Cylinder Head Overhaul

Single Use Fasteners Valve Stem Oil Seal Special Tools EN-8062 Valve Spring Compressor EN-8089 Carbon Removal Brush EN-9666 Valve Spring Tester EN-47909 Injector Bore Brush Kit Equivalent regional tools: Special Tools Removal Procedure Remove the appropriate cylinder head: Cylinder Head Replacement - Left Side Cylinder Head Replacement - Right Side Disassemble Procedure

Cylinder Head Overhaul — figure 1

1. EN-8062 Valve Spring Compressor (1) » Install
2. Valve Stem Key (2) » Remove [8x]
3. Valve Spring Cap (3) » Remove [8x]

Warning

Compressed valve springs have high tension against the valve spring compressor. Valve springs that are not properly compressed by or released from the valve spring compressor can be ejected from the valve spring compressor with intense force. Use care when compressing or releasing the valve spring with the valve spring compressor and when removing or installing the valve stem keys. Failing to use care may cause personal injury.

4. Valve Spring (4) » Remove [8x]
5. Valve Stem Oil Seal (5) » Remove and DISCARD [8x]
6. Intake Valve (6) » Remove [4x]
7. Exhaust Valve (7) » Remove [4x] Cleaning Procedure

Warning

Refer to Safety Glasses Warning.

Note

When cleaning a cylinder head in a thermal type oven, do Not exceed 204°C (400°F). Be careful not to scuff the chamber. Clean the following components: Combustion Chamber Use the EN-8089 Carbon Removal Brush to remove the carbon from the combustion chambers. Fuel Injector Bores Use the EN-47909 Injector Bore Brush Kit to remove the carbon from the fuel injector bores. Gasket surfaces – Remove all gasket and sealing material from the part using J-28410 gasket remover or equivalent. – Care must be used to avoid gouging or scraping the sealing surfaces. – Do not use any other method or technique to remove sealant or gasket material from a part. – Do not use abrasive pads, sand paper, or power tools to clean the gasket surfaces. Valve stems and heads on a buffing wheel Bolt hole threads Remove all dirt, debris, or threadlocking material from the bolt holes. Inspection Procedure

1. Inspect the cylinder head for the following conditions: 1.1. Cracks in the exhaust ports and combustion chambers 1.2. External cracks in the water chambers 1.3. Inspecting the spring seats and rocker arm pivots for damage or gouging 1.4. Gasket surfaces for excessive scratches or gouging 1.5. Bolt hole threads for debris or damaged threads: Thread Repair Thread Repair Specifications

Cylinder Head Overhaul — figure 2

2. Inspect the cylinder head (1) for warpage using a straight edge (2) and feeler gauge (3). Engine Mechanical Specifications

Cylinder Head Overhaul — figure 3

3. Use the EN-9666 Valve Spring Tester (1) to measure the valve spring tension. Engine Mechanical Specifications Assemble Procedure

4. Exhaust Valve (7) » Install [4x]

5. Intake Valve (6) » Install [4x]

6. Lubricate the valve stem and valve guide ID with clean engine oil. Adhesives, Fluids, Lubricants, and Sealers

7. Valve Stem Oil Seal (5) » Install NEW [8x]

8. Valve Spring (4) » Install [8x]

Warning

Compressed valve springs have high tension against the valve spring compressor. Valve springs that are not properly compressed by or released from the valve spring compressor can be ejected from the valve spring compressor with intense force. Use care when compressing or releasing the valve spring with the valve spring compressor and when removing or installing the valve stem keys. Failing to use care may cause personal injury.

6. Valve Spring Cap (3) » Install [8x]
7. EN-8062 Valve Spring Compressor (1) » Install
8. Valve Stem Key (2) » Install [8x] Installation Procedure Install the appropriate cylinder head: Cylinder Head Replacement - Left Side Cylinder Head Replacement - Right Side