Engine Mechanical - 4.8l, 5.3l, & 6.0l (Introduction) — Chevrolet Chevy Express G3500 (1996-2012)

Fastener Tightening Specifications

Application	Specification
Application	Metric	English
Accelerator Control Cable Bracket Bolts	10 N.m	89 lb in
Air Cleaner Outlet Duct Clamp Screws	7 N.m	62 lb in
A/C Belt Tensioner Bolt	50 N.m	37 lb ft
Automatic Transmission Bolt/Stud	50 N.m	37 lb ft
Automatic Transmission Oil Level Indicator Tube Nut	18 N.m	13 lb ft
Battery Cable Channel Bolt	12 N.m	106 lb in
Camshaft Retainer Bolts	25 N.m	18 lb ft
Camshaft Sensor Bolt	25 N.m	18 lb ft
Camshaft Sprocket Bolts	35 N.m	26 lb ft
Connecting Rod Bolts - First Pass	20 N.m	15 lb ft
Connecting Rod Bolts - Final Pass	75 degrees
Coolant Temperature Gage Sensor	20 N.m	15 lb ft
Crankshaft Balancer Bolt - Installation Pass - to Ensure the Balancer is Completely Installed	330 N.m	240 lb ft
Crankshaft Balancer Bolt - First Pass - Install a NEW Bolt After the Installation Pass and Tighten as Described in the First and Final Passes	50 N.m	37 lb ft
Crankshaft Balancer Bolt - Final Pass	140 degrees
Crankshaft Bearing Cap Bolts - Inner Bolts - First Pass in Sequence	20 N.m	15 lb ft
Crankshaft Bearing Cap Bolts - Inner Bolts - Final Pass in Sequence	80 degrees
Crankshaft Bearing Cap Bolts - Outer Bolts - First Pass in Sequence	20 N.m	15 lb ft
Crankshaft Bearing Cap Bolts - Outer Bolts - Final Pass in Sequence	51 degrees
Crankshaft Bearing Cap Side Bolts	25 N.m	18 lb ft
Crankshaft Oil Deflector Nuts	25 N.m	18 lb ft
Crankshaft Position Sensor Bolt	25 N.m	18 lb ft
Crossbar Bolts	100 N.m	78 lb ft
Cylinder Head Bolts - First Design - First Pass all M11 Bolts in Sequence	30 N.m	22 lb ft
Cylinder Head Bolts - First Design - Second Pass all M11 Bolts in Sequence	90 degrees
Cylinder Head Bolts - First Design - Final Pass all M11 Bolts in Sequence - Excluding the Medium Length Bolts at the Front and Rear of Each Cylinder Head	90 degrees
Cylinder Head Bolts - First Design - Final Pass M11 Medium Length Bolts at the Front and Rear of Each Cylinder Head	50 degrees
Cylinder Head Bolts - Second Design - First Pass all M11 Bolts in Sequence	30 N.m	22 lb ft
Cylinder Head Bolts - Second Design - Second Pass all M11 Bolts in Sequence	90 degrees
Cylinder Head Bolts - Second Design - Final Pass all M11 Bolts in Sequence	70 degrees
Cylinder Head Bolts - M8 Inner Bolts in Sequence	30 N.m	22 lb ft
Cylinder Head Coolant Plug	20 N.m	15 lb ft
Drive Belt Idler Pulley Bolt	50 N.m	37 lb ft
Engine Block Coolant Drain Plugs	60 N.m	44 lb ft
Engine Block Heater	40 N.m	30 lb ft
Engine Block Oil Gallery Plugs	60 N.m	44 lb ft
Engine Block Wire Harness Rear Ground Bolt	16 N.m	12 lb ft
Engine Coolant Air Bleed Pipe and Cover Bolts	12 N.m	106 lb in
Engine Flywheel Bolts - First Pass	20 N.m	15 lb ft
Engine Flywheel Bolts - Second Pass	50 N.m	37 lb ft
Engine Flywheel Bolts - Final Pass	100 N.m	74 lb ft
Engine Front Cover Bolts	25 N.m	18 lb ft
Engine Lift Bracket Bolt - M8	25 N.m	15 lb ft
Engine Lift Bracket Bolt - M10	50 N.m	37 lb ft
Engine Mount to Engine Bolts	50 N.m	37 lb ft
Engine Mount to Frame Bracket Bolts	60 N.m	44 lb ft
Engine Rear Cover Bolts	25 N.m	18 lb ft
Engine Service Lift Bracket M10 Bolts	50 N.m	37 lb ft
Engine Service Lift Bracket M8 Bolt	25 N.m	18 lb ft
Engine Valley Cover Bolts	25 N.m	18 lb ft
Evaporative Emission (EVAP) Purge Solenoid Bolt	10 N.m	89 lb in
Exhaust Manifold Bolts - First Pass	15 N.m	11 lb ft
Exhaust Manifold Bolts - Final Pass	25 N.m	18 lb ft
Exhaust Manifold Heat Shield Bolts	9 N.m	80 lb in
Fuel Rail Bolts	10 N.m	89 lb in
Fuel Rail Crossover Tube Bolts	3.8 N.m	34 lb in
Fuel Rail Stop Bracket Bolt	50 N.m	37 lb ft
Generator Bolt	50 N.m	37 lb ft
Generator Bracket Bolts	50 N.m	37 lb ft
Generator Output Terminal Nut	9 N.m	80 lb in
Ground Harness Bolt	25 N.m	18 lb ft
Ignition Coil-to-Bracket Bolts	8 N.m	71 lb in
Ignition Coil Bracket-to-Valve Rocker Arm Cover Bolts	12 N.m	106 lb in
Intake Manifold Bolts - First Pass in Sequence	5 N.m	44 lb in
Intake Manifold Bolts - Final Pass in Sequence	10 N.m	89 lb in
Intake Manifold Wiring Harness Stud	10 N.m	89 lb in
Knock Sensors	20 N.m	15 lb ft
Oil Filter	30 N.m	22 lb ft
Oil Filter Fitting	55 N.m	40 lb ft
Oil Level Indicator Tube Bolt	25 N.m	18 lb ft
Oil Level Sensor	13 N.m	115 lb in
Oil Pan Baffle Bolts	12 N.m	106 lb in
Oil Pan Closeout Cover Bolt - Left Side	9 N.m	80 lb in
Oil Pan Closeout Cover Bolt - Right Side	9 N.m	80 lb in
Oil Pan Cover Bolts	12 N.m	106 lb in
Oil Pan Drain Plug	25 N.m	18 lb ft
Oil Pan M8 Bolts - Oil Pan-to-Engine Block and Oil Pan-to-Front Cover	25 N.m	18 lb ft
Oil Pan M6 Bolts - Oil Pan-to-Rear Cover	12 N.m	106 lb in
Oil Pressure Sensor	20 N.m	15 lb ft
Oil Pump-to-Engine Block Bolts	25 N.m	18 lb ft
Oil Pump Cover Bolts	12 N.m	106 lb in
Oil Pump Relief Valve Plug	12 N.m	106 lb in
Oil Pump Screen Nuts	25 N.m	18 lb ft
Oil Pump Screen-to-Oil Pump Bolt	12 N.m	106 lb in
Positive Battery Cable Clip Bolt	9 N.m	80 lb in
Power Steering Pump Rear Bolt	50 N.m	37 lb ft
Spark Plugs - New Cylinder Heads	20 N.m	15 lb ft
Spark Plugs - All Subsequent Installations	15 N.m	11 lb ft
Throttle Body Nuts	10 N.m	89 lb in
Throttle Body Studs	6 N.m	53 lb in
Torque Converter Bolts	63 N.m	47 lb ft
Transmission Cover Bolt	12 N.m	106 lb in
Valve Lifter Guide Bolts	12 N.m	106 lb in
Valve Rocker Arm Bolts	30 N.m	22 lb ft
Valve Rocker Arm Cover Bolts	12 N.m	106 lb in
Water Inlet Housing Bolts	15 N.m	11 lb ft
Water Pump Bolts - First Pass	15 N.m	11 lb ft
Water Pump Bolts - Final Pass	30 N.m	22 lb ft
Water Pump Cover Bolts	15 N.m	11 lb ft

Fastener Tightening Specifications

Engine Mechanical Specifications (LR4 VIN V)

Application	Specification
Application	Metric	English
General
Bore	96.0-96.018 mm	3.779-3.78 in
Compression Ratio	9.47:1
Displacement	4.8L	293 CID
Engine Type	V8
Firing Order	1-8-7-2-6-5-4-3
RPO	LR4
Stroke	83.0 mm	3.268 in
VIN	V
Spark Plug Gap
AC Delco Type 41-974	1.524 mm	0.06 in
AC Delco Type 41-985	1.016 mm	0.04 in
Block
Camshaft Bearing Bore 1 and 5 Diameter - First Design	59.12-59.17 mm	2.327-2.329 in
Camshaft Bearing Bore 2 and 4 Diameter - First Design	58.87-58.92 mm	2.317-2.319 in
Camshaft Bearing Bore 3 Diameter - First Design	58.62-58.67 mm	2.307-2.309 in
Camshaft Bearing Bore 1 and 5 Diameter - Second Design	59.62-59.67 mm	2.347-2.349 in
Camshaft Bearing Bore 2 and 4 Diameter - Second Design	59.12-59.17 mm	2.327-2.329 in
Camshaft Bearing Bore 3 Diameter - Second Design	58.62-58.67 mm	2.307-2.309 in
Crankshaft Main Bearing Bore Diameter	69.871-69.889 mm	2.75-2.751 in
Crankshaft Main Bearing Bore Out-of-Round	0.006 mm	0.0002 in
Cylinder Bore Diameter	96.0-96.018 mm	3.779-3.78 in
Cylinder Bore Taper - Thrust Side	0.018 mm	0.0007 in
Cylinder Head Deck Height - Measuring from the Centerline of Crankshaft to the Deck Face	234.57-234.82 mm	9.235-9.245 in
Cylinder Head Deck Surface Flatness - Measured Within a 152.4 mm (6.0 in) Area	0.11 mm	0.004 in
Cylinder Head Deck Surface Flatness - Measuring the Overall Length of the Block Deck	0.22 mm	0.008 in
Valve Lifter Bore Diameter	21.417-21.443 mm	0.843-0.844 in
Camshaft
Camshaft End Play	0.025-0.305 mm	0.001-0.012 in
Camshaft Journal Diameter	54.99-55.04 mm	2.164-2.166 in
Camshaft Journal Out-of-Round	0.025 mm	0.001 in
Camshaft Lobe Lift - Exhaust	6.96 mm	0.274 in
Camshaft Lobe Lift - Intake	6.82 mm	0.268 in
Camshaft Runout - Measured at the Intermediate Journals	0.05 mm	0.002 in
Connecting Rod
Connecting Rod Bearing Clearance - Production	0.023-0.065 mm	0.0009-0.0025 in
Connecting Rod Bearing Clearance - Service	0.023-0.076 mm	0.0009-0.003 in
Connecting Rod Bore Diameter - Bearing End	56.505-56.525 mm	2.224-2.225 in
Connecting Rod Bore Out-of-Round - Bearing End - Production	0.004-0.008 mm	0.00015-0.0003 in
Connecting Rod Bore Out-of-Round - Bearing End - Service	0.004-0.008 mm	0.00015-0.0003 in
Connecting Rod Side Clearance	0.11-0.51 mm	0.00433-0.02 in
Crankshaft
Connecting Rod Journal Diameter - Production	53.318-53.338 mm	2.0991-2.0999 in
Connecting Rod Journal Diameter - Service	53.308 mm	2.0987 in
Connecting Rod Journal Out-of-Round - Production	0.005 mm	0.0002 in
Connecting Rod Journal Out-of-Round - Service	0.01 mm	0.0004 in
Connecting Rod Journal Taper - Maximum for 1/2 of Journal Length - Production	0.005 mm	0.0002 in
Connecting Rod Journal Taper - Maximum for 1/2 of Journal Length - Service	0.02 mm	0.00078 in
Crankshaft End Play	0.04-0.2 mm	0.0015-0.0078 in
Crankshaft Main Bearing Clearance - Production	0.02-0.052 mm	0.0008-0.0021 in
Crankshaft Main Bearing Clearance - Service	0.02-0.065 mm	0.0008-0.0025 in
Crankshaft Main Journal Diameter - Production	64.992-65.008 mm	2.558-2.559 in
Crankshaft Main Journal Diameter - Service	64.992 mm	2.558 in
Crankshaft Main Journal Out-of-Round - Production	0.003 mm	0.000118 in
Crankshaft Main Journal Out-of-Round - Service	0.008 mm	0.0003 in
Crankshaft Main Journal Taper - Production	0.01 mm	0.0004 in
Crankshaft Main Journal Taper - Service	0.02 mm	0.00078 in
Crankshaft Rear Flange Runout	0.05 mm	0.002 in
Crankshaft Reluctor Ring Runout - Measured 1.0 mm (0.04 in) Below Tooth Diameter	0.7 mm	0.028 in
Crankshaft Thrust Surface - Production	26.14-26.22 mm	1.029-1.0315 in
Crankshaft Thrust Surface - Service	26.22 mm	1.0315 in
Crankshaft Thrust Surface Runout	0.025 mm	0.001 in
Cylinder Head
Cylinder Head Height/Thickness - Measured from the Cylinder Head Deck to the Valve Rocker Arm Cover Seal Surface	120.2 mm	4.732 in
Surface Flatness - Block Deck - Measured Within a 152.4 mm (6.0 in) Area	0.08 mm	0.003 in
Surface Flatness - Block Deck - Measuring the Overall Length of the Cylinder Head	0.1 mm	0.004 in
Surface Flatness - Exhaust Manifold Deck	0.13 mm	0.005 in
Surface Flatness - Intake Manifold Deck	0.08 mm	0.0031 in
Valve Guide Installed Height - Measured from the Spring Seat Surface to the Top of the Guide	17.32 mm	0.682 in
Intake Manifold
Surface Flatness - Measured at Gasket Sealing Surfaces and Measured Within a 200 mm (7.87 in) Area that Includes Two Runner Port Openings	0.3 mm	0.118 in
Lubrication System
Oil Capacity - with Filter	5.68 liters	6.0 quarts
Oil Capacity - without Filter	4.73 liters	5.0 quarts
Oil Pressure - Minimum - Hot	41 kPa at 1,000 engine RPM 124 kPa at 2,000 engine RPM 165 kPa at 4,000 engine RPM	6 psig at 1,000 engine RPM 18 psig at 2,000 engine RPM 24 psig at 4,000 engine RPM
Oil Pan
Front Cover Alignment - at Oil Pan Surface	0.0-0.5 mm	0.0-0.02 in
Rear Cover Alignment - at Oil Pan Surface	0.0-0.5 mm	0.0-0.02 in
Oil Pan Alignment - to Rear of Engine Block at Transmission Bell Housing Mounting Surface	0.0-0.25 mm	0.0-0.01 in
Piston Rings
Piston Ring End Gap - First Compression Ring - Measured in Cylinder Bore - Production	0.23-0.44 mm	0.009-0.017 in
Piston Ring End Gap - First Compression Ring - Measured in Cylinder Bore - Service	0.23-0.5 mm	0.009-0.0196 in
Piston Ring End Gap - Second Compression Ring - Measured in Cylinder Bore - Production	0.44-0.7 mm	0.017-0.027 in
Piston Ring End Gap - Second Compression Ring - Measured in Cylinder Bore - Service	0.44-0.76 mm	0.0173-0.03 in
Piston Ring End Gap - Oil Control Ring - Measured in Cylinder Bore - Production	0.18-0.75 mm	0.007-0.029 in
Piston Ring End Gap - Oil Control Ring - Measured in Cylinder Bore - Service	0.18-0.81 mm	0.007-0.032 in
Piston Ring to Groove Clearance - First Compression Ring - Production	0.04-0.085 mm	0.00157-0.00335 in
Piston Ring to Groove Clearance - First Compression Ring - Service	0.04-0.085 mm	0.00157-0.00335 in
Piston Ring to Groove Clearance - Second Compression Ring - Production	0.04-0.078 mm	0.00157-0.0031 in
Piston Ring to Groove Clearance - Second Compression Ring - Service	0.04-0.078 mm	0.00157-0.0031 in
Piston Ring to Groove Clearance - Oil Control Ring - Production	0.012-0.2 mm	0.0005-0.0078 in
Piston Ring to Groove Clearance - Oil Control Ring - Service	0.012-0.2 mm	0.0005-0.0078 in
Pistons and Pins
Piston - Piston Diameter - Measured Over Skirt Coating	96.002-96.036 mm	3.779-3.78 in
Piston - Piston to Bore Clearance - Production	0.036 to 0.016 mm	0.0014 to 0.0006 in
Piston - Piston to Bore Clearance - Service Limit with Skirt Coating Worn Off	0.071 mm	0.0028 in
Pin - Piston Pin Fit in Connecting Rod Bore	0.02-0.043 mm - interference	0.00078-0.00169 in - interference
Pin - Piston Pin Clearance to Piston Pin Bore - Production	0.007-0.02 mm	0.00027-0.00078 in
Pin - Piston Pin Clearance to Piston Pin Bore - Service	0.007-0.021 mm	0.00027-0.00082 in
Pin - Piston Pin Diameter	23.997-24.0 mm	0.9447-0.9448 in
Valve System
Valves - Valve Face Angle	45 degrees
Valves - Valve Face Width	1.25 mm	0.05 in
Valves - Valve Lash	Net Lash - No Adjustment
Valves - Valve Lift - Intake	11.6 mm	0.457 in
Valves - Valve Lift - Exhaust	11.85 mm	0.466 in
Valves - Valve Seat Angle	46 degrees
Valves - Valve Seat Runout	0.05 mm	0.002 in
Valves - Valve Seat Width - Exhaust	1.78 mm	0.07 in
Valves - Seat Width - Intake	1.02 mm	0.04 in
Valves - Valve Stem Diameter - Production	7.955-7.976 mm	0.313-0.314 in
Valves - Valve Stem Diameter - Service	7.95 mm	0.313 in
Valves - Stem-to-Guide Clearance - Production - Intake	0.025-0.066 mm	0.001-0.0026 in
Valves - Stem-to-Guide Clearance - Service - Intake	0.093 mm	0.0037 in
Valves - Stem-to-Guide Clearance - Production - Exhaust	0.025-0.066 mm	0.001-0.0026 in
Valves - Stem-to-Guide Clearance - Service - Exhaust	0.093 mm	0.0037 in
Rocker Arms - Valve Rocker Arm Ratio	1.70:1
Valve Springs - Valve Spring Free Length	52.9 mm	2.08 in
Valve Springs - Installed Height	45.75 mm	1.8 in
Valve Springs - Valve Spring Load - Closed	340 N at 45.75 mm	76 lb at 1.8 in
Valve Springs - Valve Spring Load - Open	980 N at 33.55 mm	220 lb at 1.32 in

Engine Mechanical Specifications (LR4 VIN V)

Engine Mechanical Specifications (LM7 VIN T)

Application	Specification
Application	Metric	English
General
Engine Type	V8
Displacement	5.3L	325 CID
RPO	LM7
VIN	T
Bore	96.0-96.018 mm	3.779-3.78 in
Stroke	92.0 mm	3.622 in
Compression Ratio	9.49:1
Firing Order	1-8-7-2-6-5-4-3
Spark Plug Gap
AC Delco Type 41-974	1.524 mm	0.06 in
AC Delco Type 41-985	1.016 mm	0.04 in
Block
Camshaft Bearing Bore 1 and 5 Diameter - First Design	59.12-59.17 mm	2.327-2.329 in
Camshaft Bearing Bore 2 and 4 Diameter - First Design	58.87-58.92 mm	2.317-2.319 in
Camshaft Bearing Bore 3 Diameter - First Design	58.62-58.67 mm	2.307-2.309 in
Camshaft Bearing Bore 1 and 5 Diameter - Second Design	59.62-59.67 mm	2.347-2.349 in
Camshaft Bearing Bore 2 and 4 Diameter - Second Design	59.12-59.17 mm	2.327-2.329 in
Camshaft Bearing Bore 3 Diameter - Second Design	58.62-58.67 mm	2.307-2.309 in
Crankshaft Main Bearing Bore Diameter	69.871-69.889 mm	2.75-2.751 in
Crankshaft Main Bearing Bore Out-of-Round	0.006 mm	0.0002 in
Cylinder Bore Diameter	96.0-96.018 mm	3.779-3.78 in
Cylinder Bore Taper - Thrust Side	0.018 mm	0.0007 in
Cylinder Head Deck Height - Measuring from the Centerline of Crankshaft to the Deck Face	234.57-234.82 mm	9.235-9.245 in
Cylinder Head Deck Surface Flatness - Measured Within a 152.4 mm (6.0 in) Area	0.11 mm	0.004 in
Cylinder Head Deck Surface Flatness - Measuring the Overall Length of the Block Deck	0.22 mm	0.008 in
Valve Lifter Bore Diameter	21.417-21.443 mm	0.843-0.844 in
Camshaft
Camshaft End Play	0.025-0.305 mm	0.001-0.012 in
Camshaft Journal Diameter	54.99-55.04 mm	2.164-2.166 in
Camshaft Journal Out-of-Round	0.025 mm	0.001 in
Camshaft Lobe Lift - Exhaust	6.96 mm	0.274 in
Camshaft Lobe Lift - Intake	6.82 mm	0.268 in
Camshaft Runout - Measured at the Intermediate Journals	0.05 mm	0.002 in
Connecting Rod
Connecting Rod Bearing Clearance - Production	0.023-0.065 mm	0.0009-0.0025 in
Connecting Rod Bearing Clearance - Service	0.023-0.076 mm	0.0009-0.003 in
Connecting Rod Bore Diameter - Bearing End	56.505-56.525 mm	2.224-2.225 in
Connecting Rod Bore Out-of-Round - Bearing End - Production	0.004-0.008 mm	0.00015-0.0003 in
Connecting Rod Bore Out-of-Round - Bearing End - Service	0.004-0.008 mm	0.00015-0.0003 in
Connecting Rod Side Clearance	0.11-0.51 mm	0.00433-0.02 in
Crankshaft
Connecting Rod Journal Diameter - Production	53.318-53.338 mm	2.0991-2.0999 in
Connecting Rod Journal Diameter - Service	53.308 mm	2.0987 in
Connecting Rod Journal Out-of-Round - Production	0.005 mm	0.0002 in
Connecting Rod Journal Out-of-Round - Service	0.01 mm	0.0004 in
Connecting Rod Journal Taper - Maximum for 1/2 of Journal Length - Production	0.005 mm	0.0002 in
Connecting Rod Journal Taper - Maximum for 1/2 of Journal Length - Service	0.02 mm	0.00078 in
Crankshaft End Play	0.04-0.2 mm	0.0015-0.0078 in
Crankshaft Main Bearing Clearance - Production	0.02-0.052 mm	0.0008-0.0021 in
Crankshaft Main Bearing Clearance - Service	0.02-0.065 mm	0.0008-0.0025 in
Crankshaft Main Journal Diameter - Production	64.992-65.008 mm	2.558-2.559 in
Crankshaft Main Journal Diameter - Service	64.992 mm	2.558 in
Crankshaft Main Journal Out-of-Round - Production	0.003 mm	0.000118 in
Crankshaft Main Journal Out-of-Round - Service	0.008 mm	0.0003 in
Crankshaft Main Journal Taper - Production	0.01 mm	0.0004 in
Crankshaft Main Journal Taper - Service	0.02 mm	0.00078 in
Crankshaft Rear Flange Runout	0.05 mm	0.002 in
Crankshaft Reluctor Ring Runout - Measured 1.0 mm (0.04 in) Below Tooth Diameter	0.7 mm	0.028 in
Crankshaft Thrust Surface - Production	26.14-26.22 mm	1.029-1.0315 in
Crankshaft Thrust Surface - Service	26.22 mm	1.0315 in
Crankshaft Thrust Surface Runout	0.025 mm	0.001 in
Cylinder Head
Cylinder Head Height/Thickness - Measured from the Cylinder Head Deck to the Valve Rocker Arm Cover Seal Surface	120.2 mm	4.732 in
Surface Flatness - Block Deck - Measured Within a 152.4 mm (6.0 in) Area	0.08 mm	0.003 in
Surface Flatness - Block Deck - Measuring the Overall Length of the Cylinder Head	0.1 mm	0.004 in
Surface Flatness - Exhaust Manifold Deck	0.13 mm	0.005 in
Surface Flatness - Intake Manifold Deck	0.08 mm	0.0031 in
Valve Guide Installed Height - Measured from the Spring Seat Surface to the Top of the Guide	17.32 mm	0.682 in
Intake Manifold
Surface Flatness - Measured at Gasket Sealing Surfaces and Measured Within a 200 mm (7.87 in) Area that Includes Two Runner Port Openings	0.3 mm	0.118 in
Lubrication System
Oil Capacity - with Filter	5.68 liters	6.0 quarts
Oil Capacity - without Filter	4.73 liters	5.0 quarts
Oil Pressure - Minimum - Hot	41 kPa at 1,000 engine RPM 124 kPa at 2,000 engine RPM 165 kPa at 4,000 engine RPM	6 psig at 1,000 engine RPM 18 psig at 2,000 engine RPM 24 psig at 4,000 engine RPM
Oil Pan
Front Cover Alignment - at Oil Pan Surface	0.0-0.5 mm	0.0-0.02 in
Rear Cover Alignment - at Oil Pan Surface	0.0-0.5 mm	0.0-0.02 in
Oil Pan Alignment - to Rear of Engine Block at Transmission Bell Housing Mounting Surface	0.0-0.25 mm	0.0-0.01 in
Piston Rings
Piston Ring End Gap - First Compression Ring - Measured in Cylinder Bore - Production	0.23-0.44 mm	0.009-0.017 in
Piston Ring End Gap - First Compression Ring - Measured in Cylinder Bore - Service	0.23-0.5 mm	0.009-0.0196 in
Piston Ring End Gap - Second Compression Ring - Measured in Cylinder Bore - Production	0.44-0.7 mm	0.017-0.027 in
Piston Ring End Gap - Second Compression Ring - Measured in Cylinder Bore - Service	0.44-0.76 mm	0.0173-0.03 in
Piston Ring End Gap - Oil Control Ring - Measured in Cylinder Bore - Production	0.18-0.75 mm	0.007-0.029 in
Piston Ring End Gap - Oil Control Ring - Measured in Cylinder Bore - Service	0.18-0.81 mm	0.007-0.032 in
Piston Ring to Groove Clearance - First Compression Ring - Production	0.04-0.085 mm	0.00157-0.00335 in
Piston Ring to Groove Clearance - First Compression Ring - Service	0.04-0.085 mm	0.00157-0.00335 in
Piston Ring to Groove Clearance - Second Compression Ring - Production	0.04-0.078 mm	0.00157-0.0031 in
Piston Ring to Groove Clearance - Second Compression Ring - Service	0.04-0.078 mm	0.00157-0.0031 in
Piston Ring to Groove Clearance - Oil Control Ring - Production	0.012-0.2 mm	0.0005-0.0078 in
Piston Ring to Groove Clearance - Oil Control Ring - Service	0.012-0.2 mm	0.0005-0.0078 in
Pistons and Pins
Piston - Piston Diameter - Measured Over Skirt Coating	96.002-96.036 mm	3.779-3.78 in
Piston - Piston to Bore Clearance - Production	0.036 to 0.016 mm	0.0014 to 0.0006 in
Piston - Piston to Bore Clearance - Service Limit with Skirt Coating Worn Off	0.071 mm	0.0028 in
Pin - Piston Pin Fit in Connecting Rod Bore	0.02-0.043 mm - interference	0.00078-0.00169 in - interference
Pin - Piston Pin Clearance to Piston Pin Bore - Production	0.007-0.02 mm	0.00027-0.00078 in
Pin - Piston Pin Clearance to Piston Pin Bore - Service	0.007-0.021 mm	0.00027-0.00082 in
Pin - Piston Pin Diameter	23.997-24.0 mm	0.9447-0.9448 in
Valve System
Valves - Valve Face Angle	45 degrees
Valves - Valve Face Width	1.25 mm	0.05 in
Valves - Valve Lash	Net Lash - No Adjustment
Valves - Valve Lift - Intake	11.6 mm	0.457 in
Valves - Valve Lift - Exhaust	11.85 mm	0.466 in
Valves - Valve Seat Angle	46 degrees
Valves - Valve Seat Runout	0.05 mm	0.002 in
Valves - Valve Seat Width - Exhaust	1.78 mm	0.07 in
Valves - Seat Width - Intake	1.02 mm	0.04 in
Valves - Valve Stem Diameter - Production	7.955-7.976 mm	0.313-0.314 in
Valves - Valve Stem Diameter - Service	7.95 mm	0.313 in
Valves - Valve Stem-to-Guide Clearance - Production - Intake	0.025-0.066 mm	0.001-0.0026 in
Valves - Valve Stem-to-Guide Clearance - Service - Intake	0.093 mm	0.0037 in
Valves - Valve Stem-to-Guide Clearance - Production - Exhaust	0.025-0.066 mm	0.001-0.0026 in
Valves - Valve Stem-to-Guide Clearance - Service - Exhaust	0.093 mm	0.0037 in
Rocker Arms - Valve Rocker Arm Ratio	1.70:1
Valve Springs - Valve Spring Free Length	52.9 mm	2.08 in
Valve Springs - Valve Spring Installed Height	45.75 mm	1.8 in
Valve Springs - Valve Spring Load - Closed	340 N at 45.75 mm	76 lb at 1.8 in
Valve Springs - Valve Spring Load - Open	980 N at 33.55 mm	220 lb at 1.32 in

Engine Mechanical Specifications (LM7 VIN T)

Engine Mechanical Specifications (LQ4 VIN U)

Application	Specification
Application	Metric	English
General
Engine Type	V8
Displacement	6.0L	364 CID
RPO	LQ4
VIN	U
Bore	101.618-101.636 mm	4.0007-4.0014 in
Stroke	92.0 mm	3.622 in
Compression Ratio	9.41:1
Firing Order	1-8-7-2-6-5-4-3
Spark Plug Gap
AC Delco Type 41-974	1.524 mm	0.06 in
AC Delco Type 41-985	1.016 mm	0.04 in
Block
Camshaft Bearing Bore 1 and 5 Diameter - First Design	59.12-59.17 mm	2.327-2.329 in
Camshaft Bearing Bore 2 and 4 Diameter - First Design	58.87-58.92 mm	2.317-2.319 in
Camshaft Bearing Bore 3 Diameter - First Design	58.62-58.67 mm	2.307-2.309 in
Camshaft Bearing Bore 1 and 5 Diameter - Second Design	59.62-59.67 mm	2.347-2.349 in
Camshaft Bearing Bore 2 and 4 Diameter - Second Design	59.12-59.17 mm	2.327-2.329 in
Camshaft Bearing Bore 3 Diameter - Second Design	58.62-58.67 mm	2.307-2.309 in
Crankshaft Main Bearing Bore Diameter	69.871-69.889 mm	2.75-2.751 in
Crankshaft Main Bearing Bore Out-of-Round	0.006 mm	0.0002 in
Cylinder Bore Diameter	101.618-101.636 mm	4.0007-4.0017 in
Cylinder Bore Taper - Thrust Side	0.018 mm	0.0007 in
Cylinder Head Deck Height - Measuring from the Centerline of Crankshaft to the Deck Face	234.57-234.82 mm	9.235-9.245 in
Cylinder Head Deck Surface Flatness - Measured within a 152.4 mm (6.0 in) Area	0.11 mm	0.004 in
Cylinder Head Deck Surface Flatness - Measuring the Overall Length of the Block Deck	0.22 mm	0.008 in
Valve Lifter Bore Diameter	21.417-21.443 mm	0.843-0.844 in
Camshaft
Camshaft End Play	0.025-0.305 mm	0.001-0.012 in
Camshaft Journal Diameter	54.99-55.04 mm	2.164-2.166 in
Camshaft Journal Out-of-Round	0.025 mm	0.001 in
Camshaft Lobe Lift - Exhaust	7.13 mm	0.281 in
Camshaft Lobe Lift - Intake	6.96 mm	0.274 in
Camshaft Runout - Measured at the Intermediate Journals	0.05 mm	0.002 in
Connecting Rod
Connecting Rod Bearing Clearance - Production	0.023-0.065 mm	0.0009-0.0025 in
Connecting Rod Bearing Clearance - Service	0.023-0.076 mm	0.0009-0.003 in
Connecting Rod Bore Diameter - Bearing End	56.505-56.525 mm	2.224-2.225 in
Connecting Rod Bore Out-of-Round - Bearing End - Production	0.006 mm	0.0002 in
Connecting Rod Bore Out-of-Round - Bearing End - Service	0.006 mm	0.0002 in
Connecting Rod Side Clearance	0.11-0.51 mm	0.00433-0.02 in
Crankshaft
Connecting Rod Journal Diameter - Production	53.318-53.338 mm	2.0991-2.0999 in
Connecting Rod Journal Diameter - Service	53.308 mm	2.0987 in
Connecting Rod Journal Out-of-Round - Production	0.005 mm	0.0002 in
Connecting Rod Journal Out-of-Round - Service	0.01 mm	0.0004 in
Connecting Rod Journal Taper - Maximum for 1/2 of Journal Length - Production	0.005 mm	0.0002 in
Connecting Rod Journal Taper - Maximum for 1/2 of Journal Length - Service	0.02 mm	0.00078 in
Crankshaft End Play	0.04-0.2 mm	0.0015-0.0078 in
Crankshaft Main Bearing Clearance - Production	0.02-0.052 mm	0.0008-0.0021 in
Crankshaft Main Bearing Clearance - Service	0.02-0.065 mm	0.0008-0.0025 in
Crankshaft Main Journal Diameter - Production	64.992-65.008 mm	2.558-2.559 in
Crankshaft Main Journal Diameter - Service	64.992 mm	2.558 in
Crankshaft Main Journal Out-of-Round - Production	0.003 mm	0.000118 in
Crankshaft Main Journal Out-of-Round - Service	0.008 mm	0.0003 in
Crankshaft Main Journal Taper - Production	0.01 mm	0.0004 in
Crankshaft Main Journal Taper - Service	0.02 mm	0.00078 in
Crankshaft Rear Flange Runout	0.05 mm	0.002 in
Crankshaft Reluctor Ring Runout - Measured 1.0 mm (0.04 in) Below Tooth Diameter	0.7 mm	0.028 in
Crankshaft Thrust Surface - Production	26.14-26.22 mm	1.029-1.0315 in
Crankshaft Thrust Surface - Service	26.22 mm	1.0315 in
Crankshaft Thrust Surface Runout	0.025 mm	0.001 in
Cylinder Head
Cylinder Head Height/Thickness - Measured from the Cylinder Head Deck to the Valve Rocker Arm Cover Seal Surface	120.2 mm	4.732 in
Surface Flatness - Block Deck - Measured Within a 152.4 mm (6.0 in) Area	0.08 mm	0.003 in
Surface Flatness - Block Deck - Measuring the Overall Length of the Cylinder Head	0.1 mm	0.004 in
Surface Flatness - Exhaust Manifold Deck	0.13 mm	0.005 in
Surface Flatness - Intake Manifold Deck	0.08 mm	0.0031 in
Valve Guide Installed Height - Measured from the Spring Seat Surface to the Top of the Guide	17.32 mm	0.682 in
Intake Manifold
Surface Flatness - Measured at Gasket Sealing Surfaces and Measured Within a 200 mm (7.87 in) Area that Includes Two Runner Port Openings	0.3 mm	0.118 in
Lubrication System
Oil Capacity - with Filter	5.68 liters	6.0 quarts
Oil Capacity - without Filter	4.73 liters	5.0 quarts
Oil Pressure - Minimum - Hot	41 kPa at 1,000 engine RPM 124 kPa at 2,000 engine RPM 165 kPa at 4,000 engine RPM	6 psig at 1,000 engine RPM 18 psig at 2,000 engine RPM 24 psig at 4,000 engine RPM
Oil Pan
Front Cover Alignment - at Oil Pan Surface	0.0-0.5 mm	0.0-0.02 in
Rear Cover Alignment - at Oil Pan Surface	0.0-0.5 mm	0.0-0.02 in
Oil Pan Alignment - to Rear of Engine Block at Transmission Bell Housing Mounting Surface	0.0-0.25 mm	0.0-0.01 in
Piston Rings
Piston Ring End Gap - First Compression Ring - Measured in Cylinder Bore - Production	0.31-0.52 mm	0.012-0.02 in
Piston Ring End Gap - First Compression Ring - Measured in Cylinder Bore - Service	0.31-0.59 mm	0.0122-0.023 in
Piston Ring End Gap - Second Compression Ring - Measured in Cylinder Bore - Production	0.51-0.77 mm	0.02-0.03 in
Piston Ring End Gap - Second Compression Ring - Measured in Cylinder Bore - Service	0.51-0.84 mm	0.02-0.033 in
Piston Ring End Gap - Oil Control Ring - Measured in Cylinder Bore - Production	0.31-0.87 mm	0.0122-0.034 in
Piston Ring End Gap - Oil Control Ring - Measured in Cylinder Bore - Service	0.31-0.94 mm	0.0122-0.037 in
Piston Ring to Groove Clearance - First Compression Ring - Production	0.04-0.08 mm	0.00157-0.0031 in
Piston Ring to Groove Clearance - First Compression Ring - Service	0.04-0.08 mm	0.00157-0.0031 in
Piston Ring to Groove Clearance - Second Compression Ring - Production	0.039-0.079 mm	0.0015-0.0031 in
Piston Ring to Groove Clearance - Second Compression Ring - Service	0.039-0.079 mm	0.0015-0.0031 in
Piston Ring to Groove Clearance - Oil Control Ring - Production	0.015-0.199 mm	0.0006-0.0078 in
Piston Ring to Groove Clearance - Oil Control Ring - Service	0.015-0.199 mm	0.0006-0.0078 in
Pistons and Pins
Piston - Piston Diameter - Measured Over Skirt Coating	101.606-101.640 mm	4.0002-4.0016 in
Piston - Piston to Bore Clearance - Production	0.022-0.03 mm - interference	0.0009-0.0012 in - interference
Piston - Piston to Bore Clearance - Service Limit with Skirt Coating Worn Off	0.07 mm	0.0028 in
Pin - First Design Press Fit Pin Fit in Connecting Rod Bore	0.02-0.043 mm - Interference	0.00078-0.00169 in - Interference
Pin - First Design Press Fit Pin Clearance to Piston Pin Bore - Production	0.01-0.02 mm	0.0004-0.00078 in
Pin - First Design Press Fit Pin Clearance to Piston Pin Bore - Service	0.01-0.022 mm	0.0004-0.00086 in
Pin - First Design Press Fit Pin Diameter	23.997-24.0 mm	0.9447-0.9448 in
Pin - Second Design Full Floating Pin Fit in Connecting Rod Bore - Production	0.007-0.02 mm	0.00027-0.00078 in
Pin - Second Design Full Floating Pin Fit in Connecting Rod Bore - Service	0.007-0.022 mm	0.00027-0.00086 in
Pin - Second Design Full Floating Pin Clearance to Piston Pin Bore - Production	0.002-0.01 mm	0.00008-0.0004 in
Pin - Second Design Full Floating Pin Clearance to Piston Pin Bore - Service	0.002-0.015 mm	0.00008-0.0006 in
Pin - Second Design Full Floating Pin Diameter	23.952-23.955 mm	0.943-0.943 in
Valve System
Valves - Valve Face Angle	45 degrees
Valves - Valve Face Width	1.25 mm	0.05 in
Valves - Valve Lash	Net Lash - No Adjustment
Valves - Valve Lift - Intake	11.79 mm	0.464 in
Valves - Valve Lift - Exhaust	12.16 mm	0.479 in
Valves - Valve Seat Angle	46 degrees
Valves - Valve Seat Runout	0.05 mm	0.002 in
Valves - Valve Seat Width - Exhaust	1.78 mm	0.07 in
Valves - Valve Seat Width - Intake	1.02 mm	0.04 in
Valves - Valve Stem Diameter - Production	7.955-7.976 mm	0.313-0.314 in
Valves - Valve Stem Diameter - Service	7.95 mm	0.313 in
Valves - Valve Stem-to-Guide Clearance - Production - Intake	0.025-0.066 mm	0.001-0.0026 in
Valves - Valve Stem-to-Guide Clearance - Service - Intake	0.093 mm	0.0037 in
Valves - Valve Stem-to-Guide Clearance - Production - Exhaust	0.025-0.066 mm	0.001-0.0026 in
Valves - Valve Stem-to-Guide Clearance - Service - Exhaust	0.093 mm	0.0037 in
Rocker Arms - Valve Rocker Arm Ratio	1.70:1
Valve Springs - Valve Spring Free Length	52.9 mm	2.08 in
Valve Springs - Valve Spring Installed Height	45.75 mm	1.8 in
Valve Springs - Valve Spring Load - Closed	340 N at 45.75 mm	76 lb at 1.8 in
Valve Springs - Valve Spring Load - Open	980 N at 33.55 mm	220 lb at 1.32 in

Engine Mechanical Specifications (LQ4 VIN U)

Sealers, Adhesives, and Lubricants

Application	Type of Material	GM Part Number
Application	Type of Material	United States	Canada
Coolant Sensor Threads	Sealant	12346004	10953480
Cylinder Head Coolant Plugs	Threadlock	12345382	10953489
Cylinder Head Expansion Plugs - Aluminum	Threadlock	12345382	10953489
Engine Block Front Oil Gallery Plug	Threadlock	12345382	10953489
Engine Block Plug Sealing Washers	Sealant	12346004	10953480
Engine Flywheel Bolt Threads	Threadlock	12345382	10953489
Engine Oil	5W-30 Oil	12345610	993193
Engine Oil Supplement	Fluorescent Dye	12345795	10953470
Exhaust Manifold Bolt Threads	Threadlock	12345493	10953488
Fuel Rail Bolt Threads	Threadlock	12345382	10953489
Ignition Coil and Bracket Bolts	Threadlock	12345382	10953489
Ignition Coil Bracket Bolts	Threadlock	12345382	10953489
Intake Manifold Bolt Threads	Threadlock	12345382	10953489
Oil Pan Surface at Front and Rear Covers	Sealant	12378190
Oil Pressure Sensor Threads	Sealant	12346004	10953480
Thread Repair Component Cleaner	Cleaner	12346139	10953463
Thread Repair Component Cleaner	Cleaner	12377981	10953463
Thread Repair Cutting Oil	Lubricant	1052864	992881

Sealers, Adhesives, and Lubricants

Scheme 93

Scheme 93: Engine Block - Front View

Hole	Thread Size	Insert	Drill	Counterbore Tool	Tap	Driver	Drill Depth - Maximum mm (in)	Tap Depth - Maximum mm (in)
1-6	M8 x 1.25	J 42385-210	J 42385-206	J 42385-207	J 42385-208	J 42385-209	22.5 (0.885)	17.5 (0.688)
7	M10 x 1.5	J 42385-215	J 42385-211	J 42385-212	J 42385-213	J 42385-214	25.0 (0.984)	19.5 (0.767)
8	M10 x 1.5	J 42385-215	J 42385-211	J 42385-212	J 42385-213	J 42385-214	32.5 (1.28)	25.0 (0.984)
9	M8 x 1.25	J 42385-210	J 42385-206	J 42385-207	J 42385-208	J 42385-209	22.5 (0.885)	17.5 (0.688)
10	M10 x 1.5	J 42385-215	J 42385-211	J 42385-212	J 42385-213	J 42385-214	Thru	Thru
11-13	M8 x 1.25	J 42385-210	J 42385-206	J 42385-207	J 42385-208	J 42385-209	22.5 (0.885)	17.5 (0.688)
14	M8 x 1.25	J 42385-210	J 42385-206	J 42385-207	J 42385-208	J 42385-209	Thru	18.0 (0.708)
15	M8 x 1.25	J 42385-210	J 42385-206	J 42385-207	J 42385-208	J 42385-209	22.5 (0.885)	17.5 (0.688)
16	M8 x 1.25	J 42385-210	J 42385-206	J 42385-207	J 42385-208	J 42385-209	Thru	18.0 (0.708)
17-27	M8 x 1.25	J 42385-210	J 42385-206	J 42385-207	J 42385-208	J 42385-209	22.5 (0.885)	17.5 (0.688)

Engine Block - Front View Thread Repair

Scheme 94

Scheme 94: Engine Block - Rear View

Hole	Thread Size	Insert	Drill	Counterbore Tool	Tap	Driver	Drill Depth - Maximum mm (in)	Tap Depth - Maximum mm (in)
1	M10 x 1.5	J 42385-215	J 42385-211	J 42385-212	J 42385-213	J 42385-214	27.0 (1.06)	21.5 (0.846)
2-4	M8 x 1.25	J 42385-210	J 42385-206	J 42385-207	J 42385-208	J 42385-209	22.5 (0.885)	17.5 (0.688)
5-6	M10 x 1.5	J 42385-215	J 42385-211	J 42385-212	J 42385-213	J 42385-214	27.0 (1.06)	21.5 (0.846)
7-13	M8 x 1.25	J 42385-210	J 42385-206	J 42385-207	J 42385-208	J 42385-209	22.5 (0.885)	17.5 (0.688)
14-16	M10 x 1.5	J 42385-215	J 42385-211	J 42385-212	J 42385-213	J 42385-214	27.0 (1.06)	21.5 (0.846)
17-18	M8 x 1.25	J 42385-210	J 42385-206	J 42385-207	J 42385-208	J 42385-209	22.5 (0.885)	17.5 (0.688)

Engine Block - Rear View Thread Repair

Scheme 95

Scheme 95: Engine Block - Left Side View

Hole	Thread Size	Insert	Drill	Counterbore Tool	Tap	Driver	Drill Depth - Maximum mm (in)	Tap Depth - Maximum mm (in)
J 42385
1	M28 x 1.25	N/A	N/A	N/A	N/A	N/A	N/A	N/A
2	M8 x 1.25	210	206	207	208	209	28.5 (1.122)	23.0 (0.905)
3	M8 x 1.25	210	206	207	208	209	21.5 (0.846)	16.0 (0.629)
4	M10 x 1.25	215	211	212	213	214	29.0 (1.141)	23.0 (0.905)
5	M10 x 1.5	215	211	212	213	214	27.0 (1.062)	21.5 (0.846)
6	M16 x 1.5	N/A	N/A	N/A	N/A	N/A	N/A	N/A
7	M11 x 2.0 First Design	108	105	N/A	106	107	124.0 (4.88)	115.0 (4.52)
7	M11 x 2.0 Second Design	108	105	N/A	106	107	69.0 (2.72)	60.0 (2.36)
8	M11 x 2.0	108	105	N/A	106	107	69.0 (2.72)	60.0 (2.36)
Bolt holes 7, second design, and 8 have a 30 mm (1.18 in) counterbore included in the 69.0 mm (2.72 in) drill depth. Use sleeve J 42385-315 with the drill and tap. Bolt holes 7, first design, have a 85 mm (3.34 in) counterbore included in the 124.0 mm (4.88 in) drill depth.

Engine Block - Left Side View Thread Repair

Scheme 96

Scheme 96: Engine Block - Right Side View

Hole	Thread Size	Insert	Drill	Counterbore Tool	Tap	Driver	Drill Depth - Maximum mm (in)	Tap Depth - Maximum mm (in)
J 42385
1	M28 x 1.25	210	206	207	208	209	22.5 (0.885)	17.5 (0.688)
2	M8 x 1.25	210	206	207	208	209	26.5 (1.04)	19.0 (0.784)
3	M11 x 2.0	108	105	N/A	106	107	69.0 (2.72)	60.0 (2.36)
4	M10 x 1.25	215	211	212	213	214	29.0 (1.141)	23.0 (0.905)
5	M10 x 1.5	215	211	212	213	214	27.0 (1.062)	21.5 (0.846)
6	M16 x 1.5	N/A	N/A	N/A	N/A	N/A	N/A	N/A
7	M11 x 2.0 First Design	108	105	N/A	106	107	124.0 (4.88)	115.0 (4.52)
7	M11 x 2.0 Second Design	108	105	N/A	106	107	69.0 (2.72)	60.0 (2.36)
Bolt holes 7, second design, and 3 have a 30 mm (1.18 in) counterbore included in the 69.0 mm (2.72 in) drill depth. Use sleeve J 42385-315 with the drill and tap. Bolt holes 7, first design, have a 85 mm (3.34 in) counterbore included in the 124.0 mm (4.88 in) drill depth.

Engine Block - Right Side View Thread Repair

Scheme 97

Scheme 97: Engine Block - Bottom View

Hole	Thread Size	Insert	Drill	Counterbore Tool	Tap	Driver	Drill Depth - Maximum mm (in)	Tap Depth - Maximum mm (in)
1	M10 x 2.0	J 42385-104	J 42385-101		J 42385-102	J 42385-103	31.0 (1.22)	25.5 (1.0)
2	M10 x 2.0	J 42385-104	J 42385-101		J 42385-102	J 42385-103	53.5 (2.10)	44.0 (1.73)
3	M8 x 1.25	J 42385-210	J 42385-206	J 42385-207	J 42385-208	J 42385-209	22.5 (0.885)	17.5 (0.688)
4	M10 x 2.0	J 42385-104	J 42385-101		J 42385-102	J 42385-103	31.0 (1.22)	25.5 (1.0)
5	M10 x 2.0	J 42385-104	J 42385-101		J 42385-102	J 42385-103	53.5 (2.10)	44.0 (1.73)
6	M16 x 1.5
7	N/A
8	M8 x 1.25	J 42385-210	J 42385-206	J 42385-207	J 42385-208	J 42385-209	22.5 (0.885)	17.5 (0.688)
9	M10 x 2.0	J 42385-104	J 42385-101		J 42385-102	J 42385-103	31.0 (1.22)	25.5 (1.0)
10-11	M10 x 2.0	J 42385-104	J 42385-101		J 42385-102	J 42385-103	53.5 (2.10)	44.0 (1.73)
12	M10 x 2.0	J 42385-104	J 42385-101		J 42385-102	J 42385-103	31.0 (1.22)	25.5 (1.0)
13-14	M10 x 1.5	J 42385-215	J 42385-101		J 42385-213	J 42385-214	42.5 (1.67)	37.0 (1.45)
15	M8 x 1.25	J 42385-210	J 42385-206	J 42385-207	J 42385-208	J 42385-209	22.5 (0.885)	17.5 (0.688)
16	M16 x 1.5
17	M10 x 2.0	J 42385-104	J 42385-101		J 42385-102	J 42385-103	53.5 (2.10)	44.0 (1.73)
18	M10 x 2.0	J 42385-104	J 42385-101		J 42385-102	J 42385-103	31.0 (1.22)	25.5 (1.0)
19	M8 x 1.25	J 42385-210	J 42385-206	J 42385-207	J 42385-208	J 42385-209	22.5 (0.885)	17.5 (0.688)
20	M10 x 2.0	J 42385-104	J 42385-101		J 42385-102	J 42385-103	53.5 (2.10)	44.0 (1.73)
21	M10 x 2.0	J 42385-104	J 42385-101		J 42385-102	J 42385-103	31.0 (1.22)	25.5 (1.0)
22	M8 x 1.25	J 42385-210	J 42385-206	J 42385-207	J 42385-208	J 42385-209	22.5 (0.885)	17.5 (0.688)
23	M10 x 2.0	J 42385-104	J 42385-101		J 42385-102	J 42385-103	31.0 (1.22)	25.5 (1.0)
24	M10 x 2.0	J 42385-104	J 42385-101		J 42385-102	J 42385-103	53.5 (2.10)	44.0 (1.73)
25-26	M8 x 1.25	J 42385-210	J 42385-206	J 42385-207	J 42385-208	J 42385-209	22.5 (0.885)	17.5 (0.688)
27	M10 x 2.0	J 42385-104	J 42385-101		J 42385-102	J 42385-103	31.0 (1.22)	25.5 (1.0)
28-29	M10 x 2.0	J 42385-104	J 42385-101		J 42385-102	J 42385-103	53.5 (2.10)	44.0 (1.73)
30	M10 x 2.0	J 42385-104	J 42385-101		J 42385-102	J 42385-103	31.0 (1.22)	25.5 (1.0)
31	M8 x 1.25	J 42385-210	J 42385-206	J 42385-207	J 42385-208	J 42385-209	22.5 (0.885)	17.5 (0.688)
32	M28 x 1.25
33	M8 x 1.25	J 42385-210	J 42385-206	J 42385-207	J 42385-208	J 42385-209	22.5 (0.885)	17.5 (0.688)
34	M10 x 2.0	J 42385-104	J 42385-101		J 42385-102	J 42385-103	53.5 (2.10)	44.0 (1.73)
35	M10 x 2.0	J 42385-104	J 42385-101		J 42385-102	J 42385-103	31.0 (1.22)	25.5 (1.0)
36	M8 x 1.25	J 42385-210	J 42385-206	J 42385-207	J 42385-208	J 42385-209	22.5 (0.885)	17.5 (0.688)
Bolt holes 2, 5, 10, 11, 18, 21, 24, 28, 29, and 34 have a 20.5 mm (0.807 in) counterbore included in the 53.5 mm (2.10 in) drill depth. Bolt holes 1, 4, 9, 12, 17, 20, 23, 27, 30, and 35 have a 1.5 mm (0.059 in) counterbore included in the 31.0 mm (1.22 in) drill depth. Use sleeve J 42385-316 with the drill and tap. Bolt holes 13 and 14 have a 11.5 mm (0.452 in) counterbore included in the 42.5 mm (1.67 in) drill depth. Use sleeve J 42385-311 with the drill and tap.

Engine Block - Bottom View Thread Repair

Scheme 98

Scheme 98: Engine Block - Top View

Hole	Thread Size	Insert	Drill	Counterbore Tool	Tap	Driver	Drill Depth - Maximum mm (in)	Tap Depth - Maximum mm (in)
1-4	M8 x 1.25	J 42385-210	J 42385-206	J 42385-207	J 42385-208	J 42385-209	26.5 (1.04)	19.0 (0.784)
5	M16 x 1.5
6-7	M8 x 1.25	J 42385-210	J 42385-206	J 42385-207	J 42385-208	J 42385-209	26.5 (1.04)	19.0 (0.784)
8	M10 x 1.5	J 42385-216	J 42385-211	J 42385-212	J 42385-213	J 42385-214	22.5 (0.885)	17.0 (0.669)
9-10	M8 x 1.25	J 42385-210	J 42385-206	J 42385-207	J 42385-208	J 42385-209	26.5 (1.04)	19.0 (0.784)
11	M10 x 1.5	J 42385-216	J 42385-211	J 42385-212	J 42385-213	J 42385-214	22.5 (0.885)	17.0 (0.669)
12-14	M8 x 1.25	J 42385-210	J 42385-206	J 42385-207	J 42385-208	J 42385-209	26.5 (1.04)	19.0 (0.784)

Engine Block - Top View Thread Repair

Scheme 99

Scheme 99: Cylinder Head - Top View

Hole	Thread Size	Insert	Drill	Counterbore Tool	Tap	Driver	Drill Depth - Maximum mm (in)	Tap Depth - Maximum mm (in)
1-5	M8 x 1.25	J 42385-210	J 42385-206	J 42385-207	J 42385-208	J 42385-209	26.5 (1.04)	19.0 (0.784)
6-9	M6 x 1.0	J 42385-205	J 42385-201	J 42385-202	J 42385-203	J 42385-204	20.05 (0.789)	16.05 (0.632)
10-12	M8 x 1.25	J 42385-210	J 42385-206	J 42385-207	J 42385-208	J 42385-209	26.5 (1.04)	19.0 (0.784)

Cylinder Head - Top View Thread Repair

Scheme 100

Scheme 100: Cylinder Head - End View

Hole	Thread Size	Insert	Drill	Counterbore Tool	Tap	Driver	Drill Depth - Maximum mm (in)	Tap Depth - Maximum mm (in)
1	M10 x 1.5	J 42385-215	J 42385-211	J 42385-212	J 42385-213	J 42385-214	28.0 (1.10)	20.0 (0.787)
2		N/A
3	M10 x 1.5	J 42385-215	J 42385-211	J 42385-212	J 42385-213	J 42385-214	28.0 (1.10)	20.0 (0.787)
4	N/A
5-6	M10 x 1.5	J 42385-215	J 42385-211	J 42385-212	J 42385-213	J 42385-214	28.0 (1.10)	20.0 (0.787)

Cylinder Head - End View Thread Repair

Scheme 101

Scheme 101: Cylinder Head - Exhaust Manifold Deck View

Hole	Thread Size	Insert	Drill	Counterbore Tool	Tap	Driver	Drill Depth - Maximum mm (in)	Tap Depth - Maximum mm (in)
1-2	M10 x 1.5	J 42385-215	J 42385-211	J 42385-212	J 42385-213	J 42385-214	28.0 (1.10)	20.0 (0.787)
3	M8 x 1.25	J 42385-210	J 42385-206	J 42385-207	J 42385-208	J 42385-209	21.0 (0.826)	16.0 (0.629)
4	M14 x 1.25
5	M8 x 1.25	J 42385-210	J 42385-206	J 42385-207	J 42385-208	J 42385-209	21.0 (0.826)	16.0 (0.629)
6	M14 x 1.25
7-8	M8 x 1.25	J 42385-210	J 42385-206	J 42385-207	J 42385-208	J 42385-209	21.0 (0.826)	16.0 (0.629)
9	M14 x 1.25
10	M8 x 1.25	J 42385-210	J 42385-206	J 42385-207	J 42385-208	J 42385-209	21.0 (0.826)	16.0 (0.629)
11	M14 x 1.25
12	M8 x 1.25	J 42385-210	J 42385-206	J 42385-207	J 42385-208	J 42385-209	21.0 (0.826)	16.0 (0.629)
13	M12 x 1.5
14-15	M10 x 1.5	J 42385-215	J 42385-211	J 42385-212	J 42385-213	J 42385-214	28.0 (1.10)	20.0 (0.787)

Cylinder Head - Exhaust Manifold Deck View Thread Repair

Scheme 102

Scheme 102: Cylinder Head - Intake Manifold Deck View

Hole	Thread Size	Insert	Drill	Counterbore Tool	Tap	Driver	Drill Depth - Maximum mm (in)	Tap Depth - Maximum mm (in)
1-2	M6 x 1.0	J 42385-205	J 42385-201	J 42385-202	J 42385-203	J 42385-204	Thru	Thru
3-4	M6 x 1.0	J 42385-205	J 42385-201	J 42385-202	J 42385-203	J 42385-204	22.5 (0.885)	15.0 (0.688)
5-7	M6 x 1.0	J 42385-205	J 42385-201	J 42385-202	J 42385-203	J 42385-204	Thru	Thru

Cylinder Head - Intake Manifold Deck View Thread Repair

Scheme 103

Scheme 103: Disassembled Views

Callout	Component Name
307	Engine Coolant Air Bleed Pipe
308	Engine Coolant Air Bleed Pipe/Cover Gasket
308	Engine Coolant Air Bleed Pipe/Cover Gasket
309	Engine Coolant Air Bleed Pipe Bolt
310	Engine Coolant Air Bleed Hose Clamp
311	Engine Coolant Air Bleed Hose
312	Engine Coolant Air Bleed Cover Bolts
313	Engine Coolant Air Bleed Cover
500	Intake Manifold
506	Valley Cover Bolt
507	Throttle Body Nut
508	Throttle Body
509	Throttle Body Gasket
510	Fuel Rail with Injectors
511	Fuel Rail Bolt
512	Intake Manifold Bolt
513	Intake Manifold Insulator
514	Intake Manifold Gasket
520	Knock Sensor (KS) Oil Seal
544	Throttle Cable Bracket
545	Throttle Cable Bracket Bolt
546	Idle Air Control (IAC) Valve
547	IAC Bolt
548	Throttle Position Sensor (TPS) Bolt
549	TPS Sensor
555	Valley Cover
556	Valley Cover Gasket
708	Evaporative Emission (EVAP) Purge Valve
709	EVAP Purge Valve Isolator
710	EVAP Purge Valve Bolt
712	Fuel Rail Stop Bracket
713	Fuel Rail Stop Bracket Bolt
714	Manifold Absolute Pressure (MAP) Sensor
715	MAP Sensor Grommet
716	Positive Crankcase Ventilation (PCV) Hose - Dirty Air
717	KS Wire Harness
718	KS
729	EVAP Purge Valve O-Ring

Scheme 104

Callout	Component Name
209	Valve Lifter
210	Valve Lifter Guide
211	Valve Lifter Guide Bolt
212	Pushrod
213	Rocker Arm
214	Rocker Arm Bolt
215	Rocker Arm Pedestal
216	Expansion Plug
217	Cylinder Head Gasket
218	Cylinder Head
219	Cylinder Head Bolt - M8 Short
220	Cylinder Head Bolt - M11 Medium
221	Cylinder Head Bolt - M11 Long - First Design
222	Valve Stem Oil Seal and Shim Assembly
222	Valve Stem Oil Seal and Shim Assembly
223	Valve Spring
223	Valve Spring
224	Valve Spring Cap
224	Valve Spring Cap
225	Valve Stem Keys
226	Expansion Plug
227	Intake Valve
228	Exhaust Valve
229	Cylinder Head Coolant Plug
230	Cylinder Head Locating Pin
422	Oil Fill Tube O-Ring
423	Oil Fill Tube
440	Oil Fill Tube Bolt
441	Oil Fill Tube Bracket
442	Oil Fill Tube Bracket Bolt
504	Valve Cover Gasket
504	Valve Cover Gasket
505	Valve Cover
505	Valve Cover
515	Valve Cover Bolt Grommet
516	Valve Cover Bolt
600	Exhaust Manifold
601	Exhaust Manifold Gasket
602	Exhaust Manifold Bolt
603	Exhaust Manifold Heat Shield
604	Exhaust Manifold Heat Shield Bolt
700	PCV Hose - Fresh Air
719	Ignition Coil and Bracket Assembly
720	Ignition Coil and Bracket Assembly Bolt
721	Ignition Coil Wire Harness
722	Ignition Coil
723	Ignition Coil Bolt
724	Spark Plug Wire
725	Coolant Temperature Sensor
726	Spark Plug

Scheme 105

Callout	Component Name
100	Engine Block
138	Crankshaft Balancer
139	Crankshaft Balancer Bolt
140	Crankshaft Front Oil Seal
200	Camshaft
201	Camshaft Bearings
202	Camshaft Sprocket Locating Pin
203	Camshaft Retainer Plate
204	Camshaft Retainer Plate Bolt
205	Camshaft Sprocket
206	Camshaft Sprocket Bolt
207	Crankshaft Sprocket
208	Timing Chain
300	Water Pump
301	Water Pump Bolt
302	Thermostat Housing Bolt
303	Thermostat Housing
304	O-Ring
305	Thermostat
306	Water Pump Gasket
404	Crankshaft Oil Deflector Nut
405	Oil Pump Screen Bolt
406	Oil Pump Screen O-Ring
407	Oil Pump Screen
408	Oil Pump Cover Bolt
409	Oil Pump Cover
410	Drive Gear
411	Oil Pump Bolt
412	Driven Gear
413	Oil Pump Assembly
414	Pressure Relief Valve
415	Pressure Relief Valve Spring
416	Plug
417	Oil Level Indicator O-Ring
418	Oil Level Indicator
419	Oil Level Tube Bolt
420	Oil Level Tube
421	Oil Level Tube O-Ring
501	Front Cover Bolt
502	Front Cover
503	Front Cover Gasket

Scheme 106

Callout	Component Name
100	Engine Block
131	Flywheel Spacer
132	Flywheel
133	Flywheel Bolt
141	Crankshaft Rear Oil Seal
517	Rear Cover Bolt
518	Rear Cover
519	Rear Cover Gasket

Scheme 107

Callout	Component Name
100	Engine Block
102	Connecting Rod Bolt
103	Connecting Rod Cap
104	Connecting Rod Bearings
105	Connecting Rod
106	Piston Pin
107	Piston
108	Piston Rings
109	Piston Pin Clip - Second Design with Full-Floating Pin
120	Crankshaft Thrust Bearing
120	Crankshaft Thrust Bearing
121	Crankshaft Main Bearing
121	Crankshaft Main Bearing
122	Crankshaft Sprocket Key
124	Crankshaft
126	Bearing Cap
127	Bearing Cap Side Bolt
128	Bearing Cap Bolt/Stud
129	Bearing Cap Bolt
400	Oil Pan
401	Closeout Cover - Right
402	Closeout Cover Bolt - Right
403	Crankshaft Oil Deflector Nut
425	Crankshaft Oil Deflector
426	Oil Pan Gasket
427	Oil Pan Baffle Bolt
428	Oil Pan Baffle
429	Oil Pan Drain Plug O-Ring
430	Oil Pan Drain Plug
431	Closeout Cover - Left
432	Closeout Cover Bolt - Left
433	Oil Pan Cover Gasket
434	Oil Pan Cover
435	Oil Pan Cover Bolts
436	Oil Filter Bypass Valve
437	Oil Filter
438	Oil Filter Fitting
439	Oil Pan Bolt
700	Crankshaft Position Sensor Bolt
701	Crankshaft Position Sensor
702	Crankshaft Position Sensor O-Ring
727	Oil Level Sensor
728	Oil Level Sensor O-Ring

Scheme 108

Callout	Component Name
100	Engine Block
101	Engine Block Front Oil Gallery Plug
110	Engine Block Rear Oil Gallery Plug O-Ring
110	Engine Block Rear Oil Gallery Plug O-Ring
111	Engine Block Rear Oil Gallery Plug
111	Engine Block Rear Oil Gallery Plug
112	Oil Gallery Plug
113	Oil Gallery Plug Washer
114	Coolant Heater
115	Coolant Heater Washer
116	Oil Gallery Plug
117	Oil Gallery Plug Washer
130	Transmission Housing Locating Pin
145	Coolant Drain Plug Washer - Right
146	Coolant Drain Plug - Right
700	Crankshaft Position (CKP) Sensor Bolt
701	CKP Sensor
702	CKP Sensor O-Ring
703	Camshaft Position (CMP) Sensor
704	CMP Sensor O-Ring
705	CMP Sensor Bolt
706	Oil Pressure Sensor
707	Oil Pressure Sensor Washer

Scheme 109

Callout	Component Name
408	Cover Bolt
409	Cover
410	Drive Gear
412	Driven Gear
413	Oil Pump
414	Pressure Relief Valve
415	Pressure Relief Valve Spring
416	Plug

Engine Identification

The vehicle identification number (VIN) is located on the left side rear of the engine block (1) and is typically a nine digit number stamped or laser-etched onto the engine at the vehicle assembly plant.

Scheme 110

Scheme 110: Engine Identification

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 VIN.

Diagnostic Starting Point - Engine Mechanical

Begin the system diagnosis by reviewing the Disassembled Views , Engine Component Description , Lubrication Description , New Product Information , and Drive Belt System Description . Reviewing the description and operation information will help you determine the correct symptom diagnostic procedure when a malfunction exists. Reviewing the description and operation information will also help you determine if the condition described by the customer is normal operation. Refer to Symptoms - Engine Mechanical in order to identify the correct procedure for diagnosing the system and where the procedure is located.

Strategy Based Diagnostics

Perform the «Diagnostic System Check - Engine Controls»(/chevrolet/chevy-express-g3500/1996-2012/remont/testing-diagnostics/#engine-control-system-48l-53l-60l-diagnostic-information-procedures) in Engine Controls - 4.8L, 5.3L, and 6.0L before using the symptom tables, if applicable.
Review the system operations in order to familiarize yourself with the system functions. Refer to «Disassembled Views»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical/#engine-mechanical-48l-53l-60l-introduction) , «Engine Component Description»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical/#engine-mechanical-48l-53l-60l-introduction__engine-component-description) , «Lubrication Description»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical/#engine-mechanical-48l-53l-60l-introduction) , «New Product Information»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical/#engine-mechanical-48l-53l-60l-introduction__new-product-information) , and «Drive Belt System Description»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical/#engine-mechanical-48l-53l-60l-introduction__drive-belt-system-description) .

All diagnosis on a vehicle should follow a logical process. Strategy based diagnostics is a uniform approach for repairing all systems. The diagnostic flow may always be used in order to resolve a system condition. The diagnostic flow is the place to start when repairs are necessary. For a detailed explanation, refer to Strategy Based Diagnosis in General Information.

Visual/Physical Inspection

Inspect for aftermarket devices which could affect the operation of the Engine. Refer to «Checking Aftermarket Accessories»(/chevrolet/chevy-express-g3500/1996-2012/remont/body-electrical/#wiring-systems-diagnostic-information-and-procedures__checking-aftermarket-accessories) in Wiring Systems.
Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom.
Check for the correct oil level, proper oil viscosity, and correct filter application.
Verify the exact operating conditions under which the concern exists. Note factors such as engine RPM, ambient temperature, engine temperature, amount of engine warm-up time, and other specifics.
Compare the engine sounds, if applicable, to a known good engine and make sure you are not trying to correct a normal condition.

Intermittent

Test the vehicle under the same conditions that the customer reported in order to verify the system is operating properly.

Symptom List

Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom

«Base Engine Misfire without Internal Engine Noises»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical/#engine-mechanical-48l-53l-60l-introduction__base-engine-misfire-without-internal-engine)
«Base Engine Misfire with Abnormal Internal Lower Engine Noises»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical/#engine-mechanical-48l-53l-60l-introduction__base-engine-misfire-with-abnormal-internal)
«Base Engine Misfire with Abnormal Valve Train Noise»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical/#engine-mechanical-48l-53l-60l-introduction__base-engine-misfire-with-abnormal-valve)
«Base Engine Misfire with Coolant Consumption»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical/#engine-mechanical-48l-53l-60l-introduction__base-engine-misfire-with-coolant-consumption)
«Base Engine Misfire with Excessive Oil Consumption»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical/#engine-mechanical-48l-53l-60l-introduction__base-engine-misfire-with-excessive-oil)
«Engine Compression Test»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical/#engine-mechanical-48l-53l-60l-introduction__engine-compression-test)
«Engine Noise on Start-Up, but Only Lasting a Few Seconds»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical/#engine-mechanical-48l-53l-60l-introduction__engine-noise-on-start-up-but-only)
«Upper Engine Noise, Regardless of Engine Speed»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical/#engine-mechanical-48l-53l-60l-introduction__upper-engine-noise-regardless-of-engine)
«Lower Engine Noise, Regardless of Engine Speed»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical/#engine-mechanical-48l-53l-60l-introduction__lower-engine-noise-regardless-of-engine)
«Engine Noise Under Load»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical/#engine-mechanical-48l-53l-60l-introduction__engine-noise-under-load)
«Engine Will Not Crank - Crankshaft Will Not Rotate»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical/#engine-mechanical-48l-53l-60l-introduction__engine-will-not-crank-crankshaft)
«Coolant in Combustion Chamber»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical/#engine-mechanical-48l-53l-60l-introduction__coolant-in-combustion-chamber)
«Coolant in Engine Oil»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical/#engine-mechanical-48l-53l-60l-introduction__coolant-in-engine-oil)
«Oil Consumption Diagnosis»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical/#engine-mechanical-48l-53l-60l-introduction__oil-consumption-diagnosis)
«Oil Pressure Diagnosis and Testing»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical/#engine-mechanical-48l-53l-60l-introduction__oil-pressure-diagnosis-and-testing)
«Cylinder Leakage Test»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical/#engine-mechanical-48l-53l-60l-introduction__cylinder-leakage-test)
«Drive Belt Chirping Diagnosis»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical/#engine-mechanical-48l-53l-60l-introduction)
«Drive Belt Squeal Diagnosis»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical/#engine-mechanical-48l-53l-60l-introduction)
«Drive Belt Whine Diagnosis»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical/#engine-mechanical-48l-53l-60l-introduction)
«Drive Belt Rumbling Diagnosis»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical/#engine-mechanical-48l-53l-60l-introduction)
«Drive Belt Vibration Diagnosis»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical/#engine-mechanical-48l-53l-60l-introduction)
«Drive Belt Falls Off Diagnosis»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical/#engine-mechanical-48l-53l-60l-introduction)
«Drive Belt Excessive Wear Diagnosis»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical/#engine-mechanical-48l-53l-60l-introduction)
«Drive Belt Tensioner Diagnosis»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical/#engine-mechanical-48l-53l-60l-introduction)

Base Engine Misfire without Internal Engine Noises

Cause	Correction
Abnormalities, such as severe cracking, bumps, or missing areas in the accessory drive belt Abnormalities in the accessory drive system and/or components may cause engine RPM variations and lead to a misfire DTC. A misfire code may be present without an actual misfire condition.	Replace the drive belt. Refer to Drive Belt Replacement - Accessory .
Worn, damaged, or mis-aligned accessory drive components or excessive pulley runout - May lead to a misfire DTC. A misfire code may be present without an actual misfire condition.	Inspect the components, and repair or replace as required.
Loose or improperly installed engine flywheel or crankshaft balancer A misfire code may be present without an actual misfire condition.	Repair or replace the flywheel and/or balancer as required. Refer to Engine Flywheel Replacement or Crankshaft Balancer Replacement .
Restricted exhaust system A severe restriction in the exhaust flow can cause significant loss of engine performance and may set a DTC. Possible causes of restrictions include collapsed or dented pipes or plugged mufflers and/or catalytic converters.	Repair or replace as required.
Improperly installed or damaged vacuum hoses	Repair or replace as required.
Improper sealing between the intake manifold and cylinder heads or throttle body	Replace the intake manifold, gaskets, cylinder heads, and/or throttle body as required.
Improperly installed or damaged MAP sensor The sealing grommet of the MAP sensor should not be torn or damaged.	Repair or replace the MAP sensor as required.
Worn or loose rocker arms The rocker arm bearing end caps and/or needle bearings should be intact and in the proper position.	Replace the valve rocker arms as required.
Worn or bent pushrods	Replace the pushrods. Inspect the top of the pistons for valve contact. If the top of the piston shows valve contact, replace the piston and pin assembly.
Stuck valves Carbon buildup on the valve stem can cause the valve not to close properly.	Repair or replace as required.
Excessively worn or mis-aligned timing chain	Replace the timing chain and sprockets as required.
Worn camshaft lobes	Replace the camshaft and valve lifters.
Excessive oil pressure A lubrication system with excessive oil pressure may lead to excessive valve lifter pump-up and loss of compression.	Perform an oil pressure test. Refer to Oil Pressure Diagnosis and Testing . Repair or replace the oil pump as required.
Faulty cylinder head gaskets and/or cracking or other damage to the cylinder heads and engine block cooling system passages - Refer to Diagnostic Starting Point - Engine Cooling in Engine Cooling. Coolant consumption may or may not cause the engine to overheat.	Inspect for spark plugs saturated by coolant. Refer to Spark Plug Inspection in Engine Controls - 4.8L, 5.3L, and 6.0L. Inspect the cylinder heads, engine block, and/or head gaskets. Refer to Coolant in Combustion Chamber . Repair or replace as required.
Worn piston rings Oil consumption may or may not cause the engine to misfire.	Inspect the spark plugs for oil deposits. Refer to Spark Plug Inspection in Engine Controls - 4.8L, 5.3L, and 6.0L. Inspect the cylinders for a loss of compression. Refer to Engine Compression Test . Perform cylinder leak down and compression testing to identify the cause. Refer to Cylinder Leakage Test . Repair or replace as required.
A damaged crankshaft reluctor wheel A damaged crankshaft reluctor wheel can result in different symptoms depending on the severity and location of the damage. Systems with electronic communications, DIS or coil per cylinder, and severe reluctor ring damage may exhibit periodic loss of crankshaft position, stop delivering a signal, and then sync the crankshaft position. Systems with electronic communication, DIS or coil per cylinder, and slight reluctor ring damage may exhibit no loss of crankshaft position and no misfire may occur. However, a P0300 DTC may be set. Systems with mechanical communications, high voltage switch, and severe reluctor ring damage may cause additional pulses and effect fuel and spark delivery to the point of generating a P0300 DTC or P0336.	Replace the sensor and/or crankshaft as required.

Base Engine Misfire without Internal Engine Noises

Base Engine Misfire with Abnormal Internal Lower Engine Noises

Cause	Correction
Abnormalities, such as severe cracking, bumps or missing areas in the accessory drive belt Abnormalities in the accessory drive system and/or components may cause engine RPM variations, noises similar to a faulty lower engine and also lead to a misfire condition. A misfire code may be present without an actual misfire condition.	Replace the drive belt. Refer to Drive Belt Replacement - Accessory .
Worn, damaged, or mis-aligned accessory drive components or excessive pulley runout A misfire code may be present without an actual misfire condition.	Inspect the components, repair or replace as required.
Loose or improperly installed engine flywheel or crankshaft balancer A misfire code may be present without an actual misfire condition.	Repair or replace the flywheel and/or balancer as required. Refer to Engine Flywheel Replacement or Crankshaft Balancer Replacement .
Worn piston rings Oil consumption may or may not cause the engine to misfire.	Inspect the spark plugs for oil deposits. Refer to Spark Plug Inspection in Engine Controls. Inspect the cylinders for a loss of compression. Refer to Engine Compression Test . Perform cylinder leak down and compression testing to determine the cause. Refer to Cylinder Leakage Test . Repair or replace as required.
Worn crankshaft thrust bearings Severely worn thrust surfaces on the crankshaft and/or thrust bearing may permit fore and aft movement of the crankshaft and create a DTC without an actual misfire condition.	Replace the crankshaft and bearings as required.

Base Engine Misfire with Abnormal Internal Lower Engine Noises

Base Engine Misfire with Abnormal Valve Train Noise

Cause	Correction
Worn or loose rocker arms The rocker arm bearing end caps and/or needle bearings should be intact within the rocker arm assembly.	Replace the valve rocker arms as required.
Worn or bent pushrods	Replace the pushrods. Inspect the top of the pistons for valve contact. If the top of the piston shows valve contact, replace the piston and pin assembly.
Stuck valves Carbon buildup on the valve stem can cause the valve not to close properly.	Repair or replace as required.
Excessively worn or mis-aligned timing chain	Replace the timing chain and sprockets as required.
Worn camshaft lobes	Replace the camshaft and valve lifters.
Sticking lifters	Replace as required.

Base Engine Misfire with Abnormal Valve Train Noise

Base Engine Misfire with Coolant Consumption

Cause	Correction
Faulty cylinder head gaskets and/or cracking or other damage to the cylinder heads and engine block cooling system passages - Refer to Diagnostic Starting Point - Engine Cooling in Engine Cooling. Coolant consumption may or may not cause the engine to overheat.	Inspect for spark plugs saturated by coolant. Refer to Spark Plug Inspection in Engine Controls - 4.8L, 5.3L, and 6.0L. Perform a cylinder leak down test. Refer to Cylinder Leakage Test . Inspect the cylinder heads and engine block for damage to the coolant passages and/or a faulty head gasket. Refer to Coolant in Combustion Chamber . Repair or replace as required.

Base Engine Misfire with Coolant Consumption

Base Engine Misfire with Excessive Oil Consumption

Cause	Correction
Worn valves, valve guides and/or valve stem oil seals	Inspect the spark plugs for oil deposits. Refer to Spark Plug Inspection in Engine Controls - 4.8L, 5.3L, and 6.0L. Repair or replace as required.
Worn piston rings Oil consumption may or may not cause the engine to misfire.	Inspect the spark plugs for oil deposits. Refer to Spark Plug Inspection in Engine Controls - 4.8L, 5.3L, and 6.0L. Inspect the cylinders for a loss of compression. Refer to Engine Compression Test . Perform cylinder leak down and compression testing to determine the cause. Refer to Cylinder Leakage Test . Repair or replace as required.

Base Engine Misfire with Excessive Oil Consumption

Engine Noise on Start-Up, but Only Lasting a Few Seconds

Cause	Correction
Incorrect oil filter without anti-drainback feature	Install the correct oil filter.
Incorrect oil viscosity	Drain the oil. Install the correct viscosity oil.
High valve lifter leak down rate	Replace the lifters as required.
Worn crankshaft thrust bearing	Check the crankshaft end play. Inspect the thrust bearing and crankshaft. Repair or replace as required.
Damaged or faulty oil filter by-pass valve	Inspect the oil filter by-pass valve for proper operation. Repair or replace as required.

Engine Noise on Start-Up, but Only Lasting a Few Seconds

Upper Engine Noise, Regardless of Engine Speed

Cause	Correction
Low oil pressure	Perform an oil pressure test. Refer to Oil Pressure Diagnosis and Testing . Repair or replace as required.
Loose and/or worn valve rocker arm attachments	Inspect the valve rocker arm, bolt, and pedestal. Repair or replace as required.
Worn or damaged valve rocker arm	Inspect the rocker arm for wear or missing needle bearings Replace the valve rocker arms as required.
Bent or damaged push rod	Inspect the following components and replace as required: The valve rocker arm The valve push rod The valve lifter The valve lifter guide The piston Inspect the top of the pistons for valve contact. If the top of the piston shows valve contact, replace the piston and pin assembly.
Improper lubrication to the valve rocker arms	Inspect the following components and repair or replace as required: The valve rocker arm The valve push rod The valve lifter The oil filter bypass valve The oil pump and pump screen The engine block oil galleries
Broken valve spring	Replace the valve spring and spring shim.
Worn or dirty valve lifters	Replace the valve lifters.
Stretched or broken timing chain and/or damaged sprocket teeth	Replace the timing chain and sprockets.
Worn engine camshaft lobes	Inspect the engine camshaft lobes. Replace the camshaft and valve lifters as required.
Worn valve guides or valve stems	Inspect the following components and repair as required: The valves The valve guides
Stuck valves Carbon on the valve stem or valve seat may cause the valve to stay open.	Inspect the following components and repair as required: The valves The valve guides

Upper Engine Noise, Regardless of Engine Speed

Lower Engine Noise, Regardless of Engine Speed

Cause	Correction
IMPORTANT: A cold piston knock which disappears in 1.5 minutes should be considered acceptable. A cold engine knock usually disappears when the specific cylinder's secondary ignition circuit is grounded out during diagnosis. A low rumble/knocking may indicate a crankshaft or piston, lower engine concern.
Low oil pressure	Perform an oil pressure test. Refer to Oil Pressure Diagnosis and Testing . Repair or replace damaged components as required.
Worn accessory drive components Abnormalities such as severe cracking, bumps or missing areas in the accessory drive belt and/or misalignment of system components.	Inspect the accessory drive system. Repair or replace as required.
Loose or damaged crankshaft balancer	Inspect the crankshaft balancer. Repair or replace as required.
Detonation or spark knock	Verify the correct operation of the ignition controls system. Refer to Detonation/Spark Knock in Engine Controls - 4.8L, 5.3L, and 6.0L.
Loose torque converter bolts	Inspect the torque converter bolts and flywheel. Repair or replace as required.
Loose or damaged flywheel	Repair or replace the flywheel.
Oil pump screen loose, damaged or restricted	Inspect the oil pump screen. Repair or replace as required.
Excessive piston-to-cylinder bore clearance	Inspect the piston and cylinder bore. Repair as required.
Excessive piston pin-to-bore clearance	Inspect the piston, pin, and connecting rod. Replace the piston, pin and connecting rod as an assembly, as required.
Excessive connecting rod bearing clearance	Inspect the following components, and repair as required: The connecting rod bearings The connecting rods The crankshaft The crankshaft journals
Excessive crankshaft bearing clearance	Inspect the following components, and repair as required: The crankshaft bearings The crankshaft journals
Incorrect piston, piston pin and connecting rod installation. Pistons must be installed with the mark or dimple on the top of the piston facing the front of the engine. Piston pins must be centered in the connecting rod pin bore.	Verify the pistons, piston pins and connecting rods are installed correctly. Refer to Piston, Connecting Rod, and Bearing Installation . Repair as required.

IMPORTANT
A cold piston knock which disappears in 1.5 minutes should be considered acceptable. A cold engine knock usually disappears when the specific cylinder's secondary ignition circuit is grounded out during diagnosis. A low rumble/knocking may indicate a crankshaft or piston, lower engine concern.

Lower Engine Noise, Regardless of Engine Speed

Engine Noise Under Load

Cause	Correction
Low oil pressure	Perform an oil pressure test. Refer to Oil Pressure Diagnosis and Testing . Repair or replace as required.
Detonation or spark knock	Verify the correct operation of the ignition controls. Refer to Detonation/Spark Knock in Engine Controls - 4.8L, 5.3L, and 6.0L.
Loose torque converter bolts	Inspect the torque converter bolts and flywheel. Repair as required.
Cracked flywheel - automatic transmission	Inspect the flywheel bolts and flywheel. Repair as required.
Excessive connecting rod bearing clearance	Inspect the following components, and repair as required: The connecting rod bearings The connecting rods The crankshaft
Excessive crankshaft bearing clearance	Inspect the following components, and repair as required: The crankshaft bearings The crankshaft journals The cylinder block crankshaft bearing bore

Engine Noise Under Load

Engine Will Not Crank - Crankshaft Will Not Rotate

Cause	Correction
Seized accessory drive system component	Remove the accessory drive belts. Confirm that the engine will rotate. Rotate the crankshaft by hand at the crankshaft balancer or flywheel location. Repair or replace the components as required.
Seized automatic transmission torque converter	Remove the torque converter-to-flywheel bolts. Confirm that the engine will rotate. Rotate the crankshaft by hand at the crankshaft balancer or flywheel location. Repair or replace the components as required.
Broken timing chain	Inspect the timing chain and gears. Repair or replace the components as required.
Seized timing chain or timing gears	Inspect the timing chain and gears for foreign material or a seized chain. Repair or replace the components as required.
Seized or broken camshaft	Inspect the camshaft and the camshaft bearings. Repair or replace the components as required.
Bent valve in the cylinder head	Inspect the valves and the cylinder heads. Repair or replace the components as required.
Seized oil pump	Inspect the oil pump assembly. Repair or replace as required.
Hydraulically locked cylinder Coolant/antifreeze in the cylinder Oil in the cylinder Fuel in the cylinder	Remove spark plugs and check for fluid in the cylinder. When rotating the engine with the spark plugs removed, the piston, on compression stroke, will push fluid from the combustion chamber. Refer to Coolant in Combustion Chamber . Inspect for failed/broken head gaskets. Refer to Coolant in Combustion Chamber . Inspect for a cracked engine block or cylinder head. Inspect for a sticking fuel injector. Repair or replace the components as required.
Material in the cylinder Broken valve Broken piston rings Piston material Foreign material	Inspect the cylinder for damaged components and/or foreign materials. Repair or replace the components as required.
Seized crankshaft or connecting rod bearings	Inspect crankshaft and connecting rod bearings. Repair or replace the components as required.
Bent or broken connecting rod	Inspect the connecting rods. Replace the piston, pin, and connecting rod as an assembly, as required.
Broken crankshaft	Inspect the crankshaft. Repair or replace the components as required.

Engine Will Not Crank - Crankshaft Will Not Rotate

Coolant in Combustion Chamber

Cause	Correction
DEFINITION: Excessive white smoke and/or coolant type odor coming from the exhaust pipe may indicate coolant in the combustion chamber. Low coolant levels, an inoperative cooling fan, or a faulty thermostat may lead to an "overtemperature" condition which may cause engine component damage. A slower than normal cranking speed may indicate coolant entering the combustion chamber. Refer to Engine Will Not Crank - Crankshaft Will Not Rotate . Remove the spark plugs and inspect for spark plugs saturated by coolant or coolant in the cylinder bore. Inspect by performing a cylinder leak-down test. During this test, excessive air bubbles within the coolant may indicate a faulty gasket or damaged component. Inspect by performing a cylinder compression test. Two cylinders "side-by-side" on the engine block, with low compression, may indicate a failed cylinder head gasket. Refer to Engine Compression Test .
Cracked intake manifold or failed gasket	Replace the components as required.
Faulty cylinder head gasket	Replace the head gasket and components as required. Refer to Cylinder Head Cleaning and Inspection and Cylinder Head Replacement - Left or Cylinder Head Replacement - Right .
Warped cylinder head	Machine the cylinder head to the proper flatness, if applicable and replace the cylinder head gasket. Refer to Cylinder Head Cleaning and Inspection .
Cracked cylinder head	Replace the cylinder head and gasket.
Cracked cylinder liner or engine block	Replace the components as required.
Cylinder head or engine block porosity	Replace the components as required.

Coolant in Combustion Chamber

Coolant in Engine Oil

Cause	Correction
DEFINITION: Foamy or discolored oil or an engine oil "overfill" condition may indicate coolant entering the engine crankcase. Low coolant levels, an inoperative cooling fan, or a faulty thermostat may lead to an "overtemperature" condition which may cause engine component damage. Contaminated engine oil and oil filter should be changed. Inspect the oil for excessive foaming or an overfill condition. Oil diluted by coolant may not properly lubricate the crankshaft bearings and may lead to component damage. Refer to Lower Engine Noise, Regardless of Engine Speed . Inspect by performing a cylinder leak-down test. During this test, excessive air bubbles within the cooling system may indicate a faulty gasket or damaged component. Inspect by performing a cylinder compression test. Two cylinders "side-by-side" on the engine block with low compression may indicate a failed cylinder head gasket. Refer to Engine Compression Test .
Faulty external engine oil cooler	Replace the components as required.
Faulty cylinder head gasket	Replace the head gasket and components as required. Refer to Cylinder Head Cleaning and Inspection and Cylinder Head Replacement - Left or Cylinder Head Replacement - Right .
Warped cylinder head	Machine the cylinder head to proper flatness, if applicable, and replace the cylinder head gasket. Refer to Cylinder Head Cleaning and Inspection .
Cracked cylinder head	Replace the cylinder head and gasket.
Cracked cylinder liner or engine block	Replace the components as required.
Cylinder head, block, or manifold porosity	Replace the components as required.

Coolant in Engine Oil

Engine Compression Test

Charge the battery if the battery is not fully charged.
Disable the ignition system.
Disable the fuel injection system.
Remove all the spark plugs.
Block the throttle plate wide open.
Start with the compression gage at zero and crank the engine through four compression strokes, four puffs.
Make the compression check for each cylinder. Record the reading.
If a cylinder has low compression, inject approximately 15 ml (1 tablespoon) of engine oil into the combustion chamber through the spark plug hole. Check the compression again and 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). Normal - Compression builds up quickly and evenly to the specified compression for each cylinder. Piston Rings Leaking - Compression is low on the first stroke. Compression then 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 cylinders.

Cylinder Leakage Test

Tools Required: J 35667-A Cylinder Head Leakdown Tester or equivalent. See Special Tools and Equipment .

IMPORTANT

A leakage test may be performed in order to measure cylinder/combustion chamber leakage. High cylinder leakage may indicate one or more of the following conditions: Worn or burnt valves Broken valve springs Stuck valve lifters Incorrect valve lash Damaged piston Worn piston rings Worn or scored cylinder bore Damaged cylinder head gasket Cracked or damaged cylinder head Cracked or damaged engine block

Disconnect the battery ground negative cable.
Remove the spark plugs. Refer to «Spark Plug Replacement»(/chevrolet/chevy-express-g3500/1996-2012/remont/testing-diagnostics/#engine-control-system-48l-53l-60l-introduction) in Engine Controls - 4.8L, 5.3L, and 6.0L.
Rotate the crankshaft to place the piston in the cylinder being tested at top dead center (TDC) of the compression stroke.
Install the J 35667-A or equivalent.
Apply shop air pressure to the J 35667-A and adjust according to the manufacturers instructions.
Record the cylinder leakage value. Cylinder leakage that exceeds 25 percent is considered excessive and may require component service. In excessive leakage situations, inspect for the following conditions: Air leakage noise at the throttle body or air inlet hose that may indicate a worn or burnt intake valve or a broken valve spring. Air leakage noise at the exhaust system tailpipe that may indicate a worn or burnt exhaust valve or a broken valve spring. Air leakage noise from the crankcase, oil level indicator tube, or oil fill tube that may indicate worn piston rings, a damaged piston, a worn or scored cylinder bore, a damaged engine block or a damaged cylinder head. Air bubbles in the cooling system may indicate a damaged cylinder head or a damaged cylinder head gasket.
Perform the leakage test on the remaining cylinders and record the values.

Oil Consumption Diagnosis

Checks	Causes
Excessive oil consumption, not due to leaks, is the use of 1 L (1 qt) or more of engine oil within 3 200 kilometers (2,000 miles).
Preliminary	The causes of excessive oil consumption may include the following conditions: External oil leaks Refer to. Incorrect oil level or improper reading of the oil level indicator With the vehicle on a level surface, run the engine for a few minutes, allow adequate drain down time, 2-3 minutes, and check for the correct engine oil level. Improper oil viscosity Refer to the vehicle owners manual and use the recommended SAE grade and viscosity for the prevailing temperatures. Continuous high speed driving and/or severe usage Crankcase ventilation system restrictions or malfunctioning components Worn valve guides and/or valve stems Worn or improperly installed valve stem oil seals Piston rings broken, worn, or not seated properly Allow adequate time for the rings to seat. Replace worn piston rings as necessary. Piston and rings improperly installed or not fitted to the cylinder bore

Checks

Causes

Excessive oil consumption, not due to leaks, is the use of 1 L (1 qt) or more of engine oil within 3 200 kilometers (2,000 miles).

Preliminary

The causes of excessive oil consumption may include the following conditions: External oil leaks Refer to. Incorrect oil level or improper reading of the oil level indicator With the vehicle on a level surface, run the engine for a few minutes, allow adequate drain down time, 2-3 minutes, and check for the correct engine oil level. Improper oil viscosity Refer to the vehicle owners manual and use the recommended SAE grade and viscosity for the prevailing temperatures. Continuous high speed driving and/or severe usage Crankcase ventilation system restrictions or malfunctioning components Worn valve guides and/or valve stems Worn or improperly installed valve stem oil seals Piston rings broken, worn, or not seated properly Allow adequate time for the rings to seat. Replace worn piston rings as necessary. Piston and rings improperly installed or not fitted to the cylinder bore

Oil Consumption Diagnosis

Oil Pressure Diagnosis and Testing

Tools Required

J 21867 Pressure Gage. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical/#engine-mechanical-48l-53l-60l-introduction) .
J 42907 Oil Pressure Testing Tool

With the vehicle on a level surface, run the vehicle for a few minutes, allow adequate drain down time of 2-3 minutes, and measure the oil level.
If required, add the recommended grade engine oil and fill the crankcase until the oil level measures full on the oil level indicator.
Run the engine briefly, approximately 10-15 seconds, and verify low or no oil pressure on the vehicle gage or light.
Listen for a noisy valve train or a knocking noise.
Inspect for the following conditions: Oil diluted by water or glycol - anti freeze Foamy oil
Remove the oil filter and install the J 42907.
Install J 21867 or equivalent to the J 42907. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical/#engine-mechanical-48l-53l-60l-introduction) .
Run the engine and measure the engine oil pressure.
Compare the readings to «Engine Mechanical Specifications (LR4 VIN V)»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical/#engine-mechanical-48l-53l-60l-introduction__engine-mechanical-specifications-lr4-vin-v) or «Engine Mechanical Specifications (LM7 VIN T)»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical/#engine-mechanical-48l-53l-60l-introduction__engine-mechanical-specifications-lm7-vin-t) or «Engine Mechanical Specifications (LQ4 VIN U)»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical/#engine-mechanical-48l-53l-60l-introduction__engine-mechanical-specifications-lq4-vin-u) .
If the engine oil pressure is below specifications, inspect the engine for one or more of the following conditions: Oil pump worn or dirty Refer to «Oil Pump Cleaning and Inspection»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical/#engine-mechanical-removal-installation-2-of-3-48l-53l-60l__oil-pump-cleaning-and-inspection) . Oil pump-to-engine block bolts loose Refer to «Oil Pump, Pump Screen and Deflector Installation»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical/#engine-mechanical-removal-installation-3-of-3-48l-53l-60l__oil-pump-pump-screen-and-deflector) . Oil pump screen loose, plugged, or damaged Oil pump screen O-ring seal missing or damaged Malfunctioning oil pump pressure regulator valve Excessive bearing clearance Cracked, porous, or restricted oil galleries Oil gallery plugs missing or incorrectly installed Refer to «Engine Block Plug Installation»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical/#engine-mechanical-removal-installation-2-of-3-48l-53l-60l__engine-block-plug-installation) . Broken valve lifters Repair as necessary.
If the oil pressure reading on the J 21867 or equivalent is within specifications, inspect for the following conditions: See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical/#engine-mechanical-48l-53l-60l-introduction) . Plugged or incorrect oil filter and/or malfunctioning oil bypass valve Malfunctioning oil pressure gage or sensor Repair as necessary.

Oil Leak Diagnosis

Step	Action	Yes	No
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 well as the leak itself.
1	Operate the vehicle until it reaches normal operating temperature. Park the vehicle on a level surface, over a large sheet of paper or other clean surface. Wait 15 minutes. Check for drippings. Are drippings present?	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
3	Visually inspect the suspected area. Use a small mirror to assist in looking at hard to see areas. Check for leaks at the following locations: 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	Go to Step 4
4	Completely clean the entire engine and surrounding components. Operate the vehicle for several kilometers - miles at normal operating temperature and at varying speeds. Park the vehicle on a level surface, over a large sheet of paper or other clean surface. Wait 15 minutes. Identify 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 to Step 10	Go to Step 5
5	Visually inspect the suspected area. Use a small mirror to assist in looking at hard to see areas. Check for leaks at the following locations: 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	Go to Step 6
6	Completely clean the entire engine and surrounding components. Apply an aerosol-type powder, baby powder, foot powder, etc., to the suspected area. Operate the vehicle for several kilometers (miles) at normal operating temperature and at varying speeds. Identify the type of fluid, and the approximate location of the leak, from the discolorations in the powder surface. Can you identify the type of fluid and the approximate location of the leak?	Go to Step 10	Go to Step 7
7	Visually inspect the suspected area. Use a small mirror to assist in looking at hard to see areas. Check for leaks at the following locations: 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	Go to Step 8
8	Use J 28428-E High Intensity Black Light Kit in order to identify the type of fluid, and the approximate location of the leak. Refer to the manufacturer's instructions when using the tool. Can you identify the type of fluid and the approximate location of the leak?	Go to Step 10	Go to Step 9
9	Visually inspect the suspected area. Use a small mirror to assist in looking at hard to see areas. Check for leaks at the following locations: 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
10	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 malfunctioning fluid filters or pressure bypass valves Plugged or malfunctioning engine ventilation system 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 Inspect the engine for customer modifications. Is there mechanical damage, or customer 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	System OK

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 well as the leak itself.

Oil Leak Diagnosis

Crankcase Ventilation System Inspection/Diagnosis

Symptom	Correction
External oil leak	Inspect for any of the following conditions: Restricted positive crankcase ventilation (PCV) valve Restricted or kinked PCV hose or engine vent hose Damaged, incorrect, or incorrectly installed PCV valve or hose Excessive crankcase pressure
Rough Idle	Inspect for any of the following conditions: Restricted PCV valve Restricted or kinked PCV hose or engine vent hose Leaking (damaged) PCV valve or hose Vacuum hoses worn or not properly installed
Stalling or slow idle speed	Inspect for any of the following conditions: Restricted PCV valve Restricted or kinked PCV hose or engine vent hose Leaking (damaged) PCV valve or hose
High idle speed	Inspect for a leaking (damaged) PCV valve or hose
Sludge in the engine	Inspect for any of the following conditions: Restricted PCV valve Restricted or kinked PCV hose or engine vent hose

Crankcase Ventilation System Inspection/Diagnosis

Diagnostic Aids

The chirping noise may be intermittent due to moisture on the drive belt(s) or the accessory drive pulley(s). In order to duplicate the customer's concern, it may be necessary to spray a small amount of water onto the drive belt(s). If spraying water onto the drive belt(s) duplicates the symptom, cleaning the accessory drive pulley(s) may be the most probable solution.

A loose or improper installation of a body or suspension component, or other item(s) on the vehicle may also cause the chirping noise.

Test Description

The number(s) below refer to the step(s) in the diagnostic table.

2: The chirping 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 any further in this table.
3: The noise may be an internal engine noise. Remove the drive belt(s) and operate the engine for a few seconds, this will verify if the chirping noise is related to the drive belt(s) or not. With the drive belt(s) removed the water pump will not operate and the engine may overheat. Also diagnostic trouble codes (DTCs) may set when the engine is operated with the drive belt(s) removed.
4: Inspect the drive belt(s) for signs of pilling. Pilling is the small balls, pills, or strings in the drive belt grooves caused by the accumulation of rubber dust.
6: Misalignment of the accessory drive pulley(s) may be caused from improper mounting or incorrect installation of an accessory drive component, or the pulley may be bent inward or outward from a previous repair. Test for a misaligned accessory drive 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 removal and installation procedure for that pulley.
10: Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer, or washer was installed.
12: Inspection of the accessory drive pulley(s) should include inspecting for bends, dents, or other damage to the pulley(s) that would prevent the drive belt(s) from seating properly in the pulley grooves or on the smooth surface of the pulley when the back side of the drive belt is used to drive the pulley.
14: Replacing the drive belt(s) when it is not damaged or there is not excessive pilling will only be a temporary repair.

Step	Action	Yes	No
NOTE: Do not use belt dressing on the drive belt. Belt dressing causes the breakdown of the composition of the drive belt. Failure to follow this recommendation will damage the drive belt. DEFINITION: The following items are indications of chirping: A high pitched noise that is heard once per revolution of the drive belt(s) or a accessory drive pulley. Chirping may occur on cold damp start-up conditions and will subside once the vehicle reaches normal operating temperature.
1	Did you review the Symptoms - Engine Mechanical diagnostic information, and perform the necessary inspections?	Go to Step 2	Go to Symptoms - Engine Mechanical
2	Verify that there is a chirping noise. Does the engine make the chirping noise?	Go to Step 3	Go to Diagnostic Aids
3	Remove the drive belt(s). Refer to Drive Belt Replacement - Accessory or Drive Belt Replacement - Air Conditioning . Operate the engine for no longer than 30 to 40 seconds. Does the chirping noise still exist?	Go to Engine Noise on Start-Up, but Only Lasting a Few Seconds	Go to Step 4
4	Inspect for severe drive belt pilling exceeding 1/3 of the drive belt groove depth. Do the drive belt grooves have pilling?	Go to Step 5	Go to Step 6
5	Clean the accessory drive pulley(s) with a suitable wire brush. Were the accessory drive pulley(s) cleaned?	Go to Step 15
6	Inspect for a misaligned accessory drive pulley(s). Is there a misaligned accessory drive pulley(s)?	Go to Step 7	Go to Step 8
7	Replace and/or repair the misaligned accessory drive pulley(s). Were the misaligned accessory drive pulley(s) replaced and/or repaired?	Go to Step 15
8	Inspect for a bent or cracked accessory drive bracket(s). Did you find any bent or cracked accessory drive bracket(s)?	Go to Step 9	Go to Step 10
9	Replace the bent and/or cracked accessory drive bracket(s). Was the bent and/or cracked accessory drive bracket(s) replaced?	Go to Step 15
10	Inspect for incorrect, loose and/or missing fasteners. Were there any incorrect, loose, and/or missing fasteners found?	Go to Step 11	Go to Step 12
11	Replace any incorrect and/or missing fasteners. Tighten any loose fasteners. Refer to Fastener Tightening Specifications . Were the fasteners replaced and/or tightened?	Go to Step 15
12	Inspect for a bent accessory drive pulley(s). Was a bent accessory drive pulley(s) found?	Go to Step 13	Go to Step 14
13	Replace the bent accessory drive pulley(s). Was the bent accessory drive pulley(s) replaced?	Go to Step 15
14	Replace the drive belt(s). Refer to Drive Belt Replacement - Accessory or Drive Belt Replacement - Air Conditioning . Was the drive belt(s) replaced?	Go to Step 15
15	Clear any codes. Run the engine in order to verify the repair. Does the chirping noise still exist?		System OK

NOTE
Do not use belt dressing on the drive belt. Belt dressing causes the breakdown of the composition of the drive belt. Failure to follow this recommendation will damage the drive belt.

Drive Belt Chirping Diagnosis

A loose or improper installation of a body, or suspension component, or other item(s) on the vehicle may cause the squeal noise.

If the squeal is intermittent, verify that it is not the accessory drive component(s) by varying their load(s), making sure they are operating to their maximum capacity. An overcharged air conditioning (A/C) system, a power steering system restriction or the incorrect fluid, or a failing generator are suggested items to inspect.

The number(s) below refer to the step(s) in the diagnostic table.

2: The squeal 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 in this table
3: The squeal may be an internal engine noise. Remove the drive belt(s) and operate the engine for a few seconds, this will verify if the squealing noise is related to the drive belt(s) or an accessory drive component. With the drive belt(s) removed the water pump will not operate and the engine may overheat. Also diagnostic trouble codes (DTCs) may set when the engine is operated with the drive belt(s) removed.
4: This test is to verify that an accessory drive component(s) does not have a seized bearing. With the belt(s) removed, test the bearings in the accessory drive component(s) for smooth operation. Also test the accessory drive component(s) with the engine operating by varying the load on the accessory drive component(s) to verify that the component(s) is operating properly.
5: This test is to verify that the drive belt(s) tensioner(s) are not operating properly. If the drive belt tensioner(s) are not operating properly, proper belt tension may not be achieved to keep the drive belt(s) from slipping which could cause a squealing noise.
6: This test is to verify that the drive belt(s) is not too long, which would prevent the drive belt tensioner(s) from operating properly. Also if the incorrect length drive belt(s) was installed, it may not be routed correctly and may be turning an accessory drive component in the incorrect direction.
7: Misalignment of the accessory drive pulley(s) may be caused from improper mounting or incorrect installation of a accessory drive component, or the pulley may be 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 removal and installation procedure for that pulley.
8: Inspect the accessory drive pulley(s) to verify that they are the correct diameter or width. Using a known good vehicle, compare the accessory drive pulleys.

Step	Action	Yes	No
NOTE: Do not use belt dressing on the drive belt. Belt dressing causes the breakdown of the composition of the drive belt. Failure to follow this recommendation will damage the drive belt. DEFINITION: The following items are indications of drive belt squeal: A loud screeching noise that is caused by a slipping drive belt(s) (this is unusual for a drive belt with multiple ribs) The squeal occurs when a heavy load is applied to the drive belt(s), such as an A/C compressor engagement, snapping the throttle, slipping on a seized pulley, or a faulty accessory drive component.
1	Did you review the Symptoms - Engine Mechanical diagnostic information, and perform the necessary inspections?	Go to Step 2	Go to Symptoms - Engine Mechanical
2	Verify that there is a squealing noise. Does the engine make the squeal noise?	Go to Step 3	Go to Diagnostic Aids
3	Remove the drive belt(s). Refer to Drive Belt Replacement - Accessory or Drive Belt Replacement - Air Conditioning . Operate the engine for no longer than 30 to 40 seconds. Does the squealing noise still exist?	Go to Engine Noise on Start-Up, but Only Lasting a Few Seconds	Go to Step 4
4	Inspect for a seized accessory drive component bearing or a faulty accessory drive component. Did you find and correct the condition?	Go to Step 9	Go to Step 5
5	Inspect the drive belt tensioner for proper operation. Refer to Drive Belt Tensioner Diagnosis . Did you find and correct the condition?	Go to Step 9	Go to Step 6
6	Check for the correct length drive belt(s). Did you find and correct the condition?	Go to Step 9	Go to Step 7
7	Inspect for a misaligned pulley. Did you find and correct the condition?	Go to Step 9	Go to Step 8
8	Inspect for an incorrect size pulley. Did you find and correct the condition?	Go to Step 9
9	Install the drive belt(s). Refer to Drive Belt Replacement - Accessory or Drive Belt Replacement - Air Conditioning . Clear any codes. Run the engine in order to verify the repair. Does the squealing noise still exist?		System OK

NOTE
Do not use belt dressing on the drive belt. Belt dressing causes the breakdown of the composition of the drive belt. Failure to follow this recommendation will damage the drive belt.

Drive Belt Squeal Diagnosis

The drive belt(s) will not cause the whine.

If the whine is intermittent, verify that it is not the accessory drive component(s) by varying their loads, making sure they are operating to their maximum capacity. An overcharged air conditioning (A/C) system, a power steering system restriction or the incorrect fluid, or a failing generator are suggested items to inspect.

The number(s) below refer to the step(s) in the diagnostic table.

3: This test is to verify that the whine is being caused by the accessory drive component(s). Remove the drive belt(s) and operate the engine for a few seconds, this will verify if the whining noise is related to the accessory drive component. With the drive belt(s) removed the water pump will not operate and the engine may overheat. Also diagnostic trouble codes (DTCs) may set when the engine is operated with the drive belt(s) removed.
4: This 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 separately by varying their loads. Refer to the suspected accessory drive component for the proper removal and installation procedure.

Step	Action	Yes	No
NOTE: Do not use belt dressing on the drive belt. Belt dressing causes the breakdown of the composition of the drive belt. Failure to follow this recommendation will damage the drive belt. DEFINITION: A high pitched continuous noise that may be caused by an accessory drive component failed bearing.
1	Did you review the Symptoms - Engine Mechanical diagnostic information, and perform the necessary inspections?	Go to Step 2	Go to Symptoms - Engine Mechanical
2	Verify that there is a whining noise. Does the engine make the whining noise?	Go to Step 3	Go to Diagnostic Aids
3	Remove the drive belt(s). Refer to Drive Belt Replacement - Accessory or Drive Belt Replacement - Air Conditioning . Operate the engine for no longer than 30 to 40 seconds. Does the whining noise still exist?	Go to Engine Noise on Start-Up, but Only Lasting a Few Seconds	Go to Step 4
4	Inspect for a failed accessory drive component bearing. Install the drive belt(s). Refer to Drive Belt Replacement - Accessory or Drive Belt Replacement - Air Conditioning . Did you find and correct the condition?	Go to Step 5
5	Clear any codes. Run the engine in order to verify the repair. Does the whining still exist?		System OK

NOTE
Do not use belt dressing on the drive belt. Belt dressing causes the breakdown of the composition of the drive belt. Failure to follow this recommendation will damage the drive belt.

Drive Belt Whine Diagnosis

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(s) may be the only repair for the symptom.

If after replacing the drive belt(s) and completing the diagnostic table, the rumbling is only heard with the drive belt(s) installed, there might be an accessory drive component failure. Varying the load on the accessory drive component(s) may aid in identifying which component is causing the rumbling noise.

The number(s) below refer to the step(s) in the diagnostic table.

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. Rumbling 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. Operate the engine for a few seconds, this will verify if the rumbling noise is related to the drive belt(s) or not. With the drive belt(s) removed the water pump will not operate and the engine may overheat. Also diagnostic trouble codes (DTCs) may set when the engine is operated with the drive belt(s) removed.
4: Inspect the drive belt(s) to ensure that the drive belt(s) is not the cause of the noise. Small cracks across the ribs of the drive belt(s) will not cause the noise. Belt separation is identified by the plys of the belt separating, this 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(s) does not have a smooth surface for proper operation.

Step	Action	Yes	No
NOTE: Do not use belt dressing on the drive belt. Belt dressing causes the breakdown of the composition of the drive belt. Failure to follow this recommendation will damage the drive belt. DEFINITION: A low pitch tapping, knocking, or thumping noise heard at or just above idle. Heard once per revolution of the drive belt(s) or pulley(s). Rumbling may be caused from: Pilling, the accumulation of rubber dust that forms small balls (pills) or strings in the drive belt(s) pulley groove The separation of the drive belt(s) A damaged drive belt(s)
1	Did you review the Symptoms - Engine Mechanical diagnostic information, and perform the necessary inspections?	Go to Step 2	Go to Symptoms - Engine Mechanical
2	Verify that there is a rumbling noise. Does the engine make the rumbling noise?	Go to Step 3	Go to Diagnostic Aids
3	Remove the drive belt(s). Refer to Drive Belt Replacement - Accessory or Drive Belt Replacement - Air Conditioning . Operate the engine for no longer than 30 to 40 seconds. Does the rumbling noise still exist?	Go to Engine Noise on Start-Up, but Only Lasting a Few Seconds	Go to Step 4
4	Inspect the drive belt(s) for damage, separation, or sections of missing ribs. Were any of these conditions found?	Go to Step 7	Go to Step 5
5	Inspect for severe pilling of more than 1/3 of the drive belt groove depth. Do the drive belt grooves have pilling?	Go to Step 6	Go to Step 7
6	Clean the drive belt pulleys using a suitable wire brush. Reinstall the drive belt(s). Refer to Drive Belt Replacement - Accessory or Drive Belt Replacement - Air Conditioning . Did you complete the repair?	Go to Step 8
7	Install a new drive belt(s). Refer to Drive Belt Replacement - Accessory or Drive Belt Replacement - Air Conditioning . Did you complete the replacement?	Go to Step 8
8	Clear any codes. Run the engine in order to verify the repair. Does the rumbling noise still exist?		System OK

NOTE
Do not use belt dressing on the drive belt. Belt dressing causes the breakdown of the composition of the drive belt. Failure to follow this recommendation will damage the drive belt.

Drive Belt Rumbling Diagnosis

The accessory drive components may have an affect on engine vibration. An overcharged air conditioning (A/C) system, a power steering system restriction, or the incorrect fluid, or an extra load placed on the generator are suggested items to inspect. To help identify an intermittent or an improper condition, vary the loads on the accessory drive components.

The number(s) below refer to the step(s) in the diagnostic table.

2: This test is to verify that the vibration 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. Remove the drive belt(s) and operate the engine for a few seconds, this will verify if the vibration is related to the drive belt(s) or not. With the drive belt(s) removed the water pump will not operate and the engine may overheat. Also diagnostic trouble codes (DTCs) may set when the engine is operated with the drive belt(s) removed.
4: The drive belt(s) may cause a vibration. While the drive belt(s) is removed this is the best time to inspect the condition of the drive belt(s).
6: Inspection of the fasteners can eliminate the possibility that a incorrect 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 smooth operation. Inspect for a bent fan shaft or bent mounting flange.
9: Inspect the water pump drive shaft for being bent. Also inspect the water pump bearings for smooth operation 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 an extra strain on that accessory drive component causing it to vibrate.

Step	Action	Yes	No
NOTE: Do not use belt dressing on the drive belt. Belt dressing causes the breakdown of the composition of the drive belt. Failure to follow this recommendation will damage the drive belt. DEFINITION: The following items are indications of drive belt vibration: The vibration is engine-speed related. The vibration may be sensitive to accessory load.
1	Did you review the Symptoms - Engine Mechanical diagnostic information, and perform the necessary inspections?	Go to Step 2	Go to Symptoms - Engine Mechanical
2	Verify that the vibration is engine related. Does the engine make the vibration?	Go to Step 3	Go to Diagnostic Aids
3	Remove the drive belt(s). Refer to Drive Belt Replacement - Accessory or Drive Belt Replacement - Air Conditioning . Operate the engine for no longer than 30 to 40 seconds. Does the engine still make the vibration?	Go to Diagnostic Starting Point - Vibration Diagnosis and Correction in Vibration Diagnosis and Correction	Go to Step 4
4	Inspect the drive belt(s) for wear, damage, debris build-up and missing drive belt ribs. Were any of these conditions found?	Go to Step 5	Go to Step 6
5	Install a new drive belt(s). Refer to Drive Belt Replacement - Accessory or Drive Belt Replacement - Air Conditioning . Did you complete the replacement?	Go to Step 11
6	Inspect for incorrect, loose, and/or missing fasteners. Were any of these conditions found?	Go to Step 7	Go to Step 8
7	Replace any incorrect and/or missing fastener. Tighten any loose fasteners. Refer to Fastener Tightening Specifications . Were the fasteners replaced and/or tightened?	Go to Step 11
8	Inspect for damaged fan blades or a bent fan clutch shaft. Did you find and correct the condition?	Go to Step 11	Go to Step 9
9	Inspect for a bent water pump drive shaft. Did you find and correct the condition?	Go to Step 11	Go to Step 10
10	Inspect for a bent or cracked accessory drive bracket(s). Did you find and correct the condition?	Go to Step 11
11	Clear any codes. Run the engine in order to verify the repair. Does the vibration still exist?		System OK

NOTE
Do not use belt dressing on the drive belt. Belt dressing causes the breakdown of the composition of the drive belt. Failure to follow this recommendation will damage the drive belt.

Drive Belt Vibration Diagnosis

If the drive belt(s) repeatedly falls off the accessory drive pulley(s), this may be caused by a pulley misalignment.

An extra load that is quickly applied or released by an accessory drive component may also cause the drive belt(s) to fall off. Verify that the accessory drive component(s) are operating properly.

If the drive belt(s) is the incorrect length, the drive belt tensioner may not maintain the proper tension on the drive belt(s).

The number(s) below refer to the step(s) in the diagnostic table.

2: This inspection is to verify the condition of the drive belt(s). Damage may have occurred to the drive belt(s) when the drive belt(s) fell off the pulley. Inspect the drive belt(s) for cuts, tears, sections of ribs missing, or damaged belt plys.
4: Misalignment of the accessory drive pulley(s) may be caused from improper mounting or incorrect installation of a accessory drive component, or the pulley may be 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 removal and installation procedure of that pulley.
5: Inspection of the accessory drive pulley(s) should include inspecting for bends, dents, or other damage that would prevent the drive belt from seating properly in the pulley grooves or on the smooth surface of a pulley when the back side of the drive belt(s) is used to drive the pulley.
6: Accessory drive component brackets that are bent or cracked will also cause the drive belt(s) to fall off.
7: Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer, or washer was installed. Missing, loose, or incorrect fasteners may cause pulley misalignment from the accessory drive bracket(s) moving under load. Over tightening the fasteners may cause misalignment of the accessory component bracket(s).

Step	Action	Yes	No
NOTE: Do not use belt dressing on the drive belt. Belt dressing causes the breakdown of the composition of the drive belt. Failure to follow this recommendation will damage the drive belt. DEFINITION: The drive belt(s) falls off the pulleys or may not ride correctly on the pulleys.
1	Did you review the Symptoms - Engine Mechanical diagnostic information, and perform the necessary inspections?	Go to Step 2	Go to Symptoms - Engine Mechanical
2	Inspect for a damaged drive belt(s). Was a damaged drive belt(s) found?	Go to Step 3	Go to Step 4
3	Install a new drive belt(s). Refer to Drive Belt Replacement - Accessory or Drive Belt Replacement - Air Conditioning . Does the drive belt(s) continue to fall off?	Go to Step 4	System OK
4	Inspect for a misaligned accessory drive pulley(s). Did you find and correct the condition?	Go to Step 12	Go to Step 5
5	Inspect for a bent or dented accessory drive pulley(s). Did you find and correct the condition?	Go to Step 12	Go to Step 6
6	Inspect for a bent or a cracked accessory drive bracket(s). Did you find and correct the condition?	Go to Step 12	Go to Step 7
7	Inspect for incorrect, loose and/or missing fasteners. Were there any incorrect, loose and/or missing fasteners?	Go to Step 8	Go to Step 9
8	Replace any incorrect and/or missing fasteners. Tighten any loose fasteners. Refer to Fastener Tightening Specifications . Does the drive belt continue to fall off?	Go to Step 9	System OK
9	Test the drive belt tensioner for correct operation. Refer to Drive Belt Tensioner Diagnosis . Does the drive belt tensioner operate correctly?	Go to Step 11	Go to Step 10
10	Replace the drive belt tensioner. Refer to Drive Belt Tensioner Replacement - Accessory or Drive Belt Tensioner Replacement - Air Conditioning . Does the drive belt continue to fall off?	Go to Step 11	System OK
11	Inspect for a failed drive belt idler and/or tensioner pulley bearing. Did you find and repair the condition?	Go to Step 12
12	Run the engine in order to verify the repair. Does the drive belt still fall off?		System OK

NOTE
Do not use belt dressing on the drive belt. Belt dressing causes the breakdown of the composition of the drive belt. Failure to follow this recommendation will damage the drive belt.

Drive Belt Falls Off Diagnosis

Excessive wear on a drive belt(s) is usually caused by incorrect installation or the incorrect drive belt(s) for the application.

Minor misalignment of the accessory drive pulley(s) will not cause excessive wear, but will probably cause the drive belt(s) to make a noise or fall off.

Excessive misalignment of the accessory drive pulley(s) will cause excessive wear and may also make the drive belt(s) fall off.

The number(s) below refer to the step(s) in the diagnostic table.

2: This inspection is to verify that the drive belt(s) is correctly installed on all of the accessory drive pulleys. Wear on the drive belt(s) may be caused by mis-positioning the drive belt(s) by one or more grooves on a pulley(s).
3: The installation of a drive belt(s) that is too wide or too narrow will cause wear on the drive belt(s). The drive belt(s) ribs should match all of the grooves on the pulleys.
4: This inspection is to verify that the drive belt(s) is not contacting any part of the engine or body while the engine is operating. There should be sufficient clearance when the 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.

Step	Action	Yes	No
NOTE: Do not use belt dressing on the drive belt. Belt dressing causes the breakdown of the composition of the drive belt. Failure to follow this recommendation will damage the drive belt. DEFINITION: Wear at the outside ribs of the drive belt(s) due to incorrect installation of the drive belt(s).
1	Did you review the Symptoms - Engine Mechanical diagnostic information, and perform the necessary inspections?	Go to Step 2	Go to Symptoms - Engine Mechanical
2	Inspect the drive belt(s) for proper installation. Is the drive belt(s) installed properly?	Go to Step 5	Go to Step 3
3	Inspect for the correct drive belt(s). Is the correct drive belt installed?	Go to Step 5	Go to Step 4
4	Inspect the drive belt(s) for signs of rubbing against a bracket, hose, or wiring harness. Was the drive belt(s) rubbing against anything?	Go to Step 5	Go to Diagnostic Aids
5	Replace the drive belt(s). Refer to Drive Belt Replacement - Accessory or Drive Belt Replacement - Air Conditioning . Did you complete the replacement?	Go to Step 6
6	Run the engine in order to verify the repair. Is there still excessive drive belt wear?		System OK

NOTE
Do not use belt dressing on the drive belt. Belt dressing causes the breakdown of the composition of the drive belt. Failure to follow this recommendation will damage the drive belt.

Drive Belt Excessive Wear Diagnosis

Scheme 111

Scheme 111: Inspection Procedure

Remove the drive belt. Refer to «Drive Belt Replacement - Accessory»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical/#engine-mechanical-removal-installation-1-of-3-48l-53l-60l) or «Drive Belt Replacement - Air Conditioning»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical/#engine-mechanical-removal-installation-1-of-3-48l-53l-60l) .
Move the drive belt tensioner through its full travel. The movement should feel smooth. There should be no binding. The tensioner should return freely.
If any binding is observed, replace the drive belt tensioner. Refer to «Drive Belt Tensioner Replacement - Accessory»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical/#engine-mechanical-removal-installation-1-of-3-48l-53l-60l) or «Drive Belt Tensioner Replacement - Air Conditioning»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical/#engine-mechanical-removal-installation-1-of-3-48l-53l-60l) .
Install the drive belt. Refer to of «Drive Belt Replacement - Accessory»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical/#engine-mechanical-removal-installation-1-of-3-48l-53l-60l) or «Drive Belt Replacement - Air Conditioning»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical/#engine-mechanical-removal-installation-1-of-3-48l-53l-60l) .

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 equipped The air compressor, if equipped

The drive belt system may use 1 belt or 2 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 pulleys. 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.

Engine Component Description

The 4.8, 5.3, and 6.0 Liter V8 engines are identified as RPO LR4 VIN V (4.8L), RPO LM7 VIN T (5.3L) and RPO LQ4 VIN U (6.0L).

Scheme 112

Scheme 112: Engine Component Description

Camshaft and Drive System

A billet steel one piece camshaft is supported by five bearings pressed into the engine block. The camshaft has a machined camshaft sensor reluctor ring incorporated between the fourth and fifth bearing journals. The camshaft timing sprocket is mounted to the front of the camshaft and is driven by the crankshaft sprocket through the camshaft timing chain. The splined crankshaft sprocket is positioned to the crankshaft by a key and keyway. The crankshaft sprocket splines drive the oil pump driven gear. A retaining plate mounted to the front of the engine block maintains camshaft location.

Crankshaft

The crankshaft is cast nodular iron. The crankshaft is supported by five crankshaft bearings. The bearings are retained by crankshaft bearing caps which are machined with the engine block for proper alignment and clearance. The crankshaft journals are undercut and rolled. The center main journal is the thrust journal. A crankshaft position reluctor ring is press fit mounted at the rear of the crankshaft. The reluctor ring is not serviceable separately. All crankshafts will have a short rear flange, at the crankshaft rear oil seal area. Certain 4.8L and 6.0L applications require a spacer between the rear of the crankshaft and the flywheel for proper flywheel positioning. Longer bolts are required in applications using the spacer.

Cylinder Heads

The cylinder heads are cast aluminum and have pressed in place powdered metal valve guides and valve seats. Passages for the engine coolant air bleed system are at the front of each cylinder head. The valve rocker arm covers are retained to the cylinder head by four center mounted rocker arm cover bolts.

Engine Block

The engine block is a cam-in-block deep skirt 90 degree V configuration with five crankshaft bearing caps. The engine block is cast iron. The five crankshaft bearing caps each have four vertical M10 and two horizontal M8 mounting bolts. The camshaft is supported by five camshaft bearings pressed into the block. First design engine blocks have different drill and tap depths using both medium length 100 mm (3.94 in) and long 155 mm (6.1 in) M11 cylinder head bolts. Second design engine blocks use only the medium length 100 mm (3.94 in) bolt with a common drill and tap depth.

Exhaust Manifolds

The exhaust manifolds are a one piece cast iron design. The exhaust manifolds direct exhaust gasses from the combustion chambers to the exhaust system. Each manifold also has an externally mounted heat shield that is retained by bolts.

Intake Manifold

The intake manifold is a one piece composite design that incorporates brass threaded inserts for mounting the fuel rail, throttle cable bracket, throttle body, evaporative emission (EVAP) solenoid and wire harness stud. Each side of the intake manifold is sealed to the cylinder head by a nonreusable silicone sealing gasket and nylon carrier assembly. The cable actuated throttle body bolts to the front of the intake manifold. The throttle body is sealed by a one piece push in place silicone gasket. The fuel rail assembly with eight separate fuel injectors is retained to the intake by four bolts. The injectors are seated into their individual manifold bores with O-ring seals to provide sealing. A fuel rail stop bracket is retained to the rear of the left cylinder head by a mounting bolt. The manifold absolute pressure (MAP) sensor is installed and retained to the top rear of the intake manifold and sealed by an O-ring seal. The EVAP solenoid is mounted to the top front of the intake manifold and retained by one bolt. There are no coolant passages within the intake manifold.

Oil Pan

The structural oil pan is cast aluminum. Incorporated into the design are the oil filter mounting boss, drain plug opening, oil level sensor mounting bore, and oil pan baffle. The oil pan transfer cover and oil level sensor mount to the sides of the oil pan. The alignment of the structural oil pan to the rear of the engine block and transmission bell housing is critical.

Piston and Connecting Rod Assembly

The pistons are cast aluminum. The pistons use 2 compression rings and a 3-piece oil control ring assembly. The piston is a low friction, lightweight design with a barrel shaped skirt. All applications use pistons with graphite-coated skirts. The piston pins are chromium steel. First design applications use a piston pin that is floating fit to the piston and press fit to the connecting rod. Second design applications use a pin that is full-floating to both the piston and connecting rod. The connecting rods are powdered metal. The connecting rods are fractured at the connecting rod journal and then machined for the proper clearance. The first design piston, pin, and connecting rod are to be serviced as an assembly.

Valve Rocker Arm Cover Assemblies

The valve rocker arm covers are cast aluminum and use a pre-molded silicon gasket for sealing. Mounted to each rocker cover are the coil and bracket assemblies. Incorporated into the left cover is the positive crankcase ventilation (PCV) system passage. Incorporated into the right cover is the oil fill tube and engine fresh air passage.

Valve Train

Motion is transmitted from the camshaft through the hydraulic roller valve lifters and tubular pushrods to the roller type rocker arms. The nylon valve lifter guides position and retain the valve lifters. The valve rocker arms for each bank of cylinders are mounted on pedestals, pivot supports. Each rocker arm is retained on the pivot support and cylinder head by a bolt. Valve lash is net build.

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

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
A component comparison from the previous year

Torque Values and/or Fastener Tightening Strategies

All fasteners and threaded holes on the 4.8/5.3/6.0 liter engines utilize metric threads.
Cylinder head, connecting rod, crankshaft balancer, and main bearing cap bolts now apply a torque angle strategy.
Certain fasteners should not be used again. Bolts, studs, or other fasteners that must be replaced will be called out in the specific service procedure.
First design engine blocks cylinder head bolts have different torque/angle specifications using both medium length 100 mm (3.94 in) and long 155 mm (6.1 in) M11 cylinder head bolts. Second design engine blocks use only the medium length 100 mm (3.94 in) bolt with a common torque/angle specification.
Refer to «Fastener Tightening Specifications»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical/#engine-mechanical-48l-53l-60l-introduction__fastener-tightening-specifications) and «Thread Repair Specifications»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical/#engine-mechanical-48l-53l-60l-introduction) .

Disassembly and Assembly Procedure Revisions

For certain applications, a spacer plate has been added between the flywheel and rear of the crankshaft. It is necessary to remove the spacer plate prior to removal and installation of the crankshaft rear oil seal and clutch pilot bearing.
The exhaust gas recirculation (EGR) system has been removed on all applications.
The piston, pin, and connecting rod are to be serviced as an assembly.
Newer design pistons have a graphite coated piston skirt. The coated skirt outside diameter (OD) may be slightly larger than the cylinder bore inside diameter (ID) and the piston assembly may have a slight interference fit to the cylinder bore during initial installation.

Engine Mechanical Diagnostic Procedure Revisions

New Special Tools Required

A variety of new tools have been developed to assist in engine disassembly, assembly, and on-vehicle service.
Angle Meter J 45059 has been developed to provide technicians with a convenient method to tighten bolts that require the torque angle tightening strategy.
Refer to «Special Tools»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical/#engine-mechanical-48l-53l-60l-introduction__special-tools) .

A Component Comparison from the Previous Year

The EGR system has been deleted on all applications.
A spacer plate between the crankshaft and flywheel is required for applications using the 4L80-E transmission.
All 2004 applications use a piston with a graphite coated skirt.
The positive crankcase ventilation (PCV) valve is a fixed orifice type located in the left rocker arm cover.
The fuel rails for all engine applications are returnless fuel systems. The fuel pressure regulator is now a part of the fuel pump module.
First design applications use a piston pin that is floating fit to the piston and press fit to the connecting rod. Second design applications use a piston pin that is full-floating to both the piston and connecting rod.
The first design piston, pin, and connecting rod are to be serviced as an assembly.

Lubrication Flow Schematic

Engine lubrication is supplied by a gerotor type oil pump assembly. The pump is mounted on the front of the engine block and driven directly by the crankshaft sprocket. The pump gears rotate and draw oil from the oil pan sump through a pick-up screen and pipe. The oil is pressurized as it passes through the pump and is sent through the engine block oil galleries. Contained within the oil pump assembly is a pressure relief valve that maintains oil pressure within a specified range. Pressurized oil is directed through the lower gallery to the full flow oil filter where harmful contaminants are removed. A bypass valve is incorporated into the oil pan, at the oil filter boss, which will permit oil flow in the event the filter becomes restricted. At the rear of the block, oil is then directed to the upper main oil galleries which are drilled just above the camshaft assembly. From there oil is then directed to the crankshaft and camshaft bearings. Oil that has entered the upper main oil galleries also pressurizes the valve lifter assemblies and is then pumped through the pushrods to lubricate the valve rocker arms and valve stems. Oil returning to the pan is directed by the crankshaft oil deflector. Oil pressure and crankcase level are each monitored by individual sensors.

Scheme 113

Scheme 113: Lubrication Flow Schematic

An external oil cooler is available on certain applications, all 6.0L. Oil is directed from the oil pump, through the lower main oil gallery to the full flow oil filter. Oil is then directed through the oil pan outlet oil gallery, located in the left rear of the oil pan, and to the external oil cooler via a hose assembly. Oil flows through the oil cooler and returns to the engine at the oil pan inlet oil gallery, located in the left rear of the oil pan. Oil is then directed to the upper main oil galleries and the remainder of the engine assembly.

Callout	Component Name
408	Cover Bolt
409	Cover
410	Drive Gear
412	Driven Gear
413	Oil Pump
414	Pressure Relief Valve
415	Pressure Relief Valve Spring
416	Plug

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, they should be marked, organized or retained in a specific order for assembly. Refer to «Separating Parts»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical/#engine-mechanical-48l-53l-60l-introduction__separating-parts) .
At the time of installation, 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. These surfaces should be covered or protected to avoid component damage.
A liberal coating of clean engine oil should be applied to friction areas during assembly.
Proper lubrication will protect and lubricate friction surfaces during initial operation.

Separating Parts

IMPORTANT

Disassembly of the piston, press fit design piston pin, and connecting rod may create scoring or damage to the piston pin and piston pin bore. If the piston, pin, and connecting rod have been disassembled, replace the components as an assembly. Many internal engine components will develop specific wear patterns on their friction surfaces. When disassembling the engine, internal components MUST be separated, marked, or organized in a way to ensure installation to their original location and position.

Separate, mark, or organize the following components

Piston and the piston pin
Piston to the specific cylinder bore
Piston rings to the piston
Connecting rod to the crankshaft journal
Connecting rod to the bearing cap A paint stick or etching/engraving type tool are recommended. Stamping the connecting rod or cap near the bearing bore may affect component geometry.
Crankshaft main and connecting rod bearings
Camshaft and valve lifters
Valve lifters, lifter guides, pushrods and rocker arm assemblies
Valve to the valve guide
Valve spring and shim to the cylinder head location
Engine block main bearing cap location and direction
Oil pump drive and driven gears

Tools Required

J 28410 Gasket Remover. See Special Tools and Equipment .

Gasket Use and Applying Sealants

Do not use any gasket again unless specified.
Gaskets that can be used again will be identified in the service procedure.
Do not apply sealant to any gasket or sealing surface unless called out in the service information.

Separating Components

Use a rubber mallet to separate components.
Bump the part sideways to loosen the components.
Bumping should be done at bends or reinforced areas to prevent distortion of parts.

Cleaning Gasket Surfaces

Remove all gasket and sealing material from the part using the J 28410 or equivalent. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical/#engine-mechanical-48l-53l-60l-introduction) .
Care must be used to avoid gouging or scraping the sealing surfaces.
Do not use any other method or technique to remove sealant or 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 oil. This grit is abrasive and has been known to cause internal engine damage.

Assembling Components

When assembling components, use only the sealant specified or equivalent in the service procedure.
Sealing surfaces should 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.
When applying sealant to a component, apply the amount specified in the service procedure.
Tighten bolts to specifications. Do not overtighten.

Pipe Joint Compound

IMPORTANT

Three types of sealer are commonly used in engines. These are Room Temperature Vulcanizing (RTV) sealer, anaerobic gasket eliminator sealer, and pipe joint compound. The correct sealer and amount must be used in the proper location to prevent oil leaks. DO NOT interchange the 3 types of sealers. Use only the specific sealer or the equivalent as recommended in the service procedure.

Pipe joint compound is a pliable sealer that does not completely harden. This type sealer is used where two non-rigid parts, such as the oil pan and the engine block, are assembled together.
Do not use pipe joint compound in areas where extreme temperatures are expected. These areas include: exhaust manifold, head gasket, or other surfaces where gasket eliminator is specified.
Follow all safety recommendations and directions that are on the container. To remove the sealant or the gasket material, refer to «Replacing Engine Gaskets»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical/#engine-mechanical-48l-53l-60l-introduction) .
Apply the pipe joint compound to a clean surface. Use a bead size or quantity as specified in the procedure. Run the bead to the inside of any bolt holes.
Apply a continuous bead of pipe joint compound to one sealing surface. Sealing surfaces to be resealed must be clean and dry.
Tighten the bolts to specifications. Do not overtighten.

RTV Sealer

RTV sealant hardens when exposed to air. This type sealer is used where two non-rigid parts, such as the intake manifold and the engine block, are assembled together.
Do not use RTV sealant in areas where extreme temperatures are expected. These areas include: exhaust manifold, head gasket, or other surfaces where a gasket eliminator is specified.
Follow all safety recommendations and directions that are on the container. To remove the sealant or the gasket material, refer to «Replacing Engine Gaskets»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical/#engine-mechanical-48l-53l-60l-introduction) .
Apply RTV to a clean surface. Use a bead size as specified in the procedure. Run the bead to the inside of any bolt holes.
Assemble components while RTV is still wet, within 3 minutes. Do not wait for RTV to skin over.
Tighten bolts to specifications. Do not overtighten.

Anaerobic Sealer

Anaerobic gasket eliminator hardens in the absence of air. This type sealer is used where two rigid parts, such as castings, are assembled together. When two rigid parts are disassembled and no sealer or gasket is readily noticeable, the parts were probably assembled using a gasket eliminator.
Follow all safety recommendations and directions that are on the container. To remove the sealant or the gasket material, refer to «Replacing Engine Gaskets»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical/#engine-mechanical-48l-53l-60l-introduction) .
Apply a continuous bead of gasket eliminator to one flange. Surfaces to be sealed must be clean and dry.
Spread the sealer evenly with your finger to get a uniform coating on the sealing surface.
Tighten bolts to specifications. Do not overtighten.
After properly tightening the fasteners, remove the excess sealer from the outside of the joint.

Tools and Equipment

Special tools are listed and illustrated throughout this section with a complete listing at the end of the section. These tools, or their equivalents, are specially designed to quickly and safely accomplish the operations for which they are intended. The use of these 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

Special Tools

Special Tools Illustration Tool Number/Description J 3049-A Valve Lifter Remover J 6125-1B Slide Hammer J 7872 Magnetic Base Dial Indicator Set J 8001 Dial Indicator Set J 8037 Piston Ring Compressor J 8062 Valve Spring Compressor - Head Off-Vehicle J 8087 Cylinder Bore Gage J 8089 Carbon Removal Brush J 8433-1 Puller Bar J 8520 Camshaft Lobe Lift Dial Indicator Set J 9666 Valve Spring Tester J 21366 Converter Holding Strap J 21867 Pressure Gage J 22794 Spark Plug Port Adapter J 24086-9 Adjustable Installer J 24086-10 Piston Pin Remover Installer Base J 24086-C Piston Pin Remover/Installer Set J 24270 Cylinder Ridge Remover J 28410 Gasket Remover J 28428-E High-Intensity Black Light Kit J 33049 Camshaft Bearing Service Set J 35667-A Cylinder Leakdown Tester J 37378-1 Valve Guide Reamer J 38185 Hose Clamp Pliers J 38606 Valve Spring Compressor J 41476 Front and Rear Cover Alignment Tool J 41478 Crankshaft Front Oil Seal Installer J 41479 Crankshaft Rear Oil Seal Installer J 41480 Front and Rear Cover Alignment J 41556 Connecting Rod Guide J 41558 Crankshaft Sprocket Remover J 41665 Crankshaft Balancer and Sprocket Installer J 41712 Oil Pressure Switch Socket J 41798 Engine Lifting Brackets J 41816 Crankshaft Balancer Remover J 41816-2 Crankshaft End Protector J 41818 Crankshaft Bearing Cap Remover J 42078 Valve Spring Tester J 42385-100 Thread Repair Kit - Cylinder Head/Main Bearing Bolt J 42385-200 Thread Repair Kit - General Threads J 42385-300 Thread Repair Kit - Fixtures and Hardware J 42386-A Flywheel Holding Tool J 42451-1 Engine Support Adapter J 42907 Oil Pressure Testing Tool J 43690 Rod Bearing Checking Tool J 43690-100 Rod Bearing Checking Tool - Adapter Kit J 45059 Angle Meter J 45299 Engine Preluber