4.3l v6 - VIN [z] GMC Pickup R2500

ENGINE IDENTIFICATION

Note. For engine repair procedures not covered in this article, see ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION article in the GENERAL INFORMATION section.

Engine can be identified by eighth character of Vehicle Identification Number (VIN). VIN is located on a metal tag on top left corner of instrument panel. Engine identification number is stamped on a machined pad on front of cylinder block, immediately forward of right cylinder head.

ENGINE IDENTIFICATION CODES

Valve Arrangement

Left Bank - E-I-E-I-I-E (Front-to-rear).

Right Bank - E-I-I-E-I-E (Front-to-rear).

1. Rotate engine until No. 1 piston is on TDC of compression stroke. With piston in this position, adjust valves listed in appropriate VALVE CLEARANCE ADJUSTMENT table.
2. Loosen rocker arm adjusting nut until lash is present. Tighten adjusting nut until lash is removed and push rod will not rotate. When lash is removed, tighten adjusting nut one full turn.
3. Rotate crankshaft 360 degrees to bring No. 4 piston to TDC of compression stroke. Adjust remaining valves. See VALVE CLEARANCE ADJUSTMENT table.

VALVE CLEARANCE ADJUSTMENT

TROUBLE SHOOTING

Note. To trouble shoot engine mechanical components, see appropriate table in TROUBLE SHOOTING article in GENERAL INFORMATION.

ENGINE OVERHAUL

Note. See ENGINE OVERHAUL PROCEDURES article in this section for basic procedures not covered in this article.

Removal

1. Disconnect negative battery cable. On Van models, remove engine cover and air injection crossover hose. Remove air cleaner. Drain cooling system. Label and disconnect necessary brackets, wires and hoses. Disconnect fuel lines and linkages.
2. Remove distributor cap. With chalk or crayon, mark relationship of distributor rotor and housing to a stationary reference point in engine compartment. If distributor is aligned properly upon installation, and if crankshaft is not rotated while engine is apart, engine timing will not need to be reset.
3. Remove brake booster vacuum pipe. Remove carburetor or throttle body (if necessary). Remove manifold bolts. Remove intake manifold and gaskets.

Installation

Apply 3/16" bead of silicone sealer at front and rear intake manifold mounting surface of cylinder block. (Scheme 21) Extend bead of sealer 1/2" up each cylinder head.

Scheme 21

Scheme 22

Remove heat stove tube. Remove all attached brackets and heat shields. On some models, it may be necessary to remove dip stick tube. Disconnect oxygen sensor wire. Disconnect exhaust pipe from manifold. Bend over lock tabs (if equipped). Remove retaining bolts and exhaust manifold.

Clean all mating surfaces. Install manifold. Tighten bolts to specification. Bend over lock tabs (if equipped). To complete installation, reverse removal procedure.

1. Disconnect negative battery cable. Drain cooling system, including block. Remove intake and exhaust manifolds as previously described. Remove A/C compressor and bracket (if equipped). Disconnect wiring and hoses from cylinder heads. Remove alternator, spark plugs and valve covers.
2. Loosen rocker arm nuts and rotate rocker arms to side. Remove push rods in sequence and mark for reassembly in original locations. Remove cylinder head bolts. Remove cylinder heads.

1. Clean all gasket surfaces and head bolt holes. On steel head gaskets apply thin coat of sealer to both sides of gasket. Do not use sealer on steel/asbestos gaskets.
2. Position gaskets on cylinder block with bead facing upward. Ensure that all holes align. Install cylinder heads. Coat threads of head bolts with Sealant (1052080).
3. Install and tighten head bolts in sequence. (Scheme 23) Tighten head bolts to specification. To complete installation, reverse removal procedure. Lubricate valve tip, rocker arm pivot and push rod socket with Molykote prior to installation. Adjust valves. See VALVE CLEARANCE ADJUSTMENT in this article.

Scheme 23

ROCKER ARM STUDS

Rocker arm studs are a press-fit in cylinder head. Studs which are loose in head or have damaged threads can be replaced using oversize studs. Oversize studs are available in .003" (.08 mm) and .013" (.33 mm). Rocker arm studs retain push rod guide.

Removal & Installation

1. Using Stud Remover (J-5802-01), place remover over stud. Install nut and flat washer. Tighten nut to remove stud from cylinder head. Ream hole for oversize stud.
2. Use Reamer (J-5715) for .003" (.08 mm) and Reamer (J-6036) for .013" (.33 mm) oversize replacement studs. Coat press-fit area of stud with hypoid axle lubricant.
3. Using Stud Driver (J-6880), drive stud in cylinder head. Proper stud height is obtained when driver bottoms against cylinder head.

VALVE SPRINGS

Valve spring free length and tension should be checked prior to installation. See VALVE SPRINGS under ENGINE SPECIFICATIONS table at end of article for specifications.

VALVE SPRING INSTALLED HEIGHT

Installed valve spring height must be checked. If installed height exceeds specifications, shim to meet specifications. See SPRING INSTALLED HEIGHT table.

VALVE SPRING INSTALLED HEIGHT SPECIFICATIONS

VALVE GUIDES

Check valve stem-to-guide clearance. Oversize valves must be used if not within specification. See VALVES table under ENGINE SPECIFICATIONS at end of article. Valves with oversize stems are available.

1. Disconnect negative battery cable at battery. Drain cooling system. If necessary, remove radiator shroud. Remove all accessory drive belts, fan and pulley.
2. Remove vibration damper retaining bolt. Using Damper Puller/Installer (J-23523-E), remove vibration damper. Remove all mounting brackets and coolant hoses attached to water pump. Remove water pump. Remove oil pan. See OIL PAN REMOVAL at end of ENGINE section. On all models, remove front cover, timing tab (if equipped) and gasket.

Note. If timing cover alignment dowels can be removed, cover can possibly be removed and installed without removing oil pan. Replace dowel pins with cover installed and aligned. DO NOT leave dowel pins out or oil leaks will result.

1. Install gasket on front cover with gasket sealer. Install cover on engine block and timing tab (if equipped). Tighten bolts to specification. Install vibration damper using damper puller/installer.
2. Before installing vibration damper retaining bolt, apply small amount of RTV sealant at crankshaft Woodruff key and vibration damper. Install retaining bolt. Tighten to specification. Reverse removal procedure to install remaining components. Tighten bolts to specification.

Remove drive belts. Remove pulley. Remove vibration damper retaining bolt. Using Damper Puller/Installer (J-23523-E), remove vibration damper. Pry seal from cover with screwdriver. Do not damage front cover.

1. Using Seal Installer (J-35468), install new seal in front cover. Seal lip must face toward engine. Coat seal lip with engine oil. Install vibration damper.
2. Before installing vibration damper retaining bolt, apply small amount of RTV sealant at crankshaft Woodruff key and vibration damper. Install retaining bolt and tighten to specification. Reverse removal procedure to install remaining components. Tighten all bolts to specification.

Remove engine front cover as previously described. Crank engine over until timing marks on camshaft and crankshaft sprockets are aligned. Remove camshaft sprocket and timing chain. If crankshaft sprocket replacement is necessary, use Sprocket Puller (J-5825-A) to remove sprocket.

1. Install Woodruff key in crankshaft (if removed). Using Crankshaft Sprocket Installer (J-5590), install crankshaft sprocket on crankshaft. Install camshaft sprocket and timing chain.
2. Ensure timing marks on sprockets are aligned. (Scheme 24) Install and tighten sprocket bolts to specification. Reverse removal procedure to install remaining components. Tighten all bolts to specification.

Scheme 24

1. Remove intake manifold, engine front cover, timing chain and camshaft sprocket as previously described. Remove valve covers. Loosen all rocker arm nuts and rotate rockers to one side. Remove push rods and lifters. Remove lifter retainer plate then remove lifters. Mark location for reassembly reference.
2. Remove radiator and grille. Remove fuel pump and push rod on carbureted engines. Remove thrust plate retaining screws. Reinstall cam gear for ease in handling. Remove camshaft.

Cleaning & Inspection

Clean all components with clean solvent. Inspect camshaft lobes for signs of flaking or flat spots. Measure camshaft. Replace camshaft if not within specification. See CAMSHAFT table under ENGINE SPECIFICATIONS at end of article.

1. Coat camshaft lobes and journals with engine oil supplement. Install cam gear for ease in handling. Install camshaft. Remove cam gear, install thrust plate and retaining screws. Tighten to specification.
2. On all engines, temporarily place camshaft sprocket on camshaft and align timing marks. Remove sprocket. Install camshaft sprocket and chain. Tighten camshaft sprocket bolts to specification.
3. Lubricate timing chain with engine oil. When installing new camshaft, install new lifters, change oil and filter. Reverse removal procedure to install remaining components. Tighten all bolts to specification. Adjust valves. See VALVE CLEARANCE ADJUSTMENT in this article.

CAM LOBE LIFT

1. Remove valve cover and rocker arm assembly. Using Lobe Lift Indicator (J-8520), mount dial indicator on cylinder head. Position dial indicator and ball socket adapter on push rod.
2. Slowly rotate engine in direction of rotation until lifter is on base circle of camshaft. This is lowest reading. Adjust dial indicator to zero. Rotate engine until push rod is fully raised and note reading.
3. Compare reading with specification. See CAMSHAFT table under ENGINE SPECIFICATIONS at end of article. Replace camshaft and lifters if not within specification.

1. Remove engine. See ENGINE REMOVAL article in this section. Remove oil pan, oil pump, flywheel, timing cover and chain. Remove crankshaft. Remove camshaft. Move pistons upward to top of cylinder bores. Using Bearing Remover/Installer (J-6098-01), remove camshaft bearings.
2. Install front and rear camshaft bearings first, to act as guides for remover/installer pilot. Ensure that bearing oil passages are aligned with oil passages in block. Use 3/32" diameter round stock to check oil passage alignment. Coat camshaft rear bore plug with sealer. Install plug even to 1/32" below engine block surface.

OIL PAN

See OIL PAN REMOVAL article in this section.

Remove intake manifold and cylinder head as previously described. Remove oil pan and oil pump. Ensure that rods and rod caps are marked for cylinder location. Remove cylinder ridge. Remove piston and rod assembly.

Scheme 25

1. Properly position rings on piston. (Scheme 25) Ensure that notch in top of piston is toward front of engine.
2. Check connecting rod side clearance. Connecting rod side clearance must be within specification. See CRANKSHAFT MAIN & CONNECTING ROD BEARINGS table under ENGINE SPECIFICATIONS at end of article. Ensure crankshaft turns smoothly.

FITTING PISTONS

Determine cylinder taper, wear, out-of-round and piston clearance. For cylinder specifications see CYLINDER & PISTON WEAR SPECIFICATIONS table. If taper or out-of-round are not within limits, hone or bore cylinders for installation of new pistons.

CYLINDER & PISTON WEAR SPECIFICATIONS

FITTING RINGS

Check piston ring end gap and side clearance to prevent ring damage. If ring gap is not within specifications, try another ring set. See PISTONS, PINS, RINGS table under ENGINE SPECIFICATIONS at end of article.

Piston pins are press-fit in connecting rod. Remove snap rings from piston. Using an arbor press, press piston pin from piston and connecting rod. Note location of piston notches or valve area in relation to rod bearing tangs.

Inspection

Measure piston pin diameter, piston pin bore diameter and connecting rod pin bore. Determine piston pin clearance for piston and connecting rod. Replace piston, piston pin or connecting rod if not within specification. See PISTONS, PINS, RINGS table under ENGINE SPECIFICATIONS at end of article.

Lubricate piston pin holes in piston and connecting rod with engine oil. Install piston on connecting rod with valve areas opposite rod bearing tangs. Using arbor press, press piston pin into piston and connecting rod. Install snap rings. Check piston for freedom of movement on piston pin.

CONNECTING ROD BEARINGS

1. Prior to removal, ensure rod caps are marked for cylinder identification. Remove rod cap and bearings. Inspect bearings for wear or damage and replace as necessary.
2. Check crankshaft rod bearing journal for out-of-round or taper. Crankshaft out-of-round or taper must not exceed .001" (.03 mm).
3. Measure bearing clearance using Plastigage method. See CRANKSHAFT MAIN & CONNECTING ROD BEARINGS table under ENGINE SPECIFICATIONS at end of article for bearing clearance.
4. If clearance exceeds specifications, undersize bearings possibly can be used in combination to produce correct clearance. If clearance is still excessive, crankshaft must be reconditioned.
5. Clean crankshaft journal and bearing surface in rod. Insert bearings in rod and cap, then lubricate bearing surfaces with oil. Pull piston and rod assembly down onto crankshaft.
6. Install cap and tighten to specification. Check connecting rod side clearance. For specification, see CRANKSHAFT MAIN & CONNECTING ROD BEARINGS table under ENGINE SPECIFICATIONS at end of article.

MAIN BEARINGS

Note. Procedure listed describes main bearing removal and installation with engine in vehicle. Measure and change bearings one journal at a time if engine is in vehicle.

1. Remove oil pan. See OIL PAN REMOVAL at end of ENGINE section. Remove bearing cap. Use Plastigage method to check bearing clearance.
2. Mark main bearing caps for identification so caps are replaced in same direction and location. Remove main bearings from cylinder block by inserting bearing Remover/Installer (J-8080) in crankshaft oil hole. Rotate crankshaft to "roll" bearing out. If remover/installer is unavailable, use a bent cotter pin.
3. To install upper bearing half, lubricate journal and bearing. Insert plain end of bearing between crankshaft and notched side of block. With bearing remover/installer in crankshaft oil hole, rotate crankshaft to install bearing.
4. Install lower bearing half into cap and lubricate with engine oil. Install and tighten main bearing cap with arrow pointing toward front of engine.

THRUST BEARING ALIGNMENT

1. Ensure all main bearing caps, except rear main (thrust) bearing, are installed and tightened to specification. Temporarily tighten rear main bearing cap bolts to 10 ft. lbs. (14 N.m).
2. Tap end of crankshaft back and forth to line up main bearing and crankshaft thrust surfaces. Tighten thrust bearing cap to specification. Retighten all main bearing cap bolts to specification, including thrust bearing. Rotate crankshaft to confirm free movement.

Note. Some engines may contain an .008" (.20 mm) wider main bearing thrust face. These crankshafts can be identified by .008" stamped on rear counterweight. During replacement, proper bearings must be used.

CRANKSHAFT END PLAY

With all main bearings installed and torqued to specification, pry crankshaft toward front of engine and check crankshaft end play. Crankshaft end play after aligning thrust bearing should be .002-.006" (.05-.15 mm).

Remove transmission, clutch (if equipped) and flywheel. Install screwdriver in notches located on rear seal retainer. Refer to Fig. (Scheme 26). Pry seal from retainer. Note direction of seal lip.

Scheme 26

1. Ensure all surfaces are clean. Lubricate inner and outer seal area with engine oil. Place seal on Seal Installer (J-35621). Place seal installer against crankshaft.
2. Thread attaching screws in crankshaft. (Scheme 26) Tighten screws to square seal with crankshaft. Rotate handle until it bottoms. Remove seal installer and components. Install flywheel, clutch and transmission.

Disconnect negative battery cable at battery. Drain cooling system. Remove all drive belts, coolant hoses and mounting brackets attached to water pump. If necessary, remove fan shroud. Remove fan and pulley. Remove water pump and gaskets.

Clean all gasket surfaces. Using new gaskets, install and tighten water pump bolts to specification. Install remaining components in reverse order of removal.

Note. For further information on cooling systems, see ENGINE COOLING SYSTEM article in this section.

CRANKCASE CAPACITY

Crankcase capacity is 4 qts. (3.8L). Add one additional qt. (.95L) to all engines when replacing oil filter.

NORMAL OIL PRESSURE

Normal oil pressure should be obtained with engine at normal operating temperature and at specified engine RPM. See OIL PRESSURE SPECIFICATIONS table.

OIL PRESSURE REGULATOR VALVE

Oil pressure regulator valve is located in pump body. Valve is nonadjustable.

ENGINE OILING SYSTEM

Gear-type oil pump delivers full pressure lubrication to main oil gallery and through full-flow oil filter. Through drilled passages in block, main oil gallery feeds oil to all crankshaft and camshaft bearings.

Valve lifter oil gallery feeds lifters. From lifters, oil is routed through hollow push rods to upper valve train components. Timing chain and sprockets are lubricated by oil drainage from No. 1 camshaft bearing.

Scheme 27

Scheme 28

Remove oil pan. Remove pump-to-rear main bearing cap bolts. Remove pump and baffle (if equipped) and extension shaft.

Disassembly

Remove pump cover. If necessary, remove inlet tube and screen assembly. Mark gears at a meshing point, so they may be reassembled with same gear teeth indexing. Remove gears. Remove pressure regulator retaining pin. Remove washer (if equipped), pressure regulator valve and spring.

Inspect pump body and cover for cracks or excessive wear. Inspect pump gears for damage or wear. Check drive gear shaft for looseness in pump body. Check pressure regulator valve for fit in bore. Replace entire pump assembly if damaged. Inspect inlet tube and screen assembly for damage.

Reassembly

Install pump gears into pump body, with marked gear teeth indexing. Idler gear must be installed with smooth side of gear toward cover opening. If inlet tube was removed, apply sealer to end of inlet tube. Tap inlet tube into place using plastic hammer. Reassemble remaining components in reverse order of disassembly. Tighten cover screws to specification.

Prime oil pump with engine oil. Assemble pump and extension shaft to engine. Ensure slot on top of extension shaft engages with drive tang on end of distributor shaft. Install oil pump and baffle (if used). Tighten retaining bolt to specification. Install oil pan.

OIL PRESSURE SPECIFICATIONS

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

GENERAL ENGINE SPECIFICATIONS

GENERAL SPECIFICATIONS

VALVE SPECIFICATIONS

VALVE SPECIFICATIONS

PISTON/PIN/RING SPECIFICATIONS

PISTONS, PINS & RINGS SPECIFICATIONS

BEARING SPECIFICATIONS

CRANKSHAFT MAIN & CONNECTING ROD BEARINGS SPECIFICATIONS

VALVE SPRING SPECIFICATIONS

VALVE SPRINGS SPECIFICATIONS

CAMSHAFT SPECIFICATIONS

CAMSHAFT SPECIFICATIONS