Section I. GENERAL MAINTENANCE INSTRUCTIONS 3-1. OVERVIEW
Step 8 does not apply to No. 2 cylinder head
8. Two screws (26), cover plate Remove from cylinder head (9). Discard preformed packings (24).
(25), and two preformed packings (24)
9. Four pipe plugs (27) Remove two from each end of No. 3 cylinder head has two pipe
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3-35. CYLINDER HEAD AND VALVE REPAIR (Contd)3-115
b. Cleaning
WARNING
Approved solvents may be flammable and will not be used near open flame. Use only in well-ventilated area. Failure to comply may result in injury to personnel.
11. Cylinder head assembly (1) a. Clean by submerging in Circulate solvent to increase
solvent SD-3. effectiveness on salt, lime
deposits, and grease, etc.
b. Clean internal passages and Use fuel passage cleaning brush flush passages with solvent SD-3 (ST-876). Ensure lubricating oil
to remove deposits. passages are open and clean.
WARNING
Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use only with effective chip guarding and personal protective equipment goggles or shield, gloves, etc.
Failure to comply may result in injury to personnel.
c. Dry with compressed air.
12. All other parts Clean by submerging in solvent Refer to para. 3-6 for additional
SD-3 and dry with compressed cleaning instructions.
air.
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3-35. CYLINDER HEAD AND VALVE REPAIR (Contd)3-117
c. Inspection and Repair
CAUTION
Do not use disk sander to polish cylinder head. Disk sander could cause serious damage to mating surface of head.
13. Cylinder head (9) a. Polish mating surface. Use crocus cloth or orbital sander.
Polish just enough to shine finish.
This allows for a more complete inspection of mating surface.
b. Inspect for cracks, Discard cylinder head
breaks, distortion, and assembly (1) if cylinder
broken-out areas. head (9) is damaged.
c. Inspect for cracks using Discard cylinder head
magnetic method. assembly (1) if any cracks are
found.
d. Check for scratches or Use straightedge and feeler unevenness on mating surface. gauge. Perform steps 13e through
13i if mating surface is scratched or uneven more than 0.002 in.
(0.051 mm).
e. Resurface mating surface. Do not remove more than 0.005 in.
(0.127 mm) of material at one time. Total amount of material removed must not exceed 0.040 in.
(1.016 mm).
f. Inspect four valve inserts (12) Refer to steps 15a through 15e for and (15) for cracks, broken, or removal and installation. Discard chipped areas. Remove if damaged valve inserts (12) and
damaged. (15).
g. Polish mating surface. Use crocus cloth or orbital sander.
h. Measure cylinder head (9) Use suitable vernier depth gauge.
height. Discard cylinder head assembly
(1) if cylinder head is less than wear limit shown below:
Wear Limit ... 4.340 in. (11.024 cm) New Minimum ... 4.370 in. (11.100 cm) New Maximum ... 4.380 in. (11.125 cm)
i. Remove two injector sleeves (7) Refer to steps 18d and 18e.
from cylinder head (9).
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3-35. CYLINDER HEAD AND VALVE REPAIR (Contd)3-119
c. Inspection (Contd)
14. Eight valve stem guides (18) a. Inspect for chips, cracks, burrs, Replace if damaged (refer to step broken-out sections, and extensive 14d for replacement).
wear.
b. Measure protrusion. Use suitable micrometer. Replace if not within 1.270-1.280 in.
(3.226-3.251 cm). (Refer to step 14d for replacement.)
c. Set small bore gauge to Replace if gauge goes into bore or 0.4552 in. (11.562 mm) and if bore is more than wear limit attempt to insert it in bore of shown below. (Refer to step 14d
valve stem guide. for replacement.)
Wear Limit ... 0.4550 in. (11.557 mm) New Minimum ... 0.4525 in. (11.494 mm) New Maximum ... 0.4532 in. (11.511 mm)
d. Replace valve stem guide (18) Do not replace unless damaged
as follows: or not within wear limits.
(1) Drive out valve stem guide Use suitable step punch. Discard (18) from underside of cylinder valve stem guide.
head (9).
(2) Install new valve stem guide Use valve guide driver (3375282)
(18). (34). Ensure height of valve stem
guide is between 1.270-1.280 in.
(3.226-3.251 cm) after installation.
(3) Using new valve (13) or (14), If valve does not move freely in check bore of new valve stem valve stem guide (18), ream valve
guide. stem guide (18) from bottom side
of cylinder head (9) to specifica-tions shown in step 14c.
15. Four intake valve inserts a. Check for looseness by (12) and four exhaust valve carefully striking cylinder head
inserts (15) (9) with wood block or rubber
hammer.
b. Measure valve seat area Perform step 15d only if width is width (A or B in illustration). less than 0.0625 in. (1.5875 mm)
or more than 0.125 in. (3.175 mm) at any point.
c. Check valve seat for Total run out should not
concentricity with valve stem exceed 0.002 in. (0.051 mm).
guide (18).
d. Replace valve insert (12) or (15) as follows:
(1) Clean area around valve seat.
(2) Place valve seat extractor (35) Use valve seat extractor (ST-1279)
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3-35. CYLINDER HEAD AND VALVE REPAIR (Contd)3-121
c. Inspection and Repair (Contd)
15. Four intake valve inserts (5) Stake (peen) cylinder head (9). Use valve seat insert staking tool
(12) and four exhaust valve (ST-1124) (36) and driver (37)
inserts (15) (Contd) If valve seat insert staking tool
(36) and driver (37) are not available, a punch with round end can be used to stake cylinder head (9).
e. Machine valve insert counterbore for installing oversize inserts (12) or (15) as follows:
(1) Clamp base of insert tool (40) Use valve seat insert tool (ST-257)
to cylinder head (9). (40).
(2) Install cutter (39). Use valve seat insert cutter (ST-662) (39). Ensure valve seat insert tool (40) is securely clamped before starting electric drill.
(3) Using arbor (38), center cutter Use valve guide arbor (ST-663) (39) on valve seat insert (12) or (38).
(15).
(4) Cut counterbore 0.006-0.010 in. This allows room for peening (0.152-0.254 mm) deeper than of cylinder head (9) to secure valve insert thickness. valve insert (12) or (15). Allow
cut-ter to turn several revolutions to make sure counterbore surface is even. Remove valve seat insert tool (40), valve seat insert cutter (39), and valve guide arbor (38).
(5) Clean out all chips and debris from valve insert counterbore.
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3-35. CYLINDER HEAD AND VALVE REPAIR (Contd)3-123
c. Inspection and Repair (Contd)
16. Four valve crosshead a. Inspect each for straightness Replace valve crosshead guides (8)
guides (8) and for being at a right angle to that are not straight or square to
surface of cylinder head (9). cylinder head (9). (Refer to step 16d for replacement.) b. Measure outside diameter. Use suitable micrometer. Replace
if less than wear limit shown below. (Refer to step 16d for replacement.)
Wear Limit ... .0.4320 in. (10.973 mm) New Minimum ... 0.4330 in. (10.998 mm) New Maximum ... 0.4335 in. (11.011 mm)
c. Using suitable micrometer, Replace if not within
1.860-measure protrusion. 1.880 in. (4.724-4.775 cm). (Refer
to step 16d for replacement.) d. Replace valve crosshead Do not replace unless bent or not
guides (8) as follows: within wear limits.
(1) Remove guide (8) from cylinder Use dowel pin extractor (ST-1134)
head (9). (41). Discard valve crosshead
guide (8).
(2) Clean crosshead guide (8) holes thoroughly.
(3) Install new valve crosshead Use arbor press and crosshead guide (8) on cylinder head (9). guide spacer (ST-633) (42). Ensure
height of valve crosshead guide (8) is between 1.860-1.880 in. (4.724-4.775 cm) after installation.
17. Two dowels (11) Inspect for cracks, breaks, Replace if damaged or loose.
bending, or looseness.
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3-35. CYLINDER HEAD AND VALVE REPAIR (Contd)3-125
c. Inspection and Repair (Contd)
18. Two injector a. Inspect for scratches on cup Replace if any scratches are
sleeves (7) area and cracks at rolled seam. found. (Refer to step 18d for
replacement.) b. Check seating pattern as follows:
NOTE
Ensure injector assembly is new or condition of injector assembly cup is satisfactory prior to checking seating pattern.
(1) Lightly coat cup of injector assembly (43) with Prussian blue compound.
(2) Install injector assembly (43) Tighten screws (45) alternately on injector sleeve (7) and secure in 48 lb-in. (5 N•m) increments with injector damp (44) and two to 10-12 lb-ft (14-16 N•m).
screws (45).
(3) Remove two screws (45), injector clamp (44), and injector assembly (43) from injector sleeve (7).
(4) Check seating pattern in cup Seating pattern must cover seating area of injector sleeve (7). completely around injector seat
and must be at least 0.060 in.
(1.524 mm) wide and 0.469 in.
(11.913 mm) from bottom surface of cylinder head (9) (refer to illus-tration). Replace old injector sleeve (7) if not within above spec-ifications (refer to step 18d for replacement). Recut new injector sleeve (7) if not within above spec-ifications (refer to step 18e for recutting).
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3-35. CYLINDER HEAD AND VALVE REPAIR (Contd)3-127
c. Inspection and Repair (Contd)
18. Two injector c. Check protrusion of injector
sleeves (7) (Contd) assembly (43) tip as follows:
NOTE
Ensure injector assembly is new or condition of injector assembly is known to be satisfactory prior to checking protrusion of tip.
(1) Install injector assembly (43) Tighten screws (45) alternately on injector sleeve (7) with in 48 lb-in. (5 N•m) increments injector clamp (44) and two to 10-12 lb-ft (14-16 N•m).
screws (45).
(2) Measure protrusion of tip. Tip protrusion should be
0.060-0.070 in. (1.524-1.778 mm).
Replace injector sleeve if protru-sion is more than 0.070 in. (1.778 mm) (refer to step 18d for replace-ment). Recut injector sleeve (7) if protrusion is less than 0.060 in.
(1.524 mm) (refer to step 18e for recutting).
d. Replace injector sleeve (7) as Replace if damaged or not
follows: within wear limits.
(1) Install puller (47) on injector Use injector sleeve puller
sleeve (7) as shown in illustration. (ST-1244) (47). Ensure puller (47) legs of support bridge are against surface of cylinder head (9) and both nuts are loose.
(2) Strike puller (47) with hammer to push puller (47) into injector sleeve (7).
(3) Tighten small nut on Do not tighten small nut puller (47) to 50 lb-ft (68 N•m). more than 60 lb-ft (81 N•m).
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3-35. CYLINDER HEAD AND VALVE REPAIR (Contd)3-129
18. Two injector (4) Turn large nut clockwise on sleeves (7) (Contd) puller (47) and remove injector
sleeve (7) from cylinder head (9).
(5) Remove injector sleeve (7) Loosen nuts. Tap small end of from injector sleeve puller (47). injector sleeve (7) to free from
puller (47). Discard injector sleeve (7).
(6) Remove injector preformed Discard preformed packing (6).
packing (6) from injector sleeve bore of cylinder head (9).
(7) Remove all foreign material Use suitable steel brush. Refer from injector sleeve sealing area to para. 3-6 for additional
with steel brush. cleaning instructions.
(8) Inspect injector sleeve seat area of cylinder head (9) for any possible damage incurred during removal.
NOTE
Perform step 18d, tasks 9 through 18, only if injector sleeve seat area is damaged or bead is not smooth.
(9) Install bead cutting tool (48), Use bead cutting tool (ST-788) pilot (49), and holder (50) on drill (48). If drill press is not available,
press. bead cutting tool (48) may also be
turned by hand using tap wrench.
(10) Place cylinder head (9) on Adjust table height to allow for
drill press table. proper clearance so that end of
bead cutter (48) will protrude below cylinder head (9) surface into pilot hole of injector sleeve (7) seat area.
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3-35. CYLINDER HEAD AND VALVE REPAIR (Contd)3-131
c. Inspection and Repair (Contd)
18. Two injector (11) Before starting drill press
sleeves (7) (Contd) motor, insert bead cutting tool (48), pilot (49), and holder (50) in injector sleeve bore of cylinder head (9) to ensure proper alignment.
(12) Lubricate cutter (48) with Raise cutter (48) high enough
cutting oil. to lubricate.
CAUTION
•• Use extreme caution when cutting injector sleeve seat.
•• Do not run drill press at speeds higher than 75 rpm. Tool chatter may occur at speeds higher than 75 rpm, damaging injector sleeve bore.
NOTE
Do not cut more than 0.010 in. (0.254 mm) deep into cylinder head.
(13) Turn on drill press motor When proper cut depth has and make a very light cut. been reached, allow cutter (48) to
turn in position for about 10 sec-onds to ensure a good seat and clean grooves.
(14) Remove cutter (48), holder (50), and pilot (49) from drill press.
(15) Remove bead cutting tool (48) Use injector seat cutting tool from holder (50) and pilot (49), (ST-824) (51) to cut a 70° chamfer and install injector seat cutting at top edge of 60° seat. Apply
tool (51). Prussian blue compound to 60°
seat to aid in determining amount of chamfer needed.
(16) Lubricate and position Lubricate cutter (51) with cutting
cutter (51), holder (50), and oil.
pilot (49) on seat.
(17) Rotate cutter (51) while Use tap wrench. Remove cutter applying even pressure. (51), holder (50), and pilot (49)
when lower edge of 70° relief chamfer is about 0.125 in.
(3.175 mm) from top of bead.
CAUTION
To prevent damage to injector sleeve during installation, ensure sleeve seat is free from oil, carbon, or any other foreign material.
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3-35. CYLINDER HEAD AND VALVE REPAIR (Contd)3-133
c. Inspection and Repair (Contd)
18. Two injector (19) Apply a light coat of Shake off excess oil.
sleeves (7) (Contd) lubricating oil to new injector preformed packing (6).
(20) Install injector preformed packing (6) on groove of injector sleeve bore of cylinder head (9).
(21) Using driver (52), push Use injector sleeve driver injector sleeve (7) into injector (ST-1227) (52). Install injector sleeve bore until firmly seated. sleeve (7) by striking driver (52).
(22) Remove driver (52).
(23) Install holding tool (53) on Use injector sleeve holding tool
injector sleeve (7). (ST-1179) (53). Tighten nut on
holding tool (53) to 35-40 lb-ft (48-54 N•m).
(24) Insert driver (52) in injector Tighten nut on holding tool (53) sleeve (7), and strike with soft- again to 35-40 lb-ft (48-54 N•m).
nose hammer until injector sleeve (7) is seated properly against bottom of injector sleeve bore.
(25) Remove driver (52).
CAUTION
•• To avoid distorting injector sleeve, do not roll lower area of sleeve.
•• Over-rolling or peening injector sleeve will deform injector O-ring groove of sleeve.
(26) Install expander (54) on Use injector sleeve expander
injector sleeve (7). (ST-880) (54).
(27) Tighten expander (54) to 75 lb-in. (102 N•m).
(28) Remove expander (54) and holding tool (53) from injector sleeve (7).
e. Cut injector seat as follows:
NOTE
Ensure injector assembly is new or is known to be satisfactory prior to checking protrusion of tip.
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3-35. CYLINDER HEAD AND VALVE REPAIR (Contd)3-135
c. Inspection and Repair (Contd)
18. Two injector (2) Using gauge block (46), Use this measurement to
sleeves (7) (Contd) measure protrusion of injector determine amount that must be
assembly (43) tip. cut from sleeve. The protrusion
of injector tip must be 0.060-0.070 in. (1.524-1.778 mm).
(3) Remove two screws (45), injector clamp (44), and injector assembly (43) from injector sleeve (7).
(4) Install cutter (55) and pilot Use injector seat cutter (ST-884) (49) on drill press and cut (55). Ensure enough cutting oil injector sleeve (7). is used to allow cutter (55) to cut
freely without grabbing. When proper cut depth is reached, allow cutter (55) to turn in position for about 10 seconds to ensure a smooth seat.
(5) Check injector (43) seating. Refer to step 18b pattern.
(6) Check protrusion of Refer to step 18c.
injector assembly (43) tip.
19. Eight valve springs (4) a. Inspect for distortion, cracks, Discard valve spring (4) if
breaks, and collapsed coils. damaged.
b. Using tester (56), compress to Use valve spring tester
working length of 1.724 in. (3375182) (56).
(4.379 cm).
c. Record amount of force required Discard if less than wear limit
to compress valve spring (4). shown below.
Wear Limit ... 143.00 lb (64.92 kg) New Minimum ... 147.25 lb (66.85 kg) New Maximum ... 162.75 lb (73.89 kg)
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3-35. CYLINDER HEAD AND VALVE REPAIR (Contd)3-137
c. Inspection and Repair (Contd)
NOTE
Repeat step 20 for each intake and exhaust valve.
20. Valve (13) or (14) a. Polish with crocus cloth.
b. Inspect head of valve (13) or Discard if damaged or if valve (14) for cupping, cracking, pitting, head rim thickness is less than
and wear. 0.105 in. (2.667 mm).
c. Inspect stem of valve (13) or (14) Discard if damaged or if stem for cracks, scoring, galling, wear diameter is less than wear limit
or bends. shown below.
Wear Limit ... 0.449 in. (11.405 mm) New Minimum ... 0.450 in. (11.430 mm) New Maximum ... 0.451 in. (11.455 mm)
d. Check collet grooves on valve Use new valve collets (2) to check (13) or (14) stem for wear. grooves. Discard valve (13) or (14)
if collets fit loosely in grooves.
e. Inspect for cracks using magnetic method:
(1) Magnetize valve (13) or (14) Inspect area A (refer to
in coil at 100 to 300 amperes, and illustration) and discard valve (13) inspect with residual Magnaglo. or (14) with more than five If damaged, defects will show indications, longer than 0.500 in.
around circumference of valve. (12.7 mm), or indications spaced closer than 0.125 in. (3.175 mm).
(2) Magnetize valve (13) or (14) Inspect areas B, C, D, and E by headshot magnetization at (refer to illustration). No visible 500 to 700 amperes, and inspect or magnetic indication is
with residual Magnaglo. acceptable. Discard. Demagnetize acceptable valves (13) or (14).
NOTE
Repeat step 21 for each intake and exhaust valve crosshead.
21. Valve crosshead (22) or (28) a. Inspect for excessive wear, Discard if damaged.
distortion, grooving, scoring, galling, stripped threads, broken areas, and out-of-round.
b. Inspect for cracks using Discard if any cracks are found.
magnetic method.
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3-35. CYLINDER HEAD AND VALVE REPAIR (Contd)3-139
c. Inspection and Repair (Contd)
21. Valve crosshead (22) or c. Use suitable bore gauge. Discard if not within wear limit
(28) (Contd) Measure crosshead bore shown below.
diameter.
Wear Limit ... 0.440 in. (11.176 mm) New Minimum ... 0.434 in. (11.024 mm) New Maximum ... 0.436 in. (11.074 mm)
CAUTION
To prevent damage to valve crosshead, do not use plug gauge during next step.
d. Check crosshead bore at four Use suitable bore gauge.
points, spaced 90° apart, Discard if out-of-round.
for out-of-round.
e. Inspect rocker lever contact Discard if excessively worn or surface (area A) and valve stem if surface is damaged.
contact surface (area B) for wear (refer to illustration).
22. Two fuel connections (23) Inspect for cracks, breaks, and Discard if cracked, broken, or
bends. bent.
23. All other parts a. Inspect for cracks, breaks, Discard if damaged or worn.
bends, excessive wear, and other damage.
b. Inspect all threaded parts Discard any threaded parts that for stripped threads or are stripped or cross-threaded.
cross-threading.
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3-35. CYLINDER HEAD AND VALVE REPAIR (Contd)3-141
d. Assembly and Testing
NOTE
Ensure all parts are clean prior to assembling.
24. Six new expansion plugs a. Apply a coat of cup plug sealant (10), new expansion plug to expansion plugs and to inside
(16), and two new diameter of water holes on
expansion plugs (17) cylinder head (9).
b. Using drivers (57), install Use expansion plug drivers expansion plugs (10), (16), and (3375190, 3375191, and 3375192) (17) on cylinder head (9). (56). If expansion plug drivers (57)
are not available, use mandrel of correct size and ensure expansion plugs (10), (16), and (17) are installed even (flush) with, or not more than, 0.090 in. (2.286 mm) below chamfer (see illustration).
Do not push expansion plugs to bottom of counterbore.
25. Four pipe plugs (27) a. Coat threads of each pipe plug (27) with liquid thread sealant.
b. Install two on each end of No. 3 cylinder head has two pipe
cylinder head (9). plugs (27) in forward end only.
Tighten pipe plugs (27) to:
PLUG SIZE TORQUE 1/16 in. 3-6 lb-ft
(4-8 N•m)
1/8 in. 5-10 lb-ft
(7-14 N•m)
3/8 in. 35-45 lb-ft
(48-61 N•m)
1/2 in. 60-70 lb-ft
(81-95 N•m)
3/4 in. 65-75 lb-ft
(88-102 N•m)
1 in. 135-145 lb-ft
(183-197 N•m)
TM 9-2815-225-34&P
3-35. CYLINDER HEAD AND VALVE REPAIR (Contd)3-143
d. Assembly and Testing (Contd)
NOTE
Step 26 does not apply to No. 2 cylinder head.
26. Cover plate (25) and two a. Install on cylinder head (9).
new preformed packings (24)
b. Secure with two screws (26).
27. Four intake valves (13) and a. Dip valve stems into clean
exhaust valves (14) lubricating oil.
b. Install valves (13) or (14) on Ensure cylinder head is clean valve stem guides (18) from bottom and valves are installed in their side of cylinder head (9). original locations as numbered in
step 7. Ensure valve heads are fully seated on valve inserts (12) and (15).
28. Cylinder head (9) Place on wooden bench or Wooden bench or protective
protective surface with machined surface will prevent damage to
surface down. machined surface.
NOTE
A maximum of two 0.031 in. (0.794 mm) spacers may be used under lower valve spring guide when cylinder head has been resurfaced and valve seat has been reground. Do not use spacers to compensate for weak springs.
29. Eight upper valve spring a. Place over valve stem guides guides (3), valve springs (18) on cylinder head (9).
springs (4), and lower valve
spring guides (5) (spacers b. Compress valve springs (4) Use valve spring compressor
(33) if necessary) and install sixteen new valve (ST-448) (32) and head holding
collets (2) on stems of valves (13) fixture (ST-583). Stud of valve
and (14). spring compressor (32) should
be installed on rocker lever screw hole (31).
NOTE
Ensure valves and valve seats are clean and dry.
30. Cylinder head Check seal between valve (13) or Use valve vacuum tester
assembly (1) (14) and valve seat as follows: (ST-1257-A) (58).
a. Select correct size vacuum cup for size of valve being tested.
b. Put vacuum cup over head O-ring on vacuum cup must
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3-35. CYLINDER HEAD AND VALVE REPAIR (Contd)3-145
d. Assembly and Testing (Contd)
30. Cylinder head c. Turn hand shutoff valve to
assembly (1) (Contd) open position and hold down
push button to operate valve vacuum tester (58).
d. Operate vacuum tester (58) Close hand shutoff valve and until vacuum gauge indicates release push button to stop
between 18 and 25 in. of vacuum pump.
vacuum.
e. Record vacuum drop to 1. Start timing as soon as gauge determine satisfactory valve hand reaches 18 in. of vacuum.
sealing. 2. Stop timing when gauge hand
reaches 8 in. of vacuum.
3. If time is less than 10 seconds, valve seating is unsatisfactory.
Perform step 30f if valve seating is unsatisfactory.
f. Tap stem end of valve (13) or Lapping valves is permissible, if (14) with soft-nose mallet and necessary, to create an air-tight
repeat vacuum test. seal.
g. Check for leaking connections Clean if necessary.
in valve vacuum tester (58).
h. Check for leaks between valve 1. Apply a coat of grease to out-insert (12) or (15) and valve out-insert side diameter of insert to make a center bore in cylinder head (9). greade seal between insert and
counterbore.
2. Vacuum test (refer to step 30d) and inspect grease seal.
3. If there is a break in grease seal, remove valve (13) or (14). Stake valve seat with valve seat insert staking tool (36) and driver (37).
31. Two adjusting screws (30) Install on exhaust valve
and nuts (29) crossheads (28).
32. Two adjusting screws (20) Install on intake valve
and nuts (21) crossheads (22).
33. Two exhaust valve Install on valve crosshead
crossheads (28) and guides (8) on cylinder head (9).
intake valve crossheads (22)
NOTE