install the exhaust manifolds in accordance with paragraph 9-44.
Install the aftercooler in accordance with paragraph 9-42.
Install the turbochargers in accordance with the Operator and Organizational Maintenance Manual.
Install the thermostat housing assembly in accordance with the Operator and Organizational Maintenance
Install the water filter mounting heads in accordance with the Operator and Organizational Maintenance Manual.
Fill the cooling system in accordance with the Operator and Organizational Maintenance Manual.
9-11. CYLINDER HEAD ASSEMBLES OVERHAUL. Overhaul of the cylinder heads consists of the disassembly
cleaning, inspection, and repair operations covered in paragraphs 96, 9-7, 9-8, and 9-9, and the following operations.
Remove the pipe plugs (19 and 20, Figure 9-1) from each cylinder head.
Remove the ten expansion plugs (21 and 22) from each cylinder head by driving a hole through each plug with a
sharp punch, then pry out the plug using the punch.
If the dowels (22) are damaged, or if it is necessary to resurface the head, remove the dowels using puller ST-
Adds used for cleaning purposes are highly toxic to the skin, eyes, and respiratory tract.
Skin, eye, and respiratory protection Is required. Keep a base solution such as sodium
bicarbonate at hand to neutralize acid spills.
Clean rust and scale from the water jacket passages using an acid bath and inhibited hydrochloric acid MIL-H-1
3528. After the rust and scale is removed, neutralize the acid using sodium bicarbonate solution, flush with water
and spray with preservative oil MIL-L-21260 to prevent rusting.
If the valve crosshead guide dimension (B, Figure 9-8) is less than 0.433 inch (11.00 mm), remove the guides
using puller ST-1134.
Loose valve seat inserts may be tightened in accordance with the instructions given below for valve seat insert
If the valve stem guide dimension (C, Figure 9-8) is over 0.4980 inch (12.649 mm), drive out the guides from the
valve seat side of the head using a valve guide punch having a pilot diameter of 0.495 inch (12.57 mm), and a
driving diameter of 0.830 inch (21.08 mm).
If the valve seats (26, Figure 9-1) are to be replaced, or the cylinder heads are to be resurfaced, remove the
valve seats and air deflector plates (27) using extractor ST-1 323.
Repair of Eroded Water Holes.
Fabricate a sleeve from copper tubing that will restore the eroded hole to its original inside diameter. Cut
the tubing for the sleeve approximately 0.5 inch (13 mm) long and measure the outside diameter with a
Using ST-1010. bore and ream the eroded hole 0.002 to 0.005 inch (0.05 to 0.13 mm) smaller than the
Coat the sleeve with sealant MIL-S-45180, Type l1l, and install it in the hole using a bushing driver and
Being careful not to damage the gasket surface, file the sleeve flush with the head surface using a flat mill
Resurfacing. To restore a damaged gasket surface, resurface the cylinder head. Up to 0.040 inch (1.02 mm)
stock may be removed, provided a minimum head thickness of 4.715 inches (119.76 mm) is preserved.
Resurface a cylinder head as follows: (1) Measure the cylinder head thickness using a micrometer caliper, or a
surface plate and vemier depth gage. Record this measurement for future reference.
Using a cylinder head grinder to specification MILL-4851, remove sufficient stock to restore the gasket
The finished gasket
surface shall have a finish of 125 micro inch (3.18 micrometer) RMS.
Measure the head thickness as in step (1), above. If the minimum head thickness is less than 4.715 inches
(119.76 mm), replace the head.
Subtract the measurement obtained in step (3), above, from the measurement obtained in step (1), above.
This amount of stock must be removed from the valve seat counterbore depth before installing new valve
seat inserts. Also, 1 or 2 valve spring shims equaling the amount of stock removed should be used under
the valve spring guide (4, Figure 9-1) at valve installation.