CYLINDER HEAD

Figure 7-8.1. Testing Engine Compression

TM-5-6115-585-34 Generator Set Diesel Engine Driven Tactical Skid Mtd 5 KW 1 Phase 2 Wire 1 Phase-3 Wire 3 Phase-4 Wire 120 120/240 and 120/208 Volts Manual
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TM 5-6115-58S-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 7-9. a. CYLINDER HEAD. Removal (see figure 7-9). (1) Remove. Refer to the Operator and Organizational Maintenance Manual and remove air shutter assembly and intake and exhaust manifold, muffler and shroud assembly. Remove engine lifting bracket, rocker cover and gasket, fuel nozzles, and connecting oil lines to cylinder head. (2) Remove rocker arms by removing the self- locking rocker arm nuts (1, figure 7-9), rocker arm balls (2) on each rocker arm (3). Lift rocker arm (3) off. (3) Remove capscrews (4) and push rod guide plate (5), screws (6) and washers (7) holding each cylinder head (8) to cylinder block (9). (4) Remove push rod (15) and remove cylinder heads. If heads stick, rap sharply with a soft hammer. DO not use a pry. Do not strike the cooling fins. (5) Remove push rod shield (17) and packings (16), spring (18) and washers (19). (6) Remove cylinder head gaskets (10). b. Disassembly (see figure 7-11). (1) Remove valve rotator (l). Using a valve spring compressor (see figure 7-10), disassemble valve assemblies. Valve assemblies include spring retainer lock (2), (see figure 7-11), retainer (3), valve spring (5) and valves (8) and 10). (2) Remove intake valve seals (4). c. Clean and Inspect. Thoroughly clean all compo- nents of cylinder head assemblies. Remove all carbon deposits from intake and exhaust ports and clean all gasket surfaces. Inspect all cylinder head components for physical damage. Inspect cylinder head firing deck for warpage by measuring the maximum gap between the cylinder head and a steel straightedge placed in line and at a right angle to the cylinder head. If the gap exceeds 0.0015” in any direction, replace cylinder head. d. Repair. (1) Valves. Remove all carbon and check each valve (8 and 10, figure 7-11) for burning, pitting or warped head. Valves that are slightly pitted or burned, refinish on a valve grinder. Refinish intake valves to a 44” angle and exhaust valves to a 45° angle. But, if they are badly pitted, or will have a thin edge when refacing, replace them. Check refinished valves for a tight seat to the valve seat (7) with an air pressure type testing tool or by applying Prussian Blue on the valve face and rotating it against the seat. (2) Valve Guides. Check valve guides (6 and 9, figure 7-11) to valve clearance. See table 1-2. If the proper clearance cannot be obtained by replacing valve, replace valve guides. Drive the old valve guides into valve chambers. Drive new intake guides (6) in until the y protrude 11/32 inch from the rocker cover side of the head. Ream new valve guide to obtain the proper clearance. Exhaust guides (9) should protrude 5/8 inch from rocker cover side of the head. (3) Valve Seats. If the valve seats (7, figure 7-11) are pitted, refinish them. Using seat grinding equipment, reface each seat to a 45° angle. Seat width should be 3/64 to 1/16 inch for exhaust and 1/16 to 3/32 for intake. A seat can be refaced several times before it becomes necessary to replace it. If, how- ever, the valve seats are loose or cannot be refaced, replace them. Adjust tool to cut 1/64 inch from edge of seat. Oil the pilot to prevent it from seizing in the valve guide. Cut each seat down to a narrow ridge on edges and bottom and break it out with a sharp tool. Change 3 7-10.1

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