Disassembly, Inspection and Assembly

Fig. 5 Timing Chain Replacement (Part 1 Of 2):

Fig. 5 Timing Chain Replacement (Part 2 Of 2):

Fig. 6 Exploded View Of Cylinder Block:

Fig. 32 Intake Manifold Bolt Removal Sequence:

Fig. 33 Intake Manifold Collector Bolt Removal Sequence:

DISASSEMBLY
Refer to Figs. 5 and 6 when disassembling engine.
1. Disconnect battery ground cable.
2. Remove rocker cover, rocker arms, shim rocker arm guides and hydraulic lash adjusters. Keep components in the order in which they were removed.
3. Remove throttle chamber with accel-drum unit.
4. Remove EGR tube.
5. Remove exhaust manifold cover, then the exhaust manifold. Remove bolts in sequence shown in Fig. 7.
6. Remove fuel tube assembly as follows:
a. Release fuel system pressure as outlined under Technician Safety Information.
b. Disconnect injector harness connectors.
c. Disconnect vacuum hose from pressure regulator.
d. Disconnect fuel hoses from fuel tube assembly.
e. Remove injectors with fuel tube assembly.

7. Remove intake manifold bolts and manifold in sequence shown, Fig. 8.
8. Remove intake manifold collector from intake manifold in sequence shown, Fig. 9.
9. Remove water outlet.
10. Remove water connector.
11. Remove thermostat housing with water pipe.
12. Remove valve components using valve spring compression and attachment tool Nos. KV10116200 (J26339-A) and KV10115900 (J26336-20), or equivalents.
13. Remove valve oil seals using seal puller tool No. KV10107902 (J38959), or equivalent.

Fig. 34 Thermostat Housing & Water Pipe Bolt Tightening Sequence:

Fig. 33 Intake Manifold Collector Bolt Removal Sequence:

Fig. 32 Intake Manifold Bolt Removal Sequence:

Fig. 6 Exploded View Of Cylinder Block:

Fig. 35 Checking Hydraulic Lash Adjuster:

Fig. 36 Bleeding Hydraulic Lash Adjuster:

Fig. 14 Piston & Connecting Rod Front Mark Location:

ASSEMBLY
1. Apply a bead of liquid gasket to water connector mating surface.
2. Using bolt tightening sequence shown in Fig. 11, install thermostat housing with water pipe as follows:
a. Torque thermostat housing bolt A to 1.4-3.6 ft. lbs.
b. Torque water pipe bolt C to 12-15 ft. lbs.
c. Torque thermostat housing bolt A to 12-15 ft. lbs.
d. Torque thermostat housing bolt B to 12-15 ft. lbs.
e. Repeat steps b through d after installing cylinder head.

3. Apply a bead of liquid gasket to mating surface of water outlet, then install water outlet.
4. Install intake manifold collector bolts to intake manifold in reverse sequence shown in Fig. 9.
5. Install intake manifold bolts in reverse sequence shown in Fig. 8.
6. Install injector tube assembly in reverse order of removal.
7. Install exhaust manifold bolts in reverse sequence shown in Fig. 6.
8. Install exhaust manifold cover.
9. Install EGR tube.
10. Install throttle chamber with accel-drum unit. Adjust accel-drum unit.
11. Install valve oil seals using seal drift tool No. KV10115600 (J38958), or equivalent.
12. Install valve components in order of removal (except shim), using valve spring compression and attachment tool Nos. KV10116200 (J26339-A) and KV10115900 (J26336-20), or equivalents. When installing valve springs, ensure narrow pitch of spring is pointed toward cylinder head.
13. When replacing valve, cylinder head, shim, rocker arm guide and/or valve seat, select a new valve adjustment shim as follows:
a. Install dial gauge stand tool No. KV10115700, or equivalent and a suitable dial indicator onto cylinder head.
b. Measure distance between sliding surface of rocker arm guide and valve stem end. When measuring, pull lightly on dial gauge stand tool to eliminate any play in tool.
c. Shims are available in 17 different thicknesses ranging from 0.1102 inch to 0.1260 inch. Select a suitable shim to obtain a zero clearance +/- 0.0010 inch between valve shim and rocker arm guide.

14. Check hydraulic lash as follows:
a. Push on rocker arm assembly, Fig. 12.
b. If rocker arm can be moved 0.04 inch, air is trapped in the high pressure chamber.
c. Remove hydraulic lash adjuster and dip in a container of clean engine oil.
d. While pushing plunger, lightly push check ball using a thin rod. Air is completely bled when plunger no longer moves, Fig. 13.

15. Install hydraulic lash adjusters, rocker arm guides, rocker arms, shims and rocker cover.