FUEL PRESSURE RELEASE
| WARNING | Residual fuel pressure may be present in fuel system when engine is off. To avoid fire hazard, wrap a shop towel around fuel fitting before disconnecting fuel lines. |
To release fuel pressure, disconnect fuel lines at fuel pressure regulator and fuel injection manifold.
Note. Remove engine and transaxle as a unit. Engine is removed through bottom of vehicle.
INTAKE & EXHAUST MANIFOLDS
Note. For intake manifold and exhaust manifold removal and installation, see appropriate cylinder head removal and installation procedure.
CAMSHAFT
Note. For camshaft removal and installation, see appropriate cylinder head removal and installation procedure.
TIMING BELT
Note. For timing belt removal and installation, see appropriate cylinder head removal and installation procedure.
Cylinder Head
Measure cylinder head height after resurfacing. See CYLINDER HEAD table under ENGINE SPECIFICATIONS. Cylinder head warpage information is not available from manufacturer.
Valve Springs
- Remove camshafts. Remove valve tappets with magnet. Install Lifter Bore Sleeves (83 95 022) to protect lifter bores. Position Valve Spring Compressor (83 93 761) and Anvil (83 93 779). Remove keepers, springs and caps. Measure valve springs for correct free length.
- To assemble, install valves, washers and valve springs. Install spring caps and keepers using valve spring compressor and anvil. Ensure camshaft locating pins point toward internal bolts. (Схема №2)
Valve Stem Oil Seals
Remove seals using Pliers (83 94 157) Ensure protective sleeves for lifter guides are in place. Install seals using Installer (83 95 071). Tap seal into position with plastic mallet.
Valve Guides
Valve guides cannot be replaced, and must be reamed to oversize. Two oversize valve stems are available. See VALVES & VALVE SPRINGS table under ENGINE SPECIFICATIONS.
Valve Seat
Grind intake and exhaust valve seats to an angle of 45 degrees.
Valves
Grind intake valves to an angle of 44.3 degrees. DO NOT grind exhaust valve face. Use only lapping compound to finish face.
Fitting Pistons
Install piston and rod assembly with arrow on top of piston facing front of engine. Oil cylinder lightly.
Piston Rings
- Check piston rings for end gap and side clearance. Use an inverted piston to push ring down into bore. On worn bores, measure at lower end of bore. See «PISTONS, PINS & RINGS»(ref-8774-S34524442922000092200000) table under ENGINE SPECIFICATIONS.
- Lubricate pistons and rings. Install rings onto pistons. Stagger ring gaps. Compression ring gaps must be located 180 degrees from each other. Oil ring gaps must be equally spaced from each other.
Rod Bearings
Using a micrometer, measure rod bearing journal diameter, taper and out-of-round. Measure bearing clearance with Plastigage.
Crankshaft & Main Bearings
Turn engine upside down to prevent weight of crankshaft from affecting measurements. Measure bearing clearance with Plastigage positioned to one side of journal centerline.
Cylinder Block
Check each cylinder for wear, cracks or damage. Ensure oil passages are clean. Ensure freeze plugs are in good condition.