C15 and C18 On-Highway Engines Combustion Head - Remove and Install Caterpillar


Combustion Head - Remove and Install
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1.1. Removal Procedure
2.1. Installation Procedure

Removal Procedure

Table 1
Required Tools 
Tool  Part Number  Part Description  Qty 
4C-5598  Loctite C5-A Anti-Seize Lubricant 
195-4609  Seal Pick 
Isopropyl Alcohol 
5P-4996  Plug 

Start By:

  1. Remove the exhaust elbow.


NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products.

Dispose of all fluids according to local regulations and mandates.


------ WARNING! ------

Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help prevent possible injury, turn the start switch off when changing fuel filters or water separator elements. Clean up fuel spills immediately.



NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.


------ WARNING! ------

Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool.


  1. Turn the fuel supply to the OFF position and turn the power disconnect switch to the OFF.


    Illustration 1g03515340


    Illustration 2g03515737

  2. Remove bolts (1), (2), (3), and (4).

    Note: Cap all hose assemblies, with Tooling (D), and fittings that are disconnected o prevent fluid loss. This action will also keep contaminants out of the systems.



    Illustration 3g03515740

  3. Disconnect hose assemblies (5), (6), (7) and (8).


    Illustration 4g03515776

  4. Disconnect harness assemblies (9) and (10). Remove temperature sensor (11).


    Illustration 5g03515797

  5. Loosen clamp (14). Remove bolts (12) and remove pipe assembly (13). Remove the gasket (not shown).


    Illustration 6g03515816

  6. Remove nuts (19) and remove combustion head (18).

  7. Remove gasket (17), tube assembly (16), and gasket (15). Discard the gaskets.

    Note: The gaskets are for one time use only. Replace with new gaskets upon installation.

  8. If required, remove studs (20).


    Illustration 7g03515817

  9. Remove fittings (21) and (22).

  10. Remove spark plug (23) and remove fittings (24).


    Illustration 8g03515820

  11. Use Tooling (B) in order to remove O-ring seals (25) and (26) from harness assembly (10). Discard the O-ring seals.

Installation Procedure

  1. Install combustion head (18) in reverse order of removal.

    1. Apply Tooling (A) onto the threads of studs (20). Install the studs. Tighten studs (20) to a torque of 17 ± 2 N·m (150 ± 18 lb in).

    2. Apply Tooling (A) onto the threads of the studs and nuts (19). Tighten nuts (19) in a crisscross pattern to a torque of 23 ± 3 N·m (17 ± 2 lb ft). Tighten nuts (19) again in a crisscross pattern to a torque of 28 ± 3 N·m (21 ± 2 lb ft). Tighten nuts (19) again in a crisscross pattern to a torque of 28 ± 3 N·m (21 ± 2 lb ft).

      ------ WARNING! ------

      Use caution when you are using isopropyl alcohol. Avoid prolonged skin contact with isopropyl alcohol.

      Vapors may be harmful if inhaled. Use only in a well ventilated area. Do not smoke while using isopropyl alcohol.

      Isopropyl alcohol is flammable. Do not use near an open flame or near welding operations. Keep isopropyl alcohol away from heated surfaces exceeding 482°C (900°F).


      Note: This connection is an electrical connection and cannot be lubricated with a petroleum-based lubricant. Isopropyl alcohol is the only approved lubrication for this connection.

    3. Lubricate new O-ring seals (25) and (26) with Tooling (C) prior to installation.

    4. Tighten fitting (24) to a torque of 60 ± 6 N·m (44 ± 4 lb ft).

    5. Tighten fittings (21) and (22) to a torque of 30 ± 2 N·m (266 ± 18 lb in).

    6. Tighten spark plug (23) to a torque of 47 ± 4 N·m (35 ± 3 lb ft).

    7. Apply Tooling (A) to the threads of temperature sensor (11) and install the sensor. Tighten temperature sensor (11) to a torque of 45 ± 5 N·m (33 ± 3 lb ft).

    8. Check the coolant level. If necessary, refer to Operation and Maintenance Manual, "Coolant - Change" for the proper filling procedures.

    9. Perform the ARD ignition test. Refer to Troubleshooting Manual, "ARD Ignition - Test".

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