C4.4 Marine Generator Set Engines Caterpillar

Installation Procedure

Note: Thoroughly clean the top of the cylinder block and the bottom of the cylinder head. Ensure that there is no debris in the cylinder bores.

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Illustration 1	g01166540

1. Install the cylinder head gasket on dowels (9) on top of the cylinder block.

   Note: Do Not use any sealant or compound on the cylinder head gasket.

2. Install Tooling (A) in the cylinder block.

3. Use a suitable lifting device to install the cylinder head. The weight of the cylinder head is approximately 57 kg (126 lb).

   Note: Ensure that the cylinder head is positioned on dowels (9).

4. Remove Tooling (A).
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   Illustration 2	g00951563

5. Clean the threads of the cylinder head bolts. Inspect the cylinder head bolts.

   Note: Do Not use bolts if there is any visual reduction in the diameter of the Threads (Y) that has not been engaged with the cylinder block. Use a straight edge to check the bolts.

6. Lubricate the threads and the shoulder of the cylinder head bolts with clean engine oil before installation.
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   Illustration 3	g01166538

7. Install bolts (7) on cylinder head (8).

   Note: The short bolts are installed in holes that are marked 2, 5, 6, 7, 8, 9, and 10.

   Note: The long bolts are installed in holes that are marked 1, 3, and 4.

8. Tighten bolts (7) in numerical order to a torque of 50 N·m (37 lb ft). Refer to Illustration 3.

9. Tighten bolts (7) in numerical order to a torque of 100 N·m (74 lb ft). Refer to Illustration 3.
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   Illustration 4	g00951562

10. Use Tooling (B) to achieve the correct final torque.

    Note: If Tooling (B) is not used, place an index mark on each bolt.

11. Tighten bolts (7) in numerical order. Refer to Illustration 3.

    1. Turn the short bolts (2, 5, 6, 7, 8, 9, and 10) for an additional 225 degrees.

    2. Turn the long bolts (1, 3, and 4) for an additional 270 degrees.
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    Illustration 5	g01166537

12. Install new O-ring seals on bypass tube (6). Apply Tooling (C) to the O-ring seals. Install bypass tube (6) in the cylinder head. Install bolts (5).
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    Illustration 6	g01166536

13. Connect harness assembly (4) to the coolant temperature sensor.

14. Position bus bar (3) on the glow plugs. Install nuts (2) in order to secure bus bar (3) to the glow plugs.

15. Install bolt (1) and the fuel line to the cylinder head.

16. Fill the cooling system with coolant. Fill the lubrication system with engine oil. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" and Operation and Maintenance Manual, "Engine Oil - Change". Refer to Operation and Maintenance Manual, "Capacities (Refill)".

End By:

1. Install the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Remove and Install".

2. Install the rocker shaft and the pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod - Install".

3. Install the exhaust manifold. Refer to Disassembly and Assembly, "Exhaust Manifold - Remove and Install".