SECTION 4: CYLINDER HEAD AND VALVES

See new specifications at end of manual called "Specifications, Special Torque Values, and Service Tools".

EXPLODED VIEWS

EXPLODED VIEW OF CYLINDER HEAD AND RELATED PARTS

Figure 4.1 Exploded View Of Cylinder Head And Related

Parts

1. Front Lifting Eye 16. Valve Stem Key

2. Cylinder Head Short Bolt (20) 17. Valve Rotator With Seal

3. Cylinder Head Bolt Washer 18. Valve Rotator Seal

4. Fuel Injector Sleeve 19. Intake Valve Spring

5. Rear Lifting Eye 20. Valve Stem Seal With

Retainer

6. Cylinder Head Assembly With Valves 21. Valve Guide

7. Oil & Fuel Supply Manifold Gasket 22. Intake Valve Seat Insert

8. High Pressure Oil and Fuel Supply Manifold 23. Intake Valve

9. Manifold End & Oil Supply Plug O-Ring 24. Exhaust Valve Spring

10. Manifold End & Oil Supply Plug Back-up 25. Exhaust Valve Insert
Ring

11. Supply Manifold End Plug 26. Exhaust Valve

12. Flange Bolt 40mm (1.6 in.) 27. Pipe Plug 1/2 in. NPT

13. Cylinder Head Gasket 28. Pipe Plug 3/4 in. NPT

14. Supply Manifold Oil Supply Plug 29. Pipe Plug 1/8 inch NPT

15. Cup Plug 1-1/4 inch (32 mm)

 CYLINDER HEAD ASSEMBLY

CLEANING CYLINDER HEAD

1. Clean valve faces and seats with a suitable cleaning solvent to remove all dirt or foreign material. Blow dry
all new and used components using filtered compressed air.

2. Thoroughly clean all valve guides, prior to valve installation, as follows:

a. Coat a brush OEM6343 with soap and water.

NOTE: Brush must have a slightly larger diameter than the I.D. of the valve guide.

b. Insert brush into valve guide bore and clean with a turning motion to insure removal of any deposits.

c. Dry with filtered compressed air.

NOTE: PERFORM VALVE GUIDE BORE CLEANING ON:

1. NEW SERVICE VALVE GUIDES.

2. VALVE GUIDES INSTALLED IN NEW SERVICE CYLINDER HEADS (LESS VALVE).

3. VALVE GUIDES PRESENTLY INSTALLED IN CYLINDER HEAD, WHICH MEET BORE

SPECIFICATIONS.

3. Insert a large nylon brush into rear of oil rail gallery for cleaning.

4. Use compressed air to clean out the oil gallery.

5. Install a new O-Ring into the end plug and install into the supply manifold. Tighten to the special torque
value.
 Figure 4.69 Fuel Injector Installed Into Cylinder Head
Cutaway
1. 1. Cylinder Head
2. 2. Fuel Injector Sleeve
3. 3. Contact Areas

6. Insert a large nylon brush into rear of fuel rail gallery for cleaning.

7. Use compressed air to clean out fuel rail gallery.

VALVE ASSEMBLY

1. Lubricate the valve stems with clean engine oil and insert the valves into the valve guides.

2. Lubricate the I.D. of the new valve stem seal assemblies with clean engine oil and install them over the valve
and valve guide as shown in Figure 4.70 . Be sure the seal assemblies are seated down against the cylinder
head spring pockets.

Figure 4.70 Installing Valve Stem Seal Assemblies

3. Install the valve spring over the stem seal assembly.

NOTE: Be sure to install proper valve spring at proper valve location. Failure to properly locate the
springs could cause engine damage (Figure 4.71 ).

4. Install the rotator assembly over the valve spring. Refer to Figure 4.72 .

NOTE: Snap new rotator seals into bottom side (rotator cone) of valve rotators before installing rotator
assembly on engine.

5. Compress the valve spring using valve spring compressor tool ( ZTSE1846 ) and install the spring locks
(keepers) as shown in Figure 4.73 .

Figure 4.71 Intake/Exhaust Valve Spring Comparison

Figure 4.72 Installing Rotator Assembly
Figure 4.73 Install Valve Spring Locks
CYLINDER HEAD CLEANING

NOTE: Before proceeding any further, remove the lifting eyes and there mounting hardware from the
cylinder head.

Perform the following steps to clean the cylinder head.

CLEANING

1. With the valves installed to protect the seats, remove deposits and gasket material from the gasket surface
of the cylinder head using a rotary wire brush or sanding block with mineral spirits.

2. Clean all bolt holes with appropriate size tap. Clear debris from bolt holes, oil return and water passages,
using filtered compressed air.

3. Clean the cylinder head bolt threads.

4. Wash all bolts and washers with a suitable solvent and dry thoroughly.

NOTE: Dirt in threads or damaged threads may cause binding and result in a false torque reading.
CYLINDER HEAD INSPECTION

NOTE: Cylinder head condition must be evaluated by inspecting for warpage, thickness, cracks and/or
valve leakage.

INSPECT FOR WARPAGE

Using a straightedge ( OEM1293 ) and feeler gauge, check the cylinder head gasket surface for warpage
utilizing the checking pattern shown in Figure 4.29 . If specifications are NOT met check head thickness prior
to resurfacing. The minimum deck-to-deck dimension must be maintained after resurfacing.
CHECK THICKNESS

Measure cylinder head deck thickness, using a micrometer, at six locations (four corners and two center
points). Refer to " SPECIFICATIONS ". If the minimum deck to deck dimension cannot be met, replace the
cylinder head ( Figure 4.30 ).

Figure 4.29 Checking Cylinder Head For Warpage

Figure 4.30 Checking Cylinder Thickness
CHECK FOR VALVE LEAKAGE (USING MINERAL SPIRITS)

Visually inspect for valve leakage as follows:

1. Position the cylinder head on wood blocks with the gasket surface facing down.

2. Squirt mineral spirits into the the intake and exhaust ports.

Wait five minutes, use an inspection mirror and visually inspect the valve seat area for leakage of the mineral
spirits.

NOTE: THERE SHOULD BE NO LEAKAGE. RECONDITIONING IS NOT REQUIRED IF THE CYLINDER

HEAD PASSES THE MINERAL SPIRITS TEST. IF LEAKAGE IS OBSERVED, THE VALVES REQUIRE
RECONDITIONING. REFER TO "CYLINDER HEAD RECONDITIONING" IN THIS SECTION. THIS TEST
DOES NOT CHECK FOR CONDITION OF VALVE GUIDE OR VALVE STEM-TO-GUIDE CLEARANCE
INSPECT FOR CRACKS (USING DYE PENETRANT METHOD OEM1272)

Visually inspect for cylinder head cracks using the four step dye penetrant method as follows: (Refer to Figure
4.31 .)

STEP ONE - Spray the cleaner onto the lower deck (gasket surface) of the head and wipe dry.

STEP TWO - Spray on the dye penetrant. Allow the dye to remain on the surface from one (1) to ten (10)
minutes.

STEP THREE - Wipe the dye off the surface.

NOTE: Dye will remain in any cracks during the "wipe off" step.

STEP FOUR - Spray on the developer and let dry for five to fifteen minutes.
 Figure 4.31 Checking Cylinder Head For Cracks

NOTE: Cracks will show up as purple lines against the white developer. Refer to Figure 4.32 .

NOTE: IF ANY CRACKS ARE PRESENT, REPLACE THE CYLINDER HEAD.

 PRESSURE CHECK CYLINDER HEAD

Pressure testing the cylinder head will reveal cracks in ports or sleeve leakage which cannot be observed using
dye penetrant. Pressure-test the cylinder head as follows:

1. If removed, install shoulder bolt into cylinder head. Tighten to the special torque value ( Figure 4.33 ).

2. Install fuel injectors into cylinder head injector bores and secure, refer to "Fuel Injector Installation" in this
section for instructions.

3. Remove the valves, using a valve spring compressor. Refer to "CYLINDER HEAD RECONDITIONING ", in
this section for valve removal instructions.

Figure 4.32 Identifying Cylinder Head Crack

 Figure 4.33 Installing Fuel Injector Shoulder Bolt

4. Pressure test the cylinder head using the Cylinder Head Pressure Test Plate Kit ZTSE4289-1A Hardware
and Regulator and ZTSE4289-2A Plate. Refer to Figure 4.34 .

5. Fasten the pressure plate and head gasket to the cylinder head gasket surface using the twenty-four (24)
mounting bolts and nuts supplied with the kit. Refer to Figure 4.35 .

6. Remove thermostat and install air regulator. Secure to cylinder head with two (2) mounting bolts. Refer to
Figure 4.36 .

7. Remove the pipe plug next to the thermostat opening. Fill cylinder head with hot water and reinstall pipe
plug.

8. Install a hose fitting to the cylinder head at the removed plug. Apply 124-138 kPa (18-20 psi) air pressure
and visually inspect for leaks at the:

Fuel injector nozzle sleeve area

Ports
Upper deck
Lower deck

NOTE: IF LEAKAGE IS OBSERVED AT ANY PORT OR THE UPPER AND LOWER DECK, REPLACE THE
CYLINDER HEAD .
 Figure 4.34 Cylinder Head Pressure Test Kit Components
1. 1. Pressure Test Plate
2. 2. Air Regulator
3. 3. Pressure Test Plate Mounting Bolts (24)

Figure 4.35 Mounting Cylinder Head Pressure Test Plate

 Figure 4.36 Mounting Air Regulator To Cylinder Head
1. 1. Cylinder Head
2. 2. Air Regulator
CYLINDER HEAD INSTALLATION

INSTALLATION

Install the cylinder head assembly as follows:

1. Clean and dry the cylinder head gasket surfaces.

2. Clean all cylinder head bolt holes using an appropriate tap and blow out bolt holes with filtered compressed
air.

NOTE: PRIOR TO CYLINDER HEAD INSTALLATION, CHECK CYLINDER SLEEVE PROTRUSION AS

DESCRIBED IN SECTION 7.

3. Install the dowel rings into the crankcase top deck. Refer to Figure 4.74 .

NOTE: The dowel rings are used to locate the cylinder head gasket.

4. Install a new cylinder head gasket over the "locating" dowel rings.

5. Install the lifting eye on the rear of the cylinder head and tighten the mounting bolt. Install the lifting eye on
the front of the cylinder head, using one washer (1) per mounting bolt. Tighten the mounting bolts.

6. Carefully lower the cylinder head onto the gasket. Refer to Figure 4.75 .

7. Lubricate the cylinder head bolt threads, washers and under head seating area using clean engine oil. Refer
to Figure 4.76 .

NOTE: Lubricate both long and short bolts.

8. Run twenty (20) cylinder head mounting bolts in finger-tight.

Figure 4.74 Installing Dowel Rings Into Crankcase

Figure 4.75 Lower Cylinder Head Onto Crankcase

Figure 4.76 Installing Cylinder Head Mounting Bolts
NOTE: There are a lot of graphics in this procedure. Please wait for them to load. 20 graphics.

VALVE AND VALVE GUIDE RECONDITIONING

Removing Valves From Cylinder Head

Remove the intake and exhaust valves as follows:

1. Using a valve spring compressor tool ZTSE1846 , remove the valves.

2. Install the valve spring compressor over the valve to be removed and compress the spring.

3. Remove the valve spring locks (keepers). Refer to Figure 4.37 .

4. Remove the valve spring compressor tool.

5. Remove the valve rotator, valve spring, valve seal and valve as shown in Figure 4.38 . If the nylon
rotator seal becomes dislodged from the rotator and sticks to the valve stem, remove the seal from the
valve stem with your fingers. Discard all 12 rotator seals.

NOTE: SEPARATE THE INTAKE AND EXHAUST SPRINGS AT TIME OF REMOVAL. THE SPRING
RATES ARE DIFFERENT AND CANNOT BE MIXED ON CYLINDER HEAD REASSEMBLE.

6. Remove valve stem seal assemblies and valves. Discard all 12 stem seal assemblies due to damage
from removal across the valve keeper grooves.

Clean Valve Guides

With valves removed, clean all valve guides using a nylon brush (OEM6343) , soap and water. Refer to
Figure 4.39 .
Figure 4.37 Removing Valve Spring Locks
Figure 4.38 Removing Valve Components
 Figure 4.39 Cleaning Valve Guides

Inspect Valve Guides

Position an inspection light at the bottom of the valve guide bores and visually examine the walls for
burning, cracking. Replace any guides which do not pass the visual inspection.

Measure each valve guide using a ball gauge ( OEM1023 ) and outside micrometer as shown in Figures
4.40 and 4.41 .

Measure the valve guides within 0.64 mm (0.025 inch) of each end of the guide and 90 degrees from the
crankshaft center-line. Record valve guide I.D. readings so valve-to-guide running clearance may be
determined later ( Figure 4.41 ). If valve guide exceeds specifications, replace the guide.

Replace Valve Guides

Remove any valve guides which do not pass the inspection criteria as follows:

1. Insert the valve guide remover ZTSE4377 into the guide from the valve port side of the cylinder head.
2. Press out the valve guide. Refer to Figure 4.42 .

Figure 4.40 Measuring Valve Guide

Figure 4.41 Measuring Valve Guide Gauge
 Figure 4.42 Installing Valve Guide Remover
1. 1. Valve Guide Remover Tool
2. 2. Valve Guide
3. 3. Cylinder Head

Install Valve Guides

NOTE: INSTALL THE VALVE GUIDE INSERTS WITH THE LARGE 15 DEGREE CHAMFER END
DOWN.

1. Lubricate valve guide insert using clean engine oil and press into the cylinder head until installer sleeve
( ZTSE1943 ) bottoms against cylinder head. Chilling guide may facilitate installation. Refer to Figure
4.43 . DO NOT hammer or pound valve guide insert into cylinder head.

2. Deburr the valve guide, after installation, using ZTSE4393 valve guide deburring tool.

NOTE: DO NOT ream valve guide I.D. after installation. Service guides are provided in a finish
reamed condition. Clean valve guides as described in Figure 4.39 .

Clean Valves

Remove all carbon from the valve stems and valve heads.

Inspect Valves

1. Visually inspect each valve, replacing any that show evidence of burn marks, warpage, scuffing or
bending.

2. Measure each valve stem for wear using a micrometer to measure valve stem diameter. Record the
readings.

NOTE: Measure valves at three locations 90° apart. Refer to the "SPECIFICATIONS" and replace
valves which exceed the minimum stem diameter specification.

3. Using the valve stem diameter and valve guide inside diameter measurements, recorded earlier (see
"INSPECT VALVE GUIDES " in this section), determine valve stem-to-guide running clearance. Refer to
"SPECIFICATIONS" . Replace the valve or valve guide as required.
 Figure 4.43 Using Valve Guide Installer Tool

Reface Valves

NOTE: If valves are in serviceable condition, reface the valve to the specified angle, as required.
Refer to Figure 4.44 .

1. Reface the valves as follows:

a. Dress the cutting stone, prior to refacing the valves, using the dressing stud attachment on the
grinder.
 b. Install the valve in the grinder and set to the specified angle.

c. Grind the valve face. Remove only the minimum amount of material necessary to true up the valve
face. Refer to Figure 4.45 .

2. Measure valve face margin at four locations using a caliper. Refer to Figure 4.46 .

NOTE: The minimum valve face margin (See "SPECIFICATIONS") must be maintained across the
entire valve face. An insufficient margin will NOT provide proper heat dissipation and lead to
valve warpage or breakage. Intake and exhaust valve margins are different. Replace the valve if
the margin is less than the specified minimum, after grinding.

Figure 4.44 Valve Angles Specifications

Figure 4.45 Grinding The Valve Face
 Figure 4.46 Measuring The Valve Face

3. Reface the valve stem tip as follows:

a. Dress the cutting stone using the dressing stud on the grinder.

b. Install the valve in the grinder as shown in Figure 4.47 .

NOTE: WHEN RESURFACING THE VALVE STEM TIP, LEAVE SUFFICIENT MATERIAL SO THE
VALVE LEVER (ROCKER ARM) DOES NOT CONTACT THE VALVE SPRING LOCKS OR
ROTATORS, DURING OPERATION.

c. Touch the valve stem tip to the cutting stone removing only a minimum of material.

NOTE: Refacing the valve stem tip provides a new wear surface for the rocker arm.

4. After refacing valves, insert valves in clean valve guide and check valve face contact with valve seat
using Prussian Blue™ (or equivalent) as follows:

a. Spread thin film of Prussian Blue™ on valve face. Insert valve into its guide. Refer to Figure 4.48 .
b. Apply pressure on exact center of valve head while making a quarter turn in the seat. Refer to
Figure 4.49 .

c. Remove valve, inspect impression made on seat and on valve face.

d. Bluing should appear around entire contact surface of valve face and valve seat to be acceptable.
CHECK SEVERAL TIMES TO PREVENT ERROR . If acceptable, proceed with valve installation.

Figure 4.47 Placing Valve On Grinder

Figure 4.48 Applying Prussian Blue On Valve

Figure 4.49 Turning Valve In Cylinder Head

Valve Seat Grinding

1. If required, resurface the valve seat as follows: (Refer to Figure 4.50 )

a. Lightly lubricate and install the correct size valve seat installer ( ZTSE4164A ) into the valve guide.

b. Choose the correct angle grinding stone and dress the stone. Refer to " SPECIFICATIONS " for
valve seat angles.

c. Install the grinding stone over the valve seat installer.

d. Lower grinder head over valve seat installer shank until wheel barely clears the valve seat. Turn on
power. GENTLY apply grinding wheel to valve seat with little pressure other than weight of the wheel.

e. Raise wheel frequently to prevent overheating.

f. Grind seat to a smooth even finish.

 Figure 4.50 Using Valve Seat Installer ZTSE4164A

2. After resurfacing, check valve seat width using a caliper as shown in Figure 4.51 . Refer to
"SPECIFICATIONS" for seat width limits. If seat widths are excessive, they may be corrected by grinding
with a 15 degree or smaller angle stone.

3. Check valve recession using a straightedge OEM1293 and feeler gauge or a surface gauge. Refer to
Figures 4.52 and 4.53 . Refer to " SPECIFICATIONS" for recession limits. If valve recession is
excessive, install a new valve or replace the valve seat. If the valve protrudes above the deck, regrind the
valve seat.

NOTE: Clean valve guides as described in Figure 4.39 .

NOTE: IF A NEW VALVE WILL NOT CORRECT AN EXCESSIVE RECESSION CONDITION, THE
VALVE SEAT MUST BE REPLACED AND REGROUND. IF THE VALVE FACE PROTRUDES ABOVE
THE DECK, THE VALVE SEAT WILL HAVE TO BE REGROUND DEEPER INTO THE HEAD. AFTER
REGRINDING ANY SEAT, RECHECK THE SEAT WIDTH (FIGURE 4.44 ) AND CONFIRM VALVE
SEAT CONTACT USING PRUSSIAN BLUE™ (SEE FIGURES 4.43 AND 4.44.)

Figure 4.51 Checking Valve Seat After Resurfacing

Figure 4.52 Checking Valve Recession Using Straightedge
And Feeler Gauge
 Figure 4.53 Checking Valve Recession Using Surface Gauge
1. 1. Dial Indicator
2. 2. Cylinder Head
3. 3. Valve

4. After resurfacing the valve seat, check the seat for runout, using an appropriate dial indicator. Valve
seat runout should not exceed limits shown in "SPECIFICATIONS" .

NOTE: IF VALVE SEAT RUNOUT, CONCENTRICITY AND/OR SEAT WIDTH CANNOT BE

MAINTAINED, REPLACE AND RESURFACE THE VALVE SEATS.

Valve Seat Replacement

1. USE A VALVE SEAT PULLER ZTSE1951C to remove defective valve seat inserts as follows:
NOTE: These instructions are general in nature. Follow the instructions that apply to the tool.

a. Cut groove in insert using stone.

b. Choose the appropriate size collet ( ZTSE1951-20 ). Position the collet in the valve seat insert
( Figure 4.54 ).

c. Expand the collet by threading the shaft into the collet until the collet is tight inside the valve seat.
Refer to Figure 4.55 .

Figure 4.54 Installing Collet Onto Handle

 Figure 4.55 Installing Collet Into Valve Seat

d. Turn the large handle on the bridge assembly to pull the valve seat insert from the cylinder head.
Refer to Figure 4.56 .

e. Unlock the pin collet by loosening the threaded shaft and discard the valve seat insert.

2. Select the appropriate size valve seat insert. Refer to " VALVE SEAT INSERT CHART ".

VALVE SEAT INSERT CHART

OVERSIZE INSERT DIAMETER OF CYLINDER HEAD COUNTERBORE

- INTAKE EXHAUST

Standard* 46.253 mm (1.821 in.) 46.0 mm (1.811 in.)

0.05 mm (0.002 in.)* 46.304 mm (1.823 in.) 46.050 mm (1.813 in.)

0.381 mm (0.015 in.) 46.634 mm (1.836 in.) 46.380 mm (1.826 in.)

* Standard and 0.05 mm (0.002 in.) oversize service insert DOES NOT require insert
 counterbore enlargement before installing.

Figure 4.56 Removing Valve Seat Insert

NOTE: STANDARD SERVICE VALVE SEAT INSERTS ARE available thru service parts. IF THE
SEAT IS DAMAGED BEYOND THE STANDARD OR 0.05mm (.002 in.) DIAMETER, IT WILL BE
NECESSARY TO MACHINE THE INSERT COUNTERBORE IN THE CYLINDER HEAD FOR AN
OVERSIZE SEAT INSERT. STANDARD SIZE INSERTS DO NOT REQUIRE COUNTERBORE
ENLARGEMENT.

3. Install the valve seat insert as follows:

a. Chill the valve seat insert in a freezer for 30 minutes before installing.
NOTE: Chilling the valve seat insert prevents peeling of metal from the cylinder head counterbore
during installation.

b. Align the insert to avoid cocking.

c. Press the insert into its counterbore using ZTSE4164A for the intake and exhaust valve seat inserts.
Refer to Figure 4.57 .

4. Grind the new valve seat(s) to the specified angles and width. Refer to " VALVE SEAT GRINDING" in
this section.
VALVE SPRINGS

Cleaning

Clean all valve springs and seats in a suitable solvent.

Inspection

1. Visually inspect valve springs for rust, pitting and cracks. Look for spring distortion.

2. Spring ends must be flat and square to prevent lateral loads on valve stem. Refer to Figure 4.58 .

NOTE: Out of square springs place a side load on the stem causing rapid guide wear.
 Figure 4.57 Installing Valve Seat Inserts
1. 1. Valve Seat Insert
2. 2. Installation Tool

Figure 4.58 Checking Valve Springs

3. Measure valve spring tension using valve spring tester ZTSE2241 . Refer to Figure 4.59 and "
SPECIFICATIONS" .

Measure maximum spring length in use (valve closed).

Measure minimum length in use (valve open).

NOTE: Apply the appropriate test load to each spring and determine if test length is achieved.

4. Replace any valve spring which is rusted, pitted, cracked, bent or incapable of meeting tension
requirements.
Valve Rotators

CLEANING

Clean rotators in a clean solvent.

INSPECTION

1. To properly test the rotator for function, a valve spring load must be applied to the rotator.

NOTE: THE ROTATOR MUST BE LUBRICATED WITH CLEAN ENGINE OIL PRIOR TO TESTING.

2. Place the valve spring with the rotator in the spring tester ZTSE2241 . Place a ball bearing between the
rotator and ram of the spring tester. The ball bearing must be large enough to prevent ram from touching
any part of the rotator.

3. Paint a reference line on the rotator.

4. Compress the valve spring rapidly with even pressure and observe the rotator as it turns ( Figure
4.60 ).

5. Replace any rotator which does NOT turn.

Valve Spring Locks

CLEANING

Clean valve spring locks in a suitable solvent.

INSPECTION

Visually inspect inside and outside of the valve spring locks for wear. Replace any worn spring locks, as
required.
Figure 4.59 Checking Valve Spring Tension
Figure 4.60 Checking Valve Rotator
FUEL INJECTOR SLEEVE REPLACEMENT

Removal

NOTE: If the injector sleeve is going to be removed when In-chassis, place a cork plug into the
bore (to prevent debris entering bore or onto piston) before performing procedure.

Use the following steps to remove fuel injector sleeves.

1. Insert fuel injector sleeve remover tool ZTSE4302A into fuel injector sleeve ( Figure 4.61 ).

2. Turn injector sleeve remover tool to cut threads into fuel injector sleeve. Once threads have been cut
into fuel injector sleeve, remove tool from bore ( Figure 4.62 )

3. Install fuel injector sleeve puller tool ZTSE43023 into bore and tighten. BE SURE puller tool threads
into fuel injector sleeve ( Figure 4.63 ).

Figure 4.61 Installing Fuel Injector Remover Tool

 Figure 4.62 Threading The Fuel Injector Sleeve

Figure 4.63 Installing Fuel Injector Sleeve Puller Tool

4. Screw slide hammer ZTSE1879-1 into fuel injector sleeve puller tool. Remove fuel injector sleeve from
bore ( Figure 4.64 ).

5. Insert a stiff wire brush ZTSE4305 into fuel injector bore and remove deposits and hardened sealant
from bore ( Figure 4.65 ).

6. Insert a small stiff nylon brush ZTSE4320 into oil gallery for cleaning.

7. Using compressed air to clean out all fuel and oil galleries of debris.

Figure 4.64 Removing Fuel Injector Sleeve

 Figure 4.65 Cleaning Fuel Injector Bore

Installation

Use the following steps to install a new fuel injector sleeve:

1. Attach a new fuel injector sleeve to adapter ZTSE4303 and apply Loctite(r) 262 to fuel injector sleeve
at ( Figure 4.66 ):

1. Wall (end)

2. Upper Wall (top)

2. Insert sleeve into fuel injector bore ( Figure 4.67 ).

3. Using a hammer, drive sleeve into fuel injector bore ( Figure 4.68 ). Remove adapter tool once fuel
sleeve injector is in place.

4. Clean fuel injector sleeve after installation, using ZTSE4304 brush set.
Figure 4.66 Preparing Fuel Injector Sleeve For Installation
Figure 4.67 Inserting Fuel Injector Sleeve Into Bore
 Figure 4.68 Installing Fuel Injector Sleeve

5. Figure 4.69 shows a cutaway with the fuel injector sleeve installed into the fuel injector bore. Note
areas where injector sleeve lands contact cylinder head.
CYLINDER HEAD REMOVAL

Perform the following steps when removing the cylinder head from the crankcase.

REMOVING CYLINDER HEAD

1. Remove remaining twenty (20) cylinder head bolts (short bolts) ( Figure 4.26 ).

2. Using a small pry bar, carefully pry the cylinder head loose from the gasket, so the cylinder head will lift off
easily (Figure 4.27 ).

NOTE: Only light force should be required on the pry bar to break the cylinder head loose from the
gasket.

3. Lift the cylinder head from the crankcase using appropriate lifting equipment ( Figure 4.28 ).

NOTE: Place the cylinder head on wood blocks to protect the valves and bottom deck surface.

4. Remove cylinder head gasket from crankcase ( Figure 4.28 ).

 Figure 4.26 Removing The Cylinder Head Mounting Bolts

Figure 4.27 Loosening The Cylinder Head And Gasket From

The Crankcase
Figure 4.28 Lifting The Cylinder Head
DRAINING THE SUPPLY MANIFOLD

NOTE: THE SUPPLY MANIFOLD OIL RAIL MUST BE DRAINED PRIOR TO REMOVING THE FUEL
INJECTORS TO PREVENT LEAKAGE INTO THE CYLINDER BORE.

Use the following steps to remove the supply manifold end plug.

DRAIN THE SUPPLY MANIFOLD

1. Drain the supply manifold by removing the supply manifold end plug from the supply manifold ( Figure 4.10 )

NOTE: Be sure to clean any and all old Loctite(r) found on the threads of the plug prior to installation.

2. Install a new O-Ring and back-up ring onto the end plug ( Figure 4.11 ).

3. Apply Loctite(r) #277 to the end plug threads and install into the supply manifold ( Figure 4.11 ). Tighten plug
to the special torque value ( Figure 4.12 ).
Figure 4.10 Removing Supply Manifold End Plug
 Figure 4.11 End Plug O-Ring And Back-Up Ring Locations
1. 1. End Plug
2. 2. Back-up Ring
3. 3. O-Ring
Figure 4.12 Installing Supply Manifold End Plug
FUEL INJECTOR INSTALLATION

INSTALL

1. If removed install shoulder bolt and tighten to the specified torque value ( Figure 4.91 ).

2. Lubricate fuel injector and insert injector assembly in bore of cylinder head.

NOTE: DO NOT STRIKE TOP OF FUEL INJECTOR TO SEAT IT! USE HAND PRESSURE, APPLIED TO
THE TOP OF THE FUEL INJECTOR, UNTIL HOLD DOWN CLAMP CAN BE ENGAGED UNDER THE HEAD
OF THE SHOULDER BOLT (FIGURE 4.92 ).

3. Seat the fuel injector into the fuel injector bore with the hold down clamp over the shoulder bolt. Use a 5/8
inch (16 mm) open end wrench on lower edge of hold down clamp to further insert fuel injector into bore of
cylinder head, until seated ( Figure 4.93 ).

Figure 4.91 Installing Shoulder Bolt

 Figure 4.92 Installing Fuel Injector
1. 1. Fuel Injector
2. 3. Shoulder Bolt
3. 2. Hold Down Clamp
 Figure 4.93 Securing Hold Down Clamp

4. Install fuel injector hold down clamp mounting bolt and tighten to the special torque value ( Figure 4.94 ).

CAUTION:

IT IS IMPERATIVE THAT INJECTOR HOLD DOWN CLAMP BOLT BE TIGHTENED TO THE

SPECIAL TORQUE VALUE.

5. Fuel Injectors With Plastic Clip Connector: Install the oil deflector and wiring harness channel to the fuel
injector. Secure with bolts ( Figure 4.95 ).

OR
 Figure 4.94 Tightening Hold Down Clamp Mounting Bolt
1. 1. Hold Down Clamp
2. 2. Fuel Injector

Figure 4.95 Installing Wiring Harness Channel And Oil

Deflector To Fuel Injectors With Plastic Clip Connectors
1. 1. Fuel Injector
2. 2. Oil Deflector
3. 3. Wiring Harness Channel
 Fuel Injectors With Wire Clip Connector: Install the wiring harness/oil deflector assembly ( Figure 4.96 ).

6. Install the bolts securing the wiring harness/oil deflector assembly to the fuel injector and tighten ( Figure
4.97 ).

7. Fuel Injectors With Plastic Clip Connector: Connect the six (6) fuel injector solenoids to the wiring
harness. Push the wiring harness clips up into the fuel injector solenoid. BE SURE the clips lock onto the tabs
of the fuel injector solenoid.

OR

Fuel Injectors With Wire Clip Connector: Push the wiring harness connector into the fuel injector solenoid
connector ( Figure 4.6 ).

Figure 4.96 Installing Wiring Channel/Oil Deflector Assembly

To Fuel Injectors With Wire Clip Connectors
 Figure 4.97 Securing Wiring Channel/Oil Deflector Assembly

Figure 4.98 Installing Wiring Harness To Fuel Injector

Solenoid

8. Fuel Injectors With Wire Clip Connector: Push the six (6) fuel injector solenoid connector wire clips onto
the fuel injector solenoids ( Figure 4.99 ).

NOTE: If it was necessary to remove the supply manifold from the cylinder head, refer to Section 12,
"High Pressure Lube Oil System" for proper maintenance and installation procedures.
FUEL INJECTOR REMOVAL

Perform the following steps when removing the fuel injector from the cylinder head.

REMOVING FUEL INJECTORS

1. Remove all fuel injector hold down clamp mounting bolts, located at the front of the fuel injector ( Figure
4.19 ).

NOTE: Shoulder bolt at the rear of the fuel injector DOES NOT require removal.

2. Disengage fuel injector hold down clamp from shoulder bolt by sliding clamp toward rear of engine, then, up
and over head of shoulder bolt ( Figure 4.20 ).

3. Remove fuel injector from cylinder head bore. Either use fuel injector Removal Tool ZTSE4300 or a pry bar.
Insert pry bar under hold down clamp and pry up ( Figure 4.21 ).

NOTE: BE SURE THE CLAMP IS FREE OF THE SHOULDER BOLT WHEN PRYING UP ON THE CLAMP
TO PREVENT DAMAGE TO THE BOLT.

4. Lift fuel injector straight up and out of injector bore of the cylinder head. O-Rings should be replaced
whenever the fuel injector is removed. If required, remove six (6) shoulder bolts.
Figure 4.19 Removing Fuel Injector Hold Down Bolt
 Figure 4.20 Fuel Injector Hold Down Clamp
1. 1. Hold Down Clamp
2. 2. Fuel Injector
 Figure 4.21 Removing Fuel Injector
1. 1. Fuel Injector
2. 2. Hold Down Clamp
FUEL INJECTOR WIRING HARNESS REMOVAL

Once the valve cover/intake manifold and gasket have been removed, identify the fuel injectors and solenoid
connectors ( Figure 4.3 ). Place the cylinder head magnetic intake shield ( 5, Figure 4.3 ) ( PS94-831-1 ) over
the intake ports of the cylinder head. This prevents any small loose parts from falling into the crankcase.

Figure 4.3 Fuel Injector And Cylinder Head Magnetic Intake

Shield Locations
1. 1. Fuel Injector
2. 2. Main Wiring Harness Connector
3. 3. Fuel Injector Solenoid Connector
4. 4. Wiring Harness Channel
5. 5. Cylinder Head Magnetic Intake Shield (PS94-831-1)

Remove the fuel injector wiring harness per the following steps.

NOTE:

Do not pull on wires or spread clips out to far as they may bend.
FUEL INJECTORS WITH PLACTIC CONNECTOR CLIP

1. Fuel Injectors With Plastic Connector Clip: Disconnect the six (6) fuel injector solenoids from the wiring
harness by undoing the clips and pushing down from the solenoid ( Figure 4.4 ).

OR

Fuel Injectors With Wire Connector Clip: Pull back on the six (6) fuel injector solenoid connector wire
clips ( Figure 4.5 ).

2. Pull down on the solenoid connector to remove the wiring harness from the fuel injector ( Figure 4.6 ).

Figure 4.4 Plastic Clip Connector Removal

 Figure 4.5 Wire Clip Connector Location
1. 1. Fuel Injector Solenoid Connector
2. 2. Fuel Injector Solenoid Connector Clip
 Figure 4.6 Wire Clip Connector Removal

3. Fuel Injectors With Plastic Clip Connector: Remove bolts securing the wiring harness channel and oil
deflectors to the fuel injector hold down clamps ( Figure 4.7 ). Remove oil deflectors and wiring harness
channel.

OR

Fuel Injectors With Wire Clip Connector: Remove bolts securing the wiring harness/oil deflector
assembly ( Figure 4.8 ).

4. Remove wiring harness/oil deflector assembly ( Figure 4.9 ).

 Figure 4.7 Wiring Harness Channel Removal On Engines
Equipped With Fuel Injectors With Plastic Clip Connectors
1. 1. Fuel Injector
2. 2. Oil Deflector
3. 3. Wiring Harness Channel
Figure 4.8 Wiring Harness Channel Removal On Engines
Equipped With Fuel Injectors With Wire Clip Connectors

Figure 4.9 Removing Wiring Harness

INSTALLING FUEL INJECTOR O-RINGS AND SEALS

Figure 4.84 shows the proper location of seals and O-Rings when installed onto the fuel injector. Refer to the
following instructions for the proper installation procedures.

NOTE: INJECTOR O-RINGS MUST BE LUBRICATED WITH CLEAN ENGINE OIL. WHEN INSTALLING O-
RINGS ONTO THE INJECTORS, BE SURE ALL O-RINGS AND SEALS ARE LOCATED TO THE TOP OF
THE O-RING GROOVES. THIS ACTION WILL PREVENT THE O-RINGS AND SEALS FROM TRYING TO
ROLL IN THEIR RESPECTIVE GROOVES DURING THE INSTALLATION PROCEDURE.

UPPER GROVE

Install the fuel injector O-Rings as follows:

1. Locate the upper groove seals.

2. Lightly lubricate each of the three seals with new clean engine oil.

3. Gently spread the gap in the back up ring.

NOTE: THE BACK UP RING ACTS LIKE A SPRING. CARE MUST BE TAKEN WHEN INSTALLING THIS
PART. DO NOT TWIST THE RING. RING FLATNESS IS IMPORTANT.

4. Slide the back up ring over the body of the fuel injector and into the upper groove ( Figure 4.85 ).
 Figure 4.84 Fuel Injector Seal/Ring Groove ID
1. 1. Back-Up Ring (steel)
2. 2. Upper Cushion Ring (black)
3. 3. Upper O-Ring (blue)
4. 4. Middle Seal (blue and black)
5. 5. Lower O-Ring (orange)
6. 6. Gasket (copper)
 Figure 4.85 Installing Fuel Injector Back-Up Ring
1. 1. Back-up Ring
2. 2. Fuel Injector

5. Slide the cushion ring over the body of the fuel injector. Push the cushion ring into the groove. Make sure the
cushion ring is up against the back up ring ( Figure 4.86 ).

NOTE: MAKE SURE THAT THE CUSHION RING DOES NOT TWIST DURING INSTALLATION.

6. Slide the O-Ring over the body of the fuel injector. Push the O-Ring into the groove. Make sure the O-Ring is
up against the cushion ring ( Figure 4.87 ).
 Figure 4.86 Upper Groove Back-up Ring and Cushion Ring
Installed
1. 1. Back-Up Ring
2. 2. Cushion Ring
3. 3. Fuel Injector
 Figure 4.87 Upper Groove Back-up Ring, Cushion Ring And
O-Ring Installed
1. 1. Back-Up Ring
2. 2. Cushion Ring
3. 3. O-Ring Seal
4. 4. Fuel Injector
MIDDLE GROOVE

Install the middle groove seal as follows ( Figure 4.88 ):

1. Locate the middle groove seal.

2. Lightly lubricate the seal with clean engine oil.

3. Slide the middle seal over the fuel injector and push into the middle groove. Make sure the middle fuel
injector seal is up against the groove.

NOTE: MAKE SURE THAT THE MIDDLE FUEL INJECTOR SEAL DOES NOT TWIST DURING
INSTALLATION.
LOWER GROOVE

1. Locate the lower groove seal.

2. Lightly lubricate the seal with clean engine oil.

3. Slide the lower fuel injector seal over the fuel injector body and into the lower groove. Make sure the lower
fuel injector seal is up against the groove ( Figure 4.89 ).

NOTE: MAKE SURE THAT THE LOWER FUEL INJECTOR SEAL DOES NOT TWIST DURING
INSTALLATION.

4. Apply a light coat of grease to a new copper gasket and place onto fuel injector ( Figure 4.90 ).

Figure 4.88 Middle Groove Seal Installed

1. 1. Seal
2. 2. Fuel Injector
 Figure 4.89 Lower Groove Seal Installed
1. 1. Seal
2. 2. Fuel Injector
 Figure 4.90 Copper Gasket Installed
1. 1. Copper Gasket
2. 2. Fuel Injector
INSTALLING THE PUSH ROD

Install the push rods with the cup end up as shown in Figure 4.77 .

NOTE: BE SURE TO MATCH THE PUSH RODS TO THE PROPER SLOTS AS NUMBERED DURING
DISASSEMBLY.
MISCELLANEOUS INSTALLATION

Complete the installation by attaching the following items. Refer to the appropriate sections for the proper
installation procedures.

Turbocharger oil supply tube

Turbocharger oil drain tube

Turbocharger

Road Draft Tube

Exhaust manifold

ECM and Mounting Bracket, if Equipped

Main Wiring Harness

Valve Cover/Intake Manifold

Fuel supply line to supply manifold from filter header

MISCELLANEOUS REMOVAL

Refer to the appropriate section of this publication for the removal procedures for the following items:

Turbocharger oil supply tube

Turbocharger oil drain tube

Turbocharger

Road draft tube

Exhaust manifold

ECM and Mounting Bracket, if equipped

Wiring harness

Valve cover/intake manifold

Fuel supply line to supply manifold from filter header

PUSH ROD REMOVAL

NOTE: NUMBER THE PUSH RODS SO THEY CAN BE MATCHED TO THE SAME LOCATION AT
INSTALLATION. THIS HELPS TO ELIMINATE PREMATURE WEAR OF THE PUSH ROD.

Remove all push rods ( Figure 4.25 ) from cylinder head.

Figure 4.25 Removing Push Rods

REMOVING FUEL INJECTOR O-RINGS AND SEALS

NOTE: O-RINGS SHOULD BE REPLACED EACH TIME THE FUEL INJECTOR IS REMOVED. IF ANY OF
THE FUEL INJECTORS HAVE DAMAGED O-RINGS, ALL OF THE FUEL INJECTORS SHOULD BE
REMOVED AND HAVE THERE O-RINGS REPLACED. CARE MUST BE TAKEN NOT TO SCRATCH THE
SEAL GROOVES ON THE FUEL INJECTOR BODY WHILE REMOVING THE SEALS.

REMOVAL PROCEDURE

Figure 4.83 shows the proper location of seals and O-Rings when installed onto the fuel injector. Using a non-
metallic tool, i.e.; plastic or wood, remove the old seals from the fuel injector as follows:

1. Remove the copper fuel injector gasket from the bottom of the fuel injector.

2. Lift the lower O-Ring out of its groove with a wooden or plastic tool. Cut the seal and remove it.

3. Lift the middle seal out of its groove with a wooden or plastic tool. Cut the seal and remove it.

4. Lift the upper O-Ring out of its groove with a wooden or plastic tool. Cut the seal and remove it.

5. Lift the upper cushion ring out of its groove with a wooden or plastic tool. Cut the ring and remove it.

6. Lift one corner of the back up ring from its groove, slide the rest of the back up ring from its groove and over
the tip of the fuel injector.

7. Make sure that the fuel injector is clean and free of debris. Place the fuel injector into holder rack ZTSE4299
where it will be protected from debris and damage.
 Figure 4.83 Fuel Injector Seal/Ring Groove ID
1. 1. Back-Up Ring (steel)
2. 2. Upper Cushion Ring (black)
3. 3. Upper O-Ring (blue)
4. 4. Middle Seal (blue and black)
5. 5. Lower O-Ring (orange)
6. 6. Gasket (copper)
INSTALL

1. Install the fuel supply line and connect it from the fuel filter header to the supply manifold. Tighten fittings to
the special torque value.

Engines Equipped With Old Three-Way Fitting

1. Install the supply oil hose ( 3, Figure 4.100 ) to the three-way fitting and high pressure pump ( 1,
Figure 4.100 ). Tighten the nuts ( 2, Figure 4.100 ) to the special torque value.

OR

Figure 4.99 Securing Solenoid Connector With Wire Clip

 1. 1. Fuel Injector Solenoid Connector
2. 2. Fuel Injector Solenoid Connector Clip

Figure 4.100 Installing Oil Supply Hose To Engines Equipped

With The Old Three-Way Fitting
1. 1. High Pressure Pump
2. 2. Oil Supply Hose Mounting Nuts
3. 3. Oil Supply Hose

Engines Equipped With New Three-Way Fitting

1. Install the oil supply hose ( 2, Figure 4.101 ) to the three-way fitting and the high pressure pump ( 3,
Figure 4.101 ). Tighten the nuts ( 1, Figure 4.101 ) to the special torque value.

OR
Engines Equipped With Engine Mounted ECM Unit

1. Install the oil supply hose ( 2, Figure 4.102 ) to the three-way fitting and the high pressure pump ( 3,
Figure 4.102 ). Tighten the nuts ( 1, Figure 4.102 ) to the special torque value.

Figure 4.101 Installing Oil Supply Hose To Engines Equipped

With The New Three-Way Fitting
1. 1. Oil Supply Hose Mounting Nuts
2. 2. Oil Supply Hose
3. 3. High Oil Pressure Pump
Figure 4.102 Installing Oil Supply Hose To Engines Equipped
With Engine Mounted ECM Unit
1. 1. Oil Supply Hose Mounting Nuts
2. 2. Oil Supply Hose
3. 3. High Oil Pressure Pump
REMOVING

Engines Equipped With Old Three-Way Fitting

NOTE: Be sure to clean any and all old Loctite(r) found on the threads of the sensor prior to
installation.

1. Apply Loctite #277 to the threads of the ICP sensor.

2. Install ICP sensor, together with O-Ring, to the three-way fitting of the supply manifold ( Figure
4.103 ).

Engines Equipped With New Three-Way Fitting

NOTE: Be sure to clean any and all old Loctite(r) found on the threads of the sensor prior to
installation.

1. Apply Loctite #277 to the threads of the ICP sensor.

2. Install the ICP sensor, together with O-Ring, to the three-way fitting of the supply manifold ( Figure
4.104 ).

Engines Equipped With Engine Mounted ECM Unit

NOTE: Be sure to clean any and all old Loctite(r) found on the threads of the sensor prior to
installation.

1. Apply Loctite #277 to the threads of the ICP sensor.

2. Install the ICP sensor, together with O-Ring, to the supply manifold ( Figure 4.105 ).
Figure 4.103 Installing ICP Sensor To Old Three-Way Fitting
Figure 4.104 Installing ICP Sensor To New Three-Way Fitting

Figure 4.105 Installing ICP Sensor To Supply Manifold On

Engines Equipped With Engine Mounted ECM Unit
REMOVAL

Perform the following steps when removing the three-way fitting.

Engines Equipped With Old Three-Way Fitting

Loosen the nuts ( 2, Figure 4.13 ) and disconnect high pressure oil supply hose ( 3, Figure 4.13 ) from
the three-way fitting and the high pressure pump ( 1, Figure 4.13 ).

OR

Engines Equipped With New Three-Way Fitting

Loosen the nuts ( 1, Figure 4.14 ) and disconnect high pressure oil supply hose ( 2, Figure 4.14 ) from
the three-way fitting and the high pressure pump ( 3, Figure 4.14 ).

OR
 Figure 4.13 Supply Manifold Disconnect Points For Engines
Equipped With Old Three-Way Fitting
1. 1. High Pressure Pump
2. 2. Oil Supply Line Mounting Nuts
3. 3. Oil Supply Line
 Figure 4.14 Supply Manifold Disconnect Points For Engines
Equipped With New Three-Way Fitting
1. 1. Oil Supply Line Mounting Nuts
2. 2. Oil Supply Line
3. 3. High Oil Pressure Pump

Engines Equipped With Engine Mounted ECM Unit

Loosen the nuts ( 1, Figure 4.15 ) and disconnect high pressure oil supply hose ( 2, Figure 4.15 ) from
the three-way fitting and the high pressure pump ( 3, Figure 4.15 ).

If not already done, disconnect the fuel supply line from the fuel filter header to the supply manifold.

NOTE: If it is necessary to remove the supply manifold from the cylinder head, refer to Section 12,
"High Pressure Lube Oil System" for proper removal, maintenance and installation procedures.
SENSOR REMOVAL

Use the following steps when removing the Injection Control Pressure (ICP) sensor.

Engines Equipped With Old Three-Way Fitting

Remove ICP sensor, together with O-Ring, from the three-way fitting of the supply manifold ( Figure
4.16 ).

NOTE: Be sure to clean any and all old Loctite(r) found on the threads of the sensor prior to
installation.

Figure 4.15 Supply Manifold Disconnect Points For Engines

 Equipped With Engine Mounted ECM Unit & New Three-Way
Fitting
1. 1. Oil Supply Line Mounting Nuts
2. 2. Oil Supply Line
3. 3. High Oil Pressure Pump

Figure 4.16 Removing ICP Sensor From Old Three-Way

Fitting

Engines Equipped With New Three-Way Fitting

 Remove ICP sensor, together with O-Ring, from the three-way fitting of the supply manifold ( Figure
4.17 ).

NOTE: Be sure to clean any and all old Loctite(r) found on the threads of the sensor prior to
installation.

Engines Equipped With Engine Mounted ECM Unit

Remove ICP sensor, together with O-Ring, from the supply manifold ( Figure 4.18 ).

NOTE: Be sure to clean any and all old Loctite(r) found on the threads of the sensor prior to
installation.

Figure 4.17 Removing ICP Sensor From New Three-Way

Fitting

=
Figure 4.18 Removing ICP Sensor From Supply Manifold On
Engines Equipped With Engine Mounted ECM Unit
VALVE LEVER INSTALLATION

INTALL

1. Install valve lever (rocker arm) assembly onto the cylinder head using six (6) cylinder head mounting bolts as
follows:

a. Insert the rocker arm and shaft assembly with the long cylinder head bolts into their respective bolt holes.
Refer to Figure 4.78 .

b. Run the long cylinder head bolts in fingertight (except the two end bolts). Place a 0.013 mm (0.005 in.)
feeler gauge between the outside brackets and the rocker levers to prevent binding. Finger-tighten the
remaining two end bolts ( Figure 4.79 ).

2. Tighten the cylinder head bolts in three stages as specified under special torque values.

NOTE: Check the two end rocker arms for freedom of movement after tightening the cylinder head
bolts.

3. Remove the two (2) 0.013mm (0.005 in.) feeler gauges.

Figure 4.77 Installing Push Rods
 Figure 4.78 Installing Valve Lever Assembly

Figure 4.79 Installing Valve Lever Assembly Mounting Bolts

4. Adjust valve lash as follows:

NOTE: All valves are adjusted by rotating the engine only twice.

a. Rotate the crankshaft until the #1 piston is on the compression stroke and the timing arrow on the front
cover is in line with the TDC mark on the vibration damper.

NOTE: Confirm that the #1 piston is on the compression stroke by turning both push rods by hand to
verify that both valves are closed. The valves are closed when the push rods are loose and can be
turned easily.

b. Set valve lash by loosening the lock nut and turning the valve adjustment screw with the appropriate size
feeler gauge inserted between the rocker arm and valve stem tip. Tighten the valve adjustment screw until
the valve lever can support the feeler gauge. Refer to Figure 4.80 and " SPECIFICATIONS " for valve lash.

c. Tighten the lock nut once the valve adjustment is set. Remove the feeler gauge. Refer to Figure 4.81 .

Figure 4.80 Setting Valve Lash

Figure 4.81 Tightening Valve Lever Lock Nut
VALVE LASH ADJUSTMENT

Six valves are adjusted when the #1 piston is at TDC (compression) and the remaining six are adjusted when
the #6 piston is at TDC (compression). Refer to Figure 4.82 .

Figure 4.82 Valve Lash Adjustment Valve Lever Positions

VALVE LEVER REMOVAL

Use the following steps when removing the valve lever assembly from the engine.

REMOVING VALVE LEVER

1. Loosen twelve (12) valve lever adjusting screw nuts ( Figure 4.22 ).

2. Loosen twelve (12) adjusting screws ( Figure 4.22 ) one (1) full turn.

NOTE: Loosening valve lever adjusting screws one (1) full turn will avoid possible valve train damage
during installation procedure.

3. Remove six (6) (long bolts) valve bracket bolt ( Figure 4.23 ).

NOTE: Shoulder bolt at the rear of the fuel injector DOES NOT require removal.
Figure 4.22 Loosening Valve Lever Adjusting Screw
 Figure 4.23 Removing Valve Lever Assembly Mounting Bolts

4. Remove valve lever assembly from cylinder head ( Figure 4.24 ) .

Figure 4.24 Removing Valve Lever Assembly