C6.6 Industrial Engine Caterpillar

Installation Procedure

1. Thoroughly clean the gasket surfaces of the cylinder head and the cylinder block. Do not damage the gasket 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 gasket surface of the cylinder head for distortion. Refer to Specifications, "Cylinder Head" for more information. If the gasket surface of the cylinder head is distorted beyond maximum permitted limits, replace the cylinder head.
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   Illustration 1	g02411639

3. Inspect dowels (31) for damage. If necessary, replace the dowels in the cylinder block.

4. Align a new cylinder head gasket (32) with dowels (31). Install the new cylinder head gasket (32) onto the cylinder block.

5. Install Tooling (B) to the cylinder block.

6. Use a suitable lifting device to lift cylinder head. The weight of the cylinder head is approximately 96 kg (212 lb).

   Note: A spreader bar must be used to distribute the weight of the cylinder head during the lifting operation.

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

   Note: Ensure that the cylinder head is correctly positioned on dowels (31).

8. Remove Tooling (B).
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   Illustration 2	g02216034

9. Clean bolts (29). Follow Step 9.a for the procedure to inspect the bolts.

   1. Use a straight edge to check the threads of the bolts. Refer to Illustration 2. Replace any bolts that show visual reduction in the diameter of the thread over Length (Y).

10. Lubricate the threads and the shoulder of bolts (29) with clean engine oil.
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    Illustration 3	g02206215

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    Illustration 4	g02007814

11. Install bolts (29) to cylinder head (30).

12. Tighten the bolts to a torque of 50 N·m (37 lb ft) in the numerical sequence that is shown in Illustration 4.

13. Tighten the bolts to a torque of 100 N·m (74 lb ft) in the numerical sequence that is shown in Illustration 4.

14. Use Tooling (C) to tighten the bolts an additional 225 degrees in the numerical sequence that is shown in Illustration 4.

    Note: Illustration depicts the bolt head travel distance of 225 degrees

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    Illustration 5	g02206214

15. Use Tooling (D) to lubricate the O-ring seals. Install new O-ring seal (27) and O-ring seal (28) to bypass tube (25). Install the bypass tube in the cylinder head. Install bolts (24). Tighten the bolts to a torque of 9 N·m (80 lb in).

16. Follow Step 16.a through Step 16.c to connect harness assembly (22) to coolant temperature sensor (23).

    1. Connect harness assembly (22) to coolant temperature sensor (23).

    2. Slide locking tab (21) into the locked position.

    3. Position harness assembly (22) onto the bypass tube and install a new cable strap (26).
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    Illustration 6	g02206213

17. Remove the plugs and caps from the ports and tube assembly.

18. Use Tooling (C) to lubricate new O-ring seals (17) (not shown). Install the O-ring seal to tube assembly (18) for the fuel return from the cylinder head.

19. Install tube assembly (18) to the cylinder head.

20. Install bolt (16) finger tight.

21. Install bolt (20) to tube clip (19) finger tight.

22. Tighten bolt (16) and bolt (20) to a torque of 22 N·m (195 lb in).
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    Illustration 7	g02206194

23. Follow Step 23.a through Step 23.b to connect harness assembly (11) to inlet air temperature sensor (10).

    1. Connect harness assembly (11) to inlet air temperature sensor (10).

    2. Slide locking tab (12) into the locked position.

24. Follow Step 24.a through Step 24.b to connect harness assembly (15) to boost pressure sensor (13).

    1. Connect harness assembly (15) to boost pressure sensor (13).

    2. Slide locking tab (14) into the locked position.

25. Position the harness assembly onto the cylinder head. Use new cable straps to secure the harness assembly to the cylinder head. Ensure that the harness assembly is not strained.

26. On some applications there is an engine wiring harness support bracket on the rear of the cylinder head. If necessary, install the support bracket for the engine wiring harness to the cylinder head assembly. Use new cable straps to secure the engine harness assembly to the support bracket.

    Note: Ensure that the harness assembly is clear of other engine components.

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    Illustration 8	g02005213
    Typical example

27. If necessary, install water temperature regulator housing (1) to the cylinder head. Refer to Disassembly and Assembly, "Water Temperature Regulator Housing - Remove and Install" for the correct procedure.

28. Connect the upper radiator hose to water temperature regulator housing (1) on the cylinder head. Tighten hose clamp securely.

29. Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct filling procedure.

30. If necessary, fill the engine oil pan to the correct level that is indicated on the engine oil level gauge. Refer to Operation and Maintenance Manual, "Engine Oil Level - Check" for the correct procedure.

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1. Install the electronic unit injectors. Refer to Disassembly and Assembly, "Electronic Unit Injector - Remove" for the correct procedure.

2. Install the rocker shaft and pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrods - Install" for the correct procedure.

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

4. Install the fuel manifold. Refer to Disassembly and Assembly, "Fuel Manifold (rail) - Remove and Install" for the correct procedure.

5. Install the mounting bracket for the electronic control module. Refer to Disassembly and Assembly, "E.C.M. Mounting Bracket - Remove and Install" for the correct procedure.

6. If necessary, install the fuel filter base and the secondary fuel filter. Refer to Disassembly and Assembly, "Fuel Filter Base - Remove and Install" for the correct procedure.

7. If necessary, install the water separator and fuel filter (Primary). Refer to Disassembly and Assembly, "Water Separator and Fuel Filter (Primary) - Remove and Install" for the correct procedure.

8. Install the exhaust manifold. Refer to Disassembly and Assembly, "Exhaust Manifold and Turbocharger - Install" for the correct procedure.