D349 INDUSTRIAL & MARINE ENGINES Caterpillar

preparatory steps:

a) remove left front camshaft housing

b) remove fuel injection lines (left side only)

c) remove left water cooled exhaust manifold (Marine engines only)

d) remove oil filter housing

e) remove expansion tank (Marine engines only)

1. Remove oil line (2) and disconnect oil line (3) from oil temperature sensing unit.

2. Disconnect right aftercooler water elbow (1) from the aftercooler housing.

3. Remove expansion tank bottom support braces on Marine engines only.

4. Remove water bypass line (4). Disconnect water lines (6) and (7) from water temperature regulator housing. Attach hoist to regulator housing assembly and remove housing retaining bolts (5). Remove regulator housing assembly-weight 140 lbs. (64 kg).

5. Remove the two camshaft housing retaining studs (8) and dowel (9).

6. Remove exhaust manifold adapter bolts (11) on Industrial engines only.

7. Loosen water ferrule clamp (10) and remove ferrule assembly.

8. Remove cylinder head retaining bolts and washers. Install three 3/8" - 16NC forged eyebolts in head assembly. Attach a hoist and remove the cylinder head assembly- weight 300 lbs. (136 kg).

NOTE: Always replace the gasket between spacer plate and cylinder block before reinstalling cylinder head assembly. See REMOVE SPACER PLATES.

Install Left Front Cylinder Head Assembly

1. Clean the top surface of spacer plate and mating surface of cylinder head. Install new head gasket and seals (1).

NOTE: Be sure the gasket between spacer plate and cylinder block has been replaced before installing cylinder head assembly. Refer to REMOVE AND INSTALL SPACER PLATES.

2. Attach a hoist and position the cylinder head assembly on engine. Put 9S3264 Sealant Compound on the threads of the camshaft housing retaining studs (2). Install the camshaft housing retaining studs (2) and the dowel. Tighten the studs to 20 ± 3 lb.ft. (2.77 ± .42 mkg).

3. Coat the threads of the cylinder head bolts and exhaust manifold adapter retaining bolts with 9M3710 Anti-Seize Compound. Install the cylinder head bolts and washers. Tighten the bolts in following Step sequence:

1 Tighten all bolts in numerical order to 175 lb. ft. (24,2 mkg).

2 Retighten all bolts in numerical order to 250 lb. ft. (34,6 mkg).

3 Finally, retighten all bolts by hand in numerical order to 250 lb. ft. (34,6 mkg).

4 Again tighten bolt (9) between the two heads to 250 ± 10 lb.ft. (34.6 ± 1.38 mkg).

4. Install a new gasket, and install exhaust manifold adapter retaining bolts on Industrial engines only. Install the water ferrule assembly (3). Tighten the bolt in the clamp for the water ferrule and seal to 30 ± 5 lb.in. (34.56 ± 5.76 cm.kg).

5. Attach a hoist to water temperature regulator housing assembly. Position housing (4) on engine and install retaining bolts. Connect lower housing water lines. Connect right aftercooler water elbow to aftercooler housing. Install water bypass line. Install and connect oil lines to oil temperature sensing unit.

6. Install expansion tank bottom support braces on Marine engines only.

concluding steps:

a) install left front camshaft housing

b) install oil filter housing

c) install left water cooled exhaust manifold (Marine engines only)

d) install fuel injection lines (left side only)

e) install expansion tank (Marine engines only)

Remove Left Rear Cylinder Head Assembly

preparatory steps:

a) remove left rear camshaft housing

b) remove fuel injection lines (left side only)

c) remove turbochargers

d) remove left water cooled exhaust manifold (Marine engines only)

1. Remove exhaust manifold coupling-to-elbow mounting bolts (2). Remove elbow-to-cylinder head mounting bolts (1). Remove elbow assembly.

2. Remove aftercooler rear water line (4). Remove the support assembly-to-left cylinder head mounting bolts (3). Loosen the support assembly-to-right cylinder head mounting bolts.

3. Remove the governor-to-cylinder head rear support bracket (5).

4. Loosen water ferrule clamp (6) and remove water ferrule assembly. Remove the three exhaust manifold adapter bolts (7), on Industrial engines only. Remove the cylinder head retaining bolts.

5. Install three 3/8" - 16NC forged eyebolts in head assembly. Attach a hoist and remove the cylinder head assembly-weight 300 lbs. (136 kg).

NOTE: Always replace the gasket between spacer plate and cylinder block before reinstalling cylinder head assembly. See REMOVE SPACER PLATES.

Install Left Rear Cylinder Head Assembly

1. Clean the top surface of spacer plate and mating surface of cylinder head. Install a new head gasket and seals (1).

NOTE: Be sure the gasket between spacer plate and cylinder block has been replaced before installing cylinder head assembly. Refer to REMOVE AND INSTALL SPACER PLATES.

2. Attach a hoist and position the cylinder head assembly on engine.

3. Coat the threads of the cylinder head bolts and the exhaust manifold adapter retaining bolts with 9M3710 Anti-Seize Compound. Install the cylinder head bolts and washers. Tighten the bolts in following Step sequence:

1 Tighten all bolts in numerical order to 175 lb. ft. (24,2 mkg).

2 Retighten all bolts in numerical order to 250 lb. ft. (34,6 mkg).

3 Finally retighten all bolts by hand in numerical order to 250 lb. ft. (34,6 mkg).

4 Again tighten bolt (9) between the two heads to 250 ± 10 lb.ft. (34.6 ± 1.38 mkg).

4. Install a new gasket, and install the exhaust manifold adapter retaining bolts on Industrial engines only.

5. Install the water ferrule and seal assembly (2). Tighten the bolt in the clamp for the water ferrule and seal to 30 ± 5 lb.in. (34.56 ± 5.76 cm.kg). Install the governor-to-cylinder head rear support bracket.

6. Install the aftercooler rear water line (3). Install support-to-left cylinder head retaining bolts. Tighten support-to-right cylinder head retaining bolts.

7. Coat the threads of the exhaust elbow coupling bolts with 9M3710 Anti-Seize Compound. Install elbow assembly (4).

concluding steps:

a) install left rear camshaft housing

b) install turbochargers

c) install fuel injection lines (left side only)

d) install left water cooled exhaust manifold (Marine engines only)