COVER 8J0377 - Caterpillar

Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 456-6500 Engine Rollover Stand 1
284-8777 Adapter Plate (Rear) 1
284-8766 Adapter Plate (Front) 1
B 253-3272 Cylinder 2
C 178-9312 Hose As 2
D 253-3276 Distribution Coupler 1
E(1)(2) 227-6724 Electric Hydraulic Pump Gp (120 V) 1
227-8834 Electric Hydraulic Pump Gp (240 V) 1
191-5347 Hydraulic Pump Gp 1
156-7167 Manual Hydraulic Pump 1
F 284-5266 Spanner Wrench 1
(1) Use any of the pumps that are listed in Tooling (D) for this procedure.
(2) The latest pumps and hoses require 151685 kPa (22000 psi) capacity.Note: Tooling (A) is not rated for weight of entire long block. Heads must be removed prior to installation.Start By:
Remove rocker arm shaft assemblies.
Remove the engine oil pan.
Remove the front housing.
Remove the flywheel housing.
Remove the engine oil cooler.
Remove the cylinder heads.
Use Tooling (A) to rotate the engine to approximately 120 degrees.
Illustration 1 g01224384
Install Tooling (B) onto the studs for the crankshaft main bearing cap. Tighten threaded collar (1) of Tooling (B). Loosen threaded collar (1) of Tooling (B) by 1 1/2 turns. Attach Tooling (C) onto Tooling (B). Attach Tooling (C) onto Tooling (D). Attach Tooling (D) onto Tooling (E). Apply approximately 135 MPa (19580 psi) of pressure to Tooling (B). Use drive (2) on Tooling (B) to loosen the nuts for the crankshaft main bearings. Turn drive (2) on Tooling (B) by approximately three turns. Release the pressure on Tooling (B). Remove Tooling (B). Repeat for the remaining main bearing caps.Note: Refer to Reuse and Salvage Guidelines, SEBF8301, "Inspection and Reuse of Critical Fasteners in All Engines" for reuse criteria of main studs.
Illustration 2 g01432170
Remove nuts (3) for the crankshaft main bearings. Remove plate (4). Remove bolts (5) from each side of the engine.
Illustration 3 g01432171
Remove main bearing cap (6) and lower main bearing (7).
Use Tooling (A) to rotate the engine to approximately 180 degrees so that the crankshaft is on top.
Illustration 4 g01432172
Number counterweights (13) for assembly purposes. Remove bolts (11). Remove counterweights (13). The weight of counterweights (13) is approximately 18 kg (40 lb). Number the rod caps and the connecting rods for assembly purposes. Remove bolts (8). Remove rod caps (9). Lay rod caps (9) on the side to prevent damage. Position pistons (10) away from crankshaft (12).Note: Match the tabs on the ODD and EVEN connecting rod caps with the connecting rod.
Illustration 5 g01224401Note: If the counterweights are installed on the crankshaft, the weight of the crankshaft is approximately 1043 kg (2300 lb).
Attach a suitable lifting device onto crankshaft (12). The weight of crankshaft (12) is approximately 748 kg (1650 lb). Remove crankshaft (12).
Illustration 6 g01224408
Remove upper main bearings (16) from cylinder block (14). Remove thrust bearing (15) from cylinder block (14).
Illustration 7 g01224414
Install Tooling