Service Information System Page 1 of 5
Disassembly and Assembly
C1.7, C1.8 and C2.4 Tier 4 Interim and EU Stage 3A Engines for Caterpillar Built
Machines
Media Number -UENR0128-11 Publication Date -01/08/2015 Date Updated -09/06/2016
i05243602
Cylinder Head - Install
SMCS - 1100-012; 1803-012
Installation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 4C-5592 Thread Lubricant 1
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
1. Thoroughly clean the gasket surfaces of the cylinder head and the cylinder block. Do not
damage the gasket 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 gasket surface of the cylinder head for distortion. Refer to Specifications, "Cylinder
Head" for more information. If the gasket surface of the cylinder head is distorted beyond
maximum permitted limits, replace the cylinder head.
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Illustration 1 g02726037
3. Inspect the dowels for damage. If necessary, replace the dowels in the cylinder block.
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Illustration 2 g02839433
4. Align new cylinder head gasket (4) with the dowels. Install cylinder head gasket (4) onto the
cylinder block.
Table 2
D1803-M-DI
V2403-M-DI
Gasket Dimension (Number) Piston Protrusion
15 0.475 to 0.525 mm (0.0187 to 0.0207 inch)
20 0.525 ± 0.575 mm (0.0207 ± 0.0226 inch)
25 0.575 ± 0.625 mm (0.0226 ± 0.0246 inch)
30 0.625 ± 0.675 mm (0.0246 ± 0.0266 inch)
35 0.675 ± 0.725 mm (0.0266 ± 0.0285 inch)
Note: Before you replace the cylinder head gasket (4), record the mark (5) on the cylinder head
gasket of the engine. Then replace a cylinder head gasket with same mark.
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Illustration 3 g02725867
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5. Use a suitable lifting device to lift cylinder head. The weight of the cylinder head is
approximately 27 kg (60 lb).
6. Align cylinder head (1) with the cylinder block. Install cylinder head (1) to the cylinder block.
Note: Ensure that the cylinder head is correctly positioned on the dowels.
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Illustration 4 g02725865
7. Clean and inspect bolts (2).
8. Lubricate the threads and the shoulder of bolts (2) with Tooling (A).
9. Install bolts (2) to cylinder head (1).
10. Connect hose assembly (3).
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Illustration 5 g02726145
11. Tighten bolts (2) to a torque of 93 to 98 N·m (69 to 72 lb ft) in the numerical sequence. Refer to
Illustration 5. Repeat the torque procedure in the same sequence.
12. Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, "Cooling
System Coolant - Change" for the correct filling procedure.
End By:
a. Install the glow plugs.
b. Install the fuel lines.
c. Install the rocker arm shaft and pushrods.
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