FUEL PRESSURE RELEASE
| WARNING | Fuel system is under pressure. Release pressure before disconnecting fuel system components. |
- Disconnect negative battery cable. Remove filler cap. Remove protective cap from fuel pressure test port on fuel rail. Place open end of Fuel Pressure Release Hose (C-4799-1), into an approved container. Connect fitting end of hose to fuel pressure test port. Fuel pressure will bleed off through hose into container.
Fuel Lines
Fuel line clamps are not used on any fuel system component. If there is a fitting or line that needs repair it must be replaced. DO NOT use rubber hose and clamps to repair a fuel line.
Inspect all lines and quick connect fittings for leaks. Replace lines that rub against other vehicle components or show sign of wear. Ensure all lines are secured in their proper holders.
Quick-Connect Fittings
Fuel tubes connect fuel system components with plastic quick-connect fuel fittings. The fitting contains non-serviceable O-ring seals.
| CAUTION | Quick-connect fittings are not serviced separately. Do not attempt to repair damaged quick connect fittings or fuel tubes. Replace the complete fuel tube/quick-connect fitting assembly. |
Scheme 42
The quick-connect fitting consists of the O-rings, retainer and casing . When the fuel tube enters the fitting, the retainer locks the shoulder of the nipple in place and the O-rings seal the tube.
FUEL FILTER
The fuel filter mounts to the frame above the rear of the fuel tank. The inlet and outlet tubes are permanently attached to the filter.
INTAKE MANIFOLD
| WARNING | Wrap shop towels around hose to catch any fuel spillage. |
| CAUTION | To prevent damage, DO NOT set fuel injectors on their tips. |
CYLINDER HEAD
| CAUTION | A production change introduced a new Multi-Layer Steel (MLS) head gasket. See TECHNICAL SERVICE BULLETIN 09-05-98, dated November 6, 1998. |
TIMING BELT
| CAUTION | Neither camshafts or crankshaft should be rotated with timing belt removed. Damage to valve components may occur. ALWAYS align timing marks before removing timing belt. |
Note. Early engines are equipped with hydraulic tensioners. Late engines are equipped with mechanical tensioners. Late mechanical tensioner has a hydraulic retrofit kit. Kit consists of Tensioner Package (5010371-AA) and Cover (4694318-AB).
- Inspect cylinder head for cracks and warpage. Repair or replace head if warpage exceeds specification. See «CYLINDER HEAD»(ref-54187-S05338110662001011700000) table under ENGINE SPECIFICATIONS. After grinding valves or valve seats, install valve into cylinder head and measure distance from spring seat of cylinder head to tip of valve.
- Distance should be 1.889" (47.99 mm) for exhaust and 1.891" (48.04 mm) for intake. Grind valve tip and rechamfer if necessary.
Valve Springs
Measure valve spring free length, out-of-square and spring pressure. Measure installed height from valve spring lower edge to upper edge. DO NOT include spring seat or retainer flange. Replace valve spring if not within specification. See VALVES & VALVE SPRINGS table under ENGINE SPECIFICATIONS.
Valve Stem Oil Seals
Ensure oversize valve stem seals are used when oversize valves are installed. Ensure oil seal lower edge is against valve guide after installation.
Valve Guides
Note. DO NOT ream valve guides from standard to maximum in one step. Ream guides to oversize in gradual steps, so guides are reamed true in relation to valve seat.
Check valve stem oil clearance. Ensure valve stem diameter is within specification. See VALVES & VALVE SPRINGS table under ENGINE SPECIFICATIONS. Ream valve guide for valve with oversize valve stem if clearance exceeds specification. See CYLINDER HEAD table under ENGINE SPECIFICATIONS.
Valve Seat
If valve face and/or valve seats have been ground, measure valve tip-to-valve spring seat dimension. Grind valve tip (if necessary) to give a an installed height of 1.889" (47.99 mm) for exhaust valves or 1.891" (48.04 mm) for intake valves when measured from spring seat.
Valves
After grinding valves, inspect remaining margin. Intake valves with less than .047" (1.2 mm) margin and exhaust valves with less than .035" (0.9 mm) margin should be replaced.
Valve Seat Correction Angles
If seat width is too wide after grinding, use a 15-degree or 65-degree stone to alter seat width. A 15-degree stone will lower valve seat and a 65-degree stone will raise valve seat. For valve seat width, see CYLINDER HEAD table under ENGINE SPECIFICATIONS.
Fitting Pistons
To determine if piston-to-cylinder clearance is within specification, measure piston skirt diameter .551" (14.0 mm) from bottom of piston skirt, at 90-degree angle to piston pin. Ensure piston diameter is within specification. See PISTONS, PINS & RINGS table under ENGINE SPECIFICATIONS.
Piston Rings
Ensure ring end gap and side clearance are within specification. See PISTONS, PINS & RINGS table under ENGINE SPECIFICATIONS. Position ring gaps in proper locations before installing pistons. see scheme 29
Scheme 43
Rod Bearings
Note direction of connecting rod and cap installation before removing. Install connecting rod in original direction.
Crankshaft & Main Bearings
- Ensure crankshaft end play is within specification. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(ref-54187-S24549833072001011700000) table under ENGINE SPECIFICATIONS. Install main bearing shells with oil holes aligned with oil holes in block and tabs seated in block tab slots. CAUTION: DO NOT allow oil on bedplate mating surface. Oil will adversely effect ability of sealer to seal bedplate to cylinder block.
- Using fresh, clean oil, lubricate bearings and crankshaft journals and install crankshaft. Apply.059-.078" (1.5-2 mm) bead of anaerobic sealer to cylinder block. see scheme 30 CAUTION: Use only Anaerobic Sealer (4773257) on bedplate or damage may occur to engine.
- Install lower main bearings into main bearing cap/bedplate. Ensure bearing tabs are seated into bedplate slots. Install main bearing cap/bedplate onto engine. Clean and oil main bearing bolts before installation. Install main bearing bolts No. 11, 17 and 20 finger tight. Tighten these bolts together until bedplate contacts cylinder block uniformly. Tighten bolts No. 11, 17 and 20 to 20 ft. lbs. (28 N.m). see scheme 31
- Install main bearing bolts No. 1-10 and tighten in sequence to 30 ft. lbs. (41 N.m). see scheme 31 Torque main bearing bolts No. 1-10 an additional 1/4 turn. Install main bearing bolts No. 11-20 and tighten in sequence to 20 ft. lbs. (28 N.m). see scheme 31 After main bearing bedplate is installed, check crankshaft turning torque. Turning torque should not exceed 50 INCH lbs. (5.6 N.m).
Scheme 44
Scheme 45
Cylinder Block
Measure cylinder bore .394" (10.0 mm) below top of cylinder bore, at middle of bore and .394 " (10.0 mm) from bottom of cylinder bore. Measure in same plane as piston pin and at 90° to piston pin at each height. Check cylinder block deck surface warpage. Resurface cylinder block if warpage exceeds specification. See CYLINDER BLOCK table under ENGINE SPECIFICATIONS. DO NOT grind more than .008" (.20 mm) total from surface of cylinder head and deck surface of cylinder block.
Oil Pressure
Oil pressure is 4 psi (.08 k/cm 2 ) at curb idle and 25-80 psi (1.75-5.62 k/cm 2 ) at 3000 RPM.