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5 05-12
SUBJECT
DATE
Cylinder Head
May 2012
Additions, Revisions, or Updates
Publication Number / Title
Platform
Section Title
DDC-SVC-MAN-0023
EPA04 MBE
4000
Cylinder Head
DDC-SVC-MAN-0026
EPA07 MBE
4000
Additional Information
Cylinder Head
Changed the warpage spec to 0.1mm (0.004 in.)
Additional Engine
Information
All information subject to change without notice.
5 05-12
Change
Copyright © 2012 DETROIT DIESEL CORPORATION
3
The following applies to DDC-SVC-MAN-0023:
CYLINDER HEAD
The MBE 4000 engine has individual heads for each cylinder. To remove one head, follow these
instructions, step by step. To remove all the heads, repeat each step in these instructions, as applicable,
for all six cylinders.
CYLINDER HEAD REMOVAL
Remove the cylinder head as follows: See Figure 1 for an exploded view of a cylinder head.
1. High-Pressure Fuel Line
6. Coolant Line
11. Cylinder Head Gasket
2. Pushrod
7. Cylinder Head Bolt
12. Exhaust Manifold
3. Cylinder Head
8. Constant-Throttle Line
13. Exhaust Manifold Mounting Bolt
4. Seal Ring
9. Spacer
14. Guide Pin
5. Hollow Core (Banjo) Bolt
Figure 1
10. Exhaust Port Gasket
Exploded View of Cylinder Head
HOT COOLANT
To avoid scalding from the expulsion of hot coolant, never
remove the cooling system pressure cap while the engine is
at operating temperature. Wear adequate protective clothing
(face shield, rubber gloves, apron, and boots). Remove the
cap slowly to relieve pressure.
1. Drain the coolant from the radiator.
NOTE:
Clean the cylinder head cover before removing it.
2. Remove the cylinder head cover. Refer to section .
3. Remove the rocker arm assembly. Mark the valve bridges and pushrods in order of removal.
Refer to section .
4. Remove the engine trim covers to gain access to the high-pressure fuel lines.
5. Remove the charge-air intake manifold.
PERSONAL INJURY
To prevent the escape of high pressure fuel that can penetrate
skin, ensure the engine has been shut down for a minimum of
10 minutes before servicing any component within the high
pressure circuit. Residual high fuel pressure may be present
within the circuit.
NOTICE:
Do not move the thrust bolt (3) during the removal of the
high-pressure fuel line, because there is danger of causing a
change in the position of the transfer-tube. If the position of the
transfer-tube is changed, engine damage could result.
6. Using two wrenches, loosen the high-pressure fuel line (2) at the transfer-tube fitting (4). See
Figure 2.
1. Pump-End Fitting
3. Thrust Bolt
2. High-Pressure Injector Line
4. Transfer-Tube Fitting
Figure 2
High-Pressure Fuel Line Fittings
[a]
Using a paint pen, mark the location of the thrust bolt.
[b]
Place one wrench on the thrust bolt to secure the transfer-tube. Place the other wrench
on the high-pressure line fitting.
[c]
Turn the wrench on the high-pressure line fitting while holding the other wrench on the
thrust bolt.
7. Remove the high-pressure fuel line from the transfer-tube and unit pump.
8. To prevent any dirt from entering, cover the openings in the unit pump and the transfer-tube.
9. Remove the exhaust manifold bolts.
NOTE:
If removing one or two cylinder heads, loosen the bolts on the rest of the exhaust manifold.
10. Pull the exhaust manifold away from the engine, towards the frame rail. Remove all the gaskets.
NOTE:
If removing all cylinder heads, remove the exhaust manifold from the engine.
11. Remove the fuel return line from the cylinder head. Discard the seal rings. See Figure 3.
12. Disconnect the constant-throttle line from the cylinder head. Discard the seal rings. See
Figure 1.
13. Disconnect the coolant line from the cylinder head. See Figure 3.
14. Using the head bolt impact socket (J-45389), loosen the cylinder head bolts. When all the bolts
are loose, remove the bolts from the cylinder head. See Figure 3.
1. Fuel Return Line Connection
Figure 3
2. Coolant Line connection
Loosening the Head Bolts
NOTICE:
Do not place the head mating surface down on a flat surface. This
would damage the injector nozzles, which protrude slightly.
15. Remove the cylinder head and set it on wooden blocks or on its side.
16. Remove the head gasket.
17. Thoroughly clean the cylinder head, both contact surfaces (head and block), and surfaces inside
the cylinder of excess oil, grime, and paint chips.
18. With a straightedge, check the cylinder head surface for warpage. Refer to section . Listed in
Table 1 are warpage limits.
Description
Limit: mm (in.)
Over a length of 150 mm (6 in.)
Table 1
0.1 mm (0.004)
Head Warpage Limits
19. Check the cylinder liner protrusion from the cylinder block. Listed in Table 2 are the
specifications. Refer to section .
Description
Value: mm (in.)
Cylinder Liner Protrusion from block
0.230-0.330 mm (0.0090-0.0130 in.)
Difference between the four measuring points
Max.: 0.02 mm (0.0007 in.)
Table 2
Specifications for Measuring Cylinder Liner Protrusion
20. Inspect the cylinder head for cracks or signs of damage. Replace if necessary.
CYLINDER HEAD INSPECTION AND MACHINING
Inspection
1. Remove the cylinder head.
2. Remove the nozzle holder.
3. Remove the intake and exhaust valves. Refer to section .
4. Remove the constant-throttle valve. Refer to section .
5. Inspect the contact surface (bottom face or fire deck) of the cylinder head for warpage, both
lengthwise and diagonally. See Figure 4. If the gap is larger than 0.1 mm (0.004 in.), machine
the cylinder head.
1. Contact Surface (Fire Deck)
Figure 4
[a]
2. Straightedge
Measuring Cylinder Head Warpage
Place a straightedge lengthwise across the cylinder head contact surface (fire deck).
[b]
If there is a gap between the lower edge of the straightedge and the contact surface of the
cylinder head that is large enough to let light through, insert a feeler gauge into the gap.
[c]
Measure the amount of warpage with the feeler gauge and compare it to the value listed in
Table 3. If the gap is larger than 0.1 mm (0.004 in.), machine the cylinder head.
What To Measure
How To Measure
Specification: mm (in.)
Maximum Permissible Warpage of
Head Mating Surface
Lengthwise and Diagonally
0.1 (0.004)
Maximum Permissible Parallelism
Deviation of Head Mating Surface
At Each of the Four Corners
0.1 (0.004)
When New
113.85-114.15 (4.482-4.494)
After Machining
113.5 (4.46)
Overall Height of Cylinder Head
Table 3
[d]
Cylinder Head Specifications
Place the straightedge diagonally across the cylinder head. Repeat the procedure above.
6. Check the cylinder head contact surface for parallelism, at each corner. See Figure 5. If the four
measurements deviate by more than 0.1 mm (0.004 in.), machine the cylinder head.
Figure 5
[a]
Measuring Cylinder Head Parallelism
Rest the cylinder head on a flat surface, with the contact surface exposed (bottom face up).
NOTE:
Make sure the head is level before going on with this check.
[b]
Install a dial gauge so that the feeler touches the contact surface with some preload.
[c]
Fasten the dial gauge and adjust the scale to "0" (zero).
[d]
Check the reading on the dial gauge. If the reading is larger than 0.1 mm (0.004 in.),
machine the cylinder head.
[e]
Repeat this procedure at each spot marked by an arrow (each corner of the cylinder head).
7. Measure the overall height of the cylinder head. See Figure 6. Replace the head if below the
minimum height. If above the maximum height, machine the head down to the maximum
height listed in Table 3.
1. Cylinder Head
Figure 6
2. Exhaust Valve
3. Intake Valve
Measuring Cylinder Head Height
MACHINING
1. Machine the contact surface of the cylinder head, to correct any problems found during
inspection.
[a]
If rejected for warpage, check warpage again until it is within specifications.
[b]
If rejected for lack of parallelism, check parallelism again until it is within specifications.
2. After machining, check again the overall height of the cylinder head.
3. Install the constant-throttle valve. Refer to section .
4. Install the intake and exhaust valves. Refer to section .
5. Install the nozzle holder.
6. Install the cylinder head. Refer to section .
CYLINDER HEAD LEAK TESTING
Perform the following steps to conduct a cylinder head leak test to see if the cylinder head is leaking
coolant.
1. Remove the exhaust brake compressed-air line from the exhaust brake cylinder.
2. Remove the v-band clamp connecting the exhaust pipe to the brake valve housing.
3. Remove the turbocharger.
4. Remove the exhaust manifold.
5. Remove the cylinder head. Refer to section .
1. Test Plugs
5. Coolant line Hole
2. Safety Retaining Washer
6. Sealing Washer
3. Cup Plugs
7. Air Test Plug Adaptor
4. Fire Deck
8. Protective Sleeve
Figure 7
Cylinder Head Lead Test Kit J-45982–8 Installation
6. Remove the fuel injector nozzle from the cylinder head.
7. Using the Head Leak Test Kit (J-45982) part of Head and Block Leak Test Kit (J-45982),
install two plugs into the appropriate holes on firedeck of cylinder head. Tighten the nuts
to expand the plugs. See Figure 7.
8. Install the air test plug adaptor into the coolant line hole on the top of the cylinder head. See
Figure 7.
9. Place the safety retaining washer over the test plug adaptor. See Figure 7.
10. With the shutoff valve on the regulator in the off position, set the regulator to zero pressure by
pulling up on the adjusting knob and turning counter-clockwise.
EYE INJURY
To avoid injury from flying debris when using compressed air,
wear adequate eye protection (face shield or safety goggles)
and do not exceed 276 kPa (40 psi) air pressure.
11. Connect a shop air supply to the pressure regulator (J-45982–7 part of kit (J-45982) then turn
the shutoff valve to the ON position.
12. Adjust the system pressure by pulling up on the adjusting knob and turn clockwise until a
pressure reading on the gauge is 200 kPa (29 psi).
13. Connect the Regulator and Gauge (J-45982–7 part of kit J–45982) to the air test plug on the
cylinder head. See Figure 7.
14. Check for leaks around the test plugs and fittings with a soapy water solution. Repair any
leaks found.
15. With a soapy water solution, check the cup plugs on the sides of the cylinder head and the
injector nozzle protective sleeve area.
[a]
If the cup plug(s) are leaking, replace the plug(s).
[b]
If the injector protective sleeve is leaking, replace the protective sleeve O-ring.
16. Close the air supply and watch the pressure gauge for 30 seconds. If the air pressure drops
during this time the cylinder head has leakage from the cooling passages and is not suitable
for reuse.
17. Remove the test equipment from the cylinder head and repeat leak test for any additional
cylinder heads.
18. Install the fuel injector nozzle in the cylinder head.
19. Install the cylinder head. Refer to section .
20. Install the exhaust manifold.
21. Install the turbocharger.
22. Install the compressed-air line on the exhaust brake cylinder.
23. Clean the sealing surfaces on the exhaust pipe and brake valve housing.
24. Slide the exhaust pipe and clamp over the end of the housing. Tighten the clamp.
SPECIFICATIONS
This section contains the specifications for servicing the engine.
CYLINDER HEAD COVER
The torque specifications for the cylinder head cover are listed in Table 4.
Table 4
Description
Torque Value: N·m (lb·ft)
Cylinder Head Cover Bolts
20 (15 )
Cylinder Head Cover Torque Values
CYLINDER HEAD
The cylinder head warpage limits are listed in Table 5. The specifications for measuring cylinder liner
protrusion are listed in Table 6. Cylinder head bolt length is listed in Table 7. The tightening stages for
cylinder head bolts are listed in Table 8. Oil pressure readings are listed in Table 9. Cylinder head torque
values are listed in Table 10. Cylinder head specifications are listed in Table 11. The specifications for
compression testing are listed in Table 12 and listed in Table 13.
Description
Limit: mm (in.)
Over a length of 150 mm (6 in.)
Table 5
0.1 (0.004)
Head Warpage Limits
Description
Value: mm (in.)
Cylinder Liner Protrusion from block
0.2305-0.330 (0.0090-0.0130)
Difference between the four measuring points
Max.: 0.02 (0.0007)
Table 6
Specifications for Measuring Cylinder Liner Protrusion
Description
Table 7
Length: mm (in.)
Shaft length when new
210.0 (8.27)
Maximum shaft length
212.0 (8.35)
Cylinder Head Bolt Lengths
Size
Max. Shaft Length: mm
(in.)
M15 x 2
Table 8
Stage 1
10 (7)
Stage 2
50 (37)
Stage 3
100 (74)
Stage 4
200 (148)
Stage 5
additional 90°
Stage 6
additional 90°
Tightening Stages, Cylinder Head Bolts
Minimum Oil Pressure Reading: kPa (psi)
Engine at Idle Speed
50 (7)
Engine at Max. rpm
250 (36)
Oil Pressure Readings
Description
Table 10
Torque Value: N·m (lb·ft)
212.0 (8.35)
Description
Table 9
Tightening Stage
Torque Value: N·m (lb·ft)
Exhaust Manifold Bolts
50 N·m (37 lb·ft); then another 90°
High-Pressure Fuel Lines
25 N·m (18 lb·ft)
Inspection Cover on Flywheel Housing
25 N·m (18 lb·ft)
Rocker Arm Mounting Bolts
60 N·m (44 lb·ft); then another 90°
Cylinder Head Torque Values
What To Measure
How To Measure
Specification: mm (in.)
Maximum Permissible Warpage of
Head Mating Surface
Lengthwise and Diagonally
0.1 (0.004)
Maximum Permissible Parallelism
Deviation of Head Mating Surface
At Each of the Four Corners
0.1 (0.004)
When New
113.85-114.15 (4.482-4.494)
After Machining
113.5 (4.46)
Overall Height of Cylinder Head
Table 11
Cylinder Head Specifications
Description
Pressure: kPa (psi)
Minimum Compression Pressure Valve
2800 (406)
Permissible Difference Between Individual Cylinders
400 (58)
Table 12
Compression Pressure Test Data
Description
Torque Value: N·m (lb·ft)
Tensioning Arm Bolts
Table 13
50 (37)
Tensioning Arm Bolt Torque Values
CYLINDER BLOCK
The cylinder liner installation tolerances are listed in Table 14. The cylinder liner inspection tolerances
are listed in Table 15. Cylinder Liner measurements are listed in Table 16. The specifications for
measuring cylinder liner protrusion are listed in Table 17.
Description
Specification: mm (in.)
Cylinder Liner Protrusion, From Block, , Ref. A.
0.230–0.330 (0.0090–0.0130)
Height of the Cylinder Liner Collar, , Ref. B.
10.10–10.12 (0.3976–0.3984)
Depth of the Collar Seat, , Ref. C.
9.950–10.010 (0.392–0.3941)
Thickness of the Seat Insert
0.14–0.16 (0.0055–0.0063)
Table 14
Cylinder Liner Installation Tolerances
Description
Specification: mm (in.)
Admissible Out-of-Round of the Cylinder Liner, where
it contacts the O-rings
Max.: 0.02 (0.0007)
Admissible Deformation of the Cylinder Liner Collar, at
the Contact Surface with the Seat Insert
Max.: 0.02 (0.0007)
Admissible Deformation of the Liner Collar Seat, at the
Contact Surface with the Seat Insert
Max.: 0.03 (0.0011)
Table 15
Cylinder Liner Inspection Tolerances
Where To Measure
What To Measure
Specification: mm (in.)
Measuring Point 1: at the O-ring area
Inside Diameter of the Cylinder
Liner, A class
127.990–127.995 (5.0390–5.0392)
Measuring Point 1: at the O-ring area
Inside Diameter of the Cylinder
Liner, B class
127.995–128.005 (5.0392–5.0396)
Measuring Point 1: at the O-ring area
Inside Diameter of the Cylinder
Liner, C class
128.005–128.010 (5.0396–5.0398)
Measuring Point 2: Upper Reversal
Point of the First Piston Ring
Max. Wear to Cylinder Liner, Measured
Along Axis A and Axis B
0.08 (0.003)
At Measuring Point 2, Compare
Axis A to Axis B
Admissible Wear-Out
Max.: 0.08 (0.003)
Table 16
Cylinder Liner Measurements
Description
Specification: mm (in.)
Cylinder Liner Protrusion From Block
0.245–0.315 (0.0096–0.0124)
Difference Between the Four Measuring Points
Max.: 0.02 (0.0007)
Table 17
Specifications for Measuring Cylinder Liner Protrusion
The following applies to DDC-SVC-MAN-0026:
2 Description and Operation of the Cylinder Head
2
Description and Operation of the Cylinder Head
The MBE 4000 engine has individual heads for each cylinder. To remove one head, follow these instructions, step by step. To
remove all the heads, repeat each step in these instructions, as applicable, for all six cylinders.
1.
2.
3.
4.
5.
6.
7.
Pushrod
Cylinder Head
Seal Ring
Hollow Core (Banjo) Bolt
Coolant Line
Cylinder Head Bolt
Constant-Throttle Line
8.
9.
10.
11.
12.
13.
Spacer
Exhaust Port Gasket
Cylinder Head Gasket
Exhaust Manifold Mounting Bolt
Exhaust Manifold
Guide Pin
Figure 1. Exploded View of Cylinder Head
4
All information subject to change without notice.
Copyright © 2012 DETROIT DIESEL CORPORATION
5 05-12
5 05-12
3
Removal of the Cylinder Head
Removal steps are as follows:
WARNING: HOT COOLANT
To avoid scalding from the expulsion of hot coolant, never remove the cooling system pressure cap
while the engine is at operating temperature. Wear adequate protective clothing (face shield, rubber
gloves, apron, and boots). Remove the cap slowly to relieve pressure.
1. Drain the coolant from the radiator. Refer to section "Draining and Flushing the Cooling System" .
1.
2.
3.
4.
5.
6.
7.
Pushrod
Cylinder Head
Seal Ring
Hollow Core (Banjo) Bolt
Coolant Line
Cylinder Head Bolt
Constant-Throttle Line
8.
9.
10.
11.
12.
13.
Spacer
Exhaust Port Gasket
Cylinder Head Gasket
Exhaust Manifold
Exhaust Manifold Mounting Bolt
Guide Pin
Figure 2. Exploded View of Cylinder Head
NOTE: Clean the cylinder head cover before removing it.
2. Remove the trim cover frame. Refer to section "Removal of the Engine Trim Covers Frame" .
3. Remove the rocker arm assembly. Mark the valve bridges and pushrods in order of removal. Refer to section "Removal
of the Rocker Arm Assembly" .
4. Remove the EGR cooler support bracket. Refer to section "Removal of the Exhaust Gas Recirculation Cooler Support
Bracket" .
5. Remove the air intake manifold. Refer to section "Removal of the Air Intake Manifold" .
All information subject to change without notice.
5 05-12
Copyright © 2012 DETROIT DIESEL CORPORATION
5
3 Removal of the Cylinder Head
WARNING: PERSONAL INJURY
To prevent the escape of high pressure fuel that can penetrate skin, ensure the engine has been shut
down for a minimum of 10 minutes before servicing any component within the high pressure circuit.
Residual high fuel pressure may be present within the circuit.
NOTICE: Do not move the thrust bolt, because there is danger of causing a change in the position of the transfertube. If the position of the transfer-tube is changed, engine damage could result.
6. Remove the high-pressure fuel line and transfer tube. Refer to section "Removal of the High Pressure Fuel Line and
Transfer Tube" .
7. To prevent any dirt from entering, cover the openings in the unit.
NOTE: If removing one or two cylinder heads, loosen the bolts on the rest of the exhaust manifold.
8. Remove the turbocharger from the exhaust manifold. Refer to section "Removal of the Turbocharger" .
NOTE: If removing all cylinder heads, remove the exhaust manifold from the engine.
9.
10.
11.
12.
Remove the fuel return line from the cylinder head. Discard the seal rings.
Disconnect the constant throttle line from the cylinder head. Discard the seal rings.
Disconnect the coolant line from the cylinder head.
Using the head bolt impact socket (J–45389), loosen the cylinder head bolts. When all the bolts are loose, remove the
bolts from the cylinder head.
1. Fuel Return Line Connection
2. Coolant Line Connection
Figure 3. Cylinder Head Bolts
NOTICE: Do not place the head mating surface down on a flat surface. This would damage the fuel injector nozzles,
which protrude slightly.
13. Remove the cylinder head and set it on wooden blocks or on its side.
14. Remove the head gasket from the block and discard gasket.
15. Thoroughly clean the cylinder head, both contact surfaces (head and block), and surfaces inside the cylinder of excess oil,
grime, and paint chips.
6
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5 05-12
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16. With a straightedge, check the cylinder head surface for warpage. Refer to section "Inspection of the Cylinder Head" .
Table 1.
Head Warpage Limits
Description
Limit mm (in.)
Over a length of 150 mm (6 in.)
0.1 (0.004)
17. Check the cylinder liner protrusion from the cylinder block. Refer to section "Measurement of the Cylinder Liner
Protrusion" .
Table 2.
Specifications for Measuring Cylinder Liner Protrusion
Description
Specifications mm (in.)
Cylinder Liner Protrusion from block
0.230 to 0.330 (0.0090 to 0.0130)
Difference between the four measuring points
Max.: 0.02 (0.0008)
18. Inspect the cylinder head for cracks or signs of damage. Replace if necessary.
All information subject to change without notice.
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4 Inspection of the Cylinder Head
4
Inspection of the Cylinder Head
Inspection steps are as follows:
1. Remove the cylinder head. Refer to section "Removal of the Cylinder Head" .
2. Remove the fuel injector. Refer to section "Removal of the Fuel Injector" .
3. Remove the intake and exhaust valves. Refer to section "Removal of the Valve" .
4. Remove the constant throttle valve. Refer to section "Removal of the Constant-Throttle Valve" .
5. Inspect the contact surface (bottom face or fire deck) of the cylinder head for warpage, both lengthwise and diagonally.
If the gap is larger than 0.1 mm (0.004 in.), machine the cylinder head.
1. Contact Surface (Fire Deck)
2. Straightedge
Figure 4. Measuring Cylinder Head Warpage
a. Place a straightedge lengthwise across the cylinder head contact surface (fire deck).
b. If there is a gap between the lower edge of the straightedge and the contact surface of the cylinder head that is large
enough to let light through, insert a feeler gauge into the gap.
c. Measure the amount of warpage with the feeler gauge and compare it to the value listed in the Table "Cylinder Head
Specifications." If the gap is larger than 0.1 mm (0.004 in.), machine the cylinder head.
8
All information subject to change without notice.
Copyright © 2012 DETROIT DIESEL CORPORATION
5 05-12
5 05-12
Table 3.
Cylinder Head Specifications
What To Measure
How To Measure
Specifications mm (in.)
Maximum Permissible Warpage of Head
Mating Surface
Lengthwise and Diagonally
0.1 (0.004)
Maximum Permissible Parallelism
Deviation of Head Mating Surface
At Each of the Four Corners
0.1 (0.004)
Overall Height of Cylinder Head
When New
113.85 to 114.15 (4.482 to 4.494)
After Machining (Minimum Height)
113.5 (4.47)
d. Place the straightedge diagonally across the cylinder head. Repeat the procedure above.
6. Check the cylinder head contact surface for parallelism, at each corner. If the four measurements deviate by more than
0.1 mm (0.004 in.), machine the cylinder head.
Figure 5. Measuring Cylinder Head Parallelism
a. Rest the cylinder head on a flat surface, with the contact surface exposed (bottom face up).
NOTE: Make sure the head is level before going on with this check.
b. Install a dial gauge so that the feeler touches the contact surface with some preload.
c. Fasten the dial gauge and adjust the scale to "0" (zero).
d. Check the reading on the dial gauge. If the reading is larger than 0.1 mm (0.004 in.), machine the cylinder head.
e. Repeat this procedure at each spot marked by an arrow (each corner of the cylinder head).
7. Measure the overall height of the cylinder head. Replace the head if below the minimum height. If above the maximum
height, machine the head down to the maximum height the listed in the Table "Cylinder Head Specifications."
All information subject to change without notice.
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Copyright © 2012 DETROIT DIESEL CORPORATION
9
4 Inspection of the Cylinder Head
1. Cylinder Head
2. Exhaust Valve
3. Intake Valve
Figure 6. Measuring Cylinder Head Height
10
All information subject to change without notice.
Copyright © 2012 DETROIT DIESEL CORPORATION
5 05-12
5 05-12
5
Additional Engine Information - Cylinder Head Cover
The torque specifications for the cylinder head cover are listed in the table below.
Table 4.
Cylinder Head Cover Torque Values
Description
Torque N·m (lb·ft)
Cylinder Head Cover Studs
20 to 25 (15 to 18)
Cylinder Head Cover Cap Nuts
18 to 20 (13 to 15)
All information subject to change without notice.
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11
6 Additional Engine Information - Cylinder Head
6
Additional Engine Information - Cylinder Head
The cylinder head warpage limits are listed below.
Table 5.
Head Warpage Limits
Description mm (in.)
Limit mm (in.)
Over a length of 150 (6)
0.1 (0.004)
The specifications for measuring cylinder liner protrusion are listed below.
Table 6.
Specifications for Measuring Cylinder Liner Protrusion
Description
Value: mm (in.)
Cylinder Liner Protrusion from block
0.2305 to 0.330 (0.0090 to 0.0130)
Difference between the four measuring points
Max.: 0.02 (0.0008)
The specifications for measuring cylinder head bolt lengths are listed below.
Table 7.
Cylinder Head Bolt Lengths
Description
Length mm (in.)
Shaft length when new
210.0 (8.27)
Maximum shaft length
212.0 (8.35)
The specifications for the tightening stages for cylinder head bolts are listed below.
12
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Table 8.
Tightening Stages, Cylinder Head Bolts
Size
Max. Shaft Length mm (in.)
Tightening Stage
Torque N·m (lb·ft) (Repair work in
the field)
M15 x 2
212.0 (8.35)
Stage 1
10 (7)
Stage 2
50 (37)
Stage 3
100 (74)
Stage 4
200 (148)
Stage 5
90° more
Stage 6
90° more
The specifications for oil pressure readings are listed below.
Table 9.
Oil Pressure Readings
Description
Minimum Oil Pressure Reading kPa (psi)
Engine at Idle Speed
50 (7)
Engine at Max. rpm
250 (36)
Cylinder head torque values are listed below.
Table 10.
Cylinder Head Torque Values
Description
Torque N·m (lb·ft)
Exhaust Manifold Bolts
50 (37); then another 90°
Inspection Cover on Flywheel Housing
25 (18)
Rocker Arm Mounting Bolts
60 (44); then another 90°
The specifications for cylinder heads are listed below.
All information subject to change without notice.
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13
6 Additional Engine Information - Cylinder Head
Table 11.
Cylinder Head Specifications
What To Measure
How To Measure
mm (in.)
Maximum Permissible Warpage of Head
Mating Surface
Lengthwise and Diagonally
0.1 (0.004)
Maximum Permissible Parallelism Deviation of At Each of the Four Corners
Head Mating Surface
0.1 (0.004)
Overall Height of Cylinder Head
When New
113.85 to 114.15 (4.482 to 4.494)
After Machining
113.5 (4.47)
The specifications for compression testing are listed below.
Table 12.
Compression Pressure Test Data
Description
Pressure kPa (psi)
Minimum Compression Pressure Valve
2800 (406)
Permissible Difference Between Individual Cylinders
400 (58)
The specifications for compression testing are listed in below.
Table 13.
Tensioning Arm Bolt Torque Values
Description
N·m (lb·ft)
Tensioning Arm Bolts
50 (37)
14
All information subject to change without notice.
Copyright © 2012 DETROIT DIESEL CORPORATION
5 05-12
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