
Engine
Tune
up
Condition
Probable
cause
Overheat
Improper
fuel
mixture
Floor
temp
ture
too
high
California
and
FU
model
Problem
in
fuel
system
Refer
to
Inspec
tion
of
Fuel
System
Problem
in
ignition
system
Refer
to
In
spection
oflgnition
System
Corrective
action
Previously
mentioned
Check
the
fuel
system
Check
and
repair
Check
and
repair
SPECIAL
SERVICE
TOOL
Kent
Moore
No
Tool
number
tool
name
Reference
page
or
Fig
No
STl9320000
Oil
filter
wrench
125664
Page
ET
3
ET
23
Kent
Moore
No
Tool
number
tool
name
Reference
page
or
Fig
No

1
Rockel
covel
2
Cylindel
head
3
Cylinder
block
4
Cnnksbaft
5
Piston
6
Oil
pan
7
Flywheel
8
Valve
mechanism
9
Cam
haft
10
Timing
chain
11
Front
cover
12
Watel
pump
Engine
Mech
lnical
ENGiNE
COMPONENtS
I
I
I
ld
n
t
I
EM765
Fig
EM
l
Engine
ComponentJ
EM
2

PRELIMINARY
CLEANING
AND
INSPECTION
Before
disassembling
engine
ob
serve
the
following
items
I
Prior
to
disassembling
check
outer
parts
for
sign
of
leak
past
their
gasketed
surfaces
2
Check
carburetor
and
fuel
pump
for
condition
fuel
hoses
for
deteriora
t
ion
cracks
or
otherwise
leakage
of
fuel
past
their
jointed
or
connected
surfaces
3
Wipe
dust
and
mud
off
engine
4
Inspect
outer
parts
for
visual
faults
and
broken
or
missing
parts
such
as
bolts
and
nuts
5
Check
piping
and
electrical
cir
cuits
for
deterioration
breakage
fittings
discontinuity
or
insulation
DISASSEMBLY
To
remove
engine
from
car
refer
to
Section
ER
for
Removal
1
Remove
starting
motor
then
re
move
transmission
from
engine
2
Remove
clutch
assembly
3
Remove
alternator
fan
belt
alter
nator
bracket
and
alternator
adjusting
bar
4
Remove
idler
pulley
air
pump
belt
and
idier
pulley
bracket
If
so
equipped
Note
Loosen
idler
pulley
nut
and
belt
adjusting
bolt
in
that
order
@
1
Idler
pulley
nut
2
Belt
adjusting
bolt
3
Air
pump
belt
4
Idler
pulley
bracket
EM527
Fig
EM
2
Removing
Idle
Pulley
Air
Pump
Belt
and
Idle
Pulley
Bracket
Engine
Mechanical
ENGINE
DISASSEMBLY
5
Remove
air
pump
pulley
air
pump
and
air
pump
bracket
If
so
equipped
6
Remove
fan
fan
spacer
and
pul
ley
7
Remove
oil
level
gauge
8
Remove
distributor
cap
and
high
tension
cables
as
an
assembly
9
Disconnect
distributor
vacuum
line
from
distributor
and
remove
dis
tributor
10
Disconnect
fuel
line
from
carbu
retor
II
Remove
fuel
pump
and
fuel
line
12
Remove
water
outlet
and
thermostat
13
Remove
engine
mounting
brack
et
R
H
14
Remove
oil
pump
and
filter
as
sembly
EL043
Fig
EM
3
Removing
Oil
Pump
15
Remove
spark
plugs
16
Install
Engine
Attachment
KVlOI02500
to
cylinder
block
using
engine
f1
ounling
bracket
R
H
attach
ing
studs
fuel
pump
attaching
studs
and
alternator
bracket
attaching
bolt
holes
17
Mount
engine
on
Engine
Stand
ST050I
SOOO
Fig
EM
4
EM
3
18
Remove
engine
mounting
brack
et
L
H
19
Disconnect
air
vacuum
and
blow
by
hoses
from
air
cleaner
20
Remove
air
cleaner
and
air
cleaner
brackets
21
Remove
vacuum
control
valve
assembly
and
bracket
as
a
unit
22
Remove
carburetor
and
baffle
plate
23
Remove
E
G
R
control
valve
24
Remove
intake
and
exhaust
manifold
assemblies
EM528
Fig
EM
5
Removing
Manifold
25
Remove
P
C
V
hose
pipe
con
nector
to
control
valve
26
Remove
rocker
cover
27
Loosen
valve
rocker
adjusting
nut
and
turn
adjusting
screws
out
to
disengage
push
rods
Then
evenly
loosen
rocker
shaft
bolts
28
Remove
rocker
shaft
assembly
EM453
Fig
EM
6
Removing
Rocker
Shaft
Assembly
29
Withdraw
push
rods
and
keep
them
in
correct
order
1
30
Loosen
cylinder
head
bolts
a
little
at
a
time
in
the
sequence
shown
in
Fig
EM
and
remove
cylinder
head

EMA
54
Fig
EM
7
Cylinder
Head
Bolt
Looaening
S
quence
Fig
EM
8
Removing
Cylinder
Ht
ad
Note
Do
not
pry
between
head
and
block
as
gasket
surfaces
may
be
come
damaged
31
Invert
engine
32
Remove
oil
pan
and
oil
strainer
33
Invert
engine
34
kemove
water
pump
35
Remove
crank
pulley
and
timing
chain
cover
EMA
55
Fig
EM
9
Removing
Timing
Chain
Cover
36
Remove
i1
thrower
and
chain
tensioner
37
LQ9sen
camshaft
sprocket
bolt
and
remove
both
procket
and
timing
chain
an
assembly
3
Remove
connecting
rod
caps
and
push
piston
and
connecting
rod
assemblies
out
of
the
bores
Engine
Mechanical
hi
r
EM456
Fig
EM
l
0
Remooing
Piston
and
Connecling
Rod
Assembly
Note
Numbers
are
stamped
on
con
necting
rod
and
cap
rllnding
to
each
cylinder
Care
should
be
taken
to
avoid
wrong
comhination
including
bearing
39
Remove
flywheel
and
rear
plate
WARNING
When
remnving
flywheel
be
careful
not
to
drop
it
40
Gradually
loosen
main
bearing
cap
bolt
in
two
or
three
stages
and
remove
caps
See
Fig
EM
II
I
l
P
@
D
M458
Fig
EM
ll
Main
Bearing
Cap
Bolt
Loo
ning
Sequ
nce
41
Remove
rear
oil
seal
42
Lift
out
crankshaft
43
Remove
main
bearings
from
block
and
bearing
caps
44
Remove
baffie
plate
and
tee
net
EM460
Fig
EM
l2
Remooing
Baffle
Plate
and
Steel
Net
EM
4
45
RemoVe
camshaft
plate
Careful
ly
remove
camshaft
by
pulling
it
to
ward
the
front
of
engine
EM461
Fig
EM
j3
Camshaft
Plate
46
Remove
valve
lifter
and
keep
them
in
order
PISTON
AND
CONNECTING
ROD
I
Remove
piston
rings
with
a
ring
remover
EM292
Fig
EM
14
Remooing
PUton
Ring
2
Press
out
piston
pin
with
Piston
Pin
Press
Stand
KVIOIOS300
EM103
Fig
EM
15
R
moving
Piston
Pin
Note
Keep
disassembled
parts
in
order

CYLINDER
HEAD
I
Using
Valve
lifter
STl2070000
compress
valve
spring
and
remove
valve
collet
2
Release
Valve
Lifter
and
remove
spring
retainer
spring
oil
seal
spring
seat
and
valve
PREPARATION
FOR
INSPECTION
I
8efore
cleaning
check
for
signs
of
water
and
oille
s
2
Clean
oil
and
carbon
deposits
from
all
parts
They
should
be
clean
from
gaskets
and
sealant
3
Clean
all
oil
holes
with
solvent
and
dry
with
compressed
air
Make
sure
that
they
are
not
restricted
CYLINDER
HEAD
AND
VALVE
CHECKING
CYLINDER
HEAD
MATING
FACE
I
Make
a
visual
check
for
cracks
and
flaws
2
Measure
surface
of
cylinder
head
on
cylinder
block
sid
for
warpage
If
beyond
designated
limit
correct
s
rface
with
a
surface
grinder
Warpage
of
urfece
Less
than
0
1
mm
0
004
in
EM108
Fig
EM
IS
Checking
Cylinder
Head
Surface
Engine
Mechanical
EM462
Fig
EM
16
Removing
Value
3
Place
valve
components
in
order
INSPECTION
AND
REPAIR
Note
Surface
grinding
limit
The
grinding
limit
of
cylinder
head
is
determined
by
the
cylinder
block
grinding
in
an
engine
Depth
of
cylinder
head
grinding
is
A
Depth
of
cylinder
block
grinding
is
6B
The
limit
is
as
follows
A
B
0
2
mm
0
008
in
VALVE
i
Check
each
of
the
intake
and
exhaust
valve
for
worn
damaged
or
deformed
valve
caps
or
stems
Correct
or
replace
the
valve
that
is
faulty
For
standard
size
of
valve
refer
to
Service
Data
and
Specifications
2
Valve
face
or
valve
stem
end
surface
should
be
refaced
by
using
a
valve
grinder
Note
When
valve
head
has
been
worn
down
to
0
5
mm
0
020
in
in
thickness
replace
the
valve
Grinding
allowance
for
valve
stem
end
surface
is
0
5
mm
0
020
in
or
less
c
EM111
Fig
EM
19
Regrinding
Valve
Face
EM
5
C
vO@
lll@8
C
CQ8@
a
EM463
Fig
EM
17
Valve
Components
Note
Take
care
not
to
lose
valve
spring
seat
oil
seal
valve
collet
and
valve
rocker
guide
VALVE
SPRING
I
Check
valve
spring
for
squareness
using
a
steel
square
and
surface
plate
If
spring
is
out
of
square
S
more
than
specified
limit
replace
with
new
ones
Out
of
square
S
Less
than
1
6
mm
0
063
inl
L
1
EM296
Fig
EM
20
Measuring
Spring
Sguareness
2
Measure
the
free
length
and
the
tension
of
each
spring
If
the
measured
value
exceeds
the
specified
limit
re
place
spring
Refer
to
Service
Data
and
pecifica
tions
EMl13
Fig
EM
21
Measuring
Spring
Teruion

5
Fit
insert
ensuring
that
it
seats
on
bottom
face
of
its
recess
6
Newly
fitted
valve
seat
should
be
cut
or
ground
with
suitable
seat
cutter
or
grinding
stone
7
Apply
smalliunount
of
fine
grind
ing
compound
to
valve
contacting
face
and
put
valve
into
guide
Lap
valve
against
its
seat
ntil
proper
valve
seat
ing
is
obtained
Remove
valve
and
clean
valve
and
valve
seat
VALVE
ROCKER
ARM
1
AND
SHAFT
I
Check
rocker
arm
bore
and
shaft
for
scores
or
scuffs
2
Check
clearance
between
each
rocker
arm
and
shaft
by
measuring
inner
diameter
of
rocker
arm
bore
and
outer
diameter
of
shaft
If
either
clearance
is
not
within
spec
ification
replace
rocker
arm
and
or
shaft
3
Check
valve
end
contact
surface
of
rocker
arm
for
abnormal
wear
or
scuffs
VALVE
LIFTER
AND
PUSH
ROD
I
Check
valve
lifter
for
wear
or
scuffs
Check
bottom
end
of
valve
lifter
to
make
sure
it
has
a
slight
convex
Replace
valve
lifters
that
are
scored
worn
or
have
unsmooth
bot
tom
2
Check
clearance
between
lifter
hole
on
cylinder
block
and
valve
lifter
Replace
valve
lifter
if
clearance
ex
ceeds
wear
limit
3
Check
push
rod
for
bending
and
damage
Check
end
of
push
rod
for
rough
ness
or
excessive
wear
CAMSHAFT
AND
CAMSHAFT
BEARING
CAMSHAFT
BEARING
CLEARANCE
Journal
diameters
should
be
check
ed
with
a
micrometer
and
bearings
with
an
inside
dial
gauge
Measure
ments
should
then
be
compared
to
Engine
Mechanical
determine
whether
bearings
are
worn
If
worn
beyond
0
15
mm
0
0059
in
replace
using
Camshaft
Bearing
Drift
STl6Il0000
In
press
fitting
a
new
bearing
make
certain
that
oil
holes
in
block
and
bearing
are
properly
aligned
EM474
Fig
EM
27
Measuring
Camshaft
Bearing
Inner
Diameter
CAUTION
a
After
replacing
all
bearings
finish
bearing
inner
diameters
by
line
bor
ing
b
I
nstall
welch
plug
into
cylinder
block
applying
sealant
EM475
Fig
EM
28
Replacing
Cam
haft
Bearings
CAMSHAFT
ALIGNMENT
I
Check
camshaft
camshaft
journal
and
earn
surface
for
bending
wear
or
damage
If
fault
is
beyond
limits
replace
affected
parts
2
A
bend
value
is
one
half
of
the
reading
obtained
when
camshaft
is
turned
one
full
revolution
with
a
dial
gauge
applied
to
the
cen
ter
journal
Camshaft
bend
Total
indicator
reading
Less
than
0
10
mm
0
0039
in
EM
7
s
EM476
Fig
EM
29
Checking
Cam
haft
Bend
3
Camshaft
end
play
can
be
check
ed
by
installing
camshaft
camshaft
locating
plate
and
camshaft
sprocket
in
thier
respective
p
sitions
End
play
can
then
be
checked
with
a
dial
guage
or
feeler
gauge
If
end
play
exceeds
the
specified
limit
replace
locating
plate
Max
tolerance
of
camshaft
end
pley
0
10
mm
0
0039
in
EM477
Fig
EM
3D
Checking
Cam
haft
End
Play
VALVE
TIMING
This
diagram
applies
to
all
cyl
inders
If
any
valve
is
found
beyond
specifications
one
possibility
is
that
earn
lobe
is
worJ
1
or
damaged
exces
sively
calling
for
replacement
of
cam
shaft
CYLINDER
BLOCK
I
Visually
check
cylinder
block
for
cracks
or
flaws
2
Measure
top
of
cylinder
block
cylinder
head
mating
face
for
warp
age
If
warpage
exceeds
limits
correct
it
Warpage
of
cylinder
block
surface
Less
than
0
10
mm
0
0039
in

Note
If
cylinder
bore
has
worn
beyond
the
wear
limit
use
cylinder
liner
Undersize
cylinder
liners
are
avail
able
for
service
Interference
fit
of
cylinder
liner
in
cylinder
block
ahould
be
0
08
to
0
09
mm
0
003
I
to
0
0035
in
PISTON
PISTON
PIN
AND
PISTON
RING
I
Remove
carbon
from
piston
and
ring
grooves
with
a
carbon
scraper
and
a
curved
steel
wire
The
wire
will
be
useful
in
cleaning
bottom
land
of
ring
groove
Clean
out
oil
slots
in
bottom
land
of
oil
ring
groove
2
Check
for
damage
scratches
and
wear
Replace
if
fault
is
detected
3
Measure
side
clearance
of
rings
in
ring
grooves
as
each
ring
is
installed
If
side
clearance
exceeds
the
speci
fied
limit
replace
piston
together
with
piston
ring
Max
tolerance
of
side
clearance
0
1
mm
0
0039
in
Engine
Mechanical
u
EM482
Fig
EM
38
Measuring
Ring
Gap
Note
a
When
piston
ring
only
is
to
be
replaced
without
cylinder
bore
be
ing
corrected
measure
the
gap
at
the
bottom
of
cylinder
where
the
wear
is
minor
b
Oversize
piston
rings
are
available
for
service
0
5
mm
0
020
in
1
0
mm
0
039
in
oversize
5
Measure
piston
pin
hole
in
rela
tion
to
the
outer
diameter
of
pin
If
wear
exceeds
limit
replace
piston
pin
together
with
piston
on
which
it
is
installed
Piston
pin
to
piston
clearance
O
OOS
to
0
012
mm
0
0003
to
0
0005
in
Note
Determine
the
fitting
of
piston
pin
into
piston
pin
hole
to
such
an
extent
that
it
can
be
pressed
smoothly
by
fmger
at
room
tem
perature
This
piston
pin
must
be
a
tight
press
fit
into
connecting
rod
EM481
Fig
EM
37
Me
suring
Piston
Ring
Side
Clearance
4
Measure
ring
gap
with
a
feeler
gauge
placing
ring
squarely
in
cyl
inder
Ring
should
be
placed
to
diameter
at
upper
or
lower
limit
of
ring
travel
If
ring
gap
exceeds
the
specified
limit
replace
ring
Max
tolerance
of
ring
gap
1
0
mm
0
039
in
EM131
Fig
EM
39
Piston
Pin
Fitting
CONNECTING
ROD
1
If
a
connecting
rod
has
any
flaw
on
either
side
of
thrust
face
and
large
end
correct
or
replace
it
Bend
and
torsion
per
100
mm
3
94
in
length
Less
than
0
05
mm
0
0020
in
EM
9
EM133
Fig
EM
40
Checking
Rod
Alignment
2
Check
connecting
rod
for
bend
or
torsion
using
a
connecting
rod
aligner
If
bend
or
torsion
exceeds
limit
cor
rect
or
replace
3
When
replacing
connecting
rod
select
rod
so
weight
difference
be
tween
new
and
old
ones
is
within
5
gr
0
180z
4
Install
connecting
rods
with
bear
iogs
on
to
corresponding
crank
pins
and
measure
thrust
clearance
If
meas
ured
value
exceeds
limit
replace
con
necting
rod
Max
tolerance
of
big
end
play
0
4
mm
0
016
in
l
Big
end
play
l
t
t
EM483
Fig
EM
41
Checking
Big
End
Pwy
CRANKSHAFT
I
Repair
or
replace
as
required
If
faults
are
minor
correct
with
fine
crocus
cloth
2
Check
with
a
micrometer
journals
and
crank
pins
for
taper
and
out
of
round
Measurement
should
be
taken
along
journals
for
taper
and
around
journals
for
out
of
round
If
out
of
round
or
taper
exceeds
the
specified
limit
replace
or
repair

Out
of
ound
X
Y
Less
than
0
03
mm
10
0012
in
Taper
A
B
Less
than
0
03
mm
0
0012
in
Out
of
round
X
Y
Taper
A
B
B
o
r
EM716
Fig
EM
42
Mea6Urement
Point
3
After
regrinding
crankshaft
fmish
it
t
1
t
1e
necessary
s
ize
indicated
in
the
chart
under
Service
Data
and
Specifi
cations
by
using
Ill
adequate
u
dersize
bearing
according
to
the
extent
of
required
repair
4
Crankshaft
can
be
checked
for
bend
by
placing
it
on
V
blocks
and
using
a
dial
gauge
with
its
indicating
finger
resting
on
center
journal
If
bend
exceeds
the
specified
limit
replace
or
repair
Bned
Total
indicator
reading
Less
than
0
10
mm
0
0039
in
EM137
Fig
EM
43
Checking
Crankshaft
Bend
5
Measure
crankshaft
end
play
as
shown
in
Fig
EM
44
If
beyond
the
specified
limit
replace
main
bearing
Max
tolerance
of
end
play
0
3
mm
10
012
in
Engil
e
Mechllpjcal
Crsnk5haf
end
play
EM486
Fig
EM
44
Checking
Crankshaft
End
Play
6
To
replace
crankshaft
rear
pilot
bushing
proceed
as
follows
1
Pull
out
bushing
using
Pilot
Bushing
Puller
KvloI02800
Fig
EM
45
Pulling
Out
Pilot
Bushing
2
Before
installing
a
new
bushing
thoroughly
clean
bushing
hole
3
Insert
pilot
bushing
until
dis
tance
between
flange
end
and
pilot
bushing
is
the
specified
diJ1l
nce
A
Distance
A
Approximetely
2
8
mm
0
110
in
Do
not
oil
bushing
A
Pilot
bushing
EM719
Fig
EM
46
Installing
Pilot
Bushing
Note
When
installing
pilot
bushing
be
careful
not
to
damage
edge
of
EM
l0
pilot
C
snd
not
to
imat
1
1
1
BEARING
MEASURING
MAIN
BEARING
CLEARANCE
I
Thoroughly
clean
all
bearings
Check
for
scratches
melt
score
or
wear
Replace
bearings
if
fault
is
detected
2
Crankshaft
journals
and
bearings
should
be
clean
and
free
from
dust
and
dirt
before
oil
Clearance
is
meaSured
Plastigage
EM
141
Fig
EM
47
Plastigage
3
Set
main
b
e1lfing
on
cap
block
4
Cut
a
plastigage
to
width
of
bear
ing
and
place
it
in
parallel
with
crank
pin
clear
of
oil
hole
Install
cap
on
assembly
and
tighten
them
together
to
specified
torque
fj
Tightening
torque
Main
bearing
cop
bolt
5
0
to
6
0
kg
m
36
to
43
fHb
Note
Do
not
turn
crankshaft
while
plastigage
is
being
inserted
5
Remove
cap
and
compare
width
of
plastigage
at
widest
part
with
scale
printed
in
plastigage
envelope