SECTION 6A3 - ENGINE MECHANICAL -
GEN III V8 ENGINE
1. GENERAL DESCRIPTION
1.1 SERVICE INFORMATION
1.2 ENGINE SERIAL NUMBER
1.3 ENGINE CONSTRUCTION
CYLINDER BLOCK
CYLINDER HEADS
VALVE TRAIN
CRANKSHAFT
PISTONS AND CONNECTING RODS
CAMSHAFT AND DRIVE
INTAKE MANIFOLD
EXHAUST MANIFOLD
ACCESSORY DRIVE
OIL PAN
1.4 ENGINE LUBRICATION SYSTEM
OIL PUMP
CRANKSHAFT OIL SEALS
POSITIVE CRANKCASE VENTILATION SYSTEM
1.5 SERVICE NOTES
CLEANLINESS AND CARE
REPLACING ENGINE GASKETS
USE OF RTV AND ANAEROBIC SEALER
SEPARATING PARTS
TOOLS AND EQUIPMENT
FASTENERS
2. MINOR SERVICE OPERATIONS
2.1 ENGINE OIL LEVEL CHECK
2.2 ENGINE OIL - CHANGE
2.3 ENGINE OIL FILTER & ADAPTOR
REPLACE
2.4 ENGINE OIL PRESSURE - CHECK
2.5 COMPRESSION CHECK
INTERPRETING COMPRESSION READINGS
2.6 ENGINE DRIVE BELTS - REPLACE
ENGINE ACCESSORY BELT
AIR CONDITIONING COMPRESSOR BELT
2.7 ACCESSORY BELT IDLER PULLEY
REPLACE
2.8 A/C BELT IDLER PULLEY
REPLACE
2.9 ACCESSORY BELT TENSIONER
REPLACE
2.10 A/C BELT TENSIONER
REPLACE
2.11 OIL PRESSURE SENSOR
REPLACE
2.12 MANIFOLD ABSOLUTE PRESSURE SENSOR
REPLACE
2.13 FUEL SYSTEM PRESSURE RELIEF
2.14 INTAKE MANIFOLD
REMOVE
DISASSEMBLE
CLEAN AND INSPECT
REASSEMBLE
REINSTALL
2.15 VAPOUR VENT PIPE
REMOVE
REINSTALL
2.16 ENGINE VALLEY COVER
REMOVE
CLEAN AND INSPECT
REINSTALL
2.17 VALVE ROCKER ARM COVER
REMOVE
CLEAN AND INSPECT
REINSTALL
2.18 VALVE ROCKER ARMS & PUSH RODS
REMOVE
CLEAN AND INSPECT
REINSTALL
2.19 VALVE STEM OIL SEAL AND/OR VALVE SPRING
REPLACE
2.20 OIL LEVEL INDICATOR AND TUBE
REMOVE AND REINSTALL
2.21 EXHAUST MANIFOLD
REMOVE
INSPECT
REINSTALL
2.22 CYLINDER HEAD
REMOVE
DISASSEMBLE
CLEAN
INSPECT
REASSEMBLE
REINSTALL
2.23 VALVE LIFTERS
REMOVE
DISASSEMBLE
CLEAN AND INSPECT
REASSEMBLE
TEST LIFTER LEAKDOWN RATE
REINSTALL
2.24 CRANKSHAFT BALANCER
REMOVE
CLEAN AND INSPECT
REINSTALL
2.25 COOLANT PUMP
REMOVE
DISMANTLE
CLEAN AND INSPECT
REASSEMBLE
REINSTALL
2.26 CRANKSHAFT FRONT OIL SEAL
REPLACE
2.27 ENGINE MOUNTS
CHECK
REMOVE
REINSTALL
3. MAJOR SERVICE OPERATIONS
3.1 ENGINE ASSEMBLY
REMOVE
DISASSEMBLE
REASSEMBLE
REINSTALL, SET-UP AND TESTING
3.2 CAMSHAFT LOBE LIFT
MEASURE
3.3 OIL PAN
REMOVE
DISASSEMBLE
CLEAN AND INSPECT
REASSEMBLE
REINSTALL
Techline
Techline
Techline
Techline
Techline
Techline
Techline
Techline
Techline
Techline
3.4 ENGINE FRONT COVER
REMOVE
CLEAN AND INSPECT
REINSTALL
CRANKSHAFT FRONT SEAL - REINSTALL
3.5 ENGINE FLYWHEEL/FLEXPLATE
REMOVE
CLEAN AND INSPECT
REINSTALL
3.6 ENGINE FLYWHEEL RING GEAR
REPLACE
3.7 CRANKSHAFT SPIGOT BUSH
REPLACE
3.8 ENGINE REAR COVER
REMOVE
CLEAN AND INSPECT
REINSTALL
CRANKSHAFT REAR SEAL - INSTALL
3.9 OIL PUMP, PUMP SCREEN AND DEFLECTOR
REMOVE
OIL PUMP DISASSEMBLE
CLEAN AND INSPECT
OIL PUMP REASSEMBLE
REINSTALL
3.10 TIMING CHAIN AND SPROCKETS
REMOVE
CLEAN AND INSPECT
REINSTALL
3.11 CAMSHAFT
REMOVE
CLEAN AND INSPECT
REINSTALL
3.12 PISTON, CONNECTING ROD AND BEARING
REMOVE
DISASSEMBLE
CLEAN AND INSPECT
REASSEMBLE
REINSTALL
3.13 CRANKSHAFT AND BEARINGS
REMOVE
CLEAN AND INSPECT
REINSTALL
3.14 ENGINE BLOCK PLUGS
REMOVE
REINSTALL
3.15 CYLINDER BLOCK
CAMSHAFT BEARINGS - REPLACE
CYLINDER BLOCK CLEAN, INSPECT AND
MEASURE
CYLINDER BORING AND HONING
3.16 THREAD REPAIR
GENERAL INFORMATION
GENERAL THREAD REPAIR
CYLINDER HEAD BOLT HOLE THREAD
REPAIR
MAIN CAP BOLT HOLE THREAD REPAIR
3.17 THREAD REPAIR SPECIFICATIONS
ENGINE BLOCK - FRONT VIEW
ENGINE BLOCK - REAR VIEW
ENGINE BLOCK - LEFT SIDE VIEW
ENGINE BLOCK - RIGHT SIDE VIEW
ENGINE BLOCK - BOTTOM VIEW
ENGINE BLOCK - TOP VIEW
CYLINDER HEAD - TOP VIEW
CYLINDER HEAD - END VIEW
CYLINDER HEAD - EXHAUST MANIFOLD
SIDE VIEW
CYLINDER HEAD - INTAKE MANIFOLD
SIDE VIEW
4. DIAGNOSIS
4.1 BASIC ENGINE MISFIRE DIAGNOSIS
GENERAL INFORMATION
DIAGNOSTIC PROCEDURE
4.2 ENGINE NOISE DIAGNOSIS
4.3 VALVE TRAIN DIAGNOSIS
GENERAL INFORMATION
DIAGNOSTIC PROCEDURE
DIAGNOSTIC TABLE
4.4 OIL CONSUMPTION DIAGNOSIS
4.5 OIL PRESSURE DIAGNOSIS
4.6 OIL LEAK DIAGNOSIS
5. SPECIFICATIONS
6. TORQUE WRENCH SPECIFICATIONS
7. SPECIAL TOOLS