638
Platinum Member
Tools needed
10mm deep wall socket for glow plugs
7mm socket for glow plug wiring
10mm boxed end wrench
screwdriver
Number 16 drill bit
.006 feeler gauge (GO)
.007 feeler gauge (NO GO)
Using compressed air, blow dirt and debris from around the glow plugs, and remove the valve cover.
Remove the glow plugs with the 10mm deep socket. Once they are unscrewed you will have to pull them out of the head. They will be very hard to pull as they are bound up with carbon. Pull straight up with a twisting motion, they will come out. Using the number 16 drill bit clean the carbon from the glow plug holes in the head.
Turn the crank shaft until 1TC on the flywheel is aligned with the indicator on the left side of the engine and #1 cylinder is on the compression stroke. (I applied a small dab of white paint on the 1TC mark to make it easier to see.)
At this time you can set both of the #1 cylinder valve clearances, #2 cylinder intake valve, and #3 cylinder exhaust valve. Number one cylinder being on the flywheel end of the engine.
Next rotate the crank shaft one revolution and reset the 1TC mark to the indicator. Now you can set the clearances on #2 intake and #3 exhaust valves. Replace the glow plugs using never seize on the threads and replace the valve cover. The intake valves are the forward valves and the exhaust valves are the reward ones. Per the service manual "the engine must be cold". I hope this helps those without the shop manual to do their 800 hr service.
10mm deep wall socket for glow plugs
7mm socket for glow plug wiring
10mm boxed end wrench
screwdriver
Number 16 drill bit
.006 feeler gauge (GO)
.007 feeler gauge (NO GO)
Using compressed air, blow dirt and debris from around the glow plugs, and remove the valve cover.
Remove the glow plugs with the 10mm deep socket. Once they are unscrewed you will have to pull them out of the head. They will be very hard to pull as they are bound up with carbon. Pull straight up with a twisting motion, they will come out. Using the number 16 drill bit clean the carbon from the glow plug holes in the head.
Turn the crank shaft until 1TC on the flywheel is aligned with the indicator on the left side of the engine and #1 cylinder is on the compression stroke. (I applied a small dab of white paint on the 1TC mark to make it easier to see.)
At this time you can set both of the #1 cylinder valve clearances, #2 cylinder intake valve, and #3 cylinder exhaust valve. Number one cylinder being on the flywheel end of the engine.
Next rotate the crank shaft one revolution and reset the 1TC mark to the indicator. Now you can set the clearances on #2 intake and #3 exhaust valves. Replace the glow plugs using never seize on the threads and replace the valve cover. The intake valves are the forward valves and the exhaust valves are the reward ones. Per the service manual "the engine must be cold". I hope this helps those without the shop manual to do their 800 hr service.