Crankshaft Main Bearings

CYLINDER HEADS

9. Make sure the three O-ring seals are installed on injector (6) and put clean engine oil on them and in the bore for the injector.

NOTICE Do not tap or hit on the injector follower to install the injector. Damage and failure to the injector can be the result.

10. Put injector (6) in position. Install the clamp, washer and bolt. Tighten the bolt to push injector (6) all the way in its bore. Tighten the bolt to a torque of 65 + 7 N•m (48 + 5 lb. ft.).

11. Check to make sure the fuel injection rack moves freely by hand in the injector after the injector is installed.

12. Make sure the O-ring seals are installed around the three dowels in the bottom of valve cover base (7). Put the gasket and base (7) in position and install the bolts to hold them to the cylinder head.

13. Put fuel control rod assembly (9) and lever assembly (8) in position in the cylinder head. If necessary, use tool (B) to turn the engine fly 44219Xl wheel until the camshaft moves enough to permit the lever of rod assembly (9) to move into position.

14. Make sure lever assembly (8) is engaged correctly with the fuel injection rack and install the two bolts and washers to hold it in place.

15. See TESTING AND ADJUSTING section for the correct adjustment of the fuel injection control group.

16. Make sure the lever for the fuel control and assembly is in position on control shaft (10) and install the bolt and cap (11).

17. Install the access cover and seal over the camshaft and control shaft (10).

18. Make sure the 0-ring seals for the fuel manifold and lines are installed and have clean engine oil on the seals. Install fuel manifold (12) and fuel lines (13) on the engine.

19. Turn the fuel supply to the engine.

20. Fill the cooling system with coolant to the correct level. end by: a) install rocker shafts and push rods

VALVES

REMOVE VALVES 1105-11

Tools Needed A B 5S1330 Compressor Assembly 1 8S2263 Valve Spring Tester 1 start by: a) remove cylinder heads

1. Use tool (A) to put valve springs (1) under compression.

2. Remove locks (2) from the valve stem.

3. Release the tension on springs ( 1 ) with tool (A) and remove tool (A), the rotor coil assembly, springs ( 1 ) and washer from the valve stem and guide.

4. Remove the valves from the cylinder head. NOTE: If the valves can be used again, put identification on them as to their location for installation purposes.

5. Check the valve spring force with tool (B). See SPECIFICATIONS for the correct spring force values.

6. Do Steps I through 5 again for the remainder of the valves.

INSTALL VALVES 1105-12

Tools Needed A 5S1330 Compressor Assembly 1 1. Put clean engine oil on the valve stem and install valve (4) in the cylinder head.

2. Put washer (2), the inner spring, outer spring (I) and rotocoil assembly (3) over the valve stem and valve guide.

3. Put the valve springs under compression with tool (A) and install locks (5).

The locks can be thrown from the valve when the spring compressor is released if they are not in their correct position on the valve stem. To prevent possible personal injury be sure to stay away from in front of the valve retainer and springs.

4. Remove tool (A) and hit the top of the valve with a plastic hammer to be sure the locks are in their correct position on the valve stem.

5. Do Steps 1 through 4 again for the remainder of valves. end by:

a) install cylinder heads

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VALVE LIFTERS, BRIDGE DOWELS

REMOVE AND INSTALL VALVE LIFTERS 1209-10

start by: a) remove cylinder heads

NOTICE The lifter guide springs can be assembled on the lifter assembly or installed in the cylinder head lifter bore only once. If a lifter assembly is removed from the cylinder head or a lifter guide spring is removed from a lifter assembly, a new lifter guide spring must be installed at assembly.

1. Pull lifter assemblies (1) out of the cylinder head lifter bore.

2. Remove the guide springs from the lifter assemblies.

3. Install guide spring (2) on each of the lifter assemblies (i1).

4. Put lifter assemblies (I) in a container of clean engine oil before they are installed. Install lifter assemblies (1) in the lifter bore of the cylinder head. end by: a) install cylinder heads

REMOVE AND INSTALL BRIDGE DOWELS

Tools Needed A B 5P944 Dowel Puller Group 1 5P942 Extractor 1 6V4009 Dowel Driver 1

start by: a) remove valves 1. If necessary, use tooling (A) to remove bridge dowels (1) from the cylinder head.

2. Use tool (B) and a hammer to install dowels (1) in the cylinder head. The dowels must extend 66.5 + 0.5 mm (2.62 + .02 in. above the head surface. end by: a) install valves

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