C7.1 Marine 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	g03362268

3. Inspect dowels (11) for damage. If necessary, replace the dowels in the cylinder block.

4. Align a new cylinder head gasket (12) with dowels (11). Install new cylinder head gasket (12) 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 (11).

8. Remove Tooling (B).
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   Illustration 2	g03362267

9. Clean bolts (9). 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 (9) with clean engine oil.
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    Illustration 3	g03362264

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    Illustration 4	g02007814

11. Install bolts (9) to cylinder head (10).

12. Tighten bolts (9) 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 turn the bolts through an additional 225 degrees in the numerical sequence that is shown in Illustration 4.

    Note: Inspect and replace O-ring seals as necessary.

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    Illustration 5	g03362051

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    Illustration 6	g03361979

15. Install line (8). Install bolts (6) and (7).
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    Illustration 7	g03361978

16. Install hose (4). Tighten clamps (5).
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    Illustration 8	g03361977

17. Install bypass tube (2) and install bolts (3).
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    Illustration 9	g03361976

18. Position harness assembly (1) to cylinder head. Connect the electrical connectors and install the cable straps that attach the harness assembly (1) to the cylinder head.

19. 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.

2. Install the rocker shaft and pushrods.

3. Install the crankcase breather.

4. Install the air cleaner housing.

5. Install the exhaust manifold.

6. Install the fuel manifold (rail).

7. Install the expansion tank.

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