G3600 A4 Engines Caterpillar

Cylinder Head, Valves, Valve Springs and Valve Seat Inserts

Usage:

G3612 BB2

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Illustration 1	g03820943

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Table 1
Specification for 383-1760 Cylinder Head Gp
Item	Qty	Part	Specification Description
1	4	-	Use the following procedure in order to install cylinder studs: Before assembly, protect the stud threads, nuts, and top surface of washers from paint. 1. Assemble seals, gasket, and washers to cylinder head. Tighten nuts by hand. 2. Simultaneously tension each set of cylinder head studs with 8T-0895 Stud Tensioner Cylinder Gp at 40000 ± 1500 kPa (5802 ± 217 psi). 3. Tighten nuts by hand and slowly release the pressure. 4. Repeat Step 2 and Step 3. 5. After assembly, ensure stud load to be 823 kN (185019 lb).

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Illustration 2	g03820945

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Table 2
Item	Qty	Part	Specification Description
2	2	328-7496 Exhaust Valve	Before assembly, coat valve stem and inside diameter of stem seal with 8T-2998 Lubricant. Diameter of valve head is 90.00 ± 0.20 mm (3.543 ± 0.008 inch). Face angle is 20.25 ± 0.01 degrees. Diameter of valve stem is 15.977 ± 0.010 mm (0.6290 ± 0.0004 inch).
3	2	4P-2854 Inlet Valve	Before assembly, coat valve stem and inside diameter of stem seal with 8T-2998 Lubricant. Diameter (E) of valve head is 90.00 ± 0.20 mm (3.543 ± 0.008 inch). Face angle is 20.25 ± 0.01 degrees. Diameter (D) of valve stem is 15.980 ± 0.007 mm (0.6291 ± 0.0003 inch).
4	4	1W-1748 Spring	Length under test force is 84.9 mm (3.34 inch). Test force is 758 ± 76 N (170 ± 17 lb). Free length after test is 114.0 mm (4.49 inch).
5	4	1W-1749 Spring	Length under test force is 79.3 mm (3.12 inch). Test force is 361 ± 36 N (80 ± 8 lb). Free length after test is 107.0 mm (4.21 inch).
6	4	175-6344 Valve Guide	Before assembly, lubricate bores with 8T-2998 Lubricant. Assembled height (C) of valve guides is 20.0 ± 2.0 mm (0.79 ± 0.08 inch). After assembly, inside diameter (D) is 16.031 ± 0.028 mm (0.6311 ± 0.0011 inch).
A	2	6V-3538 Dowel	Assembled height of rocker arm support dowel is 8.0 ± 1.0 mm (0.32 ± 0.04 inch).
B	2	4W-5441 Bridge Guide Dowel	Assembled height of bridge dowel is 105.0 ± 2.0 mm (4.13 ± 0.08 inch).

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Illustration 3	g03820950

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Table 3
Item	Qty	Part	Specification Description
7	2	171-3993 Valve Seat Insert	Diameter (F) is 97.215 ± 0.015 mm (3.8273 ± 0.0006 inch). Face angle is 20 ± 1 degrees. Bore in head for valve seat inserts is 97.000 ± 0.025 mm (3.8189 ± 0.0010 inch).
8	2	171-3992 Valve Seat Insert	Diameter (G) is 97.195 ± 0.015 mm (3.8266 ± 0.0006 inch). Face angle is 20 ± 1 degrees. Bore in head for valve seat inserts is 97.000 ± 0.025 mm (3.8189 ± 0.0010 inch).
H	-	-	Depth of bore for valve seat insert in the cylinder head is 24.00 ± 0.15 mm (0.945 ± 0.006 inch).
J	-	-	The minimum valve lip thickness that can be used again is 7.44 ± 0.20 mm (0.293 ± 0.008 inch).

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Illustration 4	g03820954

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Table 4
Item	Qty	Part	Specification Description
9	2	6V-5061 O-Ring Seal	Before assembly, lubricate bores with rubber lubricant.
10	2	8t-6759 Pipe Plug	Before assembly, apply bores for the plugs with red Loctite 263. The passage must withstand 400 kPa (58 psi) of air pressure.
11	1	229-8567 Insert	Before assembly, coat cylinder head bores, surfaces, and threads with green Loctite 620. The assembly must withstand 300 kPa (43.51200 psi) of water pressure.
12	4	7C-4298 Cup Plug	Before assembly, apply bores for cup plugs with Loctite Low Viscosity Core Plug Adhesive.

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