4
12. If special tools are required, make arrangements to
get them before starting.
It IS frustrating and
time-consuming to start
ajob
and then be unable to com-
plete it.
13. Make diagrams (or take a Polaroid picture) wherever
similar-appearing parts are found. For instance, retaining
bolts for a particularpart may not be the same length.
It is
difficult 10remember where everything came from
-and
mistakes are costly. It is also possible that you may be
sidetracked and not return to work for days or even
weeks
-in
which time carefully laid out parts may be dis-
turbed.
14. When assembling parts, make sure all shims and
washers arc replaced exactly where they were before re-
moval.
15. Whenever a rotating part contacts a stationary part,
look for a shim or washer, Use new gaskets
if
there is any
doubt about the condition
of
the old ones. A thin coat
of
silicone sealant on non-pressure-type gaskets may help
them seal more effectively.
16. If it becomes necessary to purchase gasket material to
make a gasket for the engine, measure the thickness
of
the
old gasket (at an uncomprcsscd point) and purchase gas-
ket material with the same approximate thickness.
17. Use heavy grease to hold small parts in place
if
they
tend to fall out during assembly. However, keep grease
and oil away from electrical components.
18. Take time and do the job right. Do not forget that a
newly rebuilt engine must be broken in just like a new
one.
CHAPTER
ONE
PARTS REPLACEI\I ENT
Engine manufacturers often modify the parts
of
an en-
gine during the lifetime
ofthe
engine model. When order-
ing parts from the dealer or other parts distributor, always
order by the model and engine serial number. Refer to
Chapter Six or Seven. Write the numbers down and have
them available. Compare new parts to old
before purchas -
ing them. If they arc not alike, have the parts manager ex-
plain the difference. Table I lists model numbers.
TORQUE
SPECI
FICA
TIO;'lJ
S
Torque specifications throughout this manual are given
in Newton- meters (Nom) and foot-pounds (ft.-lb.).
Table 3 lists general torque specifications for nuts and
bolts that arc not listed in the respecti ve chapters. To usc
the table, first determine the size
ofthe
nut or bolt by mea-
suring it with a vernier caliper. Figure 4 and Figure 5
show how to do this.
FASTENERS
The materials and designs
of
the various fasteners used
on the engine are not arrived at by chance oraccident. Fas-
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