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Cylinder Head

002-004 Cylinder Head

General Information
The cylinder head group consists of the cylinder head, valves, valve guides, valve springs, valve seat inserts, crossheads, and spark plug adapter. The exhaust valves are manufactured from a material capable of operating at a higher temperature than the intake valves. In addition to being made from different materials, the intake and exhaust valves are different sizes. Mark, label, or tag the cylinder head parts, such as crossheads, valves, and valve springs with the cylinder number and location from which they were removed. It is also recommended that the intake and exhaust valve position be marked on the combustion face of the cylinder head using a paint pen to facilitate installing the correct parts in the correct locations.

Preparatory Steps WARNING

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Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations.

WARNING
Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50C [120F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury. Drain the cooling system. Refer to Procedure 008-018 in Section 8. Remove any interfering insulation blankets. Remove the rocker covers. Refer to Procedure 003-011 in Section 3. Remove the rocker assemblies. Refer to Procedure 003-009 in Section 3.

Remove
Remove the two capscrews, locking tabs, and insulation tube.

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Remove the push rods.

Remove the push rod protecting tubes (1) by drawing them up through the openings in the cylinder head. Remove the tube o-rings located in the openings in the head.

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Remove the rocker oil supply line (1).

Remove the six capscrews (1) and spacers (2) connecting the multiduct to the cylinder head. NOTE: One capscrew is located at the bottom center of the multiduct between the passages for the intake and exhaust.

Place the jacking sleeves (1) over the cylinder head studs. Check to see that they are seated on the cylinder head being removed. NOTE: Check that the jacking sleeve is not in contact with the adjacent cylinder head. Screw the jacking cylinders (2) onto the cylinder head studs. Tighten the cylinders until they make contact with the top of the jacking sleeve. Back
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off 3/4 turn (270 degrees).

Connect the hydraulic pressure hoses from the pump to the cylinders and back to the gauge as shown in the diagram. NOTE: Some pressure cylinder kits have the pressure gauge attached to the pump instead of a separate gauge. Follow the instructions provided by the manufacturer and purge the cylinders of air.

WARNING
Check that the pistons on the hydraulic jacks are fully retracted. Equipment or personal injury can occur if the piston leaves the cylinder bore while under pressure.

Close the valve on the pump and apply pressure to the jacking cylinders. Pressurize the cylinders to the indicated pressures, depending on the cylinder manufacturer. Pivicat Tool: 760 bar [11,023 psi]
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Hydratite Tool: 900 bar [13,053 psi] Test the cylinder head nuts to check if they can be loosened. If they can not be loosened, raise the pressures to: Pivicat Tool: 870 bar [12,618 psi] Hydratite Tool: 1030 bar [14,939 psi]. NOTE: This is an engineering change. Engines prior to ESN 66300406 were tensioned to the higher pressure. The head studs must be tensioned to the higher pressure to release the head nuts, but must be re-tensioned to the lower tensioning pressure.

Use the service tool pin that comes with the pressure cylinders, and work through the windows in the sleeves to loosen all four head nuts one full turn (360 degrees). NOTE: Do not loosen the nuts more than one full turn. Binding between the nuts and cylinders will occur once the pressure is relieved. Slowly open the valve on the pump and release the hydraulic pressure. Disconnect and remove all hoses, cylinders, and sleeves.

Remove the cylinder head nuts.

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WARNING
This component or assembly weighs greater than 23 kg [50 lb]. To prevent serious personal injury, be sure to have assistance or use appropriate lifting equipment to lift this component or assembly. Attach the cylinder head lifting tool, Part Number 3164694, to the cylinder head at the rocker lever mounting holes. Attach a lifting device to the eye bolt closest to the multiduct. Lift the head carefully from the block.

Remove the copper head gasket (1) and water jacket grommet (2).

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Cover the liner to prevent dirt and debris from falling into the cylinder.

Remove the old multiduct gasket and rivets.

Disassemble
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head into a tank of water. Adjust the air pressure to 710 kPa [100 psi]. Look for air bubbles which indicate a leak. If the cylinder head is leaking, it must be repaired or replaced.

Install
Use the M30 Stud Extractor (1), Part Number 3164396, to check and tighten the cylinder head studs. NOTE: If the stud had been removed, install it dry and torque to specifications. Apply Loctite 5699 Ultra to the large gap at the base of the stud to seal the stud to the block. Install a new o-ring and push it into the gap filled with the Loctite. Remove any excess sealant. Torque Value: 100 n.m [74 ft-lb]

Install a new multiduct gasket. Install new rivets to secure the gasket in
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place.

Install a new copper head gasket (1) and water grommet (2).

WARNING
This component or assembly weighs greater than 23 kg [50 lb]. To prevent serious personal injury, be sure to have assistance or use appropriate lifting equipment to lift this component or assembly. NOTE: Before installing the cylinder head, check for dirt or foreign objects in the cylinder and the intake and exhaust ports.
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Install the cylinder head lifting tool, Part Number 3164694. Lower the cylinder head into position. Check all gaskets as the head is lowered to make certain they remain in place and are aligned.

Use a lint-free cloth to clean the threads of the cylinder head studs and the base of the nuts. Install the cylinder head nuts.

Lubricate the multiduct to cylinder head capscrews (1) with anti-seize compound. Install the capscrews (1) and spacers (2). Hand tighten the capscrews.

Place the jacking sleeve over the cylinder head studs so they are seated against the face of the head.
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NOTE: Make certain the base of the sleeve does not contact the adjacent cylinder head. Screw the hydraulic cylinders onto the cylinder head studs until they touch the sleeves. Back the cylinders off 1/4 turn (90 degrees).

WARNING
Check that the pistons on the hydraulic jacks are fully retracted into the cylinders. Equipment or personal injury can occur if the piston leaves the cylinder bore while under pressure.

Connect the hydraulic pressure hoses from the pump to the cylinders and back to the gauge as shown in the diagram. NOTE: Some pressure cylinder kits have the pressure gauge attached to the pump instead of a separate gauge. Follow the instructions provided by the manufacturer and purge the cylinders of air.

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Close the valve on the pump and apply pressure to the jacking cylinders. Pressurize the cylinders to the indicated pressures, depending on the cylinder manufacturer. First stage tightening: Pivicat tool: 505 bar [7324 psi]. Hydratite tool: 600 bar [8702 psi].

Use the service tool pin that comes with the pressure cylinders. Work through the windows in the sleeves to tighten the head nuts until snug. Slowly open the valve on the pump and release the hydraulic pressure.

Screw the hydraulic cylinders down until they contact the sleeves, then back them off 1/4 turn (90 degrees).

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Close the valve on the pump and apply pressure to the jacking cylinders. Pressurize the cylinders to the indicated pressures, depending on the cylinder manufacturer. Second stage tightening: Pivicat tool: 760 bar [11,023 psi] Hydratite tool: 900 bar [13,053 psi].

Use the service tool pin, and work through the windows in the sleeves to tighten the head nuts until snug. Slowly open the valve on the pump and release the hydraulic pressure.

Disconnect and remove all hoses, hydraulic cylinders, and jacking sleeves. Repeat this procedure on the remaining cylinder heads being installed.

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Tighten the multiduct to cylinder head capscrews (1). Torque Value: 64 n.m [47 ft-lb] Repeat this procedure on the remaining cylinder heads being installed.

Install the insulation tube, locking tabs, and capscrews. Tighten the capscrews evenly to avoid misalignment. Torque Value: 1. 8 n.m [71 in-lb] 2. 22 n.m [195 in-lb]

Install the rocker assembly oil supply line (1). Repeat this procedure on the remaining cylinder heads being installed.

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Install a new o-ring in the cylinder head and cam follower assembly for the push rod protective tubes. Use clean engine oil to lubricate the o-rings and install the push rod protective tubes.

Install the push rods.

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Finishing Steps
Install the rocker lever assembly. Refer to Procedure 003-009 in Section 3. Adjust the overhead. Refer to Procedure 003-004 in Section 3. Install the rocker covers. Refer to Procedure 003-011 in Section 3. Fill the cooling system. Refer to Procedure 008-018 in Section 8. Install any insulation blankets that were removed for repairs. Operate the engine, check for leaks.

Last Modified: 06-Jun-2013

Copyright 2000-2010 Cummins Inc. All rights reserved.

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