6-60-04a

6-60-04a
SERIES 60 SERVICE MANUAL
3. If some of the bolt holes do not clean up completely, continue resurfacing remaining
holes, repeating the operation in. 0.005 in. increments. This will clean up any holes that
may not have cleaned up completely during the first cut.
4. After all counterbores have been resurfaced, remove any loose cutting chips.
5. Steam clean the complete cylinder head.
6. After steam cleaning, inspect the cylinder head for any remaining chips.
7. Reinstall the cylinder head assembly, using 38 of the new ground head bolt washers.
1.2.4
Assembly of Cylinder Head
Perform the following steps for cylinder head assembly:
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 40 psi (276 kPa) air pressure.
NOTICE:
If the cylinder head is to be replaced, the new head must
be thoroughly cleaned before installation to remove all rust
and preventive compound, especially from the fuel and oil
galleries. This can be done by immersion in a bath of fuel oil
or mineral-spirits-based solvent and scrubbing out all openings
with a soft bristle brush. When clean, blow the head dry with
compressed air.
1. Install new precoated pipe plugs or coat the used plugs with pipe sealant with Teflon,
PT-7260, or equivalent. Refer to section ADDITIONAL INFORMATION1.A, "Engine
Plug and Dowel Charts" for specifications.
2. Install all of the required cup plugs using a good grade of non-hardening sealant, such as
Loctite® 620 or equivalent, on the cup plugs. Use cup plug installation tool set, J 35653.
Refer to section ADDITIONAL INFORMATION1.A, "Engine Plug and Dowel Charts"
for specifications.
3. Ensure that all cup and pipe plugs on the front face of the cylinder head are flush or
below the surface.
4. Install valve guides and seats, valves, valve stem seals, valve springs and rotators.
Refer to section 1.4.8 and refer to section 1.4.7.
All information subject to change without notice.
(Rev. 2004)
6SE483 0401 Copyright © 2004 DETROIT DIESEL CORPORATION
From Bulletin 6-60-04
1-57
1.2
CYLINDER HEAD
1.2.5
Installation of Cylinder Head
Perform the following steps for cylinder head installation:
1. Ensure 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, clean or retap as necessary.
NOTE:
Effective with engine serial number 06R0766277 Series 60 engines will use a new
cylinder head gasket. The new gasket will be identified with a new part number and is
a darker shade of gray with a woven appearance. The new gasket must be used with
the new style 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 1-44.
Figure 1-44
Cylinder Head Guide Studs
(Rev. 2004)
1-58
From Bulletin 6-60-04
All information subject to change without notice.
6SE483 0401 Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 60 SERVICE MANUAL
3. Lift the head into position with lift bracket, J 35641. See Figure 1-45. Lower it into place
over the guide studs, J 35784, until it seats on the block deck dowels. See Figure 1-44.
Figure 1-45
Cylinder Head Installation
4. Remove the guide studs.
NOTICE:
If gasket part number 23530421 is being used, the cylinder head
bolts must not be reused. Failure to install new style bolts when
using this gasket may result in improper clamp load, which could
cause gasket failure and severe engine damage.
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.
6. For engines built before September, 2002 torque the head bolts to 250-285 N·m (185-210
lb·ft) in the following sequence. See Figure 1-46.
For engines built after September, 2002 a new style cylinder head bolt will be used for
all Series 60 Off-Highway and On-Highway engine applications. This bolt may or may
not be identified with white paint. The new bolt will be identified with a groove on top
of bolt. See Figure 1-47. 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.
All information subject to change without notice.
(Rev. 2004)
6SE483 0401 Copyright © 2004 DETROIT DIESEL CORPORATION
From Bulletin 6-60-04
1-59
1.2
CYLINDER HEAD
Figure 1-46
Cylinder Head Bolt Tightening Sequence
NOTICE:
The white paint identification for the new head bolts may or may
not be applied to the bolt head.
Figure 1-47
Bolt Identification For Series 60 Engines Built After September
2002
(Rev. 2004)
1-60
From Bulletin 6-60-04
All information subject to change without notice.
6SE483 0401 Copyright © 2004 DETROIT DIESEL CORPORATION
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