Description.................................................................................................................................................................... 6A4- 2

Disassembly..................................................................................................................................................................6A4- 4

Tools and Shop Equipment..................................................................................................................................... 6A4- 4

Accessory Removal..................................................................................................................................................6A4- 4

Cleaning.................................................................................................................................................................... 6A4- 4

Parts Identification....................................................................................................................................................6A4- 4

Draining the Engine..................................................................................................................................................6A4- 8

Air Manifold and Injection Tube Removal............................................................................................................ 6A4- 8

Manifold R em oval....................................................................................................................................................6A4- 8

Thermostat Housing R em oval...............................................................................................................................6A4- 9

Water Pump Rem oval............................................................................................................................................. 6A4- 9

Valve Train Component Removal...........................................................................................................................6A4- 9

Cylinder Head Removal........................................................................................................................................... 6A4-10

Torsional Damper Removal..................................................................................................................................... 6A4-10

Oil Pan Removal........................................................................................................................................................6A4-10

Oil Pump Removal....................................................................................................................................................6A4-10

Timing Gear Cover Removal................................................................................................................................... 6A4-11

Piston and Connecting Rod R em oval.................................................................................................................. 6A4-11

Flywheel Removal....................................................................................................................................................6A4-11

Crankshaft Removal..................................................................................................................................................6A4-12

Crankshaft Rear Oil Seal Removal (Without Removing Crankshaft).................................................................6A4-12

Main Bearing Removal (Without Removing Crankshaft)................................................................................... 6A4-12

Camshaft Removal....................................................................................................................................................6A4-13

Cleaning, Inspection, and Repair...............................................................................................................................6A4-14

Block.......................................................................................................................................................................... 6A4-14

Main Bearing Cap Replacement.............................................................................................................................6A4-14

Cylinder Bores..........................................................................................................................................................6A4-15

Piston and Connecting Rod Assemblies.............................................................................................................. 6A4-15

Intake and Exhaust Manifolds.................................................................................................................................6A4-15

Camshaft.................................................................................................................................................................... 6A4-16

Camshaft Bearings....................................................................................................................................................6A4-17

Timing Gear Cover....................................................................................................................................................6A4-17

Water Pum p.............................................................................................................................................................. 6A4-17

Oil Pan and Rocker Arm Cover...............................................................................................................................6A4-18

Oil Pump.................................................................................................................................................................... 6A4-18

Valve Train Components......................................................................................................................................... 6A4-19

Cylinder Head............................................................................................................................................................ 6A4-19

Thermostat and Housing......................................................................................................................................... 6A4-21

Torsional Damper......................................................................................................................................................6A4-22

Crankshaft and Bearings......................................................................................................................................... 6A4-22

Oil Filter Relief Valve Replacement...................................................................................................................... 6A4-23

Assembly of E n g in e....................................................................................................................................................6A4-23

Prior to Assem bly....................................................................................................................................................6A4-23

Crankshaft Rear Oil Seal Installation.................................................................................................................... 6A4-23

Main Bearing Installation (With Crankshaft Installed)....................................................................................... 6A4-25

Crankshaft and Main Bearing Installation............................................................................................................ 6A4-25

Camshaft Installation............................................................................................................................................... 6A4-26

Timing Gear Cover Installation...............................................................................................................................6A4-26

Torsional Damper Installation.................................................................................................................................6A4-27

Piston and Connecting Rod Installation.............................................................................................................. 6A4-27

Oil Pump Installation............................................................................................................................................... 6A4-28

SECTION 6A4

4.8 LITER L6

CONTENTS

6A4-1

PAGE

Table of Contents