Engine Mechanical - 3.5L: Overhaul Chevrolet Uplander I

Engine Block Disassemble

1. Remove the camshaft rear bearing hole plug.
2. Remove the rear oil gallery plugs (102, 103).
3. Remove the front oil gallery plugs (107, 110, 137).
4. Remove the engine front cover locating pins (546).
5. Remove the piston oil nozzle bolt (424) and nozzle (423).
6. Remove the engine block plug, if applicable.
7. Remove the engine block heater, if applicable.
8. Remove the transmission locating pins.
9. Remove the knock sensors.
10. Remove the engine oil pressure indicator switch.

Engine Block Assemble

1. Apply sealer GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the oil pressure switch threads.
2. Install the engine oil pressure switch. Tighten: Tighten the engine oil pressure switch to 16 N.m (12 lb ft).
3. Install the knock sensors. Tighten: Tighten the knock sensors to 25 N.m (18 lb ft).
4. Apply sealer GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the engine block plug or engine block heater, if applicable.
5. Install the engine block plug or engine block heater, if applicable. Tighten: Tighten the engine block plug or engine block heater to 60 N.m (44 lb ft).
6. Install the transmission locating pins. The installation height should be 8.3-9.3 mm (0.327-0.366 in) (A).
7. Apply sealer GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the front oil gallery plug threads (110, 137).
8. Install the front oil gallery plug (110). Tighten: Tighten the front oil gallery plug to 19 N.m (14 lb ft).
9. Install the front oil gallery plug (137). Tighten: Tighten the front oil gallery plug to 33 N.m (24 lb ft).
10. Apply sealer GM P/N 12377901 (Canadian P/N 10953504) or equivalent to the front oil gallery plug (107).
11. Install the front oil gallery plug (107) so that it is 2.3 mm (0.10 in) below flush of the engine block.
12. Install the engine front cover locating pins (546). The installation height should be 5.8-8.2 mm (0.228-0.323 in) (A).
13. Install the piston oil nozzle and bolt. Tighten: Tighten the piston oil nozzle bolt to 10 N.m (89 lb in).
14. Apply Sealer GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the rear oil gallery plugs.
15. Install the rear oil gallery plugs (103). Tighten: Tighten the rear oil gallery plugs to 19 N.m (14 lb ft).
16. Install the rear oil gallery plugs (102). Tighten: Tighten the rear oil gallery plugs to 33 N.m (24 lb ft).
17. Apply sealer GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the left and right coolant drain plug threads.
18. Install the left coolant drain plug. Tighten: Tighten the left coolant drain plug to 19 N.m (14 lb ft).
19. Install the right coolant drain plug. Tighten: Tighten the right coolant drain plug to 19 N.m (14 lb ft).

Disassembly Procedure

1. Using piston ring pliers, remove the piston rings from the piston.
2. Install fork insert J 24086-310 into fixture J 24086-10 piston pin remover/installer base, which are part of J 24086-C . See «Special Tools»(ref-241709-S09370669702006081100000) .
3. Install the piston and connecting rod assembly onto J 24086-10.
4. Install the J 24086-107 onto the piston pin and J 24086-88A through the fixture and onto J 24086-107, which are part of J 24086-C . See «Special Tools»(ref-241709-S09370669702006081100000) .
5. Press the piston pin from the piston and connecting rod assembly.
6. The piston and pin are a matched set and are not to be serviced separately. Mark, sort organize the piston and the matching piston pin.

1. Remove the heater inlet pipe stud from the right cylinder head, if required.
2. Remove the coolant temperature sensor from the right cylinder head, if required.
3. Remove the cylinder head plug.
4. Compress the valve springs using the J 38606 . See «Special Tools»(ref-241709-S09370669702006081100000) .
5. Remove the valve spring cap keys.
6. Remove the valve spring caps.
7. Remove the valve springs.
8. Remove the valves.
9. Remove the valve stem oil seals and spring seats as an assembly.

Assembly Procedure

1. Lubricate the valve stem with clean engine oil.
2. Install the valves.
3. Lightly tap the new or reconditioned valves into the valve seat.
4. Install the valve stem oil seals.
5. Install the valve springs.
6. Install the valve spring caps.
7. Compress the valve springs using the J 38606 . See «Special Tools»(ref-241709-S09370669702006081100000) .
8. Install the valve spring cap keys. Hold the valves in place with grease, if necessary.
9. Release the valve springs.
10. Ensure that the valve locks are seated.
11. Measure valve spring installed height.
12. If the valve spring installed height is not within specifications install 0.25 mm (0.010 in) rocker arm shims P/N 88894006 as needed. If more than 2 shims are needed replace the cylinder head or valve.
13. Apply sealer GM P/N 12346004 (Canadian P/N 10953480) to the coolant temperature sensor.
14. Install the coolant temperature sensor, if required. Tighten: Tighten the coolant temperature sensor to 23 N.m (17 lb ft).
15. Install the heater inlet pipe stud, if required. Tighten: Tighten the heater inlet pipe stud to 35 N.m (26 lb ft).
16. Apply sealer GM P/N 12346004 (Canadian P/N 10953480) to the cylinder head plug.
17. Install the cylinder head plug. Tighten: Tighten the cylinder head plug to 20 N.m (15 lb ft).

Oil Pump Disassemble

1. Remove the oil pump driveshaft and oil pump driveshaft retainer.
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.
7. Remove the following items: The oil pump pressure relief valve spring straight pin. The oil pump pressure relief spring. CAUTION: Refer to «CLEANING SOLVENT CAUTION»(ref-241680-S36200051022006081100000) in Cautions and Notices. The oil pump pressure relief valve. If the valve is stuck, soak the pump housing in cleaning solvent.

1. Lubricate all the internal oil pump parts using engine oil during assembly.
2. Install the oil pump gears.
3. Install the oil pump cover.
4. Install the oil pump cover bolts. Tighten: Tighten the oil pump cover bolts to 10 N.m (89 lb in).
5. Install the pressure regulator valve.
6. Install the pressure regulator spring.
7. Install the cotter pin.
8. Apply sealer P/N 21485278 or the equivalent to the new suction pipe.
9. Tap the new suction pipe into place using a plastic hammer. Use the J 22144 for 3/4 inch pipe. See «Special Tools»(ref-241709-S09370669702006081100000) .

Service Prior to Assembly

Dirt will cause premature wear of the rebuilt engine. Clean all of the components. Use the proper tools in order to measure components when inspecting for excessive wear. Repair or replace the components that are not within the manufacturers specification. When components are reinstalled into an engine, return the components to their original location, position and direction. During assembly, lubricate all of the moving parts with clean engine oil or engine assembly lubricant unless otherwise specified. This will provide initial lubrication when the engine is first started.