4.3L v6 - VIN [Z] Chevrolet Chevy Van G10

ENGINE IDENTIFICATION

Note. For engine repair procedures not covered in this article, see ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION article in the GENERAL INFORMATION section.

Engine can be identified by eighth character of Vehicle Identification Number (VIN). VIN is located on a metal tag on top left corner of instrument panel. Engine identification number is stamped on a machined pad on front of cylinder block, immediately forward of right cylinder head.

ENGINE IDENTIFICATION CODES

VALVE ARRANGEMENT

1. Left Bank - E-I-E-I-I-E (Front-to-rear).
2. Right Bank - E-I-I-E-I-E (Front-to-rear).

VALVE CLEARANCE ADJUSTMENT

1. Rotate engine until No. 1 piston is on TDC of compression stroke. With piston in this position, adjust valves listed in the VALVE CLEARANCE ADJUSTMENT table.
2. Loosen rocker arm adjusting nut until lash is present. Tighten adjusting nut until lash is removed and push rod will not rotate. When lash is removed, tighten adjusting nut one full turn.
3. Rotate crankshaft 360 degrees to bring No. 4 piston of compression stroke. Adjust remaining valves. See VALVE CLEARANCE ADJUSTMENT table.

VALVE CLEARANCE ADJUSTMENT

FUEL PRESSURE RELEASE

These engines use the model 220 TBI system. This system contains an internal constant bleed feature that relieves system pressure when ignition switch is turned OFF.

Before beginning work of fuel system components, disconnect negative battery cable and loosen fuel tank cap to relieve tank pressure. No further pressure relief is required.

TROUBLE SHOOTING

Note. To trouble shoot engine mechanical components, see appropriate table in TROUBLE SHOOTING article in GENERAL INFORMATION.

ENGINE

Note. See ENGINE article.

Removal

1. Place transmission gear selector in Park (Neutral on manual transmissions). Set parking brake and block drive wheels. Although fuel pressure drops to zero when ignition is turned off, loosen fuel filler cap to relieve tank pressure. To further minimize risk of fire and personal injury, cover surrounding areas with a shop rag while removing fuel lines. WARNING: Although fuel pressure drops to zero when ignition is turned off, loosen fuel filler cap to relieve tank pressure. To further minimize risk of fire and personal injury, cover surrounding areas with a shop rag while removing fuel lines.
2. Disconnect negative battery cable. Remove engine cover and air injection crossover hose. Remove air cleaner. Drain cooling system. Label and disconnect necessary brackets, wires and hoses. Disconnect fuel lines and linkages.
3. Remove distributor cap. With chalk or crayon, mark relationship of distributor rotor and housing to a stationary reference point in engine compartment. If distributor is aligned properly upon installation, and if crankshaft is not rotated while engine is apart, engine timing will not need to be reset.
4. Remove brake booster vacuum pipe. Remove A/C pump bracket and alternator bracket. Remove throttle body (if necessary). Remove manifold bolts. Remove intake manifold and gaskets.

Scheme 15

1. Install gaskets on cylinder head, noting rear location of coolant passage restriction and any special instructions included in gasket set.
2. Apply 3/16" bead of silicone sealer at front and rear intake manifold mounting surface of cylinder block. (Scheme 15) Extend bead of sealer 1/2" up each cylinder head.
3. Install intake manifold. Install manifold retaining bolts. Tighten bolts in sequence to specification. (Scheme 16) See the TORQUE SPECIFICATIONS table in this article. To complete installation, reverse removal procedure.

Scheme 16

Remove heat stove tube. Remove all attached brackets and heat shields. It may be necessary to remove dip stick tube. Disconnect oxygen sensor wire. Disconnect exhaust pipe from manifold. Bend over lock tabs (if equipped). Remove retaining bolts and exhaust manifold.

Installation

Clean all mating surfaces. Install manifold. Tighten bolts to specification. See appropriate TORQUE SPECIFICATIONS table in this article. Bend over lock tabs (if equipped). To complete installation, reverse removal procedure.

1. Place transmission gear selector in Park (Neutral on manual transmissions). Set parking brake and block drive wheels. Although fuel pressure drops to zero when ignition is turned off, loosen fuel filler cap to relieve tank pressure. To further minimize risk of fire and personal injury, cover surrounding areas with a shop rag while removing fuel lines. WARNING: To avoid possible personal injury and fire danger, fuel pressure must be relieved as outlined in step 1).
2. Disconnect negative battery cable. Drain cooling system, including block. Remove intake and exhaust manifolds as previously described. Remove A/C compressor and bracket (if equipped). Disconnect wiring and hoses from cylinder heads. Remove alternator, spark plugs and valve covers.
3. Loosen rocker arm nuts and rotate rocker arms to side. Remove push rods in sequence and mark for reassembly in original locations. Remove cylinder head bolts. Remove cylinder heads.

1. Clean all gasket surfaces and head bolt holes. On steel head gaskets, apply thin coat of sealer to both sides of gasket. DO NOT use sealer on steel/asbestos gaskets.
2. Position gaskets on cylinder block with bead facing upward. Ensure all holes align. Install cylinder heads. Coat threads of head bolts with Sealant (1052080).
3. Install and tighten head bolts in sequence. (Scheme 17) Tighten head bolts to specification. See appropriate TORQUE SPECIFICATIONS table in this article. To complete installation, reverse removal procedure. Lubricate valve tip, rocker arm pivot and push rod socket with Molykote before installation. Adjust valves. See VALVE CLEARANCE ADJUSTMENT in this article.

Scheme 17

1. Disconnect negative battery cable at battery. Drain cooling system. If necessary, remove radiator shroud. Remove all accessory drive belts, fan and pulley.
2. Remove vibration damper retaining bolt. Using Damper Puller/Installer (J-23523-E), remove vibration damper. Remove all mounting brackets and coolant hoses attached to water pump. Remove water pump. Remove oil pan. See OIL PAN REMOVAL article. Remove front cover, timing tab (if equipped) and gasket.

Note. If timing cover alignment dowels can be removed, cover can possibly be removed and installed without removing oil pan. Replace dowel pins with cover installed and aligned. DO NOT leave dowel pins out or oil leaks will result.

1. Install gasket on front cover with gasket sealer. Install cover and timing tab (if equipped) on engine block. Tighten bolts to specification. See appropriate TORQUE SPECIFICATIONS table in this article. Install vibration damper using damper puller/installer.
2. Before installing vibration damper retaining bolt, apply small amount of RTV sealant at crankshaft Woodruff key and vibration damper. Install retaining bolt. Tighten to specification. Reverse removal procedure to install remaining components. Tighten bolts to specification. See TORQUE SPECIFICATIONS table in this article.

Remove drive belts. Remove pulley. Remove vibration damper retaining bolt. Using Damper Puller/Installer (J-23523-E), remove vibration damper. Pry seal from cover with screwdriver. Do not damage front cover.

1. Using Seal Installer (J-35468), install new seal in front cover. Seal lip must face toward engine. Coat seal lip with engine oil. Install vibration damper.
2. Before installing vibration damper retaining bolt, apply small amount of RTV sealant at crankshaft Woodruff key and vibration damper. Install retaining bolt and tighten to specification. Reverse removal procedure to install remaining components. Tighten all bolts to specification. See TORQUE SPECIFICATIONS table in this article.

Remove engine front cover as previously described. Crank engine over until timing marks on camshaft and crankshaft sprockets are aligned. Remove camshaft sprocket and timing chain. If crankshaft sprocket replacement is necessary, use Sprocket Puller (J-5825-A) to remove sprocket.

1. Install Woodruff key in crankshaft (if removed). Using Crankshaft Sprocket Installer (J-5590), install crankshaft sprocket on crankshaft. Install camshaft sprocket and timing chain.
2. Ensure timing marks on sprockets are aligned. (Scheme 18) Install and tighten sprocket bolts to specification. Reverse removal procedure to install remaining components. Tighten all bolts to specification. See appropriate TORQUE SPECIFICATIONS table in this article.

Scheme 18

Disconnect negative battery cable at battery. Drain cooling system. Remove all drive belts, coolant hoses and mounting brackets attached to water pump. If necessary, remove fan shroud. Remove fan and pulley. Remove water pump and gaskets.

Clean all gasket surfaces. Using new gaskets, install and tighten water pump bolts to specification. See appropriate TORQUE SPECIFICATIONS table in this article. Install remaining components in reverse order of removal.

Note. For further information on cooling systems, see appropriate ENGINE COOLING article.

OIL PAN

See appropriate OIL PAN REMOVAL & INSTALLATION article at end of ENGINES.

ROCKER ARM STUDS

Rocker arm studs are a press-fit in cylinder head. Studs which are loose in head or have damaged threads can be replaced using oversize studs. Oversize studs are available in .003" (.08 mm) and .013" (.33 mm).

Removal & Installation

1. Using Stud Remover (J-5802-01), place remover over stud. Install nut and flat washer. Tighten nut to remove stud from cylinder head. Ream hole for oversize stud.
2. Use Reamer (J-5715) for .003" (.08 mm) and Reamer (J-6036) for .013" (.33 mm) oversize replacement studs. Coat press-fit area of stud with hypoid axle lubricant.
3. Using Stud Driver (J-6880), drive stud in cylinder head. Proper stud height is obtained when driver bottoms against cylinder head.

Remove intake manifold. See INTAKE MANIFOLD in this article. Remove valve covers. Loosen all rocker arm nuts and rotate rockers to one side. Remove push rods and lifters. Remove lifter retainer plate then remove lifters. Mark location for reassembly reference.

1. Remove intake manifold, engine front cover, timing chain and camshaft sprocket as previously described. Remove valve covers. Loosen all rocker arm nuts and rotate rockers to one side. Remove push rods and lifters. Remove lifter retainer plate then remove lifters. Mark location for reassembly reference.
2. Remove radiator and grille. Remove thrust plate retaining screws. Reinstall cam gear for ease in handling. Remove camshaft.

Cleaning & Inspection

Clean all components with clean solvent. Inspect camshaft lobes for signs of flaking or flat spots. Measure camshaft. Replace camshaft if not within specification. See CAMSHAFT in ENGINE SPECIFICATIONS tables at end of this article.

1. Coat camshaft lobes and journals with engine oil supplement. Install cam gear for ease in handling. Install camshaft. Remove cam gear, install thrust plate and retaining screws. Tighten to specification.
2. Temporarily place camshaft sprocket on camshaft and align timing marks. Remove sprocket. Install camshaft sprocket and chain. Tighten camshaft sprocket bolts to specification.
3. Lubricate timing chain with engine oil. When installing new camshaft, install new lifters, change oil and filter. Reverse removal procedure to install remaining components. Tighten all bolts to specification. See TORQUE SPECIFICATIONS table in this article. Adjust valves. See VALVE CLEARANCE ADJUSTMENT in this article.

CAM LOBE LIFT

1. Remove valve cover and rocker arm assembly. Using Lobe Lift Indicator (J-8520), mount dial indicator on cylinder head. Position dial indicator and ball socket adapter on push rod.
2. Slowly rotate engine in direction of rotation until lifter is on base circle of camshaft. This is lowest reading. Adjust dial indicator to zero. Rotate engine until push rod is fully raised and note reading.
3. Compare reading with specification. See CAMSHAFT SPECIFICATIONS under ENGINE SPECIFICATIONS at end of article. Replace camshaft and lifters if not within specification.

1. Remove engine. See ENGINE REMOVAL & INSTALLATION article. Remove oil pan, oil pump, flywheel, timing cover and chain. Remove crankshaft. Remove camshaft. Push pistons to top of bore. Using Bearing Remover/Installer (J-6098-01), remove camshaft bearings.
2. Install front and rear camshaft bearings first, to act as guides for remover/installer pilot. Ensure bearing oil passages are aligned with oil passages in block. Use 3/32" diameter round stock to check oil passage alignment. Coat camshaft rear bore plug with sealer. Install plug even to 1/32" below engine block surface.

Remove transmission, clutch (if equipped) and flywheel. Install the screwdriver in the notches located on rear seal retainer. (Scheme 19) Pry seal from retainer. Note direction of seal lip.

Scheme 19

1. Ensure all surfaces are clean. Lubricate inner and outer seal area with engine oil. Place seal on Seal Installer (J-35621). Place seal installer against crankshaft.
2. Thread attaching screws in crankshaft. (Scheme 19) Tighten screws to square seal with crankshaft. Rotate handle until it bottoms. Remove seal installer. Install flywheel, clutch and transmission.

VALVES

Oversized valve stems are available for worn valve guides.

VALVE SEATS

No replacement procedure given by manufacturer.

VALVE SPRINGS

Valve spring free length and tension should be checked before installation. See VALVE & VALVE SPRINGS in ENGINE SPECIFICATIONS tables at end of article for specifications.

VALVE SPRING INSTALLED HEIGHT

Installed valve spring height must be checked. If installed height exceeds specifications, shim to meet specifications. See VALVES & VALVE SPRINGS in ENGINE SPECIFICATIONS tables.

VALVE STEM OIL SEALS

Oversized valve stem oil seals are used for oversized valves. Intake and exhaust valve stem oil seals are different.

VALVE GUIDES

Check valve stem-to-guide clearance. Oversize valves must be used if not within specification. See CYLINDER HEAD under ENGINE SPECIFICATIONS tables at end of article. Valves with oversize stems are available.

Oversized valve stem oil seals are used for oversized valves. Intake and exhaust valve stem oil seals are different.

SEAT CORRECTION ANGLES

If seat width is too wide, use 20 degree and 70 degree stone for seat adjustment. The 20 degree stone will lower the seat and the 70 degree will raise the seat.

ROCKER ARM ASSEMBLY

Clean push rods, rocker arms, balls and nuts with solvent and blow dry. Inspect rocker arms and balls at mating surface. The surface should be smooth and free of damage. Inspect push rods for bends or wear. Ensure oil passages are clear.

Remove intake manifold and cylinder head as previously described. Remove oil pan and oil pump. Ensure rods and rod caps are marked for cylinder location. Remove cylinder ridge. Remove piston and rod assembly.

Scheme 20

1. Properly position rings on piston. (Scheme 20) Ensure notch in top of piston is toward front of engine.
2. Check connecting rod side clearance. Connecting rod side clearance must be within specification. See ENGINE SPECIFICATIONS tables at end of this article. Ensure crankshaft turns smoothly.

Piston pins are press-fit in connecting rod. Remove snap rings from piston. Using an arbor press, press piston pin from piston and connecting rod. Note location of piston notches or valve area in relation to rod bearing tangs.

Inspection

Measure piston pin diameter, piston pin bore diameter and connecting rod pin bore. Determine piston pin clearance for piston and connecting rod. Replace piston, piston pin or connecting rod if not within specification. See PISTONS, PINS & RINGS in ENGINE SPECIFICATIONS tables at end of this article.

Lubricate piston pin holes in piston and connecting rod with engine oil. Install piston on connecting rod with valve areas opposite rod bearing tangs. Using arbor press, press piston pin into piston and connecting rod. Install snap rings. Check piston for freedom of movement on piston pin.

FITTING PISTONS

Determine cylinder taper, wear, out-of-round and piston clearance. For cylinder specifications see CYLINDER BLOCK and PISTONS, PINS & RINGS in ENGINE SPECIFICATIONS table at end of this article. If taper or out-of-round are not within limits, hone or bore cylinders for installation of new pistons.

PISTON RINGS

Check piston ring end gap and side clearance to prevent ring damage. If ring gap is not within specifications, try another ring set. See PISTONS, PINS & RINGS in ENGINE SPECIFICATIONS tables at end of this article.

ROD BEARINGS

1. Prior to removal, ensure rod caps are marked for cylinder identification. Remove rod cap and bearings. Inspect bearings for wear or damage and replace as necessary.
2. Check crankshaft rod bearing journal for out-of-round or taper. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS in ENGINE SPECIFICATIONS table at end of this article.
3. Measure bearing clearance using Plastigage method. See CRANKSHAFT MAIN & CONNECTING ROD BEARINGS in ENGINE SPECIFICATIONS at end of article for bearing clearance.
4. If clearance exceeds specifications, undersize bearings possibly can be used in combination to produce correct clearance. If clearance is still excessive, crankshaft must be reconditioned.
5. Clean crankshaft journal and bearing surface in rod. Insert bearings in rod and cap, then lubricate bearing surfaces with oil. Pull piston and rod assembly down onto crankshaft.
6. Install cap and tighten to specification. Check connecting rod side clearance. For specification, see CRANKSHAFT MAIN & CONNECTING ROD BEARINGS table in ENGINE SPECIFICATIONS at end of article.

CRANKSHAFT & MAIN BEARINGS

1. Remove oil pan. See OIL PAN REMOVAL & INSTALLATION article. Remove bearing cap. Use Plastigage method to check bearing clearance.
2. Mark main bearing caps for identification so caps are replaced in same direction and location. Remove main bearings from cylinder block by inserting bearing Remover/Installer (J-8080) in crankshaft oil hole. Rotate crankshaft to "roll" bearing out. If remover/installer is unavailable, use a bent cotter pin.
3. To install upper bearing half, lubricate journal and bearing. Insert plain end of bearing (the end without bearing tang) between crankshaft and notched side of block. With bearing remover/installer in crankshaft oil hole, rotate crankshaft to install bearing.
4. Install lower bearing half into cap and lubricate with engine oil. Install and tighten main bearing cap with arrow pointing toward front of engine.

Note. Procedure describes main bearing removal and installation with engine in vehicle. Measure and change bearings one journal at a time.

THRUST BEARING ALIGNMENT

1. Ensure all main bearing caps, except rear main (thrust) bearing, are installed and tightened to specification. See TORQUE SPECIFICATIONS table in this article. Temporarily tighten rear main bearing cap bolts to 10 ft. lbs. (14 N.m).
2. Tap end of crankshaft back and forth to line up main bearing and crankshaft thrust surfaces. Tighten thrust bearing cap to specification. Retighten all main bearing cap bolts to specification, including thrust bearing. Rotate crankshaft to confirm free movement.

Note. Some engines may contain a wide main bearing thrust face, identified by .008" stamped on rear counterweight. During replacement, ensure proper bearings are used.

CRANKSHAFT END PLAY

With all main bearings installed and torqued to specification, pry crankshaft toward front of engine and check crankshaft end play. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS in ENGINE SPECIFICATIONS tables at end of this article.

CYLINDER BLOCK

Using feeler gauge and straightedge, inspect deck surface for warpage. Replace cylinder block if more than .010" (.25 mm) material is removed from deck surface.

ENGINE OILING SYSTEM

Gear-type oil pump delivers full pressure lubrication to main oil gallery and through full-flow oil filter. Through drilled passages in block, main oil gallery feeds oil to all crankshaft and camshaft bearings.

Valve lifter oil gallery feeds lifters. From lifters, oil is routed through hollow push rods to upper valve train components. Timing chain and sprockets are lubricated by oil drainage from No. 1 camshaft bearing.

CRANKCASE CAPACITY

Crankcase capacity is 4 qts. (3.8L). Add one additional qt. (.95L) when replacing oil filter.

OIL PRESSURE

Normal oil pressure should be obtained with engine at normal operating temperature and at specified engine RPM. See OIL PRESSURE SPECIFICATIONS table.

OIL PRESSURE SPECIFICATIONS

Remove oil pan. Remove pump-to-rear main bearing cap bolts. Remove pump and baffle (if equipped) and extension shaft.

Disassembly

Remove pump cover. If necessary, remove inlet tube and screen assembly. Mark relationship between gears at a meshing point for reassembly. Remove gears. Remove pressure regulator retaining pin. Remove washer (if equipped), pressure regulator valve and spring.

Inspect pump body and cover for cracks or excessive wear. Inspect pump gears for damage or wear. Check drive gear shaft for looseness in pump body. Check pressure regulator valve for fit in bore. Replace entire pump assembly if damaged. Inspect inlet tube and screen assembly for damage.

Reassembly

Install pump gears into pump body, with marked gear teeth indexing. Idler gear must be installed with smooth side of gear toward cover opening. If inlet tube was removed, apply sealer to end of inlet tube. Tap inlet tube into place using plastic hammer. Reassemble remaining components in reverse order of disassembly. Tighten cover screws to specification. See TORQUE SPECIFICATIONS table in this article.

Prime oil pump with engine oil. Assemble pump and extension shaft to engine. Ensure slot on top of extension shaft engages with drive tang on end of distributor shaft. Install oil pump and baffle (if used). Tighten retaining bolt to specification. See TORQUE SPECIFICATIONS table. Install oil pan.

OIL PRESSURE REGULATOR VALVE

Non-adjustable oil pressure regulator valve is located in pump body.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

GENERAL ENGINE SPECIFICATIONS

GENERAL SPECIFICATIONS

PISTON/PIN/RING SPECIFICATIONS

PISTONS, PINS & RINGS SPECIFICATIONS

BEARING SPECIFICATIONS

CRANKSHAFT MAIN & CONNECTING ROD BEARINGS SPECIFICATIONS

CONNECTING ROD SPECIFICATIONS

CONNECTING ROD SPECIFICATIONS

CYLINDER HEAD SPECIFICATIONS

CYLINDER HEAD SPECIFICATIONS

CYLINDER BLOCK SPECIFICATIONS

CYLINDER BLOCK SPECIFICATIONS

VALVE/VALVE SPRING SPECIFICATIONS

VALVES & VALVE SPRINGS SPECIFICATIONS

CAMSHAFT SPECIFICATIONS

CAMSHAFT

See also:
• ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION