Usage:
NOTE: Earlier engines have studs and later engines have bolts. The procedure for removal and installation are same for all engines.
preparatory steps:
a) remove turbocharger
b) remove fuel injection lines
c) remove camshaft housing
1. Drain the cooling system.
2. To remove right cylinder head assembly only, remove the turbocharger main lubrication line (1), mounting clamps and bolts.
3. To remove left cylinder head assembly only, disconnect and remove air compressor air supply line.
4. Disconnect wiring from water temperature shutoff sending unit (2). Disconnect all water lines from water temperature regulator housing. Attach a hoist to regulator housing. Remove all regulator housing-to-cylinder head mounting bolts (3) and nuts. Remove water temperature regulator housing (4).
5. Remove the aftercooler vent lines. Remove the aftercooler water outlet line. Remove the engine front lifting bracket.
6. Disconnect governor linkage from governor. Remove governor control channel assembly.
7. To remove right cylinder head assembly only, remove fuel transfer pump inlet and outlet lines (5). Remove fuel system bleed lines (6) and remove fuel line (7) to fuel injection pump housing. Disconnect air compressor water line from head and swing it out of the way.
8. To remove right cylinder head assembly only, remove the governor-to-right aftercooler housing mounting bracket. Remove fuel injection pump housing brackets-to-right cylinder head mounting bolts. Remove the fuel ratio control sensing line.
9. To remove left cylinder head assembly only, remove the fuel injection pump housing-to-left cylinder head mounting bracket.
10. Remove the aftercooler water inlet line mounting bolts from aftercooler housing. Remove the water inlet elbow line from water line on the cylinder head being removed.
11. Remove the four exhaust elbow bracket mounting bolts from the cylinder head being removed. Loosen the four exhaust elbow bracket mounting bolts in the other cylinder head. Remove the exhaust manifold elbow to turbocharger.
12. Remove the cylinder head retaining nuts and washers. Attach a hoist and remove the cylinder head assembly-weight 500 lbs. (227 kg).
NOTE: Always install a new gasket between spacer plate and cylinder block before reinstalling cylinder head assembly. See REMOVE SPACER PLATES.
Install Cylinder Head Assembly
NOTE: Be sure gasket between spacer plate and cylinder block has been replaced before installing cylinder head assembly. Refer to REMOVE & INSTALL SPACER PLATES.
1. Clean the top surface of spacer plate and mating surface of cylinder head. Install the head gasket and water seals (1).
2. Attach a hoist and position the cylinder head assembly on engine. Coat the threads of retaining studs with 9M3710 Anti-Seize Compound. Install washers and retaining nuts. Tighten the nuts in following Step sequence:
1 Tighten all nuts in numerical sequence shown to 175 lb. ft. (24,2 mkg).
2 Again tighten all nuts in numerical sequence shown to 250 lb. ft. (34,6 mkg).
3 Finally hand tighten all nuts in numerical sequence shown to 250 lb. ft. (34,6 mkg).
3. Install the four exhaust elbow bracket mounting bolts in cylinder head that were removed. Tighten four elbow bracket mounting bolts in the other cylinder head. Install the exhaust manifold elbow to turbocharger.
4. Install the aftercooler water inlet line, position it, and install mounting bolts.
5. To install the left cylinder head assembly only, install the fuel injection pump housing-to-left cylinder head mounting bracket. Install the air compressor air supply line.
6. To install the right cylinder head assembly only, install fuel ratio control sensing line. Install fuel injection pump housing bracket (2) mounting bolts. Install governor-to-right cylinder head mounting bracket.
7. To install the right cylinder head assembly only, connect air compressor water line to head. Install fuel line to fuel injection pump housing, and fuel system bleed lines. Install fuel transfer pump inlet and outlet lines. Install the turbocharger main lubrication line, mounting clamps and bolts.
8. Install governor control channel assembly and connect the governor linkage.
9. Install the engine front lifting bracket. Install aftercooler water outlet line. Install aftercooler vent lines.
10. Attach a hoist and position the water temperature regulator housing on engine. Install all regulator housing mounting bolts and nuts. Connect water lines to regulator housing. Connect wiring to water temperature shutoff sending unit.
11. Fill the cooling system.
concluding steps:
a) install camshaft housing
b) install fuel injection lines
c) install turbocharger