3618 Engine Caterpillar

Assembly Procedure

1. Install the cylinder head on Tooling (A). The weight of the cylinder head is approximately 205 kg (450 lb).

2. If the O-ring seals were removed from the valve guides, install new O-ring seals in the valve guides.
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   Illustration 1	g01213114

3. Lower the temperature of bridge dowels (11) to −70 °C (−94 °F). Use Tooling (J) to install the bridge dowels to a height of Dimension (Y) above the cylinder head. Dimension (Y) is 105 ± 2.0 mm (4.1 ± 0.08 inch).
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   Illustration 2	g01213116

4. Lower the temperature of valve guides (9) to −70 °C (−94 °F). Use Tooling (F) to install the valve guides to a height of Dimension (W) above the cylinder head. Dimension (W) is 20 ± 2.0 mm (0.8 ± 0.08 inch).

   The correct inside diameter of the valve guide after installation is 16.031 ± 0.028 mm (0.6311 ± 0.0011 inch).

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   NOTICE
   Do not use a hammer to install the valve seats. The use of a hammer will damage the valve seats and the cylinder head. Only use a suitable press for installation of the valve seats.

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   Illustration 3	g01213121

   Note: Do not lower the temperature of valve seats (8). Make sure that the valve seats are at room temperature before installation.

5. Apply Tooling (N) to the outside of the valve seats. Then apply Tooling (P) over Tooling (N).

6. Use Tooling (K) and a suitable press to install the valve seats for the inlet valves. Press the valve seats into the bottom of the counterbore in the cylinder head.

7. Use Tooling (L) and a suitable press to install the valve seats for the exhaust valves. Press the valve seats into the bottom of the counterbore in the cylinder head.

8. Inspect valves (7). If necessary, use a fine stone that is properly dressed for grinding the faces of valves (7). Grind the valves only enough to restore the faces.

9. Lubricate valves (7) with Tooling (Q). Install valves (7) into the original positions in the cylinder head.
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   Illustration 4	g00651686

10. After the valves are installed, install Tooling (B) onto the cylinder head. Place the round plate over the faces of the valves. The threaded end of the rod protrudes from the bottom of the cylinder head.
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    Illustration 5	g01213126

11. Rotate the cylinder head for 180 degrees to orient the valve stems upward.

12. Install spring guides (6) over the valve guides and onto the cylinder head.
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    Illustration 6	g01213129

13. Install inner valve springs (5) and outer valve springs (4).
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    Illustration 7	g00651698

14. Place rotocoils (3) on top of the valve springs.
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    Illustration 8	g00651692

15. Install Tooling (C) onto the cylinder head.
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    Illustration 9	g00651693

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    Do not remove or install the spring locks with your fingers. If the spring should move, personal injury may result.

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    Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

16. Compress the springs with Tooling (C) and use a magnet to install locks (2).
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    If the valve locks are not positioned correctly, the locks can be expelled when the spring pressure is released. To help prevent personal injury, stay away from the front of the valve retainer and springs. Ensure that the valve locks are positioned correctly.

17. Remove Tooling (C) and Tooling (B) from the cylinder head. Lightly tap the end of each valve stem with a rubber mallet.

18. Use Tooling (M) to test the seals of the valve faces. Apply a minimum vacuum of 635 mm Hg (25 inch Hg). The maximum allowable leakage is 127 mm Hg (5 inch Hg) in ten minutes.

End By:

1. Install the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Install".