Home

General Motors 8.1 L Powertrain Service

Contents

1. 0 0c cece cece teens 48 Section 4 Cylinder Head and Valves 0c cece cece eee eee eee eee eens 49 4 14 Valve Rocker Arm Cover 0 ccc eens 49 4 1 1 Replacement Left eee 49 4 1 2 Removal Left 0 0 00 ccc ccc RR ees 50 4 1 3 Cleaning and Inspection 000 c cece cee eens 50 4 1 4 Installation Left foe tie Edere hfe ar A ele xs 51 4 1 5 Replacement Right 000 cece ect tee ae 52 4 1 6 Removal Right ii oa eea ea a e a aa a a a ara 54 4 1 7 Installation Right 00 2 54 4 2 Valve Rocker Arm and Push Rod 00 e cece eect ees 55 4 2 1 Replacement oso a eUES Te A 55 4 2 2 Removal ine LL LETT 56 4 2 3 Cleaning and Inspection 000 c cece cee eee eens 57 42 4 Installation i nee tad en baw e oe 58 4 3 Valve Stem Oil Seal and Valve Spring Replacement 000005 58 4 4 Valve Spring Inspection and Measurement 0000s 60 4 5 Valve Guide Reaming Valve and Seat Grinding suasusu eunana 61 46 Nalve Lifter i a a a ta tt Dd iE 62 4 6 1 Replacement oocccccccc n 62 4 6 2 REMOVAL ois gtk niche rara Met rl Poe dino 63 4 6 3 Valve Lifters and Guides Cleaning and Inspection 64 4 6 4 Installation eoe te a ete a oe EY s 65 4 7 Cylinder Head oocccoccccc eenne tenet enneeeee 65 4 7 1 Replacement Left her e le RR HE bee OPES 65 4 7 2 Removal Left 0 0 0 0 0
2. 50 Section 4 Cylinder Head and Valves 7 Install the CPA retainer to the ignition coil electrical connector 4 1 2 Removal Left 7 B s ax Remove the valve rocker arm cover bolts 2 Remove the valve rocker arm cover Important The valve rocker arm cover gasket may be reused if not removed from valve rocker arm cover 3 Replace the valve rocker arm cover gasket if cut or damaged 4 1 3 Cleaning and Inspection Notice To ensure correct reinstallation mark the ignition wiring harness connectors for cylinders one and three and cylinders six and eight prior to disconnection Failure to reconnect the ignition wiring harness connectors to the proper ignition coils may result in serious engine damage TP 6105 8 05 Notice This component is initially installed using a self tapping bolt s Care should be taken when removing and or installing the self tapping bolt s Failure to use care when removing and or installing the self tapping bolt s can lead to damage and unnecessary replacement ofthe self tapping bolt s and or the component the self tapping bolt s is threaded into 1 Remove the white wiring harness clip locks 2 Disconnectthe ignition coil wiring harness from the ignition coils 3 Remove ignition coil wiring harness retainer bolts 4 Openthe two wiring harness retainers and remove the ignition coil wiring harness 5 Remove the ignition coil bolts 6 Remove the ignition
3. Inspect crankshaft Broken crankshaft E Repair as required 3 13 Coolant in Combustion Chamber Definition Excessive white smoke and or coolant type odor coming from the exhaust pipe may indicate coolant in the combustion chamber Low coolant levels an inoperative cooling fan or a faulty thermostat may lead to an overtemperature condition that may cause engine component damage 1 A slower than normal cranking speed may indicate coolant entering the combustion chamber See Section 3 12 Engine Will Not Crank Crankshaft Will Not Rotate Remove the spark plugs and inspect for spark plugs saturated by coolant or coolant in the cylinder bore Inspect by performing a cylinder leakdown test During this test excessive air bubbles within the coolant may indicate a faulty gasket or damaged component See Section 3 16 Cylinder Leakage Test Inspect by performing a cylinder compression test Two cylinders side by side on the engine block with low compression may indicate afailed cylinder head gasket See Section 3 15 Engine Compression Test Replace the head gasket and components as required See Section 4 7 4 Cylinder Head Cleaning and Inspection and Section 4 7 6 Cylinder Head Replacement Left or Section 4 7 9 Oylinder Head Replacement Right Faulty cylinder head gasket Cracked cylinder head Replace the cylinder head and gasket Cracked engine block Replace the components as required Cylinder hea
4. 0 ccc eee o 20 2 3 8 Exhaust Manifold 0 0 20 2 4 Lubrication Description 0 0 0 c cc tenets 20 25 Cleanliness and Care 0 cette eens 21 2 6 Separating Parts voies eed eatin tha ae M D eat he ee 21 2 7 Engine Gasket Replacement 0000 cece cee eee sees 22 2 7 1 Reusing Gasket and Applying Sealant 0c cece ee eee 22 2 7 2 Separating Components 00 cece e eee ees 22 2 74 8 Cleaning Gasket Surfaces 00 cece nes 22 2 7 4 Assembling Components 0 00sec tees 22 2 8 RTV and Anaerobic Sealer Use suua cece eee 22 2 8 1 Sealant Types ccc cect es 22 2 8 2 Aerobic Type Room Temperature Vulcanizing Sealant 23 2 8 3 Anaerobic Type Gasket Eliminator Sealant 23 2 8 4 Anaerobic Type Thread Lock Sealant 00 cece aes 23 2 85 Anaerobic Type Pipe Sealant 0 cece eee eee ee 24 2 9 Tools and Equipment a e a A aE a A eens 24 2 10 Thread Repair issus ese x ex Reb eed nk RE ne DR Re orte 24 2 11 Service Prior to Assembly oocoooccccooccc rr 25 2 12 Engine Prelubing i RIRRSDI RD ERE a sd ad e dad 25 Section 3 Diagnostic Information and Procedures 0ccceeeeeeee eee eee eee ee eee 27 3 1 Diagnostic Starting Point Engine Mechanical 00e cece ee 27 3 2 Symptoms Engine Mechanical
5. 21 Install the CPA retainer at the ignition coil harness 22 Install the engine harness bolt and studs a Tighten the bolt to 5 Nm 44 in Ib b Tighten the studs to 10 Nm 89 Jin Ib 23 Connect the following electrical connectors e MAP sensor 1 e Ignition coil harness 2 e ECT sensor 3 30 Tighten the clamps at the throttle body and air ri j cleaner 24 Install the CPA retainer at the ignition coil harness i Tighten the clamps to 4 Nm 35 in Ib 25 Position engine harness branch over the top of engine 10 1 2 Removal 26 Connect the following electrical connectors l 1 Remove the vacuum plug 513 if required e Pressure cycling switch 1 e Surge tank switch 2 e MAF sensor 3 27 Connect the engine harness clips to the studs on the front of dash 28 Connect the fuel feed and return pipes 154 Section 10 Air Intake and Exhaust System TP 6105 8 05 3 Remove the throttle body 502 and gasket 501 Important The intake manifold gaskets are not reusable 4 Remove the studs 504 if required 9 Remove and discard the intake manifold side gaskets 5 Remove the fuel injection fuel rail bolts studs 6 Remove the fuel injection fuel rail with injectors Important The splash shield is secured using a snap in fit Do not distort the splash shield The 7 Remove the intake manifold bolts splash shield is reusable Important Do not attempt to loosen the m
6. Cautions and Notices Notice Defined Notices call special attention to a necessary action or to a prohibited action If a Notice is not heeded the following consequences may occur e Damage to the equipment e Unnecessary equipment repairs e Unnecessary component replacement e Improper operation or performance of the system or component under repair e Damage to any systems or components that are dependent upon the proper operation of the system or component under repair e Improper operation or performance of any systems or components that are dependent upon the proper operation or performance of the system or component under repair e Damage to fasteners basic tools or special tools e Leaks of coolant lubricant or other vital fluids Important Defined Important statements emphasize a necessary characteristic of a diagnostic or repair procedure Important statements are designed to do the following e Clarify a procedure e Present additional information for accomplishing a procedure e Give insight into the reason or reasons for performing a procedure in the manner recommended e Present information that will help to accomplish a procedure in a more effective manner e Present information that gives the technician the benefit of past experience in accomplishing a procedure with greater ease Safety Precautions and Instructions 9 Battery Disconnect Caution Caution Disconnect the battery cabl
7. ooocococcccccccnnn e eens 95 61 Crankshaft Balancer 0 6 cece n 95 6 1 1 Heplacement co a hanna da ads 95 6 1 2 Removal ipee trim Rex a ea a id 96 6 13 Cleaning and Inspecti0N oooocococcccccccoocca rc 97 6 14 Jlnistallatloni iT aio tpe zb teg pest t eg defectus 98 6 2 Crankshaft Oil Seal ocooooocccccccncco rre 99 6 2 1 Replacement Front o ooccccccccoc sess 99 6 2 2 Replacement Rear 00000 cece sees 100 6 2 3 Removal Beat els REEL ETE Hed utere ent 100 6 2 4 Installation Rear sssse RR IRR IR IIR 101 6 3 Crankshaft and Bearings ooooccoocoooncoro rar 101 6 3 1 Removal arun a A O M ee ae EA 101 6 3 2 Cleaning and Inspection 00 ccc cece ees 102 6 3 3 Installation c enera a a pter xm ROER Land boas 104 6 4 Crankshaft and Connecting Rod Bearing 00 eee 106 6 4 1 INSPECTION 2 a ted dunce 106 6 4 2 Clearance Measurement sssssssss tees 107 6 5 Crankshaft End Play Measurement 00 cece eee eene 110 6 6 Engine Flywheel 00 0 ccc ect e 111 6 6 1 Replacement on mer thy eae oe ea Sade ee 111 6 6 2 Removal eer ERREUR ir tods 111 6 6 3 Cleaning and Inspection 000 c cece cette eee 111 6 6 4 Installation cc ei A a hee A ERAS 112 Section 7 Camshaft and Timing Gear Train ooccccccocccnnn eee n nnn 113 Ll Engine Front Gover iov ki hb ee eh eA Se ea 113 7 1 1 Replacement 3 verte Ub T
8. perform the necessary inspections Did you review Section 3 2 Symptoms Engine Mechanical for diagnostic information and Go to Section 3 2 Symptoms Engine Mechanical Go to Step 2 Verify that there is a rumbling noise Does the engine make the rumbling noise Go to Goto Steps Diagnostic Aids 2 Operate the engine for no longer than 30 40 seconds Does the rumbling noise still exist 1 Remove the drive belt s See Section 9 1 1 Drive Belt Replacement Accessory Go to Section 3 8 Engine Noise on Startup But Only Lasting a Few Seconds Go to Step 4 Was any of these conditions found Inspect the drive belt s for damage separation or sections of missing ribs Go to Step 7 Go to Step 5 Do the drive belt grooves have pilling Inspect for severe drive belt pilling exceeding 1 3 of the drive belt groove depth Go to Step 6 Go to Step 7 1 Clean the drive pulleys using a suitable wire brush Did you complete the repair 2 Reinstall the drive belt s See Section 9 1 1 Drive Belt Replacement Accessory Go to Step 8 Did you complete the replacement Install a new drive belt s See Section 9 1 1 Drive Belt Replacement Accessory Go to Step 8 1 Clear any codes 2 Run the engine to verify the repair Does the rumbling noise still exist TP 6105 8 05 Go to Step 1 System OK Section 3 Diagnostic Information and Procedures 43 3 25 Drive Be
9. possibility that a incorrect bolt nut spacer or washer was installed Missing loose or incorrect fasteners may cause pulley misalignment from the accessory drive bracket s moving under load Overtightening the fasteners may cause misalignment of the accessory component bracket s See item 7 in following table TP 6105 8 05 Notice See Belt Dressing Notice in Cautions and Notices Definition The drive belt falls off the pulleys or may not ride correctly on the pulleys Did you review Section 3 2 Symptoms Engine Mechanical for diagnostic information and perform the necessary inspections Go to Step 2 Go to Section 3 2 Symptoms Engine Mechanical Inspect for a damaged drive belt s Was a damaged drive belt s found Go to Step 3 Go to Step 4 Install a new drive belt s See Section 9 1 1 Drive Belt Replacement Accessory Does the drive belt s continue to fall off Go to Step 4 System OK Inspect for a misaligned accessory drive pulley s Did you find and correct the condition Go to Step 12 Go to Step 5 Inspect for a bent or dented accessory drive pulley s Did you find and correct the condition Go to Step 12 Go to Step 6 Inspect for a bent or cracked accessory drive bracket s Did you find and correct the condition Go to Step 12 Go to Step 7 Inspect for incorrect loose and or missing fasteners Were any incorrect loose and or missing fasteners fou
10. specifications Refer to Section 1 2 Engine Mechanical Specs If the crankshaft bearing clearances exceeds specifications install undersize crankshaft bearings to achieve the correct clearance Measure the new crankshaft bearing ID using an inside micrometer Replace the crankshaft if the proper clearances cannot be obtained with standard size bearings Section 6 Crankshaft Main Bearings and Flywheel 107 Micrometer Method for Connecting Rod Plastic Gauge Method for Crankshaft Bearings Bearings Important When bearings are removed install new Important When bearings are removed install new bearings during reassembly bearings during reassembly 1 Measure the crankpin diameter with a micrometer 1 Install the crankshaft and the new crankshaft a minimum of four places along the length bearings into the block making sure notto damage approximately 90 apart and average the the reluctor rings of the crankshaft measurements 2 Determine the taper and the out of round Refer to Section 1 2 Engine Mechanical Specs 3 Install the new connecting rod bearings into the connecting rod cap and the connecting rod Notice Refer to Fastener Notice in Cautions and Notices Important Use the original connecting rod nuts for clearance measurement During final assembly use new connecting rod nuts to obtain correct fastener tightening 2 Install the gauging plastic the full width of the 4 Install the connect
11. 106 in Ib TP 6105 8 05 20 Apply sealant GM Part No U S 12346004 Canadian 10953480 or equivalent to the threads of the engine block coolant drain hole plugs 23 Install the new camshaft rear bearing hole plug to the proper depth of a 7 600 6 200 mm 0 299 0 244 in 21 Install the engine block coolant drain hole plugs 24 Apply sealant GM Part No U S 12346004 Tighten the coolant drain hole plugs to 30 Nm Canadian 10953480 or equivalent to the threads 22 ft Ib of the oil pressure sensor J 41712 25 Install the oil pressure sensor Using J 41712 22 Apply sealer GM Part No U S 12377901 tighten the oil pressure sensor to 30 Nm 22 ft Ib Canadian 10953504 to the outside diameter of the new camshaft rear bearing hole plug TP 6105 8 05 Section 5 Engine Block Pistons and Connecting Rods 93 Notes 94 Section 5 Engine Block Pistons and Connecting Rods TP 6105 8 05 Section 6 Crankshaft Main Bearings and Flywheel 6 1 Crankshaft Balancer 5 Install J 42846 onto the end of the crankshaft 6 1 1 Replacement Tools Required J 38416 B Harmonic Balancer Remover J 42845 Crankshaft Balancer Installer J 42846 Crankshaft Balancer Protector Button J 42847 Flywheel Holding Tool Removal Procedure 6 Install J 38416 B 2 onto J 42846 1 to remove the crankshaft balancer Place legs of J 38416 B into the recesses cast into the backside of the balancer inner hub 7
12. 22 Flywheel bolt second pass Nm ft Ib Connecting rod nut first pass Nm ft Ib 30 30 22 Flywheel bolt final pass Nm ft Ib 100 74 Connecting rod nut final pass 90 Front cover bolt first pass Nm in Ib 6 53 Crankshaft balancer bolt Nm ft Ib 255 189 Front cover bolt final pass Nm in Ib 12 106 Crankshaft bearing cap inner bolts first pass Nm ft Ib 30 22 Fuel rail bolt stud Nm in Ib 106 Ignition coil bolt Nm in Ib Crankshaft bearing cap inner bolts final pass 90 Ignition coil wiring harness bolt Nm in Ib 12 12 106 12 106 Crankshaft bearing cap outer bolts studs first pass Nm ft Ib 30 22 Intake manifold bolts in sequence first pass Nm in Ib 5 44 Crankshaft bearing cap outer bolts studs final pass 80 Crankshaft oil deflector nut Nm ft Ib 50 37 Intake manifold bolts in sequence second pass Nm in Ib 8 71 Crankshaft position sensor bolt Nm in Ib 12 106 Intake manifold bolts in sequence third pass Nm in Ib Crossbar bolt Nm ft Ib 100 74 Cylinder head bolts in sequence Intake manifold bolts in sequence final pass Nm ft Ib First pass Nm ft Ib 30 22 J42847 flywheel holding tool bolt Nm ft Ib Second pass Nm ft Ib 30
13. 5 Slowly release the tension on the belt tensioner 6 Remove the breaker bar and socket from the belt tensioner bolt 7 Inspect the drive belt for proper installation and alignment TP 6105 8 05 9 1 2 Tensioner Replacement Accessory Removal Procedure 1 Remove the accessory drive belt Refer to Section 9 1 1 Drive Belt Replacement Accessory 2 Remove the drive belt tensioner bolts 3 Remove the drive belt tensioner Installation Procedure 1 Install the drive belt tensioner 2 Install the drive belt tensioner bolts Notice Refer to Fastener Notice in Cautions and Notices 3 Tighten the drive belt tensioner bolts Tighten the accessory drive belt tensioner bolts to 50 Nm 37 ft lb 4 Install the accessory drive belt Refer to Section 9 1 1 Drive Belt Replacement Accessory 9 1 3 Idler Pulley Replacement Section 9 Cooling System and Drive Belts 143 Removal Procedure 1 Loosen the drive belt idler pulley bolt 2 Remove the accessory drive belt Refer to Section 9 1 1 Drive Belt Replacement Accessory 3 Remove the drive belt idler pulley Installation Procedure 1 Install the drive belt idler pulley and bolt to the engine alternator bracket Snug bolt finger tight Notice Refer to Fastener Notice in Cautions and Notices 3 Remove the water pump bolts 2 Install the accessory drive belt Refer to Section 9 1 1 Drive Belt Replacement Accessory Tighten the dri
14. Net lash Lash intake Net lash Seat angle exhaust 46 Seat angle intake 46 Seat runout exhaust mm in 0 050 0 002 Seat runout intake mm in 0 050 0 002 Seat width exhaust mm in 1 651 2 159 0 060 0 095 Seat width intake mm in 0 8 1 2 0 03 0 06 Stem diameter exhaust mm in 9 431 9 449 0 3713 0 3720 Stem diameter intake mm in 9 436 9 454 0 3715 0 3722 Stem to guide clearance production exhaust mm in 0 30 0 079 0 0012 0 0031 Application Stem to guide clearance production intake mm in 0 025 0 074 0 0010 0 0029 Stem to guide clearance service exhaust mm in 0 030 0 104 0 0012 0 0041 Stem to guide clearance service intake mm in 0 025 0 099 0 0010 0 0039 Rocker arms Valve rocker arm ratio 1 70 1 Valve springs Free length mm in 56 35 2 218 Installed height mm in 45 923 46 685 1 808 1 838 Load closed N Ibf 381 419 86 94 45 923 mm 1 808 in Load open N Ibf 1 3 Sealers Adhesives and Lubricant Specs Application Block heater threads 962 1058 216 236 33 985 mm 1 338 in GM Part Number Material Type Sealant 12346004 Canada 10953480 Camshaft rear bearing hole plug Sealant 12377901 10953504 Crankshaft position sensor bolt Thread adhesive 1234549
15. 10 2 5 Installation Right 3 Remove the exhaust manifold heat shield TP 6105 8 05 Section 10 Air Intake and Exhaust System 163 Notice Refer to Fastener Notice in Cautions and Notices 1 Install the exhaust manifold studs into the cylinder head if necessary Tighten the exhaust manifold studs to 20 Nm 15 ft Ib 2 Install the new right exhaust manifold gasket 3 Install the right exhaust manifold 4 Install the right exhaust manifold nuts and center bolt a Tighten the right exhaust manifold center boltto 35 Nm 26 ft Ib b Tighten the right exhaust manifold nuts to 16 Nm 12 ft Ib 164 Section 10 Air Intake and Exhaust System 5 Install the right exhaust manifold heat shield 6 Install the right exhaust manifold heat shield bolts and nuts Tighten the right exhaust manifold heat shield bolts and nuts to 25 Nm 18 ft Ib 7 Install the right spark plugs Tighten the right spark plugs to 30 Nm 22 ft Ib Important Fully install the spark plug wire by pushing on the exposed end of the spark plug boot Do not push the spark plug wire on to the spark plug by using the metal heat shield 8 Install the right spark plug wires to the spark plugs and ignition coils TP 6105 8 05 Tool Description Valve lifter remover Section 11 Special Tools and Equipment Illustration Valve spring compressor Tool Description Valve spring tester Illustration Front co
16. 2 e Mass airflow MAF sensor 3 Removal Procedure Important The intake manifold throttle body fuel rail and injectors may be removed as an assembly If not servicing the individual components remove the manifold as a complete assembly 7 Reposition the engine harness branch to top of engine 8 Remove the connector position assurance CPA retainer at the ignition coil harness 1 TA the clamps at the throttle body and air 9 Disconnect the following electrical connectors cleaner e Manifold absolute pressure MAP sensor 1 2 Remove the air cleaner outlet duct e Ignition coil harness 2 e Engine coolant temperature ECT sensor 3 3 Relieve the fuel system pressure 4 Disconnect the fuel feed and return pipes 5 Disconnectthe engine harness clips from the studs on the front of dash 10 Remove the engine harness bolt and studs 11 Remove the CPA retainer at the ignition coil harness TP 6105 8 05 Section 10 Air Intake and Exhaust System 149 12 Disconnect the following electrical connectors 16 Unclip the EVAP tube from the fuel rail e Engine alternator 2 17 Disconnect the EVAP tube from the vent pipe atthe e Injector harness 3 rear of the engine e Ignition coil harness 4 e Electronic throttle control ETC 5 18 Remove the EVAP tube e Purge valve solenoid 1 studs 13 Reposition the engine harness to the drivers side of the engine compartment
17. 2 3 6 Valve Train The valve train is a ball pivottype Motion is transmitted from the camshaft through the hydraulic roller valve lifters and tubular valve push rods to the valve rocker arms The valve rocker arm pivots on a ball to open the valve The hydraulic roller valve lifters keep all parts of the valve train in constant contact Each valve lifter acts as an automatic adjuster and maintains zero lash in the valve train This eliminates the need for periodic valve adjustment The valve rocker arm stud and nut retains the valve rocker arm and ball seat The valve rocker arm stud is threaded into the cylinder head The valve stem sealis pressed overthe valve guide ofthe cylinder head 20 Section 2 Description and Operation 2 3 7 Intake Manifold The intake manifold is a one piece design The intake manifold is made of cast aluminum The throttle body is attached to the front of the intake manifold The fuel rail assembly with eight separate fuel injectors is retained to the intake manifold by four studs The fuel injectors are seated in their individual manifold bores with O ring seals to provide sealing A Manifold Absolute Pressure MAP sensor is mounted on the top of the intake manifold and sealed by an O ring seal The MAP sensor is held in place with a retainer bolt The evaporative emission canister solenoid is located in the front of the intake manifold The positive crankcase ventilation PCV system is internally cast into the
18. Bearings Important When bearings are removed install new bearings during reassembly 1 2 Install the connecting rod bearings 118 into the connecting rod 119 and the connecting rod cap 117 Using rubber fuel line over the connecting rod bolts install the piston and connecting rod assembly onto the crankpin journal Section 6 Crankshaft Main Bearings and Flywheel 109 3 Install the gauging plastic the full width of the crankpin journal Notice Refer to Fastener Notice in Cautions and Notices Important Use the original connecting rod nuts for clearance measurement During final assembly use new connecting rod nuts to obtain correct fastener tightening Install the connecting rod cap and the original used nuts a Tighten the connecting rod nuts a first pass to 30 Nm 22 ft Ib b Tighten the connecting rod nuts a second pass an additional 90 using J 45059 Remove the connecting rod nuts and cap The gauging plastic may adhere to either the crankpin journal or the connecting rod bearing surface On the edge of the gauging plastic envelope is a graduated scale Without removing the gauging plastic measure the compressed width at the widest point 110 Section 6 Crankshaft Main Bearings and Flywheel 7 10 11 12 6 5 Important 1 If the flattened gauging plastic tapers toward the middle or the ends there may be a difference in clearance ind
19. Inspect the following components and repair as required e Connecting rod bearings e Connecting rods e Crankshaft e Crankshaft journals Excessive crankshaft bearing clearance Inspect the following components and repair as required e Crankshaft bearings e Crankshaft journals Incorrect piston piston pin and connecting rod installation 3 11 Engine Noise Under Load Cause OOOO e Verify that pistons piston pins and connecting rods are installed correctly e Repair as required Correction Important A cold piston knock that disappears in 1 5 minutes should be considered acceptable A cold engine knock usually disappears when the specific cylinder s secondary ignition circuit is grounded out A light rattle knocking noise may indicate a crankshaft or piston lower during diagnosis engine concern Low oil pressure e Perform an oil pressure test Diagnosis and Testing e Repair or replace as required See Section 3 18 Oil Pressure Detonation or spark knock Verify the correct operation of the ignition controls system See Detonation Spark Knock in Engine Controls Cracked flywheel e Inspect the flywheel bolts and flywheel e Repair as required Excessive connecting rod bearing clearance Inspect the following components and repair as required e Connecting rod bearings e Connecting rods e Crankshaft Excessive crankshaft bearing clearance 32 Sectio
20. install the original piston connecting rod assembly or a new standard size piston connecting rod assembly A used piston connecting rod assembly may be reinstalled if after cleaning and inspection the piston is not damaged If the cylinder bore is not within specifications resize the cylinder to accept a new oversized piston Important If you do not check the cylinder block the boring bar may be tilted this may result in incorrect rebored cylinder wall to crankshaft angle TP 6105 8 05 1 Before you use any type of boring bar clean the top of the cylinder block to remove any dirt or burrs 2 Carefully follow the instructions furnished by the manufacturer regarding use of equipment 3 When you rebore cylinders make sure all crankshaft bearing caps are in place e Tighten the bearing caps to the proper torque to avoid distortion of the bores in the final assembly e Remove the crankshaft prior to cylinder boring 4 When you take the final cut with a boring bar leave 0 03 mm 0 001 in on the diameter for finish honing This gives the required position to the cylinder clearance specifications Carefully perform the honing and boring operation to maintain the specified clearances between pistons rings and cylinder bores Honing Procedure Important Always remove all bearings and components from engine block before cleaning boring or honing the engine block 1 When honing the cylinders follow manufa
21. the ring travel The ring must be square to the cylinder wall c Use a feeler gauge to measure the end gap d Select another size ring set if the end gap exceeds specifications 5 1 4 Connecting Rod Side Clearance Measurement Important To properly measure the connecting rod side clearance install the piston connecting rod assembly and bearings into the engine block and tighten the connecting rod nuts to specifications Refer to Section 5 1 8 Piston Connecting Rod and Bearing Installation 82 Section 5 Engine Block Pistons and Connecting Rods 1 Install J 7872 or equivalent to the cylinder block with the dial indicator plunger against the side of the pair of connecting rods 2 With the connecting rods pushed forward zero the dial indicator Firmly move the pair of connecting rods side to side and read the measurement on the dial indicator An optional method is to insert a feeler gauge between the connecting rod caps and measure the connecting rod side clearance Refer to Section 1 2 Engine Mechanical Specs 5 1 5 Connecting Rod Bearing Clearance Measurement Using J 43690 J 43690 100 Tools J 43690 and adapter kit J 43690 100 have been developed as a more accurate method to measure connecting rod bearing clearances The instructions below provide an overview of tool setup and usage For more detailed information refer to the tool instruction sheets as supplied by the tool manufacturer J 43690 Rod Bearing
22. 1 Loosen the clamps at the throttle body and air failure cleaner 6 Install the ignition coils 2 Remove the air cleaner outlet duct Notice Refer to Fastener Notice in Cautions and Notices 7 Install the ignition coil bolts Tighten the ignition coil bolts to 12 Nm 106 in Ib 3 Remove the connector position assurance CPA retainer from ignition coil electrical connector 2 4 Disconnect the ignition coil harness electrical connector 2 5 Disconnect the engine coolant temperature ECT sensor electrical connector 3 8 Install and secure the ignition coil wiring harness into the two wiring harness retainers 9 Install the ignition coil wiring harness retainer bolts Tighten the ignition coil wiring harness retainer bolts to 12 Nm 106 in Ib 10 Connect the ignition coil wiring harness to the ignition coils making sure the connectors for cylinders 1 and 3 and cylinders 6 and 8 are connected to the corresponding ignition coils 11 Install the white wiring harness clip locks 52 Section 4 Cylinder Head and Valves TP 6105 8 05 10 Important Twist the spark plug boot one half turn to release the boot Pull on the spark plug boot only Do not pull on the spark plug wire or the wire could be damaged Remove the spark plug wires from the ignition coils Loosen the valve rocker arm cover bolts Remove the valve rocker arm cover Important The valve rocker arm cover gasket m
23. 14 Remove the bypass valve vacuum hose 1 from the intake manifold 20 Remove the fuel rail Important Do not attempt to loosen the manifold by prying under the gasket surface with any tool 15 Disconnect the evaporative emission EVAP tube from the purge solenoid 150 Section 10 Air Intake and Exhaust System TP 6105 8 05 21 Remove the intake manifold bolts 22 Remove the intake manifold Important The intake manifold gaskets are not reusable 23 Remove and discard the intake manifold side gaskets 24 Remove and discard the intake manifold end seals Important The splash shield is secured using a snap in fit Do not distort the splash shield The splash shield is reusable TP 6105 8 05 25 Remove the splash shield 26 If replacing the intake manifold refer to Section 10 1 3 Intake Manifold Disassemble 27 Clean and inspect the intake manifold Refer to Section 10 1 4 Intake Manifold Cleaning and Inspection Installation Procedure 1 If replacing the intake manifold refer to Section 10 1 5 Intake Manifold Assemble 2 Install the splash shield 3 Ensure the splash shield 2 snap fits between the cylinder heads 1 Section 10 Air Intake and Exhaust System 151 4 Install the new intake manifold end seals 9 Apply thread lock GM Part No U S 12345382 Canadian 10953489 or equivalent to a minimum of eight threads of the intake manifold bolts 6
24. 7 8 9 10 11 14 16 17 Additional 60 15 18 Additional 45 4 5 12 18 Additional 30 6 Install the exhaust manifold Refer to Section 10 2 Exhaust Manifold 76 Section 4 Cylinder Head and Valves TP 6105 8 05 12 Apply sealant GM Part No U S 12346004 Canadian 10953480 or equivalent to the threads of the ECT sensor 13 Install the ECT sensor to the cylinder head Tighten the ECT sensor to 20 Nm 15 ft Ib 14 Install the ECT sensor clip to the bracket 15 Install the valve rocker arms and push rods Refer to Section 4 2 1 Valve Rocker Arm and Push Rod Replacement 16 Install the intake manifold Refer to Section 10 1 1 Intake Manifold Replacement 3 Remove the cylinder head gasket 17 Drain the cooling system Refer to Section 9 4 Discard the cylinder head gasket Cooling System and Drive Belts 4 7 9 Installation Right 4 7 8 Removal Right Tools Required J 45059 Angle Meter 1 Remove and discard the eighteen cylinder head l f bolts 227 228 229 Notice Do notuse a sealant or adhesive when installing this component Use of a sealant or adhesive can cause improper sealing A component that is not sealed properly can leak leading to extensive engine damage Notice After removal place the cylinder head on two wood blocks to prevent damage to the sealing surfaces 1 Place the cylinder head gasket in position over the cylinder head locating pins Important Gu
25. Clearance Checking Tool 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 TP 6105 8 05 J 43690 100 Rod Bearing Clearance Checking 6 Install the following Tool Adapter Kit e J 43690 2 5 e J 43690 8 4 e J 43690 1 2 e 280310 3 e J 43690 5 1 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 7 Install the swivel base 1 and dial indicator 2 Important The crankshaft must be secure with no movement or rotation to obtain an accurate reading 1 Rotate the crankshaft until the journal connecting rod to be measured is in the 12 o clock position 2 Remove bearing cap bolts 1 8 Adjust per the manufacturers instructions and 3 Remove the bearing half and bearing cap 2 measure the connecting rod bearing clearance 4 Insert a piece of paper card stock onto the A connecting rod with a clearance in excess of crankshaft journal 0 081 mm 0 0032 in is considered excessive Service components as required 5 Install the bearing half
26. Correction Repair or replace the valve rocker arms as required Worn or bent push rods Replace the push rods Sticking valves Carbon buildup on the vale stem can cause the valve not to close properly Repair or replace as required Excessively worn or misaligned timing chain Repair or replace the timing chain camshaft retainer and sprockets as required Worn camshaft lobes Replace the camshaft and valve lifters Sticking lifters 3 6 Faulty cylinder head gaskets ad or cracking or other damage to the cylinder heads and engine block cooling system passages Coolant consumption may or may not cause the engine to overheat TP 6105 8 05 Replace as required Base Engine Misfire With Coolant Consumption Correction e Inspect for spark plugs saturated by coolant Inspection in Engine Controls e Perform a pressure test to the cooling system See Loss of Coolant in Engine Cooling e Perform cylinder leakdown test See Section 3 16 Cylinder Leakage Test e Inspect the cylinder heads and engine block for damage to the coolant passages and or a faulty head gasket See Section 3 13 Coolant in Combustion Chamber e Repair or replace as required See Spark Plug Section 3 Diagnostic Information and Procedures 29 3 7 Base Engine Misfire With Excessive Oil Consumption Leaking intake gaskets Repair or replace the intake manifold bolts and or gaskets as required Worn valv
27. Measure for excessive camshaft runout using and Inspection J 7872 Tools Required J 7872 Magnetic Base Dial Indicator a Mount the camshaft in a suitable fixture 1 Clean the camshaft in solvent b Use J 7872 to measure for a bent camshaft Refer to Section 1 2 Engine Mechanical Caution Refer to Safety Glasses Caution in Specs Cautions and Notices 7 Replace the camshaft if runout exceeds 2 Dry the camshaft with compressed air specifications 3 Inspect the camshaft retainer plate for damage 8 Inspect the camshaft bearings 1 5 for 4 Inspect the camshatt for the following conditions serviceability e Camshaft bearing journals 1 that are Worn Scored Damaged Worn camshaft lobes 2 e Damaged sprocket bolt threads 3 e Damaged sprocket pin 206 9 Replace the camshaft bearings if necessary Refer to Section 7 3 3 Camshaft Bearing Removal and Section 7 3 5 Camshaft Bearing Installation TP 6105 8 05 Section 7 Camshaft and Timing Gear Train 123 7 3 5 Bearing Installation J 33049 Tools Required J 33049 Camshaft Bearing Service Set Important The outer camshaft bearings positions 1 and 5 must be installed first These bearings serve as guides for the tool and help center the inner bearings during the installation process Notice Do not shim scrape or file bearing inserts Do not touch the bearing surface of the insert with bare fingers Skin oil and acids will etch the
28. Nm ft Ib Oil pump drive bolt Nm ft Ib Engine coolant temperature ECT sensor bracket bolt Nm ft Ib Spark plug Nm ft Ib Thermostat housing bolt stud Nm ft Ib Engine harness bolt Nm in Ib Throttle body nut Nm in Ib Engine harness ground bolt Nm ft Ib Throttle body stud Nm in Ib Engine harness stud Nm in Ib Valve lifter guide retainer bolt Nm ft Ib 25 18 Engine mount bolt to engine bracket Nm ft Ib Valve rocker arm cover bolt first pass Nm in Ib 6 53 Engine mount to engine bracket bolt Nm ft Ib Valve rocker arm cover bolt final pass Nm in Ib 12 106 Engine mount frame bracket through bolt Nm ft Ib Valve rocker arm nut Nm ft Ib Engine mount frame side mount bolt Nm ft Ib Valve rocker arm stud Nm ft Ib Engine shield bolt Nm ft Ib Water crossover bolt Nm ft Ib Engine sight shield bracket nut Nm in Ib Water pump bolt first pass Nm ft Ib Engine wiring harness bolt Nm ft Ib Water pump bolt final pass Nm ft Ib EVAP purge valve bolt Nm in Ib TP 6105 8 05 Water pump pulley bolt Nm ft Ib Section 1 Specifications 11 1 2 Application General Engine Mechanical Specs Application Spec Engine type V8 Crankshaft main bearing clearance 1 2
29. Operate the engine for no longer than 30 40 seconds Does the squealing noise still exist Go to Section 3 8 Engine Noise on Startup But Only Lasting a Few Seconds Go to Step 4 Do the drive belt grooves have pilling Inspect for a seized accessory drive component bearing or a faulty accessory drive component Go to Step 9 Go to Step 5 Inspect the drive belt tensioner for proper operation See Section 3 28 Drive Belt Tensioner Diagnosis Did you find and correct the condition Go to Step 9 Go to Step 6 Check for the correct length drive belt s Did you find and correct the condition Go to Step 9 Go to Step 7 Inspect for misaligned pulley Did you find and correct the condition Go to Step 9 Go to Step 8 Inspect for an incorrect size pulley Did you find and correct the condition Go to Step 9 1 Install the drive belt s See Section 9 1 1 Drive Belt Replacement Accessory 2 Clear any codes 3 Run the engine to verify the repair Does the squealing noise still exist TP 6105 8 05 Go to Step 1 System OK Section 3 Diagnostic Information and Procedures 41 3 23 Drive Belt Whine Diagnosis operate the engine for a few seconds to verify if the whining noise is related to the accessory drive g F component With the drive belt s removed the 3 23 1 Diagnostic Aids water pump will not operate and the engine may overheat Also DTCs may set when the en
30. Part No U S 1052942 Canadian 10953466 or equivalent to the rear bearing cap sealing face or tothe rear bearing cap channel of the engine block Apply the sealantto the bearing cap mating surface and bearing cap channel from the rear seal bore to the oil pan surface Notice To prevent the possibility of cylinder block or crankshaft bearing cap damage tap the crankshaft bearing caps into the cylinder block cavity using a brass lead or 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 Notice The crankshaft position sensor reluctor wheel ring is not serviced separately Do not repair the crankshaft position sensor reluctor wheel ring If the crankshaft position sensor reluctor ring is damaged replace the crankshaft assembly Important Ensure that the triangle symbols on the crankshaft bearing caps are facing the front of the engine Install the crankshaft bearing caps in the original location as previously marked Notice Refer to Fastener Notice in Cautions and Notices TP 6105 8 05 6 T 8 9 Important Tighten the crankshaft bearing cap inner bolts before tightening the crankshaft bearing cap outer studs Install the bearing cap bolts and studs Tighten a Tighten the bearing cap 1 4 inner bolts a first pass to 30 Nm 22 ft Ib
31. Section 3 Diagnostic Information and Procedures 35 3 18 Oil Pressure Diagnosis and 1 Testing With the engine on a level surface allow adequate drain down time 2 3 minutes and measure for the proper engine oil level Too high an oil level will cause aeration within the oil Add the recommended grade engine oil and fill the crankcase until the oil level measures FULL on the oil level indicator e Plugged oil filter f Malfunctioning oil filter bypass valve Remove the oil pressure gauge sensor or another engine block oil gallery plug Install an oil pressure gauge and measure the engine oil pressure If the engine oil pressure is below specifications inspect the engine for one or more of the following 2 Operate the engine and verify low or no oil pressure a Oil pump worn or dirty on the engine oil pressure gauge or oil indicator light Listen for a noisy valve train or knocking b Malfunctioning oil pump pressure relief valve noise c Oil pump screen loose plugged or damaged 3 Inspect for the following a Engine oil diluted by moisture or unburned fuel mixtures b Improper engine oil viscosity for the expected temperature c Incorrect or faulty oil pressure gauge sensor d Excessive bearing clearance or worn bearings e Cracked porous or restricted oil galleries f Engine block oil gallery plugs missing or incorrectly installed g Broken valve lifters d Incorrect or fa
32. Section 7 Camshaft and Timing Gear Train TP 6105 8 05 Installation Procedure 6 Install the timing chain and sprocket Refer to Section 7 2 Timing Chain and Sprockets Replacement 7 Install the valve lifters Refer to Section 4 6 Valve Lifter Replacement 7 3 2 Removal 1 Apply lubricant GM Part No U S 12345501 Canadian 992704 or equivalent to the following components e Camshaft lobes e Camshaft bearing journals e Camshaft bearings diameter so care must be used in removing or installing the camshaft to avoid damage to the 2 Remove the camshaft retainer camshaft bearings 2 Install three 8 1 25x100mm bolts into the camshaft threaded bolt holes 3 Using the bolts as a handle carefully install the camshaft 4 Remove the bolts from the front of the camshaft EA j at la P Notice All camshaft journals are the same 1 Remove the camshaft retainer bolts ur dera A H aif NL MN PP 3 Install three 8 1 25 x 100 mm bolts in the camshaft front bolt holes Notice All camshaft journals are the same diameter so care must be used in removing or installing the camshaft to avoid damage to the camshaft bearings 4 Usingthe bolts as a handle carefully rotate and pull Notice Refer to Fastener Notice in Cautions and the camshaft out of the engine block Notices 5 Remove the bolts from the front of the camshaft 5 Install the camshaft retainer and bolts Tighten the b
33. and Flywheel 6 Install the crankshaft bolt and washer to the crankshaft Tighten the crankshaft balancer bolt to 255 Nm 189 ft Ib 7 Remove J 42847 8 Install the starter motor 9 Install the fan 6 1 2 Removal Tools Required J 38416 B Harmonic Balancer Remover J 42846 Crankshaft Protector Button J 42847 Flywheel Holding Tool Refer to Fastener Notice in Cautions and Notice Notices Important Ensure that the teeth of the flywheel holding tool engage the engine flywheel teeth TP 6105 8 05 1 Install J 42847 1 to the starter bolt holes Tighten 5 Tighten the center screw of J 38416 B until the J 42847 bolts to 50 Nm 37 ft Ib crankshaft balancer is removed from the end of the crankshaft 6 Remove J 38416 B 7 Remove the crankshaft balancer 8 Remove J 42846 from the end of the crankshaft 9 Remove J 42847 1 3 Install J 42846 onto the end of the crankshaft 4 Install J 38416 B 2 to remove the crankshaft balancer Place the legs of J 38416 B into the recesses cast into the back side of the balancer inner hub 6 1 3 Cleaning and Inspection 1 Clean the crankshaft balancer in solvent Caution Refer to Safety Glasses Caution in Cautions and Notices 2 Dry the crankshaft balancer with compressed air TP 6105 8 05 Section 6 Crankshaft Main Bearings and Flywheel 97 3 Inspect the crankshaft balancer for the following e Damaged belt grooves 3 e Debri
34. and Inspection Tools Required J 8089 Carbon Removal Brush J 9666 Valve Spring Tester J 8001 Dial Indicator Set Visual Inspection Procedure Cleaning Procedure Inspect the cylinder head for the following conditions Caution Refer to Safety Glasses Caution in Cautions e Damaged gasket surfaces and Notices e Damage to threaded bolt holes e e Burnt or eroded areas in the combustion chamber Important Mark sort or organize components for Cracks in the exhaust ports and combustion return to their original locations chambers 1 Clean the valve stems and heads on a buffing e External cracks in the water chamber wheel e Restrictions in the intake or exhaust passages e Restrictions in the cooling system passages 2 Clean the following components in solvent e Valve stem keys 220 e Valve spring cap 219 TP 6105 8 05 Section 4 Cylinder Head and Valves 69 Flatness Measurement Procedure 1 Measure the cylinder head for warpage with a straight edge and feeler gauge 2 Repair or replace a cylinder head block deck with warpage in excess of 0 050 mm 0 002 in withina 150 0 mm 6 0 in area e Repair or replace a cylinder head exhaust manifold deck with an overall warpage in excess of 0 102 mm 0 004 in e Repair or replace a cylinder head intake manifold deck with warpage in excess of 0 080 mm 0 003 in e Resurface a cylinder head block deck up to 0 305 mm 0 012 in maximum removal Impor
35. at hard to see areas 2 Check for leaks at the following locations e Sealing surfaces e Fittings e Cracked or damaged components Go to Step 10 Go to Step 6 Can you identify the type of fluid and the approximate location of the leak 36 Section 3 Diagnostic Information and Procedures TP 6105 8 05 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 at normal operating temperature and at varying loads 4 Identify the type of fluid and the approximate location of the leak from the discolorations in the powder surface Go to Step 10 Go to Step 7 Can you identify the type of fluid and the approximate location of the leak 1 Visually inspectthe suspected area Use a small mirrorto assist in looking at hard to see areas 2 Check for leaks at the following locations e Sealing surfaces e Fittings e Cracked or damaged components Go to Step 10 Go to Step 8 Can you identify the type of fluid and the approximate location of the leak Use J 28428 E High Intensity Black Light Kit to identify the type of fluid and the approximate location of the leak Refer to the manufacturer s instructions when using the tool Go to Step 10 Go to Step 9 Can you identify the type of fluid and the approximate location of the leak 1 Visually inspect the suspected area Use a small mirror to assist in looking at
36. b Tighten the bearing cap 1 4 outer studs a first pass to 30 Nm 22 ft Ib c Tighten the bearing cap 1 4 inner bolts a final pass an additional 90 using J 45059 d Tighten the bearing cap 1 4 outer studs a final pass an additional 80 using J 45059 e Tighten the bearing cap 5 bolts and studs to 30 Nm 22 ft Ib f Loosen the bearing cap 5 bolts and studs g Tighten the bearing cap 5 bolts and studs to 5 Nm 44 in Ib Thrust the crankshaft firmly rearward Thrust the crankshaft firmly forward 10 Tighten a Tighten the bearing cap 5 inner bolts a first pass to 30 Nm 22 ft Ib b Tighten the bearing cap 5 outer studs a first pass to 30 Nm 22 ft Ib c Tighten the bearing cap 5 inner bolts a final pass an additional 90 using J 45059 d Tighten the bearing cap 5 outer bolts a final pass an additional 80 using J 45059 2 Mr ld Section 6 Crankshaft Main Bearings and Flywheel 105 11 Measure the crankshaft end play as follows a Install J 8001 or equivalentto the cylinder block with the dial indicator plunger against one of the counterweights of the crankshaft Firmly thrust the end of the crankshaft first rearward then forward This will line up the rear crankshaft bearing and the crankshaft thrust surfaces With the crankshaft pushed forward zero the dial indicator Move the crankshaft rearward and read the end play measurement on the dial indicator An optional m
37. body 502 14 Install the throttle body nuts 503 Tighten the throttle body nuts to 10 Nm 89 in lb 2 Ensure the splash shield 2 snap fits between the cylinder heads 1 3 Apply a 5 mm 0 2 in bead of GM Part No U S 12346141 Canadian 10953433 sealer 1 to the four engine block cylinder head locations 4 Install the new intake manifold end seals 158 Section 10 Air Intake and Exhaust System TP 6105 8 05 8 Ensure the intake manifold gasket tabs align with Rad pply aom Qe Deae er GNEP an Nost S the slot in the intake manifold end seals 12346141 Canadian 10953433 sealer 1 onto the end seals at the four engine block cylinder head locations 9 Install the intake manifold onto the engine block 6 Install the new intake manifold side gaskets onto the cylinder heads Notice Ensure the intake manifold does not shift as the intake manifold bolts are tightened in the proper sequence Failure to follow the entire intake manifold bolt tightening sequence exactly may result in an oil leak and serious engine damage Important Complete the entire intake manifold tightening sequence promptly due to the anaerobic thread adhesive Complete the final pass of the tightening sequence before the adhesive starts to cure or false torque readings and ineffective thread locking may result 7 Ensure the intake manifold gasket tabs align with the hole in the head gasket Important Do not reuse
38. cause engine rpm variations and lead to a misfire diagnostic trouble code DTO A misfire code may be present without an actual misfire condition Replace the drive belt See Section 9 1 1 Drive Belt Replacement Accessory Worn damaged or misaligned accessory drive components or excessive pulley runout A misfire code may be present without an actual misfire condition Inspect the components repair or replace as required Loose or improperly installed engine flywheel or crankshaft balancer A misfire code may be present without an actual misfire condition Repair or replace the flywheel and or balancer as required See Section 6 6 1 Engine Flywheel Replacement or Section 6 1 1 Crankshaft Balancer Replacement Restricted exhaust system A severe restriction in the exhaust flow can cause significant loss of engine performance and may set a DTC Possible causes of restrictions include collapsed or dented pipes or plugged mufflers Repair or replace as required Improperly installed or damaged vacuum hoses Repair or replace as required Improper sealing between the intake manifold and cylinder heads or throttle body Replace the intake manifold gaskets cylinder heads and or throttle body as required Improperly installed or damaged MAP sensor The sealing grommet of the MAP sensor should not be torn or damaged Repair or replace the MAP sensor as required Worn or loose rocker arms R
39. coils Refer to Safety Glasses Caution in Cautions and Notices Caution Important Do not clean or submerge the ignition coils in solvent Remove the ignition coils before cleaning the cover in solvent To prevent damage to the gasket minimize solvent contact with the gaskets TP 6105 8 05 7 Clean the valve rocker arm cover in solvent 8 Dry the covers with compressed air 4 1 4 Installation Left 1 Install a new valve rocker arm cover gasket if the gasket was removed from the valve rocker arm cover 2 Install the valve rocker arm cover 3 Install the valve rocker arm cover bolts Notice Refer to Fastener Notice in Cautions and Notices 4 Tighten the valve rocker arm cover bolts in sequence using two passes a Tighten the valve rocker arm cover bolts a first pass to 6 Nm 54 in Ib b Tighten the valve rocker arm cover bolts a final pass to 12 Nm 106 in Ib 5 Inspect the covers for the following e Gouges or damage to the sealing surfaces e Cracking or damage to the valve cover gasket e Debris or damage to the bolt hole threads Section 4 Cylinder Head and Valves 51 4 1 5 Replacement Right Notice This bolt is a self tapping bolt If installing this bolt into a new component installation of the bolt may be difficult Ensure that the bolt is not Removal Procedure over torqued during the initial installation thread cutting Failure to limit torque can lead to bolt
40. components as required See Section 4 7 4 Cylinder Head Cleaning and Inspection and Section 4 7 6 Cylinder Head Replacement Left or Section 4 7 9 Oylinder Head Replacement Right Cracked cylinder head Replace the cylinder head and gasket Cracked cylinder liner or engine block Replace the components as required Cylinder head or engine block porosity Replace the components as required Oylinder head block or manifold porosity Replace the components as required Warped cylinder head Machine the cylinder head to the proper flatness if applicable and replace the cylinder head gasket See Section 4 7 4 Cylinder Head Cleaning and Inspection Faulty external engine oil cooler 3 15 Engine Compression Test 1 Disconnectthe ignition coil wire harness connector at the front of the engine on the left cylinder bank and at the rear of the engine at the right cylinder bank 2 Disconnect the fuel injector electrical harness connector at the rear of the intake manifold 3 Remove the spark plugs 4 Block the throttle plate wide open 5 Charge the battery if the battery is not fully charged 6 Start with the compression gauge at zero Crank the engine through four compression strokes four puffs 7 Make the compression check the same for each cylinder Record the reading The minimum compression in any one cylinder should not be less than 7096 ofthe highest cylinder No cylinder sh
41. cover bolts in 1 Remove the valve rocker arm cover bolts sequence using two passes 2 Remove the valve rocker arm cover a Tighten the valve rocker arm cover bolts a first pass to 6 Nm 54 in Ib Important The valve rocker arm cover gasket may be reused if not removed from the valve rocker arm b Tighten the valve rocker arm cover bolts a final cover pass to 12 Nm 106 in Ib 3 Replace the valve rocker arm cover gasket if cut or damaged 54 Section 4 Cylinder Head and Valves TP 6105 8 05 4 2 Valve Rocker Arm and Push Rod 4 2 1 Replacement Removal Procedure Important Mark organize and sort the cylinder head components Return the components to their original location during reassembly 1 Remove the valve rocker arm cover Refer to Section 4 1 1 Valve Rocker Arm Cover Replacement Left and or Section 4 1 5 Valve Rocker Arm Cover Replacement Right 2 Remove the valve rocker arm nuts the valve rocker arm balls and valve rocker arms Important The exhaust valve push rods 2 are longer than the intake valve push rods 1 TP 6105 8 05 3 Remove the valve push rods 4 Remove the valve rocker arm studs and push rod guides 5 Clean and inspect the valve rocker arms and push rods Refer to Section 4 2 3 Valve Rocker Arm and Push Rod Cleaning and Inspection Installation Procedure Important Keep parts in order Parts must be put back from where they were removed 1 Apply
42. crankcase vapors The air cleaner supplies the fresh air through a filter to the crankcase The crankcase mixes the fresh air blowby gases This mixture then passes through a pipe passage located in the intake manifold 2 2 Drive Belt System Description The drive belt system consists of the following components e Drive belt e Drive belt tensioner e Drive belt idler pulley e Crankshaft balancer pulley e Accessory drive component mounting brackets e Accessory drive components e Engine alternator e Engine cooling fan if belt driven e Water pump if belt driven The drive belt system may use one or two belts The drive belt is thin so that it can bend backwards and has several ribs to match the grooves in the pulleys There also may be a V belt style belt used to drive certain accessory drive components The drive belts are made of different types of rubbers chloroprene or EPDM and have different layers or plies containing either fiber cloth or cords for reinforcement Both sides of the drive belt may be used to drive the different accessory drive components When the back side of the drive belt is used to drive a pulley the pulley is smooth The drive belt is pulled by the crankshaft balancer pulley across the accessory drive component pulleys The spring loaded drive belt tensioner keeps constant tension on the drive belt to prevent the drive belt from slipping The drive belt tensioner arm will move when loads ar
43. cylinder head spring seat Add a maximum of one valve spring seat shim up to 0 726 mm 0 030 in thick to achieve the valve spring installed height specification The combination of valve spring seat shims to correct valve spring installed height and valve spring tension should not exceed 1 524 mm 0 060 in thick 3 Install a valve spring seat shim if the valve spring installed height measurement is above the specification 4 Recheck the valve spring installed height and replace the cylinder head if the valve spring installed height cannot be obtained Valve Installation Caution Refer to Safety Glasses Caution in Cautions and Notices Caution Compressed valve springs have high tension against the valve spring compressor Valve springs that are not properly compressed by or released from the valve spring compressor can be ejected from the valve spring compressor with intense force Use care when compressing or releasing the valve spring with the valve spring compressor and when removing or installing the valve stem keys Failing to use care may cause personal injury TP 6105 8 05 1 Lubricate the valve stems 232 with clean engine oil 2 Insert the valves into their proper locations e Install the necessary valve spring shims onto the cylinder head if applicable 4 Lubricate the rotators 216 with clean engine oil 5 Install the rotators over the guide and on top of the cylinder head or valve
44. cylinder head and the cylinder block using J 39345 Important Take appropriate precautions to assure that machining chips will not remain inside the engine For example block all intake passages oil drainback holes and exhaust passages with a towel or tape before performing thread repairs 1 Select the proper size drill as indicated in the schematic charts found in the thread repair specifications for the hole being repaired 2 Drill out the damaged threads to the original depth or completely through for through holes Caution Refer to Safety Glasses Caution in Cautions and Notices 3 Apply compressed air with a shop towel wrapped around the air spout to retain the chips forced out of the hole 4 Select the correct size tap using the appropriate chart for the hole being repaired 5 Coat the tap and the hole with spray machining oil 6 Tap the hole to the original depth To clean the threads reverse the rotation of the tap periodically TP 6105 8 05 10 11 12 13 14 Use solvent to clean out all of the chips Apply compressed air with a shop towel wrapped around the air spout to retain the chips forced out of the hole Tap the hole again to clean the threads The tap should thread in with little resistance Important Make sure all of the chips are cleared from the hole Use solvent to clean out all of the chips Apply compressed air with a shop towel wrapped around
45. e Air bubbles in the cooling system may indicate a damaged cylinder head or a damaged cylinder head gasket 7 Perform the leakage test on the remaining cylinders and record the values 3 17 Oil Consumption Diagnosis Excessive oil consumption not due to leaks is the use of more than 0 95 L 1 qt of engine oil within 379 L 100 gal of fuel used However during initial engine break in periods 5000 6500 km 3000 4000 mi oil consumption may exceed 1 9 L 2 qt or more per 379 L 100 gal of fuel used The causes of excessive oil consumption include the following conditions e External oil leaks Tighten bolts and or replace gaskets and oil seals as necessary e Incorrect oil level or improper reading of oil level indicator With the engine on a level surface allow adequate drain down time and check for the correct oil level e Improper oil viscosity Use recommended SAE viscosity for the prevailing temperatures e Continuous high speed driving and or severe usage e Crankcase ventilation system restrictions or malfunctioning components e Valve guides and or valve stem oil seals worn or the seal omitted Ream guides and install oversize service valves and or new valve stem oil seals e Piston rings broken improperly installed worn or not seated properly Allow adequate time for rings to seat Replace broken or worn rings as necessary e Piston improperly installed or piston size is incorrectly selected
46. equipment or render the equipment unsafe These Cautions and Notices are not exhaustive General Motors Powertrain cannot possibly warn of all the potentially hazardous consequences of failure to follow these instructions 2 TP 6105 8 05 Table of Contents Cautions cece ceva e aac a ma sg va tare ecKce ck eria ecce ura Rr A Res 2 nicer U m m 7 Cautions and Notices cori illo la 9 Section 1 Specifications a gt lt sese a SE 11 11 Fastener Tightening Specs 0 00 cece eee 11 1 2 Engine Mechanical Specs 00 ec rr 12 1 3 Sealers Adhesives and Lubricant Specs 000 cece eee eens 13 1 4 Component Locator 0 ccc rr 14 1 4 1 Disassembled Views ssssssss et enn es 14 1 4 2 Engine Identification 0 0 0 eens 17 Section 2 Description and Operation 0 0 cece eee eee nnn nnn 19 2 4 Crankcase Ventilation System Description 0 0 19 2 2 Drive Belt System Description 0000 cece eee cette eee 19 2 3 Engine Component Description cece eee 19 2 3 1 Cylinder Block xs e ese dv a 19 23 2 Cylinder Head i ccecs ieee eae een ee uk yeas RR oes 19 2 9 9 Camshatt io bebe abore tue bilden e HERI MP EIE 19 2 9 4 GranksShaft i rs eddie da iba 20 2 8 5 Pistons and Connecting Rods 0 cece teens 20 23 6 Valve raim kg elke ene Bk ee i ee 20 2 3 7 Intake Manifold 0
47. hard to see areas 2 Check for leaks at the following locations e Sealing surfaces e Fittings e Cracked or damaged components Go to Step 10 System OK Can you identify the type of fluid and the approximate location of the leak 1 Inspect the engine for mechanical damage Special attention should be shown to the following areas Higher than recommended fluid levels Higher than recommended fluid pressures Plugged or malfunctioning fluid filters or pressure bypass valves Plugged or malfunctioning engine ventilation system Improperly tightened or damaged fasteners Go to Step 11 System OK Cracked or porous components Improper sealants or gaskets where required Improper sealant or gasket installation e Damaged or worn gaskets or seals 2 Inspect the engine for customer modifications Is there mechanical damage or customer modifications to the engine Repair or replace all damaged or modified components Go to Step 1 System OK Does the engine still leak oil TP 6105 8 05 Section 3 Diagnostic Information and Procedures 37 3 20 Crankcase Ventilation System Inspection Diagnosis A plugged positive crankcase ventilation PCV pipe passage way may cause e Rough idle e Oil leaks e Sludge in the engine 3 21 Drive Belt Chirping Diagnosis 3 21 1 Diagnostic Aids The chirping noise may be intermittent due to moisture on the drive belt s or the accessory drive pulley s To duplicate the custo
48. in locations 15 and 18 The short Bolts ere used im iScationss4 5 12 and 18 10 Install the valve rocker arms and push rods Refer to Section 4 2 1 Valve Rocker Arm and Push Rod Replacement 11 Install the intake manifold Refer to Section 10 1 1 Intake Manifold Replacement A 4 7 2 Removal Left 18 1 Remove and discard the eighteen cylinder head bolts 227 228 229 5 Tighten the cylinder head bolts a Tighten the bolts a first pass in sequence to 30 Nm 22 ft Ib b Tighten the bolts a second pass in sequence to 30 Nm 22 ft Ib then an additional 120 using J 45059 c Tighten the bolts a final pass in sequence using J 45059 as listed Bolt Tighten 1 2 3 6 7 8 9 10 11 14 16 17 Additional 60 15 18 Additional 45 4 5 12 18 Additional 30 TP 6105 8 05 Section 4 Cylinder Head and Valves 67 Notice After removal place the cylinder head on two wood blocks to prevent damage to the sealing surfaces 3 Remove the cylinder head gasket 4 Discard the cylinder head gasket 4 7 3 Disassemble Tools Required J 8062 Valve Spring Compressor Head Off Caution Refer to Safety Glasses Caution in Cautions and Notices 68 Section 4 Cylinder Head and Valves Caution Compressed valve springs have high tension against the valve spring compressor Valve springs that are not properly compressed by or released from the valve spring compressor can be ejected from
49. intake manifold There is not a PCV valve A splash shield is installed under the intake manifold The shield prevents hot oil from contacting the bottom of the intake manifold maintaining air inlet charge density 2 3 8 Exhaust Manifold The two exhaust manifolds are constructed of cast stainless steel The exhaust manifolds direct exhaust gases from the combustion chambers to the exhaust system 2 4 Lubrication Description The gear type oil pump is driven through an extension driveshaft The extension driveshaft is driven by the oil pump drive which is gear driven by the camshaft The oil is drawn from the oil pan through a pickup screen and tube into the oil pump 7 Pressurized oil flows through the oil filter into the oil cooler 5 back into the engine 6 up to the oil pressure gauge port 2 and rear crankshaft bearing and is then distributed to the upper oil galleries Oil must flow around the oil pump drive 1 to reach the right side valve lifters properly TP 6105 8 05 The oil is delivered through internal passages to lubricate camshaft and crankshaft bearings and to provide lash control in the hydraulic valve lifters Oil is metered from the valve lifters through the valve push rods to lubricate the valve rocker arms and ball pivots Oil returning to the oil pan from the cylinder heads and the front camshaft bearing lubricates the camshaft timing chain crankshaft and camshaft sprockets There are two bypass v
50. lock sealant container e The threaded surfaces to be sealed must be clean and dry Section 2 Description and Operation 23 e Apply the thread lock sealant as specified on the thread lock sealant container Important Fasteners that are partially torqued and the thread lock sealant allowed to cure more than 5 minutes may result in incorrect clamp load of assembled components e Tighten the fasteners in sequence if specified and to the proper torque specifications Do not overtighten the fasteners 2 8 5 Anaerobic Type Pipe Sealant Anaerobic type pipe sealant cures in the absence of air and remains pliable when cured This type of sealant is used where two parts are assembled together and require a leakproof joint Use the following information when using pipe sealant e Do not use pipe sealant in areas where extreme temperatures are expected These areas include e The exhaust manifold e The head gasket e Surfaces where a different sealant is specified e Always follow all the safety recommendations and the directions that are on the pipe sealant container e The surfaces to be sealed must be clean and dry e Use a pipe sealant bead of the size or quantity as specified in the service procedure Notice Do not allow the sealant to enter a blind hole The sealant may prevent the fastener from achieving proper clamp load cause component damage when the fastener is tightened or lead to component failure e Apply th
51. of the valve stem 12 Release and remove J 8062 17 Apply sealant GM Part No U S 12346004 Canadian 10953480 or equivalent to the threads of the cylinder head coolant hole plug 13 Lightly tap the end of the valve stem with a 18 Install the cylinder head coolant hole plug into the plastic faced hammer to seat the keys left cylinder head Tighten the cylinder head coolant hole plug to 50 Nm 37 ft Ib 72 Section 4 Cylinder Head and Valves TP 6105 8 05 4 7 6 Installation Left Tools Required J 45059 Angle Meter Notice Do notuse a sealant or adhesive when installing this component Use of a sealant or adhesive can cause improper sealing A component that is not sealed properly can leak leading to extensive engine damage 1 Place the cylinder head gasket in position over the cylinder head locating pins Important Guide the cylinder head carefully into place over the locating pins and the cylinder head gasket 2 Install the cylinder head to the block Notice Do not reuse the cylinder head bolts Use new cylinder head bolts The cylinder head bolts are torque to yield bolts and cannot be reused after the initial torque is applied During the initial torque of the cylinder head bolt the cylinder head bolt is stretched to achieve proper clamp load Proper clamp load will not be achieved if a used cylinder head bolt is torqued again A stretched cylinder head bolt can also break when torqued Failure t
52. on the rear of the seal is in the 12 o clock position Second design oil seals will not have an alignment mark on the rear face The seal may be installed in any position 3 Install the crankshaft front oil seal using J 42851 4 Install the front cover locating pins 129 if required Important Install the engine front cover and tighten the fasteners while the sealant is still wet to the touch 5 Apply a 3 4 mm 0 12 0 16 in bead of sealant a GM Part No U S 12346286 Canadian 10953472 or equivalent in two sealant points 1 on the engine block where the front cover meets the oil pan 116 Section 7 Camshaft and Timing Gear Train 6 Apply a 3 4 mm 0 12 0 16 in bead of sealant GM Part No U S 12346286 Canadian 10953472 or equivalent in 2 sealant points 1 across the flange where the gasket ends at the bottom of the front cover Install the engine front cover gasket into the front cover Important Use the following method when installing the engine front cover Failure to follow the instructions will push the sealant out which may cause an oil leak Install the engine front cover TP 6105 8 05 a Hold the front cover 1 up to the crankshaft 2 b Lift the front cover 1 while sliding the cover over the crankshaft 2 c Slide the front cover toward the engine block 5 while keeping the cover raised d Lower the cover down over the dowel pin 4 allowing the
53. rocker arm nuts slowly to 35 Nm 26 ft Ib while guiding the tips of the rocker arms over the tips of the valves 4 3 Valve Stem Oil Seal and Valve Spring Replacement Tools Required J 5892 D Valve Spring Compressor J 22794 Spark Plug Port Adapter J 43105 Valve Stem Seal Installer Removal Procedure TP 6105 8 05 1 Remove the valve rocker arms and push rods 6 Slowly release J 5892 D Refer to Section 4 2 1 Valve Rocker Arm and Push Rod Replacement Important Rotate the piston in the cylinder being serviced to the bottom of its stroke to ensure that the engine does not rotate when the compressed air is applied 2 Rotate the crankshaft until both valves are closed before installing compressed air into the cylinder 3 Remove the spark plug from the cylinder being serviced 4 Remove the valve stem keys as follows a Install J 22794 into the spark plug hole 7 Remove J 5892 D from the cylinder head b Apply compressed air into the cylinder to hold 8 Remove valve spring cap 2 and valve spring 3 the valves closed 9 Remove the valve stem oil seal 4 c Lightly tap the valve spring cap to loosen the valve stem keys Installation Procedure d Install J 5892 D to the cylinder head 1 Lubricate the valve stem and outside diameter of the valve guide seal with clean engine oil 2 Lubricate the rotators with clean engine oil Important When installing valve seals use J 43105 to achieve correct
54. sealant GM Part No U S 12346004 Canadian 10953480 or equivalent to the valve rocker arm stud to cylinder head threads Notice Refer to Fastener Notice in Cautions and Notices Section 4 Cylinder Head and Valves 55 2 Install the push rod guides and valve rocker arm studs Tighten the studs to 50 Nm 37 ft Ib Important The exhaust valve push rods 2 are longer than the intake valve push rods 1 1 Remove the valve rocker arm nuts the valve rocker arm balls and the valve rocker arms 3 Install the valve push rods 4 Coatthe valve rocker arm and valve rocker arm ball bearing surfaces with lubricant GM Part No U S 12345501 Canadian 992704 or equivalent Important The exhaust valve push rods 2 are longer than the intake valve push rods 1 2 Remove the valve push rods 5 Install the valve rocker arms the valve rocker arm balls and the valve rocker arm nuts Tighten the nuts slowly to 35 Nm 26 ft Ib while guiding the tips of the rocker arms over the tips of the valves 6 Install the valve rocker arm cover Refer to Section 4 1 1 Valve Rocker Arm Cover Replacement Left or Section 4 1 5 Valve Rocker Arm Cover Replacement Right 3 Remove the valve rocker arm studs and push rod guides 4 2 2 Removal Important Mark organize and sort the cylinder head components Return the components to their original location during reassembly Make an organizer rack from a p
55. the air spout to retain the chips forced out of the hole Use a flashlight to confirm that all of the chips are removed from the hole Continue to clean the hole until all of the chips are cleared Install the heli coil insert as follows a To determine the correct size installation tool and length insert refer to the appropriate picture and chart b Screw the insert on the mandrel of the installation tool until the driving tang is fully engaged in the driving contour c Coat the insert with spray machining oil d Install the insert as follows e Slide the prewinder over the mandrel and insert e Rotate the mandrel clockwise until one or two threads of the insert are threaded into the prewinder e Place the insert in position on the threaded hole being repaired e Rotate the mandrel clockwise until the insert is flush with the top surface of the threaded hole e Remove the prewinder repairing cylinder head bolts e Continue to install the insert until reaching the original thread depth e Remove the mandrel except when e Remove the driving tang from the thread insert as follows Remove the tang to allow passage of the fastener through the insert TP 6105 8 05 15 Clean the hole using compressed air e Place the square end of the punch no chamtfer on the tang after installation e Strike the punch sharply with the hammer The tang will break off at the notch Take appropriate steps to assur
56. the valve spring compressor with intense force Use care when compressing or releasing the valve spring with the valve spring compressor and when removing or installing the valve stem keys Failing to use care may cause personal injury Important Mark sort or organize components for return to their original locations 1 Use J 8062 to compress the valve springs 2 Remove the valve stem keys 220 3 Release and remove J 8062 4 Remove the cap 219 5 Remove the valve spring 218 6 Remove the valve stem seal 217 from the valve guide 7 Remove the valve rotator 216 Important To prevent damage to the valve guide small burrs on the valve tip and at the stem key groove that interfere with the valve removal can be lightly filed with a fine file or stone to facilitate valve removal 8 Remove the valve 232 TP 6105 8 05 9 Disconnect the engine coolant temperature ECT sensor from the bracket Valve spring 218 Valve Rotators 216 Valve 232 Oylinder head Caution Refer to Safety Glasses Caution in Cautions and Notices 10 Remove the ECT sensor from the cylinder head 11 Remove the ECT sensor bracket and bolt 12 Remove the cylinder head coolant hole plug from the cylinder head 3 Dry the components with compressed air Important Be careful not to damage the chamber or the valve seat 4 Use J 8089 to clean carbon from the combustion chambers 4 7 4 Cleaning
57. to Step 6 Install a new drive belt s See Section 9 1 1 Drive Belt Replacement Accessory Did you complete the replacement Go to Step 11 Inspect for incorrect loose and or missing fasteners Were any incorrect loose and or missing fasteners found Go to Step 7 Go to Step 8 Replace any incorrect and or missing fasteners Tighten any loose fasteners See Section 1 1 Fastener Tightening Specs Were the fasteners replaced and or tightened Go to Step 11 Inspect for damaged fan blades or a bent fan clutch shaft Did you find and correct the condition Go to Step 11 Go to Step 9 Inspect for a bent water pump drive shaft Did you find and correct the condition Go to Step 11 Go to Step 10 Inspect for a bent or cracked accessory drive bracket s Did you find and correct the condition Go to Step 11 1 Clear any codes 2 Run the engine to verify the repair Does the rumbling noise still exist TP 6105 8 05 Go to Step 1 System OK Section 3 Diagnostic Information and Procedures 45 3 26 Drive Belt Falls Off Diagnosis 3 26 1 Diagnostic Aids If the drive belt s repeatedly falls off the accessory drive pulley s a pulley may be misaligned An extra load that is quickly applied or released by an accessory drive component may cause the drive belt s to fall off Verify that the accessory drive component s is operating properly If the drive belt s is t
58. 00 cece eee cette eens 27 3 2 1 Strategy Based Diagnostics 0 cece 27 3 2 2 Visual Physical Inspection 0 cece ee eee 27 3 2 3 Intermittent ts cocer xi I bedeutete asada tid eei 27 3 3 Base Engine Misfire Without Internal Engine Noises 00 000s 28 3 4 Base Engine Misfire With Abnormal Internal Lower Engine Noises 29 3 5 Base Engine Misfire With Abnormal Valve Train Noise 000005 29 3 6 Base Engine Misfire With Coolant Consumption 00 0c eee eee 29 3 7 Base Engine Misfire With Excessive Oil Consumption 00005 30 3 8 Engine Noise on Startup Only Lasting a Few Seconds 0005 30 3 9 Upper Engine Noise Regardless of Engine Speed 0 ce eens 31 3 10 Lower Engine Noise Regardless of Engine Speed cee eee 32 3 11 Engine Noise Under Load uussssssssseeses sees 32 3 12 Engine Will Not Crank Crankshaft Will Not Rotate o o 33 3 13 Coolant in Combustion Chamber 0 00 cece ee 33 3 14 Coolant in Engine Oil 00 ttt ete eeee 34 3 15 Engine Compression Test 000 cece ec eect cette eee en eeeee 34 TP 6105 8 05 Table of Contents 3 Table of Contents continued 3 16 Cylinder Leakage Test ooocococcoconorr eh 35 3 17 Oil Consumption Diagnosis 00ooooccococooorra teens 35 3 18 Oil Pressure Diagnosis and Testin
59. 105 8 05 All diagnosis on an engine should follow a logical process Strategy based diagnostics is a uniform approach for repairing all systems The diagnostic flow may always be used to resolve a system problem The diagnostic flow is the place to start when repairs are necessary For a detailed explanation refer to Strategy Based Diagnosis in General Information 3 2 2 Visual Physical Inspection e Inspect for aftermarket devices that could affect the operation of the Engine e Inspect the easily accessible or visible system components for obvious damage or conditions that could cause the symptom e Check for the correct oil level proper oil viscosity and correct filter application e Verify the exact operating conditions under which the concern exists Note factors such as engine rpm ambient temperature engine temperature amount of engine warmup time and other specifics e Compare the engine sounds if applicable to a known good engine and make sure you are not trying to correct a normal condition 3 2 3 Test the engine under the same conditions that the customer reported to verify the system is operating properly Intermittent Section 3 Diagnostic Information and Procedures 27 3 3 Base Engine Misfire Without Internal Engine Noises Correction Abnormalities such as severe cracking bumps or missing areas in the accessory drive belt Abnormalities in the accessory drive system and or components may
60. 22 120 Knock sensor Nm ft Ib Knock sensor heat shield bolt Nm in Ib Final pass long bolts 1 2 3 6 7 8 9 10 11 14 16 17 60 Lift bracket bolt Nm ft Ib Final pass medium bolts 15 16 45 MAP sensor bolt Nm in Ib Final pass short bolts 4 5 12 13 30 Oil cooler hose fittings Nm ft Ib Cylinder head coolant hole plug Nm ft Ib 50 37 Oil fill tube bolt Nm in Ib Drive belt idler pulley bolt Nm ft Ib Oil filter Nm ft Ib EGR cover nut Nm ft Ib Oil filter fitting Nm ft Ib EGR cover stud Nm in Ib Oil level indicator tube bolt Nm ft Ib Engine block coolant drain M28 plug left front Nm ft Ib Oil level sensor Nm ft Ib Oil pan bolt first pass Nm in Ib Engine block coolant drain plug sides Nm ft Ib Oil pan bolt final pass Nm ft Ib Engine block heater Nm ft Ib Oil pan drain plug Nm ft Ib Engine block oil gallery front plug Nm ft Ib Oil pan skid plate bolt Nm ft Ib Engine block oil gallery rear plug Nm ft Ib Oil pressure gauge sensor Nm ft Ib Engine block oil gallery side plug Nm ft Ib Oil pump bolt Nm ft Ib Engine block oil gallery top plug Nm ft Ib Oil pump cover bolt Nm in Ib Engine coolant temperature ECT sensor
61. 25 Nm 18 ft Ib 11 Install the oil level indicator Refer to Section 8 4 Oil Level Indicator and Tube Replacement 12 Fill the engine with oil Refer to Section 8 2 Engine Oil and Oil Filter Replacement 13 Install the starter motor 8 5 2 Removal 6 Position the battery cable channel into place 7 Install the battery cable channel bolt Tighten the bolt to 9 Nm 80 in Ib 8 Install the oil level sensor to the oil pan Tighten the sensor to 20 Nm 15 ft Ib 2 Remove the oil pan bolts Important The oil pan gasket is reusable if not cut or damaged 3 Remove the oil pan 400 and the oil pan gasket 404 TP 6105 8 05 Section 8 Lubrication System 133 8 5 3 Cleaning and Inspection 3 Install the oil pan 400 1 Removethe oil pan gasket 404 from the groove in Notice Refer to Fastener Notice in Cautions and the oil pan 400 Notices 2 Clean the oil pan in solvent 4 Install the oil pan bolts 1 12 Caution Refer to Safety Glasses Caution in Cautions and Notices 3 Dry with compressed air 4 Inspect the oil pan for the following conditions Damaged threads in the drain plug hole Gouges or damage to oil pan sealing surfaces Cracks or damage to the exterior of the oil pan Damage to the oil level indicator tube area Damage to the oil pan gasket 5 Tighten the oil pan bolts in sequence 8 5 4 Installation a Tighten the oil pan bolts a first pass in sequence to 10
62. 3 10953488 Crankshaft rear bearing cap Sealant 1052942 10953466 Cylinder head bolt threads Sealant 12346004 10953480 Cylinder head coolant hole plug Sealant 12346004 10953480 Engine block coolant drain plugs Sealant 12346004 10953480 Engine block oil gallery plugs Sealant 12346004 10953480 Engine coolant temperature ETC sensor threads Sealant 12346004 10953480 Engine front cover Sealant 12346286 10953472 Engine oil supplement Lubricant 1052367 992869 Intake manifold Sealant 12346141 10953433 Intake manifold bolt threads Thread adhesive 12345382 10953489 Intake manifold engine block cylinder head Sealant 12346141 10953433 Knock sensor threads Sealant 12346004 10953480 Oil cooler hose fittings Sealant 12346004 10953480 Oil fill tube Sealant 9985409 9985409 Oil pan corners Sealant 12346286 10953472 Oil pressure sensor threads Sealant 12346004 10953480 Purge solenoid bolt Thread adhesive 12345493 10953488 Valve rocker arm stud threads 12346004 Sealant 10953480 Water pump bolt threads TP 6105 8 05 12346004 Sealant 10953480 Section 1 Specifications 13 1 4 Component Locator 1 4 1 Disassembled Views 412 Splash shield 509 EGR cover nut 415 Oil fill tube O ring 510 EGR cover 416 Oil fill tube 511 EGR cover gasket 417 Oi
63. 3 4 production Crankshaft main bearing clearance 5 production 0 022 0 057 0 0008 0 0022 0 034 0 069 0 0013 0 0027 Displacement L CID 8 1 496 RPO L18 Crankshaft main bearing clearance 1 2 3 4 service 0 022 0 089 0 0008 0 0035 Bore mm in 107 95 4 25 Crankshaft main bearing clearance 5 service limit 0 035 0 102 0 0014 0 0040 Stroke mm in 111 00 4 37 Compression ratio 9 1 1 Crankshaft main bearing journal diameter 69 805 69 822 2 7482 2 7489 Firing order 1 8 7 2 6 5 4 3 Spark plug gap mm in 1 52 0 060 Crankshaft main journal out of round production 0 0102 0 0004 Block mm in Crankshaft main journal taper production 0 0102 0 0004 Crankshaft main bearing bore diameter 74 606 74 622 2 9372 2 9379 Crankshaft runout production 0 05 0 002 Crankshaft runout service 0 065 0 0026 Oylinder bore diameter production 107 950 107 968 4 2500 4 2507 Cylinder head mm in Oylinder bore diameter service 107 94 107 99 4 2496 4 2516 Height thickness 259 875 260 125 10 231 10 241 Surface flatness block deck 0 05 0 002 Oylinder bore out of round production max minus min bore diameter 0 018 0 0007 Surface flatness exhaust manifold deck 0 102 0 004 Cylinder bore out of round service
64. 6 in following table Misalignment of the accessory drive pulley s may be caused from improper mounting or incorrect installation of a accessory drive component or the pulley may be bent inward or outward from a previous repair Testfor a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys If a misaligned pulley is found refer to that accessory drive component for the proper removal and installation procedure for that pulley See item 7 in following table Inspect the accessory drive pulley s to verify that they are the correct diameter or width See item 8 in following table TP 6105 8 05 Notice See Belt Dressing Notice in Cautions and Notices Definition The following items are indications of drive belt squeal e A loud screeching noise that is caused by a slipping drive belt s unusual for a drive belt with multiple ribs e The squeal occurs when a heavy load is applied to the drive belt such as snapping the throttle slipping on a seized pulley or a faulty drive belt component Did you review Section 3 2 Symptoms Engine Mechanical for diagnostic information and perform the necessary inspections Go to Step 2 Go to Section 3 2 Symptoms Engine Mechanical Verify that there is a squeal noise Does the engine make the squeal noise Go to Step 3 Go to Diagnostic Aids 1 Remove the drive belt s See Section 9 1 1 Drive Belt Replacement Accessory 2
65. 6105 8 05b
66. 726 mm 0 030 in thick to increase tension valve stem keys do not move 3 If the valve spring tension is low use a shim to Remove J 5892 D from the valve assembly increase tension Remove compressed air from the cylinder 4 Recheck the valve spring tension Replace a valve being worked on spring that does not meet specifications 9 Install the spark plug Refer to Spark Plug Replacement in Engine Controls 60 Section 4 Cylinder Head and Valves TP 6105 8 05 Valve Guide Measurement Procedure Important Excessive valve stem to guide clearance may cause excessive oil consumption and may also cause a valve to break Insufficient clearance will result in noisy and sticky functioning of the valve and will disturb the engine assembly smoothness 1 Measure the valve stem to guide clearance a Clamp J 8001 on the exhaust port side of the cylinder head Important The indicator stem must contact the side of valve stem just above the valve guide b Locate the indicator so that the movement of the valve stem from side to side crosswise to the cylinder head will cause a direct movement of the indicator stem c Drop the valve head about 1 6 mm 0 064 in off the valve seat d Uselight pressure when moving the valve stem from side to side to obtain a clearance reading Refer to Section 1 2 Engine Mechanical Specs 2 Repair valve guide 2 with excessive clearance Refer to Section 4 5 Valve Guide Reaming Valve an
67. 8 05 Definition of Caution Notice and Important The diagnosis and repair procedures in the GM Powertrain Service Manual contain both general and specific Cautions Notices and Importants GM Powertrain is dedicated to the presentation of service information that helps the technician diagnose and repair the systems necessary for the proper operation of the equipment however certain procedures may present a hazard to the technician if they are not followed in the recommended manner Cautions Notices and Importants are elements designed to prevent these hazards however not all hazards can be foreseen This information is placed at strategic locations within the service manual and is designed to prevent the following e Serious bodily injury to the technician e Damage to the equipment e Unnecessary equipment repairs e Unnecessary component repairs e Improper repair or replacement equipment components Any caution or notice that appears in general information is referenced from the individual service categories Caution Defined When encountering a Caution you will be asked to take a necessary action or avoid a prohibited action If a Caution is not heeded the following consequences may occur e Serious bodily injury to the technician e Serious bodily injury to other technicians in the workplace area e Serious bodily injury to the equipment operator if the equipment has been improperly repaired TP 6105 8 05
68. ERI Needed i Red 113 71 2 REMOVAL i32 iL beng Pa RIS gl Ge hilo pad bays DDR 115 7 1 3 Installation 44 0 3 amer te o pedea aetate faece there does 116 7 2 Timing Chain and Sprockets ooooocococccccorrn sees 117 7 2 1 Replacement lo hed aed DTE eR ES UIaee ues 117 712 2 REMOVA i eer n sd kool RE DRUSI a quiate 118 7 2 3 Cleaning and Inspection o ocooocccoconorrorrr eee 119 124 Installation ica cd Pode dt hb rr oie bbe 119 1 3 Camshatt e ous UNA MERC E adem est cus RETE Une C 120 7 8 1 Replacement iio e a Ge REAPER P WC ROPA EP PI 120 7 3 2 Hemoval uc A 121 7 3 3 Bearing Removal inesse oei r i nn 122 7 8 8 Camshaft and Bearings Cleaning and Inspection 123 7 3 5 Bearing Installation nunna 0 0 ccc cece 124 13 6 Installation co ar ia A A E Ea 125 TP 6105 8 05 Table of Contents 5 Table of Contents continued Section 8 Lubrication System 00 enhn nnn 127 8 4 Draining Fluids and Oil Filter Removal 0 0 eee ee 127 8 2 Engine Oil and Oil Filter Replacement 0 eee 127 8 3 Oil Filter Adapter octal acea ed s 127 8 8 1 Bypass Valve Assembly Replacement 00 eee eens 127 8 3 2 Hemoval octobri rk tiere 128 8 3 3 Installation o a ata eet 129 8 4 Oil Level Indicator and Tube 0 0 0 cece tenes 129 8 4 1 Replacements naci pde ide dde na RUM aida RET REM cous 129 8 4 2 Removal pin dole ae quee eee aM Gane deans 130 8 4 3 Inst
69. Ensure the intake manifold gasket tabs align with the hole in the head gasket 7 Ensure the intake manifold gasket tabs align with 10 Install the intake manifold bolts the slot in the intake manifold end seals Notice Refer to Fastener Notice in Cautions and Notices 8 Install the intake manifold 152 Section 10 Air Intake and Exhaust System TP 6105 8 05 11 Tighten the intake manifold bolts in the sequence shown using four passes a Tighten the bolts a first pass to 5 Nm 44 in Ib b Tighten the bolts a second pass to 8 Nm 71 in lb c Tighten the bolts a final pass to 12 Nm 106 in Ib Important Lubricate the fuel injector O ring seals with clean engine oil and install onto the spray tip of each injector 18 Install the bypass valve vacuum hose 1 to the intake manifold 12 If replacing the intake manifold install the fuel rail 19 Position the engine harness over the engine compartment 13 Install the fuel rail studs Tighten the studs to 12 Nm 106 in Ib 20 Connect the following electrical connectors e Engine alternator 2 Injector harness 3 Ignition coil harness 4 ETC 5 Purge valve solenoid 1 14 Install the EVAP tube 15 Connect the EVAP tube to the vent pipe at the rear of the engine 16 Clip the EVAP tube to the fuel rail 17 Connect the EVAP tube to the purge solenoid TP 6105 8 05 Section 10 Air Intake and Exhaust System 153
70. Nm 89 in Ib Important Install the oil pan within 5 minutes of the sealer being applied or the sealer will begin to cure b Tighten the oil pan bolts a final pass in causing an inadequate seal sequence to 25 Nm 18 ft Ib 1 Apply sealant GM Part No U S 12346286 Canadian 10953472 to the side of the front cover 1 and rear 2 crankshaft bearing cap on both the left and right sides four locations total 8 6 Oil Pump 8 6 1 Drive Replacement Removal Procedure 2 Install the new oil pan gasket 404 into the oil pan groove 134 Section 8 Lubrication System TP 6105 8 05 1 Remove the intake manifold Refer to Section 10 1 1 Intake Manifold Replacement 2 Remove the oil pump drive bolt 3 Remove the oil pump drive 4 Clean and inspect the oil pump drive Refer to Section 8 6 8 Oil Pump Drive Cleaning and Inspection Installation Procedure 1 Apply grease to the oil pump drive gear for ease of assembly Important Correct alignment of the oil pump drive and oil pump driveshaft is critical Make sure both components mate correctly or engine damage may occur 2 Line up the oil pump drive making sure that the oil pump is fully seated in the engine block Notice Refer to Fastener Notice in Cautions and Notices 3 Install the oil pump making sure that the oil pump drive is fully seated in the engine block Tighten the bolt to 25 Nm 18 ft Ib 4 Install the intake manifold Ref
71. PUMP At cenis x ha parte bhai ca m iG Oia EU pe dame Owens 144 9 2 1 Removal sanesa wes val Eu te xr eo Widder adeps dan bre di 144 9 2 2 Cleaning and Inspection 000 lesse esses 144 9 2 8 Installatioti ise carita or 145 9 3 Water Crossover pe amari e E he 145 9 8 1 Hemoval oi een mes ubi PE ba eee 145 9 3 2 Cleaning and Inspection sslieeesesseeessenn 146 9 3 3 Iristallationi lt lt lt e pr ne eee T 146 Section 10 Air Intake and Exhaust System oooccccccocccnn nn n nnn 149 10 1 Intake Manifold rica a E LE date tad 149 10 1 1 Replacement occi mr as A eae o ei 149 10 1 2 Benmoval over Pa 154 10 1 3 Disassemble ni en eapi nien beo ex VERRE RXERE IER RE QE REIR ES 155 10 1 4 Cleaning and Inspection 00 eee eee 156 105125 Assemble xa za tbc Rede e eti d e Ede S da belt eee 157 10 1 6 Installation ieu oo ERE RECO Pema ERE Ra e ind 158 10 2 Exhaust Manifold srini eeta ED eode te Pe ater clans 160 10 21 Removal Left us ticked a deba Eden b eek cds ata 160 10 2 2 Cleaning and Inspection ooooooccccccccccc eese 161 10 2 3 Installation Left o oooooocoocooonooo o 162 10 2 4 Removal Right ers p oaeee ta nE Bima noie sns 163 10 2 5 Installation Right ceert cee 163 Section 11 Special Tools and EquipMent o oocccccccccnn nnn nnn 165 6 Table of Contents TP 6105 8 05 This service manual provides the service technician with information to ser
72. Service Engine Engine Model General Motors 8 1 L Powertrain Generator Set Models 80 125 kW TP 6105 8 05b CAUTION Caution To reduce the chance of personal injury and or property damage carefully observe the instructions that follow The service manual of General Motors Powertrain is intended for use by professional qualified technicians Attempting repairs or service without the appropriate training tools and equipment could cause injury to you or others damage the equipment or cause the equipment to operate improperly Proper equipment and repair are important to the safety of the service technician and to the safe reliable operation of the equipment If you need to replace a part use the same part number or an equivalent part Do not use a replacement part of lesser quality The service procedures recommended and described in this service manual are effective methods of performing service and repair Some of the procedures require the use of tools that are designed for specific purposes Accordingly any person who intends to use a replacement part a service procedure or atool thatis not recommended by General Motors Powertrain must first establish that there is no jeopardy to personal safety or the safe operation of the equipment This manual contains various Cautions and Notices that must be observed carefully to reduce the risk of personal injury during service or repair Improper service or repair may damage the
73. Tighten the center screw of J 38416 B until the crankshaft balancer is clear of the crankshaft nose 1 Remove the fan 2 Remove the starter motor Notice Refer to Fastener Notice in Cautions and Notices Important Ensure that the teeth of the flywheel holding tool engage the engine flywheel teeth 3 Install J 42847 to the starter bolt holes Tighten J 42847 bolts to 50 Nm 37 ft Ib 8 Remove the crankshaft balancer 4 Remove the crankshaft balancer bolt and washer 9 Remove J 42846 from the end of the crankshaft TP 6105 8 05 Section 6 Crankshaft Main Bearings and Flywheel 95 Installation Procedure Important Position the balancer onto the end of the crankshaft as straight as possible prior to tool installation Apply grease or clean engine oil to the inside of the crankshaft balancer or the end of the crankshaft to prevent galling during assembly 1 Install the balancer onto the end of the crankshaft 2 Install J 42845 to the crankshaft balancer Important Apply the lubricant that comes with J 42845 each time the tool is used Failure to lubricate J 42845 may prevent the balancer from installing completely 3 Using J 42845 install the balancer 4 Tighten J 42845 until the crankshaft balancer is completely seated against the crankshaft sprocket 5 Remove J 42845 from the crankshaft Notice Refer to Fastener Notice in Cautions and Notices 96 Section 6 Crankshaft Main Bearings
74. ace 4 for damage The purge solenoid bolt has a sealer that may Notice Refer to Fastener Notice in Cautions and come off during removal of the bolt Ensure all Notices sealant is removed from the bolt hole Intake manifold to cylinder head sealing surfaces 3 for damage Throttle body studs 5 for damage Replace as necessary e Throttle body mounting surface 6 for damage e Oil fill tube hole 7 for signs of leakage Reseal as necessary e POV port 8 for debris or varnish buildup 4 Install the EVAP valve bolt Tighten the bolt to 8 Nm 71 in Ib 5 Install the EVAP tube Important Lubricate the port of the MAP sensor with clean engine oil Avoid dipping the sensor port directly into the lubricant or using a solid type of lubricant as it may block the vacuum port signal 6 Install the MAP sensor 7 Install the MAP sensor bolt Tighten the MAP sensor bolt to 12 Nm 106 in Ib 1 Apply a very light film of clean engine oil to the EVAP valve O ring seal TP 6105 8 05 Section 10 Air Intake and Exhaust System 157 8 Lubricate the O ring seal 415 of the oil fill tube 10 1 6 Installation with clean engine oil 9 Install the oil fill tube 416 10 Install the oil fill tube bolt 419 Tighten the oil fill tube bolt to 12 Nm 106 in Ib 11 Install the oil fill cap 418 1 Install the splash shield 12 Install the throttle body gasket 501 13 Install the throttle
75. ace the cylinder head gasket Failure to replace the cylinder head gasket can lead to cylinder head bolt breakage or cylinder head gasket failure A broken cylinder head bolt or failed cylinder head gasket can lead to extensive engine damage 78 Section 4 Cylinder Head and Valves Notice Follow the cylinder head bolt tightening sequence The final angle tightening sequence of the cylinder head bolts varies depending on the length of the cylinder head bolt Failure to angle tighten the specific length bolt the proper number of degrees can lead to cylinder head bolt failure or improper clamping load of the cylinder head gasket Cylinder head bolt or cylinder head gasket failure can lead to extensive engine damage Important The long bolts are used in locations 1 2 3 6 7 8 9 10 11 14 16 and 17 The medium length bolts are used in locations 15 and 18 The short bolts are used in locations 4 5 12 and 13 Install the cylinder head bolts Tighten a Tighten the bolts a first pass in sequence to 30 Nm 22 ft Ib b Retighten the bolts a second pass in sequence to 30 Nm 22 ft Ib then an additional 120 using J 45059 c Tighten the bolts a final pass in sequence using J 45059 as listed Bolt Tighten 1 2 3 6 7 8 9 10 11 14 16 17 Additional 60 15 18 Additional 45 4 5 12 18 Additional 30 TP 6105 8 05 Section 5 Engine Block Pistons and Connecting Rods 5 1 Piston Co
76. aces TP 6105 8 05 3 With the crankshaft pushed forward zero the dial Notice Refer to Fastener Notice in Cautions and indicator Move the crankshaft rearward and read Notices the endplay measurement on the dial indicator An optional method is to insert a feeler gauge between 1 Install the engine flywheel bolts the crankshaft and the bearing surface and measure the clearance Refer to Section 1 2 a Tighten bolts a first pass to 40 Nm 30 ft Ib EID Mechaligal specs b Tighten bolts a second pass to 80Nm 4 If the correct end play cannot be obtained inspect 59 ft Ib the crankshaft thrust wall surface or surfaces for wear and or excessive runout c Tighten bolts a final pass to 100 Nm 74 ft Ib 5 Inspect the crankshaft for binding Turn the crankshaft to check for binding If the crankshaft does not turn freely loosen the crankshaft bearing bolts and studs one cap at a time until the tight bearing is located The following condition or conditions could cause a lack of clearance at the bearing e Burrs on the crankshaft bearing cap e Foreign matter between the crankshaft bearing and the block or the crankshaft bearing cap e A faulty crankshaft bearing 6 6 Engine Flywheel 6 6 2 Removal 6 6 1 Replacement Removal Procedure 1 Remove the engine flywheel bolts 2 Remove the engine flywheel 3 Clean and inspect the engine flywheel Refer to Section 6 6 3 Engine Flywheel Cleaning and I
77. al may be an internal engine noise Remove the drive belt s and operate the engine for a few seconds to verify if the squealing noise is related to the drive belt s or an accessory drive component With the drive belt s removed the water pump will not operate and the engine may overheat Also DTCs may set when the engine is operated with the drive belt s removed See item 3 in following table 3 This test is to verify that an accessory drive component s does not have a seized bearing With the belt s removed test the bearings in the accessory drive component s for smooth operation Also test the accessory drive component s with the engine operating by varying the load on the accessory drive component s to verify that the component s is operating properly See item 4 in following table 40 Section 3 Diagnostic Information and Procedures 4 This test is to verify that the drive belt s tensioner s is operating properly If the drive belt s tensioner s is not operating properly proper belt tension may not be achieved to keep the drive belt s from slipping causing a squeal noise See item 5 in following table This test is to verify that the drive belt s is not too long which would prevent the drive belt s tensioner s from operating properly Also if the incorrect length drive belt s was installed it may not be routed correctly and may be turning an accessory drive component in the incorrect direction See item
78. allation ia deer de Robey pb IG 131 8 5 SOW PAN ME TP ota ro ie o Mae tid A ets 131 8 5 1 Replacement oosid tiii gated ad o Sak ees Ga eee 131 8 5 2 NA O epatis t ed disons 133 8 5 8 Cleaning and Inspection sslsieeeeseeesseerne 134 8 5 4 Installation ee AA AA 134 8 6 OIL Pumpe iere Mitton bas sh eoe bios ete code bl o 134 8 6 1 Drive Replacement 00 cece eee eee teens 134 8 6 2 Replacement ss dips bee pant cin deeded dad bap POs T TET eed 135 8 6 3 Drive Removal os cake lieet bh Rr Ee nk ERROR Romae E oe cs 136 8 6 4 Oil Pump Pump Screen and Deflector Removal 196 8 6 5 Disassemble uk ide ERR RES Renee eibi his 137 8 6 6 Cleaning and Inspection 000 esses 137 80 77 Assemble coa ba Pe eb et bad het dae EH dees ds 138 8 6 8 Drive Cleaning and Inspection 00 e ee eee eee 139 8 6 9 Oil Pump Pump Screen and Deflector Installation 139 8 6 10 Drive Installation 0 teens 140 8 7 Engine Oil Pressure Sensor and or Switch Replacement 140 8 8 Engine Oil Level Sensor and or Switch Replacement 000 eee 141 Section 9 Cooling System and Drive Belts sseeseeeeeeee nnn 143 OFA Drive Belt ridad ia PIT 143 9 1 1 Replacement Accessory 0 eect ees 143 9 1 2 Tensioner Replacement Accessory uu aaaeeeaa 143 9 1 3 Idler Pulley Replacement 00 cece eee eee ees 143 9 2 Water
79. alve lifter guide retainer bolts to 25 Nm 18 ft Ib 4 7 Cylinder Head 4 7 1 Tools Required J 45059 Angle Meter Replacement Left Removal Procedure 1 Remove the intake manifold Refer to Section 10 1 1 Intake Manifold Replacement 2 Remove the water crossover Refer to Section 9 3 Water Crossover 3 Remove the valve rocker arms and push rods Refer to Section 4 2 1 Valve Rocker Arm and Push Rod Replacement 4 Remove the engine harness ground bolts 5 Reposition the engine harness grounds 1 and 5 and ground strap 4 from the cylinder head M A LC SERE ote a ot PRU aa we i SES 6 Remove the exhaust manifold Refer to Section 10 2 Exhaust Manifold Section 4 Cylinder Head and Valves 65 7 Remove and discard the cylinder head bolts 1 2 and 3 Important Place the cylinder head on two wood blocks to prevent damage to the sealing surfaces 9 Remove and discard the cylinder head gasket 10 Clean and inspect the cylinder head Refer to Section 4 7 4 Cylinder Head Cleaning and Inspection 66 Section 4 Cylinder Head and Valves Installation Procedure Important Make sure the threaded holes in the engine block are clean and not damaged Do not use sealer on any engines that use a composition type gasket Align the cylinder head gasket locating marks to face up Ensure that the head gasket tabs are located over the numbers 1 and 2 cylinders for correct installat
80. alve lifter guides for the following 4 6 3 Valve Lifters and Guides Cleaning and Inspection Caution Refer to Safety Glasses Caution in Cautions and Notices Important Sort or organize parts that are to be reused to return them to their original location 1 Dry the components with compressed air 2 Inspect the valve lifters for the following e A damaged mispositioned or broken clip 1 e A scored or worn push rod socket 2 64 Section 4 Cylinder Head and Valves TP 6105 8 05 5 Inspect the valve lifter guide retainer for the following e Wear damage or stress cracking in the leg areas e Wear or damage around the retainer bolt holes 4 6 4 Installation Important If a new camshaftis installed replace all the valve lifters 1 Coat the valve lifter rollers with clean engine oil Important If reusing the valve lifters install in their original location The valve lifter guide retainer must contact all of the valve lifter guides If the valve lifter guide retainer is bent replace the valve lifter guide retainer 2 Install the valve lifters 3 Install the valve lifter guides over the flats on the valve lifters making sure the rollers of the valve lifters are properly aligned with the camshaft lobes 4 Install the valve lifter guide retainer Notice Refer to Fastener Notice in Cautions and Notices TP 6105 8 05 5 Install the valve lifter guide retainer bolts Tighten the v
81. alves located in the engine block above the oil filter the oil filter bypass valve 4 and the oil cooler bypass valve 3 If the oil filter becomes plugged pressurized oil is diverted around the top of oil filter The oil filter bypass valve 1 is forced open allowing the oil to continue on to the oil cooler and engine oil passages No oil filtration occurs because the oil is not allowed into the oil filter If the oil cooler flow becomes blocked either from a plugged oil cooler or blocked or kinked oil cooler line the oil cooler bypass valve 1 is forced open allowing oil to flow directly into the engine oil passages Cil does not flow into or out of the engine oil cooler If both the oil filter and the oil cooler are plugged the pressurized oil is routed around the top of the oil filter through the oil filter bypass valve 2 through the oil cooler bypass valve 1 and directly into the engine oil passages Lubrication still occurs but the oil is not filtered or directed through the oil cooler TP 6105 8 05 2 5 Cleanliness and Care e Throughout this section it should be understood that proper cleaning and protection of machined surfaces and friction areas is part of the repair procedure This is considered standard shop practice even if not specifically stated e When any internal engine parts are serviced care and cleanliness is important e When components are removed for service they should be marke
82. and cap 2 and bolts 1 Refer to Section 1 1 Fastener Tightening Specs 5 1 6 Piston and Connecting Rod Assemble Notice Use a piston ring expander to install the piston rings The rings may be damaged if expanded more than necessary TP 6105 8 05 Section 5 Engine Block Pistons and Connecting Rods 83 1 Install the lower oil control piston ring spacer onto the piston 2 Install the lower oil control piston ring onto the piston 1 3 Install the upper oil control piston ring onto the piston 1 AA 4 Space the oil control piston ring end gaps a minimum of 90 apart 1 2 3 5 Install the lower compression piston ring onto the piston 1 The mark on the side of the piston ring should face the top of the piston 84 Section 5 Engine Block Pistons and Connecting Rods 6 Install the upper compression piston ring onto the piston The mark 1 on the side of the piston ring should face the top of the piston 7 Space the compression piston ring end gaps 120 apart 5 1 7 Cylinder Boring and Honing Boring Procedure Important The coating on the piston allows for an interference fit between the cylinder and the bore The piston diameter cannot be measured accurately because the piston coating is nota consistent thickness Do not measure the piston diameter To select the correct piston for installation measure the cylinder bore If the cylinder bore diameter is within service specifications
83. anifold 11 Remove the splash shield by prying under the gasket surface with any tool 8 Remove the intake manifold 10 1 3 Disassemble 1 Remove the vacuum plug 513 TP 6105 8 05 Section 10 Air Intake and Exhaust System 155 2 Remove the throttle body nuts 503 10 Remove the EVAP tube 3 Remove the throttle body 502 and gasket 501 4 Discard the gasket 5 Remove the throttle body studs 504 if required 6 Remove the oil fill cap 418 7 Remove the oil fill tube 416 and bolt 419 12 Inspect the O ring seal for damage Replace as needed 8 Remove the MAP sensor bolt and MAP sensor 10 1 4 Cleaning and Inspection 9 Inspect the MAP sensor grommet for damage Important Do not reuse the lower intake manifold gaskets or end seals 1 Clean the intake manifold in an approved solvent e Clean debris out of all bolt holes Clean the intake manifold gasket sealing surfaces e Clean all intake manifold ports Caution Refer to Safety Glasses Caution in Cautions and Notices 2 Dry the intake manifold with compressed air 156 Section 10 Air Intake and Exhaust System TP 6105 8 05 3 Inspect the following 2 Install the EVAP valve e ee manifold bolt holes 1 for cracks and or 3 Apply thread sealer GM Part No U S 12345493 amage Canadian 10953488 or equivalent to the threads e MAP sensor sealing surface 2 for damage of the purge solenoid bolt e Purge solenoid sealing surf
84. ated replace the a Tighten the water pump bolts a first pass to 25 Nm 18 ft Ib water pump The shaft and fan hub must turn b Tighten the water pump bolts a final pass to straight and smoothly 50 Nm 37 ft Ib e Damage to threaded bolt holes 4 e Damage to the fan clutch mounting threads 5 4 Install the water pump pulley 303 and bolts 302 5 Use J 41240 to retain the water pump pulley Tighten the water pump pulley bolts to 25 Nm 18 ft Ib 9 2 3 Installation Tools Required J 41240 Fan Clutch Remover and Installer 9 3 Water Crossover 9 3 1 Removal 1 Install the water pump and gaskets 1 Remove the drive belt tensioner bolts Notice Refer to Fastener Notice in Cautions and Notices TP 6105 8 05 Section 9 Cooling System and Drive Belts 145 2 Remove the drive belt tensioner 9 3 2 Cleaning and Inspection Cleaning Procedure 1 Clean the water crossover 308 and thermostat housing 311 in solvent Caution Refer to Safety Glasses Caution in Cautions and Notices 2 Dry the components with compressed air Inspection Procedure 1 Inspectthe water crossover 308 for the following e Corrosion or damage to the gasket sealing surfaces e Corrosion or damage to the bypass hose fitting e Corrosion or damage to the heater hose fitting 4 Remove the coolant crossover bolts e Corrosion or damage to the threads of the water outlet 5 Remove the coolant crossov
85. ations of drive belt rumbling 2 This test is to verify that the drive belt s is causing the rumbling Rumbling may be confused with an internal engine noise due to the similarity in the description Remove only one drive belt at a time if engine has multiple drive belts Operate engine for a few seconds as this will verify if the rumbling noise is related to the drive belt s With drive belt s removed the water pump will not operate and engine may overheat Also DTCs may set when the engine is operated with the drive belt s removed See item 3 of following table 3 Inspect the drive belt s to ensure that the drive belt s is not the cause of the noise Small cracks across the ribs of the drive belt s will not cause the noise Belt separation is identified by the plies of the belt separating seen at the edge of the belt or felt as a lump in the belt See item 4 of following table 4 Small amounts of pilling is a normal condition and acceptable When the pilling is severe the drive belt s does not have a smooth surface for proper operation See item 5 of following table e A low pitch tapping knocking or thumping noise heard at or just above idle e Heard once per revolution of the drive belt s or pulley s e Rumbling may be caused from e Pilling the accumulation of rubber dust that forms small balls pills or strings in the drive belt s pulley groove e Separation of the drive belt s e Damaged drive belt s
86. auge 9 Ifthe side clearance is too small try another piston ring set Refer to Section 1 2 Engine Mechanical Specs e Cracks in the piston ring lands the piston skirt or the pin bosses 10 If the proper piston ring to piston ring groove e Piston ring grooves for nicks burrs or other clearance cannot be achieved replace the piston warpage that may cause the piston ring to bind and pin assembly 6 Inspect the piston pin for scoring wear or other damage 11 Inspect the connecting rod for an out of round bearing bore 7 Measure the piston ring to piston ring groove side clearance Refer to Section 1 2 Engine Mechanical Specs a Insert the edge of the piston ring into the piston ring groove Roll the piston ring completely around the piston b If binding is caused by a distorted piston ring groove minor imperfections may be removed with a fine file c If binding is caused by a distorted piston ring replace the piston ring TP 6105 8 05 Section 5 Engine Block Pistons and Connecting Rods 81 12 Inspect the connecting rod for twisting 13 Inspect the connecting rod for damage to the connecting rod bolt threads Important Fit each compression ring to the cylinder in which it will be used 14 Measure the piston compression ring end gap a Place the compression ring into the cylinder bore b Push the compression ring into the cylinder bore to approximately 6 5 mm 0 25 in above
87. ay be reused if not removed from the valve rocker arm cover Replace the valve rocker arm cover gasket if cut or damaged Clean and inspect the valve rocker arm cover Refer to Section 4 1 3 Valve Rocker Arm Cover Cleaning and Inspection Installation Procedure Notice Refer to Fastener Notice in Cautions and Notices 3 Tighten the valve rocker arm cover bolts in sequence using two passes as shown a Tighten the bolts a first pass to 6 Nm 53 in Ib b Tighten the bolts a final pass to 12 Nm 106 in Ib 4 Install the spark plug wires to the ignition coils 5 Connect the ECT sensor electrical connector 3 1 2 Install a new valve rocker arm cover gasket if necessary Install the valve rocker arm cover TP 6105 8 05 6 Connect the ignition coil harness electrical connector 2 Section 4 Cylinder Head and Valves 53 7 Install the CPA retainer to the ignition coil electrical 4 1 7 Installation Right connector 2 8 Install the air cleaner outlet duct 1 Install a new valve rocker arm cover gasket if the gasket was removed from the valve rocker arm 9 Tighten the clamps at the throttle body and air cover cleaner Tighten the clamps to 4 Nm 35 in Ib 2 Install the valve rocker arm cover 4 1 Remowval Right i j peg 3 Install the valve rocker arm cover bolts Notice Refer to Fastener Notice in Cautions and Notices 4 Tighten the valve rocker arm
88. ay be noticeable on the end of the sensor 1 Remove the crankshaft position sensor bolt 2 Apply penetrating oil to the crankshaft position sensor to engine block mating surface Allow the penetrating oil to soak for several minutes to help loosen the O ring from the engine block Section 6 Crankshaft Main Bearings and Flywheel 101 3 Twist the sensor to loosen the O ring seal When removing the sensor pull the sensor straight out of the engine block at the same angle the sensor was installed 4 Inspect both crankshaft position sensor O ring for cuts cracks tears or damage Replace the O ring as needed Important Crankshaft bearing caps are machined with the engine block for the proper clearances Mark or identify each crankshaft bearing cap location and direction before removal Reinstall crankshaft bearing caps in their original locations 5 Remove the crankshaft bearing cap bolts and studs 6 Remove the crankshaft bearing caps 7 Remove the crankshaft lower bearings from the crankshaft bearing caps Important Care should be taken when removing the crankshaft so that the crankshaft position sensor reluctor ring is not damaged 102 Section 6 Crankshaft Main Bearings and Flywheel 9 Remove the crankshaft upper bearings from the engine block 6 3 2 Cleaning and Inspection Tools Required J 7872 Magnetic Base Dial Indicator J 43690 Rod Bearing Clearance Checking Tool J 43690 100 Rod Bearin
89. ay require lubrication during assembly e Components requiring lubrication will be identified in the service procedure e Apply only the amount of sealant specified in the Service procedure to a component e Do not allow the sealant to enter into any blind threaded holes as the sealant may prevent the fastener from clamping properly or cause component damage when tightened Important Do not overtighten the fasteners e Tighten the fasteners to the proper specifications 2 8 RTV and Anaerobic Sealer Use 2 8 4 Sealant Types Important Use the correct sealant and amount of sealant in the proper location to prevent oil leaks coolant leaks or loosening of the fasteners Do not interchange the sealants Use only the sealant or equivalent as specified in the service procedure The following two major types of sealant are commonly used in engines e Aerobic sealant Room Temperature Vulcanizing RTV e Anaerobic sealant which include the following e Gasket eliminator e Pipe e Thread lock TP 6105 8 05 2 8 2 Aerobic Type Room Temperature Vulcanizing Sealant Aerobic type RTV sealant cures when exposed to air This type of sealant is used where two components such as the intake manifold and the engine block are assembled together Use the following information when using RTV sealant e Do not use RTV sealant in areas where extreme temperatures are expected These areas include e The exhaust manifold e The
90. bearing surface Important An improperly aligned camshaft bearing oil gallery hole will restrict oil flow to the bearing and the camshaft journal 3 Drive the end bearings into the bore 4 Selectthe expanding driver 4 8 and washer 2 or Ensure the correct camshaft bearing fits into the proper 3 from J 33049 bore The camshaft bearing bores may vary in size Ensure that the camshaft bearing lubrication hole or holes align with the oil gallery hole or holes in the block On some engines the oil holes may be difficult to locate Verify that the holes are aligned 1 Assemble the tool handle 10 expanding driver 4 8 and washer 2 or 3 5 Assemble the tool 6 Insert J 33049 tool through the front of the engine block and to the inner bearing bores 2 Insert J 33049 tool into the engine block end camshaft bearings 124 Section 7 Camshaft and Timing Gear Train TP 6105 8 05 7 Install the bearing onto the expanding driver 8 10 11 Tighten the expander assembly nut until the tool is snug in the bearing Important The camshaft bearing oil holes must align with the oil galleries in the engine block After installation of the camshaft bearings inspect the camshaft bearing oil holes for proper alignment with the oil galleries An improperly aligned camshaft bearing oil gallery hole will restrict oil flow to the bearing and the camshaft journal Align the oil lubrication hole in the b
91. bent fan shaft or bent mounting flange See item 8 in following table Inspect the water pump drive shaft for being bent Also inspect the water pump bearings for smooth operation and excessive play Compare the water pump with a known good water pump See item 9 in following table Accessory drive component brackets that are bent cracked or loose may put an extra strain on that accessory drive component causing it to vibrate See item 10 in following table TP 6105 8 05 Notice See Belt Dressing Notice in Cautions and Notices Definition The following items are indications of drive belt vibration e Vibration is engine speed related e The vibration may be sensitive to accessory load perform the necessary inspections Did you review Section 3 2 Symptoms Engine Mechanical for diagnostic information and Go to Step 2 Go to Section 3 2 Symptoms Engine Mechanical Verify that the vibration is engine related Does the engine make the vibration Go to Step 3 Go to Diagnostic Aids 1 Remove the drive belt s See Section 9 1 1 Drive Belt Replacement Accessory 2 Operate the engine for no longer than 30 40 seconds Does the engine still make the vibration Go to Section 3 8 Engine Noise on Startup But Only Lasting a Few Seconds Go to Step 4 Inspect the drive belt s for wear damage debris buildup and missing belt ribs Was any of these conditions found Go to Step 5 Go
92. bolt hole is clean of any debris before installing the crankshaft sensor bolt Inspect both crankshaft position sensor O rings for cuts cracks tears or damage Replace the O rings as needed Lubricate the crankshaft position sensor O rings with clean engine oil Install the crankshaft position sensor into the block There may be a slight resistance as the O rings seat into the engine block Apply thread adhesive GM Part No U S 12345493 Canadian 10953488 or equivalent to the crankshaft position sensor bolt Install the crankshaft position sensor bolt Tighten the crankshaft position sensor bolt to 12 Nm 106 in Ib 6 4 Crankshaft and Connecting Rod Bearing 6 4 1 Inspection Important Inspect the crankshaft and connecting rod bearings only to determine what kind of damage or failure has occurred Always install new bearings after the bearings have been removed 1 Inspect the bearings for craters Flattened sections on the bearing indicate fatigue or pockets halves also TP 6105 8 05 2 Inspect the bearings for excessive scoring or discoloration 3 Inspect the bearings for dirt or debris embedded into the bearing material 4 Inspectthe bearings for improper seating indicated by bright polished sections of the bearings 6 4 2 Clearance Measurement The crankshaft and connecting rod bearings are of the precision insert type and do not use shims for adjustment Replace crankshafts with jour
93. boot only Do not pull on the spark plug wire or the wire could be damaged 1 Remove the spark plug wires from the spark plugs and ignition coils TP 6105 8 05 2 Removethe exhaust manifold heat shield bolts and 8 Remove the exhaust manifold studs if required nuts 10 2 2 Cleaning and Inspection 3 Remove the exhaust manifold heat shield 1 Clean the exhaust manifolds in solvent 4 Remove the exhaust manifold nuts and center bolt Caution Refer to Safety Glasses Caution in R h haust ifold gt Remove iioexhalshinaniiald Cautions and Notices ifol ket A A NI RRRS 2 Dry the components with compressed air 3 Inspect the exhaust manifolds for the following e Damage to the gasket sealing surfaces e Damage to the exhaust manifold studs e Broken or damaged heat shields e Cracks in the exhaust manifold e Restrictions within the exhaust passages 4 Measure the alignment or surface flatness of the exhaust manifold flanges using a straight edge and a feeler gauge Exhaust manifold surface flatness must not exceed 0 254 mm 0 01 in 5 If the surface flatness is not within specifications the exhaust manifold is warped and must be replaced TP 6105 8 05 Section 10 Air Intake and Exhaust System 161 10 2 3 Installation Left Notice Refer to Fastener Notice in Cautions and Notices 1 Install the exhaust manifold studs into the cylinder head if necessary Tighten the exhaust mani
94. c ccc ccc RR es 67 4 7 3 Disassemble ian adie enna RR Y DR Ren RR weg tip ka TR dida nc 68 4 7 4 Cleaning and Inspection 000 cece cece eens 69 4 7 5 Assemble siccus hee ERE de Pe dee veh 70 4 7 6 Installation Left eanes yearn ena aa RR RRRRRRRRRR 3 73 4 7 7 Replacement Right 0 00 cece 74 4 7 8 Removal Right cede ee packet edes ed abad 77 4 7 9 Installation Right n a A e a a a E A 77 4 Table of Contents TP 6105 8 05 Table of Contents continued Section 5 Engine Block Pistons and Connecting Rods useeeeeeeeeeeeeee 79 5 1 Piston Connecting Rod and Bearing oooooocccononco nor 79 5 1 1 ROMOVA x aiuti esas enda reta obice es 79 5 1 2 Piston and Connecting Rod Disassemble uuuuuuuse 80 5 13 Cleaning and Inspection 0 0 0 cece eee 80 5 1 4 Connecting Rod Side Clearance Measurement ss 82 5 1 5 Connecting Rod Bearing Clearance Measurement Using J 43690 J 43690 100 eens 82 5 1 6 Piston and Connecting Rod Assemble lseueuse 83 5 1 7 Cylinder Boring and Honing 0 cece nnn 84 5 1 8 Installation rer REDEEM ta 85 5 2 sEngine Block xi a ELA E RNC 87 5 2 1 Plug Removal uir A eu he a e 87 5 2 2 Cleaning and Inspection 000 cece cee eee eens 90 5 2 3 Plug Installation i c debe cl e ra iaa 91 Section 6 Crankshaft Main Bearings and Flywheel
95. code may be present without an actual misfire condition Replace the drive belt See Section 9 1 1 Drive Belt Replacement Accessory Worn damaged or misaligned accessory drive components or excessive pulley runout A misfire code may be present without an actual misfire condition Inspect the components repair or replace as required Loose or improperly installed engine flywheel or crankshaft balancer A misfire code may be present without an actual misfire condition Repair or replace the flywheel and or balancer as required See Section 6 6 1 Engine Flywheel Replacement or Section 6 1 1 Crankshaft Balancer Replacement Worn piston rings Oil consumption may or may not cause the engine to misfire e Inspect the spark plugs for oil deposits See Spark Plug Inspection in Engine Controls e Inspect the cylinders for a loss of compression See Section 3 15 Engine Compression Test Perform cylinder leakdown and compression testing to identify the cause See Section 3 16 Oylinder Leakage Test Repair or replace as required Worn crankshaft thrust bearings Severely worn thrust surfaces on the crankshaft and or thrust bearing may permit fore and aft movement of the crankshaft and create a DTC without an actual misfire condition 3 5 Worn or loose rocker arms Check the crankshaft endplay Replace the crankshaft and or bearings as required Base Engine Misfire With Abnormal Valve Train Noise
96. ct the drive belt s for signed of rubbing against a bracket hose or wiring harness Go to CIAO Diagnostic Aids Did you complete the replacement Replace the drive belt s See Section 9 1 2 Drive Belt Tensioner Replacement Accessory Go to Step 6 Run the engine to verify the repair Is there still excessive drive belt wear 3 28 Drive Belt Tensioner Diagnosis Notice Allowing the drive belt tensioner to snap into the free position may result in damage to the tensioner 1 Remove the drive belt s Refer to Section 9 1 1 Drive Belt Replacement Accessory 2 Position a hex head socket on the belt tensioner pulley bolt head 48 Section 3 Diagnostic Information and Procedures Go to Step 1 System OK 3 Move the drive belt tensioner through its full travel e The movement should feel smooth e There should be no binding e The tensioner should return freely 4 If any binding is observed replace the drive belt tensioner s Refer to Section 9 1 2 Drive Belt Tensioner Replacement Accessory 5 Install the drive belt s Refer to Section 9 1 1 Drive Belt Replacement Accessory TP 6105 8 05 Section 4 Cylinder Head and Valves 4 1 Valve Rocker Arm Cover 4 Remove the valve rocker arm cover bolts 5 Remove the valve rocker arm cover 4 1 1 Replacement Left Important Valve rocker arm cover gaskets are Removal Procedure reusable Replace the gasket only if damaged 1 Remove the connec
97. cturer s recommendations for equipment use cleaning and lubrication e Use only clean sharp stones of the proper grade for the amount of material you remove Dull dirty stones cut unevenly and generate excessive heat Do not hone to a final grade with a coarse or medium grade stone Leave sufficient metal so that all stone marks may be removed with fine grade stones The rehoned surface finish should be 0 25 0 50 micrometer 10 20 microinch e Perform final honing with a fine grade stone and hone the cylinder in a cross hatch pattern at 20 30 to obtain the proper clearance 2 During the honing operation thoroughly clean the cylinder bore TP 6105 8 05 e Repeatedly check the cylinder bore for fit with the selected oversized piston e All measurements of the cylinder bore should be made with the components at normal room temperature 3 To eliminate taper in the cylinder when honing make full strokes of the hone in the cylinder Repeatedly check the measurement at the top the middle and the bottom of the bore e The finish marks should be clean but not sharp e The finish marks should be free from embedded particles and torn or folded metal 4 When finished the reconditioned cylinder bores should have less than or meet the specified out of round or taper requirements 5 After final honing and before the piston is checked for fit clean the bores with hot water and detergent a Scrub th
98. d organized or retained in a specific order for reassembly e At the time of installation components should be installed in the same location and with the same mating surface as when removed e An engine is a combination of many machined honed polished and lapped surfaces with tolerances that are measured in millimeters or thousandths of an inch These surfaces should be covered or protected to avoid component damage e Aliberal coating of clean engine oil should be applied to friction areas during assembly e Proper lubrication will protect and lubricate friction surfaces during initial operation 2 6 Separating Parts Important Many internal engine components will develop specific wear patterns on their friction surfaces When disassembling the engine separate mark or organize internal components in a way to ensure reinstallation to original location and position Section 2 Description and Operation 21 Separate mark or organize the following components Piston to the specific cylinder bore Piston rings to the piston Connecting rod to the crankshaft journal Connecting rod to the bearing cap Crankshaft and connecting rod bearings Camshaft and valve lifters Valve lifters guides push rods pivot supports and rocker arms e Valve to the valve guide e Valve spring and shim to the cylinder head location e Engine block crankshaft bearing cap location and direction e Oil pump drive and driven gears 2 7 En
99. d Seat Grinding AL DET fe f t E E E k E Lj k s f 3 FE TP 6105 8 05 3 Replace the cylinder head if the valve guide cannot be repaired or reamed to accept an oversize valve stem 4 5 Valve Guide Reaming Valve and Seat Grinding Valve Guide Reaming Procedure for Oversized Valve Stems Notice The exhaust valve guides are replaceable components and must be serviced properly Press the exhaust valve guide out and into the cylinder head in the proper directions Remove the old exhaust valve guide by pressing out toward the combustion chamber side of the cylinder head Install the new exhaust valve guide by pressing from the combustion chamber side of the cylinder head Failure to press the exhaust valve guide out and into the cylinder head in the proper directions will damage the cylinder head 1 Ream the valve guide as necessary to achieve proper valve stem to guide clearance with the new oversized valve stems 2 Always recondition the valve seat after reaming the valve guide bores or installing new valves 3 Replace the cylinder head if the valve guide cannot be repaired or reamed to accept an oversize valve stem Section 4 Cylinder Head and Valves 61 Valve Reconditioning Procedure 1 Replace the valve if the valve stem shows excessive wear or is warped Important Several different types of equipment are available for reconditioning valves Use the manufacturer s reco
100. d or engine block porosity Replace the components as required Machine the cylinder head to the proper flatness if applicable and Warped cylinder head replace the cylinder head gasket See Section 4 7 4 Cylinder Head Cleaning and Inspection Defective external oil cooler Replace the components as required TP 6105 8 05 Section 3 Diagnostic Information and Procedures 33 3 14 Coolant in Engine Oil Definition Foamy or discolored oil or an engine oil overfill condition may indicate coolant in the engine crankcase Low coolant levels an inoperative cooling fan or a faulty thermostat may lead to an overtemperature condition that may cause engine component damage Contaminated engine oil and oil filter should be changed 1 Inspectthe oil for excessive foaming or an overfill condition Oil diluted by coolant may not properly lubricate the crankshaft bearings and may lead to component damage See Section 3 10 Lower Engine Noise Regardless of Engine Speed 2 Inspect by performing a cylinder leakdown test During this test excessive air bubbles within the coolant may indicate a faulty gasket or damaged component See Section 3 16 Cylinder Leakage Test 3 Inspect by performing a cylinder compression test Two cylinders side by side on the engine block with low compression may indicate a failed cylinder head gasket See Section 3 15 Engine Compression Test Faulty cylinder head gasket Replace the head gasket and
101. ds for following conditions e Damaged threads 1 e Excessive wear or damage made from contact between the rocker arm and rocker arm stud 2 Replace valve rocker arm studs with excessive wear and or damage Inspect the push rod guides for the following conditions e Wear between the push rod and the push rod guide 1 e Bent push rod guide 2 e Cracks Replace push rod guides with excessive wear and or damage le AN O 2 Section 4 Cylinder Head and Valves 57 4 2 4 Installation Important Keep the parts in order Parts must be put back from where they were removed 1 Apply sealer GM Part No U S 12346004 Canadian 10953480 or equivalent to the valve rocker arm stud to cylinder head threads Apply the sealer to a minimum of six threads Notice Refer to Fastener Notice in Cautions and Notices 2 Install the push rod guides and valve rocker arm studs onto the cylinder head Tighten the valve rocker arm studs to 50 Nm 37 ft Ib Important The 8 1 L engine uses different length intake and exhaust valve push rods The exhaust valve push rods 2 are longer than the intake valve push rods 1 3 Install the valve push rods 58 Section 4 Cylinder Head and Valves 4 Coatthe valve rocker arm and valve rocker arm ball bearing surfaces with clean engine oil 5 Install the valve rocker arms the valve rocker arm balls and the valve rocker arm nuts Tighten the valve
102. e Refer to Fastener Notice in Cautions and Notices 5 Install the valve lifter guide retainer bolts Tighten the valve lifter guide retainer bolts to 25 Nm 18 ft Ib 6 Install the valve rocker arms and push rods Refer to Section 4 2 1 Valve Rocker Arm and Push Rod Replacement Install the intake manifold Refer to Section 10 1 1 Intake Manifold Replacement 4 6 2 Tools Required J 3049 A Valve Lifter Remover Removal Important Mark sort or organize the valve lifters and guides for return to their original location during assembly Section 4 Cylinder Head and Valves 63 1 Remove the valve lifter guide retainer bolts and retainer A severely scuffed or worn lifter body 3 If the valve lifter body shows scuffing or wear inspect the engine block valve lifter bores for wear or 2 Remove the valve lifter guides damage e Flat spots on the roller 4 e A loose pin 5 e A plugged oil hole 6 Important Place the valve lifters in the organizer rack or tag them in a way to ensure they can be returned to the valve lifter bore from which they were removed 3 If flat spots are found on the lifter s inspect the corresponding lobe on the camshaft for damage 3 Remove the valve lifters 4 Some valve lifters may be stuck in their bore due to gum or varnish deposits These valve lifters can be removed using J 3049 A e Excessive guide slot side wear e Cracks or damage 4 Inspect the v
103. e applied to the drive belt by the accessory drive components and the crankshaft TP 6105 8 05 The drive belt system may have an idler pulley used to add wrap to the adjacent pulleys Some systems use an idler pulley in place of an accessory drive component when the engine is not equipped with the accessory 2 3 Engine Component Description 2 3 1 Cylinder Block The engine block is made of cast iron and has eight cylinders arranged in a V shape with four cylinders in each bank The engine block is a one piece casting with the cylinders encircled by coolant jackets 2 3 2 Cylinder Head The cylinder heads are made of cast iron and have parent metal intake valve guides and intake valve seats The cast iron exhaust valve guides and powdered metal valve seats are pressed into the exhaust ports A spark plug is located between the valves in the side of the cylinder head The water crossover pipe attaches to the front of each cylinder head 2 3 3 Camshaft A steel camshaft is supported by five bearings pressed into the engine block The camshaft sprocket is mounted to the front of the camshaft and is driven by the crankshaft sprocket through a camshaft timing chain Section 2 Description and Operation 19 Motion from the camshaft is transmitted to the valves by hydraulic roller valve lifters valve push rods and ball pivot type rocker arms A spiral gear machined into the camshaft near the rear journal drives a shaft assembly
104. e 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 Abrasive material may cause premature wear of new piston rings and cylinder bores Abrasive material will contaminate the engine oil and may cause premature wear of the bearings b After washing the cylinder bore dry the bore with a clean shop towel 6 Perform final measurements of the cylinder bore 7 Permanently mark the piston for the specific cylinder to which it has been fitted 8 Apply clean engine oil to each cylinder bore to prevent rusting 5 1 8 Installation Tools Required J 8037 Piston Ring Compressor J 8087 Cylinder Bore Gauge J 45059 Angle Meter Piston Selection Important The coating on the piston allows for an interference fit between the cylinder and the bore The piston diameter cannot be measured accurately because the piston coating is nota consistent thickness Do not measure the piston diameter Section 5 Engine Block Pistons and Connecting Rods 85 To select the correct piston for installation measure the cylinder bore If the cylinder bore diameter is within service specifications install the original piston connecting rod assembly or a new standard size piston connecting rod assembly A used piston connecting rod assembly may be reinstalled if after cleaning and inspection the piston is not damaged If the cylinder bore is not with
105. e crankshaft endplay Worn crankshaft thrust bearing Inspect the thrust bearing and crankshaft Repair or replace as required Inspect the oil filter bypass valve for proper operation Damaged or faulty oil filter bypass valve Repair or replace as required 30 Section 3 Diagnostic Information and Procedures TP 6105 8 05 3 9 Upper Engine Noise Regardless of Engine Speed Cause Correction Important A cold piston knock that disappears in 1 5 minutes should be considered acceptable A cold engine knock usually disappears when the specific cylinder s secondary ignition circuit is grounded out during diagnosis A light rattle tapping noise may indicate a valve train upper engine concern Plugged oil filter Replace the oil filter Low oil pressure e Verify proper oil level e Perform an oil pressure test See Section 3 18 Oil Pressure Diagnosis and Testing e Repair or replace as required Loose and or worn valve rocker arm attachments Inspect the valve rocker arm stud nut or bolt Repair or replace as required Worn valve rocker arm Replace the valve rocker arm Worn push rod guide plate Replace as required Bent or damaged push rod Inspect the following components and replace as required e Valve rocker arm e Valve push rod e Valve lifter Improper lubrication to the valve rocker arms Inspect the following components and replace as required e Valve r
106. e pipe sealant bead to the inside of any bolt hole areas e Apply a continuous bead of pipe sealant to one sealing surface e Tighten the fasteners in sequence if specified and to the proper torque specifications Do not overtighten the fasteners 2 9 Tools and Equipment Special tools are listed and illustrated throughout this section with a complete listing at the end of the manual These tools or their equivalents are specially designed to quickly and safely accomplish the operations for 24 Section 2 Description and Operation which they are intended The use of these special tools will also minimize possible damage to engine components Some precision measuring tools are required for inspection of certain critical components Torque wrenches and a torque angle meter are necessary for the proper tightening of various fasteners To properly service the engine assembly the following items should be readily available e Approved eye protection and safety gloves e Aclean well lit work area e A suitable parts cleaning tank e Acompressed air supply e Trays or storage containers to keep parts and fasteners organized e An adequate set of hand tools e Approved engine repair stand e Anapproved engine lifting device that will adequately support the weight of the components 2 10 Thread Repair Tools Required J 39345 Thread Repair Kit The following procedure is used to accomplish proper and durable thread repairs in the
107. e that chips are not blown into the engine 2 11 Service Prior to Assembly Dirt will cause premature wear of the rebuilt engine Clean all the components Use the proper tools to measure the components when checking for excessive wear Repair or replace components not within manufacturer s specification When the components are reinstalled into an engine return the components to their original location position and direction During assembly lubricate all the moving parts with clean engine oil unless otherwise specified This will provide initial lubrication when the engine is first started 2 12 Engine Prelubing Tools Required J 45299 Engine Preluber Important engine oil is required to properly prime the engine Be sure to use an approved engine oil as specified in the owners manual A constant and continuous flow of clean 1 Remove the engine oil filter fill with clean engine oil Notice Refer to Fastener Notice in Cautions and Notices 2 Install the oil filter 38 Nm 28 ft Ib Tighten the oil filter to Section 2 Description and Operation 25 3 Locate the oil gallery plug on the left side of the engine block above the oil filter housing 4 Install the 1 4 18 adapter Part No 509373 26 Section 2 Description and Operation Install the flexible hose to the adapter and open the valve Pump the handle on J 45299 to flow a minimum of 1 1 9 L 1 2 qt of engine oil Observ
108. e the flow of engine oil through the flexible hose and into the engine assembly Close the valve and remove the flexible hose and adapter from the engine Install the gallery plug to the engine Tighten the oil gallery plug to 30 Nm 22 ft Ib Top off the engine oil to the proper level TP 6105 8 05 Section 3 Diagnostic Information and Procedures 3 1 Diagnostic Starting Point Engine Mechanical Begin the system diagnosis by reviewing Section 1 4 1 Disassembled Views Section 2 3 Engine Component Description Section 2 4 Lubrication Description and Section 2 2 Drive Belt System Description Reviewing the description and operation information will help determine the correct symptom diagnostic procedure when a malfunction exists Reviewing the description and operation information will also help determine if the condition described by the customer is normal operation See Section 3 2 Symptoms Engine Mechanical to identify the correct procedure for diagnosing the system and where the procedure is located 3 2 Symptoms Engine Mechanical 3 2 1 1 Perform a diagnostic system check before using the symptom tables if applicable Strategy Based Diagnostics 2 Review the system operations to familiarize yourself with system functions See Section 1 4 1 Disassembled Views Section 2 3 Engine Component Description Section 2 2 Drive Belt System Description and Section 2 4 Lubrication Description TP 6
109. e to either the crankshaft journal or the crankshaft bearing surfaces On the edge of the gauging plastic envelope is a graduated scale Without removing the gauging plastic measure compressed width at widest point If the flattened gauging plastic tapers toward the middle or the ends there may be a difference in clearance indicating taper low spot or other irregularity of the crankshaft bearing or the crankshaft journal e Normally the crankshaft journals wear evenly and are not out of round However if a crankshaft bearing is being fitto an out of round 0 0254 mm 0 001 in maximum crankshaft journal fit to the maximum diameter of the crankshaft journal e fthe crankshaft bearing is fitted to the minimum diameter and the crankshaft journal is excessively out of round the interference between the crankshaft bearing and the crankshaft journal will result in rapid crankshaft bearing failure Compare the crankshaft bearing clearance to the specifications Refer to Section 1 2 Engine Mechanical Specs If the crankshaft bearing clearances exceeds specifications replace components as required TP 6105 8 05 10 11 12 Measure the new crankshaft bearing ID using the same method Replace the crankshaft if the proper clearances cannot be obtained with standard size bearings Remove the flattened gauging plastic Measure the remaining crankshaft journals Plastic Gauge Method for Connecting Rod
110. earing with the oil galleries in the engine block Push the guide cone into the front camshaft bearing bore to align the tool Drive the bearing into the bore 7 3 6 Installation TP 6105 8 05 Lubricate the following components with clean engine oil e The camshaft lobes e The camshaft bearing journals e The camshaft bearings Notice All camshaft journals are the same diameter so care must be used in removing or installing the camshaft to avoid damage to the camshaft bearings Install the three 8 1 25 x 100 mm bolts in the camshaft front bolt holes Using the bolts as a handle install the camshaft Remove the three bolts from the front of the camshaft Install the camshaft retainer Notice Refer to Fastener Notice in Cautions and Notices Install the camshaft retainer bolts Tighten the camshaft retainer bolts to 12 Nm 106 in Ib Section 7 Camshaft and Timing Gear Train 125 Notes 126 Section 7 Camshaft and Timing Gear Train TP 6105 8 05 Section 8 Lubrication System 8 1 Draining Fluids and Oil Filter 4 Clean the oil filter surface Removal Installation Procedure 1 Install a new oil filter 2 to the engine block Tighten the oil filter according to the oil filter manufacturer s instructions printed on the oil filter box 1 Remove the oil pan drain plug 2 Drain the engine oil 3 Remove the oil filter 2 4 Remove the left engine coolant dra
111. ection 3 2 Symptoms Engine Mechanical Verify that there is a chirping noise Does the engine make the chirping noise Go to Step 3 Go to Diagnostic Aids 2 Operate the engine for no longer than 30 40 seconds Does the chirping noise still exist 1 Remove the drive belt s See Section 9 1 1 Drive Belt Replacement Accessory Go to Section 3 8 Engine Noise on Startup But Only Lasting a Few Seconds Go to Step 4 Do the drive belt grooves have pilling Inspect for severe drive belt pilling exceeding 1 3 of the drive belt groove depth Go to Step 5 Go to Step 6 Clean the accessory drive belt pulley s with a suitable wire brush Was the accessory drive pulley s cleaned Go to Step 15 Inspect for misaligned accessory drive pulley s Is there a misaligned accessory drive pulley s Go to Step 7 Go to Step 8 Replace and or repair the misaligned accessory drive pulley s Was the misaligned accessory drive pulley s replaced and or repaired Go to Step 15 Inspect for a bent or cracked accessory drive bracket s Did you find any bent or cracked accessory drive brackets Go to Step 9 Go to Step 10 Replace any bent and or cracked accessory drive bracket s Was the bent and or cracked accessory drive bracket s replaced Go to Step 15 Go to Step 10 Inspect for incorrect loose and or missing fasteners Were any incorrect loose and or missing fasteners f
112. efer to loads and extensive engine damage Section 4 7 4 Cylinder Head Cleaning and AA Inspection Important Apply sealer to a minimum of eight threads starting at the point of the cylinder head bolt TP 6105 8 05 Section 4 Cylinder Head and Valves 75 3 If not preapplied to the new cylinder heads bolts 7 Install the water crossover Refer to Section 9 3 apply sealant GM Part No U S 12346004 Water Crossover Canadian 10953480 or equivalent to the cylinder head bolts 4 Install the cylinder head bolts 1 2 and 3 Notice Refer to Fastener Notice in Cautions and Notices Important The long bolts are used in locations 1 2 3 6 7 8 9 10 11 14 16 and 17 The medium length bolts are used in locations 15 and 18 The short bolts are used in locations 4 5 12 and 13 8 Install a new O ring seal onto the indicator tube 49 O 7 SP EN ea g FFNS 9 Install the indicator tube into the oil pan pen oe 10 Align the indicator tube bracket with the bolt hole in the block NE A 5 Tighten the cylinder head bolts 11 Install the indicator tube bolt Tighten the bolt to a Tighten the cylinder head bolts a first pass in 50 Nm 37 ft Ib sequence to 30 Nm 22 ft Ib b Tighten the cylinder head bolts a second pass in sequence to 30 Nm 22 ft lb then an additional 120 using J 45059 c Tighten the bolts a final pass in sequence using J 45059 as listed Bolt Tighten 1 2 3 6
113. eld bolt 604 Exhaust manifold bolt 605 Exhaust manifold gasket 606 Exhaust manifold stud 705 Ignition coil wire harness 706 Ignition coil wire harness bolt 707 Ignition coil bolt 708 Ignition coil 709 Spark plug wire 710 Spark plug 711 Engine coolant temperature ECT sensor 712 ECT sensor bracket 713 ECT sensor bracket bolt Figure 1 3 Cylinder Head Upper Engine TP 6105 8 05 128 122 100 Engine block 122 Crankshaft balancer 123 Crankshaft balancer bolt washer 124 Crankshaft balancer bolt 125 Crankshaft front oil seal 129 Front cover locating pin 200 Timing chain 201 Camshaft sprocket bolt 202 Camshaft sprocket 203 Crankshaft sprocket 204 Camshaft retainer bolt 205 Camshaft retainer 206 Camshaft sprocket locating pin 207 Camshaft 208 Camshaft bearings 300 Water pump 301 Water pump bolt 302 Water pump pulley bolt 303 Water pump pulley 304 Water pump bypass hose clamp 305 Water pump bypass hose 306 Water pump bypass hose clamp 307 Water crossover bolt 308 Water crossover 309 Thermostat O ring 310 Thermostat housing bolt stud 311 Thermostat housing 312 Thermostat 313 Water crossover gasket 314 Water pump gasket 407 Oil level indicator tube 408 Oil level indicator tube bolt 409 Oil level indicator 410 Oil level indicator O ring 411 Oil level indicator tube O ring 521 Front cover bolt 522 Front cover 523 Front cover gasket 716 Camshaft position sensor bolt 717 Camshaft position
114. en the engine flywheel bolts a final pass to 100 Nm 74 ft Ib TP 6105 8 05 Section 7 Camshaft and Timing Gear Train 7 1 Engine Front Cover 7 1 1 Replacement Tools Required J 42851 Front Cover Oil Seal Installer Removal Procedure 1 Remove the water pump Refer to Section 9 2 Water Pump 2 Remove the crankshaft balancer Refer to Section 6 1 Crankshaft Balancer Replacement 7 Remove the battery cable channel bolt 8 Remove and reposition the battery cable channel 9 Remove the engine front cover bolts 2 10 Remove the engine front cover 1 Important The engine front cover gasket is reusable 3 Disconnect the camshaft position CMP sensor electrical connector 1 4 Remove the engine harness clips from the battery cable channel 11 Remove the engine front cover gasket 12 Remove the crankshaft front oil seal from the front cover 5 Remove the CMP sensor bolt 6 Remove the CMP sensor TP 6105 8 05 Section 7 Camshaft and Timing Gear Train 113 Installation Procedure a Hold the front cover 1 up to the crankshaft 2 b Lift the front cover 1 while sliding the cover over the crankshaft 2 c Slide the front cover toward the engine block 5 while keeping the cover raised d Lower the cover down over the dowel pin 4 allowing front cover to rest on the sealant 8 6 Install the engine front cover bolts Notice Refer to Fastener Notice in Cautions and No
115. ener Notice in Cautions and 7 Pour clean engine oil into the oil pump pickup Notices Screen 4 Install the oil pump drive bolt Tighten the oil pump 8 Install the oil pan drain plug Tighten the oil pan drive bolt to 25 Nm 18 ft Ib drain plug to 28 Nm 21 ft Ib 9 Lubricate the oil level sensor O ring with engine oil 8 7 Engine Oil Pressure Sensor and or Switch Replacement Tools Required J 41712 Oil Pressure Sensor Socket Removal Procedure 10 Install the oil level sensor Tighten the oil level sensor to 20 Nm 15 ft Ib 8 6 10 Drive Installation 1 Disconnect the oil pressure sensor electrical connector 2 2 Using J 41712 or equivalent remove the oil pressure sensor 1 Apply grease to the oil pump drive gear for ease of assembly Notice Ensure both components are aligned correctly or serious engine damage will occur 2 Line up the oil pump drive gear with the oil pump drive shaft 140 Section 8 Lubrication System TP 6105 8 05 Installation Procedure 1 Apply sealant GM Part No U S 12346004 Canadian 10953480 or equivalent to the threads of the oil pressure sensor Notice Refer to Fastener Notice in Cautions and Notices 2 UsingJ 41712 or equivalent install the oil pressure sensor Tighten the sensor to 30 Nm 22 ft Ib 3 Connect the oil pressure sensor electrical connector 2 me o il CH h Uz f s TP 6105 8 05 8 8 Engine Oil Level Sensor and
116. epair or replace the valve rocker arms as required Worn or bent push rods Replace the push rods Sticking valves Carbon buildup on the valve stem can cause the valve not to close properly Repair or replace as required Excessively worn or misaligned timing chain Repair or replace the timing chain camshaft retainer and sprockets as required Worn camshaft lobes Replace the camshaft and valve lifters Excessive oil pressure A lubrication system with excessive oil pressure may lead to excessive valve lifter pump up and loss of compression e Perform an oil pressure test See Section 3 18 Oil Pressure Dlagnosis and Testing e Repair or replace the oil pump as required Faulty cylinder head gaskets and or cracking or other damage to the cylinder heads and engine block cooling system passages Coolant consumption may or may not cause the engine to overheat Inspect for spark plugs saturated by coolant Inspection in Engine Controls Perform apressure test to the cooling system See Loss of Coolantin Engine Cooling Inspect the cylinder heads engine block and or head gaskets See Section 3 13 Coolant in Combustion Chamber Repair or replace as required See Spark Plug Worn piston rings Oil consumption may or may not cause the engine to misfire Inspect the spark plugs for oil deposits See Spark Plug Inspection in Engine Controls Inspect the cylinders for aloss of compressio
117. er 2 Inspect the thermostat housing 311 for corrosion 6 Remove the coolant crossover gaskets or damage 9 3 3 Installation 1 Install the thermostat 312 with the seal into the water crossover 308 7 Remove the thermostat housing bolts studs 310 8 Remove the thermostat housing 311 9 Remove the thermostat 312 from the coolant crossover 308 146 Section 9 Cooling System and Drive Belts TP 6105 8 05 2 Install the thermostat housing 311 Notice Refer to Fastener Notice in Cautions and Notices 3 Install the thermostat housing bolts 310 Tighten the bolts to 30 Nm 22 ft Ib 6 Install the thermostat bypass hose and clamps Tighten the bolts to 30 Nm 22 ft Ib 4 Install the gaskets and the water crossover 5 Install the bolts Tighten the water crossover bolts to 50 Nm 37 ft Ib Important Properly position the bypass hose clamps to avoid water pump pulley interference Tighten the bolts to 30 Nm 22 ft Ib 7 Install the drive belt tensioner 8 Install the drive belt tensioner bolts Tighten the drive belt tensioner bolts to 50 Nm 37 ft Ib TP 6105 8 05 Section 9 Cooling System and Drive Belts 147 Notes 148 Section 9 Cooling System and Drive Belts TP 6105 8 05 Section 10 Air Intake and Exhaust System 10 1 Intake Manifold 6 Disconnect the following electrical connectors e Pressure cycling switch 1 10 1 1 Replacement e Surge tank switch
118. er Remover Replacement Removal Procedure 1 Remove the intake manifold Refer to Section 10 1 1 Intake Manifold Replacement 2 Remove the valve rocker arms and push rods Refer to Section 4 2 1 Valve Rocker Arm and Push Rod Replacement 3 Remove the valve lifter guide retainer bolts and retainer TP 6105 8 05 4 Remove the valve lifter guides Important Mark sort or organize the valve lifters and guides for installation in their original location 5 Remove the valve lifters 6 Some valve lifters may be stuck in their bore due to gum or varnish deposits Remove using J 3049 A 7 Clean and inspect the valve lifters Refer to Section 4 6 3 Valve Lifters and Guides Cleaning and Inspection Installation Procedure Important If a new camshaftis installed replace all the valve lifters 1 Coat the valve lifter rollers with lubricant GM Part No U S 12345501 Canadian 992704 or equivalent Important If reusing the valve lifters install the lifters in their original location The valve lifter guide retainer must contact all of the valve lifter guides If the lifter guide retainer is bent replace the valve lifter guide retainer TP 6105 8 05 2 Install the valve lifters 3 Install the valve lifter guides over the flats on the valve lifters making sure the rollers of the valve lifters are properly aligned with the camshaft lobes 4 Install the valve lifter guide retainer Notic
119. er to Section 10 1 1 Intake Manifold Replacement 8 6 2 Replacement Removal Procedure 1 Remove the oil pan Refer to Section 8 5 1 Oil Pan Replacement 2 Remove the oil pump bolt TP 6105 8 05 3 Remove and separate the oil pump retainer and drive shaft 4 Discard the drive shaft retainer 5 Remove the crankshaft oil deflector nuts 6 Remove the crankshaft oil deflector 7 Clean and inspect the oil pump Refer to Section 8 6 6 Oil Pump Cleaning and Inspection Installation Procedure Important When installing the oil pump always replace the retainer between the oil pump and the shaft Section 8 Lubrication System 135 1 Install the crankshaft oil deflector 8 6 4 Oil Pump Pump Screen and Deflector Removal Notice Refer to Fastener Notice in Cautions and Notices 2 Install the crankshaft oil deflector nuts Tighten the nuts to 50 Nm 37 ft Ib Important During assembly install a new oil pump driveshaft retainer Slightly heatthe retainer above room temperature for ease of installation onto the oil pump driveshaft 1 Remove the bolt that attaches the oil pump to the crankshaft rear bearing cap 2 Remove the oil pump driveshaft and retainer from the crankshaft rear bearing cap 3 Separate the oil pump 422 driveshaft 420 and retainer 424 4 Discard the driveshaft retainer 424 3 Assemble the oil pump driveshaft and a new retainer 4 Install
120. es Stake the tangs on the new oil bypass valves 128 Section 8 Lubrication System TP 6105 8 05 3 Inspect the oil filter fitting and replace if necessary 2 Install the oil filter fitting Tighten the oil filter fitting to 66 Nm 49 ft Ib 8 4 Oil Level Indicator and Tube 8 4 1 Replacement Removal Procedure 4 Remove the oil bypass valves if required Unstake the tangs on the oil bypass valves and remove with long nose pliers 5 Discard the oil bypass valves if removed 8 3 3 Installation 1 Remove the oil level indicator from the indicator tube 1 Ifremoved install the new oil bypass valves Stake the tangs on the oil bypass valves 2 Disconnect the engine coolant temperature ECT Notice Refer to Fastener Notice in Cautions and sensor electrical connector Notices 3 Remove the ECT sensor connector from the indicator tube TP 6105 8 05 Section 8 Lubrication System 129 4 Remove the indicator tube bolt 5 Remove the indicator tube bracket 6 Remove the O ring seal from the indicator tube Installation Procedure Important Make sure the indicator tube does not come in contact with spark plug wires Ensure that the spark plug wires are routed around the indicator tube 7 Install the oil level indicator to the indicator tube 8 4 2 Removal 1 Install a new O ring seal onto the indicator tube 2 Install the indicator tube into the oil pan 3 Align the ind
121. es valve guides and or valve stem Inspect the spark plugs for oil deposits See Spark Plug Inspection in Engine Controls oil seals e Repair or replace as required e Inspect the spark plugs for oil deposits See Spark Plug Inspection in Engine Controls Worn piston rings e Inspect the cylinders for a loss of compression See Section 3 15 Engine Compression Test Oil consumption may or may not cause the Perform cylinder leakdown and compression testing to identify the cause See Section 3 16 engine to misfire Oylinder Leakage Test e Repair or replace as required 3 8 Engine Noise on Startup Only Lasting a Few Seconds Important A cold piston knock that disappears in 1 5 minutes should be considered acceptable A cold engine knock usually disappears when the specific cylinder s secondary ignition circuit is grounded out during diagnosis A light rattle tapping noise may indicate a valve train upper engine concern or a low rumble knocking may indicate a crankshaft or piston lower engine concern Incorrect oil level E m E Add or remove oil as required to achieve proper level Too high an oil level will cause aeration within the oil Incorrect oil filter without antidrainback feature Install the correct oil filter e Drain the oil Incorrect oil viscosity DT y e Install the correct viscosity oil High valve lifter leakdown rate Replace the valve lifters as required e Check th
122. es before working on the engine Remove the negative lead first when disconnecting the battery Reconnect the negative last when reconnecting the battery Moving Parts and Hot Surfaces Caution Caution Avoid contact with moving parts and hot surfaces while working around a running engine to prevent physical injury Safety Glasses Caution Caution Always wear safety glasses io avoid eye damage Belt Drive Notice Notice Do not use belt dressing on the drive belt Belt dressing causes the breakdown of the composition of the drive belt Failure to follow this recommendation will damage the drive belt Component Fastener Tightening Notice Notice Replacement components must be the correct part number for the application Components requiring the use of the thread locking compound lubricants corrosion inhibitors or sealants are identified in the service procedure Some replacement components may come with these coatings already applied Do not use these coatings on components unless specified These coatings can affect the final torque which may affect the operation of the component Use the correct torque specifications when installing components to avoid damage 10 Safety Precautions and Instructions Fastener Notice Notice Use the correct fastener in the correct location Replacement fasteners must be the correct part number for that application Fasteners requiring replacement or fasteners requiring the use of
123. ethod is to insert a feeler gauge between the crankshaft and the bearing surface and measure the clearance Refer to Section 1 2 Engine Mechanical Specs If the correct end play cannot be obtained inspect for the following conditions e Verify that the correct size crankshaft bearing has been installed Refer to Section 1 2 Engine Mechanical Specs e Inspect the crankshaft thrust wall surface or surfaces for wear and or excessive runout Refer to Section 1 2 Engine Mechanical Specs Inspect the crankshaft for binding Turn the crankshaft to check for binding If the crankshaft does not turn freely loosen the crankshaft bearing bolts and studs one cap at a time until the tight bearing is located The following condition or conditions could cause a lack of clearance at the bearing e Burrs on the crankshaft bearing cap e Foreign material between the bearing and the block e Foreign material between the bearing and the bearing cap e Afaulty crankshaft bearing e Improper size bearing 106 Section 6 Crankshaft Main Bearings and Flywheel 12 13 14 15 Important e Ensure that the crankshaft position sensor is fully seated against the crankshaft reluctor ring The upper flange on the sensor MAY NOT seat against the engine block e The crankshaft position sensor bolt has a thread sealant applied to the threads The thread sealant may have come off during the removal of the bolt Ensure that the
124. ety recommendations and directions that are on the gasket eliminator sealant container e Apply a continuous bead of gasket eliminator sealant to one flange The surfaces to be sealed must be clean and dry Important Do not allow the gasket eliminator sealant to enter any blind threaded holes as the gasket eliminator sealant may prevent the fasteners from clamping properly seating properly or cause damage when the fastener tightened e Apply the gasket eliminator sealant evenly to get a uniform thickness of the gasket eliminator sealant on the sealing surface Important Gasket eliminator sealed joint fasteners that are partially torqued and the gasket eliminator sealant allowed to cure more than 5 minutes may result in incorrect shimming and sealing of the joint e Tighten the fasteners in sequence if specified and to the proper torque specifications Do not overtighten the fasteners e After properly tightening the fasteners remove the excess gasket eliminator sealant from the outside of the joint 2 8 4 Anaerobic Type Thread Lock Sealant Anaerobic type thread lock sealant cures in the absence of air This type of sealant is used for thread locking and sealing of bolts fittings nuts and studs This type of sealant cures only when confined between two close fitting metal surfaces Use the following information when using thread lock sealant e Always follow all safety recommendations and directions on the thread
125. fold studs to 20 Nm 15 ft Ib 2 Install the new left exhaust manifold gasket 3 Install the left exhaust manifold 4 Install the left exhaust manifold nuts and center bolt a Tighten the left exhaust manifold center bolt to 35 Nm 26 ft Ib b Tighten the left exhaust manifold nuts to 16 Nm 12 ft Ib 162 Section 10 Air Intake and Exhaust System 5 Install the left exhaust manifold heat shield 6 Install the left exhaust manifold heat shield bolts and nuts Tighten the left exhaust manifold heat shield bolts and nuts to 25 Nm 18 ft Ib 7 Install the left spark plugs Tighten the left spark plugs to 30 Nm 22 ft Ib Important Fully install the spark plug wire by pushing on the exposed end of the spark plug boot Do not push the spark plug wire on to the spark plug by using the metal heat shield 8 Install the left spark plug wires to the spark plugs and ignition coils TP 6105 8 05 10 2 4 Removal Right 4 Remove the exhaust manifold nuts and center bolt 5 Remove the exhaust manifold 6 Remove the exhaust manifold gasket Notice Twist the spark plug boot 1 2 turn to release the boot Pull on the spark plug boot only Do not pull on the spark plug wire or the wire could be damaged 1 Remove the spark plug wires from the spark plugs and ignition coils 8 Remove the exhaust manifold studs if required 2 Remove the exhaust manifold heat shield bolts and nuts
126. for a misaligned accessory drive pulley using a straight edge in the pulley grooves across two or three pulleys If a misaligned pulley is found refer to that accessory drive component for the proper removal and installation procedure for that pulley See item 6 in following table Inspection of the fasteners can eliminate the possibility that a incorrect bolt nut spacer or washer was installed See item 10 in following table Inspection of the accessory drive pulley s should include inspecting for bends dents or other damage to the pulley s that would prevent the drive belt s from not seating properly in the pulley grooves or on the smooth surface of the pulley when the back side of the drive belt is used to drive the pulley See item 12 in following table Replacing the drive belt s when it is not damaged or there is not excessive pilling will only be a temporary repair See item 14 in following table TP 6105 8 05 Notice See Belt Dressing Notice in Cautions and Notices Definition The following items are indications of chirping e High pitched noise that is heard once per revolution of the drive belt s or an accessory drive pulley e Chirping may occur on cold damp startup conditions and will subside once the engine reaches normal operating temperature perform the necessary inspections Did you review Section 3 2 Symptoms Engine Mechanical for diagnostic information and Go to Step 2 Go to S
127. front cover to rest on the sealant 3 Notice Refer to Fastener Notice in Cautions and Notices 9 Install the engine front cover bolts a Tighten the engine front cover bolts in sequence a first pass to 6 Nm 53 in Ib b Tighten the engine front cover bolts in sequence a final pass to 12 Nm 106 in Ib 10 Inspect the camshaft position sensor O ring for cuts cracks tears or damage Replace the O ring as needed TP 6105 8 05 11 12 13 7 2 7 2 1 Apply a light film of clean engine oil to the camshaft position sensor O ring Install the camshaft position sensor Notice This bolt is a self tapping bolt If installing this bolt into a new component installation of the bolt may be difficult Ensure that the bolt is not over torqued during the initial installation thread cutting Failure to limit torque can lead to bolt failure Install the camshaft position sensor bolt Tighten the camshaft position sensor bolt to 12 Nm 106 in Ib Timing Chain and Sprockets Replacement Tools Required J 22102 Crankshaft Sprocket Installer J 42846 Crankshaft Protector Button Removal Procedure Remove the engine front cover Refer to Section 7 1 Engine Front Cover Replacement Align the timing marks on the camshaft and crankshaft sprockets Remove the camshaft sprocket bolts Remove the camshaft sprocket and timing chain Section 7 Camshaft and Timing Gear Trai
128. ft Rear Seal Installer Installation Procedure Removal Procedure 1 Make sure the crankshaft is free of grit loose rust and burrs Correct as needed 1 Remove the flywheel Refer to Section 6 6 1 Engine Flywheel Replacement 2 Apply a very light film of oil onto the crankshaft sealing surface Do not apply oil to the sealing surface of the engine block 2 Install the guide pins from J 43320 into the crankshaft 3 Install the seal onto J 42849 4 Position J 42849 against the crankshaft Thread the attaching screws into the tapped holes in the crankshaft 5 Tighten the screws securely with a screwdriver to ensure that the seal is installed squarely over the crankshaft 6 Rotate the center nut until J 42849 bottoms 7 Remove J 42849 8 Install the flywheel Referto Section 6 6 1 Engine 3 Install J 43320 over the guide pins Flywheel Replacement 4 Using a suitable drill insert eight of the self drilling sheet metal screws into the rear crankshaft seal 6 2 3 Removal Rear using a crisscross pattern The self tapping f screws are included with J 43320 Tools Required J 43320 Crankshaft Rear Seal Puller 1 Install J 43320 guide pins into the crankshaft 2 Install J 43320 over the guide pins 100 Section 6 Crankshaft Main Bearings and Flywheel TP 6105 8 05 3 Using a suitable drill insert eight of the self drilling sheet metal screws 1 8 into the rear crankshaft seal using a cr
129. g 00 c cece eee tees 36 3 19 Oil Leak Diagnosis rete ey Paha e ECC ME 36 3 20 Crankcase Ventilation System Inspection Diagnosis se 38 3 21 Drive Belt Chirping Diagnosis aaaea cece tte 38 3 24 1 Diagnostic Aids rar a E a tenes 38 3 2152 Test DESCrIPtiON 235 5 ee ake ade enn ala E eU EE a TR RC dci 38 3 22 Drive Belt Squeal Diagnosis 00 cece cette eens 40 9 22 1 Diagnostic Aids eiii aie ER De Boao beatae ees 40 3 22 2 Test Description 2 ns ve sexe UR hey eme did ae 40 3 28 Drive Belt Whine Diagnosis lisse I 42 3 23 1 Diagnostic Aids sott des ita 42 3 23 2 Test Description siia setae nne A A e n nr 42 3 24 Drive Belt Rumbling Diagnosis ssl 43 3 24 1 Diagnostic Aids seurana ma a ea tenes 43 3 24 2 Test Description r sisone i aae a E A sese 43 3 25 Drive Belt Vibration Diagnosis 0 0c cece eee 44 3 25 1 Diagnostic Alds wee cicatrices SERATA 44 3 252 Test Descriptions en e eha ii aa E AA sees 44 3 26 Drive Belt Falls Off Diagnosis ssns anaana aaeeea 46 3 20 1 Diagnostic AldS ois ves iaa Ve ndn ea me DR tuas 46 3 26 2 Test Description o oooocoocccccocconconr eese 46 3 27 Drive Belt Excessive Wear Diagnosis 0 c eee eee eee 48 3 27 1 Diagnostic Alds creep E pde ux er ere Pee eee 48 3 27 2 Test Description ooooocoocccccocconnnr sees 48 3 28 Drive Belt Tensioner Diagnosis
130. g Clearance Checking Tool Adapter Kit J 45059 Angle Meter Important Use care when handling the crankshaft Avoid damage to the bearing surfaces TP 6105 8 05 1 Clean the crankshaft in solvent Remove all sludge Important Do not attempt to remove the or restrictions from the oil passages crankshaft reluctor wheels If the reluctor wheels are damaged and or removed replace the Caution Refer to Safety Glasses Caution in crankshaft Cautions and Notices 5 Inspect the reluctor wheels for cracked bent or 2 Dry the crankshaft and bearings with compressed broken teeth T e Measure between the crankshaft shoulder and 3 Inspect the crankshaft for the following conditions the front reluctor wheel 1 e Crankshaft journals 1 should be smooth with Maso dem the front and rear reluctor no evidence of scoring or damage e Deep grooves 2 e The maximum allowable gap is 0 15 mm s 0 006 in e Scratches or uneven wear 3 e Pitted surfaces 4 Wear or damage to the thrust journal surfaces Scoring or damage to the rear seal surface Restrictions to oil passages Damage to threaded bolt holes 6 Measure the crankshaft main journals and the Important The crankshaft pin isa pressed in crankpins for out of round and taper place roll pin The pin only needs to be removed from the crankshaft if the pin is damaged 4 Inspect the crankshaft pin for damage e Measure for proper installed height a Correct
131. gine concern Low oil pressure e Verify proper oil level Perform an oil pressure test Diagnosis and Testing Repair or replace damaged components as required e See Section 3 18 Oil Pressure Worn accessory drive components Abnormalities such as severe cracking bumps or missing areas in the accessory drive belt and or misalignment of system components Inspect the accessory drive system Repair or replace as required Loose or damaged crankshaft balancer e Inspect the crankshaft balancer e Repair or replace as required Detonation or spark knock Verify the correct operation of the ignition controls system See Detonation Spark Knock in Engine Controls Loose or damaged flywheel Repair or replace the flywheel Damaged oil pan contacting the oil pump screen An oil pan that has been damaged may improperly position the oil pump screen preventing proper oil flow to the oil pump e Inspect the oil pan Inspect the oil pump screen Repair or replace as required Oil pump screen loose damaged or restricted e Inspect the oil pump screen e Repair or replace as required Excessive piston to cylinder bore clearance e Inspect the piston and cylinder bore e Repair as required Excessive piston pin to bore clearance e Inspect the piston piston pin and the connecting rod e Repair or replace as required Excessive connecting rod bearing clearance
132. gine Gasket Replacement 2 7 1 Reusing Gasket and Applying Sealant e Do not reuse any gasket unless specified e Gaskets that can be reused will be identified in the service procedure e Donotapply sealant to any gasket or sealing surface unless specified in the service procedure 2 7 2 Separating Components e Use a rubber mallet to separate components e Bump the part sideways to loosen the components e Bumping of the component should be done at bends or reinforced areas of the component to prevent distortion of the components 2 7 3 Cleaning Gasket Surfaces e Use care to avoid gouging or scraping the sealing surfaces e Use a plastic or wood scraper to remove all the sealant from the components Do not use any other method or technique to remove the sealant or the gasket material from a part e Donotuse abrasive pads sand paper or power tools to clean the gasket surfaces These methods of cleaning can cause damage to the component sealing surfaces 22 Section 2 Description and Operation e Abrasive pads also produce a fine grit that the oil filter cannot remove from the engine oil This fine grit is an abrasive and can cause internal engine damage 2 7 4 Assembling Components e Assemble components using only the sealant or equivalent specified in the service procedure e Sealing surfaces must be clean and free of debris or oil e Specific components such as crankshaft oil seals or valve stem oil seals m
133. gine is The drive belt s will not cause the whine If the whine is operated with the drive belt s removed intermittent verify that it is not the accessory drive component s by varying their loads making sure they 2 are operating to their maximum capacity A failing generator is a suggested items to inspect The inspection should include checking the drive belt tensioner and the drive belt idler pulley bearings The drive belt s may have to be installed and the accessory drive components operated 3 23 2 Test Description separately by varying their loads Refer to the suspected accessory drive component for the 1 This test is to verify that the whine is being caused proper removal and installation procedure See by the accessory drive component s See Item 3 Item 4 in following table in following table Remove the drive belt s and Notice See Belt Dressing Notice in Cautions and Notices Definition A high pitched continuous noise that may be caused by an accessory drive component failed bearing Go to Section 3 2 Go to Step 2 Symptoms Engine Mechanical Did you review Section 3 2 Symptoms Engine Mechanical for diagnostic information and perform the necessary inspections Verify that there is a whining noise Go to y Go to Step 3 T Does the engine make the whining noise Diagnostic Aids Go to 1 Remove the drive belt s See Section 9 1 1 Drive Belt Replacement Accessory Section 3 8 2 Ope
134. he incorrect length the drive belt tensioner s may not maintain the proper tension on the drive belt s 3 26 2 Test Description 1 This inspection is to verify the condition of the drive belt s Damage may have occurred to the drive belt s when the drive belt s fell off the pulleys Inspect the drive belt s for cuts tears sections of ribs missing or damaged belt plies See item 2 in following table 2 Misalignment of the accessory drive pulley s may be caused from improper mounting or incorrect installation of a accessory drive component or the 46 Section 3 Diagnostic Information and Procedures pulley may be bent inward or outward from a previous repair Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys If a misaligned pulley is found refer to that accessory drive component for the proper removal and installation procedure of that pulley See item 4 in following table Inspection of the accessory drive pulley s should include inspecting for bends dents or other damage that would prevent the drive belt from seating properly in the pulley grooves or on the smooth surface of a pulley when the back side of the belt s is used to drive the pulley See item 5 in following table Accessory drive component brackets that are bent or cracked will also cause the drive belt s to fall off See item 6 in following table Inspection of the fasteners can eliminate the
135. head gasket e Anyother surfaces where a differenttype of sealant is specified in the service procedure e Always follow all the safety recommendations and the directions that are on the RTV sealant container e Use a plastic or wood scraper to remove all the RTV sealant from the plastic and aluminum components Important Do not allow the RTV sealant to enter any blind threaded holes as it may prevent the fasteners from clamping properly or cause damage when the fastener is tightened e The surfaces to be sealed must be clean and dry e Use a RTV sealant bead size as specified in the service procedure e Apply the RTV sealant bead to the inside of any bolt holes areas e Assemble the components while the RTV sealant is still wetto the touch within 3 minutes Do not wait for the RTV sealant to skin over e Tighten the fasteners in sequence if specified and to the proper torque specifications Do not overtighten the fasteners 2 8 3 Anaerobic Type Gasket Eliminator Sealant Anaerobic type gasket eliminator sealant cures in the absence of air This type of sealant is used where two rigid parts such as castings are assembled together When two rigid parts are disassembled and no sealant or gasket is readily noticeable the two parts were TP 6105 8 05 probably assembled using an anaerobic type gasket eliminator sealant Use the following information when using gasket eliminator sealant e Always follow all the saf
136. height is 2 00 2 25 mm 0 078 0 088 in e Replace the crankshaft pin if it is damaged TP 6105 8 05 Section 6 Crankshaft Main Bearings and Flywheel 103 7 Using a suitable fixture support the crankshaft a Measure the crankshaft runout using J 7872 b Crankshaft runout should not exceed 0 051 mm 0 002 in 8 Inspect the crankshaft thrust wall surface for wear 1 and or excessive runout 2 Refer to Section 1 2 Engine Mechanical Specs 2 Install the crankshaft lower bearings into the crankshaft bearing caps Apply clean engine oil to the bearing surfaces 6 3 3 Installation Tools Required J 8001 Dial Indicator Set J 45059 Angle Meter Notice To prevent damage to the crankshaft position sensor reluctor wheel ring use care when removing or installing this component 3 Install the crankshaft Important e Lubricate the crankshaft bearings and crankshaft with clean engine oil e f undersized bearings are used ensure that the bearings are fitted to the proper journals Important Seat the bearing caps within 60 minutes of applying the sealer Tighten the 1 Install the crankshaft upper bearings into the block bearing cap fasteners within 5 minutes of the Apply clean engine oil to the bearing surfaces bearing caps being installed onto the engine block 104 Section 6 Crankshaft Main Bearings and Flywheel TP 6105 8 05 4 Apply a 18 mm 0 500 in light film of sealant a GM
137. icating taper low spot or other irregularity of the crankshaft bearing or the crankpin journal Normally the crankpin journals wear evenly and are not out of round However if a connecting rod bearing is being fitted to an out of round 0 0254 mm 0 001 in maximum crankpin journal be sure to fit to the maximum diameter of the crankpin journal If the connecting rod bearing is fitted to the minimum diameter and the crankpin journal is excessively out of round the interference between the connecting rod bearing and the crankpin journal will result in rapid connecting rod bearing failure Compare the connecting rod bearing clearance to the specifications Mechanical Specs Refer to Section 1 2 Engine If the connecting rod bearing clearances exceed specifications replace components as required Remove the flattened gauging plastic Measure the remaining crankpin journals Crankshaft End Play Measurement To properly measure the crankshaft end play install the crankshaft bearings bearing caps and fasteners into the engine block and tighten the bolts to specifications Refer to Section 6 3 3 Crankshaft and Bearings Installation Install J 7872 or equivalent to the cylinder block with the dial indicator plunger against one of the counterweights of the crankshaft Firmly thrust the end of the crankshaft first rearward then forward This will line up the rear crankshaft bearing and the crankshaft thrust surf
138. icator tube bracket with the bolt hole in the block 1 Remove the oil level indicator from the oil level TN indicator tube Notice Refer to Fastener Notice in Cautions and Notices 4 Install the indicator tube bolt Tighten the bolt to 50 Nm 37 ft Ib 2 Remove the oil level indicator tube bolt 3 Remove the oil level indicator tube from the oil pan 5 Install the ECT sensor connector to the indicator 4 Remove the O ring seal from the oil level indicator tube tube 6 Connect the ECT sensor electrical connector 130 Section 8 Lubrication System TP 6105 8 05 8 4 3 Installation Important Ensure that the oil level indicator tube does not come in contact with the spark plug wires Route the spark plug wires around the oil level indicator tube 1 Install a new O ring seal onto the oil level indicator tube 2 Install the oil level indicator tube into the oil pan 3 Install the oil level indicator tube bracket to the exhaust manifold stud Notice Refer to Fastener Notice in Cautions and Notices 4 Install the oil level indicator tube bracket bolt Tighten the oil level indicator tube bolt to 25 Nm 18 ft Ib 5 Install the oil level indicator into the oil level indicator tube TP 6105 8 05 8 5 Oil Pan 8 5 1 Replacement Removal Procedure Important Do not raise the engine by the crankshaft balancer to perform this service procedure Damage to the crankshaft balancer or the c
139. ide cylinder head carefully into place over the locating pins and the cylinder head gasket 2 Remove the cylinder head TP 6105 8 05 Section 4 Cylinder Head and Valves 77 2 Install the cylinder head to the block Notice Do not reuse the cylinder head bolts Use new cylinder head bolts The cylinder head bolts are torque to yield bolts and cannot be reused after the initial torque is applied During the initial torque of the cylinder head bolt the cylinder head bolt is stretched to achieve proper clamp load Proper clamp load will not be achieved if a used cylinder head bolt is torqued again A stretched cylinder head bolt can also break when torqued Failure to replace the used cylinder head bolts with new cylinder head bolts can lead to improper clamp loads and extensive engine damage Important Apply sealer to a minimum of eight threads starting at the point of the cylinder head bolt If not preapplied to the new cylinder head bolts 1 3 apply sealer GM Part No U S 12346004 Canadian 10953480 or equivalent to the cylinder head bolts Refer to Section 2 8 RTV and Anaerobic Sealer Use Notice Refer to Fastener Notice in Cautions and Notices Notice Do not reuse a cylinder head gasket after the initial clamping loads are applied The initial tightening sequence procedure of the cylinder head bolts compresses the cylinder head gasket If any bolt must be loosened after the initial sequence is started repl
140. iece of wood 56 Section 4 Cylinder Head and Valves TP 6105 8 05 4 2 3 Cleaning and Inspection Important Sortor organize parts that are to be reused to return them to their original location 1 Clean the components with cleaning solvent Caution Refer to Safety Glasses Caution in Cautions and Notices 2 Dry the components with compressed air 3 Inspectthe valve rocker arms for wear or scoring in the ball area 4 Inspectthe valve rocker arm push rod sockets and valve stem tip mating surfaces 5 Inspect the valve rocker arm ball for wear or scoring These surfaces should be smooth with no scoring or exceptional wear 6 Inspect the push rods 1 2 for worn or scored ends These surfaces should be smooth with no scoring or exceptional wear 7 Inspect the push rods for bends Roll the push rod on a flat surface to determine if the push rod is bent Ifitrolls smoothly itis okay Ifthe push rod does not roll smoothly replace the push rod TP 6105 8 05 8 Inspect the push rod oil passages for restrictions e Clean the push rod tube with compressed air e Inspect by looking through the push rod tube for obstructions A clear push rod will allow light through e Replace push rod s that cannot be cleaned Important A light contact mark on the rocker arm stud is normal A noticeable groove in the rocker arm studis excessive wear and the rocker arm stud should be replaced Inspect rocker arm stu
141. in hole plug 1 Notice Refer to Fastener Notice in Cautions and and the right engine coolant drain hole plug Notices 5 Drain the engine coolant 2 Install the oil pan drain plug Tighten the oil pan drain plug to 28 Nm 21 ft Ib 8 2 Engine Oil and Oil Filter 3 Fill the engine with oil Refer to Section 1 Replacement Specifications Removal Procedure 8 3 Oil Filter Adapter 8 3 1 Bypass Valve Assembly Replacement Removal Procedure 1 Remove the engine oil filter Refer to Section 8 2 Engine Oil and Oil Filter Replacement 1 Remove the oil pan drain plug and allow the engine oil to drain completely 2 Clean the oil pan drain plug surface 3 Remove the oil filter 2 from the engine block and allow the engine oil to drain completely TP 6105 8 05 Section 8 Lubrication System 127 2 Loosen the oil filter fitting using a hex wrench 2 Inspect oil filter fitting and replace as necessary Notice Refer to Fastener Notice in Cautions and Notices 3 Install the oil filter fitting Tighten the oil filter fitting to 66 Nm 49 ft Ib 4 Install the oil filter Refer to Section 8 2 Engine Oil and Oil Filter Replacement 8 3 2 Removal 1 Loosen the oil filter fitting using a hex wrench 4 Remove the oil filter bypass valves Unstake the tangs on the oil bypass valves and remove with long nose pliers 5 Discard the oil bypass valves Installation Procedure 1 Install new oil bypass valv
142. in specifications resize the cylinder to accept a new oversized piston For proper piston fit the engine block cylinder bores should not have excessive wear or taper 1 Inspect the engine block cylinder bore Refer to Section 5 2 2 Engine Block Cleaning and Inspection 2 Inspect the piston connecting rod assembly for damage Refer to Section 5 1 3 Piston Connecting Rod and Bearings Cleaning and Inspection 3 Use 8087 and measure the cylinder bore diameter Refer to Section 5 2 2 Engine Block Cleaning and Inspection 4 Measure J 8087 with a micrometer and record the reading 5 Compare the cylinder bore measurement to the specifications Refer to Section 1 2 Engine Mechanical Specs 86 Section 5 Engine Block Pistons and Connecting Rods a If the cylinder bore is within specifications select the original piston or a new original size piston b Ifthe cylinder bore is not within specifications select the next oversized piston connecting rod assembly then bore and hone the cylinder bore to fit the oversize piston Piston Installation 1 Coat the following components with clean engine oil e The piston e The piston rings e The oylinder bore e The bearing surfaces 2 Install rubber fuel line onto the connecting rod bolts Important The mark on the top of the piston must face the front of the engine block When assembled the flanges on the connecting rod and cap should face to the fro
143. ine damage Section 4 Cylinder Head and Valves 73 Important The long bolts are used in locations 1 2 3 6 7 8 9 10 11 14 16 and 17 The medium length bolts are used in locations 15 and 18 The short bolts are used in locations 4 5 12 and 13 e aVe 030907092 Bla 4 Install the cylinder head bolts 5 Tighten a Tighten the bolts a first pass in sequence to 30 Nm 22 ft Ib b Retighten the bolts in a second pass in sequence to 30 Nm 22 ft lb then an additional 120 using J 45059 c Tighten the bolts a final pass in sequence using J 45059 as listed Bolt Tighten 1 2 3 6 7 8 9 10 11 14 16 17 Additional 60 15 18 Additional 45 4 5 12 18 Additional 30 4 7 7 Replacement Right Tools Required J 45059 Angle Meter Removal Procedure 1 Drain the cooling system Refer to Section 9 Cooling System and Drive Belts 2 Remove the intake manifold Refer to Section 10 1 1 Intake Manifold Replacement 74 Section 4 Cylinder Head and Valves 3 Remove the valve rocker arms and push rods Refer to Section 4 2 1 Valve Rocker Arm and Push Rod Replacement 4 Remove the engine coolant temperature ECT sensor clip from the bracket 5 Remove the ECT sensor from the cylinder head 6 Remove the indicator tube bolt 7 Remove the indicator tube bracket 8 Remove the O ring seal from the indicator tube 9 Remove the heater inlet and outlet ho
144. ing 6 Remove the rubber fuel line from the connecting rod bolts 7 Remove the remaining piston and the connecting rod assemblies 8 Remove J 42846 from the front of the crankshaft 5 1 2 Piston and Connecting Rod Disassemble Important The piston and connecting rod are only serviced as an assembly If a new piston or connecting rod is required use a complete piston connecting rod assembly Important Use new connecting rod nuts when the pistons are reinstalled in the engine Remove the piston rings 121 from the piston 80 Section 5 Engine Block Pistons and Connecting Rods 5 1 3 Cleaning and Inspection Important The piston diameter cannot be measured due to the piston coating Do not measure the piston diameter Important Measurement of all components should be taken with the components at room temperature Do not use a wire brush to clean any part of the piston 1 Clean the piston and connecting rod 119 and connecting rod cap 117 in solvent Caution Refer to Safety Glasses Caution in Cautions and Notices 2 Dry the components with compressed air 3 Clean the piston ring grooves with a suitable ring groove cleaning tool TP 6105 8 05 4 Clean the piston oil lubrication holes and slots 5 Inspect the piston for the following conditions e Eroded areas 1 on the top of the piston e Scuffed or damaged skirt 2 8 Measure the piston ring side clearance with a feeler g
145. ing rod cap and the original crankshaft journal used nuts Notice Refer to Fastener Notice in Cautions and a Tighten the connecting rod nuts a first pass to Notices 30 Nm 22 ft Ib Important Tighten the inner crankshaft bearing b Tighten the connecting rod nuts a second pass cap bolts before tightening the outer crankshaft an additional 90 using J 45059 bearing cap studs The crankshaft journal and the crankshaft bearing surface must be free from oil to 5 Measure the connecting rod bearing ID using an obtain a correct measurement Do not allow the inside micrometer crankshaft to rotate while performing measurement or an incorrect measurement will be obtained 6 Compare the connecting rod bearing clearance specifications Refer to Section 1 2 Engine 3 Install the bearing cap bolts and studs Mechanical Specs a Tighten the bearing cap 1 5 inner bolts a first 7 If the connecting rod bearing clearances exceed pass to 30 Nm 22 ft Ib specifications replace components as required b Tighten the bearing cap 1 5 outer studs a first pass to 30 Nm 22 ft Ib 108 Section 6 Crankshaft Main Bearings and Flywheel TP 6105 8 05 c Tighten the bearing cap 1 5 inner bolts a final pass an additional 90 using J 45059 d Tighten the bearing cap 1 5 outer studs a final pass an additional 80 using J 45059 4 Remove the crankshaft bearing cap bolts and the crankshaft bearing caps The gauging plastic may adher
146. installation Failure to use J43105 may cause excessive oil consumption J 5892 D 3 Install the valve stem oil seal 2 over the valve tip and onto the valve guide using J 43105 Tap the valve stem seal onto the valve guide until J 43705 fully seats the seal e Install the valve rocker arm nut Important Tighten the valve rocker arm nut enough to hold J 5892 D in place f Using J 5892 D compress the valve spring 5 Remove the valve stem keys 1 Important Do not release the compressed air from the cylinder being worked on The valve will fall into the cylinder bore TP 6105 8 05 Section 4 Cylinder Head and Valves 59 4 Install the valve spring cap and the spring Important When installing valve springs install the small end of the valve spring up 10 Install the valve rocker arms and push rods Refer to Section 4 2 1 Valve Rocker Arm and Push Rod Replacement 5 Install ia VAE Spg 3h 4 4 Valve Spring Inspection and 6 Install the valve spring cap 2 Measurement 7 Using J 5892 D compress the valve spring 8 Install the valve stem keys as follows a 1 Inspect the valve springs for broken coils or coil ends 2 Use J 9666 to measure valve spring force Refer to Section 1 2 Engine Mechanical Specs J 5892 D Apply a small amount of clean grease to hold the valve stem keys in place Important Add a maximum of one shim up to Carefully release J 5892 D Make sure the 0
147. intake manifold bolts Install new intake manifold bolts during assembly TP 6105 8 05 Section 10 Air Intake and Exhaust System 159 10 Install the new intake manifold bolts Notice Refer to Fastener Notice in Cautions and Notices 11 Tighten the intake manifold bolts in sequence using four passes a Tighten the intake manifold bolts a first pass in sequence to 5 Nm 44 in Ib b Tighten the intake manifold bolts a second pass in sequence to 8 Nm 71 in Ib Inspect the intake manifold joints for signs of intake manifold shifting Correct as required c Tighten the intake manifold bolts a third pass in sequence to 12 Nm 106 in Ib d Tighten the intake manifold bolts a final pass in sequence to 15 Nm 11 ft Ib Important Lubricate the injector O ring seals with clean engine oil and install onto the spray tip end of each injector 12 Install the fuel injection fuel rail with injectors 13 Install the fuel injection fuel rail bolts studs Tighten the fuel injection fuel rail bolts studs to 12 Nm 106 in Ib 14 Install the throttle body gasket 501 and throttle body 502 160 Section 10 Air Intake and Exhaust System 15 Install the throttle body nuts 503 Tighten the throttle body nuts to 10 Nm 89 in Ib 16 Install the vacuum plug 513 10 2 Exhaust Manifold 10 2 1 Removal Left Notice Twist the spark plug boot 1 2 turn to release the boot Pull on the spark plug
148. ion 1 Place a new cylinder head gasket into position Notice Do not reuse the cylinder head bolts Use new cylinder head bolts The cylinder head bolts are torque to yield bolts and cannot be reused after the initial torque is applied During the initial torque of the cylinder head bolt the cylinder head bolt is stretched to achieve proper clamp load Proper clamp load will not be achieved if a used cylinder head bolt is torqued again A stretched cylinder head bolt can also break when torqued Failure to replace used cylinder head bolts with new cylinder head bolts can lead to improper clamp loads and extensive engine damage Important Apply sealer to a minimum of eight threads starting at the point of the cylinder head bolt TP 6105 8 05 3 If not preapplied to the new cylinder head bolts 6 Install the exhaust manifold Refer to Section 10 2 apply sealant GM Part No U S 12346004 Exhaust Manifold Canadian 10953480 or equivalent to the cylinder head bolts 7 Install the water crossover Refer to Section 9 3 Water Crossover 4 Install the cylinder head bolts 1 2 and 3 8 Position the engine harness grounds 1 and 5 and ground strap 4 to the cylinder head Notice Refer to Fastener Notice in Cautions and Notices Important The long bolts are used in locations 1 2 9 Install the engine harness ground bolts Tighten 3 6 7 8 9 10 11 14 16 and 17 The medium o DO Le OO length bolts are used
149. ion 0 249 0 759 0 0098 0 0299 Runout production 0 051 0 002 Oil control ring service 0 373 1 138 0 015 0 045 Runout service 0 076 0 003 Piston ring to groove clearance mm in Connecting rod mm in Bearing clearance production 0 033 0 068 0 0013 0 0027 First compression ring 0 031 0 074 0 0012 0 0029 Bearing clearance service 0 033 0 081 0 0013 0 0032 Second compression ring 0 031 0 074 0 0012 0 0029 Side clearance 0 384 0 686 0 0151 0 0270 Oil control ring 0 051 0 203 0 002 0 008 Piston Crankshaft mm in Connecting rod journal diameter 55 854 55 870 2 1990 2 1996 Diameter Not measurable see Section 5 1 7 comment Connecting rod journal out of round production 0 0102 0 0004 Piston to bore clearance Interference fit Piston pin mm in Connecting rod journal taper production 0 0102 0 0004 Crankshaft end play 12 Section 1 Specifications 0 127 0 350 0 005 0 0138 Clearance to connecting rod bore 0 049 0 020 0 0019 0 0007 interference Diameter 26 416 26 419 1 0400 1 0401 TP 6105 8 05 Application Valve system Valves Face angle exhaust 45 Face angle intake 45 Head diameter exhaust mm in 43 69 1 72 Head diameter intake mm in 55 63 2 19 Lash exhaust
150. ion sensor O ring 131 Oil gallery plug side 434 Oil filter fitting 726 Crankshaft position sensor 132 Oil gallery plug left side rear 719 Knock sensor 727 Crankshaft position sensor bolt 133 Oil gallery plug rear 720 Knock sensor heat shield right 728 Oil pressure sensor 134 Oil gallery plug rear 721 Knock sensor heat shield bolt Figure 1 6 Engine Block Plugs Sensors 16 Section 1 Specifications TP 6105 8 05 1 4 2 Engine Identification The engine identification number is located in three locations There are labels on the front of the right rocker arm cover the rear of the left rocker arm cover and the right side of the engine oil pan The engine identification number is used to track and identify the engine prior to installation 422 Oil pump with pickup screen 427 Drive gear 428 Driven gear 429 Oil pump cover 430 Oil pump cover bolt 431 Pressure relief valve spring pin 432 Pressure relief valve 433 Pressure relief valve spring Rocker arm cover right Rocker arm cover left Engine oil pan right side Figure 1 7 Oil Pump Assembly TP 6105 8 05 Section 1 Specifications 17 Notes 18 Section 1 Specifications TP 6105 8 05 Section 2 Description and Operation 2 4 Crankcase Ventilation System Description The crankcase ventilation system has no serviceable components routine maintenance of the system is not required A closed crankcase ventilation system is used to provide a more complete scavenging of
151. isscross pattern The self drilling screws are included with J 43320 4 Thread the center bolt of J 43320 into the crankshaft to remove the seal 5 Remove J 43320 guide pins from the crankshaft 6 2 4 Installation Rear Tools Required J 42849 Crankshaft Rear Seal Installer Important Crankshaft rear oil seal and engine flywheel installation requires adequate space for installation If the engine stand does not allow suitable space to use TP 6105 8 05 J 42849 install the crankshaft rear oil seal and engine flywheel with the engine properly supported on the floor 1 Make sure the crankshaft rear chamfer is free of grit loose rust and burrs Correct as needed 2 Apply a very light film of oil onto the crankshaft sealing surface Do not apply oil to the sealing surface of the engine block 3 Install the seal on J 42849 4 Position J 42849 against the crankshaft Thread the attaching screws into the tapped holes in the crankshaft 5 Tighten the screws securely with a screwdriver to ensure that the seal is installed squarely over the crankshaft 6 Rotate the center nut until J 42849 bottoms 7 Remove J 42849 6 3 Crankshaft and Bearings 6 3 1 Removal Notice To prevent damage to the crankshaft position sensor reluctor wheel ring use care when removing or installing this component Important The crankshaft position sensor is designed to contact the reluctor wheel of the crankshaft Wear m
152. l fill cap O ring 512 EGR cover stud 418 Oil fill cap 513 Vacuum fitting plug 419 Oil fill tube bolt 515 Intake gasket end seal 500 Intake manifold 516 Intake gasket side 501 Throttle body gasket 700 EVAP valve bolt 502 Throttle body 701 MAP sensor 503 Throttle body nut 702 EVAP valve 504 Throttle body stud 703 EVAP valve O ring 505 Intake manifold bolt 704 EVAP tube 506 Fuel rail with injectors 729 MAP sensor grommet 507 Fuel rail bolt stud 730 MAP sensor bolt 508 Intake manifold plug Figure 1 1 Intake Manifold Upper Engine TP 6105 100 Engine block 115 Flywheel bolt 114 Flywheel 126 Crankshaft rear oil seal Figure 1 2 Engine Rear 14 Section 1 Specifications 209 Valve lifter 210 Valve lifter guide 211 Valve lifter retainer 212 Valve lifter retainer bolt 213 Cylinder head locating pin 214 Cylinder head gasket 215 Cylinder head 216 Valve rotator 217 Valve stem oil seal 218 Valve spring 219 Valve spring cap 220 Valve stem keys 221 Push rod 222 Rocker arm nut 223 Rocker arm ball 224 Rocker arm 225 Rocker arm bolt stud 226 Push rod guide 227 Cylinder head bolt long 228 Cylinder head bolt medium 229 Cylinder head bolt short 230 Cylinder head coolant plug 231 Valve guide exhaust 232 Valve 517 Valve cover gasket 518 Valve cover bolt grommet 519 Valve cover bolt 520 Valve cover 600 Exhaust manifold 601 Exhaust manifold heat shield 602 Exhaust manifold nut 603 Exhaust manifold heat shi
153. lt Vibration Diagnosis 3 25 1 Diagnostic Aids The accessory drive components may have an affect on engine vibration To help identify an intermittent or an improper condition vary the loads on the accessory drive components 3 25 2 Test Description 1 This test is to verify that the vibration is present during diagnosing Other engine components may cause a similar symptom such as the exhaust System See item 2 in following table 2 This test is to verify that the drive belt s or accessory drive components may be causing the vibration Remove the drive belt s and operate the engine for a few seconds to verify if the vibration is related to the drive belt s With the drive belt s removed the water pump will not operate and the engine may overheat Also DTCs may set when the engine is operated with the drive belt s removed See item 3 in following table 44 Section 3 Diagnostic Information and Procedures The drive belt s may cause a vibration When the drive belt s is removed inspect the condition of the drive belt s See item 4 in following table Inspection of the fasteners can eliminate the possibility that a incorrect bolt nut spacer or washer was installed See item 6 in following table This step should only be performed if the fan is driven by the drive belt s Inspect the engine cooling fan for bent twisted loose or cracked blades Inspect the fan clutch for smooth operation Inspect for a
154. lves Broken valve springs Stuck valve lifters Incorrect valve lash Damaged piston Worn piston rings Worn or scored cylinder bore Damaged cylinder head gasket Cracked or damaged cylinder head Cracked or damaged engine block Caution See Battery Disconnect Caution in Cautions and Notices 1 Disconnect the battery ground negative cable 2 Remove the spark plugs 3 Rotate the crankshaft to place the piston in the cylinder being tested at top dead center TDC of the compression stroke 4 Install J 35667 A or equivalent Important It may be necessary to hold the crankshaft balancer bolt to prevent the crankshaft from rotating 5 Apply shop air pressure to J 35667 A and adjust according to the manufacturer s instructions 6 Record the cylinder leakage value Cylinder leakage that exceeds 2596 is considered excessive and may require component service In excessive leakage situations inspect for the following conditions e Airleakage sounds atthe throttle body or air inlet hose that may indicate a worn or burnt intake valve or a broken valve spring e Air leakage sounds at the exhaust system tailpipe that may indicate a worn or burnt exhaust valve or a broken valve spring TP 6105 8 05 e Air leakage sounds from the crankcase oil level indicator tube or oil fill tube that may indicate worn piston rings a damaged piston a worn or scored cylinder bore a damaged engine block or a damaged oylinder head
155. max minus min bore diameter 0 05 0 002 Surface flatness intake manifold deck 0 08 0 003 Exhaust manifold Oylinder bore taper production 0 018 0 0007 Surface flatness mm in 0 254 0 01 Oylinder bore taper service thrust axis 0 05 0 002 Lubrication system Oylinder bore taper service pin axis 0 05 0 002 Oil capacity without filter L qt 5 7 6 Cylinder head deck height from centerline of crankshaft 259 875 260 125 10 231 10 241 Oil pressure minimum kPa psi 34 5 1000 rpm Oylinder head deck surface flatness entire face 0 10 0 004 Oil pressure maximum kPa psi 690 10 2000 rpm Cylinder head deck surface flatness within 150 mm 6 in 0 05 0 002 Piston rings Piston ring end gap mm in Valve lifter bore diameter 21 417 21 443 0 843 0 844 First compression ring production 0 30 0 45 0 012 0 018 Camshaft mm in Bearing inside diameter 49 548 49 573 1 9507 1 9517 First compression ring service 0 450 0 675 0 018 0 027 Journal diameter 49 472 49 522 1 9477 1 9497 Second compression ring production 0 450 0 650 0 018 0 025 Lobe lift exhaust 6 973 7 075 0 2745 0 2785 Second compression ring service 0 675 0 975 0 027 0 039 Lobe lift intake 6 924 7 026 0 2726 0 2766 Oil control ring product
156. mer s concern it may be necessary to spray a small amount of water onto the drive belt s If spraying water onto the drive belt s duplicates the symptom cleaning the accessory drive pulley s may be the most probable solution A loose or improper installation of other item s on the engine may also cause the chirping noise 3 21 2 Test Description 1 The chirping noise may not be engine related See item 2 in following table This step is to verify that the engine is making the noise If the engine is not making the noise do not proceed further with items in table 2 The noise may be an internal engine noise Remove the drive belt s and operate the engine for a few seconds to verify if the chirping noise is related to the drive belt s With the drive belt s 38 Section 3 Diagnostic Information and Procedures removed the water pump will not operate and the engine may overheat Also diagnostic trouble codes DTCs may set when the engine is operated with the drive belt s removed See item 3 in following table Inspect all drive belt s for signs of pilling Pilling is the small balls pills or strings in the drive belt grooves caused from the accumulation of rubber dust See item 4 in following table Misalignment of the accessory drive pulley s may be caused from improper mounting or incorrect installation of an accessory drive component or the pulley may be bent inward or outward from a previous repair Test
157. mmended equipment to obtain the proper results 2 Reface pitted valves on a valve refacing machine to ensure the correct relationship between the head and the stem 3 Replace the valve if the edge of the head is less than 0 79 mm 0 031 in thick after grinding Valve Seat Reconditioning Procedure Important Several different types of equipment are available for reconditioning valve seats Use the manufacturer s recommended equipment to obtain the proper results Important Always recondition the valve seat after reaming the valve guide bores or installing new valves 1 Recondition the valve seats 2 The valves must seat perfectly for the engine to deliver optimum power and performance 3 Ensure that the valve seat and valve are not shrouded after valve seat reconditioning Adequate flow past the valve seat and valve is essential for cooling the valve head and valve seat area 4 Correct contact 1 between each valve and its seat in the cylinder head is also essential to ensure that the heat in the valve head is properly carried away Important Regardless of what type of equipment is used itis essential thatthe valve guide bores are free from carbon or dirt to ensure the proper centering of the pilot in the guide 5 The valve seats should be concentric to within 0 050 mm 0 002 in total indicator runout 62 Section 4 Cylinder Head and Valves 4 6 Valve Lifter 4 6 1 Tools Required J 3049 A Valve Lift
158. n See Section 3 15 Engine Compression Test Perform cylinder leakdown and compression testing to identify the cause See Section 3 16 Cylinder Leakage Test Repair or replace as required A damaged crankshaft reluctor wheel A damaged crankshaft reluctor wheel can result in different symptoms depending on the severity and location of the damage e Systems with electronic communications DIS or coil per cylinder and severe reluctor ring damage may exhibit periodic loss of crankshaft position stop delivering a signal and then resync the crankshaft position e Systems with electronic communication DIS or coil per cylinder and slight reluctor ring damage may exhibit no loss of crankshaft position and no misfire may occur However a PO300 DTC may be set e Systems with mechanical communications and severe reluctor ring damage may cause additional pulses and effect fuel and spark delivery to the point of generating a P0300 DTC or P0336 28 Section 3 Diagnostic Information and Procedures Replace the sensor and or crankshaft reluctor wheel as required TP 6105 8 05 3 4 Base Engine Misfire With Abnormal Internal Lower Engine Noises Correction Abnormalities such as severe cracking bumps or missing areas in the accessory drive belt Abnormalities in the accessory drive system and or components may cause engine rpm variations noises similar to a faulty lower engine and also lead to a misfire condition A misfire
159. n 117 5 Install J 42846 1 into the end of the crankshaft 6 Remove the crankshaft sprocket using a suitable three jaw puller 7 Clean and inspect the timing chain and sprockets Refer to Section 7 2 3 Timing Chain and Sprockets Cleaning and Inspection Installation Procedure 1 Use J 22102 to install the crankshaft sprocket Align the keyway of the crankshaft sprocket with the crankshaft pin 2 Remove J 22102 3 Rotate the crankshaft until the crankshaft sprocket alignment mark is in the 12 o clock position 118 Section 7 Camshaft and Timing Gear Train Important e Install the camshaft sprocket with the alignment mark in the 6 o clock position e The sprocket teeth must mesh with the timing chain to prevent damage to the camshaft retainer e Do not use a hammer to install the camshaft sprocket onto the camshaft To do so may damage the camshaft 4 Install the camshaft sprocket and timing chain 5 Ensure that the crankshaft sprocket is aligned at the 12 o clock position and the camshaft sprocket is aligned at the 6 o clock position Notice Refer to Fastener Notice in Cautions and Notices 6 Install the camshaft sprocket bolts a Tighten the bolts a first pass to 30 Nm 22 ft lb b Tighten the bolts a final pass to 30 Nm 22 ft lb 7 Install the engine front cover Refer to Section 7 1 Engine Front Cover Replacement 7 2 2 Removal Tools Required J 42846 Crankshaft Pro
160. n 3 Diagnostic Information and Procedures Inspect the following components and repair as required e Crankshaft bearings e Crankshaft journals e Cylinder block crankshaft bearing bore TP 6105 8 05 3 12 Engine Will Not Crank Crankshaft Will Not Rotate 1 Remove the accessory drive belt or belts and or starter motor 2 Rotate crankshaft by hand at the balancer or flywheel location Seized accessory drive system component or starter motor Inspectthe timing chain gears and crankshaft sprocket locating pin Broken timing chain Repair as required Inspect camshaft and camshaft bearings Seized camshaft Repair as required Inspect valves and cylinder heads Bent valve in cylinder head Repair as required Hydraulically locked cylinder Remove spark plugs and check for fluid e Coolant antifreeze in cylinder Inspect for sticking fuel injector e Oil in cylinder Inspect for broken head gasket or gaskets e Fuel in cylinder Inspect for cracked engine block or cylinder head Material in cylinder e Broken valve e Piston material e Foreign material Inspect cylinder and cylinder head for damaged components and or foreign materials Repair or replace as required Inspect crankshaft and connecting rod bearings Seized crankshaft or connecting rod bearings Repair as required Inspect connecting rods Bent or broken connecting rod Repair as required
161. nals that measure less than minimum specifications Micrometer Method for Crankshaft Bearings Important When bearings are removed install new bearings during reassembly 1 Measure the crankshaft main journal diameter with a micrometer a minimum of four places along the length approximately 90 apart and average the measurements 2 Determine the taper and the out of round Refer to Section 1 2 Engine Mechanical Specs TP 6105 8 05 10 Install the new crankshaft bearings into the crankshaft bearing caps and the engine block Notice Refer to Fastener Notice in Cautions and Notices Important Tighten the inner crankshaft bearing cap bolts before tightening the outer crankshaft bearing cap studs Install the bearing cap bolts and studs a Tighten the bearing cap 1 5 inner bolts a first pass to 30 Nm 22 ft Ib b Tighten the bearing cap 1 5 outer studs a first pass to 30 Nm 22 ft Ib c Tighten the bearing cap 1 5 inner bolts a final pass an additional 90 using J 45059 d Tighten the bearing cap 1 5 outer studs a final pass an additional 80 using J 45059 Measure the crankshaft bearing inside diameter Measure at a places and average the ID using an inside micrometer minimum of four measurements To determine the crankshaft bearing clearance subtract the crankshaft journal diameter from the crankshaft bearing ID Compare the crankshaft bearing clearance to the
162. nd Go to Step 8 Go to Step 9 Replace any incorrect and or missing fasteners Tighten any loose fasteners See Section 1 1 Fastener Tightening Specs Does the drive belt s continue to fall off Go to Step 9 System OK Test the drive belt tensioner for correct operation See Section 3 28 Drive Belt Tensioner Diagnosis Does the drive belt tensioner operate correctly Go to Step 11 Go to Step 10 Replace the drive belt tensioner See Section 9 1 2 Drive Belt Tensioner Replacement Accessory Does the drive belt s continue to fall off Go to Step 11 System OK Inspect for a failed drive belt s idler and or tensioner pulley s bearing Did you find and repair the condition Go to Step 12 TP 6105 8 05 Run the engine to verify the repair Does the drive belt still fall off Go to Step 1 System OK Section 3 Diagnostic Information and Procedures 47 3 27 Drive Belt Excessive Wear Diagnosis 3 27 1 Diagnostic Aids Excessive wear on a drive belt s is usually caused by incorrect installation or the incorrect drive belt s for the application Minor misalignment of the accessory drive pulley s will not cause excessive wear but will probably cause the drive belt s to make a noise or fall off Excessive misalignment ofthe accessory drive pulley s will cause excessive wear and may also make the drive belt s fall off Notice See Belt Dressing Notice in Cautions and No
163. nnecting Rod and Important When connecting rod bearings are B removed install new bearings during earing assembly 5 1 1 Removal Tools Required J 24270 Cylinder Bore Ridge Reamer J 42846 Crankshaft Protector Button 2 Remove the connecting rod nuts 3 Remove the connecting rod cap and the connecting rod lower bearing J 24270 Important Do not remove the excessive material from the cylinder bore Excessive removal of material may require cylinder boring to the next oversize 1 Remove the cylinder bore ridge as necessary a Install J 42846 onto the front of the crankshaft to rotate the crankshaft b Rotate the crankshaft until the piston is at the bottom of the stroke BDC c Place a cloth on top of the piston d Perform the cutting operation with J 24270 Refer to the manufacturer s instructions before 4 Install rubber fuel line onto the connecting rod bolts using J 24270 to prevent contact with the crankshaft journal e Remove J 24270 f Rotate the crankshaft until the piston is at top dead center TDO g Remove the cloth and the cuttings h Repeat the procedure for each piston Important Place matching marks or numbers on the connecting rods and the connecting rod caps Assemble the connecting rod caps to their original connecting rods TP 6105 8 05 Section 5 Engine Block Pistons and Connecting Rods 79 5 Remove the piston connecting rod and connecting rod upper bear
164. nspection Important The flywheel may need to be tapped with a non metallic mallet from the engine side due to a slight interference fit to the crankshaft 1 Remove the engine flywheel bolts 2 Remove the engine flywheel 6 6 3 Cleaning and Inspection 1 Clean the engine flywheel in solvent instalation Procedure Caution Refer to Safety Glasses Caution in Important Make sure the flywheel is installed correctly Cautions and Notices Engine Side is stamped on the flywheel to aid with installati n 2 Dry the engine flywheel with compressed air TP 6105 8 05 Section 6 Crankshaft Main Bearings and Flywheel 111 3 Inspect the manual transmission engine flywheel for the following conditions e Pitted surface 1 e Scoring or grooves 2 e Rust or other surface damage 3 e Damaged ring gear teeth 4 e Loose or improperly positioned ring gear The ring gear has an interference fit onto the engine flywheel and should be positioned completely against the flange of the engine flywheel 112 Section 6 Crankshaft Main Bearings and Flywheel 6 6 4 Installation 1 Install the engine flywheel Notice Refer to Fastener Notice in Cautions and Notices 2 Install the engine flywheel bolts Tighten the fasteners following a crisscross pattern a Tighten the engine flywheel bolts a first pass to 40 Nm 30 ft Ib Tighten the engine flywheel bolts a second pass to 80 Nm 59 ft Ib Tight
165. nt of block on the left bank and to the rear of block on the right bank 3 Install the piston connecting rod and upper connecting rod bearing through the top of the engine block TP 6105 8 05 4 Install J 8037 onto the piston and compress the piston rings 5 Use J 8037 and lightly tap the top of the piston with a wooden hammer handle 6 Hold J 8037 firmly against the engine block until all of the piston rings have entered the cylinder bore 7 Usethe rubber fuel line to guide the connecting rod onto the crankshaft journal 8 Remove the rubber fuel line 9 Install the connecting rod cap and lower connecting rod bearing Notice Refer to Fastener Notice in Cautions and Notices TP 6105 8 05 Important When installing the piston connecting rod assembly install new connecting rod nuts 10 Install the new connecting rod nuts 11 Tighten Tighten the connecting rod nuts a first pass to 30 Nm 22 ft Ib Tighten the connecting rod nuts an additional 90 using J 45059 12 After the piston and connecting rod assemblies have been installed lightly tap each connecting rod assembly parallel to the crankpin to make sure that they have side clearance 13 Use a feeler gauge or a dial indicator to measure the side clearance between the connecting rod caps The rod side clearance should be 0 384 0 686 mm 0 0151 0 0270 in 5 2 Engine Block 5 2 1 Tools Required J 41712 Oil Pressu
166. o replace the used cylinder head bolts with new cylinder head bolts can lead to improper clamp loads and extensive engine damage TP 6105 8 05 Important Apply sealer to a minimum of eight threads starting at the point of the cylinder head bolt If not preapplied to the new cylinder head bolts apply sealer GM Part No U S 12346004 Canadian 10953480 or equivalent to the cylinder head bolts Refer to Section 2 8 RTV and Anaerobic Sealer Use Notice Refer to Fastener Notice in Cautions and Notices Notice Do not reuse a cylinder head gasket after the initial clamping loads are applied The initial tightening sequence procedure of the cylinder head bolts compresses the cylinder head gasket If any bolt must be loosened after the initial sequence is started replace the cylinder head gasket Failure to replace the cylinder head gasket can lead to cylinder head bolt breakage or cylinder head gasket failure A broken cylinder head bolt or failed cylinder head gasket can lead to extensive engine damage Notice Follow the cylinder head bolt tightening sequence The final angle tightening sequence of the cylinder head bolts varies depending on the length of the cylinder head bolt Failure to angle tighten the specific length bolt the proper number of degrees can lead to cylinder head bolt failure or improper clamping load of the cylinder head gasket Cylinder head bolt or cylinder head gasket failure can lead to extensive eng
167. ocker arm e Valve push rod e Valve lifter e Oil filter bypass valve e Oil pump and pump screen e Engine block oil galleries Broken valve spring Replace the valve spring Worn and or damaged valve rotators Replace the valve rotators as required Worn or dirty valve lifters Replace the valve lifters Stretched or broken timing chain and or damaged sprocket teeth Replace the timing chain and sprockets Worn engine camshaft lobes e Inspect the engine camshaft lobes e Replace the camshaft and valve lifters as required Worn valve guides or valve stems Inspect the following components and replace as required e Valves e Valve guides Stuck valves Carbon on the valve stem or valve seat may cause the valve to stick TP 6105 8 05 Inspect the following components and replace as required e Use GM top engine cleaner GM P N1050002 Canadian P N992872 to eliminate the carbon deposits following manufacturer s instructions e Valves e Valve guides Section 3 Diagnostic Information and Procedures 31 3 10 Lower Engine Noise Regardless of Engine Speed Correction Important A cold piston knock that disappears in 1 5 minutes should be considered acceptable A cold engine knock usually disappears when the specific cylinder s secondary ignition circuit is grounded out A light rattle knocking noise may indicate a crankshaft or piston lower during diagnosis en
168. olts to 12 Nm 106 in Ib TP 6105 8 05 Section 7 Camshaft and Timing Gear Train 121 7 3 3 Bearing Removal Tools Required J 33049 Camshaft Bearing Service Set 1 Remove the rear camshaft plug if not previously removed Insert a long bar through the front of the engine and drive the plug out of the rear bore Important A loose camshaft bearing may be caused by an enlarged out of round or damaged engine block bearing bore 2 Prior to bearing removal inspect the camshaft bearings for loose fit in the engine block bearing bores positions 1 5 Important Remove the inner bearings in positions 2 3 and 4 first The outer bearings in positions 1 and 5 serve as a guide for J 33049 5 InsertJ 33049 through the front of the engine block and into the bearing 3 Selectthe expanding driver 4 8 and washer 2 or 3 from J 83049 J 33049 122 Section 7 Camshaft and Timing Gear Train TP 6105 8 05 6 Tighten the expander assembly nut until snug 5 Measure the camshaft journals with a micrometer Refer to Section 1 2 Engine Mechanical Specs 7 Push the guide cone into the front camshaft bearing in position 1 to align J 33049 8 Drive the inner bearings in positions 2 3 and 4 from their block bores 9 Assemble J 33049 handle expanding driver and washer 10 Insert J 33049 into the outer camshaft bearings 11 Drive the outer bearings from the bore 7 3 4 Camshaft and Bearings Cleaning 6
169. or Switch Replacement Removal Procedure 1 Drain the engine oil Refer to Section 8 2 Engine Oil and Oil Filter Replacement 2 Disconnect the oil level sensor electrical connector 4 Section 8 Lubrication System 141 Installation Procedure 3 Fill the engine oil Refer to Section 8 2 Engine Oil and Oil Filter Replacement Notice Refer to Fastener Notice in Cautions and Notices 1 Install the oil level sensor to the oil pan Tighten the sensor to 20 Nm 15 ft Ib 2 Connect the oil level sensor electrical connector 4 142 Section 8 Lubrication System TP 6105 8 05 Section 9 Cooling System and Drive Belts 9 1 Drive Belt 9 1 1 Replacement Accessory Removal Procedure 1 Install a breaker bar with hex head socket to the drive belt tensioner bolt 2 Rotate the drive belt tensioner clockwise to relieve tension on the belt 3 Remove the belt from the pulleys and the drive belt tensioner 4 Slowly release the tension on the drive belt tensioner 5 Remove the breaker bar and socket from the drive belt tensioner bolt 6 Clean and inspect the belt surfaces of all pulleys Installation Procedure 1 Route the drive belt around all the pulleys except the idler pulley 2 Install the breaker bar with hex head socket to the belt tensioner bolt 3 Rotate the belt tensioner clockwise to relieve the tension on the tensioner 4 Install the drive belt under the idler pulley
170. ore both parallel and perpendicular to the centerline of the crankshaft at the top center and bottom of the bore A cylinder bore that measures 107 940 107 990 mm 4 249 4 251 in may be serviced with a standard size piston connecting rod assembly Service a cylinder bore that exceeds the maximum diameter with an oversized piston connecting rod assembly TP 6105 8 05 5 2 3 Plug Installation Tools Required J 41712 Oil Pressure Switch Socket Notice Refer to Fastener Notice in Cautions and Notices 1 Apply sealant GM Part No U S 12346004 Canadian 10953480 or equivalent to the threads of the coolant hole plug 2 Install the engine coolant hole plug into the block Tighten the engine coolant hole plug to 60 Nm 40 ft Ib 3 Apply sealant GM Part No U S 12346004 Canadian 10953480 or equivalent to the threads of the engine block heater if applicable 4 Install the engine block heater into the block Tighten the engine block heater to 50 Nm 37 ft Ib TP 6105 8 05 5 Apply sealant GM Part No U S 12346004 Canadian 10953480 or equivalent to the threads of the oil gallery plugs 6 Install the engine block top oil gallery plugs Tighten the top oil gallery plugs to 20 Nm 15 ft Ib 7 Apply sealant GM Part No U S 12346004 Canadian 10953480 or equivalent to the threads of the oil gallery plug 8 Install the engine block left side oil gallery plug Tighten the left oil galler
171. osits from the coolant passages All dirt or debris from threaded bolt holes Caution Refer to Safety Glasses Caution in Cautions and Notices Dry the block with compressed air Lubricate the cylinder bores with clean engine oil to prevent rusting Inspect the engine block for the following conditions e Gasket surfaces for deep gouges or other damage e Crankshaft bearing bores for wear e The surfaces where the crankshaft bearings contact the crankshaft bearing bore must be smooth e All crankshaft bearing bores must be round and uniform in inside diameter ID at all the bearing supports e f a crankshaft bearing cap is damaged and requires replacement refer to Section 6 3 2 Crankshaft and Bearings Cleaning and Inspection 90 Section 5 Engine Block Pistons and Connecting Rods Camshaft bearing bores for wear or damage Valve lifter bores for scuffing or wear Engine block for cracks or other damage Oylinder walls for scoring or gouges Coolant jackets for cracks Crankshaft bearing webs for cracks Engine mount bosses for damage The oil passages for restrictions Inspect the engine block cylinder head deck for flatness using a straight edge and a feeler gauge The surface must be flat within 0 100 mm 0 004 in Usea bore gauge to measure the cylinder bore for taper out of round and oversize Slide the bore gauge up and down throughout the length of the cylinder bore Check the b
172. ould read less than 690 kPa 100 psi For example if the highest pressure in any one cylinder is 1035 kPa 150 psi the lowest allowable pressure for any other cylinder would be 725 kPa 105 psi 1035 x 70 725 150 x 70 105 34 Section 3 Diagnostic Information and Procedures Replace the components as required 8 If some cylinders have low compression inject approximately 15 ml 1 tablespoon of engine oil into the combustion chamber through the spark plug hole e Normal Compression builds up quickly and evenly to the specified compression for each cylinder e Piston Rings Leaking Compression is low on the first stroke Compression then builds up with the following strokes but does not reach normal Compression improves considerably when you add oil e Valves Leaking Compression is low on the first stroke Compression usually does not build up on the following strokes Compression does not improve much when you add oil e Iftwo adjacent cylinders have lower than normal compression and injecting oil into the cylinders does not increase the compression the cause may be a head gasket leaking between the two cylinders TP 6105 8 05 3 16 Cylinder Leakage Test Tools Required J 35667 A Cylinder Head Leakdown Tester or equivalent Important Aleakage test may be performed to measure cylinder combustion chamber leakage High cylinder leakage may indicate one or more of the following Worn or burnt va
173. ound Go to Step 11 Go to Step 12 Replace any incorrect and or missing fasteners Tighten any loose fasteners See Section 1 1 Fastener Tightening Specs Were the fasteners replaced and or tightened Go to Step 15 Inspect for a bent accessory drive pulley s Was a bent accessory drive pulley s found Go to Step 13 Go to Step 14 Replace the bent accessory drive pulley s Was the bent accessory drive pulley s replaced Go to Step 15 Was the drive belt s replaced Replace the drive belt s See Section 9 1 1 Drive Belt Replacement Accessory Go to Step 15 1 Clear any codes 2 Run the engine to verify the repair Does the chirping noise still exist TP 6105 8 05 Go to Step 1 System OK Section 3 Diagnostic Information and Procedures 39 3 22 Drive Belt Squeal Diagnosis 3 22 1 Diagnostic Aids A loose or improper installation of other item s on the engine may cause the squeal noise If the squeal noise is intermittent verify that it is not the accessory drive component s by varying their load s making sure they are operating to their maximum capacity A failing engine alternator is a suggested item to inspect 3 22 2 Test Description 1 The squeal may not be engine related See item 2 in following table This step is to verify that the engine is making the noise If the engine is not making the noise do not proceed further with items in table 2 The sque
174. r a collapsed pressure relief spring 6 Inspect the pressure relief valve for scoring or wear The valve should move freely within the bore of the housing 8 6 7 Assemble Important Replace the pressure relief valve spring when reusing the oil pump 1 Install the following items e Pressure relief valve e Pressure relief spring e Retaining pin 138 Section 8 Lubrication System 2 Coat the drive gear the driven gear and the housing gear surfaces with clean engine oil 3 Install the drive gear and the driven gear into the pump body Align the matching marks on the gears Install the smooth side of the gear toward the pump cover 4 Install the oil pump cover Notice Refer to Fastener Notice in Cautions and Notices Install the oil pump cover bolts Tighten the oil pump cover bolts to 12 Nm 106 in Ib Inspect the oil pump for smoothness of operation by turning the oil pump driveshaft by hand Notice Ensure the oil pump driveshaft is inspected for wear and or damage and replaced if necessary An excessively worn or damaged oil pump driveshaft may fail causing severe engine damage TP 6105 8 05 8 6 9 Oil Pump Pump Screen and Deflector Installation 7 Install the oil pump driveshaft and the new retainer i au Lg 1 Install the crankshaft oil deflector 8 6 8 Drive Cleaning and Inspection Caution Refer to Safety Glasses Caution in Cautions and Notices Notice Refer
175. rankshaft balancer nose against the crankshaft sprocket Failure to install the crankshaft balancer properly may result in improper torque to the crankshaft balancer bolt An improperly torqued crankshaft balancer bolt may loosen causing serious engine damage TP 6105 8 05 4 Tighten J 42845 until the crankshaft balancer is Removal Procedure completely seated against the crankshaft sprocket 1 Remove the crankshaft balancer Refer to Section 6 1 1 Crankshaft Balancer Replacement Important Use care not to damage the engine front cover or the crankshaft sealing area when removing the crankshaft front cover oil seal 2 Remove the crankshaft front cover oil seal 6 Install the crankshaft balancer washer and bolt Tighten the crankshaft balancer bolt to 255 Nm 189 ft Ib 7 Remove J 42847 1 ale 1 Coat the crankshaft front cover oil seal with clean engine oil 2 Using J 42857 install the oil seal 3 Remove J 42851 4 Install the crankshaft balancer Refer to Section 6 1 1 Crankshaft Balancer Replacement 6 2 Crankshaft Oil Seal E 6 2 1 Replacement Front Tools Required J 42851 Front Cover Oil Seal Installer TP 6105 8 05 Section 6 Crankshaft Main Bearings and Flywheel 99 6 2 2 Replacement Rear 5 Thread the center bolt of J 43320 into the crankshaft to remove the seal Tools Required J 43320 Crankshaft Rear Seal Puller 6 Remove the guide pins from the crankshaft J 42849 Cranksha
176. rankshaft may occur 1 Remove the starter motor 2 Drain the engine oil Refer to Section 8 2 Engine Oil and Oil Filter Replacement 3 Remove the oil level indicator Refer to Section 8 4 Oil Level Indicator and Tube Replacement 4 Disconnect oil level sensor electrical connector 4 5 Remove the engine harness clip from the oil pan 6 Remove the oil level sensor from the oil pan Section 8 Lubrication System 131 7 Remove the battery cable channel bolt 8 Remove and reposition the battery cable channel 1 Apply sealant GM Part No U S 2346286 Canadian 10953472 or equivalent to the sides of the front 2 and rear 1 crankshaft bearing caps on both the left and right sides four locations total 2 Install a new oil pan gasket into the oil pan groove if Important The oil pan gasket is reusable if not cut required or damaged 3 Install the oil pan 10 Remove the oil pan 1 and gasket 2 4 Install the oil pan bolts Notice Refer to Fastener Notice in Cautions and Notices Installation Procedure 5 Tighten the oil pan bolts Important Install the oil pan within 5 minutes of the a Tighten the bolts a first pass in sequence to sealer being applied or the sealer will begin to cure 10 Nm 89 in Ib causing an inadequate seal 132 Section 8 Lubrication System TP 6105 8 05 b Tighten the bolts a final pass in sequence to 10 Connect oil level sensor electrical connector 4
177. rate the engine for no longer than 30 40 seconds Engine Noise on Startup But Does the whining noise still exist Only Lasting a Few Seconds Go to Step 4 1 Inspect for a failed accessory drive component bearing 2 Install the drive belt s See Section 9 1 1 Drive Belt Replacement Accessory Go to Step 5 Did you find and correct the condition 1 Clear any codes 2 Run the engine to verify the repair Go to Step 1 System OK Does the whining noise still exist 42 Section 3 Diagnostic Information and Procedures TP 6105 8 05 3 24 Drive Belt Rumbling Diagnosis 3 24 4 Diagnostic Aids Vibration from the engine operating may cause a body component or another part of the engine to make a rumbling noise The drive belt s may have a condition that cannot be seen or felt Sometimes replacing the drive belt s may be the only repair for the symptom If after replacing the drive belt s and completing the diagnostic table the rumbling is only heard with the drive belt s installed there might be an accessory drive component failure Varying the load on the different accessory drive component s may aid in identifying which component is causing the rumbling noise 3 24 2 Test Description 1 This test is to verify that the symptom is present during diagnosing Other components may cause a similar symptom Notice See Belt Dressing Notice in Cautions and Notices Definition The following items are indic
178. re Switch Socket Plug Removal Section 5 Engine Block Pistons and Connecting Rods 87 1 Remove the oil pressure switch using J 41712 2 Remove the camshaft rear bearing hole plug a b Obtain a suitable self threading screw Drill a hole into the plug Install the self threading screw Pull on the plug until it has left the bore Important Use care not to damage the camshaft bearings An alternate method to remove the plug would be to insert a long shaft or bar through the front of the engine and drive the plug from the bore 3 Remove the left side knock sensor heat shield bolts 4 Remove the left side knock sensor heat shield 88 Section 5 Engine Block Pistons and Connecting Rods 5 Remove the left side knock sensor 6 Remove the right side knock sensor heat shield 720 and bolts 721 7 Remove the right side knock sensor 719 TP 6105 8 05 9 Remove the rear oil gallery plugs 12 Remove the top oil gallery plugs TP 6105 8 05 Section 5 Engine Block Pistons and Connecting Rods 89 5 2 2 Cleaning and Inspection Boil the cylinder block in caustic solution Flush the cylinder block with clean water or steam Clean the following areas e All gasket surfaces refer to Section 2 7 Engine Gasket Replacement e Oylinder bores remove excessive cylinder ring ridge as required Main bearing caps Oil galleries remove all sludge or restrictions Scale dep
179. s in the belt grooves 3 Worn grooved or damaged hub seal surface 1 Remove minor imperfections on the hub seal surface with a polishing compound or a fine grade of emery cloth Replace a crankshaft balancer hub seal surface with excessive scoring grooves rust or other damage e Worn chunking or deteriorated rubber between the hub and pulley 2 4 Repair or replace crankshaft balancer as necessary 6 1 4 Installation Tools Required J 42845 Crankshaft Balancer Installer J 42847 Flywheel Holding Tool Refer to Fastener Notice in Cautions and Notice Notices Important Ensure that the teeth of the flywheel holding tool engage the engine flywheel teeth Position the 98 Section 6 Crankshaft Main Bearings and Flywheel balancer onto the end of the crankshaft as straight as possible prior to tool installation 1 Install J 42847 1 to the starter bolt holes Tighten J 42847 bolts to 50 Nm 37 ft Ib Important Apply grease or clean engine oil to the inside of the crankshaft balancer or the end of the crankshaft to prevent galling during assembly 2 Install the balancer onto the end of the crankshaft Important Apply the lubricant that comes with J 42845 each time the tool is used Failure to lubricate J 42845 may prevent the balancer from installing completely 3 Use J 42845 1 to install the balancer Notice Ensure the crankshaft balancer is installed to the proper depth Seat the c
180. sensor 718 Camshaft position sensor O ring Figure 1 4 Engine Front TP 6105 8 05 100 Engine block 101 Crankshaft main bearings upper 102 Crankshaft thrust bearing upper 103 Crankshaft 104 Crankshaft main bearings lower 105 Crankshaft thrust bearings lower 106 Crankshaft bearing cap 107 Crankshaft bearing cap bolt 108 Crankshaft bearing cap bolt stud 109 Crankshaft bearing cap thrust 116 Connecting rod nut 117 Connecting rod cap 118 Connecting rod bearings 119 Piston and connecting rod assembly 120 Connecting rod bolt 121 Piston rings 126 Crankshaft rear oil seal 213 Cylinder head locating pin 233 Crankshaft sprocket locating pin 400 Oil pan 401 Oil pan drain plug 402 Oil pan drain plug O ring 403 Oil pan bolt 404 Oil pan gasket 405 Crankshaft oil deflector nut 406 Crankshaft oil deflector 413 Oil pump drive bolt 414 Oil pump drive 420 Oil pump drive shaft 421 Oil pump locating pin 422 Oil pump 423 Oil pump bolt 424 Oil pump drive shaft retainer 435 Oil filter 714 Oil level sensor O ring 715 Oil level sensor Figure 1 5 Lower Engine Assembly Section 1 Specifications 15 127 Oil gallery plug top 135 Camshaft hole plug 722 Knock sensor heat shield left 128 Oil gallery plug front 136 Oil gallery plug rear 723 Knock sensor heat shield bolt 129 Front cover locating pin 425 Oil filter bypass valve 724 Block coolant heater 130 Coolant drain plug 426 Oil cooler fitting 725 Crankshaft posit
181. ses from the hose bracket 10 Remove the heater hose bracket bolts and bracket from the cylinder head 11 Remove the water crossover Refer to Section 9 3 Water Crossover 12 Remove the exhaust manifold Refer to Section 10 2 Exhaust Manifold TP 6105 8 05 13 Remove and discard the cylinder head bolts 1 2 Installation Procedure and 3 Important Make sure the threaded holes in the engine Important Place the cylinder head on two wood block are clean and not damaged Do not use sealer on block to prevent damage to the sealing surface any engines that use a composition type gasket Align the cylinder head gasket locating mark to face up Ensure that the head gasket tabs are located over the numbers 1 and 2 cylinders for correct installation 1 Place a new cylinder head gasket into position 2 Install the cylinder head Notice Do not reuse the cylinder head bolts Use new cylinder head bolts The cylinder head bolts are torque to yield bolts and cannot be reused after the initial torque is applied During the initial torque of the cylinder head bolt the cylinder head bolt is stretched to achieve proper clamp load Proper clamp load will not be achieved if a used cylinder head bolt is torqued again A stretched cylinder head bolt can also break when torqued Failure to replace the used cylinder head bolts with new cylinder head bolts can lead to improper clamp 16 Clean and inspect the cylinder head R
182. spring shims if applicable Important When installing valve stem oil seals onto the valve guides take care not to tear the seal lip Important When installing valve seals use J 43105 to achieve correct installation Failure to use J43105 may cause excessive oil consumption 6 Lubricate the valve stem seal and the outside diameter of the valve guide with clean engine oil 7 Install the valve stem oil seals 217 over the valve tip and onto the valve guides using J 43105 1 Tap the valve stem seal onto the valve guide until J 43105 fully seats the seal Important When installing valve springs install the small end of the valve spring up Section 4 Cylinder Head and Valves 71 8 Install the valve springs 218 9 Install the valve spring caps 219 14 Apply sealant GM Part No U S 12346004 Canadian 10953480 or equivalent to the threads of the engine coolant temperature ECT sensor 10 Use 48062 to compress the valve spring Notice Refer to Fastener Notice in Cautions and Compress the spring enough to clearly see the Notices valve stem key grooves of the valve 15 Install the ECT sensor into the right cylinder head 11 Install the valve stem keys Tighten the ECT sensor to 50 Nm 37 ft Ib hold the keys in place e IESO Y In piace 16 Install the ECT sensor bracket and bolt Tighten e Ensure that the keys seat properly in the upper the ECT sensor bracket bolt to 50 Nm 37 ft Ib groove
183. t sprocket alignment mark is in the 12 o clock position Section 7 Camshaft and Timing Gear Train 119 7 3 Camshaft 7 3 1 Replacement Removal Procedure Notice Do not hammer the camshaft sprocket onto the camshaft To do so may dislodge the rear camshaft plug and damage the camshaft Important Install the camshaft sprocket with the alignment mark in the 6 o clock position Important The sprocketteeth must mesh with the timing chain to prevent damage to the camshaft retainer 1 Remove the valve lifters Refer to Section 4 6 Valve Lifter Replacement 4 Install the camshaft sprocket and timing chain ae 2 Remove the timing chain and sprocket Refer to Section 7 2 Timing Chain and Sprockets Replacement 3 Remove the camshaft retainer bolts 4 Remove the camshaft retainer 5 Ensure that the crankshaft sprocket is aligned at the 12 o clock position and the camshaft sprocket is aligned at the 6 o clock position Notice Refer to Fastener Notice in Cautions and Notices 6 Install camshaft sprocket bolts Tighten the three 5 Install three 8 1 25 x 100 mm bolts into the camshaft sprocket bolts to 30 Nm 22 ft Ib camshaft front bolt holes 6 Usingthe bolts as a handle carefully rotate and pull the camshaft out of the engine block 7 Remove the bolts from the front of the camshaft 8 Clean and inspect the camshaft Refer to Section 7 3 4 Camshaft and Bearings Cleaning and Inspection 120
184. tant Excessive cylinder head resurfacing will affect compression ratio and emission control 3 Replace a cylinder head that requires excessive resurfacing Valve Inspection Procedure 1 Inspect the valves for the following conditions e Burnt or damaged areas 1 e Undersized valve margin 2 e Bent stem 3 e Scoring or other damage to the stem 4 70 Section 4 Cylinder Head and Valves e Worn key groove 5 e Worn stem tip 6 2 Inspect the valve contact surface for the following conditions Undersized margin 1 Pitted surface 2 Burnt or eroded areas 3 Acceptable edge margin 4 Important Minor imperfections ofthe valve may be corrected during reconditioning 3 Replace valves with excessive damage 4 7 5 Assemble Tools Required J 8062 Valve Spring Compressor J 43105 Valve Stem Seal Installer Checking Valve Spring Installed Height 1 Install the valve rotator 3 valve 4 valve spring cap 1 and valve stem keys 5 into the cylinder head TP 6105 8 05 2 Usinga snap gauge or inside micrometer measure the distance from the top of the valve rotator to the bottom of the valve spring cap Refer to Section 1 2 Engine Mechanical Specs for proper valve spring installed height specifications Important e Never shim the spring to obtain an installed height under the specified amount Install the valve spring seat shims under the rotator between the rotator and the
185. tector Button TP 6105 8 05 1 Measure the camshaft timing chain free play If the chain can be moved back and forth in excess of 16mm 0 625 in replace the chain and sprockets 2 Remove the camshaft sprocket bolts 3 Remove the camshaft sprocket and the timing chain 4 Install J 42846 1 into the end of the crankshaft 5 Remove the crankshaft sprocket using a three jaw puller 2 1 Clean the camshaft timing components in solvent Caution Refer to Safety Glasses Caution in Cautions and Notices 2 Dry the components with compressed air 3 Inspect the camshaft timing chain for binding or wear TP 6105 8 05 Important If the sprocket or sprockets must be replaced replace both sprockets to ensure that timing chain centerline alignment is maintained 4 Inspect the camshaft and crankshaft sprockets for the following conditions e Worn teeth 1 e Damaged teeth 2 e Chipped teeth 3 e Uneven wear on one edge of the teeth e Worn valleys between the sprocket teeth e Crankshaft sprocket keyway for wear S NS 7 2 4 Installation Tools Required J 22102 Front Cover Aligner and Seal Installer 1 Use J 22102 to install the crankshaft sprocket Align the keyway of the crankshaft sprocket with the crankshaft pin 2 Inspect the sprocket pin for proper installation Refer to Section 6 3 2 Crankshaft and Bearings Cleaning and Inspection 3 Rotate the crankshaft until the crankshaf
186. that operates the oil pump driveshaft assembly Ignition synchronization with the camshaft is provided by a physical feature integral with the camshaft sprocket 2 3 4 Crankshaft The crankshaft is made of cast nodular iron The crankshaft is supported by five crankshaft bearings The crankshaft bearings are retained by the crankshaft bearing caps The crankshaft bearing caps are machined with the engine block for proper alignment and clearance The crankshaft bearing caps are retained by two bolts and two studs each The number five crankshaft bearing at the rear of the engine block is the end thrust bearing The four connecting rod journals two rods per journal are spaced 90 degrees apart The crankshaft position sensor reluctor ring is pushed onto the rear of the crankshaft The crankshaft position sensor reluctor is constructed of powdered metal The reluctor ring has an interference fit onto the crankshaft and an internal keyway for correct positioning 2 3 5 Pistons and Connecting Rods The pistons are cast aluminum alloy that use two compression rings and one oil control ring assembly The piston pins are a floating fit in the pistons and the piston pins are retained by a press fit in the connecting rod assembly The pistons are coated to create an interference fit into the cylinder The connecting rods are forged steel and have precision insert type crankpin bearings The piston and connecting rod is only serviced as an assembly
187. the oil pump assembly Position the oil pump onto the locating pins 5 Install the oil pump bolt Tighten the bolts to 75 Nm 56 ft Ib 6 Install the oil pan Refer to Section 8 5 1 Oil Pan Replacement 8 6 3 Drive Removal 1 Remove the oil pump drive bolt 5 Remove the crankshaft oil deflector nuts 2 Remove the oil pump drive 6 Remove the crankshaft oil deflector 136 Section 8 Lubrication System TP 6105 8 05 8 6 05 Disassemble Important The oil pump pipe has a press fit into the oil pump Do not remove the pipe from the oil pump The pipe and oil pump are serviced as a complete assembly 1 Remove the oil pump driveshaft and retainer 5 Remove the following items e Retaining pin e Pressure relief spring e Pressure relief valve 8 6 6 Cleaning and Inspection Caution Refer to Safety Glasses Caution in Cautions and Notices 1 Clean the oil pump components in cleaning solvent 2 Dry the components with compressed air 3 Inspect the gears 427 428 for the following e Scoring e Chipping e Galling e Excessive wear 4 Remove the drive gear and the driven gear Match mark the gear teeth for reassembly TP 6105 8 05 Section 8 Lubrication System 137 4 Inspect the oil pump housing 422 for the following e Damaged bolt hole threads e Worn oil pump driveshaft bore e Scoring or excessive wear within the housing e Worn driven gear shaft 5 Inspect fo
188. thread locking compound or sealant are identified in the service procedure Do not use paints lubricants or corrosion inhibitors on fasteners or fastener joint surfaces unless specified These coatings affect fastener torque and joint clamping force and may damage the fastener Use the correct tightening sequence and specifications when installing fasteners to avoid damage to parts and systems Special Fastener Notice Notice This bolt is designed to permanently stretch when tightened The correct part number fastener must be used to replace this type of fastener Do notuse a bolt that is stronger in this application If the correct bolt is not used the parts will not be tightened correctly The system or the components may be damaged TP 6105 8 05 1 1 Fastener Tightening Specs Application Accessory drive belt tensioner bolt Nm ft Ib 50 37 Section 1 Specifications Application Exhaust manifold center bolt Nm ft Ib Exhaust manifold nut Nm ft Ib Air cleaner outlet duct clamp Nm in Ib 4 35 Exhaust manifold stud Nm ft Ib Battery cable channel bolt Nm in Ib 9 80 Exhaust manifold heat shield bolt Nm ft Ib Camshaft position sensor bolt Nm in Ib 12 106 Exhaust manifold heat shield nut Nm ft Ib Camshaft retainer bolt Nm in Ib 12 106 Flywheel bolt first pass Nm ft Ib Camshaft sprocket bolt Nm ft Ib
189. tices 1 Install a new crankshaft front oil seal using J 42851 2 Lubricate the sealing surface of the crankshaft front oil seal with clean engine oil Important Install the engine front cover and tighten the fasteners while the sealant is still wet to the touch 3 Apply sealant GM Part No U S 12346286 Canadian 10953472 or equivalent in two places 1 on the engine block where the front cover meets the oil pan 7 Tighten the engine front cover bolts a Tighten the engine front cover bolts in sequence a first pass to 6 Nm 53 in Ib b Tighten the engine front cover bolts in sequence a final pass to 12 Nm 106 in Ib 4 Install engine front cover gasket into front cover Important Use the following method when installing the engine front cover Failure to follow the instructions will push the sealant out which may cause an oil leak 8 Position the battery cable channel into place 5 Install the front cover and gasket 114 Section 7 Camshaft and Timing Gear Train TP 6105 8 05 9 Install the battery cable channel bolt Tighten the battery cable channel bolt to 9 Nm 80 in Ib 10 Inspect the CMP sensor O ring for cuts cracks tears or damage Replace as needed 11 Apply a light film of clean engine oil to the CMP sensor O ring 12 Install the CMP sensor Install the CMP sensor bolt Tighten the CMP sensor bolt to 12 Nm 106 in Ib 13 Install the engine harness clips
190. tices Definition Wear at the outside ribs of the drive belt s due to incorrect installation of the drive belt s 3 27 2 Test Description 1 This inspection is to verify that the drive belt s is correctly installed on all of the accessory drive pulley s Wear on the drive belt s may be caused by mispositioning the drive belt s by one or more grooves on a pulley s See item 2 in following table 2 The installation of a drive belt s that is too wide or too narrow will cause wear on the drive belt s The drive belt s ribs should match all of the grooves on the pulleys See item 3 in following table 3 This inspection is to verify the drive belt s is not contacting any part of the engine or body while the engine is operating There should be sufficient clearance when the accessory drive components load varies The drive belt s should not come in contact with an engine or a body component when snapping the throttle See item 4 in following table perform the necessary inspections Did you review Section 3 2 Symptoms Engine Mechanical for diagnostic information and Go to Section 3 2 Symptoms Engine Mechanical Go to Step 2 Inspect the drive belt s for proper installation Is the drive belt s installed properly Go to Step 5 Go to Step 3 Inspect for the drive belt s Is the correct drive belt s installed Go to Step 5 Go to Step 4 Was the drive belt s rubbing against anything Inspe
191. to Fastener Notice in Cautions and Notices 1 Clean the oil pump drive in cleaning solvent 2 Install the crankshaft oil deflector nuts Tighten the 2 Dry the oil pump drive with compressed air crankshaft oil deflector nuts to 50 Nm 37 ft Ib 3 Inspect the oil pump drive 1 for the following conditions e Excessive play in the oil pump drive bearing e Damage to the oil pump drive clamp bolt hole 2 e Damaged gear 3 for the following e Chipping e Galling e Wear e Damage to the oil pump drive shaft tang 4 Damage to the oil pump drive body 4 5 If the oil pump drive is to be reused lubricate the bearing with clean engine oil and apply grease to all Important During assembly install a new oil pump gear teeth 3 driveshaft retainer Slightly heat retainer above room temperature for ease of installation onto the oil pump driveshaft 3 Install clean engine oil into the oil pump through the outlet oil hole Rotate the pump in both directions to prime and lubricate 4 Assemble the oil pump driveshaft and a new retainer 5 Install the oil pump assembly Position the oil pump onto the locating pins TP 6105 8 05 Section 8 Lubrication System 139 6 Install the bolt attaching the oil pump to the rear 3 Install the oil pump drive making sure that the oil crankshaft bearing cap Tighten the oil pump bolt pump drive is fully seated in the engine block to 75 Nm 55 ft Ib Notice Refer to Fast
192. to the battery cable channel 14 Connect the CMP sensor electrical connector 1 15 Install the crankshaft balancer Refer to Section 6 1 Crankshaft Balancer Replacement 16 Install the water pump Refer to Section 9 2 Water Pump TP 6105 8 05 7 1 2 Removal Notice This component is initially installed using a self tapping bolt s Care should be taken when removing and or installing the self tapping bolt s Failure to use care when removing and or installing the self tapping bolt s can lead to damage and unnecessary replacement of the self tapping bolt s and or the components 1 Remove the camshaft position sensor bolt 2 Remove the camshaft position sensor 3 Inspect the camshaft position sensor O ring for cuts cracks tears or damage Replace the O ring as required 4 Remove the engine front cover bolts 521 5 Remove the engine front cover 522 Important reusable The engine front cover gasket is 6 Remove the engine front cover gasket 523 7 Remove the crankshaft front oil seal 125 from the engine front cover Section 7 Camshaft and Timing Gear Train 115 7 1 3 Installation Tools Required J 42851 Front Cover Oil Seal Installer 1 Lubricate the outer sealing surface of the crankshaft front oil seal lightly with clean engine oil DO NOT lubricate the inner portion of the seal 2 Position the new crankshaft front oil seal in the engine front cover so that the mark 1
193. tor position assurance CPA retainer from the ignition coil electrical connector 6 Inspect the valve rocker arm cover gasket for cuts or damage 7 Clean and inspect the valve rocker arm cover Refer to Section 4 1 3 Valve Rocker Arm Cover Cleaning and Inspection 2 Disconnect the ignition coil harness electrical connector 4 4 Installation Procedure Important Twist the spark plug boot 1 2 turn to release the boot Pull on the spark plug boot only Do not pull on the spark plug wire or the wire could be damaged 1 Install a new valve rocker arm cover gasket if the gasket was removed from the rocker arm cover 2 Install the valve rocker arm cover 3 Install the valve rocker arm cover bolts 3 Remove the spark plug wires from the spark plugs and ignition coils Notice Refer to Fastener Notice in Cautions and Notices TP 6105 8 05 Section 4 Cylinder Head and Valves 49 4 Tighten the valve rocker arm cover bolts in the sequence shown using two passes as shown a Tighten the bolts a first pass to 6 Nm 53 in Ib b Tighten the bolts a final pass to 12 Nm 106 in Ib Important Fully install the spark plug wire by pushing on the exposed end of the spark plug boot Do not push the spark plug wire onto the spark plug by using the metal heat shield 5 Install the spark plug wires to the spark plugs and ignition coils 6 Connect the ignition coil harness electrical connector 4
194. ulty oil pressure gauge 3 19 Oil Leak Diagnosis Action y y g repairing or replacing the component or by resealing the gasket surface Once the leak is identified determine the cause of the leak Repair the cause of the leak as well as the leak itself 1 1 Operate the engine until it reaches normal operating temperature 2 Place the engine on a level surface over a large sheet of paper or other clean surface 3 Wait 15 minutes 4 Check for drippings Go to Step 2 System OK Are drippings present Can you identify the type of fluid and the approximate location of the leak 1 Visually inspectthe suspected area Use a small mirrorto assist in looking at hard to see areas 2 Check for leaks at the following locations e Sealing surfaces e Fittings e Cracked or damaged components Go to Step 10 Go to Step 3 Go to Step 10 Go to Step 4 Can you identify the type of fluid and the approximate location of the leak 1 Completely clean the entire engine and surrounding components 2 Operate at normal operating temperature and at varying loads 3 Place the engine on a level surface over a large sheet of paper or other clean surface 4 5 Go to Step 10 Go to Step 5 Wait 15 minutes Identify the type of fluid and the approximate location of the leak Can you identify the type of fluid and the approximate location of the leak 1 Visually inspectthe suspected area Use a small mirrorto assist in looking
195. ve belt idler pulley bolt to 50 Nm 5 Remove the water pump gaskets 37 ft Ib 4 Remove the water pump 9 2 2 Cleaning and Inspection 9 2 Water Pump 9 2 1 Removal Tool Required J 41240 Fan Clutch Remover and Installer 1 Inspect the water pump pulley for damage at the belt contact area and the pulley to water pump mounting surface Important Do not immerse the water pump in solvent The solvent may enter the water pump s permanently lubricated bearings and cause premature bearing failure 1 Use J 41240 to retain the water pump pulley 2 Clean all excess dirt and debris from the water 2 Remove the water pump pulley bolts 302 and pump mousing pulley 303 3 Inspect the water pump for the following e Leakage at the hose fitting 1 e Leakage at the water pump weep hole 3 A stain around the weep hole is acceptable If leakage occurs dripping with the engine running and the cooling system pressurized replace the water pump e Gasket sealing surfaces 2 for excessive scratches or gouging e Restrictions within internal coolant passages 6 144 Section 9 Cooling System and Drive Belts TP 6105 8 05 e Excessive side to side play in the pulley shaft If 2 Install the water pump bolts shaft end play exceeds 0 381 mm 0 015 in replace the water pump 3 Tighten e Rotate the pump shaft by hand and inspect for roughness of operation If the hub wobbles is noisy or feels rough when rot
196. ver aligner and seal installer Magnetic base dial indicator Spark plug port adapter Dial indicator set Oylinder bore ridge reamer Piston ring compressor High intensity black light Valve spring compressor head off Camshaft bearing service set Oylinder bore gauge Oylinder head leakdown tester TP 6105 8 05 Carbon removal brush Engine lift bracket Attach to the rear of the right cylinder head and to the front of the left cylinder head Harmonic balancer remover Section 11 Special Tools and Equipment 165 J 39345 Tool Description Thread repair kit Illustration J 42851 Tool Description Front cover oil seal installer Illustration J 41240 Fan clutch wrench J 43105 Valve stem seal installer J 41712 Oil pressure Switch socket J 43320 Crankshaft rear seal puller J 42845 Crankshaft balancer installer J 42846 Crankshaft protector button J 43690 Rod bearing clearance checking tool See Section 5 1 5 for individual components J 42847 Flywheel holding tool J 43690 100 Rod bearing clearance checking tool adapter kit See Section 5 1 5 for individual components J 42849 Crankshaft rear seal installer 166 Section 11 Special Tools and Equipment J 45059 Angle meter J 45299 Engine preluber TP 6105 8 05 TP
197. vice the General Motors Powertrain engines In general this manual covers the service of the engine and associated standard equipment In some cases the engine is supplied with accessories and equipment unique to the application If service information is required on such unique accessories or equipment contact the generator set manufacturer who will forward the proper information or advise the service technician where it can be obtained The information in this manual is grouped in sections according to the type of work being performed The various sections are indicated in the Table of Contents of the manual TP 6105 8 05 Introduction This manual has been reprinted by the generator set manufacturer with the permission of General Motors Powertrain This manual is a reproduction of a General Motors Powertrain publication and contains information pertaining to industrial generator set engines Some information pertains to other applications of the engine The accuracy and completeness of information is the sole responsibility of General Motors Powertrain The descriptions and specifications contained in this manual were in effect at the time the book was released by General Motors Powertrain The generator set manufacturer and General Motors Powertrain reserve the right to discontinue models or change specs or design at any time without notice and without incurring obligation Introduction 7 Notes 8 Introduction TP 6105
198. y plug to 30 Nm 22 ft Ib 9 Apply sealant GM Part No U S 12346004 Canadian 10953480 or equivalent to the threads of the oil gallery plugs Section 5 Engine Block Pistons and Connecting Rods 91 10 Install the front oil gallery plugs Tighten the front oil gallery plugs to 30 Nm 22 ft Ib 11 Apply sealant GM Part No U S 12346004 Canadian 10953480 or equivalent to the threads of the oil gallery plugs 12 Install the rear oil gallery plugs Tighten the rear oil gallery plugs to 20 Nm 15 ft Ib 13 Apply sealant GM Part No U S 12346004 Canadian 10953480 or equivalent to the threads of the engine block oil cooler hose fittings 14 Install the engine block oil cooler hose fittings Tighten the engine block oil cooler hose fittings to 23 Nm 17 ft Ib Important Do not overtighten the knock sensor 92 Section 5 Engine Block Pistons and Connecting Rods 15 Install the left knock sensor to the engine block Tighten the left knock sensor to 20 Nm 15 ft Ib 16 Install the left side knock sensor heat shield 17 Install the left side knock sensor heat shield bolts Tighten the bolts to 12 Nm 106 in Ib Important Do not overtighten the knock sensor 18 Install the right knock sensor 719 to the engine block Tighten the right side knock sensor to 20 Nm 15 ft Ib 19 Install the right side knock sensor heat shield 720 and bolts 721 Tighten the bolts to 12 Nm

Download Pdf Manuals

Related Search

Related Contents

Philips 21PT2327C 21" real flat TV    SOLECTRIA Renewables PVI 1800 PVI 2500 Grid  Blixem User Manual  CC305-335-355_esp-ing (leitur  2GIG Guía del Usuario del Panel de Control  Télécharger  road and traffic information system - rti l:7 :9>i>dc - ESD  H-ISTRUZIONI FORNO A GAS  ecoTEC exclusiv  

Copyright © All rights reserved. Failed to retrieve file