Piston: Service and Repair
1. Disconnect distributor electrical connections, then remove distributor mounting bolts and distributor.
2. Loosen water pump pulley attaching bolts, then remove drive belt and alternator.
3. Disconnect hoses, lines and electrical connections, then remove intake manifold attaching bolts and the intake manifold.
4. Remove alternator mounting bracket, then the PCV connector and harness clamp.
5. Remove oil filler duct and water pipe.
6. Lock flywheel or drive plate with suitable tool to prevent crankshaft rotation, then remove crankshaft pulley attaching bolt and the crankshaft pulley.
7. Remove water pump pulley and cover, then the oil dipstick and tube.
8. Remove timing belts and covers as outlined previously.
9. Remove water pump together with hose.
Fig. 31 Crankcase & oil pump. 6-163/2700cc engine:
10. Remove oil pump mounting bolts, then the oil pump together with filter, Fig. 31.
11. Remove oil pump outer rotor from crankcase.
12. On manual transmission equipped vehicles, remove clutch pressure plate and disc.
13. Remove flywheel or drive plate, then the flywheel housing.
14. Remove cylinder heads as previously described.
15. Remove oil pan attaching bolts, then the oil pan. Do not remove oil strainer from crankcase.
16. Remove oil separator cover from rear of crankcase.
17. Remove service access plugs from both sides of front of crankcase.
18. Rotate crankshaft until pistons for No. 1 and No. 2 cylinders are at BDC.
19. Working through access holes, remove piston pin circlips for No. 1 and No. 2 pistons.
20. Using piston pin remover 499097300 or equivalent, withdraw piston pins for No. 1 and No. 2 pistons.
21. Repeat steps 17 through 19 for cylinders 5 and 6 and 3 and 4 respectively.
22. Remove all crankcase half retaining bolts except the one bolt for No. 3 cylinder.
Fig. 31 Crankcase & oil pump. 6-163/2700cc engine:
23. Position crankcase so that cylinders 1, 3 and 5 face upward, then separate crankcase halves, Fig. 31.
24. Remove coolant passage O-ring and back-up ring from crankcase, then the front and rear oil seals from crankshaft.
25. Remove crankshaft and connecting rod assembly.
26. Mark and remove pistons from crankcase halves, and mate pistons with respective pins. Keep all components in order to ensure proper assembly. Components that are to be reused should be installed in original position.
27. Remove main bearings from crankcase halves.
28. Ensure all components are clean and free from foreign material, and that oil passages are clear. Coat all friction surfaces with oil or suitable assembly lubricant.
29. Seat bearings in connecting rods and rod caps, then install connecting rods on crankshaft noting the following:
a. Ensure connecting rod and cap matching marks are aligned, and install connecting rod assemblies with crescent shaped mark facing forward.
b. Lubricate connecting rod bolt threads and ensure bolts are properly seated in cap and that caps are fully seated against connecting rods.
c. Evenly tighten connecting rod nuts until specified torque value is obtained.
30. Install main bearings into crankcase halves.
31. Install crankshaft into lefthand crankcase, then fit O-ring and backup ring to crankcase coolant passage.
32. Clean crankcase half mating surfaces with suitable solvent, then apply a thin bead of Three-Bond 1215 sealant or equivalent to one crankcase half. Ensure sealant does not enter oil or coolant passages.
Fig. 31 Crankcase & oil pump. 6-163/2700cc engine:
33. Guide righthand crankcase half onto left case, then install retaining bolts and torque to specifications shown in Fig. 31. Ensure O-ring is correctly positioned in groove.
Fig. 10 Piston Ring Installation:
34. Install piston rings onto pistons, positioning end gaps as shown, Fig. 32. After installation, bend pawl of upper oil ring rail upward and attach to hole in piston, Fig. 32.
35. Install pistons into cylinders as follows:
a. With No. 5 and 6 cylinders facing downward, turn crankshaft until No. 3 and 4 connecting rods are positioned at BDC.
b. Insert No. 4 piston into cylinder, align piston pin hole and connecting rod small end with pin guide 499017000 or equivalent, then install piston pin through access hole.
c. Install piston pin circlip, ensuring ends face outward.
d. Install remaining pistons in the following order: Nos. 3, 1, 2, 5 and 6. Ensure connecting rods are positioned at BDC before installation, and that circlip ends face outward.
36. Coat service access hole plug threads with Three-Bond 1205 sealant or equivalent, then install plugs using new gasket and torque to 46-56 ft.lbs.
37. Coat outside surface of front and rear seals with engine oil, and seal lips with grease, then install front and rear oil seals using suitable tool.
38. Install oil separator cover using new gasket, then torque attaching bolts to 4 ft.lbs.
39. Install flywheel housing and torque attaching bolts to 25-30 ft.lbs.
40. Install oil pan and torque attaching bolts to 4 ft.lbs.
41. Install cylinder heads as previously described.
42. Install flywheel or drive plate and torque attaching bolts to 51-55 ft.lbs.
43. On manual transmission equipped vehicles, install clutch disc and pressure plate, then diagonally torque attaching bolts to 10-12 ft.lbs. When installing pressure plate, ensure ``0'' marks on pressure plate and flywheel are positioned at least 120° apart.
44. Install water pump using new gasket and seal.
Fig. 33 Installing oil pump. 6-163/2700cc engine:
45. Install oil pump assembly as follows:
a. Apply a small amount of Three-Bond 1207B sealant or equivalent to crankcase as indicated by arrows in Fig. 33. Ensure no excess sealant enters rotor chamber.
b. Apply engine oil to rotor housing, then install outer rotor into housing and position as shown, Fig. 33.
c. Position oil pump pulley as shown, then install oil pump assembly.
46. Install valve lash adjusters, rockers, camshaft cases and rocker covers as outlined previously.
47. Install timing belts and center belt cover as previously described.
48. Lock crankshaft at flywheel, then install crankshaft pulley and torque attaching bolt to 72 ft.lbs.
49. Install pulley and pulley cover to water pump, then tighten bolts temporarily.
50. Apply engine oil to O-ring on dipstick tube, then install dipstick tube and dipstick.
51. Install oil filler duct and bracket.
52. Install water pump, water bypass pipe, hose and water pipe using new O-rings.
53. Install knock sensor, if removed, then the alternator brackets.
54. Install PCV connector and harness clamp.
55. Install intake manifold, then reconnect hoses, lines and electrical connections.
56. Install alternator.
Fig. 23 Positioning No. 1 Cylinder At TDC:
57. Position No. 1 cylinder at TDC, ensuring camshaft sprocket timing marks are positioned as shown, Fig. 29.
58. Align mark on distributor housing with mark on distributor gear, then install distributor and mounting bolt.
59. Reconnect distributor electrical wiring, then install left and right timing covers.
60. Install drive belt, then turn adjuster screw on tensioner to tighten belt to 143-165 lbs. for new belt, or 99-143 lbs. for used belt. After adjustment is completed, torque tensioner lock nut to 29 ft.lbs. and water pump pulley attaching bolts to 7 ft.lbs.