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Replacing
the
valve
seat
exhaust
port
2003T
Grind
down
the
valve
disc
of
a
discarded
valve
to just
below
27
mm
(1
.063
in)
diameter
.
Push
the
valve
stem
through
the
guide
.
NOTE!Do
not
push
in too
far-
the
valve
disc
should
be
just
below
the
edge
of the
seat
.
Spot
weld
the
disc
in
place
at
three points using
a
electric
welder
.
Knockout
the seat
by
hitting
the
valve
guide
with
a
plastic-headed
hammer
.
Cool
the
new
seat
to
approx
.
-20°C
(-4°F)
;
the
cylinder
head
should
beat
room
temperature
(+
20°0168°F)
.
Place
the
cooled
seat on
tool
884961-4
and
knock
it
down
until
it
bottoms.
NOTE!
Turn
the seat
with
the
valve
face
towards
the
tool
.
Valve
springs
5
.
Checkthe
free
length
of
the
valve
springs
and
the
length
when
loaded
.
L =
Length,
unloaded
42,5
mm
(1
.67323
in
.)
L
1 =
Length,
loaded
with
170±10N
(17±1
kp)
32
mm
(1
.25984
in
.)
L
2
=
Length,
loaded
with
300±20
N
(30±3
kp)
24
mm
(0
.94488
in
.)
Rocker
arm
mechanism
6
.
Disassemble
the
rocker
armmechanism
and
clean
the
parts
.
Check
the
wear
of
the
shaft
and
rockerarm
bush
i
ngs
.
Should
the
bushings
need
to
be
replaced,
usethe
mandrel
p/n
9991867
for the
removal
and
installation,
(make
sure
that
the
oil
hole
in
the
bushing
coincides
with
the
one
in
the
rocker
arm)
.
After
the
installation
the
bushings
are
reamed
to
a
close
running
fit
. When
installing
the rockerarm shaft,
it
must
be turned
so
that
the
lubrication
holes
are
facing
the
valve-side
.
Check
to
make
sure
that the
rocker
arm
contact
surface
againstthe
valve
is
concave
.
Minor
adjustments
are
made
in
a
valve
grinding
machine
.
Oil
the
shaft
and
install
the
parts
.
Pressure
testing
the
nozzles
7
.
Check
the
nozzle's
spray
pattern
at
the
correct
opening
pressure
(see
Technical
Data)
.
Check
also that the
fuel
sprays
stop
simultaneously
and
no
dripping
occurs
.
Adjust
the
opening-pressure
with
adjustment-washers
(1)
being
available
in
different
thicknesses
from
1
mm
U3937
in
.)
to 1,95
mm
(
.076772
in
.)
in
steps
of
0,05
mm
(
.001969
in
.)
.
Disassemble
the
injector
and
replace
the
adjustment-washer
againstathinneroneorathickeronedependingon
whether
the
pressure
must
be
reduced
or
increased
.
Assemble
the
injector
and
check
the
opening-pressure
and
the
spray-pattern
.
10


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