Intake & Exhaust Valves
Hydraulic valve lash adjusters are used, eliminating need for valve adjustment.
FUEL PRESSURE RELEASE
| CAUTION | Fuel system is under pressure. Release fuel pressure before disconnecting any fuel system components. DO NOT allow fuel to contact engine or electrical components. |
Open trunk access door, and disconnect fuel pump harness connector. Start engine. After engine stalls, turn ignition switch to OFF position. Disconnect negative battery cable. Reconnect fuel pump harness connector.
FRONT COVER OIL SEAL
Note. Front cover refers to cover at front of cylinder block. Cover contains oil pump, front cover oil seal and oil filter mount. Manufacturer lists oil seal removal procedure with front cover removed from engine. See OIL PUMP & FRONT COVER under ENGINE OILING.
TIMING BELT
Note. Engine is equipped with a timing belt and timing chain. Inspect timing chain when replacing timing belt.
CRANKSHAFT REAR OIL SEAL
Note. Rear crankshaft oil seal is replaced during cylinder block overhaul procedures. See CYLINDER BLOCK ASSEMBLY under OVERHAUL.
Cylinder Head
Inspect cylinder head for warpage at deck surface. Resurface cylinder head if warpage exceeds specification. See CYLINDER HEAD table under ENGINE SPECIFICATIONS. Replace cylinder head if camshaft bearing surface is damaged.
Valve Springs
Inspect valve spring free length and out-of-square. Replace valve springs if not within specification. See VALVES & VALVE SPRINGS table under ENGINE SPECIFICATIONS. Install all valve springs with painted area toward rocker arm.
Valve Stem Oil Seals
Install seal, using Valve Stem Oil Seal Installer (09222-21100) to properly position oil seal.
Valve Stems
Ensure valve stem diameter, valve guide inside diameter, and valve stem clearance are within specification. See CYLINDER HEAD and VALVES & VALVE SPRINGS tables under ENGINE SPECIFICATIONS.
Valve Guides
- Check valve stem diameter and valve guide diameter to determine clearance. See «CYLINDER HEAD»(ref-121831-S16446863792001091100000) and «VALVES & VALVE SPRINGS»(ref-121831-S37857206362001091100000) tables under ENGINE SPECIFICATIONS. If clearance exceeds service limits, valve guide can be replaced with an oversize valve guide. Remove valve guide from cylinder head using Valve Guide Remover/Installer (09222-21200 A/B and 09222-28600). Press valve guide out toward combustion chamber side of cylinder head.
- Machine cylinder head valve guide bore to specification for oversize valve guide. See «OVERSIZE VALVE GUIDE SPECIFICATIONS»(ref-121831-S13168232632001091400000) . Intake valve guides are shorter than exhaust valve guides. Using valve guide installer, press NEW valve guide into cylinder head from top. Ensure valve guide is installed to proper height. See «CYLINDER HEAD»(ref-121831-S16446863792001091100000) table under ENGINE SPECIFICATIONS. Check guide clearance of new valve guides. Ream as necessary. Check valve seat contact.
| Size Mark | Size - In. (mm) | Cylinder Head Hole Size - In. (mm) |
|---|---|---|
| 5 | .002 (.05) | .4744-.4751 (12.050-12.068) |
| 25 | .010 (.25) | .4823-.4830 (12.250-12.268) |
| 50 | .020 (.50) | .4921-.4928 (12.500-12.518) |
OVERSIZE VALVE GUIDE SPECIFICATIONS
Valve Seat
- To replace valve seats, cut away most of valve seat insert wall (at normal room temperature). Remove valve seat and machine seat insert bore to designated dimension. (Scheme 15)and (Scheme 16). See «OVERSIZE VALVE SEAT SPECIFICATIONS»(ref-121831-S29322031532001091100000) table.
- Heat cylinder head to 482°F (250°C) and press replacement seat into cylinder head. Ensure valve seat height is within specification. Cut valve seat to proper angle to obtain correct seat width.
| Size Mark | Seat Size - In. (mm) | Cylinder Head - Bore In. (mm) | Seat Height - In. (mm) | |
|---|---|---|---|---|
| Intake | ||||
| 30 | .012 (.30) | 1.3898-1.3907 (35.30092-35.32378) | .330-.338 (7.70-7.90) | |
| 60 | .024 (.60) | 1.4016-1.4026 (35.60064-35.62604) | .342-.350 (8.70-8.90) | |
| Exhaust | ||||
| 30 | .012 (.30) | 1.311-1.312 (33.2994-33.3248) | .314-.322 (8.00-8.20) | |
| 60 | .024 (.60) | 1.3228-1.3238 (33.59912-33.62452) | .327-.335 (8.30-8.50) | |
OVERSIZE VALVE SEAT SPECIFICATIONS
Scheme 15
Scheme 16
Fitting Pistons
- Measure piston skirt diameter .08" (2 mm) above bottom of piston skirt, at 90-degree angle to piston pin. If piston diameter is not within specification, replace piston. See «PISTONS, PINS & RINGS»(ref-121831-S13094622622001091100000) table under ENGINE SPECIFICATIONS.
- Measure cylinder bore diameter .47" (12 mm) from top and bottom of bore, and near center of bore. If cylinder bore diameter or taper is not within specification, machine cylinder bore. See «CYLINDER BLOCK»(ref-121831-S41130660932001091100000) table under ENGINE SPECIFICATIONS.
- If piston-to-cylinder bore clearance is not within specification, replace piston and/or machine cylinder bore. See «PISTONS, PINS & RINGS»(ref-121831-S13094622622001091100000) table under ENGINE SPECIFICATIONS.
Piston Rings
Ensure ring end gap and side clearance are within specification. See PISTONS, PINS & RINGS table under ENGINE SPECIFICATIONS. DO NOT use ring expander to install oil ring side rails. Properly position ring end gaps around circumference of piston before installing. (Scheme 17)
Rod Bearings
Note position of connecting rod in relation to bearing cap before removing. Ensure bearing oil clearance and side play are within specification. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS and CONNECTING RODS tables under ENGINE SPECIFICATIONS.
Crankshaft & Main Bearings
- Check condition of crankshaft journals and bearings. Check all oil holes for clogging. Check diameters of main bearing journals and connecting rod bearing journals. Check journals for taper and out-of-round. Check crankshaft end play. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(ref-121831-S04739823512001091100000) table under ENGINE SPECIFICATIONS.
- Install main bearing caps with arrow on top of cap pointing toward timing belt end of engine. Check oil clearance. Measure outside diameter of crankshaft journal and crank pin. Measure inside diameter of bearing. The difference between the measured outside and inside diameters is oil clearance. Ensure clearance is within specification. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(ref-121831-S04739823512001091100000) table under ENGINE SPECIFICATIONS.
Cylinder Block
- Visually check block for scoring, rusting and corrosion. Check for cracks. Check cylinder block deck warpage. Ensure warpage does not exceed specification. See «CYLINDER BLOCK»(ref-121831-S41130660932001091100000) table under ENGINE SPECIFICATIONS. If warpage exceeds specification, machine surface. DO NOT remove more than a combined total of .008" (0.20 mm) material from cylinder head and block gasket surfaces.
- Check cylinder bore wear and taper. Measure cylinder bore diameter near top, at center and near bottom of bore. If cylinder bore diameter or taper is not within specification, machine cylinder bore. See «CYLINDER BLOCK»(ref-121831-S41130660932001091100000) table under ENGINE SPECIFICATIONS.
Scheme 17
Rear Main Oil Seal
Carefully remove old seal from rear of block. Use proper installer to drive new oil seal into oil seal case.
Counterbalance Shaft Bearings
- Remove oil pump and front cover. See «OIL PUMP & FRONT COVER»(ref-121831-S03426751982001091100000) under ENGINE OILING. Remove counterbalance shafts. Use Bearing Remover (09212-32000) to remove right front counterbalance shaft bearing from cylinder block. Use Bearing Remover (09212-32100) to remove right rear counterbalance shaft bearing from cylinder block. Use Bearing Remover (09212-32100) with Remover Holder (09212-32300) to remove left rear counterbalance shaft bearing from cylinder block.
- Apply engine oil to NEW left rear counterbalance shaft bearing, and bearing hole in cylinder block. Use Installer (9212-32200) and installer holder to install left rear counterbalance shaft bearing into cylinder block. Using bearing installer to install right front and rear counterbalance shaft bearings into cylinder block. Ensure right counterbalance shaft bearing oil holes are aligned with oil hole of cylinder block.
Oil Pressure
Oil pressure is 11.4 psi (.80 kg/cm 2 ) at idle with oil temperature at 167-194°F (75-90°C).