Engine Mechanical - 5.7l - VIN J Engine Overhaul Chevrolet Corvette C4

ENGINE UNIT REPAIR

5 J LITER V8, RPO LTS VIN J

Note. When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The correct torque value must be used when installing fasteners that require it. If the above conditions are not followed, parts or system damage could result.

Throttle Body Extension and Throttle Body

The throttle body extension and the throttle body are both made of cast aluminum. The amount of incoming air is controlled by three throttle plates mounted on the throttle body. A 22 mm (0.87 in.) diameter primary plate, and two 59 mm (2.32 in.) diameter secondary plates are used. The primary throttle plate is operational when vehicle speeds are less than 113 km/h (70 mph). At full throttle operation, or after 80° of primary plate rotation, the larger secondary plates begin to open for additional airflow.

Plenum

The induction air is collected in the plenum, a one piece aluminum casting, where it is distributed evenly into the plenum primary intake runners, through the injector housings, and into the eight primary inlet ports in the cylinder heads. The eight plenum secondary intake runners feed through the injector housings and into the eight secondary inlet ports. Airflow into the secondary inlet ports is regulated by eight throttle plates in the cylinder head. The MAP sensor and ignition module are attached to the plenum.

Injector Housings

The injector housings are aluminum castings into which the sixteen fuel injectors are inserted. These housings provide an optimum point for fuel to be added to the induction airflow.

Cylinder Heads

The cylinder heads are made of aluminum and are cast from a semi-permanent mold. The cross-flow, four valve per cylinder design provides optimum induction and exhaust system breathing. The clover leaf combustion chamber, with a centrally located spark plug, contributes to smooth, efficient operation.

The valve seat inserts and valve guides are made of sintered metal. The valves are made of hardened steel.

The cylinder heads also house the secondary port throttle valves. These valves are opened and closed by a vacuum actuator whose operation is governed by the ECM. The inputs to the ECM affecting actuator operation are throttle position, engine rpm, coolant temperature, and manifold pressure.

In combination with the camshaft covers, the heads form the bearing surfaces for the camshaft journals. There are no replaceable camshaft bearings.

Cylinder Case and Liners

The cylinder case is an open deck design of cast aluminum. The upper casting houses the cylinder liners, upper main bearings, and camshaft timing chain assembly. Oil return passages are cast in the side of the cylinder case to provide proper oil drainback to the oil pan.

The cylinder liners are oriented in the case in a 90° "V" configuration. They are made of aluminum with a "Nikasil" coating plated onto the bore surface to provide superior wear characteristics.

The cylinder liners are slip-fitted into the cylinder case and sealed with special heat resistant adhesive. Coolant is circulated around the upper half of each liner, giving them the name wet liners.

Crankcase

The crankcase is an aluminum casting located immediately below the cylinder case. It houses the lower main bearings and, together with the cylinder case, retains the crankshaft. An oil passage is cast into the crankcase and runs from the oil pick-up assembly to the oil pump.

Crankshaft

The internally balanced crankshaft is made of forged steel to provide high strength and durability in high torque applications. Oil is fed through the center of the crankshaft (entering at the front) to provide lubrication to the main bearings and connecting rod bearings. For increased lubrication to the rod bearings, the crankshaft is cross-drilled.

Located on the crankshaft is the crankshaft ignition timing disc. Nine notches are machined into the disc. These notches, along with the engine timing sensor, provide exact crankshaft position information to the ECM.

Connecting Rods

The connecting rods are made of forged steel and are 145.8 mm (5.74 in.) in length, center to center. Rod caps are secured to the rods with bolts that pass through the caps and thread into the rods.

Piston and Pins

The pistons are made of a cast aluminum alloy and utilize a concave head design. There are two compression rings, upper and lower and one oil control ring.

The pistons are select-fit to cylinder liners and are not interchangeable between liners. Only piston-liner assemblies are available as replacement parts.

The piston pins float freely in the pistons and in the rods.

Camshafts and Drive System

The camshafts are made of cast iron and are positioned above the cylinder banks on the cylinder heads. One intake and one exhaust camshaft operates each bank of sixteen valves. The intake and exhaust camshaft lobes are ground to accommodate the air induction system characteristics. The secondary lobes of the intake camshafts are ground to provide a longer duration than the primary lobes of the intake camshafts.

The camshaft sprockets are driven by two duplex secondary timing chains that are routed through the front of the heads. The secondary chains are driven by the idler sprocket assembly, which is driven by the primary timing chain. The primary chain is driven by the crankshaft sprocket.

Primary chain tension is maintained by a single guide between the crankshaft sprocket and idler sprocket. Tension in the two secondary chains is maintained by hydraulic chain tensioners, one per bank. Force is applied to the chains through a pivot guide at each tensioner. There are also two fixed guides, one adjacent to each pivot guide, and two top guides, one in each camshaft cover. These guides provide a damping effect, preventing excessive chain travel and noise.

These steel roller timing chains are highly durable and provide efficient transmission of power.

Hydraulic Lifters

The hydraulic lifters maintain zero lash between the camshaft lobes and the valve stems. Due to the overhead design of this engine, cam lobe action is transferred in a straight line directly to the valve stem, contributing to smooth operation.

Exhaust Manifolds

The exhaust manifolds are made of tubular stainless steel. They are part of the manifold/converter assembly that couples exhaust manifolds with engine compartment-mounted catalytic converters. The A.I.R. injection pipes are mounted to each manifold.

LUBRICATION

The duo-centric design oil pump is a positive displacement pumping unit consisting of an inner and outer gear. The inner gear has one less tooth than the outer, with the inner gear's centerline positioned at a fixed eccentricity from the centerline of the outer gear. The pump is mounted to the front of the cylinder case and driven by two flats machined into the crankshaft. Also contained within the oil pump body is an oil pressure regulation valve. The regulation valve regulates oil pressure to provide proper lubrication to engine components.

The oil filter housing mounted on the front of the cylinder case combines three control functions: oil temperature regulation, oil cooler bypass, and oil filter bypass. The oil filter is attached to the top of the filter housing.

Engine oil temperature regulation is thermostatically controlled in the oil filter housing. When engine oil is cold, the temperature control valve is open and the cooler bypass valve is closed. This permits cold oil to be circulated throughout the engine. When the oil warms to a preset temperature, the temperature control valve closes and the cooler bypass valve opens, diverting hot oil through the cooler. Some oil is always sent to the filter before entering the engine, regardless of oil temperature.

Should the oil filter become clogged, a bypass valve in the filter housing will open so that oil is still available for lubrication. The oil filter also contains a bypass valve, thereby providing a redundant system in the event of filter restriction.

The oil filter also contains an anti-drainback valve that prevents oil spillage if filter is removed from engine in upright position when serviced.

After regulation, filtration, and cooling as required, the engine oil is directed to the crankshaft inlet holes for center feed to the main and connecting rod bearings. Oil passages direct additional oil to the engine upper components such as the camshafts, timing chains, lifters, etc.

Note. The threads of some fasteners, sensors, and fittings on the LT5 engine require the application of thread locking and sealing compounds. It is important that the correct compounds be used to ensure that parts or system damage does not occur.

THROTTLE BODY EXTENSION

(Scheme 56)

Remove or Disconnect

1. Electrical connector from MAT sensor.
2. Ventilation breather hose from left and right side of throttle body extension.
3. Screw and nuts retaining cable shield to throttle body extension and shield from engine.
4. Screws retaining extension to throttle body.
5. Extension and gasket from vehicle.

THROTTLE BODY

(Scheme 56)

1. Electrical connectors from: TPS. IAC.
2. Screws retaining throttle body to plenum.
3. Throttle body and gasket.

PLENUM ASSEMBLY

(Scheme 57)

Scheme 44

Scheme 45

Scheme 46

Scheme 47

Scheme 48

Scheme 49

Scheme 50

Scheme 51

Scheme 52

Scheme 53

Scheme 54

Scheme 55

1. Coolant air bleed hose from plenum.
2. Vacuum hose between fuel pressure regulator and plenum.
3. Vacuum hoses from mid-plenum: left and right.
4. Vacuum hose from MAP sensor and plenum. (Scheme 44): Identifying Cylinder Block And Internal Parts (Scheme 45): Identifying Cylinder Block And Internal Parts - Legend (Scheme 46): Identifying Cylinder Head And Related Parts (Scheme 47): Identifying Cylinder Head And Related Parts - Legend (Scheme 48): Exploded View Of Front Cover And Cooling (1 Of 2) (Scheme 49): Exploded View Of Front Cover And Cooling (2 Of 2) (Scheme 50): Identifying Oil Pump, Pan And Related Parts (Scheme 51): Identifying Oil Pump, Pan And Related Parts - Legend (Scheme 52): Identifying Manifolds And Fuel Related Parts (Scheme 53): Identifying Manifolds And Fuel Related Parts - Legend (Scheme 54): Identifying Fuel Related Parts (Scheme 55): Identifying Fuel Related Parts - Legend
5. Bolts retaining plenum assembly to injector housing.
6. Electrical connectors from ignition module.
7. Electrical connector from MAP sensor.
8. Purge solenoid/PCV valve hose fitting from plenum.
9. Plenum assembly and gaskets.

1. Spark plug wires from right cylinder head.
2. Oil pressure sensor from oil filter housing.
3. Bolt retaining coolant outlet pipe bracket to generator bracket.
4. Screws and right side coolant outlet from injector housing.
5. Bolt retaining fresh air pipe bracket to injector housing.
6. Bolts retaining right camshaft cover to cylinder head.
7. Right camshaft cover from cylinder head.

1. Bolt retaining A/C suction/discharge hoses to A/C compressor.
2. Spark plug wires from spark plugs.
3. Ventilation breather pipe from left camshaft cover.
4. Bolts retaining left camshaft cover to cylinder head.
5. Left camshaft cover from cylinder head.

VENTILATION HOSES, COVER AND BAFFLE

(Scheme 58) through (Scheme 60)

Scheme 56

Scheme 57

Scheme 58

Scheme 59

1. Clamps from ventilation hoses on ventilation cover and injector housings.
2. Cylinder ventilation hoses from engine.
3. A/C compressor bolts and compressor.
4. Spark plug wires from coil pack.
5. Bolts retaining coil pack bracket and purge solenoid bracket to ventilation cover and cylinder case. (Scheme 56): Exploded View Of Throttle Body And Extension (Scheme 57): Identifying Plenum Components (Scheme 58): Identifying Cylinder Case Ventilation Cover Components (Scheme 59): Identifying Secondary Port Throttle Actuation Assembly Components
6. Electrical connectors from coil pack: coil pack from vehicle.
7. Vacuum hoses from vacuum reservoir.
8. Nuts and washers retaining vacuum reservoir to ventilation cover: reservoir from engine.
9. Vacuum hoses from vacuum solenoid.
10. Electrical connector from vacuum solenoid.
11. Screw retaining vacuum solenoid to ventilation cover and solenoid from engine.
12. Vacuum hoses from secondary port throttle actuators.
13. Nuts retaining actuators to brackets.
14. Actuator retaining clips and actuators from engine.
15. Screws retaining control assembly covers to actuator brackets: covers from engine.
16. Link assemblies from lever assemblies.
17. Electrical connectors from: Coolant temperature sensor. Cooling fan switch.
18. Coolant temperature sensor and cooling fan switch from injector housing.
19. Cylinder case ventilation hose.
20. Bolts retaining cylinder case ventilation cover to cylinder case.
21. Ventilation cover and gasket from engine.
22. Bolts retaining ventilation baffle to cylinder case; baffle from engine.

(Scheme 61)

Scheme 60

Scheme 61

1. Bolts retaining fuel rail assembly to injector housings.
2. Injectors from housings and fuel rail assembly from engine.
3. PCV grommet from right injector housing. (Scheme 60): Identifying Cylinder Case Ventilation Baffle Components (Scheme 61): Identifying Injector Housing
4. Bolt retaining generator rear support bracket to generator.
5. Bolt retaining generator rear support bracket and right-side ventilation pipe to injector housing.
6. Bolts retaining right injector housing to cylinder head.
7. Right injector housing and gasket from engine.
8. PCV grommet from left injector housing.
9. Bolts retaining housing to cylinder head.
10. Left injector housing and gasket from engine.

1. Air hoses from check valves on right and left exhaust manifolds.
2. Outer heat shields from exhaust manifolds.
3. Bolts, nuts and spacers from exhaust manifolds.
4. Exhaust manifolds.

TORSIONAL DAMPENER

(Scheme 62)

Tool Required

J 24420-C Torsional Damper/Crankshaft Sprocket Puller

1. Bolt and washer retaining crankshaft torsional dampener to crankshaft.
2. Torsional dampener using J 24420-C.
3. Key from crankshaft.

Removing Torsional Dampener. Scheme 62

COOLANT PUMP AND ENGINE FRONT COVER

(Scheme 63)

1. Coolant pump pulley bolts.
2. Coolant pump pulley.
3. Drive belt tensioner bolt and tensioner.
4. Generator lower bracket bolts and bracket.
5. Bolts retaining coolant pump to engine front cover.
6. A/C compressor-to-coolant pump bolt.
7. Coolant pump and gasket.
8. Bolts and stud nuts (at top of cylinder case vee) retaining engine front cover: cover and gasket from engine.

Identifying Engine Front Cover Components. Scheme 63

1. Oil filter.
2. Electrical connectors from: Generator. Oil pressure sensor. Oil temperature sensor. Low oil pressure switch.
3. Generator bracket and generator and shield from engine. Oil filter pausing bolt and oil filter housing from engine.

CAMSHAFTS AND LIFTERS

(Scheme 64), (Scheme 65) and (Scheme 66)

Tool Required

J 38098 Crankshaft Timing Slot Locator J 38099 Timing Chain Retainers

1. Lock crankshaft into position using J 38098.
2. Remove J 38098.
3. Bolts retaining left and right secondary timing chain tensioner housings to cylinder heads: housings, O-rings, and tensioners from cylinder heads.
4. Bolts retaining camshaft sprockets using a backup wrench, washers, pins and timing plates.
5. Rotate camshafts to a neutral position (no valves open) using the cast hex head at the rear of camshafts.
6. Bolts retaining camshaft retainers: retainers and thrust washers from engine.
7. Camshafts and sprockets from engine while installing tools J38099 to retain secondary chain loops.
8. Lifters from bores.

Identifying Camshafts Components. Scheme 64

Identifying Secondary Timing Chain Retainers Components. Scheme 65

Identifying Valve Lifters Components. Scheme 66

TIMING CHAINS, SPROCKETS AND GUIDES

(Scheme 67), (Scheme 68) and (Scheme 69)

Tools Required

J 38099 Timing Chain Retainers

J 38211 Crankshaft Sprocket Remover

1. Bolts retaining primary chain guide to oil pump: guide from engine.
2. Bolts retaining idler sprocket assembly. Primary chain from idler sprocket and crankshaft sprocket: chain from engine.
3. Disengage right side secondary timing chain from idler sprocket assembly.
4. Tools J 38099.
5. Sprocket assembly and left side chain.
6. Right side chain.
7. Timing chain crankshaft sprocket using J 38211.
8. Bolts retaining fixed and pivot secondary chain guides to cylinder case: guides from engine.

Identifying Primary Timing Chain Guide Assembly Components (Engine Inverted). Scheme 67

Removing Crankshaft Sprocket. Scheme 68

Identifying Timing Chain Assembly Components. Scheme 69

1. Key and oil pump seal seat from crankshaft.
2. Bolts retaining oil pump to cylinder case and pump from engine.
3. O-ring from crankshaft.

1. Camshaft position sensor electrical connector.
2. Spark plugs.
3. Bolts retaining camshaft position sensor and sensor from left cylinder head.
4. Bolts retaining cylinder heads to cylinder case. Start with end bolts and work towards center of cylinder head.
5. Cylinder heads and gaskets from engine.

1. Bolts retaining flywheel and flywheel from crankshaft.
2. Screws retaining rear main oil seal/housing assembly: assembly from crankshaft.

OIL PAN

(Scheme 70)

Tool Required

J 37330 Liner Installation and Retainer Kit

1. Install cylinder liner retainers J 37330.
2. Invert engine.
3. Bolts retaining oil pan; remove pan and gasket from crankcase.
4. Bolts and crankcase baffle and oil pick-up assembly.

Installing Cylinder Liner Retainers. Scheme 70

PISTON-ROD ASSEMBLY

Tool Required

J 39494 Connecting Rod Guide Pin

1. Rotate crankshaft until piston is at the bottom of its stroke.
2. Bolts retaining connecting rod cap: remove cap and bearings from engine. IMPORTANT: Before removal of connecting rod cap, mark the side of the rod and the cap with the cylinder number to assure matched reassembly of rod and cap.
3. Piston-rod assembly from cylinder liner using J 39494.
4. Repeat steps for each cylinder.

1. Bolts and washers retaining crankcase at main bearing journals.
2. Bolts retaining crankcase to cylinder case.
3. Crankcase from cylinder case.
4. Crankshaft from cylinder case.
5. Main bearings from crankcase and cylinder case.

CYLINDER CASE

(Scheme 71)

Tools Required

J 37330 Cylinder Liner Retainers

J 38124 Cylinder Liner Remover

J 8092 Driver Handle

1. Liner retaining tools J 37330.
2. Cylinder liner(s) from cylinder case using J 38124 with J 8092.
3. Electrical connectors from starter, generator and crankshaft timing sensor.
4. Wiring harness ground connections and wiring harness.
5. Starter bolts and starter.
6. Bolt and crankshaft sensor.
7. Knock sensor.
8. Vee drain tube.

Removing Cylinder Liner. Scheme 71

Clean

1. Cylinder case thoroughly in cleaning solvent and clean all gasket surfaces.
2. Oil galleries and drainback passages.
3. Coolant passages.

Inspect

1. Coolant passages for blockage.
2. Cylinder case for cracks.
3. Cylinder case deck surfaces (crankcase and cylinder head) for straightness.

(Scheme 72) and (Scheme 73)

Tools Required

J 37306 Crankshaft Cup Plug Installer

1. Pilot bearing.

1. Crankshaft oil gallery passages. Taper plugs and cup plugs must be removed to access all internally drilled passages.
2. Blow out all passages with compressed air.

Inspect

1. For wear and damage.

Install or Connect

1. Coat rear cup plug with Loctite® 620 on plug sealing surface.
2. Install rear cup plug.
3. New pilot bearing.
4. Taper plugs with Loctite® 565 on the threads.
5. Remaining cup plugs with Loctite® 620 on plug sealing surface. Installation is accomplished using J37306. NOTE: Protect crankshaft journals damage when using tools near the journals.

Identifying Crankshaft And Rear Cup Plug. Scheme 72

MAIN BEARING FITTING

Main bearings are Of the precision insert type. If clearances are found to be excessive, a new bearing, both upper and lower halves, will be required.

1. In general, the lower half of the bearing (except No. 1 bearing) shows greater wear and abrasion. If the lower half of upper half shows evidence of wear or damage, both upper and lower halves should be replaced. Never replace one half without replacing the other half.
2. Wipe both upper and lower main bearing shells and crankshaft main journals clean of oil.
3. Main journals for out-of-round or taper with a micrometer. If not within specifications, replace the crankshaft.
4. Normally, main bearing journals wear evenly and are not out-of-round. However, if a bearing is being fitted to an out-of-round journal (0.001 in. max.), be sure to fit to the maximum diameter of the journal. If the bearing is fitted to the minimum diameter, and the journal is out-of-round 0.001 in., interference between the bearing and main journal will occur, resulting in rapid bearing failure. Place a piece of gaging plastic the full width of the bearing (parallel to the crankshaft) on the bearing surface. Crankshaft onto cylinder case. Crankcase onto cylinder case. Washers (oil coated) and bolts retaining crankcase at main bearing journals: finger tighten. Crankcase bolts retaining crankcase to cylinder case (at rear of engine): finger tighten. Tighten Main bearing bolts on No. 1, No. 3, No. 5 journals per sequence to 40 N.m (30 lb. ft.) and turn 45-50°. (1992 and earlier). Main bearing bolts on No. 2, No. 4 journals per sequence to 20 N.m (15 lb. ft.) and turn 77.5-82.5°. (1992 and earlier). Inner main bearing bolts per sequence to 20 N.m (15 lb. ft.) and turn 65-70°. (1993 and later). Outer main bearing bolts per sequence to 20 N.m (15 lb. ft.) and turn 50-55°. (1993 and later). NOTE: Do not turn crankshaft with the gaging plastic installed. Remove crankcase bolts, main bearing bolts, and crankcase from cylinder case. Measure the gaging plastic width at its widest point.
5. If the clearance exceeds specifications, select a new, correct size bearing and remeasure the clearance.
6. Be sure to check what size bearing is being removed in order to determine proper replacement size bearing. If clearance cannot be brought to within specifications, the crankshaft must be replaced. No crankshaft grinding is allowed.
7. If the flattened gaging plastic tapers toward the middle or ends, there is a difference in clearance indicating taper, low spot or other irregularity of the bearing or journal. Be sure to measure the journal with a micrometer if the flattened gaging plastic indicates more than 0.001 in. difference in clearance. Clean Cylinder case and crankcase surfaces onto which bearings are to be seated. Cylinder case and crankcase sealing surfaces onto which sealer is to be applied.

PISTONS, CONNECTING RODS AND CYLINDER LINERS

(Scheme 70) and (Scheme 74) through (Scheme 77)

Tool Required

J 37330 Cylinder Liner Retainers

Disassemble

1. Piston pin retainers.
2. Piston pin and connecting rod from piston.
3. Piston rings from piston using suitable ring expander tool. IMPORTANT: If piston or piston pin replacement is required, the piston, piston rings, piston pin, and cylinder liner are replaced as an assembly. Piston and liner assemblies come in matched sets marked A or B. When replacing a piston and liner assembly, the replacement assembly DOES NOT have to be of the same set as those in the remaining cylinders. Piston set identification mark is stamped on top of the piston.

1. Varnish from piston skirts and pins with a cleaning solvent. DO NOT WIRE BRUSH ANY PART OF THE PISTON.
2. Ring grooves with a groove cleaner and make sure oil ring holes and slots are clean.
3. Connecting rods in solvent and dry with compressed air.

1. Piston for cracked ring lands, skirts or pin bosses, scuffed or damaged skirts, and eroded areas at top of piston.
2. Ring grooves for nicks or burrs that might prevent the rings from seating properly in the grooves.
3. Piston pin bores and piston pins for wear. Piston pin bores and piston pins must be free of varnish of scuffing.
4. Piston pin retainer grooves for burrs.
5. Connecting rods for signs of being twisted, bent, nicked, or cracked.
6. Connecting rod bearing insert seating surface for scratches or abrasions.

1. The outer circumference of the liners, removing all old sealer. Failure to do a thorough job will cause a poor liner to cylinder case seal, resulting in coolant leakage.

Scheme 73

Scheme 74

Scheme 75

Scheme 76

1. Cylinder liners for cracked or scored walls. (Scheme 73): Identifying Crankshaft Main Bearings Components (Scheme 74): Identifying Piston-Rod Assembly Components (Scheme 75): Installing Cylinder Liner (Scheme 76): Applying Sealer To Cylinder Liner

Measure

1. Cylinder liners for out-of-round and taper.

Scheme 77

1. Liner(s) into cylinder case. DO NOT apply sealer at this time. IMPORTANT: Liner must be installed with flats positioned 90° to crankshaft axis (flats facing front and rear of cylinder case). Flats of adjacent liners should be parallel so that a small gap exists between them. Measure Liner standout height. This distance from the cylinder case deck to the lower ridge at the top of the liner should be 0.001 - 0.003 in. If standout height is not within specification, make further checks as follows: Inspect Liner ridge for damage, dirt, or burrs. Clean as required. Recheck standout height. If still not within specification, proceed to next step. Cylinder case liner seat for damage, dirt, or burrs. Clean as required. Recheck standout height. If still not within specification, proceed to next step. Replace cylinder liner. Recheck standout height. Apply a band of Loctite® 565, 12 mm (0.47 in.) - wide, around the circumference of the finer, 25.4 mm (1.0 in.) from bottom edge of liner (Scheme 76)
2. Liner(s) into cylinder case.
3. Install J 37330 to seat liner(s) into case and retain until head installation (Scheme 69) (Scheme 77): Identifying Piston Rings Components

1. Piston rings for proper fit. Slip the top compression ring in the cylinder bore: then press the ring down into the cylinder bore. Use an inverted piston to press ring into liner to a depth of second ring groove. Be sure ring is square with cylinder wall. If ring replacement is required due to excessive ring end gap, a piston and liner assembly replacement will be required. Measure The space of gap between the ends of the ring with a feeler gage (see «PISTON RING»(/chevrolet/corvette/c4-1984-1998/remont/mechanical/#engine-mechanical-57l-vin-j-engine-overhaul__piston-ring) SPECIFICATIONS). If the gap between the ends of the ring is below specifications, remove the ring and try another for fit. Repeat steps for the second compression and oil control rings. Fit each ring to the cylinder in which it is going to be used. If the pistons have not been cleaned and inspected as previously outlined, do so. Slip the outer surface of the top and second compression ring into the respective piston ring groove and roll the ring entirely around the groove to make sure that the ring is free. If binding occurs at any point, the cause should be determined. If binding is caused by ring groove, correct by dressing with a fine cut file. If the binding is caused by a distorted ring, recheck with a new ring.

Assemble

1. Piston rings onto piston (Scheme 77) IMPORTANT: Top compression ring should be installed with chamfer facing downward. Second compression ring should be installed with manufacturer mark (TOP) facing upward. Rings should be installed with gaps spaced approximately 120° apart from one another.
2. Connecting rod and piston pin to piston. IMPORTANT: Rods must be installed to pistons with the arrow on the piston facing the front of the engine and the chamfer on the journal end of the rod facing the crankshaft counterweight. Rod chamfers face to front on left bank. Rod chamfers face to rear on right bank.
3. Piston pin retaining rings. IMPORTANT: Pin retaining rings should be installed with gap facing toward top of piston.

1. Connecting rod bearings for evidence or wear or damage. Such bearings should not be installed.
2. Wipe both upper and lower bearing shells and rod journals clean of oil.
3. Rod journals for out-of-round of taper with a micrometer. If rod journals are not within specifications, replace the crankshaft. If within specifications and a new bearing is to be installed, measure the maximum diameter of the rod journal to determine new bearing size required.
4. If rod journal is within specifications, measure new or used bearing clearances with a gaging plastic. IMPORTANT: Connecting rod bearings are of the precision insert type. DO NOT FILE RODS OR ROD CAPS. If clearances are found to be excessive, a new bearing will be required.
5. If a bearing is being fitted to an out-of-round rod journal, be sure to fit to the maximum diameter of the rod journal. If the bearing is fitted to the minimum diameter, and the rod journal is out-of-round .008 mm (,0003 in.) interference between the bearing and rod journal will occur, resulting in rapid bearing failure. Place a piece of gaging plastic, the length of the bearing (parallel to the crankshaft), on the bearing surface. Gaging plastic should be positioned in the middle of the bearing shell. (Bearings are eccentric, and false readings could occur if placed elsewhere.) Install the bearing in the connecting rod and cap. Tighten rod bolts to 30 N.m (22 lb. ft.) and turn 80-85°. NOTE: Do not turn the crankshaft with the gaging plastic installed. Remove the bearing cap, and using the scale on the gaging plastic envelope, measure the gaging plastic width at the widest point.
6. If the clearance exceeds specifications, select a new, correct size bearing and remeasure the clearance. Be sure to check what size bearing is being removed in order to determine proper replacement bearing size. If clearance cannot be brought to within specifications, replace the crankshaft.

OIL PUMP

(Scheme 78)

Tool Required

J 29077-A Front Cover Seal/Oil Pump Seal Remover

1. Screws retaining pump plate to body; plate from pump.
2. Inner and outer gears.
3. Snap ring retaining pressure regulation valve.
4. Valve assembly from pump.
5. Snap ring retaining valve assembly.
6. Oil pump shaft seal from pump body using J 29077-A.
7. O-rings from pump body. IMPORTANT: Make sure position of a-rings on valve and housing is noted for reference during reassembly.

1. Pump gears, housing, and plate.

1. Pump gears, housing, and plate for abnormal wear of damage.

1. Position new a-rings on valve and housing.
2. Snap ring retaining relief valve assembly.
3. Valve assembly into pump and snap ring.
4. Inner and outer gears. IMPORTANT: Chamfer on inner gear MUST face to the rear (toward engine) so as to accommodate crankshaft a-ring.
5. Pump plate and screws. Tighten Screws to 3 N.m (27 lb. in.).

1. Bolts retaining oil pan baffles to oil pan and baffles from pan.
2. Oil level sensor from pan.

1. Oil pan baffles and bolts. Blow dry with compressed air.

1. Oil pan baffles and bolts. IMPORTANT: Apply Loctite® 262 to bolt threads. Tighten Bolts to 10 N.m (89 lb. in.).
2. Oil level sensor. Tighten Oil level sensor to 25 N.m (18 lb. ft.)

1. Oil pan and crankcase sealing surfaces..

(Scheme 78) through (Scheme 88)

Tools Required

J 8062 Valve Spring Compressor

J 8101 Valve Guide Cleaner

J 23738-A Secondary Port Throttle Valve

Vacuum Actuator Tester

J 23907 Slide Hammer

J 37281-A Valve Guide Seal Remover

J 37310 Valve Guide Seal Installer

J 37325 Secondary Port Throttle Valve

Service Kit

J 37979-A Valve Spring Compressor

Adapter/Secondary Port Throttle Valve

Bearing Remover

Scheme 78

Scheme 79

1. Secondary port shaft lever.
2. Actuator bracket.
3. Throttle valve from shaft.
4. Bearing and shaft assembly from cylinder head using J 37325-1.
5. Bearing from shaft using J 37979-A.
6. Throttle valve shaft seal from cylinder head.
7. Repeat steps for each secondary port.
8. Valve keys using J 8062 with J 37979-A.
9. Upper retainer.
10. Outer spring.
11. Inner spring.
12. Valve from cylinder head.
13. Valve guide seal using J 37281-A and J 23907 (Scheme 81)
14. Lower retainer.
15. Repeat steps for each valve. (Scheme 78): Identifying Secondary Port Throttle Valve Shaft Bearings Components (Scheme 79): Compressing Valve Spring IMPORTANT: Valve guides and seats are not replaceable components. If cylinder head is to be cleaned by soaking, DO NOT use a caustic solution as this will cause serious damage. If combustion chamber is cleaned using a wire wheel, DO NOT contact head deck with wheel.

1. Cylinder case and cylinder head sealing surfaces.
2. Valve guides of carbon using J 8101 .
3. Combustion chambers of carbon.
4. Secondary ports and valves of carbon.

Scheme 80

Scheme 81

Scheme 82

Scheme 83

Scheme 84

Scheme 85

Scheme 86

Scheme 87

Scheme 88

1. Lower retainer.
2. Valve guide seal using J 37310 (intake and exhaust valves (Scheme 84)).
3. Valve into cylinder head.
4. Inner spring.
5. Outer spring.
6. Upper retainer.
7. Valve keys using J 8062 with J 37979-A. IMPORTANT: Strike valve stem tip squarely with a wooden hammer handle to ensure valve stem keys are properly seated.
8. Repeat steps for each valve.
9. Throttle valve shaft seal into head using J 37325.
10. Bearing onto shaft using J 37325-2, J 37325-3, J 37325-4.
11. Bearing and shaft into cylinder head using J 37325-3.
12. Stake bearing in three places with center punch to prevent walkout and port throttle valve binding.
13. Repeat steps for each secondary port.
14. Actuator bracket and screws. Tighten Screws to 10 N.m (89 lb. in.).
15. Shaft lever and nut. Finger tighten into shaft.
16. Throttle valve onto shaft.
17. Apply Loctite® 262 to screws. Finger tighten into shaft.
18. Center throttle valve in bore using J 37325-5.
19. Throttle valve screws. Tighten Throttle valve screws to 1.3 N.m (l2 lb. in.). (Scheme 80): Identifying Valve Assembly Components (Scheme 81): Removing Valve Guide Seal (Scheme 82): Cleaning Valve Guide IMPORTANT: Check for proper operation by rotating valve 360°. No binding should occur. Gap between valve and bore should be 0.25 - 0.35 mm (0.010-0.14 in.).
20. Repeat steps for each secondary port.
21. Link assembly. (Scheme 83): Cleaning Combustion Chambers (Scheme 84): Installing Valve Guide Seal (Scheme 85): Installing Secondary Port Throttle Valve Shaft Seal (Scheme 86): Retaining Secondary Port Throttle Valve In Vertical Position (Scheme 87): Centering Secondary Port Throttle Valve
22. Actuator and nuts. Tighten Nuts to 6 N.m (53 lb. in.).
23. Retain throttle valves in vertical position using J 37325-6 and apply a minimum of 10 in. Hg vacuum using J 23738-A to actuator to simulate port throttle valve operation. Tighten Valve shaft lever nuts to 3 N.m (26 lb. in.).
24. Cover and screws. Tighten Screws to 3 N.m (26 lb. in.). (Scheme 88): Testing Secondary Port Throttle Valves

(Scheme 89) and (Scheme 90)

Tool Required

J 37328 Idler Sprocket Bearing Press Tool

1. Secondary chain fixed and pivot guide wear strips for excessive wear. No wear groove should exceed a depth of 1.0 mm (0.040 in.). Replace wear strips as required by driving pins out of guides.
2. Primary and secondary timing chains for abnormal wear of damage. Inside edge of chain links: metal gouged or scored. Chain for binding: when held with two hands in loop, moving each hand in opposite vertical direction, links should not kink, and chain should roll freely.
3. Primary chain guide wear strip for excessive wear. No wear groove should exceed a depth of 1.0 mm (0.040 in.). If required, replace wear strip as follows: Remove retaining screws and wear strip. Apply Loctite® 262 to screw threads. Install wear strip and screws.
4. Sprockets for abnormal wear or damage. One edge of teeth worn: teeth no longer concentric. Valley between teeth worn: smooth radius no longer evident.
5. Idler sprocket shaft bearings for abnormal wear or damage.

1. Idler sprocket assembly screw: washer and shaft from idler sprocket.
2. Idler sprocket bearings from idler sprocket assembly using J 37328 .

1. Idler sprocket shaft for abnormal wear of damage. CAMSHAFTS

1. Camshaft bearing journals for wear or damage.
2. Camshaft bearing surfaces in cylinder head and camshaft cover for wear or damage.
3. Lifter contact surfaces using straight edge.
4. Check for concave wear on face of lifter.
5. Camshaft lobes for wear. IMPORTANT: Camshaft cover and cylinder head must be replaced as a set if excessive wear or damage to bearing surfaces is found. Individual lifters should not be replaced if cam lobe is worn as this will promote early lifter failure. Lifters should be replaced in sets with camshaft.

Exploded View Of Camshaft Timing Chain Idler Sprocket Assembly. Scheme 89

Installing Idler Sprocket Bearing. Scheme 90

ENGINE FRONT COVER

(Scheme 91)

Tool Required

J 29077-A Front Cover Seal/Oil Pump Seal Remover

1. Cylinder case, engine front cover and coolant pump sealing surfaces.
2. Remove front cover seal with J 29077-A.

CAMSHAFT COVERS

(Scheme 92)

The camshaft covers are matched to the cylinder head. If the camshaft cover is damaged, the camshaft cover and cylinder head must be replaced as an assembly.

Scheme 91

Scheme 92

1. Cylinder head and camshaft cover sealing surfaces. (Scheme 91): Removing Front Cover Seal (Scheme 92): Identifying Secondary Timing Chain Top Guide Components

1. Foam inserts for contamination. Remove and clean or replace as required.
2. Secondary chain top guide wear strips. No wear groove should exceed a depth of 1.0 mm (0.040 in.). Replace if necessary. Remove wear strip from guide and screws and guide from cover. Apply Loctite® 262 to screws and install guide and screws and wear strip to guide.

OIL FILTER HOUSING

(Scheme 93)

1. Filter bypass valve retainer and valve assembly from housing (Scheme 93)
2. Temperature control valve retainer and valve assembly from housing.
3. Cooler bypass valve retainer: valve assembly from housing.
4. Temperature sensor from housing.
5. Cooler fittings from housing.

Scheme 93

1. Housing in solvent and blow out all passages with compressed air.
2. Valve components in solvent and blow dry with compressed air.
3. Cooler fittings. IMPORTANT: Install new a-rings to ensure leak-free operation. (Scheme 93): Exploded View Of Oil Filter Housing

1. Cooler fittings onto housing. IMPORTANT: Apply Loctite® 565 to fitting threads. Tighten Fittings to 11 N.m (8 lb. ft.) and turn 180°.
2. Low oil pressure switch onto housing. IMPORTANT: Apply Loctite® 565 to switch threads. Tighten Switch to 13 N.m (10 lb. ft.).
3. Temperature sensor onto housing. IMPORTANT: Apply Loctite® 565 to sensor threads. Tighten Sensor to 12 N.m (9 lb. ft.).
4. Cooler bypass valve assembly and retainer into housing.
5. Temperature control valve assembly and retainer into housing.
6. Filter bypass valve assembly and retainer into housing.

1. All gasket surfaces.

1. All gasket surfaces for any damage.
2. Hose connectors for loose fit or damage.
3. Hoses and clamps for damage.
4. Throttle body for free movement of butterflies and free rotation of pulleys.
5. Injector housings for loose plugs.

1. Exhaust manifold sealing surfaces.

1. Manifolds for cracks, broken flanges, and gasket surface damage.

CRANKSHAFT REAR OIL SEAL

Tool Required

J 37312 Crankshaft Rear Seal Installer

1. Old seal from housing.

1. New seal into housing using J 37312. IMPORTANT: Seal should be installed 1.0-1.5 mm below housing surface.

(Scheme 94)

Scheme 94

1. Main bearing upper inserts into cylinder case.
2. Main bearing lower inserts into crankcase. IMPORTANT: Lubricate bearings and crankshaft with engine oil.
3. Crankshaft onto cylinder case. Apply Permabond® A136 to crankcase.
4. Crankcase onto cylinder case. IMPORTANT: Do not attempt to rotate crankshaft until all main bearing bolts and crankcase bolts are tightened. Always install NEW main bearing bolts whenever they are removed for any service.
5. Crankcase main bearing washers (oil coated) and bolts; finger tighten.
6. Crankcase bolts along sides: finger tighten.
7. Crankcase bolts at rear: finger tighten. Tighten Main bearing bolts on No. 1, No. 3, No. 5 journals per sequence to 40 N.m (30 lb. ft.) and turn 45-50°. (1992 and earlier). Main bearing bolts on No. 2, No. 4 journals per sequence to 20 N.m (15 lb. ft.) and turn 77.5-82.5°. (1992 and earlier). Inner main bearing bolts per sequence to 20 Nom (15 lb. ft.) and turn 65-70°. (1993 and later). (Scheme 94): Identifying Main Bearing/Crankcase And Inner Bearing Bolts Tightening Sequence Outer main bearing bolts per sequence to 20 N.m (15 lb. ft.) and turn 50-55°. (1993 and later). Crankcase bolts per sequence to 26 N.m (19 lb. ft.) (Scheme 94)

PISTON-ROD ASSEMBLIES

(Scheme 95)

Tools Required

J 36660 Torque/Angle Meter

J 8037 Piston Ring Compressor

J 39494 Connecting Rod Guide Pin

1. Lubricate piston, rings and cylinder liner with engine oil.

1. Piston-rod assembly into cylinder liner using J 8037 and J 39494.
2. Bearing onto rod.
3. Bearing onto rod cap.
4. Lubricate bearings, rod journal and rod cap bolts with engine oil.
5. Rod cap and bolts. IMPORTANT: Always install NEW connecting rod bolts whenever they are removed for any service. Tighten Rod bolts to 30 N.m (22 lb. ft.) and turn 80-85° using J 36660. Repeat steps for each cylinder being serviced. Rotate crankshaft for each cylinder to ease installation of each piston-rod assembly.

1. All connecting rod side clearances (see «SPECIFICATIONS»(/chevrolet/corvette/c4-1984-1998/remont/mechanical/#engine-mechanical-57l-vin-j-engine-overhaul) ) between connecting rod caps on each crankshaft journal with a feeler gage.

(Scheme 96) through (Scheme 98)

Tools Required

J 38135 Oil Pump Aligner and Seal Installer

J 38463 Oil Pump Seal/Torsional Damper Installer

Scheme 95

Scheme 96

Scheme 97

1. New a-ring onto crankshaft.
2. Oil pump and bolts. Finger tighten only. (Scheme 95): Connecting Rod Bearings (Scheme 96): Identifying Oil Pump O-Ring (Scheme 97): Aligning Oil Pump IMPORTANT: Apply Loctite® 262 to bolt threads. Two flats of pump drive gear must be aligned with two flats on crankshaft. DO NOT force pump onto crankshaft.
3. Align pump on crankshaft using J 38135. Tighten Bolts to 26 N.m (19 lb. ft.).
4. Pump shaft seal using J 38135 with J 38463.

Installing Oil Pump Seal. Scheme 98

(Scheme 99) and (Scheme 100)

1. Apply Loctite® 262 to crankcasse baffle and oil pick-up assembly bolts.
2. Crankcase baffle, oil pick-up assembly and bolts. Tighten Baffle and oil pick-up bolts to 10 N.m (89 lb. in.).
3. New gasket and oil pan to crankcase.
4. Apply Loctite® 242 to all screws of oil pan.
5. Screws and bolts retaining pan to crankcase. Tighten Front screws to 12 N.m (106 lb. in.) in sequence. Bolts to 31 N.m (23 lb. ft.) in sequence.

Identifying Oil Pick-Up And Crankcase Baffle Components. Scheme 99

Identifying Oil Pan Bolts Tightening Sequence. Scheme 100

(Scheme 58) and (Scheme 60)

1. Starter and bolts to cylinder case. Tighten Starter bolts to 52 N.m (38 lb. ft.).
2. Ventilation baffle and bolts (Scheme 60) IMPORTANT: Apply Loctite® 262 to bolt threads. Tighten Bolts to 10 N.m (89 lb. in.).
3. New cylinder case ventilation cover gasket, cover, and bolts (Scheme 58) Tighten Bolts to 10 N.m (89 lb. in.).
4. Cylinder case ventilation hoses to cover.
5. Purge solenoid and bolt to cover.
6. Vacuum reservoir and nuts to cover. Tighten Solenoid bolt to 10 N.m (89 lb. in.). Reservoir nuts to 10 N.m (89 lb. in.).

(Scheme 101)

1. Remove liner retainers, J 37330.

1. Cylinder head locating dowels into cylinder case (if removed or loosened during cylinder head removal).
2. Cylinder head gasket, head, washers, and bolts. IMPORTANT: Head bolt threads and washers should be coated with engine oil. IMPORTANT: Head gaskets are not interchangeable between cylinder banks. Tighten Bolts per sequence in three steps to 60 N.m (45 lb. ft.), 100 N.m (74 lb. ft.), 160 N.m (118 lb. ft.) (Scheme 101)

Identifying Cylinder Head Bolts Tightening Sequence. Scheme 101

(Scheme 67), (Scheme 69) and (Scheme 102)

Tools Required

J 38132 Crankshaft Sprocket Installer

J 38099 Timing Chain Retainers

Scheme 102

1. Secondary chain guides and bolts (Scheme 69) IMPORTANT: Apply Loctite® 262 to bolt threads. Flange of guide bushings should face cylinder head. Tighten Bolts to 26 N.m (19 lb. ft.).
2. Oil pump seal seat with larger diameter side toward crankshaft and key. (Scheme 102): Installing Crankshaft Sprocket
3. Crankshaft sprocket using J 38132. IMPORTANT: Wide shoulder of sprocket faces away from engine.
4. Right (shorter) secondary chain through right head and install timing chain retaining tool J 38099. Locate right chain onto inner idler sprocket.
5. Left (longer) secondary chain through left head and install J 38099. Locate left chain onto middle idler sprocket. Engage primary chain onto outer idler sprocket and crankshaft sprocket. IMPORTANT: Apply Loctite® 262 to idler sprocket assembly and primary chain guide bolt threads. Be careful not to plug oil passage in idler sprocket assembly.
6. Idler sprocket assembly bolts.
7. Primary chain guide and bolts. Push guide so that slack is removed from chain. Do not use lever or other tool. Finger pressure is sufficient (Scheme 67) Tighten Bolts to 10 N.m (89 lb. in.).

CAMSHAFTS, LIFTERS AND CAMSHAFT TIMING

(Scheme 64) and (Scheme 103) through (Scheme 106)

Tools Required

J 37305 Camshaft Chain Pre-Tensioners

J 38098 Crankshaft Timing Slot Locator

J 37326 Camshaft Timing Pin Set

J 36660 Torque/Angle Meter

J 37303 Camshaft Temporary Retainers

J 41009 Timing Chain Tensioner Release Tool The camshafts have identifying bands to distinguish the right and left intake and exhaust camshafts. The right intake has one flat band, the right exhaust has one raised band. The left intake has one raised and one flat band and the left exhaust has two raised bands.

Scheme 103

Scheme 104

Scheme 105

Scheme 106

1. Lifters into same bores from where they were removed. IMPORTANT: When a camshaft is replaced, new lifters should always be installed. Lubricate camshaft lobes and journals with clean engine oil.
2. J 38098 into crankshaft sensor opening to locate crankshaft neutral position. Rotate engine until crankshaft timing locator locks into deep notch on crankshaft timing disc.
3. Remove J 38098.
4. Engage camshaft sprocket onto secondary timing chain while removing J 38099. Install intake camshaft first. Flat edge of sprocket faces camshaft.
5. Slide camshaft into sprocket. Locate camshaft in neutral position (no valves being opened).
6. Camshaft temporary retaining caps, J 37303.
7. Camshaft thrust washer, retainers, and bolts (Scheme 64) Tighten Bolts to 10 N.m (89 lb. in.) starting with the rear retainer.
8. Timing plates, washers and bolts, hand tight.
9. Repeat Steps 1 through 4 for remaining camshafts.
10. Camshaft secondary chain pre-tensioner J 37305. Apply tension to chains while rotating crankshaft through two revolutions. After rotation, tighten pre-tensioner an additional 90 degrees. Apply oil to timing chains.
11. J 38098 into crankshaft sensor opening. Rotate engine until crankshaft timing slot locator locks into deep notch on crankshaft timing disc. IMPORTANT: Do not rotate crankshaft after locator tool is inserted into crankshaft notch.
12. Timing pins J 37326 in camshaft retainers and indexing holes in camshafts. Camshaft can be rotated using hex cast into camshaft at rear. Oil holes at front of camshafts will be facing up. IMPORTANT: Sprocket pins are inserted with flat edge to front of engine. A NEW camshaft bolt should be installed each time a bolt is removed. Oil camshaft sprocket washers. Slide washer to sprocket plate to ensure that flat area on pin aligns with the edge of the washer. Apply Loctite® 262 on camshaft sprocket bolts. If no accessible holes line up on timing plate, reverse plate. Tighten Camshaft sprocket bolts to 25 N.m (19 lb. ft.) and turn 80-85 degrees using J 36660. (Scheme 103): Identifying Secondary Timing Chain Pre-Tensioner Components (Scheme 104): Locating Crankshaft Timing Disc Deep Notch (Scheme 105): Installing Camshaft Timing Pin Tool (Scheme 106): Installing Camshaft Sprocket Pin
13. Remove chain pre-tensioners J 37305 and crankshaft locator tool J 38098.
14. New secondary timing chain tensioner, housing, new a-ring, and bolts. IMPORTANT: Oil hole in tensioner piston must be installed in vertical position. Fork on end of tensioner must be properly engaged onto chain guide. After installing tensioner, use J 41009 to release the tensioner plunger. Tighten Bolts to 10 N.m (89 lb. in.).
15. Tensioner housing plugs.
16. Ignition timing sensor into cylinder case. Tighten Bolts to 10 N.m (89 lb. in.).
17. Remove camshaft locking pin tools J 37326.
18. Camshaft sensor and heat shield to left cylinder head. Tighten Sensor bolt to 11 N.m (97 lb. in.).

ENGINE FRONT COVER AND COOLANT PUMP

Figures 20 and (Scheme 107)

Tool Required

J 37309 Front Cover Oil Seal Alignment and Installation Tool

1. Generator spacer to top right of cylinder case near cylinder head.
2. New front cover gasket, cover, nuts, and bolts. Finger tighten only. IMPORTANT: Apply Loctite® 262 to stud threads. Apply Loctite® 565 to bolt threads.
3. New seal using J 37309. Tighten Bolts to 26 N.m (l9 lb. ft.).
4. New coolant pump gasket, pump, and bolts. Tighten Bolts to 26 N.m (19 lb. ft.).

Installing Front Cover Seal. Scheme 107

(Scheme 108)

1. Apply Permabond® A136 to camshaft cover. IMPORTANT: Make sure camshaft cover end plugs and new spark plug bore a-rings are in place prior to cover installation.
2. Camshaft cover and bolts. IMPORTANT: To ensure proper camshaft operation, camshaft cover fasteners MUST be tightened per sequence to proper specification (Scheme 108) Tighten 24 M8 bolts to 20 N.m (15 lb. ft.). Repeat 3 times. 3 M6 screws to 10 N.m (89 lb. in.).
3. Access plugs to front of cylinder heads.
4. Spark plugs. Tighten Access plugs to 20 N.m (15 lb. ft.). Spark plugs to 20 N.m (15 lb. ft.).

Identifying Camshaft Cover Bolts Tightening Sequence. Scheme 108

(Scheme 109)

Tool Required

J 38463 Oil Pump Seal/Torsional Damper Installer

1. Key to crankshaft. IMPORTANT: Key should be checked for proper seating in keyway while installing dampener.
2. Dampener onto crankshaft using J 38463 . IMPORTANT: If dampener is replaced, new balance weights must be installed on the new dampener in the same hole locations as found on the old dampener.
3. Washer and dampener bolts. Apply Loctite® 262 to dampener bolt threads. Bolt to 200 N.m (148 lb. ft.).

POWER STEERING PUMP

1. Power steering pump, reservoir and bracket assembly to left front of engine.
2. Bracket bolts. Apply Loctite® 565 to bolt threads. Bolts to 26 N.m (19 lb. ft.).

Scheme 109

1. NC compressor to top left front of engine.
2. Compressor bolts. Bolts to 26 N.m (19 lb. ft.). (Scheme 109): Installing Torsional Dampener

1. New gasket, new a-rings, housing, and bolts. Tighten Bolts to 26 N.m (19 lb. ft.).
2. Bolt retaining generator bracket and oil filter housing. Do not tighten at this time.
3. Oil pressure sensor. IMPORTANT: Apply Loctite® 565 to sensor threads. Tighten Oil pressure sensor to 12 N.m (9 lb. ft.).
4. Generator, shield and bolts. IMPORTANT: Make sure generator spacer is in position. Refer to " «ENGINE FRONT COVER AND COOLANT PUMP»(/chevrolet/corvette/c4-1984-1998/remont/mechanical/#engine-mechanical-57l-vin-j-engine-overhaul__engine-front-cover-and-coolant-pump) ". Tighten Bolts to 52 N.m (38 lb. ft.).
5. Oil filter.

1. Right and left branches of wiring harness over top of engine.
2. Camshaft sensor connector on left side.
3. Starter connector.
4. NC compressor connector.
5. Solenoid connector to purge solenoid on vent cover. Route right branch of harness under vent cover hose.
6. Generator connector.
7. Oil temperature sensor connector on filter housing.
8. Crankshaft timing sensor connector on right side. Properly orient vent hoses, install clamps and tighten.
9. Coil pack and bolts. Tighten Front bolts to 10 N.m (89 lb. in.). Rear bolts to 26 N.m (l9 lb. ft.).
10. Coil wiring harness connectors.
11. Ground wires to rear right and left cylinder heads.
12. Connector to MAP sensor and lay sensor aside.
13. Spark plug wires to plugs and coil.
14. Oil pressure sensor connector.
15. Knock sensor. Tighten Sensor to 18 N.m (13 lb. ft.).
16. Knock sensor electrical connector.

1. Left injector housing and gasket to cylinder head.
2. Temperature sensors and connectors to left injector housing.
3. Vent hose and clamp to left injector housing.
4. Right injector housing and gasket to cylinder head.
5. Vent hose and clamp to right injector housing. Tighten Hose clamps on right and left vent hoses.
6. Injector housing bolts. Right rear housing bolt secures spark plug wire clip. Tighten Generator brace bolt to 26 N.m (19 lb. ft.). Injector housing bolts to 26 N.m (19 1b. ft.) from the center outward.
7. Fuel rail assembly to injector housings and bolts. Install new fuel injector a-rings. !--ICON --> Tighten Fuel rail bolts to 26 N.m (19 lb. ft.).
8. Electrical connectors to injectors.

PLENUM, THROTTLE BODY AND EXTENSION

(Scheme 56) and (Scheme 110)

Scheme 110

1. Vacuum hoses. Secondary port throttle plate actuators. Solenoid on vent cover. Right side solenoid. Vacuum reservoir. Fuel pressure regulator.
2. Vent tubes to camshaft covers.
3. Ignition module to plenum. Tighten Module bolts to 10 N.m (89 lb. in.).
4. Plenum gaskets to injector housings.
5. Ignition module wiring harness connectors and lower plenum into place on injector housings.
6. Plenum bolts (Scheme 110) Tighten Plenum bolts in sequence to 26 N.m (19 lb. ft.).
7. MAP sensor bracket and bolts to plenum. Tighten Bolts to 10 N.m (89 lb. in.).
8. Electrical and vacuum connectors to MAP sensor.
9. Vacuum hose between fuel pressure regulator and plenum.
10. Purge canister/PCV valve dual hose fitting onto plenum.
11. New gasket, throttle body and screws (Scheme 56) Tighten Screws to 26 N.m (19 lb. ft.).
12. TPS and IAC electrical connectors.
13. Vacuum hose to bottom of throttle body extension.
14. New gasket, throttle body extension and screws. Apply Loctite® 262 to screw threads. Be sure screws have retainers in place. Tighten Screws to 6 N.m (53 lb. in.).
15. MAT sensor, if removed. Apply Loctite® 565 to threads. (Scheme 110): Identifying Plenum Bolts Tightening Sequence Tighten Sensor to 27 N.m (20 lb. ft.).
16. MAT sensor electrical connector.
17. Vent hoses from camshaft covers to throttle body extension. Clean Coolant outlet pipes and injector housing sealing surfaces.
18. Coolant outlet pipe gaskets, pipes and bolts. Tighten Bolts to 10 N.m (89 lb. in.).
19. Remaining vacuum hoses to plenum.

1. Belt tensioner, washer and bolt to coolant pump.
2. Coolant pump pulley and bolts. Tighten Tensioner bolt to 60 N.m (45 lb. ft.). Pulley bolts to 10 N.m (89 lb. in.).
3. Rotate tensioner counter clockwise and install serpentine belt.

(Scheme 111)

1. Exhaust manifold gaskets, manifolds and bolts.
2. Oil level indicator and tube. Tighten Bolts to 24 N.m (18 lb. ft.).
3. Exhaust manifold outer heat shield and screws.

Identifying Exhaust Manifold Components. Scheme 111

CRANKSHAFT REAR OIL SEAL AND FLYWHEEL

(Scheme 112)

Scheme 112

1. Seal/housing assembly onto crankshaft.
2. Housing screws. Tighten Screws to 10 N.m (89 lb. in.).
3. Vee drain pipe. Apply Loctite® 620 to pipe and drive into cylinder case.
4. Flywheel and bolts. IMPORTANT: Flywheel must be installed with the crankshaft dowel pin in the 3 o'clock position. Apply Loctite® 262 to bolt threads. Tighten Bolts to 90 N.m (66 lb. ft.). (Scheme 112): Identifying Crankshaft Rear Seal Components

SEALANT APPLICATION

Bolt, Camshaft Idler Sprocket Assembly .......................... Loctite® 262

Bolt, Camshaft Secondary Timing Chain Fixed Guide.................. Loctite® 262

Bolt, Camshaft Secondary Timing Chain Pivot Guide.................. Loctite® 262

Bolt, Camshaft Sprocket .............. Loctite® 262

Bolt, Crankshaft Dampener ........... Loctite® 262

Bolt, Engine Front Cover.............. Loctite® 565

Bolt, Engine Mount Bracket........... Loctite® 262

Bolt, Engine Timing Plate............ Loctite® 262

Bolt, Flywheel........................ Loctite® 262

Bolt, Generator Lower Bracket ........ Loctite® 565

Bolt, Generator Rear Bracket.......... Loctite® 565

Bolt, Generator Upper Bracket ........ Loctite® 565

Bolt, Oil Pan Baffle................... Loctite® 262

Bolt, Oil Pipe Pick-up/Crankcase Baffle ............................. Loctite® 262

Bolt, P/S Pump Bracket............... Loctite® 262

Bolt, Primary Chain Guide ............ Loctite® 262

Bolt, Starter Motor ................... Loctite® 262

Fitting, Oil Cooler Hose..... Loctite® 565

Joint, Camshaft Cover/Cylinder Head.........................Permabond® A136

Joint, Cylinder Case/Crankcase ... Permabond® A136

Joint, Cylinder Liner/Cylinder Case .... Loctite® 565

Plug, Camshaft....................... Loctite® 565

Plug, Camshaft Secondary Timing Chain Tensioner Housing.................. Loctite® 565

Plug (Core Type), Crankshaft.......... Loctite® 620

Plug (Threaded Taper), Crankshaft .... Loctite® 565

Plug, Cylinder Head Coolant Gallery (3/8-18)..................... Loctite® 565

Plug, Cylinder Head Lifter Gallery (1/4-18)..................... Loctite® 565

Plug, Oil Filter Housing............... Loctite® 565

Screw, Oil Pan ....................... Loctite® 242

Screw, Oil Pump Plate ................ Loctite® 262

Screw, Primary Chain Guide Wear Strip......................... Loctite® 262

Screw, Secondary Chain Top Guide..... Loctite® 262

Screw, Secondary Port Throttle Valve ... Loctite® 262

Screw, Throttle Body Extension........ Loctite® 262

Sensor, Oil Pressure .................. Loctite® 565

Sensor, Oil Temperature .............. Loctite® 565

Stud, Engine Front Cover ............. Loctite® 262

Stud, Exhaust Manifold............... Loctite® 620

Stud, Oil Pan Baffle .................. Loctite® 262

Stud, Secondary Port Throttle Valve Vacuum Actuator Reservoir ......... Loctite® 262

Switch, Engine Coolant Temperature Fan................... Loctite® 565

GENERAL INFORMATION

Type................................90° V8 DOHC

Displacement .................... 5.7L (350 cu. in.)

VIN Code.......................................J

RPO......................................... LT5

Bore...........................99.0 mm (3.897 in.)

Stroke.........................93.0 mm (3.661 in.)

Compression Ratio............................ 11:1

Firing Order ....................... 1-8-4-3-6-5-7-2

Spark Plug

Type................................. AC 41-907

Gap......................... 1.27 mm (0.050 in.)

Torque........................ 26 N.m (19 lb. ft.)

CYLINDER BORE

Diameter ....... 98.988-99.012 mm (3.897-3.898 in.)

PISTON RING

Compression Groove Clearance

1st (Upper) ... 0.050-0.085 mm (0.002-0.003 in.)

2nd (Lower) ... 0.050-0.085 mm (0.002-0.003 in.)

Gap

1st (Upper) 0 040-0.65 mm (0.016-0.026 in.)

2nd (Lower).......0.80-1.0 mm (0.031-0.039 in.)

Oil Groove Clearance ... 0.020-0.055 mm (0.001-0.002 in.)

Gap .............0.30-0.60 mm (0.012-0.024 in.)

PISTON PIN

Diameter .....24.995-25.000 mm (0.9841-0.9843 in.)

Fit in Piston .... 0.006-0.018 mm (0.0002-0.0007 in.)

Fit in Rod....... 0.012-0.022 mm (0.0005-0.0009 in.)

Main Journal

Diameter .........69.98-70.0 mm (2.755-2.756 in.)

Taper......................0.006 mm (0.0002 in.)

Out-of-Round ..............0.008 mm (0.0003 in.)

Main Bearing Clearance .... 0.018-0.0585 mm (0.0007-0.0023 in.)

Crankshaft End Play............0.26 ± 0.1 mm (0.010 ± 0.04 in.)

Rod Journal Diameter .... 53.321-53.340 mm (2.0993-2.100 in.)

Taper......................0.006 mm (0.0002 in.)

Out-of-Round ..............0.008 mm (0.0003 in.)

Rod Bearing

Clearance..... 0.018-0.069 mm (0.0007-0.0027 in.)

Rod Side Clearance ... 0.20-0.70 mm (0.008-0.028 in.)

CAMSHAFT

Lobe Lift ± 0.051 mm (0.002 in.)

Intake.......................9.9 mm (0.3898 in.)

Exhaust .....................9.9 mm (0.3898 in.)

Journal Diameter .. 28.96-28.98 mm (1.140-1.141 in.)

Camshaft End Play ....... 0.14-0.35 mm (0.0055-0.0138 in.)

VALVETRAIN SYSTEM

Type............ Dual Overhead Camshaft, 32 Valve

Lifter...................................Hydraulic

Valve Face Angle ..............................45°

Valve Seat Angle ..............................44°

Valve Seat Runout...........0.10 mm (0.003937 in.)

Valve Seat Width

Intake........ 1.446-1.863 mm (0.0569-0.0734 in.)

Exhaust ...... 1.446-1.863 mm (0.0569-0.0734 in.)

Valve Stem Clearance

Intake........ 0.030-0.065 mm (0.0012-0.0026 in.)

Exhaust ...... 0.035-0.075 mm (0.0014-0.0030 in.)

Valve Spring Inner Spring

Free Length................. 39.2 mm (1.54 in.)

Installed Height............. 30.0 mm (1.18 in.)

Pressure N (lb.) @ Length mm (in.)

Closed.............. 152-168 N (34.2-37.8 lb.) @ 30.0 mm (1.18 in.)

Open ............... 336-364 N (75.5-81.8 lb.) @ 20.0 mm (0.79 in.)

Valve Spring Outer Spring Free Length.................43.5 mm (1.71 in.)

Installed Height............. 34.0 mm (1.34 in.)

Pressure N (lb.) @ Length mm (in.)

Closed.............. 285-340 N (64.1-76.4 lb.)

@ 34.0 mm (1.34 in.)

Open .............653-740 N (146.8-166.4 lb.)

@ 24.0 mm (0.95 in.)

Engine Oil Recommendation

Recommended Synthetic Oil Viscosity SG SAE 5W-30

Engine Oil Capacity

Without Filter Change ................ 8.0 L (7.6 qt.)

With Filter Change .................. 9.0 L (8.6 qt.)

With Oil Cooler Drain and Flush, Without Filter Change ............ 10.1 L (9.6 qt.)

With Oil Cooler Drain and Flush, With Filter Change .............. 11.2 L (10.6 qt.)

With Complete System Drain

Filter Removed, Oil Pan Dry

(After Overhaul)............... 12.3 L (11.6 qt.)

Engine Oil Pressure

Oil Pressure Minimum Oil Pressure (Engine Hot)

@ Idle.........................83 kPa (12 psi)

Minimum Oil Pressure (Engine Hot) above 3000 rpm ...............276 kPa (40 psi)

FASTENER TIGHTENING SPECIFICATIONS

Access Plug-to-Cylinder Head .... 20 N.m (15 lb. ft.)

Belt Tensioner-to-Coolant Pump .. 60 N.m (45 lb. ft.)

Camshaft Bolt ................ 25 N.m (19 lb. ft.) and turn 80-85°

Camshaft Cover-to-Cylinder Head Bolt (M8) ..................... 20 N.m (15 lb. ft.)

Camshaft Cover-to-Cylinder Head Screw (M6)....................10 N.m (89 lb. in.)

Camshaft Position Sensor.........8 N.m (71 lb. in.)

Camshaft Retainer Bolt..........10 N.m (89 lb. in.)

Camshaft Secondary Timing Chain Tensioner Housing-to-Cylinder Case Bolt ................ 10 N.m (89 lb. in.)

Camshaft Secondary Timing Chain Top Guide-to-Camshaft Cover Screw .................6 N.m (53 lb. in.)

Camshaft Sensor ................ 11 N.m (97 lb. in.)

Camshaft Sprocket Bolt.......... 25 N.m (18 lb. ft.) and turn 80-85°

Camshaft Timing Chain Idler Sprocket Assembly-to-Cylinder Case Bolt ................... 26 N.m (19 lb. ft.)

Coil Pack Bracket Front Bolt .....10 N.m (89 lb. in.)

Coil Pack Bracket Rear Bolt...... 26 N.m (19 lb. ft.)

Connecting Rod Cap-to-Connecting Rod Bolt...................... 30 N.m (22 lb. ft.) and turn 80-85°

Coolant Outlet Cover Pipe Bracket-to-Generator Bracket Bolt ................ 52 N.m (38 lb. ft.)

Coolant Outlet Cover-to-Injector Housing Screw ................ 10 N.m (89 lb. in.)

Coolant Outlet Cover Pipe Bracket-to-P/S Pump Bracket Bolt ................ 26 N.m (19 lb. ft.)

Coolant Pump-to-Cylinder Case Bolt ..................... 26 N.m (19 lb. ft.)

Coolant Pump Pulley-to-Pump Hub Bolt......................10 N.m (89 lb.in.)

Coolant Temperature Sensor ..... 27 N.m (20 lb. ft.)

Coolant Pump-to-Cylinder Case Bolt ..................... 26 N.m (19 lb. ft.)

Coolant Temperature Sensor ..... 27 N.m (20 lb. ft.)

Crankcase Baffle Bolt............10 N.m (89 lb. in.)

Crankcase-to-Cylinder Case Bolt ..................... 26 N.m (19 lb. ft.)

(Outer Main Bearing, 1993 and later)

Crankcase-to-Cylinder Case Main Bearing Bolt (M8)........ 20 N.m (15 lb. ft.) and turn 50-55°

(Inner Main Bearing, 1993 and later)

Crankcase-to-Cylinder Case Main Bearing Bolt (M10)..... 20 N.m (15 lb. ft.) and turn 65-75°

(No. 1, No. 3, No. 5 Journals)

Crankcase-to-Cylinder Case Main Bearing Bolt (M/2)

(1992 and earlier) ........... 40 N.m (30 lb. ft.) and turn 45-50°

(No. 2, No. 4 Journals)

Crankcase-to-Cylinder Case

Main Bearing Bolt (M10)

(1992 and earlier) ........... 20 N.m (15 lb. ft.) and turn 77.5-82.5°

Crankshaft Rear Main Oil Seal/Housing Assembly-to-Cylinder Case Screw .................10 N.m (89 lb. in.)

Crankshaft Torsional Dampener-to-Crankshaft Bolt ......................200 N.m (148 lb. ft.)

Cylinder Case Ventilation Baffle-to-Cylinder Case Bolt .... 10 N.m (89 lb. in.)

Cylinder Case Ventilation Housing-to-Cylinder Case Bolt ........................10 N.m (89 lb. in.)

Cylinder Case Ventilation Housing-to-Cylinder Case Bolt ........................10 N.m (89 lb. in.)

Cylinder Head-to-Cylinder Case Bolt ..................... 60 N.m (45 lb. ft.)

EGR Pipe Bolt ..................10 N.m (89 lb. in.)

EGR Valve Base Bolt ............ 26 N.m (19 lb. ft.)

Engine Front Cover-to-Cylinder Case Bolt ..................... 26 N.m (19 lb. ft.)

Engine Front Cover-to-Cylinder Case Stud Nut ................ 28 N.m (21 lb. ft.)

Engine Front Cover Stud......... 11 N.m (97 lb. in.)

Engine Mount Bracket-to-Cylinder Case Bolt ........................ 52 N.m (38 lb. ft.)

Engine Mount-to-Front Crossmember Nut ............. 54 N.m (40 lb. ft.)

Engine Mount-to-Drivetrain and Suspension Frame Nut......... 54 N.m (40 lb. ft.)

Engine Timing Plate-to-Engine

Front Cover Bolt ..............10 N.m (89 lb. in.)

Exhaust Manifold Stud .......... 30 N.m (22 lb. ft.)

Exhaust Manifold-to-Cylinder Head Bolt..................... 24 N.m (18 lb. ft.)

Flywheel Bolts .................. 90 N.m (66 lb. ft.)

Fuel Rail Assembly-to-Injector Housing Bolt.................. 26 N.m (19 lb. ft.)

Idler Sprocket Assembly-to-Cylinder Case Bolt ................... 26 N->m (19 lb. ft.)

Ignition Timing Sensor...........10 N.m (89 lb. in.)

Injector Housing-to-Cylinder Head Bolt..................... 26 N.m (19 lb. ft.)

Low Oil Pressure Switch .......... 12 N.m (9 lb. ft.)

MAP Sensor Bracket-to-Plenum .. 10 N.m (89 lb. in.)

MAT Sensor......................8 N.m (71 lb. in.)

Oil Cooler Hose Fittings-to-Oil Filter Housing ................ 11 N.m (98 lb. in.) and turn 180°

Oil Drain Plug .................. 52 N.m (38 lb. ft.)

Oil Filter Housing-to-Cylinder Case Bolt ..................... 26 N.m (19 lb. ft.)

Oil Level Indicator Guide Tube-to-Exhaust Manifold Bolt........................ 24 N.m (18 lb. ft.)

Oil Level Indicator Guide Tube-to-Cylinder Case Bolt..... 26 N.m (19 lb. ft.)

Oil Level Sensor................. 25 N.m (18 lb. ft.)

Oil Pan Baffle-to-Oil Pan Bolt .... 10 N.m (89 lb. in.)

Oil Pan-to-Crankcase Bolt........ 31 N.m (23 lb. ft.)

Oil Pick-up-to-Oil Pan Bolt.......10 N.m (89 lb. in.)

Oil Pressure Sensor............... 12 N.m (9 lb. ft.)

Oil Pump Plate-to-Pump Housing Screw .................3 N.m (26 lb. in.)

Oil Pump-to-Cylinder Case Bolt ..................... 26 N.m (19 lb. ft.)

Plenum-to-Injector Housing Bolt.................. 26 N.m (19 lb. ft.)

Primary Timing Chain Tensioner-to-Cylinder Case Bolt ............... 10 N.m (89 lb. in.)

Secondary Port Throttle Valve Actuator Bracket-to-Cylinder Head Screw.................10 N.m (89 lb. in.)

Secondary Port Throttle Valve Actuator-to-Bracket Nut ........6 N.m (53 lb. in.)

Secondary Port Throttle Valve Linkage Cover-to-Cylinder Head Screw..................3 N.m (26 lb. in.)

Secondary Port Throttle Valve Shaft Lever Nut................3 N.m (26 lb. in.)

Secondary Port Throttle Valve Vacuum Actuator Adjustment Screw............3 N.m (26 lb. in.)

Secondary Port Throttle Valve Vacuum Actuator Reservoir Bolt................8 N.m (71 lb. in.)

Secondary Port Throttle Valve-to-Valve Shaft Screw .... 1.3 N.m (12 lb. in.)

Secondary Timing Chain Fixed/Pivot Guide-to-Cylinder Case Bolt ................... 26 N.m (19 lb. ft.)

Secondary Timing Chain Tensioner-to-Cylinder Head Bolt ................ 10 N.m (89 lb. in.)

Spark Plug-to-Cylinder Head..... 26 N.m (19 lb. ft.)

Throttle Body-to-Plenum Screw ... 15 N.m (11 lb. ft.)

Throttle Body Extension-to-Throttle Body Screw ..................6 N.m (53 lb. in.)

Special Tools Chart (1 Of 3). Scheme 113

Special Tools Chart (2 Of 3). Scheme 114

Special Tools Chart (3 Of 3). Scheme 115

See also:
• PISTON RING
• SPECIFICATIONS
• ENGINE FRONT COVER AND COOLANT PUMP