COVER GP-CYLINDER BLOCK 1W8897 - Caterpillar

8. Remove O-ring seal (10), the thrust washer and the bearing from the adapter with tool (A).9. Remove bolts (12) from the cover. Remove cover (11) and the gasket from the crankcase. 10. Bend down the lock on lock straps (13). Remove bolts (14) from the bearing caps.11. Put identification marks on the bearing caps for correct installation with the connecting rod. Remove the bearing caps. 12. Remove pistons (15) from the crankcase through the top of the cylinders.13. Remove crankshaft (16) from the crankcase. Remove the key from the crankshaft. 14. Remove end cover (17) from the crankcase. Remove the O-ring seal, the thrust washer and the bearing.15. Remove cover (18), the gasket and the strainer from the air inlet opening.
Be careful not to cause damage to the inlet valve seats.
16. Remove inlet valves (20) from their guides (21). Remove the inlet valve guides from around the inlet valve seats.17. Remove (unloader) spring (19), spring saddle (22) and the spring seat from the housing with needle nose pliers. 18. Remove (unloader) plunger (24) and guides (25) from the housing. Remove the guides from the plungers.19. To remove (unloader) pistons (23) from the bore, put a cover over the inlet port, then blow air pressure in the governor mounting pad (unloader) port. 20. Remove the plug and lockpin (27) that holds rod pin (26) in the piston. Remove the pin from connecting rod (28). 21. Remove the piston rings from piston (30). Remove two compression rings (29), the oil ring and the expander ring with a suitable tool.22. Remove the bearings from the connecting rod and the connecting rod cap. 23. Remove the piston pin bushing with tool (A).24. Remove the small seal rings from both ends of the housing.25. Clean all the oil passages through the housing, the crankshaft, the end cover and the adapter.Assemble Air Compressor
1. Clean and inspect all parts of the air compressor for wear or damage, and make a replacement if necessary. 2. Check (unloader) bore bushings (1) for damage and wear. If these bushings need replacement, remove the bushing by the use of a 3.18 mm (.125 in.) pipe threaded tap. Then install a 3.18 mm (.125 in.) pipe threaded rod and pull the bushing straight up and out.3. Check the cylinder bores in the crankcase housing for damage (scored or out of round). Measure the cylinder bore in several places. If the measurement difference is more than 0.03 mm (.001 in.) or taper is more than 0.05 mm (.002 in.), the cylinder bore must be made larger (rebored or honed oversize).4. Install seal rings (3) in both ends of the crankcase housing.5. Install the new (unloader) pistons in their bore.
Be careful not to cause damage to the O-ring seals or the spiral rings.
6. Put the unloader plungers in their guides. Install the plunger and guide as a unit (6) to the crankcase housing and on top of the pistons. Install the unloader spring seat in the crankcase housing.7. Put saddle (4)