C4.4 Marine Generator Set Engines Caterpillar

Installation Procedure

1. Clean all mating surfaces thoroughly.
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   Illustration 1	g01167107

2. Ensure that thrust washer (8) is aligned with hollow dowel (10). Install thrust washer (8) on camshaft (9).
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   Illustration 2	g01167108

3. Install Tooling (A) in the cylinder block in Hole (Y).

4. Position gasket (6) on Tooling (A). Install gasket (4) on the back side of front housing (3).

5. Position front housing (3) on the cylinder block. Install bolts (5) and bolts (7). Remove Tooling (A) and install the remaining bolts in order to secure front housing (3) to the cylinder block. Tighten bolts (5) and bolts (7) finger tight at this time.
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   Illustration 3	g00954906

6. Align front housing (3) and the cylinder block.

   Note: Ensure that the bottom of the front cover is aligned with the bottom of the cylinder block before the bolts are tightened. The alignment of the bottom face of the front cover and the bottom of the cylinder block must not exceed 0.00 ± 0.05 mm (0.000 ± 0.002 inch).

7. Tighten bolts (5) and bolts (7) to a torque of 22 N·m (16 lb ft).
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   Illustration 4	g00995185

8. Install new O-ring seals on bypass tube (2). Apply Tooling (B) to the O-ring seals. Install bypass tube (2) in the cylinder head. Install bolts (1).

End By:

1. Install the auxiliary water pump. Refer to Disassembly and Assembly, "Auxiliary Water Pump - Install".

2. Install the camshaft gear. Refer to Disassembly and Assembly, "Camshaft Gear - Remove and Install".

3. Install the idler gear. Refer to Disassembly and Assembly, "Idler Gear - Remove and Install".

4. Install the fuel injection pump. Refer to Disassembly and Assembly, "Fuel Injection Pump - Install".

5. Install the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove and Install".

6. Install the alternator. Refer to Disassembly and Assembly, "Alternator - Install".