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Have all the listed items ready.
Remove the air hose.
Remove the tappet plate spring.
Unscrew the screw securing the tappet plate.
Remove the tappet plate.
Remove the nozzle.
Gently unscrew the solenoid valves – be careful with the very delicate O-rings on the valve.
Using the dedicated wrench included in the kit or Seger-type safety pliers, unscrew the nozzle guide. The first engine release may not have had them included, but they are available in our store.
Using tweezers or a screwdriver, gently remove the poppet from inside the body.
Remove the tappet plate piston (you can use tweezers or a sharp knife for this, paying attention not to damage the piston).
Remove all the O-rings from the engine components except the solenoid valve (it is best to use plastic tools for this so as not to damage the aluminum surfaces of the engine – this is not covered by the warranty).
If the o-rings are not damaged, you can reuse them after cleaning them with a paper towel – it is best to avoid washing the o-rings with detergents.
If the o-rings are damaged or show signs of wear, replace them with new ones – included in the kit.
Place the engine components in a dish with petroleum ether (NOTE – does not apply to the solenoid valves. Avoid immersing them in cleaning agents).
Using a thicker brush and tweezers, thoroughly clean the engine components.
For solenoid valves, gently wipe the O-ring surfaces and remove visible dirt with a dry brush.
Set the washed parts aside on a paper towel to dry completely (you can speed up the process by blowing the parts with compressed air).
Reinstall the o-rings (you can lightly grease them before installation):
Install the o-rings according to the diagram below:
1 o-ring 16x1.5 mm and 1 o-ring 6x1 mm in the nozzle guide.
2 o-rings 8x1 mm for the poppet.
1 o-ring 4x1 mm for the tappet plate piston.
Prepare all parts with the O-rings installed, as well as grease and a smaller brush.
grease two places in the rear of the engine body:
The cylinder where the piston moves (take care not to grease the bottom of the cylinder).
Then the vertical surfaces of the cylinder where the poppet moves. Try not to grease the bottom of the cylinder. This can have a negative effect on engine performance.
Grease the o-ring on the piston and the piston.
Place the piston in its cylinder and collect excess grease.
Grease well the two o-rings in the nozzle guide (you can remove the excess with a paper towel).
In the poppet, also grease two places:
Both O-rings. As with the rear of the engine, be careful not to leave grease on the flat rear surface of the nozzle.
And the narrowed poppet surface.
Place the greased poppet in the inner part of the nozzle guide.
Then screw the nozzle guide into the engine body using a wrench or the aforementioned pliers.
Grease the nozzle guide.
Grease the nozzle from the inside in the o-ring area.
Install the nozzle on the guide.
Gently grease the thread and O-rings of the valve with a flat brush. Avoid getting grease into the moving parts of the valve.
Gently, while taking care of the solenoid valve's o-rings, screw it into the valve socket. Just do it with your bare hand, do not use tools for this.
Grease the surface over which the tappet plate moves.
Install the tappet plate. Press it well against the nozzle.
Secure the tappet plate with the screw. Tighten the screw until you feel resistance in the operation of the tappet plate and then loosen the screw so that the tappet plate can move freely and without resistance.
Install the tappet plate spring.
Screw on the air hose.
The engine is once again ready for use.
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