C175-16 Locomotive Engine Caterpillar

Removal Procedure

Start By:

1. Remove the cylinder head.

2. Remove the piston cooling jet.

1. Refer to Operation and Maintenance Manual, "Engine Oil and Filter - Change" for the correct draining and filling procedure.
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   Illustration 1	g01831951

   Note: Inspect the connecting rod and connecting rod cap for the proper identification mark. The connecting rod and the connecting rod cap should have an etched number on the side. The number should match the cylinder number. Mark the connecting rod and the connecting rod cap, if necessary. Careful handling is required for fractured connecting rods. The connecting rod and the rod cap should be placed on the sides to prevent damage. When possible, the connecting rod and the rod cap should be bolted together to prevent damage.

2. Use Tooling (A) to rotate the flywheel to access the connecting rod cap that will be removed.

3. Remove bolts (1) and connecting rod cap (2). Position the crankshaft so that the piston is at the bottom dead center. Inspect the connecting rod bearing for wear or for damage.
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   Illustration 2	g01240845

4. Install Tooling (B) onto the connecting rod.
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   Illustration 3	g01240763

5. Install Tooling (C). Hold the bolt of Tooling (C) and turn the nut. Turn the nut until the nut is tight.

6. Rotate the engine to position the cylinder pack to the proper height and install Tooling (D).
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   Illustration 4	g01997933

7. Install Tooling (D). Remove Tooling (C).

   Note: Do not remove the cylinder pack with Tooling (C).

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   Illustration 5	g01765495

8. Install Tooling (E) onto the piston liner. Rotate the engine to position the piston to the top. Attach Tooling (E) to the piston. Attach a suitable lifting device onto Tooling (E). The weight of the piston, the liner, and the connecting rod is approximately 50 kg (110 lb). Remove Tooling (D).
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   Illustration 6	g01765496

9. Remove cylinder pack (3) from the cylinder block.

Installation Procedure

Note: Ensure that the top O-ring seal for the liner is at least 20 °C (68 °F) before installation of liners into the cylinder block. Assembly with a cold seal may result in damage to the O-ring seal or to the installation tool.

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Illustration 7	g01765496

1. Rotate the engine to position the piston toward top dead center for easy access. Refer to Testing and Adjusting, "Finding Top Center Position for No. 1 Piston".

2. Attach a suitable lifting device onto Tooling (E). The weight of the piston, the liner, and the connecting rod is approximately 50 kg (110 lb). Install Tooling (B) onto the connecting rod. Coat the liner bore of the cylinder block and the O-ring seals on the outside of the cylinder liner with Tooling (H). Install cylinder pack (3) into the cylinder block.

   Note: Inspect the connecting rod bearing for wear or for damage. If necessary, replace the connecting rod bearing. Refer to Disassembly and Assembly, "Connecting Rod Bearings - Remove and Install" for the proper procedure. Position the connecting rod so that the chamfer is toward the crankshaft. Install the piston, the liner, and the connecting rod as a unit.

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   Illustration 8	g01765495

3. Remove Tooling (E).
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   Illustration 9	g01945551

4. Install Tooling (F). Use Tooling (F) to seat the liner into the cylinder block. Fully seat the cuff.
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   Illustration 10	g01240845

5. Remove Tooling (B) from the connecting rod.
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   Illustration 11	g01831951

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

6. Install connecting rod cap (2). Apply Tooling (G) under the head bolts (1), the rings, and to the threads of bolts (1). Install bolts (1).

7. Use Tooling (A) to rotate the flywheel to access the connecting rod cap that will be installed.
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   Illustration 12	g01431693

8. Use the following procedure to tighten bolts (3):

   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 8a through 8c.

   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.

      Note: Paint bolt heads to ensure the correct angle on the additional turns. The points on the bolt heads are separated by 30 degrees.

9. Refer to Operation and Maintenance Manual, "Engine Oil and Filter - Change" for correct draining and filling procedures.

End By:

1. Install the piston cooling jet.

2. Install the cylinder head.