FUEL PRESSURE RELEASE
Disconnect fuel pump connector near fuel tank. Start engine, and allow to idle until it stalls. Turn ignition off. Reconnect fuel pump connector. Disconnect negative battery cable before disconnecting fuel lines.
| CAUTION | To prevent fire hazard, release fuel pressure in fuel system before disconnecting fuel lines. |
INTAKE MANIFOLD
| CAUTION | To prevent fire hazard, release fuel pressure in fuel system before disconnecting fuel lines. |
CYLINDER HEAD
| CAUTION | Release fuel pressure in fuel system before disconnecting fuel lines. |
FRONT COVER OIL SEAL
Note. FRONT COVER refers to cover at front of cylinder block. Cover contains oil pump and front cover oil seal (crankshaft front seal). Manufacturer lists oil seal removal procedure with front cover removed from engine. See OIL PUMP & FRONT COVER .
TIMING BELT
| CAUTION | To prevent engine damage, DO NOT rotate crankshaft counterclockwise (as viewed from timing belt end of engine). |
| CAUTION | Ensure silent shafts are properly aligned with timing marks. Use a screwdriver to ensure left silent shaft weight is in the correct position. See appropriate figure. Engine will have excessive vibration if balance shaft weighs are not in correct positions. |
ROCKER ARM & VALVE LASH ADJUSTER
| CAUTION | DO NOT rotate crankshaft if timing belt has been removed. DO NOT rotate crankshaft counterclockwise (as viewed from timing belt end of engine). |
WATER PUMP
| CAUTION | Note length and location of bolts during removal. Different length bolts are used and must be installed in original location. |
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, out-of-square and installed height. Replace valve spring 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
DO NOT reuse oil seals. Install valve spring seat before installing oil seals. To provide proper positioning of oil seal, install NEW oil seals using Valve Stem Seal Installer (MD998774).
Valve Guides
Ensure valve stem diameter is within specification. Check valve stem clearance. Clearance should be within specification. See VALVES & VALVE SPRINGS table and CYLINDER HEAD under ENGINE SPECIFICATIONS. If clearance exceeds service limits, replace valve guide with an oversized valve guide.
Valves
Ensure valve stem diameter and margin are within specification. See VALVES & VALVE SPRINGS under ENGINE SPECIFICATIONS.
Valve Seat
See ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION article in GENERAL INFORMATION.
Valve Seat Correction Angles
See ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION article in GENERAL INFORMATION.
Lash Adjusters
Before installing lash adjuster, submerge lash adjuster in oil. Use a small wire to hold down internal check valve. Pump plunger up and down 4 or 5 times to bleed air from lash adjuster.
Fitting Pistons
- Measure piston skirt diameter at 90-degree angle to piston pin. If piston diameter is not within specification, replace piston. See «PISTONS, PINS & RINGS»(ref-49422-S25226661452001011500000) under ENGINE SPECIFICATIONS.
- Measure cylinder bore diameter at 3 places: near top of bore, bottom of bore and center of bore. If cylinder bore diameter or taper is not within specification, machine cylinder bore. See «CYLINDER BLOCK»(ref-49422-S42044585942001011500000) 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-49422-S25226661452001011500000) under ENGINE SPECIFICATIONS.
Piston Rings
Ensure ring end gap and side clearance are within specification. See PISTONS, PINS & RINGS under ENGINE SPECIFICATIONS. DO NOT use a ring expander to install oil ring side rails. Properly position ring end gaps around circumference of piston before installing. see scheme 22
Scheme 71
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 under ENGINE SPECIFICATIONS.
Crankshaft & Main Bearings
Check diameter of crankshaft 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 under ENGINE SPECIFICATIONS.
Thrust Bearing
Replace thrust bearing if crankshaft end play is not within specification. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS under ENGINE SPECIFICATIONS.
Cylinder Block
- Check cylinder block head surface warpage. If warpage exceeds specification, machine surface. See «CYLINDER BLOCK»(ref-49422-S42044585942001011500000) under ENGINE SPECIFICATIONS. DO NOT remove more than a combined total .008" (0.20 mm) material from original surfaces of cylinder head or cylinder block.
- Check cylinder bore wear and taper. Measure cylinder bore diameter at 3 places: near top of bore, bottom of bore and center of bore. If cylinder bore diameter or taper is not within specification, machine cylinder bore. See «CYLINDER BLOCK»(ref-49422-S42044585942001011500000) .
Oil Pressure
Oil pressure should be at least 11.4 psi (.80 kg/cm 2 ) at curb idle, and oil temperature should be 167-194°F (75-90°C).