SECTION 4.

05
CYLINDER HEAD ASSEMBLY

CYLINDER HEAD INSTALLATION 2. Position cylinder head gaskets on crankcase.

If a CEC DSM system is

installed on the engine,
run the AutoCal Program after doing any repair or
replacement of cylinder heads, gaskets, liners,
pistons, or knock sensors. The DSM AutoCal
program automatically establishes detonation lev-
els so that the DSM system can operate properly.
Failure to run the AutoCal program could result in
poor engine performance and engine damage.

NOTE: Refer to CEC Detonation Sensing Module

Installation, Operation And Maintenance Manual
Form 6278 for DSM Interface Program, version 6.0
series.

Place the cylinder heads

on a wooden board or
pallet. Place each head on its side to avoid damage
to the bottom of cylinder head.
= WATER PASSAGE OPENINGS (7)
1. Refer to “Spark Plug Sleeve, Spacer, And Spark Plug = CAPSCREW HOLES (8)
Carrier Extension Installation” in this section for installa-
= DOWEL PIN HOLES (2)
tion instructions on those items.
Figure 4.05-1. Cylinder Head Gasket
NOTE: Install head gaskets to crankcase ensuring that
the words “THIS SIDE UP” embossed on the gaskets
are facing upwards (see Figure 4.05-1). All the holes in
cylinder head gasket should line up properly with the The cylinder head weighs approximately 230 lb.
corresponding openings in cylinder head to ensure (104 kg). Use a suitable lifting device and exercise
proper installation.
caution during removal or installation to prevent
NOTE: A graphite head gasket that eliminates coolant severe personal injury or death.
leaks is standard on all VHP Series Four engines.. The
gasket has a thinner fire ring and additional material has 3. Thread two eye bolts (1/2 in.--13) into rocker arm
been added around the coolant passages. assembly capscrew bores (see Figure 4.05-2). Connect
a suitable lifting chain.

FORM 6296 First Edition 4.05 -- 1

CYLINDER HEAD ASSEMBLY

12 CYLINDER ENGINE CAPSCREWS

EYE BOLTS

7 8

3 1

2
4 Figure 4.05-3. Cylinder Head

5. To verify torque, repeat tightening sequence with

5 6 torque wrench set to total torque value. Do not
overtighten. Retightening after running engine at idle or
after load testing is not required.
Figure 4.05-2. Eye Bolt Locations
TOP VIEW OF EXHAUST PORT
To avoid damage to the CYLINDER
HEAD
deck surface or the dow-
el locating pins, raise the cylinder head at an angle
that closely approximates the angle of the firing
deck. 7 8
4. Using a suitable lifting device to install cylinder head
on crankcase.
3 1
CYLINDER HEAD TIGHTENING PROCEDURE
1. Lubricate capscrews with clean engine oil.

2. Hand secure capscrews in positions 1 and 2 (see 2

Figure 4.05-3 and Figure 4.05-4) making sure head 4
dowels are seated.

3. Hand start remaining capscrews.

5 6
NOTE: The first time through the tightening sequence
use 25 percent of the total torque value; each succeed-
ing time through the tightening sequence increase the INTAKE PORT
torque setting by 25 percent of total torque value until
final torque of 625 -- 650 ft-lb (847 -- 881 N×m) is reached. Figure 4.05-4. Tightening Sequence

4. Tighten cylinder head capscrews in sequence shown

(see Figure 4.05-4).

4.05 -- 2 FORM 6296 First Edition

 CYLINDER HEAD ASSEMBLY

PUSH ROD TUBE INSTALLATION 7. Apply Parker Super-O-Lubeä silicone lubricant

using a small paintbrush to upper, intermediate and
Oil leaks may occur if all lower push rod cover O-rings.
O-ring contact surfaces 8. Apply Parker Super-O-Lubeä silicone lubricant to
are not completely clean. Disregarding this informa- cylinder head and valve lifter guide bores. Grease inside
tion could result in product damage. diameter of bores to a depth of approximately
1/4 -- 1/2 in. (6.35 -- 12.70 mm).
1. Verify all old paint is removed from push rod covers.
Verify O-ring grooves and contact surfaces are clean 9. Fit straight end (without O-ring groove) of upper push
(see Figure 4.05-5). rod cover into flared end of lower push rod cover.
10. Hand compress push rod cover assembly. Insert
UPPER O-RING upper cover into cylinder head bore, at same time insert
UPPER COVER
lower cover into valve lifter guide bore. Release
compression on push rod covers. Verify push rod covers
SPRING SEAT
fit snugly in upper and lower bores.

ROCKER ARM OIL HEADER AND CYLINDER

HEAD OIL LINES INSTALLATION

SPRING NOTE: Loosely install all oil header components to

allow for adjustment during assembly. Once all parts are
aligned, tighten all fittings and attaching hardware.

WASHER 1. Apply pipe thread sealant to threads of all compo-

nents, and assemble tee, elbows, adapters, and mag-
netic plug on rocker arm oil header (see Figure 4.05-6).
INTERMEDIATE
O-RING

LOWER COVER

LOWER O-RING

Figure 4.05-5. Push Rod Cover

Old push rod cover

O-rings swell or become
hard and brittle with age. Oil leaks will occur if the
O-rings break or crack. Disregarding this
information could result in product damage. OIL
HEADER
2. Install new O-ring in groove at top of upper push rod
cover. Figure 4.05-6. Rocker Arm Oil Supply Header

3. Position spring on body of upper push rod cover to
contact spring seat.
4. Position washer on upper push rod cover to seat
against spring.
2. Loosely attach rocker arm oil header tube to valve
cover retaining clips, washers, lock washers, nuts and
capscrews (see Figure 4.05-7).

5. Position a new O-ring on bottom of upper push rod

cover to contact washer.

6. Install a new O-ring in groove opposite flared end of

lower push rod cover.

FORM 6296 First Edition 4.05 -- 3

CYLINDER HEAD ASSEMBLY

PUSH ROD INSTALLATION

ROCKER ARM
OIL SUPPLY TUBE
VHP Series Four engines
do not use standard VHP
pushrods. VHP Series Four engine pushrods
(P/N A153754T) can be identified by a green dot
painted on the pushrod tube and are approximately
17.732 in. long (see Figure 4.05-9) . VHP Series Four
engine pushrods (P/N A153754T) are 0.080 in. (2.03
mm) shorter than the standard pushrod. Disregard-
ing this information will result in product damage.

NOTE: A new hydraulic lifter (P/N 153752K) has been

TEE CONNECTIONS
Figure 4.05-7. Rocker Arm Oil Supply Tubes
3. Inspect rocker arm oil supply tubes (3/8 in. OD) for
cracks, cuts, holes, dents or other damage (see
Figure 4.05-7 and Figure 4.05-8). Inspect male connec-
tor tube fittings for galled or stretched threads. If
necessary, replace tubes or fittings.
released. The new lifter has been revised internally to
prevent leak down and has an improved finish in the ball
socket to reduce wear. The push rod assembly
(A153754T) has been revised to include the new
hydraulic lifter. The new hydraulic lifter can be identified
by the P/N on the side of the lifter (see Figure 4.05-9).
HYDRAULIC
LIFTER P/N

ROCKER ARM OIL

SUPPLY TUBE

FERRULE GREEN DOT

Figure 4.05 -9. VHP Series Four Pushrod

MALE 1. Install pushrods (see Figure 4.05-10).

CONNECTOR
TUBE FITTING

FERRULE NUT

Figure 4.05-8. Rocker Arm Oil Supply Tubes

4. Apply Loctiteâ 271 Adhesive Sealant (High

Strength) to large end of each male connector. Using
9/16 in. hex on connector body, install fittings in right
side of each cylinder head (see Figure 4.05-7).

5. Finger tighten ferrule nuts to install oil supply tubes

between rocker arm oil header (male branch tee tube
fittings) and cylinder heads (male connectors). Reattach PUSH RODS
both ends of each tube before tightening.
Figure 4.05-10. Push Rod Installation
6. Once all components are aligned, tighten all fittings
and clamps.

4.05 -- 4 FORM 6296 First Edition


SPARK PLUG SLEEVE AND SPARK PLUG
CARRIER EXTENSION INSTALLATION
1. Refer to Section 5.10 Ignition System “Spark Plug
Sleeve And Spark Plug Carrier Extension Installation”
and install these components in the cylinder heads.
VALVE BRIDGE AND ROCKER ARM
INSTALLATION
In any procedure where
the rocker arms may
have been removed or disturbed, the cylinder head
replaced, or if it is suspected that the valves may
have been adjusted incorrectly, do not rotate the
crankshaft until all rocker arm adjusting screws and
valve bridge adjusting screws have been backed
off. Failure to back off the adjusting screws in these
situations may cause collision between valves and
pistons and severe engine damage.
Do not back out adjust-
ing screws too far. If ad-
justing screws are backed out too far, it may push
the adjusting screw foot off the adjusting screw.
NOTE: Valve bridge assemblies and rocker arm as-
semblies are installed with adjusting screws loosened
and backed out. During valve adjustment, assemblies
are adjusted and lock nuts are secured.
1. Loosen lock nuts and adjusting screws on both valve
bridge assemblies.
2. Position valve bridge assemblies on valve bridge
guides (see Figure 4.05-11).
VALVE BRIDGE
Figure 4.05-11. Valve Bridge Assembly
3. Apply engine oil to threads of capscrews. Position
rocker arm assembly on cylinder head with four
capscrews and four flat washers (see Figure 4.05-12).
Back out adjusting screws on intake and exhaust rocker
FORM 6296 First Edition
CYLINDER HEAD ASSEMBLY
arms. Do not tighten hex jam nuts until after valve
adjustment.
Tighten the four outer
capscrews on the rocker
arm assemblies first. Once they are tightened, then
tighten the center capscrew. Failure to follow the
proper tightening sequence can cause damage to
equipment.
4. Tighten four end capscrews on rocker arm assembly
to 66 -- 70 ft-lb (89 -- 95 N×m) (see Figure 4.05-12).
END
CAPSCREWS
END
CAPSCREWS
CENTER
CAPSCREW
Figure 4.05-12. Rocker Arm Assembly
5. Move exhaust rocker up and down to check for
interference.
6. Apply engine oil to threads of remaining center
capscrew. Install remaining center capscrew and wash-
er on rocker arm assembly and tighten to 17 ft-lb
(23 N×m).
7. Refer to Section 4.10 Valve Adjustment And Web
Deflection “Valve Adjustment” and adjust the valves.
EXHAUST MANIFOLDS
1. Remove protective masking tape from exhaust outlet
port and water outlet elbow flange on each cylinder
head.
NOTE: The exhaust manifold gasket contains a metal
seam that seals the inside of the gasket halves. This
seam is located on the exhaust manifold side of the
gasket (see Figure 4.05-13).
2. Place gasket on cylinder head exhaust ports with
seam side facing exhaust manifold and smooth side
facing cylinder (see Figure 4.05-13 and
Figure 4.05-14). Be sure that hole with copper grommet
lines up with water hole in casting. Do not use gasket if
grommet is missing or damaged.
4.05 -- 5
CYLINDER HEAD ASSEMBLY

SEAM

GROMMET

Figure 4.05-13. Exhaust Manifold Gasket -- Exhaust AIR/GAS RETAINING

SUPPLY TUBE CLIP
Manifold Side

Figure 4.05-15. Prelube Motor Air/Gas Supply Tube

SMOOTH
SIDE

Do not attempt to lift the exhaust manifold without

providing adequate support for each section. Disre-
garding this information could result in severe
personal injury or death.

The exhaust manifold weighs approximately 515 lb.

(234 kg). Use a suitable lifting device and exercise
caution during removal or installation to avoid
severe personal injury or death.
Figure 4.05-14. Exhaust Manifold Gasket -- Cylinder
Head Side
Exercise care to avoid
bending or denting the
3. Install two 1/2 in.--13 x 8-1/2 in. capscrews (oiled)
rocker arm oil supply tubes. Disregarding this
with flat washers into upper bosses of each exhaust
information could result in product damage and/or
manifold section. Install two 1/2 in.--13 x 5-1/2 in.
personal injury.
capscrews (oiled) with flat washers into all lower bosses.
4. Attach three retaining clips (0.048 in. gauge, 1/2 in. 7. Position exhaust manifold on cylinder bank. Be sure
clamping diameter) to prelube motor air/gas supply tube end section with exhaust outlet port (for mounting of
(37-1/2 in. long, 1/2 in. tube OD). exhaust inlet elbow) is positioned at rear of engine (see
Figure 4.05-17).
5. Pull 5-1/2 in. capscrews from three sections (num-
bers 1, 3 and 6) of left bank exhaust manifold (see
Figure 4.05-16). End section with exhaust outlet port is
number 6.
6. Attach prelube air/gas supply tube retaining clips and
insert capscrews back into left bank exhaust manifold
(see Figure 4.05-15).

4.05 -- 6 FORM 6296 First Edition

 CYLINDER HEAD ASSEMBLY

EXHAUST OUTLET PORT

REAR ATTACH AIR/GAS SUPPLY TUBE RETAINING CLIPS FRONT

Figure 4.05-16. Exhaust Manifold -- Left Side

EXHAUST
A new water jumper elbow has been developed for all
WATER
OUTLET PORT OUTLET PORT WATER MANIFOLD VHP Series Four engines. The new water jumper elbow
MOUNTING BRACKET uses a square cut O--ring seal instead of a gasket at the
BOLT HOLES
cylinder head end. This results in longer life and a tighter
seal.
WATER
OUTLET PORT
NOTE: Previous water elbows are not machined for the
new square cut O--ring seal. If replacing either the
previous water jumper elbow (P/N 169892H) or gasket
(P/N 153139B), both the new water jumper elbow
REAR END (P/N 169892J) and O--ring seal (P/N 176883E) must be
SECTION
used (see Figure 4.05-19 and Figure 4.05-20).

9. Apply 3M Scotch Gripâ 847 Rubber and Gasket

FRONT END Adhesive into grooves of water outlet elbows. Install
SECTION
new seals into grooves (see Figure 4.05-19 and
Figure 4.05-20).
Figure 4.05-17. Exhaust Manifold End Sections
O--RING SEAL
8. Tighten outside short capscrew located in each end
section (front and rear) to 66 -- 70 ft-lb (89 -- 95 N×m) (see
Figure 4.05-18). Remove lifting device. Tighten remain-
ing capscrews to 66 -- 70 ft-lb (89 -- 95 N×m).

SEAL

Figure 4.05-19. Current Water Jumper Elbow

(P/N 169892J)

OUTSIDE
CAPSCREW

Figure 4.05-18. Exhaust Manifold End Sections

FORM 6296 First Edition 4.05 -- 7

CYLINDER HEAD ASSEMBLY

GASKET

SEAL

Figure 4.05-20. Previous Water Jumper Elbow

(P/N 169892H) END CAPS

10. Secure water outlet elbows to cylinder heads with Figure 4.05-22. Exhaust Manifold End Cover
(oiled) 3/8 in.--16 x 4-1/2 in. ferryhead capscrews and
lock washers (see Figure 4.05-21). Finger tighten only. 15. Inspect twelve stainless steel male connector tube
fittings (1/4 in. thermocouple OD) for galled or stretched
11. Secure elbows to exhaust manifold with (oiled) threads (see Figure 4.05-23). Replace fittings if neces-
1/2 in.--13 x 1-3/4 in. hex head capscrews and lock sary.
washers (see Figure 4.05-21). Finger tighten only.
16. Apply Bostik Never Seezâ Anti-Seize and Lubricat-
12. Alternately tighten four capscrews. Tighten ing Compound (capable of withstanding temperatures
3/8 in.--16 x 4-1/2 in. ferryhead capscrews (elbows to up to 1800° F/982° C) to large end of each male
cylinder heads) to 27 -- 29 ft-lb (37 -- 39 N×m). Tighten connector tube fitting. Thread fitting into exhaust port of
1/2 in.--13 x 1-3/4 in. hex head capscrews (elbows to each segment of exhaust manifold (see
exhaust manifold) to 66 -- 70 ft-lb (89 -- 95 N×m). Figure 4.05-23).

WATER OUTLET ELBOW EXHAUST MANIFOLD

MALE
CONNECTOR

Figure 4.05-21. Water Outlet Elbows -- Rear Right

13. Use a rubber mallet to seat manifold caps in front Figure 4.05-23. Thermocouple Connector
end sections of right and left bank exhaust manifolds.

14. Secure end cap to exhaust manifold end using
1/2 in.--13 x 1-5/8 in. capscrews and flat washers (see
Figure 4.05-22).
17. Repeat procedure for other bank.
NOTE: Refer to Section 5.15 Air Induction System
“Intake Manifold” for complete intake manifold installa-
tion procedures. The intake manifold must be aligned
prior to installation.

4.05 -- 8 FORM 6296 First Edition