GM 4.3L Manual Desarme

Original Issue
Dated January 2004

Publication Number 4.3LESM
4.3L
INDUSTRIAL ENGINE
SERVICE MANUAL

No part of this publication may be reproduced without the written
permission of Power Solutions, Inc. At the time of publication, all of
the information included in this publication is accurate to the best
of our knowledge. Power Solutions, Inc., cannot be responsible for
information that has changed after this book was published.

Engine Marine/Industrial 4.3L 6-1
2000 Marine/Industrial
Engine Mechanical - 4.3L
Specifications
Fastener Tightening Specifications Fastener Tightening Specifications Fastener Tightening Specifications Fastener Tightening Specifications Fastener Tightening Specifications
Specification
Application Metric English
Accelerator Control Cable Bracket Nut to Stud 12 Nm 106 lb in
Accelerator Control Cable Bracket Nut to Throttle Body 9 Nm 80 lb in
Accelerator Control Cable Bracket Stud to Intake Manifold 6 Nm 53 lb in
Accelerator Control Cable Bracket Stud to Throttle Body 12 Nm 106 lb in
Air Cleaner Adapter Stud 8 Nm 71 lb in
Balance Shaft Driven Gear Bolt
First Pass 20 Nm 15 lb ft
Final Pass 35 degrees
Balance Shaft Retainer Bolt 12 Nm 106 lb in
Battery Cable Bracket Bolt to Oil Pan 12 Nm 106 lb in
Battery Negative Cable Bolt to Engine 25 Nm 18 lb ft
Battery Positive Cable J unction Block Bracket Bolt 25 Nm 18 lb ft
Belt Idler Pulley Bolt 50 Nm 37 lb ft
Camshaft Retainer Bolt 12 Nm 106 lb in
Camshaft Sprocket Bolt 25 Nm 18 lb ft
Connecting Rod Nut
Crankshaft Balancer Bolt 95 Nm 70 lb ft
Crankshaft Bearing Cap (Preferred Method)
Crankshaft Bearing Cap Bolt 105 Nm 77 lb ft
Crankshaft Position Sensor Bolt 8 Nm 71 lb in
Crankshaft Pulley Bolt 58 Nm 43 lb ft
Crankshaft Rear Oil Seal Housing Bolt and Nut 12 Nm 106 lb in
Crankshaft Rear Oil Seal Housing Retainer Stud 6 Nm 53 lb in
Cylinder Head Bolt (Preferred Method)
All Bolts First Pass in Sequence 30 Nm 22 lb ft
Long Bolts Final Pass in Sequence 75 degrees
Medium Bolts Final Pass in Sequence 65 degrees
Short Bolts Final Pass in Sequence 55 degrees
Cylinder Head Core Hole Plug 20 Nm 15 lb ft
Distributor Cap Bolt 2.4 Nm 21 lb in
Distributor Clamp Bolt 25 Nm 18 lb ft
Drive Bolt Tensioner Bolt 50 Nm 37 lb ft
EGR Valve Bolt
First Pass 7 Nm 62 lb in
Final Pass 30 Nm 22 lb ft
6-2 Marine/Industrial 4.3L Engine
Fastener Tightening Specifications (contd) Fastener Tightening Specifications (contd) Fastener Tightening Specifications (contd) Fastener Tightening Specifications (contd) Fastener Tightening Specifications (contd)
Specification
EGR Valve Inlet Pipe Clamp Bolt 25 Nm 18 lb ft
EGR Valve Inlet Pipe Nut at Intake Manifold 25 Nm 18 lb ft
EGR Valve Inlet Pipe Nut at Exhaust Manifold 30 Nm 22 lb ft
Engine Block Left Side Oil Gallery Plug 20 Nm 15 lb ft
Engine Block Left Rear Oil Gallery Plug 30 Nm 22 lb ft
Engine Block Right Rear Oil Gallery Plug 20 Nm 15 lb ft
Engine Block Coolant Drain Hole Plug 20 Nm 15 lb ft
Engine Block Oil Gallery Plug 20 Nm 15 lb ft
Engine Coolant Heater Bolt/Screw 2 Nm 18 lb in
Engine Coolant Temperature (ECT) Sensor 20 Nm 15 lb ft
Engine Flywheel Bolt 100 Nm 74 lb ft
Engine Front Cover Bolt 12 Nm 106 lb in
Engine Lift Bracket Bolt (Special Tool J 41427) 15 Nm 11 lb ft
Engine Lift Front Bracket Stud 35 Nm 26 lb ft
Engine Mount Bolt to Engine Bracket 50 Nm 37 lb ft
Engine Mount Engine Bracket Bolt to Engine 50 Nm 37 lb ft
Engine Mount Frame Bracket Through-Bolt 75 Nm 55 lb ft
Engine Mount Frame Side Mount Bolt 65 Nm 50 lb ft
Engine Oil Level Sensor 13 Nm 115 lb in
Engine Oil Pressure Gauge Sensor 30 Nm 22 lb ft
Engine Oil Pressure Gauge Sensor Fitting (Plus Required Angle) 15 Nm 11 lb ft
Engine Wiring Harness Bracket Bolt to Battery Positive Cable J unction
Block Bracket
9 Nm 80 lb in
Engine Wiring Harness Bracket Bolt to Generator and Drive Belt
Tensioner Bracket
25 Nm 18 lb ft
Engine Wiring Harness Bracket Bolt to Rear Right Side Cylinder Head 25 Nm 18 lb ft
Engine Wiring Harness Bracket Nut to Evaporative Emission (EVAP)
Canister Purge Solenoid Valve Stud
9 Nm 80 lb in
Engine Wiring Harness Bracket Nut to Intake Manifold Stud 12 Nm 106 lb in
Evaporitive Emission (EVAP) Canister Purge Solenoid Valve Stud to
Intake Manifold
10 Nm 89 lb in
Exhaust Manifold Bolt/Stud
Final Pass 30 Nm 22 lb ft
Exhaust Manifold Heat Shield Bolt 9 Nm 80 lb in
Fan and Water Pump Pulley Bolt 25 Nm 18 lb ft
Frame Cross Bar Bolt 100 Nm 74 lb ft
Fuel Meter Body Bracket Bolt 10 Nm 89 lb in
Fuel Pipe Bracket Bolt 6 Nm 53 lb in
Fuel Pipe Retainer Nut 3 Nm 27 lb in
Fuel Supply Pipe Nut (Fuel Tank Side) 30 Nm 22 lb ft
Generator and Drive Belt Tensioner Bracket Bolt to Engine 41 Nm 30 lb ft
Generator and Drive Belt Tensioner Bracket Stud to Engine 20 Nm 15 lb ft
Specification
Generator and Drive Belt Tensioner Bracket Stud Nut 41 Nm 30 lb ft
Ground Wire Bolt to Rear of Left Side Cylinder Head 16 Nm 12 lb ft
Ground Wire Nut to Rear of Right Side Cylinder Head 16 Nm 12 lb ft
Heater Hose Bracket Bolt to Generator and Drive Belt Tensioner
Bracket
25 Nm 18 lb ft
Ignition Coil Stud 12 Nm 106 lb in
Knock Sensor 20 Nm 15 lb ft
Lower Intake Manifold Stud
First Pass in Sequence 3 Nm 27 lb in
Second Pass in Sequence 12 Nm 106 lb in
Final Pass in Sequence 15 Nm 11 lb ft
Oil Cooler Pipe Bracket to Oil Pan Bolt 12 Nm 106 lb in
Oil Filter Fitting 55 Nm 41 lb ft
Oil Level Indicator Tube Bolt 12 Nm 106 lb in
Oil Pan Baffle Bolt 12 Nm 106 lb in
Oil Pan Bolt and Nut 25 Nm 18 lb ft
Oil Pan Drain Plug 25 Nm 18 lb ft
Oil Pan Skid Plate Bolt 20 Nm 15 lb ft
Oil Pump Bolt to Rear Crankshaft Bearing Cap 90 Nm 66 lb ft
Oil Pump Cover Bolt 12 Nm 106 lb in
Power Steering Pump Bracket Bolt to Engine 41 Nm 30 lb ft
Power Steering Pump Bracket Bolt to Engine 20 Nm 15 lb in
Power Steering Pump Bracket Stud Nut 41 Nm 30 lb ft
Power Steering Pump Bolt 50 Nm 37 lb ft
Power Steering Pump Nut to Engine (Rear Bracket to Engine) 41 Nm 30 lb ft
Power Steering Pump Rear Bracket Nut 50 Nm 37 lb ft
Secondary Air Injection (AIR) Check Valve Pipe Bracket Bolt to
Exhaust Manifold
10 Nm 89 lb in
Secondary Air Injection (AIR) Check Valve Pipe Stud Nut 25 Nm 18 lb ft
Spark Plug
Initial Installation (NEW Cylinder Head) 30 Nm 22 lb ft
All Subsequent Installations 15 Nm 11 lb ft
Spark Plug Wire Support Bolt 12 Nm 106 lb in
Starter Motor Wiring Harness/Transmission Cooler Pipe Bracket to
Oil Pan Bolt
9 Nm 80 lb in
Throttle Body Stud 9 Nm 80 lb in
Transmission to Oil Pan Bolt 47 Nm 35 lb ft
Transmission Cover Bolt 12 Nm 106 lb in
Upper Intake Manifold Stud
First Pass 5 Nm 44 lb in
Final Pass 9 Nm 80 lb in
Valve Lifter Pushrod Guide Bolt 16 Nm 12 lb ft
Valve Rocker Arm Bolt 30 Nm 22 lb ft
Valve Rocker Arm Cover Bolt 12 Nm 106 lb in
Specification
Water Outlet Stud 25 Nm 18 lb ft

Water Pump Bolt 45 Nm 33 lb ft
Engine Mechanical Specifications Engine Mechanical Specifications Engine Mechanical Specifications Engine Mechanical Specifications Engine Mechanical Specifications
Specification
General Data
Engine Type V6
Regular Production Option (RPO) Code L35 VIN Code W
Displacement 4.3L 262 CID
Bore 101.60 mm 4.012 in
Stroke 88.39 mm 3.480 in
Compression Ratio 9.2:1
Firing Order 1-6-5-4-3-2
Spark Plug Gap 1.52 mm 0.060 in
42 kPa at 6.0 psig at
1,000 engine rpm 1,000 engine rpm
Oil Pressure (Minimum) at Normal Operating Temperature 125 kPa at 18.0 psig at
166 kPa at 24.0 psig at
Balance Shaft
Rear Bearing J ournal Clearance 0.050-0.088 mm 0.0020-0.0035 in
Rear Bearing J ournal Diameter 38.085-38.100 mm 1.4994-1.500 in
Camshaft
End Play 0.0254-0.2286 mm 0.0010-0.0090 in
J ournal Diameter 47.440-47.490 mm 1.8677-1.8696 in
J ournal Diameter Out-of-Round 0.025 mm (Maximum) 0.0010 in (Maximum)
Lobe Lift (Exhaust) 7.20-7.30 mm 0.283-0.287 in
Lobe Lift (Intake) 6.97-7.07 mm 0.274-0.278 in
Runout 0.065 mm 0.0026 in
Connecting Rod
Connecting Rod Bearing Clearance (Production) 0.038-0.078 mm 0.0015-0.0031 in
Connecting Rod Bearing Clearance (Service) 0.025-0.063 mm 0.0010-0.0025 in
Connecting Rod Side Clearance 0.15-0.44 mm 0.006-0.017 in
Connecting Rod J ournal Diameter 57.116-57.148 mm 2.2487-2.2497 in
Connecting Rod J ournal Taper (Production) 0.00508 mm (Maximum) 0.00030 in (Maximum)
Connecting Rod J ournal Taper (Service) 0.025 mm (Maximum) 0.0010 in (Maximum)
Connecting Rod J ournal Out-of-Round (Production) 0.007 mm (Maximum) 0.0002 in (Maximum)
Connecting Rod J ournal Out-of-Round (Service) 0.025 mm (Maximum) 0.0010 in (Maximum)
Crankshaft
Crankshaft Bearing Clearance (J ournal #1-Production) 0.02-0.0508 mm 0.0008-0.0020 in
Crankshaft Bearing Clearance (J ournal #2, #3 and #4-Production) 0.028-0.058 mm 0.0011-0.0023 in
Crankshaft Bearing Clearance (J ournal #1-Service) 0.0254-0.05 mm 0.0010-0.0020 in
Crankshaft Bearing Clearance (J ournal #2, #3 and #4-Service) 0.025-0.063 mm 0.0010-0.0250 in
Crankshaft End Play 0.050-0.20 mm 0.002-0.008 in
Crankshaft J ournal Diameter (J ournal #1) 62.199-62.217 mm 2.4488-2.4495 in
Crankshaft J ournal Diameter (J ournal #2 and #3) 62.191-62.215 mm 2.4485-2.4494 in
Engine Mechanical Specifications (contd) Engine Mechanical Specifications (contd) Engine Mechanical Specifications (contd) Engine Mechanical Specifications (contd) Engine Mechanical Specifications (contd)
Crankshaft J ournal Diameter (J ournal #4) 62.179-62.203 mm 2.4480-2.4489 in
Crankshaft J ournal Out-of-Round (Production) 0.005 mm (Maximum) 0.0002 in (Maximum)
Crankshaft J ournal Out-of-Round (Service) 0.025 mm (Maximum) 0.0010 in (Maximum)
Crankshaft J ournal Taper (Production) 0.007 mm (Maximum) 0.0003 in (Maximum)
Crankshaft Runout 0.025mm (Maximum) 0.0010 in (Maximum)
Cylinder Bore
Diameter 101.618-101.643 mm 4.0007-4.0017 in
Out-of-Round (Production) 0.0127 mm (Maximum) 0.00050 in (Maximum)
Out-of-Round (Service) 0.05 mm (Maximum) 0.002 in (Maximum)
Taper (Production Relief Side) 0.025 mm (Maximum) 0.0010 in (Maximum)
Taper (Production Thrust Side) 0.012 mm (Maximum) 0.0005 in (Maximum)
Taper (Service) 0.025 mm (Maximum) 0.0010 in (Maximum)
Cylinder Head
Surface Flatness 0.10 mm (Maximum) 0.004 in (Maximum)
Exhaust Manifold
Surface Flatness (Flange to Flange) 0.25 mm (Maximum) 0.010 in (Maximum)
Surface Flatness (Individual Flange) 0.05 mm (Maximum) 0.002 in (Maximum)
Intake Manifold
Surface Flatness 0.10 mm (Maximum) 0.004 in (Maximum)
Oil Pan
Oil Pan Alignment at Rear of Engine Block 0.3 mm (Maximum) 0.011 in (Maximum)
Piston
Piston Bore Clearance (Production) 0.018-0.061 mm 0.0007-0.0024 in
Piston Bore Clearance (Service) 0.075 mm (Maximum) 0.0029 in (Maximum)
Piston Pin
Clearance in Piston (Production) 0.013-0.023 mm 0.0005-0.0009 in
Clearance in Piston (Service) 0.025 mm (Maximum) 0.010 in (Maximum)
Diameter 23.545-23.548 mm 0.9270-0.9271 in
Fit in Connecting Rod
0.021-0.040 mm 0.0008-0.0016 in
(Interference) (Interference)
Piston Rings (End Gap Measured in Cylinder Bore)
Piston Compression Ring Gap (Production-Top Groove) 0.25-0.40 mm 0.010-0.016 in
Piston Compression Ring Gap (Production- 2nd Groove) 0.46-0.66 mm 0.018-0.026 in
Piston Compression Ring Gap (Service -Top Groove) 0.5 mm (Maximum) 0.19 in (Maximum)
Piston Compression Ring Gap (Service - 2nd Groove) 0.8 mm (Maximum) 0.31 in (Maximum)
Piston Compression Ring Groove Clearance (Production-Top Groove) 0.030-0.070 mm 0.0012-0.0027 in
Piston Compression Ring Groove Clearance (Production- 2nd Groove) 0.040-0.080 mm 0.0015-0.0031 in
Piston Compression Ring Groove Clearance (Service) 0.085 mm (Maximum) 0.0033 in (Maximum)
Piston Oil Ring Gap (Production) 0.25-0.76 mm 0.010-0.029 in
Piston Oil Ring Gap (Service) 0.90 mm(Maximum) 0.035 in (Maximum)
Piston Oil Ring Groove Clearance (Production) 0.046-0.096 mm 0.0018-0.00037 in
Piston Oil Ring Groove Clearance (Service) 0.10 mm (Maximum) 0.0039 in (Maximum)
Valve System
Valve Face Angle 45 Degrees
Valve Head Edge Margin 0.79 mm (Minimum) 0.031 in (Minimum)
Valve Lash Net Lash - No Adjustment
Valve Lift (Exhaust) 10.879 mm 0.4280 in
Valve Lift (Intake) 10.527 mm 0.4140 in
Valve Lifter Hydraulic Roller Type
Valve Rocker Arm Roller Pivot Type
Valve Rocker Arm Ratio 1.5:1
Valve Seat Angle 46 Degrees
Valve Seat Runout 0.05 mm (Maximum) 0.002 in (Maximum)
Valve Seat Width (Exhaust) 1.651-2.489 mm 0.065-0.098 in
Engine Mechanical Specifications (contd) Engine Mechanical Specifications (contd) Engine Mechanical Specifications (contd) Engine Mechanical Specifications (contd) Engine Mechanical Specifications (contd)
Valve Seat Width (Intake) 1.016-1.651 mm 0.040-0.065 in
Valve Spring Free Length 51.3 mm 2.02 in
Valve Spring Installed Height (Exhaust) 42.92-43.43 mm 1.670-1.700 in
Valve Spring Installed Height (Intake) 42.92-43.43 mm 1.670-1.700 in
Valve Spring Pressure (Closed) 338-374 N at 43.2 mm 76-84 lb at 1.70 in
Valve Spring Pressure (Open) 832-903 N at 32.3 mm 187-203 lb at 1.27 in
Valve Stem Clearance (Exhaust-Production) 0.025-0.069 mm 0.0010-0.0027 in
Valve Stem Clearance (Exhaust-Service) 0.025-0.094 mm 0.0010-0.0037 in
Valve Stem Clearance (Intake-Production) 0.025-0.069 mm 0.0010-0.0027 in
Valve Stem Clearance (Intake-Service) 0.025-0.094 mm 0.0010-0.0037 in

Valve Stem Oil Seal Installed Height (Measured from the Top of the
Large Diameter Valve Guide Bevel to the Bottom of the Valve Stem 1-2 mm 0.03937-0.07874 in
Oil Seal)
GM SPO Group Numbers GM SPO Group Numbers GM SPO Group Numbers GM SPO Group Numbers GM SPO Group Numbers
Application GM SPO Group Number
Accelerator Control Cable Bracket 3.454
Balance Shaft 0.659
Balance Shaft Bearing Kit (Rear) 0.659
Balance Shaft Gear Kit (Includes Drive and Driven Gears) 0.529
Balance Shaft Retainer 0.659
Belt Idler Pulley (Grooved) 1.062
Belt Idler Pulley (Smooth) 1.062
Camshaft Bearing 0.539
Camshaft Retainer 0.529
Camshaft Sprocket 0.736
Camshaft Timing Chain 0.724
Clutch Pilot Bearing 0.649
Connecting Rod 0.603
Connecting Rod Bearing Kit 0.616
Coolant Radiator 1.219
Crankshaft Balancer 0.659
Crankshaft Balancer Key 0.662
Crankshaft Bearing Kit 0.096
Crankshaft Front Oil Seal 0.213
Crankshaft Rear Oil Seal 0.137
Crankshaft Rear Oil Seal Housing 0.137
Crankshaft Rear Oil Seal Housing Retainer Stud 0.137
Crankshaft Rear Oil Seal Retainer Stud 0.137
Crankshaft Position Sensor 2.383
Crankshaft Position Sensor Reluctor Ring 2.383
Crankshaft Position Sensor Seal (O-ring) 2.383
Crankshaft Pulley 0.659
Crankshaft Sprocket 0.728
Cylinder Head 0.269
Cylinder Head Gasket 0.289
Distributor 2.361
Distributor Clamp 2.363
Distributor Gasket 2.363
Dowel Pin (Cylinder Head Locator) 8.939
Dowel Straight Pin (Transmission Locator) 8.939
GM SPO Group Numbers (contd) GM SPO Group Numbers (contd) GM SPO Group Numbers (contd) GM SPO Group Numbers (contd) GM SPO Group Numbers (contd)
Drive Belt Tensioner 1.060
EGR Valve 3.670
EGR Valve Gasket 3.680
EGR Valve Inlet Pipe 3.675
Evaporative Emission Canister Purge Solenoid Valve 3.130
Evaporative Emission Canister Purge Solenoid Valve Harness 3.145
Engine Block N.S.
Engine Block Core Hole Plug 0.034
Engine Block Oil Gallery Plug 1.531
Engine Camshaft 0.519
Engine Coolant Heater 1.152
Engine Coolant Temperature Sensor 1.150
Engine Coolant Temperature Gauge Sensor 1.150
Engine Coolant Thermostat 1.246
Engine Crankshaft 0.646
Engine Flywheel 0.666
Engine Front Cover 0.206
Engine Mount 0.029
Engine Mount Bracket 0.029
Engine Oil Level Sensor 1.516
Engine Oil Pressure Gauge Sensor 1.800
Engine Oil Pressure Gauge Sensor Fitting 1.800
Engine Piston Kit (Piston and Pin) 0.629
Engine Wiring Harness Bracket 2.559
Exhaust Manifold 3.601
Exhaust Manifold Gasket 3.270
Exhaust Manifold Heat Shield 3.602
Exhaust Valve 0.297
Expansion Cup Plug (Balance Shaft Rear Bearing Hole) 8.970
Expansion Cup Plug (Camshaft Rear Bearing Hole) 8.970
Fan & Water Pump & A/C Compressor & Generator & Power Steering Pump Belt 1.066
Fan & Water Pump & Generator & Power Steering Pump Belt 1.066
Fan & Water Pump Pulley 1.062
Flywheel Locator Pin 0.669
Front Groove Pin (Crankshaft Balancer) 8.940
Fuel Pipe (Included in Fuel Injection Feed and Return Pipe Kit Only) 3.163
Fuel Pipe Retainer Bracket (Included in Fuel Injection Feed and Return Pipe Kit Only) 3.163
Fuel Injector (O-ring) Seal Kit 3.331
Generator & Drive Belt Tensioner Bracket 1.060
Ignition Coil 2.170
Ignition Coil Wire Harness 2.240
Intake Valve 0.296
Knock Sensor 2.383
Lower Intake Manifold (Included in Lower Intake Manifold Kit Only) 3.265
Lower Intake Manifold Gasket Kit 3.270
MAP Sensor 3.682
MAP Sensor Seal 3.682
Oil Fill Cap 1.758
Oil Fill Tube 1.745
Oil Fill Tube (Lower Bracket) 1.750
Oil Filter 1.836
Oil Filter Bypass Valve 1.837
Oil Filter Fitting 1.855
Oil Level Indicator 1.516
Oil Level Indicator Tube 1.516
Oil Pan 1.426
Oil Pan Drain Plug 1.453
Oil Pan Drain Plug Seal (O-ring) 1.456
Oil Pan Gasket 1.429
Oil Pump 1.652
Oil Pump Cover 1.723
Oil Pump Drive Shaft 1.639
Oil Pump Drive Shaft Retainer 1.639
Oil Pump Pressure Relief Valve 1.609
Oil Pump Pressure Relief Valve Spring 1.609
Oil Pump Pressure Relief Valve Spring Bore Plug 1.609
Oil Pump Pressure Relief Valve Spring Straight Pin 1.609
Oil Pump Screen 1.656
PCV Tube 1.762
PCV Valve 1.745
PCV Valve Cover 1.745
PCV Valve Elbow 1.762
PCV Valve Hose 1.762
Pin (Oil Pump Locator) 1.723
Piston Ring Kit 0.643
Power Steering Pump Bracket 6.606
Secondary Air Injection (AIR) Check Valve 3.670
Secondary Air Injection (AIR) Check Valve Gasket 3.680
Secondary Air Injection (AIR) Check Valve (Crossover) Pipe 3.675
Secondary Air Injection (AIR) Check Valve Pipe 3.675
Spark Plug 2.270
Spark Plug Wire 2.240
Spark Plug Wire Shield 2.251
Spark Plug Wire Support 2.251
Spring Type S Pin (Crankshaft Rear Oil Seal Housing Locator) 8.940
Starter Motor 2.041
TBI Fuel Meter 3.734
Throttle Body 3.335
Throttle Body to Upper Manifold Gasket (Included in Service Kits Only) N.S.
Torque Converter Housing Access Hole Plug (Rubber/at Oil Pan) 4.104
Transmission Brace 4.081
Transmission Cover 4.105
Upper Intake Manifold (Included in Upper Intake Manifold Kit Only) 3.625
Upper Intake Manifold to Lower Intake Manifold Gasket (Included in Intake Manifold Seal Kit) 3.270
Valve Lifter 0.459
Valve Lifter Pushrod Guide 0.439
Valve Pushrod 0.426
Valve Rocker Arm Assembly 0.333
Valve Rocker Arm Cover 0.386
Valve Rocker Arm Cover Bolt Grommet 0.423
Valve Rocker Arm Cover Gasket 0.423
Valve Rocker Arm Support 0.429
Valve Spring 0.303
Valve Spring Cap 0.309
Valve Stem Key 0.310
Valve Stem Oil Seals 0.308
Water Outlet 1.153
Water Pump Gaskets 1.079
Water Pump Inlet Hose 1.097

Water Pump Kit (with Gaskets) 1.069
Application Type of Material GM Part Number
Balancer Shaft Driven Gear Bolt Threadlock 12345382
Camshaft Retainer Bolt Threadlock 12345382
Crankshaft Balancer Keyway Adhesive 12346141
Cylinder Head Bolt Sealant 12346004
Engine Block to the Crankshaft Rear Oil Seal Housing
J unction at the Oil Pan Sealing Surfaces Adhesive 12346141
Engine Block to the Engine Front Cover J unction at the Oil
Pan Sealing Surfaces Adhesive 12346141
Engine Block at the Lower Intake Manifold Sealing Surfaces Adhesive 12346141
Engine Block Coolant Drain Hole Plug Sealant 12346004
Engine Block Core Hole Plug Threadlock 12345382
Engine Block Oil Gallery Plug Sealant 12346004
Engine Coolant Temperature (ECT) Sensor Sealant 12346004
Engine Coolant Temperature (ECT) Gauge Sensor Sealant 12346004
Engine Oil SAE 5W-30 Oil 12345610
Engine Oil Pressure Sensor Sealant 12346004
Engine Oil Pressure Sensor Fitting Sealant 12346004
Engine Oil Supplement Lubricant 1052367
Evaporative Emission (EVAP) Canister Purge Solenoid Valve Stud Threadlock 12345382
Exhaust Manifold Bolt/Stud Threadlock 12345382
Expansion Cup Plug (Balance Shaft Rear Bearing Hole) Sealant 12346004
Expansion Cup Plug (Camshaft Rear Bearing Hole) Sealant 12346004
Fuel Meter Body Bracket Bolt Threadlock 12345382
Fuel Pipe Bolt Threadlock 12345382
Lower Intake Manifold Bolt Threadlock 12345382
Oil Level Indicator Tube Sealant 12346004
Oil Pump Screen Tube Sealant 12346004
Throttle Body Stud Threadlock 12345382
Upper Intake Manifold Stud Threadlock 12345382
Valve Train Component Prelube Lubricant 12345501
Water Pump Bolt Sealant 12346004
Sealers, Adhesives and Lubricants Sealers, Adhesives and Lubricants Sealers, Adhesives and Lubricants Sealers, Adhesives and Lubricants Sealers, Adhesives and Lubricants
Checks Action
Engine Performance diagnosis procedures are covered in Engine Controls and should be consulted for diagnosis of any
Drivability, Emissions or Malfunctioning Indicator Lamp (MIL) concerns.
The following diagnosis covers common concerns and possible causes.
When the proper diagnosis is made, the concern should be corrected by adjustment, repair or replacement as required.
Refer to the appropriate section of the service manual for each specific procedure.
This diagnostic table will assist in engine misfire diagnosis due to a mechanical concern such as a faulty engine camshaft,
worn or damaged bearings or bent valve pushrod.
Thsi table will not isolate a crossed fuel injector wire, faulty fuel injector or any other drivability component failure that may
cause a misfire.
The Powertrain On-Board Diagnostic System checks must be performed first.
When using this table to make a Base Engine Misfire diagnosis, begin with the preliminary information below and then
proceed to the specific category.
Preliminary 1. Perform DTC P0300 before proceeding with Base Engine Misfire Diagnosis
information.
DTC P0300 will assist in determining which cylinder or cylinders are misfiring.
2. Perform a visual inspection of the following:
A loose or improperly isnstalled engine flywheel or crankshaft balancer
Worn, damaged or misaligned accessory drive system components
3. Listen to the engine for any abnormal internal engine noises.
4. Inspect the engine for acceptable oil pressure.
5. Verify if the engine has excessive oil consumption.
6. Verify if the engine has excessive coolant consumption.
7. Perform a compression test on the engine.
Intake Manifold Leaks An intake manifold that has a vacuum leak may cause a misfire.
Inspect for the following:
Improperly installed or damaged vacuum hoses
Faulty or improperly installed lower intake manifold and/or gaskets
Cracked or damaged lower intake manifold
Improperly installed MAP sensor
The sealing grommet of the MAP sensor should not be torn or damaged
Improperly installed throttle body or damaged gasket
Warped intake manifold
Warped or damaged cylinder head sealing surface
Coolant Consumption Coolant consumption may or may not cause the engine to overheat.
Inspect for the following:
External coolant leaks
Faulty cylinder head gasket
Warped cylinder head
Cracked cylinder head
Damaged engine block
Oil Consumption Oil consumption may or may not cause the engine to misfire.
1. Remove the spark plugs and inspect for an oil fouled spark plug.
2. Perform a cylinder compression test.
3. If the compression test indicates worn valves or valve guides, inspect the following:
Worn, brittle or improperly installed valve stem oil seals
Worn valve guides
Worn valve stems
Worn or burnt valves or valve seats
4. If the compression test indicates worn or damaged piston rings, inspect the following:
Broken or improperly seated piston rings
Excessive piston ring end gap
Excessive cylinder bore wear or taper
Cylinder damage
Piston damage
Diagnostic Information and Procedures Diagnostic Information and Procedures Diagnostic Information and Procedures Diagnostic Information and Procedures Diagnostic Information and Procedures
Base Engine Misfire Diagnosis Base Engine Misfire Diagnosis Base Engine Misfire Diagnosis Base Engine Misfire Diagnosis Base Engine Misfire Diagnosis
Base Engine Misfire Diagnosis (contd) Base Engine Misfire Diagnosis (contd) Base Engine Misfire Diagnosis (contd) Base Engine Misfire Diagnosis (contd) Base Engine Misfire Diagnosis (contd)
Checks Action
Abnormal Internal Engine Noises 1. Start the engine and determine if the noise is timed to the engine camshaft speed or
the crankshaft speed.
2. Using a timing light, two knocks per flash is the crankshaft speed and one knock
per flash is the engine camshaft speed.
3. If the noise is timed to the engine camshaft speed, inspect the following:
Missing or loose valve train components
Worn or loose valve rocker arms
Worn or bent valve pushrods
Faulty valve springs
Bent or burnt valves
Worn engine camshaft lobes
Worn or damaged camshaft timing chain and/or sprockets
Important: A slight COLD knock or piston slapping noise could be considered normal
if not present after the engine has reached normal operating temperatures.
If the knock is timed to the crankshaft speed, inspect the following:
Worn crankshaft or connecting rod bearings
Piston ro cylinder damage
Worn piston or piston pin
Faulty connecting rod
Excessive carbon build-up on the top of the piston
No Abnormal Internal Engine Noise 1. Inspect for a worn or improperly installed camshaft timing chain and/or sprockets.
2. Remove the valve rocker arm cover on the side of the engine with the cylinder that
is misfiring.
3. Inspect for the following:
Loose valve rocker arm studs
Bent valve push rods
Faulty valve springs
Faulty valve lifters (bleeding down)
Worn or improperly seated valves
Engine Compression Test
1. Disconnect the positive ignition coil wire plug from
ignition coil.
2. Disconnect the fuel injector electrical connector.
3. Remove all the spark plugs.
4. Block the throttle plate wide open.
5. Charge the battery if the battery is not fully
charged.
6. Start with the compression gauge at zero. Then
crank the engine through four compression
strokes (four puffs).
7. Make the compression check the same for each
cylinder. Record the reading.
The minimum compression in any one cylinder
should not be less than 70 percent of the highest
cylinder. No cylinder should read less than 690
kPa (100 psi). For example, if the highest
pressure in any one cylinder is 1035 kPa (150
psi), the lowest allowable pressure for any other
cylinder would be 725 kPa (105 psi).
(1035 x 70% =725) (150 x 70% =105).
8. If some cylinders have low compression, inject
approximately 15 ml (one tablespoon) of engine
oil into the combustion chamber through the spark
plug
hole.
Normal - Compression builds up quickly and
evenly to the specified compression for each
cylinder.
Piston Rings Leaking - Compression is low on the
first stroke. Then compression builds up with the
following strokes but does not reach normal.
Compression improves considerably when you
add oil.
Valves Leaking - Compression is low on the first
stroke. Compression usually does not build up on
the following strokes. Compression does not
improve much when you add oil.
If two adjacent cylinders have lower than normal
compression, and injecting oil into the cylinders
does not increase the compression, the cause
may be a head gasket leaking between the two
cylinders.
9. Install the removed parts.
10. Connect the disconnected components.
Symptoms Cause
When diagnosing engine noisee complaints, use the following steps to isolate the source of the engine noise:
Determine the type of noise
For example, is the noise a light rattle/tapping or a low rumble/knocking?
The exact operating condition under which the noise exists
Note factors such as ambient temperature, the amount of engine warm-up time, the engine temperature, the engine
RPM and other specifics.
At what rate the noise occurs, and at what location on the engine
Engine noises are generally synchronized to either engine speed (crankshaft, engine flywheel, connecting rods,
crankshaft balancer or pistons and related components) or one-half engine speed (valve train noise such as valve
rocker arms, valve lifters and camshaft timing chain). Determine the rate at which the noise is occurring.
Compare the engine sounds to other engines, and make sure you are not trying to correct a normal condition.
Noise on Start-Up but Only Lasts a Improper oil viscosity. Install the recommended oil viscosity for the expected
Few seconds temperatures.
Worn or dirty valve lifters
Excessive piston-to-cylinder bore clearance
Excessive piston pin-to-bore clearance
Excessive crankshaft bearing clearance
Knocks Cold and Continues for Loose or broken crankshaft balancer or accessory drive components
1 to 2 Minutes Excessive piston-to-bore clearance
A cold piston knock which appears in 1.5 minutes should be considered
acceptable.
A cold engine knock usually disappears when the specific cylinders secondary
ignition circuit is grounded out.
Intermittent Noise on Idle, Improper oil viscosity. Install the recommended oil viscosity for the expected
Disappearing When Engine Speed is temperatures.
Increased Lower than specified oil pressure
Install an oil pressure gauge and measure the engine oil pressure.
Dirty or worn valve lifter
Valve Train Noise (Rattle/Tapping) The following conditions may cause valve train noise:
Lower than specified oil pressure
Worn or faulty oil pump
Loose oil pump-to-engine block bolt
Loose valve rocker arm attachments
Worn valve rocker arms and/or valve pushrods
Broken valve spring
Sticking valves
Worn, dirty or faulty valve lifters
Worn valve guides or valve stems
Bent, broken or damaged timing chain sprocket teeth
Knocks Hot at The following conditions may cause a knocking noise:
Idle (Rumble/Knocking) Malfunctioning accessory drive system components
Loose or broken crankshaft balancer
Detonation or spark knock
Check for proper operation of the cooling, knock and ignition control components.
Refer to diagnostic information in Engine Controls
Excessive connecting rod bearing clearance
Excessive piston pin-to-bore clearance
Bent connecting rod
Excessive crankshaft bearing clearance
Loose torque converter bolts (if equipped)
Cracked or damaged engine flywheel
Exhaust leak at the exhaust manifold
Combustion chamber deposits
Exhaust System Noise and/or Exhaust system noise and/or leakage may be caused by the following conditions:
Leakage Improperly installed or misaligned exhaust system components
A cracked or broken exhaust manifold
Damaged or worn exhaust manifold gaskets and/or seals
Burnt or rusted out exhaust system components
Broken or loose exhaust clamps and/or brackets
Engine Noise Diagnosis Engine Noise Diagnosis Engine Noise Diagnosis Engine Noise Diagnosis Engine Noise Diagnosis
Valve Train Diagnosis Valve Train Diagnosis Valve Train Diagnosis Valve Train Diagnosis Valve Train Diagnosis
General Information General Information General Information General Information General Information
Symptoms Cause
A light tapping noise at 1/2 engine speed, or any varying frequency, may indicate a valve train problem.
Tapping noises will typically increase with increased engine speed.
Before attempting to diagnose a valve train noise, check for the proper engine oil level and then allow the engine to
obtain normal operating temperature.
Following this procedure will bring all engine components to a normal state of expansion.
Sit in the drivers seat, then operate the engine at various speeds and listen for any abnormal engine noise.
Valve Train Noise Low engine oil pressure
A worn or faulty oil pump
A loose or plugged oil pump screen
Loose valve rocker arm attachments (causing excessive valve lash)
A worn or damaged valve rocker arm ball
A worn valve rocker arm and/or valve pushrod
A broken valve spring
Sticking valves
Valve lifters worn, dirty or faulty
A broken valve lifter guide
Engine camshaft lobes worn
Worn valve guides or valve stems
Bent valve pushrods
Excessive free play in the camshaft timing chain
Bent, broken or damaged camshaft sprocket teeth
DEFINITION: A light tapping noise at 1/2 engine speed, or any varying frequency.
1 Is there valve train noise? Go to Step 2 System OK
Check for a high engine oil level. An engine with the
engine oil level above the FULL mark on the oil level
indicator allows the crankshaft counterweights to churn the
2 engine oil into foam. When the foamy engine oil is pumped
into the valve lifters, the valve lifters become noisy. A solid
column of engine oil ensures proper valve lifter operation.
Is the engine oil level too high? Go to Step 3 Go to Step 4
3
Drain the engine oil to the proper level.
Is the tapping noise gone? System OK Go to Step 6
Check for a low engine oil level. An engine with the engine
oil level below the ADD mark on the oil level indicator may
4 allow the oil pump to pump air at high engine RPM.
Is the engine oil level below the ADD mark on the oil level
indicator? Go to Step 5 Go to Step 6
5
Add the engine oil as required.
Check for the proper engine oil pressure. Refer to Engine
6
Mechanical Specifications and Oil Pressure Diagnosis and 41.4 kPa
Testing. (6 psi)
Is the engine oil pressure within specifications? Go to Step 11 Go to Step 7
Diagnostic Table
Step Action Value(s) Yes No
Check the oil pump screen for damage or a loose fit to the
7
oil pump.
Is the oil pump screen loose or is the oil pump screen
damaged? Go to Step 8 Go to Step 9
8
Repair as required.
Check for a damaged oil pump or loose bolts.
9 Refer to Oil Pump Clean and Inspect.
Is the oil pump damaged or are the bolts loose? Go to Step 10 Go to Step 11
10
Repair as required.
Remove and inspect the valve lifters, the valve rocker
arms and the valve pushrods. Refer to Valve Rocker Arm
11 and Pushrods Clean and Inspect and Valve Lifters and
Guides Clean and Inspect.
Are the components worn or damaged? Go to Step 12 Go to Step 13
12
Replace the components as required.
Perform an engine camshaft lobe lift test. Refer to
13 Camshaft and Bearings Clean and Inspect.
Is the engine camshaft lobes within specifications? Go to Step 15 Go to Step 14
14
Replace the engine camshaft and valve lifters.
Remove the engine front cover and inspect the camshaft
15
timing chain and sprockets for excessive wear or damage.
Refer toTiming Chain and Sprockets Clean and Inspect.
Are the components worn or damaged? Go to Step 17 Go to Step 16
16
Perform a complete disassembly of the engine and inspect
17 all components.
Are the components worn or damaged? System OK Go to Step 11
18 Did you complete the worn or damaged component
replacement? System OK
Diagnostic Table (contd)
Excessive oil consumption (not due to leaks) is the use
1.9 liters (2 quarts) of engine oil within 3,200 kilometers
(2,000 miles). However, during initial engine break-in
periods 4,828-6,437 kilometers (3,000-4,000 miles) oil
consumption may exceed 1.9 liters (2 quarts) or more.
The causes of excessive oil consumption include the
following conditions:
External oil leaks. Tighten the bolts and/or
replace gaskets and oil seals as necessary.
Incorrect oil level or improper reading of oil
level indicator. With the vehicle on a level
surface, allow adequate drain down time and
check for the correct oil level.
Improper oil viscosity. Use a recommended
SAE viscosity for the prevailing temperatures.
Continuous high speed operation and/or
severe usage.
Crankcase ventilation system restrictions or
malfunctioning components. Possible improper
PCV valve.
Valve guides and/or valve stem oil seals worn,
damaged or the seal omitted. Ream the valve
guides and install oversize service valves and/
or new valve stem oil seals.
Piston rings broken, improperly installed, worn
or not seated properly. Allow adequate time for
the piston rings to seat. Replace broken or
worn piston rings as necessary.
Piston improperly installed or mis-fitted.
Oil Pressure Diagnosis and Testing
1. With the vehicle on a level surface, allow
adaquate drain down time (2-3 minutes) and
measure for a low engine oil level.
Add the recommended grade engine oil, and fill
the crankcase until the oil level measures FULL
on the oil level indicator.
2. Operate the engine and verify low or no oil
pressure on the vehicle oil pressure gauge or the
oil indicator light.
Listen for a noisy valve train or a knocking noise.
3. Inspect for the following:
Engine oil diluted by moisture or unburned fuel
mixtures
Improper engine oil viscosity for the expected
temperature
Incorrect or faulty oil pressure gauge sensor
Incorrect or faulty oil pressure gauge
Plugged oil filter
Malfunctioning oil filter bypass valve
4. Remove the oil pressure gauge sensor or
another engine block oil gallery plug.
5. Install an oil pressue gauge.
6. Start the engine and then allow the engine to
reach normal operation temperature.
7. Measure the engine oil pressure at the following
RPM:
Specification
7.1. 42 kPa (6psig) (minimum) at 1,000 RPM
7.2. 125 kPa (18 psig) (minimum) at 2,000 RPM
7.3. 166 kPa (24 psig) (minimum) at 4,000 RPM
8. If the engine oil pressure is below minimum
specifications, inspect the engine for one or
more of the following:
Oil pump worn or dirty
Malfunctioning oil pump pressure relief valve
Oil pump screen loose, plugged or damaged
Excessive bearing clearance
Cracked, porous or restricted oil galleries
Engine block oil gallery plugs missing or
incorrectly installed
Broken valve lifters
Important: You can repair most fluid leaks by first visually locating the leak, repairing or replacing the component, or
by resealing the gasket surface. Once the leak is identified, determine the cause of the leak. Repair the cause of the
leak as ewll as the leak itself.
1. Operate the vehicle until it reaches normal operating
1
temperature.
2. Park the vehicle on a level surface, over a large
sheet of paper or other clean surface. Go to Step 2 System OK
2
Can you identify the type of fluid and the approximate
location of the leak? Go to Step 10 Go to Step 3
1. Visually inspect the suspected area. Use a small
mirror to assist in looking at hard to see areas.
2. Check for leaks at the following locations:

3
Sealing surfaces
Fittings
Cracked or damaged components
1. Completely clean the entire engine and surrounding
components.
2. Operate the vehicle for several kilometers (miles) at
normal operating temperature and at varying speeds.
3. Park the vehicle on a level surface, over a large
4 sheet of paper or other clean surface.
4. Wait (15 minutes).
5. Idetify the type of fluid and the approximate location
of the leak.

5
Sealing surfaces
Fittings
1. Completely clean the entire engine and surrounding
components.
2. Apply an aerosol-type powder (baby powder, foot
powder, etc.) to the suspected area.
6
3. Operate the vehicle for several kilometers (miles) at
normal operating temperature and at varying speeds.
5. Idetify the type of fluid and the approximate location
of the leak, from the discolorations in the powder surface.
Oil Leak Diagnosis
6

7
Sealing surfaces
Fittings
Use J 28428-E, Dye and Light Kit, in order to identify the
type of fluid and the approximate location of the leak.
8
Refer to manufacturers instructions when using
the tool.

9
Sealing surfaces
Fittings
location of the leak? Go to Step 10 System OK
1. Inspect the engine for mechanical damage. Special
attention should be shown to the following areas:
Higher than recommended fluid levels
Higher than recommended fluid pressures
Plugged or maalfunctioning fluid filters or pressure
bypass valves
Plugged or malfunctioning engine ventilation
system
10 Improperly tightened or damaged fasteners
Cracked or porous components
Improper sealants or gaskets where required
Improper sealant or gasket installation
Damaged or worn gaskets or seals
Damaged or worn sealing surfaces
2. Inspect the engine for customer modifications.
Is there mechanical damage, or custormer modifications to
the engine? Go to Step 11 System OK
11
Repair or replace all damaged or modified components.
Does the engine still leak oil? Go to Step 1
Oil Leak Diagnosis (contd)
Symptoms - Drive Belt
Important: Review the system operation in order to
familiarize yourself with the system functions. Refer
to Drive Belt System Description.
Visual/Physical Inspection
Inspect for aftermarket devices which could
affect the operation of the drive belts.
Inspect the easily accessible or visible system
components for obvious damage or conditions
which could cause the symptom.
Inspect the drive belt for excessive wear,
shredding or missing sections.
Inspect the drive belt for contamination of
excessive dirt, oil, coolant or other substances
that may affect the drive belt operation.
Intermittent
Drive belt symptoms may be from intermittent
failure of an accessory drive component.
Drive belt symptoms may occur from changes in load of
the accessory drive components.
. Ambient temperatures, moisture or engine operating
temperature can affect the drive belt operation.
Symptoms List
Refer to a symptom diagnostic procedure from the following list
in order to diagnose the symptom:
Drive Belt Chirping Diagnosis
Drive Belt Squeal Diagnosis
Drive Belt Whine Diagnosis
Drive Belt Rumbling Diagnosis
Drive Belt Vibration Diagnosis
Drive Belt Falls Off Diagnosis
Drive Belt Excessive Wear Diagnosis
Diagnostic Aids
The symptom may be intermittent due to moisture on
the drive belt(s) or the pulleys. It may be necessary to
spray a small amount of water on the drive belt(s) in
order to duplicate the customers concern. If spraying
water on the drive belt(s) duplicates the symptom,
cleaning the belt pulleys may be the probable
solution.
A loose or improper installation of a body component,
a suspension component or other items of the vehicle
may cause the chirping noise.
Test Description
The number(s) below refer to the step number(s) on
the diagnostic table.
2. The noise may not be engine related. This step
is to verify that the engine is making the noise.
If the engine is not making the noise, do not
proceed further with this table.
3. The noise may be an internal engine noise.
Removing the drive belt and operating the
engine for a brief period will verify the noise is
related to the drive belt. When removing the
drive belt(s), the water pump may not be
operating and the engine may overheat. Also
DTCs may set when the engine is operating
with the drive belt removed.
4. Inspect all drive belt pulleys for pilling. Pilling is
the small balls or pills or it can be strings in the
drive belt grooves from the accumulation of
rubber dust.
6. Misalignment of the pulleys may be caused from improper
mounting of the accessory drive component, incorrect
installation of the accessory drive component pulley or
the pulley bent inward or outward from a previous repair.
Test for a misaligned pulley .using a straight edge in the
pulley grooves across two or three pulleys. If a misaligned
pulley is found, refer to that accessory drive component
for the proper installation procedure for that pulley.
10. Inspecting of the fasteners can eliminate the possibility
that a wrong bolt, nut, spacer or washer was installed.
12. Inspecting the pulleys for being bent should include
inspecting for a dent or other damage to the pulleys that
would prevent the drive belt from not seating properly in
all of the pulley grooves or on the smooth surface of a
pulley when the back side of the belt is used to drive the
pulley.
14. Replacing the drive belt when it is not damaged or there
is not excessive pilling will only be a temporary repair.
Notice: Refer to Belt Dressing Notice in Cautions and Notices.
DEFINITION: The following items are indications of chirping:
A high pitched noise that is heard once per revolution of the drive belt or a pulley.
It usually occurs on cold damp mornings.
1
Did you review the Drive Belt Symptom operation an d perform Go to Symptoms -
the necessary inspections? Go to Step 2 Drive Belt
2
Verify that there is a chirping noise. Go to
Does the engine make the chirping noise? Go to Step 3 Diagnostic Aids
1. Remove the drive belt.
3 2. Operate the engine for no longer than 30 to 40 seconds. Go to Engine
Does the chirping noise still exist? Noise Diagnosis Go to Step 4
4
Inspect for severe pilling exceeding 1/3 of the belt groove depth.
Does the belt grooves have pilling? Go to Step 5 Go to Step 6
5
Clean the drive belt pulleys with a suitable wire brush.
Did you complete the repair? Go to Step 15 Go to Step 6
6
Inspect for misalignment of the pulleys.
Are any of the pulleys misaligned? Go to Step 7 Go to Step 8
7
Replace or repair any misaligned pulleys.
8
Inspect for bent or cracked brackets.
Did you find any bent or cracked brackets? Go to Step 9 Go to Step 10
9
Replace any bent or cracked brackets.
10
Inspect for improper, loose or missing fasteners
Did you find the condition? Go to Step 11 Go to Step 12
Tighten any loose fasteners.
11
Replace any improper or missing fasteners. Refer to Fastener
Tightening Specifications.
12
Inspect for a bent pulley.
13
Replace the bent pulley.
14
Replace the drive belt. Refer to Drive Belt Replacement. Go to
Did you complete the repair? Go to Step 15 Diagnostic Aids
15
Operate the system in order to verify the repair.
Did you correct the condition? System OK Go to Step 3
Diagnostic Aids
A loose or improper installation of a body component,
a suspension component or other items of the vehicle
may cause the chirping noise.
If the noise is intermittent, verify the accessory drive
components by varying their loads making sure they
are operated to their maximum capacity. An
overcharged A/C system, power steering system with
a pinched hose or wrong fluid or a generator failing
are suggested items to inspect.
Test Description
2. The noise may not be engine related. This step
is to verify that the engine is making the noise.
If the engine is not making the noise, do not
proceed further with this table.
3. The noise may be an internal engine noise.
Removing the drive belt and operating the
engine for a brief period will verify the noise is
related to the drive belt. When removing the
drive belt(s), the water pump may not be
operating and the engine may overheat. Also
DTCs may set when the engine is operating
with the drive belt removed.
4. This test is to verify that an accessory drive
component does not have a seized bearing.
With the belt removed, test the bearings in the
accessory drive components for turning
smoothly. Also test the accessory drive
components with the engine operating by
varying the load on the components to verify
that the components operate properly.
5. This test is to verify that the drive belt tensioner
operates properly. If the drive belt tensioner is
not operating properly, proper belt tension may
not be achieved to keep the drive belt from
slipping, which could cause a squeal noise.
6. This test is to verify that the drive belt(s) is not
too long, which would prevent the drive belt
tensioner from working properly. Also, if an
incorrect length drive belt was installed, it may
not be routed properly and may be turning an
accessory drive component in the wrong
direction.
7. Misalignment of the pulleys may be caused
from improper mounting of the accessory drive
component, incorrect installation of the
accessory drive component pulley or the pulley
bent inward or outward from a previous repair.
Test for a misaligned pulley using a straight
edge in the pulley grooves across two or three
pulleys. If a misaligned pulley is found, refer to
that accessory drive component for the proper
installation procedure for that pulley.
8. This test is to verify that the pulleys are the
correct diameter or width. Using a known good
vehicle compare the pulley sizes.
DEFINITION: The following items are indications of drive belt squeal:
A loud screeching noise that is caused by a slipping drive belt (this is unusual for a drive belt with multiple ribs)
The noise occurs when a heavy load is applied to the drive belt, such as an air conditioning compressor engagement,
snapping the throttle or slipping on a seized pulley or a faulty accessory drive component.
1
Did you review the Drive Belt Symptom operation an d perform Go to Symptoms -
2
Verify that there is a squeal noise. Go to
Does the engine make the squeal noise? Go to Step 3 Diagnostic Aids
1. Remove the drive belt(s).
Does the chirping noise still exist? Noise Diagnosis Go to Step 4
4
Inspect for an accessory drive component seized bearing or
faulty accessory drive component.
Did you find and correct the condition? Go to Step 9 Go to Step 5
Test the drive belt tensioner for proper operation. Refer to Drive
5 Belt Tensioner Diagnosis.
Inspect for the correct drive belt length. Refer to Drive Belt
6 Replacement.
7
Inspect for a misalignment of a pulley.
8
Inspect for the correct pulley size. Go to
Did you find and correct the condition? Go to Step 9 Diagnostic Aids
9
Drive Belt Squeal Diagnosis (contd)
Diagnostic Aids
The drive belt(s) will not cause the whine noise.
If the whine noise is intermittent, verify the accessory
drive components by varying their loads making sure
they are operated to their maximum capacity. An
overcharged A/C system, power steering system with
a pinched hose or wrong fluid or a generator failing
are suggested items to inspect.
Test Description
3. This test is to verify that the noise is being
caused by the drive belt(s) or the accessory drive
components. When removing the drive belt(s), the
water pump may not be operating and the engine
may overheat. Also DTCs may set when the
engine is operating with the drive belt(s)
removed.
4. The inspection should include checking the drive
belt tensioner and the drive belt idler pulley
bearings. The drive belt(s) may have to be
installed and the accessory drive components
operated seperately by varying their loads. Refer
to the suspected accessory drive component for
the proper inspection and replacement
procedure.
DEFINITION: A high pitched continuous noise that may be caused by an accessory drive component failed bearing.
1
Did you review the Drive Belt Symptom operation and perform Go to Symptoms-
2
Verify that there is a whine noise. Go to
Does the engine make the whine noise? Go to Step 3 Diagnostic Aids
Does the whine noise still exist? Noise Diagnosis Go to Step 4
4
Inspect for a failed accessory drive component bearing. Go to
Did you find and repair the condition? Go to Step 5 Diagnostic Aids
9
Did you correct the condition? System OK
Diagnostic Aids
Vibration from the engine operating may cause a
body component or another part of the vehicle to
make rumbling noise.
The drive belt(s) may have a condition that can not be
seen or felt. Sometimes replacing the drive belt may
be the only repair for the symptom.
If replacing the drive belt(s), completing the
diagnostic table, and the noise is only heard when the
drive component with a failure. Varying the load on
the different accessory drive components may aid in
identifying which component is causing the rumbling
noise.
Test Description
2. This test is to verify that the symptom is present
during diagnosing. Other vehicle components
may cause a similar symptom.
3. This test is to verify that the drive belt(s) is
causing the rumbling noise. Rumbling noise may
be confused with an internal engine noise due to
the similarity in the description. Remove only one
drive belt at a time if the vehicle has multiple drive
belts. When removing the drive belt the water
pump may not be operating and the engine may
overheat. Also, DTCs may set when the engine is
operating with the drive belt removed.
4. Inspecting the drive belt(s) is to ensure that it is
not causing the noise. Small cracks across the
ribs of the drive belt will not cause the noise. Belt
separation is identified by the plys of the belt
separating and may be seen at the edge of the
belt, or felt as a lump in the belt.
5. Small amounts of pilling is a normal condition and
acceptable. When the pilling is severe, the drive
belt does not have a smooth surface for proper
operation.
DEFINITION:
A low pitch tapping, knocking or thumping noise heard at or just above idle.
Heard once per revolution of the drive belt or a pulley.
Rumbling may be caused from:
- Pilling, the accumulation of rubber dust that forms small balls (pills) or strings in the drive belt pulley groove
- The separation of the drive belt
- A damaged drive belt
1
2
Verify that there is a rumbling noise. Go to
Does the engine make the rumbling noise? Go to Step 3 Diagnostic Aids
Does the rumbling noise still exist? Noise Diagnosis Go to Step 4
Inspect the drive belt(s) for damage, separation or sections of
4 missing ribs.
Did you find and repair the condition? Go to Step 7 Go to Step 5
Inspect for severe pilling of more than 1/3 of the drive belt
5 pulley grooves.
Did you find severe pilling? Go to Step 6 Go to Step 7
1. Clean the drive belt pulleys using a suitable wire brush.
6 2. Reinstall the drive belt. Refer to Drive Belt Replacement.
7
Install a new drive belt. Refer to Drive Belt Replacement.
Did you complete the replacement? Go to Step 8
8
Operate the system in order to verify the repair. Go to
Did you correct the condition? System OK Diagnostic Aids
Drive Belt Rumbling Diagnosis (contd)
Diagnostic Aids
The accessory drive components can have an affect
on engine vibration. Such as, but not limited to the
A/C system overcharged, the power steering system
restricted or the incorrect fluid or an extra load on the
generator. To help identify an intermittent or an
improper condition, vary the loads on the accessory
drive components.
Test Description
2. This test is to verify that the symptom is present
during diagnosing. Other vehicle components
may cause a similar symptom such as the
exhaust system or the drivetrain.
3. This test is to verify that the drive belt(s) or
accessory drive components may be causing
the vibration. When removing the drive belt the
water pump may not be operating and the
engine may overheat. Also, DTCs may set
when the engine is operating with the drive belt
removed.
4. The drive belt(s) may cause a vibration. While the
drive belt(s) is removed, inspect the condition of
the belt.
6. Inspecting of the fasteners can eliminate the
possibility that a wrong bolt, nut, spacer or
washer was installed.
8. This step should only be performed if the fan is
driven by the drive belt. Inspect the engine
cooling fan for bent, twisted, loose or cracked
blades. Inspect the fan clutch for smoothness,
ease of turning. Inspect for a bent fan shaft or
bent mounting flange.
9. This step should only be performed if the water
pump is driven by the drive belt. Inspect the water
pump shaft for being bent. Also inpsect the water
pump bearings for smoothness and excessive
play. Compare the water pump with a known good
water pump.
10. Accessory drive component brackets that are
bent, cracked or loose may put extra strain on
that accessory component causing it to vibrate.
DEFINITION:
The vibration is engine-speed related.
The vibration may be sensitive to accessory load.
1
2
Verify that the vibration is engine related. Go to
Does the engine make the vibration? Go to Step 3 Diagnostic Aids
1. Remove the drive belt(s). Go to Engine
3 2. Operate the engine for no longer than 30 to 40 seconds. Related Vibration
Does the rumbling noise still exist? in Vibration and
Diagnosis Go to Step 4
Inspect the drive belt(s) for wear, damage, debris build-up and
4 missing drive belt ribs.
Did you find any of these conditions? Go to Step 5 Go to Step 6
5
6
Inspect for improper, loose or missing fasteners.
Did you find any of these conditions? Go to Step 5 Go to Step 6
7
Replace improper or missing fasteners. Refer to Fastener
Did you complete the repair? Go to Step 11
Inspect for damaged fan blades or bent fan clutch shaft, if the
8
fan is belt driven. Refer to Fan Clutch Replacement in Engine
Cooling.
Inspect for bent water pump shaft, if the water pump is belt
9
driven. Refer to Water Pump Replacement (4.3L Engine)
in Engine Cooling.
10
Inspect for bent or cracked brackets. Go to
Did you find and correct the condition? Go to Step 11 Diagnostic Aids
11
Drive Belt Vibration Diagnosis (contd)
Diagnostic Aids
If the drive belt(s) repeatedly falls off the drive belt
pulleys, this is because of pulley misalignment.
An extra load that is quickly applied and released by
an accessory drive component may cause the drive
belt to fall off the pulleys. Verify the accessory drive
components operate properly.
If the drive belt(s) is the incorrect length, the drive belt
tensioner may not keep the proper tension on the
drive belt.
Test Description
2. This inspection is to verify the condition of the
drive belt. Damage may of occured to the drive
belt when the drive belt fell off. The drive belt
may of been damaged, which caused the drive
belt to fall off. Inspect the belt for cuts, tears,
sections of ribs missing or damaged belt plys.
4. Misalignment of the pulleys may be caused
from improper mounting of the accessory drive
component, incorrect installation of the accessory
drive component pulley or the pulley bent inward
or outward from a previous repair. Test for a
misaligned pulley using a straight edge in the
pulley grooves across two or three pulleys. If a
misaligned pulley is found, refer to that accessory
drive component for the proper installation
procedure of that pulley.
5. Inspecting the pulleys for being bent should
include inspecting for a dent or other damage to
the pulleys that would prevent the drive belt from
not seating properly in all of the pulley grooves or
on the smooth surface of a pulley when the back
side of the belt is used to drive the pulley.
6. Accessory drive component brackets that are
bent or cracked will let the drive belt fall off.
7. Inspecting of the fasteners can eliminate the
possibility that a wrong bolt, nut, spacer or
washer was installed. Missing, loose or the wrong
fasteners may cause pulley misalignment from
the bracket moving under load. Over tightening of
the fasteners may cause misalignment of the
accessory component bracket.
DEFINITION: The drive belt falls off the pulleys or may not ride correctly on the pulleys.
1
2
Inspect for a damaged drive belt.
7
Inspect for improper, loose or missing fasteners.
Did you find loose or missing fasteners? Go to Step 8 Go to Step 9
8
Replace improper or missing fasteners. Refer to Fastener
Does the drive belt continue to fall off? Go to Step 9 System OK
Test the drive belt tensioner for operating correctly. Refer
9 to Drive Belt Tensioner Diagnosis.
Does the drive belt tensioner operate correctly? Go to Step 11 Go to Step 10
Replace the drive belt tensioner. Refer to Drive Belt Tensioner
10 Replacement.
Inspect for failed drive belt idler and drive belt tensioner pulley
11 bearings. Go to
12
3
4
Inspect for misalignment of the pulleys.
5
Inspect for a bent or dented pulley.
6
Inspect for a bent or cracked bracket.
Diagnostic Aids
Excessive ewar on a drive belt(s) is usually caused by
an incorrect installation or the wrong drive belt for the
application.
Minor misalignment of the drive belt pulleys will not
cause excessive wear, but will probably cause the
drive belt(s) to make a noise or to fall off.
Excessive misalignment of the drive belt pulleys will
cause excessive wear but may also make the drive
belt(s) fall off.
Test Description
2. This inspection is to verify the drive belt(s) is correctly
installed on all of the drive belt pulleys. Wear on the drive
belt(s) may be caused by mis-positioning the drive belt(s)
by one groove on a pulley.
3. The installation of a drive belt that is two wide or two
narrow will cause wear on the drive belt. The drive belt
ribs should match all of the grooves on all of the pulleys.
4. This inspection is to verify the drive belt(s) is not
contacting any parts of the engine or body while the
engine is operating. There should be sufficient clearance
when the drive belt accessory drive components load
varies. The drive belt(s) should not come in contact with
an engine or a body component when snapping the
throttle.
DEFINITION: Wear at the outside ribs of the drive belt due to an incorrectly installed drive belt.
1
Inspect the drive belt(s) for the proper installation. Refer to
2 Drive Belt Replacement.
3
Inspect for the proper drive belt.
Did you find this condition? Go to Step 5 Go to Step 4
Inspect for the drive belt rubbing against a bracket, hose or
4 wiring harness. Go to
5
Replace the drive belt. Refer to Drive Belt Replacement.
6
Does the drive belt continue to fall off? System OK
Drive Belt Tensioner Diagnosis
Inspection Procedure
Important
When the engine is operating the drive belt tensioner
arm will move. Do not replace the drive belt tensioner
because of movement in the drive belt tensioner arm.
Notice: Allowing the drive belt tensioner to snap into
the free position may result in damage to the
tensioner.
1. Remove the drive belt. Refer to Drive Belt
Replacement.
374176
2. Position a 3/8 inch drive wrench on the drive belt
tensioner arm and rotate the arm
counterclockwise.
3. Move the drive belt tensioner through its full
travel.
The movement should feel smooth
There should be no binding
The tensioner should return freely
4. If any binding is observed, replace the drive belt
tensioner. Refer to Drive Belt Tensioner
Replacement.
5. Install the drive belt. Refer to Drive Belt
Replacement.
Visual Identification
Dissassembled Views
Upper and Lower Intake Manifold View
334238
Legend
(1) Fuel Pipe Retainer Bracket Nut
(2) Fuel Pipe Retainer
(3) Fuel Pipe
(4) Fuel Pipe Bolt
(5) Fuel Seal Retainer
(6) Upper Fuel Seal (Yellow O-ring)
(7) Spacer Ring (Metal Flat Washer)
(8) Lower Fuel Seal (Black O-ring)
(9) Upper Manifold Attaching Stud
(10) Upper Intake Manifold
(11) Upper Intake to Lower Intake Manifold Gasket
(12) Fuel Meter Body Seal (O-ring)
(13) Fuel Meter Body
(14) Intake Manifold
(15) Throttle Body to Upper Intake Manifold Gasket
(16) Throttle Body
(17) Throttle Body Attaching Stud
Upper Engine View 1
480504
Legend
(1) Distributor Bolt
(2) Distributor
(3) Intake Manifold Bolt (Lower)
(4) Intake Manifold Gasket (Lower)
(5) Intake Manifold Assembly
(6) EGR Valve
(7) EGR Valve Bolt
(8) EGR Valve Gasket
(9) Water Outlet
(10) Water Outlet Stud
(11) Engine Coolant Thermostat
(12) Accelerator Control Cable Bracket
(13) Accelerator Control Cable Bracket Stud
(14) Ignition Coil
(15) Ignition Coil Stud
(16) EVAP Canister Purge Solenoid Valve Stud
(17) EVAP Canister Purge Solenoid Valve
Upper Engine View 2
480513
Legend
(1) Valve Rocker Arm Cover
(2) Valve Rocker Arm Cover Gasket
(3) Valve Rocker Arm Assembly
(4) Valve Rocker Arm Support
(5) Spark Plug Wire Support
(6) Spark Plug Wire Support Bolt
(7) Exhaust Manifold Gasket
(8) Exhaust Manifold
(9) Exhaust Manifold Bolt
(10) Spark Plug Wire Shields
(11) Exhaust Manifold Gasket
(12) Valve Lifter
(13) Valve Lifter Pushrod Guide
(14) Valve Pushrod
(15) Cylinder Head Gasket
(16) Engine Lift Front Bracket
(17) Cylinder Head Bolt
(18) Cylinder Head
Legend
(1) Oil Level Indicator Tube Bolt
(2) Oil Level Indicator
(3) Oil Level Indicator Tube
(4) Engine Oil Pressure Sensor Fitting
(5) Balance Shaft Bearing (Rear)
(6) Knock Sensor
(7) Expansion Cup Plug (Balance Shaft Rear
Bearing Hole)
(8) Engine Block Rear Oil Gallery Plug
(9) Expansion Cup Plug (Camshaft Rear Bearing
Hole)
(10) Engine Block
(11) Dowel Straight Pin (Transmission Locator)
(12) Left Side Oil Gallery Plug
(13) Oil Filter Adapter Gasket
(14) Oil Filter Adapter Seal (O-ring)
Lower Engine View 1
569262
(15) Oil Filter Adapter (Typical)
(16) Oil Filter Adapter Bolt
(17) Oil Filter
(18) Oil Filter Fitting
(19) Oil Filter Adapter Bolt
(20) Oil Filter Bypass Valve
(21) Engine Coolant Drain Hole Plug
(22) Engine Block Core Hole Plug
(23) Dowel Pin (Cylinder Head Locator)
(24) Water Pump Gasket
(25) Water Pump
(26) Water Pump Bolt
(27) Front Oil Gallery Plug
(28) Camshaft Bearings
(29) Engine Camshaft
(30) Camshaft Retainer
(31) Camshaft Retainer Bolt
(32) Balance Shaft Drive Gear
(33) Camshaft Sprocket
(34) Camshaft Timing Chain
(35) Camshaft Sprocket Bolt
(36) Balance Shaft Gear Bolt
(37) Balance Shaft Driven Gear
(38) Balance Shaft Retainer Bolt
(39) Balance Shaft Retainer
(40) Balance Shaft
(41) Piston Ring Set
(42) Piston
(43) Piston Pin
(44) Connecting Rod Bolt
(45) Connecting Rod
(46) Connecting Rod Bearings
(47) Connecting Rod Cap
(48) Hex Nut
Lower Engine View 2
480518
Legend
(1) Crankshaft Rear Oil Seal Housing Retainer Stud
(2) Crankshaft Rear Oil Seal Housing Nut
(3) Flywheel Locator Pin
(4) Crankshaft Rear Oil Seal Housing Bolt
(5) Crankshaft Rear Oil Seal Housing
(6) Crankshaft Rear Oil Seal Housing Gasket
(7) Crankshaft
(8) Oil Pump Drive Shaft
(9) Oil Pump Locator Pin
(10) Oil Pump Drive Shaft Retainer
(11) Oil Pump
(12) Oil Pump Bolt
(13) Oil Pan
(14) Oil Pan Bolt
(15) Oil Pan Gasket
(16) Crankshaft Bearing Cap Bolt
(17) Crankshaft Bearing Cap
(18) Crankshaft Bearings (Lower)
(19) Crankshaft Sprocket
(20) Crankshaft Position Sensor Reluctor Ring
(21) Engine Front Cover
(22) Crankshaft Front Oil Seal
(23) Crankshaft Balancer
(24) Crankshaft Balancer Bolt
(25) Crankshaft Balancer Key
(26) Crankshaft Bearings (Upper)
The Vehicle Identification Number (VIN) Derivative
is located on the left side rear of the engine block
(1) or on the right side rear (2) and typically is a
nine digit number stamped or laser etched onto the
engine at the vehicle assembly plant.
The first digit identifies the division.
The second digit identifies the model year.
The third digit identifies the assembly plant.
The fourth through ninth digits are the last six
digits of the Vehicle Identification Number (VIN).
195338
Engine Identification
Engines built at the Tonawanda engine plant have
the engine identification number located at the right
front top of the engine block.
The first digit (1) is the source code.
The second and third digits (2) are the month of
the build.
The forth and fifth digits (3) are the date of the
build.
The sixth, seventh and eighth digits (4) are the
broadcast code.
569359
195339
Engines built at the Romulus engine plant have the
engine identification number located at the right
front top of the engine block.
The first digit (1) is the source code.
The second and third digits (2) are the month of
the build.
The forth digit (3) is the hour of the build.
The fifth and sixth digits (4) are the date of the
build.
The seventh, eighth and ninth digits (5) are the
broadcast code.
Draining Fluids and Oil Filter Removal
1. Remove the oil pan drain plug and allow the engine oil to
drain into a suitable container.
2. Remove the oil filter (if applicable).
3. Discard the oil filter (if applicable).
4. Remove both the engine block coolant drain hole plugs and
allow the coolant to drain into a suitable container.
188052
188050
188048
Engine Flywheel Removal
1. Remove the engine flywheel bolts.
2. Remove the engine flywheel (automatic transmission) (1), if
applicable.
3. Remove the engine flywheel (manual transmission) (2), if
applicable.
Important: If replacing the engine flywheel (manual transmission),
then NEW flywheel weights must be installed into the NEW engine
flywheel in the same location as the old flywheel weights in the old
engine flywheel.
4. Note the position of any flywheel weights for assembly (if
applicable).
Clutch Pilot Bearing Removal
Tools Required
J 43276 Clutch Pilot Bearing Remover
Caution: Refer to Safety Glasses Caution in Cautions and
Notices
Notice: When using the J 43276 Clutch Pilot Bearing Remover,
always secure the J 43276-1 Clutch Pilot Bearing Remover tool
body using a wrench. Do not allow the J 43276-1 Clutch Pilot
Bearing Remover tool body to rotate. Failing to do so will cause
damage to the J 43276-1 Clutch Pilot Bearing Remover tool body.
1. Remove the clutch pilot bearing using the J 43276
1.1. Install the J 43276 tool body into the clutch pilot
bearing.
353275
64126
188129
1.2. Using a wrench secure the J 43276-1 tool body.
1.3. Insert the J 43276-2 forcing screw into the J 43276-1
tool body.
1.4. Rotate the J 43276-2 forcing screw clockwise into the
J 43276-1 tool body until the clutch pilot bearing is
completely removed from the crankshaft.
1.5. Rotate the J 43276-2 forcing screw counterclockwise
to remove the J 43276-2 forcing screw from the
J 43276-1 tool body.
1.6. Remove the J 43276-1 tool body from the clutch pilot
bearing.
2. Discard the clutch pilot bearing.
Exhaust Manifold Removal (Left)
Notice: Twist the spark plug boot one-half turn in order to release
the boot. Pull on the spark plug boot only. Do not pull on the spark
plug wire or the wire could be damaged.
1. Remove the spark plug wires from the spark plugs.
1.1. Rotate the spark plug wire boot one-half turn.
1.2. Pull outward on the spark plug wire boot to release
from the spark plug.
2. Remove the spark plug wires from the spark plug wire
retainers.
3. Remove the exhaust manifold bolts and the stud.
4. Remove the spark plug wire shields (if applicable) and the
exhaust manifold.
5. Remove and discard the exhaust manifold gaskets.
188045
328540
Exhaust Manifold Removal (Right)
Notice: Twist the spark plug boot one-half turn in order to release
the boot. Pull on the spark plug boot only. Do not pull on the spark
plug wire or the wire could be damaged.
1. Remove the spark plug wires from the spark plugs.
1.1. Rotate the spark plug wire boot one-half turn.
1.2. Pull outward on the spark plug wire boot to release
from the spark plug.
2. Remove the spark plug wires from the spark plug wire
retainers.
3. Remove the exhaust manifold bolts and the stud.
4. Remove the spark plug wire shields (if applicable) and the
exhaust manifold.
5. Remove and discard the exhaust manifold gaskets.
188121
328555
Oil Level Indicator and Tube Removal
1. Remove the oil level indicator from the oil level indicator
tube, if applicable.
330580
188047
317191
182853
2. Remove the oil level indicator tube bolt.
3. Remove the oil level indicator tube from the engine block.
Water Pump Removal
Tools Required
J 41240 Fan Clutch Remover and Installer
1. Remove the bolts and the fan and water pump pulley using
the J 41240.
2. Remove the clamps and water pump inlet hose.
188054
173172
188055
Crankshaft Balancer Removal
Tools Required
J 23523-F Balancer Remover and Installer
1. Remove the crankshaft balancer bolt and washer.
3. Remove the water pump bolts.
4. Remove the water pump.
5. Remove the water pump gaskets.
6. Discard the water pump gaskets.
2. Remove the bolts and the crankshaft pulley.
4059
334258
328566
Notice: Refer to Fastener Notice in Cautions and Notices.
3. Use the J 23523-F in order to remove the crankshaft
balancer.
3.1. Install the J 23523-F plate and bolts onto the
crankshaft balancer.
Tighten
Tighten the bolts to 25 Nm (18 lb ft).
3.2. Install the J 23523-F forcing screw into the plate.
3.3. Rotate the J 23523-F forcing screw clockwise in order
to remove the crankshaft balancer.
4. Remove the J 23523-F from the crankshaft balancer.
5. Note the position of any front groove pins (crankshaft
balancer) (if applicable)
Valve Rocker Arm Cover Removal (Left)
1. Remove the valve rocker arm cover bolts.
2. Remove the valve rocker arm cover bolt grommets.
3. Discard the valve rocker arm cover bolt grommets.
480519
328573
328568
4. Remove the valve rocker arm cover.
5. Remove the valve rocker arm cover gasket.
6. Discard the valve rocker arm cover gasket.
Valve Rocker Arm Cover Removal (Right)
1. Remove the valve rocker arm cover bolts.
2. Remove the valve rocker arm cover bolt grommets.
3. Discard the valve rocker arm cover bolt grommets.
480524
328573
328575
4. Remove the valve rocker arm cover.
5. Remove the valve rocker arm cover gasket.
6. Discard the valve rocker arm cover gasket.
Distributor Removal
1. Remove the ignition coil wire harness from the ignition coil
and distributor cap.
569265
523516
328579
2. Remove the distributor clamp bolt.
3. Remove the distributor and the distributor clamp.
4. Remove the distributor gasket and discard.
Intake Manifold Removal
1. Remove the evaporitive emission (EVAP) canister purge
solenoid valve harness.
1.1. Push the quick disconnect clip and hold in place.
1.2. Pull outward on the harness elbow.
31510
480526
480527
2. Remove the engine coolant temperature (ECT) sensor wire
connector (if equipped) from the engine wiring harness
bracket.
3. Remove the lower intake manifold bolts.
Important: The intake manifold may be removed as an assembly.
Do not remove the specific intake manifold components unless
component service is required.
Do not allow dirt or debris to enter the fuel system. Ensure that the
ends of the fuel system are properly sealed.
Do not dissassemble the Central Sequential Fuel Injection (SFI)
unit unless service is required.
4. Remove the intake manifold assembly.
5. Remove and discard the lower intake manifold gaskets.
Valve Rocker Arm and Push Rod Removal
Important: Mark, sort and organize all the components for
assembly.
1. Remove the valve rocker arms.
2. Remove the valve rocker arm supports.
480529
387769
387767
Cylinder Head Removal (Left)
1. Remove the engine coolant temperature sensor (if
applicable).
2. Remove the engine coolant temperature gauge sensor (if
applicable).
2. Remove the valve pushrods.
3. Remove the spark plugs.
4. Remove the bolts and the spark plug wire support.
5. Remove the cylinder head bolts.
328582
328588
480533
480536
334299
330548
Notice: After removal, place the cylinder head on two wood blocks
to prevent damage.
6. Remove the cylinder head.
7. Remove and discard the cylinder head gasket.
8. Remove the dowel pins (cylinder head locator) (if required).
328586
328590
480537
Cylinder Head Removal (Right)
1. Remove the spark plugs.
2. Remove the bolts and the spark plug wire support.
3. Remove the cylinder head bolts.
480538
334312
330553
Notice: After removal, place the cylinder head on two wood blocks
to prevent damage.
4. Remove the cylinder head.
5. Remove and discard the cylinder head gasket.
6. Remove the dowel pins (cylinder head locator) (if required).
328592
328593
31350
Valve Lifter Removal
Tools Required
J 3049-A Valve Lifter Remover
Important: Place the components in a rack so that the
components can be reinstalled to their original location.
1. Remove the bolts and the valve lifter pushrod guide.
Important: Place the valve lifters in the rack in the upright position
in order to maintain the oil inside the valve lifters.
2. Remove the valve lifters.
Important: Some valve lifters may be stuck in the valve lifter bores
because of gum or varnish deposits and may require the use of
J 3049-A for removal.
3. Use the J 3049-A in order to remove the stuck valve lifters.
387460
330559
330568
Oil Pan Removal
1. Remove and discard the engine oil level sensor (if
applicable).
2. Remove the oil pan bolts and nuts.
3. Remove the oil pan.
387757
330572
330576
4. Remove the oil pan gasket.
5. Discard the oil pan gasket.
Oil Pump Removal
1. Remove the oil pump bolt.
2. Remove the oil pump.
330578
11485
387759
3. Inspect the pins (oil pump locator) for damage, and replace
the pins if required.
Engine Front Cover Removal
1. Remove the crankshaft position sensor bolt.
2. Remove the crankshaft position sensor.
3. Remove the crankshaft position sensor seal (O-ring).
4. Discard the crankshaft position sensor seal (O-
480539
480541
480542
5. Remove the engine front cover bolts.
Important: After the composite engine front cover is removed, do
not reinstall the engine front cover. Always install a NEW engine
front cover.
6. Remove the engine front cover.
7. Discard the engine front cover.
Timing Chain and Sprockets Removal
Tools Required
J 5825-A Crankshaft Gear Remover
1. Remove the crankshaft position sensor reluctor ring.
2. Check the camshaft timing chain free play.
2.1. Rotate the camshaft sprocket (1) counterclockwise
until all slack is removed from the camshaft timing
chain (2).
2.2. Measure the free play on the slack side (3) of the
camshaft timing chain.
If the camshaft timing chain can be moved side to side
in excess of 11 mm (0.43 in), replacement of the
camshaft timing chain and the sprockets is
recommended during assembly.
480544
480546
480547
3. Remove the camshaft sprocket bolts.
4. Remove the camshaft sprocket and the camshaft timing
chain.
Notices.
5. Remove the crankshaft sprocket using the J 5825-A.
387761
9847
5136
6. Remove the crankshaft balancer key.
Balance Shaft Removal
1. Remove the balancer shaft drive gear.
Important: The balance shaft drive and balance shaft driven gears
are serviced as a set. The set includes the balance shaft driven
gear bolt.
2. Remove the balance shaft driven gear bolt from the balance
shaft.
2.1. Use a wrench in order to secure the balance shaft.
Place the wrench onto the balance shaft near to the
balance shaft front bearing.
2.2. Remove the balance shaft bolt.
2.3. Remove the wrench from the balance shaft.
3. Remove the balance shaft driven gear from the balance
shaft.
188031
5139
188030
4. Remove the bolts and the balance shaft retainer.
Camshaft Removal
1. Remove the camshaft retainer bolts and
Important: The balance shaft and the balance shaft front bearing
are serviced only as a package. Do not remove the balance shaft
front bearing from the balance shaft.
5. Use a soft-faced hammer in order to remove the balance
shaft from the engine block.
5147
11497
480549
Notice: All camshaft journals are the same diameter, so care must
be used in removing or installing the camshaft to avoid damage to
the camshaft bearings.
2. Remove the engine camshaft.
2.1. Install the three 5/16-18 x 4.0 inch bolts into the engine
camshaft front bolt holes.
2.2. Using the bolts as a handle, carefully rotate and pull
the engine camshaft out of the camshaft bearings.
2.3. Remove the bolts from the front of the engine
camshaft.
Piston, Connecting Rod, and Bearing Removal
Tools Required
J 5239 Conneting Rod Bolt Guide Set
J 24270 Cylinder Bore Ridge Reamer
1. Use the J 24270 in order to remove the cylinder ring
ridge.
1.1. Turn the crankshaft until the piston is at the bottom
of the stroke.
1.2. Place a cloth on top of the piston.
1.3. Use the J 24270 to remove all of the cylinder ring
ridge.
1.4. Turn the crankshaft so the piston is at the top of the
stroke.
1.5. Remove the cloth.
1.6. Remove the cutting debris.
Important: Place matchmarks or numbers on the connecting rods
and the connecting rod caps.
2. Remove the connecting rod nuts.
3. Remove the connecting rod cap.
31373
188017
31379
4. Use the J 5239 in order to protect the crankshaft journals
and remove the connecting rod and the piston out of the top
of the engine block.
Important: Always assemble the connecting rod caps to the
matching connecting rods.
5. Remove the connecting rod bearings.
5.1. Keep the connecting rod bearings with the original
connecting rod and connecting rod cap.
5.2. Wipe the oil from the connecting rod bearings.
5.3. Wipe the oil from the crankpins.
Crankshaft Rear Oil Seal and Housing Removal
1. Remove the crankshaft rear oil seal from the crankshaft rear
oil seal housing.
2. Insert a suitable tool into the access notches and then
carefully pry the crankshaft rear oil seal from the crankshaft
rear oil seal housing.
3. Discard the crankshaft rear oil seal.
334317
334319
334326
4. Remove the crankshaft rear oil seal housing nut and bolts.
5. Remove the crankshaft rear oil seal housing.
6. Remove the crankshaft rear oil seal housing gasket.
7. Discard the crankshaft rear oil seal housing gasket.
8. Remove the crankshaft rear oil seal housing retainer stud
from the engine block.
334329
334336
334342
Crankshaft and Bearings Removal
1. Mark or identify the crankshaft bearing cap locations,
direction and positions for assembly.
2. Remove the crankshaft bearing cap bolts.
3. Remove the crankshaft bearing caps.
4. Remove the crankshaft.
5. Remove the crankshaft bearings from the crankshaft
bearing caps.
334338
10793
188018
6. Remove the crankshaft bearings from the engine block.
Engine Block Plug Removal
Tools Required
J 41712 Oil Pressure Switch Socket
Notices.
1. Remove the knock sensor from the engine block.
2. Remove the engine oil pressure gauge sensor using the
J 41712.
188020
334350
5271
3. Remove the engine oil pressure sensor fitting.
4. Remove the dowel straight pins (transmission locator) (if
required).
5. Remove the engine block left side oil gallery plug.
6. Remove the engine block left rear oil gallery plug.
7. Remove the engine block right rear oil gallery plug.
334364
334366
334323
8. Remove the expansion cup plug (camshaft rear bearing
hole) and discard.
9. Remove the expansion cup plug (balance shaft rear bearing
hole) and discard.
10. Remove the spring type S pin (crankshaft rear oil seal
housing locator) (if required).
5270
480550
188026
11. Remove the front oil gallery plugs or balls from the front of
the engine block and discard.
12. Insert a 3/8 x 26 in. rod into the rear oil gallery holes in order
to drive out the front oil gallery plugs or balls.
13. Remove the engine block core hole plugs.
13.1. Use a suitable tool in order to drive the engine block
core hole plugs into the coolant jacket.
13.2. Use a suitable tool in order to pull the engine block
core hole plugs from the coolant jacket.
13.3. Discard the engine block core hole plugs.
14. Remove the oil filter bypass valve and discard.
334378
Engine Block Clean and Inspect
Tools Required
J 8087 Cylinder Bore Gauge
Notices.
1. Clean all the remaining sealing or gasket material from the
sealing surfaces.
2. Clean the engine block with cleaning solvent.
3. Flush the engine block with clean water or steam.
4. Clean the cylinder bores.
5. Clean the oil galleries and the oil passages.
6. Clean the scale and the deposits from the coolant
passages.
Notice: Clean all debris, dirt and coolant from the engine block
cylinder head bolt holes. Failure to remove all foreign material may
result in damaged threads, improperly tightened fasteners or
damage to the components.
7. Clean the engine block cylinder head bolt holes.
8. After cleaning the engine block, spray or wipe the cylinder
bores and the machined surfaces with clean engine oil.
9. Inspect the following areas:
Coolant jackets (1) for cracks
Cylinder bores (2) for scratches or gouging
Valve lifter bores (3) for excessive scoring or wear
Threaded holes (4) for damage
Crankshaft bearing webs (5) for cracks
Crankshaft bearing caps (6) and the crankshaft bearing
bores (7) for damage
- The crankshaft bearing bores should be round and
uniform when measuring the inside diameter (ID).
- The surface where the crankshaft bearings contact the
crankshaft bearing bore should be smooth.
- If a crankshaft bearing cap is damaged and requires
replacement, replace the crankshaft bearing cap first,
then rebore the engine block crankshaft bearing bores
and check for proper alignment. Finally, check the
crankshaft fro the proper clearances.
Engine block core hole plug bores (8) for damage
Engine block (9) fro cracks or damage
Engine mount bosses (10) for damage
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10. Measure the cylinder bores for taper and out-of-round.
10.1. Depress the plunger on the J 8087 7 mm (0.275 in)
or until the J 8087 enters the cylinder bore.
10.2. Center the J 8087 in the cylinder bore and turn the
indicator dial to 0.
10.3. Move the J 8087 up and down the cylinder bore to
determine the cylinder bore taper. Refer to Engine
Mechanical Specifications.
10.4. Turn the J 8087 to different points around the cylinder
bore to determine the cylinder bore out-of-round
condition. Refer to Engine Mechanical Specifications.
Cylinder Boring and Honing
Honing Procedure
Notices.
1. When honing the cylinder bores, follow the manufacturers
recommendations for equipment use, cleaning and
lubrication.
Use only clean sharp stones of the proper grade for the
amount of material to be removed.
Dull, dirty stones cut unevenly and generate excessive
heat.
DO NOT hone to a final grade with a coarse or medium-
grade stone.
Leave sufficient metal so that all the stone marks will be
remove with the fine grade stones.
Perform the final honing with a fine-grade stone and hone
the cylinder bore in a cross-hatch pattern at 45-65
degrees to obtain the proper clearance.
2. During the honing operation, thoroughly check the cylinder
bore.
Repeatedly check the cylinder bore fit with the selected
piston.
All measurements of the piston or cylinder bore should
be made with the components at normal room
temperature.
3. When honing to eliminate taper in the cylinder bore, use full
strokes the complete length of the cylinder bore.
4. Repeatedly check the measurement at the top, the middle
and the bottom of the cylinder bore.
The finish marks should be clean but not sharp.
The finish marks should be free from imbedded particles
or torn or folded material.
188016
5. By measuring the selected piston at the sizing point and
then by adding the average of the clearance specification,
the final cylinder bore honing dimension required can be
determined.
6. When finished, the reconditioned cylinder bores should have
less than or meet the specified out-of-round and taper
requirements.
7. After the final honing and before the piston is checked for fit,
clean the cylinder bore with hot water and detergent.
7.1. Scrub the cylinder bores with a stiff bristle brush.
7.2. Rinse the cylinder bores thoroughly with clean hot
water.
7.3. Dry the cylinder bores with a clean rag.
7.4. Do not allow any abrasive material to remain in the
cylinder bores.
Abrasive material may cause premature wear
of the new piston rings and the cylinder bores.
Abrasive material will contaminate the engine
oil and may cause premature wear of the
bearings.
8. Perform final measurements of the piston and the cylinder
bore.
9. Permanently mark the top of the piston for the specified
cylinder to which it has been fitted.
10. Apply clean engine oil to each cylinder bore in order to
prevent rusting.
Boring Procedure
Notices.
1. Before starting the honing or reboring operation, measure all
the new pistons with the micrometer contacting at points
exactly 90 degrees from the piston pin centerline.
2. File the top of the cylinder block in order to remove any dirt
or burrs before using any type of boring bar.
3. Follow the instructions furnished by the manufacturer
regarding the use of the boring equipment.
4. When reboring the cylinders, make sure all the crankshaft
bearing caps are installed in the original position and
direction.
5. Tighten the crankshaft bearing caps to the proper torque
specifications in order to avoid distortion of the cylinder
bores in the final assembly.
6. When making the final cut with the boring bar, leave 0.03
mm (0.001 in) on the cylinder bore diameter for finish
honing. This gives the required position to the cylinder
clearance specifications. (Carefully perform the honing and
boring operation in order to maintain the specified
clearances between the pistons, the piston rings and the
cylinder bores).
4967
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34671
Piston and Connecting Rod Disassemble
Tools Required
J 24086-C Piston Pin Remover/Installer
Notices.
1. Remove the piston rings from the pistons.
2. Press the piston pin from the connecting rod using the
J 24086-C.
3. The piston pin has an interference fit into the connecting rod,
and is full floating in the piston.
4. Mark, seperate and organize the parts for assembly.
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Piston, Connecting Rod and Bearings Clean/
Inspect
Important: Measurement of all components should be taken with
the components at room temperature.
Do not use a wire brush in order to clean any part of the piston.
Notices.
1. Clean the piston and connecting rod in solvent.
2. Dry the components with compressed air.
3. Clean the piston ring grooves with a suitable ring groove
cleaning tool.
4. Clean the piston oil lubrication holes and slots.
5. Inspect the piston for the following:
Eroded areas (1) on the top of the piston
Scuffed or damaged skirt (2)
Damage to the pin bore (3)
Cracks in the piston ring lands, the piston skirt or the
pin bosses
Piston ring grooves for nicks, burrs or other warpage
which may cause the piston ring to bind
6. Inspect the piston pin for scoring, wear or other damage
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7. Measure the piston ring-to-piston ring groove side
clearance.
7.1. Insert the edge of the piston ring into the piston ring
groove.
7.2. Roll the piston ring completely around the piston.
If binding is caused by a distorted piston ring
groove, MINOR imperfections may be removed
with a fine file.
If binding is caused by a distorted piston ring,
replace the piston ring.
8. Measure the piston ring side clearance with a feeler gauge.
9. If the side clearance is too small, try another piston ring set.
10. If the proper piston ring-to-piston ring groove clearance
cannot be achieved, replace the piston and pin assembly.
11. To determine the proper piston ring side clearance, refer to
Engine Mechanical Specifications.
12. To determine piston pin-to-bore clearance, use a
micrometer and measure the piston pin.
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13. To determine piston pin-to-bore clearance, use an inside
micrometer and measure the piston pin bore.
14. To determine the piston pin-to-bore clearance, subtract the
piston pin diameter from the piston pin bore diameter. Refer
to Engine Mechanical Specifications.
15. Measure the piston with a micrometer at a right angle to the
piston pin bore, measure the piston at 11 mm (0.433 in)
from the bottom of the skirt. Refer to Engine Mechanical
Specifications.
If the piston is not within specifications, replace the piston
and pin as an assembly.
16. Inspect the connecting rod for an out-of-round bearing bore.
Refer to Engine Mechanical Specifications.
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17. Inspect the connecting rod for twisting.
18. Inspect the connecting rod for damage to the bearing cap
and bolt threads.
19. Measure the piston compression ring end gap.
Important: Fit each compression ring to the cylinder in which it will
be used.
20. Place the compression ring into the cylinder bore.
20.1. Push the compression ring into the cylinder bore to
approximately 6.5 mm (0.25 in) above the ring travel.
The ring must be square to the cylinder wall.
20.2. Use a feeler gauge in order to measure the end gap.
20.3. Select another size ring set if the end gap exceeds
specifications. Refer to Engine Mechanical
Specifications.
Piston Selection
Tools Required
Important: Measurements of all components should be taken with
the comonents at normal room temperature.
For proper piston fit, the engine block cylinder bores should not
have excessive wear or taper.
A used piston and piston pin set may be reinstalled if, after
cleaning and inspection, the piston and piston pin are within
specifications.
1. Use the J 8087 in order to measure the cylinder bore
diameter. Measure at a point 64 mm (2.5 in) from the top of
the cylinder bore and 90 degrees to the crankshaft
centerline.
4974
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4965
2. Measure the J 8087 with a micrometer and record the
reading.
3. With a micrometer or caliper at a right angle to the piston pin
bore, meausre the piston 11 mm (0.433 in) from the bottom
of the skirt.
4. Subtract the piston diameter from the cylinder bore diameter
in order to determine piston-to-bore clearance. Refer to
5. If the proper clearance cannot be obtained, then select
another piston and measure the clearances.
If the proper fit cannot be obtained, the cylinder bore may
require honing or boring.
6. When the piston-to-cylinder bore clearance is within
specifications, permanently mark the top of the piston for
installation into the proper cylinder.
Piston and Connecting Rod Assemble
Tools Required
J 24086-C Piston Pin Remover/Installer
Caution: Avoid contact with HOT components. Wear safetly
glasses and protective gloves to avoid personal injury.
Notice: Applying excessive heat to the connecting rod may
damage or distort the rod. Rod temperature SHOULD NOT
exceed 315C (600F). At this temperature, the end of the
connecting rod will turn a straw color upon visual inspection.
Notice: After the J 24086-C installer hub bottoms on the support
assembly, DO NOT exceed 35,000 kPa (5,000 psi) or the tool may
be damaged.
490763
Important: When assembling the piston and connecting rod, the
mark on the top of the piston must point to the front of the engine
block. The left bank connecting rods should have the flange face
toward the front of the engine block. The right bank connecting
rods should have the flange face toward the rear of the engine
block.
The piston pin has an interference fit into the connecting rod and is
full floating in the piston.
1. Install the piston pin and connecting rod assembly.
1.1. Lubricate the piston pin bores with clean engine oil.
1.2. Use a torch and apply MILD heat to the piston pin end
of the connecting rod.
1.3. Use the J 24086-C in order to press the piston pin into
the piston and connecting rod assembly.
1.4. Inspect for the proper installation of the piston and
piston pin. The piston must move freely on the piston
pin with no binding or interference.
Notice: Use a piston ring expander to install the piston rings. The
rings may be damaged if expanded more than necessary.
2. Install the piston rings onto the piston.
2.1. Install the oil control piston ring spacer.
2.2. Install the lower oil control piston ring.
2.3. Install the upper oil control piston ring.
2.4. Install the lower compression piston ring.
The mark on the side of the piston ring should face the
top of the piston.
2.5. Install the upper compression piston ring.
The mark on the side of the piston ring should face the
top of the piston.
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3. Space the compression piston ring end gaps 120 degrees
apart.
4. Space the oil control piston ring end gaps a minimum of 90
degrees apart.
Crankshaft and Bearings Clean and Inspect
Tools Required
J 7872 Magnetic Base Dial Indicator
J 36660 Electronic Torque Angle Meter
Notices.
Important: Use care when handling the crankshaft. Avoid damage
to the crankshaft bearing surfaces.
1. Clean the crankshaft in cleaning solvent. Remove all sludge
or restrictions from the oil passages.
2. Dry the crankshaft with compressed air.
3. Clean the crankshaft bearings in cleaning solvent. Wipe the
crankshaft bearings clean with a soft cloth, do not scratch
the crankshaft bearing surface.
4. Dry the crankshaft bearings with compressed air.
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5. Inspect the crankshaft for the following:
Crankshaft journals (1) should be smooth with no
evidence of scoring or damage.
Deep grooves (2)
Scratches or uneven wear (3)
Pitted surfaces (4)
Wear or damage to the thrust journal surfaces
Scoring or damage to the rear seal surface
Restrictions to the oil passages
Damage to the threaded bolt holes
7. Measure the crankpins for out-of-round and taper. Refer to
6. Inspect the crankshaft balancer key (1), the keyway (2) and
the threaded hole (3) for damage.
Repair or replace the crankshaft as necessary.
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8. Use a suitable support to support the crankshaft on the front
and rear journals.
9. Use the J 7872 in order to measure the crankshaft journal
runout.
The crankshaft runout should not exceed 0.025 mm (0.0010
in).
10. Measure the crankshaft end play.
Important: In order to properly measure the crankshaft end play,
the crankshaft, the crankshaft bearings and the crankshaft bearing
caps, the crankshaft bearing cap bolts must be installed into the
engine block and the bolts tightened to specifications.
Firmly thrust the crankshaft first rearward, then forward. This will
align the crankshaft rear bearings and the crankshaft thrust
surfaces.
10.1. With the crankshaft pushed forward, insert a feeler
gauge between the crankshaft and the crankshaft
bearing surface and then measure the clearance.
10.2. If the correct end play cannot be obtained, verify that
the correct size crankshaft bearing has been installed.
10.3. Inspect the crankshaft for binding. Turn the crankshaft
to check for binding. If the crankshaft does not turn
freely, then loosen the crankshaft bearing cap bolts,
one bearing cap at a time, until the tight crankshaft
bearing is located.
Burrs on the crankshaft bearing cap, foreign matter
between the crankshaft bearing and the engine block
or crankshaft bearing cap or a faulty crankshaft
bearing could cause a lack of clearance at the
crankshaft bearing.
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11. Inspect the crankshaft bearings for craters or pockets.
Flattened sections on the crankshaft bearing halves also
indicate fatigue.
12. Inspect the crankshaft bearings for excessive scoring or
discoloration.
13. Inspect the crankshaft bearings for dirt or debris imbedded
into the crankshaft bearing material.
14. Inspect the crankshaft bearings for improper seating
indicated by bright, polished sections of the crankshaft
bearings.
If the lower half of the crankshaft bearing is worn or
damaged, both the upper and lower halves of the
crankshaft bearing should be replaced.
Generally, if the lower half of the crankshaft bearing is
suitable for use, the upper half of the crankshaft bearing
should also be suitable for use.
188015
Measuring Crankshaft Bearing Clearances
The crankshaft bearings are of the precision insert type and
do not use shims for adjustment. If the clearances are
excessive, then new upper and lower crankshaft bearings
will be required. The service crankshaft bearings are
available in the standard size and an undersize.
The selective fitting of the crankshaft bearings are
necessary in production in order to obtain close tolerances.
For this reason, in one journal bore you may use one-half of
a standard crankshaft bearing with one-half of an undersize
crankshaft bearing
In order to determine the correct replacement crankshaft
bearing size, the crankshaft bearing clearance must be
measured accurately. Either the micrometer or plastic gauge
method may be used; however, the micrometer method
gives more reliable results and is preferred. When checking
connecting rod bearing clearances, the plastic gauge
method will result in unreliable measurements. The use of J
43690 is preferred.
Normally the crankshaft bearing journals wear evenly and
are not out-of-round. However, if a crankshaft bearing is
being fitted to an out-of-round crankshaft bearing journal, be
sure to fit to the maximum diameter of the crankshaft
bearing journal. If the crankshaft bearing is fitted to the
minimum diameter and the crankshaft bearing journal will
result in rapid crankshaft bearing failure.
If the crankshaft bearing clearance is within specifications,
the crankshaft bearing is satisfactory. If the clearance is not
within specifications, replace the crankshaft bearing. Always
replace both the upper and lower crankshaft bearings as a
set.
A standard or oversize crankshaft bearing combination may
result in the proper clearance. If the proper crankshaft
bearing clearance cannot be achieved using the standard or
the undersize crankshaft bearings, it may be necessary to
repair or replace the crankshaft.
Micrometer Method for Crankshaft Bearings
1. Measure the crankshaft journal diameter with a micrometer
in several places, approximately 90 degrees apart, and then
average the measurements.
2. Determine the taper and the out-of-round of the crankshaft
journal. Refer to Engine Mechanical Specifications.
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3. Install the crankshaft bearings into the engine block or
connecting rod assembly.
4. Install the bearing cap bolts and tighten to specifications.
5. Measure the bearing inside diameter (ID) at two points 90
degrees apart. Average the measurements.
6. In order to determine the bearing clearance, subtract the
average journal diameter from the averate bearing inside
diameter.
7. Compare the readings to specifications. Refer to Engine
8. Replace bearing halves as required to obtain the proper
bearing clearances.
Measuring Connecting Rod Bearing Clearances (J 43690
Method)
1. Remove the oil pan and other necessary components to
gain access to the connecting rods. Remove the oil pump,
screen and deflector (when applicable).
2. Rotate the crankshaft until the crankshaft journal/connecting
rod to be measured is in the 10 oclock position.
Important: The crankshaft must be secure with no movement or
rotation in order to obtain an accurate reading. Remove an
intermediate bearing cap (as required) in order to secure the
crankshaft and allow measurement of connecting rod bearing
clearances.
3. Remove the bearing cap bolts (1), cap (2) and bearing half.
627102
4. Insert a piece of paper card stock onto the crankshaft
journal. Install the bearing half, bearing cap and bolts. Refer
to Fastener Tightening Specifications.
5. Install the foot (1) and bolt (2) to the pivot arm assembly (3).
Tighten the bolt until snug.
627106
6. Install the screw (1 or 3) to the pivot arm assembly (2).
627108
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627109
7. Install the pivot arm assembly (1) onto the connecting rod.
8. Position the foot of the pivot arm assembly over the large
end of the connecting rod bolt.
9. Position the screw (1) onto the small end of the connecting
rod bolt and tighten securely.
10. Install the base (1) and bolt (2) to the oil pan rail.
627113
11. Align the center of the base (1) with the screw (3) of the
pivot arm assembly. Tighten the bolt (2) until snug.
12. Align the link (1) of the pivot arm assembly on a plane (3)
equal to that of the connecting rod beam (2).
627111
13. With the link of the pivot arm assembly aligned to the beam
of the connecting rod, position the pivot arm to the base and
insert the pin (1).
627115
627116
627118
627122
14. Install the handle (1) to the pivot arm assembly.
15. Select the adapter (2) (as required) and install to the swivel
base (1). Tighten until snug.
Important: The clamp of the swivel base and the shaft of the
indicator should be free of oil or other debris. A loose or improperly
clamped indicator may indicate incorrect readings.
16. Install the indicator (2) to the swivel base (1). Tighten the
clamp of the base until snug.
17. Install the swivel base (1) to the oil pan rail of the engine
block. Tighten until snug.
18. Adjust the swivel base as required and position the indicator
tip slightly above the connecting rod cap. Lock the swivel
base in position by rotating the locking lever (1). Do not allow
the tip of the indicator to contact the connecting rod at this
time.
19. The tip of the indicator should be positioned above and NOT
in contact with the cap end of the connecting rod.
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20. Rotate the fine adjustment knobs on the dial indicator end of
the swivel base to position the tip of the indicator in contact
with the connecting rod.
21. Lightly actuate the handle of the pivot arm assembly
(multiple times in both directions) to ensure the oil film is
removed from the journal.
22. Load the handle in the forward position and zero the dial
indicator. Load the handle multiple times in both directions
and record the reading.
Important: During this procedure, card stock may enter the
crankshaft journal oil galleries. Be sure to remove all card stock
from the bearing journal and oil galleries prior to reassembly.
23. Remove the bearing cap bolts, cap and paper stock.
24. Replace the bearing halves as required to obtain the proper
bearing clearances.
25. Install the bearings, cap and bolts. Refer to Fastener
Measuring Crankshaft Bearing Clearances (Plastic Gauge
Method)
1. Install the crankshaft bearings into the engine block.
2. Install the crankshaft.
3. Install the gauging plastic the full width of the journal.
334338
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4. Install the crankshaft bearings into the crankshaft bearing
caps.
5. Install the crankshaft bearing caps in the original positions
and with the arrow on the crankshaft bearing caps in the
direction of the front of the engine block.
6. Install the crankshaft bearing cap bolts.
Tighten
6.1. Tighten the crankshaft bearing cap bolts on the first
pass to 20 Nm (15 lb ft).
6.2. Tighten the crankshaft bearing cap bolts on the final
pass an additional 73 degrees using the J 36660.
7. Remove the crankshaft bearing cap bolts.
8. Remove the crankshaft bearing caps. The gauging plastic
may adhere to either the crankshaft bearing journal or the
crankshaft bearing surface.
9. Without removing the gauging plastic, measure the
compressed width at the widest point using the graduated
scale on the edge of the gauging plastic envelope.
If the flattened gauging plastic tapers toward the middle or
the ends, there may be a difference in clearance indicating
taper, low spot or other irregularity of the crankshaft bearing
or the crankshaft bearing journal.
10. Remove the flattened gauging plastic.
11. Measure the remaining crankshaft bearing journals.
5163
Measuring Connecting Rod Bearing Side Clearance
1. Insert a feeler gauge between the connecting rod caps and
measure the connecting rod side clearance. Refer to Engine
2. Connecting rod side clearances may also be measured with
a dial indicator set.
334387
Crankshaft Balancer Clean and Inspect
Notices.
1. Clean the crankshaft balancer in cleaning solvent.
2. Dry the crankshaft balancer with compressed air.
3. Inspect the crankshaft balancer for the following:
Loose or improperly installed front groove pin (1)
(crankshaft balancer)
A properly installed front groove pin should be installed
until flush or below flush with the face of the crankshaft
balancer.
Important: A crankshaft front oil sealing surface with excessive
scoring, grooves, rust or other damage must be replaced.
Worn, grooved or damaged crankshaft front oil sealing
surface (2)
Minor imperfections on the crankshaft balancer
crankshaft front oil seal surface may be removed with a
polishing compound or fine grade emery cloth.
Worn, chunking or deteriorated rubber (3) between the
hub and the outer ring
Worn or damaged keyway (4)
Worn or damaged bolt hole threads (5)
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381965
Engine Flywheel Clean and Inspect
Notices.
1. Clean the engine flywheel (1) or (2) in cleaning solvent.
2. Dry the engine flywheel with compressed air.
3. Inspect the engine flywheel (automatic transmission) (if
equipped) for the following:
Stress cracks around the engine flywheel-to-torque
converter bolt hole locations (1)
Missing balance weights
Stress cracks around the engine flywheel-to-crankshaft
bolt hole locations (2) or (3)
Important: Do not attempt to repair the welded areas (if present)
that retain the ring gear to the engine flywheel plate. Always install
a NEW engine flywheel.
Welded areas that retain the ring gear onto the engine
flywheel for cracking (4) (if present)
Damaged ring gear teeth (5)
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188086
4. Inspect the engine flywheel (manual transmission) (if
equipped) for loose or improperly installed flywheel weights
(if applicable).
A properly installed flywheel weight should be installed until
flush or below flush with the face of the engine flywheel.
5. Inspect the engine flywheel (manual transmission) (if
equipped) for the following:
Pitted friction surface (1)
Scoring or grooves (2)
Rust or other surface damage (3)
Damaged ring gear teeth (4)
Loose or improperly positioned ring gear
The ring gear has an interference fit onto the engine
flywheel and the ring gear should be positioned
completely flat against the flange of the engine flywheel.
334499
Camshaft and Bearings Clean and Inspect
Tools Required
J 7872 Magnetic Base Dial Indicator
Notices.
1. Clean the engine camshaft in cleaning solvent.
2. Dry the engine camshaft with compressed air.
3. Inspect the camshaft retainer plate fro damage.
If the camshaft retainer plate is damaged, replace as
necessary.
4. Inspect the camshaft bearings for correct fit into the engine
block camshaft bearing bores.
The camshaft bearings have an interference fit to the engine
block camshaft bearing bores and must not be loose in the
engine block camshaft bearing bores.
188095
Important: If any camshaft bearing is excessively worn or scored,
replace all the camshaft bearings.
5. Inspect the camshaft bearings for excessive wear or
scoring.
6. Inspect the engine camshaft for the following:
Worn, scored or damaged bearing journals (1)
Worn engine camshaft lobes (2)
Damaged bolt hole threads (3)
Damaged camshaft sprocket locator pin (4)
188014
188012
7. Measure the engine camshaft journals with a micrometer.
If the camshaft journals are more than 0.025 mm (0.0010 in)
out-of-round, then replace the engine camshaft.
8. Measure for a bent engine camshaft or excessive engine
camshaft runout using the J 7872.
8.1. Mount the engine camshaft in a suitable stand
between centers.
8.2. Use the J 7872 in order to check the intermediate
engine camshaft journals.
9. Measure the engine camshaft lobe lift using the J 7872.
9.1. Place the engine camshaft on the V-blocks.
9.2. Use the J 7872 in order to measure the engine
camshaft lobe lift.
10. Replace the engine camshaft if the engine camshaft lobe lift
is not within specifications. Refer to Engine Mechanical
Specifications.
66100
Camshaft Bearing Removal
Tools Required
J 33049 Camshaft Bearing Service Kit
1. Select the cone (1), the handle (10), the expanding driver (4-
8), the washer (2 or 3) and the expander assembly (15) from
the J 33049.
2. Assemble the J 33049.
4985
Important: A loose camshaft bearing may be caused by an
enlarged, out-of-round or damaged engine block camshaft bearing
bore.
Important: Always remove the camshaft inner bearings #2 and #3
first. The camshaft outer bearings #1 and #4 serve as a guide for
the J 33049.
Notices.
3. Remove the camshaft inner bearings #2 and #3.
3.1. Insert the J 33049 through the front of the engine block
and into the camshaft inner bearing #2.
3.2. Tighten the J 33049 expander assembly nut until snug.
3.3. Push the J 33049 guide cone into the camshaft front
bearing in order to align the J 33049.
3.4. Drive the camshaft inner bearing #2 from the camshaft
inner bearing bore #2.
3.5. Loosen the J 33049 expander assembly nut.
3.6. Remove the camshaft inner bearing #2 from the
J 33049 expander assembly.
3.7. Insert the J 33049 expander assembly into the
camshaft inner bearing #3.
bearing in order to align the J 33049.
3.10. Drive the camshaft inner bearing #3 from the
camshaft inner bearing bore #3.
3.12. Remove the camshaft inner bearing #3 from the
J 33049 expander asssembly.
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4. Remove the J 33049 from the engine block.
5. Remove the camshaft outer bearings #1 and #4.
5.1. Insert the J 33049 into the camshaft outer bearing #1.
5.3. Drive the camshaft outer bearing #1 from the camshaft
outer bearing bore #1.
5.5. Remove the camshaft outer bearing #1 from the
5.6. Remove the J 33049 from the engine block.
5.7. Insert the J 33049 expander assembly into the
camshaft outer bearing #4.
5.9. Drive the camshaft outer bearing #4 from the
camshaft outer bearing bore #4.
J 33049 expander asssembly.
6. Remove the J 33049 from the engine block.
7. Discard the camshaft bearings.
Camshaft Bearing Installation
Tools Required
J 33049 Camshaft Bearing Service Kit
Important: When installing the camshaft bearings, always look in
order to ensure that the camshaft bearing lubrication hole is
located above the 3 oclock position (1) or the 9 oclock position
(2). The proper positioning of the camshaft bearing lubrication hole
is in order to ensure the best lubrication of the engine camshaft
journals.
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1. Select the handle (10), the expanding driver (4-8), the
washer (2 or 3) and the expander assembly (15) from the
J 33049.
2. Assemble the J 33049.
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Notices.
Important: The camshaft bearings vary in size. When ordering the
new camshaft bearings, be sure to order the correct camshaft
bearings for the application to be serviced.
Always install the camshaft outer bearings #1 and #4 first. The
camshaft outer bearings serve as a guide for the J 33049 and help
center the camshaft inner bearings during the installation process.
3. Install the NEW camshaft outer bearings #4 and #1.
3.1. Install the NEW camshaft outer bearing #4 onto the
3.3. Align the lubrication hole of the camshaft outer bearing
#4 above the 3 oclock position or the 9 oclock position
of the camshaft outer bearing bore #4 at the rear of the
engine block.
3.4. Drive the camshaft outer bearing #4 into the camshaft
outer bearing bore #4 at the rear of the engine block.
3.7. Install the NEW camshaft outer bearing #1 onto the
3.9. Align the lubrication hole of the camshaft outer bearing
of the camshaft outer bearing bore #1 at the front of
the engine block.
3.10. Drive the camshaft outer bearing #1 into the camshaft
outer bearing bore #1 at the front of the engine block.
3.12. Carefully slide the J 33049 into the engine block until
the J 33049 expander assembly is positioned
between the camshaft inner bearing bores.
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4. Install the NEW camshaft inner bearings #3 and #2.
4.1. Install the NEW camshaft inner bearing #3 onto the
4.3. Align the lubrication hole of the camshaft inner bearing
of the camshaft inner bearing bore #3 of the
engine block.
bearing bore #1 in order to align the J 33049.
4.5. Drive the camshaft inner bearing #3 into the camshaft
inner bearing bore #3 of the engine block.
4.7. Carefully slide the J 33049 until the J 33049 expander
assembly is positioned between the camshaft inner
bearing bore #2 and the camshaft outer bearing bore
#1.
4.8. Install the NEW camshaft inner bearing #2 onto the
4.9. Tighten the J 33049 expander assembly nut until
snug.
4.10. Align the lubrication hole of the camshaft inner bearing
#2 above the 3 oclock position or the 9 oclock
position of the camshaft inner bearing bore #2 of the
engine block.
bearing bore #1 in order to align the J 33049.
4.12. Drive the camshaft inner bearing #2 into the camshaft
inner bearing bore #2 of the engine block.
5. Carefully remove the J 33049 from the engine block.
Balance Shaft Bearing and/or Bushing Removal
Tools Required
J 26941 Bushing/Bearing Remover
J 38834 Balance Shaft Service Kit
Notices.
1. Use the J 38834 and the J 26941 in order to remove the
balance shaft rear bearing.
1.1. Install the J 26941 legs behind the balance shaft rear
bearing and secure.
1.2. Install the J 38834-1 with the short threaded end
through the balance shaft bore in the front of the
engine block.
1.3. Install the J 38834-1 into the J 26941.
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1.4. Slide the J 38834-2 onto the J 38834-1 and into the
balance shaft bore of the engine block.
1.5. Install the J 38834 bearing, washer and nut onto the
J 38834-1.
1.6. Using a wrench, secure the J 38834-1 and then rotate
the J 38834 nut clockwise until the balance shaft rear
bearing is removed from the engine block.
1.7. Remove the J 26941 from the balance shaft rear
bearing.
2. Discard the balance shaft rear bearing.
Balance Shaft Clean and Inspect
Notices.
are serviced only as an assembly. Do not remove the balance
shaft front bearing from the balance shaft.
1. Clean the following components in cleaning solvent:
The balance shaft (1)
The balance shaft retainer (2)
The balance shaft rear bearing
The balance shaft driven gear (4)
The balance shaft drive gear
2. Dry the following components with compressed air:
The balance shaft (1)
The balance shaft retainer (2)
The balance shaft rear bearing
The balance shaft driven gear (4)
The balance shaft drive gear
3. Inspect the balance shaft bearings for the following:
Front ball bearing for damage or wear
Front ball bearing for smoothness of operation
Rear sleeve bearing for wear, scoring or other damage
4. Inspect the balance shaft (1) for the following:
Wear or scoring on the rear bearing journal
Damaged bolt hole threads
Damaged to the balance shaft driven gear locator pin
5. Inspect the balance shaft retainer (2) for wear or damage.
6. Inspect the balance shaft retainer bolts (3) for damaged
threads.
7. Inspect the driven gear (4) for the following:
Excessive wear or damage
Nicks, burrs or scoring
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8. Inspect the driven gear bolt (5) for damaged threads.
9. Inspect the balance shaft drive gear for the following:
Excessive wear or damage
Nicks, burrs or scoring
Balance Shaft Bearing and/or Bushing
Installation
Tools Required
J 38834 Balance Shaft Service Kit
Notices.
1. Use the J 38834 in order to install the balance shaft rear
bearing.
1.1. Install the J 38834-3 onto the short threaded end of the
J 38834-1.
1.2. Install the J 38834 nut, the washer and the bearing on
the long threaded end of the J 38834-1.
1.3. Install the J 38834-2 onto the J 38834-1 so that the
smaller diameter of the J 38834-2 will be facing the
front of the engine block.
1.4. Install the J 38834-2 on the inside of the balavnce
shaft front bearing bore.
1.5. Lubricate the NEW balance shaft rear bearing with
clean engine oil.
1.6. Install the balance shaft rear bearing onto the J 38834-
2.
1.7. Align the balance shaft rear bearing for installation.
1.8. Using a wrench, secure the J 38834-1 into place.
1.9. Rotate the J 38834 nut until the balance shaft rear
bearing is properly and completely pushed into the
balance shaft rear bearing bore.
2. Remove the J 38834.
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Timing Chain and Sprockets Clean and Inspect
Notices.
1. Clean the components with cleaning solvent.
3. Inspect the camshaft timing chain for binding or wear.
4. Inspect the camshaft sprocket and the crankshaft sprocket
for the following:
Broken teeth (1)
Damaged teeth (2)
Chipped teeth (3)
Worn teeth
Uneven wear on the edge of the teeth
Worn valleys between the sprocket teeth
Crankshaft sprocket keyway for wear
Valve Rocker Arm and Push Rods Clean and
Inspect
Important: Parts that are to be reused must be marked, sorted
and organized for assembly.
1. Mark, sort and organize the components for assembly.
Notices.
4. Inspect the valve rocker arm components for the following:
Valve rocker arm valve push rod socket contact surface
(1). The contact surface must be smooth with no scoring
or excessive wear.
Valve rocker arm roller pivot for binding or damage (2)
Valve rocker arm valve stem contact surface (3)
Valve rocker arm bolt threads for damage (4)
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5. Inspect the valve push rods for the following:
Restriction of the oil passage (1)
Wear or scoring of the end contact surfaces (2). The end
contact surfaces must be smooth with no scoring or
excessive wear.
Shaft for bends (3). Roll the valve pushrod on a flat
surface to determine if the valve pushrod is bent.
6. Inspect the valve rocker arm support for excessive wear or
damage.
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Valve Lifters and Guides Clean and Inspect
Important: Parts that are to be reused must be marked, sorted
and organized for assembly.
1. Mark, sort and organize the components for assembly.
Notices.
6. Inspect the valve lifter for the following:
Broken or damaged clip (1)
Worn pushrod socket (2)
Scuffed or worn lifter body (3)
If the valve lifter shows scuffing or wear, inspect the
engine block valve lifter bores for wear.
Worn roller (4)
Loose or damaged pin (5)
Plugged oil hole (6)
4. Inspect the valve lifter pushrod guides for excessive wear.
5. Inspect the valve lifter pushrod guides for cracks or damage.
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Cylinder Head Disassemble
Tools Required
J 8062 Valve Spring Compressor
Caution: Compressed valve springs have high tension
against the valve spring compressor. Valve springs that are
not properly compressed by or released from the valve spring
compressor can be ejected from the valve spring compressor
with intense force. Use care when compressing or releasing
the valve spring with the valve spring compressor and when
removing or installing the valve stem keys. Failing to use care
may cause personal injury.
Notices.
1. Use the J 8062 in order to compress the valve springs.
Important: Mark, sort and organize the components so that the
components can be reinstalled in their original location and
position.
2. Remove the valve stem keys (1).
3. Remove the J 8062 from the cylinder head.
4. Remove the valve spring cap (2).
5. Remove the valve spring (3).
6. Remove the valve stem oil seal (4).
7. Discard the valve stem oil seal.
8. Remove the valve.
Cylinder Head Clean and Inspect
Tools Required
J 8001 Dial Indicator Set
J 8089 Carbon Removing Brush
J 9666 Valve Spring Tester
Notices.
1. Clean the valve stems and cylinder heads on a buffing
wheel.
2. Clean the following components in cleaning solvent:
Valve stem keys (1)
Valve spring cap (2)
Valve spring (3)
Cylinder head
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4. Use the J 8089 to clean the carbon from the cylinder head
combustion chambers.
Be careful not to scuff the combustion chambers.
5. Inspect the cylinder head for the following:
Damage to the gasket surfaces
Burnt or eroded areas in the combustion chambers
Cracks in the exhaust ports and combustion chambers
External cracks in the water chambers
Restrictions in the intake or exhaust passages
Restrictions in the cooling system passages
Rusted, damaged or leaking core plugs
6. Measure the cylinder head for warpage with a straight edge
and feeler gauge
A cylinder head block deck with warpage in excess of
0.10 mm (0.004 in) within a 152.4 mm (6.0 in) area must
be repaired or replaced.
A cylinder head exhaust manifold deck with warpage in
excess of 0.05 mm (0.002 in) within a 152.4 mm (6.0 in)
area must be repaired or replaced.
A cylinder head intake manifold deck with warpage in
excess of 0.10 mm (0.004 in) within a 152.4 mm (6.0 in)
area must be repaired or replaced.
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7. Use the J 9666 in order to measure the valve spring.
Replace the valve spring if the valve spring tension is less
than 338 N (76 lb) at 43.2 mm (1.70 in).
8. Inspect the valve springs for squareness.
9. Valve stems (1) with excessive valve guide (2) clearance
must be repaired or the cylinder head replaced.
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10. Measure the valve stem-to-guide clearance.
Excessive valve stem-to-guide clearance may cause an
excessive oil consumption and may also cause a valve to
break. Insufficient clearance will result in noisy and sticky
functioning of the valve and will disturb the engine assembly
smoothness.
10.1. Clamp the J 8001 on the exhaust port side of the
cylinder head.
10.2. Position the dial indicator so that the movement of the
valve stem from side to side (crosswise to the
cylinder head) will cause a direct movement of the
dial indicator stem.
The dial indicator stem must contract the side of the
valve stem just above the valve guide.
10.3. Drop the valve head about 1.6 mm (0.063 in) off the
valve seat.
10.4. Use light pressure and move the valve stem from
side to side in order to obtain a valve stem-to-guide
clearance reading. Refer to Engine Mechanical
Specifications.
Valve Guide Reaming/Valve and Seat Grinding
Tools Required
J 5830-02 Valve Guide Reamer Set
J 8001 Dial Indicator Set
1. Measure the valve stem-to-guide clearance. Refer to
Cylinder Head Clean and Inspect.
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2. Improper valve stem (1) to valve guide (2) clearance may
cause excessive oil consumption.
Notices.
Important: Exhaust valves with excessive valve stem-to-guide
clearance must be replaced with the available service valve that
has an 0.0774 mm (0.0305 in) oversize valve stem. The intake
valves are NOT available with oversize valve stems. Replace the
cylinder head if after using a NEW intake valve in order to measure
the valve stem-to-guide clearance, the valve stem-to-guide
clearance is not within specifications.
3. Use the J 5830-3 in order to ream the exhaust valve guide in
order to achieve the correct valve stem-to-guide clearance.
4. Always recondition the exhaust valve seat after reaming the
exhaust valve guide bores and installing new exhaust
valves.
5. Inspect the valves for the following:
Burnt or damaged areas (1)
Undersize margain (2)
Bent stem (3)
Scoring or other damage to the stem (4)
Worn key groove (5)
Worn stem tip (6)
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6. Inspect the valve contact surface for the following:
Undersized margin (1)
Pitted surfaces (2)
Burnt or eroded areas (3)
Acceptable edge (margain) (4)
Valves with excessive damage must be replaced.
Minor imperfections of the valve or valve seat may be
repaired.
7. Reconditioning of the valves and valve seats:
The valves must seat perfectly for the engine to deliver
optimum power and performance.
Cooling the valve heads is another important factor.
Good contact between each valve and valve seat in the
cylinder head is necessary to insure that the heat in the
valve head is properly carried away.
Regardless of what type of equipment is used, it is
essential that the valve guide bores are free from carbon
or dirt in order to ensure the proper centering of the pilot
in the valve guide.
The valve seats should be concentric to within 0.05 mm
(0.002 in) total indicator reading.
Reface pitted valves on a valve refacing machine in order
to ensure the correct relationship between the valve head
and the valve stem.
Replace the valve if the valve stem is excessively worn
or warped.
Replace the valve if the edge margin (4) of the valve
head is less than 0.79 mm (0.031 in) thick after grinding.
Several different types of equipment are available for
reconditioning valves and valve seats. Follow the
equipment manufacturers recommendations for
equipment use to attain the proper results.
Cylinder Head Assemble
Tools Required
J 8062 Valve Spring Compressor
J 42073 Valve Stem Seal Installer
Important: The exhaust valve oil stem seal has the letters EX (1)
molded into the top of the seal. The exhaust valve oil stem seal
material is brown in color (2) with a white stripe (3) painted onto
the outside diameter of the seal, or the material may be red in
color (2) with no paint stripe. The intake valve oil seal is black in
color.
1. Assemble the valve into the proper valve guide.
2. Select the proper valve stem oil seal for the specific valve
guide.
3. Lubricate the valve stem oil seal and the outside diameter of
the valve guide with clean engine oil.
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4. Assemble the valve stem oil seal onto the valve stem.
Notices.
5. Install the valve stem oil seal onto the valve guide using the
J 42073.
Tap the valve stem oil seal onto the valve guide until the
J 42073 bottoms against the valve spring seat.
6. Inspect the valve stem oil seal. The valve stem oil seal
should not be bottomed against the valve guide.
There should be a 1-2 mm (0.03937-0.07874 in) gap
between the bottom edge of the valve stem oil seal and the
valve guide.
7. Install the valve spring (3).
8. Install the valve spring cap (2) onto the valve spring (3) and
over the valve stem.
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Caution: Compressed valve springs have high tension
against the valve spring compressor. Valve springs that are
not properly compressed by or released from the valve spring
compressor can be ejected from the valve spring compressor
with intense force. Use care when compressing or releasing
the valve spring with the valve spring compressor and when
removing or installing the valve stem keys. Failing to use care
may cause personal injury.
Notices.
9. Use the J 8062 in order to compress the valve springs.
10. Install the valve stem keys.
10.1 Use grease in order to hold the valve stem keys in
place while disconnecting the J 8062.
10.2. Look to ensure that the valve stem keys seat properly
in the upper groove of the valve stem.
10.3. Tap the end of the valve stem with a plastic-faced
in order to seat the valve stem keys, if necessary.
Oil Pump Disassemble
1. Remove the oil pump driveshaft and oil pump driveshaft
retainer.
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2. Remove the oil pump screen (if necessary).
The oil pump screen has a press fit into the oil pump
cover.
DO NOT remove the oil pump screen from the pipe. The
pipe and oil pump screen are serviced as a complete
assembly.
3. Remove the oil pump cover bolts.
4. Remove the oil pump cover.
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Oil Pump Clean and Inspect
Notices.
1. Clean the oil pump components in cleaning solvent.
3. Inspect the oil pump for the following conditions:
Scoring on the top of the gears (1)
Damaged gears (2) for the following:
Chipping
Gailing
Wear
Scoring, damage or casting imperfections to the body (3)
Damaged or scored gear shaft (4)
Damaged or scored gear shaft (5)
5. Remove the oil pump drive gear and the oil pump driven
gear.
6. Matchmark the gear teeth for assembly.
Notices.
7. Remove the following items:
7.1. The oil pump pressure relief valve spring straight pin
7.2. The oil pump pressure relief spring
7.3. The oil pump pressure relief valve
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Damaged bolt hole threads
Worn oil pump driveshaft bore
Damaged or sticking oil pump pressure relief valve (minor
imperfections may be removed with a fine oil stone)
Collapsed or broken oil pump pressure relief valve spring
4. If the oil pump is to be reused, install a NEW oil pump
pressure relief valve spring.
5. During oil pump installation, install a NEW oil pump
driveshaft retainer.
Oil Pump Assemble
Tools Required
J 21882 Oil Suction Pipe Installer
1. Apply clean engine oil GM P/N 12345610 or equivalent to
the oil pump pressure relief valve, oil pump pressure relief
valve spring and oil pump body.
Notices.
Important: Replace the oil pump pressure relief valve spring when
you reuse the oil pump.
2. Install the following items:
2.1. The oil pump pressure relief valve
2.2. The oil pump pressure relief valve spring
2.3. The oil pump pressure relief valve spring straight pin
the oil pump drive gear, the oil pump driven gear and the oil
pump body internal surfaces.
4. Install the oil pump drive gear and the oil pump driven gear
into the oil pump body.
4.1. Align the matchmarks on the oil pump drive and driven
gears.
4.2. Install the smooth side of the oil pump drive and driven
gears toward the oil pump cover.
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5. Install the oil pump cover bolts.
Tighten
Tighten the bolts to 12 Nm (106 lb in).
6. Inspect the oil pump for smoothness of operation by turning
the oil pump driveshaft by hand.
4. Install the oil pump cover.
7. Install the oil pump screen.
7.1. If removed, replace the oil pump screen.
The oil pump screen must have a good press fit into
the oil pump body.
7.2. Mount the oil pump in a soft jawed vise.
7.3. Apply sealant GM P/N 12346004 or equivalent to the
end of the oil pump screen pipe.
7.4. Use the J 21882 and a soft-faced hammer in order to
tap the oil pump screen into the pump body.
The oil pump screen must align parallel with the
bottom of the oil pan when the oil pan is installed.
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Important: Install a NEW oil pump driveshaft retainer during
assembly.
8. Install the oil pump driveshaft and the NEW oil pump
driveshaft retainer.
Valve Rocker Arm Cover Clean and Inspect
Notices.
1. Clean the valve rocker arm cover in cleaning solvent.
2. Dry the valve rocker arm cover with compressed air.
3. Inspect the valve rocker arm cover for the following:
Damage to the PCV valve grommet (1)
Damage to the bolt holes (2)
A damaged valve rocker arm cover may interfere with the
valve rocker arms.
Damage to the exterior of the valve rocker arm cover (3)
Gouges or damage to the sealing surface (4)
Damage to the oil fill tube grommet (5)
Restrictions to the ventilation system passages
Oil Pan Clean and Inspect
1. Remove the oil pan baffle bolts and the oil pan baffle.
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Notices.
2. Clean the oil pan and the oil pan baffle in cleaning solvent.
3. Dry the oil pan and the oil pan baffle with compressed air.
4. Inspect the oil pan for the following:
Gouges or damage to the oil pan sealing surfaces (1)
Damage to the threaded holes (2)
Damaged oil pan drain hole threads (3)
Damage to the oil pan baffle
Damage to the exterior of the oil pan
A damaged oil pan may interfere with the proper position
of the oil pump screen, or may not distribute oil properly
in the oil pan sump area.
5. Install the oil pan baffle and the bolts.
Tighten
Tighten the oil pan baffle bolts to 12 Nm (106 lb in).
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Intake Manifold Disassemble
1. Remove the nuts, the studs and the accelerator control
cable bracket.
2. Remove the throttle body attaching studs.
3. Remove the throttle body.
4. Remove the throttle body to upper intake manifold gasket.
5. Discard the throttle body to upper intake manifold gasket.
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6. Remove the water outlet studs.
7. Remove the water outlet (1) or (2).
8. Remove the engine coolant thermostat.
Important: Note the position and direction of the exhaust gas
recirculation (EGR) valve before removal. It is possible to
improperly install the EGR valve 180 degrees from the original
position.
9. Remove the exhaust gas recirculation (EGR) valve bolts.
Notice: The linear EGR valve is an electrical component. DO NOT
soak in any liquid cleaner or solvent because damage may result.
10. Remove the EGR valve and the EGR valve gasket from the
lower intake manifold.
11. Discard the EGR valve gasket.
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12. Remove the engine coolant temperature (ECT) sensor plug
(1) or the ECT sensor (2) from the front of the lower intake
manifold (if equipped).
13. Remove the studs and the ignition coil.
14. Remove the manifold absolute pressure (MAP) sensor.
15. Remove the MAP sensor seal from the MAP sensor.
16. Discard the MAP sensor seal.
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17. Remove the fuel pipe bolt (4).
18. Remove the fuel pipe retainer nuts (1).
19. Remove the fuel pipe retainer (2).
20. Remove the fuel pipe (3).
21. Remove and discard the fuel seal retainers (5).
22. Remove and discard the fuel seals (6) (yellow O-rings).
23. Remove and discard the spacer rings (7) (flat washers).
24. Remove and discard the fuel seals (8) (black O-rings).
25. Remove the studs and the evaporative emission (EVAP)
canister purge solenoid valve.
26. Remove the nut and the engine wiring harness bracket.
27. Remove the upper intake manifold attaching studs.
28. Remove the upper intake manifold.
29. Remove the upper intake manifold to lower intake manifold
gasket.
30. Discard the upper intake manifold to lower intake manifold
gasket.
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31. Remove the fuel meter body seal and discard.
32. Remove the 6 poppet nozzles from the lower intake
manifold bores.
33. Remove the fuel meter body.
34. Remove the bolt and the fuel meter body bracket.
Intake Manifold Clean and Inspect
Notices.
1. Clean the upper intake manifold in cleaning solvent.
2. Dry the upper intake manifold with compressed air.
3. Clean the lower intake manifold in cleaning solvent.
4. Dry the lower intake manifold with compressed air.
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6. Inspect the lower intake manifold for the following:
Damage to the gasket sealing surfaces (1), (2) and (3)
Restricted exhaust gas recirculation (EGR) system
passages
Restricted cooling system passages (5)
Cracks or damage
5. Inspect the upper intake manifold for the following:
Cracks or other damage to the exterior (1)
Cracking or damage in the gasket grooves (2) and (3)
Damage to the throttle body mounting surface (4)
Loose or damaged bolt hole thread inserts (5)
Intake Manifold Assemble
1. If reusing the fastener, apply threadlock GM P/N 12345382
or equivalent to the threads of the fuel meter body bracket
bolt.
2. Install the fuel meter body bracket and bolt.
Tighten
Tighten the fuel meter body bracket bolt to 10 Nm (89 lb in).
3. Install the fuel meter body into the fuel meter body bracket.
4. Install the 6 poppet nozzles into the proper lower intake
manifold bores.
5. Inspect the poppet nozzles in order to ensure that the
poppet nozzles are firmly seated and locked in the lower
intake manifold bores.
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6. Install a NEW fuel meter body seal into the groove of the
fuel meter body.
7. Install NEW upper intake manifold to lower intake manifold
gasket into the groove of the upper intake manifold.
8. Install the upper intake manifold onto the lower intake
manifold.
9. If reusing the fasteners, apply threadlock GM P/N 12345382
or equivalent to the threads of the upper intake manifold
attaching studs.
10. Install the upper intake manifold attaching studs.
Tighten
10.1. Tighten the upper intake manifold attaching studs
on the first pass to 5 Nm (44 lb in).
10.2. Tighten the upper intake manifold attaching studs on
the final pass to 9 Nm (80 lb in).
or equivalent to the threads of the evaporative emission
(EVAP) canister purge solenoid valve studs.
12. Install the EVAP canister purge solenoid valve and studs.
Tighten
Tighten the EVAP canister purge solenoid valve studs to 10
Nm (89 lb in).
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13. Install the engine wiring harness bracket and nut.
Tighten
Tighten the engine wiring harness bracket nut to 12 Nm
(106 lb in).
14. Install the NEW fuel seals (8) (black O-rings) into the fuel
meter body.
15. Install the NEW spacer rings (7) (flat washers) into the fuel
meter body.
16. Install the NEW fuel seals (6) (yellow O-rings) into the fuel
meter body.
17. Install the NEW fuel seal retainers (5) into the fuel meter
body.
18. Install the fuel pipe (3) into the fuel meter body.
19. Install the fuel pipe retainer bracket (2) onto the fuel pipe.
20. Install the fuel pipe retainer bracket nuts (1).
or equivalent to the threads of the fuel pipe bolt.
22. Install the fuel pipe bolt (4).
Tighten
22.1. Tighten the fuel pipe bracket nuts to 3 Nm (27 lb in).
22.2. Tighten the fuel pipe bolt to 6 Nm (53 lb in).
23. Install a NEW manifold absolute pressure (MAP) sensor
seal onto the MAP sensor.
24. Apply a small amount (1 drop) of clean engine oil to the
MAP sensor seal.
25. Install the MAP sensor into the upper intake manifold.
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26. Install the ignition coil and studs.
Tighten
Tighten the ignition coil studs to 12 Nm (106 lb in).
27. If reusing the engine coolant temperature (ECT) sensor plug
(1) or the ECT sensor (2) (if equipped), apply sealant GM P/
N 12346004 or equivalent to the threads of the ECT sensor
plug (1) or the ECT sensor (2).
28. Install the ECT sensor or plug (if equipped) into the front of
the lower intake manifold.
Tighten
Tighten the ECT sensor or plug to 20 Nm (15 lb ft).
Important: The exhaust gas recirculation (EGR) valve must be
installed in the original orientation.
29. Install the NEW EGR valve gasket and the EGR valve.
30. Install the EGR valve bolts.
Tighten
30.0. Tighten the EGR valve bolts on the first pass to 7
Nm (62 lb in).
30.1. Tighten the EGR valve bolts on the final pass to 30
Nm (22 lb ft).
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31. Install the engine coolant thermostat.
32. Install the water outlet (1) or (2).
33. Install the water outlet studs.
Tighten
Tighten the water outlet studs to 25 Nm (18 lb ft).
34. Install a NEW throttle body gasket into the groove in the
upper intake manifold.
35. Install the throttle body onto the upper intake manifold.
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or equivalent to the threads of the throttle body attaching
studs.
37. Install the throttle body attaching studs.
Tighten
Tighten the throttle body attaching studs to 9 Nm (80 lb in).
38. Install the accelerator control cable bracket, the studs and
the nuts.
Tighten
38.1. Tighten the accelerator control cable bracket stud to
the intake manifold to 6 Nm (53 lb in).
38.2. Tighten the accelerator control cable bracket nuts to
12 Nm (106lb in).
38.3. Tighten the accelerator control cable bracket stud to
the throttle body to 12 Nm (106 lb in).
Exhaust Manifold Clean and Inspect
Notices.
1. Clean the exhaust manifolds in cleaning solvent.
3. Inspect the exhaust manifolds for the following:
Damage to the gasket sealing surfaces (1)
Damage to the exhaust gas recirculation (EGR) pipe
fitting (2) (left manifold).
Damage to the threaded holes (3)
Restrictions within exhaust passages
Broken or damaged exhaust manifold heat shields (4) (if
applicable)
Broken or damaged exhaust manifold
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4. Measure the alignment or surface flatness of the exhaust
manifold flanges using a straight edge and a feeler gauge.
If the surface flatness is not within the specifications, the
exhaust manifold is warped and must be replaced.
Water Pump Clean and Inspect
Notices.
1. Remove all the old gasket material from the water pump
sealing surfaces.
2. Clean all the dirt and any debris from the water pump.
3. Inspect the water pump for the following:
Leakage or damage to the housing cover or gasket (1)
Excessive scratches or gouging to the gasket sealing
surfaces (2)
Leakage from the water pump vent hole (3)
A stain around the vent hole is acceptable. If leakage
occurred (dripping) with the engine operating and the
cooling system pressurized, then replace the water
pump.
Damaged bolt hole threads (4)
Excessive side-to-side movement of the water pump
shaft (5)
Leakage around the water inlet pipe (6)
Leakage around the heater hose pipe (7)
Restrictions within the internal coolant passages
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Thread Repair
General purpose thread repair kits are available commercially.
Notices.
Important: Refer to the thread repair kit manufacturers
instructions regarding the size of the drill and which tap to use.
Always avoid any buildup of chips. Back out the tap every few turns
and remove the chips.
Determine the size, the pitch and the depth of the damaged
thread.
1. Adjust the stop collars on the cutting tool as needed. Tap the
stop collars to the required depths.
2. Drill out the damaged thread.
3. Remove the chips.
4. Apply clean engine oil to the top thread.
5. Use the tap in order to cut new thread.
6. Clean the thread.
7. Screw the thread insert onto the mandrel of the thread insert
installer. Engage the tang of the thread insert onto the end of
the mandrel.
Important: The thread insert should be flush to 1 turn below the
surface.
8. Lubricate the thread insert with clean engine oil (except
when installing in aluminum) and install the thread insert.
9. If the tang of the thread insert does not break off when
backing out the thread insert installer, break off the tang
using a drift punch.
Service Prior to Assembly
Dirt will cause premature wear of the rebuilt
engine. Clean all the components.
Use the proper tools to measure the components
when checking for excessive wear. Components
not within the manufacturers specification must
be repaired or replaced.
When the components are re-installed into an engine,
return the components to the original location,
position and direction.
During assembly, lubricate all the moving parts with
clean engine oil (unless otherwise specified). The
engine oil will provide the initial lubrication when the
engine is first started.
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Engine Block Plug Installation
Tools Required
J 41712 Oil Pressure Switch Socket
Notices.
1. Install a NEW oil filter bypass valve.
1.1. Install the oil filter bypass valve into the oil gallery bore
until slightly below flush with the surface of the engine
block.
1.2. Using a pointed punch, stake the engine block area
around the oil filter bypass valve.
2. Apply sealant GM P/N 12346004 or equivalent to the
outside diameter of the NEW front engine oil gallery plugs.
3. Install the NEW front engine block oil gallery plugs.
A properly installed front engine oil gallery plug must be
installed slightly below flush with the front face of the engine
block.
4. Apply threadlock GM P/N 12345382 or equivalent to the
outside diameter of the NEW engine block core hole plugs.
5. Install the NEW engine block core hole plugs.
A properly installed engine block core hole plug must be
insalled flush with the bottom of the chamfer (1) of the
engine block core hole.
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6. Install the spring type S pin (crankshaft rear oil seal housing
locator) (if required).
outside diameter of the NEW expansion cup plug (balance
rear bearing hole).
8. Install the NEW expansion cup plug (balance shaft rear
bearing hole).
outside diameter of the NEW expansion cup plug (camshaft
rear bearing hole).
10. Install the NEW expansion cup plug (camshaft rear bearing
hole).
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threads of the engine block right rear oil gallery plug, the
engine block left rear oil gallery plug and the engine block
left side oil gallery plug.
Tighten
11.1. Tighten the engine block left side oil gallery plug and
the engine block right rear oil gallery plug to 20 Nm
(15 lb ft).
11.2. Tighten the engine block left rear oil gallery plug to
30 Nm (22 lb ft).
13. Install the dowel straight pins (transmission locator) (if
required)
14. Install the left side dowel pins (cylinder head locator) (if
required)
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15. Install the right side dowel pins (cylinder head locator) (if
required).
threads of the engine block coolant drain hole plugs.
17. Install the engine block coolant drain hole plugs.
Tighten
Tighten the engine block coolant drain hole plugs to 20 Nm
(15 lb ft).
18. If reusing the engine oil pressure sensor fitting, apply
sealant GM P/N 12346004 or equivalent to the threads of
the engine oil pressure sensor fitting.
Important: Do not loosen the engine oil pressure fitting after the
initial torque has been obtained.
19. Install the engine oil pressure sensor fitting.
Tighten
Tighten the engine oil pressure sensor fitting to 15 Nm (11
lb ft).
Important: Do not rotate the engine oil pressure fitting clockwise
more than 359 degrees after the initial torque has been obtained.
20. Rotate the engine oil pressure sensor fitting clockwise to the
proper position (1), 50 degrees from the centerline (2).
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21. If reusing the engine oil pressure gauge sensor, apply
sealant GM P/N 12346004 or equivalent to the threads of
the engine oil pressure gauge sensor.
22. Install the engine oil pressure gauge sensor using the
J 41712.
Tighten
Tighten the engine oil pressure gauge sensor to 30 Nm (22
lb ft).
23. Install the knock sensor.
Tighten
Tighten the knock sensor to 20 Nm (15 lb ft).
Crankshaft and Bearings Installation
Tools Required
1. Install the crankshaft bearings into the engine block.
2. Apply clean engine oil to the crankshaft bearings.
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3. Apply clean engine oil to the crankshaft bearing journals.
4. Install the crankshaft.
7. Install the crankshaft bearing caps in the original position
and with the arrow on the crankshaft bearing caps in the
direction of the front of the engine block.
8. Install the crankshaft bearing cap bolts until snug.
9. Thrust the crankshaft rearward in order to set and align the
crankshaft thrust bearings and the crankshaft bearing caps.
10. Thrust the crankshaft forward in order to align the rear faces
of the crankshaft thrust bearings.
11. Tighten the crankshaft bearing cap bolts.
Tighten
11.1. Tighten the crankshaft bearing cap bolts on the first
5. Install the crankshaft bearings into the crankshaft bearing
caps.
6. Apply clean engine oil to the crankshaft bearings.
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11.2. Tighten the crankshaft bearing cap bolts on the final
pass an additional 73 degrees using the J 36660.
12. Measure the crankshaft end play.
12.1. Firmly thrust the crankshaft rearward, and then
forward.
This will align the crankshaft rear bearing thrust
surfaces.
12.2. With the crankshaft pushed forward, insert a feeler
gauge between the crankshaft and the crankshaft rear
bearing thrust surface to measure the clearance.
Specification
Crankshaft end play 0.05-0.20 mm (0.002-0.008 in)
13. Rotate the crankshaft in order to check for binding.
A bent crankshaft or lack of proper crankshaft bearing
clearance may cause binding.
14. If the crankshaft does not turn freely, loosen the crankshaft
bearing cap bolts on 1 crankshaft bearing cap at a time in
order to determine the location of the binding.
A lack of proper crankshaft bearing clearance may be
caused by the following:
Burrs on the crankshaft bearing cap
Foreign material between the crankshaft bearing and the
engine block
Foreign material between the crankshaft bearing and
the crankshaft bearing cap
Damaged crankshaft bearing
Improper size crankshaft bearing
Crankshaft Rear Oil Seal and Housing Installation
Tools Required
J 35621-B Rear Main Seal Installer
Notice: Refer to Fastener Notices in Cautions and Notices.
1. Install the crankshaft rear oil seal housing retainer stud.
Tighten
Tighten the crankshaft rear oil seal housing retainer stud to
6 Nm (53 lb in).
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Important: Always use a NEW crankshaft rear oil seal housing
gasket when installing the crankshaft rear oil seal housing.
2. Install the NEW crankshaft rear oil seal housing gasket.
3. Install the crankshaft rear oil seal housing onto the
crankshaft rear oil seal housing retainer stud.
4. Install the crankshaft rear oil seal housing nut and bolts.
Tighten
Tighten the crankshaft rear oil seal housing nut and bolts to
12 Nm (106 lb in).
5. Apply a small amount (2 to 3 drops) of clean engine oil to
the bore of the crankshaft rear oil seal housing.
the outside diameter of the engine flywheel pilot flange.
7. Apply a small amount (1 drop) of clean engine oil to the
outside diameter of the flywheel locator pin.
the crankshaft seal surface.
9. Inspect the J 35621-B flange for imperfections that may
damage the crankshaft rear oil seal.
Minor imperfections may be removed with a fine grade
emery cloth.
Important: DO NOT allow oil or any other lubricants to contact the
seal lip of the crankshaft rear oil seal.
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10. Remove the sleeve from the crankshaft rear oil seal.
the outside diameter of the crankshaft rear oil seal.
12. Install the crankshaft rear oil seal onto the J 35621-B.
13. Install the J 35621-B onto the rear of the crankshaft and
hand tighten the tool bolts until snug.
Notice: Proper alignment of the crankshft rear oil seal is critical.
Install the crankshaft rear oil seal near to flush and square to the
crankshaft rear oil seal housing. Failing to do so may cause the
crankshaft rear oil seal or the crankshaft rear oil seal installlation
tool to fail.
14. Install the crankshaft rear oil seal onto the crankshaft and
into the crankshaft rear oil seal housing.
14.1. Turn the J 35621-B wing nut clockwise until the
crankshaft rear oil seal is installed near to flush and
square to the crankshaft rear oil seal housing.
Increased resistance will be felt when the crankshaft
rear oil seal has reached the bottom of the crankshaft
rear oil seal housing bore.
14.2. Turn the J 35621-B wing nut counterclockwise to
release the J 35621-B from the crankshaft rear oil
seal.
15. Remove the J 35621-B from the crankshaft.
16. Wipe off any excess engine oil with a clean rag.
Piston, Connecting Rod and Bearing Installation
Piston Selection
Tools Required
J 5239 Connecting Rod Bolt Guide Set
J 8037 Ring Compressor
Important: Measurements of all components should be taken with
the components at normal room temperature.
For proper piston fit, the engine block cylinder bores should not
have excessive wear or taper.
A used piston and piston pin set may be reinstalled if, after
cleaning and inspection, the piston and piston pin are within
specifications.
1. Use the J 8087 in order to measure the cylinder bore
diameter. Measure at a point 64 mm (2.5 in) from the top of
the cylinder bore and 90 degrees to the crankshaft
centerline.
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2. Measure the J 8087 with a micrometer and record the
reading.
3. With a micrometer or caliper at a right angle to the piston pin
bore, measure the piston 11 mm (0.433 in) from the bottom
of the skirt.
4. Subtract the piston diameter from the cylinder bore diameter
in order to determine piston-to-bore clearance. Refer to
5. If the proper clearance cannot be obtained, then select
another piston and measure the clearances.
If the proper fit cannot be obtained, the cylinder bore may
require honing or boring.
6. When the piston-to-cylinder bore clearance is within
specifications, permanently mark the top of the piston for
installation into the proper cylinder.
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3. Install the J 8037 onto the piston and compress the piston
rings.
Installation Procedure
1. Apply clean engine oil to the following components:
The piston
The piston rings
The cylinder bore
The bearing surfaces
2. Install the J 5239 onto the connecting rod bolts.
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Important: The mark on the top of the piston must face the front of
the engine block.
When assembled, the flanges on the connecting rod and
connecting rod cap should face to the front of the engine block on
the left bank, and to the rear of the engine block on the right bank.
4. Install the piston and connecting rod assembly, and the
J 8037 into the proper cylinder bore.
5. Use the J 8037 and the J 5239 and lightly tap the top of the
piston with a wooden hammer handle.
5.1. Hold the J 8037 firmly against the engine block until all
of the piston rings have entered the cylinder bore.
5.2. Use the J 5239 in order to guide the connecting rod
onto the crankshaft journal.
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6. Remove the J 5239.
7. Install the connecting rod caps, bearings and nuts.
Tighten
7.1. Tighten the nuts evenly on the first pass to 27 Nm (20
lb ft).
7.2. Use the J 36660 in order to tighten the nuts on the final
pass an additional 70 degrees.
8. After the piston and connecting rod assemblies have been
installed, then lightly tap each connecting rod assembly
(parallel to the crankpin) in order to ensure that the
connecting rods have side clearance.
9. Use a feeler gauge or a dial indicator to measure the
connecting rod side clearance between the connecting rod
caps. The connecting rod side clearance should be 0.15-
0.44 mm (0.006-0.017 in).
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Camshaft Installation
1. Apply clean engine oil GM P/N 12345610 or equivalent, or
engine oil supplement GM P/N 1052367 or equivalent to the
following components:
The engine camshaft lobes
The camshaft bearing journals
The camshaft bearings
2. Install three 5/16-18 x 4.0 in. bolts into the engine camshaft
front bolt holes.
Notice: All camshaft journals are the same diameter, so care must
be used in removing or installing the camshaft to avoid damage to
the camshaft bearings.
3. Use the bolts as a handle in order to install the engine
camshaft.
4. Remove the 3 bolts from the front of the engine camshaft.
Balance Shaft Installation
Tools Required
J 8092 Universal Driver Handle
J 36996 Balance Shaft Installer
are serviced only as an assembly. Do not remove the balance
shaft front bearing from the balance shaft.
the balance shaft front bearing.
Notices.
2. Use the J 36996 and the J 8092 in order to install the
balance shaft.
or equivalent to the threads of the camshaft retainer bolts.
6. Install the camshaft retainer and bolts.
Tighten the camshaft retainer bolts to 12 Nm (106 lb in).
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3. Install the balance shaft retainer and bolts.
Tighten
Tighten the balance shaft retainer bolts to 12 Nm (106 lb
in).
4. Install the balance shaft driven onto the balance shaft.
or equivalent to the threads of the balance shaft driven gear
bolt.
6. Install the balance shaft driven gear bolt.
6.1. Use a wrench to secure the balance shaft.
Place the wrench onto the balance shaft near to the
balance shaft front bearing.
6.2. Install the balance shaft driven gear bolt.
Tighten
6.2.1. Tighten the balance shaft driven gear bolt on
the first pass to 20 Nm (15 lb ft).
6.2.2. Tighten the balance shaft driven gear bolt on
the final pass using the J 36660 an additional
35 degrees.
7. Remove the wrench from the balance shaft.
8. Rotate the balance shaft by hand in order to ensure that
there is clearance between the balance shaft and the valve
lifter pushrod guide. If the balance shaft does not rotate
freely, check to ensure that the retaining ring on the balance
shaft front bearing is seated on the case.
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9. Install the balance shaft drive gear. DO NOT install the
camshaft sprocket bolts at this time.
10. Rotate the engine camshaft so that the timing mark on the
balance shaft drive gear is in the 12 oclock position.
11. Remove the balance shaft drive gear.
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12. Rotate the balance shaft so that the timing mark on the
balance shaft driven gear is in the 6 oclock position.
13. Position the balance shaft drive gear onto the engine
camshaft.
14. Look to ensure that the balance shaft drive gear and the
balance shaft driven gear timing marks are aligned.
Timing Chain and Sprockets Installation
Tools Required
J 5590 Installer
1. Install the crankshaft balancer key into the crankshaft
keyway.
The crankshaft balancer key should be parallel to the
crankshaft or with a slight incline.
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2. Align the keyway of the crankshaft sprocket with the
crankshaft balancer key.
Notices.
3. Use the J 5590 in order to install the crankshaft sprocket.
4. Rotate the crankshaft until the crankshaft sprocket is at the
12 oclock position.
Important: Install the camshaft sprocket with the alignment mark
at the 6 oclock position.
5. Install the camshaft sprocket and the camshaft timing chain.
6. Look to ensure that the crankshaft sprocket is aligned at the
12 oclock position and the camshaft sprocket is aligned at
the 6 oclock position.
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Important: Do not use a hammer to install the camshaft sprocket
onto the camshaft. To do so may dislodge the expansion cup plug
(camshaft rear bearing hole).
7. Install the camshaft sprocket bolts.
Tighten
Tighten the camshaft sprocket bolts to 25 Nm (18 lb ft).
8. Install the crankshaft position sensor reluctor ring.
8.1. Align the keyway on the crankshaft position sensor
reluctor ring with the crankshaft balancer key in the
crankshaft.
8.2. Use the J 5590 in order to push the crankshaft position
sensor reluctor ring onto the crankshaft until
completely seated against the crankhshaft sproket.
Engine Front Cover Installation
Important: Once the composite engine front cover is removed,
DO NOT reinstall the engine front cover. Always install a NEW
engine front cover.
1. Install the NEW engine front cover.
Notice: Refer to Fasteners Notice in Cautions and Notices.
2. Install the engine front cover bolts.
Tighten
Tighten the engine front cover bolts to 12 Nm (106 lb in).
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Important: DONOT reuse the original crankshaft position sensor
seal (o-ring). When installing the crankshaft position sensor, be
sure the crankshaft position sensor is fully seated and held
stationary in the engine front cover crankshaft position sensor
bore. A crankshaft position sensor that is not completely seated
will cock in the engine front cover and may result in erratic engine
operation.
3. Lubricate the NEW crankshaft position sensor seal (O-ring)
with clean engine oil.
4. Install the NEW crankshaft position sensor seal (O-ring)
onto the crankshaft position sensor.
Oil Pump Installation
1. Inspect for properly installed pins (oil pump locator).
5. Install the crankshaft position sensor until fully seated into
the engine front cover.
6. Install the crankshaft position sensor bolt.
Tighten
Tighten the crankshaft position bolt to 8 Nm (71 lb in).
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Important: DO not reuse the oil pump driveshaft retainer.
During assembly, install a NEW oil pump driveshaft retainer.
2. Install the oil pump.
3. Position the oil pump onto the pins.
Oil Pan Installation
1. Apply a 5 mm (0.197 in) wide and 25 mm (1.0 in) long bead
of adhesive GM P/N 12346141 or equivalent to both the
right and left sides of the engine front cover to engine block
junction at the oil pan sealing surfaces.
Notice: Refer to Fasteners Notice in Cautions and Notices.
4. Install the oil pump bolt attaching the oil pump to the rear
crankshaft bearing cap.
Tighten
Tighten the oil pump bolt to 90 Nm (66 lb ft).
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2. Apply a 5 mm (0.197 in) wide and 25 mm (1.0 in) long bead
of adhesive GM P/N 12346141 or equivalent to both the
right and left sides of the crankshaft rear oil seal housing to
engine block junction at the oil pan sealing surfaces.
Important: The oil pan alignment must always be flush or forward
no more than 0.3 mm (0.011 in) from the rear face of the engine
block.
4. Install the oil pan onto the engine block.
Press the oil pan gasket into the grooves of the engine front
cover and crankshaft rear oil seal housing.
5. Slide the oil pan back against a suitable straight edge.
Important: Always install a NEW oil pan gasket.
The oil pan gasket and oil pan must be installed and the fasteners
tightened while the adhesive is still wet to the touch.
3. Install the NEW oil pan gasket into the groove in the oil pan.
6. Install the oil pan bolts and nuts, but do not tighten.
7. Measure the pan-to-transmission housing clearance using a
feeler gauge and a straight edge.
Use a feeler gauge to check the clearance between the oil
pan-to-transmission housing measurement points. If the
clearance exceeds 0.3 mm (0.011 in) at any of the 3 oil pan-
to-transmission housing measurement points (1), then
repeat the step until the oil pan-to-transmission housing
clearance is within the specification. The oil pan must always
be forward of the rear face of the engine block.
Notice: If the clearance is more than 0.3 mm (0.011 in),
powertrain durability may be reduced.
8. Tighten the oil pan bolts and nuts in sequence (1-12).
Tighten
Tighten the oil pan bolts to 25 Nm (18 lb ft).
9. Measure the clearance between the 3 oil pan-to-
transmission housing measurement points in order to
ensure proper alignment.
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10. Install a NEW oil pan drain plug seal (O-ring) onto the oil
pan drain plug.
11. Install the oil pan drain plug into the oil pan.
Tighten
Tighten the oil pan drain plug to 25 Nm (18 lb ft).
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12. Install the NEW engine oil level sensor (if applicable).
Tighten
Tighten the engine oil level sensor to 13 Nm (115 lb in).
Crankshaft Balancer Installation
Tools Required
J 23523-F Balancer Remover and Installer
1. Look to ensure that the front groove pin (crankshaft
balancer) is installed in the proper location (if applicable).
Notice: The inertial weight section of the crankshaft balancer is
assembled to the hub with a rubber type material. The correct
installation procedures (with the proper tool) must be followed or
movement of the inertial weight section of the hub will destroy the
tuning of the crankshaft balancer.
2. Apply a small amount of adhesive GM P/N 12346141 or
equivalent onto the crankshaft balancer keyway in order to
seal the crankshaft balancer keyway and crankshaft joint.
3. Align the keyway of the crankshaft balancer with the
crankshaft balancer key.
4. Install the crankshaft balancer onto the end of the
crankshaft.
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7. Install the crankshaft pulley and bolts.
Tighten
Tighten the crankshaft pulley bolts to 58 Nm (43 lb ft).
5. Use the J 23523-F in order to press the crankshaft balancer
onto the crankshaft.
5.1. Install the J 23523-F plate and bolts onto the front of
the crankshaft balancer.
Tighten
Tighten the J 23523-F plate bolts to 25 Nm (18 lb ft).
5.2. Install the J 23523-F screw into the end for the
crankshaft.
5.3. Install the J 23523-F bearing, the washer and the nut
onto the J 23523-F screw.
5.4. Rotate the J 23523-F nut clockwise until the crankshaft
balancer hub is completely seated against the
crankshaft position sensor reluctor ring.
6. Remove the J 23523-F.
8. Ensure that the crown of the crankshaft balancer washer (2)
is faced away from the engine.
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9. Install the crankshaft balancer washer and the bolt.
Tighten
Tighten the crankshaft balancer bolt to 95 Nm (70 lb ft).
Valve Lifter Installation
1. Apply lubricant GM P/N 12345501 or equivalent to the valve
lifter rollers.
Important: If reusing the valve lifters, install the valve lifters in the
original positions.
2. Install the valve lifters.
3. Install the valve lifter pushrod guides.
Tighten
Tighten the valve lifter pushrod guide bolts to 16 Nm (12 lb
ft).
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Cylinder Head Installation (Left)
Tools Required
1. Clean the cylinder head gasket surfaces on the engine
block.
2. Inspect the dowel pins (cylinder head locators) for proper
installation.
3. Clean the cylinder head gasket surfaces on the cylinder
head.
Important: Do not use any type of sealer on the cylinder head
gasket (unless specified).
4. Install the NEW cylinder head gasket in position over the
dowel pins (cylinder head locators).
5. Install the cylinder head onto the engine block.
Guide the cylinder head carefully into place over the dowel
pins and the cylinder head gasket.
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threads of the cylinder head bolts.
7. Install the cylinder head bolts finger tight.
8. Tighten the cylinder head bolts in sequence on the first
pass.
Tighten
Tighten the bolts in sequence on the first pass to 30 Nm
(22 lb ft).
9. Use the J 36660 in order to tighten the cylinder head bolts in
sequence on the final pass.
Tighten the long bolts (1,4,5,8 and 9) on the final pass in
sequence to 75 degrees.
Tighten the medium bolts (12 and 13) on the final pass in
Tighten the short bolts (2,3,6,7,10 and 11) on the final
pass in sequence to 55 degrees.
10. Install the spark plug wire support and bolts.
Tighten
Tighten the spark plug wire support bolts to 12 Nm (106 lb
in).
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11. Measure the NEW spark plugs for the proper gap.
Adjust the spark plug gap if necessary.
Specification
Spark plug gap to 1.52 mm (0.060 in)
12. Install the spark plugs.
Tighten
Tighten the spark plugs for a USED cylinder head to 15
Nm (11 lb ft)
Tighten the spark plugs for the initial installation of a NEW
cylinder head to 30 Nm (22 lb ft).
13. If reusing the engine coolant temperature gauge sensor (if
applicable), apply sealant GM P/N 12346004 or equivalent
to the threads of the engine coolant temperature gauge
sensor.
14. Install the engine coolant temperature gauge sensor (if
applicable).
Tighten
Tighten the engine coolant temperature gauge sensor to 20
Nm (15 lb ft).
15. If reusing the engine coolant temperature sensor (if
applicable), apply sealant GM P/N 12346004 or equivalent
to the threads of the engine coolant temperature sensor.
16. Install the engine coolant temperature sensor (if applicable).
Tighten
Tighten the engine coolant temperature sensor to 20 Nm
(15 lb ft).
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Cylinder Head Installation (Right)
Tools Required
1. Clean the cylinder head gasket surfaces on the engine
block.
2. Inspect the dowel pins (cylinder head locators) for proper
installation.
3. Clean the cylinder head gasket surfaces on the cylinder
head.
Important: Do not use any type of sealer on the cylinder head
gasket (unless specified).
4. Install the NEW cylinder head gasket in position over the
dowel pins (cylinder head locators).
5. Install the cylinder head onto the engine block.
Guide the cylinder head carefully into place over the dowel
pins and the cylinder head gasket.
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threads of the cylinder head bolts.
7. Install the cylinder head bolts finger tight.
8. Tighten the cylinder head bolts in sequence on the first
pass.
Tighten
Tighten the bolts in sequence on the first pass to 30 Nm
(22 lb ft).
9. Use the J 36660 in order to tighten the cylinder head bolts in
sequence on the final pass.
Tighten the long bolts (1,4,5,8 and 9) on the final pass in
Tighten the medium bolts (12 and 13) on the final pass in
Tighten the short bolts (2,3,6,7,10 and 11) on the final
pass in sequence to 55 degrees.
10. Install the spark plug wire support and bolts.
Tighten
Tighten the spark plug wire support bolts to 12 Nm (106 lb
in).
11. Remove the front spark plug wire support bolt.
The front spark plug wire support bolt is used to fasten the
oil level indicator tube, and will be installed within the oil level
indicator tube installation procedure.
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12. Measure the NEW spark plugs for the proper gap.
Adjust the spark plug gap if necessary.
Specification
Spark plug gap to 1.52 mm (0.060 in)
13. Install the spark plugs.
Tighten
Tighten the spark plugs for a USED cylinder head to 15
Nm (11 lb ft)
Tighten the spark plugs for the initial installation of a NEW
cylinder head to 30 Nm (22 lb ft).
Valve Rocker Arm and Push Rod Installation
Important: Be sure to keep parts in order. Parts must be
reinstalled into the original location and position.
1. Install the valve pushrods.
Important: Be sure that the arrow on the valve rocker arm support
is in the up position.
2. Install the valve rocker arm supports.
3. Apply prelube GM P/N 12345501 or equivalent to the
following valve rocker arm contact surfaces:
Valve pushrod socket (1)
Roller pivot (2)
Valve stem tip (3)
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4. Install the valve rocker arm assemblies as follows:
4.1. Finger start the bolt at location (1)
4.4. Finger start the remaining valve rocker arm bolts
5. Rotate the crankshaft balancer to position the crankshaft
balancer alignment mark (1) 57-63 degrees clockwise or
counterclockwise from the engine front cover alignment tab
(2).
Important: Once the valve rocker arm assemblies are installed
and properly torqued, no additional valve lash adjustment is
required.
6. Tighten the valve rocker arm bolts.
Tighten
Tighten the valve rocker arm bolts to 30 Nm (22 lb ft).
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Intake Manifold Installation
Notice: Applying excessive amounts of sealant may prohibit the
intake manifold gaskets from sealing properly.
1. Apply a 4.0 mm (0.157 in) patch of adhesive GM P/N
12346141 or equivalent to the cylinder head side of the
lower intake manifold gasket at each end.
Important: The lower intake manifold gasket must be installed
while the adhesive is still wet to the touch.
2. Install the lower intake manifold gasket onto the cylinder
head.
Use the gasket locator pins in order to properly seat the
lower intake manifold gasket on the cylinder head.
Notice: Care must be used to apply the correct amount of sealant
onto the gaskets. Applying excessive amounts of sealant may
prohibit the intake manifold gaskets from sealing properly.
Important: The lower intake manifold must be installed and the
fasteners tightened while the adhesive is still wet to the touch.
3. Apply a 5.0 mm (0.197 in) bead of adhesive GM P/N
12346141 or equivalent to the front top of the engine block.
Extend the adhesive bead 13 mm (0.50 in) onto each lower
intake manifold gasket.
4. Apply a 5.0 mm (0.197 in) bead of adhesive GM P/N
12346141 or equivalent to the rear top of the engine block.
Extend the adhesive bead 13 mm (0.50 in) onto each lower
intake manifold gasket.
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5. Install the lower intake manifold onto the engine block.
or equivalent to the threads of the lower intake manifold
bolts.
7. Install the lower intake manifold bolts.
Notice: Proper lower intake manifold fastener tightening sequence
and torque is critical. Always follow the tightening sequence, and
torque the intake manifold bolts using the 3 step method. Failing to
do so may distort the crankshaft bearing bore alignment and
cause damage to the crankshaft bearings.
8. Tighten the lower intake manifold bolts.
Tighten
8.1. Tighten the bolts in sequence (1-8) on the first pass to
3 Nm (27 lb in).
12 Nm (106 lb in).
15 Nm (11 lb ft).
9. Connect the evaporative emission (EVAP) canister solenoid
valve harness.
9.1. Push the elbow inward until the quick connect snaps
into place.
9.2. Pull the elbow outward in order to ensure proper
connection.
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Distributor Installation
Important: The engine front cover has 2 alignment tabs and the
crankshaft balancer has 2 alignment marks (spaced 90 degrees
apart) which are used for positioning number 1 piston at Top Dead
Center (TDC). With the piston on the compression stroke and at
top dead center, the crankshaft balancer alignment mark (1) must
align with the engine front cover tab (2) and the crankshaft
balancer alignment mark (4) must align with the engine front cover
tab (3).
Rotate the crankshaft balancer clockwise until the alignment
marks on the crankshaft balancer are aligned with the tabs on the
engine front cover and the number 1 piston is at top dead center of
the compression stroke.
1. Remove the distributor cap bolts and discard.
2. Remove the distributor cap.
3. Install a NEW distributor gasket onto the distributor.
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4. Align the indent hole on the driven gear with the paint mark
on the distributor housing.
5. Ensure that the distributor rotor segment points to the cap
hold area.
6. Align the slotted tang in the oil pump driveshaft with the
distributor driveshaft.
Rotate the oil pump driveshaft with a screwdriver if
necessary.
7. Align the flat (1) in the distributor housing toward the front of
the engine.
8. Install the distributor and distributor clamp.
The flat in the distributor housing must point toward the front
of the engine.
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9. Once the distributor is fully seated, align the distributor rotor
segment with the number 6 pointer (1) that is cast into the
distributor base.
If the distributor rotor segment does not come with a few
degrees of the number 6 pointer (1), the gear mesh between
the distributor and camshaft may be off a tooth or more.
Repeat the procedure again in order to achieve proper
alignment.
10. Install the distributor clamp bolt.
Tighten
Tighten the distributor clamp bolt to 25 N
.
m (18 lb ft).
11. Install the distributor cap and NEW distributor cap bolts.
Tighten
Tighten the distributor cap bolts to 2.4 N
.
m (21 lb in).
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12. Install the ignition coil wire harness.
Valve Rocker Arm Cover Installation (Left)
Important: Do not reuse the valve rocker arm cover gasket or the
valve rocker arm cover grommets.
1. Install the NEW valve rocker arm cover gasket into the
groove of the valve rocker arm cover.
2. Install the NEW valve rocker arm cover bolt grommets into
the valve rocker arm cover.
3. Install the valve rocker arm cover onto the cylinder head.
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4. Install the valve rocker arm cover bolts.
Tighten
Tighten the valve rocker arm cover bolts to 12 N
.
m (106 lb
in).
Valve Rocker Arm Cover Installation (Right)
Important: Do not reuse the valve rocker arm cover gasket or the
valve rocker arm cover bolt grommets.
1. Install the NEW valve rocker arm cover gasket into the
groove of the valve rocker arm cover.
2. Install the NEW valve rocker arm cover bolt grommets into
the valve rocker arm cover.
3. Install the valve rocker arm cover onto the cylinder head.
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4. Install the valve rocker arm cover bolts.
Tighten
Tighten the valve rocker arm cover bolts to 12 N
.
m (106 lb
in).
Oil Level Indicator and Tube Installation
1. Apply sealant GM P/N 12346004 or equivalent around the
oil level indicator tube 13 mm (0.50 in) below the tube bead.
2. Install the oil level indicator tube into the engine block.
Rotate the oil level indicator tube into position.
3. Install the oil level indicator tube bolt.
Tighten
Tighten the oil level indicator tube bolt to 12 Nm (106 lb in).
4. Install the oil level indicator into the oil level indicator tube, if
required.
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Water Pump Installation
Tools Required
J 41240 Fan Clutch Remover and Installer
1. If reusing the fasteners, apply sealant GM P/N 12346004 or
equivalent to the threads of the water pump bolts.
2. Install the water pump and the NEW water pump gaskets.
3. Install the water pump bolts.
Tighten
Tighten the water pump bolts to 45 N
.
m (33 lb ft).
Important: After final assembly, the water pump inlet hose clamp
tangs (water pump end) must point forward and the upper tang
should be level with the outside diameter of the water pump inlet
hose.
4. Install the water pump inlet hose and the water pump inlet
hose clamps.
5. Install the fan and water pump pulley and bolts using the
J 41240.
Tighten
Tighten the fan and water pump pulley bolts to 25 N
.
m (18 lb
ft).
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Exhaust Manifold Installation (Left)
1. Install the NEW exhaust manifold gaskets.
2. Install the exhaust manifold.
3. Install the spark plug wire shields.
or equivalent to the threads of the exhaust manifold bolts
and stud.
5. Install the exhaust manifold bolts and stud.
Tighten
5.1. Tighten the exhaust manifold bolts and stud on the first
5.2. Tighten the exhaust manifold bolts and stud on the final
6. Install the spark plug wires to the spark plug wire retainers.
7. Install the spark plug wires onto the spark plugs.
Exhaust Manifold Installation (Right)
1. Install the NEW exhaust manifold gaskets.
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Clutch Pilot Bearing Installation
Notices.
1. Install the NEW clutch pilot bearing using a suitable clutch
pilot bearing installation tool.
2. Measure to ensure the proper installation depth is obtained.
Engine Flywheel Installation
Important: If replacing the engine flywheel (manual transmission),
note the position of the original flywheel weights (if applicable).
Flywheel weights must be installed into the new engine flywheel in
the same location as the old flywheel weights were in the old
engine flywheel.
Note the position of the flywheel weights and install the NEW
flywheel weights as required.
A properly installed flywheel weight will be flush or slightly below
flush with the face of the engine flywheel.
2. Install the exhaust manifold.
3. Install the spark plug wire shields.
or equivalent to the threads of the exhaust manifold bolts
and stud.
5. Install the exhaust manifold bolts and stud.
Tighten
5.1. Tighten the exhaust manifold bolts and stud on the first
5.2. Tighten the exhaust manifold bolts and stud on the final
6. Install the spark plug wires to the spark plug wire retainers.
7. Install the spark plug wires onto the spark plugs.
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1. Install the engine flywheel (1) or (2) to the crankshaft.
Align the engine flywheel locator hole to the flywheel locator
pin.
2. Install the engine flywheel bolts.
Tighten
Tighten the engine flywheel bolts in sequence (1-6) to
100 Nm (74 lb ft).
Engine Set-Up and Testing
After overhaul, the engine must be tested before it is
installed in the vehicle. If a suitable test stand is not
available, the following procedures can be used after the
engine is installed in the vehicle.
1. Fill the crankcase with the proper quantity and
grade of engine oil.
2. Add engine oil supplement GM P/N 1052367 or
equivalent to the engine oil.
Notice: DO NOT use cooling system seal tabs (or similar
compounds) unless otherwise instructed. The use of
cooling system seal tabs (or similar compounds) may
restrict coolant flow through the passages of the cooling
system or the engine components. Restricted coolant
flow may cause engine overheating and/or damage to the
cooling system or the engine components/assembly.
3. Fill the cooling system with the proper quantity and
grade of coolant.
4. With the ignition OFF or disconnected, crank the
engine several times. Listen for any unusual noises
or evidence that any of the parts are binding.
5. Start the engine and listen for unusual noises.
6. Check the vehicle oil pressure gauge or light and
confirm that the engine has acceptable oil
pressure.
If necessary, install an oil pressure gauge and
measure the engine oil pressure.
7. Operate the engine at about 1,000 RPM until the
engine has reached normal operating temperature.
8. Listen for improperly adjusted or sticking valves,
sticking valve lifters or other unusual noises.
9. Inspect for oil and/or coolant leaks while the engine
is operating.
10. Verify that the distributor is properly positioned.
11. Perform a final inspection for the proper engine oil
and coolant levels.
Description and Operation
Engine Component Description
Balance Shaft
The cast iron balance shaft is mounted in the crankcase
above and in-line with the camshaft. A camshaft gear
drives the gear attached to the balance
shaft. The front end of the balance shaft is supported by a
ball-type bearing. The rear end of the balance shaft uses
a sleeve-type bearing.
Camshaft
The steel camshaft is supported by four bearings
pressed into the engine block. The camshaft timing chain
sprocket mounted to the front of the camshaft is driven
by the crankshaft sprocket through a camshaft timing
chain.
Crankshaft
The cast nodular iron crankshaft is supported by four
crankshaft bearings. The number four crankshaft bearing
at the rear of the engine is the end thrust bearing. The
crankshaft bearings are retained by bearing caps that are
machined with the engine block for proper alignment and
clearances. The crankshaft position sensor reluctor ring
has three lugs used for crankshaft timing and is
constructed of powdered metal. The crankshaft position
sensor reluctor ring has a slight interference fit onto the
crankshaft and an internal keyway for correct positioning.
Cylinder Heads
The cast iron cylinder heads have one intake and one
exhaust valve for each cylinder. A spark plug is located
between the valves in the side of the cylinder head. The
valve guides and seats are integral to the cylinder head.
The 4.3L heavy duty applications have pressed in
exhaust valve seats. The valve rocker arms are
positioned on the valve rocker arm supports and retained
by a bolt.
Engine Block
The cast iron engine block has six cylinders arranged in a
V shape with three cylinders in each bank. Starting at the
front side of the engine block, the cylinders in the left
bank are numbered 1-3-5 and cylinders in the right bank
are numbered 2-4-6 (when viewed from the rear). The
firing order of the cylinders is 1-6-5-4-3-2. The cylinders
are encircled by coolant jackets.
Exhaust Manifolds
The cast iron exhaust manifolds direct exhaust gases
from the combustion chambers to the exhaust system.
The left side exhaust manifold has a port for the EGR
valve inlet pipe.
Intake Manifold
The intake manifold is a two-piece design. The upper
portion is made from a composite material and the lower
portion is cast aluminum. The throttle body attaches to
the upper manifold. The lower manifold has an exhaust gas
recirculation (EGR) port cast into the manifold for mixture.
The (EGR) valve bolts into the lower intake manifold. The
Central Sequential Multiport Fuel Injection system uses
multiple fuel injectors to meter and distribute fuel to each
engine cylinder. The Central (SFI) is retained by a bracket
bolted to the lower intake manifold. The fuel meter body also
houses the pressure regulator. Metal inlet and outlet fuel
lines and nylon delivery tubes connect to the Central (SFI)
unit. The delivery tubes independently distribute fuel to each
cylinder through nozzles located at the port entrance of
each manifold runner where the fuel is atomized.
Piston and Connecting Rod Assemblies
The cast aluminum pistons use two compression rings and
one oil control assembly. The piston is a low friction,
lightweight design with a flat top and barrel shaped skirt.
The piston pins are offset 0.9 mm (0.0354 in) toward the
major thrust side (right side) to reduce piston slap as the
connecting rod travels from one side of the piston to the
other side after a stroke. The piston pins have a floating fit in
the piston and are retained by a press fit in the connecting
rod. The connecting rods are forged steel. The connecting
rods are machined with the rod cap installed for proper
clearances and alignments.
Valve Train
Motion is transmitted from the camshaft through the
hydraulic roller valve lifters and the tubular valve pushrods
to the roller type valve rocker arms. The roller type valve
rocker arm pivots on a needle type bearing in order to open
the valve. The valve rocker arms for each bank of cylinders
are mounted to a one piece valve rocker arm support. Each
valve rocker arm is retained on the valve rocker arm
support and the cylinder head by a bolt. The hydraulic valve
lifters keep all the parts of the valve train in constant
contact. Each hydraulic valve lifter acts as an automatic
adjuster and maintains zero lash in the valve train. This
eliminates the need for periodic valve adjustment.
Drive Belt System Description
The drive belt system consists of the following components:
The drive belt
The drive belt tensioner
The drive belt idler pulley
The crankshaft balancer pulley
The accessory drive component mounting brackets
The accessory drive components
The power steering pump, if belt driven
The generator
The A/C compressor, if equipped
The engine cooling fan, if belt driven
The water pump, if belt driven
The vacuum pump, if belt driven
The air compressor, if belt driven
The drive belt system may use one belt or two belts. The
drive belt is thin so that it can bend backwards and has
several ribs to match the grooves in the pulleys. There
also may be a V-belt style belt used to drive certain
accessory drive components. The drive belts are made of
different types of rubbers (chloroprene or EPDM) and
have different layers or plys containing either fiber cloth or
cords for reinforcement.
Both sides of the drive belt may be used to drive the
different accessory drive components. When the back
side of the drive belt is used to drive a pulley, the pulley is
smooth.
The drive belt is pulled by the crankshaft balancer pulley
across the accessory drive component puleys. The
spring loaded drive belt tensioner keeps constant tension
on the drive belt to prevent the drive belt from slipping.
The drive belt tensioner arm will move when loads are
applied to the drive belt by the accessory drive
components and the crankshaft.
The drive belt system may have an idler pulley, which is
used to add wrap to the adjacent pulleys. Some systems
use an idler pulley in place of an accessory drive
component when the vehicle is not equipped with the
accessory.
New Product Information
The purpose of New Product Information is to highlight or
indicate important product changes from the previous
model year.
Changes may include one or more of the following items:
A component comparison from the previous year
Fastener changes
Torque values and/or fastener tightening strategies
Changed engine specifications
New sealants and/or adhesives
Disassembly and assembly procedure revisions
Engine mechanical diagnostic procedure revisions
New special tools required
Component Comparison
Eliminated the oil filter adapter assembly
Revised the water pump seal
Revised the engine coolant thermostat
New roller type timing chain and sprockets
New roller pivot type valve rocker arm assemblies
using a one piece valve rocker arm support to
replace the ball pivot type valve rocker arm system
Cylinder heads revised using dry holes for the
valve rocker arm bolts
Torque Values and/or Fastener Tightening
Strategies
Cylinder head bolts, the crankshaft bearing cap
bolts, the connecting rod bolts and balance shaft
bolt apply a torque angle strategy.
In an on-vehicle situation where a torque angle
meter may not fit into the vehicle packaging, a
three step tightening process may be followed
using a torque wrench.
Certain fasteners should not be reused. Bolts,
studs or other fasteners that must be replaced will
be called out in the specific service procedures.
Changed Engine Specifications
Engine mechanical specifications remain the same as
the 1999 products.
New Sealants and/or Adhesives
No new sealants or adhesives have been added.
Disassembly and Assembly Procedure Revisions
Valve rocker arm and pushrod
Timing chain and sprockets
Discard all used gaskets, seals or O-ring seals
unless otherwise indicated
Gaskets, seals or O-ring seals that can be reused
will be identified in the specific service procedure.
Engine Mechanical Diagnostic Procedure Revisions
Valve Train diagnostic information is now provided
in table form.
Potential or probable causes are supplied for each
specific concern.
Engine Noise diagnostic information is now
provided in table form.
Potential or probable causes are supplied for each
specific concern.
New Special Tools Required
No new special tools are required.
Lubrication
Engine Lubrication
Full pressure lubrication, through a full-flow oil filter is supplied
by a gear-type oil pump. Oil is drawn up through the oil pump
screen and passes through the pump to the oil filter. The oil
filter is full-flow paper element unit with an anti-drain back
valve. An oil filter bypass valve is used to ensure adequate
oil supply, in the event the filter becomes plugged or develops
excessive pressure drop. Filtered oil flows into the main
gallery and then to the camshaft, the balance shaft, the rear
bearing and the crankshaft bearings. The valve lifter oil
gallery supplies oil to the valve lifters. Oil flows from the
valve lifters through the hollow valve pushrods to the valve
rocker arms. Oil drains back to the crankcase through the
oil drain holes in the cylinder head. The camshaft timing
and piston pins are lubricated by oil splash.
Cleanliness and Care
Throughout this section, it should be understood
that proper cleaning and protection of machined
surfaces and friction areas is part of the repair
procedure. This is considered standard shop
practice even if not specifically stated.
When any internal engine parts are serviced, care
and cleanliness is important.
When components are removed for service, the
components should be marked, organized or
retained in a specific order for re-assembly. chain is drip fed from the front camshaft bearing. The pistons
At the time of installation, the components should
be installed in the same location and with the same
mating surface as when removed.
An automobile engine is a combination of many
machined, honed, polished and lapped surfaces
with tolerances that are measured in millimeters or
thousandths of an inch. The surfaces should be
protected to avoid component damage.
Apply a liberal amount of clean engine oil to friction
areas during assembly.
Proper lubrication will protect and lubricate friction
areas during initial operation.
Replacing Engine Gaskets
Gasket Reuse and Applying Sealant
Do not reuse any gasket unless specified.
Gaskets that can be reused will be identified in the
service procedure.
Do not apply sealant to any gasket or sealing
surface unless specified in the service procedure.
Seperating Components
Use a rubber mallet in order to seperate the
components.
Bump the part sideways in order to loosen the
components.
Bumping of the component should be done at
bends or reinforced areas of the component to
prevent distortion of the components.
Cleaning Gasket Surfaces
Use care to avoid gouging or scraping the sealing
surfaces.
Use a plastic or wood scraper in order to remove
all the sealant from the components.
Do not use any other method or technique to
remove the sealant or the gasket material from a
part.
Do not use abrasive pads, sand paper or power
tools to clean the gasket surfaces.
These methods of cleaning can cause damage
to the component sealing surfaces.
Abrasive pads also produce a fine grit that the oil
filter cannot remove from the engine oil.
This fine grit is abrasive and can cause internal
engine damage.
Assembling Components
Assemble components using only the sealant (or
equivalent) that is specified in the service
procedure.
Sealing surfaces must be clean and free of debris
or oil.
Specific components such as crankshaft oil seals or
valve stem oil seals may require lubrication during
assembly.
Components requiring lubrication will be identified in
the service procedure.
Apply only the amount of sealant specified in the
service procedure to a component.
Do not allow the sealant to enter into any blind
threaded holes, as the sealant may prevent the
fastener from clamping properly or cause component
damage when tightened.
Tighten fasteners to the proper specifications. DO
NOT overtighten the fasteners.
Use of RTV and Anaerobic Sealer
Sealant Types
Important: The correct sealant and amount of sealant must
be used in the proper location to prevent oil leaks, coolant
leaks or the loosening of the fasteners. DO NOT interchange
the sealants. Use only the sealant (or equivalent) as
specified in the service procedure.
The following 2 major types of sealant are commonly used in
engines:
Aerobic sealant [Room Temperature Vulcanizing
(RTV)]
Anaerobic sealant, which include the following:
Gasket eliminator
Pipe
Threadlock
Aerobic Type Room Temperature Vulcanizing (RTV)
Sealant
Aerobic type Room Temperature Vulcanizing (RTV) sealant
cures when exposed to air. This type of sealant is used
where 2 components (such as the intake manifold and the
engine block) are assembled together.
Use the following information when using RTV sealant:
Do not use RTV sealant in areas where extreme
temperatures are expected. These areas include:
The exhaust manifold
The head gasket
Any other surfaces where a different type of sealant
is specified in the service procedure
Always follow all the safety recommendations and the
directions that are on the RTV sealant container.
Use a plastic or wood scraper in order to remove all
the RTV sealant from the components.
Important: Do not allow the RTV sealant to enter any blind
threaded holes, as it may prevent the fasteners from
clamping properly or cause damage when the fastener is
tightened.
The surfaces to be sealed must be clean and dry.
Use a RTV sealant bead size as specified in the service
procedure.
Apply the RTV sealant bead to the inside of any bolt hole
areas.
Assemble the components while the RTV sealant is still wet
to the touch (within 3 minutes). Do not wait for the RTV
sealant to skin over.
Tighten the fasteners in sequence (if specified) and to the
proper torque specifications. DO NOT overtighten the
fasteners.
Anaerobic Type Gasket Eliminator Sealant
Anaerobic type gasket eliminator sealant cures in the absence of
air. This type of sealant is used where 2 rigid parts (such as
castings) are assembled together. When 2 rigid parts are
disassembled and no sealant or gasket is readily noticeable, then
the 2 parts were probably assembled using an anaerobic type
gasket eliminator sealant.
Use the following information when using gasket eliminator
sealant:
Always follow all the safety recommendations and directions
that are on the gasket eliminator sealant container.
Apply a continuous bead of gasket eliminator sealant to one
flange.
The surfaces to be sealed must be clean and dry.
Important: Do not allow the gasket eliminator sealant to enter any
blind threaded holes, as the gasket eliminator sealant may prevent
the fasteners from clamping properly, seating properly or cause
damage when the fastener is tightened.
Apply the gasket eliminator sealant evenly to get a uniform
thickness of the gasket eliminator sealant on the sealing surface.
Important: Gasket eliminator sealed joint fasteners that are
partially torqued and the gasket eliminator sealant allowed to cure
more than 5 minutes, may result in incorrect shimming and sealing
of the joint.
Tighten the fasteners in sequence (if specified) and to the
proper torque specifications. DO NOT overtighten the
fasteners.
After properly tightening the fasteners, remove the excess
gasket eliminator sealant from the outside of the joint.
Anaerobic Type Threadlock Sealant
Anaerobic type threadlock sealant cures in the absence of air. This
type of sealant is used for threadlocking and sealing of bolts,
fittings, nuts and studs. This type of sealant cures only when
confined between 2 close fitting metal surfaces.
Use the following information when using threadlock sealant:
Always follow all safety recommendations and directions
that are on the threadlock sealant container.
The threaded surfaces must be clean and dry.
Apply the threadlock sealant as specified on the
threadlock sealant container.
Important: Fasteners that are partially torqued and
then the threadlock sealant allowed to cure more than
five minutes, may result in incorrect clamp load of
assembled components.
Tighten the fastener in sequence (if specified) and to
the proper torque specification. DO NOT overtighten
the fasteners.
Anaerobic Type Pipe Sealant
Anaerobic type pipe sealant cures in the absence of air
and remains pliable when cured. This type of sealant is
used where 2 parts are assembled together and
require a leak proof joint.
Use the following information when using pipe sealant:
Do not use pipe sealant in areas where extreme
temperatures are expected. These areas
include:
The exhaust manifold
The head gasket
Surfaces where a different sealant is specified
Always follow all the safety recommendations
and directions that are on the pipe sealant
container.
Ther surfaces to be sealed must be clean and
dry.
Use a pipe sealant bead of the size or quantity
as specified in the service procedure.
Important: Do not allow the pipe sealant to enter any
of the blind threaded holes, as the pipe sealant may
prevent the fastener from clamping properly, or cause
component damage when the fastener is tightened.
Apply the pipe sealant bead to the inside of any
bolt hole areas.
Apply a continuous bead of pipe sealant to 1
sealing surface.
Tighten the fasteners in sequence (if specified)
and to the proper torque specifications. DO NOT
overtighten the fasteners.
Seperating Parts
Important: Many internal engine components will
develop specific wear patterns on their friction
surfaces.
When disassembling the engine, internal components
MUST be seperated, marked and organized in a way
to ensure reinstallation to the original location and
position.
Mark or identify the following components:
Piston and the piston pin
Piston to the specific cylinder bore
Piston rings to the specific cylinder bore
Connecting rod to the crankshaft journal
Connecting rod to connecting rod cap
Crankshaft bearings and connecting rod bearings
Engine camshaft and valve lifters
Valve lifters, valve rocker arms and valve rocker
arm supports
Valve to the valve guide
Valve spring to cylinder head location
Engine block bearing cap location and direction
Oil pump drive and driven gears
Tools and Equipment
Special tools are listed and illustrated throughout this
section with a complete listing at the end of the section.
The tools (or equivalents) are specially designed to
quickly and safely accomplish the operations for which the
tools are intended. The use of special tools will also minimize
possible damage to engine components. Some precision
measuring tools are required for inspection of certain critical
components. Torque wrenches and a torque angle meter are
necessary for the proper tightening of various fasteners.
To properly service the engine assembly, the following items
should be readily available:
Approved eye protection and safety gloves
A clean, well-lit, work area
A suitable parts cleaning tank
A compressed air supply
Trays or storage containers to keep parts and
fasteners organized
An adequate set of hand tools
Approved engine repair stand
An approved engine lifting device that will adequately
support the weight of the components
Illustration Tool Number/Description Illustration Tool Number/Description
Special Tools and Equipment
J 3049-A
Valve Lifter Remover
J 5239
Connecting Rod Bolt
Guide Set
J 5590
Installer
J 8001
Dial Indicator Set
J 5825-A
Crankshaft Gear Remover
J 8037
Ring Compressor
J 5830-02
Valve Guide Reamer Set
J 8062
Valve Spring Compressor
J 8087
Cylinder Bore Gauge
J 7872
Magnetic Base Dial
Indicator
J 8089
Carbon Removing Brush
J 23523-F
Balancer Remover and
Installer
J 8092
Universal Driver Handle
J 24086-C
Piston Pin Remover/Installer
J 9666
Valve Spring Tester
J 24270
Cylinder Bore Ridge
Reamer
J 21882
Oil Suction Pipe Installer
J 26941
Bushing/Bearing Remover
J 33049
Camshaft Bearing
Service Kit
J 35621-B
Rear Main Seal Installer
J 36996
Balance Shaft Installer
J 42073
Valve Stem Seal Installer
J 38834
Balance Shaft Service Kit
J 36660
Electronic Torque
Angle Meter
J 41240
Fan Clutch Remover and
Installer
J 41427
Engine Lift Bracket
J 41712
Oil Pressure Switch Socket
J 43276
Clutch Pilot Bearing
Remover
J 43690
Rod Bearing Clearance
Checking Tool

GM 4.3L Manual Desarme

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Original Issue

Dated January 2004

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