3508C, 3512C and 3516C Marine Engines Pistons and Connecting Rods - Install Caterpillar


Pistons and Connecting Rods - Install
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1.1. Installation Procedure

Installation Procedure

Table 1
Required Tools 
Tool  Part Number  Part Description  Qty 
448-5087  Barring Tool (1) 
1P-1861  Retaining Ring Pliers 
271-0498  Expander Ring 
485-8003  Tool As 
Bel-Ray Molylube 67700(2) 
(1) The 9S-9082 Engine Turning Tool is alternative tooling.
(2) Refer to the following link to order molylube specified above - www.belray.com.


NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.


Note: Install the connecting rod bearings dry when clearance checks are performed. Refer to Disassembly and Assembly, "Bearing Clearance - Check". Apply clean engine oil on the connecting rod bearings for final assembly.



    Illustration 1g01004841

  1. Use Tooling (C) to install the piston rings onto the piston.

    1. For the oil control ring, ensure that the ends of the spring are 180 degrees from the ring gap. The white portion of the spring must be visible at the ring gap.

    2. Install the intermediate ring with the side marked "UP-2" toward the top of the piston.

    3. Install the top ring with the side marked "UP-1" toward the top of the piston.

    4. After the rings are installed, rotate the rings so that the gaps are spread apart by 120 degrees. Orient the oil control ring gap toward the bore for the piston pin.


    Illustration 2g01006026

  2. Place the piston crown into the piston skirt. Use clean engine oil to coat the bore of piston (3), piston pin (4), and the piston pin bearing in connecting rod (5). Position connecting rod (5) inside piston (3). Insert piston pin (4) through piston (3) and the bearing.


    Illustration 3g02142776

  3. Use Tooling (B) to install the retaining rings. Orient the retaining ring gaps toward the top of piston (3).

  4. Apply clean engine oil to the cylinder liner bore, to the piston rings, and to the outer surface of the piston.

    Note: Ensure that the connecting rod and pistons are installed in the correct cylinder.



    Illustration 4g02142782

  5. Use Tooling (A) to rotate the crankshaft until the connecting rod journal is at the bottom center.

  6. Use Tooling (D) to install the piston in the cylinder liner.

    Note: Be careful not to damage the cylinder liner or the crankshaft journal during the installation of the piston and the connecting rod.



    Illustration 5g00913801


    Illustration 6g06117839
    Section view of connecting rod showing torque sequence. Chamfer (7) and dowel (8) can be used to reference orientation.

  7. Install the upper half of the connecting rod bearing on the connecting rod. Ensure that the connecting rod bearing is installed so that the bearing tab fits into the notch in the connecting rod. Coat the connecting rod bearing with clean engine oil. Position the connecting rod onto a journal of the crankshaft.

  8. Install the lower half of the connecting rod bearing on connecting rod cap (2). Ensure that the connecting rod bearing is installed so that the bearing tab fits into the notch in the connecting rod cap. Coat the connecting rod bearing with clean engine oil.

    Note: The number that is on the side of the connecting rod caps must be installed next to the corresponding number that is on the side of the connecting rod. Install the chamfered side of the connecting rod cap next to the thrust surface of the crankshaft.

    Note: Reman connecting rods are not numbered for the cylinder position.

  9. Apply Tooling (E) to the threads, the shank, and the seat of bolts (1).

  10. Place connecting rod cap (2) into position. Install bolts (1). Use the following procedure to tighten the bolts:

    1. Tighten Bolt (X2) and Bolt (X4) to a torque of 90 ± 5 N·m (65 ± 4 lb ft).

    2. Tighten Bolt (X1) and Bolt (X3) to a torque of 90 ± 5 N·m (65 ± 4 lb ft).

    3. Tighten Bolt (X1) and Bolt (X3) again to a torque of 90 ± 5 N·m (65 ± 4 lb ft).

    4. Place an index mark on the bolts and the connecting rod cap. Tighten each bolt for an extra 90 ± 5 degrees (1/4 turn).

  11. Rotate the crankshaft to ensure that the crankshaft turns freely.

End By:

a. Install the piston cooling jets.

b. Install the cylinder head.

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