Engine Mechanical - 3.9L: Other Chevrolet Uplander I

Sealers, Adhesives and Lubricants

Sealers, Adhesives and Lubricants

Scheme 68

Scheme 69

Scheme 70

Scheme 71

Scheme 72

The Vehicle Identification Number - VIN derivative (1) for 3900 LZ9 is stamped or laser etched on the front and left side 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

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 .
4. Measure each cylinder on the compression stroke, with both valves closed.
5. Apply air pressure, using the J 35667-A . 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-241744-S09091524192006081100000) .
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-241744-S09091524192006081100000) . Inspect the engine block. Refer to «Engine Block Cleaning and Inspection»(ref-241709-S05416635312006081100000) .
11. Remove the J 35667-A .
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.

1. J-21867-6 Oil Pressure Adapter Fitting. See «Special Tools»(ref-241744-S39714852612006081100000) .
2. J 25087-C Oil Pressure Tester

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-241744-S40233872962006081100000) if necessary.

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-241744-S40233872962006081100000) if necessary.

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

J 41131 Engine Tilt Strap

Procedure

1. Remove the air cleaner outlet duct. Refer to «AIR CLEANER OUTLET DUCT REPLACEMENT»(ref-241687-S20617288222007030600000) .
2. Set the park brake.
3. Shift the transaxle into Neutral.
4. Loosen and remove the engine mount strut to engine mount strut bracket through bolts (2, 4) and nuts (3, 5).
5. Rotate the engine mount struts up out of the way.
6. Install the J 41131 .
7. Pull on the engine in order to rotate the engine forward.
8. Tighten the J 41131 .

1. J 22794 Spark Plug Port Adapter
2. J 5892-D Valve Spring Compressor

1. J 29113 Balancer and Crank Sprocket Installer
2. J 37096 Flywheel Holder
3. J 41816 Crankshaft Balancer Remover
4. J 45059 Angle Meter

J 41820 Ball Joint Separator

J 35468 Cover Aligner and Seal Installer

EN-47719 Tensioner Compressor. See Special Tools .

J 45059 Angle Meter

Scheme 73

1. Drain the engine oil. Refer to «Engine Oil and Oil Filter Replacement»(ref-241744-S30059072902006081100000) .
2. Drain cooling system. Refer to «DRAINING AND FILLING COOLING SYSTEM (STATIC FILL)»(ref-241700-S12524063102006081100000) .
3. Remove the lower intake manifold. Refer to «Intake Manifold Replacement - Lower»(ref-241744-S08174346002006081100000) .
4. Remove exhaust manifold. Refer to «EXHAUST MANIFOLD REPLACEMENT - LEFT (3.9L)»(ref-241745-S26771118722007030600000) .
5. Remove the exhaust crossover pipe. Refer to «EXHAUST CROSSOVER PIPE REPLACEMENT (3.9L)»(ref-241745-S32212658822007030600000) .
6. Remove oil level indicator tube. Refer to «Oil Level Indicator and Tube Replacement»(ref-241744-S26748326442006081100000) .
7. Remove the left spark plugs. Refer to «SPARK PLUG REPLACEMENT»(ref-241687-S07054642802007030600000) .
8. Remove and discard the cylinder head bolts.
9. Remove the cylinder head.
10. Remove and discard the cylinder head gasket.
11. Remove the cylinder head dowel pins, if necessary.

J 45059 Angle Meter

Scheme 74

1. Raise Vehicle. Drain cooling system. Refer to «DRAINING AND FILLING COOLING SYSTEM (STATIC FILL)»(ref-241700-S12524063102006081100000) .
2. Drain the engine oil. Refer to «Engine Oil and Oil Filter Replacement»(ref-241744-S30059072902006081100000) .
3. Lower Vehicle
4. Remove the lower intake manifold. Refer to «Intake Manifold Replacement - Lower»(ref-241744-S08174346002006081100000) .
5. Remove the exhaust manifold. Refer to «EXHAUST MANIFOLD REPLACEMENT - RIGHT (3.9L)»(ref-241745-S04622233512007030600000) .
6. Remove the right spark plugs. Refer to «SPARK PLUG REPLACEMENT»(ref-241687-S07054642802007030600000) .
7. Remove and discard cylinder head bolts.
8. Remove the cylinder head.
9. Remove and discard the cylinder head gasket.
10. Remove the cylinder head locator dowel pins, if necessary.

J 37096 Flywheel Holder

EN-4810834686 Rear Main Seal Installer

1. J 38185 (SA9111E) Hose Clamp Pliers
2. J 24319-B Steering Linkage and Tie Rod Puller
3. J 41820 Ball Joint Separator
4. J 2619-O1 Slide Hammer
5. J 29794 Axle Shaft Remover Extension
6. J 33008-A Axle Shaft Puller
7. J 42640 Steering Column Anti-Rotation Pin
8. J 39580 Engine Support Table
9. J 37096 Flywheel Holder
10. J 45059 Angle Meter

1. J 41816 Crankshaft Balancer Remover
2. EN 46359 Puller End Protector

1. J 24270 Cylinder Bore Ridge Reamer
2. J 41556 Connecting Rod Guide

J 33049 Camshaft Bearing Service Set

1. J 8001 Dial Indicator Set
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
2. J 45059 Angle Meter

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 .
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 .
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 8087 Cylinder Bore Gage

J 7872 Magnetic Base Dial Indicator Set

1. EN-47823 Valve Spring Compressor Adapter. See «Special Tools»(ref-241744-S39714852612006081100000) .
2. J 5892-D Valve Spring Compressor. See «Special Tools»(ref-241744-S39714852612006081100000) .

1. J 8089 Carbon Removing Brush
2. J 9666 Valve Spring Tester

J 8520 Camshaft Lobe Lift Indicator Set

Reaming & Grinding Procedures

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. 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.

1. EN-47823 Valve Spring Compressor Adapter. See «Special Tools»(ref-241744-S39714852612006081100000) .
2. J 5892-D Valve Spring Compressor. See «Special Tools»(ref-241744-S39714852612006081100000) .

J 22144 Oil Suction Pipe Installer

Thread Repair

General purpose thread repair kits are available commercially.

Repair Procedure

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

J 45059 Angle Meter

1. EN-47623 Anchor Bolt Socket. See «Special Tools»(ref-241744-S39714852612006081100000) .
2. J 8092 Drive Handle. See «Special Tools»(ref-241744-S39714852612006081100000) .
3. J 45059 Angle Meter

1. J 6125-1B Slide Hammer with Adapter
2. J 8037 Ring Compressor
3. J 41348 Bearing Cap Puller. See «Special Tools»(ref-241744-S39714852612006081100000) .
4. J 41556 Connecting Rod Guide
5. J 43654 Piston Pin Clip Remover and Installer. See «Special Tools»(ref-241744-S39714852612006081100000) .
6. J 43690 Rod Bearing Clearance Checking Tool. See «Special Tools»(ref-241744-S39714852612006081100000) .
7. J 43690-100 Rod Bearing Clearance Checking Tool-Adapter Kit. See «Special Tools»(ref-241744-S39714852612006081100000) .
8. J 45059 Angle Meter

Measuring Connecting Rod Bearing Clearance Using J 43690 and J 43690-100

J 43690 and J 43690-100 have been developed as a more accurate method to measure connecting rod bearing clearances. See Special Tools . The instructions below provide an overview of tool set and usage. For more detailed information, refer to the tool instruction sheets as supplied by the tool manufacturer.

1. J 43690 Rod Bearing Checking Tool includes: See «Special Tools»(ref-241744-S39714852612006081100000) . J 43690-20 Swivel Base (1) J 43690-19 Dial Indicator (2) J 43690-2 Base (3) J 43690-5,-6 Handle (4) J 43690-10,-11 Foot (5) 280307 Screw (6) J 43690-1 Pivot Arm Assembly (7) J 43690-3,-7,-8 Screws (8) 280319 Screw (9) 280311 Screw (10) J 43690-17,-18 Adapter (11) 280310 Pin (12)
2. J 43690-100 Rod Bearing Checking Tool - Adapter Kit includes: See «Special Tools»(ref-241744-S39714852612006081100000) . J 43690-104 Spacer (1) J 43690-105 Retainer Plate (2) 505478 Bolt (3) 511341 Bolt (4) J 43690-106 Retainer Plate (5) J 43690-107 Cap (6) J 43690-102 Foot (7) J 43690-101 Pivot Arm Assembly (8) J 43690-103 Adapter (9) 505439 Adapter (10)
3. Rotate the crankshaft until the journal/connecting rod to be measured is in the 12 o'clock position.
4. Remove the crankshaft main bearing cap bolts.
5. Remove the crankshaft main lower bearing cap.
6. Insert a piece of paper stock onto the crankshaft journal.
7. Install the crankshaft main bearing cap and bolts. Start the crankshaft main bearing cap bolts by hand. Ensure the bottom of the crankshaft main bearing cap is parallel to the bottom of the channel. Tighten: Tighten the crankshaft main bearing cap bolts in equal increments. Do not completely tighten one bolt at a time to prevent the cap from being cocked. Tighten the bolts to 50 N.m (37 lb ft) to fully seat the crankshaft main bearing caps. Loosen the bolts 360 degrees counterclockwise. Tighten the bolts to 20 N.m (15 lb ft), then 50 N.m (37 lb ft). Use J 45059 to tighten the bolts to 77 degrees.
8. Install the following: J 43690-101 (8) J 43690-5 (4) J 43690-2 (3) J 43690-7 (8) 280310 (12) J 43690-17 (11)
9. Install the swivel base (1) and dial indicator (2).
10. Adjust per the manufacturers instructions and measure the connecting rod bearing clearance. The connecting rod bearing clearance should be between 0.0127-0.0660 mm (0.0005-0.0026 in).

EN-47719 Tensioner Compressor. See Special Tools .

J 35468 Cover Aligner and Seal Installer

J 45059 Angle Meter

J 45059 Angle Meter

J 45059 Angle Meter

1. Install the clutch pilot bearing.
2. Install the flywheel/pressure plate.
3. Install the flywheel/pressure plate bolts. Tighten: Tighten the flywheel/pressure plate bolts to 50 N.m (37 lb ft) plus an additional 70 degrees using the J 45059 .

1. J 29113 Balancer and Crank Sprocket Puller
2. J 45059 Angle Meter

1. J-21867-6 Oil Pressure Adapter Fitting. See «Special Tools»(ref-241744-S39714852612006081100000) .
2. J 45299 Engine Preluber

Prelubing Procedure

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 and the J-21867-6 . See «Special Tools»(ref-241744-S39714852612006081100000) .
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. 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.

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 article, 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 BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE in 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.