1.2.5 Installation of Cylinder Head

1.2.5 Installation of Cylinder Head
SERIES 50 SERVICE MANUAL
1.2.5
Installation of Cylinder Head
Perform the following steps for cylinder head installation:
1. Be sure piston domes and the cylinder head and cylinder block firedeck surfaces are clean
and free of foreign matter. Inspect the head bolt holes in both block and head for the
presence of oil, water, dirt, or damaged threads, and clean or retap as necessary.
NOTE:
Series 50 Engines built after September 2002 will use a new cylinder head gasket. This
gasket will be identified with a new part number and date code. This new gasket must
be used with the new cylinder head bolts.
2. Position the head gasket on the block and install cylinder head guide studs, J 35784, at
front and rear of the block. See Figure 1-40.
Figure 1-40
Cylinder Head Guide Studs
3. Lift the head into position with lift bracket, J 35641-A. See Figure 34. Lower it into place
over the guide studs, J 35784, until it seats on the block deck dowels. See Figure 1-40.
4. Remove the guide studs.
5. Install the head bolts with special hardened washers, lubricating the threads and bolt-head
contact areas with a small amount of International Compound #2®, or equivalent.
All information subject to change without notice.
(Rev. 2004)
6SE50 0403 Copyright © 2004 DETROIT DIESEL CORPORATION
From Bulletin 3-50-04
1-53
1.2
CYLINDER HEAD
6. Torque the head bolts to 250-285 N·m (185-210 lb·ft) in the following sequence.
See Figure 1-41. As of September 2002 a new cylinder head bolt is being used for all
Series 50 engines. The new bolt may or may not be identified with white paint. This new
bolt will be identified with a groove on top of bolt. See Figure 1-42. Torque the new head
bolts to 298 N·m (220 lb·ft). There is no change to the procedure other than the new torque
value. The new head bolt can be used with the former cylinder head gaskets, the former
head bolts cannot be used with the new head gasket. Former and new bolts must not be
mixed. Refer to Table 1-1a. for cylinder head torque and reuse information.
Figure 1-41
Cylinder Head Bolt Tightening Sequence
Cylinder Head Gasket
P/N
Cylinder Head Bolt
Torque
Use Bolt Type
Reuse Head Bolt
23522589
250-285 N·m (185-210
lb·ft)
New or Old Style
Yes
23531306
298 N·m (220 lb·ft)
New Style
No
Table 1-1a
Bolt Torque and Reuse Information
1-54
From Bulletin 3-50-04
(Rev. 2004)
All information subject to change without notice.
6SE50 0403 Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 SERVICE MANUAL
NOTICE:
The white paint identification for the new head bolts may or may
not be applied to the bolt head.
Figure 1-42
Bolt Identification For Series 50 Engines Built After September
2002
NOTICE:
Failure to repeat the cylinder head bolt torque tightening
sequence can result in some head bolts may lose their torque
when others are tightened resulting in insufficient clamp load.
All information subject to change without notice.
(Rev. 2004)
6SE50 0403 Copyright © 2004 DETROIT DIESEL CORPORATION
From Bulletin 3-50-04
1-55
1.2
CYLINDER HEAD
7. Repeat the torque sequence to verify all of the head bolts are torqued to specification.
NOTE:
If a cylinder head other than the one removed from the engine, or if a resurfaced cylinder
head is being installed, the three nuts retaining the adjustable idler gear must be
loosened before installing and torquing the camshaft drive gear retaining bolt.
8. Visually inspect each injector hole tube to ensure they are clean. Install the fuel injectors.
Refer to Section 2.3.5. Be sure the injector hold-down crabs are clear of the valve and
injector springs.
NOTICE:
The hemispherical portion of the injector hold-down crab
washers must be installed facing the crab (pointing down) in
order to prevent damage to the washers. See Figure 1-43.
Figure 1-43
Injector Hold-Down Crab Washer Installation
9. Install the clamp bolts with hemispherical washers, torque to 58-66 N·m (43-49 lb·ft).
10. Install the camshaft. Refer to Section 1.22.5.
(Rev. 2004)
1-56
From Bulletin 3-50-04
All information subject to change without notice.
6SE50 0403 Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 SERVICE MANUAL
NOTICE:
The camshaft drive gear-to-adjustable idler gear lash must be
measured/adjusted before the rocker arm shaft assemblies are
installed.
11. Measure/adjust the camshaft drive gear-to-adjustable idler gear lash. Refer to Section 1.24.
12. Install the rocker arm shaft assemblies. Refer to Section 1.3.4.
13. Install Jacob’s Brake assemblies (if equipped). Refer to Section 1.30.5.
14. Feed the injector harness wires through the opening at the rear of the cylinder head.
Secure the harness mounting flange to the cylinder head by torque the bolts to 10-15
N·m (7-11 lb·ft).
15. Connect the injector harness wires to their respective injectors. Refer to Section 2.3.5.
16. Install the gear case stabilizer bracket at the right front corner of the head. Tighten the
stabilizer to gear case bolt first and then the two bolts to the head. Torque the three bolts to
58-73 N·m (43-54 lb·ft).
17. Install the thermostats and seals to the thermostat housing. Refer to Section 4.3.4.
18. Clean the coolant outlet surfaces of the head and thermostat housing.
19. With the thermostats seated in the housing counterbores, install the housing to the cylinder
head, torque the housing bolts to 58-73 N·m (43-54 lb·ft). Connect the radiator and bypass
hose couplings and vent line.
All information subject to change without notice.
(Rev. 2004)
6SE50 0403 Copyright © 2004 DETROIT DIESEL CORPORATION
From Bulletin 3-50-04
1-57
1.2
CYLINDER HEAD
20. Remove all traces of the old gasket from the cylinder head and intake manifold
joint surfaces. Install the intake manifold with new gaskets. Refer to Section 6.3.5.
See Figure 1-44.
Figure 1-44
Intake Manifold Bolt Tightening Sequence
21. Clean the intake manifold and turbocharger joint surfaces and install the turbocharger
with a new gasket. Refer to Section 6.5.7.
22. Fill and vent the cooling system. Refer to Section 13.5.4. Fill the engine lubrication
system. Refer to Section 13.5.1.
23. Connect the exhaust and air-to-air cooler air ducting and install the air cleaner, per
OEM guidelines.
24. Install any other components that were removed and, if required, fill with the proper
fluid, as recommended.
(Rev. 2004)
1-58
From Bulletin 3-50-04
All information subject to change without notice.
6SE50 0403 Copyright © 2004 DETROIT DIESEL CORPORATION
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