C3.3B Tier 4 Interim and EU Stage 3A Engines for Caterpillar Built Machines – Cylinder Head – Remove and Install – C3.3B

Removal Procedure

Start By:

1. Remove the rocker arm shaft and pushrods.
2. Remove the fuel injector nozzles.

Note: Refer to Specification UENR0995 "Engine Design" for non-specified engine Torque Values.

1. Drain the coolant from the cooling system into a suitable container for storage or for disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct draining procedure.

Illustration 1	g02796315

2. Disconnect tube assembly (1) and hose assemblies (2) and (3) .

Illustration 2	g02799171

3. Remove tube assemblies (4) and (5) .

Illustration 3	g02971560

4. Remove bolts in order from (6) through (15) .

5. Attach a suitable lifting device to cylinder head (16) . The weight of cylinder head (16) is approximately 46 kg (100 lb).

6. Use the suitable lifting device to lift cylinder head (16) off the cylinder block.

NOTICE
Place the cylinder head on a surface that will not scratch the face of the cylinder head.




Illustration 4	g02972039

7. Remove cylinder head gasket (17) from the cylinder block.

8. Notice the location of the cylinder head gasket notches in area (A) . Refer to illustration 4 and illustrations 5.

9. Note the position of the dowels in the cylinder block.

Illustration 5	g02796320

10. Notice the number of notches in area (A) .

    Table 1

    Head Gasket Notch	Head Gasket Thickness		Piston head protrusion or recessing from crankcase cylinder face
    	Before Tighten	After Tighten
    (a)-two notches	0.900 mm (0.035 inch)	0.800 mm (0.032 inch)	0.0775 to 0.150 mm (0.0031 to 0.0059 in.)
    (b)-one notch	1.00 mm (0.039 inch)	0.900 mm (0.035 inch)	0.150 to 0.250 mm (0.0059 to 0.0098 in.)
    (c)-without notch	1.10 mm (0.043 inch)	1.00 mm (0.039 inch)	0.250 to 0.343 mm (0.0098 to 0.0135 in.)

Installation Procedure

Illustration 6	g02796320

1. Notice the number of notches in area (A) . Refer to illustrations 6 and 7.

2. Thoroughly clean the gasket surfaces of the cylinder head and the cylinder block. Do not damage the gasket surfaces of the cylinder head of the cylinder block. Ensure that no debris enters the cylinder bores, the coolant passages, or the lubricant passages.

3. Inspect the dowels for damage. If necessary, replace the dowels in the cylinder block.

Illustration 7	g02972123

4. Inspect the gasket surface of the cylinder head for distortion. Refer to Specifications, "Cylinder Head" for more information. If the gasket surface of the cylinder head is distorted beyond maximum permitted limits, replace the cylinder head

5. Notice the location of the cylinder head gasket notches in area (A) and refer to table 2. Align new cylinder head gasket (17) with the dowels.

Illustration 8	g02972136

6. Use a suitable lifting device to lift cylinder head (16) . The weight of the cylinder head (16) is approximately 46 kg (100 lb).

7. Align cylinder head (16) with the cylinder block. Install cylinder head (16) to the cylinder block.

   Note: Ensure that the cylinder head is correctly positioned on the dowels.

8. Clean and inspect bolts (6) through (16) .

9. Lubricate the threads and the shoulder of bolts with engine oil.

10. Install bolts in order from (6) through (15) to cylinder head (16) .

11. Tighten bolts (6) through (15) to a torque of 187 to 196 N·m (138 to 144 lb ft) in the numerical sequence. Refer to Illustration 8. Repeat the torque procedure in the same sequence.

Illustration 9	g02799171

12. Install tube assemblies (5) and (4) . Tighten bolts for tube (4) to a torque of 16.0 to 19.0 N·m (11.80 to 14.01 lb ft).

Illustration 10	g02796315

13. Connect hose assemblies (3) and (2) . Connect tube assembly (1) .

14. Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct filling procedure.

End By:

1. Install the fuel injector nozzles.
2. Install the rocker arm shaft and pushrods.