ISC, ISCe, QSC8.3, ISL, ISLe3, ISLe4 and QSL9 Engines – 002-004   Cylinder Head

WARNING  Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.

WARNING  Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50°C [120°F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury.

WARNING  Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations.

If troubleshooting coolant in the fuel, fuel in the coolant, fuel in the oil, or oil in the fuel, pressurize the internal fuel drain line in the cylinder head and check for leaks.

Connect a regulated air supply hose to the cylinder head fuel drain port with a shut off valve on the air supply side of the pressure gauge.

Apply air pressure.

Air Pressure

Shut off the air supply to the fuel drain port and monitor the pressure gauge reading. The pressure should hold steady. If the pressure drops rapidly, check for leaks around:

• Test fittings
• Fuel connectors at the cylinder head
• Remove the radiator cap and check for air bubbles in the cooling system.

If the source of the leak can not be determined, remove the cylinder head and pressure test the complete cylinder head. See the Pressure Test step of this procedure. Replace the cylinder head if necessary.

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

WARNING  Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50°C [120°F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury.

WARNING  Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations.

• Disconnect the batteries. Refer to Procedure 013-009 in Section 13.
• Remove the air crossover tube. Refer to Procedure 010-019 in Section 10.
• Remove the air intake connection adapter. Refer to Procedure 010-131 in Section 10.
• Remove all water and heater hoses. Refer to Procedure 008-045 in Section 8.
• Remove the turbocharger actuator air line, if equipped. Refer to Procedure 010-118 in Section 10.
• Remove the turbocharger control valve, if equipped. Refer to Procedure 019-388 in Section 19 in the Troubleshooting and Repair Manual, ISB, QSB4.5, QSB5.9, QSB6.7, ISC, QSC8.3, ISL and QSL9 Engines, CM850 Electronic Control System, Bulletin 4021416.
• Remove the intake manifold cover and intake heater. Refer to Procedure 010-108 (Air Intake Manifold Cover) in Section 10. Refer to Procedure 010-080 (Air Intake Connection) in Section 10.
• Remove the injector supply lines. Refer to Procedure 006-051 in Section 6.
• Remove the fuel rail. Refer to Procedure 006-060 in Section 6.
• Remove the fuel connection tubes. Refer to Procedure 006-052 in Section 6.
• Remove the rocker lever cover. Refer to Procedure 003-011 in Section 3.
• Remove the rocker lever housing. Refer to Procedure 003-013 in Section 3.
• Remove the engine brake assembly, if equipped. Refer to Procedure 020-004 in Section 20.
• Remove the rocker lever. Refer to Procedure 003-008 in Section 3.
• Remove the crossheads. Refer to Procedure 002-001 in Section 2.
• Remove the push rods or tubes. Refer to Procedure 004-014 in Section 4.
• Remove the fuel drain lines. Refer to Procedure 006-013 in Section 6.
• Remove the turbocharger. Refer to Procedure 010-033 in Section 10.
• Remove the exhaust manifold. Refer to Procedure 011-007 in Section 11.
• Remove the drive belt. Refer to Procedure 008-002 in Section 8.

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

WARNING  Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50°C [120°F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury.

WARNING  Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations.

CAUTION  Use caution when disconnecting or removing fuel lines, replacing filters and priming the fuel system that fuel is not spilled or drained into the bilge area. Do not drop or throw filter elements into the bilge area. The fuel and fuel filters must be discarded in accordance with local environmental regulations.

CAUTION  Use caution when draining the coolant system that coolant is not spilled or drained into the bilge area. Do not drop or throw filter elements into the bilge area. The coolant and coolant filters must be discarded in accordance with local environmental regulations.

• Shut off the sea water supply, if applicable. Refer to the OEM service manual.
• Shut off the fuel supply and drain valves. Refer to the OEM service manual.
• Disconnect the batteries. Refer to Procedure 013-009 in Section 13.
• Drain the engine coolant. Refer to Procedure 008-018 in Section 8.
• Drain the sea water system, if the engine has a heat exchanger. Refer to Procedure 008-053 in Section 8.
• Remove the air crossover from the air intake connection and the aftercooler. Refer to Procedure 010-019 in Section 10.
• Remove the air intake connection. Refer to Procedure 010-080 in Section 10.
• Remove the fuel filter head bracket. Refer to Procedure 006-018 in Section 6.
• Remove the fuel lift pump. Refer to Procedure 005-045 in Section 5.
• Remove the injector fuel lines. Refer to Procedure 006-051 in Section 6.
• Remove the common fuel rail. Refer to Procedure 006-060 in Section 6.
• Disconnect and remove the intake manifold temperature sensor. Refer to Procedure 019-059 in Section 19 in the Troubleshooting and Repair Manual, Electronic Control System, ISC, QSC8.3 and ISL Engines, Bulletin 3666271.
• Disconnect and remove the intake manifold pressure sensor. Refer to Procedure 019-061in Section 19 in the Troubleshooting and Repair Manual, Electronic Control System, ISC, QSC8.3 and ISL Engines, Bulletin 3666271.
• Disconnect and remove the intake manifold temperature sensor. Refer to Procedure 019-059 in Section 19 in the Troubleshooting and Repair Manual, ISB, QSB4.5, QSB5.9, QSB6.7, ISC, QSC8.3, ISL and QSL9 Engines, CM850 Electronic Control System, Bulletin 4021416.
• Disconnect and remove the intake manifold pressure sensor. Refer to Procedure 019-061 in Section 19 in the Troubleshooting and Repair Manual, ISB, QSB4.5, QSB5.9, QSB6.7, ISC, QSC8.3, ISL and QSL9 Engines, CM850 Electronic Control System, Bulletin 4021416.
• Remove the intake manifold cover. Refer to Procedure 010-108 in Section 10.
• Remove the fuel drain lines from the rear of the cylinder head. Refer to Procedure 006-013 in Section 6.
• This step applies to QSL9 engines only. Remove the two aftercooler to cylinder head bracket mounting capscrews. Refer to Procedure 010-005 in Section 10.
• Remove all water and heater hoses. Refer to Procedure 008-045 in Section 8.
• Remove the coolant vent lines from the turbocharger and expansion tank. Refer to Procedure 008-017 in Section 8.

NOTE: This next step applies to QSL9 engines only. The expansion tank and heat exchanger on the QSC8.3 engines are a one-piece unit. Refer to Procedure 008-053 in Section 8.

• Remove the expansion tank. Refer to Procedure 008-052 in Section 8.

NOTE: Some QSL9 engines are keel cooled and do not have heat exchangers.

• Remove the heat exchanger, if equipped. Refer to Procedure 008-053 in Section 8.
• Remove the turbocharger and exhaust manifold as an assembly. Refer to Procedure 011-008 in Section 11.
• Remove the fuel connection tubes. Refer to Procedure 006-052 in Section 6.
• Remove the rocker lever cover. Refer to Procedure 003-011 in Section 3.
• Remove the rocker lever housing. Refer to Procedure 003-013 in Section 3.
• Remove the rocker lever.Refer to Procedure 003-008 in Section 3.
• Remove the crossheads. Refer to Procedure 002-001 in Section 2.
• Remove the push rods or tubes. Refer to Procedure 004-014 in Section 4.

WARNING  This component or assembly weighs greater than 23 kg [50 lb]. To prevent serious personal injury, be sure to have assistance or use appropriate lifting equipment to lift this component or assembly.

Remove the cylinder head capscrews.

Remove the cylinder head and gasket from the cylinder block.

NOTE: If a leaking valve is suspected, use valve vacuum tester, Part Number 3824277, and cup, Part Number ST-1247-6, to vacuum test the valves and valve seats. The vacuum must not drop more than 254 mm Hg [10 in Hg] in 10 seconds.

NOTE: If a vacuum tester is not available, use a lead pencil or Dykem™ marking pen with the valve removed to mark across the valve face. Install the valve in the valve guide. Hold the valve against the valve seat and rotate the valve backward and forward three or four times. Correct contact against the valve seat will break the marks on the valve face.

If out of specification, disassemble the cylinder head and inspect for damaged valves and/or valve seat inserts. Repair as necessary:

1. Clean the valve/valve seat inserts and lap the valves.
2. Replace the damaged valve/valve seat inserts (if available).
3. Replace the cylinder head.

Install the cylinder head in the cylinder head holding fixture, Part Number ST-583.

Before removing the injectors, use gauge block, Part Number 3164438, to measure the injector protrusion.

Place the injector protrusion tool on the flat surface of the head. Measure the injector protrusion to the highest point on the injector. The protrusion must be within the following specifications:

Injector Protrusion (CAPS Fuel System)

Injector Protrusion (Cummins® Common Rail Fuel System)

Remove the injector. Refer to Procedure 006-026 in Section 6.

If the injector protrusion is out of specification, check the thickness of the injector sealing washer. Refer to Procedure 006-026 in Section 6.

If the sealing washer is the correct thickness, check to make sure the injector bore is clean and free of debris. Also make sure that sealing washers are not “stacked” in the injector bore.

Standard Cylinder Head

Measure the valve recess.

Standard Head Valve Recess in Cylinder Head

If the valve recess is outside of the specifications, replace the valve. If the valve recess is still outside the specifications, the valve seat insert or cylinder head must be replaced.

Scallop Cylinder Head

Measure the valve recess.

Scallop Head Valve Recess in Cylinder Head

If the valve recess is outside of the specifications, replace the valve. If the valve recess is still outside the specifications, the valve seat insert or cylinder head must be replaced.

Compress the valve springs and remove the valve stem collets. Use valve spring compressor, Part Number 3164329.

Release the valve springs and remove the spring retainers and springs.

Use the boot pliers, Part Number 3163293, to remove the valve stem seal.

Remove and discard the valve stem seals.

Keep the valves in a labeled rack for a correct match with companion seats while making measurements.

Mark the valves to identify their location. Any numbering system can be used as long as the valves are put back in their original location if they are to be reused.

Remove the valves.

NOTE: Prior to removing the valve guide, reference the Inspect for Reuse section in this procedure. The condition of the valve guide will help to determine if it needs to be replaced.

Use valve guide driver, Part Number 3163101, to remove the old valve guides.

NOTE: Prior to the removal of the valve seat inserts, reference the Clean and Inspect for Reuse section in this procedure. The condition of the valve, the amount of recess, and the sealing of the valve on the seat insert all help to determine if a valve seat insert needs to be replaced.

1. If required, remove the valve seat inserts.
2. Inspect the valve-insert-to-cylinder-head contact area. A sufficient groove for the remover must exist.
3. If there is sufficient valve seat insert groove area, proceed to the next step.
4. If the valve seat insert groove area is not sufficient, use the valve seat insert cutting kit, Part Number 3376405, to create a sufficient groove.

Use the slide hammer remover, Part Number 3376617, with intake valve seat insert extractor, Part Number 3165113 and exhaust valve seat insert extractor, Part Number 3165114, to remove the valve seat inserts.

NOTE: Make certain the valve seat insert remover assembly is perpendicular to the cylinder head when installed. Place the valve seat insert remover assembly into the valve seat insert and rotate the t-handle clockwise until the remover loosely grips the valve seat insert.

Position the valve seat insert remover assembly into the valve seat insert groove area. Tighten the t-handle firmly, allowing the remover to expand under the valve seat insert or into the cut groove.

Strike the slide hammer remover against the top nut until the valve seat insert is removed. Turn the t-handle counterclockwise to release the valve seat insert from the remover.

Use injector bore brush, Part Number 3822509, to clean the carbon from the injector nozzle seat.

Scrape the gasket material from all gasket surfaces on the block and head.

WARNING  When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer’s recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury.

WARNING  Some solvents are flammable and toxic. Read the manufacturer’s instructions before using.

WARNING  Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.

WARNING  Wear protective eye covering while cleaning carbon deposits to prevent injury.

Clean the buildup of deposits from the coolant passages. Excessive deposits can be cleaned in an acid tank, but the expansion plugs must first be removed.

Clean the cylinder head combustion deck with an abrasive pad, Part Number 3823258, or equivalent, and diesel fuel or solvent. The surface finish (RA – roughness average) maximum is 3.2 µm [0.0001 in].

Clean carbon deposits from the valve pockets with a high quality steel wire wheel installed in a drill or a die grinder.

NOTE: An inferior quality wire wheel will lose steel bristles during operation, causing additional contamination.

Wash the cylinder head in a hot, soapy water solution.

Dry with compressed air.

Use a straight edge, Part Number 4918219, and a feeler gauge to measure the overall flatness of the cylinder block.

The overall flatness, end to end and side to side, must not exceed 0.075 mm [0.003 in].

Use a 2-foot straight edge and a 0.0254 mm [0.001 in] feeler gauge to measure local cylinder block combustion surfaces flatness. Check between the cylinder bores and also between the coolant passages. If the 0.0254 mm [0.001 in] feeler gauge fits under the 2-foot straight edge, or if the cylinder block is pitted, has grooves or other damage, the cylinder block must be replaced.

Cylinder Head Cracks – Reuse Guidelines

The reuse guidelines for a cylinder head with a crack extending from the injector bore to the intake valve seat are as follows:

• If a crack does not extend into the valve seat, the cylinder head is reusable.

Inspect the valve seats for cracks or burn spots.

• If the valve seats are cracked or burned, the valve seat must be replaced.
• If the valve seat has dropped out and caused damage to the cylinder head combustion face, the cylinder head must be replaced.

If a crack extends into or through the valve seat bore, the cylinder head must be replaced.

Use crack detection kit, Part Number 3375432, to help identify cylinder head cracks.

WARNING  When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer’s recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury.

WARNING  Wear appropriate eye and face protection when cleaning the valves. Flying debris and dirt can cause personal injury.

Use a wire brush and solvent to clean the deposits from the valve seat insert bores, if it was necessary to remove the valve seat inserts.

Dry with compressed air.

If the valve seat insert was removed in the Disassemble section, measure the inside diameter of the valve seat insert bore in the cylinder head.

Cylinder Head Insert Bore Inside Diameter (ID)

NOTE: Before cutting the cylinder head, verify the valve seat inserts are available for the engine being serviced. If none are available, the cylinder head must be replaced.

If out of specification, the valve seat insert bore can be oversized 0.254 mm [0.010 in].

Cylinder Head Insert Bore Inside Diameter (ID) for Oversized Seats

NOTE: It is very important to take precise measurements of the valve seat pocket diameter. A 4-point contact gauge is recommended for this measurement process. Failure to take proper diameter measurements will lead to a poor press fit of the valve seat, which may lead to a dropped valve seat and damage to the cylinder head combustion face.

Use a straight edge, Part Number 4918219, and a feeler gauge to inspect the cylinder head combustion surface for flatness.

Cylinder Head Flatness

Use a 2-foot straight edge and a 0.0254 mm [0.001 in] feeler gauge to measure local cylinder head combustion surface flatness. Check between the cylinder bores and also between the coolant passages. If the 0.0254 mm [0.001 in] feeler gauge fits under the 2-foot straight edge or if the cylinder head is pitted, has grooves or other damage, the cylinder head must be replaced.

WARNING  When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer’s recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury.

WARNING  Some solvents are flammable and toxic. Read the manufacturer’s instructions before using.

Clean the valve heads with a soft wire wheel.

NOTE: Keep the valves in a labeled rack to prevent mixing prior to making measurements.

Polish the valve stems with an abrasive pad, Part Number 3823258, or equivalent, and diesel fuel or solvent.

WARNING  Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.

Use a bristle brush to clean the inside diameter of the valve guide bore and blow out with compressed air.

Inspect the valve guides for scuffing, scoring, chips, or cracks.

Measure the valve guide inside diameter.

Valve Guide Inside Diameter

If the valve guide inside diameter is worn larger than the maximum specified, the cylinder head must be replaced.

Use a depth micrometer to measure the valve guide installed height. Measure from the top of the valve guide to the bottom of the recessed area.

Valve Guide Height (Installed)

If the valve guide height is outside the specification, the cylinder head must be replaced.

Verify the valve sealing area is in the center of the valve. If the sealing area extends to the top or bottom of the valve, the valve must be replaced.

After replacing the valve, recheck the valve sealing area. If the sealing area still extends to the top or bottom of the valve, the valve seat must be replaced.

Use a lead pencil or Dykem™ marking pen to mark across the valve face. Install the valve in the valve guide. Hold the valve against the valve seat and rotate the valve backward and forward three or four times. Correct contact against the valve seat will break the marks on the valve face.

Valve seat angle:

• Intake is 30 degrees
• Exhaust is 45 degrees.

Inspect for abnormal wear or scuffing on the heads and stems.

Measure the valve stem diameter.

Valve Stem Diameter

Replace any valve found outside these dimensions.

Check the valve stem tip for flatness.

Inspect for bent valves.

Measure the rim thickness.

NOTE: Measure 90 degrees apart to verify uniformity of lap.

If the valve thickness is not within the limits, a new valve must be used.

Valve Rim Thickness

Inspect the valve springs.

Measure the valve spring.

A load of 906 to 1007 N [204 to 226 lbf] is required to compress the spring to a height of 30.6 mm [1.20 in]. Use spring compressor tool, Part Number 3375182, to measure spring force.

Replace the valve spring if the load required to compress the spring is outside the specification.

WARNING  When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer’s recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury.

WARNING  Some solvents are flammable and toxic. Read the manufacturer’s instructions before using.

Use a petroleum-based solvent to clean the capscrews.

Clean the capscrews thoroughly with a wire brush or a soft wire wheel. A non-abrasive bead blaster can be used to remove deposits from the shank and the threads.

Inspect the cylinder head capscrews for damaged threads, corroded surfaces, or a reduced diameter (due to capscrew stretching).

Do not reuse cylinder head capscrews under the following conditions:

Visible corrosion or pitting exceeds 1 sq cm [0.155 sq in] in area. Example:

• Acceptable is 9.525 x 9.525 mm [3/8 x 3/8 in].
• Unacceptable is 12.700 x 12.700 mm [1/2 x 1/2 in].

• Visible corrosion or pitting exceeds 0.12 mm [0.005 in] in depth.
• Visible corrosion or pitting is located within 3.2 mm [1/8 in] of the fillet or threads
• Stretched beyond “free length” maximum. Reference the measurement procedure below.

Capscrew Length Gauge, Part Number 3823921

Free Length Measurement

NOTE: If the capscrews are not damaged, they can be reused throughout the life of the engine, unless the specified “free length” is exceeded.

To check the capscrew free length, place the head of the capscrew in the appropriate slot with the flange against the base of the slot.

If the end of the capscrew touches the foot of the gauge, the capscrew is too long and must be discarded. The maximum capscrew free length is 162.6 mm [6.4 in].

Cylinder Head Capscrew Free Length

A cylinder head test fixture can be fabricated from a flat piece of steel or aluminum. Reference the following table for test fixture dimensions.

Use a cylinder head gasket as a pattern for drilling the capscrew holes.

Install the cylinder head water test fixture.

• Install a new head gasket.
• Install the test plate.

Install the following:

• 26 – 180 mm long head capscrews, Part Number 3920781
• 26 – M12 x 1.75 hexagon flange nuts
• 52 – 12 mm washers, Part Number 3900269

Place a washer between each capscrew and the head, and between each nut and test plate. This will prevent mutilation on the surface of the cylinder head.

Tighten the 26 nuts in the sequence shown in the illustration.

WARNING  This component or assembly weighs greater than 23 kg [50 lb]. To prevent serious personal injury, be sure to have assistance or use appropriate lifting equipment to lift this component or assembly.

Connect a regulated air supply hose to the test fixture plate.

Apply air pressure.

Use a nylon lifting strap and hoist to place the cylinder head in a tank of heated water.

The cylinder head must be completely submerged in the water.

If the head leaks, it must be replaced.

Inspect the cylinder head. Bubbles indicate an air leak.

If the cylinder head leaks, it must be replaced.

WARNING  Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.

Remove the test fixture.

Use compressed air to dry the cylinder head.

Install the cylinder head in the cylinder head holding fixture, Part Number ST-583.

Use valve guide driver, Part Number 3163100, to install the new valve guides.

Verify the valve slides freely in the valve guide. If not, it may be necessary to ream the guide bore.

Reference the Clean and Inspect for Reuse step for valve guide inside diameter specifications.

Use a depth micrometer to measure the valve guide installed height. Measure from the top of the valve guide to the bottom of the recessed area.

Valve Guide Height (Installed)

If the valve guide height is not within specifications, seat the guide with the installation tool.

When installing the valve seat inserts, the exhaust and intake valve seat inserts are not the same.

Valve seat angle:

• Intake is 30 degrees
• Exhaust is 45 degrees.

If the valve seat inserts were removed in the Disassemble section, new inserts must be installed.

NOTE: The valve guide must be installed prior to installing the valve seats.

Make sure the valve seat pocket and valve seat is clean before installing.

The insert chamfer (1) must be installed toward the bottom of the counterbore.

Use valve seat installer, Part Number 3165115, to drive the intake and exhaust valve seat inserts into the counterbore.

Use a dead blow hammer with the seat drivers to install the new valve seat inserts.

The seats must be fully seated into the valve seat pocket. There should not be a gap between the seat and the bottom of the pocket.

Measure the valve-seat-to-valve-guide runout. Use arbor set, Part Number 3823186, and eccentrimeter, Part Number ST-685-4, or equivalent.

Valve-Seat-to-Valve-Guide Runout

If the valve-seat-to-valve-guide runout is not within specifications, one of the following actions can be taken:

• Apply Dykem™ marking pen to the valve seat and valve seating surfaces and allow to dry. Install the valve in the valve guide. Hold the valve against the valve seat, and rotate the valve backward and forward three to four times. Verify the contact against the valve seat forms a uniform band on the valve sealing surface. If a uniform band is formed, the assembly is within specifications.
• Clean the valve/valve seat and lap the valves.
• Remove the valve seat and make sure no debris is causing an issue under the seat. Reinstall the valve seat if debris is found.
• Remove the valve seat and machine the valve seat pocket oversize so that an oversize valve seat can be installed. Reference the Clean and Inspect for Reuse section above for valve seat pocket diameter specifications. Use the valve guide ID during machining to help position the valve seat pocket to valve guide ID, to make sure of a proper runout measurement after the oversize valve seat is installed.
• Replace the cylinder head.

If new valve seat inserts were installed and/or the valve leakage was above specification, the valve seat/valve can be lapped.

Lubricate the stems with SAE 15W-40 engine oil before installing the valves.

Use a fine lapping compound, Part Number 3375805, or equivalent. Apply a thin and even coating on the valve.

Use a power or a hand suction lapping tool to provide pressure in the center of the valve.

Turn the valve backward and forward. Continue lapping until the compound shows a continuous contact pattern on both the valve seat insert and the valve.

CAUTION  Lapping compound is an abrasive material. Damage will result if the cylinder head, valves, and valve seats are not cleaned thoroughly.

Clean the lapping compound from the parts.

Measure the valve rim thickness. Reference the Clean and Inspect for Reuse section.

Valves that are being reused must be installed in the same location from which they were removed.

Lubricate the stems with SAE 90W or 15W-40 engine oil before installing the valves.

Install the valves.

Install the valve seals over the exhaust valve guides.

Install the valve seals over the intake valve guides.

Install the valve spring retainers and valve springs.

Use valve spring compressor, Part Number 3164329, to compress the valve springs.

Install the valve collets and release the spring tension.

After assembly, hit the valve stems with a plastic hammer to make sure the collets are seated.

Standard Cylinder Head

Measure the valve recess.

Standard Head Valve Recess in Cylinder Head

If the valve recess is outside the specifications, replace the valve. If the valve recess is still outside the specifications, the valve seat insert or cylinder head must be replaced.

Scallop Cylinder Head

Measure the valve recess.

Scallop Head Valve Recess in Cylinder Head

If the valve recess is outside of the specifications, replace the valve. If the valve recess is still outside the specifications, the valve seat insert or cylinder head must be replaced.

Before installing the cylinder head, vacuum test the cylinder head again. Reference the information above in the Vacuum Test section of this procedure.

Before installing the cylinder head, check the cylinder liner protrusion. Refer to Procedure 001-028 in Section 1.

CAUTION  Make sure the cylinder head gasket is correctly aligned with holes in the cylinder block. If not aligned properly, it can cause engine damage.

Do not attempt to reuse the cylinder head gasket.

Position the new cylinder head gasket over the dowels.

WARNING  This component or assembly weighs greater than 23 kg [50 lb]. To prevent serious personal injury, be sure to have assistance or use appropriate lifting equipment to lift this component or assembly.

Carefully put the cylinder head straight down onto the cylinder block, and seat it onto the dowels.

If new capscrews are used, capscrew threads are to be burnished. To burnish new capscrews, tighten the capscrews as described below. Loosen the capscrews and repeat the tightening sequence.

Lubricate the threads and under the heads on the cylinder head capscrews with clean 15W-40 engine lubricating oil.

Tighten the cylinder head capscrews in the sequence shown in the illustration.

WARNING  Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations.

WARNING  Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

• Install the drive belt. Refer to Procedure 008-002 in Section 8.
• Install the exhaust manifold. Refer to Procedure 011-007 in Section 11.
• Install the turbocharger. Refer to Procedure 010-033 in Section 10.
• Install the turbocharger control valve, if equipped. Refer to Procedure 019-388 in Section 19 in the Troubleshooting and Repair Manual, ISB, QSB4.5, QSB5.9, QSB6.7, ISC, QSC8.3, ISL and QSL9 Engines, CM850 Electronic Control System, Bulletin 4021416.
• Install the fuel drain lines. Refer to Procedure 006-013 in Section 6.
• Install the push rods or tubes. Refer to Procedure 004-014 in Section 4.
• Install the injectors. Refer to Procedure 006-026 in Section 6.
• Install the crossheads. Refer to Procedure 002-001 in Section 2.
• Install the rocker lever. Refer to Procedure 003-008 in Section 3.
• Install the engine brake assembly, if equipped. Refer to Procedure 020-004 in Section 20.
• Install the rocker lever housing. Refer to Procedure 003-013 in Section 3.
• Install the rocker lever cover. Refer to Procedure 003-011 in Section 3.
• Install the fuel connection tubes. Refer to Procedure 006-052 in Section 6.
• Install the fuel rail. Refer to Procedure 006-060 in Section 6.
• Install the injector supply lines. Refer to Procedure 006-051 in Section 6.
• Install the turbocharger actuator air line, if equipped. Refer to Procedure 010-118 in Section 10.
• Install all water and heater hoses. Refer to Procedure 008-045 in Section 8.
• Install the intake manifold cover and intake heater. Refer to Procedure 010-108 in Section 10. Refer to Procedure 010-080 in Section 10.
• Install the crankcase breather tube. Refer to Procedure 003-018 in Section 3.
• Install the air crossover tube. Refer to Procedure 010-019 in Section 10.
• Operate the engine and check for leaks.

WARNING  Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations.

WARNING  Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

• Install the push rods or tubes. Refer to Procedure 004-014 in Section 4.
• Install the crossheads. Refer to Procedure 002-001 in Section 2.
• Install the rocker lever assembly. Refer to Procedure 003-008 in Section 3.
• Install the rocker lever housing.Refer to Procedure 003-013 in Section 3.
• Adjust the overhead. Refer to Procedure 003-004 in Section 3.
• Install the rocker lever cover. Refer to Procedure 003-011 in Section 3.
• Install the fuel connection tubes. Refer to Procedure 006-052 in Section 6.
• Install the turbocharger and exhaust manifold as an assembly. Refer to Procedure 011-008 in Section 11.

NOTE: This next step applies to QSL9 engines only. The expansion tank and heat exchanger on the QSC8.3 engines are a one-piece unit. Refer to Procedure 008-053 in Section 8.

• Install the expansion tank. Refer to Procedure 008-052 in Section 8.

NOTE: Some QSL9 engines are keel cooled and do not have heat exchangers.

• Install the heat exchanger, if equipped. Refer to Procedure 008-053 in Section 8.

• Install the coolant vent lines to the turbocharger and expansion tank. Refer to Procedure 008-017 in Section 8.
• Install all water and heater hoses. Refer to Procedure 008-045 in Section 8.
• Install the two aftercooler to cylinder head bracket mounting capscrews. Refer to Procedure 010-005 in Section 10.
• Install the fuel drain lines from the rear of the cylinder head. Refer to Procedure 006-013 in Section 6.
• Install the intake manifold cover. Refer to Procedure 010-108 in Section 10.
• Install the intake manifold temperature sensor.Refer to Procedure 019-059 in Section 19 in the Troubleshooting and Repair Manual, Electronic Control System, ISC, QSC8.3 and ISL Engines, Bulletin 3666271.
• Install the intake manifold pressure sensor. Refer to Procedure 019-061in Section 19 in the Troubleshooting and Repair Manual, Electronic Control System, ISC, QSC8.3 and ISL Engines, Bulletin 3666271.
• Install the intake manifold temperature sensor. Refer to Procedure 019-059 in Section 19 in the Troubleshooting and Repair Manual, ISB, QSB4.5, QSB5.9, QSB6.7, ISC, QSC8.3, ISL and QSL9 Engines, CM850 Electronic Control System, Bulletin 4021416.
• Install the intake manifold pressure sensor. Refer to Procedure 019-061 in Section 19 in the Troubleshooting and Repair Manual, ISB, QSB4.5, QSB5.9, QSB6.7, ISC, QSC8.3, ISL and QSL9 Engines, CM850 Electronic Control System, Bulletin 4021416.
• Install the common fuel rail. Refer to Procedure 006-060 in Section 6.
• Install the injector fuel lines. Refer to Procedure 006-051 in Section 6.
• Install the fuel lift pump. Refer to Procedure 005-045 in Section 5.
• Install the fuel filter head bracket. Refer to Procedure 006-018 in Section 6.
• Install the air intake connection. Refer to Procedure 010-080 in Section 10.
• Install the air crossover from the air intake connection and the aftercooler. Refer to Procedure 010-019 in Section 10.
• Fill the engine coolant. Refer to Procedure 008-018 in Section 8.
• Open the sea water supply, if necessary. Refer to the OEM service manual.
• Open the fuel supply and return valves. Refer to the OEM service manual.
• Connect the batteries. Refer to Procedure 013-009 in Section 13.
• Operate the engine and check for leaks.