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Service Manual, General Motors 4.3L Engine (TP

1. 156167 2000 Marine Industrial Engine To determine piston pin to bore clearance use an inside micrometer and measure the piston pin bore To determine the piston pin to bore clearance subtract the piston pin diameter from the piston pin bore diameter Refer to Engine Mechanical Specifications Measure the piston with a micrometer at a right angle to the piston pin bore measure the piston at 11 mm 0 433 in from the bottom of the skirt Refer to Engine Mechanical Specifications If the piston is not within specifications replace the piston and pin as an assembly Inspect the connecting rod for an out of round bearing bore Refer to Engine Mechanical Specifications Engine 17 Inspect the connecting rod for twisting 18 Inspect the connecting rod for damage to the bearing cap and bolt threads 19 Measure the piston compression ring end gap Important Fit each compression ring to the cylinder in which it will be used 20 Place the compression ring into the cylinder bore 20 1 Push the compression ring into the cylinder bore to approximately 6 5 mm 0 25 in above the ring travel The ring must be square to the cylinder wall 20 2 Use a feeler gauge in order to measure the end gap 20 3 Select another size ring set if the end gap exceeds specifications Refer to Engine Mechanical Specifications Piston Selection Tools Required J 8087 Cylinder Bore Gauge Important Measurements of all component
2. 188045 328540 2000 Marine Industrial 2 Engine 1 2 Using a wrench secure the J 43276 1 tool body 1 3 Insert the J 43276 2 forcing screw into the J 43276 1 tool body 1 4 Rotate the J 43276 2 forcing screw clockwise into the J 43276 1 tool body until the clutch pilot bearing is completely removed from the crankshaft 1 5 Rotate the J 43276 2 forcing screw counterclockwise to remove the J 43276 2 forcing screw from the J 43276 1 tool body 1 6 Remove the J 43276 1 tool body from the clutch pilot bearing Discard the clutch pilot bearing Exhaust Manifold Removal Left Notice Twist the spark plug boot one half turn in order 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 1 1 Rotate the spark plug wire boot one half turn 1 2 Pull outward on the spark plug wire boot to release from the spark plug Remove the spark plug wires from the spark plug wire retainers Remove the exhaust manifold bolts and the stud Remove the spark plug wire shields if applicable and the exhaust manifold Remove and discard the exhaust manifold gaskets Engine Marine Industrial 4 3L 6 37 Exhaust Manifold Removal Right Notice Twist the spark plug boot one half turn in order to release the boot Pull on the spark plug boot only Do not pull on the spark plug wire or the wire could be d
3. Engine 4 Assemble the valve stem oil seal onto the valve stem Caution Refer to Safety Glasses Caution in Cautions and Notices b Install the valve stem oil seal onto the valve guide using the J 42073 Tap the valve stem oil seal onto the valve guide until the J 42073 bottoms against the valve spring seat Inspect the valve stem oil seal The valve stem oil seal should not be bottomed against the valve guide There should be a 1 2 mm 0 03937 0 07874 in gap between the bottom edge of the valve stem oil seal and the valve guide Install the valve spring 3 Install the valve spring cap 2 onto the valve spring 3 and over the valve stem Marine Industrial 4 3L 6 105 1 0 2 0 mm 0 03937 0 07874 36373 480555 2000 Marine Industrial 6 106 Marine Industrial 4 3L Engine 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 Caution Refer to Safety Glasses Caution in Cautions and Notices 9 Use the J 8062 in order to compress the valve springs 10 Install the valve stem keys 10 1 Use grease in order
4. 32 Remove the 6 poppet nozzles from the lower intake manifold bores 33 Remove the fuel meter body 34 Remove the bolt and the fuel meter body bracket Intake Manifold Clean and Inspect Caution Refer to Safety Glasses Caution in Cautions and Notices 1 Clean the upper intake manifold in cleaning solvent 2 Dry the upper intake manifold with compressed air 334515 3 Clean the lower intake manifold in cleaning solvent 4 Dry the lower intake manifold with compressed air 480568 2000 Marine Industrial 6 118 Marine Industrial 4 3L 480569 480570 523513 2000 Marine Industrial Engine Inspect the upper intake manifold for the following Cracks or other damage to the exterior 1 Cracking or damage in the gasket grooves 2 and 3 Damage to the throttle body mounting surface 4 Loose or damaged bolt hole thread inserts 5 Inspect the lower intake manifold for the following Damage to the gasket sealing surfaces 1 2 and 3 Restricted exhaust gas recirculation EGR system passages Restricted cooling system passages 5 Cracks or damage Damage to the threaded bolt holes Intake Manifold Assemble Notice Refer to Fastener Notice in Cautions and Notices 1 If reusing the fastener apply threadlock GM P N 12345382 or equivalent to the threads of the fuel meter body bracket bolt Install the fuel meter body bracket and bolt Tighten Tighten the fuel me
5. 5 2 Wipe the oil from the connecting rod bearings 5 3 Wipe the oil from the crankpins 188017 Crankshaft Rear Oil Seal and Housing Removal 1 Remove the crankshaft rear oil seal from the crankshaft rear oil seal housing 2 Insert a suitable tool into the access notches and then carefully pry the crankshaft rear oil seal from the crankshaft rear oil seal housing 3 Discard the crankshaft rear oil seal 31379 2000 Marine Industrial 6 60 Marine Industrial 4 3L 2000 Marine Industrial 334317 334319 334326 Engine 4 Remove the crankshaft rear oil seal housing nut and bolts 5 Remove the crankshaft rear oil seal housing 6 Remove the crankshaft rear oil seal housing gasket 7 Discard the crankshaft rear oil seal housing gasket 8 Remove the crankshaft rear oil seal housing retainer stud from the engine block Engine Crankshaft and Bearings Removal 1 Mark or identify the crankshaft bearing cap locations direction and positions for assembly 2 Remove the crankshaft bearing cap bolts 3 Remove the crankshaft bearing caps 4 Remove the crankshaft 5 Remove the crankshaft bearings from the crankshaft bearing caps Marine Industrial 4 3L 6 61 334329 334336 334342 2000 Marine Industrial 6 62 Marine Industrial 4 3L Engine 6 Remove the crankshaft bearings from the engine block 334338 Engine Block Plug Removal Tools Required J 41712 Oil Pressu
6. Important The thread insert should be flush to 1 turn below the surface 8 9 Lubricate the thread insert with clean engine oil except when installing in aluminum and install the thread insert If the tang of the thread insert does not break off when backing out the thread insert installer break off the tang using a drift punch Marine Industrial 4 3L 6 125 4962 4963 2000 Marine Industrial 6 126 Marine Industrial 4 3L 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 Components not within the manufacturer s specification must be repaired or replaced 2000 Marine Industrial Engine When the components are re installed into an engine return the components to the original location position and direction During assembly lubricate all the moving parts with clean engine oil unless otherwise specified The engine oil will provide the initial lubrication when the engine is first started Engine Marine Industrial 4 3L 6 127 This page left intentionally blank 2000 Marine Industrial 6 128 Marine Industrial 4 3L 5270 480572 2000 Marine Industrial Engine Engine Block Plug Installation Tools Required J 41712 Oil Pressure Switch Socket Caution Refer to Safety Glasses Caution in Cautions and Notices Install a NEW oil filter by
7. 16 17 18 19 20 334517 21 Engine Install the engine wiring harness bracket and nut Tighten Tighten the engine wiring harness bracket nut to 12 Nem 106 Ib in Install the NEW fuel seals 8 black O rings into the fuel meter body Install the NEW spacer rings 7 flat washers into the fuel meter body Install the NEW fuel seals 6 yellow O rings into the fuel meter body Install the NEW fuel seal retainers 5 into the fuel meter body Install the fuel pipe 3 into the fuel meter body Install the fuel pipe retainer bracket 2 onto the fuel pipe Install the fuel pipe retainer bracket nuts 1 If reusing the fastener apply threadlock GM P N 12345382 or equivalent to the threads of the fuel pipe bolt Install the fuel pipe bolt 4 Tighten 22 1 Tighten the fuel pipe bracket nuts to 3 Nem 27 Ib in 22 2 Tighten the fuel pipe bolt to 6 Nem 53 Ib in Install a NEW manifold absolute pressure MAP sensor seal onto the MAP sensor Apply a small amount 1 drop of clean engine oil to the MAP sensor seal Install the MAP sensor into the upper intake manifold Engine Marine Industrial 4 3L 6 121 26 Install the ignition coil and studs Tighten Tighten the ignition coil studs to 12 Nem 106 Ib in 480561 27 If reusing the engine coolant temperature ECT sensor plug 1 or the ECT sensor 2 if equipped apply sealant GM P N 12346004 or equivalent to the threads of the ECT s
8. 8 4 9 2 mm 0 33 0 36 334543 2000 Marine Industrial 6 130 Marine Industrial 4 3L Engine 11 Apply sealant GM P N 12346004 or equivalent to the threads of the engine block right rear oil gallery plug the engine block left rear oil gallery plug and the engine block left side oil gallery plug Tighten 11 1 Tighten the engine block left side oil gallery plug and the engine block right rear oil gallery plug to 20 Nem 15 Ib ft 11 2 Tighten the engine block left rear oil gallery plug to 30 Nem 22 lb ft 5271 13 Install the dowel straight pins transmission locator if required 11 7 13 7 mm 0 47 0 53 334548 14 Install the left side dowel pins cylinder head locator if required 0 249 0 258 334303 2000 Marine Industrial Engine 15 Install the right side dowel pins cylinder head locator if required 16 Apply sealant GM P N 12346004 or equivalent to the threads of the engine block coolant drain hole plugs 17 Install the engine block coolant drain hole plugs Tighten Tighten the engine block coolant drain hole plugs to 20 Nem 15 Ib ft 18 Ifreusing the engine oil pressure sensor fitting apply sealant GM P N 12346004 or equivalent to the threads of the engine oil pressure sensor fitting Important Do not loosen the engine oil pressure fitting after the initial torque has been obtained 19 Install the engine oil pressure sensor fitting
9. oc co Caution Refer to Safety Glasses Caution in Cautions and Notices 5 Remove the crankshaft sprocket using the J 5825 A 2000 Marine Industrial 6 56 Marine Industrial 4 3L Engine 6 Remove the crankshaft balancer key Balance Shaft Removal 1 Remove the balancer shaft drive gear 9847 Important The balance shaft drive and balance shaft driven gears are serviced as a set The set includes the balance shaft driven gear bolt 2 Remove the balance shaft driven gear bolt from the balance shaft 2 1 Usea wrench in order to secure the balance shaft Place the wrench onto the balance shaft near to the balance shaft front bearing 2 2 Remove the balance shaft bolt 2 3 Remove the wrench from the balance shaft 3 Remove the balance shaft driven gear from the balance shaft 2000 Marine Industrial Engine 4 Remove the bolts and the balance shaft retainer Important The balance shaft and the balance shaft front bearing are serviced only as a package Do not remove the balance shaft front bearing from the balance shaft 5 Use a soft faced hammer in order to remove the balance shaft from the engine block Camshaft Removal 1 Remove the camshaft retainer bolts and Marine Industrial 4 3L 6 57 188031 188030 2000 Marine Industrial 6 58 Marine Industrial 4 3L Engine Notice All camshaft journals are the same diameter so care must be used in removing or installing the cams
10. 13 Valve Lifter Pushrod Guide 5 Spark Plug Wire Support 14 Valve Pushrod 6 Spark Plug Wire Support Bolt 15 Cylinder Head Gasket 7 Exhaust Manifold Gasket 16 Engine Lift Front Bracket 8 Exhaust Manifold 17 Cylinder Head Bolt 9 Exhaust Manifold Bolt 18 Cylinder Head 2000 Marine Industrial Engine Marine Industrial 4 3L 6 31 Lower Engine View 1 43 UM SS 1i N SEES x l LOB FR OL 2 e Late gt 9 ANNE ES A LAS S N ey Ke e Oo 1 AA QN e 9 Aimee a Legend 569262 1 Oil Level Indicator Tube Bolt A a Oil Filter Fitting 2 Oil Level Indicator 15 Oil Filter Bypass Valve 3 Oil Level Indicator Tube 16 Engine Coolant Drain Hole Plug 4 Engine Oil Pressure Sensor Fitting 17 Engine Block Core Hole Plug 5 Balance Shaft Bearing Rear 18 Dowel Pin Cylinder Head Locator 6 Knock Sensor 19 Water Pump Gasket 7 Expansion Cup Plug Balance Shaft Rear 20 Water Pump Bearing Hole 21 Water Pump Bolt 8 Engine Block Rear Oil Gallery Plug 22 Front Oil Gallery Plug 9 Expansion Cup Plug Camshaft Rear Bearing 23 Camshaft Bearings 206 24 Engine Camshaft KO Engine Pook l 25 Camshaft Retainer 11 Dowel Staion Pin Transmission Locator 26 Camshaft Retainer Bolt 12 Een pide Oil Gallery Plug 27 Balance Shaft Drive Gear 19 ORINE 28 Camshaft Sprocket 2000 Marine Industrial 6 32 Marine Industrial 4 3L 29 30 31 32 33 34
11. Always replace both the upper and lower crankshaft bearings as a unit Astandard or undersize crankshaft bearing combination may result in the proper clearance If the proper crankshaft bearing clearance cannot be achieved using the standard or the undersize crankshaft bearings it may be necessary to repair or replace the crankshaft 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 bearing surface 10 Remove the flattened gauging plastic 11 Measure the remaining crankshaft bearing journals Connecting Rod Side Clearance Measuring Procedure 1 Insert a feeler gauge between the connecting rod caps and measure the connecting rod side clearance Refer to Engine Mechanical Specifications 2 Connecting rod side clearances may also be measured with a dial indicator set Marine Industrial 4 3L 6 85 5163 2000 Marine Industrial 6 86 Marine Industrial 4 3L Engine Crankshaft Balancer Clean and Inspect Caution Refer to Safety Glasses Caution in Cautions and Notices 1 Clean the crankshaft balancer in cleaning solvent 2 Dry the crankshaft balancer with compressed air 3 Inspect the crankshaft balancer for the following Loose or improperly installed front groove pin 1 crankshaft balancer A properly installed front groove pin should be installed until flush or below flush with the face of the crankshaft balance
12. Engine Identification The Vehicle Identification Number VIN Derivative is located on the left side rear of the engine block 1 or on the right side rear 2 and typically is a nine digit number stamped or laser etched onto the engine at the vehicle assembly plant The first digit identifies the division The second digit identifies the model year The third digit identifies the assembly plant The fourth through ninth digits are the last six digits of the Vehicle Identification Number VIN 569359 Engines built at the Tonawanda engine plant have the engine identification number located at the right front top of the engine block The first digit 1 is the source code The second and third digits 2 are the month of the build The forth and fifth digits 3 are the date of the build The sixth seventh and eighth digits 4 are the broadcast code 195338 Engines built at the Romulus engine plant have the engine identification number located at the right front top of the engine block The first digit 1 is the source code The second and third digits 2 are the month of the build The forth digit 3 is the hour of the build The fifth and sixth digits 4 are the date of the build The seventh eighth and ninth digits 5 are the broadcast code 195339 2000 Marine Industrial Engine Lubrication Marine Industrial 4 3L 6 175
13. Engine Marine Industrial 4 3L 6 3 Fastener Tightening Specifications cont d Specification Application English Generator and Drive Belt Tensioner Bracket Stud Nut 30 Ib ft Ground Wire Bolt to Rear of Left Side Cylinder Head 12 Ib ft Ground Wire Nut to Rear of Right Side Cylinder Head 12 Ib ft t Bolt t t Drive Belt Tensi a Bracket Bolt to Generator and Drive Belt Tensioner 18 Ib ft Ignition Coil Stud 106 Ib in Knock Sensor 15 Ib ft Lower Intake Manifold Stud First Pass in Sequence 27 Ib in Second Pass in Sequence 106 Ib in Final Pass in Sequence 11 Ib ft Oil Cooler Pipe Bracket to Oil Pan Bolt 106 Ib in Oil Filter Fitting 41 Ib ft Oil Level Indicator Tube Bolt 106 Ib in 1 1 Oil Pan Baffle Bolt 106 Ib in Oil Pan Bolt and Nut 18 Ib ft Oil Pan Drain Plug 18 Ib ft Oil Pan Skid Plate Bolt 15 lb ft Oil Pump Bolt to Rear Crankshaft Bearing Cap 66 Ib ft Oil Pump Cover Bolt 106 Ib in Power Steering Pump Bracket Bolt to Engine 30 Ib ft Power Steering Pump Bracket Bolt to Engine 15 Ib in Power Steering Pump Bracket Stud Nut 30 Ib ft Power Steering Pump Bolt 37 Ib ft Power Steering Pump Nut to Engine Rear Bracket to Engine 30 Ib ft 50Nm Power Steering Pump Rear Bracket Nut 50 Nem 37 Ib ft Secondary Air Injection AIR Check Valve Pipe Bracket Bolt to Exhaust Manifold 10 Nem 89 Ib in Secondary Air Injection AIR Check Valve Pipe Stud Nut 18 Ib ft Spark Plug Initial Installation NEW Cylinder Head 30 Nem All S
14. Remove the valve rocker arms 2 Remove the valve rocker arm supports Engine 2 Remove the valve pushrods Cylinder Head Removal Left 1 Remove the engine coolant temperature sensor if applicable 2 Remove the engine coolant temperature gauge sensor if applicable Marine Industrial 4 3L 6 45 387769 387767 2000 Marine Industrial Engine 6 46 Marine Industrial 4 3L v ie a x pun a 7 o lt S E tc 328582 x o a 2 2 D o E z D a x D o E S o c Q o Re o 2 E tc lt 5 Remove the cylinder head bolts 480533 2000 Marine Industrial Engine Marine Industrial 4 3L 6 47 Notice After removal place the cylinder head on two wood blocks to prevent damage 6 Remove the cylinder head 7 Remove and discard the cylinder head gasket 334299 8 Remove the dowel pins cylinder head locator if required 330548 2000 Marine Industrial 6 48 Marine Industrial 4 3L Engine Cylinder Head Removal Right 1 Remove the spark plugs 328586 2 Remove the bolts and the spark plug wire support 328590 3 Remove the cylinder head bolts 480537 2000 Marine Industrial Engine Marine Industrial 4 3L 6 49 Notice After removal place the cylinder head on two wood blocks to prevent damage 4 Remove the cylinder head 480538 5 Remove a
15. enlarged out of round or damaged engine block camshaft bearing bore Important Always remove the camshaft inner bearings 2 and 3 first The camshaft outer bearings 1 and 4 serve as a guide for the J 33049 Caution Refer to Safety Glasses Caution in Cautions and Notices 3 Remove the camshaft inner bearings 2 and 3 3 1 Insert the J 33049 through the front of the engine block and into the camshaft inner bearing 2 3 2 Tighten the J 33049 expander assembly nut until snug 3 3 Push the J 33049 guide cone into the camshaft front bearing in order to align the J 33049 3 4 Drive the camshaft inner bearing 2 from the camshaft inner bearing bore 2 4985 3 5 Loosen the J 33049 expander assembly nut 3 6 Remove the camshaft inner bearing 2 from the J 33049 expander assembly 3 7 Insert the J 33049 expander assembly into the camshaft inner bearing 3 3 8 Tighten the J 33049 expander assembly nut until snug 3 9 Push the J 33049 guide cone into the camshaft front bearing in order to align the J 33049 3 10 Drive the camshaft inner bearing 3 from the camshaft inner bearing bore 3 3 11 Loosen the J 33049 expander assembly nut 3 12 Remove the camshaft inner bearing 3 from the J 33049 expander asssembly 4 Remove the J 33049 from the engine block 5 Remove the camshaft outer bearings 1 and 4 5 1 Insert the J 33049 into the camshaft outer bearing 1 5 2 Tighten the J 33049 expander assembly nut until snug 5 3
16. exhaust valve for each cylinder A spark plug is located between the valves in the side of the cylinder head The valve guides and seats are integral to the cylinder head The 4 3L heavy duty applications have pressed in exhaust valve seats The valve rocker arms are positioned on the valve rocker arm supports and retained by a bolt Engine Block The cast iron engine block has six cylinders arranged in a V shape with three cylinders in each bank Starting at the front side of the engine block the cylinders in the left bank are numbered 1 3 5 and cylinders in the right bank are numbered 2 4 6 when viewed from the rear The firing order of the cylinders is 1 6 5 4 3 2 The cylinders are encircled by coolant jackets Exhaust Manifolds The cast iron exhaust manifolds direct exhaust gases from the combustion chambers to the exhaust system The left side exhaust manifold has a port for the EGR valve inlet pipe Intake Manifold The intake manifold is a two piece design The upper portion is made from a composite material and the lower portion is cast aluminum The throttle body attaches to 2000 Marine Industrial Engine the upper manifold The lower manifold has an exhaust gas recirculation EGR port cast into the manifold for mixture The EGR valve bolts into the lower intake manifold The Central Sequential Multiport Fuel Injection system uses multiple fuel injectors to meter and distribute fuel to each engine cylinder The Centr
17. or the accessory drive Diagnostic Aids components When removing the drive belt s the f i water pump may not be operating and the engine The drive belt s will not cause the whine noise may overheat Also DTCs may set when the If the whine noise is intermittent verify the accessory engine is operating with the drive belt s drive components by varying their loads making sure removed Mey dio operated tote merum esperan 4 The inspection should include checking the drive overcharged A C system power steering system with a pinched hose or wrong fluid or a generator failing are suggested items to inspect belt tensioner and the drive belt idler pulley bearings The drive belt s may have to be installed and the accessory drive components Test Description operated seperately by varying their loads Refer The number s below refer to the step number s on to the suspected accessory drive component for the diagnostic table the proper inspection and replacement 3 This test is to verify that the noise is being procedure Drive Belt Whine Diagnosis Notice Refer to Belt Dressing Notice in Cautions and Notices DEFINITION A high pitched continuous noise that may be caused by an accessory drive component failed bearing Did you review the Drive Belt Symptom operation and perform Go to Symptoms the necessary inspections Go to Step 2 Drive Belt Verify that there is a whine noise Go to Does the engine make the whine noise Go to St
18. 191 62 215 mm 2 4485 2 4494 in 2000 Marine Industrial Engine Marine Industrial 4 3L 6 5 Engine Mechanical Specifications cont d 0 0010 in Maximum 4 0007 4 0017 in 0 00050 in Maximum Out of Round Service 0 002 in Maximum Taper Production Relief Side 0 0010 in Maximum 0 0005 in Maximum 0 0010 in Maximum 0 004 in Maximum 0 010 in Maximum 0 002 in Maximum 0 10 mm Maximum 0 004 in Maximum ED o ooo an i o Oil Pan Alignment at Rear of Engine Block 0 3 mm Maximum 0 011 in Maximum KI MEME a ee ae es ee l 0 0007 0 0024 in 0 0029 in Maximum EIS ims 22 gt ee AN MEM 0 0005 0 0009 in 0 010 in Maximum 0 9270 0 9271 in Interference Interference 0 010 0 016 in 0 018 0 026 in 0 19 in Maximum 0 31 in Maximum 0 0012 0 0027 in 0 0015 0 0031 in 0 0033 in Maximum 0 010 0 029 in 0 035 in Maximum 0 0018 0 00037 in 0 0039 in Maximum 0 031 in Minimum 10 879 mm 10 527 mm 0 05 mm Maximum 0 002 in Maximum 1 651 2 489 mm 2000 Marine Industrial 6 6 Marine Industrial 4 3L Engine Engine Mechanical Specifications cont d Valve Stem Oil Seal Installed Height Measured from the Top of the Large Diameter Valve Guide Bevel to the Bottom of the Valve Stem 1 2 mm 0 03937 0 07874 in Oil Seal GM SPO Group Numbers Application Accelerator Control Cable Bracket Balance Shaft Balance Shaft Bearing Kit Rear Balance Shaft Gear Kit Includes Drive and Dri
19. 2 Remove the oil filter if applicable 3 Discard the oil filter if applicable 188050 4 Remove both the engine block coolant drain hole plugs and allow the coolant to drain into a suitable container 188052 2000 Marine Industrial Engine Marine Industrial 4 3L 6 35 Engine Flywheel Removal 1 Remove the engine flywheel bolts 2 Remove the engine flywheel automatic transmission 1 if applicable 3 Remove the engine flywheel manual transmission 2 if applicable Important If replacing the engine flywheel manual transmission then NEW flywheel weights must be installed into the NEW engine flywheel in the same location as the old flywheel weights in the old engine flywheel Note the position of any flywheel weights for assembly if applicable 64126 Clutch Pilot Bearing Removal Tools Required J 43276 Clutch Pilot Bearing Remover Caution Refer to Safety Glasses Caution in Cautions and Notices Notice When using the J 43276 Clutch Pilot Bearing Remover always secure the J 43276 1 Clutch Pilot Bearing Remover tool body using a wrench Do not allow the J 43276 1 Clutch Pilot Bearing Remover tool body to rotate Failing to do so will cause damage to the J 43276 1 Clutch Pilot Bearing Remover tool body 1 Remove the clutch pilot bearing using the J 43276 1 1 Install the J 43276 tool body into the clutch pilot bearing 353275 2000 Marine Industrial 6 36 Marine Industrial 4 3L
20. Bolt Stud Expansion Cup Plug Balance Shaft Rear Bearing Hole Expansion Cup Plug Camshaft Rear Bearing Hole Fuel Meter Body Bracket Bolt Fuel Pipe Bolt Lower Intake Manifold Bolt Oil Level Indicator Tube Oil Pump Screen Tube Throttle Body Stud Upper Intake Manifold Stud Valve Train Component Prelube Water Pump Bolt Threadlock Threadlock Adhesive Sealant Adhesive Adhesive Adhesive Sealant Threadlock Sealant Sealant Sealant SAE 5W 30 Oil Sealant Sealant Lubricant Threadlock Threadlock Sealant Sealant Threadlock Threadlock Threadlock Sealant Sealant Threadlock Threadlock Lubricant 12345382 12345382 12346141 12346004 12346141 12346141 12346141 12346004 12345382 12346004 12346004 12346004 12345610 12346004 12346004 1052367 12345382 12345382 12346004 12346004 12345382 12345382 12345382 12346004 12346004 12345382 12345382 12345501 2000 Marine Industrial 6 10 Marine Industrial 4 3L Engine Diagnostic Information and Procedures Base Engine Misfire Diagnosis Engine Performance diagnosis procedures are covered in Engine Controls and should be consulted for diagnosis of any Drivability Emissions or Malfunctioning Indicator Lamp MIL concerns The following diagnosis covers common concerns and possible causes When the proper diagnosis is made the concern should be corrected by adjustment repair or replacement as required Refer to the appropriate section of the service manu
21. Diagnostic Aids Operate the system in order to verify the repair Did you correct the condition System OK Go to Step 3 Drive Belt Falls Off Diagnosis component incorrect installation of the accessory Diagnostic Aids drive component pulley or the pulley bent inward If the drive belt s repeatedly falls off the drive belt 9r outward Troarn a previous Epa les 10ER i Mn misaligned pulley using a straight edge in the pulleys this is because of pulley misalignment pulley grooves across two or three pulleys If a m Inspect for damaged fan blades or bent fan clutch shaft if the fan is belt driven Refer to Fan Clutch Replacement in Engine Cooling Did you find and correct the condition Go to Step 11 Go to Step 9 Wu Ea An extra load that is quickly applied and released by misaligned pulley is found refer to that accessory an accessory drive component may cause the drive drive component for the proper installation belt to fall off the pulleys Verify the accessory drive procedure of that pulley components operate properly 5 Inspecting the pulleys for being bent should If the drive belt s is the incorrect length the drive belt include inspecting for a dent or other damage to tensioner may not keep the proper tension on the the pulleys that would prevent the drive belt from drive belt not seating properly in all of the pulley grooves or Test Description on the smooth surface of a pulley when the back The number s below refer to th
22. Engine Lubrication Full pressure lubrication through a full flow oil filter is supplied by a gear type oil pump Oil is drawn up through the oil pump screen and passes through the pump to the oil filter The oil filter is full flow paper element unit with an anti drain back valve An oil filter bypass valve is used to ensure adequate oil supply in the event the filter becomes plugged or develops excessive pressure drop Filtered oil flows into the main gallery and then to the camshaft the balance shaft the rear bearing and the crankshaft bearings The valve lifter oil gallery supplies oil to the valve lifters Oil flows from the valve lifters through the hollow valve pushrods to the valve rocker arms Oil drains back to the crankcase through the oil drain holes in the cylinder head The camshaft timing chain is drip fed from the front camshaft bearing The pistons e z i and piston pins are lubricated by oil splash Cleanliness and Care 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 When any internal engine parts are serviced care and cleanliness is important When components are removed for service the components should be marked organized or retained in a specific order for re assembly 2000 Marine Industrial 6 176 Mar
23. Inspect for misalignment of the pulleys Did you find and repair the condition Go to Step 12 Go to Step 5 Inspect for a bent or dented pulley Did you find and repair the condition Inspect for a bent or cracked bracket Did you find and repair the condition Inspect for improper loose or missing fasteners Did you find loose or missing fasteners Tighten any loose fasteners Replace improper or missing fasteners Refer to Fastener Tightening Specifications Does the drive belt continue to fall off Does the drive belt tensioner operate correctly Replace the drive belt tensioner Refer to Drive Belt Tensioner Replacement Does the drive belt continue to fall off Inspect for failed drive belt idler and drive belt tensioner pulley bearings Did you find and repair the condition Operate the system in order to verify the repair Did you correct the condition Drive Belt Excessive Wear Diagnosis Diagnostic Aids Excessive ewar on a drive belt s is usually caused by an incorrect installation or the wrong drive belt for the application Minor misalignment of the drive belt pulleys will not cause excessive wear but will probably cause the drive belt s to make a noise or to fall off Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the drive belt s fall off Test Description The number s below refer to the step number s on the diagnostic table Test the drive b
24. Torque Values and or Fastener Tightening Strategies Marine Industrial 4 3L 6 173 e Cylinder head bolts the crankshaft bearing cap bolts the connecting rod bolts and balance shaft bolt apply a torque angle strategy In an on vehicle situation where a torque angle meter may not fit into the vehicle packaging a three step tightening process may be followed using a torque wrench Certain fasteners should not be reused Bolts studs or other fasteners that must be replaced will be called out in the specific service procedures Changed Engine Specifications Engine mechanical specifications remain the same as the 1999 products New Sealants and or Adhesives No new sealants or adhesives have been added Disassembly and Assembly Procedure Revisions Valve rocker arm and pushrod Timing chain and sprockets Discard all used gaskets seals or O ring seals unless otherwise indicated Gaskets seals or O ring seals that can be reused will be identified in the specific service procedure Engine Mechanical Diagnostic Procedure Revisions Valve Train diagnostic information is now provided in table form Potential or probable causes are supplied for each specific concern Engine Noise diagnostic information is now provided in table form Potential or probable causes are supplied for each specific concern New Special Tools Required No new special tools are required 2000 Marine Industrial 6 174 Marine Industrial 4 3L
25. Vulcanizing RTV Anaerobic sealant which include the following Gasket eliminator Pipe Threadlock Aerobic Type Room Temperature Vulcanizing RTV Sealant Aerobic type Room Temperature Vulcanizing RTV sealant cures when exposed to air This type of sealant is used where 2 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 The exhaust manifold The head gasket Any other surfaces where a different type 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 Use a plastic or wood scraper in order to remove all the RTV sealant from the components Important Do not allow the RTV sealant to enter any blind threaded holes as it may prevent the fasteners from Engine clamping properly or cause damage when the fastener is tightened The surfaces to be sealed must be clean and dry Use a RTV sealant bead size as specified in the service procedure Apply the RTV sealant bead to the inside of any bolt hole areas Assemble the components while the RTV sealant is still wet to the touch within 3 minutes Do not wait for the RTV sealant to skin over Tighten the fasteners in sequence if specified and to the pr
26. be an internal engine noise Removing the drive belt and operating the engine for a brief period will verify the noise is related to the drive belt When removing the drive belt s the water pump may not be operating and the engine may overheat Also DTCs may set when the engine is operating with the drive belt removed 4 Inspect all drive belt pulleys for pilling Pilling is the small balls or pills or it can be strings in the drive belt grooves from the accumulation of rubber dust 10 12 14 2000 Marine Industrial Engine failure of an accessory drive component Drive belt symptoms may occur from changes in load of the accessory drive components Ambient temperatures moisture or engine operating temperature can affect the drive belt operation Symptoms List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom Drive Belt Chirping Diagnosis Drive Belt Squeal Diagnosis Drive Belt Whine Diagnosis Drive Belt Rumbling Diagnosis Drive Belt Vibration Diagnosis Drive Belt Falls Off Diagnosis Drive Belt Excessive Wear Diagnosis Misalignment of the pulleys may be caused from improper mounting of the accessory drive component incorrect installation of the accessory drive component pulley or the pulley 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 pull
27. be used to apply the correct amount of sealant onto the gaskets Applying excessive amounts of sealant may prohibit the intake manifold gaskets from sealing properly Important The lower intake manifold must be installed and the fasteners tightened while the adhesive is still wet to the touch 3 Apply a 5 0 mm 0 197 in bead of adhesive GM P N 12346141 or equivalent to the front top of the engine block Extend the adhesive bead 13 mm 0 50 in onto each lower intake manifold gasket 0 50 4 Apply a 5 0 mm 0 197 in bead of adhesive GM P N 12346141 or equivalent to the rear top of the engine block Extend the adhesive bead 13 mm 0 50 in onto each lower intake manifold gasket 26743 2000 Marine Industrial 6 160 Marine Industrial 4 3L 31510 188150 328579 2000 Marine Industrial Engine 5 Install the lower intake manifold onto the engine block Notice Refer to Fastener Notice in Cautions and Notices 6 If reusing the fasteners apply threadlock GM P N 12345382 or equivalent to the threads of the lower intake manifold bolts 7 Install the lower intake manifold bolts Notice Proper lower intake manifold fastener tightening sequence and torque is critical Always follow the tightening sequence and torque the intake manifold bolts using the 3 step method Failing to do so may distort the crankshaft bearing bore alignment and cause damage to the crankshaft bearings 8 Tighten the lower intake
28. before the piston is checked for fit clean the cylinder bore with hot water and detergent 7 1 Scrub the cylinder bores with a stiff bristle brush 7 2 Rinse the cylinder bores thoroughly with clean hot water 7 3 Dry the cylinder bores with a clean rag 7 4 Do not allow any abrasive material to remain in the cylinder bores Abrasive material may cause premature wear of the new piston rings and the cylinder bores Abrasive material will contaminate the engine oil and may cause premature wear of the bearings Perform final measurements of the piston and the cylinder bore Permanently mark the top of the piston for the specified cylinder to which it has been fitted Apply clean engine oil to each cylinder bore in order to prevent rusting Boring Procedure Caution Refer to Safety Glasses Caution in Cautions and Notices 1 Before starting the honing or reboring operation measure all the new pistons with the micrometer contacting at points exactly 90 degrees from the piston pin centerline File the top of the cylinder block in order to remove any dirt or burrs before using any type of boring bar Follow the instructions furnished by the manufacturer regarding the use of the boring equipment When reboring the cylinders make sure all the crankshaft bearing caps are installed in the original position and direction Tighten the crankshaft bearing caps to the proper torque specifications in order to avoid distortion o
29. contact surfaces must be smooth with no scoring or excessive wear e Shaft for bends 3 Roll the valve pushrod on a flat surface to determine if the valve pushrod is bent 488857 6 Inspect the valve rocker arm support for excessive wear or damage 480553 2000 Marine Industrial 6 98 Marine Industrial 4 3L Engine Valve Lifters and Guides Clean and Inspect Important Parts that are to be reused must be marked sorted and organized for assembly 1 Mark sort and organize the components for assembly Caution Refer to Safety Glasses Caution in Cautions and Notices 2 Clean the components with cleaning solvent 3 Dry the components with compressed air 188118 4 Inspect the valve lifter pushrod guides for excessive wear 5 Inspect the valve lifter pushrod guides for cracks or damage 334500 6 Inspect the valve lifter for the following Broken or damaged clip 1 Worn pushrod socket 2 e Scuffed or worn lifter body 3 If the valve lifter shows scuffing or wear inspect the engine block valve lifter bores for wear Worn roller 4 Loose or damaged pin 5 Plugged oil hole 6 178485 2000 Marine Industrial Engine Marine Industrial 4 3L 6 99 Cylinder Head Disassemble Tools Required J 8062 Valve Spring Compressor Caution Compressed valve springs have high tension against the valve spring compressor Valve springs that are not properly compressed by or released from the
30. crankshaft rear oil seal is installed near to flush and square to the crankshaft rear oil seal housing Increased resistance will be felt when the crankshaft rear oil seal has reached the bottom of the crankshaft rear oil seal housing bore 14 2 Turn the J 35621 B wing nut counterclockwise to release the J 35621 B from the crankshaft rear oil seal 15 Remove the J 35621 B from the crankshaft 16 Wipe off any excess engine oil with a clean rag Piston Connecting Rod and Bearing Installation Tools Required J 5239 Connecting Rod Bolt Guide Set J 8037 Ring Compressor J 36660 Electronic Torque Angle Meter 1 Apply clean engine oil to the following components The piston The piston rings The cylinder bore The bearing surfaces 2 Install the J 5239 onto the connecting rod bolts Engine Marine Industrial 4 3L 6 137 3 Install the J 8037 onto the piston and compress the piston rings 480573 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 connecting rod cap should face to the front of the engine block on the left bank and to the rear of the engine block on the right bank 4 Install the piston and connecting rod assembly and the J 8037 into the proper cylinder bore 492144 5 Use the J 8037 and the J 5239 and lightly tap the top of the piston with a wooden hammer handle 5 1 Hold the J 8037 firmly against the engine block
31. crankshaft speed and one knock per flash is the engine camshaft speed If the noise is timed to the engine camshaft speed inspect the following Missing or loose valve train components Worn or loose valve rocker arms Worn or bent valve pushrods Faulty valve springs Bent or burnt valves Worn engine camshaft lobes Worn or damaged camshaft timing chain and or sprockets iipariant A slight COLD knock or piston slapping noise could be considered normal if not present after the engine has reached normal operating temperatures If the knock is timed to the crankshaft speed inspect the following Worn crankshaft or connecting rod bearings Piston ro cylinder damage Worn piston or piston pin Faulty connecting rod Excessive carbon build up on the top of the piston No Abnormal Internal Engine Noise Inspect for a worn or improperly installed camshaft timing chain and or sprockets Remove the valve rocker arm cover on the side of the engine with the cylinder that is misfiring Inspect for the following Loose valve rocker arm studs Bent valve push rods Faulty valve springs Faulty valve lifters bleeding down Worn or improperly seated valves Worn engine camshaft lobes Engine Compression Test 1 Disconnect the positive ignition coil wire plug from ignition coil Disconnect the fuel injector electrical connector Remove all the spark plugs Block the throttle plate wide open Charge the battery if the battery is not fully
32. gear and the balance shaft driven gear timing marks are aligned 5144 Timing Chain and Sprockets Installation Tools Required J 5590 Installer 1 Install the crankshaft balancer key into the crankshaft keyway The crankshaft balancer key should be parallel to the crankshaft or with a slight incline 387766 2000 Marine Industrial Engine Marine Industrial 4 3L 6 143 2 Align the keyway of the crankshaft sprocket with the crankshaft balancer key Caution Refer to Safety Glasses Caution in Cautions and Notices 3 Use the J 5590 in order to install the crankshaft sprocket 4 Rotate the crankshaft until the crankshaft sprocket is at the 12 o clock position Important Install the camshaft sprocket with the alignment mark at the 6 o clock position 5 Install the camshaft sprocket and the camshaft timing chain 480546 6 Look to 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 480575 2000 Marine Industrial 6 144 Marine Industrial 4 3L Engine Notice Refer to Fastener Notice in Cautions and Notices Important Do not use a hammer to install the camshaft sprocket onto the camshaft To do so may dislodge the expansion cup plug camshaft rear bearing hole 7 Install the camshaft sprocket bolts Tighten Tighten the camshaft sprocket bolts to 25 Nem 18 Ib ft 480544 7 Install the crankshaft pos
33. grooves with a suitable ring groove cleaning tool 4 Clean the piston oil lubrication holes and slots 5 Inspect the piston for the following Eroded areas 1 on the top of the piston Scuffed or damaged skirt 2 Damage to the pin bore 3 Cracks in the piston ring lands the piston skirt or the pin bosses Piston ring grooves for nicks burrs or other warpage which may cause the piston ring to bind 6 Inspect the piston pin for scoring wear or other damage Engine 7 12 Measure the piston ring to piston ring groove side clearance 7 1 Insert the edge of the piston ring into the piston ring groove 7 2 Rollthe piston ring completely around the piston If binding is caused by a distorted piston ring groove MINOR imperfections may be removed with a fine file e f binding is caused by a distorted piston ring replace the piston ring Measure the piston ring side clearance with a feeler gauge If the side clearance is too small try another piston ring set If the proper piston ring to piston ring groove clearance cannot be achieved replace the piston and pin assembly To determine the proper piston ring side clearance refer to Engine Mechanical Specifications To determine piston pin to bore clearance use a micrometer and measure the piston pin Marine Industrial 4 3L 6 71 4969 22934 4976 2000 Marine Industrial 6 72 Marine Industrial 4 3L 13 14 4975 15 188016 16
34. harness 387772 Valve Rocker Arm Cover Installation Left Important Do not reuse the valve rocker arm cover gasket or the valve rocker arm cover grommets 1 Install the NEW valve rocker arm cover gasket into the groove of the valve rocker arm cover 2 Install the NEW valve rocker arm cover bolt grommets into the valve rocker arm cover 328573 3 Install the valve rocker arm cover onto the cylinder head 480519 2000 Marine Industrial Engine Marine Industrial 4 3L 6 165 Notice Refer to Fastener Notice in Cautions and Notices 4 Install the valve rocker arm cover bolts Tighten Tighten the valve rocker arm cover bolts to 12 N m 106 Ib in 328566 Valve Rocker Arm Cover Installation Right Important Do not reuse the valve rocker arm cover gasket or the valve rocker arm cover bolt grommets 1 Install the NEW valve rocker arm cover gasket into the groove of the valve rocker arm cover 2 Install the NEW valve rocker arm cover bolt grommets into the valve rocker arm cover 328573 3 Install the valve rocker arm cover onto the cylinder head 480524 2000 Marine Industrial 6 166 Marine Industrial 4 3L 328568 330580 2000 Marine Industrial 4 Engine Notice Refer to Fastener Notice in Cautions and Notices 4 Install the valve rocker arm cover bolts Tighten Tighten the valve rocker arm cover bolts to 12 N m 106 Ib in Oil Level Indicator and Tube Installa
35. manifold bolts Tighten 8 1 Tighten the bolts in sequence 1 8 on the first pass to 3 Nem 27 lb in 8 2 Tighten the bolts in sequence 1 8 on the first pass to 12 Nem 106 lb in 8 3 Tighten the bolts in sequence 1 8 on the first pass to 15 Nem 11 Ib ft Connect the evaporative emission EVAP canister solenoid valve harness 9 1 Push the elbow inward until the quick connect snaps into place 9 2 Pull the elbow outward in order to ensure proper connection Engine Marine Industrial 4 3L 6 161 Distributor Installation Important The engine front cover has 2 alignment tabs and the crankshaft balancer has 2 alignment marks Spaced 90 degrees apart which are used for positioning number 1 piston at Top Dead Center TDC With the piston on the compression stroke and at top dead center the crankshaft balancer alignment mark 1 must align with the engine front cover tab 2 and the crankshaft balancer alignment mark 4 must align with the engine front cover tab 3 Rotate the crankshaft balancer clockwise until the alignment marks on the crankshaft balancer are aligned with the tabs on the engine front cover and the number 1 piston is at top dead center of the compression stroke 334551 1 Remove the distributor cap bolts and discard 2 Remove the distributor cap 301393 3 Install a NEW distributor gasket onto the distributor 523516 2000 Marine Industrial 6 162 Marine Industrial 4 3L
36. pulley across the accessory drive component puleys 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 are applied to the drive belt by the accessory drive components and the crankshaft The drive belt system may have an idler pulley which is used to add wrap to the adjacent pulleys Some systems use an idler pulley in place of an accessory drive component when the vehicle is not equipped with the accessory New Product Information The purpose of New Product Information is to highlight or indicate important product changes from the previous model year Changes may include one or more of the following items e A component comparison from the previous year Fastener changes Torque values and or fastener tightening strategies Changed engine specifications New sealants and or adhesives e Disassembly and assembly procedure revisions Engine mechanical diagnostic procedure revisions New special tools required Component Comparison Eliminated the oil filter adapter assembly Revised the water pump seal Revised the engine coolant thermostat New roller type timing chain and sprockets New roller pivot type valve rocker arm assemblies using a one piece valve rocker arm support to replace the ball pivot type valve rocker arm system e Cylinder heads revised using dry holes for the valve rocker arm bolts
37. pump driven gear and the oil pump body internal surfaces 4 Install the oil pump drive gear and the oil pump driven gear into the oil pump body 4 1 Align the matchmarks on the oil pump drive and driven gears 4 2 Install the smooth side of the oil pump drive and driven gears toward the oil pump cover Marine Industrial 4 3L 6 109 30401 5278 2000 Marine Industrial 6 110 Marine Industrial 4 3L Engine 4 Install the oil pump cover 5277 Notice Refer to Fastener Notice in Cautions and Notices 5 Install the oil pump cover bolts Tighten Tighten the bolts to 12 Nem 106 Ib in 6 Inspect the oil pump for smoothness of operation by turning the oil pump driveshaft by hand 7 Install the oil pump screen 7 1 If removed replace the oil pump screen The oil pump screen must have a good press fit into the oil pump body 7 2 Mount the oil pump in a soft jawed vise 7 3 Apply sealant GM P N 12346004 or equivalent to the end of the oil pump screen pipe 7 4 Use the J 21882 and a soft faced hammer in order to tap the oil pump screen into the pump body The oil pump screen must align parallel with the bottom of the oil pan when the oil pan is installed J 21882 5280 2000 Marine Industrial Engine Important Install a NEW oil pump driveshaft retainer during assembly 8 Install the oil pump driveshaft and the NEW oil pump driveshaft retainer Valve Rocker Arm Cover Clean and Inspect
38. seized pulley or a faulty accessory drive component Did you review the Drive Belt Symptom operation an d perform Go to Symptoms the necessary inspections Go to Step 2 Drive Belt Verify that there is a squeal noise Go to Does the engine make the squeal noise Go to Step 3 Diagnostic Aids 1 Remove the drive belt s 2 Operate the engine for no longer than 30 to 40 seconds Go to Engine Does the chirping noise still exist Noise Diagnosis Go to Step 4 Inspect for an accessory drive component seized bearing or faulty accessory drive component Did you find and correct the condition Go to Step 9 Go to Step 5 2000 Marine Industrial Engine Marine Industrial 4 3L 6 21 Drive Belt Squeal Diagnosis cont d Step ction vauwes Yes No Test the drive belt tensioner for proper operation Refer to Drive Belt Tensioner Diagnosis Did you find and correct the condition Go to Step 9 Go to Step 6 Inspect for the correct drive belt length Refer to Drive Belt EM MM PR Replacement Did you find and correct the condition Go to Step 9 Go to Step 7 7 Inspect for a misalignment of a pulley Did you find and correct the condition Go to Step 9 Go to Step 8 Inspect for the correct pulley size Go to Did you find and correct the condition Go to Step 9 Diagnostic Aids Operate the system in order to verify the repair Did you correct the condition System OK Go to Step 3 Drive Belt Whine Diagnosis caused by the drive belt s
39. the connecting rod bearing is satisfactory Replace the connecting rod bearing if the clearance is not within specifications Always replace both the upper and the lower connecting rod bearings as an assembly A standard or undersize connecting rod bearing combination may result in the proper clearance If the proper connecting rod bearing clearance cannot be achieved using the standard or the undersize connecting rod bearings it will be necessary to replace or repair the crankshaft Marine Industrial 4 3L 6 83 Engine Plastic Gauge Method for Crankshaft Bearings x O Q a o S o c o o fa o 2 E 7 D c oO o a d t Re Q x c g o o Z i R 7 c 1 334338 a t x c o o x T amp to E 2 334336 Es c pam 5 2 o o S S S z 5 2 o S 2 E amp ox D S Oo 3 oO D fe w s D 3 500655 2000 Marine Industrial 6 84 Marine Industrial 4 3L Engine 4 Install the crankshaft bearings into the crankshaft bearing caps 334342 5 Install the crankshaft bearing caps in the original positions and with the arrow on the crankshaft bearing caps in the direction of the front of the engine block Notice Refer to Fastener Notice in Cautions and Notices 6 Install the crankshaft bearing cap bolts Tighten 6 1 Tighten the crankshaft bearing cap bolts on the first pass to 20 Nem 15 Ib f
40. to Lower Intake Manifold Gasket Included in Intake Manifold Seal Kit 3 270 Valve Lifter 0 459 Valve Lifter Pushrod Guide 0 439 Valve Pushrod 0 426 Valve Rocker Arm Assembly 0 333 Valve Rocker Arm Cover 0 386 Valve Rocker Arm Cover Bolt Grommet 0 423 Valve Rocker Arm Cover Gasket 0 423 Valve Rocker Arm Support 0 429 Valve Spring 0 303 Valve Spring Cap 0 309 Valve Stem Key 0 310 Valve Stem Oil Seals PCB 2000 Marine Industrial Engine Marine Industrial 4 3L 6 9 GM SPO Group Numbers cont d Application GM SPO Group Number Water Outlet Water Pump Gaskets Water Pump Inlet Hose Water Pump Kit with Gaskets Sealers Adhesives and Lubricants 1 153 1 079 1 097 1 069 Application Type of Material GM Part Number Balancer Shaft Driven Gear Bolt Camshaft Retainer Bolt Crankshaft Balancer Keyway Cylinder Head Bolt Engine Block to the Crankshaft Rear Oil Seal Housing Junction at the Oil Pan Sealing Surfaces Engine Block to the Engine Front Cover Junction at the Oil Pan Sealing Surfaces Engine Block at the Lower Intake Manifold Sealing Surfaces Engine Block Coolant Drain Hole Plug Engine Block Core Hole Plug Engine Block Oil Gallery Plug Engine Coolant Temperature ECT Sensor Engine Coolant Temperature ECT Gauge Sensor Engine Oil Engine Oil Pressure Sensor Engine Oil Pressure Sensor Fitting Engine Oil Supplement Evaporative Emission EVAP Canister Purge Solenoid Valve Stud Exhaust Manifold
41. valve guide Valve spring to cylinder head location Engine block bearing cap location and direction Oil pump drive and driven gears Tools and Equipment Special tools are listed and illustrated throughout this section with a complete listing at the end of the section The tools or equivalents are specially designed to 2000 Marine Industrial Engine quickly and safely accomplish the operations for which the tools are intended The use of 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 Approved eye protection and safety gloves A clean well lit work area A suitable parts cleaning tank A compressed air supply Trays or storage containers to keep parts and fasteners organized An adequate set of hand tools Approved engine repair stand An approved engine lifting device that will adequately support the weight of the components Engine Special Tools and Equipment Tool Number Description J 3049 A Valve Lifter Remover J5239 Connecting Rod Bolt Guide Set J 5590 Installer J 5825 A Crankshaft Gear Remover J 5830 02 Valve Guide Reamer Set Marine Industrial 4 3L 6 179 Tool Number Description J 5892 D
42. 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 Caution Refer to Safety Glasses Caution in Cautions and Notices 1 Use the J 8062 in order to compress the valve springs 480554 Important Mark sort and organize the components so that the components can be reinstalled in their original location and position 2 Remove the valve stem keys 1 Remove the J 8062 from the cylinder head Remove the valve spring cap 2 Remove the valve spring 3 Remove the valve stem oil seal 4 Discard the valve stem oil seal Remove the valve ONO w 480555 Cylinder Head Clean and Inspect Tools Required J 8001 Dial Indicator Set J 8089 Carbon Removing Brush J 9666 Valve Spring Tester Caution Refer to Safety Glasses Caution in Cautions and Notices 1 Clean the valve stems and cylinder heads on a buffing wheel 2 Clean the following components in cleaning solvent Valve stem keys 1 Valve spring cap 2 Valve spring 3 Oylinder head 480555 2000 Marine Industrial 6 100 Marine Industrial 4 3L 4957 64318 2000 Marine Industrial Engine Dry the components with compressed air Use the J 8089 to clean the carbon from the cylinder head combustion chamb
43. valve stem The intake valves are NOT available with oversize valve stems Replace the cylinder head if after using a NEW intake valve in order to measure the valve stem to guide clearance the valve stem to guide clearance is not within specifications 3 Use the J 5830 3 in order to ream the exhaust valve guide in order to achieve the correct valve stem to guide clearance 4 Always recondition the exhaust valve seat after reaming the exhaust valve guide bores and installing new exhaust valves 5 Inspect the valves for the following Burnt or damaged areas 1 Undersize margain 2 Bentstem 3 e Scoring or other damage to the stem 4 e Worn key groove 5 Worn stem tip 6 156174 2000 Marine Industrial 6 104 Marine Industrial 4 3L 156173 480558 2000 Marine Industrial Engine Inspect the valve contact surface for the following Undersized margin 1 Pitted surfaces 2 Burnt or eroded areas 3 Acceptable edge margain 4 Valves with excessive damage must be replaced Minor imperfections of the valve or valve seat may be repaired Reconditioning of the valves and valve seats The valves must seat perfectly for the engine to deliver optimum power and performance Cooling the valve heads is another important factor Good contact between each valve and valve seat in the cylinder head is necessary to insure that the heat in the valve head is properly carried away Regardless of wha
44. 0 Ib ft Crankshaft Bearing Cap Preferred Method First Pass 15 Ib ft Final Pass 73 degrees Crankshaft Bearing Cap Bolt 77 lb ft Crankshaft Position Sensor Bolt 71 Ib in Crankshaft Pulley Bolt 43 lb ft Crankshaft Rear Oil Seal Housing Bolt and Nut 106 Ib in Crankshaft Rear Oil Seal Housing Retainer Stud 53 Ib in Cylinder Head Bolt Preferred Method All Bolts First Pass in Sequence 22 Ib ft Long Bolts Final Pass in Sequence 75 degrees Medium Bolts Final Pass in Sequence 65 degrees Short Bolts Final Pass in Sequence 55 degrees Oylinder Head Core Hole Plug 15 Ib ft Distributor Cap Bolt 21 Ib in Distributor Clamp Bolt 18 Ib ft Drive Bolt Tensioner Bolt 37 Ib ft EGR Valve Bolt First Pass 62 Ib in 2000 Marine Industrial 6 2 Marine Industrial 4 3L Engine Fastener Tightening Specifications cont d Specification Application Mete EGR Valve Inlet Pipe Clamp Bolt 18 Ib ft EGR Valve Inlet Pipe Nut at Intake Manifold 18 Ib ft EGR Valve Inlet Pipe Nut at Exhaust Manifold 22 Ib ft Engine Block Left Side Oil Gallery Plug 15 lb ft Engine Block Left Rear Oil Gallery Plug 22 Ib ft Engine Block Right Rear Oil Gallery Plug 15 Ib ft Engine Block Coolant Drain Hole Plug 15 Ib ft Engine Block Oil Gallery Plug 15 Ib ft Engine Coolant Heater Bolt Screw 18 Ib in Engine Coolant Temperature ECT Sensor 15 Ib ft Engine Flywheel Bolt 74 Ib ft Engine Front Cover Bolt 106 Ib in Engine Lift Bracket Bolt Special Tool J 41427 1
45. 0 Marine Industrial 6 40 Marine Industrial 4 3L Engine Notice Refer to Fastener Notice in Cautions and Notices 3 Use the J23523 F in order to remove the crankshaft balancer 3 1 Install the J 23523 F plate and bolts onto the crankshaft balancer Tighten Tighten the bolts to 25 Nem 18 lb ft 3 2 Install the J 23523 F forcing screw into the plate 3 3 Rotate the J 23523 F forcing screw clockwise in order to remove the crankshaft balancer 4 Remove the J 23523 F from the crankshaft balancer N M iE wW 7 4059 5 Note the position of any front groove pins crankshaft balancer if applicable 334258 Valve Rocker Arm Cover Removal Left 1 Remove the valve rocker arm cover bolts 2 Remove the valve rocker arm cover bolt grommets 3 Discard the valve rocker arm cover bolt grommets 328566 2000 Marine Industrial Engine Marine Industrial 4 3L 6 41 4 Remove the valve rocker arm cover 480519 5 Remove the valve rocker arm cover gasket 6 Discard the valve rocker arm cover gasket 328573 Valve Rocker Arm Cover Removal Right 1 Remove the valve rocker arm cover bolts 2 Remove the valve rocker arm cover bolt grommets 3 Discard the valve rocker arm cover bolt grommets 328568 2000 Marine Industrial 6 42 Marine Industrial 4 3L Engine 4 Remove the valve rocker arm cover LB I 5 Remove the valve rocker arm cover gasket 6 Discard the valve rocker ar
46. 1 Ib ft Engine Lift Front Bracket Stud 26 Ib ft Engine Mount Bolt to Engine Bracket 37 Ib ft Engine Mount Engine Bracket Bolt to Engine 37 Ib ft Engine Mount Frame Bracket Through Bolt 55 Ib ft Engine Mount Frame Side Mount Bolt 50 Ib ft Engine Oil Level Sensor 115 Ib in Engine Oil Pressure Gauge Sensor 22 Ib ft Engine Oil Pressure Gauge Sensor Fitting Plus Required Angle 11 Ib ft Engine Wiring Harness Bracket Bolt to Battery Positive Cable Junction Block Bracket 9 Nem 80 Ib in Engine Wiring Harness Bracket Bolt to Generator and Drive Belt Tensioner Bracket 25 Nem 18 Ib ft Engine Wiring Harness Bracket Bolt to Rear Right Side Cylinder Head 18 Ib ft Engine Wiring Harness Bracket Nut to Evaporative Emission EVAP 9 Ne 80 Ibi Canister Purge Solenoid Valve Stud m Engine Wiring Harness Bracket Nut to Intake Manifold Stud 106 Ib in Evaporitive Emission EVAP Canister Purge Solenoid Valve Stud to Intake Manifold 10 Nem 89 Ib in Exhaust Manifold Bolt Stud First Pass 15 Nem 11 Ib ft Final Pass 22 Ib ft Exhaust Manifold Heat Shield Bolt 80 Ib in Fan and Water Pump Pulley Bolt 18 Ib ft Frame Cross Bar Bolt 74 lb ft Fuel Meter Body Bracket Bolt 89 Ib in Fuel Pipe Bracket Bolt 53 Ib in Fuel Pipe Retainer Nut 27 Ib in Fuel Supply Pipe Nut Fuel Tank Side 22 Ib ft Generator and Drive Belt Tensioner Bracket Bolt to Engine 30 Ib ft Generator and Drive Belt Tensioner Bracket Stud to Engine 15 Ib ft 2000 Marine Industrial
47. 10 Verify that the distributor is properly positioned 11 Perform a final inspection for the proper engine oil and coolant levels Marine Industrial 4 3L 6 171 2000 Marine Industrial 6 172 Marine Industrial 4 3L Description and Operation Engine Component Description Balance Shaft The cast iron balance shaft is mounted in the crankcase above and in line with the camshaft A camshaft gear drives the gear attached to the balance shaft The front end of the balance shaft is supported by a ball type bearing The rear end of the balance shaft uses a sleeve type bearing Camshaft The steel camshaft is supported by four bearings pressed into the engine block The camshaft timing chain sprocket mounted to the front of the camshaft is driven by the crankshaft sprocket through a camshaft timing chain Crankshaft The cast nodular iron crankshaft is supported by four crankshaft bearings The number four crankshaft bearing at the rear of the engine is the end thrust bearing The crankshaft bearings are retained by bearing caps that are machined with the engine block for proper alignment and clearances The crankshaft position sensor reluctor ring has three lugs used for crankshaft timing and is constructed of powdered metal The crankshaft position sensor reluctor ring has a slight interference fit onto the crankshaft and an internal keyway for correct positioning Cylinder Heads The cast iron cylinder heads have one intake and one
48. 151 328593 328592 2000 Marine Industrial 6 152 Marine Industrial 4 3L Engine Cylinder Head Installation Left Tools Required J 36660 Electronic Torque Angle Meter 1 Clean the cylinder head gasket surfaces on the engine block 2 Inspect the dowel pins cylinder head locators for proper installation 3 Clean the cylinder head gasket surfaces on the cylinder head 6 3 6 8 mm 0 249 0 258 334303 Important Do not use any type of sealer on the cylinder head gasket unless specified 4 Install the NEW cylinder head gasket in position over the dowel pins cylinder head locators 334299 5 Install the cylinder head onto the engine block Guide the cylinder head carefully into place over the dowel pins and the cylinder head gasket 480536 2000 Marine Industrial Engine 6 Apply sealant GM P N 12346004 or equivalent to the threads of the cylinder head bolts Notice Refer to Fastener Notice in Cautions and Notices 7 Install the cylinder head bolts finger tight 8 Tighten the cylinder head bolts in sequence on the first pass Tighten Tighten the bolts in sequence on the first pass to 30 Nem 22 Ib ft Use the J 36660 in order to tighten the cylinder head bolts in sequence on the final pass Tighten the long bolts 1 4 5 8 and 9 on the final pass in sequence to 75 degrees Tighten the medium bolts 12 and 13 on the final pass in sequence to 65 degrees T
49. 33049 expander assembly nut until snug 4 10 Align the lubrication hole of the camshaft inner bearing 2 above the 3 o clock position or the 9 o clock position of the camshaft inner bearing bore 2 of the engine block 4 11 Push the J 33049 guide cone into the camshaft front bearing bore 1 in order to align the J 33049 4 12 Drive the camshaft inner bearing 2 into the camshaft inner bearing bore 2 of the engine block 4 13 Loosen the J 33049 expander assembly nut 5 Carefully remove the J 33049 from the engine block Balance Shaft Bearing and or Bushing Removal Tools Required J 26941 Bushing Bearing Remover J 38834 Balance Shaft Service Kit J 38834 1 Caution Refer to Safety Glasses Caution in Cautions and Notices 1 Usethe J 38834 and the J 26941 in order to remove the balance shaft rear bearing 1 1 Install the J 26941 legs behind the balance shaft rear bearing and secure 1 2 Install the J 38834 1 with the short threaded end through the balance shaft bore in the front of the engine block 1 3 Install the J 38834 1 into the J 26941 J 38834 2 J 26941 340081 2000 Marine Industrial 6 94 Marine Industrial 4 3L 2000 Marine Industrial 188106 2 Engine 1 4 Slide the J 38834 2 onto the J 38834 1 and into the balance shaft bore of the engine block 1 5 Install the J 38834 bearing washer and nut onto the J 38834 1 1 6 Using a wrench secure the J 38834 1 and then rotate the J 38834 nut cl
50. 35 36 Camshaft Timing Chain Camshaft Sprocket Bolt Balance Shaft Gear Bolt Balance Shaft Driven Gear Balance Shaft Retainer Bolt Balance Shaft Retainer Balance Shaft Piston Ring Set 2000 Marine Industrial 37 38 39 40 41 42 43 Engine Piston Piston Pin Connecting Rod Bolt Connecting Rod Connecting Rod Bearings Connecting Rod Cap Hex Nut Engine Marine Industrial 4 3L 6 33 Lower Engine View 2 480518 Legend 1 Crankshaft Rear Oil Seal Housing Retainer Stud 2 Crankshaft Rear Oil Seal Housing Nut 3 Flywheel Locator Pin 4 Crankshaft Rear Oil Seal Housing Bolt 5 Crankshaft Rear Oil Seal Housing 6 Crankshaft Rear Oil Seal Housing Gasket 7 Crankshaft 8 Oil Pump Drive Shaft 20 Crankshaft Position Sensor Reluctor Ring 13 Oil Pan 14 Oil Pan Bolt 15 Oil Pan Gasket 16 Crankshaft Bearing Cap Bolt 17 Crankshaft Bearing Cap 18 Crankshaft Bearings Lower 19 Crankshaft Sprocket E Oil Pump Locator Pin 21 Engine Front Cover 10 Oil Pump Drive Shaft Retainer 22 Crankshaft Front Oil Seal 11 Oil Pump 23 Crankshaft Balancer 12 Oil Pump Bolt 24 Crankshaft Balancer Bolt 25 Crankshaft Balancer Key 26 Crankshaft Bearings Upper 2000 Marine Industrial 6 34 Marine Industrial 4 3L Engine Draining Fluids and Oil Filter Removal 1 Remove the oil pan drain plug and allow the engine oil to drain into a suitable container 188048
51. 3523 F in order to press the crankshaft balancer onto the crankshaft 5 1 Install the J 23523 F plate and bolts onto the front of the crankshaft balancer Tighten Tighten the J 23523 F plate bolts to 25 Nem 18 lb ft 5 2 Install the J 23523 F screw into the end for the crankshaft 5 3 Install the J 23523 F bearing the washer and the nut onto the J 23523 F screw 5 4 Rotate the J 23523 F nut clockwise until the crankshaft balancer hub is completely seated against the crankshaft position sensor reluctor ring 6 Remove the J 23523 F 4065 Notice Refer to Fastener Notice in Cautions and Notices 7 Install the crankshaft pulley and bolts Tighten Tighten the crankshaft pulley bolts to 58 Nem 43 Ib ft 188055 8 Ensure that the crown of the crankshaft balancer washer 2 is faced away from the engine M 342203 2000 Marine Industrial Engine 9 Install the crankshaft balancer washer and the bolt Tighten Tighten the crankshaft balancer bolt to 95 Nem 70 Ib ft Valve Lifter Installation 1 Apply lubricant GM P N 12345501 or equivalent to the valve lifter rollers Important If reusing the valve lifters install the valve lifters in the original positions 2 Install the valve lifters Notice Refer to Fastener Notice in Cautions and Notices 3 Install the valve lifter pushrod guides Tighten Tighten the valve lifter pushrod guide bolts to 16 Nem 12 Ib ft Marine Industrial 4 3L 6
52. Caution Refer to Safety Glasses Caution in Cautions and Notices 1 Clean the valve rocker arm cover in cleaning solvent 2 Drythe valve rocker arm cover with compressed air 3 Inspect the valve rocker arm cover for the following Damage to the PCV valve grommet 1 Damage to the bolt holes 2 A damaged valve rocker arm cover may interfere with the valve rocker arms Damage to the exterior of the valve rocker arm cover 3 e Gouges or damage to the sealing surface 4 Damage to the oil fill tube grommet 5 Restrictions to the ventilation system passages Marine Industrial 4 3L 6 111 5274 334508 2000 Marine Industrial 6 112 Marine Industrial 4 3L Engine Oil Pan Clean and Inspect 1 Remove the oil pan baffle bolts and the oil pan baffle 387763 Caution Refer to Safety Glasses Caution in Cautions and Notices 2 Cleanthe oil pan and the oil pan baffle in cleaning solvent 3 Drythe oil pan and the oil pan baffle with compressed air 4 Inspect the oil pan for the following Gouges or damage to the oil pan sealing surfaces 1 Damage to the threaded holes 2 Damaged oil pan drain hole threads 3 Damage to the oil pan baffle Damage to the exterior of the oil pan A damaged oil pan may interfere with the proper position of the oil pump screen or may not distribute oil properly in the oil pan sump area 334509 Notice Refer to Fastener Notice in Cautions and Notices 5 In
53. Drive the camshaft outer bearing 1 from the camshaft outer bearing bore 1 5 4 Loosen the J 33049 expander assembly nut 5 5 Remove the camshaft outer bearing 1 from the J 33049 expander assembly 5 6 Remove the J 33049 from the engine block 5 7 Insert the J 33049 expander assembly into the camshaft outer bearing 4 5 8 Tighten the J 33049 expander assembly nut until snug 5 9 Drive the camshaft outer bearing 4 from the camshaft outer bearing bore 4 5 10 Loosen the J 33049 expander assembly nut 5 11 Remove the camshaft outer bearing 4 from the J 33049 expander asssembly 6 Remove the J 33049 from the engine block 7 Discard the camshaft bearings sy ra SS E UT j esed wm WR uuo Sf Sa E a poe CS io T och Sr Bean ime or TUER a Nu eg ae eI fs Es SL A RR Ls J 33049 63219 2000 Marine Industrial Engine Marine Industrial 4 3L 6 91 Camshaft Bearing Installation Tools Required J 33049 Camshaft Bearing Service Kit Important When installing the camshaft bearings always look in order to ensure that the camshaft bearing lubrication hole is located above the 3 o clock position 1 or the 9 o clock position 2 The proper positioning of the camshaft bearing lubrication hole is in order to ensure the best lubrication of the engine camshaft journals 594647 1 Select the handle 10 the expanding driver 4 8 the washer 2 or 3 and the expander assem
54. Engine Upper and Lower Intake Manifold View Legend 1 Fuel Pipe Retainer Bracket Nut 2 Fuel Pipe Retainer 3 Fuel Pipe FuelPipe Bolt Fuel Seal Retainer 6 Upper Fuel Seal Yellow O ring Spacer Ring Metal Flat Washer Lower Fuel Seal Black O ring 9 Upper Manifold Attaching Stud 10 Upper Intake Manifold 2000 Marine Industrial 334238 Upper Intake to Lower Intake Manifold Gasket Fuel Meter Body Seal O ring Fuel Meter Body Intake Manifold Throttle Body to Upper Intake Manifold Gasket Throttle Body Throttle Body Attaching Stud Engine Marine Industrial 4 3L 6 29 Upper Engine View 1 480498 Legend 1 Distributor Bolt 10 Water Outlet Stud 2 Distributor 11 Engine Coolant Thermostat 3 Intake Manifold Bolt Lower 12 Accelerator Control Cable Bracket 4 Intake Manifold Gasket Lower 13 Accelerator Control Cable Bracket Stud 5 Intake Manifold Assembly 14 Ignition Coil 6 EGR Valve 15 Ignition Coil Stud 7 EGR Valve Bolt 16 EVAP Canister Purge Solenoid Valve Stud 8 EGR Valve Gasket 17 EVAP Canister Purge Solenoid Valve 9 Water Outlet 2000 Marine Industrial 6 30 Marine Industrial 4 3L Engine Upper Engine View 2 480513 Legend 1 Valve Rocker Arm Cover 10 Spark Plug Wire Shields 2 Valve Rocker Arm Cover Gasket 11 Exhaust Manifold Gasket 3 Valve Rocker Arm Assembly 12 Valve Lifter 4 Valve Rocker Arm Support
55. M SPO Group Numbers cont d Application GM SPO Group Number Oil Level Indicator 1 516 Oil Level Indicator Tube 1 516 Oil Pan 1 426 Oil Pan Drain Plug 1 453 Oil Pan Drain Plug Seal O ring 1 456 Oil Pan Gasket 1 429 Oil Pump 1 652 Oil Pump Cover 1 723 Oil Pump Drive Shaft 1 639 Oil Pump Drive Shaft Retainer 1 639 Oil Pump Pressure Relief Valve 1 609 Oil Pump Pressure Relief Valve Spring 1 609 Oil Pump Pressure Relief Valve Spring Bore Plug 1 609 Oil Pump Pressure Relief Valve Spring Straight Pin 1 609 Oil Pump Screen 1 656 PCV Tube 1 762 PCV Valve 1 745 PCV Valve Cover 1 745 PCV Valve Elbow 1 762 PCV Valve Hose 1 762 Pin Oil Pump Locator 1 723 Piston Ring Kit 0 643 Power Steering Pump Bracket 6 606 Secondary Air Injection AIR Check Valve 3 670 Secondary Air Injection AIR Check Valve Gasket 3 680 Secondary Air Injection AIR Check Valve Crossover Pipe 3 675 Secondary Air Injection AIR Check Valve Pipe 3 675 Spark Plug 2 270 Spark Plug Wire 2 240 Spark Plug Wire Shield 2 251 Spark Plug Wire Support 2 251 Spring Type S Pin Crankshaft Rear Oil Seal Housing Locator 8 940 Starter Motor 2 041 TBI Fuel Meter 3 734 Throttle Body 3 335 Throttle Body to Upper Manifold Gasket Included in Service Kits Only N S Torque Converter Housing Access Hole Plug Rubber at Oil Pan 4 104 Transmission Brace 4 081 Transmission Cover 4 105 Upper Intake Manifold Included in Upper Intake Manifold Kit Only 3 625 Upper Intake Manifold
56. Nn 492137 523746 310298 2000 Marine Industrial Engine 4 Align the indent hole on the driven gear with the paint mark on the distributor housing 5 Ensure that the distributor rotor segment points to the cap hold area 6 Align the slotted tang in the oil pump driveshaft with the distributor driveshaft Rotate the oil pump driveshaft with a screwdriver if necessary 7 Align the flat 1 in the distributor housing toward the front of the engine 8 Install the distributor and distributor clamp The flat in the distributor housing must point toward the front of the engine Engine Marine Industrial 4 3L 6 163 9 Once the distributor is fully seated align the distributor rotor segment with the number 6 pointer 1 that is cast into the distributor base If the distributor rotor segment does not come with a few degrees of the number 6 pointer 1 the gear mesh between the distributor and camshaft may be off a tooth or more Repeat the procedure again in order to achieve proper alignment 334555 Notice Refer to Fastener Notice in Cautions and Notices 10 Install the distributor clamp bolt Tighten Tighten the distributor clamp bolt to 25 N m 18 Ib ft 11 Install the distributor cap and NEW distributor cap bolts Tighten Tighten the distributor cap bolts to 2 4 N m 21 Ib in 301393 2000 Marine Industrial 6 164 Marine Industrial 4 3L Engine 12 Install the ignition coil wire
57. Service Engine Engine Model General Motors 4 3 L Powertrain Generator Models 30 45 kW TP 6103 1 01 CAUTION Caution In order 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 we recommend and describe 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 a tool that is 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 you must observe carefully to reduce the risk of personal injury during service or repair Improper service or repair may damag
58. Tighten Tighten the engine oil pressure sensor fitting to 15 Nem 11 Ib ft Important Do not rotate the engine oil pressure fitting clockwise more than 359 degrees after the initial torque has been obtained 20 Rotate the engine oil pressure sensor fitting clockwise to the proper position 1 50 degrees from the centerline 2 Marine Industrial 4 3L 6 131 6 3 6 6 mm 0 249 0 258 334314 188052 334549 2000 Marine Industrial 6 132 Marine Industrial 4 3L 188018 10793 334338 2000 Marine Industrial 21 22 23 Engine If reusing the engine oil pressure gauge sensor apply sealant GM P N 12346004 or equivalent to the threads of the engine oil pressure gauge sensor Install the engine oil pressure gauge sensor using the J41712 Tighten Tighten the engine oil pressure gauge sensor to 30 Nem 22 Ib ft Install the knock sensor Tighten Tighten the knock sensor to 20 Nem 15 Ib ft Crankshaft and Bearings Installation Tools Required J 36660 Electronic Torque Angle Meter 1 2 Apply clean engine oil to the crankshaft bearings Install the crankshaft bearings into the engine block Engine 3 Apply clean engine oil to the crankshaft bearing journals 4 Install the crankshaft 5 Install the crankshaft bearings into the crankshaft bearing caps 6 Apply clean engine oil to the crankshaft bearings 7 Install the crankshaft bearing caps in the original posit
59. Valve Spring Compressor J 7872 Magnetic Base Dial Indicator J 8001 Dial Indicator Set J 8037 Ring Compressor J 8062 Valve Spring Compressor 2000 Marine Industrial 6 180 Marine Industrial 4 3L Mustration Tool Number Description J 8087 Cylinder Bore Gauge J 8089 Carbon Removing Brush J 8092 Universal Driver Handle J 9666 Valve Spring Tester J 21882 Oil Suction Pipe Installer 2000 Marine Industrial Engine Miustraion Tool Number Description J 22794 Spark Plug Port Adapter d J 23523 F Balancer Remover and Installer J 24270 Oylinder Bore Ridge Reamer J 26941 Bushing Bearing Remover J 28428 E High Intensity Black Light Kit J 33049 Camshaft Bearing Service Kit J 35468 Cover Aligner Seal Installer J 35621 B Rear Main Seal Installer J 36660 Electronic Torque Angle Meter Marine Industrial 4 3L 6 181 J 36996 Balance Shaft Installer J 38606 Valve Spring Compressor J 38834 Balance Shaft Service Kit J 39580 Engine Support Table J 41240 Fan Clutch Remover and Installer 2000 Marine Industrial 6 182 Marine Industrial 4 3L Mlustration Tool Number Deseription J 41427 Engine Lift Bracket J 41602 Body Protection Hoist Adapter Set J 41712 Oil Pressure Switch Socket J 42073 Valve Stem Seal Installer J 43276 Clutch Pilot Bearing Remover 2000 Marine Industrial Engine Notes Notes Notes TP 6103 1 01
60. Valve stem tip 3 480551 Notice Refer to Fastener Notice in Cautions and Notices 4 Install the valve rocker arm assemblies as follows 4 1 Finger start the bolt at location 1 4 2 Finger start the bolt at location 2 4 3 Finger start the bolt at location 3 4 4 Finger start the remaining valve rocker arm bolts 480580 5 Rotate the crankshaft balancer to position the crankshaft balancer alignment mark 1 57 63 degrees clockwise or counterclockwise from the engine front cover alignment tab 2 Important Once the valve rocker arm assemblies are installed and properly torqued no additional valve lash adjustment is required 6 Tighten the valve rocker arm bolts Tighten Tighten the valve rocker arm bolts to 30 Nem 22 Ib ft 334551 2000 Marine Industrial Engine Marine Industrial 4 3L 6 159 Intake Manifold Installation Notice Applying excessive amounts of sealant may prohibit the intake manifold gaskets from sealing properly 1 Apply a 4 0 mm 0 157 in patch of adhesive GM P N 12346141 or equivalent to the cylinder head side of the lower intake manifold gasket at each end Important The lower intake manifold gasket must be installed while the adhesive is still wet to the touch O 4 0 mm 2 Install the lower intake manifold gasket onto the cylinder 0 157 head Use the gasket locator pins in order to properly seat the j lower intake manifold gasket on the cylinder head Notice Care must
61. aft bearings Inspect the camshaft bearings for excessive wear or scoring Inspect the engine camshaft for the following Worn scored or damaged bearing journals 1 Worn engine camshaft lobes 2 Damaged bolt hole threads 3 e Damaged camshaft sprocket locator pin 4 Engine 7 Measure the engine camshaft journals with a micrometer If the camshaft journals are more than 0 025 mm 0 0010 in out of round then replace the engine camshaft 8 Measure for a bent engine camshaft or excessive engine camshaft runout using the J 7872 8 1 Mount the engine camshaft in a suitable stand between centers 8 2 Use the J 7872 in order to check the intermediate engine camshaft journals Measure the engine camshaft lobe lift using the J 7872 9 1 Place the engine camshaft on the V blocks 9 2 Use the J 7872 in order to measure the engine camshaft lobe lift Replace the engine camshaft if the engine camshaft lobe lift is not within specifications Refer to Engine Mechanical Specifications Camshaft Bearing Removal Tools Required J 33049 Camshaft Bearing Service Kit 1 Select the cone 1 the handle 10 the expanding driver 4 8 the washer 2 or 3 and the expander assembly 15 from the J 33049 Assemble the J 33049 Marine Industrial 4 3L 6 89 188014 188012 66100 2000 Marine Industrial 6 90 Marine Industrial 4 3L Engine Important A loose camshaft bearing may be caused by an
62. al SFI is retained by a bracket bolted to the lower intake manifold The fuel meter body also houses the pressure regulator Metal inlet and outlet fuel lines and nylon delivery tubes connect to the Central SFI unit The delivery tubes independently distribute fuel to each cylinder through nozzles located at the port entrance of each manifold runner where the fuel is atomized Piston and Connecting Rod Assemblies The cast aluminum pistons use two compression rings and one oil control assembly The piston is a low friction lightweight design with a flat top and barrel shaped skirt The piston pins are offset 0 9 mm 0 0354 in toward the major thrust side right side to reduce piston slap as the connecting rod travels from one side of the piston to the other side after a stroke The piston pins have a floating fit in the piston and are retained by a press fit in the connecting rod The connecting rods are forged steel The connecting rods are machined with the rod cap installed for proper clearances and alignments Valve Train Motion is transmitted from the camshaft through the hydraulic roller valve lifters and the tubular valve pushrods to the roller type valve rocker arms The roller type valve rocker arm pivots on a needle type bearing in order to open the valve The valve rocker arms for each bank of cylinders are mounted to a one piece valve rocker arm support Each valve rocker arm is retained on the valve rocker arm support and th
63. al for each specific procedure This diagnostic table will assist in engine misfire diagnosis due to a mechanical concern such as a faulty engine camshaft worn or damaged bearings or bent valve pushrod Thsi table will not isolate a crossed fuel injector wire faulty fuel injector or any other drivability component failure that may cause a misfire The Powertrain On Board Diagnostic System checks must be performed first When using this table to make a Base Engine Misfire diagnosis begin with the preliminary information below and then proceed to the specific category Preliminary Perform DTC P0300 before proceeding with Base Engine Misfire Diagnosis information DTC P0300 will assist in determining which cylinder or cylinders are misfiring Perform a visual inspection of the following A loose or improperly isnstalled engine flywheel or crankshaft balancer Worn damaged or misaligned accessory drive system components Listen to the engine for any abnormal internal engine noises Inspect the engine for acceptable oil pressure Verify if the engine has excessive oil consumption Verify if the engine has excessive coolant consumption Perform a compression test on the engine Intake Manifold Leaks An intake manifold that has a vacuum leak may cause a misfire Inspect for the following Improperly installed or damaged vacuum hoses Faulty or improperly installed lower intake manifold and or gaskets Cracked or damaged low
64. alent to the threads of the balance shaft driven gear bolt Install the balance shaft driven gear bolt 6 1 Use a wrench to secure the balance shaft Place the wrench onto the balance shaft near to the balance shaft front bearing 6 2 Install the balance shaft driven gear bolt Tighten 6 2 1 Tighten the balance shaft driven gear bolt on the first pass to 20 Nem 15 Ib ft 6 2 2 Tighten the balance shaft driven gear bolt on the final pass using the J 36660 an additional 35 degrees Remove the wrench from the balance shaft Rotate the balance shaft by hand in order to ensure that there is clearance between the balance shaft and the valve lifter pushrod guide If the balance shaft does not rotate freely check to ensure that the retaining ring on the balance shaft front bearing is seated on the case Engine 9 Install the balance shaft drive gear DO NOT install the camshaft sprocket bolts at this time 10 Rotate the engine camshaft so that the timing mark on the balance shaft drive gear is in the 12 o clock position 11 Remove the balance shaft drive gear Marine Industrial 4 3L 6 141 9847 9848 9847 2000 Marine Industrial 6 142 Marine Industrial 4 3L Engine 12 Rotate the balance shaft so that the timing mark on the balance shaft driven gear is in the 6 o clock position 9849 13 Position the balance shaft drive gear onto the engine camshaft 14 Look to ensure that the balance shaft drive
65. amaged 1 Remove the spark plug wires from the spark plugs 1 1 Rotate the spark plug wire boot one half turn 1 2 Pull outward on the spark plug wire boot to release from the spark plug 2 Remove the spark plug wires from the spark plug wire retainers 3 Remove the exhaust manifold bolts and the stud 4 Remove the spark plug wire shields if applicable and the exhaust manifold 188121 5 Remove and discard the exhaust manifold gaskets 328555 Oil Level Indicator and Tube Removal 1 Remove the oil level indicator from the oil level indicator tube if applicable 330580 2000 Marine Industrial 6 38 Marine Industrial 4 3L Engine 2 Remove the oil level indicator tube bolt 3 Remove the oil level indicator tube from the engine block 188047 Water Pump Removal Tools Required J 41240 Fan Clutch Remover and Installer 1 Remove the bolts and the fan and water pump pulley using the J 41240 J 41240 317191 2 Remove the clamps and water pump inlet hose 182853 2000 Marine Industrial Engine 3 Remove the water pump bolts Remove the water pump Remove the water pump gaskets Discard the water pump gaskets oo R Crankshaft Balancer Removal Tools Required J 23523 F Balancer Remover and Installer 1 Remove the crankshaft balancer bolt and washer 2 Remove the bolts and the crankshaft pulley Marine Industrial 4 3L 6 39 188054 173172 188055 200
66. an engine oil to the outside diameter of the engine flywheel pilot flange 7 Apply a small amount 1 drop of clean engine oil to the outside diameter of the flywheel locator pin 8 Apply a small amount 2 to 3 drops of clean engine oil to the crankshaft seal surface 9 Inspect the J 35621 B flange for imperfections that may damage the crankshaft rear oil seal Minor imperfections may be removed with a fine grade emery cloth Important DO NOT allow oil or any other lubricants to contact the seal lip of the crankshaft rear oil seal J35621 B 334550 2000 Marine Industrial 6 136 Marine Industrial 4 3L 2000 Marine Industrial 387765 Engine 10 Remove the sleeve from the crankshaft rear oil seal 11 Apply a small amount 2 to 3 drops of clean engine oil to the outside diameter of the crankshaft rear oil seal 12 Install the crankshaft rear oil seal onto the J 35621 B 13 Install the J 35621 B onto the rear of the crankshaft and hand tighten the tool bolts until snug Notice Proper alignment of the crankshft rear oil seal is critical Install the crankshaft rear oil seal near to flush and square to the crankshaft rear oil seal housing Failing to do so may cause the crankshaft rear oil seal or the crankshaft rear oil seal installlation tool to fail 14 Install the crankshaft rear oil seal onto the crankshaft and into the crankshaft rear oil seal housing 14 1 Turn the J 35621 B wing nut clockwise until the
67. anifold Installation lssissesseeee RR 6 159 Distributor Installation 2 0 0 0 RH HH I n 6 161 Valve Rocker Arm Cover Installation 2 0 0 0 00 0 ccc ccc eee II 6 164 Oil Level Indicator and Tube Installation ssseseesee IR 6 166 Water Pump Installation trer teena E e se nennen 6 167 Exhaust Manifold Installation llsssseeseeeeee RII 6 168 Clutch Pilot Bearing Installation 00 00 ccc III 6 169 Engine Flywheel Installation 0 00 000 cece III 6 169 Engine Setup and Testing cc cece cece eect eee eee nnn eee nnn 6 171 Description and Operation 0c cece eee eee hn nenn nennen nenne 6 172 Engine Component Description 0 0 0 ccc see 6 172 Drive Belt System Description 000 c cece cet en 6 172 New Product Information 0 c cee m ras 6 173 Lubrication erre a ee BI Ae ed 6 175 Gleanliness and Gare ui rss ana ee HR DANH RD KU aa 6 175 Replacing Engine Gaskets 0 0 0 c e eect tee mn 6 176 Use of RTV and Anaerobic Sealer 00 ccc cee ene nn 6 176 Separating Parts ra a e nent e m 6 177 Tools and Equipment s 7i 343 EEE har chalks pede mele nea 6 178 Special Tools and Equipment 0 0c ccc cece n n nnn nnn nnn 6 179 TP 6103 1 01 Table of Contents continued Table of Contents continued TP 6103 1 01 This service manual provides the service technician with information to service the General Motor
68. ar or damage Nicks burrs or scoring Engine Marine Industrial 4 3L 6 95 8 Inspect the driven gear bolt 5 for damaged threads 9 Inspect the balance shaft drive gear for the following Excessive wear or damage Nicks burrs or scoring 9848 Balance Shaft Bearing and or Bushing Installation J 38834 1 Tools Required J 38834 Balance Shaft Service Kit Caution Refer to Safety Glasses Caution in Cautions and Notices 1 Usethe J 38834 in order to install the balance shaft rear bearing 1 1 Install the J 38834 3 onto the short threaded end of the J 38834 1 1 2 Install the J 38834 nut the washer and the bearing on the long threaded end of the J 38834 1 1 3 Install the J 38834 2 onto the J 38834 1 so that the smaller diameter of the J 38834 2 will be facing the front of the engine block 1 4 Install the J 38834 2 on the inside of the balavnce shaft front bearing bore 1 5 Lubricate the NEW balance shaft rear bearing with clean engine oil 1 6 Install the balance shaft rear bearing onto the J 38834 2 1 7 Align the balance shaft rear bearing for installation 1 8 Using a wrench secure the J 38834 1 into place 1 9 Rotate the J 38834 nut until the balance shaft rear bearing is properly and completely pushed into the balance shaft rear bearing bore 2 Remove the J 38834 J 38834 3 340085 2000 Marine Industrial 6 96 Marine Industrial 4 3L Engine Timing Chain and Sprockets Clean and Inspe
69. bly 15 from the J 33049 2 Assemble the J 33049 66100 2000 Marine Industrial 6 92 Marine Industrial 4 3L y SI SIT ES Se pal er nf AA SE nni ENCORE fem EROS eM EN ES Es cS J 33049 63219 2000 Marine Industrial Engine Caution Refer to Safety Glasses Caution in Cautions and Notices Important The camshaft bearings vary in size When ordering the new camshaft bearings be sure to order the correct camshaft bearings for the application to be serviced Always install the camshaft outer bearings 1 and 4 first The camshaft outer bearings serve as a guide for the J 33049 and help center the camshaft inner bearings during the installation process 3 Install the NEW camshaft outer bearings 4 and 1 3 1 Install the NEW camshaft outer bearing 4 onto the J33049 expander assembly 3 2 Tighten the J 33049 expander assembly nut until snug 3 3 Align the lubrication hole of the camshaft outer bearing 4 above the 3 o clock position or the 9 o clock position of the camshaft outer bearing bore 4 at the rear of the engine block 3 4 Drive the camshaft outer bearing 4 into the camshaft outer bearing bore 4 at the rear of the engine block 3 5 Loosen the J 33049 expander assembly nut 3 6 Remove the camshaft outer bearing 4 from the J33049 expander assembly 3 7 Install the NEW camshaft outer bearing 1 onto the J33049 expander assembly 3 8 Tighten the J 33049 expander assembly nut
70. charged 6 Start with the compression gauge at zero Then 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 70 percent of the highest cylinder No cylinder should 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 8 If some cylinders have low compression inject approximately 15 ml one tablespoon of engine ak ON oil into the combustion chamber through the spark plug hole Normal Compression builds up quickly and evenly to the specified compression for each cylinder Piston Rings Leaking Compression is low on the first stroke Then compression builds up with the following strokes but does not reach normal Compression improves considerably when you add oil 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 If two 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 9 Install the removed parts 10 Connect
71. ct Caution Refer to Safety Glasses Caution in Cautions and Notices 1 Clean the components with cleaning solvent 2 Dry the components with compressed air 3 Inspect the camshaft timing chain for binding or wear 480575 4 Inspect the camshaft sprocket and the crankshaft sprocket 1 for the following Broken teeth 1 Damaged teeth 2 Chipped teeth 3 Worn teeth 2 Uneven wear on the edge of the teeth Worn valleys between the sprocket teeth Crankshaft sprocket keyway for wear A 188097 Valve Rocker Arm and Push Rods Clean and Inspect Important Parts that are to be reused must be marked sorted and organized for assembly 1 Mark sort and organize the components for assembly Caution Refer to Safety Glasses Caution in Cautions and Notices 2 Clean the components with cleaning solvent 3 Dry the components with compressed air 4 Inspect the valve rocker arm components for the following Valve rocker arm valve push rod socket contact surface 1 The contact surface must be smooth with no scoring or excessive wear Valve rocker arm roller pivot for binding or damage 2 Valve rocker arm valve stem contact surface 3 480551 Valve rocker arm bolt threads for damage 4 2000 Marine Industrial Marine Industrial 4 3L 6 97 Engine 5 Inspect the valve push rods for the following Restriction of the oil passage 1 Wear or scoring of the end contact surfaces 2 The end
72. ctioning oil pump pressure relief valve Oil pump screen loose plugged or damaged Excessive bearing clearance Cracked porous or restricted oil galleries Engine block oil gallery plugs missing or incorrectly installed Broken valve lifters 2000 Marine Industrial 6 16 Marine Industrial 4 3L Engine Oil Leak Diagnosis Sep Action Vawe s Yes No Important You can repair most fluid leaks by first visually locating the leak repairing or replacing the component or by resealing the gasket surface Once the leak is identified determine the cause of the leak Repair the cause of the leak as ewll as the leak itself Operate the vehicle until it reaches normal operating temperature Park the vehicle on a level surface over a large sheet of paper or other clean surface Go to Step 2 System OK Can you identify the type of fluid and the approximate Go to Step 10 Go to Step 3 Go to Step 5 Go to Step 10 Go to Step 6 location of the leak 1 Visually inspect the suspected area Use a small mirror to assist in looking at hard to see areas 2 Check for leaks at the following locations Sealing surfaces Fittings Cracked or damaged components 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 hard to see areas 2 Check for leaks at the following locations Sealing surfaces Fittings Cracked or damage
73. d e 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 the stone marks will be remove with the fine grade stones e Perform the final honing with a fine grade stone and hone 186747 the cylinder bore in a cross hatch pattern at 45 65 degrees to obtain the proper clearance 2 During the honing operation thoroughly check the cylinder bore e Repeatedly check the cylinder bore fit with the selected piston All measurements of the piston or cylinder bore should be made with the components at normal room temperature 3 When honing to eliminate taper in the cylinder bore use full strokes the complete length of the cylinder bore 4 Repeatedly check the measurement at the top the middle and the bottom of the cylinder bore e The finish marks should be clean but not sharp The finish marks should be free from imbedded particles or torn or folded material 2000 Marine Industrial 6 68 Marine Industrial 4 3L 2000 Marine Industrial 188016 10 Engine By measuring the selected piston at the sizing point and then by adding the average of the clearance specification the final cylinder bore honing dimension required can be determined When finished the reconditioned cylinder bores should have less than or meet the specified out of round and taper requirements After the final honing and
74. d Notices Notice Defined Notices call special attention to a necessary action orto a prohibited action If a Notices 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 l Moving Parts and Hot Surfaces Caution Caution Avoid contact with moving parts an
75. d and the fasteners tightened while the adhesive is still wet to the touch 3 Install the NEW oil pan gasket into the groove in the oil pan 387757 Important The oil pan alignment must always be flush or forward no more than 0 3 mm 0 011 in from the rear face of the engine block 4 Install the oil pan onto the engine block Press the oil pan gasket into the grooves of the engine front cover and crankshaft rear oil seal housing 5 Slide the oil pan back against a suitable straight edge 330568 2000 Marine Industrial 6 148 Marine Industrial 4 3L Engine Notice Refer to Fastener Notice in Cautions and Notices 6 Install the oil pan bolts and nuts but do not tighten 7 Measure the pan to transmission housing clearance using a feeler gauge and a straight edge Use a feeler gauge to check the clearance between the oil pan to transmission housing measurement points If the clearance exceeds 0 3 mm 0 011 in at any of the 3 oil pan to transmission housing measurement points 1 then repeat the step until the oil pan to transmission housing clearance is within the specification The oil pan must always be forward of the rear face of the engine block 38496 Notice If the clearance is more than 0 3 mm 0 011 in powertrain durability may be reduced 8 Tighten the oil pan bolts and nuts in sequence 1 12 Tighten Tighten the oil pan bolts to 25 Nem 18 Ib ft 9 Measure the clearance between the 3 oi
76. d components Can you identify the type of fluid and the approximate location of the leak Completely clean the entire engine and surrounding components Apply an aerosol type powder baby powder foot powder etc to the suspected area Operate the vehicle for several kilometers miles at normal operating temperature and at varying speeds Idetify the type of fluid and the approximate location of the leak from the discolorations in the powder surface Completely clean the entire engine and surrounding components Operate the vehicle for several kilometers miles at normal operating temperature and at varying speeds Parkthe vehicle on a level surface over a large sheet of paper or other clean surface Wait 15 minutes ldetify 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 Go to Step 10 2000 Marine Industrial Engine Marine Industrial 4 3L 6 17 Oil Leak Diagnosis cont d Value s Yes No Can you identify the type of fluid and the approximate location of the leak Go to Step 10 Go to Step 4 Go to Step 10 Go to Step 8 Go to Step 10 Go to Step 9 Visually inspect the suspected area Use a small mirror to assist in looking at hard to see areas Check for leaks at the following locations Sealing surfaces Fittings Cracked or damaged components Can you identify the type of fluid and the approximate loca
77. d hot surfaces while working around a running engine in order to prevent physical injury Safety Glasses Caution Caution Always wear safety glasses to 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 in order to avoid damage l 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 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 an
78. d joint clamping force and may damage the fastener Use the correct tightening sequence and specifications when installing fasteners in order 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 not use 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 6103 1 01 Engine Marine Industrial 4 3L 6 1 Engine Mechanical 4 3L Specifications Fastener Tightening Specifications Specification Application Mero Accelerator Control Cable Bracket Nut to Stud 106 Ib in Accelerator Control Cable Bracket Nut to Throttle Body 80 Ib in Accelerator Control Cable Bracket Stud to Intake Manifold 53 Ib in Accelerator Control Cable Bracket Stud to Throttle Body 106 Ib in Air Cleaner Adapter Stud 71 Ib in Balance Shaft Driven Gear Bolt First Pass 15 Ib ft Final Pass 35 degrees Balance Shaft Retainer Bolt 12 Nem 106 Ib in Battery Cable Bracket Bolt to Oil Pan 106 Ib in Battery Negative Cable Bolt to Engine 18 Ib ft Battery Positive Cable Junction Block Bracket Bolt 18 Ib ft Belt Idler Pulley Bolt 37 Ib ft Camshaft Retainer Bolt 106 Ib in Camshaft Sprocket Bolt 18 Ib ft Connecting Rod Nut First Pass 20 Ib ft Final Pass 70 degrees Crankshaft Balancer Bolt 95 Nem 7
79. e accessory drive A loose or improper installation of a body component componente wih the engine operating by i varying the load on the components to verify a suspension component or other items of the vehicle ee f that the components operate properly may cause the chirping noise ne 5 This test is to verify that the drive belt tensioner If the noise is intermittent verify the accessory drive operates properly If the drive belt tensioner is components by varying their loads making sure they not operating properly proper belt tension may are operated to their maximum capacity An i l not be achieved to keep the drive belt from overcharged A C system power steering system with slipping which could cause a squeal noise a pinched hose or wrong fluid or a generator failing i j are suggested items to inspect 6 This test is to verify that the drive belt s is not Test D ipti too long which would prevent the drive belt core corp tensioner from working properly Also if an The number s below refer to the step number s on incorrect length drive belt was installed it may ihe diagnostic table not be routed properly and may be turning an 2 The noise may not be engine related This step accessory drive component in the wrong is to verify that the engine is making the noise direction If the engine is not making the noise do not 7 Misalignment of the pulleys may be caused proceed further
80. e cylinder head by a bolt The hydraulic valve lifters keep all the parts of the valve train in constant contact Each hydraulic valve lifter acts as an automatic adjuster and maintains zero lash in the valve train This eliminates the need for periodic valve adjustment Drive Belt System Description The drive belt system consists of the following components The drive belt The drive belt tensioner The drive belt idler pulley The crankshaft balancer pulley The accessory drive component mounting brackets The accessory drive components The power steering pump if belt driven The generator The A C compressor if equipped The engine cooling fan if belt driven The water pump if belt driven The vacuum pump if belt driven The air compressor if belt driven Engine The drive belt system may use one belt 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 plys 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
81. e only one drive belt at a time if the vehicle has multiple drive belts When removing the drive belt the water pump may not be operating and the engine may overheat Also DTC s may set when the engine is operating with the drive belt removed Inspecting the drive belt s is to ensure that it is not causing the noise Small cracks across the ribs of the drive belt will not cause the noise Belt separation is identified by the plys of the belt separating and may be seen at the edge of the belt or felt as a lump in the belt Small amounts of pilling is a normal condition and acceptable When the pilling is severe the drive belt does not have a smooth surface for proper operation Drive Belt Rumbling Diagnosis Step ction Vawe s Yes No Notice Refer to Belt Dressing Notice in Cautions and Notices DEFINITION A low pitch tapping knocking or thumping noise heard at or just above idle Heard once per revolution of the drive belt or a pulley Rumbling may be caused from Pilling the accumulation of rubber dust that forms small balls pills or strings in the drive belt pulley groove The separation of the drive belt A damaged drive belt Did you review the Drive Belt Symptom operation and perform 4 the necessary inspections Verify that there is a rumbling noise 2 Does the engine make the rumbling noise Remove the drive belt s 2 Operate the engine for no longer than 30 to 40 seconds Does
82. e spark plug wires to the spark plug wire retainers 7 Install the spark plug wires onto the spark plugs 188121 Clutch Pilot Bearing Installation Caution Refer to Safety Glasses Caution in Cautions and Notices 1 Install the NEW clutch pilot bearing using a suitable clutch pilot bearing installation tool 2 Measure to ensure the proper installation depth is obtained 17 65 18 65 mm 0 70 0 73 334385 Engine Flywheel Installation Important If replacing the engine flywheel manual transmission note the position of the original flywheel weights if applicable Flywheel weights must be installed into the new engine flywheel in the same location as the old flywheel weights were in the old engine flywheel Note the position of the flywheel weights and install the NEW flywheel weights as required A properly installed flywheel weight will be flush or slightly below flush with the face of the engine flywheel 64126 2000 Marine Industrial 6 170 Marine Industrial 4 3L 188129 63174 2000 Marine Industrial 1 Engine Install the engine flywheel 1 or 2 to the crankshaft Align the engine flywheel locator hole to the flywheel locator pin Notice Refer to Fastener Notice in Cautions and Notices 2 Install the engine flywheel bolts Tighten Tighten the engine flywheel bolts in sequence 1 6 to 100 Nem 74 Ib ft Engine Engine Set Up and Testing After overhau
83. e step number s on side of the belt is used to drive the pulley the diagnostic table 6 Accessory drive component brackets that are 2 This inspection is to verify the condition of the bent or cracked will let the drive belt fall off drive belt Damage may of occured to the drive 7 Inspecting of the fasteners can eliminate the belt when the drive belt fell off The drive belt possibility that a wrong bolt nut spacer or may of been damaged which caused the drive washer was installed Missing loose or the wrong belt to fall off Inspect the belt for cuts tears fasteners may cause pulley misalignment from sections of ribs missing or damaged belt plys the bracket moving under load Over tightening of 4 Misalignment of the pulleys may be caused the fasteners may cause misalignment of the from improper mounting of the accessory drive accessory component bracket 2000 Marine Industrial Engine Marine Industrial 4 3L 6 25 Drive Belt Falls Off Diagnosis Notice Refer to 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 the Drive Belt Symptom operation and perform Go to Symptoms the necessary inspections Go to Step 2 Drive Belt 2 Inspect for a damaged drive belt Did you find the condition Go to Step 3 Go to Step 4 3 Install a new drive belt Refer to Drive Belt Replacement Does the drive belt continue to fall off Go to Step 4 System OK 4
84. e the 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 Table of Contents Caution ae er al ee Inside Front Cover Introduction en NE MR EINE REA MERI MCA Da Rc MR RR UU E i Cautions and Nolices su asne ier RE REOR Ne Diese Seb phn Tae Eni RR ee I Fastener Tightening Specifications 0c ccc cece eee nennen n nn 6 1 Engine Mechanical Specifications sssseeeeeeeee m nnn 6 4 GM SPO Group Numbers luueel eeee ne nn nn nn nn nun nn nn 6 6 Sealers Adhesives and Lubricants seeeeseeeeeeeh hh hh hh hh hr 6 9 Diagnostic Information and Procedures 0 ccc cece eee nnn nnn 6 10 Base Engine Misfire Diagnostic 0 0 6 10 Engine Compression TeSt 000 cece ccc ee ete eee E ERE ene EEEE 6 11 Engine Noise Diagnostic 0 0 0 c cc et nett teens 6 12 Valve Train DIAQnOSIS 1 tapis ope ee Rd nbi dd ut etd tage dees 6 13 Excessive Oil Consumption ssssssssssseeee ens 6 15 Oil Pressure Diagnosis and Testing ssssssssssseee nern nennen 6 15 Oil Leak Diagnosis eese needed verae ea Ye du e d edu 6 16 Drive Belts nA ss ee UR SRM ESUNUII COR SM ORDER 6 18 Dtive Belt CHIPPING arisane eth e etes dps ste iot tasted Mdb bae tdt e 6 18 Drive Belt Squeal 2 rs et lo aseo etae eed 6 20 D
85. ead Installation Right Tools Required J 36660 Electronic Torque Angle Meter 1 Clean the cylinder head gasket surfaces on the engine block 2 Inspect the dowel pins cylinder head locators for proper installation 3 Clean the cylinder head gasket surfaces on the cylinder head Important Do not use any type of sealer on the cylinder head gasket unless specified 4 Install the NEW cylinder head gasket in position over the dowel pins cylinder head locators 5 Install the cylinder head onto the engine block Guide the cylinder head carefully into place over the dowel pins and the cylinder head gasket Marine Industrial 4 3L 6 155 6 3 6 6 mm 0 249 0 258 334314 334312 Ed 480538 2000 Marine Industrial 6 156 Marine Industrial 4 3L Engine 6 Apply sealant GM P N 12346004 or equivalent to the threads of the cylinder head bolts Notice Refer to Fastener Notice in Cautions and Notices 7 Install the cylinder head bolts finger tight 480537 8 Tighten the cylinder head bolts in sequence on the first pass Tighten Tighten the bolts in sequence on the first pass to 30 Nem 22 Ib ft 9 Use the J 36660 in order to tighten the cylinder head bolts in sequence on the final pass Tighten the long bolts 1 4 5 8 and 9 on the final pass in sequence to 75 degrees Tighten the medium bolts 12 and 13 on the final pass in sequence to 65 degrees Tighten the short bol
86. ecified Always follow all the safety recommendations and directions that are on the pipe sealant container Ther surfaces to be sealed must be clean and dry Use a pipe sealant bead of the size or quantity as specified in the service procedure Important Do not allow the pipe sealant to enter any of the blind threaded holes as the pipe sealant may prevent the fastener from clamping properly or cause component damage when the fastener is tightened Apply the pipe sealant bead to the inside of any bolt hole areas Apply a continuous bead of pipe sealant to 1 sealing surface Tighten the fasteners in sequence if specified and to the proper torque specifications DO NOT overtighten the fasteners Separating Parts Important Many internal engine components will develop specific wear patterns on their friction surfaces When disassembling the engine internal components MUST be seperated marked and organized in a way to ensure reinstallation to the original location and position Mark or identify the following components 2000 Marine Industrial 6 178 Marine Industrial 4 3L Piston and the piston pin Piston to the specific cylinder bore Piston rings to the specific cylinder bore Connecting rod to the crankshaft journal Connecting rod to connecting rod cap Crankshaft bearings and connecting rod bearings Engine camshaft and valve lifters Valve lifters valve rocker arms and valve rocker arm supports Valve to the
87. elt tensioner for operating correctly Refer to Drive Belt Tensioner Diagnosis Go to Step 12 Go to Step 6 Go to Step 8 Go to Step 9 Go to Step 9 System OK Go to Go to Step 12 Diagnostic Aids This inspection is to verify the drive belt s is correctly installed on all of the drive belt pulleys Wear on the drive belt s may be caused by mis positioning the drive belt s by one groove on a pulley The installation of a drive belt that is two wide or two narrow will cause wear on the drive belt The drive belt ribs should match all of the grooves on all of the pulleys This inspection is to verify the drive belt s is not contacting any parts of the engine or body while the engine is operating There should be sufficient clearance when the drive belt 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 2000 Marine Industrial 6 26 Marine Industrial 4 3L Engine Drive Belt Excessive Wear Diagnosis Notice Refer to Belt Dressing Notice in Cautions and Notices DEFINITION Wear at the outside ribs of the drive belt due to an incorrectly installed drive belt Did you review the Drive Belt Symptom operation and perform Go to Symptoms the necessary inspections Go to Step 2 Drive Belt Inspect the drive belt s for the proper installation Refer to Drive Belt eee Did you find the condition Go to Step 5 Go to Step 3 3 Inspect for t
88. ely loosen the crankshaft bearing cap bolts on 1 crankshaft bearing cap at a time in order to determine the location of the binding A lack of proper crankshaft bearing clearance may be caused by the following Burrs on the crankshaft bearing cap Foreign material between the crankshaft bearing and the engine block Foreign material between the crankshaft bearing and the crankshaft bearing cap Damaged crankshaft bearing Improper size crankshaft bearing Crankshaft Rear Oil Seal and Housing Installation Tools Required J 35621 B Rear Main Seal Installer Notice Refer to Fastener Notices in Cautions and Notices 1 Install the crankshaft rear oil seal housing retainer stud Tighten Tighten the crankshaft rear oil seal housing retainer stud to 6 Nem 53 Ib in Engine Marine Industrial 4 3L 6 135 Important Always use a NEW crankshaft rear oil seal housing gasket when installing the crankshaft rear oil seal housing 2 Install the NEW crankshaft rear oil seal housing gasket 334319 3 Install the crankshaft rear oil seal housing onto the crankshaft rear oil seal housing retainer stud 4 Install the crankshaft rear oil seal housing nut and bolts Tighten Tighten the crankshaft rear oil seal housing nut and bolts to 12 Nem 106 Ib in 334317 5 Apply a small amount 2 to 3 drops of clean engine oil to the bore of the crankshaft rear oil seal housing 6 Apply a small amount 2 to 3 drops of cle
89. ensor plug 1 or the ECT sensor 2 28 Install the ECT sensor or plug if equipped into the front of the lower intake manifold Tighten Tighten the ECT sensor or plug to 20 Nem 15 Ib ft 480566 Important The exhaust gas recirculation EGR valve must be installed in the original orientation 29 Install the NEW EGR valve gasket and the EGR valve 480565 2000 Marine Industrial 6 122 Marine Industrial 4 3L 480559 12853 2000 Marine Industrial 30 31 32 33 34 35 Engine Install the EGR valve bolts Tighten 30 0 Tighten the EGR valve bolts on the first pass to 7 Nem 62 Ib in 30 1 Tighten the EGR valve bolts on the final pass to 30 Nem 22 lb ft Install the engine coolant thermostat Install the water outlet 1 or 2 Install the water outlet studs Tighten Tighten the water outlet studs to 25 Nem 18 lb ft Install a NEW throttle body gasket into the groove in the upper intake manifold Install the throttle body onto the upper intake manifold Engine 36 37 38 If reusing the fasteners apply threadlock GM P N 12345382 or equivalent to the threads of the throttle body attaching studs Install the throttle body attaching studs Tighten Tighten the throttle body attaching studs to 9 Nem 80 Ib in Install the accelerator control cable bracket the studs and the nuts Tighten 38 1 Tighten the accelerator control cable bracket stud to the
90. ep 3 Diagnostic Aids 1 Remove the drive belt s 2 Operate the engine x no lenge than 30 to 40 seconds Go to Engine Does the whine noise still exist Noise Diagnosis Go to Step 4 4 Inspect for a failed accessory drive component bearing Go to Did you find and repair the condition Go to Step 5 Diagnostic Aids Operate the system in order to verify the repair Did you correct the condition System OK 2000 Marine Industrial 6 22 Marine Industrial 4 3L Drive Belt Rumbling Diagnosis Diagnostic Aids Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise The drive belt s may have a condition that can not be seen or felt Sometimes replacing the drive belt may be the only repair for the symptom If replacing the drive belt s completing the diagnostic table and the noise is only heard when the drive component with a failure Varying the load on the different accessory drive components may aid in identifying which component is causing the rumbling noise Test Description The number s below refer to the step number s on the diagnostic table Engine This test is to verify that the symptom is present during diagnosing Other vehicle components may cause a similar symptom This test is to verify that the drive belt s is causing the rumbling noise Rumbling noise may be confused with an internal engine noise due to the similarity in the description Remov
91. epth Does the belt grooves have pilling Go to Step 5 Go to Step 6 Clean the drive belt pulleys with a suitable wire brush Did you complete the repair Go to Step 15 Go to Step 6 Inspect for misalignment of the pulleys Are any of the pulleys misaligned Go to Step 7 Go to Step 8 7 Replace or repair any misaligned pulleys Did you complete the repair Go to Step 15 Go to Step 8 Inspect for bent or cracked brackets Did you find any bent or cracked brackets Go to Step 9 Go to Step 10 Replace any bent or cracked brackets Did you complete the repair Go to Step 15 Go to Step 10 Inspect for improper loose or missing fasteners Did you find the condition Go to Step 11 Go to Step 12 Tighten any loose fasteners Replace any improper or missing fasteners Refer to Fastener Tightening Specifications Did you complete the repair Go to Step 15 Go to Step 12 Replace the bent pulley Did you complete the repair Go to Step 15 Go to Step 14 Replace the drive belt Refer to Drive Belt Replacement Did you complete the repair Operate the system in order to verify the repair Did you correct the condition Inspect for a bent pulley Did you find the condition Go to Step 13 Go to Step 14 Go to Go to Step 15 Diagnostic Aids System OK Go to Step 3 12 13 14 5 1 2000 Marine Industrial 6 20 Marine Industrial 4 3L Engine Drive Belt Squeal Diagnosis accessory drive components for turning Diagnostic Aids smoothly Also test th
92. er intake manifold Improperly installed MAP sensor The sealing grommet of the MAP sensor should not be torn or damaged Improperly installed throttle body or damaged gasket Warped intake manifold Warped or damaged cylinder head sealing surface Coolant Consumption Coolant consumption may or may not cause the engine to overheat Inspect for the following External coolant leaks Faulty cylinder head gasket Warped cylinder head Cracked cylinder head Damaged engine block Oil Consumption Oil consumption may or may not cause the engine to misfire 1 Remove the spark plugs and inspect for an oil fouled spark plug 2 Perform a cylinder compression test 3 If the compression test indicates worn valves or valve guides inspect the following Worn brittle or improperly installed valve stem oil seals Worn valve guides Worn valve stems Worn or burnt valves or valve seats 4 If the compression test indicates worn or damaged piston rings inspect the following Broken or improperly seated piston rings Excessive piston ring end gap Excessive cylinder bore wear or taper Cylinder damage Piston damage 2000 Marine Industrial Engine Marine Industrial 4 3L 6 11 Base Engine Misfire Diagnosis cont d Checks tio 0 Abnormal Internal Engine Noises Start the engine and determine if the noise is timed to the engine camshaft speed or the crankshaft speed Using a timing light two knocks per flash is the
93. ers Be careful not to scuff the combustion chambers Inspect the cylinder head for the following Damage to the gasket surfaces Damage to the threaded bolt holes Burnt or eroded areas in the combustion chambers Cracks in the exhaust ports and combustion chambers External cracks in the water chambers Restrictions in the intake or exhaust passages Restrictions in the cooling system passages Rusted damaged or leaking core plugs Measure the cylinder head for warpage with a straight edge and feeler gauge A cylinder head block deck with warpage in excess of 0 10 mm 0 004 in within a 152 4 mm 6 0 in area must be repaired or replaced A cylinder head exhaust manifold deck with warpage in excess of 0 05 mm 0 002 in within a 152 4 mm 6 0 in area must be repaired or replaced A cylinder head intake manifold deck with warpage in excess of 0 10 mm 0 004 in within a 152 4 mm 6 0 in area must be repaired or replaced Engine 7 Use the J 9666 in order to measure the valve spring Replace the valve spring if the valve spring tension is less than 338 N 76 Ib at 43 2 mm 1 70 in 8 Inspect the valve springs for squareness 9 Valve stems 1 with excessive valve guide 2 clearance must be repaired or the cylinder head replaced Marine Industrial 4 3L 6 101 4960 40075 156172 2000 Marine Industrial 6 102 Marine Industrial 4 3L 35214 35214 2000 Marine Industrial 10 Engine Meas
94. ey is found refer to that accessory drive component for the proper installation procedure for that pulley Inspecting of the fasteners can eliminate the possibility that a wrong bolt nut spacer or washer was installed Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley Replacing the drive belt when it is not damaged or there is not excessive pilling will only be a temporary repair Engine Marine Industrial 4 3L 6 19 Drive Belt Chirping Diagnosis Sep Action value Yes No Notice Refer to Belt Dressing Notice in Cautions and Notices DEFINITION The following items are indications of chirping A high pitched noise that is heard once per revolution of the drive belt or a pulley t usually occurs on cold damp mornings Did you review the Drive Belt Symptom operation an d perform Go to Symptoms the necessary inspections Go to Step 2 Drive Belt Verify that there is a chirping noise Go to Does the engine make the chirping noise Go to Step 3 Diagnostic Aids 1 Remove the drive belt 2 Operate the engine for no longer than 30 to 40 seconds Go to Engine Does the chirping noise still exist Noise Diagnosis Go to Step 4 Inspect for severe pilling exceeding 1 3 of the belt groove d
95. f the cylinder bores in the final assembly When making the final cut with the boring bar leave 0 03 mm 0 001 in on the cylinder bore diameter for finish honing This gives the required position to the cylinder clearance specifications Carefully perform the honing and boring operation in order to maintain the specified clearances between the pistons the piston rings and the cylinder bores Engine Marine Industrial 4 3L 6 69 Piston and Connecting Rod Disassemble Tools Required C J 24086 C Piston Pin Remover Installer C Caution Refer to Safety Glasses Caution in Cautions and Notices C 1 Remove the piston rings from the pistons 4967 2 Pressthe piston pin from the connecting rod using the J 24086 C 3 The piston pin has an interference fit into the connecting rod and is full floating in the piston J24086 C 4965 4 Mark seperate and organize the parts for assembly 34671 2000 Marine Industrial 6 70 Marine Industrial 4 3L 34671 4977 156168 2000 Marine Industrial Engine Piston Connecting Rod and Bearings Clean Inspect Important Measurement of all components should be taken with the components at room temperature Do not use a wire brush in order to clean any part of the piston Caution Refer to Safety Glasses Caution in Cautions and Notices 1 Clean the piston and connecting rod in solvent 2 Dry the components with compressed air 3 Clean the piston ring
96. flywheel weights if applicable A properly installed flywheel weight should be installed until flush or below flush with the face of the engine flywheel Inspect the engine flywheel manual transmission if equipped for the following Pitted friction surface 1 e Scoring or grooves 2 Rustor other surface damage 3 Damaged ring gear teeth 4 Loose or improperly positioned ring gear The ring gear has an interference fit onto the engine flywheel and the ring gear should be positioned completely flat against the flange of the engine flywheel Marine Industrial 4 3L 6 87 381965 64126 188086 2000 Marine Industrial 6 88 Marine Industrial 4 3L 334499 188095 2000 Marine Industrial Engine Camshaft and Bearings Clean and Inspect Tools Required J 7872 Magnetic Base Dial Indicator Caution Refer to Safety Glasses Caution in Cautions and Notices Clean the engine camshaft in cleaning solvent Dry the engine camshaft with compressed air Inspect the camshaft retainer plate fro damage If the camshaft retainer plate is damaged replace as necessary Inspect the camshaft bearings for correct fit into the engine block camshaft bearing bores The camshaft bearings have an interference fit to the engine block camshaft bearing bores and must not be loose in the engine block camshaft bearing bores Important If any camshaft bearing is excessively worn or scored replace all the camsh
97. gine Front Cover 0 206 Engine Mount 0 029 Engine Mount Bracket 0 029 Engine Oil Level Sensor 1 516 Engine Oil Pressure Gauge Sensor 1 800 Engine Oil Pressure Gauge Sensor Fitting 1 800 Engine Piston Kit Piston and Pin 0 629 Engine Wiring Harness Bracket 2 559 Exhaust Manifold 3 601 Exhaust Manifold Gasket 3 270 Exhaust Manifold Heat Shield 3 602 Exhaust Valve 0 297 Expansion Cup Plug Balance Shaft Rear Bearing Hole 8 970 Expansion Cup Plug Camshaft Rear Bearing Hole 8 970 Fan amp Water Pump amp A C Compressor amp Generator amp Power Steering Pump Belt 1 066 Fan amp Water Pump amp Generator amp Power Steering Pump Belt 1 066 Fan amp Water Pump Pulley 1 062 Flywheel Locator Pin 0 669 Front Groove Pin Crankshaft Balancer 8 940 Fuel Pipe Included in Fuel Injection Feed and Return Pipe Kit Only 3 163 Fuel Pipe Retainer Bracket Included in Fuel Injection Feed and Return Pipe Kit Only 3 163 Fuel Injector O ring Seal Kit 3 331 Generator amp Drive Belt Tensioner Bracket 1 060 Ignition Coil 2 170 Ignition Coil Wire Harness 2 240 Intake Valve 0 296 Knock Sensor 2 383 Lower Intake Manifold Included in Lower Intake Manifold Kit Only 3 265 Lower Intake Manifold Gasket Kit 3 270 MAP Sensor 3 682 MAP Sensor Seal 3 682 Oil Fill Cap 1 758 Oil Fill Tube 1 745 Oil Fill Tube Lower Bracket 1 750 Oil Filter 1 836 Oil Filter Bypass Valve 1 837 Oil Filter Fitting 2000 Marine Industrial 6 3 Marine Industrial 4 3L Engine G
98. haft bearing clearance to the specifications Refer to Engine Mechanical Specifications 11 Replace or repair the crankshaft if the proper clearances cannot be obtained Marine Industrial 4 3L 6 81 334342 353091 2000 Marine Industrial 6 82 Marine Industrial 4 3L 2000 Marine Industrial 188015 Engine Micrometer Method for Connecting Rod Bearings 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 bearing surface 1 3 Measure the crankpin diameter with a micrometer in several places approximately 90 degrees apart and then average the measurements Determine the taper and the out of round Refer to Engine Mechanical Specifications Install the connecting rod bearings into the connecting rod cap and the connecting rod Notice Refer to Fastener Notice in Cautions and Notices 4 Install the connecting rod caps and the nuts Tighten 4 1 Tighten the connecting rod nuts on the first pass evenly to 27 Nem 20 lb ft 4 2 Tighten the connecting rod nuts on the final pass an additional 70 degrees using the J 36660 Measure the connecting rod bearing inside diameter ID at the top and the bottom using an inside micrometer Compare the connecting rod bearing clearance to the specifications Refer to Engine Mechanical Specifications If the connecting rod bearing clearance is within specifications
99. haft to avoid damage to the camshaft bearings 2 Remove the engine camshaft 2 1 Install the three 5 16 18 x 4 0 inch bolts into the engine camshaft front bolt holes 2 2 Using the bolts as a handle carefully rotate and pull the engine camshaft out of the camshaft bearings 2 3 Remove the bolts from the front of the engine camshaft Piston Connecting Rod and Bearing Removal Tools Required e J5239 Conneting Rod Bolt Guide Set e J 24270 Cylinder Bore Ridge Reamer 1 Use the J 24270 in order to remove the cylinder ring ridge 1 1 Turn the crankshaft until the piston is at the bottom of the stroke 1 2 Place a cloth on top of the piston 1 3 Use the J 24270 to remove all of the cylinder ring ridge 1 4 Turn the crankshaft so the piston is at the top of the stroke J 24270 1 5 Remove the cloth 1 6 Remove the cutting debris Important Place matchmarks or numbers on the connecting rods and the connecting rod caps 2 Remove the connecting rod nuts 3 Remove the connecting rod cap 2000 Marine Industrial Engine Marine Industrial 4 3L 6 59 4 Use the J 5239 in order to protect the crankshaft journals and remove the connecting rod and the piston out of the top of the engine block 31373 Important Always assemble the connecting rod caps to the matching connecting rods 5 Remove the connecting rod bearings 5 1 Keep the connecting rod bearings with the original connecting rod and connecting rod cap
100. he proper drive belt Did you find this condition Go to Step 5 Go to Step 4 Inspect for the drive belt rubbing against a bracket hose or wiring harness Go to Did you find and repair the condition Go to Step 6 Diagnostic Aids 5 Replace the drive belt Refer to Drive Belt Replacement Did you complete the replacement Go to Step 6 Operate the system in order to verify the repair Does the drive belt continue to fall off System OK Drive Belt Tensioner Diagnosis 2 Position a 3 8 inch drive wrench on the drive belt Inspection Procedure tensioner arm and rotate the arm Important counterclockwise When the engine is operating the drive belt tensioner 3 Move the drive belt tensioner through it s full arm will move Do not replace the drive belt tensioner travel because of movement in the drive belt tensioner arm s The movement should feel smooth There should be no binding Thetensioner should return freely 4 Ifany binding is observed replace the drive belt tensioner Refer to Drive Belt Tensioner Replacement 5 Install the drive belt Refer to Drive Belt Replacement 374176 Notice Allowing the drive belt tensioner to snap into the free position may result in damage to the tensioner 1 Remove the drive belt Refer to Drive Belt Replacement 2000 Marine Industrial Engine Marine Industrial 4 3L 6 27 2000 Marine Industrial 6 28 Marine Industrial 4 3L Visual Identification Dissassembled Views
101. help identify an intermittent or an 8 This step should only be performed if the fan is improper condition vary the loads on the accessory driven by the drive belt Inspect the engine drive components cooling fan for bent twisted loose or cracked blades Inspect the fan clutch for smoothness ease of turning Inspect for a bent fan shaft or bent mounting flange 9 This step should only be performed if the water pump is driven by the drive belt Inspect the water pump shaft for being bent Also inpsect the water pump bearings for smoothness and excessive play Compare the water pump with a known good water pump 10 Accessory drive component brackets that are bent cracked or loose may put extra strain on that accessory component causing it to vibrate Test Description The number s below refer to the step number s on the diagnostic table 2 This test is to verify that the symptom is present during diagnosing Other vehicle components may cause a similar symptom such as the exhaust system or the drivetrain 3 This test is to verify that the drive belt s or accessory drive components may be causing the vibration When removing the drive belt the water pump may not be operating and the engine may overheat Also DTC s may set when the engine is operating with the drive belt removed Drive Belt Vibration Diagnosis Notice Refer to Belt Dressing Notice in Cautions and Notices DEFINITION The vibration is engine speed rela
102. ighten the short bolts 2 3 6 7 10 and 11 on the final pass in sequence to 55 degrees Install the spark plug wire support and bolts Tighten Tighten the spark plug wire support bolts to 12 Nem 106 Ib in Marine Industrial 4 3L 6 153 480533 5132 328588 2000 Marine Industrial 6 154 Marine Industrial 4 3L 328582 13 14 387767 15 16 387769 2000 Marine Industrial 11 12 Engine Measure the NEW spark plugs for the proper gap Adjust the spark plug gap if necessary Specification Spark plug gap to 1 52 mm 0 060 in Install the spark plugs Tighten e Tighten the spark plugs for a USED cylinder head to 15 Nem 11 Ib ft e Tighten the spark plugs for the initial installation of a NEW cylinder head to 30 Nem 22 Ib ft If reusing the engine coolant temperature gauge sensor if applicable apply sealant GM P N 12346004 or equivalent to the threads of the engine coolant temperature gauge sensor Install the engine coolant temperature gauge sensor if applicable Tighten Tighten the engine coolant temperature gauge sensor to 20 Nem 15 Ib ft If reusing the engine coolant temperature sensor if applicable apply sealant GM P N 12346004 or equivalent to the threads of the engine coolant temperature sensor Install the engine coolant temperature sensor if applicable Tighten Tighten the engine coolant temperature sensor to 20 Nem 15 Ib ft Engine Cylinder H
103. ightening the fasteners remove the excess gasket eliminator sealant from the outside of the joint Anaerobic Type Threadlock Sealant Anaerobic type threadlock sealant cures in the absence of air This type of sealant is used for threadlocking and sealing of bolts fittings nuts and studs This type of sealant cures only when confined between 2 close fitting metal surfaces Use the following information when using threadlock sealant Always follow all safety recommendations and directions that are on the threadlock sealant container Marine Industrial 4 3L 6 177 The threaded surfaces must be clean and dry Apply the threadlock sealant as specified on the threadlock sealant container Important Fasteners that are partially torqued and then the threadlock sealant allowed to cure more than five minutes may result in incorrect clamp load of assembled components Tighten the fastener in sequence if specified and to the proper torque specification DO NOT overtighten the fasteners 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 2 parts are assembled together and require a leak proof joint Use the following information when using pipe sealant Do not use pipe sealant in areas where extreme temperatures are expected These areas include The exhaust manifold The head gasket Surfaces where a different sealant is sp
104. ine Industrial 4 3L Atthe time of installation the components should be installed in the same location and with the same mating surface as when removed e Anautomobile engine is a combination of many machined honed polished and lapped surfaces with tolerances that are measured in millimeters or thousandths of an inch The surfaces should be protected to avoid component damage Apply a liberal amount of clean engine oil to friction areas during assembly Proper lubrication will protect and lubricate friction areas during initial operation Replacing Engine Gaskets Gasket Reuse and Applying Sealant e Do not reuse any gasket unless specified Gaskets that can be reused will be identified in the service procedure Do not apply sealant to any gasket or sealing surface unless specified in the service procedure Separating Components Usearubber mallet in order to seperate the components Bump the part sideways in order to loosen the components Bumping of the component should be done at bends or reinforced areas of the component to prevent distortion of the components Cleaning Gasket Surfaces Usecare to avoid gouging or scraping the sealing surfaces Usea plastic or wood scraper in order 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 Do not use abrasive pads sand paper or power tools to clean the ga
105. ine Industrial 4 3L Engine Exhaust Manifold Installation Left 1 Install the NEW exhaust manifold gaskets 328540 2 Install the exhaust manifold 3 Install the spark plug wire shields Notice Refer to Fastener Notice in Cautions and Notices 4 If reusing the fasteners apply threadlock GM P N 12345493 or equivalent to the threads of the exhaust manifold bolts and stud 5 Install the exhaust manifold bolts and stud Tighten 5 1 Tighten the exhaust manifold bolts and stud on the first pass to 15 Nem 11 Ib ft 5 2 Tighten the exhaust manifold bolts and stud on the final pass to 30 Nem 22 Ib ft 6 Install the spark plug wires to the spark plug wire retainers 7 Install the spark plug wires onto the spark plugs 188045 Exhaust Manifold Installation Right 1 Install the NEW exhaust manifold gaskets 328555 2000 Marine Industrial Engine Marine Industrial 4 3L 6 169 2 Install the exhaust manifold 3 Install the spark plug wire shields Notice Refer to Fastener Notice in Cautions and Notices 4 Ifreusing the fasteners apply threadlock GM P N 12345493 or equivalent to the threads of the exhaust manifold bolts and stud 5 Install the exhaust manifold bolts and stud A S 3 pie c Tighten e 5 1 Tighten the exhaust manifold bolts and stud on the first pass to 15 Nem 11 Ib ft 5 2 Tighten the exhaust manifold bolts and stud on the final pass to 30 Nem 22 Ib ft 6 Install th
106. ine Industrial 4 3L Engine Diagnostic Table cont d Step Action Value Yes No Check the oil pump screen for damage or a loose fit to the oil pump Is the oil pump screen loose or is the oil pump screen damaged Go to Step 8 Go to Step 9 Repair as required Is the tapping noise gone System OK Go to Step 9 Check for a damaged oil pump or loose bolts Refer to Oil Pump Clean and Inspect Is the oil pump damaged or are the bolts loose Go to Step 10 Go to Step 11 Repair as required Is the tapping noise gone System OK Go to Step 11 Remove and inspect the valve lifters the valve rocker arms and the valve pushrods Refer to Valve Rocker Arm and Pushrods Clean and Inspect and Valve Lifters and Guides Clean and Inspect Are the components worn or damaged Go to Step 12 Go to Step 13 Replace the components as required Is the tapping noise gone System OK Go to Step 13 Replace the engine camshaft and valve lifters Is the tapping noise gone System OK Go to Step 13 Remove the engine front cover and inspect the camshaft timing chain and sprockets for excessive wear or damage Refer to Timing Chain and Sprockets Clean and Inspect Are the components worn or damaged Go to Step 17 Go to Step 16 6 Replace the components as required Is the tapping noise gone System OK Go to Step 17 Perform a complete disassembly of the engine and inspect all components Are the components worn or damaged System OK Go to Step 11 Replace the components a
107. intake manifold to 6 Nem 53 Ib in 38 2 Tighten the accelerator control cable bracket nuts to 12 Nem 106lb in 38 3 Tighten the accelerator control cable bracket stud to the throttle body to 12 Nem 106 Ib in Exhaust Manifold Clean and Inspect Caution Refer to Safety Glasses Caution in Cautions and Notices 1 2 3 Clean the exhaust manifolds in cleaning solvent Dry the components with compressed air Inspect the exhaust manifolds for the following Damage to the gasket sealing surfaces 1 Damage to the exhaust gas recirculation EGR pipe fitting 2 left manifold Damage to the threaded holes 3 Restrictions within exhaust passages Broken or damaged exhaust manifold heat shields 4 if applicable Broken or damaged exhaust manifold Marine Industrial 4 3L 6 123 12852 374902 523519 2000 Marine Industrial 6 124 Marine Industrial 4 3L 334528 480571 2000 Marine Industrial Engine Measure the alignment or surface flatness of the exhaust manifold flanges using a straight edge and a feeler gauge Refer to Engine Mechanical Specifications If the surface flatness is not within the specifications the exhaust manifold is warped and must be replaced Water Pump Clean and Inspect Caution Refer to Safety Glasses Caution in Cautions and Remove all the old gasket material from the water pump sealing surfaces Clean all the dirt and any debris from the water
108. into the engine front cover 6 Install the crankshaft position sensor bolt Tighten Tighten the crankshaft position bolt to 8 Nem 71 Ib in 11485 Inspect for properly installed pins oil pump locator 5 9 6 9 mm 0 24 0 27 I AA ath iy 330578 2000 Marine Industrial 6 146 Marine Industrial 4 3L 330576 330572 317310 2000 Marine Industrial Engine Important DO not reuse the oil pump driveshaft retainer During assembly install a NEW oil pump driveshaft retainer 2 3 Install the oil pump Position the oil pump onto the pins Notice Refer to Fasteners Notice in Cautions and Notices 4 Install the oil pump bolt attaching the oil pump to the rear crankshaft bearing cap Tighten Tighten the oil pump bolt to 90 Nem 66 Ib ft Cil Pan Installation 1 Apply a 5 mm 0 197 in wide and 25 mm 1 0 in long bead of adhesive GM P N 12346141 or equivalent to both the right and left sides of the engine front cover to engine block junction at the oil pan sealing surfaces Engine Marine Industrial 4 3L 6 147 2 Apply a 5 mm 0 197 in wide and 25 mm 1 0 in long bead of adhesive GM P N 12346141 or equivalent to both the right and left sides of the crankshaft rear oil seal housing to 5 mm engine block junction at the oil pan sealing surfaces 0 197 317313 Important Always install a NEW oil pan gasket The oil pan gasket and oil pan must be installe
109. ion and with the arrow on the crankshaft bearing caps in the direction of the front of the engine block Notice Refer to Fastener Notice in Cautions and Notices 8 Install the crankshaft bearing cap bolts until snug 9 Thrustthe crankshaft rearward in order to set and align the crankshaft thrust bearings and the crankshaft bearing caps 10 Thrust the crankshaft forward in order to align the rear faces of the crankshaft thrust bearings 11 Tighten the crankshaft bearing cap bolts Tighten 11 1 Tighten the crankshaft bearing cap bolts on the first pass to 20 Nem 15 Ib ft Marine Industrial 4 3L 6 133 334336 334342 334329 2000 Marine Industrial 6 134 Marine Industrial 4 3L 188467 334326 2000 Marine Industrial Engine 11 2 Tighten the crankshaft bearing cap bolts on the final pass an additional 73 degrees using the J 36660 12 Measure the crankshaft end play 12 1 Firmly thrust the crankshaft rearward and then forward This will align the crankshaft rear bearing thrust surfaces 12 2 With the crankshaft pushed forward insert a feeler gauge between the crankshaft and the crankshaft rear bearing thrust surface to measure the clearance Specification Crankshaft end play 0 05 0 20 mm 0 002 0 008 in 13 Rotate the crankshaft in order to check for binding A bent crankshaft or lack of proper crankshaft bearing clearance may cause binding 14 If the crankshaft does not turn fre
110. itable for use the upper half of the crankshaft bearing should also be suitable for use Marine Industrial 4 3L 6 79 52051 52053 52056 2000 Marine Industrial 6 80 Marine Industrial 4 3L 188015 334338 2000 Marine Industrial Engine Bearing Clearance Measuring Procedures The crankshaft bearings are of the precision insert type and do not use shims for adjustment If the clearances are excessive then new upper and lower crankshaft bearings will be required The service crankshaft bearings are available in the standard size and an undersize The selective fitting of the crankshaft bearings are necessary in production in order to obtain close tolerances For this reason in one journal bore you may use one half of a standard crankshaft bearing with one half of an undersize crankshaft bearing Important Do not use the plastic gauge method to measure connecting rod bearing clearances The plastic gauge method for measuring connecting rod bearing clearances will result in unreliable measurements Use only the micrometer method to correctly determine the connecting rod bearing clearances In order to determine the correct replacement crankshaft bearing size the crankshaft bearing clearance must be measured accurately Either the micrometer or plastic gauge method may be used however the micrometer method gives more reliable results and is preferred Micrometer Method for Crankshaft Bearings 1 Meas
111. ition 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 repairthe 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 6103 1 01 Cautions an
112. ition sensor reluctor ring 7 1 Align the keyway on the crankshaft position sensor reluctor ring with the crankshaft balancer key in the crankshaft 7 2 Use the J 5590 in order to push the crankshaft position sensor reluctor ring onto the crankshaft until completely seated against the crankhshaft sproket Engine Front Cover Installation Important Once the composite engine front cover is removed DO NOT reinstall the engine front cover Always install a NEW engine front cover 1 Install the NEW engine front cover Notice Refer to Fasteners Notice in Cautions and Notices 2 Install the engine front cover bolts Tighten Tighten the engine front cover bolts to 12 Nem 106 Ib in 480539 2000 Marine Industrial Oil Pump Installation 1 Engine Marine Industrial 4 3L 6 145 Important DONOT reuse the original crankshaft position sensor seal o ring When installing the crankshaft position sensor be sure the crankshaft position sensor is fully seated and held stationary in the engine front cover crankshaft position sensor bore A crankshaft position sensor that is not completely seated will cock in the engine front cover and may result in erratic engine operation 3 Lubricate the NEW crankshaft position sensor seal O ring with clean engine oil 4 Install the NEW crankshaft position sensor seal O ring onto the crankshaft position sensor 387759 Install the crankshaft position sensor until fully seated
113. ket 480565 2000 Marine Industrial Engine 12 Remove the engine coolant temperature ECT sensor plug 1 orthe ECT sensor 2 from the front of the lower intake manifold if equipped 13 Remove the studs and the ignition coil 14 Remove the manifold absolute pressure MAP sensor 15 Remove the MAP sensor seal from the MAP sensor 16 Discard the MAP sensor seal Marine Industrial 4 3L 6 115 480566 480561 480562 2000 Marine Industrial 6 116 Marine Industrial 4 3L 334517 334511 334513 2000 Marine Industrial 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Engine Remove the fuel pipe bolt 4 Remove the fuel pipe retainer nuts 1 Remove the fuel pipe retainer 2 Remove the fuel pipe 3 Remove and discard the fuel seal retainers 5 Remove and discard the fuel seals 6 yellow O rings Remove and discard the spacer rings 7 flat washers Remove and discard the fuel seals 8 black O rings Remove the studs and the evaporative emission EVAP canister purge solenoid valve Remove the nut and the engine wiring harness bracket Remove the upper intake manifold attaching studs Remove the upper intake manifold Remove the upper intake manifold to lower intake manifold gasket Discard the upper intake manifold to lower intake manifold gasket Engine Marine Industrial 4 3L 6 117 31 Remove the fuel meter body seal and discard
114. l the engine must be tested before it is installed in the vehicle If a suitable test stand is not available the following procedures can be used after the engine is installed in the vehicle 1 Fill the crankcase with the proper quantity and grade of engine oil 2 Add engine oil supplement GM P N 1052367 or equivalent to the engine oil Notice DO NOT use cooling system seal tabs or similar compounds unless otherwise instructed The use of cooling system seal tabs or similar compounds may restrict coolant flow through the passages of the cooling system or the engine components Restricted coolant flow may cause engine overheating and or damage to the cooling system or the engine components assembly 3 Fill the cooling system with the proper quantity and grade of coolant 4 With the ignition OFF or disconnected crank the engine several times Listen for any unusual noises or evidence that any of the parts are binding 5 Start the engine and listen for unusual noises 6 Check the vehicle oil pressure gauge or light and confirm that the engine has acceptable oil pressure If necessary install an oil pressure gauge and measure the engine oil pressure 7 Operate the engine at about 1 000 RPM until the engine has reached normal operating temperature 8 Listen for improperly adjusted or sticking valves sticking valve lifters or other unusual noises 9 Inspect for oil and or coolant leaks while the engine is operating
115. l pan to n d transmission housing measurement points in order to BEN ensure proper alignment yapn N IEAJ 38481 10 Install a NEW oil pan drain plug seal O ring onto the oil pan drain plug 11 Install the oil pan drain plug into the oil pan Tighten Tighten the oil pan drain plug to 25 Nem 18 Ib ft 188048 2000 Marine Industrial Engine 12 Install the NEW engine oil level sensor if applicable Tighten Tighten the engine oil level sensor to 13 Nem 115 Ib in Crankshaft Balancer Installation Tools Required J 23523 F Balancer Remover and Installer 1 Look to ensure that the front groove pin crankshaft balancer is installed in the proper location if applicable Notice The inertial weight section of the crankshaft balancer is assembled to the hub with a rubber type material The correct installation procedures with the proper tool must be followed or movement of the inertial weight section of the hub will destroy the tuning of the crankshaft balancer 2 Apply a small amount of adhesive GM P N 12346141 or equivalent onto the crankshaft balancer keyway in order to seal the crankshaft balancer keyway and crankshaft joint 3 Align the keyway of the crankshaft balancer with the crankshaft balancer key 4 Install the crankshaft balancer onto the end of the crankshaft Marine Industrial 4 3L 6 149 387460 188059 2000 Marine Industrial 6 150 Marine Industrial 4 3L Engine 5 Use the J 2
116. m cover gasket 328573 Distributor Removal 1 Remove the ignition coil wire harness from the ignition coil and distributor cap 328575 2000 Marine Industrial Engine 2 Remove the distributor clamp bolt 3 Remove the distributor and the distributor clamp 4 Remove the distributor gasket and discard Intake Manifold Removal 1 Remove the evaporitive emission EVAP canister purge solenoid valve harness 1 1 Push the quick disconnect clip and hold in place 1 2 Pull outward on the harness elbow Marine Industrial 4 3L 6 43 569265 523516 328579 2000 Marine Industrial 6 44 Marine Industrial 4 3L 31510 2000 Marine Industrial Engine 2 Remove the engine coolant temperature ECT sensor wire connector if equipped from the engine wiring harness bracket 3 Remove the lower intake manifold bolts Important The intake manifold may be removed as an assembly Do not remove the specific intake manifold components unless component service is required Do not allow dirt or debris to enter the fuel system Ensure that the ends of the fuel system are properly sealed Do not dissassemble the Central Sequential Fuel Injection SFI unit unless service is required 4 Remove the intake manifold assembly 5 Remove and discard the lower intake manifold gaskets Valve Rocker Arm and Push Rod Removal Important Mark sort and organize all the components for assembly 1
117. n valve lifter guide Engine camshaft lobes worn Worn valve guides or valve stems Bent valve pushrods Excessive free play in the camshaft timing chain Bent broken or damaged camshaft sprocket teeth Diagnostic Table DEFINITION A light tapping noise at 1 2 engine speed or any varying frequency Is there valve train noise Check for a high engine oil level An engine with the Go to Step 3 Go to Step 4 engine oil level above the FULL mark on the oil level indicator allows the crankshaft counterweights to churn the engine oil into foam When the foamy engine oil is pumped into the valve lifters the valve lifters become noisy A solid column of engine oil ensures proper valve lifter operation Is the engine oil level too high Check for a low engine oil level An engine with the engine oil level below the ADD mark on the oil level indicator may allow the oil pump to pump air at high engine RPM Is the engine oil level below the ADD mark on the oil level indicator Go to Step 5 Go to Step 6 System OK Go to Step 6 Check for the proper engine oil pressure Refer to Engine Mechanical Specifications and Oil Pressure Diagnosis and 41 4 kPa Testing 6 psi Is the engine oil pressure within specifications Go to Step 11 Go to Step 7 2000 Marine Industrial Add the engine oil as required Is the tapping noise gone Drain the engine oil to the proper level Is the tapping noise gone System OK Go to Step 6 6 14 Mar
118. nd discard the cylinder head gasket 334312 6 Remove the dowel pins cylinder head locator if required 330553 2000 Marine Industrial 6 50 Marine Industrial 4 3L Engine Valve Lifter Removal Tools Required J 3049 A Valve Lifter Remover Important Place the components in a rack so that the components can be reinstalled to their original location 1 Remove the bolts and the valve lifter pushrod guide Important Place the valve lifters in the rack in the upright position in order to maintain the oil inside the valve lifters 2 Remove the valve lifters 328593 Important Some valve lifters may be stuck in the valve lifter bores because of gum or varnish deposits and may require the use of J 3049 A for removal 3 Usethe J 3049 A in order to remove the stuck valve lifters 31350 2000 Marine Industrial Engine Oil Pan Removal 1 Remove and discard the engine oil level sensor if applicable 2 Remove the oil pan bolts and nuts 3 Remove the oil pan Marine Industrial 4 3L 6 51 387460 330559 330568 2000 Marine Industrial 6 52 Marine Industrial 4 3L Engine 4 Remove the oil pan gasket 5 Discard the oil pan gasket 387757 Oil Pump Removal 1 Remove the oil pump bolt 330572 2 Remove the oil pump 330576 2000 Marine Industrial Engine Marine Industrial 4 3L 6 53 3 Inspect the pins oil pump locator for damage and replace the pin
119. nder Head Removal 0 tenet n 6 45 Valve Lifter Removal onere reatu Pettis eier 6 50 Oil Pan Removal aan a eile ei ee ee ed ba 6 51 Oil P mp REMOVAL persie Austern keinen kan ana et eade clot s 6 52 Engine Front Cover Removal ssssssssssss emen 6 53 Timing Chain and Sprockets Removal ssssssssssseee een 6 54 Balance Shaft Removal sssssssssssseeee hne 6 56 Camshaft Removal cue EYVED IW RETE IQ IU ESI UN T UN qi e HUE 6 57 Piston Connecting Rod and Bearing Removal 00 cece cence teens 6 58 TP 6103 1 01 Table of Contents Table of Contents continued Crankshaft Rear Oil Seal Removal 0 0 cece nn 6 59 Crankshaft and Bearings Removal sess nnn 6 61 Engine Block Plug Removal 0 00 cece eee n 6 62 Inspection 25 ru RE a eig RE ee rk ER RE eae able RR AER 6 66 Engine Block Clean and Inspect slsssssssssssssssss rh 6 66 Cylinder Boring and Honing 0 aasre cece eee n 6 67 Boring Procedure siss 3 Feen eher p Tei nerd 6 68 Piston and Connecting Rod Disassemble ssssssssse ees 6 69 Piston Connecting Rod and Bearings Clean Inspect 0 0 cece eee eee 6 70 Piston Selection Sss 22 mis cen tga teenie eR ke nal kona Rs c enge 6 73 Piston and Connecting Rod Assemble 000 cece cee cece teen nennen 6 74 Crankshaft and Bearings Clean and Inspect 0 eee eect eens 6 76 Bea
120. ning solvent 2 Dry the components with compressed air 3 Inspectthe oil pump for the following conditions Scoring on the top of the gears 1 Damaged gears 2 for the following Chipping Gailing Wear Scoring damage or casting imperfections to the body 3 Damaged or scored gear shaft 4 Damaged or scored gear shaft 5 186750 2000 Marine Industrial Engine Damaged bolt hole threads e Worn oil pump driveshaft bore Damaged or sticking oil pump pressure relief valve minor imperfections may be removed with a fine oil stone e Collapsed or broken oil pump pressure relief valve spring 4 If the oil pump is to be reused install a NEW oil pump pressure relief valve spring 5 During oil pump installation install a NEW oil pump driveshaft retainer Oil Pump Assemble Tools Required J 21882 Oil Suction Pipe Installer 1 Apply clean engine oil GM P N 12345610 or equivalent to the oil pump pressure relief valve oil pump pressure relief valve spring and oil pump body Caution Refer to Safety Glasses Caution in Cautions and Notices Important Replace the oil pump pressure relief valve spring when you reuse the oil pump 2 Install the following items 2 1 The oil pump pressure relief valve 2 2 The oil pump pressure relief valve spring 2 3 The oil pump pressure relief valve spring straight pin 3 Apply clean engine oil GM P N 12345610 or equivalent to the oil pump drive gear the oil
121. nstall the piston rings The rings may be damaged if expanded more than necessary 2 Install the piston rings onto the piston 2 1 Install the oil control piston ring spacer 2 2 Install the lower oil control piston ring 2 3 Install the upper oil control piston ring 2 4 Install the lower compression piston ring The mark on the side of the piston ring should face the top of the piston 2 5 Install the upper compression piston ring The mark on the side of the piston ring should face the top of the piston 490763 2000 Marine Industrial 6 76 Marine Industrial 4 3L Engine 3 Space the compression piston ring end gaps 120 degrees apart 4 Space the oil control piston ring end gaps a minimum of 90 degrees apart 4967 Crankshaft and Bearings Clean and Inspect Tools Required J 7872 Magnetic Base Dial Indicator J 36660 Electronic Torque Angle Meter Caution Refer to Safety Glasses Caution in Cautions and Notices Important Use care when handling the crankshaft Avoid damage to the crankshaft bearing surfaces 1 Clean the crankshaft in cleaning solvent Remove all sludge or restrictions from the oil passages 2 Dry the crankshaft with compressed air 334383 3 Clean the crankshaft bearings in cleaning solvent Wipe the crankshaft bearings clean with a soft cloth do not scratch the crankshaft bearing surface 4 Dry the crankshaft bearings with compressed air 334386 2000 Marine Indu
122. o seat Replace broken or worn piston rings as necessary Piston improperly installed or mis fitted Oil Pressure Diagnosis and Testing 1 With the vehicle on a level surface allow adaquate drain down time 2 3 minutes and measure for a low engine oil level Add the recommended grade engine oil and fill the crankcase until the oil level measures FULL on the oil level indicator 2 Operate the engine and verify low or no oil pressure on the vehicle oil pressure gauge or the oil indicator light Listen for a noisy valve train or a knocking noise 3 Inspect for the following Engine oil diluted by moisture or unburned fuel mixtures Improper engine oil viscosity for the expected temperature Incorrect or faulty oil pressure gauge sensor Incorrect or faulty oil pressure gauge e Plugged oil filter e Malfunctioning oil filter bypass valve Marine Industrial 4 3L 6 15 Remove the oil pressure gauge sensor or another engine block oil gallery plug Install an oil pressue gauge Start the engine and then allow the engine to reach normal operation temperature Measure the engine oil pressure at the following RPM Specification T 1 42 kPa 6psig minimum at 1 000 RPM 7 2 125 kPa 18 psig minimum at 2 000 RPM 7 3 166 kPa 24 psig minimum at 4 000 RPM If the engine oil pressure is below minimum specifications inspect the engine for one or more of the following Oil pump worn or dirty Malfun
123. ockwise until the balance shaft rear bearing is removed from the engine block 1 7 Remove the J 26941 from the balance shaft rear bearing Discard the balance shaft rear bearing Balance Shaft Clean and Inspect Caution Refer to Safety Glasses Caution in Cautions and Notices Important The balance shaft and the balance shaft front bearing are serviced only as an assembly Do not remove the balance shaft front bearing from the balance shaft 1 Clean the following components in cleaning solvent e The balance shaft 1 e The balance shaft retainer 2 The balance shaft rear bearing The balance shaft driven gear 4 The balance shaft drive gear Dry the following components with compressed air The balance shaft 1 The balance shaft retainer 2 The balance shaft rear bearing The balance shaft driven gear 4 The balance shaft drive gear Inspect the balance shaft bearings for the following Front ball bearing for damage or wear e Front ball bearing for smoothness of operation Rear sleeve bearing for wear scoring or other damage Inspect the balance shaft 1 for the following Wear or scoring on the rear bearing journal Damaged bolt hole threads Damaged to the balance shaft driven gear locator pin Inspect the balance shaft retainer 2 for wear or damage Inspect the balance shaft retainer bolts 3 for damaged threads Inspect the driven gear 4 for the following Excessive we
124. oid damage to the camshaft bearings 3 Usethe bolts as a handle in order to install the engine camshaft 4 Remove the 3 bolts from the front of the engine camshaft Notice Refer to Fastener Notice in Cautions and Notices 5 Ifreusing the fasteners apply threadlock GM P N 12345382 or equivalent to the threads of the camshaft retainer bolts 6 Install the camshaft retainer and bolts Tighten the camshaft retainer bolts to 12 Nem 106 Ib in Balance Shaft Installation Tools Required J 8092 Universal Driver Handle J 36660 Electronic Torque Angle Meter J 36996 Balance Shaft Installer Important The balance shaft and the balance shaft front bearing are serviced only as an assembly Do not remove the balance shaft front bearing from the balance shaft 1 Apply clean engine oil GM P N 12345610 or equivalent to the balance shaft front bearing Caution Refer to Safety Glasses Caution in Cautions and Notices 2 Use the J 36996 and the J 8092 in order to install the balance shaft Marine Industrial 4 3L 6 139 5141 2000 Marine Industrial 6 140 Marine Industrial 4 3L 188031 2000 Marine Industrial Engine Notice Refer to Fastener Notice in Cautions and Notices 3 Install the balance shaft retainer and bolts Tighten Tighten the balance shaft retainer bolts to 12 Nem 106 Ib in Install the balance shaft driven onto the balance shaft If reusing the fastener apply threadlock GM P N 12345382 or equiv
125. old Clean and inspect 0 0 cece cece tee eee nennen 6 117 Intake Manifold Assemble 00ers 6 118 Exhaust Manifold Clean and inspect 000 cece cece tte ee 6 123 Water Pump Clean and inspect anaran 6 124 Thread Repair iire Rees erat Rah had es beeen habe ee belied lee t 6 125 Service Prior to Assembly 4 4 ics coil nenne Gard TAR added weg 6 126 Installation 2 54242 bI Drac Gna nid De ee cR E Rc GE o8 aca e eil 6 128 Engine Block Plug Installation esinen e er a A III IIIA 6 128 Crankshaft and Bearings Installation 0 0 cece eect eee ee 6 132 Crankshaft Rear Oil Seal and Housing Installation eese 6 134 Piston Connecting Rod and Bearing Installation 00 c cece c eee eee eee 6 136 Balance Shaft Installation 0000 0 eter nn 6 139 Timing Chain and Sprockets Installation 0000 c cece cee tenet neeeee 6 142 Engine Front Cover Installation 000 ccc ec cece cette III 6 144 Oil Pump Installation Mo eda Han kalender 6 145 Gil Pari Installation a p eeepc Ra RE URS M ae ERU 6 146 Crankshaft Balancer Installation lssessleee II 6 149 Valve Lifter Installation 1 4 tin sikl e a a is 6 151 Cylinder Head Installation 00 ccc cette ete e eee I 6 152 Table of Contents continued TP 6103 1 01 Table of Contents continued Valve Rocker Arm and Push Rod Installation lesse 6 157 Intake M
126. oper torque specifications DO NOT overtighten the fasteners Anaerobic Type Gasket Eliminator Sealant Anaerobic type gasket eliminator sealant cures in the absence of air This type of sealant is used where 2 rigid parts Such as castings are assembled together When 2 rigid parts are disassembled and no sealant or gasket is readily noticeable then the 2 parts were probably assembled using an anaerobic type gasket eliminator sealant Use the following information when using gasket eliminator sealant Always follow all the safety recommendations and directions that are on the gasket eliminator sealant container 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 is tightened 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 After properly t
127. pass valve 1 1 Install the oil filter bypass valve into the oil gallery bore until slightly below flush with the surface of the engine block 1 2 Using a pointed punch stake the engine block area around the oil filter bypass valve Apply sealant GM P N 12346004 or equivalent to the outside diameter of the NEW front engine oil gallery plugs Install the NEW front engine block oil gallery plugs A properly installed front engine oil gallery plug must be installed slightly below flush with the front face of the engine block Apply threadlock GM P N 12345382 or equivalent to the outside diameter of the NEW engine block core hole plugs Install the NEW engine block core hole plugs A properly installed engine block core hole plug must be insalled flush with the bottom of the chamfer 1 of the engine block core hole Engine Marine Industrial 4 3L 6 129 6 Install the spring type S pin crankshaft rear oil seal housing locator if required 7 3 7 9mm 0 29 0 81 334546 7 Apply sealant GM P N 12346004 or equivalent to the outside diameter of the NEW expansion cup plug balance rear bearing hole 8 Install the NEW expansion cup plug balance shaft rear bearing hole 8 4 9 2 mm 0 33 0 36 334540 9 Apply sealant GM P N 12346004 or equivalent to the outside diameter of the NEW expansion cup plug camshaft rear bearing hole 10 Install the NEW expansion cup plug camshaft rear bearing hole
128. plugs from the coolant jacket 13 3 Discard the engine block core hole plugs 14 Remove the oil filter bypass valve and discard 188026 2000 Marine Industrial 6 66 Marine Industrial 4 3L 2000 Marine Industrial 334378 Engine Engine Block Clean and Inspect Tools Required J 8087 Cylinder Bore Gauge Caution Refer to Safety Glasses Caution in Cautions and Notices 1 oar wD Clean all the remaining sealing or gasket material from the sealing surfaces Clean the engine block with cleaning solvent Flush the engine block with clean water or steam Clean the cylinder bores Clean the oil galleries and the oil passages Clean the scale and the deposits from the coolant passages Notice Clean all debris dirt and coolant from the engine block cylinder head bolt holes Failure to remove all foreign material may result in damaged threads improperly tightened fasteners or damage to the components Clean the engine block cylinder head bolt holes After cleaning the engine block spray or wipe the cylinder bores and the machined surfaces with clean engine oil Inspect the following areas e Coolant jackets 1 for cracks e Cylinder bores 2 for scratches or gouging Valve lifter bores 3 for excessive scoring or wear Threaded holes 4 for damage e Crankshaft bearing webs 5 for cracks e Crankshaft bearing caps 6 and the crankshaft bearing bores 7 for damage The crankshaft bearing bore
129. pump Inspect the water pump for the following Leakage or damage to the housing cover or gasket 1 Excessive scratches or gouging to the gasket sealing surfaces 2 Leakage from the water pump vent hole 3 A stain around the vent hole is acceptable If leakage occurred dripping with the engine operating and the cooling system pressurized then replace the water pump Damaged bolt hole threads 4 Excessive side to side movement of the water pump shaft 5 Leakage around the water inlet pipe 6 Leakage around the heater hose pipe 7 Restrictions within the internal coolant passages Engine Thread Repair General purpose thread repair kits are available commercially Caution Refer to Safety Glasses Caution in Cautions and Notices Important Refer to the thread repair kit manufacturer s instructions regarding the size of the drill and which tap to use Always avoid any buildup of chips Back out the tap every few turns and remove the chips Determine the size the pitch and the depth of the damaged thread 1 NOooOcRGQOI I Adjust the stop collars on the cutting tool as needed Tap the stop collars to the required depths Drill out the damaged thread Remove the chips Apply clean engine oil to the top thread Use the tap in order to cut new thread Clean the thread Screw the thread insert onto the mandrel of the thread insert installer Engage the tang of the thread insert onto the end of the mandrel
130. pushed forward insert a feeler gauge between the crankshaft and the crankshaft bearing surface and then measure the clearance Refer to Engine Mechanical Specifications 10 2 Ifthe correct end play cannot be obtained verify that the correct size crankshaft bearing has been installed Refer to Engine Mechanical Specifications 10 3 Inspect the crankshaft for binding Turn the crankshaft to check for binding If the crankshaft does not turn freely then loosen the crankshaft bearing cap bolts one bearing cap at a time until the tight crankshaft bearing is located Burrs on the crankshaft bearing cap foreign matter between the crankshaft bearing and the engine block or crankshaft bearing cap or a faulty crankshaft bearing could cause a lack of clearance at the crankshaft bearing Engine 11 12 Inspect the crankshaft bearings for craters or pockets Flattened sections on the crankshaft bearing halves also indicate fatigue Inspect the crankshaft bearings for excessive scoring or discoloration Inspect the crankshaft bearings for dirt or debris imbedded into the crankshaft bearing material Inspect the crankshaft bearings for improper seating indicated by bright polished sections of the crankshaft bearings e Ifthe lower half of the crankshaft bearing is worn or damaged both the upper and lower halves of the crankshaft bearing should be replaced Generally if the lower half of the crankshaft bearing is su
131. quipped Cracked or damaged engine flywheel Exhaust leak at the exhaust manifold Combustion chamber deposits Exhaust System Noise and or Exhaust system noise and or leakage may be caused by the following conditions Leakage e Improperly installed or misaligned exhaust system components A cracked or broken exhaust manifold Damaged or worn exhaust manifold gaskets and or seals Burnt or rusted out exhaust system components Broken or loose exhaust clamps and or brackets 2000 Marine Industrial Engine Marine Industrial 4 3L 6 13 Valve Train Diagnosis General Information A light tapping noise at 1 2 engine speed or any varying frequency may indicate a valve train problem Tapping noises will typically increase with increased engine speed Before attempting to diagnose a valve train noise check for the proper engine oil level and then allow the engine to obtain normal operating temperature Following this procedure will bring all engine components to a normal state of expansion Sit in the driver s seat then operate the engine at various speeds and listen for any abnormal engine noise Valve Train Noise Low engine oil pressure A worn or faulty oil pump A loose or plugged oil pump screen Loose valve rocker arm attachments causing excessive valve lash A worn or damaged valve rocker arm ball A worn valve rocker arm and or valve pushrod A broken valve spring Sticking valves Valve lifters worn dirty or faulty A broke
132. r Important A crankshaft front oil sealing surface with excessive Scoring grooves rust or other damage must be replaced Worn grooved or damaged crankshaft front oil sealing surface 2 334387 Minor imperfections on the crankshaft balancer crankshaft front oil seal surface may be removed with a polishing compound or fine grade emery cloth Worn chunking or deteriorated rubber 3 between the hub and the outer ring Worn or damaged keyway 4 Worn or damaged bolt hole threads 5 Engine Flywheel Clean and Inspect Caution Refer to Safety Glasses Caution in Cautions and Notices 1 Clean the engine flywheel 1 or 2 in cleaning solvent 2 Drythe engine flywheel with compressed air 188129 2000 Marine Industrial Engine 3 Inspect the engine flywheel automatic transmission if equipped for the following e Stress cracks around the engine flywheel to torque converter bolt hole locations 1 Missing balance weights Stress cracks around the engine flywheel to crankshaft bolt hole locations 2 or 3 Important Do not attempt to repair the welded areas if present that retain the ring gear to the engine flywheel plate Always install a NEW engine flywheel 4 Welded areas that retain the ring gear onto the engine flywheel for cracking 4 if present Damaged ring gear teeth 5 Inspect the engine flywheel manual transmission if equipped for loose or improperly installed
133. re Switch Socket Caution Refer to Safety Glasses Caution in Cautions and Notices 1 Remove the knock sensor from the engine block 2 Remove the engine oil pressure gauge sensor using the J 41712 188018 2000 Marine Industrial Engine 3 Remove the engine oil pressure sensor fitting 4 Remove the dowel straight pins transmission locator if required 5 Remove the engine block left side oil gallery plug 6 Remove the engine block left rear oil gallery plug 7 Remove the engine block right rear oil gallery plug Marine Industrial 4 3L 6 63 188020 334350 5271 2000 Marine Industrial 6 64 Marine Industrial 4 3L Engine 8 Remove the expansion cup plug camshaft rear bearing hole and discard 9 Remove the expansion cup plug balance shaft rear bearing hole and discard 334366 10 Remove the spring type S pin crankshaft rear oil seal housing locator if required 334323 2000 Marine Industrial Engine Marine Industrial 4 3L 6 65 11 Remove the front oil gallery plugs or balls from the front of the engine block and discard 12 Insert a 3 8 x 26 in rod into the rear oil gallery holes in order to drive out the front oil gallery plugs or balls 5270 13 Remove the engine block core hole plugs 13 1 Use a suitable tool in order to drive the engine block core hole plugs into the coolant jacket 13 2 Use a suitable tool in order to pull the engine block core hole
134. re clearance A cold piston knock which appears in 1 5 minutes should be considered acceptable A cold engine knock usually disappears when the specific cylinders secondary ignition circuit is grounded out Intermittent Noise on Idle Improper oil viscosity Install the recommended oil viscosity for the expected Disappearing When Engine Speed is temperatures Increased Lower than specified oil pressure Install an oil pressure gauge and measure the engine oil pressure Dirty or worn valve lifter Valve Train Noise Rattle Tapping The following conditions may cause valve train noise Lower than specified oil pressure Worn or faulty oil pump Loose oil pump to engine block bolt Loose valve rocker arm attachments Worn valve rocker arms and or valve pushrods Broken valve spring Sticking valves Worn dirty or faulty valve lifters Worn engine camshaft lobes Worn valve guides or valve stems Bent broken or damaged timing chain sprocket teeth Knocks Hot at The following conditions may cause a knocking noise Idle Rumble Knocking Malfunctioning accessory drive system components Loose or broken crankshaft balancer Detonation or spark knock Check for proper operation of the cooling knock and ignition control components Refer to diagnostic information in Engine Controls Excessive connecting rod bearing clearance Excessive piston pin to bore clearance Bent connecting rod Excessive crankshaft bearing clearance Loose torque converter bolts if e
135. ring Clearance Measuring Procedure 0 0 cece eects 6 80 Crankshaft Balancer Clean and Inspect 0 c ccc ett 6 86 Engine Flywheel Clean and Inspect 0 c cece centre eee 6 86 Camshaft and Bearings Clean and Inspect 0 cee eect tenes 6 88 Camshaft Bearing Removal 0 cece cece teeta 6 89 Camshaft Bearing Installation 0 ccc een nnn 6 91 Balance Shaft Bearing and or Bushing Removal 0 0 0 ranerne 6 93 Balance Shaft Clean and Inspect 0 ccc cette 6 94 Balance Shaft Bearing and or Bushing Installation uuaa ccc cece 6 95 Timing Chain and Sprockets Clean and Inspect 00 cece tte eens 6 96 Valve Rocker Arm and Push Rods Clean and Inspect 0 cece eee eee 6 96 Valve Lifters and Guides Clean and Inspect 0 0 0 cece eee teenies 6 98 Cylinder Head Disassemble 0 0 0 6 99 Cylinder Head Clean and Inspect 00 cece cece 6 99 Valve Guide Reaming Valve and Seat Grinding 0 cece eens 6 102 Cylinder Head Assemble 0 cect 6 104 Oil Pump Disassemble sssssssssee mh 6 106 Oll Pump Clean and Inspect 0 IH 6 108 Gil Pump Assetble 2s zer Rod Pha RR ERU Aaa ae pease 6 109 Valve Rocker Arm Cover Clean and Inspect 00 cece eee eee eee 6 111 Oil Pan Clean and Inspect 0 00 c cect mn 6 112 Intake Manifold Disassemble 0 0 6 113 Intake Manif
136. rive Belt WING 52 2 2 aa ee EUER E 6 21 Drive Belt Rumbling 2 se ttem eani Reeds nr ar 6 22 Drive Belt Vibration 41259 hi aie ee IL REN ER UV Ue HMM eS 6 23 Dtive Belt Ealls Off 5 523 222 820 2a a ae lota tds todo 6 24 Drive Belt Excessive Wear 0 00 ccc ccc se en 6 25 Drive Belt Tensioner eee a ee eg Re e AN 6 26 Component Locator diusia occ chs a ED ne eng e 6 28 Intake Manifold 5 t aee Same ee a toe nde e t ecd bordel 6 28 Cylinder Head and Exhaust Manifold 0 c ccc eee nern nenn 6 30 Cylinder Block and Components sssssssssssssese nn 6 31 Lower Engine Block and Oil Pan 0 cece eee nn 6 33 Repair Instruction Removal 000 ccc cece eee eee eee eee hh hn 6 34 Draining Fluids and Oil Filter Removal 0 0 0 cece eee II 6 34 Engine Flywheel Removal 0 ccc eee eee tenet ete ne mn 6 35 Clutch Pilot Bearing Removal 00 cece eee 6 35 Exhaust Manifold Removal 00 nennen een nern 6 36 Oil Level Indicator and Tube Removal 0 0 cece cece cece ee 6 37 Water Pump Removal 0 cece cece heme 6 38 Crankshaft Balancer Removal ssssssssssssseee enn 6 39 Valve Rocker Arm Cover Removal ssssssssseee seen 6 40 Distributor Removal ru HERRIN ER RR C EE n 6 42 Intake Manifold Removal 000s cece hme 6 43 Valve Rocker Arm and Push Rod Removal 000 ccc eee cece ene 6 44 Cyli
137. s 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 that are 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 6103 1 01 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 i Notes ii Introduction TP 6103 1 01 Defin
138. s if required 5 9 6 9 mm 0 24 0 27 330578 Engine Front Cover Removal 1 Remove the crankshaft position sensor bolt 2 Remove the crankshaft position sensor 3 Remove the crankshaft position sensor seal O ring 4 Discard the crankshaft position sensor seal O 387759 2000 Marine Industrial 6 54 Marine Industrial 4 3L Engine 5 Remove the engine front cover bolts Important After the composite engine front cover is removed do not reinstall the engine front cover Always install a NEW engine front cover 6 Remove the engine front cover 7 Discard the engine front cover Timing Chain and Sprockets Removal Tools Required J 5825 A Crankshaft Gear Remover 1 Remove the crankshaft position sensor reluctor ring 2 Check the camshaft timing chain free play 2 1 Rotate the camshaft sprocket 1 counterclockwise until all slack is removed from the camshaft timing chain 2 2 2 Measure the free play on the slack side 3 of the camshaft timing chain If the camshaft timing chain can be moved side to side in excess of 11 mm 0 43 in replacement of the camshaft timing chain and the sprockets is recommended during assembly 480542 2000 Marine Industrial Marine Industrial 4 3L 6 55 Engine 3 Remove the camshaft sprocket bolts Oo amp f az i 77 E amp o c S o c c D x O fe m a o a c c o E Oo o c o 2 Qe E SG
139. s required 18 Did you complete the worn or damaged component replacement System OK Perform an engine camshaft lobe lift test Refer to 13 Camshaft and Bearings Clean and Inspect Is the engine camshaft lobes within specifications Go to Step 15 Go to Step 14 2000 Marine Industrial Engine Excessive oil consumption not due to leaks is the use 1 9 liters 2 quarts of engine oil within 3 200 kilometers 2 000 miles However during initial engine break in periods 4 828 6 437 kilometers 3 000 4 000 miles oil consumption may exceed 1 9 liters 2 quarts or more The causes of excessive oil consumption include the following conditions External oil leaks Tighten the bolts and or replace gaskets and oil seals as necessary Incorrect oil level or improper reading of oil level indicator With the vehicle on a level surface allow adequate drain down time and check for the correct oil level Improper oil viscosity Use a recommended SAE viscosity for the prevailing temperatures e Continuous high speed operation and or Severe usage Crankcase ventilation system restrictions or malfunctioning components Possible improper PCV valve e Valve guides and or valve stem oil seals worn damaged or the seal omitted Ream the valve guides and install oversize service valves and or new valve stem oil seals Piston rings broken improperly installed worn or not seated properly Allow adequate time for the piston rings t
140. s should be round and uniform when measuring the inside diameter ID The surface where the crankshaft bearings contact the crankshaft bearing bore should be smooth If a crankshaft bearing cap is damaged and requires replacement replace the crankshaft bearing cap first then rebore the engine block crankshaft bearing bores and check for proper alignment Finally check the crankshaft fro the proper clearances Engine block core hole plug bores 8 for damage Engine block 9 fro cracks or damage Engine mount bosses 10 for damage Engine Marine Industrial 4 3L 6 67 10 Measure the cylinder bores for taper and out of round 10 1 Depress the plunger on the J 8087 7 mm 0 275 in or until the J 8087 enters the cylinder bore 10 2 Center the J 8087 in the cylinder bore and turn the indicator dial to 0 10 3 Move the J 8087 up and down the cylinder bore to determine the cylinder bore taper Refer to Engine Mechanical Specifications 10 4 Turn the J 8087 to different points around the cylinder bore to determine the cylinder bore out of round condition Refer to Engine Mechanical Specifications Cylinder Boring and Honing Honing Procedure Caution Refer to Safety Glasses Caution in Cautions and Notices 1 When honing the cylinder bores follow the manufacturer s recommendations for equipment use cleaning and lubrication e Use only clean sharp stones of the proper grade for the amount of material to be remove
141. s should be taken with the comonents at normal room temperature For proper piston fit the engine block cylinder bores should not have excessive wear or taper A used piston and piston pin set may be reinstalled if after cleaning and inspection the piston and piston pin are within specifications 1 Use the J 8087 in order to measure the cylinder bore diameter Measure at a point 64 mm 2 5 in from the top of the cylinder bore and 90 degrees to the crankshaft centerline Marine Industrial 4 3L 6 73 156169 4968 2000 Marine Industrial 6 74 Marine Industrial 4 3L 4974 188016 J 24086 C 4965 2000 Marine Industrial Engine 2 Measure the J 8087 with a micrometer and record the reading 3 With a micrometer or caliper at a right angle to the piston pin bore meausre the piston 11 mm 0 433 in from the bottom of the skirt 4 Subtractthe piston diameter from the cylinder bore diameter in order to determine piston to bore clearance Refer to Engine Mechanical Specifications 5 Ifthe proper clearance cannot be obtained then select another piston and measure the clearances If the proper fit cannot be obtained the cylinder bore may require honing or boring 6 When the piston to cylinder bore clearance is within specifications permanently mark the top of the piston for installation into the proper cylinder Piston and Connecting Rod Assemble Tools Required J 24086 C Piston Pin Remo
142. sket surfaces These methods of cleaning can cause damage to the component sealing surfaces Abrasive pads also produce a fine grit that the oil filter cannot remove from the engine oil This fine grit is abrasive and can cause internal engine damage Assembling Components e Assemble components using only the sealant or equivalent that is specified in the service procedure Sealing surfaces must be clean and free of debris 2000 Marine Industrial Engine or oil e Specific components such as crankshaft oil seals or valve stem oil seals may require lubrication during assembly Components requiring lubrication will be identified in the service procedure Apply only the amount of sealant specified in the service procedure to a component 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 Tighten fasteners to the proper specifications DO NOT overtighten the fasteners Use of RTV and Anaerobic Sealer Sealant Types Important The correct sealant and amount of sealant must be used in the proper location to prevent oil leaks coolant leaks or the loosening of the fasteners DO NOT interchange the sealants Use only the sealant or equivalent as specified in the service procedure The following 2 major types of sealant are commonly used in engines Aerobic sealant Room Temperature
143. stall the oil pan baffle and the bolts Tighten Tighten the oil pan baffle bolts to 12 Nem 106 Ib in 387763 2000 Marine Industrial Marine Industrial 4 3L 6 113 Engine 374902 12852 AD MCA Na Y A N N a Y T c fe s w e 9 2 ra Q o lt lt vo c G 7 o 2 a t o amp a g 2 o m gt E o tc x o t ed a Q a o 4 Remove the throttle body to upper intake manifold gasket 5 Discard the throttle body to upper intake manifold gasket 77 o 2 2 a D E o i i gt o o 2 E o S o de o 2 E tc N 3 Remove the throttle body 1 Intake Manifold Disassemble 12853 2000 Marine Industrial 6 114 Marine Industrial 4 3L Engine 6 Remove the water outlet studs 7 Remove the water outlet 1 or 2 8 Remove the engine coolant thermostat 480559 Important Note the position and direction of the exhaust gas recirculation EGR valve before removal It is possible to improperly install the EGR valve 180 degrees from the original position 9 Remove the exhaust gas recirculation EGR valve bolts 480563 Notice The linear EGR valve is an electrical component DO NOT soak in any liquid cleaner or solvent because damage may result 10 Remove the EGR valve and the EGR valve gasket from the lower intake manifold 11 Discard the EGR valve gas
144. strial Engine 5 Inspect the crankshaft for the following Crankshaft journals 1 should be smooth with no evidence of scoring or damage Deep grooves 2 Scratches or uneven wear 3 Pitted surfaces 4 Wear or damage to the thrust journal surfaces Scoring or damage to the rear seal surface Restrictions to the oil passages Damage to the threaded bolt holes 6 Inspect the crankshaft balancer key 1 the keyway 2 and the threaded hole 3 for damage Repair or replace the crankshaft as necessary 7 Measure the crankpins for out of round and taper Refer to Engine Mechanical Specifications Marine Industrial 4 3L 6 77 156170 188090 188015 2000 Marine Industrial 6 78 Marine Industrial 4 3L 35210 188467 2000 Marine Industrial Engine Use a suitable support to support the crankshaft on the front and rear journals Use the J 7872 in order to measure the crankshaft journal runout The crankshaft runout should not exceed 0 025 mm 0 0010 10 Measure the crankshaft end play Important In order to properly measure the crankshaft end play the crankshaft the crankshaft bearings and the crankshaft bearing caps the crankshaft bearing cap bolts must be installed into the engine block and the bolts tightened to specifications Firmly thrust the crankshaft first rearward then forward This will align the crankshaft rear bearings and the crankshaft thrust 10 1 With the crankshaft
145. t 6 2 Tighten the crankshaft bearing cap bolts on the final pass an additional 73 degrees using the J 36660 7 Remove the crankshaft bearing cap bolts 8 Remove the crankshaft bearing caps The gauging plastic may adhere to either the crankshaft bearing journal or the crankshaft bearing surface 334329 9 Without removing the gauging plastic measure the compressed width at the widest point using the graduated scale on the edge of the gauging plastic envelope 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 bearing journal Normally the crankshaft bearing journals wear evenly and are not ou of round However if a crankshaft bearing is being fitted to an out of round 0 0254 mm 0 0010 in maximum crankshaft bearing journal be sure to fit to the maximum diameter of the crankshaft bearing journal If the crankshaft bearing is fitted to the minimum diameter and the crankshaft bearing journal is excessively out of round the interference between the crankshaft bearing and the crankshaft bearing journal will result in rapid crankshaft bearing failure 500656 2000 Marine Industrial Engine e If the crankshaft bearing clearance is within specifications the crankshaft bearing is satisfactory If the clearance is not within specifications replace the crankshaft bearing
146. t type of equipment is used it is essential that the valve guide bores are free from carbon or dirt in order to ensure the proper centering of the pilot in the valve guide The valve seats should be concentric to within 0 05 mm 0 002 in total indicator reading Reface pitted valves on a valve refacing machine in order to ensure the correct relationship between the valve head and the valve stem Replace the valve if the valve stem is excessively worn or warped Replace the valve if the edge margin 4 of the valve head is less than 0 79 mm 0 031 in thick after grinding Several different types of equipment are available for reconditioning valves and valve seats Follow the equipment manufacturer s recommendations for equipment use to attain the proper results Cylinder Head Assemble Tools Required J 8062 Valve Spring Compressor J 42073 Valve Stem Seal Installer Important The exhaust valve oil stem seal has the letters EX 1 molded into the top of the seal The exhaust valve oil stem seal material is brown in color 2 with a white stripe 3 painted onto the outside diameter of the seal or the material may be red in color 2 with no paint stripe The intake valve oil seal is black in color 1 2 Assemble the valve into the proper valve guide Select the proper valve stem oil seal for the specific valve guide Lubricate the valve stem oil seal and the outside diameter of the valve guide with clean engine oil
147. ted The vibration may be sensitive to accessory load Did you review the Drive Belt Symptom operation and perform Go to Symptoms the necessary inspections Go to Step 2 Drive Belt Verify that the vibration is engine related Go to Does the engine make the vibration Go to Step 3 Diagnostic Aids 1 Remove the drive belt s Go to Engine 2 Operate the engine 3n no Songer than 30 to 40 seconds Related Vibration Does the rumbling noise still exist in Vibration and Diagnosis Go to Step 4 Inspect the drive belt s for wear damage debris build up and missing drive belt ribs Did you find any of these conditions Go to Step 5 Go to Step 6 2000 Marine Industrial 6 24 Marine Industrial 4 3L Engine Drive Belt Vibration Diagnosis cont d Stp ction Value Yes No 5 Install a new drive belt Refer to Drive Belt Replacement Did you complete the replacement Go to Step 11 Inspect for improper loose or missing fasteners Go to Step 5 Go to Step 6 Did you find any of these conditions Tighten any loose fasteners Replace improper or missing fasteners Refer to Fastener Tightening Specifications Did you complete the repair Go to Step 11 Inspect for bent water pump shaft if the water pump is belt driven Refer to Water Pump Replacement 4 3L Engine in Engine Cooling Did you find and correct the condition Inspect for bent or cracked brackets Did you find and correct the condition 0 to Go to Step 11
148. ter body bracket bolt to 10 Nem 89 Ib in Install the fuel meter body into the fuel meter body bracket Install the 6 poppet nozzles into the proper lower intake manifold bores Inspect the poppet nozzles in order to ensure that the poppet nozzles are firmly seated and locked in the lower intake manifold bores Engine 6 Install aNEW fuel meter body seal into the groove of the fuel meter body Install NEW upper intake manifold to lower intake manifold gasket into the groove of the upper intake manifold Install the upper intake manifold onto the lower intake manifold If reusing the fasteners apply threadlock GM P N 12345382 or equivalent to the threads of the upper intake manifold attaching studs Install the upper intake manifold attaching studs Tighten 10 1 Tighten the upper intake manifold attaching studs on the first pass to 5 Nem 44 lb in 10 2 Tighten the upper intake manifold attaching studs on the final pass to 9 Nem 80 lb in If reusing the fasteners apply threadlock GM P N 12345382 or equivalent to the threads of the evaporative emission EVAP canister purge solenoid valve studs Install the EVAP canister purge solenoid valve and studs Tighten Tighten the EVAP canister purge solenoid valve studs to 10 Nem 89 Ib in Marine Industrial 4 3L 6 119 334516 334511 2000 Marine Industrial 6 120 Marine Industrial 4 3L 22 480562 2000 Marine Industrial 13 14 15
149. the disconnected components 2000 Marine Industrial 6 12 Marine Industrial 4 3L Engine Engine Noise Diagnosis When diagnosing engine noisee complaints use the following steps to isolate the source of the engine noise Determine the type of noise For example is the noise a light rattle tapping or a low rumble knocking The exact operating condition under which the noise exists Note factors such as ambient temperature the amount of engine warm up time the engine temperature the engine RPM and other specifics At what rate the noise occurs and at what location on the engine Engine noises are generally synchronized to either engine speed crankshaft engine flywheel connecting rods crankshaft balancer or pistons and related components or one half engine speed valve train noise such as valve rocker arms valve lifters and camshaft timing chain Determine the rate at which the noise is occurring Compare the engine sounds to other engines and make sure you are not trying to correct a normal condition Noise on Start Up but Only Lasts a Improper oil viscosity Install the recommended oil viscosity for the expected Few seconds temperatures Worn or dirty valve lifters Excessive piston to cylinder bore clearance Excessive piston pin to bore clearance Excessive crankshaft bearing clearance Knocks Cold and Continues for Loose or broken crankshaft balancer or accessory drive components 1 to 2 Minutes Excessive piston to bo
150. the rumbling noise still exist Inspect the drive belt s for damage separation or sections of missing ribs Did you find and repair the condition Inspect for severe pilling of more than 1 3 of the drive belt pulley grooves Did you find severe pilling 1 Clean the drive belt pulleys using a suitable wire brush 2 Reinstall the drive belt Refer to Drive Belt Replacement Did you complete the repair 2000 Marine Industrial Go to Symptoms Go to Step 2 Drive Belt Go to Go to Step 3 Diagnostic Aids ae ed cs Noise Diagnosis Go to Step 4 ME P m Lione i La Linnaei Engine Marine Industrial 4 3L 6 23 Drive Belt Rumbling Diagnosis cont d Step ction Value Yes No 7 Install a new drive belt Refer to Drive Belt Replacement Did you complete the replacement Go to Step 8 Operate the system in order to verify the repair Go to Did you correct the condition System OK Diagnostic Aids Drive Belt Vibration Diagnosis 4 The drive belt s may cause a vibration While the pe drive belt s is removed inspect the condition of Diagnostic Aids i the belt The accessory drive components can have an affect i ne on engine vibration Such as but not limited to the 6 Inspecting of the fasteners can eliminate the A C system overcharged the power steering system possibility that a wrong bolt nut spacer or restricted or the incorrect fluid or an extra load on the washer was installed generator To
151. the system operation in order to familiarize yourself with the system functions Refer to Drive Belt System Description 2 Visual Physical Inspection Inspect for aftermarket devices which could affect the operation of the drive belts Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom Inspect the drive belt for excessive wear n shredding or missing sections Inspect the drive belt for contamination of excessive dirt oil coolant or other substances that may affect the drive belt operation Intermittent Drive belt symptoms may be from intermittent Drive Belt Chirping Diagnosis Diagnostic Aids 6 The symptom may be intermittent due to moisture on the drive belt s or the pulleys It may be necessary to spray a small amount of water on the drive belt s in order to duplicate the customers concern If spraying water on the drive belt s duplicates the symptom cleaning the belt pulleys may be the probable solution A loose or improper installation of a body component a suspension component or other items of the vehicle may cause the chirping noise Test Description The number s below refer to the step number s on the diagnostic table 2 The noise may not be engine related 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 this table 3 The noise may
152. tion 1 Apply sealant GM P N 12346004 or equivalent around the oil level indicator tube 13 mm 0 50 in below the tube bead Install the oil level indicator tube into the engine block Rotate the oil level indicator tube into position Notice Refer to Fastener Notice in Cautions and Notices 3 Install the oil level indicator tube bolt Tighten Tighten the oil level indicator tube bolt to 12 Nem 106 Ib in Install the oil level indicator into the oil level indicator tube if required Engine Water Pump Installation Tools Required J 41240 Fan Clutch Remover and Installer 1 If reusing the fasteners apply sealant GM P N 12346004 or equivalent to the threads of the water pump bolts 2 Install the water pump and the NEW water pump gaskets Notice Refer to Fastener Notice in Cautions and Notices 3 Install the water pump bolts Tighten Tighten the water pump bolts to 45 N m 33 Ib ft Important After final assembly the water pump inlet hose clamp tangs water pump end must point forward and the upper tang should be level with the outside diameter of the water pump inlet hose 4 Install the water pump inlet hose and the water pump inlet hose clamps 5 Install the fan and water pump pulley and bolts using the J 41240 Tighten Tighten the fan and water pump pulley bolts to 25 N m 18 Ib ft Marine Industrial 4 3L 6 167 188054 182853 J 41240 317191 2000 Marine Industrial 6 168 Mar
153. tion of the leak Use J 28428 E Dye and Light Kit in order to identify the type of fluid and the approximate location of the leak Refer to manufacturer s instructions when using the tool Can you identify the type of fluid and the approximate location of the leak 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 maalfunctioning fluid filters or pressure bypass valves Plugged or malfunctioning engine ventilation system Improperly tightened or damaged fasteners Cracked or porous components Improper sealants or gaskets where required Improper sealant or gasket installation Damaged or worn gaskets or seals Damaged or worn sealing surfaces 2 Inspect the engine for customer modifications Is there mechanical damage or custormer modifications to the engine T Repair or replace all damaged or modified components Does the engine still leak oil Go to Step 11 System OK brew e Visually inspect the suspected area Use a small mirror to assist in looking at hard to see areas Check for leaks at the following locations Sealing surfaces Fittings Cracked or damaged components Can you identify the type of fluid and the approximate location of the leak Go to Step 10 System OK 2000 Marine Industrial 6 18 Marine Industrial 4 3L Symptoms Drive Belt Important Review
154. to hold the valve stem keys in place while disconnecting the J 8062 10 2 Look to ensure that the valve stem keys seat properly in the upper groove of the valve stem 480554 10 3 Tap the end of the valve stem with a plastic faced in order to seat the valve stem keys if necessary Oil Pump Disassemble 1 Remove the oil pump driveshaft and oil pump driveshaft retainer 5274 2000 Marine Industrial Engine Marine Industrial 4 3L 6 107 2 Remove the oil pump screen if necessary The oil pump screen has a press fit into the oil pump cover N i Y AS M AA M A se xX M N M n Se EEE lt 2 S DO NOT remove the oil pump screen from the pipe The pipe and oil pump screen are serviced as a complete assembly D 5275 3 Remove the oil pump cover bolts 5276 4 Remove the oil pump cover 5277 2000 Marine Industrial 6 108 Marine Industrial 4 3L Engine 5 Remove the oil pump drive gear and the oil pump driven gear 6 Matchmark the gear teeth for assembly 5278 Caution Refer to Safety Glasses Caution in Cautions and Notices 7 Remove the following items 7 1 The oil pump pressure relief valve spring straight pin 7 2 The oil pump pressure relief spring 7 3 The oil pump pressure relief valve 30401 Oil Pump Clean and Inspect Caution Refer to Safety Glasses Caution in Cautions and Notices 1 Clean the oil pump components in clea
155. ts 2 3 6 7 10 and 11 on the final pass in sequence to 55 degrees 5132 10 Install the spark plug wire support and bolts Tighten Tighten the spark plug wire support bolts to 12 Nem 106 Ib in 11 Remove the front spark plug wire support bolt The front spark plug wire support bolt is used to fasten the oil level indicator tube and will be installed within the oil level indicator tube installation procedure OS III CANO NO a 328590 2000 Marine Industrial Engine Marine Industrial 4 3L 6 157 12 Measure the NEW spark plugs for the proper gap Adjust the spark plug gap if necessary Specification Spark plug gap to 1 52 mm 0 060 in 13 Install the spark plugs Tighten Tighten the spark plugs for a USED cylinder head to 15 Nem 11 Ib ft Tighten the spark plugs for the initial installation of a NEW cylinder head to 30 Nem 22 Ib ft 328586 Valve Rocker Arm and Push Rod Installation Important Be sure to keep parts in order Parts must be reinstalled into the original location and position 1 Install the valve pushrods 480529 Important Be sure that the arrow on the valve rocker arm support is in the up position 2 Install the valve rocker arm supports 480578 2000 Marine Industrial 6 158 Marine Industrial 4 3L Engine 3 Apply prelube GM P N 12345501 or equivalent to the following valve rocker arm contact surfaces Valve pushrod socket 1 Roller pivot 2
156. ubsequent Installations Spark Plug Wire Support Bolt Starter Motor Wiring Harness Transmission Cooler Pipe Bracket to Throttle Body Stud Transmission to Oil Pan Bolt Transmission Cover Bolt Upper Intake Manifold Stud EE First Pass Final Pass Valve Lifter Pushrod Guide Bolt Valve Rocker Arm Bolt Valve Rocker Arm Cover Bolt 2000 Marine Industrial 6 4 Marine Industrial 4 3L Engine Fastener Tightening Specifications cont d Specification Application Metric English Water Outlet Stud 18 Ib ft Water Pump Bolt 45 Nem 33 Ib ft Engine Mechanical Specifications Application were v6 262 CID 4 012 in 3 480 in Firing Order 1 6 5 4 3 2 Spark Plug Gap 0 060 in 42 kPa at 6 0 psig at 1 000 engine rpm 1 000 engine rpm Oil Pressure Minimum at Normal Operating Temperature 125 kPa at 18 0 psig at 2 000 engine rpm 2 000 engine rpm 166 kPa at 24 0 psig at 4 000 engine rpm 4 000 engine rpm 0 050 0 088 mm 0 0020 0 0035 in Rear Bearing Journal Diameter 38 085 38 100 mm 1 4994 1 500 in 0 0010 0 0090 in 1 8677 1 8696 in 0 0010 in Maximum 0 283 0 287 in 0 274 0 278 in 0 0026 in 0 0015 0 0031 in 0 0010 0 0025 in 0 006 0 017 in 2 2487 2 2497 in 0 00030 in Maximum 0 0010 in Maximum 0 0002 in Maximum 0 0010 in Maximum Crankshaft End Play 0 050 0 20 mm 0 002 0 008 in Crankshaft Journal Diameter Journal 1 62 199 62 217 mm 2 4488 2 4495 in Crankshaft Journal Diameter Journal 2 and 3 62
157. until all of the piston rings have entered the cylinder bore 5 2 Use the J 5239 in order to guide the connecting rod onto the crankshaft journal 5159 2000 Marine Industrial 6 138 Marine Industrial 4 3L Engine 6 Remove the J 5239 31373 Notice Refer to Fastener Notice in Cautions and Notices 7 Install the connecting rod caps bearings and nuts Tighten 7 1 Tighten the nuts evenly on the first pass to 27 Nem 20 Ib ft 7 2 Use the J 36660 in order to tighten the nuts on the final pass an additional 70 degrees 480549 8 After the piston and connecting rod assemblies have been installed then lightly tap each connecting rod assembly parallel to the crankpin in order to ensure that the connecting rods have side clearance 9 Use a feeler gauge or a dial indicator to measure the connecting rod side clearance between the connecting rod caps The connecting rod side clearance should be 0 15 0 44 mm 0 006 0 017 in 5163 2000 Marine Industrial Engine Camshaft Installation 1 Apply clean engine oil GM P N 12345610 or equivalent or engine oil supplement GM P N 1052367 or equivalent to the following components The engine camshaft lobes The camshaft bearing journals The camshaft bearings 2 Install three 5 16 18 x 4 0 in bolts into the engine camshaft front bolt holes Notice All camshaft journals are the same diameter so care must be used in removing or installing the camshaft to av
158. until snug 3 9 Align the lubrication hole of the camshaft outer bearing 1 above the 3 o clock position or the 9 o clock position of the camshaft outer bearing bore 1 at the front of the engine block 3 10 Drive the camshaft outer bearing 1 into the camshaft outer bearing bore 1 at the front of the engine block 3 11 Loosen the J 33049 expander assembly nut 3 12 Carefully slide the J 33049 into the engine block until the J 33049 expander assembly is positioned between the camshaft inner bearing bores Engine Marine Industrial 4 3L 6 93 4 Install the NEW camshaft inner bearings 3 and 2 4 1 Install the NEW camshaft inner bearing 3 onto the J33049 expander assembly 4 2 Tighten the J 33049 expander assembly nut until snug 4 3 Align the lubrication hole of the camshaft inner bearing 3 above the 3 o clock position or the 9 o clock position of the camshaft inner bearing bore 3 of the engine block 4 4 Push the J 33049 guide cone into the camshaft front bearing bore 1 in order to align the J 33049 4 5 Drive the camshaft inner bearing 3 into the camshaft inner bearing bore 3 of the engine block 4 6 Loosen the J 33049 expander assembly nut 4 7 Carefully slide the J 33049 until the J 33049 expander assembly is positioned between the camshaft inner bearing bore 2 and the camshaft outer bearing bore 1 4985 4 8 Install the NEW camshaft inner bearing 2 onto the J33049 expander assembly 4 9 Tighten the J
159. ure the crankshaft journal diameter with a micrometer in several places approximately 90 degrees apart and then average the measurements 2 Determine the taper and the out of round of the crankshaft journal Refer to Engine Mechanical Specifications 3 Install the crankshaft bearings into the engine block Engine 4 Install the crankshaft bearings into the crankshaft bearing caps 5 Install the crankshaft bearing caps in the original positions and with the arrow on the crankshaft bearing caps in the direction of the front of the engine block Notice Refer to Fastener Notice in Cautions and Notices 6 Install the crankshaft bearing cap bolts Tighten 6 1 Tighten the crankshaft bearing cap bolts on the first pass to 20 Nem 15 Ib ft 6 2 Tighten the crankshaft bearing cap bolts on the final pass an additional 73 degrees using the J 36660 7 Measure the crankshaft bearing inside diameter ID at the top and the bottom using an inside micrometer 8 In order to determine the crankshaft bearing clearance subtract the journal diameter from the crankshaft bearing ID 9 Compare the crankshaft bearing clearance to the specifications Refer to Engine Mechanical Specifications 10 Ifthe crankshaft bearing clearances exceeds specifications install the new crankshaft bearings as follows 10 1 Measure the crankshaft bearing inside diameter ID at the top and the bottom using an inside micrometer 10 2 Compare the cranks
160. ure the valve stem to guide clearance Excessive valve stem to guide clearance may cause an 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 10 1 10 2 10 3 10 4 Clamp the J 8001 on the exhaust port side of the cylinder head Position the dial indicator so that the movement of the valve stem from side to side crosswise to the cylinder head will cause a direct movement of the dial indicator stem The dial indicator stem must contract the side of the valve stem just above the valve guide Drop the valve head about 1 6 mm 0 063 in off the valve seat Use light pressure and move the valve stem from side to side in order to obtain a valve stem to guide clearance reading Refer to Engine Mechanical Specifications Valve Guide Reaming Valve and Seat Grinding Tools Required J 5830 02 Valve Guide Reamer Set J 8001 Dial Indicator Set 1 Measure the valve stem to guide clearance Refer to Cylinder Head Clean and Inspect Engine Marine Industrial 4 3L 6 103 2 Improper valve stem 1 to valve guide 2 clearance may cause excessive oil consumption Caution Refer to Safety Glasses Caution in Cautions and Notices Important Exhaust valves with excessive valve stem to guide clearance must be replaced with the available service valve that has an 0 0774 mm 0 0305 in oversize
161. ven Gears Balance Shaft Retainer Belt Idler Pulley Grooved Belt Idler Pulley Smooth Camshaft Bearing Camshaft Retainer Camshaft Sprocket Camshaft Timing Chain Clutch Pilot Bearing Connecting Rod Connecting Rod Bearing Kit Coolant Radiator Crankshaft Balancer Crankshaft Balancer Key Crankshaft Bearing Kit Crankshaft Front Oil Seal Crankshaft Rear Oil Seal Crankshaft Rear Oil Seal Housing Crankshaft Rear Oil Seal Housing Retainer Stud Crankshaft Rear Oil Seal Retainer Stud Crankshaft Position Sensor Crankshaft Position Sensor Reluctor Ring Crankshaft Position Sensor Seal O ring Crankshaft Pulley Crankshaft Sprocket Cylinder Head Cylinder Head Gasket Distributor Distributor Clamp Distributor Gasket Dowel Pin Cylinder Head Locator Dowel Straight Pin Transmission Locator 2000 Marine Industrial Engine Marine Industrial 4 3L 6 7 GM SPO Group Numbers cont d Application GM SPO Group Number Drive Belt Tensioner 1 060 EGR Valve 3 670 EGR Valve Gasket 3 680 EGR Valve Inlet Pipe 3 675 Evaporative Emission Canister Purge Solenoid Valve 3 130 Evaporative Emission Canister Purge Solenoid Valve Harness 3 145 Engine Block N S Engine Block Core Hole Plug 0 034 Engine Block Oil Gallery Plug 1 531 Engine Camshaft 0 519 Engine Coolant Heater 1 152 Engine Coolant Temperature Sensor 1 150 Engine Coolant Temperature Gauge Sensor 1 150 Engine Coolant Thermostat 1 246 Engine Crankshaft 0 646 Engine Flywheel 0 666 En
162. ver Installer Caution Avoid contact with HOT components Wear safetly glasses and protective gloves to avoid personal injury Notice Applying excessive heat to the connecting rod may damage or distort the rod Rod temperature SHOULD NOT exceed 315 C 600 F At this temperature the end of the connecting rod will turn a straw color upon visual inspection Notice After the J 24086 C installer hub bottoms on the support assembly DO NOT exceed 35 000 kPa 5 000 psi or the tool may be damaged Engine Marine Industrial 4 3L 6 75 Important When assembling the piston and connecting rod the mark on the top of the piston must point to the front of the engine block The left bank connecting rods should have the flange face toward the front of the engine block The right bank connecting rods should have the flange face toward the rear of the engine block The piston pin has an interference fit into the connecting rod and is full floating in the piston 1 Install the piston pin and connecting rod assembly 1 1 Lubricate the piston pin bores with clean engine oil 1 2 Use a torch and apply MILD heat to the piston pin end of the connecting rod 1 3 Use the J 24086 C in order to press the piston pin into the piston and connecting rod assembly 1 4 Inspect for the proper installation of the piston and piston pin The piston must move freely on the piston pin with no binding or interference Notice Use a piston ring expander to i
163. with this table from improper mounting of the accessory drive 3 The noise may be an internal engine noise component incorrect installation of the Removing the drive belt and operating the accessory drive component pulley or the pulley engine for a brief period will verify the noise is bent inward or outward from a previous repair related to the drive belt When removing the Test for a misaligned pulley using a straight drive belt s the water pump may not be edge in the pulley grooves across two or three operating and the engine may overheat Also pulleys If a misaligned pulley is found refer to DTCs may set when the engine is operating that accessory drive component for the proper with the drive belt removed installation procedure for that pulley 4 This test is to verify that an accessory drive 8 This test is to verify that the pulleys are the component does not have a seized bearing correct diameter or width Using a known good With the belt removed test the bearings in the vehicle compare the pulley sizes Drive Belt Squeal Diagnosis Notice Refer to Belt Dressing Notice in Cautions and Notices DEFINITION The following items are indications of drive belt squeal A loud screeching noise that is caused by a slipping drive belt this is unusual for a drive belt with multiple ribs The noise occurs when a heavy load is applied to the drive belt such as an air conditioning compressor engagement snapping the throttle or slipping on a

Service Manual, General Motors 4.3L Engine (TP

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