C175-16 Locomotive Engine Caterpillar

Removal Procedure

Start By:

1. Remove the electronic unit injector.

2. Remove the fuel pump.

3. Remove the fuel filter housing.

4. Remove the engine oil cooler.

5. Remove the engine oil pump.

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

2. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change" for the correct draining and filling procedure.

3. If necessary, remove components for access to the side covers. Remove the panel, the starting motor, and the alternator.
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   Illustration 1	g03347966

4. Remove bolts (1). Remove side cover (2).

5. Use Tooling (A) to turn the flywheel in order to access the connecting rod cap that will be removed.
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   Illustration 2	g01431477

   Note: Inspect and carefully handle the fractured connecting rod and the connecting rod cap for the proper identification mark. The connecting rod and the connecting rod cap should have an etched number on the side. Clean with Tooling (D) if the etching is hard to view. The number should match the cylinder number. Mark the connecting rod and the connecting rod cap, if necessary. Improper handling of the fractured connecting rods and the connecting rod caps can cause misalignment during assembly. The connecting rod caps should be placed on the side in order to prevent damage.

6. Remove bolts (3) and the spacer. Remove connecting rod caps (4).
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   Illustration 3	g02076133

   Note: Notice the location of the tabs when the connecting rod bearings are removed from the ODD and EVEN connecting rod caps.

7. Remove the lower half of connecting rod bearing (5) from connecting rod cap (4).
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   Illustration 4	g02049074

8. If necessary, rotate the crankshaft in order to install Tooling (B).
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   Illustration 5	g02049093

9. Install Tooling (C) in order to hold the piston in place.

10. Use the adjusting nut to raise the piston until the connecting rod is above the crankshaft journal. Remove Tooling (B) that is not against the crankshaft journal. Remove the upper half of the connecting rod bearing.

11. Push the connecting rod into position and remove the rest of Tooling (B). The connecting rod should swing over the crankshaft journal. Check in order to avoid contact between the connecting rod and the connecting rod journal.

Installation Procedure

1. Clean the connecting rod cap and the connecting rod bearing bore with Tooling (D) and clean lint free rag. Inspect both the connecting rod cap and the connecting rod bearing bore. Check for carbon on the connecting rod cap and the connecting rod bearing bore.

2. Inspect the fractured joints and remove any loose material. Clean the face with a clean paint brush to remove loose material on the fractured areas.

3. Check the clearance of the bearings. Refer to Disassembly and Assembly, "Bearing Clearance - Check" for the correct procedure.

4. Use Tooling (D) and a lint free rag to clean the new bearing. Apply a light film of clean oil to back of bearing surface and a generous amount of oil on the front of each bearing

5. Install the upper half of the connecting rod bearing in the connecting rod. Inspect in order to ensure that the tab on the back of the bearing is in the bearing tab groove on the connecting rod.

6. Inspect the connecting rod bearing and the crankshaft journal for seating, alignment, and cleanliness. Apply clean engine oil.

7. Push the connecting rod into position over the connecting rod journal and install Tooling (B).

8. Position the connecting rod over the crankshaft. Use Tooling (C) to lower the piston on the crankshaft journal.
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   Illustration 6	g02049074

9. Remove Tooling (B).
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   Illustration 7	g02076133

   Note: Notice the location of the tabs on the ODD and EVEN connecting rod caps before installing the connecting rod bearings. Install the tab of the connecting rod bearing in the slot of the connecting rod cap or the connecting rod first. The joint of the connecting rod bearing and the connecting rod cap or the connecting rod should be aligned. Push the opposite side of the connecting rod bearing simultaneously away from the joint into the bore.

10. Install the lower half of connecting rod bearing (5) in connecting rod cap (4). Inspect in order to ensure that the tab on the back of the bearing is in the bearing tab groove on connecting rod cap (4).
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    Illustration 8	g01431477

11. Position connecting rod cap (4) onto the connecting rod. Ensure that the number on the side of connecting rod cap (4) corresponds to the number that is on the connecting rod.

    Note: When, the connecting rod cap is positioned onto the connecting rod avoid contact with the crankshaft journal.

12. Determine the position of the bearing tab ODD or EVEN. Designate the center bolt on the bearing tab side as the bolt 1 for the tightening procedure.

13. Clean the bolts and inspect the bolts for thread damage. If necessary, use new bolts.

14. Apply Tooling (E) under the heads and to the threads of bolts (3). Install the spacer and bolts (3) finger tight. Do not use air gun to run down the bolts.
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    Illustration 9	g02049093

15. Remove Tooling (C).

16. Use Tooling (A) to rotate the flywheel in order to access the connecting rod cap that will be installed.
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    Illustration 10	g01431693

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

    Note: Bolt (1), on the tab side of the bearing, must be tightened first.

    1. Tighten Bolts (1) then (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 17.a through 17.c.

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

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

    7. Turn Bolts (1) and (2) for an additional 90 ± 5 degrees.

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

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    Illustration 11	g01206105

18. Position side cover (2). Install bolts (1).

19. If necessary, install the components for access to the side covers. Install the panel, the starting motor, and the alternator.

End By:

1. Install the engine oil pump.

2. Install the engine oil cooler.

3. Install the fuel filter housing.

4. Install the fuel pump.

5. Install the electronic unit injector.