Waukesha VHP SUBJECT: MODELS AFFECTED: NOTE: Table § lists all special tools required. INTAKE AND EXHAUST VALVES INTAKE AND EXHAUST VALVE REMOVAL 4 WARNING Use caution when removing or installing the valve springs. They are under tension and can eject from the cylinder head during the removal process. Use the correct valve spring compressor for this procedure. Wear safety goggles. Disregarding this information could result severe personal injury or death. Valve spring compressor (P/N 474031 or P/N 474033) ig avaiable for use on PIN 204702 series cylinder heads, This too! is designed so that all four valve tprings can be compressed at once. Use ofthis tol greatly reduces service time for such tasks as valve stom teal replacement, valve replacement, and cylin: der head overhaul. The tool may be used with the cyl inder heads on or off the engine. it removing the valve ACAUTION J tapers, springs, — or valve stem seals with the cylinder heads on the engine, the piston below each cylinder head must be at top dead center. if each piston is not at top dead center, the valves will fall into the combus- tion chamber, damaging the valves. Cylinder head removal will be required to remove the valves from the combustion chamber. Disregarding this infor- n could result in product damage and/or per- sonal injury 1. If not already removed, refer to the appropriate Repair and Overhaul Manual, and remove rocker arm assemblies, valve bridge assemblies, and spark plug sleeve, SERVICE BULLETIN TOPIC: Cylinder Heads IDENT NO: 7-2984B SUPERSEDES: 7-2984A DATE: October 15, 2008 Cylinder Head Overhaul Procedures All Non Series Four® VHP Engines NOTE: Current head assemblies do not use oll deflectors. If the head being disassembled has oil deflectors on the intake valves, proceed with Step 2. Otherwise, go to Step 3. 2. GSI only ~ Remove and discard retaining rings, rings, and oll deflectors from intake valves, equipped, 3. Install spring compressor center guide stud in cylinder head Look through the holes A CAUTION Jin tne pressure pate to ensure that they are aligned with the valve stems, threaded studs, and valve bridge guide studs. Fall- ure to align the pressure plate properly could cause damage to equipment. Disregarding this information could result in product damage andlor personal injury 4. Position pressure plate over vaive stems, threaded studs, and valve bridge guide studs. Ensure large diameter countersunk holes are facing up and are aligned aver valve stems (see Figuro 1). 5. Apply engine oil to threads of center guide stud. PRESSURE, PLATE Figure 1. Valve Spring Compressor Page 1 of 22Service Bulletin No. 7-2984B 6. Install thrust bearing and compression nut on center guide stud 7. Tighten compression nut down until pressure plate compresses valve springs just enough to release valve tapers (see Figure 1 and Figure 2). 8 Remove valve tapers from valve stems (see Figure 2). 9. Loosen and remove compression nut and thrust bearing from center guide stud, 10. Remove pressure plate from cylinder head, Remove two nuts and center guide stud from cylinder head. 11. Remove valve spring retainers (see Figure 3). - VALVE TAPER. Figure 2, Remove Valve Taper 12, Tag and remove inner and outer valve springs and washers 19, Tag and remove valves. 14, Remove valve stem seals from tops of valve guides (see Figure 3) 15. Inspect intake and exhaust valves for wear. Discard any valve with visible signs of stem galling, ‘overheating, or other abnormalities. TAPERS ——— N ‘eo S Intake. “| © SPRING vg — RETAINER Ss Inner VALVE ‘SPRING € ~ OUTER VALvE| SPRING SA \avesonne a WASHERS VALVE STEM SEAL 1 EXHAUST - VALVE GUIDE ExnausT x“ ‘VALVE Figure 3. Cylinder Head Assembly Page 2 of 22Service Bulletin No. 7-2984B VALVE SEAT INSERT AND VALVE GUIDE REMOVAL 1. Move cylinder head to a suitable workbench. 2. Grind or machine the head diameter of several discarded valves until they fit within the valve seat inserts. 3. Apply anti-spatter compound to protect the cylinder head deck surface and to facilitate the removal of weld spatter. 4, Insert the ground-down valves into the cylinder head unti the valve head makes contact with the valve seat bore, 4 WARNING or Protective clothing and a face shield must be worn. Never weld or cut near combustible materials. Disregarding this information could result in severe personal injury or death. 5. Using a mild stool rod, weld a series of tack welds around the perimeter of each valve head where it contacts the valve seat bore (see Figure 4). VALVE HEAD ‘TACK WELD ‘TACK WELD THREE PLACES: ‘TO REMOVE INSERT Figure 4. Tack Weld Valve to Valve Seat a CAUTION J", “2, "ts breaks during the removal of the insert, the seat may turn, causing it to break or to become lodged in the counterbore. A crooked or broken seat may make removal more difficult and can cause damage to the seat coun- terbore. Disregarding this information could result in product damage and/or personal injury. 6. Tap on the welds to check for cracks. 4 WARNING Use a soft-faced hammer and wear proper eye protection to avoid severe personal injury or death when removing the valve seat insert. 7. Tap the valve stem seat insert with a softfaced hammer to romove the valve seat insort (soo Figure 5). VALVE SEAT INSERTS Figure 5. Valve Seat Insert Removal 8, Wipe off the anti-spatter compound, Use crocus cloth to remove all dirt, slag, weld spatter, and debris from the lower deck surface and the valve seat insert counterbore. Page 3 of 22Service Bulletin No. 7-2984B The exhaust valve ACAUTION | guises’ are machined with two outside diameters and can only be removed in one direction. Failure to press out the Valve guides through the bottom of the cylinder head (piston side) can eause damage to the equip- ment. 9. Using a valve guide remover (P/N 494257), press. out the valve guides. Guides must be pressed out through the bottom of the cylinder head toward the piston side. CYLINDER HEAD CLEANING AND INSPECTION Generally, the cylinder head casting does not require any unusual maintenance other than resurfacing of the lower deck, if necessary (see “Cylinder Head Lower Deck Reconditioning” on page 7). Items needing replacement within the casting are removable fittings, such as valve guides and valve seats. All core plugs and removable fittings may be removed to adequately clean the casting. [ NOTE: Core plug removal is necessary only if excessive scale or deposits are found in the coolant passages. Scale buildup in a cylinder head can cause itto fail. An accumulation of scale deposits within the cylinder head inhibits the proper transfer of heat around critical engine parts, causing overheating. This overheating and expansion cause the casting to crack. Preventing scale buildup will help prevent a cracked cylinder head. During an engine overhaul, hot tank the compo- nent to remove any scale. When the cylinder head is cleaned and air dried, check thoroughly for cracks. Magnaflux® products can assist with such an inspection. When checking for cracks, special attention must be paid to the combus- tion side of the cylinder head. The area between the valve inserts must be inspected carefully. Only after the cylinder head casting is found to be free of cracks can the removable fittings be replaced. These fittings must also meet the required specifications. If they do not meet the specifications or guidelines for the reuse of used parts, replace with new genuine Waukesha Engine parts. 11. If excessive scale or deposits are found in the coolant passages, it may be necessary to remove the eleven countersunk headless core plugs from each cylinder head (eight 9/4 in. NPT, three 1 in. NPT (see Figure 6 through Figute 10) Figure 7. Core Plug Location — Front | [2 e OUTER BAND Figure 26. Install Valve Stem Seal 4. Position the valve stem seal installation tool (P/N 7.82158) over the valve stem and seal. The tool bore allows insertion of the valve stem, while the counterbore fits over the valve stem seal, 5. With the paim of your hand, lightly strike the end of the tool to seat the seal evenly on the valve guide. 6. Install two washers over the valve guide shoulders until they come to rest on the cylinder head casting. The washers are needed to retain proper tension on the inner spring (see Figure 27). ova Page 19 of 22Service Bulletin No. 7-2984B > 6 O~— senna a RETAINER, TAPERS — INNER VALVE ‘SPRING OUTERVALVE SPRING ‘VALVESPRING WASHER ‘CYLINDER, HEAD ExnausT ‘VALVE INTAKE VALVE Figure 27. Cylinder Head Assembly 4 WARNING Use caution when removing or installing the valve springs. They are under tension and can eject from the cylinder head during the removal process. Use the special valve spring compressor tools for this procedure. Wear safety goggles. Failure to take adequate precautions can result in severe personal injury. 7. Install the inner and outer valve springs on the intake and exhaust valve guides. The intake valve springs are dyed orange. NOTE: Do not intermix the intake and exhaust valve springs. Intake valve springs can be distinguished from the exhaust valve springs by the direction of the helix (see Table 4 for valve spring reference). Table 4, Valve Spring Reference vawe | cotor | DIRECTION OF HELIX INTAKE wer | Oanae aan EnAUT 8. Install the spring retainer on top of the inner and outer valve springs. The smaller diameter flange fis inside tho inner valve spring. Tho largor diameter flange separates Inner and outer springs. Look through the holes ACAUTION J inthe pressure piate to ensure that they are aligned with the valve stems, threaded studs, and valve bridge guide studs. Fal- ure to align the pressure plate properly could cause damage to equipment. Disregarding this information could result in product damage and/or personal injury. 9. Install center guide stud 10. Position pressure plate over valve stems, threaded studs, and valve bridge guide studs. Ensure large diameter countersunk holes are facing up and are aligned over valve stems (see Figure 28) 7" CENTER | _ auibe stu Figure 28, Position Pressure Plate Compression Nut ‘and Thrust Bearing 11. Apply engine oil to threads of center guide stud. 12, Install thrust bearing and compression nut on center guide stud, Page 20 of 22Service Bulletin 18. Tighten compression nut down until pressure plate No. 7-2984B compresses valve springs just enough to install valve spring tapers. 14. Install valve spring tapers on valve stems (see Figure 29). 18.Loosen compression nut, and remove compression nut and thrust bearing from center guide stud, 16. Remove pressure plate from cylinder head. 17. Remove center guide stud from cylinder head. 18. Inspect to ensure valve spring tapers are fully seated in valve spring retainers and valve grooves. Figure 29. Install Tapers TAPERS SPRING RETAINER, _ VALVE STEM SEAL INNER VALVE SPRING. OUTER VALVE SPRING - VALVE SPRING WASHERS wauwe cups “Y EXHAUST VALVE ‘VALVE SEATINSERT (CYLINDER HEAD WATER PASSAGES Figure 30, Assembled Cylinder Head — Cross Sectional View of Exhaust Valve ‘Waukesr= Page 21 of 22Service Bulletin No. 7-2984B Table 5, Special Tools DESCRIPTION PIN Valve Spring Compressor (G/SSi) ‘70031 Valve Spring Compressor (GU) ‘70033 Valve Guide Reamer “74086 20 Degrees Seat Angle Grinding Stone anova Valve Guide Removalinstalation Too! 494257 Valve Seat Grinder 498277 Dial ndiator Gauge (housanaihs) 90278 Magnafln® Dye Penevant 484283 Valve Adjusting Wrench 484087 0 Degree Seat Angle Grinding Stone 484805 Piet Mandel aaa Valve Siem Seal instalation Tool Tus21s8 Valve Seat instalation Tool Tu982981 ‘Saighiness and Finshed 1D. Gauge ‘74088 Page 22 of 22