3608 Engine Caterpillar

Disassembly Procedure

Start By:

1. Remove the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Remove".

Note: Use 8T-0447 Dial Calipers to measure the dimensions in the following procedure.

Note: Refer to Disassembly and Assembly, "General Information (Reference Material)" for more information.

1. Put the cylinder head assembly in position on Tooling (A). Put the cylinder head assembly in position so that the valve seat faces upward.
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   Illustration 1	g00614352

   Note: Use the hydraulic cylinder only in the position that is shown in Illustration 1.

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   Illustration 2	g00614355

2. Install Tooling (B) in the position that is shown in Illustration 2. The threaded end of the bolt must face downward.
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   Illustration 3	g00572756

3. Turn the cylinder head to a position of 90° on Tooling (A). Install plate (1) and the nut. Plate (1) can be fabricated from 35.5 mm (1.40 inch) flat stock. The plate must measure 32.0 mm (1.25 inch) by 133.0 mm (5.25 inch) with a 16.5 mm (0.65 inch) hole at the center. The plate will hold the valves when the valve stems are turned upward.
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   Illustration 4	g00572757

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   Personal injury can result from parts and/or covers under spring pressure. Spring force will be released when covers are removed. Be prepared to hold spring loaded covers as the bolts are loosened.

4. Install compressor plate (3). This plate is part of Tooling (B). Install the nut and the washer.

   Note: Loosen the nut that holds plate (1) to allow the bolt to move. The nut is a part of Tooling (B).

5. Loosen the nut that holds plate (1) to allow the bolt to move enough to compress springs (4). This action also allows you to remove locks (2). The nut is a part of Tooling (B).

6. Compress the springs with Tooling (C) and remove locks (2).

   Note: The following two steps show an alternate method of compressing the valve springs.

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   Illustration 5	g00614360

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   Personal injury can result from parts and/or covers under spring pressure. Spring force will be released when covers are removed. Be prepared to hold spring loaded covers as the bolts are loosened.

7. Install Tooling (D) and install Tooling (B) without the hydraulic cylinder. Refer to Illustration 5. Move the handle downward to compress spring (4).
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   Illustration 6	g00572759

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   Do not remove or install the spring locks with your fingers. If the spring should move, personal injury may result.

8. Use a magnet to remove locks (2).
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   Illustration 7	g00572760

9. Release the pump pressure from Tooling (C). Remove compressor plate (3) from Tooling (B).
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   Illustration 8	g00614365

10. Remove rotocoil assemblies (5).
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    Illustration 9	g00614376

11. Remove outer valve springs (6) and inner valve springs (7).

12. Inspect outer valve spring (6) and inner valve spring (7).

13. The free length of inner valve spring (7) is 107.00 mm (4.213 inch). The force that is required to compress inner valve spring (7) to a length of 79.25 mm (3.120 inch) is 325 to 397 N (73 to 89 lb). Refer to Specifications, "Cylinder Head" for more information.

14. The free length of outer valve spring (6) is 114.00 mm (4.488 inch). The force that is required to compress outer valve spring (6) to a length of 84.9 mm (3.34 inch) is 682 to 834 N (153 to 187 lb). Refer to Specifications, "Cylinder Head" for more information.
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    Illustration 10	g00614382

15. Remove spring guides (8).

16. Turn the cylinder head to a position of 90° on Tooling (A). Remove Tooling (B). Be careful not to allow the valves to come out of the cylinder head.

17. Turn the cylinder head in Tooling (A) so the valve seat faces upward.
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    Illustration 11	g00614393

18. Use a paint stick to put the identification marks on each valve so that the valves can be installed in the original positions.

19. Remove each valve (9).

20. Inspect each valve (9) and valve seat (10) for wear. Reface the valves to get a new sealing surface.

21. If necessary, use Tooling (E) to remove valve seat (10).
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    Illustration 12	g00572773

22. Be sure that the Tooling is against the bottom of the valve seat. Hand tighten the puller nut to hold the Tooling against the bottom of the valve seat.
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    Illustration 13	g00614409

    Note: The cylinder must be installed so that the hydraulic hose coupling faces downward.

23. Assemble Tooling (E) in accordance with Illustration 13. Engage the seat removal plate (11) with the lower edge of valve seat (10). This plate is a part of Tooling (E).
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    NOTICE
    Do not strike the highly finished surface of the cylinder head with hammer at any time, or damage to this surface will occur.

24. Attach Tooling (C) to the cylinder of Tooling (E). Operate Tooling (C) to move valve seat (10) out of the cylinder head. Do not allow Tooling (E) to fall as valve seat (10) is free of the cylinder head.
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    Illustration 14	g00614424

25. Inspect valve guides (12). The inside diameter of the new valve guides is 16.031 ± 0.028 mm (0.6311 ± 0.0011 inch).
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    Illustration 15	g00572778

26. If necessary, use Tooling (F) to hydraulically remove the valve guide.
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    Illustration 16	g01300512

    Note: Use the hydraulic cylinder only in the position that is shown in Illustration 16.

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    The hydraulic cylinder is capable of applying more force than the threaded removal tool can withstand. Using this tooling without the safety retainer group in place could result in serious injury or death.

27. Inspect bridge dowels (13). If necessary, use Tooling (G) to remove these dowels. Do not allow Tooling (G) to fall as bridge dowels (13) are free of the cylinder head.

28. Run Tooling (C) to pull the bridge dowels out of the plugs in the cylinder head.

29. Inspect the dowel plugs that are in the cylinder head. If a replacement is necessary, remove the dowels.

30. Thoroughly clean the cylinder head and inspect the cylinder head.

31. Inspect the water jacket of the cylinder head. If cleaning is necessary, remove all the plugs from the cylinder head before using the hot tank process for cleaning.
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    Illustration 17	g01425292
    Earlier

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    Illustration 18	g00641827
    Later

    Note: Your cylinder head may not have this hole.

32. Remove cylinder pressure pickup plug (14) and seal (15).
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    Illustration 19	g01425294

33. Remove plug (16) and gasket (17).
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    Illustration 20	g01425296

34. Remove plug (18) and the O-ring seal.
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    Illustration 21	g01299854

35. Remove plug (19) and the O-ring seal.
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    Illustration 22	g01425300

36. Remove plugs (20), plugs (21), and the O-ring seals.

37. Repeat Step 36 for the opposite side of the cylinder head.
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    Illustration 23	g01425304

38. Remove plugs (22), plugs (23), plug (24), and the O-ring seals.