Work Procedure Gh Action

WORK SEQUENCE

IMPORTANT: In order to remove injector inserts engine must be at operating temperature (engine oil temperature approximately 80 degrees centigrade).


A. Check for Carbon Build-up

(Naturally aspirated and turbo charged engines)

-- Disconnect battery.

-- Remove fuel injector retaining bar. (Naturally aspirated only)

-- Disconnect cruise control and throttle linkage from throttle housing. (Turbo only)

-- Remove air deflector plate. (Turbo only)

-- Unclip and remove fuel injection lines retaining bracket.

-- Remove cylinder #1 and #2 fuel injectors with lines attached. Cover fuel injector openings.

-- Remove cylinder #2 fuel injector insert.

-- Use flashlight and mirror to check for carbon deposits on intake valve.



--If intake valve does not show any deposits-see Illustration 1, valve display 1 through 3 - no cleaning is required. Proceed by reinstalling and reconnecting parts in reverse order.

-- If intake valve shows deposits - see Illustration 1, valve display 4 through 10 - proceed according to preparation and cleaning procedure B and C.
B. Preparation

(Naturally aspirated engines)






Note position of clamps and tie wraps; they must be reinstalled in the original position and location.

-- Disconnect throttle and cruise control linkage from throttle body.

-- Disconnect air intake hose from air filter housing.

-- Remove air filter housing.

-- Disconnect terminal from cold start valve, remove cold start valve with fuel line attached.

-- Remove remaining fuel injecters with lines attached and set aside.

Injecters must be covered to avoid dust entry or damage.

-- Remove CO tube.

-- Remove all spark plugs so that engine can easily be turned by hand.

-- Disconnect terminals from idle stabilizer valve and throttle switches.

-- Remove idle stabilizer valve, disconnect vacuum hoses and ground wire from intake manifold.

-- Disconnect hose from air injector port on cylinder head.

-- Remove intake manifold.

-- Clean gasket areas of intake manifold and cylinder head.

-- Remove remaining fuel injector inserts.



(Turbo charged engines)

-- Remove remaining fuel injecters with fuel lines attached.

Injecters must be covered to avoid dust entry or damage.

-- Remove throttle and cruise control linkage/bracket from intake manifold.

-- Disconnect air hose from air injecter port on cylinder head.

-- Remove air intake hose from manifold to inter cooler.

-- Disconnect throttle switch terminal.

-- Remove air intake tube from inter cooler to air intake boot.
Note position of clamps and tie wraps; they must be reinstalled in the original position and location.



-- Remove air filter housing.


-- Remove CO tube.



-- Remove oxygen sensor.

-- Disconnect cold start valve terminal.

-- Remove clamps and tie-wraps.

-- Remove idle stabilizer and disconnect vacuum hose from manifold.



-- Remove cold start valve with fuel line attached.

-- Remove intake manifold.

-- Remove remaining fuel injecter inserts.

-- Remove all spark plugs so that engine can easily be turned by hand.

-- Clean gasket areas of intake manifold and cylinder head.






C. Cleaning of Intake Valves and Ports

(Naturally aspirated and turbo charged engines)

-- Set up carbon blaster as per attached instructions.

[Adhere to safety precautions]

-- To clean cylinder #1 intake valve and port, set engine to TDC of #1 cylinder.

TDC marking "0" must align with casting marking on clutch housing and marking on camshaft sprocket align with seal as per illustration.
-- Load carbon blaster metering chamber by turning "Fill/Run" control knob to "Fill" position for 15 seconds and then to "Run" position.

-- Clean threads of fuel injector insert port.



-- Install adapter (21) into insert port and connect return hose to adapter.

-- Install cover plate (18 dual/19 single) with cleaning nozzle to intake port.
-- Cover air injector port on cylinder head with CO tube cap.

-- Stuff rags into adjacent insert ports of cylinder head to prevent cleaning particles from entering.

-- Turn carbon blaster knob to "Blast" position.

-- Move and rotate blasting/cleaning nozzle by hand to reach all areas of the intake valve and port for one (1) minute.

-- Turn carbon blaster knob to "Clean" position, clean for one (1) minute.



-- Remove cover plate with cleaning nozzle.

-- Inspect intake valve with mirror and flashlight.

-- Blow out any remaining particles.

-- Remove return hose and adapter.

-- To clean cylinder #2, 4, 5, and 3 (in firing order) turn engine by hand to set cylinder to TDC.
-- Repeat cleaning procedure as described for cylinder #1.

-- After cleaning of all valves is completed use compressed air to clean all intake ports.

-- Reassemble engine by using the following new parts:

1984 (naturally aspirated and turbo charged engines)

Quantity Description Part Number

1 or 5 (if necessary) Insert 063 133 555A

1 or 5 Insert sealing washer N013 844.3

2 or 5 Injecter O-ring 063 133 557

1 (if required) Gasket (intake) 035 129 717F

1 (if required) Gasket (cold start valve) 063 906 179

Loctite 325 Locally Available

5 Tie wrap N900 603.01

1 (if required) Plug 049 133 777B


1985-87 (naturally aspirated and turbo charged engines)

Quantity Description Part Number

1 or 5 (if necessary) Insert 035 133 554

1 or 5 (if necessary) Insert 035 133 555C

1 or 5 Insert sealing washer 035 133 557

2 or 5 Injecter O-ring (small) 035 133 557A

2 or 5 Injecter O-ring (large) 063 133 557

1 (if required) Gasket (intake) 035 129 717F

1 (if required) Gasket (cold start valve) 063 906 179

Loctite 325 Locally Available

5 Tie wrap N900 603.01

1 (if required) Plug 049 133 777B
IMPORTANT

-- Ensure that during reassembly all connectors and hoses are properly reinstalled identical to original position.

-- Install inserts with Loctite and torque to 15-20 N-m.


-- Check CO, adjust if necessary.