Modern Automotive Technology xxv
Grinding Valve Seats . . . . . . . . . . . . . . . . . . . 1182
Cutting Valve Seats. . . . . . . . . . . . . . . . . . . . . 1183
Checking Seat Concentricity and Width . . . 1183
Narrowing Valve Seats . . . . . . . . . . . . . . . . . 1185
Moving the Seat Contact Point. . . . . . . . . . . 1185
Valve Retrusion. . . . . . . . . . . . . . . . . . . . . . . . 1185
Valve Seat Replacement. . . . . . . . . . . . . . . . . 1186
Valve Seat Machine. . . . . . . . . . . . . . . . . . . . . . . . 1187
Grinding Engine Valves . . . . . . . . . . . . . . . . . . . . 1187
Valve Grinding Machine . . . . . . . . . . . . . . . . 1188
Valve Grinder Setup. . . . . . . . . . . . . . . . . . . . 1188
Grinding Valve Faces . . . . . . . . . . . . . . . . . . . 1189
Grinding Valve Stem Tips . . . . . . . . . . . . . . . 1190
Checking Valve-to-Seat Contact . . . . . . . . . . 1190
Valve Spring Service . . . . . . . . . . . . . . . . . . . . . . . 1193
Inspecting Valve Springs . . . . . . . . . . . . . . . . 1193
Shimming Valve Springs . . . . . . . . . . . . . . . . 1193
Cylinder Head Reassembly . . . . . . . . . . . . . . . . . 1195
Installing Valve Seals . . . . . . . . . . . . . . . . . . . 1195
Installing Valve Springs. . . . . . . . . . . . . . . . . 1196
Checking for Valve Leakage . . . . . . . . . . . . . 1198
In-Vehicle Valve Seal Service. . . . . . . . . . . . . . . . 1199
Camshaft Service. . . . . . . . . . . . . . . . . . . . . . . . . . 1199
Measuring Camshaft Wear . . . . . . . . . . . . . . 1199
Camshaft Grinding. . . . . . . . . . . . . . . . . . . . . 1200
Installing an Overhead Valve Camshaft . . . 1201
Camshaft End Play. . . . . . . . . . . . . . . . . . . . . 1201
OHC Bearing Service . . . . . . . . . . . . . . . . . . . . . . 1201
Rocker Assembly Service. . . . . . . . . . . . . . . . . . . 1202
Rocker Arm Stud Service. . . . . . . . . . . . . . . . 1203
Push Rod Service. . . . . . . . . . . . . . . . . . . . . . . . . . 1203
Lifter (Tappet) and Follower Service . . . . . . . . . 1203
Inspecting Lifters . . . . . . . . . . . . . . . . . . . . . . 1204
Testing Lifter Leak-Down Rate. . . . . . . . . . . 1204
Rebuilding Hydraulic Lifters
and Followers . . . . . . . . . . . . . . . . . . . . . . . 1204
Bleeding Cam Followers . . . . . . . . . . . . . . . . 1204
Chapter 60
Engine Front End Service . . . . . . . . . . . . . . . . 1209
Timing Chain Service . . . . . . . . . . . . . . . . . . . . . . 1209
Timing Chain Problems. . . . . . . . . . . . . . . . . 1210
Inspecting a Timing Chain . . . . . . . . . . . . . . 1210
Installing a Timing Chain . . . . . . . . . . . . . . . 1211
Installing a Chain Tensioner . . . . . . . . . . . . . 1212
Installing an Oil Slinger. . . . . . . . . . . . . . . . . 1212
Engine Front Cover Service. . . . . . . . . . . . . . . . . 1212
Front Seal Service . . . . . . . . . . . . . . . . . . . . . . 1213
Installing a Front Cover. . . . . . . . . . . . . . . . . 1214
Vibration Damper Installation . . . . . . . . . . . . . . 1215
Timing Gear Service . . . . . . . . . . . . . . . . . . . . . . . 1215
Measuring Timing Gear Backlash . . . . . . . . 1215
Replacing Timing Gears . . . . . . . . . . . . . . . . 1216
Measuring Timing Gear Runout . . . . . . . . . 1217
Timing Belt Service . . . . . . . . . . . . . . . . . . . . . . . . 1218
Inspecting the Timing Belt Mechanism. . . . 1218
Installing the Timing Belt Sprockets . . . . . . 1219
Installing the Timing Belt . . . . . . . . . . . . . . . 1220
Adjusting Timing Belt Tension . . . . . . . . . . . 1220
Installing the Timing Belt Cover . . . . . . . . . 1221
Chapter 61
Engine Reassembly, Installation,
and Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . 1225
General Engine Assembly Rules. . . . . . . . . . . . . 1225
Engine Reassembly. . . . . . . . . . . . . . . . . . . . . . . . 1226
Installing the Oil Pump . . . . . . . . . . . . . . . . . 1226
Installing the Oil Pan . . . . . . . . . . . . . . . . . . . 1227
Installing Accessory Units. . . . . . . . . . . . . . . 1227
Cylinder Head Installation . . . . . . . . . . . . . . . . . 1228
Installing the Head Gasket . . . . . . . . . . . . . . 1228
Diesel Cylinder Head Installation . . . . . . . . 1229
Installing the Cylinder Head . . . . . . . . . . . . 1229
Installing and Torquing Head Bolts. . . . . . . 1231
Lifter Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 1232
Intake Manifold Installation . . . . . . . . . . . . . . . . 1232
Inspecting the Intake Manifold . . . . . . . . . . 1233
Installing the Intake Manifold Gasket . . . . 1233
Torquing the Intake Manifold Bolts. . . . . . . 1234
Checking the Engine Thermostat . . . . . . . . . . . . 1235
Exhaust Manifold Installation. . . . . . . . . . . . . . . 1235
Camshaft Housing Installation . . . . . . . . . . . . . . 1237
Overhead Camshaft Installation. . . . . . . . . . . . . 1237
Installing a Camshaft
with One-Piece Bearings . . . . . . . . . . . . . . 1237
Installing a Camshaft
with Two-Piece Bearings . . . . . . . . . . . . . . 1238
Assembling the Valve Train. . . . . . . . . . . . . . . . . 1239
Installing Push Rods and Rocker Arms. . . . 1239
Adjusting Valve Train Clearance . . . . . . . . . 1239
Camshaft and Valve Cover Installation. . . . . . . 1242
Camshaft Cover Installation . . . . . . . . . . . . . 1242
Valve Cover Installation . . . . . . . . . . . . . . . . 1242
Painting the Engine. . . . . . . . . . . . . . . . . . . . . . . . 1244
Final Engine Assembly. . . . . . . . . . . . . . . . . . . . . 1245
Installing External Engine Parts. . . . . . . . . . 1246
Installing the Engine Flywheel. . . . . . . . . . . 1246
Camshaft Position Sensor Indexing. . . . . . . 1247
Installing the Clutch. . . . . . . . . . . . . . . . . . . . 1247
Installing the Torque Converter . . . . . . . . . . 1248
Servicing Hybrid Motor-Generators . . . . . . 1248
Installing the Transmission or Transaxle. . . 1248