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SERIES 40E CYLINDER HEAD ASSEMBLY

Before assembly, clean the cylinder head as follows: ‪

To avoid injury from flying debris when using compressed air, wear adequate eye protection (face shield or safety goggles) and do not exceed 40 psi (276 kPa) air pressure.

  1. Clean valve faces and seats with a suitable cleaning solvent to remove all dirt or foreign material. Blow dry all new and used components using filtered compressed air.
  2. Thoroughly clean all valve guides prior to valve installation.
    1. Coat a brush with soap and water. See Figure 31083 .
    2. Note: Brush must have a slightly larger diameter than the I.D. of the valve guide.

      1. Valve Guide ‪

      2. Brush ‪

      Valve Guide Cleaning

    3. Insert brush into valve guide bore and clean with a turning motion to ensure removal of any deposits.
    4. To avoid injury from flying debris when using compressed air, wear adequate eye protection (face shield or safety goggles) and do not exceed 40 psi (276 kPa) air pressure.

    5. Dry with filtered compressed air.
  3. Perform valve guide bore cleaning on the new service valve guides and the valve guides installed in the new service cylinder heads (less valves). Also clean bores on the valve guides that meet bore specifications presently installed in the cylinder head.
  4. Insert a large nylon brush into the rear of the oil rail gallery and into the rear of the fuel rail gallery for cleaning.

    To avoid injury from flying debris when using compressed air, wear adequate eye protection (face shield or safety goggles) and do not exceed 40 psi (276 kPa) air pressure.

  5. Use compressed air to clean out the oil gallery and the fuel oil gallery.
  6. Install a new O-ring into the end plug and install into the supply manifold. Torque to specifications. Refer to Specifications in Section 1.A.

Installation of Valve Assembly

To install the valve assembly, follow these steps. ‪

  1. Lubricate the valve stems with clean engine oil and insert the valves into the valve guides.
  2. Lubricate the I.D. of the new valve stem seal assemblies with clean engine oil and install them over the valve and valve guide. See Figure 31104 . Ensure the seal assemblies are seated down against the cylinder head spring pockets.

    1. Valve Stem ‪

    3. Stem Seal Assembly ‪

    2. Valve Guide ‪

    Valve Stem Seal Installation

  3. Install the valve spring over the stem seal assembly.
  4. Install the rotator assembly over the valve spring. See Figure 31105 .

    1. Valve Spring ‪

    2. Valve Rotator ‪

    Rotator Assembly Installation

  5. Compress the valve spring and install the spring locks (keepers). See Figure 31106 .

    1. Spring Compressor ‪

    2. Spring Lock (Keepers) ‪

    Spring Lock Installation

Installation of Cylinder Head

Install the cylinder head assembly as follows: ‪

  1. Clean and dry the cylinder head gasket surfaces.

    Note: Prior to cylinder head installation, check the cylinder liner protrusion.

    To avoid injury from flying debris when using compressed air, wear adequate eye protection (face shield or safety goggles) and do not exceed 40 psi (276 kPa) air pressure.

  2. Clean all cylinder head bolt holes with an appropriate tap and blow out the bolt holes with filtered compressed air.
  3. Install the dowel rings into the crankcase top deck. See Figure 31107 .

    1. Crankcase ‪

    2. Dowel Ring ‪

    Rotator Assembly Installation

  4. Install a new cylinder head gasket over the locating dowel rings.
  5. Carefully lower the cylinder head onto the gasket. See Figure 31108 .

    1. Cylinder Head ‪

    3. Crankcase ‪

    2. Cylinder Head Gasket ‪

    Cylinder Head Gasket Installation

  6. Lubricate the cylinder head bolt threads, washers and under head seating area with clean engine oil. See Figure 31109 .

    1. Cylinder Head Bolt ‪

    2. Cylinder Head ‪

    Lubricate Bolt Threads

  7. Run 20 cylinder head mounting bolts in finger-tight.
  8. Install the pushrods with the cup end up. See Figure 31075 .

    1. Pushrod ‪

    2. Cylinder Head ‪

    Install Pushrods

Installation of Rocker Arm

Install the valve lever (rocker arm) assembly as follows: ‪

  1. Install the valve lever (rocker arm) assembly onto the cylinder head using six cylinder head mounting bolts.
    1. Insert the rocker arm and shaft assembly with the long cylinder head bolts, into their respective bolt holes. See Figure 31110 .
    2. 1. Rocker Shaft Bracket ‪

      2. Cylinder Head ‪

      Rocker Arm and Shaft Assembly

    3. Run the long cylinder head bolts in finger-tight (except the two end bolts). Place a 0.005 in. (0.013 mm) feeler gage between the outside brackets and the rocker levers to prevent binding. Finger-tighten the remaining two end bolts. See Figure 31111 .
    4. 1. Bracket ‪

      3. Feeler Gage ‪

      2. Wrench ‪

      4. Rocker Lever ‪

      Rocker Arm Assembly Installation

  2. Tighten the cylinder head bolts in three stages.

    Note: Check the two end rocker arms for freedom of movement after tightening the cylinder head bolts.

  3. Remove the two 0.005 in. (0.013 mm) feeler gages.
  4. Adjust valve lash as follows
    1. Rotate the crankshaft until the #1 piston is on the compression stroke and the timing pointer on the front cover is in line with the TDC mark on the vibration damper.
    2. Set valve lash by loosening the locknut and turning the valve adjustment screw with the appropriate size feeler gage inserted between the rocker arm and valve stem tip. Tighten the valve adjustment screw until the valve lever can support the feeler gage. See Figure 31112 .
    3. 1. Locknut ‪

      2. Insert Feeler Gage ‪

      Valve Lash Adjustment

    4. Tighten the locknut once the valve adjustment is set. Remove the feeler gage. See Figure 31113 .
    5. Valve Lash Adjustment

Valve Lash Adjustment Sequence

Six valves are adjusted when the No. 1 piston is at TDC (compression) and the remaining six are adjusted when the No. 6 piston is at TDC. See Figure 31114 . ‪

Valve Lash Adjustment Sequence

  1. Install gasket onto the cylinder head and align valve cover/intake manifold cover and gasket. Tighten valve cover/intake manifold mounting bolts to specified torque. See Figure 31115 . Refer to Specifications in Section 1.A.

    Note: Ensure valve cover gasket is aligned before tightening.

    Valve Cover/Intake Manifold Cover and Gasket

  2. Install the following components. Refer to the appropriate manual section for installation procedures.