| Required Tools | |||
| Tool | Part Number | Part Description | Qty |
| A(1) | 9U-6198 | Crankshaft Turning Tool | 1 |
| A(2) | 9U-7336 | Housing | 1 |
| 5P-7305 | Engine Turning Tool | 1 | |
| B | 367-8608 | Engine Timing Pin | 1 |
| C | 370-4657 | Rocker Arm Spacer | 6 |
| (1) | The Crankshaft Turning Tool is used on the front pulley. |
| (2) | This Tool is used in the aperture for the electric starting motor. |
Start By:
- Remove the valve mechanism cover.
Note: Either Tooling (A) can be used. Use the Tooling that is most suitable.
| NOTICE |
|---|
|
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
- Remove plug (2) from the cylinder block. Remove O-ring seal (1) from the plug.
- Use Tooling (A) to rotate the crankshaft so that number one piston is at top dead center on the compression stroke. Refer to System Operation, Testing and Adjusting, "Position the Valve Mechanism Before Maintenance Procedures" for the correct procedure. Install Tooling (B) through Hole (W) in order to lock the crankshaft.
- Remove Tooling (B).
- Use Tooling (A) to rotate the crankshaft in a clockwise direction and position the crankshaft at 60 degrees after top dead center.
Show/hide table
Illustration 2 g01992077 - Loosen threaded inserts (4) on all rocker arms (3). Unscrew threaded inserts (4) on all rocker arms (3) until all valves are fully closed. Ensure that guides (5) for the pushrods are left in position on threaded inserts (4).
Note: Ensure that ALL threaded inserts are fully unscrewed.
Show/hide table
Illustration 3 g02003036 Show/hide table
Illustration 4 g02003035 - Loosen Torx screws (7). Begin at the ends of rocker shaft assembly (2) and work toward the center.
Note: To avoid distortion of the rocker shaft assembly, each Torx screw should be loosened by half a turn at one time. Repeat the procedure until all Torx screws are loosened.
- Remove Torx screws (7) from rocker shaft assembly (8).
Note: Note Position (X) of different length Torx screws (7).
- Remove rocker shaft assembly (8) from the cylinder head.
- Place an identification mark on pushrods (9) to show the location. Remove the pushrods from the cylinder head.
Note: Identification will ensure that the pushrods can be reinstalled in the original positions. Do not interchange the positions of used pushrods.
- Make a temporary mark on valve bridges (6) to show the location and the orientation. Remove the valve bridges from the cylinder head.
Note: Identification will ensure that the valve bridges can be reinstalled in the original location and the original orientation. Do not interchange the location or the orientation of used valve bridges.
| |
| Illustration 1 | g01992076 |
Note: Either Tooling (A) can be used. Use the Tooling that is most suitable.
- Clean valve bridges (6). Inspect the valve bridges for wear and damage. Replace any valve bridges that are worn or damaged.
- Lubricate valve bridges (6) with clean engine oil.
Show/hide table
NOTICE Failure to ensure that ALL valve bridges are correctly seated onto the valve stems will cause interference between the pistons and the valves, resulting in damage to the engine.
- Install valve bridges (6) to the valve stems.
Note: Install used valve bridges in the original location and in the original orientation. Ensure that the valve bridges are correctly seated on the valves. New valve bridges may be installed in either orientation.
Show/hide table
Illustration 6 g02004093 - Clean the pushrods. Inspect the pushrods for wear and damage. Replace any pushrods that are worn or damaged.
- Apply clean engine lubricating oil to both ends of pushrods (9). Install the pushrods to the engine with the cup upward.
Note: Ensure that the pushrods are installed in the original location and that the ball end of each pushrod is correctly seated in the valve lifters.
Show/hide table
Illustration 7 g02085993 - If necessary, use Tooling (A) to rotate the crankshaft so that number one piston is at top dead center on the compression stroke. Refer to System Operation, Testing and Adjusting, "Position the Valve Mechanism Before Maintenance Procedures" for the correct procedure. Install Tooling (B) through Hole (W) to lock the crankshaft.
Note: Do not use excessive force to install Tooling (B). Do not use Tooling (B) to hold the crankshaft during repairs.
- Remove Tooling (B).
Show/hide table
NOTICE Failure to ensure that the crankshaft is positioned at 60 degrees after top dead center will result in interference between the pistons and the valves. Failure to ensure that the crankshaft is positioned at 60 degrees after top dead center will result in damage to the engine.
- Use Tooling (A) to rotate the crankshaft in a clockwise direction and position the crankshaft at 60 degrees after top dead center.
Show/hide table
Illustration 8 g02003035 Show/hide table
Illustration 9 g02307257 - Ensure that the rocker shaft assembly is clean and free from wear and damage.
- Position the rockershaft assembly with Spotfaces (Y) for Torx screws (7) in the up ward position.
- Install Tooling (C) to rocker shaft assembly.
- Install Torx screws (7) to the rocker shaft.
Note: Ensure that correct Torx screw (7) is installed to Position (X).
Show/hide table
Illustration 10 g02004078 Show/hide table
Illustration 11 g02003036 Show/hide table
Illustration 12 g02047334 - Ensure that ALL threaded inserts are fully unscrewed. Position rocker shaft assembly (8) onto the cylinder head. The retaining clip (10) should face the front of the engine.
Note: Ensure that the threaded inserts are correctly seated in ends of pushrods (9).
- Tighten Torx screws (7) hand tight.
- Remove Tooling (C) from the rocker shaft. Install the remaining Torx screws (7) to the rocker shaft. Tighten the Torx screws (7) hand tight.
- Tighten the Torx screws to a torque of
35 N·m (26 lb ft) in the numerical sequence that is shown in Illustration 12. - Ensure that valve bridges (6) are correctly located on the valve stems.
Show/hide table
Illustration 13 g01992077 - Ensure that guides (5) for the pushrods are correctly positioned on threaded inserts (4). Tighten threaded inserts (4) on all the rocker arms. Tighten the threaded inserts to a torque of
30 N·m (265 lb in) .Note: When the threaded insert is tightened, the threaded insert must seat correctly into the cup for the pushrod.
Show/hide table
Illustration 14 g01992076 - Install a new O-ring seal (1) to plug (2). Install the plug into Hole (W) in the cylinder block. Tighten plug (2) to a torque of
21 N·m (186 lb in) . - The engine should not be operated for a period 30 minutes after the threaded inserts on all the rocker arms have been tightened. This period will allow the force of the valve springs to purge off excessive engine oil from the hydraulic lifters.
| |
| Illustration 5 | g02004077 |
|
The correct location of valve bridges on valve stems is shown. | |
End By:
- Install the valve mechanism cover.