C1.5 and C2.2 Generator Set Engines Caterpillar

Installation Procedure

1. Thoroughly clean the mating surfaces of the cylinder head and the cylinder block. Do not damage the mating surfaces of the cylinder head or the cylinder block. Ensure that no debris enters the cylinder bores, the coolant passages, or the lubricant passages.

2. Inspect the mating surface of the cylinder head for distortion. Refer to Specifications, "Cylinder Head" for more information. If the mating surface of the cylinder head is distorted beyond maximum permitted limits, replace the cylinder head.
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   Illustration 1	g01317467
   Typical example

3. Inspect dowels (3) for damage. If necessary, replace the dowels in the cylinder block.

4. Install Tooling (A) to the cylinder block. Refer to Illustration 1.
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   Illustration 2	g06084915
   Typical example

   Note: During the following procedure, a new cylinder head gasket thickness must be calculated if the crankshaft, a connecting rod, or a piston has been replaced. Refer to Systems Operation, Testing, and Adjusting, Piston Height - Inspect.

   Note: During the following procedure, if the crankshaft, a connecting rod or a piston has not been replaced, obtain a new cylinder head gasket of the same part number as the gasket that was removed. The part number of the cylinder head gasket is marked at position (X).

5. Align cylinder head gasket (4) with Tooling (A) and with dowels (3). Install the cylinder head gasket onto the cylinder block.

6. Use a suitable lifting device to lift the cylinder head. The weight of the cylinder head is approximately 30 kg (66 lb).
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   Illustration 3	g01309672
   Typical example

7. Use Tooling (A) to align cylinder head (2) with the cylinder block. Install the cylinder head to the cylinder block.

   Note: Ensure that the cylinder head is correctly positioned onto dowels (3).

8. Remove Tooling (A).

9. Install bolts (1) to cylinder head (2).
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   Illustration 4	g01309552
   Tightening sequence

10. Tighten bolts (1) to a torque of 101 N·m (75 lb ft). Use the numerical sequence that is shown in Illustration 4.

11. If necessary, install the water temperature regulator to the cylinder head. Refer to Disassembly and Assembly, "Water Temperature Regulator- Remove and Install".

End By:

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

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

3. Install the glow plugs. Refer to Disassembly and Assembly, "Glow Plugs - Remove and Install".

4. Install the fuel injectors. Refer to Disassembly and Assembly, "Fuel Injector - Install".

5. Install the fuel filter base. Refer to Disassembly and Assembly, "Fuel filter Base - Remove and Install".

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