Guideline For Reusable Parts And Salvage Operations

Specifications for Cylinder Head Assemblies 3500 Engines

Media Number -SEBF8155-11 Publication Date -10/02/2004 Date Updated -10/02/2004

   
SEBF81550001

Specifications for Cylinder Head Assemblies 3500 Engines

SMCS - 1101

ILLAR®

INE FOR
BLE PARTS
LVAGE OPERATIONS
ions for Cylinder Head
es 3500 Engines
 

Summary of Revisions

Page Description

ALL Revised format and added new

information.
Introduction

This guideline enables dealers and their customers to benefit from cost reductions made possible
through an established parts reusability and salvage program. Every effort has been made to provide
the most current and relevant information known to Caterpillar Inc. Since the Company makes
ongoing changes and improvements to its products, this guideline must be used with the latest
technical information available from Caterpillar to ensure such changes and improvements are
incorporated where applicable.
 

For questions or additional information concerning this guideline, contact Caterpillar Service
Support Division, Dealer Support (309) 494-1934.

Summary

The information given in this guideline can be used to inspect and measure a used or reconditioned
cylinder head to see if it can be used again. If a cylinder head meets these guidelines and other
applicable guidelines, it can be expected to give normal performance until the next overhaul when
used again in the same application.

A used or reconditioned cylinder head must be checked for leaks, cracks, and flatness. Individual
components must be checked for recommended specifications.

Refer to SEBF8162 for general information on procedures, methods, and visual inspection.

Chart A.

Effective Engine Serial Numbers for 3500 Engines

Application 3508 3512 3516

4XF650-
Generator 23Z6689- 24Z7621- Up
Set Up Up
5SJ491-
Up

25Z5336-
Up
95Y998- 1LM113- 27Z770-
Industrial Up Up Up

68Z874- 49Y829- 71Z324-

Up Up Up

65Z853-
Up
 Locomotive 6TJ14-Up 2WK72- 9KF104-
Up Up
96Y1676- 50Y1469- 4MJ177-
Marine Up Up Up

69Z723- 66Z685- 29Z1212-

Up Up Up

72Z518-
Up

Vehicular 97Y716- 51Y758- 28Z642-

Up Up Up

References

References

Media Title
Number

SEBF8002 Valves, Valve Springs, Valve

Rotators and Locks

SEBF8034 Valves and Valve Springs

Specifications

SEBF8162 Procedures to Measure and

Salvage Cylinder Head
Assemblies and Related
Components

SEBF8076 Specifications to Salvage

Cylinder Blocks and Cylinder
Head Contact Surfaces

For details of other specific cylinder head component reconditioning operations, refer to the
Guideline for Reusable Parts in the chart.

View Image
 When replacement parts are required for this
product Caterpillar recommends using
Caterpillar replacement parts or parts with
equivalent specifications including, but not
limited to, physical dimensions, type, strength
and material.

Failure to heed this warning can lead to

premature failures, product damage, personal
injury or death.This text is part of the warning.
This text is part of the warning.

Overall Size

General Dimensions

Engine Model 3500

Cylinder Head Part 131-0410, 131-0411,

Number 1310423

Length 268 mm (10.6 in)

Width 368 mm (14.5 in)

Height 142 mm (5.6 in)

Nomenclature
Illustration 1

Valves.

(1) Inner spring

(2) Guide
(3) Outer spring
(4) Valve
(5) Dowel
(6) Valve
(7) Lock
(8) Rotator
(9) Washer

General Procedures

Follow these general steps:

         Clean the cylinder head. Refer to SEBF8162.

         Remove the gaskets. Refer to SEBF8162.

         Check the cylinder head thickness.

         Measure the flatness of the combustion surface.

         Check for cracks in the combustion surface and the top deck. Refer to SEBF8162.

         Inspect the combustion surface for damage and erosion. Refer to SEBF8162.

         Measure the depth of the valve seats.

         Inspect the valve guides. Refer to SEBF8162.

         Inspect for other cylinder head damage.

         Inspect the threads.

         Inspect the adapter seat.

Inspect for valve head clearance (after assembly).

Specific Reconditioning Factors

The critical factor when reconditioning the cylinder block and head on 3500 Engines is the
compression ratio. The compression ratio increases as material is removed from the cylinder head.
Note that the minimum dimension means the valve is recessed into the head, and the maximum
dimension means the valve is projecting.

Material can be removed from the head without reseating the valves if the head thickness dimension
is 141.62 mm (5.576 in) or larger. When the head thickness dimension is less than the minimum,
valves will have to be reseated to conform to the valve projection dimensions given in Chart
I.Cylinder Head Thickness

Measure the cylinder head for thickness and compare the dimensions to the specification chart
shown in this guideline. Maintain the ORIGINAL specifications for cylinder head surface flatness
during reconditioning.

Chart B.

Cylinder Head Thickness and Flatness

Engine New Head Minimum Surface

Model Thickness Head Flatness
Thickness
(A)

All 142.00 ± 141.00 (B) 0.10

3500 0.15 (5.590 (5.551) (.004)
± .006) overall

      (C) 0.05
(.002)
within an
area
bounded by
an Outer
 Diameter of
205.00 mm
(8.071 in)
and an
Inner
Diameter of
190.00 mm
(7.480 in)
about the
center of
the cylinder
head.

Note: All dimensions are in mm (in).

Illustration 2

Cylinder head minimum thickness.

(A)     141.00 mm (5.551 in)

Combustion Surface Flatness

Maintain the original specifications for cylinder head flatness during reconditioning. Refer to Chart
B for recommended flatness.

Note: Critical factors when reconditioning the cylinder block and head on the 3500 Family of
Engines are the compression ratio and valve to piston clearance. The compression ratio increases as
material is removed from the cylinder block.
Illustration 3

Surface flatness. Refer to Chart B. Arrow points to center of 190.00 mm (7.480 in) diameter and
205.00 mm (8.071 in) diameter.

Reworking Cylinder Head Bolt Holes

This procedure machines a radius around the fire deck edges of three cylinder head bolt holes.
Cracks can originate from these three holes as a result of high operating temperatures. Machining a
radius around these holes can greatly reduce the potential for cracks that could lead to cylinder head
failure.

This procedure can only be used on heads that do not have cracks. If cracks are present, they will
appear on the combustion side of the head and will radiate outward from the bolt hole. If cracks are
found anywhere in the head, it must not be used again.

Tooling and Equipment

Chart C.

Required Tools

Part Part Description Qty.

Number

4C-8624 Reconditioning Star 1 to 2

per head
 4C-8629 Mandrel 1

4C-3845 Grinding Wheel or 1 to 2

Mounted Point per head

4C-9929 Drill (0 to 1200 rpm) 1

1U-5778 Angle Grinder 1

4C-6852 Air Drill 1

Cylinder Head Bolt Hole Location

Illustration 4

Location of three bolt holes that should be reworked.

(1) Hole 1, 1 o’clock

(2) Hole 2, 2 o’clock
(3) Hole 3, 4 o’clock.

Specifications
Illustration 5

Section A-A. (refer to illustration 4) Machine a 1.9 ± 0.3 mm (.07 ± .01 in) radius (4).

Illustration 6

Enlarged section of radius (4).

(A) 1.9 ± 0.3 mm (0.07 ± 0.01 in) radius

(B) 23.25 mm (0.915 in) maximum
(C) 0.5 mm (0.02 in)
(D) Remove cross hatch area using a 4C-8624 Reconditioning Star.

Rework Procedure

1.      Put a 4C-3845 Mounted Point in the chuck of the air or electric drill.

2.      Operate the drill at full rated speed and lightly insert the mounted point into the bolt hole.
3.      Apply steady pressure equal to two times the weight of the drill for one and one half to two
seconds. This should create a 0.5 mm (0.02 in) corner break on the edge of the bolt hole.

4.      Make sure the chamfered diameter is not larger than 23.25 mm (0.915 in).

5.      Repeat procedure for each bolt hole.

Note: On some cylinder heads, the bolt hole at the 2 o’clock position, may already have a
chamfered diameter larger than 23.25 mm (0.915 in). Do not add additional corner break to this
hole, but polish it with the reconditioning star (as described below).

6.      After all the holes have been reworked with a corner break, put a 4C-8629 Mandrel and a 4C-
8624 Reconditioning Star into the drill.

7.      With the drill running clockwise at full rated speed, insert the reconditioning star half-way into
the bolt hole and apply light pressure to the chamfered edge of the hole. Apply steadily increasing
pressure to flex the “arms” of the reconditioning star into the hole.

8.      Insert and remove the star from each hole several times. Do this until the edges of the chamfers
are removed, and a smooth and polished radius is formed.

9.      Clean the head thoroughly before putting it back into service.

Valve Guides

This section has the “Use again” specifications for cylinder head valve guides for the 3500 Family
of Engines. Engine cylinder head valve guides must be measured for installation height from the top
deck surface and the inside bore diameter.

NOTICE

Do not use any valve guides with obvious

damage or with more wear than is permitted
according to available specifications. Loose or
damaged valve guides must be removed and
new ones installed. Correct any conditions that
could have caused the original damage or wear.

The valve guide installed height for cylinder heads for the 3500 Family of Engines can be measured
using a 6V-2012 Micrometer Depth Gauge Group, or a 152.0 mm (6.00 in) dial caliper.
 

NOTICE

Do not force or turn the plug gauge into the

valve guide bore. This will damage or wear the
gauge, resulting in a higher replacement rate.

The inside bore diameter of the valve guide can be measured using a 6V-7068 Plug Gauge,
telescoping gauge, or a small hole gauge and an outside micrometer.

All the valve guides should be measured on both ends 19.0 mm (0.75 in) from the end of the bore. If
the valve guide is counterbored, the measure must not be taken in this area. If the plug gauge is used
and the end of the gauge goes into the guide bore more than 19.0 mm (0.75 in), the guide bore is
worn more than the maximum “Use again” diameter.

Chart D.

Valve Guide Bore Specifications (Installed)

Engine Valve Guide Intake and

Bore Exhaust
Valve
Intake Exhaust Guide
Installed
Height

3500 Diesel 9.487 ± 0.025 26.0 ± 0.50

(new) (.3735 ± .001) (1.024 ± .
020)

3500 Diesel 9.54 -

(max. used (.3755)
inside
diameter)

3500 Landfill 9.467 ± 0.013 26.0 ± 0.50

Spark Ignited (.3727 ± .0005) (1.024 ± .
(new) 020)

3500 Landfill 9.52 (.3748) -

 Spark Ignited
(max. used
inside
diameter)
       

Note: All dimensions are mm (in).

Note: Do not use a valve and guide combination that has a difference of 0.10 mm (0.004 in) or
larger.

Illustration 7

Valve Guide Height.

(C)    Height = 26.00 ± 0.50 ± 0.020 mm (1.024 ± 0.020 in)

Precision Valve Guides

Precision machined valve guides along with precision machined valve seat inserts (discussed in a
following section) are used in all 3500 diesel engines. These parts will improve the concentricity of
the valve and valve seat in the head and will improve the quality of field rebuilt heads.

Oversize O.D. valve guides are available to replace the standard parts. These parts are 0.508 mm
(.020 in) oversize.

Valve Guide Part Numbers

Intake and Exhaust

Standard O.D. Oversize O.D.

133-9306 149-1982

Valves

The valve stem diameter for the 3500 Family of Engines can be measured using the 6V-0087 Valve
Stem Gauge or a 0 to 25 mm (0 to 1.0 in) micrometer.

Valve head diameter can be measured using a 50 to 75 mm (2.0 to 3.0 in) micrometer or a 0 to 150
mm (0 to 6.0 in) dial caliper.

The valve lip thickness can be measured using a 6V-7059 Multiple Anvil Micrometer used with a
6V-2034 Adapter or a 5P-6518 Fixture Group or a 0 to 150 mm (0 to 6.0 in) dial caliper.

 
Illustration 8

Dimensions of cylinder head valves used in Chart E.

Chart E.1

3500 Engine Intake and Exhaust Valve Specifications

  Valve Overall Valve Valve New Stem Valve Minimum

Part Length Head Face Diameter Stem Lip
Number Diameter Angle Minimum Thickness
Reuse
Diameter
2

Fuel Exhaust (E) (C) (D) (A) (A) (B)

Type and Inlet

Diesel 121-9839 219.00 ± 56.00 ± 29 1/2 9.441 ± 9.43 3.61

0.45 0.15 (2.205 ± 1/4° 0.008 (.3713) (.142)
(8.622 ± . ± .006) (.3717 ± .
018) 0003)

Diesel 121-9835 219.00 ± 56.00 ± 44 ± 9.441 ± 9.43 3.61

0.45 0.15 (2.205 1/4° 0.008 (.3713) (.142)
(8.622 ± . ± .006) (.3717 ± .
018) 0003)

Diesel 121-2028 219.00 ± 56.00 ± 19 ± 9.441 ± 9.43 3.61

 0.45 0.15 (2.205 1/4º 0.008 (.3713) (.142)
(8.622 ± . ± .006) (.3717 ± .
018) 0003)

Diesel 7E-4609 219.00 ± 56.00 ± 29 1/2 9.441 ± 9.43 3.61

0.45 0.15 (2.205 ± 1/4° 0.008 (.3713) (.142)
(8.622 ± . ± .006) (.3717 ± .
018) 0003)

Diesel 7C- 219.00 ± 56.00 ± 29 1/4 9.441 ± 9.43 3.61

6217crb3 0.45 0.15 (2.205 ± 1/4° 0.008 (.3713) (.142)
7E-4609 (8.622 ± . ± .006) (.3717 ± .
018) 0003)

Diesel 4W- 219.00 ± 56.00 ± 29 1/4 9.441 ± 9.43 3.61

1300crb3 0.45 0.15 (2.205 ± 1/4° 0.008 (.3713) (.142)
7C-6217 (8.622 ± . ± .006) (.3717 ± .
018) 0003)

Diesel 4W- 219.00 ± 56.00 ± 29 1/2 9.441 ± 9.43 3.61

6802crb4 0.45 0.15 (2.205 ± 1/4° 0.008 (.3713) (.142)
7E-4609 (8.622 ± . ± .006) (.3717 ± .
018) 0003)

Diesel 1W- 219.00 ± 56.00 ± 29 1/2 9.441 ± 9.43 3.61

3359crb4 0.45 0.15 (2.205 ± 1/4° 0.008 (.3713) (.142)
4W-6802 (8.622 ± . ± .006) (.3717 ± .
018) 0003)

Diesel 7N- 219.00 ± 56.00 ± 29 1/2 9.441 ± 9.43 3.61

1820crb4 0.45 0.15 (2.205 ± 1/4° 0.008 (.3713) (.142)
1W-3359 (8.622 ± . ± .006) (.3717 ± .
018) 0003)

Heavy 7C-5188 219.00 ± 56.00 ± 30 1/4 9.441 ± 9.43 3.61

Fuel 0.45 0.15 (2.205 ± 1/4° 0.008 (.3713) (.142)
(8.622 ± . ± .006) (.3717 ± .
018) 0003)

Spark- 7E- 219.00 ± 56.00 ± 19 3/4 9.441 ± 9.43 3.61

Ignited 4610crb5 0.45 0.15 (2.205 ± 1/4° 0.008 (.3713) (.142)
4P-2852 (8.622 ± . ± .006) (.3717 ± .
018) 0003)

Spark- 4P- 219.00 ± 56.00 ± 19 3/4 9.441 ± 9.43 3.61

Ignited 2852crb5 0.45 0.15 (2.205 ± 1/4° 0.008 (.3713) (.142)
104-7184 (8.622 ± . ± .006) (.3717 ± .
 018) 0003)

Spark- 7W- 219.00 ± 56.00 ± 19 1/4 9.441 ± 9.43 3.61

Ignited 6884crb5 0.45 0.15 (2.205 ± 1/4° 0.008 (.3713) (.142)
7E-4610 (8.622 ± . ± .006) (.3717 ± .
018) 0003)

Spark- 104-7184 219.00 ± 56.00 ± 19 1/4 9.441 ± 9.43 3.61

Ignited 0.45 0.15 (2.205 ± 1/4° 0.008 (.3713) (.142)
(8.622 ± . ± .006) (.3717 ± .
018) 0003)

1 Unless noted otherwise, all dimensions are in mm (in).

2 The valve stem must be measured approximately 12.7 mm (.50 in) up from the bottom of the travel and the same
distance down from the top. Do not use a valve and guide combination that has a difference of 0.10 mm (.004 in) or
larger.
3 Valve was originally manufactured with a valve face angle of 29 1/4°. When this valve is reused, grind the valve face
angle to 29 3/4°.
4 Do not reuse. Replace with 7E-4609 Valves.
5 Serviced by 104-7184.

Valve Seat Inserts

NOTICE

The prefinished inserts should not be ground to

correct the valve projection. Excessive valve
projection indicates that the insert is not seated
or material was not cleaned from the bottom of
the counterbore.

 
Illustration 9

Valve seat insert dimensions. Refer to Chart F for item identification.

Chart F.1

Valve Seat Insert Specifications

Dimensions Intake Exhaust Spark

Ignited
Intake and
Exhaust

Valve seat 14.00 ± 14.00 ± 16.00 ±

bore depth 0.15 0.15 0.15 (.630
(K)2 (.551 ± . (.551 ± . ± .006)
006) 006)

Valve seat 60.627 ± 60.119 ± 60.132 ±

insert 0.015 0.015 0.015
outside (2.3869 (2.3669 (2.3674 ± .
diameter ± .0006) ± .0006) 0006)
(L)

Valve seat 60.508 ± 60.000 ± 60.000 ±

insert bore 0.025 0.025 0.025
inside (2.3822 (2.3622 (2.3622 ± .
diameter ± .0010) ± .0010) 0010)
(L)

Valve seat 30.25 ± 30.25 ± -

insert angle 0.50° 0.50°
(M) Diesel 20.25 ± 20.25 ±
Spark 0.25° 0.25°
Ignited

Minimum 55.00 55.00 -

outside (2.1654) (2.1654)
diameter of
sealing face
of valve
seat insert
(N)

Maximum 3.50 2.50 -

 seat face (.138) (.098)
width

1 All dimensions are in mm (in) unless otherwise noted.

2 “B” series diesel and all gas engines (spark ignited) have 16.00 ± 0.15 mm (0.630 ± 0.006 in) deep
counterbores.

Valve/Valve Seat Contact Area

It has been an acceptable practice to rebuild cylinder heads so the valve seat insert contacts the valve
head sealing face at the middle of the valve sealing face. With the introduction of the 3500 Engine,
the traditional sealing area moved to near the edge of the valve. More recently, premachined seat
inserts and precision valve guides, have moved the sealing area further out to 0.51 mm to 1.02 mm
(.020 to .040 inch) from the O.D. of the valve head. If new, premachined valve seat inserts are
installed during a head rebuild, do not machine or grind the inserts’ sealing faces. The precise way
the components are manufactured makes post-installation machining not necessary.

Premachined Valve Seat Inserts

New, premachined valve seat inserts are used on all 3500 Diesel Engines except Landfill Gas
Engines. These parts will improve the concentricity of the valve and valve seat in the head and will
improve the quality of field rebuilt heads.

  Standard Size Oversize Valve

Valve Seat Seat

  Part Outside Part Outside

Number Diameter Number Diameter

Exhaust 131- 60.119 149- 60.627

4340 mm 0246 mm
(2.3669 (2.3869
in) in)

130- 60.119 166- 60.627

2608 mm 5945 mm
(2.3669 (2.3869
in) in)

Intake 136- 60.627 149- 61.135

9630 mm 0245 mm
 (2.3869 (2.4069
in) in)

130- 60.627 149- 61.135

2607 mm 1981 mm
(2.3869 (2.4069
in) in)

Illustration 10

Typical cylinder head assembly (side view).

(1) 131-4340 Exhaust Valve Seat Insert

(2) 136-9630 Inlet Valve Seat Insert

NOTICE

Because the valve seat inserts are similar in size

(outside diameter), make sure the correct insert
is placed in the appropriate counterbore. If
smaller counterbore, damage to the head and/or
insert will result.

Installation
1.      Freeze the insert to -60°C (-76°F).

2.      Install the insert with a hammer and a drive plate. Make sure the insert is fully seated in the
counterbore.

3.      After installation, use a 0.038 mm (0.0015 in) feeler gauge to ensure the insert is in contact with
the bottom of the cylinder head counterbore. If the gauge goes into a gap under the insert, reseat
the insert.

3500 Gas Engine Valve Seat Specifications

Illustration 11

G3500 Gas Engine valve seat. Refer to Illustrations 12 and 13 for Detail A.

Standard Gas Engine Valve Seat Specifications

Illustration 12

Detail A from Illustration 11 of double-angle intake and exhaust valve seats.

Chart G.1

Landfill Cylinder Head Valve Seat

Specifications

(Two Angles)

Item Intake and Exhaust

A2 20.25 ± 0.25 degrees

B 10.0 ± 0.5 degrees

C 52.0 (2.05) gauge diameter

D 55.8 (2.20) gauge diameter

E 0.60 ± 0.05 (.024 ± .002)

F 5.3 ± 0.10 (.21 ± .004)

1 Gauge Plane

1 All dimensions are in mm (in) unless otherwise noted.

2 Runout of the 20.25° angle is 0.065 mm (.0026 in) maximum relative to the centerline of the valve guide bore in the
cylinder head.

Landfill Gas Engine Valve Seat Specifications

Illustration 13

Detail A from Illustration 11 of triple-angle intake and exhaust valve seats.

Chart H.1

Landfill Cylinder Head Valve Seat

Specifications

(Three Angles)

Item Intake and Exhaust

A 60.0 ± 0.50 degrees

B2 20.25 ± 0.50 degrees

C 15.0 ± 0.50 degrees

D 55.8 (2.20) gauge diameter

E 54.0 (2.13) diameter

F 52.0 (2.05) gauge diameter

G 49.00 ± 0.15 (1.929 ± .006)

diameter

H 0.61 ± 0.05 (.024 ± .002)

 I 5.3 ± 0.10 (.21 ± .004)

1 Gauge Plane

1 All dimensions are in mm (in) unless otherwise noted.

2 Runout of the 20.25° angle is 0.05 mm (.0026 in) maximum relative to the centerline of the valve guide bore in the
cylinder head.

Valve Projection

After the cylinder head has been reconditioned, it must be measured for valve projection. Valve
projection is measured from the combustion surface of the cylinder head to the valve head when the
valve is closed.

Illustration 14

Recessed Valve. A negative valve projection number represents a recessed valve in respect to the
cylinder head surface (valve head is below the surface).

 
Illustration 15

Protruding Valve. A positive valve projection number represents a protruding valve in respect to the
head surface (valve head is above the surface).

Tools

The valve projection can be measured using any of the following tools:

a.      (1) 3P-1565 Collet Clamp

(2) 8S-3158 Gauge
(3) 5P-4156 Base
(the above tools are part of the 5P-4165 Indicator Group).

b.      6V-2012 Micrometer Depth Gauge Group

c.      8H-8581 Feeler Gauge Group and a

150 mm (6.0 in) straight edge.

Illustration 16

5P-4165 Indicator Group.

(1) 3P-1565 Collet Clamp

(2) 8S-3158 Gauge
(3) 5P-4156 Base

The maximum dimensions for intake and exhaust valves are listed in Chart I. The dimensions are for
maximum permissible projection and recession. Positive values indicate projecting valves and
negative values indicate recessed valves. A valve that projects too far can contact the piston during
normal engine operation. A valve that is recessed too much will not adjust, will bind in the guide,
cause abnormal wear, and yield poor engine performance.

NOTICE

The new, premachined valve seat inserts should

not be ground to correct out-of-spec valve
projection. Excessive valve projection indicates
that the insert is not seated or material was not
cleaned from the bottom of the counterbore.

Chart I.

Cylinder Head Valve Projection

Valve Part Inlet & Inlet &

Number Exhaust (Max. Exhaust Max.
Valve Valve
Recession) Projection)
(Illustration (Illustration
14) 15)

Diesel -0.70R 0.61

(A-Series) (-.028)R (.024)

Diesel None -2.498 ± 0.43

(B-Series) (-.0983 ± .
017)

Spark Ignited -0.50R 0.30

(All) (-.019)R (.011)

Note: All dimensions are mm (in).

(-) & R = Recessed Valve.

Valve Springs

This section has the “Use again” specifications for the 3500 Engine cylinder head valve springs. For
a description of the tools needed to measure valve spring dimensions, refer to SEBF8162.

 
Illustration 17

Valve spring dimensions. Refer to Chart J for item identification.

Chart J. 1

Valve Spring Specifications

Dimensions 2 Outer Inner Outer Inner

7N-1904 7N-1903 194-4901 194-4902

Approximate free 62.5 (2.46) 51.5 (2.03) 75.8 (2.98) 60.7 (2.39)
length (E)

Approximate outside 44.0 (1.73) 29.24 (1.151) 43.47 (1.711) 30.7 (1.209)
diameter (B)

Assembled or test 56.4 (2.22) 45.5 (1.79) 59.29 (2.33) 50.34 (1.98)
length (D)

Minimum load at 212 N (47.6 lb) 104 N (23.4 lb) 534 N (120 lb) 139 (31.2 lb)
assembled length

Length at valve open 42.1 (1.66) 31.3 (1.23) 40.49 (1.59) 31.54 (1.24)
position (C)
 Minimum load at valve 733N (176 lb) 382 N (85.8 lb) 1188 N (267 418 N (94 lb)
open position lb)

Spring must be square 2.20 (.086) 1.80 (.071) 2.65 (.104) 2.12 (.083)
with ends within: (A)

1 All dimensions are in mm (in) unless otherwise noted.

2 Specifications do not apply to “B” series diesel engines.

Valve Rotators

During cylinder head reconditioning, the valve rotators must be checked for reusability. Inspect,
clean, and test all valve rotators for correct operation.

Illustration 18

Valve rotator.

Cleaning Rotators

The rotator assembly must rotate the valve during engine operation. The clearances inside rotators
have very close tolerances, and foreign material can wear the parts quickly, causing damage to the
rotator. Use a good, clean solvent to clean rotators, and keep the solvent clean by using a filter.

 
Inspecting Rotators

The inner part of the rotator must rotate smoothly. Some new rotators can be so tight that the inner
part will not rotate smoothly. Inspect all used rotators for signs of deep grooves and notches on the
outer surfaces and in the area of the tapered valve lock seat.

Testing Rotator Operation

After assembling the valves, valve springs, rotocoils, and valve locks into the head, place a chalk
mark in line with each other at locations (Y) and (Z). This provides a starting reference point to
check for correct rotation.

Illustration 19

Mark rotators at locations (Y) and (Z) to check for movement.

Tap the valve straight down with a 1S-0258 Hammer (soft tip) six to eight times. If the rotator
makes the valve move, the rotator is operating correctly.

Note: This procedure could damage valve seats because of the seating shock load. It is better to run
the engine at idle to check for rotation.

Vacuum Test Valves

Refer to SEBF8162 for methods and procedures to vacuum test the valves.

 
 
 
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