Engine Mechanical - 3.5L: Other Chevrolet Uplander I

Sealers, Adhesives and Lubricants

Sealers, Adhesives and Lubricants

Scheme 31

Scheme 32

Scheme 33

Scheme 34

Scheme 35

The Vehicle Identification Number - VIN derivative (1) for 3500 LX9 is stamped or laser etched on the left side rear of the engine block. The Vehicle Identification Number - VIN derivative is nine digits long and can be used to determine if a vehicle contains the original engine.

1. The first digit identifies the division.
2. The second digit identifies the model year.
3. The third digit identifies the assembly plant.
4. The fourth through ninth digits are the last six digits of the Vehicle Identification Number - VIN.

Intermittent

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

Base Engine Misfire without Internal Engine Noises

Base Engine Misfire without Internal Engine Noises

Base Engine Misfire with Abnormal Internal Lower Engine Noises

Base Engine Misfire with Abnormal Internal Lower Engine Noises

Base Engine Misfire with Coolant Consumption

Base Engine Misfire with Coolant Consumption

Base Engine Misfire with Excessive Oil Consumption

Base Engine Misfire with Excessive Oil Consumption

Engine Will Not Crank - Crankshaft Will Not Rotate

Engine Will Not Crank - Crankshaft Will Not Rotate

Coolant in Combustion Chamber

Coolant in Combustion Chamber

Coolant in Engine Oil

Coolant in Engine Oil

Tools Required

J 35667-A Cylinder Leakdown Tester. See Special Tools .

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 negative battery cable.
2. Remove the spark plugs. Refer to «Spark Plug Replacement»(ref-241686-S36085824072006081100000) in Engine Controls.
3. Install the J 35667-A . See «Special Tools»(ref-241709-S09370669702006081100000) .
4. Measure each cylinder on the compression stroke, with both valves closed.
5. Apply air pressure, using the J 35667-A . See «Special Tools»(ref-241709-S09370669702006081100000) . Refer to the manufacturer's instructions.
6. Record the cylinder leakage readings for each cylinder.
7. Inspect the 4 primary areas in order to properly diagnose a leaking cylinder.
8. If air is heard from the intake or exhaust system, perform the following procedure: Remove the valve rocker arm cover of the suspect cylinder head. Ensure that both valves are closed. Inspect the cylinder head for a broken valve spring. Remove and inspect the suspect cylinder head. Refer to «Cylinder Head Cleaning and Inspection»(ref-241709-S36573750802006081100000) .
9. If air is heard from the crankcase system at the crankcase - oil filler tube, perform the following procedure: Remove the piston from the suspect cylinder. Inspect the piston and connecting rod assembly. Refer to «Piston, Connecting Rod and Bearings Cleaning and Inspection»(ref-241709-S04155503832006081100000) . Inspect the engine block. Refer to «Engine Block Cleaning and Inspection»(ref-241709-S05416635312006081100000) .
10. If bubbles are found in the radiator, perform the following procedure: Remove and inspect both cylinder heads. Refer to «Cylinder Head Cleaning and Inspection»(ref-241709-S36573750802006081100000) . Inspect the engine block. Refer to «Engine Block Cleaning and Inspection»(ref-241709-S05416635312006081100000) .
11. Remove the J 35667-A . See «Special Tools»(ref-241709-S09370669702006081100000) .
12. Install the spark plugs. Refer to «Spark Plug Replacement»(ref-241686-S36085824072006081100000) in Engine Controls.
13. Connect the negative battery cable. Refer to «BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE»(ref-241706-S19444827352007022100000) in Engine Electrical.

J 25087-C Oil Pressure Tester. See Special Tools .

Low or No Oil Pressure

The following conditions may cause low or no oil pressure

1. Low oil level-Fill to the full mark on the oil level indicator.
2. Incorrect or malfunctioning oil pressure switch-Replace the oil pressure switch.
3. Incorrect or malfunctioning oil pressure gauge-Replace the oil pressure gauge.
4. Improper oil viscosity or diluted oil Install oil of proper viscosity for expected temperature. Install new oil if the oil is diluted.
5. A worn or dirty oil pump-Clean or replace the oil pump.
6. A plugged oil filter-Replace the oil filter.
7. A loose or plugged oil pickup screen-Replace the oil pickup screen.
8. A hole in the oil pickup tube-Replace the oil pickup tube.
9. Excessive rod, main or cam bearing clearance-Replace the bearings.
10. Cracked, porous or plugged oil gallery-Repair or replace the engine block.
11. Missing or improperly installed gallery plugs- Install or repair the plugs as needed.
12. A stuck pressure regulator valve Inspect the pressure regulator valve for sticking in the bore. Inspect the bore for scoring and burrs.
13. A worn or poorly machined camshaft-Replace the camshaft.
14. Worn valve guides-Repair the valve guides as needed.

J 28428-E High Intensity Black Light Kit

You may repair most fluid leaks by first visually locating the leak, repairing or replacing the component or by resealing the gasket surface. Once the leak is identified, determine the cause of the leak. Repair the leak and the cause of leak.

Locating and Identifying the Leak

Use the visual inspection method in order to determine if the leaking fluid is one of the following items

1. Engine oil
2. Transmission fluid
3. Power steering fluid
4. Brake fluid
5. Some other fluid

Powder Method

1. Completely clean the entire engine and surrounding components.
2. Apply an aerosol-type powder, baby powder, foot powder, etc., to the suspected area.
3. Operate the vehicle for several miles at normal operation temperature and at varying speeds.
4. Identify the type of fluid and the approximate location of the leak, from the discolorations in the powder surface.
5. Visually inspect the suspected area. Use a small mirror to assist in looking at hard to see areas. Refer to «Possible Causes for Leaks»(ref-241709-S42708353412006081100000) .

Black Light and Dye Method

A dye and light kit is available for finding leaks.

1. Use the J 28428-E or the equivalent. Refer to the manufacturer's instructions when using the tool.
2. Visually inspect the suspected area. Use a small mirror if necessary Refer to «Possible Causes for Leaks»(ref-241709-S42708353412006081100000) .

Possible Causes for Leaks

Inspect the vehicle for the following conditions

1. Higher than recommended fluid levels
2. Higher than recommended fluid pressures
3. Plugged or malfunctioning fluid filters or pressure bypass valves
4. Plugged or malfunctioning engine ventilation system
5. Improperly tightened or damaged fasteners
6. Cracked or porous components
7. Improper sealants or gaskets where required
8. Improper sealant or gasket installation
9. Damaged or worn gaskets or seals
10. Damaged or worn sealing surfaces

1. J 28467-34 Lift Hook Wing Nut and Washer (2). See «Special Tools»(ref-241709-S09370669702006081100000) .
2. J 28467-6A Bracket Assembly (2). See «Special Tools»(ref-241709-S09370669702006081100000) .
3. J 28467-7A Bolt Hook (2). See «Special Tools»(ref-241709-S09370669702006081100000) .
4. J 28467-500 Engine Support Fixture. See «Special Tools»(ref-241709-S09370669702006081100000) .
5. J 28467-B Universal Engine Support Fixture. See «Special Tools»(ref-241709-S09370669702006081100000) .
6. J 45057 Engine Support Bar Assembly. See «Special Tools»(ref-241709-S09370669702006081100000) .
7. J 45057-2 Lower Support Bar. See «Special Tools»(ref-241709-S09370669702006081100000) .

J 41131 Engine Tilt Strap. See Special Tools .

Access Procedure

1. Remove the throttle body air inlet duct. Refer to «Air Cleaner Intake Duct Replacement»(ref-241686-S30580330962006081100000) in Engine Controls - 3.5L.
2. Set the park brake.
3. Shift the transaxle into Neutral.
4. Remove the engine mount strut bolts. Swing the engine mount struts aside. Refer to «Engine Mount Strut Replacement - Left»(ref-241709-S09230890912006081100000) and «Engine Mount Strut Replacement - Right»(ref-241709-S29966733752006081100000) .
5. Install the J 41131 . See «Special Tools»(ref-241709-S09370669702006081100000) .
6. Pull on the engine in order to rotate the engine forward.
7. Tighten the J 41131 . See «Special Tools»(ref-241709-S09370669702006081100000) .

1. J 22794 Spark Plug Port Adapter. See «Special Tools»(ref-241709-S09370669702006081100000) .
2. J 38606 Valve Spring Compressor. See «Special Tools»(ref-241709-S09370669702006081100000) .

1. J 29113 Balancer and Crank Sprocket Installer. See «Special Tools»(ref-241709-S09370669702006081100000) .
2. J 37096 Flywheel Holder. See «Special Tools»(ref-241709-S09370669702006081100000) .
3. J 41816 Crankshaft Balancer Remover. See «Special Tools»(ref-241709-S09370669702006081100000) .

J 35468 Cover Aligner and Seal Installer. See Special Tools .

J 45059 Angle Meter. See Special Tools .

J 45059 Angle Meter. See Special Tools .

J 37096 Flywheel Holder. See Special Tools .

J 34686 Rear Main Seal Installer. See Special Tools .

1. J 41816-A Crankshaft Balancer Remover. See «Special Tools»(ref-241709-S09370669702006081100000) .
2. EN 46359 Puller End Protector. See «Special Tools»(ref-241709-S09370669702006081100000) .

1. J 24270 Cylinder Bore Ridge Reamer. See «Special Tools»(ref-241709-S09370669702006081100000) .
2. J 41556 Connecting Rod Guide. See «Special Tools»(ref-241709-S09370669702006081100000) .

J 33049 Camshaft Bearing Service Set. See Special Tools .

1. J 8001 Dial Indicator Set. See «Special Tools»(ref-241709-S09370669702006081100000) .
2. J 8087 Cylinder Bore Gage

Boring Procedure

1. Before honing or boring, measure all of the new pistons. Select the smallest piston for the piston fitting. Slightly varied pistons in a set may provide correction, if the first piston is too loosely fitted.
2. Before using any type of boring bar, file the top of the engine block to remove any dirt or burrs. If the cylinder block is not straight, the boring bar may be tilted, causing the bored cylinder wall to have incorrect right angles to the crankshaft.
3. Carefully follow the instructions furnished by the manufacturer regarding use of equipment.
4. Install all crankshaft main bearing caps to specification when boring cylinders. Cover or tape the crankshaft bearings and other internal parts to protect these parts during the boring or honing operation.
5. Leave 0.03 mm (0.001 in) on the diameter for finish honing when performing the final cut with a boring bar. Carefully perform the honing and boring operation to maintain the specified clearances between pistons, rings and cylinder bores.

Honing Procedure

1. Follow the manufacturer's recommendations for use, cleaning and lubrication when honing the cylinders. 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. When using coarse or medium-grade stones, leave sufficient metal so all stone marks may be removed with the fine stones used for finishing to provide the proper clearance.
2. During the honing operation, thoroughly clean the cylinder bore. Check for the correct piston fit.
3. Make full strokes in the cylinder to eliminate taper. Repeatedly check the measurement at the top, the middle and the bottom of the cylinder bore.
4. When finish honing a cylinder bore to fit a piston, move the hone up and down at a sufficient speed to obtain a fine and uniform surface finish in a cross hatch pattern.
5. The finish marks should be clean but not sharp. The finish marks should be free from imbedded particles and torn or folded metal.
6. Determine the finish hone cylinder measurement by measuring the piston to be installed and by adding the average of the clearance specification. Measure the block and the piston at normal room temperature.
7. True up the refinished cylinder bores. Final hone each cylinder bore to remove all stone or cutter marks.
8. After final honing and before the piston is checked for fit, clean the bores with hot water and detergent. Scrub the bores with a stiff bristle brush and rinse the bores thoroughly with hot water. Do not allow any abrasive material to remain in the cylinder bores. This abrasive material will wear the new rings, the cylinder bores and the bearings lubricated by the contaminated oil. After washing dry the bore.
9. Permanently mark the piston for the cylinder to which the piston has been fitted.
10. Apply clean engine oil to each bore to prevent rusting.

1. J 8087 Cylinder Bore Gage. See «Special Tools»(ref-241709-S09370669702006081100000) .
2. J 45059 Angle Meter. See «Special Tools»(ref-241709-S09370669702006081100000) .

Bearing Selection

Measure the bearing clearance to determine the correct replacement bearing insert size. There are two methods to measure bearing clearance. Method A gives more reliable results and is preferred.

1. Method A yields measurement from which the bearing clearance can be computed.
2. Method B yields the bearing clearance directly. Method B does not give any indication of bearing run-out.

Method A

1. Measure the crankshaft bearing journal diameter with a micrometer in several places, 90 degrees apart. Average the measurements.
2. Measure the crankshaft bearing journal taper and runout.
3. Install the crankshaft bearing inserts. Tighten the bearing cap bolts to specification using J 45059 . See «Special Tools»(ref-241709-S09370669702006081100000) .
4. Measure the connecting rod inside diameter in the same direction as the length of the rod with an inside micrometer.
5. Measure the crankshaft main bearing inside diameter with an inside micrometer.
6. Select a set of bearing inserts that will produce the desired clearance.
7. If the specified clearances cannot be met, the crankshaft journals must be reconditioned and undersized bearing inserts installed.

Method B

1. Clean the used bearing inserts.
2. Install the used bearing inserts.
3. Place a piece of gaging plastic across the entire bearing width.
4. Install the bearing caps. NOTE: In order to prevent the possibility of cylinder block or crankshaft bearing cap damage, the crankshaft bearing caps are tapped into the cylinder block cavity using a brass, lead or a leather mallet before the attaching bolts are installed. Do not use attaching bolts to pull the crankshaft bearing caps into the seats. Failure to use this process may damage a cylinder block or a bearing cap.
5. Install the bearing cap bolts to specification using J 45059 . See «Special Tools»(ref-241709-S09370669702006081100000) .
6. Remove the bearing cap, leaving the gaging plastic in place. It does not matter whether the gaging plastic adheres to the journal or to the bearing cap.
7. Measure the gaging plastic at its widest point with the scale printed on the gaging plastic package.
8. Remove the gaging plastic.
9. Select a set of bearing inserts that will produce the desired clearance.

J 24086-C Piston Pin Remover/Installer Set. See Special Tools .

J 8087 Cylinder Bore Gage. See Special Tools .

J 24086-C Piston Pin Remover/Installer Set. See Special Tools .

J 7872 Magnetic Base Dial Indicator Set. See Special Tools .

J 38606 Valve Spring Compressor. See Special Tools .

1. J 8089 Carbon Removing Brush. See «Special Tools»(ref-241709-S09370669702006081100000) .
2. J 9666 Valve Spring Tester

J 8520 Camshaft Lobe Lift Indicator Set. See Special Tools .

Procedure

1. Inspect the valves for the following conditions: Burnt or eroded areas (1) A worn margin (2) A bent stem (3) A worn or scored stem (4) A worn key groove (5) A worn stem tip (6)
2. Inspect the valve face for the following conditions: Worn margin (4) No margin (1) Pitted surfaces (2) Burnt or eroded areas (3)
3. Inspect the valve seats for a loose fit in the cylinder head.
4. Inspect for excessive valve stem (1) to guide (2) clearance.
5. Use a dial indicator in order to measure the valve stem-to-guide clearance. Complete the following steps: Install the valve into the guide. Install the J 8520 onto the cylinder head. See «Special Tools»(ref-241709-S09370669702006081100000) . Locate 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 on the indicator stem. Ensure that the indicator stem contacts the side of the valve stem just above the valve guide. Drop the valve head about 2 mm (1/8 in) off the valve seat. Use light pressure and move the valve stem side to side in order to obtain a clearance reading. If the valve stem to guide clearance is not within specification, replace the valve and/or repair the guide in order to obtain the proper clearances.
6. Ream the valve guides for oversize valves if the clearance exceeds the specifications.
7. Ream the valve guide in order to obtain the proper specification.
8. Inspect the valves for excessive scoring.
9. Inspect the valve face. Replace the valve if the valve margin is not within specifications after grinding.
10. Reface pitted valves on a valve refacing machine in order to ensure the correct relationship between the head and the stem.
11. Recondition the valve seats after reaming the valve guide bores or installing the new valve guides.
12. The valve seats should be concentric to within 0.05 mm (0.031 in) total indicator reading.

J 38606 Valve Spring Compressor. See Special Tools .

J 22144 Oil Suction Pipe Installer. See Special Tools .

J 21882 Oil Suction Pipe Installer. See Special Tools .

Thread Repair

General purpose thread repair kits are available commercially.

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.
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 33049 Camshaft Bearing Service Set. See Special Tools .

J 45059 Angle Meter. See Special Tools .

1. Dip the crankshaft bearing cap bolts in clean engine oil.
2. Place the crankshaft bearing inserts into the crankshaft bearing cap and into the engine block.
3. Lubricate the crankshaft main bearing surface with clean engine oil.
4. Install the crankshaft.
5. Install the crankshaft main bearing caps. Apply a small amount of sealer GM P/N 1052942 (Canadian P/N 10953466) to the rear of the #4 crankshaft main bearing cap sealing surface.
6. Install the crankshaft main bearing cap bolts. Tighten: Use the J 45059 in order to tighten the crankshaft main bearing cap bolts to 50 N. See «Special Tools»(ref-241709-S09370669702006081100000) .m (37 lb ft) plus 77 degrees.
7. Measure the crankshaft end play. Thrust the crankshaft forward or rearward. Insert a feeler gage between the number 3 crankshaft bearing and the bearing surface of the crankshaft and measure the bearing clearance. The proper crankshaft end play clearance is 0.06-0.21 mm (0.002-0.008 in). If the bearing clearance is not within specifications, inspect the thrust surfaces for nicks, gouges or raised metal. Minor imperfections may be removed with a fine stone.
8. Install the crankshaft position sensor into the side of the engine block.
9. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or the equivalent to the crankshaft position sensor stud threads.
10. Install the crankshaft position sensor stud. Tighten: Tighten the crankshaft position sensor stud to 11 N.m (98 lb in).
11. Install the crankshaft position sensor shield and nut. Tighten: Tighten the crankshaft position sensor shield nut to 11 N.m (98 lb in).

J 34686 Rear Main Seal Installer. See Special Tools .

1. J 8037 Ring Compressor. See «Special Tools»(ref-241709-S09370669702006081100000) .
2. J 45059 Angle Meter. See «Special Tools»(ref-241709-S09370669702006081100000) .
3. J 41556 Connecting Rod Guide. See «Special Tools»(ref-241709-S09370669702006081100000) .

J 35468 Cover Aligner and Seal Installer. See Special Tools .

J 45059 Angle Meter. See Special Tools .

J 45059 Angle Meter. See Special Tools .

J 29113 Balancer and Crank Sprocket Puller. See Special Tools .

1. Apply sealer GM P/N 12378521 (Canadian P/N 88901148) or the equivalent to the keyway of the crankshaft balancer.
2. Place the crankshaft balancer into position over the key in the crankshaft.
3. Install the J 29113 onto the crankshaft. See «Special Tools»(ref-241709-S09370669702006081100000) .
4. Rotate the hex nut on the J 29113 to install the crankshaft balancer onto the crankshaft. See «Special Tools»(ref-241709-S09370669702006081100000) .
5. Remove the J 29113 from the crankshaft. See «Special Tools»(ref-241709-S09370669702006081100000) .
6. Install the crankshaft balancer washer and bolt. Tighten: Tighten the crankshaft balancer bolt to 160 N.m (118 lb ft).

J 45299 Engine Preluber. See Special Tools .

1. Remove the engine oil filter, fill with clean engine oil and reinstall. Tighten: Tighten the oil filter to 30 N.m (22 lb ft).
2. Locate the engine oil pressure indicator switch on the left side of the engine and remove.
3. Install the 1/4 inch adapter P/N 509373.
4. Install the flexible hose to the adapter and open the valve.
5. Pump the handle on J 45299 to flow a minimum of 1-2 quarts of engine oil. See «Special Tools»(ref-241709-S09370669702006081100000) . 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 engine oil pressure indictor switch. Tighten: Tighten the engine oil pressure indictor switch to 16 N.m (12 lb ft).
8. Top off the engine oil to the proper level.

Scheme 36

A crankcase ventilation system is used to consume crankcase vapors (1) in the combustion process instead of venting them to atmosphere. Fresh air from the throttle body is supplied to the crankcase, mixed with blow by gases and then passed through a positive crankcase ventilation (PCV) valve (3) into the intake manifold.

Scheme 37

The primary control is through the positive crankcase ventilation (PCV) valve which meters the flow at a rate depending on inlet vacuum. To maintain idle quality, the PCV valve restricts the flow when inlet vacuum is high. If abnormal operating conditions arise, the system is designed to allow excessive amounts of blow by gases to back flow through the crankcase vent into the throttle body to be consumed by normal combustion.

Cleanliness and Care

An automobile engine is a combination of many of the following surfaces

1. Machined
2. Honed
3. Polished
4. Lapped

The tolerances of these surfaces are measured in the ten-thousandths of an inch. When you service any internal engine part, cleanliness and care are important. Apply a liberal coating of engine oil to the friction areas during assembly in order to protect and lubricate the surfaces on initial operation. Throughout this procedure, practice proper cleaning and protection procedures to the machined surfaces and to the friction areas.

Note. Engine damage may result if an abrasive paper, pad or motorized wire brush is used to clean any engine gasket surfaces.

Whenever you remove the valve train components, keep the components in order. Follow this procedure in order to install the components in the same locations and with the same mating surfaces as when removed.

Disconnect the negative battery cables before you perform any major work on the engine. For more information on the disconnection of the battery, refer to ENGINE ELECTRICAL .

Separating Parts

In addition to the room temperature vulcanizing (RTV) sealant's sealing capabilities, the RTV sealants may form an adhesive bond between the components. This may make the components difficult to remove or to separate. If possible, bump the components sideways rather than using prying tools in order to remove the components. This technique prevents damage when the bonding strength of the RTV sealant is stronger than the component itself. Perform bumping at the bends or at the reinforced areas in order to prevent part distortion.

Replacing Engine Gaskets

1. Do not reuse any gasket unless otherwise specified. Reusable gaskets will be identified in the service procedure. Do not apply sealant to any gasket or sealing surface unless called out in the service procedure.
2. Use a rubber mallet in order to separate components. Bump the part sideways in order to loosen the components. Perform the bumping at the bends or at the reinforced areas in order to prevent the distortion of components.
3. Remove all of the gasket and the sealing material from the component using a plastic or a wood scraper. Do not gouge or scrape the sealing surfaces.
4. When assembling components, use only the sealant specified in the service procedure. Ensure that the sealing surfaces are clean and free of debris or oil. When applying sealant to a component, apply a bead size as specified in the service procedure.
5. Tighten the bolts to the specifications.

Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealer

The following 2 types of sealer are commonly used in engines

1. The RTV sealer
2. The anaerobic gasket eliminator sealer

Follow the service procedure instructions. Use the correct sealer in the proper place in order to prevent oil leaks. Do not interchange the 2 types of sealers. Use the sealer recommended in the service procedure.

Applying RTV Sealer

1. Do not use the room temperature vulcanizing (RTV) sealant in areas where extreme temperatures are expected. These areas include the following locations: The exhaust manifold The head gasket The other surfaces where gasket eliminator is specified
2. Use a rubber mallet in order to separate the components sealed with RTV sealant. Bump the part sideways in order to shear the RTV sealer. Perform the bumping at the bends or the reinforced areas in order to prevent distortion of the components. The RTV sealant is weaker in shear (lateral) strength than in tensile (vertical) strength.
3. Do not use the following items in order to clean the gasket surfaces: Abrasive pads Sand Paper Power tools

These methods of cleaning may damage the part.

Abrasive pads also produce a fine grit that the oil filter cannot remove from the oil. This grit is abrasive and may cause internal engine damage.

1. Remove all of the gasket material from the component using a plastic or a wood scraper. Use Loctite® brand gasket remover P/N 4MA or the equivalent. Follow all of the safety recommendations and the directions that are on the container. IMPORTANT: Do not allow the sealer to enter the blind threaded holes. The sealer may cause the following conditions: Prevent you from properly seating the bolt Cause damage when you tighten the bolt
2. Apply the RTV sealant to a clean surface. Use a bead size as specified in the procedure. Apply the bead to the inside of any bolt holes.
3. Assemble the components while the RTV sealant is still wet (within 3 minutes). Do not wait for the RTV sealant to skin over.
4. Tighten the bolts to specifications.

Applying Anaerobic Sealer

The anaerobic gasket eliminator hardens in the absence of air. This type of sealer is used where 2 rigid parts (such as castings) are assembled together. When 2 rigid parts are disassembled and no sealer or gasket is readily noticeable, the parts were probably assembled using a gasket eliminator.

Do not use the following items in order to clean the gasket surfaces

1. Abrasive pads
2. Sand paper
3. Power tools

These methods of cleaning may damage the part.

Abrasive pads also produce a fine grit that the oil filter cannot remove from the oil. This grit is abrasive and may cause internal engine damage.

1. Remove all of the gasket material from the component using a plastic or a wood scraper. Use Loctite® brand gasket remover P/N 4MA or the equivalent. Follow all of the safety recommendations and the directions that are on the container.
2. Apply a continuous bead of the gasket eliminator to 1 flange. Clean and dry any surfaces that you will reseal.
3. Do not allow the sealer to enter the blind threaded holes. The sealer may cause the following conditions: Prevent you from properly seating the bolt Cause damage when you tighten the bolt
4. Spread the sealer evenly in order to get a uniform coating on the sealing surface.
5. Tighten the bolts to the specifications.
6. Remove the excess sealer from the outside of the joint.

Tools and Equipment

Work in a clean and well-lit area. Have the following components available before you begin to work

1. A suitable parts cleaning tank
2. A compressed air supply
3. Trays, in order to keep the parts and the fasteners organized
4. An adequate set of hand tools

An approved engine repair stand will prevent personal injury or damage to the engine components. The special tools are designed in order to quickly and safely accomplish the operations for which the tools are intended. Using the tools will minimize possible damage to the engine components. Precision measuring tools are required for the inspection of certain critical components. Torque wrenches are needed for the correct assembly of various parts.