Required Tools | |||
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Tool | Part Number | Part Description | Qty |
A | 207-5034(1) | Stud Tensioner Tool Gp | 1 |
301-5215(2) | Stud Tensioner Tool Gp | 1 | |
B | 8T-0820 | Hydraulic Pressure Gauge | 1 |
3S-6224(3) | Electric Hydraulic Pump | 1 | |
8S-8033(3) | Electric Hydraulic Pump | 1 | |
9U-6600(3) | Hand Hydraulic Pump | 1 | |
8T-3035 | Hydraulic Line | 1 | |
C | 126-6918(4)
or 126-6919(5) |
Lifting Bracket | 1 |
126-6920 | Handle Rod | 1 | |
5D-1972 | Bolt | 2 | |
D | 229-3639 | Overhaul Protection Gp | 1 |
F | 183-3424 | Water and Temperature Resistant Grease | 1 |
(1) | Operating pressure is |
(2) | Operating pressure is |
(3) | There are three pumps that are listed in the tool chart. Any one of the pumps may be used for this procedure. |
(4) | Use with V-engines |
(5) | Use with In-line engines |
NOTICE |
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Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
Note: Tooling (D) provides all the protective covers and plugs for one cylinder. Use these protective covers in order to maximize the protection during these procedures.
- Thoroughly clean the sealing surfaces on top of the cylinder block assembly.
- Remove all debris from the inside of the cylinder liner and top of the piston. Apply clean engine oil to the inside of the cylinder liner.
- Earlier engines may have RTV coating on the cylinder head studs. Remove all debris from the holes in the cylinder block. Thoroughly clean the cylinder head studs and the top surface of the cylinder block. Paint the cylinder head studs if the cylinder head studs were cleaned to the bare metal.
- If the cylinder head studs were removed, use the following procedure to install the cylinder head studs:
- Before installing the cylinder head studs, coat the lower half of the cylinder head studs with Tooling (F). Apply an extra bead of grease around the cylinder head studs at the base of the cylinder head studs on the face of the block. This will help ensure that the counterbore in the top of the block is full of grease.
- Thoroughly clean the top of the cylinder block.
- Install the cylinder head studs in the block and tighten to a torque of
100 ± 20 N·m (75 ± 15 lb ft) .
- Coat the entire length of the cylinder head studs with Tooling (F) after the cylinder head studs are installed in the cylinder block.
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NOTICE Always install the seal plates after the cylinder liners are installed. Aluminum debris shaved from the plates by the cylinder liners will prevent the cylinder liners from sealing if the plates are installed first.
Note: Steps 6 through 10 are for engines that are equipped with flange cooled cylinder liners.
Show/hide tableIllustration 1 g01337529 Flange Cooled Cylinder Liners - Be sure that the O-ring seals and plugs (17) are installed at four locations around each flange cooled cylinder liner.
Note: Later cylinder blocks do not have the plugs that are shown in the photo.
- Install O-ring seals (16) on cylinder liner (14). Apply clean petroleum jelly to the O-ring seals.
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Illustration 2 g01337530 The photo shows the bottom side of seal plate (15). - Put a new O-ring seal at Locations (20) and (19) in seal plate (15). Put new O-ring seals at Locations (21) and (18) in seal plate (15). Apply petroleum jelly in the bore in the seal plate for the cylinder liner.
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Illustration 3 g01337531 - Turn seal plate (15) so that the top side is facing upward. Place the seal plate over the cylinder head studs and then place the seal plate onto the cylinder block.
- Put a new O-ring seal at Locations (20) and (19) in seal plate (15). Put new O-ring seals at Locations (21) and (18) in seal plate (15).
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Illustration 4 g01337525 Cuffed liner Note: The following Steps are for cuffed liners and for noncooled liners.
- Put a new O-ring seal on both sides of the seal plates at Locations (20) and (19). Put new O-ring seals on the seal retainers at Location (18). Install the seal plates and the seal retainers. Put new O-ring seals on both sides of the adapter at Location (21) on the seal plates.
- Put the combustion gasket in position on top of the cylinder liner.
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Illustration 5 g01337526 - Attach Tooling (C) and a suitable lifting device to cylinder head (10). The weight of cylinder head (10) is approximately
204 kg (450 lb) . - Carefully lower cylinder head (10) onto the cylinder head studs. While the cylinder head is being lowered, reach through the side opening and hold rod assembly (4) so that the rod assembly does not interfere with the cylinder head assembly.
- Be sure that the cylinder head assembly is seated on the dowels and be sure that the seal plates and the O-ring seals are seated properly.
- Install the nuts and the washers in order to hold the cylinder head. Tighten the nuts by hand.
Note: Lubricate the washer face and the threads of the cylinder head studs with Tooling (F) before assembly.
Show/hide tableIllustration 6 g01337528 - Install Tooling (A) over the nuts, and attach Tooling (B) to Tooling (A).
- Tighten collars (6) with a ratchet lever (1/2 inch drive). Loosen the collars for 1/4 turn.
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Personal injury can result from oil under high pressure.
DO NOT allow high pressure oil to contact skin.
Wear appropriate protective equipment while working with high pressure oil systems.
Note: The stud tensioner tool groups in Tooling (A) require different operating pressure.
- Run the pump in Tooling (B) until the operating pressure is registered on the gauge.
- Place dowel handle (7) through the slot in each pedestal in order to tighten each nut. Tighten each nut hand tight.
- Slowly release the hydraulic pressure, and repeat Steps 19 and 20.
- Remove Tooling (A) from the cylinder head assembly, the cylinder head studs, and the nuts.
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Illustration 7 g00639825 - Install oil supply tube assembly (5).
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Illustration 8 g00639824 - Connect rod assembly (4) to lever (3).
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Illustration 9 g01337117 - Install exhaust manifold section (1).
- Install water manifold segment (2).
- Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change".
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- If necessary, install the engine lifting bracket. Refer to Disassembly and Assembly, "Engine Lifting Bracket - Remove and Install".
- Install the fuel injector. Refer to Disassembly and Assembly, "Fuel Injector - Install".
- Install the exhaust manifold shields. Refer to Disassembly and Assembly, "Exhaust Manifold Shield - Remove and Install".