ENGINE SHOP REBUILD & SERVICE PARTS MANUAL - Jacobsen

ENGINE REASSEMBLY
Install the Front Timing Belt Cover
(See Fig. E-5 “Timing Belt Covers, Drive and Cam Pulleys, Idler and
Timing Belt” on page D-10)
A. Hold the cover (ITEM 17) in place and install three (3)
bolts (ITEM 18, M6x1.0x12L, 10mm socket). Tighten
the bolts to specified torque.
Install the Front Cylinder Baffle
(See Fig. E-5 “Timing Belt Covers, Drive and Cam Pulleys, Idler and
Timing Belt” on page D-10)
A. Hold the baffle (ITEM 19) in place and install and
tighten two (2) bolts (ITEM 20, M6x1.0x8L, 10mm
socket) to specified torque.
Install the Rear Cylinder Baffle
(See Fig. E-5 “Timing Belt Covers, Drive and Cam Pulleys, Idler and
Timing Belt” on page D-10)
A. Hold the baffle (ITEM 21) in place and install and
tighten four (4) bolts (ITEM 22, M6x1.0x8L, 10mm
socket) to specified torque. (Later models have five
(5) bolts)
Install the Exhaust Manifold and Gasket
(See Fig. E-5 “Timing Belt Covers, Drive and Cam Pulleys, Idler and
Timing Belt” on page D-10)
(See Fig. E-7 “Timing Belt Covers, Drive and Cam Pulleys, Idler and
Timing Belt con’t” on page D-12)
(Later models have exhaust manifold as part of head)
Some early model engines were assembled
with two small gaskets. These have been
replaced with a one-piece gasket.
A. Insert four (4) bolts (ITEM 25, M8x1.25x50L, 12mm
socket) through the manifold and position the gasket
over the bolts.
B. Hold the manifold in place and start the bolts into the
cylinder head. Tighten the bolts to specified torque in
two stages, in the order shown. (DETAIL B)
Install the Blower Housing
(See Fig. E-5 “Timing Belt Covers, Drive and Cam Pulleys, Idler and
Timing Belt” on page D-10)
(See Fig. E-7 “Timing Belt Covers, Drive and Cam Pulleys, Idler and
Timing Belt con’t” on page D-12)
A. Hold the housing in place and route the oil pressure
switch wire and pulser coil wire from behind the housing
through the groove as shown. (DETAIL C)
B. Install three (3) mounting bolts (ITEMS 27, 28, AND
29, M6x1.0x18L, 10mm socket). Do not tighten them
at this time.
Install the Coil Mounting Bracket and Coil
Assembly
(See Fig. E-5 “Timing Belt Covers, Drive and Cam Pulleys, Idler and
Timing Belt” on page D-10)
(Later models have a slightly different mounting)
A. Position the bracket (ITEM 30) on the mounting stud
as shown.
B. Install the bracket/blower housing mounting bolt
(ITEM 31, M6x1.0x23L, 10mm socket) and nut (ITEM
32, M6x10, 10mm socket).
C. Tighten the bolts (ITEMS 27,28,29, and 31) and nut
(ITEM 32) to specified torques.
Adjust the Valves
(See Fig. E-1 “Valves and Valve Clearance” on page D-6)
A. Rotate the camshaft so that the intake and exhaust
cam lobes for one cylinder are oriented downward
and the rocker arms rest on the heels of the lobes as
shown. (DETAIL B)
B. Adjust the exhaust valve clearance.
1. Insert a .004 feeler gauge between the cam lobe
heel and the rocker arm.
2. Using a medium flatblade screwdriver, turn the
adjusting screw until the feeler gauge slides
between the lobe heel and rocker arm with very
slight resistance.
3. Hold the adjusting screw at this position and
tighten the rocker arm locknut to specified torque
with a 10mm box end wrench.
4. Check the valve with the feeler gauge again, and
readjust if necessary.
C. Adjust the intake valve clearance the same as the
exhaust valve clearance.
D. Rotate the camshaft so that the cam lobes for the
second cylinder are oriented downward for adjustment.
E. Adjust the intake and exhaust valve clearances.
F. Recheck rocker arm locknut torque.
Install the Spark Plugs
(See Fig. E-5 “Timing Belt Covers, Drive and Cam Pulleys, Idler and
Timing Belt” on page D-10)
A. With a wire gauge, set the spark plug gaps at. 030
and install them in the engine. Tighten them to specified
torque.
B. Install the plug wires (ITEM 34) on the plugs.
Page E-4
Engine Shop Rebuild and Parts Manual