Inspection

1. Thoroughlycleanthesurfaceofthecylinderheadand checkfordamageand/orpittingofthecombustionchambers.

2. Usingastraightedgeandfeelergauges,checkthecylinderheadgasketfaceforwarp,whichcouldleadtogasketfailure.Replacethecylinderheadifwarpedbeyondtheflatnesslimit.

Checkingheadflatness

Installation

1.Thoroughlycleantheupperfacesofthecrankcaseandliners.Alsocleanthelinertocrankcasematingfaces.

2. Fitthecylinderliners(seepage5.19).

3.Movethecamchainrubbingbladestoapositionthatallowstheheadtofitoverthem.

4.Ensurethatbothheaddowelsremaininpositioninthecrankcase.

1

'"""

1.Dowels

Cylinderheadflatness 0.030mmtolerance

3. Checkthecamchainrubbingblades.Renewifwornordamaged.

5. Positionanewcylinderheadgaskettothecrankcase.

6. Lowerthecylinderheadoverthecamchainrubbingbladesandlocateitontothedowels.

^3.16 ServiceManual-Rocket Ill

5. Intheordershownbelow,tightenthecylinderhead boltsinthree stagesasfollows:

Valvesand ValveStemSeals

Removalfromthecylinderhead

ci>ql

Cylinderheadbolttighteningsequence

1. Removeeach valvefrom theheadusingavalvespringcompressor.Thecompressormustactonthetopcuptoallowremovalofthevalvecollets.

Oncethecolletsarereleased,removethefollowingitems:

collels

valvespringcapvalvespringvalvestemseal

valvespringthrustwasher

5. Inthesequenceshownabove,tightenboltsthrough8to20Nm.

6. Inthesequenceshownabove,tightenbolts1through8to50Nm.

7. Inthesequenceshownabove,tightenbolts1through8throughafurther90°usingtoolT3880105orsimilartomeasurethetorque­angle.

8. Tightenbolts9and10to12Nm.

9. Lubricatethetappetbucketswitha50/50solutionofmolybdenumdisulphidegreaseandengineoil,thenrefitthemandthevalveshimstotheiroriginallocationsinthehead.

10. Refitthecamshafts(seepage3.12).

11. Checkandadjustthevalveclearances(seepage

3.14).

5. Reconnectthecoolanttemperaturesensor.

6. Refitthebypassandtophoses.

7. Refitthe oiltank(seepage9.16).

8. Refitthethrottlebodies(seepage11.123).

9. Refitthe exhaustsystem(seepage11.136).

10. Refillthecoolingsystem(seepage12.7).

11. Refitthe fueltank(seepage11.101).

12. Refitbothenginein-fillpanels,tighteningthefixingsto 4Nm.

13. Starttheengineandallowiitoidlewhilecheckingforair,oil,coolantandexhaustleaks.Rectifyasnecessary.

14. Checkandtopupthecoolingsystem(seepage

12.5).

5. Check andtopuptheoillevel(see page9.7).

Installation

1. Applyathincoatofmolybdenumdisulphidegreasetothevalvestem.

2. Installthevalveintothevalveguideandrefitthethrustwashertothevalvespringrecess(ifremoved).

3. Fitthevalvestemsealoverthevalvestemand,usingasuitabletool,pressdownfullyuntilthesealiscorrectlyseatedoverthevalveguide.

Note:

• Duringfitmentofthevalvestemseal,twodistinctlydifferentdegreesofresistancewillbenotedwhenthesealiscorrectlyfitted.

Firstly,pressthesealdownthevalvestemuntilthe lowersideofthesealcomesintocontactwiththevalveguide.Greaterresistanceisfeltatthiscontactpointandfurthergentlepressureisthenrequiredtolocatethesealoverthetopendofthevalveguide.

Onapplicationofthispressure,thesealcanbefelttopositivelylocateoverthetopfaceofthevalveguide.Oncecorrectlypositioned,thesealcannotbepusheddown anyfurther.

6. Installthevalvespring.

• ServiceManual-RocketIll

3.17

7. Compressthevalvespringensuringthatthespringiscompressedsquarelytopreventdamagetocomponents.

8. Fitthevalvecolletsensuring theircorrectlocationinthespringcapandvalveasthespringcompressorisreleased.

CamChain