USAfixTM - Repair Guide (RG) - Master Email RG
- Set Valves and Recheck Compression
 Level of Difficulty - HIGH  Estimated Completion Time - 45 minutes
AZTEC - RELIANT P24K17

Tools Required
Tool 
Compression Tester
Feeler gauge-metric .006in / 0.152mm
Ratchet-Socket metric 10mm
Ratchet-Socket metric 14mm
Ratchet-Socket standard 11/16 in
Screwdriver-flat tip
Spark plug socket wrench 13/16
Wrench-Allen metric 3.0mm
Wrench-metric-14mm

Parts Required


Step Procedure & Parts & Tools
1 PULL THE BONNET OFF THE CAGE

2 REMOVE THE 4 ACORN NUTS
Ratchet-Socket metric 10mm

3 LIFT THE CAGE OFF THE ENGINE

4 LOCATE SPARK PLUG WIRE

5 PULL TO DISCONNECT SPARK PLUG WIRE

6 LOCATE SPARK PLUG

7 UNSCREW SPARK PLUG AND INSPECT. REGAP OR REPLACE IF NECESSARY. SPARK PLUG GAP =.025 INCH GAP Note: Use a 13/16" Spark plug socket.
Spark plug socket wrench 13/16

8 (YOU CAN SKIP STEPS 8 THRU 10 IF YOU RECORDED THIS INFO EARLIER) TWIST COMPRESSION TESTER IN SPARK PLUG OPENING ON ENGINE
Compression Tester

9 DON’T START MACHINE, JUST TURN ENGINE OVER, BELOW 90LBS PSI=SET VALVES. 120IBS PSI IS GOOD
Compression Tester

10 COMPRESSION TEST BOTH SIDES AND WRITE DOWN RESULTS AND SET ASIDE
Compression Tester

11 LOCATE THE VALVE COVER

12 REMOVE 2 BOLTS FROM VALVE COVER
Ratchet-Socket metric 10mm

13 PULL TO REMOVE VALVE COVER (ROCKER ARMS ARE NOW VISIBLE)

14 TURN THE FLYWHEEL UNTIL EACH ROCKER ARM GOES IN AND OUT AND STOPS (MAY NOT BE AT THE SAME TIME)
Ratchet-Socket standard 11/16 in

15 INSERT A LONG SCREWDRIVER IN SPARK PLUG HOLE AND TURN THE FLYWHEEL UNTIL IT PUSHES THE SCREWDRIVER OUT AND STOPS-THIS IS TOP DEAD CENTER
Ratchet-Socket standard 11/16 in
Screwdriver-flat tip

16 INSERT FEELER GAUGE BETWEEN ROCKER ARM AND SPRING (CHECK GAP ON TOP AND BOTTOM ROCKER ARMS)
Feeler gauge-metric .006in / 0.152mm

17 IF GAP IS TOO TIGHT OR TOO BIG, LOOSEN NUT (ON TOP AND BOTTOM ROCKER ARMS)
Ratchet-Socket metric 14mm

18 HOLD THE NUT AND LOOSEN SET SCREW (ON TOP AND BOTTOM ROCKER ARMS)
Wrench-Allen metric 3.0mm

19 INSERT FEELER GAUGE BETWEEN ROCKER ARM AND SPRING, HOLD AND TIGHTEN NUT (TOP AND BOTTOM ROCKER ARMS)
Feeler gauge-metric .006in / 0.152mm

20 HOLD BOLT WITH WRENCH AND TIGHTEN SET SCREW AND TIGHTEN BOLT AT THE SAME TIME. RECHECK GAP. (TOP AND BOTTOM ROCKER ARMS)
Wrench-Allen metric 3.0mm

21 REPEAT STEPS 6 THRU 23 ON OTHER VALVE. (COMPLETE THE VALVES ON EACH SIDE BEFORE STARTING THE OTHER SIDE)
Wrench-Allen metric 3.0mm
Feeler gauge-metric .006in / 0.152mm
Ratchet-Socket standard 11/16 in
Screwdriver-flat tip
Wrench-metric-14mm
Spark plug socket wrench 13/16
Compression Tester

22 REPEAT STEPS 11 THRU 13 ON BOTH VALVES TO RETEST COMPRESSION FOR COMPARISON.
Compression Tester
Ratchet-Socket metric 10mm

23 COMPARE SECOND COMPRESSION TEST TO RESULTS FROM FIRST. COMPRESSION SHOULD HAVE INCREASED. REPEAT STEPS 1 THRU 10 TO REASSEMBLE MACHINE.
Ratchet-Socket metric 10mm
Spark plug socket wrench 13/16
Compression Tester