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(11) Install the water pump. Tighten the mounting bolts to 31 N·m (23 ft. lbs.) torque. (12) Lubricate the oil filter seal with clean engine oil. Tighten oil filter to 18 N·m (156 in. lbs.) torque. (13) Install the engine into the vehicle. to Group 0, Lubrication and Maintenance). (15) Fill the cooling system. CLEANING AND INSPECTION INTAKE AND EXHAUST MANIFOLD Clean the mating surfaces of the cylinder head and the manifold if the original manifold is to be CYLINDER HEAD CLEANING Thoroughly clean the engine cylinder head and cyl- inder block mating surfaces. Clean the intake and Check to ensure that no coolant or foreign material has fallen into the tappet bore area. Remove the carbon deposits from the combustion chambers and top of the pistons. INSPECTION Use a straightedge and feeler gauge to check the flatness of the engine cylinder head and block mating CYLINDER HEAD COVER CLEANING Remove any original sealer from the cover sealing surface of the engine cylinder head and clean the Remove all residue from the sealing surface using a clean, dry cloth. INSPECTION Inspect the engine cylinder head cover for cracks. Replace the cover, if cracked. The original dark grey gasket material should NOT be removed. If sections of the gasket material ROCKER ARMS AND PUSH RODS CLEANING Clean all the components with cleaning solvent. the rocker arms and push rods. INSPECTION Inspect the pivot surface area of each rocker arm. Replace any that are scuffed, pitted, cracked or Inspect the valve stem tip contact surface of each rocker arm and replace any rocker arm that is deeply Inspect each push rod end for excessive wear and replace as required. If any push rod is excessively Inspect the push rods for straightness by rolling them on a flat surface or by shining a light between A wear pattern along the length of the push rod is not normal. Inspect the engine cylinder head for HYDRAULIC TAPPETS CLEANING Clean each tappet assembly in cleaning solvent to remove all varnish, gum and sludge deposits. INSPECTION Inspect for indications of scuffing on the side and base of each tappet body. Inspect each tappet base for concave wear with a straightedge positioned across the base. If the base is After cleaning and inspection, test each tappet for specified leak-down rate tolerance to ensure zero-lash Swing the weighted arm of the hydraulic valve tap- pet tester away from the ram of the Leak-Down (1) Place a 7.925-7.950 mm (0.312-0.313 inch) diameter ball bearing on the plunger cap of the tap- (2) Lift the ram and position the tappet (with the ball bearing) inside the tester cup. (3) Lower the ram, then adjust the nose of the ram until it contacts the ball bearing. DO NOT tighten (4) Fill the tester cup with hydraulic valve tappet test oil until the tappet is completely submerged. 9 - 54 4.0L ENGINE WJ DISASSEMBLY AND ASSEMBLY (Continued) |