Visual Service Procedures for 3500 Off-Highway Truck Engines{1000} Caterpillar

Off-Highway Truck/Tractor:

793D (S/N: JXG1-UP)

Introduction

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.

Illustration 1	g00008666

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.

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.

General Information

Graphic Color Description

Table 1

Graphic Color Description
Color	Description
Blue	The primary component of focus for a particular step. Target or primary component to be installed or removed. Installation implied unless otherwise noted with a symbol.
Cat® Yellow	Description of parts
Yellow	Components places aside for access, but not removed: highlighted areas of adjustment, inspection, or special attention
Light Blue	Special tools or other equipment required used in a particular step
Purple	Special tools or other equipment required used in a particular step
Light Gray	Components used for reference (Glass with transparency of 80%)
Magenta	Any fastener, retainer, or electrical connector to install or remove the primary component

Graphic Symbol Description

Apply Sealant - To apply an unbroken line of sealing material having the specified thickness or diameter.

Clean - To remove foreign or undesired material.

Compress, Load - To press together, to squeeze. To transfer weight or force to an object. The weight or force carried by an object.

Cool - To reduce the temperature of an object or system.

Discard, Do Not Reuse - To cast aside as useless or undesirable in approved and responsible manner.

Disconnect - To remove from an electrical circuit. To separate.

Finger Tighten - To apply tension or torque with one's digits and unaided by a tool or lever.

Grease - To apply a thick sticky lubricant.

Keep, Store - To retain for reinstallation or reuse.

Level - To position a surface in a horizontal orientation. To position in vertical dimension. To align to assist positioning a surface in a horizontal orientation.

Loosen - To make less tight. To set free. To release.

Lubricate, Oil - To apply a material to a surface to reduce friction. To smear, lubricate, or supply with oil or a lubricating fluid.

Measure - To determine the dimension, area, volume, or other quantifiable property of an object; a desired quantity of something.

Persons Required - To specify the number of people required to safely perform the procedure.

Remove - To take off.

Support - To bear the weight of an object.

Tighten - To make nearer to fully stretched; without slack; to apply tension or torque.

Special Tool - To work with a nonstandard device.

Weld - To join by heating until liquid portions of two or more pieces of metal in contact with each other and allowing the common puddle to solidify.

Inspect

Torque Specifications

English (SAE) Fasteners

Table 2

Nuts and Bolts
Thread Size Inch	Standard Torque
1/4	12 ± 3 N·m (9 ± 2 lb ft)
5/16	25 ± 5 N·m (18 ± 5 lb ft)
3/8	47 ± 10 N·m (35 ± 5 lb ft)
7/16	70 ± 15 N·m (50 ± 10 lb ft)
1/2	105 ± 20 N·m (75 ± 15 lb ft)
9/16	160 ± 30 N·m (120 ± 20 lb ft)
5/8	215 ± 40 N·m (160 ± 30 lb ft)
3/4	370 ± 50 N·m (275 ± 37 lb ft)
7/8	620 ± 80 N·m (460 ± 60 lb ft)
1	900 ± 100 N·m (660 ± 75 lb ft)
1 1/8	1300 ± 150 N·m (960 ± 110 lb ft)
1 1/4	1800 ± 200 N·m (1320 ± 150 lb ft)
1 3/8	2400 ± 300 N·m (1780 ± 220 lb ft)
1 1/2	3100 ± 350 N·m (2280 ± 260 lb ft)

Metric (ISO) Fasteners

The following table has the recommended standard torque values.

Table 3

Nuts and Bolts
Thread Size Metric	Standard Torque
M6	12 ± 3 N·m (9 ± 2 lb ft)
M8	30 ± 5 N·m (20 ± 5 lb ft)
M10	55 ± 10 N·m (40 ± 5 lb ft)
M12	100 ± 20 N·m (75 ± 15 lb ft)
M14	160 ± 30 N·m (120 ± 20 lb ft)
M16	240 ± 40 N·m (175 ± 30 lb ft)
M20	460 ± 60 N·m (340 ± 45 lb ft)
M24	800 ± 100 N·m (590 ± 75 lb ft)
M30	1600 ± 200 N·m (1180 ± 150 lb ft)
M36	2700 ± 300 N·m (2000 ± 220 lb ft)

Hydraulic Four Bolt Flange

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Illustration 2	g02724217

1. Position the flanges parallel over the port.

2. Evenly install bolts hand-tight, keeping the gap between flanges at a minimum.

3. Put the hose in a position so that the hose does not contact the machine or with another hose.

4. Tighten using one of the assembly torque values for bolts, used in Illustration 2 for proper torque sequence of various flange fittings.

Straight Thread O-ring Fittings

The following tables have the recommended standard torque values.

Note: Straight Thread O-Ring fittings for medium pressure usage will have shorter threaded ends than high-pressure fittings. The torque value for medium pressure Straight Thread O-Ring fittings will be lower than the torque values that are required for Straight Thread O-Ring fittings for high-pressure fittings.

Table 4

Ferrous Straight Thread O-Ring Fitting Torques for Mating with Ferrous Materials Medium Pressure use Fittings
Nominal Outer Diameter of the Tube	Thread Size Inch	Standard Torque
3.18 mm (.125 inch)	5/16 - 24	10 ± 2 N·m (7 ± 1. lb ft)
4.76 mm (.188 inch)	3/8 - 24	17 ± 3 N·m (13 ± 2 lb ft)
6.35 mm (.250 inch)	7/16 - 20	35 ± 5 N·m (26 ± 4 lb ft)
7.94 mm (.312 inch)	1/2 - 20	45 ± 7 N·m (33 ± 5 lb ft)
9.52 mm (.375 inch)	9/16 - 18	45 ± 7 N·m (33 ± 5 lb ft)
12.70 mm (.500 inch)	3/4 - 16	80 ± 12 N·m (59 ± 9 lb ft)
15.88 mm (.625 inch)	7/8 - 14	110 ± 17 N·m (81 ± 13 lb ft)
19.05 mm (.750 inch)	1 1/16 - 12	130 ± 20 N·m (96 ± 15 lb ft)
22.22 mm (.875 inch)	1 3/16 - 12	200 ± 30 N·m (148 ± 22 lb ft)
25.40 mm (1.000 inch)	1 5/16 - 12	220 ± 33 N·m (162 ± 24 lb ft)
31.75 mm (1.250 inch)	1 5/8 - 12	300 ± 45 N·m (221 ± 33 lb ft)
38.10 mm (1.500 inch)	1 7/8 - 12	350 ± 53 N·m (258 ± 39 lb ft)
50.80 mm (2.000 inch)	2 1/2 - 12	420 ± 63 N·m (310 ± 46 lb ft)

Note: Straight Thread O-Ring fittings for high-pressure usage will have longer threaded ends than medium pressure fittings. The torque value for high-pressure Straight Thread O-Ring fittings will be higher than the torque values that are required for Straight Thread O-Ring fittings for medium pressure fittings.

Table 5

Ferrous Straight Thread O-Ring Fittings Torques for Mating with Ferrous Materials High Pressure use with O-Ring Face Seal Fittings
Nominal Outer Diameter of the Tube	Thread Size Inch	Standard Torque
4.76 mm (0.188 inch)	3/8 - 24	25 ± 4 N·m (18 ± 3 lb ft)
6.35 mm (0.250 inch)	7/16 - 20	35 ± 5 N·m (26 ± 4 lb ft)
7.94 mm (0.312 inch)	1/2 - 20	50 ± 8 N·m (37 ± 6 lb ft)
9.52 mm (0.375 inch)	9/16 - 18	70 ± 11 N·m (52 ± 8 lb ft)
12.7 mm (0.500 inch)	3/4 - 16	110 ± 17 N·m (81 ± 13 lb ft)
15.88 mm (0.625 inch)	7/8 - 14	140 ± 21 N·m (103 ± 15 lb ft)
19.05 mm (0.750 inch)	1 1/16 - 12	220 ± 33 N·m (162 ± 24 lb ft)
22.22 mm (0.875 inch)	1 3/16 - 12	260 ± 39 N·m (192 ± 29 lb ft)
25.40 mm (1.000 inch)	1 5/16 - 12	350 ± 53 N·m (258 ± 39 lb ft)
31.75 mm (1.250 inch)	1 5/8 -12	400 ± 60 mm (16 ± 2 inch)
38.10 mm (1.500 inch)	1 7/8 - 12	420 ± 63 N·m (3100 ± 46 lb ft)
63.50 mm (2.500 inch)	21/2 - 12	600 ± 90 N·m (443 ± 66 lb ft)

Table 6

Metric Ferrous Straight Thread O-Ring Fittings Torques for Mating with Ferrous Materials Medium Pressure use Fittings
Ref Nominal Outer Diameter of the Tube	Thread Size	Standard Torque Tolerance
4 mm	M8 X 1	10 ± 2 N·m (7 ± 1. lb ft)
5 mm	M10 X 1	17 ± 3 N·m (13 ± 2 lb ft)
6 mm	M12 X 1.5	35 ± 5 N·m (26 ± 4 lb ft)
8 mm	M14 X 1.5	45 ± 7 N·m (33 ± 5 lb ft)
10 mm	M16 X 1.5	45 ± 7 N·m (33 ± 5 lb ft)
12 mm	M18 X 1.5	80 ± 12 N·m (59 ± 9 lb ft)
16 mm	M22 X 1.5	110 ± 17 N·m (81 ± 13 lb ft)
20 mm	M27 X 2	130 ± 20 N·m (96 ± 15 lb ft)
22 mm	M30 X 2	200 ± 30 N·m (148 ± 22 lb ft)
25 mm	M33 X 2	220 ± 33 N·m (162 ± 24 lb ft)
30 mm	M42 X 2	300 ± 45 N·m (221 ± 33 lb ft)
38 mm	M48 X 2	350 ± 53 N·m (258 ± 39 lb ft)
50 mm	M60 X 2	420 ± 63 N·m (310 ± 46 lb ft)

Table 7

Metric Ferrous Straight Thread O-Ring Fittings Torques for Mating with Ferrous Materials High Pressure use with O-Ring Face Seal Fittings
Ref Nominal Outer Diameter of the Tube	Thread Size	Standard Torque Tolerance
5 mm	M10 X 1	25 ± 4 N·m (18 ± 3 lb ft)
6 mm	M12 X 1.5	35 ± 5 N·m (26 ± 4 lb ft)
8 mm	M14 X 1.5	50 ± 8 N·m (37 ± 6 lb ft)
10 mm	M16 X 1.5	70 ± 11 N·m (52 ± 8 lb ft)
12 mm	M18 X 1.5	110 ± 17 N·m (81 ± 13 lb ft)
16 mm	M22 X 1.5	140 ± 21 N·m (103 ± 15 lb ft)
20 mm	M27 X 2	220 ± 33 N·m (162 ± 24 lb ft)
22 mm	M30 X 2	260 ± 39 N·m (192 ± 29 lb ft)
25 mm	M33 X 2	350 ± 53 N·m (258 ± 39 lb ft)
30 mm	M42 X 2	400 ± 60 mm (16 ± 2 inch)
38 mm	M48 X 2	420 ± 63 N·m (3100 ± 46 lb ft)
50 mm	M60 X 2	600 ± 90 N·m (443 ± 66 lb ft)

O-ring Faced Seal Fittings

The following table has the recommended standard torque values.

Table 8

Ferrous ORFS Fitting
Thread Size Inch	Standard Torque for Nut (3)
9/16 - 18	30 ± 5 N·m (266 ± 44 lb in)
11/16 - 16	50 ± 8 N·m (37 ± 6 lb ft)
13/16 - 16	70 ± 11 N·m (52 ± 8 lb ft)
1 - 14	110 ± 17 N·m (81 ± 13 lb ft)
1 13/16 - 12	160 ± 24 N·m (118 ± 18 lb ft)
1 7/16 - 12	260 ± 39 N·m (192 ± 29 lb ft)
1 11/16 - 12	300 ± 45 N·m (221 ± 33 lb ft)
2 - 12	350 ± 53 N·m (258 ± 39 lb ft)

Tapered Pipe Thread Fittings

The following table has the recommended standard torque values.

Table 9

Tapered Pipe Thread Fittings
Diameter of the Pipe Thread (Inch)	Standard Torque
	Assembly Turns after Hand Tight	Torque
1/16	3	10 ± 2 N·m (89 ± 18 lb in)
1/8	3	20 ± 3 N·m (177 ± 27 lb in)
1/4	3	35 ± 5 N·m (26 ± 4 lb ft)
3/8	3	60 ± 9 N·m (44 ± 7 lb ft)
1/2	2.5	80 ± 12 N·m (60 ± 9 lb ft)
3/4	2.5	100 ± 15 N·m (74 ± 11 lb ft)
1	2.5	120 ± 18 N·m (89 ± 13 lb ft)
1 1/4	2.5	140 ± 21 N·m (103 ± 15 lb ft)
1 1/2	2.5	160 ± 24 N·m (118 ± 18 lb ft)
2	2.5	180 ± 27 N·m (132 ± 20 lb ft)

Hose Clamps

The following tables have the recommended standard torque values.

Table 10

Worm Drive Band Type Hose Clamps
Width of Clamp	Torque for New Hose
7.5 mm (0.3 inch) or smaller	1.4 ± 0.3 N·m (12 ± 3 lb in)
12 mm (0.5 inch) or smaller	4.5 ± 0.7 N·m (40 ± 6 lb in)
14 mm (0.6 inch) or smaller	7.5 ± 1 N·m (66 ± 9 lb in)
Width of Clamp	Torque for Reused Hose (1)
7.5 mm (0.3 inch) or smaller	0.8 ± 0.3 N·m (7 ± 3 lb in)
12 mm (0.5 inch) or smaller	3.0 ± 0.5 N·m (27 ± 4 lb in)
14 mm (0.6 inch) or smaller	4.5 ± 0.7 N·m (40 ± 6 lb in)

( 1 )

Use this value when the hose is reused. The clamp may be new or reused.

Table 11

Constant Torque Hose Clamps Belleville Washer
Diameter of Hose Clamp	Standard Torque
Up to 50.8 mm (2 inch)	7.5 ± 1 N·m (65 ± 10 lb in)
Greater than 50.8 mm (2 inch)	11 ± 1 N·m (95 ± 10 lb in)

Table 12

Constant Torque Hose Clamps Tee Bolt and Spring
Diameter of Hose Clamp	Standard Torque
All	7.5 ± 1 N·m (65 ± 10 lb in)

Engine Oil Cooler - Remove

Parts List

Illustration 3	g03723234
(1) 332-7331 Oil Cooler Core As

Removal Procedure

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

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NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

Illustration 4	g03724215

Illustration 5	g03724313

Illustration 6	g03724355

Transmission Oil Cooler - Remove

Parts List

Illustration 7	g03746496

Table 13

Parts List
Item	Qty	Part Number	Description
1	6	0L-1178	Bolt
2	1	243-5773	Oil Cooler Core Gp

Removal Procedure

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NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

Illustration 8	g03746394

Illustration 9	g03746395

Aftercooler - Remove

Parts List

Illustration 10	g03766858

Table 14

Parts List
Item	Qty	Part Number	Description
1	1 c	217-7062	Cover
2	10	0S-1590	Bolt
3	1	348-4965	Aftercooler Core As
4	1	210-2603	Housing
5	6	376-7740	Bolt
6	6	5J-4715	Washer
7	6	7C-8246	Spacer
8	4	371-5944	Adapter

Removal Procedure

Illustration 11	g03774168

Illustration 12	g03774171

Illustration 13	g03774216

Illustration 14	g03774378

Illustration 15	g03774399

Engine Oil Filter Housing - Remove

Parts List

Illustration 16	g03752016

Table 15

Parts List
Item Number	Qty	Part Number	Description
1	1	235-0283	Engine Oil Filter Gp
2	6	9X-8873	Bolt
3	6	5P-8245	Hard Washer
4	4	275-2604	Engine Oil Filter

Removal Procedure

Table 16

Required Tools
Tool	Part Number	Part Description	Qty
A	138-7573	Link Bracket	2
B	187-2718	Filter Wrench Assembly	1

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NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

Illustration 17	g03752217

Illustration 18	g03752218

Illustration 19	g03752219

Inlet Manifold - Remove

Parts List

Illustration 20	g03731457

Table 17

Parts List
Item	Qty	Part Number	Description
1	4	308-0901	Air Inlet Manifold
2	64	4S-5898	O-Ring Seal

Removal Procedure

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

Illustration 21	g03730914

Illustration 22	g03731279

Alternator - Remove

Parts List

Illustration 23	g03721053

Table 18

Parts List
Item	Qty	Part Number	Description
1	1	437-0125	Charging Alternator Gp
2	2	1A-5183	Bolt
3	4	5M-2984	Washer
4	2	8F-8544	Bolt
5	1	374-8497	Belt

Removal Procedure

Illustration 24	g03721967

Illustration 25	g03720144

Illustration 26	g03721988

Engine Oil Pan - Remove

Parts List

Illustration 27	g03725508

Table 19

Parts List
Item	Qty	Part Number	Description
1	1	7E-2632	Oil Pan Gasket
2	1	6V-5101	O-Ring Seal
3	18	5P-0076	Bolt
4	18	8M-3175	Hard Washer
5	2	0S-1588	Bolt
6	2	5M-2894	Hard Washer
7	1	246-5530	Oil Pan Gp
8	50	3H-7654	Hard Washer
9	50	5P-5855	Bolt

Removal Procedure

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NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

Illustration 28	g03725563

Illustration 29	g03844390

Illustration 30	g03844440

Illustration 31	g03844452

Sump Pump - Remove

Parts List

Illustration 32	g03773045

Table 20

Parts List
Item	Qty	Part Number	Description
1	4	3H-2750	Bolt
2	1	144-8267	Engine Oil Scavenge Pump
3	2	6V-1581	Clip
4	1	1N-4381	Tube
5	2	0S-1590	Bolt
6	1	1N-3193	Housing

Removal Procedure

Illustration 33	g03773295

Illustration 34	g03773360

Illustration 35	g03773429

Engine Oil Pump - Remove

Parts List

Illustration 36	g03756959

Table 21

Parts List
Item	Qty	Part Number	Description
1	1	375-7412	Engine Oil Pump Gp
2	4	0S-1590	Bolt
3	4	5M-2894	Hard Washer
4	1	274-6746	Adapter
5	1	425-1062	Gear Fastener Gp

Removal Procedure

Table 22

Required Tools
Tool	Part Number	Part Description	Qty
A	138-7573	Link Bracket	1

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NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

Illustration 37	g03757349

Illustration 38	g03757360

Air Compressor - Remove

Parts List

Illustration 39	g03764360

Table 23

Parts List
Item	Qty	Part Number	Description
1	1	113-8193	Air Compressor Gp
2	1	127-4422	Gasket

Removal Procedure

Illustration 40	g03764379

Illustration 41	g03764439

Exhaust Elbow - Remove

Parts List

Illustration 42	g03759183

Table 24

Parts List
Item Number	Qty	Part Number	Description
1	1	7C-2023	Exhaust Elbow
2	6	5M-2894	Hard Washer
3	6	6V-1943	High Temperature Bolt

Removal Procedure

Illustration 43	g03759178

Turbocharger - Remove

Parts List

Illustration 44	g03736464

Table 25

Parts List
Item	Qty	Part Number	Description
1	4	376-6453	Turbocharger Gp
2	4	121-5736	Gasket

Removal Procedure

Illustration 45	g03736484

Illustration 46	g03739053

Illustration 47	g03739100

Fuel Priming Pump - Remove

Parts List

Illustration 48	g03763061

Table 26

Parts List
Item	Qty	Part Number	Description
1	4	235-8725	Fuel Transfer Pump and Filter Gp
2	4	0L-1143	Bolt
2	1	5M-2894	Hard Washer

Removal Procedure

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

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NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

Illustration 49	g03763066

Fuel Transfer Pump - Remove

Parts List

Illustration 50	g03745405

Table 27

Parts List
Item	Qty	Part Number	Description
1	2	3H-3243	Bolt
2	2	5L-1761	Bolt
3	1	322-3830	Fuel Transfer Pump Gp

Removal Procedure

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

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NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

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NOTICE
Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel system component that will be disconnected. Fit a suitable cover over disconnected fuel system component.

Illustration 51	g03745413

Fuel Filter Housing - Remove

Parts List

Illustration 52	g03746807

Table 28

Parts List
Item	Qty	Part Number	Description
1	4	1A-2029	Bolt
2	4	5M-2894	Hard Washer
2	1	283-6373	Support As
3	2	1R-0755	Fuel Filter

Removal Procedure

Table 29

Required Tools
Tool	Part Number	Part Description	Qty
A	2P-8250	Strap Wrench As	1

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NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

Note: Put identification marks on all hoses, on all hose assemblies, on all wires, and on all tube assemblies for installation purposes. Plug all hose assemblies and all tube assemblies. This action helps to prevent fluid loss, and to keep contaminants from entering the system.

Illustration 53	g03746817

Illustration 54	g03746822

Valve Cover Base - Remove

Parts List

Illustration 55	g03842029

Table 30

Parts List
Item	Qty	Part Number	Description
1	1	287-5790	Fuel Injection Lines Gp
2	1	247-8339	Rocker Arm Base

Removal Procedure

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NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

Illustration 56	g03842030

Rocker Shaft and Push Rods - Remove

Removal Procedure

Illustration 57	g03774994

Illustration 58	g03774995

Damper and Pulley - Remove

Removal Procedure

Table 31

Required Tools
Tool	Part Number	Part Description	Qty
A	-	Guide Bolts 3/8 - 16 NC by 4 inch	2
B	-	Guide Bolts 1/2 - 13 NC by 4 inch	2
C	138-7575	Link Bracket	2
D	1U-9393	Damper Guide Pin	2

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NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "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 59	g03774034

Measure the shaft

Illustration 60	g03774041

Mark the pulley

Illustration 61	g03774217

Illustration 62	g03774218

Illustration 63	g03774219

Water Temperature Regulator Housing - Remove

Parts List

Illustration 64	g03744220

Table 32

Parts List
Item	Qty	Part Number	Description
1	1	157-2838	Regulator Housing
2	1	7N-4927	Housing Cover Gasket
3	4	248-5513	Temperature Regulator
4	4	3S-9643	Lip Type Seal

Removal Procedure

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

Show/hide table

NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

Illustration 65	g03744205

Illustration 66	g03744207

Illustration 67	g03744223

Water Pump - Remove

Parts List

Illustration 68	g03750679

Table 33

Parts List
Item	Qty	Part Number	Description
1	4	0S-1594	Bolt
2	1	235-4536	Auxiliary Water Pump Gp

Removal Procedure

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

Show/hide table

NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "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 69	g03750457

Illustration 70	g03750458

Front Housing - Remove

Parts List

Illustration 71	g03890702

Table 34

Parts List
Item	Qty	Part Number	Description
1	1	102-8634	Accessory Drive Housing
2	1	7N-3049	Gasket

Removal Procedure

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

Table 35

Required Tools
Tool	Part Number	Part Description	Qty
A	138-7573	Link Bracket	2

Illustration 72	g03890694

Illustration 73	g03890696

Front Block Mounting Gear - Remove

Parts List

Illustration 74	g03890722

Table 36

Parts List
Item	Qty	Part Number	Description
1	1	2W-2895	Crankshaft Gear
2	1	144-8263	Idler Gear As
2	1	7C-3260	Shaft

Removal Procedure

Illustration 75	g03890725

Illustration 76	g03890727

Illustration 77	g03890749

Illustration 78	g03890750

Flywheel - Remove

Parts List

Illustration 79	g03890758

Table 37

Parts List
Item	Qty	Part Number	Description
1	1	275-0691	Flywheel As

Removal Procedure

Table 38

Required Tools
Tool	Part Number	Part Description	Qty
A	138-7573	Link Bracket	2

Illustration 80	g03890759

Illustration 81	g03890760

Illustration 82	g03890761

Rear Housing - Remove

Parts List

Illustration 83	g03890797

Table 39

Parts List
Item	Qty	Part Number	Description
1	1	398-3068	Flywheel Housing

Removal Procedure

Table 40

Required Tools
Tool	Part Number	Part Description	Qty
A	138-7573	Link Bracket	2

Illustration 84	g03890801

Illustration 85	g03890802

Illustration 86	g03890803

Rear Block Mounting Gear - Remove

Parts List

Illustration 87	g03890808

Table 41

Parts List
Item	Qty	Part Number	Description
1	2	156-9744	Camshaft Drive Gears
2	1	136-3279	Idler Gear
3	1	399-7361	Crankshaft Gear
4	2	443-3642	Idler Gears
5	2	442-2324	Gear Shaft

Removal Procedure

Illustration 88	g03890809

Illustration 89	g03890811

Illustration 90	g03890812

Illustration 91	g03890823

Illustration 92	g03890824

Illustration 93	g03890825

Illustration 94	g03890826

Exhaust Manifold - Remove

Parts List

Illustration 95	g03739244

Table 42

Parts List
Item	Qty	Part Number	Description
1	4	5P-3961	Bolt
2	64	5M-2894	Hard Washer
3	4	4P-7680	Spacer
4	60	5P-3875	Bolt
5	60	203-2163	Spacer
6	1	454-2670	Exhaust Manifold Gp
7	16	7N-5080	Manifold Gasket

Removal Procedure

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NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

Illustration 96	g03739933

Cylinder Head - Remove

Parts List

Illustration 97	g03772217

Table 43

Parts List
Item	Qty	Part Number	Description
1	64	131-0420	Cylinder Head Fastener Gp
2	16	362-8264	Cylinder Head Gasket
3	64	420-0653	Water Seal Assembly
4	64	420-0652	Water Seal Assembly
5	16	144-5692	Plate Gasket
6	32	5P-0840	O-Ring Seal

Removal Procedure

Table 44

Required Tools
Tool	Part Number	Description	Qty
A	138-7573	Link Bracket	2

Show/hide table

NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "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 98	g03772783

Illustration 99	g03772794

Illustration 100	g03772836

Illustration 101	g03772753

Illustration 102	g03772853

Illustration 103	g03772899

Illustration 104	g03772902

Piston Cooling Jets - Remove

Parts List

Illustration 105	g03891182

Table 45

Parts List
Item	Qty	Part Number	Description
1	16	204-5447	Piston Cooling Jet As

Removal Procedure

Illustration 106	g03891183

Illustration 107	g03891184

Pistons and Connecting Rods - Remove

Parts List

Illustration 108	g03772847

Table 46

Parts List
Item	Qty	Part Number	Description
1	1	173-7674	Piston
2	1	230-2515	Rod
3	4	7N-2405	Bolt
4	1	230-2515	Rod-cap

Removal Procedure

Illustration 109	g03772857

Illustration 110	g03772861

Illustration 111	g03772868

Cylinder Liner - Remove

Parts List

Illustration 112	g03767960

Table 47

Parts List
Item	Qty	Part Number	Description
1	16	211-7826	Cylinder Block Liner
2	16	352-6061	Liner Seal
3	48	7N-2046	O-Ring Seal

Removal Procedure

Table 48

Required Tools
Tool	Part Number	Part Description	Qty
A	5P-8665	Cylinder Liner Puller Gp	1

Illustration 113	g03767979

Crankshaft - Remove

Parts List

Illustration 114	g03773503

Table 49

Parts List
Item	Qty	Part Number	Description
1	1	375-3642	Crankshaft Gp

Removal Procedure

Table 50

Required Tools
Tool	Part Number	Part Description	Qty
A	4C-9832	Engine Rollover Stand	1
B	138-7576	Link Bracket	2

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NOTICE
Failure to remove the rocker shaft assemblies and push rods can result in damaged valves when the pistons and connecting rods are pushed away from the crankshaft. To help avoid damage to the valves, remove the rocker shaft assemblies and push rods before you remove the crankshaft.

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

Illustration 115	g03773508

Illustration 116	g03773521

Illustration 117	g03773510

Camshaft - Remove

Parts List

Illustration 118	g03774005

Table 51

Parts List
Item	Qty	Part Number	Description
1	2	8N-9885	Cover Gasket
2	2	7N-4320	Gasket

Removal Procedure

Table 52

Required Tools
Tool	Part Number	Part Description	Qty
A	238-9586	Camshaft Drive Group	1
B	1P-0820	Hydraulic Puller	1
	8B-7548	Push-Puller Tool Group	1
	8B-7559	Adapter	2
	5H-1504	Hard Washer	3
	9U-6600	Hand Hydraulic Pump	1
C	125-0200	Camshaft Pilot As	2
D	125-0201	Camshaft Guide As	1
E	8T-3169	Crank Assembly	1

Show/hide table

NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "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 119	g03773798

Illustration 120	g03773829

Illustration 121	g03773856

Illustration 122	g03773874

Illustration 123	g03773888

Illustration 124	g03773951

Illustration 125	g03773998

Camshaft Bearings - Remove

Parts List

Illustration 126	g03841853

Table 53

Parts List
Item	Qty	Part Number	Description
1	18	101-1198	Camshaft Bearings

Removal Procedure

Illustration 127	g03841857

Illustration 128	g03841858

Turbocharger - Disassemble

Parts List

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

Illustration 129	g03736154

Table 54

Parts List
Item Number	Qty	Part Number	Description
1	1	301-4201	Cover
2	1	189-5124	Compressor Clamp Assembly
3	1	337-1986	Turbocharger Cartridge Gp
4	1	349-3361	Turbine Clamp As
5	1	252-1799	Housing
6	1	121-5736	Gasket

Disassembly Procedure

Illustration 130	g03736168

Illustration 131	g03736172

Turbocharger - Assemble

Parts List

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

Illustration 132	g03736154

Table 55

Parts List
Item Number	Qty	Part Number	Description
1	1	301-4201	Cover
2	1	189-5124	Compressor Clamp Assembly
3	1	337-1986	Turbocharger Cartridge Gp
4	1	349-3361	Turbine Clamp As
5	1	252-1799	Housing
6	1	121-5736	Gasket

Assembly Procedure

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 133	g03747561

Illustration 134	g03747668

Water Pump - Disassemble

Parts List

Illustration 135	g03705626

Table 56

Parts List
Item Number	Qty	Part Number	Description
1	1	5H-6734	O-Ring Seal
2	4	8T-8442	Bolt
3	1	235-4543	Retainer
4	8	0L-1351	Bolt
5	8	5M-2894	Hard Washer
6	1	257-2002	Bearing Housing
7	1	0259-4596	O-Ring Seal
8	1	258-8726	Pump Shaft
9	1	235-4181	Bearing As
10	1	229-5469	Bearing Locknut
11	1	235-4643	Water Pump Seal
12	1	336-2212	Water Pump Seal As
13	1	313-2760	Impeller
14	1	206-4278	Housing
15	4	3B-1915	Bolt

Disassembly Procedure

Table 57

Required Tools
Tool	Part Number	Part Description	Qty
A	1P-0510	Driver Gp	1

Illustration 136	g03705831

Illustration 137	g03715375

Illustration 138	g03705915

Illustration 139	g03705967

Water Pump - Assemble

Parts List

Illustration 140	g03705626

Table 58

Parts List
Item Number	Qty	Part Number	Description
1	1	5H-6734	O-Ring Seal
2	4	8T-8442	Bolt
3	1	235-4543	Retainer
4	8	0L-1351	Bolt
5	8	5M-2894	Hard Washer
6	1	257-2002	Bearing Housing
7	1	0259-4596	O-Ring Seal
8	1	258-8726	Pump Shaft
9	1	235-4181	Bearing As
10	1	229-5469	Bearing Locknut
11	1	235-4643	Water Pump Seal
12	1	336-2212	Water Pump Seal As
13	1	313-2760	Impeller
14	1	206-4278	Housing
15	4	3B-1915	Bolt

Assembly Procedure

Table 59

Required Tools
Tool	Part Number	Part Description	Qty
A	1P-0510	Driver Gp	1

Illustration 141	g03839627

Illustration 142	g03839631

Illustration 143	g03839635

Illustration 144	g03839669

Engine Oil Pump - Disassemble

Disassembly Procedure

Table 60

Required Tools
Tool	Part Number	Part Description	Qty
A	1P-0510	Driver Group	1
B	156-7100	Slide Hammer Puller Gp	1

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

Illustration 145	g03747737

Illustration 146	g03747744

Illustration 147	g03747765

Illustration 148	g03747771

Engine Oil Pump - Assemble

Assembly Procedure

Table 61

Required Tools
Tool	Part Number	Part Description	Qty
A	1P-0510	Driver Group	1
B	156-7100	Slide Hammer Puller Gp	1

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

Illustration 149	g03839724

Illustration 150	g03839727

Illustration 151	g03839728

Illustration 152	g03839733

Cylinder Head - Disassemble

Parts List

Illustration 153	g03862742

Table 62

Parts List
Item	Qty	Part Number	Description
1	8	197-7055	Retainer Lock
2	4	316-5979	Rotocoil As
3	4	316-5977	Spring
4	4	316-5976	Spring
5	4	316-5980	Valve Stem Seal
6	4	133-9306	Valve Guide
7	1	101-1176	Cylinder Head
8	4	130-2608	Valve Seat Insert
9	2	443-2712	Exhaust Valve
10	2	210-2542	Inlet Valve

Disassembly Procedure

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

Illustration 154	g03862847

Illustration 155	g03862849

Illustration 156	g03862851

Illustration 157	g03862853

Illustration 158	g03862854

Cylinder Head - Assemble

Parts List

Illustration 159	g03862742

Table 63

Parts List
Item	Qty	Part Number	Description
1	8	197-7055	Retainer Lock
2	4	316-5979	Rotocoil As
3	4	316-5977	Spring
4	4	316-5976	Spring
5	4	316-5980	Valve Stem Seal
6	4	133-9306	Valve Guide
7	1	101-1176	Cylinder Head
8	4	130-2608	Valve Seat Insert
9	2	443-2712	Exhaust Valve
10	2	210-2542	Inlet Valve

Assembly Procedure

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

Illustration 160	g03862864

Illustration 161	g03862867

Illustration 162	g03862869

Illustration 163	g03862870

Illustration 164	g03862871

Fuel Transfer Pump - Disassemble

Disassembly Procedure

Illustration 165	g03754744

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

Illustration 166	g03754796

Illustration 167	g03754836

Illustration 168	g03754856

Fuel Transfer Pump - Assemble

Assembly Procedure

Table 64

Required Tools
Tool	Part Number	Part Description	Qty
A	1P-0510	Driver Group	1

Illustration 169	g03864010

Illustration 170	g03864011

Illustration 171	g03774791

Illustration 172	g03864016

Engine Oil Cooler - Disassemble

Parts List

Illustration 173	g03763137

Table 65

Parts List
Item	Qty	Part Number	Description
1	4	0S-1594	Bolt
2	1	244-5867	Elbow
3	1	152-0993	Tube
4	4	0L-1352	Bolt
5	1	247-4806	Elbow
6	1	253-8284	Bonnet
8	1	332-7331	Oil Cooler Core As
9	1	8T-6765	Pipe Plug
10	1	124-4273	Bypass Valve
11	1	2W-1635	Spring
12	1	5P-4892	O-Ring Seal
13	1	136-3296	Plate As
14	2	0S-1591	Bolt
15	1	8N-7641	Tube
16	1	8N-0386	Flange

Disassembly Procedure

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

Illustration 174	g03763156

Illustration 175	g03763157

Illustration 176	g03763159

Illustration 177	g03764076

Illustration 178	g03764198

Engine Oil Cooler - Assemble

Parts List

Illustration 179	g03763137

Table 66

Parts List
Item	Qty	Part Number	Description
1	4	0S-1594	Bolt
2	1	244-5867	Elbow
3	1	152-0993	Tube
4	4	0L-1352	Bolt
5	1	247-4806	Elbow
6	1	253-8284	Bonnet
8	1	332-7331	Oil Cooler Core As
9	1	8T-6765	Pipe Plug
10	1	124-4273	Bypass Valve
11	1	2W-1635	Spring
12	1	5P-4892	O-Ring Seal
13	1	136-3296	Plate As
14	2	0S-1591	Bolt
15	1	8N-7641	Tube
16	1	8N-0386	Flange

Assembly Procedure

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

Illustration 180	g03774506

Illustration 181	g03774586

Illustration 182	g03774587

Illustration 183	g03774592

Illustration 184	g03774593

Fuel Filter Housing - Disassemble

Parts List

Illustration 185	g03842455

Table 67

Parts List
Item Number	Qty	Part Number	Description
1	1	173-2944	Support
2	2	1R-0755	Fuel Filters
3	2	8N-3481	Filter Plates
4	1	3K-0360	O-Ring Seal
5	1	4W-5940	Pump Adapter
6	4	2K-8198	O-Ring Seals

Disassembly Procedure

Illustration 186	g03842459

Illustration 187	g03842461

Illustration 188	g03842464

Fuel Filter Housing - Assemble

Parts List

Illustration 189	g03842455

Table 68

Parts List
Item Number	Qty	Part Number	Description
1	1	173-2944	Support
2	2	1R-0755	Fuel Filters
3	2	8N-3481	Filter Plates
4	1	3K-0360	O-Ring Seal
5	1	4W-5940	Pump Adapter
6	4	2K-8198	O-Ring Seals

Disassembly Procedure

Illustration 190	g03842476

Illustration 191	g03842478

Illustration 192	g03842489

Engine Oil Filter Housing - Disassemble

Parts List

Illustration 193	g03753256

Table 69

Parts List
Item Number	Qty	Part Number	Description
1	8	2B-2695	Bolt
2	8	9M-1974	Hard Washer
3	4	1S-7106	Cover
4	4	9Y-8387	Gasket
5	4	7G-6713	Spring
6	4	1P-1367	Plunger
7	16	0S-1594	Bolt
8	16	5M-2894	Hard Washer
9		304-3339	Support As

Disassembly Procedure

Illustration 194	g03753497

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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.

Illustration 195	g03753599

Engine Oil Filter Housing - Assemble

Parts List

Illustration 196	g03753256

Table 70

Parts List
Item Number	Qty	Part Number	Description
1	8	2B-2695	Bolt
2	8	9M-1974	Hard Washer
3	4	1S-7106	Cover
4	4	9Y-8387	Gasket
5	4	7G-6713	Spring
6	4	1P-1367	Plunger
7	16	0S-1594	Bolt
8	16	5M-2894	Hard Washer
9		304-3339	Support As

Assembly Process

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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.

Illustration 197	g03754077

Illustration 198	g03754081

Camshaft Bearings - Install

Parts List

Illustration 199	g03841853

Table 71

Parts List
Item	Qty	Part Number	Description
1	18	101-1198	Camshaft Bearings

Installation Procedure

Table 72

Required Tools
Tool	Part Number	Part Description	Qty
A	238-9586	Camshaft Drive Gp	1
B	125-0200	Camshaft Pilot As	2

Illustration 200	g03844012

Illustration 201	g03844013

Camshaft - Install

Parts List

Illustration 202	g03774005

Table 73

Parts List
Item	Qty	Part Number	Description
1	2	8N-9885	Cover Gasket
2	2	7N-4320	Gasket

Installation Procedure

Table 74

Required Tools
Tool	Part Number	Part Description	Qty
A	238-9586	Camshaft Drive Group	1
B	1P-0820	Hydraulic Puller	1
	8B-7548	Push-Puller Tool Group	1
	8B-7559	Adapter	2
	5H-1504	Hard Washer	3
	9U-6600	Hand Hydraulic Pump	1
C	125-0200	Camshaft Pilot As	2
D	125-0201	Camshaft Guide As	1
E	8T-3169	Crank Assembly	1

Show/hide table

NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "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 203	g03863297

Illustration 204	g03863299

Illustration 205	g03863300

Illustration 206	g03863303

Illustration 207	g03863305

Illustration 208	g03863306

Illustration 209	g03863311

Crankshaft - Install

Parts List

Illustration 210	g03773503

Table 75

Parts List
Item	Qty	Part Number	Description
1	1	375-3642	Crankshaft Gp

Installation Procedure

Table 76

Required Tools
Tool	Part Number	Part Description	Qty
A	4C-9832	Engine Rollover Stand	1
B	138-7576	Link Bracket	2

Show/hide table

NOTICE
Failure to remove the rocker shaft assemblies and push rods can result in damaged valves when the pistons and connecting rods are pushed away from the crankshaft. To help avoid damage to the valves, remove the rocker shaft assemblies and push rods before you remove the crankshaft.

Show/hide table

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

Illustration 211	g03860486

Illustration 212	g03860490

Illustration 213	g03860491

Illustration 214	g03860493

Cylinder Liner - Install

Parts List

Illustration 215	g03767960

Table 77

Parts List
Item	Qty	Part Number	Description
1	16	211-7826	Cylinder Block Liner
2	16	352-6061	Liner Seal
3	48	7N-2046	O-Ring Seal

Installation Procedure

Table 78

Required Tools
Tool	Part Number	Part Description	Qty
A	5P-8665	Cylinder Liner Puller Gp	1

Illustration 216	g03844655

Pistons and Connecting Rods - Install

Parts List

Illustration 217	g03863171

Table 79

Parts List
Item	Qty	Part Number	Description
1	64	144-5695	Piston Ring
2	16	321-7880	Piston
3	16	381-6555	Rod As
4	64	230-2520	Connecting Rod Bearing

Installation Procedure

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NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

Table 80

Required Tools
Tool	Part Number	Part Description	Qty
A	5R-7425	Barring	1
B	1P-1861	Retaining Ring Pliers	1
C	6V-4020	Piston Ring Expander	1
H	1U-7616	Piston Ring Compressor	1
J	6V-4876	Lubricant	1

Illustration 218	g03861105

Illustration 219	g03861099

Illustration 220	g03861179

Illustration 221	g03861344

Illustration 222	g03861345

Piston Cooling Jets - Install

Parts List

Illustration 223	g03891182

Table 81

Parts List
Item	Qty	Part Number	Description
1	16	204-5447	Piston Cooling Jet As

Installation Procedure

Illustration 224	g03891196

Illustration 225	g03891197

Cylinder Head - Install

Parts List

Illustration 226	g03843652

Table 82

Parts List
Item	Qty	Part Number	Description
1	1	380-5795	Cylinder Head Gp
2	2	5P-0840	O-Ring Seals
3	1	362-9677	Spacer Plate
4	1	362-8264	Cylinder Head Gasket
5	4	420-0652	Water Seal Assemblies
6	4	420-0653	Water Seal Assemblies
7	4	420-0650	Water Seal Assemblies
8	4	420-0651	Water Seal Assemblies

Installation Procedure

Illustration 227	g03843656

Illustration 228	g03843657

Illustration 229	g03843659

Illustration 230	g03843660

Illustration 231	g03843661

Illustration 232	g03843662

Exhaust Manifold - Install

Parts List

Illustration 233	g03739244

Table 83

Parts List
Item	Qty	Part Number	Description
1	4	5P-3961	Bolt
2	64	5M-2894	Hard Washer
3	4	4P-7680	Spacer
4	60	5P-3875	Bolt
5	60	203-2163	Spacer
6	1	454-2670	Exhaust Manifold Gp
7	16	7N-5080	Manifold Gasket

Installation Procedure

Illustration 234	g03739935

Rear Block Mounting Gear - Install

Parts List

Illustration 235	g03890808

Table 84

Parts List
Item	Qty	Part Number	Description
1	2	156-9744	Camshaft Drive Gears
2	1	136-3279	Idler Gear
3	1	399-7361	Crankshaft Gear
4	2	443-3642	Idler Gears
5	2	442-2324	Gear Shaft

Installation Procedure

Illustration 236	g03890873

Illustration 237	g03890875

Illustration 238	g03890876

Illustration 239	g03890878

Illustration 240	g03890881

Illustration 241	g03890887

Illustration 242	g03890889

Rear Housing - Install

Parts List

Illustration 243	g03890797

Table 85

Parts List
Item	Qty	Part Number	Description
1	1	398-3068	Flywheel Housing

Installation Procedure

Table 86

Required Tools
Tool	Part Number	Part Description	Qty
A	138-7573	Link Bracket	2

Illustration 244	g03890869

Illustration 245	g03890870

Illustration 246	g03890872

Flywheel - Install

Parts List

Illustration 247	g03890758

Table 87

Parts List
Item	Qty	Part Number	Description
1	1	275-0691	Flywheel As

Installation Procedure

Table 88

Required Tools
Tool	Part Number	Part Description	Qty
A	138-7573	Link Bracket	2

Illustration 248	g03890914

Illustration 249	g03890915

Illustration 250	g03890917

Front Block Mounting Gear - Install

Parts List

Illustration 251	g03890722

Table 89

Parts List
Item	Qty	Part Number	Description
1	1	2W-2895	Crankshaft Gear
2	1	144-8263	Idler Gear As
2	1	7C-3260	Shaft

Installation Procedure

Illustration 252	g03890924

Illustration 253	g03890925

Illustration 254	g03890928

Illustration 255	g03890929

Front Housing - Install

Parts List

Illustration 256	g03890702

Table 90

Parts List
Item	Qty	Part Number	Description
1	1	102-8634	Accessory Drive Housing
2	1	7N-3049	Gasket

Installation Procedure

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

Table 91

Required Tools
Tool	Part Number	Part Description	Qty
A	138-7573	Link Bracket	2

Illustration 257	g03890940

Illustration 258	g03890941

Illustration 259	g03890944

Water Temperature Regulator Housing - Install

Parts List

Illustration 260	g03744220

Table 92

Parts List
Item	Qty	Part Number	Description
1	1	157-2838	Regulator Housing
2	1	7N-4927	Housing Cover Gasket
3	4	248-5513	Temperature Regulator
4	4	3S-9643	Lip Type Seal

Installation Procedure

Illustration 261	g03775091

Illustration 262	g03775094

Illustration 263	g03775097

Water Pump - Install

Parts List

Illustration 264	g03750679

Table 93

Parts List
Item	Qty	Part Number	Description
1	4	0S-1594	Bolt
2	1	235-4536	Auxiliary Water Pump Gp

Installation Procedure

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

Illustration 265	g03774797

Illustration 266	g03774798

Damper and Pulley - Install

Installation Procedure

Table 94

Required Tools
Tool	Part Number	Part Description	Qty
A	-	Guide Bolts 3/8 - 16 NC by 4 inch	2
B	-	Guide Bolts 1/2 - 13 NC by 4 inch	2
C	138-7575	Link Bracket	2
D	1U-9393	Damper Guide Pin	2

Show/hide table

NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "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 267	g03774445

Illustration 268	g03774449

Illustration 269	g03774450

Illustration 270	g03774453

Illustration 271	g03774454

Rocker Shaft and Push Rods - Install

Installation Procedure

Illustration 272	g03775016

Illustration 273	g03775018

Illustration 274	g03775027

Illustration 275	g03775031

Valve Cover Base - Install

Parts List

Illustration 276	g03842029

Table 95

Parts List
Item	Qty	Part Number	Description
1	1	287-5790	Fuel Injection Lines Gp
2	1	247-8339	Rocker Arm Base

Installation Procedure

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NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

Illustration 277	g03842069

Fuel Filter Housing - Install

Parts List

Illustration 278	g03746807

Table 96

Parts List
Item	Qty	Part Number	Description
1	4	1A-2029	Bolt
2	4	5M-2894	Hard Washer
2	1	283-6373	Support As
3	2	1R-0755	Fuel Filter

Installation Procedure

Table 97

Required Tools
Tool	Part Number	Part Description	Qty
A	2P-8250	Strap Wrench As	1

Illustration 279	g03774801

Illustration 280	g03774802

Fuel Transfer Pump - Install

Parts List

Illustration 281	g03745405

Table 98

Parts List
Item	Qty	Part Number	Description
1	2	3H-3243	Bolt
2	2	5L-1761	Bolt
3	1	322-3830	Fuel Transfer Pump Gp

Installation Procedure

Illustration 282	g03745417

Fuel Priming Pump - Install

Parts List

Illustration 283	g03763061

Table 99

Parts List
Item	Qty	Part Number	Description
1	4	235-8725	Fuel Transfer Pump and Filter Gp
2	4	0L-1143	Bolt
2	1	5M-2894	Hard Washer

Installation Procedure

Show/hide table

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

Show/hide table

NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "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 284	g03763062

Turbocharger - Install

Parts List

Illustration 285	g03736464

Table 100

Parts List
Item	Qty	Part Number	Description
1	4	376-6453	Turbocharger Gp
2	4	121-5736	Gasket

Installation Procedure

Illustration 286	g03747868

Illustration 287	g03747869

Illustration 288	g03747871

Exhaust Elbow - Install

Parts List

Illustration 289	g03759183

Table 101

Parts List
Item Number	Qty	Part Number	Description
1	1	7C-2023	Exhaust Elbow
2	6	5M-2894	Hard Washer
3	6	6V-1943	High Temperature Bolt

Installation Procedure

Illustration 290	g03759260

Air Compressor - Install

Parts List

Illustration 291	g03764360

Table 102

Parts List
Item	Qty	Part Number	Description
1	1	113-8193	Air Compressor Gp
2	1	127-4422	Gasket

Installation Procedure

Illustration 292	g03764602

Illustration 293	g03764600

Engine Sump Pump - Install

Parts List

Illustration 294	g03840615

Table 103

Parts List
Item	Qty	Part Number	Description
1	4	3H-2750	Bolt
2	1	144-8267	Engine Oil Scavenge Pump
3	2	6V-1581	Clip
4	1	1N-4381	Tube
5	2	0S-1590	Bolt
6	1	1N-3193	Housing

Installation Procedure

Illustration 295	g03840639

Illustration 296	g03840641

Illustration 297	g03840642

Engine Oil Pump - Install

Parts List

Illustration 298	g03756959

Installation Procedure

Table 104

Required Tools
Tool	Part Number	Part Description	Qty
A	138-7573	Link Bracket	1

Illustration 299	g03758738

Illustration 300	g03758739

Engine Oil Pan - Install

Parts List

Illustration 301	g03725508

Table 105

Parts List
Item	Qty	Part Number	Description
1	1	7E-2632	Oil Pan Gasket
2	1	6V-5101	O-Ring Seal
3	18	5P-0076	Bolt
4	18	8M-3175	Hard Washer
5	2	0S-1588	Bolt
6	2	5M-2894	Hard Washer
7	1	246-5530	Oil Pan Gp
8	50	3H-7654	Hard Washer
9	50	5P-5855	Bolt

Installation Procedure

Show/hide table

NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

Illustration 302	g03844473

Illustration 303	g03844494

Illustration 304	g03844495

Illustration 305	g03844523

Alternator - Install

Parts List

Illustration 306	g03721053

Table 106

Parts List
Item	Qty	Part Number	Description
1	1	437-0125	Charging Alternator Gp
2	2	1A-5183	Bolt
3	4	5M-2984	Washer
4	2	8F-8544	Bolt
5	1	374-8497	Belt

Installation Procedure

Illustration 307	g03721347

Illustration 308	g03721989

Illustration 309	g03721990

Inlet Manifold - Install

Parts List

Illustration 310	g03731457

Table 107

Parts List
Item	Qty	Part Number	Description
1	4	308-0901	Air Inlet Manifold
2	64	4S-5898	O-Ring Seal

Installation Procedure

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

Illustration 311	g03731335

Illustration 312	g03731418

Engine Oil Filter Housing - Install

Parts List

Illustration 313	g03752016

Table 108

Parts List
Item Number	Qty	Part Number	Description
1	1	235-0283	Engine Oil Filter Gp
2	6	9X-8873	Bolt
3	6	5P-8245	Hard Washer
4	4	275-2604	Engine Oil Filter

Installation Procedure

Table 109

Required Tools
Tool	Part Number	Part Description	Qty
A	138-7573	Link Bracket	2
B	187-2718	Filter Wrench Assembly	1

Show/hide table

NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

Illustration 314	g03754120

Illustration 315	g03754122

Illustration 316	g03754138

Aftercooler - Install

Parts List

Illustration 317	g03766858

Table 110

Parts List
Item	Qty	Part Number	Description
1	1 c	217-7062	Cover
2	10	0S-1590	Bolt
3	1	348-4965	Aftercooler Core As
4	1	210-2603	Housing
5	6	376-7740	Bolt
6	6	5J-4715	Washer
7	6	7C-8246	Spacer
8	4	371-5944	Adapter

Installation Procedure

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

Show/hide table

NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "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 318	g03774599

Illustration 319	g03774767

Illustration 320	g03774805

Illustration 321	g03774806

Illustration 322	g03774809

Illustration 323	g03774811

Illustration 324	g03774810

Illustration 325	g03774812

Illustration 326	g03774814

Transmission Oil Cooler - Install

Parts List

Illustration 327	g03746496

Table 111

Parts List
Item	Qty	Part Number	Description
1	6	0L-1178	Bolt
2	1	243-5773	Oil Cooler Core Gp

Installation Procedure

Illustration 328	g03746683

Illustration 329	g03746684

Engine Oil Cooler - Install

Parts List

Illustration 330	g03723234
(1) 332-7331 Oil Cooler Core As

Installation Procedure

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

Illustration 331	g03745165

Illustration 332	g03745167

Illustration 333	g03745176