2.9l v6 - VIN [t] Ford Bronco II 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.

Engine is identified by the eighth character of Vehicle Identification Number (VIN). The VIN is stamped on a metal plate visible through windshield on left upper side of instrument panel. VIN is also located on Safety Compliance Certification Label, attached to left door lock pillar.

ENGINE IDENTIFICATION CODES

VALVE CLEARANCE ADJUSTMENT

1. Adjust one cylinder at a time. Rotate crankshaft and position valve being adjusted on lowest portion of camshaft lobe (valve completely closed). Loosen adjusting screw until rocker arm backlash is achieved. Turn in adjusting screw until rocker arm initially contacts valve tip.
2. To achieve nominal working position of valve lifter, turn in adjusting screw 1.5 turns, or the equivalent of .07" (1.8 mm). Feeler gauge method is not used on the 2.9L engine. Repeat procedure to adjust remaining valves.

ENGINE

1. Disconnect negative battery cable and drain cooling system. Disconnect or remove all thermactor components that may interfere with engine removal. Remove hood, air cleaner and intake duct assembly.
2. Remove fan shroud and position over fan. Remove radiator with hoses and shroud. Remove alternator and power brake vacuum hose from engine. If equipped, remove A/C compressor and power steering pump with hoses attached.
3. Disconnect heater hoses from engine. Disconnect and plug fuel tank line at fuel pump. Disconnect throttle cable linkage at carburetor and intake manifold. Disconnect primary wire from coil.
4. Disconnect wiring from oil pressure and engine coolant temperature sending units. Raise vehicle to disconnect exhaust pipes from manifolds. Remove starter and front engine mount nuts or through bolts.
5. If automatic transmission equipped, remove converter inspection cover and disconnect flex plate from converter. Remove kickdown rod and bellhousing mounting bolts. Remove adapter plate-to-converter housing bolt.
6. Remove clutch linkage (manual transmission). Lower vehicle and attach engine hoist to brackets at exhaust manifolds. Support transmission. Remove engine from vehicle.

ENGINE OVERHAUL

Note. See the OVERHAUL PROCEDURES article in this section for all basic procedures not covered in this article.

DEPRESSURIZING FUEL SYSTEM

Note. Before disconnecting any fuel system component that may be under pressure, perform the following procedure.

Disconnect battery cable. Remove fuel tank cap. Remove cap from pressure relief valve located on fuel supply manifold and attach EFI Pressure Gauge (T80L-9974-B). Use pressure release button on gauge to bleed off pressure and fuel into an approved container.

Another method of depressurizing system is by disconnecting inertia switch and cranking engine for a minimum of 20 seconds.

Note. On all engines discharge A/C and remove A/C lines to remove oil pan (if necessary).

INTAKE MANIFOLD

Scheme 1

Removal (Upper)

1. Disconnect negative battery cable. Remove air inlet tube from throttle body. Mark and disconnect electrical connectors from upper intake manifold. Remove snow/ice shield to expose throttle linkage on throttle body. Disconnect throttle cable from throttle body.
2. Mark and disconnect vacuum hoses from upper intake manifold, EGR valve and fuel pressure regulator. Disconnect breather hose from under throttle body. Disconnect PCV vacuum tube from under the upper intake manifold. Remove canister purge line from fitting near power steering pump.
3. Disconnect EGR tube from EGR valve. Loosen bolt retaining A/C line at upper rear of upper intake manifold and disengage retainer. Remove 6 upper intake manifold bolts. Remove upper intake manifold and throttle body assembly from lower intake manifold.

Installation

Clean and inspect upper and lower intake manifold mating surfaces. Install sealing compound to upper and lower intake manifold mating surfaces. Position new gasket on lower intake manifold. Install aligning pins to ensure gasket stays in place. Install upper intake manifold assembly and tighten in five steps to levels stated in TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure.

Removal (Lower)

1. Remove upper intake manifold assembly. See REMOVAL (UPPER) under «INTAKE MANIFOLD»(/ford/bronco-ii/i-1984-1990/remont/mechanical/#29l-v6-vin-t__intake-manifold) in this article. Drain coolant system. Remove upper radiator hose and heater hose from thermostat housing. Mark and remove spark plug wires from spark plugs. Remove distributor cap with spark plug wires.
2. Rotate crankshaft and position ignition rotor on No. 1 cylinder with crankshaft harmonic balancer at TDC. Mark ignition rotor-to-distributor housing position. Remove distributor assembly.
3. Remove fuel tank filler cap. Disconnect vacuum line from fuel pressure regulator, located on fuel rail. Attach a vacuum pump to pressure regulator and apply approximately 25 in. Hg (84 kPa) pressure to pressure regulator. This will release fuel into fuel tank through fuel return hose.
4. Remove valve cover and rocker arm shaft assembly. See «VALVE COVER & ROCKER ARM SHAFT ASSEMBLY»(/ford/bronco-ii/i-1984-1990/remont/mechanical/#29l-v6-vin-t) under VALVES in this article. Remove lower intake manifold retaining bolts and nuts. Note length of bolts to ensure installation to original location.
5. Lightly tap lower intake manifold with plastic hammer to break seal. Lift lower intake manifold off engine. Remove all gasket material and check gasket mating surfaces.

1. Apply sealing compound to joining surfaces. Position lower intake manifold gaskets on cylinder head. Ensure tab on right cylinder head gasket fits into cutout of lower intake manifold gasket. Apply sealing compound to bottom surface of bolt holes on lower intake manifold. Install lower intake manifold.
2. Install lower intake manifold bolts to original location. Tighten bolts evenly to specifications. See «TORQUE SPECIFICATIONS»(/ford/bronco-ii/i-1984-1990/remont/mechanical/#29l-v6-vin-t) table at end of this article.
3. To complete installation, reverse removal procedure. When installing rocker arm shaft assembly, tighten retaining bolts evenly, 2 turns at a time, until specifications are obtained. Fill and bleed cooling system. See «COOLING SYSTEM PURGE»(/ford/bronco-ii/i-1984-1990/remont/mechanical/#29l-v6-vin-t__cooling-system-purge) in this article.

EXHAUST MANIFOLD

Disconnect inlet pipe from exhaust manifold. Disconnect EGR tube from manifold. Remove exhaust manifold-to-cylinder head bolts. Lift exhaust manifold from cylinder head and out of vehicle. To install, reverse removal procedure. Tighten all bolts to specifications.

Removal

Remove cylinder head and related parts following the procedures described under CYLINDER HEAD REMOVAL & INSTALLATION below. Remove hydraulic tappets with a magnet. Place them in a rack in sequence. If tappets are stuck in bores, use plier-type tool to remove them. Rotate tappets back and forth to loosen them from gum or varnish deposits.

Clean tappets. Tappets and bores are to be lubricated with heavy oil SF before installation. Install tappets in their original bores with a magnet. Check any new tappet for proper fit in bore which it is to installed. Install cylinder head and related parts following the procedures described under CYLINDER HEAD REMOVAL & INSTALLATION below.

1. Remove upper and lower intake manifolds. See «INTAKE MANIFOLD»(/ford/bronco-ii/i-1984-1990/remont/mechanical/#29l-v6-vin-t__intake-manifold) in this article. Remove push rods and keep in order for installation to original location. Remove exhaust manifold from cylinder head being removed.
2. Loosen and remove cylinder head bolts evenly. Discard cylinder head bolts. Remove cylinder head. Remove and discard cylinder head gasket.

Inspection

Clean all carbon from cylinder head combustion chambers. Remove all gasket material from cylinder head and cylinder block. Use caution not to scratch surfaces. Measure cylinder block and cylinder head mating surfaces for warpage. See WARPAGE SPECIFICATIONS TABLE at end of this article.

1. Position head gasket on engine block with marked words in proper position. Install fabricated alignment dowels in cylinder block to keep gasket in place and assist in cylinder head alignment. Position cylinder head on block. Install NEW cylinder head bolts.
2. Tighten cylinder head bolts to levels stated in «TORQUE SPECIFICATIONS»(/ford/bronco-ii/i-1984-1990/remont/mechanical/#29l-v6-vin-t) in four steps, step 1) 22ft.lbs.(30Nm), step 2) 51-55ft.lbs.(70-75Nm), step 3) wait 5 minutes, step 4) turn each bolt a further 90 degrees. Each step must follow the correct tightening sequence. (Scheme 2) Apply heavy SF engine oil to both ends of push rods and install. To complete installation, reverse removal procedure. Fill and bleed cooling system. See «COOLING SYSTEM PURGE»(/ford/bronco-ii/i-1984-1990/remont/mechanical/#29l-v6-vin-t__cooling-system-purge) in this article.

Scheme 2

Valve Arrangement

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

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

Scheme 3

1. Remove spark plug wires. Clean fuel supply and return fittings prior to separation. Some fittings may stick between seals and tubing. Twist fitting on tube, then push and pull fitting until it move freely. Two types of fuel line fittings are used. One uses a hairpin clip connector and one uses a metal spring lock connector.
2. On hairpin clip type, first bend tab downward until it clears fitting body. (Scheme 3) Second, spread the 2 clip legs 1/8" each, to disengage body and push legs into fitting. Pull clip from fitting and discard clip. Pulling in an axial direction, separate tube from fitting.
3. On metal spring lock type, use Spring Lock Coupling Disconnect Tool (T81P-19623-G2) to separate coupling fitting. Match mark mating connectors to ensure proper mating at installation. CAUTION: Valve cover bolts have different reinforcement pieces at different locations. DO NOT mix pieces as they must be installed to original location.
4. On models with A/C, remove dipstick tube and bracket. Remove left engine lifting hook. Remove valve cover bolts and reinforcement pieces and note location for installation. Lightly tap valve cover with plastic hammer to break valve cover seal and remove valve cover.
5. Remove rocker arm shaft assembly retaining bolts evenly 2 turns at a time. Remove rocker arm shaft assembly and oil baffle. Remove push rods and keep in order to ensure installation to original location.

Disassembly & Reassembly

Remove roll pin and spring washer from each end of rocker arm shaft. Keeping components in order, slide components off rocker arm shaft. DO NOT mix components as they must be reassembled to original position. Position oil holes and notch on end of shaft down. Install a roll pin and spring washer on one end of shaft. Coat all parts with heavy SF engine oil. To complete reassembly, reverse disassembly procedure.

1. Loosen all valve clearance adjusting screws. Apply heavy SF engine oil to rocker arm shaft assembly. Install oil baffle and rocker arm shaft assembly. Install rocker arm shaft bolts. Tighten bolts evenly, 2 turns at a time to specifications.
2. Adjust valve clearance. See «VALVE CLEARANCE ADJUSTMENT»(/ford/bronco-ii/i-1984-1990/remont/mechanical/#29l-v6-vin-t__valve-clearance-adjustment) in this article. Remove all old valve cover gasket material. Install new gaskets on valve covers. Install valve covers. Install retaining bolts with reinforcement pieces to the proper position. (Scheme 4) CAUTION: Failure to properly install reinforcement pieces will result in valve cover damage and oil leakage.
3. Tighten retaining bolts to specifications. To complete installation, reverse removal procedure.

Scheme 4

Note. Valve spring and/or seal may be removed with cylinder head installed.

Scheme 5

1. Measure installed height of valve spring with divider. (Scheme 5) Use a vernier caliper and measure distance of divider for spring height. If height is greater than specifications, install spacer(s) between cylinder head and valve spring. Replace the valve spring(s) if necessary. CAUTION: DO NOT install spacers unless necessary. Use of excess spacers will cause premature component failure.
2. With valve springs removed, check springs for squareness, free length and pressure at specified length. If not within specifications, replace spring(s). See the «VALVE SPRINGS SPECIFICATIONS»(/ford/bronco-ii/i-1984-1990/remont/mechanical/#29l-v6-vin-t) table at the end of this article.

VALVE GUIDE SERVICING

Valve guide replacement information is not available from manufacturer. If valve guides need service, ream valve guide for proper fit of oversize valves. Valves are available with .008" (.20 mm), .016" (.41 mm) and .032" (.81 mm) oversize stems.

1. Remove oil pan. See «OIL PAN REMOVAL»(/ford/bronco-ii/i-1984-1990/remont/mechanical/#29l-v6-vin-t__oil-pan-removal) . Drain cooling system. Remove heater, radiator hoses and radiator. Remove drive belts. Remove A/C compressor, power steering pump and bracket (if equipped). Remove alternator and thermactor pump.
2. Remove clutch fan assembly using Fan Clutch Pulley Holder (T83T-6312-A) and Fan Clutch Nut Wrench (T83T-6312-B). Remove belt pulley from crankshaft harmonic balancer. Remove crankshaft harmonic balancer. Remove front cover retaining bolts. Guides For Removing Harmonic Balancer: When removing the harmonic balancer, be aware that the apparent nose of the crankshaft that extends out from the harmonic balancer IS NOT PART OF THE CRANK. It is a separate "nose piece" that slides over the front of the crank. It sandwiches the harmonic balancer between it and the crank. Attempting to pull the balancer off by leveraging against the nose piece (which is sandwiching the balancer in) will be unsuccessful and damage the puller. Unfortunately, the bolt that secures the nose piece and balancer to the crank cannot be used to leverage off the actual crank because it is too short to pull the nose piece/balancer all the way off (the nose piece runs into it before the job is finished). Therefore, two options exist. First, find a longer version of the the same bolt, thread it in, and pull away. Second, find or manufacture a rod that meets the following requirements: It should be approximately 4.5" in length and have a 7/16" OD. The end going into the crankshaft should be turned down to a 3/8" OD for 1". This will prevent the rod from seating against (and damaging) the balancer bolt threads inside the crank. Make the ends of the rod square so it will sit straight. Insert the rod through the nose piece, small end first, and pull away. When reinstalling the harmonic balancer, a legitimate press will be needed. Unfortunately, the fastening bolt cannot be used as a press because (again) it is not long enough. Hammering is not a solution either because the balancer can be easily damaged.
3. Lightly tap front cover with plastic hammer to break seal. Remove front cover and water pump as an assembly. Remove front cover seal. Remove 2 bolts retaining back cover plate to cylinder block and remove cover plate. Remove guide sleeves and discard seal rings.

1. Coat front cover seal with heavy SF engine oil and install seal. Apply sealing compound to engine block and cover plate mating surfaces. Install new gasket on plate cover and install plate cover. Install guide sleeves with new sealing rings with chamfered edge toward front cover.
2. Install and tighten 2 cover plate bolts. Apply sealing compound to front cover gasket surface and place gasket on front cover. Position front cover on engine and start retaining bolts 2 turns.
3. Evenly tighten front cover attaching bolts to specifications. To complete installation, reverse removal procedure. Fill and bleed cooling system. See «COOLING SYSTEM PURGE»(/ford/bronco-ii/i-1984-1990/remont/mechanical/#29l-v6-vin-t__cooling-system-purge) in this article. Operate engine at fast idle and check for coolant and oil leaks.

Removal (In Chassis)

Drain cooling system and remove radiator. Remove water pump drive belt and crankshaft pulley. Using a 3 finger seal puller and slide hammer, remove front cover oil seal.

Coat new seal with heavy SF engine oil. Slide oil seal and Seal Installer (T74P-6700-A) onto crankshaft. Tighten bolt into crankshaft until installer contacts front cover. To complete installation, reverse removal procedure.

1. Position No. 1 cylinder on TDC of compression stroke. Ensure damper timing marks align properly. Remove engine front cover. See REMOVAL under «ENGINE FRONT COVER»(/ford/bronco-ii/i-1984-1990/remont/mechanical/#29l-v6-vin-t) in this article. Note timing mark alignment for camshaft and crankshaft sprockets for installation reference.
2. Remove timing chain tensioner. Check timing chain deflection. See TIMING CHAIN DEFLECTION at the end of this paragraph. Remove camshaft sprocket retaining bolt. Remove camshaft sprocket and timing chain. Using a gear puller, remove crankshaft sprocket.

Timing Chain Deflection

1. Rotate crankshaft counterclockwise just enough to take up chain slack on left side (opposite side of tensioner). Mark a reference point on block, mid-point between sprockets.
2. Measure and record distance from reference point to chain. Rotate crankshaft clockwise just enough to take up chain slack on right side (tensioner side). Pull out left side of chain and measure distance from chain to reference point. NOTE: Timing chain deflection specifications are not available from manufacturer.
3. The difference between both measurements is the deflection. Replace timing chain and sprockets as necessary. If wear on tensioner face exceeds .06" (1.5 mm), replace tensioner. Return sprockets to TDC.

Note. Timing mark alignment illustration not available from manufacturer.

1. Align crankshaft sprocket keyway with key on crankshaft. Install crankshaft sprocket with an installer. (Scheme 6) Ensure timing mark on crankshaft sprocket is aligned as noted at removal. Place timing chain on camshaft sprocket.
2. Align camshaft sprocket keyway with key on camshaft and slide sprocket and chain onto camshaft. Ensure timing marks align as noted at removal. Install and tighten camshaft retaining bolt. Check camshaft end play. See CAMSHAFT END PLAY CHECK in this article. To complete installation, reverse removal procedure.

Scheme 6

Remove lower intake manifold. See REMOVAL (LOWER) under INTAKE MANIFOLD in this article. Remove timing chain and sprocket. See TIMING CHAIN & SPROCKETS in this article. Using lifter remover, remove lifters and keep in order for installation to original location. Remove camshaft thrust plate. Carefully draw camshaft out of cylinder block.

Coat camshaft journals and lobes with heavy SF engine oil (50w). Install spacer ring with chamfered side toward camshaft (if removed). Carefully install camshaft into engine block. Install thrust plate and tighten bolts. Ensure thrust plate covers main oil hole. To complete installation, reverse removal procedure.

Camshaft End Play Check

1. Remove engine front cover. See «ENGINE FRONT COVER»(/ford/bronco-ii/i-1984-1990/remont/mechanical/#29l-v6-vin-t) in this article. Remove valve covers. See «VALVE COVER & ROCKER ARM SHAFT ASSEMBLY»(/ford/bronco-ii/i-1984-1990/remont/mechanical/#29l-v6-vin-t) in this article. Loosen rocker arm shaft bolts evenly 2 turns at a time to release pressure from camshaft.
2. Push camshaft fully rearward. Install a dial indicator with pointer on center of camshaft. Zero dial indicator and pull camshaft forward and release it. If reading is greater than specifications, replace thrust plate. See «CAMSHAFT SPECIFICATIONS TABLE»(/ford/bronco-ii/i-1984-1990/remont/mechanical/#29l-v6-vin-t) at end of article.

Cam Lobe Lift Check

With camshaft removed, measure distance "A" and "B" in consecutive order. (Scheme 7) Distance "A" minus distance "B" is cam lobe lift. If reading is not within specifications, replace camshaft and all lifters.

Scheme 7

Remove engine. See ENGINE REMOVAL in this section. Remove camshaft. See CAMSHAFT REMOVAL & INSTALLATION in this article. Remove flywheel/flexplate. Remove rear bearing bore plug. Using Camshaft Bearing Replacer (T71P-6250-A), remove camshaft bearings.

Install camshaft bearings using camshaft bearing replacer. Ensure oil hole in bearing is aligned with oil hole in engine block. Front bearing must be installed .040-.060" (1.02-1.52 mm) from front face of block. Check oil hole alignment of number 2 and 3 bearings with a rod of smaller diameter. Insert rod into oil passage. Rod should pass into camshaft bore. To complete installation, reverse removal procedure.

REAR BEARING CORE PLUG

Remove flywheel/flexplate. Drill a hole in core plug and pull out core plug using a slide hammer. Oversize core plugs are available and and identified by "OS" stamped on core plug. Bore the core plug bore to next oversize plug available. Coat sealing edge of core plug with oil resistant sealer. Use a proper size driver ONLY and install core plug.

CYLINDER BLOCK INSPECTION

Check cylinder bore for wear, taper, out-of-round and piston fit. See appropriate ENGINE SPECIFICATIONS tables at end of this article. Install all main bearing caps and tighten to specifications prior to cylinder bore honing.

OIL PAN REMOVAL

1. Disconnect battery cable. Remove air intake. Remove fan shroud. Remove distributor. Drain crankcase and remove transmission filler tube (if equipped). Remove oil filter. Disconnect muffler inlet (except 2WD Ranger). Disconnect and lower oil cooler bracket.
2. Remove starter motor. Disconnect front stabilizer bar (if equipped) and position forward. Position jack under engine. Raise engine to install wooden blocks between front insulator mounts and No. 2 crossmember. Lower engine onto blocks and remove jack. Lower pan. Remove oil pump and pick-up assembly into pan (except Ranger 2WD). Remove pan. To install, reverse removal procedures.

Scheme 8

PISTON & ROD ASSEMBLY INSPECTION

Note. The following procedure is with cylinder head, oil pan, oil pump and pick-up tube removed. Components must be marked, to ensure installation to original position and location.

1. Ensure pistons and rods are installed in cylinder from which it was removed. Ensure notch on piston top faces front of engine. Check piston fit before reassembling piston on rod. See «FITTING PISTONS»(/ford/bronco-ii/i-1984-1990/remont/mechanical/#29l-v6-vin-t__fitting-pistons) in this article.
2. Check piston pin fit. If not within specifications, remove pin and measure pin bore in piston and rod. Replace as necessary. If piston pin is to be replaced, replace piston and pin as an assembly. See appropriate SPECIFICATIONS tables at end of this article.

FITTING PISTONS

Note. Make all measurements with piston and block at normal room temperature of 70°F (21°C).

Each cylinder bore must be measured for out-of-round, taper and piston-to-cylinder bore clearance. If taper, out-of-round or piston-to-cylinder bore clearance are beyond specifications, or cylinder walls are deeply scored, cylinders must be honed or bored. See appropriate SPECIFICATIONS tables at end of this article. Pistons are available in .020" (.51 mm) oversize. A Red coded piston is standard size.

Scheme 9

FITTING RINGS

1. Place NEW ring (one at a time) in cylinder bore, in which it will be installed. Position where normal ring wear is not encountered. Use head of piston to ensure ring is square in bore. Measure piston ring end gap.
2. Install rings on piston and check side clearance of rings-to-piston. If not within specifications, replace rings and/or piston as necessary. With proper rings selected, position ends of rings properly on piston. (Scheme 9)

PISTON PIN REPLACEMENT

Match mark piston pin-to-rod and rod-to-piston for installation reference. Press pin from piston with Piston Pin Set (T68P-6135-A). Check pin-to-piston clearance. Replace if not within specifications. See ENGINE SPECIFICATIONS tables at end of this article. Apply a light coat of engine oil to all components. Align match marks. To complete installation, reverse removal procedure.

1. Remove oil pan. See «OIL PAN»(/ford/bronco-ii/i-1984-1990/remont/mechanical/#29l-v6-vin-t__oil-pan-removal) in this article. Position rod to be serviced in full down stroke. Remove rod nuts and remove rod cap with bearing insert. Place protectors over rod bolts. Push piston up just enough to remove upper rod bearing insert.
2. Clean crankshaft journal and rod bearing bore. Ensure oil hole on rod is not restricted. Check each crankshaft journal for out-of-round. Replace or machine crankshaft as necessary.

1. Install upper bearing insert. Ensure tabs are positioned properly. Install bearing insert in rod cap. Use Plastigage method for proper selection of rod bearing inserts. Standard bearing insert may be used in combination with .001-.002" (.03-.05 mm) undersize bearing insert to obtain proper clearance.
2. Repeat procedure for all rod bearing inserts. With proper bearing inserts selected, apply engine oil to journal and bearing inserts. To complete installation, reverse removal procedure. Tighten bolts and nuts to specifications.

MAIN BEARINGS

Note. If rear main bearing is to replaced, remove engine. Position jack under counterweight adjoining main bearing being serviced.

Remove oil pan. See OIL PAN in this article. Remove ONLY one main bearing cap at a time. Remove main bearing cap (with bearing) being serviced. Install Main Bearing Insert (TOOL-6331-E) in journal oil hole. (Scheme 10) Rotate crankshaft in normal operating direction and force upper main bearing out.

Scheme 10

1. Apply heavy SF engine oil to upper main bearing. Start upper main bearing into locking tab side of block enough to install main bearing insert tool. With tool inserted, rotate crankshaft in opposite direction of normal operation until bearing tab is seated.
2. Plastigage main bearing to obtain proper clearance. Standard bearing may be used in combination with .001-.002" (.03-.05 mm) undersize bearing insert to obtain proper clearance. If undersize bearing is used with standard, place undersize bearing in cylinder block side only.
3. With proper bearing selected, coat journal and main bearing with heavy SF engine oil. Install main bearing caps and tighten bolts to specifications. If replacing rear main bearing, apply sealer to notched portion of rear face of cap.

THRUST BEARING ALIGNMENT

Loosen No. 3 main bearing cap. Align thrust bearing surfaces by forcing crankshaft forward and thrust bearing cap rearward. While holding this position tighten main bearing cap bolts evenly to specifications.

REAR MAIN BEARING OIL SEAL

Remove transmission flywheel/flexplate. Use a slide hammer and remove rear main oil seal evenly. Use care not to damage crankshaft sealing surface. Coat seal surfaces with heavy SF engine oil. Use a proper size seal installer and install seal until firmly seated. To complete installation, reverse removal procedure.

ENGINE OILING SYSTEM

System is pressure fed from rotor-type oil pump. Oil flows through oil filter before entering main oil gallery.

Crankcase Capacity

Crankcase capacity is 4 qts. (3.8L) without filter and 5 qts (4.75L) with oil filter.

Normal Oil Pressure

Normal oil pressure should be 40-60 psi (2.8-4.2 kg/cm 2 ) with engine at normal operating temperature and 2000 RPM.

Oil Pressure Regulator Valve

Oil pressure regulator valve is located in oil pump body. Valve is nonadjustable.

OIL PUMP

Remove oil pan. See OIL PAN in this article. Remove oil pump attaching bolts. Remove oil pump and oil pump drive shaft.

Note. Oil pump is serviced as an assembly only. See the OIL PUMP SPECIFICATIONS table. Replace assembly if not within specifications.

OIL PUMP SPECIFICATIONS

Fill oil pump inlet and rotate drive shaft until oil flows from oil pump outlet. Install drive shaft with pointed end in block. Install oil pump with new gasket. Tighten bolts to specifications. To complete installation, reverse removal procedure.

Scheme 11

1. Drain cooling system. Remove lower radiator hose and heater return hose from water pump. Remove fan and clutch assembly using Fan Clutch Holder and Nut Wrench (T83T-6312-A and B). (Scheme 11) Remove by turning nut clockwise as nut has left-hand thread.
2. Remove alternator belt. Remove alternator and bracket (if A/C equipped). Remove water pump pulley. Remove water pump attaching bolts and note different bolt lengths for installation reference. Remove water pump assembly.

Ensure all old gasket material is removed. Apply sealer to both sides of new gasket. Place gasket on water pump. Position water pump and install 2 bolts finger tight. Install remaining bolts to proper location and tighten to specifications. To complete installation, reverse removal procedure. Fill and bleed cooling system.

COOLING SYSTEM PURGE

1. Disconnect upper heater hose at heater. Fill cooling system with 50/50 mixture until level is even with filler neck seat. Connect heater hose at heater. Install radiator cap tight, then back off to first stop. WARNING: NEVER remove radiator cap with engine operating under any conditions. Failure to follow instruction could result in damage to cooling system, engine or personal injury. Always wrap protective material around radiator cap to avoid injury from hot steam or scalding hot coolant.
2. Turn heater controls to full hot. Start engine and operate engine at 2000 RPM until upper radiator hose is warm. Stop engine and CAREFULLY remove radiator cap with protective material. Add necessary coolant to obtain proper level.
3. Install radiator cap tight, then back off to first stop. Start engine and allow to operate for 2 minutes. Check heater operation to ensure system circulation. Stop engine and CAREFULLY remove radiator cap with protective material. Add necessary coolant to obtain proper level.

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

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

GENERAL ENGINE SPECIFICATIONS

GENERAL ENGINE 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

WARPAGE SPECIFICATIONS

WARPAGE SPECIFICATIONS

CYLINDER WALL SPECIFICATIONS

CYLINDER WALL SPECIFICATIONS

See also:
• ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION
• TORQUE SPECIFICATIONS
• INTAKE MANIFOLD
• COOLING SYSTEM PURGE
• VALVE CLEARANCE ADJUSTMENT
• OIL PAN REMOVAL
• FITTING PISTONS