Cylinder Head Assembly: Service and Repair

Fig. 13 Cylinder head bolt markings:

Fig. 14 Pre-chamber installation:

New head bolts with increased torque capacity were introduced into production and are now available, Fig. 13.
When replacing a cylinder head, it is recommended new head bolts be used if they have not already been installed in the engine. When installing later production model head bolts, be sure to clean and oil the threads. Before installation of the cylinder head, ensure bolt holes are tapped deep enough into the block. Blow out any chips or liquid in the bolt holes. Then position cylinder head on cylinder block without the cylinder head gasket. Install bolt and tighten by hand until bolt head contacts the cylinder head. This will indicate that the holes are tapped deep enough into the block, allowing for proper torque. For cylinder head bolt location, part number and size, refer to Fig. 14.

Fig. 15 Cylinder head bolt identification:

Fig. 16 Cylinder head tightening sequence. V8 engine:

Fig. 17 Cylinder head bolt tightening sequence. V6 engine:

New design head gaskets are available for service and will supersede previous gaskets used on V8-350 diesel engines. These gaskets are the same gaskets recommended for use on engines using .030 inch oversize pistons and will now be used for all applications. The use of these gaskets on standard engines should prevent loss of compression due to the gasket sealing ring falling into the combustion chamber. On 1983 engines, use new gasket, Part No. 22519416. This gasket is evident by the grey seal located on the gasket face. On 1982 engines, use new gasket, Part No. 22510719, evident by the purple seal on the gasket face. No gasket sealer should be used on either gasket during installation.

When servicing cylinder head, ensure that prechambers are not recessed into cylinder head or protrude out of cylinder head more than .004 inch, since head gasket leakage may result. Measure the difference between flat or prechamber and the flat surface of cylinder head at two or more points around circumference of prechamber, using a straightedge and feeler gauge. If prechamber is recessed more than specified, replace prechamber or cylinder head, depending on which is at fault. If prechamber protrudes more than specified, grind top of prechamber for a flush fit, or replace as necessary.
1. Remove intake manifold as outlined previously.
2. Remove valve cover. It may be necessary to remove any interfering accessory brackets.
3. Disconnect glow plug wiring.
4. Remove ground strap from right cylinder head, if removing.
5. Remove rocker arm bolts, pivots, rocker arms and pushrod. Note locations of valve train components so they can be installed in original locations.
6. Remove fuel return lines from injection nozzles if equipped.
7. Remove exhaust manifold.
8. Remove engine block drain plug on side of block that cylinder head is being removed.
9. Remove cylinder head bolts and cylinder head. On 1982 V8 diesel remove TCC temperature switch located on exposed right rear cylinder head bolt.
10. If necessary to remove pre-chamber, remove a glow plug or injection nozzle, then tap out pre-chamber with a suitable drift, Fig. 15.
11. Reverse procedure to install. Do not use any sealing compound on cylinder head gasket. On 8 cylinder engines, torque cylinder head bolts in sequence, Fig. 16, to 100 ft. lbs., then to 130 ft. lbs. On 6 cylinder engines, torque cylinder head bolts except bolts 5, 6, 11, 12, 13 and 14, Fig. 17, to 142 ft. lbs. Torque bolts 5, 6, 11, 12, 13 and 14 to 59 ft. lbs.