G3512H and G3516H Generator Set Engines Cylinder Head - Assemble Caterpillar

Assembly Procedure

Bridge Dowels

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Illustration 1	g06607004

1. Install dowels (16).

Adapter

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Illustration 2	g06606737

1. Install O-ring seal (14) and washer (15).
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   Illustration 3	g06606721

2. Apply Tooling (H) to adapter (13) and install adapter (13). Tighten adapter (13) to a torque of 180 ± 10 N·m (133 ± 7 lb ft).

Inlet and Exhaust Valve Guides

1. Thoroughly clean the bores in cylinder head (2) for the valve guides.
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   Illustration 4	g02738336

2. Apply clean engine oil to the valve guide prior to installation. Use Tooling (L), Tooling (K), and a suitable press to install inlet valve guides (11) and exhaust valve guides (12) (not shown) into cylinder head (2). The valve guides are at the correct height when Tooling (L) contacts Tooling (K). The valve guides should be pressed in with one smooth stroke.

   Note: Do not use a manual hydraulic press.

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   Illustration 5	g02738627

   Note: Coat valve (7) with clean engine oil prior to assembly.

3. Insert valves (7) into valve guides (12). If the valve does not move freely in the valve guide, repeat the step with another valve. If the second valve does not move freely in the valve guide, the valve guide must be removed and replaced.

Inlet and Exhaust Valve Seat Inserts

1. Thoroughly clean the cylinder head.

2. Reduce the temperature of the valve seat insert and maintain the temperature for approximately 8 hours.
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   Illustration 6	g02738839
   Cross section view of the bore for the valve seat insert. (17) Upper press fit (18) Lower press fit (19) Circumferential Coolant Passage

3. Apply a thin coating of Tooling (J) to areas (17) and (18).
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   Illustration 7	g02739064

4. Locate a valve seat insert (10) on Tooling (M)

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

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   Illustration 8	g02740019

5. Place valve seat insert (10) and Tooling (M) into the cylinder head.
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   Illustration 9	g02739138

6. Use Tooling (N) against Tooling (M) to install valve seat insert (10) into the cylinder head.

   Note: Do not use a hammer to install the valve seat inserts.

   Note: The amount of force that is required to install the valve seat insert is approximately 3175 kg (7000 lb). Do not exceed 5443 kg (12000 lb) of force to install the valve seat insert.

   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.

Inlet and Exhaust Valves

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Illustration 10	g06606568

Note: Coat valve (7) with clean engine oil prior to assembly.

1. Install valve (7).

2. Install washer (8), valve spring (4), valve spring (5), and rotocoil assembly (9) onto valve (7).
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   Illustration 11	g06607081

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   Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

3. Install Tooling (A) to compress valve spring (5) and valve spring (4).

4. Install retainer locks (6) onto valve (7).

5. Remove Tooling (A).

6. Repeat Step 1 through Step 4 to install the remaining valves.

Valve Lifters

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Illustration 12	g06606291

1. Install lifter guide springs (3) onto lifter assemblies (1).
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   Illustration 13	g06606272

   Note: The lifter assemblies are stamped "LEFT".

2. Install lifter assemblies (1) into cylinder head (2).

End By:

1. Install the cylinder head. Refer to "Cylinder Head - Remove and Install".