002-021 Cylinder Head Gasket: General Information

Cylinder Head Gasket Page 1 of 9
002-021 Cylinder Head Gasket
General Information
4.5L and 6.7L engines do not

have graded gaskets. QSB5.9
Marine engines also do not
have graded gaskets. Use like
part numbers.
3.9L and 5.9L engines have

graded gaskets. There are also
service gaskets available for
5.9L engines with EGR when
oversize pistons or a repair
sleeve is installed. Measure
piston protrusion to determine
which grade to use.
No specific cylinder head

gasket with an increased
thickness is available for
combustion deck resurfacing of
the cylinder block or cylinder
head. If the combustion deck
can not be resurfaced such that
the correct specifications can
be maintained, the block and/or
cylinder head must be
replaced.
Remove and install instructions

and specifications can be found
in the following procedures:
l Refer to Procedure 001-

026 in Section 1.
l Refer to Procedure 002-
004 in Section 2.
mk:@MSITStore:C:\Users\jorispc\Downloads\Quick%20Serve%20DVD\MR_D.CHM::/e... 09-Mar-19
Preparatory Steps
WARNING
This assembly weighs
greater thaan 23 kg [50 lb] .
To prevent serious personal
injury, be sure to have
assistance or use the
appropriate lifting equipment
to lift this component or
assembly.
Remove the cylinder head.

Refer to Procedure 002-004 in
Section 2
Remove
Remove the cylinder head

gasket.
Clean and Inspect for Reuse
NOTE: Cylinder head

gaskets can not be reused.
A new cylinder head
gasket must be used.
Clean the cylinder block and

cylinder head combustion
deck. Inspect and measure
the cylinder block and
cylinder head combustion
deck flatness. Refer to
Procedure 002-004 in
Section 2
Measure
For engines requiring

cylinder head gasket
grading, measure piston
protrusion.
NOTE: This procedure is

only required after a
piston, crankshaft,
connecting rod, or block
replacement. Otherwise,
use the same grade gasket
that was previously
installed.
4.5L, 6.7L, and QSB5.9L

Marine engines do not use
graded gaskets.
Install depth gauge

assembly, Part Number
3164438, on the block
combustion deck and zero
the gauge.
Use a barring tool, Part Number

3824591, to rotate the
crankshaft to top dead center.
Move the dial indicator directly

over the piston pin to eliminate
any side-to-side movement.
Rotate the crankshaft

clockwise and
counterclockwise to find
the highest dial indicator
reading.
Record the reading.
Repeat on the remaining

cylinders.
Calculate the average height

by adding all numbers
recorded and dividing by the
number of cylinders.
Record the number

calculated. This number will
be used to determine which
grade of cylinder head
gasket to use.
Each graded cylinder head

gasket has a grade
identification tab that
indicates the thickness of the
cylinder head gasket, thick or
thin.
The location of the tab will

vary according to the type of
engine.
CAUTION
The cylinder head gaskets

for 5.9 L engines without
EGR and 5.9 L engines
with EGR with oversize
pistons or repair sleeve
may visually appear similar,
but the cylinder head
gaskets can not be
interchanged. Engine
damage will result.
3.9L and 5.9L engines without

EGR will have the grade
identification tab on the
exhaust side of the cylinder
head gasket between
cylinders 3 and 4 for 4 cylinder
engines and between
cylinders 5 and 6 for 6 cylinder
engines.
5.9L engines with EGR, that

have had oversize pistons or
repair sleeves installed, will
also have the identification tab
on the exhaust side between
cylinders 5 and 6.
The thickness of the cylinder

head gasket can be
determined by the location of
the holes in the cylinder head
gasket grade identification
tab. For thin cylinder head
gaskets (A), the holes are
spaced close together. For
thick cylinder head gaskets
(B), the holes are more
widely spaced.
5.9 L engines with EGR have

the grade identification tab
located on the portion of the
cylinder head gasket
corresponding to the front of
the engine on the intake
side.
If a repair sleeve or oversize

pistons have been installed,
the grade identification tab
will be on the exhaust side,
as explained previously.
The thickness of the cylinder

head gasket can be
determined by the number of
holes in the cylinder head
gasket grade identification
tab. There is 1 hole for thin
cylinder head gaskets (A).
There are 2 holes for thick
cylinder head gaskets (B).
Using the average piston

protrusion recorded earlier,
determine which cylinder
head gasket is needed from
the following table:
Head Gasket
Determination
Average Head
Piston Gasket
Protrusion Grade
>= 0.30 mm
Thick (B)
[0.012 in]
< 0.30 mm
Thin (A)
[0.012 in]
Install
CAUTION
For 5.9 L engines with

EGR, when using oversize
pistons or repair sleeves a
service specific cylinder
head gasket must be used
to make sure proper
sealing of the combustion
seal ring is acquired.
Failure to use the correct
cylinder head gasket can
result in engine damage.
Only 5.9L engines with EGR

have a service cylinder head
gasket available when
oversize pistons or repair
sleeves are installed. The
production cylinder head
gasket combustion ring is not
completely circular. The

service gasket has an
increased diameter
combustion seal. This gasket
must be used to make sure
proper sealing of the
combustion seal ring is
acquired.
QSB 5.9 Marine 425 engines

have a special cylinder head
gasket that accommodates this
engine's cylinder pressure
requirements.
This gasket can be identified

by:
l Witness marks at the front

edge and front side of the
gasket.
l Cummins Inc.'s “C's”
printed on the gasket
surface in dark blue ink.
QSB5.9 Marine gaskets do not

have graded gaskets or service
gaskets for oversize bores.
A new gasket must be

installed. Do not reuse an
old gasket.
Install the cylinder head

gasket.
Finishing Steps
WARNING
This assembly weighs
greater thaan 23 kg [50 lb] .
To prevent serious personal
injury, be sure to have
assistance or use the
appropriate lifting equipment
to lift this component or
assembly.
l Install the cylinder head.

Refer to Procedure 002-
004 in Section 2
Last Modified: 13-Mar-2013
Copyright © 2000-2010 Cummins Inc. All rights reserved.

002-021 Cylinder Head Gasket: General Information

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Cylinder Head Gasket Page 1 of 9

002-021 Cylinder Head Gasket

4.5L and 6.7L engines do not

3.9L and 5.9L engines have

No specific cylinder head

Remove and install instructions

l Refer to Procedure 001-

Remove the cylinder head.

Remove the cylinder head

Clean and Inspect for Reuse

NOTE: Cylinder head

Clean the cylinder block and

For engines requiring

NOTE: This procedure is

4.5L, 6.7L, and QSB5.9L

Install depth gauge

Use a barring tool, Part Number

Move the dial indicator directly

Rotate the crankshaft

Record the reading.

Repeat on the remaining

Calculate the average height

Record the number

Each graded cylinder head

The location of the tab will

The cylinder head gaskets

3.9L and 5.9L engines without

5.9L engines with EGR, that

The thickness of the cylinder

5.9 L engines with EGR have

If a repair sleeve or oversize

The thickness of the cylinder

Using the average piston

For 5.9 L engines with

Only 5.9L engines with EGR

completely circular. The

QSB 5.9 Marine 425 engines

This gasket can be identified

l Witness marks at the front

QSB5.9 Marine gaskets do not

A new gasket must be

Install the cylinder head

l Install the cylinder head.

Last Modified: 13-Mar-2013

Copyright © 2000-2010 Cummins Inc. All rights reserved.

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