INSTALL CYLINDER HEAD (Refer to Figures 16, 17, 18 and 19.)
This procedure applies to either or both cylinder heads.
Torque Wrench, 50 ft. lb. capacity
Socket, Socket Wrench, Deep Well, 13 mm
Cylinder head assembled
Timing cover installed
Piston protrusion checked
Refer to Figure 16.
Clean each pushrod (1). Ensure lubrication passages in pushrods are clean and clear.
Measure overall length of pushrod (2). Using a depth micrometer, measure depth of pushrod cup (3). Subtract cup depth
from overall length. The result should be 6.362-6.386 in. (161.6-162.2 mm). If measurement is out of tolerance, replace
While holding cylinder in place, slowly turn engine crankshaft to position piston at Top Dead Center (TDC).
Clean carbon, dirt and other foreign material from piston surface. Remove any remaining gasket materials.
Refer to Figure 17.
Insert the same number of copper washers (1) in fuel injector port as were removed from cylinder head (2).
Temporarily secure fuel injector in cylinder head by installing injector (3), brace (4), flat washer (5) and nut (6) on stud
(7). Tighten nut.
Using a depth gauge (8), measure protrusion of fuel injector tip (9) into combustion chamber (10) of cylinder head.
Protrusion should be 0.069-0.088 in. (1.75-2.25 mm). If adjustment is required, remove the fuel injector and remove or
add new copper washer(s) (1) to adjust the tip protrusion.
Remove fuel injector (3), brace (4), flat washer (5) and nut (6) after protrusion check is completed.
Refer to Figure 18.
Install new O-rings (1) on the pushrod pipes (2) and insert pipes in crankcase. Insert pushrods (3) in same pipes they
were removed from.
10. Install new head gasket (4) on cylinder.
11. Install cylinder head (5) on cylinder. Ensure pushrods are aligned with rocker arms (6) and pushrod pipes are aligned
with cylinder head.
12. Install cylinder head nuts (7) and washers (8) finger tight, with lifting eye studnut in same location as observed during
Refer to Figure 19.
13. Place a straight edge (1) across intake and exhaust ports to align the cylinder heads. Use a 13 mm socket to snug the
cylinder head nuts (2).
14. Gradually torque the head nuts in an alternating diagonal pattern. to 15 ft. lbs. (21.8 Nm), then to 23 ft. lbs. (33.5 Nm)
and finally to 30 ft. lbs. (43.7 Nm).