Service Manual
Table Of Contents
- GENERAL INFORMATION
- MAINTENANCE
- ELECTRONIC FUEL INJECTION
- SPECIAL TOOLS
- Part Numbers / Descriptions
- Fuel Pressure Gauge Kit - PU-43506-A
- Fuel Pressure Gauge Adaptor - PS-48762
- Throttle Position Sensor Tester Kit - 2201519
- Digital Wrench™ Diagnostic Software PU-47063
- Digital Wrench™ SmartLink Module Kit - PU-47471
- Digital Wrench™ - Diagnostic Connector
- Digital Wrench™ - Download Website
- FUEL TANK
- FUEL LINE
- EFI SERVICE NOTES
- EFI SYSTEM LAYOUT
- EFI COMPONENTS
- ELECTRONIC FUEL INJECTION
- ELECTRONIC CONTROL UNIT (ECU)
- FUEL PUMP
- FUEL PRESSURE REGULATOR
- FUEL INJECTORS
- CRANKSHAFT POSITION SENSOR (CPS)
- TEMP / MANIFOLD ABSOLUTE PRESSURE SENSOR (T-MAP)
- IDLE AIR CONTROL VALVE (IAC)
- THROTTLE POSITION SENSOR (TPS)
- ENGINE COOLANT TEMPERATURE SENSOR (ECT)
- IGNITION COIL
- EFI DIAGNOSTICS
- FUEL SYSTEM TROUBLESHOOTING
- EFI SYSTEM BREAK-OUT DIAGRAMS
- Fuel Injector Circuit (PTO)
- Fuel Injector Circuit (MAG)
- Idle Air Control (IAC) Circuit
- Crankshaft Position Sensor (CPS) Circuit
- Fuel Pump / Fuel Level Sensor Circuit
- Fuel Pump Circuit
- Fuel Gauge Circuit
- Engine Coolant Temperature Sensor (ECT) Circuit
- Throttle Position Sensor (TPS) Circuit
- Intake Air Temperature / Manifold Absolute Pressure Sensor (T-MAP) Circuit
- Diagnostic Connector Circuit
- Diagnostic Connector Circuit (EPS Models)
- SPECIAL TOOLS
- COOLING SYSTEM
- ENGINE
- GENERAL INFORMATION - ENGINE
- ENGINE ASSEMBLY VIEWS AND TORQUE VALUES
- Torque & Torque Sequence - Main Engine Components
- Valve Cover / Breather Valve
- Camshaft Carrier / Camshaft / Rocker Arm
- Cylinder Head / Valve / IAFM
- Valve & Spring Height Detail
- Piston / Connecting Rod
- Crankshaft
- Crankcase
- Crankcase - Upper
- Balance Shaft / Balance Shaft Timing
- Crankcase (Lower) With Oil Pump
- Water Pump Coupler
- Water Pump / Water Pump Coupler / Stator / Flywheel
- Drive Coupler (Rear) / Starter Gear
- ENGINE SERVICE
- ENGINE DISASSEMBLY AND INSPECTION
- Valve Cover / Breather Valve
- Rocker Carrier / Camshaft Removal
- Rocker Arm / Rocker Arm Shaft Inspection
- Camshaft / Camshaft Bore Inspection
- Cylinder Head Removal
- Cylinder Head Cleaning
- Cylinder Head Warp Inspection
- Cylinder Head
- Valve Inspection
- Combustion Chamber
- Valve Guide Removal / Installation
- Valve Seat Reconditioning
- Cylinder Head Assembly
- Valve Sealing Test
- Cylinder Head Installation
- Camshaft / Carrier Assembly
- Camshaft / Camshaft Carrier Installation
- Camshaft Timing
- Cam Chain Tensioner Installation
- Camshaft Timing - Quick Reference
- Crankcase Disassembly
- Crankcase (Lower) / Oil Pump Disassembly
- Crankcase Disassembly (Upper)
- Piston / Connecting Rod Removal
- Counterbalance Shaft Removal / Inspection
- Counterbalance Split Gear Replacement
- Crankshaft / Cam Chain Removal
- Cam Chain / Sprocket Inspection
- Crankcase Inspection (Lower)
- Crankshaft Inspection
- Connecting Rod Inspection
- Connecting Rod Big End Bearing Selection
- Piston / Piston Ring Inspection
- Piston Ring Removal
- Piston Ring Installed Gap
- Piston Pin Bore Inspection
- Cylinder Inspection
- Piston-to-Cylinder Clearance
- Honing - Important Information
- ENGINE ASSEMBLY
- Crankcase Preparation - Upper
- Piston Ring Installation
- Piston / Connecting Rod Assembly
- Piston / Connecting Rod Installation
- Crankshaft Installation
- Oil Passage Tube
- Crankcase Assembly - Upper
- Balance Shaft Installation
- Balance Shaft Timing
- Crankcase Preparation (Lower)
- Crankcase Sealant and Torque Values
- Crankcase Assembly
- WATER PUMP
- TROUBLESHOOTING
- TRANSMISSION
- CLUTCHING (PVT)
- FINAL DRIVE
- BODY / FRAME
- STEERING / SUSPENSION
- BRAKES
5.5
ENGINE
5
Engine Specifications - EH085OLE-011
CYLINDER HEAD (IN. / MM)
Camshaft
Cam Lobe Height - Intake (Standard) 0.897" (22.795 mm)
Cam Lobe Height - Exhaust (Standard) 0.908" (23.067 mm)
Camshaft Journal Outer Diameter - (All) .8632" ± 0.0004" (21.925 ± 0.01 mm)
Camshaft Journal Bore Inner Diameter - (All) .8661" ± 0.0004" (22.000 ± 0.01 mm)
Camshaft Oil Clearance 0.0034" ± 0.0008" (0.086 ± 0.02 mm)
Camshaft End Play 0.008" ± 0.004" (0.20 ± 0.10 mm)
Rocker Arm and
Shaft
Rocker Shaft O.D. (Intake and Exhaust) 0.5501" (13.973 - 13.984 mm)
Rocker Arm I.D. (Intake and Exhaust) 0.5514" - 0.5525" (14.006 - 14.033 mm)
Rocker Shaft Bore I.D. (Intake and Exhaust) 0.5514" - 0.5525" (14.006 - 14.033 mm)
Cylinder Head
Cylinder Head - Surface warp limit 0.004" (0.1 mm)
Cylinder Head - Standard height 3.611" (91.71 mm)
Valve Seat
Valve Seat - Contacting Width - Intake
0.047" ± 0.008" - 0.0039"
(1.20 ± 0.20 mm)
Valve Seat - Contacting Width - Exhaust
0.047" ± 0.008" - 0.0039"
(1.20 ± 0.20 mm)
Valve Seat Angle 45.5° ± 0.25°
Valve Guide
Valve Guide Inner diameter 0.217" + .0005" - 0.0 (5.52 + .012 - 0.0 mm)
Valve Guide Protrusion Above Head - Intake 0.361" ± 0.010" (9.18 ± 0.25 mm)
Valve Guide Protrusion Above Head - Exhaust 0.276" ± 0.010" (7.00 ± 0.25 mm)
Valv e
Valve Lash (Cold) - Intake 0.006" (.152 mm ± 0.025 mm)
Valve Lash (Cold) - Exhaust 0.009" (.228 mm ± 0.025 mm)
Valve Margin Thickness - Intake 0.016" (.41 mm)
Valve Margin Thickness - Exhaust 0.023" (.59 mm)
Valve Stem Diameter - Intake 0.2163" ± 0.0003" (5.495 ± 0.0075 mm)
Valve Stem Diameter - Exhaust 0.2159" ± 0.0003" (5.485 ± 0.0075 mm)
Valve Stem Oil Clearance - Intake 0.0014" ± 0.0005" (0.035 ± 0.0135 mm)
Valve Stem Oil Clearance - Exhaust 0.0018" ± 0.0005" (0.045 ± 0.0135 mm)
Valve Stem Overall Length - Intake 4.6681" ± 0.012" (118.57 ± 0.30 mm)
Valve Stem Overall Length - Exhaust 4.5649" ±
.012" (1
15.95 ± 0.30 mm)
Valve Spring
Valve Spring Free Length 1.861" (47.26 mm)
Valve Spring Installed Height
Intake - 1.650" (41.91 mm)
Exhaust - 1.650" (41.91 mm)