200 BENCH PROCEDURES

[213 FP] Cylinder Head Cup Plugs

DESCRIPTION

The cylinder head has two different-size cup plugs: 13/16 inch (20.64 mm) and 1-1/16 inch (26.99 mm).

CYLINDER HEAD CUP PLUG INSTALLATION

1.Clean cup bore thoroughly.

2.Use Loctite 277 sealer, or equivalent, and apply to cup plug and cup plug bore in head.

Refer to Figure 5-54.

3.Install cup plugs in cylinder head, using cylinder head core plug installer J 34684 for 13/16-inch cup plugs, and cylinder head core plug installer J 34687 for 1-1/16 inch cup plugs.

Cup should be installed flush with machined surface to 0.020 inch (0.508 mm) below cylinder head.

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200 Bench Procedures

Cylinder Head Pipe Plugs

CYLINDER HEAD PIPE PLUG INSTALLATION

1.Apply dry pipe thread sealant to pipe plug and pipe plug bore in head.

Refer to Figure 5-55.

2.Install a 1/8-inch pipe plug in top of rear cylinder head.

3.Install two 3/4-inch core hole pipe plugs in cylinder head. Torque to 28 lb-ft (38 N•m).

200 Bench Procedures

[213 NB] INLET AND EXHAUST VALVES

Inspection

Refer to Figure 5-56.

Visually inspect valves for cracks, pits or other conditions that may cause improper operation. Check valve seat angle. Also check stem length, diameter and condition.

Valve Identification

The Pyromet exhaust valve cannot be used on E7 engines equipped with a Dynatard engine brake. The Pyromet exhaust valve head is 0.020 inch (0.508 mm) thicker than a conventional exhaust valve; therefore, valve-topiston contact may occur when engine brake is activated.

To permit positive identification, exhaust valve has two stem grooves and inlet valve has one stem groove.

The valves are also identified by letters

“I” (30-degree inlet), “2” (20-degree inlet), “E” (exhaust) or “Y” (Pyromet exhaust), which are forged in a slight depression on bottom face of valve head.

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