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	g02216033

3. Inspect dowels (31) for damage. If necessary, replace the dowels in the cylinder block.

4. Align a new cylinder head gasket (32) with dowels (31). Install the new cylinder head gasket (32) 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 (31).

8. Remove Tooling (B).

9. Lubricate the threads and the shoulder of bolts (29) with clean engine oil.

   Note: Bolts (29) should be replaced with new.

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   Illustration 2	g02206215

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   Illustration 3	g03417152

10. Install bolts (29) to cylinder head (30).

11. Tighten the bolts to a torque of 50 N·m (37 lb ft) in the numerical sequence that is shown in Illustration 3.

12. Tighten the bolts to a torque of 100 N·m (74 lb ft) in the numerical sequence that is shown in Illustration 3.

13. Use Tooling (C) to turn the bolts through an extra 225 degrees in the numerical sequence that is shown in Illustration 3.
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    Illustration 4	g02206214

14. Use Tooling (D) to lubricate the O-ring seals. Install new O-ring seal (27) and O-ring seal (28) to bypass tube (25). Install the bypass tube in the cylinder head. Install bolts (24). Tighten the bolts to a torque of 9 N·m (80 lb in).

15. Follow Step 15.a through Step 15.c to connect harness assembly (22) to coolant temperature sensor (23).

    1. Connect harness assembly (22) to coolant temperature sensor (23).

    2. Slide locking tab (21) into the locked position.

    3. Position harness assembly (22) onto the bypass tube and install a new cable strap (26).
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    Illustration 5	g02206213

16. Remove the plugs and caps from the ports and tube assembly.

17. Use Tooling (C) to lubricate new O-ring seals (17) (not shown). Install the O-ring seal to tube assembly (18) for the fuel return from the cylinder head.

18. Install tube assembly (18) to the cylinder head.

19. Install bolt (16) finger tight.

20. Install bolt (20) to tube clip (19) finger tight.

21. Tighten bolt (16) and bolt (20) to a torque of 22 N·m (195 lb in).
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    Illustration 6	g02206194

22. Follow Step 22.a through Step 22.b to connect harness assembly (11) to inlet air temperature sensor (10).

    1. Connect harness assembly (11) to inlet air temperature sensor (10).

    2. Slide locking tab (12) into the locked position.

23. Follow Step 23.a through Step 23.b to connect harness assembly (15) to boost pressure sensor (13).

    1. Connect harness assembly (15) to boost pressure sensor (13).

    2. Slide locking tab (14) into the locked position.

24. Position the harness assembly onto the cylinder head. Use new cable straps to secure the harness assembly to the cylinder head. Ensure that the harness assembly is not strained.

    Note: Ensure that the harness assembly is clear of other engine components.

25. On some applications there is an engine wiring harness support bracket on the rear of the cylinder head. If necessary, install the support bracket for the engine wiring harness to the cylinder head assembly. Use new cable straps to secure the engine harness assembly to the support bracket.
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    Illustration 7	g02005213
    Typical example

26. If necessary, install water temperature regulator housing (1) to the cylinder head. Refer to Disassembly and Assembly, "Water Temperature Regulator Housing - Remove and Install" for the correct procedure.

End By:

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

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

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

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

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

6. If necessary, install 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.

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