ENGINE SHOP REBUILD & SERVICE PARTS MANUAL - Jacobsen

ENGINE REASSEMBLY
CYLINDER HEAD ASSEMBLY
Tool List
Qty. Required
Compressor, piston ring .............................................. 1
Drill, electric ................................................................ 1
Gauge, feeler
(E-Z-GO P/N 72525-G01) ........................................... 1
Gauge, wire spark plug ............................................... 1
Valve seat cutter
(E-Z-GO P/N 72516-G01) ........................................... 1
Installer, piston ring
(E-Z-GO P/N 72521-G01) ........................................... 1
Grinder, valve, cup type
(E-Z-GO P/N 72522-G01) ........................................... 1
Compound, 4 oz. valve grinding
(E-Z-GO P/N 72523-G01) ........................................ AR
Extension, 3/8” drive, 4" .............................................. 1
Extension, 3/8” drive, 6" .............................................. 1
Mallet, Medium wood or rubber .................................. 1
Cam pulley alignment tool
(E-Z-GO P/N 26850-G01) ........................................... 1
Punch, nonferrous....................................................... 1
Ratchet, 3/8” drive....................................................... 1
Screwdriver, small flat blade ....................................... 1
Screwdriver, medium flat blade................................... 1
Screwdriver, #2 phillips ............................................... 1
Screwdriver, #3 phillips ............................................... 1
Socket, 8 mm, 3/8” drive ............................................. 1
Socket, 10 mm, 3/8” drive ........................................... 1
Socket, 12 mm, 3/8” drive ........................................... 1
Socket, oil pressure switch ......................................... 1
Socket, 13/16” spark plug, 3/8” drive .......................... 1
Wrench, 7 mm combination ........................................ 1
Wrench, 10 mm combination ...................................... 1
Wrench 12 mm combination ....................................... 1
Wrench, torque, Inch and Ft. Lbs............................... 1
Install Valve Guides
(See Fig. E-1 “Valves and Valve Clearance” on page D-6)
E
A. If the valve guides (ITEM 1) were removed from the
cylinder head (ITEM 2), use a mechanical press to
install new over size valves guides. [If valve guides
are replaced, valve seats must be resurfaced. (See
Valve Guides and Seats in section C]). (DETAIL A)
Cutting Valve Seats
A. Using the E-Z-GO valve seat cutter, insert the reamer
pilot tool in the valve guide and rotate in a clockwise
direction only using firm consistent pressure.
B. Remove no more material than is necessary to clean
the valve seat.
C. Refer to additional instructions included with cutter.
Lap the Valves
(See Fig. E-1 “Valves and Valve Clearance” on page D-6)
(See Fig. E-2 “Valves con’t” on page D-7)
A. Turn the cylinder head upside down.
B. Lightly lubricate the stem of one of the intake valves
(ITEM 4) with engine oil and insert it into one of the
middle (intake) valve guides. The heads of the intake
valves are larger in diameter than the heads of the
exhaust valves (ITEM 5). (If the original valves are
used, place them in the guides from which they
came.)
C. Moisten the suction cup on the valve lapping tool and
attach it to the valve.
D. Apply a small amount of valve grinding compound
evenly around the valve seat.
E. Grind the valve face against the seat by applying
slight downward pressure on the lapping tool and
rotating it back and forth between the palms of your
hands five or six times. Lift the tool, turn it about 90°
and repeat until both the valve and seat show even
polished contact surfaces of. 040 to .050 wide.
F. Repeat this process for each of the valves.
G. Thoroughly clean the valves and the cylinder head to
remove all of the lapping compound.
H. Test the valve seat seal by installing the springs and
keys. Stand the cylinder head on the exhaust port
and pour a few ounces of clean solvent into the
intake ports. Check the valve seats for any sign of
wetness. If solvent seeps out, repeat the lapping process
and retest. Pour out solvent, turn over, and
repeat for the exhaust valves.
Engine Shop Rebuild and Parts Manual
Page E-1