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1984-1995 Honda Civic/ CRX Positive Crankcase Ventilation (PCV) System Repair Manual

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Filed Under (Honda Manuals) by admin on 22-04-2012

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The PCV system is designed to prevent blow-by gas from escaping to the atmosphere by drawing it directly into the intake manifold. The PCV valve contains a spring-loaded plunger which is lifted in proportion to intake manifold vacuum. Under high vacuum, blow-by is returned directly to the manifold through the breather chamber and PCV valve with fresh air. When intake manifold vacuum decreases (wide open throttle) and vacuum in the air cleaner increases, the PCV valve closes and the blow-by is returned through the cylinder head cover breather hose and into the air cleaner. The PCV valve also acts as a check valve when the engine backfires to prevent crankcase explosion. Fig. 1: PCV system components-1984-87 1.5L engines Fig. 2: PCV system components-1988-91 1.6L engines Fig. 3: PCV system components-1992-95 engines Fig. 4: PCV system components-1984-87 carbureted engines SERVICE Positive Crankcase Ventilation (PCV) Valve For PCV valve removal, refer to Routine Maintenance of this information. 1. Locate the PCV valve. With the engine running at idle, use pliers to pinch the PCV hose between the valve and the intake manifold. It should be possible to hear the spring loaded valve click shut. 2. If no click is heard, remove the valve from the engine but leave it connected to the intake manifold. A hissing sound should be heard and vacuum should be felt at the valve inlet. 3. If no vacuum is felt, remove the valve from the intake manifold hose. The engine should stall or almost stall. This will indicate a stuck valve or clogged hose. Check the breather hose for clogging or leaks and replace any defective parts. Exhaust Gas Recirculation (EGR) System FUEL INJECTED ENGINES General Information See Figure 3 The Exhaust Gas Recirculation (EGR) system is used to control emissions measured at the tailpipe. Components included are the EGR valve and controls. The EGR system uses a poppet type valve to regulate the amount of exhaust gas flowing into the intake manifold. The flow path is cast into the cylinder head and does not use any external tubing. A control solenoid valve regulates the amount of vacuum to the EGR valve. A Constant Volume Control (CVC) valve provides a constant amount of vacuum to the control solenoid valve over a wide range of engine vacuum. When servicing or repairing any part of the emissions system, it is absolutely essential to check for any obvious mechanical faults or failures. Remember, a trouble code only indicates which sensor or circuit is affected by the problem. Simple mechanical faults such as a vacuum leak or poor electrical connection can cause a fault code. The EGR valve is not simply open or closed but is modulated by controlling the amount of engine vacuum to the valve diaphragm, up to a maximum of 8 in. Hg of vacuum. The EGR valve has a sensor in the top of the valve that reports valve lift to the ECU (same as ECM, 1992-95). The ECU modulates the position of the control solenoid valve to control the EGR valve lift according to an internal program. Upstream of the control solenoid valve, the CVC provides a constant supply of vacuum so EGR control is precise under all manifold vacuum conditions

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Honda Civic/ CRX Positive Crankcase Ventilation (PCV) System OPERATION MANUAL

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Filed Under (Honda Manuals) by admin on 28-01-2012

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The PCV system is designed to prevent blow-by gas from escaping to the atmosphere by drawing it directly into the intake manifold. The PCV valve contains a spring-loaded plunger which is lifted in proportion to intake manifold vacuum. Under high vacuum, blow-by is returned directly to the manifold through the breather chamber and PCV valve with fresh air. When intake manifold vacuum decreases (wide open throttle) and vacuum in the air cleaner increases, the PCV valve closes and the blow-by is returned through the cylinder head cover breather hose and into the air cleaner. The PCV valve also acts as a check valve when the engine backfires to prevent crankcase explosion. Fig. 1: PCV system components-1984-87 1.5L engines Fig. 2: PCV system components-1988-91 1.6L engines Fig. 3: PCV system components-1992-95 engines Fig. 4: PCV system components-1984-87 carbureted engines
SERVICE Positive Crankcase Ventilation (PCV) Valve For PCV valve removal, refer to Routine Maintenance of this information. 1. Locate the PCV valve. With the engine running at idle, use pliers to pinch the PCV hose between the valve and the intake manifold. It should be possible to hear the spring loaded valve click shut. 2. If no click is heard, remove the valve from the engine but leave it connected to the intake manifold. A hissing sound should be heard and vacuum should be felt at the valve inlet. 3. If no vacuum is felt, remove the valve from the intake manifold hose. The engine should stall or almost stall. This will indicate a stuck valve or clogged hose. Check the breather hose for clogging or leaks and replace any defective parts. Exhaust Gas Recirculation (EGR) System FUEL INJECTED ENGINES General Information See Figure 3 The Exhaust Gas Recirculation (EGR) system is used to control emissions measured at the tailpipe. Components included are the EGR valve and controls. The EGR system uses a poppet type valve to regulate the amount of exhaust gas flowing into the intake manifold. The flow path is cast into the cylinder head and does not use any external tubing. A control solenoid valve regulates the amount of vacuum to the EGR valve. A Constant Volume Control (CVC) valve provides a constant amount of vacuum to the control solenoid valve over a wide range of engine vacuum.

1994 Toyota Paseo ENGINE IDENTIFICATION/ VALVE CLEARANCE ADJUSTMENT

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Filed Under (Toyota Manuals) by admin on 12-11-2011

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1) Disconnect PCV hose, necessary electrical connections and spark plug wires to access valve cover. Remove nuts, seal washers, valve cover and gasket. 2) Rotate crankshaft clockwise so cylinder No. 1 is at TDC on compression stroke. Cylinder No. 1 is front cylinder at timing belt end of engine. Ensure timing mark on crankshaft pulley aligns with “0″ mark on timing belt cover. 3) Ensure valve lifters on cylinder No. 1 are loose and valve lifters on cylinder No. 4 are tight. If conditions are not as described, rotate crankshaft clockwise one complete revolution (360 degrees). 4) Using feeler gauge, measure valve clearance between valve lifter and camshaft on intake valves of cylinders No. 1 and 2, and exhaust valves of cylinders No. 1 and 3. Record valve clearance. Rotate crankshaft clockwise one complete revolution (360 degrees). 5) Measure and record valve clearance on intake valves of cylinders No. 3 and 4, and exhaust valves of cylinders No. 2 and 4. Ensure valve clearance is within specification. See VALVE CLEARANCE SPECIFICATIONS table. VALVE CLEARANCE SPECIFICATIONS TABLE (1) Application In. (mm) Exhaust Valve ………….. .012-.016 (.31-.41) Intake Valve …………… .006-.010 (.15-.25) (1) – Adjust valve clearance with engine cold. 6) If valve clearance requires adjustment, rotate camshaft so lobe on valve to be adjusted is facing upward, away from valve lifter. Position notch area on valve lifter toward inside of cylinder head. DO NOT align notch area with camshaft. Use Valve Clearance Adjuster (SST 09248-55040) to adjust valve clearance. 7) Using SST “A” of valve clearance adjuster, push downward on valve lifter. Place SST “B” between camshaft and valve lifter. See Fig. 2. Ensure enough clearance exists for adjusting shim removal. Remove SST “A”. Fig. 2: Adjusting Valve Clearance Courtesy of Toyota Motor Sales, U.S.A., Inc. 8) Using small screwdriver and magnet, remove adjusting shim. Measure and record thickness of removed shim. Using measured clearance and adjusting shim thickness, select proper replacement adjusting shim. See Figs. 4 and 5. 9) Install replacement adjusting shim. Recheck valve clearance. Apply sealant at indicated valve cover sealing areas on cylinder head. See Fig. 3. 10) Using NEW gasket, install valve cover and sealing washers. Install and tighten nuts to specification. See TORQUE SPECIFICATIONS. To install remaining components, reverse removal procedure. NEW SHIM THICKNESS TAB

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2008 Ford Focus A/T Main Control Valve Body Removal And Installation

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Filed Under (Ford Manuals) by admin on 01-07-2012

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Disassembly 12 7Z490 Separator plate and gasket assembly 1. Remove the solenoid body bolts and the 13 7A101 Body — control valve lower solenoid body. 14 7R294 Stop — main regulator valve 15 7F445 Retainer plate — main regulator valve 16 7A270 Spring — main fluid pressure regulator valve 17 7C338 Valve — main fluid pressure regulator 18 7G411 Spring — solenoid regulator valve 19 7H392 Valve — solenoid regulator valve 20 7D400 Spring — intermediate servo accumulator 21 7D398 Piston — intermediate servo 2. Remove and discard the solenoid body gaskets. accumulator 22 7G408 Valve — converter pressure relief 23 7G316 Spring — converter regulator valve 24 7M040 Valve — lock up control 25 7Z490 Gasket — solenoid body 26 7G179 Valve — low reverse shift 27 7M040 Valve — 3-4 shift 28 7H148 Shift Solenoid B (SSB) (on/off) valve 29 7H148 Shift Solenoid A (SSA) (on/off) valve ISASSEMBLY AND ASSEMBLY (Continued) 3. Remove and discard the seals. 3. Install the seals. 4. Disassemble the main control valve body. 4. Install a new solenoid body gasket. Assembly 1. Install a new separator plate and gasket assembly. 2. NOTE: Do not fully tighten the bolts at this stage. Assemble the main control valve body and loosely install the bolts. DISASSEMBLY AND ASSEMBLY (Continued) 5. Install the solenoid body and loosely install the 6. Tighten the solenoid body bolts in the sequence bolts. shown. •Tighten to 9 Nm (80 lb-in)

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1996 Ford Taurus Transmission and Drivetrain Automatic Transmission/Transaxle Removal and installation Manual

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Filed Under (Ford Manuals) by admin on 20-04-2012

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REMOVAL NOTE: The oil pump and valve body are removed as an assembly. 1. Disconnect battery ground cable, then remove battery, battery tray, and remote air cleaner. 2. Position supply hoses, vacuum hoses, and wiring away from pump and valve body cover. 3. Remove shift lever. 4. On models equipped with Anti-lock Brake System (ABS) , remove splash shield cover, then disconnect brake reservoir hose and cap to prevent contamination. 5. On all models, remove EGR bracket attaching bolts, then install lifting eye. 6. Remove throttle body bracket attaching bolt, install lifting eye, then using suitable equipment support engine. 7. Remove lefthand transaxle mount. 8. Remove transaxle side pan upper attaching bolts. 9. Raise and support vehicle. 10. Remove lefthand front wheel and tire assembly. 11. Remove inner fender cover and position aside, then disconnect ride height sensor. 12. Remove rear transaxle mount attaching bolt. 13. Loosen but do not remove two lefthand subframe attaching bolts. 14. Remove two engine support mount attaching bolts. 15. Remove four lefthand engine support attaching bolts, then remove the engine support. 16. Position suitable drain pan, then remove remaining transaxle side pan attaching bolts and remove pan. 17. Using suitable screwdriver, place manual shift shaft in Park position. 18. Disconnect upper bulkhead electrical connector wiring retainer clip from valve body. 19. Disconnect electrical connectors 20. Remove valve body attaching bolts, then disengage linkage and remove valve body. NOTE: Do not remove oil pump cover attaching bolts. INSTALLATION 1. Install new pump and valve body to chain cover gasket. 2. Slide pump and valve body onto pump shaft. 3. Rotate pump and valve body assembly toward dash panel, then engage manual valve link with manual valve. 4. Slightly rotate pump and valve body assembly to engage oil pump shaft splines with oil pump rotor splines. Valve body should slide flush with chain cover. A suitable 7/8 inch deep well socket on crankshaft pulley may be required for complete engagement. 5. On models less anti-skid, if engagement is not as indicated in step 4, proceed as follows: a. Remove manual valve from valve body. b. Rotate assembly to allow full engagement, up to 360° . c. After full engagement, return assembly to installed position, then install manual valve. Zoom Sized for Print Oil Pump And Valve Body Bolt Tightening Sequence

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1999 Chevrolet Silverado The service engine soon light is on with trouble code P1416 present

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Filed Under (Chevrolet Manuals) by admin on 07-05-2012

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Tests/Procedures: 1. Use a scanner and command the air pump on with the engine running at idle. Check if the O2 sensors go lean. 2. If the O2 sensor does not go lean on one bank, see if the check valve at the exhaust manifold is stuck closed, not allowing air into the manifold. Potential Causes: Defective Check Valve Diagnostic Codes: P1416 Author: Christopher Pittman Average Reported Mileage: 85812 Confirmed Fix Summary Confirmed Fix 18 – Air Injection Reaction (AIR) Check Valve 1 – Air Injection Reaction (AIR) Check Valve, Air Injection Reaction (AIR) Pump Confirmed Fix Details Tech Reported Fix Details Confirmed Fix Lee Stroup Sr. November 15, 2007 2001 Chevrolet Silverado 1500, 5.3L, Vin T, Eng Cfg V8 * A.I.R. Check Valve – removed check valves, found one rusted closed, one restricted, replaced both valves. Moisture from exhaust seems to have rusted both valves. Air Injection Reaction (AIR) Check Valve Paul Puleo August 20, 2009 1999 Chevrolet Camaro, Z28 5.7L * Replaced Both Air Injection Reaction (AIR) Check Valves – bank 2 AIR check valve restrticted, bank 1 slightly restricted replaced both Air Injection Reaction (AIR) Check Valve SouthGate January 05, 2009 2000 Chevrolet Silverado 1500, 4.8L, Vin V, Eng Cfg V8 * Replaced Air Injection Reaction (AIR) Check Valve – replaced boht check valves. fix the code. Air Injection Reaction (AIR) Check Valve Dwight Heckman July 31, 2008 2000 Chevrolet Blazer, 4.3L * Check Valve – replacing the check valve and cleaning out the lines repaired the problem. Air Injection Reaction (AIR) Check Valve Nick Secchitano June 16, 2009 2000 Chevrolet Silverado 1500, 5.3L, Vin T, Eng Cfg V8 * Replaced Both Air Injection Reaction (AIR) Check Valves – Air injection check valves Air Injection Reaction (AIR) Check Valve Mark Bertelsen 1998 Chevrolet Camaro, Z28 5.7L * Replaced Air Injection Reaction (AIR) Check

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DTC P0446 (Restricted/Blocked EVAP Vent Path) Set, Check Engine Light On (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit)

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Filed Under (Toyota Manuals) by admin on 11-04-2012

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Tighten Tighten the bracket mounting bolt to 12 N?m (106 lb in). Connect the vent valve pipe to the EVAP canister. • Install the two vent valve pipe clips into the existing underbody holes. • Connect the EVAP canister vent valve electrical connector, if equipped. • Attach bulk 5/8″ heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. • Cut the hose to determined length and install the supplied filter box. Secure using a clamp. • Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. • Raise the transmission and reinstall the transmission support. • Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch*points and heat sources. • Lower the vehicle. • 2004-2007 Model Year (Use Service Kit P/N 19152349) Raise the vehicle. Suitably support the vehicle. • Disconnect the EVAP canister vent valve electrical connector. • Disconnect the canister pipe from the vent valve. • Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. • Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Extended Cab Short Box Shown Below, Other Configurations Similar Install the new canister vent valve to the fuel tank clip or mounting bracket. • Cut bulk 5/8″ heater hose to a length of approximately 76 mm (3 in). Install the hose between the vent valve and the canister pipe and secure using clamps. • Attach bulk 5/8″ heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. • Cut the hose to determined length and install the supplied filter box. Secure using a clamp. •

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Steering, Brake And Suspension Specialists Proportioning Valve Diagram

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Filed Under (More Manuals) by admin on 01-10-2011

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This diagram is the most common way to plumb a proportioning valve. In some cases, the right front line will be plugged off at the proportioning valve and the left front line will go to a “T” fitting. From the “T” fitting, the front lines then split off and go to the left and right wheels. Our proportioning valve has a warning light switch built in (this is not a stop light switch.) The warning light will detect any loss of pressure, for example, a leaky wheel cylinder. We recommend you wire this light into your system. Any two wire light socket will work. One wire goes to the accessory power and the other goes to the warning light. Our proportioning valves provide four functions: 1. Proportion pressure front and rear 2. 10 psi. residual check valve 3. Metering valve to apply pressure to the rear brakes before the front brakes 4. A brake warning light to detect a loss in pressure Proportioning Valve Plumbing Diagram: There are two proportioning valve lines that connect to the master cylinder provided in our kits. The first is a 90 degree bend with one leg longer than the other. This line must be oriented with the long leg connected into the front top hole of the proportioning valve and the short end in the front hole on the master cylinder. The second line has two 90 degree bends and has color coded fittings. The larger blue fitting goes into the back hole on the master cylinder and the smaller gold fitting goes into the back top hole on the proportion valve as shown in the diagram

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1991 Honda Civic Si FUSES AND CIRCUIT BREAKERS Identification

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Filed Under (Honda Manuals) by admin on 17-05-2011

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IDENTIFICATION FUSE PANEL LOCATION The fuse box is located under dashboard on driver’s side. Underhood fuse panel is located in engine compartment beside battery. Cars equipped with anti-lock brake system have a third fuse box for ABS in front of the engine compartment on passenger’s side. FUSE PANEL IDENTIFICATION (1988-91) Fig. 1: Fuse Panel Identification (1988-91) Courtesy of AMERICAN HONDA MOTOR CO., INC. Fuse & Circuit Breaker Identification z 1 – 10 Amp Integrated Control Unit, Combination Switch, Gauge Assembly, Back-Up Lights Switch, Shift Position Console Switch, Clock (1990) , Shift Lock Solenoid (1990) , Interlock Control Unit (1990) , 1991 Honda Civic Si FUSES & CIRCUIT BREAKERS’ ‘Fuses & Circuit Breakers 1988-91 Honda 1991 Honda Civic Si FUSES & CIRCUIT BREAKERS’ ‘Fuses & Circuit Breakers 1988-91 Automatic Seat Belts (If Equipped) z 2 – 10 Amp Starter Solenoid, PGM-FI Main Relay, PGM-FI Electronic Control Unit, Integrated Control Unit z 3 – 20 Amp Power Door Locks (If Equipped) z 4 – 10 Amp Right Headlight High Beam, High Beam Indicator Light, Daytime Running Lights Relay (Canada) z 5 – 10 Amp Left Headlight High Beam z 6 – 30 Amp Sun Roof Motor (If Equipped) z 7 – 10 Amp Rear Lights (Canada Only) z 8 – 10 Amp Integrated Control Unit, Interior & Exterior Lighting z 9 – Blank z 10 – 10 Amp Left Headlight Low Beam z 11 – 10 Amp Right Headlight Low Beam z 12 – 15 Amp Integrated Control Unit, Luggage Compartment Light, Dome Light, Ignition Switch, Clock, Radio, Cigarette Lighter z 13 – 15/20 Amp Power Windows, Windshield Wipers & Washer, Sun Roof Relay (1990), Integrated Control Unit (Canada), Combination Switch (1990 CRX) z 14 – 10 Amp Gauge Assembly, Engine Sensors & Controls, PGM-FI Main Relay (Wagon & CRX Only), PGM-FI ECU (Wagon & CRX Only), Fuel Pump (Wagon & CRX Only), ELD Unit (Wagon & CRX Only), EACV (Wagon & CRX Only) z 15 – 15 Amp Cooling Fan Motor (Except 4WD A/T Wagon), Cooling Fan Relay z 16 – 10 Amp Daytime Running Lights (Canada Only) z 17 – 10 Amp Radio, Cigarette Lighter Relay (1990 only) z 18 – 10 Amp Rear Window Defogger, Power Door Mirrors, Air Conditioning z 19 – 30 Amp Blower Motor z 20 – 20 Amp Right Front Power Window z 21 – 20 Amp Left Front Power Window z 22 – 20 Amp Right Rear Power Window z 23 – 20 Amp Left Rear Power Window UNDERHOOD FUSE PANEL IDENTIFICATION (1988-91)

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Chevrolet Aluminum Cylinder Heads INSTALLATION INSTRUCTIONS

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Filed Under (Chevrolet Manuals) by admin on 20-02-2012

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Before final installation of the cylinder heads, several things need to be checked to assure proper engine operation: 1. Piston to valve clearance – Minimum intake valve clearance should be .080″. Minimum exhaust valve clearance should be .100″. The point of minimum intake valve to piston clearance will usually occur somewhere between 5 and 15º ATDC during valve overlap. The point of minimum exhaust valve to piston clearance will usually occur 15º to 5º BTDC during valve overlap. Re-machining of the piston top eyebrows may be required with some pistons. 2. Proper lifter adjustment and rocker geometry – Check Lifter pre-load. Check clearance of push rod to guideplate. Rocker geometry should be checked making sure that the contact point of the roller remains properly on the valve tip and does not roll off the edge. Visual inspection of the rockers, valve springs, retainers, and pushrods should be made to ensure that none of these components come into improper contact with each other. If problems with valve train geometry occur, simple changes such as pushrod length may have to be made. OTHER ASSEMBLY TIPS When installing the sparkplugs and exhaust headers, be sure to use a high temperature anti-seize compound on the threads to reduce the possibility of thread damage in the future. Do not exceed a torque of 25 ft./lbs. on the intake manifold bolts and lubricate the bolt threads prior to assembly. If pushrod to cylinder head contact is a problem, loosen rocker studs and re-position guideplate as needed for clearance. INSTALLATION: Installation is the same as for original equipment cylinder heads. Consult service manual for specific procedures, if necessary. For 350 and smaller engines, use Fel-Pro head gasket #1003. #1003 has a flattened steel O-ring around each bore and will provide an excellent, long lasting seal. However, it will compress the aluminum and you must use #1003 for subsequent gasket changes to get a good seal. For 400 c.i.d. small blocks, use Fel-Pro #1014. YOU MUST DRILL “STEAM HOLES” IN CYLINDER HEADS FOR 400 ENGINES (see Figure 2). Be sure that the surface of the block and the surface of the head are thoroughly cleaned to remove any oily film before installation. Use alcohol or lacquer thinner on a lint-free rag to clean. Apply Loctite PST or suitable thread sealer to head bolt threads. Torque to 65 ft./lbs. in three steps (30-50-65) following the factory tightening sequence (see Figure 1). A re-torque is recommended after initial start-up and cool-down (allow 2-3 hours for adequate cooling)

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