PLUG 2H9099 - Caterpillar

Start By:a. remove radiator and guard **This operation is in the Disassembly And Assembly Module, 3204 Vehicular Engine Supplement For D3C, D3C SA And 931C, Form No. SENR3803. This operation is done on a D3C SA with a 5F/4R direct drive transmission.1. Drain the hydraulic tank and shut off the fuel supply.2. Remove the floor plates.3. Put identification on all wires, tubes and hoses prior to disconnecting or removing. 4. Disconnect tube (1) from the air cleaner elbow and fuel line hoses (4) from the fuel line tubes. Remove the bolts that fasten the fuel hose bracket to the flywheel housing.5. Remove muffler (2).6. Disconnect governor linkage from lever (3). Remove linkage mounting bracket (6) from the cylinder block.7. Disconnect wiring harnesses (5) and (8) from the alternator and the sending unit.8. Loosen hose clamp (7) and disconnect radiator lower hose. 9. Disconnect water temperature sending unit (9) and tube assembly (10).10. Disconnect electric starter motor wires (11) and cylinder block to frame ground strap (12).11. Remove all bolts and clamps that fasten wiring harnesses in the engine compartment. Remove the wiring harness from the engine. 12. Disconnect tube assembly (13) at the flywheel housing.13. Place wooden blocks (14) under the transmission. 14. Disconnect hose assembly (15). 15. Disconnect wiring harness at connectors (16).16. Disconnect tube assemblies (17) from each side of the transmission oil filter. Remove the transmission filter from the transmission.17. Disconnect drive shaft (18) from the transmission. 18. Disconnect electrical plug (19) from the transmission. Remove the bolts that fasten the wiring harness clips to the transmission. 19. Disconnect hose assembly (20) from the transmission oil pump. Disconnect transmission linkage rods (21) and (22). Remove gear shift linkage (23) from the top of transmission. 20. Remove the bolts to disconnect block (24) from transmission. 21. Disconnect tube assemblies (25) from the transmission oil pump. 22. Remove bolt (26) from each side of machine for clearance.23. Install tooling (A) and a hoist on the engine lifting brackets. 24. Remove the rear mount assemblies. Remove mounting bracket (27) from both sides of transmission for clearance. 25. Remove engine front mount assemblies (28) 26. Remove the engine and transmission assembly from the vehicle chassis. The engine and transmission assembly weighs approximately 999 kg (2200 lb.). The following steps are for installation of the engine and transmission.27. Attach a hoist and tool (A) to the engine and position the engine and transmission in the vehicle chassis.28. Install engine front mount assemblies (28).29. Install mounting bracket (27) on both sides of the transmission. Install the rear mount assemblies.30. Remove the hoist and tool (A)31. Install bolt (26) on both sides of the machine.32. Connect tube assemblies (25) to the transmission oil pump.33. Install the bolts that fasten block assembly (24) to the transmission.34. Install transmission gear shifter linkage (23) in the top of transmission.35. Connect transmission linkage rods (21) and (22). Connect hose assembly (20) to the transmission oil pump.36. Install the wiring harness on the transmission. Install electrical plug