How to Remove the Cylinder Head of a Caterpillar 320D2 Excavator

 Start: a. Remove the fine fuel filter, fuel filter holder, and bracket. For correct procedures, see Disassembly and Assembly, "Fuel Filter Holder - Removal and Installation".

 

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 b. Remove the oil-water separator, fuel pre-filter, and bracket. For correct procedures, see Disassembly and Assembly, "Oil-Water Separator and Fuel Pre-Filter - Removal and Installation". 

c. Remove the rocker arm shaft and pushrod. For correct procedures, see Disassembly and Assembly, "Rocker Arm Shaft and Pushrod - Removal". 

 d. Remove the exhaust manifold. See Disassembly and Assembly, "Exhaust Manifold - Removal and Installation" for the correct procedure. 

 e. Remove the crankcase breather filter canister and plastic tubing assembly. For correct procedures, see Disassembly and Assembly, "Crankcase Breather - Removal".

  f. Remove the fuel injectors. For the correct procedure, see Disassembly and Assembly, "Injector - Removal". 

 g. Remove the glow plug. See Disassembly and Assembly, "Glow Plug - Removal and Installation" for the correct procedure.

 1. Drain the coolant from the cooling system into a suitable container for storage or disposal. For the correct draining procedure, 

 ee the Operation and Maintenance Manual, "Cooling System Coolant - Replacement".

 see the Operation and Maintenance Manual, "Cooling System Coolant - Replacement". 

 

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 2. Disconnect the upper radiator hose from the water temperature regulator housing (1) on the cylinder head.

 

 

 

 

3. Loosen the hose clamps and then disconnect the hose assembly and hose assembly from the connector (11). 

 4. Remove bolt (3) and then remove bracket (2) from the cylinder head. 

 5. Remove bolts (4) and (9) from brackets (5) and (10). 

6. Disconnect the plastic tube assembly (6) and plastic tube assembly (8) from the fuel injection pump (7)

. 7. Use tool (A) to plug the plastic tube assembly (6) and plastic tube assembly (8). 

 8. Use tool (A) to cover the connector of the fuel injection pump (7). 

 9. If necessary, remove the tube assembly from the cylinder head and the boost control of the fuel injection pump. For correct procedures, see Disassembly and Assembly, "Fuel Injection Pump - Removal (with Boost Control)". 

10. Remove bolt (12) from the clamp of the tube assembly (13). 

 11. Remove bolt (14) from the bypass pipe (15). 

12. Remove the bypass pipe (15) from the cylinder head. 13. Remove O-rings (16) and (17) from the bypass pipe (15). 14. Loosen bolts (18) in the reverse numerical order of tightening. See Illustration 6.

 Note: Following the correct order helps prevent cylinder head deformation.

 15. Remove bolts (18) from the cylinder head (19). 

 

 16. Attach suitable lifting equipment to the cylinder head (19). Support the weight of the cylinder head. The cylinder head weighs approximately 96 kg (212 lb).

 

  Note: During lifting, a strut must be used to distribute the weight of the cylinder head.

 17. Use suitable lifting equipment to lift the cylinder head (19) away from the cylinder block.

 Note: Do not use levers to separate the cylinder head from the cylinder block. Take care not to damage the machined surfaces of the cylinder head during disassembly.

 

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 18. Remove the cylinder head gasket (21). 

 19. Record the position of the locating pin (20) in the cylinder block. 

 20. If necessary, remove the water temperature regulator from the cylinder head. For correct procedures, see Disassembly and Assembly, "Water Temperature Regulator - Removal and Installation".

How to disassemble and install the Caterpillar 320D2 Excavator DNP intake and exhaust valve guides

 Start: a. Remove the intake and exhaust valves. See Disassembly and Assembly, "Intake and Exhaust Valves - Removal and Installation".

 

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 Note: Valve guides and valve seats must be removed by a properly trained professional. Specialized machinery is also required. For more information,

 Note: Keep all parts clean and free of contaminants. Contaminants cause rapid wear and shorten component life.

 

 

Use appropriate presses and tools (A) to remove the valve guide (2) (not shown) from the cylinder head (1).

 

2. Repeat step 1 for the remaining valve guides. 

 

Note: Valve guides and valve seats must be removed by a properly trained professional. Specialized 

machinery is also required. For more information, 

 

Note: Keep all parts clean and free of contaminants. Contaminants cause rapid wear and shorten 

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component life. 1. Clean the valve guide bore in the cylinder head. 

 

 

2. Lubricate the new valve guide (2) with clean engine oil. Position the valve guide (2) in place on the cylinder head (1).

 
Carefully tap the valve guide to begin installation.  

 

3. Use appropriate presses and tools (A) to install the valve guide into the cylinder head. 

 

4. Repeat steps 2 through 3 for the remaining valve guides.  

 

 5. Check the protrusion (X) of the valve guide (2). The valve guide should protrude 12.7 mm (0.500 in) above the valve spring recess.

 

 

For more information, see the technical specifications, "Cylinder Head Valves".  

 

6. After installing the valve guide (2), the valve guide must be enlarged, and the valve seat insert must be cut to the finishing diameter. Follow steps 6.a through 6.d to ream the large valve guide and cut the valve seat insert. 

a. Lubricate the bore of the valve guide (2) with clean engine oil. 

 

b. Ream the large valve guide using tool (B). Ensure even pressure is applied to tool (B). 

 

c. Cut the valve seat using tool (B). Ensure even pressure is applied to tool (B). 

 

d. Ensure the cylinder head is clean and free of machining debris.

 

7. Check the finishing diameter of the valve guide (2). For more information, see Technical Specifications, "Cylinder Head - Valve".    

 

8. Check the depth of the valve below the cylinder head surface. For more information, see System Operation, Testing and Adjustment, "Valve Depth - Check". 

 

End: a. Install the intake and exhaust valves. See Disassembly and Assembly, "Intake and Exhaust Valves - Removal and Installation".  

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How to Install Caterpillar 320D2 Excavator Intake and Exhaust Valves

  Installation Steps

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  Note: Keep all parts clean and free of impurities.

  Impurities will cause rapid wear and shorten component life.

 Note: The valve hard surfaces have been polished. Do not use abrasives on the valves. Abrasives will damage the valve hard surface polishing.

  1. Clean all parts of the cylinder head assembly. Ensure that all openings, coolant passages, and lubrication passages in the cylinder head are free of debris. Inspect the cylinder head assembly parts according to steps 1.a through 1.e. Replace any damaged or worn parts.

 a. Inspect the cylinder head for wear or damage. For correct procedures, see System Operation, Testing, and Adjustment, 

 "Cylinder Head Inspection".

 b. Inspect the valve seats for wear or damage. For more information, see the technical specifications, "Cylinder Head Valves".

 c. Inspect the valve guides for wear or damage. For more information, please refer to the Technical Specifications, "Cylinder Head Valves" and System Operation, Testing and Adjustment, "Valve Guides - Inspection". 

 d. Inspect the valves for wear or damage. For more information, please refer to the Technical Specifications, "Cylinder Head Valves".

 e. Inspect the valve springs for wear and for correct length. For more information, please refer to the Technical Specifications, "Cylinder Head Valves".

 

  2. Lubricate the valve (5) stems with clean engine oil. Install the valve (5) in its appropriate position on the cylinder head. Check the depth of the valve below the cylinder head surface. For more information, please refer to System Operation, Testing and Adjustment, "Valve Depth - Inspection".

 3. Use appropriate lifting equipment to flip the cylinder head. The cylinder head weighs approximately 96 kg (212 lb).

 Note: Ensure all valves remain in place.

 4. Install the new valve stem seals (4) onto the individual valve guides. The intake and exhaust valve stem seals are different and can be distinguished using color markings.

 

Note: The outer surface of the valve guide must be clean and dry before installing the valve stem seal (4).

 

 

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  5. Install the valve spring (3) onto the cylinder head. Place the valve spring seat (2) onto the valve spring (3).

 Warning: Being struck by parts propelled by the spring force can cause personal injury.

  Ensure you wear all necessary protective equipment.

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

  6. Install tool (A) in the appropriate position on the cylinder head to compress the valve spring (3).

  Caution: Ensure the valve spring is compressed evenly at all four corners; otherwise, damage to the valve stem may occur.

 7. Apply sufficient pressure to tool (A) to install the valve retainer (1).

 

 Note: When compressing the spring, do not allow the valve spring seat (2) to contact the valve stem seal (4).

  Warning

When the valve spring compressor is released, the valve spring retainer will pop out of the valve. Ensure

The valve spring retainer is correctly installed on the valve pushrod. To prevent personal injury, keep away from the front of the valve spring retainer and the valve spring when installing the valve.  

 8. Carefully release the pressure on tool (A). 

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 9. Repeat steps 5 through 8 for the remaining valves. 

10. Remove tool (A) from the cylinder head.

  End: a. Install the cylinder head. For correct procedures, see Disassembly and Assembly, "Cylinder Head - Installation".

 

 

How to Remove Intake and Exhaust Valves (320D2 Excavator)

 Start: a. Remove the cylinder head. For the correct procedure, refer to Disassembly and Assembly, "Cylinder Head - Remove".

 NOTICE

 Keep all parts clean and free of contaminants. Contaminants can cause rapid wear and shorten component service life.

 1. Clean the gasket surface on the bottom of the cylinder head. Before removing the valve springs, measure the depth of the valves below the cylinder head surface. Refer to Specifications, "Cylinder Head Valves," for the correct dimensions. 

2. Make temporary identification marks on the valve heads to ensure correct positioning. Note: Intake valves have a recess in the center of the valve head. 

3. Use appropriate lifting equipment to position the cylinder head with the valve springs facing upward. The weight of the cylinder head is approximately 96 kg (212 lb). Note: Ensure the cylinder head is placed on a clean, soft surface to prevent damage to machined surfaces.

4. Install tool (A) onto the cylinder head to compress the corresponding valve spring (3). NOTICE Ensure the valve spring is compressed evenly; uneven compression may damage the valve stem.

 5. Apply sufficient pressure to tool (A) to remove the valve retainer (1). Note: When compressing the spring, do not allow the valve spring retainer (2) to contact the valve stem seal (4). 

 6. Slowly release the pressure on tool (A).  

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 WARNING

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

Ensure all necessary protective equipment is worn. Follow the recommended procedures and use all recommended tools to release spring force. 

 

 

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7. Make a temporary identification mark on the valve spring (3) to identify its correct position. 

 

8. Remove the valve spring retainer (2). Remove the valve spring (3). 

 

9. Repeat steps 4 through 8 for the remaining valves. 

 

10. Remove tool (A).  

 

11. Remove the valve stem seals (4). Intake and exhaust valve stem seals are different; they can be distinguished by color coding. Identify the location of the valve stem seals based on their color to ensure correct installation. 

 

12. Turn over the cylinder head using appropriate lifting equipment. 13. Make a temporary identification mark on the valves (5). Remove the valves (5) from the cylinder head.

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How to Install Caterpillar 320D2 Excavator Intake and Exhaust Valves

 Start: Caution Keep all parts clean and free of impurities.

Impurities cause rapid wear and shorten component life. 

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Note: The valve hard surfaces are polished. Do not use abrasives on the valves. Abrasives will damage the valve hard surface polishing. 

1. Clean all parts of the cylinder head assembly. Ensure all openings, coolant passages, and lubrication passages in the cylinder head are free of debris. Inspect the cylinder head assembly parts according to steps 1.a through 1.e. Replace any damaged or worn parts.  

a. Inspect the cylinder head for wear or damage. For correct procedures, see System Operation, Testing, and Adjustment, "Cylinder Head Inspection". 

 b. Inspect the valve seats for wear or damage. For more information, see the technical specifications, "Cylinder Head Valves".

c. Inspect the valve guides for wear or damage. For more information, please refer to the Technical Specifications, "Cylinder Head Valves" and System Operation, Testing and Adjustment, "Valve Guides - Inspection". 

d. Inspect the valves for wear or damage. For more information, please refer to the Technical Specifications, "Cylinder Head Valves". 

e. Inspect the valve springs for wear and for correct length. For more information, please refer to the Technical Specifications, "Cylinder Head Valves". 

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 2. Lubricate the valve (5) stems with clean engine oil. Install the valve (5) in its appropriate position on the cylinder head. Check the depth of the valve below the cylinder head surface. For more information, please refer to System Operation, Testing and Adjustment, "Valve Depth - Inspection".

3. Use appropriate lifting equipment to flip the cylinder head. The cylinder head weighs approximately 96 kg (212 lb). 

 

   Note: Ensure all valves remain in place.

 4. Install the new valve stem seals (4) onto the individual valve guides. The intake and exhaust valve stem seals are different and can be distinguished by color markings.

Note: The outer surface of the valve guide must be clean and dry before installing the valve stem seal (4).

   5. Install the valve spring (3) onto the cylinder head. Place the valve spring seat (2) onto the valve spring (3).

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Being struck by parts propelled by the spring force can cause personal injury. 

 Ensure you wear all necessary protective equipment.

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

  6. Install tool (A) in the appropriate position on the cylinder head to compress the valve spring (3).

Caution: Ensure the valve spring is compressed evenly at all four corners; otherwise, damage to the valve stem may occur. 

 

 7. Apply sufficient pressure to tool (A) to install the valve retainer (1).

 Note: Do not allow the valve spring seat (2) to contact the valve stem seal (4) when compressing the spring. When the valve spring compressor is released, the valve spring retainer will pop out of the valve. Ensure the valve spring retainer is correctly installed on the valve pushrod. To prevent personal injury, keep away from the front of the valve spring retainer and the valve spring when installing the valve.

 

8. Carefully release the pressure on tool (A). 

 9. Repeat steps 5 through 8 for the remaining valves. 

10. Remove tool (A) from the cylinder head.

 

How to disassemble the intake and exhaust valves of a Caterpillar 320D2 Excavator

 Start: a. Remove the cylinder head. For the correct procedure, see Disassembly and Assembly, "Cylinder Head - Removal".

 Caution: Keep all parts clean and free of contaminants.

 Contaminants cause rapid wear and shorten component life.

 1. Clean the surface of the bottom gasket of the cylinder head. Before removing the valve springs, check the depth of the valves below the cylinder head surface.

 See the technical specifications, "Cylinder Head Valves," for the correct dimensions.

2. Make temporary identification marks on the valve heads to determine the correct position. 

 Note: There is a recess in the center of the intake valve cover.

 

3. Using appropriate lifting equipment, position the cylinder head with the valve springs facing upwards. The cylinder head weighs approximately 96 kg (212 lb). 

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Note: Ensure the cylinder head is kept on a clean, soft surface to prevent damage to machined surfaces. 

 

 Warning Being struck by parts ejected by the spring force can cause personal injury.

 Ensure you wear all necessary protective gear.

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

 

 4. Install tool (A) in place on the cylinder head to compress the corresponding valve spring (3).

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 Caution Ensure that the valve spring is compressed evenly at all four corners; otherwise, the valve stem may be damaged. 

  Note: Do not allow the valve spring seat (2) to contact the valve stem seal (4) when compressing the spring.

 

6. Slowly release the pressure on tool (A). 

 

 7. Make a temporary identification mark on the valve spring (3) to identify the correct position.

8. Remove the valve spring seat (2). Remove the valve spring (3). 

9. Repeat steps 4 through 8 for the remaining valves.  

10. Remove tool (A).  

  11. Remove valve stem seals (4). Intake and exhaust valve stem seals are different and can be distinguished using color markings. Identify the location of the valve stem seals according to their different colors for installation. 

 12. Use appropriate lifting equipment to flip the cylinder head. 

13. Make a temporary identification mark on the valve (5). Remove the valve (5) from the cylinder head.

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Caterpillar 320D2 Excavator Intake and Exhaust Valve Springs - Removal and Installation

 Removal Procedure 

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 Caution Keep all parts clean and free of impurities. Impurities will cause rapid wear and shorten the life of the parts.

 Note: When installing the cylinder head onto the engine, the valve springs should be removed using the following steps. Please refer to Disassembly and Assembly, "Intake and Exhaust Valves - Removal and Installation," for the procedure for removing the valve springs from the cylinder head (which has been removed from the engine).

  Note: Ensure that the corresponding piston is at top dead center before removing the valve spring. Failure to ensure that the piston is at top dead center may result in the valve falling into the cylinder bore.

  Caution Ensure that the valve spring is compressed evenly at all four corners; otherwise, the valve stem may be damaged.

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1. Set the corresponding piston to top dead center following steps 1.a through 1.d. 

a. Install tool (A) in the corresponding position on the cylinder head to compress the valve spring (3) for the corresponding cylinder. b. Using tool (A), compress the valve spring (3) and slightly open the valve. 

 

Note: When compressing the spring, do not allow the valve spring seat (2) to contact the valve stem seal (4).  

 c. Using tool (B), carefully rotate the crankshaft until the piston contacts the valve.

 Note: Do not apply excessive force when rotating the crankshaft. Excessive force may cause the valve stem to bend.

 d. Continue rotating the crankshaft, gradually releasing the pressure on tool (A) until the piston is at top dead center. The valve is now in a position where the valve spring can be safely removed.

 Note: The valve springs for the intake or exhaust valves of each cylinder must be replaced in pairs. If all valve springs need to be replaced, this procedure can be performed simultaneously on two cylinders. This procedure can be performed simultaneously on the following cylinder pairs: 1 and 6, 2 and 5 and 3 and 4. Ensure that all valve springs are installed before moving from one pair of cylinders to another. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... Friday, October 26, 2018

 Caution:

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1. Do not rotate the crankshaft during valve spring removal.

 

 2. Apply sufficient pressure to tool (A) to remove the valve retainer (1). Note: Do not allow the valve spring seat (2) to contact the valve stem seal (4) when compressing the spring. 

 3. Slowly release the pressure on tool (A).

  4. Remove the valve spring seat (2). 

 5. Remove the valve spring (3). 

 6. If necessary, remove the valve stem seal (4). Intake and exhaust valve stem seals are different and can be distinguished using color markings. Identify the location of the valve stem seals according to their different colors for installation. 

 7. Repeat steps 2 through 6 to remove the remaining valve springs from their respective cylinders. 

 8. Remove tool (A).