K 2500 Truck 4WD V8-6.6L DSL Turbo VIN 1 (2002)
Cleaning Procedure
1. Remove the old head gasket using service manual procedures. Save the gasket for reference until the repair is completed.
2. Place clean rags in the cylinder bores and pushrod openings in order to keep out debris.
3. Use the J-28410 or equivalent to carefully clean the gasket sealing surface of large sealing or corrosion matter. When scraping, take care not to
scratch or gouge the metal surfaces. Do not push the debris into oil, coolant, and combustion openings or bolt holes.
4. Inspect the gasket sealing surfaces for corrosion, especially in the areas that were in contact with the crimped tabs of the first generation head
gasket. If corrosion is present, continue with the rest of the steps in this procedure for proper cleaning. If the sealing surface is sufficiently clean
and smooth, use the revised torque specification listed towards the end of this bulletin and continue with published service manual procedures to
complete the repair.
5. For surfaces that have corrosion or pitting, wrap a piece of flat steel (4"x 2" or larger) with 600 grit wet grade sand paper. Using Moisture
Displacing Lubricant, P/N 88862629 (in Canada, use 89020803) or equivalent, wet sand the block surface to remove any remaining gasket
material or corrosion. Do not use any paper coarser than 600 grit.
Notice
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Do not use any power type sanding devices.
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Do not use a wire brush or wheel to clean gasket surfaces.
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Do not use chemical cleaning agents on gasket surfaces.
6. Take care to keep the sanding block parallel to the block surface and evenly sand the sealing surface. Some areas of corrosion will still show a
stain. Do not attempt to wet sand these areas down to a shiny metal surface.
7. Change the sanding paper when it becomes clogged. Carefully and frequently wipe the surface, using a clean cloth each time, to prevent sanding
debris from building up and contaminating the oil and coolant cavities.
8. Clean the bolt threads and holes and remove the rags from the bore cavities and pushrod openings.
9. Repeat the above cleaning procedure on the cylinder head gasket surface.
10. Clean the engine block and cylinder head gasket surfaces with Brake Parts Cleaner, P/N 88862650 (in Canada, use 88901247) or equivalent, to
remove any traces of oil or debris.
11. Using the revised head bolt torque specification below, reassemble the engine with NEW M12 cylinder head bolts according to service manual
procedures.
Torque Specification Change
The second design head gasket requires a lower torque angle specification for the M12 bolts than the torque required by the first generation gasket. The
M8 bolt torque remains the same for both designs. The M12 bolts on engines using the second generation head gasket should be torqued using the
angular tightening method to the following specifications:
Important
SI will be updated with the revised torque specification.
Parts Information
