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Engine Mechanical - 8.1L: Overhaul Chevrolet Silverado Classic 1500

Mechanical ~1089 words

Piston and Connecting Rod Disassemble

  1. Remove the connecting rod bearings (118) from the rod (119) and cap (117).
  2. Using piston ring pliers, remove the piston rings from the piston.
  3. Rotate the piston pin retainers until the retainer end gap is positioned in the cutout area (1) of the pin bore.
  4. Remove the retainers starting in the cutout area of the pin bore.
  5. Remove the pin from the piston and connecting rod.
  6. The piston and pin are a matched set and are not to be serviced separately. Mark, sort or organize the piston and matching piston pin.

Piston and Connecting Rod Assemble

  1. Assemble the right bank pistons and connecting rods with the arrow (1) on the top of the piston facing front of engine and the master or larger flange (2) of the connecting rod facing rear of engine.
  2. Assemble the left bank pistons and connecting rods with the arrow (1) on the top of the piston facing front of engine and the master or larger flange (2) of the connecting rod facing front of engine.
  3. Install the retainer. The retainer should be seated in the groove of the pin bore.
  4. Lubricate the pin and pin bore with clean engine oil.
  5. Install the piston pin to the piston and connecting rod.
  6. Install the retainer. The retainer should be seated in the groove of the pin bore. Ensure the pin moves freely within the piston pin bore.
  7. Using piston ring pliers, install the piston rings onto the piston.
  8. Install the lower oil control piston ring spacer onto the piston.
  9. Install the lower oil control piston ring onto the piston (1).
  10. Install the upper oil control piston ring onto the piston (1).
  11. Position the oil control piston ring end gaps a minimum of 90 degrees apart (1, 2, 3).
  12. Install the lower compression piston ring onto the piston. The mark (1) on the side of the piston ring should face the top of the piston.
  13. Install the upper compression piston ring onto the piston. The mark (1) on the side of the piston ring should face the top of the piston.
  14. Position the compression ring end gaps 120 degrees apart.
  15. Install the connecting rod bearings (118) to the rod (119) and cap (117).

Cylinder Head Disassemble

  1. Use the J 8062 in order to compress the valve springs.
  2. Remove the valve stem keys (220).
  3. Release and remove the 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»(ref-277941-S08724385302008012100000) .

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 valve spring The pressure relief valve

Oil Pump Assemble

  1. Install the following items: The pressure relief valve The pressure relief valve spring The retaining pin
  2. Apply clean engine oil to the drive gear, the driven gear, and the housing gear surfaces.
  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 smooth 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 canister purge solenoid 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) canister purge solenoid 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 oil fill tube O-ring seal (415) 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 causes premature wear in the rebuilt engine. Clean all components.
  2. Use the proper tools to measure the components when inspecting for excessive wear. Components not within the manufacturers specification must be repaired or replaced.
  3. When the components are installed into an engine, return the components to their original location, position, and direction.
  4. During assembly, lubricate all moving parts with clean engine oil, unless otherwise specified. This provides 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.

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