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Caterpillar C16 7CZ Diesel Engine Complete Service Manual

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Covers: Caterpillar C16 Diesel Engine with serial prefix-

  • 7CZ 001 and up

Pages: 1,751
Format: PDF files (zipped)
File size: 59mb
Compatibility: Windows/Mac computers
Notes: Instant download only.

This 7-volume service manual set contains complete specifications, systems operation information, disassembly and assembly procedures, testing and adjusting instructions and troubleshooting steps for the Caterpillar C16 7CZ diesel engine. Additionally, the Cat C16 7CZ engine wiring diagrams are included in high resolution PDF format. This is a complete OEM reference for professional mechanics to service and repair the engine. View the manuals on your computer or print off pages as needed.

Please contact us with your engine serial number if you have compatibility questions.

Topics in the Caterpillar C16 7CZ Diesel Engine Complete Service Manual:

Engine Specifications

Engine Systems Operation

  • General Information
  • Electronic Control System Components
  • Fuel System
  • Air Inlet and Exhaust System
  • Lubrication System
  • Cooling System
  • Basic Engine
  • BrakeSaver
  • Compression Brake
  • Electrical System

Disassembly and Assembly

  • Fuel Priming Pump – Remove and Install
  • Fuel Filter Base – Remove
  • Fuel Filter Base – Disassemble
  • Fuel Filter Base – Assemble
  • Fuel Filter Base – Install
  • Fuel Transfer Pump – Remove
  • Fuel Transfer Pump – Install
  • Electronic Unit Injector – Remove
  • Electronic Unit Injector – Install
  • Electronic Unit Injector Sleeve – Remove
  • Electronic Unit Injector Sleeve – Install
  • Turbocharger – Remove
  • Turbocharger – Disassemble
  • Turbocharger – Assemble
  • Turbocharger – Install
  • Exhaust Manifold – Remove and Install
  • Inlet and Exhaust Valve Springs – Remove and Install
  • Inlet and Exhaust Valves – Remove and Install
  • Inlet and Exhaust Valve Guides – Remove and Install
  • Inlet and Exhaust Valve Seat Inserts – Remove and Install
  • Inlet and Exhaust Valve Seals – Remove and Install
  • Engine Oil Filter Base – Remove
  • Engine Oil Filter Base – Disassemble
  • Engine Oil Filter Base – Assemble
  • Engine Oil Filter Base – Install
  • Engine Oil Cooler – Remove
  • Engine Oil Cooler – Disassemble
  • Engine Oil Cooler – Assemble
  • Engine Oil Cooler – Install
  • Engine Oil Pump – Remove
  • Engine Oil Pump – Disassemble
  • Engine Oil Pump – Assemble
  • Engine Oil Pump – Install
  • Water Pump – Remove
    Water Pump – Disassemble
  • Water Pump – Assemble
  • Water Pump – Install
  • Water Temperature Regulator – Remove and Install
  • Engine Support (Front) – Remove and Install
  • Flywheel – Remove
  • Flywheel – Install
  • Crankshaft Rear Seal – Remove
  • Crankshaft Rear Seal – Install
  • Flywheel Housing – Remove and Install
  • Vibration Damper and Pulley – Remove and Install
  • Crankshaft Front Seal – Remove
  • Removal Procedure
  • Crankshaft Front Seal – Install
  • Front Cover – Remove
  • Front Cover – Install
  • Gear Group (Front) – Remove
  • Gear Group (Front) – Install
  • Housing (Front) – Remove
  • Housing (Front) – Install
  • Accessory Drive – Remove
  • Accessory Drive – Disassemble
  • Accessory Drive – Assemble
  • Accessory Drive – Install
  • Valve Mechanism Cover – Remove and Install
  • Valve Mechanism Cover Base – Remove and Install
  • Compression Brake – Remove – If Equipped
  • Compression Brake – Disassemble – If Equipped
  • Compression Brake – Assemble – If Equipped
  • ◦ Assembly Procedure
  • Compression Brake – Install – If Equipped
  • Rocker Arm and Shaft – Remove
  • Rocker Arm – Disassemble
  • Rocker Arm – Assemble
  • Rocker Arm and Shaft – Install
  • Cylinder Head – Remove
  • Cylinder Head – Install
  • Camshaft – Remove
  • Camshaft – Install
  • Camshaft Gear – Remove and Install
  • Camshaft Bearings – Remove
  • Camshaft Bearings – Install
  • Engine Oil Pan – Remove and Install
  • Cylinder Liner – Remove
  • Cylinder Liner – Install
  • Piston Cooling Jets – Remove and Install
  • Pistons and Connecting Rods – Remove
  • Pistons and Connecting Rods – Disassemble
  • Pistons and Connecting Rods – Assemble
  • Pistons and Connecting Rods – Install
  • Connecting Rod Bearings – Remove
  • Connecting Rod Bearings – Install
  • Crankshaft Main Bearings – Remove
  • Crankshaft Main Bearings – Install
  • Crankshaft – Remove
  • Crankshaft – Install
  • Bearing Clearance – Check
  • BrakeSaver – Remove
  • BrakeSaver – Disassemble
  • BrakeSaver – Assemble
  • BrakeSaver – Install
  • BrakeSaver Engine Oil Pan – Remove and Install
  • BrakeSaver Engine Oil Pump – Remove
  • BrakeSaver Engine Oil Pump – Disassemble
  • BrakeSaver Engine Oil Pump – Assemble
  • BrakeSaver Engine Oil Pump – Install
  • BrakeSaver Control Valve – Remove
  • BrakeSaver Control Valve – Disassemble
  • BrakeSaver Control Valve – Assemble
  • BrakeSaver Control Valve – Install
  • Atmospheric Pressure Sensor – Remove and Install
  • Camshaft Position Sensor – Remove and Install
  • Crankshaft Position Sensor – Remove and Install
  • Coolant Temperature Sensor – Remove and Install
  • Engine Oil Pressure Sensor – Remove and Install
  • Fuel Temperature Sensor – Remove and Install
  • Boost Pressure Sensor – Remove and Install
  • Inlet Air Temperature Sensor – Remove and Install
  • Belt Tensioner – Remove and Install
  • Fan Drive – Remove
  • Fan Drive – Disassemble
  • Fan Drive – Assemble
  • Fan Drive – Install
  • Engine Control Module – Remove and Install
  • Electric Starting Motor – Remove and Install
  • Air Compressor – Remove and Install
  • Air Compressor Drive Gear – Remove
  • Air Compressor Drive Gear – Install – Two Cylinder
  • Air Compressor Drive Gear – Install

Testing and Adjusting

  • Fuel System – Inspect
  • Air in Fuel – Test
  • Electronic Unit Injector – Adjust
  • Electronic Unit Injector – Test
  • Finding Top Center Position for No. 1 Piston
  • Fuel Quality – Test
  • Fuel System – Prime
  • Fuel System Pressure – Test
  • Gear Group (Front) – Time
  • Air Inlet and Exhaust System – Inspect
  • Turbocharger – Inspect
  • Inlet Manifold Pressure – Test
  • Exhaust Temperature – Test
  • Aftercooler – Test
  • Inlet Manifold Pressure
  • Engine Crankcase Pressure (Blowby) – Test
  • Compression – Test
  • Engine Valve Lash – Inspect/Adjust
  • Engine Oil Pressure – Test
  • Excessive Bearing Wear – Inspect
  • Excessive Engine Oil Consumption – Inspect
  • Increased Engine Oil Temperature – Inspect
  • Cooling System – Check – Overheating
  • Cooling System – Inspect
  • Cooling System – Test
  • Water Temperature Regulator – Test
  • Water Pump – Test
  • Piston Ring Groove – Inspect
  • Connecting Rod Bearings – Inspect
  • Main Bearings – Inspect
  • Cylinder Block – Inspect
  • Cylinder Liner Projection – Inspect
  • Flywheel – Inspect
  • Flywheel Housing – Inspect
  • Vibration Damper – Check
  • Jake Brake Compression Brake Adjustment
  • Pacbrake Compression Brake Adjustment
  • Control Valve (Compression Brake) – Test
  • Solenoid Valve (Compression Brake) – Test
  • Battery – Test
  • Charging System – Test
  • Electric Starting System – Test
  • Pinion Clearance – Adjust

Troubleshooting

  • Electronic Service Tools
  • Replacing the ECM
  • Sensors and Electrical Connectors
  • Engine Wiring Harness Diagram
  • Vehicle Wiring Harness Diagram
  • Programming Parameters
  • Test ECM Mode
  • Customer Passwords
  • ECM Date-Time Stamped Information
  • ECM Snapshot
  • Factory Passwords
  • Factory Passwords Worksheet
  • Flash Programming
  • Service Information Report
  • Customer Specified Parameters
  • Customer Specified Parameters Table
  • Customer Specified Parameters Worksheet
  • System Configuration Parameters
  • Can Not Reach Top Engine RPM
  • Can Not Reach Vehicle Speed Limit
  • Check Engine Lamp or Warning Lamp Is Malfunctioning
  • Cooling Fan Is Always ON
  • Cruise Control, Idle, or PTO Can Not Be Set
  • Driver Questionnaire
  • Driver Questionnaire Response
  • ECM Will Not Accept Factory Passwords
  • Electronic Service Tool Will Not Communicate with ECM
  • Engine Cranks but Will Not Start
  • Engine Misfires, Runs Rough or Is Unstable
  • Engine Retarder (Compression Brake) Will Not Turn ON
  • Engine Vibration
  • Engine Will Not Crank
  • Excessive Black Smoke
  • Excessive Fuel Consumption
  • Excessive White Smoke
  • Intermittent Cruise Control, Idle, or PTO Kickout
  • Intermittent Engine Shutdown
  • Intermittent Low Power or Power Cutout
  • Low Power – Poor or No Response to Throttle
  • Poor Acceleration or Response
  • Diagnostic Codes
  • No Diagnostic Code Detected -55
  • 5 Volt Engine Pressure Sensor Supply Circuit – Test
  • Accelerator Pedal (Throttle) Position Sensor Circuit – Test
  • Air Inlet Shutoff Circuit – Test
  • ATA (SAE J1587 J1708) Data Link Circuit – Test
  • Auxiliary Brake Circuit – Test
  • Check Engine Lamp Circuit – Test
  • Clutch Pedal Position Switch Circuit – Test
  • Coolant Level Sensor Circuit – Test
  • Cooling Fan Circuit and AC High Pressure Switch Circuit
  • Cruise Control Switch Circuit – Test
  • Diagnostic Enable Switch Circuit – Test
  • Eaton Top 2 Transmission Circuit – Test
  • ECM Memory – Test
  • Electrical Connectors – Inspect
  • Engine Pressure Sensor Open or Short Circuit – Test
  • Engine Running Output Circuit – Test
  • Engine Shutdown Output Circuit – Test
  • Engine Speed Timing Sensor Circuit – Test
  • Engine Temperature Sensor Open or Short Circuit – Test
  • Fan Override Switch Circuit – Test
  • Idle Shutdown Timer – Test
  • Ignition Keyswitch Circuit and Battery Supply Circuit – Test
  • Ignore Brake Clutch Switch Circuit – Test
  • Ignore Brake Clutch Switch Circuit – Test
  • Multi-Torque – Test
  • Neutral Switch Circuit – Test
  • Powertrain Data Link Circuit – Test
  • PTO Engine RPM Set Speed (Input A and Input
  • PTO Shutdown Timer – Test
  • PTO Switch Circuit – Test
  • PTO Switch ON Lamp Circuit – Test
  • Remote PTO Accelerator Position Sensor Circuit – Test
  • Retarder (Compression Brake) Solenoid Circuit – Test
  • Service Brake Pedal Position (Switch 1) Circuit – Test
  • Service Brake Pedal Position (Switch 2) Circuit – Test
  • Starting Aid Output Circuit – Test
  • Starting Aid Switch Circuit – Test
  • Tachometer Circuit – Test
  • Torque Limit Switch Circuit – Test
  • Two Speed Axle Switch Circuit – Test
  • Vehicle Speed and Speedometer Circuit – Test
  • Warning Lamp Circuit – Test
  • Engine Speed Timing Sensor – Calibrate
  • Injector Code – Calibrate
  • Vehicle Speed Circuit – Calibrate
  • Code-based Troubleshooting
  • 0001-11 Cylinder #1 Injector current fault (72)
  • 0002-11 Cylinder #2 Injector current fault (72)
  • 0003-11 Cylinder #3 Injector current fault (73)
  • 0004-11 Cylinder #4 Injector current fault (73)
  • 0005-11 Cylinder #5 Injector current fault (74)
  • 0006-11 Cylinder #6 Injector current fault (74)
  • 0022-11 Primary to Secondary Engine Speed Signal Calibration (42)
  • 0022-13 Engine Speed Signal Calibration Not Performed (42)
  • 0030-08 PTO Throttle signal invalid (29)
  • 0030-13 PTO Throttle out of calibration (29)
  • 0041-03 8 Volt Supply voltage high (21)
  • 0041-04 8 Volt Supply voltage low (21)
  • 0043-02 Key Switch Fault (71)
  • 0052-11 Air Inlet Shutoff Shutdown (00)
  • 0054-05 Auxiliary Output #06 current low (66)
  • 0054-06 Auxiliary Output #06 current high (66)
  • 0055-05 Auxiliary Output #07 current low (67)
  • 0055-06 Auxiliary Output #07 current high (67)
  • 0064-12 Secondary Engine Speed loss of signal (34)
  • 0071-00 Idle Shutdown Override (01)
  • 0071-01 Idle Shutdown (47)
  • 0071-14 PTO Shutdown (47)
  • 0084-00 Vehicle Overspeed Warning (41)
  • 0084-01 Vehicle Speed loss of signal (31)
  • 0084-02 Vehicle Speed signal invalid (36)
  • 0084-08 Vehicle Speed signal out of range (36)
  • 0084-10 Vehicle Speed signal rate of change (36)
  • 0084-14 Quick Stop Occurrence
  • 0091-08 Throttle Position Invalid (32)
  • 0091-13 Throttle Position out of calibration (28)
  • 0100-01 Low Oil Pressure Warning (46)
  • 0100-03 Oil Pressure voltage high (24)
  • 0100-04 Oil Pressure voltage low (24)
  • 0100-11 Very Low Oil Pressure (46)
  • 0102-00 Excessive Boost Pressure
  • 0102-03 Boost Pressure voltage high (25)
  • 0102-04 Boost Pressure voltage low (25)
  • 0105-00 High Intake Manifold Air Temperature Warning (64)
  • 0105-03 Intake Manifold Air Temperature voltage high (38)
  • 0105-04 Intake Manifold Air Temperature voltage low (38)
  • 0105-11 Very High Intake Manifold Air Temperature (64)
  • 0108-03 Barometric Pressure voltage high (26)
  • 0108-04 Barometric Pressure voltage low (26)
  • 0110-00 High Coolant Temperature Warning (61) (1)
  • 0110-00 High Coolant Temperature Warning (61)
  • 0110-04 Coolant Temperature voltage low (27) (1)
  • 0110-04 Coolant Temperature voltage low (27) (2)
  • 0110-04 Coolant Temperature voltage low (27)
  • 0111-02 Coolant Level signal invalid (12)
  • 0111-03 Coolant Level voltage high (12) (1)
  • 0111-03 Coolant Level voltage high (12)
  • 0111-11 Very Low Coolant Level (62)
  • 0121-05 Low High Retarder current low (14) (1)
  • 0121-05 Low High Retarder current low (14)
  • 0122-05 Med High Retarder current low (14)
  • 0122-06 Med High Retarder current high (14)
  • 0168-01 Low ECM Battery Power (17)
  • 0168-02 ECM Battery Power Intermittent (51) (1)
  • 0168-02 ECM Battery Power Intermittent (51) (2)
  • 0168-02 ECM Battery Power Intermittent (51) (3)
  • 0168-02 ECM Battery Power Intermittent (51)
  • 0174-00 High Fuel Temperature Warning (65)
  • 0174-03 Fuel Temperature voltage high (13)
  • 0174-04 Fuel Temperature voltage low (13)
  • 0190-00 Engine Overspeed Warning (35)
  • 0190-12 Primary Engine Speed loss of signal (34)
  • 0191-07 Transmission Not Responding (68)
  • 0224-11 Theft Deterrent Active (00)
  • 0224-14 Theft Deterrent Active with Engine Cranking (00)
  • 0231-02 J1939 Data Incorrect (58)
  • 0231-11 J1939 Data Link Fault (58)
  • 0231-12 J1939 Device Not Responding
  • 0232-03 5 Volt Supply voltage high (21)
  • 0232-04 5 Volt Supply voltage low (21)
  • 0246-11 Brake Pedal Switch #1 Fault
  • 0247-11 Brake Pedal Switch #2 Fault
  • 0249-11 J1922 Data Link Fault (58)
  • 0252-11 Engine Software Incorrect (59)
  • 0253-02 Check Customer or System Parameters (56)
  • 0253-11 Check Transmission Customer Parameters (56)

Wiring Schematics (Foldout and Collage sizes)

On-Highway Engines Electronic PTO Installation and Application Guide

General Torque Specifications for All Caterpillar Products

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Bore … 140.0 mm (5.5 inch)
Stroke … 171.0 mm (6.7 inch)
Displacement … 15.8 L (964 cu in)
Cylinder arrangement … In-Line six cylinder
Valves per cylinder … 4
The adjustment for the inlet valve lash is the following value. … 0.38 mm (0.015 inch)
The adjustment for the exhaust valve lash is the following value. … 0.76 mm (0.030 inch)
Firing order (Injection Sequence) … 1, 5, 3, 6, 2, 4
Crankshaft rotation is viewed from the flywheel. Crankshaft rotation … counterclockwise
Note: The front end of the engine is opposite the flywheel end. The left side and the right side of the
engine are viewed from the flywheel end. The No. 1 cylinder is the front cylinder.

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