Content

General, technical data

• Instructions for use of service manual
• Engine and vehicle identification
• Vehicle identification number locations
• Technical data

Crankcase and cylinder head

• Engine and model survey
• Overview - engines
• Removal and installation of bottom engine compartment cover
• Testing compression pressure
• Testing cylinder leaktightness
• Illuminating cylinders
• Removal and installation of engine
• Crankcase ventilation - function
• Measuring, boring and honing cylinders
• Facing crankcase parting surface
• Removal and installation of steel balls in main oil gallery
• Replacing core plug in crankcase
• Removal and installation of timing case cover
• Removal and installation of end cover
• Removal and installation of oil pan
• Repair instructions for crankcase
• Removal and installation of cylinder head cover
• Reconditioning spark plug thread in cylinder head
• Removal and installation of cylinder head .
• Matching measuring sensors to cylinder head
• Facing cylinder head mating face
• Enlarging camshaft bearing bores
• Pressure-testing cylinder head

Crankshaft assembly

• Checking, replacing and torquing conrod bolts
• Reconditioning and checking angles on bearing bores
• Removal and installation of pistons
• Checking and reconditioning crankshaft
• Installation of crankshaft bearings
• Replacing front crankshaft radial seal
• Replacing rear crankshaft radial seal
• Removal and installation of grooved bail bearing in crankshaft
• Removal and installation of vibration damper
• Checking and correcting setting of TDC pulse generator
• Removal and installation of crankshaft gear
• Removal and installation of flywheel or flex plate
• Remachining flywheel
• Replacing ring gear on flywheel

Engine timing, valvetrain

• Checking and replacement of hydraulic valve clearance compensating element
• Checking and correcting the installation position of hydraulic valve clearance
• Checking and adjusting camshaft timing
• Removal and installation of camshaft
• Removal and installation of rocker arm bearing supports with rocker arms
• Replacement of rocker arms and rocker arm bearing supports
• Removal and installation of valve springs
• Checking valve springs
• Replacement of valve stem seals
• Checking and machining valves
• Checking and replacing valve guides
• Replacing valve seat ring
• Machining valve seats
• Removal and installation of chain tensioner
• Replacement of timing chain
• Installation of oil spray nozzle retroactively
• Removal and installation of tensioning blade
• Removal and installation of guide rails
• Removal and installation of idler gear shaft
• Removal and installation of oil pressure pump drive