Engine Mechanical 6.5l v8 Diesel - VIN [P] Chevrolet Chevy Van G3500

ENGINE IDENTIFICATION

Engine can be identified by eighth character of Vehicle Identification Number (VIN). VIN is stamped on a metal plate, on top left end of instrument panel, near windshield. See ENGINE IDENTIFICATION CODES table. Engine can also identified by engine identification (ID) number, stamped on cylinder block in one of the following locations

1. On right side of timing chain case casting.
2. On engine-to-transmission mating flange, near left cylinder head.
3. At left front of engine block, near cylinder head-to-block mating surface.

ENGINE IDENTIFICATION CODES

VALVE CLEARANCE ADJUSTMENT

Engine is equipped with non-adjustable hydraulic valve lifters.

INJECTION PUMP TIMING ADJUSTMENT

Note. DTC 88 indicates incorrect pump timing.

Preliminary Information (Timing Marks)

Look for timing marks where injection pump flange mates with engine front cover. At the factory, a static timing mark (straight line) and a dynamic timing mark (oval) are scribed in this area.

Replacement pumps do not have a dynamic timing mark on them. Some replacement pumps have a static timing mark. If replacement pump has a static timing mark on it, align static marks during installation. If replacement pump does not have a static timing mark on it, scribe one on it (you will need it for movement reference during adjustment procedure).

Preliminary Information (Rotating Pump)

Use Injector Pump Rotator (J-29872) to rotate pump. If you rotate the pump one millimeter, the timing changes by about 2 degrees. Correct timing is 3.5 degrees BTDC (before TDC).

1. To advance timing, rotate pump toward passenger's side.
2. To retard timing, rotate pump toward driver's side.

Adjustment Procedure

1. Connect Tech 1 scan tool. Run engine at idle until warm. Leave engine running. Select OUTPUT TEST/INJ PUMP. Select TDC TIME SET.
2. If engine does not stall, go to next step. If engine stalls, loosen pump nuts. Slightly rotate pump toward driver's side of vehicle. Tighten nuts. Repeat step 1). NOTE: To observe MEASURED INJ TIM, engine must be running. MEASURED INJ TIM will fluctuate; this is normal.
3. In TDC TIME SET mode, the value of DESIRED INJ TIM displayed on Tech 1 will be "0". Observe MEASURED INJ TIM value (this is the current timing). If timing is not 3.5 degrees BTDC, shut engine off. Loosen pump nuts. Rotate pump as necessary (one mm = 2 degrees). Tighten pump nuts. Start engine. Observe MEASURED INJ TIM value. If necessary, adjust again.

REMOVAL & INSTALLATION

Note. For reassembly reference, label all electrical connectors, vacuum hoses and fuel lines before removal. Also place mating marks on engine hood and other major assemblies before removal.

1. Disconnect batteries. Remove headlight bezels, grille, bumper and lower valance panel. Remove hood latch, coolant recovery bottle, upper fan shroud and tie bar. Remove engine cover. Discharge A/C system using approved refrigerant recovery/recycling equipment, disconnect A/C condenser lines and remove condenser (if equipped).
2. Drain cooling system. Remove radiator, fan and lower shroud. Remove intake manifold. See «INTAKE MANIFOLD»(/chevrolet/chevy-van-g3500/1996-1998/remont/mechanical/#engine-mechanical-65l-v8-diesel-vin-p) . Remove injection pump. See «INJECTION PUMP»(/chevrolet/chevy-van-g3500/1996-1998/remont/mechanical/#engine-mechanical-65l-v8-diesel-vin-p__injection-pump) .
3. Raise and support vehicle. Remove P/S pump with hoses attached and lay aside. Disconnect exhaust pipes from manifolds. Remove flywheel cover and torque converter bolts (A/T). Remove long bolts from engine mounts. Disconnect cylinder block heater wires.
4. Remove starter. Disconnect fuel line from fuel pump. Lower vehicle. Remove bellhousing bolts. Discharge A/C system using approved refrigerant recovery/recycling equipment and remove A/C compressor (if equipped). Remove oil filler tube upper bracket.
5. Disconnect engine harness electrical connectors and lay harness aside. Remove air cleaner resonator and bracket. Remove transmission dipstick tube. Disconnect heater hoses from engine. Remove alternator upper bracket.
6. Remove coolant crossover pipe. Attach Engine Lifting Fixture (J-33888) to center intake manifold bolt holes. Support transmission. Remove engine. To install, reverse removal procedure. Fill cooling system. Evacuate and charge A/C system.

Removal

1. Disconnect batteries. If equipped, remove engine cover or floor panel. Remove air cleaner. Remove clamp at turbocharger connection hose. Run a small flat-blade screwdriver between connection hose and upper intake manifold to loosen silicone sealer. Remove PCV and EGR hoses. Remove fuel line bracket and ground strap. Remove A/C compressor rear bracket (if equipped).
2. Remove EPR/EGR solenoids and bracket. Remove heater hose bracket. Remove crankcase depression relief tube. Upper intake manifold and connection at turbo charger. Remove intake manifold bolts and fuel line clips. Remove intake manifold, gaskets and cover intake ports.

Installation

Install NEW manifold gaskets and intake manifold. Using teflon sealer, seal bolts No. 9, 11, 13 and 15 (exposed to crankcase). Apply threadlock sealer to bolts and studs No. 1-8, 10, 12, 14 and 16. Tighten intake manifold bolts in sequence to specification. (Scheme 44) See TORQUE SPECIFICATIONS. To complete installation, reverse removal procedure.

Scheme 44

Removal (Left Side)

Disconnect batteries. Raise vehicle. Disconnect exhaust pipe from manifold. Lower vehicle. Disconnect glow plug wires and remove plugs. Remove air conditioning bracket (if equipped). Remove dipstick tube (if necessary). Remove left exhaust manifold.

Removal (Right Side)

Disconnect batteries. Remove air cleaner box and intake duct. Raise vehicle. Disconnect exhaust pipe from manifold. Lower vehicle. Using Glow Plug Connector Tool (J39083) disconnect glow plug wires. Using Glow Plug Socket (J41515-A) remove glow plugs. Remove oil feed line and oil return line. Remove all brackets from turbocharger. Remove exhaust manifold and turbocharger assembly.

Install exhaust manifold. Tighten bolts to specification. See TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure.

CYLINDER HEAD

Note. DO NOT pull on glow plug harness wires.

1. Remove intake manifold. See «INTAKE MANIFOLD»(/chevrolet/chevy-van-g3500/1996-1998/remont/mechanical/#engine-mechanical-65l-v8-diesel-vin-p) . Remove injection line clips from brackets. Disconnect injection lines from injector nozzles.
2. Disconnect injection lines from injection pump. Remove injection lines. Remove upper fan shroud. Raise and support vehicle. Disconnect exhaust pipe from manifold. Lower vehicle.
3. Remove valve covers. Mark component location for reassembly reference, including crankshaft position. Remove rocker arm bolts and rocker arm shafts. Note hardened upper end of push rod, indicated by paint stripe. Mark push rods if no paint stripe is visible. Remove push rods.
4. Drain coolant. Remove air cleaner resonator and bracket. Remove transmission fluid and engine oil dipstick tubes. Disconnect necessary coolant hoses. Remove alternator and upper bracket. Remove coolant crossover pipe. Remove power steering pump.
5. Disconnect necessary coolant hoses and ground straps. Remove coolant crossover pipe. Using Glow Plug Connector Tool (J39083), disconnect glow plug wires. Remove cylinder head bolts (rear bolt in left cylinder head may need to remain in head during removal). Remove cylinder head bolts, cylinder head and gasket.

1. Clean cylinder head and cylinder block gasket surfaces. Clean cylinder head bolt thread and bolt holes. Apply Sealant (1052080) to head bolt threads and underside of bolt heads. DO NOT apply sealant to head gasket surface. Install rear head bolt in left cylinder head. Install cylinder head. CAUTION: Install push rods with hardened end (indicated by paint stripe) upward to prevent damaging engine. To prevent valve and piston contact during rocker arm shaft installation, rotate crankshaft until positioned as noted in step 3) before tightening rocker arm shaft bolts.
2. Install head bolts and tighten in sequence to specification. (Scheme 45) See TORQUE SPECIFICATIONS. Install push rods in original location with hardened end upward.
3. Rotate crankshaft until timing mark on crankshaft damper aligns with "0" mark on timing tab, then rotate crankshaft counterclockwise 3 1/2" (estimate this distance by aligning crankshaft damper mark with first lower water pump bolt). (Scheme 50)
4. Install rocker arm shafts, ensuring push rods are seated in rocker arms. Alternately tighten shaft bolts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/chevy-van-g3500/1996-1998/remont/mechanical/#engine-mechanical-65l-v8-diesel-vin-p__torque-specifications). To complete installation, reverse removal procedure.

Scheme 45

Disconnect batteries. Remove drive belts. Raise and support vehicle. Remove crankshaft pulley bolts and pulley. Remove crankshaft damper bolt and washer. Using Damper Puller (J-39046), remove crankshaft damper. Pry seal from cover.

Ensure seal area is free of burrs. Coat seal lip and crankshaft damper sealing surface with engine oil. Install NEW seal using Seal Installer (J-22101). Install crankshaft damper, washer and bolt. Tighten bolt to specification. See TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure.

TIMING CHAIN & SPROCKETS

Note. Adjust injection pump timing if timing chain, sprockets or injection pump gears are replaced. See INJECTOR PUMP TIMING ADJUSTMENT under ADJUSTMENTS .

1. Disconnect batteries. Drain coolant. Remove water pump and plate. See «WATER PUMP»(/chevrolet/chevy-van-g3500/1996-1998/remont/mechanical/#engine-mechanical-65l-v8-diesel-vin-p). Remove intake manifold. See INTAKE MANIFOLD.
2. Remove crankshaft pulley bolts and pulley. Remove crankshaft damper bolt and washer. Using Damper Puller (J-39046), remove crankshaft damper. Pry front cover oil seal.
3. Rotate crankshaft until mark on crankshaft damper aligns with "0" mark on timing tab with injection pump gear-to-camshaft gear timing marks aligned. (Scheme 46) Remove injection pump gear-to-injection pump bolts. Remove injection pump gear.
4. Remove baffle. Scribe mark injection pump flange in relation to front cover (if unmarked). Remove injection pump mounting nuts. Pull pump from front cover and lay on cylinder block. Remove oil pan-to-front cover bolts and front cover-to-cylinder block bolts.
5. Remove front cover. Measure timing chain free play. See TIMING CHAIN FREE PLAY. Remove camshaft gear from camshaft sprocket. (Scheme 47) Note alignment of timing marks on crankshaft and camshaft sprockets. Remove camshaft sprocket and timing chain. Remove crankshaft sprocket (if necessary).

Timing Chain Free Play

1. Position dial indicator on front of cylinder block with dial indicator tip in contact with center of timing chain between sprockets. Pull chain away from crankshaft and adjust dial indicator to zero.
2. Push chain toward crankshaft and note indicator reading. If chain deflection exceeds .80" (20.3 mm) on used parts or .50" (12.7 mm) on new parts, replace chain. Replace sprockets if worn.

Scheme 46

Scheme 47

1. Install crankshaft sprocket (if removed). Install camshaft sprocket and timing chain as an assembly, ensuring timing marks are aligned. (Scheme 47) Install camshaft gear, washer and bolt. Tighten camshaft gear bolt.
2. Install NEW front cover oil seal using Seal Installer (J-22102). Coat seal lip and crankshaft damper sealing surface with engine oil. Apply 3/32" (2 mm) bead of anaerobic sealant to front cover at front cover-to-cylinder block sealing surface. Apply 3/16" (5 mm) bead of RTV sealant to front cover at front cover-to-oil pan sealing surface.
3. Install front cover. Tighten front cover bolts and oil pan bolts to specification. Install baffle. If installing new front cover, place a timing mark on new cover. See MARKING TDC ON FRONT COVER.
4. Install injection pump gasket and injection pump, aligning timing marks on injection pump flange and front cover. Install injection pump gear, ensuring timing marks on injection pump gear and camshaft gear are aligned. (Scheme 46) Tighten gear bolts.
5. Ensure.040" (1.0 mm) minimum clearance exists between baffle and injection pump gear. To complete installation, reverse removal procedure. Fill cooling system. Adjust injection pump timing if timing chain, sprockets or injection pump gears were replaced.

Marking TDC On Front Cover

1. Rotate crankshaft until cylinder No. 1 is on TDC of compression stroke (timing marks on injection pump gear and camshaft gear will be aligned, and slot in injection pump gear will be in 6 o'clock position). (Scheme 46)and (Scheme 47).
2. Install Timing Fixture (J-33042) in place of injection pump without gasket. Install injection pump gear bolts to fasten gear to timing fixture. Install nut finger tight on upper front cover stud to secure timing fixture.
3. Tighten large bolt (18-mm head) on timing fixture to 35 ft. lbs. (47 N.m). Tighten nut on upper front cover stud. Ensure crankshaft did not rotate and timing fixture is not binding. Strike scriber with hammer to mark TDC indicator on front housing. (Scheme 48) Remove timing fixture.

Scheme 48

INJECTION PUMP

Note. When rotating crankshaft, a loose fuel injection pump drive gear could become lodged in front cover and cause gear damage.

1. Disconnect batteries. Remove intake manifold. See «INTAKE MANIFOLD»(/chevrolet/chevy-van-g3500/1996-1998/remont/mechanical/#engine-mechanical-65l-v8-diesel-vin-p) . Remove fuel injection lines. Disconnect control cables from injection pump.
2. Disconnect wiring, fuel return line and fuel supply line from injection pump. Cap all fuel line openings. Remove A/C hose retainer bracket (if equipped). Remove oil filler tube and vent hose assembly. Remove grommet.
3. Scribe an alignment mark on front cover and injection pump flange. Remove injection pump gear-to-injection pump bolts, accessible through oil filler neck hole (rotate crankshaft as necessary). Remove injection pump mounting nuts. Remove injection pump and gasket.

1. Install injection pump gasket. Install injection pump, aligning locating pin on injection pump hub with slot in injection pump gear. Loosely install injection pump mounting nuts.
2. Align timing marks on injection pump flange and front cover. Tighten injection pump mounting nuts to specification. Install injection pump gear-to-injection pump bolts. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/chevy-van-g3500/1996-1998/remont/mechanical/#engine-mechanical-65l-v8-diesel-vin-p__torque-specifications).
3. To complete installation, reverse removal procedure. Ensure fuel lines are properly connected to ports on injection pump. (Scheme 49)

Scheme 49

1. Rotate engine until mark on crankshaft balancer is at 2 o'clock position, or until timing mark on crankshaft damper aligns with "0" mark on timing tab. Rotate crankshaft counterclockwise 3 1/2" (88 mm). Estimate this distance by aligning crankshaft damper mark with first lower water pump bolt, about 12:30 position. (Scheme 50) Remove intake manifold. See «INTAKE MANIFOLD»(/chevrolet/chevy-van-g3500/1996-1998/remont/mechanical/#engine-mechanical-65l-v8-diesel-vin-p). Remove fuel injection lines and valve covers.
2. Remove rocker arm shaft bolts and rocker arm shaft. Mark component location for reassembly reference. To disassemble rocker arm shaft, see «VALVE TRAIN»(/chevrolet/chevy-van-g3500/1996-1998/remont/mechanical/#engine-mechanical-65l-v8-diesel-vin-p__valve-train) under OVERHAUL.
3. If removing push rods, note paint stripe on hardened end of push rod (end closest to rocker arm). If no paint stripe is present, mark hardened end of push rod for reassembly reference.
4. Insert a screwdriver into valve rocker arm shaft bore and break off end of nylon valve rocker arm retainers. Remove valve rocker arm retainers with a pair of pliers. Slide valve rocker arms from shaft.

Inspection

Check rocker arms and shafts for scoring or other damage. Check pushrods for bending, scoring or roughness. Check valve lifter guides and retainers for damage. Check oil passages in pushrods for obstructions.

1. Install push rods with hardened end upward in original location (if removed). Install rocker arm assembly in original location, ensuring push rods are seated in rocker arms.
2. Install rocker arm shaft bolts. Alternately tighten shaft bolts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/chevy-van-g3500/1996-1998/remont/mechanical/#engine-mechanical-65l-v8-diesel-vin-p__torque-specifications) . Turn engine over by hand to ensure valves clear pistons. To complete installation, reverse removal procedure.

Scheme 50

1. Remove intake manifold. See «INTAKE MANIFOLD»(/chevrolet/chevy-van-g3500/1996-1998/remont/mechanical/#engine-mechanical-65l-v8-diesel-vin-p) . Remove rocker arm assembly. See «ROCKER ARM ASSEMBLY»(/chevrolet/chevy-van-g3500/1996-1998/remont/mechanical/#engine-mechanical-65l-v8-diesel-vin-p__rocker-arm-assembly) . On Express and Savana, remove cylinder head. Remove guide plate clamps, guide plates and lifters.
2. On other models, remove guide plate clamps and guide plates through access holes in cylinder head using mechanical fingers. Remove lifters using Lifter Remover (J-29834) and magnet. Mark lifter location.

Note. Some engines are equipped with standard size and .010" (.25 mm) oversize diameter lifters. Bores fitted with oversize lifters are identified by O.S. stamped on cylinder block pad, adjacent to lifter bore, and on top rail of cylinder case, above lifter bore. Oversize lifters are identified by a number 10 stamped on side of lifter.

1. Check for nicks, burrs or scoring on parts. Ensure lifter roller operates smoothly without excessive play and contains no flat spots.
2. Measure lifter oil clearance. If oil clearance is not within specification, replace lifter with .010" (.25 mm) oversize lifter if resulting oil clearance is within specification. See «VALVE LIFTERS»(/chevrolet/chevy-van-g3500/1996-1998/remont/mechanical/#engine-mechanical-65l-v8-diesel-vin-p) table under ENGINE SPECIFICATIONS.

1. Submerge NEW lifters in clean kerosene or diesel fuel and operate plunger several times. Coat lifter roller and bearings with Assembly Lubricant (1052365). Install lifter into original bore. Install guide plate and guide plate clamp. Tighten clamp bolts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/chevy-van-g3500/1996-1998/remont/mechanical/#engine-mechanical-65l-v8-diesel-vin-p__torque-specifications) .
2. After all clamps are installed, rotate crankshaft by hand 2 complete turns to ensure free movement of lifters in guide plates. If crankshaft will not rotate, lifter(s) may be binding in guide plate.
3. Install rocker arm assemblies in proper sequence to prevent piston and valve damage. See «ROCKER ARM ASSEMBLY»(/chevrolet/chevy-van-g3500/1996-1998/remont/mechanical/#engine-mechanical-65l-v8-diesel-vin-p__rocker-arm-assembly) . To complete installation, reverse removal procedure.

Removal (Except Express & Savana)

1. Disconnect batteries. Drain cooling system. Remove alternator, grille, A/C compressor, condenser, radiator and power steering pump as necessary. Remove engine speed sensor.
2. Remove hydraulic valve lifters. See «HYDRAULIC VALVE LIFTERS»(/chevrolet/chevy-van-g3500/1996-1998/remont/mechanical/#engine-mechanical-65l-v8-diesel-vin-p__hydraulic-valve-lifters) . Remove timing chain and sprockets. See TIMING CHAIN & SPROCKETS.
3. Remove long bolts from engine mounts. Raise and support engine to ease camshaft removal. Remove camshaft thrust plate and spacer. Remove camshaft.

Removal (Express & Savana)

1. Disconnect batteries. Drain cooling system. Remove grille, bumper, lower valance, coolant bottle and upper tie bar. Remove engine cover. Remove A/C compressor, condenser, radiator, shroud and fan. Remove engine speed sensor. Remove cylinder heads. See CYLINDER HEAD.
2. Remove timing chain and sprockets. See TIMING CHAIN & SPROCKETS. Remove valve lifters. See «HYDRAULIC VALVE LIFTERS»(/chevrolet/chevy-van-g3500/1996-1998/remont/mechanical/#engine-mechanical-65l-v8-diesel-vin-p__hydraulic-valve-lifters) . Remove camshaft thrust plate and spacer (if equipped). Remove camshaft.

Inspect camshaft lobes for signs of flaking or flat spots. Measure camshaft journal diameter. Determine oil clearance. Replace camshaft and/or bearings as necessary if not within specification. See CAMSHAFT table under ENGINE SPECIFICATIONS.

Note. Replace hydraulic lifters if installing new camshaft.

1. If replacing camshaft bearings, see «CAMSHAFT BEARINGS»(/chevrolet/chevy-van-g3500/1996-1998/remont/mechanical/#engine-mechanical-65l-v8-diesel-vin-p). Coat camshaft journals with engine oil and lobes with High Viscosity Oil/Zinc (12345501). Install camshaft. Install thrust spacer with inside chamfer toward camshaft. Install thrust plate.
2. Ensure camshaft end play is within specification. See «CAMSHAFT»(/chevrolet/chevy-van-g3500/1996-1998/remont/mechanical/#engine-mechanical-65l-v8-diesel-vin-p) table under ENGINE SPECIFICATIONS. Install camshaft sprocket and timing chain, ensuring timing marks are aligned. (Scheme 47) To complete installation, reverse removal procedure.

Remove rear camshaft plug. Remove inner camshaft bearings using Bearing Remover/Installer (J-6098-01) and Adapter (J-6098-10). Rear inner bearing must be removed with pilot fitted in rear camshaft bearing. Remove front and rear camshaft bearings.

Install rear camshaft bearings, then front camshaft bearings to act as guides for remover/installer pilot. Install inner camshaft bearings. Coat NEW rear camshaft bore plug with Loctite Sealer (592). Install plug even with to 1/32" below block surface.

REAR CRANKSHAFT OIL SEAL

Note. When removing flexplate/flywheel, identify and mark location of retainers.

Remove transmission, clutch (M/T) and flywheel. Remove flexplate (A/T). See TRANSMISSION REMOVAL & INSTALLATION - A/T article under TRANSMISSION SERVICING. Pry seal from housing.

1. Lubricate inner and outer diameter of seal with engine oil. Place seal on Seal Installer (J-39084). Position seal installer against crankshaft.
2. Mount seal installer on crankshaft flange. Rotate seal installer handle until it bottoms on flange. Remove seal installer. Install flywheel, clutch (M/T) and transmission.

1. Disconnect batteries. Drain coolant. Remove accessory drive belts, fan, fan shroud and pulley. Remove alternator, power steering pump and related brackets as necessary.
2. Disconnect coolant by-pass hose and lower radiator hose from water pump. Remove water pump bolts. Remove water pump and water pump plate as an assembly. Remove water pump plate-to-water pump bolt. Separate water pump from plate.

1. Apply Anaerobic Sealant (1052357) to sealing surface of plate and water pump. Install plate to pump with NEW gasket. Coat water pump bolt threads with Sealant (1052080).
2. Install pump and plate assembly to front cover with NEW gasket. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/chevy-van-g3500/1996-1998/remont/mechanical/#engine-mechanical-65l-v8-diesel-vin-p__torque-specifications) . To complete installation, reverse removal procedure.

Removal (Commercial Van)

1. Disconnect batteries. Raise and support vehicle. Drain crankcase. Remove oil filter. Remove flywheel cover. Remove long bolt from left engine mount. Raise and support engine. Remove strut rods.
2. Remove battery cables, automatic transmission fluid cooler lines and clamps from oil pan. Move cylinder block heater wire aside (if equipped). Raise and support engine. Remove oil pan bolts, oil pan and oil pan rear seal.

1. Disconnect batteries. Remove engine cover. Remove engine oil dipstick and tube from valve cover. Raise and support vehicle. Remove flywheel cover. Drain crankcase. Disconnect engine oil cooler lines from cylinder block.
2. Remove starter. Remove battery cables, automatic transmission fluid lines and clamps from oil pan. Remove oil pan bolts. Lower oil pan from engine (DO NOT attempt to remove oil pan).
3. Rotate crankshaft until forward crankshaft throw for connecting rods No. 1 and 2 is up. Remove oil pump bolt. Allow oil pump and extension shaft to fall into oil pan. Remove oil pan and oil pump. Remove oil pan rear seal.

Apply 3/16" bead of RTV sealant to oil pan sealing surface, inboard of bolt holes. Install oil pan rear seal. Install oil pan. Lower engine. Tighten oil pan bolts. To complete installation, reverse removal procedure.

OVERHAUL

If surface warpage exceeds specification, replace cylinder head. See CYLINDER HEAD table under ENGINE SPECIFICATIONS. DO NOT machine cylinder head surface. Measure cylinder head thickness (distance between valve cover gasket surface and cylinder head gasket surface). If thickness is less than specified, replace cylinder head.

Pre-Chamber

1. Inspect pre-chamber for surface cracks. Replace pre-chamber if surface crack length exceeds 3/16" or if crack reaches combustion chamber sealing mark. To remove pre-chamber, insert small nylon punch through injector hole. Drive pre-chamber from cylinder head.
2. To install pre-chamber, align pre-chamber with alignment notch in cylinder head. Using 1 1/4" (32 mm) socket and hammer, tap pre-chamber into bore.
3. Measure pre-chamber installed height in 2 or more locations where pre-chamber seats against head gasket shield and sealing ring. Ensure pre-chamber is even with cylinder head or does not protrude from cylinder head more than .002" (.05 mm). Pre-chamber must not be recessed in cylinder head.

Valve Springs

Measure valve spring pressure. Measure valve spring installed height between spring seat (or top of shim, if shimmed) and top of spring shield. Replace valve spring if pressure or installed height is not within specification. See VALVES & VALVE SPRINGS table under ENGINE SPECIFICATIONS.

Valve Stem Oil Seals

Intake valve uses upper "O" ring seal. Exhaust valve uses upper "O" ring seal and lower umbrella seal, seated against cylinder head.

Valve Guides

Valve guides are part of cylinder head (not replaceable). If valve stem-to-guide oil clearance is not within specification, ream valve guides using Reamer Set (J-7049) and install oversize valves. See CYLINDER HEAD table under ENGINE SPECIFICATIONS. Oversize valves are available in .003" (.08 mm) and .015" (.38 mm) oversize.

Valve Seat

No replacement procedure is available from manufacturer. Valve seats are induction hardened. Excessive removal of material may damage valve seat. Measure seat width and runout. See CYLINDER HEAD table under ENGINE SPECIFICATIONS .

Valves

Valves with .003" (.08 mm) and .015" (.38 mm) oversize stems are available for worn valve guides.

VALVE TRAIN

Rocker Arm Assembly

1. To disassemble rocker arm assembly, insert screwdriver into rocker arm shaft bore. Break off end of retainer. Pull out retainer with pliers. Mark rocker arms for reassembly to original location on shaft. Remove rocker arms from shaft.
2. Inspect rocker arms and rocker arm shaft at mating surface for damage. Inspect push rods for bend and wear. Ensure oil passages are clear.
3. To assemble rocker arm assembly, coat rocker arms with engine oil and install on shaft in original locations. Center rocker arms with their corresponding holes on shaft. Install retainers with a 1/2" minimum diameter drift punch.

Hydraulic Valve Lifters

Engine is equipped with roller type hydraulic valve lifters. Lifters are serviced as complete assemblies only. Parts are not interchangeable between lifters.

CYLINDER BLOCK ASSEMBLY

Piston & Rod Assembly

1. Mark piston and rod assembly for installation to original bore. Mark rod and cap in relation to piston. Assemble rod to piston with rod bearing tang on same side of piston as piston crown indent.
2. Properly position ring end gaps around circumference of piston. (Scheme 51) Install piston and rod assembly in bore with piston crown indent toward outside of engine.

Fitting Pistons

1. Measure cylinder bore diameter .79" (20 mm), 3.8" (96 mm) and 6.1" (155 mm) below cylinder block deck surface. Measure piston diameter at 90-degree angle to piston pin and on pin center line. Determine piston clearance.
2. If clearance is not within specification, replace piston and/or machine cylinder bore. See «CYLINDER BLOCK»(/chevrolet/chevy-van-g3500/1996-1998/remont/mechanical/#engine-mechanical-65l-v8-diesel-vin-p) table and PISTONS, PINS & RINGS table under «ENGINE SPECIFICATIONS»(/chevrolet/chevy-van-g3500/1996-1998/remont/mechanical/#engine-mechanical-65l-v8-diesel-vin-p) .

Piston Pins

Using a small screwdriver and Piston Pin Retaining Ring Installer (J39507), install retaining rings. Opening in an installed retaining ring should face downward (toward crankshaft).

Note. Top compression ring uses a Keystone type (ring land is tapered). Piston ring side clearance cannot be measured.

Piston Rings

Measure piston ring end gap and side clearance. If not within specification, replace piston and/or rings as necessary. See PISTONS, PINS & RINGS table under ENGINE SPECIFICATIONS. Install rings with mark on ring facing upward. Position ring end gaps on piston. (Scheme 51)

Scheme 51

Rod Bearings

1. Mark rod caps in relation to rod for reassembly reference. Measure rod bearing journal out-of-round, taper and oil clearance. If measurement is not within specification, install NEW rod bearings. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table under «ENGINE SPECIFICATIONS»(/chevrolet/chevy-van-g3500/1996-1998/remont/mechanical/#engine-mechanical-65l-v8-diesel-vin-p) .
2. Undersize bearings may be used in combination with standard bearings to produce correct clearance. If clearance is not within specification after installing new bearings, replace crankshaft. DO NOT machine crankshaft. Ensure rod side play is within specification.

Note. Some engines may contain both standard and .003" (.08 mm) oversize connecting rod bearings, identified by O.S. stamped on bearing cap lower end.

Crankshaft & Main Bearings

1. Mark main bearing caps in relation to cylinder block. Measure main bearing journal diameter, out-of-round and taper. Determine main bearing oil clearance.
2. If measurement is not within specification, replace main bearings. DO NOT machine crankshaft. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table under «ENGINE SPECIFICATIONS»(/chevrolet/chevy-van-g3500/1996-1998/remont/mechanical/#engine-mechanical-65l-v8-diesel-vin-p) . CAUTION: Crankshaft is a rolled fillet type. DO NOT machine crankshaft. Main bearings are select fit to bearing bores in block. Match bearing shells to number (1, 2 or 3) stamped near oil pan rail and color (Blue, Orange or White) painted on crankshaft journals.
3. Apply a thin film of RTV to crankshaft seal area of rear main bearing cap. Lightly oil cap bolt threads. Tap rear main bearing cap into place with brass or leather mallet. Install cap bolts and tighten slightly. Align thrust bearing surfaces and measure crankshaft end play. See THRUST BEARING.

Thrust Bearing

1. Main bearing No. 3 is thrust bearing. Tighten all other main bearing caps to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/chevy-van-g3500/1996-1998/remont/mechanical/#engine-mechanical-65l-v8-diesel-vin-p__torque-specifications) . Tighten thrust bearing to 10 ft. lbs. (14 N.m). Tap crankshaft rearward then forward.
2. Tighten thrust bearing cap to specification. Measure crankshaft end play at front face of thrust bearing. If crankshaft end play is not within specification, replace thrust bearing or crankshaft. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table under «ENGINE SPECIFICATIONS»(/chevrolet/chevy-van-g3500/1996-1998/remont/mechanical/#engine-mechanical-65l-v8-diesel-vin-p) .

Cylinder Block

Measure warpage of cylinder block deck surface. If warpage exceeds specification, replace cylinder block. DO NOT machine cylinder block deck surface. See CYLINDER BLOCK table under ENGINE SPECIFICATIONS. If cylinder bore taper and out-of-round are not with specification, machine cylinder bore and/or replace piston.

ENGINE LUBRICATION SYSTEM

Pressurized lubrication is provided by gear-type oil pump. (Scheme 52) Camshaft drives oil pump through shaft of a gear-driven engine speed sensor. Lubrication flows through external oil cooler then into full-flow oil filter. Non-adjustable oil pressure regulator valve is located in oil pump body.

Main oil gallery supplies oil through drilled passages to camshaft and crankshaft bearings. Oil flows through galleries to valve lifters then through hollow push rods to rocker arms.

Scheme 52

Note. Manufacturer recommends changing oil filter at EVERY oil change.

Crankcase Capacity

Crankcase capacity is 7 quarts (6.6L) including oil filter change.

Oil Pressure

Normal oil pressure is 10 psi (.70 kg/cm 2 ) at idle and 40-45 psi (2.81-3.16 kg/cm 2 ) at 2000 RPM.

Removal & Disassembly

1. Remove oil pan, oil pump and extension shaft. See OIL PAN under «REMOVAL & INSTALLATION»(/chevrolet/chevy-van-g3500/1996-1998/remont/mechanical/#engine-mechanical-65l-v8-diesel-vin-p__removal-installation) . Remove pump cover screws and pump cover. Mark gears so they may be reassembled with same tooth indexed. Remove idler gear, drive gear and shaft from pump housing.
2. Remove pressure regulator valve retaining pin from pump cover. Remove regulator valve components from pump cover. Note order of removal. DO NOT disassemble pick-up screen and pipe. Screen and pipe are serviced only as an assembly with pump.

1. 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.
2. Check pressure regulator valve for fit in bore. Inspect inlet tube and screen assembly for damage. Replace entire pump assembly if damaged.

Reassembly & Installation

1. Install pump gears into pump body with marked gear teeth indexed. Reassemble remaining components in reverse order of disassembly. On Express and Savana, place pump and extension shaft inside oil pan. Position oil pan in place.
2. On all models, install pump and extension shaft on engine, ensuring slot on top of extension shaft engages with drive tang on end of pump drive or vacuum pump. Tighten mounting bolt to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/chevy-van-g3500/1996-1998/remont/mechanical/#engine-mechanical-65l-v8-diesel-vin-p__torque-specifications) . Install oil pan.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

CRANKSHAFT, MAIN BEARINGS & CONNECTING ROD BEARINGS SPECIFICATIONS

CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS

CONNECTING RODS SPECIFICATIONS

CONNECTING RODS

PISTONS, PISTON PINS & PISTON RINGS SPECIFICATIONS

PISTONS, PINS & RINGS

CYLINDER BLOCK SPECIFICATIONS

CYLINDER BLOCK

ENGINE VALVES & VALVE SPRINGS SPECIFICATIONS

VALVES & VALVE SPRINGS

CYLINDER HEAD SPECIFICATIONS

CYLINDER HEAD

CAMSHAFT SPECIFICATIONS

CAMSHAFT

VALVE LIFTERS SPECIFICATIONS

VALVE LIFTERS

See also:
• INTAKE MANIFOLD
• INJECTION PUMP
• TORQUE SPECIFICATIONS
• VALVE TRAIN
• ROCKER ARM ASSEMBLY
• HYDRAULIC VALVE LIFTERS
• REMOVAL & INSTALLATION