the top of the

valves with a soft faced hammer in order to ensure
that valve spring keepers (1) are properly installed
on the valve stems.
6. Apply clean engine oil to the stem of inlet valves
(6). Install the inlet valve into inlet valve guide.

Note: Ensure that valve stem seal (8) is installed on

inlet valve guide (9).
98 KENR6055-14
Disassembly and Assembly Section

7. Install inner valve spring (3) and outer valve spring

(4) on inlet valve guide (9).
8. Position valve rotator (2) on the stem of the inlet
valve.
9. Use Tooling (A) to compress inner valve spring (3)
and outer valve spring (4). Install valve spring
keepers (1) on the inlet valve.

The valve spring keepers can be thrown from the

valve when the valve spring compressor is re-
leased. Ensure that the valve spring keepers are
properly installed on the valve stem. To help pre- Illustration 242 g01133624
vent personal injury, keep away from the front of
the valve spring keepers and valve springs dur-
ing the installation of the valves. 1. Remove valve stem seal (3) from inlet valve guide
(2).
10. Carefully remove Tooling (A). Strike the top of the
Note: The valve stem seal is not installed on exhaust
valves with a soft faced hammer in order to ensure valve guide (1).
that valve spring keepers (1) are properly installed
on the valve stems. 2. Turn the cylinder head upside-down. Use Tooling
End By: (A) and a hammer to remove the valve guides
from the cylinder head.
a. Install the cylinder head. Refer to Disassembly
and Assembly, “Cylinder Head - Install”. Installation Procedure
Table 36
i02492614
Required Tools

Inlet and Exhaust Valve Guides Tool Part Number Part Description Qty

- Remove and Install A 7M-3975 Valve Guide Driver 1

B 5P-1729 Valve Guide Bushing 1

SMCS Code: 1104-010

Removal Procedure Note: If you replace the valve guides, you must
replace the valve seats with new valve seats.
Table 35
Required Tools Note: Inspect the valve guides. Do not use valve
guides with obvious damage or with excessive wear.
Tool Part Number Part Description Qty
Check available specifications. Remove valve guides
A 7M-3975 Valve Guide Driver 1 that are loose or damaged. Replace the valve guides
with new components, if necessary. Correct any
condition that could cause the original damage or
Start By: wear.
a. Remove the inlet valves and the exhaust valves.
Refer to Disassembly and Assembly, “Inlet and NOTICE
Exhaust Valves - Remove and Install”. Keep all parts clean from contaminants.

NOTICE Contaminants may cause rapid wear and shortened

Keep all parts clean from contaminants. component life.

Contaminants may cause rapid wear and shortened

component life. Note: Use new valve guides for assembly.
KENR6055-14 99
Disassembly and Assembly Section

S/N: DPD1–Up
S/N: PXD1–Up
S/N: TTD1–Up
S/N: PXE1–Up
S/N: TTE1–Up
S/N: PAF1–Up
S/N: PXF1–Up
S/N: TTF1–Up
S/N: PXG1–Up

Illustration 243 g01133624

S/N: TTG1–Up
S/N: PXH1–Up
1. Coat the outside of the valve guide with clean
engine oil prior to installation. S/N: TTH1–Up

2. Use Tooling (A) and Tooling (B) to install exhaust S/N: PXJ1–Up
valve guide (1) and inlet valve guide (2) in the S/N: TTJ1–Up
cylinder head.
S/N: SLM1–Up
3. Install new valve stem seal (3) on inlet valve guide
(2). S/N: MXN1–Up
S/N: MXP1–Up
Note: Valve stem seals are not installed on exhaust
valve guide (1). S/N: JTS1–Up
End By: S/N: MXT1–Up
a. Install the inlet valves and the exhaust valves. S/N: E3W1–Up
Refer to Disassembly and Assembly, “Inlet and
Exhaust Valves - Remove and Install”. S/N: FLW1–Up
S/N: PXW1–Up
i02707237
S/N: TTW1–Up
Inlet and Exhaust Valve Seat S/N: E3X1–Up
Inserts - Remove and Install S/N: PXX1–Up
SMCS Code: 1103-010 S/N: E3Y1–Up
S/N: ML21–Up S/N: TTY1–Up
S/N: BG31–Up S/N: E3Z1–Up
S/N: ML31–Up S/N: PXZ1–Up
S/N: T251–Up S/N: TTZ1–Up
S/N: PXA1–Up Removal Procedure
S/N: TTA1–Up Table 37

S/N: DPB1–Up Required Tools

S/N: PXB1–Up Tool Part Number Part Description Qty

S/N: TTB1–Up A 166-7441 Valve Seat Extractor Tool 1

S/N: DPC1–Up
S/N: PXC1–Up
S/N: TTC1–Up
100 KENR6055-14
Disassembly and Assembly Section

Start By:
a. Remove the inlet valves and the exhaust valves.
Refer to Disassembly and Assembly, “Inlet and
Exhaust Valves - Remove and Install”.
Note: For information on the reusability of valve
seats, refer to Guideline For Reusable Parts And
Salvage Operation, SEBF8155.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Illustration 245 g01133494

1. Lower the temperature of valve seat inserts (2).

2. Use Tooling (B) to install valve seat inserts (2) in
cylinder head (1).
End By:
a. Install the inlet valves and the exhaust valves.
Refer to Disassembly and Assembly, “Inlet and
Exhaust Valves - Remove and Install”.

i02486937

Accessory Drive (Front) -

Illustration 244 g01133493 Remove
1. Use Tooling (A) to remove valve seat inserts (2)
(Engine Oil Pump and Water
from cylinder head (1). Pump)
2. Thoroughly clean the valve seat bores in the SMCS Code: 1207-011
cylinder head.

Installation Procedure Removal Procedure

Table 39
Table 38
Required Tools
Required Tools
Tool Part Number Part Description Qty
Tool Part Number Part Description Qty
Forcing Screw
B 1P-0510 Driver Gp 1 A - 2
3/8 - 16 by 1 1/2 inch

Forcing Screw
Note: Do not machine the prefinished valve seat B - 2
1/2 - 13 by 1 1/2 inch
inserts in order to correct the valve stem projection.
An excessive valve stem projection indicates that the
valve seat insert is not seated or material was not
cleaned from the bottom of the counterbore.
Note: If the valve seats are replaced, you must
replace the valve guides.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
KENR6055-14 101
Disassembly and Assembly Section

Start By: 4. Use Tooling (B) to remove pump adapter assembly

(5) from front housing (3). Remove the O-ring seal
a. Remove the auxiliary water pump. Refer to from the pump adapter assembly.
Disassembly and Assembly, “Auxilary Water
Pump - Remove”.
i02493585
b. Remove the engine oil pump. Refer to
Disassembly and Assembly, “Engine Oil Pump Accessory Drive (Front) -
- Remove”.
Remove
c. Remove the water pump. Refer to Disassembly
and Assembly, “Water Pump - Remove”. SMCS Code: 1207-011

NOTICE Removal Procedure

Keep all parts clean from contaminants.
Table 40
Contaminants may cause rapid wear and shortened Required Tools
component life.
Tool Part Number Part Description Qty

Forcing Screw
A - 2
1/2 - 13 by 1 1/2 inch

Start By:
a. Remove the alternator. Refer to Disassembly
and Assembly, “Alternator - Remove and
Install”.
b. Remove the electronic control module. Refer to
Disassembly and Assembly, “Electronic
Control Module - Remove and Install”.

NOTICE
Keep all parts clean from contaminants.
Illustration 246 g01132543 Contaminants may cause rapid wear and shortened
component life.
1. Remove bolts (2).
2. Use Tooling (A) to remove pump adapter assembly 1. Drain the coolant from the cooling system into a
(1) from front housing (3). Remove the O-ring seal suitable container for storage or for disposal. Refer
from the pump adapter assembly. to Operation and Maintenance Manual, “Cooling
System Coolant - Change”.

Illustration 247 g01132545

Illustration 248 g01125984
3. Remove bolts (4).
2. Remove adapter (5). Remove the gaskets from the
adapter.
102 KENR6055-14
Disassembly and Assembly Section

3. Remove bolts (3). Remove alternator pulley (1). Start By:

4. Remove bolts (2). Use Tooling (A) to remove a. Remove the accessory drive (front). Refer to
adapter assembly (4) from the front housing. Disassembly and Assembly, “Accessory Drive
Remove the O-ring seal from the adapter (Front) - Remove”.
assembly.
NOTICE
5. Remove the lip seal from adapter assembly (4). Keep all parts clean from contaminants.
6. Remove cover (7) from the adapter assembly. Contaminants may cause rapid wear and shortened
Remove the gasket from the cover. component life.
7. Remove bolts (6).

Illustration 250 g01126654

Illustration 249 g01126268

1. Remove O-ring seal (2) and O-ring seal (4) from

8. Remove adapter assembly (8), the shaft, and the adapter assembly (1).
drive gear as a unit from the drive housing.
Remove the O-ring seal from the adapter 2. Use Tooling (A) and a suitable press to remove
assembly. sleeve bearing (3).
3. If necessary, remove pipe plug (5).
i02234450

Accessory Drive (Front) -

Disassemble
SMCS Code: 1207-015

Disassembly Procedure
Table 41
Required Tools

Tool Part Number Part Description Qty

A 1P-0520 Driver Group 1

Illustration 251 g01126667

4. Remove O-ring seal (13) and O-ring seal (6) from

adapter assembly (12).
5. Remove bolts (10). Remove gear (9) from shaft
(15).
6. Remove bolts (8) and thrust washer (7).
7. Remove shaft (15) from adapter assembly (12).
KENR6055-14 103
Disassembly and Assembly Section

8. Use Tooling (A) and a suitable press to remove

sleeve bearing (14) from adapter assembly (12).
9. If necessary, remove pipe plug (11).

i02249939

Accessory Drive (Front) -

Disassemble
(Engine Oil Pump and Water
Pump)
SMCS Code: 1207-015
Illustration 253 g01132967
Disassembly Procedure
Table 42 3. Remove bolts (5).
Required Tools 4. Remove thrust washers (6) from pump adapter
assembly (4).
Tool Part Number Part Description Qty
5. Remove pump adapter assembly (4) from pump
A 1P-0520 Driver Group 1
drive shaft (7).

Start By:
a. Remove the accessory drive for the engine oil
pump and the water pump. Refer to
Disassembly and Assembly, “Accessory Drive
(Front) - Remove”.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Illustration 254 g01132971

6. Remove bolts (8).

7. Remove accessory drive gear (9) from pump drive
shaft (7).
8. If necessary, remove the socket setscrew from the
end of pump drive shaft (7).

Illustration 252 g01132964

1. Remove O-ring seal (3) from pump adapter

assembly (2).
2. Use Tooling (A) and a suitable press to remove
sleeve bearing (1) from pump adapter assembly
(2).
104 KENR6055-14
Disassembly and Assembly Section

Illustration 255 g01132974 Illustration 256 g01126667

9. Remove O-ring seal (11) and O-ring seal (12) from 1. Align the oil hole in sleeve bearing (14) and the oil
pump adapter assembly (4). hole in adapter assembly (12). Use Tooling (A)
and a suitable press to install sleeve bearing (14)
10. Use Tooling (A) and a suitable press to remove
into adapter assembly (12).
sleeve bearing (10) from pump adapter assembly
(4). 2. Install pipe plug (11) in adapter assembly (12).
3. Apply clean engine oil on sleeve bearing (14) and
i02234452
install shaft (15) in adapter assembly (12).
Accessory Drive (Front) - 4. Install thrust washer (7) and bolts (8).
Assemble 5. Position gear (9) on shaft (15) and install bolts
(10).
SMCS Code: 1207-016
6. Install O-ring seal (6) and O-ring seal (13) on
Assembly Procedure adapter assembly (12). Apply clean engine oil on
the O-ring seals.
Table 43
Required Tools

Tool Part Number Part Description Qty

A 1P-0520 Driver Group 1

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Illustration 257 g01126654

7. Align the oil hole in sleeve bearing (3) and the oil
hole in adapter assembly (1). Use Tooling (A) and
a suitable press to install sleeve bearing (3) into
adapter assembly (1).
8. Install O-ring seal (2) and O-ring seal (4) on
adapter assembly (1). Apply clean engine oil on
the O-ring seals.
9. Install pipe plug (5) in adapter assembly (1).
KENR6055-14 105
Disassembly and Assembly Section

End By:
a. Install the accessory drive (front). Refer to
Disassembly and Assembly, “Accessory Drive
(Front) - Install”.

i02249940

Accessory Drive (Front) -

Assemble
(Engine Oil Pump and Water
Pump)
SMCS Code: 1207-016
Illustration 259 g01133098

Assembly Procedure 3. Position accessory drive gear (9) on pump drive

Table 44 shaft (7). Install bolts (8).
Required Tools 4. If necessary, install socket setscrew (13) in the end
Part Description Qty
of pump drive shaft and tighten to a torque of
Tool Part Number
6 ± 1 N·m (53 ± 9 lb in).
A 1P-0520 Driver Group 1

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Illustration 260 g01133086

5. Install pump adapter assembly (4) onto pump drive

shaft (7).
6. Install thrust washer (6) and bolts (5).
7. Install O-ring seal (12) and O-ring seal (11) on
pump adapter assembly (4).
Illustration 258 g01133092

1. Align the oil hole in sleeve bearing (10) and the oil
hole in pump adapter assembly (4). Use Tooling
(A) and a suitable press to install sleeve bearing
(10) into pump adapter assembly (4).
Note: The sleeve bearing must not project above the
pump adapter assembly.

2. Apply clean engine oil to sleeve bearing (10).

106 KENR6055-14
Disassembly and Assembly Section

Illustration 261 g01132964 Illustration 262 g01132545

8. Align the oil hole in sleeve bearing (1) and the oil 1. Install the O-ring seal in pump adapter assembly
hole in pump adapter assembly (2). Use Tooling (5). Apply clean engine oil to the bore in front
(A) and a suitable press to install sleeve bearing housing (3) for pump adapter assembly (5).
(1) into pump adapter assembly (2).
2. Position pump adapter assembly (5) in the front
9. Install O-ring seal (3) on the pump adapter housing and install bolts (4).
assembly.
End By:
a. Install the accessory drive for the engine oil
pump and the water pump. Refer to
Disassembly and Assembly, “Accessory Drive
(Front) - Install”.

i02487020

Accessory Drive (Front) -

Install
(Engine Oil Pump and Water
Pump) Illustration 263 g01132543

SMCS Code: 1207-012

3. Install the O-ring seal in pump adapter assembly
(1). Apply clean engine oil to the bore in front
Installation Procedure housing (3) for pump adapter assembly (1).
NOTICE 4. Position pump adapter assembly (1) in the front
Keep all parts clean from contaminants. housing and install bolts (2).
Contaminants may cause rapid wear and shortened
component life.
KENR6055-14 107
Disassembly and Assembly Section

End By:
a. Install the water pump. Refer to Disassembly
and Assembly, “Water Pump - Install”.
b. Install the engine oil pump. Refer to
Disassembly and Assembly, “Engine Oil Pump
- Install”.
c. Install the auxiliary water pump. Refer to
Disassembly and Assembly, “Auxiliary Water
Pump - Install”.

i02493646

Accessory Drive (Front) -

Install Illustration 265 g01126268

SMCS Code: 1207-012 2. Install the O-ring seal on adapter assembly (8).
Apply clean engine oil to the O-ring seal. Install the
drive gear, the shaft, and adapter assembly (8) as
Installation Procedure a unit. Make sure that the teeth of the drive gear
Table 45
are properly aligned with the teeth of the drive
Required Tools gear for the oil pump and the water pump.
Tool Part Number Part Description Qty

B 1P-0520 Driver Gp 1

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Illustration 266 g01125984

3. Install bolts (6).

4. Install the gasket and cover (7) on the adapter
assembly.
5. Install the O-ring seal on adapter assembly (4).
Apply clean engine oil to the O-ring seal and the
lip seal. Install adapter assembly (4) on the front
housing and install bolts (2).
Illustration 264 g01142452
6. Position alternator pulley (1) on the auxiliary drive
1. Use Tooling (B) to install lip seal (9) in adapter shaft and install bolts (3).
assembly (4). 7. Install the gaskets and adapter (5).
8. Fill the cooling system with coolant. Refer to
Operation and Maintenance Manual, “Cooling
System Coolant - Change”.
108 KENR6055-14
Disassembly and Assembly Section

End By:
a. Install the electronic control module. Refer to
Disassembly and Assembly, “Electronic
Control Module - Remove and Install”.
b. Install the alternator. Refer to Disassembly and
Assembly, “Alternator - Remove and Install”.

i04188249

Housing (Front) - Remove

SMCS Code: 1151-011

Removal Procedure Illustration 267 g01246380

Table 46
Required Tools 1. Remove bolts and covers (1). Remove the gaskets
from front housing (2).
Tool Part Number Part Description Qty

1P-0074 Slide Hammer Puller 1

2. Remove bolts and cover (3). Remove the O-ring
A seal from the cover.
8B-7557 Threaded Adapter 1

B 138-7573 Link Bracket 2

C 1P-0520 Driver Group 1

Guide Stud
D - 2
5/8 - 11 by 8 inch

Start By:
a. Remove the engine oil filter housing. Refer to
Disassembly and Assembly, “Engine Oil Filter
Housing - Remove”.
b. Remove the crankshaft front seal and the wear
sleeve. Refer to Disassembly and Assembly,
“Crankshaft Front Seal and Wear Sleeve -
Remove”. Illustration 268 g01131889

c. If necessary, remove the accessory drive. Refer 3. Remove bolts (7). Use Tooling (A) to remove shaft
to Disassembly and Assembly, “Accessory
(4) from front housing (2). Remove O-ring seal (8)
Drive (Front) - Remove”.
from the shaft.
d. If necessary, remove the engine oil pump and
water pump drive. Refer to Disassembly and 4. Remove idler gear (5) and thrust washer (9) from
Assembly, “Accessory Drive (Front) - Remove”. the front housing.
5. Use Tooling (C) and a suitable press to remove
NOTICE sleeve bearing (6) from idler gear (5).
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
KENR6055-14 109
Disassembly and Assembly Section

S/N: PAF1–Up
S/N: PXF1–Up
S/N: TTF1–Up
S/N: PXG1–Up
S/N: TTG1–Up
S/N: PXH1–Up
S/N: TTH1–Up
S/N: PXJ1–Up
S/N: TTJ1–Up

Illustration 269 g01131907

S/N: SLM1–Up
S/N: MXN1–Up
6. Attach Tooling (B) and attach a suitable lifting
device to front housing (2). The weight of front S/N: MXP1–Up
housing (2) is approximately 181 kg (400 lb). S/N: JTS1–Up
Remove two bolts (10) and install Tooling (D).
Remove remaining bolts (10) that hold the front S/N: MXT1–Up
housing to the cylinder block. Remove the front S/N: E3W1–Up
housing.
S/N: FLW1–Up
7. Remove gasket (11) from the front housing and the
cylinder block. S/N: PXW1–Up
S/N: TTW1–Up
i04188291
S/N: E3X1–Up
Housing (Front) - Install S/N: PXX1–Up
SMCS Code: 1151-012 S/N: E3Y1–Up

S/N: ML21–Up S/N: TTY1–Up

S/N: BG31–Up S/N: E3Z1–Up

S/N: ML31–Up S/N: PXZ1–Up

S/N: T251–Up S/N: TTZ1–Up

S/N: PXA1–Up Installation Procedure

S/N: TTA1–Up Table 47
Required Tools
S/N: DPB1–Up
Tool Part Number Part Description Qty
S/N: PXB1–Up
B 138-7573 Link Bracket 2
S/N: TTB1–Up
C 1P-0520 Driver Group 1
S/N: DPC1–Up
Guide Stud
S/N: PXC1–Up D - 2
5/8 - 11 by 8 inch

S/N: TTC1–Up
S/N: DPD1–Up NOTICE
Keep all parts clean from contaminants.
S/N: PXD1–Up
Contaminants may cause rapid wear and shortened
S/N: TTD1–Up component life.
S/N: PXE1–Up
S/N: TTE1–Up
110 KENR6055-14
Disassembly and Assembly Section

Illustration 270 g01131907 Illustration 272 g01246380

1. Install gasket (11) on the cylinder block. Install 8. Install the O-ring seal in cover (3). Position cover
Tooling (D) into the cylinder block. (3) on front housing (2) and install the bolts.
2. Attach Tooling (B) and attach a suitable lifting 9. Position the gaskets and covers (1) on front
device to front housing (2). The weight of front housing (2) and install the bolts.
housing (2) is approximately 181 kg (400 lb). End By:
Position the front housing onto Tooling (D).
a. If necessary, install the engine oil pump and
3. Install bolts (10) that hold front housing (2) to the water pump drive. Refer to Disassembly and
cylinder block. Remove Tooling (D) and install Assembly, “Accessory Drive (Front) - Install”.
remaining bolts (10). Tighten the bolts evenly.
b. If necessary, install the accessory drive. Refer
4. Cut any excess gasket (11) from the bottom of the to Disassembly and Assembly, “Accessory
front housing. Drive (Front) - Install”.
c. Install the crankshaft front seal and the wear
sleeve. Refer to Disassembly and Assembly,
“Crankshaft Front Seal and Wear Sleeve -
Install”.
d. Install the engine oil filter housing. Refer to
Disassembly and Assembly, “Engine Oil Filter
Housing - Install”.

i06704985

Vibration Damper - Remove

and Install
SMCS Code: 1205-010
Illustration 271 g01131955

Removal Procedure
5. Use Tooling (C) to install sleeve bearing (6) in idler Table 48
gear (5).
Required Tools
6. Install O-ring seal (8) on shaft (4). Apply clean
engine oil to the bore in front housing (2) for the Tool Part Number Part Description Qty
shaft. A 138-7573 Lifting Bracket 2
7. Position thrust washer (9), idler gear (5), and shaft Guide Stud
B - 2
(4) in the front housing. Install bolts (7). 1 - 14 by 10 inch
KENR6055-14 111
Disassembly and Assembly Section

3. Install the vibration damper on Tooling (B). Install

bolts (1). Remove Tooling (B) and install remaining
bolts (1). Tighten bolts (1) to a torque of
1125 ± 100 N·m (820 ± 74 lb ft).
4. Remove Tooling (A). Apply Tooling (C) to the
threads of bolts (3). Install bolts (3) and tighten to
a torque of 55 ± 7 N·m (41 ± 5 lb ft).

i06616604

Crankshaft Front Seal and

Wear Sleeve - Remove
Illustration 273 g01137704 SMCS Code: 1160-011; 7558-011

1. Remove two bolts (1) and install Tooling (B). Removal Procedure
Table 50
2. Remove two bolts (3) and attach Tooling (A) and a
suitable lifting device to vibration damper (2). The Required Tools
weight of vibration damper (2) is approximately Tool Part Number Part Description Qty
175 kg (385 lb). Remove remaining bolts (1).
Remove vibration damper (2). A 1U-7600 Slide Hammer Puller 1

1U-7325 Distorter Adapter -

Installation Procedure B
6V-3143 Distorter Adapter(1) -
Table 49
Required Tools C 5P-7409 Sleeve Distorter 1
(1) For use with engines equipped with a seal adapter.
Tool Part Number Part Description Qty

A 138-7573 Lifting Bracket 2 Start By:

Guide Stud a. Remove the vibration damper. Refer to

B - 2 Disassembly and Assembly, “Vibration
1 - 14 by 10 inch
Damper - Remove and Install”.
C Loctite 243 -
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

NOTICE
Every time that the crankshaft seal is removed from
the wear sleeve, a new wear sleeve and crankshaft
seal must be installed.

Illustration 274 g01137704

1. Install Tooling (B) in the crankshaft.

2. Attach Tooling (A) and a suitable lifting device to
vibration damper (2). The weight of vibration
damper (2) is approximately 175 kg (385 lb).
112 KENR6055-14
Disassembly and Assembly Section

Repeat this procedure several times around wear

sleeve (2) until wear sleeve (2) can be removed by
hand.

i06603184

Crankshaft Front Seal and

Wear Sleeve - Install
SMCS Code: 1160-012; 7558-012

Installation Procedure For Seals

113-8432 and 113-8433
Illustration 275 g00659180 Table 51
Required Tools
1. Drill three evenly spaced holes in crankshaft front
Tool Part Number Part Description Qty
seal (1) and use Tooling (A) to remove crankshaft
front seal (1) from the front housing. 6V-4003(1) Seal Locator As 1
D
2N-5006(1) Bolt 2

E 8T-3099(1) Seal Installer 1

F 9S-8858(1) Nut 1

G - (Loctite 620) -

H 484-7863 (2) Tool As 1

(1) For installation of seals 113-8432 and 113-8433
(2) For Installation of seals 436-1478 and 436-1479

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Illustration 276 g00659181

2. Insert Tooling (B) between the front housing and Note: The crankshaft front seal and the wear sleeve
wear sleeve (2). must be replaced at the same time. Once the
crankshaft front seal and the wear sleeve are
NOTICE separated, these components cannot be used again.
The use of excessive force on the sleeve distorter
can cause the distorter adapter to crack the housing. Note: Do not use any type of lubricant during the
To help avoid damage to the engine, do not use ex- installation of the crankshaft front seal and the wear
cessive force to remove the wear sleeve. sleeve.

1. Before installation of the crankshaft front seal and

3. Insert Tooling (C) between Tooling (B) and wear the wear sleeve, inspect the crankshaft for
sleeve (2). Carefully turn Tooling (C) until the edge scratches. Also, inspect the crankshaft for any
of the tool creates a crease in wear sleeve (2). distortion on the surface that may lead to an out of
round condition. Use a polishing cloth to remove
any imperfections on the crankshaft.
KENR6055-14 113
Disassembly and Assembly Section

Illustration 277 g01136390 Illustration 278 g06042396

2. Clean the outside diameter of crankshaft (3) and 1. Using Tooling (H), install front seal (1) as outlined
the inside diameter of the new wear sleeve (2). in the following steps:
Clean the bore for the crankshaft front seal in front
a. Install pilot (H1) to the crankshaft and install
housing (4).Apply Tooling (G) to the inner diameter
bolts (H2).
of the wear sleeve and the surface of the
crankshaft prior to assembly. b. Position front seal (1) onto pilot (H1).
3. Install Tooling (D) on crankshaft (3). c. Install driver (H3) onto the shaft of pilot (H1).
Mark driver (H3) at the 12 O' CLOCK position.
4. Place crankshaft front seal (1) and wear sleeve (2)
Install bearing (H4) and nut (H5).
onto Tooling (D).
d. Tighten nut (H5) until the base of driver (H3)
5. Position Tooling (E) onto Tooling (D). Lubricate the
contacts the skirt of pilot (H1). Loosen nut (H5)
face of the washer on Tooling (F). Install Tooling
and rotate driver (H3) 180 degree. Retighten
(F) onto Tooling (E). Tighten Tooling (F) until
nut (H5) until driver (H3) contacts the skirt of
Tooling (E) contacts Tooling (D).
pilot (H1).
6. Remove the Tooling from the crankshaft.
2. Remove Tooling (H).
7. Check the crankshaft front seal and the wear
End By:
sleeve for the correct installation.
a. Install the vibration damper.
Installation Procedure For Seals
436-1478 and 436-1479 i02488070

NOTICE Flywheel - Remove and Install

Keep all parts clean from contaminants.
SMCS Code: 1156-010
Contaminants may cause rapid wear and shortened
component life.
Removal Procedure
Table 52
NOTICE Required Tools
Do not place engine oil on the crankshaft seal for in-
stallation. Lubrication of the crankshaft seal can give Tool Part Number Part Description Qty
a false indication of leakage at a later time.
A 138-7573 Lifting Bracket 2

Guide Stud
Note: Ensure that there are no imperfections on the B -
1 - 14 by 6 inch
2
mating surfaces of the crankshaft, the installation
tooling, or on the sealing surface of the crankshaft.
Surface imperfections can distort the seal during
installation and will cause the seal to malfunction.
114 KENR6055-14
Disassembly and Assembly Section

Start By:
NOTICE
a. Remove the engine speed sensor. Refer to Keep all parts clean from contaminants.
Disassembly and Assembly, “Engine Speed Contaminants may cause rapid wear and shortened
Sensor - Remove and Install”. component life.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Illustration 280 g01126776

1. Raise the temperature of new ring gear (3). Install

the ring gear on flywheel (1). Ensure that the
chamfer of the gear teeth will be toward the pinion
Illustration 279 g01126776 of the starting motor.

1. Attach Tooling (A) and a suitable lifting device to 2. Install Tooling (B) in the end of the crankshaft.
flywheel (1). The weight of flywheel (1) is 3. Attach Tooling (A) and a suitable lifting device to
approximately 170 kg (375 lb). flywheel (1). The weight of flywheel (1) is
2. Remove two bolts (2) on each side of the approximately 170 kg (375 lb).
crankshaft and install Tooling (B). 4. Lift the flywheel into position onto Tooling (B).
3. Remove remaining bolts (2). Ensure that the mark on the flywheel is aligned
with the mark on the crankshaft.
4. Remove flywheel (1).
5. Apply clean engine oil to the threads of bolts (2).
Note: If necessary, Use a prybar against Tooling (A) Install bolts (2).
to remove the flywheel from the crankshaft.
6. Remove Tooling (A) and Tooling (B). Install
5. Use a hammer and a punch in order to remove ring remaining bolts (2). Tighten bolts (2) to a torque of
gear (3) from flywheel (1). 1150 ± 60 N·m (848 ± 44 lb ft).

Installation Procedure
Table 53
Required Tools

Tool Part Number Part Description Qty

A 138-7573 Lifting Bracket 2

Guide Stud
B - 2
1 - 14 by 6 inch
KENR6055-14 115
Disassembly and Assembly Section

End By:
a. Install the engine speed sensor. Refer to
Disassembly and Assembly, “Engine Speed
Sensor - Remove and Install”.

i03565063

Crankshaft Rear Seal and

Wear Sleeve - Remove
SMCS Code: 1161-011; 7558-011

Removal Procedure
Table 54 Illustration 281 g00659239
Required Tools
1. Drill three evenly spaced holes in crankshaft rear
Tool Part Number Part Description Qty
seal (1). Use Tooling (A) in order to remove
A 1U-7600 Slide Hammer Puller 1 crankshaft rear seal (1).
6V-3143
B or Distorter Adapter 1
1U-7325
C 5P-7409 Sleeve Distorter 1

Start By:
a. Remove the flywheel. Refer to Disassembly
and Assembly, “Flywheel - Remove and
Install”.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life. Illustration 282 g00659240

2. Insert Tooling (B) between the rear housing and

NOTICE
Every time that the crankshaft seal is removed from wear sleeve (2).
the wear sleeve, a new wear sleeve and crankshaft
seal must be installed. NOTICE
The use of excessive force on the sleeve distorter
can cause the distorter adapter to crack the housing.
To help avoid damage to the engine, do not use ex-
cessive force to remove the wear sleeve.

3. Insert Tooling (C) between Tooling (B) and wear

sleeve (2). Carefully turn Tooling (C) until the edge
of the tool causes a crease in wear sleeve (2).
116 KENR6055-14
Disassembly and Assembly Section

Repeat this procedure several times around wear

sleeve (2) until wear sleeve (2) can be removed by
hand.

i06986865

Crankshaft Rear Seal and

Wear Sleeve - Install
SMCS Code: 1161-012; 7558-012

Installation Procedure For Seals

113-8432 and 113-8433
Table 55 Illustration 283 g01136390
Required Tools
2. Clean the outside diameter of crankshaft (3) and
Tool Part Number Part Description Qty
the inside diameter of the new wear sleeve (2).
6V-4003 (1) Seal Locator As 1 Clean the bore for the crankshaft front seal in front
D housing (4).Apply Tooling (G) to the inner diameter
2N-5006 Bolt 2
of the wear sleeve and the surface of the
E 8T-3099 Seal Installer 1 crankshaft prior to assembly.
F 9S-8858 Nut 1
3. Install Tooling (D) on crankshaft (3).
G - (Loctite 620) -
4. Place crankshaft front seal (1) and wear sleeve (2)
H 484-7863 (2) Tool As 1 onto Tooling (D).
(1) For installation of seals 113-8432 and 113-8433
(2) For Installation of seals 436-1478 and 436-1479 5. Position Tooling (E) onto Tooling (D). Lubricate the
face of the washer on Tooling (F). Install Tooling
(F) onto Tooling (E). Tighten Tooling (F) until
NOTICE Tooling (E) contacts Tooling (D).
Keep all parts clean from contaminants.
6. Remove the Tooling from the crankshaft.
Contaminants may cause rapid wear and shortened
component life. 7. Check the crankshaft front seal and the wear
sleeve for the correct installation.
Note: The crankshaft front seal and the wear sleeve Installation Procedure For Seals
must be replaced at the same time. Once the
crankshaft front seal and the wear sleeve are 436-1478 and 436-1479
separated, these components cannot be used again.
NOTICE
Note: Do not use any type of lubricant during the Keep all parts clean from contaminants.
installation of the crankshaft front seal and the wear
sleeve. Contaminants may cause rapid wear and shortened
component life.
1. Before installation of the crankshaft front seal and
the wear sleeve, inspect the crankshaft for
scratches. Also, inspect the crankshaft for any NOTICE
Do not place engine oil on the crankshaft seal for in-
distortion on the surface that may lead to an out of stallation. Lubrication of the crankshaft seal can give
round condition. Use a polishing cloth to remove a false indication of leakage at a later time.
any imperfections on the crankshaft.

Note: Ensure that there are no imperfections on the

mating surfaces of the crankshaft, the installation
tooling, or on the sealing surface of the crankshaft.
Surface imperfections can distort the seal during
installation and will cause the seal to malfunction.
KENR6055-14 117
Disassembly and Assembly Section

(Table 56, contd)

1P-0820 Hydraulic Puller 1

5H-1504 Hard Washer 3

9U-6600 Hand Hydraulic Pump 1

C 138-7573 Link Bracket 2

Guide Stud
D - 2
5/8 - 11 by 6 inch

E Loctite 7649 -

Start By:
a. Remove the starting motor. Refer to
Illustration 284 g06042396 Disassembly and Assembly, “Air Starting
Motor - Remove”. Refer to Disassembly and
1. Using Tooling (H), install rear seal (1) as outlined in Assembly, “Electric Starting Motor - Remove
and Install”.
the following steps:
b. If the exhaust elbow is attached to the flywheel
a. Install pilot (H1) to the crankshaft and install
housing, remove the exhaust elbow and
bolts (H2). remove the bracket for the exhaust elbow.
Refer to Disassembly and Assembly, “Exhaust
b. Position rear seal (1) onto pilot (H1). Elbow - Remove and Install”.
c. Install driver (H3) onto the shaft of pilot (H1). c. Remove the engine oil pan. Refer to
Mark driver (H3) at the 12 O' CLOCK position. Disassembly and Assembly, “Engine Oil Pan -
Install bearing (H4) and nut (H5). Remove”.
d. Tighten nut (H5) until the base of driver (H3) d. Remove the engine speed sensor. Refer to
contacts the skirt of pilot (H1). Loosen nut (H5) Disassembly and Assembly, “Engine Speed
and rotate driver (H3) 180 degree. Retighten Sensor - Remove and Install”.
nut (H5) until driver (H3) contacts the skirt of e. Remove the engine speed/timing sensor. Refer
pilot (H1). to Disassembly and Assembly, “Engine Speed/
Timing Sensor - Remove and Install”.
2. Remove Tooling (H).
End By: NOTICE
Keep all parts clean from contaminants.
a. Install the flywheel.
Contaminants may cause rapid wear and shortened
i06705117
component life.

Flywheel Housing - Remove

SMCS Code: 1157-011

Removal Procedure
Table 56
Required Tools

Tool Part Number Part Description Qty

A 238-9586 Camshaft Drive Group 1

8B-7548 Push-Puller Tool Group 1

B 8B-7559 Adapter 2

8B-7561 Step Plate 1

Illustration 285 g01126909

(continued)
1. Remove rear camshaft covers (1).
2. Remove timing pin (2) from the storage position.
118 KENR6055-14
Disassembly and Assembly Section

3. Remove timing bolt (5) from the storage position.

Remove cover (3) and plug (4) from the flywheel
housing.
4. Use Tooling (A) to turn the flywheel in order to
install timing bolt (5) in the flywheel and timing pin
(2) in both camshafts. Refer to Testing and
Adjusting, “Camshaft Timing”. Refer to Testing and
Adjusting, “Finding the Top Center Position for the
No. 1 Piston”.
5. Remove the timing bolt from the flywheel.
6. Remove the crankshaft rear seal and the wear
sleeve. Refer to Disassembly and Assembly,
“Crankshaft Rear Seal and Wear Sleeve - Illustration 287 g01316299
Remove”.
10. Remove bolt (9) and plate (10). Place the three
washers from Tooling (B) behind plate (10) and
install bolt (9). Install Tooling (B) on camshaft drive
gear (11). Apply 51675 kPa (7500 psi) to the
puller. Strike the screw on the puller with a
hammer until camshaft drive gear (11) is free from
the camshaft. Remove Tooling (B) from the
camshaft drive gear. Remove camshaft drive gear
(11) from the camshaft.
Note: Plate (10) must be installed in order to keep
camshaft drive gear (11) on the camshaft during the
removal procedure.

Illustration 286 g01126908

7. Remove tube (6).

8. Remove drain tubes (7) for the turbochargers.
Remove the gaskets from the elbows.
9. Remove covers (8) and the gasket.

Illustration 288 g01316301

11. Remove bolt (12). Remove ring (13).

KENR6055-14 119
Disassembly and Assembly Section

Note: Ensure that the rear gear group and the

crankshaft are properly protected during the cleaning
procedure. Ensure that the bolts are cleaned with a
wire brush in order to remove debris or residue.
Ensure that the bores for the bolts in the cylinder
block are tapped again. Ensure that the bores for the
bolts are cleaned in order to remove debris or
residue.

16. After removing flywheel housing (16), clean the

mating surface of the cylinder block and the
mating surface of the flywheel housing with
Tooling (E). If necessary, use a gasket scraper and
a solvent in order to remove any residual gasket
material. Both mating surfaces must be clean, dry,
Illustration 289 g01316307 and free of any oil before installation.

12. Place the three washers from Tooling (B) behind i07522043
plate (10) and install bolt (12). Install Tooling (B)
on camshaft drive gear (14). Use Tooling (B) in Flywheel Housing - Install
order to remove camshaft drive gear (14) from the
camshaft. Apply 51675 kPa (7500 psi) to the SMCS Code: 1157-012
puller. Strike the screw on the puller with a
hammer until camshaft drive gear (14) is free from Installation Procedure
the camshaft. Remove Tooling (B) from the Table 57
camshaft drive gear. Remove camshaft drive gear
Required Tools
(14) from the camshaft.
Tool Part Number Part Description Qty
Note: Plate (10) must be installed in order to keep
camshaft drive gear (14) on the camshaft during the C 138-7573 Link Bracket 2
removal procedure. Guide Stud
D - 2
5/8 - 11 by 6 inch

F -(1) Loctite 5127 -

(1) EAME

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

NOTICE
Do not turn the crankshaft or the camshaft while the
camshaft gear is removed. If the front gear group is
not correctly timed during installation, interference
Illustration 290 g01316311
can occur between the pistons and the valves, result-
ing in damage to the engine.
13. Install Tooling (C) and a suitable lifting device on
flywheel housing (16). The weight of flywheel Note: Refer to Engine News, 27 March 2006,
housing (16) is approximately 235 kg (518 lb). “Sealing and Installing the Flywheel Housing” for
more information.
14. Remove two bolts (17) and install Tooling (D).
Remove the remaining bolts (17) and remove 1. Ensure that the mating surfaces of the flywheel
flywheel housing (16) from the cylinder block. housing and the engine block are clean. Both
15. If necessary, remove plugs (15) from the flywheel mating surfaces must be clean, dry, and free of
housing. any oil before Tooling (F) is applied.
120 KENR6055-14
Disassembly and Assembly Section

7. Tighten bolts (17) evenly. Tighten the 1/2 - NC

bolts to a torque of 135 ± 20 N·m (100 ± 15 lb ft).
Tighten the 5/8 - NC bolts to a torque of
270 ± 40 N·m (200 ± 30 lb ft).
8. Tighten plugs (15) to a torque of 70 ± 15 N·m
(50 ± 11 lb ft).
9. Install the crankshaft rear seal and the wear
sleeve. Refer to Disassembly and Assembly,
“Crankshaft Rear Seal and Wear Sleeve - Install”.

Illustration 291 g01317446

2. Apply a 6.0 mm (0.25 inch) bead of Tooling (F) to

the mating surface of the flywheel housing. Refer
to Illustration 291 .
Illustration 293 g01140296

10. Install timing bolt (5) in the flywheel. Ensure that

timing pin (2) is installed in each camshaft. Refer
to Testing and Adjusting, “Camshaft Timing”. Refer
to Testing and Adjusting, “Finding the Top Center
Position for the No. 1 Piston”.

Illustration 292 g01316311

3. Install Tooling (D) into the cylinder block.

4. Install Tooling (C) and a suitable lifting device on
flywheel housing (16). The weight of flywheel
housing (16) is approximately 235 kg (518 lb).
5. Lift the flywheel housing into position onto Tooling
(D).
6. Install bolts (17) and the hard washers that secure
the flywheel housing to the cylinder block. Remove
Tooling (D) and install remaining bolts (17) and the
hard washers.

Note: Refer to Parts Manual for the correct positions

for bolts that secure the flywheel housing to the
cylinder block.
KENR6055-14 121
Disassembly and Assembly Section

Note: For “Standard Rotation” engines, turn the

camshaft drive gears COUNTERCLOCKWISE. For
“Reverse Rotation” engines, turn the camshaft
drive gears CLOCKWISE.

d. Install bolt (9) and plate (10).

e. Install bolt (12) and ring (13). Ensure that the
hole in the ring is properly seated on the
locating pin.
f. Tighten the bolt to a torque of 360 N·m
(265 lb ft).
g. Place a mark on the bolt.

Illustration 294 g01316352

h. Place a driver against the retaining plate of the
camshaft drive gear. Strike the driver with a
hammer, three times, or four times.
i. Tighten the bolt again to a torque of 360 N·m
(265 lb ft).
j. Repeat Steps 11h and 11i until the mark has
turned at least 90 degrees.

Illustration 295 g01316354

11. Use the following procedure to install camshaft

drive gear (11) and camshaft drive gear (14).
a. Clean the taper of the camshaft and the
tapered bore of the camshaft gear with a lint
free cloth saturated with solvent to remove oil. Illustration 296 g01126909

Clean the parts again with a lint free alcohol

wipe to remove any residue. The alcohol wipe 12. Remove the timing pin from the camshafts. Install
will dirty after cleaning the parts. Clean the timing pin (2) in the storage position. Install rear
parts again with a lint free alcohol wipe until no camshaft covers (1).
residue is left on the alcohol wipe. 13. Remove the timing bolt from the flywheel. Install
plug (4) in the timing hole. Install cover (3) and
Note: The taper of the camshaft and the tapered
bore of the camshaft gear must be clean, dry, and timing bolt (5) in the storage position on the
free of residue before assembly. flywheel housing.

b. Ensure that the camshaft timing pins and the

timing pin for the flywheel are installed.
c. Place camshaft drive gear (11) and camshaft
drive gear (14) in position. Remove the
backlash by rotating the gears in the opposite
direction of camshaft rotation.
122 KENR6055-14
Disassembly and Assembly Section

End By:
a. Install the engine speed/timing sensor. Refer to
Disassembly and Assembly, “Engine Speed/
Timing Sensor - Remove and Install”.
b. Install the engine speed sensor. Refer to
Disassembly and Assembly, “Engine Speed
Sensor - Remove and Install”.
c. Install the engine oil pan. Refer to Disassembly
and Assembly, “Engine Oil Pan - Install”.
d. If the exhaust elbow was removed, install the
exhaust elbow. Refer to Disassembly and
Assembly, “Exhaust Elbow - Remove and
Install”.
Illustration 297 g01126908
e. Install the starting motors. Refer to
14. Install tube (6) if equipped. Disassembly and Assembly, “Air Starting
Motor - Install”. Refer to Disassembly and
15. Install the gaskets on the elbows. Install drain Assembly, “Electric Starting Motor - Remove
tubes (7) for the turbochargers. and Install”.

16. Install the gasket and covers (8) on the flywheel i07525193
housing.
Engine Oil Sequence Valves -
Remove and Install
SMCS Code: 1332-010

Removal Procedure
Start By:
a. Remove the front housing. Refer to
Disassembly and Assembly, “Housing (Front) -
Remove”.
b. Remove the flywheel housing. Refer to
Disassembly and Assembly, “Flywheel
Housing - Remove”.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
KENR6055-14 123
Disassembly and Assembly Section

Illustration 298 g01135024 Illustration 300 g01135030

1. Remove bolts (1) and thrust plate (2). Remove 4. Remove bolts (12) and thrust plate (13). Remove
balancer gear (3) from the balancer gear shaft. cluster idler gear (14) from the rear of the cylinder
block.
Note: The balancer gear is for the 3508C engine.
The 3512C Engine, 3512E Engine, and the 3516C 5. Remove bolts (8), idler shaft (9), camshaft idler
Engine do not have the balancer gear on the front of gear (10), and thrust washer (11).
the engine.

Illustration 301 g01135029

Illustration 299 g01135028

Personal injury can result from parts and/or cov-

Personal injury can result from parts and/or cov- ers under spring pressure.
ers under spring pressure.
Spring force will be released when covers are
Spring force will be released when covers are removed.
removed. Be prepared to hold spring loaded covers as the
Be prepared to hold spring loaded covers as the bolts are loosened.
bolts are loosened.
6. Remove bolts (15) and cover (16) from the rear of
2. Remove bolts (4) and cover (5) from the front of the cylinder block.
the cylinder block. 7. Remove plunger assembly (17) and spring (18)
3. Remove plunger assembly (6) and spring (7) from from the cylinder block.
the cylinder block.
124 KENR6055-14
Disassembly and Assembly Section

Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Illustration 303 g01135030

4. Apply clean engine oil to the sleeve bearing in

camshaft idler gear (10) and idler shaft (9). Install
idler shaft (9) in camshaft idler gear (10). Position
camshaft idler gear (10) and thrust washer (11)
and install bolts (8). Tighten bolts (8) to a torque of
240 ± 20 N·m (177 ± 15 lb ft).
Illustration 302 g01135029
5. Apply clean engine oil on the sleeve bearing in
cluster idler gear (14) and the cluster gear shaft.
Install cluster idler gear (14) on the cluster gear
Improper assembly of parts that are spring shaft. Make sure that the marks on cluster idler
loaded can cause bodily injury. gear (14) and the crankshaft gear are in alignment
with the rotation of the engine. Install thrust plate
To prevent possible injury, follow the established (13) and bolts (12).
assembly procedure and wear protective
equipment.

1. Apply clean engine oil on spring (18) and plunger

assembly (17).
2. Install spring (18) and plunger assembly (17) in the
cylinder block.
3. Install cover (16) and bolts (15).

Illustration 304 g01135028

Improper assembly of parts that are spring

loaded can cause bodily injury.
To prevent possible injury, follow the established
assembly procedure and wear protective
equipment.

6. Apply clean engine oil on spring (7) and plunger

assembly (6).
KENR6055-14 125
Disassembly and Assembly Section

7. Install spring (7) and plunger assembly (6) in the Start By:
cylinder block.
a. Remove the flywheel housing.
8. Install cover (5) and bolts (4).
b. Remove the crankshaft rear seal and wear
sleeve.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Illustration 305 g01135024

9. Apply clean engine oil on the sleeve bearing in

balancer gear (3) and the balancer gear shaft.
Install balancer gear (3) on the balancer gear
shaft. Make sure that the marks on balancer gear
(3) and the crankshaft gear are in alignment with
the rotation of the engine. Install thrust plate (2)
and bolts (1).

Note: The balancer gear is for the 3508C engine.

The 3512C engine, 3512E Engine, and the 3516C
Engine do not have the balancer gear on the front of
the engine.
Illustration 306 g06320914
End By:
a. Install the flywheel housing. Refer to 1. Remove bolts (1) and thrust plate (2). Remove
Disassembly and Assembly, “Flywheel cluster idler gear (3).
Housing - Install”.
b. Install the front housing. Refer to Disassembly
and Assembly, “Housing (Front) - Install”.

i07430741

Gear Group (Rear) - Remove

SMCS Code: 1206-011; 1212-011

Removal Procedure
Table 58
Required Tools

Tool Part Number Part Description Qty

A 1P-0520 Driver Group 1

126 KENR6055-14
Disassembly and Assembly Section

Illustration 307 g06321115 Illustration 309 g06321154

2. Use Tooling (A) and a suitable press to remove 5. Remove thrust washers (8) from gears (7).
sleeve bearing (4) from cluster idler gear (3).

Illustration 310 g06321151

Illustration 308 g06321120
6. Use Tooling (A) and a suitable press to remove
3. Remove bolts (5). sleeve bearing (9) from camshaft idler gears (7).
4. Remove idler shaft (6) with camshaft idler gears
(7).
KENR6055-14 127
Disassembly and Assembly Section

Illustration 311 g06321167 Illustration 312 g06321170

7. Remove bolts (11). Remove cluster gear shaft 8. Remove bolts (12). Remove crankshaft gear (13).
(10).
i07430753

Gear Group (Rear) - Install

SMCS Code: 1206-012; 1212-012

Installation Procedure
Table 59
Required Tools

Tool Part Number Part Description Qty

A 1P-0520 Driver Gp 1

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
128 KENR6055-14
Disassembly and Assembly Section

Illustration 313 g06321170 Illustration 315 g06321151

1. Position crankshaft gear (13) and install 12 bolts

(12).

Illustration 316 g06321204

(7) Camshaft Idler Gear.(9) Bearing. (E)
81.060 ± 0.010 mm (3.1913 ± 0.0004 inch). (F)
Illustration 314 g06321167
1.00 ± 0.25 mm (0.040 ± 0.010 inch).
2. Position gear shaft (11) and install four bolts (10). 3. Use Tooling (A) and a suitable press to install the
a. Tighten four bolts (10) to a torque of bearings in camshaft idler gears (7). Install bearing
140 ± 10 N·m (105 ± 5 lb ft). (9) into gear (7) to Depth (F), as shown.
KENR6055-14 129
Disassembly and Assembly Section

Illustration 317 g06321198 Illustration 319 g06259470

4. Place clean engine oil on the bearings and install 7. Position gears (7) with idler shafts (6) into place
idler shafts (6). and install six bolts (5).
5. Machine the inside diameter of bearing (9) to Tighten six bolts (5) to a torque of 240 ± 20 N·m
Dimension (E), as shown. (177 ± 14.8 lb ft).
Note: The surface finish of Bore (E) must be 0.8
micrometers. Pitch Diameter (H) must be concentric
with a total indicator reading of 0.12 mm
(0.005 inch). Surface (G) of gear (4) must be square
with Bore (E) within 0.05 mm (0.002 inch).

Illustration 320 g06321213

(3) Cluster Idler Gear.(4) Bearing. (A)
75.060 ± 0.010 mm (2.9551 ± 0.0004 inch). (B)
1.5 ± 0.5 mm (0.06 ± 0.02 inch).

Illustration 318 g06321208

6. Place clean engine oil on the thrust washer (8) and

install.
130 KENR6055-14
Disassembly and Assembly Section

10. Place clean engine oil on gear (3) and install gear
(3) onto shaft (11).
11. Install plate (2) and four bolts (1).
End By:
a. Remove the flywheel housing.
b. Remove the crankshaft rear seal and wear
sleeve.

i02235598

Piston Cooling Jets - Remove

and Install
SMCS Code: 1331

Removal Procedure
Start By:
Illustration 321 g06321115 a. Remove the engine oil pump, if necessary.
Refer to Disassembly and Assembly, “Engine
8. Use Tooling (A) and a suitable press to install Oil Pump - Remove”.
bearing (4) in cluster gear (3). Install bearing (4) to
Depth (B), as shown. NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Illustration 323 g01127415

Illustration 322 g06259447 1. Remove cylinder block side cover (1).

Note: When you install the rear cluster gear

assembly to the crank gear, there are no timing
marks on the 3516 engines.

9. Put clean engine oil on the bearing and install the

gear assembly on the shaft. Make sure that the
marks on the gear assembly and the crankshaft
are in alignment with the rotation of the engine, as
shown.
KENR6055-14 131
Disassembly and Assembly Section

Illustration 324 g01127419 Illustration 326 g01127415

2. Remove bolts (2) and retainer (3). 3. Install cylinder block side cover (1).
3. Remove piston cooling jet (4) from the inside of the End By:
cylinder block.
a. Install the engine oil pump, if necessary. Refer
to Disassembly and Assembly, “Engine Oil
Installation Procedure Pump - Install”.
NOTICE
Keep all parts clean from contaminants. i05977048

Contaminants may cause rapid wear and shortened Bearing Clearance - Check
component life.
SMCS Code: 1203-535; 1219-535

Measurement Procedure
Table 60
Required Tools

Tool Part Number Part Description Qty

Plastic Gauge (Green)

198-9142 0.025 to 0.076 mm 1
(0.001 to 0.003 inch)

Plastic Gauge (Red)

198-9143 0.051 to 0.152 mm 1
(0.002 to 0.006 inch)
A
Plastic Gauge (Blue)
198-9144 0.102 to 0.229 mm 1
Illustration 325 g01127419 (0.004 to 0.009 inch)

Plastic Gauge (Yellow)

1. Position piston cooling jet (4) in the cylinder block. 198-9145 0.230 to 0.510 mm 1
Ensure that the oil holes in the end of the piston (0.009 to 0.020 inch)
cooling jet are facing toward the piston.
2. Install retainer (3) and bolts (2). Note: Plastic gauge may not be necessary when the
engine is in the chassis.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
132 KENR6055-14
Disassembly and Assembly Section

Note: Cat does not recommend the checking of the

actual bearing clearances particularly on small
engines. This is because of the possibility of
obtaining inaccurate results and the possibility of
damaging the bearing or the journal surfaces. Each
Cat engine bearing is quality checked for specific wall
thickness.
Note: The measurements should be within
specifications and the correct bearings should be
used. If the crankshaft journals and the bores for the
block and the rods were measured during
disassembly, no further checks are necessary.
However, if the technician still wants to measure the
bearing clearances, Tooling (A) is an acceptable
method. Tooling (A) is less accurate on journals with
small diameters if clearances are less than 0.10 mm
(0.004 inch).

NOTICE
Lead wire, shim stock or a dial bore gauge can dam- Illustration 327 g01152855
age the bearing surfaces. Typical Example

The technician must be very careful to use Tooling 4. Remove all of Tooling (A) before you install the
(A) correctly. The following points must be bearing cap.
remembered:
Note: When Tooling (A) is used, the readings can
• Ensure that the backs of the bearings and the sometimes be unclear. For example, all parts of
bores are clean and dry. Tooling (A) are not the same width. Measure the
• Ensure that the bearing locking tabs are properly major width in order to ensure that the parts are
seated in the tab grooves. within the specification range. Refer to Specifications
Manual, “Connecting Rod Bearing Journal” and
• The crankshaft must be free of oil at the contact Specifications Manual, “Main Bearing Journal” for the
points of Tooling (A). correct clearances.

1. Put a piece of Tooling (A) on the crown of the i06705159

bearing that is in the cap.
Connecting Rod Bearings -
Note: Do not allow Tooling (A) to extend over the
edge of the bearing. Remove and Install
2. Use the correct torque-turn specifications in order SMCS Code: 1219-010
to install the bearing cap. Do not use an impact
S/N: ML21–Up
wrench. Be careful not to dislodge the bearing
when the cap is installed. S/N: BG31–Up

Note: Do not turn the crankshaft when Tooling (A) is S/N: ML31–Up
installed. S/N: T251–Up
3. Carefully remove the cap, but do not remove S/N: PXA1–Up
Tooling (A). Measure the width of Tooling (A) while
Tooling (A) is in the bearing cap or on the S/N: TTA1–Up
crankshaft journal. Refer to Illustration 327 . S/N: DPB1–Up
S/N: PXB1–Up
S/N: TTB1–Up
S/N: DPC1–Up
S/N: PXC1–Up
S/N: TTC1–Up
KENR6055-14 133
Disassembly and Assembly Section

S/N: DPD1–Up Start By:

S/N: PXD1–Up a. Remove the engine oil pump. Refer to
Disassembly and Assembly, “Engine Oil Pump
S/N: TTD1–Up - Remove”.
S/N: PXE1–Up
NOTICE
S/N: TTE1–Up Keep all parts clean from contaminants.
S/N: PAF1–Up Contaminants may cause rapid wear and shortened
component life.
S/N: PXF1–Up
S/N: TTF1–Up 1. Use Tooling (A) to turn the flywheel in order to
S/N: PXG1–Up access the connecting rod cap that will be
removed.
S/N: TTG1–Up
S/N: PXH1–Up
S/N: TTH1–Up
S/N: PXJ1–Up
S/N: TTJ1–Up
S/N: SLM1–Up
S/N: MXN1–Up
S/N: MXP1–Up
S/N: JTS1–Up
S/N: MXT1–Up
S/N: E3W1–Up Illustration 328 g00913801

S/N: FLW1–Up Note: Inspect the connecting rod and connecting rod
cap for the proper identification mark. The connecting
S/N: PXW1–Up
rod and the connecting rod cap should have an
S/N: TTW1–Up etched number on the side. The number should
match the cylinder number. Mark the connecting rod
S/N: E3X1–Up and the connecting rod cap, if necessary.
S/N: PXX1–Up
2. Remove bolts (1) and connecting rod cap (2) from
S/N: E3Y1–Up the crankshaft.
S/N: TTY1–Up 3. Push the connecting rod away from the crankshaft.
Remove the upper half of the connecting rod
S/N: E3Z1–Up
bearing.
S/N: PXZ1–Up
Note: Be careful not to damage the cylinder liner or
S/N: TTZ1–Up the crankshaft journal.

Removal Procedure 4. Remove the lower half of the connecting rod

Table 61 bearing from connecting rod cap (2).
Required Tools Installation Procedure
Tool Part Number Part Description Qty Table 62

A 9S-9082 Engine Turning Tool 1 Required Tools

Tool Part Number Part Description Qty

A 9S-9082 Engine Turning Tool 1

B Loctite Moly 50 -
134 KENR6055-14
Disassembly and Assembly Section

3. Install the lower half of the connecting rod bearing

NOTICE
Keep all parts clean from contaminants. on connecting rod cap (2). Ensure that the
connecting rod bearing is installed so that the
Contaminants may cause rapid wear and shortened bearing tab fits into the notch in the connecting rod
component life. cap. Coat the connecting rod bearing with clean
engine oil.
Note: Install the connecting rod bearings dry when Note: The number that is on the side of the
clearance checks are performed. Refer to connecting rod caps must be installed next to the
Disassembly and Assembly, “Bearing Clearance - corresponding number that is on the side of the
Check”. Apply clean engine oil on the connecting rod connecting rod. Install the chamfered side of the
bearings for final assembly. connecting rod cap next to the thrust surface of the
crankshaft.
1. Use Tooling (A) to rotate the crankshaft until the
connecting rod journal is at the bottom center. 4. Apply Tooling (B) to the threads, the shank, and
the seat of bolts (1).
5. Place connecting rod cap (2) into position. Install
bolts (1). Use the following procedure to tighten
the bolts:
a. Tighten Bolt (A) and Bolt (B) to a torque of
90 ± 5 N·m (65 ± 4 lb ft).
b. Tighten Bolt (C) and Bolt (D) to a torque of
90 ± 5 N·m (65 ± 4 lb ft).
c. Tighten Bolt (C) and Bolt (D) again to a torque
of 90 ± 5 N·m (65 ± 4 lb ft).
d. Place an index mark on the bolts and the
connecting rod cap. Tighten each bolt for an
Illustration 329 g00913801
additional 90 ± 5 degrees (1/4 turn).
6. Rotate the crankshaft in order to ensure that the
crankshaft turns freely.
End By:
a. Install the engine oil pump.

i02724262

Crankshaft Main Bearings -

Remove
SMCS Code: 1203-011

Removal Procedure
Illustration 330 g03746219
Table 63
Section view of connecting rod showing torque
sequence. Chamfer (3) and dowel (4) can be used to Required Tools
reference orientation. Part Description Qty
Tool Part Number

2. Install the upper half of the connecting rod bearing A 9S-9082 Engine Turning Tool 1
on the connecting rod . Ensure that the connecting Main Bearing Wrench
B 9U-5023 1
rod bearing is installed so that the bearing tab fits
into the notch in the connecting rod. Coat the C 2P-5517 Main Bearing Tool 1
connecting rod bearing with clean engine oil. D 236-6688 Main Bearing Cap Tool 2
Position the connecting rod onto a journal of the
crankshaft.
KENR6055-14 135
Disassembly and Assembly Section

Start By:
a. Remove the oil pump. Refer to Disassembly
and Assembly, “Engine Oil Pump - Remove”.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Illustration 333 g01125192

4. Install Tooling (D) until Tooling (D) bottoms out in

the block. Adjust the nuts on Tooling (D) until the
nuts make contact with main bearing cap (2).
Remove bolts (3) from the main bearing cap.

Illustration 331 g01125228

1. Remove side cover (1) from the cylinder block.

2. Use Tooling (A) to rotate the counterweight on the
crankshaft to the top of the cylinder block.

Illustration 334 g01125205

5. Loosen the nuts on Tooling (D) evenly in order to

lower main bearing cap (2). Lower main bearing
cap (2) to the end of the bolt on Tooling (D) in
order to gain access to the main bearings.

Illustration 332 g01125196

3. Use Tooling (B) and loosen bolts (3) for the main
bearing cap. Remove the outer bolts from main
bearing cap (2).
136 KENR6055-14
Disassembly and Assembly Section

Illustration 335 g01125209 Illustration 336 g01125211

6. Use Tooling (A) and rotate the crankshaft until the 8. Remove lower main bearing (4) from main bearing
oil hole of the crankshaft journal is just below the cap (2).
side of the main bearing without the tab. Install
Tooling (C) and remove the upper bearing. i07047070

7. The following step is for removing the thrust plates

from the cylinder block. Remove the thrust plates
Crankshaft Main Bearings -
on each side of the center main bearing. It may be Install
necessary to move the crankshaft with a prybar in
order to remove the thrust bearing from the SMCS Code: 1203-012
cylinder block.
Installation Procedure
Table 64
Required Tools

Tool Part Number Part Description Qty

A 9S-9082 Engine Turning Tool 1

B 9U-5023 Main Bearing Wrench 1

C 2P-5517 Main Bearing Tool 1

D 236-6688 Main Bearing Cap Tool 2

E 9S-7351 Torque Wrench 1

F 8T-5096 Dial Indicator Gp 1

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Note: Install the main bearings dry when clearance

checks are preformed. Refer to Disassembly and
Assembly, “Bearing Clearance - Check”. Apply clean
engine oil on the main bearings for final assembly.
KENR6055-14 137
Disassembly and Assembly Section

4. Remove Tooling (C).

5. The following step is for installing the thrust plates
on each side of the center main bearing. Place
clean engine oil on the thrust plates. Install the
thrust plates on each side of the center main
bearing. It may be necessary to move the
crankshaft with a prybar in order to install a new
thrust bearing. Use Tooling (F) to measure the end
play of the crankshaft. The end play must not
exceed 0.17 to 0.63 mm (0.007 to 0.025 inch).

Illustration 337 g01125211

1. Install lower main bearing (4) in main bearing cap

(2). Ensure that the main bearing is installed so
that the bearing tab fits into the notch in the main
bearing cap.
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. Illustration 339 g01125192

2. Install the upper main bearing with the side without 6. Tighten the nuts on Tooling (D) in order to raise
the tab into the side of the cylinder block with the main bearing cap (2) to the cylinder block. The
tab. Use your hand and roll the upper main nuts must be tightened evenly in order for main
bearing into position. Use Tooling (A) and rotate bearing cap (2) to fit into the block.
the crankshaft. Rotate the crankshaft until the oil
7. Coat the underside of the bolt heads and the
hole is positioned in front of the side of the upper
threads of bolts (3) with clean engine oil. Install the
main bearing with the tab.
inner bolts for the main bearing cap. Remove
Tooling (D) and install the outer bolts for the main
bearing cap.

Illustration 338 g01125209

3. Install Tooling (C) and finish rolling the upper main

bearing into position. Make sure that Tooling (C)
does not slide under the upper main bearing.
Ensure that the main bearing is installed so that
the bearing tab fits into the notch in the cylinder
block.
138 KENR6055-14
Disassembly and Assembly Section

Illustration 340 g01139473 Illustration 342 g01125228

11. Install side covers (1) onto the cylinder block.

End By:
a. Install the oil pump. Refer to Disassembly and
Assembly, “Engine Oil Pump - Install”.

i03898935

Pistons and Connecting Rods

- Remove
SMCS Code: 1225-011

Removal Procedure
Illustration 341 g01124192
Table 65
Bolt tightening sequence for the main bearing caps
Required Tools
8. Use Tooling (E) and Tooling (B) and tighten bolts Tool Part Number Part Description Qty
(3) in sequence to a torque of 190 ± 14 N·m
(140 ± 10 lb ft). A 5R-7425 Barring Gp (1) 1

B 1P-1861 Retaining Ring Pliers 1

9. Place an index mark on the bolts and the main
bearing cap. Tighten the bolts for an additional 180 C 271-0498 Expander Ring 1
± 5 degrees (1/2 turn). (1) The 9S-9082 Engine Turning Tool is alternative tooling.
10. Rotate the crankshaft in order to ensure that the
crankshaft turns freely. Start By:
a. Remove the cylinder head. Refer to
Disassembly and Assembly, “Cylinder Head -
Remove”.
b. Remove the piston cooling jets. Refer to
Disassembly and Assembly, “Piston Cooling
Jets - Remove and Install”.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
KENR6055-14 139
Disassembly and Assembly Section

Illustration 343 g00913801 Illustration 344 g01051820

1. Use Tooling (A) to rotate the crankshaft until bolts 6. Use Tooling (B) to remove the retaining rings that
(1) can be removed. hold piston pin (4). Remove piston pin (4).
Remove piston (3) from connecting rod (5).
2. Remove the carbon ridge from the top inside
surface of the cylinder liner. 7. Remove the bearings from connecting rod (5) and
the connecting rod cap.
3. Inspect the connecting rod and connecting rod cap
for the proper identification mark. The connecting Note: If necessary, separate the piston skirt from the
rod and the connecting rod cap should have an piston crown.
etched number on the side. The number should
match the cylinder number. Mark the connecting
rod and the connecting rod cap, if necessary.

Note: Do not stamp the connecting rod assembly.

4. Remove bolts (1) and connecting rod cap (2). Push

the connecting rod until the piston rings are out of
the cylinder liner.
5. Remove the piston and the connecting rod from
the cylinder liner.
Note: Be careful not to damage the cylinder liner or
the crankshaft journal during the removal of the
piston and the connecting rod.
140 KENR6055-14
Disassembly and Assembly Section

Illustration 345 g00913818 Illustration 346 g01004841

8. Use Tooling (C) to remove piston rings (6) from 1. Use Tooling (C) to install the piston rings onto the
piston (3). piston.
a. For the oil control ring, ensure that the ends of
i07587533
the spring are 180 degrees from the ring gap.
The white portion of the spring must be visible
Pistons and Connecting Rods at the ring gap.
- Install b. Install the intermediate ring with the side
SMCS Code: 1225-012 marked “UP-2” toward the top of the piston.
c. Install the top ring with the side marked “UP-1”
Installation Procedure toward the top of the piston.
Table 66
d. After the rings are installed, rotate the rings so
Required Tools that the gaps are spread apart by 120 degrees.
Tool Part Number Part Description Qty Orient the oil control ring gap toward the bore
for the piston pin.
A 448-5087 Barring Tool (1) 1

B 1P-1861 Retaining Ring Pliers 1

C 271-0498 Expander Ring 1

D 485-8003 Tool As 1

E - Bel-Ray Molylube 67700(2) -

(1) The 9S-9082 Engine Turning Tool is alternative tooling.
(2) Refer to the following link to order molylube specified above -
www.belray.com.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life. Illustration 347 g01006026

Note: Install the connecting rod bearings dry when 2. Place the piston crown into the piston skirt. Use
clearance checks are performed. Refer to clean engine oil to coat the bore of piston (3),
Disassembly and Assembly, “Bearing Clearance - piston pin (4), and the piston pin bearing in
Check”. Apply clean engine oil on the connecting rod connecting rod (5). Position connecting rod (5)
bearings for final assembly. inside piston (3). Insert piston pin (4) through
piston (3) and the bearing.
KENR6055-14 141
Disassembly and Assembly Section

Illustration 348 g02142776 Illustration 350 g00913801

3. Use Tooling (B) to install the retaining rings. Orient

the retaining ring gaps toward the top of piston (3).
4. Apply clean engine oil to the cylinder liner bore, to
the piston rings, and to the outer surface of the
piston.
Note: Ensure that the connecting rod and pistons are
installed in the correct cylinder.

Illustration 351 g06117839

Section view of connecting rod showing torque
sequence. Chamfer (7) and dowel (8) can be used to
reference orientation.

7. Install the upper half of the connecting rod bearing

on the connecting rod. Ensure that the connecting
rod bearing is installed so that the bearing tab fits
into the notch in the connecting rod. Coat the
Illustration 349 g02142782 connecting rod bearing with clean engine oil.
Position the connecting rod onto a journal of the
5. Use Tooling (A) to rotate the crankshaft until the crankshaft.
connecting rod journal is at the bottom center.
8. Install the lower half of the connecting rod bearing
6. Use Tooling (D) to install the piston in the cylinder on connecting rod cap (2). Ensure that the
liner. connecting rod bearing is installed so that the
bearing tab fits into the notch in the connecting rod
Note: Be careful not to damage the cylinder liner or cap. Coat the connecting rod bearing with clean
the crankshaft journal during the installation of the engine oil.
piston and the connecting rod.
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. Install the chamfered side of the
connecting rod cap next to the thrust surface of the
crankshaft.
Note: Reman connecting rods are not numbered for
the cylinder position.
142 KENR6055-14
Disassembly and Assembly Section

9. Apply Tooling (E) to the threads, the shank, and S/N: PXF1–Up
the seat of bolts (1).
S/N: TTF1–Up
10. Place connecting rod cap (2) into position. Install
S/N: PXG1–Up
bolts (1). Use the following procedure to tighten
the bolts: S/N: TTG1–Up
a. Tighten Bolt (X2) and Bolt (X4) to a torque of S/N: PXH1–Up
90 ± 5 N·m (65 ± 4 lb ft).
S/N: TTH1–Up
b. Tighten Bolt (X1) and Bolt (X3) to a torque of
S/N: PXJ1–Up
90 ± 5 N·m (65 ± 4 lb ft).
S/N: TTJ1–Up
c. Tighten Bolt (X1) and Bolt (X3) again to a
torque of 90 ± 5 N·m (65 ± 4 lb ft). S/N: SLM1–Up
d. Place an index mark on the bolts and the S/N: MXN1–Up
connecting rod cap. Tighten each bolt for an
S/N: MXP1–Up
extra 90 ± 5 degrees (1/4 turn).
S/N: JTS1–Up
11. Rotate the crankshaft to ensure that the
crankshaft turns freely. S/N: MXT1–Up
End By: S/N: E3W1–Up

a. Install the piston cooling jets. S/N: FLW1–Up

b. Install the cylinder head. S/N: PXW1–Up

S/N: TTW1–Up
i02220615
S/N: E3X1–Up
Cylinder Liner - Remove S/N: PXX1–Up
SMCS Code: 1216-011 S/N: E3Y1–Up

S/N: ML21–Up S/N: TTY1–Up

S/N: BG31–Up S/N: E3Z1–Up

S/N: ML31–Up S/N: PXZ1–Up

S/N: T251–Up S/N: TTZ1–Up

S/N: PXA1–Up Removal Procedure

S/N: TTA1–Up Table 67
Required Tools
S/N: DPB1–Up
Tool Part Number Part Description Qty
S/N: PXB1–Up
A 5P-8665 Cylinder Liner Puller 1
S/N: TTB1–Up
S/N: DPC1–Up Start By:
S/N: PXC1–Up
a. Remove the pistons and the connecting rod
S/N: TTC1–Up assemblies. Refer to Disassembly and
Assembly, “Pistons and Connecting Rods -
S/N: DPD1–Up Remove”.
S/N: PXD1–Up
NOTICE
S/N: TTD1–Up Keep all parts clean from contaminants.

S/N: PXE1–Up Contaminants may cause rapid wear and shortened

component life.
S/N: TTE1–Up
S/N: PAF1–Up
KENR6055-14 143
Disassembly and Assembly Section

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

1. Check the cylinder liner projection. Refer to Testing

and Adjusting, “Cylinder Liner Projection”.

Illustration 352 g01120797

1. Use Tooling (A) to remove cylinder liner (1).

Illustration 354 g03326886

2. After the cylinder liner is prepared, use Tooling (B)

Illustration 353 g01004993 to press the cylinder liner into the cylinder block.
2. Remove O-ring seals (3) and filler band (2) from 3. Use a 0.02 mm (0.001 inch) feeler gauge to verify
cylinder liner (1). that the cylinder liner is against the cylinder block.
Check for gaps in multiple places. A gap between
i07591847 the cylinder liner and the cylinder block can
indicate a liner seal that is pinched. A liner seal
Cylinder Liner - Install that is pinched will compromise the life of the liner
seal and the cylinder head gasket.
SMCS Code: 1216-012
Types of Cylinder Liner Seals
Installation Procedure
Table 68 There are two types of seals that can be used on the
cylinder liners.
Required Tools

Tool Part Number Part Description Qty

B 2P-8260 Cylinder Liner Installer 1

Loctite Silicone Lubricant / Di-

- electric Grease —
C LB 8801/LB 8423 (1)

- LB-8104 1652339 (2) —

D - Emery Cloth (Fine) 1

(1) Preferred lubricant
(2) For EAME use only
144 KENR6055-14
Disassembly and Assembly Section

Type 1 Type 2

Illustration 355 g02130336 Illustration 357 g02175641

1. Liner seal (4) requires a machined chamfer at the

top edge of the liner bore to install the liner seal.
2. A chamfer can be machined into the top edge of
the bore in the block for the cylinder liner. Refer to
Special Instruction, SEBF9203 for the correct
procedure for machining the chamfer.

Note: Liner seat inserts that include the chamfer are

also available. Refer to Reuse and Salvage
Guidelines, SEBF8255.

3. Use Tooling (D) on the inside surface of the top

bore, Location (M).
4. Ensure that the liner groove for liner seal (4) is
clean and dry. Install liner seal (4) on cylinder liner
(2). Apply a thin coat of Tooling (C) to the cylinder
block on the machined chamfer to a distance of
5 mm (0.2 inch) below the machined chamfer.
Apply Tooling (C) to liner seal (4).
Illustration 356 g02248239 Note: Do not apply Tooling (C) to the liner flange or
the top of the cylinder block.
1. Apply liquid soap on the grooves for O-ring seals
(1) and on O-ring seals (1). Install O-ring seals (1) 5. Apply liquid soap on the grooves for O-ring seals
on cylinder liner (2). Also, coat the bottom cylinder (1) and on O-ring seals (1). Install O-ring seals (1)
block bore, Location (N), with liquid soap. on cylinder liner (2). Also, coat the bottom cylinder
block bore, Location (N), with liquid soap.
2. Dip filler band (3) in clean engine oil. Immediately
install filler band (3) onto cylinder liner (2).
3. Immediately install cylinder liner (2) before filler
band (3) can expand.
KENR6055-14 145
Disassembly and Assembly Section

End By:
a. Install the pistons and the connecting rod
assemblies.

i07525215

Camshaft - Remove
SMCS Code: 1210-011

Removal Procedure
Table 69
Required Tools

Tool Part Number Part Description Qty Illustration 358 g01122149

1P-0820 Hydraulic Puller 1 1. Remove camshaft covers (1).

8B-7548 Push-Puller Tool Group 1

8B-7559 Adapter 2
A
8B-7561 Step Plate 1

5H-1504 Hard Washer 3

9U-6600 Hand Hydraulic Pump 1

B 125-0200 Camshaft Pilot As 2

C 125-0201 Camshaft Guide As 1

D 8T-3169 Crank Assembly 1

Start By:
a. Remove the rocker shaft assemblies and the
pushrods. Refer to Disassembly and Assembly, Illustration 359 g01157699
“Rocker Shaft and Pushrod - Remove”.
2. Remove cover (2) from the front housing.
b. It is necessary to remove the electronic control
module in order to remove the camshaft from
the left hand side of the engine. Refer to
Disassembly and Assembly, “Electronic
Control Module (Engine) - Remove and Install”.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Note: The following procedure is for removing the

camshaft from the left hand side of the engine.

Illustration 360 g01122147

3. Push valve lifters (3) away from the camshaft. Hold

the valve lifters in position with O-ring seals.
146 KENR6055-14
Disassembly and Assembly Section

Note: Plate (9) must be installed in order to keep

camshaft drive gear (8) on the camshaft during the
removal procedure. Plate (9) can be used from the
right hand camshaft drive gear. If necessary,
fabricate a plate that has a diameter of 76 mm
(3.0 inch). The thickness of the plate must be
19.00 mm (0.750 inch) thick. Drill a hole 22.00 mm
(0.875 inch) in the center of the plate.

Illustration 361 g01122151

4. Remove cover (4) from the flywheel housing.

Remove speed/timing sensor (5) from the flywheel
housing.

Illustration 364 g01122324

NOTICE
Do not apply more than 51675 kPa (7500 psi) pres-
sure to the hydraulic puller. The adapters are rated at
6 1/2 tons each and the hydraulic puller is rated at 17
tons at 68900 kPa (10000 psi). If too much pressure
is applied, the gear may be damaged.

7. Install Tooling (A) on camshaft drive gear (8).

Apply 51675 kPa (7500 psi) to the puller. Strike
Illustration 362 g01122250 the screw on the puller with a hammer until
camshaft drive gear (8) is free from the camshaft.
5. Remove bolt (6). Remove ring (7). Remove Tooling (A) from the camshaft drive gear.
Remove the camshaft drive gear from the
camshaft.

Illustration 363 g01122265

6. Place the three washers from Tooling (A) behind Illustration 365 g01122334
plate (9) and install bolt (6).
8. Remove bolts (11) and thrust washer (10).
9. Remove bolts (12) from the front housing.
KENR6055-14 147
Disassembly and Assembly Section

Illustration 366 g01122335 Illustration 367 g01122346

10. Install Tooling (B) onto both ends of the camshaft. 15. Remove bolts (14). Separate the camshafts and
remove spacer (13).
11. Install Tooling (C) on the front housing.
16. Remove the dowel from the front of the camshaft,
Note: Tooling (C) can be installed on the flywheel if necessary.
housing in order to remove the camshaft from the
rear.
i07680373

12. Install Tooling (D) on the end of Tooling (B).

Camshaft Bearings - Remove
Note: The following Step is for 3508C Engines.
SMCS Code: 1211-011
13. Rotate the camshaft with Tooling (D) and pull the
camshaft out of the cylinder block until a suitable Removal Procedure
lifting device can be attached. The weight of the Table 70
camshaft for 3508C Engine is approximately 50 kg
Required Tools
(110 lb). Remove the camshaft from the cylinder
block. Tool Part Number Part Description Qty

Note: The following Steps are for 3512C , 3512E, A 6V-4077 Camshaft Bearing Tool 1
and 3516C Engines. Camshaft Bearing Tool
B 8S-2241 1
Group
14. Rotate the camshaft with Tooling (D) and pull the
camshaft out of the engine until a suitable lifting C 5P-5247 Hydraulic Puller(1) 1
device can be attached. The weight of the D 8H-0684 Ratchet Wrench 1
camshaft for 3512C and 3512E Engine is (1) Do not exceed 27580 kPa (4000psi).
approximately 90 kg (198 lb). The weight of the
camshaft for 3516C Engine is approximately 95 kg Start By:
(209 lb). Remove the camshaft from the cylinder
block. a. Remove the camshafts. Refer to Disassembly
and Assembly, “Camshaft - Remove”.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
148 KENR6055-14
Disassembly and Assembly Section

Note: Tooling (D) can be used in place of Tooling (C),

if necessary.

i07680381

Camshaft Bearings - Install

SMCS Code: 1211-012

Installation Procedure
Table 71
Required Tool

Tool Part Number Part Description Qty

Illustration 368 g00914509 A 6V-4077 Camshaft Bearing Tool 1
Typical example
Camshaft Bearing Tool
B 8S-2241 1
Group
1. Use the following steps to install Tooling (A).
C 5P-5247 Hydraulic Puller(1) 1
a. Install the pilot group in the camshaft bearing.
D 8H-0684 Ratchet Wrench 1
b. Place the backup plate in position and ensure (1) Do not exceed 27580 kPa (4000 psi).
that the bearing is between the two parts.
c. Install the bolt that holds Tooling (A) together. NOTICE
d. Use the extensions to obtain the correct length Keep all parts clean from contaminants.
for Tooling (A). Contaminants may cause rapid wear and shortened
component life.
e. Install the puller plate on the bolt and the
flywheel housing or the front housing.

Note: Tooling (B) can be used to remove the

camshaft bearings when the flywheel housing and
the front housing have been removed.

Illustration 370 g00578338

1. Install camshaft bearing (1) on Tooling (A).

Note: Tooling (B) can be used to install the camshaft

Illustration 369 g00914512 bearings when the flywheel housing and the front
Typical example housing have been removed.

2. Install Tooling (C) on Tooling (A). Pull the bearing

from the cylinder block.
KENR6055-14 149
Disassembly and Assembly Section

End By:
a. Install the camshafts. Refer to Disassembly
and Assembly, “Camshaft - Install”.

i07525238

Camshaft - Install
SMCS Code: 1210-012

Installation Procedure
Table 72
Required Tools
Illustration 371 g02108639 Part Description Qty
Tool Part Number
Rear View
B 125-0200 Camshaft Pilot As 2
(X) Location of camshaft bearing joints
(Y) Location of oil holes C 125-0201 Camshaft Guide As 1

D 8T-3169 Crank Assembly 1

2. Position camshaft bearing (1) and Tooling (A) in
the bore. E 238-9586 Camshaft Drive Group 1

Note: The camshaft bearing joint must be on the F 5P-3931 Anti-Seize Compound -
horizontal centerline of the bore. The upper oil hole
must be 20 ± 5 degrees above the horizontal
centerline of the bore. The lower oil hole of the NOTICE
camshaft bearing must be 20 ± 5 degrees below the Keep all parts clean from contaminants.
horizontal centerline of the bore. The camshaft
Contaminants may cause rapid wear and shortened
bearing joints must face the inside the cylinder block. component life.

Note: The following procedure is for installing the

camshaft in the left-hand side of the engine.

Note: The following Step is for 3512C, 3512E, and

3516C Engines.

Illustration 372 g00578349

3. Install Tooling (C) on Tooling (A) and pull camshaft

bearing (1) into the bore.

Note: Tooling (D) can be used in place of Tooling (C).

4. After the camshaft bearing is installed, measure

the bore. The bore must be 92.00 ± 0.06 mm
(3.622 ± 0.002 inch).
150 KENR6055-14
Disassembly and Assembly Section

Illustration 373 g01122346 Illustration 374 g01123198

1. Attach a suitable lifting device to rear half of the 3. Install Tooling (C) on the front housing. Do not
camshaft. The weight of one-half of the camshaft tighten the bolts on Tooling (C).
for 3516C Engine is approximately 47 kg (104 lb).
The weight of one-half of the camshaft for 3512C Note: Tooling (C) can be installed on the flywheel
housing in order to install the camshaft from the rear
and 3512E Engine is approximately 45 kg (99 lb).
of the engine.
Install spacer (13) and the rear half of the
camshaft onto the front half of the camshaft. Install 4. Install Tooling (B) on the ends of the camshaft.
bolts (14) and tighten to a torque of 55 ± 7 N·m Install Tooling (D) on Tooling (B) which is installed
(41 ± 5 lb ft). on the front of the camshaft.
Note: Ensure that the camshafts are assembled 5. Ensure that the camshaft and the camshaft
according to the marks on the ends of the camshafts. bearings are clean. Place clean engine oil on the
If the dowel was removed from the front half of the lobes and the journals of the camshaft. Also place
camshaft, install the dowel. Install the dowel to clean engine oil on the camshaft bearings.
12.0 ± 0.5 mm (0.47 ± 0.02 inch) from the surface of
the camshaft. 6. Rotate the camshaft and insert the camshaft into
the engine. Position the camshaft in the engine
Note: The following Step is for 3508C Engines. until Tooling (B) is in the front camshaft bearing.
Rotate the camshaft in order to align Tooling (C)
2. Attach a suitable lifting device to the camshaft. The
and the camshaft bores. Tighten the bolts for
weight of the camshaft for 3508C Engine is
Tooling (C).
approximately 50 kg (110 lb).
7. Rotate the camshaft and insert the camshaft into
Note: Ensure that the camshaft is installed according
the engine. Remove Tooling (D) from Tooling (B).
to the marks on the ends of the camshaft. If the dowel
Remove Tooling (B) from the camshaft. Remove
was removed from the front half of the camshaft,
install the dowel. Install the dowel to 12.0 ± 0.5 mm Tooling (C) from the front housing.
(0.47 ± 0.02 inch).
KENR6055-14 151
Disassembly and Assembly Section

Illustration 375 g01122334 Illustration 377 g01123337

8. Install thrust washer (10) and bolts (11). 12. Remove bolts (17), cover (16), and plug (18) from
flywheel housing (19).
9. Install bolts (12).
13. Install one bolt (17) into the flywheel housing
NOTICE through the hole for plug (18). Use Tooling (E) and
If the camshaft is out of time more than 18 degrees a ratchet to turn the flywheel until bolt (17) can be
(approximately 1/2 of the timing pin is out of the
groove), the valves can make contact with the pis- installed through the hole and into the flywheel.
tons. This will cause damage to the engine. Refer to Doing so will position the No. 1 cylinder at the top
Testing and Adjusting, “Camshaft Timing” for more center. Refer to Testing and Adjusting, “Finding the
information. Top Center Position for the No. 1 Piston” for more
information.

Illustration 376 g01122583 Illustration 378 g01123380

10. Remove timing plate (15) from the storage 14. Use the following procedure in order to install
position under the rear camshaft cover. camshaft drive gear (8).
11. Turn the camshaft until the timing pin can be a. Clean the taper of the camshaft and the
installed through the cylinder block and into the tapered bore of the camshaft gear with a lint
groove that is in the camshaft. Refer to Testing free cloth saturated with solvent to remove oil.
and Adjusting, “Camshaft Timing” for more Clean the parts again with a lint free alcohol
information. wipe in order to remove any residue. The the
alcohol wipe will dirty after cleaning the parts.
Clean the parts again with a lint free alcohol
wipe until no residue is left on the alcohol wipe.

Note: The camshaft and the tapered bore of the

camshaft gear must be clean, dry, and free of
residue before assembly.
152 KENR6055-14
Disassembly and Assembly Section

b. Ensure that the camshaft timing pins and the

timing pin for the flywheel are installed.
c. Place camshaft drive gear (8) in position.
Remove the backlash by rotating the gears in
the opposite direction of camshaft rotation.
Note: For “Standard Rotation” engines, turn the
camshaft drive gears COUNTERCLOCKWISE. For
“Reverse Rotation” engines, turn the camshaft
drive gears CLOCKWISE.

d. Install bolt (6) and ring (7). Ensure that the hole
in the ring is properly seated on the locating pin.
e. Tighten the bolt to a torque of 360 N·m
(265 lb ft). Illustration 380 g01123337

f. Place a Mark on the bolt. 19. Remove the timing bolt from the flywheel. Install
g. Place a driver against the retaining plate of the plug (18) in the timing hole. Install cover (16) and
camshaft gear. Strike the driver solidly with a bolts (17) on flywheel housing (19).
hammer 3 to 4 times.
h. Tighten the bolt again to a torque of 360 N·m
(265 lb ft).
i. Repeat Steps 14g and 14h until the Mark has
turned at least 90 degrees.
15. Remove the timing pin from the camshaft. Install
the timing pin in the storage position under the
rear camshaft cover.

Illustration 381 g01157699

20. Install cover (2) on the front housing.

Illustration 379 g01122151

16. Install the O-ring seal on engine speed/timing

sensor (5). Extend the sliphead of the speed/
timing sensor to a minimum distance of 4.0 mm
(0.16 inch) prior to installation.
17. Apply Tooling (F) to the threads of engine speed/
timing sensor (5). Install the engine speed/timing Illustration 382 g01122147
sensor in the flywheel housing and tighten to a
torque of 40 ± 5 N·m (30 ± 4 lb ft). 21. Remove the O-ring seals from valve lifters (3).
Push the valve lifters against the camshaft.
18. Install cover (4) on the flywheel housing.
KENR6055-14 153
Disassembly and Assembly Section

Start By:
a. Remove the rocker shaft assemblies and the
pushrods. Refer to Disassembly and Assembly,
“Rocker Shaft and Pushrod - Remove”.
b. Remove the flywheel housing. Refer to
Disassembly and Assembly, “Flywheel
Housing - Remove”.
c. Remove the front housing. Refer to
Disassembly and Assembly, “Housing (Front) -
Remove”.
d. Remove the piston cooling jets. Refer to
Disassembly and Assembly, “Piston Cooling
Jets - Remove and Install”.
Illustration 383 g01122149
NOTICE
22. Install camshaft covers (1) on the cylinder block. Failure to remove the rocker shaft assemblies and
push rods can result in damaged valves when the
End By: pistons and connecting rods are pushed away from
the crankshaft.
a. Install the electronic control module. Refer to
the Disassembly and Assembly, “Electronic To help avoid damage to the valves, remove the rock-
Control Module (Engine) - Remove and Install”. er shaft assemblies and push rods before you re-
move the crankshaft.
b. Install the rocker shaft assemblies and the
pushrods. Refer to Disassembly and Assembly,
“Rocker Shaft and Pushrod - Install”.
NOTICE
Keep all parts clean from contaminants.
i07525285
Contaminants may cause rapid wear and shortened
Crankshaft - Remove component life.

SMCS Code: 1202-011

1. Use Tooling (A) to turn the engine to a horizontal
position. The engine can be supported with
Removal Procedure Tooling (A) or with blocks.
Table 73
Required Tools • The weight of the 3508C Engine is
approximately 4535 kg (10000 lb).
Tool Part Number Part Description Qty

Engine Rollover Stand

• The weight of the 3512C and 3512E Engine is
A 4C-9832 1
approximately 6800 kg (15000 lb).
B 138-7576 Link Bracket 2
• The weight of the 3516C Engine is
approximately 9100 kg (20000 lb).
Note: It is not necessary to remove the
counterweights from the crankshaft, if the piston and
connecting rod assemblies have been removed from
the engine.
154 KENR6055-14
Disassembly and Assembly Section

Illustration 384 g01124519 Illustration 386 g01124538

2. Place identification marks on counterweights (2). 4. Attach Tooling (B) to each end of crankshaft (7).
Remove bolts (1) and counterweights (2) from the Attach a suitable lifting device to Tooling (B). The
crankshaft. weight of the 3508C crankshaft is approximately
400 kg (880 lb). The weight of the 3512C and
Note: Do not reuse bolts (1). Use new bolts in order 3512E crankshaft is approximately 600 kg
to secure the counterweight to the crankshaft.
(1325 lb). The weight of the 3516C crankshaft is
approximately 800 kg (1765 lb).
5. Remove bolts (5) and main bearing caps (6).
6. Remove thrust plates (8) from each side of the
center main bearing.
7. Remove crankshaft (7) from the cylinder block.
8. Remove the upper halves of the main bearings
from the cylinder block.
9. Remove the upper halves of the connecting rod
bearings from the connecting rods.

Illustration 385 g01124522

Note: Number the connecting rod caps and the

connecting rods for installation purposes.

3. Remove bolts (3). Remove connecting rod cap (4)

and push the connecting rod away from the
crankshaft.
Note: Ensure that the journals of the crankshaft are
not scratched by the connecting rods.
KENR6055-14 155
Disassembly and Assembly Section

Illustration 387 g01124543 Illustration 388 g01124614

10. If necessary, remove bolts (9) and crankshaft 1. Install plugs (11) and tighten to a torque of
gear (10) from each end of the crankshaft. 50 ± 7 N·m (37 ± 5 lb ft).
2. Position crankshaft gear (10) on the crankshaft
i07525310
and install bolts (9).
Crankshaft - Install
SMCS Code: 1202-012

Installation Procedure
Table 74
Required Tools

Tool Part Number Part Description Qty

A 4C-9832 Engine Rollover Stand 1

B 439-3941 Link Bracket As 2

C - Bel-Ray Molylube 67700 (1) -

D 8T-5096 Dial Indicator Gp 1

Illustration 389 g01124115
(1) Refer to the following link to order molylube specified above -
www.belray.com. Note: Install the main bearings dry when clearance
checks are performed. Refer to Disassembly and
NOTICE Assembly, “Bearing Clearance - Check”. Apply clean
Keep all parts clean from contaminants. engine oil on the main bearings for final assembly.
Contaminants may cause rapid wear and shortened 3. Install the upper half of main bearing (12) in the
component life. cylinder block. Ensure that the main bearing is
installed so that the bearing tab fits into the notch
in the cylinder block. Coat the main bearing with
clean engine oil.
Note: The upper half of the main bearing has an oil
hole in the center.

4. Install the upper halves of connecting rod bearings

(13) in the connecting rod assemblies. Coat the
connecting rod bearing with clean engine oil.
156 KENR6055-14
Disassembly and Assembly Section

8. Coat the underside of the bolt heads and the

threads of bolts (5) with clean engine oil. Position
main bearing caps (6) and install the bolts and
washers. Do not tighten the bolts now.
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.

9. Tighten bolts (5) in sequence to a torque of

190 ± 14 N·m (140 ± 10 lb ft).

Illustration 390 g01124538

10. Place an index mark on the bolts and the main
bearing cap. Tighten the bolts for an extra 180 ± 5
degrees (1/2 turn).
11. Rotate the crankshaft to ensure that the
crankshaft turns freely.
12. Use Tooling (D) to measure the end play of the
crankshaft. The end play must not exceed
0.17 to 0.63 mm (0.007 to 0.025 inch).

Illustration 391 g01124192

Bolt tightening sequence for the main bearing caps

Note: Ensure that the word “FRONT” that is on the

end of the crankshaft is toward the front of the
engine.

5. Attach Tooling (B) and a suitable lifting device to

each end of crankshaft (7). The weight of the Illustration 392 g01124522

3508C crankshaft is approximately 400 kg

(880 lb). The weight of the 3512C and 3512E
crankshaft is approximately 600 kg (1325 lb). The
weight of the 3516C crankshaft is approximately
800 kg (1765 lb). Position the crankshaft in the
cylinder block.
6. Place clean engine oil on thrust plates (8). Install
thrust plates (8) on each side of the center main
bearing.
7. Install the lower half of the main bearing in the
main bearing cap. Ensure that the main bearing is
installed so that the bearing tab fits into the notch
in main bearing cap (6). Coat the main bearing
with clean engine oil.
Illustration 393 g06120079
Bolt tightening sequence for the connecting rod caps
KENR6055-14 157
Disassembly and Assembly Section

Note: Install the connecting rod bearings dry when

clearance checks are performed. Refer to
Disassembly and Assembly, “Bearing Clearance -
Check”. Apply clean engine oil on the connecting rod
bearings for final assembly.

13. Install the upper half of the connecting rod

bearing on the connecting rod . Ensure that the
connecting rod bearing is installed so that the
bearing tab fits into the notch in the connecting
rod. Coat the connecting rod bearing with clean
engine oil. Position the connecting rod onto a
journal of the crankshaft.
14. Install the lower half of the connecting rod bearing
on connecting rod cap (4). Ensure that the Illustration 394 g01124519
connecting rod bearing is installed so that the
bearing tab fits into the notch in the connecting rod 18. If the counterweights have been removed, install
cap. Coat the connecting rod bearing with clean counterweights (2). Use the correct tightening
engine oil. procedure for the specific engine model:

Note: The number that is on the side of the 19. The following procedure is for the installation
connecting rod caps must be installed next to the of the counterweights in 3508C Engines.
corresponding number that is on the side of the
connecting rod. Install the chamfered side of the Note: Do not reuse counterweight bolts.
connecting rod cap next to the thrust surface of the
a. Ensure that the dowels are in the correct
crankshaft.
position and install the counterweights on the
Note: Reman connecting rods are not numbered for crankshaft.
the cylinder position.
b. Apply Tooling (C) to the bolt threads, shanks,
15. Apply Tooling (C) to the threads, the shank, and and seats.
the seat of bolts (3). c. Tighten the outer bolts first then the inner bolt to
16. Place connecting rod cap (4) into position. Install a torque of 200 ± 5 N·m (150 ± 4 lb ft).
bolts (3). Use the following procedure to tighten d. Loosen the bolts.
the bolts:
e. Tighten the bolts in the same sequence to a
a. Tighten Bolt (X1) and Bolt (X3) to a torque of torque of 70 ± 5 N·m (50 ± 4 lb ft).
90 ± 5 N·m (65 ± 4 lb ft).
f. Tighten the bolts in the same sequence for an
b. Tighten Bolt (X2) and Bolt (X4) to a torque of extra 120 ± 5 degrees (1/3 turn).
90 ± 5 N·m (65 ± 4 lb ft).
20. The following procedure is for the installation
c. Tighten Bolt (X2) and Bolt (X4) again to a of the counterweights in 3512B, 3512C, 3512E,
torque of 90 ± 5 N·m (65 ± 4 lb ft). and 3516C Engines.
d. Place an index mark on the bolts and the Note: Do not reuse counterweight bolts.
connecting rod cap. Tighten each bolt for an
extra 90 ± 5 degrees (1/4 turn). a. Ensure that the dowels are in the correct
17. Rotate the crankshaft to ensure that the position and install the counterweights on the
crankshaft turns freely. crankshaft.
b. Apply Tooling (C) to the bolt threads, shanks,
NOTICE and seats.
Each counterweight is numbered and must be in-
stalled in the same position as the corresponding c. Tighten the outer bolts first then the inner bolt to
number on the crankshaft mounting pad in order to a torque of 70 ± 5 N·m (50 ± 4 lb ft).
prevent damage to the crankshaft.
d. Tighten the bolts in the same sequence for an
extra 120 ± 5 degrees (1/3 turn).
158 KENR6055-14
Disassembly and Assembly Section

21. Use Tooling (A) to turn the engine to a vertical 1. Drain the coolant from the cooling system into a
position. suitable container for storage or disposal. Refer to
Operation and Maintenance Manual, “Cooling
End By: System Coolant - Change”.
a. Install the piston cooling jets. 2. Disconnect the elbows from the heat exchanger.
b. Install the front housing. Remove the heat exchanger from the engine.

c. Install the flywheel housing. Note: It is not necessary to remove the heat
exchanger in order to disassemble the heat
d. Install the rocker shaft assemblies and the exchanger. The disassembly procedure can be
pushrods. performed on the engine.

i06736505 Note: Put identification marks on all plate assemblies

for installation purposes.
Heat Exchanger - Disassemble
SMCS Code: 1379-015

Disassembly Procedure
Table 75
Required Tools

Tool Part Number Part Description Qty

A 366-3469 Mounting Bar 2

Guide Stud
- 8
5/8 - 11 by 12 inch

B 8T-4122 Hard Washer 8

6V-4803 Thrust Bearing 8 Illustration 395 g02104414

4K-0367 Full Nut 16 3. Use suitable cribbing to place the heat exchanger
C 4C-5591 Anti-Seize Compound - in a flat position on the rear frame. This position
can help ensure proper alignment during the
D - Scotch Brite 1
procedure.

Note: The following story is for 300-5617 4. Remove bolts (1) from the corners. Install Tooling
and 300-5622 Sea Water Heat Exchanger Gp. (B) in spacers (4). Apply Tooling (C) to the threads
of the nut and the threads of the guide stud prior to
NOTICE installation. Install the thrust bearing, the hard
Care must be taken to ensure that fluids are con- washer, and the nuts on the guide stud. Ensure
tained during performance of inspection, mainte- that Tooling (B) is securely installed. Place two
nance, testing, adjusting, and repair of the product. nuts together and tighten the outer nut in order to
Be prepared to collect the fluid with suitable contain- install Tooling (B). Position the thrust bearing, the
ers before opening any compartment or disassem-
bling any component containing fluids. hard washer, and one nut against the front frame.
5. Remove bolts (3) from front frame (2). Install
Refer to Special Publication, PERJ1017, “Dealer
Service Tool Catalog” for tools and supplies suitable Tooling (B) in the same manner as Step 4.
to collect and contain fluids on Cat ® products.
Note: It is not necessary to remove the bolts from the
Dispose of all fluids according to local regulations rear frame.
and mandates.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
KENR6055-14 159
Disassembly and Assembly Section

Illustration 396 g02104417 Illustration 398 g02141318

6. Remove bolts (5) and the spacers from the front 8. Remove Tooling (B) from the spacers.
frame. Install Tooling (A).
9. Remove front frame (2). Remove the collars and
the liners from front frame (2).

Note: A gasket may stick to the front frame during

removal.

Note: Ensure that the collars and the liners are not
damaged during removal from the front frame.
Note: The liners are removed from the front of the
front frame.
Note: Note the order and orientation of the heat
exchanger plates and the gaskets during removal.

10. Remove heat exchanger plates (6).

Illustration 397 g02104418 Note: Check the O-ring seals, the gaskets, and the
seals for wear or for damage. Replace the
7. Loosen the nuts on Tooling (B) evenly. Ensure that components, if necessary.
Tooling (B) does not loosen from the spacers.
Note: Do not loosen the nuts more than one turn per
nut until the heat exchanger plates are no longer
compressed.
Note: As the front frame rises, the heat exchanger
plates will slide along Tooling (A).

Illustration 399 g06097990

11. Remove gaskets (9) from heat exchanger plates

(6).
160 KENR6055-14
Disassembly and Assembly Section

Instructions for Cleaning

1. Clean the plates with a coarse nylon brush or new
Tooling (D). Do not use a dirty Tooling (D), steel
wool, or a wire brush, which may scratch the
titanium plates. Any iron scratches in the titanium
plates can lead to corrosion of the plates. The
recommended cleaning solution for scale buildup
(calcium carbonate) and sediment buildup
(corrosion products) is a maximum of 4 percent
solution of nitric, citric, or sulfuric acid. The
recommended cleaning solution for cleaning
biological growth is a 4 percent solution of sodium
hydroxide. Rinse plates thoroughly with water.
Illustration 400 g06097989
i04159425
12. Remove gasket (9) and ring seals (10) from the
last heat exchanger plate (6). Heat Exchanger - Assemble
SMCS Code: 1379-016

S/N: BS21–Up
S/N: ML21–Up
S/N: BG31–Up
S/N: ML31–Up
S/N: MA51–Up
S/N: T251–Up
S/N: FT61–Up
S/N: TT61–Up
Illustration 401 g02130836 S/N: TT71–Up

13. Remove collars (7) and liners (8) from the ports of S/N: PXA1–Up
the rear frame. Clean any deposits from the ports. S/N: DPB1–Up
Note: Ensure that the collars and the liners are not S/N: PXB1–Up
damaged during removal from the rear frame.
S/N: DPC1–Up
Note: The liners are removed from the rear of the
rear frame. S/N: PXC1–Up
S/N: DPD1–Up
S/N: PXD1–Up
S/N: TTD1–Up
S/N: PXE1–Up
S/N: PAF1–Up
S/N: PXF1–Up
S/N: PXG1–Up
S/N: PXH1–Up
S/N: TTH1–Up
S/N: PXJ1–Up
KENR6055-14 161
Disassembly and Assembly Section

S/N: TTJ1–Up
NOTICE
S/N: MXN1–Up Keep all parts clean from contaminants.

S/N: MXP1–Up Contaminants may cause rapid wear and shortened

component life.
S/N: JTS1–Up
S/N: MXT1–Up
S/N: FLW1–Up
S/N: PXW1–Up
S/N: TTW1–Up
S/N: PXX1–Up
S/N: TTY1–Up
S/N: E3Z1–Up
S/N: PXZ1–Up
S/N: TTZ1–Up

Assembly Procedure Illustration 402 g02130836

Table 76
1. Install liners (8) and collars (7) in the ports of the
Required Tools rear frame.
Tool Part Number Part Description Qty
Note: The liners are installed through the rear of the
A 366-3469 Mounting Bar 2 rear frame.
Guide Stud
- 8
5/8 - 11 by 12 inch

B 8T-4122 Hard Washer 8

6V-4803 Thrust Bearing 8

4K-0367 Full Nut 16

C 4C-5591 Anti-Seize Compound -

F 366-3468 Cover Plate 6

2D-7325 Pipe Tee 3

8T-0853 Pressure Gauge 3

4C-7121 Nipple 3
G
129-3078 Shutoff Valve Assembly 3

4C-7158 Fitting 3

5P-3413 Pipe Sealant -

4C-7121 Nipple 3

129-3078 Shutoff Valve Assembly 3

4C-7000 Bushing 3
H
7W-8705 Fitting 3

5P-0720 Hose 1

5P-3413 Pipe Sealant -

Note: The following story is for 300-5622 Sea

Water Heat Exchanger Gp.
162 KENR6055-14
Disassembly and Assembly Section

Illustration 403 g06097989

Illustration 404 g02146927

2. Position gasket (9) on the heat exchanger plate

(6). Install tabs (X) of the gasket into the slots of
heat exchanger plate (6). Install ring seals (10)
into the grooves of first heat exchanger plate.

Note: Use tape to hold ring seal (10) in the grooves

of the first heat exchanger plate.

Illustration 405 g06097990

3. Install gaskets (9) onto the rest of the heat

exchanger plates (6).
KENR6055-14 163
Disassembly and Assembly Section

Illustration 406 g02141318

164 KENR6055-14
Disassembly and Assembly Section

Illustration 407 g02105981

KENR6055-14 165
Disassembly and Assembly Section

(A) Rear frame (M) 327-1135 Plate Assembly 149-2213 (S) 327-1135 Plate Assembly 149-2213
(B) Front of the engine Seal Seal
(J) 327-1133 Plate Assembly (N) 327-1136 Plate Assembly 149-2213
(K) 327-1134 Plate Assembly Seal
(L) 327-1136 Plate Assembly 449-3078 (P) 327-1137 Plate Assembly
Seal (R) 327-1115 Plate Assembly

NOTICE
149-2213 Seal must be cut to match each plate.

Note: Ensure the proper order and orientation of the

heat exchanger plates and the gaskets.
Note: The gaskets on the heat exchanger plates
should face the rear frame during installation.
Note: Use Tooling (A) to ensure that the heat
exchanger plates are properly aligned.

Note: Ensure that the edges of the heat exchanger

plates are properly aligned and the gaskets are in the
proper grooves in the heat exchanger plates.
Illustration 408 g02104418

Note: If the heat exchanger plates do not lay flat

during installation on the rear frame, Tooling (A) may 7. Tighten the nuts on Tooling (B) evenly until the
be loosened and retightened to accommodate the front frame contacts the spacers.
heat exchanger plates.
Note: As the front frame lowers, the heat exchanger
Note: If the heat exchanger plates appear stuck plates will slide along Tooling (A).
together or do not align during installation, the edges
of the heat exchanger plates can be lightly lifted and Note: Check the heat exchanger plates, the gaskets,
adjusted. and the gasket tabs frequently during compression to
ensure proper alignment. Ensure that the gaskets are
4. Install heat exchanger plates (6) and the gaskets. not pinched during compression. A pinched gasket
will be observed by the edges of the adjacent heat
5. Install the liners and the collars in front frame (2). exchanger plates separating slightly.
Install front frame (2).
Note: If proper alignment of the heat exchanger
Note: The liners are installed from the front of the plates is not achieved during compression, the front
front frame. frame can be loosened and the heat exchanger
plates lightly adjusted.
6. Install Tooling (B) in the spacers. Ensure that
Tooling (B) is securely installed. Apply Tooling (C)
to the threads of the nut and the threads of the
guide stud prior to installation.

Illustration 409 g02104417

8. Remove Tooling (A) and install the spacers and

bolts (5).
166 KENR6055-14
Disassembly and Assembly Section

Leak Checking the Heat Exchanger

Illustration 410 g02104414

Illustration 412 g02388416

Note: Leak checking of the heat exchanger should

be completed before installation on the engine.

1. Install Tooling (F), (G), and (H) on the ports of the

heat exchanger.
Note: Each circuit on the heat exchanger will require
two Tooling (F), one Tooling (G), and one Tooling (H).

a. Attach an air hose to the end of Tooling (G) on

the sea water (SW) circuit.
b. Verify that flow through is achieved on (SW).
Illustration 411 g02105860 c. Pressurize (SW) at 275 kPa (40 psi) and close
off the circuit.
9. Remove Tooling (B) and install bolts (3) in spacers
d. Close Tooling (G) on the end of jacket water
(4) through front frame (2).
(JW) circuit and separate circuit aftercooler
10. Remove Tooling (B) and install bolts (1) in circuit (SCAC).
spacers (4) through front frame (2).
e. Attach some hoses to the ends of Tooling (H)
11. Tighten the bolts in a numerical sequence to a on (JW) and (SCAC). Place the ends of the
torque of 260 N·m (190 lb ft). hoses under water and check for bubbles with
(SW) pressurized. A continuous stream of
12. Install the heat exchanger on the engine.
bubbles from the hoses would indicate an
Connect the elbows to the heat exchanger.
internal leakage in the heat exchanger. An
13. Fill the cooling system. Refer to Operation and internal leakage indicates the heat exchanger
Maintenance Manual, “Cooling System Coolant - was improperly assembled.
Change”.
f. Leave (SW) pressurized. Repeat Step 1a
through Step 1c with the (JW).
g. Leave (SW) and (JW) pressurized. Repeat Step
1a through Step 1c with the (SCAC).
KENR6055-14 167
Disassembly and Assembly Section

S/N: BM21–Up
S/N: DE21–Up
S/N: MA21–Up
S/N: MB21–Up
S/N: ML21–Up
S/N: PR21–Up
S/N: RL21–Up
S/N: SB21–Up
S/N: TT21–Up

Illustration 413 g02178220

S/N: BG31–Up
Top View S/N: MA31–Up
S/N: MB31–Up
S/N: ML31–Up
S/N: TT31–Up
S/N: MB41–Up
S/N: TT41–Up
S/N: T251–Up
Illustration 414 g02183700
Cross-section of Plate Assembly S/N: TT51–Up
S/N: PXA1–Up
2. With all circuits pressurized and closed off,
submerge the entire heat exchanger and check for S/N: TTA1–Up
a continuous stream of bubbles from the heat S/N: DPB1–Up
exchanger. Bubbles may be present initially when
the heat exchanger is submerged, but the bubbles S/N: PXB1–Up
should stop after a few minutes. It is common to S/N: TTB1–Up
see a stream of bubbles in a straight line at
Locations (G). The bubbles should stop after a few S/N: DPC1–Up
minutes. S/N: PXC1–Up
3. The gaskets on the heat exchanger plates contain S/N: TTC1–Up
weep holes at Locations (H). As a result, bubbles
may be present near Locations (H). The bubbles S/N: DPD1–Up
should stop after a few minutes. Leave the entire S/N: PXD1–Up
heat exchanger submerged until bubbles stop
coming from the weep holes. S/N: PXE1–Up

Note: Once the heat exchanger is installed on the S/N: TTE1–Up

engine and started, water may leak out of the weep S/N: PXF1–Up
holes. After a short time, the water leak will stop. This
is not an indication of a faulty heat exchanger. S/N: TTF1–Up
S/N: PXG1–Up
i04159424
S/N: TTG1–Up
Heat Exchanger - Assemble S/N: PXH1–Up
SMCS Code: 1379-016 S/N: EWJ1–Up
S/N: 2A21–Up S/N: PXJ1–Up
S/N: BG21–Up S/N: SLM1–Up
168 KENR6055-14
Disassembly and Assembly Section

S/N: TTM1–Up (Table 77, contd)

S/N: MXN1–Up Required Tools

S/N: MXP1–Up Tool Part Number Part Description Qty

S/N: TTP1–Up 4C-7000 Bushing 3

S/N: MXT1–Up 7W-8705 Fitting 3

5P-0720 Hose 1
S/N: E3W1–Up
5P-3413 Pipe Sealant -
S/N: FLW1–Up
S/N: MNW1–Up Note: The following story is for 300-5617 Sea
S/N: PXW1–Up Water Heat Exchanger Gp.

S/N: TTW1–Up
NOTICE
S/N: E3X1–Up Keep all parts clean from contaminants.

S/N: PXX1–Up Contaminants may cause rapid wear and shortened

component life.
S/N: TTX1–Up
S/N: E3Y1–Up
S/N: TTY1–Up
S/N: PXZ1–Up
S/N: TTZ1–Up

Assembly Procedure
Table 77
Required Tools

Tool Part Number Part Description Qty

A 366-3469 Mounting Bar 2

Guide Stud
- 8 Illustration 415 g02130836
5/8 - 11 by 12 inch

B 8T-4122 Hard Washer 8 1. Install liners (8) and collars (7) in the ports of the
6V-4803 Thrust Bearing 8 rear frame.

4K-0367 Full Nut 16 Note: The liners are installed through the rear of the
rear frame.
C 4C-5591 Anti-Seize Compound -

F 366-3468 Cover Plate 6

2D-7325 Pipe Tee 3

8T-0853 Pressure Gauge 3

4C-7121 Nipple 3
G
129-3078 Shutoff Valve Assembly 3

4C-7158 Fitting 3

5P-3413 Pipe Sealant -

4C-7121 Nipple 3
H
129-3078 Shutoff Valve Assembly 3

(continued)
KENR6055-14 169
Disassembly and Assembly Section

Illustration 416 g06097989

Illustration 417 g02146927

2. Position gasket (9) on the heat exchanger plate

(6). Install tabs (X) of the gasket into the slots of
heat exchanger plate (6). Install ring seals (10)
into the grooves of first heat exchanger plate.

Note: Use tape to hold ring seal (10) in the grooves

of the first heat exchanger plate.

Illustration 418 g06097990

3. Install gaskets (9) onto the rest of the heat

exchanger plates (6).
170 KENR6055-14
Disassembly and Assembly Section

Illustration 419 g02141318

KENR6055-14 171
Disassembly and Assembly Section

Illustration 420 g02105674

172 KENR6055-14
Disassembly and Assembly Section

(A) Rear frame (M) 327-1135 Plate Assembly 149-2213 (S) 327-1135 Plate Assembly 149-2213
(B) Front of the engine Seal Seal
(J) 327-1133 Plate Assembly (N) 327-1136 Plate Assembly 149-2213
(K) 327-1134 Plate Assembly Seal
(L) 327-1136 Plate Assembly 449-3078 (P) 327-1137 Plate Assembly
Seal (R) 327-1115 Plate Assembly

Note: Seal 149-2213 needs to be cut to match each

plate
Note: Ensure the proper order and orientation of the
heat exchanger plates and the gaskets.

Note: The gaskets on the heat exchanger plates

should face the rear frame during installation.

Note: Use Tooling (A) to ensure that the heat

exchanger plates are properly aligned.
Note: Ensure that the edges of the heat exchanger
plates are properly aligned and the gaskets are in the
proper grooves in the heat exchanger plates.
Note: If the heat exchanger plates do not lay flat Illustration 421 g02104418
during installation on the rear frame, one side of
Tooling (A) may be loosened and retightened to 7. Tighten the nuts on Tooling (B) evenly until the
accommodate the heat exchanger plates. front frame contacts the spacers.
Note: If the heat exchanger plates appear stuck Note: As the front frame lowers, the heat exchanger
together or do not align during installation, the edges plates will slide along Tooling (A).
of the heat exchanger plates can be lightly lifted and
adjusted. Note: Check the heat exchanger plates, the gaskets,
and the gasket tabs frequently during compression to
4. Install heat exchanger plates (6) and the gaskets. ensure proper alignment. Ensure that the gaskets are
not pinched during compression. A pinched gasket
5. Install the liners and the collars in front frame (2).
will be observed by the edges of the adjacent heat
Install front frame (2). exchanger plates separating slightly.
Note: The liners are installed from the front of the Note: If proper alignment of the heat exchanger
front frame. plates is not achieved during compression, the front
frame can be loosened and the heat exchanger
6. Install Tooling (B) in the spacers. Ensure that
plates lightly adjusted.
Tooling (B) is securely installed. Apply Tooling (C)
to the threads of the nut and the threads of the
guide stud prior to installation.

Illustration 422 g02104417

8. Remove Tooling (A) and install the spacers and

bolts (5).
KENR6055-14 173
Disassembly and Assembly Section

Leak Checking the Heat Exchanger

Illustration 423 g02104414

Illustration 425 g02388416

Note: Leak checking of the heat exchanger should

be completed before installation on the engine.

1. Install Tooling (F), (G), and (H) on the ports of the

heat exchanger.
Note: Each circuit on the heat exchanger will require
two Tooling (F), one Tooling (G), and one Tooling (H).

a. Attach an air hose to the end of Tooling (G) on

the sea water (SW) circuit.
b. Verify that flow through is achieved on (SW).
Illustration 424 g02105860 c. Pressurize (SW) at 275 kPa (40 psi) and close
off the circuit.
9. Remove Tooling (B) and install bolts (3) in spacers
d. Close Tooling (G) on the end of jacket water
(4) through front frame (2).
(JW) circuit and separate circuit aftercooler
10. Remove Tooling (B) and install bolts (1) in circuit (SCAC).
spacers (4) through front frame (2).
e. Attach some hoses to the ends of Tooling (H)
11. Tighten the bolts in a numerical sequence to a on (JW) and (SCAC). Place the ends of the
torque of 260 N·m (190 lb ft). hoses under water and check for bubbles with
(SW) pressurized. A continuous stream of
12. Install the heat exchanger on the engine.
bubbles from the hoses would indicate an
Connect the elbows to the heat exchanger.
internal leakage in the heat exchanger. An
13. Fill the cooling system. Refer to Operation and internal leakage indicates the heat exchanger
Maintenance Manual, “Cooling System Coolant - was improperly assembled.
Change”.
f. Leave (SW) pressurized. Repeat Step 1a
through Step 1c with the (JW).
g. Leave (SW) and (JW) pressurized. Repeat Step
1a through Step 1c with the (SCAC).
174 KENR6055-14
Disassembly and Assembly Section

Note: Once the heat exchanger is installed on the

engine and started, water may leak out of the weep
holes. After a short time, the water leak will stop. This
is not an indication of a faulty heat exchanger.

i02487338

Balancer Group (Front) -

Remove and Install
(3508C Engine)
SMCS Code: 1220-010

S/N: ML21–Up
Illustration 426 g02178220
Top View S/N: PR21–Up
S/N: TT21–Up
S/N: BG31–Up
S/N: ML31–Up
S/N: TT31–Up
S/N: MB41–Up
S/N: T251–Up
Illustration 427 g02183700
S/N: PXA1–Up
Cross-section of Plate Assembly
S/N: TTA1–Up
2. With all circuits pressurized and closed off, S/N: DPB1–Up
submerge the entire heat exchanger and check for
a continuous stream of bubbles from the heat S/N: PXB1–Up
exchanger. Bubbles may be present initially when S/N: TTB1–Up
the heat exchanger is submerged, but the bubbles
should stop after a few minutes. It is common to S/N: DPC1–Up
see a stream of bubbles in a straight line at S/N: PXC1–Up
Locations (G). The bubbles should stop after a few
minutes. S/N: DPD1–Up
3. The gaskets on the heat exchanger plates contain S/N: PXD1–Up
weep holes at Locations (H). As a result, bubbles S/N: PXE1–Up
may be present near Locations (H). The bubbles
should stop after a few minutes. Leave the entire S/N: PXF1–Up
heat exchanger submerged until bubbles stop S/N: PXG1–Up
coming from the weep holes.
S/N: PXH1–Up
S/N: PXJ1–Up
S/N: TTM1–Up
S/N: MXN1–Up
S/N: MXP1–Up
S/N: TTP1–Up
S/N: MXT1–Up
S/N: FLW1–Up
S/N: PXW1–Up
KENR6055-14 175
Disassembly and Assembly Section

S/N: TTW1–Up
NOTICE
S/N: PXX1–Up Keep all parts clean from contaminants.

S/N: TTY1–Up Contaminants may cause rapid wear and shortened

component life.
S/N: PXZ1–Up
S/N: TTZ1–Up

Removal Procedure
Table 78
Required Tools

Tool Part Number Part Description Qty

A 1P-0520 Driver Group 1

Start By:
a. Remove the front housing. Refer to
Disassembly and Assembly, “Housing (Front) -
Remove”.
Illustration 429 g01135236
NOTICE
Keep all parts clean from contaminants. 1. Use Tooling (A) and a suitable press to install
Contaminants may cause rapid wear and shortened sleeve bearing (6) in balancer gear (5).
component life.
Note: Sleeve bearing (6) must be machined to the
correct inside diameter. Refer to Special Instructions,
SEHS9282, “Machining of Replacement Sleeve
Bearings”.

2. Install gear shaft (2) and bolts (1). Tighten bolts (1)
to a torque of 140 ± 10 N·m (103 ± 7 lb ft).
3. Apply clean engine oil on the sleeve bearing in
balancer gear (5) and gear shaft (2). Install
balancer gear (5) on gear shaft (2). Make sure that
the marks on balancer gear (5) and the crankshaft
gear are in alignment with the rotation of the
engine. Install thrust plate (4) and bolts (3).

Illustration 428 g01135236

1. Remove bolts (3) and thrust plate (4).

2. Remove balancer gear (5) from gear shaft (2).
3. Use Tooling (A) and a suitable press to remove
sleeve bearing (6) from balancer gear (5).
4. Remove bolts (1) and gear shaft (2) from the front
of the cylinder block.

Installation Procedure
Table 79
Required Tools

Tool Part Number Part Description Qty

A 1P-0520 Driver Group 1

176 KENR6055-14
Disassembly and Assembly Section

End By: 4. Remove the O-ring seal from the engine oil
pressure sensor.
a. Install the front housing. Refer to Disassembly
and Assembly, “Housing (Front) - Install”. Installation Procedure
i02241445 NOTICE
Keep all parts clean from contaminants.
Engine Oil Pressure Sensor -
Contaminants may cause rapid wear and shortened
Remove and Install component life.
SMCS Code: 1924-010

Removal Procedure
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Refer to Special Publication, PERJ1017, “Dealer
Service Tool Catalog” for tools and supplies suitable
to collect and contain fluids on Cat ® products.
Dispose of all fluids according to local regulations
and mandates. Illustration 431 g01129710

1. Install a new O-ring seal on filtered engine oil

NOTICE pressure sensor (1). Apply clean engine oil to the
Keep all parts clean from contaminants. O-ring seal.
Contaminants may cause rapid wear and shortened 2. Install filtered engine oil pressure sensor (1) and
component life. tighten to a torque of 10 ± 2 N·m (89 ± 18 lb in).
3. Connect the harness assembly.
4. Install a new O-ring seal on unfiltered engine oil
pressure sensor (2). Apply clean engine oil to the
O-ring seal.
5. Install unfiltered engine oil pressure sensor (2) and
tighten to a torque of 10 ± 2 N·m (89 ± 18 lb in).
6. Connect the harness assembly.

i02240085

Turbocharger Inlet Pressure

Sensor - Remove and Install
Illustration 430 g01129710 SMCS Code: 1917-010

1. Disconnect the harness assembly and remove Removal Procedure

filtered engine oil pressure sensor (1).
2. Remove the O-ring seal from the engine oil NOTICE
Keep all parts clean from contaminants.
pressure sensor.
Contaminants may cause rapid wear and shortened
3. Disconnect the harness assembly and remove component life.
unfiltered engine oil pressure sensor (2).
KENR6055-14 177
Disassembly and Assembly Section

3. Connect the harness assembly.

i02239883

Turbocharger Outlet Pressure

Sensor - Remove and Install
SMCS Code: 1917-010

Removal Procedure
NOTICE
Keep all parts clean from contaminants.

Illustration 432 g01129348

Contaminants may cause rapid wear and shortened
component life.
1. Disconnect the harness assembly and remove
turbocharger inlet pressure sensor (1).
2. Remove the O-ring seal from the turbocharger inlet
pressure sensor.

Installation Procedure
Table 80
Required Tools

Tool Part Number Part Description Qty

A 1U-6396 O-Ring Assembly Compound -

NOTICE
Keep all parts clean from contaminants.
Illustration 434 g01129223
Contaminants may cause rapid wear and shortened
component life. 1. Disconnect the harness assembly and remove
turbocharger outlet pressure sensor (1).
2. Remove the O-ring seal from the turbocharger
outlet pressure sensor.

Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Illustration 433 g01129348

1. Install a new O-ring seal on turbocharger inlet

pressure sensor (1). Apply Tooling (A) to the O-
ring seal.
2. Install turbocharger inlet pressure sensor (1) and
tighten to a torque of 10 ± 2 N·m (89 ± 18 lb in).
178 KENR6055-14
Disassembly and Assembly Section

Illustration 435 g01129223 Illustration 436 g01129266

1. Install a new O-ring seal on turbocharger outlet 2. Disconnect the harness assembly and remove
pressure sensor (1). coolant temperature sensor (1).
2. Install turbocharger outlet pressure sensor (1) and 3. Remove the O-ring seal from the coolant
tighten to a torque of 10 ± 2 N·m (89 ± 18 lb in). temperature sensor.
3. Connect the harness assembly. 4. If necessary, remove the adapter from the water
temperature regulator housing. Remove the O-ring
i02710195 seal from the adapter.

Coolant Temperature Sensor - Installation Procedure

Remove and Install NOTICE
Keep all parts clean from contaminants.
SMCS Code: 1906-010
Contaminants may cause rapid wear and shortened
Removal Procedure component life.

NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Refer to Special Publication, PERJ1017, “Dealer
Service Tool Catalog” for tools and supplies suitable
to collect and contain fluids on Cat ® products.
Dispose of all fluids according to local regulations
and mandates.

NOTICE
Keep all parts clean from contaminants. Illustration 437 g01129266

Contaminants may cause rapid wear and shortened 1. Install a new O-ring seal on the adapter. Install the
component life. adapter in the water temperature regulator
housing.
1. Drain the coolant from the cooling system to a 2. Install a new O-ring seal on coolant temperature
level below the coolant temperature sensor into a sensor (1).
suitable container for storage or disposal. Refer to
Operation and Maintenance Manual, “Cooling 3. Install coolant temperature sensor (1) and tighten
System Coolant - Change”. to a torque of 20 ± 5 N·m (15 ± 4 lb ft).
KENR6055-14 179
Disassembly and Assembly Section

4. Connect the harness assembly.

5. Fill the cooling system. Refer to Operation and
Maintenance Manual, “Cooling System Coolant -
Change”.

i02710224

Aftercooler Coolant
Temperature Sensor - Remove
and Install
SMCS Code: 1906-010

Removal Procedure Illustration 438 g01130042

NOTICE 2. Disconnect the harness assembly and remove

Care must be taken to ensure that fluids are con- aftercooler coolant temperature sensor (1).
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product. 3. Remove the O-ring seal from the aftercooler
Be prepared to collect the fluid with suitable contain- coolant temperature sensor.
ers before opening any compartment or disassem-
bling any component containing fluids. Installation Procedure
Refer to Special Publication, PERJ1017, “Dealer NOTICE
Service Tool Catalog” for tools and supplies suitable Keep all parts clean from contaminants.
to collect and contain fluids on Cat ® products.
Contaminants may cause rapid wear and shortened
Dispose of all fluids according to local regulations component life.
and mandates.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

1. Drain the coolant from the cooling system to a

level below the aftercooler coolant temperature
sensor into a suitable container for storage or
disposal. Refer to Operation and Maintenance
Manual, “Cooling System Coolant - Change”.

Illustration 439 g01130042

1. Install a new O-ring seal on aftercooler coolant

temperature sensor (1).
2. Install aftercooler coolant temperature sensor (1)
and tighten to a torque of 10 ± 2 N·m
(89 ± 18 lb in).
3. Connect the harness assembly.
180 KENR6055-14
Disassembly and Assembly Section

4. Fill the cooling system with coolant. Refer to

Operation and Maintenance Manual, “Cooling
System Coolant - Change”.

i02237506

Engine Speed/Timing Sensor -

Remove and Install
SMCS Code: 1912-010

Removal Procedure
NOTICE
Keep all parts clean from contaminants. Illustration 441 g01128407

Contaminants may cause rapid wear and shortened 1. Install the O-ring seal on engine speed/timing
component life. sensor (2). Extend sliphead (3) to a minimum
distance of 4.0 mm (0.16 inch) prior to installation.
2. Apply Tooling (A) to the threads of engine speed/
timing sensor (2). Install the engine speed/timing
sensor in the flywheel housing and tighten to a
torque of 40 ± 5 N·m (30 ± 4 lb ft).
3. Connect harness assembly (1).

i02241924

Crankcase Pressure Sensor -

Remove and Install
SMCS Code: 1916-010

Illustration 440 g01128361

Removal Procedure
1. Disconnect harness assembly (1). NOTICE
2. Remove engine speed/timing sensor (2) from the Keep all parts clean from contaminants.
flywheel housing. Remove the O-ring seal from the Contaminants may cause rapid wear and shortened
engine speed/timing sensor. component life.

Installation Procedure
Table 81
Required Tools

Tool Part Number Part Description Qty

A 5P-3931 Anti-Seize Compound -

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
KENR6055-14 181
Disassembly and Assembly Section

3. Connect the harness assembly.

i02237707

Atmospheric Pressure Sensor

- Remove and Install
SMCS Code: 1923-010

S/N: ML21–Up
S/N: BG31–Up
S/N: ML31–Up
S/N: T251–Up
Illustration 442 g01129987
S/N: PXA1–Up
1. Disconnect the harness assembly and remove
S/N: TTA1–Up
crankcase pressure sensor (1).
S/N: DPB1–Up
2. Remove the O-ring seal from the crankcase
pressure sensor. S/N: PXB1–Up

Installation Procedure S/N: TTB1–Up

S/N: DPC1–Up
NOTICE
Keep all parts clean from contaminants. S/N: PXC1–Up
Contaminants may cause rapid wear and shortened S/N: TTC1–Up
component life.
S/N: DPD1–Up
S/N: PXD1–Up
S/N: TTD1–Up
S/N: PXE1–Up
S/N: TTE1–Up
S/N: PAF1–Up
S/N: PXF1–Up
S/N: TTF1–Up
S/N: PXG1–Up
S/N: TTG1–Up
S/N: PXH1–Up
Illustration 443 g01129987
S/N: TTH1–Up
1. Install a new O-ring seal on the crankcase S/N: PXJ1–Up
pressure sensor (1).
S/N: TTJ1–Up
2. Install crankcase pressure sensor (1) and tighten
to a torque of 10 ± 2 N·m (89 ± 18 lb in). S/N: SLM1–Up
S/N: MXN1–Up
S/N: MXP1–Up
S/N: JTS1–Up
S/N: MXT1–Up
S/N: E3W1–Up
182 KENR6055-14
Disassembly and Assembly Section

S/N: FLW1–Up
S/N: PXW1–Up
S/N: TTW1–Up
S/N: E3X1–Up
S/N: PXX1–Up
S/N: E3Y1–Up
S/N: TTY1–Up
S/N: E3Z1–Up
S/N: PXZ1–Up
S/N: TTZ1–Up Illustration 445 g01128579

Removal Procedure 1. Install a new O-ring seal on atmospheric pressure

sensor (1).
NOTICE
Keep all parts clean from contaminants. 2. Install atmospheric pressure sensor (1) and tighten
Contaminants may cause rapid wear and shortened to a torque of 10 ± 2 N·m (89 ± 18 lb in).
component life. 3. Connect the harness assembly.

i05421239

Engine Speed Sensor -

Remove and Install
SMCS Code: 1907-010

Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Illustration 444 g01128579

1. Disconnect the harness assembly and remove

atmospheric pressure sensor (1).
2. Remove the O-ring seal from the atmospheric
pressure sensor.

Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Illustration 446 g03421326

1. Disconnect harness assembly (1).

KENR6055-14 183
Disassembly and Assembly Section

2. Loosen the locknut and remove engine speed

NOTICE
sensor (2) from the flywheel housing. Keep all parts clean from contaminants.
Installation Procedure Contaminants may cause rapid wear and shortened
component life.
NOTICE
Keep all parts clean from contaminants.
1. Turn the fuel shutoff valve to the OFF position.
Contaminants may cause rapid wear and shortened
component life.

Illustration 448 g03421516

2. Disconnect the harness assembly and remove

Illustration 447 g03421401 filtered fuel pressure sensor (1).

1. Install engine speed sensor (2) in the flywheel 3. Disconnect the harness assembly and remove fuel
housing. Turn the engine speed sensor until there pressure sensor (2).
is contact with the tooth of the ring gear of flywheel 4. Remove the O-ring seals.
(3). Turn the engine speed sensor for 1/2 of a turn
away from the ring gear. Tighten the locknut to a Installation Procedure
torque of 25 ± 5 N·m (18 ± 4 lb ft). Table 82
2. Connect harness assembly (1). Required Tools

Tool Part Number Part Description Qty

i06707581
A 369-9451 Grease -
Fuel Pressure Sensor -
Remove and Install NOTICE
Keep all parts clean from contaminants.
SMCS Code: 7414-010
Contaminants may cause rapid wear and shortened
Removal Procedure component life.

NOTICE 1. Install fuel pressure sensor (1) and fuel pressure

Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte- sensor (2) in the reverse order of removal.
nance, testing, adjusting, and repair of the product. a. Tighten fuel pressure sensor (1) and fuel
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem- pressure sensor (2) to a torque of 10 ± 2 N·m
bling any component containing fluids. (89 ± 18 lb in).

Refer to Special Publication, PERJ1017, “Dealer

Service Tool Catalog” for tools and supplies suitable
to collect and contain fluids on Cat ® products.
Dispose of all fluids according to local regulations
and mandates.
184 KENR6055-14
Index Section

Index
A Installation Procedure .................................... 175
Removal Procedure ....................................... 175
Accessory Drive (Front) - Assemble.................... 104 Bearing Clearance - Check ................................ 131
Assembly Procedure ...................................... 104 Measurement Procedure ................................ 131
Accessory Drive (Front) - Assemble (Engine Oil
Pump and Water Pump)................................... 105
Assembly Procedure ...................................... 105 C
Accessory Drive (Front) - Disassemble ............... 102
Disassembly Procedure ................................. 102 Camshaft - Install .............................................. 149
Accessory Drive (Front) - Disassemble (Engine Installation Procedure .................................... 149
Oil Pump and Water Pump) .............................. 103 Camshaft - Remove .......................................... 145
Disassembly Procedure ................................. 103 Removal Procedure ....................................... 145
Accessory Drive (Front) - Install.......................... 107 Camshaft Bearings - Install ................................ 148
Installation Procedure .................................... 107 Installation Procedure .................................... 148
Accessory Drive (Front) - Install (Engine Oil Camshaft Bearings - Remove ............................ 147
Pump and Water Pump)................................... 106 Removal Procedure ....................................... 147
Installation Procedure .................................... 106 Connecting Rod Bearings - Remove and Install ... 132
Accessory Drive (Front) - Remove ...................... 101 Installation Procedure .................................... 133
Removal Procedure ....................................... 101 Removal Procedure ....................................... 133
Accessory Drive (Front) - Remove (Engine Oil Coolant Temperature Sensor - Remove and
Pump and Water Pump)................................... 100 Install ............................................................. 178
Removal Procedure ....................................... 100 Installation Procedure .................................... 178
Aftercooler - Remove and Install...........................21 Removal Procedure ....................................... 178
Installation Procedure ......................................22 Crankcase Breather - Remove and Install .............79
Removal Procedure .........................................21 Installation Procedure ......................................80
Aftercooler Coolant Temperature Sensor - Removal Procedure .........................................79
Remove and Install .......................................... 179 Crankcase Pressure Sensor - Remove and
Installation Procedure .................................... 179 Install ............................................................. 180
Removal Procedure ....................................... 179 Installation Procedure .................................... 181
Air Inlet Manifold - Remove and Install ..................24 Removal Procedure ....................................... 180
Installation Procedure ......................................25 Crankshaft - Install ............................................ 155
Removal Procedure .........................................25 Installation Procedure .................................... 155
Air Regulator - Remove and Install (Air Starting) ......5 Crankshaft - Remove......................................... 153
Installation Procedure ........................................7 Removal Procedure ....................................... 153
Removal Procedure ...........................................6 Crankshaft Front Seal and Wear Sleeve - Install .. 112
Alternator - Remove and Install ..............................8 Installation Procedure For Seals 113-8432 and
Installation Procedure ........................................9 113-8433 ..................................................... 112
Removal Procedure ...........................................8 Installation Procedure For Seals 436-1478 and
Alternator Mounting Group - Remove and Install......9 436-1479..................................................... 113
Installation Procedure ........................................9 Crankshaft Front Seal and Wear Sleeve -
Removal Procedure ...........................................9 Remove.......................................................... 111
Atmospheric Pressure Sensor - Remove and Removal Procedure ....................................... 111
Install ............................................................. 181 Crankshaft Main Bearings - Install ...................... 136
Installation Procedure .................................... 182 Installation Procedure .................................... 136
Removal Procedure ....................................... 182 Crankshaft Main Bearings - Remove................... 134
Auxiliary Water Pump - Assemble.........................51 Removal Procedure ....................................... 134
Assembly Procedure ........................................51 Crankshaft Rear Seal and Wear Sleeve - Install... 116
Auxiliary Water Pump - Assemble (Auxiliary Installation Procedure For Seals 113-8432 and
Pump (Type 1)) .................................................52 113-8433 ..................................................... 116
Assembly Procedure ........................................52 Installation Procedure For Seals 436-1478 and
Auxiliary Water Pump - Disassemble ....................50 436-1479..................................................... 116
Disassembly Procedure ...................................50 Crankshaft Rear Seal and Wear Sleeve -
Auxiliary Water Pump - Disassemble (Auxiliary Remove.......................................................... 115
Pump (Type 1)) .................................................44 Removal Procedure ....................................... 115
Disassembly Procedure ...................................44 Cylinder Head - Install .........................................90
Auxiliary Water Pump - Install...............................61 Installation Procedure ......................................90
Installation Procedure ......................................61 Cylinder Head - Remove......................................89
Auxiliary Water Pump - Remove ...........................43 Removal Procedure .........................................89
Removal Procedure .........................................43 Cylinder Liner - Install ........................................ 143
Installation Procedure .................................... 143
Cylinder Liner - Remove .................................... 142
B Removal Procedure ....................................... 142
Balancer Group (Front) - Remove and Install
(3508C Engine) ............................................... 174
KENR6055-14 185
Index Section

D Installation Procedure ......................................26

Removal Procedure .........................................25
Disassembly and Assembly Section .......................5 Exhaust Manifold - Remove and Install ........... 26, 28
Installation Procedure ................................ 27, 30
E Removal Procedure ................................... 26, 29
Electric Starting Motor - Remove and Install ............7
Installation Procedure ........................................8 F
Removal Procedure ...........................................7 Flywheel - Remove and Install............................ 113
Electronic Control Module (Engine) - Remove Installation Procedure .................................... 114
and Install .........................................................10 Removal Procedure ....................................... 113
Installation Procedure ...................................... 11 Flywheel Housing - Install .................................. 119
Removal Procedure .........................................10 Installation Procedure .................................... 119
Electronic Unit Injector - Install .............................88 Flywheel Housing - Remove .............................. 117
Installation Procedure ......................................88 Removal Procedure ....................................... 117
Electronic Unit Injector - Remove..........................87 Fuel Filter Housing - Install...................................12
Removal Procedure .........................................87 Installation Procedure ......................................12
Engine Oil Cooler - Assemble...............................64 Fuel Filter Housing - Remove ............................... 11
Assembly Procedure ........................................64 Removal Procedure ......................................... 11
Engine Oil Cooler - Disassemble ..........................63 Fuel Pressure Sensor - Remove and Install......... 183
Disassembly Procedure ...................................63 Installation Procedure .................................... 183
Engine Oil Cooler - Install ....................................65 Removal Procedure ....................................... 183
Installation Procedure ......................................65 Fuel Priming Pump - Remove and Install...............13
Engine Oil Cooler - Remove.................................62 Installation Procedure ......................................13
Removal Procedure .........................................62 Removal Procedure .........................................13
Engine Oil Filter Housing - Assemble ....................72 Fuel Transfer Pump - Assemble ...........................16
Assembly Procedure ........................................72 Assembly Procedure ........................................16
Engine Oil Filter Housing - Disassemble ...............71 Fuel Transfer Pump - Disassemble .......................14
Disassembly Procedure ...................................71 Disassembly Procedure ...................................14
Engine Oil Filter Housing - Install..........................73 Fuel Transfer Pump - Install .................................18
Installation Procedure ......................................73 Installation Procedure ......................................18
Engine Oil Filter Housing - Remove ......................70 Fuel Transfer Pump - Remove..............................14
Removal Procedure .........................................70 Removal Procedure .........................................14
Engine Oil Pan - Assemble ..................................76 Fumes Filter - Remove and Install ........................81
Assembly Procedure ........................................77 Installation Procedure ......................................81
Engine Oil Pan - Disassemble ..............................75 Removal Procedure .........................................81
Disassembly Procedure ...................................75
Engine Oil Pan - Install ........................................78
Installation Procedure ......................................78 G
Engine Oil Pan - Remove.....................................74
Removal Procedure .........................................74 Gear Group (Rear) - Install................................. 127
Engine Oil Pressure Sensor - Remove and Installation Procedure .................................... 127
Install ............................................................. 176 Gear Group (Rear) - Remove ............................. 125
Installation Procedure .................................... 176 Removal Procedure ....................................... 125
Removal Procedure ....................................... 176
Engine Oil Pump - Assemble................................68
Assembly Procedure ........................................68 H
Engine Oil Pump - Disassemble ...........................67 Heat Exchanger - Assemble........................160, 167
Disassembly Procedure ...................................67 Assembly Procedure ...............................161, 168
Engine Oil Pump - Install......................................69 Heat Exchanger - Disassemble .......................... 158
Installation Procedure ......................................69 Disassembly Procedure ................................. 158
Engine Oil Pump - Remove ..................................66 Housing (Front) - Install ..................................... 109
Removal Procedure .........................................66 Installation Procedure .................................... 109
Engine Oil Sequence Valves - Remove and Housing (Front) - Remove.................................. 108
Install ............................................................. 122 Removal Procedure ....................................... 108
Installation Procedure .................................... 124
Removal Procedure ....................................... 122
Engine Speed Sensor - Remove and Install ........ 182 I
Installation Procedure .................................... 183
Removal Procedure ....................................... 182 Important Safety Information ..................................2
Engine Speed/Timing Sensor - Remove and Inlet and Exhaust Valve Guides - Remove and
Install ............................................................. 180 Install ...............................................................98
Installation Procedure .................................... 180 Installation Procedure ......................................98
Removal Procedure ....................................... 180 Removal Procedure .........................................98
Exhaust Bypass Valve - Remove and Install ..........31 Inlet and Exhaust Valve Seat Inserts - Remove
Installation Procedure ......................................32 and Install .........................................................99
Removal Procedure .........................................32 Installation Procedure .................................... 100
Exhaust Elbow - Remove and Install.....................25 Removal Procedure .........................................99
186 KENR6055-14
Index Section

Inlet and Exhaust Valve Springs - Remove and Water Pump - Remove ........................................35
Install ...............................................................94 Removal Procedure .........................................35
Installation Procedure ......................................95 Water Temperature Regulators - Install .................34
Removal Procedure .........................................94 Installation Procedure ......................................34
Inlet and Exhaust Valves - Remove and Install.......96 Water Temperature Regulators - Remove .............33
Installation Procedure ......................................97 Removal Procedure .........................................33
Removal Procedure .........................................96

P
Piston Cooling Jets - Remove and Install ............ 130
Installation Procedure .................................... 131
Removal Procedure ....................................... 130
Pistons and Connecting Rods - Install................. 140
Installation Procedure .................................... 140
Pistons and Connecting Rods - Remove ............. 138
Removal Procedure ....................................... 138

R
Rocker Shaft - Assemble .....................................85
Assembly Procedure ........................................85
Rocker Shaft - Disassemble.................................84
Disassembly Procedure ...................................84
Rocker Shaft and Push Rods - Install....................85
Installation Procedure ......................................85
Rocker Shaft and Pushrod - Remove ....................83
Removal Procedure .........................................83

T
Table of Contents ..................................................3
Turbocharger - Install ..........................................20
Installation Procedure ......................................20
Turbocharger - Remove.......................................18
Removal Procedure .........................................19
Turbocharger Inlet Pressure Sensor - Remove
and Install ....................................................... 176
Installation Procedure .................................... 177
Removal Procedure ....................................... 176
Turbocharger Outlet Pressure Sensor -
Remove and Install .......................................... 177
Installation Procedure .................................... 177
Removal Procedure ....................................... 177

V
Valve Mechanism Cover - Remove and Install .......82
Installation Procedure ......................................82
Removal Procedure .........................................82
Valve Mechanism Cover Base - Remove and
Install ...............................................................82
Installation Procedure ......................................82
Removal Procedure .........................................82
Vibration Damper - Remove and Install ............... 110
Installation Procedure .................................... 111
Removal Procedure ....................................... 110

W
Water Pump - Assemble ......................................39
Assembly Procedure ........................................39
Water Pump - Disassemble..................................36
Disassembly Procedure ...................................36
Water Pump - Install ............................................42
Installation Procedure ......................................42
KENR6055 CAT, CATERPILLAR, LET’S DO THE WORK, their respective logos, “Caterpillar Yellow”, the
©2019 Caterpillar “Power Edge” and Cat “Modern Hex” trade dress as well as corporate and product identity used
All Rights Reserved herein, are trademarks of Caterpillar and may not be used without permission.

188 December 2019