Inspection
1. On engines with high mileage, or which have not been regularly serviced (especially oil change), there is a possibility that the valve lifters are dirty inside. At best, this can result in increased noise and wear. To reduce the possibility of problems during engine operation, it is recommended to disassemble and clean the hydraulic tappets each time the cylinder head is rebuilt. Please note that pushrod replacement parts are not available and if any of the components are unserviceable, the complete assembly must be replaced (see illustration).
2. After removing and disassembling the cylinder head as described in Chapters 21 and 23, first inspect the tappet seats in the head. If there is excessive wear, the head must be replaced. Also check that the lubrication holes of the tappets in the head are not clogged.
3. Starting with tappet #1, carefully remove the bearing from the top of the tappet cylinder. It can be removed by hand, then be careful not to distort the bearing.
4. Remove the plunger from the cylinder and remove the spring.
5. Using a small screwdriver, carefully remove the cap from the plunger base. Remove the spring and ball from under the cover, do not lose them.
6. Gently clean all components with kerosene or thinner, paying special attention to machined cylinder surfaces (inside), and piston (outside). Dry all components thoroughly (lint-free) cloth. Carefully inspect the springs for damage or deformation. If the springs are in poor condition, the pusher must be replaced.
7. Lubricate the components with clean engine oil, then assemble the tappets as follows.
8. Turn the plunger over and insert the ball into the hole in the base of the plunger (see illustration).
9. Install the smaller spring in the seat in the plug cap, then carefully install the cap with the spring. At the same time, make sure that the spring rests on the ball. Gently crimp around the perimeter of the bonnet flange, using a small screwdriver if necessary, until the flange is securely seated in the groove in the base of the plug (see illustrations).
10. Install the big spring (properly oriented) in the plunger cap, insert the plunger-spring assembly into the cylinder (see illustrations).
11. Slide the bearing onto the top of the plunger, gently squeeze the plunger with your hands until the bearing is securely seated in the cylinder groove (see illustration).
12. Repeat the above procedure with the remaining valve lifters.
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