Part 2
Piston and Connecting Rod AssembleTools Required
- J 24086-C Piston Pin Remover/Installer
Caution: Wear safety glasses in order to avoid eye damage.
Notice: After the J 24086-C installer hub bottoms on the support assembly, DO NOT exceed 35000 kPa (5,000 psi) or the tool may be damaged.
Important:
When assembling the piston and connecting rod, the mark on the top of the piston must point to the front of the engine block. The left bank connecting rods should have the flange face toward the front of the engine block. The right bank connecting rods should have the flange face toward the rear of the engine block.
The piston pin has an interference fit into the connecting rod and is full floating in the piston.
1. Install the piston pin and connecting rod assembly.
1. Lubricate the piston and connecting rod pin bores with clean engine oil.
2. Use the J 24086-C in order to press the piston pin into the piston and connecting rod assembly.
3. Inspect for the proper installation of the piston and piston pin.
The piston should move freely on the piston pin with no binding or interference.
Notice: Use a piston ring expander to install the piston rings. The rings may be damaged if expanded more than necessary.
2. Install the piston rings onto the piston.
1. Install the oil control piston ring spacer.
2. Install the lower oil control piston ring.
3. Install the upper oil control piston ring.
4. Install the lower compression piston ring.
The mark on the side of the piston ring should face the top of the piston.
5. Install the upper compression piston ring.
The mark on the side of the piston ring should face the top of the piston.
3. Space the compression piston ring end gaps 120 degrees apart.
4. Space the oil control piston ring end gaps a minimum of 90 degrees apart.
Camshaft Bearing Removal
Tools Required
- J 33049 Camshaft Bearing Service kit
1. Select the cone (1), the handle (10), the expanding driver (4-8), and the washer (2 or 3) from the J 33049.
2. Assemble the J 33049.
Important: A loose camshaft bearing may be caused by an enlarged, out-of-round, or damaged engine block camshaft bearing bore.
Important: Remove the inner camshaft bearings #2 and #3 first. The outer camshaft bearings #1 and #4 serve as a guide for the J 33049.
3. Insert the J 33049 through the front of the engine block and into the inner camshaft bearing #2 and #3.
4. Tighten the expander assembly nut until snug.
5. Push the guide cone into the front camshaft bearing to align the tool.
6. Drive the inner camshaft bearings from the inner camshaft bearing bores.
7. Remove the outer camshaft bearings #1 and #4.
1. Assemble the tool handle, the expanding driver, and the washer.
2. Insert the J 33049 into the engine block front or rear camshaft bearings #1 or #4.
3. Drive the camshaft bearings from the camshaft bearing bores.
Camshaft and Bearings Clean and Inspect
Tools Required
- J 7872 Magnetic Base Dial Indicator
Caution: Wear safety glasses in order to avoid eye damage.
1. Clean the engine camshaft in cleaning solvent.
2. Dry the engine camshaft with compressed air.
3. Inspect the camshaft retainer plate for damage.
4. Inspect the engine camshaft for the following:
- Worn, scored, or damaged bearing journals (1)
- Worn engine camshaft lobes (2)
- Damaged bolt hole threads (3) Damaged camshaft sprocket locator pin (4)
5. Measure the engine camshaft journals with a micrometer
If the camshaft journals are more than 0.025 mm (0.0010 in) out-of-round, then replace the engine camshaft.
6. Measure for a bent engine camshaft or excessive engine camshaft runout using the J 7872.
1. Mount the engine camshaft in a suitable stand between centers.
2. Use the J 7872 in order to check the intermediate engine camshaft journals.
If the runout exceeds 0.065 mm (0.0026 in), the engine camshaft is bent and should be replaced.
7. Measure the engine camshaft lobe lift using the J 7872.
1. Place the engine camshaft on the V-blocks.
2. Use the J 7872 in order to measure the engine camshaft lobe lift.
8. Replace the engine camshaft if the engine camshaft lobe lift is not within specifications.
Camshaft Bearing Installation
Tools Required
- J 33049 Camshaft Bearing Service Kit
Important:
The outer camshaft bearings #1 and #4 must be installed first. The outer camshaft bearings serve as guides for the tool and help center the inner camshaft bearings during the installation process.
Look to ensure that the camshaft bearing lubrication hole or holes align with the oil gallery hole or holes in the engine block. On some engines, the oil holes may be difficult to see. Verify that the holes are aligned.
1. Assemble the J 33049 handle (10), the expanding driver (4 - 8),and the washer (2 or 3).
2. Insert the J 33049 into the engine block end camshaft bearings #1 or #4.
Important:
The camshaft bearing oil holes must align with the oil galleries in the engine block.
After installation of the camshaft bearings, inspect the camshaft bearing oil holes for proper alignment with the oil galleries.
An improperly aligned camshaft bearing oil gallery hole will restrict oil flow to the camshaft bearing and the camshaft journal
3. Drive the end camshaft bearings #1 and #4 into the engine block end camshaft bearing bores.
4. Select the tool handle(1) , the cone, the expanding driver, and the washer from the J33049.
5. Assemble the J 33049.
6. Insert the J 33049 through the front of the engine block and to the inner camshaft bearing bores #2 and #3.
7. Install the camshaft bearing onto the expanding driver.
8. Tighten the expander assembly nut until the J 33049 is snug in the camshaft bearing.
Important:
The camshaft bearing oil holes must align with the oil galleries in the engine block.
After installation of the camshaft bearings, inspect the camshaft bearing oil holes for proper alignment with the oil galleries.
An improperly aligned camshaft bearing oil gallery hole will restrict oil flow to the camshaft bearing and the camshaft journal.
9. Align the oil lubrication hole in the camshaft bearing with the oil galleries in the engine block.
10. Push the guide cone into the front camshaft bearing bore to align the J 33049.
11. Drive the camshaft bearing into the camshaft bearing bore.
12. Remove the J 33049.
Balance Shaft Bearing and/or Bushing Removal
Tools Required
- J 26941 Bushing/Bearing Remover
- J 38834 Balance shaft Service Kit
1. Use the J 38834 and the J 26941 in order to remove the balance shaft rear bearing.
1. Install J 26941 legs behind the balance shaft and bearing and secure.
2. Install the J 38834-1 With the short threaded and through the balance shaft.
3. Install the J 38834-1 into J26941.
4. Install the J 38834-2 on the J38834-1 and into the balances shaft bore of the engine block.
5. Install the J 38834 bearing, washer, and nut onto the J38834-1.
6. Using a wrench secure the J 38834-1 and then rotate the J38834-1 nut clockwise until the balance shaft rear bearing is removed from the engine block.
7. Remove the J 26941 from the balance shaft rear bearing.
2. Discard the balance shaft rear bearing.
Balance Shaft Clean and Inspect
Important: The balance shaft and the balance shaft front bearing are serviced only as an assembly. Do not remove the balances shaft.
1. Inspect the balance shaft bearing for the following:
- Front roller bearing for damage or wear
- Front roller bearing for smoothness of operation
- Rear sleeve bearing for wear, scoring, or other damage
2. Inspect the driven gear retaining bolt (1) for damaged threads.
3. Inspect the driven gear (2) for wear, damage to the teeth or excessive backlash.
4. Inspect the balance shaft retainer plate (3) for wear or damage.
5. Inspect the balance shaft (4) for the following:
- Wear or scoring on the rear sleeve bearing end
- Damaged bolt hole thread
- Damage to the driven gear locating pin
6. Inspect the drive gear for wear and damage to the teeth, or excessive backlash.
Balance Shaft Bearing and/or Bushing Installation
Tools Required
- J 38834 Balance Shaft Service kit
1. Use the J 38834 in order to install the balance shaft rear bearing.
1. Install the J 38834-3 onto the short threaded end of the J 38834-1.
2. Install the J 38834 nut, the washer, and the bearing on the long threaded end of the J 38834-1.
3. Install the J 38834-2 onto the J 38834-1 so that the smaller diameter of the J 38834-2 will be facing the front of the engine block.
4. Install the J 38834-2 on the inside of the balance shaft front bearing bore.
5. Lubricate the NEW balance shaft rear bearing with clean engine oil.
6. Install the balance shaft rear bearing onto the J 38834-2.
7. Align the balance shaft rear bearing for installation.
8. Using a wrench secure the J 38834-1 into place.
9. Rotate the J 38834 nut until the balance shaft rear bearing is properly and completely pushed into the balance shaft rear bearing bore.
2. Remove the J 38834.
Timing Chain and Sprockets Clean and Inspect
Caution: Wear safety glasses in order to avoid eye damage.
1. Clean the components with cleaning solvent.
2. Dry the components with compressed air.
3. Inspect the camshaft timing chain for binding or wear.
4. Inspect the camshaft sprocket and the crankshaft sprocket for:
- Broken teeth (1)
- Damaged teeth (2)
- Chipped teeth (3)
- Worn teeth
- Uneven wear on the edge of the teeth
- Worn valleys between the sprocket teeth
- Crankshaft sprocket keyway for wear
Valve Rocker Arm and Push Rods Clean and Inspect
Important: Parts that are to be reused must be marked, sorted, and organized for assembly.
1. Mark, sort, and organize the components for assembly.
Caution: Wear safety glasses in order to avoid eye damage.
2. Clean the components with cleaning solvent.
3. Dry the components with compressed air.
4. Inspect the valve rocker arms for wear or scoring in the valve rocker arm ball area.
5. Inspect the valve rocker arm pushrod sockets and valve stem contact surfaces The contact surfaces should be smooth with no scoring or excessive wear.
6. Inspect the valve pushrods for worn or scored ends. The surfaces should be smooth with no scoring or excessive wear.
7. Inspect the valve pushrods for bends.
Roll the valve pushrod on a flat surface to determine if the valve pushrod is bent.
8. Inspect the valve pushrod oil passages for any restrictions.
9. Inspect the valve rocker arm ball studs for unusual wear or damage to the threads.
Valve Lifters and Guides Clean and Inspect
Important: Components that are to be reused must be marked, sorted, and organized for assembly.
1. Mark, sort, and organize the components for assembly.
Caution: Wear safety glasses in order to avoid eye damage.
2. Clean the components in cleaning solvent.
3. Dry the components with compressed air.
4. Inspect the valve lifter pushrod guides for excessive wear.
5. Inspect the valve lifter pushrod guides for cracks or damage.
6. Inspect the valve lifter for the following:
- Broken or damaged clip (1)
- Worn pushrod socket (2)
- Scuffed or worn lifter body (3)
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
Caution: Compressed valve springs have high tension against the valve spring compressor. Valve springs that are not properly compressed by or released from the valve spring compressor can be ejected from the valve spring compressor with intense force. Use care when compressing or releasing the valve spring with the valve spring compressor and when removing or installing the valve stem keys. Falling to use care may cause personal injury.
Caution: Wear safety glasses in order to avoid eye damage.
1. Use the J 8062 in order to compress the valve springs.
Important: Mark, sort, and organize the components so that the components can be reinstalled in their original location and position.
2. Remove the valve stem keys (1).
3. Remove the J 8062 from the cylinder head.
4. Remove the valve spring cap (2).
5. Remove the valve spring (3).
6. Remove the valve stem oil seal (4).
7. Discard the valve stem oil seal.
8. Remove the valve.
Cylinder Head Clean and Inspect
Tools Required
- J 8001 Dial Indicator Set
- J 8089 Carbon Removing Brush
- J 9666 Valve Spring Tester
Caution: Wear safety glasses in order to avoid eye damage.
1. Clean the valve stems and cylinder heads on a buffing wheel.
2. Clean the following components in cleaning solvent:
- Valve stem keys (1)
- Valve spring cap (2)
- Valve spring (3)
- Cylinder head
3. Dry the components with compressed air.
4. Use the J 8059 to clean the carbon from the cylinder head combustion chambers.
Be careful not to scuff the combustion chambers.
5. Inspect the cylinder head for the following:
- Damage to the gasket surfaces
- Damage to the threaded bolt holes
- Burnt or eroded areas in the combustion chamber
- Cracks in the exhaust ports and combustion chambers
- External cracks in the water chamber
- Restrictions in the intake or exhaust passages
- Restrictions in the cooling system passages
- Rusted, damaged, or leaking core plugs
6. Measure the cylinder head for warpage with a straight edge and feeler gauge.
- 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.
- 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.
- 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.
7. Use the J 9666 in order to measure the valve spring.
Replace the valve spring if the valve spring tension is less than 338 N (76 lb) at 43.2 mm (1.70 in).
8. Inspect the valve springs for squareness.
9. Valve stems (1) with excessive valve guide (2) clearance must be repaired or replaced.
10. Measure the valve stem-to-guide clearance.
Excessive valve stem-to-guide clearance may cause an 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.
1. Clamp the J 8001 on the exhaust port side of the cylinder head.
2. Position the dial 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 dial indicator stem.
The dial indicator stem must contract the side of the valve stem just above the valve guide.
3. Drop the valve head about 1.6 mm (0.063 in) off the valve seat.
4. Use light pressure and move the valve stem from side to side in order to obtain a valve stem-to-guide clearance reading. Refer to Engine; Specifications; Mechanical.
Valve Guide Reaming/Valve and Seat Grinding
Tools 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.
1. Ream the valve guide oversize to accept a valve guide sleeve.
2. Insert the valve guide sleeve into the guide bore.
3. Ream the sleeve to achieve proper valve stem-to-guide clearance.
Always recondition the valve and valve seat after reaming the valve guide bores or installing new valves.
4. Inspect the valves for the following:
- Burnt or damaged areas (i)
- Undersized valve margin (2)
- Bent stem (3)
- Scoring or other damage to the stem (4)
- Worn key groove (5) Worn stem tip (6)
5. Inspect the valve contact surface for the following:
- Undersized margin (1)
- Pitted surface (2)
- Burnt or eroded areas (3)
- Acceptable edge (margin) (4)
Valves with excessive damage must be replaced.
Minor imperfections of the valve or valve seat may be repaired.
6. 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 valve 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 valve 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 manufacturer's recommendations for equipment use to attain the proper results.
Cylinder Head Assemble
Tools Required
- J 8062 Valve Spring Compressor
- J 42073 Valve Stem Seal Installer
Important: The exhaust valve oil stem seal has the letters EX (1) molded into the top of the seat The exhaust valve oil stem seal material is brown in color(2) with a white stripe (3) painted onto the outside diameter of the seal, or the material may be off-white in color (2) with no paint stripe. The intake valve oil seal is black in color.
1. Assemble the valve into the proper valve guide.
2. Select the proper valve stem oil seal for the specific valve guide.
3. Lubricate the valve stem oil seal and the outside diameter of the valve guide with clean engine oil.
4. Assemble the valve stem oil seal onto the valve stem.
Caution: Wear safety glasses in order to avoid eye damage.
5. Install the valve stem oil seal onto the valve guide using the J 42073.
Tap the valve stem oil seal onto the valve guide until the J 42073 bottoms against the valve spring seat.
6. Inspect the valve stem oil seal. The valve stem oil 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 valve stem oil seal and the valve guide.
7. Install the valve spring(3).
8. Install the valve spring cap (2) onto the valve spring (3) and over the valve stem.
Caution: Compressed valve springs have high tension against the valve spring compressor. Valve springs that are not properly compressed by or released from the valve spring compressor can be ejected from the valve spring compressor with intense force. Use care when compressing or releasing the valve spring with the valve spring compressor and when removing or installing the valve stem keys. Failing to use care may cause personal injury.
9. Use the J 8062 in order to compress the valve spring.
10. Install the valve stem keys.
1. Use grease in order to hold the valve stem keys in place while disconnecting the J 8062.
2. Look to ensure that the valve stem keys seat properly in the upper groove of the valve stem.
3. Tap the end of the valve stem with a plastic-faced hammer in order to seat the valve stem keys, if necessary.
Oil Pump Disassemble
1. Remove the oil pump drive shaft and oil pump drive shaft retainer.
2. Remove the oil pump screen (If necessary).
- The oil pump screen has a press fit into 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 oil pump drive gear and the oil pump driven gear.
6. Matchmark the gear teeth for assembly.
Caution: Wear safety glasses in order to avoid eye damage.
7. Remove the following items:
1. The oil pump pressure relief valve spring straight pin
2. The oil pump pressure relief spring
3. The oil pump pressure relief valve
Oil Pump Clean and Inspect
Caution: Wear safety glasses in order to avoid eye damage.
1. Clean the oil pump components in cleaning solvent.
2. Dry the components with compressed air.
3. Inspect the oil pump for the following conditions:
- Scoring on the top of the gears (1)
- Damaged gears (2) for the following:
- Chipping
- Galling
- Wear
- Scoring, damage or casting imperfections to the body (3)
- Damaged or scored gear shaft (4)
- Damaged or scored gear shaft (5)
- Damaged bolt hole threads
- Worn oil pump drive shaft bore
- Damaged or sticking oil pump pressure relief valve (minor imperfections may be removed with a fine oil stone).
- Collapsed or broken oil pump pressure relief valve spring
4. If the oil pump is to be reused, install a NEW oil pump pressure relief valve spring.
5. During oil pump installation, install a NEW oil pump drive shaft retainer.
Oil Pump Assemble
Tools Required
- J 21882 Oil Suction Pipe Installer
1. Apply clean engine oil to the oil pump pressure relief valve, the oil pump pressure relief valve spring, and the oil pump body.
Caution: Wear safety glasses in order to avoid eye damage.
Important: Replace the oil pump pressure relief valve spring when you reuse the oil pump.
2. Install the following items:
1. The oil pump pressure relief valve
2. The oil pump pressure relief valve spring
3. The oil pump pressure relief valve spring straight pin
3. Apply clean engine oil to the oil pump drive gear, the oil pump driven gear, and the oil pump body internal surfaces.
4. Install the oil pump drive gear and the oil pump driven gear into the oil pump body.
1. Align the matchmarks on the oil pump drive and the driven gears.
2. Install the smooth side of the oil pump drive and the driven gears toward the oil pump cover.
5. Install the oil pump cover.
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 drive shaft by hand.
8. Install the oil pump screen.
1. If removed, replace the oil pump screen The oil pump screen must have a good press fit into the oil pump body
2. Mount the oil pump in a soft jawed vise.
3. Apply sealant to the end of the oil pump screen pipe.
4. Use the J 21882 and a soft faced hammer in order to tap the oil pump screen into the pump body.
The oil pump screen must align parallel with the bottom of the oil pan when the oil pan is installed.
Important: Install a NEW oil pump drive shaft retainer during assembly.
9. Install the oil pump drive shaft and the NEW oil pump drive shaft retainer.