3512E Engines Caterpillar

Removal Procedure

Start By:

1. Remove the rocker shaft assemblies and pushrods.

2. Remove the front housing.

3. Remove the balancer gear from the rear gear group.

4. Remove the flywheel housing.

5. Remove the piston cooling jets.

1. Use Tooling (A) to turn the engine to a horizontal position. The engine can be supported with Tooling (A) or with blocks. The engine has the following weight:

   • 3512F Engines weigh approximately 5902 kg (13,000 lb).

   Note: It is not necessary to remove the counterweights from the crankshaft, if the piston and connecting rod assemblies have been removed from the engine.

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   Illustration 1	g00914774

2. Place identification marks on counterweights (1). Remove counterweights (1) from the crankshaft.
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   Illustration 2	g00914776

   Note: Ensure that the journals of the crankshaft are not scratched by the connecting rods.

3. Remove connecting rod caps (2) and push the connecting rods away from the crankshaft.
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   Illustration 3	g00914800

4. Remove the center main bearing cap and thrust plates (3) from each side of the center main bearing.
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   Illustration 4	g00930694

5. Attach Tooling (B) to each end of the crankshaft.

6. Attach a suitable lifting device to Tooling (B) (Illustration 4). The weight of crankshaft (5) is approximately 590 kg (1300 lb). Remove remaining main bearing caps (4). Remove crankshaft (5) from the engine.

7. Remove the upper halves of the main bearings.

8. Remove the upper halves of the connecting rod bearings.
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   Illustration 5	g00914805

9. If necessary, remove bolts (6) and crankshaft gear (7) from each end of the crankshaft.

Installation Procedure

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Illustration 6	g01049072

1. If crankshaft gear (7) was removed, install the gear on crankshaft (5).

2. Check the clearance of the main bearings. Refer to Disassembly and Assembly, "Bearing Clearance - Check".
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   Illustration 7	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 bearings with clean engine oil.

4. Install the upper halves of connecting rod bearings (9) in the connecting rod assemblies. Coat the bearings with clean engine oil.
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   Illustration 8	g00930694

   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 (5). The weight of crankshaft (5) is approximately 590 kg (1300 lb).

6. Ensure that the lower halves of the main bearings are in position in the main bearing caps. Coat the bearings with clean engine oil.

   Note: Main bearing caps (4) 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.

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   Illustration 9	g03887353

7. Coat the threads of the bolts for the main bearing caps 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 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 10	g01049103

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

9. Install the center main bearing. Use the tightening procedure that is in Step 7.

10. Use Tooling (D) to measure the end play of the crankshaft. The end play must not exceed 0.17 mm to 0.63 mm (0.007 inch to 0.025 inch).

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

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

13. 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 11	g01049104

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    Illustration 12	g01049105

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

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

    1. Tighten Bolts (1) and (2) to a torque of 90 ± 5 N·m (65 ± 4 lb ft).

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

    3. Tighten Bolts (3) and (4) 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.

16. After measuring the clearance of the connecting rod bearing, coat the 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 13	g01049106

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

    Note: Do not reuse counterweight bolts.

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

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

20. Tighten the outer bolts first then the inner bolt to a torque of 70 ± 5 N·m (50 ± 4 lb ft).

21. Tighten the bolts in the same sequence for an additional 120 ± 5 degrees (1/3 turn).

22. Use Tooling (A) to turn the engine to a vertical position.