Downloaded from www.Manualslib.com manuals search engine ASSEMBLE
(1) Install pump rotors and shaft, using new parts
as required.
(2) Position the oil pump cover onto the pump
body. Tighten cover bolts to 11 N´m (95 in. lbs.)
torque.
(3) Install the relief valve and spring. Insert the
cotter pin.
(4) Tap on a new retainer cap.
(5) Prime oil pump before installation by filling
rotor cavity with engine oil.
CLEANING AND INSPECTION
CYLINDER HEAD COVER
CLEANING
Clean cylinder head cover gasket surface.
Clean head rail, if necessary.
INSPECTION
Inspect cover for distortion and straighten, if nec-
essary.
Check the gasket for use in head cover installation.
If damaged, use a new gasket.
CYLINDER HEAD ASSEMBLY
CLEANING
Clean all surfaces of cylinder block and cylinder
heads.
Clean cylinder block front and rear gasket surfaces
using a suitable solvent.
INSPECTION
Inspect all surfaces with a straightedge if there is
any reason to suspect leakage. If out-of-flatness
exceeds 0.00075 mm/mm (0.00075 inch/inch) times
the span length in inches in any direction, either
replace head or lightly machine the head surface.
FOR EXAMPLE:A 305 mm (12 inch) span is
0.102 mm (0.004 inch) out-of-flat. The allowable out-
of-flat is 305 X 0.00075 (12 X 0.00075) equals 0.23
mm (0.009 inch). This amount of out-of-flat is accept-
able.
The cylinder head surface finish should be
1.78-3.00 microns (70-125 microinches).
PISTON AND CONNECTING ROD ASSEMBLY
INSPECTION
Check the crankshaft connecting rod journal for
excessive wear, taper and scoring.
Check the cylinder block bore for out-of-round,
taper, scoring and scuffing.Check the pistons for taper and elliptical shape
before they are fitted into the cylinder bore (Fig. 83).
OIL PAN
CLEANING
Clean the block and pan gasket surfaces.
Trim or remove excess sealant film in the rear
main cap oil pan gasket groove.DO NOT remove
the sealant inside the rear main cap slots.
If present, trim excess sealant from inside the
engine.
Clean oil pan in solvent and wipe dry with a clean
cloth.
Clean oil screen and pipe thoroughly in clean sol-
vent. Inspect condition of screen.
INSPECTION
Inspect oil drain plug and plug hole for stripped or
damaged threads. Repair as necessary.
Inspect oil pan mounting flange for bends or distor-
tion. Straighten flange, if necessary.
OIL PUMP
INSPECTION
Mating surface of the oil pump cover should be
smooth. Replace pump assembly if cover is scratched
or grooved.
Lay a straightedge across the pump cover surface
(Fig. 84). If a 0.038 mm (0.0015 inch) feeler gauge
can be inserted between cover and straightedge,
pump assembly should be replaced.
Fig. 83 Piston Measurements
1 ± 49.53 mm
(1.95 IN.)
9 - 182 5.9L ENGINEDN
DISASSEMBLY AND ASSEMBLY (Continued)
Downloaded from www.Manualslib.com manuals search engine DESCRIPTION SPECIFICATION
PISTONS
Clearance at Top of Skirt 0.013 ± 0.038 mm
(0.0005 ± 0.0015 in.)
Land Clearance (Diam.) 0.508 ± 0.660 mm
(0.020 ± 0.026 in.)
Piston Length 81.03 mm (3.19 in.)
Piston Ring Groove
DepthÐ
#1&2 4.761 ± 4.912 mm
(0.187 ± 0.193 in.)
Piston Ring Groove
DepthÐ
#3 3.996 ± 4.177 mm
(0.157 ± 0.164 in.)
Weight 582 ± 586 grams
(20.53 ± 20.67 oz.)
PISTON PINS
Clearance in Piston 0.006 ± 0.019 mm
(0.00023 ± 0.00074 in.)
Diameter 25.007 ± 25.015 mm
(0.9845 ± 0.9848 in.)
End Play NONE
Length 67.8 ± 68.3 mm
(2.67 ± 2.69 in.)
PISTON RINGS
Ring Gap
Compression Ring (Top) 0.30 ± 0.55 mm
(0.012 ± 0.022 in.)
Compression Ring (2nd) 0.55 ± 0.80 mm
(0.022 ± 0.031 in.)
Oil Control (Steel Rails) 0.381 ± 1.397 mm
(0.015 ± 0.055 in.)
Ring Side Clearance
Compression Rings 0.040 ± 0.085 mm
(0.0016 ± 0.0033 in.)
Oil Ring (Steel Rails) 0.05 ± 0.21 mm
(0.002 ± 0.008 in.)
Ring Width
Compression rings 1.530 ± 1.555 mm
(0.060 ± 0.061 in.)DESCRIPTION SPECIFICATION
Oil Ring (Steel Rails) ±
Max.0.447 ±0.473 mm
(0.018 ± 0.019 in.)
VALVE TIMING
Exhaust Valve
Closes (ATDC) 33É
Opens (BBDC) 56É
Duration 269É
Intake Valve
Closes (ATDC) 62É
Opens (BBDC) 7É
Duration 249É
Valve Overlap 41É
OVERSIZE AND UNDERSIZE ENGINE
COMPONENT MARKINGS CHART
ITEM U/S
(O/S)IDENTI-
FICATIONIDENTI-
FICATION
LOCATION
Crank-
shaft
Journals0.0254
mm
(0.001
in.) U/SR or M M-2-3
ect.
(indicating
No. 2 and 3
main bearing
journal)
and/or R-1-4
ect.
(indicating
No. 1 and 4
connecting
rod journal)Milled flat on
No. 8
crankshaft
counterweight.
Hydraulic
Tappets0.2032
mm
(0.008
in.)
(O/S)lDiamond-
shaped stamp
top pad - front
of engine and
flat ground on
outside
surface of
each O/S
tappet bore.
Valve
Stems0.127
mm
(0.005
in.)
(O/S)X Milled pad
adjacent to
two tapped
holes (3/8 in.)
on each end
of cylinder
head.
9 - 188 5.9L ENGINEDN
SPECIFICATIONS (Continued)
