C4.4 Marine Generator Set Caterpillar

Removal Procedure

Start By:

1. Remove the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install" for the correct procedure.

Note: Either Tooling (A) can be used. Use the Tooling that is most suitable.

1. Use Tooling (A) in order to rotate the crankshaft in a clockwise direction and position the crankshaft the safe position. Refer to System Operation, Testing and Adjusting, "Position the Valve Mechanism Before Maintenance Procedures" for the correct procedure.
   Show/hide table

   Illustration 1	g03731599

2. Use Tooling (B) in order to loosen threaded inserts (2) on all rocker arms (1). Unscrew threaded inserts (2) on all rocker arms (1) until all valves are fully closed.

   Note: Ensure that ALL threaded inserts are fully unscrewed.

   Show/hide table

   Illustration 2	g03731602

   Show/hide table

   Illustration 3	g03731603

   Show/hide table

   Illustration 4	g03731604
   Sequence for tightening the bolts for the rocker shaft assembly

3. Use Tooling (C) to loosen Torx screws (4) in the reverse numerical order to the tightening sequence. Refer to the Illustration 4.

4. Loosen Torx screws (4) sufficiently in order to allow removal of rocker shaft assembly (5).

   Note: Note Position (X) of different length Torx screws (4).

5. Remove rocker shaft assembly (5) from the cylinder head. Ensure that rocker shaft assembly (5) does not come into contact with the electronic unit injector identification tag (7).

6. Place an identification mark on pushrods (6) in order to show the location. Remove the pushrods from the cylinder head.

   Note: Identification will ensure that the pushrods can be reinstalled in the original positions. Do not interchange the positions of used pushrods.

7. Make a temporary mark on valve bridges (3) in order to show the location and the orientation. Remove the valve bridges from the cylinder head.

   Note: Identification will ensure that the valve bridges can be reinstalled in the original location and the original orientation. Do not interchange the location or the orientation of used valve bridges.

Installation Procedure

Note: Either Tooling (A) can be used. Use the Tooling that is most suitable.

Show/hide table

Illustration 5	g03731605
The correct location of valve bridges on valve stems is shown.

1. Clean valve bridges (3). Inspect the valve bridges for wear and damage. Replace any valve bridges that are worn or damaged.

2. Lubricate valve bridges (3) with clean engine oil.
   Show/hide table

   NOTICE
   Failure to ensure that ALL valve bridges are correctly seated onto the valve stems will cause interference between the pistons and the valves, resulting in damage to the engine.

3. Install valve bridges (3) to the valve stems.

   Note: Install used valve bridges in the original location and in the original orientation. Ensure that the valve bridges are correctly seated on the valves. New valve bridges may be installed in either orientation.

   Show/hide table

   Illustration 6	g03731606

4. Clean pushrods (6). Inspect the pushrods for wear and damage. Replace any pushrods that are worn or damaged.

5. Apply clean engine oil to both ends of pushrods (6). Install the pushrods to the engine with the cup upward.

   Note: Ensure that the pushrods are installed in the original location and that the ball end of each pushrod is correctly seated in the valve lifters.

   Show/hide table

   NOTICE
   Failure to ensure that the crankshaft is set in the safe position will result in interference between the pistons and the valves. Interference between the pistons and the valves will result in damage to the engine.

6. Use Tooling (A) in order to rotate the crankshaft in a clockwise direction and position the crankshaft at the safe position. Refer to System Operation, Testing and Adjusting, "Position the Valve Mechanism Before Maintenance Procedures" for the correct procedure.
   Show/hide table

   Illustration 7	g03731607

   Show/hide table

   Illustration 8	g02623177

7. Ensure that the rocker shaft assembly is clean and free from wear and damage.

8. Position the rocker shaft assembly with Spotfaces (Z) for Torx screws (4) in the up ward position.

9. Install Tooling (D) to rocker shaft assembly.

10. Install Torx screws (4) in the rocker shaft in Positions (Y).

    Note: Ensure that the correct Torx screw (4) is installed to Position (X).

    Show/hide table

    Illustration 9	g03731608

    Show/hide table

    Illustration 10	g03731602

    Show/hide table

    Illustration 11	g03731604
    Sequence for tightening the bolts for the rocker shaft assembly

11. Ensure that ALL threaded inserts are fully unscrewed.

12. Position rocker shaft assembly (5) onto the cylinder head. The retaining clip (8) should face the front of the engine. Ensure that the rocker shaft assembly (5) does not come into contact with the electronic unit injector identification tag (7).

    Note: Ensure that the threaded inserts are correctly seated in ends of the pushrods.

13. Use Tooling (C) in order to tighten Torx screws (4).

14. Remove Tooling (D) from rocker shaft assembly. Install remaining Torx screws (4). Use Tooling (C) in order to tighten the remaining Torx screws (4).

15. Tighten Torx screws (4) to a torque of 35 N·m (26 lb ft) in the numerical sequence. Refer to Illustration 11.

16. Ensure that valve bridges (3) are still located correctly on the valve stems.
    Show/hide table

    Illustration 12	g03731599

17. Use Tooling (B) in order to tighten threaded inserts (2) on all the rocker arms. Tighten the threaded inserts to a torque of 30 N·m (265 lb in).

    Note: When the threaded insert is tightened, the threaded insert must be seated correctly in the cup for the pushrod.

18. The engine should not be operated for a period 30 minutes after the threaded inserts on all the rocker arms have been tightened. This period will allow the force of the valve springs to purge off excessive engine oil from the hydraulic lifters.

End By:

1. Install the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install" for the correct procedure.