1608595 ENGINE AR-COMPLETE Caterpillar parts
95E
Rating:
Alternative (cross code) number:
CA1608595
160-8595
1608595
CA1608595
160-8595
1608595
Weight: 2458 pounds 1114 kg.
CHALLENGER,
Related part:
1608595
SHORT BLOCK
0R8209
R
Compatible equipment models: 1608595:
For full view, you need register
Information:
Removal Procedure
Start By:
Drain the coolant from the engine oil cooler into a suitable container for storage or disposal. Drain the engine oil from the engine oil cooler into a suitable container. Refer to Operation and Maintenance Manual for the procedure on draining the engine coolant and the engine oil.
Remove the hose from the air filter to the integral air inlet. Refer to the OEM information for further details.
Remove the fuel priming pump. Refer to this Disassembly and Assembly Manual, "Fuel Priming Pump and Fuel Filter Base - Remove and Install".
Remove the pipe for the boost control.
Remove the fuel injectors. Refer to this Disassembly and Assembly Manual, "Fuel Injection Nozzles - Remove".
Remove the exhaust manifold. Refer to Disassembly and Assembly, "Exhaust Manifold - Remove and Install".
Remove the rocker shaft assembly and the pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod - Remove".
Remove the glow plugs. Refer to this Disassembly and Assembly Manual, "Glow Plugs - Remove and Install".
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat products.Dispose of all fluids according to local regulations and mandates.
Note: Refer to Operation and Maintenance Manual, "Refill Capacities" for the coolant capacity and the engine oil capacity of the engine.
Illustration 1 g00951472
Remove the setscrew (1) and the fuel line from the cylinder head.
Disconnect the harness assembly (4) from the coolant temperature sensor.
Disconnect tube assembly (5) from the cylinder head.
Illustration 2 g00954953
Remove the setscrews (6). Remove the bypass tube (7) from the cylinder head. Remove the O-ring seals from the bypass tube. Discard the O-ring seals.
Illustration 3 g00951484
Gradually loosen the setscrews (8) in reverse numerical order. Refer to Illustration 3. This will help prevent distortion of the cylinder head.
Remove the setscrews (8) from the cylinder head (9).
Use a suitable lifting device and carefully lift the cylinder head off the cylinder block. The weight of the cylinder head is approximately 57 kg (126 lb). Note: Take care not to damage the machined surfaces of the cylinder head (9) during removal.Note: Do not use a lever to separate the cylinder head from the cylinder block.
Place the cylinder head on a surface that will not scratch the face of the cylinder head.
Remove the cylinder head gasket. Discard the cylinder head gasket. Note: Note the location of the dowels on the cylinder block.
Start By:
Drain the coolant from the engine oil cooler into a suitable container for storage or disposal. Drain the engine oil from the engine oil cooler into a suitable container. Refer to Operation and Maintenance Manual for the procedure on draining the engine coolant and the engine oil.
Remove the hose from the air filter to the integral air inlet. Refer to the OEM information for further details.
Remove the fuel priming pump. Refer to this Disassembly and Assembly Manual, "Fuel Priming Pump and Fuel Filter Base - Remove and Install".
Remove the pipe for the boost control.
Remove the fuel injectors. Refer to this Disassembly and Assembly Manual, "Fuel Injection Nozzles - Remove".
Remove the exhaust manifold. Refer to Disassembly and Assembly, "Exhaust Manifold - Remove and Install".
Remove the rocker shaft assembly and the pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod - Remove".
Remove the glow plugs. Refer to this Disassembly and Assembly Manual, "Glow Plugs - Remove and Install".
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat products.Dispose of all fluids according to local regulations and mandates.
Note: Refer to Operation and Maintenance Manual, "Refill Capacities" for the coolant capacity and the engine oil capacity of the engine.
Illustration 1 g00951472
Remove the setscrew (1) and the fuel line from the cylinder head.
Disconnect the harness assembly (4) from the coolant temperature sensor.
Disconnect tube assembly (5) from the cylinder head.
Illustration 2 g00954953
Remove the setscrews (6). Remove the bypass tube (7) from the cylinder head. Remove the O-ring seals from the bypass tube. Discard the O-ring seals.
Illustration 3 g00951484
Gradually loosen the setscrews (8) in reverse numerical order. Refer to Illustration 3. This will help prevent distortion of the cylinder head.
Remove the setscrews (8) from the cylinder head (9).
Use a suitable lifting device and carefully lift the cylinder head off the cylinder block. The weight of the cylinder head is approximately 57 kg (126 lb). Note: Take care not to damage the machined surfaces of the cylinder head (9) during removal.Note: Do not use a lever to separate the cylinder head from the cylinder block.
Place the cylinder head on a surface that will not scratch the face of the cylinder head.
Remove the cylinder head gasket. Discard the cylinder head gasket. Note: Note the location of the dowels on the cylinder block.