3618 Marine 2MW00001-UP (SEBP3774 - 107) - Systems & Components

9/3/2018 3618 Marine 2MW00001-UP(SEBP3774 - 107) - Systems & Components
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Welcome: q631tm
Product: MARINE ENGINE
Model: 3618 MARINE ENGINE 2MW
Configuration: 3618 Marine 2MW00001-UP
Reuse And Salvage Guidelines

Reuse and Salvage for Cylinder Head Assemblies {1100, 1101, 1103, 1104, 1105, 1106, 1108, 1109, 1115, 1117, 1121, 1124,
1125}
Media Number -SEBF8162-38 Publication Date -15/01/2015 Date Updated -29/08/2018
Caterpillar: Confidential Yellow
i07398238
Reuse and Salvage for Cylinder Head Assemblies {1100, 1101, 1103, 1104, 1105, 1106, 1108,
1109, 1115, 1117, 1121, 1124, 1125}
SMCS - 1100; 1101; 1103; 1104; 1105; 1106; 1108; 1109; 1115; 1117; 1121; 1124; 1125
Caterpillar Products
All Cat Engines
Introduction
Table 1
Revision Summary of Changes in SEBF8162
38 Added Rottler information.
37 Added Exhaust Stud and Bolt Removal Tools.
Combined information from SEBF8061, SEBF8106, SEBF8129, SEBF8155, SEBF8218, SEBF8229, SEBF8270, SEBF8281,
36 SEBF8373, SEBF8374, SEBF8375, SEBF8376, SEBF8382, SEBF8737, SEBF8819, SEBF9006, SEBF9045, SEBF9137,
SEBF9182, SEBF9193, SEBF9237, SEBF9313, added 61 part numbers and repaired 66 pixelated illustrations.
© 2018 Caterpillar All Rights Reserved. This guideline is for the use of Cat dealers only. Unauthorized use of this document or the proprietary
processes therein without permission may be violation of intellectual property law.
Information contained in this document is considered Caterpillar: Confidential Yellow.
This Reuse and Salvage Guideline contains the necessary information to allow a dealer to establish a parts reusability program. Reuse and
salvage information enables Caterpillar dealers and customers to benefit from cost reductions. Every effort has been made to provide the most
current information that is known to Caterpillar. Continuing improvement and advancement of product design might have caused changes to
your product which are not included in this publication. This Reuse and Salvage Guideline must be used with the latest technical information
that is available from Caterpillar.
For technical questions when using this document, work with your Dealer Technical Communicator (TC). To report suspected errors,
inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System (SIS Web) interface.
Canceled Part Numbers and Replaced Part Numbers

This document may not include canceled part numbers and replaced part numbers. Use NPR on SIS for information about canceled part
numbers and replaced part numbers. NPR will provide the current part numbers for replaced parts.
Important Safety Information
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Illustration 1 g02139237
Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or
precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert
to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly. Safety
precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death
could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If a tool, a procedure, a work method,
or operating technique that is not recommended by Caterpillar is used, ensure that it is safe for you and for other people to use. Ensure that the
product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are
used.
Improper operation, lubrication, maintenance or repair of this product

can be dangerous and could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on

this product, until you have read and understood the operation,
lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death
could occur to you or to other persons.
The hazards are identified by the safety alert symbol which is followed by a signal word such as danger, warning, or caution. The "WARNING"
safety alert symbol is shown below.
This safety alert symbol means:
Pay attention!
Become alert!
Your safety is involved.
The message that appears under the safety alert symbol explains the hazard.
Operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The safety information in this
document and the safety information on the machine are not all inclusive. Determine that the tools, procedures, work methods, and
operating techniques are safe. Determine that the operation, lubrication, maintenance, and repair procedures will not damage the
machine. Also, you must determine that the operation, lubrication, maintenance, and repair procedures will not make the machine
unsafe.
The information, the specifications, and the illustrations that exist in this guideline are based on information which was available at the time of
publication. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These
changes can affect the service that is given to the product. Obtain the complete, most current information before you start any job. Caterpillar q631tm
dealers can supply the most current information. Caterpillar: Confidential Yellow
Summary
This guideline gives the measurements and salvage specifications for the inspection of a used or reconditioned cylinder head that can be used
again. It also contains information to rebuild a cylinder head. Two suggested layouts for the area of rebuild for cylinder heads and a flow chart is
provided to illustrate the recommended steps in the process for the rebuild.
If a cylinder head meets the specifications in this guideline and other applicable guidelines, then the head assembly can be expected to give
normal performance in the same application until the next overhaul.
Before reusing a cylinder head, check for leaks, cracks, and flatness. All cylinder head components must meet the recommended specifications
in the guideline before being reused.
This guideline should be used with the specific guidelines that are listed in the Reference section.
When the cylinder head will not be inspected within 1 hour, the cylinder head should be coated with a rust or corrosion inhibitor or coated with
clean engine oil.
Note: This guideline covers the inspection of valve seats and replacing the valve seats. Some valve seats cannot be machined. Refer to Table
59 to determine if a valve seat can be machined. Specialized manufacturing processes were used on these parts. Machining these parts
will significantly decrease the life of the engine.
NOTICE
The valve projection and recession specifications within this guideline
are for measurement of wear from newly manufactured cylinder heads.
Due to the multiple machining steps and compounding of tolerances in
rebuilt cylinder heads, some rebuilt heads (REMAN or dealership
rebuilds) may not meet the valve projection and recession
specifications found within this document.
Service Letters and Technical Information Bulletins
NOTICE
The most recent Service Letters and Technical Information Bulletins
that are related to this component shall be reviewed before beginning
work. Often Service Letters and Technical Information Bulletins
contain upgrades in repair procedures, parts, and safety information
that pertain to the parts or components being repaired.
References
Table 2
References
Media
Title
Number
NEHS0675 Tool Operating Manual, "Using the 143-2099 Sleeve Replacement Tool Group on 3114, 3116, and 3126 Engines"
Tool Operating Manual, "188-3922 Broken Exhaust Bolt and Stud Removal Group for 3114, 3116, 3126, 3126B, 3176,
, NEHS0787
3176B, C-10, and C12 Engines"
, SEBD1757 Service Magazine, "Cylinder Head Water Directors No Longer Needed In Direct Injection Engines "
, SEBF2119 Reuse and Salvage Guideline, "Thermal Spray Procedures for Cylinder Head"
, SEBF8002 Reuse and Salvage Guideline, "Reuse & Salvage for Valvetrain Components"
, SEBF8061 Reuse and Salvage Guideline, "Engine Precombustion Chamber and 3400 Series Engine Direct Injection Nozzle Adapters"
, SEBF8076 Reuse and Salvage Guideline, "Specifications to Salvage Cylinder Block Contact Surfaces"
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, SEBF8187 Reuse and Salvage Guidelines"Standardized Parts Marking Procedures" Caterpillar: Confidential Yellow
SEBF8301 Reuse and Salvage Guideline, "Inspection and Reuse of Critical Fasteners Used in All Engines"
, SEBF8302 Reuse and Salvage Guideline, "Reuse Specifications for 3600 Combustion Gaskets"
, SEBF8882 Reuse and Salvage Guideline, "Using Lock-N-Stitch Procedures for Casting Repair"
, SEBF9238 Reuse and Salvage Guideline, "Fundamentals of Arc Spray for Reconditioning Components"
, SEHS9031 Special Instructions, "Storage Procedure for Caterpillar Products"

, SEHS9120 Special Instructions, "Using the 4C-4462 Sleeve Replacement Tool"
, SEBF9240 Reuse and Salvage Guideline, "Fundamentals of Flame Spray for Reconditioning Components"
, SEHS9246 Special Instructions, "Using 9U-6860 Tool Group to Replace Unit Injector Sleeves"
, SEHS9416 Special Instructions, "Using the 6V-7770 Valve Guide Kit and 6V-7755 Spring Seat Guide"
, SEHS9498 Special Instructions, "Using the 9U-5383 Vacuum Tester"
,
Special Instructions, "Instructions For The Use Of 5P-6518 Fixture Group - Parts Reusability"
SMHS6998
,
Special Instruction, "Use of 6V-4805 Valve Seat Extractor Tool Group"
SMHS7072
SMHS7935 Special Instruction, "Using 5P-0733 Tool Group for Bridge Dowel Repair - 3400 Engines"
SMHS8276 Special Instruction, "Repair of Precombustion Chamber and Direct Injection Adapter Seating Surfaces"
SMHS8277 Special Instruction, "Use of 6V-7770 Tool Kit and 6V-7755 Adapter."
Tooling and Equipment
NOTICE
Failure to follow the recommended procedure or the specified tooling
that is required for the procedure could result in damage to
components.
To avoid component damage, follow the recommended procedure using

the recommended tools.
Table 3
Part Number Description
1D-4720 Nut 5/8-11 NC

1P-0510 Driver
1P-1855 Retaining Ring Pliers

1P-3042 Tap
1S-0258 Hammer (soft tip)

1U-5230 Hand Pump
1U-6685 Valve Guide and Seat Tool Group
1U-8869 Dial Indicator

1U-9168 Valve Guide Collar
1U-9169 Valve Guide Driver

1U-9170 Valve Seat Driver
3P-1565 Collet Clamp

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3P-1568 Dial Indicator Caterpillar: Confidential Yellow
4C-3845 Grinding Wheel
4C-4462 Repair Tool Group

4C-5552 Large Bore Brush
4C-5590 Anti-Seize Compound

4C-5593 Anti-Seize Compound
4C-4707 Dial Gauge

4C-4709 Grinding Wheel
4C-4710 Pilot Wrench

4C-4711 Diamond Dresser
4C-4804 Penetrant Oil
4C-8624 Mandrel
4C-8629 Mandrel
4C-8719 Shank
4C-8769 Valve Seat Driver
4C-9442 Flashlight
4C-9507 Retaining Compound
4C-9734 Valve Guide Gauge
5P-1729 Valve Guide Bushing

5P-2396 Bushing
5P-3413 Pipe Sealant

5P-3536 Valve Guide Gauge
5P-4156 Indicator Base

5P-4160 Indicator Contact Point
5P-6518 Dial indicator Fixture
5P-7324 Plug
5P-7333 Repair Tool
5P-8400 Lifting Bracket

5P-8700 Lifting Bracket
5P-9718 Holder 178.0 mm (7.00 inch)

5P-9709 Abrasive Disc 127.0 mm (5.00 inch)
5S-1330 Valve Spring Compressor
6V-0087 Valve Stem Gauge Group

6V-2010 Polishing Stone
6V-2012 Micrometer Depth Gauge

6V-2032 Adapter
6V-2033 Brush
6V-2034 Micrometer Adapter
6V-4197 Grinder Base

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6V-4198 Grinder Caterpillar: Confidential Yellow
6V-4801 Dressing Stone
6V-4802 Grinding Wheel

6V-4805 Valve Seat Extractor Tool
6V-4876 Lubricant
6V-6640 Sealant
6V-7047 Hydraulic Cylinder
6V-7058 Plug Gauge

6V-7059 Micrometer
6V-7068 Valve Guide Gauge


6V-7926 Dial Indicator
6V-9050 Stud Removal Group
7B-0337 Surface Plate

7M-3975 Valve Guide Driver
8C-8422 Sealant
8H-8581 Feeler Gauge
8S-3158 Feeler Gauge

8S-2257 Eye Loupe
8S-3158 Indicator Gauge
8T-2674 Valve Seat Driver

8T-2676 Valve Guide Driver
8T-2781 Valve Guide Support Pedestal

8T-2998 Lubricant
8T-3096 Hand Tap
8T-5096 Dial Indicator Group

9S-3263 Thread Lock Compound
9S-9087 Tool Cabinet
9U-5096 Bridge Assembly

9U-5099 Seat Puller Group
9U-5383 Vacuum Tester
9U-6895 Valve Guide Driver
9U-6399 Valve Guide Installation Gauge

9U-6401 Valve Guide Wear Gauge
9U-6460 Guide Collar
9U-6860 Injector Sleeve Tool

9U-6891 Injector Tool Group
9U-6894 Guide Collar
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9U-6895 Valve Guide Driver Caterpillar: Confidential Yellow

9U-7237 Brush Extension
9U-7244 End Brush

124-2946 Lifting Bracket As
124-9057 Guide Collar
130-1449 Valve Seat Puller
131-8362 Reamer
134-5506 Pilot
134-5507 Pilot
134-5508 Pilot
138-7573 Link Bracket
138-7575 Link Bracket
143-2099 Sleeve Replacement Tool Group
147-1642 Angle Gauge

147-1643 Angle Gauge
147-2285 Valve Gauge
151-0968 Cordless Drill

151-4832 Remover Assembly - Sleeve
151-8689 Seal Template
162-5791 Shop Towels
163-3951 Blast Media

166-7441 Valve Seat Extractor Tool
173-5524 Guide Collar
187-6273 Repair Tool

188-3922 Broken Exhaust Bolt and Stud Removal Tool
222-3061 Air Drill
222-3071 Angle Grinder
222-3074 Wheel Grinder

222-3121 Penetrating Oil
Microscope, Pocket
262-8390
40x
263-7184 Crack Detection Kit

283-0052 Valve Guide Driver
284-1503 Valve Guide Collar
288-4209 Paper Towel
316-1496 Hydraulic Cylinder

359-4208 Valve Insert Removal Tool
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359-4286 Collet Assembly
359-4287 Drawbar
361-0074 Lower Side
362-4253 Depth Micrometer Kit
362-9108 Insert Tool-Valve Seat
364-3081 Installation Guide

367-9109 Digital Caliper
384-2802 Pilot
384-2804 Indicator Gauge Group

386-3364 Straight Edge Ruler
415-4055 Ultrasonic Tool Group
420-5317 Suitable Cribbing

Digital Caliper
423-4373 0.0 - 203.2 mm
(0.00 - 8.00 inch)
Micrometer, External
431-4150
25 mm (1 inch)
441-0714 Spring Tester
459-0184 UV Lamp Group

Micrometer, Outside
473-8690
0.00 - 4.00 inch
Micrometer, Outside
473-8691
2.00 - 6.00 inch
Micrometer, Outside
473-8691 50.8 - 152.4 mm
(2.00 - 6.00 inch)
Micrometer, Outside
473-8692
152.4 - 304.8 mm (6.00 - 12.00 inch)
482-0188 Valve Guide Stop Collar
482-0190 Valve Guide Finish Reamer

483-7533 Valve Guide Stop Collar
483-7534 Valve Guide Reamer
533-1152 Broken Exhaust Bolt and Stud Removal Plate (C6.6 Drill Guide)
533-1153 Broken Exhaust Bolt and Stud Removal Plate (C4.4 Drill Guide)
533-1155 Broken Exhaust Bolt and Stud Removal Tool Group (C7.1 Drill Guide)
FT-0806 Bench
FT-1656 Thickness Gauge

FT-1674 Plug Gauge
FT-1741 Valve Stem Protector
FT-1753 Vacuum Tester
FT-1766 Adapter q631tm

- Plug Gauges
- Hydraulic Press
- Valve Guide Removal Tool

- 90° holding block with a collet
- Loctite 242
Standardized Parts Marking Procedure

Reference: SEBF8187Reuse and Salvage Guidelines, "Standardized Parts Marking Procedures".
The code is a Cat standard and is used to record the history of a component. The code will identify the number of rebuilds and hours at the time
of each rebuild. This information is important and should be considered for any decision to reuse a component.
Ensure that the mark is not covered by a mating part. Use a metal marking pen to mark the code onto the component.
NOTICE
Do not use numbering stamp punches to mark internal components.
The impact from striking the stamp will cause an abnormal stress riser.
The added stress riser may cause premature part failure.
DO NOT use numbering stamp punches to mark internal components.
The procedure for marking components is a Cat standard. This code is helpful when the machine is sold into a different territory after the first
rebuild. During an overhaul, the previous code of a part should never be removed.
Example 1
Typical Example
Illustration 4 shows code (1-15). The first number (1) indicates that the gear had been rebuilt once. The second number (15) indicates that there
were 15,000 hours on the gear at the time of rebuild. q631tm
Example 2
Typical Example
Illustration 5 shows code (1-12) and code (2-10). Code (2-10) represents the information from the second rebuild. The first number (2) indicates
that the gear had been rebuilt twice. The second number (10) indicates that 10,000 hours accumulated on the gear between the first and second
rebuild.
Note: Add the first and second rebuild hours to obtain the total number of hours for the gear in Illustration 5. In this example, the gear has a
total of 22,000 hours.
Recommended Layouts for the Shop

A well designed shop area contributes to more efficient rebuilds. Two suggested layouts for the shop have been provided in this guideline.
Choose the layout for rebuilding that best suits your needs.
The area for the rebuild should accommodate the staging of the parts while the cylinder head components are being processed. Enough space
should be available to rebuild the cylinder head without any interference. The area should have access from a jib crane to provide an effective
way of moving the components.
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Flow Chart for the Rebuild
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This flow chart provides a quick reference to the steps for rebuilding a cylinder head. For detailed information, refer to "Process for Rebuilding
Cylinder Heads" section.
Process for Rebuilding Cylinder Heads

The area of the shop for disassembly should be located next to the general cleaning area. Locating the area for disassembly next to the cleaning
area will reduce the effort in transporting the disassembled parts to the cleaning area. The area for disassembly and the area for cleaning should
be separated from the area for the rebuild by a wall to prevent contamination to exposed parts.
(1) Lifting bar is installed. q631tm
(2) Tape covering the exhaust ports. Caterpillar: Confidential Yellow
Lifting bar is installed on a 3500 Engine.
Specifications for the lifting bar for a 3500 Engine
1. Remove the cylinder head from the engine.
Efficiency in the process for rebuilding a cylinder head begins with the removal of the head or heads from the engine. The cylinder heads
can be removed in groups on engines with multiple cylinder heads such as the 3500 Series Engines if a lifting bar is fabricated. It is more
efficient to remove multiple cylinder heads simultaneously instead of removing each head individually. Reconditioning cylinder heads in
groups is more efficient than reconditioning cylinder heads individually.
Remove the cylinder head with the exhaust manifolds, intake manifolds, and elbows to reduce the overall time of engine rebuild. The
entire assembly can be disassembled and reconditioned while the engine is being reconditioned. This procedure will enable the
reconditioning of the cylinder head assembly to be synchronized with the reconditioning of the engine so that all the parts can be ready
for engine assembly at the same time.
NOTICE
Prior to precleaning, remove or protect any component that could be
damaged by the cleaning solution.
2. Clean the cylinder head.
Use a hot spray wash cabinet to remove the dirt, oil, and grease from the cylinder head.
The washer should have the option for automatic washing and the option for manual washing. Caustic solutions are effective for cleaning q631tm
the ferrous parts. Do not use caustic solutions to clean the nonferrous parts. Soaps that are safe for aluminum should be used
Caterpillar: for theseYellow
Confidential
parts.
The washer should contain a rotating table. The automatic cycle will wash most of the soap solution at the end of the cycle. The option for
the manual wash is needed to manually wash the parts after the automatic wash is complete.
3. Inspect the cylinder head.
Visually inspect the cylinder head for obvious defects that will cause the casting to be scrapped or replaced.
(1) 9S-9087 Tool Cabinet
(2) FT-0806 Bench
Adjustable work bench for cylinder heads
Adjustable work bench for cylinder heads that can be fabricated
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4. Disassemble the cylinder head.
Disassembly requires the removal of all components from the cylinder head casting. Refer to the specific Service Manual for the required
tooling and procedures for this operation.
The disassembly should be done on a work bench at a comfortable height. The work area must be large enough to accommodate cylinder
heads when the cylinder heads are removed in groups. Make sure that the work area has enough space to disassemble the cylinder heads
without interference.
Use a work bench that enables the cylinder head to be rotated during the process of rebuild. The work bench for rebuilding cylinder heads
should be equipped with air supply, racks for tooling, and cabinets for all required tooling and parts. 9S-9087 Tool Cabinet and FT-0806
Bench are recommended.
Overhead lights and local lights are recommended. These lights provide enough source of light to visually inspect the cylinder head and
components. Overhead lights and local lights prevent shaded areas. Fluorescent lights above the work bench also provide the necessary
lighting for inspection of most of the components.
5. Remove the exhaust manifold gaskets.
Abrasive buffing or blasting may be required to remove the exhaust manifold gaskets and the heavy carbon from the cylinder head. High
temperatures make cleaning some areas of the cylinder head difficult. Cleaning these areas before washing often eliminates excess cycles
in the washer and contamination of components later in the process of rebuild.
Typical basket for cleaning small parts
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Typical basket for cleaning small parts
Typical basket for cleaning small parts that can be used in a high-pressure wash
6. Separate the parts into wire baskets that can be put into a hot spray wash cabinet or a tank of solvent as the cylinder head is disassembled.
These baskets can be used in high pressure cleaning systems or low pressure cleaning systems. Choose a basket that fits the application.
The most effective baskets allow each part to have the direct impact of the cleaning solution. Direct impact of the cleaning solution
eliminates a second cycle of cleaning. Baskets should be transported with a crane rather than a lift truck to reduce time of transport, labor,
and space in the shop.
Design of a fixture for cleaning valves
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Valves in the fixture
a. Clean all the components.
Components of the cylinder head such as the valves, valve lifters, valve springs, keepers, valve rotators, and other parts can be
cleaned in a separate system from the cylinder head casting. Clean these parts prior to inspection to allow easier identification of
defects unless obvious defects are visible.
Cleaning fixtures can be designed to work with cleaning equipment that will result in a more efficient cleaning and a better quality
of rebuild.
Various different equipment is available for cleaning small parts.
b. Inspect each part for reusability.
The valves, valve springs, lifters, and rotators must be inspected.
c. Grind the valves to determine reusability.
All valves must be ground to ensure proper seating between the valve and the insert.
Rack for the cylinder head that will fit in a washer
Rack with a cylinder head
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Cradle for the cylinder head with a stand for a washer
7. Clean the cylinder head casting in a hot spray wash cabinet.
Note: The most effective washers for cleaning cylinder heads are hot spray wash cabinets.
8. Remove the gaskets and carbon deposits from the cylinder head.
Remove the gaskets and joint seals immediately after washing. The gaskets will typically be loosened from the wash. Abrasive cleaning
will then remove the gaskets. The gaskets can be removed easily if the gaskets are scraped immediately after the cycle of wash.
The carbon deposits may need to be removed by hand after the first cycle of cleaning. A second cycle of cleaning may then be necessary
to rinse the remaining carbon deposits.
Flush the internal passages. Blow out the internal passages and the blind cavities. Apply a rust inhibitor to the cylinder head after rinsing.
Serdi SPT1500 Cylinder Head Pressure Tester
9. Inspect and check the cylinder head casting.
Make sure that the cylinder head meets the specifications for thickness and criteria for reusability in the specific reusability guideline for
the cylinder head.
Pressure test the cylinder head casting for internal cracks when the cylinder head is tested for integrity. The operating conditions and
temperatures of a cylinder head need to be simulated during the pressure test in a heated tank under pressure. Steel plates must be
fabricated to cover the openings in the head during testing. Gaskets, seals, and fittings are needed to connect the air supply.
The tank must be large enough to hold the largest cylinder head that will be tested. The dimensions in Table 4 are reference dimensions
for the tank for the corresponding engine models. The water in the tank needs to be heated to a temperature of 82 °C (180.0 °F). A
minimum air supply of 415 kPa (60.0 psi) is required for the testing. q631tm
Note: The dimensions in Table 4 are not reconditioning dimensions for cylinder heads. Use the dimensions to determine the correct size
of a tank for the pressure test.
Table 4
Dimensions for Cylinder Heads
Model Length Width Height
1273.0 mm 740.0 mm 595.0 mm

D348
(50 inch) (29 inch) (23.4 inch)
387.0 mm 344.0 mm 325.0 mm

D353E
(15.2 inch) (13.5 inch) (12.8 inch)
109.0 mm 146.0 mm 179.0 mm
D399
(4.3 inch) (5.7 inch) (7.0 inch)
848 mm 305 mm 158 mm

C7
(33.4 inch) (12.0 inch) (6.2 inch)
871 mm 345 mm 163 mm

C9 2007
(34.3 inch) (13.6 inch) (6.4 inch)
C9 890 mm 300 mm 130 mm
C-9 (35.0 inch) (11.8 inch) (5.1 inch)
C-10 972 mm 320 mm 105 mm

C-12 (38.3 inch) (12.5 inch) (4.1 inch)
997 mm 395 mm 165 mm
C11
(39.3 inch) (15.6 inch) (6.5 inch)
972 mm 397 mm 165 mm

C13
(38.3 inch) (15.6 inch) (6.5 inch)
C15
C-15
C16 1118 mm 360 mm 250 mm
C-16 (44.0 inch) (14.2 inch) (9.8 inch)
C18
C-18
C27 1185 mm 455 mm 250 mm
C32 (46.7 inch) (18.0 inch) (9.8 inch)
1185 mm 320 mm 114 mm

C30
(46.7 inch) (12.5 inch) (4.5 inch)
430.0 mm 300.0 mm 208.0 mm

C175
(16.93 inch) (11.81 inch) (8.19 inch)
478 mm 216 mm 85 mm
3044C
(18.8 inch) (8.5 inch) (3.3 inch)
343 mm 205 mm 100 mm

3066
(13.5 inch) (8.0 inch) (3.9 inch)
590 mm 252 mm 105 mm
3114
(23.2 inch) (9.9 inch) (4.1 inch)
840 mm 252 mm 105 mm

3116
(33.0 inch) (9.9 inch) (4.1 inch)
840 mm 252 mm 105 mm

3126
(33.0 inch) (9.9 inch) (4.1 inch)
848 mm 285 mm 160 mm
3126E
(33.4 inch) (11.2 inch) (6.3 inch)
3145
632 mm 290 mm 140 mm
3150
(24.9 inch) (11.4 inch) (5.5 inch) q631tm
3160
3176 972 mm 320 mm 130 mm
(38.3 inch) (12.6 inch) (5.1 inch)
972 mm 320 mm 130 mm

3196
(38.3 inch) (12.6 inch) (5.1 inch)
632 mm 290 mm 140 mm
3204
(24.9 inch) (11.4 inch) (5.5 inch)
632 mm 290 mm 140 mm

3208
(24.9 inch) (11.4 inch) (5.5 inch)
662 mm 350 mm 100 mm

3304
(26.1 inch) (13.8 inch) (3.9 inch)
960 mm 375 mm 100 mm
3306
(37.8 inch) (14.8 inch) (3.9 inch)
662 mm 330 mm 100 mm

G3304
(26.1 inch) (13.0 inch) (3.9 inch)
960 mm 350 mm 100 mm

G3306
(37.8 inch) (13.8 inch) (3.9 inch)
3304B
3306B 662 mm 350 mm 100 mm
3306BH (26.1 inch) (13.8 inch) (3.9 inch)
3306C
3406
1118 mm 368 mm 114 mm
3406B
(44.0 inch) (14.5 inch) (4.5 inch)
3406C
1118 mm 345 mm 250 mm
3406E
(44.0 inch) (13.6 inch) (9.8 inch)
1118 mm 368 mm 114 mm

G3406
(44.0 inch) (14.5 inch) (4.5 inch)
3408
3408B
845 mm 320 mm 114 mm
3408C
(33.3 inch) (12.6 inch) (4.5 inch)
3408E
G3408
3412
3412C 1185 mm 320 mm 114 mm
3412D (46.7 inch) (12.6 inch) (4.5 inch)
3412E
1118 mm 345 mm 250 mm

3456
(44.0 inch) (13.6 inch) (9.8 inch)
3508
268 mm 408 mm 145 mm
3508B
(10.6 inch) (16.0 inch) (5.7 inch)
3508C
3512 268 mm 455 mm 145 mm
G3512 (10.6 inch) (18.0 inch) (5.7 inch)
3512B 268 mm 408 mm 145 mm

3512C (10.6 inch) (16.0 inch) (5.7 inch)
268 mm 455 mm 145 mm
3516
(10.6 inch) (18.0 inch) (5.7 inch)
3516B 268 mm 408 mm 145 mm

3516C (10.6 inch) (16.0 inch) (5.7 inch)
268 mm 408 mm 145 mm

3524B
(10.6 inch) (16.0 inch) (5.7 inch)
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3606 750 mm 420 mm 280 mm Caterpillar: Confidential Yellow
(29.5 inch) (16.5 inch) (11.0 inch)
750 mm 420 mm 280 mm

3608
(29.5 inch) (16.5 inch) (11.0 inch)
750 mm 420 mm 280 mm

3612
(29.5 inch) (16.5 inch) (11.0 inch)
750 mm 420 mm 280 mm
3616
(29.5 inch) (16.5 inch) (11.0 inch)
615 mm 420 mm 280 mm

3618
(24.2 inch) (16.5 inch) (11.0 inch)
Procedure for the Pressure Test

If the engine contains a water jacket, a fuel passage, or an oil passage, the water jacket, the fuel passage, and the oil passage must be checked
separately.
1. Heat the water in the tank to a minimum temperature of 82 °C (180.0 °F).
2. Cover the openings on the cylinder head with a steel plate and seals or gaskets.
3. Attach a fitting to the plate to connect the air supply.
4. Use a hoist and a lift to submerge the cylinder head in the tank so that the water level covers all surfaces.
5. Apply a constant air pressure of 415 kPa (60.0 psi) minimum to the submerged cylinder head for one hour.
6. Observe the submerged cylinder head for any signs of air bubbles during the one hour test.
Note: If no air bubbles are observed during the test, the cylinder head does not have any internal leaks.
7. Coat the cylinder head with a rust preventive to prevent rusting.
8. Inspect the valves, valve seat inserts, and the valve guides.
Fabricated hydraulic puller for valve seat inserts
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Pulling a valve seat insert with a fabricated puller
9. Remove the valve seat inserts from the cylinder head.
10. Inspect the valve seat inserts for reusability. If the valve seat insert is cracked or damaged, replace the valve seat insert.
Note: A damaged valve seat insert may cause engine failure.
11. Install the valve seat inserts into the cylinder head.
Serdi 100 Valve Seat and Guide Cutting Machine
12. Machine the valve seat inserts or the bores for the valve seat inserts.
Note: Some valve seats cannot be machined. Specialized manufacturing processes were used on these parts. Machining these parts
will significantly decrease the life of the engine.
Cutting tools for the valve seats are more effective than grinding in several ways. Cutters are faster and more accurate than grinding
stones. Cutters maintain the dimensions longer. However, cutters are more expensive.
Stones for grinding wear every time of use. Stones for grinding periodically need to be shaped resulting in additional labor for each job
and one more step for error. Grinding produces dust and debris which adds more contamination to the process of reconditioning.
The cylinder head must be protected from corrosion, external damage, and dirt after cleaning if the cylinder head is stored.
13. Assemble the cylinder head.
Assemble the cylinder head after all necessary parts were replaced and all components were thoroughly inspected, tested, cleaned, and
salvaged.
14. Measure the projection of the valve.
15. Perform a vacuum test on the valve seats.
The vacuum test will identify a good seal between the valve and the valve seat. The cylinder head must be assembled before the vacuum
test can be performed. q631tm
Procedure to Pressure Test the Cylinder Head on 3600, G3600, and C280 Engines
The head must be checked for cracks after everything has been removed from the head. A fabricated plate can be made to block the water
passages during the air test. The air pressure should be set to 300 kPa (43.5 psi). It is not necessary to remove the valve guides, or the bridge
dowels during the testing procedure.
Refer to Table 5 for the descriptions of callouts.
Table 5
Required Part for Pressure Testing a Cylinder Head
Callout Quantity Description
1 1 Combustion surface plate
2 1 Rubber gasket for combustion surface plate

3 4 Bolt, 3/4-10 thread by 343 mm (13.5 inch) long
4 4 Spacer
5 4 Nut, 3/4-10 thread

6 1 Air inlet plate
7 1 Rubber gasket for air inlet plate
8 3 Bolt, 3/8-16 thread by 32 mm (1.3 inch)

9 3 Flat washer 9.6 mm (0.38 inch) diameter hole
10 1 Connection for shop air
1. Fabricate the parts shown in illustrations 29 through 33.
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Combustion surface plate made from mild steel
Rubber gasket for the combustion surface plate.
Spacer for bolt
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Air inlet plate
Rubber gasket for air inlet plate
2. Install bolts (3) through plate (1) and rubber gasket (2). Set plate (1) on a flat surface.
3. Lower the cylinder head onto the bolts until the bottom surface of the head is flat against the rubber gasket. Center the head on the plate
and the gasket.
4. Install spacers (4) and nuts (5) on the top surface of the head.
5. Tighten four nuts (5) to seal the bottom combustion surface.
6. Install rubber gasket (7), air inlet plate (6), bolts (8), and flat washers (9) to the water outlet port on the top surface of the cylinder head.
7. Tighten three bolts (8) to seal the air inlet plate.
8. Install the fitting to the air inlet plate and attach the hose for the shop air.
9. The recommended air pressure is 300 kPa (43.5 psi).
10. Lower the cylinder head into a tank of water. Look for signs of a leak. Care should be taken to make sure that the signs of air bubbles are
not from a leaking gasket or air connection.
11. Remove all water from the internal surfaces and the external surfaces of the cylinder head. If the head will be stored, coat all the surfaces
with a coating of rust preventive. It is important to protect the bottom surface of the head and the top surface of the valve train from
rusting or damage.
Replacement Parts
Consult the applicable Parts Identification manual for your engine.
When replacement parts are required for this product Caterpillar

recommends using Caterpillar replacement parts or parts with
equivalent specifications including, but not limited to, physical
dimensions, type, strength and material.
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Failure to heed this warning can lead to premature failures, product Caterpillar: Confidential Yellow
damage, personal injury or death.
General Procedures
Use the following guidelines when you are inspecting and reconditioning a cylinder head.
Clean the cylinder head. Remove the gasket material.
Measure the cylinder head thickness.
Measure the flatness of the combustion area.
Inspect the combustion area for cracks or leaks.
Check the combustion area for damage and/or erosion.
Inspect the valve seats, and valve guides for damage.
Recondition the components that are requiring salvage and replace the parts that do not meet the guidelines.
Measure the projection and the recession of the valves.
After you have assembled the cylinder head, you will need to run a vacuum test of the valves for the correct sealing.
Protect the head against storage or shipping damage.
Nomenclature
(1) Lock
(2) Rotocoil
(3) Outer Spring
(4) Inner Spring
(5) Jacket Seal
(6) Spring Seat
(7) Guide
(8) Valve q631tm
Nomenclature for the 3200 Engine
(1) Intake port
(2) Surface of the valve cover gasket
(3) Seat of the valve spring
(4) Post for the valve guide
(5) Face of the Exhaust port
(6) Exhaust port
(7) Valve seat insert
(8) Combustion area
(9) Face of the Intake port
Nomenclature for the 3400 Engine except 3406E
(1) Intake port
(3) Seat of the valve spring
(4) Post for the valve guide
(5) Face of the Exhaust port
(6) Exhaust port
(7) Valve seat insert
(8) Combustion area
(9) Face of the Intake port
(10) Bridge dowel
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(1) Lock
(2) Rotocoil
(3) Outer Spring
(4) Inner Spring
(5) Washer
(6) Guide
(7) Head
(8) Valve
(1) Intake port (front or right side)
(4) Valve guide
(6) Exhaust port (rear or left side)
(8) Combustion area
(10) Bridge dowel
(11) Bore of the roller lifter
Nomenclature for the C175 Cylinder Head
(1) Intake port
(2) Surface for the valve cover gasket
(4) Valve guide
(6) Exhaust port
Reconditioning Factors
Use the information that is below for factors on common problems that can occur when you are reconditioning the cylinder head.
The compression ratio is the critical factor that needs to be considered when the cylinder head is reconditioned. The compression ratio
increases as the material is removed from the cylinder head.
For minor erosion of 0.28 mm (0.011 inch) that is on the surface of the cylinder head, shave the area or resurface the area. In all the
following reconditioning procedures, remove the minimum material that is necessary to make the repair. q631tm
To find the amount of wear, a comparison can be made between the measurement of a worn part and the specifications of a new part. A
part that is worn may be safe to use if an estimate of the remainder of service life of the part can be made. If this estimate shows that a
short service life is expected, replace that part.
Valve stems with diameters below the minimum or valve guides with diameters above the maximum can be used if the clearance
specification is determined by subtracting the “use again minimum stem diameter” from the “use again valve guide diameter”.
Several factors affect the amount of material that can be removed from the surface of a component. The factors for removing material are
the backlash for the gear drive of the cam, projections of the valves, flatness, and surface texture. Measure these areas and the dimension
for minimum thickness of the cylinder head whenever you recondition the block and the mating surface of the head.
Note: Dimensions for the thickness of the head assume that no material has been removed from the rail of the valve cover and the centerline of
the crankshaft has not been raised. Adjust the specifications accordingly if machining has already occurred.
Cleaning the Cylinder Head and Removing the Gasket
Personal injury can result from working with cleaning solvent.
Because of the volatile nature of many cleaning solvents, extreme

caution must be exercised when using them. If unsure about a particular
cleaning fluid, refer to the manufacturer's instructions and directions.
Always wear protective clothing and eye protection when working with
cleaning solvents.
Use one of these methods to clean the cylinder head. Remove all oil, dirt, and carbon from the cylinder head casting. If the initial cleaning of the
engine has been performed, the time for cleaning of the cylinder head will be reduced considerably.
NOTICE
Shot blasting is not a Caterpillar recommended cleaning procedure.
Shot blasting can cause shot to become lodged in internal passages. If
all the shot material is not removed after cleaning with this method, the
shot can become dislodged after reconditioning and move into the
lubrication and injection systems. The result can be serious damage to
the engine.
Dip Tank
Use a hot caustic solution to clean the cylinder head in a dip tank with a platform that oscillates.
Hot Spray Wash Cabinet
Put the cylinder head into position so the Exhaust ports and the combustion area are in line with the high-pressure stream from the nozzles. The
spray must go directly into the ports and the face of the cylinder to remove all the carbon.
NOTICE
If a caustic cleaning solution is used, brass injector sleeves and seals
can be damaged. If these parts are not going to be replaced in a
cylinder head, a soft cleaning solution should be used.
Removing the Gasket
Use caution in order to avoid breathing dust that may be generated q631tm
from handling any friction material, regardless of whether or not the Caterpillar: Confidential Yellow
material contains asbestos. If the dust is inhaled, the dust can be
hazardous to you health.
Wear a proper protective breathing device when handling friction

material.
Moisten the gasket material for a cleaner and easier removal. To make the removal of gaskets easier and safer, put the cylinder head into a hot
tank or a hot spray wash cabinet. A hot cleaning solution will make the gasket material soft so that large pieces can be pulled off by hand and
the gasket material is easily removed with a scraper or a grinder. However, if the wet gasket material is permitted to dry, the gasket material can
harden to the part.
There are specific factors for reconditioning the G3600 cylinder head. The surface on which the gasket for the prechamber seats must be
thoroughly inspected. This area is prone to leaks without proper reconditioning.
Scraping
Use a putty knife to scrape off most of the gasket. Scraping is preferred over sanding discs. This preference is due to the number of airborne
contaminants that are created by the discs. Disks for metal reconditioning that are mounted on an air tool can be used to remove gasket material
that cannot be removed by hand.
Grinding
NOTICE
If the metal reconditioning disc is used to remove gasket material,
caution should be used to prevent the removal of any metal. If used too
long in a small area, the disc may remove so much metal that sealing
surfaces could be affected.
A disk for metal reconditioning that is mounted on an air tool can be used to remove gasket material that cannot be removed by hand.
Removing the gasket by grinding
When you are using this method, the speed of the disc is important. The best results will be obtained if the disc is flat to the surface and using
only the weight of the air tool as downward pressure. Do not use too much downward pressure or operate the disc on the edge, because the pad
may separate from the holder. The speed of the disc should be set between 3500 and 4500 rpm for 5P-9709 Abrasive Disc and 10,000 rpm for
6V-0185 Abrasive Disc. If the disk for metal reconditioning is used to remove gasket material, be careful not to remove any metal from the
cylinder head.
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Discs and holder
(12) 6V-0186 Holder ( 127 mm (5.0 inch))
(13) 5P-9718 Holder ( 178 mm (7.0 inch))
(14) 6V-0185 Discs ( 127 mm (5.0 inch))
(15) 5P-9709 Discs ( 178 mm (7.0 inch))
Protection After Cleaning

If the casting is being stored before making a repair, then the cylinder head must be protected from corrosion and external damage after
cleaning.
Visual Inspection of Cylinder Head

Cylinder Head Casting
Inspect the cylinder head for visible damage. The following examples of damage were taken from 3200 and 3400 Engines and the examples
also apply to all engines.
The damage to the cylinder head is at the seal between the valve cover and the head.
USE THE PART AGAIN.
The cylinder head can be used again after the burr has been removed.
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Cylinder head is badly damaged in the seat area of the bolt. This area must have a flat surface and complete contact with a bolt.
USE THE PART AGAIN.
The cylinder head can be used again after damage is repaired.
Cylinder head is badly damaged in the seat area of the bolt. This area must have a flat surface and complete contact with a bolt or a mating
surface.
USE THE PART AGAIN.
The cylinder head can be used again after damage is repaired.
The part can be used again after the hole has been repaired using Lock-N-Stitch. For complete information on Lock-N-Stitch, refer to Reuse and
Salvage Guideline, SEBF8882, "Using Lock-N-Stitch Procedures for Casting Repair".
Inspecting the Combustion Area for Damage from Erosion

Make a visual inspection of the combustion area to check for damage and erosion. Erosion in these areas will have a negative effect on engine
operation:
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Inspect the indicated areas for damage and erosion.
(16) Fire ring
(17) Seat area
(18) The area between the hole of the injector nozzle and the valve seat. Erosion in other areas should not affect engine operation.
Minor pitting or erosion
USE THE PART AGAIN.
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Foreign material caused this damage. The valve seats must be replaced.
USE THE PART AGAIN.
Erosion across the fire ring
The cylinder head can be used again after the surface has been machined and all erosion is removed. The part must still be within the reusable specifications.
USE THE PART AGAIN.
Damage across the fire ring
The cylinder head can be used again after the surface has been machined to remove all damage.
USE THIS PART AGAIN.
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Concentrated area of erosion
The cylinder head can be used again if a channel is ground out to remove erosion.
A small amount of erosion
Bad erosion around the area of the valve seat.
DO NOT USE THE PART AGAIN.
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Engine failure caused this damage.
DO NOT USE THE PART AGAIN.
Erosion
The flow of coolant through the engine is known for causing erosion. This example is shown in Illustration 52. The erosion will not damage the
engine if the coolant does not go from the coolant passage to any of the following:
Fire ring in the combustion chamber
Oil passages
Bolt holes
Outside of the engine
Erosion that is caused from the flow of coolant
(16) Fire ring
(19) Outer surface
(20) Coolant passage
(21) Oil passage
(22) Erosion must not extend beyond this area.
(23) Bolt hole
For traditional head gaskets, if the distance between the erosion and any feature that is specified in Illustration 54 is less than 4.0 mm
(0.16 inch), do not use the cylinder head again. Use the part again only if the erosion has been removed to leave a minimum of 4.0 mm
(0.16 inch) sealing area. q631tm
Multiple layered steel "MLS" gasket
The arrows indicate a raised layer of the gasket. Erosion cannot come in contact with this area.
Note the sealing area of the "MLS" gasket. The seal is created by the raised area of the gasket. Any erosion or an uneven surface could create a
bad seal.
Erosion is acceptable in areas (24) and (25). Erosion is not acceptable in area (26). This photo shows acceptable erosion, and the head can be used again.
(24) Coolant passage and the inside diameter of the O-ring
(25) Seal and the outside diameter of the O-ring
(26) Seal and the gasket
Erosion is not acceptable in area (27).
Only reuse the cylinder head if the erosion has been machined from area (27). That area is at the point of contact between the O-ring or seal and the cylinder head. q631tm
USE THIS PART AGAIN..
Illustration 56 and Illustration 57 show the location of O-rings or seals around the holes of the coolant passages. Erosion will not harm the
engine between these areas.
Erosion is not acceptable at the point of contact between the O-ring or seal and the cylinder head. If any erosion occurs, then the combustion
area must be machined.
Lifter Bore Erosion for 3500 Engines
Lifter bore erosion is allowable if the erosion path is contained within Zone A and does not exceed 0.5 mm (0.01969 inch)
Table 6
Lifter Bore for 3500 Engines
Callout Dimension
(A) 5.0 mm (0.19685 inch)

(B) 5.0 mm (0.19685 inch)
(C) 31.0 mm (1.22047 inch) MAX
Reuse of Cylinder Heads on C9, C-9, and 3176 Engines with Injector Tip Damage
Inspection
All the heads shown that in the photos have been milled to near minimum thickness to remove as much damage as possible. The damage that
remains is inside the gasket sealing area. This area is shown by the black circle drawn on the head.
Heads with damage in the fire ring seat area after machining should not be used again.
Identification Stamp and Nomenclature

Cylinder heads that are reworked by the criteria in this guideline should be stamped with a dealer-selected stamp in area (1) shown in
Illustration 59. This stamp will identify the cylinder heads as having injector tip damage and not casting porosity. Caterpillar Reman heads will
be stamped with a 6 mm (0.24 inch) upper case "M".
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(1) Reworked C9 cylinder heads have identification stamp in this area.
(2) Reworked 3176 cylinder heads have identification stamp in this area.
(3) Fly cut area between intake valves
Minimal damage on surface of deck and in valve port (angled area above valve insert)
Use again
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More areas of damage on surface of deck
Use again
Heavy damage to surfaces that extend into the valve ports
Do not use again
Heavy damage to surfaces that extend into the valve ports and damage to the fly cut between the intake valves q631tm
Do not use again
Heavy damage to surface of deck and valve ports
Do not use again
Deep gouges in surface and gouges that extend into valve port.
Do not use again
Inspection of the Combustion on 3600, G3600, C280 Engines
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Cylinder head combustion surface
Inspect the surface between dimensions (A) and (B) in Illustration 67 for signs of pitting, erosion, or other damage. The area between (A) and
(B) must be smooth, free of nicks, gouges, and/or any damage that may result in incorrect seal ring sealing.
Note: Tooling 151-8689 Seal Template can be used to quickly define the area between dimension (A) and (B).
Tooling 151-8689 Seal Template
1. Place a 151-8689 Seal Template on the cylinder head. Align the center locator on the template with the hole for the injector on the
cylinder head.
2. Use a marker to mark the inside diameter and the outside diameter of the template on the surface of the cylinder head.
3. Remove the template for the seal.
Note: The thickness of the cylinder head must be checked again if the cylinder head is reconditioned.
Table 7
Specifications For Surface of Combustion
380.00 ± 1.00 mm
Dimension (A)
(14.961 ± 0.040 inch)
330.00 ± 1.00 mm
Dimension (B)
(12.992 ± 0.040 inch)
406.0 mm
Surface Width (minimum)
(16.00 inch)
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Surface Texture (maximum) except within (A) and (B) 3.2 µm Caterpillar: Confidential Yellow
(125 µinch)
1.6 µm
Surface Texture (maximum) between (A) and (B)
(63 µinch)
0.1 per 100 mm
Flatness (maximum) except within (A) and (B)
(0.004 per 4 inch)
0.05 mm
Flatness (maximum) between (A) and (B)
(0.002 inch)
Thread Inspection
Make a visual inspection of all threaded holes for damaged threads and broken bolts or studs.
Damaged threads
The part can be used again after the hole has been repaired using Lock-N-Stitch. For complete information on Lock-N-Stitch, refer to Reuse and Salvage Guideline, SEBF8882,
"Using Lock-N-Stitch Procedures for Casting Repair".
Exhaust Stud and Bolt Removal Tool
The 188-3922, 533-1152, 533-1153, and 533-1152 Exhaust Stud and Bolt Removal Tool Group, when bolted to the cylinder head will
accurately locate the center of the broken stud or bolt. This tool allows broken bolts or studs to be drilled out without damaging the existing
threads in the cylinder head. This tool group is similar to the 6V-9050 Stud Removal Group except that it is designed to repair metric exhaust
manifold bolts and studs.
Tool188-3922 can be used on cylinder heads of 3114, 3116, 3126, 3126B, 3176, 3176B, C-10, and C-12 Engines.
Tool 533-1152 can be used on cylinder heads of C6.6 Engines.
Refer to NEHS0787Tool Operating Manual, "188-3922 Broken Exhaust Bolt and Stud Removal Group for 3114, 3116, 3126, 3126B, 3176,
3176B, C-10, and C12 Engines" for more information.
Crack Detection Methods
NOTICE
Regardless of which crack detection method is used, it is important
that the instructions furnished with the detection equipment are
followed closely when checking any component. Failure to do so may
cause inaccurate results or may cause injury to the operator and/or
surroundings.
Crack detection methods or Non-Destructive Testing (NDT) are utilized for examining components for cracks without damaging the
component. Visual inspection (VT), Liquid Penetrant Testing (PT), Magnetic Particle Inspection (MT), Ultrasonic Testing (UT), Radiographic
Testing (RT) and Eddy-Current Testing (ET) are recommended methods. There may be more than one acceptable crack detection method for the
inspection of a given part, though the liquid penetrant is the most versatile. For example, the liquid penetrant method can be used when
inspecting smooth machined components such as shafts, gear teeth, and splines, but using the Wet Magnetic Particle Inspection is more
accurate. Refer to Table 8 for advantages and disadvantages and Table 9 for standards and requirements for these NDT methods.
Table 8
Crack Inspection Method Advantages vs. Disadvantages
Inspection Method Advantages Disadvantages
Visual Surface - Least expensive - Limited to surface-only defects q631tm

Inspection (VT) - Detects most damaging defects Caterpillar:
- Requires inspectors to have broad knowledge of welding andConfidential
fabricationYellow
- Immediate results inch addition to non-destructive testing
- Minimum part preparation
- Inexpensive
- Least sensitive
Liquid Penetrant - Minimal training
- Detects surface cracks only
(PT) - Portable
- Rough or porous surfaces interfere with test
- Works on nonmagnetic material
- Portable
Dry Magnetic - Fast/Immediate Results - Works on magnetic material only
Particle (MT) - Detects surface and subsurface - Less sensitive than Wet Magnetic Particle
discontinuities
- More sensitive than Liquid Penetrant - Requires Power for Light
Wet Magnetic
- Detects subsurface as much as - Works on magnetic parts only
Particle (MT)
0.13 mm (0.005 inch) - Liquid composition and agitation must be monitored
- Most sensitive
- Detects deep material defects - Most expensive
Ultrasonic Testing
- Immediate results - Requires operator training and certification
(UT)
- Wide range of materials and - Surface must be accessible to probe
thickness can be inspected
- Surface and near surface flaws - Difficult to interpret
Eddy-Current detectable - Only for metals
Testing (ET) -Moderate speed/Immediate results -Rough surfaces interfere with test
-Sensitive too small discontinuities - Surface must be accessible to probe
-Detects surface and internal flaws - Not for porous materials

Radiographic
- Minimum part preparation - Radiation protection needed
Testing (RT)
- Can inspect hidden areas - Defect able to be detected is limited to 2% of thickness
Table 9
Applicable Crack Detection Standards
Required
Acceptance
Inspection Method Standard Personnel
Criteria
Qualifications
EN-ISO 5817 EN-ISO 5817 - Level B EN-ISO 9712 - Level 2
Visual Surface Inspection (VT)
AWS D1.1 AWS D1.1 - Table 6.1 ANSI-ASNT SNT-TC-1A Level 2
EN-ISO 3452 EN-ISO 23277 EN-ISO 9712 - Level 2
Liquid Penetrant Testing (PT)
ASTM E165 AWS - D1.1 ANSI-ASNT SNT-TC-1A Level 2
EN-ISO 17638 EN-ISO 23278 - Level 1 EN-ISO 9712 - Level 2

Magnetic Particle Testing (MT)
ASTM E709 AWS D1.1 - Table 6.1 ANSI-ASNT SNT-TC-1A Level 2
EN-ISO 17640 - Level B EN-ISO 11666 Technique 2 - Level 2 EN-ISO 9712 - Level 2
Ultrasonic Testing (UT)
AWS D1.1 AWS D1.1 - Class A - Table 6.3 ANSI-ASNT SNT-TC-1A Level 2
EN-ISO 15549 EN-ISO 9712 - Level 2

Eddy-Current Testing (ET) EN-ISO 20807
ASTM E426 ANSI-ASNT SNT-TC-1A Level 2
EN-ISO 5579 EN-ISO 9712 - Level 2

Radiographic Testing (RT) EN-ISO 10657-1
ASTM E94 ANSI-ASNT SNT-TC-1A Level 2
Visual Surface Inspection (VT)
Example of Visual Inspection Tools
(A) Flashlight or adequate light source
(B) Magnifying eye loupe
(C) Tape measure or other measuring device
(D) Inspection mirror
(E) Weld size inspection gauges
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Components and welds that are to be inspected using PT, MT, or UT shall first be subject to Visual Surface Inspection (VT). Visual Inspection is
often the most cost-effective inspection method and requires little equipment as seen in Illustration 70. It is suggested that at a minimum
personnel performing Visual Inspection are either trained to a company standard or have sufficient experience and knowledge regarding the
components being inspected. It is also suggested that personnel performing visual inspections take some type of eyesight test regularly.
Liquid Penetrant Testing (PT)
Personal injury can result from improper handling of chemicals.
Make sure you use all the necessary protective equipment required to do
the job.
Make sure that you read and understand all directions and hazards
described on the labels and material safety data sheet of any chemical
that is used.
Observe all safety precautions recommended by the chemical

manufacturer for handling, storage, and disposal of chemicals.
Materials and Equipment Required
Refer to Tooling and Equipment Table 3 for part numbers.
Cleaner: Removes dirt before dye application and dissolves the penetrant making possible to wipe the surface clean.
Penetrant: This solution is highly visible, and will seep into openings at the surface of a part with capillary action.
Developer: Provides a blotting action, bringing the penetrant out of the discontinuities and providing a contrasting background to increase
the visibility of the penetrant indications.
Wire Brush: Removes dirt and paint.
Cloth or Wipes: Use with cleaner and for other miscellaneous uses.
Procedure
1. Preclean inspection area. Spray on cleaner / remover to loosen any scale, dirt, or any oil. Wipe the area to inspect with a solvent
dampened cloth to remove remaining dirt and allow the area to dry.
2. Apply penetrant by spraying to the entire area to be examined. Allow 10 to 15 minutes for penetrant to soak. After the penetrant has been
allowed to soak, remove the excess penetrant with clean, dry wipe.
3. The last traces of penetrant should be removed with the cleaner solvent dampened cloth or wipe. Allow the area to dry thoroughly.
4. Before using developer, ensure that it is mixed thoroughly by shaking can. Holding can approximately 203.20 - 304.80 mm
(8.00 - 12.00 inch) away from part, apply an even, thin layer of developer over the area being inspected. A few thin layers are a better
application method than one thick layer.
5. Allow the developer to dry completely for 10–15 minutes before inspecting for cracks. Defects will show as red lines in white developer
background. Clean the area of application of the developer with solvent cleaner.
Use a black light to check the inserts of the valve seat.
Dye will penetrate into cracks. q631tm
6. Check the surface with a 459-0184 Ultraviolet Lamp. This lamp will highlight the location of any cracks or damage.
Cracks begin at the precombustion chamber or the hole of the direct injection adapter. The length of the crack on the combustion area must not be more than 6.35 mm
(0.250 inch). The crack must not be more than three threads deep. Use the method of dye penetrant to find the depth of the cracks.
The following illustrations show examples of cracks that would constitute replacing the cylinder head.
Crack in the nozzle hole (3200 Engine)
DO NOT USE THIS PART AGAIN.
The crack goes into the valve seat. If the crack does not go into the counterbore of the area of the valve seat, the head can be salvaged. Refer to Reuse and Salvage Guideline,
SEBF8374, "Specifications for Cylinder Head Assemblies 3200 Engines".
Cracks between the valve seats (3200 and 3400 Engines)
Cracks between the precombustion chamber or the hole for the direct injection adapter and valve seats (3400 Engine).
Cracks between the hole of the core plug and the bore of the valve guide on the top deck (3400 Engine)
Dry Magnetic Particle Testing (MT)
Materials and Equipment Required
(A) Indications shown by magnetic particle testing.
(B) Typical electromagnetic yoke.
(C) Dry powder bulb.
An electromagnet in the shape of a yoke that is checking for cracks
1. Dry magnetic powder shall be of high permeability and low retentively and of suitable sizes and shapes to produce magnetic particle q631tm
indications. The powder shall be of a color that will provide adequate contrast with the background of the surface being inspected.
2. Dry magnetic particles shall be stored in suitable containers to resist contamination such as moisture, grease, oil, non-magnetic particles
such as sand, and excessive heat. Contaminants will manifest in the form of particle color change and particle agglomeration. The degree
of contamination will determine further use of the powder.
3. Dry magnetic powder shall be tested in accordance with ASTM E709 Section 18 (Evaluation of System Performance/Sensitivity) when
not performing.
4. Equipment should include a "U" shaped electromagnetic yoke made from highly permeable magnetic material, which has a coil wound
around the yoke. This coil carries a magnetizing current to impose a localized longitudinal magnetic field into the part. The magnetizing
force of the yoke is related to the electromagnetic strength and can be tested by determining the lifting power of a steel plate. The yoke
shall have a lifting force of at least 4.5 kg (10 lbs).
5. Check dry powder blower routinely to ensure that the spray is a light, uniform, dust-like coating of the dry magnetic particles. Blower
should also have sufficient force to remove excess particles without disturbing those particles that are evidence of indications.
6. All equipment shall be inspected at a minimum of once a year or when accuracy is questionable.
Procedure
1. Ensure surface to be inspected is dry and free from oil, grease, sand, loose rust, mil scale, paint, and other contaminants.
2. Apply the magnetic field using the yoke against the faces and inside diameter of each bore.
3. Simultaneously apply the dry powder using the dry powder blower.
4. Remove excess powder by lightly blowing away the dry particles.
5. Continue around the entire circumference of each bore. Position the yoke twice in each area at 1.57 rad (90°) to ensure that multiple
directions of the magnetic field are created.
6. Inspect the area for cracks. If there is a crack between the arms of the yoke, the magnetic powder will go into the crack. The crack will
then appear as a line of magnetic particles.
Observe particles and note if any clusters of particles appear revealing an indication.
7. Record the size and shape of any discontinuities or indications found.
Wet Magnetic Particle Testing (MT)
Materials and Equipment
(A) Indications shown by magnetic particle testing.
(B) Typical electromagnetic yoke.
(D) UV Lamp used in wet magnetic particle inspection process.
Pear Shaped Centrifuge Tube
1. Wet magnetic particles are fluorescent and are suspended in a vehicle in a given concentration that will allow application to the test
surface by spraying.
2. Concentration:
a. The concentration of the suspended magnetic particles shall be as specified by the manufacturer and be checked by settling volume
measurements.
b. Concentrations are determined by measuring the settling volume by using an ASTM pear shaped centrifuge tube with a 1 mL
q631tm
(0.034 oz) stem with 0.05 mL (0.0017 oz) 1.0 mL (0.034 oz) divisions, refer to Illustration 84. Before sampling, the suspension
shall be thoroughly mixed to assure suspension of all particles, which could have settled. A 100 mL (3.40 oz) sample of the
suspension shall be taken and allowed to settle for 30 minutes. The settling volume should be between 0.1 mL (0.0034 oz) and
0.25 mL (0.0085 oz) in a 100 mL (3.40 oz) sample.
c. Wet magnetic particles may be suspended in a low viscosity oil or conditioned water.
d. The oil shall have the following characteristics:
Low viscosity not to exceed 50 mSt (5.0 cSt) at any temperature at which the vehicle is to be used.
Low inherent fluorescence and be non-reactive.
e. The conditioning agents used in the conditioned water shall have the following characteristics:
Impart good wetting characteristics and good dispersion.
Minimize foaming and be non-corrosive.
Low viscosity shall not exceed a maximum viscosity of 50 mSt (5.0 cSt) at 38° C (100° F).
Non-fluorescent, non-reactive, and odorless.
Alkalinity shall not exceed a pH of 10.5.
3. Equipment should include a "U" shaped electromagnetic yoke made from highly permeable magnetic material, which has a coil wound
around the yoke. This coil carries a magnetizing current to impose a localized longitudinal magnetic field into the part. The magnetizing
force of the yoke is related to the electromagnetic strength and can be tested by determining the lifting power of a steel plate. The yoke
shall have a lifting force of at least 4.5 kg (10 lbs).
Procedure
1. Ensure surface to be inspected is dry and free from oil, grease, sand, loose rust, mil scale, paint, and any other contaminants.
2. Apply the magnetic field using the yoke against the surface in the area to be inspected.
3. For case hardened and ground surfaces:
Due to the sensitivity required to locate the grinding cracks, inspection of case hardened and ground surfaces require that the yoke
is applied so that the magnetic field is 1.57 rad (90°) to the expected direction of the indications. Also, due to the increased
sensitivity resulting when the yoke is energized, the yoke is not moved until the evaluation is completed in the first direction. An
AC yoke shall be used.
4. Visually inspect for indications of discontinuities using the proper illumination.
5. Record the size and shape of any discontinuities found.
Ultrasonic Testing (UT)
Note: Crack depth cannot be accurately determined by UT, only full depth cracking can be consistently determined. For cracks that are not full
depth, an indication of a partial depth cracks can be detected by an experienced technician.
NOTICE
All personnel involved in ultrasonic testing shall be qualified to Level 2
in accordance to standards stated in Table 9.
1. Ultrasonic Testing (UT) is a method of Non-Destructive Testing (NDT) using short ultrasonic pulse waves (with frequencies from 0.1-15
MHz up to 50 MHz) to detect the thickness of the object. Ultrasonic testing consists of an ultrasound transducer connected to a diagnostic
machine and passed over the object being inspected.
2. There are two methods of receiving the ultrasound waveform from the transducer: reflection and attenuation.
a. Reflection - Ultrasonic pulses exit the transducer and travel throughout the thickness of the material. When the sound waves
propagate into an object being tested, the waves return to the transducer when a discontinuity is discovered along the sonic path.
These waves continue and reflect form the backsurface of the material to project the thickness of the material.
q631tm
b. Attenuation - A transmitter sends ultrasound through one surface, and a separate receiver detects the amount that has reached it on
another surface after traveling through the medium. Any discontinuities or other conditions within the medium will reduce the
amount of sound transmitted, revealing the presence of the imperfections.
Eddy-Current Testing (ET)
NOTICE
All personnel involved in Eddy-Current Testing shall be qualified to
Level 2 in accordance to standards stated in Table 9.
Eddy-Current Testing
Eddy-Current Testing (ET) is a Non-Destructive Testing (NDT) method in which eddy-current flow is induced in the test object. Changes in the
flow caused by variations in the specimen are reflected in to a nearby coil or coils for subsequent analysis by suitable instrumentation and
techniques. Major applications of eddy-current testing are surface inspection and tubing inspections.
Radiographic Testing (RT)
Note: CAUTION: This process is dangerous. Only qualified personnel and test equipment should be appointed to perform this type of testing.
NOTICE
All personnel involved in radiographic testing shall be qualified to
Level 2 in accordance to standards stated in Table 9.
Radiographic Testing
Radiographic Testing (RT) is a Non-Destructive Testing (NDT) method in which short wavelength of electromagnetic radiation is used to
penetrate materials to find hidden discontinuities such as cracks. In radiographic testing, the test object is placed between the radiation source
and the film, or x-ray detector. The electromagnetic radiation will penetrate the thickness of the test object and, when all the way through, will
project onto the film any indications that have been in the path of the radiation waves.
Lock-N-Stitch Full Torque Threaded Inserts
If a bolt hole contains cracked threads or stripped threads, Lock-N-Stitch Full Torque Threaded Inserts should be used. The cracks must be no
deeper than 6.4 mm (0.25 inch) down the counterbore of the bolt hole. The cracks cannot run into the cylinders. The cracks must only run into
water jackets. The number of cracks per hole does not matter. Mark all bad holes with a paint pen.
The procedure utilizes Lock-N-Stitch products that were introduced in Reuse and Salvage Guideline, SEBF8882, "Using Lock-N-Stitch
Procedures for Casting Repair". Full Torque Thread Insert Kits are used to repair the cracked bolt holes and stripped bolt holes. The threaded
inserts and the parts that accompany the threaded inserts are included in FFB5SP010K Full Torque Thread Insert Kit from LOCK-N-STITCH.
These parts can be ordered through LOCK-N-STITCH. This kit is not stocked by Caterpillar. Refer to Reuse and Salvage Guideline,
SEBF8882, "Using Lock-N-Stitch Procedures for Casting Repair" for other LOCK-N-STITCH parts that are stocked by Caterpillar.
Installing a Threaded Insert can be done in a short amount of time. Installing a Threaded Insert will increase the strength of the threads.
For more information or questions concerning LOCK-N-STITCH, contact LOCK-N-STITCH. For a complete catalog of products, contact
LOCK-N-STITCH. See www.locknstitch.com for more repair procedures, training, and catalogs.
LOCK-N-STITCH Inc.
1015 S. Soderquist Rd. q631tm
Turlock, CA 95380 Caterpillar: Confidential Yellow
www.locknstitch.com
(209) 632-2345
(800) 736-8261
Measurement Requirements
NOTICE
Precise measurements shall be made when the component and
measurement equipment are at 20° (68° F). Measurements shall be
made after both the component and measurement equipment have had
sufficient time to soak at 20° (68° F). This will ensure that both the
surface and core of the material is at the same temperature.
Cylinder Head Thickness

Before the cylinder head can be reused, the cylinder head thickness must be measured.
The cylinder head can be machined to remove any damage. At the time of this publication, some cylinder heads must remain within factory
specifications. Refer to the Tables for specifications for the minimum thickness of the cylinder head. The cylinder head must be within the
minimum thickness specifications to comply with the regulations on emissions. If the thickness of the head is beyond the minimum thickness,
the head can be reconditioned by utilizing thermal spray.
Note: An alternative solution will be provided in the future for the engines that must remain within factory specifications.
If the head surface requires reconditioning, the surface must be built up utilizing metal spray so the cylinder head thickness will be maintained
at the original specifications. Refer , SEBF2119, "Thermal Spray Procedures for Cylinder Head".
Illustration 88 is of a C7 cylinder head, but is illustrative of where to measure for C7 through C32 cylinder heads.
The thickness of the cylinder head is measured from the valve spring base to the combustion surface. The valve spring base makes for a good
datum for measuring cylinder head thickness because it receives minimum wear through the engine life. Also the valve spring base remains
unchanged during cylinder head salvage such as machining and/or metal spray procedures.
C7 through C32 Cylinder Heads
Valve spring base to combustion face measurement
(A) Thickness of Cylinder Head
C175 Cylinder Heads
(A) Thickness of the cylinder head
3044, 3046, 3064, and 3066 Cylinder Heads
Cylinder head cross section
3114,3116, and 3126 Cylinder Heads
q631tm
Earlier Cylinder Heads
Cylinder head cross section of later cylinder heads
(1) Sleeve
(A) Thickness of the head
Refer to Tool Operating Manual, NEHS0675, "Using the 143-2099 Sleeve Replacement Tool Group on 3114, 3116, and 3126 Engines".
3176, and 3196 Cylinder Heads
Cylinder head cross section
(1) Sleeve
(A) Thickness of new cylinder head
3400 Cylinder Heads
3406E, 3456Cylinder Heads
(A) Thickness of the cylinder head
3500 Cylinder Heads
Note: Material can be removed from the cylinder head without reseating the valves if the thickness of the cylinder head is at least
141.62 mm (5.57558 inch). When the thickness of the cylinder head is less than the minimum thickness of the cylinder head, the valves
must be reseated to achieve the proper valve recession. These dimensions are listed in Table 111.
(A) Minimum thickness of the cylinder head
3600, G3600, C280 Cylinder Heads
(A) Minimum thickness of the cylinder head
Table 10
Specifications for the Cylinder Head Thickness
Model Part Number Thickness of the Head (A) Minimum Thickness of the Head
111.25 mm 110.99 mm
D318 N/A
(4.37991 inch) (4.36968 inch)
127.00 ± 0.08 mm 125.56 mm

D320 N/A
(5.00 ± 0.00315 inch) (4.94330 inch)
D342 136.72 ± 0.06 mm 134.70 mm q631tm

N/A
G342 (5.38267 ± 0.00236 inch) (5.30314 inch) Caterpillar: Confidential Yellow
D343 N/A 167.64 ± 0.05 mm 167.49 mm
G343 (6.59999 ± 0.00197 inch) (6.59408 inch)
D346
G346
D348 109.22 ± 0.10 mm 108.96 mm
N/A
G348 (4.29999 ± 0.00394 inch) (4.28976 inch)
D349
G349
D353 146.11 ± 0.06 mm 144.27 mm
N/A
G353 (5.75235 ± 0.00236 inch) (5.67991 inch)
D379
G379
D398 179.45 ± 0.10 mm 178.05 mm
N/A
G398 (7.06495 ± 0.00394 inch) (7.00983 inch)
D399
G399
100.95 mm
C4.4 N/A N/A
(3.974 inch)
150.8 mm
C4.4 (Tier 4) N/A N/A
(5.9370 inch)
94.80 mm
C6.6 and C7.1(Elect) (Tier 2/3) N/A N/A
(3.732 inch)
C7.1 (Mech) (Tier 0/2/3) N/A N/A 117.95 mm (4.644 inch)

C7.1 (Tier 4) N/A N/A 150.8 mm (5.937 inch)
219-5844
227-5951
259-8305
278-3490 110.5 ± 0.25 mm 110.00 mm
C7
280-7503 (4.350 ± 0.010 inch)(1) (4.33 inch)
314-4183
314-4184
314-4185
201-2180
241-8392
252-8438
255-4961 130.00 ± 0.15 mm 129.60 mm
311-7226 (5.118 ± 0.006 inch) (5.102 inch)
311-7228
311-7229
C9 332-3619
C-9
C9.3 311-7218 163 ± 0.15 mm
N/A
328-7475 (6.41731 ± 0.0059 inch)
158.00 ± 0.15 mm 157.60 mm

314-4184
(6.221 ± 0.006 inch) (6.205 inch)
163.0 mm 162.6 mm
491-1831
(6.41731 inch) (6.40156 inch)
C-10
148-2135 105.00 ± 0.15 mm 104.35 mm
C-12
179-9458 (4.134 ± 0.006 inch) (4.108 inch)
C12
C11 245-4031 120.00 ± 0.15 mm 119.50 mm

C13 257-2170 (4.724 ± 0.006 inch) (4.705 inch)
C-13 265-9120
C15 289-3210
C-15 300-9512
C16 302-2297
C-16 308-6358 q631tm
331-1981 Caterpillar: Confidential Yellow
C18 342-4397
C-18 344-0059
345-3752
346-1984
346-1999
520-4381
520-4382
185-2246
222-1983
223-7263
120.00 ± 0.15 mm 119.45 mm
243-0943
(4.724 ± 0.006 inch) (4.703 inch)
245-4324
263-4890
281-1640
284-2787
C27 357-7398 120.00 ± 0.15 mm 119.60 mm
C32 396-8374 (4.724 ± 0.006 inch) (4.709 inch)
431-1153
6I-3606
105-3798
105-3799
105-3800
123-7338
124-7373
143-0046
C-30 112.78 ± 0.25 mm 111.51 mm
143-3615
C-32 (4.440 ± 0.001 inch) (4.390 inch)
151-4951
151-1335
151-5241
151-5243
198-6523
198-6524
206-7744
328-7082
345-8447
208.00 mm 207.85 mm
C175 456-2406
(8.189 inch) (8.1831 inch)
515-8766
517-4407
3044 85.00 ± 0.10 mm 84.90 mm

N/A
3046 (3.347 ± 0.004 inch) (3.343 inch)
103.59 mm 102.48 mm
3054(2) N/A
(4.07834 inch) (4.03464 inch)
103.59 mm 102.79 mm
3056 N/A
(4.07834 inch) (4.04684 inch)
3064 95.00 ± 0.10 mm 94.90 mm

N/A
3066 (3.740 ± 0.004 inch) (3.736 inch)
103.00 ± 0.20 mm 102.55 mm

3114 (4.055 ± 0.008 inch)
(4.037 inch)(3)
3116 N/A Early Model
3126 158.00 ± 0.20 mm 157.55 mm
(6.220 ± 0.008 inch) (6.202 inch)(3)
3176 105.00 ± 0.15 mm 104.35 mm
N/A
3196 (4.134 ± 0.006 inch) (4.108 inch)
96.14 ± 0.15 mm 95.86 mm
3204 DI N/A
(3.78503 ± 0.00591 inch) (3.77401 inch)
95.0 ± 0.13 mm 94.59 mm

3204 PC N/A
(3.74015 ± 0.00512 inch) (3.72401 inch) q631tm
3208 N/A 96.14 ± 0.15 mm 95.86 mm
(3.78503 ± 0.00591 inch) (3.77401 inch)
3304
3306 100.03 ± 0.76 mm 98.89 mm

(3.938 ± 0.030 inch) (3.893 inch)
7N-8866
G3306
148-2138
100.03 ± 0.76 mm 98.51 mm
DI (3.938 ± 0.030 inch) (3.878 inch)
PC
3406
112.78 ± 0.25 mm 111.51 mm
3408 143-0040
(4.440 ± 0.010 inch) (4.390 inch)
3412
125.00 ± 0.25 mm 123.72 mm
G3406 (4.921 ± 0.010 inch) (4.871 inch)
G3408 N/A
G3412 112.78 ± 0.25 mm 111.51 mm
(4.440 ± 0.010 inch) (4.390 inch)
3406E 120.00 ± 0.15 mm 119.45 mm
N/A
3456 (4.724 ± 0.006 inch) (4.703 inch)
4P-6571
7C-3471
7E-5861
7E-8760
101-1175
122-5961
128-1141
131-0410
131-0411
131-0423
144-6409
145-3215
153-8397
154-1612
161-2508
172-0834 141.0 mm
3500 172-0836 142.00 ± 0.15 mm (5.55 inch)
G3500 184-5496 (5.591 ± 0.006 inch)
206-1554
206-1555
206-1560
206-1563
229-9942
290-1351
295-2047
418-9804
424-7545
462-4740
480-3132
487-3422
495-2062
525-6572
269-0040 141.5 mm
315-2630 (5.5709 inch)
280.00 mm 279.00 mm
3600, G3600, C280 N/A
(11.024 inch) (10.984 inch)
(1) As measured from the Intake valve seat base.
(2) Maximum permissible projection of the fuel injection nozzle below the face of the cylinder head after resurfacing should not exceed 4.45 mm (0.17520 inch)
(3) A maximum removal of 0.25 mm (0.010 inch) is permissible for resurfacing.
Flatness of the Surface q631tm

Maintain the original specifications for all cylinder head assemblies during reconditioning.
Note: The critical factors that need to be considered during the reconditioning of the cylinder block and the cylinder head, the compression
ratios, and the clearance between the valve and the piston. The compression ratio increases when material is removed from the cylinder block.
Measurement of total surface for flatness (3200 Engine)
Measurement of total surface for flatness (3400 Engine)
Flatness of the cylinder head can be measured by using a straight edge and a feeler gauge. Shown in Illustration 98 and Illustration 99. A
straight edge for measuring the total flatness of surface is required. A straight edge should be used for measuring a small area.
Measure the flatness of the combustion area on the cylinder head. Use a straight edge and a feeler gauge to measure the flatness. Measure the
surface in two positions crosswise and measure the surface in two positions lengthwise.

(B) Diameter of the combustion chamber

Flatness of the surface for 3500
(B) Diameter of the combustion chamber
(C) Cylinder head surface
(D) Combustion chamber surface
Table 11
Specifications for the Cylinder Head Flatness
Flatness of
Diameter of the
Flatness of the the
Part Combustion Sealing Surface Sealing Surface
Model Cylinder Head Combustion
Number Chamber Texture Waviness Spec.
Surface (C) Chamber
(B)
Surface (D)
The overall flatness is 0.13 mm

(0.005 inch) 3.2 µm
D318 N/A N/A N/A N/A
0.05 mm (0.002 inch) for any (125.98 µinch) Ra Max
150 mm (5.9 inch) span
(0.005 inch) 3.2 µm
D320 N/A N/A N/A N/A

D342 (0.005 inch) 3.2 µm
N/A N/A N/A N/A
G342 0.05 mm (0.002 inch) for any (125.98 µinch) Ra Max
D343 (0.005 inch) 3.2 µm
N/A N/A N/A N/A
D346 N/A N/A The overall flatness is 0.13 mm N/A 3.2 µm N/A
G346 (0.005 inch) (125.98 µinch) Ra Max q631tm
D348 0.05 mm (0.002 inch) for any Caterpillar: Confidential Yellow
G348 150 mm (5.9 inch) span
D349
G349

D353 (0.005 inch) 3.2 µm
N/A N/A N/A N/A
D379
G379 The overall flatness is 0.13 mm
D398 (0.005 inch) 3.2 µm
N/A N/A N/A N/A
D399 150 mm (5.9 inch) span
G399
219-5844 Minimum
227-5951 Waviness
259-8305 The overall flatness is 0.13 mm Height -
0.5 - 1.6 µm
278-3490 (0.005 inch) 0.0125 mm
C7 N/A N/A (19.6850 - 62.9921µinch)
280-7503 0.05 mm (0.002 inch) for any (0.00049 inch)
Ra Max
314-4183 150 mm (5.9 inch) span per 5.0 mm
314-4184 (0.20 inch) of
314-4185 spacing(2)
201-2180
241-8392
252-8438 Minimum
255-4961 Waviness
C9 0.0125 mm
311-7218 (0.006 inch) 3.2 µm (125.98 µinch)
C-9 N/A N/A
311-7228 0.05 mm (0.002 inch) for any Ra Max (0.00049 inch)
C9.3
314-4184 (0.20 inch) of
328-7475 spacing(2)
332-3619
491-1831
Minimum
Waviness
The overall flatness is 0.15 mm Height -
C-10
179-9458 (0.006 inch) 3.2 µm (125.98 µinch) 0.0125 mm
C-12 N/A N/A
148-2135 0.05 mm (0.002 inch) for any Ra Max (0.00049 inch)
C12
150 mm (5.9 inch) span per 5.0 mm
(0.20 inch) of
spacing(2)
245-4031
257-2170
265-9120
289-3210 Minimum
300-9512
Waviness
302-2297
The overall flatness is 0.15 mm Height -
C11 308-6358
(0.006 inch) 3.2 µm (125.98 µinch) 0.0125 mm
C13 331-1981 N/A N/A (0.00049 inch)
0.05 mm (0.002 inch) for any Ra Max
C-13 342-4397
344-0059
(0.20 inch) of
345-3752
spacing(2)
346-1984
346-1999
520-4381
520-4382
Minimum
185-2246
Waviness
222-1982
C15 The overall flatness is 0.15 mm Height -
223-7263
C-15 (0.006 inch) 3.2 µm (125.98 µinch) 0.0125 mm
243-0943 N/A N/A
C18 0.05 mm (0.002 inch) for any Ra Max (0.00049 inch)
245-4324
C-18 150 mm (5.9 inch) span per 5.0 mm
263-4890
(0.20 inch) ofq631tm
281-1640 Caterpillar: spacing
Confidential
(2) Yellow
C16 223-7263 N/A The overall flatness is 0.15 mm N/A 3.2 µm (125.98 µinch) Minimum
C-16 243-0943 (0.006 inch) Ra Max Waviness
263-4890 0.05 mm (0.002 inch) for any Height -
281-1640 150 mm (5.9 inch) span 0.0125 mm
(0.00049 inch)
per 5.0 mm
(0.20 inch) of
spacing(2)
Minimum
Waviness
C27 357-7398 (0.006 inch) 1.6 µm 0.0125 mm
N/A N/A
C32 396-8374 0.05 mm (0.002 inch) for any (62.9921µinch) Ra Max (0.00049 inch)
(0.20 inch) of
spacing(2)
6I-3606
105-3798
105-3799
105-3800
Minimum
123-7338 Waviness
124-7373 Height -
143-0046
C-30 (0.006 inch) 3.2 µm (125.98 µinch) 0.0125 mm
143-3615 N/A N/A
C-32 0.05 mm (0.002 inch) for any Ra Max (0.00049 inch)
151-4951
151-1335 (0.20 inch) of
151-5241
spacing(2)
151-5243
198-6523
198-6524
206-7744
328-7082
345-8447
201.4 ± 0.3 mm 0.05 mm (0.002 inch) for any 3.2 µm
C175 456-2406 N/A N/A
(7.93 ± 0.02 inch) 150 mm (5.9 inch) span (125.98 µinch) Ra Max
515-8766
517-4407
3044 (0.008 inch) 3.2 µm
N/A N/A N/A N/A
3046 0.05 mm (0.002 inch) for any (125.98 µinch) Ra Max
150.00 mm (5.91 inch) span

(0.006 inch) 3.2 µm
3054 N/A N/A N/A N/A
150.00 mm (5.91 inch) span

(0.00984 inch) 3.2 µm
3064 (0.008 inch) 3.2 µm
N/A N/A N/A N/A
150.00 mm (5.91 inch) span

3114
(0.006 inch) 3.2 µm
3126
150.00 mm (5.91 inch) span
3176 (0.01181 inch) 3.2 µm
N/A N/A N/A N/A
150.00 mm (5.91 inch) span q631tm
3204 N/A N/A The overall flatness is 0.15 mm N/A 3.2 µm N/A
DI (0.006 inch) (125.98 µinch) Ra Max
3204 0.05 mm (0.002 inch) for any
PC 150.00 mm (5.91 inch) span
3208
3304
0.10 mm
3306 (0.004 in) overall
7N-8866 3.2 µm
G3306 N/A 0.05 mm N/A N/A
148-2138 (125.98 µinch) Ra Max
(0.002 in)
DI for any 150 mm
(6.0 in) span
PC

3406
(0.005 inch). 0.05 mm 3.2 µm
(0.002 inch) for any 150 mm (125.98 µinch) Ra Max
3412
(6.0 inch) span
G3406
(0.005 inch). 0.05 mm 3.2 µm
G3408 N/A N/A N/A N/A
(0.002 inch) for any 150 mm (125.98 µinch) Ra Max
G3412
(6.0 inch) span
0.26 mm (0.010 inch) overall

3406E 3.2 µm
N/A N/A 0.05 mm (0.002 inch) for any N/A N/A
3456 (125.98 µinch) Ra Max
3500 4P-6571 205.0 mm The overall flatness is 0.10 mm 0.05 mm

G3500 7C-3471 (8.07 inch) (0.00394 inch). (0.002 inch)
7E-5861 (1)
7E-8760 0.05 mm (0.002 inch) for any

101-1175 150 mm (6 inch) span
122-5961
128-1141
131-0410
131-0411
131-0423
144-6409
145-3215
153-8397
Minimum
154-1612
Waviness
161-2508 3.2 µm
Height -
172-0834 (125.98 µinch) Ra 0.0125 mm
172-0836 Roughness Sampling
(0.00049 inch)
184-5496 Length or Cutoff -
per 5.0 mm
206-1554 2.54 mm (0.10000 inch)
(0.20 inch) of
206-1555
spacing (2)
206-1560
206-1563
229-9942
269-0040
290-1351
295-2047
315-2630
418-9804
424-7545
462-4740
487-3422
495-2062
525-6572
480-3132 3.2 µm (125.98 µinch) Minimum
Ra Waviness
Roughness Sampling Height -
Length or Cutoff - 0.0125 mm
2.54 mm (0.10000 inch) (0.00049 inch)
Average per 5.0 mm q631tm
Roughness PeakCaterpillar: Confidential Yellow
to Valley Height - (0.20 inch) of
19.0 µm (748.03 µinch) spacing(2)
Rz

(0.00394 inch).
1.6 µm
3600 N/A N/A N/A Circular Lay
(62.9921µinch) Ra Max
0.05 mm (0.002 inch) for any
150 mm (6 inch) span
(1) This is within an area that is outlined by an outer diameter of 205.0 mm (8.07 inch) and an inner diameter of 190.0 mm (7.48 inch) about the center of the cylinder head.
(2) For waviness spacing smaller than 5.0 mm (0.20 inch) use maximum waviness height of 0.00254 PER mm (0.00010 PER inch) spacing.
Permissible Distortion for C4.4, C6.6, and C7.1 Cylinder Heads

Typical example of a C4.4 engine


1. The maximum distortion of the cylinder head is given in Table 12.
Table 12
Maximum Permissible Distortion
0.03 mm
Width (A) (0.00118 inch),
0.08 mm (0.0032 inch) for C4.4 Tier 4 and C7.1
0.05 mm
Length (B) (0.00197 inch),
0.05 mm
Diagonal Line (C) (0.00197 inch),
Table 13
Average ≤ .15 µm
(5.905512 µinch)
Surface Texture of Cylinder Head
Max ≤ 0.20 µm
(7.874016 µinch)
Machining the C175 Cylinder Head Combustion Face Using Rottler Equipment
Like many engine machining operations there is more than one method that can be used to obtain results. Your dealership may own a variety of
machining tools that are capable of performing the machining operation. Depending on the particular machine tool, the machining operation
maybe more or less automated. This section outlines the four most commonly used Rottler machines. Other machines, set-upand methods are
viable alternatives that could be used if the ones outlined here are not available.
For the user program, questions or more information and a complete catalog of products, contact:
Rottler
8029 South 200th Street
Kent, WA 98032 q631tm
(253) 872-7050 Caterpillar: Confidential Yellow
(800) 452-7050
www.rottlermfg.com
CATSOP@rottlermfg.com
Cutting Inserts
The use of the correct cutting inserts is crucial to obtaining the desired finish results. If the incorrect inserts are used the finish standards will not
be achievable.
6303B Round CBN
This is a good general purpose insert that is most economical to use. It is round and can be used on both sides. If carefully indexed there will as
many as 36 cutting edges per inserts.
6303V Octagon CBN
This is an excellent insert that will maximize surface flatness and at the same time. The are 16 cutting edges per insert – 8 edges per side.
Fixturing System
There are two basic fixturing principles that are used for fixturing cylinder heads when re-machining the combustion surface. They each have
their benefits.

Example of 7209M Universal Leveling Table
7209M Universal Leveling Table
This fixturing system is manufactured by Rottler and has been the standard for many years in the remanufacturing industry. It has three main
benefits:
It can fixture a large variety of work pieces. Not only cylinder heads but manifolds and other work pieces that are difficult to hold on to.
The two axis adjustment then makes it easy to align the surface that is required to be cut with the axis of the machine tool.
If the goal is to make the new surface as parallel to the old surface as possible this is the best method to use. An example where this
would be desirable would be with overhead cam cylinder heads.
Support Parallels
This fixturing system consist of two simple parallels. In some cases one large parallel is required instead of two. The cylinder head is placed on
top of the parallels and clamped in place using toe clamps or other devices. This is an acceptable system when machining cylinder heads where
the fixturing surface on the head is parallel to the combustion surface that is going to be surfaced or re-cut. Generally speaking using this system
will guarantee the surface being cut is parallel to the surface on the opposite side of the head.
Machine Tool and Cutterheads
There are a wide variety of machine tools that are capable of doing this surfacing machining operation on C175 cylinder heads. Below are
various models that are available from Rottler Mfg. Below is a brief description of each.
F60 – Series

Example of F69A Machine
There are several models of this machine. They are general purpose machining centers commonly used for machining automotive sized engine
blocks and have the capacity to machine the C175 Cylinder head. Once the cylinder head is fixtured this machine can automatically probe and
remove the material.

Example of 650-2-8F 14” diameter fly cutter head
Use the optional 650-2-8F 14” diameter fly cutter head with this machine. q631tm
F70 – Series

Example of F70 Machine
This machine is designed for a wide variety of engine remanufacturing work. This machine has the capacity to machine a C175 cylinder head.
Once the cylinder head is fixtured this machine can automatically probe and remove the material.

Example of 650-2-8F 14” diameter fly cutter head
Use the optional 650-2-8F 14” diameter fly cutter head with this machine.
S80 – Series

Example of S86A Machine
There are two models. The S85 and S86. These are very basic machines used for “surfacing” operations only for example they cannot bore
cylinders. They are extremely simple to use. They are excellent machines for production surfacing operations or for low volume and a high
variety of work. If the requirement is to simply put a new flat surface on a work piece – these are the simplest machines to use.
Use the standard fly cutterhead that comes installed on this machine.
F103/4/5

These machines are designed for a wide variety of engine remanufacturing work. They have the capacity to machine a C175 cylinder head.
Once the cylinder head is fixtured these machines can automatically probe and remove the material. These machines were preceded by the F90
Series.

Example of 6294T 18” diameter fly cutter head
Use the optional 6294T 18” diameter fly cutter head with this machine.
F107/9

These machine are designed for a wide variety of engine remanufacturing work. They have the capacity to machine a C175 cylinder head. Once
the cylinder head is fixtured these machines can automatically probe and remove the material.

Example of 6294T 18” diameter fly cutter head
Use the optional 6294T 18” diameter fly cutter head with this machine.
Use the 10115 18” diameter fly cutter head if the machine has the optional HSK80 spindle.
The Cutting Process

q631tm
Regardless of what type of machine is being used for the actual cutting process the basic cutting parameters are the same.
All of the cutter heads have the capability of holding two inserts – one in each end.
Note: For the purposes of the cutting process it is important to only use one insert. Do not use two inserts. One cutting insert will give
the most consistent and reliable surface texture.
Use the Spindle RPM and Feed Rate specified for the particular machine being used. See Table 15. Pleasenotethe feed rate per revolution varies
depending on which cutting insert is being used. The intent of machining the C175 cylinder head is to put a new surface on fire deck. The
amount of material required to make a new surface will be dependent on the condition of the old surface. Generally speaking the depth of cut
should be somewhere between 0.05 mm (0.00197 inch) and 0.15 mm (0.00591 inch). Remove the least of amount of material to reduce the
chance of the cylinder head not meeting the minimum overall thickness dimension of 207.85 mm (8.18305 inch).
Set-up Procedure
Table 14
Rottler Required Machine Components and Tools for C175 Cylinder Head
Machine Models
Machine Components and Tools F60 F70 S80 with standard cutter head F103/4/5 F107/9
7209M Universal Leveling Table X X X X X
7152A Dual Axis Level X X X X X
6303B Round CBN or 6303V Octagon CBN Cutting Inserts X X X X X

650-3-37 Toe Clamp Kit X X X X X
6370Y 10” T-Slot Parallels N/A N/A N/A X X
11114 16” T-Slot Parallels X X N/A X X

6370M 18” Support Parallels N/A N/A N/A N/A X
650-2-8F 14” Diameter Fly Cutter Head (1) X X N/A N/A N/A
6294T 18” Diameter Fly Cutter Head (1) N/A N/A N/A X N/A
10115 18” Diameter Fly Cutter Head (1) N/A N/A N/A N/A X
650-3-59Y Wireless Probe with Rottler 650-3-59C Stub Stylus X X N/A X N/A
10110 Wireless Probe with Rottler 650-3-59C Stub Stylus N/A N/A N/A N/A X
502-12-7B Digital Runout Probe or Precision Dial Gauge X X N/A X X

(1) Do not use two inserts. One cutting insert will give the most consistent and reliable surface texture.
Perform these steps only as initial set-up
1. Ensure that the machine bed is clean and free of debris.

Example of 7209M Leveling Table placed on the S80.

Example of 16" parallels and 7209M Leveling Table placed on the F60/70

Example of 10", 16" parallels and 7209M Leveling Table placed on the F103/4/5.

Example of 10", 16", 18" parallels and 7209M Leveling Table placed on the F107/9. q631tm
2. Depending on the machine, set parallels or Rottler 7209M Leveling Table on machine bed, anchor loosely and adjust positioning to
ensure full and flat contact, refer to Table 14 for correct support parallels.
3. Depending on the machine, use one of the following methods to level Rottler 7209M Leveling Table:
Place Rottler 7152A Dual Axis Level on table, aligned with X and Y axes, and adjust table until bubbles are accurately centered
Attach a digital runout probe or dial gauge to spindle and run along table in the X and Y directions, adjusting table until values are
equal in both directions
4. Set C175 Cylinder Head, combustion side up, on leveling table and use 650-3-37 Toe Clamp Kit as pictured to secure the head to the
table.
Machining
Table 15
Feed Rate 6303B Feed Rate 6303V
Machine Model Spindle RPM Depth of Cut
Round CBN Octagon CBN
F60 750 0.38 mm (0.01496 inch) 0.25 mm (0.00984 inch) 0.05 - 0.15 mm (0.00197 - 0.00591 inch)
F70 750 0.38 mm (0.01496 inch) 0.25 mm (0.00984 inch) 0.05 - 0.15 mm (0.00197 - 0.00591 inch)
S80 750 0.38 mm (0.01496 inch) 0.25 mm (0.00984 inch) 0.05 - 0.15 mm (0.00197 - 0.00591 inch)
F103/4/5 600 0.38 mm (0.01496 inch) 0.25 mm (0.00984 inch) 0.05 - 0.15 mm (0.00197 - 0.00591 inch)
F107/9 600 0.38 mm (0.01496 inch) 0.25 mm (0.00984 inch) 0.05 - 0.15 mm (0.00197 - 0.00591 inch)
If Machining to Maintain Parallelism Between Cylinder Head Faces
1. Insert wireless probe with 650-3-59C Stub stylus in machine spindle and run Go-No-Go check on mounted cylinder head. Refer to Table
14 for correct wireless probe.
2. Switch tool to fly cutter head, with ONE insert installed. Do not use two inserts. One cutting insert will give the most consistent and
reliable surface texture. Refer to Table 14 for correct fly cutter head.
3. Set machine spindle position to allow the cutter to pass over the entire width of the cylinder head.
4. Refer to Table 15 for machine speeds, feeds and depth of cut.
5. Start spindle and feed and allow the cutter to pass fully over cylinder head.
If Machining to Remove the Minimum Amount of Material from Existing Head
1. Insert wireless probe with 650-3-59C Stub stylus in machine spindle and run Go-No-Go check on mounted cylinder head. Refer to Table
14 for correct wireless probe.
2. Switch tool to fly cutter head, with ONE insert installed. Do not use two inserts. One cutting insert will give the most consistent and
reliable surface texture. Refer to Table 14 for correct fly cutter head.
3. Set machine spindle position to allow the cutter to pass over the entire width of the cylinder head.
4. Refer to Table 15 for machine speeds, feeds and depth of cut.
5. Start spindle and feed and allow the cutter to pass fully over cylinder head.
Cylinder Heads with Camshaft Bores

Table 16
Dimensions for Cylinder Heads with Camshaft Bores
Part New Camshaft Bore in the Outside q631tm

Number of the Bearing Cylinder Head Bearing Diameter Caterpillar: Confidential Yellow
216-5582 90.985 ± 0.020 mm 91.100 ± 0.020 mm
(3.5821 ± 0.0008 inch) (3.5866 ± 0.0008 inch)
217-0751 91.224 ± 0.020 mm 91.339 ± 0.020 mm

oversize (3.5915 ± 0.0008 inch) (3.5960 ± 0.0008 inch)
217-0752 91.732 ± 0.020 mm 91.847 ± 0.020 mm

261-3429 92.748 ± 0.020 mm 92.863 ± 0.020 mm

261-3430 92.24 ± 0.020 mm 92.355 ± 0.020 mm

Bridge Dowel for 3400 Engines

Check the bridge dowels for movement by using the following procedure.
1. Use a torque wrench and MAC AST 100 7/16 inch tool.
2. Set the torque wrench at 13.6 N·m (10.00 lb ft).

Inspect the bridge dowels for movement.
3. Grip the bridge dowel and turn the torque wrench. The bridge dowel should not rotate at 13.6 N·m (10.00 lb ft).
If there is movement, repair the hole with the 5P-7333 Repair Tool and the 5P-7324 Plug. Refer to Special Instruction, SMHS7072, "Use of the
5P-7333 Repair Tool for Bridge Dowel Repair".
Precombustion Chambers and Direct Injection Nozzle Adapter for 3400 Engines

Precombustion chamber nomenclature.
(1) Injector Inlet
(2) O-ring Groove
(3) Nozzle Seat
(4) Gasket Face
(5) Chamber Outlet
(6) Injector Outlet

Direct Injection Nozzle Adapter nomenclature.
(1) Injector Inlet
(2) O-ring Groove
(3) Nozzle Seat
(4) Gasket Face
(5) Chamber Outlet
(6) Injector Outlet
Visual inspect precombustion chambers and direct injection nozzle adapters. Refer to Illustrations 84, that have pitting (small holes in the
surface) or other surface damage, can be used again.
Pitting, which can be caused by high heat during combustion or when coolant comes in contact with the body of the precombustion chamber or
adapter, is permissible, according to its location and amount. For example, heavy pitting on the main body between the O-ring groove and the
gasket face of the adapter is acceptable if it has not worn completely through. Similarly, pitting in the O-ring groove is acceptable if 70% or
more of the groove on the inlet side shows no signs of pitting. Pitting on the gasket face is acceptable only in the outer 10% of the radius
0.64 - 0.76 mm (0.02520 - 0.02992 inch).
Visual Inspection q631tm

Pitting

Pitting on the surface between the O-ring groove and gasket face (area (A).
Use Again - if the pitting has not worn through. The pitting can be heavier than shown in this photo and still be used again.

Example of pitting extending into the top 70% (B) of the O-ring groove of a precombustion chamber.
Do Not Use Again

Example of pitting extending into the top 70% (B) of the O-ring groove of a direct injection adapter.
Do Not Use Again

Example of pitting extending into the top 70% (B) of the O-ring groove of a precombustion chamber.
Use Again
NOTICE
If pitting is a major problem, be sure to correct the reason for pitting.
It is very important to maintain the cooling system correctly and at
regular intervals.

Example of pitting extending into the top 10% of the outer radius of the gasket face.
Do Not Use Again

Example of pitting that has not extended beyond 10% of the outer radius of the outer radius of the gasket face of a precombustion chamber.
Use Again

Example of pitting that has not extended beyond 10% of the outer radius of the outer radius of the gasket face of a direct injection adapter.
Use Again

A small nick on the precombustion chamber splines.
Use Again - if sharp edges can be smooth with a 6V-2010 Polishing Stone or file. (Splines are not needed for correct engine operation. It
is needed for manufacturing purposes only.)
q631tm
Nicks, Cracks, and Other Surface Damage Caterpillar: Confidential Yellow
Check for cracks on the threaded section of the precombustion chamber and direct injection nozzle adapters. Cracks are not acceptable.

Damage is light and limited mainly to the lower half of the threads.
(C) Upper half of threads
(D) Lower half of threads
Use Again - only if the damage threads can be repaired using a thread file.
Heavy damage on upper half (C) of the threads is also not acceptable. If the damage is light and limited to the lower half (D) of the threads, the
threads can be repaired using a thread restorer (thread file).
NOTICE
Only light damage is permissible in upper half (C) of the threads. The
upper threads are the most important because they help prevent
combustion gases from reaching the seal area.
Note: Both the precombustion chamber and direct injection nozzle adapters have 12 threads per inch.
Measurement of Precombustion Chamber Outlet

Use the correct size plug gauge to measure the chamber outlet diameter.
Use the correct size plug gauge to measure the chamber outlet diameter (Illustration 84.). If the plug gauge slides into the opening, do not use
the precombustion chamber again. Be sure the plug gauge and the precombustion chamber are at the same temperature, within ± 3°C (5°F),
when checking the outlet diameter.
Table 17
Precombustion Chamber Specifications
Outlet Diameters Thread Size

Part Maximum Erosion of Gasket
New Diameter (2)
Number Maximum "Use Again Diameter (inches Threads Per Face (1)
0.051 mm
Diameter (1) only) Inch
(0.00201 inch)
8.38 mm
2P-0484 8.68 mm (0.34173 inch) ⅞ 12 0.64 mm (0.02520 inch)
(0.32992 inch)
9.40 mm
2P-1816 9.70 mm (0.38189 inch) 1 12 0.64 mm (0.02520 inch)
(0.37008 inch)
7.16 mm
3S-5445 7.47 mm (0.29409 inch) ⅞ 12 0.64 mm (0.02520 inch)
(0.28189 inch)
10.69 mm
4N-3714 10.90 mm (0.42913 inch) (3) ⅞ 12 0.64 mm (0.02520 inch)
(0.42087 inch) (3)
5.71 mm
5S-1820 6.02 mm (0.23701 inch) ⅞ 12 0.64 mm (0.02520 inch)
(0.22480 inch)
6.35 mm
5S-1822 6.65 mm (0.26181 inch) ⅞ 12 0.64 mm (0.02520 inch)
(0.25000 inch)
6.35 mm
5S-1823 6.65 mm (0.26181 inch) ⅞ 12 0.64 mm (0.02520 inch)
(0.25000 inch)
6.65 mm
5S-1824 6.96 mm (0.27402 inch) ⅞ 12 0.64 mm (0.02520 inch)
(0.26181 inch)
6.65 mm q631tm
5S-1825 6.96 mm (0.27402 inch) ⅞ 12 0.64 mm (0.02520
Caterpillar: inch) Yellow
Confidential
(0.26181 inch)
5S-1826 7.16 mm 7.47 mm (0.29409 inch) ⅞ 12 0.64 mm (0.02520 inch)

(0.28189 inch)
7.16 mm
5S-1827 7.47 mm (0.29409 inch) ⅞ 12 0.64 mm (0.02520 inch)
(0.28189 inch)
5.71 mm
5S-1831 6.02 mm (0.23701 inch) ¾ 12 0.64 mm (0.02520 inch)
(0.22480 inch)
5.71 mm
5S-1832 6.02 mm (0.23701 inch) ¾ 12 0.64 mm (0.02520 inch)
(0.22480 inch)
6.35 mm
5S-1833 6.65 mm (0.26181 inch) ¾ 12 0.64 mm (0.02520 inch)
(0.25000 inch)
7.16 mm
5S-1836 7.47 mm (0.29409 inch) ¾ 12 0.64 mm (0.02520 inch)
(0.28189 inch)
9.91 mm
5S-4131 10.20 mm (0.40157 inch) ⅞ 12 0.64 mm (0.02520 inch)
(0.39016 inch)
7.16 mm
5S-6795 7.47 mm (0.29409 inch) ⅞ 12 0.64 mm (0.02520 inch)
(0.28189 inch)
8.74 mm
5S-9608 9.04 mm (0.35590 inch) ⅞ 12 0.64 mm (0.02520 inch)
(0.34409 inch)
10.69 mm
6N-6969 10.90 mm (0.42913 inch) 1 12 0.64 mm (0.02520 inch)
(0.42087 inch)
10.16 mm
7M-6848 10.46 mm (0.41181 inch) 1 12 0.64 mm (0.02520 inch)
(0.40000 inch)
10.16 mm
7S-5787 10.46 mm (0.41181 inch) 1 12 0.64 mm (0.02520 inch)
(0.40000 inch)
9.91 mm
8S-1523 10.20 mm (0.40157 inch) ⅞ 12 0.64 mm (0.02520 inch)
(0.39016 inch)
10.16 mm
8S-3617 10.46 mm (0.41181 inch) 1 12 0.64 mm (0.02520 inch)
(0.40000 inch)
7.49 mm
8S-3970 7.79 mm (0.30669 inch) ⅞ 12 0.64 mm (0.02520 inch)
(0.29488 inch)
10.69 mm
9S-6743 10.90 mm (0.42913 inch) 1 12 0.64 mm (0.02520 inch)
(0.42087 inch)
7.92 mm
9S-8679 8.23 mm (0.32402 inch) ⅞ 12 0.64 mm (0.02520 inch)
(0.31181 inch)
(1) Approximately 10% of the gasket face radius. Refer to Illustrations 84, 84, and 84.
(2) If the Maximum "Use Again" Diameter exceeds the specifications, the part can be drilled to the next size diameter and restamped with a new part number. Do not install this
part into an engine which requires the former part.
(3) Outlet diameters are precombustion chambers only not direct injection nozzle adapters.
Precombustion and Direct Injection Adapter Seats for 3400 Engines

Visually inspect the seat for the adapter. The seat needs to be repaired if the seat is pitted or damaged. Refer to Special Instruction, SMHS8276,
"Repair of Precombustion Chamber and Direct Injection Adapter Seating Surfaces" for procedures to recondition the seat. FT-1766 Adapter will
be needed to recondition the seat.
Chamfer (A) at the threads for the adapter must be remachined to 1.50 ± 0.50 mm (0.060 ± 0.020 inch) by 30 degrees. For the cylinder heads on
diesel engines, the maximum removal of stock from the seat is 0.38 mm (0.015 inch). The minimum dimension from the seat to the combustion
area is 16.89 mm (0.665 inch). For the cylinder heads on gas engines, the maximum removal of stock from the seat is 0.35 mm (0.014 inch).
The minimum dimension from the seat to the combustion area is 10.37 mm (0.408 inch).

q631tm
(A) Chamfer 1.50 ± 0.50 mm (0.060 ± 0.020 inch) by 30 degrees
(B) Minimum thickness
(6) Combustion area
(10) Top deck
(11) Seat for the adapter

Visually inspect the seat for damage. The cylinder head in this illustration was cut for photographic purposes.
Use the cylinder head again.
118-0373118-0372118-0373118-0372118-0373118-0372118-0373118-0372Installation of
118-0372, 118-0373 Oversize Water Directors
Water directors are used in the cylinder heads of some engines. These water directors improve the cooling of the heads by directing cooling
water to specific locations in the head. In order to function properly, the orientation and the installation depth of the water director in the head is
very important.
Through normal wear, the water director bore can become oversized or eroded which can reduce the press fit of the water director.
Previously, the only salvage technique has been to build up the bore with weld or Belzona®. A more cost effective solution is to install an
oversize water director.

Water director puller.

Water director driver.
The removal and installation tooling for water directors must be fabricated. One puller and four drivers are required to repair all the different
cylinder heads that use water directors. Fabricate the tooling, using the dimensions shown in Illustrations 136and 137.
Table 18
Water Director Driver Dimensions
Driver Number (A) (B) (C)
1 2.50 mm (0.09843 inch)
2 N/A
16.235 ± 0.025 mm (0.63917 ± 0.00098 inch) 18.925 ± 0.125 mm (0.74508 ± 0.00492 inch)
3 5.3 mm (0.20866 inch)
4 7.1 mm (0.27953 inch)
Inspection
1. Check the water director for signs of movement within the bore.
2. Make sure the alignment notch in the water director is in line with the "V" stamped in the head.
3. Make sure the water director is tight in the bore. If the water director has moved or is loose in the bore, the bore should be machined, and
an oversize water director installed
Removal
If a water director shows signs of movement, remove it using a water director puller as shown in Illustration 136. Water directors that do not
show signs of having moved and fit tightly in the bore, do not need to be replaced
Salvage
To use oversize water directors, the bores in the head must be machined.
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Table 19
Specifications for Installing Oversize Water Directors
Part Number for

5H-7071 1S-3062
Standard Size Water Director
Bore Diameter (A) for

19.02 ± 0.03 mm (0.74882 ± 0.00118 inch) 19.012 ± 0.038 mm (0.74850 ± 0.00150 inch)
Standard Water Director
Part Number for
118-0372 118-0373
Oversize Size Water Director
Bore Diameter (A) for
19.774 ± 0.038 mm (0.77850 ± 0.00150 inch) 19.782 ± 0.038 mm (0.77882 ± 0.00150 inch)
Oversize Water Director
1. Machine the bore to the oversize dimension shown in Table
2. Thoroughly clean the head, and remove all machining debris.
Installation

Water director installed in head with counterbore. Always install the water director flush with top of counterbore, using driver number 2.
(A) Bore diameter

Water director installed in head without counterbore.
(A) Bore diameter
(B) Installation depth
There are two types of water director bores, with or without counterbores. The two designs are shown in Illustrations 138 and 139. Some engine
models may have both designs, depending on the engine configuration.
For the head to be properly cooled, the water director must be installed properly.
1. Install the water director with the notch aligned with the "V" stamped in the head.
2. Use the correct driver to ensure the water director is installed to the proper depth.
Note: When there is a counterbore, the director is installed flush with the bottom of the counterbore, using driver number 2. If no
counterbore is present, install the water director to the correct depth.
3. After the water director is installed, make sure the water director notch is still in line with the "V" stamped in the head.
4. Check the installation depth.
Sleeves for the Injectors of Cylinder Heads

A stainless steel sleeve is used between each unit injector and the cylinder head casting. The injector sleeve is used to seat the injector. The
injector sleeve is also used to seal the injector into the casting. The injector sleeves are reusable unless the sleeves become damaged.
Refer to the Disassembly and Assembly for your machine to find the tooling that is used to remove a unit injector sleeve. Refer to the
Disassembly and Assembly for your machine for Disassembly and Assembly information.
Inspect the inside surface of the sleeves for cracks, pitting, erosion, and other visual damage. Sleeves should be replaced during the general
overhaul of the cylinder head with high hours.
NOTICE
When reaming the injector seat area, be careful not to damage the
surface. Do not drop the reamer onto the seat, or apply too much
downward pressure with the tool because it may create radial lines on
the sealing surface of the sleeve. Radial lines will cause poor sealing
q631tm
between the sleeve cone and the injector tip, which may result in fuel
leakage into the cylinder, or combustion pressure leakage into the fuel.
Check the area at the bottom of the valve seat for normal wear. If the valve seat appears worn or distorted slightly, the sleeve must be replaced.
Check the guide for Disassembly and Assembly for the procedures and the lists for tooling.
Injector Sleeves

Injector Sleeve
(1) O-ring Seals
(2) Location for clean engine oil
(3) Injector Sleeve
(4) Location for 4C-9507 Retaining Compound
Stainless steel injector sleeves (3) with O-rings (1) are used between each unit injector and the cylinder head casting. The injector sleeves seal
coolant within the head. The injector sleeves will not usually need to be replaced. The three O-rings should be replaced when the head is
removed for reworking the valves or if the head is placed into a hot tank for cleaning.
Before you install the injector sleeves (3), 4C-9507 Retaining Compound should be applied to area (4). Clean engine oil should be applied to
area (2). Use the 9U-6891 Injector Tool Group and a suitable hammer to install the injector sleeve (3) into the cylinder head.
Injector Sleeves for C175 Engines
A stainless steel sleeve is used between each unit injector and the cylinder head casting. The injector sleeve is used to seat the injector. The
injector sleeve is also used to seal the injector into the casting. The injector sleeves are reusable unless the sleeves become damaged.
Refer to the Disassembly and Assembly for your machine to find the tooling that is used to remove a unit injector sleeve. Refer to the
Disassembly and Assembly for your machine for Disassembly and Assembly information.
Inspection of the injector sleeve seat:

Example of cleaned continuous shiny band 360 degrees around the seat surface.
OK TO REUSE

Example of damaged seat surface.
DO NOT REUSE
The seat and threads must be free of any debris.
The seat must not have any visible burs, burns, etc. around the surface.
After cleaning injector sleeve seat, there should be a continuous shiny band 360 degrees around the seat surface. Refer to Illustration 141.

Example of bur (A) on sleeve seat.
DO NOT REUSE

Example of burn (B) on sleeve seat.
DO NOT REUSE
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Example of burn (B) on sleeve seat.
DO NOT REUSE
Injector Sleeves for 3114, 3116, and 3126

The arrow above indicates the injector sleeve. (A) is the O-ring.

Illustration 147 is an example of a Stainless Steel Injector Sleeve. Notice the grooves (B) on the outside of the sleeve that holds the sleeve in place.
A brass or stainless steel injector sleeve is between each unit injector and the cylinder head casting. The injector sleeve is used to seat the
injector. The injector sleeve is also used to seal the injector into the casting. The injector sleeves will not usually need to be replaced. The O-
rings (A) should be replaced when the head is removed for reworking the valves or if the head is placed into a hot tank for cleaning. Lubricate
the new O-rings with clean engine oil before assembly. Apply Loctite 242 to the bore in the cylinder head for diameter (C) of the injector sleeve
prior to assembly.
Refer to the Disassembly and Assembly Manual for your machine to find information on the removal and installation of unit injector sleeves.
NOTICE
Check the area at the bottom of the seat for normal wear. If the seat appears worn or distorted slightly, the sleeve must be replaced. The seat can
be refinished with a 4C-8719 Shank and 131-8362 Reamer. Use the reamer for machining the seat of the injector to ensure a tight seal when the
sleeve is assembled. If machining does not clean up the damaged seat, the sleeve must be replaced.
Refer to Tool Operating Manual, NEHS0675, "Using the 143-2099 Sleeve Replacement Tool Group on 3114, 3116, and 3126 Engines".
Stainless Steel Injector Sleeve

Illustration 147 and illustration 147 are both examples of stainless steel injector sleeves. Notice that the inside of the sleeve is smooth when installed.
Use 151-4832 tooling to remove Stainless Steel Injector Sleeves. A stainless steel injector sleeve can be told apart from Bronze Swaged Sleeves
by looking at the top of the inside of the sleeve when installed. The stainless steel sleeve will be smooth on the inside while the bronze sleeves
will have two grooves because of them being swaged into place during installation. The Tool Operating Manual, NEHS0675, "Using the 143-
2099 Sleeve Replacement Tool Group on 3114, 3116, and 3126 Engines" provides instructions on how to properly remove the Bronze Swaged
Injector Sleeves.
Bronze Swaged Injector Sleeve

Illustration 149 is an example of a Bronze Swaged Injector Sleeve. Notice that the inside of the sleeve is initially straight, but are then is Swaged into place during installation.
Use the 143-2099 Tooling to remove Bronze Swaged Injector Sleeves. An installed bronze injector sleeve is differentiated from stainless steel q631tm
sleeves by the grooves at the top of the sleeve due to the sleeve being Swaged into place during installation. The ToolCaterpillar:
OperatingConfidential
Manual, Yellow
NEHS0675, "Using the 143-2099 Sleeve Replacement Tool Group on 3114, 3116, and 3126 Engines" provides instructions on how to properly
remove the Bronze Swaged Injector Sleeves.
Injector Sleeves for 3176, and 3196

A brass sleeve is used between each unit injector and the cylinder head casting. The injector sleeve is used to seat the injector. The injector
sleeve is also used to seal the injector into the casting. The injector sleeves are reusable unless the sleeves become damaged.
Refer to the Disassembly and Assembly for more information.
NOTICE
Check the area at the bottom of the seat for normal wear. If the seat appears worn or distorted slightly, the sleeve must be replaced. The seat can
be refinished with a 9U-6860 Injector Sleeve Tool. Use the reamer for machining the seat of the injector to ensure a tight seal when the sleeve is
assembled. If machining does not clean up the damaged seat, the sleeve must be replaced.
Refer to Special Instruction, SEHS9246, "Using 9U-6860 Injector Sleeve Tool to Replace Unit Injector Sleeves" for more information.
Valve Guides
Valve guides must be measured for installed height and inside bore diameter.
NOTICE
Do not use any valve guides with obvious damage. Do not use valve
guides with wear that is beyond the specifications that are provided.
Loose or damaged valve guides must be removed and new valve guides
must be installed. Correct any conditions that could have caused the
original damage or wear.
Table 20
Valve Guide Measurement Tools
Dimensions Which Gauge (Green

Part Dimensions and Engines inch Which Gauge (Red End) Is Used to Check Worn
End) is Used to Check New or
Number Valve
Knurled Value Guides
4C-9734 8.08 mm (0.318 inch) (3114, 3116) 8.035 mm (0.316 inch)
7.92 mm (0.312 inch), 9.52 mm (0.375), and 12.7 mm (0.500 inch) (D379, D398, D399, G379, G398, G399, C7 through C32,
5P-3536
3176 and 3196)
9.55 mm (0.376 inch) [1673, 1693, 1100, Series, 3100 Series, 3204 3208, 3304, 3306,
9.5 mm (0.374 inch), 1100 Series, 3100
6V-7058 D330C, D333C, D342, D343, D346, D348, D349, D353, D379, D398, D399, 137.2
Series, 3204 and 3208
(5.4 inch) Bore 90 degree V-8]
9.54 mm (0.3755 inch) (3406, 3408, 3412, 3508, 3512, 3516, 9.65 mm (0.38 inch)
6V-7068 9.460 mm (0.3725 inch)
Intake and Exhaust valve)
6V-7895 12.775 mm (0.503 inch) (D379, D398, D399) N/A

16.059 x 50.8 mm (0.6322 x 2.0 inch)
9U-6399 16.003 x 175 mm (0.630 x 6.9 inch) (Go)
(No-Go)
q631tm
9U-6401 16.106 x 50.8 mm (0.634 x 2.0 inch) (Go) 16.209 x 50.8 mm (0.6381
Caterpillar: x 2.0 inch)
Confidential Yellow
(No-Go)
12.672 mm (0.498 inch) (3508, 3512, 3516) 12.594 mm (0.4958 inch)
261-3687
12.7 mm (0.5 inch) (3500 Engines - Exhaust valves only) N/A
This section shows the tools for inspecting valve guides in Caterpillar engines. Valve guides must be measured for installed height from the top
deck and the inside bore diameter. Refer to the appropriate. Refer to the appropriate Disassembly and Assembly Manual for removal and
installation instructions for the valve guides.
Note: Do not reuse any valve guide with obvious damage. Do not use a valve guide if the wear exceeds the permitted allowance according to
available specifications. Loose valve guides or damaged valve guides must be removed and new valve guides must be installed. Correct any
condition that could have caused the original damage or wear. The valve guide will not require any machining after installation.

5P-3536 Valve Guide Gauge

Typical plug gauge

Measure the diameter of the bore.

The end of the plug gauge must not go into the bore of the valve guide more than 19.0 mm (0.75 inch).
Measure both ends of each valve guide. The measurement should be taken 19.0 mm (0.75 inch) from each end of the bore. If the valve guide is
counterbored, measurements must be taken in this area. If plug gauges are used, the end of the gauge should not extend into the valve guide
more than 19.0 mm (0.75 inch). If the measurement of the valve guide exceeds the dimension, then the valve guide is worn beyond the
allowable dimension for reusability.
Note: Do not force the plug gauge or turn the plug gauge into the guide of the bore. Doing so will damage the gauge.
The specifications of installed height for valve guides in all current Caterpillar cylinder heads can be measured with a 6V-2012 Micrometer
Depth Gauge. The dial caliper, and the 8H-8581 Feeler Gauge are also needed.
The inside diameter of the valve guide can be measured with tools such as a 5P-3536 Valve Guide Gauge, 6V-7058 Plug Gauge, and 6V-7068
Valve Guide Gauge. The rest of the tooling available is in Table 20, along with their corresponding engines. There are different tools for the
different sizes of valve guides.
Inspection for Valve Guides

Type 1 for C7 through C32
Height to the top of the valve guide
(B) The installed height for the valve guide

Type 2 for C7 through C32
Height from the top of the head to the square shoulder that is just below the top of the valve guide

q631tm
Type 3 for C7 through C32 Caterpillar: Confidential Yellow
Height to the top of the valve guide

C175 Cylinder Heads

3126B Cylinder Heads

Using a Depth Micrometer

(B) Height of an installed valve guide
Valve Guides for D Models, and 1404 Engines
Table 21
Dimensions for the Valve Guides for D Models, and 1404 Engines
Installed Valve Guide

Installed
Model Maximum Bore
Intake Exhaust Height

9.550 mm 9.550 mm
1404 N/A
(0.37598 inch) (0.37598 inch)
11.201 mm 11.201 mm 44.45 mm
D318
(0.44098 inch) (0.44098 inch) (1.75000 inch)
9.575 mm 9.575 mm 33.3 ± 0.5 mm
D320
(0.37697 inch) (0.37697 inch) (1.31102 ± 0.01969 inch)
9.550 mm 9.550 mm
D342 (0.37598 inch) (0.37598 inch) 42.93 mm
G342 12.775 mm 12.775 mm (1.69015 inch)
(0.50295 inch) (0.50295 inch)
D343 9.550 mm 9.550 mm (1)

G343 (0.37598 inch) (0.37598 inch)
9.550 mm 9.550 mm
169390° V8 N/A
(0.37598 inch) (0.37598 inch)
D346 9.550 mm 9.550 mm 26.21 ± 0.51 mm
G346 (0.37598 inch) (0.37598 inch) (1.03189 ± 0.02008 inch)(2)
D348 9.550 mm 9.550 mm (3)

G348 (0.37598 inch) (0.37598 inch)
D349 9.550 mm 9.550 mm

N/A
G349 (0.37598 inch) (0.37598 inch)
9.550 mm 9.550 mm
D353 (0.37598 inch) (0.37598 inch)
N/A
G353 12.775 mm 12.775 mm
(0.50295 inch) (0.50295 inch)
D379 9.550 mm 9.550 mm N/A

G379 (0.37598 inch) (0.37598 inch)
D398 12.775 mm 12.775 mm
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G398 (0.50295 inch) (0.50295 inch)
D399
G399
(1) The height of the valve guide as measured from the bottom of the counterbore is 30.28 mm
(1.19212 inch).
(2) Measure from bottom of counterbore.
(3) Valve guide "with shoulder" to be installed flush with the bottom of the counterbore. Valve guide "without shoulder" to be installed to 26.21 mm
(1.03189 inch) as measured from the top surface of the cylinder head.
Valve Guides for C4.4, C6.6, and C7.1

INTAKE valve guide (A). EXHAUST valve guide (B) for C4.4 engines.


This procedure details the steps necessary to salvage the cylinder heads in the C4.4, C6.6 and C7.1 engines. This procedure will involve the
machining of the cylinder head for the installation of new valve guides and valve seat inserts. The machining procedures in this document only
apply to cylinder heads that have the valve guides cast into the cylinder head.
New valve guide inserts can be used if the valve guide bore in the cylinder head is worn beyond specifications. Each valve seat insert bore
diameter should be measured with a dial indicator to find the centerline position for machining the valve guide bore. The valve guide parent
bore should be machined to a positional tolerance of 0.10 mm (0.004 inch) to the centerline. Use the following procedure to install new valve
guide inserts.
Note: This step is to be used on cylinder heads that do not have separate valve guides installed into the cylinder head. Only cylinder heads
with the valve guide that is cast into the cylinder head should use this machining procedure.
1. Machine the cylinder head to the specifications found in the following table.
Table 22
Specifications for C4.4, C6.6, and C7.1
Item Description Value

15.0 mm
(H) Diameter of Counterbore (0.59 inch) - 15.5 mm
(0.61 inch)
11.4 mm
(I) Diameter of Chamfer (0.45 inch) - 11.6 mm
(0.46 inch)
(J) Total Chamfer Angle 90 Degrees
Maximum Radius of 0.6 mm

(K) Radius
(0.024 inch)
66.75 mm
(L) Bottom of Counterbore to Bottom of Cylinder Head (2.628 inch) - 67.25 mm
(2.648 inch)
10.000 mm
(M) Hole Diameter (0.3937 inch) - 10.022 mm q631tm
(0.3946 inch) Caterpillar: Confidential Yellow
Table 23
Valve Guide Part Number
Valve Guides 380-2073
2. Install the new valve guides. Machine the EXHAUST valve guide to the dimensions that are shown in the following table.
Table 24
Exhaust Valve Guide Dimensions for C4.4, C6.6, and C7.1
Item Description Value
0.4 mm
N Max Radius
(0.02 inch)
38.25 mm
O Depth (1.506 inch) to 38.75 mm
(1.526 inch)
7 mm
P Diameter (0.28 inch) to 7.5 mm
(0.30 inch)
3. Install new valve seat inserts (R), as shown.
4. Obtain a suitable reamer and cutter assembly. The valve guides will be reamed using one operation.
Table 25
Cutting Speeds and Feed Rates for Valve Guides for C4.4, C6.6, and C7.1
Tool Type Cutting Speed (M/min) Feed Rate (mm/rev)
Single Flute Solid Carbide 30-40 0.18 - 0.21
Single Adjustable Carbide Blade 40-50 0.20 - 0.25

Single Adjustable Pitch Circle Diameter (PCD) Blade 40-50 or 60-70 0.20 - 0.25 or 0.10 - 0.20
Table 26
Additional Valve Guide Related Tooling for C7.1 Engines
Part
Description Usage Notes
Number
Valve Guide 482- Installs valve guide to height of 12.65 mm (0.49803 inch). Uses the 482-0190 Reamer to finish installed
Stop Collar 0188 valve guide to correct ID of 9.0 mm (0.35433 inch).
Valve Guide 482- Installs new valve guides with internal diameter of 8.0 mm (0.31496 inch) before reaming. Uses the 482-
Driver 0189 0190 Reamer to finish the installed valve guide to correct ID of 9.0 mm (0.35433 inch).
Valve Guide
482-
Finish Finishes the 335-6264 Valve Guide to the proper diameter.
0190
Reamer
Valve Guide 483- Installs valve guide to height of 11.0 mm (0.43307 inch). Uses the 385-8470 Reamer to finish the installed
Stop Collar 7533 valve guide to correct ID of 7.0 mm (0.27559 inch).
Valve Guide 483- Installs new valve guides with an internal diameter of 6.5 mm (0.25590 inch) before reaming. Uses the
Reamer 7534 385-8470 Reamer to finish the installed valve guide to correct ID of 7.0 mm (0.27559 inch).
q631tm
Table 27 Caterpillar: Confidential Yellow
Valve Guide Bore
5.97 mm (0.235 inch) to 5.99 mm (0.236 inch)

Diameter of Valve Guide Bore (Q)
9.000 mm (0.3543 inch) to 9.022 mm (0.3552 inch) (C7.1 Tier 2/3 Mech)
1.6 µm (62.99213 µinch) Maximum

Surface Texture of Valve Guide Bore
0.8 µm (31.49606 µinch) Maximum (C7.1 Tier 2/3 Mech)
5. Install the reamer into the valve guide. Carefully turn the handle in a clockwise direction. Gradually move the reamer into the valve guide
until the valve guide. Lubricant is not necessary.
6. Clean the cylinder head. The following table lists the maximum contaminant levels for the cylinder head after the machining process.
Table 28
Contaminant Levels
Maximum
Maximum
Particulate
Maximum Maximum Maximum Particulate
Maximum Maximum Size in any
Particulate Size Particle Particle Size in any
Particle Particle Direction
in any Direction Weight Weight Direction
Feature Weight Weight (micro
(micro meters) C7.1 (Tier C7.1 (Tier (micro
C4.4 C6.6 meters)
C6.6 and C4.4 2/3 Mech) 4) meters)
engines engines C7.1 (Tier
engines Engines Engines C7.1 (Tier
2/3 Mech)
4) Engines
Engines
Top face including push rod

holes, glow plug holes, oil
500 40 60 48 1000 60 500
drains, all wetted surfaces,
and the oil feed passage
Total inlet ports and inlet

- 40 60 48 1000 60 -
manifold
Exhaust ports - 40 60 48 1000 60 -
Cylinder head gasket face - 10 15 - - 15 -

Water jacket including 1000 x
housing for water temp 1500 100 150 90 1000 y 150 500
regulator 500 z
Injector bores and fuel return
1200 10 10 N/A N/A 10 1200
gallery
1200 x
Fire Face and Valve Seat
N/A N/A N/A 10 500 y N/A N/A
Faces
150 z
Filtration Level - 30 micrometers

Typical example for C4.4 and C6.6 engines.

Typical example for C7.1 engines.
7. Inspect the gasket surface (E) and all threaded holes of the cylinder head for wear or damage. Inspect the pads (D) for the rocker shaft for
wear or damage.
The cylinder head should be pressure tested to 200 kPa (29 psi).
Illustration 169 g06277688 q631tm

8. Install a new plug (F) for the fuel return galley.
9. Install a new plug (N) in the return fuel galley.
Installing Valve Guides for C4.4, C6.6, and 7.1 Cylinder Heads
Note: The following parts are needed to replace the valve guides.

Typical example
1. Use a suitable press to remove the valve guides (H) from the cylinder head. There are 16 valve guides for C4.4 and 24 valves guides for
C6.6, and C7.1 (H) per cylinder head.

Typical example
2. Use a suitable press to install new valve guides (H) to dimension (J). The guide must be reamed to size (K).
Note: The valve guides should be machined after all components are installed.
Table 29
Dimensions for Valve Guides (C4.4 Tier 4), C6.6 and C7.1
(J) Height of 10.75 mm (0.4232 in) to 11.25 mm (0.4429 in). Surface Texture is 1.6 µm (62.99213 µinch) Ra Maximum
(K) Diameter of 7.007 mm (0.2759 in) to 7.020 mm (0.2764 in)
Valve Guides for C7 through C32
Table 30
Dimensions for the Valve Guides for C7 through C32
Valve guide Comment Type Maximum Bore Diameter (B) Installed Height
9.584 mm 22.0 ± 0.5 mm

100-8150 N/A 2
(0.3773 inch) (0.87 ± 0.02 inch)
0.51 mm 9.585 mm 35.0 ± 0.5 mm

122-0447 1
(0.0201 inch) oversize (0.3774 inch) (1.38 ± 0.02 inch)
9.584 mm 35.0 ± 0.5 mm

122-7375 N/A 1
(0.3773 inch) (1.38 ± 0.02 inch)
0.13 mm 9.585 mm 35.0 ± 0.5 mm

122-8612 1
8.143 mm 23.0 ± 0.5 mm

140-9670 N/A 1
(0.3206 inch) (0.91 ± 0.02 inch)
9.594 mm 22.0 ± 0.5 mm

144-2904 N/A 2
(0.3777 inch) (0.87 ± 0.02 inch)
9.594 mm 17.8 ± 0.5 mm

147-8220 N/A 1
(0.3777 inch) (0.70 ± 0.02 inch)
9.584 mm 32.26 ± 0.76 mm
173-7188 N/A 1
(0.3773 inch) (1.270 ± 0.030 inch)
0.13 mm 9.596 mm 17.8 ± 0.5 mm
187-8278 1 q631tm
187-8279 0.51 mm 1 9.595 mm 17.8 ± 0.5 mm
0.13 mm 8.145 mm 23.0 ± 0.5 mm

187-8280 1
0.51 mm 8.144 mm 23.0 ± 0.5 mm
187-8281 1
9.590 mm 22.0 ± 0.5 mm
224-3124 N/A 1
(0.3776 inch) (0.87 ± 0.02 inch)
8.143 mm 48.4 ± 0.5 mm
255-8665 2007 3
(0.3206 inch) (1.91 ± 0.02 inch)
9.590 mm 22.0 ± 0.5 mm
259-2186 N/A 2
(0.3776 inch) (0.87 ± 0.02 inch)
8.143 mm 12.0 ± 0.5 mm

259-5829 N/A 1
(0.3206 inch) (0.47 ± 0.02 inch)
9.590 mm 12.0 ± 0.5 mm

260-4856 N/A 1
(0.3776 inch) (0.47 ± 0.02 inch)
9.590 mm 20.0 ± 0.05 mm

268-2953 N/A 2
(0.3776 inch) (0.787 ± 0.002 inch)
9.590 mm 22.0 ± 0.5 mm

277-9775 N/A N/A
(0.3776 inch) (0.87 ± 0.02 inch)
9.584 mm 35.0 ± 0.5 mm

376-6566 N/A 1
(0.3773 inch) (1.38 ± 0.02 inch)
Valve Guides for C175 Engines

Table 31
Specifications for C175 Valve Guides
Part Numbers of Valve Bore in the Head for the Installed Height of the Valve Bore Diameter of INSTALLED Valve
Guides Guide Guide Guide
236-0544 22.000 ± 0.013 mm
Valve Guide (Standard) (0.8661 ± 0.0005 inch)
393-6466 22.254 ± 0.013 mm 42.00 ± 0.50 mm 12.626 ± 0.020 mm
Valve Guide (0.25-MM OS) (0.8761 ± 0.0005 inch) (1.654 ± 0.020 inch) (0.4971 ± 0.0008 inch)
393-6467 22.508 ± 0.013 mm

Valve Guide (0.50-MM OS) (0.8861 ± 0.0005 inch)
Valve Guides for 3044, 3046, 3064, and 3066 Engines
Table 32
Dimensions for 3044, 3046, 3064, and 3066 Valve Guides
Sales Model 3044, 3046 3064, 3066
8.080 ± 0.015 mm 8.070 ± 0.015 mm

The bore of the inlet valve guide that is installed in the cylinder head
(0.3181 ± 0.0006 inch) (0.3177 ± 0.0006 inch)
8.150 mm 8.150 mm
The maximum bore of the inlet valve guide that is installed in the cylinder head
(0.3209 inch) (0.3209 inch)
8.097 ± 0.017 mm 8.087 ± 0.017 mm

The bore of the exhaust valve guide that is installed in the cylinder head
(0.3188 ± 0.0007 inch) (0.3184 ± 0.0007 inch)
8.200 mm 8.200 mm
The maximum bore of the exhaust valve guide that is installed in the cylinder head
(0.3228 inch) (0.3228 inch)
q631tm
The height of installed valve guides (B) 11.50 ± 0.10 mm 17.00 ± 0.30
Caterpillar: mm
Confidential Yellow
(0.453 ± 0.004 inch) (0.669 ± 0.012 inch)
Installation of the Valve Guides
For removal of valve guides, use the 4C-6366 Valve Guide Driver. Install the valve guides with the 4C-6370 Installer Tool. Refer to the service
manual for Disassembly and Assembly Manual for removal and installation instructions of the valve guides.

Valve guides that are being removed from the cylinder head by using the appropriate tooling
Valve Guides for 3054, and 3056 Engines
Note: When new valve guides are installed, new valves and new valve seat inserts must be installed. The valve guides and the valve seat inserts
are supplied as partially finished parts. The unfinished valve guides and unfinished valve seat inserts are installed in the cylinder head. Then, the
guides and inserts are cut and reamed in one operation with special tooling. This procedure ensures the concentricity of the valve seat to the
valve guide to create a seal that is tight. Refer to the Disassembly and Assembly Manual for removal and installation procedures
Table 33
Dimensions for the Intake and Exhaust Valve Guides for 3054, and 3056 Engines
Description Dimension
9.51 to 9.56 mm
Inside Diameter
(0.37441 to 0.37638 inch)
15.90 to 15.91 mm
Outside Diameter
(0.62598 to 0.62638 inch)
15.87 to 15.89 mm
Bore diameter in cylinder head for valve guide
(0.62480 to 0.62559 inch)
0.03 to 0.07 mm
Interference fit of valve guide in cylinder head
(0.00118 to 0.00276 inch)
57.94 mm
Overall length for inlet valve guide
(2.28110 inch)
61.10 mm
Overall length for exhaust valve guide
(2.40551 inch)
15.10 mm
Projection of valve guide above valve spring recess
(0.59449 inch)
0.02 to 0.10 mm
Clearance of inlet valve in valve guide
(0.00079 to 0.00394 inch)
0.13 mm
Maximum permissible clearance of inlet valve in valve guide
(0.00512 inch)
0.05 to 0.13 mm
Clearance of exhaust valve in valve guide
(0.00197 to 0.00512 inch)
0.15 mm
Maximum permissible clearance of exhaust valve in valve guide
(0.00591 inch)
Minimum 1.28 mm
(0.05039 inch)
Valve depth below the cylinder head face
Maximum 1.60 mm
(0.06299 inch)
1.85 mm
Service wear limit
(0.07283 inch)
Inlet 0.20 mm
(0.00787 inch)
Valve Lash
Exhaust 0.45 mm
(0.01772 inch) q631tm
Valve Guides for 3114, 3116, 3126 Engines
Table 34
Dimensions for the Valve Guides for 3114, 3116, 3126 Engines
Installed Valve Guide Bore 8.054 ± 0.026 mm

New (0.3171 ± 0.0010 inch)
Installed Valve Guide Bore 8.130 mm

Used Maximum (0.3201 inch)(1)
23.000 ± 0.500 mm
Height of Installed Valve Guide (B)
(0.9055 ± 0.0197 inch)
23.000 ± 0.500 mm
Height of Installed Intake Valve Guide (C) on 3126B Cylinder Heads
(0.9055 ± 0.0197 inch)
Height of Installed Exhaust Valve Guide (D) on 3126B Cylinder Heads (measured to the shoulder of the valve 17.8 ± 0.5 mm
guide) (0.70 ± 0.02 inch)
(1) Valve guides should not be reused if the measurement of the bore is greater than 8.130 mm (0.3201 inch). The valve and the guide must have a combined difference less than
0.10 mm (0.004 inch).
Valve Guides for 3176, 3196 Engines
Note: Do not reuse the valve guide if the measurement of the bore is greater than 9.538 mm (0.3755 inch). Do not use a valve and a guide that
has a measured difference of 0.10 mm (0.004 inch). Replacement is required if the gauge is inserted to a depth that is greater than 19.0 mm
(0.75 inch).
Installation
Use a 1U-9169 Valve Guide Driver and a Guide Collar that corresponds to the guide to install valve guides to the appropriate height of the valve
guide.

Pointed valve guide
(B) Height to the shoulder of valve guide
Use a 9U-6460 Guide Collar to install pointed valve guides. The 9U-6460 Guide Collar will install the valve guide to a height of 22.0 ± 0.5 mm
(0.87 ± 0.020 inch) to the shoulder.

Flat valve guide
(B) Height of valve guide
Use a 1U-9168 Valve Guide Collar to install flat valve guides. The 1U-9168 Valve Guide Collar will install the valve guide to a height of
28.0 ± 0.5 mm (1.10 ± 0.02 inch).
Table 35
Dimensions for the Valve Guides for 3176, 3196 Engines
Installed Valve Guide Bore 9.484 ± 0.026 mm

New (0.3734 ± 0.0010 inch)
Installed Valve Guide Bore 9.538 mm

Used Maximum (0.3755 inch)
28.00 ± 0.05 mm
Height of Installed Valve Guide (B)(1)
(1.102 ± 0.002 inch)
22.00 ± 0.05 mm q631tm

Height of Installed Valve Guide from shoulder (B)(2) Caterpillar: Confidential Yellow
(0.866 ± 0.002 inch)
(1) Flat valve guide
(2) Pointed valve guide
Valve Guides for 1100, 3100, 3204, and 3208 Engines
Table 36
Dimensions for the Valve Guides for 1100, 3100, 3204, and 3208 Engines
Installed Valve Guide

Installed
Model Maximum Bore
Intake Exhaust Height
1100
N/A
3100 9.550 mm 9.550 mm
3204 (0.37598 inch) (0.37598 inch) 20.19 mm
3208 (0.79488 inch)
Valve Guides for 3300 Engines
Table 37
Installed Valve Guide Max. Bore for 3300 Engines
Intake Exhaust
9.581 mm 9.581 mm
(0.3772 in) (0.3772 in)
Table 38
Installed Valve Guide Height for 3300 Engines
Part Number Height

22.22 ± 0.25 mm
Former 8N-6796 Valve Guide.
(0.87480 ± 0.00984 inch)
16.22 ± 0.25 mm
Current 8N-6796 Valve Guide.
(0.63858 ± 0.00984 inch)
Valve Guides for 3400 Engines
If the valve guides are removed from the cylinder head, use 9U-6895 Valve Guide Driver to remove the valve guides. New valve guides should
then be installed in the cylinder head. There are two types of valve guides that are used in 3400 Engines. Use 9U-6895 Valve Guide Driver and
5P-2396 Bushing to install the straight valve guides in the diesel engines. Use 9U-6895 Valve Guide Driver and 124-9057 Guide Collar to
install the stepped valve guides in the diesel engines. Use 9U-6895 Valve Guide Driver to install the valve guides in the gas engines. Refer to
Illustrations 176 and 177 for the types of valve guides. The bore in the cylinder head for the valve guide should be lubricated with SAE 15W-40
engine oil before installing the valve guides.

Straight valve guide

Stepped valve guide
The valve guides must be measured for the installed height and the inside bore diameter.
Use 6V-2012 Depth Micrometer to measure the height of the installed valve guide (B). Refer to Table 39 or Table 40 for the correct height.
Use 5P-3536 Valve Guide Gauge to measure the inside diameter of the valve guide. The correct probe is 9.525 mm (0.3750 inch). This probe
has a usable range of 0.38 mm (0.015 inch).
q631tm
6V-7068 Valve Guide Gauge is also available for use as a quick go/no-go gauge. If the larger end of the tooling fits in farther than 19.0 mm
(0.75 inch), the valve guide must be replaced.

(B) Height of an installed valve guide
Table 39
Specifications for the Valve Guides on 3400 Engines
Diesel Engines
Engine Bore for an Installed Valve Maximum Bore for Installed Valve Height of an installed valve guide
Model Guide Guide (B)
27.2 ± 0.8 mm
9.487 ± 0.020 mm 9.560 mm (1.07 ± 0.03 inch)(1)
3406
(0.3735 ± 0.0008 inch) (0.3764 inch) 32.26 ± 0.76 mm
(1.270 ± 0.030 inch)(2)
9.487 ± 0.020 mm 9.560 mm 32.26 ± 0.76 mm
3408
(0.3735 ± 0.0008 inch) (0.3764 inch) (1.270 ± 0.030 inch)(2)
9.487 ± 0.020 mm 9.560 mm 32.26 ± 0.76 mm

3412
(0.3735 ± 0.0008 inch) (0.3764 inch) (1.270 ± 0.030 inch)(2)
(1) Stepped valve guide
(2) Straight valve guide
Table 40
Specifications for the Valve Guide on 3400 Engines
Gas Engines
Part Number of the Valve Bore for an Installed Valve Maximum Bore for Installed Valve Height of an installed valve
Guide Guide Guide guide (B)
32.26 ± 0.76 mm
151-6235
9.487 ± 0.025 mm 9.560 mm (1.270 ± 0.030 inch)
(0.3735 ± 0.0010 inch) (0.3764 inch) 24.0 ± 0.8 mm
246-1300
(0.94 ± 0.03 inch)
9.487 ± 0.025 mm 9.560 mm 32.26 ± 0.76 mm
7W-1636
(0.3735 ± 0.0010 inch) (0.3764 inch) (1.270 ± 0.030 inch)
151-1300 9.487 ± 0.025 mm 32.26 ± 0.76 mm
173-7188 (0.3735 ± 0.0010 inch) (1.270 ± 0.030 inch)
213-7536 9.560 mm 26.0 ± 0.8 mm

Inlet (0.3764 inch) (1.02 ± 0.03 inch)
9.484 ± 0.008 mm
213-7537 (0.3734 ± 0.0003 inch) 32.26 ± 0.76 mm
Exhaust (1.270 ± 0.030 inch)
Note: Do not reuse a valve guide if the measurement of the bore is greater than 9.560 mm (0.3764 inch). Do not reuse a valve and valve guide if
the difference between the valve stem diameter and the inner diameter of the valve guide is 0.13 mm (0.005 inch).
Valve Guides for 3406E, 3456 Engines

If the valve guides are removed from the cylinder head, use 9U-6895 Valve Guide Driver to remove the valve guides. New valve guides should
then be installed in the cylinder head. Use 9U-6895 Valve Guide Driver and 9U-6894 Guide Collar to install the valve guides. The bore in the
cylinder head for the valve guide should be lubricated with SAE 15W-40 engine oil before installing the valve guides.
Table 41
Specifications for the Valve Guide on 3406E, 3456 Engines
Engine Bore for an Installed Valve Maximum Bore for Installed Valve Height of an installed valve guide
q631tm
Model Guide Guide (B)
3406E 9.484 ± 0.013 mm 9.560 mm 35.0 ± 0.5 mm
(0.3734 ± 0.0005 inch) (0.3764 inch) (1.38 ± 0.02 inch)
9.484 ± 0.013 mm 9.560 mm 35.0 ± 0.5 mm

3456
(0.3734 ± 0.0005 inch) (0.3764 inch) (1.38 ± 0.02 inch)
Note: Do not reuse a valve guide if the measurement of the bore is greater than 9.560 mm (0.3764 inch). Do not reuse a valve and valve guide if
the difference between the valve stem diameter and the inner diameter of the valve guide is 0.13 mm (0.005 inch).
Oversized valve guides are also available. The oversized valve guides must have the valve guide bore of the cylinder head machined oversized.
Table 42
Cylinder Head Bore Dimensions on 3406E, 3456 Engines
Valve Guide Size (OD) Bore Size (C) in the Cylinder Head for the Valve Guide
15.970 ± 0.013 mm
Standard Size
(0.6287 ± 0.0005 inch)
0.13 mm 16.097 ± 0.013 mm

(0.005 inch) Oversized (0.6337 ± 0.0005 inch)
0.51 mm 16.478 ± 0.013 mm

(0.020 inch) Oversized (0.6487 ± 0.0005 inch)
Precision Valve Guides for 3500 Engines
Precision machined valve guides and inserts for the valve seats are used in all 3500 engines. These parts will improve the concentricity of the
valve and concentricity of the valve seat in the cylinder head. These parts will improve the quality of cylinder heads that are rebuilt in the field.
Valve guides with oversize outside diameters are available to replace the standard parts. These parts are 0.127 mm (0.0050 inch), 0.254 mm
(0.0100 inch), 0.381 mm (0.0150 inch), and 0.508 mm (0.0200 inch) oversize outer diameter.

Guides for 3500
(F) Height to the top of the valve guides from the top of the head
Table 43
Specifications for the Valve Guides for 3500 Engines
Part Number
of the Intake or Part Numbers of Bore inch the Head for the Installed Height of the Valve
Size
Cylinder Exhaust Valve Guides Guide Guide (F)
Head
7E-5861 133-9306 17.473 ± 0.008 mm 26.000 ± 1.000 mm

Standard
7E-8760 449-7117 (0.6879 ± 0.0003 inch) (1.0236 ± 0.0394 inch)
101-1175
131-0410 0.127 mm 17.6 ± 0.008 mm
273-3553
131-0411 (0.0050 inch) (0.6929 ± 0.0003 inch)
131-0423
145-3215 0.254 mm 17.727 ± 0.008 mm
Intake 273-3554
(0.0100 inch) (0.6979 ± 0.0003 inch)
154-1612
161-2508 0.381 mm 17.854 ± 0.008 mm
172-0834 301-9248
(0.0150 inch) (0.7029 ± 0.0003 inch)
172-0836
290-1351 0.508 mm 17.981 ± 0.008 mm
295-2047 149-1982
(0.0200 inch) (0.7079 ± 0.0003 inch)
462-4740
480-3132 Exhaust 197-6995 17.473 ± 0.008 mm
Standard
495-2062 449-7118 (0.6879 ± 0.0003 inch)
q631tm
525-6572
0.127 mm 276-3875 17.6 ± 0.008 mm Caterpillar: Confidential Yellow
(0.0050 inch) (0.6929 ± 0.0003 inch)
0.254 mm 17.727 ± 0.008 mm
276-3876
(0.0100 inch) (0.6979 ± 0.0003 inch)
17.473 ± 0.008 mm
Standard 191-6766
(0.6879 ± 0.0003 inch)
0.254 mm 17.727 ± 0.008 mm

Intake 206-1544
(0.0100 inch) (0.6979 ± 0.0003 inch)
0.508 mm 17.981 ± 0.008 mm

4P-6571 206-1545
(0.0200 inch) (0.7079 ± 0.0003 inch)
7C-3471
128-1141 17.473 ± 0.008 mm
122-5961 Standard 206-1541
(0.6879 ± 0.0003 inch)
144-6409
153-8397 0.254 mm 17.727 ± 0.008 mm 26.000 ± 1.000 mm
Exhaust 206-1542
184-5496 (0.0100 inch) (0.6979 ± 0.0003 inch) (1.0236 ± 0.0394 inch)
206-1554
206-1555 0.508 mm 17.981 ± 0.008 mm
206-1543
206-1560 (0.0200 inch) (0.7079 ± 0.0003 inch)
206-1563
424-7545 17.473 ± 0.008 mm
Standard 255-0897
(0.6879 ± 0.0003 inch)
0.254 mm 17.727 ± 0.008 mm
Exhaust 255-1261
(0.0100 inch) (0.6979 ± 0.0003 inch)
0.508 mm 17.981 ± 0.008 mm
255-1262
(0.0200 inch) (0.7079 ± 0.0003 inch)
17.473 ± 0.008 mm
Standard 191-6766
(0.6879 ± 0.0003 inch)
0.127 mm 17.600 ± 0.008 mm

322-3664
(0.0050 inch) (0.6929 ± 0.0003 inch)
Intake
0.254 mm 17.727 ± 0.008 mm
322-3665
(0.0100 inch) (0.6979 ± 0.0003 inch)
0.508 mm 17.981 ± 0.008 mm

269-0040 322-3666
(0.0200 inch) (0.7079 ± 0.0003 inch) 26.000 ± 0.5 mm
315-2630
17.473 ± 0.008 mm (1.0236 ± 0.0197 inch)
418-9804 Standard 336-1338
(0.6879 ± 0.0003 inch)
0.127 mm 17.600 ± 0.008 mm

322-3661
(0.0050 inch) (0.6929 ± 0.0003 inch)
Exhaust
0.254 mm 17.727 ± 0.008 mm
322-3662
(0.0100 inch) (0.6979 ± 0.0003 inch)
0.508 mm 17.981 ± 0.008 mm

322-3663
(0.0200 inch) (0.7079 ± 0.0003 inch)
Installation and Removal of the Valve Guides for G3500 Engines
Remove all oil, dirt, and carbon from the cylinder head casting.
Clean the mounting surface of the cylinder head with a 5P-9718 Disc Pad. The pneumatic tool must be 3500 rpm to 4500 rpm. The method and
the speed of the disc are critical to the performance of the disc. The best results will be obtained if the disc is flat to the surface. Only the weight
of the tool should be used as downward pressure. Do not use the edge of the disc because the disc may come off the holder. Do not use the disc
for long periods of time in one area. Metal can be removed if the disc is used in one area for too long.

This cylinder head has siloxane deposits from a landfill environment.
q631tm
Remove all dirt and debris from the combustion surface and the valve seat insert bore. The insert removal tool will not seat properly if there is
any remaining debris in the insert bore.
When cleaning the ports, do so while the old seat is still in place.
Table 44
Required Tooling
Part Number Part Description
7M-3975 Valve Guide Driver
1. Place the cylinder head upside-down in a hydraulic press.
2. Clean the surface of the valve guide that contacts the valve guide driver. This will prevent harmful debris from traveling through the bore
for the valve guide.
3. Install 7M-3975 Valve Guide Driver into a valve guide.
4. Press the valve guides out of the cylinder head. Repeat this process for the remaining three valve guides.
Note: Do not use a hammer to remove the valve guides.

235-9751 Drive Adapter As

(2) Spark Plug Adapter
Use the 235-9751 Drive Adapter As to remove the spark plug adapter. Remove and replace the gasket and the o-ring.
The adapter threads should be inspected for any damage. If the threads have any damage or wear, the adapter should be replaced.

Stiff bristle brush for cleaning bores
1. Clean the bores for the valve guides with a stiff bristle brush. Spray 222-3123 Penetrating Oil in the bores before inserting the brush. The
bores for the valve guides should be cleaned with a clean shop towel after using the brush. The towel will remove any remaining debris.
2. Position the cylinder head in the upright position.

The guide should have at least 63.0 mm (2.48 inCH) length of coating from the bottom of the guide.
3. Lubricate the outside of each valve guide and the bore in the head with clean engine oil prior to installation.
Note: The entire bore should be coated in oil.
q631tm
(7) 364-3081 Installation Guide
4. Place the 364-3081 Install Guide on the cylinder head as shown in Illustration 189. Make sure that 191-6766 Valve Guides are installed in
the intake ports of the cylinder head. Make sure that 366-1338 Valve Guides are installed in the exhaust ports of the cylinder head.
For oversize valve guides part numbers and information on the bore size in the cylinder head for oversize valve guides, refer to Table 45.
Table 45
Specifications for the Valve Guides on G3500 Engines
Part Number of the Intake or Part Numbers of Bore in the Head for the Installed Height of the
Size
Cylinder Head Exhaust Valve Guides Guide Valve Guide (F)
17.473 ± 0.008 mm
Intake Standard 9Y-1847
(0.6879 ± 0.0003 inch)
4P-6571 7N-1819 17.473 ± 0.008 mm

Intake Standard
7C-3471 130-2613 (0.6879 ± 0.0003 inch)
122-5961
9Y-6883
128-1141 17.473 ± 0.008 mm
Intake Standard 184-5495 26.00 ± 1.00 mm
144-6409 (0.6879 ± 0.0003 inch)
191-6766 (1.0236 ± 0.0394 inch)
184-5496
206-1554 7W-9487 17.473 ± 0.008 mm
229-9942 Exhaust Standard
9Y-1846 (0.6879 ± 0.0003 inch)
269-0040
9Y-6882
17.473 ± 0.008 mm
Exhaust Standard 184-5494
(0.6879 ± 0.0003 inch)
366-1338
184-5495 17.473 ± 0.008 mm

Standard
191-6766 (0.6879 ± 0.0003 inch)
0.13 mm 17.600 ± 0.008 mm

322-3664
(0.0051 inch) (0.6929 ± 0.0003 inch)
Intake
0.254 mm 17.727 ± 0.008 mm
322-3665
(0.0100 inch) (0.6979 ± 0.0003 inch)
0.508 mm 17.981 ± 0.008 mm
322-3666
(0.0200 inch) (0.7079 ± 0.0003 inch)
184-5494 17.473 ± 0.008 mm
Standard
366-1338 (0.6879 ± 0.0003 inch)
153-8397
0.13 mm 17.600 ± 0.008 mm 26.000 ± 0.5 mm
315-2630 322-3661
(0.0051 inch) (0.6929 ± 0.0003 inch) (1.0236 ± 0.0197 inch)
418-9804 Exhaust
0.254 mm 17.727 ± 0.008 mm
322-3662
(0.0100 inch) (0.6979 ± 0.0003 inch)
0.508 mm 17.981 ± 0.008 mm

322-3663
(0.0200 inch) (0.7079 ± 0.0003 inch)
184-5494 17.473 ± 0.008 mm

Standard
366-1338 (0.6879 ± 0.0003 inch)
0.254 mm 17.727 ± 0.008 mm

Exhaust 366-1339
(0.0100 inch) (0.6979 ± 0.0003 inch)
0.508 mm 17.981 ± 0.008 mm

366-1340
(0.0200 inch) (0.7079 ± 0.0003 inch)
206-1555 Intake 17.473 ± 0.008 mm 26.00 ± 1.00 mm

Standard 191-6766
242-5328 (0.6879 ± 0.0003 inch) (1.0236 ± 0.0394 inch)
487-3422 q631tm
0.254 mm 206-1544 17.727 ± 0.008 mm
(0.0100 inch) (0.6979 ± 0.0003 inch)
0.508 mm 17.981 ± 0.008 mm

206-1545
(0.0200 inch) (0.7079 ± 0.0003 inch)
17.473 ± 0.008 mm
Standard 255-0897
(0.6879 ± 0.0003 inch)
0.254 mm 17.727 ± 0.008 mm 26.00 ± 1.00 mm
Exhaust 255-1261
(0.0100 inch) (0.6979 ± 0.0003 inch) (1.0236 ± 0.0394 inch)
0.508 mm 17.981 ± 0.008 mm
255-1262
(0.0200 inch) (0.7079 ± 0.0003 inch)
17.473 ± 0.008 mm
Standard 206-1541
(0.68791 ± 0.0003 inch)
0.254 mm 17.727 ± 0.008 mm 26.00 ± 1.00 mm

Exhaust 206-1542
(0.0100 inch) (0.6979 ± 0.0003 inch) (1.0236 ± 0.0394 inch)
0.508 mm 17.981 ± 0.008 mm

206-1543
(0.0200 inch) (0.7079 ± 0.0003 inch)

(8) 366-5728 Valve Guide Driver
5. Insert the 366-5728 Valve Guide Driver (8) in the valve guide.
6. Press the valve guide into the cylinder head. The valve guide is at the correct depth when the valve guide driver contacts the 364-3081
Installation Guide. The valve guides should be pressed in with one smooth stroke. Use an electrohydraulic press to install the valve
guides.
Note: Do not use a manual hydraulic press.
7. Insert valves into the valve guides. If the valve does not move freely in the valve guide, repeat this step with another valve. If the second
valve does not move freely in the valve guide, the valve guide must be removed and replaced.
When installing the valves in the heads during assembly, repeat Step 7 to assure that the valve being installed passes freely in the guide. Once a
guide and valve have been checked, keep the valve matched to the guide in which it was test fit. If for any reason a valve is removed from the
head during assembly, this step must be performed to assure that the valve and guide have proper clearance.

Pilot Wrench

Pilot

Dial Indicator

q631tm
1. Insert the pilot into the pilot wrench.
2. Insert the pilot in the dial gauge.
1. Insert the pilot into the valve guide.
2. Tighten the pilot wrench.
Note: To prevent damage to the tooling or the valve guide, the pilot wrench only needs to be lightly tightened by hand.
3. Place the tip on the face of the valve seat and zero out the dial indicator.
4. Rotate the tip around the face of the valve seat.
5. Measure the runout of the valve seat insert. The valve guide to seat runout should be no more than 0.05 mm (0.002 inch). A valve seat
dial indicator from Hall Toledo was used in Illustration 203.
If runout is in excess of 0.05 mm (0.002 inch) remove the valve guide and install a new one. After installation, measure the runout again.
If the runout is still excessive, replace the seat and measure the runout. If the runout is still excessive, the bores for the valve seat and
guide should be checked and the head should be replaced.
Note: No guide or valve seat insert should ever be reused after being removed from the head.
Valve Guides for 3600, G3600, C280 Engines
Valve guides should be drilled as much as possible before being removed. If this is not done, small cracks may appear in the cylinder head
casting as a result. After installation, check the dimensions of the valve guides to make sure that the guides meet the specifications for new
valve guides.
To remove the bridge dowels, use the 9U-5099 Valve Seat Puller to remove the bridge dowels and dowel plugs from the cylinder head casting.
Replace the bridge dowels by following the specifications for minimum height.
Initial Inspection
1. Inspect the valve guides for wear, cracks, erosion, or other damage.
2. Use the valve guide gauge to measure the inside diameter of the valve guide.
3. Remove excessively worn valve guides with one of the following methods.
Removal q631tm
There are three different methods for removal of valve guides.
Note: Drill the inside diameter of the guide. This will ease the process of removing the valve guide. This will also eliminate damage to the bore
of the guide.
1. Remove the valve guides with the valve guide driver and a hammer.
Note: Be careful not to strike the highly finished surface of the cylinder head with the hammer during removal of the valve guides.
2. The valve guides may also be removed with a hydraulic press and the valve guide driver.

(11) Puller assembly
(12) Puller rod assembly
(13) Nut
(14) Hand pump
(15) Pedestal
Installation
The tooling that is used to install valve guides into the cylinder head must produce consistent results.
1. Put clean engine oil on the outside diameter of the valve guide before installation. The guides can also be frozen to −70° C (−94.0° F).
Installation will be easier if the guides are frozen.
2. Install four valve guides until the guides extend 18.00 mm (0.709 inch) to 22.00 mm (0.866 inch) above the top surface of the cylinder
head. Use either of the methods shown in Illustrations 208,209, and 210.
3. If the valve guides were frozen prior to installation, the guides should be allowed to return to room temperature before measuring critical
specifications.
4. After installing the valve guides into the head casting, measure the inside diameter with the valve guide gauge.
Note: After installation, the valve guide must pass the specified load test.

(11) Valve guide driver

(12) Puller rod assembly
(13) Nut
(14) Hand pump
(16) Expander bridge assembly

Valve Guide Specifications. Refer to Table 46 for the reuse specifications.
q631tm
Valve Guide Specifications for 3600, G3600, C280 Engines
Dimensions 7C-2424
16.209 mm
Maximum Allowable ID at bottom (A)(1)
(0.6380 inch)
170.00 ± 1.00 mm
Length (B)
(6.693 ± 0.040 inch)
16.106 mm
Maximum Allowable ID at top (C)(2)
(0.6340 inch)
26.040 ± 0.010 mm
OUTSIDE diameter (D)
(1.0252 ± 0.0004 inch)
16.055 ± 0.013 mm
Unassembled INSIDE diameter (E)
(0.6321 ± 0.0005 inch)
16.003 mm
Assembled inside diameter (E)(3) (0.6300 inch) to 16.059 mm
(0.6322 inch)
18.00 mm
Assembled Height (0.709 inch) to 22.00 mm
(0.866 inch)
(1) As measured from the bottom of the valve guide bore when assembled in the head casting. Maximum depth allowed 19.0 mm (0.75 inch).
(2) As measured from the top of the valve guide bore when assembled in the head casting. Maximum depth allowed 19.0 mm (0.75 inch).
(3) Measure the bore 45.0 mm (1.77 inch) from the bottom of the cylinder head. This is the surface where the casting press fit reduces the inside diameter of the valve guide.
Valve Guide & Seat Bore for C7 through C32 Engines
Table 47
Specifications for the Cylinder Head for C7 through C32 Engines
Part Number Bore for the Valve Guide Bore for the Valve Seat
6I-3606
105-3798
105-3799
105-3800
123-7338
Intake
124-7373
45.949 ± 0.025 mm
143-0046
17.473 ± 0.013 mm (1.8090 ± 0.0010 inch)
143-3615
(0.6879 ± 0.0005 inch) Exhaust
151-4951
42.774 ± 0.025 mm
151-1335
(1.6840 ± 0.0010 inch)
151-5241
151-5243
198-6523
198-6524
206-7744
179-9458 15.970 ± 0.013 mm Intake
148-2135 (0.6287 ± 0.0005 inch) 45.961 ± 0.013 mm
245-4031 (1.8095 ± 0.0005 inch)
257-2170 Exhaust
265-9120 43.320 ± 0.025 mm
289-3210 (1.7055 ± 0.0010 inch)
300-9512
302-2297
308-6358
331-1981
342-4397
344-0059
345-3752
346-1984
346-1999 q631tm
520-4381
520-4382
219-5844
227-5951 Intake Intake
259-8305 13.000 ± 0.013 mm 41.931 ± 0.013 mm
278-3490 (0.5118 ± 0.0005 inch) (1.6508 ± 0.0005 inch)
280-7503 Exhaust Exhaust
314-4183 15.970 ± 0.013 mm 45.931 ± 0.013 mm
314-4184 (0.6287 ± 0.0005 inch) (1.8083 ± 0.0005 inch)
314-4185
Intake
201-2180 37.000 ± 0.015 mm
255-4961 15.970 ± 0.013 mm (1.4567 ± 0.0006 inch)
311-7226 (0.6287 ± 0.0005 inch) Exhaust
311-7228 37.500 ± 0.015 mm
(1.4764 ± 0.0006 inch)
Intake
40.000 ± 0.015 mm
241-8392 15.970 ± 0.013 mm (1.5748 ± 0.0006 inch)
252-8438 (0.6287 ± 0.0005 inch) Exhaust
37.500 ± 0.015 mm
(1.4764 ± 0.0006 inch)
Intake
42.5 ± 0.015 mm
311-7218 13.000 ± 0.013 mm (1.67323 ± 0.00059 inch)
328-7475 (0.5118 ± 0.0005 inch) Exhaust
39 ± 0.015 mm
(1.5354 ± 0.0006 inch)
Intake Intake
13.000 ± 0.013 mm 40.000 ± 0.015 mm
311-7229 (0.5118 ± 0.0005 inch) (1.5748 ± 0.0006 inch)
332-3619 Exhaust Exhaust
15.970 ± 0.013 mm 37.500 ± 0.015 mm
(0.6287 ± 0.0005 inch) (1.4764 ± 0.0006 inch)
Intake Intake
13.000 ± 0.013 mm 42.5 ± 0.015 mm
(0.5118 ± 0.0005 inch) (1.67323 ± 0.00059 inch)
314-4184
Exhaust Exhaust
15.970 ± 0.013 mm 39.0 ± 0.015 mm
(0.6287 ± 0.0005 inch) (1.53543 ± 0.00059 inch)
Intake Intake
13.000 ± 0.013 mm 41.931 ± 0.013 mm
(0.5118 ± 0.0005 inch) (1.6508 ± 0.0005 inch)
491-1831
Exhaust Exhaust
13.000 ± 0.013 mm 45.931 ± 0.013 mm
(0.5118 ± 0.0005 inch) (1.8083 ± 0.0005 inch)
185-2246
222-1982
223-7263
Intake
243-0943
47.950 ± 0.025 mm
245-4324
15.970 ± 0.013 mm (1.8878 ± 0.0010 inch)
263-4890
(0.6287 ± 0.0005 inch) Exhaust
281-1640
42.774 ± 0.025 mm
284-2787
(1.6840 ± 0.0010 inch)
357-7398
396-8374
431-1153
Valve Seals and Retainers

q631tm
Components may vary. Check the following originally installed components: Caterpillar: Confidential Yellow
Valve type
Type of seal
Type of retainer
Other components

Old style valve guide seals

New style valve guide seals
Note: Refer to the Service Manual for removal and installation procedures. Also refer to the current parts manual for the current configuration
for valve seals in a particular application.

Valve retainers with polished surfaces
Valve Seats
This section contains specifications of reusability for valve seats which are used in Caterpillar engines. Valve guide bores must be measured for
the diameter of the valve guide bore.
If the thickness of the head is machined beyond factory specifications, the valve seats must also be machined. Machine the surface of the insert
so the same amount of material is removed from the head and the insert to maintain the proper projection of the valve. After the head has been
machined, the sealing angle must be within like-new specifications.

Machining the valve seat to like-new specifications after machining the head
Never use any kind of hammer to push the valve seat into the head. Installation of the valve seat insert requires a careful technique. The valve
seat inserts are installed in a counterbore in the cylinder head under a press fit. Care must be taken with valve seat inserts. The inserts must be
properly seated in the counterbore. The insert must be in full contact with the bottom of the counterbore. The inserts are chilled on dry ice
before installation. Frost may build up on the bottom of the insert. This frost may not allow the insert to seat properly. Installation frequently
involves hammering of the insert, which does not allow the valve seat insert to seat properly. The best results have been obtained by installing
the valve seat insert at room temperature with steady hydraulic pressure.
The initial firing of the engine will seat an improperly seated precision insert. The only impact from an improperly placed precision insert is a
reduction in lash for the valve.
An insert that is machined after installation that does not seat properly will cause problems. The insert will be machined when the insert is not
fully seated. When the valve seat insert seats properly, there will be an improper seating face. Elevated wear rates will occur and the valve may
fail.
Valve Seat Inserts for D & G Model Engine

Table 48
Specifications for Valve Seat Angle for D & G Model Engines
Diesel Gas
Model
Intake Exhaust Intake Exhaust
D318 45° ± 0.5° 45° ± 0.5° N/A N/A
D320 30° ± 1° 30° ± 1° N/A N/A

q631tm
D342 45° ± 0.25° 45° ± 0.25° 45° ± 0.25° 45° ± 0.25° Caterpillar: Confidential Yellow
G342
D343
45° ± 0.25° 45° ± 0.25° N/A N/A
G343
D346
G346
D348
45° ± 0.25° 45° ± 0.25° N/A N/A
G348
D349
G349
D353
G353
D379
G379
30° ± 0.25° 30° ± 0.25° 30° ± 0.25° 30° ± 0.25°
D398
G398
D399
G399
Removal, Machining, and Installation of the Valve Seats Inserts for C4.4, C6.6, and C7.1 Engines
Removal
Remove the valve seat inserts. Check the bore diameters and the bore depths for the valve seat inserts. Oversized valve seat inserts are not
available currently. If the bore diameters or the bore depths are not within specifications, the cylinder head must be replaced.
Table 49
Bore Diameters and Bore Depths in the Cylinder Head for the Valve Seat Inserts for C4.4 (Tier 2/3) Engines
Item Dimension
8.735 mm
(H) Depth of Bore for Intake Insert (0.3438 inch) to 8.865 mm
(0.3490 inch)
7.975 mm
(G) Depth of Bore for Exhaust Insert (0.3139 inch) to 8.105 mm
(0.3190 inch)
35.000 mm
(J) Diameter of Bore for Intake Insert (1.3779 inch) to 35.025 mm
(1.3789 inch)
33.500 mm
(I) Diameter of Bore for Exhaust Insert (1.3188 inch) to 33.525 mm
(1.3198 inch)
Table 50
Bore Diameters and Bore Depths in the Cylinder Head for the Valve Seat Inserts for C4.4 (Tier 4) Engines
Item Dimension
8.735 mm
(0.34902 inch)
9.435 mm
(0.37657 inch)
(J) Diameter of Bore for Intake Insert 36.930 mm q631tm
(1.45393 inch) to 36.955 mm Caterpillar: Confidential Yellow
(1.45492 inch)
34.930 mm
(1.37618 inch)
Table 51
Bore Diameters and Bore Depths in the Cylinder Head for the Valve Seat Inserts for C7.1 Engines (Tier 2/3 Mechanical)
Item Dimension
10.32 mm
(0.414 inch)
9.94 mm
(0.39921 inch)
47.820 mm
(1.8837 inch)
42.420 mm
(1.6711 inch)
Table 52
Bore Diameters and Bore Depths in the Cylinder Head for the Valve Seat Inserts for C7.1 Engines (Tier 4)
Item Dimension
8.735 mm
(0.3490 inch)
9.435 mm
(0.3766 inch)
36.930 mm
(1.4549 inch)
34.930 mm
(1.3762 inch)
Machining
Table 53
Valve Seat Insert Part Numbers for C4.4, C6.6, and C7.1 Engines
Exhaust Valve Seat Insert 377-0400

Intake Valve Seat Insert 377-0399
Obtain a suitable cutter assembly. The valve seats will be cut using one operation. Set the blades of the cutters to the diameter of the valve seat
to be cut, using the proper angle. Refer to the following tables for cutting speeds, tooling, and diameters.
Table 54
Tooling, Cutting Speeds and Feed Rates for Valve Seat Inserts for C4.4, C6.6, and C7.1 Engines q631tm
Tool Type Cutting Speed (M/min) Feed Rate (mm/rev)
Carbide 70-90 0.10 to 0.12
Cubic Boron Nitride (CBN) > 150 or 50-70 0.05 to 0.08 or 0.15 to 0.18
Table 55
Valve Seat Angles for C4.4, C6.6, and C7.1 Engines
89 degrees to 89.30 degrees total angle
Exhaust Valve Seat Angle (S)
120.65 degrees to 120.75 total angle (C7.1 Tier 2/3 Mech)
119 degrees to 119.3 degrees total angle
Intake Valve Seat Angle (S)
112.16 degrees to 120.66 degrees total angle (C7.1 Tier 2/3 Mech)
3.2 µm
Surface Texture for Valve Seat Angles
(125.9843 µinch) max
Concentricity of Valve Seats 0.05 mm (0.002 inch) max TIR
1. Install the cutter assembly into the valve seat. Carefully turn the handle in a clockwise direction. Lubricant is not necessary.
Note: The valve seats have a hardened finish. Grinding compound must not be used or damage may result to the valve seats.
2. Continue to turn the handle in a clockwise direction to cut the valve seat. Remove only the minimum amount of material.
3. When the valve seat is cut, remove the reamer and cutter assembly. Clean any debris after the machining procedure.
Installing
A tool must be fabricated for installation of the valve seat inserts. Use the following information for fabricating the installation tool.

Dimensions for the Valve Seat Insert Installation Tool
Fabricate a tool to the following dimensions used to press in the valve seats.
Table 56
Valve Seat Insert Installation Tool Specifications for C4.4
Dimension Value
(A) As Required
(B) As Required
25 mm
(C)
(0.98 inch)
4 mm
(D)
(0.16 inch)
(E) Intake 30 Degrees
Tier 2/3
Tier 2/3 Exhaust 45 degrees
(E) Intake 60 Degrees

Tier 4
Tier 4 Exhaust 45 degrees
Intake 35 mm
(1.37795 inch)
(F)
Exhaust 33 mm
(1.29921 inch)
Intake 33 mm
(1.29921 inch)
(G)
Exhaust 32 mm
(1.26 inch) q631tm
Table 57
Valve Seat Insert Installation Tool for C6.6 and C7.1
Dimension Value
(A) As Required
(B) As Required
25 mm
(C)
(0.98 inch)
4 mm
(D)
(0.16 inch)
Intake 41 Degrees
(E) Tier 2/3
Exhaust 30 degrees
Intake 60 Degrees
(E) Tier 4
Exhaust 45 degrees
Intake 43 mm
(1.69 inch)
(F) Tier 2/3
Exhaust 40 mm
(1.57 inch)
Intake 33 mm
(1.29921 inch)
(F) Tier 4
Exhaust 32 mm
(1.26 inch)
Intake 35 mm
(1.37795 inch)
(G) Tier 4
Exhaust 33 mm
(1.29921 inch)
Use the Tooling to press the valve seats into the cylinder head.
Table 58
Intake Valve Seat Specifications for C4.4, C6.6, and C7.1 Engines
3.00 mm
(L) (0.1181 inch) to 3.010 mm
(0.1185 inch)
(M) 89-89.30' (Total Angle)
Exhaust Valve Seat Specifications for C4.4, C6.6, and C7.1 Engines
3.370 mm
(L) (0.1327 inch) to 3.380 mm
(0.1331 inch)
(M) 119-119.30' (Total Angle)
Installation of the Valve Seats Inserts for C7 through C32 Engines

Replace the valve seat inserts when machining cannot be performed. Refer to the service manual for disassembly and assembly for the removal
and installation instructions of valve seat inserts. Refer to the "Replacing Valve Seats Inserts for C7 through C32" section of this guideline for
the proper procedure to replace a valve seat.
Note: Some valve seats cannot be machined. Refer to Table 59 to determine if a valve seat can be machined. Specialized manufacturing
processes were used on these parts. Machining these parts will significantly decrease the life of the engine.
NOTICE
Some C7 engines are experiencing corrosion on the 217-5213 Valve
Seat Insert and the 155-9504 Valve Seat Insert. q631tm
If corrosion is found on 217-5213 Valve Seat Inserts, replace the valve
seat inserts with 272-9813 Valve Seat Inserts. The 272-9813 Valve Seat
Inserts are made from an alloy that is corrosion resistant.

seat inserts with 278-0453 Valve Seats. The 278-0453 Valve Seats are
made from an alloy that is more corrosion resistant.
Part numbers are etched on the outer surface of the valve seat inserts.
The 278-0453 Valve Seats and 272-9813 Valve Seat Inserts are pre-
finished. Pre-finished valve seat inserts do not require any additional
machining in the cylinder head.

(C) Depth of the bore for the valve seat
(D) Valve seat insert outside diameter
(E) Valve seat insert inside diameter
(F) Sealing angle of the valve seat insert
Table 59
Specifications for Valve Seat Inserts for C7 through C32 Engines
Depth of the Bore for the Valve Seat Inside Diameter Sealing
Valve Seat Comment Outside Diameter (D)
(C) (E) angle (F)
13.01 ± 0.10 mm 42.850 ± 0.013 mm 36.5 ± 0.5 mm 44.75° ±
1W-5283 Exhaust
(0.512 ± 0.004 inch) (1.6870 ± 0.0005 inch) (1.44 ± 0.02 inch) 0.50°
13.01 ± 0.10 mm 46.025 ± 0.013 mm 39.1 ± 0.5 mm 30.25° ±
4N-5893 Intake
(0.512 ± 0.004 inch) (1.8120 ± 0.0005 inch) (1.54 ± 0.02 inch) 0.50°
14.10 ± 0.10 mm 43.400 ± 0.015 mm 36.00 ± 0.13 mm 44.75° ±
133-7030 Exhaust
(0.555 ± 0.004 inch) (1.7087 ± 0.0006 inch) (1.417 ± 0.005 inch) 0.50°
14.10 ± 0.06 mm 43.400 ± 0.015 mm 36.00 ± 0.13 mm 44.75° ±

138-2005 Exhaust
(0.555 ± 0.002 inch) (1.7087 ± 0.0006 inch) (1.417 ± 0.005 inch) 0.25°
15.00 ± 0.06 mm 46.025 ± 0.013 mm 39.1 ± 0.5 mm 29.75° ±
138-2006 Intake
(0.591 ± 0.002 inch) (1.8120 ± 0.0005 inch) (1.54 ± 0.02 inch) 0.25°
11.55 ± 0.06 mm 46.000 ± 0.013 mm 39.50 ± 0.50 mm 45.50° ±

147-8218 Exhaust
(0.455 ± 0.002 inch) (1.8110 ± 0.0005 inch) (1.560 ± 0.020 inch) 0.25°
13.90 ± 0.05 mm 42.840 ± 0.013 mm 36.5 ± 0.5 mm 44.75° ±
152-7582 Exhaust
(0.547 ± 0.002 inch) (1.6866 ± 0.0005 inch) (1.44 ± 0.02 inch) 0.50°
10.00 ± 0.05 mm 42.000 ± 0.013 mm 35.80 ± 0.13 mm 30.25° ±

155-9504 Intake
(0.394 ± 0.002 inch) (1.6535 ± 0.0005 inch) (1.409 ± 0.005 inch) 0.25°
0.76 mm
13.90 ± 0.05 mm 43.602 ± 0.013 mm 36.5 ± 0.5 mm 44.75° ±
167-0642 (0.030 inch)
(0.547 ± 0.002 inch) (1.7166 ± 0.0005 inch) (1.44 ± 0.02 inch) 0.50°
oversize
0.76 mm
14.00 ± 0.05 mm 48.787 ± 0.013 mm 41.0 ± 0.5 mm 30.25° ±
167-0643 (0.030 inch)
(0.551 ± 0.002 inch) (1.9207 ± 0.0005 inch) (1.61 ± 0.02 inch) 0.50°
oversize
0.51 mm
13.90 ± 0.05 mm 43.348 ± 0.013 mm 36.5 ± 0.5 mm 44.75° ±
170-4737 (0.020 inch)
(0.547 ± 0.002 inch) (1.7066 ± 0.0005 inch) (1.44 ± 0.02 inch) 0.50°
oversize
0.51 mm
14.00 ± 0.05 mm 48.533 ± 0.013 mm 41.0 ± 0.5 mm 30.25° ±
170-4738 (0.020 inch)
(0.551 ± 0.002 inch) (1.9107 ± 0.0005 inch) (1.61 ± 0.02 inch) 0.50°
oversize
14.00 ± 0.05 mm 48.025 ± 0.013 mm 41.0 ± 0.5 mm 30.25° ±
175-3617 Intake q631tm
(0.551 ± 0.002 inch) (1.8907 ± 0.0005 inch) (1.61 ± 0.02 inch) 0.50°
176-7688 Intake 12.00 ± 0.06 mm 37.060 ± 0.013 mm 30.8 ± 0.5 mm 25.00° ±
(0.472 ± 0.002 inch) (1.4591 ± 0.0005 inch) (1.21 ± 0.02 inch) 0.25°
13.50 ± 0.05 mm 37.560 ± 0.013 mm 31.0 ± 0.5 mm 45.00° ±
176-7690 Exhaust
(0.532 ± 0.002 inch) (1.4787 ± 0.0005 inch) (1.22 ± 0.02 inch) 0.25°
14.10 ± 0.06 mm 43.390 ± 0.013 mm 36.0 ± 0.5 mm 44.75° ±

179-9453 Exhaust
(0.555 ± 0.002 inch) (1.7083 ± 0.0005 inch) (1.42 ± 0.02 inch) 0.25°
15.00 ± 0.06 mm 46.025 ± 0.013 mm 39.1 ± 0.5 mm 29.75° ±
179-9454(1) Intake
(0.591 ± 0.002 inch) (1.8120 ± 0.0005 inch) (1.54 ± 0.02 inch) 0.25°
10.40 ± 0.06 mm 37.560 ± 0.013 mm 31.0 ± 0.5 mm 45.00° ±

212-8917 Exhaust
(0.409 ± 0.002 inch) (1.4787 ± 0.0005 inch) (1.22 ± 0.02 inch) 0.25°
9.51 ± 0.06 mm 37.060 ± 0.013 mm 30.8 ± 0.5 mm 25.00° ±
212-8918 Exhaust
(0.374 ± 0.002 inch) (1.4591 ± 0.0005 inch) (1.21 ± 0.02 inch) 0.25°
9.00 ± 0.06 mm 42.000 ± 0.013 mm 35.80 ± 0.13 mm 30.25° ±

217-5213 Intake
(0.354 ± 0.0024 inch) (1.6535 ± 0.0005 inch) (1.409 ± 0.005 inch) 0.25°
11.30 ± 0.06 mm 42.390 ± 0.015 mm 36.0 ± 0.5 mm 44.75° ±
224-1270 Exhaust
(0.4449 ± 0.0024 inch) (1.6689 ± 0.0006 inch) (1.42 ± 0.02 inch) 0.25°
12.63 ± 0.06 mm 45.525 ± 0.013 mm 39.1 ± 0.5 mm 29.75° ±

224-2410(1) Intake
(0.497 ± 0.002 inch) (1.7923 ± 0.0005 inch) (1.54 ± 0.02 inch) 0.25°
14.00 ± 0.08 mm 48.025 ± 0.013 mm 41.0 ± 0.5 mm 30.25° ±
224-3983(1) Intake
(0.551 ± 0.003 inch) (1.8907 ± 0.0005 inch) (1.61 ± 0.02 inch) 0.25°
13.90 ± 0.06 mm 42.840 ± 0.013 mm 36.5 ± 0.5 mm 45.25° ±
226-5561(1) Exhaust
(0.547 ± 0.002 inch) (1.6866 ± 0.0005 inch) (1.44 ± 0.02 inch) 0.25°
11.55 ± 0.06 mm 46.000 ± 0.013 mm 39.50 ± 0.50 mm 45.50° ±
232-1285 Exhaust
(0.455 ± 0.002 inch) (1.8110 ± 0.0005 inch) (1.560 ± 0.020 inch) 0.25°
9.30 ± 0.06 mm 40.060 ± 0.013 mm 34.0 ± 0.5 mm 30.25° ±
241-8388 Intake
(0.366 ± 0.002 inch) (1.5772 ± 0.0005 inch) (1.34 ± 0.02 inch) 0.25°
Intake
0.51 mm 12.63 ± 0.06 mm 46.035 ± 0.013 mm 39.1 ± 0.5 mm 29.75° ±
254-3943
(0.020 inch) (0.497 ± 0.002 inch) (1.81240 ± 0.00051 inch) (1.54 ± 0.02 inch) 0.25°
oversize
Exhaust
0.51 mm 11.30 ± 0.06 mm 42.900 ± 0.015 mm 36.0 ± 0.5 mm 44.75° ±
254-3944
oversize
9.30 ± 0.05 mm 42.560 ± 0.013 mm 36.50 ± 0.50 mm 30.25° ±
255-8666 Intake
(0.366 ± 0.002 inch) (1.6756 ± 0.0005 inch) (1.440 ± 0.020 inch) 0.25°
12.63 ± 0.06 mm 45.525 ± 0.013 mm 39.1 ± 0.5 mm 29.75° ±

260-4855(1) Intake
(0.497 ± 0.002 inch) (1.7923 ± 0.0005 inch) (1.54 ± 0.02 inch) 0.25°
10.40 ± 0.05 mm 39.060 ± 0.013 mm 32.5 ± 0.5 mm 45.00° ±
262-2959 Exhaust
(0.409 ± 0.002 inch) (1.5378 ± 0.0005 inch) (1.28 ± 0.02 inch) 0.25°
9.00 ± 0.06 mm 42.000 ± 0.013 mm 35.80 ± 0.13 mm 30.25° ±

264-6157 Intake
(0.354 ± 0.0024 inch) (1.6535 ± 0.0005 inch) (1.409 ± 0.005 inch) 0.25°
9.00 ± 0.06 mm 42.000 ± 0.013 mm 35.80 ± 0.13 mm 30.25° ±
272-9813(1) Intake
(0.354 ± 0.0024 inch) (1.6535 ± 0.0005 inch) (1.409 ± 0.005 inch) 0.25°
14.00 ± 0.08 mm 48.025 ± 0.013 mm 41.0 ± 0.5 mm 30.25° ±
280-3979(1) Intake
(0.551 ± 0.003 inch) (1.8907 ± 0.0005 inch) (1.61 ± 0.02 inch) 0.25°
Intake
0.51 mm 14.00 ± 0.08 mm 48.535 ± 0.013 mm 41.0 ± 0.5 mm 30.25° ±
288-4881
oversize
q631tm
288-4882 Intake 14.00 ± 0.08 mm 48.785 ± 0.013 mm 41.0 ±Caterpillar:
0.5 mm Confidential
30.25° Yellow
±
0.76 mm (0.551 ± 0.003 inch) (1.92067 ± 0.00051 inch) (1.61 ± 0.02 inch) 0.25°
https://sisweb.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/productsearch/productheaderinfoframeset.jsp&c… 100/140
(0.030 inch)
oversize
Exhaust
0.51 mm 13.90 ± 0.06 mm 43.350 ± 0.013 mm 36.5 ± 0.5 mm 45.25° ±
288-4883
oversize
Exhaust
0.76 mm 13.90 ± 0.06 mm 43.6000 ± 0.013 mm 36.5 ± 0.5 mm 45.25° ±
288-4884
oversize
Intake 12.63 ± 0.06 mm 45.525 ± 0.013 mm 39.1 ± 0.5 mm 29.75° ±
314-3055
Short (0.497 ± 0.002 inch) (1.7923 ± 0.0005 inch) (1.54 ± 0.02 inch) 0.25°
Intake
0.13 mm 12.63 ± 0.06 mm 45.655 ± 0.013 mm 39.1 ± 0.5 mm 29.75° ±
314-3056
oversize
Intake
Short
12.63 ± 0.06 mm 45.655 ± 0.013 mm 39.1 ± 0.5 mm 29.75° ±
314-3057 0.13 mm
(0.497 ± 0.002 inch) (1.79744 ± 0.00051 inch) (1.54 ± 0.02 inch) 0.25°
(0.00512 inch)
oversize
Intake
0.26 mm 12.63 ± 0.06 mm 45.785 ± 0.013 mm 39.1 ± 0.5 mm 29.75° ±
314-3058
oversize
Intake
Short
12.63 ± 0.06 mm 45.785 ± 0.013 mm 39.1 ± 0.5 mm 29.75° ±
314-3060 0.51 mm
(0.497 ± 0.002 inch) (1.80256 ± 0.00051 inch) (1.54 ± 0.02 inch) 0.25°
(0.020 inch)
oversize
Intake
Short
12.63 ± 0.06 mm 46.035 ± 0.013 mm 39.1 ± 0.5 mm 29.75° ±
314-3061 0.51 mm
(0.497 ± 0.002 inch) (1.81240 ± 0.00051 inch) (1.54 ± 0.02 inch) 0.25°
(0.020 inch)
oversize
Intake 14.00 ± 0.08 mm 48.025 ± 0.013 mm 41.0 ± 0.5 mm 30.25° ±

314-3063
Short (0.551 ± 0.003 inch) (1.8907 ± 0.0005 inch) (1.61 ± 0.02 inch) 0.25°
Intake
0.13 mm 14.00 ± 0.08 mm 48.155 ± 0.013 mm 41.0 ± 0.5 mm 30.25° ±
314-3064
oversize
Intake
Short
14.00 ± 0.08 mm 48.155 ± 0.013 mm 41.0 ± 0.5 mm 30.25° ±
314-3065 0.13 mm
(0.551 ± 0.003 inch) (1.89586 ± 0.00051 inch) (1.61 ± 0.02 inch) 0.25°
(0.00512 inch)
oversize
Intake
0.26 mm 14.00 ± 0.08 mm 48.285 ± 0.013 mm 41.0 ± 0.5 mm 30.25° ±
314-3066
oversize
Intake
Short
14.00 ± 0.08 mm 48.285 ± 0.013 mm 41.0 ± 0.5 mm 30.25° ±
314-3067 0.26 mm
(0.551 ± 0.003 inch) (1.90098 ± 0.00051 inch) (1.61 ± 0.02 inch) 0.25°
(0.01024 inch)
oversize
314-3068 Intake 14.00 ± 0.08 mm 48.535 ± 0.013 mm 41.0 ± 0.5 mm 30.25° ±
0.51 mm (0.551 ± 0.003 inch) (1.91082 ± 0.00051 inch) (1.61 ± 0.02 inch) 0.25°q631tm
(0.020 inch)
oversize
Intake
Short
14.00 ± 0.08 mm 48.535 ± 0.013 mm 41.0 ± 0.5 mm 30.25° ±
314-3069 0.51 mm
(0.551 ± 0.003 inch) (1.91082 ± 0.00051 inch) (1.61 ± 0.02 inch) 0.25°
(0.020 inch)
oversize
Exhaust
0.13 mm 11.30 ± 0.06 mm 42.52 ± 0.015 mm 36.0 ± 0.5 mm 44.75° ±
331-5010
oversize
Exhaust
0.26 mm 11.30 ± 0.06 mm 42.65 ± 0.015 mm 36.0 ± 0.5 mm 44.75° ±
331-5011
oversize
(1) Do not machine the valve seat. Specialized manufacturing processes were used on this part. Machining will significantly decrease the life of the engine.
Replacing Valve Seats Inserts for C7 through C32
Use this section to determine the procedure to be used to replace valve inserts. More options will be added in the future.
Note: The circular runout between the valve seat and the valve guide must be within 0.08 mm (0.003 inch).
Note: If your engine is a marine engine, do not machine the inserts for the Intake. You must use the original inserts. You must machine the
depth of the bore for the valve seat. Remove the same amount of material from the bottom of the bore as the amount of material from the head.
Table 60
Replacements for Valve Seat Inserts on C7
Valve
Condition of the Head Seat Comment Machining the Valve Seat Insert
Insert
155-9504
The head has been machined. The bore of the Intake Machine the surface of the insert so that the same amount of
N/A
head does not have damage. 147-8218 material is removed from the head and the insert.
Exhaust
0.13 mm
187-8285 (0.005 inch)
Machine the surface of the insert so that the same amount of
The head has been machined. The bore of the Intake oversize
material is removed from the head and the insert. Enlarge the
head has damage. 187-8282 0.13 mm
bore diameter by 0.13 mm (0.005 inch).
Exhaust (0.005 inch)
oversize
0.26 mm
187-8286 (0.010 inch)
The head has been machined. The bore of the Machine the surface of the insert so that the same amount of
Intake oversize
head has damage and an oversized insert has material is removed from the head and the insert. Enlarge the
187-8283 0.26 mm
already been used. bore diameter by 0.51 mm (0.020 inch).
oversize
0.51 mm
187-8287 (0.020 inch)
The head has been machined. The bore of the Machine the surface of the insert so that the same amount of
Intake oversize
head has damage and an oversized insert has material is removed from the head and the insert. Enlarge the
187-8284 0.51 mm
already been used. bore diameter by 0.51 mm (0.020 inch).
oversize
Table 61
Replacements for Valve Seat Inserts on C9 and C-9
Valve
Condition of the Head Seat Comment Machining the Valve Seat Insert q631tm
Insert Caterpillar: Confidential Yellow
The head has been machined. The 241-8388 N/A Machine the surface of the insert so that the same amount of material is
bore of the head does not have Intake removed from the head and the insert.
damage. 212-8917
Exhaust
0.51 mm
254-3946 (0.020 inch)
Machine the surface of the insert so that the same amount of material is
The head has been machined. The Intake oversize
removed from the head and the insert. Enlarge the bore diameter by
bore of the head has damage. 254-3947 0.51 mm
0.51 mm (0.020 inch).
oversize
Table 62
Replacements for Valve Seat Inserts on C15, C16, C18, C27, and C32
Valve Seat
Condition of the Head Comment Machining the Valve Seat Insert
Insert
224-3983(1)
The thickness of the head is within like-new
Intake
dimensions. See Table 10 for specifications. The bore N/A Do not machine the insert.
226-5561
of the head does not have damage.
Exhaust
175-3617
The head has been machined beyond factory Machine the sealing angle of the insert so that the same
Intake
specifications. The bore of the head does not have N/A amount of material is removed from the head and the
226-5561
damage. insert.
Exhaust
0.51 mm
170-4738 (0.020 inch) Machine the sealing angle of the insert so that the same
The head has been machined beyond factory Intake oversize amount of material is removed from the head and the
specifications. The bore of the head has damage. 170-4737 0.51 mm insert. Enlarge the bore diameter by 0.51 mm
Exhaust (0.020 inch) (0.020 inch).
oversize
0.76 mm
167-0643 (0.030 inch) Machine the sealing angle of the insert so that the same
The head has been machined beyond factory
Intake oversize amount of material is removed from the head and the
specifications. The bore of the head has damage and
167-0642 0.76 mm insert. Enlarge the bore diameter by 0.76 mm
an oversized insert has already been used.
Exhaust (0.030 inch) (0.030 inch).
oversize
(1) Do not machine the valve seat. Specialized manufacturing processes were used on this part. Machining will significantly decrease the life of the engine.
Valve Seat Inserts for C175 Engines

The C-175 engines use two types of cylinder heads, depending on the application. Engines that are used in generator sets use cylinder heads
with water-cooled valve seat inserts (A). Generally, engines that are in machines use cylinder heads with conventional non-water cooled valve
seat inserts (B). The exception is some 793F Off-Highway Trucks S/N:B7B100-118 that used water-cooled valve seat inserts.

Water-Cooled Valve Seat Inserts

Conventional Non Water-Cooled Valve Seat Inserts
NOTICE
Do not rework valve inserts. If the insert does not meet dimensional
specifications, then the insert must be replaced.
q631tm
Sealing face on the different types of valve seat inserts
(H) Height of allowed wear of the sealing face
Use the following chart to determine the maximum height of allowed wear of the sealing face on the valve seat insert. The maximum height of
allowed wear is provided in the following chart with the corresponding valve. The maximum height of allowed wear is found from the
corresponding valves outer diameter of the sealing face and the valve seats inserts inner diameter of the sealing face. The angle of the valve
must meet the specifications in Table 63 to ensure proper sealing.
Table 63
Maximum Height of Allowed Wear of the Sealing Face on the Valve Seat Insert for C175 Engines
2.5 mm
(0.10 inch)
Conventional Valve Seat Inserts
Conventional valve seat inserts can be replaced at overhaul. If the valve seat bore is damaged, then the bore can be machined oversized.
Oversized seats and dimensions are listed in Table 64. Machine the bore according to the specifications given in Table 64 .

(J) Outside diameter of the valve seat insert
(K) Sealing angle for the valve seat insert
Table 64
Specifications of the Conventional Valve Seat Insert for C175 Engines
Valve Seat Insert Outside diameter of the valve seat insert (J) Sealing angle for the valve seat insert (K)
Inlet Valve Seat Insert

273-1223
456-2468 62.100 ± 0.013 mm
Valve Seat Insert (2.4449 ± 0.0005 inch)
(Standard)
393-6470 20° ± 0.25°

Valve Seat Insert 62.354 ± 0.013 mm (2.4549 ± 0.0005 inch)
(0.25-MM OS, INLET)
393-6471 Valve Seat Insert
62.609 ± 0.013 mm (2.4649 ± 0.0005 inch)
(0.51-MM OS, INLET)
Exhaust Valve Seat Insert
331-3688 Valve Seat Insert 61.120 ± 0.013 mm
(Standard) (2.4063 ± 0.0005 inch)

61.374 ± 0.013 mm (2.4163 ± 0.0005 inch) 45° ± 0.25°
(0.25-MM OS, EXHAUST)
61.629 ± 0.013 mm (2.4263 ± 0.0005 inch)
(0.51-MM OS, EXHAUST)

Conventional valve seat inserts
(L) Diameter of the bore for the valve seat insert
(M) Depth of the bore for the valve seat insert
NOTICE
The runnout of the valve seat bore center to guide bore center must be
less than 0.04 mm (0.002 inch). q631tm
Note: The C175 cylinder head has different-sized intake and exhaust seat bores. Take note of the bore location and size prior to machining.
Table 65
Dimensions for the Bore in the Cylinder Head for the Valve Seat Insert for C175 Engines
Part Number Intake or Exhaust Depth of the bore for the valve seat (M) Diameter of the bore for the valve seat insert (L)
Standard
62.000 ± 0.015 mm
(2.4409 ± 0.0006 inch)
Intake 16.00 ± 0.15 mm (0.630 ± 0.006 inch) 0.254 mm Oversize
62.254 ± 0.015 mm (2.4509 ± 0.0006 inch)
328-7082 0.508 mm Oversize

345-8447 62.508 ± 0.015 mm (2.4609 ± 0.0006 inch)
456-2406 Standard
515-8766 61.000 ± 0.015 mm (2.4016 ± 0.0006 inch)
517-4407
0.254 mm Oversize
61.254 ± 0.015 mm
Exhaust 16.00 ± 0.15 mm (0.630 ± 0.006 inch)
(2.4116 ± 0.0006 inch)
0.508 mm Oversize
61.508 ± 0.015 mm
(2.4216 ± 0.0006 inch)
Water-Cooled Valve Seat Inserts
Do not reuse water-cooled valve seat inserts.

Water-cooled insert
(K) Sealing angle for the valve seat insert
(N) Upper diameter of the valve seat insert
(P) Lower diameter of the valve seat insert
Table 66
Specifications of the Water-Cooled Valve Seat Insert for C175 Engines
Inlet Valve Seat Inserts

Valve Seat Upper diameter of the valve seat Lower diameter of the valve seat Sealing angle for the valve seat
Insert insert (N) insert (P) insert (K)
67.150 ± 0.013 mm 60.635 ± 0.013 mm
333-9179 20° ± 0.25°
(2.6437 ± 0.0005 inch) (2.3872 ± 0.0005 inch)
Exhaust Valve Seat Inserts
66.900 ± 0.013 mm 60.385 ± 0.013 mm
333-9180 45° ± 0.25°
(2.6339 ± 0.0005 inch) (2.3774 ± 0.0005 inch)

(M) Depth of the lower bore for the valve seat insert
(Q) Diameter of the upper bore for the valve seat insert
(R) Diameter of the lower bore for the valve seat insert
(S) Depth of the upper bore for the valve seat insert
Table 67
Dimensions for the Bore in the Cylinder Head for the Valve Seat Insert for C175 Engines
Intake or Depth of the lower bore Diameter of the upper bore for Diameter of the lower bore for Depth of the upper bore
q631tm
Exhaust for the valve seat (M) the valve seat insert (Q) the valve seat insert (R) for the valve seat (S)
Intake 36.03 ± 0.15 mm 66.995 ± 0.020 mm 60.495 ± 0.020 mm 14.03 ± 0.15 mm
(1.419 ± 0.006 inch) (2.6376 ± 0.0006 inch) (2.3817 ± 0.0008 inch) (0.553 ± 0.006 inch)
36.63 ± 0.30 mm 66.745 ± 0.020 mm 60.245 ± 0.020 mm 14.63 ± 0.15 mm
Exhaust
Valve Seat Inserts for 3044, 3046, 3064, and 3066 Engines

Valve seat insert
(Q) Depth of the Bore for the Valve Seat Insert
(R) Valve Seat Insert Inside Diameter
(S) Valve Seat Insert Outside Diameter
(T) Sealing Angle of the Valve Seat Insert
Table 68
Specifications for Valve Seat Inserts for 3044, 3046, 3064, and 3066 Engines
Sales Model 3044, 3046 3064, 3066

Description Intake Exhaust Intake Exhaust
Depth of the Bore for the Valve Seat 5.00 mm 5.00 mm 6.60 mm 6.60 mm
Insert (Q) (0.197 inch) (0.197 inch) (0.260 inch) (0.260 inch)
38.00 mm 31.00 mm 40.00 mm 39.00 mm

Valve Seat Insert Inside Diameter (R)
(1.496 inch) (1.221 inch) (1.575 inch) (1.535 inch)
Valve Seat Insert Outside Diameter 46.012 ± 0.012 mm 37.012 ± 0.012 mm 48.012 ± 0.012 mm 39.012 ± 0.012 mm
(S) (1.8115 ± 0.0005 inch) (1.4572 ± 0.0005 inch) (1.8902 ± 0.0005 inch) (1.5359 ± 0.0005 inch)
Sealing Angle of the Valve Seat Insert

60 60 60 60
(T)
Valve Seat Inserts for 3054, and 3056 Engines

Refer to Table 69 for dimensions of the valve seat insert.
(A) Depth of bore of valve seat
(B) Diameter of bore of valve seat insert
(C) Maximum radius

Refer to Table 69 and Table 71 for dimensions of the valve seat insert.
(D) Angle of valve seat insert
(E) Dimension of chamfer
(F) Angle of chamfer
Note: When a new valve seat insert is installed, a new valve and valve guide must be installed. Refer to the Disassembly and Assembly for
removal and installation procedures.
Table 69
Specifications for 3054, and 3056 Engines
Description Intake Exhaust

7.19 to 7.32 mm 9.52 to 9.65 mm
Depth of bore of valve seat (A)
(0.28307 to 0.28819 inch) (0.37480 to 0.37992 inch)
51.22 to 51.24 mm 42.62 to 42.65 mm

Diameter of bore of valve seat insert (B) q631tm
(2.01653 to 2.01732 inch) (1.67795 to 1.67913 inch)
Maximum radius (C) 0.38 mm
(0.01496 inch)
Angle of valve seat with 46° valve seats (D) 88°
Angle of valve seat with 31° valve seats (D) 118°
0.9 to 1.3 mm
Dimension of chamfer (E)
(0.03543 to 0.05118 inch)
Angle of chamfer (F) 30°
Valve Seat Inserts for 3114, 3116, 3126 Engines
The valve seat inserts should be replaced when the width of the valve seat or the face of the valve head cannot be machined to the correct
specification. Refer to the appropriate Service Manual for your engine application for removal and installation instructions of valve seat inserts.
NOTICE
Some 3126B engines are experiencing corrosion on the 217-5213 Valve
Seat Insert and the 155-9504 Valve Seat Insert.

seat inserts with 272-9813 Valve Seat Inserts. The 272-9813 Valve Seat
Inserts are made from an alloy that is corrosion resistant.

seat inserts with 278-0453 Valve Seats. The 278-0453 Valve Seats are
made from an alloy that is more corrosion resistant.
Part numbers are etched on the outer surface of the valve seat inserts.
The 278-0453 Valve Seats and 272-9813 Valve Seat Inserts are pre-
finished. Pre-finished valve seat inserts do not require any additional
machining in the cylinder head.
Machine the seat face of the insert after the inserts are installed to be sure of the following:
Flatness of the seat
Angle of the seat
Alignment of the seat

Refer to Table 69 and Table 71 for dimensions of the valve seat insert.
(C) Diameter of bore of valve seat insert
(D) Inside diameter of valve seat insert
(E) Angle of valve seat insert
(F) Depth of bore of valve seat
(G) Outside diameter of face of seat insert
Table 70
Early Model
Specifications for 3114, 3116, 3126 Engines
Intake Exhaust
Description
7W-8065 1W-2713
43.29 ± 0.13 mm 37.00 ± 0.13 mm

Inside diameter of valve seat insert (D)
(1.704 ± 0.005 inch) (1.457 ± 0.005 inch)
49.931 ± .013 mm 42.931 ± .013 mm
Diameter of bore of valve seat insert (C)
(1.9658 ± 0.0005 inch) (1.6903 ± 0.0005 inch) q631tm
Angle of valve seat insert (E) 30.25° ± 0.50° 45.50° ± 0.50°
10.00 ± 0.13 mm 10.00 ± 0.13 mm

Depth of bore of valve seat (F)
(0.394 ± 0.005 inch) (0.394 ± 0.005 inch)
48.0 mm 40.4 mm
Outside diameter of face of seat insert (G)(1)
(1.89 inch) (1.59 inch)
(1) The seat insert should not be reused if the outside diameter is greater than specifications.
Table 71
HEUI Model
Specifications for 3114, 3116, 3126 Engines
Intake Exhaust
Description
217-5213 147-8218
35.80 ± 0.13 mm 39.50 ± 0.13 mm

Inside diameter of valve seat insert (D)
(1.409 ± 0.005 inch) (1.555 ± 0.005 inch)
42.000 ± 0.013 mm 46.000 ± 0.013 mm
Diameter of bore of valve seat insert (C)
(1.6535 ± 0.0005 inch) (1.8110 ± 0.0005 inch)
Angle of valve seat insert (E) 30.25° ± 0.25° 45.5° ± 0.25°
5.50 ± 0.05 mm 6.05 ± 0.05 mm

Depth of bore of valve seat (F)
(0.217 ± 0.002 inch) (0.238 ± 0.002 inch)
37.351 mm 40.8 mm
Outside diameter of face of seat insert (G)(1)
(1.4705 inch) (1.61 inch)
(1) The seat insert should not be reused if the outside diameter is greater than specifications.
Valve Seat Inserts for 3176, 3196 Engines
Removal
Use the 166-7441 Valve Seat Extractor Tool to remove the valve seat.
Refer to Special Instruction, SMHS7935, "Use of 6V-4805 Valve Seat Extractor Tool Group" for additional information.
Note: The 6V-4805 Valve Seat Extractor Tool Group has been replaced by the 166-7441 Valve Seat Extractor Tool.
Conduct further inspection of the bores after the removal of the valve seat.
Installation
Lower the temperature of the seats before installation. The temperature of the valve seat should not exceed −60 °C (−76.0 °F).
Use the 1U-9170 Valve Seat Driver to install the valve seat.
Note: Make sure that the projection of the valve is correct. Make sure that the depth of the valve seat is correct and that the valve seat is fully
inserted into the bore.
Machine the seat face of the insert after the inserts are installed to be sure of the following:
Flatness of the seat
Angle of the seat
Alignment of the seat to the valve guide
Correct valve recession

Refer to Table 72 and Table 73 for dimensions of valve seat.
(A) Depth of valve seat bore
(C) Diameter of valve seat bore
q631tm
(B) Inside diameter of valve seat
(D) Sealing angle of valve seat
Table 72
Dimensions of Inlet Valve Seat in 3176 and 3196 Engines
Part Depth of valve seat bore Sealing angle of valve seat Diameter of valve seat bore Inside diameter of valve seat
Number (A) (D) (C) (B)
15.27 ± 0.20 mm
4N-5893 30.00° ± 1.00°
(0.601 ± 0.008 inch)
138-1999 46.025 ± 0.013 mm 39.1 ± 0.5 mm
15.27 ± 0.11 mm (1.8120 ± 0.0005 inch) (1.54 ± 0.02 inch)
138-2006 29.75° ± 0.25°
(0.601 ± 0.004 inch)
179-9454
Table 73
Dimensions of Exhaust Valve Seat in 3176 and 3196 Engines
Part Depth of valve seat bore Sealing angle of valve seat Diameter of valve seat bore Inside diameter of valve seat
Number (A) (D) (C) (B)
7W-5554
14.60 ± 0.20 mm
133-7030 45.00° ± 1.00°
(0.575 ± 0.008 inch)
133-6997 43.4 ± 0.015 mm 36.00 ± 0.13 mm
179-9453 (1.71 ± 0.0006 inch) (1.417 ± 0.005 inch)
14.60 ± 0.11 mm
138-1997 44.75° ± 0.25°
(0.575 ± 0.004 inch)
138-2005
14.27 ± 0.11 mm 46.025 ± 0.013 mm 39.1 ± 0.5 mm

138-2006 29.75° ± 0.25°
(0.5618 ± 0.0043 inch) (1.8120 ± 0.0005 inch) (1.54 ± 0.02 inch)
Valve Seat for 3200 Engines

Use this procedure to remove erosion or cracks between the valve seat and injector nozzle hole only in 3200 Engines. Use a 6V-4168 Air
Grinder with a 6V-4802 Stone. A 6V-4801 Dressing Stone is needed to make the edges of the 6V-4802 Stone round.
1. Grind channel, but do not grind into the bottom of the valve seat area.
2. Make the edges of the 6V-4802 Stone round before grinding the head.
3. Channel specifications for crack removal.
Maximum depth 3.2 mm (0.12598 inch).
Maximum width 4.8 mm (0.18898 inch).
Minimum radius 1.6 mm (0.06299 inch).
NOTICE
Do not damage the bottom of the valve seat area with the stone. If the
crack extends into the valve seat area, the cylinder head cannot be
reused.

(A) Valve Seat Angle
Table 74
Diesel q631tm
Model
Intake Exhaust Caterpillar: Confidential Yellow
3204 30.5° ± 0.5° 45.5° ± 0.5°

3208 30.5° ± 0.5° 45.5° ± 0.5°
Valve Seat Depth for 3208 Engines Only
Two gauges are used to measure the depth of valve seats on 3208 Engines Only. Use a 6V-7098 Gauge for intake valves and a 6V-7097 Gauge
for exhaust valves.
1. Place the small diameter end of gauge into the valve guide, making sure gauge is seated on the face of the valve.
2. Use straight edge to check the depth of the seat.
3. If gauge surface is below the bottom surface of the straight edge, the seat is too deep.
4. If gauge surface is above the bottom of the straight edge, the seat is too high and must be ground again.
5. If the straight edge is between faces and, the seat is positioned correctly.
Valve Seat Inserts for 3300 Engines

(A) Valve Seat Angle
Table 75
Valve Seat Angle (A) for 3304 and 3306 Engines
Diesel Gas
Intake Exhaust Intake Exhaust
29.25° ± 0.5° 30.25° ± 0.5° 30.0° ± 0.5° 30.0° ± 0.5°
The valve seat inserts have an interference fit of 0.076 mm (0.003 inch) with the cylinder head. Use the following information when using
oversized valve seat inserts.
Table 76
Valve Seat Insert Bore Diameters in Cylinder Head for 3300 Engines
Intake
Valve Exhaust
Lead
Seat Intake Bore Exhaust Bore Lead in Intake Bore Exhaust Bore
Chamfer (B) in
Insert Depth (A) Depth (C) Angle Diameter (F) Diameter (G)
Angle
Type (E)
(D)
Standard .76 ± 0.25 mm
12.28 ± 0.13 mm 12.28 ± 0.13 mm 25 +/- 30 +/- 51.956 ± 0.030 mm 50.813 ± 0.030 mm
Size (0.030 ± 0.010 in)
(0.483 ± 0.005 in) (0.483 ± 0.005 in) 2° 2° (2.0455 ± 0.0012 in) (2.0005 ± 0.0012 in)
Inserts by 45°
0.13 mm .76 ± 0.25 mm
12.28 ± 0.13 mm 12.28 ± 0.13 mm 25 +/- 30 +/- 52.086 ± 0.030 mm 50.943 ± 0.030 mm
(0.005 in) (0.030 ± 0.010 in)
(0.483 ± 0.005 in) (0.483 ± 0.005 in) 2° 2° (2.0506 ± 0.0012 in) (2.0056 ± 0.0012 in)
Oversized by 45°
0.25 mm .76 ± 0.25 mm

12.28 ± 0.13 mm 12.28 ± 0.13 mm 25 +/- 30 +/- 52.206 ± 0.030 mm 51.063 ± 0.030 mm
(0.010 in) (0.030 ± 0.010 in)
(0.483 ± 0.005 in) (0.483 ± 0.005 in) 2° 2° (2.0554 ± 0.0012 in) (2.0104 ± 0.0012 in)
Oversized by 45°
0.51 mm .76 ± 0.25 mm
12.28 ± 0.13 mm 12.28 ± 0.13 mm 25 +/- 30 +/- 52.466 ± 0.030 mm 51.323 ± 0.030 mm
(0.020 in) (0.030 ± 0.010 in)
(0.483 ± 0.005 in) (0.483 ± 0.005 in) 2° 2° (2.0656 ± 0.0012 in) (2.0206 ± 0.00118 in)
Oversized by 45°
q631tm
0.76 mm 12.28 ± 0.13 mm .76 ± 0.25 mm 12.28± 0.13 mm 25 +/- 30 +/- Caterpillar:
52.716 ± 0.030 mm 51.573 Confidential
± 0.030 mm Yellow
(0.030 in) (0.483 ± 0.005 in) (0.030 ± 0.010 in) (0.483 ± 0.005 in) 2° 2° (2.0754 ± 0.0012 in) (2.0304 ± 0.0012 in)
Oversized by 45°
The valve seat inserts should be replaced when the width of the valve seat or the valve head to the cylinder head face cannot be machined to the
correct specification. Use 166-7441 Valve Seat Extractor Tool to remove the valve seat inserts. Refer to Special Instruction, SMHS7935, "Use
of 6V-4805 Valve Seat Extractor Tool" to remove the valve seat inserts.
After the inserts are installed, grind the seat face of the insert to ensure the following:
The face of the insert is flat.
The insert has the correct angle.
The insert is in alignment with the bore of the valve guide.
Note: If the valve seat insert is premachined, the insert does not need to be ground after installation into the cylinder head.
Refer to Table 79 or Table 80 for the correct dimensions.
When the valve seat insert is ground, refer to Table 79 or Table 80 for the minimum finished width of the valve seat (G). The maximum width of
the valve seat is the intersection of the ground face with the bore of the insert in the cylinder head.
Oversized valve seat inserts are available for use in 3400 Series Engines. These inserts provide increased serviceability of the cylinder head.
When these inserts are used, the bore in the cylinder head must be machined to the correct size to achieve the correct press fit of the valve seat
insert. Refer to Table 77 or Table 78 for the dimensions to machine the cylinder head.
Table 77
Oversized Valve Seat Inserts for 3400 Engines
Diesel Engines
Oversize Dimension Bore for Inlet Seat in Cylinder Head Bore for Exhaust Seat in Cylinder Head
0.13 mm 46.076 ± 0.025 mm
N/A
(0.005 inch) (1.8140 ± 0.0010 inch)
0.25 mm 46.203 ± 0.025 mm
N/A
(0.010 inch) (1.8190 ± 0.0010 inch)
0.51 mm 46.457 ± 0.025 mm 43.282 ± 0.025 mm

(0.020 inch) (1.8290 ± 0.0010 inch) (1.7040 ± 0.0010 inch)
0.76 mm 46.711 ± 0.025 mm 43.536 ± 0.025 mm
(0.030 inch) (1.8390 ± 0.0010 inch) (1.7140 ± 0.0010 inch)
Table 78
Oversized Valve Seat Inserts for 3400 Engines
Gas Engines
0.127 mm 46.076 ± 0.025 mm 42.901 ± 0.025 mm
(0.0050 inch) (1.8140 ± 0.0010 inch) (1.6890 ± 0.0010 inch)
0.254 mm 46.203 ± 0.025 mm 43.028 ± 0.025 mm

(0.0100 inch) (1.8190 ± 0.0010 inch) (1.6940 ± 0.0010 inch)
0.381 mm 46.330 ± 0.025 mm 43.155 ± 0.025 mm
(0.0150 inch) (1.8240 ± 0.0010 inch) (1.6990 ± 0.0010 inch)
0.508 mm 46.457 ± 0.025 mm 43.282 ± 0.025 mm

(0.0200 inch) (1.8290 ± 0.0010 inch) (1.7040 ± 0.0010 inch)
0.762 mm 46.711 ± 0.025 mm 43.536 ± 0.025 mm q631tm
(0.0300 inch) (1.8390 ± 0.0010 inch) (1.7140 ± 0.0010 inch) Caterpillar: Confidential Yellow
Table 79
Specifications for the Valve Seat Insert for 3400 Engines
Diesel Engines
Angle
of
Depth of the bore in Bore diameter in Inside diameter Minimum width of
Part Outside diameter of valve
head for valve seat head for valve seat of valve seat the valve seat insert
Number valve seat insert seat
insert (C) insert (D) insert (E) (G)
insert
(F)
115-2358 13.01 ± 0.15 mm 45.949 ± 0.025 mm 46.025 ± 0.013 mm 39.1 ± 0.3 mm 30 ± 1 2.286 ± 0.635 mm
Inlet (0.512 ± 0.006 inch) (1.8090 ± 0.0010 inch) (1.8120 ± 0.0005 inch) (1.54 ± 0.01 inch) degree (0.0900 ± 0.0250 inch)
30.25 ±
4N-5893 13.01 ± 0.15 mm 45.949 ± 0.025 mm 46.025 ± 0.013 mm 39.1 ± 0.5 mm 2.286 ± 0.635 mm
0.50
Inlet (0.512 ± 0.006 inch) (1.8090 ± 0.0010 inch) (1.8120 ± 0.0005 inch) (1.54 ± 0.02 inch) (0.0900 ± 0.0250 inch)
degree
1W-5283 13.01 ± 0.15 mm 42.774 ± 0.025 mm 42.850 ± 0.013 mm 36.5 ± 0.5 mm 45 ± 1 1.524 ± 0.508 mm
Exhaust (0.512 ± 0.006 inch) (1.6840 ± 0.0010 inch) (1.6870 ± 0.0005 inch) (1.44 ± 0.02 inch) degree (0.0600 ± 0.0200 inch)
Table 80
Specifications for the Valve Seat Insert for 3400 Engines
Gas Engines
Angle
of
Depth of the bore Bore diameter in Inside diameter of Minimum width of
in head for valve head for valve seat valve seat insert the valve seat insert
seat insert (C) insert (D) (E) (G)
insert
(F)
20.25
214-3286 11.48 ± 0.10 mm 45.949 ± 0.025 mm 46.025 ± 0.015 mm 39.10 ± 0.25 mm
± 0.50 N/A(1)
Inlet (0.452 ± 0.004 inch) (1.8090 ± 0.0010 inch) (1.8120 ± 0.0006 inch) (1.539 ± 0.010 inch)
degree
20.25
122-7352 13.01 ± 0.15 mm 45.949 ± 0.025 mm 46.025 ± 0.013 mm 39.10 ± 0.25 mm 3.0 ± 0.5 mm
± 0.50
degree
20.25
6I-4019 13.01 ± 0.15 mm 45.949 ± 0.025 mm 46.025 ± 0.013 mm 39.10 ± 0.25 mm 3.0 ± 0.5 mm
± 0.50
degree
30.25
4N-5893 13.01 ± 0.15 mm 45.949 ± 0.025 mm 46.025 ± 0.013 mm 39.1 ± 0.5 mm 2.286 ± 0.635 mm
± 0.50
degree
20.25
212-0938 11.48 ± 0.10 mm 42.774 ± 0.025 mm 42.850 ± 0.015 mm 33.50 ± 0.25 mm
± 0.25 N/A(1)
Exhaust (0.452 ± 0.004 inch) (1.6840 ± 0.0010 inch) (1.6870 ± 0.0006 inch) (1.319 ± 0.010 inch)
degree
20.25
212-0936 11.48 ± 0.10 mm 42.774 ± 0.025 mm 42.840 ± 0.015 mm 33.50 ± 0.25 mm
± 0.25 N/A(1)
Exhaust (0.452 ± 0.004 inch) (1.6840 ± 0.0010 inch) (1.6866 ± 0.0006 inch) (1.319 ± 0.010 inch)
degree
20.25
198-6529 13.01 ± 0.15 mm 42.774 ± 0.025 mm 42.840 ± 0.013 mm 35.71 ± 0.25 mm 3.1 ± 0.5 mm
± 0.50
Exhaust (0.512 ± 0.006 inch) (1.6840 ± 0.0010 inch) (1.6866 ± 0.0005 inch) (1.406 ± 0.010 inch) (0.12 ± 0.02 inch)
degree
20.25
118-4715 13.01 ± 0.15 mm 42.774 ± 0.025 mm 42.850 ± 0.013 mm 35.71 ± 0.25 mm 3.1 ± 0.5 mm
± 0.50
degree
30.25
4W-4325 13.01 ± 0.15 mm 42.774 ± 0.025 mm 42.850 ± 0.013 mm 35.71 ± 0.25 mm 2.970 ± 0.508 mm
± 0.50
degree
1W-5283 13.01 ± 0.15 mm 42.774 ± 0.025 mm 42.850 ± 0.013 mm 36.5 ± 0.5 mm 45 ± 1 1.524 ± 0.508 mm
q631tm
(1) Premachined Insert
Valve Seat Inserts for 3406E, 3456 Engines

The valve seat inserts should be replaced when the width of the valve seat cannot be machined to the correct specification. Use 166-7441 Valve
Seat Extractor Tool to remove the valve seat inserts. Refer to Special Instruction, SMHS7935, "Use of 6V-4805 Valve Seat Extractor Tool
Group" to remove the valve seat inserts.
Use 9U-6897 Valve Seat Driver to install the valve seat inserts for the inlet valves. Use 9U-6898 Valve Seat Driver to install the valve seat
inserts for the exhaust valves. After the inserts are installed, grind the seat face of the insert to ensure the following:
The face of the insert is flat.
The insert has the correct angle.
The insert is in alignment with the bore of the valve guide.
Note: If the valve seat insert is premachined, the insert does not need to be ground after installation into the cylinder head.
Refer to Table 82 for the correct dimensions.
When the valve seat is ground, refer to Table 82 for the minimum finished width of the valve seat (G). The maximum width of the valve seat is
the intersection of the ground face with the bore of the insert in the cylinder head.
Oversized valve seat inserts are available for use in 3406E Engines and 3456 Engines. These inserts provide increased serviceability of the
cylinder head. When these inserts are used, the bore in the cylinder head must be machined to the correct size to achieve the correct press fit of
the valve seat insert. Refer to Table 81 for the dimensions to machine the cylinder head.
Shortened valve seat inserts are available for use in 3406E Engines and 3456 Engines. These inserts can be used to replace the 224-3983 Seat
Insert and the oversized inserts for the 224-3983 Seat Insert.
Table 81
Oversized Valve Seat Inserts for 3406E, 3456 Engines
0.13 mm 48.08 ± 0.025 mm
N/A
(0.0051 inch) (1.8929 ± 0.0010 inch)
0.26 mm 48.21 ± 0.025 mm
N/A
(0.0102 inch) (1.8980 ± 0.0010 inch)
0.51 mm 48.46 ± 0.025 mm 43.284 ± 0.025 mm

(0.0201 inch) (1.9079 ± 0.0010 inch) (1.7041 ± 0.0010 inch)
0.76 mm 43.534 ± 0.025 mm
N/A
(0.0299 inch) (1.7139 ± 0.0010 inch)
Table 82
Specifications for the Valve Seat Insert for 3406E, 3456 Engines
Angle
of
Depth of the bore Bore diameter in Inside diameter of Minimum width of
in head for valve head for valve seat valve seat insert the valve seat insert
seat insert (C) insert (D) (E) (G)
insert
(F)
108-5912 14.00 ± 0.05 mm 47.950 ± 0.025 mm 48.025 ± 0.013 mm 41.00 ± 0.13 mm 30 ± 1 2.334 mm
Inlet (0.551 ± 0.002 inch) (1.8878 ± 0.0010 inch) (1.8907 ± 0.0005 inch) (1.614 ± 0.005 inch) degree (0.0919 inch)
152-8379 14.00 ± 0.05 mm 47.950 ± 0.025 mm 48.025 ± 0.013 mm 41.00 ± 0.13 mm 30 ± 1 2.334 mm
Inlet (0.551 ± 0.002 inch) (1.8878 ± 0.0010 inch) (1.8907 ± 0.0005 inch) (1.614 ± 0.005 inch) degree (0.0919 inch)
175-3617 14.00 ± 0.05 mm 47.950 ± 0.025 mm 48.025 ± 0.013 mm 41.0 ± 0.5 mm 30 ± 1 2.334 mm q631tm
Inlet (0.551 ± 0.002 inch) (1.8878 ± 0.0010 inch) (1.8907 ± 0.0005 inch) (1.61 ± 0.02 inch) degree
Caterpillar:(0.0919 inch) Yellow
Confidential
224-3983 14.00 ± 0.05 mm 47.950 ± 0.025 mm 48.025 ± 0.013 mm 41.0 ± 0.5 mm 30.25 2.377 mm
Inlet (0.551 ± 0.002 inch) (1.8878 ± 0.0010 inch) (1.8907 ± 0.0005 inch) (1.61 ± 0.02 inch) ± 0.25 (0.0936 inch)
degree
314-3063 30.25
14.00 ± 0.05 mm 47.950 ± 0.025 mm 48.025 ± 0.013 mm 41.0 ± 0.5 mm 2.377 mm
± 0.25
Inlet(1) (0.551 ± 0.002 inch) (1.8878 ± 0.0010 inch) (1.8907 ± 0.0005 inch) (1.61 ± 0.02 inch) (0.0936 inch)
degree
30.25
314-3065 14.00 ± 0.05 mm 48.08 ± 0.025 mm 48.155 ± 0.013 mm 41.0 ± 0.5 mm 2.377 mm
± 0.25
degree
30.25
314-3067 14.00 ± 0.05 mm 48.21 ± 0.025 mm 48.285 ± 0.013 mm 41.0 ± 0.5 mm 2.377 mm
± 0.25
degree
30.25
314-3069 14.00 ± 0.05 mm 48.460 ± 0.025 mm 48.535 ± 0.013 mm 41.0 ± 0.5 mm 2.377 mm
± 0.25
degree
1W-5283 13.90 ± 0.05 mm 42.774 ± 0.025 mm 42.850 ± 0.013 mm 36.5 ± 0.5 mm 45 ± 1 1.524 ± 0.508 mm
152-7582 13.90 ± 0.05 mm 42.774 ± 0.025 mm 42.840 ± 0.013 mm 36.5 ± 0.5 mm 45 ± 1 1.507 mm
Exhaust (0.547 ± 0.002 inch) (1.6840 ± 0.0010 inch) (1.6866 ± 0.0005 inch) (1.44 ± 0.02 inch) degree (0.0593 inch)
45.25
226-5561 13.90 ± 0.05 mm 42.774 ± 0.025 mm 42.840 ± 0.013 mm 36.5 ± 0.5 mm 1.508 mm
± 0.25
Exhaust (0.547 ± 0.002 inch) (1.6840 ± 0.0010 inch) (1.6866 ± 0.0005 inch) (1.44 ± 0.02 inch) (0.0594 inch)
degree
(1) 0.55 mm (0.0217 inch) shortened insert
NOTICE
The prefinished inserts should not be ground to correct the valve
projection. Excessive valve projection indicates that the insert is not
seated or the material was not cleaned from the bottom of the
counterbore.
Table 83
Part Numbers for Valve Seat Inserts for 3500 Engines
Part Number of the
Valve Seat Inserts for Intake Exhaust Valve Seat Inserts
Cylinder Head
7E-5861
101-1175
131-0410
131-0423
145-3215
130-2607 183-8809 130-2608 289-9745
154-1612
161-2508
172-0834
290-1351
295-2047
462-4740
480-3132
456-0780
487-3422 456-0411
480-7205
495-2062
525-6572
7E-8760
131-0411 130-2607 130-2608
172-0836 q631tm
4P-6571 257-9166 266-8718(1) 266-8721(2) 191-6760
7C-3471
122-5961
128-1141
144-6409
153-8397
184-5496
206-1554
206-1555
206-1560
206-1563
424-7545
269-0040
315-2630 308-7100
418-9804
(1) Low Swirl.
(2) 2.0 Swirl.
Table 84
Oversize Valve Seat Inserts for 3500 Engines
0.254 mm 0.508 mm
Standard
(0.0100 inch) Oversize Valve Seats (0.0200 inch) Oversize Valve Seats
130-2607 N/A 149-1981
130-2608 N/A 166-5945
183-8809 N/A N/A

191-6760 206-1546 206-1547
257-9166 257-9168 257-9169
266-8718 266-8719 266-8720

266-8721 266-8722 266-8723
289-9745
521-4489 521-4490
494-9516
308-7100 322-3659 322-3660

Detail views of the width of the sealing face of 3500 valve seat inserts.
(M) Width of the sealing face for 308-7100 Valve Seat Insert
(N) Width of the sealing face for 130-2607 Valve Seat Insert and 183-8809 Valve Seat Insert
(P) Width of the sealing face for 266-8718 Valve Seat Insert and 266-8721 Valve Seat Insert
(R) Width of the sealing face for 130-2608 Valve Seat Insert and 289-9745 Valve Seat Insert
(S) Width of the sealing face for 191-6760 Valve Seat Insert and 257-9166 Valve Seat
Use the following chart to determine the maximum width of the sealing face of the valve seat insert. The maximum width of the sealing face of
the valve seat insert is given in the following chart with the corresponding valve. The maximum width is found from the corresponding valve's
outer diameter of the sealing face and the valve seats insert's inner diameter of the sealing face. The angle of the valve must be greater than the
angle of the valve seat insert to ensure proper sealing.
Table 85
Maximum Width of the Valve Seat Insert's Sealing Face for 3500 Engines
Valve Valve Seat Insert Max Width
210-2542 130-2607 3.4904 mm

468-8824 (0.1374 inch)
183-8809
1.8970 mm
257-9166
(0.0747 inch) q631tm
266-8718 2.9804 mm
266-8721 (0.1173 inch)
194-4897 130-2608 2.6640 mm

498-1593 289-9745 (0.1049 inch)
2.4066 mm
104-7184 191-6760
(0.0947 inch)
307-4641
308-9177
3.5000 mm
498-1692 308-7100
(0.1378 inch)
500-8527
500-8528

Refer to Table 86 for dimensions of the valve seat inserts and identification.
Table 86
Specifications of the Valve Seat Insert for 3500 Engines
Inlet Valve Seat Inserts
Sealing Angle For the Valve Seat
Valve Seat Insert Part Number Valve Seat Insert Outside Diameter (T)
Insert (U)
130-2607
60.627 ± 0.015 mm
456-0780 70° ± 0.25°
(2.3869 ± 0.0006 inch)
480-7205
60.627 ± 0.015 mm
183-8809 69.75° ± 0.25°
(2.3869 ± 0.0006 inch)
60.640 ± .015 mm
257-9166 69.75° ± 0.25°
(2.3874 ± 0.0006 inch)
60.640 ± .015 mm
266-8718(1) 69.75° ± 0.25°
(2.3874 ± 0.0006 inch)
60.640 ± .015 mm
266-8721(2) 69.75° ± 0.25°
(2.3874 ± 0.0006 inch)
Exhaust Valve Seat Inserts
130-2608 60.119 ± 0.015 mm
45° ± 0.25°
289-9745 (2.3669 ± 0.0006 inch)
60.132 ± 0.015 mm
191-6760 69.75° ± 0.25°
(2.3674 ± 0.0006 inch)
(1) Low Swirl.
(2) 2.0 Swirl.

Inner diameter and depth of the bore for the valve seat inserts for the cylinder head.
(V) Depth of the bore for valve seat inserts.
(W) Diameter of the bore for the valve seat insert
Table 87
Dimensions for the Bore inch the Cylinder Head for the Valve Seat Insert for 3500 Engines
Intake Depth of the bore Inside diameter of the bore Bore for 0.254 mm Bore for 0.508 mm
Part
or for the valve seat for the valve seat insert (0.0100 inch) oversize valve (0.0200 inch) oversize valve
Number
Exhaust (V) (W) seats (W) seats (W)
7E-5861 14.00 ± 0.15 mm 60.508 ± 0.025 mm 60.762 ± .025 mm 61.016 ± .025 mm q631tm
Intake Caterpillar: Confidential
7E-8760 (0.551 ± 0.006 inch) (2.3822 ± 0.0010 inch) (2.3922 ± 0.0010 inch) (2.4022 ± 0.0010 inch) Yellow
131-0410 Exhaust 14.00 ± 0.15 mm 60.000 ± 0.025 mm 60.254 ± .025 mm 60.508 ± 0.025 mm
131-0411 (0.551 ± 0.006 inch) (2.3622 ± 0.0010 inch) (2.3722 ± 0.0010 inch) (2.3822 ± 0.0010 inch)
172-0834
172-0836
295-2047
4P-6571
7C-3471
101-1175
122-5961
128-1141 16.00 ± 0.15 mm 60.508 ± .025 mm 60.762 ± .025 mm 61.016 ± .025 mm
131-0423 Intake
144-6409
145-3215
153-8397
154-1612
161-2508
184-5496
206-1554
206-1555
206-1560
206-1563
290-1351 16.00 ± 0.15 mm 60.000 ± 0.025 mm 60.254 ± .025 mm 60.508 ± 0.025 mm
Exhaust
418-9802 (0.630 ± 0.006 inch) (2.3622 ± 0.0010 inch) (2.3722 ± 0.0010 inch) (2.3822 ± 0.0010 inch)
424-7545
480-3132
495-2062
525-6572
Specifications of the Valve Seat Insert for 256-4407 Cylinder Head

Cross Section view of the bore for the valve seat insert for 256-4407 Cylinder Head.
(W) Upper bore of the head for the valve seat insert.
(X) Lower bore of the head for the valve seat insert.
Table 88
Dimensions for the Bore of the Cylinder Head Valve Seat for 256-4407
Size Bore at location (W) Bore at location (X)
60.000 ± 0.025 mm 55.000 ± 0.025 mm

Standard
(2.3622 ± 0.0010 inch) (2.1654 ± 0.0010 inch)
0.254 mm 60.254 ± 0.025 mm 55.254 ± 0.025 mm
(0.0100 inch) oversize valve seat inserts (2.3722 ± 0.0010 inch) (2.1753 ± 0.0010 inch)
0.508 mm 60.508 ± 0.025 mm 55.508 ± 0.025 mm

(0.0200 inch) oversize valve seat inserts (2.3822 ± 0.0010 inch) (2.1853 ± 0.0010 inch)

Water-cooled valve seat insert for 269-0040 Cylinder Head and the 315-2630 Cylinder Head
(Y) Upper Diameter
(Z) Lower Diameter
Table 89
Dimensions for the Inlet and Exhaust Valve Seat Insert for Cylinder Head 256-4407
q631tm
Valve Seat Insert Upper Diameter (Y) Lower Diameter (Z) Sealing Angle (U) Caterpillar: Confidential Yellow
203-0843 60.115 ± 0.015 mm 55.108 ± 0.015 mm 20.25° ± 0.25°
308-7100 (2.3667 ± 0.0006 inch) (2.1696 ± 0.0006 inch)
Standard
322-3659
60.369 ± 0.015 mm 55.362 ± 0.015 mm
0.254 mm
(2.3767 ± 0.0006 inch) (2.1796 ± 0.0006 inch)
(0.0100 inch) oversize
322-3660
60.623 ± 0.015 mm 55.616 ± 0.015 mm
0.254 mm
(2.3867 ± 0.0006 inch) (2.1896 ± 0.0006 inch)
(0.0100 inch) oversize
Contact Area for the Valve and Valve Seat
In the past, cylinder heads could be rebuilt so that the insert for the valve seat contacts the sealing face of the valve head at the middle of the
sealing face of the valve. Then, the 3500 engine was introduced. Currently, the traditional sealing area for the valve moved to a location that was
close to the edge of the valve. More recently, premachined inserts for the seat and precision valve guides have moved the sealing area. This
distance is now at 0.51 mm (0.020 inch) to 1.02 mm (0.040 inch) from the outside diameter of the valve head. New, premachined valve seat
inserts may be installed during the rebuild of a cylinder head. Do not machine the sealing faces of the inserts or grind the sealing faces of the
inserts. Modern manufacturing processes make machining after installation unnecessary.
Installation
1. Freeze the insert to −60 °C (−76 °F).
2. Install the insert with a hammer and a drive plate. Make sure that the insert is fully seated in the counterbore.
3. After installation, use a 0.038 mm (0.0015 inch) feeler gauge to ensure that the insert is in contact with the bottom of the counterbore for
the cylinder head. If the gauge goes into a gap under the insert, reseat the insert.
Premachined Valve Seat Inserts
Premachined valve seat inserts are used on all gas and diesel 3500 engines except for the G3500A landfill applications. Do not machine
premachined valve seat inserts. These parts will improve the concentricity of the valve and valve seat in the cylinder head. This will also
improve the quality of cylinder heads that are rebuilt in the field.

Typical cylinder head assembly
(15) Valve seat insert for the exhaust valve
(16) Valve seat insert for the intake valve
NOTICE
The valve seat inserts are similar in size. Make sure that the correct
insert is placed in the appropriate counterbore. Damage can be caused
to the head and damage could be caused to the insert.
Specifications for the Machinable Valve Seats for the 3500 Gas Engine

Valve seats for the 3500 Gas engine
See Illustration 253 and Illustration 254 for details about Area (AA).
Installation and Removal of the Water-Cooled Valve Seat Inserts for G3500 Engines
q631tm
1. Insert the insert removal tool into the bore of the valve seat.
2. Slide the plate to lock the insert removal tool in place.
3. Activate the hydraulic pump to remove the valve seat.
4. Lift the insert removal tool off the cylinder head.
5. Slide the plate to unlock the insert removal tool.
6. Slide the insert and the collets back.
7. Remove the insert.
Cleaning the Internal Passages
Clean the cylinder head thoroughly after disassembly. The fastest method to clean a cylinder head is to soak it in a hot caustic acid solution. The
hot caustic acid should be in a tank with a platform that oscillates. The cylinder heads can also be soaked in a carbon remover. A cabinet washer
is also acceptable for removing carbon.
After the cylinder head has been cleaned, use a flashlight to inspect the bores in the cylinder head. Inspect the bores of the valve guides and
valve seat inserts for signs of cavitation, scratches, or any other type of damage.
If the bores in the cylinder head show signs of cavitation, replace the cylinder head.
If the bores in the cylinder head have scratches that travel from the coolant passage through the press fit areas, replace the cylinder head.
If the scratches travel around the circumference of the press fit areas, use 5P-1720 Seal Pick to inspect the scratches. If the scratches can be felt,
replace the cylinder head.
Replace the cylinder head if there is any damage that will reduce the amount of press fit between the valve seat insert and the cylinder head.
Measure the bores in the cylinder head for the valve seats. If the bores need to be machined oversize, refer to Table 90.

(A) Smaller Outside Diameter
(B) Larger Outside Diameter
Table 90
Diameters for Valve Seats and Bores for G3500 Engines
q631tm
Size Seat Outside Diameter Outside Diameter Bore in Cylinder Head for Bore in Cylinder
Caterpillar: Head for
Confidential Yellow
(A) (B) Valve Seat Insert (A) Valve Seat Insert (B)
55.108 ± 0.015 mm 60.115 ± 0.015 mm 55.000 ± 0.025 mm 60.000 ± 0.025 mm
Standard 308-7100
(2.1696 ± 0.0006 in) (2.3667 ± 0.0006 in) (2.1654 ± 0.0010 in) (2.3622 ± 0.0010 in)
Oversize 1
0.25 mm 55.362 ± 0.015 mm 60.369 ± 0.015 mm 55.254 ± 0.025 mm 60.254 ± 0.025 mm
322-3659
(0.010 in) (2.1796 ± 0.0006 in) (2.3767 ± 0.0006 in) (2.1754 ± 0.0010 in) (2.3722 ± 0.0010 in)
Oversized
Oversize 2
0.51 mm 55.616 ± 0.015 mm 60.623 ± 0.015 mm 55.508 ± 0.025 mm 60.508 ± 0.025 mm
322-3660
(0.020 in) (2.1896 ± 0.0006 in) (2.3867 ± 0.0006 in) (2.1854 ± 0.0010 in) (2.3822 ± 0.0010 in)
Oversized
Specifications for the Valve Seats for the Standard Gas Engine

Detail (AA) from Illustration 244 of double angle valve seats for intake valves and exhaust valves.
Table 91
Specifications for the valve seats for G3500A Cylinder Heads for Landfill Applications
Two Angles
Item Intake Valve and Exhaust Valve

(AB) 20.25 ± 0.25 degrees
(AC) 10.0 ± 0.5 degrees
52.0 mm
(AD)
(2.05 inch) gauge diameter
55.8 mm
(AE)
0.6 ± 0.05 mm
(AF)
(0.02 ± 0.002 inch)
5.3 ± 0.10 mm
(AG)
(0.21 ± 0.004 inch)
(17) Gauge Plane
Runout of the 20.25° angle is 0.065 mm (0.0026 inch) maximum relative to the centerline of the valve guide bore in the cylinder head.
Specifications for the Valve Seat for the G3500A Landfill Gas Engine
Table 92
Specifications for the Valve Seats on the Cylinder Head for the G3500A Landfill Applications
Three Angles
Item Intake and Exhaust

(AB) 60.00 ± 0.50 degrees
(AC) 20.25 ± 0.50 degrees
52.0 mm
(AD)
q631tm
(AE) 55.8 mm Caterpillar: Confidential Yellow
0.61 ± 0.05 mm
(AF)
(0.024 ± 0.002 inch)
5.3 ± 0.10 mm
(AG)
(0.21 ± 0.004 inch)
49.00 ± 0.15 mm
(AH)
(1.929 ± 0.006 inch) diameter
54.0 mm
(AJ)
(2.13 inch)
(AK) 15.00 ± 0.50 degrees

(17) Gauge Plane
Installation of the Valve Seat Inserts
Note: Make sure that there is no residue from prior retaining compound before installing the valve seat inserts.
1. Clean the valve seat inserts and the cylinder head. The components must meet the ISO 16/13 specifications for cleanliness. The
components must be assembled in a clean environment.
2. Reduce the temperature of the valve seat inserts to −20 °C (−4.0 °F).
Note: The valve seat inserts must be placed in the freezer for approximately 8 hours.

(3) Lower press fit
(4) Upper press fit
(5) Circumferential coolant passage

Cross section view of the bore for the valve seat insert.
(3) Lower press fit
(4) Upper press fit
(5) Circumferential coolant passage
3. Apply a thin layer of 4C-9507 Retaining Compound to area (3) and area (4) of the bores in the cylinder head.

Cross section view of the cylinder head
(6) Bottom of first counterbore
(C) Gap between valve seat insert and bottom of the bore
4. Remove one of the valve seat inserts from the freezer. Locate the valve seat insert on the installation tool.
Note: The valve seat must be installed within 30 seconds of removal from the freezer. This will prevent the seat from warming prior
to installation.

q631tm
5. Place the insert and tool into the bore in the head. Caterpillar: Confidential Yellow
Note: Visually inspect the valve seat insert to verify that the valve seat insert is seated properly into the bore.
6. Use a hydraulic press and the insert installation tool to install the valve seat insert into the cylinder head.
Note: Do not use a hammer to install the valve seat insert. The impact from a hammer will damage the valve seat insert.
Note: A typical force of 35586 N (8000 lb) to 44482 N (10000 lb) is required to press in the inserts. The pressure gauge will increase
rapidly when the valve seat insert is seated.
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. Refer to Illustration 257.
Note: The freezer and the press should be close to each other to keep the valve seat inserts from increasing in temperature. Only remove
one valve seat insert from the freezer at a time.
If a pressure gauge is being used, force will need to be converted into pressure.
Calculate the piston area with the use of the following equation:
Table 93
Calculation of the Piston Area for the Cylinder
Piston Area = 3.1416 × Cylinder Diameter2 ÷ 4
Calculating the Piston Area for the Cylinder

Hydraulic Cylinder Diameter = 34.80 mm (1.370 inch)
Example 3.1416 × 34.80 mm2 ÷ 4 = 951.15 mm2
Example 3.1416 × (1.370 inch)2 ÷ 4 = (1.474 inch)2
Calculate the pressure. Use the calculation for the area of the piston and applied force with the following equation:
Table 94
Calculation of Pressure
Pressure = Applied Force ÷ Cylinder's Piston Area
Example of a Calculation for Pressure

Load = 10000 N (2250.0 lb)
Piston Area = 951.15 mm2 (1.474 inch2)

10,000 ÷ 951.06 = 10,515 kPa
(2250) ÷ (1.474) = (1527 psi)
Valve Seat Inserts for 3600, G3600, C280 Engines

The surface of the prechamber seat needs to be resurfaced during a rebuild. Use 187-6273 Repair Tool. Follow the instructions in Tool
Operating Manual, NEHS0790. The maximum amount that can be removed is 0.05 mm (0.002 inch).
If the valve seat inserts are not reusable, the seats need to be removed and replaced with new seats. To replace the seat with an insert that is a
standard size, the dimension of the bore for a standard insert must meet the specification of 97.000 ± 0.025 mm (3.8189 ± 0.0001 inch)
throughout the entire depth of the bore. Heavy fuel cylinder heads have a bore diameter for the insert of 108.5 ± 0.025 mm (4.27 ± 0.0010 inch).
If the bore of the seat is within specifications, then a new insert can be pressed in using the procedure that involves freezing the insert. The
insert should be ground to the final specification for the valve seat angle. The valve and the face of the insert should be checked.
Removal
To remove the valve seat insert on some earlier cylinder heads, a relief must be ground at the bottom of the insert. The relief should be ground q631tm
in the area where the insert contacts the head casting. This relief will allow the 9U-5099 Seat Puller to engage the bottom edge of
Caterpillar: the insert.Yellow
Confidential
It is not recommended to remove or replace the water-cooled prechamber insert for the G3600. If the insert appears to be damaged in any way, a
remanufactured head must be used.

Grinding the relief in the head casting for the 9U-5099 Seat Puller Group
(17) 6V-4198 Grinder group
(18) 6V-4802 Grinding wheel

(C) 4.0 mm (0.16 inch)
(D) 83.0 mm (3.27 inch)
Remove the valve seat insert from the head casting.
Note: Heat may be required to remove the water-cooled exhaust valve seat insert. Applying a weld bead to the inside diameter of the insert will
also assist with removal.

(19) Seat puller group
Valve Seat Insert Grinding
Note: For G3600 valve seat inserts that are not prefinished, the seat face angle should be 20.5° ± 0.15°. Prefinished valve seat inserts do not
require grinding.. Protrusion of the valve must be within the specification if the valve seats are ground.

Valve seat insert dimensions. Refer to Table 95 for the reuse specifications.
Table 95
Valve Seat Insert specifications for 3600, G3600, C280 Engines
7C-2423 (Intake)
Dimensions
7W-9779 (Exhaust)
24.00 ± 0.15 mm
Valve Seat Bore Depth (L)
(0.945 ± 0.006 inch)
97.195 ± 0.015 mm
Valve Seat Insert Diameter (M)
(3.8266 ± 0.0006 inch)
97.000 ± 0.025 mm
Valve Seat Insert Bore Diameter (M)
(3.8189 ± 0.0010 inch)
Valve Seat Insert Angle (N) 30.25 ± 0.50 degrees
0.50 mm
Maximum Valve Recess (P) (0.020 inch) above to 2.00 mm
(0.079 inch) below
0.15 mm
Maximum Valve Seat Runout
(0.006 inch)
63.5 cm
Maximum Vacuum
(25.0 inch) Hg
12.7 cm
Maximum Allowable Vacuum Loss in 10 seconds
(5.0 inch) Hg
q631tm
Illustration 265 g06175869 Caterpillar: Confidential Yellow
Valve Seat Specification Guide. Refer to Table 96 for the reuse specifications.
Table 96
Valve Seat Insert Specifications (Heavy Fuel) for 3600, G3600, C280 Engines
Dimensions 4P-3078 Exhaust
108.700 ± 0.015 mm
Valve Seat Insert Diameter (R)
(4.2795 ± 0.0006 inch)
93.650 ± 0.015 mm
Valve Seat Insert Diameter (S)
(3.6870 ± 0.0006 inch)
108.500 ± 0.025 mm
Valve Seat Insert Bore Diameter (R)
(4.2717 ± 0.0010 inch)
93.500 ± 0.025 mm
Valve Seat Insert Bore Diameter (S)
(3.6811 ± 0.0010 inch)
40.00 ± 0.25 mm
Valve Seat Insert Bore Depth (T)
(1.575 ± 0.010 inch)
20.00 ± 0.15 mm
Valve Seat Insert Bore Depth (U)
(0.787 ± 0.006 inch)
Valve Seat Insert Angle (V) 30.25 ± 0.25 degrees
7.00 mm
Maximum Valve Recess (W)
(0.276 inch)
Maximum Valve Seat Runout N/A
Minimum Vacuum N/A
Maximum Allowable Vacuum Loss in 10 seconds N/A
Grinding Equipment
The valve seat grinder in this guideline has an eccentric motion with a feed control for the micrometer. Eccentric grinding is the simultaneous
application of two rotary motions to a grinding wheel. Eccentric grinding results in point contact grinding. Material will be removed from the
high spots and hard spots of the valve seat first. No side pressure or spring action will be exerted on the pilot. Side pressure and spring action
can cause inaccuracies in the valve seat.
Grinding Wheels
It is important to dress the grinding wheel during grinding operation. Material from the valve seat insert becomes embedded in the wheel,
resulting in excessive grinding times and incorrect ground seats.

Minimum dressing limits for reusing the wheel
(E) Minimum Thickness
A small amount of the wheel will be removed each time the wheel is dressed. Replace the wheel when the thickness reaches 8.0 mm (0.31 inch).
Vibration of the wheel can occur if a wheel becomes too thin. This results in an unacceptable seat face and this also prevents the full 360
degrees of contact to the face. This also prevents the vacuum seal that is recommended.

(22) Valve seat grinder
(23) Grinding wheel
(24) Diamond dresser
Before doing any finish grinding, it is necessary to match the valve seat grinder to the specified valve seat angle. This can be completed by
using the 147-2285 Valve Gauge.
Grinding Procedure q631tm


(25) Pilot
(26) Pilot Wrench
1. Select the correct diameter of pilot. Install the pilot wrench onto the correct pilot. Insert the pilot into the valve guide bore.
Note: The pilot should have a snug fit in the bore of the valve guide. This will eliminate movement of the pilot during the grinding
operation. Movement of the pilot can cause damage to the cylinder head, the pilot, and the grinder.
2. Remove the pilot wrench.

Dial gauge (27) installed on pilot
3. If the valve seat requires grinding, proceed with the following steps:
a. Mark the area or areas requiring the most stock removal.
b. Mark the seat face every 30 degrees with a black felt pen. This will provide a visual inspection of the progress for seat face
grinding.
c. When the black markings have disappeared, the surface of the valve seat face has been ground 360 degrees.
d. Remove dial indicator from the pilot.

Positioning the grinder on the pilot
4. Carefully install the seat grinder onto the shaft of the pilot.
Note: Do not drop the grinder on the valve seat. Damage to the wheel of the grinder and the head may occur.
5. While the seat grinder is resting on the surface of the valve seat, loosen the setscrew. This will allow the center positioning rod to touch
the top of the pilot shaft. Tighten the setscrew to provide a positive stop for the micrometer adjustment.

Adjust height of the wheel with the micrometer adjustment.
(29) Micrometer adjustment
6. Use the micrometer adjustment to back the wheel away from the valve seat face. Rotate the wheel by hand 360 degrees. Adjust the wheel
upward until the wheel no longer touches the seat face at any point.

Install the magnetic base and the post to support the grinder.
(30) Post
(31) Magnetic base
7. Install the 8S-2329 Magnetic Base and the 8S-2327 Post. This allows the operator to leave the grinder and to perform other operations.
Place a piece of rubber tubing on the upright shaft. This will eliminate vibration during the grinding operation. Lift the seat grinder up
approximately 12.0 mm (0.47 inch) and turn on the grinder. Lower the grinder until the positioning rod engages the top of the pilot shaft.
At this point, the grinding wheel should not be touching the seat face. q631tm
8. Adjust the micrometer by one click at a time until the wheel barely touches the seat face. This can be felt by placing a finger against the
handle on the side of the grinder. You can feel when the wheel has finished grinding. Allow the grinder to spark out for 2 to 3 minutes.
Then raise the grinder to check the seat face for 360 degrees of contact. Observe the black marks on the seat face. Repeat the adjustment.
Spark out the grinder until the marks have been removed from the entire surface. Remove the grinder carefully when the job is finished.
9. Install the dial gauge. Sweep the face of the seat 360 degrees to check the Total Indicator Runout (TIR). TIR should be 0.10 mm
(0.004 inch). Repeat the grinding and checking procedures until the TIR is within the specification. Always allow the wheel to spark out
before a measurement is taken.
10. After the recommended TIR is reached, install the pilot wrench onto the pilot. Use a slight twisting motion to unseat the pilot. Remove
the pilot from the bore.
11. Apply a light coat of Prussian Blue on the 147-1642 Gauge seat face. Install the gauge into the valve guide bore until the gauge is
approximately 25.4 mm (1.00 inch) from the valve seat face. Allow the gauge to drop onto the valve seat face. Use one finger to slightly
push down on the head of the gauge and rotate the gauge 15 to 30 degrees. Remove the gauge and check the contact pattern on the valve
seat face. If the seat is machined correctly, the line contact will be at the top edge of the insert with contact for the full 360 degrees. If the
line contact is not at the top edge, it is necessary to adjust the angle by adjusting the dresser, redressing the wheel, and regrinding the seat.
12. Apply a light coat of Prussian Blue on the 147-1642 Gauge seat face. Install the gauge into the valve guide bore until the gauge is
approximately 25.4 mm (1.00 inch) from the valve seat face. Allow the gauge to drop onto the valve seat face. Use one finger to slightly
push down on the head of the gauge and rotate the gauge 15 to 30 degrees. Remove the gauge and check the contact pattern on the valve
seat face. If the seat is machined correctly, the line contact will be at the bottom edge of the seat insert.

(F) Projection of the valve
13. Install the valve in the original position. Measure the projection of the valve in relation to the surface of the cylinder head. A depth
micrometer or a straight edge with a thickness gauge can be used to measure the projection of the valve. The maximum valve recess is
2.00 mm (0.079 inch). The maximum projection of the valve is 0.50 mm (0.020 inch).
14. Check the projection of the valve to make sure that the valve is within the specification. It may be necessary to grind the valve again to
obtain this dimension. If the valve cannot be ground anymore, the valve will have to be replaced.
Installation
Inspect the counterbores of valve seat inserts before installing the inserts. The counterbores should be clean. The counterbores should be free of
raised burrs that are caused by the insert removal tool. The bottom of the counterbore must be flat in order for the insert to make 360 degrees of
contact.

(A) Heavy fuel insert
(B) Standard Insert
Caterpillar currently has two types of inserts. The water-cooled insert is used in exhaust ports in heavy fuel applications. The water-cooled
inserts require a special counterbore in the cylinder head. The standard insert is used in inlet ports for all applications and in exhaust ports of
distillate fuel applications. q631tm
Installing Water-Cooled Inserts
Note: This method is also applicable to a standard insert.
1. Make sure that the valve seat insert is at room temperature prior to installation. Do not freeze water-cooled inserts.
2. Before installing the water-cooled insert, apply 6V-1541 Quick Cure Primer to the outside diameter of the insert. Then apply 9S-3265
Retaining Compound over the primer.
3. Install the insert using the water-cooled insert seat driver and the hydraulic press. Press the insert to the bottom of the counterbore in the
cylinder head casting.

Installing a water-cooled insert
(20) Insert driver
Installing Standard Inserts
Note: The standard valve seat insert can be installed by using either method.
1. Lower the temperature of the standard insert to −60° C (−76.0° F).
2. Put clean engine oil on the outside diameter and the radius at the bottom of the insert.
3. Install the standard insert using 8T-2674 Standard Insert Driver and a hammer. Install the insert to the bottom of the counterbore in the
cylinder head casting.
Note: Excessive pounding may cause the insert to bounce off the bottom of the counterbore. Use a 0.038 mm (0.0015 inch) feeler gauge to
make sure that the insert is in contact with the bottom of the counterbore.

Installing a standard insert
(21) Standard insert seat driver
Reconditioning Factors
Determining the projection of the valve and the recession of the valve through a measurement is no guarantee that the valves and valve seats
have been correctly reconditioned. The following criteria will help to determine the reusability of both valves and valve seats.
1. The wide valve seats do not cause problems with valves. The outer diameter of the finished seat insert can be larger than the diameter of
the valve head. This should not cause any problems.
2. While the width of the seat will vary with the engine model, the width of the finished insert must be at least 1.0 mm (0.04 inch) for good
valve life. There is no need for an upper limit on the width of the seat.
3. Grind the finished surface of the valve seat after the valve seat inserts have been installed into the head. Grinding the seat insert correctly
is essential to valve life. This process is not necessary on recent 3500 Heads with premachined inserts.
4. Contacting the valve seat insert to the sealing face of the valve head at the middle of the sealing face of the valve was an acceptable
practice for rebuilding cylinder heads. With the introduction of the 3500 Engine, the traditional sealing area moved closer to the edge of
the valve head. Premachined seat inserts and precision valve guides moved the sealing area to 0.51 to 1.02 mm (0.020 to 0.040 inch) from
the outer dimension of the valve head. Do not grind the sealing faces of the inserts if new premachined valve seat inserts are installed
during the rebuild of a head. The components do not need to be machined after installation due to the precise manufacturing process.
5. If the seat face cannot be ground without grinding into the head, replace the insert. Do not grind the head under any circumstance.
6. Never use a valve with less than the specified minimum thickness of lip.
7. Heads that have been resurfaced may require the bores of the inserts to be machined to a deeper dimension. This will ensure the correct
location of the insert in relation to the head.
8. Valve seat inserts should not extend above the surface of the head. Recessing the inserts 0.25 mm (0.010 inch) below the surface is a good
habit. q631tm
9. Lapping valves and lapping seat inserts is not recommended or necessary if the correct angles of the valve seat are maintained during the
process of resurfacing the valves and valve seats.
Reconditioning Factors for D330, D330C, D333B, D333, D333B, D333C, D334, D336, 1673,
1674, and 1676
114.30 mm (4.5 inch), 120.65 mm (4.75 inch), 137.16 mm (5.4 inch) Bore Engines
On all overhead cam engines, backlash for the cam drive gear is the critical factor for cylinder head reconditioning. The backlash must be larger
than 0.038 mm (0.00150 inch).
Reconditioning Factors for D330C, D333C, D334, 1673, and 1674

146.05 mm (5.75 inch), 158.75 mm (6.25 inch) Bore Engines
Correct valve projection dimensions will help prevent piston contact.
Note: If the centerline of the crankshaft bore has been raised from its original location, it affects cylinder height dimensions. This is similar to
removing material from the head surface. There must still be a minimum of 0.030 mm (0.00118 inch) of backlash in the cam drive gear after the
head is assembled. If the top of the cylinder block has been machined and the crankshaft centerline also is raised, it will be almost impossible to
maintain the correct minimum backlash.
Reconditioning Factors for C15 through C32

After machining the head, the Exhaust valve seats must be machined in place to achieve the proper projection of the valve. Use a standard
replacement valve seat only if the bore for the Exhaust valve is undamaged. If the bore for the Exhaust valve is damaged, the bore must be
rebored and an oversized valve seat must be used.
NOTICE
Some valve seats cannot be machined. Specialized manufacturing
processes were used on these parts. Machining these parts will
significantly decrease the life of the engine.
Some inlet seats cannot be machined under any circumstance. Caterpillar uses specialized manufacturing techniques on inlet valve seats of some
engine models. If the thickness of the head has been machined beyond factory specifications, do not machine these inlet seats. These inlet seats
must be replaced with seats that can be machined.

Finding the pin location by using a probe
To keep the valve guide and the valve seat concentric, use a dial indicator and a tapered pilot pin to find the center line of the valve guide.
Oversized seats are available if the head has been damaged. If an oversized insert has already been installed, second oversized inserts are
available for certain models. If an oversized seat will be used, use either a probe or a dial indicator to keep the valve guide and the valve seat
concentric.
1. If an oversize valve seat will be used, locate the center of the valve guide with a gauge pin.
2. Find the center of the tapered pilot pin as close as possible to the valve guide.
3. Use a dial indicator to find the center of the tapered pilot pin.
4. Machine the bore for the valve seat in the location that is concentric with the valve guide.
The tapered pins are supplied with the grinder for the valve seat. If the tapered pilot pins need to be purchased, contact the supplier for your
valve seat grinder.
Reconditioning Factors for 1100, 3100, and 3200 Engines

On 1100, 3100, 3200 direct injection engines, head thickness is measured from the combustion surface to the top of the nozzle seat throughq631tm
the
nozzle bore. On (precombustion chamber) 3204 Engines, the head thickness is measured from the top of the valve spring seat to the combustion
surface.
Reconditioning Factors for G3600 Engines

There are specific factors for reconditioning the G3600 cylinder head. The surface on which the gasket for the prechamber seats must be
thoroughly inspected. This area is prone to leaks without proper reconditioning.
Water-Cooled Prechamber Insert for G3600

The insert is located at the center of the cylinder head to help cool the prechamber assembly. This insert should not be removed or
repaired. A remanufactured cylinder head is required if the insert is damaged in any way.
The angle of the face on intake and exhaust valve seats is 20°.
The exhaust valves are not water cooled.
A new design of the cylinder head contains prefinished intake and exhaust valve seat inserts. The premachined inserts do not require a
final grinding operation if the inserts are used with the correct cylinder head.
Valve Recession and Projection

After the cylinder head has been reconditioned, the cylinder head must be measured for the recession of the valves or the projection of the valve.
The recession and projection of the valve is measured from the combustion area of the cylinder head to the valve head when the valve is closed.
Increased valve recession or decreased valve projection can be caused by wear of the valve face or wear of the sealing surface on the insert.
Note: The minimum dimension means that the valve is recessed into the cylinder head. The maximum dimension means that the valve is
projecting from the cylinder head.

(B) Valve Recession
A positive value for the recession of a valve represents a recessed valve as it relates to the cylinder head surface. The valve head is below the
surface.

(C) Projection of the Valve
Tools

The recession of the valve is being measured with a depth micrometer.

6V-7926 Indicator Group
(29) 3P-1565 Collet Clamp
(30) 8S-3158 Indicator
(31) 5P-4156 Indicator Base
The valve recession can be measured by using any of the following tools.
1. 6V-7926 Indicator Group
a. 8S-3158 Indicator
b. 3P-1565 Collet Clamp
c. 5P-4165 Indicator Base

q631tm
2. 6V-2012 Micrometer Depth Gauge Group Caterpillar: Confidential Yellow
3. 8H-8581 Feeler Gauge and a 386-3364 Straight Edge.
Measurement Procedure
Take these measurements after the valves are installed in the head.
1. Before starting this procedure, set the gauge to zero.
a. Place the indicator on a flat surface.
b. Move the dial face, and align the hand of the gauge to the zero mark.
c. Tighten the lock on the dial face.
2. Take the measurements and record the measurements on all valves.
a. For a recessed valve, set the gauge on surface of the head and over the center of the valve. Record the measurement.
b. For a projected valve, set the gauge on top of the valve. The tip of the indicator should be on the surface of the head. Record the
measurement.
3. If the measurements do not meet the required specifications, refer to the section "Correcting the Excessive Projection of the Valves".
The excessive projection of valves can cause the head of the valve to contact the piston during normal engine operation.
Correcting the Excessive Projection of the Valves
There are two ways to correct a valve that exceeds the maximum dimension of projection.
1. Material can be ground from the sealing angle of the seat insert and the valve face.
2. The seat insert can be recessed farther into the counterbore.
Note: For example, if 0.25 mm (.010 inch) has been removed from the bottom of the head, the counterbore can be recessed 0.25 mm
(.010 inch).
Note: If a valve exceeds the maximum recessed dimension, the valve position is too deep. To correct this condition, either a new valve must be
installed. Replacing the valve seat may also be necessary.
The minimum and the maximum dimensions for intake and exhaust valves are listed in Table 111. The table lists the dimensions for the
following minimum permissible recession or projection, maximum recession or projection, and maximum recession for reusability. The
maximum recession for reusability applies when the cylinder head has been machined or the valve has been ground. For the minimum recession
for reusability, refer to the minimum permissible recession. A valve that projects too far can contact the piston during normal engine operation.
A valve that is recessed too much will not adjust. A valve that is recessed too much will create the following conditions:
Binding in the guide
Abnormal wear
Poor engine performance
NOTICE
The prefinished inserts should not be ground to correct the valve
projection. Excessive valve projection indicates that the insert is not
seated or the material was not cleaned from the bottom of the
counterbore.
Table 97
Valve Projection for D & G Models Cylinder Heads
Exhaust Intake
Valve Part Maximum Minimum Valve Part Maximum Minimum
Number Projection Projection Number Projection Projection
2.390 mm 1.080 mm 2.390 mm 1.080 mm q631tm

4F-0212 6H-3026
(0.09409 inch) (0.04252 inch) (0.09409 inch) Caterpillar:
(0.04252 inch) Yellow
Confidential
1M-0982 2.810 mm 1.380 mm 9H-4811 2.990 mm 1.560 mm
2M-7727 (0.11063 inch) (0.05433 inch) (0.11772 inch) (0.06142 inch)
9M-4163 3.50 mm 2.30 mm 3.49 mm 2.04 mm

7M-7358
8N-3724 (0.13780 inch) (0.09055 inch) (0.13740 inch) (0.08031 inch)
5S-6449
6N-9916
3.50 mm 2.30 mm 2W-2621 3.49 mm 2.04 mm
8N-0875
(0.13780 inch) (0.09055 inch) 247-6892 (0.13740 inch) (0.08031 inch)
100-7861
148-7455
3.07 mm 1.840 mm 3.07 mm 1.840 mm
1S-2903 2S-8143
3.00 mm 1.670 mm 3.00 mm 1.670 mm
8N-3737 7H-6891
8H-1994 3.47 mm 2.24 mm 1W-1818 4.94 mm 3.60 mm

1W-1819 (0.13661 inch) (0.08819 inch) 8H-1993 (0.19449 inch) (0.14173 inch)
3.48 mm 1.910 mm 1N-4885 3.48 mm 1.910 mm
7E-7830
(0.13701 inch) (0.07520 inch) 1N-4886 (0.13701 inch) (0.07520 inch)
1W-1822
2W-3211 4.470 mm 3.00 mm 4.470 mm 3.18 mm
7M-7817
8N-3723 (0.17598 inch) (0.11811 inch) (0.17598 inch) (0.12520 inch)
5S-5323
Table 98
Recession of the Cylinder Head Valve for C7 through C32 Engines
Intake/Exhaust Part Number Minimum Valve Recess Maximum Valve Recess
145-7390
Intake 157-7129
1.09 mm 1.71 mm
252-7801
(0.043 inch) (0.067 inch)
147-8211
Exhaust
157-7130
241-8382
1.19 mm 1.81 mm
262-2957
(0.047 inch) (0.0713 inch)
490-1726
Intake
163-2442
1.18 mm 1.8 mm
187-4123
(0.046 inch) (0.071 inch)
490-1719
241-8383
255-8676 1.19 mm 1.81 mm
490-1723 (0.047 inch) (0.0713 inch)
Exhaust 490-1728
188-3122 2.79 mm 3.41 mm
490-1721 (0.110 inch) (0.134 inch)
157-0672 2.19 mm 2.81 mm

Intake
192-9213 (0.086 inch) (0.111 inch)
157-0671 1.09 mm 1.71 mm
Exhaust
133-7029 (0.043 inch) (0.067 inch)
252-7802 2.59 mm 3.21 mm

Intake
224-3028 (0.102 inch) (0.126 inch)
224-3030 1.34 mm 1.76 mm q631tm

Exhaust Caterpillar: Confidential Yellow
248-1467 (0.053 inch) (0.069 inch)
Intake 236-5605 2.17 mm 2.83 mm

490-7198 (0.085 inch) (0.111 inch)
153-7023
490-7199
289-9231
464-4668 1.19 mm 1.81 mm
Exhaust
153-7024 (0.047 inch) (0.071 inch)
490-7200
Table 99
Recession of the Cylinder Head Valve for C175 Engines
Valve Max Recession

2.268 ± 0.35 mm
Intake
(0.0893 ± 0.0138 inch)
2.268 ± 0.33 mm
Exhaust
(0.0893 ± 0.0130 inch)

See Table 100 for specifications for the valve.
(H) Width of the valve seat
(J) Valve Margin
(K) Valve Recess
(L) Valve Seat Angle
Table 100
Specifications for 3044, 3046, 3064, 3066 Engines
Sales Model 3044, 3046 3064, 3066
Description Intake Exhaust Intake Exhaust

1.40 ± 0.14 mm 1.40 ± 0.14 mm 1.40 ± 0.20 mm 1.40 ± 0.14 mm
Width of the valve seat (H)
0.40 ± 0.10 mm 0.50 ± 0.10 mm 0.40 ± 0.10 mm 0.50 ± 0.10 mm
Valve Recess (K)
Valve Seat Angle (L) 30° 30° 30° 30°

Width of valve seat (F)
Refer to Table 101 and Table 102 for specifications.
(R) Minimum width of finished seat
Table 101
Specifications for Intake Valves Recession on 3176, and 3196 Engines
Maximum distance from head of valve to Minimum distance from head of valve to
Part Minimum width of
cylinder head face cylinder head face
Number finished seat (F)
closed valve closed valve
7C-5215
7E-9578
124-2692 0.762 mm −3.81 mm −2.10 mm
136-4336 (0.0300 inch) (−0.150 inch)(1) (−0.083 inch)(1)
157-0672
192-9213
(1)
q631tm
Recessed projection of valve
Table 102
Specifications for Exhaust Valves Recession on 3176, and 3196 Engines
Maximum distance from head of valve to Minimum distance from head of valve to
Part Minimum width of
cylinder head face cylinder head face
Number finished seat (F)
7C-1586
109-5334
124-2693 0.762 mm −2.83 mm −1.10 mm
133-3550 (0.0300 inch) (−0.111 inch)(1) (−0.043 inch)(1)
133-7029
157-0671
(1) Recessed projection of valve
Table 103
Specifications for Intake Valves Recession on 3114, and 3116 Engines
Maximum distance from head of valve to cylinder head Minimum distance from head of valve to cylinder head
Part
face face
Number
−2.05 mm −1.13 mm
7W-8064
(−0.08071 inch) (−0.04449 inch)
Table 104
Specifications for Exhaust Valves Recession on 3114, and 3116 Engines
Maximum distance from head of valve to cylinder head Minimum distance from head of valve to cylinder head
Part
face face
Number
2.22 mm −1.51 mm
7W-2699
(0.08740 inch) (−0.05945 inch)
Table 105
Valve Projection for 3200 Cylinder Heads
Exhaust Intake
Valve Part No. Maximum Projection Minimum Projection Valve Part No. Maximum Projection Minimum Projection
1.31 mm 0.20 mm 1.6 mm -0.05 mm
9N-0185 9N-0180
(0.05157 inch) (0.00787 inch) (0.06299 inch) (-0.00197 inch)
-1.50 mm -2.83 mm -0.87 mm -2.40 mm

9N-5125 9L-7682
(-0.05906 inch) (-0.11142 inch) (-0.03425 inch) (-0.09449 inch)
Table 106
Model Configuration Intake Exhaust Head Assembly
2.43 mm 2.43 mm
PCNA 8N-1454
(0.096 inch) (0.096 inch)
2.69 mm 2.69 mm
DI 7C-4004
(0.106 inch) (0.106 inch)
3304
2.69 mm 2.69 mm
PCT 8N-1454
(0.106 inch) (0.106 inch)
2.69 mm 2.69 mm
SI 7W-8304
(0.106 inch) (0.106 inch)
3306 2.69 mm 2.69 mm
DI 7C-4006 q631tm
G3306 (0.106 inch) (0.106 inch)
SI 2.69 mm 2.69 mm 7W-8306
(0.106 inch) (0.106 inch)
2.43 mm 2.43 mm
PCNA 8N-1446
(0.096 inch) (0.096 inch)
2.02 mm 2.11 mm
DIT 7C-4006
(0.079 inch) (0.083 inch)
Table 107
Exhaust Intake
Valve Part No. Maximum Projection2 Minimum Projection2 Valve Part No. Maximum Projection2 Minimum Projection2
2.98 mm 1.44 mm 3.51 mm 1.97 mm
5S-6449 5S-6452
−0.81 mm −2.10 mm −0.03 mm −1.31 mm

6N-9916 (−0.032 inch) (−0.083 inch) 2W-2620 (−0.001 inch) (−0.052 inch)
R R R R
2W-2621
8N-0875 3.26 mm 1.97 mm 3.51 mm 2.22 mm
2W-2877 (0.128 inch) (0.078 inch) (0.138 inch) (0.087 inch)
247-6892
2.98 mm 1.69 mm 3.51 mm 2.22 mm

7W-7491 7W-7490
−0.81 mm −2.10 mm −0.03 mm −1.31 mm
6N-9916 (−0.032 inch) (−0.083 inch) 2W-2620 (−0.001 inch) (−0.052 inch)
R R R R
2.98 mm 1.69 mm 3.51 mm 2.22 mm

7W-7491 7W-7490
2.98 mm 1.44 mm 3.51 mm 1.97 mm
5S-6449 5S-6452
−1.38 mm −2.67 mm −0.68 mm −1.96 mm

148-7455 (−0.054 inch) (−0.105 inch) 100-7860 (−0.027 inch) (−0.077 inch)
R R R R
Table 108
Recession of the Cylinder Head Valve for 3400
Diesel Engines
Maximum Valve Recess Minimum Valve Recess Maximum Valve Recess Minimum Valve Recess
Part Number of the Valve
New New Reusability Reusability
164-2543 1.11 mm −0.10 mm 2.14 mm −0.10 mm

Inlet (0.044 inch) (−0.004 inch) (0.084 inch) (−0.004 inch)
122-0322 1.11 mm −0.10 mm 1.98 mm −0.10 mm
115-2368 1.11 mm −0.10 mm 1.98 mm −0.10 mm

164-2542 1.04 mm −0.22 mm 2.41 mm −0.22 mm
Exhaust (0.041 inch) (−0.009 inch) (0.095 inch) (−0.009 inch)
122-0321 1.04 mm −0.22 mm 2.41 mm −0.22 mm

115-2367 1.04 mm −0.22 mm 2.41 mm −0.22 mm
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Recession of the Cylinder Head Valve for 3400
Gas Engines
Maximum Valve Recess Minimum Valve Recess Maximum Valve Recess Minimum Valve Recess
Part Number of the Valve
212-0932 0.82 mm 0.10 mm 1.37 mm 0.10 mm

Inlet (0.032 inch) (0.004 inch) (0.054 inch) (0.004 inch)
122-0322 1.11 mm −0.10 mm 1.98 mm −0.10 mm
122-7353 1.06 mm −0.16 mm 1.86 mm −0.16 mm

4W-5374 1.11 mm −0.25 mm 1.91 mm −0.25 mm
311-7555 −0.09 mm −0.79 mm
−0.79 mm (−0.031 inch) 0.90 mm (0.035 inch)
Exhaust (−0.004 inch) (−0.031 inch)
122-0321 1.04 mm −0.22 mm 2.41 mm −0.22 mm
212-0933 1.01 mm 0.31 mm 1.56 mm 0.31 mm
Exhaust (0.040 inch) (0.012 inch) (0.061 inch) (0.012 inch)
101-8314 1.64 mm −0.16 mm
1.06 mm (0.042 inch) −0.16 mm (−0.006 inch)
Exhaust (0.065 inch) (−0.006 inch)
100-4639 0.06 mm −1.16 mm 1.05 mm −1.16 mm
2W-2443 1.30 mm 0.07 mm 2.10 mm 0.07 mm

Table 110
Recession of the Cylinder Head Valve for 3406E, 3456 Engines
Maximum Valve Minimum Valve Maximum Valve Minimum Valve
Part Number of the Valve Recess Recess Recess Recess
153-7023 2.83 mm 2.17 mm 3.88 mm 2.17 mm
153-7023
3.38 mm 2.72 mm 4.43 mm 2.72 mm
Inlet with shortened valve seat
insert
153-7024 1.81 mm 1.19 mm 3.12 mm 1.19 mm
152-8380 2.86 mm 1.86 mm 3.64 mm 1.86 mm
152-7585 3.55 mm 2.75 mm 4.86 mm 2.75 mm

Table 111
Recession of the Cylinder Head Valve for 3500 Engines
Intake Valves Exhaust Valves
Part Number
of Maximum Maximum
Cylinder Minimum Maximum Recession Minimum Maximum Recession
Head Recession Recession for Recession Recession for
Reusability Reusability
7E-5861 0.080 mm 0.920 mm 2.010 mm 0.100 mm 0.900 mm 2.590 mmq631tm
7E-8760 (0.0031 inch) (0.0362 inch) (0.0791 inch) (0.0039 inch) (0.0354 inch)
Caterpillar: (0.1020 inch)Yellow
Confidential
131-0410
131-0411
172-0834
172-0836
295-2047
101-1175
131-0423
145-3215 2.008 mm 2.920 mm 4.010 mm 2.100 mm 2.900 mm 4.590 mm
154-1612 (0.0819 inch) (0.1150 inch) (0.1579 inch) (0.0827 inch) (0.1142 inch) (0.1807 inch)
161-2508
290-1351
4P-6571
7C-3471
122-5961
128-1141
144-6409
+0.155 mm -0.654 mm 2.031 mm +0.155 mm -0.654 mm 2.031 mm
153-8397
(+0.00610 inch) (-0.0258 inch) (0.0800 inch) (+0.00610 inch) (-0.0258 inch) (0.0800 inch)
184-5496
206-1554
206-1555
206-1560
206-1563
269-0040 +0.115 mm -0.685 mm 1.860 mm +0.115 mm -0.685 mm 1.860 mm

315-2630 (+0.0045 inch) (-0.0270 inch) (0.0732 inch) (+0.0045 inch) (-0.0270 inch) (0.0732 inch)
Vacuum Test for Valves

Testing the valves by vacuum in a cylinder head is used to identify a poor seal between the valve and the valve seat. This procedure should be
performed after a cylinder head has been reconditioned. The cylinder head must be assembled before the vacuum test.
Note: The procedure for the vacuum test should only be used to identify leakage between the valve and the valve seat. This test procedure
should only be used if the leakage is out of the acceptable specification.
An unavoidable minor amount of leakage between the valve and the valve seat is permissible. It is impractical to use the vacuum test to identify
minor leaks between the valve and the valve seat. The following specifications and equipment can be used to identify the gross leak. Any
combination of valve and valve seat that does not maintain 40 cm Hg (16.0 inch Mercury) or more is considered to be a gross leak.
Equipment and Tooling

9U-5383 Vacuum Tester
The 9U-5383 Vacuum Tester consists of a hand-held vacuum pump and connecting parts. Most Caterpillar engines will work with the set of
eight adapters that can be fabricated from the drawing of the fabricated tool FT-1741 Vacuum Tester. For a complete list of all parts and
fabricated dimensions, request a drawing of the FT-1741 Vacuum Tester.
Test Procedure
The 9U-5383 Vacuum Tester is suitable for use when a vacuum test of 46 cm Hg (18 inch Mercury) or less is required. For complete
information on the vacuum tester, refer to Special Instruction, SEHS9498, "Using the 9U-5383 Vacuum Tester".
The gauge has detected a leak if a drop in vacuum occurs. An adjustment screw is provided on the top of the tool to vary the sensitivity of the
gauge. To check valve seats for leaks, the adjustment screw must be set for maximum sensitivity. When a constant vacuum of 46 cm Hg
(18 inch Mercury) is applied for 15 seconds, the vacuum should not drop below 41 cm Hg (16 inch Mercury). A gauge reading of less than
41 cm Hg (16 inch Mercury) can have enough magnitude to affect valve life.
1. Plug in the inlet for the vacuum, and pull out the trigger for the air supply.
2. Back out the adjustment screw until maximum vacuum is attained. The maximum reading should be less than 38 cm Hg
(15 inch Mercury).
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3. Turn the adjustment screw inward until a drop in vacuum of 2.5 cm Hg (1 inch Mercury) occurs. The minimum adjusted set point is now
35.5 cm Hg (14.0 inch Mercury).
4. Tighten the nylon jam nut to prevent any air leaks from giving a false leakage reading.
5. After adjusting the screw for sensitivity has been adjusted, attach the correct adapter to the vacuum tester.
6. Place the adapter over the valve to be tested.
7. Hold the trigger for the air supply in the open position for a minimum of 15 seconds.
Note: Make sure that the adapter is in full contact with the combustion area of the cylinder head.
8. The seal between the valve and the valve seat is not acceptable if the gauge indicates a reading less than the Test Specification in Table
112. The Maximum Capability of the Gun determines the Test Specification that should be applied.
9. Apply slight pressure with a press the top of the valve stem and test again.
10. If the gauge still indicates a low reading, the valve must be removed and the sealing surfaces must be inspected. Grinding or lapping the
valve seat or the valve face again might also be necessary.
Table 112
Specifications for Testing by Vacuum
Maximum
Adjusted Test
Capability of
Set Point Specification
the Gun
53 cm Hg (21 inch Mercury) 51 cm Hg (20 inch Mercury) 42 cm Hg (16.5 inch Mercury)

52 cm Hg (20.5 inch Mercury) 49.5cm Hg (19.5 inch Mercury) 41 cm Hg (16 inch Mercury)
51 cm Hg (20 inch Mercury) 48 cm Hg (19 inch Mercury) 41 cm Hg (16 inch Mercury)
49.5 cm Hg (19.5 inch Mercury) 47 cm Hg (18.5 inch Mercury) 39 cm Hg (15.5 inch Mercury)
47 cm Hg (18.5 inch Mercury) 44.5 cm Hg (17.5 inch Mercury) 37 cm Hg (14.5 inch Mercury)
46 cm Hg (18 inch Mercury) 43 cm Hg (17 inch Mercury) 35.5 cm Hg (14.0 inch Mercury)
44.5 cm Hg (17.5 inch Mercury) 42 cm Hg (16.5 inch Mercury) 35.5 cm Hg (14.0 inch Mercury)
42 cm Hg (16.5 inch Mercury) 39 cm Hg (15.5 inch Mercury) 32 cm Hg (12.5 inch Mercury)

41 cm Hg (16 inch Mercury) 38 cm Hg (15 inch Mercury) 32 cm Hg (12.5 inch Mercury)
39.4 cm Hg (15.5 inch Mercury) 37 cm Hg (14.5 inch Mercury) 30.5 cm Hg (12.0 inch Mercury)
38 cm Hg (15 inch Mercury) 35.5 cm Hg (14.0 inch Mercury) 29 cm Hg (11.5 inch Mercury)
Probable Causes of Leaks

Incorrect texture of valve face or contact area of the valve seat
The valve seat is improperly installed or the valve seat is not seated in the head (Incorrect Total Indicator Readout).
Damaged valve face
Debris between valve face and valve seat
Damaged contact area of the valve seat
Bent valve
Cracked valve face or valve seat
q631tm
Reusing Cylinder Head Bolts for 3500 Caterpillar: Confidential Yellow
3500 cylinder head bolts may be reused for a maximum of five standard rebuilds. The cylinder head bolts must be inspected for cracks and wear
during each rebuild. For the inspection procedure, refer to Reuse And Salvage Guideline, SEBF8301, "Inspection and Reuse of Critical
Fasteners Used in All Engines".
Reworking Cylinder Head Bolt Holes for 3500

This procedure machines a radius around the edges of the surface for combustion of the three bolt holes for the cylinder head. Cracks can
originate from these three holes as a result of high operating temperatures. Machining a radius around these holes can greatly reduce the
potential for cracks. These cracks could lead to failure of the cylinder head.
This procedure can only be used on heads that do not have cracks. If cracks are present, the cracks will appear on the combustion side of the
head. The cracks will radiate outward from the bolt hole. If cracks are found anywhere in the cylinder head, the cylinder head must not be used
again.
Hole Location for the Cylinder Head Bolt

The location of the three bolt holes that should be reworked.
(10) Top position
(11) Middle position
(12) Lower position
Specifications

Profile of the holes to be reworked
(13) Radius
Machine a 1.9 ± .3 mm (0.07 ± 0.01 inch) radius at location (13).

The enlarged section of radius at location (14) Refer to Illustration 293.
(C) 23.25 mm (0.915 inch) maximum
(D) 0.5 mm (0.02 inch)
(E) 1.9 ± 0.3 mm (0.07 ± 0.01 inch) radius
(14) Remove the area of the crosshatch by using a 4C-8624 mandrel.
Rework Procedure
1. Put 4C-3845 Grinding Wheel in the chuck of the air drill or in the chuck of the electric drill.
2. Operate the drill at full rated speed and lightly insert the mounted point into the bolt hole.
3. Apply a steady pressure that is equal to two times the weight of the drill for one and one half to two seconds. This should create a 0.5 mm
(0.02 inch) chamfer on the edge of the bolt hole.
4. Ensure that the chamfered diameter is not larger than 23.25 mm (0.915 inch) (C).
5. Repeat this procedure for each bolt hole.
Note: The bolt hole at the middle position may already have a chamfered diameter on some cylinder heads. This diameter may be larger
than 23.25 mm (0.915 inch) (C). Do not add an extra chamfer to this hole. Polish the hole with the reconditioning tool that is described in
the following procedure:
6. After all the holes have been reworked to have smooth corners put 4C-8629 Mandrel and 4C-8624 Mandrel in the drill.
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7. Operate the drill in a clockwise direction at full rated speed. Insert the drill halfway into the bolt hole. Apply light pressure to the
chamfered edge of the hole. Steadily increase the pressure to flex the arms of the drill into the hole.
8. Insert the drill and remove the drill from each hole several times. Continue to perform this procedure until the edges of the chamfers are
removed, and a smooth radius and a polished radius is formed.
9. Clean the cylinder head thoroughly before putting the cylinder head back into service.
Inspection and Repair Procedure for the Saddle of the Rocker Arm Shaft in C15, C16,
C18, 3406E, C27, C32, and 3456 Engines
Inspection Procedure
1. Fix the indicator and the surface probe to the 90° holding block. Find the area that is unworn between the saddle of the rocker shaft and
the rocker arm shaft. Remove the burrs by lightly filing the edges at the top of the saddle on the rocker shaft. Set the indicator on the
milled face of the head over the saddle of the rocker shaft. Locate the lowest point of the saddle by moving the block back and forth.
Ensure that the block is perpendicular to the axis of the camshaft. Zero the indicator. Move the indicator back and forth to recheck the
zero. If necessary, reset the indicator to zero.
2. When the indicator is reset move the indicator to the worn portion of the saddle of the rocker shaft at the end of the rocker arm shaft.
Again, move the block back and forth to make sure that the block is perpendicular to the axis of the camshaft. Record the lowest negative
number as the maximum amount of wear. The lowest number will be the lowest point.
3. Repeat the procedure to measure the worn portion of the saddle at both edges of the support for the center of the rocker arm shaft, and the
worn portion of the saddle at the opposite end of the rocker arm shaft.

Move the gauge back and forth to zero the gauge and measure the wear step.

Places to measure

Callout (B) shows a maximum of 3 mm (0.118 inch) is allowed around the bolt hole.
Note: If the rocker arm shaft saddle has a wear step of 0.10160 mm (0.004 inch) or more the head must be repaired by skim cutting the saddle
area.

While using a coordinate measuring machine measurement, (C) should be a minimum of 86.66 mm (3.41180 inch).
For proper measurement of (C) use surface (D) and not surface (E)
Storage Procedures
Proper protection of the cylinder head from corrosion is important. Corrosion will start in as little as one hour after the cylinder head has been
cleaned.
When the cylinder head will not be inspected for one hour or less the cylinder head should be coated with a rust or corrosion inhibitor or coated
with clean engine oil. The cylinder head should be individually wrapped to prevent contamination, and the cylinder head should be stored in a
protected area to avoid damage. See Illustration 299.
When the cylinder head will not be inspected in two days or more the cylinder head should be coated with a rust or corrosion inhibitor or coated
with clean engine oil and the cylinder head should be placed in a container which is clean and structurally solid. The container should be
covered or wrapped in plastic to prevent damage and contamination to the cylinder head. See Illustration 300.
Refer to SEHS9031Special Instruction, "Storage Procedure for Caterpillar Products" for more information.
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Example of protection for a component that is stored for a shorter term

Example of protection for a component that is stored for a longer period
Copyright 1993 - 2018 Caterpillar Inc. Mon Sep 03 2018 08:49:17 GMT+0300 (Arabian Standard Time)
All Rights Reserved.
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Private Network For SIS Licensees.
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Reuse And Salvage Guidelines

37 Added Exhaust Stud and Bolt Removal Tools.

Information contained in this document is considered Caterpillar: Confidential Yellow.

Canceled Part Numbers and Replaced Part Numbers

Important Safety Information

Improper operation, lubrication, maintenance or repair of this product

Do not operate or perform any lubrication, maintenance or repair on

This safety alert symbol means:

Your safety is involved.

Service Letters and Technical Information Bulletins

, SEHS9031 Special Instructions, "Storage Procedure for Caterpillar Products"

Tooling and Equipment

To avoid component damage, follow the recommended procedure using

1D-4720 Nut 5/8-11 NC

1P-1855 Retaining Ring Pliers

1S-0258 Hammer (soft tip)

1U-6685 Valve Guide and Seat Tool Group

1U-8869 Dial Indicator

1U-9169 Valve Guide Driver

3P-1565 Collet Clamp

4C-3845 Grinding Wheel

4C-4462 Repair Tool Group

4C-5590 Anti-Seize Compound

4C-4707 Dial Gauge

4C-4710 Pilot Wrench

4C-4804 Penetrant Oil

4C-9734 Valve Guide Gauge

5P-1729 Valve Guide Bushing

5P-3413 Pipe Sealant

5P-4156 Indicator Base

5P-6518 Dial indicator Fixture

5P-8400 Lifting Bracket

5P-9718 Holder 178.0 mm (7.00 inch)

5S-1330 Valve Spring Compressor

6V-0087 Valve Stem Gauge Group

6V-2012 Micrometer Depth Gauge

6V-4197 Grinder Base

6V-4801 Dressing Stone

6V-4802 Grinding Wheel

6V-7047 Hydraulic Cylinder

6V-7058 Plug Gauge

6V-7068 Valve Guide Gauge

6V-7098 Valve Guide Gauge

6V-9050 Stud Removal Group

7B-0337 Surface Plate

8S-3158 Feeler Gauge

8S-3158 Indicator Gauge

8T-2674 Valve Seat Driver

8T-2781 Valve Guide Support Pedestal

8T-5096 Dial Indicator Group

9U-5096 Bridge Assembly

9U-6399 Valve Guide Installation Gauge

9U-6860 Injector Sleeve Tool

9U-6897 Valve Seat Driver

9U-7244 End Brush

147-1642 Angle Gauge

151-0968 Cordless Drill

163-3951 Blast Media

187-6273 Repair Tool

222-3074 Wheel Grinder

263-7184 Crack Detection Kit