ENGINE SHOP REBUILD & SERVICE PARTS MANUAL - Jacobsen

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<strong>ENGINE</strong> MEASUREMENTS Notes: Page C-14 Engine Shop Rebuild and Parts Manual
<strong>ENGINE</strong> REASSEMBLY TABLE OF CONTENTS FOR SECTION ‘D’ SECTION TITLE D PAGE NO. CRANKCASE ASSEMBLY.............................................................................................................. D - 1 Hone the Crankcase Cylinder Bore ...................................................................................... D - 1 Reassemble the Pistons and Connecting Rods ................................................................... D - 1 Install the Piston Rings ......................................................................................................... D - 2 Reassemble the Crankcase End Cover ............................................................................... D - 2 Install New Crankcase Bearing ............................................................................................ D - 2 Install New Crankshaft Bearing ............................................................................................ D - 3 Install New Crankshaft Seal ................................................................................................. D - 3 Install Crankshaft into Crankcase......................................................................................... D - 3 Install the Pistons in the Crankcase ..................................................................................... D - 3 Install the Balancer Shaft...................................................................................................... D - 3 Set the Crankshaft and Balancer Shaft Endplay .................................................................. D - 3 Install Crankshaft Endplay Spacer and Balancer Endplay Spacer....................................... D - 4 Install Alignment Dowel Pins ................................................................................................ D - 4 Install New Oil Feed O-Ring ................................................................................................. D - 4 Install Crankcase End Cover Gasket.................................................................................... D - 4 Install the Crankcase End Cover .......................................................................................... D - 4 Install the Oil Pump Gear Rotors.......................................................................................... D - 4 Install the Oil Pressure Switch.............................................................................................. D - 4 Install the Pulser Coil............................................................................................................ D - 4 Install the Fan Hub ............................................................................................................... D - 4 Set the Pulser Coil Air Gap................................................................................................... D - 5 Install the PVC Valve............................................................................................................ D - 5 Install the Oil Filter................................................................................................................ D - 5 LIST OF ILLUSTRATIONS Fig. D-1 Crankcase Cylinder .......................................................................................................... D - 6 Fig. D-2 Piston and Connecting Rods ............................................................................................ D - 7 Fig. D-3 Pistons and Connecting Rods con’t.................................................................................. D - 8 Fig. D-4 Crankcase End Cover, PCV Valve and Oil Filter.............................................................. D - 9 Fig. D-5 Crankshaft, Pistons and Balancer Shaft......................................................................... D - 10 Fig. D-6 Crankshaft, Pistons and Balancer Shaft con’t ................................................................ D - 11 Fig. D-7 Crankshaft and Balancer Shaft Endplay......................................................................... D - 12 Fig. D-8 Oil Pump Gear Rotors, Oil Pressure Switch, Pulser Coil and Fan Hub.......................... D - 13 Fig. D-9 Oil Pump Gear Rotors, Oil Pressure Switch, Pulser Coil and Fan Hub con’t ................. D - 14 Fig. D-10 Pulser Coil Air Gap ....................................................................................................... D - 15 Engine Shop Rebuild and Parts Manual Page D-i
Page 1: 19 13 17 9 11 16 15 7 18 3 4 6 5 8
Page 4 and 5: NOTES TO OBTAIN A COPY OF THE LIMIT
Page 6 and 7: TABLE OF CONTENTS Section Page No.
Page 8 and 9: TABLE OF CONTENTS Notes: Page vi En
Page 10 and 11: HOW TO USE THIS MANUAL viii Engine
Page 12 and 13: ENGINE DISASSEMBLY Notes: Page A-ii
Page 14 and 15: ENGINE DISASSEMBLY D. Remove the ti
Page 16 and 17: 14 13 18 15 16 17 20 21 19 22 25 27
Page 18 and 19: ENGINE DISASSEMBLY A 2 6 3 Push spr
Page 20 and 21: ENGINE DISASSEMBLY Notes: Page B-ii
Page 22 and 23: ENGINE DISASSEMBLY Remove the Crank
Page 24 and 25: ENGINE DISASSEMBLY 1 3 2 Crankcase
Page 26 and 27: ENGINE DISASSEMBLY 1 5 4 6 3 2 A Se
Page 28 and 29: ENGINE DISASSEMBLY A 1 2 4 5 6 8 3
Page 30 and 31: ENGINE DISASSEMBLY Notes: Page B-10
Page 32 and 33: ENGINE MEASUREMENTS Notes: Page C-i
Page 34 and 35: ENGINE MEASUREMENTS F. Turn the cyl
Page 36 and 37: ENGINE MEASUREMENTS Measure each po
Page 38 and 39: 0 ENGINE MEASUREMENTS C 10 20 30 40
Page 40 and 41: ENGINE MEASUREMENTS Cylinder head C
Page 42 and 43: 0 50 0 50 ENGINE MEASUREMENTS Valve
Page 44 and 45: ENGINE MEASUREMENTS 1" Recommended
Page 48 and 49: ENGINE REASSEMBLY Notes: Page D-ii
Page 50 and 51: ENGINE REASSEMBLY A. Apply a coat o
Page 52 and 53: ENGINE REASSEMBLY C. Using a depth
Page 54 and 55: ENGINE REASSEMBLY An electric drill
Page 56 and 57: ENGINE REASSEMBLY C 120 o Compressi
Page 58 and 59: ENGINE REASSEMBLY 14 12 8 2 13 4 7
Page 60 and 61: ENGINE REASSEMBLY Make sure the gea
Page 62 and 63: ENGINE REASSEMBLY A Follow numbers
Page 64 and 65: ENGINE REASSEMBLY Notes: Page D-16
Page 66 and 67: ENGINE REASSEMBLY Notes: Page E-ii
Page 68 and 69: ENGINE REASSEMBLY Install New Valve
Page 70 and 71: ENGINE REASSEMBLY Install the Front
Page 72 and 73: ENGINE REASSEMBLY A 8 7 6 1 3 2 5 B
Page 74 and 75: ENGINE REASSEMBLY 7 17 10 12 9 8 13
Page 76 and 77: ENGINE REASSEMBLY 29 31 27 28 25 23
Page 78 and 79: ENGINE REASSEMBLY B 3 2 1 4 Follow
Page 80 and 81: ENGINE REASSEMBLY 7 6 1 4 3 2 5 Fig
Page 82 and 83: ENGINE Illustrated Parts Breakdown
Page 96 and 97:
LIMITED WARRANTY Notes: Page G-ii E
Page 98 and 99:
LIMITED WARRANTY - FEDERAL deny war
Page 100 and 101:
LIMITED WARRANTY - FEDERAL (2001) Y
Page 102 and 103:
LIMITED WARRANTY - CALIFORNIA (1995
Page 104 and 105:
Page 106 and 107:
Page 108 and 109:
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Page 112:
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ENGINE SHOP REBUILD & SERVICE PARTS MANUAL - Jacobsen

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