C6.6 Engines for Caterpillar Built Machines Cylinder Head - Install Caterpillar

Installation Procedure

1. Thoroughly clean the mating surfaces of the cylinder head and the cylinder block. Do not damage the mating surfaces of the cylinder head of the cylinder block. Ensure that no debris enters the cylinder bores, the coolant passages, or the lubricant passages.

2. Inspect the mating surface of the cylinder head for distortion. Refer to Specifications, "Cylinder Head" for more information. If the mating surface of the cylinder head is distorted beyond maximum permitted limits, replace the cylinder head.

3. If necessary, install the inlet manifold to the cylinder head. Refer to Disassembly and Assembly, "Inlet manifold - Remove and Install".
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   Illustration 1	g01340176

4. Inspect dowels (18) for damage. If necessary, replace the dowels in the cylinder block.

5. Install Tooling (A) to the cylinder block.

6. Align cylinder head gasket (17) with dowels (18). Install cylinder head gasket (17) onto the cylinder block.
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   Illustration 2	g01340086
   Typical example

7. Use a suitable lifting device (16) to lift cylinder head (15). The weight of the cylinder head is approximately 66 kg (145.5 lb).

   Note: A spreader bar must be used in order to distribute the weight of the cylinder head during the lifting operation.

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

   Note: Ensure that the cylinder head is correctly positioned on dowels (18).

9. Remove Tooling (A).
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   Illustration 3	g01340188

10. Clean bolts (14). Follow Steps 10.a for the procedure to inspect the bolts.

    1. Use a straight edge to check the threads of the bolts. Refer to Illustration 3. Replace any bolts that show visual reduction in the diameter of the thread over length (Y).

11. Lubricate the threads and the shoulder of bolts (14) with clean engine oil.
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    Illustration 4	g01340081

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    Illustration 5	g01340192

12. Install bolts (14) to cylinder head (16).

13. Tighten the bolts to a torque of 50 N·m (37 lb ft) in the numerical sequence. Refer to Illustration 5.

14. Tighten the bolts to a torque of 100 N·m (74 lb ft) in the numerical sequence. Refer to Illustration 5.

15. Turn the bolts through an additional 225 degrees in the numerical sequence. Refer to Illustration 5. Use Tooling (B) to achieve the correct final torque.
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    Illustration 6	g01340080
    Typical example

16. Use Tooling (C) in order to lubricate the O-ring seals. Install new O-ring seals (12) and (13) to bypass tube (11). Install the bypass tube in the cylinder head. Install bolts (10). Tighten the bolts to a torque of 22 N·m (16 lb ft).
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    Illustration 7	g01340077
    Typical example

17. Remove the plugs and caps from the ports and tube assemblies.

18. Install tube assembly (8) for the fuel return to the cylinder head and to the transfer pump. Secure the tube clips for tube assembly (8).

19. If the engine has a wastegate solenoid, install tube assembly (9) for the wastegate solenoid to the cylinder head. Secure the tube clips for tube assembly (9).
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    Illustration 8	g01340075
    Typical example

20. Follow Steps 20.a and 20.b in order to connect harness assembly (4) to inlet air temperature sensor (7).

    1. Connect harness assembly (4) to inlet air temperature sensor (7).

    2. Slide the locking tab into the locked position.

21. Follow Steps 21.a and 21.b in order to connect harness assembly (4) to boost pressure sensor (6).

    1. Connect harness assembly (4) to boost pressure sensor (6).

    2. Slide the locking tab into the locked position.

22. Follow Steps 22.a and 22.b in order to connect harness assembly (4) to coolant temperature sensor (5).

    1. Connect harness assembly (4) to coolant temperature sensor (5).

    2. Slide the locking tab into the locked position.

23. Use new cable straps in order to secure the harness assembly to the cylinder head and to the inlet manifold. Ensure that the harness assembly is not strained.

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

24. Install the inlet hose to inlet connection (3) on inlet manifold (2).
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    Illustration 9	g01340072
    Typical example

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

26. Connect the upper radiator hose to water temperature regulator housing (1) on the cylinder head.

27. Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct filling procedure.

28. If necessary, fill the engine oil pan to the correct level that is indicated on the engine oil level gauge. Refer to Operation and Maintenance Manual, "Engine Oil Level - Check".

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

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

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

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

5. Install the fuel manifold. Refer to Disassembly and Assembly, "Fuel Manifold - Remove and Install".

6. Install the electronic control module and the mounting bracket. Refer to Disassembly and Assembly, "Electronic Control Module - Remove and Install".

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

8. If necessary, install the fuel priming pump and the primary fuel filter. Refer to Disassembly and Assembly, "Fuel Priming Pump - Remove and Install".

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