Related Manuals for Doosan G30P-3
Summarization of Contents
GENERAL INFORMATION
Shop Safety
Safety in the workplace is everyone's responsibility. Pay attention to your actions for personal and collective safety.
Fuel Information
Information regarding the fuel used in the engine, including its properties and safety considerations.
What is LPG?
Explanation of LPG properties, composition, and comparison to gasoline, detailing its characteristics.
Air Temperature Versus Power Output
Explains how intake air temperature affects engine horsepower output due to density changes.
Altitude Versus Power Output
Discusses how altitude affects engine power output due to changes in atmospheric pressure and air density.
General Description & Operation
Overview of engine operation and how its components work together to generate power.
Engine Component Description
Detailed description of key engine components like the block, head, crankshaft, and camshaft.
Lubrication
Explains the engine's lubrication system, oil pump, filter, and oil flow paths.
Thread Repair
Instructions for using thread repair kits, including drilling and tapping procedures.
Replacing Engine Gaskets
Guidelines for removing, cleaning, and installing engine gaskets and sealing surfaces.
Use of RTV and Anaerobic Sealer
Information on using RTV and anaerobic sealers for various engine sealing applications.
Separating Parts
Procedures for marking and organizing engine components during disassembly and reassembly.
Tools and Equipment
Lists special tools and general equipment required for engine service.
SPECIFICATIONS
Technical Data
Provides general technical data about the engine type, displacement, bore, stroke, and other key parameters.
General Description
Lists engine type, combustion system, displacement, bore, stroke, compression ratio, firing order, etc.
Fuel System
Details specifications for both standard and low emission LP fuel systems, including pressures and components.
Cooling System
Specifies cooling system parameters like water pump rotation, thermostat temperatures, and capacity.
Lubrication System
Lists oil pressure, temperature limits, crankcase capacity, and engine oil specifications.
Engine Electrical
Details ignition type, starter motor, alternator, and sensor specifications.
Engine Mechanical Data
Provides specifications for engine mechanical components like bore, stroke, and piston dimensions.
Fastener Tightening Specifications
Lists torque specifications for various engine fasteners, ensuring correct assembly.
Sealers, Adhesives and Lubricants
Specifies part numbers and types of sealants, adhesives, and lubricants for engine assembly.
Piston
Provides specifications for piston-to-bore clearance and related measurements.
Piston Rings
Details specifications for piston ring groove clearance and ring gaps.
Piston Pin
Specifies piston pin diameter and clearance in the piston and connecting rod.
Crankshaft
Specifies dimensions and clearances for crankshaft journals, tapers, and end play.
Connecting Rod
Details specifications for connecting rod journals, bearings, and side clearance.
Camshaft
Provides specifications for camshaft journal diameter, end play, sprocket runout, and lobe lift.
Valve System
Covers valve lifter type, rocker arm ratio, valve lash, and seat specifications.
MAINTENANCE
Shop Safety
Safety in the workplace is everyone's responsibility. Pay attention to your actions for personal and collective safety.
Test fuel system for leaks
Procedures for testing the fuel system for leaks using a soap solution.
Inspect engine for fluid leaks
Steps to inspect the engine for oil and coolant leaks after bringing it to operating temperature.
Engine Crankcase Oil
Information on selecting the proper engine oil based on temperature and viscosity recommendations.
Checking/Filling Engine Oil Level
Detailed steps for correctly checking and filling the engine oil level using the dipstick.
Changing Engine Oil And Filter
Procedure for changing the engine oil and oil filter, emphasizing warm engine operation.
Accessory Drive Belts
Guidance on inspecting and checking the tension of accessory drive belts.
Inspect electrical system
Steps for inspecting the battery, cables, and insulation for damage or corrosion.
Inspect vacuum lines and fittings
Instructions for visually inspecting vacuum lines and fittings for damage like cracks or brittleness.
Inspect fuel lines and fittings
Visual inspection of fuel lines and fittings for physical damage and proper support.
Engine Compression Check
Procedure for checking engine compression in each cylinder and interpreting readings.
Cooling System
General information and caution regarding the engine's cooling system.
Checking coolant Level
Steps for checking the coolant level, with a caution about hot coolant.
Inspect coolant hoses
Visual inspection of coolant hoses and clamps for signs of swelling or cracking.
Inspect ignition system
Steps for inspecting spark plugs, wires, distributor cap, and rotor.
Replace spark plugs
Procedure for removing, gapping, and installing spark plugs.
Replace LP Fuel Filter Element
Steps for replacing the LP fuel filter element in a refueling area.
Test fuel lock (electric)
Procedure for testing the electric fuel lock by locating its electrical connector.
Inspect pressure regulator/vaproizer
Refers to the LP fuel system section for checking the pressure regulator/vaporizer.
Inspect LP mixer (standard LP truck)
Refers to the LP fuel system section for checking the LP mixer.
Inspect variable venturi air/fuel mixer (low emission LP truck)
Refers to the LP fuel system section for checking the variable venturi air/fuel mixer.
Inspect complete exhaust system for leaks, damage
Visual inspection of the exhaust system for leaks or damage.
Engine Control Unit (ECU) and others (low emission LP truck)
Notes that commander, oxygen sensor, and solenoid are not serviceable and must be replaced.
Maintenance Schedule
General Maintenance Section
Details general maintenance tasks and their recommended intervals.
Engine Coolant Section
Outlines maintenance tasks related to the engine coolant system.
Engine Ignition Section
Specifies maintenance for the engine ignition system components.
Fuel Lock-Off/Filter Section
Details maintenance for the fuel lock-off and filter.
Pressure Regulator Section
Outlines maintenance checks for the pressure regulator.
Carburetor Section
Specifies maintenance tasks related to the carburetor.
Engine Exhaust Section (Low Emission Version only)
Details maintenance for the exhaust system in low emission versions.
TROUBLESHOOTING
Engine Performance
Lists symptoms and probable causes for poor engine idle and poor engine acceleration.
Engine Starting Problems
Provides information to help locate starting problems by checking fuel, spark, and compression.
Engine Starting Problems (Continued)
Lists symptoms and causes for 'No spark' and 'Engine will not crank over'.
Charging System Problems
Lists symptoms and causes for no battery charge and noisy alternators.
Instrument Problems
Lists symptoms and causes for malfunctioning instruments or gauges.
Engine Noise
Guide to diagnosing engine noise sources by timing, stethoscope use, and cylinder isolation.
Engine Noise (Continued)
Further lists symptoms and potential causes for various engine noises.
Oil Pressure Diagnostics
Table providing information for checking oil pressure conditions and their implications.
Oil Pressure Problems
Lists symptoms and probable causes for low, high, and excessive oil pressure issues.
Water in Engine
Information on determining water source in the engine and common causes.
Engine Overheating
Lists symptoms and causes for engine overheating, categorized by mechanical or cooling system issues.
LP Fuel system (Sandard and/or Low Emission Version)
A guide to probable causes of engine performance complaints related to carburetion.
Quick Checks for a Stalled Engine
Basic checks for fuel, fuel delivery, and spark when an engine stalls.
Will Not Start/FCV Staying On
Table listing probable causes and solutions for engine not starting or Fuel Control Valve staying on.
Difficult to Start
Table listing probable causes and solutions for an engine that is difficult to start.
Won’t Run Continuously Accelerate/Hesitation During Acceleration
Table listing causes and solutions for engine not running continuously or hesitating.
Engine Stalls
Table listing causes and solutions for the engine stalling.
Engine Stalls (Continued)
Table listing causes and solutions for engine stalling related to pressure regulator, carburetor, and mechanical issues.
Rough Idle/Weak Ignition/Lean Condition
Table listing causes and solutions for rough idle or lean conditions.
High Idle Speed
Table listing causes and solutions for high idle speed.
Carburetor Backfire
Table listing causes and solutions for carburetor backfire.
Poor High Speed Performance/Lean Condition
Table listing causes and solutions for poor high speed performance or lean condition.
Excessive Fuel Consumption/LPG Exhaust Smell/Closed Loop System Not Working
Table listing causes and solutions for excessive fuel consumption or exhaust smell.
STARTING SYSTEM
General Description
Explains the function of the starting motor and solenoid in turning the engine flywheel.
General Information
Describes the four elements of a starting system: ignition switch, start relay, solenoid, and motor.
Typical 12 Volt Starting Circuit
Illustrates and explains a typical 12-volt starting circuit diagram.
Diagnosis Procedure
Procedure for troubleshooting slow cranking or no crank conditions using a multimeter.
Start Relay Tests
Step-by-step procedure for testing the start relay using a multimeter.
Starting Motors
Provides specifications and coverage for starting motors.
Remove & Install Electric Starting Motor
Steps for removing and installing the electric starting motor.
CHARGING SYSTEM
General Description
Explains the function of the alternator in charging the battery during engine operation.
Alternators
Details alternator coverage, including manufacturer, part number, and series.
Remove & Install Alternator
Step-by-step instructions for removing and installing the alternator.
IGNITION SYSTEM
General Information
Introduction to ignition systems and the evolution from breaker points to electronic systems.
Conventional Ignition Systems
Explains the operation and limitations of conventional breaker point ignition systems.
High Energy Ignition Systems
Describes the High Energy Ignition (HEI) system, its benefits, and distributor types.
Module
Explains the function of the electronic module and transistor in controlling primary circuit current.
Pulse Generator
Describes the magnetic pulse generator assembly and its role in timing the primary circuit.
Magnetic Flux Path
Explains the magnetic flux path in the distributor and its relation to electric current generation.
Current Limiting Circuit
Discusses the function of the current limiting circuit in protecting electronic devices.
Dwell Control Circuit
Explains how the dwell control circuit regulates primary current for optimal coil saturation.
Ignition Coil
Details the design and construction of the ignition coil and its impact on system output.
HEl Models
Describes two basic HEI distributor types: integral coil and remotely mounted coil.
Part Identification
Mentions minor differences in HEI system applications and part identification.
Pickup Coil
Explains the pickup coil assembly and its serviceability.
Coil Identification
Identifies remote and integral ignition coils used with EST distributors.
Electronic Spark Timing (EST) Distributor
Introduces the EST distributor system used in G430 engines, highlighting its improvements.
Spark Plug Wires
Describes the construction and handling of spark plug wires.
Resistance Testing
Procedure for testing spark plug wire resistance and replacement criteria.
Spark Advance Curves
Graph showing spark advance curves for the G430 Engine EST Distributor.
Delco Electronic Spark Timing (EST) Distributor Service
General description of the Delco EST ignition system and its components.
General Description
Details the EST ignition system, its distributor, coil, and lack of points.
EST Distributor Component Testing
Instructions for testing ignition coil and distributor components.
Module Testing
Procedure for testing the distributor module using a specified tester.
Pickup Coil Testing
Procedure for testing the pickup coil's continuity and resistance.
Ignition Coil Testing
Procedure for testing the ignition coil's resistance between terminals and to the high-voltage tower.
EST Distributor Removal
Steps for removing the EST distributor, including timing marks and clamp removal.
EST Distributor Disassembly
Detailed steps for disassembling the EST distributor, including component identification.
Cleaning and Inspection
Instructions for cleaning and inspecting distributor housing, gear, shaft, and wires.
EST Distributor Reassembly
Steps for reassembling the EST distributor, including proper lubrication and component placement.
EST Distributor Installation (Engine Not Disturbed)
Steps for installing the distributor when the engine is not disturbed.
EST Distributor Installation (Engine Disturbed)
Steps for installing the distributor when the engine is disturbed, ensuring correct timing.
Ignition Timing - EST System
Procedure for checking and adjusting initial spark timing for the EST system.
Ignition Timing - EST System (Continued)
Detailed steps for setting ignition timing using a timing light and plug configuration.
LP FUEL SYSTEM
General Information
Overview of the LP fuel system components and their functions.
Electric Fuelock Models
Explains the electric fuelock's function in controlling fuel flow from the container.
Fuel Filter
Describes the fuel filter's location and function in cleaning fuel before it reaches the fuelock.
Converter
Details converter components and their roles in changing liquid fuel to vapor.
Converter (Continued)
Further explains converter components and the vaporizing chamber.
Fuel Tank
Information on the LP fuel tank's construction and sizing.
LP Relief Valve
Explains the LP relief valve's function in preventing damage from overpressure.
Carburetor
Describes the air valve type carburetor, its operation, and mixture adjustments.
Tests or Adjustments
Warnings and procedures for performing tests and adjustments on the engine.
Carburetor Adjustment
Procedures for adjusting low idle speed and idle mixture on the carburetor.
Power Mixture Adjustment
Methods for adjusting the power mixture using CO meter, vacuum gauge, or engine speed.
Fuel System Leak Check
Procedures for checking the fuel system for leaks using soap and water solution.
Fuel Filter Check
How to identify a dirty fuel filter by frost formation and its effect on performance.
Converter Leak Test
Procedure for testing the converter for leakage using compressed air.
Recommendation For LP Fuel Systems
Advice on operating the engine in freezing temperatures and potential converter damage.
LP Converter - Check, Clean
Procedure for testing and cleaning the LP-Gas converter.
Inspect Converter for Oil Accumulation
Steps for inspecting the converter's secondary chamber for oil accumulation.
LP Gas Carburetor
Instructions for removing and installing the LP gas carburetor.
Disassemble LP Gas Carburetor
Steps for disassembling the LP gas carburetor, including component removal.
Assemble LP Gas Carburetor
Steps for assembling the LP gas carburetor after disassembly.
LP Gas Fuelock
Procedures for removing and installing the LP gas fuelock.
LP Gas Converter
Instructions for removing and installing the LP gas converter.
Disassembly of LP Gas Converter
Steps for disassembling the LP gas converter, including component removal.
Inspection, Assembly of LP Gas Converter
Guidelines for inspecting and assembling the LP gas converter.
LP FUEL SYSTEM (LOW EMISSION VERSION)
General Description
Overview of the low emission LP fuel system, highlighting differences from standard.
System Overivew
Diagram illustrating the components and flow of the low emission LP fuel system.
LP Fuel System (Low Emission Version)
Explains how the engine controller regulates air/fuel ratio using sensors.
Open-Loop LP Carburetion System
Block diagram of the open-loop LP carburetion system.
Closed-Loop LP Carburetion System
Block diagram of the closed-loop LP carburetion system with ECU control.
Fuel Lock (Electric)
Explains the function of the electric fuel lock as a safety device.
Pressure Regulator/Vaporizer
Describes the two-stage regulator/vaporizer and its connection to the cooling system.
Pressure Regulator/Vaporizer (Continued)
Further explanation of the regulator's operation and its connection to engine coolant.
Pressure Regulator Theory of Operation
Detailed explanation of how the pressure regulator operates based on vacuum and pressure signals.
Pressure Regulator Theory of Operation (Continued)
Continues the explanation of the pressure regulator's operation and fuel flow control.
Variable Venturi Air/Fuel Mixer
Describes the variable venturi air/fuel mixer and its role in drawing fuel from the discharge jet.
Variable Venturi Air/Fuel Mixer Theory of Operation
Explains the theory of operation for the variable venturi air/fuel mixer, including air valve vacuum.
Catalytic Muffler
Explains the function of the catalytic muffler in reducing exhaust gas constituents.
Engine Control Unit (ECU)
Explains the ECU's role in controlling air/fuel ratio using various sensors.
Oxygen Sensor
Describes the oxygen sensor's principle of operation and its role in feedback control.
Vacuum Switch (MAP)
Explains the vacuum switch's function as a pressure switch activated by vacuum.
Fuel Control Valve
Describes the fuel control valve's operation, controlled by a pulse width modulated signal.
Tests or Adjustments
Warnings and procedures for performing tests and adjustments on the engine.
LP Carburetor-Check, Clean
Steps for checking and cleaning the LP carburetor, including idle speed adjustment.
Inspection of Fuel Lock Valve
Procedure for checking the fuel lock valve's operation by listening for sound.
Inspection of Fuel Control Valve
Procedure for inspecting the fuel control valve using a vacuum pump and checking for abnormalities.
Inspection of Vacuum Switch(MAP)
Procedure for testing the vacuum switch's continuity under vacuum application.
Inspection of Oxygen Sensor
Procedure for measuring the oxygen sensor's output voltage after warming up the engine.
Disassembly & Assembly
Steps for disassembling and assembling the LP converter.
LP Converter
Lists removal steps for the LP converter components.
GOVERNOR SYSTEM
General Description
Explains the function of governors in maintaining constant engine speed under various loads.
Components
Illustrations of governor installation and mechanism.
Governor Operation
Explains how governors control engine speed by limiting fuel and air.
High Engine Load
Describes how high engine loads affect governor operation and fuel supply.
Adjustment Procedures
Procedures for adjusting engine speed and governor settings.
Engine Speed
Steps for adjusting maximum engine speed to specification after warming up the engine.
Surging
Steps to correct engine surging by adjusting the governor.
No Surging But RPM Variance Greater Than 100 RPM
Procedure to address RPM variance between no load and full load conditions.
LUBRICATION SYSTEM
General Description
Explains the engine lubrication system, including oil pump, filter, and oil flow.
Testing & Adjusting
Warnings and procedures for testing and adjusting lubrication system components.
Lubrication System Problems
Lists common lubrication system problems such as oil consumption, pressure, and component wear.
Low Oil Pressure
Lists causes for low oil pressure, including low oil level and oil pump issues.
High Oil Pressure
Explains that high oil pressure is usually due to a stuck oil pressure relief valve.
Too Much Component Wear
Discusses wear due to restricted oil passages or insufficient lubrication.
Oil Pressure Check
Procedure for checking engine oil pressure at 2000 RPM.
COOLING SYSTEM
General Description
Explains the engine cooling system, including water pump, thermostat, and radiator functions.
Testing & Adjusting
Warnings and procedures for testing and adjusting cooling system components.
Cooling System Visual Inspection
Steps for visually inspecting the cooling system for leaks and damage.
Cooling System Tests
Emphasizes checking temperature and pressure together for diagnosis.
Pressure Cap Test
Procedure for testing the radiator pressure cap's opening pressure.
Cooling System Leak Check
Procedure for testing the cooling system for leaks using a pressure pump.
Thermostat
Explains the function of the pellet-type thermostat in controlling coolant flow.
Thermostat Test
Procedure for testing the thermostat's opening temperature.
Cooling System Heat Problems
Lists indications of heat problems and procedures to follow if they occur.
Cooling System Recommendation
Recommendations for coolant mixture, freeze protection, and avoiding adding coolant to hot engines.
Coolant Water
Discusses acceptable water quality for cooling systems and DAEWOO's preference for distilled water.
Antifreeze
Recommendations for antifreeze concentration and type, including warnings.
Belt Adjustment
Instructions for adjusting drive belts, including tension specifications and checks.
V-Belt Diagnosis
Lists causes of belt failure and types of belt damage like base cracking and fabric tears.
Service Procedures
General statement about service procedures for draining and filling the cooling system.
Draining and Filling the Cooling System
Steps for draining and filling the engine cooling system.
Filling
Steps for filling the cooling system with coolant and checking the level.
Flushing the Cooling System
Methods for flushing the cooling system, including precautions for internal engine damage.
Radiator Service
Discusses radiator internal deposits and the effect of scale on engine overheating.
Scale Removal
Procedure for removing scale from the cooling system using chemical action.
Thermostat Replacement
Steps for removing and installing the thermostat, including cleaning and filling.
Water Pump Replacement
Instructions for removing and installing the water pump, including gasket replacement and tightening.
Water Temperature Sender
Steps for removing and installing the water temperature sender, including thread sealant use.
BASE ENGINE SERVICE PROCEDURE
Disassembled View (1 of 4)
Illustrated view of disassembled engine components, with numbered parts list.
Disassembled View (2 Of 4)
Illustrated view of disassembled engine components, with numbered parts list.
Disassembled View (3 Of 4)
Illustrated view of disassembled cylinder head components, with numbered parts list.
Disassembled View (4 Of 4)
Illustrated view of disassembled oil pump components, with numbered parts list.
Draining Fluids and Oil Filter Removal
Steps for draining engine oil and coolant, and removing the oil filter.
Engine Flywheel Removal
Instructions for removing the engine flywheel, noting position and direction.
Distributor Removal
Steps for removing the distributor, including disconnecting wires and hold-down bolt.
Ignition Coil Removal
Steps for removing the ignition coil and its bracket.
Lift Bracket Removal
Instructions for removing the lift bracket.
Spark Plug Removal
Simple instruction to remove the spark plugs.
Intake/Exhaust Manifold Removal
Steps for removing the intake/exhaust manifold and gasket.
Crankshaft Pulley Removal
Instructions for removing the crankshaft pulley using a specific tool.
Valve Rocker Arm Cover Removal
Steps for removing the valve rocker arm cover and gasket.
Pushrod Cover Removal
Instructions for removing the pushrod cover and gasket.
Intake/Exhaust Manifold Disassemble and Assemble
Steps for disassembling and assembling the intake/exhaust manifold, including tightening.
Intake/Exhaust Manifold Clean and Inspect
Areas to clean and inspect on the intake/exhaust manifold.
Water Pump Removal
Steps for removing the water pump, including draining coolant and inspecting the pump.
Valve Rocker Arm and Pushrod Removal
Instructions for removing valve rocker arms and pushrods from the cylinder head.
Measuring Camshaft Lobe Lift
Procedure for measuring camshaft lobe lift using a dial indicator.
Valve Lifter Removal
Instructions for removing valve lifters using specialized tools.
Valve Train Components Inspect (Cylinder Head)
Areas to inspect on the cylinder head, including rocker arms, pushrods, and valve seats.
Cylinder Head Removal
Steps for removing the cylinder head, including bolts and gasket.
Oil Pan Removal
Instructions for removing the oil pan and gasket.
Oil Pump Removal
Steps for removing the oil pump and gasket.
Oil Level Indicator and Tube Removal
Instructions for removing the oil level indicator and tube.
Engine Front Cover Removal
Steps for removing the engine front cover, gasket, and oil seal.
Measuring Crankshaft and Camshaft Sprocket Runout
Procedure for measuring crankshaft and camshaft sprocket runout using a dial indicator.
Measuring Timing Sprocket Teeth Backlash
Procedure for measuring backlash between timing sprocket teeth using a dial indicator.
Crankshaft Sprocket Removal
Instructions for removing the crankshaft sprocket using a puller.
Camshaft Removal
Steps for removing the camshaft, emphasizing care for bearings.
Crankshaft and Camshaft Sprocket Inspect
Inspecting camshaft and crankshaft sprockets for wear, teeth condition, and keyways.
Timing Gear Oil Nozzle Removal
Instructions for removing the timing gear oil nozzle.
Piston, Connecting Rod and Bearing Removal
Steps for removing the piston ring ridge, piston, connecting rod, and bearings.
Piston, Connecting Rod and Bearing Removal (Continued)
Continues the removal of piston, connecting rod, and bearings, emphasizing matchmarking.
Crankshaft and Bearings Clean and Inspect (Connecting Rod Bearing Clearance)
Procedure for cleaning and inspecting connecting rod bearings and measuring clearance.
Crankshaft and Bearings Clean and Inspect (Connecting Rod Bearing Clearance) (Continued)
Continues crankshaft bearing inspection and measurement of clearance using gauging plastic.
Crankshaft and Bearings Clean and Inspect (Connecting Rod Bearing Clearance) (Continued)
Final steps for measuring connecting rod bearing clearance and comparing to specifications.
Crankshaft Rear Oil Seal and Housing Removal
Steps for removing the crankshaft rear oil seal housing, seal, and gasket.
Crankshaft, Bearings and Bearing Cap Removal
Instructions for removing crankshaft bearing caps and the crankshaft itself.
Crankshaft and Bearings Clean and Inspect
Procedure for cleaning and inspecting crankshaft bearings for damage and proper seating.
Crankshaft and Bearings Clean and Inspect (Continued)
Continues inspection of crankshaft bearings and measurement of runout.
Crankshaft and Bearings Clean and Inspect (Main Bearing Clearance)
Procedure for inspecting main bearing clearances using gauging plastic.
Crankshaft and Bearings Clean and Inspect (Main Bearing Clearance) (Continued)
Continues main bearing clearance measurement and checks for crankshaft end play.
Camshaft Bearing Removal
Steps for removing camshaft bearings using a specialized tool.
Distributor Lower Bushing and Thrust Washer Removal
Instructions for removing the distributor lower bushing and thrust washer.
Oil Filter Bypass Valve Removal and Installation
Steps for removing and installing the oil filter bypass valve.
Cylinder Block Clean and Inspect
Instructions for cleaning and inspecting the cylinder block and its various passages.
Cylinder Bore Measurements
Procedure for measuring cylinder bore taper and out-of-round using a bore gauge.
Cylinder Boring and Honing
Procedures for boring and honing cylinder blocks to fit pistons, including safety and measurement advice.
Distributor Lower Bushing and Thrust Washer Installation
Instructions for installing the distributor lower bushing and thrust washer.
Piston and Connecting Rod Disassemble
Steps for disassembling the piston and connecting rod, including ring removal and pin removal.
Piston and Connecting Rod Clean and Inspect
Procedure for cleaning and inspecting pistons and connecting rods for wear and damage.
Piston and Connecting Rod Clean and Inspect (Continued)
Continues inspection of pistons and connecting rods, including pin bore clearance and ring end gap measurement.
Piston Selection
Guidance on selecting pistons based on cylinder bore measurements and inspection.
Piston and Connecting Rod Assemble
Steps for assembling the piston and connecting rod, including lubrication and pin installation.
Camshaft and Bearings Clean and Inspect
Procedure for cleaning and inspecting camshaft and bearings for wear and scoring.
Camshaft and Bearings Clean and Inspect (Continued)
Continues inspection of camshaft bearings and measurement of camshaft runout.
Camshaft Sprocket and Retainer Removal and Installation
Instructions for checking camshaft end play and removing/installing the camshaft sprocket.
Camshaft Bearing Installation
Steps for installing camshaft bearings, ensuring proper alignment of oil holes.
Oil Pump Disassemble
Steps for disassembling the oil pump, including removing the screen and cover.
Oil Pump Clean and Inspect
Procedure for cleaning and inspecting oil pump components for wear and damage.
Oil Pump Assemble
Steps for assembling the oil pump, including installing the pressure relief valve and gears.
Cylinder Head Disassemble
Steps for disassembling the cylinder head, including measuring valve spring height and compressing springs.
Cylinder Head Clean and Inspect
Procedure for cleaning and inspecting the cylinder head, including carbon removal and bolt hole checks.
Cylinder Head Clean and Inspect (Continued)
Continues inspection of cylinder head for cracks, valve condition, and valve stem-to-bore clearance.
Valve Guide Reaming/Valve and Seat Grinding
Procedures for reaming valve guides and grinding valve seats for proper fit.
Rocker Arm Stud Removal and Installation
Steps for removing and installing rocker arm studs, including reaming for oversize studs.
Cylinder Head Assemble
Steps for assembling the cylinder head, including installing valves, springs, and rocker arms.
Cylinder Head Assemble (Continued)
Continues cylinder head assembly, emphasizing proper lubrication and component placement.
Crankshaft, Bearings and Bearing Cap Installation
Steps for installing crankshaft bearings, caps, and crankshaft, including tightening specifications.
Crankshaft Rear Oil Seal and Housing Installation
Instructions for installing the crankshaft rear oil seal and housing.
Piston, Connecting Rod and Bearing Installation
Steps for installing piston, connecting rod, and bearings, including proper lubrication and alignment.
Timing Gear Oil Nozzle Installation
Instructions for installing the timing gear oil nozzle.
Crankshaft Sprocket Installation
Steps for installing the crankshaft sprocket onto the crankshaft.
Camshaft Installation
Steps for installing the camshaft, aligning timing marks, and tightening retainer bolts.
Engine Front Cover and Oil Seal Installation
Instructions for installing the engine front cover and its oil seal.
Oil Pan Installation
Steps for installing the oil pan, gasket, and fasteners, including sealer application.
Oil Pump Installation
Instructions for installing the oil pump, including cleaning passages and tightening bolts.
Crankshaft Pulley Installation
Steps for installing the crankshaft pulley using a special tool.
Cylinder Head Installation
Steps for installing the cylinder head, gasket, and bolts, including tightening sequence.
Valve Lifter Installation
Instructions for installing valve lifters, including lubrication and original location.
Valve Rocker Arm and Pushrod Installation
Steps for installing valve pushrods, rocker arms, balls, and nuts.
Valve Rocker Arm Adjustment
Detailed procedure for adjusting valve rocker arm nuts for correct lash at specified engine timing.
Pushrod Cover Installation
Instructions for installing the pushrod cover and gasket.
Valve Rocker Arm Cover Installation
Instructions for installing the valve rocker arm cover and gasket.
Oil Level Indicator and Tube Installation
Instructions for installing the oil level indicator tube and indicator.
Water Pump Installation
Steps for installing the water pump, gasket, and bolts, including tightening.
Intake/Exhaust Manifold Installation
Instructions for installing the intake/exhaust manifold, gasket, and bolts, including tightening.
Spark Plug Installation
Instructions for installing spark plugs and tightening them to specifications.
Lift Bracket Installation
Instructions for installing the lift bracket and its bolts.
Ignition Coil Installation
Instructions for installing the ignition coil and its bracket bolts.
Distributor Installation
Steps for installing the distributor, ensuring correct position for ignition timing.
Engine Flywheel Installation
Instructions for installing the engine flywheel, noting position and tightening bolts.
Engine Block Coolant Plug/Oil Filter Installation
Steps for installing engine block coolant plugs and the oil filter.
SPECIAL TOOS AND EQUIPMENT
Camshaft Sprocket Remover
Image and name of the Camshaft Sprocket Remover tool.
Crankshaft Sprocket Installer
Image and name of the Crankshaft Sprocket Installer tool.
Valve Lifter Remover
Image and name of the Valve Lifter Remover tool.
Rocker Stud Hole Reamer
Image and name of the Rocker Stud Hole Reamer tool.
ITK-1 Pressure Gauge Kit
Description of the IMPCO ITK-1 pressure gauge kit for fuel systems.
FSA-1000 Fuel System Analyzer (Low Emission Version Only)
Name and description of the FSA-1000 Fuel System Analyzer for air/fuel mixture checks.
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