C9 Petroleum Engines Caterpillar

Installation Procedure

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Illustration 1	g01141531

1. Apply Tooling (A) to cup plugs (12). Install the cup plugs in the cylinder head.

2. Install pipe plugs (15) in the cylinder head.

3. Install the O-rings on plug assemblies (13) and plug assemblies (14). Install the plug assemblies in the cylinder head.

4. Thoroughly clean the mating surfaces of the cylinder head and the cylinder block.

5. Install Tooling (B) in the cylinder block.

6. Install a new cylinder head gasket assembly on the cylinder block.
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   Illustration 2	g01140918

7. Attach a suitable lifting device to cylinder head (10). The weight of cylinder head (10) is approximately 100 kg (220 lb). Position the cylinder head on Tooling (B).

8. Apply clean engine oil to the threads of cylinder head bolts (11) and under the bolt head. Install cylinder head bolts (11). Remove Tooling (B). Install the remaining cylinder head bolts.
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   Illustration 3	g01140758

9. Tighten the cylinder head bolts according to the following procedure:

   1. In a numerical sequence, tighten Bolts 1 through 26 to a torque of 130 ± 15 N·m (96 ± 11 lb ft).

   2. In a numerical sequence, tighten Bolts 1 through 26 again to a torque of 130 ± 15 N·m (96 ± 11 lb ft).

   3. In a numerical sequence, tighten Bolts 1 through 26 for an additional 90 ± 5 degrees (1/4 turn).

      Note: If Tooling (C) is not used, place an index mark on the bolt and the cylinder head.

   4. Completely loosen Bolts 1 through 26.

   5. In a numerical sequence, tighten Bolts 1 through 26 to a torque of 130 ± 15 N·m (96 ± 11 lb ft).

   6. In a numerical sequence, tighten Bolts 1 through 26 again to a torque of 130 ± 15 N·m (96 ± 11 lb ft).

   7. In a numerical sequence, tighten Bolts 1 through 26 for an additional 90 ± 5 degrees (1/4 turn).

      Note: If Tooling (C) is not used, place an index mark on the bolt and the cylinder head.

   8. In a numerical sequence, tighten Bolts 27 through 31 to a torque of 28 ± 7 N·m (21 ± 5 lb ft).
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   Illustration 4	g01027265

10. Install tube assembly (9) to cylinder head (10).
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    Illustration 5	g01436177

11. Connect harness assembly (7) and harness assembly (8).

12. Connect harness assembly (5).

13. Connect injection actuation pressure sensor (6).
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    Illustration 6	g00976251

14. Connect fuel return tube assembly (4).

15. Connect inlet air pressure sensor (2).

16. Connect inlet air temperature sensor (3).

17. Connect coolant temperature sensor (1).

End By:

1. Install the fan drive. Refer to Disassembly and Assembly, "Fan Drive - Install".

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

3. Install the aftercooler. Refer to Disassembly and Assembly, "Aftercooler - Install".

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

5. Install the electronic unit injectors. Refer to Disassembly and Assembly, "Electronic Unit Injector - Install".

6. Install the rocker arm and shaft. Refer to Disassembly and Assembly, " Rocker Arm and Shaft - Install".

7. Install the valve mechanism cover base. Refer to Disassembly and Assembly, " Valve Mechanism Cover Base - Remove and Install".