Specifications and Repair Procedures For C4.4 Cylinder Blocks

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Reuse And Salvage Guidelines

Specifications and Repair Procedures for C4.4 Cylinder Blocks{0599, 1201}
Media Number -SEBF9312-00 Publication Date -06/08/2012 Date Updated -06/08/2012
i04947410
Specifications and Repair Procedures for C4.4 Cylinder

Blocks{0599, 1201}
SMCS - 0599; 1201
Engine: C4.4 Engines
Introduction
© 2012 Caterpillar All Rights Reserved. This guideline is for the use of Caterpillar Dealers only.
Unauthorized use of this document or the proprietary processes therein without permission may be
violation of intellectual property law.
This Reuse and Salvage Guideline contains the necessary information in order 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 in order 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 questions or additional information concerning this guideline, submit a form for feedback in
the Service Information System. In order to address an urgent issue, please use the following
resources in order to communicate your request to Caterpillar Repair Process Engineering:
• Caterpillar Dealer Technical Communicator
• Dealer Solution Network
• Caterpillar Technical Representative
• Knowledge Network
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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.
General Information
Illustration 1 g03133817
Bottom view of cylinder block
Locations of the center of the cylinder bores are measured from the center of the dowel location on
the mounting surface for the oil pan.
(A) 420.27 ± 0.2 mm (16.546 ± 0.008 inch)
(B) 302.795 ± 0.2 mm (11.921 ± 0.008 inch)
(C) 178.97 ± 0.02 mm (7.046 ± 0.008 inch)
(D) 61.495 ± 0.2 mm (2.421 ± 0.008 inch)
Table 1
Item Description Dimension
Average ≤ 15 micrometers (6 microinch)

Top Deck Surface Finish
(E) Max ≤ 20 micrometers (8 microinch)
Flatness of Top Deck 0.05-0.025 / 100 x 100
New Bore 105.000 mm (4.1338 inch) to

105.025 mm (4.1348 inch)
(F)
Oversize Bore 105.500 mm (4.1535 inch) to

105.525 mm (4.1545 inch)
Top Deck Height of NEW Block 352.27 mm (13.869 inch) to

352.37 mm (13.873 inch)
(G)
Top Deck Height After Skim Cut 352.024 mm (13.8592 inch) to

352.124 mm (13.8631 inch)
Cylinders can be bored 0.5 mm (0.02 inch) oversized. The cylinder bore diameter of the stock
head gasket is still acceptable to be used with the oversized bore diameter. The standard head
gasket can still be used as long as the top deck height is still within the NEW specifications listed
in Table 1.
If the top deck surface of the cylinder block must be milled, the top deck must be milled prior to
boring the cylinders. The top deck height is measured from the centerline of the main bearing bore
to the top deck surface of the engine block. When 0.25 mm (0.010 inch) is removed from the top
deck surface, a new thicker head gasket must be used.
Table 2
Head Gaskets
Cylinder Bore / Piston
Part Number Top Deck Height
Size
Standard Bore and Piston

310-8520 and
Standard Dimensions
(Stock Gasket) 0.5 mm (0.020 inch)
Oversized Piston
369-3707 Standard Bore and Piston Used when

( and
0.25 mm (0.010 inch) is removed from
0.25 mm (0.010 inch) 0.5 mm (0.020 inch)
the top deck surface.
Thicker Gasket) Oversized Piston
396-4482
0.5 mm (0.020 inch) Oversized Piston Kit
When 0.25 mm (0.010 inch) is removed from the top deck surface, the projection of the piston
should then be 0.46 mm (0.018 inch) to 0.61 mm (0.024 inch). The thicker head gasket must then
be used.
The projection of the piston must be measured after any of the following components are replaced
or if the top deck surface is machined.
• Crankshaft
• Cylinder head
• Connecting rod
• Bearing for the piston pin
Refer to ""Measuring Piston Projection" " in this document for the correct procedure.
Note: The top of the piston should NEVER be machined to obtain the correct projection of the
piston.
Cleaning the Cylinder Block

The following table lists the maximum permitted contaminant levels for the finished machined
cylinder block.
Table 3
Contaminant Levels
Max Contaminant Max Particulate

Feature Weight (mg), Cpk = Size in any
1.33 Direction (µm)
All of the main bearing cap surfaces including

the butt faces, bolt holes and the main bearing
20 -
cap bolt holes after machining has been
completed.
Oil passage holes 40 500
All cylinder bores 4 -

All lubricated surfaces of the cylinder block.
This includes the pushrod apertures, chamber 86 -
for the lifters, bearing caps, and bolts.
Main bearing cap butt faces, bolt holes and
60 -
bolts. All surfaces after machining.
Water jacket 100 -
Filtration level - 30 µm
Measuring Piston Projection

If the original piston is used again, the original connecting rod should also be used in the original
cylinder that the piston and rod assembly was removed from.
Table 4
Tooling
Tool Part Number Description
H 1P-2403 Dial Indicator

I 1P-2402 Gauge Body
If the projection of the piston is not within the allowed range, a different length of connecting rod
may be used to achieve the correct projection of the piston. Different lengths of connecting rods
are available to help maintain the correct projection of the piston. The length of the connecting rod
is determined by offset machining the inner bore of the piston pin bearing. This will move the
position of the piston, making the overall length of the connecting rod shorter or longer. The
projection of the piston will determine what length of connecting rod should be used.
The other option of correcting piston projection is to purchase a new piston pin bushing. The new
bushing can have the center of the inside finished diameter offset machined to change the
projection of the piston. Refer to Reuse and Salvage Guideline, SEBF9242, "Specifications and
Salvage Procedures for Connecting Rods in C4.4 and C6.6 Engines"
Use the following procedure to measure the projection of the piston. Use the top surface of the
cylinder block to zero Tooling (H) .
1. Rotate the crankcase until the piston is just before top dead center.
2. Position Tooling (H) and Tooling (I) and slowly rotate the crankshaft to determine when the
piston is at the highest position. Record this dimension and determine if the piston
projection is within specifications.
Cylinder Bore Chamfers

The top of all cylinder bores must be chamfered. Refer to the following illustration and table for
the correct dimensions.
Table 5
Chamfer Dimensions
(J) 15°-17°
(K)
0.35 ± 0.15 mm (0.014 ± 0.006 inch)
Surface Finish of Cylinder Bores

The surface finish of the cylinder bores must meet the following requirements. The angle of the
crosshatch is required to be 30°-35° off the horizontal axis of the bore.
Table 6
Parameter Limit
Rpk
0.0002 mm (0.00001 inch)
Rk 0.0002 mm (0.00001 inch)-

0.0006 mm (0.00002 inch)
Rvk 0.0008 mm (0.00003 inch)-

0.0018 mm (0.00007 inch)
Mr1 <10%
Mr2 65-85%
• Rpk, Rk, Mr1, and Mr2 are defined by BS EN ISO 13565-2:1998
• Rz value may be expected to be less than 5 microns
• Rz as defined by BS EN ISO 4287:2000
• The crosshatch of the honing finish is required with a horizontal (tangential to axis of the
cylinder bore) inclusive circumferential angle of 30 degrees to 35 degrees when measured
midway along the bore.
• The surface finish shall be cleanly cut and free from excessive tearing, folding, smearing,
and foiling. Surface to be uniformly cut in both directions throughout the length of the
cylinder bore.
Camshaft Bushing
When replacing the camshaft bushing, the bushing should not protrude past the face of the engine
block. The bushing should be installed to a depth of 0.2 mm (0.008 inch). The oil hole (L) in the
bushing should be aligned with the oil supply hole in the engine block. The bushing should be
installed dry without the use of any lubricant. Be sure not to damage the block during the removal
of the old bushing.
Copyright 1993 - 2012 Caterpillar Inc. Mon Aug 13 00:01:04 UTC+0200 2012
All Rights Reserved.
Private Network For SIS Licensees.

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Media Search - SEBF9312 - Specifications and Repair Procedures for C4.4 Cylinder...

Product: NO EQUIPMENT SELECTED

Reuse And Salvage Guidelines

Specifications and Repair Procedures for C4.4 Cylinder

Engine: C4.4 Engines

• Caterpillar Dealer Technical Communicator

• Dealer Solution Network

• Caterpillar Technical Representative

Canceled Part Numbers and Replaced Part Numbers

Bottom view of cylinder block

(A) 420.27 ± 0.2 mm (16.546 ± 0.008 inch)

(B) 302.795 ± 0.2 mm (11.921 ± 0.008 inch)

(C) 178.97 ± 0.02 mm (7.046 ± 0.008 inch)

(D) 61.495 ± 0.2 mm (2.421 ± 0.008 inch)

Average ≤ 15 micrometers (6 microinch)

New Bore 105.000 mm (4.1338 inch) to

Oversize Bore 105.500 mm (4.1535 inch) to

Top Deck Height of NEW Block 352.27 mm (13.869 inch) to

Top Deck Height After Skim Cut 352.024 mm (13.8592 inch) to

Standard Bore and Piston

369-3707 Standard Bore and Piston Used when

• Bearing for the piston pin

Cleaning the Cylinder Block

Max Contaminant Max Particulate

All of the main bearing cap surfaces including

Oil passage holes 40 500

All cylinder bores 4 -

Measuring Piston Projection

H 1P-2403 Dial Indicator

Cylinder Bore Chamfers

Surface Finish of Cylinder Bores

Rk 0.0002 mm (0.00001 inch)-

Rvk 0.0008 mm (0.00003 inch)-

• Rpk, Rk, Mr1, and Mr2 are defined by BS EN ISO 13565-2:1998

• Rz value may be expected to be less than 5 microns

• Rz as defined by BS EN ISO 4287:2000

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