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INSTALLATION
If only cylinder head work was needed, reinstall cylinder head
following these instructions. If further repair is required, see
CYLINDER AND PISTON
on
1.
See
Figure 3-9.
Coat mating surfaces of cylinder studs
(12) and head screws (1, 2) with parts cleaning solution.
2.
Scrape old oil and any carbon deposits from threads by
using a back-and-forth motion, threading each head
screw onto its mating cylinder stud.
3.
Remove head screws from studs. Wipe or blow dry
thread surfaces.
4.
Apply oil to stud threads and to the underside of the head
screw shoulder.
CAUTION
Only oil film must remain on the head screw surfaces.
Too much oil will pool in the head screw sleeve. Pooled
oil may prevent proper torque application and full thread
engagement.
5.
Blow or wipe off excess oil from head screws.
6.
Thoroughly clean and dry the gasket surfaces of cylinder
(19) and cylinder head (18).
7.
Install a new O-ring (14) on each dowel (15).
CAUTION
O-rings (14) help to properly position the head gasket (4).
O-rings must be installed before the head gasket.
8.
Install a new head gasket (4) to cylinder.
9.
Carefully lower cylinder head over studs and position on
dowels. Use great care so as not to disturb head gasket.
10. Install head screws (1, 2) finger tight.
CAUTION
The procedure for tightening the head screws is critical
to proper distribution of pressure over gasket area. It pre-
vents gasket leaks, stud failure, and head and cylinder
distortion.
11. See
Figure 3-8.
For each cylinder head, start with screw
numbered one, as shown. In increasing numerical
sequence (i.e. – 1, 2, 3 and 4), tighten head screws in
three stages:
FIRST STAGE:
Tighten each screw to 7-9 ft-lbs
(9-12 Nm).
SECOND STAGE:
Tighten each screw to 12-14 ft-lbs
(16-19 Nm).
THIRD STAGE:
See
Figure 3-26.
and head screw shoulder with a line as
shown (View A). Tighten each screw a
1/4-turn (90 ) (View B).
12. See
Figure 3-10.
Rotate engine so that both tappets (6),
from the cylinder being serviced, will be installed on the
base circle (lowest position) of the cam.
3-20
page
3-22.
Mark cylinder head
www.PlanDeGraissage.org
b0094x3x
View
A
Tighten head screws 1/4-turn in
the third stage of installation
Figure 3-26. Tightening Head Screws
13. Apply a liberal amount of engine oil to tappet assembly
(especially roller needles) for smooth initial operation.
14. Insert tappet (6) into bore in crankcase (1). Rotate tappet
so that flats at upper end of tappet face the front and rear
of the engine. If the tappet is installed incorrectly, pins (2)
cannot be inserted.
15. Insert pins (2) in the holes in crankcase. Place new O-
rings (3) over ends of pins. Install plate (4) using screw
(5) with washer (14). Tighten screw (5) to 80-110 in-lbs.
(9.0-12.4 Nm).
16. Slide new seal (8), and place retainer (9), over top of
push rod cover (7). Position new O-ring (10) at top of
push rod cover. Hold cover at an angle and insert top
through hole in cylinder head. Push up on cover while
aligning bottom of cover with tappet bore in crankcase.
Lower retainer (9) with seal (8) onto crankcase, aligning
locating pin (15) with hole in retainer.
17. Insert screw (11) with washer (13) through hole in
retainer (9), and thread into tapped hole in crankcase.
Tighten screw (11) to 15-18 ft-lbs (20-24 Nm).
18. Identify push rod color coding, length and respective push
rod positions in engine. See
exhaust push rods (1, 2) onto seat at top of tappet (6).
Table 3-4. Push Rod Selection Table
POSITION
Exhaust (Front & Rear)
Intake (Front & Rear)
19. See
Figure 3-5.
Install new gaskets (16, 17) with the
bead facing up. Place lower rocker box assembly (with
rocker arms and shafts) into position. Place push rods in
rocker arm sockets.
View
B
Table 3-4.
Place intake and
COLOR CODE,
PART NUMBER,
LENGTH
3 Band - Pink,
17904-89,
10.800 in.
1 Band - Brown,
17897-89,
10.746 in.
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