GENERAL PRECAUTIONS
| CAUTION | When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery. |
Note. For reassembly reference, label all electrical connectors, vacuum hoses and fuel lines before removal. Place mating marks on engine hood and other major assemblies before removal.
FUEL PRESSURE RELEASE
| WARNING | Fuel system is under pressure. Pressure must be released before fuel system components are serviced. |
- Remove fuel filler cap. Remove protective cap from fuel pressure test port on fuel rail. (Scheme 8)
- Place open end of Fuel Pressure Release Hose (C-4799-1) into an approved gasoline container. Connect other end of hose to fuel pressure test port. Fuel pressure will bleed off through hose into gasoline container.
Scheme 8
INTAKE MANIFOLD
| CAUTION | Fuel system is under pressure. Fuel pressure must be released before fuel lines are disconnected. |
CAMSHAFT
Note. Manufacturer lists camshaft service procedure with engine removed only.
Cylinder Head
Inspect cylinder head for cracks and warpage. Repair or replace cylinder head if warpage exceeds specification. Refer to CYLINDER HEAD table under ENGINE SPECIFICATIONS. DO NOT grind more than .008" (.20 mm) combined total from surfaces of cylinder head and cylinder block deck.
Valve Springs
- Inspect valve spring tension and free length. Replace spring if it is not within specification. See «VALVES & VALVE SPRINGS»(ref-48416-S00944658592001011500000) table under ENGINE SPECIFICATIONS.
- Measure valve spring installed height from spring seat to bottom of spring retainer. If spacers are installed, measure from top of spacer. If height exceeds 1 19/32" (40.6 mm), install a 1/32" (.794 mm) thick spacer in cylinder head counterbore to obtain correct installed height. See «VALVES & VALVE SPRINGS»(ref-48416-S00944658592001011500000) table.
Valve Stem Oil Seals
Use oversize valve stem seals when oversize valves are installed.
Valve Guides
- Check valve stem oil clearance. Ensure valve stem diameter is within specification. Valve guide must be reamed for valve with oversize valve stem if clearance exceeds specification. Refer to «CYLINDER HEAD»(ref-48416-S13358786642001011500000) table under ENGINE SPECIFICATIONS. NOTE: DO NOT ream valve guides from standard to maximum oversize in one step. Ream guides to oversize in gradual steps so guides are reamed true in relation to valve seat.
- Valves are available with oversize valve stems of .006" (.15 mm), .016" (.40 mm) and .031" (.80 mm). Cylinder head must be replaced if guide cannot be cleaned using a .031" (.80 mm) reamer.
Valve Seat
Worn or burned valve seats can be reworked, provided proper angles and seat width are obtained. Cylinder head must be replaced if valve seat cannot be corrected.
Valves
Oversize valves are available in .006" (.15 mm), .016"(.40 mm) and .031" (.80 mm).
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.
Fitting Pistons
- To determine if piston-to-cylinder clearance is within specification, measure piston skirt diameter 1.65" (42.0 mm) from top of piston at 90-degree angle to piston pin. Piston diameter must be within specification. See «PISTONS»(ref-48416-S14752000582001011500000) , PINS & RINGS table under ENGINE SPECIFICATIONS. NOTE: Measure piston diameter at normal room temperature of 70°F (21°C).
- Measure cylinder bore about .47" (12.0 mm) below top surface of cylinder bore, middle of bore and about .47" (12.0 mm) from bottom of cylinder bore.
Piston Rings
Check ring end gap and side clearance. See PISTONS, PINS & RINGS table under ENGINE SPECIFICATIONS. Position ring gaps in proper locations before installation. (Scheme 9)
Scheme 9
Rod Bearings
Before installing rod bearings, hold a straightedge across threads of connecting rod bolts. Ensure connecting rod bolt threads contact straightedge in all areas. If threads fail to contact straightedge, bolts are stretched and must be replaced. Apply light coat of engine oil to connecting rod bolt threads before tightening nut to specification. See TORQUE SPECIFICATIONS .
| CAUTION | Crankshaft journal grinding should not exceed .012"(.30 mm) under standard size. DO NOT grind thrust surfaces of main bearing No. 2. Final paper or cloth polishing after regrind must be done in same direction as engine rotation. |
Crankshaft & Main Bearings
- Before installing main bearings, hold a straightedge across threads of main bearing cap bolts. Ensure main bearing cap bolt threads contact straightedge in all areas. If threads fail to contact straightedge, bolts are stretched and must be replaced.
- Apply light coat of engine oil to threads before tightening bolt to specification. See «TORQUE SPECIFICATIONS»(ref-48416-S14832020102001011500000) .
Note. Measure cylinder bore at normal room temperature of 70°F (21°C).
Cylinder Block
- Check cylinder bore, out-of-round and taper. Measure at about .50" (12.7 mm) below top surface of cylinder bore, middle of bore and about .50" (12.7 mm) from bottom of cylinder bore.
- Check valve lifter bore diameter. Repair or replace cylinder block if it is not within specification. See «CYLINDER BLOCK»(ref-48416-S38824289362001011500000) and «VALVE LIFTERS»(ref-48416-S16789610782001011500000) tables under ENGINE SPECIFICATIONS.
Oil Pressure
Normal oil pressure is 5 psi (.35 kg/cm 2 ) at curb idle and 30-80 psi (2.1-5.5 kg/cm 2 ) at 3000 RPM.
Scheme 10
OIL PUMP
Note. Oil pan and timing chain cover must be removed to service oil pump. Pressure relief valve can be serviced by removing oil pan and pick-up tube only.