C15 On-Highway Engine Caterpillar

Installation Procedure

Note: A new spacer plate gasket and a cylinder head gasket must be installed when the cylinder head is removed.

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Illustration 1	g01380021

1. Install O-ring seal (24) onto the dowel in the cylinder block.

2. Install a new gasket (23) onto the cylinder block.
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   Illustration 2	g01380020

3. Install spacer plate (22) onto the cylinder block.
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   Illustration 3	g01379999

4. Install a new gasket (21) onto the cylinder block. Install water seals (20) and oil seal (19).
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   Illustration 4	g01379996

5. Use a suitable lifting device to install cylinder head (18). The weight of cylinder head (18) is approximately 293 kg (645 lb).

   Note: Install the cylinder head on the dowel pins on the cylinder block.

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   Illustration 5	g01379991

6. Apply Tooling (A) to the threads of the cylinder head bolts (17) and both sides of the washers. Install bolts (17).
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   Illustration 6	g01072801

   Note: The bolts that are marked "x" are 216 mm (8.5 inch) long: 11, 12, 13, 14, 16, 18, 20, 22, 24 and 26. The remaining bolts are 194 mm (7.6 inch) long.

7. Tighten the cylinder head bolts according to the following procedure.

   1. Tighten bolts 1 through 26 to a torque of 270 ± 15 N·m (200 ± 11 lb ft) in a numerical sequence.

   2. Tighten bolts 1 through 26 to a torque of 450 ± 15 N·m (330 ± 11 lb ft) in a numerical sequence.

   3. Tighten bolts 1 through 26 again to a torque of 450 ± 15 N·m (330 ± 11 lb ft) In a numerical sequence.
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   Illustration 7	g01379980

8. Position manifold (14) and install bolts (13).

9. Install tube assemblies (12) and (16).

10. Connect hose (15).
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    Illustration 8	g01377746

11. Connect harness assembly (11).
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    Illustration 9	g01377737

12. Connect harness assembly (10).
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    Illustration 10	g01377739

13. Apply a 50/50 mixture of Tooling (B) and clean engine oil onto O-ring seal (8) and O-ring seal (9) into sealing plate (7).
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    Illustration 11	g01377738

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    Illustration 12	g01377731

14. Install sealing plate (6).

15. Position plate (5) and install bolts (4).

16. Apply Tooling (C) onto the threads of bolts (1). Position adapter (3) and install thrust plate (2). Install bolts (1). Tighten bolts (1) until sealing plate (6) and the O-ring seal are seated against the cylinder head.

17. Install bolts (1).

End By:

1. Install the valve mechanism cover base. Refer to Disassembly and Assembly, "Valve Mechanism Cover Base - Remove and Install".

2. Install the electronic unit injectors. Refer to Disassembly and Assembly, "Electronic Unit Injectors - Install".

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

4. Install the rocker arm shafts. Refer to Disassembly and Assembly, "Rocker Arm and Shaft - Install".

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

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