Remove Pistons & Connecting Rod Assemblies
Start By:
a. remove cylinder head assembly
b. remove oil pump
Fluid Spillage Containment
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to “Tools And Shop Products Guide”, NENG2500 for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose of fluids according to local regulations and mandates.
1. Remove the carbon ridge from the top inside surface of the cylinder liners.
2. Turn the crankshaft until two pistons are at bottom center.
3. Remove bolts (1) and the bearing caps. Push the rods and pistons up until the rings are out of the cylinder liners.
4. Remove pistons (2) and connecting rods from the cylinder liners.
5. Do Steps 1 through 4 for the remainder of the pistons and connecting rods.
Install Pistons And Connecting Rod Assemblies
1. Put clean engine oil on piston rings, connecting rod bearings and cylinder liners.
2. Use Tool (A), and install piston (2) and the connecting rod in the cylinder liner. Be sure the number on the tab groove side of the connecting rod is on the opposite side from the camshaft.
3. Install the bearing cap on the connecting rod with the number on the side of the bearing cap on the same side and same number as on the connecting rod.
4. Put 4C-5593 Anti-Seize Compound on the bolt and threads. Install the bolts and bearing cap. Tighten each bolt in the bearing cap to a torque of 90 ± 8 N·m (66 ± 6 lb ft). Put a mark on each bolt and the bearing cap. Tighten each bolt an additional 90 ± 5 degrees.
5. Do Steps 1 through 4 for the remainder of the pistons and connecting rods.
End By:
a. install oil pump
b. install cylinder head assembly
Disassemble & Assemble Pistons And Connecting Rod Assemblies
Start By:
a. remove pistons and connecting rod assemblies
Fluid Spillage Containment
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to “Tools And Shop Products Guide”, NENG2500 for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose of fluids according to local regulations and mandates.
1. Remove bearings (3) from the connecting rod and connecting rod cap.
2. Remove retainer rings (1) with Tool (A).
3. Remove pin (2) and connecting rod (4) from the piston.
NOTE: Separate the piston crown from the piston skirt.
4. Remove piston rings (5) from the piston crown with Tool (B). Clean the piston ring grooves in the piston crown with an acceptable ring groove cleaning tool.
NOTE: See, Use Of Piston Pin Bearing Removal And Installation Tools, Special Instructions, SMHS7295.
5. Heat connecting rod (4) in an oven to a temperature of 177° to 260°C (350° to 500°F). Never use a direct flame to heat a connecting rod.
6. Put connecting rod (4) in position on the base plate of Tooling (C). Put a new rod pin bearing (6) on the adapter part of Tooling (C).
NOTE: The old bearing is pushed out by Tooling (C) as the new bearing is installed.
7. Use Tooling (C) to push the new bearing into the connecting rod until the push adapter of Tooling (C) makes full contact with the connecting rod surface.
8. Use a pin boring machine to make the rod pin bearing the correct size. The bore in the new rod pin bearing must be 55.035 ± 0.008 mm (2.1667 ± .0003 in).
9. Check the clearance between the ends of the piston rings. See the Specifications Module for additional information.
10. Install the oil ring spring in the oil ring groove of the piston crown.
NOTE: The oil ring is to be installed over the spring with the oil ring end gap 180 degrees from the oil ring spring joint.
11. Install the oil ring on the piston crown with Tool (B).
12. Install the second (intermediate) piston ring with the side that has the identification “UP-2” toward the top of the piston. Use Tool (B) to install the ring.
13. Install the first (top) piston ring with the side that has the identification “UP-1” toward the top of the piston. Use Tool (B) to install the ring.
NOTE: After the installation of all three piston rings, put the piston rings in position so the end gaps are 120 degrees apart.
NOTE: Install the piston crown into the piston skirt.
14. Put the piston in position on connecting rod (4). Put clean engine oil on pin (2), and install the pin. Install retainer rings (1) with Tool (A). Make sure the retainer rings are in the grooves of the piston.
15. Install bearings (3) in the connecting rod and connecting rod cap.
NOTE: Be sure the tabs in back of the bearings are in tab slots of the connecting rod and connecting rod cap.
End By:
a. install pistons and connecting rod assemblies