Reuse and Salvage for Cylinder Head Assemblies {1100, 1101, 1103, 1104, 1105, 1106, 1108, 1109, 1115, 1117, 1121, 1124, 1125} Caterpillar

Caterpillar Products

All Cat Engines

Introduction

Table 1

Revision	Summary of Changes in SEBF8162
39	Added C4.4 fuel galley plug installation.
38	Added Rottler information.
37	Combined information from SEBF2119, SEBF8061, SEBF8106, SEBF8129, SEBF8155, SEBF8218, SEBF8229, SEBF8270, SEBF8281, SEBF8373, SEBF8374, SEBF8375, SEBF8376, SEBF8382, SEBF8737, SEBF8819, SEBF9006, SEBF9045, SEBF9137, SEBF9182, SEBF9193, SEBF9237, SEBF9313, added 61 part numbers and repaired 66 pixelated illustrations.

© 2019 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.

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Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.

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

This guideline gives the measurements and salvage specifications for the inspection of a used or reconditioned cylinder head that can be used again. It also contains information to rebuild a cylinder head. Two suggested layouts for the area of rebuild for cylinder heads and a flow chart is provided to illustrate the recommended steps in the process for the rebuild.

If a cylinder head meets the specifications in this guideline and other applicable guidelines, then the head assembly can be expected to give normal performance in the same application until the next overhaul.

Before reusing a cylinder head, check for leaks, cracks, and flatness. All cylinder head components must meet the recommended specifications in the guideline before being reused.

This guideline should be used with the specific guidelines that are listed in the Reference section.

When the cylinder head will not be inspected within 1 hour, the cylinder head should be coated with a rust or corrosion inhibitor or coated with clean engine oil.

Note: This guideline covers the inspection of valve seats and replacing the valve seats. Some valve seats cannot be machined. Refer to Table 59 to determine if a valve seat can be machined. Specialized manufacturing processes were used on these parts. Machining these parts will significantly decrease the life of the engine.

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NOTICE
The valve projection and recession specifications within this guideline are for measurement of wear from newly manufactured cylinder heads. Due to the multiple machining steps and compounding of tolerances in rebuilt cylinder heads, some rebuilt heads (REMAN or dealership rebuilds) may not meet the valve projection and recession specifications found within this document.

Service Letters and Technical Information Bulletins

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NOTICE
The most recent Service Letters and Technical Information Bulletins that are related to this component shall be reviewed before beginning work. Often Service Letters and Technical Information Bulletins contain upgrades in repair procedures, parts, and safety information that pertain to the parts or components being repaired.

References

Table 2

References
NEHS0675	Tool Operating Manual, "Using the 143-2099 Sleeve Replacement Tool Group on 3114, 3116, and 3126 Engines"
, NEHS0787	Tool Operating Manual, "188-3922 Broken Exhaust Bolt and Stud Removal Group for 3114, 3116, 3126, 3126B, 3176, 3176B, C-10, and C12 Engines"
, SEBD1757	Service Magazine, "Cylinder Head Water Directors No Longer Needed In Direct Injection Engines "
, SEBF8002	Reuse and Salvage, "Reuse & Salvage for Valvetrain Components"
SEBF8148	Reuse and Salvage Guideline, "General Salvage and Reconditioning Techniques"
, SEBF8187	Reuse and Salvage, "Standardized Parts Marking Procedures"
, SEBF8301	Reuse and Salvage, "Inspection and Reuse of Critical Fasteners Used in All Engines"
, SEBF8302	Reuse and Salvage, "Reuse Specifications for 3600 Combustion Gaskets"
, SEBF8882	Reuse and Salvage, "Using Lock-N-Stitch Procedures for Casting Repair"
, SEHS9031	Special Instructions, "Storage Procedure for Caterpillar Products"
, SEHS9120	Special Instructions, "Using the 4C-4462 Sleeve Replacement Tool"
, SEHS9246	Special Instructions, "Using 9U-6860 Tool Group to Replace Unit Injector Sleeves"
, SEHS9416	Special Instructions, "Using the 6V-7770 Valve Guide Kit and 6V-7755 Spring Seat Guide"
, SEHS9498	Special Instructions, "Using the 9U-5383 Vacuum Tester"
, SMHS6998	Special Instructions, "Instructions For The Use Of 5P-6518 Fixture Group - Parts Reusability"
, SMHS7072	Special Instructions, "Use of 6V-4805 Valve Seat Extractor Tool Group"
, SMHS7935	Special Instructions, "Using 5P-0733 Tool Group for Bridge Dowel Repair - 3400 Engines"
, SMHS8276	Special Instructions, "Reuse & Salvage for Valvetrain Components"
, SMHS8277	Special Instructions, "Use of 6V-7770 Tool Kit and 6V-7755 Adapter"
, SMHS8297	Special Instructions, "Use Of 6V-9050 Exhaust Stud Removal Group"

Tooling and Equipment

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NOTICE
Failure to follow the recommended procedure or the specified tooling that is required for the procedure could result in damage to components. To avoid component damage, follow the recommended procedure using the recommended tools.

Table 3

Tooling and Equipment
Part Number	Description
1D-4720	Nut 5/8-11 NC
1P-0510	Driver
1P-1855	Retaining Ring Pliers
1P-3042	Tap
1S-0258	Hammer (soft tip)
1U-5230	Hand Pump
1U-6685	Valve Guide and Seat Tool Group
1U-8869	Dial Indicator
1U-9168	Valve Guide Collar
1U-9169	Valve Guide Driver
1U-9170	Valve Seat Driver
3P-1565	Collet Clamp
3P-1568	Dial Indicator
4C-3845	Grinding Wheel
4C-4462	Repair Tool Group
4C-5552	Large Bore Brush
4C-5590	Anti-Seize Compound
4C-5593	Anti-Seize Compound
4C-4707	Dial Gauge
4C-4709	Grinding Wheel
4C-4710	Pilot Wrench
4C-4711	Diamond Dresser
4C-4804	Penetrant Oil
4C-8624	Mandrel
4C-8629	Mandrel
4C-8719	Shank
4C-8769	Valve Seat Driver
4C-9442	Flashlight
4C-9507	Retaining Compound
4C-9734	Valve Guide Gauge
5P-1729	Valve Guide Bushing
5P-2396	Bushing
5P-3413	Pipe Sealant
5P-3536	Valve Guide Gauge
5P-4156	Indicator Base
5P-4160	Indicator Contact Point
5P-6518	Dial indicator Fixture
5P-7324	Plug
5P-7333	Repair Tool
5P-8400	Lifting Bracket
5P-8700	Lifting Bracket
5P-9718	Holder 178.0 mm (7.00 inch)
5P-9709	Abrasive Disc 127.0 mm (5.00 inch)
5S-1330	Valve Spring Compressor
6V-0087	Valve Stem Gauge Group
6V-2010	Polishing Stone
6V-2012	Micrometer Depth Gauge
6V-2032	Adapter
6V-2033	Brush
6V-2034	Micrometer Adapter
6V-4197	Grinder Base
6V-4198	Grinder
6V-4801	Dressing Stone
6V-4802	Grinding Wheel
6V-4805	Valve Seat Extractor Tool
6V-4876	Lubricant
6V-6640	Sealant
6V-7047	Hydraulic Cylinder
6V-7058	Plug Gauge
6V-7059	Micrometer
6V-7068	Valve Guide Gauge
6V-7097	Valve Guide Gauge
6V-7098	Valve Guide Gauge
6V-7926	Dial Indicator
6V-9050	Stud Removal Group
7B-0337	Surface Plate
7M-3975	Valve Guide Driver
8C-8422	Sealant
8H-8581	Feeler Gauge
8S-3158	Feeler Gauge
8S-2257	Eye Loupe
8S-3158	Indicator Gauge
8T-2674	Valve Seat Driver
8T-2676	Valve Guide Driver
8T-2781	Valve Guide Support Pedestal
8T-2998	Lubricant
8T-3096	Hand Tap
8T-5096	Dial Indicator Group
9S-3263	Thread Lock Compound
9S-9087	Tool Cabinet
9U-5096	Bridge Assembly
9U-5099	Seat Puller Group
9U-5383	Vacuum Tester
9U-6895	Valve Guide Driver
9U-6399	Valve Guide Installation Gauge
9U-6401	Valve Guide Wear Gauge
9U-6460	Guide Collar
9U-6860	Injector Sleeve Tool
9U-6891	Injector Tool Group
9U-6894	Guide Collar
9U-6895	Valve Guide Driver
9U-6897	Valve Seat Driver
9U-6898	Valve Seat Driver
9U-7237	Brush Extension
9U-7244	End Brush
124-2946	Lifting Bracket As
124-9057	Guide Collar
130-1449	Valve Seat Puller
131-8362	Reamer
134-5506	Pilot
134-5507	Pilot
134-5508	Pilot
138-7573	Link Bracket
138-7575	Link Bracket
143-2099	Sleeve Replacement Tool Group
147-1642	Angle Gauge
147-1643	Angle Gauge
147-2285	Valve Gauge
151-0968	Cordless Drill
151-4832	Remover Assembly - Sleeve
151-8689	Seal Template
162-5791	Shop Towels
163-3951	Blast Media
166-7441	Valve Seat Extractor Tool
173-5524	Guide Collar
187-6273	Repair Tool
188-3922	Broken Exhaust Bolt and Stud Removal Tool
222-3061	Air Drill
222-3071	Angle Grinder
222-3074	Wheel Grinder
222-3121	Penetrating Oil
262-8390	Microscope, Pocket 40x
263-7184	Crack Detection Kit
283-0052	Valve Guide Driver
284-1503	Valve Guide Collar
288-4209	Paper Towel
316-1496	Hydraulic Cylinder
359-4208	Valve Insert Removal Tool
359-4286	Collet Assembly
359-4287	Drawbar
361-0074	Lower Side
362-4253	Depth Micrometer Kit
362-9108	Insert Tool-Valve Seat
364-3081	Installation Guide
366-5728	Valve Guide Driver
367-9109	Digital Caliper
384-2802	Pilot
384-2804	Indicator Gauge Group
386-3364	Straight Edge Ruler
415-4055	Ultrasonic Tool Group
420-5317	Suitable Cribbing
423-4373	Digital Caliper 0.0 - 203.2 mm (0.00 - 8.00 inch)
431-4150	Micrometer, External 25 mm (1 inch)
441-0714	Spring Tester
459-0184	UV Lamp Group
473-8690	Micrometer, Outside 0.00 - 4.00 inch
473-8691	Micrometer, Outside 2.00 - 6.00 inch
473-8691	Micrometer, Outside 50.8 - 152.4 mm (2.00 - 6.00 inch)
473-8692	Micrometer, Outside 152.4 - 304.8 mm (6.00 - 12.00 inch)
482-0188	Valve Guide Stop Collar
482-0189	Valve Guide Driver
482-0190	Valve Guide Finish Reamer
483-7533	Valve Guide Stop Collar
483-7534	Valve Guide Reamer
533-1152	Broken Exhaust Bolt and Stud Removal Plate (C6.6 Drill Guide)
533-1153	Broken Exhaust Bolt and Stud Removal Plate (C4.4 Drill Guide)
533-1155	Broken Exhaust Bolt and Stud Removal Tool Group (C7.1 Drill Guide)
FT-0806	Bench
FT-1656	Thickness Gauge
FT-1674	Plug Gauge
FT-1741	Valve Stem Protector
FT-1753	Vacuum Tester
FT-1766	Adapter
-	Plug Gauges
-	Hydraulic Press
-	Valve Guide Removal Tool
-	90° holding block with a collet
-	Loctite 242

Replacement Parts

Consult the applicable Parts Identification manual for your engine.

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When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength and material. Failure to heed this warning can lead to premature failures, product damage, personal injury or death.

Standardized Parts Marking Procedure

Reference: SEBF8187 Reuse and Salvage Guidelines, "Standardized Parts Marking Procedures".

The code is a Cat standard and is used to record the history of a component. The code will identify the number of rebuilds and hours at the time of each rebuild. This information is important and should be considered for any decision to reuse a component.

Ensure that the mark is not covered by a mating part. Use a metal marking pen to mark the code onto the component.

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NOTICE
Do not use numbering stamp punches to mark internal components. The impact from striking the stamp will cause an abnormal stress riser. The added stress riser may cause premature part failure.

Illustration 3	g06124077
DO NOT use numbering stamp punches to mark internal components.

The procedure for marking components is a Cat standard. This code is helpful when the machine is sold into a different territory after the first rebuild. During an overhaul, the previous code of a part should never be removed.

Example 1

Illustration 4	g03856853
Typical Example

Illustration 4 shows code (1-15). The first number (1) indicates that the gear had been rebuilt once. The second number (15) indicates that there were 15,000 hours on the gear at the time of rebuild.

Example 2

Illustration 5	g03856857
Typical Example

Illustration 5 shows code (1-12) and code (2-10). Code (2-10) represents the information from the second rebuild. The first number (2) indicates that the gear had been rebuilt twice. The second number (10) indicates that 10,000 hours accumulated on the gear between the first and second rebuild.

Note: Add the first and second rebuild hours to obtain the total number of hours for the gear in Illustration 5. In this example, the gear has a total of 22,000 hours.

Recommended Layouts for the Shop

A well designed shop area contributes to more efficient rebuilds. Two suggested layouts for the shop have been provided in this guideline. Choose the layout for rebuilding that best suits your needs.

The area for the rebuild should accommodate the staging of the parts while the cylinder head components are being processed. Enough space should be available to rebuild the cylinder head without any interference. The area should have access from a jib crane to provide an effective way of moving the components.

Illustration 6	g01271598

Illustration 7	g01271599

Flow Chart for the Rebuild

Illustration 8	g06277244

This flow chart provides a quick reference to the steps for rebuilding a cylinder head. For detailed information, refer to "Process for Rebuilding Cylinder Heads" section.

Process for Rebuilding Cylinder Heads

The area of the shop for disassembly should be located next to the general cleaning area. Locating the area for disassembly next to the cleaning area will reduce the effort in transporting the disassembled parts to the cleaning area. The area for disassembly and the area for cleaning should be separated from the area for the rebuild by a wall to prevent contamination to exposed parts.

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Illustration 9	g01271643
(1) Lifting bar is installed. (2) Tape covering the exhaust ports.

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Illustration 10	g01271645
Lifting bar is installed on a 3500 Engine.

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Illustration 11	g01271646
Specifications for the lifting bar for a 3500 Engine

1. Remove the cylinder head from the engine.

   Efficiency in the process for rebuilding a cylinder head begins with the removal of the head or heads from the engine. The cylinder heads can be removed in groups on engines with multiple cylinder heads such as the 3500 Series Engines if a lifting bar is fabricated. It is more efficient to remove multiple cylinder heads simultaneously instead of removing each head individually. Reconditioning cylinder heads in groups is more efficient than reconditioning cylinder heads individually.

   Remove the cylinder head with the exhaust manifolds, intake manifolds, and elbows to reduce the overall time of engine rebuild. The entire assembly can be disassembled and reconditioned while the engine is being reconditioned. This procedure will enable the reconditioning of the cylinder head assembly to be synchronized with the reconditioning of the engine so that all the parts can be ready for engine assembly at the same time.

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   NOTICE
   Prior to precleaning, remove or protect any component that could be damaged by the cleaning solution.

2. Clean the cylinder head.

   Use a hot spray wash cabinet to remove the dirt, oil, and grease from the cylinder head.

   The washer should have the option for automatic washing and the option for manual washing. Caustic solutions are effective for cleaning the ferrous parts. Do not use caustic solutions to clean the nonferrous parts. Soaps that are safe for aluminum should be used for these parts.

   The washer should contain a rotating table. The automatic cycle will wash most of the soap solution at the end of the cycle. The option for the manual wash is needed to manually wash the parts after the automatic wash is complete.

3. Inspect the cylinder head.

   Visually inspect the cylinder head for obvious defects that will cause the casting to be scrapped or replaced.

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   Illustration 12	g01271660
   (1) 9S-9087 Tool Cabinet (2) FT-0806 Bench

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   Illustration 13	g01271662
   Adjustable work bench for cylinder heads

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   Illustration 14	g01271663
   Adjustable work bench for cylinder heads that can be fabricated

4. Disassemble the cylinder head.

   Disassembly requires the removal of all components from the cylinder head casting. Refer to the specific Service Manual for the required tooling and procedures for this operation.

   The disassembly should be done on a work bench at a comfortable height. The work area must be large enough to accommodate cylinder heads when the cylinder heads are removed in groups. Make sure that the work area has enough space to disassemble the cylinder heads without interference.

   Use a work bench that enables the cylinder head to be rotated during the process of rebuild. The work bench for rebuilding cylinder heads should be equipped with air supply, racks for tooling, and cabinets for all required tooling and parts. 9S-9087 Tool Cabinet and FT-0806 Bench are recommended.

   Overhead lights and local lights are recommended. These lights provide enough source of light to visually inspect the cylinder head and components. Overhead lights and local lights prevent shaded areas. Fluorescent lights above the work bench also provide the necessary lighting for inspection of most of the components.

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   Illustration 15	g01276782

5. Remove the exhaust manifold gaskets.

   Abrasive buffing or blasting may be required to remove the exhaust manifold gaskets and the heavy carbon from the cylinder head. High temperatures make cleaning some areas of the cylinder head difficult. Cleaning these areas before washing often eliminates excess cycles in the washer and contamination of components later in the process of rebuild.

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   Illustration 16	g01271670
   Typical basket for cleaning small parts

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   Illustration 17	g01271671
   Typical basket for cleaning small parts

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   Illustration 18	g01271672
   Typical basket for cleaning small parts that can be used in a high-pressure wash

6. Separate the parts into wire baskets that can be put into a hot spray wash cabinet or a tank of solvent as the cylinder head is disassembled.

   These baskets can be used in high pressure cleaning systems or low pressure cleaning systems. Choose a basket that fits the application.

   The most effective baskets allow each part to have the direct impact of the cleaning solution. Direct impact of the cleaning solution eliminates a second cycle of cleaning. Baskets should be transported with a crane rather than a lift truck to reduce time of transport, labor, and space in the shop.

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   Illustration 19	g01271682
   Design of a fixture for cleaning valves

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   Illustration 20	g01271684
   Valves in the fixture

   1. Clean all the components.

      Components of the cylinder head such as the valves, valve lifters, valve springs, keepers, valve rotators, and other parts can be cleaned in a separate system from the cylinder head casting. Clean these parts prior to inspection to allow easier identification of defects unless obvious defects are visible.

      Cleaning fixtures can be designed to work with cleaning equipment that will result in a more efficient cleaning and a better quality of rebuild.

      Various different equipment is available for cleaning small parts.

   2. Inspect each part for reusability.

      The valves, valve springs, lifters, and rotators must be inspected.

   3. Grind the valves to determine reusability.

      All valves must be ground to ensure proper seating between the valve and the insert.

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   Illustration 21	g01271920
   Rack for the cylinder head that will fit in a washer

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   Illustration 22	g01271921
   Rack with a cylinder head

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   Illustration 23	g01271924
   Cradle for the cylinder head with a stand for a washer

7. Clean the cylinder head casting in a hot spray wash cabinet.

   Note: The most effective washers for cleaning cylinder heads are hot spray wash cabinets.

8. Remove the gaskets and carbon deposits from the cylinder head.

   Remove the gaskets and joint seals immediately after washing. The gaskets will typically be loosened from the wash. Abrasive cleaning will then remove the gaskets. The gaskets can be removed easily if the gaskets are scraped immediately after the cycle of wash.

   The carbon deposits may need to be removed by hand after the first cycle of cleaning. A second cycle of cleaning may then be necessary to rinse the remaining carbon deposits.

   Flush the internal passages. Blow out the internal passages and the blind cavities. Apply a rust inhibitor to the cylinder head after rinsing.

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   Illustration 24	g01271962
   Serdi SPT1500 Cylinder Head Pressure Tester

9. Inspect and check the cylinder head casting.

   Make sure that the cylinder head meets the specifications for thickness and criteria for reusability in the specific reusability guideline for the cylinder head.

   Pressure test the cylinder head casting for internal cracks when the cylinder head is tested for integrity. The operating conditions and temperatures of a cylinder head need to be simulated during the pressure test in a heated tank under pressure. Steel plates must be fabricated to cover the openings in the head during testing. Gaskets, seals, and fittings are needed to connect the air supply.

   The tank must be large enough to hold the largest cylinder head that will be tested. The dimensions in Table 4 are reference dimensions for the tank for the corresponding engine models. The water in the tank needs to be heated to a temperature of 82 °C (180.0 °F). A minimum air supply of 415 kPa (60.0 psi) is required for the testing.

   Note: The dimensions in Table 4 are not reconditioning dimensions for cylinder heads. Use the dimensions to determine the correct size of a tank for the pressure test.

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   Table 4

   Dimensions for Cylinder Heads
   Model	Length	Width	Height
   D348	1273.0 mm (50 inch)	740.0 mm (29 inch)	595.0 mm (23.4 inch)
   D353E	387.0 mm (15.2 inch)	344.0 mm (13.5 inch)	325.0 mm (12.8 inch)
   D399	109.0 mm (4.3 inch)	146.0 mm (5.7 inch)	179.0 mm (7.0 inch)
   C7	848 mm (33.4 inch)	305 mm (12.0 inch)	158 mm (6.2 inch)
   C9 2007	871 mm (34.3 inch)	345 mm (13.6 inch)	163 mm (6.4 inch)
   C9 C-9	890 mm (35.0 inch)	300 mm (11.8 inch)	130 mm (5.1 inch)
   C-10 C-12	972 mm (38.3 inch)	320 mm (12.5 inch)	105 mm (4.1 inch)
   C11	997 mm (39.3 inch)	395 mm (15.6 inch)	165 mm (6.5 inch)
   C13	972 mm (38.3 inch)	397 mm (15.6 inch)	165 mm (6.5 inch)
   C15 C-15 C16 C-16 C18 C-18	1118 mm (44.0 inch)	360 mm (14.2 inch)	250 mm (9.8 inch)
   C27 C32	1185 mm (46.7 inch)	455 mm (18.0 inch)	250 mm (9.8 inch)
   C30	1185 mm (46.7 inch)	320 mm (12.5 inch)	114 mm (4.5 inch)
   C175	430.0 mm (16.93 inch)	300.0 mm (11.81 inch)	208.0 mm (8.19 inch)
   3044C	478 mm (18.8 inch)	216 mm (8.5 inch)	85 mm (3.3 inch)
   3066	343 mm (13.5 inch)	205 mm (8.0 inch)	100 mm (3.9 inch)
   3114	590 mm (23.2 inch)	252 mm (9.9 inch)	105 mm (4.1 inch)
   3116	840 mm (33.0 inch)	252 mm (9.9 inch)	105 mm (4.1 inch)
   3126	840 mm (33.0 inch)	252 mm (9.9 inch)	105 mm (4.1 inch)
   3126E	848 mm (33.4 inch)	285 mm (11.2 inch)	160 mm (6.3 inch)
   3145 3150 3160	632 mm (24.9 inch)	290 mm (11.4 inch)	140 mm (5.5 inch)
   3176	972 mm (38.3 inch)	320 mm (12.6 inch)	130 mm (5.1 inch)
   3196	972 mm (38.3 inch)	320 mm (12.6 inch)	130 mm (5.1 inch)
   3204	632 mm (24.9 inch)	290 mm (11.4 inch)	140 mm (5.5 inch)
   3208	632 mm (24.9 inch)	290 mm (11.4 inch)	140 mm (5.5 inch)
   3304	662 mm (26.1 inch)	350 mm (13.8 inch)	100 mm (3.9 inch)
   3306	960 mm (37.8 inch)	375 mm (14.8 inch)	100 mm (3.9 inch)
   G3304	662 mm (26.1 inch)	330 mm (13.0 inch)	100 mm (3.9 inch)
   G3306	960 mm (37.8 inch)	350 mm (13.8 inch)	100 mm (3.9 inch)
   3304B 3306B 3306BH 3306C	662 mm (26.1 inch)	350 mm (13.8 inch)	100 mm (3.9 inch)
   3406 3406B 3406C	1118 mm (44.0 inch)	368 mm (14.5 inch)	114 mm (4.5 inch)
   3406E	1118 mm (44.0 inch)	345 mm (13.6 inch)	250 mm (9.8 inch)
   G3406	1118 mm (44.0 inch)	368 mm (14.5 inch)	114 mm (4.5 inch)
   3408 3408B 3408C 3408E G3408	845 mm (33.3 inch)	320 mm (12.6 inch)	114 mm (4.5 inch)
   3412 3412C 3412D 3412E	1185 mm (46.7 inch)	320 mm (12.6 inch)	114 mm (4.5 inch)
   3456	1118 mm (44.0 inch)	345 mm (13.6 inch)	250 mm (9.8 inch)
   3508 3508B 3508C	268 mm (10.6 inch)	408 mm (16.0 inch)	145 mm (5.7 inch)
   3512 G3512	268 mm (10.6 inch)	455 mm (18.0 inch)	145 mm (5.7 inch)
   3512B 3512C	268 mm (10.6 inch)	408 mm (16.0 inch)	145 mm (5.7 inch)
   3516	268 mm (10.6 inch)	455 mm (18.0 inch)	145 mm (5.7 inch)
   3516B 3516C	268 mm (10.6 inch)	408 mm (16.0 inch)	145 mm (5.7 inch)
   3524B	268 mm (10.6 inch)	408 mm (16.0 inch)	145 mm (5.7 inch)
   3606	750 mm (29.5 inch)	420 mm (16.5 inch)	280 mm (11.0 inch)
   3608	750 mm (29.5 inch)	420 mm (16.5 inch)	280 mm (11.0 inch)
   3612	750 mm (29.5 inch)	420 mm (16.5 inch)	280 mm (11.0 inch)
   3616	750 mm (29.5 inch)	420 mm (16.5 inch)	280 mm (11.0 inch)
   3618	615 mm (24.2 inch)	420 mm (16.5 inch)	280 mm (11.0 inch)

Procedure for the Pressure Test

If the engine contains a water jacket, a fuel passage, or an oil passage, the water jacket, the fuel passage, and the oil passage must be checked separately.

1. Heat the water in the tank to a minimum temperature of 82 °C (180.0 °F).

2. Cover the openings on the cylinder head with a steel plate and seals or gaskets.

3. Attach a fitting to the plate to connect the air supply.

4. Use a hoist and a lift to submerge the cylinder head in the tank so that the water level covers all surfaces.

5. Apply a constant air pressure of 415 kPa (60.0 psi) minimum to the submerged cylinder head for one hour.

6. Observe the submerged cylinder head for any signs of air bubbles during the one hour test.

   Note: If no air bubbles are observed during the test, the cylinder head does not have any internal leaks.

7. Coat the cylinder head with a rust preventive to prevent rusting.

8. Inspect the valves, valve seat inserts, and the valve guides.
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   Illustration 25	g06277267
   Fabricated hydraulic puller for valve seat inserts

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   Illustration 26	g01272411
   Pulling a valve seat insert with a fabricated puller

9. Remove the valve seat inserts from the cylinder head.

10. Inspect the valve seat inserts for reusability. If the valve seat insert is cracked or damaged, replace the valve seat insert.

    Note: A damaged valve seat insert may cause engine failure.

11. Install the valve seat inserts into the cylinder head.
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    Illustration 27	g01272433
    Serdi 100 Valve Seat and Guide Cutting Machine

12. Machine the valve seat inserts or the bores for the valve seat inserts.

    Note: Some valve seats cannot be machined. Specialized manufacturing processes were used on these parts. Machining these parts will significantly decrease the life of the engine.

    Cutting tools for the valve seats are more effective than grinding in several ways. Cutters are faster and more accurate than grinding stones. Cutters maintain the dimensions longer. However, cutters are more expensive.

    Stones for grinding wear every time of use. Stones for grinding periodically need to be shaped resulting in additional labor for each job and one more step for error. Grinding produces dust and debris which adds more contamination to the process of reconditioning.

    The cylinder head must be protected from corrosion, external damage, and dirt after cleaning if the cylinder head is stored.

13. Assemble the cylinder head.

    Assemble the cylinder head after all necessary parts were replaced and all components were thoroughly inspected, tested, cleaned, and salvaged.

14. Measure the projection of the valve.

15. Perform a vacuum test on the valve seats.

    The vacuum test will identify a good seal between the valve and the valve seat. The cylinder head must be assembled before the vacuum test can be performed.

Procedure to Pressure Test the Cylinder Head on 3600, G3600, and C280 Engines

The head must be checked for cracks after everything has been removed from the head. A fabricated plate can be made to block the water passages during the air test. The air pressure should be set to 300 kPa (43.5 psi). It is not necessary to remove the valve guides, or the bridge dowels during the testing procedure.

Illustration 28	g01939054
Refer to Table 5 for the descriptions of callouts.

Table 5

Required Part for Pressure Testing a Cylinder Head
Callout	Quantity	Description
1	1	Combustion surface plate
2	1	Rubber gasket for combustion surface plate
3	4	Bolt, 3/4-10 thread by 343 mm (13.5 inch) long
4	4	Spacer
5	4	Nut, 3/4-10 thread
6	1	Air inlet plate
7	1	Rubber gasket for air inlet plate
8	3	Bolt, 3/8-16 thread by 32 mm (1.3 inch)
9	3	Flat washer 9.6 mm (0.38 inch) diameter hole
10	1	Connection for shop air

1. Fabricate the parts shown in illustrations 29 through 33.
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   Illustration 29	g01939853
   Combustion surface plate made from mild steel

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   Illustration 30	g01940401
   Rubber gasket for the combustion surface plate.

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   Illustration 31	g01940637
   Spacer for bolt

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   Illustration 32	g01940756
   Air inlet plate

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   Illustration 33	g01940776
   Rubber gasket for air inlet plate

2. Install bolts (3) through plate (1) and rubber gasket (2). Set plate (1) on a flat surface.

3. Lower the cylinder head onto the bolts until the bottom surface of the head is flat against the rubber gasket. Center the head on the plate and the gasket.

4. Install spacers (4) and nuts (5) on the top surface of the head.

5. Tighten four nuts (5) to seal the bottom combustion surface.

6. Install rubber gasket (7), air inlet plate (6), bolts (8), and flat washers (9) to the water outlet port on the top surface of the cylinder head.

7. Tighten three bolts (8) to seal the air inlet plate.

8. Install the fitting to the air inlet plate and attach the hose for the shop air.

9. The recommended air pressure is 300 kPa (43.5 psi).

10. Lower the cylinder head into a tank of water. Look for signs of a leak. Care should be taken to make sure that the signs of air bubbles are not from a leaking gasket or air connection.

11. Remove all water from the internal surfaces and the external surfaces of the cylinder head. If the head will be stored, coat all the surfaces with a coating of rust preventive. It is important to protect the bottom surface of the head and the top surface of the valve train from rusting or damage.

Replacement Parts

Consult the applicable Parts Identification manual for your engine.

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When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength and material. Failure to heed this warning can lead to premature failures, product damage, personal injury or death.

General Procedures

Use the following guidelines when you are inspecting and reconditioning a cylinder head.

• Clean the cylinder head. Remove the gasket material.

• Measure the cylinder head thickness.

• Measure the flatness of the combustion area.

• Inspect the combustion area for cracks or leaks.

• Check the combustion area for damage and/or erosion.

• Inspect the valve seats, and valve guides for damage.

• Recondition the components that are requiring salvage and replace the parts that do not meet the guidelines.

• Measure the projection and the recession of the valves.

• After you have assembled the cylinder head, you will need to run a vacuum test of the valves for the correct sealing.

• Protect the head against storage or shipping damage.

Nomenclature

Illustration 34	g06229689
(1) Lock (2) Rotocoil (3) Outer Spring (4) Inner Spring (5) Jacket Seal (6) Spring Seat (7) Guide (8) Valve

Illustration 35	g01955530
Nomenclature for the 3200 Engine (1) Intake port (2) Surface of the valve cover gasket (3) Seat of the valve spring (4) Post for the valve guide (5) Face of the Exhaust port (6) Exhaust port (7) Valve seat insert (8) Combustion area (9) Face of the Intake port

Illustration 36	g01955731
Nomenclature for the 3400 Engine except 3406E (1) Intake port (2) Surface of the valve cover gasket (3) Seat of the valve spring (4) Post for the valve guide (5) Face of the Exhaust port (6) Exhaust port (7) Valve seat insert (8) Combustion area (9) Face of the Intake port (10) Bridge dowel

Illustration 37	g06189548
Nomenclature for the 3500 Engine (1) Lock (2) Rotocoil (3) Outer Spring (4) Inner Spring (5) Washer (6) Guide (7) Head (8) Valve

Illustration 38	g01936936
Nomenclature for the 3500 Engine (1) Intake port (front or right side) (2) Surface of the valve cover gasket (4) Valve guide (6) Exhaust port (rear or left side) (8) Combustion area (10) Bridge dowel (11) Bore of the roller lifter

Illustration 39	g06176173
Nomenclature for the C175 Cylinder Head (1) Intake port (2) Surface for the valve cover gasket (4) Valve guide (6) Exhaust port

Reconditioning Factors

Use the information that is below for factors on common problems that can occur when you are reconditioning the cylinder head.

• The compression ratio is the critical factor that needs to be considered when the cylinder head is reconditioned. The compression ratio increases as the material is removed from the cylinder head.

• For minor erosion of 0.28 mm (0.011 inch) that is on the surface of the cylinder head, shave the area or resurface the area. In all the following reconditioning procedures, remove the minimum material that is necessary to make the repair.

• To find the amount of wear, a comparison can be made between the measurement of a worn part and the specifications of a new part. A part that is worn may be safe to use if an estimate of the remainder of service life of the part can be made. If this estimate shows that a short service life is expected, replace that part.

• Valve stems with diameters below the minimum or valve guides with diameters above the maximum can be used if the clearance specification is determined by subtracting the “use again minimum stem diameter” from the “use again valve guide diameter”.

• Several factors affect the amount of material that can be removed from the surface of a component. The factors for removing material are the backlash for the gear drive of the cam, projections of the valves, flatness, and surface texture. Measure these areas and the dimension for minimum thickness of the cylinder head whenever you recondition the block and the mating surface of the head.

Note: Dimensions for the thickness of the head assume that no material has been removed from the rail of the valve cover and the centerline of the crankshaft has not been raised. Adjust the specifications accordingly if machining has already occurred.

Cleaning the Cylinder Head and Removing the Gasket

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Personal injury can result from working with cleaning solvent. Because of the volatile nature of many cleaning solvents, extreme caution must be exercised when using them. If unsure about a particular cleaning fluid, refer to the manufacturer's instructions and directions. Always wear protective clothing and eye protection when working with cleaning solvents.

Use one of these methods to clean the cylinder head. Remove all oil, dirt, and carbon from the cylinder head casting. If the initial cleaning of the engine has been performed, the time for cleaning of the cylinder head will be reduced considerably.

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NOTICE
Shot blasting is not a Caterpillar recommended cleaning procedure. Shot blasting can cause shot to become lodged in internal passages. If all the shot material is not removed after cleaning with this method, the shot can become dislodged after reconditioning and move into the lubrication and injection systems. The result can be serious damage to the engine.

Dip Tank

Use a hot caustic solution to clean the cylinder head in a dip tank with a platform that oscillates.

Hot Spray Wash Cabinet

Put the cylinder head into position so the Exhaust ports and the combustion area are in line with the high-pressure stream from the nozzles. The spray must go directly into the ports and the face of the cylinder to remove all the carbon.

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NOTICE
If a caustic cleaning solution is used, brass injector sleeves and seals can be damaged. If these parts are not going to be replaced in a cylinder head, a soft cleaning solution should be used.

Removing the Gasket

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Use caution in order to avoid breathing dust that may be generated from handling any friction material, regardless of whether or not the material contains asbestos. If the dust is inhaled, the dust can be hazardous to you health. Wear a proper protective breathing device when handling friction material.

Moisten the gasket material for a cleaner and easier removal. To make the removal of gaskets easier and safer, put the cylinder head into a hot tank or a hot spray wash cabinet. A hot cleaning solution will make the gasket material soft so that large pieces can be pulled off by hand and the gasket material is easily removed with a scraper or a grinder. However, if the wet gasket material is permitted to dry, the gasket material can harden to the part.

There are specific factors for reconditioning the G3600 cylinder head. The surface on which the gasket for the prechamber seats must be thoroughly inspected. This area is prone to leaks without proper reconditioning.

Scraping

Use a putty knife to scrape off most of the gasket. Scraping is preferred over sanding discs. This preference is due to the number of airborne contaminants that are created by the discs. Disks for metal reconditioning that are mounted on an air tool can be used to remove gasket material that cannot be removed by hand.

Grinding

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NOTICE
If the metal reconditioning disc is used to remove gasket material, caution should be used to prevent the removal of any metal. If used too long in a small area, the disc may remove so much metal that sealing surfaces could be affected.

A disk for metal reconditioning that is mounted on an air tool can be used to remove gasket material that cannot be removed by hand.

Illustration 40	g01276547
Removing the gasket by grinding

When you are using this method, the speed of the disc is important. The best results will be obtained if the disc is flat to the surface and using only the weight of the air tool as downward pressure. Do not use too much downward pressure or operate the disc on the edge, because the pad may separate from the holder. The speed of the disc should be set between 3500 and 4500 rpm for 5P-9709 Abrasive Disc and 10,000 rpm for 6V-0185 Abrasive Disc. If the disk for metal reconditioning is used to remove gasket material, be careful not to remove any metal from the cylinder head.

Illustration 41	g06176191
Discs and holder (12) 6V-0186 Holder ( 127 mm (5.0 inch)) (13) 5P-9718 Holder ( 178 mm (7.0 inch)) (14) 6V-0185 Discs ( 127 mm (5.0 inch)) (15) 5P-9709 Discs ( 178 mm (7.0 inch))

Protection After Cleaning

If the casting is being stored before making a repair, then the cylinder head must be protected from corrosion and external damage after cleaning.

Visual Inspection of Cylinder Head

Cylinder Head Casting

Inspect the cylinder head for visible damage. The following examples of damage were taken from 3200 and 3400 Engines and the examples also apply to all engines.

Illustration 42	g01277373
The damage to the cylinder head is at the seal between the valve cover and the head.

USE THE PART AGAIN.

The cylinder head can be used again after the burr has been removed.

Illustration 43	g01277404
Cylinder head is badly damaged in the seat area of the bolt. This area must have a flat surface and complete contact with a bolt.

USE THE PART AGAIN.

The cylinder head can be used again after damage is repaired.

Illustration 44	g01277417

Cylinder head is badly damaged in the seat area of the bolt. This area must have a flat surface and complete contact with a bolt or a mating surface.

USE THE PART AGAIN.

The cylinder head can be used again after damage is repaired.

The part can be used again after the hole has been repaired using Lock-N-Stitch. For complete information on Lock-N-Stitch, refer to Reuse and Salvage Guideline, SEBF8882, "Using Lock-N-Stitch Procedures for Casting Repair".

Inspecting the Combustion Area for Damage from Erosion

Make a visual inspection of the combustion area to check for damage and erosion. Erosion in these areas will have a negative effect on engine operation:

Illustration 45	g06176233
Inspect the indicated areas for damage and erosion. (16) Fire ring (17) Seat area (18) The area between the hole of the injector nozzle and the valve seat. Erosion in other areas should not affect engine operation.

Illustration 46	g01296874
Minor pitting or erosion

USE THE PART AGAIN.

Illustration 47	g01296931
Foreign material caused this damage. The valve seats must be replaced.

USE THE PART AGAIN.

Illustration 48	g01296968
Erosion across the fire ring The cylinder head can be used again after the surface has been machined and all erosion is removed. The part must still be within the reusable specifications.

USE THE PART AGAIN.

Illustration 49	g01296991
Damage across the fire ring The cylinder head can be used again after the surface has been machined to remove all damage.

USE THIS PART AGAIN.

Illustration 50	g01297021
Concentrated area of erosion The cylinder head can be used again if a channel is ground out to remove erosion.

USE THIS PART AGAIN.

Illustration 51	g01297085
A small amount of erosion

USE THIS PART AGAIN.

Illustration 52	g01297091
Bad erosion around the area of the valve seat.

DO NOT USE THE PART AGAIN.

Illustration 53	g01297298
Engine failure caused this damage.

DO NOT USE THE PART AGAIN.

Erosion

The flow of coolant through the engine is known for causing erosion. This example is shown in Illustration 52. The erosion will not damage the engine if the coolant does not go from the coolant passage to any of the following:

• Fire ring in the combustion chamber

• Oil passages

• Bolt holes

• Outside of the engine

Illustration 54	g01297592
Erosion that is caused from the flow of coolant (16) Fire ring (19) Outer surface (20) Coolant passage (21) Oil passage (22) Erosion must not extend beyond this area. (23) Bolt hole

For traditional head gaskets, if the distance between the erosion and any feature that is specified in Illustration 54 is less than 4.0 mm (0.16 inch), do not use the cylinder head again. Use the part again only if the erosion has been removed to leave a minimum of 4.0 mm (0.16 inch) sealing area.

Illustration 55	g06176240
Multiple layered steel "MLS" gasket The arrows indicate a raised layer of the gasket. Erosion cannot come in contact with this area.

Note the sealing area of the "MLS" gasket. The seal is created by the raised area of the gasket. Any erosion or an uneven surface could create a bad seal.

Illustration 56	g01297863
Erosion is acceptable in areas (24) and (25). Erosion is not acceptable in area (26). This photo shows acceptable erosion, and the head can be used again. (24) Coolant passage and the inside diameter of the O-ring (25) Seal and the outside diameter of the O-ring (26) Seal and the gasket

USE THIS PART AGAIN.

Illustration 57	g06176243
Erosion is not acceptable in area (27). Only reuse the cylinder head if the erosion has been machined from area (27). That area is at the point of contact between the O-ring or seal and the cylinder head.

USE THIS PART AGAIN..

Illustration 56 and Illustration 57 show the location of O-rings or seals around the holes of the coolant passages. Erosion will not harm the engine between these areas.

Erosion is not acceptable at the point of contact between the O-ring or seal and the cylinder head. If any erosion occurs, then the combustion area must be machined.

Lifter Bore Erosion for 3500 Engines

Illustration 58	g06275759

Lifter bore erosion is allowable if the erosion path is contained within Zone A and does not exceed 0.5 mm (0.01969 inch)

Table 6

Lifter Bore for 3500 Engines
Callout	Dimension
(A)	5.0 mm (0.19685 inch)
(B)	5.0 mm (0.19685 inch)
(C)	31.0 mm (1.22047 inch) MAX

Reuse of Cylinder Heads on C9, C-9, and 3176 Engines with Injector Tip Damage

Inspection

All the heads shown that in the photos have been milled to near minimum thickness to remove as much damage as possible. The damage that remains is inside the gasket sealing area. This area is shown by the black circle drawn on the head.

Heads with damage in the fire ring seat area after machining should not be used again.

Identification Stamp and Nomenclature

Cylinder heads that are reworked by the criteria in this guideline should be stamped with a dealer-selected stamp in area (1) shown in Illustration 59. This stamp will identify the cylinder heads as having injector tip damage and not casting porosity. Caterpillar Reman heads will be stamped with a 6 mm (0.24 inch) upper case "M".

Illustration 59	g06277285
(1) Reworked C9 cylinder heads have identification stamp in this area.

Illustration 60	g06277292
(2) Reworked 3176 cylinder heads have identification stamp in this area. (3) Fly cut area between intake valves

Illustration 61	g06277299
Minimal damage on surface of deck and in valve port (angled area above valve insert)

Use again

Illustration 62	g06277300
More areas of damage on surface of deck

Use again

Illustration 63	g06277307
Heavy damage to surfaces that extend into the valve ports

Do not use again

Illustration 64	g02350589
Heavy damage to surfaces that extend into the valve ports and damage to the fly cut between the intake valves

Do not use again

Illustration 65	g06277312
Heavy damage to surface of deck and valve ports

Do not use again

Illustration 66	g06277317
Deep gouges in surface and gouges that extend into valve port.

Do not use again

Inspection of the Combustion on 3600, G3600, C280 Engines

Illustration 67	g01937034
Cylinder head combustion surface

Inspect the surface between dimensions (A) and (B) in Illustration 67 for signs of pitting, erosion, or other damage. The area between (A) and (B) must be smooth, free of nicks, gouges, and/or any damage that may result in incorrect seal ring sealing.

Note: Tooling 151-8689 Seal Template can be used to quickly define the area between dimension (A) and (B).

Illustration 68	g03236258
Tooling 151-8689 Seal Template

1. Place a 151-8689 Seal Template on the cylinder head. Align the center locator on the template with the hole for the injector on the cylinder head.

2. Use a marker to mark the inside diameter and the outside diameter of the template on the surface of the cylinder head.

3. Remove the template for the seal.

Note: The thickness of the cylinder head must be checked again if the cylinder head is reconditioned.

Table 7

Specifications For Surface of Combustion
Dimension (A)	380.00 ± 1.00 mm (14.961 ± 0.040 inch)
Dimension (B)	330.00 ± 1.00 mm (12.992 ± 0.040 inch)
Surface Width (minimum)	406.0 mm (16.00 inch)
Surface Texture (maximum) except within (A) and (B)	3.2 µm (125 µinch)
Surface Texture (maximum) between (A) and (B)	1.6 µm (63 µinch)
Flatness (maximum) except within (A) and (B)	0.1 per 100 mm (0.004 per 4 inch)
Flatness (maximum) between (A) and (B)	0.05 mm (0.002 inch)

Thread Inspection

Make a visual inspection of all threaded holes for damaged threads and broken bolts or studs.

Illustration 69	g01298139
Damaged threads The part can be used again after the hole has been repaired using Lock-N-Stitch. For complete information on Lock-N-Stitch, refer to Reuse and Salvage Guideline, SEBF8882, "Using Lock-N-Stitch Procedures for Casting Repair".

USE THIS PART AGAIN.

Exhaust Stud and Bolt Removal Tool

The 188-3922, 533-1152, 533-1153, and 533-1152 Exhaust Stud and Bolt Removal Tool Group, when bolted to the cylinder head will accurately locate the center of the broken stud or bolt. This tool allows broken bolts or studs to be drilled out without damaging the existing threads in the cylinder head. This tool group is similar to the 6V-9050 Stud Removal Group except that it is designed to repair metric exhaust manifold bolts and studs.

• Tool188-3922 can be used on cylinder heads of 3114, 3116, 3126, 3126B, 3176, 3176B, C-10, and C-12 Engines.

• Tool 533-1152 can be used on cylinder heads of C6.6 Engines.

• Tool 533-1153 can be used on cylinder heads of C4.4 Engines.

• Tool 533-1155 can be used on cylinder heads of C7.1 Engines.

Refer to NEHS0787Tool Operating Manual, "188-3922 Broken Exhaust Bolt and Stud Removal Group for 3114, 3116, 3126, 3126B, 3176, 3176B, C-10, and C12 Engines" for more information.

• Tool 6V-9050 can be used on cylinder heads of C-15, C-16, C18, C27, C32, 3100, 3200, 3300, and 3400 Engines.

Refer to , SMHS8297Special Instruction, "Use Of 6V-9050 Exhaust Stud Removal Group" for more information.

Crack Detection Methods

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NOTICE
Regardless of which crack detection method is used, it is important that the instructions furnished with the detection equipment are followed closely when checking any component. Failure to do so may cause inaccurate results or may cause injury to the operator and/or surroundings.

Crack detection methods or Non-Destructive Testing (NDT) are utilized for examining components for cracks without damaging the component. Visual inspection (VT), Liquid Penetrant Testing (PT), Magnetic Particle Inspection (MT), Ultrasonic Testing (UT), Radiographic Testing (RT) and Eddy-Current Testing (ET) are recommended methods. There may be more than one acceptable crack detection method for the inspection of a given part, though the liquid penetrant is the most versatile. For example, the liquid penetrant method can be used when inspecting smooth machined components such as shafts, gear teeth, and splines, but using the Wet Magnetic Particle Inspection is more accurate. Refer to Table 8 for advantages and disadvantages and Table 9 for standards and requirements for these NDT methods.

Table 8

Crack Inspection Method Advantages vs. Disadvantages
Inspection Method	Advantages	Disadvantages
Visual Surface Inspection (VT)	- Least expensive - Detects most damaging defects - Immediate results - Minimum part preparation	- Limited to surface-only defects - Requires inspectors to have broad knowledge of welding and fabrication inch addition to non-destructive testing
Liquid Penetrant (PT)	- Inexpensive - Minimal training - Portable - Works on nonmagnetic material	- Least sensitive - Detects surface cracks only - Rough or porous surfaces interfere with test
Dry Magnetic Particle (MT)	- Portable - Fast/Immediate Results - Detects surface and subsurface discontinuities	- Works on magnetic material only - Less sensitive than Wet Magnetic Particle
Wet Magnetic Particle (MT)	- More sensitive than Liquid Penetrant - Detects subsurface as much as 0.13 mm (0.005 inch)	- Requires Power for Light - Works on magnetic parts only - Liquid composition and agitation must be monitored
Ultrasonic Testing (UT)	- Most sensitive - Detects deep material defects - Immediate results - Wide range of materials and thickness can be inspected	- Most expensive - Requires operator training and certification - Surface must be accessible to probe
Eddy-Current Testing (ET)	- Surface and near surface flaws detectable -Moderate speed/Immediate results -Sensitive too small discontinuities	- Difficult to interpret - Only for metals -Rough surfaces interfere with test - Surface must be accessible to probe
Radiographic Testing (RT)	-Detects surface and internal flaws - Minimum part preparation - Can inspect hidden areas	- Not for porous materials - Radiation protection needed - Defect able to be detected is limited to 2% of thickness

Table 9

Applicable Crack Detection Standards
Inspection Method	Standard	Acceptance Criteria	Required Personnel Qualifications
Visual Surface Inspection (VT)	EN-ISO 5817 AWS D1.1	EN-ISO 5817 - Level B AWS D1.1 - Table 6.1	EN-ISO 9712 - Level 2 ANSI-ASNT SNT-TC-1A Level 2
Liquid Penetrant Testing (PT)	EN-ISO 3452 ASTM E165	EN-ISO 23277 AWS - D1.1	EN-ISO 9712 - Level 2 ANSI-ASNT SNT-TC-1A Level 2
Magnetic Particle Testing (MT)	EN-ISO 17638 ASTM E709	EN-ISO 23278 - Level 1 AWS D1.1 - Table 6.1	EN-ISO 9712 - Level 2 ANSI-ASNT SNT-TC-1A Level 2
Ultrasonic Testing (UT)	EN-ISO 17640 - Level B AWS D1.1	EN-ISO 11666 Technique 2 - Level 2 AWS D1.1 - Class A - Table 6.3	EN-ISO 9712 - Level 2 ANSI-ASNT SNT-TC-1A Level 2
Eddy-Current Testing (ET)	EN-ISO 15549 ASTM E426	EN-ISO 20807	EN-ISO 9712 - Level 2 ANSI-ASNT SNT-TC-1A Level 2
Radiographic Testing (RT)	EN-ISO 5579 ASTM E94	EN-ISO 10657-1	EN-ISO 9712 - Level 2 ANSI-ASNT SNT-TC-1A Level 2

Visual Surface Inspection (VT)

Illustration 70	g06085008
Example of Visual Inspection Tools (A) Flashlight or adequate light source (B) Magnifying eye loupe (C) Tape measure or other measuring device (D) Inspection mirror (E) Weld size inspection gauges

Components and welds that are to be inspected using PT, MT, or UT shall first be subject to Visual Surface Inspection (VT). Visual Inspection is often the most cost-effective inspection method and requires little equipment as seen in Illustration 70. It is suggested that at a minimum personnel performing Visual Inspection are either trained to a company standard or have sufficient experience and knowledge regarding the components being inspected. It is also suggested that personnel performing visual inspections take some type of eyesight test regularly.

Liquid Penetrant Testing (PT)

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Personal injury can result from improper handling of chemicals. Make sure you use all the necessary protective equipment required to do the job. Make sure that you read and understand all directions and hazards described on the labels and material safety data sheet of any chemical that is used. Observe all safety precautions recommended by the chemical manufacturer for handling, storage, and disposal of chemicals.

Materials and Equipment Required

Refer to Tooling and Equipment Table 3 for part numbers.

• Cleaner: Removes dirt before dye application and dissolves the penetrant making possible to wipe the surface clean.

• Penetrant: This solution is highly visible, and will seep into openings at the surface of a part with capillary action.

• Developer: Provides a blotting action, bringing the penetrant out of the discontinuities and providing a contrasting background to increase the visibility of the penetrant indications.

• Wire Brush: Removes dirt and paint.

• Cloth or Wipes: Use with cleaner and for other miscellaneous uses.

Procedure

1. Preclean inspection area. Spray on cleaner / remover to loosen any scale, dirt, or any oil. Wipe the area to inspect with a solvent dampened cloth to remove remaining dirt and allow the area to dry.
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   Illustration 71	g01298464

2. Apply penetrant by spraying to the entire area to be examined. Allow 10 to 15 minutes for penetrant to soak. After the penetrant has been allowed to soak, remove the excess penetrant with clean, dry wipe.

3. The last traces of penetrant should be removed with the cleaner solvent dampened cloth or wipe. Allow the area to dry thoroughly.

4. Before using developer, ensure that it is mixed thoroughly by shaking can. Holding can approximately 203.20 - 304.80 mm (8.00 - 12.00 inch) away from part, apply an even, thin layer of developer over the area being inspected. A few thin layers are a better application method than one thick layer.

5. Allow the developer to dry completely for 10–15 minutes before inspecting for cracks. Defects will show as red lines in white developer background. Clean the area of application of the developer with solvent cleaner.
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   Illustration 72	g01298518
   Use a black light to check the inserts of the valve seat.

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   Illustration 73	g01298740
   Dye will penetrate into cracks.

6. Check the surface with a 459-0184 Ultraviolet Lamp. This lamp will highlight the location of any cracks or damage.

Illustration 74	g01298757
Cracks begin at the precombustion chamber or the hole of the direct injection adapter. The length of the crack on the combustion area must not be more than 6.35 mm (0.250 inch). The crack must not be more than three threads deep. Use the method of dye penetrant to find the depth of the cracks.

USE THIS PART AGAIN.

The following illustrations show examples of cracks that would constitute replacing the cylinder head.

Illustration 75	g01298781
Crack in the nozzle hole (3200 Engine)

DO NOT USE THIS PART AGAIN.

Illustration 76	g01299782
The crack goes into the valve seat. If the crack does not go into the counterbore of the area of the valve seat, the head can be salvaged. Refer to Reuse and Salvage Guideline, SEBF8374, "Specifications for Cylinder Head Assemblies 3200 Engines".

DO NOT USE THIS PART AGAIN.

Illustration 77	g01298740
Cracks between the valve seats (3200 and 3400 Engines)

DO NOT USE THIS PART AGAIN.

Illustration 78	g01299804
Cracks between the precombustion chamber or the hole for the direct injection adapter and valve seats (3400 Engine).

DO NOT USE THIS PART AGAIN.

Illustration 79	g01299842
Cracks between the hole of the core plug and the bore of the valve guide on the top deck (3400 Engine)

DO NOT USE THIS PART AGAIN.

Dry Magnetic Particle Testing (MT)

Materials and Equipment Required

Refer to Tooling and Equipment Table 3 for part numbers.

Illustration 80	g06085930
(A) Indications shown by magnetic particle testing. (B) Typical electromagnetic yoke. (C) Dry powder bulb.

Illustration 81	g01299867
An electromagnet in the shape of a yoke that is checking for cracks

1. Dry magnetic powder shall be of high permeability and low retentively and of suitable sizes and shapes to produce magnetic particle indications. The powder shall be of a color that will provide adequate contrast with the background of the surface being inspected.

2. Dry magnetic particles shall be stored in suitable containers to resist contamination such as moisture, grease, oil, non-magnetic particles such as sand, and excessive heat. Contaminants will manifest in the form of particle color change and particle agglomeration. The degree of contamination will determine further use of the powder.

3. Dry magnetic powder shall be tested in accordance with ASTM E709 Section 18 (Evaluation of System Performance/Sensitivity) when not performing.

4. Equipment should include a "U" shaped electromagnetic yoke made from highly permeable magnetic material, which has a coil wound around the yoke. This coil carries a magnetizing current to impose a localized longitudinal magnetic field into the part. The magnetizing force of the yoke is related to the electromagnetic strength and can be tested by determining the lifting power of a steel plate. The yoke shall have a lifting force of at least 4.5 kg (10 lbs).

5. Check dry powder blower routinely to ensure that the spray is a light, uniform, dust-like coating of the dry magnetic particles. Blower should also have sufficient force to remove excess particles without disturbing those particles that are evidence of indications.

6. All equipment shall be inspected at a minimum of once a year or when accuracy is questionable.

Procedure

1. Ensure surface to be inspected is dry and free from oil, grease, sand, loose rust, mil scale, paint, and other contaminants.

2. Apply the magnetic field using the yoke against the faces and inside diameter of each bore.

3. Simultaneously apply the dry powder using the dry powder blower.

4. Remove excess powder by lightly blowing away the dry particles.

5. Continue around the entire circumference of each bore. Position the yoke twice in each area at 1.57 rad (90°) to ensure that multiple directions of the magnetic field are created.
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   Illustration 82	g01300124

6. Inspect the area for cracks. If there is a crack between the arms of the yoke, the magnetic powder will go into the crack. The crack will then appear as a line of magnetic particles.

   Observe particles and note if any clusters of particles appear revealing an indication.

7. Record the size and shape of any discontinuities or indications found.

Wet Magnetic Particle Testing (MT)

Materials and Equipment

Refer to Tooling and Equipment Table 3 for part numbers.

Illustration 83	g06085937
(A) Indications shown by magnetic particle testing. (B) Typical electromagnetic yoke. (D) UV Lamp used in wet magnetic particle inspection process.

Illustration 84	g06003178
Pear Shaped Centrifuge Tube

1. Wet magnetic particles are fluorescent and are suspended in a vehicle in a given concentration that will allow application to the test surface by spraying.

2. Concentration:

   1. The concentration of the suspended magnetic particles shall be as specified by the manufacturer and be checked by settling volume measurements.

   2. Concentrations are determined by measuring the settling volume by using an ASTM pear shaped centrifuge tube with a 1 mL (0.034 oz) stem with 0.05 mL (0.0017 oz) 1.0 mL (0.034 oz) divisions, refer to Illustration 84. Before sampling, the suspension shall be thoroughly mixed to assure suspension of all particles, which could have settled. A 100 mL (3.40 oz) sample of the suspension shall be taken and allowed to settle for 30 minutes. The settling volume should be between 0.1 mL (0.0034 oz) and 0.25 mL (0.0085 oz) in a 100 mL (3.40 oz) sample.

   3. Wet magnetic particles may be suspended in a low viscosity oil or conditioned water.

   4. The oil shall have the following characteristics:

      • Low viscosity not to exceed 50 mSt (5.0 cSt) at any temperature at which the vehicle is to be used.

      • Low inherent fluorescence and be non-reactive.

   5. The conditioning agents used in the conditioned water shall have the following characteristics:

      • Impart good wetting characteristics and good dispersion.

      • Minimize foaming and be non-corrosive.

      • Low viscosity shall not exceed a maximum viscosity of 50 mSt (5.0 cSt) at 38° C (100° F).

      • Non-fluorescent, non-reactive, and odorless.

      • Alkalinity shall not exceed a pH of 10.5.

3. Equipment should include a "U" shaped electromagnetic yoke made from highly permeable magnetic material, which has a coil wound around the yoke. This coil carries a magnetizing current to impose a localized longitudinal magnetic field into the part. The magnetizing force of the yoke is related to the electromagnetic strength and can be tested by determining the lifting power of a steel plate. The yoke shall have a lifting force of at least 4.5 kg (10 lbs).

Procedure

1. Ensure surface to be inspected is dry and free from oil, grease, sand, loose rust, mil scale, paint, and any other contaminants.

2. Apply the magnetic field using the yoke against the surface in the area to be inspected.

3. For case hardened and ground surfaces:

   • Due to the sensitivity required to locate the grinding cracks, inspection of case hardened and ground surfaces require that the yoke is applied so that the magnetic field is 1.57 rad (90°) to the expected direction of the indications. Also, due to the increased sensitivity resulting when the yoke is energized, the yoke is not moved until the evaluation is completed in the first direction. An AC yoke shall be used.

4. Visually inspect for indications of discontinuities using the proper illumination.

5. Record the size and shape of any discontinuities found.

Ultrasonic Testing (UT)

Note: Crack depth cannot be accurately determined by UT, only full depth cracking can be consistently determined. For cracks that are not full depth, an indication of a partial depth cracks can be detected by an experienced technician.

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NOTICE
All personnel involved in ultrasonic testing shall be qualified to Level 2 in accordance to standards stated in Table 9.

Refer to Tooling and Equipment Table 3 for part numbers.

1. Ultrasonic Testing (UT) is a method of Non-Destructive Testing (NDT) using short ultrasonic pulse waves (with frequencies from 0.1-15 MHz up to 50 MHz) to detect the thickness of the object. Ultrasonic testing consists of an ultrasound transducer connected to a diagnostic machine and passed over the object being inspected.

2. There are two methods of receiving the ultrasound waveform from the transducer: reflection and attenuation.

   1. Reflection - Ultrasonic pulses exit the transducer and travel throughout the thickness of the material. When the sound waves propagate into an object being tested, the waves return to the transducer when a discontinuity is discovered along the sonic path. These waves continue and reflect form the backsurface of the material to project the thickness of the material.

   2. Attenuation - A transmitter sends ultrasound through one surface, and a separate receiver detects the amount that has reached it on another surface after traveling through the medium. Any discontinuities or other conditions within the medium will reduce the amount of sound transmitted, revealing the presence of the imperfections.

Eddy-Current Testing (ET)

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NOTICE
All personnel involved in Eddy-Current Testing shall be qualified to Level 2 in accordance to standards stated in Table 9.

Illustration 85	g06090873
Eddy-Current Testing

Eddy-Current Testing (ET) is a Non-Destructive Testing (NDT) method in which eddy-current flow is induced in the test object. Changes in the flow caused by variations in the specimen are reflected in to a nearby coil or coils for subsequent analysis by suitable instrumentation and techniques. Major applications of eddy-current testing are surface inspection and tubing inspections.

Radiographic Testing (RT)

Note: CAUTION: This process is dangerous. Only qualified personnel and test equipment should be appointed to perform this type of testing.

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NOTICE
All personnel involved in radiographic testing shall be qualified to Level 2 in accordance to standards stated in Table 9.

Illustration 86	g06090892
Radiographic Testing

Radiographic Testing (RT) is a Non-Destructive Testing (NDT) method in which short wavelength of electromagnetic radiation is used to penetrate materials to find hidden discontinuities such as cracks. In radiographic testing, the test object is placed between the radiation source and the film, or x-ray detector. The electromagnetic radiation will penetrate the thickness of the test object and, when all the way through, will project onto the film any indications that have been in the path of the radiation waves.

Lock-N-Stitch Full Torque Threaded Inserts

Illustration 87	g01042620

If a bolt hole contains cracked threads or stripped threads, Lock-N-Stitch Full Torque Threaded Inserts should be used. The cracks must be no deeper than 6.4 mm (0.25 inch) down the counterbore of the bolt hole. The cracks cannot run into the cylinders. The cracks must only run into water jackets. The number of cracks per hole does not matter. Mark all bad holes with a paint pen.

The procedure utilizes Lock-N-Stitch products that were introduced in Reuse and Salvage Guideline, SEBF8882, "Using Lock-N-Stitch Procedures for Casting Repair". Full Torque Thread Insert Kits are used to repair the cracked bolt holes and stripped bolt holes. The threaded inserts and the parts that accompany the threaded inserts are included in FFB5SP010K Full Torque Thread Insert Kit from LOCK-N-STITCH. These parts can be ordered through LOCK-N-STITCH. This kit is not stocked by Caterpillar. Refer to Reuse and Salvage Guideline, SEBF8882, "Using Lock-N-Stitch Procedures for Casting Repair" for other LOCK-N-STITCH parts that are stocked by Caterpillar.

Installing a Threaded Insert can be done in a short amount of time. Installing a Threaded Insert will increase the strength of the threads.

For more information or questions concerning LOCK-N-STITCH, contact LOCK-N-STITCH. For a complete catalog of products, contact LOCK-N-STITCH. See www.locknstitch.com for more repair procedures, training, and catalogs.

LOCK-N-STITCH Inc.
1015 S. Soderquist Rd.
Turlock, CA 95380
www.locknstitch.com
(209) 632-2345
(800) 736-8261

Measurement Requirements

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NOTICE
Precise measurements shall be made when the component and measurement equipment are at 20° (68° F). Measurements shall be made after both the component and measurement equipment have had sufficient time to soak at 20° (68° F). This will ensure that both the surface and core of the material is at the same temperature.

Cylinder Head Thickness

Before the cylinder head can be reused, the cylinder head thickness must be measured.

The cylinder head can be machined to remove any damage. At the time of this publication, some cylinder heads must remain within factory specifications. Refer to the Tables for specifications for the minimum thickness of the cylinder head. The cylinder head must be within the minimum thickness specifications to comply with the regulations on emissions. If the thickness of the head is beyond the minimum thickness, the head can be reconditioned by utilizing thermal spray.

Note: An alternative solution will be provided in the future for the engines that must remain within factory specifications.

If the head surface requires reconditioning, the surface must be built up utilizing metal spray so the cylinder head thickness will be maintained at the original specifications. Refer to "Thermal Spray Procedures for Cylinder Head" for more information.

Illustration 88 is of a C7 cylinder head, but is illustrative of where to measure for C7 through C32 cylinder heads.

The thickness of the cylinder head is measured from the valve spring base to the combustion surface. The valve spring base makes for a good datum for measuring cylinder head thickness because it receives minimum wear through the engine life. Also the valve spring base remains unchanged during cylinder head salvage such as machining and/or metal spray procedures.

C7 through C32 Cylinder Heads

Illustration 88	g03843866
Valve spring base to combustion face measurement (A) Thickness of Cylinder Head

C175 Cylinder Heads

Illustration 89	g06229711
(A) Thickness of the cylinder head

3044, 3046, 3064, and 3066 Cylinder Heads

Illustration 90	g06277328
Cylinder head cross section

3114, 3116, and 3126 Cylinder Heads

Illustration 91	g01324622
Earlier Cylinder Heads

Illustration 92	g06277333
Cylinder head cross section of later cylinder heads (1) Sleeve (A) Thickness of the head

Refer to Tool Operating Manual, NEHS0675, "Using the 143-2099 Sleeve Replacement Tool Group on 3114, 3116, and 3126 Engines".

3176, and 3196 Cylinder Heads

Illustration 93	g06277337
Cylinder head cross section (1) Sleeve (A) Thickness of new cylinder head

3400 Cylinder Heads

Illustration 94	g01456775

3406E, 3456Cylinder Heads

Illustration 95	g06277341
(A) Thickness of the cylinder head

3500 Cylinder Heads

Note: Material can be removed from the cylinder head without reseating the valves if the thickness of the cylinder head is at least 141.62 mm (5.57558 inch). When the thickness of the cylinder head is less than the minimum thickness of the cylinder head, the valves must be reseated to achieve the proper valve recession. These dimensions are listed in Table 111.

Illustration 96	g01632454
(A) Minimum thickness of the cylinder head

3600, G3600, C280 Cylinder Heads

Illustration 97	g06175819
(A) Minimum thickness of the cylinder head

Table 10

Specifications for the Cylinder Head Thickness
Model	Part Number	Thickness of the Head (A)	Minimum Thickness of the Head
D318	N/A	111.25 mm (4.37991 inch)	110.99 mm (4.36968 inch)
D320	N/A	127.00 ± 0.08 mm (5.00 ± 0.00315 inch)	125.56 mm (4.94330 inch)
D342 G342	N/A	136.72 ± 0.06 mm (5.38267 ± 0.00236 inch)	134.70 mm (5.30314 inch)
D343 G343	N/A	167.64 ± 0.05 mm (6.59999 ± 0.00197 inch)	167.49 mm (6.59408 inch)
D346 G346 D348 G348 D349 G349	N/A	109.22 ± 0.10 mm (4.29999 ± 0.00394 inch)	108.96 mm (4.28976 inch)
D353 G353	N/A	146.11 ± 0.06 mm (5.75235 ± 0.00236 inch)	144.27 mm (5.67991 inch)
D379 G379 D398 G398 D399 G399	N/A	179.45 ± 0.10 mm (7.06495 ± 0.00394 inch)	178.05 mm (7.00983 inch)
C4.4	N/A	N/A	100.95 mm (3.974 inch)
C4.4 (Tier 4)	N/A	N/A	150.8 mm (5.9370 inch)
C6.6 and C7.1(Elect) (Tier 2/3)	N/A	N/A	94.80 mm (3.732 inch)
C7.1 (Mech) (Tier 0/2/3)	N/A	N/A	117.95 mm (4.644 inch)
C7.1 (Tier 4)	N/A	N/A	150.8 mm (5.937 inch)
C7	219-5844 227-5951 259-8305 278-3490 280-7503 314-4183 314-4184 314-4185	110.5 ± 0.25 mm (4.350 ± 0.010 inch)(1)	110.00 mm (4.33 inch)
C9 C-9 C9.3	201-2180 241-8392 252-8438 255-4961 311-7226 311-7228 311-7229 332-3619	130.00 ± 0.15 mm (5.118 ± 0.006 inch)	129.60 mm (5.102 inch)
	311-7218 328-7475	163 ± 0.15 mm (6.41731 ± 0.0059 inch)	N/A
	314-4184	158.00 ± 0.15 mm (6.221 ± 0.006 inch)	157.60 mm (6.205 inch)
	491-1831	163.0 mm (6.41731 inch)	162.6 mm (6.40156 inch)
C-10 C-12 C12	148-2135 179-9458	105.00 ± 0.15 mm (4.134 ± 0.006 inch)	104.35 mm (4.108 inch)
C11 C13 C-13 C15 C-15 C16 C-16 C18 C-18	245-4031 257-2170 265-9120 289-3210 300-9512 302-2297 308-6358 331-1981 342-4397 344-0059 345-3752 346-1984 346-1999 520-4381 520-4382	120.00 ± 0.15 mm (4.724 ± 0.006 inch)	119.50 mm (4.705 inch)
	185-2246 222-1983 223-7263 243-0943 245-4324 263-4890 281-1640	120.00 ± 0.15 mm (4.724 ± 0.006 inch)	119.45 mm (4.703 inch)
C27 C32	284-2787 357-7398 396-8374 431-1153	120.00 ± 0.15 mm (4.724 ± 0.006 inch)	119.60 mm (4.709 inch)
C-30 C-32	6I-3606 105-3798 105-3799 105-3800 123-7338 124-7373 143-0046 143-3615 151-4951 151-1335 151-5241 151-5243 198-6523 198-6524 206-7744	112.78 ± 0.25 mm (4.440 ± 0.001 inch)	111.51 mm (4.390 inch)
C175	328-7082 345-8447 456-2406 515-8766 517-4407	208.00 mm (8.189 inch)	207.85 mm (8.1831 inch)
3044 3046	N/A	85.00 ± 0.10 mm (3.347 ± 0.004 inch)	84.90 mm (3.343 inch)
3054(2)	N/A	103.59 mm (4.07834 inch)	102.48 mm (4.03464 inch)
3056	N/A	103.59 mm (4.07834 inch)	102.79 mm (4.04684 inch)
3064 3066	N/A	95.00 ± 0.10 mm (3.740 ± 0.004 inch)	94.90 mm (3.736 inch)
3114 3116 3126	N/A	103.00 ± 0.20 mm (4.055 ± 0.008 inch) Early Model	102.55 mm (4.037 inch)(3)
		158.00 ± 0.20 mm (6.220 ± 0.008 inch)	157.55 mm (6.202 inch)(3)
3176 3196	N/A	105.00 ± 0.15 mm (4.134 ± 0.006 inch)	104.35 mm (4.108 inch)
3204 DI	N/A	96.14 ± 0.15 mm (3.78503 ± 0.00591 inch)	95.86 mm (3.77401 inch)
3204 PC	N/A	95.0 ± 0.13 mm (3.74015 ± 0.00512 inch)	94.59 mm (3.72401 inch)
3208	N/A	96.14 ± 0.15 mm (3.78503 ± 0.00591 inch)	95.86 mm (3.77401 inch)
3304 3306 G3306 DI PC	7N-8866 148-2138	100.03 ± 0.76 mm (3.938 ± 0.030 inch) 100.03 ± 0.76 mm (3.938 ± 0.030 inch)	98.89 mm (3.893 inch) 98.51 mm (3.878 inch)
3406 3408 3412	143-0040	112.78 ± 0.25 mm (4.440 ± 0.010 inch)	111.51 mm (4.390 inch)
G3406 G3408 G3412	N/A	125.00 ± 0.25 mm (4.921 ± 0.010 inch)	123.72 mm (4.871 inch)
		112.78 ± 0.25 mm (4.440 ± 0.010 inch)	111.51 mm (4.390 inch)
3406E 3456	N/A	120.00 ± 0.15 mm (4.724 ± 0.006 inch)	119.45 mm (4.703 inch)
3500 G3500	4P-6571 7C-3471 7E-5861 7E-8760 101-1175 122-5961 128-1141 131-0410 131-0411 131-0423 144-6409 145-3215 153-8397 154-1612 161-2508 172-0834 172-0836 184-5496 206-1554 206-1555 206-1560 206-1563 229-9942 290-1351 295-2047 418-9804 424-7545 462-4740 480-3132 487-3422 495-2062 525-6572	142.00 ± 0.15 mm (5.591 ± 0.006 inch)	141.0 mm (5.55 inch)
	269-0040 315-2630		141.5 mm (5.5709 inch)
3600, G3600, C280	N/A	280.00 mm (11.024 inch)	279.00 mm (10.984 inch)

(1)	As measured from the Intake valve seat base.
(2)	Maximum permissible projection of the fuel injection nozzle below the face of the cylinder head after resurfacing should not exceed 4.45 mm (0.17520 inch)
(3)	A maximum removal of 0.25 mm (0.010 inch) is permissible for resurfacing.

Flatness of the Surface

Maintain the original specifications for all cylinder head assemblies during reconditioning.

Note: The critical factors that need to be considered during the reconditioning of the cylinder block and the cylinder head, the compression ratios, and the clearance between the valve and the piston. The compression ratio increases when material is removed from the cylinder block.

Illustration 98	g01300274
Measurement of total surface for flatness (3200 Engine)

Illustration 99	g01300282
Measurement of total surface for flatness (3400 Engine)

Flatness of the cylinder head can be measured by using a straight edge and a feeler gauge. Shown in Illustration 98 and Illustration 99. A straight edge for measuring the total flatness of surface is required. A straight edge should be used for measuring a small area.

Illustration 100	g01456778

Measure the flatness of the combustion area on the cylinder head. Use a straight edge and a feeler gauge to measure the flatness. Measure the surface in two positions crosswise and measure the surface in two positions lengthwise.

Illustration 101	g06229716
(B) Diameter of the combustion chamber

Illustration 102	g06189553
Flatness of the surface for 3500 (B) Diameter of the combustion chamber (C) Cylinder head surface (D) Combustion chamber surface

Table 11

Specifications for the Cylinder Head Flatness
Model	Part Number	Diameter of the Combustion Chamber (B)	Flatness of the Cylinder Head Surface (C)	Flatness of the Combustion Chamber Surface (D)	Sealing Surface Texture	Sealing Surface Waviness Spec.
D318	N/A	N/A	The overall flatness is 0.13 mm (0.005 inch) 0.05 mm (0.002 inch) for any 150 mm (5.9 inch) span	N/A	3.2 µm (125.98 µinch) Ra Max	N/A
D320	N/A	N/A	The overall flatness is 0.13 mm (0.005 inch) 0.05 mm (0.002 inch) for any 150 mm (5.9 inch) span	N/A	3.2 µm (125.98 µinch) Ra Max	N/A
D342 G342	N/A	N/A	The overall flatness is 0.13 mm (0.005 inch) 0.05 mm (0.002 inch) for any 150 mm (5.9 inch) span	N/A	3.2 µm (125.98 µinch) Ra Max	N/A
D343 G343	N/A	N/A	The overall flatness is 0.13 mm (0.005 inch) 0.05 mm (0.002 inch) for any 150 mm (5.9 inch) span	N/A	3.2 µm (125.98 µinch) Ra Max	N/A
D346 G346 D348 G348 D349 G349	N/A	N/A	The overall flatness is 0.13 mm (0.005 inch) 0.05 mm (0.002 inch) for any 150 mm (5.9 inch) span	N/A	3.2 µm (125.98 µinch) Ra Max	N/A
D353 G353	N/A	N/A	The overall flatness is 0.13 mm (0.005 inch) 0.05 mm (0.002 inch) for any 150 mm (5.9 inch) span	N/A	3.2 µm (125.98 µinch) Ra Max	N/A
D379 G379 D398 G398 D399 G399	N/A	N/A	The overall flatness is 0.13 mm (0.005 inch) 0.05 mm (0.002 inch) for any 150 mm (5.9 inch) span	N/A	3.2 µm (125.98 µinch) Ra Max	N/A
C7	219-5844 227-5951 259-8305 278-3490 280-7503 314-4183 314-4184 314-4185	N/A	The overall flatness is 0.13 mm (0.005 inch) 0.05 mm (0.002 inch) for any 150 mm (5.9 inch) span	N/A	0.5 - 1.6 µm (19.6850 - 62.9921µinch) Ra Max	Minimum Waviness Height - 0.0125 mm (0.00049 inch) per 5.0 mm (0.20 inch) of spacing(2)
C9 C-9 C9.3	201-2180 241-8392 252-8438 255-4961 311-7226 311-7218 311-7228 311-7229 314-4184 328-7475 332-3619 491-1831	N/A	The overall flatness is 0.15 mm (0.006 inch) 0.05 mm (0.002 inch) for any 150 mm (5.9 inch) span	N/A	3.2 µm (125.98 µinch) Ra Max	Minimum Waviness Height - 0.0125 mm (0.00049 inch) per 5.0 mm (0.20 inch) of spacing(2)
C-10 C-12 C12	179-9458 148-2135	N/A	The overall flatness is 0.15 mm (0.006 inch) 0.05 mm (0.002 inch) for any 150 mm (5.9 inch) span	N/A	3.2 µm (125.98 µinch) Ra Max	Minimum Waviness Height - 0.0125 mm (0.00049 inch) per 5.0 mm (0.20 inch) of spacing(2)
C11 C13 C-13	245-4031 257-2170 265-9120 289-3210 300-9512 302-2297 308-6358 331-1981 342-4397 344-0059 345-3752 346-1984 346-1999 520-4381 520-4382	N/A	The overall flatness is 0.15 mm (0.006 inch) 0.05 mm (0.002 inch) for any 150 mm (5.9 inch) span	N/A	3.2 µm (125.98 µinch) Ra Max	Minimum Waviness Height - 0.0125 mm (0.00049 inch) per 5.0 mm (0.20 inch) of spacing(2)
C15 C-15 C18 C-18	185-2246 222-1982 223-7263 243-0943 245-4324 263-4890 281-1640	N/A	The overall flatness is 0.15 mm (0.006 inch) 0.05 mm (0.002 inch) for any 150 mm (5.9 inch) span	N/A	3.2 µm (125.98 µinch) Ra Max	Minimum Waviness Height - 0.0125 mm (0.00049 inch) per 5.0 mm (0.20 inch) of spacing(2)
C16 C-16	223-7263 243-0943 263-4890 281-1640	N/A	The overall flatness is 0.15 mm (0.006 inch) 0.05 mm (0.002 inch) for any 150 mm (5.9 inch) span	N/A	3.2 µm (125.98 µinch) Ra Max	Minimum Waviness Height - 0.0125 mm (0.00049 inch) per 5.0 mm (0.20 inch) of spacing(2)
C27 C32	284-2787 357-7398 396-8374 431-1153	N/A	The overall flatness is 0.15 mm (0.006 inch) 0.05 mm (0.002 inch) for any 150 mm (5.9 inch) span	N/A	1.6 µm (62.9921µinch) Ra Max	Minimum Waviness Height - 0.0125 mm (0.00049 inch) per 5.0 mm (0.20 inch) of spacing(2)
C-30 C-32	6I-3606 105-3798 105-3799 105-3800 123-7338 124-7373 143-0046 143-3615 151-4951 151-1335 151-5241 151-5243 198-6523 198-6524 206-7744	N/A	The overall flatness is 0.15 mm (0.006 inch) 0.05 mm (0.002 inch) for any 150 mm (5.9 inch) span	N/A	3.2 µm (125.98 µinch) Ra Max	Minimum Waviness Height - 0.0125 mm (0.00049 inch) per 5.0 mm (0.20 inch) of spacing(2)
C175	328-7082 345-8447 456-2406 515-8766 517-4407	201.4 ± 0.3 mm (7.93 ± 0.02 inch)	0.05 mm (0.002 inch) for any 150 mm (5.9 inch) span	N/A	3.2 µm (125.98 µinch) Ra Max	N/A
3044 3046	N/A	N/A	The overall flatness is 0.20 mm (0.008 inch) 0.05 mm (0.002 inch) for any 150.00 mm (5.91 inch) span	N/A	3.2 µm (125.98 µinch) Ra Max	N/A
3054	N/A	N/A	The overall flatness is 0.15 mm (0.006 inch) 0.05 mm (0.002 inch) for any 150.00 mm (5.91 inch) span	N/A	3.2 µm (125.98 µinch) Ra Max	N/A
3056	N/A	N/A	The overall flatness is 0.25 mm (0.00984 inch) 0.05 mm (0.002 inch) for any 150 mm (5.9 inch) span	N/A	3.2 µm (125.98 µinch) Ra Max	N/A
3064 3066	N/A	N/A	The overall flatness is 0.20 mm (0.008 inch) 0.05 mm (0.002 inch) for any 150.00 mm (5.91 inch) span	N/A	3.2 µm (125.98 µinch) Ra Max	N/A
3114 3116 3126	N/A	N/A	The overall flatness is 0.15 mm (0.006 inch) 0.05 mm (0.002 inch) for any 150.00 mm (5.91 inch) span	N/A	3.2 µm (125.98 µinch) Ra Max	N/A
3176 3196	N/A	N/A	The overall flatness is 0.30 mm (0.01181 inch) 0.05 mm (0.002 inch) for any 150.00 mm (5.91 inch) span	N/A	3.2 µm (125.98 µinch) Ra Max	N/A
3204 DI 3204 PC 3208	N/A	N/A	The overall flatness is 0.15 mm (0.006 inch) 0.05 mm (0.002 inch) for any 150.00 mm (5.91 inch) span	N/A	3.2 µm (125.98 µinch) Ra Max	N/A
3304 3306 G3306 DI PC	7N-8866 148-2138	N/A	0.10 mm (0.004 in) overall 0.05 mm (0.002 in) for any 150 mm (6.0 in) span	N/A	3.2 µm (125.98 µinch) Ra Max	N/A
3406 3408 3412	N/A	N/A	The overall flatness is 0.13 mm (0.005 inch). 0.05 mm (0.002 inch) for any 150 mm (6.0 inch) span	N/A	3.2 µm (125.98 µinch) Ra Max	N/A
G3406 G3408 G3412	N/A	N/A	The overall flatness is 0.13 mm (0.005 inch). 0.05 mm (0.002 inch) for any 150 mm (6.0 inch) span	N/A	3.2 µm (125.98 µinch) Ra Max	N/A
3406E 3456	N/A	N/A	0.26 mm (0.010 inch) overall 0.05 mm (0.002 inch) for any 150 mm (6.0 inch) span	N/A	3.2 µm (125.98 µinch) Ra Max	N/A
3500 G3500	4P-6571 7C-3471 7E-5861 7E-8760 101-1175 122-5961 128-1141 131-0410 131-0411 131-0423 144-6409 145-3215 153-8397 154-1612 161-2508 172-0834 172-0836 184-5496 206-1554 206-1555 206-1560 206-1563 229-9942 269-0040 290-1351 295-2047 315-2630 418-9804 424-7545 462-4740 487-3422 495-2062 525-6572	205.0 mm (8.07 inch)	The overall flatness is 0.10 mm (0.00394 inch). 0.05 mm (0.002 inch) for any 150 mm (6 inch) span	0.05 mm (0.002 inch) (1)	3.2 µm (125.98 µinch) Ra Roughness Sampling Length or Cutoff - 2.54 mm (0.10000 inch)	Minimum Waviness Height - 0.0125 mm (0.00049 inch) per 5.0 mm (0.20 inch) of spacing (2)
	480-3132				3.2 µm (125.98 µinch) Ra Roughness Sampling Length or Cutoff - 2.54 mm (0.10000 inch) Average Roughness Peak to Valley Height - 19.0 µm (748.03 µinch) Rz	Minimum Waviness Height - 0.0125 mm (0.00049 inch) per 5.0 mm (0.20 inch) of spacing(2)
3600	N/A	N/A	The overall flatness is 0.10 mm (0.00394 inch). 0.05 mm (0.002 inch) for any 150 mm (6 inch) span	N/A	1.6 µm (62.9921µinch) Ra Max	Circular Lay

(1)	This is within an area that is outlined by an outer diameter of 205.0 mm (8.07 inch) and an inner diameter of 190.0 mm (7.48 inch) about the center of the cylinder head.
(2)	For waviness spacing smaller than 5.0 mm (0.20 inch) use maximum waviness height of 0.00254 PER mm (0.00010 PER inch) spacing.

Permissible Distortion for C4.4, C6.6, and C7.1 Cylinder Heads

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Illustration 103	g06277552
Typical example of a C4.4 engine

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Illustration 104	g06277555
Typical example of a C6.6 engine

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Illustration 105	g06277562
Typical example of a C7.1 engine

1. The maximum distortion of the cylinder head is given in Table 12.
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   Table 12

   Maximum Permissible Distortion
   Width (A)	0.03 mm (0.00118 inch), 0.08 mm (0.0032 inch) for C4.4 Tier 4 and C7.1
   Length (B)	0.05 mm (0.00197 inch), 0.08 mm (0.0032 inch) for C4.4 Tier 4 and C7.1
   Diagonal Line (C)	0.05 mm (0.00197 inch), 0.08 mm (0.0032 inch) for C4.4 Tier 4 and C7.1

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   Table 13

   Surface Texture of Cylinder Head

   Average ≤ .15 µm (5.905512 µinch) Max ≤ 0.20 µm (7.874016 µinch)

Machining the C175 Cylinder Head Combustion Face Using Rottler Equipment

Like many engine machining operations there is more than one method that can be used to obtain results. Your dealership may own a variety of machining tools that are capable of performing the machining operation. Depending on the particular machine tool, the machining operation maybe more or less automated. This section outlines the four most commonly used Rottler machines. Other machines, set-upand methods are viable alternatives that could be used if the ones outlined here are not available.

For the user program, questions or more information and a complete catalog of products, contact:

Rottler
8029 South 200th Street
Kent, WA 98032
(253) 872-7050
(800) 452-7050
www.rottlermfg.com
CATSOP@rottlermfg.com

Cutting Inserts

The use of the correct cutting inserts is crucial to obtaining the desired finish results. If the incorrect inserts are used the finish standards will not be achievable.

6303B Round CBN

This is a good general-purpose insert that is most economical to use. It is round and can be used on both sides. If carefully indexed there will as many as 36 cutting edges per inserts.

6303V Octagon CBN

This is an excellent insert that will maximize surface flatness and at the same time. The are 16 cutting edges per insert – 8 edges per side.

Fixturing System

There are two basic fixturing principles that are used for fixturing cylinder heads when remachining the combustion surface. They each have their benefits.

Illustration 106	g06319048
Example of 7209M Universal Leveling Table

7209M Universal Leveling Table

This fixturing system is manufactured by Rottler and has been the standard for many years in the remanufacturing industry. It has three main benefits:

• It can fixture a large variety of work pieces. Not only cylinder heads but manifolds and other work pieces that are difficult to hold on to.

• The two axis adjustment then makes it easy to align the surface that is required to be cut with the axis of the machine tool.

• If the goal is to make the new surface as parallel to the old surface as possible this is the best method to use. An example where this would be desirable would be with overhead cam cylinder heads.

Support Parallels

This fixturing system consists of two simple parallels. In some cases one large parallel is required instead of two. The cylinder head is placed on top of the parallels and clamped in place using toe clamps or other devices. This is an acceptable system when machining cylinder heads where the fixturing surface on the head is parallel to the combustion surface that is going to be surfaced or recut. Generally speaking using this system will guarantee the surface being cut is parallel to the surface on the opposite side of the head.

Machine Tool and Cutterheads

There are a wide variety of machine tools that are capable of doing this surfacing machining operation on C175 cylinder heads. Below are various models that are available from Rottler Mfg. Below is a brief description of each.

F60 – Series

Illustration 107	g06319808
Example of F69A Machine

There are several models of this machine. They are general-purpose machining centers commonly used for machining automotive sized engine blocks and have the capacity to machine the C175 Cylinder head. Once the cylinder head is fixtured this machine can automatically probe and remove the material.

Illustration 108	g06319063
Example of 650-2-8F 14” diameter fly cutter head

Use the optional 650-2-8F 14” diameter fly cutter head with this machine.

F70 – Series

Illustration 109	g06319811
Example of F70 Machine

This machine is designed for a wide variety of engine remanufacturing work. This machine has the capacity to machine a C175 cylinder head. Once the cylinder head is fixtured this machine can automatically probe and remove the material.

Illustration 110	g06319063
Example of 650-2-8F 14” diameter fly cutter head

Use the optional 650-2-8F 14” diameter fly cutter head with this machine.

S80 – Series

Illustration 111	g06319852
Example of S86A Machine

There are two models. The S85 and S86. These are basic machines used for “surfacing” operations only for example they cannot bore cylinders. They are simple to use. They are excellent machines for production surfacing operations or for low volume and a high variety of work. If the requirement is to simply put a new flat surface on a work piece – these are the simplest machines to use.

Use the standard fly cutterhead that comes installed on this machine.

F103/4/5

Illustration 112	g06319854
Example of F105 Machine

These machines are designed for a wide variety of engine remanufacturing work. They have the capacity to machine a C175 cylinder head. Once the cylinder head is fixtured these machines can automatically probe and remove the material. These machines were preceded by the F90 Series.

Illustration 113	g06319070
Example of 6294T 18” diameter fly cutter head

Use the optional 6294T 18” diameter fly cutter head with this machine.

F107/9

Illustration 114	g06319856
Example of F109 Machine

These machines are designed for a wide variety of engine remanufacturing work. They have the capacity to machine a C175 cylinder head. Once the cylinder head is fixtured these machines can automatically probe and remove the material.

Illustration 115	g06319070
Example of 6294T 18” diameter fly cutter head

Use the optional 6294T 18” diameter fly cutter head with this machine.

Use the 10115 18” diameter fly cutter head if the machine has the optional HSK80 spindle.

The Cutting Process

Regardless of what type of machine is being used for the actual cutting process the basic cutting parameters are the same.

All of the cutter heads have the capability of holding two inserts – one in each end.

Note: For the purposes of the cutting process it is important to only use one insert. Do not use two inserts. One cutting insert will give the most consistent and reliable surface texture.

Use the Spindle RPM and Feed Rate specified for the particular machine being used. See Table 15. Pleasenotethe feed rate per revolution variesdepending on which cutting insert is being used. The intent of machining the C175 cylinder head is to put a new surface on fire deck. The amount of material required to make a new surface will be dependent on the condition of the old surface. Generally speaking the depth of cut should be somewhere between 0.05 mm (0.00197 inch) and 0.15 mm (0.00591 inch). Remove the least of amount of material to reduce the chance of the cylinder head not meeting the minimum overall thickness dimension of 207.85 mm (8.18305 inch).

Set-up Procedure

Table 14

Rottler Required Machine Components and Tools for C175 Cylinder Head
	Machine Models
Machine Components and Tools	F60	F70	S80 with standard cutter head	F103/4/5	F107/9
7209M Universal Leveling Table	X	X	X	X	X
7152A Dual Axis Level	X	X	X	X	X
6303B Round CBN or 6303V Octagon CBN Cutting Inserts	X	X	X	X	X
650-3-37 Toe Clamp Kit	X	X	X	X	X
6370Y 10” T-Slot Parallels	N/A	N/A	N/A	X	X
11114 16” T-Slot Parallels	X	X	N/A	X	X
6370M 18” Support Parallels	N/A	N/A	N/A	N/A	X
650-2-8F 14” Diameter Fly Cutter Head (1)	X	X	N/A	N/A	N/A
6294T 18” Diameter Fly Cutter Head (1)	N/A	N/A	N/A	X	N/A
10115 18” Diameter Fly Cutter Head (1)	N/A	N/A	N/A	N/A	X
650-3-59Y Wireless Probe with Rottler 650-3-59C Stub Stylus	X	X	N/A	X	N/A
10110 Wireless Probe with Rottler 650-3-59C Stub Stylus	N/A	N/A	N/A	N/A	X
502-12-7B Digital Runout Probe or Precision Dial Gauge	X	X	N/A	X	X

(1)	Do not use two inserts. One cutting insert will give the most consistent and reliable surface texture.

Perform these steps only as initial set-up

1. Ensure that the machine bed is clean and free of debris.
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   Illustration 116	g06319579
   Example of 7209M Leveling Table placed on the S80.

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   Illustration 117	g06319581
   Example of 16" parallels and 7209M Leveling Table placed on the F60/70

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   Illustration 118	g06319583
   Example of 10", 16" parallels and 7209M Leveling Table placed on the F103/4/5.

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   Illustration 119	g06319585
   Example of 10", 16", 18" parallels and 7209M Leveling Table placed on the F107/9.

2. Depending on the machine, set parallels or Rottler 7209M Leveling Table on machine bed, anchor loosely and adjust positioning to ensure full and flat contact, refer to Table 14 for correct support parallels.

3. Depending on the machine, use one of the following methods to level Rottler 7209M Leveling Table:

   • Place Rottler 7152A Dual Axis Level on table, aligned with X and Y axes, and adjust table until bubbles are accurately centered

   • Attach a digital runout probe or dial gauge to spindle and run along table in the X and Y directions, adjusting table until values are equal in both directions
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   Illustration 120	g06319590

4. Set C175 Cylinder Head, combustion side up, on leveling table and use 650-3-37 Toe Clamp Kit as pictured to secure the head to the table.

Machining

Table 15

Machine Model	Spindle RPM	Feed Rate 6303B Round CBN	Feed Rate 6303V Octagon CBN	Depth of Cut
F60	750	0.38 mm (0.01496 inch)	0.25 mm (0.00984 inch)	0.05 - 0.15 mm (0.00197 - 0.00591 inch)
F70	750	0.38 mm (0.01496 inch)	0.25 mm (0.00984 inch)	0.05 - 0.15 mm (0.00197 - 0.00591 inch)
S80	750	0.38 mm (0.01496 inch)	0.25 mm (0.00984 inch)	0.05 - 0.15 mm (0.00197 - 0.00591 inch)
F103/4/5	600	0.38 mm (0.01496 inch)	0.25 mm (0.00984 inch)	0.05 - 0.15 mm (0.00197 - 0.00591 inch)
F107/9	600	0.38 mm (0.01496 inch)	0.25 mm (0.00984 inch)	0.05 - 0.15 mm (0.00197 - 0.00591 inch)

If Machining to Maintain Parallelism Between Cylinder Head Faces

1. Insert wireless probe with 650-3-59C Stub stylus in machine spindle and run Go-No-Go check on mounted cylinder head. Refer to Table 14 for correct wireless probe.

2. Switch tool to fly cutter head, with ONE insert installed. Do not use two inserts. One cutting insert will give the most consistent and reliable surface texture. Refer to Table 14 for correct fly cutter head.

3. Set machine spindle position to allow the cutter to pass over the entire width of the cylinder head.

4. Refer to Table 15 for machine speeds, feeds, and depth of cut.

5. Start spindle and feed and allow the cutter to pass fully over cylinder head.

If Machining to Remove the Minimum Amount of Material from Existing Head

1. Insert wireless probe with 650-3-59C Stub stylus in machine spindle and run Go-No-Go check on mounted cylinder head. Refer to Table 14 for correct wireless probe.

2. Switch tool to fly cutter head, with ONE insert installed. Do not use two inserts. One cutting insert will give the most consistent and reliable surface texture. Refer to Table 14 for correct fly cutter head.

3. Set machine spindle position to allow the cutter to pass over the entire width of the cylinder head.

4. Refer to Table 15 for machine speeds, feeds, and depth of cut.

5. Start spindle and feed and allow the cutter to pass fully over cylinder head.

Cylinder Heads with Camshaft Bores

Table 16

Dimensions for Cylinder Heads with Camshaft Bores
Part Number of the Bearing	New Camshaft Bore in the Cylinder Head	Outside Bearing Diameter
216-5582	90.985 ± 0.020 mm (3.5821 ± 0.0008 inch)	91.100 ± 0.020 mm (3.5866 ± 0.0008 inch)
217-0751 oversize	91.224 ± 0.020 mm (3.5915 ± 0.0008 inch)	91.339 ± 0.020 mm (3.5960 ± 0.0008 inch)
217-0752 oversize	91.732 ± 0.020 mm (3.6115 ± 0.0008 inch)	91.847 ± 0.020 mm (3.6160 ± 0.0008 inch)
261-3429 oversize	92.748 ± 0.020 mm (3.6515 ± 0.0008 inch)	92.863 ± 0.020 mm (3.6560 ± 0.0008 inch)
261-3430 oversize	92.24 ± 0.020 mm (3.6315 ± 0.0008 inch)	92.355 ± 0.020 mm (3.6360 ± 0.0008 inch)

Bridge Dowel for 3400 Engines

Check the bridge dowels for movement by using the following procedure.

1. Use a torque wrench and MAC AST 100 7/16 inch tool.

2. Set the torque wrench at 13.6 N·m (10.00 lb ft).
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   Illustration 121	g06277575
   Inspect the bridge dowels for movement.

3. Grip the bridge dowel and turn the torque wrench. The bridge dowel should not rotate at 13.6 N·m (10.00 lb ft).

If there is movement, repair the hole with the 5P-7333 Repair Tool and the 5P-7324 Plug. Refer to Special Instruction, SMHS7072, "Use of the 5P-7333 Repair Tool for Bridge Dowel Repair".

Precombustion Chambers and Direct Injection Nozzle Adapter for 3400 Engines

Illustration 122	g06309676
Precombustion chamber nomenclature. (1) Injector Inlet (2) O-ring Groove (3) Nozzle Seat (4) Gasket Face (5) Chamber Outlet (6) Injector Outlet

Illustration 123	g06309680
Direct Injection Nozzle Adapter nomenclature. (1) Injector Inlet (2) O-ring Groove (3) Nozzle Seat (4) Gasket Face (5) Chamber Outlet (6) Injector Outlet

Visually inspect precombustion chambers and direct injection nozzle adapters. Refer to Illustrations 84, that have pitting (small holes in the surface) or other surface damage, can be used again.

Pitting, which can be caused by high heat during combustion or when coolant comes in contact with the body of the precombustion chamber or adapter, is permissible, according to its location and amount. For example, heavy pitting on the main body between the O-ring groove and the gasket face of the adapter is acceptable if it has not worn completely through. Similarly, pitting in the O-ring groove is acceptable if 70% or more of the groove on the inlet side shows no signs of pitting. Pitting on the gasket face is acceptable only in the outer 10% of the radius 0.64 - 0.76 mm (0.02520 - 0.02992 inch).

Visual Inspection

Pitting

Illustration 124	g06309694
Pitting on the surface between the O-ring groove and gasket face (area (A).

Use Again - if the pitting has not worn through. The pitting can be heavier than shown in this photo and still be used again.

Illustration 125	g06309993
Example of pitting extending into the top 70% (B) of the O-ring groove of a precombustion chamber.

Do Not Use Again

Illustration 126	g06309995
Example of pitting extending into the top 70% (B) of the O-ring groove of a direct injection adapter.

Do Not Use Again

Illustration 127	g06310002
Example of pitting extending into the top 70% (B) of the O-ring groove of a precombustion chamber.

Use Again

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NOTICE
If pitting is a major problem, be sure to correct the reason for pitting. It is important to maintain the cooling system correctly and at regular intervals.

Illustration 128	g06310007
Example of pitting extending into the top 10% of the outer radius of the gasket face.

Do Not Use Again

Illustration 129	g06310010
Example of pitting that has not extended beyond 10% of the outer radius of the outer radius of the gasket face of a precombustion chamber.

Use Again

Illustration 130	g06310013
Example of pitting that has not extended beyond 10% of the outer radius of the outer radius of the gasket face of a direct injection adapter.

Use Again

Illustration 131	g06310020
A small nick on the precombustion chamber splines.

Use Again - if sharp edges can be smooth with a 6V-2010 Polishing Stone or file. (Splines are not needed for correct engine operation. It is needed for manufacturing purposes only.)

Nicks, Cracks, and Other Surface Damage

Check for cracks on the threaded section of the precombustion chamber and direct injection nozzle adapters. Cracks are not acceptable.

Illustration 132	g06310022
Damage is light and limited mainly to the lower half of the threads. (C) Upper half of threads (D) Lower half of threads

Use Again - only if the damage threads can be repaired using a thread file.

Heavy damage on upper half (C) of the threads is also not acceptable. If the damage is light and limited to the lower half (D) of the threads, the threads can be repaired using a thread restorer (thread file).

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NOTICE
Only light damage is permissible in upper half (C) of the threads. The upper threads are the most important because they help prevent combustion gases from reaching the seal area.

Note: Both the precombustion chamber and direct injection nozzle adapters have 12 threads per inch.

Measurement of Precombustion Chamber Outlet

Illustration 133	g06310026
Use the correct size plug gauge to measure the chamber outlet diameter.

Use the correct size plug gauge to measure the chamber outlet diameter (Illustration 84.). If the plug gauge slides into the opening, do not use the precombustion chamber again. Be sure the plug gauge and the precombustion chamber are at the same temperature, within ± 3°C (5°F), when checking the outlet diameter.

Table 17

Precombustion Chamber Specifications
Part Number	Outlet Diameters		Thread Size		Maximum Erosion of Gasket Face (1)
	New Diameter (2) 0.051 mm (0.00201 inch)	Maximum "Use Again Diameter (1)	Diameter (inches only)	Threads Per Inch
2P-0484	8.38 mm (0.32992 inch)	8.68 mm (0.34173 inch)	⅞	12	0.64 mm (0.02520 inch)
2P-1816	9.40 mm (0.37008 inch)	9.70 mm (0.38189 inch)	1	12	0.64 mm (0.02520 inch)
3S-5445	7.16 mm (0.28189 inch)	7.47 mm (0.29409 inch)	⅞	12	0.64 mm (0.02520 inch)
4N-3714	10.69 mm (0.42087 inch) (3)	10.90 mm (0.42913 inch) (3)	⅞	12	0.64 mm (0.02520 inch)
5S-1820	5.71 mm (0.22480 inch)	6.02 mm (0.23701 inch)	⅞	12	0.64 mm (0.02520 inch)
5S-1822	6.35 mm (0.25000 inch)	6.65 mm (0.26181 inch)	⅞	12	0.64 mm (0.02520 inch)
5S-1823	6.35 mm (0.25000 inch)	6.65 mm (0.26181 inch)	⅞	12	0.64 mm (0.02520 inch)
5S-1824	6.65 mm (0.26181 inch)	6.96 mm (0.27402 inch)	⅞	12	0.64 mm (0.02520 inch)
5S-1825	6.65 mm (0.26181 inch)	6.96 mm (0.27402 inch)	⅞	12	0.64 mm (0.02520 inch)
5S-1826	7.16 mm (0.28189 inch)	7.47 mm (0.29409 inch)	⅞	12	0.64 mm (0.02520 inch)
5S-1827	7.16 mm (0.28189 inch)	7.47 mm (0.29409 inch)	⅞	12	0.64 mm (0.02520 inch)
5S-1831	5.71 mm (0.22480 inch)	6.02 mm (0.23701 inch)	¾	12	0.64 mm (0.02520 inch)
5S-1832	5.71 mm (0.22480 inch)	6.02 mm (0.23701 inch)	¾	12	0.64 mm (0.02520 inch)
5S-1833	6.35 mm (0.25000 inch)	6.65 mm (0.26181 inch)	¾	12	0.64 mm (0.02520 inch)
5S-1836	7.16 mm (0.28189 inch)	7.47 mm (0.29409 inch)	¾	12	0.64 mm (0.02520 inch)
5S-4131	9.91 mm (0.39016 inch)	10.20 mm (0.40157 inch)	⅞	12	0.64 mm (0.02520 inch)
5S-6795	7.16 mm (0.28189 inch)	7.47 mm (0.29409 inch)	⅞	12	0.64 mm (0.02520 inch)
5S-9608	8.74 mm (0.34409 inch)	9.04 mm (0.35590 inch)	⅞	12	0.64 mm (0.02520 inch)
6N-6969	10.69 mm (0.42087 inch)	10.90 mm (0.42913 inch)	1	12	0.64 mm (0.02520 inch)
7M-6848	10.16 mm (0.40000 inch)	10.46 mm (0.41181 inch)	1	12	0.64 mm (0.02520 inch)
7S-5787	10.16 mm (0.40000 inch)	10.46 mm (0.41181 inch)	1	12	0.64 mm (0.02520 inch)
8S-1523	9.91 mm (0.39016 inch)	10.20 mm (0.40157 inch)	⅞	12	0.64 mm (0.02520 inch)
8S-3617	10.16 mm (0.40000 inch)	10.46 mm (0.41181 inch)	1	12	0.64 mm (0.02520 inch)
8S-3970	7.49 mm (0.29488 inch)	7.79 mm (0.30669 inch)	⅞	12	0.64 mm (0.02520 inch)
9S-6743	10.69 mm (0.42087 inch)	10.90 mm (0.42913 inch)	1	12	0.64 mm (0.02520 inch)
9S-8679	7.92 mm (0.31181 inch)	8.23 mm (0.32402 inch)	⅞	12	0.64 mm (0.02520 inch)

(1)	Approximately 10% of the gasket face radius. Refer to Illustrations 84, 84, and 84.
(2)	If the Maximum "Use Again" Diameter exceeds the specifications, the part can be drilled to the next size diameter and restamped with a new part number. Do not install this part into an engine which requires the former part.
(3)	Outlet diameters are precombustion chambers only not direct injection nozzle adapters.

Precombustion and Direct Injection Adapter Seats for 3400 Engines

Visually inspect the seat for the adapter. The seat needs to be repaired if the seat is pitted or damaged. Refer to Special Instruction, SMHS8276, "Repair of Precombustion Chamber and Direct Injection Adapter Seating Surfaces" for procedures to recondition the seat. FT-1766 Adapter will be needed to recondition the seat.

Chamfer (A) at the threads for the adapter must be remachined to 1.50 ± 0.50 mm (0.060 ± 0.020 inch) by 30 degrees. For the cylinder heads on diesel engines, the maximum removal of stock from the seat is 0.38 mm (0.015 inch). The minimum dimension from the seat to the combustion area is 16.89 mm (0.665 inch). For the cylinder heads on gas engines, the maximum removal of stock from the seat is 0.35 mm (0.014 inch). The minimum dimension from the seat to the combustion area is 10.37 mm (0.408 inch).

Illustration 134	g01528760
(A) Chamfer 1.50 ± 0.50 mm (0.060 ± 0.020 inch) by 30 degrees (B) Minimum thickness (6) Combustion area (10) Top deck (11) Seat for the adapter

Illustration 135	g06277636
Visually inspect the seat for damage. The cylinder head in this illustration was cut for photographic purposes.

Use the cylinder head again.

Installation of 118-0372, and 118-0373 Oversize Water Directors

Water directors are used in the cylinder heads of some engines. These water directors improve the cooling of the heads by directing cooling water to specific locations in the head. In order to function properly, the orientation and the installation depth of the water director in the head is important.

Through normal wear, the water director bore can become oversized or eroded which can reduce the press fit of the water director.

Previously, the only salvage technique has been to build up the bore with weld or Belzona®. A more cost effective solution is to install an oversize water director.

Illustration 136	g06310280
Water director puller.

Illustration 137	g06310283
Water director driver.

The removal and installation tooling for water directors must be fabricated. One puller and four drivers are required to repair all the different cylinder heads that use water directors. Fabricate the tooling, using the dimensions shown in Illustrations 136and 137.

Table 18

Water Director Driver Dimensions
Driver Number	(A)	(B)	(C)
1	16.235 ± 0.025 mm (0.63917 ± 0.00098 inch)	18.925 ± 0.125 mm (0.74508 ± 0.00492 inch)	2.50 mm (0.09843 inch)
2			N/A
3			5.3 mm (0.20866 inch)
4			7.1 mm (0.27953 inch)

Inspection

1. Check the water director for signs of movement within the bore.

2. Make sure that the alignment notch in the water director is in line with the "V" stamped in the head.

3. Make sure that the water director is tight in the bore. If the water director has moved or is loose in the bore, the bore should be machined, and an oversize water director installed

Removal

If a water director shows signs of movement, remove it using a water director puller as shown in Illustration 136. Water directors that do not show signs of having moved and fit tightly in the bore, do not need to be replaced

Salvage

To use oversize water directors, the bores in the head must be machined.

Table 19

Specifications for Installing Oversize Water Directors
Part Number for Standard Size Water Director	5H-7071	1S-3062
Bore Diameter (A) for Standard Water Director	19.02 ± 0.03 mm (0.74882 ± 0.00118 inch)	19.012 ± 0.038 mm (0.74850 ± 0.00150 inch)
Part Number for Oversize Size Water Director	118-0372	118-0373
Bore Diameter (A) for Oversize Water Director	19.774 ± 0.038 mm (0.77850 ± 0.00150 inch)	19.782 ± 0.038 mm (0.77882 ± 0.00150 inch)

1. Machine the bore to the oversize dimension shown in Table

2. Thoroughly clean the head, and remove all machining debris.

Installation

Illustration 138	g06310326
Water director installed in head with counterbore. Always install the water director flush with top of counterbore, using driver number 2. (A) Bore diameter

Illustration 139	g06310330
Water director installed in head without counterbore. (A) Bore diameter (B) Installation depth

There are two types of water director bores, with or without counterbores. The two designs are shown in Illustrations 138 and 139. Some engine models may have both designs, depending on the engine configuration.

For the head to be properly cooled, the water director must be installed properly.

1. Install the water director with the notch aligned with the "V" stamped in the head.

2. Use the correct driver to ensure that the water director is installed to the proper depth.

   Note: When there is a counterbore, the director is installed flush with the bottom of the counterbore, using driver number 2. If no counterbore is present, install the water director to the correct depth.

3. After the water director is installed, make sure that the water director notch is still in line with the "V" stamped in the head.

4. Check the installation depth.

Sleeves for the Injectors of Cylinder Heads

A stainless steel sleeve is used between each unit injector and the cylinder head casting. The injector sleeve is used to seat the injector. The injector sleeve is also used to seal the injector into the casting. The injector sleeves are reusable unless the sleeves become damaged.

Refer to the Disassembly and Assembly for your machine to find the tooling that is used to remove a unit injector sleeve. Refer to the Disassembly and Assembly for your machine for Disassembly and Assembly information.

Inspect the inside surface of the sleeves for cracks, pitting, erosion, and other visual damage. Sleeves should be replaced during the general overhaul of the cylinder head with high hours.

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NOTICE
When reaming the injector seat area, be careful not to damage the surface. Do not drop the reamer onto the seat, or apply too much downward pressure with the tool because it may create radial lines on the sealing surface of the sleeve. Radial lines will cause poor sealing between the sleeve cone and the injector tip, which may result in fuel leakage into the cylinder, or combustion pressure leakage into the fuel.

Check the area at the bottom of the valve seat for normal wear. If the valve seat appears worn or distorted slightly, the sleeve must be replaced. Check the guide for Disassembly and Assembly for the procedures and the lists for tooling.

Clean the seat of injector sleeves with the appropriate size nylon bristle brush, solvent, and a lint free cloth.

Injector Sleeves

Illustration 140	g06277638
Injector Sleeve (1) O-ring Seals (2) Location for clean engine oil (3) Injector Sleeve (4) Location for 4C-9507 Retaining Compound

Stainless steel injector sleeves (3) with O-rings (1) are used between each unit injector and the cylinder head casting. The injector sleeves seal coolant within the head. The injector sleeves will not usually need to be replaced. The three O-rings should be replaced when the head is removed for reworking the valves or if the head is placed into a hot tank for cleaning.

Before you install the injector sleeves (3), 4C-9507 Retaining Compound should be applied to area (4). Clean engine oil should be applied to area (2). Use the 9U-6891 Injector Tool Group and a suitable hammer to install the injector sleeve (3) into the cylinder head.

Injector Sleeves for C175 Engines

Inspection of the injector sleeve seat:

Illustration 141	g06231160
Example of cleaned continuous shiny band 360 degrees around the seat surface. OK TO REUSE

Illustration 142	g06231194
Example of damaged seat surface. DO NOT REUSE

• The seat and threads must be free of any debris.

• The seat must not have any visible burs, burns, etc. around the surface.

• After cleaning injector sleeve seat, there should be a continuous shiny band 360 degrees around the seat surface. Refer to Illustration 141.

Illustration 143	g06231168
Example of bur (A) on sleeve seat. DO NOT REUSE

Illustration 144	g06231169
Example of burn (B) on sleeve seat. DO NOT REUSE

Illustration 145	g06231171
Example of burn (B) on sleeve seat. DO NOT REUSE

Injector Sleeves for 3114, 3116, and 3126

Illustration 146	g06277641
The arrow above indicates the injector sleeve. (A) is the O-ring.

Illustration 147	g02720383
Illustration 147 is an example of a Stainless Steel Injector Sleeve. Notice the grooves (B) on the outside of the sleeve that holds the sleeve in place.

The O-rings (A) should be replaced when the head is removed for reworking the valves or if the head is placed into a hot tank for cleaning. Lubricate the new O-rings with clean engine oil before assembly. Apply Loctite 242 to the bore in the cylinder head for diameter (C) of the injector sleeve prior to assembly.

Check the area at the bottom of the seat for normal wear. If the seat appears worn or distorted slightly, the sleeve must be replaced. The seat can be refinished with a 4C-8719 Shank and 131-8362 Reamer. Use the reamer for machining the seat of the injector to ensure a tight seal when the sleeve is assembled. If machining does not clean up the damaged seat, the sleeve must be replaced.

Refer to Tool Operating Manual, NEHS0675, "Using the 143-2099 Sleeve Replacement Tool Group on 3114, 3116, and 3126 Engines".

Stainless Steel Injector Sleeve

Illustration 148	g03679584
Illustration 147 and illustration 147 are both examples of stainless steel injector sleeves. Notice that the inside of the sleeve is smooth when installed.

Use 151-4832 tooling to remove stainless steel injector sleeves. A stainless steel injector sleeve can be told apart from bronze swaged sleeves by looking at the top of the inside of the sleeve when installed. The stainless steel sleeve will be smooth on the inside while the bronze sleeves will have two grooves because of them being swaged into place during installation. The Tool Operating Manual, NEHS0675, "Using the 143-2099 Sleeve Replacement Tool Group on 3114, 3116, and 3126 Engines" provides instructions on how to properly remove the Bronze Swaged Injector Sleeves.

Bronze Swaged Injector Sleeve

Illustration 149	g03679596
Illustration 149 is an example of a Bronze Swaged Injector Sleeve. Notice that the inside of the sleeve is initially straight, but are then is Swaged into place during installation.

Use the 143-2099 Tooling to remove Bronze Swaged Injector Sleeves. An installed bronze injector sleeve is differentiated from stainless steel sleeves by the grooves at the top of the sleeve due to the sleeve being Swaged into place during installation. The Tool Operating Manual, NEHS0675, "Using the 143-2099 Sleeve Replacement Tool Group on 3114, 3116, and 3126 Engines" provides instructions on how to properly remove the Bronze Swaged Injector Sleeves.

Injector Sleeves for 3176, and 3196

The seat can be refinished with a 9U-6860 Injector Sleeve Tool. Use the reamer for machining the seat of the injector to ensure a tight seal when the sleeve is assembled. If machining does not clean up the damaged seat, the sleeve must be replaced.

Refer to Special Instruction, SEHS9246, "Using 9U-6860 Injector Sleeve Tool to Replace Unit Injector Sleeves" for more information.

Valve Guides

Valve guides must be measured for installed height and inside bore diameter.

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NOTICE
Do not use any valve guides with obvious damage. Do not use valve guides with wear that is beyond the specifications that are provided. Loose or damaged valve guides must be removed and new valve guides must be installed. Correct any conditions that could have caused the original damage or wear.

Table 20

Valve Guide Measurement Tools
Part Number	Dimensions and Engines inch Which Gauge (Red End) Is Used to Check Worn Valve	Dimensions Which Gauge (Green End) is Used to Check New or Knurled Value Guides
4C-9734	8.08 mm (0.318 inch) (3114, 3116)	8.035 mm (0.316 inch)
5P-3536	7.92 mm (0.312 inch), 9.52 mm (0.375), and 12.7 mm (0.500 inch) (D379, D398, D399, G379, G398, G399, C7 through C32, 3176 and 3196)
6V-7058	9.55 mm (0.376 inch) [1673, 1693, 1100, Series, 3100 Series, 3204 3208, 3304, 3306, D330C, D333C, D342, D343, D346, D348, D349, D353, D379, D398, D399, 137.2 (5.4 inch) Bore 90 degree V-8]	9.5 mm (0.374 inch), 1100 Series, 3100 Series, 3204 and 3208
6V-7068	9.54 mm (0.3755 inch) (3406, 3408, 3412, 3508, 3512, 3516, 9.65 mm (0.38 inch) Intake and Exhaust valve)	9.460 mm (0.3725 inch)
6V-7895	12.775 mm (0.503 inch) (D379, D398, D399)	N/A
9U-6399	16.003 x 175 mm (0.630 x 6.9 inch) (Go)	16.059 x 50.8 mm (0.6322 x 2.0 inch) (No-Go)
9U-6401	16.106 x 50.8 mm (0.634 x 2.0 inch) (Go)	16.209 x 50.8 mm (0.6381 x 2.0 inch) (No-Go)
261-3687	12.672 mm (0.498 inch) (3508, 3512, 3516)	12.594 mm (0.4958 inch)
	12.7 mm (0.5 inch) (3500 Engines - Exhaust valves only)	N/A

This section shows the tools for inspecting valve guides in Caterpillar engines. Valve guides must be measured for installed height from the top deck and the inside bore diameter. Refer to the appropriate. Refer to the appropriate Disassembly and Assembly Manual for removal and installation instructions for the valve guides.

Note: Do not reuse any valve guide with obvious damage. Do not use a valve guide if the wear exceeds the permitted allowance according to available specifications. Loose valve guides or damaged valve guides must be removed and new valve guides must be installed. Correct any condition that could have caused the original damage or wear. The valve guide will not require any machining after installation.

Illustration 150	g01300432
5P-3536 Valve Guide Gauge

Illustration 151	g01300451
Typical plug gauge

Illustration 152	g01300601
Measure the diameter of the bore.

Illustration 153	g01300692
The end of the plug gauge must not go into the bore of the valve guide more than 19.0 mm (0.75 inch).

Measure both ends of each valve guide. The measurement should be taken 19.0 mm (0.75 inch) from each end of the bore. If the valve guide is counterbored, measurements must be taken in this area. If plug gauges are used, the end of the gauge should not extend into the valve guide more than 19.0 mm (0.75 inch). If the measurement of the valve guide exceeds the dimension, then the valve guide is worn beyond the allowable dimension for reusability.

Note: Do not force the plug gauge or turn the plug gauge into the guide of the bore. Doing so will damage the gauge.

The specifications of installed height for valve guides in all current Caterpillar cylinder heads can be measured with a 6V-2012 Micrometer Depth Gauge. The dial caliper, and the 8H-8581 Feeler Gauge are also needed.

The inside diameter of the valve guide can be measured with tools such as a 5P-3536 Valve Guide Gauge, 6V-7058 Plug Gauge, and 6V-7068 Valve Guide Gauge. The rest of the tooling available is in Table 20, along with their corresponding engines. There are different tools for the different sizes of valve guides.

Inspection for Valve Guides

Illustration 154	g01667479
Type 1 for C7 through C32 Height to the top of the valve guide (B) The installed height for the valve guide

Illustration 155	g01668733
Type 2 for C7 through C32 Height from the top of the head to the square shoulder that is just below the top of the valve guide (B) The installed height for the valve guide

Illustration 156	g01668114
Type 3 for C7 through C32 Height to the top of the valve guide (B) The installed height for the valve guide

Illustration 157	g06229841
C175 Cylinder Heads

Illustration 158	g06277648
3126B Cylinder Heads

Illustration 159	g06277651
Using a Depth Micrometer

Illustration 160	g06277655
(B) Height of an installed valve guide

Valve Guides for D Models, and 1404 Engines

Table 21

Dimensions for the Valve Guides for D Models, and 1404 Engines
Model	Installed Valve Guide Maximum Bore		Installed
	Intake	Exhaust	Height
1404	9.550 mm (0.37598 inch)	9.550 mm (0.37598 inch)	N/A
D318	11.201 mm (0.44098 inch)	11.201 mm (0.44098 inch)	44.45 mm (1.75000 inch)
D320	9.575 mm (0.37697 inch)	9.575 mm (0.37697 inch)	33.3 ± 0.5 mm (1.31102 ± 0.01969 inch)
D342 G342	9.550 mm (0.37598 inch) 12.775 mm (0.50295 inch)	9.550 mm (0.37598 inch) 12.775 mm (0.50295 inch)	42.93 mm (1.69015 inch)
D343 G343	9.550 mm (0.37598 inch)	9.550 mm (0.37598 inch)	(1)
169390° V8	9.550 mm (0.37598 inch)	9.550 mm (0.37598 inch)	N/A
D346 G346	9.550 mm (0.37598 inch)	9.550 mm (0.37598 inch)	26.21 ± 0.51 mm (1.03189 ± 0.02008 inch)(2)
D348 G348	9.550 mm (0.37598 inch)	9.550 mm (0.37598 inch)	(3)
D349 G349	9.550 mm (0.37598 inch)	9.550 mm (0.37598 inch)	N/A
D353 G353	9.550 mm (0.37598 inch) 12.775 mm (0.50295 inch)	9.550 mm (0.37598 inch) 12.775 mm (0.50295 inch)	N/A
D379 G379 D398 G398 D399 G399	9.550 mm (0.37598 inch) 12.775 mm (0.50295 inch)	9.550 mm (0.37598 inch) 12.775 mm (0.50295 inch)	N/A

(1)	The height of the valve guide as measured from the bottom of the counterbore is 30.28 mm (1.19212 inch).
(2)	Measure from bottom of counterbore.
(3)	Valve guide "with shoulder" to be installed flush with the bottom of the counterbore. Valve guide "without shoulder" to be installed to 26.21 mm (1.03189 inch) as measured from the top surface of the cylinder head.

Valve Guides for C4.4, C6.6, and C7.1

Illustration 161	g06277658
INTAKE valve guide (A). EXHAUST valve guide (B) for C4.4 engines.

Illustration 162	g06277673
INTAKE valve guide (A). EXHAUST valve guide (B) for C6.6 engines.

Illustration 163	g03773000
INTAKE valve guide (A). EXHAUST valve guide (B) for C7.1 engines.

This procedure details the steps necessary to salvage the cylinder heads in the C4.4, C6.6 and C7.1 engines. This procedure will involve the machining of the cylinder head for the installation of new valve guides and valve seat inserts. The machining procedures in this document only apply to cylinder heads that have the valve guides cast into the cylinder head.

New valve guide inserts can be used if the valve guide bore in the cylinder head is worn beyond specifications. Each valve seat insert bore diameter should be measured with a dial indicator to find the centerline position for machining the valve guide bore. The valve guide parent bore should be machined to a positional tolerance of 0.10 mm (0.004 inch) to the centerline. Use the following procedure to install new valve guide inserts.

Note: This step is to be used on cylinder heads that do not have separate valve guides installed into the cylinder head. Only cylinder heads with the valve guide that is cast into the cylinder head should use this machining procedure.

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Illustration 164	g06277675

1. Machine the cylinder head to the specifications found in the following table.
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   Table 22

   Specifications for C4.4, C6.6, and C7.1
   Item	Description	Value
   (H)	Diameter of Counterbore	15.0 mm (0.59 inch) - 15.5 mm (0.61 inch)
   (I)	Diameter of Chamfer	11.4 mm (0.45 inch) - 11.6 mm (0.46 inch)
   (J)	Total Chamfer Angle	90 Degrees
   (K)	Radius	Maximum Radius of 0.6 mm (0.024 inch)
   (L)	Bottom of Counterbore to Bottom of Cylinder Head	66.75 mm (2.628 inch) - 67.25 mm (2.648 inch)
   (M)	Hole Diameter	10.000 mm (0.3937 inch) - 10.022 mm (0.3946 inch)

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   Table 23

   Valve Guide Part Number
   Valve Guides	380-2073

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   Illustration 165	g06277677

2. Install the new valve guides. Machine the EXHAUST valve guide to the dimensions that are shown in the following table.
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   Table 24

   Exhaust Valve Guide Dimensions for C4.4, C6.6, and C7.1
   Item	Description	Value
   N	Max Radius	0.4 mm (0.02 inch)
   O	Depth	38.25 mm (1.506 inch) to 38.75 mm (1.526 inch)
   P	Diameter	7 mm (0.28 inch) to 7.5 mm (0.30 inch)

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   Illustration 166	g06277681

3. Install new valve seat inserts (R), as shown.

4. Obtain a suitable reamer and cutter assembly. The valve guides will be reamed using one operation.
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   Table 25

   Cutting Speeds and Feed Rates for Valve Guides for C4.4, C6.6, and C7.1
   Tool Type	Cutting Speed (M/min)	Feed Rate (mm/rev)
   Single Flute Solid Carbide	30-40	0.18 - 0.21
   Single Adjustable Carbide Blade	40-50	0.20 - 0.25
   Single Adjustable Pitch Circle Diameter (PCD) Blade	40-50 or 60-70	0.20 - 0.25 or 0.10 - 0.20

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   Table 26

   Additional Valve Guide Related Tooling for C7.1 Engines
   Description	Part Number	Usage Notes
   Valve Guide Stop Collar	482-0188	Installs valve guide to height of 12.65 mm (0.49803 inch). Uses the 482-0190 Reamer to finish installed valve guide to correct ID of 9.0 mm (0.35433 inch).
   Valve Guide Driver	482-0189	Installs new valve guides with internal diameter of 8.0 mm (0.31496 inch) before reaming. Uses the 482-0190 Reamer to finish the installed valve guide to correct ID of 9.0 mm (0.35433 inch).
   Valve Guide Finish Reamer	482-0190	Finishes the 335-6264 Valve Guide to the proper diameter.
   Valve Guide Stop Collar	483-7533	Installs valve guide to height of 11.0 mm (0.43307 inch). Uses the 385-8470 Reamer to finish the installed valve guide to correct ID of 7.0 mm (0.27559 inch).
   Valve Guide Reamer	483-7534	Installs new valve guides with an internal diameter of 6.5 mm (0.25590 inch) before reaming. Uses the 385-8470 Reamer to finish the installed valve guide to correct ID of 7.0 mm (0.27559 inch).

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   Table 27

   Valve Guide Bore
   Diameter of Valve Guide Bore (Q)	5.97 mm (0.235 inch) to 5.99 mm (0.236 inch) 9.000 mm (0.3543 inch) to 9.022 mm (0.3552 inch) (C7.1 Tier 2/3 Mech)
   Surface Texture of Valve Guide Bore	1.6 µm (62.99213 µinch) Maximum 0.8 µm (31.49606 µinch) Maximum (C7.1 Tier 2/3 Mech)

5. Install the reamer into the valve guide. Carefully turn the handle in a clockwise direction. Gradually move the reamer into the valve guide until the valve guide. Lubricant is not necessary.

6. Clean the cylinder head. The following table lists the maximum contaminant levels for the cylinder head after the machining process.
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   Table 28

   Contaminant Levels
   Feature	Maximum Particulate Size in any Direction (micro meters) C6.6 and C4.4 engines	Maximum Particle Weight C4.4 engines	Maximum Particle Weight C6.6 engines	Maximum Particle Weight C7.1 (Tier 2/3 Mech) Engines	Maximum Particulate Size in any Direction (micro meters) C7.1 (Tier 2/3 Mech) Engines	Maximum Particle Weight C7.1 (Tier 4) Engines	Maximum Particulate Size in any Direction (micro meters) C7.1 (Tier 4) Engines
   Top face including push rod holes, glow plug holes, oil drains, all wetted surfaces, and the oil feed passage	500	40	60	48	1000	60	500
   Total inlet ports and inlet manifold	-	40	60	48	1000	60	-
   Exhaust ports	-	40	60	48	1000	60	-
   Cylinder head gasket face	-	10	15	-	-	15	-
   Water jacket including housing for water temp regulator	1500	100	150	90	1000 x 1000 y 500 z	150	500
   Injector bores and fuel return gallery	1200	10	10	N/A	N/A	10	1200
   Fire Face and Valve Seat Faces	N/A	N/A	N/A	10	1200 x 500 y 150 z	N/A	N/A
   Filtration Level - 30 micrometers

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   Illustration 167	g06277687
   Typical example for C4.4 and C6.6 engines.

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   Illustration 168	g03774048
   Typical example for C7.1 engines.

7. Inspect the gasket surface (E) and all threaded holes of the cylinder head for wear or damage. Inspect the pads (D) for the rocker shaft for wear or damage.

   The cylinder head should be pressure tested to 200 kPa (29 psi).

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   Illustration 169	g06277688

8. Install a new plug (F) for the fuel return galley.
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   Illustration 170	g03780534

9. Install a new plug (N) in the return fuel galley.

The method of fitting the Avdel® plug is similar to that used for a pop-rivet. The plug must be fitted using the appropriate Avdel® air-tool and the correct 10.0 mm (0.39370 inch) jaw set.

Note: The plug should be fitted dry, no sealant or locking compound applied. The is to avoid contamination of the fuel return system.

Place the plug in the jaws of the air-tool. insert into the bore and activate the trigger on the tool. This should pull the steel pin and wedge into the aluminum plug body until the correct force is achieved to snap off the steel pin.

The finished plug installation should be fully seated inside the bore and not protruding from the face of the head. If the plug protrudes from the head, brackets and other mounting hardware will not mount correctly.

Installing Valve Guides for C4.4, C6.6, and 7.1 Cylinder Heads

Note: The following parts are needed to replace the valve guides.

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Illustration 171	g06277692
Typical example

1. Use a suitable press to remove the valve guides (H) from the cylinder head. There are 16 valve guides for C4.4 and 24 valves guides for C6.6, and C7.1 (H) per cylinder head.
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   Illustration 172	g06277696
   Typical example

2. Use a suitable press to install new valve guides (H) to dimension (J). The guide must be reamed to size (K).

   Note: The valve guides should be machined after all components are installed.

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   Table 29

   Dimensions for Valve Guides (C4.4 Tier 4), C6.6 and C7.1
   (J)	Height of 10.75 mm (0.4232 in) to 11.25 mm (0.4429 in). Surface Texture is 1.6 µm (62.99213 µinch) Ra Maximum
   (K)	Diameter of 7.007 mm (0.2759 in) to 7.020 mm (0.2764 in)

Valve Guides for C7 through C32

Table 30

Dimensions for the Valve Guides for C7 through C32
Valve guide	Comment	Type	Maximum Bore Diameter	(B) Installed Height
100-8150	N/A	2	9.584 mm (0.3773 inch)	22.0 ± 0.5 mm (0.87 ± 0.02 inch)
122-0447	0.51 mm (0.0201 inch) oversize	1	9.585 mm (0.3774 inch)	35.0 ± 0.5 mm (1.38 ± 0.02 inch)
122-7375	N/A	1	9.584 mm (0.3773 inch)	35.0 ± 0.5 mm (1.38 ± 0.02 inch)
122-8612	0.13 mm (0.005 inch) oversize	1	9.585 mm (0.3774 inch)	35.0 ± 0.5 mm (1.38 ± 0.02 inch)
140-9670	N/A	1	8.143 mm (0.3206 inch)	23.0 ± 0.5 mm (0.91 ± 0.02 inch)
144-2904	N/A	2	9.594 mm (0.3777 inch)	22.0 ± 0.5 mm (0.87 ± 0.02 inch)
147-8220	N/A	1	9.594 mm (0.3777 inch)	17.8 ± 0.5 mm (0.70 ± 0.02 inch)
173-7188	N/A	1	9.584 mm (0.3773 inch)	32.26 ± 0.76 mm (1.270 ± 0.030 inch)
187-8278	0.13 mm (0.0051 inch) oversize	1	9.596 mm (0.3778 inch)	17.8 ± 0.5 mm (0.70 ± 0.02 inch)
187-8279	0.51 mm (0.0201 inch) oversize	1	9.595 mm (0.3778 inch)	17.8 ± 0.5 mm (0.70 ± 0.02 inch)
187-8280	0.13 mm (0.0051 inch) oversize	1	8.145 mm (0.3207 inch)	23.0 ± 0.5 mm (0.91 ± 0.02 inch)
187-8281	0.51 mm (0.0201 inch) oversize	1	8.144 mm (0.3206 inch)	23.0 ± 0.5 mm (0.91 ± 0.02 inch)
224-3124	N/A	1	9.590 mm (0.3776 inch)	22.0 ± 0.5 mm (0.87 ± 0.02 inch)
255-8665	2007	3	8.143 mm (0.3206 inch)	48.4 ± 0.5 mm (1.91 ± 0.02 inch)
259-2186	N/A	2	9.590 mm (0.3776 inch)	22.0 ± 0.5 mm (0.87 ± 0.02 inch)
259-5829	N/A	1	8.143 mm (0.3206 inch)	12.0 ± 0.5 mm (0.47 ± 0.02 inch)
260-4856	N/A	1	9.590 mm (0.3776 inch)	12.0 ± 0.5 mm (0.47 ± 0.02 inch)
268-2953	N/A	2	9.590 mm (0.3776 inch)	20.0 ± 0.05 mm (0.787 ± 0.002 inch)
277-9775	N/A	N/A	9.590 mm (0.3776 inch)	22.0 ± 0.5 mm (0.87 ± 0.02 inch)
376-6566	N/A	1	9.584 mm (0.3773 inch)	35.0 ± 0.5 mm (1.38 ± 0.02 inch)

Valve Guides for C175 Engines

Table 31

Specifications for C175 Valve Guides
Part Numbers of Valve Guides	Bore in the Head for the Guide	Installed Height of the Valve Guide	Bore Diameter of INSTALLED Valve Guide
236-0544 Valve Guide (Standard)	22.000 ± 0.013 mm (0.8661 ± 0.0005 inch)	42.00 ± 0.50 mm (1.654 ± 0.020 inch)	12.626 ± 0.020 mm (0.4971 ± 0.0008 inch)
393-6466 Valve Guide (0.25-MM OS)	22.254 ± 0.013 mm (0.8761 ± 0.0005 inch)
393-6467 Valve Guide (0.50-MM OS)	22.508 ± 0.013 mm (0.8861 ± 0.0005 inch)

Valve Guides for 3044, 3046, 3064, and 3066 Engines

Table 32

Dimensions for 3044, 3046, 3064, and 3066 Valve Guides
Sales Model	3044, 3046	3064, 3066
The bore of the inlet valve guide that is installed in the cylinder head	8.080 ± 0.015 mm (0.3181 ± 0.0006 inch)	8.070 ± 0.015 mm (0.3177 ± 0.0006 inch)
The maximum bore of the inlet valve guide that is installed in the cylinder head	8.150 mm (0.3209 inch)	8.150 mm (0.3209 inch)
The bore of the exhaust valve guide that is installed in the cylinder head	8.097 ± 0.017 mm (0.3188 ± 0.0007 inch)	8.087 ± 0.017 mm (0.3184 ± 0.0007 inch)
The maximum bore of the exhaust valve guide that is installed in the cylinder head	8.200 mm (0.3228 inch)	8.200 mm (0.3228 inch)
The height of installed valve guides (B)	11.50 ± 0.10 mm (0.453 ± 0.004 inch)	17.00 ± 0.30 mm (0.669 ± 0.012 inch)

Installation of the Valve Guides

For removal of valve guides, use the 4C-6366 Valve Guide Driver. Install the valve guides with the 4C-6370 Installer Tool. Refer to the service manual for Disassembly and Assembly Manual for removal and installation instructions of the valve guides.

Illustration 173	g06277915
Valve guides that are being removed from the cylinder head by using the appropriate tooling

Valve Guides for 3054, and 3056 Engines

Note: When new valve guides are installed, new valves and new valve seat inserts must be installed. The valve guides and the valve seat inserts are supplied as partially finished parts. The unfinished valve guides and unfinished valve seat inserts are installed in the cylinder head. Then, the guides and inserts are cut and reamed in one operation with special tooling. This procedure ensures the concentricity of the valve seat to the valve guide to create a seal that is tight. Refer to the Disassembly and Assembly Manual for removal and installation procedures

Table 33

Dimensions for the Intake and Exhaust Valve Guides for 3054, and 3056 Engines
Description	Dimension
Inside Diameter	9.51 to 9.56 mm (0.37441 to 0.37638 inch)
Outside Diameter	15.90 to 15.91 mm (0.62598 to 0.62638 inch)
Bore diameter in cylinder head for valve guide	15.87 to 15.89 mm (0.62480 to 0.62559 inch)
Interference fit of valve guide in cylinder head	0.03 to 0.07 mm (0.00118 to 0.00276 inch)
Overall length for inlet valve guide	57.94 mm (2.28110 inch)
Overall length for exhaust valve guide	61.10 mm (2.40551 inch)
Projection of valve guide above valve spring recess	15.10 mm (0.59449 inch)
Clearance of inlet valve in valve guide	0.02 to 0.10 mm (0.00079 to 0.00394 inch)
Maximum permissible clearance of inlet valve in valve guide	0.13 mm (0.00512 inch)
Clearance of exhaust valve in valve guide	0.05 to 0.13 mm (0.00197 to 0.00512 inch)
Maximum permissible clearance of exhaust valve in valve guide	0.15 mm (0.00591 inch)
Valve depth below the cylinder head face	Minimum 1.28 mm (0.05039 inch)
	Maximum 1.60 mm (0.06299 inch)
Service wear limit	1.85 mm (0.07283 inch)
Valve Lash	Inlet 0.20 mm (0.00787 inch)
	Exhaust 0.45 mm (0.01772 inch)

Valve Guides for 3114, 3116, 3126 Engines

Table 34

Dimensions for the Valve Guides for 3114, 3116, 3126 Engines
Description	Dimension
Installed Valve Guide Bore New	8.054 ± 0.026 mm (0.3171 ± 0.0010 inch)
Installed Valve Guide Bore Used Maximum	8.130 mm (0.3201 inch)(1)
Height of Installed Valve Guide (B)	23.000 ± 0.500 mm (0.9055 ± 0.0197 inch)
Height of Installed Intake Valve Guide (C) on 3126B Cylinder Heads	23.000 ± 0.500 mm (0.9055 ± 0.0197 inch)
Height of Installed Exhaust Valve Guide (D) on 3126B Cylinder Heads (measured to the shoulder of the valve guide)	17.8 ± 0.5 mm (0.70 ± 0.02 inch)

(1)	Valve guides should not be reused if the measurement of the bore is greater than 8.130 mm (0.3201 inch). The valve and the guide must have a combined difference less than 0.10 mm (0.004 inch).

Valve Guides for 3176, 3196 Engines

Note: Do not reuse the valve guide if the measurement of the bore is greater than 9.538 mm (0.3755 inch). Do not use a valve and a guide that has a measured difference of 0.10 mm (0.004 inch). Replacement is required if the gauge is inserted to a depth that is greater than 19.0 mm (0.75 inch).

Installation

Use a 1U-9169 Valve Guide Driver and a Guide Collar that corresponds to the guide to install valve guides to the appropriate height of the valve guide.

Illustration 174	g06277920
Pointed valve guide (B) Height to the shoulder of valve guide

Use a 9U-6460 Guide Collar to install pointed valve guides. The 9U-6460 Guide Collar will install the valve guide to a height of 22.0 ± 0.5 mm (0.87 ± 0.020 inch) to the shoulder.

Illustration 175	g06277928
Flat valve guide (B) Height of valve guide

Use a 1U-9168 Valve Guide Collar to install flat valve guides. The 1U-9168 Valve Guide Collar will install the valve guide to a height of 28.0 ± 0.5 mm (1.10 ± 0.02 inch).

Table 35

Dimensions for the Valve Guides for 3176, 3196 Engines
Description	Dimension
Installed Valve Guide Bore New	9.484 ± 0.026 mm (0.3734 ± 0.0010 inch)
Installed Valve Guide Bore Used Maximum	9.538 mm (0.3755 inch)
Height of Installed Valve Guide (B)(1)	28.00 ± 0.05 mm (1.102 ± 0.002 inch)
Height of Installed Valve Guide from shoulder (B)(2)	22.00 ± 0.05 mm (0.866 ± 0.002 inch)

(1)	Flat valve guide
(2)	Pointed valve guide

Valve Guides for 1100, 3100, 3204, and 3208 Engines

Table 36

Dimensions for the Valve Guides for 1100, 3100, 3204, and 3208 Engines
Model	Installed Valve Guide Maximum Bore		Installed
	Intake	Exhaust	Height
1100 3100	9.550 mm (0.37598 inch)	9.550 mm (0.37598 inch)	N/A
3204 3208			20.19 mm (0.79488 inch)

Valve Guides for 3300 Engines

Table 37

Installed Valve Guide Max. Bore for 3300 Engines
Intake	Exhaust
9.581 mm (0.3772 in)	9.581 mm (0.3772 in)

Table 38

Installed Valve Guide Height for 3300 Engines
Part Number	Height
Former 8N-6796 Valve Guide.	22.22 ± 0.25 mm (0.87480 ± 0.00984 inch)
Current 8N-6796 Valve Guide.	16.22 ± 0.25 mm (0.63858 ± 0.00984 inch)

Valve Guides for 3400 Engines

If the valve guides are removed from the cylinder head, use 9U-6895 Valve Guide Driver to remove the valve guides. New valve guides should then be installed in the cylinder head. There are two types of valve guides that are used in 3400 Engines. Use 9U-6895 Valve Guide Driver and 5P-2396 Bushing to install the straight valve guides in the diesel engines. Use 9U-6895 Valve Guide Driver and 124-9057 Guide Collar to install the stepped valve guides in the diesel engines. Use 9U-6895 Valve Guide Driver to install the valve guides in the gas engines. Refer to Illustrations 176 and 177 for the types of valve guides. The bore in the cylinder head for the valve guide should be lubricated with SAE 15W-40 engine oil before installing the valve guides.

Illustration 176	g01461628
Straight valve guide

Illustration 177	g01461631
Stepped valve guide

The valve guides must be measured for the installed height and the inside bore diameter.

Use 6V-2012 Depth Micrometer to measure the height of the installed valve guide (B). Refer to Table 39 or Table 40 for the correct height.

Use 5P-3536 Valve Guide Gauge to measure the inside diameter of the valve guide. The correct probe is 9.525 mm (0.3750 inch). This probe has a usable range of 0.38 mm (0.015 inch).

6V-7068 Valve Guide Gauge is also available for use as a quick go/no-go gauge. If the larger end of the tooling fits in farther than 19.0 mm (0.75 inch), the valve guide must be replaced.

Illustration 178	g01461950
(B) Height of an installed valve guide

Table 39

Specifications for the Valve Guides on 3400 Engines Diesel Engines
Engine Model	Bore for an Installed Valve Guide	Maximum Bore for Installed Valve Guide	Height of an installed valve guide (B)
3406	9.487 ± 0.020 mm (0.3735 ± 0.0008 inch)	9.560 mm (0.3764 inch)	27.2 ± 0.8 mm (1.07 ± 0.03 inch)(1) 32.26 ± 0.76 mm (1.270 ± 0.030 inch)(2)
3408	9.487 ± 0.020 mm (0.3735 ± 0.0008 inch)	9.560 mm (0.3764 inch)	32.26 ± 0.76 mm (1.270 ± 0.030 inch)(2)
3412	9.487 ± 0.020 mm (0.3735 ± 0.0008 inch)	9.560 mm (0.3764 inch)	32.26 ± 0.76 mm (1.270 ± 0.030 inch)(2)

(1)	Stepped valve guide
(2)	Straight valve guide

Table 40

Specifications for the Valve Guide on 3400 Engines Gas Engines
Part Number of the Valve Guide	Bore for an Installed Valve Guide	Maximum Bore for Installed Valve Guide	Height of an installed valve guide (B)
151-6235	9.487 ± 0.025 mm (0.3735 ± 0.0010 inch)	9.560 mm (0.3764 inch)	32.26 ± 0.76 mm (1.270 ± 0.030 inch)
246-1300			24.0 ± 0.8 mm (0.94 ± 0.03 inch)
7W-1636	9.487 ± 0.025 mm (0.3735 ± 0.0010 inch)	9.560 mm (0.3764 inch)	32.26 ± 0.76 mm (1.270 ± 0.030 inch)
151-1300	9.487 ± 0.025 mm (0.3735 ± 0.0010 inch)	9.560 mm (0.3764 inch)	32.26 ± 0.76 mm (1.270 ± 0.030 inch)
173-7188
213-7536 Inlet	9.484 ± 0.008 mm (0.3734 ± 0.0003 inch)		26.0 ± 0.8 mm (1.02 ± 0.03 inch)
213-7537 Exhaust			32.26 ± 0.76 mm (1.270 ± 0.030 inch)

Note: Do not reuse a valve guide if the measurement of the bore is greater than 9.560 mm (0.3764 inch). Do not reuse a valve and valve guide if the difference between the valve stem diameter and the inner diameter of the valve guide is 0.13 mm (0.005 inch).

Valve Guides for 3406E, 3456 Engines

If the valve guides are removed from the cylinder head, use 9U-6895 Valve Guide Driver to remove the valve guides. New valve guides should then be installed in the cylinder head. Use 9U-6895 Valve Guide Driver and 9U-6894 Guide Collar to install the valve guides. The bore in the cylinder head for the valve guide should be lubricated with SAE 15W-40 engine oil before installing the valve guides.

Table 41

Specifications for the Valve Guide on 3406E, 3456 Engines
Engine Model	Bore for an Installed Valve Guide	Maximum Bore for Installed Valve Guide	Height of an installed valve guide (B)
3406E	9.484 ± 0.013 mm (0.3734 ± 0.0005 inch)	9.560 mm (0.3764 inch)	35.0 ± 0.5 mm (1.38 ± 0.02 inch)
3456	9.484 ± 0.013 mm (0.3734 ± 0.0005 inch)	9.560 mm (0.3764 inch)	35.0 ± 0.5 mm (1.38 ± 0.02 inch)

Note: Do not reuse a valve guide if the measurement of the bore is greater than 9.560 mm (0.3764 inch). Do not reuse a valve and valve guide if the difference between the valve stem diameter and the inner diameter of the valve guide is 0.13 mm (0.005 inch).

Oversized valve guides are also available. The oversized valve guides must have the valve guide bore of the cylinder head machined oversized.

Illustration 179	g06277951

Table 42

Cylinder Head Bore Dimensions on 3406E, 3456 Engines
Valve Guide Size (OD)	Bore Size (C) in the Cylinder Head for the Valve Guide
Standard Size	15.970 ± 0.013 mm (0.6287 ± 0.0005 inch)
0.13 mm (0.005 inch) Oversized	16.097 ± 0.013 mm (0.6337 ± 0.0005 inch)
0.51 mm (0.020 inch) Oversized	16.478 ± 0.013 mm (0.6487 ± 0.0005 inch)

Precision Valve Guides for 3500 Engines

Precision machined valve guides and inserts for the valve seats are used in all 3500 engines. These parts will improve the concentricity of the valve and concentricity of the valve seat in the cylinder head. These parts will improve the quality of cylinder heads that are rebuilt in the field.

Valve guides with oversize outside diameters are available to replace the standard parts. These parts are 0.127 mm (0.0050 inch), 0.254 mm (0.0100 inch), 0.381 mm (0.0150 inch), and 0.508 mm (0.0200 inch) oversize outer diameter.

Illustration 180	g06189568
Guides for 3500 (F) Height to the top of the valve guides from the top of the head

Table 43

Specifications for the Valve Guides for 3500 Engines
Part Number of the Cylinder Head	Intake or Exhaust	Size	Part Numbers of Valve Guides	Bore inch the Head for the Guide	Installed Height of the Valve Guide (F)
7E-5861 7E-8760 101-1175 131-0410 131-0411 131-0423 145-3215 154-1612 161-2508 172-0834 172-0836 290-1351 295-2047 462-4740 480-3132 495-2062 525-6572	Intake	Standard	133-9306 449-7117	17.473 ± 0.008 mm (0.6879 ± 0.0003 inch)	26.000 ± 1.000 mm (1.0236 ± 0.0394 inch)
		0.127 mm (0.0050 inch)	273-3553	17.6 ± 0.008 mm (0.6929 ± 0.0003 inch)
		0.254 mm (0.0100 inch)	273-3554	17.727 ± 0.008 mm (0.6979 ± 0.0003 inch)
		0.381 mm (0.0150 inch)	301-9248	17.854 ± 0.008 mm (0.7029 ± 0.0003 inch)
		0.508 mm (0.0200 inch)	149-1982	17.981 ± 0.008 mm (0.7079 ± 0.0003 inch)
	Exhaust	Standard	197-6995 449-7118	17.473 ± 0.008 mm (0.6879 ± 0.0003 inch)
		0.127 mm (0.0050 inch)	276-3875	17.6 ± 0.008 mm (0.6929 ± 0.0003 inch)
		0.254 mm (0.0100 inch)	276-3876	17.727 ± 0.008 mm (0.6979 ± 0.0003 inch)
4P-6571 7C-3471 128-1141 122-5961 144-6409 153-8397 184-5496 206-1554 206-1555 206-1560 206-1563 424-7545	Intake	Standard	191-6766	17.473 ± 0.008 mm (0.6879 ± 0.0003 inch)	26.000 ± 1.000 mm (1.0236 ± 0.0394 inch)
		0.254 mm (0.0100 inch)	206-1544	17.727 ± 0.008 mm (0.6979 ± 0.0003 inch)
		0.508 mm (0.0200 inch)	206-1545	17.981 ± 0.008 mm (0.7079 ± 0.0003 inch)
	Exhaust	Standard	206-1541	17.473 ± 0.008 mm (0.6879 ± 0.0003 inch)
		0.254 mm (0.0100 inch)	206-1542	17.727 ± 0.008 mm (0.6979 ± 0.0003 inch)
		0.508 mm (0.0200 inch)	206-1543	17.981 ± 0.008 mm (0.7079 ± 0.0003 inch)
	Exhaust	Standard	255-0897	17.473 ± 0.008 mm (0.6879 ± 0.0003 inch)
		0.254 mm (0.0100 inch)	255-1261	17.727 ± 0.008 mm (0.6979 ± 0.0003 inch)
		0.508 mm (0.0200 inch)	255-1262	17.981 ± 0.008 mm (0.7079 ± 0.0003 inch)
269-0040 315-2630 418-9804	Intake	Standard	191-6766	17.473 ± 0.008 mm (0.6879 ± 0.0003 inch)	26.000 ± 0.5 mm (1.0236 ± 0.0197 inch)
		0.127 mm (0.0050 inch)	322-3664	17.600 ± 0.008 mm (0.6929 ± 0.0003 inch)
		0.254 mm (0.0100 inch)	322-3665	17.727 ± 0.008 mm (0.6979 ± 0.0003 inch)
		0.508 mm (0.0200 inch)	322-3666	17.981 ± 0.008 mm (0.7079 ± 0.0003 inch)
	Exhaust	Standard	336-1338	17.473 ± 0.008 mm (0.6879 ± 0.0003 inch)
		0.127 mm (0.0050 inch)	322-3661	17.600 ± 0.008 mm (0.6929 ± 0.0003 inch)
		0.254 mm (0.0100 inch)	322-3662	17.727 ± 0.008 mm (0.6979 ± 0.0003 inch)
		0.508 mm (0.0200 inch)	322-3663	17.981 ± 0.008 mm (0.7079 ± 0.0003 inch)

Installation and Removal of the Valve Guides for G3500 Engines

Remove all oil, dirt, and carbon from the cylinder head casting.

Clean the mounting surface of the cylinder head with a 5P-9718 Disc Pad. The pneumatic tool must be 3500 rpm to 4500 rpm. The method and the speed of the disc are critical to the performance of the disc. The best results will be obtained if the disc is flat to the surface. Only the weight of the tool should be used as downward pressure. Do not use the edge of the disc because the disc may come off the holder. Do not use the disc for long periods of time in one area. Metal can be removed if the disc is used in one area for too long.

Illustration 181	g02150205
This cylinder head has siloxane deposits from a landfill environment.

Illustration 182	g06277972

Remove all dirt and debris from the combustion surface and the valve seat insert bore. The insert removal tool will not seat properly if there is any remaining debris in the insert bore.

When cleaning the ports, do so while the old seat is still in place.

Table 44

Required Tooling
Part Number	Part Description
7M-3975	Valve Guide Driver

1. Place the cylinder head upside-down in a hydraulic press.

2. Clean the surface of the valve guide that contacts the valve guide driver. This will prevent harmful debris from traveling through the bore for the valve guide.
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   Illustration 183	g02157991

3. Install 7M-3975 Valve Guide Driver into a valve guide.

4. Press the valve guides out of the cylinder head. Repeat this process for the remaining three valve guides.

   Note: Do not use a hammer to remove the valve guides.

Illustration 184	g02192018
235-9751 Drive Adapter As

Illustration 185	g02194699
(2) Spark Plug Adapter

Use the 235-9751 Drive Adapter As to remove the spark plug adapter. Remove and replace the gasket and the o-ring.

The adapter threads should be inspected for any damage. If the threads have any damage or wear, the adapter should be replaced.

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Illustration 186	g06277993
Stiff bristle brush for cleaning bores

1. Clean the bores for the valve guides with a stiff bristle brush. Spray 222-3123 Penetrating Oil in the bores before inserting the brush. The bores for the valve guides should be cleaned with a clean shop towel after using the brush. The towel will remove any remaining debris.

2. Position the cylinder head in the upright position.
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   Illustration 187	g02201893
   The guide should have at least 63.0 mm (2.48 inch) length of coating from the bottom of the guide.

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   Illustration 188	g02203414

3. Lubricate the outside of each valve guide and the bore in the head with clean engine oil prior to installation.

   Note: The entire bore should be coated in oil.

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   Illustration 189	g02201993
   (7) 364-3081 Installation Guide

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   Illustration 190	g02202313

4. Place the 364-3081 Install Guide on the cylinder head as shown in Illustration 189. Make sure that 191-6766 Valve Guides are installed in the intake ports of the cylinder head. Make sure that 366-1338 Valve Guides are installed in the exhaust ports of the cylinder head.

   For oversize valve guides part numbers and information on the bore size in the cylinder head for oversize valve guides, refer to Table 45.

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   Table 45

   Specifications for the Valve Guides on G3500 Engines
   Part Number of the Cylinder Head	Intake or Exhaust	Size	Part Numbers of Valve Guides	Bore in the Head for the Guide	Installed Height of the Valve Guide (F)
   4P-6571 7C-3471 122-5961 128-1141 144-6409 184-5496 206-1554 229-9942 269-0040	Intake	Standard	9Y-1847	17.473 ± 0.008 mm (0.6879 ± 0.0003 inch)	26.00 ± 1.00 mm (1.0236 ± 0.0394 inch)
   	Intake	Standard	7N-1819 130-2613	17.473 ± 0.008 mm (0.6879 ± 0.0003 inch)
   	Intake	Standard	9Y-6883 184-5495 191-6766	17.473 ± 0.008 mm (0.6879 ± 0.0003 inch)
   	Exhaust	Standard	7W-9487 9Y-1846	17.473 ± 0.008 mm (0.6879 ± 0.0003 inch)
   	Exhaust	Standard	9Y-6882 184-5494 366-1338	17.473 ± 0.008 mm (0.6879 ± 0.0003 inch)
   153-8397 315-2630 418-9804	Intake	Standard	184-5495 191-6766	17.473 ± 0.008 mm (0.6879 ± 0.0003 inch)	26.000 ± 0.5 mm (1.0236 ± 0.0197 inch)
   		0.13 mm (0.0051 inch)	322-3664	17.600 ± 0.008 mm (0.6929 ± 0.0003 inch)
   		0.254 mm (0.0100 inch)	322-3665	17.727 ± 0.008 mm (0.6979 ± 0.0003 inch)
   		0.508 mm (0.0200 inch)	322-3666	17.981 ± 0.008 mm (0.7079 ± 0.0003 inch)
   	Exhaust	Standard	184-5494 366-1338	17.473 ± 0.008 mm (0.6879 ± 0.0003 inch)
   		0.13 mm (0.0051 inch)	322-3661	17.600 ± 0.008 mm (0.6929 ± 0.0003 inch)
   		0.254 mm (0.0100 inch)	322-3662	17.727 ± 0.008 mm (0.6979 ± 0.0003 inch)
   		0.508 mm (0.0200 inch)	322-3663	17.981 ± 0.008 mm (0.7079 ± 0.0003 inch)
   	Exhaust	Standard	184-5494 366-1338	17.473 ± 0.008 mm (0.6879 ± 0.0003 inch)
   		0.254 mm (0.0100 inch)	366-1339	17.727 ± 0.008 mm (0.6979 ± 0.0003 inch)
   		0.508 mm (0.0200 inch)	366-1340	17.981 ± 0.008 mm (0.7079 ± 0.0003 inch)
   206-1555 242-5328 487-3422	Intake	Standard	191-6766	17.473 ± 0.008 mm (0.6879 ± 0.0003 inch)	26.00 ± 1.00 mm (1.0236 ± 0.0394 inch)
   		0.254 mm (0.0100 inch)	206-1544	17.727 ± 0.008 mm (0.6979 ± 0.0003 inch)
   		0.508 mm (0.0200 inch)	206-1545	17.981 ± 0.008 mm (0.7079 ± 0.0003 inch)
   	Exhaust	Standard	255-0897	17.473 ± 0.008 mm (0.6879 ± 0.0003 inch)	26.00 ± 1.00 mm (1.0236 ± 0.0394 inch)
   		0.254 mm (0.0100 inch)	255-1261	17.727 ± 0.008 mm (0.6979 ± 0.0003 inch)
   		0.508 mm (0.0200 inch)	255-1262	17.981 ± 0.008 mm (0.7079 ± 0.0003 inch)
   	Exhaust	Standard	206-1541	17.473 ± 0.008 mm (0.68791 ± 0.0003 inch)	26.00 ± 1.00 mm (1.0236 ± 0.0394 inch)
   		0.254 mm (0.0100 inch)	206-1542	17.727 ± 0.008 mm (0.6979 ± 0.0003 inch)
   		0.508 mm (0.0200 inch)	206-1543	17.981 ± 0.008 mm (0.7079 ± 0.0003 inch)

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   Illustration 191	g02202376
   (8) 366-5728 Valve Guide Driver

5. Insert the 366-5728 Valve Guide Driver (8) in the valve guide.
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   Illustration 192	g02202546

6. Press the valve guide into the cylinder head. The valve guide is at the correct depth when the valve guide driver contacts the 364-3081 Installation Guide. The valve guides should be pressed in with one smooth stroke. Use an electrohydraulic press to install the valve guides.

   Note: Do not use a manual hydraulic press.

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   Illustration 193	g02215035

7. Insert valves into the valve guides. If the valve does not move freely in the valve guide, repeat this step with another valve. If the second valve does not move freely in the valve guide, the valve guide must be removed and replaced.

When installing the valves in the heads during assembly, repeat Step 7 to assure that the valve being installed passes freely in the guide. Once a guide and valve have been checked, keep the valve matched to the guide in which it was test fit. If for any reason a valve is removed from the head during assembly, this step must be performed to assure that the valve and guide have proper clearance.

Illustration 194	g06278058
Pilot Wrench

Illustration 195	g02476049
Pilot

Illustration 196	g02476601
Dial Indicator

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Illustration 197	g02477237

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Illustration 198	g02477356

1. Insert the pilot into the pilot wrench.
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   Illustration 199	g02477441

2. Insert the pilot in the dial gauge.

Illustration 200	g02477516

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Illustration 201	g02478266

1. Insert the pilot into the valve guide.

2. Tighten the pilot wrench.

   Note: To prevent damage to the tooling or the valve guide, the pilot wrench only needs to be lightly tightened by hand.

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   Illustration 202	g06278081

3. Place the tip on the face of the valve seat and zero out the dial indicator.

4. Rotate the tip around the face of the valve seat.
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   Illustration 203	g02155320

5. Measure the runout of the valve seat insert. The valve guide to seat runout should be no more than 0.05 mm (0.002 inch). A valve seat dial indicator from Hall Toledo was used in Illustration 203.

   If runout is in excess of 0.05 mm (0.002 inch) remove the valve guide and install a new one. After installation, measure the runout again. If the runout is still excessive, replace the seat and measure the runout. If the runout is still excessive, the bores for the valve seat and guide should be checked and the head should be replaced.

   Note: No guide or valve seat insert should ever be reused after being removed from the head.

Valve Guides for 3600, G3600, C280 Engines

Valve guides should be drilled as much as possible before being removed. If this is not done, small cracks may appear in the cylinder head casting as a result. After installation, check the dimensions of the valve guides to make sure that the guides meet the specifications for new valve guides.

To remove the bridge dowels, use the 9U-5099 Valve Seat Puller to remove the bridge dowels and dowel plugs from the cylinder head casting. Replace the bridge dowels by following the specifications for minimum height.

Initial Inspection

1. Inspect the valve guides for wear, cracks, erosion, or other damage.
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   Illustration 204	g01941500

2. Use the valve guide gauge to measure the inside diameter of the valve guide.

3. Remove excessively worn valve guides with one of the following methods.

Removal

There are three different methods for removal of valve guides.

Note: Drill the inside diameter of the guide. This will ease the process of removing the valve guide. This will also eliminate damage to the bore of the guide.

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Illustration 205	g01941573

1. Remove the valve guides with the valve guide driver and a hammer.

   Note: Be careful not to strike the highly finished surface of the cylinder head with the hammer during removal of the valve guides.

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   Illustration 206	g01941818

2. The valve guides may also be removed with a hydraulic press and the valve guide driver.

Illustration 207	g01941953
(11) Puller assembly (12) Puller rod assembly (13) Nut (14) Hand pump (15) Pedestal

Installation

The tooling that is used to install valve guides into the cylinder head must produce consistent results.

1. Put clean engine oil on the outside diameter of the valve guide before installation. The guides can also be frozen to −70° C (−94.0° F). Installation will be easier if the guides are frozen.

2. Install four valve guides until the guides extend 18.00 mm (0.709 inch) to 22.00 mm (0.866 inch) above the top surface of the cylinder head. Use either of the methods shown in Illustrations 208,209, and 210.

3. If the valve guides were frozen prior to installation, the guides should be allowed to return to room temperature before measuring critical specifications.

4. After installing the valve guides into the head casting, measure the inside diameter with the valve guide gauge.

Note: After installation, the valve guide must pass the specified load test.

Illustration 208	g01943948
(11) Valve guide driver

Illustration 209	g01943970

Illustration 210	g01944259
(11) Puller assembly (12) Puller rod assembly (13) Nut (14) Hand pump (16) Expander bridge assembly

Illustration 211	g06175874
Valve Guide Specifications. Refer to Table 46 for the reuse specifications.

Table 46

Valve Guide Specifications for 3600, G3600, C280 Engines
Dimensions	7C-2424
Maximum Allowable ID at bottom (A)(1)	16.209 mm (0.6380 inch)
Length (B)	170.00 ± 1.00 mm (6.693 ± 0.040 inch)
Maximum Allowable ID at top (C)(2)	16.106 mm (0.6340 inch)
OUTSIDE diameter (D)	26.040 ± 0.010 mm (1.0252 ± 0.0004 inch)
Unassembled INSIDE diameter (E)	16.055 ± 0.013 mm (0.6321 ± 0.0005 inch)
Assembled inside diameter (E)(3)	16.003 mm (0.6300 inch) to 16.059 mm (0.6322 inch)
Assembled Height	18.00 mm (0.709 inch) to 22.00 mm (0.866 inch)

(1)	As measured from the bottom of the valve guide bore when assembled in the head casting. Maximum depth allowed 19.0 mm (0.75 inch).
(2)	As measured from the top of the valve guide bore when assembled in the head casting. Maximum depth allowed 19.0 mm (0.75 inch).
(3)	Measure the bore 45.0 mm (1.77 inch) from the bottom of the cylinder head. This is the surface where the casting press fit reduces the inside diameter of the valve guide.

Valve Guide & Seat Bore for C7 through C32 Engines

Table 47

Specifications for the Cylinder Head for C7 through C32 Engines
Part Number	Bore for the Valve Guide	Bore for the Valve Seat
6I-3606 105-3798 105-3799 105-3800 123-7338 124-7373 143-0046 143-3615 151-4951 151-1335 151-5241 151-5243 198-6523 198-6524 206-7744	17.473 ± 0.013 mm (0.6879 ± 0.0005 inch)	Intake 45.949 ± 0.025 mm (1.8090 ± 0.0010 inch) Exhaust 42.774 ± 0.025 mm (1.6840 ± 0.0010 inch)
179-9458 148-2135 245-4031 257-2170 265-9120 289-3210 300-9512 302-2297 308-6358 331-1981 342-4397 344-0059 345-3752 346-1984 346-1999 520-4381 520-4382	15.970 ± 0.013 mm (0.6287 ± 0.0005 inch)	Intake 45.961 ± 0.013 mm (1.8095 ± 0.0005 inch) Exhaust 43.320 ± 0.025 mm (1.7055 ± 0.0010 inch)
219-5844 227-5951 259-8305 278-3490 280-7503 314-4183 314-4184 314-4185	Intake 13.000 ± 0.013 mm (0.5118 ± 0.0005 inch) Exhaust 15.970 ± 0.013 mm (0.6287 ± 0.0005 inch)	Intake 41.931 ± 0.013 mm (1.6508 ± 0.0005 inch) Exhaust 45.931 ± 0.013 mm (1.8083 ± 0.0005 inch)
201-2180 255-4961 311-7226 311-7228	15.970 ± 0.013 mm (0.6287 ± 0.0005 inch)	Intake 37.000 ± 0.015 mm (1.4567 ± 0.0006 inch) Exhaust 37.500 ± 0.015 mm (1.4764 ± 0.0006 inch)
241-8392 252-8438	15.970 ± 0.013 mm (0.6287 ± 0.0005 inch)	Intake 40.000 ± 0.015 mm (1.5748 ± 0.0006 inch) Exhaust 37.500 ± 0.015 mm (1.4764 ± 0.0006 inch)
311-7218 328-7475	13.000 ± 0.013 mm (0.5118 ± 0.0005 inch)	Intake 42.5 ± 0.015 mm (1.67323 ± 0.00059 inch) Exhaust 39 ± 0.015 mm (1.5354 ± 0.0006 inch)
311-7229 332-3619	Intake 13.000 ± 0.013 mm (0.5118 ± 0.0005 inch) Exhaust 15.970 ± 0.013 mm (0.6287 ± 0.0005 inch)	Intake 40.000 ± 0.015 mm (1.5748 ± 0.0006 inch) Exhaust 37.500 ± 0.015 mm (1.4764 ± 0.0006 inch)
314-4184	Intake 13.000 ± 0.013 mm (0.5118 ± 0.0005 inch) Exhaust 15.970 ± 0.013 mm (0.6287 ± 0.0005 inch)	Intake 42.5 ± 0.015 mm (1.67323 ± 0.00059 inch) Exhaust 39.0 ± 0.015 mm (1.53543 ± 0.00059 inch)
491-1831	Intake 13.000 ± 0.013 mm (0.5118 ± 0.0005 inch) Exhaust 13.000 ± 0.013 mm (0.5118 ± 0.0005 inch)	Intake 41.931 ± 0.013 mm (1.6508 ± 0.0005 inch) Exhaust 45.931 ± 0.013 mm (1.8083 ± 0.0005 inch)
185-2246 222-1982 223-7263 243-0943 245-4324 263-4890 281-1640 284-2787 357-7398 396-8374 431-1153	15.970 ± 0.013 mm (0.6287 ± 0.0005 inch)	Intake 47.950 ± 0.025 mm (1.8878 ± 0.0010 inch) Exhaust 42.774 ± 0.025 mm (1.6840 ± 0.0010 inch)

Valve Seals and Retainers

Components may vary. Check the following originally installed components:

• Valve type

• Type of seal

• Type of retainer

• Other components

Illustration 212	g02721295
Old style valve guide seals

Illustration 213	g06278157
New style valve guide seals

Note: Refer to the Service Manual for removal and installation procedures. Also refer to the current parts manual for the current configuration for valve seals in a particular application.

Illustration 214	g06278159
Valve retainers with polished surfaces

Valve Seats

This section contains specifications of reusability for valve seats which are used in Caterpillar engines. Valve guide bores must be measured for the diameter of the valve guide bore.

If the thickness of the head is machined beyond factory specifications, the valve seats must also be machined. Machine the surface of the insert so the same amount of material is removed from the head and the insert to maintain the proper projection of the valve. After the head has been machined, the sealing angle must be within like-new specifications.

Illustration 215	g06176254
Machining the valve seat to like-new specifications after machining the head

Never use any kind of hammer to push the valve seat into the head. Installation of the valve seat insert requires a careful technique. The valve seat inserts are installed in a counterbore in the cylinder head under a press fit. Care must be taken with valve seat inserts. The inserts must be properly seated in the counterbore. The insert must be in full contact with the bottom of the counterbore. The inserts are chilled on dry ice before installation. Frost may build up on the bottom of the insert. This frost may not allow the insert to seat properly. Installation frequently involves hammering of the insert, which does not allow the valve seat insert to seat properly. The best results have been obtained by installing the valve seat insert at room temperature with steady hydraulic pressure.

The initial firing of the engine will seat an improperly seated precision insert. The only impact from an improperly placed precision insert is a reduction in lash for the valve.

An insert that is machined after installation that does not seat properly will cause problems. The insert will be machined when the insert is not fully seated. When the valve seat insert seats properly, there will be an improper seating face. Elevated wear rates will occur and the valve may fail.

Valve Seat Inserts for D & G Model Engine

Table 48

Specifications for Valve Seat Angle for D & G Model Engines
Model	Diesel		Gas
	Intake	Exhaust	Intake	Exhaust
D318	45° ± 0.5°	45° ± 0.5°	N/A	N/A
D320	30° ± 1°	30° ± 1°	N/A	N/A
D342 G342	45° ± 0.25°	45° ± 0.25°	45° ± 0.25°	45° ± 0.25°
D343 G343	45° ± 0.25°	45° ± 0.25°	N/A	N/A
D346 G346 D348 G348 D349 G349	45° ± 0.25°	45° ± 0.25°	N/A	N/A
D353 G353 D379 G379 D398 G398 D399 G399	30° ± 0.25°	30° ± 0.25°	30° ± 0.25°	30° ± 0.25°

Removal, Machining, and Installation of the Valve Seats Inserts for C4.4, C6.6, and C7.1 Engines

Removal

Illustration 216	g06278166

Remove the valve seat inserts. Check the bore diameters and the bore depths for the valve seat inserts. Oversized valve seat inserts are not available currently. If the bore diameters or the bore depths are not within specifications, the cylinder head must be replaced.

Table 49

Bore Diameters and Bore Depths in the Cylinder Head for the Valve Seat Inserts for C4.4 (Tier 2/3) Engines
Item	Dimension
(H) Depth of Bore for Intake Insert	8.735 mm (0.3438 inch) to 8.865 mm (0.3490 inch)
(G) Depth of Bore for Exhaust Insert	7.975 mm (0.3139 inch) to 8.105 mm (0.3190 inch)
(J) Diameter of Bore for Intake Insert	35.000 mm (1.3779 inch) to 35.025 mm (1.3789 inch)
(I) Diameter of Bore for Exhaust Insert	33.500 mm (1.3188 inch) to 33.525 mm (1.3198 inch)

Table 50

Bore Diameters and Bore Depths in the Cylinder Head for the Valve Seat Inserts for C4.4 (Tier 4) Engines
Item	Dimension
(H) Depth of Bore for Intake Insert	8.735 mm (0.34390 inch) to 8.865 mm (0.34902 inch)
(G) Depth of Bore for Exhaust Insert	9.435 mm (0.37146 inch) to 9.565 mm (0.37657 inch)
(J) Diameter of Bore for Intake Insert	36.930 mm (1.45393 inch) to 36.955 mm (1.45492 inch)
(I) Diameter of Bore for Exhaust Insert	34.930 mm (1.37519 inch) to 34.955 mm (1.37618 inch)

Table 51

Bore Diameters and Bore Depths in the Cylinder Head for the Valve Seat Inserts for C7.1 Engines (Tier 2/3 Mechanical)
Item	Dimension
(H) Depth of Bore for Intake Insert	10.32 mm (0.406 inch) to 10.52 mm (0.414 inch)
(G) Depth of Bore for Exhaust Insert	9.94 mm (0.39134 inch) to 10.14 mm (0.39921 inch)
(J) Diameter of Bore for Intake Insert	47.820 mm (1.8827 inch) to 47.845 mm (1.8837 inch)
(I) Diameter of Bore for Exhaust Insert	42.420 mm (1.6701 inch) to 42.445 mm (1.6711 inch)

Table 52

Bore Diameters and Bore Depths in the Cylinder Head for the Valve Seat Inserts for C7.1 Engines (Tier 4)
Item	Dimension
(H) Depth of Bore for Intake Insert	8.735 mm (0.3438 inch) to 8.865 mm (0.3490 inch)
(G) Depth of Bore for Exhaust Insert	9.435 mm (0.3715 inch) to 9.565 mm (0.3766 inch)
(J) Diameter of Bore for Intake Insert	36.930 mm (1.4539 inch) to 36.955 mm (1.4549 inch)
(I) Diameter of Bore for Exhaust Insert	34.930 mm (1.3752 inch) to 34.955 mm (1.3762 inch)

Machining

Illustration 217	g06277681

Table 53

Valve Seat Insert Part Numbers for C4.4, C6.6, and C7.1 Engines
Exhaust Valve Seat Insert	377-0400
Intake Valve Seat Insert	377-0399

Obtain a suitable cutter assembly. The valve seats will be cut using one operation. Set the blades of the cutters to the diameter of the valve seat to be cut, using the proper angle. Refer to the following tables for cutting speeds, tooling, and diameters.

Table 54

Tooling, Cutting Speeds and Feed Rates for Valve Seat Inserts for C4.4, C6.6, and C7.1 Engines
Tool Type	Cutting Speed (M/min)	Feed Rate (mm/rev)
Carbide	70-90	0.10 to 0.12
Cubic Boron Nitride (CBN)	> 150 or 50-70	0.05 to 0.08 or 0.15 to 0.18

Table 55

Valve Seat Angles for C4.4, C6.6, and C7.1 Engines
Exhaust Valve Seat Angle (S)	89 degrees to 89.30 degrees total angle 120.65 degrees to 120.75 total angle (C7.1 Tier 2/3 Mech)
Intake Valve Seat Angle (S)	119 degrees to 119.3 degrees total angle 112.16 degrees to 120.66 degrees total angle (C7.1 Tier 2/3 Mech)
Surface Texture for Valve Seat Angles	3.2 µm (125.9843 µinch) max
Concentricity of Valve Seats	0.05 mm (0.002 inch) max TIR

1. Install the cutter assembly into the valve seat. Carefully turn the handle in a clockwise direction. Lubricant is not necessary.

   Note: The valve seats have a hardened finish. Grinding compound must not be used or damage may result to the valve seats.

2. Continue to turn the handle in a clockwise direction to cut the valve seat. Remove only the minimum amount of material.

3. When the valve seat is cut, remove the reamer and cutter assembly. Clean any debris after the machining procedure.

Installing

A tool must be fabricated for installation of the valve seat inserts. Use the following information for fabricating the installation tool.

Illustration 218	g06278174
Dimensions for the Valve Seat Insert Installation Tool

Fabricate a tool to the following dimensions used to press in the valve seats.

Table 56

Valve Seat Insert Installation Tool Specifications for C4.4
Dimension		Value
(A)		As Required
(B)		As Required
(C)		25 mm (0.98 inch)
(D)		4 mm (0.16 inch)
(E) Tier 2/3	Tier 2/3	Intake 30 Degrees Exhaust 45 degrees
(E) Tier 4	Tier 4	Intake 60 Degrees Exhaust 45 degrees
(F)		Intake 35 mm (1.37795 inch) Exhaust 33 mm (1.29921 inch)
(G)		Intake 33 mm (1.29921 inch) Exhaust 32 mm (1.26 inch)

Table 57

Valve Seat Insert Installation Tool for C6.6 and C7.1
Dimension		Value
(A)		As Required
(B)		As Required
(C)		25 mm (0.98 inch)
(D)		4 mm (0.16 inch)
(E)	Tier 2/3	Intake 41 Degrees Exhaust 30 degrees
(E)	Tier 4	Intake 60 Degrees Exhaust 45 degrees
(F)	Tier 2/3	Intake 43 mm (1.69 inch) Exhaust 40 mm (1.57 inch)
(F)	Tier 4	Intake 33 mm (1.29921 inch) Exhaust 32 mm (1.26 inch)
(G)	Tier 4	Intake 35 mm (1.37795 inch) Exhaust 33 mm (1.29921 inch)

Use the Tooling to press the valve seats into the cylinder head.

Table 58

Intake Valve Seat Specifications for C4.4, C6.6, and C7.1 Engines
(L)	3.00 mm (0.1181 inch) to 3.010 mm (0.1185 inch)
(M)	89-89.30' (Total Angle)
Exhaust Valve Seat Specifications for C4.4, C6.6, and C7.1 Engines
(L)	3.370 mm (0.1327 inch) to 3.380 mm (0.1331 inch)
(M)	119-119.30' (Total Angle)

Installation of the Valve Seats Inserts for C7 through C32 Engines

Replace the valve seat inserts when machining cannot be performed. Refer to the service manual for disassembly and assembly for the removal and installation instructions of valve seat inserts. Refer to the "Replacing Valve Seats Inserts for C7 through C32" section of this guideline for the proper procedure to replace a valve seat.

Note: Some valve seats cannot be machined. Refer to Table 59 to determine if a valve seat can be machined. Specialized manufacturing processes were used on these parts. Machining these parts will significantly decrease the life of the engine.

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NOTICE
Some C7 engines are experiencing corrosion on the 217-5213 Valve Seat Insert and the 155-9504 Valve Seat Insert. If corrosion is found on 217-5213 Valve Seat Inserts, replace the valve seat inserts with 272-9813 Valve Seat Inserts. The 272-9813 Valve Seat Inserts are made from an alloy that is corrosion resistant. If corrosion is found on 155-9504 Valve Seat Inserts, replace the valve seat inserts with 278-0453 Valve Seats. The 278-0453 Valve Seats are made from an alloy that is more corrosion resistant. Part numbers are etched on the outer surface of the valve seat inserts. The 278-0453 Valve Seats and 272-9813 Valve Seat Inserts are pre-finished. Pre-finished valve seat inserts do not require any additional machining in the cylinder head.

Illustration 219	g01667504
(C) Depth of the bore for the valve seat (D) Valve seat insert outside diameter (E) Valve seat insert inside diameter (F) Sealing angle of the valve seat insert

Table 59

Specifications for Valve Seat Inserts for C7 through C32 Engines
Valve Seat	Comment	Depth of the Bore for the Valve Seat (C)	Outside Diameter (D)	Inside Diameter (E)	Sealing angle (F)
1W-5283	Exhaust	13.01 ± 0.10 mm (0.512 ± 0.004 inch)	42.850 ± 0.013 mm (1.6870 ± 0.0005 inch)	36.5 ± 0.5 mm (1.44 ± 0.02 inch)	44.75° ± 0.50°
4N-5893	Intake	13.01 ± 0.10 mm (0.512 ± 0.004 inch)	46.025 ± 0.013 mm (1.8120 ± 0.0005 inch)	39.1 ± 0.5 mm (1.54 ± 0.02 inch)	30.25° ± 0.50°
133-7030	Exhaust	14.10 ± 0.10 mm (0.555 ± 0.004 inch)	43.400 ± 0.015 mm (1.7087 ± 0.0006 inch)	36.00 ± 0.13 mm (1.417 ± 0.005 inch)	44.75° ± 0.50°
138-2005	Exhaust	14.10 ± 0.06 mm (0.555 ± 0.002 inch)	43.400 ± 0.015 mm (1.7087 ± 0.0006 inch)	36.00 ± 0.13 mm (1.417 ± 0.005 inch)	44.75° ± 0.25°
138-2006	Intake	15.00 ± 0.06 mm (0.591 ± 0.002 inch)	46.025 ± 0.013 mm (1.8120 ± 0.0005 inch)	39.1 ± 0.5 mm (1.54 ± 0.02 inch)	29.75° ± 0.25°
147-8218	Exhaust	11.55 ± 0.06 mm (0.455 ± 0.002 inch)	46.000 ± 0.013 mm (1.8110 ± 0.0005 inch)	39.50 ± 0.50 mm (1.560 ± 0.020 inch)	45.50° ± 0.25°
152-7582	Exhaust	13.90 ± 0.05 mm (0.547 ± 0.002 inch)	42.840 ± 0.013 mm (1.6866 ± 0.0005 inch)	36.5 ± 0.5 mm (1.44 ± 0.02 inch)	44.75° ± 0.50°
155-9504	Intake	10.00 ± 0.05 mm (0.394 ± 0.002 inch)	42.000 ± 0.013 mm (1.6535 ± 0.0005 inch)	35.80 ± 0.13 mm (1.409 ± 0.005 inch)	30.25° ± 0.25°
167-0642	0.76 mm (0.030 inch) oversize	13.90 ± 0.05 mm (0.547 ± 0.002 inch)	43.602 ± 0.013 mm (1.7166 ± 0.0005 inch)	36.5 ± 0.5 mm (1.44 ± 0.02 inch)	44.75° ± 0.50°
167-0643	0.76 mm (0.030 inch) oversize	14.00 ± 0.05 mm (0.551 ± 0.002 inch)	48.787 ± 0.013 mm (1.9207 ± 0.0005 inch)	41.0 ± 0.5 mm (1.61 ± 0.02 inch)	30.25° ± 0.50°
170-4737	0.51 mm (0.020 inch) oversize	13.90 ± 0.05 mm (0.547 ± 0.002 inch)	43.348 ± 0.013 mm (1.7066 ± 0.0005 inch)	36.5 ± 0.5 mm (1.44 ± 0.02 inch)	44.75° ± 0.50°
170-4738	0.51 mm (0.020 inch) oversize	14.00 ± 0.05 mm (0.551 ± 0.002 inch)	48.533 ± 0.013 mm (1.9107 ± 0.0005 inch)	41.0 ± 0.5 mm (1.61 ± 0.02 inch)	30.25° ± 0.50°
175-3617	Intake	14.00 ± 0.05 mm (0.551 ± 0.002 inch)	48.025 ± 0.013 mm (1.8907 ± 0.0005 inch)	41.0 ± 0.5 mm (1.61 ± 0.02 inch)	30.25° ± 0.50°
176-7688	Intake	12.00 ± 0.06 mm (0.472 ± 0.002 inch)	37.060 ± 0.013 mm (1.4591 ± 0.0005 inch)	30.8 ± 0.5 mm (1.21 ± 0.02 inch)	25.00° ± 0.25°
176-7690	Exhaust	13.50 ± 0.05 mm (0.532 ± 0.002 inch)	37.560 ± 0.013 mm (1.4787 ± 0.0005 inch)	31.0 ± 0.5 mm (1.22 ± 0.02 inch)	45.00° ± 0.25°
179-9453	Exhaust	14.10 ± 0.06 mm (0.555 ± 0.002 inch)	43.390 ± 0.013 mm (1.7083 ± 0.0005 inch)	36.0 ± 0.5 mm (1.42 ± 0.02 inch)	44.75° ± 0.25°
179-9454(1)	Intake	15.00 ± 0.06 mm (0.591 ± 0.002 inch)	46.025 ± 0.013 mm (1.8120 ± 0.0005 inch)	39.1 ± 0.5 mm (1.54 ± 0.02 inch)	29.75° ± 0.25°
212-8917	Exhaust	10.40 ± 0.06 mm (0.409 ± 0.002 inch)	37.560 ± 0.013 mm (1.4787 ± 0.0005 inch)	31.0 ± 0.5 mm (1.22 ± 0.02 inch)	45.00° ± 0.25°
212-8918	Exhaust	9.51 ± 0.06 mm (0.374 ± 0.002 inch)	37.060 ± 0.013 mm (1.4591 ± 0.0005 inch)	30.8 ± 0.5 mm (1.21 ± 0.02 inch)	25.00° ± 0.25°
217-5213	Intake	9.00 ± 0.06 mm (0.354 ± 0.0024 inch)	42.000 ± 0.013 mm (1.6535 ± 0.0005 inch)	35.80 ± 0.13 mm (1.409 ± 0.005 inch)	30.25° ± 0.25°
224-1270	Exhaust	11.30 ± 0.06 mm (0.4449 ± 0.0024 inch)	42.390 ± 0.015 mm (1.6689 ± 0.0006 inch)	36.0 ± 0.5 mm (1.42 ± 0.02 inch)	44.75° ± 0.25°
224-2410(1)	Intake	12.63 ± 0.06 mm (0.497 ± 0.002 inch)	45.525 ± 0.013 mm (1.7923 ± 0.0005 inch)	39.1 ± 0.5 mm (1.54 ± 0.02 inch)	29.75° ± 0.25°
224-3983(1)	Intake	14.00 ± 0.08 mm (0.551 ± 0.003 inch)	48.025 ± 0.013 mm (1.8907 ± 0.0005 inch)	41.0 ± 0.5 mm (1.61 ± 0.02 inch)	30.25° ± 0.25°
226-5561(1)	Exhaust	13.90 ± 0.06 mm (0.547 ± 0.002 inch)	42.840 ± 0.013 mm (1.6866 ± 0.0005 inch)	36.5 ± 0.5 mm (1.44 ± 0.02 inch)	45.25° ± 0.25°
232-1285	Exhaust	11.55 ± 0.06 mm (0.455 ± 0.002 inch)	46.000 ± 0.013 mm (1.8110 ± 0.0005 inch)	39.50 ± 0.50 mm (1.560 ± 0.020 inch)	45.50° ± 0.25°
241-8388	Intake	9.30 ± 0.06 mm (0.366 ± 0.002 inch)	40.060 ± 0.013 mm (1.5772 ± 0.0005 inch)	34.0 ± 0.5 mm (1.34 ± 0.02 inch)	30.25° ± 0.25°
254-3943	Intake 0.51 mm (0.020 inch) oversize	12.63 ± 0.06 mm (0.497 ± 0.002 inch)	46.035 ± 0.013 mm (1.81240 ± 0.00051 inch)	39.1 ± 0.5 mm (1.54 ± 0.02 inch)	29.75° ± 0.25°
254-3944	Exhaust 0.51 mm (0.020 inch) oversize	11.30 ± 0.06 mm (0.4449 ± 0.0024 inch)	42.900 ± 0.015 mm (1.68897 ± 0.00059 inch)	36.0 ± 0.5 mm (1.42 ± 0.02 inch)	44.75° ± 0.25°
255-8666	Intake	9.30 ± 0.05 mm (0.366 ± 0.002 inch)	42.560 ± 0.013 mm (1.6756 ± 0.0005 inch)	36.50 ± 0.50 mm (1.440 ± 0.020 inch)	30.25° ± 0.25°
260-4855(1)	Intake	12.63 ± 0.06 mm (0.497 ± 0.002 inch)	45.525 ± 0.013 mm (1.7923 ± 0.0005 inch)	39.1 ± 0.5 mm (1.54 ± 0.02 inch)	29.75° ± 0.25°
262-2959	Exhaust	10.40 ± 0.05 mm (0.409 ± 0.002 inch)	39.060 ± 0.013 mm (1.5378 ± 0.0005 inch)	32.5 ± 0.5 mm (1.28 ± 0.02 inch)	45.00° ± 0.25°
264-6157	Intake	9.00 ± 0.06 mm (0.354 ± 0.0024 inch)	42.000 ± 0.013 mm (1.6535 ± 0.0005 inch)	35.80 ± 0.13 mm (1.409 ± 0.005 inch)	30.25° ± 0.25°
272-9813(1)	Intake	9.00 ± 0.06 mm (0.354 ± 0.0024 inch)	42.000 ± 0.013 mm (1.6535 ± 0.0005 inch)	35.80 ± 0.13 mm (1.409 ± 0.005 inch)	30.25° ± 0.25°
280-3979(1)	Intake	14.00 ± 0.08 mm (0.551 ± 0.003 inch)	48.025 ± 0.013 mm (1.8907 ± 0.0005 inch)	41.0 ± 0.5 mm (1.61 ± 0.02 inch)	30.25° ± 0.25°
288-4881	Intake 0.51 mm (0.020 inch) oversize	14.00 ± 0.08 mm (0.551 ± 0.003 inch)	48.535 ± 0.013 mm (1.91082 ± 0.00051 inch)	41.0 ± 0.5 mm (1.61 ± 0.02 inch)	30.25° ± 0.25°
288-4882	Intake 0.76 mm (0.030 inch) oversize	14.00 ± 0.08 mm (0.551 ± 0.003 inch)	48.785 ± 0.013 mm (1.92067 ± 0.00051 inch)	41.0 ± 0.5 mm (1.61 ± 0.02 inch)	30.25° ± 0.25°
288-4883	Exhaust 0.51 mm (0.020 inch) oversize	13.90 ± 0.06 mm (0.547 ± 0.002 inch)	43.350 ± 0.013 mm (1.70669 ± 0.00051 inch)	36.5 ± 0.5 mm (1.44 ± 0.02 inch)	45.25° ± 0.25°
288-4884	Exhaust 0.76 mm (0.030 inch) oversize	13.90 ± 0.06 mm (0.547 ± 0.002 inch)	43.6000 ± 0.013 mm (1.71653 ± 0.00051 inch)	36.5 ± 0.5 mm (1.44 ± 0.02 inch)	45.25° ± 0.25°
314-3055	Intake Short	12.63 ± 0.06 mm (0.497 ± 0.002 inch)	45.525 ± 0.013 mm (1.7923 ± 0.0005 inch)	39.1 ± 0.5 mm (1.54 ± 0.02 inch)	29.75° ± 0.25°
314-3056	Intake 0.13 mm (0.00512 inch) oversize	12.63 ± 0.06 mm (0.497 ± 0.002 inch)	45.655 ± 0.013 mm (1.79744 ± 0.00051 inch)	39.1 ± 0.5 mm (1.54 ± 0.02 inch)	29.75° ± 0.25°
314-3057	Intake Short 0.13 mm (0.00512 inch) oversize	12.63 ± 0.06 mm (0.497 ± 0.002 inch)	45.655 ± 0.013 mm (1.79744 ± 0.00051 inch)	39.1 ± 0.5 mm (1.54 ± 0.02 inch)	29.75° ± 0.25°
314-3058	Intake 0.26 mm (0.01024 inch) oversize	12.63 ± 0.06 mm (0.497 ± 0.002 inch)	45.785 ± 0.013 mm (1.80256 ± 0.00051 inch)	39.1 ± 0.5 mm (1.54 ± 0.02 inch)	29.75° ± 0.25°
314-3060	Intake Short 0.51 mm (0.020 inch) oversize	12.63 ± 0.06 mm (0.497 ± 0.002 inch)	45.785 ± 0.013 mm (1.80256 ± 0.00051 inch)	39.1 ± 0.5 mm (1.54 ± 0.02 inch)	29.75° ± 0.25°
314-3061	Intake Short 0.51 mm (0.020 inch) oversize	12.63 ± 0.06 mm (0.497 ± 0.002 inch)	46.035 ± 0.013 mm (1.81240 ± 0.00051 inch)	39.1 ± 0.5 mm (1.54 ± 0.02 inch)	29.75° ± 0.25°
314-3063	Intake Short	14.00 ± 0.08 mm (0.551 ± 0.003 inch)	48.025 ± 0.013 mm (1.8907 ± 0.0005 inch)	41.0 ± 0.5 mm (1.61 ± 0.02 inch)	30.25° ± 0.25°
314-3064	Intake 0.13 mm (0.00512 inch) oversize	14.00 ± 0.08 mm (0.551 ± 0.003 inch)	48.155 ± 0.013 mm (1.89586 ± 0.00051 inch)	41.0 ± 0.5 mm (1.61 ± 0.02 inch)	30.25° ± 0.25°
314-3065	Intake Short 0.13 mm (0.00512 inch) oversize	14.00 ± 0.08 mm (0.551 ± 0.003 inch)	48.155 ± 0.013 mm (1.89586 ± 0.00051 inch)	41.0 ± 0.5 mm (1.61 ± 0.02 inch)	30.25° ± 0.25°
314-3066	Intake 0.26 mm (0.01024 inch) oversize	14.00 ± 0.08 mm (0.551 ± 0.003 inch)	48.285 ± 0.013 mm (1.90098 ± 0.00051 inch)	41.0 ± 0.5 mm (1.61 ± 0.02 inch)	30.25° ± 0.25°
314-3067	Intake Short 0.26 mm (0.01024 inch) oversize	14.00 ± 0.08 mm (0.551 ± 0.003 inch)	48.285 ± 0.013 mm (1.90098 ± 0.00051 inch)	41.0 ± 0.5 mm (1.61 ± 0.02 inch)	30.25° ± 0.25°
314-3068	Intake 0.51 mm (0.020 inch) oversize	14.00 ± 0.08 mm (0.551 ± 0.003 inch)	48.535 ± 0.013 mm (1.91082 ± 0.00051 inch)	41.0 ± 0.5 mm (1.61 ± 0.02 inch)	30.25° ± 0.25°
314-3069	Intake Short 0.51 mm (0.020 inch) oversize	14.00 ± 0.08 mm (0.551 ± 0.003 inch)	48.535 ± 0.013 mm (1.91082 ± 0.00051 inch)	41.0 ± 0.5 mm (1.61 ± 0.02 inch)	30.25° ± 0.25°
331-5010	Exhaust 0.13 mm (0.00512 inch) oversize	11.30 ± 0.06 mm (0.4449 ± 0.0024 inch)	42.52 ± 0.015 mm (1.67401 ± 0.00059 inch)	36.0 ± 0.5 mm (1.42 ± 0.02 inch)	44.75° ± 0.25°
331-5011	Exhaust 0.26 mm (0.01024 inch) oversize	11.30 ± 0.06 mm (0.4449 ± 0.0024 inch)	42.65 ± 0.015 mm (1.67913 ± 0.00059 inch)	36.0 ± 0.5 mm (1.42 ± 0.02 inch)	44.75° ± 0.25°

(1)	Do not machine the valve seat. Specialized manufacturing processes were used on this part. Machining will significantly decrease the life of the engine.

Replacing Valve Seats Inserts for C7 through C32

Use this section to determine the procedure to be used to replace valve inserts. More options will be added in the future.

Note: The circular runout between the valve seat and the valve guide must be within 0.08 mm (0.003 inch).

Note: If your engine is a marine engine, do not machine the inserts for the Intake. You must use the original inserts. You must machine the depth of the bore for the valve seat. Remove the same amount of material from the bottom of the bore as the amount of material from the head.

Table 60

Replacements for Valve Seat Inserts on C7
Condition of the Head	Valve Seat Insert	Comment	Machining the Valve Seat Insert
The head has been machined. The bore of the head does not have damage.	155-9504 Intake 147-8218 Exhaust	N/A	Machine the surface of the insert so that the same amount of material is removed from the head and the insert.
The head has been machined. The bore of the head has damage.	187-8285 Intake 187-8282 Exhaust	0.13 mm (0.005 inch) oversize 0.13 mm (0.005 inch) oversize	Machine the surface of the insert so that the same amount of material is removed from the head and the insert. Enlarge the bore diameter by 0.13 mm (0.005 inch).
The head has been machined. The bore of the head has damage and an oversized insert has already been used.	187-8286 Intake 187-8283 Exhaust	0.26 mm (0.010 inch) oversize 0.26 mm (0.010 inch) oversize	Machine the surface of the insert so that the same amount of material is removed from the head and the insert. Enlarge the bore diameter by 0.51 mm (0.020 inch).
The head has been machined. The bore of the head has damage and an oversized insert has already been used.	187-8287 Intake 187-8284 Exhaust	0.51 mm (0.020 inch) oversize 0.51 mm (0.020 inch) oversize	Machine the surface of the insert so that the same amount of material is removed from the head and the insert. Enlarge the bore diameter by 0.51 mm (0.020 inch).

Table 61

Replacements for Valve Seat Inserts on C9 and C-9
Condition of the Head	Valve Seat Insert	Comment	Machining the Valve Seat Insert
The head has been machined. The bore of the head does not have damage.	241-8388 Intake 212-8917 Exhaust	N/A	Machine the surface of the insert so that the same amount of material is removed from the head and the insert.
The head has been machined. The bore of the head has damage.	254-3946 Intake 254-3947 Exhaust	0.51 mm (0.020 inch) oversize 0.51 mm (0.020 inch) oversize	Machine the surface of the insert so that the same amount of material is removed from the head and the insert. Enlarge the bore diameter by 0.51 mm (0.020 inch).

Table 62

Replacements for Valve Seat Inserts on C15, C16, C18, C27, and C32
Condition of the Head	Valve Seat Insert	Comment	Machining the Valve Seat Insert
The thickness of the head is within like-new dimensions. See Table 10 for specifications. The bore of the head does not have damage.	224-3983(1) Intake 226-5561 Exhaust	N/A	Do not machine the insert.
The head has been machined beyond factory specifications. The bore of the head does not have damage.	175-3617 Intake 226-5561 Exhaust	N/A	Machine the sealing angle of the insert so that the same amount of material is removed from the head and the insert.
The head has been machined beyond factory specifications. The bore of the head has damage.	170-4738 Intake 170-4737 Exhaust	0.51 mm (0.020 inch) oversize 0.51 mm (0.020 inch) oversize	Machine the sealing angle of the insert so that the same amount of material is removed from the head and the insert. Enlarge the bore diameter by 0.51 mm (0.020 inch).
The head has been machined beyond factory specifications. The bore of the head has damage and an oversized insert has already been used.	167-0643 Intake 167-0642 Exhaust	0.76 mm (0.030 inch) oversize 0.76 mm (0.030 inch) oversize	Machine the sealing angle of the insert so that the same amount of material is removed from the head and the insert. Enlarge the bore diameter by 0.76 mm (0.030 inch).

(1)	Do not machine the valve seat. Specialized manufacturing processes were used on this part. Machining will significantly decrease the life of the engine.

Valve Seat Inserts for C175 Engines

The C-175 engines use two types of cylinder heads, depending on the application. Engines that are used in generator sets use cylinder heads with water-cooled valve seat inserts (A). Generally, engines that are in machines use cylinder heads with conventional non-water cooled valve seat inserts (B). The exception is some 793F Off-Highway Trucks S/N:B7B100-118 that used water-cooled valve seat inserts.

Illustration 220	g06229695
Water-Cooled Valve Seat Inserts

Illustration 221	g06229698
Conventional Non Water-Cooled Valve Seat Inserts

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NOTICE
Do not rework valve inserts. If the insert does not meet dimensional specifications, then the insert must be replaced.

Illustration 222	g01961623
Sealing face on the different types of valve seat inserts (H) Height of allowed wear of the sealing face

Use the following chart to determine the maximum height of allowed wear of the sealing face on the valve seat insert. The maximum height of allowed wear is provided in the following chart with the corresponding valve. The maximum height of allowed wear is found from the corresponding valves outer diameter of the sealing face and the valve seats inserts inner diameter of the sealing face. The angle of the valve must meet the specifications in Table 63 to ensure proper sealing.

Table 63

Maximum Height of Allowed Wear of the Sealing Face on the Valve Seat Insert for C175 Engines
2.5 mm (0.10 inch)

Conventional Valve Seat Inserts

Conventional valve seat inserts can be replaced at overhaul. If the valve seat bore is damaged, then the bore can be machined oversized. Oversized seats and dimensions are listed in Table 64. Machine the bore according to the specifications given in Table 64 .

Illustration 223	g01961841
(J) Outside diameter of the valve seat insert (K) Sealing angle for the valve seat insert

Table 64

Specifications of the Conventional Valve Seat Insert for C175 Engines
Valve Seat Insert	Outside diameter of the valve seat insert (J)	Sealing angle for the valve seat insert (K)
Inlet Valve Seat Insert
273-1223 456-2468 Valve Seat Insert (Standard)	62.100 ± 0.013 mm (2.4449 ± 0.0005 inch)	20° ± 0.25°
393-6470 Valve Seat Insert (0.25-MM OS, INLET)	62.354 ± 0.013 mm (2.4549 ± 0.0005 inch)
393-6471 Valve Seat Insert (0.51-MM OS, INLET)	62.609 ± 0.013 mm (2.4649 ± 0.0005 inch)
Exhaust Valve Seat Insert
331-3688 Valve Seat Insert (Standard)	61.120 ± 0.013 mm (2.4063 ± 0.0005 inch)	45° ± 0.25°
393-6468 Valve Seat Insert (0.25-MM OS, EXHAUST)	61.374 ± 0.013 mm (2.4163 ± 0.0005 inch)
393-6469 Valve Seat Insert (0.51-MM OS, EXHAUST)	61.629 ± 0.013 mm (2.4263 ± 0.0005 inch)

Illustration 224	g06229842
Conventional valve seat inserts (L) Diameter of the bore for the valve seat insert (M) Depth of the bore for the valve seat insert

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NOTICE
The runnout of the valve seat bore center to guide bore center must be less than 0.04 mm (0.002 inch).

Note: The C175 cylinder head has different-sized intake and exhaust seat bores. Take note of the bore location and size prior to machining.

Table 65

Dimensions for the Bore in the Cylinder Head for the Valve Seat Insert for C175 Engines
Part Number	Intake or Exhaust	Depth of the bore for the valve seat (M)	Diameter of the bore for the valve seat insert (L)
328-7082 345-8447 456-2406 515-8766 517-4407	Intake	16.00 ± 0.15 mm (0.630 ± 0.006 inch)	Standard 62.000 ± 0.015 mm (2.4409 ± 0.0006 inch)
			0.254 mm Oversize 62.254 ± 0.015 mm (2.4509 ± 0.0006 inch)
			0.508 mm Oversize 62.508 ± 0.015 mm (2.4609 ± 0.0006 inch)
	Exhaust	16.00 ± 0.15 mm (0.630 ± 0.006 inch)	Standard 61.000 ± 0.015 mm (2.4016 ± 0.0006 inch)
			0.254 mm Oversize 61.254 ± 0.015 mm (2.4116 ± 0.0006 inch)
			0.508 mm Oversize 61.508 ± 0.015 mm (2.4216 ± 0.0006 inch)

Water-Cooled Valve Seat Inserts

Do not reuse water-cooled valve seat inserts.

Illustration 225	g01969318
Water-cooled insert (K) Sealing angle for the valve seat insert (N) Upper diameter of the valve seat insert (P) Lower diameter of the valve seat insert

Table 66

Specifications of the Water-Cooled Valve Seat Insert for C175 Engines
Inlet Valve Seat Inserts
Valve Seat Insert	Upper diameter of the valve seat insert (N)	Lower diameter of the valve seat insert (P)	Sealing angle for the valve seat insert (K)
333-9179	67.150 ± 0.013 mm (2.6437 ± 0.0005 inch)	60.635 ± 0.013 mm (2.3872 ± 0.0005 inch)	20° ± 0.25°
Exhaust Valve Seat Inserts
333-9180	66.900 ± 0.013 mm (2.6339 ± 0.0005 inch)	60.385 ± 0.013 mm (2.3774 ± 0.0005 inch)	45° ± 0.25°

Illustration 226	g06229845
(M) Depth of the lower bore for the valve seat insert (Q) Diameter of the upper bore for the valve seat insert (R) Diameter of the lower bore for the valve seat insert (S) Depth of the upper bore for the valve seat insert

Table 67

Dimensions for the Bore in the Cylinder Head for the Valve Seat Insert for C175 Engines
Intake or Exhaust	Depth of the lower bore for the valve seat (M)	Diameter of the upper bore for the valve seat insert (Q)	Diameter of the lower bore for the valve seat insert (R)	Depth of the upper bore for the valve seat (S)
Intake	36.03 ± 0.15 mm (1.419 ± 0.006 inch)	66.995 ± 0.020 mm (2.6376 ± 0.0006 inch)	60.495 ± 0.020 mm (2.3817 ± 0.0008 inch)	14.03 ± 0.15 mm (0.553 ± 0.006 inch)
Exhaust	36.63 ± 0.30 mm (1.442 ± 0.012 inch)	66.745 ± 0.020 mm (2.6278 ± 0.0008 inch)	60.245 ± 0.020 mm (2.3719 ± 0.0008 inch)	14.63 ± 0.15 mm (0.576 ± 0.006 inch)

Valve Seat Inserts for 3044, 3046, 3064, and 3066 Engines

Illustration 227	g06278422
Valve seat insert (Q) Depth of the Bore for the Valve Seat Insert (R) Valve Seat Insert Inside Diameter (S) Valve Seat Insert Outside Diameter (T) Sealing Angle of the Valve Seat Insert

Table 68

Specifications for Valve Seat Inserts for 3044, 3046, 3064, and 3066 Engines
Sales Model	3044, 3046		3064, 3066
Description	Intake	Exhaust	Intake	Exhaust
Depth of the Bore for the Valve Seat Insert (Q)	5.00 mm (0.197 inch)	5.00 mm (0.197 inch)	6.60 mm (0.260 inch)	6.60 mm (0.260 inch)
Valve Seat Insert Inside Diameter (R)	38.00 mm (1.496 inch)	31.00 mm (1.221 inch)	40.00 mm (1.575 inch)	39.00 mm (1.535 inch)
Valve Seat Insert Outside Diameter (S)	46.012 ± 0.012 mm (1.8115 ± 0.0005 inch)	37.012 ± 0.012 mm (1.4572 ± 0.0005 inch)	48.012 ± 0.012 mm (1.8902 ± 0.0005 inch)	39.012 ± 0.012 mm (1.5359 ± 0.0005 inch)
Sealing Angle of the Valve Seat Insert (T)	60	60	60	60

Valve Seat Inserts for 3054, and 3056 Engines

Illustration 228	g06272356
Refer to Table 69 for dimensions of the valve seat insert. (A) Depth of bore of valve seat (B) Diameter of bore of valve seat insert (C) Maximum radius

Illustration 229	g06272361
Refer to Table 69 and Table 71 for dimensions of the valve seat insert. (D) Angle of valve seat insert (E) Dimension of chamfer (F) Angle of chamfer

Note: When a new valve seat insert is installed, a new valve and valve guide must be installed. Refer to the Disassembly and Assembly for removal and installation procedures.

Table 69

Specifications for 3054, and 3056 Engines
Description	Intake	Exhaust
Depth of bore of valve seat (A)	7.19 to 7.32 mm (0.28307 to 0.28819 inch)	9.52 to 9.65 mm (0.37480 to 0.37992 inch)
Diameter of bore of valve seat insert (B)	51.22 to 51.24 mm (2.01653 to 2.01732 inch)	42.62 to 42.65 mm (1.67795 to 1.67913 inch)
Maximum radius (C)	0.38 mm (0.01496 inch)
Angle of valve seat with 46° valve seats (D)	88°
Angle of valve seat with 31° valve seats (D)	118°
Dimension of chamfer (E)	0.9 to 1.3 mm (0.03543 to 0.05118 inch)
Angle of chamfer (F)	30°

Valve Seat Inserts for 3114, 3116, 3126 Engines

The valve seat inserts should be replaced when the width of the valve seat or the face of the valve head cannot be machined to the correct specification. Refer to the appropriate Service Manual for your engine application for removal and installation instructions of valve seat inserts.

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NOTICE
Some 3126B engines are experiencing corrosion on the 217-5213 Valve Seat Insert and the 155-9504 Valve Seat Insert. If corrosion is found on 217-5213 Valve Seat Inserts, replace the valve seat inserts with 272-9813 Valve Seat Inserts. The 272-9813 Valve Seat Inserts are made from an alloy that is corrosion resistant. If corrosion is found on 155-9504 Valve Seat Inserts, replace the valve seat inserts with 278-0453 Valve Seats. The 278-0453 Valve Seats are made from an alloy that is more corrosion resistant. Part numbers are etched on the outer surface of the valve seat inserts. The 278-0453 Valve Seats and 272-9813 Valve Seat Inserts are pre-finished. Pre-finished valve seat inserts do not require any additional machining in the cylinder head.

Machine the seat face of the insert after the inserts are installed to be sure of the following:

• Flatness of the seat

• Angle of the seat

• Alignment of the seat

Illustration 230	g06278428
Refer to Table 69 and Table 71 for dimensions of the valve seat insert. (C) Diameter of bore of valve seat insert (D) Inside diameter of valve seat insert (E) Angle of valve seat insert (F) Depth of bore of valve seat (G) Outside diameter of face of seat insert

Table 70

Early Model Specifications for 3114, 3116, 3126 Engines
Description	Intake 7W-8065	Exhaust 1W-2713
Inside diameter of valve seat insert (D)	43.29 ± 0.13 mm (1.704 ± 0.005 inch)	37.00 ± 0.13 mm (1.457 ± 0.005 inch)
Diameter of bore of valve seat insert (C)	49.931 ± .013 mm (1.9658 ± 0.0005 inch)	42.931 ± .013 mm (1.6903 ± 0.0005 inch)
Angle of valve seat insert (E)	30.25° ± 0.50°	45.50° ± 0.50°
Depth of bore of valve seat (F)	10.00 ± 0.13 mm (0.394 ± 0.005 inch)	10.00 ± 0.13 mm (0.394 ± 0.005 inch)
Outside diameter of face of seat insert (G)(1)	48.0 mm (1.89 inch)	40.4 mm (1.59 inch)

(1)	The seat insert should not be reused if the outside diameter is greater than specifications.

Table 71

HEUI Model Specifications for 3114, 3116, 3126 Engines
Description	Intake 217-5213	Exhaust 147-8218
Inside diameter of valve seat insert (D)	35.80 ± 0.13 mm (1.409 ± 0.005 inch)	39.50 ± 0.13 mm (1.555 ± 0.005 inch)
Diameter of bore of valve seat insert (C)	42.000 ± 0.013 mm (1.6535 ± 0.0005 inch)	46.000 ± 0.013 mm (1.8110 ± 0.0005 inch)
Angle of valve seat insert (E)	30.25° ± 0.25°	45.5° ± 0.25°
Depth of bore of valve seat (F)	5.50 ± 0.05 mm (0.217 ± 0.002 inch)	6.05 ± 0.05 mm (0.238 ± 0.002 inch)
Outside diameter of face of seat insert (G)(1)	37.351 mm (1.4705 inch)	40.8 mm (1.61 inch)

(1)	The seat insert should not be reused if the outside diameter is greater than specifications.

Valve Seat Inserts for 3176, 3196 Engines

Removal

Use the 166-7441 Valve Seat Extractor Tool to remove the valve seat.

Refer to Special Instruction, SMHS7935, "Use of 6V-4805 Valve Seat Extractor Tool Group" for additional information.

Note: The 6V-4805 Valve Seat Extractor Tool Group has been replaced by the 166-7441 Valve Seat Extractor Tool.

Conduct further inspection of the bores after the removal of the valve seat.

Installation

Lower the temperature of the seats before installation. The temperature of the valve seat should not exceed −60 °C (−76.0 °F).

Use the 1U-9170 Valve Seat Driver to install the valve seat.

Note: Make sure that the projection of the valve is correct. Make sure that the depth of the valve seat is correct and that the valve seat is fully inserted into the bore.

Machine the seat face of the insert after the inserts are installed to be sure of the following:

• Flatness of the seat

• Angle of the seat

• Alignment of the seat to the valve guide

• Correct valve recession

Illustration 231	g02419839
Refer to Table 72 and Table 73 for dimensions of valve seat. (A) Depth of valve seat bore (C) Diameter of valve seat bore (B) Inside diameter of valve seat (D) Sealing angle of valve seat

Table 72

Dimensions of Inlet Valve Seat in 3176 and 3196 Engines
Part Number	Depth of valve seat bore (A)	Sealing angle of valve seat (D)	Diameter of valve seat bore (C)	Inside diameter of valve seat (B)
4N-5893	15.27 ± 0.20 mm (0.601 ± 0.008 inch)	30.00° ± 1.00°	46.025 ± 0.013 mm (1.8120 ± 0.0005 inch)	39.1 ± 0.5 mm (1.54 ± 0.02 inch)
138-1999	15.27 ± 0.11 mm (0.601 ± 0.004 inch)	29.75° ± 0.25°
138-2006
179-9454

Table 73

Dimensions of Exhaust Valve Seat in 3176 and 3196 Engines
Part Number	Depth of valve seat bore (A)	Sealing angle of valve seat (D)	Diameter of valve seat bore (C)	Inside diameter of valve seat (B)
7W-5554	14.60 ± 0.20 mm (0.575 ± 0.008 inch)	45.00° ± 1.00°	43.4 ± 0.015 mm (1.71 ± 0.0006 inch)	36.00 ± 0.13 mm (1.417 ± 0.005 inch)
133-7030
133-6997
179-9453	14.60 ± 0.11 mm (0.575 ± 0.004 inch)	44.75° ± 0.25°
138-1997
138-2005
138-2006	14.27 ± 0.11 mm (0.5618 ± 0.0043 inch)	29.75° ± 0.25°	46.025 ± 0.013 mm (1.8120 ± 0.0005 inch)	39.1 ± 0.5 mm (1.54 ± 0.02 inch)

Valve Seat for 3200 Engines

Use this procedure to remove erosion or cracks between the valve seat and injector nozzle hole only in 3200 Engines. Use a 6V-4168 Air Grinder with a 6V-4802 Stone. A 6V-4801 Dressing Stone is needed to make the edges of the 6V-4802 Stone round.

1. Grind channel, but do not grind into the bottom of the valve seat area.

2. Make the edges of the 6V-4802 Stone round before grinding the head.

3. Channel specifications for crack removal.

   • Maximum depth 3.2 mm (0.12598 inch).

   • Maximum width 4.8 mm (0.18898 inch).

   • Minimum radius 1.6 mm (0.06299 inch).

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NOTICE
Do not damage the bottom of the valve seat area with the stone. If the crack extends into the valve seat area, the cylinder head cannot be reused.

Illustration 232	g06278434
(A) Valve Seat Angle

Table 74

Model	Diesel
	Intake	Exhaust
3204	30.5° ± 0.5°	45.5° ± 0.5°
3208	30.5° ± 0.5°	45.5° ± 0.5°

Valve Seat Depth for 3208 Engines Only

Two gauges are used to measure the depth of valve seats on 3208 Engines Only. Use a 6V-7098 Gauge for intake valves and a 6V-7097 Gauge for exhaust valves.

1. Place the small diameter end of gauge into the valve guide, making sure gauge is seated on the face of the valve.

2. Use straight edge to check the depth of the seat.

3. If gauge surface is below the bottom surface of the straight edge, the seat is too deep.

4. If gauge surface is above the bottom of the straight edge, the seat is too high and must be ground again.

5. If the straight edge is between faces and, the seat is positioned correctly.

Valve Seat Inserts for 3300 Engines

Illustration 233	g06278434
(A) Valve Seat Angle

Table 75

Valve Seat Angle (A) for 3304 and 3306 Engines
Diesel		Gas
Intake	Exhaust	Intake	Exhaust
29.25° ± 0.5°	30.25° ± 0.5°	30.0° ± 0.5°	30.0° ± 0.5°

The valve seat inserts have an interference fit of 0.076 mm (0.003 inch) with the cylinder head. Use the following information when using oversized valve seat inserts.

Illustration 234	g06278442

Table 76

Valve Seat Insert Bore Diameters in Cylinder Head for 3300 Engines
Valve Seat Insert Type	Intake Bore Depth (A)	Chamfer (B)	Exhaust Bore Depth (C)	Intake Lead in Angle (D)	Exhaust Lead in Angle (E)	Intake Bore Diameter (F)	Exhaust Bore Diameter (G)
Standard Size Inserts	12.28 ± 0.13 mm (0.483 ± 0.005 in)	.76 ± 0.25 mm (0.030 ± 0.010 in) by 45°	12.28 ± 0.13 mm (0.483 ± 0.005 in)	25 +/- 2°	30 +/- 2°	51.956 ± 0.030 mm (2.0455 ± 0.0012 in)	50.813 ± 0.030 mm (2.0005 ± 0.0012 in)
0.13 mm (0.005 in) Oversized	12.28 ± 0.13 mm (0.483 ± 0.005 in)	.76 ± 0.25 mm (0.030 ± 0.010 in) by 45°	12.28 ± 0.13 mm (0.483 ± 0.005 in)	25 +/- 2°	30 +/- 2°	52.086 ± 0.030 mm (2.0506 ± 0.0012 in)	50.943 ± 0.030 mm (2.0056 ± 0.0012 in)
0.25 mm (0.010 in) Oversized	12.28 ± 0.13 mm (0.483 ± 0.005 in)	.76 ± 0.25 mm (0.030 ± 0.010 in) by 45°	12.28 ± 0.13 mm (0.483 ± 0.005 in)	25 +/- 2°	30 +/- 2°	52.206 ± 0.030 mm (2.0554 ± 0.0012 in)	51.063 ± 0.030 mm (2.0104 ± 0.0012 in)
0.51 mm (0.020 in) Oversized	12.28 ± 0.13 mm (0.483 ± 0.005 in)	.76 ± 0.25 mm (0.030 ± 0.010 in) by 45°	12.28 ± 0.13 mm (0.483 ± 0.005 in)	25 +/- 2°	30 +/- 2°	52.466 ± 0.030 mm (2.0656 ± 0.0012 in)	51.323 ± 0.030 mm (2.0206 ± 0.00118 in)
0.76 mm (0.030 in) Oversized	12.28 ± 0.13 mm (0.483 ± 0.005 in)	.76 ± 0.25 mm (0.030 ± 0.010 in) by 45°	12.28± 0.13 mm (0.483 ± 0.005 in)	25 +/- 2°	30 +/- 2°	52.716 ± 0.030 mm (2.0754 ± 0.0012 in)	51.573 ± 0.030 mm (2.0304 ± 0.0012 in)

Valve Seat Inserts for 3400 Engines

The valve seat inserts should be replaced when the width of the valve seat or the valve head to the cylinder head face cannot be machined to the correct specification. Use 166-7441 Valve Seat Extractor Tool to remove the valve seat inserts. Refer to Special Instruction, SMHS7935, "Use of 6V-4805 Valve Seat Extractor Tool" to remove the valve seat inserts.

After the inserts are installed, grind the seat face of the insert to ensure the following:

• The face of the insert is flat.

• The insert has the correct angle.

• The insert is in alignment with the bore of the valve guide.

Note: If the valve seat insert is premachined, the insert does not need to be ground after installation into the cylinder head.

Refer to Table 79 or Table 80 for the correct dimensions.

When the valve seat insert is ground, refer to Table 79 or Table 80 for the minimum finished width of the valve seat (G). The maximum width of the valve seat is the intersection of the ground face with the bore of the insert in the cylinder head.

Illustration 235	g01478243

Oversized valve seat inserts are available for use in 3400 Series Engines. These inserts provide increased serviceability of the cylinder head. When these inserts are used, the bore in the cylinder head must be machined to the correct size to achieve the correct press fit of the valve seat insert. Refer to Table 77 or Table 78 for the dimensions to machine the cylinder head.

Table 77

Oversized Valve Seat Inserts for 3400 Engines Diesel Engines
Oversize Dimension	Bore for Inlet Seat in Cylinder Head	Bore for Exhaust Seat in Cylinder Head
0.13 mm (0.005 inch)	46.076 ± 0.025 mm (1.8140 ± 0.0010 inch)	N/A
0.25 mm (0.010 inch)	46.203 ± 0.025 mm (1.8190 ± 0.0010 inch)	N/A
0.51 mm (0.020 inch)	46.457 ± 0.025 mm (1.8290 ± 0.0010 inch)	43.282 ± 0.025 mm (1.7040 ± 0.0010 inch)
0.76 mm (0.030 inch)	46.711 ± 0.025 mm (1.8390 ± 0.0010 inch)	43.536 ± 0.025 mm (1.7140 ± 0.0010 inch)

Table 78

Oversized Valve Seat Inserts for 3400 Engines Gas Engines
Oversize Dimension	Bore for Inlet Seat in Cylinder Head	Bore for Exhaust Seat in Cylinder Head
0.127 mm (0.0050 inch)	46.076 ± 0.025 mm (1.8140 ± 0.0010 inch)	42.901 ± 0.025 mm (1.6890 ± 0.0010 inch)
0.254 mm (0.0100 inch)	46.203 ± 0.025 mm (1.8190 ± 0.0010 inch)	43.028 ± 0.025 mm (1.6940 ± 0.0010 inch)
0.381 mm (0.0150 inch)	46.330 ± 0.025 mm (1.8240 ± 0.0010 inch)	43.155 ± 0.025 mm (1.6990 ± 0.0010 inch)
0.508 mm (0.0200 inch)	46.457 ± 0.025 mm (1.8290 ± 0.0010 inch)	43.282 ± 0.025 mm (1.7040 ± 0.0010 inch)
0.762 mm (0.0300 inch)	46.711 ± 0.025 mm (1.8390 ± 0.0010 inch)	43.536 ± 0.025 mm (1.7140 ± 0.0010 inch)

Table 79

Specifications for the Valve Seat Insert for 3400 Engines Diesel Engines
Part Number	Depth of the bore in head for valve seat insert (C)	Bore diameter in head for valve seat insert (D)	Outside diameter of valve seat insert	Inside diameter of valve seat insert (E)	Angle of valve seat insert (F)	Minimum width of the valve seat insert (G)
115-2358 Inlet	13.01 ± 0.15 mm (0.512 ± 0.006 inch)	45.949 ± 0.025 mm (1.8090 ± 0.0010 inch)	46.025 ± 0.013 mm (1.8120 ± 0.0005 inch)	39.1 ± 0.3 mm (1.54 ± 0.01 inch)	30 ± 1 degree	2.286 ± 0.635 mm (0.0900 ± 0.0250 inch)
4N-5893 Inlet	13.01 ± 0.15 mm (0.512 ± 0.006 inch)	45.949 ± 0.025 mm (1.8090 ± 0.0010 inch)	46.025 ± 0.013 mm (1.8120 ± 0.0005 inch)	39.1 ± 0.5 mm (1.54 ± 0.02 inch)	30.25 ± 0.50 degree	2.286 ± 0.635 mm (0.0900 ± 0.0250 inch)
1W-5283 Exhaust	13.01 ± 0.15 mm (0.512 ± 0.006 inch)	42.774 ± 0.025 mm (1.6840 ± 0.0010 inch)	42.850 ± 0.013 mm (1.6870 ± 0.0005 inch)	36.5 ± 0.5 mm (1.44 ± 0.02 inch)	45 ± 1 degree	1.524 ± 0.508 mm (0.0600 ± 0.0200 inch)

Table 80

Specifications for the Valve Seat Insert for 3400 Engines Gas Engines
Part Number	Depth of the bore in head for valve seat insert (C)	Bore diameter in head for valve seat insert (D)	Outside diameter of valve seat insert	Inside diameter of valve seat insert (E)	Angle of valve seat insert (F)	Minimum width of the valve seat insert (G)
214-3286 Inlet	11.48 ± 0.10 mm (0.452 ± 0.004 inch)	45.949 ± 0.025 mm (1.8090 ± 0.0010 inch)	46.025 ± 0.015 mm (1.8120 ± 0.0006 inch)	39.10 ± 0.25 mm (1.539 ± 0.010 inch)	20.25 ± 0.50 degree	N/A(1)
122-7352 Inlet	13.01 ± 0.15 mm (0.512 ± 0.006 inch)	45.949 ± 0.025 mm (1.8090 ± 0.0010 inch)	46.025 ± 0.013 mm (1.8120 ± 0.0005 inch)	39.10 ± 0.25 mm (1.539 ± 0.010 inch)	20.25 ± 0.50 degree	3.0 ± 0.5 mm (0.12 ± 0.02 inch)
6I-4019 Inlet	13.01 ± 0.15 mm (0.512 ± 0.006 inch)	45.949 ± 0.025 mm (1.8090 ± 0.0010 inch)	46.025 ± 0.013 mm (1.8120 ± 0.0005 inch)	39.10 ± 0.25 mm (1.539 ± 0.010 inch)	20.25 ± 0.50 degree	3.0 ± 0.5 mm (0.12 ± 0.02 inch)
4N-5893 Inlet	13.01 ± 0.15 mm (0.512 ± 0.006 inch)	45.949 ± 0.025 mm (1.8090 ± 0.0010 inch)	46.025 ± 0.013 mm (1.8120 ± 0.0005 inch)	39.1 ± 0.5 mm (1.54 ± 0.02 inch)	30.25 ± 0.50 degree	2.286 ± 0.635 mm (0.0900 ± 0.0250 inch)
212-0938 Exhaust	11.48 ± 0.10 mm (0.452 ± 0.004 inch)	42.774 ± 0.025 mm (1.6840 ± 0.0010 inch)	42.850 ± 0.015 mm (1.6870 ± 0.0006 inch)	33.50 ± 0.25 mm (1.319 ± 0.010 inch)	20.25 ± 0.25 degree	N/A(1)
212-0936 Exhaust	11.48 ± 0.10 mm (0.452 ± 0.004 inch)	42.774 ± 0.025 mm (1.6840 ± 0.0010 inch)	42.840 ± 0.015 mm (1.6866 ± 0.0006 inch)	33.50 ± 0.25 mm (1.319 ± 0.010 inch)	20.25 ± 0.25 degree	N/A(1)
198-6529 Exhaust	13.01 ± 0.15 mm (0.512 ± 0.006 inch)	42.774 ± 0.025 mm (1.6840 ± 0.0010 inch)	42.840 ± 0.013 mm (1.6866 ± 0.0005 inch)	35.71 ± 0.25 mm (1.406 ± 0.010 inch)	20.25 ± 0.50 degree	3.1 ± 0.5 mm (0.12 ± 0.02 inch)
118-4715 Exhaust	13.01 ± 0.15 mm (0.512 ± 0.006 inch)	42.774 ± 0.025 mm (1.6840 ± 0.0010 inch)	42.850 ± 0.013 mm (1.6870 ± 0.0005 inch)	35.71 ± 0.25 mm (1.406 ± 0.010 inch)	20.25 ± 0.50 degree	3.1 ± 0.5 mm (0.12 ± 0.02 inch)
4W-4325 Exhaust	13.01 ± 0.15 mm (0.512 ± 0.006 inch)	42.774 ± 0.025 mm (1.6840 ± 0.0010 inch)	42.850 ± 0.013 mm (1.6870 ± 0.0005 inch)	35.71 ± 0.25 mm (1.406 ± 0.010 inch)	30.25 ± 0.50 degree	2.970 ± 0.508 mm (0.1169 ± 0.0200 inch)
1W-5283 Exhaust	13.01 ± 0.15 mm (0.512 ± 0.006 inch)	42.774 ± 0.025 mm (1.6840 ± 0.0010 inch)	42.850 ± 0.013 mm (1.6870 ± 0.0005 inch)	36.5 ± 0.5 mm (1.44 ± 0.02 inch)	45 ± 1 degree	1.524 ± 0.508 mm (0.0600 ± 0.0200 inch)

(1)	Premachined Insert

Valve Seat Inserts for 3406E, 3456 Engines

The valve seat inserts should be replaced when the width of the valve seat cannot be machined to the correct specification. Use 166-7441 Valve Seat Extractor Tool to remove the valve seat inserts. Refer to Special Instruction, SMHS7935, "Use of 6V-4805 Valve Seat Extractor Tool Group" to remove the valve seat inserts.

Use 9U-6897 Valve Seat Driver to install the valve seat inserts for the inlet valves. Use 9U-6898 Valve Seat Driver to install the valve seat inserts for the exhaust valves. After the inserts are installed, grind the seat face of the insert to ensure the following:

• The face of the insert is flat.

• The insert has the correct angle.

• The insert is in alignment with the bore of the valve guide.

Note: If the valve seat insert is premachined, the insert does not need to be ground after installation into the cylinder head.

Refer to Table 82 for the correct dimensions.

When the valve seat is ground, refer to Table 82 for the minimum finished width of the valve seat (G). The maximum width of the valve seat is the intersection of the ground face with the bore of the insert in the cylinder head.

Illustration 236	g01402505

Oversized valve seat inserts are available for use in 3406E Engines and 3456 Engines. These inserts provide increased serviceability of the cylinder head. When these inserts are used, the bore in the cylinder head must be machined to the correct size to achieve the correct press fit of the valve seat insert. Refer to Table 81 for the dimensions to machine the cylinder head.

Shortened valve seat inserts are available for use in 3406E Engines and 3456 Engines. These inserts can be used to replace the 224-3983 Seat Insert and the oversized inserts for the 224-3983 Seat Insert.

Table 81

Oversized Valve Seat Inserts for 3406E, 3456 Engines
Oversize Dimension	Bore for Inlet Seat in Cylinder Head	Bore for Exhaust Seat in Cylinder Head
0.13 mm (0.0051 inch)	48.08 ± 0.025 mm (1.8929 ± 0.0010 inch)	N/A
0.26 mm (0.0102 inch)	48.21 ± 0.025 mm (1.8980 ± 0.0010 inch)	N/A
0.51 mm (0.0201 inch)	48.46 ± 0.025 mm (1.9079 ± 0.0010 inch)	43.284 ± 0.025 mm (1.7041 ± 0.0010 inch)
0.76 mm (0.0299 inch)	N/A	43.534 ± 0.025 mm (1.7139 ± 0.0010 inch)

Table 82

Specifications for the Valve Seat Insert for 3406E, 3456 Engines
Part Number	Depth of the bore in head for valve seat insert (C)	Bore diameter in head for valve seat insert (D)	Outside diameter of valve seat insert	Inside diameter of valve seat insert (E)	Angle of valve seat insert (F)	Minimum width of the valve seat insert (G)
108-5912 Inlet	14.00 ± 0.05 mm (0.551 ± 0.002 inch)	47.950 ± 0.025 mm (1.8878 ± 0.0010 inch)	48.025 ± 0.013 mm (1.8907 ± 0.0005 inch)	41.00 ± 0.13 mm (1.614 ± 0.005 inch)	30 ± 1 degree	2.334 mm (0.0919 inch)
152-8379 Inlet	14.00 ± 0.05 mm (0.551 ± 0.002 inch)	47.950 ± 0.025 mm (1.8878 ± 0.0010 inch)	48.025 ± 0.013 mm (1.8907 ± 0.0005 inch)	41.00 ± 0.13 mm (1.614 ± 0.005 inch)	30 ± 1 degree	2.334 mm (0.0919 inch)
175-3617 Inlet	14.00 ± 0.05 mm (0.551 ± 0.002 inch)	47.950 ± 0.025 mm (1.8878 ± 0.0010 inch)	48.025 ± 0.013 mm (1.8907 ± 0.0005 inch)	41.0 ± 0.5 mm (1.61 ± 0.02 inch)	30 ± 1 degree	2.334 mm (0.0919 inch)
224-3983 Inlet	14.00 ± 0.05 mm (0.551 ± 0.002 inch)	47.950 ± 0.025 mm (1.8878 ± 0.0010 inch)	48.025 ± 0.013 mm (1.8907 ± 0.0005 inch)	41.0 ± 0.5 mm (1.61 ± 0.02 inch)	30.25 ± 0.25 degree	2.377 mm (0.0936 inch)
314-3063 Inlet(1)	14.00 ± 0.05 mm (0.551 ± 0.002 inch)	47.950 ± 0.025 mm (1.8878 ± 0.0010 inch)	48.025 ± 0.013 mm (1.8907 ± 0.0005 inch)	41.0 ± 0.5 mm (1.61 ± 0.02 inch)	30.25 ± 0.25 degree	2.377 mm (0.0936 inch)
314-3065 Inlet(1)	14.00 ± 0.05 mm (0.551 ± 0.002 inch)	48.08 ± 0.025 mm (1.893 ± 0.001 inch)	48.155 ± 0.013 mm (1.8959 ± 0.0005 inch)	41.0 ± 0.5 mm (1.61 ± 0.02 inch)	30.25 ± 0.25 degree	2.377 mm (0.0936 inch)
314-3067 Inlet(1)	14.00 ± 0.05 mm (0.551 ± 0.002 inch)	48.21 ± 0.025 mm (1.898 ± 0.001 inch)	48.285 ± 0.013 mm (1.9010 ± 0.0005 inch)	41.0 ± 0.5 mm (1.61 ± 0.02 inch)	30.25 ± 0.25 degree	2.377 mm (0.0936 inch)
314-3069 Inlet(1)	14.00 ± 0.05 mm (0.551 ± 0.002 inch)	48.460 ± 0.025 mm (1.9079 ± 0.0010 inch)	48.535 ± 0.013 mm (1.9108 ± 0.0005 inch)	41.0 ± 0.5 mm (1.61 ± 0.02 inch)	30.25 ± 0.25 degree	2.377 mm (0.0936 inch)
1W-5283 Exhaust	13.90 ± 0.05 mm (0.547 ± 0.002 inch)	42.774 ± 0.025 mm (1.6840 ± 0.0010 inch)	42.850 ± 0.013 mm (1.6870 ± 0.0005 inch)	36.5 ± 0.5 mm (1.44 ± 0.02 inch)	45 ± 1 degree	1.524 ± 0.508 mm (0.0600 ± 0.0200 inch)
152-7582 Exhaust	13.90 ± 0.05 mm (0.547 ± 0.002 inch)	42.774 ± 0.025 mm (1.6840 ± 0.0010 inch)	42.840 ± 0.013 mm (1.6866 ± 0.0005 inch)	36.5 ± 0.5 mm (1.44 ± 0.02 inch)	45 ± 1 degree	1.507 mm (0.0593 inch)
226-5561 Exhaust	13.90 ± 0.05 mm (0.547 ± 0.002 inch)	42.774 ± 0.025 mm (1.6840 ± 0.0010 inch)	42.840 ± 0.013 mm (1.6866 ± 0.0005 inch)	36.5 ± 0.5 mm (1.44 ± 0.02 inch)	45.25 ± 0.25 degree	1.508 mm (0.0594 inch)

(1)	0.55 mm (0.0217 inch) shortened insert

Valve Seat Inserts for 3500 Engines

Show/hide table

NOTICE
The prefinished inserts should not be ground to correct the valve projection. Excessive valve projection indicates that the insert is not seated or the material was not cleaned from the bottom of the counterbore.

Table 83

Part Numbers for Valve Seat Inserts for 3500 Engines
Part Number of the Cylinder Head	Valve Seat Inserts for Intake			Exhaust Valve Seat Inserts
7E-5861 101-1175 131-0410 131-0423 145-3215 154-1612 161-2508 172-0834 290-1351 295-2047	130-2607	183-8809		130-2608	289-9745
462-4740 480-3132 487-3422 495-2062 525-6572	456-0780 480-7205			456-0411
7E-8760 131-0411 172-0836	130-2607			130-2608
4P-6571 7C-3471 122-5961 128-1141 144-6409 153-8397 184-5496 206-1554 206-1555 206-1560 206-1563 424-7545	257-9166	266-8718(1)	266-8721(2)	191-6760
269-0040 315-2630 418-9804	308-7100

(1)	Low Swirl.
(2)	2.0 Swirl.

Table 84

Oversize Valve Seat Inserts for 3500 Engines
Standard	0.254 mm (0.0100 inch) Oversize Valve Seats	0.508 mm (0.0200 inch) Oversize Valve Seats
130-2607	N/A	149-1981
130-2608	N/A	166-5945
183-8809	N/A	N/A
191-6760	206-1546	206-1547
257-9166	257-9168	257-9169
266-8718	266-8719	266-8720
266-8721	266-8722	266-8723
289-9745 494-9516	521-4489	521-4490
308-7100	322-3659	322-3660

Illustration 237	g06189664
Detail views of the width of the sealing face of 3500 valve seat inserts. (M) Width of the sealing face for 308-7100 Valve Seat Insert (N) Width of the sealing face for 130-2607 Valve Seat Insert and 183-8809 Valve Seat Insert (P) Width of the sealing face for 266-8718 Valve Seat Insert and 266-8721 Valve Seat Insert (R) Width of the sealing face for 130-2608 Valve Seat Insert and 289-9745 Valve Seat Insert (S) Width of the sealing face for 191-6760 Valve Seat Insert and 257-9166 Valve Seat

Use the following chart to determine the maximum width of the sealing face of the valve seat insert. The maximum width of the sealing face of the valve seat insert is given in the following chart with the corresponding valve. The maximum width is found from the corresponding valve's outer diameter of the sealing face and the valve seats insert's inner diameter of the sealing face. The angle of the valve must be greater than the angle of the valve seat insert to ensure proper sealing.

Table 85

Maximum Width of the Valve Seat Insert's Sealing Face for 3500 Engines
Valve	Valve Seat Insert	Max Width
210-2542 468-8824	130-2607	3.4904 mm (0.1374 inch)
	183-8809
	257-9166	1.8970 mm (0.0747 inch)
	266-8718	2.9804 mm (0.1173 inch)
	266-8721
194-4897 498-1593	130-2608	2.6640 mm (0.1049 inch)
	289-9745
104-7184	191-6760	2.4066 mm (0.0947 inch)
307-4641 308-9177 498-1692 500-8527 500-8528	308-7100	3.5000 mm (0.1378 inch)

Illustration 238	g06189668
Refer to Table 86 for dimensions of the valve seat inserts and identification.

Table 86

Specifications of the Valve Seat Insert for 3500 Engines
Inlet Valve Seat Inserts
Valve Seat Insert Part Number	Valve Seat Insert Outside Diameter (T)	Sealing Angle For the Valve Seat Insert (U)
130-2607 456-0780 480-7205	60.627 ± 0.015 mm (2.3869 ± 0.0006 inch)	70° ± 0.25°
183-8809	60.627 ± 0.015 mm (2.3869 ± 0.0006 inch)	69.75° ± 0.25°
257-9166	60.640 ± .015 mm (2.3874 ± 0.0006 inch)	69.75° ± 0.25°
266-8718(1)	60.640 ± .015 mm (2.3874 ± 0.0006 inch)	69.75° ± 0.25°
266-8721(2)	60.640 ± .015 mm (2.3874 ± 0.0006 inch)	69.75° ± 0.25°
Exhaust Valve Seat Inserts
130-2608 289-9745	60.119 ± 0.015 mm (2.3669 ± 0.0006 inch)	45° ± 0.25°
191-6760	60.132 ± 0.015 mm (2.3674 ± 0.0006 inch)	69.75° ± 0.25°

(1)	Low Swirl.
(2)	2.0 Swirl.

Illustration 239	g06189678
Inner diameter and depth of the bore for the valve seat inserts for the cylinder head. (V) Depth of the bore for valve seat inserts. (W) Diameter of the bore for the valve seat insert

Table 87

Dimensions for the Bore inch the Cylinder Head for the Valve Seat Insert for 3500 Engines
Part Number	Intake or Exhaust	Depth of the bore for the valve seat (V)	Inside diameter of the bore for the valve seat insert (W)	Bore for 0.254 mm (0.0100 inch) oversize valve seats (W)	Bore for 0.508 mm (0.0200 inch) oversize valve seats (W)
7E-5861 7E-8760 131-0410 131-0411 172-0834 172-0836 295-2047	Intake	14.00 ± 0.15 mm (0.551 ± 0.006 inch)	60.508 ± 0.025 mm (2.3822 ± 0.0010 inch)	60.762 ± .025 mm (2.3922 ± 0.0010 inch)	61.016 ± .025 mm (2.4022 ± 0.0010 inch)
	Exhaust	14.00 ± 0.15 mm (0.551 ± 0.006 inch)	60.000 ± 0.025 mm (2.3622 ± 0.0010 inch)	60.254 ± .025 mm (2.3722 ± 0.0010 inch)	60.508 ± 0.025 mm (2.3822 ± 0.0010 inch)
4P-6571 7C-3471 101-1175 122-5961 128-1141 131-0423 144-6409 145-3215 153-8397 154-1612 161-2508 184-5496 206-1554 206-1555 206-1560 206-1563 290-1351 418-9802 424-7545 480-3132 495-2062 525-6572	Intake	16.00 ± 0.15 mm (0.630 ± 0.006 inch)	60.508 ± .025 mm (2.3822 ± 0.0010 inch)	60.762 ± .025 mm (2.3922 ± 0.0010 inch)	61.016 ± .025 mm (2.4022 ± 0.0010 inch)
	Exhaust	16.00 ± 0.15 mm (0.630 ± 0.006 inch)	60.000 ± 0.025 mm (2.3622 ± 0.0010 inch)	60.254 ± .025 mm (2.3722 ± 0.0010 inch)	60.508 ± 0.025 mm (2.3822 ± 0.0010 inch)

Specifications of the Valve Seat Insert for 256-4407 Cylinder Head

Illustration 240	g01436450
Cross Section view of the bore for the valve seat insert for 256-4407 Cylinder Head. (W) Upper bore of the head for the valve seat insert. (X) Lower bore of the head for the valve seat insert.

Table 88

Dimensions for the Bore of the Cylinder Head Valve Seat for 256-4407
Size	Bore at location (W)	Bore at location (X)
Standard	60.000 ± 0.025 mm (2.3622 ± 0.0010 inch)	55.000 ± 0.025 mm (2.1654 ± 0.0010 inch)
0.254 mm (0.0100 inch) oversize valve seat inserts	60.254 ± 0.025 mm (2.3722 ± 0.0010 inch)	55.254 ± 0.025 mm (2.1753 ± 0.0010 inch)
0.508 mm (0.0200 inch) oversize valve seat inserts	60.508 ± 0.025 mm (2.3822 ± 0.0010 inch)	55.508 ± 0.025 mm (2.1853 ± 0.0010 inch)

Illustration 241	g06189709

Illustration 242	g06189712
Water-cooled valve seat insert for 269-0040 Cylinder Head and the 315-2630 Cylinder Head (Y) Upper Diameter (Z) Lower Diameter

Table 89

Dimensions for the Inlet and Exhaust Valve Seat Insert for Cylinder Head 256-4407
Valve Seat Insert	Upper Diameter (Y)	Lower Diameter (Z)	Sealing Angle (U)
203-0843 308-7100 Standard	60.115 ± 0.015 mm (2.3667 ± 0.0006 inch)	55.108 ± 0.015 mm (2.1696 ± 0.0006 inch)	20.25° ± 0.25°
322-3659 0.254 mm (0.0100 inch) oversize	60.369 ± 0.015 mm (2.3767 ± 0.0006 inch)	55.362 ± 0.015 mm (2.1796 ± 0.0006 inch)
322-3660 0.254 mm (0.0100 inch) oversize	60.623 ± 0.015 mm (2.3867 ± 0.0006 inch)	55.616 ± 0.015 mm (2.1896 ± 0.0006 inch)

Contact Area for the Valve and Valve Seat

In the past, cylinder heads could be rebuilt so that the insert for the valve seat contacts the sealing face of the valve head at the middle of the sealing face of the valve. Then, the 3500 engine was introduced. Currently, the traditional sealing area for the valve moved to a location that was close to the edge of the valve. More recently, premachined inserts for the seat and precision valve guides have moved the sealing area. This distance is now at 0.51 mm (0.020 inch) to 1.02 mm (0.040 inch) from the outside diameter of the valve head. New, premachined valve seat inserts may be installed during the rebuild of a cylinder head. Do not machine the sealing faces of the inserts or grind the sealing faces of the inserts. Modern manufacturing processes make machining after installation unnecessary.

Installation

1. Freeze the insert to −60 °C (−76 °F).

2. Install the insert with a hammer and a drive plate. Make sure that the insert is fully seated in the counterbore.

3. After installation, use a 0.038 mm (0.0015 inch) feeler gauge to ensure that the insert is in contact with the bottom of the counterbore for the cylinder head. If the gauge goes into a gap under the insert, reseat the insert.

Premachined Valve Seat Inserts

Premachined valve seat inserts are used on all gas and diesel 3500 engines except for the G3500A landfill applications. Do not machine premachined valve seat inserts. These parts will improve the concentricity of the valve and valve seat in the cylinder head. This will also improve the quality of cylinder heads that are rebuilt in the field.

Illustration 243	g06189713
Typical cylinder head assembly

(15) Valve seat insert for the exhaust valve

(16) Valve seat insert for the intake valve

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NOTICE
The valve seat inserts are similar in size. Make sure that the correct insert is placed in the appropriate counterbore. Damage can be caused to the head and damage could be caused to the insert.

Specifications for the Machinable Valve Seats for the 3500 Gas Engine

Illustration 244	g06189716
Valve seats for the 3500 Gas engine

See Illustration 253 and Illustration 254 for details about Area (AA).

Installation and Removal of the Water-Cooled Valve Seat Inserts for G3500 Engines

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Illustration 245	g02149060

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Illustration 246	g02149112

1. Insert the insert removal tool into the bore of the valve seat.
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   Illustration 247	g02149197

2. Slide the plate to lock the insert removal tool in place.

3. Activate the hydraulic pump to remove the valve seat.
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   Illustration 248	g02149745

4. Lift the insert removal tool off the cylinder head.
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   Illustration 249	g02149771

5. Slide the plate to unlock the insert removal tool.
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   Illustration 250	g02149872

6. Slide the insert and the collets back.
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   Illustration 251	g02150002

7. Remove the insert.

Cleaning the Internal Passages

Clean the cylinder head thoroughly after disassembly. The fastest method to clean a cylinder head is to soak it in a hot caustic acid solution. The hot caustic acid should be in a tank with a platform that oscillates. The cylinder heads can also be soaked in a carbon remover. A cabinet washer is also acceptable for removing carbon.

After the cylinder head has been cleaned, use a flashlight to inspect the bores in the cylinder head. Inspect the bores of the valve guides and valve seat inserts for signs of cavitation, scratches, or any other type of damage.

If the bores in the cylinder head show signs of cavitation, replace the cylinder head.

If the bores in the cylinder head have scratches that travel from the coolant passage through the press fit areas, replace the cylinder head.

If the scratches travel around the circumference of the press fit areas, use 5P-1720 Seal Pick to inspect the scratches. If the scratches can be felt, replace the cylinder head.

Replace the cylinder head if there is any damage that will reduce the amount of press fit between the valve seat insert and the cylinder head.

Measure the bores in the cylinder head for the valve seats. If the bores need to be machined oversize, refer to Table 90.

Illustration 252	g02157274
(A) Smaller Outside Diameter (B) Larger Outside Diameter

Table 90

Diameters for Valve Seats and Bores for G3500 Engines
Size	Seat	Outside Diameter (A)	Outside Diameter (B)	Bore in Cylinder Head for Valve Seat Insert (A)	Bore in Cylinder Head for Valve Seat Insert (B)
Standard	308-7100	55.108 ± 0.015 mm (2.1696 ± 0.0006 in)	60.115 ± 0.015 mm (2.3667 ± 0.0006 in)	55.000 ± 0.025 mm (2.1654 ± 0.0010 in)	60.000 ± 0.025 mm (2.3622 ± 0.0010 in)
Oversize 1 0.25 mm (0.010 in) Oversized	322-3659	55.362 ± 0.015 mm (2.1796 ± 0.0006 in)	60.369 ± 0.015 mm (2.3767 ± 0.0006 in)	55.254 ± 0.025 mm (2.1754 ± 0.0010 in)	60.254 ± 0.025 mm (2.3722 ± 0.0010 in)
Oversize 2 0.51 mm (0.020 in) Oversized	322-3660	55.616 ± 0.015 mm (2.1896 ± 0.0006 in)	60.623 ± 0.015 mm (2.3867 ± 0.0006 in)	55.508 ± 0.025 mm (2.1854 ± 0.0010 in)	60.508 ± 0.025 mm (2.3822 ± 0.0010 in)

Specifications for the Valve Seats for the Standard Gas Engine

Illustration 253	g06189717
Detail (AA) from Illustration 244 of double angle valve seats for intake valves and exhaust valves.

Table 91

Specifications for the valve seats for G3500A Cylinder Heads for Landfill Applications Two Angles
Item	Intake Valve and Exhaust Valve
(AB)	20.25 ± 0.25 degrees
(AC)	10.0 ± 0.5 degrees
(AD)	52.0 mm (2.05 inch) gauge diameter
(AE)	55.8 mm (2.20 inch) gauge diameter
(AF)	0.6 ± 0.05 mm (0.02 ± 0.002 inch)
(AG)	5.3 ± 0.10 mm (0.21 ± 0.004 inch)
(17)	Gauge Plane

Runout of the 20.25° angle is 0.065 mm (0.0026 inch) maximum relative to the centerline of the valve guide bore in the cylinder head.

Specifications for the Valve Seat for the G3500A Landfill Gas Engine

Illustration 254	g01910533

Table 92

Specifications for the Valve Seats on the Cylinder Head for the G3500A Landfill Applications Three Angles
Item	Intake and Exhaust
(AB)	60.00 ± 0.50 degrees
(AC)	20.25 ± 0.50 degrees
(AD)	52.0 mm (2.05 inch) gauge diameter
(AE)	55.8 mm (2.20 inch) gauge diameter
(AF)	0.61 ± 0.05 mm (0.024 ± 0.002 inch)
(AG)	5.3 ± 0.10 mm (0.21 ± 0.004 inch)
(AH)	49.00 ± 0.15 mm (1.929 ± 0.006 inch) diameter
(AJ)	54.0 mm (2.13 inch)
(AK)	15.00 ± 0.50 degrees
(17)	Gauge Plane

Installation of the Valve Seat Inserts

Note: Make sure that there is no residue from prior retaining compound before installing the valve seat inserts.

1. Clean the valve seat inserts and the cylinder head. The components must meet the ISO 16/13 specifications for cleanliness. The components must be assembled in a clean environment.

2. Reduce the temperature of the valve seat inserts to −20 °C (−4.0 °F).

   Note: The valve seat inserts must be placed in the freezer for approximately 8 hours.

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   Illustration 255	g02196094
   (3) Lower press fit (4) Upper press fit (5) Circumferential coolant passage

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   Illustration 256	g02196834
   Cross section view of the bore for the valve seat insert. (3) Lower press fit (4) Upper press fit (5) Circumferential coolant passage

3. Apply a thin layer of 4C-9507 Retaining Compound to area (3) and area (4) of the bores in the cylinder head.
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   Illustration 257	g02196964
   Cross section view of the cylinder head (6) Bottom of first counterbore (C) Gap between valve seat insert and bottom of the bore

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   Illustration 258	g02150960

4. Remove one of the valve seat inserts from the freezer. Locate the valve seat insert on the installation tool.

   Note: The valve seat must be installed within 30 seconds of removal from the freezer. This will prevent the seat from warming prior to installation.

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   Illustration 259	g02151016

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   Illustration 260	g06278509

5. Place the insert and tool into the bore in the head.

   Note: Visually inspect the valve seat insert to verify that the valve seat insert is seated properly into the bore.

6. Use a hydraulic press and the insert installation tool to install the valve seat insert into the cylinder head.

   Note: Do not use a hammer to install the valve seat insert. The impact from a hammer will damage the valve seat insert.

   Note: A typical force of 35586 N (8000 lb) to 44482 N (10000 lb) is required to press in the inserts. The pressure gauge will increase rapidly when the valve seat insert is seated.

   Note: The bottom of the valve seat insert does not contact the bottom of the bore. The bottom of the upper press fit will contact the bottom of the first counterbore in the cylinder head. There will be a gap of approximately 0.50 mm (0.020 inch) between the bottom of the valve seat insert and the bottom of the bore. Refer to Illustration 257.

   Note: The freezer and the press should be close to each other to keep the valve seat inserts from increasing in temperature. Only remove one valve seat insert from the freezer at a time.

If a pressure gauge is being used, force will need to be converted into pressure.

Calculate the piston area with the use of the following equation:

Table 93

Calculation of the Piston Area for the Cylinder
Piston Area = 3.1416 × Cylinder Diameter2 ÷ 4
Calculating the Piston Area for the Cylinder
Hydraulic Cylinder Diameter = 34.80 mm (1.370 inch)
Example	3.1416 × 34.80 mm2 ÷ 4 = 951.15 mm2
Example	3.1416 × (1.370 inch)2 ÷ 4 = (1.474 inch)2

Calculate the pressure. Use the calculation for the area of the piston and applied force with the following equation:

Table 94

Calculation of Pressure

Pressure = Applied Force ÷ Cylinder's Piston Area

Example of a Calculation for Pressure

Load = 10000 N (2250.0 lb)

Piston Area = 951.15 mm2 (1.474 inch2)

10,000 ÷ 951.06 = 10,515 kPa

(2250) ÷ (1.474) = (1527 psi)

Valve Seat Inserts for 3600, G3600, C280 Engines

The surface of the prechamber seat needs to be resurfaced during a rebuild. Use 187-6273 Repair Tool. Follow the instructions in Tool Operating Manual, NEHS0790. The maximum amount that can be removed is 0.05 mm (0.002 inch).

If the valve seat inserts are not reusable, the seats need to be removed and replaced with new seats. To replace the seat with an insert that is a standard size, the dimension of the bore for a standard insert must meet the specification of 97.000 ± 0.025 mm (3.8189 ± 0.0001 inch) throughout the entire depth of the bore. Heavy fuel cylinder heads have a bore diameter for the insert of 108.5 ± 0.025 mm (4.27 ± 0.0010 inch). If the bore of the seat is within specifications, then a new insert can be pressed in using the procedure that involves freezing the insert. The insert should be ground to the final specification for the valve seat angle. The valve and the face of the insert should be checked.

Removal

To remove the valve seat insert on some earlier cylinder heads, a relief must be ground at the bottom of the insert. The relief should be ground in the area where the insert contacts the head casting. This relief will allow the 9U-5099 Seat Puller to engage the bottom edge of the insert.

It is not recommended to remove or replace the water-cooled prechamber insert for the G3600. If the insert appears to be damaged in any way, a remanufactured head must be used.

Illustration 261	g01944673
Grinding the relief in the head casting for the 9U-5099 Seat Puller Group (17) 6V-4198 Grinder group (18) 6V-4802 Grinding wheel

Illustration 262	g01944700
(C) 4.0 mm (0.16 inch) (D) 83.0 mm (3.27 inch)

Remove the valve seat insert from the head casting.

Note: Heat may be required to remove the water-cooled exhaust valve seat insert. Applying a weld bead to the inside diameter of the insert will also assist with removal.

Illustration 263	g01944749
(11) Puller assembly (19) Seat puller group

Valve Seat Insert Grinding

Note: For G3600 valve seat inserts that are not prefinished, the seat face angle should be 20.5° ± 0.15°. Prefinished valve seat inserts do not require grinding.. Protrusion of the valve must be within the specification if the valve seats are ground.

Illustration 264	g06175864
Valve seat insert dimensions. Refer to Table 95 for the reuse specifications.

Table 95

Valve Seat Insert specifications for 3600, G3600, C280 Engines
Dimensions	7C-2423 (Intake) 7W-9779 (Exhaust)
Valve Seat Bore Depth (L)	24.00 ± 0.15 mm (0.945 ± 0.006 inch)
Valve Seat Insert Diameter (M)	97.195 ± 0.015 mm (3.8266 ± 0.0006 inch)
Valve Seat Insert Bore Diameter (M)	97.000 ± 0.025 mm (3.8189 ± 0.0010 inch)
Valve Seat Insert Angle (N)	30.25 ± 0.50 degrees
Maximum Valve Recess (P)	0.50 mm (0.020 inch) above to 2.00 mm (0.079 inch) below
Maximum Valve Seat Runout	0.15 mm (0.006 inch)
Maximum Vacuum	63.5 cm (25.0 inch) Hg
Maximum Allowable Vacuum Loss in 10 seconds	12.7 cm (5.0 inch) Hg

Illustration 265	g06175869
Valve Seat Specification Guide. Refer to Table 96 for the reuse specifications.

Table 96

Valve Seat Insert Specifications (Heavy Fuel) for 3600, G3600, C280 Engines
Dimensions	4P-3078 Exhaust
Valve Seat Insert Diameter (R)	108.700 ± 0.015 mm (4.2795 ± 0.0006 inch)
Valve Seat Insert Diameter (S)	93.650 ± 0.015 mm (3.6870 ± 0.0006 inch)
Valve Seat Insert Bore Diameter (R)	108.500 ± 0.025 mm (4.2717 ± 0.0010 inch)
Valve Seat Insert Bore Diameter (S)	93.500 ± 0.025 mm (3.6811 ± 0.0010 inch)
Valve Seat Insert Bore Depth (T)	40.00 ± 0.25 mm (1.575 ± 0.010 inch)
Valve Seat Insert Bore Depth (U)	20.00 ± 0.15 mm (0.787 ± 0.006 inch)
Valve Seat Insert Angle (V)	30.25 ± 0.25 degrees
Maximum Valve Recess (W)	7.00 mm (0.276 inch)
Maximum Valve Seat Runout	N/A
Minimum Vacuum	N/A
Maximum Allowable Vacuum Loss in 10 seconds	N/A

Grinding Equipment

The valve seat grinder in this guideline has an eccentric motion with a feed control for the micrometer. Eccentric grinding is the simultaneous application of two rotary motions to a grinding wheel. Eccentric grinding results in point contact grinding. Material will be removed from the high spots and hard spots of the valve seat first. No side pressure or spring action will be exerted on the pilot. Side pressure and spring action can cause inaccuracies in the valve seat.

Grinding Wheels

It is important to dress the grinding wheel during grinding operation. Material from the valve seat insert becomes embedded in the wheel, resulting in excessive grinding times and incorrect ground seats.

Illustration 266	g01945859
Minimum dressing limits for reusing the wheel (E) Minimum Thickness

A small amount of the wheel will be removed each time the wheel is dressed. Replace the wheel when the thickness reaches 8.0 mm (0.31 inch). Vibration of the wheel can occur if a wheel becomes too thin. This results in an unacceptable seat face and this also prevents the full 360 degrees of contact to the face. This also prevents the vacuum seal that is recommended.

Illustration 267	g01945791
(22) Valve seat grinder (23) Grinding wheel (24) Diamond dresser

Before doing any finish grinding, it is necessary to match the valve seat grinder to the specified valve seat angle. This can be completed by using the 147-2285 Valve Gauge.

Grinding Procedure

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Illustration 268	g01946226
(25) Pilot (26) Pilot Wrench

1. Select the correct diameter of pilot. Install the pilot wrench onto the correct pilot. Insert the pilot into the valve guide bore.

   Note: The pilot should have a snug fit in the bore of the valve guide. This will eliminate movement of the pilot during the grinding operation. Movement of the pilot can cause damage to the cylinder head, the pilot, and the grinder.

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   Illustration 269	g01946340

2. Remove the pilot wrench.
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   Illustration 270	g01946376
   Dial gauge (27) installed on pilot

3. If the valve seat requires grinding, proceed with the following steps:

   1. Mark the area or areas requiring the most stock removal.

   2. Mark the seat face every 30 degrees with a black felt pen. This will provide a visual inspection of the progress for seat face grinding.

   3. When the black markings have disappeared, the surface of the valve seat face has been ground 360 degrees.

   4. Remove dial indicator from the pilot.
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   Illustration 271	g01946596
   Positioning the grinder on the pilot

4. Carefully install the seat grinder onto the shaft of the pilot.

   Note: Do not drop the grinder on the valve seat. Damage to the wheel of the grinder and the head may occur.

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   Illustration 272	g01946790

5. While the seat grinder is resting on the surface of the valve seat, loosen the setscrew. This will allow the center positioning rod to touch the top of the pilot shaft. Tighten the setscrew to provide a positive stop for the micrometer adjustment.
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   Illustration 273	g01946809
   Adjust height of the wheel with the micrometer adjustment. (29) Micrometer adjustment

6. Use the micrometer adjustment to back the wheel away from the valve seat face. Rotate the wheel by hand 360 degrees. Adjust the wheel upward until the wheel no longer touches the seat face at any point.
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   Illustration 274	g01947013
   Install the magnetic base and the post to support the grinder. (30) Post (31) Magnetic base

7. Install the 8S-2329 Magnetic Base and the 8S-2327 Post. This allows the operator to leave the grinder and to perform other operations. Place a piece of rubber tubing on the upright shaft. This will eliminate vibration during the grinding operation. Lift the seat grinder up approximately 12.0 mm (0.47 inch) and turn on the grinder. Lower the grinder until the positioning rod engages the top of the pilot shaft. At this point, the grinding wheel should not be touching the seat face.
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   Illustration 275	g01947062

8. Adjust the micrometer by one click at a time until the wheel barely touches the seat face. This can be felt by placing a finger against the handle on the side of the grinder. You can feel when the wheel has finished grinding. Allow the grinder to spark out for 2 to 3 minutes. Then raise the grinder to check the seat face for 360 degrees of contact. Observe the black marks on the seat face. Repeat the adjustment. Spark out the grinder until the marks have been removed from the entire surface. Remove the grinder carefully when the job is finished.
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   Illustration 276	g01947102

9. Install the dial gauge. Sweep the face of the seat 360 degrees to check the Total Indicator Runout (TIR). TIR should be 0.10 mm (0.004 inch). Repeat the grinding and checking procedures until the TIR is within the specification. Always allow the wheel to spark out before a measurement is taken.
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   Illustration 277	g01947113

10. After the recommended TIR is reached, install the pilot wrench onto the pilot. Use a slight twisting motion to unseat the pilot. Remove the pilot from the bore.
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    Illustration 278	g01947177

11. Apply a light coat of Prussian Blue on the 147-1642 Gauge seat face. Install the gauge into the valve guide bore until the gauge is approximately 25.4 mm (1.00 inch) from the valve seat face. Allow the gauge to drop onto the valve seat face. Use one finger to slightly push down on the head of the gauge and rotate the gauge 15 to 30 degrees. Remove the gauge and check the contact pattern on the valve seat face. If the seat is machined correctly, the line contact will be at the top edge of the insert with contact for the full 360 degrees. If the line contact is not at the top edge, it is necessary to adjust the angle by adjusting the dresser, redressing the wheel, and regrinding the seat.

12. Apply a light coat of Prussian Blue on the 147-1642 Gauge seat face. Install the gauge into the valve guide bore until the gauge is approximately 25.4 mm (1.00 inch) from the valve seat face. Allow the gauge to drop onto the valve seat face. Use one finger to slightly push down on the head of the gauge and rotate the gauge 15 to 30 degrees. Remove the gauge and check the contact pattern on the valve seat face. If the seat is machined correctly, the line contact will be at the bottom edge of the seat insert.
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    Illustration 279	g01947221

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    Illustration 280	g01947228
    (F) Projection of the valve

13. Install the valve in the original position. Measure the projection of the valve in relation to the surface of the cylinder head. A depth micrometer or a straight edge with a thickness gauge can be used to measure the projection of the valve. The maximum valve recess is 2.00 mm (0.079 inch). The maximum projection of the valve is 0.50 mm (0.020 inch).

14. Check the projection of the valve to make sure that the valve is within the specification. It may be necessary to grind the valve again to obtain this dimension. If the valve cannot be ground anymore, the valve will have to be replaced.

Installation

Inspect the counterbores of valve seat inserts before installing the inserts. The counterbores should be clean. The counterbores should be free of raised burrs that are caused by the insert removal tool. The bottom of the counterbore must be flat in order for the insert to make 360 degrees of contact.

Illustration 281	g06278515
(A) Heavy fuel insert (B) Standard Insert

Caterpillar currently has two types of inserts. The water-cooled insert is used in exhaust ports in heavy fuel applications. The water-cooled inserts require a special counterbore in the cylinder head. The standard insert is used in inlet ports for all applications and in exhaust ports of distillate fuel applications.

Installing Water-Cooled Inserts

Note: This method is also applicable to a standard insert.

1. Make sure that the valve seat insert is at room temperature prior to installation. Do not freeze water-cooled inserts.

2. Before installing the water-cooled insert, apply 6V-1541 Quick Cure Primer to the outside diameter of the insert. Then apply 9S-3265 Retaining Compound over the primer.

3. Install the insert using the water-cooled insert seat driver and the hydraulic press. Press the insert to the bottom of the counterbore in the cylinder head casting.

Illustration 282	g01944818
Installing a water-cooled insert (20) Insert driver

Installing Standard Inserts

Note: The standard valve seat insert can be installed by using either method.

1. Lower the temperature of the standard insert to −60° C (−76.0° F).

2. Put clean engine oil on the outside diameter and the radius at the bottom of the insert.

3. Install the standard insert using 8T-2674 Standard Insert Driver and a hammer. Install the insert to the bottom of the counterbore in the cylinder head casting.

Note: Excessive pounding may cause the insert to bounce off the bottom of the counterbore. Use a 0.038 mm (0.0015 inch) feeler gauge to make sure that the insert is in contact with the bottom of the counterbore.

Illustration 283	g01945093
Installing a standard insert (21) Standard insert seat driver

Reconditioning Factors

Determining the projection of the valve and the recession of the valve through a measurement is no guarantee that the valves and valve seats have been correctly reconditioned. The following criteria will help to determine the reusability of both valves and valve seats.

1. The wide valve seats do not cause problems with valves. The outer diameter of the finished seat insert can be larger than the diameter of the valve head. This should not cause any problems.

2. While the width of the seat will vary with the engine model, the width of the finished insert must be at least 1.0 mm (0.04 inch) for good valve life. There is no need for an upper limit on the width of the seat.

3. Grind the finished surface of the valve seat after the valve seat inserts have been installed into the head. Grinding the seat insert correctly is essential to valve life. This process is not necessary on recent 3500 Heads with premachined inserts.

4. Contacting the valve seat insert to the sealing face of the valve head at the middle of the sealing face of the valve was an acceptable practice for rebuilding cylinder heads. With the introduction of the 3500 Engine, the traditional sealing area moved closer to the edge of the valve head. Premachined seat inserts and precision valve guides moved the sealing area to 0.51 to 1.02 mm (0.020 to 0.040 inch) from the outer dimension of the valve head. Do not grind the sealing faces of the inserts if new premachined valve seat inserts are installed during the rebuild of a head. The components do not need to be machined after installation due to the precise manufacturing process.

5. If the seat face cannot be ground without grinding into the head, replace the insert. Do not grind the head under any circumstance.

6. Never use a valve with less than the specified minimum thickness of lip.

7. Heads that have been resurfaced may require the bores of the inserts to be machined to a deeper dimension. This will ensure the correct location of the insert in relation to the head.

8. Valve seat inserts should not extend above the surface of the head. Recessing the inserts 0.25 mm (0.010 inch) below the surface is a good habit.

9. Lapping valves and lapping seat inserts is not recommended or necessary if the correct angles of the valve seat are maintained during the process of resurfacing the valves and valve seats.

Reconditioning Factors for D330, D330C, D333B, D333, D333B, D333C, D334, D336, 1673, 1674, and 1676

114.30 mm (4.5 inch), 120.65 mm (4.75 inch), 137.16 mm (5.4 inch) Bore Engines

On all overhead cam engines, backlash for the cam drive gear is the critical factor for cylinder head reconditioning. The backlash must be larger than 0.038 mm (0.00150 inch).

Reconditioning Factors for D330C, D333C, D334, 1673, and 1674

146.05 mm (5.75 inch), 158.75 mm (6.25 inch) Bore Engines

Correct valve projection dimensions will help prevent piston contact.

Note: If the centerline of the crankshaft bore has been raised from its original location, it affects cylinder height dimensions. This is similar to removing material from the head surface. There must still be a minimum of 0.030 mm (0.00118 inch) of backlash in the cam drive gear after the head is assembled. If the top of the cylinder block has been machined and the crankshaft centerline also is raised, it will be almost impossible to maintain the correct minimum backlash.

Reconditioning Factors for C15 through C32

After machining the head, the Exhaust valve seats must be machined in place to achieve the proper projection of the valve. Use a standard replacement valve seat only if the bore for the Exhaust valve is undamaged. If the bore for the Exhaust valve is damaged, the bore must be rebored and an oversized valve seat must be used.

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NOTICE
Some valve seats cannot be machined. Specialized manufacturing processes were used on these parts. Machining these parts will significantly decrease the life of the engine.

Some inlet seats cannot be machined under any circumstance. Caterpillar uses specialized manufacturing techniques on inlet valve seats of some engine models. If the thickness of the head has been machined beyond factory specifications, do not machine these inlet seats. These inlet seats must be replaced with seats that can be machined.

Illustration 284	g06176262
Finding the pin location by using a probe

To keep the valve guide and the valve seat concentric, use a dial indicator and a tapered pilot pin to find the center line of the valve guide.

Oversized seats are available if the head has been damaged. If an oversized insert has already been installed, second oversized inserts are available for certain models. If an oversized seat will be used, use either a probe or a dial indicator to keep the valve guide and the valve seat concentric.

1. If an oversize valve seat will be used, locate the center of the valve guide with a gauge pin.

2. Find the center of the tapered pilot pin as close as possible to the valve guide.

3. Use a dial indicator to find the center of the tapered pilot pin.

4. Machine the bore for the valve seat in the location that is concentric with the valve guide.

The tapered pins are supplied with the grinder for the valve seat. If the tapered pilot pins need to be purchased, contact the supplier for your valve seat grinder.

Reconditioning Factors for 1100, 3100, and 3200 Engines

On 1100, 3100, 3200 direct injection engines, head thickness is measured from the combustion surface to the top of the nozzle seat through the nozzle bore. On (precombustion chamber) 3204 Engines, the head thickness is measured from the top of the valve spring seat to the combustion surface.

Reconditioning Factors for G3600 Engines

There are specific factors for reconditioning the G3600 cylinder head. The surface on which the gasket for the prechamber seats must be thoroughly inspected. This area is prone to leaks without proper reconditioning.

Water-Cooled Prechamber Insert for G3600

• The insert is located at the center of the cylinder head to help cool the prechamber assembly. This insert should not be removed or repaired. A remanufactured cylinder head is required if the insert is damaged in any way.

• The angle of the face on intake and exhaust valve seats is 20°.

• The exhaust valves are not water cooled.

• A new design of the cylinder head contains prefinished intake and exhaust valve seat inserts. The premachined inserts do not require a final grinding operation if the inserts are used with the correct cylinder head.

Valve Recession and Projection

After the cylinder head has been reconditioned, the cylinder head must be measured for the recession of the valves or the projection of the valve. The recession and projection of the valve is measured from the combustion area of the cylinder head to the valve head when the valve is closed. Increased valve recession or decreased valve projection can be caused by wear of the valve face or wear of the sealing surface on the insert.

Note: The minimum dimension means that the valve is recessed into the cylinder head. The maximum dimension means that the valve is projecting from the cylinder head.

Illustration 285	g01953705
(B) Valve Recession

A positive value for the recession of a valve represents a recessed valve as it relates to the cylinder head surface. The valve head is below the surface.

Illustration 286	g01954044
(C) Projection of the Valve

Tools

Illustration 287	g06229850
The recession of the valve is being measured with a depth micrometer.

Illustration 288	g01954142
6V-7926 Indicator Group (29) 3P-1565 Collet Clamp (30) 8S-3158 Indicator (31) 5P-4156 Indicator Base

The valve recession can be measured by using any of the following tools.

1. 6V-7926 Indicator Group

   1. 8S-3158 Indicator

   2. 3P-1565 Collet Clamp

   3. 5P-4165 Indicator Base

2. 6V-2012 Micrometer Depth Gauge Group

3. 8H-8581 Feeler Gauge and a 386-3364 Straight Edge.

Measurement Procedure

Take these measurements after the valves are installed in the head.

1. Before starting this procedure, set the gauge to zero.

   1. Place the indicator on a flat surface.

   2. Move the dial face, and align the hand of the gauge to the zero mark.

   3. Tighten the lock on the dial face.

2. Take the measurements and record the measurements on all valves.

   1. For a recessed valve, set the gauge on surface of the head and over the center of the valve. Record the measurement.

   2. For a projected valve, set the gauge on top of the valve. The tip of the indicator should be on the surface of the head. Record the measurement.

3. If the measurements do not meet the required specifications, refer to the section "Correcting the Excessive Projection of the Valves".

The excessive projection of valves can cause the head of the valve to contact the piston during normal engine operation.

Correcting the Excessive Projection of the Valves

There are two ways to correct a valve that exceeds the maximum dimension of projection.

1. Material can be ground from the sealing angle of the seat insert and the valve face.

2. The seat insert can be recessed farther into the counterbore.

Note: For example, if 0.25 mm (.010 inch) has been removed from the bottom of the head, the counterbore can be recessed 0.25 mm (.010 inch).

Note: If a valve exceeds the maximum recessed dimension, the valve position is too deep. To correct this condition, either a new valve must be installed. Replacing the valve seat may also be necessary.

The minimum and the maximum dimensions for intake and exhaust valves are listed in Table 111. The table lists the dimensions for the following minimum permissible recession or projection, maximum recession or projection, and maximum recession for reusability. The maximum recession for reusability applies when the cylinder head has been machined or the valve has been ground. For the minimum recession for reusability, refer to the minimum permissible recession. A valve that projects too far can contact the piston during normal engine operation. A valve that is recessed too much will not adjust. A valve that is recessed too much will create the following conditions:

• Binding in the guide

• Abnormal wear

• Poor engine performance

Show/hide table

NOTICE
The prefinished inserts should not be ground to correct the valve projection. Excessive valve projection indicates that the insert is not seated or the material was not cleaned from the bottom of the counterbore.

Table 97

Valve Projection for D & G Models Cylinder Heads
Exhaust			Intake
Valve Part Number	Maximum Projection	Minimum Projection	Valve Part Number	Maximum Projection	Minimum Projection
4F-0212	2.390 mm (0.09409 inch)	1.080 mm (0.04252 inch)	6H-3026	2.390 mm (0.09409 inch)	1.080 mm (0.04252 inch)
1M-0982 2M-7727	2.810 mm (0.11063 inch)	1.380 mm (0.05433 inch)	9H-4811	2.990 mm (0.11772 inch)	1.560 mm (0.06142 inch)
9M-4163 8N-3724	3.50 mm (0.13780 inch)	2.30 mm (0.09055 inch)	7M-7358	3.49 mm (0.13740 inch)	2.04 mm (0.08031 inch)
5S-6449 6N-9916 8N-0875 100-7861 148-7455	3.50 mm (0.13780 inch)	2.30 mm (0.09055 inch)	2W-2621 247-6892	3.49 mm (0.13740 inch)	2.04 mm (0.08031 inch)
1S-2903	3.07 mm (0.12087 inch)	1.840 mm (0.07244 inch)	2S-8143	3.07 mm (0.12087 inch)	1.840 mm (0.07244 inch)
8N-3737	3.00 mm (0.11811 inch)	1.670 mm (0.06575 inch)	7H-6891	3.00 mm (0.11811 inch)	1.670 mm (0.06575 inch)
8H-1994 1W-1819	3.47 mm (0.13661 inch)	2.24 mm (0.08819 inch)	1W-1818 8H-1993	4.94 mm (0.19449 inch)	3.60 mm (0.14173 inch)
7E-7830	3.48 mm (0.13701 inch)	1.910 mm (0.07520 inch)	1N-4885 1N-4886	3.48 mm (0.13701 inch)	1.910 mm (0.07520 inch)
1W-1822 2W-3211 8N-3723 5S-5323	4.470 mm (0.17598 inch)	3.00 mm (0.11811 inch)	7M-7817	4.470 mm (0.17598 inch)	3.18 mm (0.12520 inch)

Table 98

Recession of the Cylinder Head Valve for C7 through C32 Engines
Intake/Exhaust	Part Number	Minimum Valve Recess	Maximum Valve Recess
Intake	145-7390	1.09 mm (0.043 inch)	1.71 mm (0.067 inch)
	157-7129
	252-7801
Exhaust	147-8211
	157-7130
Intake	241-8382 262-2957 490-1726	1.19 mm (0.047 inch)	1.81 mm (0.0713 inch)
	163-2442 187-4123 490-1719	1.18 mm (0.046 inch)	1.8 mm (0.071 inch)
Exhaust	241-8383 255-8676 490-1723 490-1728	1.19 mm (0.047 inch)	1.81 mm (0.0713 inch)
	188-3122 490-1721	2.79 mm (0.110 inch)	3.41 mm (0.134 inch)
Intake	157-0672 192-9213	2.19 mm (0.086 inch)	2.81 mm (0.111 inch)
Exhaust	157-0671	1.09 mm (0.043 inch)	1.71 mm (0.067 inch)
	133-7029
Intake	252-7802	2.59 mm (0.102 inch)	3.21 mm (0.126 inch)
	224-3028
Exhaust	224-3030 248-1467	1.34 mm (0.053 inch)	1.76 mm (0.069 inch)
Intake	236-5605 490-7198	2.17 mm (0.085 inch)	2.83 mm (0.111 inch)
	153-7023 490-7199
Exhaust	289-9231 464-4668	1.19 mm (0.047 inch)	1.81 mm (0.071 inch)
	153-7024 490-7200

Table 99

Recession of the Cylinder Head Valve for C175 Engines
Valve	Max Recession
Intake	2.268 ± 0.35 mm (0.0893 ± 0.0138 inch)
Exhaust	2.268 ± 0.33 mm (0.0893 ± 0.0130 inch)

Illustration 289	g01201427
See Table 100 for specifications for the valve. (H) Width of the valve seat (J) Valve Margin (K) Valve Recess (L) Valve Seat Angle

Table 100

Specifications for 3044, 3046, 3064, 3066 Engines
Sales Model	3044, 3046		3064, 3066
Description	Intake	Exhaust	Intake	Exhaust
Width of the valve seat (H)	1.40 ± 0.14 mm (0.055 ± 0.006 inch)	1.40 ± 0.14 mm (0.055 ± 0.006 inch)	1.40 ± 0.20 mm (0.055 ± 0.008 inch)	1.40 ± 0.14 mm (0.055 ± 0.006 inch)
Valve Recess (K)	0.40 ± 0.10 mm (0.016 ± 0.004 inch)	0.50 ± 0.10 mm (0.020 ± 0.004 inch)	0.40 ± 0.10 mm (0.016 ± 0.004 inch)	0.50 ± 0.10 mm (0.020 ± 0.004 inch)
Valve Seat Angle (L)	30°	30°	30°	30°

Illustration 290	g02419820
Width of valve seat (F) Refer to Table 101 and Table 102 for specifications. (R) Minimum width of finished seat

Table 101

Specifications for Intake Valves Recession on 3176, and 3196 Engines
Part Number	Minimum width of finished seat (F)	Maximum distance from head of valve to cylinder head face closed valve	Minimum distance from head of valve to cylinder head face closed valve
7C-5215 7E-9578 124-2692 136-4336 157-0672 192-9213	0.762 mm (0.0300 inch)	−3.81 mm (−0.150 inch)(1)	−2.10 mm (−0.083 inch)(1)

(1)	Recessed projection of valve

Table 102

Specifications for Exhaust Valves Recession on 3176, and 3196 Engines
Part Number	Minimum width of finished seat (F)	Maximum distance from head of valve to cylinder head face closed valve	Minimum distance from head of valve to cylinder head face closed valve
7C-1586 109-5334 124-2693 133-3550 133-7029 157-0671	0.762 mm (0.0300 inch)	−2.83 mm (−0.111 inch)(1)	−1.10 mm (−0.043 inch)(1)

(1)	Recessed projection of valve

Table 103

Specifications for Intake Valves Recession on 3114, and 3116 Engines
Part Number	Maximum distance from head of valve to cylinder head face closed valve	Minimum distance from head of valve to cylinder head face closed valve
7W-8064	−2.05 mm (−0.08071 inch)	−1.13 mm (−0.04449 inch)

Table 104

Specifications for Exhaust Valves Recession on 3114, and 3116 Engines
Part Number	Maximum distance from head of valve to cylinder head face closed valve	Minimum distance from head of valve to cylinder head face closed valve
7W-2699	2.22 mm (0.08740 inch)	−1.51 mm (−0.05945 inch)

Table 105

Valve Projection for 3200 Cylinder Heads
Exhaust			Intake
Valve Part No.	Maximum Projection	Minimum Projection	Valve Part No.	Maximum Projection	Minimum Projection
9N-0185	1.31 mm (0.05157 inch)	0.20 mm (0.00787 inch)	9N-0180	1.6 mm (0.06299 inch)	-0.05 mm (-0.00197 inch)
9N-5125	-1.50 mm (-0.05906 inch)	-2.83 mm (-0.11142 inch)	9L-7682	-0.87 mm (-0.03425 inch)	-2.40 mm (-0.09449 inch)

Table 106

Valve Projection for 3300 Cylinder Heads
Model	Configuration	Intake	Exhaust	Head Assembly
3304	PCNA	2.43 mm (0.096 inch)	2.43 mm (0.096 inch)	8N-1454
	DI	2.69 mm (0.106 inch)	2.69 mm (0.106 inch)	7C-4004
	PCT	2.69 mm (0.106 inch)	2.69 mm (0.106 inch)	8N-1454
	SI	2.69 mm (0.106 inch)	2.69 mm (0.106 inch)	7W-8304
3306 G3306	DI	2.69 mm (0.106 inch)	2.69 mm (0.106 inch)	7C-4006
	SI	2.69 mm (0.106 inch)	2.69 mm (0.106 inch)	7W-8306
	PCNA	2.43 mm (0.096 inch)	2.43 mm (0.096 inch)	8N-1446
	DIT	2.02 mm (0.079 inch)	2.11 mm (0.083 inch)	7C-4006

Table 107

Valve Projection for 3300 Cylinder Heads
Exhaust			Intake
Valve Part No.	Maximum Projection2	Minimum Projection2	Valve Part No.	Maximum Projection2	Minimum Projection2
5S-6449	2.98 mm (0.117 inch)	1.44 mm (0.057 inch)	5S-6452	3.51 mm (0.138 inch)	1.97 mm (0.078 inch)
6N-9916	−0.81 mm (−0.032 inch) R	−2.10 mm (−0.083 inch) R	2W-2620	−0.03 mm (−0.001 inch) R	−1.31 mm (−0.052 inch) R
8N-0875 2W-2877	3.26 mm (0.128 inch)	1.97 mm (0.078 inch)	2W-2621 247-6892	3.51 mm (0.138 inch)	2.22 mm (0.087 inch)
7W-7491	2.98 mm (0.117 inch)	1.69 mm (0.067 inch)	7W-7490	3.51 mm (0.138 inch)	2.22 mm (0.087 inch)
6N-9916	−0.81 mm (−0.032 inch) R	−2.10 mm (−0.083 inch) R	2W-2620	−0.03 mm (−0.001 inch) R	−1.31 mm (−0.052 inch) R
7W-7491	2.98 mm (0.117 inch)	1.69 mm (0.067 inch)	7W-7490	3.51 mm (0.138 inch)	2.22 mm (0.087 inch)
5S-6449	2.98 mm (0.117 inch)	1.44 mm (0.057 inch)	5S-6452	3.51 mm (0.138 inch)	1.97 mm (0.078 inch)
148-7455	−1.38 mm (−0.054 inch) R	−2.67 mm (−0.105 inch) R	100-7860	−0.68 mm (−0.027 inch) R	−1.96 mm (−0.077 inch) R

Table 108

Recession of the Cylinder Head Valve for 3400 Diesel Engines
Part Number of the Valve	Maximum Valve Recess New	Minimum Valve Recess New	Maximum Valve Recess Reusability	Minimum Valve Recess Reusability
164-2543 Inlet	1.11 mm (0.044 inch)	−0.10 mm (−0.004 inch)	2.14 mm (0.084 inch)	−0.10 mm (−0.004 inch)
122-0322 Inlet	1.11 mm (0.044 inch)	−0.10 mm (−0.004 inch)	1.98 mm (0.078 inch)	−0.10 mm (−0.004 inch)
115-2368 Inlet	1.11 mm (0.044 inch)	−0.10 mm (−0.004 inch)	1.98 mm (0.078 inch)	−0.10 mm (−0.004 inch)
164-2542 Exhaust	1.04 mm (0.041 inch)	−0.22 mm (−0.009 inch)	2.41 mm (0.095 inch)	−0.22 mm (−0.009 inch)
122-0321 Exhaust	1.04 mm (0.041 inch)	−0.22 mm (−0.009 inch)	2.41 mm (0.095 inch)	−0.22 mm (−0.009 inch)
115-2367 Exhaust	1.04 mm (0.041 inch)	−0.22 mm (−0.009 inch)	2.41 mm (0.095 inch)	−0.22 mm (−0.009 inch)

Table 109

Recession of the Cylinder Head Valve for 3400 Gas Engines
Part Number of the Valve	Maximum Valve Recess New	Minimum Valve Recess New	Maximum Valve Recess Reusability	Minimum Valve Recess Reusability
212-0932 Inlet	0.82 mm (0.032 inch)	0.10 mm (0.004 inch)	1.37 mm (0.054 inch)	0.10 mm (0.004 inch)
122-0322 Inlet	1.11 mm (0.044 inch)	−0.10 mm (−0.004 inch)	1.98 mm (0.078 inch)	−0.10 mm (−0.004 inch)
122-7353 Inlet	1.06 mm (0.042 inch)	−0.16 mm (−0.006 inch)	1.86 mm (0.073 inch)	−0.16 mm (−0.006 inch)
4W-5374 Inlet	1.11 mm (0.044 inch)	−0.25 mm (−0.010 inch)	1.91 mm (0.075 inch)	−0.25 mm (−0.010 inch)
311-7555 Exhaust	−0.09 mm (−0.004 inch)	−0.79 mm (−0.031 inch)	0.90 mm (0.035 inch)	−0.79 mm (−0.031 inch)
122-0321 Exhaust	1.04 mm (0.041 inch)	−0.22 mm (−0.009 inch)	2.41 mm (0.095 inch)	−0.22 mm (−0.009 inch)
212-0933 Exhaust	1.01 mm (0.040 inch)	0.31 mm (0.012 inch)	1.56 mm (0.061 inch)	0.31 mm (0.012 inch)
101-8314 Exhaust	1.06 mm (0.042 inch)	−0.16 mm (−0.006 inch)	1.64 mm (0.065 inch)	−0.16 mm (−0.006 inch)
100-4639 Exhaust	0.06 mm (0.002 inch)	−1.16 mm (−0.046 inch)	1.05 mm (0.041 inch)	−1.16 mm (−0.046 inch)
2W-2443 Exhaust	1.30 mm (0.051 inch)	0.07 mm (0.003 inch)	2.10 mm (0.083 inch)	0.07 mm (0.003 inch)

Table 110

Recession of the Cylinder Head Valve for 3406E, 3456 Engines
Part Number of the Valve	Maximum Valve Recess New	Minimum Valve Recess New	Maximum Valve Recess Reusability	Minimum Valve Recess Reusability
153-7023 Inlet	2.83 mm (0.111 inch)	2.17 mm (0.085 inch)	3.88 mm (0.153 inch)	2.17 mm (0.085 inch)
153-7023 Inlet with shortened valve seat insert	3.38 mm (0.133 inch)	2.72 mm (0.107 inch)	4.43 mm (0.174 inch)	2.72 mm (0.107 inch)
153-7024 Exhaust	1.81 mm (0.071 inch)	1.19 mm (0.047 inch)	3.12 mm (0.123 inch)	1.19 mm (0.047 inch)
152-8380 Inlet	2.86 mm (0.113 inch)	1.86 mm (0.073 inch)	3.64 mm (0.143 inch)	1.86 mm (0.073 inch)
152-7585 Exhaust	3.55 mm (0.140 inch)	2.75 mm (0.108 inch)	4.86 mm (0.191 inch)	2.75 mm (0.108 inch)

Table 111

Recession of the Cylinder Head Valve for 3500 Engines
Part Number of Cylinder Head	Intake Valves			Exhaust Valves
	Minimum Recession	Maximum Recession	Maximum Recession for Reusability	Minimum Recession	Maximum Recession	Maximum Recession for Reusability
7E-5861 7E-8760 131-0410 131-0411 172-0834 172-0836 295-2047	0.080 mm (0.0031 inch)	0.920 mm (0.0362 inch)	2.010 mm (0.0791 inch)	0.100 mm (0.0039 inch)	0.900 mm (0.0354 inch)	2.590 mm (0.1020 inch)
101-1175 131-0423 145-3215 154-1612 161-2508 290-1351	2.008 mm (0.0819 inch)	2.920 mm (0.1150 inch)	4.010 mm (0.1579 inch)	2.100 mm (0.0827 inch)	2.900 mm (0.1142 inch)	4.590 mm (0.1807 inch)
4P-6571 7C-3471 122-5961 128-1141 144-6409 153-8397 184-5496 206-1554 206-1555 206-1560 206-1563	+0.155 mm (+0.00610 inch)	-0.654 mm (-0.0258 inch)	2.031 mm (0.0800 inch)	+0.155 mm (+0.00610 inch)	-0.654 mm (-0.0258 inch)	2.031 mm (0.0800 inch)
269-0040 315-2630	+0.115 mm (+0.0045 inch)	-0.685 mm (-0.0270 inch)	1.860 mm (0.0732 inch)	+0.115 mm (+0.0045 inch)	-0.685 mm (-0.0270 inch)	1.860 mm (0.0732 inch)

Vacuum Test for Valves

Testing the valves by vacuum in a cylinder head is used to identify a poor seal between the valve and the valve seat. This procedure should be performed after a cylinder head has been reconditioned. The cylinder head must be assembled before the vacuum test.

Note: The procedure for the vacuum test should only be used to identify leakage between the valve and the valve seat. This test procedure should only be used if the leakage is out of the acceptable specification.

An unavoidable minor amount of leakage between the valve and the valve seat is permissible. It is impractical to use the vacuum test to identify minor leaks between the valve and the valve seat. The following specifications and equipment can be used to identify the gross leak. Any combination of valve and valve seat that does not maintain 40 cm Hg (16.0 inch Mercury) or more is considered to be a gross leak.

Equipment and Tooling

Illustration 291	g01303479
9U-5383 Vacuum Tester

The 9U-5383 Vacuum Tester consists of a hand-held vacuum pump and connecting parts. Most Caterpillar engines will work with the set of eight adapters that can be fabricated from the drawing of the fabricated tool FT-1741 Vacuum Tester. For a complete list of all parts and fabricated dimensions, request a drawing of the FT-1741 Vacuum Tester.

Test Procedure

The 9U-5383 Vacuum Tester is suitable for use when a vacuum test of 46 cm Hg (18 inch Mercury) or less is required. For complete information on the vacuum tester, refer to Special Instruction, SEHS9498, "Using the 9U-5383 Vacuum Tester".

The gauge has detected a leak if a drop in vacuum occurs. An adjustment screw is provided on the top of the tool to vary the sensitivity of the gauge. To check valve seats for leaks, the adjustment screw must be set for maximum sensitivity. When a constant vacuum of 46 cm Hg (18 inch Mercury) is applied for 15 seconds, the vacuum should not drop below 41 cm Hg (16 inch Mercury). A gauge reading of less than 41 cm Hg (16 inch Mercury) can have enough magnitude to affect valve life.

1. Plug in the inlet for the vacuum, and pull out the trigger for the air supply.

2. Back out the adjustment screw until maximum vacuum is attained. The maximum reading should be less than 38 cm Hg (15 inch Mercury).

3. Turn the adjustment screw inward until a drop in vacuum of 2.5 cm Hg (1 inch Mercury) occurs. The minimum adjusted set point is now 35.5 cm Hg (14.0 inch Mercury).

4. Tighten the nylon jam nut to prevent any air leaks from giving a false leakage reading.

5. After adjusting the screw for sensitivity has been adjusted, attach the correct adapter to the vacuum tester.

6. Place the adapter over the valve to be tested.

7. Hold the trigger for the air supply in the open position for a minimum of 15 seconds.

   Note: Make sure that the adapter is in full contact with the combustion area of the cylinder head.

8. The seal between the valve and the valve seat is not acceptable if the gauge indicates a reading less than the Test Specification in Table 112. The Maximum Capability of the Gun determines the Test Specification that should be applied.

9. Apply slight pressure with a press the top of the valve stem and test again.

10. If the gauge still indicates a low reading, the valve must be removed and the sealing surfaces must be inspected. Grinding or lapping the valve seat or the valve face again might also be necessary.

Table 112

Specifications for Testing by Vacuum
Maximum Capability of the Gun	Adjusted Set Point	Test Specification
53 cm Hg (21 inch Mercury)	51 cm Hg (20 inch Mercury)	42 cm Hg (16.5 inch Mercury)
52 cm Hg (20.5 inch Mercury)	49.5cm Hg (19.5 inch Mercury)	41 cm Hg (16 inch Mercury)
51 cm Hg (20 inch Mercury)	48 cm Hg (19 inch Mercury)	41 cm Hg (16 inch Mercury)
49.5 cm Hg (19.5 inch Mercury)	47 cm Hg (18.5 inch Mercury)	39 cm Hg (15.5 inch Mercury)
48 cm Hg (19 inch Mercury)	46 cm Hg (18 inch Mercury)	38 cm Hg (15 inch Mercury)
47 cm Hg (18.5 inch Mercury)	44.5 cm Hg (17.5 inch Mercury)	37 cm Hg (14.5 inch Mercury)
46 cm Hg (18 inch Mercury)	43 cm Hg (17 inch Mercury)	35.5 cm Hg (14.0 inch Mercury)
44.5 cm Hg (17.5 inch Mercury)	42 cm Hg (16.5 inch Mercury)	35.5 cm Hg (14.0 inch Mercury)
43 cm Hg (17 inch Mercury)	41 cm Hg (16 inch Mercury)	33 cm Hg (13 inch Mercury)
42 cm Hg (16.5 inch Mercury)	39 cm Hg (15.5 inch Mercury)	32 cm Hg (12.5 inch Mercury)
41 cm Hg (16 inch Mercury)	38 cm Hg (15 inch Mercury)	32 cm Hg (12.5 inch Mercury)
39.4 cm Hg (15.5 inch Mercury)	37 cm Hg (14.5 inch Mercury)	30.5 cm Hg (12.0 inch Mercury)
38 cm Hg (15 inch Mercury)	35.5 cm Hg (14.0 inch Mercury)	29 cm Hg (11.5 inch Mercury)

Probable Causes of Leaks

• Incorrect texture of valve face or contact area of the valve seat

• The valve seat is improperly installed or the valve seat is not seated in the head (Incorrect Total Indicator Readout).

• Damaged valve face

• Debris between valve face and valve seat

• Damaged contact area of the valve seat

• Bent valve

• Cracked valve face or valve seat

Reusing Cylinder Head Bolts for 3500

3500 cylinder head bolts may be reused for a maximum of five standard rebuilds. The cylinder head bolts must be inspected for cracks and wear during each rebuild. For the inspection procedure, refer to Reuse And Salvage Guideline, SEBF8301, "Inspection and Reuse of Critical Fasteners Used in All Engines".

Reworking Cylinder Head Bolt Holes for 3500

This procedure machines a radius around the edges of the surface for combustion of the three bolt holes for the cylinder head. Cracks can originate from these three holes as a result of high operating temperatures. Machining a radius around these holes can greatly reduce the potential for cracks. These cracks could lead to failure of the cylinder head.

This procedure can only be used on heads that do not have cracks. If cracks are present, the cracks will appear on the combustion side of the head. The cracks will radiate outward from the bolt hole. If cracks are found anywhere in the cylinder head, the cylinder head must not be used again.

Hole Location for the Cylinder Head Bolt

Illustration 292	g06189556
The location of the three bolt holes that should be reworked. (10) Top position (11) Middle position (12) Lower position

Specifications

Illustration 293	g06189557
Profile of the holes to be reworked (13) Radius

Machine a 1.9 ± .3 mm (0.07 ± 0.01 inch) radius at location (13).

Illustration 294	g01298672
The enlarged section of radius at location (14) Refer to Illustration 293.

(C) 23.25 mm (0.915 inch) maximum

(D) 0.5 mm (0.02 inch)

(E) 1.9 ± 0.3 mm (0.07 ± 0.01 inch) radius

(14) Remove the area of the crosshatch by using a 4C-8624 mandrel.

Rework Procedure

1. Put 4C-3845 Grinding Wheel in the chuck of the air drill or in the chuck of the electric drill.

2. Operate the drill at full rated speed and lightly insert the mounted point into the bolt hole.

3. Apply a steady pressure that is equal to two times the weight of the drill for one and one half to two seconds. This should create a 0.5 mm (0.02 inch) chamfer on the edge of the bolt hole.

4. Ensure that the chamfered diameter is not larger than 23.25 mm (0.915 inch) (C).

5. Repeat this procedure for each bolt hole.

   Note: The bolt hole at the middle position may already have a chamfered diameter on some cylinder heads. This diameter may be larger than 23.25 mm (0.915 inch) (C). Do not add an extra chamfer to this hole. Polish the hole with the reconditioning tool that is described in the following procedure:

6. After all the holes have been reworked to have smooth corners put 4C-8629 Mandrel and 4C-8624 Mandrel in the drill.

7. Operate the drill in a clockwise direction at full rated speed. Insert the drill halfway into the bolt hole. Apply light pressure to the chamfered edge of the hole. Steadily increase the pressure to flex the arms of the drill into the hole.

8. Insert the drill and remove the drill from each hole several times. Continue to perform this procedure until the edges of the chamfers are removed, and a smooth radius and a polished radius is formed.

9. Clean the cylinder head thoroughly before putting the cylinder head back into service.

Inspection and Repair Procedure for the Saddle of the Rocker Arm Shaft in C15, C16, C18, 3406E, C27, C32, and 3456 Engines

Inspection Procedure

1. Fix the indicator and the surface probe to the 90° holding block. Find the area that is unworn between the saddle of the rocker shaft and the rocker arm shaft. Remove the burrs by lightly filing the edges at the top of the saddle on the rocker shaft. Set the indicator on the milled face of the head over the saddle of the rocker shaft. Locate the lowest point of the saddle by moving the block back and forth. Ensure that the block is perpendicular to the axis of the camshaft. Zero the indicator. Move the indicator back and forth to recheck the zero. If necessary, reset the indicator to zero.

2. When the indicator is reset move the indicator to the worn portion of the saddle of the rocker shaft at the end of the rocker arm shaft. Again, move the block back and forth to make sure that the block is perpendicular to the axis of the camshaft. Record the lowest negative number as the maximum amount of wear. The lowest number will be the lowest point.

3. Repeat the procedure to measure the worn portion of the saddle at both edges of the support for the center of the rocker arm shaft, and the worn portion of the saddle at the opposite end of the rocker arm shaft.

Illustration 295	g06278535
Places to measure

Illustration 296	g06278533
Move the gauge back and forth to zero the gauge and measure the wear step.

Illustration 297	g06241147
Callout (B) shows a maximum of 3 mm (0.118 inch) is allowed around the bolt hole.

Note: If the rocker arm shaft saddle has a wear step of 0.10160 mm (0.004 inch) or more the head must be repaired by skim cutting the saddle area using a 40.0 ± 0.12 mm (1.57480 ± 0.00472 inch) ball mill.

The maximum allowable depth from the flats on both sides of the rocker valley to the bottom of the rocker valley is 12.702 mm (0.50008 inch).

Illustration 298	g06241135
While using a coordinate measuring machine measurement, (C) should be a minimum of 86.66 mm (3.41180 inch). For proper measurement of (C) use surface (D) and not surface (E)

Thermal Spray Procedures for Cylinder Head

Part Description

Table 113

Base Metal	Cast Iron
Hardness	ACERT: 196-254 BHN C27 and C32: Brinell 3.8 - 4.3 mm (0.15 - 0.17 inch) C175: 170-230 BHN

Arc Spray Equipment and Procedure

Table 114

Maximum Surface Texture	ACERT: 1.6 µm (63 µinch) C27 and C32: Brinell 1.6 µm (63 µinch) C175: 0.8 µm (32 µinch) MHI 3044-3066 - (-)
Reason for Spraying	Wear, erosion, head dimension under minimum due to rework
Mating Part Contact Area & Material	Head gasket
Arc Spray Equipment Type	SmartArcby Oerlikon Metco, TAFA 8830 MHU, or TAFA 8835 MHU
Wire	TAFA 60T Wire Top Coat, TAFA 75B Bond Coat
Finish Thickness	0.25 ± 0.38 mm (0.010 ± 0.015 inch)
Finishing Allowance	Machine 0.64 mm (0.025 inch) Grind 0.51 mm (0.020 inch)
Spray Angle	90°
Substrate Pre-Heat Temperature	66.0° C (150° F) Do not direct arc on area to be sprayed
Substrate Temperature During Spraying Not to Exceed	148.0° C (300° F)
Auxiliary Cooling	Filtered shop air
Surface Preparation Method	Undercut and grit blast If the entire head gasket-mating surface is to be arc sprayed, some shops prefer to pre-grind the head. Remove any major damage. Allowing for a minimum 0.25 mm (0.010 inch) coating, reduces technique dependency in producing an even coating and reduces material cost and finish grinding time.
Machining Method	Mill
Equipment Required	Milling Machine
Recommended Cutting Tool	ISCAR DNMG 432 TFIC507
Blast Media Recommendation	Pressure Type Only (Aluminum Oxide Grit)
Grinding Equipment	Standard head and block grinder
Recommended Abrasive	Norton 32A 46-H8VBE
Remarks	A low spot ONLY repair should not be considered unless at least 0.05 - 0.08 mm (0.002 - 0.003 inch) can be removed from the head thickness during the finishing operation.

Table 115

Arc Spray		Procedure		Check List
Clean Part		Degrease in hot Aluminum safe cleaner
Undercut		If the entire head gasket-mating surface is to be arc sprayed, some shops prefer to pre-grind the head. Remove any major damage. Allowing for a minimum 0.25 mm (0.010 inch) coating, reduces technique dependency in producing an even coating and reduces material cost and finish grinding time.
Chamfer		All edges must have at least 0.79 -1.58 mm (0.031 - 0.062 inch) chamfer.
Remove Oxide		Use fiber flap brush or Clean/strip disc
Clean Spray Area		Commercial degreaser
Mask for Grit Blaster		Use rubber or metal mask
Grit Blast Equipment		Pressure type only
Grit Type and Size		20 mesh aluminum oxide
Blast Air Pressure		690 kPa (100.0 psi)
Blast Nozzle to Work Distance		51 mm to 150 mm (2.0 inch to 6.0 inch)
Remove Blast Mask		Make sure that surface is clean
Mask for Metal Spray		Anti-Bond or Blue Layout Dye
Metal Spray Equipment Type		Smart Arc byOerlikon Metco	TAFA
	Consumable (Bondcoat)	TAFA 75B	TAFA 75B
	Clamp Pressure	275 kPa (40 psi)
	Air Jets/Pressure	415 kPa (60 psi)	415 kPa (60 psi)
	Arc Load Volts	30V	30V
	Amps	125 Amps	150 Amps
	Gun to Work Distance (Standoff)	128 mm (5.0 inch)	128 mm (5.0 inch)
	Spray Rate/Bond Pass	0.038 mm (0.0015 inch)/pass	0.038 mm (0.0015 inch)/pass
	Consumable (Topcoat)	TAFA 60T	TAFA 60T
	Clamp Pressure	275 kPa (40 psi)
	Air Jets/Pressure	415 kPa (60 psi)	415 kPa (60 psi)
	Arc Load Volts	30V	31V
	Amps	150 Amps	175 Amps
	Gun to Work Distance (Standoff)	76 mm (3.0 inch)	76 mm (3.0 inch)
	Spray Rate/Build Up	0.038 mm (0.0015 inch)/pass	0.038 mm (0.0015 inch)/pass
	Rotation Speed of Part	91.4 SMPM (300.00 SFPM)
	Traverse Rate of Gun	12.2 SMPM (40.00 SFPM)
Gun Fixturing Method		Machine mount or hand held
Finishing Equipment		Head and block grinder, milling machine
Part/Cutter Rotation Roughing		50 SMPM (150 SFPM)
Part/Cutter Rotation Finishing		75 SMPM (250 SFPM)
Coolant		Oil base synthetic - 40:1 ratio
Traverse Speed		0.30 mm (0.012 inch)
Depth of Rough Cut		0.51 mm (0.020 inch)
Depth of Finish Cut		0.25 mm (0.010 inch)

- METCO Anti-Bond should be applied at least 76 mm (3.0 inch) wide around the blasted area.

- The valve seat areas, casting relief areas, and dowel pin holes can be masked with METCO Anti-Bond, silicon rubber, bulk ceramic fiber, or a combination of these materials.

- Grind coating back to base on edges where possible.

- Pressure flush head with high-pressure water and wash to remove all grit.

Flame Spray Equipment and Procedure

Table 116

Maximum Surface Texture	ACERT: 1.6 µm (63 µinch) C27 and C32: Brinell 1.6 µm (63 µinch) C175: 0.8 µm (32 µinch) MHI 3044-3066 - (-)
Reason for Spraying	Wear, erosion, head dimension under due to rework
Mating Part Contact Area & Material	Head gasket
Metco Equipment Type	6P-II by Oerlikon Metco
Metco Material	Metco 453
Finish Thickness	0.25 ± 0.38 mm (0.010 ± 0.015 inch)
Finishing Allowance	Machine 0.64 mm (0.025 inch) Grind 0.51 mm (0.020 inch)
Spray Angle	90°
Substrate Pre-Heat Temperature	66.0° C (150° F) Do not direct flame on area to be sprayed
Substrate Temperature During Spraying Not to Exceed	148° C (300° F)
Auxiliary Cooling	If desired
Rotation/Traverse Device	Lathe or headstock/tailstock arrangement, rotary turntable
Rotation/Traverse Device	91.4 SMPM (300.00 SFPM)
Surface Preparation Method	Grit Blast If the entire head gasket-mating surface is to be arc sprayed, some shops prefer to pre-grind the head. Remove any major damage. Allowing for a minimum 0.25 mm (0.010 inch) coating, reduces technique dependency in producing an even coating and reduces material cost and finish grinding time.
Finishing Method	Machine
Recommended Wheel	Norton 23A 30E12VBEP or SGL abrasive HSA24F13-VKP
Machining Equipment Type	Milling machine or Lathe
Recommended Cutter Grade	Sandvik 310-K-10 LNCK, C2, 883 Carboloy, or equivalent
Remarks	A low spot ONLY repair should not be considered unless at least 0.05 - 0.08 mm (0.002 - 0.003 inch) can be removed from the head thickness during the finishing operation.

Table 117

Flame Spray Process (6P)	Procedure	Check List
Clean Part	Degrease in hot caustic solution
Undercut	If the entire head gasket-mating surface is to be arc sprayed, some shops prefer to pre-grind the head. Remove any major damage. Allowing for a minimum 0.25 mm (0.010 inch) coating, reduces technique dependency in producing an even coating and reduces material cost and finish grinding time.
Chamfer	All edges must have at least 0.79 -1.58 mm (0.031 - 0.062 inch) chamfer.
Remove Oxide	Use fiber flap brush or Clean/strip disc
Clean Spray Area	Metco cleaning solvent or equivalent
Mask for Blast	Duct tape
Blast Equipment	Pressure type only
Grit Type and Size	24 mesh aluminum oxide
Blast Air Pressure	690 kPa (100.0 psi)
Blast Nozzle to Work Distance	51 mm to 150 mm (2.0 inch to 6.0 inch)
Remove Blast Mask	Remove mask, make sure that surface is clean
Mask for Spray	Metco Antibond or blue layout dye
Spray Equipment Type	6P-II Hand Held Thermo Spray System by Oerlikon Metco
Auxiliary Cooling	If desired
Nozzle	6P-7CA-K "K" Nozzle
Air Capacity/Pressure	6P-3/Cooling air 140 - 170 kPa (20.0 - 25.0 psi)
Oxygen Pressure	210 kPa (30.0 psi)
Oxygen Flow	1190 L/h (42.0 cfh)
Fuel Gas Pressure	100 kPa (15.0 psi)
Fuel Gas Flow	1415 L/h (50.0 cfh)
Carrier Gas Pressure	380 kPa (55.0 psi)
Carrier Gas Flow	1050 L/h (37.0 cfh)
Spray Rate/Build Up	5.5 kg (12.00 lb) per hour or 90 gr (3.2 oz) per minute
Gun to Work Distance	230 mm (9.0 inch)
Rotation Speed of Part	91.4 SMPM (300.00 SFPM)
Traverse Rate of Gun	15.24 SMPM (50.00 SFPM)
Gun Fixturing Method	Machine mount or hand held
Top Coat/Thickness	0.10 mm to 0.15 mm (0.004 inch to 0.006 inch) per pass
Finishing Equipment	Head or block grinder, milling machine
Part/Cutter Rotation	91.4 SMPM (300.00 SFPM)
Traverse Speed	0.05 mm (0.002 inch) to 0.10 mm (0.004 inch) per revolution
Depth of Rough Cut	0.03 mm (0.001 inch) to 0.05 mm (0.002 inch), 0.25 mm (0.010 inch) to 0.38 mm (0.015 inch)
Depth of Finish Cut	0.03 mm (0.001 inch), 0.13 mm (0.005 inch) to 0.25 mm (0.010 inch)
Additional Finish Method	Emery cloth for desired finish

- METCO Anti-Bond should be applied at least 76 mm (3.0 inch) wide around the blasted area.

- The valve seat areas, casting relief areas, and dowel pin holes can be masked with METCO Anti-Bond, silicon rubber, bulk ceramic fiber, or a combination of these materials.

- Grind coating back to base on edges where possible.

- Pressure flush head with high-pressure water and wash to remove all grit.

Storage Procedures

Proper protection of the cylinder head from corrosion is important. Corrosion will start in as little as one hour after the cylinder head has been cleaned.

When the cylinder head will not be inspected for one hour or less the cylinder head should be coated with a rust or corrosion inhibitor or coated with clean engine oil. The cylinder head should be individually wrapped to prevent contamination, and the cylinder head should be stored in a protected area to avoid damage. See Illustration 299.

When the cylinder head will not be inspected in two days or more the cylinder head should be coated with a rust or corrosion inhibitor or coated with clean engine oil and the cylinder head should be placed in a container which is clean and structurally solid. The container should be covered or wrapped in plastic to prevent damage and contamination to the cylinder head. See Illustration 300.

Refer to SEHS9031Special Instruction, "Storage Procedure for Caterpillar Products" for more information.

Illustration 299	g06278538
Example of protection for a component that is stored for a shorter term

Illustration 300	g06278539
Example of protection for a component that is stored for a longer period