C7.1 Marine Engine Caterpillar

Rocker Arm and Shaft - Install

Usage:

C7.1 JEZ

Installation Procedure

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Table 1
Required Tools
Tool	Part Number	Part Description	Qty
A⁽¹⁾	9U-6198	Crankshaft Turning Tool	1
A⁽²⁾	9U-7336	Housing	1
A⁽²⁾	5P-7305	Engine Turning Tool	1
B	367-8608	Engine Timing Pin	1
C	298-5564	T40 Torx Socket	1
D	227-4389	E10 Torx Socket	1
E	370-4657	Rocker Arm Spacer	6
F	322-4113	Retainers	24

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⁽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 (A) can be used. Use the Tooling that is most suitable.

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NOTICE

Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

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Illustration 1	g03454236
The correct location of valve bridges on valve stems is shown.

Engines that have valve bridge clips (9) originally installed on valve bridges (5). Remove the valve bridge clips from the valve bridges.
Clean valve bridges (5). Inspect the valve bridges for wear and damage. Replace any valve bridges that are worn or damaged.
Install Tooling (F) onto valve bridges (5).
Lubricate valve bridges (5) with clean engine oil.

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NOTICE

Failure to ensure that ALL valve bridges are correctly seated onto the valve stems will cause interference between the pistons and the valves, resulting in damage to the engine.
Install valve bridges (5) to the valve stems. Ensure that valve bridge clips (9) are correctly located.
Note: Install used valve bridges in the original location and in the original orientation. Ensure that the valve bridges are correctly seated on the valves. New valve bridges may be installed in either orientation.
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Illustration 2 g03454237
Clean the pushrods. Inspect the pushrods for wear and damage. Replace any pushrods that are worn or damaged.
Apply clean engine lubricating oil to both ends of pushrods (8). Install the pushrods to the engine with the cup upward. Ensure that when the pushrods are installed into the hydraulic lift there should be a noticeable snap when the pushrods are correctly installed.
Note: Ensure that the pushrods are installed in the original location.
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Illustration 3 g02085993
If necessary, use Tooling (A) to rotate the crankshaft so that number one piston is at top dead center on the compression stroke. Refer to System Operation, Testing and Adjusting, "Position the Valve Mechanism Before Maintenance Procedures" for the correct procedure. Install Tooling (B) through Hole (W) to lock the crankshaft.
Note: Do not use excessive force to install Tooling (B). Do not use Tooling (B) to hold the crankshaft during repairs.

Remove Tooling (B).

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NOTICE

Failure to ensure that the crankshaft is positioned at 60 degrees after top dead center will result in interference between the pistons and the valves. Failure to ensure that the crankshaft is positioned at 60 degrees after top dead center will result in damage to the engine.

Use Tooling (A) to rotate the crankshaft in a clockwise direction and position the crankshaft at 60 degrees after top dead center.
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Illustration 4 g03454356

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Illustration 5 g02307257
Ensure that the rocker shaft assembly is clean and free from wear and damage.
Position the rocker shaft assembly with Spotfaces (Y) for Torx screws (6) is in the up ward position.
Install Tooling (E) to rocker shaft assembly.
Install Torx screws (6) to the rocker shaft.
Note: Ensure that correct Torx screw (6) is installed to Position (X).
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Illustration 6 g03454240

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Illustration 7 g03453722

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Illustration 8 g03454241
Ensure that ALL threaded inserts are fully unscrewed.

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NOTICE

Damage to the engine will occur if all threaded inserts are not fully unscrewed.
Position rocker shaft assembly (7) onto the cylinder head. The retaining clip (10) should face the front of the engine.
Note: Ensure that the threaded inserts are correctly seated in ends of pushrods (8).
Use Tooling (D) to tighten Torx screws (7) hand tight.
Remove Tooling (E) from the rocker shaft. Install the remaining Torx screws (6) to the rocker shaft. Tighten the Torx screws hand tight.
Tighten Torx screws (6) to a torque of 35 N·m (26 lb ft) in the numerical sequence that is shown in Illustration 8.
Ensure that valve bridges (5) are correctly located on the valve stems.Failure to ensure that ALL valve bridges are correctly seated onto the valve stems will result in interference between the pistons and the valves, resulting in damage to the engine.
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Illustration 9 g03453721
Use Tooling (C) to tighten threaded inserts (4) on all rocker arms (3). Tighten the threaded inserts to a torque of 30 N·m (265 lb in).
Note: When the threaded insert is tightened, the threaded insert must seat correctly into the cup for the pushrod.
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Illustration 10 g01992076
Install a new O-ring seal (1) to plug (2). Install the plug into Hole (W) in the cylinder block. Tighten plug (2) to a torque of 21 N·m (186 lb in).
Do not operate the engine for a period 30 minutes after the threaded inserts on all the rocker arms have been tightened. This period will allow the force of the valve springs to purge off excessive engine oil from the hydraulic lifters.