C3.3 and C4.4 Generator Sets 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, the coolant passages, and the lubricant passages.

Note: Thoroughly clean the hole in the cylinder head for the gas that is ventilated from the crankcase. Ensure that the hole is not restricted by debris and/or oil deposits.

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Illustration 1	g01253350

1. Install the cylinder head gasket on the dowels (13) 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 (13). Take care not to damage the machined surfaces of the cylinder head during installation.

4. Remove Tooling (A).

   Note: New bolts (12) should be used to secure cylinder head (11).

5. Apply clean engine oil to the threads and the shoulder of bolts (12) that secure the cylinder head (11) before installation.
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   Illustration 2	g03372792

6. Install bolts (12) in cylinder head (11).

   Note: The short bolts (12) are installed in holes that are marked 2, 5, 6, 7, 8, 9, and 10.

   Note: Long bolts (12) are installed in holes that are marked 1, 3, and 4.

7. Tighten bolts (12) in numerical order to a torque of 50 N·m (37 lb ft). Refer to Illustration 2.

8. Tighten bolts (12) in numerical order to a torque of 100 N·m (74 lb ft). Refer to Illustration 2.
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   Illustration 3	g01151296

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

   Note: If the Tooling (B) is not available, place an index mark on each bolt (12).

10. Tighten bolts (12) in numerical order. Refer to Illustration 2.

    1. Turn short bolts (12) (2, 5, 6, 7, 8, 9, and 10) for an additional 225 degrees.

    2. Turn long bolts (12) (1, 3, and 4) for an additional 270 degrees.
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    Illustration 4	g01253283

11. Install new O-ring seals on tube assembly (9). Install tube assembly (9).
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    Illustration 5	g01253275

12. Install bolts (8) and bolts (6). Connect harness assembly (5). Connect hose (7) and hose (4).
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    Illustration 6	g01253262

13. position air cleaner assembly (1). Install bolts (2). Tighten clamp (3).

14. Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change".

End By:

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

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

5. Install the fuel priming pump. Refer to Disassembly and Assembly , "Fuel Priming Pump and Fuel Filter Base - Remove and Install".

6. Install the fan guard. Refer to Disassembly and Assembly , "Fan Guard - Remove and Install".

7. Install the engine lifting group. Refer to Disassembly and Assembly , "Engine Lifting Group - Remove and Install".