CYLINDER HEAD AND CYLINDER HEAD COMPONENTS INSTALLATION

TM 9-2815-225-34&P · Work Package 0043 00

CYLINDER HEAD, FUEL INJECTOR, ROCKER ARM HOUSING, ENGINE BRAKE RETARDER, ROCKER COVER

INITIAL SETUP

Tools and Special Tools                             Equipment Condition
 General mechanic’s tool kit: automotive             Engine mounted on maintenance stand
    (Item 1, WP 0061 00)                               (WP 0009 00).
 Maintenance and repair shop equipment:
    automotive (Item 2, WP 0061 00)
 Automotive maintenance and repair
    supplemental set no. 2 (Item 3, WP 0061 00)
 Fuel injector puller (Item 8, WP 0061 00)

Material/Parts
 Twelve O-rings (Item 1, Table 26, WP 0062 00)
 Three cylinder head gaskets
   (Item 2, Table 26, WP 0062 00)
 Three gaskets (Item 3, Table 26, WP 0062 00)
 Three gaskets (Item 4, Table 26, WP 0062 00)
 Three gaskets (Item 5, Table 26, WP 0062 00)
 Eighteen O-rings
   (Item 6, Table 26, WP 0062 00)
 Rust preventative lubricant
   (Item 16, WP 0060 00)
 OE/HDO 10 lubricating oil
   (Item 19, WP 0060 00)
 60-80/140 lubricating oil
   (Item 21, WP 0060 00)
TM page 0043 00-2
Figure 1. Cylinder Head Installation.

CYLINDER HEAD

NOTE The following procedure covers installation of one cylinder head assembly. Installation of remaining cylinder heads is similar. Perform steps 1 through 10 to install each additional cylinder head assembly as required. Ensure marks made on each cylinder head and cylinder block during removal are matched together during installation so that each cylinder head assembly is installed in its original position on cylinder block. Ensure new cylinder head gasket has the side with word TOP facing upwards.

1. Install new cylinder head gasket (7) on cylinder head (5).

2. Install cylinder head (5) on cylinder block (6).

3. Apply rust preventative lubricant to twelve screws (4). Allow excess lubricant to drip from screw threads before installation.

4. Install twelve screws (4) and washers (3) on cylinder head (5). Tighten screws (4) 25 lb-ft (34 N•m) in sequence shown in figure 1.

5. Tighten screws (4) 100 lb-ft (136 N•m) in sequence shown in figure 1.

NOTE Perform step 6 for Big Cam I only.

6. Tighten screws (4) 305 lb-ft (414 N•m) in sequence shown in figure 1.

NOTE Perform step 7 for Big Cam III only.

7. Tighten screws (4) 285 lb-ft (387 N•m) in sequence shown in figure 1.

8. Apply OE/HDO 10 lubricating oil to four new O-rings (8).

9. Install O-rings (8) on counterbores of cylinder head (5).

10. Install two fuel crossover connections (1) on cylinder head (5) with four screws (2). Tighten screws (2) 38 lb-in (4.3 N•m).

2 3

5      E

I H D

L               A
B               K

C F J G

7 6 TIGHTENING SEQUENCE

TM page 0043 00-3
Figure 2. Fuel Injector Installation.

FUEL INJECTOR

CAUTION If injector assembly fails to seat completely, remove and check for a twisted or damaged O-ring. Failure to comply may result in damage to equipment. **NOTE** Inspect fuel cooling sleeve in cylinder head prior to installing injector. Remove any dirt with a lint-free cloth. The following procedure covers installation of one injector assembly. Installation of remaining five injectors are similar. Ensure injectors are installed in same location as noted during removal.

1. Apply OE/HDO 10 lubricating oil to three new O-rings (12) and fuel injector (13).

2. Using injector puller, install fuel injector (13) in cylinder head (5).

3. Install retaining plate (11) on fuel injector (13) with two screws (9). Do not tighten screws.

4. Install detent plunger (10) on fuel injector (13).

NOTE Check for free movement of detent plunger after tightening screws. If detent plunger does not move freely, loosen two screws and retighten. Detent plunger must move freely.

5. Tighten screws (9) in steps of 5 lb-ft (7 N•m) until a final torque of 12 lb-ft (16 N•m) is obtained.

TM page 0043 00-4

ROCKER ARM HOUSING

NOTE The following procedure covers the installation of one rocker arm housing assembly. The installation of the remaining rocker arm housing assemblies is similar.

1. Install new gasket (6) on cylinder head (5).

2. Loosen six adjusting screws (2) three complete turns.

3. Apply GO-80/140 lubricating oil to ball ends of four intake and exhaust pushrods (4) and two injector pushrods (3).

NOTE The injector pushrods are larger in diameter than the valve pushrods. The valve pushrods are 0.007 in. (0.178 mm) longer than injector pushrods. Ensure each pushrod is installed in same position as noted during removal. Ball end of pushrods must fit into socket of cam followers. The injector pushrod is installed on center injector cam follower.

4. Install four intake and exhaust pushrods (4) and two injector pushrods (3) on cam followers of cylinder head (5).

NOTE Position six rocker levers so ball end of adjusting screw drops into sockets of six pushrods.

5. Install rocker arm housing (7) on cylinder head (5).

6. Install six new washer bearings (8) on rocker arm housing (7).

NOTE There are three different sizes of rocker housing studs. Install correct rocker housing stud in correct rocker arm housing. Damage to rocker housing stud threads may result if substitution of length is made.

7. Install six rocker housing studs (1), (9), and (10) on rocker housings (7) as shown in figure 3. Tighten studs (1), (9), and (10) 65 lb-ft (68 N•m) in sequence shown in figure 3.

TM page 0043 00-5
Figure 3. Rocker Arm Housing Installation.
Figure 3. Rocker Arm Housing Installation.
STUD TIGHTENING

F

C                            B
D                             E

A

8 2

STUD INSTALLATION SEQUENCE

9 10 9 10 9

                                                         9        10           9        10   7       9
5                                            7                         7
FRONT                                       REAR
TM page 0043 00-6

ROCKER ARM HOUSING (Contd)

NOTE Engine cylinders are numbered in sequence, starting at front with No. 1 cylinder. The engine firing order is 1-5-3-6-2-4. Valves and injectors for the same cylinder are not adjusted at same index mark on accessory drive pulley. One pair of valves from one cylinder and one injector on a different cylinder are adjusted at each pulley index mark before rotating accessory drive to next index mark. Two crankshaft revolutions are required to adjust all valves and injectors.

8. Using medium grit emery cloth, remove paint on timing marks (2), (3), and (4) on accessory drive pulley (1).

9. Rotate accessory drive pulley (1) clockwise until line in front of timing mark (2) aligns with pointer (6) on front gear cover (5).

NOTE Steps 10 through 16 covers adjustment for cylinder No. 3.

10. Loosen adjusting screw nut (8) several turns.

11. Tighten adjusting screw (9) until all clearance is removed between rocker lever (10) and injector detent plunger.

12. Tighten adjusting screw (9) one additional turn.

13. Loosen adjusting screw (9) one complete turn until spring washer inside injector is against stop of injector.

14. Tighten adjusting screw (9) 5–6 lb-in (0.6–0.7 N•m).

15. Repeat step 14 several times to make certain adjusting screw (9) is correctly tightened.

NOTE If torque driver ST-669 is used, tighten adjusting screw nut 35 lb-ft (48 N•m).

16. Prevent adjusting screw (9) from turning and tighten adjusting screw nut (8) 45 lb-ft (61 N•m).

NOTE Adjustment for intake valve is similar to exhaust valve except for valve clearance difference. Steps 17 through 20 covers intake and exhaust valve adjustment for cylinder No. 5.

17. Loosen adjusting screw nut (8).

NOTE Cold valve clearance for exhaust valve is 0.023 in. (0.584 mm) and valve clearance for intake valve is 0.011 in. (0.279 mm).

18. Place feeler gauge between rocker lever (10) and crosshead (11).

19. Slowly tighten screw (9) until rocker lever (10) touches feeler gauge.

TM page 0043 00-7
Figure 4. Injector Timing.

ROCKER ARM HOUSING (Contd)

NOTE If torque driver ST-669 is used, tighten adjusting screw nut 40 lb-ft (54 N•m).

20. Hold adjusting screw (9) in place and tighten adjusting screw nut (8) 45 lb-ft (61 N•m).

21. Slowly rotate accessory drive pulley (1) clockwise until line in front of timing mark (3) aligns with pointer (6) on front gear cover (5).

22. Perform steps 10 through 16 for cylinder No. 6 injector.

23. Perform steps 17 through 20 for cylinder No. 3 intake and exhaust valves.

24. Slowly rotate accessory drive pulley (1) clockwise until line in front of timing mark (4) aligns with pointer (6) on front gear cover (5).

25. Perform steps 10 through 16 for cylinder No. 2 injector.

26. Perform steps 17 through 20 for cylinder No. 6 intake and exhaust valves.

27. Slowly rotate accessory drive pulley (1) clockwise until line in front of timing mark (2) aligns with pointer (6) on front gear cover (5).

28. Perform steps 10 through 16 for cylinder No. 4 injector.

29. Perform steps 17 through 20 for cylinder No. 2 intake and exhaust valves.

30. Slowly rotate accessory drive pulley (1) clockwise until line in front of timing mark (3) aligns with pointer (6) on front gear cover (5).

31. Perform steps 10 through 16 for cylinder No. 1 injector.

32. Perform steps 17 through 20 for cylinder No. 4 intake and exhaust valves.

33. Slowly rotate accessory drive pulley (1) clockwise until line in front of timing mark (4) aligns with pointer (6) on front gear cover (5).

34. Perform steps 10 through 16 for cylinder No. 5 injector.

35. Perform steps 17 through 20 for cylinder No. 1 intake and exhaust valves.

5 9 7 8 6 10

TM page 0043 00-8

ENGINE BRAKE RETARDER

NOTE The following procedure covers installation of one engine brake retarder. Installation of remaining engine brake retarders are similar.

1. Install new gasket (11) on rocker arm housing (13).

2. Install engine brake retarder (3) on two rocker arm housing studs (14).

3. Install fan bracket (1) and two spacers (5) on two rocker housing studs (14).

4. Install six nuts (2) on rocker housing studs (14). Tighten nuts (2) 60 lb-ft (81 N•m) in sequence shown in figure 4.

NOTE The following procedure covers adjustment for one slave piston. There are two slave pistons per brake retarder, or one per cylinder. The adjustment for the remaining five slave pistons is similar. Ensure locknuts are loose before adjusting setscrew. The adjustment procedure for slave piston requires engine crankshaft to be rotated and accessory drive pulley assembly positioned on timing mark A, B, or C. When positioned at timing mark A, cylinders No. 5 or 2 can be adjusted. When positioned at timing mark B, cylinders No. 3 or 4 can be adjusted. When positioned at timing mark C, cylinders No. 6 or 1 can be adjusted.

5. Loosen locknut (8) and setscrew (9) until there is no pressure or tension.

6. Using feeler gauge, check slave piston (12) clearance between slave piston (12) and crosshead (4). Adjust clearance to 0.018 in. (0.457 mm).

CAUTION After slave piston adjusting screw locknut has been tightened to specified value, check clearance with feeler gauge again. Do not overtighten adjusting screw locknut or clearance may change and result in damage to engine.

7. Tighten locknut (8) 40 lb-ft (54 N•m).

8. Using feeler gauge, recheck slave piston (12) clearance.

9. Connect spade end of solenoid harness (7) to solenoid valve (6).

10. Connect receiver end of solenoid harness (7) to terminal (10) inside engine brake retarder (3).

TM page 0043 00-9
Figure 5. Engine Brake Retarder Installation.
TM page 0043 00-10
Figure 6. Rocker Cover Installation.

ROCKER COVER

NOTE This procedure covers installation of one rocker cover. All three rocker covers are installed the same.

Install new gasket (3) and rocker cover (2) on engine brake retarder (4) with five screws (1). Tighten screws (1) 12–17 lb-ft (16–23 N•m).

END OF WORK PACKAGE

TM page 0044 00-1