Inspection and Service Procedures Part 6

VALVE LIFTERS AND GUIDES CLEAN AND INSPECT

IMPORTANT: Components that are to be reused must be marked, sorted or organized for assembly.

1. Mark, sort, or organize the components for assembly.
2. Clean the components in cleaning solvent.

CAUTION: Wear safety glasses in order to avoid eye damage.

3. Dry the components with compressed air.
4. Inspect the valve lifter guides for excessive wear.
5. Inspect the valve lifter guides for cracks or damage.





6. Inspect the valve lifter body for the following:
- Broken or damaged clip (1)
- Worn pushrod socket (2)
- Scuffed or worn lifter (3)

NOTE: If the valve lifter shows scuffing or wear; inspect the engine block valve lifter bores for wear.

- Worn roller (4)
- Loose or damaged pin (5)
- Plugged oil hole (6)



CYLINDER HEAD DISASSEMBLE

Tools Required
- J 8062 Valve Spring Compressor





1. Use J 8062 in order to compress the valve springs.





IMPORTANT: Mark, sort, or organize the components so that they may be reinstalled to their original location and position.

2. Remove the valve stem keys (1).
3. Remove the cap (3).
4. Remove the valve spring (4).
5. Remove the valve stem oil seal (2).
6. Discard the valve stem oil seal.
7. Remove the valve.



CYLINDER HEAD CLEAN AND INSPECT

Tools Required
- J 8001 Dial Indicator
- J 8089 Carbon Removal Brush
- J 9666 Valve Spring Tester





1. Use the J 8089 in order to clean the carbon from the combustion chambers. Be careful not to scuff the chambers.

CAUTION: Wear safety glasses In order to avoid eye damage.

2. Clean the valve stems and heads of a buffing wheel.





3. Clean the following components in solvent:
- Valve stem keys (1)
- Valve spring cap (3)
- Valve spring (4)
- Cylinder head

CAUTION: Wear safety glasses In order to avoid eye damage.

4. Dry the components with compressed air.





5. Measure the cylinder head for warpage with a straight edge and feeler gauge.
5.1. A cylinder head block deck with warpage in excess of 0.10 mm (0.004 in) within a 152.4 mm (6.0 in) area must be repaired or replaced.
5.2. A cylinder head exhaust manifold deck with warpage in excess of 0.5 mm (0.002 in) within a 152.4 mm (6.0 in) area must be repaired or replaced.
5.3. A cylinder head intake manifold deck with warpage in excess of 0.10 mm (0.004 in) within a 152.4 mm (6.0 in) area must be repaired or replaced.




6. Use the J 9666 in order to measure the valve spring.

NOTE: Replace the valve spring if the spring tension is less than 338 N (76 lb) at 43.2 mm (1.70 in).





7. Inspect the valve springs for squareness.





8. Valve stems (1) with excessive guide (2) clearance must be repaired or replaced.





9. Measure the valve stem4o-guide clearance.
- Excessive valve stem-to-guide clearance may cause excessive oil consumption and may also cause a valve to break. Insufficient clearance will result in noisy and sticky functioning of the valve and will disturb the engine assembly smoothness.
- Clamp the J 8001 on the exhaust port side of the cylinder head.
- Locate the indicator so that the movement of the valve stem from side to side (crosswise to the cylinder head) will cause a direct movement of the indicator stem.

NOTE: The indicator stem must contact the side of the valve stem just above the valve guide.

- Drop the valve head about 1.6 mm (0.0064 in) off the valve seat.
- Use light pressure when moving the valve stem from side to side in order to obtain a clearance reading.

VALVE GUIDE REAMING/VALVE AND SEAT GRINDING

Tool Required
- J 8001 Dial Indicator Set





1. Use the J 8001 to measure the valve stem-to-guide clearance. Refer to Cylinder Head Clean and Inspect.





2. Improper valve stem (1) to valve guide (2) clearance may cause excessive oil consumption.





3. Ream the valve guide as necessary to achieve proper valve stem-to-guide clearance.
3.1. Ream the valve guide oversize to accept a valve guide sleeve.
3.2. Insert the valve guide sleeve into the guide bore.
3.3. Ream the sleeve to achieve proper valve stem-to-guide clearance.
4. Always recondition the valve and valve seat after reaming the valve guide bores or installing new valves.





5. Inspect the valves for the following:
- Burnt or damaged areas (1)
- Undersized valve margin (2)
- Bent stem (3)
- Scoring or other damage to the stem (4)
- Worn key groove (5) Worn stem tip (6)





6. Inspect the valve contact surface for the following:
- Undersized margin (1)
- Pitted surface (2)
- Burnt or eroded areas (3)
- Acceptable edge (margin) (4)
7. Valves with excessive damage must be replaced.

NOTE: Minor imperfections of the valve or valve seat may be repaired.

8. Reconditioning of the valves and valve seats:
- The valves must seat perfectly for the engine to deliver optimum power and performance.
- Cooling the valve heads is another important factor. Good contact between each valve and its seat in the cylinder head is necessary to insure that the heat in the valve head is properly carried away.
- Regardless of what type of equipment is used, it is essential that the valve guide bores are free from carbon or dirt to ensure the proper centering of the pilot in the guide. The valve seats should be concentric to within 0.05 mm (0.031 in) total indicator reading.
- Reface pitted valves on a valve refacing machine in order to insure the correct relationship between the head and the stem.
- Replace the valve stems that show excessive wear or are warped.
- Replace the valve if the edge of the head is less than 0.79 mm (0.031 in) thick after grinding.
- Several different types of equipment are available for reconditioning valves and valve seats. Follow the manufacturers recommendations for equipment use to attain the proper results.


CYLINDER HEAD ASSEMBLE

Tools Required
- J 8062 Valve Spring Compressor
- J 42073 Valve Stem Oil Seal Installer

IMPORTANT: The exhaust valve oil seal has the letters EX (1) molded into the top of the seal. The seal material is brown in color (2) with a white stripe (3) painted onto the outside diameter of the seal.

1. Assemble the valve into the proper guide.
2. Select the proper valve stem oil seal for the specific valve guide.
3. Lubricate the valve stem oil seal and guide with clean engine oil.

NOTE: The exhaust and intake valve seals are not interchangeable.





4. Assemble the valve stem oil seal onto the valve guide using the J 42073.

NOTE: Install the oil seal onto the valve guide until the installation tool bottoms against the valve spring seat.





5. Inspect the oil seal. The seal should not be bottomed against the valve guide. There should be a 1-2 mm (0.03937-0.07874 in) gap between the bottom edge of the seal and the guide.





6. Install the valve spring (4).
7. Install the spring cap (2) onto the spring (4) and over the valve stem (5) or (6).





8. Use the J 8062 in order to compress the valve spring.
9. Install the valve stem keys (1).
9.1. Use grease in order to hold the keys (1) in place while disconnecting the J 8062.
9.2. Ensure that the keys seat properly in the upper groove of the valve stem.
9.3. Tap the end of the stem with a plastic-faced hammer in order to seat the keys, if necessary.






OIL PUMP DISASSEMBLE
1. Remove the oil pump driveshaft and oil pump driveshaft retainer.





2. If necessary, remove the oil pump screen.
- The oil pump screen has a press fit in to the oil pump cover.
- Do not remove the oil pump screen from the pipe. The pipe and oil pump screen are serviced as a complete assembly.





3. Remove the oil pump cover bolts.





4. Remove the oil pump cover.





5. Remove the drive gear and the driven gear. Matchmark the gear teeth for assembly.





6. Remove the following items:
- The locator pin
- The oil pressure relief spring The oil pressure relief valve

OIL PUMP CLEAN AND INSPECT
1. Clean the oil pump components in solvent.

CAUTION: Wear safety glasses in order to avoid eye damage.

2. Dry the components with compressed air.





3. Inspect the oil pump for the following:
- Scoring, damage or casting imperfections to the housing (3)
- Damage gears (chipping, galling, or wear) (2)
- Scoring on the top of the gears (1)
- Damaged or scored gear shaft (5)
- Damaged bolt threads
- Worn driveshaft housing bore
- Damaged or sticking pressure relief valve (minor imperfections may be removed with a fine oil stone).
- Collapsed or broken pressure relief valve spring
4. If the oil pump is to be reused, install a NEW pressure relief valve spring.
5. During oil pump installation, install a NEW oil pump driveshaft retainer.

OIL PUMP ASSEMBLE

Tools Required
- J 21882 Oil Pump Screen Installer

1. Lubricate the oil pressure relief valve, spring, and oil pump housing with clean engine oil.

IMPORTANT: Replace the pressure relief valve spring when you reuse the oil pump.





2. Install the following items:
2.1. The oil pressure relief valve
2.2. The oil pressure relief spring
2.3. The locator pin





3. Coat the drive gear, the driven gear and the housing gear surfaces with clean engine oil.
4. Install the drive gear and the driven gear into the pump body.

NOTE: Align the matchmarks on the gears. Install the smooth side of the gear toward the pump cover.





5. Install the oil pump cover.

NOTE: Refer to Fastener Notice in Caution and Notices.





6. Install the oil pump cover bolts.

Tighten
- Tighten the bolts to 12 N.m (106 lb in).

7. Inspect the oil pump for smoothness of operation by turning the oil pump driveshaft by hand.





8. Install the oil pump screen.
8.1. If removed, replace the oil pump screen. The oil pump screen must have a good press fit into the oil pump body.
8.2. Mount the oil pump in a soft jawed vise.
8.3. Apply sealant to the end of the pipe.
8.4. Use the J 21882 and a soft-faced hammer in order to tap the oil pump screen into the pump body. The screen must align parallel with the bottom of the oil pan when it is installed.

IMPORTANT: Install a NEW oil pump driveshaft retainer during assembly.





9. Install the oil pump driveshaft and the NEW retainer.






VALVE ROCKER ARM COVER CLEAN AND INSPECT
1. Clean the valve rocker arm cover in solvent.

CAUTION: Wear safety glasses In order to avoid eye damage.

2. Dry the component with compressed air.
3. Inspect the valve rocker arm cover for the following:
- Cracks or damage to the exterior of the cover
- Damaged gasket groove
- Restrictions to the ventilation system passages
- Cracking around the cover retaining bolt holes
- Damaged PCV valve grommet Damage to the oil fill opening






OIL PAN CLEAN AND INSPECT
1. Remove the oil pan baffle bolts and baffle.
2. Clean the oil pan and baffle in solvent.

CAUTION: Wear safety glasses In order to avoid eye damage.

3. Dry the components with compressed air.
4. Inspect the oil pan for the following:
- Damage or gouges in the gasket sealing surface
- Damage to threaded bolt holes
- Damage to the exterior of the pan

NOTE: Refer to Fastener Notice in Cautions and Notices.

5. Install the oil pan baffle and bolts.

Tighten
- Tighten the oil pan baffle bolts to 12 N.m (106 lb in).





INTAKE MANIFOLD DISASSEMBLE
1. Remove the ignition coil studs and ignition coil.




2. Remove the evaporative emission (EVAP) canister purge valve and bolts.





3. Remove the manifold absolute pressure (MAP) sensor.





4. Remove the engine coolant temperature (ECT) sensor from the front of the lower intake manifold.

IMPORTANT: Note the position and direction of the EGR valve before removal. It is possible to improperly install the EGR valve 180 degrees from the original position.





5. Remove the exhaust gas recirculation (EGR) valve bolts.

NOTICE: The Linear EGR valve is an electrical component. DO NOT soak in any liquid cleaner or solvent because damage may result.





6. Remove the EGR valve and gasket.
7. Discard the gasket.





8. Remove the water outlet studs, water outlet, and engine coolant thermostat.





9. Remove the throttle body studs.





10. Remove the throttle body and gasket.
11. Discard the gasket.





12. Remove the fuel pipe, nuts, bolt, 0-ring seals, and grommets.





13. Remove the upper intake manifold, gasket, and bolts.
14. Discard the gasket.





15. Remove the fuel meter body.
16. Remove the fuel meter body bracket and bolts.






INTAKE MANIFOLD CLEAN AND INSPECT
1. Clean the upper intake manifold in solvent.





IMPORTANT: The fuel meter body must be removed from the lower intake manifold prior to cleaning. Do not allow cleaning solvent to contact the fuel meter body.

2. Clean the lower intake manifold in solvent.

CAUTION: Wear safety glasses In order to avoid eye damage.

3. Dry the components with compressed air.





4. Inspect the upper intake manifold for the following:
- Cracks or other damage to the exterior of the manifold
- Cracking or damage in the gasket grooves
- Loose or damaged bolt thread inserts
- Damage to the throttle body mounting surface







INTAKE MANIFOLD ASSEMBLE

NOTICE: Refer to Fastener Notice in Cautions and Notices.

1. Install the fuel meter body bracket and bolt.

Tighten
- Tighten the fuel meter body bracket bolt to 10 N.m (88 lb in).

2. Install the fuel meter body into the mounting bracket.
3. Insert the six separate poppet nozzles into their proper lower intake manifold bores.
4. Inspect the poppet nozzles in order to ensure they are firmly seated and locked in the casting socket.





5. Install a NEW upper intake manifold gasket into the groove of the upper intake manifold.
6. Install a NEW fuel meter body gasket into the groove of the upper intake manifold.
7. Install the upper intake manifold onto the lower intake manifold.
8. Install the upper intake manifold bolts and studs.

Tighten
8.1. Tighten the upper intake manifold bolts and studs on the first pass to 5 N.m (44 lb in).
8.2. Tighten the upper intake manifold bolts and studs on the final pass to 10 N.m (88 lb in).





9. Install the fuel pipe, nuts, bolt, 0-ring seals, and grommets.

NOTE: The 0-ring seals and grommets must be installed in the proper order.

Tighten
9.1. Tighten the fuel pipe nuts to 3 N.m (27 lb in).
9.2. Tighten the fuel pipe bolt to 6 N.m (53 lb in).





10. Install the throttle body and a NEW gasket.





11. Install the throttle body studs.

Tighten
- Tighten the throttle body studs to 9 N.m (80 lb in).





12. Install the engine coolant thermostat, water outlet, and studs.

Tighten
- Tighten the water outlet studs to 25 N.m (18 lb ft).





13. Install the exhaust gas recirculation (EGR) valve and gasket.





14. Install the EGR valve bolts.

Tighten
14.1. Tighten the EGR valve bolts on the first pass to 7 N.m (62 lb in).
14.2. Tighten the EGR valve bolts on the final pass to 25 N.m (18 lb ft).





15. Apply sealant to the threads of the engine coolant temperature (ECT) sensor.
16. Install the ECT sensor to the front of the lower intake manifold.

Tighten
- Tighten the ECT sensor to 20 N.m (15 lb ft).





17. Lubricate the grommet of the manifold absolute pressure (MAP) sensor with clean engine oil.
18. Install the MAP sensor.





19. Install the evaporative emission (EVAP) canister purge valve and bolts.

Tighten
- Tighten the EVAP canister purge valve bolts to 12 N.m (108 lb in).





20. Install the ignition coil and studs.

Tighten
- Tighten the ignition coil studs to 12 N.m (106 lb in).







EXHAUST MANIFOLD CLEAN AND INSPECT
1. Clean the manifolds in solvent.

CAUTION: Wear safety glasses In order to avoid eye damage.

2. Dry the components with compressed air.
3. Inspect the exhaust manifolds for the following:
- Damage to the gasket sealing surfaces
- Damage to the EGR pipe fitting (if applicable)
- Damage to the take down studs
- Restrictions within the exhaust passages
- Broken or damaged heat shields (if applicable)





4. Measure the alignment or surface flatness of the exhaust manifold flanges using a straight edge and a feeler gauge. Refer to Engine Mechanical Specifications.

NOTE: If the surface flatness is not within specifications, the exhaust manifold is warped and must be replaced.





WATER PUMP CLEAN AND INSPECT
1. Remove the old gasket material from the water pump sealing surfaces.
2. Clean all excess dirt and debris from the water pump housing.
3. Inspect the water pump for the following:
- Gasket sealing surfaces for excessive scratches or gouging
- Restrictions within the internal coolant passages
- Excessive side-to-side play in the pulley shaft
- Leakage at the water outlet housing or rear cover gasket
- Leakage at the water pump vent hole

NOTE: A stain around the vent hole is acceptable. If leakage occurs (dripping) with the engine running and the cooling system pressurized, replace the water pump.