Installation Of Remanufactured Cylinder Head Groups{1101} Caterpillar


Installation Of Remanufactured Cylinder Head Groups{1101}

Usage:

1100, 3100, 3204 and 3208 Engines

Introduction

This instruction gives the information needed, by engine model, for installation of the Remanufactured Cylinder Head and any additional parts that may be necessary.

Reference: Service Manual, Parts Book.

Parts Information


DINADINA -Direct Injection, Natural Aspiration.


DITDIT -Direct Injection, Turbocharged.


DITADITA -Direct Injection, Turbocharged, Aftercooled.


N/AN/A -Not available at this time.


1This Exchange Cylinder Head Group has a "new" cylinder head casting. Other parts in the Group may be Remanufactured.

These Remanufactured Cylinder Head Groups can be used as a service replacement for the cylinder head(s) on the engines listed in the chart. They can not however, be used on 1100 or 3100 Engines, except as indicated in the topic entitled "1100 and 3100 Engines" in this publication. These cylinder heads also can not be used on 3204 PC Engines.

These cylinder head groups have the intake and exhaust valves, valve springs, washers, locks and retainers installed on the cylinder head. Additional parts sent with each cylinder head group are for use in specific applications.

Not all of the parts in each cylinder head group will be needed on a specific engine. Put 5P3413 Pipe Sealant on all threaded plugs and cap plugs used in the cylinder head installation.


2Refer to the topic entitled "1100 and 3100 Engines" in this publication.

All 3200 Engines

NOTE: The mounting holes in the cylinder head at location (A), used for a lifting bracket (or for other brackets), may be a different size than the mounting holes in the original cylinder head, therefore, some rework and additional parts may be needed.

Earlier cylinder heads had bracket mounting holes with 3/8"-16-2B threads. Later cylinder heads have bracket mounting holes with 1/2"-13-2B threads.

1. If an earlier type cylinder head is used as a replacement for a later type cylinder head, the replacement cylinder head will have 3/8"-16-2B threads in the mounting holes at location (A). Install the bracket with 0S1594 Bolts and 5M2894 Washers.
2. If a later type cylinder head is used as a replacement for an earlier type cylinder head, the holes in the lifting bracket (or other bracket) must be enlarged to 13.0 mm (0.53")Ø. Use 6H1717 Bolts and 5P8245 Washers to fasten the lifting bracket to the replacement cylinder head.

All 3200 DINA Engines

NOTE: These engines use two different types of fuel injection nozzles. Parts needed will depend on the type of nozzles used in the engine being repaired.

1. The two types of fuel injection nozzles that are used on 3200 DINA engines are the pencil-type nozzle (1), and 7000 Series nozzle (2). Fuel enters from the side in pencil-type nozzle (1), and from the top on 7000 Series nozzle (2).
2. For those engines that have pencil-type nozzle (1), the nozzles must be installed in the Remanufactured cylinder head using the new 1W2459 Fuel Nozzle Clamp Assemblies provided.

For those engines that have 7000 Series nozzle (2), use the original type clamps.

All 3208 Engines

1. If the cylinder head is to be used on the left side of the engine, install a 9L7657 Cup Plug at location (A). If the cylinder head is to be used on the right side of the engine, install a 9L7657 Cup Plug at location (B).

On all cylinder heads, install a 7H3171 Hex Countersunk Head Plug at location (C).

2. Install 5M6213 Plugs at locations (D) as necessary. Due to the different size holes in earlier and later cylinder heads, install either a 2B0858, or a 5M6214 Plug in the opening at location (E).

NOTE: Some earlier DINA engines had cylinder heads with different (shorter) length head bolts at locations (F). These cylinder heads can be identified by the casting part number at location (G).

Former cylinder heads with a 9L9270 casting part number use three 2B0947 Bolts [57.0 mm (2.25") long]. These bolts must be replaced with three 0L1329 Bolts [76.0 mm (3.00") long], that are not included in this cylinder head group.

3. Install the new cylinder head gasket. Put the cylinder head in position on the cylinder block. Put 6V4876 Molykote Lubricant on the threads of the cylinder head bolts, then install the bolts in their correct location


NOTICE

Do not put oil in the threaded holes. It could cause a hydraulic lock when the head bolts are installed. This could result in damaged threads or a cracked block.

Tighten the bolts in the correct sequence and to the correct torque; refer to Special Instruction SEHS8612, that is sent with the new head gasket.


3204 DI Engines

The replacement cylinder head group for a 3204 Engine is built according to direct injection turbocharged (DIT) specifications. This cylinder head can also be used for direct injection naturally aspirated (DINA) engines. This cylinder head is not for use on 3208 engines.

The cylinder head for 3208 engines has additional features that may not be available on the 3204 cylinder head group.

1. Install a 7H3171 Hex Countersunk Head Plug at location (A), a 9L7657 Cup Plug at location (B), and 5M6213 Plugs at locations (C) as necessary.

2. Two different water lines groups have been used on these engines. Each water lines group has vent line parts that are different. (These vent line parts are not part of the Remanufactured Cylinder Head Groups.)

If the replacement cylinder head and the original cylinder head that is being replaced, each have a different thread size at hole locations (D), refer to the illustrations that follow for the parts that are needed to make a new vent line.

3. The illustrations show the parts needed to make either of the two vent lines that are used for these engines.

4. Put the cylinder head in position on the cylinder block. Put 6V4876 Molykote Lubricant on the threads of the cylinder head bolts. Install the bolts in their correct locations.

5. Tighten the bolts in the correct sequence and to the correct torque; refer to Special Instruction SEHS8612 that is sent with the new head gasket.

6. Connect the vent lines as shown.

NOTE: Earlier 3204 DI Engines with the interim Scroll Fuel System (ISFS) have fuel lines routed over the valve cover to fuel line adapters that are installed in the cylinder head at location (E), on the left side of the engine (as viewed from the flywheel).

Later 3204 DI Engines with the New Scroll Fuel System (NSFS) have the fuel line adapters installed in the valve cover base on the right side of the engine (as viewed from the flywheel). On these engines, use 5P3413 Pipe Sealant to install four 8F6575 Cup Plugs in the cylinder head at locations (E).

1100 and 3100 Engines

For 1160 and 3160 Engines with a rated speed of 2800 rpm or less, and a high idle speed of 3050 rpm or less, the 3208 DINA Remanufactured Cylinder Head Group may be used.

Other 1100 and 3100 Engines that have a rated speed above 2800 rpm, or a high idle speed above 3050 rpm, may use the 3208 DINA Remanufactured Cylinder Head Group if the double valve springs, washers/spacers and retainers from the original cylinder head are installed on the Remanufactured Cylinder Head.

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