PISTON 1096781 - Caterpillar

Installation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 6V-6640 Sealant 1
B - Guide Bolt
M8 by 80 mm 2
C 319-6486 Alignment Tool 1
- Bolts
M10 by 50 mm 3
D - Straight Edge 1
E 1U-6396 O-Ring Assembly Compound 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Ensure that the front housing is clean and free from damage. If necessary, replace the front housing. If necessary, install blanking plugs to a new front housing. Use Tooling (A) to seal all D-plugs.
Check the condition of the crankshaft front seal. If the front seal is damaged, remove the front seal from the front housing.
Clean the mating surfaces of the cylinder block.
Illustration 1 g01350337
Typical example
Install thrust washer (11) into the recess in the cylinder block. Refer to Disassembly and Assembly, "Camshaft - Install" for more information.
Illustration 2 g01419960
Typical example
Install Tooling (B) to the cylinder block.
Install Tooling (C) to the cylinder block.
Align a new joint (8) with Tooling (B). Install the joint to the cylinder block. Note: Ensure that Tabs (X) on the joint are engaged in the Holes (Y) in the cylinder block.
Install the front housing over Tooling (B) and over Tooling (C) onto the cylinder block.
Illustration 3 g01419961
(9) M8 by 20 mm
(10) M8 by 25 mm
Illustration 4 g01438254
Typical example
Install bolts (10) to front housing (4) finger tight.
Remove Tooling (B).
Install bolts (9).
Align the bottom face of front housing (4) to the lower machined face of the cylinder block. Use a Tooling (D) and a feeler gauge in order to check the alignment between the front housing and the cylinder block. Refer to Specifications, "Front Housing and Covers" for further information.
Illustration 5 g01269949
Tightening sequence for the front housing
Tighten bolts (9) and (10) to a torque of 28 N m (20 lb ft). Note: Ensure that the housing and the cylinder block are correctly aligned.
Remove Tooling (C) from the cylinder block.
If necessary, install a new crankshaft front seal. Refer to Disassembly and Assembly, "Crankshaft Front Seal - Remove and Install".
Illustration 6 g01419665
Typical example
If the engine is equipped with a heavy duty idle gear. Install plate (7). Refer to Disassembly and Assembly, "Idler Gear - Install" for the correct procedure.
Illustration 7 g01419651
Install new O-ring seal (5) and O-ring seal (6) to bypass tube (3). Use Tooling (E) in order to lubricate O-ring seal (5). Install bypass tube (3) to the cylinder head. Install bolts (1). Tighten the bolts to a torque of 22 N m (16 lb ft).
Install hose to bypass tube (3) and securely tighten hose clamp (2). End By:
Install the fuel injection pump. Refer to Disassembly and Assembly, "Fuel Injection Pump - Install".
Install the timing gears. Refer to Disassembly and Assembly, "Gear Group (Front) - Install".
Install the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove and Install".
Install the crankshaft pulley. Refer to Disassembly and Assembly, "Crankshaft Pulley - Remove and Install".
Install the alternator. Refer to Disassembly and Assembly, "Alternator - Install".
Install the fan. Refer to Disassembly and Assembly, "Fan - Remove and Install".