C9.3 Engines for Caterpillar Built Machines Combustion Head - Remove and Install - Clean Emissions Module Caterpillar

Removal Procedure

Start By:

1. Remove the Exhaust Elbow.

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Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help prevent possible injury, turn the start switch off when changing fuel filters or water separator elements. Clean up fuel spills immediately.

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Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool.

1. Turn the fuel supply to the OFF position and turn the power disconnect switch to the OFF.
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   Illustration 1	g02151651

2. Disconnect clamp assembly (1).

3. Remove three bolts (3).

4. Remove bolt (4). Remove tube assembly (2) and the gasket.
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   Illustration 2	g02583797

   Note: Cap all tube assemblies and fittings that are disconnected to prevent fluid loss. This action will also keep contaminants out of the systems.

5. Disconnect tube assemblies (5) and (6). Plug tube assemblies (6) with Tooling (D).
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   Illustration 3	g02153363

6. Disconnect cable assembly (7) and cable assembly (8).

7. Remove allen bolt (9), the clamp assembly, and position cable assembly (10) out of the way.

8. Disconnect flame detection temperature sensor (11).
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   Illustration 4	g02153382

9. Remove nuts (16) and remove combustion head (15).

10. Remove gasket (14), tube assembly (13), and gasket (12).

    Note: The gaskets are for one time use only. Replace with new gaskets upon installation.

11. If required, remove studs (17).
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    Illustration 5	g02153383

12. Remove fittings (18) and (19).

13. Remove spark plug (20) and remove fitting (21).
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    Illustration 6	g02481277

14. Use Tooling (B) to remove O-ring seals (22) and (23) from cable assembly (10). Discard the O-ring seals.

Installation Procedure

1. Install combustion head (15) in reverse order.

   1. Apply Tooling (A) onto the threads of studs (17). Install the studs. Tighten studs (17) to a torque of 17 ± 2 N·m (150 ± 18 lb in).

   2. Apply Tooling (A) onto the threads of the studs and nuts (16). Tighten nuts (16) in a crisscross pattern to a torque of 23 ± 3 N·m (17 ± 2 lb ft). Tighten nuts (16) again in a crisscross pattern to a torque of 28 ± 3 N·m (21 ± 2 lb ft). Tighten nuts (16) again in a crisscross pattern to a torque of 28 ± 3 N·m (21 ± 2 lb ft).
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      Use caution when you are using isopropyl alcohol. Avoid prolonged skin contact with isopropyl alcohol. Vapors may be harmful if inhaled. Use only in a well ventilated area. Do not smoke while using isopropyl alcohol. Isopropyl alcohol is flammable. Do not use near an open flame or near welding operations. Keep isopropyl alcohol away from heated surfaces exceeding 482°C (900°F).

      Note: This connection is an electrical connection and cannot be lubricated with a petroleum-based lubricant. Isopropyl alcohol is the only approved lubrication for this connection.

   3. Lubricate new O-ring seals (22) and (23) with Tooling (C) prior to installation.

   4. Tighten fitting (21) to a torque of 60 ± 6 N·m (44 ± 4 lb ft).

   5. Tighten fittings (19) and (18) to a torque of 30 ± 2 N·m (266 ± 18 lb in).

   6. Tighten spark plug (20) to a torque of 57.5 ± 4 N·m (42 ± 3lb ft).

   7. Apply Tooling (A) to the threads of flame detection temperature sensor (11) and install the sensor. Tighten flame detection temperature sensor (11) to a torque of 45 ± 5 N·m (33 ± 3 lb ft).

   8. Tighten tube assemblies (5) to a torque of 16 ± 2 N·m (142 ± 18 lb in).

   9. Tighten tube assembly (6) to a torque of 11 ± 2 N·m (97 ± 18 lb in).

   10. Check the coolant level. If necessary, refer to Operation and Maintenance Manual, "Coolant - Change" for the proper filling procedures.

2. Perform the ARD ignition test. Refer to Troubleshooting Manual, "ARD Ignition - Test".