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262 CID (4.3L)
Table of Contents
Page Torque Specifications 4.3L/4.3LX Engines . . . 3A-1 Tools/Lubricants/Sealants . . . . . . . . . . . . . . . . . 3A-3 Engine Specifications . . . . . . . . . . . . . . . . . . . . . 3A-4 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-14 Engine Identification . . . . . . . . . . . . . . . . . . 3A-14 Cylinder Head Identification . . . . . . . . . . . . 3A-14 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-15 Piston and Connecting Rods . . . . . . . . . . . 3A-15 Camshaft and Drive . . . . . . . . . . . . . . . . . . . 3A-15 Balance Shaft . . . . . . . . . . . . . . . . . . . . . . . . 3A-15 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . 3A-15 Valve Train . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-15 Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . 3A-15 Lubrication System . . . . . . . . . . . . . . . . . . . 3A-16 Bearing Failures . . . . . . . . . . . . . . . . . . . . . . . . 3A-17 Piston Failures . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-17 Pre-Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-17 Detonation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-18 Engine Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-19 Rocker Arm Cover . . . . . . . . . . . . . . . . . . . . . . . 3A-19 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-19 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-19 Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . 3A-20 Rocker Arm/Push Rod . . . . . . . . . . . . . . . . . . . 3A-22 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-22 Cleaning and Inspection . . . . . . . . . . . . . . . 3A-22 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-22 Hydraulic Roller Valve Lifters . . . . . . . . . . . . . 3A-22 Locating Noisy Lifters . . . . . . . . . . . . . . . . . 3A-23 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-23 Cleaning and Inspection . . . . . . . . . . . . . . . 3A-24 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-24 Valve Stem Oil Seal/Valve Spring . . . . . . . . . . 3A-25 Removal - Head Installed . . . . . . . . . . . . . . 3A-25 Valve Assembly (Exploded View) . . . . . . . 3A-25 Installation - Head Installed . . . . . . . . . . . . 3A-26 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-26 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-26 Cleaning and Inspection . . . . . . . . . . . . . . . 3A-26 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-27 Cylinder Head and Valve Conditioning . . . . . 3A-27 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 3A-27 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-28 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-28 Valve Guide Bore Repair . . . . . . . . . . . . . . 3A-29 Valve Springs - Checking Tension . . . . . . . 3A-29 Valve Seat Repair . . . . . . . . . . . . . . . . . . . . 3A-30 Valve Grinding . . . . . . . . . . . . . . . . . . . . . . . 3A-30 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 3A-31 Dipstick Specifications . . . . . . . . . . . . . . . . . . . 3A-32 All Engines . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-32 Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-33 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-33 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-33 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 3A-34 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-33 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-34 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 3A-34 Cleaning and Inspection . . . . . . . . . . . . . . . 3A-34
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . Torsional Damper . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankcase Front Cover/Oil Seal . . . . . . . . . . . Oil Seal Replacement (Without Removing Front Cover) . . . . . . . . Crankcase Front Cover . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Main Oil Seal . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Main Oil Seal Retainer . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Clearances . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . Connecting Rod Bearings . . . . . . . . . . . . . . . . Inspection and Replacement . . . . . . . . . . . Connecting Rod/Piston Assembly . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . Timing Chain and Sprocket . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection . . . . . . . . . . . . . . . Installation - Timing Chain . . . . . . . . . . . . . Crankshaft Sprocket . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Timing Chain Deflection . . . . . . Balance Shaft/Gears . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Measuring Lobe Lift . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft Bearings . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection . . . . . . . . . . . . . . . Oil Filter By-Pass Valve . . . . . . . . . . . . . . . . . . Inspection and/or Replacement . . . . . . . . .
Page 3A-35 3A-35 3A-35 3A-35 3A-36 3A-36 3A-37 3A-37 3A-37 3A-37 3A-38 3A-38 3A-38 3A-38 3A-39 3A-39 3A-39 3A-40 3A-40 3A-40 3A-40 3A-40 3A-40 3A-41 3A-41 3A-42 3A-43 3A-43 3A-44 3A-44 3A-45 3A-45 3A-46 3A-47 3A-48 3A-48 3A-49 3A-49 3A-50 3A-50 3A-50 3A-50 3A-51 3A-51 3A-51 3A-51 3A-52 3A-52 3A-53 3A-53 3A-54 3A-54 3A-55 3A-55 3A-55 3A-55 3A-55 3A-56 3A-56 3A-57 3A-57 3A-60 3A-60
3A-0 - ENGINES
Torque Specifications 4.3L/4.3LX Engines
NOTE: Any Differences in Gen + Engines Will Be Noted With ”Gen +”.
DESCRIPTION Alternator Brace to Alternator Alternator Brace to Engine Alternator to Mounting Bracket Alternator Mounting Bracket Balance Shaft Drive Gear Retaining Stud Balance Shaft Driven Gear Bolt (Torque Plus 35°) Balance Shaft Thrust Plate Camshaft Sprocket Camshaft Thrust Plate Carburetor Connecting Rod Cap Nuts (Torque Plus 60°) Connecting Rod Cap Nuts Gen + (Torque Plus 70°) Coupler/Flywheel Crankcase Front Cover Crankshaft Pulley Bolt (Cast Aluminum) Cylinder Head Bolts Cylinder Head Bolts Gen + First Sequence Angle Torque Second Sequence Short Bolt Medium Bolt Long Bolt Distributor Hold Down Exhaust Manifold Flywheel Flywheel Housing to Block Flywheel Housing Cover Front Mount Bracket Fuel Filter Bracket Bolt Fuel Pump Bracket Bolt Fuel Pump Inlet Fitting (Large Diameter See Note) Fuel Pump Inlet Fitting (Small Diameter See Note) Intake Manifold Bolts Intake Manifold Bolts Gen + Knock Sensor 96 84 35 11 15 80 30 25 25 124 40 65 22 55 Degrees 65 Degrees 75 Degrees 25 20 75 30 34 27 100 41 9 41 25 25 10.8 9.6 48 15 20 20 35 27 48 14 54 88 30 106 132 120 20 120 15 Lb. In. 192 30 35 30 Lb. Ft. N·m 28 41 48 41 14 20 14 27 12 15
NOTE: Hold fuel pump using flat surface at outlet before tightening brass fitting.
ENGINES - 3A-1
In.ENGINES INDEX 90-823226--1 896 . 75 15 15 N·m 100 20 20 9 19 68 9 41 41 15 54 5.3L/4.5 12 27 16 41 41 20 68 41 54 41 27 Note : Hold fuel pump using wrench on flat surface at outlet before tightening brass fitting 3A-2 . Lb.3LX Engines (continued) DESCRIPTION Main Bearing Cap Oil Filter Adapter Bolts Oil Pan Drain Plug Oil Pan Screw (1/4-20) Oil Pan Nuts (5/16-20) Oil Pump Oil Pump Cover Power Steering Pump Brace to Block Power Steering Pump Bracket Rear Crankshaft Oil Seal Retainer Screws and Nuts Rear Mount (MCM) Rocker Arm Cover Rocker Arm Cover Gen + Rocker Arm Nuts Roller Lifter Restrictor Plate Seawater Pump Brace (if equipped) Seawater Pump Bracket (if equipped) Spark Plugs Starter Motor Thermostat Housing Torsional Damper Water Circulating Pump Water Temperature Sender 50 106 20 12 30 30 15 50 30 40 30 20 133 40 80 30 30 80 165 65 Lb. Ft.Torque Specifications 4.
Lubricant Obtained Locally Part Number Obtain Locally Description General Motors Cam and lifter Prelube or Equivalent NOTE: Kent-Moore Special Tools can be ordered from: Kent-Moore Tools Inc. J5892 J8062 J8056 J8101 J5830-2 J7049 J8089 J24086-B J3936-03 J8037 J5239 J21882 J6098-01 J8520-1 J23523-E J35468 J5825-A J5590 J23590 J8080 J26817-A J26941 J33834 Description Valve Spring Compressor Valve Spring Compressor Valve Spring Tester Valve Guide Cleaner Valve Guide Reamer Valve Guide Reamer Carbon Remover Brush Piston Pin Remover Kit Piston Ring Groove Cleaner Piston Ring Compressor Connecting Rod Bolt Guide Set (3/8-24) Oil Pump Suction Pipe Installer Camshaft Bearing Remover and Installer Set Ball Socket Adaptor Tool Kit (Lift Indicator) Torsional Damper Remover and Installer Crankcase Front Cover Seal Installer Crankshaft Gear and Sprocket Puller Crankshaft Gear and Sprocket Installer Air Adaptor Main Bearing Remover/Installer Rear Main Seal Installer Balance Shaft Rear Bearing Remover Balance Shaft Bearing Remover/Installer Snap-On Special Tools (see note) Part Number TA 360 Description Torque Angle Gauge (Degree Wheel Torquing) NOTE: Snap-On Tools can be ordered from your nearest Snap-On branch sales office or distributor.1 92-91601-1 92-34227--1 Description Piston Ring Expander Engine Coupler Wrench Quicksilver Loctite 8831 Quicksilver RTV Sealer Quicksilver Perfect Seal Kent-Moore Special Tools (see note) Part No. 29784 Little Mack Roseville. 90-823226--1 896 INDEX ENGINES .Tools/Lubricants/Sealants Mercury Marine Part Number 91-24697 91-35547 92-823089 .3A-3 . MI 48066 Phone: (800) 345-2233.
Engine Specifications UNIT OF MEASUREMENT In.9.ENGINES INDEX 90-823226--1 896 .05:1 (Gen + .6) 3.3LX 262 CID (4.4:1) Cast Iron Cast Iron Cast Iron (2 Bolt Main Bearing Caps) Forged Steel Cast Aluminum Cast Iron Steel LH ROTATION FRONT Firing Order 1-6-5-4-3-2 72976 3A-4 .39) 9.3L/4.3 Litre) 4.00 (101. (mm) Engine Model Displacement Bore Stroke Compression Ratio Heads Intake manifold Block Rods Pistons Crankshaft Camshaft 4.48 (88.
0005 (0.508) .0027 (0.9273 (23.254-0.025 (0.051) Maximum .0007-4.0203-0.0431) .001 (0.0032 (0.010 (0.0406) Interference Production Service Production Service Production Service Production Service Top 2nd Top 2nd .254) Production Service .015-.381-1.0007-.002 (0.025) Over Production Taper T 90-823226--1 896 INDEX ENGINES .0177) .3L Engine Specifications (Does Not Include Gen +) CYLINDER BORE Diameter Out-of-Round Production Service PISTON Clearance PISTON RING Groove Side Clearance Compression C i Gap G Groove Side Clearance C Oil Gap PISTON PIN Diameter Clearance in Piston Fit in Rod Production Service .001 (0.0178-0.177) High Limit Production + .001 (0.9270-.5458-23.0008-.0002-.025) .010 (0.025 (0.025) .397) High Limit Production + .0032 (0.0007 (0.07) Maximum Production Service Thrust Side Relief Side 4.010-.0017 (101.0012-.3A-5 .025) Maximum .001 (0.0012-.5534) .002-.0305-0.508) High Limit Production + .262 CID / 4.0813) High Limit Production + .055 (0.6178-1016431) .007 (0.025) Maximum .0127) Maximum .010-.001 (0.254-0.0051-0.254) .0813) .051-0.0017 (0.025) Maximum .0305-0.0016 (0.001 (0.
2. 1 Diameter Di Main Journal M i J l No.03) .002-.2497 (57.2487-2.0002 (0.15) 2. 1 Production P d i Main Bearing M i B i g Clearance C Service S i Crankshaft End Play Diameter Connecting R d C i Rod Journal Taper Out-of-Round Rod Bearing Clearance Rod Side Clearance Crankshaft Runout Production Service Production Service Production Service No.02) Maximum .4479-2.0015 (0.0002 (0. 2.ENGINES INDEX 90-823226--1 896 .4490 (62.1423) . 2.0584) .0813) . 3 No.006 (0.4481-2.001 (0.07) Maximum . 1 No.0025-.3-0.02) Maximum .4488 (62.02) Maximum .1170-57.0023 (0.2122) 2.0013-. 4 Taper Out-of-Round Production Service Production Service No.001 (0.4493 (62.4484-2.1995) .1894-62.356) .262 CID / 4.0032 (0. 4 No. 3 No.0508) .0005 (0.0015 (0.0127) Maximum .0035 (0.005) Maximum . 4 2.05-0.0279-0.005) Maximum .0889) .02) Maximum .003 (0.001 (0.1767-62.0035 (0.014 (0.08) .001 (0.0127) Maximum .2046) 2. 3 No.1817-62.0020 (0.152-0.07-0.06) .0011-.0005 (0.0010-.0330-0.0381) Maximum 3A-6 .0010-.0432-0.0203-0.006-.0017-.0025 (0.0008-.3L Engine Specifications (Does Not Include Gen +) CRANKSHAFT No.
372 (9.0047 (0.11) .262 CID / 4.6) .062-.051) Maximum .0037 (0.50 to 1 .3A-7 .031-.062 (0.0027 (0.0010-.0027 (0 0254-0 0686) .45) 1.394 (10.0254-0.0686) 0010.002 (0.09) .6-2.28) 1.404 (10.26) Fixed Lash 45° 46° .091 (1.79) Valve Lash (Intake and Exhaust) Face Angle (Intake and Exhaust) Seat Angle (Intake and Exhaust) Seat Runout (Intake and Exhaust) Seat Width Production Stem Cl S Clearance Service Stem Diameter Valve Diameter Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust Valve Margin Intake and Exhaust 90-823226--1 896 INDEX ENGINES .3) .341 (8.1) 1/32 (0.50 (38.8-1.3L Engine Specifications (Does Not Include Gen +) VALVE SYSTEM Lifter Type Rocker Arm Ratio Valve Lift Intake Exhaust Roller Hydraulic 1.00) .94 (49.66) .
30) Maximum 3/8 (10) From Taut Position [3/4 (19) Total] 3A-8 .16) ( ) Open at 1.875-1.8682-1.70 (43) 1.86 (47) 4 Valve Spring V l S i Pressure P Installed Height Damper Free Length Approximate Number of Coils NOTE: Test spring pressure with damper removed CAMSHAFT AND DRIVE Lobe Lift + .025) Maximum .002 (0.873-1.10) Overall Maximum .1812-1.3L Engine Specifications (Does Not Include Gen +) VALVE SPRING Free Length Closed at 1.4209-1.273 (6.8692 (47.012 (0.850) .002 (0. (863-916 N) Lbs 1.503 (37.70 (43.478) .03 (51.934) 1.051) 002 (0 051) Journal Diameter Journal Out-of-Round Cam Shaft Runout Camshaft End Play Timing Chain Deflection FLYWHEEL Runout CYLINDER HEAD Gasket Surface Flatness BALANCE SHAFT Front Bearing Journal Rear Bearing Journal Rear Bearing Inside Diameter Assembled Rear Bearing Outside Diameter Rear Cylinder Block Housing Bore Production Production Production 1.004 (0.203) Maximum Intake Exhaust .008 (0.75) ( ) 2.ENGINES INDEX 90-823226--1 896 .051) Maximum .525-37.874 (46.900) 1.825-46.876 (46.004 -.5014-1.6) 76-84 Lbs (338-374 N) Lbs.010) 1.11-0.301) 1.452-47. 194-206 Lbs.091-36.892) .4215 (36.875-46.001 (0.815 (30.262 CID / 4.25 p (31.269 (6.575) 1.002-30.
032) .035 (1.040) Interference 90-823226--1 896 INDEX ENGINES .066) Maximum 0.06-0.0042 (0.012) Maximum .107) Maximum .548) .51-2.0017 (101.52) .0002-.51-0.0008-.001 (0.40) . (mm) CYLINDER BORE Diameter Out of Round Production Production Service Thrust Side Relief Side 4.017-0.051) Maximum .06 (0.04-.025) Maximum .025) Maximum .08 (1.618-101.050 (0.02-2.0178) .002 (0.08 (0.524-0.27) 0.0007-.9267-.545-23.65) Top 2nd Top 2nd .025) Maximum .0007-4.23-1.51-1.002-.002 (0.015-.0005 (0.001) PISTON RING: COMPRESSION (MEASURED IN CYLINDER BORE) Production Service Gap G Production Service PISTON RING: OIL Groove Clearance Gap Production Service Production Service Limit .001 (0.25-0.3L Gen + Engine Specifications Unit of Measurement in.9271 (23.262 CID / 4.38-1.88) Maximum Groove Clearance G Cl PISTON PIN Diameter Clearance Production Service Limit Fit in Rod .016 (0.0007 (0.02-.018-.046-.007 (0.001 (0.010-.001 (0.065 (0.643) .3A-9 .0016 (0.02-0.05) .0024 (.009-0.026 (.005-0.03) .20) 0.021-0.025) Maximum Taper T Service PISTON CLEARANCE Production Service .
215) 2.0020 (0.15-0.ENGINES INDEX 90-823226--1 896 . 2.025) Maximum . 3.1.0002 (0.051) .001 (0.635) .007) Maximum .0051) Maximum .0010-.203) .007) Maximum .03-0.005) Maximum .179-62.2497 (57.0035 (0.051) .017 (0.025-0.0030 (0.001 (0.43) .0008-.0010-.088) .008 (0.002-.191-62.4479-2.199-62.0003 (0.3L Engine Gen + Specifications Unit of Measurement in.1 No.0002 (0. 3.1 Diameter Di Main M i Journal No.117-57.0010 .20) 2.006-.05-0.0020 (0.025) Maximum .03 0.217) 2.0010-.142) . 2 3 2.4494 (62.4485-2.025 (0.051) 0010 0020 (0 03 0 051) .033-0.4495 (62.4 Taper Out of Round Production Service Crankshaft End Play Diameter Connecting R d C i Rod Journal Taper Out of Round Rod Bearing Clearance Rod Side Clearance Crankshaft Runout Production Service Production Service Production Service Production Service Production Service No.2487-2.4488-2.001 (0.025) Maximum g Main Bearing Clearance C 3A-10 . 4 No.025-0. (mm) CRANKSHAFT No.4489 (62.076) .025) Maximum .2.0020 (0.001 (0.025) Maximum . 3 No.001 (0.0013-.020-0. 4 No 1 2.0003 (0.262 CID / 4.
16 mm) 187-203 Lb.001 (0.0027 (0. (338-374 N) at 1.25 mm) 1.89-1.069) 0010.87) Net Lash No Adjustment 45° 46° .025-0.636-8.58-2.093 (1.43 mm) Installed Height 90-823226--1 896 INDEX ENGINES . (mm) VALVE SYSTEM Lifter Rocker Arm Ratio Valve Lift Intake Exhaust Hydraulic Roller 1.060 (0.7 in (43.035-.0027 (0 025-0 069) .414 (10.6) 76-84 Lb.062-.0010-.002 (0.05) Maximum .3A-11 .79) Valve Lash (Intake and Exhaust) Face Angle (Intake & Exhaust) Seat Angle (Intake & Exhaust) Seat Runout (Intake & Exhaust) Seat Width Production Stem S Clearance C Service Stem Diameter Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust Valve Margin Intake and Exhaust VALVE SPRING Free Length Valve Spring V l S i Pressure Valve Closed Valve Open 2.27 in (32.690-1.52) .428 (10. (832-903 N) at 1.50 to 1 .025) Maximum .3407 (8.93-43.3400-.262 CID / 4.52) .002 (0.51) Maximum .3407 (8 636-8 653) .710 in (42.03 (51.031 (0.38) .653) 3400.3L Gen + Engine Specifications Unit of Measurement in.
452-47.025-.010 (0.286-.290 (7.4994-1.296 (7.292-.0254-0.100) .5) from taut position [total .008 (0.3L Gen + Engine Specifications Unit of Measurement in.009 (0.ENGINES INDEX 90-823226--1 896 .203) Maximum Intake Exhaust .001-.42-7.52) 1.091) .478) . (mm) CAMSHAFT AND DRIVE Lobe Lift ± .0036 (.985-55.051) Maximum .2286) .262 CID / 4.002 (0.36) .025) Maximum .002(0.254) Overall Maximum .084-38.1648-2.001) 1.75 (19)] 3A-12 .8682-1.001-.8692 (47.500 (38.051) ( ) Journal Diameter Journal Out of Round Camshaft Runout Camshaft End Play Timing Chain Deflection FLYWHEEL Runout CYLINDER HEAD Gasket Surface Flatness BALANCE SHAFT Front Bearing Journal Rear Bearing Journal Rear Bearing Journal Clearance 2.1654 (54.001 (0.26-7.375(9.
8692 (47.3L Gen + Engine Specifications Unit of Measurement in.875-1.75 (19)] 90-823226--1 896 INDEX ENGINES .203) Maximum Intake Exhaust .375(9.001) 1. (mm) CAMSHAFT AND DRIVE Lobe Lift ± .873-1.084-38.002 (0.008 (0.254) Overall Maximum .985-55.100) 1.002(0.1648-2.010 (0..3A-13 .876 (46.575) 1.850) .874 (46.1654 (55.001 (0.500 (38.0254-0.26-7.875-46.262 CID / 4.4994-1.36) .5) from taut position [total .292-.286-.009 (0.452-47.051) Maximum .503 (37.52) 1.825-46.478) .001-.290 (7.900) 1.525-37.2286) .025) Maximum .051) ( ) Journal Diameter Journal Out of Round Camshaft Runout Camshaft End Play Timing Chain Deflection FLYWHEEL Runout CYLINDER HEAD Gasket Surface Flatness BALANCE SHAFT Front Bearing Journal Rear Bearing Journal Rear Bearing Inside Diameter Assembled Rear Bearing Outside Diameter Rear Cylinder Block Housing Bore Production Production Production 2.42-7.8682-1.296 (7.5014-1.
LK LH LJ Rotation 72001 a .3LX Gen + Alpha and Bravo Three 4. To clarify.3 Engine Identification The MerCruiser Model can be determined by looking at the last two letters of the engine code stamped into the cylinder block.General Some of the repairs in this section must be completed with engine removed from boat. This code number is stamped on all MerCruiser power packages and replacement partial engines. and on threads of all cylinder block external bolts. Apply Quicksilver Perfect Seal on threads of and under heads of cylinder head bolts.Location of GM Engine Code (Front Starboard Side. make certain that battery cables are disconnected at the battery prior to performing any on-board engine repair procedure. Place engine on repair stand for major repairs. Lubricate all moving parts (during reassembly) with engine oil. Near Cylinder Head Mating Surface) MCM (Stern Drive) 4. Cylinder Head Identification 4. screws and studs.All Stern Drive Engines LH LK 3A-14 .3LXH Gen + Alpha and Bravo 262 Magnum EFI Gen + Code LG. 72875 Engine Rotation Engine rotation terminology at times has caused confusion.ENGINES INDEX 90-823226--1 896 . Do not rely on propeller rotation in determining engine rotation.Left Hand Rotation (CCW) . the engine code letters may help in determining the engine models. Engine removal depends upon type of repair and boat design. When engine removal is not required. engine rotation is determined by observing flywheel rotation from the rear (transmission or stern drive end) of the engine looking forward (water pump end).3L Alpha 4. LJ. a a 72873 a . but not replacement cylinder block assemblies. If the engine serial number and/or model decals are missing.3LX Alpha 4. PROPELLER ROTATION IS NOT NECESSARILY THE SAME as engine rotation.
90-823226--1 896 INDEX ENGINES .Crankshaft The crankshaft is supported in the block by four insert type bearings. The function of the balance shaft is to equalize the dynamic forces inherent in particular engine designs. Piston and Connecting Rods Piston pins are offset slightly toward the thrust side of the pistons to provide a gradual change in thrust pressure against the cylinder wall as the piston travels its path. Valve tips have been hardened to extend valve life. Crankshaft end thrust is controlled by flanges on the No. All camshafts are driven at one-half crankshaft speed by a timing chain and sprockets. A helical gear on the aft end of the camshaft drives the distributor and oil pump. and are supported by four main bearings. thus minimizing engine vibration. Exhaust valve rotators are used to help extend valve life. Intake Manifold The manifold is of the single level design for efficient fuel distribution. The roller lifters are restrained from rotating by two retainers (restrictors) located in the valley. Pins have a floating fit in the piston and a press fit in the connecting rod (to hold them in place). 4 bearing. The valve lifters also are used to lubricate the valve train bearing surfaces. Connecting rods are made of forged steel and are connected to the crankshaft through insert type bearings. Valve Train The valves and valve springs are of a heavy-duty design to withstand the high engine speeds encountered. A torsional damper on the forward end of the crankshaft serves to help dampen any engine torsional vibration. the hydraulic lifters also serve to remove any clearance (lash) from the valve train to keep all parts in constant contact. All passages are of approximately equal length to assure more even fuel-air mixture to the cylinders. except on engines with roller lifters which have camshafts made of steel.3A-15 . Camshaft and Drive Camshafts are generally made of cast iron. Cylinder Head The cylinder heads are made of cast iron and have individual intake and exhaust ports for each cylinder. The balance shaft extends the entire length of the engine and is supported on each end by a bearing. Hydraulic valve roller lifters ride directly on the camshaft lobes and transmit the thrust of the lobes to the push rods which in turn actuate the valves through the rocker arm. In addition to transmitting thrust of the cam lobes. Balance Shaft The balance shaft is located in the engine block valley directly above and parallel to the camshaft. It is also driven by the camshaft through a helical gear set. Stainless steel or graphite composition head gaskets are used to retard corrosion. which are pressed into the block.
A hole in each rocker arm push rod seat allows the oil to pass through the rocker arm and lubricate the valve train bearing surfaces. a relief valve in the screen will open and continue to allow oil to be drawn into the system. The remainder of the oil is routed to the main oil gallery. connecting rods. oil drains back to the oil pan through oil return holes in the cylinder head and block. The oil that is forced out the front end of the No. after leaving the oil cooler and/or filter.Lubrication System The engine lubrication system is of the force-feed type in which oil is supplied under full pressure to the crankshaft. cylinder walls. 1 camshaft bearing drains down onto the camshaft drive and keeps it lubricated. Some of the oil is then routed to the connecting rod bearings through grooves in the upper half of the crankshaft main bearings and oil passages in the crankshaft. camshaft bearings and valve lifters. the oil also flows through the cooler before returning to the block. 3A-16 . A bypass valve allows oil to bypass the filter and oil cooler should they become restricted.ENGINES INDEX 90-823226--1 896 . From the main oil gallery. the oil is routed through individual oil passages to an annular groove in each camshaft bearing bore. From here. The distributor shaft and gear also is lubricated by the oil flowing through the right valve lifter oil gallery. Oil which is forced out the ends of the connecting rod bearings and crankshaft main bearings is splashed onto the camshaft. the oil is forced through the metering valve in each of the lifters (which controls the volume of oil flow) and then up through the push rods to the rocker arms. The remainder of the oil is routed to the valve lifter oil galleries and No. keeping them lubricated. Once the oil reaches the pump. If the screen should become clogged. is routed to the No. A spring-loaded relief valve in the pump limits the maximum pump output pressure. pistons and piston pins. After leaving the pump. After lubricating the valve train. the pump forces the oil through the lubrication system. A positive displacement gear-type oil pump is mounted on the rear main bearing cap and is driven by an extension shaft from the distributor (which is driven by the camshaft). All other moving parts are lubricated by gravity flow or splash. Oil which reaches the valve lifter oil galleries is forced into each hydraulic valve lifter through holes in the side of the lifter. the pressurized oil flows through a full-flow oil filter. 4 crankshaft main bearing. 1. and is supplied under controlled volume to the push rods and rocker arms. Oil which is forced out the front end of the No. 1 crankshaft main bearing also assists in lubricating the camshaft drive. Oil from the bottom of the pump in the rear of the oil pan is drawn into the oil pump through an oil pickup screen and pipe assembly. Some of the oil is then used to lubricate camshaft bearings. 2 and 3 crankshaft main bearings by means of individual oil passages which intersect with the annular grooves. The oil which reaches the crankshaft main bearings is forced through a hole in the upper half of each bearing and flows in-between the bearings and the crankshaft journals. The camshaft bearings have holes which align with the oil passages or annular grooves in the block and allow oil to flow in-between the bearings and the camshaft journals. which is located directly above the camshaft and runs the entire length of the block. Some of the oil. On engines with an engine oil cooler.
Overheated spark plug electrodes (improper heat range or defective plug). 3. The upward motion on the piston is opposed by the pressure rise. Any other protuberance in the combustion chamber. which result from the foregoing conditions. are beyond the control of Mercury Marine. 2. 72424 Pre-Ignition Damage 72314 90-823226--1 896 ENGINES . no warranty will apply to failures which occur under these conditions. an improperly seated valve or any other inadequately cooled section of material which can serve as a source. therefore. This can result in extensive damage to the internal parts from the high increase in combustion chamber temperature. causing power loss and rough running.Bearing Failures Scratches Dirt Imbedded Scratched into Bearing Material by Dirt Overlay Wiped Out Lack of Oil Bright (Polished) Sections Improper Seating Overlay Gone from Entire Surface Tapered Journal Radius Ride Radius Ride Craters or Pockets Fatigue Failure 70436 Piston Failures Pre-Ignition Pre-ignition is abnormal fuel ignition. Control of the start of ignition is lost. PRE-IGNITION CAUSES 1. caused by combustion chamber hot spots. such as an overhanging piece of gasket. Hot spots in the combustion chamber from glowing deposits (due in turn to the use of improper oils and/or fuels). as combustion pressure rises too early.3A-17 INDEX . Engine failures.
results in pre-ignition. 2. 3. causes overheating or damage to the spark plugs. in turn. Use of low octane gasoline is one of the most common causes of detonation. 5. valves and.” “spark knock” or “carbon knock. Even with high octane gasoline. Cross-firing spark plugs. commonly called “fuel knock. pistons. Inadequate cooling of engine by deterioration of cooling system. Excess accumulation of deposits on piston and/ or combustion chamber (results in higher compression ratio). Over-advanced ignition timing. 1. The explosion.Detonation Detonation. 4. in severe cases. Engine failures. OTHER CAUSES OF DETONATION IMPORTANT: Use of improper fuels will cause engine damage and poor performance. which result from the foregoing conditions.” is abnormal combustion of the fuel which causes the fuel to explode violently.ENGINES INDEX 90-823226--1 896 . therefore. 72425 Detonation Damage 72315 3A-18 . detonation could occur if engine maintenance is neglected. no warranty will apply to failures which occur under these conditions. Lean fuel mixture at or near full throttle (could be caused by carburetor or leaking intake manifold). are beyond the control of MerCruiser.
Start engine and check for oil leaks. 5. IMPORTANT: DO NOT pry rocker arm cover loose. 72316 Installation 1. Install exhaust manifolds. Front Mount a Rear Mount/Flywheel Housing a . (5.5 N·m).Gasket Used on MCM Engines Only 72318 a 72874 a . in.3A-19 . 7. Install any items which were removed to allow removal of rocker arm covers. Install rocker arm cover. 3. Clean sealing surfaces on cylinder head and rocker arm cover with degreaser. may be loosened by bumping end of rocker cover from the rear with palm of hand or a rubber mallet. Place new rocker arm cover gasket in position in rocker arm cover. 2. 6. 4. which may adhere to cylinder head and rocker arm cover.Engine Mounts Rocker Arm Cover Removal It may be necessary to remove exhaust manifold before removing rocker arm cover. Torque screws to 50 lb. if removed. 90-823226--1 896 INDEX ENGINES . Refer to Section 7B for removal. Disconnect crankcase ventilation hoses.Rocker Arm Cover Gasket 3. Connect crankcase ventilation hoses to rocker arm covers. 1. 2. Gaskets. Remove any items that interfere with the removal of rocker arm covers. Remove rocker arm cover.
Machined surfaces must be clean and free of all marks and deep scratches or leaks may result. Remove distributor cap and mark position of rotor on distributor housing.Gaskets 3A-20 . Disconnect any other miscellaneous items that will prevent removal of manifold. Remove oil sending unit. then remove intake manifold and carburetor assembly. in next step. 1. mark position of distributor housing on intake manifold. Without this opening the “automatic” carburetor choke will not operate properly.Intake Manifold Removal 1. • All MerCruiser V-6 GM engines that have “automatic” carburetor chokes must use an intake gasket that has an opening for the exhaust crossover port in the intake manifold. Clean gasket material from all mating surfaces. The choke will remain ON longer causing rough engine operation and wasted fuel. transfer all remaining parts to new manifold. IMPORTANT: It may be necessary to pry intake manifold away from cylinder heads and block. Installation IMPORTANT: When installing intake manifold gaskets. 4. Remove fuel line running between fuel pump and carburetor. 10. 8. Inspect manifold for cracks or scratches. Remove intake manifold bolts. • On engines with 2 barrel carburetor. Drain engine cooling system. Use extreme care to prevent damage to sealing surfaces. IMPORTANT: Do not crank engine over after distributor has been removed. Also. a b a 71850 a .Coolant Passages b . Cleaning and Inspection 1.ENGINES INDEX 90-823226--1 896 . 2. Place gaskets on cylinder heads. 9. Clean as necessary. 3. Remove other ignition components. 7. a 71850 a . Disconnect electrical leads interfering with removal. 2.Exhaust Crossover Port Opening in Gasket NOTE: If intake manifold requires replacement. Disconnect hoses from thermostat housing. IMPORTANT: When cleaning cylinder head mating surface. Apply Quicksilver Perfect Seal to intake manifold gaskets especially around coolant passages (both sides). 6. 5. Check intake passages for varnish buildup and other foreign material. Remove distributor. observe the following: • Be sure to install gasket with marked side up. remove metal insert from manifold gasket to be used on starboard (right) cylinder head to provide clearance for heat pipe on intake manifold. 3. do not allow gasket material to enter engine crankcase or cylinder head ports. Disconnect crankcase ventilation hoses from rocker arm covers. Both gaskets are identical. 2. in next step. Disconnect throttle cable from carburetor.
Adjust ignition timing and carburetor. Install distributor. 10. Install other ignition components and reconnect wires. Carefully install manifold assembly and torque bolts to 35 lb. Inspect fuel line connections for fuel leaks. Connect any other items which were disconnected from manifold during removal. Connect all electrical leads. a 4. 12. (5 mm) wide bead of Quicksilver RTV Sealer to engine block as shown. Install fuel line to carburetor and fuel pump. ft. 11. a 72878 Intake Manifold Torque Sequence (All Engines Except Gen +) a . Position rotor and housing to align with marks made during removal.RTV Sealer (Typical Both Ends) a 7 3 2 6 72878 Intake Manifold Torque Sequence (Gen + Engine Only) a .Front 5. Extend sealer 1/2 in. 71851 b . Start engine.3.3A-21 . 14. Apply a 3/16 in. Coat threads of oil pressure sending unit with Quicksilver Perfect Seal and install. 8. Connect crankcase ventilation hoses to rocker arm covers. gaskets and seals for leaks. (13 mm) up on intake gaskets. (48 N·m) in sequence as shown. 9. IMPORTANT: DO NOT get Quicksilver RTV Sealer into oil sending unit hole at rear of engine. then install distributor cap. 13. 7.Front a 71850 5 1 4 8 a . b 6. Check hose connections.Oil Sending Unit Hole 90-823226--1 896 INDEX ENGINES . Connect hoses to thermostat housing.
Hydraulic Roller Valve Lifters Hydraulic valve lifters require little attention. one on each side of the engine beneath the intake manifold. Inspect all contact surfaces for wear.Roller Lifter Flat Portion 3A-22 . coat bearing surfaces of rocker arms and rocker arm balls with engine oil. IMPORTANT: Place rocker arm assemblies and push rods in a rack for reassembly in their original locations. bring No. 1. rocker arm balls and rocker arm nuts in their original locations. 2. ft. Valve lash is automatically set when rocker arm nuts are torqued to specification.Retainer b . Remove rocker arm assemblies and push rods. bring that cylinder’s piston up to TDC before removing rocker arms. 1 piston up to TDC before removing rocker arms. Be sure push rods seat in lifter socket. Clean parts with solvent and dry with compressed air. 3. Torque rocker arm nuts to 20 lb. Install push rods in their original locations. When servicing all rocker arms. Lifters are extremely simple in design. 72031 Installation IMPORTANT: When installing rocker arms and rocker arm balls. 2. 1 2 3 4 5 6 7 8 9 - Push Rod Seat Retainer Push Rod Seat Metering Valve Plunger Check Ball Check Ball Spring Check Ball Retainer Plunger Spring Lifter Body Valve lifters are retained in position and prevented from rotating by two valve retainers. 1. 2. Normally. 1 2 3 4 5 6 7 8 9 Cleaning and Inspection 1. (27 N·m). No valve adjustment is required. Install rocker arms. a b 71853 a . Care should be exercised when installing the retainers to see that the flat portions of the lifters are properly positioned into the retainers.Rocker Arm/Push Rod Removal NOTE: When servicing only one cylinder’s rocker arms. Remove rocker arm covers as outlined. readjustments are not necessary and servicing requires only that care and cleanliness be exercised in the handling of parts.ENGINES 90-823226--1 896 INDEX . Replace all damaged parts.
Leaky check valve seat. cleaned in solvent. Another method is to place a finger on face of valve spring retainer. sound is localized. making it easy to determine which lifter is at fault. Remove fasteners from lifter retainers (restrictors) and remove retainers. causing abnormal stickiness. if reused). etc.Roller Lifter Retainer b . b. c. to allow reassembly in exact position on camshaft lobes (so that the roller’s bearing and roller will roll in the same direction on the same lobe.this will. Moderate rapping noise .probable causes are: a. b. a distinct shock will be felt when valve returns to its seat. c. Hard rapping noise . Rocker arm assemblies and push rods. If dirt. Place one end of hose near end of each intake and exhaust valve. A microscopic piece of dirt momentarily caught between ball seat and check valve ball. thus it would only be a matter of time before all lifters caused trouble. Improper adjustment. Intake manifold. Intermittent clicking .probable causes are: a. corrosion.Lifter Retainer (Restrictor) b . in most cases. Probable causes are: a.Roller Lifter(s) c . IMPORTANT: Keep valve push rod and hydraulic lifter from each valve together as a matched set and mark or store them so they can be reinstalled in the same location later. c a b b 71853 a . where noise exists in one or more lifters. reassembled and reinstalled in engine.Locating Noisy Lifters Locate a noisy valve lifter by using a piece of garden hose approximately 4 ft. 4. General noise throughout valve train . be a definite indication of insufficient oil supply or improper adjustment.3A-23 . In this manner. c. Remove as previously outlined: a. usually caused by an abrasive piece of dirt or metal wedged between plunger and lifter body. Improper adjustment. 2. b a 71852 a .Fasteners 3. Do not disturb lifters at this time. disassembled. Excessive varnish or carbon deposit. 3. Galling or “pickup” between plunger and bore of lifter body.2 m) in length. b. Make matching marks on all retainers and lifters as to location and orientation in bores. Removal 1. is shown to exist in one unit. In rare cases. it more likely exists in all the units. all lifter units should be removed.. with other end of hose to the ear. Excessively high leakdown rate.usually caused by plunger becoming tight in bore of lifter body so that return spring cannot push plunger back up to working position. General types of valve lifter noise are as follows: 1. carbon. If lifter is not functioning properly. (1.Matching Marks 90-823226--1 896 INDEX ENGINES . In most cases. b. ball itself may be out of round or have a flat spot. Rocker arm covers. Remove valve lifters. 2.
If any parts are damaged or worn. (16 N·m). Intake manifold. 2. in. Install the following as previously outlined: a. inspect cylinder block lifter bore. NOTE: Components shown removed in upper drawing for visual clarity c a Installation IMPORTANT: It is recommended that the engine oil be changed and a new oil filter be installed whenever servicing valve lifters or camshaft. If outer lifter body wall is scuffed or worn. 3A-24 . b. IMPORTANT: Before installation. ft. Align match marks made prior to disassembly. Thoroughly clean all parts in cleaning solvent and inspect them carefully. (5.ENGINES INDEX 90-823226--1 896 . If new lifters or a new camshaft have been installed. c. ft. coat entire valve lifter with engine oil. Install rocker arms and rocker arm nuts.Matching Marks b b 71853 b a 71852 a . (27 N·m). IMPORTANT: Before installing roller lifters.Roller Lifter(s) c .Cleaning and Inspection 1. If roller is worn or damaged. coat the roller with engine oil.Fasteners 7. 5. Torque roller lifter retainer (restrictor) plate fasteners to 12 lb. If push rod seat is scuffed or worn. Be sure push rods seat in lifter socket. 3.5 N·m). Install rocker arm cover. and install hydraulic valve lifters and components. IMPORTANT: DO NOT install used valve lifters if a new camshaft has been installed. entire lifter assembly should be replaced.Roller Lifter Retainer b . 4. an additive containing EP lube (such as General Motors Cam and Lifter Prelube or equivalent) should be poured over camshaft lobes before installing lifters. inspect push rod. 6. d. inspect camshaft lobe. Torque nuts to 20 lb. Torque fasteners to 50 lb. 8. Install push rods.Lifter Retainer (Restrictor) b . Start engine and check for leaks. a .
IMPORTANT: Keep air pressure in cylinder while springs. Remove: a. Slowly release valve spring compressor. 2. Remove seals from valve stems and valve guide. Rocker arm cover. compress valve spring and remove valve locks. 72882 1 2 3 4 5 6 7 8 9 10- Valve Locks Retainer Rotator Cap Valve Guide Oil Seal Valve Stem Oil Seal Damper Outer Spring Intake Valve Exhaust Valve ENGINES . caps. retainers.Valve Spring Compressor (J-5892) b .Valve Guide Seal 72330 Valve Assembly (Exploded View) 1 2 b 5 3 4 6 7 a 72881 1 8 9 10 a .Head Installed 1. a . Install air line adaptor tool (J-23590) in spark plug hole and apply compressed air to hold valves in place. Spark plug of affected cylinder. IMPORTANT: Do not turn crankshaft while valve springs. a NOTE: If compressed air is not available.Valve Stem Oil Seal/Valve Spring Removal . and valve locks are removed or valves will fall into cylinder. and valve spring. c. Remove cap. retainer or rotator. and locks are removed or valves will fall into cylinder. Using valve spring compressor as shown. 5.Rocker Arm Nut 4. piston may be brought up to TDC and used to keep valves from falling out of valve guides. 3.3A-25 90-823226--1 896 INDEX . b. Rocker arm assembly.
Cylinder Head Removal 1. 2. Inspect for corrosion around cooling passages. a 72881 Cleaning and Inspection 1.Valve Spring Compressor (J-5892) b . DO NOT drop cylinder heads. Place retainer on intake valve and/or rotator on exhaust valve. 3A-26 . Clean gasket material and sealer from engine block and cylinder heads. 2. (5. While compressing valve spring with valve spring compressor. Install valve guide seal (intake valve only) over valve stem and push down until seated against head. Rocker arm covers. in. making sure locks seat properly in upper grooves of valve stem. Install valve locks (Quicksilver Needle Bearing Assembly Lubricant may be used to hold them in place) and slowly release tool. 3. Exhaust manifolds. (20 N·m)]. Inspect sealing surfaces for deep nicks and scratches.ENGINES INDEX 90-823226--1 896 . 3. 7. Rocker arm assemblies and push rods (keep in order for reassembly in their original locations). 3.Installation . Clean head bolt threads and engine block bolt hole threads.Head Installed 1. d. f. Intake manifold. ft. old oil or coolant remain. 4. Any components attached to front or rear of cylinder head. a . 8. b ! CAUTION The head gasket may be holding cylinder head to block. Install rocker arm cover [torque to 50 lb. 5.Rocker Arm Nut 6. A light coating of oil will help prevent twisting. c. Drain engine cooling system. Install push rods and rocker arm assemblies. (27 N·m). e. Spark plugs. DO NOT damage gasket surfaces. Set valve spring (with damper installed) and cap in place. Use care when prying off cylinder heads. b. Torque rocker arm nuts to 20 lb. ft. making sure seal is not twisted. install oil seal in lower groove of valve stem. g. 2. Head bolts. Place cylinder head on wooden blocks to prevent damage to gasket surfaces. Remove as outlined: a. 4.5 N·m)] and spark plug [torque to 15 lb. making sure no dirt.
6. and provide adequate water supply to seawater pickup. Install as outlined: a. 1. Remove valves from cylinder head and place in a rack. Spark plugs. DO NOT use sealer on graphite composition head gaskets. Intake manifold. b. for reassembly in their original locations. a a 72883 Cylinder Head Torque Sequence a . following torque sequence for each step. 8. Exhaust manifolds. 2. ft. d. ft. c. ENGINES . ! CAUTION Ensure that cooling water supply is available before starting the engine. 7. Carefully set cylinder head in place over dowel pins. Slowly release tool. Second Pass (Angle Torque) Short Bolt 55 Degrees Medium Bolt 65 Degrees Long Bolts 75 Degrees e. compress valve spring and remove valve locks. Using valve spring compressor. (54 N·m). Start first step at 20 lb. ft. rocker arm assemblies and lifter restrictors in their original positions. (88 N·m). b. set idle speed. 3.3A-27 INDEX . Closed Cooled Models: Refill closed cooling section (see Section 6B). 9. Follow procedures in Section 6A or 6B of this manual: Seawater Cooled Models: Provide for adequate water supply to seawater pickup (see Section 6A).Valve Spring Compressor (J-8062) 2. Coat threads of head bolts with Quicksilver Perfect Seal and install finger-tight. Gen +: Torque first pass to 22 lb. All Engines (Except Gen +): Torque head bolts in three steps. Any components removed from front or rear of cylinder heads. Rocker arm covers.Front 5. ft. Start engine. ft. (33 N·m). set timing. Cylinder Head and Valve Conditioning Disassembly 1. Torque rocker arm nuts to 20 lb. in order. and finish with a final torque of 65 lb. Too much sealer may hold gasket away from head or block causing leakage. Remove all valve components. 90-823226--1 896 72884 a . (27 N·m). 4. (27 N·m). second step at 40 lb. 3. Place head gasket in position over dowel pins. apply a thin coating of Quicksilver Perfect Seal to both sides of gasket. Install push rods.Installation ! CAUTION When using ribbed stainless steel head gaskets. To insure gasket sealing: a. and check for leaks.
nicks. cracked faces or damaged stems. (2 mm).Take Measurements Diagonally Across Head (Both Ways) and Straight Down Center Head a . 4. Inspect cylinder head gasket surface for burrs. Inspect cylinder heads for cracks in exhaust ports. move valve stem back and forth in direction shown.Carbon Remover Brush (J-8089) 5. Clean push rods and rocker arm assemblies. 72335 a . When head resurfacing is required. Thoroughly clean valve guides with valve guide cleaner. cylinder head-to-intake manifold gasket surface on head must be milled to provide proper alignment between intake manifold and head. 2. Insufficient clearance will result in noisy and sticky valves. Measure valve stem clearance as follows: a.Valve Guide Cleaner (J-8101) b. or erosion or other damage. Replace heads if any cracks are found. 3A-28 . Clean all carbon from combustion chambers and valve ports using carbon remover brush. Attach a dial indicator to cylinder head.Feeler Gauge c .Straight Edge b . Holding valve head off seat about 1/16 in. IMPORTANT: Cylinder head-to-block gasket surface should be resurfaced if warped more than specified. and combustion chambers (especially around spark plug holes and valve seats). Compare stem clearance with specifications. Also. Refer to “Specifications. a IMPORTANT: Excessive valve stem to bore clearance will cause excessive oil consumption and possible valve breakage. Clean carbon from valves using a wire wheel. check flatness of cylinder head gasket surface. positioning it against the valve stem and close to the valve guide. 2. Clean gasket material from cylinder head mating surfaces. using a machinist’s straight edge and feeler gauges as shown. Inspect valves for burned heads.ENGINES INDEX 90-823226--1 896 .” a b 72885 72334 a . 4. water jackets. 3. a Inspection 1.Cleaning 1. 3.
” 2. Valve Guide Bore Repair IMPORTANT: Be sure to measure valve stem diameter of both the intake and exhaust valve. If clearance exceeds specifications.015 In.Valve Stem b .Dial Indicator c .” IMPORTANT: Springs should be replaced if not within 10 lbs.Valve Spring Tester (J-8056) b . oversize valves are required. (44 N) of specified tension.015 in. If . it will be necessary to ream valve guides for oversized valves. b a Standard Valve Stem Diameter . as shown. Oversize Valve J-5830-2 J-7049 72308 a . Refer to “Specifications. Remove the sharp corner created by reamer at top of valve guide. as valve stem diameter may or may not be the same for both valves.3A-29 . as shown.372 In Reamer Required for . Ream valve guide bores.341 In .Valve Guide Valve Springs .Checking Tension Using valve spring tester. ream valve guide bores for oversize valves. as follows: 1. Measure valve stem diameter of old valve being replaced and select proper size valve guide reamer from chart below. b c 72886 a 72336 3. as outlined under “Valve Guide Bore Repair. check valve spring tension with dampers removed.Torque Wrench 90-823226--1 896 INDEX ENGINES .c. a .
16 mm) b .1/32 [. Good contact between each valve and its seat in head is important to ensure that heat in valve head will be properly dispersed. however. EXHAUST INTAKE a 50668 a Typical “3-Angle” Valve Seat a b c d Top Angle (30°) Seat Angle (46°) Bottom Angle (60°) Seat Width b b Regardless of type of equipment.372 In (9.ENGINES INDEX 90-823226--1 896 . Several different types of equipment are available for refacing valves. or valves that are warped excessively.8 mm) after grinding. (0. The recommendation of the manufacturer of the equipment being used should be carefully followed to attain proper results.. or pre-ignition due to heat localizing on this knife edge. ensuring concentricity. When a valve head which is warped excessively is refaced.031] In (0.341 In (8. since seating of valves must be perfect for engine to deliver maximum power and performance.45 mm) b . Several different types of equipment are available for reseating valve seats.1/32 [. Valve stems which show excessive wear.Valve Seat Repair Valve seat reconditioning is very important.. Equipment manufacturer’s recommendations should be followed carefully to attain proper results. due to the amount of metal that must be removed to completely reface.79 mm) Min 72338 Measuring Valve Seat Concentricity 3A-30 . Another important factor is valve head cooling.031] In (0. a knife edge will be ground on part or all of the valve head. burning. Knife edges lead to breakage. a b c d Valve Grinding Valves that are pitted must be refaced to the proper angle. must be replaced. If the edge of the valve head is less than 1/32 in.79 mm) Min Intake a . 50695 Exhaust a . replace the valve. it is essential that valve guide bores be free from carbon or dirt to achieve proper centering of pilot in valve guide.
Place retainer on intake valve and/or rotator on exhaust valve. install oil seal in lower groove of valve stem. While compressing valve spring with valve spring compressor. 7. It is replaced with a quad ring as shown below. making sure locks seat properly in upper grooves of valve stem. If repairing heads with seals. 6.Valve Seal b 75307 9 10 4. Install valve locks (grease may be used to hold them in place) and slowly release tool.3A-31 . 2. Install each valve in the port from which it was removed or to which it was fitted. IMPORTANT: Some Gen+ engines that have the exhaust valve guide seals removed. replace them with the quad ring upon reassembly. making sure seal is not twisted. Lubricate valve guides and valve stems with engine oil. Install valve guide seal (intake valve only) over valve stem and push down until seated against head.Reassembly 1. A light coating of oil will help prevent twisting.Quad Ring b . 3. 1 2 1 3 5 4 6 7 8 a a . Set valve spring (with damper installed) and cap in place. 5.Valve Spring Compressor (J-8062) 90-823226--1 896 INDEX ENGINES . a 72882 1 2 3 4 5 6 7 8 9 10- Valve Locks Retainer Rotator Cap Valve Guide Oil Seal Valve Stem Oil Seal (See Important) Damper Outer Spring Intake Valve Exhaust Valve 72884 a .
ENGINES INDEX 90-823226--1 896 .8. as shown. Dipstick Specifications All Engines UNIT OF MEASUREMENT In. Measure from spring seat to top of valve spring. DO NOT shim valve springs to give an installed height less than the minimum specified. (mm) 05037 Cutaway Scale a 1/2 (13) 25-7/16 (646) 26-7/8 (682) FULL ADD 72339 3/4 (19) a . thin scale. If measurement exceeds specified height. Check installed height of valve springs using a narrow. install a valve spring shim and recheck.Valve Spring Installed Height 41092-1 MCM 72887 3A-32 .
4.Joints of Front Cover 3. Install dipstick tube and dipstick.Oil Pan Gasket 90-823226--1 896 INDEX ENGINES . (25 N·m). in.Joints of Rear Seal Retainer b . ft. in. 2. Fill crankcase with required quantity of oil of specified viscosity. torn or otherwise damaged. Install oil pan gasket in position as shown.” Installation 1. (19 N·m). Remove dipstick and tube.“Maintenance. tighten 1/4-20 threaded fasteners to 80 lb. See Section 1B . Clean sealing surfaces of engine block and oil pan. Gen + engines torque to nuts and bolts to 18 lb. a 1 2 3 4 5 6 7 8 9 101112- Extension Shaft Shaft Coupling Pump Body Drive Gear and Shaft Idler Gear Pickup Screen and Pipe Pump Cover Pressure Regulator Valve Pressure Regulator Spring Plug Retaining Pin Screws The oil pump consists of two gears and a pressure regulator valve enclosed in a two-piece housing. IMPORTANT: Quicksilver RTV Sealer sets up in about 15 minutes. Apply a small amount of Quicksilver RTV Sealer to joints of rear seal retainer and joints of front cover. Install oil pan. b a Oil Pump 3 5 9 7 8 12 11 4 1 10 2 Oil Pump Assembly 6 72145 72888 a . 72889 a . NOTE: A one-piece oil pan gasket may be reused if it is still pliable and is not cracked. (9 N·m) and 5/16-18 threaded fasteners to 165 lb. 3. Be sure to complete assembly promptly. Remove oil pan. 6. Starting from the center and working outward in each direction. 5.3A-33 .Oil Pan Removal 1. 2. Oil pump is driven by distributor shaft which is driven by a helical gear on camshaft. Drain crankcase oil.
spring. 3.ENGINES INDEX 90-823226--1 896 . 7. and pressure regulator valve from pump cover. 4. 4. (12 N·m). If pickup screen and pipe assembly was removed. 3. a 72889 IMPORTANT: Pump gears and body are not serviced separately. 4. IMPORTANT: Do not remove pickup screen and pipe assembly.Removal 1. etc. 3. 5. b Cleaning and Inspection 1. 2. Loss of press fit condition could result in an air leak and loss of oil pressure. Install pressure regulator valve and related parts. This is serviced as an assembly. Install pump cover and torque attaching bolts to 80 lb. Remove gasket carefully as the one-piece gasket for the oil pan may be reused if still pliable and not cracked. If pickup screen and pipe assembly requires replacement.Pickup Screen and Pipe Reassembly ! CAUTION Be careful of twisting. Inspect pump body and cover for cracks or excessive wear. 3A-34 . Wash all parts in cleaning solvent and dry with compressed air. Inspect pickup screen and pipe assembly for damage to screen and pipe. mount pump in a soft-jawed vise and extract pipe from pump. shearing or collapsing pipe while installing in pump. Gen + 106 lb. a . Check for loose drive gear shaft in pump body. Inspect pump gears for damage and excessive wear. Turn extension shaft by hand to check for smooth operation. (9 N·m). Remove oil pan as previously outlined. unless replacement is necessary. apply Quicksilver Perfect Seal to end of new pipe and. Remove oil pump Disassembly 1. in. 6. 3. mount pump in a soft-jawed vise. 5. Remove idler gear and drive gear from pump body. 1. IMPORTANT: Oil internal parts liberally before installation. 2. IMPORTANT: Mark gear teeth for reassembly with same teeth indexing.Oil Pump b . Remove pump cover. If pump gears or body are damaged or worn. Check pressure regulator valve for fit. Fill gear cavity with engine oil. Pickup screen must be parallel to oil pan bottom when oil pump is installed. tap the pipe in place with a hammer. torn. replacement of entire oil pump assembly is necessary. 6. Remove retaining pin. Inspect inside of pump cover for wear that would permit oil to leak past ends of gears. 2. Align marks made in disassembly. Install idler gear in pump body with smooth side of gear toward pump cover opening. in. IMPORTANT: Do not disturb pickup screen on pipe. Install drive gear in pump body. 2. using oil pump suction pipe installer (J-21882).
Remove torsional damper with torsional damper remover and installer. a 72346 a . 3. To prevent oil leakage. 2.Torsional Damper Remover and Installer (J-23523-E) 90-823226--1 896 INDEX ENGINES . to rear main bearing. then remove torsional damper retaining bolt. (95 N·m). a 72890 5. Gen + 74 lb. The one-piece gasket for the oil pan may be reused if still pliable and not cracked. IMPORTANT: Do not use a universal claw type puller to remove torsional damper (in next step) as outside ring of torsional damper is bonded in rubber to the hub and use of claw type puller may break the bond. (48 N·m). Remove drive belts. c. Install appropriate end of threaded rod into crankshaft. Torque to 70 lb. Remove tool from crankshaft. Install torsional damper bolt. using torsional damper remover and installer as follows: a. Install pump. f. a 72889 a . 2. 3.Torsional Damper Remover and Installer (J-23523-E) d. Remove drive pulley. a . with extension shaft. Tighten oil pump bolt to 65 lb. ft. The installation procedure (with proper tool) must be followed or movement of the inertia weight on the hub will destroy the tuning of the torsional damper. Install drive pulley(s). (100 N·m).Pickup Screen and Pipe IMPORTANT: Be sure to install threaded rod in crankshaft at least 1/2 in. washer and nut on rod. Coat seal surface of torsional damper with engine oil.3A-35 . b. torn. (88 N·m).Installation 1. ft. Install torsional damper on crankshaft. 4. Replace key in crankshaft if it is damaged. ft. (13 mm) to prevent damage to threads. Torque bolts to 35 lb. Install plate. b Installation IMPORTANT: The inertia weight section of torsional damper is assembled to the hub with a rubber type material. e. Install and adjust drive belts. etc. 1. apply Quicksilver RTV sealant to torsional damper keyway. aligning extension shaft with distributor drive shaft. ft. Install oil pan as outlined. Install torsional damper on crankshaft by turning nut until it bottoms out. 2. Torsional Damper Removal 1. thrust bearing. 3.Oil Pump b .
Seal Lip Toward Inside of Engine c .Can Be Used on Any Rotation Engine b .Seal Lip Toward Inside of Engine b c a 73124 Front Seals WITH Helical Grooves a . Remove torsional damper. Reinstall torsional damper as outlined.MCM (LH) Rotation Engines b . Install new seal with open end of seal inward. INSTALLATION IMPORTANT: Correct rotation oil seal must be used to prevent oil leak. 1.Rotation of Crankshaft as Viewed from Front End Looking Toward Flywheel End 3A-36 . Apply Quicksilver Perfect Seal to seal retainer mating surface and apply grease to seal lips. Do not use excessive force. Drive seal in until it just bottoms out.Crankcase Front Cover/Oil Seal Oil Seal Replacement (Without Removing Front Cover) REMOVAL 1. using crankcase front cover seal installer. 2.Crankcase Front Cover Seal Installer (J-35468) 3. being careful not to distort front cover or damage crankshaft. Pry seal out of cover from the front with a large screwdriver. a 72347 a . b a 73123 Front Seal WITHOUT Helical Grooves a . 2.ENGINES 90-823226--1 896 INDEX .
5. Start engine and check for water and oil leaks. Install oil seal in cover with lip of seal toward inside of engine. using crankcase front cover seal installer. Closed Cooled Models: Refill closed cooling section (see Section 6B). and provide adequate water supply to seawater pickup. making sure holes in cover align with dowel pins in block. Installation 1. Install front cover.3A-37 . in. Support cover around seal area with appropriate tool as shown. 4. Install water circulating pump. drive oil seal out of front cover (from the rear) using a punch. Torque front cover attaching screws to 100 lb. If damaged. a b 72348 a . 3. Install oil pan and torsional damper as outlined. Coat both sides of front cover gasket with Quicksilver Perfect Seal and place in position on engine. Fill crankcase with engine oil. 3. Cleaning and Inspection Clean front cover in solvent and dry with compressed air. 2.Crankcase Front Cover Removal 1. 5. 4. Check gasket surface on front cover for distortion. Remove water circulating pump. ! CAUTION Ensure that cooling water supply is available before starting the engine. 2. and true if necessary. 7. 6. Surfaces must be clean and flat or oil leakage may result. Remove engine from boat if necessary to gain access to cover. Remove torsional damper and oil pan.Support (to Prevent Distorting Cover) 90-823226--1 896 INDEX ENGINES . Reinstall engine in boat. Remove crankcase front cover.Crankcase Front Cover Seal Installer (J-35468). 9. Follow procedures in Section 6A or 6B of this manual: Seawater Cooled Models: Provide for adequate water supply to seawater pickup (see Section 6A). (11 N·m). Clean old gasket material and sealer from mating surfaces on cover and cylinder block. b . 8.
008 In. (0. 3. (41 N·m). 3A-38 . Installation 1. Remove engine from boat. Maximum runout . 5. Clean mating surfaces of flywheel and crankshaft. Push in on flywheel to remove crankshaft end play. Refer to Section 2 “Removal and Installation” and install engine.. ft.“Removal and Installation”. a .203 mm) Max Runout b . Refer to SECTION 2 . (0. Inspect splines in coupler for wear. c. 3. Remove coupler. Torque bolts to 80 lb. Remove flywheel. install flywheel. Check flywheel ring gear for worn and missing teeth. (48 N·m). 4. b a 72353 a . 2. 2.. 2. Remove any burrs.ENGINES INDEX 90-823226--1 896 . Take readings around outer edge of flywheel. Attach a dial indicator to engine block.008 in. Torque bolts to 30 lb. b. 72349 a Alpha One Coupler Inspection 1. 7. ft. Check flywheel runout as follows: a.Rubber Bumper 72354 4. Torque bolts to 75 lb. 6. Refer to “Flywheel Housing” description in this section and remove flywheel housing and related parts. (100 N·m). Mating surfaces must be clean bare metal.Push Flywheel and Crankshaft Froward as Far as it will Go when Taking Reading IMPORTANT: Insert three rubber bumpers in Alpha coupler before installation on flywheel. (9 N·m). Torque bolts to 35 lb. Aligning dowel hole in flywheel with dowel in crankshaft.Flywheel Removal 1.203 mm). Install flywheel housing and related parts. ft. in. Install flywheel housing cover. Install drive coupler.
MCM (LH) Rotation Engines b .Rear Main Oil Seal The rear crankshaft oil seal can be replaced without removing the oil pan or rear main bearing cap from engine. Cleaning and Inspection Clean crankshaft/seal running surface and seal retainer. Removal Remove seal by using a screwdriver to pry it out of retainer as shown.Rotation Of Crankshaft As Viewed From Flywheel End Looking Forward 90-823226--1 896 INDEX ENGINES .Seal Lip Toward Inside Of Engine a b 72355 b a . IMPORTANT: Correct rotation oil seal must be used to prevent oil leak.Can Be Used On Any Rotation Engine b .Rear Seal b .3A-39 . b a 73126 Rear Seal WITHOUT Helical Grooves c a .Seal Retainer c .Seal Lip Toward Inside Of Engine c .Slots (Three) c a 73127 Rear Seal WITH Helical Grooves a .
009 in. and .001 in. a NOTE: A one-piece oil pan gasket may be re-used if it is still pliable and is not cracked. Install oil pan fasteners. Remove oil pan. b a 72464 a .Fasteners b .Rear Main Seal Installer (J-26817-A) Rear Main Oil Seal Retainer Removal 1. 2. Inspect oil seal retainer for cracks or scored surface. Coat seal lips with clean 30W motor oil. in. Apply grease to seal lips. Coat threads of oil seal retainer fasteners with Loctite Pipe Sealant with Teflon. 3. .020 in. undersize bearings are not available for service. mark them for reassembly in their original locations. Inspect alignment pin for damage. Selective fitting of both rod and main bearing inserts is necessary in production in order to obtain close tolerances.001 in. 2. Service bearings are available in standard size and . 4. (25 N·m) a . (9 N·m) and 5/16-18 threaded fasteners to 165 lb. Clean gasket material from mating surfaces. Main Bearings IMPORTANT: Before removing main bearing caps or connecting rod caps. replace if necessary. from using a full standard bearing. If clearances are found to be excessive. in. undersize bearing as . a 72356 4. For this reason you may find one half of a standard insert with one half of a . Cleaning and Inspection 1. torn or otherwise damaged. undersize insert which will decrease the clearance .. Apply Quicksilver Perfect Seal to seal retainer mating surface.010 or .020 in. 2. in.ENGINES INDEX . 3. 2. journal must be reconditioned to accept a . 3.Torque Gen+ engine oil pan nuts and bolts 18 lb. Main bearings are of the precision insert type and do not use shims for adjustment. Installation 1. Torque 1/4-20 threaded fasteners to 80 lb. Install gasket and oil seal retainer with rear main seal. (19 N·m). dry or torn rubber. undersize. (15 N·m).010 in. will be required. Remove oil seal retainer. Install fasteners and torque to 133 lb. Inspect oil seal for worn. Install seal using rear main seal installer. both upper and lower halves. ft.0005 in. Remove oil seal retainer fasteners. 90-823226--1 896 3A-40 .Oil Seal Retainer IMPORTANT: If crankshaft has an undersize journal and a new bearing is required. Replace if necessary (refer to “Rear Main Oil Seal” as outlined).Installation 1. 5. a new bearing.
Journal 72357 NOTE: Normally main bearing journals wear evenly and are not out of round. In addition.Gauging Plastic b . upon inspection. preparatory to checking fit of bearings. difference. Install the bearing cap and evenly torque the retaining bolts to specifications. If the flattened gauging plastic tapers toward the middle or ends. The flattened gauging plastic will be found adhering to either the bearing cap or journal. 3. be sure to fit to the maximum diameter of the journal: If the bearing is fitted to the minimum diameter.001 in. there is a difference in clearance indicating taper.001 in. or its equivalent. 4. a b a a .). the surface of the crankshaft journal and bearing should be wiped clean of oil.Inspection In general. remove bearing cap and wipe oil from journal and bearing cap to be inspected. the lower half is suitable for use. it can be assumed that the upper half is also satisfactory. Place a piece of gauging plastic the full width of the bearing (parallel to the crankshaft) on the journal as shown. both upper and lower halves should be replaced. 90-823226--1 896 INDEX ENGINES . max. Variations in torque affect the compression of the plastic gauge. the lower half of the bearing (except No. engine must be out of the boat and upside down so crankshaft will rest on the upper bearings and total clearance can be measured between lower bearing and journal. Never replace one half without replacing the other half.Compressed Gauging Plastic b .001 in. all bearing cap bolts should be at their specified torque. IMPORTANT: Do not rotate the crankshaft while the gauging plastic is between the bearing and journal. 5.. On the edge of the gauging plastic envelope there is a graduated scale which is correlated in thousandths of an inch. 1 bearing) shows a greater wear and the most distress from fatigue. However. To assure the proper seating of the crankshaft.Graduated Scale 72358 b a . low spot or other irregularity of the bearing or journal. measure its compressed width (at the widest point) with the graduations on the gauging plastic envelope as shown. Bearing cap MUST be torqued to specification in order to assure proper reading. Without removing the gauging plastic. 2. Checking Clearances To obtain accurate measurements while using Plastigage. and the journal is out of round .3A-41 . If the lower half shows evidence of wear or damage. if a bearing is being fitted to an out-of-round journal (. Be sure to measure the journal with a micrometer if the flattened gauging plastic indicates more than . 1. If. Remove bearing cap. interference between the bearing and journal will result in rapid bearing failure. With the oil pan and oil pump removed.
Main Bearing Inserts b . correct size. When checking No.Cotter Pin 72622 3A-42 . 4. Always replace both upper and lower inserts as a unit. Install the crankshaft.6.Force Crankshaft to Extreme Forward Position a a .152)]. Measure at the front end of the rear main bearing with a feeler gauge as shown [Specifications . a cotter pin may be bent. Install main bearing remover/installer in oil hole in crankshaft journal. loosen accessory drive belts so as to prevent tapered reading with plastic gauge. 2. a. A standard. Coat bearing surfaces of new. main bearings with oil and install in the cylinder block and main bearing caps. 2. to do the job. or . new bearing. replace the insert. the bearing insert is satisfactory. If not.001 in. Measure crankshaft end play by forcing the crankshaft to the extreme front position. Remove and inspect the crankshaft as outlined. a WITHOUT CRANKSHAFT REMOVED 1. rotate the crankshaft to see that there is no excessive drag. oil pump and spark plugs removed. a b c 72359 8.Oil Groove WITH CRANKSHAFT REMOVED 1.002-. Proceed to the next bearing.. Remove the main bearings from the cylinder block and main bearing caps.ENGINES INDEX 90-823226--1 896 . recheck Replacement NOTE: Main bearings may be replaced with or without removing crankshaft. After selecting clearance. 9. undersize bearing may produce the proper clearance.051-0. it will be necessary to regrind the crankshaft journal for use with the next undersize bearing. 1 main bearing. With oil pan. as shown. If the clearance is not within specifications. After all bearings have been checked. 3. 7. b 72360 a .Upper Bearing Insert (Install in Block) d .Lower Bearing Insert (Install in Cap) c .Main Bearing Remover/Installer (J-8080) b .006 (0. If such a tool is not available. remove cap on main bearing requiring replacement and remove bearing from cap. If the bearing clearance is within specifications.
and . the length of the bearing (parallel to the crankshaft). 3. DO NOT FILE RODS OR ROD CAPS. Measure the crankpin for out-of-round or taper with a micrometer. then tap end of crankshaft. 5.010 in. ft. Oil new lower bearing and install in bearing cap. Install the bearing in the connecting rod and cap. undersize for use with reconditioned crankshafts.020 in. Oil new selected size upper bearing and insert plain (un-notched) end between crankshaft and indented or notched side of block. If the bearing is fitted to the minimum diameter. a Inspection and Replacement IMPORTANT: Before you remove the connecting rod cap.002 in. 7. Service bearings are available in standard size and .3A-43 . EXCEPT THE REAR MAIN CAP.010 in. measure new or used bearing clearances with gauging plastic or its equivalent. Rotate the bearing into place and remove tool from oil hole in crankshaft journal. Wipe both upper and lower bearing shells and crankpin clean of oil. If not within specifications. a.. interference between the bearing and crankpin will result in rapid bearing failure. Torque rear main bearing cap to 75 lb. Install main bearing cap with arrows pointing toward front of engine. This will line up rear main bearing and crankshaft thrust surfaces. replace or recondition the crankshaft. If clearances are found to be excessive. Torque rear main bearing cap to 10-12 lb. (102 N·m). ft. 5. Position the gauging plastic in the middle of the bearing shell. a . These are used in manufacturing for selective fitting. Install the bearing cap and evenly torque nuts to 45 lb. and the crankpin is out of round . remove the connecting rod cap and bearing. Do not reinstall a worn or damaged bearing.Gauging Plastic 72361 b. ft. 4. first rearward then forward with a lead hammer.3. be sure to fit to the maximum diameter of the crankpin. undersize for use with new and used standard size crankshafts. IMPORTANT: Do not turn the crankshaft with the gauging plastic installed. On removing a connecting rod cap. 4. and . Rotate the crankshaft clockwise as viewed from the front of engine. Place a piece of gauging plastic. Inspect the bearing for evidence of wear and damage. c. and in . Torque all main bearing caps. 2. a new bearing will be required. undersize bearing. If a bearing is being fitted to an out-of-round crankpin. 1.) Connecting Rod Bearings Connecting rod bearings are of the precision insert type and do not use shims for adjustment. If within specifications and a new bearing is to be installed. This will roll upper bearing out of block. (Bearings are eccentric and false readings could occur if placed elsewhere. (14-16 N·m). With oil pan and oil pump removed. on the crankpin or bearing surface as shown. (102 N·m). 90-823226--1 896 INDEX ENGINES .001 in. mark the side of the rod and cap with the cylinder number to assure matched reassembly of rod and cap. to 75 lb. 6. ft.001 in. (61 N·m). measure the maximum diameter of the crankpin to determine new bearing size required. If within specifications. it is possible to find a .
Measure all connecting rod side clearances between connecting rod caps as shown [Specifications . If the clearance exceeds specifications. b. IMPORTANT: Before ridge and/or deposits are removed. Oil pump. Cylinder heads. 72362 6. and 6 from front to rear on same side as piston thrust).d. 3. tap each rod lightly (parallel to the crankpin) to make sure they have clearance. Remove connecting rod cap and install connecting rod bolt guide (3/8-24) on bolts. a 72891 72892 a .006-. 3. and 5. (61 N·m). 4. 8. d. right bank 2. Remove the bearing cap and using the scale on the gauging plastic envelope. Use a ridge reamer to remove any ridge and/or deposits from upper end of cylinder bore.014 (0. Oil pan and dipstick tube. install the rod cap and torque nuts to 45 lb. 9. Push connecting rod and piston assembly out of top of cylinder block. then remove cloth and cuttings. measure the gauging plastic width at the widest point as shown. After ridge and/or deposits are removed. replace crankshaft.152-0. 2. ft. Mark connecting rods and bearing caps (left bank 1. the crankpin will have to be ground undersize. c.356)”].ENGINES INDEX 90-823226--1 896 . Coat the bearing surface with oil.. turn crankshaft until piston is at bottom of stroke and place a cloth on top of piston to collect cuttings. select a new. Connecting Rod/Piston Assembly Removal 1. 4. 7. If clearance cannot be brought to within specifications. Remove as outlined: a. Distributor and intake manifold. If the crankpin is already at maximum undersize. NOTE: Be sure to check what size bearing is being removed in order to determine proper replacement size bearing. NOTE: It will be necessary to turn crankshaft slightly to disconnect and remove some connecting rod and piston assemblies. turn crankshaft until piston is at top of stroke. When all connecting rod bearings have been installed. correct size bearing and measure the clearance.Connecting Rod Bolt Guide (3/8-24) [J-5239] 3A-44 .
recheck with another ring. remove by dressing with a fine cut file. 1. Clean varnish from piston skirts with a cleaning solvent. Measure piston skirt and check clearance as outlined under “Piston Selection. Therefore. scuffed or damaged skirts. DO NOT WIRE BRUSH ANY PART OF PISTON. Check for twisted and bent rods and inspect for nicks and cracks. and eroded areas at top of piston.3A-45 .” NOTE: Cylinder bore and taper must be within specifications before pistons can be considered for re-use. Replace pistons which are damaged or show signs of excessive wear. Inspect grooves for nicks and burrs that might cause rings to hang up. determine cause. b a 5. 2. 2. 4. If binding is caused by a distorted ring. c d e a b c d e Piston Pin Remover (J-24086-B) Arched Base Piston Connecting Rod Rod Support 72893 Cleaning and Inspection CONNECTING RODS 1. when fitting new rings. If binding occurs at any point. wavy worn ring lands. Proper clearance of piston ring in its piston ring groove is very important to provide proper ring action and reduce wear. Replace damaged connecting rods. Wash connecting rods in cleaning solvent and dry with compressed air.Disassembly Disassemble piston from connecting rod using piston pin remover as shown. Inspect piston for cracked ring lands. Clean ring grooves with a groove cleaner and make sure oil ring holes are clean. Slip outer surface of a new top and second compression ring into respective piston ring groove and roll ring entirely around the groove to make sure that ring is free as shown. Follow instructions supplied with kit. clearances between ring and groove surfaces should be measured. skirts and pin bosses. 3.” 90-823226--1 896 72895 INDEX ENGINES . PISTONS 72894 6. See “Specifications. If caused by ring groove.
Assemble piston to connecting rod using piston pin remover as shown. Because of this. a . Inspect piston pin bores and piston pins for wear. the following must be kept in mind.Rod Bearing Tangs 3A-46 . Measure piston pin with a micrometer and piston pin bore with a dial bore gauge or inside micrometer. Piston should move freely in all directions.Piston Pin Remover (J-24086-B) 72368 2. • Connecting rod bearing tangs are always toward outside of cylinder block. 2. If it does not. replace piston and piston pin assembly. check piston for freedom of movement (back-and-forth and up-and-down) on connecting rod. (0. piston pin bore is tight and piston/pin assembly must be replaced. • Notch in piston must be positioned facing toward the front of the engine. a a . If clearance is in excess of the . Once assembled. 72897 a a . Piston pin clearance is designed to maintain adequate clearance under all engine operating conditions. Do not intermix pistons and pins. piston and piston pin are a matched set and not serviced separately.ENGINES INDEX 90-823226--1 896 . • Piston and pin are machine fitted to each other and must remain together as a matched set.Notch 72896 1. be sure to assemble pistons and connecting rods so they can be reinstalled in same cylinder from which they were removed. Piston pin bores and piston pins must be free of varnish and scuffing when measured. • If original pistons and/or connecting rods are being used. a Reassembly PISTONS AND PISTON PINS IMPORTANT: When reassembling pistons and connecting rods.001 in.025 mm) wear limit. Follow instructions supplied with kit.PISTON PINS 1.
then wipe with a clean dry cloth. Then clean with hot water and detergent wash. then press ring down into cylinder bore about 1/4 in. If gap between ends of ring is below specifications. If binding is caused by a distorted ring. as necessary. 7. (6 mm) (below ring travel). Measure gap between ends of ring with a feeler gauge as shown. d. Install oil ring spacer in groove and insert antirotation tang in oil hole. using ring expander. After cleaning. rings and cylinder walls with light engine oil. mark connecting rod and cap (on side of rod and cap with slots for connecting rod bearing tangs) with cylinder number in which it will be installed. remove ring and try another for fit. b. Select rings comparable in size to cylinder bore and piston size. IMPORTANT: Be sure ring gaps are properly positioned as shown.3. ENGINE LEFT ENGINE FRONT ENGINE RIGHT 72372 4. Installation IMPORTANT: Cylinder bores must be clean before piston installation. Install top compression ring with marked side up. Clean and inspect pistons. If binding occurs at any point. the cause should be determined and. Hold spacer ends butted and install lower steel oil ring rail with gap properly located. 3. Fit each compression ring to cylinder in which it is going to be used. Lightly coat pistons.3A-47 . if not previously done. 1. Oil control rings are a three-piece type. f. 3. Flex the oil ring assembly to make sure ring is free. e. Install piston rings as follows: a. 1. When installing compression rings. With bearing caps removed. Be sure that ring is square with cylinder wall. swab bores several times with light engine oil and clean cloth. c. 5. PISTON RINGS All compression rings are marked on upper side of ring. using ring expander. 90-823226--1 896 1-3-5 Cylinders 2-4-6 Cylinders 72373 Ring Gap Location a b c d Oil Ring Spacer Gap (Tang in Hole or Slot within Arc) Oil Ring Rail Gaps 2nd Compression Ring Gap Top Compression Ring Gap INDEX ENGINES . Lubricate connecting rod bearings and install in rods and rod caps. if caused by ring groove. install connecting rod bolt guide (3/8-24) (J-5239) on connecting rod bolts. use a new ring. 2. Slip compression ring in cylinder bore. Install upper steel oil ring rail with gap properly located. Clean with a light honing. If a new connecting rod has been installed. make sure that marked side is toward top of piston. 6. consisting of two rings and a spacer. removed by dressing groove with a fine cut file. Install lower compression ring with marked side up. 2. IMPORTANT: Use piston ring expander (91-24697) for compression ring installation.
4. Install each connecting rod and piston assembly in its respective bore. Install with connecting rod bearing tangs toward outside of cylinder block. Use piston ring compressor to compress rings. Guide connecting rod into place on crankshaft journal with connecting rod bolt guide. Use a hammer handle with light blows to install piston into bore. Hold ring compressor firmly against cylinder block until all piston rings have entered cylinder bore. IMPORTANT: Be sure to install new pistons in same cylinders for which they were fitted, and used pistons in same cylinder from which they were removed. Each connecting rod and bearing cap should be marked, beginning at front of engine (1, 3 and 5 in left bank and 2, 4 and 6 in right bank). Numbers on connecting rod and bearing cap must be on same side when installed in cylinder bore. If a connecting rod is ever transposed from one block or cylinder to another, new bearings should be fitted and connecting rod should be numbered to correspond with new cylinder number.
8. Install as previously outlined: a. Oil pump. b. Dipstick and oil pan. c. Cylinder heads. d. Intake manifold. e. Distributor. 9. Fill crankcase with oil. Refer to Section 1 - “Maintenance.” 10. Torque rocker arm nuts to 20 lb. ft. (27 N·m).
1. Remove engine from boat. 2. Drain crankcase oil. 3. Remove as outlined: a. Starter. b. Flywheel housing. c. Drive coupler and flywheel. d. Belts. e. Water pump. f. Crankshaft pulley and torsional damper.
g. Spark plugs. h. Oil pan and dipstick tube. i. j. Oil pump. Timing chain cover.
4. Turn crankshaft to align timing mark with camshaft mark.
5. Remove camshaft sprocket. 6. Remove rear main seal and retainer. 7. Make sure all bearing caps (main and connecting rods) are marked so they can be reinstalled in their original locations. 8. Remove connecting rod bearing caps, then push piston and rod assemblies toward heads. 9. Remove main bearing caps and carefully lift crankshaft out of cylinder block. 10. If new main and/or connecting rod bearings are to be installed, remove main bearing inserts from cylinder block and bearing caps, and/or connecting rod bearing inserts from connecting rod and caps. Install new bearings following procedures outlined.
a - Piston Ring Compressor (J-8037)
5. Remove connecting rod bolt guide. 6. Install bearing caps and torque nuts to 20 lb. ft. (27 N·m), then tighten nuts an additional 60 degrees angular torque using a Torque Angle Gauge. 7. Check connecting rod side clearance as previously described.
NOTE: If bearing replacement is required, refer to “Connecting Rod Bearings.”
3A-48 - ENGINES
Cleaning and Inspection
1. Wash crankshaft in solvent and dry with compressed air. 2. Measure main bearing journals and crankpin dimensions with a micrometer for out-of-round, taper or undersize (see “Specifications”). 3. Check crankshaft for runout (by supporting at front and rear main bearings journals in V-blocks) and check at front and rear intermediate journals with a dial indicator (see “Specifications”). 4. Replace or recondition crankshaft if not within specifications.
4. Check clearance of each main bearing, following procedure outlined under “Main Bearings.” If bearing clearances are satisfactory, apply engine oil to journals and bearings. 5. Install main bearing caps. Torque bolts to 75 lb. ft. (102 N·m). When tightening rear main bearing cap, follow procedure outlined under “Main Bearings.” 6. Check crankshaft end play as previously outlined. 7. Install rear main seal retainer and seal. Torque fasteners to 133 lb. in. (15 Nm). 8. Check clearance for each connecting rod bearing, following procedure under “Connecting Rod Bearings.” If bearing clearances are satisfactory, apply engine oil to journals and bearings. 9. Install rod caps and torque nuts to 45 lb. ft. (61 N·m). 10. Turn crankshaft so mark on timing sprocket is facing camshaft. 11. Install as outlined: a. Timing chain and sprocket on camshaft align marks with crankshaft. b. Timing chain cover. c. Oil pump. d. Dipstick tube and oil pan. e. Spark plugs.
1. If a new crankshaft is being installed, remove timing sprocket from old crankshaft and reinstall on new crankshaft as outlined. IMPORTANT: Be sure that all bearings and crankshaft journals are clean. 2. Install main bearings in engine block as follows. a b
Torsional damper and crankshaft pulley.
g. Water pump. h. Belts. i. j. Flywheel and drive coupler. Flywheel housing.
Main Bearing Inserts
a - Lower Bearing Insert (Install in Cap) b - Upper Bearing Insert (Install in Block) c - Oil Groove
3. Carefully lower crankshaft into place. Be careful not to damage bearing surface.
k. Starter. 12. Install new oil filter. Fill crankcase with oil.
ENGINES - 3A-49
Timing Chain and Sprocket
1. Remove torsional damper, oil pan and crankcase front cover as previously outlined. 2. Turn crankshaft until timing marks on crankshaft and camshaft sprockets are in alignment as shown.
Cleaning and Inspection
1. Clean all parts in solvent and dry with compressed air. 2. Inspect timing chain for wear and damage. 3. Inspect sprockets for wear and damage.
Installation - Timing Chain
1. If crankshaft sprocket was removed, install as outlined in “Crankshaft Sprocket.”
2. Install timing chain on camshaft sprocket. Hold sprocket vertical with chain hanging down. Align marks on camshaft and crankshaft sprockets. IMPORTANT: Do not attempt to drive sprocket on camshaft, as welsh plug at rear of engine can be dislodged.
3. Install sprocket on camshaft. Torque bolts to 18 lb. ft. (24 N·m). 4. Lubricate timing chain with engine oil. Install crankcase front cover and torsional damper as outlined.
a - Timing Marks Aligned b - Locating Pin
When timing marks are aligned in this procedure, the No. 4 cylinder is on compression (TDC); therefore, if the distributor is to be installed, the rotor MUST BE positioned at the No. 4 post on the distributor cap.
3. Remove camshaft sprocket and timing chain. (If sprocket does not come off easily, a light tap on the lower edge of the sprocket, using a plastic mallet, should dislodge it.) 4. If crankshaft sprocket requires replacement, remove as outlined.
3A-50 - ENGINES
and using crankshaft gear and sprocket puller (P/N J-5825-A). Installation 1. If the deflection exceeds 3/4 in. 4. Remove camshaft timing chain as outlined. Install timing chain as outlined. Establish a reference point on the block (on taut side of chain) and measure from this point to the chain. timing chain should be replaced. Rotate camshaft in the opposite direction to slacken the chain. 3. a a 72377 a .Crankshaft Gear and Sprocket Installer (J-5590) 2. Remove torsional damper and crankcase front cover as previously outlined. 3. remove crankshaft sprocket. Install crankcase cover and torsional damper as outlined. (19 mm). a . as follows: 1.3A-51 . Rotate camshaft (in either direction) to place tension on one side of the chain. Checking Timing Chain Deflection With timing chain and sprockets installed. Using crankshaft gear and sprocket installer. as shown.Reference Point 72899 90-823226--1 896 INDEX ENGINES . check timing chain deflection. 2. 2. The deflection is the difference between these two measurements. then force chain out with fingers and again measure the distance between reference point and timing chain. install sprocket on crankshaft.Crankshaft Sprocket Removal 1.
Unscrew stud and remove balance shaft drive gear on camshaft as shown. Balance shaft rear bearing can be replaced using balance shaft remover and installer tool in conjunction with bearing puller.Balance Shaft/Gears Removal 1.Drive Gear NOTE: When replacing balance shaft rear bearing. IMPORTANT: Care should be taken in next step as damage to cylinder block and/or balance shaft could result. 3.Bearing Housing 72900 c 72902 a . Insert hard wood wedge between gear teeth and remove TORX bolt retaining balance shaft driven gear.Wedge b . 6. Remove two TORX bolts retaining balance shaft thrust plate.Driven Gear c . 7.Stud b . b a 72901 a . Remove manifold as previously outlined. Remove gear. 5. 4. place a cloth in valley to prevent any debris from entering the crankcase.Pry Bar b . a b a b c a . 2. remove balance shaft from bearing housing and cylinder block.Balance Shaft c . Insert pry bar in aft section between balance shaft and cylinder block.ENGINES INDEX 90-823226--1 896 . Gently applying forward pressure.Drive Gear 72903 3A-52 . Remove timing chain as previously outlined. Remove crankcase front cover as previously outlined. 8.
Apply thread adhesive to threads of balance shaft bolt and install. Inspect balance shaft gear key way and shaft dowel pin for excessive wear. 2. 2. 90-823226--1 896 INDEX ENGINES . Installation NOTE: GM shim (10229872) is placed on installer tool prior to the bearing.3A-53 .Cylinder Block b 72904 4. a 72905 a . Inspect front cylinder block bore for scoring or evidence of bearing spinning in bore. in. Install bolts to retain camshaft sprocket and torque to 20 ft. a . Also check for scored bearings or roughness while rotating. 6.Cleaning and Inspection 1. (27 N·m). Align marks on drive and driven gear and install drive gear on camshaft. Install thrust plate and two TORX bolts. Inspect gears for chips or excessive wear on teeth. 6.Alignment Marks 7. Torque to 120 lb.Retaining Ring b . 3. Wash balance shaft in solvent and blow dry with compressed air. Lubricate bearings with engine oil and install balance shaft. 5. This will assure proper depth setting of rear bearing when installed. tap shaft until front bearing retaining ring seats against cylinder block. Use balance shaft remover and installer tool along with GM shim to insert bearing. 4. Install driven gear on balance shaft. (14 N·m). Using a soft face mallet. 1. Inspect rear bearing for wear or damage (refer to “Specifications”). a NOTE: Front bearing is not serviceable and may be replaced only with the balance shaft assembly. 3. in. Inspect front bearing for secure fit on shaft or excessive side to side play. 73176 8. 5.
Rotate crankshaft torsional damper slowly in direction of rotation until lifter is on heel of cam lobe. If camshaft readings for all lobes are within specifications. (27 N·m). Torque nuts to 20 lb.Ball Socket Adaptor Tool (J-8520-1) 72907 3.9. measure lift of each push rod in consecutive order and record readings. with “Specifications. 1. Compare total lift. 12. ft. 72906 a . Be sure that push rod is in lifter socket. Install crankcase front cover as previously outlined. then rotate balancer slowly (or attach an auxiliary starter switch and “bump” engine over) until push rod is in fully raised position. 7. ft. Remove valve mechanism as previously outlined. Continue to rotate engine until indicator reads zero. This will be a check on accuracy of original indicator reading.Wedge b . Set dial indicator on zero. Camshaft Measuring Lobe Lift NOTE: Procedure is similar to checking valve timing. 8. Install manifold as previously outlined. then tighten bolt an additional 35 degrees angular torque using a Torque Angle Gauge. Position indicator with ball socket adaptor tool on push rod. Install rocker arm and push rod. 5.” 6. At this point. (20 N·m). If improper valve operation is indicated. push rod will be in its lowest position.Driven Gear 4. 11. remove dial indicator assembly. Insert hard wood wedge between gear teeth and torque driven gear retaining bolt to 15 lb.ENGINES INDEX 90-823226--1 896 . 2. 10. Install timing chain as previously outlined. recorded from dial indicator. a b a a . 3A-54 .
drive camshaft rear plug from cylinder block. being careful not to damage bearings. camshaft should be replaced. remove camshaft and crankshaft. 3. If out more than . bolts in camshaft bolt holes and carefully remove camshaft as shown.Removal 1.3A-55 . then lubricate camshaft journals with engine oil and install camshaft. With camshaft and crankshaft removed. Install crankcase front cover and valve lifters as previously outlined. When bearing has been pulled from bore.001 in. leaving cylinder heads attached and pistons in place. sprocket and camshaft thrust plate. fasten connecting rods against sides of engine so that they will not interfere while replacing camshaft bearings. 4.025 mm) out-of-round. Install two 5/16-18 x 5 in. If journals exceed . remove tool and bearing from puller screw. b. bolts in camshaft bolt holes. Inspection Measure camshaft bearing journals with a micrometer for out-of-round condition. Using two wrenches. 2. thus requiring a minimum amount of turns to remove all bearings. Remove valve lifters as previously outlined. Using camshaft bearing remover and installer set (J-6098-01) (with nut and thrust washer installed to end of threads). c. NOTE: This procedure is based on removal of bearings from center of engine first.002 in. Be sure a sufficient amount of threads are engaged. Camshaft Bearings Removal Camshaft bearings can be replaced while engine is disassembled for overhaul or without complete disassembly. To replace bearings without complete disassembly. b. 2. Remove crankcase front cover as previously outlined. 72908 1. Installation 1. (0. Lubricate camshaft lobes with General Motors Cam and Lifter Prelube or equivalent. hold puller screw while turning nut. Install timing chain as previously outlined. 72909 Checking Camshaft Alignment 90-823226--1 896 INDEX ENGINES . 3. 2. Before removing crankshaft. Install tool with shoulder toward bearing. Also check camshaft for alignment with V-blocks and dial indicator which indicates exact amount camshaft is out of true.051 mm) (dial indicator reading) camshaft should be replaced. Remove camshaft as follows: a. (0. Install camshaft as follows: a. position pilot in front camshaft bearing and install puller screw through pilot. Install two 5/16-18 x 5 in. Remove timing chain.
IMPORTANT: All camshaft bearings are not the same. Install nut and thrust washer all the way onto puller screw.ENGINES INDEX 90-823226--1 896 . d. Intermediate and center bearings must be positioned so that oil holes are at the 5 o’clock position (toward left side of block and at a position even with bottom of cylinder bore). Remove remaining bearings (except front and rear) in same manner. 3A-56 . (13 mm) of threads are engaged. Be sure grooves and drilled oil passages are clean. It will be necessary to position pilot in rear camshaft bearing to remove rear intermediate bearing. Installing intermediate and center bearings: a. It will be necessary to position pilot in rear camshaft bearing bore to install rear intermediate bearing. 1. then position appropriate size remover and installer tool in bearing and thread puller screw into tool. c a b. then position pilot in front camshaft bearing bore and insert screw through pilot. Remove the remover and installer tool and check to ensure that oil hole(s) in bearing are positioned correctly.5. Be sure at least 1/2 in. Rear bearing must be positioned so that oil hole is at the 12 o’clock position. hold puller screw and turn nut until bearing has been pulled into position. c.Driver Handle c . Index center camshaft bearing.Driver b . b 72870 a . Install intermediate bearings in same manner being sure to index bearings correctly. Assemble driver on driver handle and remove front and rear camshaft bearings by driving toward center of cylinder block. Lubricate outer surface of new camshaft bearings with engine oil to ease installation. Be sure to install bearings in proper locations (Indicated by bearing manufacturer) and to position bearings as follows (directional references are in reference to engine in its normal operating position): • Front bearing must be positioned so that oil holes are equal distance from 6 o’clock position in the block. Installation Front and rear bearings must be installed last as pilot will not fit into bearing bores if bearings are installed. a c b d a b c d Index Point Puller Screw Driver Bearing 72383 6. Using two wrenches.Bearing (Hidden In This View) Inspection Clean camshaft bearing bores in cylinder block with solvent and blow out with compressed air.
Parallel to Centerline of Engine “Out of Round” is the difference between “A” and “B”. Cylinder Block Cleaning and Inspection 1. Install crankshaft and camshaft as previously outlined. out-of-round or excessive ridge at top of ring travel. 7. c. Carefully work gauge up and down cylinder to determine taper and turn it to different points around cylinder wall to determine out-of-round condition. b. 6. Install appropriate size remover and installer tool on drive handle. boring and/or honing will be necessary.2. “Taper” is the Difference between Measurement “A” At Top of Cylinder Bore and “A” Measurement at Bottom of Cylinder Bore NOTE: These plugs may be removed with a sharp punch.3A-57 . This should be done with a dial indicator or inside micrometer. 3. 3. (0. 72385 Cylinder Measurement a . 2. Measure cylinder walls for taper. or they may be drilled and pried out. Remove expansion plugs. 72386 Measuring Cylinder Bore 90-823226--1 896 INDEX ENGINES . IMPORTANT: Plug must be installed flush to 1/32 in. 4. being sure to index bearing correctly. Wash cylinder block thoroughly in cleaning solvent and clean all gasket surfaces.8 mm) deep and must be parallel with rear surface of cylinder block. Check position of oil hole(s) in bearing to ensure bearing is positioned correctly. Remove oil gallery plugs and clean all oil passages. Index front bearing (as explained in “Important” above). 5. If cylinders exceed specifications. Install a new camshaft rear plug. Install rear bearing in same manner. Inspect cylinder block for cracks in cylinder walls.At Right Angle to Centerline on Engine b . and drive it into position with tool. Installing front and rear bearings: a. 4. Clean and inspect water passages in cylinder block. water jacket valve lifter bores and main bearing webs. Remove all engine components as previously outlined.
CYLINDER BORING 1. Before using any type boring bar.005 in. (0. 72910 a . swab cylinder bores several times with light engine oil and a clean cloth.127 mm) taper or wear. To entirely clean up the bore. they can be conditioned by honing or boring. Measure piston to be fitted with a micrometer. wear or taper may not clean up entirely when fitted to a high limit piston.005 in. If cylinder block inspection indicates that block is suitable for continued use (except for out-of-round or tapered cylinders). 3. When pistons are being fitted and honing is not necessary. If cylinders have less than . If surfaces are warped more than . taper or wear. (0. This is very important to prevent boring bar tilt. b a 72387 Measuring Cylinder Bore 8. NOTE: Hone cylinders as outlined under “Cylinder Honing” and “Piston Selection. measuring at center of piston skirt and at right angles to piston pin. If more than .005 in.007 in. bore and hone to smallest oversize that will permit complete resurfacing of all cylinders. Performance of the following operation depends upon engine condition at time of repair. 2. Check cylinder head gasket surfaces for warpage with a machinist’s straight-edge and a feeler gauge. Bore cylinder to same diameter as piston and hone to give specified clearance. 2. A cylinder bore of more than . Take measurements diagonally across surfaces (both ways) and straight down center. 3A-58 .CYLINDER CONDITIONING 1.003 in. block must be resurfaced by an automotive machine shop. file off top of cylinder block to remove dirt or burrs. (0.Machinist’s Straight Edge b .” following. it will be necessary to bore for an oversize piston.Feeler Gauge 3. with result that bored cylinder wall is not at right angles to crankshaft. area or .2 mm) overall. Carefully observe instructions furnished by manufacturer of equipment being used.07 mm) in a 6 in. 4. they can be conditioned with a hone and fitted with high limit standard size piston.ENGINES INDEX 90-823226--1 896 . then wipe with a clean dry cloth. as shown. cylinder bores may be cleaned with a hot water and detergent wash. After cleaning.
as this type piston can be distorted by careless handling. Check used piston to cylinder bore clearance as follows: a. 3. 4. Occasionally. It is extremely essential that a good cleaning operation be performed. If cylinder bore must be reconditioned. Cylinder should not be cleaned with kerosene or gasoline. Thoroughly clean cylinder bores with hot water and detergent. Measure cylinder bore diameter with a telescope gauge 2-1/2 in. Mark piston to identify cylinder for which it was fitted. Scrub well with a stiff bristle brush and rinse thoroughly with hot water. If any abrasive material remains in cylinder bores. 4. 72911 c. 5.CYLINDER HONING 1. Swab bores several times with light engine oil on a clean cloth. Clean remainder of cylinder block to remove excess material spread during honing operation. Measure piston diameter at skirt across center line of piston pin as shown. move hone up and down at a sufficient speed to obtain very fine uniform surface finish marks in a crosshatch pattern of approximately 30 degrees to cylinder bore. When finish-honing a cylinder bore to fit a piston. Finish marks should be clean but not sharp. free from imbedded particles and torn or folded metal. (64 mm) from top of cylinder bore as shown. determine if a new piston can be selected to fit cylinder bore within acceptable range. 3. it will rapidly wear new rings and cylinder bores in addition to bearings lubricated by the contaminated oil. Follow hone manufacturer’s recommendations for use of hone and cleaning and lubrication during honing. IMPORTANT: Handle pistons with care and do not attempt to force them through cylinder until cylinder is honed to correct size. d. PISTON SELECTION 1. thoroughly clean cylinder bore and check piston for correct fit in cylinder.3A-59 . Subtract piston diameter from cylinder bore diameter to determine piston-to-bore clearance. 72386 b. during the honing operation. If used piston is not satisfactory. measure new piston diameter (across centerline of piston pin). Determine if piston-to-bore clearance is in acceptable range shown in “Specifications. 90-823226--1 896 INDEX ENGINES . then hone cylinder bore to correct clearance (preferable range). 2.” 2. Permanently mark piston (for cylinder to which it has been fitted) and proceed to hone cylinders and fit remaining pistons. then wipe with a clean dry cloth.
3A-60 . Install by-pass valve or cylinder block adaptor to engine block.Oil Filter By-Pass Valve Inspection and/or Replacement Oil by-pass valve should be inspected whenever engine is disassembled for major repair or whenever inadequate oil filtration is suspected. Wipe out valve chamber in cylinder block to remove any foreign material. Refer to “Engine Parts List” when ordering parts for oil filter by-pass valve. Lubricate oil filter rubber seal and install hand-tight only.Fiber Valve (Be Sure Valve Fits Tightly Against the Seal) 4. 5. 2. by-pass valve should be replaced. 3. If valve operation is questionable. a 72912 Typical By-Pass Valve a . Push valve down and release it. 1. Check that valve fits tightly against its seat. Valve should return freely to its seat.ENGINES INDEX 90-823226--1 896 . Inspect fiber valve for cracks or other damage. Clean by-pass valve in solvent and blow dry with compressed air. 6. Remove oil filter from cylinder block and remove by-pass valve.
THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE 90-823226--1 896 INDEX ENGINES .3A-61 .
THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE 3A-62 .ENGINES INDEX 90-823226--1 896 .
THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE 90-823226--1 896 INDEX ENGINES .3A-63 .
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