joeco911

does anyone know the specs for how many thousandths is allowable for the head and block to be, i have a good straight edge and feeler gauges just don't know how famu is too much, thanks

vzdude

Removal and installation
CYLINDER HEAD

These cylinder heads can only be used on engines with an intercooler. DO NOT interchange with earlier models.
REMOVAL

Drain the coolant. DO NOT waste reusable coolant. If the solution is clean, drain the coolant into a clean container for reuse.
Drain the engine oil. Dispose of the used oil properly.
Disconnect the radiator and heater hoses (refer to Cooling System)
Remove the turbocharger.
Remove the EGR tube and gaskets.
Remove the exhaust manifold Exhaust Manifold .
Remove the fuel lines and injector nozzles as an assembly (refer to Fuel System)
Remove the valve covers.
Remove the rocker levers and push rods.
Remove the fuel filter/water separator Fuel/Water Separator Filter Refer to Fuel System, for the proper procedures. Remove the remote fuel filter/water separator head..
If the engine is hot, remove the cylinder head bolts in the sequence shown in Cylinder Head Bolt Removal Sequence - Cylinder Head Hot The removal sequence is not important if the engine is cold. There are 3 sizes of head bolts. Note the position of each bolt for future installation.
Remove the cylinder head and gasket from the cylinder block.
INSTALLATION

The cylinder block and head must be clean and dry.
Position the gasket onto the dowels Cylinder Head/Gasket Alignment Make sure the gasket is correctly aligned with the holes in the cylinder block.
Carefully put the cylinder head onto the gasket and cylinder block. Make sure the cylinder head is installed onto the dowels in the cylinder block Cylinder Head/Gasket Alignment .
Install the push rods and rocker levers.
Use clean engine oil to lubricate the cylinder head bolt threads and under the bolt heads.
The cylinder head bolts are 3 different sizes. Install the bolts in the proper hole. Tighten the bolts as follows:
Step 1 - Tighten all bolts, in sequence Cylinder Head Tightening Sequence , to 90 N·m (66 ft. lbs.) torque. Check the torque. If lower than 90 N·m (66 ft. lbs.), tighten to this torque.
Step 2 - Tighten all long 12 mm bolts (Nos. 4, 5, 12, 13, 20 and 21), in sequence Cylinder Head Tightening Sequence , to 120 N·m (89 ft. lbs.) torque. Check the torque. If lower than 120 N·m (89 ft. lbs.), tighten to this torque.
Step 3 - Tighten all bolts, in sequence Cylinder Head Tightening Sequence , an additional 90°.
.
Be sure to lubricate the push rod sockets with clean engine oil. Be sure push rod is seated properly in the tappet.
Install the rocker lever pedestal bolts and tighten to 24 N·m (18 ft. lbs.) torque.
Adjust the valve clearance.
Install the valve covers. Tighten the bolts to 24 N·m (18 ft. lbs.) torque.
Install the injector nozzles and fuel lines (refer to Fuel System)
Install the remote fuel filter/water separator head. Install the fuel filter/water separator (refer to Fuel System for the proper procedures)
Install the exhaust manifold (refer to Exhaust System and Intake Manifold)
Install the EGR tube and start fasteners by hand.
Tighten all bolts/nuts to 24 N·m (212 in. lbs.) torque. When tightening bolts at EGR valve end of tube, alternate between the upper and lower bolt to allow face of EGR valve to remain square to tube mounting flange on EGR tube.
Install the turbocharger.
Connect the radiator and heater hoses.
Fill the engine with new coolant or the clean drained coolant (refer to Cooling System for the proper procedure)
Fill the engine with clean lubricating oil (refer to Lubrication and Maintenance)
Cleaning and inspection
CYLINDER HEAD

INSPECTION

Remove the cup plugs and inspect the coolant passages. A large build up of rust and lime will require removal of the cylinder block for cleaning in a hot tank.
Inspect the cylinder bores for damage or excessive wear. Rotate the crankshaft so the piston is at Bottom Dead Center (BDC) to inspect the bores.
Measure the cylinder bores Cylinder Bore Diameter DO NOT proceed with in-chassis repair if the bores are damaged or worn beyond the limits (refer to Cylinder Bore Repair - Cylinder Block)
Check the top surface for damage caused by the cylinder head gasket leaking between cylinders.
Inspect the block and head surface for nicks, erosion, etc.
Check the head distortion Cylinder Head Combustion Deck Face Measurement The distortion of the combustion deck face is not to exceed 0.010 mm (0.0004 inch) in any 50.8 mm (2.00 inch) diameter. Overall variation end to end or side to side 0.30 mm (0.012 inch)
DO NOT proceed with the in-chassis overhaul if the cylinder head or block surface is damaged or not flat (within specifications)
REFACING HEAD SURFACE

The cylinder head combustion deck may be refaced in whatever increments necessary to clean up the surface and maintain the surface finish and flatness tolerances. The combined total of stock removed must not exceed 1.00 mm (0.03937 inch) The amount of stock removed each time must be steel stamped above combustion deck edge, on the lower right hand corner of the rear face Cylinder Head Stock Removal Check valve protrusion after head surface refacing.
Surface finish requirements are 1.5-3.2 micrometers (60-126 microinch)
CLEANING

Clean the carbon from the injector nozzle seat with a nylon or brass brush.
Scrape the gasket residue from all gasket surfaces.
Wash the cylinder head in hot soapy water solution (88°C or 140°F)
After rinsing, use compressed air to dry the cylinder head.
Polish the gasket surface with 400 grid paper. Use an orbital sander or sanding block to maintain a flat surface.
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#35 10-15-2007, 09:57 PM
vzdude
Registered User Join Date: Jan 2007
Location: Indiana
Posts: 1,842

continued.......

ENGINE CYLINDER HEAD GASKET FAILURE DIAGNOSIS
A leaking engine cylinder head gasket usually results in loss of power, loss of coolant, and engine misfiring.

An engine cylinder head gasket leak can be located between adjacent cylinders or between a cylinder and the adjacent water jacket.

An engine cylinder head gasket leaking between adjacent cylinders is indicated by a loss of power and/or engine misfire.
An engine cylinder head gasket leaking between a cylinder and an adjacent water jacket is indicated by coolant foaming or overheating and loss of coolant.
CYLINDER-TO-CYLINDER LEAKAGE TEST
To determine if an engine cylinder head gasket is leaking between adjacent cylinders, follow the procedures outlined in Cylinder Compression Pressure Test. An engine cylinder head gasket leaking between adjacent cylinders will result in approximately a 50-70% reduction in compression pressure.

CYLINDER-TO-WATER JACKET LEAKAGE TEST
WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING. DO NOT STAND IN A DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE PULLEYS, BELTS, OR THE FAN. DO NOT WEAR LOOSE CLOTHING.

Remove the radiator cap.

Start the engine and allow it to warm up until the engine thermostat opens.

If a large combustion/compression pressure leak exists, bubbles will be visible in the coolant.

If bubbles are not visible, install a radiator pressure tester and pressurize the coolant system.

If a cylinder is leaking combustion pressure into the water jacket, the tester pointer will pulsate with every combustion stroke of the cylinder.


CYLINDER BLOCK
Remove the engine assembly from the vehicle.
Remove the cylinder head from the block.
Remove the camshaft.
Remove the piston/connecting rod assemblies.
INSPECTION
Measure the combustion deck face using a straight edge and a feeler gauge Combustion Deck Face Measurement The distortion of the combustion deck face is not to exceed 0.010 mm (0.0004 inch) in any 50.00 mm (2.0 inch) diameter. Overall variation end to end or side to side is 0.075 mm (0.003 inch)

If the surface exceeds the limit, refer to Cylinder Block Refacing.

Inspect the cylinder bores for damage or excessive wear.

Measure the cylinder bores Cylinder Bore Diameter If the cylinder bores exceeds the limit, refer to Cylinder Bore Repair.

Inspect the camshaft bores for scoring or excessive wear.

Measure the camshaft bores. Refer to engine specifications at the rear of this section. Limit for the No.1 bore applies to the ID of the bushing.

If a bore exceeds the limit, refer to Camshaft Bore Repair.

Inspect the tappet bores for scoring or excessive wear Tappet Bore Diameter If out of limits, replace the cylinder block.


CYLINDER BLOCK REFACING
The combustion deck can be refaced twice. The first reface should be 0.25 mm (0.0098 inch) If additional refacing is required, an additional 0.25 mm (0.0098 inch) can be removed. Total allowed refacing is 0.50 mm (0.0197 inch) - Refacing Dimensions of the Cylinder Block
Cylinder Block Refacing Dimensions
DIMENSION "A"
1st Reface 0.25mm (0.0098 in.)
2nd Reface 0.25mm (0.0098 in.)
Dim (A) Total 0.50 mm (0.0197 in.)
DIMENSION "B"
Dim. "B" (STD.) 323.00 mm ± 0.10 mm (12.7165 in. ± 0.0039 in.)
1st Reface 322.75 mm ± 0.10 mm (12.7067 in. ± 0.0039 in.)
2nd Reface 322.50 mm ± 0.10 mm (12.6968 in. ± 0.0039 in.)

The upper right corner of the rear face of the block must be stamped with a X when the block is refaced to 0.25 mm (0.0098 inch) A second X must be stamped beside the first when the block is refaced to 0.50 mm (0.0197 inch) - Stamp Block after Reface .
Consult the parts catalog for the proper head gaskets which must be used with refaced blocks to ensure proper piston-to-valve clearance.

joeco911

Thanks i appreciate the info