2.8L V6 Volvo 780 I

ENGINE CODING

Note. For engine repair procedures not covered in this article, see ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION article in the GENERAL INFORMATION section.

ENGINE IDENTIFICATION

Engine identification number is located on plate on front left side of engine block, in front of oil filter. Vehicle Identification Number (VIN) is located on top of instrument panel at lower left of windshield.

ENGINE IDENTIFICATION CODES

Scheme 9

1. Rotate crankshaft to bring No. 1 piston to TDC. (Scheme 25) In this position, both rocker arms for No. 1 cylinder should have clearance.
2. Check and adjust following cylinders for clearance: intake valves on cylinders 1, 2, and 4; exhaust valves on cylinders 1, 3, and 6. (Scheme 9) VALVE CLEARANCE SPECIFICATIONS Valve In. (mm) Intake (1).004-.006" (.10-.15 mm) Exhaust (1).010-.012" (.25-.30 mm) (1) Cold engine.
3. Rotate crankshaft one full turn, with mark again opposite "0" degree mark. Rocker arms for No. 1 cylinder will not have clearance. Check and adjust following cylinders for clearance: intake valves on cylinders 3, 5, and 6; exhaust valves on cylinders 2, 4, and 5. (Scheme 9)

REMOVAL

1. Remove air cleaner, grille, grille crossmember, fan shroud and engine splash guard. Drain engine and transmission oil. Drain cooling system (each side of block) and disconnect all coolant hoses. Disconnect A/C compressor and move aside. DO NOT disconnect A/C hoses.
2. Remove radiator. Disconnect throttle cable, speedometer and battery ground cable. Disconnect and mark all electrical connections, hoses, and tubing that will interfere with engine removal.
3. Move gear selector to "P" and disconnect kickdown cable at throttle pulley. Drain transmission oil by disconnecting oil filler tube at oil pan.
4. Disconnect automatic transmission oil cooler pipes at radiator. Disconnect control rods at transmission. Disconnect solenoid wiring plug below shifter.
5. Attach a Crossmember Lifting Cradle (2810) and 2 Lifting Cradle Slings (5100) to engine. Support lifting cradle on engine hoist. Disconnect drive shaft at transmission.
6. Disconnect exhaust pipe at joint in front of catalytic converter and remove exhaust pipe from exhaust pipe bracket. Remove rear engine mount and crossmember assembly. Remove nuts from front engine mounts and lift engine/transmission assembly from vehicle.

INSTALLATION

To install, reverse removal procedure.

Scheme 10

Scheme 11

Scheme 12

Scheme 13

Scheme 14

Scheme 15

Scheme 16

1. The engine is equipped with camshaft driven counterweights at each end of the right bank cylinder head. The counterweights are timed in relation to the camshaft. The counterweights are installed in the front of the cylinder head, inside a support, and in the rear of the cylinder head.
2. If one or more cylinder heads are to be removed, the timing chain and sprocket assembly must be kept under tension. This procedure will avoid the removal of the timing chain cover. On the right cylinder head, keep the front counterweight drive pinion from turning. Move the countershaft support from its centering dowels seated in the head. DO NOT separate pinions from each other.
3. If both cylinder heads are to be removed, always remove the right cylinder head first. If one cylinder head is to be removed, follow the removal steps for that cylinder head only. Ensure cooling system is drained. Disconnect electrical and mechanical connections as necessary between intake manifold accessories and engine. Remove intake manifold. If removing right cylinder head, go to next step. If removing left cylinder head, go to step 8).
4. To remove right cylinder head, remove air filter, airflow sensor and junction hose assembly. Remove front grille, air intake preheat system, upper radiator hose and left header pipe at catalytic converter. Remove right header pipe. Remove fan, shroud and coolant hose.
5. Remove valve cover, plugs and bolts from end of head. (Scheme 10) Loosen camshaft pinion bolt. Turn crankshaft clockwise until No. 6 cylinder valves are in rocking position. Turn engine until end of rocker arm shaft is visible through left cut-out in camshaft sprocket.
6. Install camshaft Pinion Support (0134 W) on timing chain housing. Place tab of plate into pinion teeth. Hand tighten and lock bolts. (Scheme 11) Install bolt into counterweight support but DO NOT tighten. Remove counterweight support bolts through access holes. Insert 2 screwdrivers into slots "A" and "B" and carefully pry support out of centering dowels. (Scheme 12)
7. Install Support (0134 X) on rear of head with pin "C" between 2 gear teeth. Tighten 2 bolts. (Scheme 13) Remove head bolts and rocker arm assembly. Loosen camshaft retainer bolts. Remove camshaft retainer from camshaft groove. Remove retainer bolt to clear camshaft from timing chain sprocket. Using 2 screwdrivers, move camshaft until it contacts support. Using Levers (91.41), tilt and remove heads. To continue removal procedure for right cylinder head, go to step 11).
8. To remove left cylinder head, remove battery, overflow tank and bracket, and left exhaust manifold. Loosen power steering fluid reservoir and set aside. Remove valve cover. Turn crankshaft clockwise until No. 2 cylinder valves are in rocking position. Rotate crankshaft an additional turn until camshaft pinion is positioned. (Scheme 14)
9. Remove distributor cap, rotor, distributor mounting bolts and camshaft sprocket mounting bolt. Remove coolant hose and fitting. (Scheme 15) Install Support (0134 N) on timing chain housing. Install bolts finger tight. Lock camshaft. Tighten support bolts. (Scheme 16)
10. Remove or pull head bolts out as far as possible. Loosen camshaft retainer clamp bolts and pull clamp away from camshaft groove. Using a screwdriver, pry camshaft away from sprocket. Using Levers (91.41), tilt and remove heads. CAUTION: When removing cylinder heads, Ensure cylinder liners DO NOT separate from seals at lower seat. If this happens, coolant can flow into crankcase.
11. After removal, place cylinder head on wooden blocks to protect it from damage. Remove gasket and install Cylinder Liner Holders (5093). Use needle nose pliers to remove guide sleeves. When cleaning, remove cylinder holders one at a time. CAUTION: When cleaning, use plastic scraper to prevent scratching. Use compressed air to clean cylinder head bolt holes.
12. When replacing cylinder head gasket only, clean gasket surfaces and check for warpage. Clean valve cover. Use a steel rule and feeler gauge to check warpage. Maximum warpage is.002" (.05 mm) over 4" (100 mm) of length. If warpage exceeds measurement, replace cylinder head.

Scheme 17

Scheme 18

1. Ensure drive lugs of camshaft pinions are positioned as illustrated. (Scheme 17) Using same bolt as was used during removal, lock camshaft pinion. Reinstall locking Plate (0134 W). Insert a 3 mm pin in each dowel pin hole. Install centering dowels butted against pins. Use care not to drive dowels in too far.
2. Install new head gasket. Install camshaft retainer plate without locking bolt. Install head on engine block. Using an Allen wrench, tighten camshaft sprocket bolt. Coat camshaft retainer bolt with loctite and tighten to 114 INCH lbs. (12 N.m).
3. Clean all grease from rocker arm pads. Spray a light coat of Molykote on rocker arm pads. Install rocker arm assembly. Lubricate head bolts with engine oil and install. Tighten bolts, in order, to 44 ft. lbs. (60 N.m). Loosen all bolts, in order, and retighten to 15 ft. lbs. (20 N.m). Angle tighten all bolts, in order, an additional 105 degrees. (Scheme 18)
4. On right cylinder head install counterweight support and tighten bolt to 108 ft. lbs. (12 N.m). Tighten camshaft pinion bolt to 59 ft. lbs. (80 N.m). Coat Allen head plugs with Loctite and install. On left cylinder head tighten camshaft pinion bolt to 59 ft. lbs. (80 N.m). Install distributor cap and rotor.
5. Adjust valve clearance with engine cold. See «VALVE CLEARANCE ADJUSTMENT»(/volvo/780/i-1986-1991/remont/mechanical/#28l-v6). Install valve covers and gaskets. Warm-up engine to normal operating temperature. Allow engine to cool for a minimum of 2 hours. Angle tighten all head bolts in sequence an additional 45 degrees. Complete reassembly by reversing removal procedure. Check and adjust throttle control cable, ignition timing, idle speed and CO.

1. Remove valve covers, timing chain housing and crankshaft key. Measure deflection of oil pump chain. Deflection should be less than .27" (7 mm). If not, oil pump chain should be replaced. Remove oil pump pinion and chain, oil pump driving pinion, spacer, key and oil pump.
2. Loosen rocker arm shaft assembly bolts in same sequence as tightening. From right cylinder head remove front counterweight bolt and pinion. Loosen rear counterweight pinion bolt. Remove counterweight support, right and left camshaft pinion and chains. Mark all parts for reassembly reference. Remove timing chain tensioners, pads, filters, crankshaft pinion and key.
3. Remove bolt securing rear counterweight driving pinion. Remove camshaft retaining fork, rear counterweight driving pinion, camshaft and rear counterweight.

Scheme 19

1. Install valve seals and valves. Install rear counterweight in right cylinder head. Tighten counterweight pinion bolt and retaining fork bolt to 10 ft. lbs. (12 N.m). Final tighten counterweight pinion bolt after drive chains are installed. Install camshafts into correct cylinder heads. Install camshaft retaining forks and tighten to 10 ft. lbs. (12 N.m). Install rear sealing plate onto left cylinder head.
2. Install rocker shafts, inserting a 5 mm shim between exhaust and intake rockers and an 8 mm shim between exhaust rockers and rocker pads. Lubricate rocker pads with grease. Install valve rocker shafts on cylinder heads. Position camshafts as indicated. (Scheme 19) Install timing gears and chains. See TIMING GEARS & CHAINS. Adjust counterweights. See COUNTERWEIGHTS in this article.
3. Install timing chain tensioner tool and remove timing gear chain support bracket tool from cylinder block face. Push camshaft into timing gear sprocket. Install timing gear sprocket bolt but DO NOT tighten. NOTE: Ensure camshaft does not catch on locking plate and sprocket fits correctly on camshaft.
4. Remove timing chain tensioner tool. Position camshaft locking plate and tighten bolt. Using an Allen wrench and screwdriver to hold chain, tighten timing gear sprocket.
5. Install timing gear cover and replace upper bolts. Install timing gear plug on left cylinder head.
6. Check camshaft end play. If end play exceeds.006" (.15 mm), replace lock plate. Install cover plate on right side using a new "O" ring. Install cover plate at rear of cylinder head with a new gasket.

1. Disconnect battery ground cable. Remove splash guard, A/C compressor, and oil tube from oil cooler. Disconnect electrical leads from thermal sensor on radiator. Remove fan shroud, radiator and hoses, alternator and power steering pump belts.
2. Remove power steering pump from bracket. Remove fan, water pump pulley and drive belts, air intake duct, vacuum pump, oil filler cap, control pressure regulator and ignition system connector. Turn crankshaft so pulley mark No. 1 is opposite "0" degree mark. (Scheme 20) Remove both valve covers and flywheel cover at left side of transmission.
3. Install Flywheel Locking Bracket (5112) at flywheel opening of transmission. Using a 1 7/16" (36 mm) socket, remove crankshaft nut. Remove pulley while key is on top of shaft (to prevent dropping key in crankcase). Remove timing gear cover. Remove timing gear seal.

Scheme 20

1. Clean surfaces and place gaskets on block and timing gear cover. Install cover and tighten bolts to 7-11 ft. lbs. (10-15 N.m). Using Crankshaft Oil Seal Driver (5103), install crankshaft oil seal.
2. Using flywheel locking bracket and a 1 7/16" (36 mm) socket, install crankshaft pulley and tighten crankshaft nut. Complete installation by reversing removal procedure.

INSPECTION

To perform a visual inspection of timing chain wear, remove left camshaft cover. Check position of chain tensioner rubbing block. (Scheme 21) Chain tensioner rubbing block should not protrude more than 0.315" (8 mm). Replace chains if beyond specification.

Scheme 21

1. Remove timing gear cover. Use a 10 mm Allen wrench and screwdriver to remove camshaft bolts. Turn each timing gear chain tensioner lock 1/4 turn counterclockwise and push in piston to slacken camshaft chains.
2. Remove oil pump sprocket and chain, both tensioners, oil strainers, and all dampers. Remove camshaft sprockets and chains. Cover holes into crankcase to prevent items from falling in crankcase. From crankshaft, remove outer sprocket, inner double sprocket, and key. (Scheme 22)

Scheme 22

Scheme 23

Scheme 24

1. Place inner key on crankshaft. Install inner double sprocket (line on sprocket should face outward). Install outer key and sprocket, new strainers, chain tensioners, and curved and straight dampers. Apply locking fluid to bolts.
2. Rotate crankshaft aligning key with camshaft in left bank (No. 1 cylinder at TDC). Position the camshaft with the key pointing upward (rocker arms for No. 1 cylinder should have no clearance). (Scheme 23)
3. Place chain on camshaft sprocket with mark on sprocket between 2 marks on timing chain. (Scheme 23) Place chain on inner crankshaft sprocket so timing mark on sprocket is facing mark on crankshaft sprocket.
4. Chain should be stretched on tension side (side against straight chain damper). Install left camshaft sprocket onto camshaft so that pin on sprocket slips into recess in camshaft. Use a screwdriver to hold sprocket and tighten center bolt.
5. Rotate crankshaft clockwise so that key points straight downward. Set right side camshaft with keyway in position. (Scheme 23) Place chain on crankshaft center sprocket with mark on sprocket aligned to mark on timing chain. Place chain on camshaft sprocket so that mark on sprocket is between 2 marked timing chain links.
6. Install sprocket on camshaft with chain stretched on tension side. Pin (on sprocket) should slip into camshaft recess. Use a screwdriver to hold sprocket and tighten center bolt.
7. Turn lock on each chain tensioner 1/4 turn clockwise. Set chain tension by rotating crankshaft 2 full revolutions in direction of rotation (clockwise). Install chain and chain sprocket for oil pump. NOTE: After initial rotation of crankshaft, marks on chains and sprockets will not coincide. It is necessary to rotate crankshaft several times before marks coincide.
8. Place non-aligned end of Gauge (0.0167) on face "A" of front counterweight. Place angled end of gauge under face "B" of rear counterweight. Check distance "D" between counterweight faces "A", "B" and valve cover gasket plane of cylinder head. Ensure distance lies within gauge marks. Incorrect counterweight setting by one tooth will cause a.20-.40" (5-10 mm) variation of distance "D". If variation is excessive, counterweights must be repositioned. (Scheme 24)
9. Install new gasket with timing gear cover. Apply locking compound to bolts and tighten to 11 ft. lbs. (15 N.m). Attach wiring harness to timing gear cover.
10. Install idler roller to timing gear cover. Using oil seal driver, install oil seal in timing cover. Install flywheel locking bracket at flywheel cover plate opening. Install pulley on crankshaft.
11. Tighten crankshaft nut. Remove flywheel locking bracket and install flywheel cover plate at transmission. Complete installation by reversing removal procedure.

Scheme 25

1. Remove intake manifold and water pump. Remove rear plug at top front of engine block. Rotate crankshaft so No. 1 TDC mark on pulley is at 20 degree mark on timing plate. (Scheme 20)
2. Insert a long 5/16" drill bit or similar rod into hole and against crankshaft counterweight. (Scheme 25) Rotate crankshaft in direction of normal rotation until drill fits into recess in counterweight (TDC for No. 1 cylinder). CAUTION: DO NOT allow drill bit to slip into engine. Use a drill or rod 10" long or longer, when possible.
3. Loosen 2 bolts and adjust timing plate so that "0" degree mark is aligned with pulley mark. Tighten 2 bolts and remove drill bit or rod. Install plug with new seal and tighten to 26-30 ft. lbs. (35-40 N.m). Install water pump and intake manifold.

1. Remove valve cover from cylinder head. Loosen rocker arm shaft bolts in sequence and remove rocker arm shaft assembly. Remove lock ring from end of shaft. Remove rocker arms, shaft supports, spacer sleeves and springs.
2. Keep all parts in order for correct assembly. Remove lock bolt and rocker shaft support from rocker shaft. Check shaft-to-arm clearance. Clearance when new is .0005-.002" (.012-.054 mm). Replace worn parts as necessary.

1. Install rocker shaft support on rocker shaft with lubricating holes pointing downward. Flat top surface should face toward lock ring groove in other end of shaft. Tighten lock bolt.
2. Install thick spacer, exhaust rocker arm, thin spacer, intake rocker arm, spring and rocker shaft support, in order. Install lock ring in rocker shaft groove. (Scheme 26)

Scheme 26

Right Bank

E-I-E-I-E-I (Front-to-rear).

Left Bank

I-E-I-E-I-E (Front-to-rear).

VALVE SPRINGS & OIL SEALS

With cylinder head removed from engine, remove spark plugs, rear cover plate, lock plate and camshaft. Using a valve spring compressor, remove valve keepers, spring retainer, spring, lower spring seat and valve. Remove valve guide seal from guide. Mark valves for installation reference.

VALVE GUIDES

1. Check valve guides for wear. If replacement is necessary, press out guide using Removal Drift (5218). Ream hole in cylinder head to first or second oversize.
2. Heat cylinder head to 300°F (150°C) and cool valve guides to -95°F (-70°C). Press valve guides into cylinder head within 3-4 seconds. Use Installing Drift (5108) for intake or (5109) for exhaust, to press in new guides.
3. Using Reamer (5224), ream guides to .3150-.3158" (8.00-8.02 mm). Check for burrs and ensure valves move freely in guides. Install valve guide seals.

Scheme 27

1. Remove lower crankcase and cylinder heads. Install cylinder liner holders to keep liners from being pushed out with piston. Check connecting rod and crankshaft markings so piston assemblies can be installed in their original positions.
2. Connecting rods are marked "A" through "F" from rear of engine to front. Remove bearing cap nuts, bearing caps and push piston assembly out through top of bore. Remove big end bearing.
3. Remove piston rings. Clean ring grooves and piston of any carbon deposits. Measure side clearance and end gap of piston rings with a feeler gauge. Replace any components not within specifications.

1. Install piston rings with end gaps at 120 degree angles from each other. Offset gaps on oil control rings. Note position marking on compression rings and install with markings pointing up. (Scheme 27)
2. Lightly lubricate rings. Using Piston Installer (5106), press piston into proper bore. Ensure stamped arrow on top of piston is pointing toward front of engine.
3. Check rod offset position. Connecting rod offset should be positioned behind for cylinders 1, 2 and 3, and in front for cylinders 4, 5 and 6. Install connecting rod bearing cap and tighten to 33-37 ft. lbs. (45-50 N.m).

Scheme 28

1. Pistons and liners are available only as matched sets. Pistons are classified by diameter in 3 categories. Marking on piston top is either "A", "B" or "C", and corresponds to liners marked "1", "2" or "3" respectively.
2. Liners are marked in recesses at top of liner. Pistons and piston pins are also classified by diameters, with Blue, Red and White markings being used instead of numbers for proper matching. PISTON DIAMETER Piston Designation Diameter In. (mm) "A" (for liner "1") 3.5815-3.5819 (90.97-90.98) "B" (for liner "2") 3.5819-3.5823 (90.98-90.99) "C" (for liner "3") 3.5823-3.5827 (90.99-91.00) LINER DIAMETER Liner Designation Diameter In. (mm) "1" (for piston "A") 3.5827-3.5831 (91.00-91.01) "2" (for piston "B") 3.5831-3.5835 (91.01-91.02) "3" (for piston "C") 3.5835-3.5839 (91.02-91.03)
3. Measure piston diameter at right angles to pin bore. Take measurements.32" (8.0 mm) above lower edge. With an bore gauge dial indicator, check cylinder liner taper, wear and out-of-round.
4. DO NOT remove pistons from connecting rods, unless piston and liner replacement is necessary. If liner is to be removed for cleaning or inspection, mark liner and block. DO NOT damage gasket surface. Remove liner holders and pull up liners.
5. When installing liners, ensure contact surfaces on block and liner are clean and without defects. Install No. 1 liner first (without shims) using previous markings for alignment.
6. Hand tighten liner, using 2 liner holders. Using a dial indicator, measure liner height above block at 3 points. Largest measurement should not exceed smallest measurement by more than.002" (.05 mm).
7. Liner should be.006-.008" (.14-.21 mm) above block face. Use correct shims to achieve dimension. LINER SHIM THICKNESSES Color Thickness - In. (mm) Blue.0028-.0041 (.070-.105) White.0033-.0047 (.085-.120) Red.0041-.0055 (.105-.140) Yellow.0051-.0065 (.130-.165)
8. Install shims with color marking up. (Scheme 28) Inner tabs on shims should be in liner groove.
9. After shimming, install 4 liner holders for each bank. Measure each liner at 3 points. Largest and smallest dimensions should be within.002" (.05 mm). (Scheme 29) If height difference exceeds specifications, change shims.

Scheme 29

Remove oil pan, gasket, oil strainer and baffle plate. Remove crankcase bolts and main bearing nuts. Remove lower crankcase. Install main Bearing Cap Retainers (5096) on 2 outer bearings.

Scheme 30

1. Install rubber "O" ring and sleeve for oil gallery. Clean and apply sealing compound to crankcase, and block surfaces. Remove main bearing cap retainers and install lower crankcase.
2. Ensure crankcase and block are flush at rear. Tighten bellhousing-to-crankcase bolts to 48 INCH lbs. (5 N.m). Tighten oiled crankcase bearing bolts to 22 ft. lbs. (30 N.m), then tighten an additional 75 degrees. Tighten crankcase pan-to-block bolts to 13 ft. lbs. (18 N.m). (Scheme 30) Install baffle plate, oil strainer, gasket and oil pan.

1. Remove engine from chassis. See «ENGINE R & I»(/volvo/780/i-1986-1991/remont/mechanical/#28l-v6) . Remove oil pan, lower crankcase, and drive plate and spacer for automatic transmission. Remove rear crankshaft seal holder and pry out oil seal. Press in new seal, flush with seal holder.
2. Remove front pulley and timing chain cover. Remove timing chains and oil pump drive chain. Note location of markings on connecting rods. Remove connecting rod caps.
3. Check main bearing cap markings (marked 1 through 4, from rear-to-front). Remove main bearing retainers and caps. Remove upper and lower thrust bearings and lift out crankshaft. Remove main bearing inserts from block and caps.

Note. Thrust bearing is located on flywheel end of crankshaft.

1. Inspect crankshaft and measure journals for wear. Position oiled main bearings with oil holes to engine block. Carefully set crankshaft into place. Oil and install thrust bearings with notched ends in engine block groove.
2. Oil and install unnotched thrust bearings on crankshaft. Lubricate bearing shell and position in bearing cap. Install bearing cap and bearing retainers. Note that cap identification number faces front of engine.
3. Using a dial indicator, measure crankshaft end play and install thrust washers to adjust end play to .003-.011" (.07-.27 mm). Oil remaining bearing shells, place in caps and install. Ensure bearing cap numbers reference toward front of engine.
4. Install main bearing retainer on rear main cap and 1 nut on each remaining bearing cap to keep them in place until installation of lower crankcase. Install timing chains and tensioners.
5. Install connecting rod caps and tighten to specification. Check and adjust camshaft timing and install front chain cover. Install lower crankcase and tighten main caps. To complete installation reverse removal procedures.

Remove engine from chassis. See ENGINE R & I . Remove lower oil pan and crankcase. Install main bearing retainers to hold crankshaft in place. Note location of identifying marks on connecting rods and caps. Remove caps and bearings.

INSPECTION & SERVICE

Side clearance between connecting rod and crankshaft journal is .008-.015" (.20-.38 mm). If side clearance exceeds specification rod must be replaced. Connecting rod bolts are pressed in. Piston and rod assembly must be removed to replace bolts. Bearing clearance is .0011-.0031 (.030-.080 mm), check with Plastigage.

Lubricate and install bearing inserts. Tighten connecting rod nuts. Remove main bearing cap retainers. Install sleeve and "O" ring for oil gallery. Apply sealant and install lower crankcase. Tighten main bearing cap nuts to specification. Install lower oil pan.

ENGINE OILING SYSTEM

Engine utilizes a force-feed lubrication system. Oil moves from oil pan through strainer to oil pump and full-flow oil filter mounted outside of engine block assembly. Oil is pressure fed from filter to drilled galleries in block.

Lubricant moves under pressure to main bearings, which are drilled to pass oil on to connecting rod and camshaft bearings, upward in block to rocker arm shafts.

Excess or run-off oil drains back down into oil pan through drain holes in cylinder head. Cylinder walls and piston rings are lubricated by splash from connecting rods.

CRANKCASE CAPACITY

Crankcase capacity is 6.9 quarts (6.5L) with oil filter change, and 6.3 quarts (6.0L) without filter change.

OIL PRESSURE

With engine warm and a new filter installed, minimum pressure should be 14.2 psi (1.0 kg/cm 2 ) @ 900 RPM, and 57 psi (4 kg/cm 2 ) @ 3000 RPM.

OIL PUMP SPECIFICATIONS

OIL PUMP R & I

Oil pump is serviced as a complete unit (housing cover with impeller and relief valve). Inspect housing, cover and gears for damage or wear. Replace if necessary.

Remove drive belts, crankshaft pulley and timing gear cover. Remove oil pump drive sprocket and chain. Remove 4 retaining bolts and lift out oil pump with gears.

Place gears on shaft and lubricate pump housing, gears and shaft. Install pump assembly, ensuring pump gears and shafts are centered in housing before tightening bolts. Install pump drive sprocket and chain. Install remaining components in reverse of removal order.

WATER PUMP R & I

1. Disconnect negative battery cable. Drain coolant from both sides of block. Remove intake manifold, splash guard, wiring from thermal switch in radiator, upper radiator hose and automatic transmission oil cooler pipes. Remove fan shroud, radiator and fan.
2. Remove hoses from pump to block. Remove fan belts, water pump pulley and remaining hose clamps. Remove senders from water pump and pump from block. Remove cover and thermostat from pump body. Install in reverse order.

Note. For further information on cooling systems, see ENGINE COOLING section.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

GENERAL ENGINE SPECIFICATIONS

GENERAL ENGINE SPECIFICATIONS

VALVE SPECIFICATIONS

VALVE SPECIFICATIONs

PISTONS, PINS & RINGS SPECIFICATIONS

PISTONS, PINS & RINGS SPECIFICATIONS

MAIN & CONNECTING ROD BEARINGS SPECS

MAIN & CONNECTING ROD BEARINGS SPECS

VALVE SPRING SPECIFICATIONS

VALVE SPRING SPECIFICATIONS

CAMSHAFT SPECIFICATIONS

CAMSHAFT SPECIFICATIONS

See also:
• VALVE CLEARANCE ADJUSTMENT