OVERHAUL
Note. Limited information is provided from manufacturer. See ENGINE SPECIFICATIONS.
Disassembly
| CAUTION | Do not use a magnet to remove shims. Failure to follow these instructions may result in damage to the vehicle. If the cylinder head valve components are to be reused, mark the position of the valve components to make sure they are reassembled in the same position. |
Note. Special tool required: Valve Spring Compressor (303-252). see scheme 220
- If not previously removed, remove the camshafts, lifter and shim assemblies. (Scheme 185)
- Remove the Camshaft Position (CMP) sensor bolt and remove the CMP. Remove and discard the "O" ring. (Scheme 186)
- Using the Valve Spring Compressor (303-252), compress the valve springs and remove the valve collets. (Scheme 187)
- Remove the valve spring retainers, valve springs, valve stem oil seals and valves from the cylinder head. (Scheme 185)
- Remove the pipe plugs and alignment dowels as necessary to clean the cylinder heads.
Assembly
- Install the pipe plugs and alignment dowels as necessary to the cylinder head.
- Install the valves into the cylinder head. Install the valve spring seats, retainers and springs. (Scheme 185)
- Using the valve spring compressor, compress the valve springs and install the valve collets. (Scheme 187)
- Using a NEW "O" ring, install the CMP sensor. (Scheme 186) Install CMP sensor bolt and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-161157-S07430046262004032200000).
- Lubricate each tappet assembly. Install each tappet and shim assembly to its previously noted position in the cylinder head. see scheme 116
- Apply oil (EP-90) to the camshaft and bearing surfaces as follows: Upper face of each bearing surface (2 places) in the cylinder head. Upper face of each bearing surface (2 places) in each bearing cap. On the cam lobes ONLY, not on the base circle area. see scheme 117
- Install the camshafts in the cylinder head with the timing flats in the uppermost position. Install the camshaft bearing caps to their respective locations (intake 0 to 4 and exhaust 5 to 9 from the front) and in the correct orientation (arrow to front of engine). Install and tighten the bearing cap bolts evenly and in stages to specification. See «TORQUE SPECIFICATIONS»(ref-161157-S07430046262004032200000).
Scheme 184
Scheme 185
Scheme 186
Scheme 187
Scheme 188
Scheme 189
Scheme 190
Scheme 191
Scheme 192
Scheme 193
Scheme 194
Scheme 195
CYLINDER BLOCK ASSEMBLY
Note. Mark the pistons to the original connecting rods to make sure correct installation in the same cylinders from which they were removed.
Note. Special tools required: Crankshaft Rear Oil Seal Remover/Installer (303-538), Cylinder Bore Protectors (303-538) and Piston Ring Compressor (303-372). see scheme 218, see scheme 221 and see scheme 222.
Piston & Rod Assembly
| WARNING | The retaining rings have a tendency to spring out during removal. Cover the end of the pin bore with a hand or a rag when removing the retaining ring. Eye protection should be worn. Failure to follow these instructions may result in personal injury. |
- Remove the piston pin retaining clips. (Scheme 197)
- Remove piston pin and connecting rod from piston. (Scheme 198)
- Clean the piston skirt, pin bush, ring grooves and crown and check for wear or cracks. (Scheme 199) If there are signs of wear on the piston skirt, check whether the connecting rod is twisted or bent.
- Measure the connecting rod bearing bore in 2 directions. (Scheme 200) The difference is the connecting rod bore out-of-round. Verify the out-of-round is within specification. See «CONNECTING RODS»(ref-161157-S28498361132004040500000) table under ENGINE SPECIFICATIONS.
- Using a micrometer, measure the piston diameter at the height of the piston pin bore, but offset by 90 degrees. (Scheme 201) Verify that measurements are within specification. See «PISTONS, PINS & RINGS»(ref-161157-S18731105492004040500000) table under ENGINE SPECIFICATIONS. If measurements are not within specification, install both a new piston and a new piston pin.
- Measure the diameter of the piston pin bore in 2 directions. (Scheme 202) Verify that measurements are within specification. See «CONNECTING RODS»(ref-161157-S28498361132004040500000) table under ENGINE SPECIFICATIONS. If measurements are not within specification, install both a new piston and a new piston pin.
- Using a micrometer, measure the piston pin diameter in 2 directions. see scheme 179 Verify that measurements are within specification. See «CONNECTING RODS»(ref-161157-S28498361132004040500000) table under ENGINE SPECIFICATIONS. If measurements are not within specification, install both a new piston and a new piston pin.
- Lubricate the piston pin and piston bore and install the connecting rod and piston pin to the piston. (Scheme 198)
- Install the piston pin retaining clips. (Scheme 197)
