C0.5, C0.7, C1.1/3011C, C1.5/3013C, C1.6 and C2.2/3024C/3024CT Industrial Engines and Engines for Caterpillar Built Machines Caterpillar

Illustration 1	g06221869
Type One cylinder head bolts

Illustration 2	g06220283
Type Two cylinder head bolts

Installation Procedure for Type One Cylinder Head Bolts

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 mating surface of the cylinder head is distorted beyond maximum permitted limits, replace the cylinder head.
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   Illustration 3	g01317467
   Typical example

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   Illustration 4	g01317471
   Typical example

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   Illustration 5	g06221686
   Typical example

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

4. Install Tooling (A) to the cylinder block. Refer to Illustration 3.

5. Ensure that the new cylinder head gasket (4) is the same thickness as the cylinder head gasket that was previously removed. The thickness of the cylinder head gasket is indicated by the number that is shown at Position (X). Refer to Specifications, "Cylinder Head" for more information.

6. Align cylinder head gasket (4) with Tooling (A) and with dowels (3). Install the cylinder head gasket onto the cylinder block.

7. Use a suitable lifting device to lift the cylinder head. The weight of the cylinder head is approximately 30 kg (66 lb).

8. Use Tooling (A) to align cylinder head (2) with the cylinder block. Install the cylinder head to the cylinder block.

   Note: Ensure that the cylinder head is correctly positioned onto dowels (3).

9. Remove Tooling (A).
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   Illustration 6	g06221780
   Inspection of Type One cylinder head bolts

10. Clean Type One bolts (1). Follow Step 10.a through 10.b to inspect the Type One bolts.

    1. Check the length of Type One bolts (1).

    2. Use Tooling (B) to check the threads of bolts (1). Refer to Illustration 6. If any Type One bolts show visual reduction in the diameter of the thread over Length (Y), replace the bolts with a new set of Type Two bolts. If Type One bolts are replaced with a new set of Type Two bolts, refer to the installation procedure for Type Two bolts.

11. Install bolts (1) to cylinder head (2).
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    Illustration 7	g01317351
    The tightening sequence for a three cylinder engine

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    Illustration 8	g01309552
    The tightening sequence for a four cylinder engine

12. For three cylinder engines, tighten the bolts to a torque of 101 N·m (75 lb ft). Use the numerical sequence that is shown in Illustration 7.

13. For four cylinder engines, tighten the bolts to a torque of 101 N·m (75 lb ft). Use the numerical sequence that is shown in Illustration 8.

14. If necessary, install the water temperature regulator to the cylinder head. Refer to Disassembly and Assembly, "Water Temperature Regulator- Remove and Install".

End By:

1. Install the water pump. Refer to Disassembly and Assembly, "Water Pump - Install".

2. Install the rocker shaft and the pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod - Install".

3. Install the glow plugs. Refer to Disassembly and Assembly, "Glow Plugs - Remove and Install".

4. Install the fuel injectors. Refer to Disassembly and Assembly, "Fuel Injector - Install".

5. Install the fuel filter base. Refer to Disassembly and Assembly, "Fuel filter Base - Remove and Install".

6. Install the exhaust manifold. Refer to Disassembly and Assembly, "Exhaust Manifold - Remove and Install".

Installation Procedure for Type Two Cylinder Head Bolts

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 mating surface of the cylinder head is distorted beyond maximum permitted limits, replace the cylinder head.
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   Illustration 9	g01317467
   Typical example

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   Illustration 10	g01317471
   Typical example

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   Illustration 11	g06221686
   Typical example

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

4. Install Tooling (A) to the cylinder block. Refer to Illustration 9.

5. Ensure that the new cylinder head gasket (4) is the same thickness as the cylinder head gasket that was previously removed. The thickness of the cylinder head gasket is indicated by the number that is shown at Position (X). Refer to Specifications, "Cylinder Head" for more information.

6. Align cylinder head gasket (4) with Tooling (A) and with dowels (3). Install the cylinder head gasket onto the cylinder block.

7. Use a suitable lifting device to lift the cylinder head. The weight of the cylinder head is approximately 30 kg (66 lb).

8. Use Tooling (A) to align cylinder head (2) with the cylinder block. Install the cylinder head to the cylinder block.

   Note: Ensure that the cylinder head is correctly positioned onto dowels (3).

9. Remove Tooling (A).

10. Install new bolts (1) to cylinder head (2).
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    Illustration 12	g06221839
    The tightening sequence for a three cylinder engine

11. For three cylinder engines, tighten the bolts to a torque of 50 N·m (37 lb ft). Use the numerical sequence that is shown in Illustration 12. Use Tooling (B) to turn the bolts a further 150 degrees in the numerical sequence as shown in Illustration 12.
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    Illustration 13	g06221890
    The tightening sequence for a four cylinder engine

12. For four cylinder engines, tighten the bolts to a torque of 50 N·m (37 lb ft). Use the numerical sequence that is shown in Illustration 13. Use Tooling (B) to turn the bolts a further 150 degrees in the numerical sequence as shown in Illustration 13.

13. If necessary, install the water temperature regulator to the cylinder head. Refer to Disassembly and Assembly, "Water Temperature Regulator- Remove and Install".

End By:

1. Install the water pump. Refer to Disassembly and Assembly, "Water Pump - Install".

2. Install the rocker shaft and the pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod - Install".

3. Install the glow plugs. Refer to Disassembly and Assembly, "Glow Plugs - Remove and Install".

4. Install the fuel injectors. Refer to Disassembly and Assembly, "Fuel Injector - Install".

5. Install the fuel filter base. Refer to Disassembly and Assembly, "Fuel filter Base - Remove and Install".

6. Install the exhaust manifold. Refer to Disassembly and Assembly, "Exhaust Manifold - Remove and Install".