3618 Engine Caterpillar

Installation Procedure

1. Remove Tooling (E) from the cylinder block.

Note: Protect the stud threads from paint.

2. Remove all debris from the holes in the cylinder block. Thoroughly clean the studs. If the studs are cleaned to the bare metal, paint the studs.

3. Thoroughly clean the top of the cylinder block and the sealing surfaces on the cylinder block.

4. Remove all debris from the inside of the cylinder and the top of the piston. Lubricate the inside of the cylinder liner with clean engine oil.

5. If the cylinder head studs were removed, use the following Steps to install the studs:

   1. Coat the lower halves of the studs with approximately 1.5 mm (0.06 inch) of Tooling (H) .

   2. Carefully lower the studs into the cylinder block and start the threads by hand.

   3. Tighten the studs to a torque of 100 ± 20 N·m (75 ± 15 lb ft).

   4. Coat the entire length of the studs with Tooling (H) .

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NOTICE
Always install the seal carriers after the cylinder liners are installed. Aluminum debris that is shaved from the plates by the cylinder liners will prevent the cylinder liners from sealing if the seal carriers are installed first.

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Illustration 1	g01213276
Bottom of seal carriers

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Illustration 2	g01213278
Top of seal carriers

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Illustration 3	g01213037

6. Install new O-ring seals in the bottom of seal carriers (8) and (11) .

7. Place seal carriers (8) and (11) over the studs and onto the cylinder block. Install new O-ring seals in the top of the seal carriers.

8. Place combustion gasket (13) in position on top of cylinder liner (12) and place sleeve (9) in position.

9. 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 4	g00651274
Typical example

10. Carefully lift the cylinder head over the studs. Reach through the opening in the side cover in order to hold rod (1) so that the rod does not interfere with the installation of the cylinder head. Slowly lower the cylinder head onto the cylinder block.

    Make sure that the cylinder head is seated on the dowels and the seal carriers. Make sure that the O-ring seals are properly seated.

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Illustration 5	g00651169

11. Lubricate the washers and the threads of nuts (7) with Tooling (J). Use Tooling (D) to install the washers and nuts (7) onto the studs. Tighten the nuts by hand.

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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 6	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.

12. 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 studs, make sure that sufficient threads are exposed on the studs. To calculate the minimum length of the threads, multiply the diameter of the stud by 0.8.

13. 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 studs. Use the 1/2 inch square drive on the cylinders in order to fully thread the cylinders onto the studs. After the cylinders have been fully tightened, reverse the threads for 1/4 of a turn (90 degrees).

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

14. Use Tooling (C) to verify the gauge on the hydraulic pump. 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.

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

16. Operate the pump to a pressure of 125 ± 2.5 MPa (18,130 ± 365 psi). Make sure that the pressure is maintained. This will stretch the stud in order to move the nut away from the cylinder head.

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Illustration 7	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.

17. Use the square drive on the cylinder support of Tooling (A) to tighten the nuts. Do not apply more than 100 N·m (75 lb ft) of torque to the cylinders.

18. Slowly release the hydraulic pressure. Then repeat Steps 16 and 17.

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

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

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Illustration 8	g00651069

21. Make sure that the O-ring seals for tube (5) and flange (6) are positioned in good condition. Push tube (5) and flange (6) toward the cylinder head. Install bolts (4) and the washers that attach the tube and the flange to the air inlet of the cylinder head.

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Illustration 9	g00651054

22. Install tube assembly (3) .

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Illustration 10	g01213013

23. Connect rod (1) to lever (2) .

24. Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change".

End By:

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