Install the cylinder head in the cylinder head holding fixture, Part Number ST-583.
Scrape the gasket material and clean the combustion deck surfaces on the cylinder block and cylinder head.
Use a straightedge and a feeler gauge to inspect the cylinder head combustion surface for flatness.
If out of specification determine if the cylinder head can be resurfaced, or if the cylinder head must be replaced
by:
โข Measuring and recording valve depth
โข Measuring and recording injector protrusion.
If valve depth and injector protrusion specifications can be maintained, the cylinder head can be resurfaced. If the
specifications can not be maintained, the cylinder head must be replaced.
Install depth gauge assembly, Part Number 3164438, on the cylinder head combustion deck and zero the gauge.
Rotate the depth gauge to measure the injector protrusion at the highest point on the injector.
Record the injector protrusion for each injector.
NOTE: Do not use thicker or double stacked injector sealing washers to correct injector protrusion. This will
cause misalignment of the high pressure fuel connector.
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.
If the injector protrusion is within specification, remove the injectors. Refer to Procedure 006-026 in Section 6.
Install depth gauge assembly, Part Number 3164438, on the cylinder head combustion deck and zero the gauge.
Rotate the depth gauge to measure the valve recession into the cylinder head (B).
Record the valve depth for each valve.
NOTE: Valve depth can be increased slightly for resurfacing of the cylinder head by lapping the valves.
If a leaking valve is suspected or if the cylinder head was recently rebuilt, vacuum test the valves and valve seats.
Use valve vacuum tester, Part Number 3824277, and cup, Part Number ST-1257-6. The vacuum must not drop more
than 25.4 mm Hg [1.0 in Hg] in five seconds.
NOTE: If a vacuum tester is not available, with the valve removed, use a lead pencil or DykemTM 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 seats. Repair as
necessary by:
โข Cleaning the valve/valve seat and lap the valves
โข Replacing the damaged valve/valve seat (if available)
โข Replacing the cylinder head.
Use a straightedge and feeler gauge to measure the overall flatness of the cylinder block.
Inspect the combustion deck for any localized dips or imperfections.
If out of specification, determine if the cylinder block can be resurfaced or if the cylinder block must be replaced.
Refer to Procedure 001-026 in Section 6.
