2.2l 4-cyl - Vins [c,d,e,f,l,8] Dodge Aries I

ENGINE IDENTIFICATION

Note. For engine repair procedures not covered in this article, see ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION article in the GENERAL INFORMATION section.

Note. In addition to information on the 1985-87 2.2L 4-Cylinder engines, information is also included in this article on the 1984 2.2L 4-Cylinder 2-Bbl. High Output engine.

Engine may be identified from the Vehicle Identification Number (VIN) stamped on a Gray colored metal tab located on top of instrument panel at lower left of windshield. The VIN number code also appears as part of a production or unit number stamped on left rear of cylinder block, below cylinder head. The VIN number contains 17 characters. The 8th character identifies the engine and the 10th character establishes the model year.

ENGINE IDENTIFICATION CODES

ENGINE REMOVAL

See ENGINE REMOVAL article in this section.

Removal (2-BBL.)

1. Disconnect battery. Drain cooling system. Remove air cleaner and disconnect all electrical wiring. Remove vacuum lines and fuel lines at carburetor. Remove throttle linkage. Loosen power steering pump and remove belt (if equipped).
2. Remove water hoses from water crossover. Raise vehicle on hoist and remove exhaust pipe at manifold. Remove power steering pump from mounting brackets and position aside leaving hoses connected (if equipped). Remove intake manifold support bracket and EGR tube.
3. Lower vehicle. Remove intake manifold bolts in a decreasing spiral pattern and remove intake manifold. Remove exhaust manifold bolts in a decreasing spiral pattern and remove exhaust manifold.

Note. Before removing fuel line, loosen gas cap and relieve system pressure. Remove wiring harness connector from injector and ground one injector terminal. Connect a 12-volt jumper wire to other terminal and apply for 10 seconds ONLY.

Removal (Throttle Body)

1. Disconnect battery negative cable. Disconnect fuel injector wiring connector and 6-way throttle body connector. Remove ground wire from 6-way connector. Remove air cleaner hose, throttle cable, speed control and transmission kickdown cables (if equipped).
2. Remove return spring and vacuum hoses. Loosen fuel intake and return hose clamps. Using a shop towel, twist and pull off each hose. Remove intake manifold mounting screws. Lift intake manifold from vehicle. Remove exhaust manifold bolts and exhaust manifold.

Removal (Turbocharger)

Before beginning any unit removal/replacement procedures on a turbocharging system, several precautions should be considered.

1. Clean area around turbocharger with non-caustic solution before disassembly.
2. Use care during removal/replacement procedure to avoid damaging turbine blades. Any damage may result in turbocharger failure when engine is started.

1. Raise vehicle. Disconnect battery and drain radiator. Disconnect exhaust pipe at turbine housing. Remove O2 sensor electrical connector. Remove turbocharger housing-to-block supporting bracket.
2. Loosen oil drain hose clamps and move tube down to block nipple. Disconnect coolant tube bracket and coolant tube nut at block outlet (below steering pump bracket).
3. Lower vehicle. Remove air cleaner assembly with throttle body adapter, hose, air cleaner box and bracket. Disconnect accelerator linkage, throttle body wiring connector and vacuum hoses.
4. Loosen throttle body inlet hose clamps. Loosen turbocharger discharge hose (end clamps ONLY). Relocate fuel rail by removing 4 intake manifold bracket screws and 2 heat shield bracket clips. Move out of way.
5. Disconnect turbocharger oil feed line at sending unit tee. Disconnect upper radiator hose at thermostat housing. Remove cylinder head with manifolds attached as a unit. NOTE: Do NOT disturb center deswirler retaining clamp.
6. Remove throttle body from intake manifold. Remove 3 screws holding heat shield to manifold. Remove heat shield. Remove coolant return tube assembly from turbocharger to water box. Remove tube assembly and tube support from cylinder head. Disconnect and remove oil feed line from oil sending unit tee and turbocharger bearing housing.
7. Remove 4 nuts holding turbocharger to exhaust manifold. Lift turbocharger off exhaust manifold studs, push passenger side of unit downward, and lift out of engine compartment. Remove exhaust manifold bolts and exhaust manifold.

Installation

1. Clean all gasket surfaces and inspect for cracks, distortion and surface flatness. Gasket surfaces must be flat within.006" (.15 mm) per foot of manifold length. On non-turbo models, coat cylinder head side of intake and exhaust manifold gasket with sealer. Install gasket on cylinder head. NOTE: Apply anti-seize compound to exhaust manifold studs.
2. On turbo models, install 2-sided Grafoil or equivalent gaskets. Position exhaust manifold on cylinder head and install bolts. Tighten bolts or nuts, starting in center and working outward in both directions.
3. Position intake manifold on cylinder head and install bolts. Raise vehicle. Tighten bolts, starting in center and working outward in both directions. Reverse removal procedure to complete installation. (Scheme 14)

Tightening Sequence for Intake and Exhaust Manifolds Begin tightening in center and work outward. Scheme 14

Removal

1. Remove intake and exhaust manifolds as previously described. With alternator mounting brackets removed, position alternator aside. If equipped with A/C, remove compressor mounting brackets and position compressor aside, leaving refrigerant lines connected.
2. Remove water pump and crankshaft pulley bolts. Remove pulleys. Raise vehicle and remove right inner fender splash shield. Remove crankshaft pulley. Remove upper and lower timing belt cover. Position jack under engine.
3. Remove right engine mounting bolt and raise engine slightly. Loosen timing belt tensioner and remove timing belt. Remove camshaft cover. Install Camshaft Sprocket Holder (C-4687), and hold sprocket while removing sprocket bolt. Remove camshaft sprocket.
4. Remove air pump pulley bolt and pulley, making sure not to turn camshaft when removing air pump pulley. Loosen and remove cylinder head bolts in reverse order (number 10 to number 1) of installation. (Scheme 15) Remove cylinder head and gasket.

Cylinder Head Tightening Sequence Loosen in reverse order. Scheme 15

Note. New head bolts are used on 1986 models. Old bolts will thread into hole but will strip cylinder block bolt hole.

1. Clean all gasket surfaces. Check cylinder head and block for distortion. If more than.004" (.10 mm) distortion on either cylinder head or block, surface cylinder head and/or block.
2. Place new gasket on block. Install cylinder head and bolts, tightening in 4 stages: 1st to 45 ft. lbs. (61 N.m); 2nd to 65 ft. lbs. (88 N.m); 3rd, check again at 65 ft. lbs. (88 N.m); and 4th, turn another 1/4 turn. (Scheme 15) NOTE: Bolt torque should be over 90 ft. lbs. (122 N.m.) after stage 4. If not, replace bolt.
3. Reverse removal procedure to complete installation and adjust timing belt. Refer to installation procedure under TIMING BELT.

1. Disconnect battery. Remove alternator and mounting brackets and position aside, leaving wiring connected. If equipped, remove A/C compressor and mounting brackets and position aside. Leave refrigerant lines connected. Remove water pump, crankshaft pulley bolts and remove pulleys.
2. Raise vehicle on hoist and remove right inner fender splash shield. Remove crankshaft pulley. Remove upper and lower timing belt cover. Position jack under engine. Remove right engine mounting bolt and raise engine slightly. Loosen timing belt tensioner and remove timing belt.

Engine Timing Marks. Scheme 16

Note. Do not allow oil or solvent to contact timing belt as it will deteriorate the rubber, causing belt to skip teeth.

1. Remove spark plugs and place No. 1 cylinder on TDC. Align timing marks on crankshaft and intermediate sprockets. (Scheme 16) Turn camshaft sprocket until arrows on hub are in line with No. 1 camshaft cap-to-cylinder head line. Small hole must be at 12 o'clock position. (Scheme 16)
2. Install timing belt. Install Timing Belt Tensioner (C-4703) horizontally on large hex of belt tensioner pulley and loosen tensioner lock nut.
3. If necessary, reset belt tensioner to have axis within 15° of horizontal. Turn engine clockwise 2 complete revolutions to TDC and recheck timing. Tighten tensioner lock nut while holding belt tensioner wrench in position.

Note. Do not reverse rotate crankshaft or rotate engine by turning camshaft sprocket bolt or intermediate shaft sprocket bolt during timing belt adjustment.

1. Remove timing belt cover and timing belt. Install Camshaft Sprocket Holder (C-4687). Remove sprocket bolt, sprocket and camshaft cover. Mark rocker arms for reinstallation in original positions.
2. On each rocker arm, rotate camshaft until base circle of cam is in contact with rocker arm. Install Spring Compressor (4682) and compress valve spring. Remove rocker arm and keep in order for reinstallation.
3. Loosen camshaft bearing cap nuts several turns. Using soft-faced mallet, tap rear of camshaft to loosen bearing caps. Remove camshaft cap nuts and bearing caps so that cam does not cock in cylinder head. Remove camshaft and oil seals.

1. Check bearing cap oil holes for blockage. Install camshaft into cylinder head and align bearing caps in proper sequence, with bearing cap No. 1 at timing belt end and bearing cap No. 5 at transmission end.
2. Make sure arrows on bearing caps No. 1, 2, 3 and 4 point toward timing belt to prevent bearing cap breakage. Apply anaerobic sealer to No. 1 and No. 5 bearing caps at sealing surfaces. Install bearing cap nuts and tighten.
3. Mount dial indicator at timing belt end of camshaft and slide cam rearward. Zero dial indicator and slide cam all the way forward and read dial indicator reading. End play should be .005-.015" (.12 mm) maximum. If end play exceeds specification, camshaft and/or cylinder head should be replaced.
4. Lightly coat outside diameter of new oil seal with Loctite (P/N 4057987) for steel case or use soapy water for rubber coated steel case. Using Oil Seal Installer (C-4680), install oil seal flush with camshaft bearing cap. Reverse removal procedure to complete installation.

1. Remove fuel pump and distributor assembly. Remove timing belt cover and timing belt. Install Intermediate Sprocket Holder (C-4687). Remove sprocket bolt and sprocket.
2. Remove oil seal using Oil Seal Remover (C-4679), being careful not to nick shaft seal surface or seal bore. Remove intermediate shaft retainer bolts, retainer and intermediate shaft.
3. Remove intermediate shaft front bushing using Bushing Remover (C-4697-2), and remove intermediate shaft rear bushing using Bushing Remover (C-4686-2).

1. Install intermediate shaft rear bushing using Bushing Installer (C-4686-1), until tool is flush with block. Install intermediate shaft front bushing using Bushing Installer (C-4697-1), until tool is flush with block.
2. Install intermediate shaft, retainer and bolts. Lightly coat outside diameter of new oil seal with Loctite (P/N 4057987) for steel case or use soapy water for rubber coated steel case. Using Oil Seal Installer (C-4680), install oil seal flush with oil seal retainer. Install oil seal flush with retainer.
3. Install intermediate sprocket and Sprocket Holder (C-4687). Install sprocket bolt and tighten. Align intermediate shaft, crankshaft and camshaft sprocket timing marks. (Scheme 16) Align slot in oil pump shaft parallel to centerline of crankshaft.
4. Remove distributor cap and align rotor to No. 1 firing position and install in engine. Install fuel pump and distributor cap. Reverse removal procedure to complete installation.

Valve Arrangement

E-I-E-I-E-I-E-I (Front-to-rear).

Valve Guide Inspection

1. Insert valve with valve head positioned .40" (10 mm) above cylinder head gasket surface. Attach dial indicator to cylinder head and position against valve head at right angle to valve stem.
2. Rock valve in guide and measure guide wear as shown on dial indicator. Maximum clearance is .020" (.5 mm) on intake valves and .027" (.7 mm) on exhaust valves.
3. If valve guide clearance is excessive, guides should either be reamed to next oversize or replaced. Service valves are available in .006" (.15 mm), .016" (.40 mm), and .031" (.80 mm) oversize.

Note. Do not ream valve guides from standard to maximum oversize. Ream guides oversize in steps so guides may be reamed true in relation to valve seat.

Valve Guide Replacement

Note. Valve Guides cannot be replaced. Cylinder head must be replaced. See CYLINDER HEAD removal and installation in this article.

Valve Stem Oil Seals

Oil seals are installed on all valve guides and must be replaced whenever valve service is performed. See VALVE SPRING REMOVAL for disassembly. Lightly coat valve stems with engine oil and install new seals. Push seals firmly and squarely over guide so center bead of seal seats in groove on valve guide and lower edge of seal is resting on valve guide boss. When oversize valves are used, make sure oversize seals are used also.

Note. Excessive valve guide wear may result if oversize seals are not used with oversize valves.

Scheme 17

1. Remove camshaft cover. On each rocker arm, rotate camshaft until base circle of cam is in contact with rocker arm.
2. Depress valve spring using Spring Compressor (4682) and slide rocker arm out. Keep rocker arms in order for reinstallation. Remove hydraulic lash adjuster. Rotate crankshaft until piston of cylinder concerned is at TDC.
3. Remove spark plug. Install air line adapter to spark plug port and apply 90-120 psi (6.3-8.4 kg/cm 2 ) air pressure to hold valves closed. Install Spring Compressor (4682) and compress valve spring. (Scheme 17) (Scheme 17): Removing and Installing Valve Spring Assembly Each cylinder must be at TDC to remove valves.
4. Remove valve locks, valve spring, retainer and valve spring seat. Remove oil seal by gently prying oil seal side-to-side using screwdriver blade until seal is dislodged from valve guide groove.

1. Test valve springs using Spring Tester (C-647). Replace springs if not within specifications. See «VALVE SPRING»(/dodge/aries/i-1981-1989/remont/mechanical/#22l-4-cyl-vins-cdefl8) table. Install oil seals, valve spring seats, valve springs and retainers.
2. Using Spring Compressor (4682), compress valve spring and install valve locks. Reverse removal procedure to complete installation.

Valve Spring Installed Height

Measure valve spring installed height from lower edge of valve spring to upper edge. Do not include valve spring seat or retainer. Specified height is 1.62-1.68" (41.20-42.70 mm). If valve seats have been reground, an additional spring seat may be required to maintain proper spring height.

Valve Stem Installed Height

Measure the valve stem installed height from tip of valve stem to spring seat. Specified height is 1.960-2.009" (49.76-51.04 mm). Check clearance after grinding valves or seats. If necessary, grind the tip of valve stem to obtain clearance when valve is installed in cylinder head. (Scheme 18)

Measuring Valve Stem Installed Height Measure from spring seat to tip of stem. Scheme 18

VALVE TIMING

See installation procedure under TIMING BELT .

HYDRAULIC VALVE LASH ADJUSTERS

Note. Lash adjusters are serviced as complete assemblies only. Parts are not interchangeable.

No adjustment of lash adjusters is required. Servicing of adjusters requires only that care and cleanliness be exercised in handling of parts. If disassembled for cleaning purposes, reassemble using new spring clip. Adjusters must be full of oil prior to installation and oiling holes in cylinder head must be free of any obstruction.

Dry Lash

Dry lash is amount of clearance between base circle of an installed camshaft and the rocker arm pad, with the adjuster completely collapsed. Remove and drain adjuster of any engine oil to perform this check. Install adjuster completely collapsed.

Measure clearance between base circle and rocker arm pad using feeler gauge. Specified clearance is .024-.060" (.62-1.52 mm). If not within specifications, check wear on parts and replace as required. Refill adjusters with engine oil before final assembly and allow 10 minutes for adjusters to bleed down before rotating camshaft.

ROCKER ARM ASSEMBLY

Install hydraulic valve lash adjusters and rocker arms in original positions. Measure rocker arm-to-valve stem installed height between projecting ears of rocker arms on either side of valve stem tip and valve spring retainer. Specified clearance should be a minimum of .050" (1.27 mm). If clearance is not sufficient, grind rocker arm ears as required to obtain clearance.

OIL PAN

See ENGINE OIL PAN REMOVAL - 4-CYL & V8 article in the ENGINES section.

1. With cylinder head and oil pan removed, use ridge reamer to remove any deposits or ridge from top of cylinder bore. Piston must be at bottom of stroke and covered with cloth to collect cuttings.
2. If necessary, mark pistons, connecting rods and caps for cylinder identification and reinstallation in original positions. Remove rod cap nuts and rod cap. Push piston and rod assembly out top of cylinder block.

Scheme 19

1. Lightly coat piston rings and cylinder bores with engine oil. Make sure "TOP" mark on upper and intermediate piston rings point toward top of piston. Make sure ring gaps are properly spaced on upper and intermediate rings. Oil ring rail gaps are installed 180° apart from each other. (Scheme 19) (Scheme 19): Piston Ring Gap Spacing Install rings with "TOP" mark facing top of piston.
2. Rotate crankshaft so connecting rod journal is at center of cylinder bore. Install rod bolt protectors before installing piston and rod assembly in block. Using ring compressor, compress rings. Install piston in cylinder bore with indent on piston and oil hole in connecting rod pointing toward timing belt side of engine. (Scheme 20)

Piston and Rod Installation Piston indent and connecting rod oil hole face front of engine. Scheme 20

Scheme 21

1. Measure cylinder bore at 3 points: 3/8" (10 mm) down from top, 3/8" (10 mm) up from bottom of bore and at center of bore. Measure in line with thrust face and at 90° angle to thrust face. Cylinder bore wear limit is.0027" (.07 mm) for non-turbocharged models. For turbocharged models, wear limit is.00037" (.0955). Maximum cylinder out-of-round is.002" (.050 mm) and maximum cylinder bore taper is.005" (.125 mm).
2. Measure pistons with pins removed at points "A", "B", "C" and "D". (Scheme 21) First, measure point "B". Piston diameter should be 3.4430-3.4450" (87.442-87.507 mm) on non-turbocharged models. On turbocharged models, piston diameter should be 3.4416-3.4440" (87.465-87.4815 mm). Now measure point "A": Due to elliptical shape of piston skirt, point "A" should be.012-.014" (.305-.356 mm) less than measurement taken at point "B", for non-turbocharged engines. On turbocharged engines, the measurement would be.0074-.0106" (.1886-.2686 mm). (Scheme 21): Measuring Piston Fit
3. Measure point "C" and point "D". Piston diameter at point "D" should be.002" (.05 mm) larger than the measurement taken at point "C", for the non-turbocharged engine. On turbocharged engine, the measurement would be.0012" (.0302 mm). Measure piston diameter at ring lands on the head of the piston. Measurement should be.010" (.25 mm) less than measurement taken at point "C".
4. If piston is not within specifications, replace as required. Pistons are available in standard and.020" oversize.

Fitting Rings

1. Place cylinder block upside down. Position ring in cylinder block bore that it will be used in. Using head of piston, push ring into bore approximately .62" (16mm) from bottom.
2. Measure gap between ends of ring using feeler gauge. If not within specifications, substitute another ring set until rings are within specifications.

Piston Pins

Pins are press fit in rods. Remove and install piston pins using arbor press and adapters. With piston and rod separated, inspect pin and pin bore for wear. Measure clearance. If pin bore clearance exceeds .00075" (.019 mm), replace piston and pin as an assembly.

CONNECTING ROD BEARINGS

Note. Main and connecting rod bolts are tightened using new method. Before tightening bolts, bolt threads should be checked for "necking" by holding a straightedge against threads. If threads do not fully touch straightedge, bolt should be replaced.

1. Use Plastigage method to check rod bearings. Turn crankshaft until connecting rod to be checked just starts moving toward top of engine. Place Plastigage across full width of lower bearing 1/4" off center and away from oil holes.
2. Install rod cap and tighten nuts to 40 ft. lbs. (55 N.m) plus 1/4 turn. Remove rod cap and determine amount of clearance by measuring width of compressed Plastigage with scale furnished on package. Clearance should be .0008-.0034" (.019-.087 mm) for non-turbocharged engines. On turbocharged engines, clearance should be .0008-.0031" (.019-.079 mm).
3. If clearance exceeds specifications, bearings must be replaced. New bearings are available in standard, .001" and .002" undersize for use with standard size crankshaft. Bearings are also available in .010", .011", .012", .020" and .030" undersize for use with reconditioned crankshaft. NOTE: Do not use bearings with more than .001" (.025 mm) difference in size on same journal.
4. Check rod journal for out-of-round condition. If journals are more than .003" (.08 mm) out-of-round, crankshaft must be reconditioned or replaced. When all bearings have been checked and/or replaced, measure rod side clearance using feeler gauge. Clearance should be .005-.013" (.13-.32 mm).

Note. If clearance cannot be brought within specifications, grind crankshaft to next undersize. If already at maximum undersize, replace crankshaft.

MAIN BEARINGS

Note. Main and connecting rod bolts are tightened using new method. Before tightening bolts, bolt threads should be checked for "necking" by holding a straightedge against threads. If threads do not fully touch straightedge, bolt should be replaced.

1. Using Plastigage method, place Plastigage across full width of lower bearing 1/4" off center and away from oil holes. Install main bearing cap with bearing and tighten bolts to 30 ft. lbs. (41 N.m) plus 1/4 turn.
2. Remove main cap and determine amount of clearance by measuring width of compressed Plastigage with scale furnished on package. Clearance should be .0003-.0031" (.007-.080 mm). If clearance exceeds specifications, bearings must be replaced.
3. New bearings are available in standard, .001" and .002" undersize for use with standard size crankshaft. Bearings are also available in .010", .011", .012", .020" and .030" undersize for use with reconditioned crankshaft. NOTE: Do not use bearings with more than .001" (.025 mm) difference in size on same journal.
4. Check crankshaft journal for out-of-round condition. If journals are more than .0005" (.013 mm) out-of-round, crankshaft must be reconditioned or replaced. When all bearings have been checked and/or replaced, measure crankshaft end play using dial indicator.
5. Mount dial indicator on front of engine with stem on nose of crankshaft. Move crankshaft all the way rearward and zero dial indicator. Move crankshaft all the way forward and read dial indicator reading. End play should be .002-.007" (.05-.18 mm).

1. Remove timing belt cover and remove timing belt. Remove crankshaft sprocket bolt.
2. Install Crankshaft Sprocket Puller (C-4685), and remove crankshaft sprocket. Install Oil Seal Puller (C-4679), and remove oil seal, being careful not to nick shaft seal surface or seal bore.

Lightly coat outside diameter of new oil seal with Loctite (P/N 4057987) for steel case or use soapy water for rubber coated steel case. Using Oil Seal Installer (C-4680), install oil seal flush with front of oil seal retainer. Reverse removal procedure to complete installation.

Engine or transmission must be removed for seal service. Using large screwdriver, pry out seal from crankshaft oil seal retainer, being careful not to nick/damage flange seal surface or retainer bore.

Lightly coat outside diameter of new oil seal with Loctite (P/N 4057987). Position seal and Oil Seal Installer (C-4681) flush with retainer and tap into place using plastic hammer.

CRANKCASE CAPACITY

Crankcase capacity is 4 quarts (3.8L) on non-turbocharged engines and 5 quarts with turbocharged engine. On all engines, amounts are with or without filter change.

NORMAL OIL PRESSURE

Normal oil pressure is 50 psi (3.52 kg/cm 2 ) @ 3000 RPM.

PRESSURE REGULATOR VALVE

Pressure regulator valve is located in oil pump cover and is adjustable.

Remove oil pan. On 2.2L engines, remove bolt holding oil pick-up tube to No. 3 main bearing cap bolt. On all engines, remove bolt on pump cover holding oil pick-up tube to oil pump. Remove pick-up tube and "O" ring. Remove 2 bolts holding oil pump to cylinder block and remove pump.

Disassembly

Remove 4 oil pump cover-to-pump housing bolts and remove pump cover. Remove gear and rotor. Remove oil pressure relief valve pin, cup, spring and valve from oil pump housing.

Inspection

1. Install gear and rotor into pump housing and check gear end play by placing straightedge across pump housing. Using feeler gauge, measure clearance between gear and straightedge. Clearance should be .001-.003" (.03-.08 mm).
2. Using micrometer, measure rotor thickness. Minimum thickness should be .944" (23.97 mm). Now measure rotor diameter. Minimum diameter should be 2.469" (62.70 mm).
3. Using feeler gauge, measure gear-to-rotor clearance. Maximum clearance should be .008" (.20 mm). Measure rotor-to-pump housing clearance. Maximum clearance should be .014" (.35 mm). Place straightedge across pump cover and measure pump cover wear using feeler gauge. Maximum clearance should be .003" (.076 mm).
4. Measure relief valve spring. Free length is 1.95" (49.5 mm) and loaded is 15-25 lbs. at 1.34" (67-89 N at 34 mm). If any measurement is not within specifications, replace oil pump as an assembly.

Reassembly

Install rotor with large chamfered edge facing down into pump housing. Install drive gear. Install pump cover with 5 attaching bolts and tighten. Insert pressure relief valve, spring, cup and pin into pump housing.

Reverse removal procedure, making sure to install new "O" ring seal on pick-up tube and align slot in oil pump shaft parallel to centerline of crankshaft.

Exploded View of 2.2L Engine Oil Pump Assembly. Scheme 22

Note. It is not necessary to remove timing belt to remove water pump. See .

1. Disconnect negative battery cable and drain cooling system. Remove upper radiator hose. Remove air conditioning compressor from engine bracket and set aside. Remove alternator and set aside.
2. Remove water pump by disconnecting lower hose, by-pass hose and 4 bolts holding water pump housing to engine. Remove water pump from housing. (Scheme 23)and (Scheme 24).

1. If installing new water pump, transfer pulley from old pump. Clean all sealing surfaces.
2. Apply a bead of sealer to water pump sealing surface. While sealer is wet, install water pump and tighten attaching bolts.
3. Install all accessories and drive belts. Connect battery cable.

Note. For further information on cooling system capacities and other cooling system components, see ENGINE COOLING SYSTEMS article in this section.

Scheme 23

Scheme 24

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

GENERAL ENGINE SPECIFICATIONS

GENERAL SPECIFICATIONS

VALVE SPECIFICATIONS

VALVE SPECIFICATIONS

PISTONS, PINS & RINGS SPECIFICATIONS

PISTONS, PINS & RINGS SPECIFICATIONS

CRANKSHAFT MAIN & CONNECTING ROD BEARINGS SPECS

CRANKSHAFT MAIN & CONNECTING ROD BEARINGS SPECS

VALVE SPRINGS SPECIFICATIONS

VALVE SPRINGS SPECIFICATIONS

CAMSHAFT SPECIFICATIONS

CAMSHAFT SPECIFICATIONS

See also:
• ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION
• VALVE SPRING