Usage:
215 ( 57Y, 14Z*),
225 ( 51U, 61X***),
613 ( 38W***),
943 ( 3Y, 31Y, 4Z, 19Z*),
953 ( 76Y, 77Y, 5Z, 20Z*),
953 ( 78Y, 44Z**)
*3204 Engine serial number 10X1 - 10X2210
**3204 Engine serial number 45V29936 - 45V32874
1W4259 Valve Spring, 1W9897 Valve Spring Seat Washer and 1W4260 Valve Spring Retainers are the service replacement parts for the former valve springs, seats and retainers on the above engines. If these new parts are installed, new 1W2459 Fuel Nozzle Clamp Assemblies must also be installed. These new valve springs have a larger outside diameter than the former valve springs. On some early engines, the spring seat area must be made larger before these new springs can be installed; the installation procedure for these engines is different; see page 7. These new valve springs can be installed without removal of the cylinder heads, except for the engines that need the valve spring seat to be made larger. Use this instruction along with the Service Manual and Parts Book for the correct installation procedure.
1 There are no identification marks or part numbers on the former or the new valve springs. The easiest way to tell the springs apart is to measure the outside diameter of the springs. The diameter of new spring (1) is 39.60 (1.56"0). The diameter of former spring (2) is 36.60 (1.44"0). NOTE: The valve spring itself must be measured and not the valve spring retainer. Both the former and new retainers have the same outside diameter. A visual identification of the valve springs and components can be made if a careful inspection is made. Former valve spring (2) has a smaller outside diameter than former retainer (3), also retainer (3) fits down over the top of spring (2). New retainers (4) may have different thickness as shown but they do not fit down over the top of spring (1). This inspection will tell what type of spring is in the engine.
***3208 Engine serial number 79V1 - 79V8713
Tools Needed For Valve Spring Installation
1 Use a grinder to remove section (A) from 8S2277 Adapter Assembly (1) to the dimensions shown. Remove adapter (2) from 7F4291 Compressor Assembly (3). Grind the head off rivet (4) and remove spacer (5).
2 Use a grinder to remove the corners and make a radius around the end of spacer (5) as shown. Install spacer (5) in compressor assembly (3) with 1D4533 Bolt (6) and 2D6235 Nut. Install adapter (1) with S1615 Bolt (7), 4F7957 Bolt (8) and two 2D6235 Nuts. Bolt (7) must be on the same side that had section (A) removed. Do not tighten bolts (7) and (8) enough to bend adapter (1).
3 Remove valve cover (9). Inspect the valve springs and retainers (10) to tell if it is necessary to install the new size valve springs; see the procedure on page 2. Remove rocker shaft (11) and fuel injector nozzles (12). The former fuel nozzle clamp assemblies must not be used again.
4 For engines that need new valve springs, but do not need the modifications shown in step 8, page 7, rotate the engine until the number one cylinder is at TDC (top dead center). In this position, number four will also be at TDC. Install compressor assembly (3) on the exhaust valve with 1D4540 Bolt (13) and 4B5270 Flat Washer. Lift up on the handle to compress the valve spring. Use 8S2293 Magnet Assembly (14) to remove the two valve spring locks. Slowly lower the handle until the compression is removed from the valve spring. Remove the valve spring, retainers, washers and spring seat from each valve stem. All the former parts must be removed from the valve stem. Keep only the two valve spring locks; they will be used again. All the other parts must not be used again. Install new 1W9897 Washer (15), 1W4259 Spring (16) and 1W4260 Retainer (17). Put the locks in 5S1322 Valve Keeper Inserter (18). Do not mix the former parts with the new parts. Carefully compress the valve spring and install the locks.
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Be sure both locks are fully seated in the retainer and in both grooves in the valve stem. Failure to do so can cause the valve to break and the spring to be thrown out. This could cause personal injury or death. |
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5 Use the same procedure to remove and install the valve spring on the intake valve. Install the new springs in number four cylinder. NOTE: To remove the intake valve springs, spacer (5) must be turned as shown.
6 For 3204 Engines, rotate the engine to TDC on number three cylinder; number two cylinder will also be at TDC. For 3208 Engines, rotate the engine to TDC on number five cylinder; number two cylinder will also be at TDC. Use the procedure given on page 5 to remove and install the valve springs on number three and number two cylinders (3204) or number five and number two cylinders (3208). Rotate 3208 engines to TDC on number seven cylinder; number six cylinder will also be at TDC. Remove and install the valve springs on number seven and number six cylinders; see page 5. Rotate 3208 engines to TDC for number three cylinder; number eight cylinder will also be at TDC. Remove and install the valve springs on number three and number eight cylinders.
7 Install former fuel nozzles (12) and new 1W2459 Nozzle Clamp Assemblies (19). Install the rocker shaft and valve cover (9). Operate the engine and check for its correct operation.
8 For any engine with 9L7230, 9L9145, 9L9270, 9N1107 or 9N2362 Cylinder Heads, (see location (X), above, for the part number location on the cylinder heads), the valve spring seat area must be machined to make it larger so the larger valve springs can be installed. To machine the new seats, the cylinder heads must first be removed from the engine. Do not machine the new spring seats with the cylinder head installed on the engine. See Special Instruction Form SMHS8131, "USE OF 6V7028 SPRING SEAT ENLARGER FOR 3208 CYLINDER HEADS" for the tools needed and the procedure to make the spring seats larger. Assemble the cylinder heads before they are installed on the engine; use the new parts shown earlier for the assembly procedure.