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Zenith ZPP 428 Service Manual

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Z P P 4 2 8
ZPP 428 ENGINE.................................................................. 1
ENGINE ........................................................................2
LUBRICATION SYSTEM .............................................2
CYLINDER BLOCK.......................................................5
CYLINDER HEAD .........................................................5
CRANKSHAFT .............................................................5
PISTON AND CONNECTING ROD .............................6
CAMSHAFT ..................................................................6
ROCKERARM ..............................................................6
VALVES .......................................................................6
VALVE SPRING ...........................................................7
CYLINDER HEAD COVER ..........................................7
HYDRAULIC TAPPET ..................................................7
VALVE GUIDE .............................................................7
OIL PAN .......................................................................7
VALVE STEM SEAL ....................................................8
INTAKE MANIFOLD .....................................................8
EXHAUST MANIFOLD ................................................. 8
ENGINE DIAGNOSIS-INTRODUCTION ...................8
SERVICE DIAGNOSIS-MECHANICAL ...................................10
INTAKE MANIFOLD LEAKAGE DIAGNOSIS ......................13
DIAGNOSIS .............................................................13
LEAKAGE TEST .........................................................................................13
ENGINE OIL LEAK INSPECTION ...................................................14
ENGINE OIL PRESSURE ............................................15
VALVE TIMING ...................................................................................................15
VALVE, GUIDE AND SEAL ....................................................................15
PISTON-FITTING .........................................................................................17
PISTON RING-FITTING .........................................................................18
FORM-IN-PLACE GASKETS......................................25
ENGINE PERFORMANCE ........................................26
HONING CYLINDER BORES ....................................26
ENGINE
T A B L E O F C O N T E N T S
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TABLE OF CONTENTS

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HYDROSTATIC LOCK ...............................................27
ENGINE OIL SERVICE ................................................27
ENGINE MOUNTS-FRONT .....................................29
ENGINE MOUNT-REAR ..........................................30
ENGINE ......................................................................31
INTAKE MANIFOLD ...................................................33
EXHAUST MANIFOLD ...............................................35
CYLINDER HEAD COVER ........................................35
ROCKER ARMS AND PUSH RODS .........................36
VALVE SPRING AND SEAL ......................................37
CYLINDER HEAD .......................................................38
CYLINDER HEAD .......................................................40
HYDRAULIC TAPPETS ..............................................40
VIBRATION DAMPER.................................................41
TIMING CASE COVER OIL SEAL .............................41
TIMING CASE COVER ..............................................42
TIMING CHAIN AND SPROCKETS ...........................43
CAMSHAFT ................................................................44
CAMSHAFT PIN REPLACEMENT .............................45
CAMSHAFT BEARINGS ............................................47
CRANKSHAFT MAIN BEARINGS .............................47
OIL PAN .....................................................................49
OIL PUMP ..................................................................50
PISTON AND CONNECTING ROD ...........................51
REAR MAIN OIL SEAL .................................................52
CYLINDER BLOCK .......................................................53
ROCKER ARMS AND PUSH RODS .........................53
ENGINE CYLINDER HEAD ........................................54
CYLINDER BLOCK .......................................................54
ENGINE SPECIFICATIONS........................................55
SPECIFICATIONS-TORQUE ....................................59
2.8L ENGINE SPECIAL TOOLS ................................60
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Summary of Contents for Zenith ZPP 428

  • Page 1: Table Of Contents

    Z P P 4 2 8 ENGINE T A B L E O F C O N T E N T S page ZPP 428 ENGINE..............1 Z P P 4 2 8 E N G I N E TABLE OF CONTENTS page...

  • Page 2: Zpp 428 Engine

    9 - 2 ZPP 428 ENGINE D E S C R I P T I O N A N D O P E R A T I O N E N G I N E DESCRIPTION The 2.8 liter (169 CID) four-cylinder engine is an In-line, lightweight, overhead valve engine.
  • Page 3 Z P P 4 2 8 E N G I N E 9 - 3 DESCRIPTION AND OPERATION (Continued) sprocket to the timing chain. Oil drains back to the oil hole in the corresponding rocker arm. Oil from the pan under the number one main bearing cap. rocker arm lubricates the valve train components, then The oil supply for the rocker arms and bridged pivot passes down through the push rod guide holes in the...
  • Page 4 9 - 4 Z P P 4 2 8 E N G I N E D E S C R I P T I O N A N D O P E R A T I O N ( C o n t i n u e d ) O i l L u b r i c a t i o n S y s t e m —...

  • Page 5: Cylinder Block

    ZPP 428 ENGINE 9 - 5 D E S C R I P T I O N A N D O P E R A T I O N ( C o n t i n u e d )

  • Page 6: Piston And Connecting Rod

    9 - 6 ZPP 428 ENGINE D E S C R I P T I O N A N D O P E R A T I O N ( C o n t i n u e d )

  • Page 7: Valve Spring

    ZPP 428 ENGINE 9-7 D E S C R I P T I O N A N D O P E R A T I O N ( C o n t i n u e d ) VALVE SPRING...

  • Page 8: Valve Stem Seal

    9 - 8 ZPP 428 ENGINE D E S C R I P T I O N A N D O P E R A T I O N ( C o n t i n u e d )

  • Page 9: Service Diagnosis-Performance

    Z P P 4 2 8 E N G I N E 9 - 9 D I A G N O S I S A N D T E S T I N G ( C o n t i n u e d ) S E R V I C E D I A G N O S I S —...

  • Page 10: Service Diagnosis-Mechanical

    9 - 1 0 Z P P 4 2 8 E N G I N E D I A G N O S I S A N D T E S T I N G ( C o n t i n u e d ) CONDITION POSSIBLE CAUSES CORRECTION...
  • Page 11 Z P P 4 2 8 E N G I N E 9 - 1 1 D I A G N O S I S A N D T E S T I N G ( C o n t i n u e d ) CONDITION POSSIBLE CAUSES CORRECTION...

  • Page 12: Oil Leaks

    9 - 1 2 Z P P 4 2 8 E N G I N E D I A G N O S I S A N D T E S T I N G ( C o n t i n u e d ) CONDITION POSSIBLE CAUSES CORRECTION...

  • Page 13: Intake Manifold Leakage Diagnosis

    ZPP 428 ENGINE 9 - 13 D I A G N O S I S A N D T E S T I N G ( C o n t i n u e d ) INTAKE MANIFOLD LEAKAGE DIAGNOSIS dures outlined in Cylinder Compression Pressure Test.

  • Page 14: Engine Oil Leak Inspection

    9 - 14 ZPP 428 ENGINE D I A G N O S I S A N D T E S T I N G ( C o n t i n u e d ) CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART...

  • Page 15: Engine Oil Pressure

    ZPP 428 ENGINE 9 - 15 D I A G N O S I S A N D T E S T I N G ( C o n t i n u e d ) filter runoff, and main bearing cap to cylinder block pointer indicates 0.305 mm (0.012 inch) travel distance...
  • Page 16 9 - 16 ZPP 428 ENGINE S E R V I C E P R O C E D U R E S ( C o n t i n u e d ) NOTE: If the valve guides are reamed oversize, the valve seats must be ground to ensure that the valve seat is concentric to the valve guide.

  • Page 17: Piston-Fitting

    Z P P 4 2 8 E N G I N E 9 - 1 7 S E R V I C E P R O C E D U R E S ( C o n t i n u e d ) inch).

  • Page 18: Piston Ring-Fitting

    9 - 1 8 Z P P 4 2 8 E N G I N E S E R V I C E P R O C E D U R E S ( C o n t i n u e d ) PISTON SIZE CHART CYLINDER BORE SIZE PISTON LETTER SIZE...

  • Page 19: Specification

    Z P P 4 2 8 E N G I N E 9 - 1 9 S E R V I C E P R O C E D U R E S ( C o n t i n u e d ) Fig.
  • Page 20 9 - 2 0 Z P P 4 2 8 Fig. 23 Top Compression ring identification 1 – TOP COMPRESSION RING Fig. 26 Compression Ring Installation 1 – COMPRESSION RING 2 – RING EXPANDER RECOMMENDED Fig. 24 Second Compression Ring Identification 1 –...

  • Page 21: Connecting Rod Bearings-Fitting

    Z P P 4 2 8 E N G I N E 9 - 2 1 S E R V I C E P R O C E D U R E S ( C o n t i n u e d ) C O N N E C T I N G R O D B E A R I N G S —...

  • Page 22: Crankshaft Journal

    9 - 2 2 Z P P 4 2 8 E N G I N E S E R V I C E P R O C E D U R E S ( C o n t i n u e d ) Engine Specifications for the proper clearance.

  • Page 23: Fitting Crankshaft Main Bearings

    ZPP 428 ENGINE 9 - 23 S E R V I C E P R O C E D U R E S ( C o n t i n u e d ) (11) FOR EXAMPLE: If the initial clearance was 0.0762 mm (0.003 inch), 0.025 mm (0.001 inch)
  • Page 24 9 - 24 ZPP 428 ENGINE S E R V I C E P R O C E D U R E S ( C o n t i n u e d ) NOTE: When replacing inserts, the odd size inserts ing inserts is not necessary.

  • Page 25: Form-In-Place Gaskets

    ZPP 428 ENGINE 9 - 25 S E R V I C E P R O C E D U R E S ( C o n t i n u e d ) MAIN BEARING FITTING CHART CRANKSHAFT JOURNALS...

  • Page 26: Engine Performance

    9 - 2 6 Z P P 4 2 8 E N G I N E S E R V I C E P R O C E D U R E S ( C o n t i n u e d ) ZPP Silicone Rubber Adhesive Sealant should be abrasive materials from entering the crankshaft area.

  • Page 27: Zpp 428 Engine

    ZPP 428 ENGINE 9 - 27 S E R V I C E P R O C E D U R E S ( C o n t i n u e d ) to wash parts with a solution of hot water and deter-gent.

  • Page 28: Engine Oil Change

    9 - 28 ZPP 428 ENGINE S E R V I C E P R O C E D U R E S ( C o n t i n u e d ) (5) Remove dipstick, with handle held above the tip, note oil level reading (Fig.

  • Page 29: Engine Oil Filter Change

    All ZPP engines are equipped with a high quality full-flow, throw-away type oil filter. Zenith Power Fig. 41 Oil Filter Sealing Surface—Typical Products recommends a ZPP or equivalent oil filter be 1 –...

  • Page 30: Engine Mount-Rear

    9 - 3 0 Z P P 4 2 8 E N G I N E R E M O V A L A N D I N S T A L L A T I O N ( C o n t i n u e d ) Fig.

  • Page 31: Automatic Transmission

    Z P P 4 2 8 E N G I N E 9 - 3 1 R E M O V A L A N D I N S T A L L A T I O N ( C o n t i n u e d ) Fig.
  • Page 32 9 - 3 2 Z P P 4 2 8 E N G I N E R E M O V A L A N D I N S T A L L A T I O N ( C o n t i n u e d ) (9) Remove fan assembly and install a 5/16 x 1/2-inch SAE capscrew through fan pulley into water pump flange.

  • Page 33: Intake Manifold

    Z P P 4 2 8 E N G I N E 9 - 3 3 R E M O V A L A N D I N S T A L L A T I O N ( C o n t i n u e d ) (32) Raise the engine slightly off the front sup-ports.
  • Page 34 9 - 34 Z P P 4 28 ENG IN E R E M O V A L A N D I N S T A L L A T I O N ( C o n t i n u e d ) (5) Perform fuel system pressure release procedure (refer to Group 14, Fuel System for correct procedure).

  • Page 35: Exhaust Manifold

    Z P P 4 2 8 E N G I N E 9 - 3 5 R E M O V A L A N D I N S T A L L A T I O N ( C o n t i n u e d ) (10) Install the power steering pump and bracket assembly to the water pump and intake manifold.

  • Page 36: Rocker Arms And Push Rods

    9 - 36 ZPP 428 ENGINE REMOVAL (1) Remove the engine cylinder head cover. (Refer to procedure in this section) (2) Check for rocker arm bridges which are causing misalignment of the rocker arm to valve tip area. (3) Remove the capscrews at each bridge and pivot assembly (Fig.

  • Page 37: Valve Spring And Seal

    ZPP 428 ENGINE 9-37 R E M O V A L A N D I N S T A L L A T I O N ( C o n t i n u e d ) pivot contacts. Install rocker arms, pivots and bridge above each cylinder in their original position.

  • Page 38: Cylinder Head

    9 - 3 8 Z P P 4 2 8 E N G I N E R E M O V A L A N D I N S T A L L A T I O N ( C o n t i n u e d ) (9) Install the engine cylinder head cover.
  • Page 39 Z P P 4 2 8 E N G I N E 9 - 3 9 R E M O V A L A N D I N S T A L L A T I O N ( C o n t i n u e d ) Fig.

  • Page 40: Cylinder Head

    9 - 4 0 Z P P 4 2 8 E N G I N E R E M O V A L A N D I N S T A L L A T I O N ( C o n t i n u e d ) LINE WITH THE FAN.

  • Page 41: Vibration Damper

    ZPP 428 ENGINE 9 - 41 R E M O V A L A N D I N S T A L L A T I O N ( C o n t i n u e d ) Fig. 61 Vibration Damper Removal Tool 7697 1 –...

  • Page 42: Timing Case Cover

    9 - 4 2 Z P P 4 2 8 E N G I N E R E M O V A L A N D I N S T A L L A T I O N ( C o n t i n u e d ) Fig.

  • Page 43: Timing Chain And Sprockets

    Z P P 4 2 8 E N G I N E 9 - 4 3 R E M O V A L A N D I N S T A L L A T I O N ( C o n t i n u e d ) (6) Install the timing case cover-to-cylinder block and the oil pan-to-timing case cover bolts.

  • Page 44: Camshaft Sprocket

    9 - 4 4 Z P P 4 2 8 E N G I N E R E M O V A L A N D I N S T A L L A T I O N CAM SHAFT R E M O V A L WARNING: THE COOLANT IN A RECENTLY OPER- ATED ENGINE IS HOT AND PRESSURIZED.

  • Page 45: Camshaft Pin Replacement

    Z P P 4 2 8 E N G I N E 9 - 4 5 R E M O V A L A N D I N S T A L L A T I O N ( C o n t i n u e d ) (2) Inspect the bearing journals for uneven wear pattern or finish.
  • Page 46 9 - 4 6 Z P P 4 2 8 E N G I N E R E M O V A L A N D I N S T A L L A T I O N ( C o n t i n u e d ) (a) Remove the A/C compressor serpentine drive belt idler pulley.

  • Page 47: Camshaft Bearings

    Z P P 4 2 8 E N G I N E 9 - 4 7 R E M O V A L A N D I N S T A L L A T I O N ( C o n t i n u e d ) (17) If equipped with air conditioning: (a) Install the A/C compressor serpentine drive belt idler pulley.
  • Page 48 9 - 48 Z P P 4 28 ENG IN E R E M O V A L A N D I N S T A L L A T I O N ( C o n t i n u e d ) Fig.

  • Page 49: Oil Pan

    Z P P 4 2 8 E N G I N E 9 - 4 9 R E M O V A L A N D I N S T A L L A T I O N ( C o n t i n u e d ) (9) Push the crankshaft forward and backward.

  • Page 50: Oil Pump

    9 - 5 0 Z P P 4 2 8 E N G I N E R E M O V A L A N D I N S T A L L A T I O N ( C o n t i n u e d ) Fig.

  • Page 51: Piston And Connecting Rod

    Z P P 4 2 8 E N G I N E 9 - 5 1 R E M O V A L A N D I N S T A L L A T I O N ( C o n t i n u e d ) I N S T A L L A T I O N through an inlet tube and strainer assembly that is pressed into the pump body.

  • Page 52: Rear Main Oil Seal

    9 - 5 2 Z P P 4 2 8 E N G I N E R E M O V A L A N D I N S T A L L A T I O N ( C o n t i n u e d ) Fig.

  • Page 53: Disassembly And Assembly

    ZPP 428 ENGINE 9 - 53 R E M O V A L A N D I N S T A L L A T I O N ( C o n t i n u e d ) (4) Remove the vibration damper.

  • Page 54: Engine Cylinder Head

    9 - 54 ZPP 428 ENGINE C L E A N I N G A N D I N S P E C T I O N ( C o n t i n u e d ) Inspect the valve stem tip contact surface of each rocker arm and replace any rocker arm that is deeply pitted.

  • Page 55: Specifications Engine Specifications

    Z P P 4 2 8 E N G I N E 9 - 5 5 S P E C I F I C A T I O N S DESCRIPTION SPECIFICATION ENGINE SPECIFICATIONS Bearing Journal Diameter ENGINE DESCRIPTION No. 1 51.54-51.56mm (2.029 - 2.030 in.) DESCRIPTION...
  • Page 56 9 - 5 6 Z P P 4 2 8 E N G I N E S P E C I F I C A T I O N S ( C o n t i n u e d ) DESCRIPTION SPECIFICATION DESCRIPTION...
  • Page 57 Z P P 4 2 8 E N G I N E 9 - 5 7 S P E C I F I C A T I O N S ( C o n t i n u e d ) DESCRIPTION SPECIFICATION DESCRIPTION...
  • Page 58 9 - 5 8 Z P P 4 2 8 E N G I N E S P E C I F I C A T I O N S ( C o n t i n u e d ) DESCRIPTION SPECIFICATION DESCRIPTION...

  • Page 59: Specifications-Torque

    Z P P 4 2 8 E N G I N E 9 - 5 9 S P E C I F I C A T I O N S ( C o n t i n u e d ) S P E CI F I C A T I O N S —...

  • Page 60: Special Tools

    9 - 6 0 Z P P 4 2 8 E N G I N E _________________________________________________________________________________ S P E C I A L T O O L S 2 . 8 L E N G I N E S P E C I A L T O O L S Vibration Damper Removal Tool 7697 Valve Spring Compressor Tool MD-998772A Rear Main Seal Installer Tool 6271A...

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