ENGINE SHOP REBUILD & SERVICE PARTS MANUAL - Jacobsen

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<strong>ENGINE</strong> 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
<strong>ENGINE</strong> REASSEMBLY Install the Rocker Cover (See Fig. E-8 “Rocker Cover” on page D-13) A. Install a new rocker cover gasket (ITEM 2) in the cover. Match the shape of the gasket to the shape of the cover for proper orientation. B. Match the shape of the rocker cover (ITEM 1) to the shape of the mounting surface for proper orientation, and position the cover on the cylinder head. Make certain that the six (6) spacers sleeves (ITEM 4) are installed in rocker cover. (DETAIL A) C. Using a 10mm socket, install and tighten six (6) bolts (ITEM 3, M6x1.0x23L) to specified torque in two stages, in the order shown. Install the Carburetor (See Fig. E-9 “Carburetor” on page D-14) A. Install the gasket (ITEM 2), plastic insulator (ITEM 3), and gasket (ITEM 4) on the carburetor mounting studs. B. Place the carburetor on the mounting studs with the choke side out. C. Insert one carburetor vent hose (ITEM 5) through the hole in the PCV cover plate. Be certain that it is not crimped or blocked in any way. D. Install new gasket (ITEM 6) and the air cleaner/carburetor seal plate (ITEM 7). Engine Shop Rebuild and Parts Manual Page E-5
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19 13 17 9 11 16 15 7 18 3 4 6 5 8
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NOTES TO OBTAIN A COPY OF THE LIMIT
Page 6 and 7:
TABLE OF CONTENTS Section Page No.
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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
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ENGINE DISASSEMBLY D. Remove the ti
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14 13 18 15 16 17 20 21 19 22 25 27
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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 46 and 47: ENGINE MEASUREMENTS Notes: Page C-1
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 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 112: LIMITED WARRANTY - CALIFORNIA (2004
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ENGINE SHOP REBUILD & SERVICE PARTS MANUAL - Jacobsen

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