C3.3 Industrial Engine Caterpillar

Installation Procedure

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Illustration 1	g01027152

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Illustration 2	g01027338
Typical example

Note: Ensure that the upper bearing shells (1), the appropriate main bearing caps (2), and the appropriate lower bearing shells (3) are kept in sets and in the correct sequence for installation.

1. Ensure that all of the housings (4) in the cylinder block for the upper bearing shells (1) are clean and dry. Ensure that all of the lubrication passages in the housings (4) are clean and free from debris.

2. Gently wipe the lower bearing shells (3) and the upper bearing shells (1) in order to ensure that the bearing shells are clean and dry. Inspect the lower bearing shells (3) and the upper bearing shells (1). If necessary, replace the bearing shells that are worn or damaged.

   Note: Bearing shells must be replaced in pairs. If a pair of bearing shells need to be replaced, consider replacing all of the bearing shells at the same time.

   Note: The upper bearing shell for the No. 1 crankshaft journal has a lubricating oil slot. The remaining upper bearing shells (1) have an oil hole for lubrication. All new upper bearing shells (1) will have the slot for lubrication.

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   Illustration 3	g01027337

3. Install the upper main bearing shells (1). The bearing tabs (5) for the upper main bearing shells (1) must be located in the correct position in the cylinder block (5). Lubricate the upper main bearing shells (1) with clean engine oil.

4. Ensure that all of the main bearing caps (2) are clean and dry. Ensure that both of the hollow dowels (6) are not damaged and that two hollow dowels are securely in place within each of the main bearing caps (2).

   Note: This procedure assumes that the engine has been removed from the application and that the engine has been inverted. If the engine has not been inverted, ensure that the crankshaft is completely supported until the main bearing caps (2) and setscrews are completely installed.

5. Gently wipe the main journals of the crankshaft in order to ensure that the main journals are clean and dry. Attach suitable lifting straps to the crankshaft.

6. Take care to ensure that you do not scratch any of the finished surfaces on the crankshaft and that you do not damage the upper main bearing shells (1) or dislodge the upper main bearing shells. The crankshaft is heavy. Use suitable lifting equipment to carefully lift the crankshaft into the upper main bearing shells (1).

7. Install the appropriate lower main bearing shells (3) into main bearing caps (2) with the bearing tabs (7) in the correct position. Lubricate the lower main bearing caps (2) with clean engine oil.
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   Illustration 4	g01027339

   Note: Do not install the No. 3 main bearing cap of the three cylinder or the center main bearing cap of the four cylinder engine at this time.

8. Use the hollow dowels (6) in order to locate the appropriate main bearing caps (2) and install the main bearing caps into the appropriate housing (4) in the cylinder block. Insert the setscrews (8) finger tight.

   Note: Thrust washers (9) and (10) are installed onto one main bearing in order to limit crankshaft end play. These thrust washers are installed onto the No. 3 main bearing of the three cylinder and the center main bearing of the four cylinder engine. The installation procedure is identical for the three cylinder and the four cylinder engines. The appropriate illustrations show the four cylinder engine.

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   Illustration 5	g01026869
   Typical example

9. Clean the upper half of the thrust washers (9) and lubricate the upper half of thrust washers. Place the upper half of the thrust washers (9) into both side recesses in the cylinder block next to the housing for the appropriate main bearing shell. The grooves on the thrust washer (9) must be located against the crankshaft.
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   Illustration 6	g01026870
   Typical example

10. Clean the lower half of the thrust washers (10) and lubricate the lower half of thrust washers. Place the lower half of the thrust washers (10) on both sides of the appropriate main bearing cap. The grooves on the thrust washers (10) must be located against the crankshaft.

11. Install the No. 3 main bearing cap onto the crankshaft of the three cylinder or the center main bearing cap onto the crankshaft of the four cylinder engine. Install the remaining setscrews (8).

12. Tighten all of the setscrews (8) to a torque of 245 N·m (181 lb ft).

13. If the piston assemblies were removed previously, install the piston assemblies. Refer to this Disassembly and Assembly Manual, "Pistons and Connecting Rods - Install". Go to Step 19.

14. If the piston assemblies are still inside the cylinder bores, ensure that the upper bearing shells for the connecting rods are centered in the connecting rods. Ensure that the lower bearing shells for the connecting rods are centered in the connecting rod caps (11). Lubricate the faces of the bearing shell with clean engine oil.
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    Illustration 7	g01027370
    Typical example

15. Install the connecting rod caps (11). Install new setscrews (12) into the connecting rods. Tighten the setscrews (12) evenly to an initial torque of 18 N·m (13 lb ft).

    Note: Do not reuse the old setscrews (12) in order to secure the connecting rod caps (11).

    Note: Ensure that the etched number on the connecting rod bearing cap matches the etched number on the connecting rod. Ensure that the etched numbers are on the same side.

16. The setscrews must be tightened again to a higher torque. Tighten the setscrews (12) to a torque of 70 N·m (52 lb ft).

17. Use Tooling (C) to achieve the correct final torque.

    Note: If Tooling (C) is not used, place an index mark on each bolt.

18. Finally tighten the setscrews (12) for an additional 120 degrees. Refer to the insert in the Illustration 7 in order to achieve the correct final torque.

19. Rotate the crankshaft in order to ensure that there is no binding.
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    Illustration 8	g01027384

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    Illustration 9	g00541498

20. Clean the bridge (13) and the face of the cylinder block. Apply a thin bead of Tooling (A) onto the corners of the seat for the bridge. Also apply Tooling (A) around the thread holes in the seat for the bridge. Use the following steps when you apply Tooling (A) to the cylinder block and the bridge.

    1. Apply a 3.0 mm (0.12 inch) bead of Tooling (A) along the corner of the top recess in the cylinder block.

       Note: The maximum protrusion for the bridge (13) from the outside of the cylinder block is 0.075 mm (0.0029 inch).

    2. Install the bridge (13). Use a straight edge to line up the bridge with the face of the cylinder block. Tighten the socket head screws (14) to a torque of 16 N·m (12 lb ft). Tighten the socket head screws (14) evenly.

    3. When the bridge (13) is positioned and the socket head screws (14) have been tightened, inject Tooling (A) into the groove that is at each end of the bridge. The groove must be completely filled.
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    Illustration 10	g00975364

21. Check the crankshaft end play. Use a prybar to move the crankshaft toward the front of the engine. Use Tooling (B) to measure the end play between the rear thrust washer and the crankshaft. Refer to the Specifications Manual, "Crankshaft" for the further information.

End By:

1. Install the front housing. Refer to this Disassembly and Assembly Manual, "Housing (Front) - Install".

2. Install the crankshaft rear seal. Refer to this Disassembly and Assembly Manual, "Crankshaft Rear Seal - Install".

3. Install the flywheel housing. Refer to this Disassembly and Assembly Manual, "Flywheel Housing - Remove and Install".

4. If the engine is equipped with a balancer, install the balancer. Refer to this Disassembly and Assembly Manual, "Balancer - Install".

5. If the engine is not equipped with a balancer, install the engine oil pump. Refer to this Disassembly and Assembly Manual, "Engine Oil Pump - Install".

6. Install the engine oil pan. Refer to this Disassembly and Assembly Manual, "Engine Oil Pan - Remove and Install".