C1.5 and C2.2 Generator Set Engines Caterpillar

Installation Procedure

Note: Check the clearance between the connecting rod bearing and the connecting rod bearing journal of the crankshaft. Install the connecting rod bearings dry when the clearance checks are made.

1. Apply clean engine oil to the following components:
   • Crankshaft journals

   • Inside of the cylinder bores

   • Piston rings

   • Connecting rod bearings

2. Rotate the crankshaft until the bearing journal is at the bottom center.

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Illustration 1	g01201722

3. Place the piston and connecting rod in the cylinder bore. Align the Identification Marks on the top of the piston to the front of the cylinder block. Align Identification Marks (X) on the side of the connecting rod to the right side of the cylinder block. Position Tooling (B) on the cylinder block and compress the piston rings.

   Note: Ensure that the piston rings on the pistons are separated by approximately 90 degrees.

Note: Use tape or rubber tubing on connecting rod bolts (6) in order to protect the crankshaft journals.

4. Align the piston and the connecting rod with the crankshaft. Use a soft faced hammer in order to tap the piston into the cylinder bore until Tooling (B) comes off the piston.

   Note: Ensure that Tooling (B) is installed correctly in order to allow the piston and the connecting rod to easily slip into the cylinder block.

5. Before the connecting rod contacts the crankshaft, install the upper half of connecting rod bearing (7) in connecting rod (5). Make sure that the bearing tab properly engages with the slot in the connecting rod.

6. Apply clean engine oil to the surface of the upper half of the connecting rod bearing. Guide the connecting rod into position on the crankshaft.

7. Install the lower half of connecting rod bearing (7) in the correspondingly marked connecting rod cap (8). Apply clean engine oil to the surface of the lower half of the connecting rod bearing and on the connecting rod bolts.

8. Install connecting rod cap (8) and connecting rod nuts (9). Tighten the nuts for the connecting rod cap to a torque of 52 N·m (38 lb ft).

9. Repeat Steps 1 through 8 for the remainder of the pistons and connecting rods.

10. Rotate the crankshaft in order to ensure that no binding occurs.

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Illustration 2	g01201721

11. Install O-ring seal (1) on tube assembly (2) .

12. Install tube assembly (2) in the cylinder block.

13. Install oil strainer (4) on the cylinder block and tighten bolts (3) to a torque of 11 N·m (97 lb in).

End By:

1. Install the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove and Install".
2. Install the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Install".