Inspect the cover for cracks, scratches/nicks on the sealing surfaces, or damaged threads. Remove minor scratches/nicks with 180 grit emery. Repair thread damage with helicoil inserts. Replace part if damaged (Figure 2-129). Inspect the adapter plate for cracks, scratches on mating and sealing surfaces, dents, pitting, and corrosion. Repair minor scratches with 180 grit emery.… Read More »
Clean the camshaft and gear train parts in solvent. Wipe the cam dry with shop towels only. Compressor can be used to dry the other parts. Inspect the cam bearing journals for wear, scoring, scuffing, or discoloration from overheating. Replace camshaft if damaged or discolored (Figure 2-128). Inspect oil pump drive gear on camshaft for… Read More »
1. Check end gap of all rings. Insert ring in bore and push it down until its about 1-2 inches (2.5-5 cm) below top edge of bore. Verify that ring is level, then check end gap with feeler gauge (Figure 2-126). Correct end gaps are: • Oil ring is 0.009-0.020 in. (0.25-0.51 mm) • Bottom… Read More »
1. Lubricate piston pin, pin bore in piston, and bushing in rod with engine oil. 2. Install new bolts in rod and install rod cap. 3. Start pin and piston bore. 4. Position piston on rod. Relief in piston crown and rod bearing tangs/notches must be aligned (Figure 2-122). 5. Push piston pin through rod… Read More »
Production engines are equipped with different grade size pistons. The different grades allow factory select fitting of pistons. Correctly, three grades are used with the ID letters JT, KT, and GT or J, K, G, or T. The different grades are to accommodate minor variances in bore size. The ID letters are on the cylinder… Read More »
Remove and discard the old piston rings. Use a remover/installer tool similar to parallel jaw type tool shown (Figure 2-116). Discard rings after removal. Use a ring groove tool to remove carbon and oil deposits from the ring grooves. Using a section from an old piston ring is not recommended for this purpose. Disassembly the… Read More »
There are three main journal diameter ranges. These ranges are identified by a color code paint mark near one of the journals. The three size range color codes are blue, orange/red, and white. Note the code on the crankshaft and refer to the specification charts at the end of this section for size ranges. Use… Read More »
Clean the crankshaft with solvent and clear the journal oil holes with a wire brush if necessary. Dry the crankshaft with compressed air or lint free shop towels. Inspect condition of rod and main journals (Figure 2-113). The journals must be smooth and free from scoring, grooves, taper, cracks, and checking/galling. Minor nicks and burrs… Read More »
1. Remove camshaft plug at rear of block (Figure 2-109). Use long wood dowel or pipe tool and hammer to tap plug out rear of block. Discard plug afterward. It is not reusable. 2. Remove No. 2 bearing as follows: a. Insert pilot from tool set J–33049 in No. 1 bearing (Figure 2-109). b. Slide… Read More »
Camshaft bearing tool set J–33049 plus adapters J–6098-11 and J–6098-12 and tool set J–6098-01 are required for bearing replacement. During removal, bearings 1 and 5 are removed last because they must be in place to support the pilot tool. For this reason, these bearings must be installed first during replacement. The front (no. 1) bearing… Read More »