Vortec 1600 - Industrial 1.6 L Engine Mechanical 1-1 Section 1 Engine Mechanical

Industrial 1.6L Engine Mechanical 1-1
Section 1
Engine Mechanical
Fastener Notice ..........................................................1-2
Engine Mechanical - 1.6L ........................................1-3
Specifications...........................................................1-3
Fastener Tightening Specifications .............................1-4
Sealers, Adhesives and Lubricants ............................1-6
Engine Mechanical Specifications..............................1-7
Engine Identification Code/Engine Number.................1-7
Engine Management ..................................................1-7
Cylinder Head ............................................................1-8
Crank Drive, Cylinder Block ..................................... 1-10
Diagnostic Information and Procedures ...............1-17
Tension Check, Ribbed V-belt .................................. 1-17
Engine Compression Test ........................................ 1-17
Engine Loss of Compression Test ........................... 1-18
Oil Pressure Check .................................................. 1-19
Timing Check...........................................................1-20
Timing Adjustment ................................................... 1-20
Toothed Belt Tension Check .................................... 1-23
Toothed Belt Tension Adjust .................................... 1-24
Repair Instructions................................................. 1-25
Engine Timing Side .................................................. 1-25
Ribbed V-belt, Remove and Install ........................... 1-25
Toothed Belt Cover, Upper Part, Remove and Install 1-26
Toothed Belt Cover, Lower Part, Remove and Install 1-27
Toothed Belt, Remove and Install ............................ 1-28
Toothed Belt Tension Roller, Remove and Install ..... 1-29
Seal Ring in Front Camshaft Housing, Replace ........ 1-30
Rear Toothed Belt Cover, Remove and Install.......... 1-32
Cylinder Head .......................................................... 1-34
Seal Ring in Rear Camshaft Housing, Replace......... 1-34
Exhaust Manifold, Remove and Install ..................... 1-35
Intake Manifold, Remove and Install - Port Fuel Injected
Models ............................................................... 1-36
Intake Manifold, Remove and Install - Throttle Body Fuel
Injected Models .................................................. 1-38
Heat Shields, Remove and Install ............................ 1-40
Camshaft and Cam Follower, Remove and Install
(Cylinder head Installed) ..................................... 1-40
Hydraulicd Valve Lifter, Replace (Cylinder Head
Installed)............................................................ 1-43
Camshaft, Remove and Install (Cylinder Head
Removed) ..........................................................1-44
Camshaft Housing, Replace .....................................1-44
Camshaft Housing, Check for Plane Surface ........... 1-47
Cylinder Head, Remove and Install .......................... 1-47
Cylinder Head, Check for Plane Surface .................. 1-53
Crank Drive, Cylinder Block ..................................... 1-54
Drive Disc, Remove and Install ................................1-54
Flywheel, Remove and Install .................................. 1-54
Seal Ring - Rear Crankshaft, Replace ...................... 1-55
Engine Vent Flange or Gasket, Remove and Install . 1-56
Piston with Con-rod, Remove and Install.................. 1-57
Piston Rings, Remove and Install ............................ 1-61
Con-rod Bearing, Replace ........................................ 1-63
Con-rod Bearing Clearance, Check (Determine
Bearing Clearance with 50 Plastigage) ..................... 1-64
Con-rod Bearing Clearance, Check (Determine Bearing
Clearance with Micrometer and Inside
Micrometer) ........................................................ 1-65
Piston, Replace ....................................................... 1-66
Crankshaft, Remove and Install ............................... 1-68
Crankshaft, Check ................................................... 1-70
Crankshaft End Clearance, Check ........................... 1-70
Crankshaft Out-of-round, Check ............................... 1-70
Crankshaft Bearing Play, Check (Determine Bearing
Play with Plastigage) ......................................... 1-70
Crankshaft Bearing Clearance, Check (Determine
Crankshaft Bearing Clearnace Using External
Micrometer and Inside Micrometer).................... 1-71
Cylinder Block, Check for Plane Surface ................. 1-72
Oil Circuit ................................................................. 1-73
Oil Filter, Replace .................................................... 1-73
Bypass Valve, Replace............................................ 1-73
Front Seal Ring - Crankshaft, Replace ..................... 1-73
Oil Pan, Remove and Install .................................... 1-76
Oil Pump, Remove and Install.................................. 1-77
Oil Pump, Check...................................................... 1-79
Safety Valve, Remove and Install ............................ 1-81
Oil Intake Pipe, Remove and Install ......................... 1-81
Oil Baffle Plate, Remove and Install ........................ 1-82
Oil Pressure Switch, Remove and Install ................. 1-82
Oil Dipstick Tube, Remove and Install ..................... 1-83
Crankshaft Position Sensor, Remove and Install ..... 1-83
Reference Gap Between Crankshaft Position Sensor
and Increment Disc, Check ............................... 1-83
Coolant Thermostat, Remove and Install ................. 1-84
Coolant Pump, Remove and Install .......................... 1-84
Fuel Pressure Check ............................................... 1-84
Coolant Temperature Sensor, Remove and Install.... 1-85
Starter......................................................................1-86
Starter, Remove and Install...................................... 1-86
Alternator ................................................................. 1-86
Alternator, Remove and Install ................................. 1-86
Special Tools and Equipment ............................... 1-88