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*00-III
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GROUP 05 INDEX
---------------
CONDITION OF VLALVE LIFTERS, CHECK 2013 971023
VALVE SEALS, REPL. 3514 971215
VALVE GUIDES 3731 E9
VALVES 4201 F9
VALVE SEATS 4511 930608
ROCKER ARMS BRACKET/BRIDGE 5522 971205
CAMSHAFTS BASIC SETTING 6072 971030
CAMSHAFT(S), R & R / REPL. 6232 930125
TIMING CHAIN 7601 N9
TIMING CHAIN TENSIONER 7800 O9
TIMING CHAIN TENSIONING & GUIDE RAILS 8424 971030
TIMING CHAIN GUIDE RAILS - ON LEFT/RIGHT CYL. HEAD 8456 971030
TIMING CHAIN GUIDE RAILS - ON CRANKCASE 8484 971030
INCLUDED OPERATIONS AS REQUIRED
05- A EFF DATE: 11-01-03
+ 05-D21
+ 05-D22
+ 05-TTT
-
CONDITION OF VALVE LIFTERS, CHECK
---------------------------
05-2013 * CONDITION OF VALVE LIFTERS - ALL- CHECK, PERFORM .2 K1/K2/K3/K4/K5/L1
(VALVE COVER(S) REMOVED) L2
05-2023 * CONDITION OF VALVE LIFTERS-ON LEFT CYL. HEAD-CHECK, PERFORM .3 K1/K2/K3/K4/K5/L1
(VALVE COVER REMOVED) L2
05-2033 * CONDITION OF VALVE LIFTERS-ON RIGHT CYL. HEAD-CHECK,PERFORM .3 K1/K2/K3/K4/K5/L1
(VALVE COVER REMOVED) L2
05-2313 * VALVE LIFTERS, ALL - (VALVE COVER REMOVED), REPL. 2.6 K1/K5
2.8 K2/K4
05-2322 VALVE LIFTERS (ALL) ON CAM "A" - (AFTER TEST), REPLACE .0 K3/K5
05-2327 VALVE LIFTERS (ALL) ON CAM "B" - (AFTER TEST), REPLACE .0 K3/K5
05-003 EFF DATE: 11-01-03
+ 05-TTT
-
VALVE SEALS, REPL.
-----------
05-3514 * VALVE SEALS, ALL - (CYLINDER HEAD(S) REMOVED), REPL. 2.1 K1/K5
2.7 K2/K3/K4/L1/L2
05-3516 * VALVE SEALS, ALL - (CAMSHAFT(S) REMOVED), REPL. 2.5 K1/K5
3.1 K2/K3/K4/L1/L2
05-3526 * VALVE SEALS, ALL - ON CAMSHAFT "A" VALVES, REPL. 1.6 K1/K5
(CAMSHAFT REMOVED) 1.8 K2/K3/K4/L1/L2
05-3536 * VALVE SEALS, ALL - ON CAMSHAFT "B" VALVES, REPL. 1.6 K1/K5
(CAMSHAFT REMOVED) 1.8 K2/K3/K4/L1/L2
05-3564 * VALVE SEALS, ALL - ON LEFT OR RIGHT CYL. HEAD, REPL. 1.2 K1/K5
(CYLINDER HEAD REMOVED) 1.6 K2/K3/K4/L1/L2
05-3566 * VALVE SEALS, ALL - ON LEFT OR RIGHT CYL. HEAD, REPL. 1.6 K1/K5
(CAMSHAFT(S) REMOVED) 2.1 K2/K3/K4/L1/L2
05-004 EFF DATE: 11-01-03
+ 05-TTT
-
VALVE GUIDES
------------
05-3731 INTAKE & EXHAUST VALVE GUIDES - ALL, REPL. 1.4 K1/K5
(VALVES REMOVED) 1.9 K2/K3/K4/L1/L2
05-3732 INTAKE VALVE GUIDE - ONE, REPL. .2 00
(VALVE REMOVED)
05-3734 INTAKE VALVE GUIDES - ALL, REPL. .8 K1/K5
(VALVES REMOVED) 1.1 K2/K3/K4/L1/L2
05-3735 INTAKE VALVE GUIDES - ALL ON LEFT OR RIGHT CYL. HEAD, REPL. .5 K1/K5
(VALVES REMOVED) .7 K2/K3/K4/L1/L2
05-3736 EXHAUST VALVE GUIDE - ONE, REPL. .3 00
(VALVE REMOVED)
05-3738 EXHAUST VALVE GUIDES - ALL, REPL. .6 K1/K5
(VALVES REMOVED) .8 K2/K3/K4/L1/L2
05-3739 EXHAUST VALVE GUIDES - ALL ON LEFT OR RIGHT CYL. HEAD, REPL. .4 K1/K5
(VALVES REMOVED) .5 K2/K3/K4/L1/L2
05-005 EFF DATE: 11-01-03
+ 05-TTT
-
VALVES
------
05-4201 INTAKE & EXHAUST VALVES - ALL, CLEAN / REFACE 1.6 K1/K5
(VALVES REMOVED) 2.1 K2/K3/K4/L1/L2
05-4202 INT. & EXH. VALVES - FROM LEFT OR RIGHT HEAD, CLEAN & REFACE .8 K1/K5
(VALVES REMOVED) 1.1 K2/K3/K4/L1/L2
05-4211 INTAKE VALVES - ALL, CLEAN AND REFACE 1.0 K1/K5
(VALVES REMOVED) 1.3 K2/K3/K4/L1/L2
05-4212 INTAKE VALVES - ALL FROM LEFT OR RIGHT HEAD, CLEAN & REFACE .6 K1/K5
(VALVES REMOVED) .8 K2/K3/K4/L1/L2
05-4221 EXHAUST VALVES - ALL, CLEAN AND REFACE .6 K1/K5
(VALVES REMOVED) .8 K2/K3/K4/L1/L2
05-4222 EXHAUST VALVES - ALL FROM LEFT OR RIGHT HEAD, CLEAN & REFACE .3 K1/K5
(VALVES REMOVED) .4 K2/K3/K4
05-006 EFF DATE: 11-01-03
+ 05-TTT
-
VALVE SEATS
-----------
05-4511 * VALVE SEATS - ALL, RECONDITION 6.8 K1/K5
(CYLINDER HEAD(S) REMOVED) 8.2 K2/K3/K4/L1/L2
05-4515 VALVE SEAT (1)-CYLINDER HEAD DISASSEMBLED, MACHINE .2 K0
05-4531 * VALVE SEATS - ALL ON LEFT OR RIGHT CYL. HEAD, RECONDITION 2.6 K1/K5
(CYLINDER HEAD REMOVED) 3.5 K2/K4
05-5521 * ROCKER ARM BRACKET/S-BRIDGE ALL REPL. 2.8 K1/K5
(VALVE COVER REMOVED) 3.1 K2/K3/K4/L1/L2
05-007 EFF DATE: 11-01-03
+ 05-TTT
-
ROCKER ARMS BRACKET/BRIDGE
--------------------------
05-5522 * ROCKER ARM BRACKET/BRIDGE - ONE, R & R 2.2 K1/K5
(VALVE COVER REMOVED) 2.3 K2/K3/K4/L1/L2
05-5541 * ROCKER ARM BRACKETS - ALL, D & A / REPL. NEC. PARTS .6 K1/K5
(BRACKETS REMOVED) .7 K2/K3/K4
.8 L1/L2
05-5542 * ROCKER ARM BRACKET/BRIDGE - ONE, D & A / REPL. NEC. PARTS .4 L1/L2
(BRACKET/BRIDGE REMOVED)
CAMSHAFTS BASIC SETTING
-----------------------
05-6072 * CAMSHAFTS BASIC SETTING, CHECK .2 K0
(VALVE COVER(S) REMOVED) L1/L2
05-6074 * CAMSHAFTS BASIC SETTING, CORRECT .0 K1/K2/K3/K4/K5/L1
(AFTER BASIC SETTING CHECK) .0 L2
05-008 EFF DATE: 11-01-03
+ 05-TTT
-
CAMSHAFT(S), R & R / REPL.
-----------
05-6232 * CAMSHAFT A - (VALVE COVER REMOVED), R & R 3.0 K1/K5
3.2 K2/K3/K4/L1/L2
05-6292 * CAMSHAFT A - (VALVE COVER(S) REMOVED), REPL. 3.2 K1/K5
3.3 K2/K3/K4/L1/L2
05-6302 * CAMSHAFT A - (CAM(S) ON OPPOSITE HEAD REMOVED), REPL. 1.1 K1/K5
05-6432 * CAMSHAFT B - (VALVE COVER(S) REMOVED), R & R 1.6 L1/L2
3.0 K1/K5
3.2 K2/K3/K4
05-6442 * CAMSHAFT B - (CAM(S) ON OPPOSITE HEAD REMOVED), R & R .9 K1/K5
05-6492 * CAMSHAFT B - (VALVE COVER(S) REMOVED), REPL. 3.2 K1/K5
3.3 K2/K3/K4/L1/L2
05-6502 * CAMSHAFT B - (CAM(S) ON OPPOSITE HEAD REMOVED), REPL. 1.1 K1/K5
05-6992 * CAMSHAFTS, ALL - (VALVE COVER(S) REMOVED), R & R 3.8 K1/K5
4.2 K2/K3/K4/L1/L2
05-6996 * CAMSHAFTS, ALL - (VALVE COVER(S) REMOVED), REPL. 3.3 L1/L2
4.2 K1/K5
4.5 K2/K3/K4
05-7295 * CAM TIMING ADJUSTER SOLENOID - ON CAMSHAFT B, REPL. .2 L1/L2
(AFTER TEST)
05-009 EFF DATE: 11-01-03
+ 05-TTT
-
TIMING CHAIN
------------
05-7601 * TIMING CHAIN - (VALVE COVER(S) REMOVED), REPL. .0 K2/K3/K4/L1/L2
2.2 K1/K5
05-7603 * TIMING CHAIN - (CYLINDER HEAD(S) REMOVED), REPL. .8 K0
L1/L2
TIMING CHAIN TENSIONER
----------------------
05-7800 * TIMING CHAIN TENSIONER, R & R / REPL. IF REQ. 1.1 K1/K2/K3/K4/K5
2.2 L1/L2
05-7801 * TIMING CHAIN TENSIONER - (VALVE COVER REMOVED), R & R/REPL. .0 K0
05-8052 TIMING CHAIN IDLER SPROCKET, REPL. .2 K1/K2/K3/K4/K5/L1
(TIMING CHAIN COVER REMOVED) L2
05-8126 * TIMING CHAIN TENSIONING RAIL, REPL. .2 K1/K2/K3/K4/K5/L1
(TIMING CHAIN COVER REMOVED) L2
05-010 EFF DATE: 11-01-03
+ 05-TTT
-
TIMING CHAIN TENSIONING & GUIDE RAILS
-------------------------------------
05-8424 * TIMING CHAIN TENSIONING & GUIDE RAILS - ALL, REPL. .2 K1/K2/K3/K4/K5/L1
(TIMING CHAIN COVER REMOVED) L2
05-8427 TIMING CHAIN TENSIONING & GUIDE RAILS - ALL, REPL. .0 L1/L2
(TIMING CHAIN COVER & CYLINDER HEAD REMOVED)
05-8446 TIMING CHAIN GUIDE RAILS - LEFT SIDE (EXPOSED), REPLACE .2 K1/K2/K3/K4/K5/L1
L2
TIMING CHAIN GUIDE RAILS - ON LEFT/RIGHT CYL. HEAD
------------------------
05-8456 TIMING CHAIN GUIDE RAILS - ON ONE CYL. HEAD, REPL. .2 K1/K2/K3/K4/K5/L1
(GUIDE RAIL EXPOSED) L2
05-8466 TIMING CHAIN GUIDE RAILS - ON BOTH CYL. HEADS, REPL. .3 K1/K2/K3/K4/L1/L2
(GUIDE RAILS EXPOSED)
05-011 EFF DATE: 11-01-03
+ 05-TTT
-
TIMING CHAIN GUIDE RAILS - ON CRANKCASE
------------------------
05-8484 * TIMING CHAIN GUIDE RAILS - ON CRANKCASE, REPL. .0 K1/K2/K3/K4
(TIMING COVER REMOVED)
05-012 EFF DATE: 11-01-03
+ 05-XXX
-
05 0000 +INCLUDES:
JOBS IN GROUP 05 INCLUDE OPERATION (S) AS REQ.
ENGINE COOLANT, CHECK FOR PROPER ANTIFREEZE PROTECTION
COOLING SYST., PRESSURE TEST & CHECK FOR LEAK (AFTER REPAIR)
JOBS IN GROUP 05 DO NOT INCLUDE OPERATION (S) FOR:
ENGINE COMPARTMENT PANEL(S) - BOTTOM, R & R WHERE/WHEN REQ.
0______________________________________________________________________________________________________
0 05 2013 +INCLUDES:
2023 VALVE LIFTERS, CHECK ACCORDING TO WORK INSTRUCTION
2033
0______________________________________________________________________________________________________
0 05 2313 +INCLUDED
FAN AND FAN SHROUD, R & R
CHAIN TENSIONING DEVICE, R & R
CAMSHAFT, R & R
ELEMENTS, UNPACK
+NOT INCLUDED
HYDRAULIC VAVE ADJUSTERS, CHECK
BASIC ADJUSTMENT SETTING, MEASURE
0______________________________________________________________________________________________________
0 05 3514 +INCLUDES:
CYLINDER HEAD, MOUNTING & REMOVAL FROM ASSEMBLY DEVICE
VALVE SPRINGS, R & R
05-X001
+ 05-XXX
-
05 3516 +INCLUDES:
3526 SPARK PLUGS, R & R
3536 LIFTERS/ HYDRAULIC ELEMENTS, R & R
3566
0______________________________________________________________________________________________________
0 05 4511 +INCLUDES:
4531 EXHAUST ELBOW, R & R
VALVES, R & R
VALVE GUIDES, CHECK FIRM FIT AND INSPECT FOR WEAR
VALVE SEATS, REWORK WITH VALVE TURNING DEVICE
VALVES, INSPECT FOR LEAKS
VALVE SEALS, REPLACE
+DOES NOT INCLUDE:
PRECHAMBERS, R & R
INJECTION NOZZLES, CHECK
VALVES, CLEAN & REWORK
VALVE GUIDES, REPLACE
CYLINDER HEAD(S), PRESSURE TEST
CYLINDER HEAD(S), MILL SURFACE
0______________________________________________________________________________________________________
05-X002
+ 05-XXX
-
05 5521 +INCLUDES:
FAN SHROUD, R & R
OIL DIPSTICK (M 113), R & R
BELT, REMOVE
GENERATOR, R & R
CHAIN TENSIONING DEVICE, R & R
CAMSHAFT TIMING GEAR A, R & R
CAMSHAFT TIMING GEAR B, R & R
CAMSHAFT BEARING BRIDGE - LEFT AND RIGHT, R & R
0______________________________________________________________________________________________________
0 05 5522 +INCLUDES:
FAN SHROUD, R & R
OIL DIPSTICK ( M 113), R & R
BELT, R & R
GENERATOR, R & R
CHAIN TENSIONING DEVICE, R & R
CAMSHAFT TIMING GEAR A, R & R
0______________________________________________________________________________________________________
0 05 5541 +INCLUDES:
CAMSHAFT BEARING BRIDGE - LEFT AND RIGHT, R & R
VALVE LIFTERS, R & R
0______________________________________________________________________________________________________
0 05 5542 +INCLUDES:
CAMSHAFT BEARING BRIDGE, R & R
VALVE LIFTERS, R & R
05-X003
+ 05-XXX
-
05 6072 +INCLUDES:
POSITION OF CAMSHAFTS IN RELATION TO CRANKSHAFT, ESTABLISH
0______________________________________________________________________________________________________
0 05 6074 +INCLUDES:
FRONT COVER TO CYLINDER HEAD, R & R
ENGINE, SET TO TDC CYLINDER NO. 1
CAMSHAFTS, TURN WITH SPECIAL TOOL AND LOCK WITH PINS
CHAIN TENSIONING DEVICE, R & R
0______________________________________________________________________________________________________
0 05 6232 +INCLUDES:
6292 FAN AND SHROUD, R & R
FRONT COVER TO CYLINDER HEAD, R & R
CAMSHAFT GEAR TO TIMING CHAIN, MARK
ENGINE, CRANK AND CHECK SETTINGS
GENERATOR, R & R
CHAIN TENSIONING DEVICE, R & R
CAMSHAFT TIMING GEAR A, MARK AND R & R
LIFTERS, R & R
ENGINE - START, CHECK FOR LEAKS
+ADDITIONALLY FOR M112,M113
ENGINE TO TDC, SET
OIL FILTER, R & R
+AFTER DIAGNOSIS
LIFTERS, REPLACE
05-X004
+ 05-XXX
-
05 6432 +INCLUDES:
6492 FAN AND SHROUD, R & R
FRONT COVER TO CYLINDER HEAD, R & R
CHAIN TENSIONING DEVICE, R & R
LIFTERS, R & R
+AFTER DIAGNOSIS
LIFTERS, REPLACE
+ADDITIONALLY WITH M 112 AND M 113
OIL FILTER, R & R
ENGINE TO TDC, SET
0______________________________________________________________________________________________________
0 05 6992 +INCLUDES:
6996 SEE INCLUDED TEXT FOR OP CODE 05-6432
0______________________________________________________________________________________________________
0 05 7601 +INCLUDES:
CHAIN TENSIONING DEVICE, R & R
CHAIN GUIDE, R & R
SPARK PLUGS, R & R
CHAIN LINK, R & R USING SPECIAL TOOL
NEW CHAIN, MOUNT WITH OLD CHAIN
CHAIN LINK, RIVET USING SPECIAL TOOL
TIMING, CHECK
05-X005
+ 05-XXX
-
05 7603 +INCLUDES:
CHAIN, OPEN
CHAIN, RIVET USING SPECIAL TOOL
0______________________________________________________________________________________________________
0 05 8424 +INCLUDES:
TDC, INSPECT
0______________________________________________________________________________________________________
0 05 8484 +INCLUDES:
TDC, INSPECT
0______________________________________________________________________________________________________