Engine Mechanical - 6.6l (4 of 5) Chevrolet Chevy Express H1500

Oil Filter Adapter and Oil Cooler Assembly Removal

1. Remove the engine coolant pipe.
2. Remove the engine coolant pipe O-ring and discard.
3. Remove the five oil filter adapter and oil cooler assembly bolts.
4. Remove the oil filter adapter and oil cooler assembly.

Tools Required

J 44644 Crankshaft Front Oil Seal Remover. See Special Tools .

1. Install the J 44644 to the crankshaft front oil seal. See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) .
2. Remove crankshaft front oil seal using J 44644 . See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) .

J 37228 Seal Cutter. See Special Tools .

1. Remove the crankshaft position sensor bolt.
2. Remove the crankshaft position sensor.
3. Remove the engine front cover bolts.
4. Separate the engine front cover from the cylinder block using J 37228 . See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) .
5. Remove the engine front cover.

Oil Pump Pipe and Screen Assembly Removal

1. Remove the oil pump pipe and screen assembly bolts and nuts.
2. Remove the oil pump pipe and screen assembly.
3. Remove the oil pump pipe and screen assembly gasket and discard.

Piston Oil Cooling Nozzle Removal

1. Rotate crankshaft as necessary to obtain access to piston oil cooling nozzles.
2. Remove the piston oil cooling nozzle eye bolt.
3. Remove the piston oil cooling nozzle.

J 24270 Ridge Reamer

1. Rotate the crankshaft to place the piston at the bottom of the piston stroke.
2. Place a cloth on top of the piston.
3. Use the J 24270 to remove the ridge at the top of the cylinder bore.
4. Remove cloth.
5. Remove cutting debris from the cylinder and piston.
6. Remove the connecting rod cap bolts. Set the bolts aside for use in plastic gauging if needed. New bolts will be used for final assembly.
7. Remove the connecting rod cap.
8. Remove the bearing insert from connecting rod.
9. Push piston assembly out of cylinder.
10. Reassemble the connecting rod bearing, cap, and bolts upon removal.

J 7872 Dial Indicator Set.

1. Measure the camshaft end play using J 7872 . The production value is 0.050-0.114 mm (0.002-0.0045 in) and service limit is 0.20 mm (0.008 in). Replace the camshaft or the camshaft thrust plate if the measured value exceeds the service limit.
2. Block the crankshaft from turning with a wooden handle.
3. Loosen the camshaft gear bolt and leave the bolt finger tight.
4. Remove the camshaft exciter ring bolts.
5. Remove the camshaft exciter ring.
6. Align the threaded hole with a suitable tool and install an exciter ring bolt to secure the spring tension.
7. Remove the camshaft thrust plate bolts through the holes in the camshaft gear.
8. Remove the camshaft with the camshaft gear attached.
9. Remove the camshaft gear bolt and washer.
10. Remove the camshaft gear.
11. Remove the camshaft thrust plate.

J 7872 Dial Indicator Set

1. Remove the oil pressure sensor.
2. Measure crankshaft end play using J 7872 . The production value is 0.04-0.205 mm (0.0016-0.0081 in) and the service limit is 0.54 mm (0.0213 in). Replace the thrust bearings upon reassembly if the measured value exceeds the service limit.
3. Remove the crankshaft bearing cap side bolts.
4. Remove the crankshaft bearing cap bolts.
5. Remove the crankshaft bearing caps.
6. Set the bolts aside for use in plastic gauging if needed.
7. Remove the crankshaft assembly.
8. Remove the crankshaft bearings from the engine block and the bearing caps.
9. Mark crankshaft bearings and caps so they may be installed in their original position.

Engine Block Cleaning and Inspection

Engine Block Cleaning and Inspection

1. Inspect the block for stampings (1) indicating cylinder overbore or a milled deck.
2. Remove the engine block heater.
3. Remove the O-ring from the block heater and discard.
4. Remove the oil gallery plugs.
5. Remove the left engine mount bolts.
6. Remove the left engine mount.
7. Remove the right engine mount bolts.
8. Remove the right engine mount.
9. Clean the sealing material from the gasket mating surfaces of the block.
10. Clean the block in cleaning solvent.
11. Flush the engine block with clean water or steam.
12. Clean the oil passages.
13. Clean the cylinder bores.
14. Inspect the block for cracks. Use the Magnaflux Spot check dye method, or the equivalent. Inspect the cylinder walls. Inspect the coolant jackets. Inspect the crankshaft bearing webs.
15. Inspect the crankshaft bearing bores and caps. The crankshaft bearing bore inside diameters should be round and uniform at all of the bearing supports.
16. Inspect the area where the crankshaft bearing inserts contact the crankshaft bearing bore. This area must be free of burrs and scratches.
17. Inspect the engine mount bosses.
18. Inspect the cylinder head gasket mating surfaces for pitting.
19. Inspect the engine block to cylinder head gasket surface area for warping. Use a straight edge and feeler gauge. Replace the block if it is warped more than 0.15 mm (0.006 in) longitudinally or more than 0.08 mm (0.003 in) transversely.
20. Apply sealer to the oil gallery plugs.
21. Install the oil gallery plugs. Tighten: Tighten the oil gallery plugs to 53 N.m (39 lb ft).
22. Install the left engine block coolant plugs. Tighten: Tighten the left engine block coolant plugs to 18 N.m (13 lb ft).
23. Install the right engine block coolant plugs. Tighten: Tighten the right engine block coolant plugs to 18 N.m (13 lb ft).
24. Install the left engine mount and engine mount bolts. Tighten: Tighten the engine mount bolts to 58 N.m (43 lb ft).
25. Install the right engine mount and engine mount bolts. Tighten: Tighten the right engine mount bolts to 58 N.m (43 lb ft).
26. Install a new O-ring to the block heater.
27. Lubricate the O-ring with engine coolant.
28. Install the engine block heater.

Upper Oil Pan Cleaning and Inspection

1. Clean the upper oil pan.
2. Carefully clean the sealer from the threaded holes.
3. Inspect the upper oil pan for cracks.
4. Inspect the upper oil pan sealing surfaces for damage.
5. Replace the upper oil pan if any damage is found.

J 7872 Dial Indicator Set

1. Clean the camshaft.
2. Visually inspect the camshaft bearings in the engine block for the following conditions: Scoring Nicks Damage caused by lack of lubrication Misaligned oil feed holes
3. Measure the camshaft journal diameter. The production value is 60.932-60.962 mm (2.3990-2.4001 in) and service limit is 60.920 mm (2.3984 in). Replace the camshaft if the measured value is less than service limit.
4. Measure the camshaft lobe lift. The production value for intake is 7.273 mm (0.2863 in).
5. The production value for exhaust is 5.907 mm (0.2326 in).
6. Replace the camshaft if the measured value is less than the service limit.
7. Measure the camshaft runout. Mount the camshaft on the V-blocks. Use J 7872 to measure the camshaft runout. The runout service limit is 0.05 mm (0.0020 in).
8. Replace the camshaft if the run-out is over the service limit.

Crankshaft and Bearings Cleaning and Inspection

1. J 7872 Dial Indicator Set
2. J 45059 Angle Meter

1. Clean the crankshaft and bearings.
2. Inspect the crankshaft for the following conditions. Excessive wear or damage on the surface of the crankshaft journals. Excessive wear or damage to the crankshaft gear. Excessive wear or damage on the oil seal fitting surface. Inspect the oil ports for obstructions. Replace the crankshaft if there is excessive wear or damage to the journals, oil seal fitting surface or to the crankshaft gear.
3. Measure the crankshaft run out. Mount the crankshaft in wooden V-blocks. Set J 7872 on the center of the crankshaft journal. Turn the crankshaft in the normal direction of rotation. Record readings. The production value is 0.05 mm (0.0020 in) and the service limit is 0.44 mm (0.0173 in).
4. Measure the crankshaft journal diameter across four points. The crankshaft journal outside diameter is 79.905-79.925 mm (3.1459-3.1466 in) and the service limit is 79.89 mm (3.1453 in). Replace the crankshaft if the measured value is less than the service limit.
5. Measure the crankpin outside diameter across four points. The crankpin outside diameter is 62.902-62.922 mm (2.4765-2.4772 in) and the service limit is 62.88 mm (2.4756 in). Replace the crankshaft if the measured value is less than the service limit.

Crankshaft Bearing Selection

There are two methods for selecting the proper size crankshaft bearings. The first one is to select the bearing grade (color code) based on the cylinder block grade and the crankshaft journal grade from the Crankshaft Bearing Grade chart. The second is the plastic gauge method.

Crankshaft Bearing Selection Grade Chart Method

Crankshaft and Bearings Cleaning and Inspection

1. Inspect the crankshaft for stamping (1) indicating undersized main and/or rod journals.
2. The cylinder block grade is indicated on the right lower portion of the cylinder block.
3. The crankshaft journal grade is indicated on the number 1 crankshaft counterweight.
4. Match the cylinder block grade and the crankshaft journal grade, refer to «Crankshaft Bearings Selection Specifications»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__crankshaft-bearings-selection-specifications) .
5. From the Crankshaft Bearing Grade chart, determine which bearing grade (color code) is required.
6. Verify the crankshaft bearing clearance using the plastic gage method.

J 45059 Angle Meter

1. Clean the cylinder block bearing fitting surfaces.
2. Clean the crankshaft and upper bearings (1) and lower bearings (2).
3. Install the bearings into the cylinder block and the bearing caps.
4. Install the crankshaft into the cylinder block.
5. Rotate the crankshaft approximately 30 degrees to seat the bearings.
6. Place the plastic gage over the crankshaft journal across the full width of the bearing. Note: Do not allow the crankshaft to rotate at any time during bearing cap installation and tightening or the plastic gauge measurement will be inaccurate.
7. Install the crankshaft bearing caps.
8. Install the crankshaft bearing cap bolts.
9. Tighten the crankshaft bearing cap bolts in the proper sequence. Tighten: 1st step 98 N.m (72 lb ft). 2nd step 132 N.m (97 lb ft). 3rd step 30 degrees using J 45059 .
10. Install the crankshaft bearing cap side bolts. Tighten: Tighten the crankshaft bearing cap side bolts in the proper sequence to 70 N.m (52 lb ft).
11. Remove the crankshaft bearing cap bolts.
12. Remove the crankshaft bearing caps.
13. Compare the width of the plastic gauge with the scale printed on the plastic gauge container.
14. Select the crankshaft bearing grade that provides the proper oil clearances. The production specification for crankshaft bearing clearance is 0.039-0.070 mm (0.0015-0.0028 in) and the service limit is 0.014 mm (0.0055 in).

Crankshaft Balancer Cleaning and Inspection

1. Clean the crankshaft balancer.
2. Inspect the crankshaft balancer for damage to belt drive surface and to crankshaft balancer hub.
3. Inspect the balancer hub groove for damage or wear.
4. Replace the crankshaft balancer if any concerns exist.

Engine Flywheel Cleaning and Inspection

1. Clean the flywheel assembly.
2. Inspect the flywheel assembly for cracks or excessive wear on the teeth.
3. Replace the flywheel assembly if any concerns exist.

J 43654 Piston Pin Retainer Remover/Installer. See Special Tools .

1. Mark orientation of the piston to the connecting rod.
2. Remove the piston rings using a piston ring expander.
3. Remove the connecting rod bearing inserts.
4. Use J 43654 to remove the piston pin retainers. See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) .
5. Remove the piston pin. The pin is a full-floating style and should slide from the piston.
6. Remove the piston from the connecting rod.

Piston, Connecting Rod, and Bearings Cleaning and Inspection

1. Clean the deposits from the following components: Connecting rod and bearings Piston Piston pin
2. Inspect the piston for the following conditions: Scoring on the piston skirt (2) Scoring in the piston pin area (3) Cracks (1) Broken ring groove lands
3. Measure the piston ring end gap. Use a piston to square the piston ring near the top of the cylinder. Use a feeler gauge to measure the piston ring gap. The 1st compression ring production gap is 0.30-0.45 mm (0.0118-0.0177 in) and the service limit is 1.37 mm (0.0539 in). The 2nd compression ring production gap is 0.50-0.65 mm (0.0197-0.0256 in) and the service limit is 1.35 mm (0.0531 in). The oil ring production gap is 0.15-0.35 mm (0.0059-0.0138 in) and the service limit is 1.20 mm (0.0472 in). Replace the piston ring if the measured value exceeds the service limit.
4. Measure the piston ring to piston ring groove clearance. Use a feeler gauge to measure the clearance between the piston ring and the piston ring groove at several points around the piston. The 1st compression ring production clearance is 0.08-0.17 mm (0.0030-0.0007 in) and the service limit is 0.26 mm (0.0102 in). The 2nd compression ring production clearance is 0.01-0.03 mm (0.0004-0.0012 in) and the service limit is 0.10 mm (0.0039 in). The oil ring production clearance is 0.01-0.03 mm (0.0004-0.0012 in) and the service limit is 0.12 mm (0.0047 in). Replace the piston ring if the measured value exceeds the service limit.
5. Measure the piston pin outside diameter. Measure the piston pin outside diameter at several points. The production value is 34.495-34.50 mm (1.3581-1.3563 in) and the service limit is 34.450 mm (1.3563 in). Replace the piston pin if the measured value is less than the service limit.
6. Measure the piston pin to piston pin bore clearance. Measure the piston pin bore. Subtract the piston pin measurement that was taken previously from the piston pin bore measurement. The difference between these two measurements will be the piston pin to piston pin bore clearance. The production clearance is 0.004-0.017 mm (0.0002-0.0007 in) and the service limit is 0.017 mm (0.0007 in). If the piston pin to piston pin bore clearance is beyond specifications then replace the piston.
7. Measure the piston pin to connecting rod small end clearance. Measure the inside diameter of the connecting rod small end. Subtract the piston pin measurement that was taken previously from the connecting rod small end measurement. The difference between these two measurements will be the piston pin to connecting rod clearance. The production clearance is 0.012-0.027 mm (0.0005-0.0011 in) and the service limit is 0.08 mm (0.0031 in). Replace the connecting rod if the piston pin to connecting rod small end clearance is beyond specifications. The connecting rod small end bushing is not serviceable.

J 43654 Piston Pin Retainer Remover/Installer. See Special Tools .

1. Apply engine oil to the connecting rod small end bushing and to the piston pin bore of the piston.
2. Install the piston pin into the piston and connecting rod.
3. Install the piston pin retaining rings.
4. Apply engine oil to the piston ring grooves.
5. Install the piston rings using a piston ring expander.
6. Orientate the piston ring end gaps as illustrated.

J 8062 Valve Spring Compressor

J 38820 Valve Stem Oil Seal Remover. See Special Tools .

1. Use the J 8062 to compress the valve spring.
2. Remove the valve keys (1).
3. Remove the J 8062 from the cylinder head.
4. Remove the valve spring upper seat (2).
5. Remove the valve spring (3).
6. Remove the valve (6).
7. Remove the valve stem seal (4) using J 38820 . See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) .
8. Remove the valve spring lower seat (5).

J 9666 Valve Spring Tester

1. Clean the cylinder head of all foreign material. Do not use a motorized wire brush on any gasket sealing surface.
2. Clean the threaded holes.
3. Inspect the cylinder head for the following: Damage to the gasket surfaces Damage to the threaded bolt holes Cracks in the exhaust ports External cracks in the water chamber Cracks between the valve seats Restrictions in the intake or exhaust passages Restrictions in the cooling system passages Rusted, damaged or leaking core plugs
4. Measure the cylinder head for warpage with a straight edge and a feeler gauge. A cylinder head block deck with warpage in excess of 0.075 mm (0.0030 in) within a 516.5 mm (20.33 in) area must be replaced.
5. Measure the cylinder head exhaust manifold deck for warpage. A cylinder head exhaust manifold deck with warpage in excess of 0.1 mm (0.0039 in) within a 453 mm (17.83 in) area must be replaced.
6. Measure the cylinder head intake manifold deck for warpage. A cylinder head intake manifold deck with warpage in excess of 0.3 mm (0.011 in) within a 493 mm (19.41 in) area must be replaced.
7. Measure the valve spring tension using J 9666 . Replace the valve spring if the valve spring tension is less than 315.5 N (7.09 lb) at 41 mm (1.6142 in)
8. Measure the valve spring for squareness. Replace the valve spring if squareness is beyond 2.0 mm (0.0787 in).
9. Measure the valve spring free length. The production free length is 56.6 mm (2.2283 in).
10. Measure the valve stem to guide clearance. Set a dial indicator to the valve stem measuring point. Move the valve stem from side to side while reading the total movement on the dial indicator. If the measured valve exceeds 0.20 mm (0.0079 in), replace the cylinder head.
11. If the valve stem to guide clearance is over 0.25 mm (0.098 in) for the exhaust valve guides or 0.20 mm (0.0079 in) for the intake valve guides, the cylinder head must be replaced.
12. Inspect the valves for the following: Bent valve stem Scored valve stem Worn valve key grooves Pitted surfaces
13. Measure the valve margin. The intake valve production margin is 1.2 mm (0.0472 in) and the service limit is 0.88 mm (0.0346 in). The exhaust valve production margin is 1.0 mm (0.0394 in) and the service limit is 0.73 mm (0.0287 in). Replace the valve if the valve margin is below the service limit.
14. Measure the valve depression. Insert a new valve into the cylinder head (1). Use a depth gauge or a straight edge to measure the valve depression from the cylinder head gasket surface (2). The intake valve depression is 0.6 mm (0.0236 in) and the service limit is 2.5 mm (0.0984 in). The exhaust valve depression is 0.9 mm (0.0354 in) and the service limit is 2.0 mm (0.0787 in). Recondition the valve seat if the valve depression is above specifications.
15. Measure the valve contact width. Inspect the valve contact area for roughness or unevenness. The intake valve contact width is 2.1 mm (0.0827 in) and the service limit is 2.5 mm (0.0984 in). The exhaust valve contact width is 2.1 mm (0.0827 in) and the service limit is 2.5 mm (0.0984 in). Recondition the valve seats to bring the contact width into specifications.

Valve and Seat Grinding

1. Remove the carbon from the valve guide and valve seat surface.
2. Resurface the valve face to 45 degrees. If valve margin falls below specifications after resurfacing then discard valve.
3. Use a suitable tool to bring the valve contact width to the standard value. The valve seat angle is 45 degrees.
4. Apply valve lapping compound to the valve seat surface.
5. Insert the valve into the cylinder head.
6. Turn the valve back and forth in its seat to lap the valve face to the valve seat.

Cylinder Head Assemble

Tools Required

1. J 44640 Valve Stem Seal Installer. See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) .
2. J 8062 Valve Spring Compressor

1. Install the valves into the cylinder head.
2. Install the valve spring lower seat.
3. Install the valve stem seal using J 44640 . See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) .
4. Install the valve spring with the painted end towards the cylinder head.
5. Install the valve spring upper seat.
6. Use the J 8062 to compress the valve spring.
7. Install the valve keys.
8. Remove the J 8062 from the cylinder head.
9. Measure the valve installed height using a ruler. Measure from the base of the valve spring to the top of the valve. Refer to «Engine Mechanical Specifications»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__engine-mechanical-specifications) .
10. Install the remaining valves, springs, and other components.

Valve Lifters Cleaning and Inspection

1. Push the roller towards the roller lifter body and measure the distance between the bottom of the roller and the roller lifter body. The production value is 0.989-1.0 mm (0.0389-0.0394 in) and the service limit is 0.9 mm (0.0354 in).
2. Replace the valve lifter if the measurement exceeds the service limit.
3. Inspect the valve lifters for the following: The valve lifter body for scuffing and wear The valve lifter roller assembly for wear The valve lifter roller for smooth rotation

Valve Rocker Arm and Shaft Cleaning and Inspection

1. Measure the rocker arm shaft outside diameter where the rocker arm is located. The production value is 21.979-22.0 mm (0.8653-0.8661 in) and the service limit is 21.85 mm (0.8602 in).
2. Replace the rocker arm shaft if the measured value is less than the service limit.
3. Measure the rocker arm inside diameter. The production value is 22.01-22.035 mm (0.8665-0.8675 in).
4. Calculate the rocker arm shaft to rocker arm clearance. Subtract the rocker arm shaft outside diameter from the rocker arm inside diameter. Replace the rocker arm if the rocker arm shaft to rocker arm clearance is over 0.2 mm (0.0079 in).
5. Inspect the valve lash adjusting screw and lock nut for damage. Replace the valve lash adjusting screw if any damage is found.
6. Measure the pushrods for warpage.
7. Replace the pushrod if the warpage exceeds 0.8 mm (0.031 in).

Piston Oil Cooling Nozzle Cleaning and Inspection

1. Inspect the piston oil cooling nozzle for damage.
2. Replace the piston oil cooling nozzle if any damage is found.

Oil Pump Cleaning and Inspection

1. Remove the oil pump gear cover bolts.
2. Remove the oil pump gear cover.
3. Use a feeler gauge to measure the clearance between the gear teeth and the oil pump housing. The production clearance is 0.125-0.221 mm (0.0049-0.0087 in) and the service limit is 0.221 mm (0.0087 in).
4. Replace the oil pump assembly if the clearance exceeds the service limit.
5. Use a feeler gauge and a straightedge to measure the clearance between the side of the gear and the cover. The production clearance is 0.064-0.109 mm (0.0025-0.0043 in) and the service limit is 0.109 mm (0.0043 in).
6. Replace the oil pump assembly if the clearance exceeds the service limit.
7. Calculate the driven gear shaft to bushing clearance. Measure the driven gear shaft outside diameter. The production specification is 19.947-19.960 mm (0.7853-0.7858 in) and the service limit is 19.86 mm (0.7819 in). Measure the driven gear bushing inside diameter. The production value is 20 mm (0.7874 in). Calculate the driven gear shaft to bushing clearance. The service limit is 0.14 mm (0.0055 in)
8. Replace the oil pump assembly if the clearance exceeds the service limit.
9. Install the oil pump gear cover to the oil pump assembly.
10. Install the oil pump gear cover bolts. Tighten: Tighten the oil pump gear cover bolts to 21 N.m (15 lb ft).

Engine Front Cover Cleaning and Inspection

1. Remove the O-ring (1) from the engine front cover.
2. Remove the oil pressure relief valve from the engine front cover.
3. Clean the engine front cover.
4. Clean the engine front cover mating surfaces.
5. Inspect the engine front cover mating surfaces for damage.
6. Inspect the engine front cover O-ring sealing surface for damage.
7. Inspect the crankshaft front oil seal bore for damage.
8. Replace the engine front cover if any damage is found.
9. Install the oil pressure relief valve with a new O-ring. Tighten: Tighten the oil pressure relief valve to 39 N.m (29 lb ft).

Lower Oil Pan Cleaning and Inspection

1. Remove the oil level sensor (1) and retaining clip (3).
2. Clean the lower oil pan (4). Remove any sludge or other deposits.
3. Clean the lower oil pan mating surface.
4. Inspect the lower oil pan (4) for dents or distortion.
5. Inspect the lower oil pan mating surface for damage.
6. Replace the lower oil pan (4) if any damage is found.
7. Install the oil level sensor (1) and retaining clip (3).

Valve Rocker Arm Cover Cleaning and Inspection - Lower

1. Remove the grommets.
2. Clean the lower valve rocker arm cover. Remove any sludge or other deposits.
3. Clean the lower valve rocker arm cover mating surfaces.
4. Inspect the lower valve rocker arm cover for cracks or other damage.
5. Inspect the lower valve rocker arm cover mating surfaces for damage.
6. Replace the lower valve rocker arm cover if any damage is found.
7. Inspect the grommets for damage.
8. Replace the grommets if any damage is found.
9. Install the grommets.

Valve Rocker Arm Cover Cleaning and Inspection - Upper

1. Remove the PCV cover screws.
2. Remove the PCV cover, diaphragm, and spring.
3. Clean the upper valve rocker arm cover. Remove any sludge or other deposits.
4. Clean the upper valve rocker arm cover mating surface.
5. Inspect the upper valve rocker arm cover for cracks or other damage.
6. Inspect the upper valve rocker arm cover mating surfaces for damage.
7. Replace the upper valve rocker arm cover if any damage is found.
8. Inspect the PCV cover, diaphragm, and spring for damage.
9. Install the PCV spring.
10. Install the PCV diaphragm.
11. Install the PCV cover.
12. Install the PCV cover screws. Tighten: Tighten the PCV cover screws to 4 N.m (35 lb in).

Intake Manifold Cleaning and Inspection

1. Clean the intake manifold crossover.
2. Clean the intake manifold mating surfaces.
3. Clean the intake manifolds.
4. Clean the intake manifold mating surfaces.
5. Inspect the intake manifolds for cracks.
6. Inspect the intake manifold mating surfaces for damage.
7. Replace the intake manifolds if any damage is found.

Oil Filter Adapter and Oil Cooler Assembly Cleaning and Inspection

1. Clean the coolant tube.
2. Inspect the coolant tube for cracks.
3. Inspect the coolant tube mating surfaces for damage.
4. Clean the oil filter adapter.
5. Inspect the oil filter adapter mating surfaces for damage.
6. Replace the O-rings.

Engine Coolant Thermostat Housing Cleaning and Inspection

1. Clean the thermostat housing.
2. Clean the thermostat housing mating surfaces.
3. Inspect the thermostat housing for cracks.
4. Inspect the thermostat housing mating surfaces for damage.
5. Replace the thermostat housing if any damage is found.

Exhaust Manifold Cleaning and Inspection

1. Clean the exhaust manifold.
2. Clean the exhaust manifold mating surfaces.
3. Inspect the exhaust manifold for cracks.
4. Inspect the exhaust manifold mating surfaces for damage.
5. Replace the exhaust manifold if any damage is found.
6. Measure the exhaust manifold flange for warpage with feeler gauge and a straightedge. Replace the exhaust manifold if the warpage is more than 0.3 mm (0.0118 in).
7. Install the exhaust manifold heat shield.
8. Install the exhaust manifold heat shield bolts. Tighten: Tighten the exhaust manifold heat shield bolts to 8 N.m (71 lb in).

Exhaust Pipe Cleaning and Inspection

1. Clean the exhaust pipe.
2. Clean the exhaust pipe mating surfaces.
3. Inspect the exhaust pipe for dents or cracks.
4. Replace the exhaust pipe if any damage is found.

Exhaust Outlet Cleaning and Inspection

1. Clean the exhaust outlet.
2. Clean the exhaust outlet mating surfaces.
3. Inspect the exhaust outlet for dents or cracks.
4. Replace the exhaust outlet if any damage is found.

Fuel Injection Pump Cleaning and Inspection

1. Remove the fuel injection pump adapter bolts.
2. Remove the fuel injection pump adapter.
3. Remove the O-ring from the fuel injection pump and discard.
4. Remove the O-ring from the fuel injection pump adapter and discard.
5. Clean the fuel injection pump adapter mating surfaces.
6. Clean the fuel injection pump mating surfaces.
7. Inspect the fuel injection pump and adapter for damage.
8. Replace component if any damage is found.
9. Install a new O-ring onto fuel injection pump.
10. Install a new O-ring onto fuel injection pump adapter.
11. Lubricate the O-rings with engine oil.
12. Install the fuel injection pump adapter to the fuel injection pump.
13. Install the fuel injection pump adapter bolts. Tighten: Tighten the fuel injection pump adapter bolts to 21 N.m (15 lb ft).

Fuel Injector Cleaning and Inspection

1. Use a soft bristle non-metallic brush and top engine cleaner, GM P/N 1052626 or equivalent, to remove any deposits from the nozzle tip (1) and the copper washer sealing area (2) before reinstallation.
2. Inspect the fuel injector nozzle tip (1) for cracks, dents, or other damage.
3. Inspect the nozzle tip (1) for any signs of discoloration - dark yellow, tan, or blue due to excessive heat.
4. Replace the injector if any damage is found.
5. Clean the fuel injector high pressure line.
6. Inspect the fuel injector high pressure line for excessive corrosion or damage to the sealing surfaces (1, 2). Replace the line if any damage is found.

Turbocharger Cleaning and Inspection

Completely inspect the turbocharger and all other engine components that may cause similar conditions before replacing the turbocharger.

Use the following information to diagnose problems caused by the turbocharger.

The turbocharger is serviced as a complete unit.

1. Remove the turbocharger oil return pipe bolts.
2. Remove the turbocharger oil return pipe and gasket.
3. Clean mating surfaces.
4. Inspect for damage to the compressor wheel, compared to a normal compressor wheel.
5. Inspect for damage to the compressor wheel, by a soft object.
6. Inspect for damage to the compressor wheel, by a hard object.
7. Inspect compressor blades for heavy rubbing. Ensure that the following conditions do not exist on the compressor wheel blades: Cracks Bends Erosion of the blades Broken blades
8. Check the housing for signs of rubbing.
9. Install the turbocharger oil return pipe and new gasket.
10. Install the turbocharger oil return pipe bolts. Tighten: Tighten the turbocharger oil return pipe bolts to 21 N.m (15 lb ft).
11. Inspect the coolant outlet lines for damage.
12. Clean the turbocharger inlet duct.
13. Clean the turbocharger inlet duct mating surfaces.
14. Inspect the turbocharger inlet duct for cracks.
15. Inspect the turbocharger inlet duct mating surfaces for damage.
16. Replace the turbocharger inlet duct if any damage is found. Tighten: Tighten the inlet duct clamp to 5 N.m (44 lb in).

Engine Flywheel Housing Cleaning and Inspection

1. Remove the O-rings from the flywheel housing and discard.
2. Clean the flywheel housing.
3. Clean the flywheel housing mating surfaces.
4. Clean the flywheel housing O-ring sealing area.
5. Inspect the flywheel housing for cracks.
6. Inspect the flywheel housing mating surfaces for damage.
7. Inspect the crankshaft rear oil seal bore for damage.
8. Replace the flywheel housing if any damage is found.

Water Pump Cleaning and Inspection

1. Remove the O-ring from the water pump and discard.
2. Remove the water pump to water pump housing bolts.
3. Remove the water pump from the water pump housing.
4. Remove the O-ring from the water pump housing and discard.
5. Clean the water pump assembly.
6. Clean the water pump mating surfaces.
7. Inspect the water pump gear for damage.
8. Inspect the water pump mating surfaces for damage.
9. Inspect the water pump shaft for looseness.
10. Inspect the water pump assembly for damage.
11. Replace the water pump if any damage is found.
12. Install a new O-ring to the water pump housing.
13. Lubricate the O-ring with engine coolant.
14. Install the water pump to the water pump housing.
15. Install the water pump to water pump housing bolts. Tighten: Tighten the water pump to water pump housing bolts to 21 N.m (15 lb ft).
16. Install a new O-ring to the water pump.

Exhaust Gas Recirculation Cooler Cleaning and Inspection

1. Remove the exhaust gas recirculation (EGR) cooling hoses.
2. Clean and inspect the EGR gasket surfaces.
3. Clean and inspect the EGR and cooler.
4. Replace the EGR or cooler if damaged.

Thread Repair

General purpose thread repair kits are available commercially.

1. Determine the size, the pitch, and the depth of the damaged thread.
2. Adjust the stop collars on the cutting tool as needed. Tap the stop collars to the required depth.
3. Drill out the damaged thread.
4. Remove the chips.
5. Apply clean engine oil to the top thread.
6. Use the tap in order to cut new thread.
7. Clean the thread.
8. Screw the thread insert onto the mandrel of the thread insert installer. Engage the tang of the thread insert onto the end of the mandrel.
9. Lubricate the thread insert with clean engine oil - except when installing in aluminum - and install the thread insert.
10. If the tang of the thread insert does not break off when backing out the thread insert installer, break off the tang using a drift punch.

Scheme 151

The torque of a fuel line fitting is critical to prevent fuel leaks in a high pressure direct injection fuel system. The preferred method is through the use of a flare nut socket. With the use of a flare nut socket, the torque wrench can be set to the listed torque specification. Refer to Fastener Tightening Specifications .

If a crows foot is used to torque the fuel lines, then special attention to the position of the crows foot in relation to the torque wrench is required.

1. If the crows foot is kept perpendicular (90 degrees) to the torque wrench during the entire tightening procedure, then the torque wrench can be set to the listed torque specification. Refer to «Fastener Tightening Specifications»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__fastener-tightening-specifications) .
2. If the crows foot is positioned straight with the torque wrench, then the torque setting needs to be corrected to compensate for the increased leverage.
3. If the crows foot is held at any position other than 90 degrees or inline to the wrench, more complex corrections of the torque setting are required, and therefore, positioning the crows foot in this manner is not recommended.

If it is necessary to position a crows foot in line with the torque wrench, the procedure for adjusting the torque specification is as follows

1. Measure the distance between the center of the crows foot wrench end to the center of the square drive hole.
2. Measure the length of the torque wrench from the center of the square drive to the center of the handle.
3. Divide the measurement of the crows foot length by the torque wrench length. This figure is the percentage of additional torque, over the torque wrench setting, that will be applied to the fitting.
4. Subtract the results of step 3 from the number 1. This figure is the percentage of the listed torque specification that the torque wrench should be set to.
5. Multiply the results of step 4 by the listed torque setting. Refer to «Fastener Tightening Specifications»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__fastener-tightening-specifications) . This figure is the proper setting the torque wrench should be set at when using a crows foot in line with the torque wrench.

Example

1. Crows foot measurement = 25 mm (1.0 in)
2. Torque wrench measurement = 355 mm (14.0 in)
3. 25 mm/355 mm (1.0 in/14.0 in) = 0.07, or 7 %
4. 1 - 0.07 = 0.93, or 93 %
5. 0.93 x 41 N.m (30 lb ft) = 38 N.m (28 lb ft)

Service Prior to Assembly

1. Dirt will cause premature wear of the rebuilt engine. Clean all the components.
2. Use the proper tools to measure the components when checking for excessive wear. Components not within the manufacturer's specification must be repaired or replaced.
3. When the components are reinstalled into an engine, return the components to their original location, position, and direction.
4. During assembly, lubricate all the moving parts with clean engine oil (unless otherwise specified). This will provide initial lubrication when the engine is first started.

J 45059 Angle Meter

1. Install the upper crankshaft bearings into the cylinder block. The bearing halves to be inserted into the crankshaft main bearing saddle have a wide groove and oil hole in the center of the bearing (1).
2. Install the lower crankshaft bearings into the crankshaft bearing caps. The bearing halves to be inserted into the crankshaft main bearing caps do NOT have an oil hole or groove in the bearing (2).
3. Install the upper thrust bearings to the cylinder block. There are 2 thrust bearings (1 and 3) in the cylinder block and one lower thrust bearing in the No. 5 crankshaft bearing cap (2).
4. Lubricate the crankshaft bearing surfaces with engine oil.
5. Install the crankshaft into the cylinder block.
6. Install the No. 5 crankshaft bearing cap with the lower thrust bearing (2).
7. Install the remaining 4 crankshaft bearing caps.
8. Install the NEW crankshaft bearing cap bolts.
9. Tighten the crankshaft bearing cap bolts in the proper sequence. Tighten: 1st step 98 N.m (72 lb ft). 2nd step 132 N.m (97 lb ft). 3rd step 30 degrees using J 45059 .
10. Clean the crankshaft bearing side cap bolt threads, sealing flange and mounting holes with GM P/N 12377981 (Canadian P/N 10953463) or equivalent. Dry the bolts and mounting holes with compressed air.
11. Apply GM P/N 12346004 (Canadian P/N 10953480) to the threads and sealing flange of the bolts.
12. Install the ten bolts. Tighten: Tighten the crankshaft bearing cap side bolts to 70 N.m (52 lb ft).
13. Install the oil pressure sensor. Tighten: Tighten the oil pressure sensor to 41 N.m (30 lb ft).

J 7872 Dial Indicator Set

1. Install the camshaft thrust plate to the camshaft.
2. Install the camshaft driven gear.
3. Install a new camshaft driven gear bolt. Leave the bolt finger tight.
4. Install the camshaft and gear assembly into the cylinder block, aligning the camshaft gear to the crankshaft gear as shown.
5. Install the camshaft thrust plate bolts. Tighten: Tighten the camshaft thrust plate bolts to 22 N.m (16 lb ft).
6. Install the camshaft position sensor exciter ring to the camshaft gear.
7. Install the camshaft position sensor exciter ring bolts. Tighten: Tighten the camshaft position sensor exciter ring bolts to 9 N.m (80 lb in).
8. Block the crankshaft from turning using a wooden handle.
9. Install the new camshaft gear bolt. Tighten: Tighten the new camshaft gear bolt to 234 N.m (173 lb ft).
10. Measure the camshaft end play with J 7872 . The production value is 0.050-0.114 mm (0.0020-0.0045 in) and service limit is 0.2 mm (0.0079 in). Replace the camshaft gear or the camshaft thrust plate if measured value exceeds the service limit.

Piston, Connecting Rod, and Bearing Installation

Tools Required

1. J 8037 Piston Ring Compressor
2. J 45059 Angle Meter

1. Select the connecting rod bearing according to the «Connecting Rod Bearings Selection Specifications»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__connecting-rod-bearings-selection-specifications) chart.
2. Position the crankshaft so the connecting rod journal is opposite the piston and connecting rod assembly being installed.
3. Install the connecting rod bearing inserts.
4. Lubricate the cylinder wall and piston rings with engine oil.
5. Install the J 8037 to the piston to compress the piston rings.
6. Orientate the piston front mark and the piston inside mark to the engine block.
7. Push the piston and connecting rod assembly into the engine.
8. Install the gauging plastic onto the connecting rod journal. Install the gauging plastic the full width of the journal.
9. Install the connecting rod cap with its stamped cylinder number aligned with the stamped cylinder number on the connecting rod.
10. Install the original connecting rod cap bolts for the plastic gauging. NEW bolts will be used for final assembly.
11. Tighten the bolts in three steps. Tighten: 1st step 64 N.m (47 lb ft) 2nd step 30 degrees using J 45059 3rd step 30 degrees using J 45059
12. Remove the connecting rod cap bolts.
13. Compare the width of the gauging plastic with the scale printed on the gauging plastic container. The connecting rod bearing clearance should be 0.10 mm (0.0039 in).
14. Discard the original connecting rod bolts once the plastic gauging is completed. NEW connecting rod bolts will be used for final assembly.
15. Carefully clean the gauging plastic from the bearing surface and the crankpin.
16. Lubricate the connecting rod bearing inserts with engine oil.
17. Install the connecting rod caps with the stamped cylinder number aligned with the stamped cylinder number on the connecting rods.
18. Install NEW connecting rod cap bolts.
19. Tighten the connecting rod cap bolts in three steps. Tighten: 1st step 64 N.m (47 lb ft) 2nd step 30 degrees using J 45059 3rd step 30 degrees using J 45059

Piston Oil Cooling Nozzle Installation

1. Install the piston oil cooling nozzle.
2. Install the piston oil cooling nozzle bolt. Tighten: Tighten the piston oil cooling nozzle bolts to 21 N.m (15 lb ft).

Oil Pump Installation

1. Install a new O-ring to the engine block.
2. Lubricate the O-ring with engine oil.
3. Install the oil pump.
4. Install the oil pump bolts. Tighten: Tighten the oil pump bolts to 21 N.m (15 lb ft).
5. Install the oil pump drive gear and crank sensor reluctor assembly.
6. Install the oil pump driven gear.
7. While holding the secondary oil pump shaft with a hex driver, install the oil pump driven gear nut. Tighten: Tighten the oil pump driven gear nut to 100 N.m (74 lb ft).

Oil Pump Pipe and Screen Assembly Installation

1. Install the oil pump pipe and screen gasket.
2. Install the oil pump pipe and screen.
3. Install the oil pump pipe and screen assembly bolts and nuts. Tighten: Tighten the oil pump pipe and screen assembly bolts to 25 N.m (18 lb ft). Tighten the oil pump pipe and screen assembly nuts to 25 N.m (18 lb ft).

See also:
• Special Tools
• Crankshaft Bearings Selection Specifications
• Engine Mechanical Specifications
• Fastener Tightening Specifications
• Connecting Rod Bearings Selection Specifications