C175-16 Locomotive Engine Caterpillar

Removal Procedure

Note: Tooling (A) is not rated for weight of entire long block. Heads must be removed prior to installation.

Start By:

1. Remove rocker arm shaft assemblies.

2. Remove the cylinder heads.

3. Remove the engine oil pan.

4. Remove the front housing.

5. Remove the flywheel housing.

6. Remove the engine oil cooler.

1. Use Tooling (A) to rotate the engine to approximately 120 degrees.
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   Illustration 1	g01224384

2. Install Tooling (B) onto the studs for the crankshaft main bearing cap. Tighten threaded collar (1) of Tooling (B). Loosen threaded collar (1) of Tooling (B) by 1 1/2 turns. Attach Tooling (C) onto Tooling (B). Attach Tooling (C) onto Tooling (D). Attach Tooling (D) onto Tooling (E). Apply approximately 135 MPa (19580 psi) of pressure to Tooling (B). Use drive (2) on Tooling (B) to loosen the nuts for the crankshaft main bearings. Turn drive (2) on Tooling (B) by approximately three turns. Release the pressure on Tooling (B). Remove Tooling (B). Repeat for the remaining main bearing caps.
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   Illustration 2	g01432170

3. Remove nuts (3) for the crankshaft main bearings. Remove plate (4). Remove bolts (5) from each side of the engine.
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   Illustration 3	g01432171

4. Remove main bearing cap (6) and lower main bearing (7).

5. Use Tooling (A) to rotate the engine to approximately 180 degrees so that the crankshaft is on top.
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   Illustration 4	g01432172

6. Number counterweights (13) for assembly purposes. Remove bolts (11). Remove counterweights (13). The weight of counterweights (13) is approximately 18 kg (40 lb). Number the rod caps and the connecting rods for assembly purposes. Remove bolts (8). Remove rod caps (9). Lay rod caps (9) on the side to prevent damage. Position pistons (10) away from crankshaft (12).

   Note: Match the tabs on the ODD and EVEN connecting rod caps with the connecting rod.

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   Illustration 5	g01224401

   Note: If the counterweights are installed on the crankshaft, the weight of the crankshaft is approximately 1043 kg (2300 lb) for the C175-16 and 1215 kg (2680 lb) for the C175-20.

7. Attach a suitable lifting device onto crankshaft (12). The weight of crankshaft (12) is approximately 690 kg (1522 lb) for the C175-16 and 826 kg (1822 lb) for the C175-20. Remove crankshaft (12).
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   Illustration 6	g01224408

8. Remove upper main bearings (16) from cylinder block (14). Remove thrust bearing (15) from cylinder block (14).
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   Illustration 7	g01224414

9. Install Tooling (F) onto main bearing stud (17). Use a suitable ratchet and Tooling (F) to remove main bearing stud (17).

Installation Procedure

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Illustration 8	g01224414

1. Lubricate main bearing studs (17) with clean engine oil. Install main bearing stud (17). Use Tooling (F) and a suitable torque wrench to tighten main bearing stud (17). Tighten main bearing stud (17) to a torque of 100 ± 20 N·m (74 ± 15 lb ft).
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   Illustration 9	g01224408

2. Install thrust bearing (15) into the rear of cylinder block (14). Lightly lubricate upper main bearings (16) and the upper connecting rod bearings with clean engine oil. Install upper main bearings (16) into cylinder block (14).
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   Illustration 10	g01224401

3. Attach a suitable lifting device onto crankshaft (12). The weight of crankshaft (12) is approximately 748 kg (1650 lb). Install crankshaft (12).

4. Use Tooling (A) to rotate the engine slightly above the horizontal position.
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   Illustration 11	g01432463

   Note: Match the tabs on the ODD and EVEN connecting rod caps with the connecting rod.

5. Position pistons (10) toward crankshaft (12). Lubricate the bearings for rod caps (9) with clean engine oil. Install rod caps (9). Apply Tooling (G) under the bolt heads (8) and to the bolt threads (8). Install bolts (8) finger tight.
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   Illustration 12	g01431693

6. Use the following procedure to tighten bolts (8):

   1. Tighten Bolts (1) and (2) to a torque of 85 ± 5 N·m (63 ± 4 lb ft).

   2. Tighten Bolts (3) and (4) to a torque of 85 ± 5 N·m (63 ± 4 lb ft).

   3. Tighten Bolts (5) and (6) to a torque of 85 ± 5 N·m (63 ± 4 lb ft).

   4. Repeat Steps 6.a through 6.c.

   5. Turn Bolts (3) and (4) for an extra 90 ± 5 degrees.

   6. Turn Bolts (5) and (6) for an extra 90 ± 5 degrees.

   7. Turn Bolts (1) and (2) for an extra 90 ± 5 degrees.
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   Illustration 13	g01432454

7. Install counterweights (13). The weight of counterweights (13) is approximately 18 kg (40 lb). Apply Tooling (G) to the threads, the shank, the washer, and the seat of bolts (11). Install bolts (11) and Tooling (E). Tighten bolts (11) to a torque of 220 ± 20 N·m (162 ± 15 lb ft). Turn bolts (11) an extra 90 ± 5 degrees.
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   Illustration 14	g01432171

8. Lubricate lower main bearing (7) with clean engine oil. Install lower main bearing (7) into main bearing cap (6). Install main bearing cap (6).
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   Illustration 15	g01432170

9. Lubricate the main bearing studs with clean engine oil. Install plate (4). Install nuts (3) for the crankshaft main bearings finger tight. Lubricate bolts (5) with clean engine oil. Install bolts (5) finger tight.

10. Start at the front of the engine and tighten bolts (5) on the right side of the cylinder block to a torque of 100 ± 20 N·m (74 ± 15 lb ft).
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    Illustration 16	g01224384

11. Install Tooling (B) onto the studs for the crankshaft main bearing cap. Tighten threaded collar (1) of Tooling (B). Attach Tooling (C) onto Tooling (B). Attach Tooling (C) onto Tooling (D). Attach Tooling (D) onto Tooling (E). Apply approximately 135 MPa (19580 psi) of pressure to Tooling (B). Use drive (2) on Tooling (B) to tighten the nuts for the crankshaft main bearings. Release the pressure on Tooling (B). Reapply approximately 135 MPa (19580 psi) of pressure to Tooling (B). Recheck nuts (2) for tightness. Remove Tooling (B).
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    Illustration 17	g01225172

12. Start at the front of the engine and tighten bolts (5) on the left side of the cylinder block to a torque of 100 ± 20 N·m (74 ± 15 lb ft).

13. Start at the front of the engine and tighten bolts (5) on the right side of the cylinder block to a torque of 530 ± 70 N·m (391 ± 52 lb ft).

14. Start at the front of the engine and tighten bolts (5) on the left side of the cylinder block to a torque of 530 ± 70 N·m (391 ± 52 lb ft).

End By:

1. Install the engine oil cooler.

2. Install the flywheel housing.

3. Install the front housing.

4. Install the engine oil pan.

5. Install rocker arm shaft assemblies.