Installation Of Replacement Cylinder Head Assemblies{1101} Caterpillar

Reference: Service Manual

This cylinder head assembly is the service replacement cylinder head for all of the above engines. The additional parts that are sent with this cylinder head assembly are for use in specific applications. Not all of the parts will be needed to install the cylinder head on a specific engine. This instruction gives the installation information needed for the cylinder head assembly and for the additional parts. Put 5P3413 Pipe Thread Sealer on all threaded plugs and cup plugs used in the cylinder head installation.

1100, 3100, 3200 Series Direct Injection Engines

NOTE: The mounting holes in the cylinder head at location (A), used for a lifting eye bracket (or other brackets) may be a different size than the original head; therefore, rework and extra parts may be needed. Cylinder heads on earlier engines had bracket mounting holes with 3/8"-16-2B threads. Later cylinder heads had bracket mounting holes with 1/2"-13-2B threads.

1 If a cylinder head of the earlier type is replacing a later cylinder head, the replacement cylinder head will have 3/8"-16-2B threads in the mounting holes. Install the bracket with S1594 Bolts and 5M2894 Washers.

2 If a cylinder head of the later type is replacing an earlier cylinder head, the holes in the lifting eye bracket (or other brackets) must be enlarged to 13.0 mm Ø (0.53" Ø). Use 6H1717 Bolts and 5P8245 Washers to install the lifting eye bracket on the replacement cylinder head.

1100, 3100, 3208 Engines

1 If the cylinder head is to be used on the left side of the engine, install a 9L7657 Cup Plug at location (A). If the cylinder head is to be used on the right side of the engine, install a 9L7657 Cup Plug at location (B). On all cylinder heads, install a 7H3171 Hex Countersunk Head Plug at location (C). Install 5M6213 Plugs at locations (D) as necessary. Due to the different size holes in earlier and later cylinder heads, install either a 2B858 or a 5M6214 Plug in the opening at (E).

2 Put the cylinder head in position on the engine. Put engine oil on the threads of the cylinder head bolts, and install the bolts in their correct positions. Tighten the bolts in sequence and to the torque shown in the Service Manual.

3204 Direct Injection Engines

NOTE: Because two different water lines groups [with different size holes in the cylinder head at location (D)] have been used on these engines, it may be necessary to obtain some additional parts. See step 1 and the illustrations for the parts needed.

1 Install a 7H3171 Hex Countersunk Head Plug at location (A), a 9L7657 Cup Plug at location (B), and 5M6213 Plugs at locations (C) as necessary.

2 New vent line parts (not part of the cylinder head group) will be needed if the threaded hole at location (D) is a different size than the hole in the former cylinder head. See the illustrations for the parts needed to make a new vent line.

3 Put the cylinder head in position on the engine. Put engine oil on the threads of the cylinder head bolts. Install the bolts in their correct positions. Tighten the bolts in sequence and to the torque shown in the Service Manual.

NOTE: Earlier 3204 DI Engines with Interim Scroll Fuel System (ISFS) have fuel lines routed over the valve cover to fuel line adapters installed in the cylinder head at location (E) on the left side of the engine (as viewed from the flywheel). Later 3204 DI Engines with New Scroll Fuel System (NSFS) have the fuel line adapters installed in the valve cover base on the right side of the engine. On these engines, install four 8F6575 Cup Plugs in the cylinder head at locations (E).