C7.1 Marine Engine Caterpillar

Removal Procedure

Start By:

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

2. If necessary, remove 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.

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

4. Remove the crankcase breather canister and plastic tube assemblies. Refer to Disassembly and Assembly, "Crankcase Breather - Remove" for the correct procedure.

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

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

7. Remove the mounting bracket for the electronic control module. Refer to Disassembly and Assembly, "ECM Mounting Bracket - Remove and Install" for the correct procedure.

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

1. Drain the coolant from the cooling system into a suitable container for storage or for disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct draining procedure.
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   Illustration 1	g02005213

2. Disconnect the upper radiator hose from water temperature regulator housing (1) on the cylinder head.
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   Illustration 2	g02206193

3. Remove plastic tube assembly (2), plastic tube assembly (3), and plastic tube assembly (7) from clips (9).

4. Cut all cable straps (5) from engine wiring harness assembly (6). Position engine wiring harness assembly away from the engine.

   Note: Ensure that all cable straps are removed from the engine wiring harness.

5. Remove bolts (8) and remove bracket (4) from the cylinder head.
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   Illustration 3	g02206194

6. Follow Step 6.a through Step 6.b to disconnect harness assembly (15) from boost pressure sensor (13).

   1. Slide locking tab (14) into the unlocked position.

   2. Disconnect harness assembly (15) from boost pressure sensor (13).

7. Follow Step 7.a through Step 7.b to disconnect harness assembly (11) from inlet air temperature sensor (10).

   1. Slide locking tab (12) into the unlocked position.

   2. Disconnect harness assembly (11) from inlet air temperature sensor (10).

8. Remove all cable straps that secure the harness assembly to the cylinder head. The harness assembly should be positioned away from the cylinder head to avoid causing an obstruction during the removal of the cylinder head.

9. On some application there is an engine wiring harness support bracket on the rear of the cylinder head. if necessary, cut the cable straps and remove the engine wiring harness from the support bracket. Remove the support bracket from the cylinder head before removal the cylinder head assembly.
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   Illustration 4	g02206213

10. Remove bolt (16) from tube assembly (18). Remove bolt (20) from tube clip (19).

11. Remove tube assembly (18) from the cylinder head. Remove O-ring seal (17) (not shown) from the tube assembly. Plug the port in the cylinder head with a new plug. Cap the tube assembly with new cap.
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    Illustration 5	g02206214

12. Follow Step 12.a through Step 12.c to disconnect harness assembly (22) from coolant temperature sensor (23).

    1. Slide locking tab (21) into the unlocked position.

    2. Disconnect harness assembly (22) from coolant temperature sensor (23).

    3. Cut cable strap (26) and remove harness assembly (22) from bypass tube (25).

13. Remove bolts (24).

14. Remove bypass tube (25) from the cylinder head. Remove O-ring seal (27) and O-ring seal (28) from bypass tube (25).
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    Illustration 6	g02206215

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    Illustration 7	g03417150
    Sequence for loosening the bolts for the cylinder head

15. Gradually loosen bolts (29) in the reverse numerical order to the tightening sequence. Refer to the Illustration 7.

    Note: Follow the correct sequence to help prevent distortion of the cylinder head.

16. Remove bolts (29) from cylinder head (30).

17. Attach a suitable lifting device to cylinder head (30). Support the weight of the 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.

18. Use the suitable lifting device to lift cylinder head (30) off the cylinder block.

    Note: Do not use a lever to separate the cylinder head from the cylinder block. Take care not to damage the machined surfaces of the cylinder head during the removal procedure.

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    NOTICE
    Place the cylinder head on a surface that will not scratch the face of the cylinder head.

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    Illustration 8	g02206217

19. Remove cylinder head gasket (32).

20. Note the position of dowels (31) in the cylinder block.

21. If necessary, remove the water temperature regulator from the cylinder head. Refer to Disassembly and Assembly, "Water Temperature Regulator - Remove and Install" for the correct procedure.