Home ReviewsRefund
Home/Chevrolet/Silverado 3500/Chevrolet Silverado 3500 (2002-2006)/Repair manual/Mechanical/Engine Mechanical - 8.1L: Overhaul
Contents Wiring diagrams Section: Mechanical All sections

Engine Mechanical - 8.1L: Overhaul Chevrolet Silverado 3500

Mechanical ~730 words

Cylinder Head Disassemble

Tools Required

J 8062 Valve Spring Compressor - Head Off

  1. Use J 8062 in order to compress the valve springs.
  2. Remove the valve stem keys (220).
  3. Release and remove J 8062 .
  4. Remove the cap (219).
  5. Remove the valve spring (218).
  6. Remove the valve stem oil seal (217) from the valve guide.
  7. Remove the valve rotator (216).
  8. Remove the valve (232).
  9. Disconnect the engine coolant temperature (ECT) sensor from the bracket.
  10. Remove the ECT sensor from the cylinder head.
  11. Remove the ECT sensor bracket and bolt.
  12. Remove the cylinder head coolant hole plug from the cylinder head.

Cylinder Head Assemble

Tools Required

  1. J 8062 Valve Spring Compressor
  2. J 43105 Valve Stem Seal Installer. See «Special Tools and Equipment»(ref-184189-S37698181962005082200000) .

Oil Pump Disassemble

  1. Remove the oil pump driveshaft and retainer.
  2. Remove the oil pump cover bolts.
  3. Remove the pump cover.
  4. Remove the drive gear and the driven gear. Matchmark the gear teeth for assembly.
  5. Remove the following items: The retaining pin The pressure relief spring The pressure relief valve

Oil Pump Assemble

  1. Install the following items: The pressure relief valve The pressure relief spring The retaining pin
  2. Coat the drive gear, the driven gear and the housing gear surfaces with clean engine oil.
  3. Install the drive gear and the driven gear into the pump body. Align the matching marks on the gears. Install the smooth side of the gear toward the pump cover.
  4. Install the oil pump cover.
  5. Install the oil pump cover bolts. Tighten: Tighten the oil pump cover bolts to 12 N.m (106 lb in).
  6. Inspect the oil pump for smoothness of operation by turning the oil pump driveshaft by hand.
  7. Install the oil pump driveshaft and the new retainer.

Intake Manifold Disassemble

  1. Remove the vacuum plug (513).
  2. Remove the throttle body nuts (503).
  3. Remove the throttle body (502) and gasket (501).
  4. Discard the gasket.
  5. Remove the throttle body studs (504), if required.
  6. Remove the oil fill cap (418).
  7. Remove the oil fill tube (416) and bolt (419).
  8. Remove the bolt and manifold absolute pressure (MAP) sensor.
  9. Inspect the MAP sensor grommet for damage.
  10. Remove the evaporative emission (EVAP) tube.
  11. Remove the EVAP purge valve and bolt.
  12. Inspect the O-ring seal for damage. Replace as needed.

Intake Manifold Assemble

  1. Apply a very light film of clean engine oil to the evaporative emission (EVAP) purge valve O-ring seal.
  2. Install the EVAP purge valve.
  3. Apply thread sealer GM P/N 12345493, (Canadian P/N 10953488), or equivalent to the threads of the EVAP purge valve bolt.
  4. Install the EVAP purge valve bolt. Tighten: Tighten the bolt to 8 N.m (71 lb in).
  5. Install the EVAP tube.
  6. Install the MAP sensor.
  7. Install the MAP sensor bolt. Tighten: Tighten the MAP sensor bolt to 12 N.m (106 lb in).
  8. Lubricate the O-ring seal (415) of the oil fill tube with clean engine oil.
  9. Install the oil fill tube (416).
  10. Install the oil fill tube bolt (419). Tighten: Tighten the oil fill tube bolt to 12 N.m (106 lb in).
  11. Install the oil fill cap (418).
  12. Install the throttle body gasket (501).
  13. Install the throttle body (502).
  14. Install the throttle body nuts (503). Tighten: Tighten the throttle body nuts to 10 N.m (89 lb in).
  15. Install the vacuum plug (513).

Service Prior to Assembly

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

Assembling Components

  1. Assemble components using only the sealant (or equivalent) that is specified in the service procedure.
  2. Sealing surfaces must be clean and free of debris or oil.
  3. Specific components such as crankshaft oil seals or valve stem oil seals may require lubrication during assembly.
  4. Components requiring lubrication will be identified in the service procedure.
  5. Apply only the amount of sealant specified in the service procedure to a component.
  6. Do not allow the sealant to enter into any blind threaded holes, as the sealant may prevent the fastener from clamping properly or cause component damage when tightened.
  7. Tighten the fasteners to the proper specifications.

More articles — Engine Mechanical - 8.1L