GM - Engine Builder Magazine
Contents
1. Engine Failure and Close Coupled Cat Converter Information For 2004 2007 GM Vehicles While GM vehicles using clos coupled catalytic converters may provide improved vehicle emissions at cold ambient temperatures they present a possible concern if engine failure occurs Certain 2004 2007 General Motors products may be equipped with anew style of catalytic convert er technically known as the clos coupled catalytic converter Figure 1 below providing quick catalyst warm up resulting in lower tail pipe emissions earlier in the vehicle oper ating cycle If an engine breakdown or non function were to occur such as bro ken intake exhaust valve or piston debris may be deposted in the con verter through the engine exhaust ports If the engine is non function ing due to severe overheating dam age to the ceramic brick internal to the catalytic converter may occur This may result in ceramic debris being drawn into the engine through the cylinder head exhaust ports If a replacement engine is installed in either of these instances the replacement engine may fail due to the debris being introduced into the combustion chambers when started n Therefore when replacing an engine an inspection of the catalytic converters and ALL transferred com ponents such as exhaust intake man ifolds should be performed Any debris found should be removed In cases of engine failure due to severe overheating ins2. ALSUCQUERQUE ETT 767 0700 305 761 0100 DALLAS B00 284 5348 214 637 3301 HOUSTON B00 284 6548 mi3 Be2 229 PORTLAND B00 876 5752 S03 232 2270 TACOMA cz ai GAI BETS DENVER BOO 288 2970 303 572 8844 SAN ANTONIO FBO 423 2707 200 234 1410 eae 272 S10 544 8802 OG 272 0197 AMCHORAGE mre 7 5577 PELES 907 563 7278 OAKLAND PHOENIX 272 0191 Circle 210 for more information 10 AERA TECH SOLUTIONS GUIDE February 2008 800 876 5152 ORS R emove the valve cover valve springs and valve seals on the affect ed cylinder s A small wire tie or rubber bands can be placed in the valve tem keeper groove to prevent the valve from falling into the cylin der R otate the valve while moving it up and down in the guide to see if it binds If a binding valve is found remove both cylinder heads and increase the valve stem to guide clearance In these instances it is recom mended to provide a minimum valve stem to guide clearance of 0020 051 mm for all guides Even though the service manual specification for valve stem clearance is listed as 0010 0030 025 076 mm the clearance must be increased In certain driving gtuations when combustion temperatures are at their maximum the minimum list ed specification may be insuf ficient One method of increasing the clearance is to hone the guide with a 9 mm hone until a clearance of 002 is obtain
3. a logo such as the one hhown in Figure 5 left 2000 GM 4 3 5 0 amp 5 7L VIN W M R Engines An engine misfire on 2000 GM 4 3 5 0 and 5 7L VIN W M and R engines may be encounted and a P0300 diagnostic trouble code may be set on certain situa tions when the vehicle is under extreme load such as cruising uphill pulling a trailer or on hard acceleration If the P0300 diagnostics did not isolate a concern to resolve Figure 5A porosity condition may exist on certain C astech castings A bove arrow shows C astech logo found on some GM 4 8 and the trouble code the following 5 3L engines may help The Best Solutions are available from Engine amp Performance Warehouse Now order online at www epwi net with KIT WIZARD Traditional quality meets high technology Ordering online is as easy as 1 2 3 24 Just click on Engine Kits the vehicle make amp your kit number select type of kit oversizes amp undersizes amp warranty option P Click add to order and you re done in as fittle as 30 seconds Getting the best engine kits and parts in the business is now even faster ANYTIME Find out more at www epwi net or call an EPWI branch warehouse convenient to you KIT WIZAR D is the newest customer convenience and it s only available trom Engine amp Performance Warehouse ENGINE amp PERFORMANCE Mie ol dane oe 5 A ee i OKLAHOMA CITY BO 537 3652 WAREHOUSE
4. on 2004 2007 GM 1 6L VIN 6 engines may be troubling to cus tomers especially if the oil is leaking out of the oil pump area The oil pump to engine block gasket may leak near the top of the oil pump assembly resulting in a leak that reads oil on the front of the engine and oil pump Technicians may misdi agnose the source of the leak and unnecessarily replace the oil pump along with the gasket if they are unable to determine the exact loca tion of the oil leak The oil pump gasket may develop a crack that cannot withstand high oil pressure under operating conditions GM has developed anew metal rein forced oil pump gasket p n 90573301 that should be used any time the oil pump is removed Figure 2 page 8 RTV sealant should not be used when installing a new gaxet Cylinder Head Replacement For 1996 2005 GM 3 4L VIN E Engines Any time you are replacing a cylinder head on 1996 2005 GM 3 4LVIN E engines the following information should be reviewed To date there have been two dif ferent rocker mounting bolts used to secure the non adjustable rockers to the cylinder head W hile the cylinder heads are otherwise interchangeable the rocker arms and bolts may not be Figure2G M has developed a new metal reinforced oil pump gasket for 2004 2006 1 6L engines There is at least one cylinder head casting number that has been manu factured with both 8mm and 10mm rocker bolt holes Above isa list of casting num
5. to aid the installation If the tool is not available through local dealership an aftermarket equivalent is acceptable Postion the crankshaft serv ice cup plug into the crankshaft flange bore with the service cup plug dih sde outward Figure 3 page 9 Note Do not use an impact socket with hammer to drive the service cup plug into place Damage to the crankshaft thrust bearing may result Assemble arbor forcing screw attaching bolts and socket Install the tool press assembly to the end of the crankshaft flange and postion the socket and service cup plug into the bore of the crankshaft flange Be sure you have the proper tool set up Figure 3 Install service ap plug dish side out on GM 4 2L qankshafts Do not drive plug in place with impact sock et and hammer as damage may result before pressing the cup plug into the end of the crankshaft The forcing screw will fit insde an 18 mm or 19 mm end of the impact style socket with the 1 2 drive sde of the socket facing the service cup plug T he forcing screw Should bottom on the 15 mm step inside the socket Hand tighten forcing screw into the socket mak ing sure that it is centered on the service cup plug Mark forcing screw and arbor for reference then tighten forcing screw two complete turns and an additional 90 degrees or 1 4 turn more W hen completed remove installation tool assembly and confirm the installation depth of the service cup plug P
6. 02 15423 1GCHK29U53E134735 16780 1GCFG25T531118273 17380 1GCEK19T332141308 19142 1GCFG29T531120924 19395 1GCHK24U437147718 20127 1GCGK13U43F 122519 20214 1GCGK13U33F 120549 20455 16CGC13U23F 120748 28209 16CGC13U63F 122633 28276 1GCGK13U23F 122616 30148 1GCGC13U33F 121133 30152 1G6CGC13U33F 126672 30360 1GCGC13U13F 120627 32544 1G6CGK13U13F 120534 36475 1GCHC24U33E134723 44526 1GCGRK13U63F 122635 47280 1GCHK29U73E 132534 47473 16CGK13U33F 122558 03293 1GBJK34U63E 132530 04075 1GCGK13U83F 120756 04606 1GCGK13U13F 126527 05764 1GCGK13U73F 121624 06912 1GCHK24U832150296 07120 1GCHK29U437147713 07127 1GCGK13UX3F 126686 07403 1GBHC24UX3E 133296 07608 16CGC24U832142515 08504 1GCHC29UX3E 133304 09230 1GBFG15T231118200 17083 1GTHK29U332142521 21047 1GDFG15T331107309 40365 1GTHK29U632142500 42009 1GTHC29U33E 137064 44403 1GTHK23U93F 120663 47318 1GDFG15T231120908 08074 1GTFG25T931132550 08211 1GTFG15T031117946 32325 1GCHK23U63F 120703 nd Ras a b i ha j Te a a i Do not reuse the cylinder head bolts because the bolts may stretch or break causng engine damage If not pre applied to the new cylinder head bolts apply sealer GM P N 12346004 or equivalent to the cylinder head bolts R efer to Use of RTV and Aneerobic Sealer T he sealer must be applied to a minimum of eight threads darting at the point of the cylinder head bolt Install all 16 bolts finger tight 3 Tighten all of the cylinder head bolts in the seq
7. bers with bolt desgn used and appropri ate rocker arm part numbers to assist in identifying which head is required Oil Leak at Rear of Crankshaft on 2005 2007 GM 4 2L VIN S Engines T his leak from the rear of crankshaft is due to porosty problems in the crankshaft GM offers the following solution to the problem Verify the leak by looking at the end of the crankshaft If oil is present MAHLE Driven by performance Circle 208 for more information S AERA TECH SOLUTIONS GUIDE February 2008 DRS k Head Casting Number Bolt Design Rocker Arm Part Number 24507487 12568234 12580234 8mm 12576628 24507487 10218170 10mm 24504436 in the bore where the torque con verter nose engages the crankshaft a special service procedure should be performed If the bore is dry or oll appears to be from the seal area per form normal oil leak analygs A serv ice cup plug has been developed to stop leakage that may occur in this area and can be ordered under p n WPC 340 only through the Warranty Parts C enter Clean the crankshaft flange bore area with brake clean or equivalent Thoroughly dry the area and examine the bore surface for irregularities If the bore surface needs additional cleaning use sand paper or equivalent and clean as necessary Once the crankshaft bore is clean and gnooth apply a thin bead of Loctitite 620 TM completely around the inside of the crank shaft flange bore General M otors offers a tool
8. ed Doing so will usu ally only take about 4 strokes of the hone Exhaust Manifold Bolt amp Torque Update For 1998 2003 GEN Ill 4 8 5 3 5 7 6 0L Engines A new exhaust manifold bolt and torque specification was introduced to GEN III Vortec small block V8 engines beginning in the 2004 model year to update the 1998 2003 GEN Ill 4 8 5 3 5 7 and 6 0L engines W hen servicing any of the GEN III small block exhaust manifolds the exhaust manifold bolts should be replaced These exhaust manifold bolts can be purchased from GM p n 11518860 W hen installing the bolts into the mounting hole apply a 200 5 mm wide bead of high temperature thread locker GM p n 12345493 US and p n 10953488 Canada or equivalent to the threads of the exhaust manifold bolts before installation Tightening the exhaust manifold bolts should be done in two passes First tighten the two center bolts on the exhaust manifold T hen tighten the rest of the bolts alternating from g de to side while working toward the outside bolts During the first pass of bolt tightening tighten bolts to 59 in Ibs Then on the final bolt torque pass tighten the bolts to 15 ft lbs Revised Connecting Rod Bolt Torque For 1997 2007 GM 4 8 5 3 5 7 and 6 0L Engines This information regarding revised connecting rod bolt torque for 1997 2007 GM 4 8 5 3 5 7 and 6 0L engines applies to all current GEN Ill and IV design gnall block engine varia
9. er additional 85 using a Torque Angle Meter J45059 and inspect the cylinder block for any indications of porosty in the sealing areas If porosity is found any where on the sealing surface use RTV p n 8 12778 521 0 to fill in any porosty locations W ipe a mall amount of the RTV sealant onto the surface using a plastic scraper to fill in the porosty holes on the mating surface of the cylinder block Remove any excesive RTV that may have been applied especially from the high pressure oil passage as Shown with arrow in picture below MAHLE Driven by performance state of the art aon technology as part of the EGES volume production to ensure quality standards www mahleclevite com Circle 212 for more information 12 AERA TECH SOLUTIONS GUIDE February 2008 ingalling the rear cover tighten the engine rear cover bolts to 18 ft lbs Recommended Spark Plug For 2003 GM 5 3 amp 6 0L VIN T amp U Engines The following information regard ing the correct spark plug for 2003 GM 5 3 and 6 0L VIN T and U engines is being provided in con junction with a voluntary recall from General M otors Certain 2003 Chevrolet Silverado and Express trucks as well as GMC Sierra and Savanna model vehicles equipped with a 5 3L RPO LM7 VIN T or 6 0L RPO LQ4 VIN T engines may have been built with wrong spark plugs The incorrect spark plugs could lead to idle degrada tion or engine piston damage under high load and o
10. lace a Straight edge across the center of the crankshaft flange as the measurement point Measure from the ctraight edge to the center of the installed cup plug The depth of the installed cup plug should be 16 17 mm 630 670 HASTINGS Coolant in the Engine Oil on 2002 2006 GM 4 8 and 5 3L Engines Some 2002 2006 GM 4 8 and 5 3L VIN V T B and M engines may expe rience a coolant leak into the engine oil Two different locations may be responsble and should be investigated when coolant loss is noted and cylin der head service is appropriate A possible coolant leak may exist between the cylinder head valve guide bore and the interior of the cylinder head casting or a porosity condition may exist on certain C astech castings as shown if Figure 4 right Under pressure while the cylinder head casting is hot coolant may collect in the leaking areas of affected heads and if allowed to con tinue eventual oil and coolant mix Fige 4 A possible colant leak may ocur between the cylinder head valve guide bore and the interior of the aylinder head astingon GM 4 8 and 5 3L engines ing will occur resulting in engine damage To determine if a cylinder head is We Can Do Any Ring Size t 1 75 to over 10 Bores Rings Piston 800 776 1088 hastingsmfg com Circle 209 for more information www enginebuildermag com ENGINEBUILDER 9 manufactured by Castech inspect the insde cornersfor
11. r high temperature operation such as trailer towing Vehicles involved are shown in Chart 1 page 13 and they should have their Soark plugs replaced with p n 12563707 if they have not already been replaced If a GM dealer has already made this repair there should be a label attached to the radiator core support It remains unclear if all aftermarket parts catalogs reflect the correct spark plug part number for the GM p n 12563707 or AC Delco 41 974 Head Bolt Replacement For 1999 2001 GM 7 4L VIN B D J amp S Engines GM ad AERA now recom mend replacing the head bolts after one usage on 1999 2001 GM 7 4L VIN B D J amp S engines Doing so provides a better likelihood the following installa tion process will provide a longer lat ing gasket seal M ake sure the threaded holes in the engine block are clean and not damaged Do not use sealer on any engines that use a compostion type gasket Align the cylinder head gasket locating mark to face up 1 Place the cylinder head gasket in postion over the cylinder head locat ing pins and guide the cylinder head carefully into place over the locating pins and the cylinder head gasket 2 Always use NEW cylinder head bolts when servicing the cylinder head Dealer VIN 10060 1GCHK23U03F 122625 11367 1GCFG15T431106982 11377 1GBFG15T731121142 11377 1GBFG15T931119263 14420 1GCHK29U83E141596 14505 1GCHK29U03E 133282 15133 1GCHK24U93E134180 15410 1GCHK23U53F 1216
12. tallers should also insoect each catalytic converter for ggns of melting or cracking of the ceramic brick If damage is found the converter should be replaced Engine Misfire on 2004 2007 GM 1 6L Engines Some customers may comment on an intermitent engine misfire on GM vehicles ung the Eco Tec II 1 6L four cylinder engine VIN 6 RPO L91 found in 2004 2007 Chevrolet Aveo and 2005 2007 Pontiac Wave Canada Only Typically misfires related to this valve sealing concern will be very intermittent and may or may not be felt by the driver T hey will normally occur during engine warm up deceleration highway driv ing wide open throttle acceleration and or uphill driving The engine misfire may be expe rienced due to a valve sealing condi tion If thisconcern hasbeen noticed and it has been ongoing a previous GM repair involving replacement of only intake valves and seals may have been performed Figure 1C lose coupled catalytic converters on GM vehicles may become damaged after certain engine failures AERA TECH SOLUTIONS GUIDE February 2008 T he current recommended repair is to replace all valves and seals with the part numbers shown in the table below if they have not been replaced previousy by GM Part Number Description 96440081 Intake Valve 96830500 Exhaust Valve 968401022 Valve Stem Oil Seal Oil Leak at Front of Engine on 2004 2007 GM 1 6L VIN 6 Engines An oil leak at the front of the engine
13. tions This information should be consdered any time the bolts are being installed Additional final torque may be applied to the con necting rod bolts in the above mentioned engines Although the bolt tighten ing method uses the now familiar torque turn the bolts do not require replace ment unless damaged The bolts should be tightened in a two step process with the second step including an additional 10 turn from the original spec ification Figre6 An oil leak on 2003 06 GM 4 8 5 3 5 7 6 0 and 7 0L engines may suggest that the leak seems to be coming from the rear cover gasket area We Can Do Any uingionapel Barrel Torsional Keystone Wiper Piston 800 776 1088 HASTINGS E FAA sass hastingsmig com Circle 211 for more information www enginebuildermag com ENGINE BUILDER 11 Tech Solutio Application 1st Step 2nd Step Allow the RTV to cure 10 minutes GEN II amp GEN IV 15 ft lbs 20 Nm Rotate Each Bolt an before installing the rear cover W hen Rear Engine Oil Leak on 2003 06 GM 4 8 5 3 5 7 6 0 and 7 0L Engines W hile an initial investigation of a rear engine oil leak on 2003 06 GM 4 8 5 3 5 7 6 0 and 7 0L may suggest that the leak seems to be coming from the rear cover gasket area this condition may actually be caused by engine block porosty on the engine block sealing surface If the leak is found to be coming from the rear cover gasket area see Figure 6 page 11 remove the cov
14. uence shown in Figure 7 above to 37 ft Ibs 50 N m 4 R otate bolts numbered 1 2 3 6 7 8 9 12 14 and 15 in sequence an additional 150 Chat 17 hese vehides have turn the incorrect spark plugs and should be reolaced 5 R otate bolts numbered 13 and Figure 7 Cylinder head bolt torque sequence for GM 7 4L engines 16 In sequence an additional 150 turn 6 R otate bolts numbered 4 5 10 and 11 in sequence an additional 150 turn After the cylinder head is secured to the cylinder block install and e Tighten the spark plugs in a new cylinder head to 22 ft lbs 30 N m e Tighten the ark plugs in srv iced cylinder heads to 15 ftlbs 20 Nm TSG We Can Do Iron Hi Tensile Iron Any Ring Material Steet 800 776 1088 hastingsmfg com mg cam Circle 213 for more information www enginebuildermag com ENGINE BUILDER 13
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