Releasing Pressure
Start engine. Remove fuel pump relay from fuse/relay block on left front inner fender. (Scheme 53) After engine stalls, turn ignition off. Install fuel pump relay. Place rag over fuel system components before disconnecting. After servicing, prime system before starting engine.
Priming System
Ensure fuel system is closed. Connect jumper wire between "F/P" and "GRN" terminals of data link connector. (Scheme 54) Turn ignition on for about 10 seconds and check for fuel leaks. Turn ignition off. Disconnect jumper wire.
Scheme 53
Scheme 54
COOLING SYSTEM BLEEDING
| CAUTION | If engine overheats during procedure, system contains excessive air. Stop engine and allow it to cool, then repeat step 1). |
- Slowly pour coolant into radiator at a rate of 1.1 qt. (1.0L) per minute maximum until coolant is level with filler port. Fill coolant reservoir to "F" mark. Securely install radiator cap. Start engine.
- Run engine at idle until it reaches normal operating temperature. Run engine at 2200-2800 RPM for 5 minutes. Stop engine and allow it to cool.
- Repeat steps 1) and 2). Remove radiator cap. If engine coolant is not level with filler neck, repeat entire procedure. If engine coolant is level with filler neck, fill reservoir to "F" mark.
ENGINE
Note. Remove engine and transaxle as an assembly through top.
CYLINDER HEAD
| CAUTION | To prevent engine damage, DO NOT rotate crankshaft counterclockwise as viewed from timing belt end of engine. |
FRONT COVER
Note. Front cover contains oil pump. For removal and installation procedures, see OIL PUMP & FRONT COVER under ENGINE OILING.
TIMING BELT
| CAUTION | To prevent engine damage, DO NOT rotate crankshaft if timing belt is not installed. If timing belt is installed, DO NOT rotate crankshaft counterclockwise as viewed from timing belt end of engine. |
HYDRAULIC LASH ADJUSTERS
| CAUTION | If reusing Hydraulic Lash Adjusters (HLA), always install them to original location. Premature camshaft failure will occur if not returned to original location. |
OIL PAN
Note. If removing oil pan to access crankshaft or other components at bottom of cylinder block, oil pan upper block must also be removed. See OIL PAN UPPER BLOCK. see scheme 14
Check cylinder head warpage. If warpage exceeds specification, resurface head, but DO NOT exceed grinding limit. See CYLINDER HEAD table under ENGINE SPECIFICATIONS. After resurfacing cylinder head, check cylinder head height. Replace cylinder head if height is less than minimum specification.
| CAUTION | Install valve spring with tight coil windings toward cylinder head. |
Valve Springs
Measure valve spring dimensions and pressure. See VALVES & VALVE SPRINGS table under ENGINE SPECIFICATIONS. Replace valve springs if dimensions and pressure are not within specification.
Valve Stem Oil Seals
Exhaust valve stem oil seal has ridges on top. To remove oil seals, use Valve Stem Oil Seal Remover (49-S120-170). To install, position NEW oil seal onto valve guide. Using Valve Stem Oil Seal Installer (49-L012-001, -002 and -005) and hand pressure, press (DO NOT hammer) oil seal onto valve guide until installer contacts cylinder head.
Valve Guides
- Replace valve and/or valve guide if dimensions are not within specification. See CYLINDER HEAD table under ENGINE SPECIFICATIONS. Intake and exhaust valve guides are the same. To remove, drive valve guide out through top of cylinder head using Valve Guide Remover (49-B012-005).
- Using Valve Guide Installer (49-L012-002, -003 and -004), drive valve guide into bore until installer contacts cylinder head. Ensure valve guide installed height (distance from spring seat to top of valve guide) is within specification.
Valve Seats
Replacement procedure is not available.
Valves
- Replace valves if valve dimensions are not within specification. See VALVES & VALVE SPRINGS table under ENGINE SPECIFICATIONS.
- Slide valve into guide bore. With spring seat removed, measure valve installed height (distance between tip of valve stem and cylinder head). If installed height exceeds serviceable limit, replace cylinder head. See VALVE INSTALLED HEIGHT SPECIFICATIONS table.
| Application | In. (mm) |
|---|---|
| Normal | 1.536-1.555 (39.0-39.5) |
| Serviceable | 1.556-1.597 (39.6-40.5) |
VALVE INSTALLED HEIGHT SPECIFICATIONS
Valve Seat Correction Angles
Check seat width. See CYLINDER HEAD table under ENGINE SPECIFICATIONS. If seat width is not within specification or if valve face does not contact center of valve seat, correct seat using grinding stone of specified angle. See VALVE SEAT CORRECTION ANGLES table. After correcting seat, lightly finish seat with 45-degree grinding stone.
| Application | Angle | |
|---|---|---|
| Too High (1) | ||
| Intake | 65° | |
| Exhaust | 75° | |
| Too Low (2) | 35° | |
| (1) Point of contact on valve face is too close to stem. (2) Point of contact on valve face is too close to margin. | ||
| (1) | Point of contact on valve face is too close to stem. |
| (2) | Point of contact on valve face is too close to margin. |
VALVE SEAT CORRECTION ANGLES
VALVE TRAIN
Note. If hydraulic lash adjusters are persistently noisy, check manufacturer for availability of modified adjusters.
Hydraulic Lash Adjuster (HLA)
Hydraulic lash adjusters are not serviceable.
Fitting Pistons
- Measure cylinder bore diameter about 1/2" from top and bottom of bore, and at center of bore. Measure piston diameter at .65" (16.5 mm) below oil ring groove, at 90-degree angle to piston pin.
- Calculate piston clearance. Replace piston or machine cylinder block bore if clearance is not within specification. See PISTONS, PINS & RINGS table under ENGINE SPECIFICATIONS.
Piston Rings
- If ring end gap and side clearance are not within specification, replace piston and/or rings as necessary. See PISTONS, PINS & RINGS table under ENGINE SPECIFICATIONS.
- Install oil ring spacer. Ensure ends DO NOT overlap. (Scheme 55) Upper and lower rails are the same and are interchangeable. Install rails, ensuring rails are expanded by spacer tangs (oil rings when assembled should rotate freely). Install rings No. 1 (top) and No. 2 (second) with "R" mark toward top of piston. Ensure ring end gaps are properly positioned around piston. (Scheme 56)
Scheme 55
Scheme 56
Rod Bearings
Note alignment marks on side of connecting rod and cap for reassembly reference. If dimensions of crankshaft connecting rod journal and connecting rod are not as specified, machine or replace components as necessary. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table and CONNECTING RODS table under ENGINE SPECIFICATIONS. Tighten rob bearing cap bolts evenly to specification. See TORQUE SPECIFICATIONS.
Crankshaft & Main Bearings
- Machine for undersize bearings or replace crankshaft if dimensions are not as specified. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table under ENGINE SPECIFICATIONS. Main bearing upper halves are grooved.
- Install thrust bearings with oil groove facing crankshaft. Install main bearing caps with square mark facing front of engine. Tighten main bearing cap bolt in 2-3 step, working outward from center bearing. Tighten bolts to specification. See TORQUE SPECIFICATIONS.
Thrust Bearing
If crankshaft end play exceeds specification, grind crankshaft and replace thrust bearings with oversize thrust bearings, or replace crankshaft and thrust bearings. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table under ENGINE SPECIFICATIONS. Thrust bearings are located at main bearing No. 3. Install thrust bearings with oil groove facing crankshaft.
Cylinder Block
Machine or replace cylinder block if dimensions are not as specified. See CYLINDER BLOCK table under ENGINE SPECIFICATIONS.
Oil Pressure
Oil pressure should be 57-71 psi (4-5 kg/cm 2 ) at 3000 RPM.
Scheme 57
CRANKSHAFT, MAIN & CONNECTING
ROD BEARINGS SPECIFICATIONS
| Application | In. (mm) | ||||
|---|---|---|---|---|---|
| Crankshaft | |||||
| End Play | |||||
| Standard | .0031-.0111 (.080-.282) | ||||
| Service Limit | .0118 (.300) | ||||
| Runout | .0012 (.030) | ||||
| Thrust Bearing Width | |||||
| Standard | .0984-.1004 (2.500-2.550) | ||||
| .010" (.25 mm) Oversize | .1033-.1053 (2.625-2.675) | ||||
| .020" (.50 mm) Oversize | .1083-.1102 (2.750-2.800) | ||||
| .030" (.75 mm) Oversize | .1132-.1152 (2.875-2.925) | ||||
| Main Bearings | |||||
| Journal Diameter | |||||
| Standard Bearings | |||||
| Standard | 2.2022-2.2030 (55.937-55.955) | ||||
| Service Limit | 2.2020 (55.932) | ||||
| .010" (.25 mm) Undersize | |||||
| Standard | 2.1924-2.1931 (55.687-55.705) | ||||
| Service Limit | 2.1922 (55.682) | ||||
| Journal Out-Of-Round | .0001 (.003) | ||||
| Journal Taper | .0002 (.006) | ||||
| Oil Clearance | |||||
| Except Journal No. 3 | |||||
| Standard | .0009-.0020 (.024-.050) | ||||
| Service Limit | .0026 (.067) | ||||
| Journal No. 3 | |||||
| Standard | .0012-.0022 (.030-.056) | ||||
| Service Limit | .0026 (.067) | ||||
| Connecting Rod Bearings | |||||
| Journal Diameter | |||||
| Standard Bearings | |||||
| Standard | 1.8874-1.8880 (47.940-47.955) | ||||
| Service Limit | 1.8872 (47.935) | ||||
| .010" (.25 mm) Undersize | |||||
| Standard | 1.8776-1.8781 (47.690-47.705) | ||||
| Service Limit | 1.8774 (47.685) | ||||
| .020" (.50 mm) Undersize | |||||
| Standard | 1.8677-1.8683 (47.440-47.455) | ||||
| Service Limit | 1.8675 (47.435) | ||||
| Journal Out-Of-Round | .0001 (.003) | ||||
| Journal Taper | .0002 (.006) | ||||
| Oil Clearance | |||||
| Standard | .0009-.0024 (.024-.061) | ||||
| Service Limit | .0026 (.067) | ||||
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS