Service Information

Document Title: Function Group: Information Type: Date:

Cylinder head, 211 Service Information 17/04/2025
reconditioning
Profile:
D13F

Cylinder head, reconditioning

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D13F

Op nbr 211-069

Total procedure time (hr): 17.00

Tools:
9986173 Puller
9986485 Support
9990006 Puller
9990106 Sealing plate
9990107 Connection plate
9990176 Press tool
9990210 Valve spring compressor
9990262 Adapter
9992479 Retainer
9996159 Adapter
9996400 Impact puller
9996662 Pressure gauge
9998250 Ring
9998250 Ring
9998250 Ring
9998250 Ring
9998250 Ring
9998250 Ring
9998250 Ring
9998250 Ring
9998250 Ring
9998250 Ring
9998250 Ring
9998250 Ring
9998251 Sealing plug
9998251 Sealing plug
9998251 Sealing plug
9998251 Sealing plug
9998251 Sealing plug
9998251 Sealing plug
9998266 Sealing plate
9998666 Sealing plate
11666043 Jack
88800058 Fixture
88800062 Drift
88800147 Drift
88800151 Drift
88800196 Flaring tool (copper sleeve)
88800387 Puller
88800550 Brush set
88830175 Pump

Dial indicator with magnetic stand

Drift, 10 mm (0.4 in), 1 pc.
Graphite paste 85132765, GRAFEX GTL or GRAFOIL GTS
Lifting eye, M8, 3 pcs.
Loctite 7649 or similar
Sling, 2 m, 2 pcs.
Ratchet block, 500 kg (1102 lb), 1 pc.
Sealant 1161059

NOTICE
It is important that the greatest cleanliness is exercised when working with the cylinder head.

Dirt particles in fuel and oil ducts may cause breakdown of the unit injectors.

1. Install 88800058 Fixture on the cylinder head. Install three lifting eyes, M8, on the cylinder head. Connect a ratchet
block, 500 kg (1102 lb), and two slings, 2 m, to the lifting eyes and connect these to a lifting device. Lift the cylinder
head and secure it to 9986485 Support.
Weight, cylinder head: approx. 200 kg (530 lb)

Figure 1

1. 88800058 Fixture
2. 9986485 Support

2. Remove the thermostat housing and the thermostat.

 Figure 2

1. Thermostat
2. Thermostat housing

3. Remove the manifold.

Weight, manifold: approx. 20 kg (44 lb)

Figure 3

1. Manifold

4. Clean thoroughly around the unit injectors. Disconnect the connectors. Remove the bolts for the attaching yokes. Use
9996400 Impact puller, 9990262 Adapter and 9990006 Puller to remove the unit injectors with the attaching yokes.
NOTE!
Place each unit injector in a separate, new plastic bag. On each bag, note the cylinder number from which the unit
injector was removed. It is very important to not mix up the unit injectors since they are classed for a specific cylinder.
 Figure 4

1. 9996400 Impact puller

2. 9990262 Adapter
3. 9990006 Puller

5. Install 9998251 Sealing plug in the injector sleeves and tighten them with the unit injector's attaching yoke.

Figure 5
 1. 9998251 Sealing plug

Cylinder head, checking for leaks

6. Install 9998666 Sealing plate, 9998266 Sealing plate, 9990106 Sealing plate and 9990107 Connection plate on the
cylinder head. Use a clamp for the connection plate.

Figure 6

1. 9998666 Sealing plate

2. 9998266 Sealing plate
3. 9990106 Sealing plate
4. 9990107 Connection plate

7. Connect 9996662 Pressure gauge to 9990107 Connection plate.

8. Connect the pressure gauge to the workshop's compressed air system. Adjust the pressure to 100 kPa (14.5 psi) with
the reduction valve. Use soapy water to check that there is a tight seal between the cylinder head and the sealing
plates.
 Figure 7

1. Reduction valve

9. Close the shut-off valve for 2 minutes. The pressure should not drop during this time.

Figure 8

1. Shut-off valve

10. Connect a lifting device to the cylinder head. Submerge the cylinder head in water with a temperature of 70 °C (158 °F).

Figure 9

1. Temperature 70 °C (158 °F)

11. Adjust the pressure to 50 kPa (7.3 psi) with the reduction valve. Hold the pressure for 1 minute.

12. Increase the pressure to 150 kPa (21.8 psi). Lock the reduction valve with the lock ring. Check after 2 minutes. If the
pressure drops, check where the bubbles come from.

13. Lower the pressure with the reduction valve. Lift the cylinder head out of the water. Remove the sealing plates and the
 tools. Blow the water off the cylinder head.

Injector sleeves, removing

NOTE!
There are two methods for removing the injector sleeves, pull out with 88800387 Puller and 9986173 Puller or tap out with drift.

Pull out with puller

14. Remove 9998251 Sealing plug from one of the injector holes while working on it.

15. Install 88800387 Puller and press it down so that it bottoms in the sleeve.
Tightening torque, see Fuel system, tightening torques.
NOTE!
On the tool there is a line marking at a depth of 66 mm (2.6 in). If the tool bottoms so deep that the line cannot be
seen, it may be difficult to pull up the injector sleeve, since this indicates that it has been deformed.

Figure 10

1. Puller (included in 88800387 Puller)

2. Support ring (included in 88800387 Puller)

16. Install 9986173 Puller and tighten it.

 Figure 11

1. 9986173 Puller

17. Pull up the injector sleeve with the puller.

 Figure 12

1. Injector sleeve

Tap out with drift

18. Remove 9998251 Sealing plug from one of the injector holes while working on it.

19. Use a drift, 10 mm (0.4 in), to tap out the injector sleeves from the underside of the cylinder head.

Figure 13

Injector holes, cleaning

20. Clean the injector sleeve’s seat in the cylinder head. The tools are included in 88800550 Brush set. Install 9998580
Socket with the spacer washer and bolt M10. It should be used to prevent dirt from entering the fuel channel and
protect the cylinder head’s walls.

Figure 14

1. Extension
2. Bolt M10 and spacer washer
3. 9998580 Socket
4. Adapter bolt
5. Holder, brush head
6. 9808614 Brush

21. Clean the cylinder head’s walls. The tools are included in 88800550 Brush set.

Figure 15

1. 9808618 Brush
2. Bolt M10 and spacer washer
3. 9998580 Socket

22. Clean the bottom hole in the cylinder head. The tools are included in 88800550 Brush set.
 Figure 16

1. 9808617 Brush
2. Bolt M10 and spacer washer
3. 9998580 Socket

23. Install 9998251 Sealing plug in the cleaned injector hole.

NOTE!
Protect the injector holes while not working on them.

24. Remove the remaining injector sleeves, one at a time, in the same way.

Injector sleeves, installing

25. Measure the diameter at the widest point on 88880054 Pin included in 88800196 Flaring tool (copper sleeve) to make
sure it is not worn. The diameter should be 7.9 ±0.05 mm (0.311 ±0.00197 in).

26. Install a new O-ring on the injector sleeve and lube it with soapy water.

27. Place the injector sleeve on 88800196 Flaring tool (copper sleeve). Smear grease on the threads and under the nut on
88800196 Flaring tool (copper sleeve). Screw in 88880054 Pin until it reaches the bottom of the injector sleeve, then
screw it back out half a revolution. Lube 88880054 Pin with oil.

Figure 17

1. 88880054 Pin
2. Injector sleeve
3. 88800196 Flaring tool (copper sleeve)

28. Remove 9998251 Sealing plug from one of the injector holes while working on it.

29. Install the tools with the injector sleeve in the injector hole. Install the injector’s yoke to press down the injector sleeve.
Tightening torque, see Fuel system, tightening torques.
By holding the pin and tighten the nut, 88880054 Pin is pulled upp through the injector sleeve.
NOTE!
Use a measuring tool to check the piston’s position in the cylinder head before installing the injector sleeve. The
measuring tool should bottom against the piston at least 200 mm (7.87 in) below the cylinder head’s upper surface, so
that 88880054 Pin does not damage the piston.
 Figure 18

1. Injector’s yoke
2. 88800196 Flaring tool (copper sleeve)

30. Install 9998251 Sealing plug in the injector hole after installing the injector sleeve.
NOTE!
Protect the injector holes while not working on them.

31. Install the remaining injector sleeves in the same way.

32. Pressurize and check with soapy water that there is a tight seal at the injector sleeves.

33. Remove the pressure gauge and all the sealing plates from the cylinder head.

34. Remove 9998251 Sealing plug from the injector sleeves.

35. Install two 9998250 Ring in each injector hole.

Valves, removing

36. Install 9990210 Valve spring compressor in one of the injector sleeves and fasten it in the hole for the unit injector's
attaching bolt.
 Figure 19

1. 9990210 Valve spring compressor

37. Press down the valve washer and remove the valve collets.

38. Remove the valve washer, spring, and valve. Remove the remaining valves on the same cylinder.

39. Remove 9990210 Valve spring compressor from the injector sleeve.

40. Remove the remaining valves in the same way.

NOTE!
Mark and place each valve together with its valve washer and spring so that they can be reinstalled in the same place in
the cylinder head when assembling.

41. Remove the valve seals.

Figure 20
Valve seals

Valve guides, checking

42. Place a new valve in the valve guide, so that the valve spindle's end is flush with the guide's edge.

43. Place a dial indicator with magnetic stand so that the dial indicator's tip makes contact with the valve disc's edge. Move
the valve sideways in the direction of the exhaust and inlet channels. Read off the value on the dial indicator.
 Figure 21
Dial indicator with magnetic stand

44. Check all valve guides, see Engine, specifications. If the measured value exceeds the highest permitted value, the valve
guide must be replaced.

Valve guides, replacing

45. Install 9990176 Press tool in the holes for the cylinder head's attaching bolts. Install 11666043 Jack in 9990176 Press
tool and press out the valve guides with 88800147 Drift, 9996159 Adapter, and 88830175 Pump.

Figure 22

1. 88830175 Pump
2. 11666043 Jack
3. 9990176 Press tool
4. 9996159 Adapter
5. 88800147 Drift
 46. Clean the holes for the valve guides in the cylinder head.

47. Lubricate the outside of the valve guides with engine oil before installing them.

48. Press in the valve guides with 88800062 Drift. Press until the tool bottoms against the cylinder head's surface. Clean the
cylinder head.

Figure 23

1. 11666043 Jack
2. 88830175 Pump
3. 9990176 Press tool
4. 9996159 Adapter
5. 88800062 Drift

Valve seats, checking

49. Check the valve seat's depth in relation to the cylinder head, see Engine, specifications. The valve seats must be
replaced if the distance (A), measured with a new valve, exceeds tolerance. Otherwise they shall only be cleaned from
soot and ground.

Figure 24
 1. 9992479 Retainer
2. Dial indicator

Valve seats, replacing

50. Grind down two edges on the disc of a discarded valve.

Figure 25

51. Weld the valve in the valve seat.

Figure 26

52. Place a suitable sleeve as protection over the valve guide. Carefully tap out the valve and valve seat with a hammer.
NOTE!
Work carefully so that the cylinder head is not damaged.
 Figure 27

53. Thoroughly clean the seat’s position and check that the cylinder head has no cracks.

54. Measure the diameter of the valve seat's position. Check if a seat of standard dimension shall be used. If needed,
rework the valve seat's position.

55. Tap in the valve seat with a suitable drift and hammer.

56. Rework the valve seat to correct angle and width, see Engine, specifications.

57. Replace the remaining valve seats in the same way.

Valves, grinding

58. Check the valve disc's edge thickness (A). If the measured value is less than according to specifications, the valve must
be replaced, see Engine, specifications.

Figure 28
Inlet valve

A. Valve disc's edge thickness

B. Valve's seat angle
C. Valve seat's angle
 Figure 29
Exhaust valve

A. Valve disc's edge thickness

B. Valve's seat angle
C. Valve seat's angle

59. Check the valves' sealings with marking paint. In case of leakage, grind the valve seat again, then check again.

60. The sealing surface should be ground as little as possible, but enough to grind off all damage.

Valves, installing

61. Install the valves.

62. Thoroughly clean the contact surface with degreaser or similar before the new valve seals are installed.

63. Install 9998335 Guide sleeve on the valve stem.

Figure 30

1. 9998335 Guide sleeve

64. Install the new valve seal over the valve guide with 88800151 Drift.
NOTE!
Make sure that the valve seal are pressed all the way down so that the seals' underside seal tight against the valve
guide.
 Figure 31

1. 88800151 Drift

65. Repeat the procedure for the remaining valve seals.

66. Install the valve washers on the springs and install the springs.

67. Install 9990210 Valve spring compressor and fasten it in the hole for the unit injector's attaching bolt. Compress the
valve washer and the spring with 9990210 Valve spring compressor. Install the valve collets.

Figure 32

1. 9990210 Valve spring compressor

68. Install the remaining valves in the same way.

Cylinder head, assembling

69. Install the thermostat and the thermostat cover.

 Figure 33

1. Thermostat
2. Thermostat housing

70. Install the new seals and rings on the manifold. Turn the steel side of the seals to face the manifold.

Figure 34

1. Seal rings
2. Seals

71. Install the manifold.

Tightening torque, see Inlet and exhaust system, tightening torques.

Unit injectors, installing

72. Note the trim code on the connector for the new unit injectors. This code must be used later for parameter
programming with Tech Tool Service Tool.
 Figure 35

1. Trim code

73. Unit injector with flat surface: Install a new O-ring and gasket on the unit injector. Lubricate the O-ring with soapy
water.
Unit injector with tapered surface: Install a new upper O-ring on the unit injector and lubricate it with diesel. Lube the
unit injector's tapered surface with graphite paste 85132765, GRAFEX GTL or GRAFOIL GTS.

74. Remove 9998250 Ring from the injector holes.

75. Install and centre the unit injectors between the valve springs.
Tightening torque, see Fuel system, tightening torques.

76. Connect a ratchet block, 500 kg (1102 lb), and two slings, 2 m, to the lifting eyes on the cylinder head and connect
these to a lifting device. Lift away the cylinder head from 9986485 Support.
Weight, cylinder head: approx. 200 kg (440 lb)

77. Remove the lifting device and the lifting eyes from the cylinder head.

78. Remove 88800058 Fixture from the cylinder head.