Reuse And Salvage Guidelines

Specifications for Cylinder Head Assembly 3176, 3176B, 3196, C10 and C12 Engines

Media Number -SEBF8229-06 Publication Date -17/02/2004 Date Updated -17/02/2004

   
SEBF82290001

Specifications for Cylinder Head Assembly 3176, 3176B, 3196,

C10 and C12 Engines
SMCS - 1000; 1100

ILLAR®

INE FOR
BLE PARTS
LVAGE OPERATIONS
ions for Cylinder Head
3176, 3176B, 3196, C10 and

 
Summary of Revisions

Page Description

1 Revised Title to include all models

ALL Revised format.

Introduction

This guideline enables dealers and their customers to benefit from cost reductions made possible
through an established parts reusability and salvage program. Every effort has been made to provide
the most current and relevant information known to Caterpillar Inc. Since the Company makes
ongoing changes and improvements to its products, this guideline must be used with the latest
technical information available from Caterpillar to ensure such changes and improvements are
incorporated where applicable.

For questions or additional information concerning this guideline, contact Caterpillar Service
Support Division, Dealer Support (309) 675-5434

Summary

The specifications in this guideline can be used with SEBF8162 to inspect and measure cylinder
head assemblies.

If a cylinder head assembly meets the specifications in this guideline and other applicable
guidelines, it can be expected to give normal performance until the next overhaul when used in the
same application.

A used and/or reconditioned cylinder head assembly must be checked for leaks, cracks, and flatness.
The individual components must meet the recommended specifications listed in this guideline

References

The tooling and equipment used to measure the reusability and salvage of the components listed in
this guideline are identified in the following reference material.

References

Media Title
Number

GMG02562 Using the 5P-3536 Dial Bore

Gauge Group to Check Cylinder
Valve Guides

SEBF2000 Metal Spray Guide

 SEBF8002 Valves, Valve Springs, Valve
Rotators and Locks

SEBF8034 Valves and Valve Spring

Specifications

SEBF8162 Procedures to Measure and

Salvage Cylinder Head
Assemblies and Related
Components

SEBF8262 Reusability of Cylinder Heads

with Bottom Deck Damage on
3176 Engines

SEHS9031 Storage Procedures for

Caterpillar Products

SEHS9246 Using the 4C-4054 Sleeve

Replacement Tool

SENR3908 Service Manual, Specification

Module, 3176 (2YG1-UP) Diesel
Engine

SENR3914 Service Manual, Disassembly

and Assembly Module, 3176
(2YG1-UP) Diesel Engine

SENR5107 Service Manual, Specification

Module, 3176 (7LG1-UP) Diesel
Engine

SENR5109 Service Manual, Disassembly

and Assembly Module, 3176
(7LG1-UP) Diesel Engine

SENR5560 Service Manual, Specification

Module, 3176B Diesel Engine

SENR5567 Service Manual, Disassembly

and Assembly Module, 3176B
Diesel Engine

 
Equipment and Tooling

Caterpillar Dealer Support Division, Remanufacturing and Service Support, will provide, upon
request, information on suppliers of salvage equipment to recondition valves and valve seat inserts,
grind castings, cleaning, etc., not listed in this guideline.

Required Tools

Part Number Part Description

1U-9654 Valve Guide and Seat Insert Tool

Group [for the “pointed” valve
guides (3176B)]

1U-6685 Valve Guide and Seat Insert Tool

Group [for the “flat” valve guides
(3176)]

4C-4054 Sleeve Replacement Tool Group

4C-4462 Sleeve Tool Group

4C-8717 Sleeve Reaming Tool Group

5P-3536 Valve Guide Gauge Group

6V-2012 Depth Gauge Group or a 150 mm

(6.0 in) dial caliper

6V-7059 Anvil Micrometer used with a

6V-2034 Adapter 5P-6518
Fixture Group or a 0 to 152.4 mm
(0 to 6.0 in) dial caliper.

6V-7068 Valve Guide Gauge

Overall Size

General Dimensions

Engine Model 3176

 Cylinder Head Part 104-3844
No.

Length 972 mm (38.3 in)

Width 317 mm (12.5 in)

Height 105 mm (41 in)

Former Part No. 104-2963

Torque Specifications

View Image

Illustration 1

Cylinder block torque specifications.

(1) M16 Bolts.
(2) M8 Bolts.
(3) Plug.

1.      Put 2P-2506 Thread Lubricant on the threads of the bolts (1) and (2) and tighten as follows:

a.      Tighten M16 bolts in numerical sequence (1 through 26) shown in Illustration 1 to a
torque of 150 ± 15 N·m (110 ± 11 lb ft).
 b.      Tighten M16 bolts in numerical sequence (1 through 26) to a torque of 275 ± 15 N·m
(200 ±11 lb ft).

c.      Retighten M16 bolts in numerical sequence (1 through 26) to a torque of 275 ± 15 N·m
(200 ± 11 lb ft).

d.      Tighten M8 bolts in the numerical sequence (27 through 33) to a torque of 25 ± 7 N·m
(18 ± 5 lb ft).

2.      Install all cup plugs (3) to a depth of 1.25 ± 0.25 mm (0.049 ± 0.010 in). This depth is measured
from the head face to the top edge of the plug.

General Procedures

Use the following guidelines when inspecting and reconditioning a cylinder head.

         Clean the cylinder head. Refer to SEBF8162.

         Remove the gasket material. Refer to SEBF8162.

         Check the cylinder head thickness.

         Check the flatness of the combustion surface.

         Check for cracks or leaks in the combustion surface. Refer to SEBF8162.

         Check the combustion surface for damage and/or erosion. Refer to SEBF8162.

         Inspect the valves, valve seats, valve springs, valve guides, and valve rotators for damage. Refer
to SEBF8162.

         Recondition the components requiring salvage, and replace the parts not meeting reuse
guidelines.

         After assembly, vacuum test the valves for correct sealing. Refer to SEBF8162.

         Protect head against storage or shipping damage. Refer to SEBF8162.

Cylinder Head Thickness

Check the thickness of the cylinder head.

A maximum stock removal of 0.25 mm (0.010 in) is permissible when resurfacing the head.

 
If the head surface requires reconditioning, the surface must be built up utilizing metal spray so the
head thickness will be maintained at original specifications. Refer to SEBF8162 for additional
information.

View Ima

ge

Illustration 2

Cylinder head cross section.

(8) Sleeve.
(A) New cylinder head thickness 105.00 ± 0.15 mm (4.134 ± 0.006 in). Minimum reusable head
thickness 104.35 mm (4.108 in).

Chart A.
Cylinder Head Thickness and Flatness
Specifications

Surface
Thickness Minimum Surface Flatness
(New Thickness Flatness (“Use
Head) (A) (New) again”)

105.00 ± 104.35 0.15 0.30 (.012)

0.15 (4.108) (.006) overall;
(4.134 ± . overall; 0.05 (.002)
006) 0.05 for any
(.002) 150 (6.0)
for any span
150 (6.0)
span
Note: All dimensions are mm (in).

For replacement of a unit injector sleeve (8), refer to Special Instruction SEHS9246, “Using the 4C-
4054 Sleeve Replacement Tool Group”.

Flatness of Combustion Surface

Maintain the original specification for cylinder head flatness during reconditioning. Refer to Chart
A for the recommended flatness.

Cylinder Head Injector Sleeves

A brass sleeve is used between each unit injector and the cylinder head casting. This sleeve is used
to seat the injector and seal it into the casting. These sleeves normally will not need to be replaced
unless they become loose or damaged.

Inspect the inside surface of the sleeves for cracks, pitting, erosion, and other visual damage.
Sleeves should be replaced during general cylinder head overhaul at high hours.

NOTICE

When reaming the injector seat area, be very

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 between the sleeve cone and the injector
tip that may result in fuel leakage into the
cylinder, or combustion pressure leakage into
the fuel.

The injector seat area at the bottom of the sleeve may be worn due to normal operation. If the seat
appears worn or distorted slightly, it can be refinished with a 4C-8717 Sleeve Reaming Tool Group.
Use reamer assembly for machining the injector seat to ensure a good seal when the sleeve is
assembled. If machining does not clean up the damaged seat, the sleeve must be replaced. Follow
the procedures and tooling list given in Special Instruction SEHS9246, “Using The 4C-4054 Sleeve
Replacement Tool Group,” for replacement of any sleeves.

Valve Guide Inspection

Valve guides must be measured for installed height and inside bore diameter.

Use the 5P-3536 Dial Bore Gauge Group to measure the inside diameter of the valve guide. The
correct probe, 9.525 mm (0.3750 in), has a usable range of 0.38 mm (0.015 in). Special Instruction
GMG02562, “Using the 5P-3536 Dial Bore Gauge Group to Check Valve Guides”, gives complete
instructions on the use of the 5P-3536 Dial Bore Gauge Group.

A 6V-7068 Valve Guide Gauge is also available for a quick, “Go/No-Go” evaluation. If the “No-
Go” end fits in farther than 19.0 mm (0.75 in), the guide is over the “Use Again Maximum”
diameter and must be replaced.

Chart B.
Valve Guide Dimensions

Description Dimension

Bore in valve guides with 9.484 ± 0.026

guides (0.3734 ±
installed in head (new). 0.0010)

“Use Again Maximum” bore 9.538

in valve (0.3755)
guides with guides installed in
head.

Installed valve guide height 28.00 ± 0.05

(B). (1.102 ± 0.002)

Note: All dimensions are mm (in).

Refer to the appropriate Service Manual for your engine application, for removal and installation of
valve guides depending upon the type of valve guide (“flat” or “pointed”).

Note: Do not reuse a valve guide if the measurement of the bore is greater than 9.538 mm (0.3755
in). Do not use a valve and guide combination that has a difference of 0.10 mm (0.004 in) or larger.
 View
Image

Illustration 3

Height to top of “pointed” valve guide (3176B).

(B) Installed valve guide height.

View I
mage

Illustration 4

Height to top of “flat” valve guide (3176).

(B) Installed valve guide height.

Valve Guide Installation

For removal and installation of valve guides, use the 1U-9654 Valve Guide and Seat Insert Tool
Group for the “pointed” valve guides (3176B) and the 1U-6685 Valve Guide and Seat Insert Tool
Group for the “flat” valve guides (3176). Refer to the appropriate Service Manual for your engine
application for removal and installation instructions of valve guides.

View Imag e

Illustration 5

Valve guides being removed from the cylinder head using the appropriate tooling (9).

Valve Seat Inspection

The valve seat inserts should be replaced when the valve seat width or valve head-to-cylinder head
face cannot be machined to the correct specification. Refer to the Service Manual Module
SENR5109, “Disassembly and Assembly 3176 Diesel Truck Engine” and SENR5567 “3176B
Diesel Truck Engine Disassembly and Assembly” for removal and installation instructions of valve
seat inserts.

After the inserts are installed, grind the seat face of the insert to be sure it is flat, has the correct
angle, and is in alignment with the bore in the valve guide. For specifications, see Chart D,
Specifications For Valves and Valve Projection.

Valve Springs

Refer to SEBF8162 for methods and procedures to measure valve spring straightness and perform a
load test.

View Image

Illustration 6

Valve spring dimensions. Refer to Chart C.

 
 

Chart C.
Valve Spring Specifications

Description 7W-7082 7W-7083 214-0586 224-4441

(Outer) (Inner) (Outer) (Inner)

Approximate free 59.89 61.39 62.7 (2.47) 64.1 (2.5)

length (C) (2.358) (2.417)
 Approximate 34.00 23.24 34 23.24
outside diameter (1.339) (0.915) (1.34) (0.91)
(D)

Assembled or test 51.69 49.19 52.95 50.47

length (E) (2.035) (1.937) (2.08) (2)

Load at assembled 240 ± 24 N 136 ± 14 N 320 ± 31 N 160 ± 13 N

length (new) (54 ± 5 lb) (31 ± 3 lb) (71.9 ± 7 lb) (36 ± 2.9 lb)

Minimum load at 216 N 122 N 289 N 147N

assembled length (48.6 lb) (27.4 lb) (65 lb) (33.05 lb)

Length at valve 37.72 35.22 37.4 34.92

open position (F) (1.485) (1.387) (1.47) (1.37)

Load at valve open 650 ± 32 N 292 ± 15 N 860 ± 34 N 385 ± 18 N

position (new) 146 ± 7 lb) (66 ± 3 lb) (193.3 ± 7.6 (86.6 ± 4.05
lb) lb)

Minimum load at 618 N 277 N 826 N 367 N

valve open position (139.0 lb) (63.3 lb) (185.7 lb) (82.5 lb)

Spring must be 2.09 2.14 2.19 2.24

square (0.082) (0.084) (0.086) (0.088)
with ends within
(G)

Note: Unless stated otherwise, all dimensions are mm (in).

Valves

Note: Intake and exhaust valve stems are to be coated with 8T-2998 Break-in Lubricant prior to
installation in the cylinder head.

When regrinding a valve tip, a maximum limit of 0.20 mm (0.008 in) is allowed. The overall length
of the valve must also be within the limits specified.

When regrinding a valve seat, the minimum finished seat width (M) is 0.762 mm (0.030 in), while
the maximum limit is the intersection of the ground face with the insert bore.

 
 View Im

age

Illustration 7

Nomenclature. (14) Intake valve. (15) Exhaust valve. (16) Spring. (17) Top of valve guides. (H)
Valve stem diameter.

View Image

Illustration 8

Dimensions for cylinder head valves. Refer to Chart D for specifications.

 View Im

age

Illustration 9

Dimension (M) for valve seat width. Refer to Chart D for specifications.

Chart D.
Specifications For Valves and Valve Projection

Description 3176 3176B 3176 3176B

Intake (14) Exhaust (15)

Valve part number 7E-9578, 7C- 157-0671 7C-1586, 109- 157-0672

5215 5334

Minimum finished seat width (M) 0.762 (0.030)

New valve head diameter (K) 45.00 ± 0.13 (1.772 ± 0.005) 42.00 ± 0.13 (1.654 ± 0.005)

Valve face angle (L) 29.25 ± 0.25º 44.25 ± 0.25º

New valve lip thickness (N) 3.5 ± 0.2 (0.14 ± 0.008)

New valve stem diameter (H) 9.441 ± 0.008 (.3717 ± 0.0003)

“Use Again Minimum” valve stem 9.408 (0.3704)

diameter

Overall length (J) 174.00 ± 0.45 (6.850 ± 0.018)

Maximum distance valve head to -3.81 -2.83

cylinder head face (closed valve) (-0.15) R (-0.111) R

Minimum distance valve head to -2.10 -1.10

 cylinder head face (closed valve) (-0.083) R (-0.043) R
         

Note: All dimensions are mm (in)

Valve Projection - R = Recessed valve projection.

Valve Seat

Chart E.
Valve Seat Insert Dimensions

3176 & 3176B 3176 3176B

Description Intake Exhaust

Valve seat part number 4N-5893 7W-5554 133-7030

Valve seat insert inner diameter (P) 39.1 ± 0.5 36.00 ± 0.13
(1.54 ± 0.02) (1.417 ± 0.005)

Valve seat bore diameter (O) 46.025 ± 0.013 43.320 ± 0.025

(1.812 ± 0.0005) (1.7055 ± 0.0009)

Valve seat insert sealing angle (Q) 30 ± 1º 45 ± 1º 45 ± 1º

Valve seat bore depth (N) 15.00 ± 0.10 14.10 ± 0.10

(.591 ± 0.004) (0.555 ± 0.004)

Note: All dimensions are mm (in).

View Image
Illustration 10

Valve seat insert dimensions. Refer to Chart E.

Vacuum Test for Valves

Refer to SEBF8162 for methods and procedures to vacuum test valves.

Shipment and Storage of Reconditioned Cylinder Heads

Refer to SEBF8162 for methods and procedures for shipment and storage of reconditioned cylinder
heads.

 
 
 
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