Engine Mechanical - 4.3L: Other Chevrolet Silverado 1500 HD

Intermittent

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

Tools Required

J 35667-A Cylinder Head Leakdown Tester With the use of air pressure, a cylinder leakage test will aid in the diagnosis. Use the cylinder leakage test in conjunction with the engine compression test in order to isolate the cause of leaking cylinders.

1. Disconnect the battery ground negative cable.
2. Remove the spark plugs. Refer to «SPARK PLUG»(ref-157348-S39708791382003090200000) .
3. Rotate the crankshaft to place the piston in the cylinder being tested at top dead center (TDC) of the compression stroke, with both valves closed.
4. Install the J 35667-A . IMPORTANT: It may be necessary to hold the crankshaft balancer bolt to prevent piston movement.
5. Apply shop air pressure to the J 35667-A and adjust according to the manufacturer instructions. IMPORTANT: Perform the leakage test on all cylinders and record the values before doing any repairs.
6. Record the cylinder leakage value. Cylinder leakage that exceeds 25 percent is considered excessive and may require component service. In excessive leakage situations, inspect for the following conditions: 6.1. Air leakage from the intake or exhaust system may indicate a worn or burnt valve or a broken valve spring. 6.1.1. Remove the valve rocker arm cover of the suspect cylinder head. Refer to «Valve Rocker Arm Cover Replacement - Left»(ref-188990-S32770270612005091300000) or «Valve Rocker Arm Cover Replacement - Right»(ref-188990-S12943198792005091300000) . 6.1.2. Ensure that both valves are closed. 6.1.3. Inspect the cylinder head for a broken valve spring. 6.1.4. Remove and inspect the suspect cylinder head. Refer to «Cylinder Head Replacement - Left»(ref-188990-S22174477792005091300000) or «Cylinder Head Replacement - Right»(ref-188990-S14134447862005091300000) . 6.2. Air leakage from the crankcase, oil level indicator, or oil fill tube may indicate worn piston rings, a damaged piston, a worn or scored cylinder bore, a damaged engine block or a damaged cylinder head. 6.2.1. Remove the piston from the suspect cylinder. Refer to «Piston, Connecting Rod, and Bearing Removal»(ref-188990-S24365232262005091300000) or «Piston, Connecting Rod, and Bearing Installation»(ref-188990-S22015787392005091300000) . 6.2.2. Inspect the piston and connecting rod assembly. Refer to «Piston, Connecting Rod, and Bearings Cleaning and Inspection»(ref-188990-S38317294252005091300000) . . 6.2.3. Inspect the engine block. Refer to «Engine Block Cleaning and Inspection»(ref-188990-S07471905532005091300000) . 6.2.4. Inspect the cylinder head. Refer to «Cylinder Head Cleaning and Inspection»(ref-188990-S37728736272005091300000) . 6.3. Air bubbles in the cooling system may indicate a damaged cylinder head or a damaged cylinder head gasket. 6.3.1. Remove both cylinder heads. Refer to «Cylinder Head Replacement - Left»(ref-188990-S22174477792005091300000) or «Cylinder Head Replacement - Right»(ref-188990-S14134447862005091300000) . 6.3.2. Inspect both cylinder heads. Refer to «Cylinder Head Cleaning and Inspection»(ref-188990-S37728736272005091300000) . 6.3.3. Inspect the engine block. Refer to «Engine Block Cleaning and Inspection»(ref-188990-S07471905532005091300000) .
7. Remove the J 35667-A .
8. Install the spark plugs. Refer to «SPARK PLUG»(ref-157348-S39708791382003090200000) . CAUTION: Refer to «BATTERY DISCONNECT CAUTION»(ref-175132-S30614301632005041500000) .
9. Connect the battery ground negative cable.

Functional Check

With these systems, any blow-by in excess of the system capacity, from a badly worn engine, sustained heavy load, etc., is exhausted into the air cleaner and is drawn into the engine.

Proper operation of the crankcase ventilation system depends upon a sealed engine. If oil slugging or dilution is noted and the crankcase ventilation system is functioning properly, check the engine for a possible cause. Correct any problems.

If an engine is idling rough, check for a clogged crankcase ventilation valve, a dirty vent filter, air cleaner element, or plugged hose. Replace as required. Use the following procedure

1. Remove the crankcase ventilation valve from the rocker arm cover.
2. Operate the engine at idle.
3. Place your thumb over the end of the valve in order to check for a vacuum. If there is no vacuum at the valve, check for the following items: Plugged hoses The manifold port The crankcase ventilation valve
4. Turn OFF the engine. Remove the crankcase ventilation valve. Shake the valve. Listen for the rattle of the check needle inside of the valve. If valve does not rattle, replace the valve.

1. J 22794 Spark Plug Port Adapter
2. J 38606 Valve Spring Compressor
3. J 5892-D Valve Spring Compressor
4. J 42073 Valve Stem Oil Seal Installer

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1. Remove the required valve rocker arms. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-188990-S34861579492005091300000) .
2. Remove the required spark plugs. Refer to «SPARK PLUG»(ref-157348-S39708791382003090200000) .
3. Install the J 22794 into the spark plug hole.
4. Connect a shop air supply hose and apply compressed air in order to hold the valves in place.
5. Install a flat washer onto the removed rocker arm bolt.
6. Install the bolt and rocker arm for the valve spring requiring removal. CAUTION: Compressed valve springs have high tension against the valve spring compressor. Valve springs that are not properly compressed by or released from the valve spring compressor can be ejected from the valve spring compressor with intense force. Use care when compressing or releasing the valve spring with the valve spring compressor and when removing or installing the valve stem keys. Failing to use care may cause personal injury.
7. Using J 5892-D compress the valve spring. 7.1. Hook the slotted end of J 5892-D under the washer on the rocker arm bolt. 7.2. Apply steady pressure on the valve spring cap until the valve keys are accessible. NOTE: Completely engage the J 38606 jaws on the valve spring. The J 38606 may slip off and scratch the valve spring. Replace the valve spring if the valve spring becomes scratch.
8. Use J 38606 when J 5892-D will not fit.
9. Remove the valve keys (1).
10. Carefully release the valve spring tension.
11. Remove the J 5892-D or the J 38606 .
12. Remove the valve spring cap (2) and valve spring (3).
13. Remove the valve stem oil seal (4).

J 3049-A Valve Lifter Remover

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1. Remove the intake manifold. Refer to «Intake Manifold Replacement - Lower»(ref-188990-S10715529002005091300000) .
2. Remove the pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-188990-S34861579492005091300000) . IMPORTANT: Place the components in a rack so that the components can be installed to their original location.
3. Remove the bolts and lifter pushrod guide. IMPORTANT: Place the valve lifters in the rack in the upright position in order to maintain the oil inside the valve lifters.
4. Remove the lifters. IMPORTANT: Some valve lifters may be stuck in the valve lifter bores because of gum or varnish deposits and may require the use of J 3049-A for removal.
5. Use the J 3049-A in order to remove the stuck valve lifters.
6. Use a cleaning solvent and a shop towel to clean any varnish from the valve lifter bores.
7. Inspect the lifter bores for excessive wear or scoring. Replace the engine block if there is excessive wear or deep scoring.
8. Inspect the camshaft for wear or damage. If the wear is questionable remove the camshaft and inspect. Refer to «Camshaft and Bearings Cleaning and Inspection»(ref-188990-S11949042142005091300000) .
9. Clean and inspect the lifters, if necessary. Refer to «Valve Lifters and Guides Cleaning and Inspection»(ref-188990-S15160220342005091300000) .

J 36660-A Torque Angle Meter

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1. Drain the cooling system. Refer to «DRAINING AND FILLING COOLING SYSTEM»(ref-188992-S10584397332005091300000) .
2. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-188990-S25259374762005091300000) .
3. Remove the lower intake manifold. Refer to «Intake Manifold Replacement - Lower»(ref-188990-S10715529002005091300000) .
4. Remove the left exhaust manifold. Refer to «EXHAUST MANIFOLD REPLACEMENT - LEFT (4.3L ENGINE)»(ref-203989-S23015432972005110700000) .
5. Remove the left side pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-188990-S34861579492005091300000) .
6. Remove the junction block bracket bolt.
7. Position the bracket and wiring harness aside.
8. Loosen the power steering (P/S) pump rear bracket nut.
9. Remove the P/S pump rear bracket front nut.
10. Remove the bolts and nut for the P/S pump bracket.
11. Leave the air conditioning (A/C) compressor, if equipped, and the P/S pump on the bracket.
12. Slide the P/S pump bracket off of the stud and set aside.
13. Remove the P/S pump bracket stud.
14. Remove the harness ground bolt.
15. Position the harness ground (4) and ground strap (5).
16. Remove the engine coolant temperature (ECT) sensor.
17. Remove the spark plugs.
18. Remove the spark plug wire support bolts and support.
19. Remove the cylinder head bolts.
20. Remove the cylinder head.
21. Remove and discard the cylinder head gasket.
22. Remove the cylinder head locator pins, if necessary.
23. Clean and inspect the cylinder head, if necessary. Refer to «Cylinder Head Cleaning and Inspection»(ref-188990-S37728736272005091300000) .
24. Disassemble the cylinder head, if necessary. Refer to «Cylinder Head Disassemble»(ref-188990-S06356725892005091300000) .

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1. Assemble the cylinder head, if necessary. Refer to «Cylinder Head Assemble»(ref-188990-S00243288822005091300000) .
2. Install the cylinder head locator pins, if necessary. IMPORTANT: Do not use any type of sealer on the cylinder head gasket.
3. Install a NEW cylinder head gasket.
4. Install the cylinder head.
5. Apply sealant GM P/N 12346004, (Canadian P/N 109534480), or equivalent to the threads of the cylinder head bolts. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
6. Install the cylinder head bolts until snug.
7. Tighten the cylinder head bolts using the sequence shown. Tighten 7.1. Tighten the bolts a first pass to 30 N.m (22 lb ft). 7.2. Tighten the long bolts (1, 4, 5, 8, 9) a final pass to 75 degrees using the J 36660-A. 7.3. Tighten the medium bolts (12,13) a final pass to 65 degrees using the J 36660-A. 7.4. Tighten the short bolts (2, 3, 6, 7, 10, 11) a final pass to 55 degrees using the J 36660-A.
8. Install the spark plug wire support and bolts. Tighten Tighten the bolts to 12 N.m (106 lb in).
9. Install the spark plugs.
10. If installing NEW spark plugs measure for the correct gap. Adjust the spark plug gap if necessary. Specification Spark plug gap to 1.52 mm (0.060 in). Tighten Tighten the plugs in a USED cylinder head to 15 N.m (11 lb ft). Tighten the plugs on the initial installation of a NEW cylinder head to 30 N.m (22 lb ft).
11. Install the ECT sensor. If reusing the old sensor, apply sealant GM P/N 12346004 (Canadian P/N 109534480), or equivalent to the threads. Tighten Tighten the sensor to 20 N.m (15 lb ft).
12. Position the ground strap (5) and harness ground (4).
13. Install the harness ground bolt. Tighten Tighten the bolt to 16 N.m (12 lb ft).
14. Install the P/S pump bracket stud. Tighten Tighten the stud to 20 N.m (15 lb ft).
15. Slide the P/S pump bracket rearward.
16. Install the bolts and nuts for the P/S pump bracket.
17. Install the P/S pump rear bracket front nut.
18. Tighten the P/S pump rear bracket nut. Tighten Tighten the bolts and nuts to 41 N.m (30 lb ft).
19. Position the bracket and wiring harness.
20. Install the junction block bracket bolt. Tighten Tighten the bolt to 25 N.m (18 lb ft).
21. Install the left side pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-188990-S34861579492005091300000) .
22. Install the left exhaust manifold. Refer to «EXHAUST MANIFOLD REPLACEMENT - LEFT (4.3L ENGINE)»(ref-203989-S23015432972005110700000) .
23. Install the lower intake manifold. Refer to «Intake Manifold Replacement - Lower»(ref-188990-S10715529002005091300000) .
24. Install the drive belt. Refer to «Drive Belt Replacement»(ref-188990-S25259374762005091300000) .
25. Fill the cooling system. Refer to «DRAINING AND FILLING COOLING SYSTEM»(ref-188992-S10584397332005091300000) .

J 36660-A Torque Angle Meter

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1. Drain the cooling system. Refer to «DRAINING AND FILLING COOLING SYSTEM»(ref-188992-S10584397332005091300000) .
2. Remove the generator bracket.
3. Remove the intake manifold. Refer to «Intake Manifold Replacement - Lower»(ref-188990-S10715529002005091300000) .
4. Remove the right exhaust manifold. Refer to «EXHAUST MANIFOLD REPLACEMENT - RIGHT (4.3L ENGINE)»(ref-203989-S19178439462005110700000) .
5. Remove the right pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-188990-S34861579492005091300000) .
6. Remove the generator bracket stud from the cylinder head.
7. Remove the spark plugs.
8. Remove the spark plug wire support bolts and support.
9. Remove the cylinder head bolts.
10. Remove the cylinder head.
11. Remove and discard the cylinder head gasket.
12. Remove the cylinder head locator pins, if necessary.
13. Clean and inspect the cylinder head, if necessary. Refer to «Cylinder Head Cleaning and Inspection»(ref-188990-S37728736272005091300000) .
14. Disassemble the cylinder head, if necessary. Refer to «Cylinder Head Disassemble»(ref-188990-S06356725892005091300000) .

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1. Assemble the cylinder head, if necessary. Refer to «Cylinder Head Assemble»(ref-188990-S00243288822005091300000) .
2. Install the cylinder head locator pins, if necessary. IMPORTANT: Do not use any type of sealer on the cylinder head gasket.
3. Install a NEW cylinder head gasket.
4. Install the cylinder head.
5. Apply sealant GM P/N 12346004, (Canadian P/N 109534480), or equivalent to the threads of the cylinder head bolts. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
6. Install the cylinder head bolts until snug.
7. Tighten the cylinder head bolts using the sequence shown. Tighten Tighten the bolts a first pass to 30 N.m (22 lb ft). Tighten the long bolts (1, 4, 5, 8, 9) a final pass to 75 degrees using the J 36660-A . Tighten the medium bolts (12, 13) a final pass to 65 degrees using the J 36660-A . Tighten the short bolts (2, 3, 6, 7, 10, 11) a final pass to 55 degrees using the J 36660-A .
8. Install the spark plug wire support and bolts. Tighten Tighten bolts to 12 N.m (106 lb in).
9. Install the spark plugs.
10. If installing NEW spark plugs measure for the correct gap. Adjust the spark plug gap if necessary. Specification Spark plug gap to 1.52 mm (0.060 in). Tighten Tighten the plugs on a USED cylinder head to 15 N.m (11 lb ft). Tighten the plugs on the initial installation of a NEW cylinder head to 30 N.m (22 lb ft).
11. Install the generator bracket stud. Tighten Tighten the stud to 20 N.m (15 lb ft).
12. Install the right pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-188990-S34861579492005091300000) .
13. Install the exhaust manifold. Refer to «EXHAUST MANIFOLD REPLACEMENT - RIGHT (4.3L ENGINE)»(ref-203989-S19178439462005110700000) .
14. Install the intake manifold. Refer to «Intake Manifold Replacement - Lower»(ref-188990-S10715529002005091300000) .
15. Install the generator bracket.
16. Fill the cooling system. Refer to «DRAINING AND FILLING COOLING SYSTEM»(ref-188992-S10584397332005091300000) .

J 23523-F Crankshaft Balancer Remover and Installer

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1. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-188990-S25259374762005091300000) .
2. Remove the cooling fan. Refer to «FAN REPLACEMENT»(ref-188992-S38409126652005091300000) . NOTE: To prevent damage to the end of the crankshaft when using a crankshaft balancer removal tool install a bolt in the crankshaft. Use a shorter bolt with the same threads as the crankshaft balancer bolt. This bolt will allow a place for the tool to push against. The shorter bolt is to keep from going past the threads in the crankshaft and damaging the crankshaft threads.
3. Remove the crankshaft balancer bolt and washer.
4. Remove the crankshaft pulley bolts and pulley.
5. Using J 23523-F , remove the crankshaft balancer. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) . 5.1. Install the J 23523-F plate and bolts onto the crankshaft balancer. Tighten Tighten the bolts to 25 N.m (18 lb ft). 5.2. Install the J 23523-F forcing screw into the plate. 5.3. Rotate the J 23523-F forcing screw clockwise in order to remove the crankshaft balancer.
6. Remove the J 23523-F from the crankshaft balancer.
7. Note the position and length of any crankshaft balancer weights, if necessary.
8. Clean and inspect the crankshaft balancer, if necessary. Refer to «Crankshaft Balancer Cleaning and Inspection»(ref-188990-S37655904892005091300000) .

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1. Apply a small amount of grease to the crankshaft front cover seal sealing surface if reusing the seal. IMPORTANT: The length and location of the weight(s) must be the same as the original.
2. Ensure that the crankshaft balancer weight(s) is installed in the proper location, if necessary. NOTE: The inertial weight section of the crankshaft balancer is assembled to the hub with a rubber type material. The correct installation procedures (with the proper tool) must be followed or movement of the inertial weight section of the hub will destroy the tuning of the crankshaft balancer.
3. Apply a small amount of adhesive GM P/N 12346141, (Canadian P/N 10953433), or equivalent into the crankshaft balancer keyway in order to seal the crankshaft balancer keyway and crankshaft joint.
4. Align the keyway of the crankshaft balancer with the crankshaft balancer key.
5. Install the crankshaft balancer onto the end of the crankshaft.
6. Using J 23523-F , press the crankshaft balancer onto the crankshaft. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) . 6.1. Install the J 23523-F plate and bolts onto the front of the crankshaft balancer. Tighten Tighten the bolts to 25 N.m (18 lb ft). 6.2. Install the J 23523-F forcing screw into the end for the crankshaft. 6.3. Install the J 23523-F bearing, the washer, and the nut onto the forcing screw. 6.4. Rotate the J 23523-F nut clockwise until the crankshaft balancer hub is completely seated against the crankshaft position sensor reluctor ring.
7. Remove the J 23523-F .
8. Install the crankshaft pulley and bolts. Tighten Tighten the bolts to 58 N.m (43 lb ft).
9. Ensure that the crown of the crankshaft balancer washer (2) is faced away from the engine.
10. Install the crankshaft balancer washer and bolt. Tighten Tighten the bolt to 95 N.m (70 lb ft).
11. Install the cooling fan. Refer to «FAN REPLACEMENT»(ref-188992-S38409126652005091300000) .
12. Install the drive belt. Refer to «Drive Belt Replacement»(ref-188990-S25259374762005091300000) .

J 35468 Cover Aligner and Seal Installer

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1. Remove the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-188990-S24817733472005091300000) .
2. Use a suitable seal puller, remove the crankshaft front oil seal.
3. Inspect the engine front cover seal bore area for damage.

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1. Lubricate the exterior of the NEW seal with clean engine oil.
2. Using J 35468 and a hammer, install the crankshaft front oil seal.
3. Ensure the crankshaft front oil seal is flush and square to the engine front cover.
4. Install the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-188990-S24817733472005091300000) .

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1. Remove the water pump. Refer to «WATER PUMP REPLACEMENT (4.3L ENGINE)»(ref-188992-S16947220012005091300000) .
2. Remove the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-188990-S24817733472005091300000) .
3. Remove the oil pan. Refer to «Oil Pan Replacement»(ref-188990-S12863742982005091300000) .
4. Remove the engine shield bolts and shield.
5. Disconnect the crankshaft position (CKP) sensor electrical connector (5).
6. Remove the CKP sensor bolt and sensor.
7. Remove and discard the CKP sensor O-ring seal.
8. Remove the front cover bolts. IMPORTANT: After the composite front cover is removed do not reinstall the front cover. Always install a NEW front cover.
9. Remove and discard the front cover.
10. Clean all sealing surfaces.

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1. Install a NEW front cover. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
2. Install the front cover bolts. Tighten Tighten the bolts to 12 N.m (106 lb in). IMPORTANT: DO NOT reuse the original CKP sensor O-ring seal.
3. Lubricate a NEW CKP sensor O-ring seal with clean engine oil.
4. Install the NEW O-ring seal onto the CKP sensor. IMPORTANT: When installing the CKP sensor, make sure the sensor is fully seated before tightening the bolt. A poorly seated sensor may perform erratically and may set false DTCs.
5. Install the CKP sensor and bolt. Tighten Tighten the bolt to 8 N.m (71 lb in).
6. Connect the CKP sensor electrical connector (5).
7. Install the engine shield and bolts. Tighten Tighten the bolts to 20 N.m (15 lb ft).
8. Install the oil pan. Refer to «Oil Pan Replacement»(ref-188990-S12863742982005091300000) .
9. Install the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-188990-S24817733472005091300000) .
10. Install the water pump. Refer to «WATER PUMP REPLACEMENT (4.3L ENGINE)»(ref-188992-S16947220012005091300000) .

J 5590 Rear Pinion Bearing Race Installer

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1. Remove the engine front cover. Refer to «Engine Front Cover Replacement»(ref-188990-S15972686922005091300000) .
2. Remove the crankshaft position (CKP) sensor reluctor ring.

1. J 5825-A Crankshaft Gear Remover
2. J 5590 Rear Pinion Bearing Race Installer

1. J 8092 Universal Driver Handle
2. J 36660-A Torque Angle Meter
3. J 36996 Balance Shaft Installer

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1. Remove the radiator. Refer to «RADIATOR REPLACEMENT»(ref-188992-S41168071262005091300000) .
2. Remove the air conditioning (A/C) condenser. Refer to «CONDENSER REPLACEMENT»(ref-188960-S27462254692005091100000) .
3. Remove the lifter pushrod guide. Refer to «Valve Lifter Replacement»(ref-188990-S17616145452005091300000) .
4. Remove the timing chain and camshaft sprocket. Refer to «Timing Chain and Sprockets Replacement»(ref-188990-S23294840662005091300000) .
5. Remove the balance shaft drive gear.
6. Remove the balance shaft driven gear bolt. 6.1. Use a wrench in order to secure the balance shaft. Place the wrench onto the balance shaft near to the balance shaft front bearing. 6.2. Remove the balance shaft bolt. 6.3. Remove the wrench from the balance shaft.
7. Remove the balance shaft driven gear.
8. Remove the balance shaft retainer bolts and retainer. IMPORTANT: The balance shaft and the balance shaft front bearing are serviced only as a package. Do not remove the balance shaft front bearing from the balance shaft.
9. Use a soft-faced hammer in order to remove the balance shaft from the engine block.
10. Clean and inspect the balance shaft, if necessary. Refer to «Balance Shaft Cleaning and Inspection»(ref-188990-S41738271522005091300000) .

1. J 26941 Bushing and Bearing Remover
2. J 38834 Balance Shaft Service Kit

J 41712 Oil Pressure Switch Socket

J 35621-B Rear Main Seal Installer

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1. Remove the flywheel. Refer to «Engine Flywheel Replacement»(ref-188990-S34336475872005091300000) .
2. Insert a flat-tipped screwdriver into the access notches and carefully pry the seal from the housing.
3. Discard the seal.
4. Clean off any dirt or rust in the area.

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1. Apply 2 to 3 drops of clean engine oil to the bore of the housing.
2. Apply 2 to 3 drops of clean engine oil to the outside diameter of the engine flywheel pilot flange.
3. Apply 1 drop of clean engine oil to the outside diameter of the flywheel locator pin.
4. Apply 2 to 3 drops of clean engine oil to the crankshaft seal surface.
5. Inspect the J 35621-B flange for imperfections that may damage the NEW seal. Minor imperfections may be removed with a fine grade emery cloth. IMPORTANT: DO NOT allow oil or any other lubricants to contact the seal lip surface of the seal.
6. Remove the sleeve from the seal.
7. Apply 2 to 3 drops of clean engine oil to the outside diameter of the seal.
8. Install the seal onto the J 35621-B.
9. Install the J 35621-B onto the rear of the crankshaft and hand tighten the tool bolts until snug. NOTE: Proper alignment of the crankshaft rear oil seal is critical. Install the crankshaft rear oil seal near to flush and square to the crankshaft rear oil seal housing. Failing to do so may cause the crankshaft rear oil seal or the crankshaft rear oil seal installation tool to fail.
10. Install the seal onto the crankshaft and into the housing. 10.1. Turn the J 35621-B wing nut clockwise until the seal is installed close to flush and square to the housing. Increased resistance will be felt when the seal has reached the bottom of the housing bore. 10.2. Turn the J 35621-B wing nut counterclockwise to release the J 35621-B from the seal.
11. Remove the J 35621-B .
12. Wipe off any excess engine oil with a clean rag.
13. Install the engine flywheel. Refer to «Engine Flywheel Replacement»(ref-188990-S34336475872005091300000) .

J 41427 Engine Lift Brackets

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Scheme 579

1. Raise the hood to the service position, perform the following: 1.1. Remove the hood hinge bolts (1). 1.2. Raise the hood until vertical. 1.3. Install the hood hinge bolts until snug in the service position (2).
2. Disconnect the negative battery cable. Refer to «BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE (SINGLE BATTERY)»(ref-188993-S31717251372005091300000) .
3. Drain the cooling system. Refer to «DRAINING AND FILLING COOLING SYSTEM»(ref-188992-S10584397332005091300000) .
4. Remove the fuel pipes/hoses. Refer to «FUEL HOSES & PIPES»(ref-159093-S06507509882003111200000) .
5. Remove the lower fan shroud. Refer to «FAN SHROUD REPLACEMENT-LOWER»(ref-188992-S11200099902005091300000) .
6. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-188990-S25259374762005091300000) .
7. Raise and suitably support the vehicle. Refer to «JACKING AND LIFTING»(ref-188958) .
8. If equipped, remove the oil pan skid plate bolts and plate.
9. If equipped, remove the engine shield. «ENGINE PROTECTION SHIELD REPLACEMENT»(ref-204199-S23788761892005110900000)
10. Remove the starter. Refer to «STARTER MOTOR»(ref-168656-S31439200122004111300000) .
11. Remove the transmission cover.
12. Remove the positive battery cable clip bolt (2).
13. Remove the catalytic converter. Refer to «CATALYTIC CONVERTER REPLACEMENT (4.3L, 4.8L AND 5.3L ENGINES)»(ref-203989-S08615031552005110700000) .
14. Remove the battery cable bracket bolts.
15. Disconnect the oil level sensor electrical connector (7).
16. Disconnect the crankshaft position (CKP) sensor electrical connector (5) and remove the harness from the retainer clip.
17. Remove the ground bolt (3) holding the negative battery cable (6) and ground cable (4) to the engine.
18. If equipped, remove the torque converter bolts.
19. Remove the transmission bolts.
20. Lower the vehicle.
21. Reposition the radiator inlet hose clamp.
22. Remove the radiator inlet hose from the thermostat housing.
23. Reposition the radiator outlet hose clamps.
24. Remove the radiator outlet hose from the surge tank.
25. Remove the radiator outlet hose from the water pump.
26. If equipped, disconnect the cruise control cable from the throttle lever.
27. If equipped, remove the cruise control cable from the accelerator control cable bracket.
28. Remove the accelerator cable from the throttle body lever. CAUTION: In order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle. In order to avoid cruise control cable damage, position the cable out of the way while you remove or install the engine. Do not pry or lean against the cruise control cable and Do not kink the cable. You must replace a damaged cable.
29. Remove the accelerator cable from the accelerator control cable bracket.
30. Remove the accelerator cable from the throttle body lever.
31. Remove the accelerator control cable bracket nuts.
32. Remove the accelerator control cable bracket with the cables attached, from the throttle body.
33. Reposition and secure the bracket and cable out of the way.
34. If equipped, remove the air conditioning (A/C) hoses.
35. Disconnect the following electrical connectors: A/C pressure switch (4), if equipped A/C compressor clutch (1), if equipped
36. Remove the positive cable nut and cable from the generator.
37. Disconnect the following electrical connectors: Throttle position (TP) sensor (1) Idle air control (IAC) motor (2) Control port injector module (3) Engine coolant temperature (ECT) sensor (5)
38. Remove the engine wiring harness clip bolt (4).
39. Disconnect the following electrical connectors: Evaporative emission (EVAP) canister purge solenoid valve (1) Manifold absolute pressure (MAP) sensor (2)
40. Disconnect the following electrical connectors: Ignition coil (1) Ignition coil driver (2) Generator (3)
41. Remove the engine wiring harness ground nut and ground wire (4) from the rear of the right cylinder head.
42. Disconnect the following electrical connectors: Knock sensor (1) Camshaft position (CMP) sensor (2) Fuel pump/oil pressure sensor (3) Distributor (2)
43. Remove the harness ground bolt.
44. Reposition the harness ground (4) and ground strap (5).
45. Remove the engine wiring harness bracket nuts.
46. Remove the engine wiring harness bracket from the studs.
47. Remove the junction block bracket bolt.
48. Reposition the bracket and wiring harness aside.
49. Remove the engine wiring harness rear bracket nut at the EVAP canister purge solenoid valve.
50. Remove the stud holding the engine wiring harness bracket.
51. Reposition the engine wiring harness with the bracket aside.
52. Remove the heater hoses. Refer to HEATER HOSE REPLACEMENT-INLET (LU3) or HEATER HOSE REPLACEMENT-OUTLET (LU3) .
53. Remove the distributor cap. Refer to «DISTRIBUTOR»(ref-157348-S39798927472003081100000) .
54. Disconnect the EVAP canister harness from the purge solenoid valve.
55. Disconnect the power brake booster vacuum hose from the vacuum fitting.
56. Loosen the power steering (P/S) pump rear bracket nut.
57. Remove the P/S pump rear bracket front nut.
58. Remove the bolts and the nut for the P/S pump bracket.
59. Leave the A/C compressor, if equipped, and the P/S pump on the bracket.
60. Slide the P/S pump bracket forward off the stud and set aside.
61. Remove the thermostat and water outlet. Refer to «THERMOSTAT REPLACEMENT (4.3L ENGINE)»(ref-188992-S07590252002005091300000) .
62. Remove the left front and right rear intake manifold lower bolts.
63. Install J 41427 to the left front and right rear intake manifold bolts, using the following procedure: 63.1. Install the J 41427 marked RIGHT REAR. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) . 63.2. Install the lift bracket bolts. Tighten Tighten the bolts to 15 N.m (11 lb ft). 63.3. Install the J 41427 marked LEFT FRONT with the arrow pointing to the front of the engine. 63.4. Install the lift bracket bolts. Tighten Tighten the bolts to 15 N.m (11 lb ft).
64. Install a suitable lifting devise to the engine lift brackets.
65. Remove the engine mount to engine mount bracket nuts.
66. Support the transmission with a suitable floor jack.
67. Remove the engine.

Scheme 580

Scheme 581

Scheme 582

Scheme 583

Scheme 584

Scheme 585

Scheme 586

Scheme 587

Scheme 588

Scheme 589

Scheme 590

Scheme 591

Scheme 592

Scheme 593

Scheme 594

Scheme 595

Scheme 596

Scheme 597

Scheme 598

Scheme 599

Scheme 600

Scheme 601

Scheme 602

Scheme 603

Scheme 604

Scheme 605

Scheme 606

1. Install the engine. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
2. Install the engine mount to engine mount bracket bolts. Tighten Tighten the bolts to 65 N.m (48 lb ft).
3. Remove the lifting devise and the J 41427
4. Apply threadlock GM P/N 12345382, (Canadian P/N 10953489), or equivalent to the threads of the intake manifold lower bolts.
5. Install the intake manifold bolts. Tighten 5.1. Tighten the bolts a first pass to 3 N.m (27 lb in). 5.2. Tighten the bolts a second pass to 12 N.m (106 lb in). 5.3. Tighten the bolts a final pass to 15 N.m (11 lb ft).
6. Install one transmission bolt until snug.
7. Remove the support jack from under the transmission.
8. Install the thermostat and water outlet. Refer to THERMOSTAT REPLACEMENT (4.3L ENGINE)
9. Slide the P/S pump bracket onto the stud.
10. Install the bolts and the nut for the P/S pump bracket.
11. Install the P/S pump rear bracket front nut.
12. Tighten the P/S pump rear bracket nut. Tighten Tighten the bolts and nuts to 41 N.m (30 lb ft).
13. Connect the power brake booster vacuum hose to the vacuum fitting.
14. Connect the EVAP canister harness to the purge solenoid valve.
15. Install the distributor cap. Refer to «DISTRIBUTOR»(ref-157348-S39798927472003081100000) .
16. Install the heater hoses. Refer to HEATER HOSE REPLACEMENT-INLET (LU3) and HEATER HOSE REPLACEMENT-OUTLET (LU3) .
17. Position the engine wiring harness.
18. Install the stud holding the engine wiring harness bracket.
19. Install the engine wiring harness rear bracket nut at the EVAP canister purge solenoid valve. Tighten Tighten the nut to 9 N.m (80 lb in).
20. Position the bracket and wiring harness.
21. Install the junction block bracket bolt. Tighten Tighten the bolt to 25 N.m (18 lb ft).
22. Install the engine wiring harness bracket to the studs.
23. Install the engine wiring harness bracket nuts. Tighten Tighten the nuts to 12 N.m (106 lb in).
24. Position the harness ground (4) and ground strap (5).
25. Install the harness ground bolt. Tighten Tighten the bolt to 16 N.m (12 lb ft).
26. Connect the following electrical connectors: Knock sensor (1) CMP sensor (2) Fuel pump/oil pressure sensor (3) Distributor (2)
27. Install the engine wiring harness ground nut and ground wire (4) to the rear of the right cylinder head. Tighten Tighten the nut to 16 N.m (12 lb ft).
28. Connect the following electrical connectors: Ignition coil (1) Ignition coil driver (2) Generator (3)
29. Connect the following electrical connectors: EVAP canister purge solenoid valve (1) MAP sensor (2)
30. Install the engine wiring harness clip bolt (4). Tighten Tighten the bolt to 9 N.m (80 lb in).
31. Connect the following electrical connectors: TP sensor (1) IAC motor (2) Control port injector module (3) ECT sensor (5)
32. Install the positive cable and nut to the generator. Tighten Tighten the nut to 18 N.m (13 lb ft).
33. Connect the following electrical connectors: A/C pressure switch (4), if equipped A/C compressor clutch (1), if equipped
34. If equipped, install the A/C hoses.
35. Position the bracket and cables.
36. Install the accelerator control cable bracket with the cables attached, to the throttle body.
37. Install the accelerator control cable bracket nuts. Tighten Tighten the nuts to 9 N.m (80 lb in).
38. Install the accelerator cable to the throttle body lever. CAUTION: In order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle. In order to avoid cruise control cable damage, position the cable out of the way while you remove or install the engine. Do not pry or lean against the cruise control cable and do not kink the cable. You must replace a damaged cable.
39. Install the accelerator cable to the accelerator control cable bracket.
40. Install the accelerator cable to the throttle body lever.
41. If equipped, install the cruise control cable to the accelerator control cable bracket.
42. If equipped, connect the cruise control cable to the throttle body lever.
43. Install the radiator outlet hose to the water pump.
44. Install the radiator outlet hose to the surge tank.
45. Position the radiator outlet hose clamps.
46. Install the radiator inlet hose to the thermostat housing.
47. Position the radiator inlet hose clamp.
48. Install the drive belt. Refer to «Drive Belt Replacement»(ref-188990-S25259374762005091300000) .
49. Install the lower fan shroud. Refer to «FAN SHROUD REPLACEMENT-LOWER»(ref-188992-S11200099902005091300000) .
50. Install the fuel pipes/hoses. Refer to «FUEL HOSES & PIPES»(ref-159093-S06507509882003111200000) .
51. Remove the hood hinge bolt from the service position (2).
52. Lower the hood to the normal position.
53. Install the hood hinge bolts. Tighten Tighten the bolts to 25 N.m (18 lb ft).
54. Raise the vehicle.
55. Install the transmission bolts Tighten Tighten the bolts to 50 N.m (37 lb ft).
56. If equipped, Install the torque converter bolts. Tighten Tighten the bolts to 63 N.m (47 lb ft).
57. Install the ground bolt (3) holding the negative battery cable (6) and ground cable (4) to the engine.
58. Connect the CKP sensor electrical connector (5) and install the harness to the retainer clip.
59. Connect the oil level sensor electrical connector (7).
60. Install the battery cable bracket bolts. Tighten Tighten the bolts to 12 N.m (106 lb in).
61. Install the catalytic converter. Refer to «CATALYTIC CONVERTER REPLACEMENT (4.3L, 4.8L AND 5.3L ENGINES)»(ref-203989-S08615031552005110700000) .
62. Install the positive battery cable clip bolt (2).
63. Install the transmission cover. Tighten Tighten the bolts to 12 N.m (106 lb in).
64. Install the starter. Refer to «STARTER MOTOR»(ref-168656-S31439200122004111300000) .
65. If equipped, install the engine shield. «ENGINE PROTECTION SHIELD REPLACEMENT»(ref-204199-S23788761892005110900000)
66. If equipped, install the oil pan skid plate and bolts. Tighten Tighten the bolts to 20 N.m (1 lb ft).
67. Lower the vehicle.
68. Connect the negative battery cable. Refer to «BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE (SINGLE BATTERY)»(ref-188993-S31717251372005091300000) .
69. Perform the engine prelube procedure. Refer to «Engine Prelubing»(ref-188990-S14284979692005091300000) .
70. Add engine oil supplement GM P/N 1052367 (Canadian P/N 99869), or equivalent to the engine oil.
71. Fill the cooling system. Refer to «DRAINING AND FILLING COOLING SYSTEM»(ref-188992-S10584397332005091300000) .
72. If equipped, bleed the hydraulic clutch. Refer to «HYDRAULIC CLUTCH BLEEDING»(ref-189000-S15003825882005091300000) .
73. Recharge the A/C system. Refer to «REFRIGERANT RECOVERY AND RECHARGING»(ref-188960-S19924538782005091100000) . IMPORTANT: After an overhaul, the engine should be tested. Use the following procedure after the engine is installed in the vehicle.
74. Disable the ignition system.
75. Crank the engine several times. Listen for any unusual noises or evidence that parts are binding.
76. Start the engine and listen for unusual noises.
77. Check the oil pressure gauge or light and confirm that the engine has acceptable oil pressure.
78. If necessary, install an oil pressure gauge and measure the oil pressure.
79. Run the engine speed at about 1,000 RPM until the engine has reached normal operating temperature.
80. Listen for sticking valve lifters, or other unusual noises.
81. Inspect for fuel, oil, and/or coolant leaks while the engine is running.
82. Verify that the distributor is properly positioned.
83. Perform a final inspection for the proper oil and coolant levels.
84. Close the hood.

Scheme 607

Scheme 608

1. Raise and suitably support the vehicle. Refer to «JACKING AND LIFTING»(ref-188958) .
2. Remove the drain plug and drain the engine oil in a suitable container.
3. Remove the oil filter.
4. Inspect to ensure the engine oil filter gasket is removed.

Scheme 609

Scheme 610

1. Lubricate the oil filter gasket with clean engine oil. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
2. Install the oil filter. Tighten Tighten the filter to 30 N.m (22 lb ft).
3. Install the drain plug. Tighten Tighten the plug to 25 N.m (18 lb ft).
4. Lower the vehicle.
5. Fill the engine with the proper capacity and quality of engine oil.
6. Operate the engine, check for leaks, and oil pressure.

Scheme 611

Scheme 612

Scheme 613

1. Remove the oil pan drain plug and allow the engine oil to drain into a suitable container.
2. Remove the oil filter, if applicable.
3. Discard the oil filter, if applicable.
4. Remove both the engine block coolant drain hole plugs and allow the coolant to drain into a suitable container.

Scheme 614

Scheme 615

1. Remove the engine flywheel bolts.
2. Remove the engine flywheel (1), automatic transmission, if applicable.
3. Remove the engine flywheel (2), manual transmission, if applicable. IMPORTANT: If replacing the engine flywheel, manual transmission, NEW flywheel weights must be installed into the NEW engine flywheel in the same location as the old flywheel weights in the old engine flywheel.
4. Note the position of any flywheel weights for assembly, if applicable.

J 43276 Clutch Pilot Bearing Remover

Note. When using the J 43276 Clutch Pilot Bearing Remover always secure the J 43276-1 Clutch Pilot Bearing Remover tool body using a wrench. Do not allow the J 43276-1 tool body to rotate. Failing to do so will cause damage to the J 43276-1 tool body.

Scheme 616

1. Remove the clutch pilot bearing using the J 43276 . 1.1. Install the J 43276-1 tool body into the clutch pilot bearing. 1.2. Using a wrench secure the J 43276-1 tool body. 1.3. Insert the J 43276-2 forcing screw into the J 43276-1 tool body. 1.4. Rotate the J 43276-2 forcing screw clockwise into the J 43276-1 tool body until the clutch pilot bearing is completely removed from the crankshaft. 1.5. Rotate the J 43276-2 forcing screw counterclockwise to remove the J 4376-2 forcing screw from the J 43276-1 tool body. 1.6. Remove the J 43276-1 tool body from the clutch pilot bearing.
2. Discard the clutch pilot bearing.

J 41240 Fan Clutch Remover and Installer

Scheme 617

Scheme 618

Scheme 619

1. Remove the bolts and the fan and water pump pulley using the J 41240 .
2. Remove the clamps and the water pump inlet hose.
3. Remove the water pump bolts.
4. Remove the water pump.
5. Remove the water pump gaskets.
6. Discard the water pump gaskets.

J 23523-F Balancer Remover and Installer

Scheme 620

Scheme 621

Scheme 622

Scheme 623

1. Remove the crankshaft balancer bolt and washer.
2. Remove the bolts and the crankshaft pulley. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
3. Use the J 23523-F in order to remove the crankshaft balancer. 3.1. Install the J 23523-F plate and bolts onto the crankshaft balancer. Tighten Tighten the bolts to 25 N.m (18 lb ft). 3.2. Install the J 23523-F forcing screw into the plate. 3.3. Rotate the J 23523-F forcing screw clockwise in order to remove the crankshaft balancer.
4. Remove the J 23523-F from the crankshaft balancer. IMPORTANT: If replacing the crankshaft balancer, NEW weights must be installed into the NEW crankshaft balancer, in the same location as the old weights in the old balancer.
5. Note the position and length of any crankshaft balancer front groove pins, if applicable.

Scheme 624

Scheme 625

Scheme 626

1. Remove the valve rocker arm cover bolts.
2. Remove the valve rocker arm cover bolt grommets.
3. Discard the valve rocker arm cover bolt grommets.
4. Remove the valve rocker arm cover.
5. Remove the valve rocker arm cover gasket.
6. Discard the valve rocker arm cover gasket.

Scheme 627

Scheme 628

Scheme 629

1. Remove the valve rocker arm cover bolts.
2. Remove the valve rocker arm cover bolt grommets.
3. Discard the valve rocker arm cover bolt grommets.
4. Remove the valve rocker arm cover.
5. Remove the valve rocker arm cover gasket.
6. Discard the valve rocker arm cover gasket.

Scheme 630

Scheme 631

Scheme 632

1. Remove the ignition coil wire harness from the ignition coil and distributor cap.
2. Remove the distributor clamp bolt.
3. Remove the distributor and the distributor clamp.
4. Remove the distributor gasket and discard.

Scheme 633

Scheme 634

1. Remove the evaporative emission (EVAP) canister purge solenoid valve harness. 1.1. Push the quick disconnect clip and hold in place. 1.2. Pull outward on the harness elbow.
2. Remove the engine coolant temperature (ECT) sensor wire connector, if equipped, from the engine wiring harness bracket.
3. Remove the lower intake manifold bolts. IMPORTANT: The intake manifold may be removed as an assembly. Do not remove the specific intake manifold components unless component service is required. Do not allow dirt or debris to enter the fuel system. Ensure that the ends of the fuel system are properly sealed. Do not disassemble the Central Sequential Fuel Injection (SFI) unit, unless service is required.
4. Remove the intake manifold assembly.
5. Remove and discard the lower intake manifold gaskets.

J 3049-A Valve Lifter Remover

Scheme 635

Scheme 636

Scheme 637

1. Remove the bolts and valve lifter pushrod guide. IMPORTANT: Place the valve lifters in the rack in the upright position in order to maintain the oil inside the valve lifters.
2. Remove the valve lifters. IMPORTANT: Some valve lifters may be stuck in the valve lifter bores because of gum or varnish deposits and may require the use of J 3049-A for removal.
3. Use the J 3049-A in order to remove the stuck valve lifters.

Scheme 638

Scheme 639

Scheme 640

Scheme 641

1. Remove and discard the engine oil level sensor, if applicable.
2. Remove the oil pan bolts and nuts.
3. Remove the oil pan.
4. Remove the oil pan gasket.
5. Discard the oil pan gasket.

Scheme 642

Scheme 643

Scheme 644

1. Remove the oil pump bolt.
2. Remove the oil pump.
3. Inspect the oil pump locator pins for damage, and replace the pins if required.

Scheme 645

Scheme 646

Scheme 647

1. Remove the crankshaft position sensor bolt.
2. Remove the crankshaft position sensor.
3. Remove the crankshaft position sensor seal, O-ring.
4. Discard the crankshaft position sensor seal, O-ring.
5. Remove the engine front cover bolts. IMPORTANT: After the composite engine front cover is removed do not reinstall the engine front cover. Always install a NEW engine front cover.
6. Remove the engine front cover.
7. Discard the engine front cover.

J 5825-A Crankshaft Gear Remover

Scheme 648

Scheme 649

Scheme 650

Scheme 651

Scheme 652

Scheme 653

1. Remove the crankshaft position sensor reluctor ring.
2. Check the camshaft timing chain free play. 2.1. Rotate the camshaft sprocket (1) counterclockwise until all slack is removed from the camshaft timing chain (2). 2.2. Measure the free play on the slack side (3) of the camshaft timing chain. If the camshaft timing chain can be moved side to side in excess of 11 mm (0.43 in), replacement of the camshaft timing chain and the sprockets is recommended during assembly.
3. Remove the camshaft sprocket bolts.
4. Remove the camshaft sprocket and the camshaft timing chain. CAUTION: Refer to «SAFETY GLASSES CAUTION»(ref-175132-S23208358672005041500000) .
5. Remove the crankshaft sprocket using the J 5825-A.
6. Remove the crankshaft balancer key.

Scheme 654

Scheme 655

Scheme 656

Scheme 657

1. Remove the balance shaft drive gear. IMPORTANT: The balance shaft drive and balance shaft driven gears are serviced as a set. The set includes the balance shaft driven gear bolt.
2. Remove the balance shaft driven gear bolt from the balance shaft. 2.1. Use a wrench in order to secure the balance shaft. Place the wrench onto the balance shaft near to the balance shaft front bearing. 2.2. Remove the balance shaft bolt. 2.3. Remove the wrench from the balance shaft.
3. Remove the balance shaft driven gear from the balance shaft.
4. Remove the bolts and the balance shaft retainer. IMPORTANT: The balance shaft and the balance shaft front bearing are serviced only as a package. Do not remove the balance shaft front bearing from the balance shaft.
5. Use a soft-faced hammer in order to remove the balance shaft from the engine block.

Scheme 658

Scheme 659

1. Remove the camshaft retainer bolts and retainer. NOTE: All camshaft journals are the same diameter, so care must be used in removing or installing the camshaft to avoid damage to the camshaft bearings.
2. Remove the engine camshaft. 2.1. Install the three 5/16-18 x 4.0 inch bolts into the engine camshaft front bolt holes. 2.2. Using the bolts as a handle, carefully rotate and pull the engine camshaft out of the camshaft bearings. 2.3. Remove the bolts from the front of the engine camshaft.

1. J 5239 Connecting Rod Bolt Guide Set
2. J 24270 Cylinder Bore Ridge Reamer

Scheme 660

Scheme 661

Scheme 662

Scheme 663

1. Use the J 24270 in order to remove the cylinder ring ridge. 1.1. Turn the crankshaft until the piston is at the bottom of the stroke. 1.2. Place a cloth on top of the piston. 1.3. Use the J 24270 to remove all of the cylinder ring ridge. 1.4. Turn the crankshaft so the piston is at the top of the stroke. 1.5. Remove the cloth. 1.6. Remove the cutting debris. IMPORTANT: Place matchmarks or numbers on the connecting rods and the connecting rod caps.
2. Remove the connecting rod nuts.
3. Remove the connecting rod cap.
4. Use the J 5239 in order to protect the crankshaft journals and remove the connecting rod and the piston out of the top of the engine block. IMPORTANT: Always assemble the connecting rod caps to the matching connecting rods.
5. Remove the connecting rod bearings. Keep the connecting rod bearings with the original connecting rod and connecting rod cap. Wipe the oil from the connecting rod bearings. Wipe the oil from the crankpins.

Scheme 664

Scheme 665

Scheme 666

Scheme 667

1. Remove the crankshaft rear oil seal from the crankshaft rear oil seal housing. Insert a suitable tool into the access notches and then carefully pry the crankshaft rear oil seal from the crankshaft rear oil seal housing.
2. Discard the crankshaft rear oil seal.
3. Remove the crankshaft rear oil seal housing nut and bolts.
4. Remove the crankshaft rear oil seal housing.
5. Remove the crankshaft rear oil seal housing gasket.
6. Discard the crankshaft rear oil seal housing gasket.
7. Remove the crankshaft rear oil seal housing retainer stud from the engine block.

Scheme 668

Scheme 669

Scheme 670

Scheme 671

1. Mark or identify the crankshaft bearing cap locations, direction, and positions for assembly.
2. Remove the crankshaft bearing cap bolts.
3. Remove the crankshaft bearing caps.
4. Remove the crankshaft.
5. Remove the crankshaft bearings from the crankshaft bearing caps.
6. Remove the crankshaft bearings from the engine block.

J 41712 Oil Pressure Switch Socket

Scheme 672

Scheme 673

Scheme 674

Scheme 675

Scheme 676

Scheme 677

Scheme 678

Scheme 679

Scheme 680

Scheme 681

Scheme 682

1. Remove the knock sensor retaining bolt (1).
2. Remove the knock sensor (2).
3. Remove the engine oil pressure gage sensor using the J 41712.
4. Remove the engine oil pressure sensor fitting.
5. Remove the transmission locator dowel straight pins, if required.
6. Remove the engine block left side oil gallery plug.
7. Remove the engine block left rear oil gallery plug.
8. Remove the engine block right rear oil gallery plug.
9. Remove the expansion cup plug from the camshaft rear bearing hole and discard.
10. Remove the expansion cup plug from the balance shaft rear bearing hole and discard.
11. Remove the crankshaft rear oil seal housing locator spring type S pin, if required.
12. Remove the front oil gallery plugs or balls from the front of the engine block and discard. Insert a 3/8 x 26 inch rod into the rear oil gallery holes in order to drive out the front oil gallery plugs or balls.
13. Remove the engine block core hole plugs. 13.1. Use a suitable tool in order to drive the engine block core hole plugs into the coolant jacket. 13.2. Use a suitable tool in order to pull the engine block core hole plugs from the coolant jacket. 13.3. Discard the engine block core hole plugs.
14. Remove the oil filter bypass valve and discard.

J 8087 Cylinder Bore Gage

Scheme 683

Scheme 684

1. Clean all the remaining sealing or gasket material from the sealing surfaces.
2. Clean the engine block with cleaning solvent.
3. Flush the engine block with clean water or steam.
4. Clean the cylinder bores.
5. Clean the oil galleries and the oil passages.
6. Clean the scale and the deposits from the coolant passages. NOTE: Clean all dirt, debris, and coolant from the engine block cylinder head bolt holes. Failure to remove all foreign material may result in damaged threads, improperly tightened fasteners or damage to components.
7. Clean the engine block cylinder head bolt holes.
8. After cleaning the engine block, spray or wipe the cylinder bores and the machined surfaces with clean engine oil.
9. Inspect the following areas: Coolant jackets (1) for cracks Cylinder bores (2) for scratches or gouging Valve lifter bores (3) for excessive scoring or wear Threaded holes (4) for damage Crankshaft bearing webs (5) for cracks Crankshaft bearing caps (6) and the crankshaft bearing bores (7) for damage The crankshaft bearing bores should be round and uniform when measuring the inside diameter (ID). The surface where the crankshaft bearings contact the crankshaft bearing bore should be smooth. If a crankshaft bearing cap is damaged and requires replacement, replace the crankshaft bearing cap first, then rebore the engine block crankshaft bearing bores and check for the proper alignment. Finally, check the crankshaft for the proper clearances. Engine block core hole plug bores (8) for damage Engine block (9) for cracks or damage Engine mount bosses (10) for damage
10. Measure the cylinder bores for taper and out-of-round. 10.1. Depress the plunger on the J 8087 to 7 mm (0.275 in) or until the J 8087 enters the cylinder bore. 10.2. Center the J 8087 in the cylinder bore and turn the indicator dial to 0. 10.3. Move the J 8087 up and down the cylinder bore to determine the cylinder bore taper. Refer to «Engine Mechanical Specifications»(ref-188990-S11849719982005091300000) . 10.4. Turn the J 8087 to different points around the cylinder bore to determine the cylinder bore out-of-round condition. Refer to «Engine Mechanical Specifications»(ref-188990-S11849719982005091300000) .

Honing Procedure

Scheme 685

1. When honing the cylinder bores, follow the manufacturer's recommendations for equipment use, cleaning, and lubrication. Use only clean sharp stones of the proper grade for the amount of material to be removed. Dull, dirty stones cut unevenly and generate excessive heat. DO NOT hone to a final grade with a coarse or medium-grade stone. Leave sufficient metal so that all the stone marks will be removed with the fine grade stones. Perform the final honing with a fine-grade stone and hone the cylinder bore in a cross hatch pattern at 45-65 degrees to obtain the proper clearance.
2. During the honing operation, thoroughly check the cylinder bore. Repeatedly check the cylinder bore fit with the selected piston. All measurements of the piston or cylinder bore should be made with the components at normal room temperature.
3. When honing to eliminate taper in the cylinder bore, use full strokes the complete length of the cylinder bore. Repeatedly check the measurement at the top, the middle, and the bottom of the cylinder bore. The finish marks should be clean but not sharp. The finish marks should be free from imbedded particles or torn or folded metal.
4. When finished, the reconditioned cylinder bores should have less than or meet the specified out-of-round and taper requirements.
5. After the final honing and before the piston is checked for fit, clean the cylinder bore with hot water and detergent. 5.1. Scrub the cylinder bores with a stiff bristle brush. 5.2. Rinse the cylinder bores thoroughly with clean hot water. 5.3. Dry the cylinder bores with a clean rag. 5.4. Do not allow any abrasive material to remain in the cylinder bores. Abrasive material may cause premature wear of the new piston rings and the cylinder bores. Abrasive material will contaminate the engine oil and may cause premature wear of the bearings.
6. Perform final measurements of the piston and the cylinder bore.
7. Permanently mark the top of the piston for the specified cylinder to which it has been fitted.
8. Apply clean engine oil to each cylinder bore in order to prevent rusting.

Boring Procedure

1. Before starting the honing or reboring operation, measure all the new pistons with the micrometer contacting at points exactly 90 degrees from the piston pin centerline.
2. File the top of the cylinder block in order to remove any dirt or burrs before using any type of boring bar.
3. Follow the instructions furnished by the manufacturer regarding use of the boring equipment.
4. When reboring the cylinders, make sure all the crankshaft bearing caps are installed in the original position and direction.
5. Tighten the crankshaft bearing caps to the proper torque specifications in order to avoid distortion of the cylinder bores in the final assembly.
6. When making the final cut with the boring bar, leave 0.03 mm (0.001 in) on the cylinder bore diameter for finish honing. This gives the required position to the cylinder clearance specifications. Carefully perform the honing and boring operation in order to maintain the specified clearances between the pistons, the piston rings, and the cylinder bores.

J 24086-C Piston Pin Remover/Installer

Scheme 686

Scheme 687

Scheme 688

1. Remove the piston rings from the pistons.
2. Press the piston pin from the connecting rod using the J 24086-C . The piston pin has an interference fit into the connecting rod, and is full floating in the piston.
3. Mark, separate, and organize the parts for assembly.

J 24086-C Piston Pin Remover/Installer

Note. Applying excessive heat to the connecting rod may damage or distort the rod. Rod temperature SHOULD NOT exceed 315°C (600°F). At this temperature the end of the connecting rod will turn a straw color upon visual inspection.

Note. After the J 24086-C installer hub bottoms on the support assembly, DO NOT exceed 35,000 kPa (5,000 psi) or the tool may be damaged.

Scheme 689

The new piston pin has an interference fit into the connecting rod and is full floating in the piston.

Scheme 690

Scheme 691

1. Install the new piston pin and connecting rod assembly. 1.1. Lubricate the piston pin bores with clean engine oil. 1.2. Use a torch and apply MILD heat to the piston pin end of the connecting rod. 1.3. Use the J 24086-C in order to press the new piston pin into the piston and connecting rod assembly. 1.4. Inspect for the proper installation of the piston and piston pin. The piston must move freely on the new piston pin with no binding or interference. NOTE: Use a piston ring expander to install the piston rings. The rings may be damaged if expanded more than necessary.
2. Install the piston rings onto the piston. 2.1. Install the oil control piston ring spacer. 2.2. Install the lower oil control piston ring. 2.3. Install the upper oil control piston ring. 2.4. Install the lower compression piston ring. The mark on the side of the piston ring should face the top of the piston. 2.5. Install the upper compression piston ring. The mark on the side of the piston ring should face the top of the piston.
3. Space the compression piston ring end gaps 120 degrees apart.
4. Space the oil control piston ring end gaps a minimum of 90 degrees apart.

1. J 7872 Magnetic Base Dial Indicator
2. J 36660-A Torque Angle Meter
3. J 43690 Rod Bearing Clearance Checking Tool

Scheme 692

Scheme 693

Scheme 694

Scheme 695

Scheme 696

Scheme 697

Scheme 698

Scheme 699

Scheme 700

Scheme 701

1. Clean the crankshaft in cleaning solvent. Remove all sludge or restrictions from the oil passages.
2. Dry the crankshaft with compressed air.
3. Clean the crankshaft bearings in cleaning solvent. Wipe the crankshaft bearings clean with a soft cloth, do not scratch the crankshaft bearing surfaces.
4. Dry the crankshaft bearings with compressed air.
5. Inspect the crankshaft for the following: Crankshaft journals (1) should be smooth with no evidence of scoring or damage. Deep grooves (2) Scratches or uneven wear (3) Pitted surfaces (4) Wear or damage to the thrust journal surfaces Scoring or damage to the rear seal surface Restrictions to the oil passages Damage to the threaded bolt holes
6. Inspect the crankshaft balancer key (1), the keyway (2), and the threaded hole (3) for damage. Repair or replace the crankshaft as necessary.
7. Measure the crankpins for out-of-round and taper. Refer to «Engine Mechanical Specifications»(ref-188990-S11849719982005091300000) .
8. Use a suitable support to support the crankshaft on the front and rear journals.
9. Use the J 7872 in order to measure the crankshaft journal runout. The proper crankshaft journal runout is 0.025 mm maximum (0.0010 in maximum).
10. Measure the crankshaft end play. IMPORTANT: In order to properly measure the crankshaft end play, the crankshaft, the crankshaft bearings, the crankshaft bearing caps, and the crankshaft bearing cap bolts must be installed into the engine block and the bolts tightened using J 36660-A . The proper crankshaft bearing cap bolt tightening specification first pass is 20 N.m (15 lb ft), final pass is 73 degrees. 10.1. Firmly thrust the crankshaft first rearward, then forward. This will align the crankshaft rear bearings and the crankshaft thrust surfaces. 10.2. With the crankshaft pushed forward, insert a feeler gage between the crankshaft and the crankshaft bearing surface and then measure the clearance. The proper crankshaft end play clearance specification is 0.050-0.20 mm (0.002-0.008 in). 10.3. Turn the crankshaft to check for binding. If the crankshaft does not turn freely, then loosen the crankshaft bearing cap bolts, one crankshaft bearing cap at a time, until the tight crankshaft bearing is located. Burrs on the crankshaft bearing cap or engine block, foreign matter between the crankshaft bearing and the crankshaft bearing cap or the engine block, or a faulty crankshaft bearing could cause a lack of clearance between the crankshaft and crankshaft bearing.
11. Inspect the crankshaft bearings for craters or pockets. Flattened sections on the crankshaft bearing halves also indicate fatigue.
12. Inspect the crankshaft bearings for excessive scoring or discoloration.
13. Inspect the crankshaft bearings for dirt or debris imbedded into the crankshaft bearing material.
14. Inspect the crankshaft bearings for improper seating indicated by bright, polished sections of the crankshaft bearings. If the lower half of the crankshaft bearing is worn or damaged, both the upper and lower halves of the crankshaft bearing should be replaced. Generally, if the lower half of the crankshaft bearing is suitable for use, the upper half of the crankshaft bearing should also be suitable for use.

Measuring Crankshaft Bearing Clearances

1. The crankshaft bearings are of the precision insert type and do not use shims for adjustment. If the clearances are excessive, then new upper and lower crankshaft bearings will be required. The service crankshaft bearings are available in the standard size and an undersize.
2. The selective fitting of the crankshaft bearings are necessary in production in order to obtain close tolerances. For this reason, in one journal bore you may use one-half of a standard crankshaft bearing with one-half of an undersize crankshaft bearing.
3. In order to determine the correct replacement bearing size, the bearing clearance must be measured accurately. When checking main bearing clearances, either the micrometer or plastic gage method may be used; however, the micrometer method gives more reliable results and is preferred. When checking connecting rod bearing clearances, the plastic gage method will result in unreliable measurements. The use of J 43690 is preferred.
4. Normally the crankshaft bearing journals wear evenly and are not out-of-round. However, if a crankshaft bearing is being fitted to an out-of-round crankshaft bearing journal, be sure to fit to the maximum diameter of the crankshaft bearing journal. If the crankshaft bearing is fitted to the minimum diameter and the crankshaft bearing journal is excessively out-of-round, the interference between the crankshaft bearing and the crankshaft bearing journal will result in rapid crankshaft bearing failure.
5. If the crankshaft bearing clearance is within specifications, the crankshaft bearing is satisfactory. If the clearance is not within specifications, replace the crankshaft bearing. Always replace both the upper and lower crankshaft bearings as a set.
6. A standard or undersize crankshaft bearing combination may result in the proper clearance. If the proper crankshaft bearing clearance cannot be achieved using the standard or the undersize crankshaft bearings, it may be necessary to repair or replace the crankshaft.

Scheme 702

Scheme 703

Scheme 704

1. Measure the crankshaft journal diameter with a micrometer in several places, approximately 90 degrees apart. Average the measurements.
2. Determine the taper and out-of-round of the journal. Refer to «Engine Mechanical Specifications»(ref-188990-S11849719982005091300000) .
3. Install the bearings into the engine block or connecting rod assembly.
4. Install the bearing cap bolts and tighten to specifications. Refer to «Fastener Tightening Specifications»(ref-188990-S09925640772005091300000) .
5. Measure the bearing inside diameter (ID) at two points 90 degrees apart. Average the measurements.
6. In order to determine the bearing clearance, subtract the average journal diameter from the average bearing inside diameter.
7. Compare the readings to specifications. Refer to «Engine Mechanical Specifications»(ref-188990-S11849719982005091300000) .
8. Replace bearing halves as required to obtain the proper bearing clearances.

Scheme 705

Scheme 706

Scheme 707

Scheme 708

Scheme 709

Scheme 710

Scheme 711

Scheme 712

Scheme 713

Scheme 714

Scheme 715

Scheme 716

Scheme 717

Scheme 718

Scheme 719

Scheme 720

Scheme 721

Scheme 722

1. Remove the oil pan and other necessary components to gain access to the connecting rods. Remove the oil pump, screen, and deflector, when applicable.
2. Rotate the crankshaft until the crankshaft journal/connecting rod to be measured is in the 10 o'clock position. IMPORTANT: The crankshaft must be secure with no movement or rotation in order to obtain an accurate reading. Remove an intermediate bearing cap, as required, in order to secure the crankshaft and allow measurement of connecting rod bearing clearances.
3. Remove the bearing cap bolts, cap and bearing half. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
4. Insert a piece of paper card stock onto the crankshaft journal. Install the bearing half, bearing cap, and bolts. Refer to «Fastener Tightening Specifications»(ref-188990-S09925640772005091300000) .
5. Install the foot (1) and bolt (2) to the pivot arm assembly (3). Tighten the bolt until snug.
6. Install the screw (1 or 3) to the pivot arm assembly (2).
7. Install the pivot arm assembly (1) onto the connecting rod.
8. Position the foot of the pivot arm assembly over the large end of the connecting rod bolt.
9. Position the screw (1) onto the small end of the connecting rod bolt and tighten securely.
10. Install the base (1) and bolt (2) to the oil pan rail.
11. Align the center of the base (1) with the screw (3) of the pivot arm assembly. Tighten the bolt (2) until snug.
12. Align the link (1) of the pivot arm assembly on a plane (3) equal to that of the connecting rod beam (2).
13. With the link of the pivot arm assembly aligned to the beam of the connecting rod, position the pivot arm to the base and insert the pin (1).
14. Insert the handle (1) to the pivot arm assembly.
15. Select the adapter (2), as required, and install to the swivel base (1). Tighten until snug. IMPORTANT: The clamp of the swivel base and the shaft of the indicator should be free of oil or other debris. A loose or improperly clamped indicator may indicate incorrect readings.
16. Install the indicator (2) to the swivel base (1). Tighten the clamp of the base until snug.
17. Install the swivel base (1) to the oil pan rail of the engine block. Tighten until snug.
18. Adjust the swivel base as required and position the indicator tip slightly above the connecting rod cap. Lock the swivel base in position by rotating the locking lever (1). Do not allow the tip of the indicator to contact the connecting rod at this time.
19. The tip of the indicator should be positioned above and NOT in contact with the cap end of the connecting rod.
20. Rotate the fine adjustment knobs on the dial indicator end of the swivel base to position the tip of the indicator in contact with the connecting rod.
21. Lightly actuate the handle of the pivot arm assembly, multiple times in both directions, to ensure the oil film is removed from the journal.
22. Load the handle in the forward position and zero the dial indicator. Load the handle multiple times in both directions and record the reading. IMPORTANT: During this procedure, card stock may enter the crankshaft journal oil galleries. Be sure to remove all card stock from the bearing journal and oil galleries prior to reassembly.
23. Remove the bearing cap bolts, cap, and paper stock.
24. Replace bearing halves as required to obtain the proper bearing clearances.
25. Install the bearings, cap, and bolts. Refer to «Fastener Tightening Specifications»(ref-188990-S09925640772005091300000) .

Scheme 723

Scheme 724

Scheme 725

Scheme 726

Scheme 727

Scheme 728

1. Install the crankshaft bearings into the engine block.
2. Install the crankshaft.
3. Install the gaging plastic the full width of the journal.
4. Install the crankshaft bearings into the crankshaft bearing caps.
5. Install the crankshaft bearing caps in the original positions and with the arrow on the crankshaft bearing caps in the direction of the front of the engine block.
6. Install the crankshaft bearing cap bolts. Tighten Tighten the crankshaft bearing caps to 105 N.m (77 lb ft).
7. Remove the crankshaft bearing cap bolts.
8. Remove the crankshaft bearing caps. The gaging plastic may adhere to either the crankshaft bearing journal or the crankshaft bearing surface.
9. Without removing the gaging plastic, measure the compressed width at the widest point using the graduated scale on the edge of the gaging plastic envelope. If the flattened gaging plastic tapers toward the middle or the ends, there may be a difference in clearance indicating taper, low spot or other irregularity of the crankshaft bearing or the crankshaft bearing journal.
10. Remove the flattened gaging plastic.
11. Measure the remaining crankshaft bearing journals.

Scheme 729

1. Insert a feeler gage between the connecting rod caps and measure the connecting rod side clearance. The proper connecting rod side clearance specification is 0.15-0.44 mm (0.006-0.017 in).
2. Connecting rod side clearances may also be measured with a dial indicator set.

J 7872 Magnetic Base Dial Indicator

Scheme 730

Scheme 731

Scheme 732

Scheme 733

1. Clean the engine camshaft in cleaning solvent.
2. Dry the engine camshaft with compressed air.
3. Inspect the camshaft retainer plate for damage. If the camshaft retainer plate is damaged, replace as necessary.
4. Inspect the camshaft bearings for correct fit into the engine block camshaft bearing bores. The camshaft bearings have an interference fit to the engine block camshaft bearing bores and must not be loose in the engine block camshaft bearing bores. IMPORTANT: If any camshaft bearing is excessively worn or scored, replace all the camshaft bearings.
5. Inspect the camshaft bearings for excessive wear or scoring.
6. Inspect the engine camshaft for the following: Worn, scored, or damaged bearing journals (1) Worn engine camshaft lobes (2) Damaged bolt hole threads (3) Damaged camshaft sprocket locator pin (4)
7. Measure the engine camshaft journals with a micrometer. If the camshaft journals are more than 0.025 mm (0.0010 in) out-of-round, then replace the engine camshaft.
8. Measure for a bent engine camshaft or excessive engine camshaft runout using the J 7872. 8.1. Mount the engine camshaft in a suitable stand between centers. 8.2. Use the J 7872 in order to check the intermediate engine camshaft journals. If the runout exceeds 0.065 mm (0.0026 in), the engine camshaft is bent and must be replaced.
9. Measure the engine camshaft lobe lift using the J 7872 . 9.1. Place the engine camshaft on the V-blocks. 9.2. Use the J 7872 in order to measure the engine camshaft lobe lift.
10. Replace the engine camshaft if the engine camshaft lobe lift is not within specifications. Refer to «Engine Mechanical Specifications»(ref-188990-S11849719982005091300000) .

J 33049 Camshaft Bearing Service Kit

Scheme 734

Scheme 735

1. Select the cone (1), the handle (10), the expanding driver (4-8), the washer (2 or 3), and the expander assembly (15) from the J 33049.
2. Assemble the J 33049 . CAUTION: Refer to «SAFETY GLASSES CAUTION»(ref-175132-S23208358672005041500000) . IMPORTANT: A loose camshaft bearing may be caused by an enlarged, out-of-round, or damaged engine block camshaft bearing bore. Always remove the camshaft inner bearings #2 and #3 first. The camshaft outer bearings #1 and #4 serve as a guide for the J 33049 .
3. Remove the camshaft inner bearings #2 and #3. 3.1. Insert the J 33049 through the front of the engine block and into the camshaft inner bearing #2. 3.2. Tighten the J 33049 expander assembly nut until snug. 3.3. Push the J 33049 guide cone into the camshaft front bearing in order to align the J 33049 . 3.4. Drive the camshaft inner bearing #2 from the camshaft inner bearing bore #2. 3.5. Loosen the J 33049 expander assembly nut. 3.6. Remove the camshaft inner bearing #2 from the J 33049 expander assembly. 3.7. Insert the J 33049 expander assembly into the camshaft inner bearing #3. 3.8. Tighten the J 33049 expander assembly nut until snug. 3.9. Push the J 33049 guide cone into the camshaft front bearing in order to align the J 33049 . 3.10. Drive the camshaft inner bearing #3 from the camshaft inner bearing bore #3. 3.11. Loosen the J 33049 expander assembly nut. 3.12. Remove the camshaft inner bearing #3 from the J 33049 expander assembly.
4. Remove the J 33049 from the engine block.
5. Remove the camshaft outer bearings #1 and #4. 5.1. Insert the J 33049 into the camshaft outer bearing #1. 5.2. Tighten the J 33049 expander assembly nut until snug. 5.3. Drive the camshaft outer bearing #1 from the camshaft outer bearing bore #1. 5.4. Loosen the J 33049 expander assembly nut. 5.5. Remove the camshaft outer bearing #1 from the J 33049 expander assembly. 5.6. Remove the J 33049 from the engine block. 5.7. Insert the J 33049 into the camshaft outer bearing #4. 5.8. Tighten the J 33049 expander assembly nut until snug. 5.9. Drive the camshaft outer bearing #4 from the camshaft outer bearing bore #4. 5.10. Loosen the J 33049 expander assembly nut. 5.11. Remove the camshaft outer bearing #4 from the J 33049 expander assembly.
6. Remove the J 33049 from the engine block.
7. Discard the camshaft bearings.

J 33049 Camshaft Bearing Service Kit

Scheme 736

Scheme 737

Scheme 738

1. Assemble the J 33049 handle (10), the expanding driver (4-8), the washer (2 or 3), and the expander assembly (15). CAUTION: Refer to «SAFETY GLASSES CAUTION»(ref-175132-S23208358672005041500000) . IMPORTANT: The camshaft bearings vary in size. When ordering the new camshaft bearings, be sure to order the correct camshaft bearings for the application to be serviced. Always install the camshaft outer bearings #1 and #4 first. The camshaft outer bearings serve as a guide for the J 33049 and help center the camshaft inner bearings during the installation process.
2. Install the NEW camshaft outer bearings #4 and #1. 2.1. Install the NEW camshaft outer bearing #4 onto the J 33049 expander assembly. 2.2. Tighten the J 33049 expander assembly nut until snug. 2.3. Align the lubrication hole of the camshaft outer bearing #4 above the 3 o'clock position or the 9 o'clock position of the camshaft outer bearing bore #4 at the rear of the engine block. 2.4. Drive the camshaft outer bearing #4 into the camshaft outer bearing bore #4 at the rear of the engine block. 2.5. Loosen the J 33049 expander assembly nut. 2.6. Remove the camshaft outer bearing #4 from the J 33049 expander assembly. 2.7. Install the NEW camshaft outer bearing #1 onto the J 33049 expander assembly. 2.8. Tighten the J 33049 expander assembly nut until snug. 2.9. Align the lubrication hole of the camshaft outer bearing #1 above the 3 o'clock position or the 9 o'clock position of the camshaft outer bearing bore #1 at the front of the engine block. 2.10. Drive the camshaft outer bearing #1 into the camshaft outer bearing bore #1 at the front of the engine block. 2.11. Loosen the J 33049 expander assembly nut. 2.12. Carefully slide the J 33049 into the engine block until the J 33049 expander assembly is positioned between the camshaft inner bearing bores.
3. Install the NEW camshaft inner bearings #3 and #2. 3.1. Install the NEW camshaft inner bearing #3 onto the J 33049 expander assembly. 3.2. Tighten the J 33049 expander assembly nut until snug. 3.3. Align the lubrication hole of the camshaft inner bearing #3 above the 3 o'clock position or the 9 o'clock position of the camshaft inner bearing bore #3 of the engine block. 3.4. Push the J 33049 guide cone into the camshaft front bearing bore #1 in order to align the J 33049 . 3.5. Drive the camshaft inner bearing #3 into the camshaft inner bearing bore #3. 3.6. Loosen the J 33049 expander assembly nut. 3.7. Carefully slide the J 33049 until the J 33049 expander assembly is positioned between the camshaft inner bearing bore #2 and the camshaft outer bearing bore #1. 3.8. Install the NEW camshaft inner bearing #2 onto the J 33049 expander assembly. 3.9. Tighten the J 33049 expander assembly nut until snug. 3.10. Align the lubrication hole of the camshaft inner bearing #2 above the 3 o'clock position or the 9 o'clock position of the camshaft inner bearing bore #2 of the engine block. 3.11. Push the J 33049 guide cone into the camshaft front bearing bore #1 in order to align the J 33049 . 3.12. Drive the camshaft inner bearing #2 into the camshaft inner bearing bore #2. 3.13. Loosen the J 33049 expander assembly nut.
4. Carefully remove the J 33049 from the engine block.

1. J 26941 Bushing/Bearing Remover
2. J 38834 Balance Shaft Service Kit

Scheme 739

1. Use the J 38834 and the J 26941 in order to remove the balance shaft rear bearing. 1.1. Install J 26941 legs behind the balance shaft rear bearing and secure. 1.2. Install the J 38834-1 with the short threaded end through the balance shaft bore in the front of the engine block. 1.3. Install the J 38834-1 into J 26941. 1.4. Slide the J 38834-2 onto the J 38834-1 and into the balance shaft bore of the engine block. 1.5. Install the J 38834 bearing, washer, and nut onto the J 38834-1. 1.6. Using a wrench secure the J 38834-1 and then rotate the J 38834 nut clockwise until the balance shaft rear bearing is removed from the engine block. 1.7. Remove the J 26941 from the balance shaft rear bearing.
2. Discard the balance shaft rear bearing.

J 38834 Balance Shaft Service Kit

Scheme 740

1. Use the J 38834 in order to install the balance shaft rear bearing. 1.1. Install the J 38834-3 onto the short threaded end of the J 38834-1. 1.2. Install the J 38834 nut, the washer, and the bearing on the long threaded end of the J 38834-1. 1.3. Install the J 38834-2 onto the J 38834-1 so that the smaller diameter of the J 38834-2 will be facing the front of the engine block. 1.4. Install the J 38834-2 on the inside of the balance shaft front bearing bore. 1.5. Lubricate the NEW balance shaft rear bearing with clean engine oil. 1.6. Install the balance shaft rear bearing onto the J 38834-2. 1.7. Align the balance shaft rear bearing for installation. 1.8. Using a wrench secure the J 38834-1 into place. 1.9. Rotate the J 38834 nut until the balance shaft rear bearing is properly and completely pushed into the balance shaft rear bearing bore.
2. Remove the J 38834 .

J 8062 Valve Spring Compressor

Scheme 741

Scheme 742

1. Use the J 8062 in order to compress the valve springs. IMPORTANT: Mark, sort, and organize the components so that the components can be reinstalled in their original location and position.
2. Remove the valve stem keys (1).
3. Remove the J 8062 from the cylinder head.
4. Remove the valve spring cap (2).
5. Remove the valve spring (3).
6. Remove the valve stem oil seal (4).
7. Discard the valve stem oil seal.
8. Remove the valve.

1. J 8001 Dial Indicator Set
2. J 8089 Carbon Removing Brush
3. J 9666 Valve Spring Tester

Scheme 743

Scheme 744

Scheme 745

Scheme 746

Scheme 747

Scheme 748

Scheme 749

1. Clean the valve stems and cylinder heads on a buffing wheel.
2. Clean the following components in cleaning solvent: Valve stem keys (1) Valve spring cap (2) Valve spring (3) Cylinder head
3. Dry the components with compressed air.
4. Use the J 8089 to clean the carbon from the cylinder head combustion chambers. Be careful not to scuff the combustion chambers.
5. Inspect the cylinder head for the following: Damage to the gasket surfaces Damage to the threaded bolt holes Burnt or eroded areas in the combustion chamber Cracks in the exhaust ports and combustion chambers External cracks in the water chamber Restrictions in the intake or exhaust passages Restrictions in the cooling system passages Rusted, damaged, or leaking core plugs
6. Measure the cylinder head for warpage with a straight edge and feeler gage. A cylinder head block deck with warpage in excess of 0.10 mm (0.004 in) within a 152.4 mm (6.0 in) area must be repaired or replaced. A cylinder head exhaust manifold deck with warpage in excess of 0.05 mm (0.002 in) within a 152.4 mm (6.0 in) area must be repaired or replaced. A cylinder head intake manifold deck with warpage in excess of 0.10 mm (0.004 in) within a 152.4 mm (6.0 in) area must be repaired or replaced.
7. Use the J 9666 in order to measure the valve spring. Replace the valve spring if the valve spring tension is less than 338 N (76 lb) at 43.2 mm (1.70 in).
8. Inspect the valve springs for squareness.
9. Valve stems (1) with excessive valve guide (2) clearance must be repaired or the cylinder head replaced.
10. Measure the valve stem-to-guide clearance. Excessive valve stem-to-guide clearance may cause an excessive oil consumption and may also cause a valve to break. Insufficient clearance will result in noisy and sticky functioning of the valve and will disturb the engine assembly smoothness. 10.1. Clamp the J 8001 on the exhaust port side of the cylinder head. 10.2. Position the dial indicator so that the movement of the valve stem from side to side, crosswise to the cylinder head, will cause a direct movement of the dial indicator stem. The dial indicator stem must contract the side of the valve stem just above the valve guide. 10.3. Drop the valve head about 1.6 mm (0.063 in) off the valve seat. 10.4. Use light pressure and move the valve stem from side to side in order to obtain a valve stem-to-guide clearance reading. Refer to «Engine Mechanical Specifications»(ref-188990-S11849719982005091300000) .

J 5830-02 Valve Guide Reamer Set

Scheme 750

Scheme 751

Scheme 752

Scheme 753

1. Measure the valve stem-to-guide clearance. Refer to «Cylinder Head Cleaning and Inspection»(ref-188990-S37728736272005091300000) .
2. Improper valve stem (1) to valve guide (2) clearance may cause excessive oil consumption. CAUTION: Refer to «SAFETY GLASSES CAUTION»(ref-175132-S23208358672005041500000) . IMPORTANT: Exhaust valves with excessive valve stem-to-guide clearance must be replaced with the available service valve that has an 0.774 mm (0.0305 in) oversize valve stem. The intake valves are NOT available with oversize valve stems. Replace the cylinder head if after using a NEW intake valve in order to measure the valve stem-to-guide clearance, the valve stem-to-guide clearance is not within specifications.
3. Use the J 5830-3 in order to ream the exhaust valve guide in order to achieve the correct valve stem-to-guide clearance.
4. Always recondition the exhaust valve seat after reaming the exhaust valve guide bores and installing new exhaust valves.
5. Inspect the valves for the following: Burnt or damaged areas (1) Undersized margin (2) Bent stem (3) Scoring or other damage to the stem (4) Worn key groove (5) Worn stem tip (6)
6. Inspect the valve contact surface for the following: Undersized margin (1) Pitted surface (2) Burnt or eroded areas (3) Acceptable edge margin (4) Valves with excessive damage must be replaced. Minor imperfections of the valve or valve seat may be repaired.
7. Reconditioning of the valves and valve seats: The valves must seat perfectly for the engine to deliver optimum power and performance. Cooling the valve heads is another important factor. Good contact between each valve and valve seat in the cylinder head is necessary to insure that the heat in the valve head is properly carried away. Regardless of what type of equipment is used, it is essential that the valve guide bores are free from carbon or dirt in order to ensure the proper centering of the pilot in the valve guide. The valve seats should be concentric to within 0.05 mm (0.002 in) total indicator reading. Reface pitted valves on a valve refacing machine in order to ensure the correct relationship between the valve head and the valve stem. Replace the valve if the valve stem is excessively worn or warped. Replace the valve if the edge margin (4) of the valve head is less than 0.79 mm (0.031 in) thick after grinding. Several different types of equipment are available for reconditioning valves and valve seats. Follow the equipment manufacturer's recommendations for equipment use to attain the proper results.

1. J 8062 Valve Spring Compressor
2. J 42073 Valve Stem Seal Installer

Scheme 754

Scheme 755

Scheme 756

Scheme 757

1. Assemble the valve into the proper valve guide.
2. Select the proper valve stem oil seal for the specific valve guide.
3. Lubricate the valve stem oil seal and the outside diameter of the valve guide with clean engine oil.
4. Assemble the valve stem oil seal onto the valve stem. CAUTION: Refer to «SAFETY GLASSES CAUTION»(ref-175132-S23208358672005041500000) .
5. Using the J 42073 , install the valve stem oil seal onto the valve guide. 5.1. Tap the valve stem oil seal onto the valve guide until the J 42073 bottoms against the valve spring seat. 5.2. Inspect the valve stem oil seal. The valve stem oil seal should not be bottomed against the valve guide. There should be a 1-2 mm (0.03937-0.07874 in) gap between the bottom edge of the valve stem oil seal and the valve guide.
6. Install the valve spring (3).
7. Install the valve spring cap (2) onto the valve spring (3), over the valve stem. CAUTION: Compressed valve springs have high tension against the valve spring compressor. Valve springs that are not properly compressed by or released from the valve spring compressor can be ejected from the valve spring compressor with intense force. Use care when compressing or releasing the valve spring with the valve spring compressor and when removing or installing the valve stem keys. Failing to use care may cause personal injury.
8. Use the J 8062 to compress the valve spring.
9. Install the valve stem O-ring seal.
10. Install the valve stem keys. 10.1. Use grease to hold the valve stem keys in place while disconnecting the J 8062 . 10.2. Tap the end of the valve stem with a plastic-faced hammer to seat the valve stem keys. 10.3. Inspect the valve stem keys to ensure that they are seated in the upper groove of the valve stem.

Scheme 758

Scheme 759

Scheme 760

Scheme 761

Scheme 762

Scheme 763

1. Remove the oil pump driveshaft and oil pump driveshaft retainer. IMPORTANT: Do not remove the oil pump screen from the pipe. The pipe and oil pump screen are serviced as a complete assembly.
2. Remove the oil pump screen, if necessary. The oil pump screen has a press fit into the oil pump cover.
3. Remove the oil pump cover bolts.
4. Remove the oil pump cover.
5. Remove the oil pump drive gear and the oil pump driven gear.
6. Matchmark the gear teeth for assembly. CAUTION: Refer to «SAFETY GLASSES CAUTION»(ref-175132-S23208358672005041500000) .
7. Remove the following items: 7.1. The oil pump pressure relief valve spring straight pin 7.2. The oil pump pressure relief spring 7.3. The oil pump pressure relief valve

J 21882 Oil Suction Pipe Installer

Scheme 764

Scheme 765

Scheme 766

Scheme 767

Scheme 768

Scheme 769

1. Apply clean engine oil GM P/N 12345610 (Canadian P/N 9931930) or equivalent, to the oil pump pressure relief valve, oil pump pressure relief valve spring, and oil pump body. CAUTION: Refer to «SAFETY GLASSES CAUTION»(ref-175132-S23208358672005041500000) . IMPORTANT: Replace the oil pump pressure relief valve spring when you reuse the oil pump.
2. Install the following items: 2.1. The oil pump pressure relief valve 2.2. The oil pump pressure relief valve spring 2.3. The oil pump pressure relief valve spring straight pin
3. Apply clean engine oil GM P/N 12345610 (Canadian P/N 993193) or equivalent, to the oil pump drive gear, the oil pump driven gear, and the oil pump body internal surfaces.
4. Install the oil pump drive gear and the oil pump driven gear into the oil pump body. 4.1. Align the matchmarks on the oil pump drive and driven gears. 4.2. Install the smooth side of the oil pump drive and driven gears toward the oil pump cover.
5. Install the oil pump cover. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
6. Install the oil pump cover bolts. Tighten Tighten the bolts to 12 N.m (106 lb in).
7. Inspect the oil pump for smoothness of operation by turning the oil pump driveshaft by hand.
8. Install the oil pump screen. 8.1. If removed, replace the oil pump screen. The oil pump screen must have a good press fit into the oil pump body. 8.2. Mount the oil pump in a soft jawed vise. 8.3. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the end of the oil pump screen pipe. 8.4. Use the J 21882 and a soft-faced hammer in order to tap the oil pump screen into the pump body. The oil pump screen must align parallel with the bottom of the oil pan when the oil pan is installed. IMPORTANT: Install a NEW oil pump driveshaft retainer during assembly.
9. Install the oil pump driveshaft and the NEW oil pump driveshaft retainer.

Thread Repair

General purpose thread repair kits are available commercially.

Always avoid any buildup of chips. Back out the tap every few turns and remove the chips.

Scheme 770

Scheme 771

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

J 45299 Engine Preluber

Note. Refer to FASTENER NOTICE .

Scheme 772

Scheme 773

1. Remove the engine oil filter, fill with clean engine oil, and install the oil filter again. Tighten Tighten the oil filter to 30 N.m (22 lb ft).
2. Locate the engine block left oil gallery plug.
3. Install the M16 x 1.5 adapter P/N 509375.
4. Install the flexible hose to the adapter and open the valve.
5. Pump the handle on the J 45299 in order to flow a minimum of 1-1.9 liters (1-2 quarts) engine oil. Observe the flow of engine oil through the flexible hose and into the engine assembly.
6. Close the valve and remove the flexible hose and adapter from the engine.
7. Install the gallery plug to the engine. Tighten Tighten the oil gallery plug to 60 N.m (44 lb ft).
8. Top-off the engine oil to the proper level.

J 41712 Oil Pressure Switch Socket

Scheme 774

Scheme 775

Scheme 776

Scheme 777

Scheme 778

Scheme 779

Scheme 780

Scheme 781

Scheme 782

Scheme 783

Scheme 784

Scheme 785

Scheme 786

Scheme 787

1. Install a NEW oil filter bypass valve. 1.1. Install the oil filter bypass valve into the oil gallery bore until slightly below flush with the surface of the engine block. 1.2. Using a pointed punch, stake the engine block area around the oil filter bypass valve. Stake in 3 locations 120 degrees apart.
2. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the outside diameter of the NEW front engine oil gallery plugs.
3. Install the NEW front engine block oil gallery plugs. A properly installed front engine oil gallery plug must be installed slightly below flush with the front face of the engine block.
4. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent, to the outside diameter of the NEW engine block core hole plugs.
5. Install the NEW engine block core hole plugs. A properly installed engine block core hole plug must be installed flush or below the bottom of the chamfer (1) of the engine block core hole.
6. Install the crankshaft rear oil seal housing locator spring type S pin, if required.
7. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the outside diameter of the NEW expansion cup plug.
8. Install the NEW expansion cup plug into the balance shaft rear bearing hole.
9. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the outside diameter of the NEW expansion cup plug.
10. Install the NEW expansion cup plug into the camshaft rear bearing hole.
11. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the threads of the engine block right rear oil gallery plug, the engine block left rear oil gallery plug, and the engine block left side oil gallery plug. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
12. Install the engine block right rear oil gallery plug, the engine block left rear oil gallery plug, and the engine block left side oil gallery plug. Tighten Tighten the engine block left side oil gallery plug and the engine block right rear oil gallery plug to 20 N.m (15 lb ft). Tighten the engine block left rear oil gallery plug to 30 N.m (22 lb ft).
13. Install the transmission locator dowel straight pins, if required.
14. Install the left side cylinder head locator dowel pins, if required. The installation height should be 6.3-6.5 mm (0.248-0.256 in) (a).
15. Install the right side cylinder head locator dowel pins, if required. The installation height should be 6.3-6.5 mm (0.248-0.256 in) (a).
16. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the threads of the engine block coolant drain hole plugs.
17. Install the engine block coolant drain hole plugs. Tighten Tighten the engine block coolant hole plugs to 20 N.m (15 lb ft).
18. If reusing the engine oil pressure sensor fitting, apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the threads of the engine oil pressure sensor fitting. IMPORTANT: Do not loosen the engine oil pressure fitting after the initial torque has been obtained.
19. Install the engine oil pressure sensor fitting. Tighten Tighten the engine oil pressure sensor fitting to 15 N.m (11 lb ft). IMPORTANT: Do not rotate the engine oil pressure fitting clockwise more than 359 degrees after the initial torque has been obtained.
20. Rotate the engine oil pressure sensor fitting clockwise to the proper position (1), 50 degrees from the centerline (2).
21. If reusing the engine oil pressure gage sensor, apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the threads of the engine oil pressure gage sensor.
22. Install the engine oil pressure gage sensor using the J 41712 . Tighten Tighten the engine oil pressure gage sensor to 30 N.m (22 lb ft).
23. Install the knock sensor (2).
24. Install the knock sensor retaining bolt (1). Tighten Tighten the knock sensor to 25 N.m (18 lb ft).

J 36660-A Torque Angle Meter

Scheme 788

Scheme 789

Scheme 790

Scheme 791

Scheme 792

1. Install the crankshaft bearings into the engine block.
2. Apply clean engine oil to the crankshaft bearings.
3. Apply clean engine oil to the crankshaft bearing journals.
4. Install the crankshaft.
5. Install the crankshaft bearings into the crankshaft bearing caps.
6. Apply clean engine oil to the crankshaft bearings.
7. Install the crankshaft bearing caps in the original position and with the arrow on the crankshaft bearing caps in the direction of the front of the engine block.
8. Install the crankshaft bearing cap bolts until snug.
9. Thrust the crankshaft rearward in order to set and align the crankshaft thrust bearings and the crankshaft bearing caps.
10. Thrust the crankshaft forward in order to align the rear faces of the crankshaft thrust bearings. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
11. Tighten the crankshaft bearing cap bolts. Tighten 11.1. Tighten the crankshaft bearing cap bolts on the first pass to 20 N.m (15 lb ft). 11.2. Tighten the crankshaft bearing cap bolts on the final pass an additional 73 degrees using the J 36660-A .
12. Measure the crankshaft end play. 12.1. Firmly thrust the crankshaft rearward, and then forward. This will align the crankshaft rear bearing thrust surfaces. 12.2. With the crankshaft pushed forward, insert a feeler gage between the crankshaft and the crankshaft rear bearing thrust surface to measure the clearance. Specification Crankshaft end play 0.05-0.20 mm (0.002-0.008 in)
13. Rotate the crankshaft in order to check for binding. A bent crankshaft or lack of proper crankshaft bearing clearance may cause binding.
14. If the crankshaft does not turn freely, loosen the crankshaft bearing cap bolts on 1 crankshaft bearing cap at a time in order to determine the location of the binding. A lack of proper crankshaft bearing clearance may be caused by the following: Burrs on the crankshaft bearing cap Foreign material between the crankshaft bearing and the engine block Foreign material between the crankshaft bearing and the crankshaft bearing cap Damaged crankshaft bearing Improper size crankshaft bearing

J 35621-B Rear Main Seal Installer

Note. Refer to FASTENER NOTICE .

Scheme 793

Scheme 794

Scheme 795

Scheme 796

1. Install the crankshaft rear oil seal housing retainer stud. Tighten Tighten the crankshaft rear oil seal housing retainer stud to 6 N.m (53 lb in). IMPORTANT: Always use a NEW crankshaft rear oil seal housing gasket when installing the crankshaft rear oil seal housing.
2. Install the NEW crankshaft rear oil seal housing gasket.
3. Install the crankshaft rear oil housing onto the crankshaft rear oil seal housing retainer stud.
4. Install the crankshaft rear oil seal housing nut and bolts. Tighten Tighten the crankshaft rear oil seal housing nut and bolts to 12 N.m (106 lb in).
5. Apply a small amount (2 to 3 drops) of clean engine oil to the bore of the crankshaft rear oil seal housing.
6. Apply a small amount (2 to 3 drops) of clean engine oil to the outside diameter of the engine flywheel pilot flange.
7. Apply a small amount (1 drop) of clean engine oil to the outside diameter of the flywheel locator pin.
8. Apply a small amount (2 to 3 drops) of clean engine oil to the crankshaft seal surface.
9. Inspect the J 35621-B flange for imperfections that may damage the crankshaft rear oil seal. Minor imperfections may be removed with a fine grade emery cloth. IMPORTANT: DO NOT allow oil or any other lubricants to contact the seal lip surface of the crankshaft rear oil seal.
10. Remove the sleeve from the crankshaft rear oil seal.
11. Apply a small amount (2 to 3 drops) of clean engine oil to the outside diameter of the crankshaft rear oil seal.
12. Install the crankshaft rear oil seal onto the J 35621-B .
13. Install the J 35621-B onto the rear of the crankshaft and hand tighten the tool bolts until snug. NOTE: Proper alignment of the crankshaft rear oil seal is critical. Install the crankshaft rear oil seal near to flush and square to the crankshaft rear oil seal housing. Failing to do so may cause the crankshaft rear oil seal or the crankshaft rear oil seal installation tool to fail.
14. Install the crankshaft rear oil seal onto the crankshaft and into the crankshaft rear oil seal housing. 14.1. Turn the J 35621-B wing nut clockwise until the crankshaft rear oil seal is installed near to flush and square to the crankshaft rear oil seal housing. Increased resistance will be felt when the crankshaft rear oil seal has reached the bottom of the crankshaft rear oil seal housing bore. 14.2. Turn the J 35621-B wing nut counterclockwise to release the J 35621-B from the crankshaft rear oil seal.
15. Remove the J 35621-B from the crankshaft.
16. Wipe off any excess engine oil with a clean rag.

1. J 5239 Connecting Rod Bolt Guide Set
2. J 8037 Ring Compressor
3. J 8087 Cylinder Bore Gage
4. J 36660-A Torque Angle Meter

Piston Selection

For proper piston fit, the engine block cylinder bores should not have excessive wear or taper.

A used piston and piston pin set may be reinstalled if, after cleaning and inspection, the piston and piston pin are within specifications.

Scheme 797

Scheme 798

Scheme 799

1. Use the J 8087 in order to measure the cylinder bore diameter. Measure at a point 64 mm (2.5 in) from the top of the cylinder bore and 90 degrees to the crankshaft centerline.
2. Measure the J 8087 with a micrometer and record the reading.
3. With a micrometer or caliper at a right angle to the piston pin bore, measure the piston 11 mm (0.433 in) from the bottom of the skirt.
4. Subtract the piston diameter from the cylinder bore diameter in order to determine piston-to-bore clearance. Refer to «Engine Mechanical Specifications»(ref-188990-S11849719982005091300000) .
5. If the proper clearance cannot be obtained, then select another piston and measure the clearances. If the proper fit cannot be obtained, the cylinder bore may require honing or boring.
6. When the piston-to-cylinder bore clearance is within specifications, permanently mark the top of the piston for installation into the proper cylinder.

Scheme 800

Scheme 801

Scheme 802

Scheme 803

Scheme 804

Scheme 805

Scheme 806

1. Apply clean engine oil to the following components: The piston The piston rings The cylinder bore The bearing surfaces
2. Install the J 5239 onto the connecting rod bolts.
3. Install the J 8037 onto the piston and compress the piston rings. IMPORTANT: The mark on the top of the piston must face the front of the engine block. When assembled, the flanges on the connecting rod and connecting rod cap should face to the front of the engine block on the left bank, and to the rear of the engine block on the right bank.
4. Install the piston and connecting rod assembly, and the J 8037 into the proper cylinder bore.
5. Use the J 8037 and the J 5239 and lightly tap the top of the piston with a wooden hammer handle. 5.1. Hold the J 8037 firmly against the engine block until all of the piston rings have entered the cylinder bore. 5.2. Use the J 5239 in order to guide the connecting rod onto the crankshaft journal.
6. Remove the J 5239 . NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
7. Install the connecting rod caps, bearings, and nuts. Tighten 7.1. Tighten the nuts evenly on the first pass to 27 N.m (20 lb ft). 7.2. Use the J 36660-A in order to tighten the nuts on the final pass an additional 70 degrees.
8. After the piston and connecting rod assemblies have been installed, lightly tap each connecting rod assembly, parallel to the crankpin, in order to ensure that the connecting rods have side clearance.
9. Use a feeler gage or a dial indicator to measure the connecting rod side clearance between the connecting rod caps. The connecting rod side clearance should be 0.15-0.44 mm (0.006-0.017 in).

Scheme 807

Scheme 808

1. Apply clean engine oil GM P/N 12345610 (Canadian P/N 993193) or equivalent, or engine oil supplement GM P/N 1052367 (Canadian P/N 992367) or equivalent, to the following components: The engine camshaft lobes The camshaft bearing journals The camshaft bearings The distributor drive gear
2. Install three 5/16-18 x 4.0 inch bolts into the engine camshaft front bolt holes. NOTE: All camshaft journals are the same diameter, so care must be used in removing or installing the camshaft to avoid damage to the camshaft bearings.
3. Use the bolts as a handle in order to install the engine camshaft.
4. Remove the 3 bolts from the front of the engine camshaft.
5. If reusing the fasteners, apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent, to the threads of the camshaft retainer bolts. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
6. Install the camshaft retainer and bolts. Tighten Tighten the camshaft retainer bolts to 12 N.m (106 lb in).

1. J 8092 Universal Driver Handle
2. J 36660-A Torque Angle Meter
3. J 36996 Balance Shaft Installer

Scheme 809

Scheme 810

Scheme 811

Scheme 812

Scheme 813

Scheme 814

Scheme 815

Scheme 816

1. Apply clean engine oil GM P/N 12345610 (Canadian P/N 993193) or equivalent, to the balance shaft front bearing. CAUTION: Refer to «SAFETY GLASSES CAUTION»(ref-175132-S23208358672005041500000) .
2. Use the J 36996 and the J 8092 in order to install the balance shaft. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
3. Install the balance shaft retainer and bolts. Tighten Tighten the bolts to 12 N.m (106 lb in).
4. Install the balance shaft driven gear onto the balance shaft.
5. If reusing the fastener, apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent, to the threads of the balance shaft driven gear bolt.
6. Install the balance shaft driven gear bolt. 6.1. Use a wrench to secure the balance shaft. Place the wrench onto the balance shaft near to the balance shaft front bearing. 6.2. Install the balance shaft driven gear bolt. Tighten 6.2.1. Tighten the balance shaft driven gear bolt on the first pass to 20 N.m (15 lb ft). 6.2.2. Tighten the balance shaft driven gear bolt on the final pass using the J 36660-A an additional 35 degrees.
7. Remove the wrench from the balance shaft.
8. Rotate the balance shaft by hand in order to ensure that there is clearance between the balance shaft and the valve lifter pushrod guide. If the balance shaft does not rotate freely, check to ensure that the retaining ring on the balance shaft front bearing is seated on the case. IMPORTANT: DO NOT install the camshaft sprocket bolts at this time.
9. Install the balance shaft drive gear.
10. Rotate the engine camshaft so that the timing mark on the balance shaft drive gear is in the 12 o'clock position.
11. Remove the balance shaft drive gear.
12. Rotate the balance shaft so that the timing mark on the balance shaft driven gear is in the 6 o'clock position.
13. Position the balance shaft drive gear onto the engine camshaft.
14. Look to ensure that the balance shaft drive gear and the balance shaft driven gear timing marks are aligned.

J 5590 Pinion Bearing Race Installer-Rear

Scheme 817

Scheme 818

Scheme 819

Scheme 820

Scheme 821

Scheme 822

1. Install the crankshaft balancer key into the crankshaft keyway. The crankshaft balancer key should be parallel to the crankshaft or with a slight incline.
2. Align the keyway of the crankshaft sprocket with the crankshaft balancer key. CAUTION: Refer to «SAFETY GLASSES CAUTION»(ref-175132-S23208358672005041500000) .
3. Use the J 5590 in order to install the crankshaft sprocket.
4. Rotate the crankshaft until the crankshaft sprocket alignment mark is at the 12 o'clock position. IMPORTANT: Install the camshaft sprocket with the alignment mark at the 6 o'clock position.
5. Install the camshaft sprocket and the camshaft timing chain.
6. Look to ensure that the crankshaft sprocket is aligned at the 12 o'clock position and camshaft sprocket is aligned at the 6 o'clock position. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) . IMPORTANT: Do not use a hammer to install the camshaft sprocket onto the camshaft. To do so may dislodge the expansion cup plug, camshaft rear bearing hole.
7. Install camshaft sprocket bolts. Tighten Tighten the camshaft sprocket bolts to 25 N.m (18 lb ft).
8. Install the crankshaft position sensor reluctor ring. 8.1. Align the keyway on the crankshaft position sensor reluctor ring with the crankshaft balancer key in the crankshaft. 8.2. Use the J 5590 in order to push the crankshaft position sensor reluctor ring onto the crankshaft until completely seated against the crankshaft sprocket.

J 23523-F Balancer Remover and Installer

Scheme 823

Scheme 824

Scheme 825

Scheme 826

Scheme 827

Scheme 828

1. Look to ensure that the crankshaft balancer front groove pin is installed in the proper location, if applicable. The length and location of the pins must be the same as the original length and location. NOTE: The inertial weight section of the crankshaft balancer is assembled to the hub with a rubber type material. The correct installation procedures (with the proper tool) must be followed or movement of the inertial weight section of the hub will destroy the tuning of the crankshaft balancer.
2. Apply a small amount of adhesive GM P/N 12346141 (Canadian P/N 10953433) or equivalent, onto the crankshaft balancer keyway in order to seal the crankshaft balancer keyway and crankshaft joint.
3. Align the keyway of the crankshaft balancer with the crankshaft balancer key.
4. Install the crankshaft balancer onto the end of the crankshaft. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
5. Use the J 23523-F in order to press the crankshaft balancer onto the crankshaft. 5.1. Install the J 23523-F plate and bolts onto the front of the crankshaft balancer. Tighten Tighten the J 23523-F plate bolts to 25 N.m (18 lb ft). 5.2. Install the J 23523-F screw into the end for the crankshaft. 5.3. Install the J 23523-F bearing, the washer, and the nut onto the J 23523-F screw. 5.4. Rotate the J 23523-F nut clockwise until the crankshaft balancer hub is completely seated against the crankshaft position sensor reluctor ring.
6. Remove the J 23523-F .
7. Install the crankshaft pulley and bolts. Tighten Tighten the crankshaft pulley bolts to 58 N.m (43 lb ft).
8. Ensure that the crown of the crankshaft balancer washer (2) is faced away from the engine.
9. Install the crankshaft balancer washer and the bolt. Tighten Tighten the crankshaft balancer bolt to 95 N.m (70 lb ft).

Scheme 829

Scheme 830

1. Apply lubricant GM P/N 12345501 (Canadian P/N 992704) or equivalent, to the valve lifter rollers. IMPORTANT: If reusing the valve lifters, install the valve lifters in the original positions.
2. Install the valve lifters. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
3. Install the valve lifter pushrod guides. Tighten Tighten the valve lifter pushrod guide bolts to 16 N.m (12 lb ft).

J 36660-A Torque Angle Meter

Scheme 831

Scheme 832

Scheme 833

Scheme 834

Scheme 835

Scheme 836

Scheme 837

Scheme 838

Scheme 839

1. Clean the cylinder head gasket surfaces on the engine block.
2. Inspect the cylinder head locator dowel pins for proper installation. The installation height should be 6.3-6.5 mm (0.248-0.256 in) (a).
3. Clean the cylinder head gasket surfaces on the cylinder head. IMPORTANT: Do not use any type sealer on the cylinder head gasket, unless specified.
4. Install the NEW cylinder head gasket in position over the cylinder head locator dowel pins.
5. Install the cylinder head onto the engine block. Guide the cylinder head carefully into place over the dowel pins and the cylinder head gasket.
6. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the threads of the cylinder head bolts.
7. Install the cylinder head bolts finger tight. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
8. Tighten the cylinder head bolts in sequence on the first pass. Tighten Tighten the bolts in sequence on the first pass to 30 N.m (22 lb ft).
9. Use the J 36660-A in order to tighten the cylinder head bolts in sequence on the final pass. Tighten Tighten the long bolts (1, 4, 5, 8, and 9) on the final pass in sequence to 75 degrees. Tighten the medium bolts (12 and 13) on the final pass in sequence to 65 degrees. Tighten the short bolts (2, 3, 6, 7, 10, and 11) on the final pass in sequence to 55 degrees.
10. Install the spark plug wire support and bolts. Tighten Tighten the spark plug wire support bolts to 12 N.m (106 lb in).
11. Measure the NEW spark plugs for the proper gap. Adjust the spark plug gap if necessary. Specification Spark plug gap to 1.52 mm (0.060 in).
12. Install the spark plugs. Tighten Tighten the spark plugs for a USED cylinder head to 15 N.m (11 lb ft). Tighten the spark plugs for the initial installation of a NEW cylinder head to 30 N.m (22 lb ft).
13. If reusing the engine coolant temperature gage sensor, if applicable, apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the threads of the engine coolant temperature gage sensor.
14. Install the engine coolant temperature gage sensor, if applicable. Tighten Tighten the engine coolant temperature gage sensor to 20 N.m (15 lb ft).
15. If reusing the engine coolant temperature sensor, if applicable, apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the threads of the engine coolant temperature gage sensor.
16. Install the engine coolant temperature sensor, if applicable. Tighten Tighten the engine coolant temperature sensor to 20 N.m (15 lb ft).

J 36660-A Torque Angle Meter

Scheme 840

Scheme 841

Scheme 842

Scheme 843

Scheme 844

Scheme 845

Scheme 846

1. Clean the cylinder head gasket surfaces on the engine block.
2. Inspect the cylinder head locator dowel pins for proper installation. The installation height should be 6.3-6.5 mm (0.248-0.256 in) (a).
3. Clean the cylinder head gasket surfaces on the cylinder head. IMPORTANT: Do not use any type sealer on the cylinder head gasket, unless specified.
4. Install the NEW cylinder head gasket in position over the cylinder head locator dowel pins.
5. Install the cylinder head onto the engine block. Guide the cylinder head carefully into place over the dowel pins and the cylinder head gasket.
6. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the threads of the cylinder head bolts.
7. Install the cylinder head bolts finger tight. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
8. Tighten the cylinder head bolts in sequence on the first pass. Tighten Tighten the bolts in sequence on the first pass to 30 N.m (22 lb ft).
9. Use the J 36660-A in order to tighten the cylinder head bolts in sequence on the final pass. Tighten Tighten the long bolts (1, 4, 5, 8, and 9) on the final pass in sequence to 75 degrees. Tighten the medium bolts (12 and 13) on the final pass in sequence to 65 degrees. Tighten the short bolts (2, 3, 6, 7, 10, and 11) on the final pass in sequence to 55 degrees.
10. Install the spark plug wire support and bolts. Tighten Tighten only the rear spark plug wire support bolt to 12 N.m (106 lb in).
11. Remove the front spark plug wire support bolt. The front spark plug wire support bolt is used to fasten the oil level indicator tube, and will be installed within the oil level indicator tube installation procedure.
12. Measure the NEW spark plugs for the proper gap. Adjust the spark plug gap if necessary. Specification Spark plug gap to 1.52 mm (0.060 in).
13. Install the spark plugs. Tighten Tighten the spark plugs for a USED cylinder head to 15 N.m (11 lb ft). Tighten the spark plugs for the initial installation of a NEW cylinder head to 30 N.m (22 lb ft).

J 41240 Fan Clutch Remover and Installer

Scheme 847

Scheme 848

Scheme 849

1. If reusing the fasteners, apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the threads of the water pump bolts.
2. Install the water pump and the NEW water pump gaskets. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
3. Install the water pump bolts. Tighten Tighten the water pump bolts to 45 N.m (33 lb ft). IMPORTANT: After final assembly, the water pump inlet hose clamp tangs, water pump end, must point forward and the upper tang should be level with the outside diameter of the water pump inlet hose.
4. Install the water pump inlet hose and the water pump inlet hose clamps.
5. Install the fan and water pump pulley and bolts using the J 41240 . Tighten Tighten the fan and water pump pulley bolts to 25 N.m (18 lb ft).

Scheme 850

Scheme 851

1. Install the NEW exhaust manifold gaskets.
2. Install the exhaust manifold.
3. Install the spark plug wire shields.
4. If reusing the fasteners, apply threadlock GM P/N 12345493 (Canadian P/N 10953488) or equivalent, to the threads of the exhaust manifold bolts and stud. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
5. Install the exhaust manifold bolts and stud. Tighten 5.1. Tighten the exhaust manifold bolts and stud on the first pass to 15 N.m (11 lb ft). 5.2. Tighten the exhaust manifold bolts and stud on the final pass to 30 N.m (22 lb ft).
6. Install the spark plug wires to the spark plug wire retainers.
7. Install the spark plug wires onto the spark plugs.

Scheme 852

Scheme 853

1. Install the NEW exhaust manifold gaskets.
2. Install the exhaust manifold.
3. Install the spark plug wire shields.
4. If reusing the fasteners, apply threadlock GM P/N 12345493 (Canadian P/N 10953488) or equivalent, to the threads of the exhaust manifold bolts. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
5. Install the exhaust manifold bolts. Tighten 5.1. Tighten the exhaust manifold bolts on the first pass to 15 N.m (11 lb ft). 5.2. Tighten the exhaust manifold bolts on the final pass to 30 N.m (22 lb ft).
6. Install the spark plug wires to the spark plug wire retainers.
7. Install the spark plug wires onto the spark plugs.

Balance Shaft

The cast iron balance shaft is mounted in the crankcase above and in-line with the camshaft. A camshaft gear drives the gear attached to the balance shaft. The front end of the balance shaft is supported by a ball-type bearing. The rear end of the balance shaft uses a sleeve-type bearing.

Camshaft

The steel camshaft is supported by four bearings pressed into the engine block. The camshaft timing chain sprocket mounted to the front of the camshaft is driven by the crankshaft sprocket through a camshaft timing chain.

Crankshaft

The cast nodular iron crankshaft is supported by four crankshaft bearings. The number four crankshaft bearing at the rear of the engine is the end thrust bearing. The crankshaft bearings are retained by bearing caps that are machined with the engine block for proper alignment and clearances. The crankshaft position sensor reluctor ring has three lugs used for crankshaft timing and is constructed of powdered metal. The crankshaft position sensor reluctor ring has a slight interference fit onto the crankshaft and an internal keyway for correct positioning.

Cylinder Heads

The cast iron cylinder heads have one intake and one exhaust valve for each cylinder. A spark plug is located between the valves in the side of the cylinder head. The valve guides and seats are integral to the cylinder head. The 4.3L heavy duty applications have pressed in exhaust valve seats. The valve rocker arms are positioned on the valve rocker arm supports and retained by a bolt.

Engine Block

The cast iron engine block has six cylinders arranged in a V shape with three cylinders in each bank. Starting at the front side of the engine block, the cylinders in the left bank are numbered 1-3-5 and cylinders in the right bank are numbered 2-4-6 (when viewed from the rear). The firing order of the cylinders is 1-6-5-4-3-2. The cylinders are encircled by coolant jackets.

Exhaust Manifolds

The cast iron exhaust manifolds direct exhaust gases from the combustion chambers to the exhaust system.

Intake Manifold

The intake manifold is a two-piece design. The upper portion is made from a composite material and the lower portion is cast aluminum. The throttle body attaches to the upper manifold. The Central Multipoint Flexible Injection system uses multiple fuel injectors to meter and distribute fuel to each engine cylinder. The Central (MFI) is retained by a bracket bolted to the lower intake manifold. The fuel meter body also houses the pressure regulator. Metal inlet and outlet fuel lines and nylon delivery tubes connect to the Central (MFI) unit. The delivery tubes independently distribute fuel to each cylinder through injectors located at the port entrance of each manifold runner where the fuel is atomized.

Valve Train

Motion is transmitted from the camshaft through the hydraulic roller valve lifters and the tubular valve pushrods to the roller type valve rocker arms. The roller type valve rocker arm pivots on a needle type bearing in order to open the valve. The valve rocker arms for each bank of cylinders are mounted to a one piece valve rocker arm support. Each valve rocker arm is retained on the valve rocker arm support and the cylinder head by a bolt. The hydraulic valve lifters keep all the parts of the valve train in constant contact. Each hydraulic valve lifter acts as an automatic adjuster and maintains zero lash in the valve train. This eliminates the need for periodic valve adjustment.

New Product Information

The purpose of New Product Information is to highlight or indicate important product changes from the previous model year.

Changes may include one or more of the following items

1. A component comparison from the previous year
2. Fastener changes
3. Torque values and/or fastener tightening strategies
4. Changed engine specifications
5. New sealants and/or adhesives
6. Disassembly and assembly procedure revisions
7. Engine mechanical diagnostic procedure revisions
8. New special tools required

Component Comparison

1. New Central Multipoint Flexible Injection (MFI) fuel system.
2. EGR valve and components are deleted.
3. Revised lower intake manifold due to the deletion of the EGR.

New Sealants and/or Adhesives

No new sealants or adhesives have been added.

Cleanliness and Care

1. Throughout this section, it should be understood that proper cleaning and protection of machined surfaces and friction areas is part of the repair procedure. This is considered standard shop practice even if not specifically stated.
2. When any internal engine parts are serviced, care and cleanliness is important.
3. When components are removed for service, the components should be marked, organized or retained in a specific order for re-assembly.
4. At the time of installation, the components should be installed in the same location and with the same mating surface as when removed.
5. An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in millimeters or thousandths of an inch. The surfaces should be protected to avoid component damage.
6. Apply a liberal amount of clean engine oil to friction areas during assembly.
7. Proper lubrication will protect and lubricate friction areas during initial operation.

Separating Parts

When disassembling the engine, internal components MUST be separated, marked and organized in a way to ensure reinstallation to original location and position.

Mark or identify the following components

1. Piston and the piston pin
2. Piston to the specific cylinder bore
3. Piston rings to the specific cylinder bore
4. Connecting rod to the crankshaft journal
5. Connecting rod to connecting rod cap
6. Crankshaft bearings and connecting rod bearings
7. Engine camshaft and valve lifters
8. Valve lifters, valve rocker arms, and valve rocker arm supports
9. Valve to the valve guide
10. Valve spring to cylinder head location
11. Engine block bearing cap location and direction
12. Oil pump drive and driven gears

Gasket Reuse and Applying Sealant

1. Do not reuse any gasket unless specified.
2. Gaskets that can be reused will be identified in the service procedure.
3. Do not apply sealant to any gasket or sealing surface unless specified in the service procedure.

Separating Components

1. Use a rubber mallet in order to separate the components.
2. Bump the part sideways in order to loosen the components.
3. Bumping of the component should be done at bends or reinforced areas of the component to prevent distortion of the components.

Cleaning Gasket Surfaces

1. Use care to avoid gouging or scraping the sealing surfaces.
2. Use a plastic or wood scraper in order to remove all the sealant from the components. Do not use any other method or technique to remove the sealant or the gasket material from a part.
3. Do not use abrasive pads, sand paper, or power tools to clean the gasket surfaces. These methods of cleaning can cause damage to the component sealing surfaces. Abrasive pads also produce a fine grit that the oil filter cannot remove from the engine oil. This fine grit is an abrasive and can cause internal engine damage.

Sealant Types

The following 2 major types of sealant are commonly used in engines

1. Aerobic sealant Room Temperature Vulcanizing (RTV)
2. Anaerobic sealant, which include the following: Gasket eliminator Pipe Threadlock

Aerobic Type Room Temperature Vulcanizing (RTV) Sealant

Aerobic type Room Temperature Vulcanizing (RTV) sealant cures when exposed to air. This type of sealant is used where 2 components, such as the intake manifold and the engine block, are assembled together.

Use the following information when using RTV sealant

1. Do not use RTV sealant in areas where extreme temperatures are expected. These areas include: The exhaust manifold The head gasket Any other surfaces where a different type of sealant is specified in the service procedure
2. Always follow all the safety recommendations and the directions that are on the RTV sealant container.
3. Use a plastic or wood scraper in order to remove all the RTV sealant from the components.

Note. Do not allow the RTV sealant to enter any blind threaded hole. RTV sealant that is allowed to enter a blind threaded hole can cause hydraulic lock of the fastener when the fastener is tightened. Hydraulic lock of a fastener can lead to damage to the fastener and/or the components. Hydraulic lock of a fastener can also prevent the proper clamping loads to be obtained when the fastener is tightened. Improper clamping loads can prevent proper sealing of the components allowing leakage to occur. Preventing proper fastener tightening can allow the components to loosen or separate leading to extensive engine damage.

1. The surfaces to be sealed must be clean and dry.
2. Use a RTV sealant bead size as specified in the service procedure.
3. Apply the RTV sealant bead to the inside of any bolt holes areas. IMPORTANT: Do not wait for the RTV sealant to skin over.
4. Assemble the components while the RTV sealant is still wet to the touch, within 3 minutes. IMPORTANT: Do not overtighten the fasteners.
5. Tighten the fasteners in sequence, if specified, and to the proper torque specifications.

Anaerobic Type Gasket Eliminator Sealant

Anaerobic type gasket eliminator sealant cures in the absence of air. This type of sealant is used where 2 rigid parts, such as castings, are assembled together. When 2 rigid parts are disassembled and no sealant or gasket is readily noticeable, then the 2 parts were probably assembled using an anaerobic type gasket eliminator sealant.

Use the following information when using gasket eliminator sealant

1. Always follow all the safety recommendations and directions that are on the gasket eliminator sealant container.
2. Apply a continuous bead of gasket eliminator sealant to one flange. The surfaces to be sealed must be clean and dry.

Note. Do not allow the sealant to enter a blind hole. The sealant may prevent the fastener from achieving proper clamp load, cause component damage when the fastener is tightened, or lead to component failure.

Anaerobic Type Threadlock Sealant

Anaerobic type threadlock sealant cures in the absence of air. This type of sealant is used for threadlocking and sealing of bolts, fittings, nuts, and studs. This type of sealant cures only when confined between 2 close fitting metal surfaces.

Use the following information when using threadlock sealant

1. Always follow all safety recommendations and directions that are on the threadlock sealant container.
2. The threaded surfaces to be sealed must be clean and dry.
3. Apply the threadlock sealant as specified on the threadlock sealant container.

Anaerobic Type Pipe Sealant

Anaerobic type pipe sealant cures in the absence of air and remains pliable when cured. This type of sealant is used where 2 parts are assembled together and require a leak proof joint.

Use the following information when using pipe sealant

1. Do not use pipe sealant in areas where extreme temperatures are expected. These areas include: The exhaust manifold The head gasket Surfaces where a different sealant is specified
2. Always follow all the safety recommendations and the directions that are on the pipe sealant container.
3. The surfaces to be sealed must be clean and dry.
4. Use a pipe sealant bead of the size or quantity as specified in the service procedure. NOTE: Do not allow the sealant to enter a blind hole. The sealant may prevent the fastener from achieving proper clamp load, cause component damage when the fastener is tightened, or lead to component failure.
5. Apply the pipe sealant bead to the inside of any bolt hole areas.
6. Apply a continuous bead of pipe sealant to 1 sealing surface. IMPORTANT: Do not overtighten the fasteners.
7. Tighten the fasteners in sequence, if specified, and to the proper torque specifications.

Tools and Equipment

Special tools are listed and illustrated throughout this section with a complete listing at the end of the section. The tools (or the equivalents) are specially designed to quickly and safely accomplish the operations for which the tools are intended. The use of special tools will also minimize possible damage to engine components. Some precision measuring tools are required for inspection of certain critical components. Torque wrenches and a torque angle meter are necessary for the proper tightening of various fasteners.

To properly service the engine assembly, the following items should be readily available

1. Approved eye protection and safety gloves
2. A clean, well-lit, work area
3. A suitable parts cleaning tank
4. A compressed air supply
5. Trays or storage containers to keep parts and fasteners organized
6. An adequate set of hand tools
7. Approved engine repair stand
8. An approved engine lifting device that will adequately support the weight of the components

Scheme 854

Scheme 855

Scheme 856

Scheme 857

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Scheme 859

Scheme 860

Scheme 861