AFTERCOOLER 4L6902 - Caterpillar

Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 5R-7425 Barring Gp(1) 1
B 1P-1861 Retaining Ring Pliers 1
C 271-0498 Expander Ring 1
(1) The 9S-9082 Engine Turning Tool is alternative tooling.Start By:
Remove the spacer plates.
Remove the piston cooling jets.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Note: The front end of the engine is the end that is opposite of the flywheel. The number one cylinder is the right front cylinder and the number two cylinder is the front left cylinder.
Remove the cover from the front right side of the flywheel housing. Use Tooling (A) to rotate the flywheel until all four bolts in the connecting rod cap can be removed.
Mark the cylinder number on each connecting rod and on the corresponding connecting rod cap.
Illustration 1 g02042295
Illustration 2 g02042296
Remove bolts (1) and connecting rod cap (2) from connecting rod (5).
Remove the piston and connecting rod assembly.
Use Tooling (B) to remove retaining rings (4) that hold piston pin (6). Remove piston pin (6). Remove piston (3) from connecting rod (5).
Remove the bearings from connecting rod (5) and connecting rod cap (2). Note: If necessary, separate the piston skirt from the piston crown.
Illustration 3 g02042299
Use Tooling (C) to remove piston rings (7) from piston (3).
Clean the piston ring grooves with an acceptable ring groove tool. Refer to Reuse and Salvage Guidelines, SEBF8059, "Procedures and Specifications for Pistons" for the correct procedure for cleaning the pistons.