location to another. If this is done it
Non-Fluorescent Penetrant Method: The test area
could result in permanent damage to
being inspected is sprayed with "Spotcheck" or Dye
Check. Allow one to thirty minutes to dry. Remove the
excess surface penetrant with clean cloths premoisened
b. Install scrap or dummy injectors to ensure
with cleaner / remover. DO NOT flush surface with
proper seating of the injector tubes. Dummy
cleaner / remover because this will impair sensitivity.
injectors may be made from old injector nuts
Repeat this procedure with additional wipings until
and bodies -the injector spray tips are not
residual surface penetrant has been removed. Shake
necessary. Tighten the injector clamp bolts to
developer thoroughly until agaitator rattles. Invert spray
20-25 Ib-ft (27-34 Nm) torque.
can and spray short bursts to clear valve. Then spray
c. Apply 40 psi (276 kPa) air pressure to the water
this developer film evenly over the test area being
jacket. Then immerse the cylinder head in a
inspected. Allow developer film to dry completely
tank of water, previously heated to 180-200°F
before inspecting. Recommended developing time is 5
(8293 C), for about twenty minutes to thoroughly
to 15 minutes.
heat the head. Observe the water in the tank
for bubbles which indicate a leak or crack.
The above four methods provide basic instructions.
Check for leaks at the top and bottom of the
Specific details should be obtained from the supplier of
injector tubes, oil gallery, exhaust ports, fuel
the equipment or material.
manifolds and the top and bottom of the cylinder
Pressure Check Method: Pressure check the cylinder
d. Relieve the air pressure and remove the
head as follows:
cylinder head from the water tank.
remove the plates, gaskets and injectors and
a. To seal off the water holes in the cylinder head,
dry the head with compressed air.
assemble tool set J 28454 as follows (Fig. 7):
2. Check the bottom (fire deck) of the cylinder head for
1. Install the rubber stoppers on the bridges.
a. Large stoppers are installed on the
long center bridge feet opposite the
a. Use a heavy, accurate straight-edge and feeler
notch and on the long end bridge
gages, tool J 3172, to check for transverse
feet closest together.
warpage at each end and between all cylinders.
Also check for longitudinal warpage in six places
as shown in Fig. 8. Refer to Table 1 for
opposite the large stoppers on
maximum allowable warpage.
center bridge and end bridge feet
and on all short bridges.
2. Install the necessary parts, loosely, on the
3. Tighten the hold down bolts until the
stoppers start to distort. A 5 Ib-ft (7 Nm)
NOTE: Do not overtighten the hold
b. Use the measurements obtained and the limits
down bolts. The rubber stopper could
given in Table I as a guide to determine the
distort enough to seal both the inner and
advisability of reinstalling the head on the
outer diameter of the water nozzles. If
engine or of refacing it. The number of times a
the outer diameter is sealed, a leak
cylinder head may be refaced will depend upon
from the outer diameter would not be
the amount of stock previously removed.
c. If the head is to be refaced, remove the injector
4. Install the air supply plate.
tubes prior to machining. Do not remove more
metal from the fire deck of any cylinder head
below the minimum distance of 3.536" (Fig. 9).
Do not hook onto the
pressure checking tool, or any part of it,
to move the cylinder head from one