ENGINE
TABLE OF CONTENTS
page page
ENGINE - 8.3L
DESCRIPTION ..........................3
DIAGNOSIS AND TESTING
INTRODUCTION .......................3
ENGINE DIAGNOSIS - PERFORMANCE .....4
ENGINE DIAGNOSIS - MECHANICAL .......5
CYLINDER COMPRESSION PRESSURE
TEST ................................7
CYLINDER COMBUSTION PRESSURE
LEAKAGE TEST .......................7
CYLINDER HEAD GASKET FAILURE
DIAGNOSIS ...........................8
INTAKE MANIFOLD LEAKS ...............8
HYDRAULIC TAPPET NOISE DIAGNOSIS ....9
ENGINE OIL LEAK INSPECTION ...........9
STANDARD PROCEDURE
ENGINE CORE AND OIL GALLERY PLUGS . . 10
FORM-IN-PLACE GASKETS AND SEALERS . 10
ENGINE GASKET SURFACE PREPARATION . 12
HYDROSTATIC LOCKED ENGINE .........12
REMOVAL - ENGINE ASSEMBLY ...........12
INSTALLATION - ENGINE ASSEMBLY ........16
SPECIFICATIONS
ENGINE .............................17
TORQUE ............................20
SPECIAL TOOLS
ENGINE .............................21
AIR CLEANER ELEMENT
REMOVAL .............................24
INSTALLATION .........................24
AIR CLEANER HOUSING
REMOVAL .............................25
INSTALLATION .........................25
ENGINE MOUNTS
REMOVAL .............................26
INSTALLATION .........................26
INTAKE MANIFOLD
REMOVAL .............................27
INSPECTION ..........................29
INSTALLATION .........................29
EXHAUST MANIFOLD
REMOVAL .............................30
INSPECTION ..........................30
INSTALLATION .........................31
CYLINDER HEAD(S)
REMOVAL - CYLINDER HEAD(S) ...........31
CLEANING / INSPECTION ................32
INSTALLATION - CYLINDER HEAD(S) .......32
CYLINDER HEAD COVER(S)
REMOVAL .............................33
INSTALLATION .........................34
ROCKER ARMS
REMOVAL .............................34
INSTALLATION .........................35
VALVE SPRINGS/SEALS
DESCRIPTION .........................35
DIAGNOSIS AND TESTING
VALVE SPRING TESTING ...............35
STANDARD PROCEDURE - VALVE SPRING/
SEAL SERVICE IN-CAR .................36
REMOVAL .............................37
INSTALLATION .........................37
INTAKE/EXHAUST - VALVES/SEATS/GUIDES
STANDARD PROCEDURE - VALVE AND
VALVE SEAT - REFACING ...............38
INSPECTION ..........................39
TIMING CHAIN COVER
REMOVAL .............................40
INSTALLATION .........................40
TIMING CHAIN AND SPROCKETS
REMOVAL .............................42
INSTALLATION .........................43
LUBRICATION
DESCRIPTION .........................43
OPERATION ...........................43
DIAGNOSIS AND TESTING
CHECKING ENGINE OIL PRESSURE ......44
ENGINE OIL LEAK .....................44
OIL
STANDARD PROCEDURE
CHECKING ENGINE OIL LEVEL ..........45
ENGINE OIL AND FILTER CHANGE .......46
OIL COOLER & LINES
DESCRIPTION .........................46
OPERATION ...........................46
STANDARD PROCEDURE - OIL COOLER LINE
QUICK CONNECT FITTING DISASSEMBLY/
ASSEMBLY ..........................46
REMOVAL .............................48
INSTALLATION .........................48
OIL PAN
REMOVAL .............................49
INSTALLATION .........................49
OIL PUMP
REMOVAL .............................50
DISASSEMBLY .........................50
CLEANING ............................51
INSPECTION ..........................51
ASSEMBLY ............................52
INSTALLATION .........................53
ZB ENGINE 9 - 1
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