Valve Cover Base Threaded Insert Repair {0599, 0676, 0700, 0701, 1107} Caterpillar

Caterpillar Products

All C27 Engines

All C32 Engines

Introduction

© 2018 Caterpillar® All Rights Reserved. This guideline is for the use of Cat dealers only. Unauthorized use of this document or the proprietary processes therein without permission may be violation of intellectual property law.

Information contained in this document is considered Caterpillar: Confidential Yellow.

This Reuse and Salvage Guideline contains the necessary information to allow a dealer to establish a parts reusability program. Reuse and salvage information enables Caterpillar dealers and customers to benefit from cost reductions. Every effort has been made to provide the most current information that is known to Caterpillar. Continuing improvement and advancement of product design might have caused changes to your product which are not included in this publication. This Reuse and Salvage Guideline must be used with the latest technical information that is available from Caterpillar.

For technical questions when using this document, work with your Dealer Technical Communicator (TC).

To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System (SIS Web) interface.

Canceled Part Numbers and Replaced Part Numbers

This document may not include canceled part numbers and replaced part numbers. Use NPR on SIS for information about canceled part numbers and replaced part numbers. NPR will provide the current part numbers for replaced parts.

Important Safety Information

Illustration 1	g02139237

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly. Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar is used, ensure that it is safe for you and for other people to use. Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the safety alert symbol which is followed by a signal word such as danger, warning, or caution. The "WARNING" safety alert symbol is shown below.

Illustration 2	g00008666

This safety alert symbol means:

Pay attention!

Become alert!

Your safety is involved.

The message that appears under the safety alert symbol explains the hazard.

Operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The safety information in this document and the safety information on the machine are not all inclusive. Determine that the tools, procedures, work methods, and operating techniques are safe. Determine that the operation, lubrication, maintenance, and repair procedures will not damage the machine. Also, you must determine that the operation, lubrication, maintenance, and repair procedures will not make the machine unsafe.

The information, the specifications, and the illustrations that exist in this guideline are based on information which was available at the time of publication. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete, most current information before you start any job. Caterpillar dealers can supply the most current information.

Summary

Do not perform any procedure in this Reuse and Salvage Guideline until you read this information and you understand this information. On certain C27 and C32 engines the threads in the valve cover base can become damaged. The damaged threads will cause the valve covers to not properly seal and leak oil.

Service Letters and Technical Information Bulletins

References

Tooling and Equipment

Replacement Parts

Consult the applicable Parts Identification manual for your engine.

Measurement Requirements

Visual Inspection

Illustration 3	g03733478
Potential affected holes.

Clean the valve cover base and inspect the valve cover bolt threads individually. Look for any damaged threads. If any damaged threads are found, then salvage machining will be necessary.

Threaded Insert Repair

The salvage machining procedure will include removing the existing threads, counterboring the valve cover base, tapping new threads and installing a threaded insert.

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Illustration 4	g06382284
(A) 2.00 mm (0.08 inch) (B) 13.00 mm (0.51 inch) (C) 10.50 mm (0.41 inch) (D) 19.00 mm (0.75 inch)

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Illustration 5	g03733785
Removing existing threads.

1. Remove damaged threads.

   • Refer to Illustration 4 for dimensional guidance.

   • Keep drill square to surface of the hole. Use cutting oil and remove old threads with a 1U-5614 Drill Bit (29/64"). Drill approximately 19 mm (0.75 inch) deep into the base.
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   Illustration 6	g03734018
   Cutting the counterbore

2. Counterbore the hole.

   • Refer to Illustration 4 for dimensional guidance.

   • Use cutting oil and a standard 13.00 mm (0.50 inch) countersink tool with an angle from 82 to 100 degrees. Drill approximately 2.00 mm (0.08 inch) deep into the bore.
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   Illustration 7	g03734028
   Cutting new insert threads.

3. Cut new insert threads.

   • Use cutting oil and a 1P-3029 Plug Tap to cut new threads into the valve cover base.

   • Use compressed air and carefully clean the bore free of any remaining chips.
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   Illustration 8	g06382288
   (1) Driver Insert Tool (2) Insert

4. Insert Driver

   • Oil the bottom threads of the driver tool and screw an insert onto the driver. Thread the insert into the prepared bore.

   • As the flange of the insert is seated into the counterbore, the driver and insert connection will tighten. Use slightly more power and the insert will loosen.

   • Remove the driver.
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   Illustration 9	g03734040

5. Inspect the finished bore for any potential defects.