G3508, G3512 and G3516 Engines Caterpillar

Removal Procedure

Start By:

1. Remove the rocker shaft assemblies and the pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Push Rod - Remove".
2. Remove the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove".
3. Remove the front drive housing. Refer to Disassembly and Assembly, "Drive Housing (Front) - Remove and Install".
4. Remove the balancer gear from the rear gear group. Refer to Disassembly and Assembly, "Gear Group (Rear) - Remove".
5. Remove the piston cooling jets. Refer to Disassembly and Assembly, "Piston Cooling Jets - Remove and Install".

1. Use Tooling (A) to turn the engine to a horizontal position. The engine can be supported with Tooling (A) or with blocks. The engines have the following weights:
   • G3508 Engines weigh approximately 4300 kg (9500 lb).

   • G3512 Engines weigh approximately 5443 kg (12000 lb).

   • G3516 Engines weigh approximately 6440 kg (14200 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.

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Illustration 1	g00914774

2. Place identification marks on counterweights (1). Remove counterweights (1) from the crankshaft.

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Illustration 2	g00914776

Note: Ensure that the journals of the crankshaft are not scratched by the connecting rods.

3. Remove connecting rod caps (2) and push the connecting rods away from the crankshaft.

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Illustration 3	g00914800

4. Remove the center main bearing cap and thrust plates (3) from each side of the center main bearing.

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Illustration 4	g01256795

5. Attach Tooling (B) and a suitable lifting device to each end of crankshaft (4). The crankshafts have the following weights:
   • For G3508 Engines, the crankshaft weighs approximately 398 kg (877 lb).

   • For G3512 Engines, the crankshaft weighs approximately 590 kg (1300 lb).

   • For G3516 Engines, the crankshaft weighs approximately 800 kg (1764 lb).

6. Remove remaining main bearing caps (5). Remove crankshaft (4) from the engine.

7. Remove the upper halves of the main bearings.

8. Remove the upper halves of the connecting rod bearings.

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Illustration 5	g01256801

9. If necessary, remove bolts (7) and crankshaft gear (6) from each end of the crankshaft.