G3508, G3512 and G3516 Engines Caterpillar

Installation Procedure

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Illustration 1	g01256801

1. If crankshaft gear (6) was removed, install crankshaft gear (6) and bolts (7) on the crankshaft.

2. Check the clearance of the main bearings. Refer to Disassembly and Assembly, "Bearing Clearance - Check".

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Illustration 2	g01049073

Note: The upper halves of the main bearings have an oil hole in the center.

3. Install the upper halves of main bearings (8) in the cylinder block. Coat the main bearings with clean engine oil.

4. Install the upper halves of connecting rod bearings (9) in the connecting rod assemblies. Coat the connecting rod bearings with clean engine oil.

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Illustration 3	g01256795

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Illustration 4	g01049012

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 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. Position crankshaft (4) in the cylinder block.

7. Ensure that the lower halves of the main bearings are in position in main bearing caps (5) . Coat the main bearings with clean engine oil.

Note: Main bearing caps (5) 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.

8. Coat the threads of the bolts for main bearing caps (5) with clean SAE 30 engine oil. Except for the center main bearing cap, place the main bearing caps into position. Install the bolts and washers.

   Tighten the bolts according to the sequence that is shown in Illustration 4. Arrow (X) points to the front of the engine. Tighten the bolts to a torque of 190 ± 14 N·m (140 ± 10 lb ft). Then tighten the bolts for an additional 180 ± 5 degrees (1/2 turn).

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Illustration 5	g00914800

9. Place clean engine oil on thrust plates (3) . Install thrust plates (3) .

10. Install the center main bearing. Use the tightening procedure that is in Step 8.

11. 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).

12. Make sure that the upper halves of the connecting rod bearings are in position on the connecting rods. Make sure that the lower halves of the connecting rod bearings are in position on the connecting rod caps.

13. Check the clearance of the connecting rod bearings. Refer to Disassembly and Assembly, "Bearing Clearance - Check".

14. Position one connecting rod onto a journal of the crankshaft.

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.

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Illustration 6	g00914776

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Illustration 7	g01256938

15. Place Tooling (C) on the bolt threads, shanks, and seats.

16. Place connecting rod cap (2) into position. Install the bolts. Use the following procedure to tighten the bolts:

    1. Tighten Bolts (A) and (B) to a torque of 90 ± 5 N·m (65 ± 4 lb ft).

    2. Tighten Bolts (C) and (D) to a torque of 90 ± 5 N·m (65 ± 4 lb ft).

    3. Tighten Bolts (C) and (D) again to a torque of 90 ± 5 N·m (65 ± 4 lb ft).

    4. Tighten each bolt for an additional 90 ± 5 degrees (1/4 turn). An impact wrench may be used.

17. After measuring the clearance of the connecting rod bearing, coat the connecting rod bearings with clean engine oil. Use the same procedure to install the remaining connecting rod caps.

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NOTICE
Each counterweight is numbered and must be installed in the same position as the corresponding number on the crankshaft mounting pad in order to prevent damage to the crankshaft.

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Illustration 8	g00914774

18. If the counterweights have been removed, install counterweights (1) . Use the correct tightening procedure for the specific engine model:

19. The following procedure is for the installation of the counterweights in G3508 Engines.

    Note: Do not reuse counterweight bolts.

    1. Ensure that the dowels are in the correct position and install the counterweights on the crankshaft.

    2. Apply Tooling (C) to the bolt threads, shanks, and seats.

    3. Tighten the bolts evenly to a torque of 200 ± 5 N·m (150 ± 4 lb ft).

    4. Loosen the bolts.

    5. Tighten the bolts evenly to a torque of 70 ± 5 N·m (50 ± 4 lb ft).

    6. Tighten the bolts for an additional 120 ± 5 degrees (1/3 turn).

20. The following procedure is for the installation of the counterweights in G3512 and G3516 Engines.

    Note: Do not reuse counterweight bolts.

    1. Ensure that the dowels are in the correct position and install the counterweights on the crankshaft.

    2. Apply Tooling (C) to the bolt threads, shanks, and seats.

    3. Tighten the bolts evenly to a torque of 70 ± 5 N·m (50 ± 4 lb ft).

    4. Tighten the bolts for an additional 120 ± 5 degrees (1/3 turn).

21. Use Tooling (A) in order to turn the engine to a vertical position. 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: For more information on the crankshaft, refer to Specifications, "Crankshaft".

End By:

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