3618 Engine Caterpillar

Removal Procedure

Start By:

1. Remove the water manifold segments for the cylinder heads that will be serviced. Refer to Disassembly and Assembly, "Water Lines - Remove and Install".
2. Disconnect the bellows from the exhaust manifold segments for the cylinder heads that will be serviced. Refer to Disassembly and Assembly, "Exhaust Manifold - Remove and Install".
3. Remove the engine lifting bracket, if necessary. Refer to Disassembly and Assembly, "Engine Lifting Bracket - Remove and Install".
4. Remove the rocker shaft and pushrods for the cylinder heads that will be serviced. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod - Remove".

1. Drain the coolant from the cooling system to a level that is below the cylinder heads into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change".

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Illustration 1	g01213013

2. Disconnect rod (1) from lever (2) .

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Illustration 2	g00651054

3. Remove tube assembly (3) .

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Illustration 3	g00651069

4. Remove bolts (4) and the washers. Push tube (5) and flange (6) toward the lower housing of the aftercooler. Allow sufficient clearance between flange (6) and the cylinder head for removal of the cylinder head.

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NOTICE
Use the proper procedure in order to apply tension to the cylinder head studs. Failure to follow the correct procedure will result in damage to the cylinder head assembly and the cylinder block assembly.

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Illustration 4	g00651076

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Personal injury or death can result from escaping fluid under pressure. Escaping fluid under pressure, even a very small pin-hole size leak, can penetrate body tissue and cause serious injury and possible death. If fluid is injected into your skin, it must be treated by a doctor familiar with this type of injury. Always use a board or cardboard when checking for a leak.

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Because of high pressure, a tight bending radius or a kink in a hose could cause the hose to break and result in personal injury. Do not allow the hoses to bend in a radius that is less than 250 mm (10 inch). Before you use a hose, always inspect the hose. Never use a hose that is damaged, defective, or kinked.

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A hydraulic cylinder and/or a hose that is not secure can be released when hydraulic pressure is applied. This can cause severe personal injury. When you are applying hydraulic pressure, always stay a distance of 3 to 5 m (10 to 16 ft) away from the cylinders and the hoses. When pressure is applied to the cylinders, always keep body parts away from the direction of the force. Always wear safety glasses when you work with hydraulic equipment. Use the minimum amount of pressure that is necessary. Always release the pressure when the equipment is not supervised. Never modify the equipment without written permission from the manufacturer.

5. Apply Tooling (F) to the threads of the cylinder head studs. Install the cylinder supports of Tooling (A) onto the cylinder head studs. Rotate each support in order to engage the drive ring of the support with the flats of the nut. When the support is properly installed, the support will rest flat on the washer.

Note: Before you thread the cylinders onto the cylinder head studs, make sure that sufficient threads are exposed on the cylinder head studs. To calculate the minimum length of the threads, multiply the diameter of the cylinder head stud by 0.8.

6. Make sure that the bushing of the 1/2 inch square drive on top of each hydraulic cylinder is flush with the top of the cylinder. Position the four cylinders of Tooling (A) in alignment with the threads of the cylinder head studs. Use the 1/2 inch square drive on the cylinders in order to fully thread the cylinders onto the cylinder head studs. After the cylinders have been fully tightened, reverse the threads for one and one-half turns (540 degrees).

   Do not reverse the threads excessively. The hydraulic cylinders will not operate properly if the distance is more than the maximum stroke.

7. Verify the gauge on the hydraulic pump with Tooling (C) . If the readings of the two gauges vary by more than one percent of the maximum gauge pressure, do not use the pump.

   For example, two gauges have a maximum pressure of 160 MPa (23206 psi). The pressure of the gauges must be within 1.6 MPa (232 psi).

   Make sure that the gauge on the pump is correct. Position the pump so that the pressure gauge and the hydraulic cylinders can be observed.

8. Connect the hoses of Tooling (A) to the hydraulic pump and to the hydraulic cylinders.

9. Operate the pump to a pressure of 125 ± 2.5 MPa (18130 ± 365 psi). Make sure that the pressure is maintained. This will stretch the cylinder head stud in order to move the nut away from the cylinder head.

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Illustration 5	g00651159

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Personal injury can result from removing hoses and/or disconnecting couplings in a pressurized system. Failure to relieve the pressure can cause personal injury. Do not remove the hoses or disconnect the couplings until the pressure has been relieved.

10. Use the square drive on the cylinder support of Tooling (A) to loosen the nuts until the nuts contact the cylinders. Do not apply more than 100 N·m (75 lb ft) of torque to the cylinders. Look in the windows of Tooling (A) in order to make sure that the nuts are separated from the washers. If the nut does not separate from the washer, tap the washer.

    If the nuts will not loosen, Repeat Step 9 and apply an additional 5 MPa (725 psi) of hydraulic pressure.

11. Slowly release the hydraulic pressure. After the hydraulic pressure has been released, disconnect the hoses from the hydraulic cylinders.

12. Remove the hydraulic cylinders and the cylinder supports from the cylinder head.

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Illustration 6	g00651169

13. Use Tooling (D) to remove nuts (7) and the washers from the cylinder head studs.

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Illustration 7	g00651176

14. Attach Tooling (B) and a suitable lifting device to the rocker arm support on the cylinder head. The weight of the cylinder head is approximately 205 kg (450 lb).

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Illustration 8	g00639829
Typical example

15. Before the cylinder head is lifted, carefully use Tooling (G) in order to loosen the cylinder head.

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Illustration 9	g00651274
Typical example

Note: Hold rod (1) so that the rod does not interfere with the removal of the cylinder head.

16. Carefully raise the cylinder head from the studs and remove the cylinder head.

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Illustration 10	g01213037

17. Remove seal carriers (8) and (11) from studs (10) . Remove the O-ring seals from both sides of the seal carriers.

18. If necessary, remove studs (10) .

19. Remove combustion gasket (13) and sleeve (9) from cylinder liner (12) .

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Illustration 11	g01213038

20. Measure the thickness of combustion gasket (13) all the way around. The correct thickness is 4.20 ± 0.05 mm (0.165 ± 0.002 inch). The differences in the measurements around the combustion gasket must not be more than 0.03 mm (0.001 inch).

21. Install Tooling (E) on the cylinder block.