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Doc No. GEK-76768, Rev. -

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Inspection, 7FDM-8/12/16

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Steel-Head Engine Cylinders
GEK-76768

© 2008 General Electric Company. All rights reserved. The information contained in this
publication is the property of General Electric Company and is disclosed in confidence. This
publication is intended for use by GE customers solely for purposes of operating and
performing routine maintenance of purchased or licensed GE products, and it shall not be
reproduced, redistributed, retransmitted, translated, abridged, adapted, condensed, revised
or otherwise modified, in any form, in whole or in part, or used for any other purpose, or
disclosed to third parties, without the express written consent of GE.

GE and Customer agree that the information contained herein does not purport to cover all

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details or variations in GE products or to provide for every possible contingency with

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installation, operation or maintenance. Should further information be desired or should

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particular problems arise that are not covered sufficiently for the user’s purposes, the matter

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should be referred to General Electric Company. Any applicable Federal, State or local

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regulations or company safety or operating rules must take precedence over any
information or instructions given in the Technical Documentation. GE has no obligation to

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keep the material up to date after the original publication.
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GENERAL ELECTRIC COMPANY EXPLICITLY DISCLAIMS ALL WARRANTIES OF ACCURACY,
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MERCHANTABILITY OR FITNESS FOR ANY PURPOSE IN CONNECTION WITH THIS PUBLICATION

AND USE THEREOF.
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If you are not an authorized recipient of this publication, you are hereby notified that any
perusal, use, distribution, copying or disclosure is strictly prohibited. If you have received this
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publication in error, please immediately return to GE at the following address: GE

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Transportation, Technical Publications Department, Building 14, 2901 East Lake Rd., Erie, PA
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16531.
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 GEK–76768
STEEL HEAD ENGINE CYLINDERS
INSPECTION
GE 7FDM–8/12/16 DIESEL ENGINES

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CONTENTS

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Page

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1. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1. SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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1.2. APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

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1.3. SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

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2.2. SERIAL NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

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2.3. VALVE ARRANGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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2.4. HEAD AND LINER ARRANGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.5. FUEL-OIL INJECTION-PUMP PUSHROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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2.6. UPPER CYLINDER ARRANGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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2.7. COMPRESSION RELEASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.8. FUEL-OIL INJECTION EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.9. FUEL–OIL INJECTION NOZZLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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2.10. VALVE PUSHRODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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2.11. CYLINDER COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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3. INSPECTION AND MAINTENANCE (WITH CYLINDERS ON ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.1. MECHANICAL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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3.2. WATER TESTING CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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3.3. AIR INLET PORT CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

4. CYLINDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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5. CYLINDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.1. APPLYING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.2. INSERTING PUSHRODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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5.3. SETTING VALVE TAPPET CLEARANCE AND INJECTION-PUMP TIMING . . . . . . . . . . . . . . . . . . . . . . 23

6. DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7. TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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1. GENERAL INFORMATION

1.1. SCOPE
This instruction covers inspection and service procedures only and not any distinct detail. When extensive repair
and overhaul are indicated, refer to the Disassembly and Assembly instructions in GEK–76738, STEEL-HEAD EN-
GINE CYLINDERS, DISASSEMBLY AND REASSEMBLY publication located either in this Maintenance Manual.

Copyright 2004 General Electric Company. All rights reserved. This copyrighted document may be reproduced free of charge by General
Electric Company customers, if such reproduction is used exclusively in connection with equipment used in that customer’s internal
operation.

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to be met in connection with installation, operation, or mainte-
nance. Should further information be desired or should particular problems arise which are not covered sufficiently for the user’s purposes, the matter should be referred to the General
Electric Company. Any applicable Federal, State or local regulations or company safety or operating rules must take precedence over any instructions given in this material. GE has no
obligation to keep the material up to date after the original publication.

THERE ARE NO WARRANTIES OF ACCURACY, MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE.

Verify numbers for parts, tools, or material by using the Renewal Parts or Tool Catalogs, or contact your
General Electric representative for assistance.
Do not order from this publication.
GEK–76768, Steel–Head Engine Cylinders, Inspection

1.2. APPLICATION

This instruction covers steel-head engine cylinders used as original equipment and replacements on General Elec-
tric 7FDM–8/12/16 Engines.
1.3. SAFETY INFORMATION

Safety precautions which must be observed when working on Steel–Head Engine Cylinders appear throughout
this publication. WARNINGS indicate the potential for personal injury, and CAUTIONS indicate the potential for equip-
ment damage.

2. DESCRIPTION

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2.1. GENERAL

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The basic cylinder consists of three major components: the cylinder liner, the cylinder head with valves and the

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cylinder jacket. These parts are sealed and gasketed, assembled, aligned by the compression release adapter, and

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secured by a clamping-ring and special bolts (Figure 1). This sub-assembly is sometimes referred to as a “short as-
sembly.” Figure 2 illustrates the power assembly.

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CAUTION: The power assembly (including short, long, and full configurations) is a Critical Component.
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Consult the latest revision of the manufacturer’s Parts Catalog to obtain the correct replacement part.
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The cylinder liner is a heavy-wall tube, hardened or chrome-plated in the bore for extended life. These cylinders
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have a welded head and liner, and the liner is steel. Cooling water from the water inlet header coming through the
cylinder jacket wall is forced around the liner in the lower water band by the restriction formed by the distribution dam
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on the outside diameter of the liner and the inside diameter of the jacket. Passing through the 1/8-in. annular space
into the upper water band, the water continues into the head through many longitudinal holes drilled in the upper liner
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wall.
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The steel cylinder head is fabricated from an alloy steel casting, an alloy steel forging and baffles. Cooling water
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from the top of the cylinder liner passes through angularly drilled holes to cavities in the steel head. After cooling the
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head, the water passes through the outlet opening in the top of the head and a cored passage in the top portion of the
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jacket to the water discharge header. The head also has cast-in passages for inlet air and exhaust gases. The four
valve seats are weld-faced with hard metal prior to machining. The valve guides, springs and valves are assembled to
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the steel head.

The one-piece cast-iron cylinder jacket houses the cylinder head and the cylinder liner. In addition, the upper cavity
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of the jacket accommodates the fuel-oil injection pump, the fuel-oil injection nozzle, the valve rocker arms and shafts
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and the crossover pushrod.

The cylinder assembly is secured to the engine main frame by four large mounting bolts. The outer diameter of the
cylinder jacket casting below the mounting flange forms a rabbet fit into the main frame. O-rings seal the joint between
the jacket casting and the main frame.

The basic cylinder sub-assembly (“short assembly”) must be equipped with a compression release plug, valve
operating parts and fuel-oil injection equipment when it is applied to an engine. The air inlet manifold body, exhaust
manifold elbow and the water inlet and discharge headers are bolted to the jacket casting.

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 Steel–Head Engine Cylinders, Inspection, GEK–76768

10 11
REF. DESCRIPTION
7
6 1 EPDM SEAL (WATER DISCHARGE OPENING)
9 12 2 O–RING (UPPER, CYLINDER HEAD TO JACKET
5 8 13 3 VITON SEAL (INJECTOR–NOZZLE OPENING)
3 4 GASKET (INJECTOR–NOZZLE)
5 O–RING (NOZZLE AND UPPER CYLINDER JACKET)
6 INJECTOR
1
7 INJECTOR FLANGE
8 STAT–O–SEAL WASHER
2 9 STUD
10 CLAMP BAR
31 11 CLAMP KNOB

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12 STOP NUT

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13 LOCTITE (APPLIED TO THREADS)
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14 PUSH ROD
15 TAPPET–ROD ADJUSTING NUT
16 INSPECTION PLATE

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4 17 TAPPET–ROD UMBRELLA NUT
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18 LOCKWASHER AND BOLT
15 19 INSPECTION PLATE GASKET
16 20 CYLINDER TO FRAME FUEL DRAIN

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22 TAPPET–ROD
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23 CYLINDER BOLT AND LUBRICANT
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24 CYLINDER HEAD LINER
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25 CYLINDER BOLT AND LUBRICANT

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26 CYLINDER LINER CLAMPING–RING
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27 20 27 RETAINING RING
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28 O–RING (LINER TO JACKET AND CLAMPING RING)
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26 29 O–RING AND LUBRICANT (LINER TO JACKET)

25 23 30 SEAL (CYLINDER HEAD TO JACKET WATER)
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22 31 CYLINDER HEAD
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E–45295
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Figure 1. Steel–Head Gasketed Cylinder Assembly, Sectional View.

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2.2. SERIAL NUMBERS

The cylinder jacket drawing number and serial number will be found on the top left flat-machined surface of the
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cylinder jacket. The jacket serial number also is used to identify the entire cylinder assembly.
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2.3. VALVE ARRANGEMENT

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Four valves, two inlet and two exhaust, are assembled to the cylinder head (Figure 4). Exhaust valve heads are
made of a special heat-resistant material, with stems made of a milder material friction-welded to the heads. Inlet
valves are made from a single piece of material. The valves operate in cast-iron guides pressed into the steel head.

A valve spring is mounted above each valve (Figure 5). Spring seats, split keepers and spring retainers or valve
rotators secure the valve and spring assemblies. All four valves on recent design cylinders have an umbrella on the
upper stem inside the spring.

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GEK–76768, Steel–Head Engine Cylinders, Inspection

HIGH
PRESSURE
NUT NOZZLE CLAMP
NUT

SOLENOID
LEAK OFF
HOSE

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SHIELDING

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Figure 2. Upper Cylinder Components.
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HEADER BLOCK BOLTS

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TERMINAL SCREWS
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FUEL
HEADER
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INLET BLOCK
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TUBE
ASSEMBLY
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OUTLET TUBE
ASSEMBLY
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HP FUEL PUMP MOUNTING BOLTS E–46475

Figure 3. Header Block with Tube Assemblies.

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 Steel–Head Engine Cylinders, Inspection, GEK–76768

VALVE INLET
EXHAUST ROTATORS VALVES
VALVES

STEEL
CYLINDER
HEAD

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SPRING
SEAT

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LOWER
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AIR
HEAD TO COMPRESSION
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INLET
JACKET RELEASE OPENING
SEAL HOLE
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E–27079
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Figure 4. Cylinder Head, Top View, With Valves Installed.

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E–34011

Figure 5. Valve Arrangement Details.

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GEK–76768, Steel–Head Engine Cylinders, Inspection

2.4. HEAD AND LINER ARRANGEMENT

CAUTION: The head liner assembly is a Critical Component. Consult the latest revision of the manufactur-
er’s Parts Catalog to obtain the correct replacement part.
The steel head is machined for the proper fit in the cylinder jacket. Three gaskets fit in grooves in the top of the
jacket to seal the openings between the jacket and the upper end of the head (Figure 6). One seals the water dis-
charge opening, one seals the fuel-oil injection nozzle opening, and the larger gasket seals the outer edge of the head
to the jacket. A fourth gasket fits on the lower flange around the head and seals the water passages around the head
and jacket (Figure 7).

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4

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REF. DESCRIPTION
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1 CYLINDER JACKET
2 SEAL AROUND FUEL–INJECTOR NOZZLE
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OPENING
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3 SEAL BETWEEN HEAD AND CYLINDER

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JACKET
4 WATER INLET OPENINGS
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5 AIR INLET OPENINGS

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6 SEAL AROUND WATER DISCHARGE

OPENING
7 EXHAUST GAS OPENING
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E–14988

Figure 6. View of Open End of Cylinder Jacket.

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The heavy-walled liner has an interference fit in the jacket, and is secured to the jacket by a large clamping- ring.
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The clamping-ring is attached to the jacket by twelve special bolts.

Two O–rings, applied to grooves in the liner just above the liner clamping flange, seal the lower portion of the liner to
the jacket. An additional square-cut O–ring compressed between the jacket and the clamping-ring and supported
around the circumference by retaining rings, assures no water leakage at the lower end of the cylinder.

2.5. FUEL-OIL INJECTION-PUMP PUSHROD

The fuel-oil injection-pump pushrod assembly includes a tappet rod and a pushrod. The pushrod is guided by a
reamed bore in the cylinder jacket, while the tappet rod operates in a renewable bronze guide which is pressed into the
jacket flange. A hardened tappet-adjusting nut and umbrella locknut at the upper end of the tappet rod provides pump

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 Steel–Head Engine Cylinders, Inspection, GEK–76768

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E–15066A

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Figure 7. Cylinder Head Seals and Gaskets.
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timing adjustment. The umbrella constructed on the tappet locknut prevents fuel-oil drainage from running down the
tappet rod through the bushing into the crankcase.
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2.6. UPPER CYLINDER ARRANGEMENT

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The valve rocker arms are supported on two shafts through the top of the cylinder jacket. The rocker arms are fitted
with renewable bushings. Adjusting screws and locknuts in the rocker arms provide valve tappet adjustment (Figure
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5).
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The valve rocker arms are operated by hollow pushrods extending downward through passages in the jacket cast-
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ing to cam-operated crossheads. A bell crank mounted on the inlet rocker shaft transmits motion from the main ex-
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haust pushrod through a second short pushrod to operate the exhaust rocker arm.
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2.7. COMPRESSION RELEASE

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A compression release plug is located on the left side of each cylinder. Figure 5 shows the location of the compres-
sion release in the steel head, and Figure 8 shows the compression release mounted on the cylinder.
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Turning the plug counterclockwise (CCW) one turn is sufficient to release cylinder compression. A flat copper gas-
ket seals the inner end of the plug (Figure 9). During engine operation, compression release plugs must be tightly
closed to prevent high-pressure gas leakage from damaging the plug seats. See DATA Section for required torque
values on adapters and plugs.

When replacing the flat copper gasket, apply a light film of grease to the gasket to position it and to keep it from
falling over while installing the plug.

2.8. FUEL-OIL INJECTION EQUIPMENT

The fuel-oil injection pump is mounted in an enclosure at the upper end of each cylinder jacket. The fuel-oil injection
nozzle extends through the cylinder jacket, with its spray tip protruding from the center of the steel head.

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GEK–76768, Steel–Head Engine Cylinders, Inspection

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E–22584
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Figure 8. Compression Release Plug Installed in Cylinder.
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E–22580
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Figure 9. Compression Release Valve, Sectional View.

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CAUTION: It is imperative that one (and only one) good copper gasket be used to seal the nozzle to the
head. Lack of a gasket allows the escape of high-pressure gases; more than one gasket changes the fuel
spray pattern. Both faults lower engine efficiency and damage engine components.

NOTE: Items are illustrated in Figure 2.

Electronic Fuel Injection (EFI): The nozzle is held in place by two nozzle clamp nuts and thread seal washers
which secure the nozzle hold–down clamp plate. Rubber collars are fitted over the nozzle studs underneath the nozzle
hold–down clamp plate.

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 Steel–Head Engine Cylinders, Inspection, GEK–76768

CAUTION: Handle the fuel–oil injection nozzle with care, and take measures to prevent dirt from entering
the nozzle. DO NOT BUMP THE TIP. Place protective caps or plugs over connections, and put a protective
cover over the tip end. RETURN INJECTION NOZZLES FOR REPAIR PROTECTED IN THE SAME MANNER
AS NEW NOZZLES ARE RECEIVED.

2.9. FUEL–OIL INJECTION NOZZLE

Refer to GEK–76766, BOSCH II ELECTRONIC FUEL–OIL INJECTION located in this Manual for procedures to
inspect, remove and replace the fuel–oil injection nozzle.

2.10. VALVE PUSHRODS

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Each cylinder contains three valve pushrods constructed of steel tubing with hardened-steel ends. The two long

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pushrods are interchangeable and may be installed either end up. The short crossover pushrod also may be installed

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either way. All three pushrods pass pressurized lubricating oil through their length for the rocker-arm bushings and the

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valve tappet buttons.

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2.11. CYLINDER COVER

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A lightweight aluminum cover encloses the top of the cylinder sealing off the upper cylinder area from atmosphere.
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A formed gasket is fitted into a groove on the underside of the cover to produce a lubricating oil seal. The top of the
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cover is marked with the position of the inlet and exhaust valves in the cylinder and the settings for the tappet clearance
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of the valves. The cover is secured by a clamp bar tightened by a threaded tee-handle.
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3. INSPECTION AND MAINTENANCE (WITH CYLINDERS ON ENGINE)

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3.1. MECHANICAL INSPECTION

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Some of the checks listed below are routine operations performed at periodic inspection and maintenance inter-
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vals; other checks are those that should be performed following reported troubles or failures.
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With the engine idling:

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1. Inspect the engine externally for leaks. Lubricating-oil and fuel-oil leaks will be evident by oily films or flow
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patterns. Cooling-water leaks will be evident by discoloration from the water treatment. Exhaust leaks cause
discolored or peeled paint and leave a carbon film adjacent to the leak.
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2. Listen for excessive or unusual noises at each cylinder and at the exhaust stack. In addition to detecting such
faults as excessive valve tappet clearance (a clicking noise) or a defective exhaust valve (a louder-than-normal
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periodic noise out the stack), this inspection could also identify other engine defects, such as a pounding bear-
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ing (excessive clearance).

3. Perform a pop test by toggling the Fuel Injection Pop Test Switch. This switch provides the EGU with a request
to start a “pop” test sequence of the fuel injection pumps. The EGU will only permit this test if the engine speed
is commanded to 335 RPM or 440 RPM IDLE.
4. Observe the color of the exhaust. A clear to light grey exhaust color is desirable. A blue cast indicates exces-
sive lubricating oil in the exhaust, possibly resulting from scored cylinder liners, faulty piston rings or bad turbo-
charger bearings and/or seals. A white cast indicates water in the exhaust which is probably caused by a de-
fective liner top seal in a cylinder assembly. The white cast could also be a temporary condition from the engine
running cold.

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GEK–76768, Steel–Head Engine Cylinders, Inspection

With the engine shut down:

1. Check water tank sight glass for black foreign material, an indication of cylinder liner top seal leaks.
CAUTION: Do not bar over or crank the diesel engine with any of the camshaft sections removed. Doing
so WILL damage valve train components.

2. Remove the crankcase inspection covers and make a visual and manual check of engine components. Look
for parts that show evidence of excessive heat, broken components (such as cylinder liner skirts), and bearing
metal (sometimes deposited on the side shelves of the main frame). Bar the crankshaft to raise pistons to their
top position and check for scored liners. Use both eyes and hands for this inspection. Then bar the crankshaft
to lower pistons to their lowest position and check for scored piston skirts.

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3. Remove the fuel-oil injection nozzles and use a boroscope to check for damaged cylinder valves, liner top seal

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water leaks, scored liners and excessive liner wear steps at top piston ring reversal.

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NOTE: Do not mistake lacquer-deposit stains or heat-treatment stains found in some hardened liners as

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scored surfaces in the liner.

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4. Check cylinder valve tappet clearance and fuel-oil injection pump timing.

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5. Remove the cylinder covers and note any dry areas which are an indication of lack of lubrication. Also look for
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metal particles from excessively worn parts and sludge deposits from improper lubrication.
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6. Use a compression test to identify defective cylinder valves, liners and piston rings.
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7. Apply water tests to locate cylinder liner top and bottom seal leaks.
am Co

8. Clean cylinder inlet ports which have heavy carbon deposits.

an nd

3.2. WATER TESTING CYLINDERS

i/P a
m ry

Several different water tests can be made with cylinders on the engine. In addition to finding defective cylinder liner
ia ta

top and bottom seals, these tests may also serve to find leaks in other engine and cooling-water system components.
M rie

3.2.1. Test “A” - For Detecting Liner Top and Bottom Seal Leaks
sa p
in Pro

1. Drain the cooling-water system.

GE

2. Disconnect the cooling-water system from the engine at the following points:

a. Water pump inlet,

ar
M

b. Air compressor supply pipe coupling at the water pump discharge elbow, if so equipped,

c. Water discharge header above the right intercooler,

d. Fuel-oil heater discharge hose (if used),

e. Cab heater supply at rear of water outlet header, if so equipped,

f. Any other water connections to or from the engine that may exist on specific marine applications.

3. Blank or plug all disconnected pipes and hoses.

4. Fill the engine water system and purge all air from the system.

10
 Steel–Head Engine Cylinders, Inspection, GEK–76768

5. Apply pressure of 50 psi (345 kPa) maximum and observe any leakage, especially in the crankcase at the bot-
tom of each cylinder liner. Remove the fuel-oil injection nozzles and observe with a boroscope any water pass-
ing through the liner top seal into the combustion chamber.

NOTE: Slight leakage at the water pump tell-tale hole may result from leakage by the water seal when it is
not rotating. Check this point again with the engine running before disqualifying the water seal.

6. Restore all cooling water system connections and fill the system with properly treated water.

3.2.2. Test “B” - For Detecting Liner Bottom Seal Leaks

1. Block the water tank fill cap so it will not relieve pressure.

63
31 n
8- tio
08
2. Connect a regulated water supply with a pressure of 20 psi maximum to the cooling-water system. An ideal

83 ma
connection point is the system water drain, as it has a shut-off valve.

10 or
3. Watch for water leakage, especially in the crankcase at the bottom of each cylinder liner.

#3 l Inf
NOTE: Slight leakage at the water pump tell-tale hole may result from leakage by the water seal when it is
not rotating. Check this point again with the engine running before disqualifying the water seal.

ne ia
gi nt
4. Disconnect the water supply, reactivate the water tank fill cap and correct the system water level. Add water
En de
treatment if needed.
a, nfi

3.2.3. Test “C” - For Detecting Liner Top Seal Leaks

am Co

1. Disconnect and remove all compression elbows at the water discharge header. Keep the water discharge pipe
an nd

from each cylinder in position.

i/P a

2. Fill the cooling-water system so that the water level is to the top of each vertical cylinder water discharge pipe.
m ry
ia ta

3. Install a 1.050-in. governor tail rod block (GE Tool 147X2228-1) between the governor tail rod clevis and the
M rie

governor case. It may be necessary to move the fuel linkage manually to give enough clearance.
sa p

CAUTION: The above step is mandatory to prevent the engine from starting during testing.
in Pro

4. The following additional safeguards are suggested to prevent the engine from starting during testing:
GE

a. Place the Combined Power or Throttle handle in SHUTDOWN position.

ar

b. Disconnect the control governor electrical connector.

M

c. On engines equipped with an overspeed link, remove the oil line at the link and cap both the end of the line
and the fitting on the link to prevent oil spillage.

d. Pull out the Low Oil Pressure Shutdown button if the governor is so equipped.

5. Using the START button, crank the engine and watch the cylinder water discharge pipes. A cylinder with a
defective liner top seal will blow water out of its discharge pipe.

6. Restore the engine to normal. Correct the cooling-water system level. Add water treatment if needed.

11
GEK–76768, Steel–Head Engine Cylinders, Inspection

3.2.4. Test “D” - For Detecting Liner Top Seal Leaks

1. Drain the cooling-water system.

2. Disconnect and remove all compression elbows at the water discharge header. Keep the water discharge pipe
from each cylinder in position.

3. Place SARAN WRAP on top of each vertical cylinder water discharge pipe, allowing the SARAN WRAP to sag
down into the inside of the pipe. Fasten the SARAN WRAP with tape or a rubber band around the outside of the
pipe.

4. Install a 1.050-in. governor tail rod block (GE Tool 147X2228-1) between the governor tail rod clevis and the

63
31 n
governor case. It may be necessary to move the fuel linkage manually to give enough clearance.

8- tio
08
83 ma
CAUTION: The above step is mandatory to prevent the engine from starting during testing.

10 or
5. The following additional safeguards are suggested to prevent the engine from starting during testing:

#3 l Inf
a. Place the Combined Power or Throttle handle in SHUTDOWN position.

ne ia
b. Disconnect the control governor electrical connector.
gi nt
c. On engines equipped with an overspeed link, remove the oil line at the link and cap both the end of the line
En de

and the fitting on the link to prevent oil spillage.

a, nfi

d. Pull out the Low Oil Pressure Shutdown button if the governor is so equipped.
am Co

6. Using the START button, crank the engine for 30 seconds. The SARAN WRAP will blow up at the discharge
an nd

pipe of a cylinder with a defective liner top seal.

i/P a

CAUTION: Do NOT advance any fuel-oil injection pump racks manually, as that could cause a false indica-
m ry

tion.
ia ta
M rie

7. Restore the engine to normal. Fill the cooling water system with properly treated water.
sa p

3.3. AIR INLET PORT CLEANING

in Pro

Remove the air inlet manifold clamp rings, manifold tubes, manifold bodies and manifold heads (Figure 10) to ex-
GE

pose the cylinder air inlet ports (Figure 11). Note the degree of carbon deposits on all visible surfaces of the cylinder
jacket, cylinder head and cylinder inlet valves. If carbon deposits exceed 1/8 in. (3.18 mm) on any surface, clean the
ar

inlet ports of all cylinders on the engine using the HOTSY cleaner, similar to HOTSY Cleaner Kit (GE Tool 147X2332,
M

Figure 12).

Failure to keep the cylinder air inlet ports clean could result in turbocharger surging, with resultant damage to turbo-
charger components. It also causes poor combustion with resultant heavy black exhaust smoke. Most important, it
increases cylinder exhaust temperatures dramatically.

12
 Steel–Head Engine Cylinders, Inspection, GEK–76768

CLAMP
RINGS

CYLINDER
JACKET

63
31 n
8- tio
WATER

08
INLET
HEADER

83 ma
MANIFOLD MANIFOLD MANIFOLD

10 or
HEAD BODY TUBE

#3 l Inf
E–25559

ne ia
Figure 10. Air Inlet Manifold Assembly.
gi nt
En de
a, nfi
am Co
an nd

CYLINDER
JACKET INLET
i/P a

VALVE
STEM
m ry
ia ta
M rie

CYLINDER
sa p

HEAD
in Pro
GE
ar
M

E–25560

Figure 11. Cylinder Air Inlet Port.

13
14
M GE
ar
in Pro
sa p
M rie
ia ta
m ry
i/P a
an nd
am Co
GEK–76768, Steel–Head Engine Cylinders, Inspection

a, nfi
En de
gi nt

Figure 12. HOTSY Cleaner Kit.

ne ia
#3 l Inf
10 or
83 ma
8- tio
31 n
08
63
E–27506
 Steel–Head Engine Cylinders, Inspection, GEK–76768

4. CYLINDER REMOVAL

A cylinder may be replaced either with or without its respective piston and connecting rod, depending on the nature
of the work to be performed. The cooling water must be drained before cylinder removal. The lubricating oil should be
drained if extensive work is to be performed to guard against contamination of the oil.

To remove a cylinder, proceed as follows:

1. Disconnect and remove the following parts from the cylinder. Refer to Figure 2 for EFI engines.

a. Cylinder cover.

63
31 n
b. Fuel-oil header at flexible hose joints. Cap the hoses and the fuel-oil injection pump fitting to keep dirt out.

8- tio
08
83 ma
c. Water inlet and discharge headers. Loosen the compression couplings and remove the bolts from the
flanges. Remove the upper water discharge connection and compression elbow.

10 or
d. Exhaust manifold at the cylinder flange.

#3 l Inf
e. Air intake manifold. Unbolt the clamp rings and slip the tubes free of the intake manifold body (Figure 10).

ne ia
gi nt
f. Fuel linkage vertical link. Remove the bolt and nut from the upper fuel linkage lever bearing.
En de
CAUTION: Do not bar over or crank the diesel engine with any of the camshaft sections removed. Doing
so WILL damage valve train components.
a, nfi
am Co

2. Bar the crankshaft so the piston in the cylinder to be removed is near top dead center with all valves closed.
an nd

3. Remove the short crossover pushrod, and then the two vertical pushrods. Use the rocker arm depressor (GE
Tool 147X1040-1) to rotate the rocker arms for clearance to free the pushrods (Figure 13). The fuel pushrod
i/P a

assembly will be removed with the cylinder.

m ry
ia ta

4. When removed from an engine, the valve pushrods must be checked for straightness, cracks and abnormal
M rie

wear on their ends as follows and replaced if any defects are found:
sa p
in Pro

a. Straightness check - Roll back and forth on a flat surface: the pushrods will roll smoothly without wobble if
straight.
GE

b. Crack inspection - Check visually all surfaces including the ends and, if suspect, use a dye-penetrant or
magnetic-particle inspection.
ar

c. Abnormal wear - Check the ends visually for scuffing, galling or surface roughness.
M

d. Inspect the interior passage of the rods. If not clearly open, clean to remove dirt or sludge.

5. Remove the four cylinder hold-down bolts as follows:

NOTE: Use the Pneutorque wrench (GE Tool 147X1568-1) or torque multiplier (GE Tool 147X2360) with
manual wrench and the TESCO Air Motor Support Bracket (Figure 14). An impact wrench (GE Tool
147X1684-2) also can be used to remove the bolts.

CAUTION: If it should be necessary to apply heat to a bolt head to facilitate removal, scrap that bolt. Heat
changes the tensile strength of the bolt.

15
GEK–76768, Steel–Head Engine Cylinders, Inspection

63
31 n
8- tio
08
83 ma
10 or
#3 l Inf
ne ia
gi nt
En de
a, nfi
am Co

E–20915
an nd

Figure 13. Rotating Rocker Arm With Rocker Arm Depressor.

i/P a
m ry

a. Firmly grasp and lift Air Motor Support Bracket. Avoiding pinch points, place tool on top of power assembly
ia ta

(Figure 14).
M rie

b. Ensure all four “L” brackets are positioned inside rocker arm shaft cover bolts (Figure 15).
sa p
in Pro

c. Rotate “T” handles until flat side of clamping plates are squared to bottom of head clamping boss and “T”
handles are parallel with the rocker arm shafts (Figure 16).
GE

d. Fully tighten the knurled clamping rods below the “T” handle and then verify clamping plates are fully en-
gaged.
ar

e. Assemble the air motor, extension and socket. Avoiding pinch points, carefully lift and place the air motor on
M

the support rack pins and on bolt head (Figure 17). Verify clamping plates are still properly aligned and
retighten both knurled clamping rods.

WARNING: EVERY TIME you proceed to another bolt, ALWAYS ensure clamping plates are still properly
aligned and re–tighten the knurled clamping rods.

f. Remove the four cylinder hold-down bolts as follows:

1) Ensure support bracket is positioned properly and air motor is applied.

2) Apply air hose to air motor ensuring air motor rotation control is in OFF position.

16
 Steel–Head Engine Cylinders, Inspection, GEK–76768

63
31 n
8- tio
08
83 ma
10 or
#3 l Inf
ne ia
gi nt
En de
a, nfi
am Co
an nd
i/P a

E–44589
m ry
ia ta

Figure 14. Applying TESCO Air Motor Support Bracket.

M rie

3) Apply air to motor.

sa p
in Pro

4) Start air motor and remove your hand from motor control while the bolt is being turned.

WARNING: EVERY TIME you proceed to another bolt, ALWAYS ensure clamping plates are still properly
GE

aligned and re–tighten the knurled clamping rods.

ar

5) Repeat Steps 1) through 4) for remaining bolts.

M

NOTE: If the connecting rod and piston are to be removed with the cylinder assembly, proceed as fol-
lows:
1. To hold the piston assembly in the cylinder, apply the piston retainer (GE Tool 147X1406-2, Figure 18).

2. If an articulated rod is to be removed, remove the articulated rod pin bolts.

3. If a master rod is to be removed, disconnect and push the articulated rod and piston up in the cylinder and
secure with the piston retainer (GE Tool 147X2322-1) to provide working room. Remove the master rod bear-
ing cap. Use a rod shank pad (GE Tool 147X1828) on the master rod to avoid damage to other parts during
removal.

17
GEK–76768, Steel–Head Engine Cylinders, Inspection

63
31 n
“L” BRACKET

8- tio
08
83 ma
10 or
ROCKER ARM

#3 l Inf
SHAFT COVER
BOLT

ne ia
gi nt ROCKER ARM
SHAFT COVER
“L” BRACKET BOLT
En de
a, nfi
am Co
an nd
i/P a
m ry

E–44590
ia ta

Figure 15. Properly Position TESCO Air Motor Support Bracket.

M rie
sa p
in Pro
GE

“T” HANDLE
ar
M

CLAMPING PLATES

E–44591

Figure 16. Align TESCO Air Motor Support Bracket Clamping Plates and “T” Handles.

18
 Steel–Head Engine Cylinders, Inspection, GEK–76768

63
31 n
8- tio
08
83 ma
SOCKET ON

10 or
BOLT HEAD

#3 l Inf
ne ia
gi nt
En de
a, nfi
am Co

E–44592
an nd

Figure 17. Positioning Air Motor, Extension and Socket on Bolt Head.
i/P a
m ry
ia ta
M rie
sa p
in Pro
GE

PISTON RETAINER,
TOOL 147X1406–2
ar
M

CYLINDER
LINER

CONNECTING
PISTON SKIRT ROD
E–19821A

Figure 18. Cylinder Piston Retainer.

19
GEK–76768, Steel–Head Engine Cylinders, Inspection

4. Attach the cylinder lifter (GE Tool 147X1606) over the water discharge opening on the back of the cylinder
(Figure 19). Use only the high-strength bolts supplied with the cylinder lifter. Ensure the bolts are tight.

63
31 n
8- tio
08
83 ma
10 or
#3 l Inf
ne ia
gi nt E–13553A
En de
Figure 19. Cylinder Lifter Applied for Angular Lift.
a, nfi

5. After ensuring the cylinder has been completely disconnected, carefully lift the cylinder, using the angular lifting
am Co

eye and guiding the cylinder. See DATA Section for lifting weights.
an nd

NOTE: If the piston and connecting rod are not removed with the cylinder, open the cylinder compres-
i/P a

sion release plug. Protect the piston from damage which could be caused by the piston falling and scuff-
m ry

ing against the engine frame as the cylinder is lifted off. Apply the piston protector (GE Tool 147X1951) to
ia ta

protect and guide the piston when the crankshaft is rotated with cylinders removed.
M rie

CAUTION: If pistons and rods are not properly supported when cylinders are removed, in certain positions
sa p

of the crankshaft the articulated connecting rods can contact and damage the articulated pin bushings.
in Pro

NOTE: If desired, with the cylinder removed, the piston may be removed while the rod remains in the
GE

engine. See PISTON instructions.

5. CYLINDER INSTALLATION
ar
M

5.1. APPLYING CYLINDER

A cylinder may be installed either with its piston and connecting rod assembly or separately. The general proce-
dure is the same in either case. Proceed as follows:

CAUTION: On 7FDM–8/12/16 emission–compliant diesel engines, the piston crown is a Critical Compo-
nent. Consult the latest revision of the manufacturer’s Parts Catalog to obtain the correct replacement part.
Refer to Figure 20.
NOTE: When replacing cylinders only, install new piston rings. See PISTON instructions.
CAUTION: Do not bar over or crank the diesel engine with any of the camshaft sections removed. Doing
so WILL damage valve train components.

20
 Steel–Head Engine Cylinders, Inspection, GEK–76768

63
31 n
8- tio
08
E–44453

83 ma
Figure 20. Piston Crown.

10 or
#3 l Inf
1. Ensure piston is in good condition. If the piston and rod assembly is in the engine, remove the piston protector
(GE Tool 147X1951) and place the piston support bar (GE Tool 147X1090) under the piston across the main

ne ia
frame opening (Figure 21). Bar the crankshaft to lower the piston firmly onto the cradle of the support bar.
gi nt
Stagger the end gaps of adjacent piston rings approximately 90 degrees with no two in line. Coat the piston with
a liberal quantity of clean engine lubricating oil. Apply the ring compressor (GE Tool 147X1089, Figure 22).
En de
a, nfi
am Co
an nd
i/P a
m ry
ia ta
M rie
sa p
in Pro
GE
ar

E–19823A
M

Figure 21. Piston Support Bar.

CAUTION: Do NOT use chrome piston rings with chrome cylinder liners. Do NOT use iron piston rings in
hardened cylinder liners. Refer to your Renewal Parts Catalog for the proper ring and liner combinations. If
improper combinations are installed, severe cylinder liner scoring will occur very quickly.

2. Back out all four cylinder valve tappet adjusting screws to provide maximum clearance between the tappet
buttons and the valve stems. Adjust the fuel-oil injection-pump tappet rod to its minimum length. Open the
cylinder compression release plug.

21
GEK–76768, Steel–Head Engine Cylinders, Inspection

63
31 n
8- tio
08
83 ma
10 or
E–19819

#3 l Inf
Figure 22. Applying Piston Ring Compressor.

3.
ne ia
Apply new O-rings, lubricated with Lubriplate Spray Lube A* (GE Part 147X1614), to the cylinder assembly at
gi nt
the bottom frame fit radius, the valve pushrod ferrules, and the fuel-oil injection-pump pushrod guide.
En de

CAUTION: Do not bar over or crank the diesel engine with any of the camshaft sections removed. Doing
a, nfi

so WILL damage valve train components.

am Co

4. Install two guide pins (GE Tool 147X1367) in diagonally opposite frame hold-down bolt holes. Using the angu-
lar lifting eye on the cylinder lifter (GE Tool 147X1606, Figure 19), lift the cylinder and lower it carefully over the
an nd

piston. The ring compressor can be removed after it is pushed down and drops free of the bottom ring. Then
i/P a

bar the crankshaft to raise the piston sufficiently to remove the support bar from under the piston. Lower the
m ry

cylinder into place.

ia ta

NOTE: If the piston and rod assembly is to be installed at the same time as the cylinder, the piston may be
M rie

held in the cylinder by using the piston retainer (Figure 18). Install left-bank cylinders with master rods
sa p

first, followed by right-bank cylinders with articulated rods. Use suitable protection with the master rod
in Pro

to avoid damage to other parts. Complete the installation of connecting rods as described in CONNECT-
ING ROD instructions.
GE

5. Coat the threads and washer face of the four cylinder hold-down bolts with Lubriplate 630-AA* grease (GE Part
147X2163). Install two bolts finger-tight in the empty holes, then remove the two guide pins and install the other
ar

two bolts. Tighten all four cylinder hold-down bolts EVENLY to the torque specified in the DATA Section. Refer
M

to procedure presented in Step 5, Page 15, for proper use of the TESCO Air Motor Support Bracket (Figure
14).

NOTE: Separate hardened washers should be used with all cylinder hold-down bolts, regardless of bolt
style.

6. Connect the air intake and exhaust manifolds and the water headers using new gaskets. Connect the fuel-oil
header hoses. Connect the fuel linkage vertical link. Check the pump control rack travel as described in FUEL-
OIL INJECTION-PUMP CONTROL RACK SETTING instructions and adjust as necessary.

*Product of Fiske Brothers Refining Company, Newark, NJ.

22
 Steel–Head Engine Cylinders, Inspection, GEK–76768

5.2. INSERTING PUSHRODS

To obtain sufficient clearance when installing pushrods, each valve crosshead roller must be on the base circle of
its cam.
1. Insert the vertical pushrods into their sockets in the crossheads; then install the short crossover pushrod.
2. Rotate the rocker arms using rocker arm depressor (GE Tool 147X1040-1, Figure 13) until the vertical push-
rods can be inserted into their respective rocker arm sockets.
5.3. SETTING VALVE TAPPET CLEARANCE AND INJECTION-PUMP TIMING
NOTE: Correct cylinder valve tappet clearance is essential for proper combustion and engine reliability.

63
31 n
8- tio
5.3.1. Cylinder Valve Tappet Clearance

08
83 ma
Check cylinder valve tappet clearance as follows:

10 or
1. Back off the compression release plugs one full turn on all cylinders.

#3 l Inf
2. Remove the cylinder head cover from all cylinders.

ne ia
3. Remove the timing window cover and the barring–over access cover from the right side of the camshaft gear
gi nt
cover on the cable side of the locomotive.
En de
4. Install the barring arbor tool (TESCO T58440), ensuring the arbor tool is fully inserted with the tool housing tight
a, nfi

against the gear cover. Then bolt the arbor tool to the gear cover using the bolts from the barring–over access
cover.
am Co

5. After moving the barring–over gear inward to engagement with the camshaft gear, apply either a 1.0 in. drive
an nd

ratchet wrench (Tool 147X1982) or an air–operated wrench (Tool 147X2204) to the barring–over gear.
i/P a

CAUTION: The use of an impact wrench for this operation is NOT recommended, as engine internal dam-
m ry

age may result.

ia ta

6. Using the ratchet wrench or air–operated wrench, slowly bar over the crankshaft in its normal direction of rota-
M rie

tion until the pointer in the barring–over gearbox timing window aligns with the degree mark for the cylinder
being worked on as specified on the timing nameplate near the gearbox.
sa p
in Pro

Timing nameplates vary by the number of cylinders on the engine. Figure 23 shows the timing nameplates for the
various engines.
GE

7. Assure that all valves are closed on the cylinder being adjusted, which should be on its compression stroke. If
the valves are closed, a small amount of free movement will be noted by manually moving the rocker arms.
ar

Another check is to observe the radial position of the fuel and valve cams for the cylinder being adjusted. If the
M

cylinder is on its compression stroke, the valve crosshead rollers will be off the lobe and on the base circle of the
cam. The fuel crosshead roller will be rising on the lobe of its cam.

NOTE: While this step is not mandatory, it is recommended since it assures the integrity of the camshaft
assemblies and the engine firing order.

8. Loosen each cylinder valve tappet locknut, using a feeler gauge to adjust the tappet screw to give the following
valve tappet clearances:
Intake – 0.018 to 0.020 in. (0.46 to 0.51 mm).
Exhaust – 0.028 to 0.030 in. (0.71 to 0.76 mm).
9. Tighten all lock–nuts with 50 to 55 lb.–ft (68 to 75 Nm) of torque and recheck the clearance.

23
GEK–76768, Steel–Head Engine Cylinders, Inspection

ADJUST FUEL PUMP PUSH RODS & SET ADJUST FUEL PUMP PUSH RODS & SET
VALVE LASH FOR ”EFI” EQUIPPED ENGINE VALVE LASH FOR ”EFI” EQUIPPED ENGINE
SET DEGREE SET DEGREE SET DEGREE SET DEGREE

FIRING ORDER
FIRING ORDER

1R 319 4R 139 1L 63.5 4L 243.5

1L 341.5 4L 161.5 1R 41.0 4R 221
2R 49 3R 229 3L 153.5 2L 333.5
2L 71.5 3L 251.5 3R 131 2R 311

63
31 n
8- tio
SET POINTER AT 0 DEGREES WITH SET POINTER AT 0 DEGREES WITH

08
#1 CYLINDER AT FIRING T.D.C. #1 CYLINDER AT FIRING T.D.C.

83 ma
CCW 8–CYLINDER ENGINE CW

10 or
#3 l Inf
ADJUST FUEL PUMP PUSH RODS & SET ADJUST FUEL PUMP PUSH RODS & SET
VALVE LASH FOR ”EFI” EQUIPPED ENGINE VALVE LASH FOR ”EFI” EQUIPPED ENGINE
SET DEGREE SET
ne ia
DEGREE SET DEGREE SET DEGREE
gi nt FIRING ORDER
FIRING ORDER

1R 319 6R 139 1L 63.5 6L 243.5

En de
1L 341.5 6L 161.5 1R 41.0 6R 221
a, nfi

5R 19 2R 199 4L 3.5 3L 183.5

5L 41.5 2L 221.5 4R 341 3R 161
am Co

3R 79 4R 259 2L 303.5 5L 123.5

3L 101.5 4L 281.5 2R 281 5R 101
an nd
i/P a

SET POINTER AT 0 DEGREES WITH SET POINTER AT 0 DEGREES WITH

m ry

#1 CYLINDER AT FIRING T.D.C. #1 CYLINDER AT FIRING T.D.C.

ia ta

CCW 12–CYLINDER ENGINE CW

M rie
sa p
in Pro

ADJUST FUEL PUMP PUSH RODS & SET ADJUST FUEL PUMP PUSH RODS & SET
VALVE LASH FOR ”EFI” EQUIPPED ENGINE VALVE LASH FOR ”EFI” EQUIPPED ENGINE
GE

SET DEGREE SET DEGREE SET DEGREE SET DEGREE

FIRING ORDER
FIRING ORDER

1R 319 8R 139 1L 63.5 8L 243.5

1L 341.5 8L 161.5 1R 41.0 8R 221
ar

3R 4 6R 184 5L 108.5 4L 288.5

3L 26.5 6L 206.5 5R 86 4R 266
M

7R 49 2R 229 2L 153.5 7L 333.5

7L 71.5 2L 251.5 2R 131 7R 311
4R 94 5R 274 6L 198.5 3L 18.5
4L 116.5 5L 296.5 6R 176 3R 356
SET POINTER AT 0 DEGREES WITH SET POINTER AT 0 DEGREES WITH
#1 CYLINDER AT FIRING T.D.C. #1 CYLINDER AT FIRING T.D.C.

CCW 16–CYLINDER ENGINE CW

E–46455

Figure 23. 7FDM–8/12/16–Cylinder CCW and CW Timing Plates

24
 Steel–Head Engine Cylinders, Inspection, GEK–76768

10. Bar the crankshaft to the next cylinder in the firing order and adjust the valve tappet clearances. Repeat until all
valve tappets have been properly adjusted.
11. After all the cylinder valve tappets have been properly adjusted, replace the cylinder head covers. Tighten the
cylinder compression release plugs. Remove the barring arbor tool, and replace the timing window cover and
the barring–over access cover on the camshaft gear cover.

6. DATA

6.1. WEIGHTS
Approximate Weights (lifting purposes only) Pounds Kilograms

63
31 n
Cylinder assembly 750 340

8- tio
Piston and articulated rod assembly 94 43

08
83 ma
Piston and master rod assembly 207 94
Cylinder Valve Tappet Clearance Minimum Maximum

10 or
All engines with sectional camshafts: In. mm In. mm
Inlet valves 0.018 0,457 0.020 0,508

#3 l Inf
Exhaust valves 0.028 0,711 0.030 0,762

ne ia
6.2. TORQUE VALUES gi nt
En de
Lb.-Ft. N–m
Bolts, cylinder hold-down* 1300-1400 1762-1898
a, nfi

Locknuts, valve tappet screw 50-55 68-75

am Co

Bolts, rocker shaft end plate 30-35 41-47

Adapter, compression release 60-65 81-88
an nd

Set screws, compression release adapter 15-20 20-27

Plug, compression release 20-25 27-34
i/P a

Studs, fuel-oil injection nozzle 55-65 75-88

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Nuts, fuel-oil injection nozzle mounting 30–35 40.65–47.42

ia ta

Nuts, high-pressure fuel line (Injector Side) 140–150 189.69–203.24

M rie

Nuts, high-pressure fuel line (Pump Side) 140–150 189.69–203.24

Bolts, fuel-oil injection-pump mounting 85-93 115.17-126.01
sa p
in Pro

Fittings, to fuel-oil injection-pump inlet and outlet tee fittings 70-75 94.84-101.62
Fuel–oil solenoid terminal screws 30-35 0.79-1.02
Bolts, exhaust elbow to cylinder 100-110 136-149
GE

Nuts, water inlet and discharge coupling 20-25 27-34

*When using the older Pneutorque No. 5 wrench, set the regulator with motor running unloaded at 42 psi (290 kPa) to
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achieve this torque value; when using the newer Pneutorque No. 5X wrench (with green band), set the regulator at 35
M

psi (241 kPa). When removing these bolts, set the regulator at 65 to 80 psi (448 to 552 kPa); after removing bolts,
reset the regulator to 42 (or 35) psi to avoid accidental over-tightening (and excessive stretching) of cylinder hold-
down bolts.
NOTE: Air pressure versus torque readings are only approximate. Actual torque should be verified using
torque verifier.

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GEK–76768, Steel–Head Engine Cylinders, Inspection

63
31 n
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GE
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GE Transportation
Systems
NEW 09–04, DJS 2901 East Lake Road
Erie, Pennsylvania 16531
PRINTED
IN
U.S.A.
E

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