11/1/23, 11:38 AM Overhead Set
General Information
Overhead setting is only required at the interval specified in
the appropriate Operation and Maintenance Manual/Owners
Manual or when engine repairs cause removal of the rocker
levers and/or loosening of the adjusting screws.
Excessive valve lash prior to this can indicate an overhead set
incorrectly from a previous repair, worn valve stems,
crossheads, push rods, or rocker levers*.
Loose rocker levers and the need to reset the valve clearance
frequently can also indicate camshaft lobe or tappet wear. If an
inspection of the rocker levers, valve stems, crossheads, and
push rod does not show wear, then tappet and/or camshaft
lobe wear can be suspected.
Refer to Procedure 001-008 in Section 1.
(/qs3/pubsys2/xml/en/procedures/44/[Link]) Refer
to Procedure 004-015 in Section 4.
(/qs3/pubsys2/xml/en/procedures/44/[Link])
Preparatory Steps
WARNING
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate the
compartment before servicing the batteries. To reduce the
possibility of arcing, remove the negative (-) battery cable
first and attach the negative (-) battery cable last.
Disconnect the batteries. Refer to Procedure 013-009 in
Section 13. (/qs3/pubsys2/xml/en/procedures/44/44-013-
[Link])
Remove the rocker lever cover and gasket. Refer to
Procedure 003-011 in Section 3.
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11/1/23, 11:38 AM Overhead Set
(/qs3/pubsys2/xml/en/procedures/44/[Link])
Adjust
All Applications Except Marine
Note : Engine coolant temperature must be less than
60°C [140°F].
Note : For marine engines equipped with a TDC mark
on the vibration damper, use the Adjust step for All
Applications Except Marine.
Note : For marine engines not equipped with a TDC
mark on the vibration damper, use the Adjust step for
Marine Applications.
Use the barring tool, Part Number 3824591 to rotate the
crankshaft until the number 1 cylinder is at TDC.
TDC can be determined by the following methods:
For 3.9 L and 5.9 L Engines without EGR, align the crankshaft
speed indicator ring on the front of the crankshaft so that the
unpunched area of the crankshaft speed indicator ring is at the
12-o'clock position. If both number 1 cylinder rocker levers are
loose, move to the following steps. If both number 1 cylinder
rocker levers are not loose, rotate the crankshaft 360 degrees.
Note : The TDC indicator is on the vibration
damper/crankshaft speed indicator ring.
For all 4.5 L, 5.9 L engines with EGR, and 6.7 L engines, align
the vibration damper/crankshaft speed indicator ring so that the
TDC indicator is at the 12-o'clock position. If both number 1
cylinder rocker levers are loose, move to the following steps. If
both number 1 cylinder rocker levers are not loose, rotate the
crankshaft 360 degrees.
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11/1/23, 11:38 AM Overhead Set
Note : If no TDC mark is present on either the vibration
damper or the crankshaft speed indicator ring, align the
large gap in the crankshaft speed indicator ring to the 5-
o'clock position (2). The dowel pin could also be visible
in the 9-o'clock position (1). Check that both number 1
cylinder rocker levers are loose. If they are not loose,
rotate the crankshaft 360 degrees and recheck.
Check the engine dataplate for correct valve lash overhead set
specifications.
The engine dataplate is typically located on the engine rocker
lever cover, but the dataplate may also be located on the left
side of the engine rocker lever cover.
Refer to Procedure 100-001
(/qs3/pubsys2/xml/en/procedures/44/[Link]) in
Section E.
With the engine in this position, lash can be measured on the
following rocker levers:
(E = exhaust, I = Intake)
Four-cylinder 1I, 1E, 2l, and 3E:
Six-cylinder 1I, 1E, 2I, 3E, 4I, and 5E.
Lash Check Limits
mm in
Intake 0.152 MIN 0.006
0.381 MAX 0.015
Exhaust 0.381 MIN 0.015
0.762 MAX 0.030
Note : Checking the overhead setting is usually
performed as part of a troubleshooting procedure, and
resetting is not required during checks as long as the
lash measurements are within the above ranges.
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11/1/23, 11:38 AM Overhead Set
Note : The clearance is correct when some resistance
is “felt” when the feeler gauge is slipped between the
crosshead and the rocker lever socket.
Measure lash by inserting a feeler gauge between the
crosshead and the rocker lever socket. If the lash
measurement is out of specification, loosen the locknut, and
adjust the lash to nominal specifications.
Valve Lash Specifications (Nominal)
mm in
Intake 0.254 0.010
Exhaust 0.508 0.020
Tighten the locknut and measure the lash again.
Torque Value: 24 n•m [ 212 in-lb ]
Using barring tool, Part Number 3824591, rotate the crankshaft
360 degrees.
Following the same steps and specifications as previously
stated, measure lash for the following rocker levers:
(E = exhaust, I = Intake)
Four-cylinder 2E, 3I, 4E, and 4I:
Six-cylinder 2E, 3I, 4E, 5I, 6I, and 6E.
Reset if out of specification.
Marine Applications
Note : The engine coolant temperature must be less
than 60°C [140°F].
Note : For marine engines equipped with a TDC mark
on the vibration damper, use the Adjust step for All
Applications Except Marine.
Note : For marine engines not equipped with a TDC
mark on the vibration damper, use the Adjust step for
Marine Applications.
Use barring tool, Part Number 3824591, to rotate the
crankshaft until the number 1 cylinder is at top-dead-center
(TDC).
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11/1/23, 11:38 AM Overhead Set
To determine TDC when setting the overhead on marine
engines, rotate the crankshaft until either cylinder Number 1 or
cylinder Number 6 exhaust and intake rocker levers are both
loose.
Note : If a more precise way is needed to determine
TDC, remove the injector from cylinder Number 1. Use
a rod with a dial indicator to find TDC.
With the engine in this position, lash can be adjusted on the
following rocker levers:
(E = exhaust, I = intake)
Four-cylinder - 1I, 1E, 2I, and 3E
Six-cylinder - 1I, 1E, 2I, 3E, 4I, and 5E.
Note : The clearance is correct when some resistance
is felt when the feeler gauge is slipped between the
crosshead and the rocker lever socket.
Loosen the locknut and adjust the lash to nominal
specifications.
Valve Lash Specifications (Nominal)
mm in
Intake 0.254 0.010
Exhaust 0.508 0.020
Tighten the locknut and measure the lash again.
Torque Value: 24 n•m [ 212 in-lb ]
Use barring tool, Part Number 3824591, to rotate the
crankshaft 360 degrees.
Follow the same steps and specifications as previously stated
to continue adjusting the valve lash.
(E = exhaust, I = intake)
Four-cylinder - 2E, 3I, 4E, and 4I
Six-cylinder - 2E, 3I, 4E, 5I, 6I, and 6E.
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11/1/23, 11:38 AM Overhead Set
Finishing Steps
WARNING
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate the
compartment before servicing the batteries. To reduce the
possibility of arcing, remove the negative (-) battery cable
first and attach the negative (-) battery cable last.
Install the gasket and rocker lever cover. Refer to
Procedure 003-011 in Section 3.
(/qs3/pubsys2/xml/en/procedures/44/[Link])
Connect the batteries. Refer to Procedure 013-009 in
Section 13. (/qs3/pubsys2/xml/en/procedures/44/44-013-
[Link])
Operate the engine and check for leaks.
Last Modified: 29-Oct-2020
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