Section 1.2 Cylinder Head

The series 60 cylinder head combine intake and exhaust valve porting and fuel injector seats with water jacketing come cool the ports, injectors and also combustion room area. See number "Cylinder Head Assembly and Mating Components" .‪


Figure 1. Cylinder Head Assembly and Mating Components

With the overhead camshaft design, the cylinder head assembly includes: ‪

Cylinder headValve and also injector operating mechanismInjector, valve guide and related partsCamshaft and also camshaft bearings

The nested roller follower form rocker arms transmit camshaft motion straight to the valves and also injectors. See figure "Cylinder Head Assembly" .‪


1. Roller Follower‪

4. Exhaust Valve Rocker Arm‪

2. Injector Rocker Arm‪

5. Camshaft‪

3. Input Valve Rocker Arm‪

Figure 2. Cylinder Head Assembly

The nested roller follower form rocker eight transmit video camer motion straight to the valves. See number "Cylinder Head Assembly (Series 60G Engine)" .‪


1. Roller Follower‪

3. Exhaust Valve Rocker Arm‪

2. Input Valve Rocker Arm‪

4. Camshaft‪

5. Spacer‪

Figure 3. Cylinder Head Assembly (Series 60G Engine)

The porting within the cylinder head is cross-flow, with intake and also exhaust ports on opposite sides for minimum restriction and maximum exposure come coolant flow. 4 valves are used per cylinder, two intake and also two exhaust. See number "Intake and Exhaust Valve Porting" .‪


Figure 4. Intake and Exhaust Valve Porting

Replaceable valve guides, valve spring seats, valve stem seals, valve rotators and valve seat inserts are offered on every valves. See figure "Valve Guides and also Related Parts" .‪


1. Valve Guide‪

5. Valve Stem Oil Seal‪

2. Valve feather Seat‪

6. Valve Spring‪

3. Valve seat Insert‪

7. Valve Rotator‪

4. Valve‪

8. Valve Keepers‪

Figure 5. Valve Guides and Related Parts

Copper injector tubes prolonging through the cylinder head water coat are compelled for the fuel injectors. The pipe are straight exposed come the coolant. One O-ring seals the injector tube upper finish in the recess. The lower end of the injector tube must be expanded and flared during the installation process to save a tight fit in the firedeck bore. A beveled chair machined in the tube provides a compression-tight seal as soon as the injector is seated, and also affording reliable heat transfer facilitating injector cooling. Describe "2.4 N2 Fuel Injector Tube and O-Ring" .‪

Fuel galleries machined into the head supply fuel under fuel pump press to all injectors, and also excess fuel is returned to the fuel tank. The fuel gallery outlet (restricted) installation is installed in the behind of the cylinder head. See figure "Fuel gallery Inlet and Outlet Fittings" .‪

Figure 6. Fuel collection Inlet and Outlet Fittings

Section 1.2.1 Repair or replacement of Cylinder Head

To recognize if repair is possible or instead of is necessary, perform the complying with procedure. See number "Flowchart because that Repair or instead of of Cylinder Head" .‪

Figure 7. Flowchart because that Repair or instead of of Cylinder Head

Section 1.2.2 Removal and also Cleaning that Cylinder Head

Because optional and also accessory equipment varies with the engine application, this procedure covers just the an easy engine. If the engine is equipped through accessories that impact cylinder head removal, note the mounting details of each to assure correct installation at reassembly.‪

Remove the cylinder head as follows:‪

Seal the turbocharger compressor inlet and also discharge with covers or masking tape. Plug the oil it is provided fitting in the turbocharger housing.Open the drain dick location in ~ the bottom that the thermostat real estate to permit the coolant in the real estate to drain.Blow low press compressed air into the inlet fitting because that 20 come 30 seconds or until every one of the fuel is purged indigenous the cylinder head.Remove the gear situation stabilizer bracket at the appropriate and/or left front corner of the head.Section 1.2.3 cleaning of Cylinder Head

Clean the cylinder head together follows:‪

Keep parts segregated follow to initial position to assure appropriate reassembly, if parts are to it is in reused.Remove every threaded plugs.Steam clean the cylinder head once it has been stripped.Clean the camshaft and also camshaft bearings, valves, springs, valve rotators and also rocker shafts in fuel oil and also blow dry through compressed air.Clean the rocker arm assemblies.Section inspection of Cylinder Head

The adhering to steps must be performed prior to inspecting the cylinder head:‪

Install new cup plugs making use of a good grade non-hardening sealant such as Loctite® 620 or equivalent.Perform the adhering to tests for cylinder head inspection.Section Pressure trial and error of Cylinder Head

Perform the adhering to steps to pressure test the cylinder head:‪

Attach one air water tap to the fitting on the thermostat opened cover plate.Apply 207 kPa (30 psi) air pressure to the cylinder head and also immerse the head in a water bath heated come 82-93°C (180-200°F).Leave the head in the bath because that at the very least 20 minute to warmth thoroughly, when watching because that bubbles denote a cracked or leak.Section Inspection and also Rework for Firedeck Straightness

The huge mass and also length of the head spreading may save on computer longitudinal warp after it is unbolted and removed indigenous the engine block. At the time of factory manufacture, the longitudinal warp is normalized by using a fixture and also clamping the casting during machining. The casting is put in a fixture and clamped native its locating surfaces (datums). As soon as unclamped, the head casting resumes its initial shape till it is bolted and also tightened to the engine block.‪

Inspect the bottom (firedeck) that the cylinder head because that straightness together follows:‪

If the cylinder head flatness is outside of the specifications, Detroit Diesel corporation recommends replacing the cylinder head.‪

Section verification of Countersink Geometry

To verify countersink geometry, perform the adhering to steps.‪

Section Inspection and Reworking that Head Bolt Counterbore

To guarantee clean and also non-brinnelled cylinder head bolt counterbores, use J–38189 come resurface the head bolt washer area.‪

The procedure and also steps for suitable use of the tool space as follows:‪


There need to be no space between the bottom that the cylinder head and the table height to properly resurface the counterbores.‪

Protect the valve springs and injector counterbore to store any loose metal shavings from acquiring into valve springs and counterbore throughout cutting operation.With cylinder head ~ above a flat surface using the 1/8 in. Hex wrench provided with tool, loosen the stop collar and cutter to allow sliding on pilot.Starting in ~ the prior of the cylinder head, ar the pilot the the cutter right into a cylinder head bolt hole till the pilot contacts the level surface beneath the cylinder head.Allow the cutter to contact the counterbore surface. Lock the stop collar while against the cutter. The cutter now will resurface the counterbore 0.508 mm (0.020 in.).Remove the tool and place a 0.020 in. Feeler gage between the cutter and also the locked protect against collar.With feeler gage in place, lock the set screw of the cutter, then eliminate the feeler gage and also loosen the set screw ~ above the protect against collar and also slide it under tight versus the cutter and retighten.

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Perform the adhering to steps come resurface the counterbore 0.508 mm (0.020 in.):‪

Using a drill motor through a 1/2 in. Chuck and a best of 450 r/min and a suitable cutting oil to extend the life that the cutter and also to lubricate the pilot turning in bolt hole,If several of the bolt holes do not clean increase completely, continue resurfacing continuing to be holes, repeating the operation in. 0.005 in. Increments. This will certainly clean up any kind of holes that may not have actually cleaned up completely during the an initial cut.After every counterbores have been resurfaced, remove any loose cutting chips. Steam clean the finish cylinder head.After heavy steam cleaning, inspect the cylinder head for any remaining chips.Reinstall the cylinder head assembly, utilizing 38 of the new ground head bolt washers.Section 1.2.4 Assembly the Cylinder Head

Perform the complying with steps because that cylinder head assembly:‪


To avoid injury from paris debris once using compressed air, wear adequate eye security (face shield or security goggles) and also do no exceed 276 kPa (40 psi) wait pressure.‪


If the cylinder head is to it is in replaced, the brand-new head must be thoroughly cleaned before installation to eliminate all rust and also preventive compound, especially from the fuel and also oil galleries. This deserve to be excellent by immersion in a bath of fuel oil or mineral-spirits-based solvent and scrubbing the end all openings with a soft bristle brush. Once clean, blow the head dry v compressed air.‪

Ensure the all cup and also pipe plugs on the front face of the cylinder head are flush or listed below the surface.Section 1.2.5 environment of Cylinder Head

Perform the adhering to steps for cylinder head installation:‪

Ensure piston domes and the cylinder head and also cylinder block firedeck surfaces are clean and free of international matter. Inspect the head bolt holes in both block and also head for the visibility of oil, water, dirt, or damaged threads, clean or retap as necessary.

Note: effective with engine serial number 06R0766277 collection 60 engines will usage a brand-new cylinder head gasket. The new gasket will be determined with a new part number and is a darker the shade of gray with a woven appearance. The brand-new gasket need to be supplied with the brand-new style cylinder head bolts.

Remove the guide studs.


If gasket part number 23530421 is being used, the cylinder head bolts need to not it is in reused. Failure to install brand-new style bolts when using this gasket may an outcome in not correct clamp load, i m sorry could reason gasket failure and severe engine damage.‪

Install the head bolts with special hardened washers, lubricating the threads and bolt-head contact areas with a small amount of global Compound #2®, or equivalent.Install the clamp bolts with hemispherical washers, torque come 58-66 N·m (43-49 lb·ft).Feed the injector exploit wires through the opened at the behind of the cylinder head. For sure the exploit mounting flange come the cylinder head by speak the bolts to 10-15 N·m (7-11 lb·ft). Clean the coolant outlet surfaces of the head and thermostat housing. Through the thermostats sit in the housing counterbores, download the housing to the cylinder head, speak the housing bolts come 58-73 N·m (43-54 lb·ft). Connect the radiator or warm exchanger and bypass water tap couplings and also vent line.Connect the exhaust and air-to-air cooler wait ducting and also install the waiting cleaner or waiting separator.Install any type of other contents that to be removed and also fill through the forced fluids, together recommended. Describe OEM guidelines.


Diesel engine exhaust and some that its constituents are known to the State that California to cause cancer, birth defects, and also other reproductive harm.‪

Always start and also operate an engine in a fine ventilated area.If operation an engine in an attached area, vent the exhaust come the outside.Do no modify or tamper through the exhaust device or emission manage system.

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Start the engine and check because that fuel, coolant or oil leaks. Store the engine to run while you check.Shut under the engine.