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Intake and exhaust valve clearance and fuel injector height are adjusted by means of an adjusting set screw and locknut located at the valve end of the rocker arm.
Note: Ensure the height gage seats on the machined surface with the tip in the pilot hole. Foreign material in the pilot hole or on the machined surface may prevent accurate setting of the injector height.
The fuel injector height is measured using the required Injector Height Gage
On engines equipped with a Jake Brake®, move the handle on the injector height gage to the alternate position, 90 degrees to the shank. A height gage locating hole is provided in the injector body on the machined surface contacted by the injector clamp near the solenoid
Figure 2. Using Timing Gage on DDEC II, DDEC III, and DDEC IV
FUEL INJECTOR HEIGHTS Models: 6067GT40, 6067WT40, 6067WU40,6067GU40, 6063WU00, 6063GU00,6067WU60, 6067GU60, 6067GU91 (All DDEC I and DDEC II / 1986 - 1993)?
78.2 mm (3.079 in.) Use tool J-35637-A ?
77.95 - 78.45 mm (3.069 - 3.089 in.)?
FUEL INJECTOR HEIGHTS Models: 6064TKXX, 6063TKXX, 6063EKXX, 606XGKXX, 606XWKXX, 606XSKXX (All DDEC III 1994-1997)?
78.8 mm (3.102 in.) Use tool J-39697 32J cam?
77.55 - 79.05 mm (3.053 - 3.112 in.)?
FUEL INJECTOR HEIGHTS Models: 6067TKXX, 606XPKXX, 606XGKXX (1997-98 DDEC IV and later 1997 DDEC III)?
80.3 mm (3.161 in.)Use tool J-42665 47J cam?
80.05 - 80.55 mm (3.152 - 3.171 in.)?
FUEL INJECTOR HEIGHTS Models: 6067EKXX, 606XBKXX, 606XMKXX, 606XLKXX, 606XHKXX, 606XFKXX (1998 & 1999 DDEC IV)?
81.0 mm (3.189 in.)Use tool J-42749 65J cam 92J cam?
80.75 - 81.25 mm(3.179 - 3.199 in.)?
FUEL INJECTOR HEIGHTS Models: §?
6067BKXX, MKXX, HKXX?
82.1 mm (3.23 in.) Use tool J-45002 w/101J cam?
81.0 mm (3.189 in.) Use tool J-42749 w/92J cam?
82.1 mm (3.23 in.) Use tool J-45002 w/107J cam on off-highway units only?
0.8128 mm (0.032 in.)?
FUEL INJECTOR HEIGHTS Models:?
6062HKXX, 6062TKXX (2000-2003)?
81.0 mm (3.189 in.)?
80.75 - 81.25 mm?
3.179 - 3.199 in.)?
INTAKE VALVE CLEARANCE?
0.203 mm(0.008 in.)?
0.127 - 0.280 mm(0.005 - 0.011 in.)?
EXHAUST VALVE CLEARANCE - * "U" Models: 6067GT40, 6067WT40, 6067WU40, 6067GU40, 6063XX00, (1986 - 1990 All DDEC I & Early DDEC II)?
0.508 mm(0.020 in.)?
0.432 - 0.584 mm(0.017 - 0.023 in.)?
EXHAUST VALVE CLEARANCE - * "H" Models: 606XWUXX, 606XGUXX, 606XXKXX, (1991 - 1999 All DDEC IV, III and later DDEC II)?
0.660 mm(0.026 in.)?
0.584 - 0.736 mm(0.023 - 0.029 in.)?
EXHAUST VALVE CLEARANCE - * "H" Models: 6062HKXX, 6062TKXX (2000 - 2003)?
0.711 mm (0.028 in.)?
0.635 - 0.787 mm (0.025 - 0.031 in.)?
*"H" valves have a machined identification ring above the valve lock groove. "U" valves do not. Refer to section 1.4 for valve identification.† When setting injector heights or valve clearances, the component should be set to the "Setting Dimension" shown. ‡ XX Any character in these positions, set to the adjacent column.§ Check option label on valve cover for correct setting.
Adjust the valves and set the fuel injector heights as follows:?
Disconnect starting power for engine.
Remove the engine valve rocker cover as outlined
Insert a 3/4 in. drive breaker bar or ratchet into the square hole in the center of the crankshaft pulley
Bar the engine in the direction of rotation and observe the intake and exhaust valve rollers at any cylinder that is close to TDC (top dead center).
Choose a cylinder that has the exhaust valves almost completely closed. Just as the exhaust valves are closing, the intake valves will start to open. This is the valve overlap period.
Stop engine rotation at the time of valve overlap. Note which cylinder this is, and follow the sequence
Cylinder with Valve Overlap?
Set Valves on Cylinder No.?
Set Injector Height on Cylinder No.?
To adjust the intake valves, insert a 0.203 mm (0.008 in.) feeler gage between the tip of the valve stem and the valve button at the end of the rocker arm.
Loosen the locknut, and turn the adjusting set screw until the feeler gage produces an even smooth pull between the valve stem and valve button. Torque the locknut to 41 - 47 N·m (30 - 35 lb·ft) and remove the feeler gage. Reinsert the feeler gage to ensure that the adjustment did not change when the locknut was tightened. Readjust as necessary. The exhaust valves are adjusted the same way as the intake valves, except use a 0.660 mm (0.026 in.) feeler gage (1991 and later models only). Early models (pre-1991 models) use 0.508 mm (0.020 in.) feeler gage
After each set of intake and exhaust valves is adjusted, adjust the corresponding injector
Adjust the fuel injector height for the engine models in parentheses by placing the small end of the height gage in the hole provided in the fuel injector body, with the flat of the gage toward the fuel injector plunger.
Loosen the fuel injector rocker arm locknut and turn the adjusting set screw until the extended part (flag) of the gage will just pass over the top of the injector follower. An accurate "feel" will be developed. The objective is to adjust all six injectors to the same feel. Torque the locknut to 41 - 47 N·m (30 - 35 lb·ft). Check the adjustment with the height gage and, if necessary, readjust the set screw. Remove the height gage.
Refer to the adjusting sequence and proceed to the next cylinder in the adjustment sequence. Bar the engine over in the direction of normal rotation until the next cylinder in the adjustment sequence is in its valve overlap period. Repeat the valve adjustment and fuel injector height adjustments procedures until all the valves and fuel injectors have been adjusted. Replace the engine rocker cover. Reconnect starting power to the engine.