BEPAIR INSTBUCTIONS, PART 1

1271 C8,264 DP1 usinq alorque wrench, l¡ghlenlhelasleñefs a€oding lo specmcatun.

Assemble lhé allémalo. mouñrinq brackel onlo lho cylind6r block. Ighlon ih6 Iastere6 a.cordang to spe¡licalion.

2, ll ¡emoved and nol ppiolsly installed, á$émbl6lhé lronl énginé supporl mounling báckel on lhe cy inder block. This brackel also pr@ldes lhe mounlinq poinls io¡ lhe

Using á lorque wBnch,lighlén lhé lasleneB lor the b€ckei ánd ñou áccording lo lf €mN¿d, assemb e the bett tensioñ idter ll a hárnBss is installéd. secuely connect the eLectlical wi nqáslagg€ddu ng

Using a lorqúe wrench, lighlen lhe lalene6 ácordino to specf cár on.

Assemble lhe be I pulleys on lh€ állénaror and compressor hubs, r reñóved.

Wiring Harness lnstallat¡on

l3 wñqHafÉss

1. Roule añd pGition the harnéss on fie engine s noled durlng di6a6sembly,

2. lnsén lhé unil injéclor ponion ol lhe h.me$ throqgh the holé l¡ the tlñlnq gear housi¡g.

3. Connecl ihe hamess lo each iñiectóf.

4, Conneclthehamessiotheengiñébáké mnlrcl valve t lnslalléd.

Usinq hioh-lémpéÉlue wne Íes. 983472, aliach ihe harness lo lhe cyLinder head. ¡t nol previously done, caelul y ror,lo lhe wiring harness @er lhe engine brake control valve. secure the hafn€ss lo lhé cónrfol Blve as shown iñ Figué 363. i¡ák€ suro thal lhé ham€s is pGilioned lo the s¡de of the boss al the lóp of the Elw assémbly.

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Do Nof mute the hames o@¡ the bos at rhe lop oÍ the engine tuake @nlrcl hlve. Therc ¡s nat enough deatatu belween the valve añd the wive @ver far lhe hatñess when rhe @ver is insblled. fhe hatress ñusl be pós¡ioned ¡ó lhe s¡de af the b6s ro awid da@ge ¡o the hahess.

ahe énernal podon ol lhe w ng hame6s is encGed in a@fdion lubinq. Th€rá afa séváEl unils éách of which ¡s tilled w¡lh end connecto6 thai permn .o¡veniont st n ging ¡ jóininq a¡d allachmerl lo the block in úrious localions.

Connecting The Eecu

L Ch€ck l¡\é lénsio. ol lhe lermanal ¿on n6cto I p¡ns úshq ihe tésl pins roól kit 999000a.

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ll lerminal pins are damaged or coroded, ¡ep ace

2. Caelullyengagetheuppera¡dlowerwiring haiñess connécroF lo lhe EEcu. v€rify lhai lhe connecloG are lalched and propedy

Ue aE to entute ¡hat the EECU teminat pks aE sla¡qft an.l undanaged,

5.

Cylinder Head (Valve) Cover r lnslallation [211 JBI

1. C ean lhé g6két sáaling sllace ol lhe cylhder héad. The su¡la@s shóuld bó cléár of a¡y di¡l or debrls and l¡ee ol any oil.

2. lnspecl lhe gaskel lof damage. li @pla€mént is necéssary caEtully plácá a ñe gdk6t intó the channel, ñákiño sué lhat I ¡s propeny *aled and tollds lhe @nrour of rhé chanñé|.

FlguEscyn.&fH*dcov¿lG'3k¿t

Cónnecl thé vanous le¡mináls as lagged al di*ssembly lo áll ssnso6, rslays áñd componenls such as ihe stailef, allernalof and Élli96€nl cómprcssrámong olhé6. Anach rh€ clamps lo hold lhe hamess on lhe

3. Appry a 2 mm i0.079 ¡nch) bead of MAoK séalanliolh¿ areawhere lhe liming @ver ándlhecylinderhoad mééi. This paning liné is on bolh s¡des of the cyli¡der héád. Ca€lully posilion lhe valve cover on the cylindsr h6ad and make su€ lhal lhe seal rema¡ns pope y séátéd.