Guideline For Reusable Parts And Salvage Operations

Specifications for Cylinder Head Assemblies 3114, 3116, 3126, and C7 Engines

Media Number -SEBF8218-04 Publication Date -27/09/2004 Date Updated -27/09/2004

   
SEBF82180001

Specifications for Cylinder Head Assemblies 3114, 3116, 3126,

and C7 Engines
SMCS - 1000; 1100

RPILLAR®

ELINE FOR
ABLE PARTS
ALVAGE OPERATIONS
ations for Cylinder Head Assemblies 3114, 3116, 3126, and C7
 
    

Summary of Revisions

Page Description

1 Revised title to include all models.

ALL Revised guideline in new 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) 494-1934.

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.

The information in this guideline updates and replaces Guideline for Reusable Parts, SEBR8184.

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.

Reference Material

Form No. Title

GMG02562 Using the 5P-3536 Dial Bore

Gauge Group to Check Cylinder
Valve Guides

SEBD1967 Service Magazine, May 15, 1989

SEBD9147 Engine News, May, 1989; "New

Valve Stem Seal Used On Inlet
Valves And Added To Exhaust
Valves"
 SEBF2000 Metal Spray Guide

SEBF8002 Valves, Valve Springs, Valve

Rotators and Locks

SEBF8034 Valves and Valve Spring

Specifications

SEBF8076 Specifications To Salvage Cylinder

Blocks and Cylinder Head Contact
Surfaces

SEBF8162 Procedures to Measure and

Salvage Cylinder Head Assemblies
and Related Components

SEBF8167 Reconditioning Procedures 3114

and 3116 Engines

SEHS9031 Storage Procedures for Caterpillar

Products

SEHS9120 Using the 4C-4462 Sleeve

Replacement Tool

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.

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.

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

         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.

Torque Specifications

View Image

Illustration 1

Cylinder block torque specifications.

(1) M20 Bolts

(2) M10 Bolts
(3) Plug

For all early model engines, use the following Torque Specifications:

1.      Put 5P-2506 Thread Lubricant on the threads of the bolts (1) and (2) and tighten them as
follows:

a.      Tighten large bolts (1) in number sequence shown in Illustration 1 to a torque of 150 ±
15 N·m (110 ± 11 lb ft).
 b.      Tighten large bolts (1) in the number sequence shown to a torque of 435 ± 20 N·m (320
± 15 lb ft).

c.      Retorque large bolts (1) in the number sequence shown to a torque of 435 ± 20 N·m (320
± 15 lb ft).

d.      Tighten small bolts (2) in the number sequence shown to a torque of 55 ± 7 N·m (41 ± 5
lb ft).

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

Use 6V-1541 Quick Cure Primer and 9S-3265 Retaining Compound in the plug bores at
assembly.

For HEUI Engines use the following Torque Specifications:

 

1)      Tighten Bolts 1 thru 14 By Numerical Sequence To A Torque Of 300 ± 15 N·m

(220 ± 11 lb ft).

2)      Loosen Bolts 1 Thru 14 To A Torque Of 0 N·m.

3)      Tighten Bolts 1 Thru 14 By Numerical Sequence To 130 ± 15 N·m (95 ± 11 lb ft).

4)      Retighten Bolts 1 Thru 14 By Numerical Sequence To 130 ± 15 N·m (95 ± 11 lb ft).

5)      Turn Bolts 1 Thru 14 By Numerical Sequence An Additional 90 degrees (1/4 Turn).

6)      Tighten Bolts 15 Thru 20 To A Torque Of 55 ± 7 N·m (41 ± 5 lb ft).

Cylinder Head Thickness

Check the thickness of the cylinder head.

Chart A.
Cylinder Head Thickness and Flatness
Specifications

Thickness Minimum Surface Flatness

 (New Head) Thickness
(A)

103.00 ± 0.20 102.55 1 0.15 (0.006)

(4.055 ± (4.037) overall; 0.05
0.008) (Early (0.002) for any
Model) 150.0 (5.91)
span

158.00 ± 0.20 157.55 1 0.15 (0.006)

(6.220 ± (6.202) overall; 0.05
0.008) (HEUI (0.002) for any
Model) 150.0 (5.91)
span

Note: Dimensions are mm (inch).

1
A maximum stock removal of 0.25 mm (0.010 inch) is permissible when resurfacing the head.

Note: Some engine arrangements use "quiescent" (non-swirl) cylinder heads and combustion
system components (pistons, camshafts, and injectors). Other engines use "swirl" cylinder heads
and related components. The cylinder head castings are not the same. Be sure that the correct
cylinder head is used for the particular engine application.

View Image

Illustration 2

Cylinder head cross section

(8) Sleeve
(A) Cylinder head thickness 103.00 ± 0.20 mm (4.055 ± 0.008 inch)

 
For replacement of a unit injector sleeve (8), refer to Special Instruction SEHS9120, "Using the 4C-
4462 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, which 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-5562 Reamer Assembly. Use
reamer assembly for machining the injector seat to insure 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 SEHS9120, "Using The 4C-4462 Sleeve
Replacement Tool," for replacement of any sleeves.
 

Valve Guide

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

Refer to SEBF8162 for commonly available tools to measure valve guides.

If using the 5P-3536 Dial Bore Gauge Group to measure the inside diameter of the valve guide, use
a 7.92 mm (0.312 inch) probe with a usable range of 0.38 mm (0.015 inch). 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.

All the valve guides should be measured at both ends, 19.0 mm (0.75 inch) from the end of the bore.
If the valve guide is counterbored, measurements must be taken in this area. Compare the measured
values with those given in Chart B, Valve Guide Specifications.

Chart B.
Valve Guide Specifications

Description Dimension

Bore in valve guides with 8.054 ± 0.026

guides installed in head (new) (0.317 ±
0.001)

"Use Again Maximum" bore in 8.130 1

valve guides with guides (0.3201)
installed in head.

Installed valve guide height 23.00 ± 0.50

(B). (0.906 ±
0.020)

Note: All dimensions are mm (inch).

Refer to the appropriate Service Manual for your engine application, for removal and installation of
valve guides.
1
Do not reuse a valve guide if the measurement of the bore is greater than 8.130 mm (0.3201 inch).
Do not use a valve and guide combination that has a difference of 0.10 mm (0.004 inch) or larger.

View Image

Illustration 3

Height to top of guide valve

(B) Installed valve guide height

Valve Seals and Retainers

When reconditioning a cylinder head, check the type of valves, seals, retainers, etc. originally
installed. Various versions have different valves, guides, seals, and retainers.

View Image
Illustration 4

Earlier version

View Image

Illustration 5

Later version

Refer to May 15, 1989 Service Magazine, SEBD1967, or May, 1989 Engine News, SEBD9147, for
complete description of the two different versions (Illustrations 4 and 5). In 3116 Truck Engines, the
exhaust valve seal was removed and replaced with a 9Y-7355 Seat (Washer).

Note: Refer to service manual for removal and installation procedures. Also refer to current parts
manual for correct valve seal configuration for a particular application.

View Image
Illustration 6

Typical example of a valve retainer with a polished surface (the affected area is indicated by the
arrow)

Use again

Valves, Seats, and Springs Valve Seat

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 appropriate Service Manual for
your engine application, 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, refer to Chart E,
Valve Specifications.

View Image

Illustration 7
Valve seat insert dimensions. Refer to Chart C for specifications.

Chart C. (Early Model)

Valve Seat Specifications

Description Intake Exhaust

7W-8065 1W-2713

Valve seat 43.29 ± 0.13 37.0 ± 0.13

insert inner (1.704 ± (1.457 ±
diameter (Q) 0.005) 0.005)

Valve seat 49.931 ± 42.931 ±

insert bore 0.013 (1.9658 0.013 (1.6903
diameter (P) ± 0.005) ± 0.005)

Valve seat
30.25 ± 0.5° 45.5 ± 0.5°
insert angle (R)

Valve seat bore 10.00 ± 0.13 10.00 ± 0.13

depth (S) (0.394 ± (0.394 ±
0.005) 0.005)

Outside
diameter of
48.0 (1.89) 40.4 (1.59)
face of seat
insert (T) 1

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

Chart C. (HEUI Model)

Valve Seat Specifications

Description Intake Exhaust

217-5213 147-8218

Valve seat 35.80 ± 0.13 39.50 ± 0.13

insert inner (1.41 ± 0.005) (1.555 ±
diameter (Q) 0.005)

Valve seat 42.000 ± 46.000 ±

 insert bore 0.013 (1.654 0.013 (1.811
diameter (P) ± 0.005) ± 0.005)

Valve seat
30.25 ± 0.25° 45.5 ± 0.25°
insert angle (R)

Valve seat bore 5.50 ± 0.05 6.05 ± 0.05

depth (S) (0.217 ± (0.238 ±
0.002) 0.005)

Outside
diameter of
37.351 (1.47) 40.8 (1.61)
face of seat
insert (T) 1

 
1
Do not reuse or recondition seat inserts if the outside diameter is greater than specified.

Valve Springs

Refer to SEBF8162 for valve spring specifications.

View Image

Illustration 8

Valve spring dimensions. Refer to Chart D.

 
 

Chart D.
Valve Spring Specifications

Description 7C-4273 6I-2307 137-6718 140-6188

Approximate Free 71.0 81.0 92.08 67.5

Length (E) (2.79) (3.19) (3.63) (2.7)

Approximate 28.82 28.59

28.81 28.66
outside diameter (1.13) (1.13)
(1.134) (1.128)
(B)

Assembled or test 65.86 70.8 80.27 60.4

length (D) (2.593) (2.787) (3.16) (2.37)

Load at assembled 217 ± 22 N 612 ± 31 N 662 ± 33 N 302.5 ± 18 N

length (new) (48.8 ± 4.9 (137.7 ± 6.98 (148.8 ± 7.42 (68 ± 4.05 lb)
lb) lb) lb)

Minimum load at 185.5 N 581 N 629 N 284.5 N

assembled length (43.8 lb) (130.6 lb) (141.4 lb) (64 lb)

Length at valve 50.7 59.0 66.27 46.4

open position (C) (1.99) (2.32) (2.61) (1.83)

Load at valve open 858 ± 43 N 1325 ± 66 N 1445 ± 58 898.5 ± 36 N

position (new) (192.9 ± 9.7 (298.1 ± 14.8 (324.8 ± 13 (202 ± 8.1 lb)
lb) lb) lb)

Minimum load at 815 N 1259 N 1387 N 862.5 N

valve open (181.1 lb) (283 lb) (311.8 lb) (193.9 lb)
position

Spring must be 2.48 2.83 3.22 2.36

square with ends (0.098) (0.111) (0.127) (0.093)
within (A)

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

Valves
Refer to SEBF8034 for valve specifications. Refer to Charts E and F for reuse specifications.

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 inch) is allowed. The overall
length of the valve must also be within the limits specified.

View Image

Illustration 9

Nomenclature.

(13) Exhaust valve

(14) Intake valve
(15) Spring
(16) Top of valve guides
(H) Valve stem diameter

View Image
Illustration 10

Dimensions for cylinder head valves. See Chart E for specifications.

Chart E.
Valve Specifications

Description Exhaust (13) Intake (14)

Cylinder Head --- ---

Reference

Seat angle 45 1/2 ± ½° 30 1/4 ± ½°

Seat gauge 37.316 43.491

diameter (new) (1.4691) (1.7122)

Max. OD of seat 39.181 45.965

face of valve seat (1.5426) (1.8096)
insert

Angle to grind 15° 15°

insert to reduce
max. OD

Valve Part 7W-2699 7W-8064/6I-

Number 1589

New valve head 40.00 ± 0.13 47.00 ± 0.13

diameter (K) (1.575 ± (1.850 ±
0.005) 0.005)

Valve face angle 45 ± ¼° 29 1/4 ± ¼°

(L)

New valve lip 2.81 ± 0.20 3.19 ± 0.20

thickness (N) (0.111 ± (0.126 ±
0.008) 0.008)

Minimum valve 1.57 1.956

lip thickness (N) (0.062) (0.077)

Maximum
distance valve -2.22 -2.05
head to cylinder (0.087) (0.081)
head face (closed
valve)

Minimum
distance valve -1.51 -1.13
head to cylinder (0.059) (0.044)
head face (closed
valve)

"Use Again 7.965 7.965

Minimum" Valve (0.3136) (0.3136)
stem diameter
New valve stem 8.000 ± 8.000 ± 0.008
diameter (H) 0.008 (0.3150 ±
[tolerance ± (0.3150 ± 0.0003)
0.0008 (0.0003)] 0.0003)
 
Length of area  
(M) Distance 84.6 (3.33)
from end 84.6 (3.33) 29.4 (1.16)
29.4 (1.16)

Overall Length 177.19 ± 176.81 ± 0.25

(J) 0.25 (6.976 ± (6.961 ±
0.01) 0.01)

Note: All dimensions are mm (inch).

Valve Lip Thickness

Refer to SEBF8034 for the specifications for valve lip thickness.

Minimum Lip Thickness

Intake Exhaust
 1.80 (0.071) 1.51 (0.059)

Exhaust

Part Number 7W-2699

Head Diameter 40.00 (1.575)

Minimum Stem 7.965 (0.3136)

Diameter

Valve Seat Angle 45.5 ± 0.5

Projection Maximum -1.51 (-0.059) R

Projection Minimum -2.85 (-0.112) R

Intake

Part Number 7W-8064/6I-1589

Head Diameter 47.00 (1.850)

Minimum Stem 7.965 (0.3136)

Diameter

Valve Seat Angle 30.25 ± 0.5°

Projection Maximum -1.13 (-0.044) R

Projection Minimum -2.67 (-0.105) R

Head Assembly

Part Number 7W-3278

Note: All dimensions are in mm (inch).

Valve projection—R = Recessed valve projection.

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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