3608 Engine Caterpillar

Assembly Procedure

Note: Use 8T-0447 Dial Calipers and 6V-7030 Micrometer Depth Gauge Group to measure the dimensions in the following procedure.

Note: Refer to Disassembly and Assembly, "General Information (Reference Material)" for more information. Refer to page 7 for torque values.

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Illustration 1	g01425420

1. Put the cylinder head in position on Tooling (A).

2. Install new O-ring seals on plugs (23), plug (24), and plugs (22).

3. Apply clean engine oil to the O-ring seals. Install the plugs in the cylinder head. Use Tooling (J) to install the bridge dowel plugs.
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   Illustration 2	g01425300

4. Apply clean engine oil to the O-ring seals. Install plugs (20) and plugs (21).

5. Repeat Step 4 for the opposite side of the cylinder head.
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   Illustration 3	g01299854

6. Apply clean engine oil to the O-ring seal. Install plug (19).
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   Illustration 4	g01425296

7. Apply clean engine oil to the O-ring seal. Install plug (18).
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   Illustration 5	g01425294

8. Apply Tooling (P) to new gasket (17). Install plug (16) with a new gasket (17) into the port for the pressure relief. Tighten plug (16) to a torque of 275 ± 25 N·m (200 ± 18 lb ft).
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   Illustration 6	g01425292
   Earlier

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   Illustration 7	g00641827
   Later

   Note: Your cylinder head may not have this hole.

9. Apply Tooling (Q) on the threads of cylinder pressure pickup plug (14).

10. Put a new seal (15) on cylinder pressure pickup plug (14). Coat the bore lightly with glycerin.

11. Install cylinder pressure pickup plug (14), and tighten the cylinder pressure pickup plug to a torque of 100 ± 15 N·m (75 ± 11 lb ft).
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    Illustration 8	g01299883

12. Cool the valve guides to a temperature of −70 °C (−94 °F). Apply clean engine oil to the outside of valve guide (12). Use Tooling (F) and a hammer to install valve guide (12) into the cylinder head. Be careful not to damage the cylinder head with the hammer.

13. Install valve guides (12) until the valve guides extend 20.0 ± 2.0 mm (0.79 ± 0.08 inch) above the cylinder head. This is Dimension (X).

    Note: The Step that follows shows an alternate method of installing the valve guides.

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    Illustration 9	g01299886

14. Install valve guides (12) hydraulically with Tooling (H) and Tooling (K).

15. After installation, the inside diameter of a new valve guide must be 16.031 ± 0.028 mm (0.6311 ± 0.0011 inch).
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    Illustration 10	g01300338

16. Use Tooling (J) and a hammer to install bridge dowels (13) into the plugs in the cylinder head.

17. Install bridge dowels (13) to Dimension (Y). Dimension (Y) is 105.0 ± 2.0 mm (4.13 ± 0.08 inch).
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    Illustration 11	g01300340

18. Use a driver and a hammer to install rocker arm support dowels (25) into the cylinder head.

19. Install rocker arm support dowels (25) to Dimension (Z). Dimension (Z) is 8.0 ± 1.0 mm (0.32 ± 0.04 inch).
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    Illustration 12	g01300342

20. Check the installed dimension of the following components: valve guides (12), bridge dowels (13), and rocker arm support dowels (25). Refer to the following Steps for the correct procedure of measurement: Step 13, Step 17, and Step 19.
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    Illustration 13	g01300348

21. Be sure that the valve seat bores in the cylinder head are clean.

22. Cool valve seat (10) to a temperature of −60 °C (−76 °F). Standard valve seats can also be installed at room temperature. Apply clean oil to the outside diameter and on the radius at the bottom of the valve seat.

23. Use Tooling (L) and a hammer to install standard valve seat (10). Install the valve seat to the bottom of the counterbore in the cylinder head. The new diameter of the valve seats is 97.195 ± 0.015 mm (3.8266 ± 0.0006 inch).

    Note: The exhaust valve seats may have a smaller ID than the inlet valve seats.

    Note: The water-cooled exhaust valve seats and the standard valve seats can be installed with the following method.

    1. Make sure that the valve seats are at room temperature prior to installation. Do not freeze water-cooled exhaust valve seat inserts.

    2. Before you install the water-cooled exhaust valve seat inserts, apply Tooling (R) to the outside diameter of the valve seat. Apply Tooling (S) over the primer.

    3. Install the water-cooled exhaust valve seat inserts with Tooling (N). Press the water-cooled exhaust valve seat inserts to the bottom of the counterbore in the cylinder head casting.

       Note: Use only a hydraulic press to install the valve seats. Do not use a hammer.

       Note: Be sure to use a fine stone that is properly dressed for grinding the valves.

    4. Inspect the valves. If necessary, grind the valves only enough to restore the face of the valves.
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    Illustration 14	g00573379

24. Install each valve in the original position. Use a straight edge and a thickness gauge to determine the amount of material that will be removed from the valve seat. Measure the projection of the valve head relative to the bottom deck of the cylinder head. Dimension (W) measures this distance, and this dimension must be 0.50 to -2.00 mm (0.020 to -0.079 inch).

    Note: Install the intake valves in line with the air inlet opening in the cylinder head.

    Note: Be sure that you use a fine stone that has the correct diameter to polish the valve seat.

25. Use an orbital valve seat grinder such as a Chris Marine MSB. Repeat Step 24 frequently to be sure that the correct dimension is obtained.
    Chris Marine AB
    Malmo Sweden
    Telex 32867 Chrisma S
    46-40 21 03 20
    
    USA, Inc.
    Jacksonville, Fla. 32202
    (904) 354-6566
    
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    Illustration 15	g01300351

26. Put a light coat of Prussian Blue on the valve seat of each valve. Install each valve (9) in the original location.

27. Check the contact pattern on the valve face. A continuous line that is 3.0 mm (0.12 inch) around the valve face indicates a good fit.

28. If a continuous line is not obtained, use a light lapping compound on the valve to fit the components. Refer to Step 27.

    Note: Be sure that the lapping compound is removed from the cylinder head before the valve is installed.

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    Illustration 16	g00614355

29. Install each valve in the original location. Install Tooling (B) over the valves.

    Note: Coat the intake valve stems and the exhaust valve stems with Tooling (T) prior to installation in the cylinder head.

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    Illustration 17	g00572756

30. Turn the cylinder head for 90 degrees (1/4 Turn) on Tooling (A). Install plate (1) and the nut. Plate (1) can be fabricated from 1/4 inch flat stock. Make the plate that measures 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 18	g00614382

31. Turn the cylinder head for another 90 degrees (1/4 Turn) on Tooling (A) so the valve stems are upward.

32. Install spring guides (8) over the valve guide and against the cylinder head.
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    Illustration 19	g00614376

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    Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

33. Install inner valve springs (7) and outer valve springs (6).
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    Illustration 20	g00614365

34. Put rotocoil assemblies (5) on top of the valve springs.
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    Illustration 21	g01300352

35. Put compressor plate (3) in position on the valve springs and install the nut to hold the compressor plate. Compressor plate (3) is part of Tooling (B).

    Note: Loosen the nut that holds plate (1) so that the bolt can move.

36. Loosen the nut that holds plate (1) so the bolt can move enough to compress the valve springs enough to install the locks. Plate (1) is part of Tooling (B).
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    Illustration 22	g01300353

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    The valve spring keepers can be thrown from the valve when the valve spring compressor is released. Ensure that the valve spring keepers are properly installed on the valve stem. To help prevent personal injury, keep away from the front of the valve spring keepers and valve springs during the installation of the valves.

37. Run Tooling (K) until the springs are compressed enough to install locks (2). Use a magnet bar to install the locks.

38. Remove Tooling (B) and tap the end of each valve stem with a soft faced hammer.
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    Illustration 23	g01300354

39. Use Tooling (M) to check the valve face seal. Apply a vacuum of 25 in hg (minimum). The maximum allowable leak rate is 5 in hg in 10 seconds.

End By:

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