Usage:
preparatory steps:
a) remove right front and right rear camshaft housings (for right front cylinder head)
b) remove left front and right rear camshaft housings (for left front cylinder head)
c) remove oil filter housing
d) remove water cooled exhaust manifold
1. Remove the tachometer cable (2).
2. Disconnect the water temperature sending unit. Remove the aftercooler housing water outlet line (1). Disconnect the oil pressure gauge line from the oil block on left side aftercooler housing.
3. Disconnect the turbocharger heat shield water line.
4. For left side only, remove the gauge panel mounting bolts and lay the gauge panel (3) aside.
5. Remove the bolts (5) that connect the inlet water line to the water temperature regulator housing. Remove the exhaust manifold water outlet line (from side not being removed).
6. Connect a hoist and remove the water temperature regulator housing mounting bolts (4). Remove the housing-weight 140 lbs. (64 kg).
7. Remove the air equalizer line (6). Remove the aftercooler water inlet line (9). Remove the turbocharger heat shield retaining bracket from the aftercooler housing.
8. Remove the heat shield water lines (8). Disconnect the governor linkage and remove the governor control channel (10). Loosen the bolts retaining the elbow (7) to turbocharger.
9. Remove bolts that retain the aftercooler housing to the cylinder heads.
| NOTICE |
|---|
Two of the aftercooler housing retaining bolts in rear can be left loose, to stabilize housing or raise housing enough for removal of cylinder head. Do not drop any foreign objects in cylinder head. Damage to the engine can result. |
10. Remove the water ferrule that connects the heads together.
11. Remove the two camshaft housing retaining studs (12) and dowel (11), (left side only).
12. Remove cylinder head retaining bolts and washers. Connect a hoist and remove the cylinder head assembly-weight 300 lbs. (136 kg).
NOTE: Always replace the gasket between spacer plate and cylinder block before reinstalling cylinder head assembly. See REMOVE SPACER PLATES.
Install Right Front Or Left Front Cylinder Head Assembly (Alternate Method, with Limited Overhead Clearance)
1. Clean the top surface of spacer plate and mating surface of cylinder head. Install new head gasket and seals (1).
NOTE: Be sure the gasket between spacer plate and cylinder block has been replaced before installing cylinder head. Refer to REMOVE AND INSTALL SPACER PLATES.
2. Connect a hoist and position the cylinder head on engine. Put 9S3264 Sealant Compound on threads of camshaft housing retaining studs. Install the camshaft housing retaining studs and dowel, (left side only). Tighten the studs to 20 ± 3 lb.ft. (2.77 ± .42 mkg).
3. Coat the threads of the cylinder head bolts with 9M3710 Anti-Seize Compound. Install the head bolts and washers. Tighten the bolts in following Step sequence:
1 Tighten all bolts in numerical order to 175 lb.ft. (24.2 mkg).
2 Retighten all bolts in numerical order to 250 lb.ft. (34.6 mkg).
3 Finally, retighten all bolts by hand in numerical order to 250 lb.ft. (34.6 mkg).
4 Again tighten bolt (9) between the two heads to 250 ± 10 lb.ft. (34.6 ± 1.38 mkg).
4. Install the water ferrule, seal and clamp that connects the two heads together. Tighten the bolt in the clamp for the water ferrule and seal to 30 ± 5 lb.in. (34.56 ± 5.76 cm.kg).
| NOTICE |
|---|
Do not tighten the bolt more than the specification. If the bolt is tightened more, the seal will be damaged. |
5. Inspect the gaskets between the aftercooler housing and the cylinder heads.
| NOTICE |
|---|
If the gaskets were damaged during removal, new gaskets will have to be installed. Do not let any foreign material fall in the cylinder head. Damage to the engine can result. |
6. Install the bolts that hold the aftercooler housing to the heads. Install the aftercooler water inlet line. Install the air equalizer tube. Install the turbocharger heat shield water lines and retaining bracket.
7. Tighten the bolts retaining the air outlet elbow to the turbocharger and aftercooler. Connect the governor control linkage and install the control channel.
8. On left side only, position the gauge panel on aftercooler housing and install the mounting bolts. Connect the oil pressure gauge line to the oil block on aftercooler housing.
9. Connect a hoist, and position the water temperature regulator housing on engine. Install the mounting bolts.
10. Install the regulator housing water inlet line bolts. Install the water outlet line bolts. Install the water outlet line on the exhaust manifold, that was not removed. Install the aftercooler water outlet line. Install the tachometer cable. Connect the water temperature sending unit. Connect the turbocharger heat shield water line.
concluding steps:
a) install water cooled exhaust manifold
b) install oil filter housing
c) install left front and left rear camshaft housing (for left front cylinder head)
d) install right front and right rear camshaft housings (for right cylinder head)