Valve Train Component Removal.................. 64 Cylinder Head Removal ................................ 65 Torsional Damper Removal........................... 66 Oil Pan Removal........................................... 66 Oil Pump Removal........................................ 67 Engine Front Cover Removal ........................ 67 Timing Chain and Camshaft Sprocket Removal ..................................................................... 67 Camshaft Removal ....................................... 68 Balance Shaft Removal................................. 68 Piston and Connecting Rod Removal............ 69 Crankshaft Rear Oil Seal Removal................
70 Crankshaft Rear Oil Seal Housing Removal .. 70 Crankshaft Removal...................................... 71 Cleaning, Inspection, and Repair...................... 72 Cylinder Block............................................... 72 Cylinder Bore................................................ 73 Measuring Cylinder Bore Taper and Out-Of- Round........................................................... 73 Cylinder Bore Reconditioning........................ 74 Boring.................................................... 75 Honing................................................... 75 Piston Disassembly....................................... 76 Measuring Piston Pin-To-Piston Clearance ...
77 Piston Selection............................................ 78 Piston Assembly ........................................... 78 Intake and Exhaust Manifolds ....................... 80 Camshaft ...................................................... 80 Camshaft Bearings ....................................... 81 Balance Shaft ............................................... 82 Timing Chain and Sprockets ......................... 82 Crankshaft Sprocket Replacement ................ 82 Coolant Pump............................................... 83 Oil Pan and Valve Rocker Covers ................. 83 Oil Pump.......................................................
83 Valve Train Components............................... 85 Valve Lifters.................................................. 86 Cylinder Head............................................... 86 Disassembly .......................................... 86 Cleaning, Inspection, and Measurement .... 86 Repair.................................................... 88 Valve Rocker Arm Stud Replacement .... 89 Assembly............................................... 89 Thermostat and Coolant Outlet ..................... 90 Torsional Damper ......................................... 90 Crankshaft Bearings...................................... 91 Crankshaft Runout........................................
93 Crankshaft End Play ..................................... 93 Connecting Rod Bearings ............................. 93 Connecting Rod Side Clearance ................... 94 Assembly of Engine .......................................... 95 Prior to Assembly ......................................... 95 Crankshaft And Crankshaft Bearing Installation ..................................................................... 95 Crankshaft Rear Oil Seal Housing Installation ... 96 Crankshaft Rear Oil Seal Installation............. 96 Piston and Connecting Rod Installation......... 96 Balance Shaft Installation ............................. 98 Camshaft Installation ....................................
99 Timing Chain and Camshaft Sprocket Installation...................................................100 Engine Front Cover Installation....................100 Torsional Damper Installation ......................100 Torsional Damper Installation ......................101 Oil Pump Installation....................................101 Oil Pan Installation.......................................102 Cylinder Head Installation ............................104 Cylinder Head Installation ............................104 Valve Train Component Installation..............104 Valve Adjustment.........................................105 Intake Manifold Installation...........................105 Rocker Arm Cover Installation......................105 Exhaust Manifold Installation .......................107 Flywheel Housing Installation.......................107 Engine Flywheel Installation.........................108 Coolant Pump Installation............................109 Engine Accessory Installation ......................109 Engine Setup and Testing............................109 Chapter 4.
ENGINE ELECTRICAL SYSTEM Specifications...................................................110 Ignition Timing.............................................110 Ignition Sequence (Firing Order)..................110 Ignition Coil .................................................110 Spark Plug...................................................110 Distributor....................................................111 Sensor Gap.................................................111 Ignition System.................................................112 General Description.....................................112 Ignition System Control.........................113 lgnition System Schematic for G643E...114 lgnition System Schematic for G643 .....114 Ignition System Inspection....................115 G643(E) Service Manual Index 4