SECTION 3.
00
CYLINDER HEAD DISASSEMBLY AND OVERHAUL
CYLINDER HEAD DISASSEMBLY
ROCKER ARMS DISASSEMBLY
Always wear safety glasses when removing retain-
ing (snap) rings. Verify the correct retaining ring
pliers is used and in good condition. If the retaining
ring slips off the pliers when being installed or
removed, it can be propelled with enough force to
cause a serious eye injury. Disregarding this infor-
mation could cause serious personal injury.
NOTE: Tag rocker arm assemblies and components for
later identification. Do not mix components between
rocker arm assemblies. Rocker arms should be as-
sembled with original components to account for wear
patterns.
1. Remove retaining ring from intake side of rocker
shaft support, and remove intake rocker arm assembly
and rocker arm shaft (see Figure 3.00-1). Mark parts
with a tag for later identification.
2. Remove retaining ring from exhaust side of rocker
shaft support, and remove exhaust rocker arm assem-
bly and rocker arm shaft. Mark with a tag parts for later
identification.
3. If necessary, remove set screws from rocker arm
shafts.
4. If necessary, remove set screw from rocker arm shaft
support.
FORM 6296 First Edition
5. If necessary, remove two seal-lok studs from rocker
arm shaft support.
6. Remove jam nut and adjusting screw assembly from
intake rocker arm.
7. Press out bushings from intake rocker arm. Discard
bushings.
8. If necessary, press out rocker ball from intake rocker
arm (press from top).
9. If necessary, remove two expander plugs from intake
rocker arm.
NOTE: It is not necessary to remove roll pin from intake
rocker arm assembly.
10. Remove hex jam nut and adjusting screw assembly
from exhaust rocker arm.
11. Press out bushings from exhaust rocker arm.
12. If necessary, press out rocker ball from exhaust
rocker arm (press from top).
13. If necessary, remove two expander plugs from
exhaust rocker arm.
14. Remove two valve bridge assemblies from valve
bridge guides (see Figure 3.00-17).
15. Remove hex jam nuts and adjusting screw assem-
blies from valve bridge assemblies (see Figure 3.00-7).
3.00 -- 1
CYLINDER HEAD DISASSEMBLY AND OVERHAUL

3/8²--16 X 6-3/4²
RETAINING CAPSCREW
RING 3/8²
WASHER
SEAL LOK 1/2²--13 X 5.50²
STUD CAPSCREW
ROCKER ARM
SHAFT

1/2² LOCK
WASHER
SOCKET HEAD
SET SCREW
ROCKER ARM
SHAFT SUPPORT

JAM NUT
EXPANDER ROCKER ARM
PLUG SHAFT RETAINING
RING

INTAKE
BUSHING ROCKER ARM

SET
SCREW JAM NUT
SOCKET HEAD
SET SCREW

EXPANDER PLUG

ADJUSTING
SCREW ADJUSTING
SCREW

ROCKER EXHAUST
BALL ROCKER ARM
EXPANDER BUSHING
PLUG

ROCKER BALL
EXPANDER PLUG

Figure 3.00-1. Rocker Arm Assembly

ROCKER ARM CLEANING AND INSPECTION

OIL
PASSAGE

Compressed air can pierce the skin and cause

severe personal injury or death. Never use your
hand to check for leaks or to determine air flow
rates. Wear safety glasses to shield your eyes from
flying dirt and debris.

1. Inspect rocker ball assemblies for scratches or
cracks on round contact area. Look for cracks or
breakage around oil holes/expander plugs and exces-
sive wear from contact with lifter socket.
2. Direct compressed air through rocker ball oil pas-
sage to ensure its cleanliness (see Figure 3.00-2).
Replace rocker ball if damaged or excessively worn.
Figure 3.00-2. Rocker Ball
3. Inspect adjusting screws for damaged threads. Look
for cracks or breakage around ball tappet insert. Verify
ball rotates freely in all directions. Direct compressed air
through oil passage to ensure its cleanliness (see
Figure 3.00-3). Replace adjusting screw if damaged.

3.00 -- 2 FORM 6296 First Edition

 CYLINDER HEAD DISASSEMBLY AND OVERHAUL
ADJUSTING
SCREW
HEX JAM
NUT
OIL
PASSAGE
BALL TAPPET
INSERT
Figure 3.00-3. Rocker Arm Adjusting Screws
4. Inspect rocker arm adjusting screws for damaged
threads. Look for cracks or breakage around ball tappet
insert. Verify ball rotates freely in all directions. Direct
compressed air through oil passage (see
Figure 3.00-3). Replace adjusting screw if damaged.
5. Carefully inspect rocker arm shafts for damage (see
Figure 3.00-4). Replace shafts if they are scratched,
pitted, galled or seized.
Figure 3.00-4. Rocker Arm Shaft
6. Check rocker arm shafts for excessive wear. Refer to
Table 1.20-10 and Table 1.20-11 in Section 1.20
Specifications for new part tolerances for rocker arm
shafts.
7. Polish rocker arm shafts with fine grit crocus cloth to
remove minor scuff marks and scratches.
8. Inspect ID (see Figure 3.00-1) of rocker arm bore to
verify that it is clean and smooth, free of burrs and high
spots.
FORM 6296 First Edition
Always use approved cleaning solvents in a well
ventilated area. Contact with skin could result in
severe personal injury or death.
9. Thoroughly clean all parts of rocker arm assemblies
in a non-volatile cleaning solution or solvent. Dry with
moisture free compressed air.
ROCKER ARM ASSEMBLY
NOTE: There was a change in rocker shaft retention on
Series Four cylinder heads. The retaining rings are
replaced with set screws located in the bottom of shaft
support P/N 211790A. New shaft P/N A204169A re-
places P/N 204169. Set screw P/N 26418 retains each
shaft in P/N 211790A shaft support (see
Figure 3.00-10). These modifications are recom-
mended at cylinder head overhaul. Engines shipped
after April 15, 2001, have the new rocker shafts and
supports.
NOTE: New valve bridge and valve rocker arm sealing
plug expanders (P/N 28798) are available (see
Figure 3.00-13). The new sealing plug expanders have
been installed on VHP Series Four engines since
February 2003. The expanders replace the seal lok stud
(P/N 28462) and the cup plug (P/N 157109B) previously
used on the valve bridge. See “Valve Bridge and Rocker
Arm Sealing Plug Expanders” in this section.
NOTE: Previous rocker arm bushings were two piece,
current bushings are one piece. One piece bushings are
identified by an ink dot placed near the notch on the
outside diameter of bushing P/N 211798E.
1. If removed, apply Loctiteâ 620, 640 or 648 to threads
of set screws, and install set screws in end of rocker arm
shafts. Thread set screws until approximately 0.13 in.
(3.3 mm) protrudes from end of rocker arm shaft (see
Figure 3.00-1 and Figure 3.00-4).
2. If removed, apply Loctiteâ 620, 640 or 648 to
threads, and install Allen head plug on rocker shaft
support (see Figure 3.00-1).
3. If removed, press in two seal-lok studs on rocker
shaft support.
4. Press in new bushing in exhaust rocker arm.
Bearings must be flush with ends of rocker arm and
oversized holes must be lined up with rocker arm holes
(see Figure 3.00-5).
3.00 -- 3
CYLINDER HEAD DISASSEMBLY AND OVERHAUL
EXHAUST ROCKER ARM
GRIND HEAD OF PLUG
FLAT TO HEIGHT NOT LESS
THAN 0.060 IN. (1.52 MM)
EXPANDER
PLUGS
INTAKE ROCKER ARM
Figure 3.00-5. Rocker Arms
5. If a new one piece bushing is used, the bushing
inside diameter must be bored out to 1.363 – 1.364 in.
(34.620 – 34.645 mm).
6. If removed, install new expander plugs into oil
passages of exhaust rocker arm.
7. Seal lok plug, if applicable—Grind rounded head of
seal lok plug on adjusting screw side flat to a height not
less than 0.060 in. (1.52 mm) (see Figure 3.00-5).
8. Using a 5/8²--18 UNF-2B tap, chase threads of
adjusting screw mounting hole.
Compressed air can pierce the skin and cause
severe personal injury or death. Never use your
hand to check for leaks or to determine air flow
rates. Wear safety glasses to shield your eyes from
flying dirt and debris.
9. Use compressed air to remove all metal debris from
threads.
NOTE: Press in rocker ball from bottom of rocker arm.
10. If removed, press in a new rocker ball on shorter,
unthreaded end of rocker arm (see Figure 3.00-5).
11. Lightly oil a rocker arm shaft and insert it into rocker
arm bore to feel for proper interference fit. Shaft should
slide in and out of rocker arm bushing without binding,
pivoting or rocking.
3.00 -- 4
EXPANDER
PLUGS
BEARINGS FLUSH
12. Apply engine oil to threads and loosely install
adjusting screw and hex jam nut on exhaust rocker arm
(see Figure 3.00-6).
NOTE: Previous rocker arm bushings were two piece,
current bushings are one piece.
13. Press in new bushing in intake rocker arm. Bearings
must be flush with ends of rocker arm and oversized
holes must be lined up with rocker arm holes (see
Figure 3.00-5).
NOTE: If a new one piece bushing is used, the bushing
inside diameter must be bored out to 1.363 – 1.364 in.
(34.620 – 34.645 mm).
NOTE: New valve bridge and valve rocker arm sealing
plug expanders (P/N 28798) are available (see
Figure 3.00-13). The new sealing plug expanders have
been installed on VHP Series Four engines since
February 2003. The expanders replace the seal lok stud
(P/N 28462) and the cup plug (P/N 157109B) previously
used on the valve bridge. See “Valve Bridge and Rocker
Arm Sealing Plug Expanders” in this section.
14. Install expander plugs into intake rocker arm (see
Figure 3.00-5).
15. Using a 5/8 in.--18 UNF-2B tap, chase threads of
adjusting screw mounting hole.
16. Use compressed air to remove all metal debris from
threads.
FORM 6296 First Edition
 CYLINDER HEAD DISASSEMBLY AND OVERHAUL

ADJUSTING
ADJUSTING SCREW
SCREW HEX JAM NUT
HEX JAM NUT

EXHAUST ROCKER ARM INTAKE ROCKER ARM

Figure 3.00-6. Rocker Arms

NOTE: Press in rocker ball from bottom of rocker arm. 24. Position intake rocker arm on rocker arm shaft
support.
17. If removed, press in a new rocker ball on shorter,
unthreaded end of rocker arm (see Figure 3.00-5).

18. Lightly oil a rocker arm shaft and insert it into rocker
arm bore to feel for proper interference fit. Shaft should The set screw end of the rocker arm shaft must face
slide in and out of rocker arm bushing without binding, outside. Installing the rocker arm shaft backwards
pivoting or rocking. in the support will cause damage to equipment.

19. Apply engine oil to threads and loosely install
adjusting screw and hex jam nut on exhaust rocker arm.
20. Install expander plugs into valve bridge assemblies
(see Figure 3.00-5).
21. Using a 9/16 in.--18 UNF-2B tap, chase threads of
adjusting screw mounting hole.
25. Insert rocker arm shaft into rocker arm support and
intake rocker arm. Set screw end of rocker arm shaft
must face outwards (see Figure 3.00-8).
ROCKER
ARM SHAFT

22. Use compressed air to remove all metal debris from

threads.

23. Apply engine oil to threads and loosely install

adjusting screw and hex jam nut on valve bridge
assemblies (see Figure 3.00-7).

ADJUSTING SCREW

HEX JAM NUT RETAINING RING

SET SCREWS MUST BE VISIBLE

Figure 3.00-8. Rocker Shaft Support

Figure 3.00-7. Valve Bridge Assembly

FORM 6296 First Edition 3.00 -- 5

CYLINDER HEAD DISASSEMBLY AND OVERHAUL

2. Place rocker arms into support and insert shaft.

Install set screw (P/N 26418), one per shaft, in support
Always wear safety glasses when removing retain- (see Figure 3.00-10). Apply Loctiteâ 620 on set screw
ing (snap) rings. Verify the correct retaining ring threads.
pliers is used and in good condition. If the retaining
P/N 204169A
ring slips off the pliers when being installed or ROCKER SHAFT
removed, it can be propelled with enough force to P/N 211790A
cause a serious eye injury. Disregarding this infor- ROCKER ARM
SUPPORT
mation could result in severe personal injury.

RETAINING P/N 204169A

RING ROCKER
SHAFT
The set screw end of the rocker arm shaft must face
outside. Installing the rocker arm shaft backwards
in the support will cause damage to equipment.

26. Secure rocker arm shaft in place with retaining ring.

27. Position exhaust rocker arm on rocker shaft sup- P/N 26418
SET SCREW RETAINING RING
port.
Figure 3.00-10. Rocker Shaft Modifications
28. Insert rocker arm shaft into rocker arm support and
exhaust rocker arm. Set screw end of rocker arm shaft
must face outwards (see Figure 3.00-8).

29. Secure rocker arm shaft in place with retaining ring.

ROCKER SHAFT ASSEMBLY MODIFICATIONS

Current rocker arm assemblies use set screws instead
of retaining rings to secure the rocker shafts in the rocker
arm assembly (P/N 211790A). A new shaft
(P/N A204169A) and set screw (P/N 26418) is required
(see Figure 3.00-10). SET SCREW LOCATIONS
NOTE: These modifications are recommended at cylin-
Figure 3.00-11. Rocker Shaft P/N 211790A
der head overhaul. Engines shipped after April 15, 2001,
have the new rocker shafts and supports.
3. Rocker arm support is replaced with P/N 211790A
1. Replace rocker shafts with P/N A204169A (two per (see Figure 3.00-11). Original may be modified by
cylinder head). New rocker shaft uses a plug for end drilling and tapping two holes for #10--32 set screws
sealing. Shaft is drilled to accept set screw (see (see Figure 3.00-12).
Figure 3.00-9).

SET SCREW

Figure 3.00-9. Rocker Shaft P/N A204169A

3.00 -- 6 FORM 6296 First Edition

 CYLINDER HEAD DISASSEMBLY AND OVERHAUL

#10--32 TAP

2.350² 2.350²
(5.969 mm) (5.969 mm)

Figure 3.00-12. Rocker Shaft Support Modifications (P/N 211790)

VALVE BRIDGE AND ROCKER ARM SEALING 2. Original dimension for holes was
PLUG EXPANDERS 2 x 0.187+0.006/--0.002. New dimension for all assem-
blies is 2 x 0.197 +0.005/ 0.000.
New valve bridge and valve rocker arm sealing plug
expanders (P/N 28798) are available (see NOTE: Do not clean or lubricate the new seal plug
Figure 3.00-13). The new sealing plug expanders have expander before installation. The bore of bridge or
been installed on VHP Series Four engines since rocker arm must be free of oil, grease and chips.
February 2003. The expanders replace the seal lok stud
(P/N 28462) and the cup plug (P/N 157109B) previously 3. Sealing plug expanders (see Figure 3.00-13) are
used on the valve bridge. installed using a pop rivet tool. When expander sleeve is
installed it expands and the end breaks off.
NOTE: Intake valve bridge (P/N A211792D), with seal-
ing plugs already installed, is used with GSI cylinder
head assembly (AA205002D). +.005
.197 --.000
+.005
.197 --.000

Figure 3.00-13. Sealing Plug Expander P/N A211792D

DOES NOT
CONTAIN
The expanders are used on valve bridge assemblies OIL PASSAGES
(P/N A211792B and P/N A211792C) and intake and
exhaust rocker arm assemblies (P/N A204065J,
Figure 3.00-14. Re--drill Dimensions -- P/N A211792C
P/N A204065K, P/N A204066J, and P/N A204066K).

1. Expanders may be used on previous assemblies if

holes are re--drilled to dimensions shown in
Figure 3.00-14, Figure 3.00-15 and Figure 3.00-16.

FORM 6296 First Edition 3.00 -- 7

CYLINDER HEAD DISASSEMBLY AND OVERHAUL
+.005
.197 --.000
Figure 3.00-15. Re--drill Dimensions P/N A204065J
And P/N A204065K
+.005
.197 --.000
Figure 3.00-16. Re--drill Dimensions P/N A204066J
And P/N A204066K
VALVE BRIDGE MODIFICATIONS
For improved durability the guide pin diameter has
changed from 1/2 -- 5/8 in. (12.7 -- 15.875 mm) diame-
ter. The valve bridge inside diameter is changed to
match the guide pin. The first production engine built
with the larger guides and bridges is C-13635/1. All
engines built after April 3, 2001 already have the larger
diameter guide pins installed.
Retrofit Information
The valve bridge guide update may be performed in the
field (with the cylinder head installed on the engine) or
during cylinder head overhaul (with the cylinder head
removed from the engine).
· If an engine in the field requires valve bridge guide
updates, contact Waukesha Product Support
(262) 549--2636 for use of a special tool kit with
instructions.
· If valve bridge guide is updated during cylinder head
overhaul, retrofit MUST be done by a qualified
machine shop.
Valve Bridge Guide Retrofit
If a field installed engine requires updates, contact
Waukesha Product Support for use of a special tool kit.
The kit includes retrofit instructions.
Valve bridge guide (P/N 211793A) and valve bridge
(P/N A211792B) are used with this procedure.
3.00 -- 8
P/N A211792B
VALVE BRIDGE
P/N 211793A
VALVE BRIDGE GUIDE
Figure 3.00-17. Valve Bridge Guide
During cylinder head overhaul (with the cylinder head
removed from the engine), the following steps must be
completed to update the engine to 5/8 in. valve bridge
guides:
1. Remove valve spring tapers, retainers, springs,
washers, and valves from the cylinder head assembly.
2. Remove two 1/2² bridge guides from cylinder head
using Valve Bridge Guide Puller for Series Four engines
(Tool P/N 474040) and a slide hammer. The top of the
guide is threaded 0.25² x 20 UNC.
Do not drill valve bridge
guide bores deeper than
0.95² (24.13 mm) or damage to the cylinder head will
occur.
3. Machine guide bores to a finished ID of 0.6215²
± 0.0003² (15.786 mm ± 0.0076 mm) and 0.90”
(22.86 mm) deep. Maximum drill depth is not to
exceed 0.95² (24.13 mm) and bore centers must be
maintained.
4. Make sure valve bridge guides and guide bores are
clean and dry.
5. Apply Loctiteâ 640 to new valve bridge guides
(P/N 211793A) and apply Loctiteâ 7471 primer to guide
bores.
6. Drive new guide (P/N 211793A) with threaded end up
into machined bore so that 2.935² (74.549 mm) of guide
is exposed.
7. Allow 24 hours for Loctiteâ to cure then reassemble
cylinder head.
FORM 6296 First Edition
 CYLINDER HEAD DISASSEMBLY AND OVERHAUL

INTAKE AND EXHAUST VALVES

RETAINING RING
INTAKE AND EXHAUST VALVE REMOVAL

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 valve spring compressor tools for this proce-
dure. Wear safety goggles. Failure to take adequate
precautions can result in severe personal injury.

A new valve spring compressor (P/N 474034) for use on OIL

P/N 205002 series cylinder heads is available. This tool DEFLECTORS O--RING
is designed so that all four valve springs can be
compressed at once. Use of this tool greatly reduces Figure 3.00-18. GSI Oil Deflectors
service time for such tasks as valve stem seal replace-
ment, valve replacement, and cylinder head overhaul. 3. Install center stud guide over two threaded mounting
The tool may be used with the cylinder heads on or off studs until plate rests on nuts securing spark plug sleeve
the engine. (see Figure 3.00-19).

If removing the valve CENTER

keepers, springs or valve GUIDE STUD
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 combustion chamber,
damaging the valves. Cylinder head removal will be
required to remove the valves from the combustion
chamber.

1. If not already removed, refer to Section 2.00 Cylinder

Head Removal and remove rocker arm assemblies,
valve bridge assemblies, and spark plug sleeve.
NOTE: Cylinder head assembly (P/N AA205002D) is
the current cylinder head for VHP Series Four GSI
engines. This cylinder head uses oil deflectors on the
intake valves along with O--rings and retaining rings
(see Figure 3.00-18).
2. GSI only—Remove retaining rings and O--rings from
intake valves (see Figure 3.00-18). Replace retaining
rings and O--rings with new during assembly.
NUTS
Figure 3.00-19. Position Center Guide Stud
4. Secure center guide stud in cylinder head with spark
plug extension nuts.
Look through the holes
in the pressure plate to
ensure that they are aligned with the valve stems,
threaded studs, and valve bridge guide studs.
Failure to align the pressure plate properly could
cause damage to equipment.

5. 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 3.00-20).

FORM 6296 First Edition 3.00 -- 9

CYLINDER HEAD DISASSEMBLY AND OVERHAUL

10. Loosen and remove compression nut and thrust

PRESSURE COMPRESSION bearing from center stud guide.
PLATE NUT
11. Remove pressure plate from cylinder head. Re-
move two nuts and center guide stud from cylinder head.

12. Remove valve spring retainers (see Figure 3.00-22

and Figure 3.00-23).

13. GSI only — Remove oil deflectors from GSI intake

valves (see Figure 3.00-18 and Figure 3.00-22).

14. Tag and remove inner and outer valve springs.

15. Remove valve stem seals from tops of valve guides

(see Figure 3.00-23). Tag and remove valves.
THRUST
BEARING 16. Inspect intake and exhaust valves for wear. Discard
any valve that is not within allowable limits.
Figure 3.00-20. Valve Spring Compressor
RETAINING RING
KEEPERS
6. Apply engine oil to threads of center stud guide.
O--RING SPRING
RETAINER
7. Install thrust bearing and compression nut on center
stud guide.

8. Tighten compression nut down until pressure plate OIL INNER VALVE
DEFLECTOR SPRING
compresses valve springs just enough to release valve
keepers (see Figure 3.00-20).
OUTER VALVE
9. Remove valve keepers from valve stems (see SPRING
Figure 3.00-21).

VALVE SPRING
VALVE KEEPER WASHERS

CYLINDER
HEAD
VALVE KEEPER
INTAKE
Figure 3.00-21. Remove Valve Keepers VALVE EXHAUST
VALVE

Figure 3.00-22. GSI Cylinder Head Assembly

3.00 -- 10 FORM 6296 First Edition

 CYLINDER HEAD DISASSEMBLY AND OVERHAUL

KEEPERS VALVE SEAT REMOVAL

SPRING
RETAINER
NOTE: Oversized intake valve seats and exhaust valve
seats are available (see Table 3.00-1).

INNER VALVE Table 3.00-1. Oversized Valve Seats

SPRING
OVERSIZED PART NUMBERS
VALVE BRIDGE
GUIDE VALVE SEAT 0.020 in. 0.030 in.
OUTER VALVE
SPRING Intake 211801 2 211801 3
IGNITER Exhaust 211802B 2 211802B 3
SLEEVE
STUD
VALVE SPRING NOTE: If installing oversized valve seats, cylinder head
WASHERS
should be bored to appropriate size to provide a 0.001 --
0.003 in. (0.025 -- 0.076 mm) interference fit (see
VALVE Table 3.00-2, Table 1.20-14 and Table 1.20-15).
STEM SEAL
Table 3.00-2. Cylinder Head Inside Diameter
INTAKE EXHAUST
OVERSIZED BORE CYLINDER HEAD
VALVE GUIDE VALVE GUIDE
VALVE SEAT 0.020 in. 0.030 in.
3.020 -- 3.021 in. 3.030 -- 3.031 in.
Intake (76.708 -- 76.733 mm) (76.962 - 76.987 mm)
2.620 -- 2.621 in. 2.630 -- 2.631 in.
Upper Exhaust (66.55 -- 66.573 mm) (66.802 -- 66.827 mm)
3.220 -- 3.221 in. 3.230 -- 3.231 in.
Lower Exhaust (81.788 -- 81.813 mm) (82.042 -- 82.067 mm)

1. Move cylinder head to a suitable workbench.

NOTE: The valve seat remover tool collet removes

valve seats by gripping a small lip on the back of the
valve seats. The collet must be seated correctly to
CYLINDER ensure proper removal of valve seats.
HEAD
2. Using valve seat extractor tool P/N 474038, remove
exhaust valve seat inserts from bottom of cylinder head
INTAKE VALVE EXHAUST using following steps:
SEAT INSERT VALVE SEAT
INSERT
A. Adjust remover collet to fit exhaust valve seat by
INTAKE adjusting nut on threaded rod and install collet in
VALVE
EXHAUST
exhaust valve seat (see Figure 3.00-24).
VALVE

Figure 3.00-23. LT Cylinder Head Assembly

FORM 6296 First Edition 3.00 -- 11

CYLINDER HEAD DISASSEMBLY AND OVERHAUL

3. Using valve seat extractor tool P/N 474038, remove

COLLET intake valve seat inserts from bottom of cylinder head
using following steps:

A. Install spacer on top edge of collet (see

Figure 3.00-26).
NUT

SPACER COLLET

Figure 3.00-24. Exhaust Valve Seat Removal

B. Tighten adjusting nut until collet is seated firmly in

exhaust valve seat. NUT

C. Slide retainer and spacer down threaded rod (see Figure 3.00-26. Intake Valve Removal
Figure 3.00-25).
B. Adjust remover collet to fit intake valve seat by
adjusting nut on threaded rod and install collet in
RETAINER
intake valve seat (see Figure 3.00-26).

C. Tighten adjusting nut until collet is seated firmly in

intake valve seat.

D. Slide retainer and spacer down threaded rod

(see Figure 3.00-25).

E. Thread nut down threaded rod to contact spacer.

F. Tighten nut until valve seat is removed from

cylinder head.

SPACER NUT VALVE GUIDE REMOVAL

Figure 3.00-25. Retainer And Spacer
D. Thread nut down threaded rod to contact spacer.
E. Tighten nut until valve seat is removed from
cylinder head.
1. Position cylinder head on a suitable press in such a
manner that valve guides will be pressed out towards
piston side of cylinder head.
2. Using a Valve Guide Remover (P/N 494257)
(see Figure 3.00-27), press out exhaust valve guides. It
is recommended to press guides out through bottom of
cylinder head towards piston side (see Figure 3.00-27).

3.00 -- 12 FORM 6296 First Edition

 CYLINDER HEAD DISASSEMBLY AND OVERHAUL

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 Wauke-
sha Engine parts.
NOTE: The oil tube (see Figure 3.00-28), 1/4 in. NPT
core plug on each cylinder head (location 10,
Figure 3.00-31) and the 1/2 in. NPT plug located on the
PRESS TOOL upper edge of the intake flange (see Figure 3.00-30),
does not need to be removed.
VALVE GUIDE
1. Remove countersunk headless core plugs
(3/4 in. NPT) from each cylinder head (locations
1 through 9) and the 1/4 in. NPT plug (location 10) (see
Figure 3.00-28, Figure 3.00-29, Figure 3.00-30 and
Figure 3.00-31).

2. Remove two capscrews, lock washers and gas

CYLINDER HEAD BOTTOM admission valve well cover from cylinder head (see
(PISTON SIDE)
Figure 3.00-30). Clean any Permatexâ Aviation Form-
Figure 3.00-27. Removing Valve Guides A-Gasketâ Sealant from cover and cylinder head
surfaces.
VALVE BRIDGE GUIDE REMOVAL
NOTE: The valve bridge guides are press fit in the OIL TUBE
cylinder head. It is not normally required to remove the 1
valve bridge guides unless they are bent or damaged.

1. If necessary, remove valve bridge guides using Valve

Bridge Guide Puller (P/N 474040)(see Figure 3.00-23).

CYLINDER HEAD CLEANING AND INSPECTION

Generally the cylinder head casting does not require any
unusual maintenance other than resurfacing of the
lower deck, if required (see “Cylinder Head Lower Deck
Reconditioning” in this section). Items needing replace-
ment within the casting are removable fittings, such as
valve guides and valve seats. Designated water plugs
and removable fittings must be removed to adequately 2
clean the casting.
Figure 3.00-28. Core Plug Locations -- Top
Scale buildup in a cylinder head can cause it to 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 ex-
pansion cause the casting to crack. Preventing scale
buildup will help prevent a cracked cylinder head. During
an engine overhaul, hot tank the component to remove
any scale.
3 5
When the cylinder head is cleaned and air dried, check
thoroughly for cracks. MagnafluxR Products can assist
with such an inspection. When checking for cracks,
special attention must be paid to the combustion side of
the cylinder head. The area between the valve inserts 4 6
must be inspected carefully.
Figure 3.00-29. Core Plug Locations -- Exhaust Side

FORM 6296 First Edition 3.00 -- 13

CYLINDER HEAD DISASSEMBLY AND OVERHAUL
DO NOT REMOVE
9 3/4-14 in. NPT (locations 1 through 9) countersunk
8 7. Install nine 3/4 in. NPT (locations 1 through 9), core
7 Figure 3.00-29, Figure 3.00-30 and Figure 3.00-31).
Figure 3.00-30. Core Plug Locations -- Intake Side
10
Figure 3.00-31. Core Plug Locations -- Side View
Use of caustic solutions should be restricted to a
well ventilated area. Contact with skin, clothing and
eyes could result in severe personal injury or death.
Compressed air can pierce the skin and cause
severe personal injury or death. Never use your
hand to check for leaks or to determine air flow
rates. Wear safety glasses to shield your eyes from
flying dirt and debris.
3. Submerse cylinder heads in a caustic hot tank to
remove all paint, dirt, grease, oil, carbon and varnish
deposits. Follow up with a thorough hot rinse. Dry
cylinder heads with moisture free compressed air.
4. Inspect cylinder head through a water passage
opening for accumulation of lime and mineral scale
deposits. If use of an untested water supply or lack of a
suitable water treatment program resulted in an accu-
mulation of deposits, then special cleaning may be
required.
3.00 -- 14
5. Buff gasket surfaces to ensure a tight seal at the
crankcase, rocker arm cover and intake and exhaust
ports.
6. Apply a removable pipe sealant (Loctiteâ 242
Removable Threadlocker) to threads of nine
headless core plugs.
plugs on each cylinder head (see Figure 3.00-28,
Tighten the core plugs to 50 ft-lb (68 N×m).
8. Apply Loctiteâ 271 to threads of 1/4-20 in. NPT,
(location 10) core plug.
9. Install 1/4 in. NPT, (location 10) core plug on each
cylinder head (see Figure 3.00-31).
10. If the 1/2-14 in. NPT plug located on upper edge of
the intake flange was removed, apply Loctiteâ 271 to
threads of plug and tighten plug to 50 ft-lb (68 N×m).
11. If oil tube was removed, apply Loctiteâ 620, 640 or
648 and install oil tube in cylinder head.
12. Apply Loctiteâ 271 to threads of male oil line
connectors.
13. Install male oil line connectors in the side of each
cylinder head.
14. With valve seat side facing upward, position a
straight edge diagonally across length of cylinder head
intersecting seats of one intake and one exhaust valve
(see Figure 3.00-32). Slide a feeler gauge beneath
straight edge to check head for warpage. Place straight
edge across other intake and exhaust valve seats and
repeat procedure. If gap between straight edge and
lower deck surface exceeds 0.002 in. (0.051 mm) refer
to “Cylinder Head Lower Deck Reconditioning” in this
section.
FORM 6296 First Edition
 CYLINDER HEAD DISASSEMBLY AND OVERHAUL

CYLINDER HEAD CASTING PRESSURE TESTING

EXHAUST METAL
VALVE SEAT STRAIGHT EDGE Water test the cylinder head casting for leaks.
1. Make a deck plate using 3/4 to 1 in. thick (19 to
25 mm) steel (use cylinder head gasket as a pattern)
(see Figure 3.00-33). Drill holes in plate to match all
eight cylinder head capscrew holes. Plate should have
an open center so any leakage around the exhaust valve
guides or between valve seat inserts can be observed.
Do not drill holes for the two locating dowels or the
seven water passage openings. The rubber grommets
in the head gasket point out the location of the water
passage openings.

MALE AIR
LINE FITTING
WATER OUTLET
ELBOW PLATE

WATER OUTLET
WATER HOLE ELBOW GASKET
COVER
METAL INTAKE
STRAIGHT EDGE VALVE SEAT DECK PLATE

GASKET

Figure 3.00-33. Cylinder Head Pressure Test Plates

2. Fabricate a steel plate 3/4 to 1 in. thick

(19 to 25 mm) to cover water outlet elbow connection at
top of cylinder head. Drill and tap plate to accept a 3/8 in.
CYLINDER HEAD or 1/2 in. pipe fitting. Fit pipe fitting with a male air line
Figure 3.00-32. Check Cylinder Head Deck For fitting.
Warpage
3. Using plates as a stencil, cut rubber gaskets to seal
plates onto the cylinder head.

4. Bolt plates on cylinder head.

5. Fabricate a small plate or plug to close off water

outlet hole centered below exhaust outlet port (see
Figure 3.00-34).

6. Refer to Section 5.10 Ignition System for procedures

and install spark plug sleeve and spark plug carrier
extension and O-rings in cylinder head.

FORM 6296 First Edition 3.00 -- 15

CYLINDER HEAD DISASSEMBLY AND OVERHAUL
WATER OUTLET
ELBOW CONNECTION
WATER HOLE TO
EXHAUST MANIFOLD
Figure 3.00-34. Water Outlet Hole
Never use air pressure alone to test a cylinder head
casting. The cylinder head must be filled with water
prior to applying air pressure or the casting will
break, hurling fragments in all directions. Air
pressure cannot exceed 32 psi (221 kPa). Failure to
follow proper procedures will result in severe
personal injury or death.
7. Fill cylinder head with water.
8. Attach an air source to male air fitting and ap-
ply 32 psi (221 kPa) air pressure on top of water.
9. Inspect cylinder head for leaks. Carefully check
lower deck surface between two exhaust seats and
between intake and exhaust seats. Check for leaks at
both ends of exhaust guides. On rare occasions, leaks
may be found around core plugs or inside spark plug
carrier bore.
10. Carefully release air pressure.
11. Drain water from cylinder head.
3.00 -- 16
CYLINDER HEAD CASTING MAGNAFLUXä
Always carefully read the manufacturer’s instruc-
tions to avoid severe personal injury or death.
NOTE: The Magnafluxä Dye Penetrant Test Kit
(P/N 494283), is used to inspect the cylinder head for
surface cracks. The small area between the exhaust
seat inserts is the location where most cracks occur.
1. To remove oily residues, apply Magnafluxä Spot-
check Cleaner/Remover (SKC-S) directly to test area.
Thoroughly wipe area with a clean cloth. Repeat
procedure as necessary. Final wiping should result in a
clean cloth. Allow test area to dry.
NOTE: Wear rubber gloves to avoid hard-to-remove
stains on hands.
2. Spray test area with Magnafluxä Spotcheck Pene-
trant (SKL-SP). Wait 1 to 30 minutes.
3. Spray Magnafluxä Spotcheck Cleaner/Remover
(SKC-S) on a clean cloth (not on the test area). Wiping in
one direction, remove all surface penetrant. Repeat as
necessary.
4. Spray test area with Magnafluxä Spotcheck Devel-
oper (SKD-S2). Apply a thin even film. Allow film to dry
completely. The proper application dries to an even
white layer.
5. Carefully inspect test area for cracks. A bright
colored solid or dotted line marks a crack. Fine cracks
may take up to 15 minutes to appear. Large cracks can
be seen almost immediately. If the crack is wide and
deep, the indication will grow and spread.
6. Wipe test area clean if cracks are not found.
Do not weld cracked
cylinder heads. Welding
has been found to be an unsuccessful repair.
Disregarding this information could result in prod-
uct damage and/or personal injury.
7. Discard cylinder head if cracks are found.
FORM 6296 First Edition
 CYLINDER HEAD DISASSEMBLY AND OVERHAUL
CYLINDER HEAD LOWER DECK RECONDITIONING
If it is determined that the lower deck needs to be
reconditioned by milling, this reconditioning should be
done prior to any other cylinder head reconditioning.
The lower deck should be reconditioned until the surface
is clean. Remove only sufficient material to clean up the
lower deck surface.
If the lower deck of the
cylinder head is recondi-
tioned, the valve seat insert counterbore depth will
have to be recut as required to maintain the proper
depth of the valve heads in the cylinder head.
Failure to recut the valve seat insert counterbore
depth could cause damage to equipment.
The height of a new cylinder head is 9.50 in.
(241.30 mm) (see Figure 3.00-35). During recondition-
ing, not more than 0.020 in. (0.508 mm) may be
removed from the lower deck. If more material is
removed from the lower deck, the casting strength will
be reduced, making it incapable of withstanding the
firing pressure of rated horsepower. In addition this may
cause misalignment problems. These misalignment
problems include misalignment between the exhaust
manifold and intake manifold. The cylinder head must
be marked to indicate it has been reconditioned.
9.50² (241.30 mm)
HEIGHT (NEW HEAD)
Figure 3.00-35. Cylinder Head -- Intake Port Side
If the lower deck is reconditioned, it may be necessary to
recut the valve seat insert counterbore depth to maintain
the proper depth of the valve heads in the cylinder head.
Refer to Section 1.20 Specifications (see Table 1.20-16)
for proper values of valve head depth in cylinder head.
The valve seat insert counterbore depth will have to be
recut to the amount as was taken off the cylinder head.
FORM 6296 First Edition
VALVE FAILURE ANALYSIS
We have listed only a few of the reasons why valves fail,
there are, many others. In the list under the heading
“Valve Failure Analysis,” we have identified ten most
common causes; however, they are not necessarily in
any priority of probable occurrence.
The major causes for valve failures include:
· Valve recession
· Wear
· Scuffing of the valve stem
· Excessive deposits on the valve
· Carbon buildup in the guide
· Distortion of the valve seat
· Incorrect valve adjustment
· Torching
· Heat fatigue/cracking
· Valve erosion
· Other
Valve And Guide Wear
Abnormal component wear leads to excessive valve
recession. Wear can occur on the valve face, valve
stems, valve guides, and valve seats. Valve guides
typically wear from poor valve-to-seat contact, causing
a side thrust on the guide. Out-of-round valve seats can
also cause the same type of guide wear. In addition,
combustion air or fuel gas can contain abrasives that
can also wear the valve face, seat, and the lower end of
the guide.
Worn guides can cause the valves to meet the valve
seat at a variety of angles, causing a sliding motion that
will further wear the valve and its seat. This improper
seating leads to blowby of combustion gases and seat
burning or torching. Other reasons for worn valve guides
are:
· Poor lubrication in the guide, either too much or too
little.
· Carbon deposits on the valve stem that cause the
valve guide to wear into a bell-mouthed shape at the
lower end.
· Incorrect valve or seat angle due to grinding during
rebuilding.
3.00 -- 17
CYLINDER HEAD DISASSEMBLY AND OVERHAUL
Valve Stem Scuffing
Scuffing of the valve stem can result from a lack of
lubrication and too much, or too little, stem to guide
clearance. Poor disassembly or assembly practices can
cause damage to the surface finish of the valve stem or
valve guide, which will scuff the valve or guide.
Valve Deposits
Valve deposits are normal. Deposits on exhaust valves
should be dry and white, to tan in color. Deposits
typically occur on the head of the valve and the blended
area between the valve head and stem. The seating
surface of the valve will typically exhibit a matted
appearance with some small pock marks due to
deposits being caught between the valve and the seat.
This is also considered normal unless the pitting allows
gas leakage.
Deposits will also build up on intake valves; however,
they are typically darker in color and on the blended area
between the head and the valve stem. They will be black
and carbonaceous with some oil present.
The majority of combustion chamber deposits are made
up of burnt lube oil and lube oil additives. These deposits
are commonly called ash, and the proper amount of ash
is desirable to retard valve recession, or wear. Ash
deposits should be seen on the valve face and seat.
Valve Guide Deposits
Deposits (carbon or lacquering) in the valve guide can
cause the valve to stick in the guide, causing the valve to
be held in the open position. Inspect the valve guides for
deposits or wear. Replace worn guides.
Valve Seat Distortion
NOTE: Oversized intake valve seats and exhaust valve
seats are available (see Table 1.20-14 and
Table 1.20-15).
Distortion of a valve seat can lead to burnt valves. This is
usually caused by:
· Poor grinding practice.
· Loose or improperly seated valve seats that may
reduce or stop the transfer of heat between the valve
seat insert and the cylinder head.
· Failure of the cooling system.
Torching
Burnt or torched valves are always caused by combus-
tion gases leaking between the valve and seat. This
leakage occurs when the valve is supposed to be
closed, but is, in fact, held open due to excessive
deposits, improper adjustment, or sticking valves. It can
also be caused by improper valve grinding practices or
valve adjustment procedures.
3.00 -- 18
Valve Heat Fatigue/Cracking
Heat fatigue, caused by overheating, can lead to valve
head cracking, burning, or breakage. Heat fatigue can
include worn valve guides, distorted valve seats,
excessive deposits, and/or improper air/fuel ratios.
Valve Breaks
When a valve breaks, it generally is from a bending
fatigue or impact with the piston. Fatigue occurs usually
from mechanical damage where the valve and piston
have made contact, bending the valve slightly, and over
a period of time, the flexing at the stem-head interfaces,
breaks the valve stem. Impact with the piston, if severe
enough, will break the valve immediately or induce the
condition that causes a bending fatigue type failure.
Valve Erosion
Erosion of the valve stem under the valve head can
cause valve breakage. Causes of valve erosion include
fuel gas with high hydrogen sulfide levels, faulty
combustion, or excessively high valve temperatures.
Improper air/fuel mixture ratios that overheat and erode
valves, can cause such high temperature valve failure
as well.
Valve Wear Limits
Waukesha provides the following wear limits to assist in
deciding as to the reuse of engine parts. Many parts can
be reused at overhaul time if wear limits do not exceed
those listed in Table 3.00-3. Under no circumstances
can the use of any part exceeding the established wear
limits be justified. When using these wear limits, the
decision to reuse engine parts must be tempered with
the consideration of:
· Number of mating parts being reused.
· Service life expected until the next overhaul.
· Problems that might occur in the future.
· Engine application.
·· Horsepower requirement
·· Maintenance intervals
·· Type of installation
Waukesha Engine’s position for these wear limits is that
the reuse of an engine part that does not meet the new
part specifications is solely the responsibility of the
person making the inspection and repair. Under no
circumstances is the reuse of any part exceeding the
following wear limits justified.
FORM 6296 First Edition
 CYLINDER HEAD DISASSEMBLY AND OVERHAUL

Table 3.00-3. Valve Wear Limits

MEASUREMENT INCHES (in.) METRIC (mm)
0.001 0.025 mm
Minimum stem diameter total wear total wear
Valve guide --
maximum ID 0.0015 0.038 mm

Valve seat
maximum width Original width +15%

Valve Inspection
At overhaul, it is recommended that all valves be
replaced. If the valves are to be reused, they must be
inspected before grinding. The valve must be cleaned
thoroughly prior to inspection. The following checks
should be made for each valve.
1. Valve stem diameter should be measured in three
locations along wear area length. In addition, each
location should consist of two measurements, 90° to
each other to check for stem roundness.

2. Valve stem straightness -- Valve stem straightness

can be examined using two V-blocks and a dial indicator
(see Figure 3.00-36). Total indicator reading must not
exceed 0.002 in. (0.050 mm). Never attempt to straight-
en a bent valve. Bent valves must be discarded.

Figure 3.00-37. Checking Head Perpendicularity

NOTE: “Stelliteâ is a registered trademark of Stoody

ROTATE Deloro Stellite, Inc.”

5. Grind valve face to remove wear marks (see

Figure 3.00-39). If valve is Stelliteâ coated, removing
Stelliteâ will cause valve to heat or burn during
operation. Valve should be discarded in this case.

6. Valves must be inspected for hairline cracks. Inspect

using dye penetrant process. Magnetic particle inspec-
Figure 3.00-36. Checking Valve Stems For Straightness tion will not locate fissures or cracks in non-ferrous
materials.
3. Head must be perpendicular to valve stem or
improper seating will result (see Figure 3.00-37). Total
runout must be within 0.002 in. (0.050 mm).

4. Stem end surface must be flat and perpendicular to

prolong life of valve and tappet ball (see
Figure 3.00-38).

NOTE: Exhaust valves and landfill intake valves are

Stelliteâ faced. Standard intake valves are one piece
Silcrome #1 with no Stelliteâ facing.

FORM 6296 First Edition 3.00 -- 19

CYLINDER HEAD DISASSEMBLY AND OVERHAUL

7. Verify two retainer grooves have not become dis-
torted. Grooves are machined with a 0.094 in.
(2.388 mm) radius. Any valve with distorted grooves
must be discarded (see Figure 3.00-38).
STEM END IS
PERPENDICULAR
CENTERLINE
VALVE KEEPER INSPECTION
NOTE: New valve spring keepers are available. The
new keepers improve the fit between the retainer and
valve stem. The new keeper (P/N 73629A) has a black
oxide finish instead of the bright metal finish of the
previous keeper. All engines built after February 2003
will use new keepers.

During cylinder head overhaul, be certain to inspect the

valve keepers before installing the valves in the cylinder
RETAINER GROOVES head (see Figure 3.00-40). These parts are subject to
wear and should be inspected carefully before
STEEL installation.

INSPECT BOSS
INSPECT BOSS
WELD

STELLITEâ INSPECT OD
FACE

INSPECT INSPECT BOSS

SEAT MARGIN BOSS
ANGLE INSPECT EDGE

Figure 3.00-40. Valve Keeper

HEAD PERPENDICULAR
TO STEM CENTERLINE
HEAD STAMPED FOR Inspect the keepers at the following locations:
INTAKE/EXHAUST PLUS P/N

Figure 3.00-38. Checking Stem End Perpendicularity · The upper edges of the inside bosses for grooves.

· The lower circumference of the keepers for burrs.

· The outer circumference of the keepers for radial

scoring.
If signs of wear are found, replace the keepers.
MARGIN VALVE GUIDE INSTALLATION
NEW VALUE
30° INTAKE VALVES
0.203² (5.156 mm) Only a small amount of
20° EXHAUST VALVES
0.225² (5.715 mm) grease is required, do not
apply grease to necked-down portion of the exhaust
MINIMUM AFTER GRINDING
30° INTAKE VALVES guide. Disregarding this information could result in
0.173² (4.394 mm) product damage.
20° EXHAUST VALVES
0.195² (4.953 mm)
1. Apply a small amount of grease to outside surface of
new intake and exhaust valve guides.

Figure 3.00-39. Checking Margin Wear 2. Position a shop towel to prevent metal chips and
debris from falling into cylinder heads.

NOTE: Press valve guides into cylinder head gradually

so that valve guide depth in cylinder head is not
exceeded.

3.00 -- 20 FORM 6296 First Edition

 CYLINDER HEAD DISASSEMBLY AND OVERHAUL

NOTE: The exhaust valve guides are marked with a
green dot for easier identification.
3. Press valve guides gradually (in stages) from top of
cylinder head. Measure depth of valve guide in cylinder
head ensuring depth in cylinder head is not exceeded
(Figure 3.00-42). Start new valve guides in their respec-
tive bores.
4. Use valve guide remover/installer (P/N 494257) (see
Figure 3.00-41). Any contact between press and lower
deck of cylinder head must be avoided. If fully seated,
valve guides will protrude approximately 1.40 in.
(35.56 mm) from top of valve guide bores (see
Figure 3.00-42).
Always start the reamer
from the valve seat insert
side of the cylinder head and never turn the reamer
backwards. Failure to follow these procedures will
cause damage to equipment.
5. Using a Carboloy-tip reamer (P/N 499953), ream
valve guides, starting from valve seat insert side of
cylinder head.
6. Carefully remove shop towel to prevent metal chips
and debris from falling into cylinder head.
VALVE BRIDGE GUIDE INSTALLATION
NOTE: The valve bridge guides are press fit in the
cylinder head. It is not normally required to remove valve
bridge guides unless they were bent or damaged.

1. Install valve bridge guides using a suitable press.

Valve bridge guides must not extend more than 2.935 in.
(74.54 mm) from boss (see Figure 3.00-42).

VALVE SEAT INSTALLATION

NOTE: Oversized intake valve seats and exhaust valve
seats are available (see Table 3.00-4).
Table 3.00-4. Oversized Valve Seats
CYLINDER
HEAD TOP PART NUMBERS
OVERSIZED
PRESS TOOL VALVE SEAT
P/N 494257 0.020 in. 0.030 in.
Intake 211801 2 211801 3
VALVE
GUIDE Exhaust 211802B 2 211802B 3

1. Thoroughly clean parts and inspect valve seat bores

for cracks, pits, wear or any deformations. Bores must
be perfectly smooth.

2. If installing oversized valve seats, cylinder head

Figure 3.00-41. Installing Valve Guides should be bored to appropriate size to provide a 0.001 --
0.003 in. interference fit (see Table 3.00-5,
Table 1.20-14 and Table 1.20-15).

2.935²
Table 3.00-5. Cylinder Head Inside Diameter
(74.54 mm) BORE CYLINDER HEAD
OVERSIZED
VALVE SEAT 0.020 in. 0.030 in.
3.020 -- 3.021 in. 3.030 -- 3.031 in.
Intake (76.708 -- 76.733 mm) (76.962 - 76.987 mm)
1.40 ±0.03² 2.620 -- 2.621 in. 2.630 -- 2.631 in.
(35.56 ±0.76 mm) Upper Exhaust (66.55 -- 66.573 mm) (66.802 -- 66.827 mm)
3.220 -- 3.221 in. 3.230 -- 3.231 in.
Lower Exhaust (81.788 -- 81.813 mm) (82.042 -- 82.067 mm)

Figure 3.00-42. Cylinder Head Cutaway View

FORM 6296 First Edition 3.00 -- 21

CYLINDER HEAD DISASSEMBLY AND OVERHAUL
Comply with the liquid nitrogen/Dry Ice manufactur-
er’s recommendations for proper use and handling
of liquid nitrogen/Dry Ice. Improper handling or use
of liquid nitrogen/Dry Ice will result in severe
personal injury or death.
Liquid nitrogen --196° F (--126° C) and Dry Ice --78° F
(--61° C) are extremely cold and will cause severe
burns if they come into contact with human skin. To
prevent burns to the skin, wear protective equip-
ment when working with liquid nitrogen or Dry Ice.
Disregarding this information could result in severe
personal injury or death.
Do not drive the valve
seat insert into the cylin-
der head at room temperature. The valve seat
inserts are a shrink fit in the valve seat counterbore
and must be cooled with liquid nitrogen/Dry Ice
before installation. Disregarding this information
could result in product damage.
NOTE: Liquid nitrogen is recommended for shrink
fitting valve seat inserts and is the method used in the
factory for seat installation. The low temperatures
provided by liquid nitrogen guarantee maximum shrink-
age, thereby reducing the risk of damage to the
counterbore or improper seating of the valve seat insert.
3. Chill each valve seat insert prior to installation.
Chilling decreases the diameter of the insert to ensure
an easy fit. Submerse valve seat inserts in liquid
nitrogen or a solution of Dry Ice and alcohol.
4. Allow inserts to remain submersed until solution
stops boiling. At this point, temperature of insert will not
drop any further.
Install the valve seat
with the beveled side fac-
ing outwards. Disregarding this information could
result in product damage.
3.00 -- 22
Apply Loctiteâ 620, 640
or 648 to the contact sur-
faces of exhaust valve seat bores. The exhaust
valve seats are water cooled and require the
Loctiteâ product to prevent coolant leaks. Disre-
garding this information could result in product
damage.
5. Apply Loctiteâ 620, 640 or 648 to contact surfaces of
exhaust valve seat bores.
NOTE: The inserts warm up rapidly, and must be
properly installed before diameter increases to the point
where installation becomes difficult.
6. Use a wire bent in the shape of a hook to pick up valve
seat inserts and position them into counterbore with
beveled side facing outward (see Figure 3.00-43).
7. Wait for several minutes for valve seat inserts to
warm to temperature of cylinder head. As inserts warm,
they expand to form a metal-to-metal contact with
counterbore. Use a 0.001 in. (0.0254 mm) feeler gauge
to verify inserts are properly set in bottom of counter-
bore. Verify inserts fit tightly around circumferences.
BEVEL
INTAKE
CHECK WITH A 0.001²
(0.0254 mm) FEELER
GAUGE TO ENSURE
PROPER INSTALLATION
EXHAUST
BEVEL
Figure 3.00-43. Valve Seat Inserts
FORM 6296 First Edition
 CYLINDER HEAD DISASSEMBLY AND OVERHAUL

VALVE SEAT GRINDING

NOTE: Use of the Hall-Toledo EDP valve seat grinder
(P/N 494277) is the only factory approved service
method of grinding valve seats (an eccentric grinder,
diamond dresser, stand and necessary wrenches are TIGHTEN PILOT
included). Other commercially available devices such MANDREL
as the SERDI machining system may be used.

Machining accuracy
depends upon the fit of
the pilot mandrel. The pilot mandrel should fit
snugly in the guide and in the hub of the grinder
stone. Be sure that the upper end of the mandrel
does not wobble during the grinding procedure.
Upper end movement will produce a seat that is not
ground true, causing damage to equipment. REMOVE HANDLE

NOTE: The pilot mandrel allows each valve seat to be

ground concentric with the valve guide. The Waukesha
supplied pilot mandrels (P/N 494344) are made only for
use with the Hall-Toledo EDP valve seat grinder.

1. Install handle on pilot mandrel. Insert mandrel

0.564 in. (14.325 mm) into intake or exhaust valve
guide. Turn round knob until mandrel is snug (see
Figure 3.00-44).

2. Remove handle from pilot mandrel (see

Figure 3.00-44). Position a dial indicator gauge gra- INSTALL DIAL
INDICATOR GAUGE
duated in thousandths of an inch (P/N 494278) on pilot
mandrel.

3. Measure valve seat concentricity to determine

amount of valve seat grinding required (see
Figure 3.00-44).

Do not grind the valve

seats too long and do not
apply too much pressure to the grinding stone.
Disregarding this information could result in prod-
uct damage.

Figure 3.00-44. Measure Valve Seat Concentricity

Always dress the stone
before grinding, failure to Table 3.00-6. Valve Seat Insert Grinding Stones
dress the stone could cause damage to equipment. TYPE STONE ANGLE TOOL P/N
The stone should be dressed to the proper angle
Seat Angle 20 Degrees 494014
after each seat is ground.
Seat Angle 30 Degrees 494305
4. Refer to Table 3.00-6 to select proper degree angle
grinding stone. Rough grind valve seat insert to obtain a 5. Install a fine dress stone for a final cut. Grind valve
total indicator runout of 0.002 in. (0.0508 mm) seats until a highly polished seat with a total indicator
maximum. runout less than 0.002 in. (0.0508 mm) is achieved.

6. Repeat grinding procedure as necessary.

FORM 6296 First Edition 3.00 -- 23

CYLINDER HEAD DISASSEMBLY AND OVERHAUL
Compressed air can pierce the skin and cause
severe personal injury or death. Never use your
hand to check for leaks or to determine air flow
rates. Wear safety glasses to shield your eyes from
flying dirt and debris.
Always use approved cleaning solvents in a well
ventilated area. Contact with skin could result in
severe personal injury or death.
7. Use compressed air to blow away all loose dust.
Wipe down valve seat and seat insert surfaces with a
non-volatile cleaning solution or solvent and dry with a
clean cloth.
VALVE SEAT LAPPING
1. Apply a good fine grinding compound sparingly
around entire valve face.
NOTE: Lap the valves in the locations in which they will
be installed. The valve type, whether (INT)ake or
(EXH)aust, is stamped on the head of the valve.
2. Install a light lifting spring over valve stem. Apply a
small amount of lubricating oil into valve guide bore and
slide valve into cylinder head. The spring should just
barely hold valve off its seat.
3. Press down until valve is seated. Rotate valve a
quarter turn, first in one direction, then in the other. Do
this three or four times.
4. Release pressure on valve stem, so that spring lifts
valve straight off its seat. Turn valve about 10 to 15 de-
grees clockwise and repeat grinding procedure. Contin-
ue this operation until valve has been rotated a complete
360 degrees and all grinding compound has been
rubbed off valve seat.
Ensure that all lapping
compound is completely
removed from the valve and valve seat. Failure to
completely clean all lapping compound from the
valve and valve seat could cause damage to
equipment.
5. Remove valve and spring from cylinder head and
thoroughly clean valve and valve seat insert of any
lapping compound.
3.00 -- 24
6. Carefully inspect mating surfaces. A properly lapped
valve will show a gray, frosty seating surface located
either near center of valve face for 30° valves, or near
valve head end for 20° valves. If properly lapped, the
lapped surface width will equal valve seat width values
listed in Section 1.20 Specifications.
7. Repeat lapping procedure if necessary. Regrind
valve seat insert if results are not acceptable.
8. Apply Permatexâ Prussian Blue dye sparingly
around entire circumference of valve seat surface.
9. Install valve in cylinder head. Gently push down on
valve stem until valve face just contacts valve seat.
Do not rotate or turn valve. Carefully pull valve straight
out of cylinder head.
10. Inspect valve face for Permatexâ Prussian Blue
transfer (see Figure 3.00-45). The dye transfers from
valve seat to valve face wherever a good face-to-seat
contact exists. A definite Prussian Blue transfer around
entire valve face circumference is desirable.
VALVE
FACE
WIDTH OF
PRUSSIAN BLUE
TRANSFER
Figure 3.00-45. Good Valve And Seat Contact
11. Repeat lapping procedure if necessary. If results
are not acceptable, regrind valve seat insert before
relapping.
VALVE SPRING INSPECTION
Always use approved cleaning solvents in a well
ventilated area. Avoid contact with skin. Failure to
follow proper procedures could cause severe per-
sonal injury or death.
1. Clean inner and outer valve springs, washers,
retainers and keepers in a non-volatile cleaning solution
or solvent. Although replacement of these parts is
uncommon, they should be inspected for damage, rust
pits or excessive wear. Replace as necessary (see
Table 1.20-19 in Section 1.20 Specifications).
FORM 6296 First Edition
 CYLINDER HEAD DISASSEMBLY AND OVERHAUL

2. Position intake and exhaust valve springs on a level
surface and use a straight edge to check for proper
squareness and height (see Figure 3.00-46). Springs
that are less than the required minimum height will result
in reduced preload on spring. Load test springs in a
valve spring tester.
STRAIGHT EDGE
1. Lubricate valve stems and valve guide bores with
clean engine oil.
NOTE: The best maintenance procedure is to install
valves in valve guides prior to installation of valve stem
seals and to use the valve stem seal installation tool.
The valve stems hold the valve stem seal installation
tool straight to ensure a fully seated square fit.
2. Install valves in valve guides.

3. Position cylinder head assembly valve side down on

a flat clean surface.

4. Using valve stem seal installation tool (P/N 474029)

(see Figure 3.00-48), slide valve stem seals down over
the lubricated valve stems, and tap lightly until seals are
SCRAP fully seated on valve guides. Ensure that seals are fully
OK seated and are square on valve guides.

OK
VALVE SPRING

Figure 3.00-46. Checking Valve Spring Height

VALVE STEM SEAL INSTALLATION

Current valve stem seals are a product improvement
that is intended to improve oiling of the valve stems and
guides (see Figure 3.00-47). The seals are color coded
for easy identification.

Figure 3.00-48. Valve Stem Seal Installation Tool

Figure 3.00-47. Current Seal

Proper installation of valve stem seals is required for

seals to operate properly. A valve stem seal installation
tool (P/N 474029) is provided to ensure that seals are
seated properly on valve guides. The following installa-
tion procedures should be followed when installing valve
stem seals.
NOTE: The valve guides should already be installed in
the cylinder head.

FORM 6296 First Edition 3.00 -- 25

CYLINDER HEAD DISASSEMBLY AND OVERHAUL

KEEPERS 2. Position inner and outer valve springs on intake and

SPRING exhaust valve guides.
RETAINER
KEEPERS
RETAINING
RING SPRING
INNER VALVE O--RING RETAINER
SPRING

OUTER VALVE INNER VALVE

SPRING OIL SPRING
DEFLECTOR

VALVE SPRING OUTER VALVE

WASHER SPRING

VALVE SPRING
WASHER

CYLINDER
HEAD

INTAKE EXHAUST
VALVE VALVE
CYLINDER
HEAD

INTAKE
VALVE EXHAUST
Figure 3.00-49. LT Cylinder Head Assembly VALVE

INTAKE AND EXHAUST VALVE INSTALLATION

NOTE: A new cylinder head assembly (P/N
AA205002D) is available for all VHP Series Four GSI
engines. The new cylinder head has been redesigned to
improve oil drain back and to meter the correct amount Figure 3.00-50. GSI Cylinder Head Assembly
of oil to the intake valves. The head assembly contains
new intake valves, “white” intake valve stem seals, NOTE: Do not intermix the intake and exhaust valve
springs. Intake valve springs can be distinguished from
intake valve bridges, oil deflectors, O--rings and retain-
the exhaust valve springs by the direction of the helix
ing rings. These cylinder heads are standard on all GSI
engines built after November 15, 2003. See Service (see Table 3.00-7 for valve spring reference).
Bulletin 7--2927a for information on upgrading previous Table 3.00-7. Valve Spring Reference
GSI cylinder heads.
VALVE COLOR DIRECTION OF HELIX
(Top To Bottom)
NOTE: The valve stem seals should already be
installed, if not, refer to “Valve Stem Seal Installation” in INTAKE
this section and install these items. Inner Blue Stripes Right
Outer Blue Stripes Left
1. Install washer over each valve guide shoulder until
EXHAUST
they come to rest on cylinder head casting. Washers are
needed to retain proper tension on inner spring. For LT Inner White Stripes Left
cylinder heads see Figure 3.00-49 and Figure 3.00-56. Outer White Stripes Right
For GSI cylinder heads see Figure 3.00-50 and
Figure 3.00-54.

3.00 -- 26 FORM 6296 First Edition

 CYLINDER HEAD DISASSEMBLY AND OVERHAUL

3. GSI cylinder heads only—Install oil deflector over

each intake valve spring (see Figure 3.00-51 and GUIDE STUD
Figure 3.00-54). Do not install O--ring and retaining ring
at this time.

SPRING RETAINING
RETAINER RING

NUTS

Figure 3.00-52. Position Center Guide Stud

OIL
DEFLECTOR O--RING
Figure 3.00-51. GSI Oil Deflectors
4. Position spring retainer on top of inner and outer
valve springs (Figure 3.00-49 and Figure 3.00-50). The
smaller diameter flange fits inside inner valve spring.
The larger diameter flange separates inner and outer
springs.
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.
Look through the holes
in the pressure plate to
ensure that they are aligned with the valve stems,
threaded studs, and valve bridge guide studs.
Failure to align the pressure plate properly could
cause damage to equipment.
6. 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 3.00-53).
PRESSURE COMPRESSION
PLATE NUT

5. Using two nuts that were removed from spark plug

extension, secure guide stud of valve spring compres-
sor (P/N 474034) in cylinder head (see Figure 3.00-52).

THRUST BEARING

Figure 3.00-53. Position Pressure Plate Compression

Nut And Thrust Bearing

7. Apply engine oil to threads of center stud guide.

8. Install thrust bearing and compression nut on center

stud guide.

FORM 6296 First Edition 3.00 -- 27

CYLINDER HEAD DISASSEMBLY AND OVERHAUL

OIL SPRING KEEPERS

DEFLECTOR RETAINING O--RING
RING RETAINER
OUTER VALVE SPRING
VALVE SPRING
WASHERS
INNER VALVE SPRING

VALVE STEM SEAL

VALVE GUIDE

WATER PASSAGES

INTAKE VALVE EXHAUST VALVE VALVE SEAT INSERT

Figure 3.00-54. GSI Cylinder Head Assembly

9. Tighten compression nut down until pressure plate

compresses valve springs just enough to install valve
spring keepers.

NOTE: New valve spring keepers are available. The

new keepers improve the fit between the retainer and
valve stem. The new keeper (P/N 73629A) has a black
oxide finish instead of the bright metal finish of the
previous keeper. All engines built after February 2003
will use new keepers.

10. Install valve spring keepers on valve stems (see KEEPERS

Figure 3.00-55).
Figure 3.00-55. Valve Spring Keepers
11. Loosen compression nut, and remove compression
nut and thrust bearing from center stud guide. 14. Inspect to ensure valve spring keepers are fully
seated in valve spring retainers and valve grooves.
12. Remove pressure plate from cylinder head.
15. GSI cylinder heads only—Install new O--ring and
13. Remove two nuts and center guide stud from
retaining ring onto each intake valve stem (see
cylinder head.
Figure 3.00-51 and Figure 3.00-54).

3.00 -- 28 FORM 6296 First Edition

 CYLINDER HEAD DISASSEMBLY AND OVERHAUL

SPRING
RETAINER
KEEPERS
OUTER VALVE SPRING
VALVE SPRING
WASHERS
INNER VALVE SPRING

VALVE STEM SEAL

VALVE GUIDE

WATER PASSAGES

EXHAUST VALVE VALVE SEAT INSERT

Figure 3.00-56. LT Cylinder Head -- Sectional View

FORM 6296 First Edition 3.00 -- 29