3608 Engine Caterpillar

Illustration 1	g00287638
Right Side View

(1) Cylinder head studs

Install the cylinder head studs with the following procedure:

1. Coat the lower half of each stud with 1.5 mm (0.06 inch) thick coating of 4C-4774 Water and Temperature Resistant Grease.

2. Thoroughly clean the top of the cylinder block.

3. Install the cylinder head studs.

   Tighten the cylinder head studs to the following torque. ... 100 ± 20 N·m (75 ± 15 lb ft)

4. Apply a bead of sealant at the top of the block around each stud. This will ensure that the counterbore is filled with grease.

5. Coat the upper half of each stud with 1.5 mm (0.06 inch) thick coating of 4C-4774 Water and Temperature Resistant Grease.

(2) The dowels protrude from the front face of the cylinder block at the following distance. ... 8.0 ± 1.0 mm (0.32 ± 0.04 inch)

(3) The dowels protrude from the rear face of the cylinder block at the following distance. ... 20.0 ± 1.0 mm (0.79 ± 0.04 inch)

(4) The dowels protrude from the front face of the cylinder block at the following distance.

6V-3540 Dowel ... 55.0 ± 1.0 mm (2.17 ± 0.04 inch)

7N-2328 Dowel ... 20.0 ± 1.0 mm (0.79 ± 0.04 inch)

Illustration 2	g00287639
Front View Of Cylinder Block

(5) The dowels protrude above the cylinder block face at the following distance. ... 8.0 ± 1.0 mm (0.32 ± 0.04 inch)

(6) The dowels protrude above the cylinder block face at the following distance. ... 60.0 ± 1.0 mm (2.36 ± 0.04 inch)

Apply 4C-4774 Water and Temperature Resistant Grease to the dowel before the head is assembled.

(7) Bore in the block for main bearings ... 265.000 ± 0.020 mm (10.4330 ± 0.0008 inch)

1.00 mm (0.040 inch) oversize ... 266.000 ± 0.020 mm (10.4724 ± 0.0008 inch)

2.00 mm (0.080 inch) oversize ... 267.000 ± 0.020 mm (10.5118 ± 0.0008 inch)

(8) The centerline of the crankshaft bearing bore to the top surface of the cylinder block ... 946.00 mm (37.244 inch)

(9) Procedure for tightening the main bearings

1. Torque the studs in the cylinder block again.

   Torque for the studs ... 100 ± 20 N·m (75 ± 15 lb ft)

2. Assemble the main bearing cap and the washer. Hand tighten the nut.

3. Assemble the side bolts on the side of the cap with the tab slot. Tighten the side bolts by hand. Lubricate the washer face and the threads with engine oil before assembly.

4. Start at the front face of the block.

   Tighten the side bolts on the side of the cap with the tab slot to the following torque. ... 215 ± 40 N·m (160 ± 30 lb ft)

5. Start at the front face of the block. Use the 4C-5850 Stud Tensioner Tool Group in order to apply tension on the studs.

   Apply tension on each pair of studs at the same time to the following pressure. ... 65000 ± 2400 kPa (9400 ± 350 psi)

6. Repeat Step 5.

7. Tighten the side bolts on the side of the cap opposite the tab slot hand tight. Lubricate the washer face and the threads with engine oil before assembly.

8. Start at the front face of the block.

   Tighten the side bolts on the side of the cap opposite the tab slot to the following torque. ... 215 ± 40 N·m (160 ± 30 lb ft)

9. Start at the front face of the block.

   Tighten the side bolts on the side of the cap with the tab slot to the following torque. ... 1825 ± 175 N·m (1340 ± 130 lb ft)

10. Start at the front face of the block.

    Tighten the side bolts on the side of the cap opposite the tab slot to the following torque. ... 1825 ± 175 N·m (1340 ± 130 lb ft)

(11) Width of main bearing cap ... 499.95 ± 0.03 mm (19.683 ± 0.001 inch)

Width of cylinder block for main bearing cap ... 500.00 ± 0.05 mm (19.685 ± 0.002 inch)

Clearance between the sides of the main bearing cap and the cylinder block ... 0.03 to 0.13 mm (0.001 to 0.005 inch)

Illustration 3	g00287640
Main Bearing Cap

(12) The dowel protrudes from the main bearing cap at the following distance. ... 10.0 ± 0.5 mm (0.39 ± 0.02 inch)

(13) Main bearing cap