C6.6 Industrial Engine Inlet and Exhaust Valve Springs - Remove and Install Caterpillar


Inlet and Exhaust Valve Springs - Remove and Install
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1.1. Removal Procedure
2.1. Installation Procedure

Removal Procedure

Table 1
Required Tools 
Tool  Part Number  Part Description  Qty 
9U-6193  Valve Spring Compressor 
416-0288 Adapter 
416-0292 Head 
B(1)  9U-6198  Crankshaft Turning Tool 
B(2)  5P-7306  Housing 
5P-7305 Engine Turning Tool 
(1) The Crankshaft Turning Tool is used on the front pulley.
(2) This Tool is used in the aperture for the electric starting motor.

Start By:

  1. Remove the rocker shaft assembly. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod - Remove" for the correct procedure.

Note: Either Tooling (B) can be used. Use the Tooling that is most suitable.


NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.


Note: The following procedure should be adopted to remove the valve springs when the cylinder head is installed to the engine. Refer to Disassembly and Assembly, "Inlet and Exhaust Valves - Remove and Install" for the procedure to remove the valve springs from a cylinder head that has been removed from the engine.

Note: Ensure that the appropriate piston is at top dead center before the valve spring is removed. Failure to ensure that the piston is at top dead center may allow the valve to drop into the cylinder bore.

------ WARNING! ------

Personal injury can result from being struck by parts propelled by a released spring force.

Make sure to wear all necessary protective equipment.

Follow the recommended procedure and use all recommended tooling to release the spring force.



NOTICE

Plug the apertures for the push rods in the cylinder head to prevent the entry of loose parts into the engine.




    Illustration 1g01978813

  1. Follow Step 1.a through Step 1.h to remove the harness assemblies for the electronic unit injectors.

    1. Place a temporary identification mark on connections (1) for harness assembly (3) for electronic unit injectors (2).

    2. Use a deep socket to remove connections (1) from electronic unit injectors (2).

    3. Cut cable straps (4) and remove the remaining sections of the cable straps from the cylinder head.

    4. Disconnect plug (6) from harness assembly (3).

    5. Remove bolt (5) from harness assembly (3).

    6. Withdraw harness assembly (3) from the cylinder head.

    7. Remove O-ring seal (7) from harness assembly (3).

    8. Repeat Step 1.a through Step 1.g to remove the remaining harness assemblies.


    Illustration 2g01978814


    NOTICE

    Ensure that the valve spring is compressed squarely or damage to the valve stem may occur.


  2. Follow Step 2.a through Step 2.d to position the appropriate piston at top dead center.


      Illustration 3g02202973

    1. Install Tooling (A) into position on the cylinder head to compress a valve spring (10) for the appropriate cylinder.

      Note: Ensure that the electronic unit injector label code (12) is not damaged when Tooling (A) is compressed.

    2. Use Tooling (A) to compress valve spring (10) and open the valve slightly.

      Note: Do not compress the spring so that valve spring retainer (9) touches valve stem seal (11).

    3. Use Tooling (B) to rotate the crankshaft carefully, until the piston touches the valve.

      Note: Do not use excessive force to turn the crankshaft. The use of force can result in bent valve stems.

    4. Continue to rotate the crankshaft and gradually release the pressure on Tooling (A) until the piston is at the top dead center position. The valve is now held in a position that allows the valve spring to be safely removed.

    Note: Valve springs must be replaced in pairs for the inlet valve or the exhaust valve of each cylinder. If all valve springs require replacement, the procedure can be carried out on two cylinders at the same time. The procedure can be carried out on the following pairs of cylinders. 1 with 6, 2 with 5 and 3 with 4. Ensure that all the valve springs are installed before changing from one pair of cylinders to another pair of cylinders.


    NOTICE

    Do not turn the crankshaft while the valve springs are removed.


  3. Apply sufficient pressure to Tooling (A) to allow removal of valve keepers (8).

    Note: Do not compress the spring so that valve spring retainer (9) touches valve stem seal (11).

  4. Remove valve keepers (8).

  5. Slowly release pressure on Tooling (A).

  6. Remove valve spring retainer (9) and remove valve spring (10).

  7. If necessary, remove valve stem seals (11).

  8. Repeat Step 3 through Step 7 to remove the remaining valve springs from the appropriate cylinder.

  9. Remove Tooling (A).

Installation Procedure

Table 2
Required Tools 
Tool  Part Number  Part Description  Qty 
9U-6193  Valve Spring Compressor 
416-0288 Adapter 
416-0292 Head 
B(1)  9U-6198  Crankshaft Turning Tool 
B(2)  5P-7306  Housing 
5P-7305 Engine Turning Tool 
247-5377  Torque Wrench 
(1) The Crankshaft Turning Tool is used on the front pulley.
(2) This Tool is used in the aperture for the electric starting motor.

Note: Either Tooling (B) can be used. Use the Tooling that is most suitable.


NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.



NOTICE

Do not turn the crankshaft while the valve springs are removed.



    NOTICE

    Plug the apertures for the push rods in the cylinder head to prevent the entry of loose parts into the engine




    Illustration 4g01978814

  1. Inspect valve springs (10) for damage and for the correct length. Refer to Specifications, "Cylinder Head Valves" for the correct dimensions.

  2. If necessary, install a new valve stem seal (11) onto the valve guide.

    Note: The outer face of the valve guide must be clean and dry before installing the valve stem seal.

  3. Install valve spring (10) onto the cylinder head. Position valve spring retainer (9) on valve spring (10).


    Illustration 5g02202973

    ------ WARNING! ------

    Improper assembly of parts that are spring loaded can cause bodily injury.

    To prevent possible injury, follow the established assembly procedure and wear protective equipment.



    NOTICE

    Ensure that the valve spring is compressed squarely or damage to the valve stem may occur.


  4. Install Tooling (A) in the appropriate position on the cylinder head to compress valve spring (10).

    Note: Ensure that the electronic unit injector label code (12) is not damaged when Tooling (A) is compressed.

  5. Apply sufficient pressure to Tooling (A) to install valve keepers (8).

    Note: Do not compress the spring so that valve spring retainer (9) touches valve stem seal (11).

  6. Install valve spring keepers (8).

  7. Carefully release the pressure on Tooling (A).

  8. Repeat Step 2 through Step 7 for the remaining valve springs.

    ------ WARNING! ------

    The valve spring keepers can be thrown from the valve when the valve spring compressor is released. Ensure that the valve spring keepers are properly installed on the valve stem. To help prevent personal injury, keep away from the front of the valve spring keepers and valve springs during the installation of the valves.


  9. Remove Tooling (A).

    Note: If all valve springs require replacement, the procedure can be carried out on two cylinders at the same time. The procedure can be carried out on the following cylinders. 1 and 6, 2 and 5 and 3 and 4. Remember that the crankshaft must not be turned while the valve springs are removed. Ensure that all the valve springs are installed before changing from one pair of cylinders to the other pair of cylinders. If all valve springs do not require replacement, the springs must be replaced in pairs.



    Illustration 6g01978813

  10. Follow Step 10.a through Step 10.h to install the harness assemblies for electronic unit injectors (2).

    1. Ensure that harness assembly (3) for the electronic unit injectors is clean and free from damage. Replace any damaged components.

    2. Install a new O-ring seal (7) onto harness assembly (3) for electronic unit injectors (2).

      Note: Do not lubricate the O-ring seal.

    3. Push harness assembly (3) into the cylinder head.

    4. Install bolt (5) and tighten the bolt to a torque of 9 N·m (80 lb in).

    5. Connect plug (6) to harness assembly (3).

    6. Use a deep socket to install connections (1) to electronic unit injectors (2). Use Tooling (C) to tighten the connections to a torque of 2.0 N·m (18 lb in).

    7. Install new cable strap assemblies (4) to harness assembly (3).

      Note: Ensure that the cable strap assemblies are correctly installed into the cylinder head.

    8. Repeat Step 10.a through Step 10.g for the remaining harness assemblies.

End By:

  1. Install the rocker shaft assembly. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod - Install"for the correct procedure.

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