TIMING BELT TENSION
Note. Routine timing belt tension adjustment is usually not necessary.
Remove A/C compressor belt (if equipped). Remove timing belt tensioner bolt access cover located above crankshaft pulley. Loosen tensioner bolt 1-2 turns. Rotate crankshaft clockwise 2 revolutions. Tighten timing belt tensioner bolt. Install access cover and A/C compressor belt.
Intake & Exhaust Valves
Hydraulic valve lash adjusters are used and valve adjustment is unnecessary.
FUEL PRESSURE RELEASE
| WARNING | Always relieve fuel pressure before disconnecting any fuel injection-related component. DO NOT allow fuel to contact engine or electrical components. |
Disconnect fuel pump harness connector under rear seat. Start engine. After engine stalls, turn ignition switch to OFF position. Disconnect negative battery cable. Reconnect fuel pump harness connector.
FRONT COVER OIL SEAL
See OIL PUMP under ENGINE OILING.
Scheme 30
- Remove all drive belts. Support oil pan with jack and block of wood. Remove power steering pump with hoses connected. Remove engine support bracket bolts in sequence. Slowly remove reamer bolt. (Scheme 30) NOTE: Reamer bolt may sometimes become seized on engine support bracket. Remove reamer bolt carefully without damaging threads.
- Ensure piston No. 1 is on TDC of compression stroke and timing marks are aligned. Remove crankshaft pulley and timing belt covers. If reusing timing belt, mark direction of belt rotation. Loosen timing belt tensioner bolt and pivot tensioner counterclockwise. Lock tensioner in retracted position. Remove timing belt.
CAMSHAFT
See ROCKER ARM SHAFT ASSEMBLY.
WATER PUMP
Note. Note bolt length and location during removal. Different length bolts are used and must be installed in original locations.
Cylinder Head
Check for cracks, damage and coolant leakage. Remove scale, sealing compound and carbon deposits. Clean oil passages, and blow compressed air through passages to ensure they are not clogged. Inspect cylinder head for warpage at deck surface. Resurface cylinder head if warpage exceeds specification. See CYLINDER HEAD under ENGINE SPECIFICATIONS.
Valve Springs
Inspect valve spring free length, tension and installed height. Installed spring height is measured from spring seat to valve spring retainer. Using a square, test squareness of each spring. Replace spring(s) if not within specification. See VALVES & VALVE SPRINGS under ENGINE SPECIFICATIONS. Install all valve springs with painted area toward rocker arm.
Valve Stem Oil Seals
Use Valve Seal Installer (09222-32100) for seal installation to properly position oil seal.
Valve Guides
- Ensure valve stem diameter and valve stem clearance are within specification. See «CYLINDER HEAD»(ref-49498-S37539652642001011500000) under ENGINE SPECIFICATIONS.
- If clearance exceeds service limits, replace valve guide. Drive valve guides out toward bottom of cylinder head. Machine cylinder head valve guide bore to specification for oversized valve guide. See «OVERSIZED VALVE GUIDE SPECIFICATIONS»(ref-49498-S19665669082001011500000) . OVERSIZED VALVE GUIDE SPECIFICATIONS Size Mark Guide Oversize: In. (mm) Cylinder Head Bore: In. (mm) 5 .002 (.05) .5140-.5145 (13.050-13.068) 25 .010 (.25) .5217-.5224 (13.250-13.268) 50 .020 (.50) .5315-.5322 (13.500-13.518)
- Press NEW guides into cylinder head from top using Valve Guide Installer (09222-32200).
- Intake valve guides are shorter than exhaust valve guides. DO NOT install valve guide with same diameter as guide removed. Check guide clearance with new valve, and ream as necessary. Check valve seat contact.
Valve Seats
- To replace valve seats, cut away old valve seat and remove. Machine cylinder head to proper dimension. See «OVERSIZE VALVE SEAT SPECIFICATIONS»(ref-49498-S10488089302001011500000) .
- Heat cylinder head to 482°F (250°C) and press replacement seat in cylinder head. Valve seat height should be within specification. Cut valve seat to proper angle and obtain correct seat width.
| Size Mark | Seat Size | Cyl. Head Bore | Seat Height | |
|---|---|---|---|---|
| Intake Valve | ||||
| 30 | .012 (.30) | 1.7441-1.7451 (44.300-44.325) | .311-.319 (7.9-8.1) | |
| 60 | .024 (.60) | 1.7559-1.7569 (44.600-44.625) | .323-.331 (8.2-8.4) | |
| Exhaust Valve | ||||
| 30 | .012 (.30) | 1.5079-1.5089 (38.300-38.325) | .311-.319 (7.9-8.1) | |
| 60 | .024 (.60) | 1.5197-1.5207 (38.600-38.625) | .323-.331 (8.2-8.4) | |
| (1) Specifications in In. (mm). | ||||
| (1) | Specifications in In. (mm). |
OVERSIZE VALVE SEAT SPECIFICATIONS (1)
Valves
Inspect each valve for wear, damage and distortion of head and stem. If stem end is pitted or worn, resurface as necessary. This correction must be held to a minimum. Resurface valve face. If valve margin has decreased to less than service limit, replace valve. See VALVES & VALVE SPRINGS under ENGINE SPECIFICATIONS.
Fitting Pistons & Rings
Ensure ring end gap and side clearance are within specifications. See PISTONS, PINS & RINGS under ENGINE SPECIFICATIONS. Position ring gaps correctly prior to installation. (Scheme 31)
Scheme 31
Crankshaft & Main Bearings
Install main bearings with oil hole and groove on cylinder block side.
Thrust Bearing
Install thrust bearings in No. 3 main bearing cap with oil groove facing outward.
Cylinder Block
Visually inspect cylinder block for scores, rust and corrosion. Check for cracks or other defects. Repair or replace block if defective. Measure cylinder bore in 3 areas from top to bottom of bore, checking for taper and out-of-round.
Oil Pressure
At curb idle and with oil temperature 167-194°F (75-90°C), normal oil pressure should be at least 11 psi (.77 kg/cm 2 ).
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS
| Application | In. (mm) | ||
|---|---|---|---|
| Crankshaft | |||
| End Play | .002-.010 (.05-.25) | ||
| Main Bearings | |||
| Journal Diameter | 2.361-2.362 (59.98-60.00) | ||
| Journal Out-Of-Round | .0012 (.030) | ||
| Journal Taper | .0002 (.005) | ||
| Oil Clearance | .0008-.0019 (.020-.048) | ||
| Connecting Rod Bearings | |||
| Journal Diameter | 1.968-1.969 (49.98-50.00) | ||
| Journal Out-Of-Round | .0012 (.030) | ||
| Journal Taper | .0002 (.005) | ||
| Oil Clearance | |||
| Standard | .0006-.0018 (.016-.046) | ||
| Maximum | .0039 (.100) | ||
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS
CONNECTING RODS
| Application | In. (mm) |
|---|---|
| Maximum Bend | .002 (.05) |
| Maximum Twist | .0039 (.100) |
| Side Play | .0039-.0098 (.100-.250) |
CONNECTING RODS
PISTONS, PINS & RINGS
| Application | In. (mm) | |||
|---|---|---|---|---|
| Pistons | ||||
| Clearance | .0008-.0016 (.020-.040) | |||
| Diameter | 3.586-3.587 (91.08-91.10) | |||
| Pins | ||||
| Piston Fit | Slip Fit | |||
| Rod Fit | (1) Press Fit | |||
| Rings | ||||
| No. 1 | ||||
| End Gap | ||||
| Standard | .012-.018 (.30-.45) | |||
| Maximum | .031 (.8) | |||
| Side Clearance | ||||
| Standard | .0012-.0035 (.030-.090) | |||
| Maximum | .0039 (.100) | |||
| No. 2 | ||||
| End Gap | ||||
| Standard | .018-.023 (.45-.60) | |||
| Maximum | .031 (.8) | |||
| Side Clearance | ||||
| Standard | .0008-.0024 (.020-.060) | |||
| Maximum | .0039 (.100) | |||
| No. 3 (Oil) | ||||
| End Gap | ||||
| Standard | .018-.023 (.20-.60) | |||
| Maximum | .039 (1.00) | |||
| (1) Press fit in rod using 1686-3934 lbs. (765-1785 kg). DO NOT exceed 5000 lbs. (2268 kg) pressure. | ||||
| (1) | Press fit in rod using 1686-3934 lbs. (765-1785 kg). DO NOT exceed 5000 lbs. (2268 kg) pressure. |
PISTONS, PINS & RINGS
| Application | In. (mm) | |
|---|---|---|
| Cylinder Bore | ||
| Standard Diameter | 3.587-3.588 (91.10-91.14) | |
| Maximum Taper | .0008 (.020) | |
| Maximum Out-Of-Round | .0008 (.020) | |
| Maximum Deck Warpage | .002 (.05) | |
CYLINDER BLOCK
VALVES & VALVE SPRINGS
| Application | Specification | ||
|---|---|---|---|
| Intake Valves | |||
| Face Angle | 45-45.5° | ||
| Minimum Margin | .028" (.70 mm) | ||
| Stem Diameter | .3143-.3148" (7.982-7.995 mm) | ||
| Exhaust Valves | |||
| Face Angle | 45-45.5° | ||
| Minimum Margin | .059" (1.5 mm) | ||
| Stem Diameter | .3126-.3134" (7.940-7.960 mm) | ||
| Valve Springs | |||
| Free Length | |||
| Standard | 1.988" (50.50 mm) | ||
| Minimum | 1.949" (49.50 mm) | ||
| Installed Height | (1) 1.591" (40.40 mm) | ||
| Out-Of-Square | 2-4° | ||
| Lbs. @ In. (kg @ mm) | |||
| Pressure Valve Closed | 74 @ 1.591 (32.9 @ 40.4) | ||
| (1) Service limit is 1.630" (41.4 mm). | |||
| (1) | Service limit is 1.630" (41.4 mm). |
VALVES & VALVE SPRINGS
| Application | Specification | ||
|---|---|---|---|
| Maximum Warpage | .008" (.2 mm) | ||
| Valve Seats | |||
| Intake Valve | |||
| Seat Angle | 45° | ||
| Seat Width | .035-.051" (.9-1.3 mm) | ||
| Exhaust Valve | |||
| Seat Angle | 45° | ||
| Seat Width | .035-.051" (.9-1.3 mm) | ||
| Valve Guides | |||
| Intake Valve | |||
| Valve Guide Installed Height | (1) | ||
| Valve Stem-To-Guide Oil Clearance | .0012-.0024" (.03-.06 mm) | ||
| Exhaust Valve | |||
| Valve Guide Installed Height | (1) | ||
| Valve Stem-To-Guide Oil Clearance | .0020-.0035" (.05-.09 mm) | ||
| (1) Use Valve Guide Installer (09222-32200) to set guide height. | |||
| (1) | Use Valve Guide Installer (09222-32200) to set guide height. |
CYLINDER HEAD
| Application | In. (mm) |
|---|---|
| End Play | .004-.008 (.10-.20) |
| Journal Diameter | 1.336-1.337 (33.935-33.950) |
| Lobe Height | 1.620-1.628 (41.15-41.35) |
| Oil Clearance | .0020-.0035 (.05-.09) |
CAMSHAFT