C7 On-Highway Engine Caterpillar

Installation Procedure

1. Apply clean engine oil to the pistons, the piston rings, and the cylinder bore.
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   Illustration 1	g00954373

2. Position the piston rings so that the end gaps are located 120 degrees from each other. Install Tooling (A) in order to compress the piston rings.

   Note: Install the piston and connecting rod so that the forging number on the connecting rod points toward the flywheel end of the engine.

3. With the number one crankshaft throw at the bottom center, install the piston and connecting rod in the engine. Ensure that the proper piston and connecting rod are in the corresponding cylinder with the bearing retainer notch toward the right side of the engine.

4. Line up the piston and the connecting rod with the crankshaft. Use a soft faced hammer and tap the piston into the cylinder bore until Tooling (A) comes off of the piston.
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   Illustration 2	g01261959

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   Illustration 3	g01261956

5. Before connecting rod (3) comes in contact with the crankshaft, install the upper half of connecting rod bearing (4). Ensure that the bearing tab engages with the slot in connecting rod (3).

6. Apply clean engine oil to the surface of the upper half of connecting rod bearing (4). Use a soft faced hammer in order to tap the piston into the cylinder bore while you guide connecting rod (3) onto the crankshaft.

7. Place the lower half of connecting rod bearing (4) in corresponding connecting rod cap (2). Ensure that the bearing tab engages with the groove in connecting rod cap (2).

8. Apply clean engine oil to the surface of the lower half of connecting rod bearing (4). Install connecting rod bearing cap (2) on connecting rod (3). Ensure that the number on connecting rod cap (2) matches the number on connecting rod (3). Ensure that the numbers are on the same side.

9. Lubricate the new connecting rod bolts with Tooling (B).

10. Install new bolts (1). Tighten bolts (1) to a torque of 70 ± 5 N·m (52 ± 4 lb ft).

11. Place an index mark on each bolt. Tighten each bolt (1) for an additional 120 ± 5 degrees (1/3 turn).

End By:

1. Install the piston cooling jets. Refer to the Disassembly and Assembly, "Piston Cooling Jets - Remove and Install".

2. Install the engine oil pump. Refer to the Disassembly and Assembly, "Engine Oil Pump - Install".

3. Install the cylinder head. Refer to the Disassembly and Assembly, "Cylinder Head - Install".