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Cylinder head service for 1998-2002 Cummins 5.9L ISB/QSB engines
Engine Builders: The AERA Technical Committee offers the following information regarding cylinder head service for 1998-2002 Cummins 5.9L ISB/QSB engines, also known as "24 valve" or "4 valves per cylinder" engines (current service information is found in Bulletin 366193, revision 01 published in February 1999). Previously published service information may be incorrect due to updated service information that has changed.
• Valve Seat Inserts – Currently there are no service replacement valve seat inserts available from Cummins. If a crack occurs across the valve seat, replace the head.
• Valve Guides – These engines use integral valve guides. There are currently no oversize valve stems or guides available from Cummins. When valve guides become available, a replacement procedure will be published.
• Cylinder Head Gasket – The current minimum cylinder head thickness of 4.1240˝ (104.75 mm) must be maintained because there is currently no oversize thickness head gasket available to allow machining of the cylinder head. When a gasket becomes available, additional service limitations will be published.
• Injector Protrusion – The injector tip protrusion specification is .150˝-.171˝ (3.817-4.353 mm). There is only one .060˝ (1.5 mm) shim available for use during assembly.
• Valve Recession – Intake valve recession must be between .038˝-.058˝ (.965-1.473 mm). Exhaust valve recession must be between .023˝-.043˝ (.584-1.092 mm).
NOTE: Deviations from the above specifications may result in piston-to-valve contact, white smoke or engine misfire.
Engine Builders: The AERA Technical Committee says excessive oil consumption in 1993-1997 Ford 2.0L VIN A engines may be due to installation of incorrect valve stem seals.
During the 1996 model year a running change was made to the cylinder heads used on these engines after manufacturing date of 3-13-1996. The valve guide O.D. and seal dimensions were reduced approximately .020˝ smaller in diameter. They are also taller.
The correct valve stem seal will center on the valve guide and will restrict and minimize the oil flow through the guide. The early seal may not center properly on the revised guide and valve, resulting in excessive oil consumption.
Figure 2 shows the taller seal used after 3/13/1996 on the left, and the shorter seal before 3/14/1996 on the right. The specifications are also shown in Figure 2.
AERA is currently aware of one aftermarket supplier of both valve seals for this engine.
Engine Builders: A clip comes with replacement pistons for the Porsche 911 3.2L engine from 1990-’99. Whether you are installing pistons in a turbo or non-turbo engine, this information is important.
According to AERA’s Technical Committee, to prevent damage to the cylinder walls during shipping, special clips are used to retain the wrist pin in the piston. These clips must not be used in engine assembly. Clips used for engine assembly are provided along with the shipping-only clips which will not hold up during engine operation and should be discarded.
Engine Builders: The AERA Technical Committee offers the following information regarding cylinder head torque on D342 Caterpillar engines produced from 1960-1985. Head torque values differ from spacer plate and non-spacer plate blocks; using the wrong torque could result in engine damage.
The major difference in these engines is that the spacer plate engines use 27 head bolts while the non-spacer plate engines use 21 nuts to clamp the cylinder head to the block. To properly torque these different types of cylinder heads, follow the torque sequences listed below and follow numbers and letters in sequence.
Spacer Plate Engines
- Tighten bolts 1-13 to 100 ft.lbs.
- Tighten bolts A-H to 210 ft.lbs.
- Tighten bolts A-H to 420 ft.lbs.
- Tighten bolts 1-13 to 200 ft.lbs.
- Tighten bolts 14-19 to 75 ft.lbs.
- Tighten bolts A-H to 420 ft.lbs. (repeat).
- Tighten bolts 1-13 to 200 ft.lbs (repeat).
Non-Spacer Plate Engines
- 1.Tighten numbered nuts to 60 ft.lbs.
- Tighten letter nuts to 150 ft.lbs.
- Tighten letter nuts to 300 ft.lbs.
- Tighten numbered nuts to 120 ft.lbs.
- Tighten letter nuts to 300 ft.lbs (repeat).
- Tighten numbered nuts to 120 ft.lbs (repeat).
- Check nuts in number sequence after engine test for minimum torque of 105 ft.lbs.
- Check all nuts in letter sequence after engine test for minimum torque of 260 ft.lbs.
Note: Engine builders should coat all bolt threads for both spacer plate and non-spacer plate engine head bolts with 4S9416 or aftermarket equivalent anti-seize before starting.