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GMC Powertrain 4.3 L, Service Manual, Page: 80 / 196

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GMC Powertrain 4.3 L Service Manual Download Page 80

6-70

Marine/Industrial 4.3L

   Engine

2000 Marine/Industrial

34671

    4977

156168

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.

Caution: Refer to Safety Glasses Caution in Cautions and
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

Summary of Contents for Powertrain 4.3 L

Page 1: ...Engine Engine Model General Motors 4 3 L Powertrain Generator Models 30 45 kW TP 6103 1 01 Service ...

Page 2: ...quality The service procedures we recommend and describe in this service manual are effective methods of performing service and repair Some of the procedures require the use of tools that are designed for specific purposes Accordingly any person who intends to use a replacement part a service procedure or a tool that is not recommended by General Motors Powertrain must first establish that there i...

Page 3: ...Drive Belt Excessive Wear 6 25 Drive Belt Tensioner 6 26 Component Locator 6 28 Intake Manifold 6 28 Cylinder Head and Exhaust Manifold 6 30 Cylinder Block and Components 6 31 Lower Engine Block and Oil Pan 6 33 Repair Instruction Removal 6 34 Draining Fluids and Oil Filter Removal 6 34 Engine Flywheel Removal 6 35 Clutch Pilot Bearing Removal 6 35 Exhaust Manifold Removal 6 36 Oil Level Indicator...

Page 4: ...Rocker Arm and Push Rods Clean and Inspect 6 96 Valve Lifters and Guides Clean and Inspect 6 98 Cylinder Head Disassemble 6 99 Cylinder Head Clean and Inspect 6 99 Valve Guide Reaming Valve and Seat Grinding 6 102 Cylinder Head Assemble 6 104 Oil Pump Disassemble 6 106 OIl Pump Clean and Inspect 6 108 Oil Pump Assemble 6 109 Valve Rocker Arm Cover Clean and Inspect 6 111 Oil Pan Clean and Inspect ...

Page 5: ...stallation 6 167 Exhaust Manifold Installation 6 168 Clutch Pilot Bearing Installation 6 169 Engine Flywheel Installation 6 169 Engine Setup and Testing 6 171 Description and Operation 6 172 Engine Component Description 6 172 Drive Belt System Description 6 172 New Product Information 6 173 Lubrication 6 175 Cleanliness and Care 6 175 Replacing Engine Gaskets 6 176 Use of RTV and Anaerobic Sealer ...

Page 6: ...TP 6103 1 01 Table of Contents continued ...

Page 7: ... work being performed The various sections are indicated in the Table of Contents of the manual This manual has been reprinted by the generator set manufacturer with the permission of General Motors Powertrain This manual is a reproduction of a General Motors Powertrain publication and contains information pertaining to industrial generator set engines Some information pertains to other applicatio...

Page 8: ...TP 6103 1 01 ii Introduction Notes ...

Page 9: ...us bodily injury to the technician D Serious bodily injury to other technicians in the workplace area D Serious bodily injury to the equipment operator if the equipment has been improperly repaired Notice Defined Notices call special attention to a necessary action or to a prohibited action If a Notices not heeded the following consequences may occur D Damage to the equipment D Unnecessary equipme...

Page 10: ...ffect the final torque which may affect the operation of the component Use the correct torque specifications when installing components in order to avoid damage Fastener Notice Notice Use the correct fastener in the correct location Replacement fasteners must be the correct part number for that application Fasteners requiring replacement or fasteners requiring the use of thread locking compound or...

Page 11: ... Bolt 50 N m 37 lb ft Camshaft Retainer Bolt 12 N m 106 lb in Camshaft Sprocket Bolt 25 N m 18 lb ft Connecting Rod Nut First Pass 27 N m 20 lb ft Final Pass 70 degrees Crankshaft Balancer Bolt 95 N m 70 lb ft Crankshaft Bearing Cap Preferred Method First Pass 20 N m 15 lb ft Final Pass 73 degrees Crankshaft Bearing Cap Bolt 105 N m 77 lb ft Crankshaft Position Sensor Bolt 8 N m 71 lb in Crankshaf...

Page 12: ...m 50 lb ft Engine Oil Level Sensor 13 N m 115 lb in Engine Oil Pressure Gauge Sensor 30 N m 22 lb ft Engine Oil Pressure Gauge Sensor Fitting Plus Required Angle 15 N m 11 lb ft Engine Wiring Harness Bracket Bolt to Battery Positive Cable Junction Block Bracket 9 N m 80 lb in Engine Wiring Harness Bracket Bolt to Generator and Drive Belt Tensioner Bracket 25 N m 18 lb ft Engine Wiring Harness Brac...

Page 13: ...ankshaft Bearing Cap 90 N m 66 lb ft Oil Pump Cover Bolt 12 N m 106 lb in Power Steering Pump Bracket Bolt to Engine 41 N m 30 lb ft Power Steering Pump Bracket Bolt to Engine 20 N m 15 lb in Power Steering Pump Bracket Stud Nut 41 N m 30 lb ft Power Steering Pump Bolt 50 N m 37 lb ft Power Steering Pump Nut to Engine Rear Bracket to Engine 41 N m 30 lb ft Power Steering Pump Rear Bracket Nut 50 N...

Page 14: ...ft 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 Journal Diameter 57 116 57 148 mm 2 2487 2 2497 in Co...

Page 15: ... 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 ...

Page 16: ...lication 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...

Page 17: ...racket 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 Locato...

Page 18: ...y 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...

Page 19: ...dlock 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 Va...

Page 20: ...r 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 Fault...

Page 21: ...t lobes 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 comp...

Page 22: ... 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 tra...

Page 23: ...haft 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 ...

Page 24: ... 12 Replace the components as required Is the tapping noise gone System OK Go to Step 13 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 Is the tapping noise gone System OK Go to Step 13 Remove the engine front cover and inspe...

Page 25: ...iagnosis 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 val...

Page 26: ...tire 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 Can you identify the type of fluid and the approximate location of the leak Go...

Page 27: ... to see areas 2 Check for leaks at the following locations 9 Sealing surfaces Fittings Cracked or damaged components Can you identify the type of fluid and the approximate 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 Plugge...

Page 28: ...allation 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 intern...

Page 29: ...o 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 Did you complete the repair Go to Step 15 Go to Step 8 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 Did you complete the repair Go to Step 15 Go...

Page 30: ...erify 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 acces...

Page 31: ...rify 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...

Page 32: ...ise 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 Notice Refer to Belt Dressing Notice in Cautions and Notices DEFINITION A low pitch tapping knocking or...

Page 33: ...nspecting 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 performe...

Page 34: ...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 The number s below refer to the step number s on the diagnostic table 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 d...

Page 35: ... the drive belt continue to fall off Go to Step 4 System OK 4 Inspect for misalignment of the pulleys Did you find and repair the condition Go to Step 12 Go to Step 5 5 Inspect for a bent or dented pulley Did you find and repair the condition Go to Step 12 Go to Step 6 6 Inspect for a bent or cracked bracket Did you find and repair the condition Go to Step 12 Go to Step 7 Drive Belt Excessive Wear...

Page 36: ... drive belt Refer to Drive Belt Replacement Did you complete the replacement Go to Step 6 6 Operate the system in order to verify the repair 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 ...

Page 37: ...Engine Marine Industrial 4 3L 6 27 2000 Marine Industrial ...

Page 38: ...l 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 Att...

Page 39: ...ke 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 CoolantThermostat 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 ...

Page 40: ...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 ...

Page 41: ...Cup Plug Camshaft Rear Bearing Hole 10 Engine Block 11 Dowel Straight Pin Transmission Locator 12 Left Side Oil Gallery Plug 13 Oil Filter Lower Engine View 1 569262 14 Oil Filter Fitting 15 Oil Filter Bypass Valve 16 Engine Coolant Drain Hole Plug 17 Engine Block Core Hole Plug 18 Dowel Pin Cylinder Head Locator 19 Water Pump Gasket 20 Water Pump 21 Water Pump Bolt 22 Front Oil Gallery Plug 23 Ca...

Page 42: ...haft Sprocket Bolt 31 Balance Shaft Gear Bolt 32 Balance Shaft Driven Gear 33 Balance Shaft Retainer Bolt 34 Balance Shaft Retainer 35 Balance Shaft 36 Piston Ring Set 37 Piston 38 Piston Pin 39 Connecting Rod Bolt 40 Connecting Rod 41 Connecting Rod Bearings 42 Connecting Rod Cap 43 Hex Nut ...

Page 43: ...il 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 Cran...

Page 44: ...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 ...

Page 45: ...el 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 Be...

Page 46: ...he 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 wi...

Page 47: ...lugs 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 Indic...

Page 48: ...e 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 ...

Page 49: ...ft 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 ...

Page 50: ...he bolts to 25 N m 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 val...

Page 51: ...e 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 ...

Page 52: ...strial 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 ...

Page 53: ...tor 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 ...

Page 54: ... 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 Impo...

Page 55: ...6 45 2000 Marine Industrial 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 ...

Page 56: ...6 46 Marine Industrial 4 3L Engine 2000 Marine Industrial 3 Remove the spark plugs 4 Remove the bolts and the spark plug wire support 5 Remove the cylinder head bolts 328582 328588 480533 ...

Page 57: ...e Industrial 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 ...

Page 58: ...rine Industrial 4 3L Engine 2000 Marine Industrial 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 ...

Page 59: ...e Industrial 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 ...

Page 60: ... 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 ord...

Page 61: ... Marine Industrial 4 3L 6 51 2000 Marine Industrial 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 ...

Page 62: ...6 52 Marine Industrial 4 3L Engine 2000 Marine Industrial 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 ...

Page 63: ...ect 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 ...

Page 64: ...hain 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 move...

Page 65: ...e Industrial 480544 480546 480547 3 Remove the camshaft sprocket bolts 4 Remove the camshaft sprocket and the camshaft timing chain Caution Refer to Safety Glasses Caution in Cautions and Notices 5 Remove the crankshaft sprocket using the J 5825 A ...

Page 66: ...riven 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 ...

Page 67: ...t 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 ...

Page 68: ...ts 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 ridg...

Page 69: ...he 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 p...

Page 70: ...e 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 ...

Page 71: ...haft 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 ...

Page 72: ...crankshaft bearings from the engine block Engine Block Plug Removal Tools Required J 41712 Oil Pressure Switch Socket Caution Refer to Safety Glasses Caution in Cautions and Notices 1 Remove the knock sensor from the engine block 2 Remove the engine oil pressure gauge sensor using the J 41712 ...

Page 73: ...71 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 ...

Page 74: ...ial 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 ...

Page 75: ...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 val...

Page 76: ...d 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 bo...

Page 77: ... 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 patt...

Page 78: ...iston 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 Caution Refer to Safety Glasses Caution in Cautions and 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 t...

Page 79: ...in Remover Installer Caution Refer to Safety Glasses Caution in Cautions and 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 ...

Page 80: ...n 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 ...

Page 81: ...s 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 clearanc...

Page 82: ...eter 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 ro...

Page 83: ...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 J 8087 Cylinder Bore Gauge 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 exc...

Page 84: ...d 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 N...

Page 85: ...t 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...

Page 86: ...onic Torque Angle Meter Caution Refer to Safety Glasses Caution in Cautions and 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 bear...

Page 87: ...hes 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 Engine Mechanical Specifications 6 Inspect the crankshaft balancer key 1 the keyway 2 and the threaded hole 3 for damage Repair or replace the cr...

Page 88: ...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 Refer to Engine Mechanical Specifications 10 2 If the correct end play cannot be obtained verify that the correct size crankshaft bearing has been installed Refer to Engine Mechanical Specifications 1...

Page 89: ...he 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 beari...

Page 90: ...e method to measure connecting rod bearing clearances The plastic gauge method for measuring connecting rod bearing clearances will result in unreliable measurements Use only the micrometer method to correctly determine the connecting rod bearing clearances In order to determine the correct replacement crankshaft bearing size the crankshaft bearing clearance must be measured accurately Either the ...

Page 91: ...l 73 degrees using the J 36660 7 Measure the crankshaft bearing inside diameter ID at the top and the bottom using an inside micrometer 8 In order to determine the crankshaft bearing clearance subtract the journal diameter from the crankshaft bearing ID 9 Compare the crankshaft bearing clearance to the specifications Refer to Engine Mechanical Specifications 10 If the crankshaft bearing clearances...

Page 92: ...rod nuts on the first pass evenly to 27 N m 20 lb ft 4 2 Tighten the connecting rod nuts on the final pass an additional 70 degrees using the J 36660 5 Measure the connecting rod bearing inside diameter ID at the top and the bottom using an inside micrometer 6 Compare the connecting rod bearing clearance to the specifications Refer to Engine Mechanical Specifications 7 If the connecting rod bearin...

Page 93: ... 83 2000 Marine Industrial 334338 334336 500655 Plastic Gauge Method for Crankshaft Bearings 1 Install the crankshaft bearings into the engine block 2 Install the crankshaft 3 Install the gauging plastic the full width of the journal ...

Page 94: ...ing 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 cranks...

Page 95: ...e achieved using the standard or the undersize crankshaft bearings it may be necessary to repair or replace the crankshaft Notice Do not shim scrape or file bearing inserts Do not touch the bearing surface of the insert with bare fingers Skin oil and acids will etch the bearing surface 10 Remove the flattened gauging plastic 11 Measure the remaining crankshaft bearing journals Connecting Rod Side ...

Page 96: ...ace 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 b...

Page 97: ...ain the ring gear onto the engine flywheel for cracking 4 if present Damaged ring gear teeth 5 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 equi...

Page 98: ...eplace 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 Important If any camshaft bearing is excessively worn or scored replace all the camshaft bearings 5 Inspect the camshaft bearings fo...

Page 99: ...e 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 Camshaft Bearing Rem...

Page 100: ...9 expander assembly nut until snug 3 9 Push the J 33049 guide cone into the camshaft front bearing in order to align the J 33049 3 10 Drive the camshaft inner bearing 3 from the camshaft inner bearing bore 3 3 11 Loosen the J 33049 expander assembly nut 3 12 Remove the camshaft inner bearing 3 from the J 33049 expander asssembly 4 Remove the J 33049 from the engine block 5 Remove the camshaft oute...

Page 101: ...look in order to ensure that the camshaft bearing lubrication hole is located above the 3 o clock position 1 or the 9 o clock position 2 The proper positioning of the camshaft bearing lubrication hole is in order to ensure the best lubrication of the engine camshaft journals 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 t...

Page 102: ...position or the 9 o clock 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 5 Loosen the J 33049 expander assembly nut 3 6 Remove the camshaft outer bearing 4 from the J33049 expander assembly 3 7 Install the NEW camshaft outer bearing 1 onto the J33049 expand...

Page 103: ...2 onto the J33049 expander assembly 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 o clock position or the 9 o clock position of the camshaft inner bearing bore 2 of the engine block 4 11 Push the J 33049 guide cone into the camshaft front bearing bore 1 in order to align the J 33049 4 12 Drive the camshaft inner...

Page 104: ...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 shaf...

Page 105: ... 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 In...

Page 106: ...n 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 Caution Refer to Safety Glasses Caution in Cautions and Notices 2 Clean the components with cleaning solvent 3 Dry the components with compressed air 4 In...

Page 107: ...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 ...

Page 108: ... Cautions and Notices 2 Clean the components with cleaning solvent 3 Dry the components with compressed air 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 valv...

Page 109: ...ses Caution in Cautions and 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...

Page 110: ...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 man...

Page 111: ...e 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 ...

Page 112: ...at 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 gu...

Page 113: ...OT 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 ...

Page 114: ...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 Follo...

Page 115: ...g 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 c...

Page 116: ...emoving or installing the valve stem keys Failing to use care may cause personal injury Caution Refer to Safety Glasses Caution in Cautions and 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 up...

Page 117: ...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 ...

Page 118: ...he 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 Caution Refer to Safety Glasses Caution in Cautions and Notices 7 Remove the following items 7 1 The oil...

Page 119: ...pressure relief valve oil pump pressure relief valve spring and oil pump body Caution Refer to Safety Glasses Caution in Cautions and 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 ...

Page 120: ...d 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 b...

Page 121: ...Cautions and 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 se...

Page 122: ...ompressed 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 Notice Refer to Fast...

Page 123: ...ake 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 ...

Page 124: ... 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 manifo...

Page 125: ...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 ...

Page 126: ...eals 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 lowe...

Page 127: ...es 33 Remove the fuel meter body 34 Remove the bolt and the fuel meter body bracket Intake Manifold Clean and Inspect Caution Refer to Safety Glasses Caution in Cautions and 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 ...

Page 128: ... to the throttle body mounting surface 4 Loose or damaged bolt hole thread inserts 5 Intake Manifold Assemble Notice Refer to Fastener Notice in Cautions and Notices 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 N m 89 l...

Page 129: ...t 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 N m 44 lb in 10 2 Tighten the upper intake manifold attaching studs on the final pass to 9 N m 80 lb in 11 If reusing the fasteners apply threadlock GM P N 12345382 or equivalent to the threads of th...

Page 130: ...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 21 If reusing the fastener apply threadlock GM P N 12345382 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 N m 27 lb in 22...

Page 131: ...ug 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 N m 15 lb ft Important The exhaust gas recirculation EGR valve must be installed in the original orientation 29 Install the ...

Page 132: ... EGR valve bolts on the final pass to 30 N m 22 lb ft 480563 12853 480559 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 N m 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 ...

Page 133: ...in 38 2 Tighten the accelerator control cable bracket nuts to 12 N m 106lb in 38 3 Tighten the accelerator control cable bracket stud to the throttle body to 12 N m 106 lb in Exhaust Manifold Clean and Inspect Caution Refer to Safety Glasses Caution in Cautions and Notices 1 Clean the exhaust manifolds in cleaning solvent 2 Dry the components with compressed air 3 Inspect the exhaust manifolds for...

Page 134: ...rial 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 th...

Page 135: ...p 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 ins...

Page 136: ... checking for excessive wear Components not within the manufacturer s 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 i...

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Page 138: ...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 o...

Page 139: ...alant GM P N 12346004 or equivalent to the outside diameter of the NEW expansion cup plug balance rear bearing hole 8 Install the NEW expansion cup plug balance shaft rear bearing hole 9 Apply sealant GM P N 12346004 or equivalent to the outside diameter of the NEW expansion cup plug camshaft rear bearing hole 10 Install the NEW expansion cup plug camshaft rear bearing hole ...

Page 140: ...ar 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 N m 15 lb ft 11 2 Tighten the engine block left rear oil gallery plug to 30 N m 22 lb ft 13 Install the dowel straight pins transmission locator if required 14 Install the left side dowel pins cylinder head locat...

Page 141: ... 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 N m 11 lb ft Important Do not rotate the engine oil p...

Page 142: ... sensor 22 Install the engine oil pressure gauge sensor using the J 41712 Tighten Tighten the engine oil pressure gauge sensor to 30 N m 22 lb ft 23 Install the knock sensor Tighten Tighten the knock sensor to 20 N m 15 lb ft Crankshaft and Bearings Installation Tools Required J 36660 Electronic Torque Angle Meter 1 Install the crankshaft bearings into the engine block 2 Apply clean engine oil to ...

Page 143: ...ice in Cautions and Notices 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 bolt...

Page 144: ...er 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 bloc...

Page 145: ...2 N m 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 6 Apply a small amount 2 to 3 drops of clean engine oil to 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 8 Apply a small amount 2 to 3 drops of clean engine oil to...

Page 146: ...ear 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 ...

Page 147: ...hould 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 entere...

Page 148: ... 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 connectin...

Page 149: ... the front of the engine camshaft Balance Shaft Installation Tools Required J 8092 Universal Driver Handle J 36660 Electronic Torque Angle Meter J 36996 Balance Shaft Installer Important The balance shaft and the balance shaft front bearing are serviced only as an assembly Do not remove the balance shaft front bearing from the balance shaft 1 Apply clean engine oil GM P N 12345610 or equivalent to...

Page 150: ...ench 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 N m 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...

Page 151: ...47 9848 9847 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 o clock position 11 Remove the balance shaft drive gear ...

Page 152: ...ition 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 ...

Page 153: ... J 5590 in order to install the crankshaft sprocket 4 Rotate the crankshaft until the crankshaft sprocket is at the 12 o clock position Important Install the camshaft sprocket with the alignment mark at the 6 o clock position 5 Install the camshaft sprocket and the camshaft timing chain 6 Look to ensure that the crankshaft sprocket is aligned at the 12 o clock position and the camshaft sprocket is...

Page 154: ... 7 1 Align the keyway on the crankshaft position sensor reluctor ring with the crankshaft balancer key in the crankshaft 7 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 fro...

Page 155: ...sor 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 se...

Page 156: ...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 ...

Page 157: ...t 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 instal...

Page 158: ...at 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 N m 18 lb ft 9 Measure the clearance between the 3 o...

Page 159: ...otice 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 orde...

Page 160: ...e J 23523 F plate and bolts onto the front of the crankshaft balancer Tighten Tighten the J 23523 F plate bolts to 25 N m 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 positi...

Page 161: ...b 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 Notice Refer to Fastener Notice in Cautions and Notices 3 Install the valve lifter pushrod guides Tighten Tighten the valve lifter pushrod guide bolts to 16 N m 12 lb ft ...

Page 162: ...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 ...

Page 163: ...s Tighten Tighten the bolts in sequence on the first pass to 30 N m 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 sequence to 65 degrees Tighten the short bolts 2 3 6 7 10 and 11 on the final pass in sequence...

Page 164: ... 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 N m 15 lb ft 15 If reusing the engine coolant temperature sensor if applicable apply sealant...

Page 165: ...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 ...

Page 166: ...ighten 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 sequence to 65 degrees 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 ...

Page 167: ... the spark plugs for a USED cylinder head to 15 N m 11 lb ft Tighten the spark plugs for the initial installation of a NEW cylinder head to 30 N m 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 ...

Page 168: ...the bolt at location 1 4 2 Finger start the bolt at location 2 4 3 Finger start the bolt at location 3 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 prop...

Page 169: ...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...

Page 170: ...ightening 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 N m 27 lb in 8 2 Tighten the bolts in sequence 1 8 on the first pass to 12 N m 106 lb in 8 3 Tight...

Page 171: ...nd 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 com...

Page 172: ...utor 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 ...

Page 173: ...e 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 Notice Refer to Fastener Notice in Cautions and Notices 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 ...

Page 174: ...allation 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 ...

Page 175: ... 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 t...

Page 176: ...llation 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 Notice Refer to Fastener Notice in Cautions and Notices 3 Install the oil level indicator tube bolt Tighten Tighten the oil level indicator tube bolt to 12 N m 106 l...

Page 177: ...er to Fastener Notice in Cautions and Notices 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...

Page 178: ...y threadlock GM P N 12345493 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 pass to 15 N m 11 lb ft 5 2 Tighten the exhaust manifold bolts and stud on the final pass to 30 N m 22 lb ft 6 Install the spark plug wires to the spark plug wire retainers 7 Install the s...

Page 179: ... 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 Notice Refer to Fastener Notice in Cautions and Notices 4 If reusing the fasteners apply threadlock GM P N ...

Page 180: ... the engine flywheel 1 or 2 to the crankshaft Align the engine flywheel locator hole to the flywheel locator pin Notice Refer to Fastener Notice in Cautions and Notices 2 Install the engine flywheel bolts Tighten Tighten the engine flywheel bolts in sequence 1 6 to 100 N m 74 lb ft ...

Page 181: ...heating 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 co...

Page 182: ...he 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 ...

Page 183: ...nd 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 ...

Page 184: ...cation 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 ...

Page 185: ...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 protecti...

Page 186: ...ivalent 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 se...

Page 187: ...c 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 thre...

Page 188: ...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 ...

Page 189: ...ion Special Tools and Equipment J 3049 A Valve Lifter Remover J 5239 Connecting Rod Bolt Guide Set J 5892 D Valve Spring Compressor J 7872 Magnetic Base Dial Indicator 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 ...

Page 190: ...ion J 8087 Cylinder Bore Gauge J 8089 Carbon Removing Brush J 22794 Spark Plug Port Adapter 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 ...

Page 191: ...High Intensity Black Light Kit J 33049 Camshaft Bearing Service Kit J 36996 Balance Shaft Installer J 38606 Valve Spring Compressor J 35468 Cover Aligner Seal Installer J 38834 Balance Shaft Service Kit J 35621 B Rear Main Seal Installer J 39580 Engine Support Table J 36660 Electronic Torque Angle Meter J 41240 Fan Clutch Remover and Installer ...

Page 192: ... 2000 Marine Industrial Illustration Tool Number Description J 41427 Engine Lift Bracket J 41602 Body Protection Hoist Adapter Set J 41712 Oil Pressure Switch Socket J 42073 Valve Stem Seal Installer J 43276 Clutch Pilot Bearing Remover ...

Page 193: ...Notes ...

Page 194: ...Notes ...

Page 195: ...Notes ...

Page 196: ...TP 6103 1 01 ...

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