C15 On-highway Engine Caterpillar

Installation Procedure

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Illustration 1	g01020078

Note: Thoroughly clean the spacer plate and the bottom surface of the cylinder head. A new spacer plate gasket must be installed when the cylinder head is removed.

1. Install the O-ring seals, spacer plate (19) , and cylinder head gasket (18) .

2. Attach a suitable lifting device to the cylinder head. The weight of the cylinder head is approximately 235 kg (518 lb).

3. Carefully install the cylinder head on the dowel pins on the cylinder block.

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Illustration 2	g01020075

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Illustration 3	g01020264

Note: The following bolts are 216 mm (8.5 inch) long: 11, 12, 13, 14, 16, 18, 20, 22, 24 and 26. The following bolts are 198.8 mm (7.83 inch) long: 2, 8 and 10. The rest of the bolts are 194 mm (7.6 inch) long.

Note: Apply Tooling (A) to the bolt threads and both sides of the washers. Tighten the bolts in the following step sequence:

4. Install cylinder head bolts (15) according to the following procedure.

   1. In a numerical sequence, tighten bolts 1 through 26 to a torque of 270 ± 15 N·m (200 ± 11 lb ft).

   2. In a numerical sequence, tighten bolts 1 through 26 to a torque of 450 ± 15 N·m (330 ± 11 lb ft).

   3. In a numerical sequence, again tighten bolts 1 through 26 to a torque of 450 ± 15 N·m (330 ± 11 lb ft).

Note: The flatness of the cylinder head should be within a total of 0.13 mm (0.005 inch). Also, the flatness of the cylinder head should be within a maximum of 0.05 mm (0.002 inch) for any 150 mm (5.9 inch) span.

5. Install strap (17) .

6. Connect hose (16) .

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Illustration 4	g01020071

7. Install harness assembly in position. Install clips (14) .

8. Connect hose assembly (13) .

9. Connect hose assembly (12) .

10. Install fuel filter base (10) in position. Install bolts (11) that connect fuel filter base (10) to the cylinder head.

11. Connect hose (7) . Install tube assembly (8) and tube assembly (9) .

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Illustration 5	g01020267

12. Install O-ring seal (5) and O-ring seal (6) on seal assembly (3) .

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Illustration 6	g01020269

13. Install seal assembly (3) and adapter (4) .

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Illustration 7	g01020270

14. Install bolts (2) and thrust plate (1) .

End By:

1. Install the turbochargers. Refer to Disassembly and Assembly, "Turbocharger - Install".
2. Install the valve mechanism cover base. Refer to Disassembly and Assembly, "Valve Mechanism Cover Base - Remove and Install".
3. Install the electronic unit injectors. Refer to Disassembly and Assembly, "Electronic Unit Injector - Install".
4. Install the camshaft gear. Refer to Disassembly and Assembly, "Camshaft Gear - Install".