Cylinder Head Replacement

TM 9-2320-363-34-1 · Chapter 3 — Power Package Maintenance

This task covers: a. Removal b. Cleaning c. Inspection d. Installation

Tools and Special Equipment:                          Equipment Description (Cont):

                                                       Reference              Condition Description
Shop Equipment, SC 4910-95-CL-A31
Tool Kit, SC 5180-90-CL-N05
                                                      TM 9-2320-363-20        Alternator Removed
Lifter, J35641
Gear Pilot, J35906
                                                       Page 3-162             Camshaft and Bearings
Retaining Tool, J35652
                                                                              Removed
Materials/Parts:
                                                       Page 3-108             Injector Removed
Gasket                 P/N 23506120
                                                       Page 4-2               Injector Wiring Harness
International                                                                 Removed
Compound No. 2         Appendix B, Item 29
                                                       TM 9-2320-363-20       Water Level Sensor
                                                                              Removed
References:

TM 9-2320-363-20                                       TM 9-2320-363-20       Transmission Tunnel
                                                                              Access Cover Removed

Equipment Condition:                                   General Safety Instructions:

Reference              Condition Description
                                                                         WARNING

Page 3-67 or 3-70.1    Exhaust Manifold Removed
                                                            Cylinder head weighs 421 lb (191 kg). Use
                                                            suitable lifting device to lift and support
TM 9-2320-363-20       Thermostat and Thermostat
                                                            cylinder head. Failure to do so could result
                       Housing Cover Removed
                                                            in injury to personnel.
 Page 3-61 or 3-66.1   Air Intake Manifold
                                                            Make sure lifting device is securely
                       Removed
                                                            fastened and weight being lifted does not
                                                            exceed capacity of lifting device. Failure to
 TM 9-2320-363-20      Air Compressor Cooling
                                                            do so may cause personal injury.
                       Lines Disconnected

TM page 3-81

Illustration from TM 9-2320-363-34-1 (PDF page 157)

1. DISCONNECT TWO FUEL LINES (1 AND 2) FROM CYLINDER HEAD (3).

2. REMOVE BOLT (4) AND SET BRACKET (5) ASIDE.

3. REMOVE TWO BOLTS (6) AND TWO WASHERS (7) AND SET WIRING HARNESS (8) ASIDE.

TM page 3-82

Illustration from TM 9-2320-363-34-1 (PDF page 158)

4. DISCONNECT AIR COMPRESSOR HOSE (9) FROM CYLINDER HEAD (3).

5. REMOVE TWO BOLTS (10), NUT (11), BOLT (12), AND BRACKET (13).

6. REMOVE 38 CYLINDER HEAD BOLTS (14) AND 38 WASHERS (15).

TM page 3-83

Illustration from TM 9-2320-363-34-1 (PDF page 159)

7. INSTALL LIFTER (16) BETWEEN FUEL INJECTOR HOLES NO. 3 AND NO. 4. INSTALL BOLT (17) USING BOLT HOLE FOR CENTER CAM CAP BOLT. INSTALL TWO BOLTS (18) USING TWO TAPPED HOLES FOR ENGINE RETARDER ASSEMBLY.

TM page 3-84

Illustration from TM 9-2320-363-34-1 (PDF page 160)

WARNING Cylinder head weighs 421 lb (191 kg). Use suitable lifting device to lift and support cylinder head. Failure to do so could result in injury to personnel. Make sure lifting device is securely fastened and weight being lifted does not exceed capacity of lifting device. Failure to do so may cause personal injury.

8. ATTACH SUITABLE LIFTING DEVICE TO LIFTER EYE (19) AND REMOVE CYLINDER HEAD (3).

9. REMOVE AND DISCARD CYLINDER HEAD GASKET (20).

10. REMOVE THREE BOLTS (21) AND LEFT REAR LIFTER BRACKET (22).

CAUTION Tag elbows prior to removal to aid in installation. Failure to do so could result in damage to equipment.

11. REMOVE TWO ELBOWS (23 AND 24) FROM CYLINDER HEAD (3).

12. REMOVE AIR COMPRESSOR FITTING (25) FROM CYLINDER HEAD (3).

Use general cleaning methods to clean all parts (page 2-30).

TM page 3-85

Illustration from TM 9-2320-363-34-1 (PDF page 161)

1. MAKE SURE PISTON DOMES, CYLINDER HEAD, CYLINDER BLOCK DECK SURFACES, AND INJECTOR TUBES ARE CLEAN AND FREE OF FOREIGN MATTER.

2. INSPECT CYLINDER BLOCK BOLT HOLES AND BLOCK-TO-HEAD GASKET MATING SURFACES FOR OIL, WATER, OR DIRT. CLEAN AS NECESSARY.

1. INSTALL LEFT REAR LIFTER BRACKET (1) AND THREE BOLTS (2). TIGHTEN BOLTS TO 75-93 LB-FT (101-126 N.m).

2. INSTALL NEW CYLINDER HEAD GASKET (3) ON CYLINDER BLOCK (4).

TM page 3-86

Illustration from TM 9-2320-363-34-1 (PDF page 162)

3. INSTALL AIR COMPRESSOR FITTlNG (5) IN CYLINDER HEAD (6).

4. INSTALL TWO ELBOWS (7 AND 8) IN CYLINDER HEAD (6).

5. INSTALL LIFTER (9) BETWEEN FUEL INJECTORS NO. 3 AND NO. 4. INSTALL BOLT (10) USING BOLT HOLE FOR CENTER CAM CAP BOLT. INSTALL TWO BOLTS (11 ) USING TWO TAPPED HOLES FOR ENGINE RETARDER ASSEMBLY.

TM page 3-87

Illustration from TM 9-2320-363-34-1 (PDF page 163)

WARNING Cylinder head weighs 421 lb (191 kq). Use suitable Iifting device to lift and support cylinder head. Failure to do so could result in injury to personnel. Make sure lifting device is securely fastened and weight being lifted does not exceed capacity of lifting device. Failure to do so may cause personal injury. **NOTE** Make sure diamond shaped seal (12) is fully seated in groove.

6. ATTACH SUITABLE LIFTING DEVICE TO LIFTER EYE (13) AND INSTALL CYLINDER HEAD (6).

7. SEAT CYLINDER HEAD (6) ON DIAMOND DOWEL (14) AND ROUND DOWEL (15) UNTIL FULL CONTACT IS MADE WITH CYLINDER HEAD GASKET (3).

TM page 3-88

Illustration from TM 9-2320-363-34-1 (PDF page 164)

8. REMOVE LIFTING DEVICE.

NOTE If cylinder head other than one removed, or if resurfaced cylinder head is being installed, three nuts retaining adjustable idler gear (page 12-99) must be loosened before installing and tightening camshaft drive gear retaining bolt. Notify general support maintenance to perform adjustment.

9. REMOVE THREE BOLTS (10 AND 11) AND LIFTER (9).

10. LUBRICATE THREADS 0F 38 CYLINDER HEAD BOLTS AND BOLT-HEAD CONTACT AREAS WITH SMALL AMOUNT OF INTERNATIONAL COMPOUND NO. 2.

11. INSTALL 38 W ASHERS (16) ON 38 BOLTS (17) AND INSTALL 38 BOLTS (17) IN CYLINDER HEAD (6).

TM page 3-89

Illustration from TM 9-2320-363-34-1 (PDF page 165)

TIGHTEN 38 BOLTS TO 185-210 LB-FT (250-285 N.m) IN SEQUENCE SHOWN. REPEAT TIGHTENING SEQUENCE.

14. INSTALL BRACKET (18) ON CYLINDER HEAD (6) AND INSTALL TWO BOLTS (19). TIGHTEN BOLTS TO 43-54 LB-FT (58-73 N.m).

15. INSTALL BOLT (20) THRU GEAR CASE COVER AND GEAR HOUSING ASSEMBLY (21 ). INSTALL NUT (22). TIGHTEN NUT TO 43-54 LB-FT (58-73 N.m).

TM page 3-90

Illustration from TM 9-2320-363-34-1 (PDF page 166)

16. CONNECT AIR COMPRESSOR HOSE (23) TO CYLINDER HEAD (6).

17. POSITION WIRING HARNESS (24) IN PLACE AND INSTALL TWO WASHERS (25) AND TWO BOLTS (26).

18. POSITION BRACKET (27) IN PLACE AND INSTALL BOLT (28).

TM page Change 1 3-91

Illustration from TM 9-2320-363-34-1 (PDF page 167)

19. CONNECT TWO FUEL LINES (29 AND 30) TO CYLINDER HEAD (6).

NOTE Follow-on Maintenance:

Install camshaft and bearings (page 3-162). Install injector (page 3-108). Install injector wiring harness (page 4-2). Install water level sensor (TM 9-2320-363-20). Install thermostat and thermostat housing cover (TM 9-2320-363-20). Install exhaust manifold (page 3-67 or 3-70.1). Connect air compressor cooling lines (TM 9-2320-363-20). Install air intake manifold (page 3-61 or 3-66.1). Install alternator (TM 9-2320-363-20). Install transmission tunnel access cover (TM 9-2320-363-20).

TM page 3-92

Illustration from TM 9-2320-363-34-1 (PDF page 168)