Cylinder head and Valves/Special tools

RG5100 -UN-23AUG88

Tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG680

Used to restore threaded holes in cylinder block for

cylinder head cap screws.

RG,JDG680 -19-02APR90

Nozzle Puller Adapter . . . . . . . . . . . . . . . . . JDG716

Use with JDE38-2 and JDE38-3 to pull Stanadyne

9.5 mm injection nozzles.

-UN-07MAR95
05

CD30338
3
CD,JDG716 -19-12NOV92

CTM3274 (01JUL99) 05-3 Saran Liter Engines

060799
PN=40
 Cylinder head and Valves/Specifications

SPECIFICATIONS
DIMENSIONS OF NEW PARTS WEAR TOLERANCE

Thickness of new cylinder head . . . . . . . . . . . . . . . . . . . 104.87—105.13 mm

(4.129—4.139 in.)

Maximum permissible amount to be machined

from cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.76 mm (0.03 in.)

Minimum thickness of cylinder head . . . . . . . . . . . . . . . . 104.11 mm (4.099 in.)

Maximum permissible out-of-flat of cylinder

head sealing surface . . . . . . . . . . . . . . . . . . . . . . . . . . 0.08 mm (0.003 in.)

Combustion face surface finish . . . . . . . . . . . . . . . . . . . approx. 0.0025 mm C.L.A.*

(0.0001 in. C.L.A.)
05
4
Valve stem diameter (standard)
Intake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.864—7.884 mm
(0.3096—0.3104 in.)
Exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.848—7.874 mm
(0.3090—0.3100 in.)

Bore for valve stem . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.912—7.938 mm

(0.3115—0.3125 in.)

Clearance between bore and valve stem . . . . . . . . . . . . . 0.05 to 0.10 mm 0.15 mm

(0.002 to 0.004 in.) (0.006 in.)

Valve stem oversize, stem diameter larger

than standard by . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.38 mm (0.015 in.)
0.76 mm (0.030 in.)

Valve seat angle (intake and exhaust) . . . . . . . . . . . . . . 30˚

Valve face angle (intake and exhaust) . . . . . . . . . . . . . . 29.25˚

Maximum valve seat runout . . . . . . . . . . . . . . . . . . . . . 0.08 mm (0.003 in.)

Maximum valve face runout . . . . . . . . . . . . . . . . . . . . . 0.038 mm (0.0015 in.)

Valve recess (below cylinder head surface):

Intake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.61—1.11 mm 1.63 mm
(0.024—0.044 in.) (0.064 in.)
Exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22—1.72 mm 2.26 mm
(0.048—0.068 in.) (0.089 in.)

Valve seat width (intake and exhaust) . . . . . . . . . . . . . . 1.50—2.00 mm

(0.059—0.079 in.)

(Continued on next page)

* C.L.A. (Center Line Average) corresponds to a measure of surface

texture. CD,3274,G05,49 -19-04JAN99

CTM3274 (01JUL99) 05-4 Saran Liter Engines

060799
PN=41
 Cylinder head and Valves/Specifications

SPECIFICATIONS - CONTINUED
DIMENSIONS OF NEW PARTS WEAR TOLERANCE

Valve seat insert outside diameter:

Intake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.205—47.231 mm
(1.858—1.859 in.)
Exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43.087—43.113 mm
(1.696—1.697 in.)

Valve head diameter:

Intake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.47—46.73 mm
(1.830—1.840 in.)
Exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.37—42.63 mm
(1.668—1.678 in.)

Firing order:
05
3-cylinder engines . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2 - 3 5
4-cylinder engines . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3 - 4 - 2
6-cylinder engines . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5 - 3 - 6 - 2 - 4

Valve clearance (engine cold):

Intake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.35 mm (0.014 in.)
Exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.45 mm (0.018 in.)

Valve lift (zero valve clearance):

Intake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.56—12.37 mm 11.13 mm
(0.455—0.487 in) (0.438 in.)
Exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.28—12.12 mm 10.85 mm
(0.444—0.477 in.) (0.427 in.)

Rocker arm shaft diameter . . . . . . . . . . . . . . . . . . . . . . 19.99—20.02 mm 19.94 mm

(0.787—0.788 in.) (0.785 in.)

Rocker arm bore diameter . . . . . . . . . . . . . . . . . . . . . . 20.07—20.12 mm 20.17 mm

(0.790—0.792 in.) (0.794 in.)

Rocker arm shaft spring tension

at a length of 46 mm (1.81 in.) . . . . . . . . . . . . . . . . . . . 18—27 N (4—6 lb)

Valve springs free height . . . . . . . . . . . . . . . . . . . . . . . approx. 54 mm (2.125 in.)

Valve spring tension:

at a length of 46 mm (1.81 in.) 240—180 N (54—62 lb)
at a length of 34.5 mm (1.36 in.) 590—680 N (133—153 lb)

CD,3274,G05,50 -19-04JAN99

CTM3274 (01JUL99) 05-5 Saran Liter Engines

060799
PN=42
 Cylinder head and Valves/Cylinder head exploded view

TORQUES FOR HARDWARE

Rocker arm shaft clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 N·m (35 lb-ft)

Cylinder head cap screws:
Step 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........... . . . . . . . 100 N·m (75 lb-ft)
Step 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........... . . . . . . . 150 N·m (110 lb-ft)
Step 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wait 5 minutes and verify 150 N·m (110 lb-ft)
Step 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........... . Tighten additional 60˚ ± 10˚
Fuel injection nozzles to cylinder head . . . . . . . . . . . . . . . . . . . ........... . . . . . . . . 40 N·m (30 lb-ft)
Intake manifold to cylinder head . . . . . . . . . . . . . . . . . . . . . . . ........... . . . . . . . . 50 N·m (37 lb-ft)
Exhaust manifold to cylinder head . . . . . . . . . . . . . . . . . . . . . . ........... . . . . . . . . 50 N·m (37 lb-ft)
Rocker arm cover to cylinder head . . . . . . . . . . . . . . . . . . . . . ........... . . . . . . . . . 10 N·m (7 lb-ft)
CD,3274,G05,52 -19-01FEB94

CYLINDER HEAD - EXPLODED VIEW

05
6

-UN-10MAY95
CD30378

1—Cylinder head 3—Cylinder head gasket 5—Rocker arm cover 6—Vent tube
2—Valve seat 4—Cylinder head bolt
(1/2-13UNC X 112 mm;
4.41 in.)

CD,3274,G05,53 -19-01FEB94

CTM3274 (01JUL99) 05-6 Saran Liter Engines

060799
PN=43
 Cylinder head and Valves/Check valve lift

CHECK VALVE LIFT

NOTE: Measuring valve lift can give an indication of

wear on cam lobes.

-UN-18JAN95
1. Rotate engine and determine valve locations as
indicated under “Valve Clearance” in this group.

2. Adjust valve to zero clerance.

L103621
3. Position dial indicator on valve spring cap or rotator
and adjust indicator to “0”.

4. Rotate engine and observe indicator reading as valve

moves to the fully open position. Compare readings with
specifications given below:
05
VALVE LIFT at 0.00 mm (in.) clearance
7
Intake valves . . . . . . . . . . . . . . . . . . . . . . .
11.56—12.37 mm
(0.455—0.487 in.)
Wear tolerance . . . . . . . . . . . . . . . . . . 11.13 mm (0.438 in.)

Exhaust valves . . . . . . . . . . . . . . . . . . . . . .11.28—12.12 mm

(0.444—0.477 in.)
Wear tolerance . . . . . . . . . . . . . . . . . . 10.85 mm (0.427 in.)

5. Repeat above procedure for all valves and readjust

valves to specified clearance after this operation.

6. If valve lift is not within specification, remove and

inspect camshaft.

CD,3274,G05,2 -19-24FEB92

CTM3274 (01JUL99) 05-7 Saran Liter Engines

060799
PN=44
 Cylinder head and Valves/Cleaning injection nozzle bores

REMOVING CYLINDER HEAD

Remove intake and exhaust manifolds.

Using special puller JDG716, remove the fuel injection

-UN-17FEB95
nozzles.

NOTE: Removal of fuel injection nozzles is necessary to

prevent them being damaged when cylinder head
is removed.

CD30324
NOTE: Before removal, mark all parts so that they can
be reinstalled in their original positions.

Remove rocker arm shaft.

05 Remove cylinder head cap screws and lift off cylinder

8 head assembly.

-UN-07MAR95
NOTE: Do not turn crankshaft after removal of cylinder
head until each liner has been secured with a
washer and cap screw.

L103623
CD,3274,G05,4 -19-24FEB92

CLEANING INJECTION NOZZLE BORES

Using special tool JDE39, remove carbon deposits from

bores of fuel injection nozzles.

-UN-18JAN95
IMPORTANT: Always turn the tool clockwise through
the bore, even when pulling back.
Otherwise tool will get dull.

Check cooling passages for lime deposits. Clean when

L103626
necessary, using a suitable cooling system cleaning
solution.

CD,3274,G05,5 -19-24FEB92

CTM3274 (01JUL99) 05-8 Saran Liter Engines

060799
PN=45
 Cylinder head and Valves/Valve actuating exploded view

VALVE ACTUATING PARTS

05
9

-UN-10MAY95
CD30379
1—Cam follower 4—Support 7—Keepers 10—Metering seal
2—Push rod 5—Shaft 8—Rotator 11—Valve seat insert
3—Rocker arm 6—Plug 9—Spring 12—Valve

CD,3274,G05,54 -19-01FEB94

CTM3274 (01JUL99) 05-9 Saran Liter Engines

060799
PN=46
 Cylinder head and Valves/Checking cylinder head flatness

REMOVE VALVES AND VALVE SPRINGS

1. Using JDE138 Valve Spring Compressor, compress

the valve springs far enough to remove keepers.

-UN-07MAR95
2. Release spring tension and remove valve rotator and
valve spring. Mark each part so that it can be
reassembled in the same position it was removed from.

3. Remove valves, marking them for reassembly.

L103629
4. Remove valve stem seals from valve guide tower.

05
10
CD,3274,G05,8 -19-24FEB92

CHECKING CYLINDER HEAD FLATNESS

Maximum permissible flatness is 0.08 mm (0.003 in.).

Machined surface of cylinder head must be refaced if

flatness is more than specified maximum.

NOTE: Maximum permissible amount to be machined

-UN-08AUG89
from cylinder head is 0.76 mm (0.03 in.).
After any head remachining, always recheck
valve recesses.

L30699
CD,3274,G05,6 -19-24FEB92

CTM3274 (01JUL99) 05-10 Saran Liter Engines

060799
PN=47
 Cylinder head and Valves/Cleaning valve guides

CLEANING VALVE SEATS

Use an electric hand drill with D17024BR End Brush to

remove all carbon deposits.

-UN-25MAY89
Z20754
05
11
CD,3274,G05,9 -19-24FEB92

CLEANING VALVE GUIDES

Using a plastic brush, clean valve guides.

NOTE: A few drops of light oil or kerosene will make

-UN-07MAR95
cleaning of valve guides easier.

CD7254
CD,3274,G05,10 -19-24FEB92

CTM3274 (01JUL99) 05-11 Saran Liter Engines

060799
PN=48
 Cylinder head and Valves/Valve seats

MEASURE VALVE GUIDES

Using a micrometer, measure valve guides then compare

with specifications.

-UN-04MAY98
VALVE GUIDE SPECIFICATIONS

Valve guide bore diameter

in a new cylinder head . . . . . . . . . . . . . . . . . 7.912—7.938 mm
(0.312—0.313in.)
New guide-to-valve

CD30550
stem clearance . . . . . . . . . . . . . . . . . . . . . . . . 0.05—0.10 mm
(0.002—0.004 in.)
Maximum permissible
clearance . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)

If valve guide-to-stem oil clearance exceeds the wear

limit, 0.38 mm (0.015 in.) and 0.76 mm (0.030 in.)
05 oversize valve stems are available. Have valve guides
12 reamed by a qualified workshop to assure a proper
guide-to-stem clearance.

NOTE: Production valve guides have a very shallow

spiral cut (arrow), similar to a thread, to lubricate
the valve stem with a metered supply of oil. Be
sure, when valve guides are reamed that this
groove is restored.

-UN-19MAY98
CD30548
CD,CTM125,027 -19-01DEC97

LAPPING VALVE SEATS

Check seat width and contact pattern between seat and

valve with blueing. If necessary lap the valve onto its
seat using a lapping tool and lapping compound.
-UN-10MAY95

IMPORTANT: Always check valve recess in cylinder

head after lapping, as described in this
group.
CD30380

CD,3274,G05,55 -19-01FEB94

CTM3274 (01JUL99) 05-12 Saran Liter Engines

060799
PN=49
 Cylinder head and Valves/Valve seats

CHECK VALVE RECESS

After lapping valve seat or remachining combustion face,

install refaced or new valves in cylinder head and check
valve recess (A).

-UN-06DEC88
VALVE RECESS SPECIFICATIONS

Intake . . . . . . . . . . . . . . . . . 0.61—1.11 mm (0.024—0.044 in.)

Wear tolerance . . . . . . . . . . . . . . . . . . . 1.63 mm (0.064 in.)

RG4756
Exhaust . . . . . . . . . . . . . . . . 1.22—1.72 mm (0.048—0.068 in.)
Wear tolerance . . . . . . . . . . . . . . . . . . . 2.26 mm (0.089 in.)

When maximum valve recess is reached, replace valve

seat inserts.
05
13

-UN-07NOV88
T81869
CD,3274,G05,13 -19-01FEB94

CTM3274 (01JUL99) 05-13 Saran Liter Engines

060799
PN=50
 Cylinder head and Valves/Valve seats

REMOVE VALVE SEAT INSERTS

Valve seat inserts are made of sintered metal. Following

method, performed by experienced personnel or
specialized workshop, can be used to remove inserts.

-UN-10NOV97
• Using an arc welder

1. Protect the valve guide by installing a cap screw or

RG7761
dowel in guide to protect from weld spatter.

2. Protect the cylinder head surface with a

non-flammable welder’s cloth (A). Apply a thin bead of
weld (B) around internal diameter of valve seat insert.
Allow insert to cool and use a screwdriver (C) or similar
05 tool and carefully pry insert from bore.
14

-UN-13NOV97
3. After removal of inserts, thoroughly clean area around
valve seat bore and inspect for damage or cracks.
Replace cylinder head as necessary.

RG7813
-UN-10NOV97
RG7763

CD,CTM125,030 -19-01DEC97

CTM3274 (01JUL99) 05-14 Saran Liter Engines

060799
PN=51
 Cylinder head and Valves/Valve seats

• Machining valve seat insert

1. Machine insert according to valve seat bore

specifications as shown, until a thin layer of material
stays in cylinder head.

-UN-10MAR90
2. Remove rest of material and clean valve seat bore.

A—Exhaust: 42.987—43.013 mm (1.6924—

1.6934 in.)
Intake: 47.104—47.130 mm (1.8545—1.8555 in.)
B—Exhaust: 3.82 mm (0.150 in.) Reference

RG5606
Intake: 3.45 mm (0.136 in.) Reference
C—9.936—10.064 mm (0.3912—0.3962 in.)
D—38—42˚
E—Maximum radius 0.5 mm (0.019 in.)

05
15
CD,CTM125,031 -19-29JUN99

VALVE SEAT INSERT INSTALLATION

1. Freeze the valve seat inserts to -30˚C (-22˚F).

2. Using JDG676 Pilot Driver (A) and JDG675 Valve

Seat Insert Installing Adapter (B), install valve seat
inserts.

3. Lap valve seats to maintain correct valve recess and

valve to valve seat sealing. (See “Lapping valve seats”,

-UN-12APR90
in this group)

RG5653
CD,3274,G05,16 -19-01FEB94

CTM3274 (01JUL99) 05-15 Saran Liter Engines

060799
PN=52
 Cylinder head and Valves/Valves

CHECK VALVES

Thoroughly clean and inspect valves to help determine if

they can be reused. Replace valves that are burned,
cracked, eroded, or chipped.

-UN-07NOV88
1. Measure valve stem diameter and compare with
corresponding valve guide diameter to check clearance
(See “Measure valve guides”, in this group).

T82053
VALVE STEM DIAMETER SPECIFICATIONS

Intake valve . . . . . . . . . . . . . . . . . . . . . . . . 7.864—7.884 mm

(0.3096—0.3104 in.)

Exhaust valve . . . . . . . . . . . . . . . . . . . . . . . 7.848—7.874 mm

(0.3090—0.3100 in.)
05
16

-UN-05DEC97
2. Check for valve face runout and bent valves.

Maximum permissible
runout of valve face . . . . . . . . . . . . . . . . 0.038 mm (0.0015 in.)

RG4234
CD,CTM125,032 -19-01DEC97

GRIND VALVES

Serviceable valves should be refaced to specified angle

(A). Face angle on intake and exhaust valves is 29.25˚ ±
0.25˚.

-UN-19NOV89
RG4755
CD,3274,G05,3 -19-24FEB92

CHECK VALVE SPRING TENSION

VALVE SPRING COMPRESSION

Free length . . . . . . . . . . . . . . . . . . . . approx. 54 mm (2.125 in.)

-UN-08NOV88

Load with spring compressed

to 46 mm (1.81 in.) . . . . . . . . . . . . . . . 240—280 N (54—62 lb)

Load with spring compressed

to 34.5 mm (1.36 in.) . . . . . . . . . . . . . 590—680 N (133—153 lb)
T82054

CD,3274,G05,19 -19-01FEB94

CTM3274 (01JUL99) 05-16 Saran Liter Engines

060799
PN=53
 Cylinder head and Valves/Valves

INSPECT VALVE ROTATORS

Insure that valve rotators turn freely in both directions.

Replace if defective.

-UN-28OCT88
T91224
CD,3274,G05,20 -19-24FEB92

INSTALL VALVES

1. Apply engine oil to valve stems and guides. 05

17
2. Insert valves in head (in same location as found

-UN-12APR90
during removal).

NOTE: Valves must move freely and seat properly.

3. Using JDG678 Valve Stem Seal Installer (A), slide

RG5654
seal (B) over valve stem and onto valve guide tower (C).

4. Install valve springs and rotators.

5. Compress valve springs using JDE138 Valve Spring

Compressor and install new keepers on valves.

NOTE: After having installed the valves, strike end of

-UN-12APR90
each valve three times with a soft mallet to
ensure proper positioning of the keepers.

RG5655
-UN-07MAR95
CD30233

CD,3274,G05,21 -19-01FEB94

CTM3274 (01JUL99) 05-17 Saran Liter Engines

060799
PN=54
 Cylinder head and Valves/Install cylinder head

INSTALL CYLINDER HEAD

1. Clean tapped holes in cylinder block using JDG680

Tap (or any 1/2-13 UNC-2A tap). Use compressed air to
remove debris or any fluids from cap screw holes.

-UN-13DEC88
2. Install new cylinder head gasket dry (without sealant)

IMPORTANT: Insure that cam followers are present

before cylinder head installation.

RG4718
3. Install two guide studs in cylinder block at locating
holes (D).

IMPORTANT: Without guide studs, the Viton O-ring

attached to cylinder head gasket (at
05 rocker arm lube oil passage) could be
18 damaged when repositioning cylinder
head on engine block to align cap
screw holes.

4. Position cylinder head over guide studs and lower into

place on cylinder block.

5. Dip cap screws entirely in clean engine oil.

6. Remove guide studs and install cap screws in all

open bores.

7. Tighten cap screws in sequence to the torque

specified, beginning with No. 1. Use JD-307 Torque
Wrench Adapter if necessary.

• Step 1 - Tighten all cap screws to 100 N·m (75 lb-ft)

• Step 2 - Tighten all cap screws to 150 N·m (110 lb-ft)
• Step 3 - Wait 5 minutes and recheck to insure
150 N·m (110 lb-ft) on all cap screws
• Step 4 - Tighten each cap screw an additional
60˚ ± 10˚

A—3 cylinder engine

B—4 cylinder engine
C—6 cylinder engine
D—Guide stud locations
E—Front of engine
-UN-06DEC88
RG4773

CD,3274,G05,23 -19-01FEB94

CTM3274 (01JUL99) 05-18 Saran Liter Engines

060799
PN=55
 Cylinder head and Valves/Torque turn tightening method

TORQUE TURN TIGHTENING METHOD

To ensure that the full 60˚ angle is reached (4th step),

the following procedure can be used:

• Step A - Make a mark on socket and make a second

-UN-31OCT97
mark 60˚ counterclockwise from the first
• Step B - Make a mark on cylinder head next to each
cap screw
• Step C - Place socket on cap screw so that first mark
aligns with mark on cylinder head

RG5587
• Step D - Tighten (in sequence) all cap screws until
second mark on socket aligns with mark on cylinder
head

NOTE: The torque turn method eliminates the need to A—Reference mark
retorque the cylinder head bolts after the first B—60˚ mark
05
hours of engine operation. However, valve 19
clearance adjustment is still required.

CD,CTM125,035 -19-01DEC97

CTM3274 (01JUL99) 05-19 Saran Liter Engines

060799
PN=56
 Cylinder head and Valves/Rocker arm shaft

CHECKING ROCKER ARM SHAFT

Disassembling and checking

1. Remove plugs (A) and bowed washers (B) from

-UN-10MAY95
rocker arm shaft.
2. Slide springs, rocker arms and supports off rocker arm
shaft, identifying their sequence for reassembly in the
same order.
3. Clean all parts with solvent and dry with compressed

CD30381
air.
4. Check all parts for good condition (See
“Specifications” for part dimensions).
5. Replace parts as necessary.

NOTE: If the rocker arm has been damaged by a valve

05 failure, replace it together with the corresponding
20 push rod, valve rotator and keepers.

-UN-18MAY95
Reassembling

1. Lubricate shaft, bores of rocker arms and supports.

2. Slide springs, rocker arms and supports onto shaft.

CD30382
Assemble in the same order in which they were removed
during disassembly.

IMPORTANT: The hole (C) in the shaft must be in

line with the oil supply hole (D) of A—Plug
cylinder head. B—Bowed washer
C—Oil supply hole in rocker arm shaft
3. Install bowed washers (B) and new plugs (A) on shaft. D—Oil supply hole in cylinder head

CD,3274,G05,56 -19-01FEB94

CTM3274 (01JUL99) 05-20 Saran Liter Engines

060799
PN=57
 Cylinder head and Valves/Valve clearance

INSTALL ROCKER ARM ASSEMBLY

1. Install push rods in same location from which they

were removed.

-UN-07MAR95
NOTE: Valve stem tips are specially hardened, wear
caps are not required.

2. Position rocker arm assembly on engine.

L103631
3. Lubricate the rocker arms with engine oil.

4. Tighten attaching cap screws to 50 N·m (35 lb-ft).

05
21
CD,3274,G05,29 -19-01FEB94

VALVE CLEARANCE

The valve clearance must be adjusted when engine is

cold.

-UN-19MAY98
Using JDE83 or JDG820 Flywheel Turning Tool (A),
rotate engine flywheel in running direction (clockwise
viewed from water pump) until No.1 piston (front) has
reached top dead center (TDC) on compression stroke.
Insert timing pin JDE81-4 (B) into flywheel bore.

CD30544
NOTE: When No. 1 piston is at TDC on compression
stroke, valve springs of No. 1 cylinder are not
under tension.

VALVE CLEARANCE SPECIFICATIONS

Intake valve . . . . . . . . . . . . . . . . . . . . . . . 0.35 mm (0.014 in.)

-UN-19MAY98
Exhaust valve . . . . . . . . . . . . . . . . . . . . . . 0.45 mm (0.018 in.)

Adjust valve clearance as directed in the following

CD30545

module.

CD,CTM125,036 -19-01DEC97

CTM3274 (01JUL99) 05-21 Saran Liter Engines

060799
PN=58
 Cylinder head and Valves/Valve adjustment sequence

VALVE ADJUSTMENT SEQUENCE

• 3- Cylinder engine:
Adjust valve clearance on No.1 and 2 exhaust valves
and No.1 and 3 intake valves.

-UN-08MAR95
Turn crankshaft 360˚ and reinsert timing pin.

Adjust valve clearance on No.3 exhaust valve and No.2

intake valve.

CD30000
• 4- Cylinder engine:
Adjust valve clearance on No.1 and 3 exhaust valves
and No.1 and 2 intake valves.

Turn crankshaft 360˚ so that No.4 piston is at TDC

05 (compression stroke) and reinsert timing pin.
22

-UN-08MAR95
Adjust valve clearance on No.2 and 4 exhaust valves
and No.3 and 4 intake valves.

• 6- Cylinder engine:
Adjust valve clearance on No.1, 3 and 5 exhaust valves

CD7103
and No.1, 2 and 4 intake valves.

Turn crankshaft 360˚ so that No.6 piston is at TDC

(compression stroke) and reinsert timing pin.

Adjust valve clearance on No.2, 4 and 6 exhaust valves

and No.3, 5 and 6 intake valves.

-UN-08MAR95
A—Front of engine
B—Exhaust valve
C—Intake valve
D—No. 1 piston at TDC compression stroke
E—No. 6 piston at TDC compression stroke
(6-cylinder engine)

CD30237
F—No. 4 piston at TDC compression stroke
(4-cylinder engine)
G—No. 1 piston at TDC exhaust stroke
(3-cylinder engine)

CD,3274,G05,7 -19-24FEB92

CTM3274 (01JUL99) 05-22 Saran Liter Engines

060799
PN=59
 Cylinder head and Valves/Final work

INSTALL ROCKER ARM COVER

Two types of rocker arm cover are used:

Sheet metal cover (A)

-UN-07MAR95
• Install rocker arm cover with gasket (without sealant)
and tighten cap screws to 10 N·m (7 lb-ft).
• Gasket can continue to be used until it starts to leak.

Composite material cover (B)

CD30152
• Install rocker arm cover with built-in sealing ring
(without sealant).
• Install the cap screws by hand and tighten to 10 N·m
(7 lb-ft), starting from center and moving towards both
front and rear ends of the cover.
• The sealing ring is reusable. In case of leak, proceed
as follows: 05
1. Remove sealing ring. 23

-UN-07MAR95
2. Clean cover sealing ring groove with acetone and dry
with compressed air.
3. Install new sealing ring with grease in cover groove.
4. Cut the sealing ring slightly longer than necessary.
5. Put the sealing ring ends edge to edge then press the

CD30153
sealing ring all along the groove to ensure proper
installation.

CD,3274,G05,31 -19-24FEB92

FINAL WORK

1. Re-install parts previously removed.

2. Check crankcase vent tube hose (A) for proper
condition. Replace if necessary. When re-installing, be
sure that the hose is not pinched.
3. Start engine and check for oil or coolant leaks.
4. Run engine for 30 minutes at 1500 rpm or perform
break-in in case of engine overhaul.
5. Recheck valve clearances and readjust when
necessary.

NOTE: Retorque of cylinder head bolts is not required.

-UN-17JUN98
CD30547

CD,CTM125,039 -19-01DEC97

CTM3274 (01JUL99) 05-23 Saran Liter Engines

060799
PN=60