Service Buletin 07-2965D

SERVICE BULLETIN
TOPIC: Cylinder Heads

IDENT NO: 7-2965D
DATE: May 2011
SUPERSEDES: 7-2965C and 7-2950C
SUBJECT: Cylinder Head Overhaul Procedures
MODELS AFFECTED: VHP Series Four!
HIGHLIGHTS OF THIS REVISION ARE: • Tools, lubes and sealers – page 29

• New exhaust valve (P/N 204436K) and cylinder NOTE: Part numbers in this bulletin supersede Part
head assemblies for GSI engines (see Table 3 and Catalogs dated prior to May 2010.
Figure 34). This valve reduces carbon buildup CYLINDER HEAD DISSASSEMBLY
between the valve and the guide.
• New tool for the removal and installation of the valve NOTE: Table 8 Special Tools on page 29 lists all
guides special tools required.
• Combined listing of processes and components for INTAKE AND EXHAUST VALVE REMOVAL
easy reference when rebuilding heads
• Index of activities for quick reference of specific ! WARNING
processes Always use caution when removing
or installing the valve springs. They
• New processes for component assembly
are under tension and can eject
The significant changes to this bulletin require the user from the cylinder head during the
to read and understand all of these instructions before removal process. Use the correct
proceeding with the rebuilding process. valve spring compressor for this
procedure. Wear safety goggles.
• Intake and exhaust valve removal – page 1
• Valve seat removal – page 3 1. Refer to the appropriate Repair and Overhaul
• Valve guide removal – page 4 Manual, Section 2.00 “Cylinder Head Removal”
and remove rocker arm assemblies, valve bridge
• Cylinder head cleaning and inspection – page 5 assemblies and spark plug sleeve.
• Flatness check procedure – page 7 Valve spring compressor (P/N 474034) is available for
• Valve seat bore inspection – page 7 use on Series Four cylinder heads. This tool is
designed so that all four valve springs can be
• Cylinder head lower deck reconditioning – page 8 compressed at once. Use of this tool greatly reduces
• Valve spring inspection – page 8 service time for such tasks as valve stem seal
replacement, valve replacement and cylinder head
• Valve guide installation – page 9 overhaul. The tool may be used with the cylinder
• Valve bridge guide installation – page 10 heads on or off the engine.
• Valve seat installation – page 10 NOTICE

• Installation of spark plug carriers – page 12 If removing the valve spring tapers, springs or valve
• Cylinder head casting pressure testing – page 14 stem seals with the cylinder heads on the engine,
the piston below each cylinder head must be at top
• Valve seat grinding – page 15 dead center. If each piston is not at top dead center,
• Pre-assembly cylinder head cleaning – page 17 the valves will fall into the combustion chamber,
damaging the valves. Cylinder head removal will be
• Valve stem seal installation – page 17 required to remove the valves from the combustion
• Spring installation – page 17 chamber.
Service Bulletin 7-2965D

© 5/27/2011 Page 1 of 29
Service Bulletin No. 7-2965D
2. Install center guide stud over two threaded 5. Apply anti-sieze to threads of center guide stud.
mounting studs until plate rests on nuts securing
6. Install thrust bearing and compression nut on
spark plug sleeve (see Figure 1).
center guide stud (see Figure 2).
7. Tighten compression nut down until pressure plate
compresses valve springs just enough to release
1 valve spring tapers.
8. Remove valve spring tapers from valve stems (see
Figure 3).
Figure 1
1 - Center Guide Stud 2 - Nuts
3. Secure center guide stud in cylinder head with

spark plug extension nuts.
NOTICE
Look through the holes in the pressure plate to Figure 3
ensure that they are aligned with the valve stems,
threaded studs and valve bridge guide studs. 9. Loosen and remove compression nut and thrust
bearing from center guide stud.
4. Position pressure plate over valve stems, threaded 10. Remove pressure plate from cylinder head.
studs and valve bridge guide studs. Ensure large Remove two nuts and center guide stud from
diameter countersunk holes are facing up and are cylinder head.
aligned over valve stems (see Figure 2).
NOTE: GSI engines use valve rotators instead of
retainers (see Figure 4).
1 2
1 2
Figure 4
1 - Retainer 2 - Rotator
Figure 2
1 - Pressure Plate 3 - Thrust Bearing

2 - Compression Nut

Page 2 of 29 © 5/27/2011
11. Remove valve spring retainers or rotators (see VALVE SEAT REMOVAL
Figure 4 and Figure 5).
! WARNING
Always use an appropriate device
along with correctly positioned
chains, straps and hooks of
adequate strength to safely lift the
cylinder head. Never allow the
cylinder head to swing from the
lifting device.
1 2 1. Move cylinder head to a suitable workbench.

NOTE: The valve seat extractor tool collet removes
valve seats by gripping a small lip on the back of the
valve seats. The collet must be seated correctly to
Figure 5 ensure proper removal of valve seats.
1 - Retainer Taper 2 - Rotator Taper 2. Using valve seat extractor tool (P/N 474038),
remove exhaust valve seat inserts from bottom of
12. Tag and remove inner and outer valve springs and cylinder head using the following steps:
washers. a. Adjust valve seat extractor collet to fit exhaust
13. Tag and remove valves. valve seat by adjusting nut on threaded rod, and
install collet in exhaust valve seat (see
14. Remove valve stem seals from tops of valve Figure 6).
guides (see Figure 5).
NOTE: This is not required if the guides are to be
pressed out and replaced.
1
15. Inspect intake and exhaust valves for wear.
Discard any valve with visible signs of stem galling,
overheating or other abnormalities.
2
Figure 6
1 - Collet 2 - Nut
b. Tighten adjusting nut until collet is seated firmly

in exhaust valve seat.
c. Slide spacer cup and bearing down threaded
rod (see Figure 7).

© 5/27/2011 Page 3 of 29
b. Adjust valve seat remover tool collet to fit intake

valve seat by adjusting nut on threaded rod, and
1 install collet in intake valve seat (see Figure 8).
c. Tighten adjusting nut until collet is seated firmly
engaged in the seat, assuring the lip of the tool
is below the seat.
d. Slide spacer cup and bearing down threaded
rod (see Figure 7).
e. Thread nut down threaded rod to contact
bearing.
2 f. Tighten nut until valve seat is removed from

3 cylinder head.
NOTE: As an alternate to tightening the nut to remove
Figure 7 the exhaust or intake seats, hydraulic ram (P/N
473027) may be installed over the threaded rod to
1 - Spacer Cup 3 - Bearing hydraulically remove the seats.
2 - Nut
VALVE GUIDE REMOVAL
d. Thread nut down threaded rod to contact spacer NOTE: New valve guide removal/installation tools
(see Figure 7). were released October 2010. Reference Service
e. Tighten nut until valve seat is removed from Bulletin 15-3050 for details.
cylinder head.
NOTICE
3. Using valve seat extractor tool (P/N 474038),
remove intake valve seat inserts from bottom of Any contact between the press and the firedeck of
cylinder head using the following steps: the cylinder head must be avoided.
a. Install spacer on top edge of collet (see
Figure 8). Using arbor (P/N 495336), press valve guides out from
the firedeck (piston) side of the cylinder head (see
Figure 9).
1
Figure 8
1 - Spacer 3 - Nut
2 - Collet
NOTE: Always block the rocker side of the head with

a non-marring material to prevent the guide pins
and/or spark plug carrier studs from contacting the
work surface.

Page 4 of 29 © 5/27/2011
CYLINDER HEAD CLEANING AND INSPECTION

Items needing replacement, valve guides and valve
$
seats must be removed to adequately clean the
# cylinder head casting.
NOTE: The oil tube does not need to be removed
(see Figure 10). Thoroughly inspect coolant passages
for scale or deposits. Remove core plugs as needed to
ensure proper cleaning of these coolant passages.
Figure 9
1 - Arbor (P/N 495336) 3 - Valve Guide

2 - Bottom Surface
(firedeck side) of
Cylinder Head Figure 10: Oil Tube Location – Top
Valve Bridge Guide Removal

1. If equipped, remove two capscrews, lock washers
NOTE: The valve bridge guides are press-fit in the and gas admission valve well cover from cylinder
cylinder head. It is not normally required to remove the head. Clean any Permatex! Aviation Form-A-
valve bridge guides unless they are bent or damaged. Gasket! Sealant from cover and cylinder head
If necessary, remove valve bridge guides using valve surfaces.
bridge guide puller (P/N 474040). 2. Clean gasket surfaces to ensure a tight seal at the
crankcase, rocker arm cover and intake and
exhaust ports.
3. After the cylinder head has been cleaned and air
dried, check thoroughly for cracks. When checking
for cracks, special attention must be paid to the
combustion side of the cylinder head. The area
between the valve inserts must be inspected
carefully.

© 5/27/2011 Page 5 of 29
Cylinder Head Casting Magnaflux! 4. Inspect cylinder head through a water passage
opening for accumulation of lime and mineral scale
deposits. An accumulation of scale deposits within
! WARNING the cylinder head inhibits the proper transfer of
Always read and follow the heat around critical engine parts, causing
manufacturers’ instructions and overheating. This overheating and expansion
warnings on all containers of cause the casting to crack. Preventing scale
sealants, adhesives, lubricants and buildup will help prevent a cracked cylinder head. If
other shop aids. use of an untested water supply or lack of a
suitable water treatment program resulted in an
NOTE: The Magnaflux Dye Penetrant Test Kit accumulation of deposits, special cleaning may be
(P/N 494283) is used to inspect the cylinder head for required. Special procedures and biodegradable
surface cracks. The areas that should be checked products are available to safely dissolve water
include the areas between the valve inserts, and the scale, lime and rust deposits from the water
areas between the valve seat inserts and the spark passages inside the cylinder head.
plug carrier bore.
a. To remove oily residues, apply Magnaflux ! WARNING
Spotcheck Cleaner/Remover (SKC-S) directly Never use chemical cleaning
to test area. Thoroughly wipe area with a clean solutions in areas that are not well-
cloth. Repeat procedure as necessary. Final ventilated. Always wear protective
wiping should result in a clean cloth. Allow test equipment when using chemical
area to dry. cleaning solutions.
NOTE: Wear rubber gloves to avoid hard-to-remove
stains on hands.
b. Spray test area with Magnaflux Spotcheck
Penetrant (SKL-SP). Wait 1 – 30 minutes.
c. Spray Magnaflux Spotcheck Cleaner/Remover
(SKC-S) on a clean cloth (not on the test area). ! WARNING
Wiping in one direction, remove all surface Never use your hand to check for
penetrant. Repeat as necessary. leaks or determine air flow rates
d. Spray test area with Magnaflux Spotcheck when using compressed air.
Developer (SKD-S2). Apply a thin, even film. Compressed air can pierce the skin.
Allow film to dry completely. The proper Always wear protective equipment
application dries to an even white layer. to protect your skin. Always wear
safety glasses to shield your eyes
e. Carefully inspect test area for cracks. A bright- from flying dirt and debris.
colored solid or dotted line marks a crack. Fine
cracks may take up to 15 minutes to appear.
Large cracks can be seen almost immediately. If 5. Submerse cylinder heads in a hot tank to remove
the crack is wide and deep, the indication will all paint, dirt, grease, oil, carbon and varnish
grow and spread. deposits. Follow up with a thorough hot rinse. Dry
f. Wipe test area clean if cracks are not found. cylinder heads with moisture-free compressed air.
6. If oil tube was removed, apply Loctite! 620™,
NOTICE 640™ or 648™ and install oil tube in cylinder head.
Do not weld cracked cylinder heads. Welding has 7. Apply Loctite! 271™ to threads of male oil line
been found to be an unsuccessful repair. connectors.
8. Install male oil line connectors in the side of each
g. Discard cylinder head if cracks are found. cylinder head.

Page 6 of 29 © 5/27/2011
FLATNESS CHECK PROCEDURE

1
1. Prior to checking firedeck flatness, deburr the edge
of the spark plug carrier bore and lightly sand the
outer edges of the firedeck. Failure to do these
preparation steps may lead to inaccurate flatness
measurements.
2. Position a straightedge across the firedeck of the
cylinder head as shown. Flatness must be
checked across the center and around the
perimeter of the head surface. Slide a feeler gauge
beneath the straightedge to check head warpage
(see Figure 11 and Figure 12).
2
1
Figure 12: Procedure B: Check Around Perimeter of

Head
1 - Metal Straightedge 2 - Feeler Gauge
a. If the gap between the straightedge and deck

surface exceeds 0.007 in. (0.178 mm), see
Cylinder Head Lower Deck Reconditioning on
page 8. Warpage around the spark plug carrier
bore is typically caused by overtorquing of the
spark plug carrier nuts.
b. If the gap between the straightedge and deck
surface exceeds 0.002 in. (0.051 mm) around
2 the perimeter of the head, see Cylinder Head
Lower Deck Reconditioning on page 8.
Figure 11: Procedure A: Check Across Spark Plug VALVE SEAT BORE INSPECTION
Carrier Bore NOTE: Oversized intake and exhaust valve seats are
available (see Table 6).
1 - Metal Straightedge 2 - Cylinder Head
1. Thoroughly clean parts and inspect valve seat
bores for cracks, pits, wear or any deformations.
Bores must be perfectly smooth. The surface finish
must not exceed 32 Ra.
2. Measure the bore diameters with a dial bore gauge
or a T-gauge and micrometer. The measuring
device must read accurately to the fourth decimal
place (tenths of thousands).
• If a dial bore gauge is used, locate the maximum
and minimum diameters at the midpoint of the
surface.
• If a T-gauge and micrometer are used, measure
the diameter at two locations, at the midpoint of
the surface, 90° apart.

© 5/27/2011 Page 7 of 29
Oversized valve seats should be installed whenever a

cylinder head is overhauled for coolant leaks or the
machined seat bores in the head are not within any of
the specifications shown in Table 6.
If installing oversized valve seats, cylinder head should
be bored to provide a 0.002 – 0.004 in. (0.051 –
0.102 mm) interference fit (see Table 5 and Table 6).
A
NOTICE
New guides should be installed and used as pilot
bores when machining the seat bores.
CYLINDER HEAD LOWER DECK

RECONDITIONING
If it is determined that the lower deck needs to be Figure 13: Cylinder Head – Intake Port Side
reconditioned by milling, this reconditioning should be
done prior to any other cylinder head reconditioning. A = 9.50 in. (241.30 mm) Height (New Head)
The lower deck should be reconditioned until the
surface is clean. Remove only sufficient material to If the lower deck is reconditioned, it may be necessary
clean up the lower deck surface. to recut the valve seat insert counterbore depth to
maintain the proper depth of the valve heads in the
NOTICE cylinder head. See Table 4 through Table 6 for proper
values of valve seat depth in cylinder head. The valve
If the lower deck of the cylinder head is seat insert counterbore depth will have to be recut to
reconditioned, the valve seat insert counterbore the amount as was taken off the cylinder head.
depth will have to be recut as required to maintain
VALVE SPRING INSPECTION
the proper depth of the valve heads in the cylinder
head. Failure to recut the valve seat insert
counterbore depth could cause damage to ! WARNING
equipment. Never use chemical cleaning
solutions in areas that are not well-
The height of a new cylinder head is 9.50 in. ventilated. Always wear protective
(241.30 mm) (see Figure 13). During reconditioning, equipment when using chemical
not more than 0.020 in. (0.508 mm) may be removed cleaning solutions.
from the lower deck. If more material is removed from
the lower deck, the casting strength will be reduced,
making it incapable of withstanding the firing pressure
of rated horsepower. In addition, this may cause
misalignment problems. These misalignment problems
include misalignment between the exhaust manifold 1. Clean inner and outer valve springs, washers,
and intake manifold. retainers and tapers in a non-volatile cleaning
solution or solvent. Inspect for damage, rust pits or
excessive wear. Replace as necessary.
2. Position intake and exhaust valve springs on a
level surface and use a straightedge to check for
proper squareness and height. Springs that are
less than the required minimum height will result in
reduced preload on spring. Load-test springs in a
valve spring tester (see Table 7).

Page 8 of 29 © 5/27/2011
VALVE GUIDE INSTALLATION

!
NOTE: New valve guide removal/installation tools
were released October 2010. Reference Service
Bulletin 15-3050 for details. + .
NOTE: The Series Four valve guides currently )
supplied are precision-fit guides that do not require
reaming after installation.
."/0$%&'"
NOTE: The exhaust valve guides are marked with a )"#0$%&'" (/$"1/%,,-
(11"+*%,,-
green dot, and the intake valve guides are marked with
a yellow dot for easier identification. 2$"$!$%&'"
2$"$!$%&'" ($".*%,,-
1. Apply a small amount of press-fit lubricant/oil ($".*%,,-
(such as Sunnen B-200L) to the inside of the guide

bore and the outside of the guide.
NOTE: If press-fit lubricant is unavailable, grease may 34
35
be used. !"#$$%&'"
()*"*+%,,-
* #
NOTICE
Avoid any contact between the press and the Figure 14: Installing Valve Guides
firedeck of the cylinder head.
* Guide bushing is designed to press valve guides 0.010 in.
(0.25 mm) shallower than cylinder head assembly drawing
2. Align new valve guides in their respective bores. specifies. This is done to allow for up to 0.020 in. (0.51 mm)
Using a press, arbor (P/N 495336) and guide machining of cylinder head bottom surface during head rebuild.
bushing (P/N 495498), start the guide in the bore
by tapping with a soft-faced mallet. Once started, 1 - Arbor (P/N 495336) 4 - Intake Valve Guide
2 - Guide Bushing (P/N (P/N 204209E)
press into position using a hydraulic press. The 495498) in Proper 5 - Exhaust Valve Guide
guide bushing (P/N 495498) is orientated Position to Press (P/N 204209F)
differently between pressing in the intake valve Series Four Intake 6 - Guide Bushing (P/N
guide and the exhaust valve guide (see Figure 14). Valve Guide (P/N 495498) in Proper
Press the valves guides into place until the arbor 204209E) to Correct Position to Press
and guide bushing are firmly contacting the Depth Series Four Exhaust
3 - Bottom Surface Valve Guide (P/N
firedeck side of the cylinder head.
(firedeck side) of 204209F) to Correct
Cylinder Head Depth
3. Use valve guide removal tool (P/N 495336). Any

contact between press and deck of cylinder head
must be avoided. If fully seated, valve guides will
protrude approximately 1.40 in. (35.56 mm) from
top of valve guide bores (see Figure 15).

© 5/27/2011 Page 9 of 29
VALVE SEAT INSTALLATION

1. With compressed air, blow out the valve seat bore
A holes to remove any dust and debris. Use a paper
towel to remove any remaining residue.
2. Thoroughly clean the inside of the bores using a
cloth and residue-free cleaner such as brake clean
B or lacquer thinner to ensure the bores are free
from any grease, oil or residue.
3. Using a clean, lint-free shop towel, wipe the bores
and seats clean of any debris and grease,
removing all traces of the cleaner. Use a clean
cloth for each set of bores and seats to prevent
cross contamination. After this step, do not touch
the bores with hands, tools or towels.
Figure 15: Cylinder Head Cutaway View
4. Spray a coating of Loctite! 7471™ Primer T™
A = 2.935 in. (74.54 mm) anaerobe primer to the seat bore and let dry.
B = 1.40 ± 0.03 in. (35.56 ± 0.76 mm)
NOTE: Guide bores must be cleaned with a lightly ! DANGER

oiled lint-free cloth to assure any contamination is Always comply with the liquid
removed before the GO/NO GO gauge is inserted. nitrogen manufacturer’s
4. Straightness of the guides must be held to recommendations for proper use
0.0005 in. (0.0127 mm). This can be checked with and handling of liquid nitrogen.
a simple GO/NO GO gauge shown in Figure 16.
This gauge, P/N 474044, is now available from
Dresser Waukesha. The long pin must pass freely
through the guide. The short pin should not pass
! WARNING
freely through the guide. Liquid nitrogen is -320°F (-196°C)
and will cause severe burns if it
comes into contact with human
A B skin. Always wear protective
equipment when working with
liquid nitrogen.
NOTE: The valve seat inserts are shrunk so that they

1 can be properly pressed into the valve seat bore. This
C
shrinking is done by chilling the valve seat insert. The
process of freezing reduces the outside diameter of
Figure 16: GO/NO GO Gauge (P/N 474044) the valve seat, which decreases the amount of
pressure required to press the seat into position.
1 - Class X ANSI B1.2-1983 Liquid nitrogen must be used for shrink-fitting the valve
seat inserts and is the method used at Dresser
A = 5.56 in. (141.2 mm) Waukesha for seat installation. The low temperatures
B = Ø 0.56190 +0.00000 / -0.00004 provided by liquid nitrogen guarantee maximum
C = Ø 0.56070 +0.00004 / -0.00000
shrinkage, reducing the risk of damage to the
counterbore or improper seating of the valve seat
VALVE BRIDGE GUIDE INSTALLATION
insert.
NOTE: The valve bridge guides are press-fit in the To freeze valve inserts with liquid nitrogen:
cylinder head. It is not normally required to remove
valve bridge guides unless they were bent or 5. Attach a thin wire with a hook on the end to each
damaged. valve seat and place in a container of liquid
nitrogen. The wire must be long enough to extend
Install valve bridge guides using bridge guide installer out of the container and allow easy removal
(P/N 495330, was TL84308) and a suitable press. without placing a hand in the container. Make sure
Valve bridge guides must not extend more than that there is enough liquid nitrogen to completely
2.935 in. (74.54 mm) from boss (see Figure 16). cover all inserts.

Page 10 of 29 © 5/27/2011
7. Allow inserts to remain submersed until solution

NOTICE stops boiling. At this point, temperature of insert
will not drop any further.
Do not touch the cylinder head insert bores with
hands, tools or shop towels once coated with
Loctite! 2422™. This is necessary to prevent NOTICE
cleaned part contamination. Contamination of the Install the valve seat with the beveled side facing
insert bores may affect the bond of the valve seats to outward.
the insert bores, causing coolant leakage.
Apply Loctite 2422 to the contact surfaces of exhaust 8. Use a wire bent in the shape of a hook to pick up
valve seat bores. The exhaust valve seats are water- valve seat inserts one at a time.
cooled and require the Loctite product to prevent
9. Using the insert installer tool, intake (P/N 495328)
coolant leaks.
or exhaust (P/N 495329), install the seat onto the
tool and hold in place with your finger. Insert the
6. Apply several dabs of Loctite 2422 around the tool into the guide.
sealing surfaces in the head (see Figure 17) and
distribute evenly around the surface with a gloved 10. Use the insert installer tool to press the seat
hand (see Figure 18). against the bore housing. Using a hammer, tap
lightly on the tool to ensure that the seat has
bottomed out.
11. After the seat is inserted, allow the seat to come
up to temperature (when the frost subsides from
the seat), then provide a secondary hit to the tool
to ensure the seat is down. Use a 0.001 in.
(0.025 mm) feeler gauge to ensure that the insert
is in contact with the bottom of the counterbore.
Verify insert fits tightly around circumference (see
Figure 19).
Figure 17
Figure 18
NOTE: The inserts warm up rapidly, and must be

properly installed before diameter increases to the
point where installation becomes difficult.

© 5/27/2011 Page 11 of 29
INSTALLATION OF SPARK PLUG CARRIERS

1. Lubricate four O-rings with O-ring lubricant and
install them on spark plug sleeve.
2. Clean and degrease lower bore of cylinder head,
being sure to provide a clean surface free of
remaining existing sealant, rust or other materials.
a. Clean and degrease the spark plug carrier
2 surface where the seal is located.
3 b. Apply Loctite 7471 Primer T to the spark plug

carrier seal area and allow to dry.
1 c. Apply Loctite 2422 to the spark plug carrier seal
area in an approximately 1/16 in. (1.6 mm) thick
4 layer.
d. Install the spark plug carrier seal. Be sure to
center the seal once it is in the undercut section
2 of the spark plug carrier. Centering of the seal is
important (see Figure 20).
Figure 19: Valve Seat Inserts
1 - Check with a 0.001 3 - Intake

in. (0.025 mm) Feeler 4 - Exhaust
Gauge to Ensure
Proper Installation
2 - Bevel
NOTE: Installation of a seat cooled in liquid nitrogen

should require minimal effort. If you have difficulty, Figure 20: Seal Washer Pressed into Initial Layer of
check that the following conditions are met: Sealer
• The insert is in liquid nitrogen for sufficient e. Apply another layer of Loctite 2422 to the upper
length of time. surface of the seal. Spread across the whole
sealing area of the carrier to a minimum depth
• The insert is placed in the bore immediately.
of 1/32 in. (0.8 mm), assuring the entire seal
• The cylinder head bores are within washer is covered (see Figure 21).
specification.
• The insert diameters are within specification.
12. Repeat the above steps for each valve seat insert.
13. After seats are installed, it is recommended to wait
2 hours before water testing. This allows the
sealant to cure and component temperatures
stabilize.
NOTE: To minimize the potential for leaks, the final

assembly of the spark plug carrier should be done
before water testing (i.e., do not use a temporary
carrier to test).

Page 12 of 29 © 5/27/2011
4
3
Figure 23: Previous Spark Plug Carrier Extension

Figure 21: Top Layer of Sealer Applied over the Seal
1 - O-Ring 3 - Spark Plug Sleeve
Washer
2 - Apply GE Red RTV 4 - Spark Plug Carrier
106 Extension
f. Do not allow the Loctite product to come into
contact with the spark plug threads.
NOTE: Previous CSA applications used a spacer
between the spark plug carrier extension and the
NOTICE spark plug sleeve. The current carrier extension
Use caution when installing the spark plug sleeve to eliminates the spacer.
avoid damaging or displacing the seal. The seal 5. Lubricate O-ring with O-ring lubricant and install
must be seated properly. on spark plug carrier extension (see Figure 23).
NOTE: Previous applications used a bead of GE Red
3. Position the carrier in the head and press into RTV 106 between the spark plug carrier extension and
place using a suitable diameter wooden dowel or a the spark plug sleeve (see Figure 23).
rubber-coated hammer handle; press the spark
plug sleeve into the head. The mounting studs are 6. For previous applications, apply a bead of GE Red
offset so the position must be correct before RTV 106 to circumference of lower projection of
pressing into head (see Figure 22). spark plug carrier extension along joint formed by
flange and projection (see Figure 23 and
Figure 24).
Figure 22 2
1 - Spark Plug Sleeve 2 - Suitable Soft-Faced

Tool or Dowel Figure 24
4. Secure spark plug sleeve and seal in cylinder head 1 - Spark Plug 2 - Bead of GE Red RTV
with two nuts (see Figure 23). Tighten nuts to Extension 106
17 ft-lb (23 N·m) oiled.

© 5/27/2011 Page 13 of 29
7. Current production uses a square sealing ring to

seal joint between spark plug carrier and extension 3
(see Figure 25).
2
1
1 4
2
4
3
Figure 25: Current Spark Plug Carrier Extension 5
1 - O-Ring 3 - Spark Plug Sleeve Figure 26: Cylinder Head Pressure Test Plates
2 - Square Sealing Ring 4 - Spark Plug Carrier
Extension
1 - Water Hole Cover 4 - Water Outlet Elbow
2 - Water Outlet Elbow Gasket
8. Install spark plug carrier extension on spark plug Plate 5 - Gasket
sleeve and spacer with two washers and nuts. 3 - Male Air Line Fitting 6 - Deck Plate
Tighten nuts to 17 ft-lb (23 N·m) oiled (see
Figure 25). 2. Fabricate a steel plate 3/4 – 1 in. (19 – 25 mm)
CYLINDER HEAD ASSEMBLY PRESSURE thick to cover water outlet elbow connection at top
of cylinder head. Drill and tap plate to accept a
TESTING
3/8 in. or 1/2 in. pipe fitting. Fit pipe fitting with a
Pressure Test Information male air line fitting.
The head assemblies must be tested for leakage. 3. Using plates as a stencil, cut rubber gaskets to
Fabricate the test fixture and use one of the following seal plates onto the cylinder head.
test methods.
4. Bolt plates on cylinder head.
• Test with air/water
5. Fabricate a small plate or plug to close off water
• Test with air only outlet hole centered below exhaust outlet port (see
Figure 27).
Fabricate the Test Fixture
1. Make a deck plate using 3/4 – 1 in. (19 – 25 mm)
thick steel (use cylinder head gasket as a pattern)
(see Figure 26). Drill holes in plate to match all
eight cylinder head capscrew holes. Plate should
have an open center so any leakage around the
exhaust valve guides or between valve seat inserts
can be observed. Do not drill holes for the two
locating dowels or the seven water passage
openings. The rubber grommets in the head
gasket point out the location of the water passage
openings.

Page 14 of 29 © 5/27/2011
3. Inspect cylinder head for leaks. Pay particular

attention to the area between the valve seats,
around the spark plug carrier bore and behind the
1 exhaust seats.
4. Carefully release air pressure.
5. Drain water from cylinder head.
Test with Air Only
! WARNING
Never exceed 15 psi (103 kPa) of air
pressure when performing the test
with air only. Excessive air pressure
may cause the cylinder head to
break. Wear protective equipment
when pressure testing the cylinder
head.
1. Attach an air source to the male fitting and apply

15 psi (103 kPa) of air pressure.
2 NOTE: The leak rate should not exceed 10 cubic
centimeters per minute.
Figure 27: Water Outlet Hole
2. Inspect cylinder head for leaks. Pay particular
attention to the area between the valve seats,
1 - Water Outlet Elbow 2 - Water Hole to
Connection Exhaust Manifold
around the spark plug carrier bore and behind the
exhaust seats.
3. Carefully release air pressure.
Test with Air / Water
VALVE SEAT GRINDING
! WARNING NOTE: Use of the Hall-Toledo EDP valve seat grinder

(P/N 494277) is a factory-approved service method of
Never exceed 32 psi (221 kPa) of air grinding valve seats (an eccentric grinder, diamond
pressure when performing the test dresser, stand and necessary wrenches are included).
with air and water. The cylinder Other commercially available devices such as the
head must be filled with water prior SERDI machining system may be used.
to applying air pressure. Applying
air pressure prior to filling the NOTICE
cylinder head with water or
applying air pressure that exceeds Machining accuracy depends upon the fit of the pilot
32 psi (221 kPa) will cause the mandrel. The pilot mandrel should fit snugly in the
cylinder head to break. Wear guide and in the hub of the grinder stone. Be sure
protective equipment when that the upper end of the mandrel does not wobble
pressure testing the cylinder head. during the grinding procedure. Upper end movement
will produce a seat that is not ground true.
1. Fill cylinder head with water.
NOTE: The pilot mandrel allows each valve seat to be
2. Attach an air source to the male air fitting and ground concentric with the valve guide. The Dresser
apply 32 psi (221 kPa) air pressure on top of water. Waukesha-supplied pilot mandrels (P/N 494344) are
made only for use with the Hall-Toledo EDP valve seat
grinder.
1. Install handle on pilot mandrel. Insert mandrel
0.564 in. (14.325 mm) into intake or exhaust valve
guide. Turn round knob until mandrel is snug (see
Figure 28).

© 5/27/2011 Page 15 of 29
NOTICE
Do not grind the valve seats too long and do not
apply too much pressure to the grinding stone.
1 Always dress the stone before grinding; failure to
dress the stone could cause damage to equipment.
The stone should be dressed to the proper angle
after each seat is ground.
4. See Table 1 to select proper degree angle grinding

stone. Rough-grind valve seat insert to obtain a
total indicator runout of 0.002 in. (0.05 mm)
maximum.
Table 1: Valve Seat Insert Grinding Stones
TYPE STONE ANGLE TOOL P/N

2
Seat Angle 20° 494014
Seat Angle 30° 494305
5. Install a fine-dress stone for a final cut. Grind valve

seats until a highly polished seat with a total
indicator runout less than 0.002 in. (0.05 mm) is
achieved.
6. Repeat grinding procedure as necessary.
3 ! WARNING
Never use your hand to check for
leaks or determine air flow rates
when using compressed air.
Compressed air can pierce the skin.
Always wear protective equipment
to protect your skin. Always wear
safety glasses to shield your eyes
from flying dirt and debris.
Figure 28: Measure Valve Seat Concentricity

! WARNING
1 - Tighten Pilot Mandrel 3 - Install Dial Indicator Never use chemical cleaning
2 - Remove Handle Gauge solutions in areas that are not well-
ventilated. Always wear protective
2. Remove handle from pilot mandrel. Position a dial equipment when using chemical
indicator gauge graduated in thousandths of an cleaning solutions.
inch (P/N 494278) on pilot mandrel.
3. Measure valve seat concentricity to determine
amount of valve seat grinding required (see
Figure 28). If total indicator runout does not
exceed 0.002 in. (0.05 mm) maximum, then valve
seat grinding is not required. 7. Use compressed air to blow away all loose dust.
Wipe down valve seat and seat insert surfaces
with a non-volatile cleaning solution or solvent and
dry with a clean cloth.

Page 16 of 29 © 5/27/2011
8. Valve seat lapping and/or blueing is not required if 2. Using valve stem seal installer tool (P/N 495327,
valve seat runout has been verified to be within was TL82158) (see Figure 30), slide valve stem
specification. seals down over the lubricated valve guides, and
tap lightly until seals are fully seated. Ensure that
9. Inspect valve face for Permatex Prussian Blue
seals are fully seated and are square on valve
transfer (see Figure 29). The dye transfers from
guides.
valve seat to valve face wherever a good face-to-
seat contact exists. A definite Prussian Blue
transfer around entire valve face circumference is
desirable.
Figure 30: Valve Stem Seal Installer Tool (P/N 495327)
Figure 29: Good Valve and Seat Contact 3. Install valves in valve guides by hand, slowly
pushing valve tips through the seals, being careful
1 - Valve Face 2 - Width of Prussian not to damage the seals.
Blue Transfer
4. Position cylinder head assembly valve side down
10. Repeat lapping procedure if necessary. If results on a flat surface.
are not acceptable, regrind valve seat insert before NOTE: Valve spring tapers used with rotators are
relapping. longer than valve spring tapers used with retainers.
PRE-ASSEMBLY CYLINDER HEAD CLEANING They are not interchangeable.
1. Thoroughly clean any debris or residue that may Inspect the valve spring tapers at the following
be left from the grinding or lapping procedures. locations:
2. Follow up with thorough hot rinse. Dry cylinder • The upper edges of the inside bosses for grooves
head with moisture-free compressed air. • The lower circumference of the tapers for burrs
3. Ensure the guides are clean by passing a clean, • The outer circumference of the tapers for radial
lightly oiled cloth through the guide bore. scoring
VALVE STEM SEAL INSTALLATION If signs of wear are found, replace the valve spring
Current valve stem seals are a product improvement tapers.
that is intended to improve oiling of the valve stems SPRING INSTALLATION
and guides. The seals are color-coded for easy
identification. 1. Install washers over each valve guide until they
come to rest on cylinder head casting. Washers
Proper installation of valve stem seals is required for are needed to retain proper tension on inner spring
seals to operate properly. A valve installer tool (P/N and to center the valve springs. For LT cylinder
495327, was TL82158) is provided to ensure that heads, see Figure 35 and Figure 36. For GSI
seals are seated properly on valve guides. The cylinder heads, see Figure 34.
following installation procedures should be followed
when installing valve stem seals. 2. Position inner and outer valve springs on intake
and exhaust valve guides.
NOTE: The valve guides should already be installed
in the cylinder head. NOTE: Do not intermix the intake and exhaust valve
springs. Intake valve springs can be distinguished
1. Lubricate the inside of the valve stem seals, the from the exhaust valve springs by the stripe color and
valve guide bores and the tops of the valve guides the direction of the helix.
with clean engine oil.

© 5/27/2011 Page 17 of 29
Table 2: Valve Spring Reference

NOTICE
DIRECTION OF HELIX
VALVE COLOR Look through the holes in the pressure plate to
(TOP TO BOTTOM)
ensure that they are aligned with the valve stems,
INTAKE threaded studs and valve bridge guide studs. Failure
to align the pressure plate properly could cause
Inner Blue Stripes Right damage to equipment.
Outer Blue Stripes Left
5. Position pressure plate over valve stems, threaded
EXHAUST studs and valve bridge guide studs. Ensure large
Inner White Stripes Left
diameter countersunk holes are facing up, and are
aligned over valve stems (see Figure 32).
Outer White Stripes Right
3. Position spring retainer, or rotator, on top of inner 2

and outer valve springs (see Figure 34, Figure 35 1
and Figure 36). The smaller diameter flange fits
inside inner valve spring. The larger diameter
flange separates inner and outer springs.
! WARNING
Always use caution when removing
or installing the valve springs. They
are under tension and can eject
from the cylinder head during the 3
removal process. Use the correct
valve spring compressor for this
procedure. Wear safety goggles.
4. Using two nuts that were removed from spark plug

Figure 32: Position Pressure Plate Compression Nut and
extension, secure guide stud of valve spring Thrust Bearing
compressor (P/N 474034) in cylinder head (see
Figure 31). 1 - Pressure Plate 3 - Thrust Bearing
2 - Compression Nut
1 6. Apply engine oil to threads of center guide stud.

7. Install thrust bearing and compression nut on
center guide stud.
8. Tighten compression nut down until pressure plate
compresses valve springs just enough to install
valve spring tapers.
2
NOTE: Longer valve spring tapers are required with
valve rotators. They are not interchangeable with
standard valve spring retainer tapers.
9. Install valve spring tapers on valve stems (see
Figure 33).
Figure 31: Position Center Guide Stud
1 - Center Guide Stud 2 - Nuts

Page 18 of 29 © 5/27/2011
Figure 33
10. Loosen compression nut, and remove

compression nut and thrust bearing from center
guide stud.
11. Remove pressure plate from cylinder head.
12. Remove two nuts and center guide stud from
cylinder head.
13. Inspect to ensure valve spring tapers are fully
seated in valve spring retainers and valve grooves.
Cylinder Head Casting (P/N 205002F and 205002G)
The exhaust valve seat bore dimension was changed
to increase the interference fit of the valve seat from
0.002 – 0.004 in. (0.05 – 0.1 mm). This results in a
tighter seal that prevents coolant leaks. Use Table 6 to
determine the proper valve seats to use for a particular
cylinder head.
NOTICE
All previous cylinder heads not meeting this
specification must be reworked to provide an
interference fit of 0.004 in. (0.1 mm).

© 5/27/2011 Page 19 of 29
Table 3: Cylinder Head Assembly
Engine Model New Cylinder Head Previous Cylinder Head Cylinder Head
Assembly P/N Assembly P/N Gasket P/N
L5794LTD CC205002G, CE205002F, CA205002E,
(Landfill Applications) CE205002G 204000V
CC205002F
5794LT (Landfill) CE205002G CC205002G, EE205002F, DC205002F 204000V
AC205002G, AE205002F, AA205002E,
L5774LT (Natural Gas) AE205002G 204000V
AC205002F
5774LT AE205002G AC205002G, DE205002F, EC205002F 204000V
AC205002G, AC205002G, AA205002E,
L5794LT (Natural Gas) AE205002G 204000V
AC205002F
DA205002G, AD205002F, AA205002F,
L5794GSI/GSIE AD205002G AC205002D CC205002D, CA205002F, 204000V
AA205002G
AD205002G, DA205002G, AD205002F,
L7044GSI/GSIE CD205002G AA205002F, AC205002D CC205002D, 205100C
CA205002F, AA205002G
AD205002G, DA205002G, AD205002F,
F3514/F3524GSI/GSIE CD205002G AA205002F, AC205002D CC205002D, 205100C
CA205002F, AA205002G

Page 20 of 29 © 5/27/2011
2 8 3 2 9 3
5 7
1 6
4
10 11 12
10
14
13
16 15
Figure 34: F3514/F3524, L5794 and L7044 GSI/GSIE Cylinder Head Assembly (P/N CD205002G)
)
Item Part Description Qty

Number
1 D205002G Cylinder Head 1
2 73629C Valve Spring Taper 8
3 214230 Valve Rotator Assembly 4
4 204235C Inside Exhaust Valve Spring (White Stripes) 2
5 204335C Outside Exhaust Valve Spring (White Stripes) 2
6 204235B Inside Intake Valve Spring (Blue Stripes) 2
7 204335B Outside Intake Valve Spring (Blue Stripes) 2
8 204436K 20° Exhaust Valve 2
9 204436A 20° Intake Valve 2
10 153883B Valve Spring Washer 4
11 176450G Exhaust Valve Stem Seal (Green) 2
12 214229 Intake Valve Stem Seal (Blue) 2
13 204209E Intake Valve Guide 2
14 204209F Exhaust Valve Guide 2
15 211801J 20° Intake Valve Seat 2
16 211802B 20° Exhaust Valve Seat (std. size, ref. Table 6) 2
17* 21197 Hex Nut 2
18* 304745G O-Ring 2
19* 211796C Spark Plug Sleeve 1
20* 211795A Igniter Sleeve Seal 1
* See Figure 37 for component location.

© 5/27/2011 Page 21 of 29
2 8 3 2 9 3
7
1 5
6
10 11 4 12
10
14
13
16 15
Figure 35: L5794LTD and L5794LT (Landfill Applications) Cylinder Head Assembly (P/N CE205002G)

Number
1 E205002G Cylinder Head 1
2 73629A Valve Spring Taper 8
3 153884B Valve Spring Retainer 4
8 204336Z 20° Exhaust Valve 2
9 204336B 30° Intake Valve 2
12 176450F Intake Valve Stem Seal (Black) 2
15 211801 30° Intake Valve Seat 2
17* 21197 Hex Nut 2
18* 304745G O-Ring 2

Page 22 of 29 © 5/27/2011
2 8 3 2 9 3
7
5
1
6
4
10 11 12
10
14
13
16 15
Figure 36: L5774LT and L5794LT (Natural Gas Applications) Cylinder Head (P/N AE205002G)

Number
1 E205002G Cylinder Head 1
2 73629A Valve Spring Taper 8
3 153884B Valve Spring Retainer 4
8 204336Y 20° Exhaust Valve 2
9 204336B 30° Intake Valve 2
12 176450F Intake Valve Stem Seal (Black) 2
15 211801 30° Intake Valve Seat 2
17* 21197 Hex Nut 2
18* 304745G O-Ring 2

© 5/27/2011 Page 23 of 29
17
18
20 19
Figure 37: Head Assembly with Carrier
Part
Item Number Description Qty
17 21197 Hex Nut 2

18 304745G O-Ring 2
19 211796C Spark Plug Sleeve 1
20 211795A Igniter Sleeve Seal 1

Page 24 of 29 © 5/27/2011
Table 4: Intake and Exhaust Valves
G
G
B F**
F**
F*
F*
A
E
E
D*
F F
1 2
C D
1 - Intake – Marked with a Yellow Dot 2 - Exhaust – Marked with a Green Dot
MEASUREMENT INCHES (in.) METRIC (mm)
(A) Valve Overall Length
10.742 – 10.752 272.847 – 273.101
(Intake) GSI
10.802 – 10.812 274.370 – 274.624
(Intake) Non-GSI
10.771 – 10.781 273.583 – 273.837
(Exhaust)
(B) Valve Stem Diameter (Intake and Exhaust) 0.557 – 0.558 14.147 – 14.173
(B) Valve Stem Straightness and Perpendicularity with Valve Head 0.002 (TIR) 0.050 (TIR)
(C) Valve Head Diameter
(Intake) 2.935 – 2.945 74.549 – 74.803
(Exhaust) 2.925 – 2.935 74.295 – 74.549
(D) Valve Face Angle
(Intake) GSI 19.5° ±15′ 19.5° ±15′
(Intake) non-GSI 30° ±15′ 30° ±15′
(Exhaust) 20° ±15′ 20° ±15′
(D*) Valve Seat Width

0.1605 – 0.1836 4.077 – 4.663
(Intake) 30°
0.1719 – 0.1931 4.366 – 4.905
(Exhaust) 20°
(E) Valve Guide Length
(Intake) 5.52 140.21
(Exhaust) 4.82 122.42
(F) Valve Guide Lower Outside Diameter (Intake and Exhaust) 1.0015 – 1.0025 25.438 – 25.463
(F*) Valve Guide Middle Outside Diameter (Intake and Exhaust) 0.915 – 0.920 23.241 – 23.368
(F**) Valve Guide Upper Outside Diameter (Intake and Exhaust) 0.870 – 0.880 22.098 – 22.352
(G) Guide Inside Diameter (Not Installed) 0.5618 – 0.5625 14.27 – 14.29
(G) Guide Inside Diameter (Installed) (Below Spring Deck) 0.5612 – 0.5619 14.25 – 14.27
(G) Guide Inside Diameter (Installed) (Above Spring Deck) (Reference 0.5618 – 0.5625 14.27 – 14.29
only)
(G) Valve Guide to Valve Stem Clearance (Intake and Exhaust) 0.0032 – 0.0049 0.0.0813 – 0.1245

© 5/27/2011 Page 25 of 29
Table 5: Standard Intake and Exhaust Seats
1 2
A
B
A
C
B C
D* D D
D*
A
F
F
E E
G G
1 2
1 - Intake 2 - Exhaust
MEASUREMENT INCHES (in.) METRIC (mm)
(A) Valve Seat Outside Diameter (Standard Size)
(Intake) 3.002 – 3.003 76.251 – 76.276
(Exhaust) (Upper) 2.602 – 2.603 66.091 – 66.116
(Exhaust) (Lower) 3.202 – 3.203 81.331 – 81.356
(B) Valve Seat Inside Diameter
(Intake) 2.435 – 2.445 61.849 – 62.103
(Exhaust) 2.130 – 2.170 54.102 – 55.118
(C) Valve Seat Height
(Intake) 0.413 – 0.417 10.490 – 10.592
(Exhaust) 1.153 – 1.179 29.286 – 29.947
(D) Valve Seat Angle (Not Assembled)
(Intake) GSI 20.25° ± 15′ 20.25° ± 15′
(Intake) Non-GSI 30° ± 30′ 30° ± 30′
(Exhaust) 20° ± 15′ 20° ± 15′
(D*) Valve Seat Width (Standard Size)
(Intake) 30° 0.2935 – 0.299 7.4549 – 7.5946
(Exhaust) (Upper) 20° 0.216 – 0.2365 5.486 – 6.007
(Exhaust) (Lower) 20° 0.516 – 0.5365 13.106 – 13.627
(E) Valve Guide Extension Above Boss 1.40 ± 0.03 35.56 ± 0.76
(F) Valve Bridge Guide Extension Above Boss 2.935 (max) 74.54 (max)
(G) Valve Seat Depth in Head
(Intake) 0.241 – 0.275 6.121 – 6.985
(Exhaust) 0.281 – 0.317 7.137 – 8.052

Page 26 of 29 © 5/27/2011
Table 6: Oversized Valve Seats
E B
Exhaust (A) (B) (C) (D)

Valve Seat P/N Exhaust Valve Seat Exhaust Valve Seat Exhaust Valve Seat Exhaust Valve Seat
Upper Bore ID Lower Bore ID Upper OD Lower OD
Standard 20° 211802B 2.599 – 2.600 in. 3.199 – 3.200 in. 2.602 – 2.603 in. 3.202 – 3.203 in.
(66.015 – 66.040 mm) (81.255 – 81.280 mm) (66.091 – 66.116 mm) (81.331– 81.356 mm)
Oversized 211802B 4 2.604 – 2.605 in. 3.204 – 3.205 in. 2.607 – 2.608 in. 3.207 – 3.208 in.
0.005 in. (66.142 – 66.167 mm) (81.382 – 81.407 mm) (66.218 – 66.243 mm) (81.458 – 81.483 mm)
0.010 in. (66.269 – 66.294 mm) (81.509 – 81.534 mm) (66.345 – 66.370 mm) (81.585 – 81.610 mm)
Oversized 2.614 – 2.615 in. 3.214 – 3.215 in. 2.617 – 2.618 in. 3.217 – 3.218 in.
0.015 in. 211802B 5 (66.396 – 66.421 mm) (81.636– 81.661 mm) (66.479– 66.497 mm) (81.712 – 81.737 mm)
Oversized 2.619 – 2.620 in. 3.219 – 3.220 in. 2.622 – 2.623 in. 3.222 – 3.223 in.
0.020 in. 211802B 2 (66.523 – 66.548 mm) (81.763 – 81.788 mm) (66.599 – 66.624 mm) (81.839 – 81.864 mm)
0.025 in. (66.650 – 66.675 mm) (81.890 – 81.915 mm) (66.726 – 66.751 mm) (81.966 – 81.991 mm)
0.030 in. (66.777 – 66.802 mm) (82.017 – 82.042 mm) (66.853 – 66.878 mm) (82.093 – 82.118 mm)
Intake Valve P/N (E) Intake Valve Seat Bore ID (F) Intake Valve Seat OD
Seat
3.000 – 3.001 in. 3.002 – 3.003 in.
Standard 30° 211801
(76.200 – 76.225 mm) (76.251 – 76.276 mm)
Oversized 3.020 – 3.021 in. 3.022 – 3.023 in.
0.020 in. 211801 2 (76.708 – 76.733 mm) (76.759 – 76.784 mm)
Oversized 3.030 – 3.031 in. 3.032 – 3.033 in.
0.030 in. 211801 3 (76.962 – 76.987 mm) (77.0128 – 77.038 mm)
Standard 20° 211801J 3.000 – 3.001 in. 3.002 – 3.003 in.

(76.200 – 76.225 mm) (76.251 – 76.276 mm)
Oversized 3.010 – 3.011 in. 3.012 – 3.013 in.
0.010 in. 211801 J 1 (76.454 – 76.479 mm) (76.505 – 76.530 mm)
Oversized 3.020 – 3.021 in. 3.022 – 3.023 in.
211801 J 2
0.020 in. (76.708 – 76.733 mm) (76.759 – 76.784 mm)
Oversized 211801 J 3 3.030 – 3.031 in. 3.032 – 3.033 in.
0.030 in. (76.962 – 76.987 mm) (77.0128 – 77.038 mm)

© 5/27/2011 Page 27 of 29
Table 7: Valve Springs
MEASUREMENT SAE METRIC

(A) Intake Valve Spring Free Length:
Intake 204235B (Inner) 3.444 in. 87.477 mm
Intake 204335B (Outer) 3.800 in. 96.520 mm
(A) Exhaust Valve Spring Free Length:
Exhaust 204235C (Inner) 3.411 in. 86.639 mm
Exhaust 204335C (Outer) 3.810 in. 96.774 mm
Intake Valve Closed Spring Length:
204235B (Inner) 2.721 in. @ 59.2 lb ±3.5 lb 69.113 mm @ 26.85 kg ±1.59 kg
204335B (Outer) 3.137 in. @ 124.8 lb ±7.5 lb 79.68 mm @ 56.61 kg ±3.4 kg
Exhaust Valve Closed Spring Length:
204235C (Inner) 2.680 in. @ 69.5 lb ±2.7 lb 68.07 mm @ 31.52 kg ±1.22 kg
204335C (Outer) 3.096 in. @ 151.2 lb ±5.5 lb 78.64 mm @ 68.58 kg ±2.49 kg
Intake Valve Open Spring Length:
204235B (Inner) 1.964 in. @ 121.2 lb ±5.7 lb 49.89 mm @ 54.98 kg ±2.59 kg
204335B (Outer) 2.380 in. @ 267.3 lb ±19.4 lb 60.45 mm @ 27.42 kg ±8.8 kg
Exhaust Valve Open Spring Length:
204235C (Inner) 1.891 in. @ 144.5 lb ±5.4 lb 48.03 mm @ 21.79 kg ±2.45 kg
204335C (Outer) 2.307 in. @ 318.3 lb ±11.5 lb 58.6 mm @ 26.58 kg ±5.22 kg
NOTE: The values listed in Table 7 are new part tolerances. Used parts may vary with age and use.
NOTE: Visually inspect springs for broken ends, pitting or cracks. Use appropriate dye penetrant or Magnaflux inspection process to inspect
for cracks.

Page 28 of 29 © 5/27/2011
Table 8: Special Tools

Description P/N
Valve Spring Compressor 474034
Valve Seat Extractor 474038
Valve Bridge Guide Puller 474040
Valve Guide Straightness Gauge 474044
20° Seat Angle Grinding Stone 494014
Valve Seat Grinder 494277
Dial Indicator Gauge (thousandths) 494278
Magnaflux Dye Penetrant 494283
Valve Adjusting Wrench 494287
30° Seat Angle Grinding Stone 494305
Pilot Mandrel 494344
Valve Stem Seal Installer 495327 (was TL82158)
Intake Valve Seat Installer 495328 (was TL82981)
Exhaust Valve Seat Installer 495329 (was TL82982)
Bridge Guide Pin Driver 495330 (was TL84308)
Arbor 495336
Guide Bushing 495498

© 5/27/2011 Page 29 of 29

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SERVICE BULLETIN

TOPIC: Cylinder Heads

HIGHLIGHTS OF THIS REVISION ARE: • Tools, lubes and sealers – page 29

• Valve seat installation – page 10 NOTICE

Service Bulletin 7-2965D

1 - Center Guide Stud 2 - Nuts

3. Secure center guide stud in cylinder head with

1 - Pressure Plate 3 - Thrust Bearing

Service Bulletin 7-2965D

1 2 1. Move cylinder head to a suitable workbench.

b. Tighten adjusting nut until collet is seated firmly

Service Bulletin 7-2965D

b. Adjust valve seat remover tool collet to fit intake

2 f. Tighten nut until valve seat is removed from

NOTE: Always block the rocker side of the head with

Service Bulletin 7-2965D

CYLINDER HEAD CLEANING AND INSPECTION

1 - Arbor (P/N 495336) 3 - Valve Guide

Valve Bridge Guide Removal

Service Bulletin 7-2965D

Service Bulletin 7-2965D

FLATNESS CHECK PROCEDURE

Figure 12: Procedure B: Check Around Perimeter of

1 - Metal Straightedge 2 - Feeler Gauge

a. If the gap between the straightedge and deck

Service Bulletin 7-2965D

Oversized valve seats should be installed whenever a

CYLINDER HEAD LOWER DECK

Service Bulletin 7-2965D

VALVE GUIDE INSTALLATION

(such as Sunnen B-200L) to the inside of the guide

3. Use valve guide removal tool (P/N 495336). Any

Service Bulletin 7-2965D

VALVE SEAT INSTALLATION

NOTE: Guide bores must be cleaned with a lightly ! DANGER

NOTE: The valve seat inserts are shrunk so that they

Service Bulletin 7-2965D

7. Allow inserts to remain submersed until solution

NOTE: The inserts warm up rapidly, and must be

Service Bulletin 7-2965D

INSTALLATION OF SPARK PLUG CARRIERS

3 b. Apply Loctite 7471 Primer T to the spark plug

Figure 19: Valve Seat Inserts

1 - Check with a 0.001 3 - Intake

NOTE: Installation of a seat cooled in liquid nitrogen

NOTE: To minimize the potential for leaks, the final

Service Bulletin 7-2965D

Figure 23: Previous Spark Plug Carrier Extension

1 - Spark Plug Sleeve 2 - Suitable Soft-Faced

Service Bulletin 7-2965D

7. Current production uses a square sealing ring to

Figure 25: Current Spark Plug Carrier Extension 5

Service Bulletin 7-2965D

3. Inspect cylinder head for leaks. Pay particular

1. Attach an air source to the male fitting and apply

! WARNING NOTE: Use of the Hall-Toledo EDP valve seat grinder

Service Bulletin 7-2965D

4. See Table 1 to select proper degree angle grinding

TYPE STONE ANGLE TOOL P/N

Seat Angle 30° 494305