Pistons and Connecting Rods - Disassemble

SMCS - 1225-015

Disassembly Procedure

Table 1

Required Tools

Tool Part Number Part Description Qty

A 1U-6683 Ring Expander 1

B 1P-1857 Retaining Ring Pliers 1

C 1P-0510 Driver Group 1

Start By:

a. Remove the pistons and the connecting rods. Refer to Disassembly and Assembly,
"Piston and Connecting Rods - Remove".

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Note: The forged marks (X) must be installed toward the front of the engine.

2. Use Tooling (A) in order to remove compression rings (1) and (2), and oil control ring (3)
from piston (6).
3. Use Tooling (B) in order to remove retaining rings (8) that hold the piston pin in position.
4. Remove piston pin (7) from the piston.

Note: If the piston pin cannot be removed by hand, heat the piston to a temperature of 45
± 5 °C (113 ± 9 °F). Do not use a torch to heat the piston.

5. Use Tooling (C) and a suitable press in order to remove bushing (4) from connecting rod
(5).
6. Repeat Steps 1 through 5 in order to disassemble the remaining pistons and connecting
rods.
Pistons and Connecting Rods - Assemble

SMCS - 1225-016

Assembly Procedure

Table 1
Required Tools
Tool Part Number Part Description Qty
A 1P-1857 Retaining Ring Pliers 1
B 1U-6683 Ring Expander 1

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

NOTICE
Installation of the piston pin bushing must be carried out by personnel
with the correct training. Also special machinery is required.

Note: A new piston pin bushing is in a shape of a wedge. For further information on installation
of the piston pin bushing, refer to your authorized Caterpillar dealer or your Caterpillar
distributor for assistance.

1. Refer to Testing and Adjusting, "Connecting Rod - Inspect" for the correct height grade
for the fractured split connecting rod.
2. The bearing shells for the connecting rod and the connecting rod cap must be aligned by a
tool before the bearing shells are installed. Refer to illustration 1. Check the alignment of
the bearing shells and remove the alignment tool from the assembly. The bearing shell
must be an equal distance from each end. Refer to illustration 2.

3. Align the mark (1) on the connecting rod to the boss cutout (2) of the piston. Also check
that the arrow (3) that is marked on top of the piston is aligned. Install the piston pin into
the piston and through the connecting rod.

Note: If the piston pin cannot be installed by hand, use hot water in order to heat the
piston to a temperature of 45° ± 5°C (113° ± 9°F).

4. Use the Tooling (A) in order to install the circlips (4) that hold the piston pin in position.
 5. Use the Tooling (B) in order to install the piston rings on the piston with the following
steps.

a. Install the spring (6) for the oil control piston ring (7) in the groove (4) that is
lowest on the piston. The latch pin (5) must be located inside the ends of the
spring. Locate the oil control ring (7) over the internal spring (6) .

Note: Ensure that the latch pin is 180 degrees from the oil control ring gap.

Pistons and Connecting Rods - Install

SMCS - 1225-012

Installation Procedure

Table 1

Required Tools

Tool Part Number Part Description Qty

A 1U-6684 Piston Ring Compressor 1

B 8T-3052 Degree Wheel 1

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

2. Lubricate the piston and the cylinder bore with clean engine oil.

Note: The piston and connecting rod are matched to a specific cylinder. Ensure that the
connecting rod and pistons are installed in the correct cylinder.

3. Rotate the crankshaft until the connecting rod journal is at the bottom center. Lubricate
the connecting rod journal with clean engine oil.

4. Lubricate the upper connecting rod bearing with clean engine oil.

5. Install the Tooling (A) on the piston.

Note: Ensure that the Tooling (A) is installed correctly and that the piston can easily slide
from the tool.

Note: The arrow that is on the top of the piston must be toward the front of the engine.

6. Push the piston and the connecting rod assembly into the cylinder bore and onto the
connecting rod journal.

7. Lubricate the lower connecting rod bearing with clean engine oil.

Note: The connecting rod is a forging. The connecting rod has been hydraulically split in
order to separate the connecting rod cap and the connecting rod. This process provides
accurately matched surfaces. Do not mix the connecting rod cap and the connecting rod.

8. Install the connecting rod cap (2) .

Note: Do not reuse the old setscrews in order to secure the connecting rod cap.

10. Tighten the setscrews evenly to a torque of 18 N·m (13 lb ft).

11. Tighten the setscrews evenly to a torque of 70 N·m (52 lb ft).

12. Use the Tooling (B) to achieve the correct final torque.

Note: If the Tooling (B) is not used, place an index mark on each setscrew.

13. Turn the setscrews for an additional 120 degrees.

14. Rotate the crankshaft in order to ensure that there is no binding.

15. Repeat Steps 2 through 14 in order to install the remaining pistons and connecting rods.

16. Refer to Testing and Adjusting, "Piston Height - Inspect" for the correct procedure on
checking the height of the piston above the cylinder block.

End By:

a. Install the piston cooling jets. Refer to Disassembly and Assembly, "Piston Cooling Jets -
Remove and Install".
b. Install the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump -
Install".
c. Install the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove
and Install".
d. Install the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Install".

Connecting Rod Bearings - Install

SMCS - 1219-012

Installation Procedure

Table 1

Required Tools

Tool Part Number Part Description Qty

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

1. Install the upper connecting rod bearing (4) in the connecting rod. The upper connecting
rod bearing must be centered in the connecting rod. Lubricate the bearing face with
clean engine oil.

2. Pull the connecting rod into position against the crankshaft.

Note: Do not allow the connecting rod to contact the piston cooling jet.

3. Clean the connecting rod cap (2) and the lower connecting rod bearing (3) . Lubricate
the bearing face with clean engine oil.

4. Install the lower connecting rod bearing (3) in the connecting rod cap (2) . The lower
connecting rod bearing must be centered in the connecting rod cap. Lubricate the
bearing face with clean engine oil.

Note: The connecting rod is a forging. The connecting rod has been hydraulically split in
order to separate the connecting rod cap and the connecting rod. This process provides
accurately matched surfaces. Do Not mix the connecting rod cap and the connecting rod.

Note: Ensure that the etched number on connecting rod bearing cap (2) matches the
etched number on the connecting rod (5) . Ensure that the numbers (Y) are on the same
side.
 5. Install the connecting rod cap (2) .

6. Install new setscrews (1) in the connecting rod.

Note: Do not reuse the old setscrews in order to secure the connecting rod cap.

7. Tighten the setscrews evenly to a torque of 18 N·m (13 lb ft).

8. Tighten the setscrews evenly to a torque of 70 N·m (52 lb ft).

9. Use the Tooling (A) to achieve the correct final torque.

Note: If the Tooling (A) is not used, place an index mark on each setscrew.

10. Turn the setscrews for an additional 120 degrees.

11. Rotate the crankshaft in order to ensure that there is no binding.

12. Repeat Steps 1 through 11 for the remaining connecting rod bearings.

End By:

a. Install the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump -
Install".
b. Install the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove
and Install".