By Engine Manual

Workshop Manual C
Engine Components 2(0)

“BY” Models
Safety Warning
This Workshop IVlanual will alert you to certain proceduresthat

must be done very carefully, if you ignore this information,
you could...
® injure yourself or people around you

® Injure the boat operator, boat passengers, or
people around the boat
® Damagethe Volvo Penta product or its systems
Understand the following symbols before proceeding:
Alerts you to the possibility of dangerand

Z~ Safety Warning identifies information that will help pre-
vent injuries.
Identifies information that will help pre-
vent damageto machinery.
Appearsnext to information that controls

correct assembly and operation of the
product.
This WorkshopManual is ,written for qualified, factory trained

service technicians familiar with the use of Volvo Penta special
tools.
This Workshop Manual tells you how to correctly maintain and

service Volvo Penta products and systems. When correctly
serviced, the Volvo Penta product ,will be reliable and safe to
operate.
WhenVolvo Penta special tools are called for, use them.

Where mentioned, the tools are required to perform the service
procedure.
If you use service proceduresor service tools that are not

recommendedin this manual, YOU ALONEmust decide if
your actions might injure people or damagethe Volvo Penta
product.
Contents
General information .................................... ~ii~
General Engine Mechanical- V6 and V8 Models ..........
3.0GS Engine .......................................... ~

/
4.3GL, 4.3GS and 4.3Gi Engines ......................... ~
5.0GL, 5.0Gi, 5.7GS and 5.7GSi Engines .................. ~
7.4Gi Engines ......................................... ~;~
70.4GSi and 8.2GSi Engines .............................. ~/
Steering Systems g m aa m~ m ~= w = = m [] Eim m m ~ = m [] ~ ¯ m E [] [] == [] ! m~ B es m B ea m~ m o m :~

m~
Throttle and Shift Control Systems ...................... =-~

Hi
cooling Systems s m i= [] [] [] n m m == ~ [] B = = g m B ~ ~ ~ [] IS m = m m = R m [] i m u [] m n m st
~[0~
Engine Removal and Installation ......................... ~ml
Safety Section ......................................... ~
© 1998VolvoPentaof the Americas,Inc, All rights reserved.

i
This workshop
manualis oneof a set of four that coversVolvoPentastern-
drive "BY" modelso
Arl four bookscanbe orderedas a set from VolvoPenta
Parts. OrderP/N 7797450-9.
Individual workshopmanuals
coveringthesemodelsare also available. Or-
der the folJowingpart numbers
from VolvoPentaParts.
, PIN 7797451=7Engine Components
Includesinformation on Engineservice andtroubleshooting;Engineremoval
andinstallation; Steeringsystems;Throttle andShift Controlsystems;and
Coolingsystems.
, PIN 7797452=5
Electrical & Ignition System
Includesservice andtroubleshootinginformationon Crankingsystems;
Chargingsystems;Trim/Tilt electrical systems;Ignition systems;andEngine
and Instrument wMngdiagrams.
¯ PIN 7797453-3Fuel System
Includesserviceandtroubleshootinginformationon all carburetor,MFIand
TBI fuel systemsand related components.
¯ PIN 7797454-1EFI Diagnostic ManualGM
Containstroubleshootingprocedures
for all Electronic Fue[ injected GM
modelsand related components.
¯ PIN 7797455-8SX and DP-SSterndrives and Transom
Shield
Includes information on TransomShield, UpperGearUnit and LowerGear
Unit service; DriveUnit removalandinstallation; Propellers;andTrim/Tilt
hydraulicoperation.
This VolvoPentaWorkshop Manualis part of a set that
coversthe following VolvoPenta"BY"Models
Engine Steering Model Number TransomShield Drive Unit
3.0 GS Manual 30GSMBYCCE 3868844 3865895 (1.97:1) SX-M

Manual 30GSMBYCCE 3868844 3868896 (2.18:1) SX-M
Power 30GSPBYCCE 3868844 3868895 (1.97:1) SX-M
4.3 GL Power 43GLPBYC 3868844 3868892 (1.66:1) SX-M

Power 43GLPBYC 3868844 3868893 (1.79:1) SX-M
Power 43GLPBYC 3868844 3868894 (1.89:1) SX-M
Power 43GLPBYC 3868844 3868913 (1.95:1) DP-SM
Power 43GLPBYC 3868846 3868892 (1.66:1) SX=M
Power 43GLPBYC 3868846 3868893 (1.79:1) SX-M
Power 43GLPBYC 3868846 3868894 (1.89:1) SX-M
Power 43GLPBYC 3868846 3868914 (2,32:1) DP-SM
Power 43GSJBYA 3868694 PJX-C1

Power 43GSPBYC 3868844 3868892 (1.66:1 SX-M
Power 43GSPBYC 3868844 3868893 (1.79:1 SX-M
Power 43GSPBYC 3868844 3868913 (1.95:1 DP-SM
Power 43GSPBYC 3868846 3868892 {1.66:1 SX-M
Power 43GSPBYC 3868846 3868893 (1.79:1 SX-M
Power 43GSPBYC 3868846 3868913 {1.95:1 DP-SM
4,3 Gi Power 43GIJBYA m= 3868694 PJX-C1

Power 43GIPBYCCE 386884,4 3868892 (1.66:1 SX=M
Power 43GIPBYCCE 3868844 3868893 (1.79:1 SX-M
Power 43GIPBYCCE 386884,4 3868913 (1.95:1 DP-SM
Power 43GIPBYCCE 3868844 3868914 (2.32:1 DP-SM
5.0 GL Power 50GLPBYC 3868844 3868891(1 .60:1 SX-M

Power 50GLPBYC 3868844 3868890(1 .51:1 SX=M
Power 50GLPBYC 3868844 3868912(1 .78:1 DP-SM
Power 50GLPBYC 3868846 3868891(1 .60:1 SX-M
Power 50GLPBYC 3868846 3868890(1 .51:1 SX-M
iii
This VolvoPentaWorkshopManualis part of a set that
covers the foUowingVolvoPenta "BY"Models
Engine Steering Model Number TransomShiend Drive Unit
5.0 Gi Power 50GIPBYCCE 3868844 3868891(1 .60:1 SX-M

Power 50GIPBYCCE 3868844 3868890(1 .51:1 SX-M
Power 50GIPBYCCE 3868844 3868912(1 .78:1 DP-SM
Power 50GIPBYCCE 3868848 3868891(1 .60:1 SX-M
Power 50GLPBYCCE 3888846 3868890(1 .51:1 SX-M
5.7 GS Power 57GSPBYC 3868844 3868889(1 .43:1 SX-M

Power 57GSPBYC 3868844 3868890(1 .51:1 SX-M
Power 57GSPBYC 3868844 3868912(1 .78:1 DP-SM
Power 57GSPBYC 3868846 3868889(1 .43:1 SX-M
Power 57GSPBYC 3868846 3868890(1 .51:1 SX-M
5.7 GSi Power 57GSIPBYCCE 3868844 3868889 (1.43:1 SX-M

Power 57GSIPBYCCE 3868844 3868912 (1.78:1 DP-SM
Power 57GSIPBYCCE 3868846 3868889 (1.43:1 SX-M
7.4 Gi Power 74GIPBYCCE 3868844 3868889 (1.43:1) SX-M

Power 74GIPBYCCE 3868844 3868911 (1.68:1) DP-SM
Power 74GIPBYCCE 3868846 3868889 (1.43:1) SX-M
7.4 GSi Power 74GSIPBYCCE 3868850 3868911 (1.68:1)DP-SM

Power 74GSiPBYCCE 3868850 3868912 (1.78:t) DP-SM
Power 74GSIPBYCCE 3868916 3868911 (1.68:1) DP-SM
8.2 GSi Power 82GSIPBYCCE 3868850 3868911 (1.68:1) DP-SM

Power 82GSIPBYOCE 3868850 3888912 (1.78:1) DP-SM
DPX 385 Xact DPX385XBYDCE 3868289 3868637 1.59:1) DPX-S1

Xact DPX385XBYDCE 3868289 3868638 1.68:1) DPX-S1
DPX 415 Xact DPX415XBYDCE 3868289 3868637 1.59:1) DPX-S1

iv
EN~All sterndnve systems must be matched for either single or dual
engine instatmations. Failure to properly matchengine, transombracket and
st erndrive will result irl poor boat performance,and risk or damage
to the
engineandor drive becauseof incorrect drive gear ratio.
The model identificatien is located on the engine valve cover, and MUST
correspondwith the transombracket and sterndrive numbersas listed in this
document.
¯ Engine Model Number [~ [~ DRl14!
® Transom Bracket Model Number E~
o Sterndrive Model Number E~
DR4282
DR4944
DR2058
DR4957
v Englne/eng
NOTES
Section 1
General information
Table of Contents
Battery Cable Requirements .................................. 1 -3g

Belt Adjustments
Alternator ................................................ 1-25
Power Steering Pump...................................... 1-25
Raw=WaterPump.......................................... 1-25
Belt Tension .............................................. 1-24
CompressionPressure Limit Chart .............................. 1=7
Conversion Charts
Drill ..................................................... 1=41
Metric ................................................... 1=40
Crankcase Oil ................................................ 1-11
Engine Break-in .............................................. 1-21
Engine CompressionTesting .................................... 1-5
Gasolines Containing Alcohol .................................. 1-10
Gasoline Requirements ....................................... 1-10
intake Manifold VacuumTests ................................... 1-8
introduction ................................................. 1=2
Volvo Penta Dealer Service = 20-HourCheck...................... 1-23
Off=SeasonStorage Preparations .............................. 1 ~13
Oil Filter ................................................... 1-12
Periodic Maintenance Chart ................................... 1=43
PowerSteering Fluid Level .................................... 1-13
PowerTrim/Tilt Fluid Level .................................... 1-13
Preparation for Boating After Storage ........................... 1-20
Steering SystemLubrication .................................. 1-13
SubmergedEngine .......................................... 1=23
Symbois ................................................... 1-42
Torque Specifications, General ................................ 1-39
Troubleshooting
Engine .................................................. 1-28
SystemIsoration .......................................... 1-27
Tune-up Specifications ....................................... 1-35
Tuning the Engine ............................................ 1-5
Safety Warning
Before working on arty part of any Volvo Penta® engine, read the
section called Safety at the end of this manual.
Engine/erlg
1-1
Introduction
This service manualcovers Volvo PentaSterndrive models.It is divided into
sections concerningvarious systemsand assemblies. Refer to the Contents
to locate the section coveringthe systemor assemblyrequiring service.
Eachsection title pagehasan additional listing that will describethe
section’s contentsin moredetail. Be sure to read the Safety Section at the
end of this manual,and payspecial attention to all safety warningsas they
appearthroughoutthe text. Since modelsare subject to changeat any time,
somephotos maynot depict actual product.
GoodService Practice
Service required for Volvo PentaSterndrivesis generally one of three ki

nds:
Normalcare and maintenance - which includes putting a

newstern drive into operation, storing engines,lubrication,
and care under special operating conditions such as salt
water and cold weather.
Operating malfunctions - due to improper engine or drive

mounting,propeller condition or size, boat condition, or the
malfunctionof somepart of the engine. This includes
engine servicing proceduresto keep the engine in prime
operating condition.
Complete disassemblyand overhau| - such as major

service or rebuilding a unit.
It is importantto determinebefore disassemblyjust what the trouble is and

howto correct it quickly, with minimumexpenseto the owner.
Whenrepairing an assembly,the most reliabJe wayto ensure a goodjob is

to do a completeoverhaul on that assembly,rather than just to replace the
bad part. Wearnot readily apparent on other parts could cause malfunction
soonafter the repair job. Repairkits andseal kits contain all the parts
neededto ensure a completerepair, to eliminate guesswork,and to save
time.
Repair time can also be minimizedby the use of special tools. Volvo Penta
special tools are designedto perform service proceduresuniqueto the
product that cannotbe completedusing tools from other sources. TheyaEso
speedrepair workto help achieveservice flat rate times. [n somecases,the
use of substitute tools can damagethe part.
~Do not operate engine out of water even momentarily. If

operatedin test tank, use proper test wheel. Failure to do so can damage
supply pump,overheat engine, or allow excessive engine RPM.
1-2 Eng[ne/eng
Preparationfor Service
Properpreparationis extremelyhelpful for efficient service work. A clean
workarea at the start of each job will minimizetools and parts becoming
misplaced.Cleanan enginethat is excessivelydirty before workstarts.
CleaningwiJl occasionally uncovertrouble sources.Obtain tools, instru-
mentsand parts neededfor the job before work is started. Interrupting a job
to locate special tools or repair kits is a needlessdelay.
~Useproper lifting and handling equipment. Workingon sterndrive~==

without proper equipmentcan cause damageand personaUinjury.
Alwaysuse clean fresh fuel whentesting engines. Troublescan often be

tracedto the useof old or dirty fuel.
Service Policy
Whetherwithin or following the warranty period, Volvo Pentahas a constant

interest in their products.
It is an Volvo Pentapolicy to providedealers with service knowledge so they

can give professional service demanded by today’s consumer.Volvo Penta
.Training Centers,Service Bulletins, Letters and Promotions,Special Tools
and this Service Manualrepresent the latest VolvoPentaeffort to assist
dealers in giving consumersthe best and most promptservice possible.
This Service Manualcovers all phasesof servicing the Volvo PentaStern-
drive unit. If a service questiondoesnot appearto be answered in this
manual,you are invited to write or call the VolvoPentaService Department
for additional help. Alwaysbe sure to havecompleteinformation available,
including engine modeJnumberand serial number.
Be sure that you are ~amiliar with the Volvo PentaWarranty.If you haveany
questions, write the Volvo PentaService Department.If other than genuine
Volvo Penta replacementcomponentsor parts are used, Volvo Penta may
refuse subsequentwarranty claims involving that engine.
Whena brand-name product or specific tool is called for, another item may
be used. However,the substitute musthave equivalent characteristics,
including type, strength, and material. Youmustdetermineif incorrect
substitution could result in product malfunctionand personalinjury to
anyone. To avoid hazards, equivalent products which are used must meet all
current U.S. Coast GuardSafety Regulations and ABYCstandards.
ReplacementParts
/~ Whenreplacement parts are required, always use genuine Volvo
Pentaparts, or parts with equivalentcharacteristics, including type,
strength, andmaterial. Failure to do so mayresult in productmalfunc-
tion andpossible injury to the operator and/or passengers.
Parts Catalogs
Parts Catalogsare a goodsourceof information for ordering parts. They

are NOTa goodsource for disassemblyand reassembfyinformation of the
engines, sterndrive, or related systems.Theexplodedviews in the Parts
Catalogsare representationsand maynot reflect detatls of the actual
assembly.TheWorkshopManualhas detailed information and is the ONLY
source of disassemblyand reassebly information.
Special Service Tools
Volvo Pentahas specially designedtools to simplify someof the disas-

semblyand assemblyoperations. Thesetools are illustrated in this Service
Manual,in manycasesin actual use. All Volvo Pentaspecial tools can be
order from Volvo Penta GenuineParts. Individual purchasersof Service
Manualsmust order Special Tools through an authorized dealer.
ProductReferences,illustrations & Specifications
Volvo Pentaof the Americas,Inc. reserves the right to makechangesat

anytime, without notice, in specifications and modelsand also to discon-
tinue models.Volvo Pentaalso reserves the right to changeany specifica-
tions or parts at any time without incurring any obligation to equip sameon
modelsmanufactured prior to date of such change.All information, illustra-
tions and specifications containedin this manualare basedon the latest
productinformationavailable at the time of printing.
All photographsand illustrations usedin this manualmaynot depict actuat

modelsor equipment,but are intended as representative views for refer-
ence only. The continuing accuracy of this manualcannot be guaranteed.
//~ Safety Related

1-4 Englne/eng
’Tuning The Engine
I he purposeof an engine tune-up is to restore powerand performancethat
has beenlost through wear and deterioration of one or morecomponents.
tr~ the normaloperation of an engine, these changescan take p~aceg~’adJ-
ally at a numberof points. It is seldomadvisable to attempt improvement in
performanceby correcting one or two items only. Lasting results will be
obtained by following a definite and thorough procedureof analysis and
correcting all items affecting powerand performance.
Economical,dependableoperation can be ensuredif a completetune up is

performedonce every’ boating season,preferably at the beginningof the
seasonwhenthe boat is brought out of off seasonstorage.
Components
that affect powerand performancecan be divided into three.
groups:
Componentsaffecting compression
® Components
affecting ignition
® Components
affecting fuel system
Proceduresfor performinga completeengine tune-up will be covered in

this manual.
Engine CompressionTesting
1. CompressionCheck: Proper compressionis essential for good engine
performance. An engine with low or unevencompressioncannot be
properly tuned.
~Use extreme care around engine while running or cranking. Remove;

loose clothing and jewelry to prevent entanglementwith rotating pulleys
anddrive belts.
a. Runengine up to normal operating temperature.
I~ Engine must NOTbe started and run without water for cooling.
b. Removeany foreign matter from around spark pUugsby
blowing out with compressedair.
c. Removeand inspect all spark plugs. Install thread-type

compression gauge in spark plug hole.
d. To Prevent Sparking:
¯ All Models Except 5.7 GL, GS and 7.4 GL: Remove
(grey) 2-wire connector, with purple and grey wires,
at ignition coil.
¯ 5.7 GL and GSModels Only: Removeboth distribu-
tor primary wires from the ignition coil Tape wire
terminals to prevent accidental grounding.
¯ 7.4 GL Models Only: Remove14-wire connector at

ignition module.
e. With choke and/or throttle plates wide open, crank

engine through at least four compressionstrokes.
Test Conclusion
The indicated compression pressures are considered normal if

the lowest reading cylinder is within 75%of the highest.
Example:
ff the highest pressure reading was 140 PSI, 75%of 140 is 105.
Therefore, any cylinder reading tess than 105 PSi indicates an
improperly seated vaBve, worn valve guides, piston, cylinder, or
worn or broken piston rings. Any cylinder reading 105 PSi or
greater is within specifications, and compressionis considered
normal.
if one or more cylinders read low, squirt approximately one

tablespoonof engine oil on top of the pistons in the low reading
cylinders. Repeat compressionpressure check on the cylinders.
1. if compressionimproves considerably, the piston rings are at

fault.
2. if compressiondoesnot improve, valves are sticking or seating

poorly, or valve guides are worn.
3. If two adjacent cylinders indicate low compressionpressures

and squirting oil on the pistons does not increase the compres-
sion, the cause maybe a cylinder head gasket neak betweenthe
cylinders. This problem could allow engine oil and/or coolant to
enter the cylinders.
Safety Related 1-8 Engme/eng

It is recommendedthe following quick reference chart be used whenchecking cylinder compressionpres-
sures. Thechart has beencalculated so that the lowest reading numberis 75%of the highest reading.
CompressionPressure Limit Chart
Max Min Max Min Max Min Max Min

134 101 154 115 174 131 194 145
136 102 156 117 176 132 196 147
138 104 158 118 178 133 198 148
140 105 160 120 180 135 200 1 50
142 107 162 121 182 13G 202 151
144 108 164 123 184 138 2 04 153
146 110 166 124 186 140 206 154
148 111 168 126 188 141 208 156
150 113 t 70 127 190 142 210 157
152 114 172 129 192 144 212 158
After checking cylinder compression,repairs should be madeas necessary. Subsequentadjustments to an

engine that does not have proper compressionwill not measurablyimprove performanceor correct opera-
tional problems.After verifying compression,checkignition and fuel systemcomponents.
¯ SparkPlugs ¯ FueITankPickup and Screen

¯ SparkPlug Leads ¯ FueITankVent
¯ Distributor Cap Q Anti-SiphonValve(if equipped)
° Rotor Q Fuel OctaneandQuality
,, IgritionCoil ® Boat Fuel Lines andValves
o High TensionLeads ¯ ExternalEngineFuel Filter or Screen
¯ Igr~itionSwitch ¯ Fuel Pumpsand Lines
¯ Circuit WiringandConnectors ¯ CarburetorFuelFilter or Screen
Q Electronic ControlModule * CarburetorAdjustments
¯ Engine PCVValve
FlameArrestor
® PressureRegulatorand Injectors
All of the these components

are not necessarily part of an engine tune-
up, but must be consideredwhenattempting to correct engine/boat per-
formanceproblems. Repair or replace componentsonly as required.
L~Do not substitute automotive parts. Volvo Penta marine compo-
nents meetU.S. Coast GuardRegulationsfor external ignition proof
operation and marine use. The use of automotiveparts mayresult
irk fire andexplosion.
~,oe~ ~ Safety Related 1-7

intake ManifoldVacuum
Tests
1. Install a vacuum gaugeto a goodintake manifold source, following the gauge
manufacturer’sinstructions. Start and warmup the engine.
2. Observethe vacuumgaugewhile operation the engine over a range of engine

speeds.
3. A steady vacuumreading between18 and 22 in. Hg. (60,7- 74,3 kPa) at idle
indicates an engine in goodmechanicalcondition.
4. A vacuumreading below18 in. Hg. (60,7 kPa) at idle, indicates an enginethat is not
developing enoughvacuum.Further testing for mechanicalproblemsis required.
Test Resu|ts
1. A steady vacuumreading between17 and 21 in. Hg. (60,7 -- 74,3 kPa) at idle
indicates normal engine vacuum.
2. A vacuumreading below18 in Hg. (60,7 -- 74,3 kPa) at idle indicates an enginethat

is not developing enoughvacuum.Further testing for mechanicalproblemsis needed.
3. Possible causesof low vacuumare late ignition timing, low compression,poor engine
sealing, leaks at vacuumline connections, or a bad MAPsensor.
5. Vacuumgaugefluctuates at idle but smoothsout as the engine RPMincreases,

poorly seating valves, worncamshaft,or a sticking hydraulic lifter.
6. Vacuumgaugefluctuates morewith increases in engine RPM,check for weakor

brokenvalve springs, poorly seatedvalves, ignition miss, or a leaking headgasket.
7. Vacuum
gaugefluctuates with each engine cycle check for bad vatve.
8. Vacuum
reading drops steadily as RPM
is increased, check for exhaustrestriction.
E~ NORMAL:
Steady reading at 17-21 in. Hg.
[]LATEIGNITIONTIMING:14-17 in. Hg. at idle.
LATEVALVE
TIMING:8-15 in. Hg. at idle.
[~ INTAKELEAK: Low steady reading.
[~ NORMAL
CONDiTiON:
Drops to 2, then rises to 25 whenaccelerated rapidly.
WORN
PISTONRINGS:Drops to 0, then rises to 22 whenaccelerated rapidEy.
[~ STiCKiNGVALVES:Normally steady, intemittently ticks downward4 in. from

highest reading.
1-8 Englne/eng
LEAKING
VALVE!:Regular drop approximately2 in. from highest reading.
[~ BURNED OR WARPED VALVE:Vacuum gauge fluctuates evenly with a down-

scale pulse approximately5 in. with eachengine RPM
at idle, checkfor a burnedor
warpedvalve.
[~0"U WORN VALVE GUUDES: Vacuumgaugeoscillates approximately 4 in. Hg. Check

valve guides for excessivewear.
[~1]~]] WEAK VALVE SPRINGS:Vacuumgaugegive violent or sharp oscillations as the

RPM is increased, checkfor weakvalve springs.
r12~ IMPROPER IDLE! MmXTURE: Vacuumgaugesteadily floats between13 - 17 in.

Hg., checkand/or adjust the idle mixture.
J~3~ EXHAUST RESTRICTION: Vacuumgauge gives a normal reading on engine start

but drops to 0 as engine RPMis increased. The vacuummayeventually rise to approxi-
mately16 in. Hg. Checkfor restrictions in the exhaustsystem.
[~4~ LEAKING HEADGASKET:

Vacuumgauge floats between5 - 20 in. Hg., check for
leaking headgasket.
[] SPARKPLUGGAP TO CLOSEOR DEFECTIVEPOINTS: Vacuum gauge gives a

slight float between14 - 16 in. Hg. checkfor defective ignition points on ergines
equippedwith ignition IDoints or small spark plug gap.
DRC6688
Engme/eng 1-9
Gasoline Requirements
Volvo Penta engines are designed for maximum performance using
gasoline with the following minimum
octane specifications:
¯ Anti-knock Index Number(AKI) -
o Research Octane Number (RON) -
4.3GL, GSAND5.7GL, GSModels:The ignition timing must be retarded if

fuels are used with less than 88 AKl (90 RON)octane are used. Refer
"Timing and Fuel Requirementsin the TuneUp Section of this manualfor
details. Whenignition timing is retarded, a slight decreasein performance
can be expected.
Useof gasoline with lower than 89 AKI (93 RON)octane in 4,3GL,

GSand 5.7GL, GSmodels,without retarding ignition timing as specified,
will result in serious damage
to your engine and will void the engine
warranty.
All Other Models:Lower octane fuels, lower than 88 AKI (90 RON)
octane, can be used. With the use of lower octanefuel, a slight decreasein
power can be expected.
Every attempt should be madeto use unleadedfuel, however, some

marinasonly sell fuel with lead additives. If unmeaded
fuel is unavailable, the
substitution of leadedfuel for temporaryuse will not harmthe fuel system.
Premiumgrade fuels contain injector cleaners and other additives that
protect the fuel system and provide optimumperformance.The use of
premiumgrade fuels is strongly recommended. Do not use leaded fuel in
Certified Emissionengines. Leadedfuel will void the certification of
emissions.
CarburetedModels:Useof lead-free or leaded gasoline is acceptable.

i
Note j Engine damageresulting from the use of gasominewith octane
lower than 87 AKI (91 RON)is consideredmisuseof the engine and will
void the engine warranty. Volvo Penta suggeststhe use of 89 AKI or higher
fuels. Thesefuels have additives that are beneficial to maximumengine
performanceand long life of service components.To prevent gumformation
TM Marine Fuel Cleaner P/N
and corrosion in the fuel system, use DuraPlus
3855830-0in the gasoline. DuraPlusTM Marine Fuel Cleaner P/N 3855830-
0 is available throughyour VolvoPentadealer.
Z~ Gasoline is extremely flammable and highly explosive under

certain conditions. Alwaysstop engine and do not smokeor allow
open flames near the boat whenrefueling. Whenfueling, always
groundthe tank to the fuel sourceby holding the hosenozzle firmSy
against the side of the deckfiller plate, or groundit by someother
means.This action prevents static electricity buildup whichcould
cause sparksand ignite fuel vapors.
Gasolines Containing Alcohol

Manygasolines being sold today contain alcohol. Twocommonlyused
alcohol additives are Ethanol (ethyl alcohol) and Methanol(methyl alcohol).
Z~ Safety Related 1-10 Engme/eng

Seethe Operator’s Manualto determineif the boat’s fuel systemis compat-
ible with a}coholblendedfuels. If it is, your enginemayuse gasolines
blendedwith no more; than 10%Ethanol (ethyl alcohol) meetingthe mini-
mumoctane specification. Do not use any gasoline which contains
METHANOL (methyl alcohol).
[~ Continued use of METHANOL (methyl alcohol) fuel will cause

serious damage
to the fuel system.
If you use gasoline containing alcohol, be awareof the following:
The engine will operate leaner. This maycause engine

problemssuch as vapor lock, low speedstalling, or hard
starting.
Alcohol blendedfuels attract and hold moisture. Moisture

cancausefuel tank corrosion. Inspect fuel tanks at least
annually. Replacecorrodedor leaking fuel tanks.
® Frequently inspect non-metallic parts of fuel systemand
replaceif excessivelystiff, deterioratedor leaking.
FueOleakagecan contribute to a fire and/or explosion.
CrankcaseOil
[~ Initial factory fial is a high quality motoroil for API ServiceSG/CD.
During the break-in period (20 hours), frequently checkthe oil level. Some°
what higher oil consumption is normaluntil the piston rings are seated. The
oil level should be maintainedin the safe range betweenthe Addand Full
markson the dipstick. This range representsapproximately1 litre (1 quart).
If it is necessary to addor changethe motoroil, usea quality oil with API
service category SG/CDthat meets General Motors Standard GM60g4-M.
At the end of the break-in period (20 hours), changethe crankcaseoil and
replace the oil filter. Refer to Lubrication and Inspection Chart for
recommended oil changeintervals.
E~ The use of multi-viscosity oits, such as lOW-30 or lOW40, is

not recommended.
Draining and Filling the Engine Crankcase
Drain and refill crankcaseevery 50 hours of operation or 6 months,which-

everoccursfirst.
L~To prevent fire ,and explosion, always make sure engine compart-
ment is free of gasoline fumes before using any sparkproducingtools
such as the electric drill motor used with oil withdrawal pumpkit.
Engme/eng Z~ Safety Related 1-11

[~] "~[~ Checkthe motor oil frequently. Whenoil is to be
changed,removedipstick and drawoil from crankcasethrough dip-
stick tube with a suction pump.Thedipstick tube is intendedto be
usedfor drainageof the engineoil so it will not haveto be drained
into the bilge.
Fill the crankcaseto recommended capacity with a quality motoroil
labeled for SAEservice category SGwhich meet General Motors
Standard GM-6094-M. Oils conforming to this standard contain de-
tergent andanti-wear additives that will prolongengineJife. Volvo
Penta Dura PlusTMSynthetic Motor Off P/N 3851230-7exceedsthis
37904
standard.
Whenchangingmotor oil, select the viscosity that matchesthe tem-
perature range in which the boat will be operated. Use the samevis-
cosity whenaddingmotoroil, do not mix different viscosity oils.
LowestAnticipated SAE Viscosity

Temperature Oil Recommended
32°F(0°C)andabove SAE30
0°F(-18°C)
to 32°F(0°C) SAE20W-20
Below0°F(-18°C) SAE10W
34101
,~CAUTION: DOnot fill abovefull mark. Overfilling results in high

operatingtemperatures,foamingthe oil (mixing air in the oil), loss
power,and reducedenginelife.
Crankcase Capacities
Model LessFilter WithFilter

3.0GS 3.5qts.(3,3liters) 4.0qts.(3,8liters)
14.3GL,GS,Gi 4.0qts. (3,8liters) 4.5qts.(4,3liters) 37210
5.7GL,GSGJand GSi 5.0qts. (4,7liters) 6.0qts. (5,7liters)

7.4GL,Gi, GSi 8.0qts. (7,5liters) 9.0qts.(8,5liters)
8.2GSi 8.0qts. (7,5liters) 9.0qts. (8,5liters)
DPX300 5.0qts. (4,7liters) 6.0qts.(5,7liters)
DPX385,DPX415, 8.0qts. (7,5liters) 9.0qts.(8,5liters)
DPX500
DR2497
Oil Filter
[~ Replace the oil filter whenever the motoroil is changed.Thisfilter is a
self contained,screw-on type. Toremove,unscrew filter canister
couterclockwise, remove anddrain residualoil into a suitablecontainer.
Disposeof the oil andfilter properly.When attachinga newfiltwer, be sure
the gasketis lightly lubricatedwith freshmotoroil. handtightenonly, run
engineto checkfor leaks. Donot run enginewithoutsupplyingcooling
water. SeeTune-Up Specifications for modelandfilter requirements.
1-12 Eng~ne/eng
PowerSteering Fluid Leve
[5~] [~ Maintain the level with DuraPlusTM PowerTrim/Tilt & Steering
Fluid. Approvedpowersteering fluids suchas GMpowersteering fluid or
DexronII automatictransmission fluid canalso be used.Donot overfill the
pumpreservoir.
Steering SystemLubrication
~] Every60 days, greasethe steering ram(~) with Volvo Penta
Grease. GR980726
Power
Trirn/Tilt-Fluid Level
L’~Atthe beginning
of eachboatingseason,checkthe fluid level in the
~’eservoir
asfollows:
~Thetrim/tilt hydraulicsare pressurizedwhenthe drive unit is in
the down position.Thedrive unit mustbe tilted full up to retieve
hydraulicpressure beforeremoving level/fill plug(~. Failureto tilt the
drive unit to the full up positionbeforeremoving level/fill plugwould
result in a hazardous sprayof hydraulicoil= Cautionshouldalwaysbe
takenwhenremoving level/fill plugbyplacinga rag overthe level/fill
pmug to preventresidual pressurefromsprayingoil.
1. Withthe driveunit lilted full up, slowlyandcarefullyremove

the level/fill
plug.
2. Checkthe fluid level. Thefluid shouldbelevel with the bottomof the ’ill
holewhenthe drive unit is at full tilt. If necessary, addDuraPiusTM Power
Trim/Tilt & SteeringFluid. Replacethe level/fill plugandtighten securely.
Off-SeasonStoragePreparations
Step 1. Condition Fuel System:
AddDuraPlus TM MarineFuelStabilizer to fuel system.Followinstructions
for addingconditionerandrunningengineas statedonthe container.This

will stabilizethe fuel andpreventformationof varnishandgumin entire fuel
system.Dothis beforecontinuingwith the followingprocedures.
I~N~Modelsequi~opedwith 4 BBLcarburetors should be run under a

loadat a highenoughthrottle setting to circulate conditionerthroughthe
secondaryfloat bowl.
GR980723
En~line/eng
1-13
Step 2. ChangeMotorOil andOil Fi|ter:
Engineshouldfirst be operatedunderload until oil is

thoroughly warmedup. If oil is allowed to warmup before
draining, a morecompaetedraining will be accomplished.In
addition, accumulatedimpurities wilt be held in suspension
by the oil and be removedduring draining operation.
Removemotor oil by siphoningit out of oil withdrawaltube.

Follow the procedureunder Draining and Filling the Engine
Crankcase.
® Install a newoil filter and fill crankcasewith recommended

oil.
Notel Vertical drive must be submergedin water or an accessoryflushing

adaptor must be used while operating engine.
Whenusing a flushing adaptor, removepropeller before starting engineto

preventaccidental contact with rotating propeller.
¯ With vertical drive in full downposition, run engineat a fast

idle for a few minutesto distribute clean oil throughengine.
Shutoff engineand checkoil level. Checkoil filter gasket

for leaks. Addoil if necessary
to bring oil level up to, but not
over, the full mark.
Step 3. ChangeVertical Drive Lubricant:
TMGL-5Synthetic GearLubricant. Refer

Drain and refiJl with fresh DuraPlus
to Vertical Drive Service Manual.
Step 4. Fog Engine:
o ® - -® V =0*
o Warmup engine to ensure fuel conditioner is throughout

fuel system.UseV2pint (0,24 iitre) of Volvo PentaFogging
Oil P/N 4414651°810 oz. (355 ml) spray can to fog engine.
Remove flame arrestor from carburetor. Following in-

structions on container, bring engineup to a fast idle and
slowly spray 2/3 of the foggingoil into carburetor. Keep
enginerunning while spraying fogging oil into carburetor
throat.
Reduce throttle to idle andlet enginedie. Turnoff ignition

and replaceflame arrestor. Closefuel shutoff valve (if so
equipped).
~1 Safety Related 1-14 Engme/eng

Preparean engine"storagemixture"in an outboardsix gallonfuie tank. il
mustconsistof 5 gallonsof fuel; 4 pints (84 oz.) Fogging
Oil; and1/3 cup
TM Marine
(2.5 oz.) DuraPlus Fuel Stabilizer. Mixtheseingredientsthor-
oughly.
- Disconnectboat fuel line at the enginefuel pump.Connect

the "storagemixture"to the fuel pump fitting. Runthe enine
on the "storagemixture"for approximately 5 minutesat
t500 RPM. This will ensurethat all fuel systemandinternal
enginecomponenets are thoroughlyprotected. Shut off the
enginebeforethe "storagemixture"is usedup.
E~Donot run the engineout of fuel. Theelectric fuel pumpswill be

damaged
if allowedto run dry.
Step 5. Drain CoolingSystem:
~No~When draining the enginecooling system,raise or lower the bos of

the boatto positionthe enginein a horozonta[plane.Thiswill providefor
completedrainageof the engineblock andexhaustmanifolds,if the bowof
the boat is higheror lowerthan the stern, sore watermaybe trappedin the
engineblock or exhaustmanifolds. Improperor incompletedraining may
relult in freeze damage to the engine,manifolds, sterndrive or other
cemponenets. Freeze damage is not coveredunder the Volvo Penta
limited warranty,
Starboard
O Disconnectand drain large hoseat circulating pump.
@)Removeexhaustmanifolddrain plug. Clear hole with a small wire to

ensurecompletedraiqage.
O Remove
cylinder block drain plug. Clear hole with a small wire to
ensurecompletedrainage.
Er~gine/eng
1-15
Front
~) Disconnectthe small waterby-passhoseat the top of the thermostat

housing.
Rear
Disconnectthe waterdischargehose.Lowerto the rear of the block. Blow

out waterby applyingair to the by-passhose.
42859"a"
[~ Front
(.~ Disconnectanddrain large hoseat circulating pump.
Starboard
Removeexhaustmanifolddrain plug. Clearhole with a small wire to

@Removecylinder block petcockstem.Clear hole with a small wire to
ensurecompletedrainage. 44195
Port
® Removeexhaustmanifolddrain plug. Clear hole with a small wire to

Removecylinder blockdrain plug. Clearhole with a small wire to ensure
completedrainage.
34102
1-18 Englne/eng
[1-’] Front
O Disconnectthe small water by-passhoseat the top of the thermostat

housing.
[~ Rear
(~) Disconnectthe w~terdischargehose.Lowerthe hosebelowthe level

the engine. Blowout waterby applyingcompressed
air to the by-pass
hose. 42859b
["6-~ Front
C3>Disconnect
the large hoseat the circulation pump.
r=~ Starboard
~ Remove
the exhaustmanifold drain plug.
(~> Remove
the cylinder blockdrain plug. Clearhole with a small wire to
ensure completedrainage.
ES~ Port
C_6>Remove
the exhaustmanifolddrain plug.
~>Remove the cylinder block drain plug. Clear the drain hole with a small
wire to ensurecompletedrainage.
En~ine/eng
1-17
[~ Front
(~ Disconnectthe water bypasshose at large diameter of check valve.
® Drain or blow out valve and short hose to thermostat

housing.
= Drain or blow out Eonghoseto fuel resovoir.
[33 Front
42863
® Disconnectand drain the large hoseat the circulation pump.
[Z] Starboard
® Loosen clamp and remove rubber hose.
® Removecylinder block drain plug. Clear hole with small wire to

ensure complete drainage.
[33 Port 28283
® Loosenclamp and reove rubber hose.
® Removecylinder block drain plug. Cleanhole with a small wire to

ensure complete drainage.
28284
1 - 18 Engme/eng
L~ Remove
lowest water hosefrom cooler (A) from oil cooler to drain.
~ Remove one waler hose(B) from oil cooler, loosen mountingbolt

(C,), andtip oil coolerdownward
to drain.
Remove
lowestwaterhosefrom cooler (D) fromoil cooler to drain.
21122
E~’="~Loosenandslide hoseclampsback. Remove hosesfrom the rear of

the raw-waterpumpand drain. Crankthe engineno morethan 2 seconds
(DONOTSTART) to expel any water trapped in the raw-waterpump.
Reinstall raw-waterpumphoses.
Step6. DrainPivot Housing:
Todraincavityin pivot housing,tilt driveunit to the full tilt (up) position

andremove the waterdrain plug (E) fromthe port side of the pivot housing.
Tilt the drive unit to the full down
position.Allowunit to drain. After unit
hascompletelydrained,replacepivot housingplug. Inspect drive unit
waterintake screenfor obstructions.
Thedrain plug (E) is deletedon later modelSX-Mpivot hosings.Todrain

thesemodels,lower the sterndnveto its lowestposition.
~ Failure to completly drain the cooling systemwill result in serious

damage to the engine, exhaustmanifolds, andsterndrive whentemperature
go belowfreezing. If completedrainageis in doubt, checkdrain opening
with a smallpieceof wire.
Step 7. Inspect sterndrive water pick-upfor obstructions.
Step 8. Disconnectthe Battery andplace in storage.Whenstorage will

be for a considerable
lengthof time, periodically rechargethe battery
following the manufacturer’srecommendations.
Step 9. SprayEntire EngineandDrive Unit WithVolvoPenteDura-

TM Corrosion
PhJs Shield. Followdirections on the container.
Engine/eng
1-19
Preparationfor BoatingAfter Storage
1. Install stemsand close atl drain petcocks.Install cooling hosesand
clamps. Checkcondition of hoses, manifold end caps and clamps. Connect
hosesto engineand tighten clampssecurely, install boat drain plug, if
removed.
2. Removethe distributor cap and rotor. Wipethe inside of the distributor

cap dry with a clean cbth and spray with DuraPlus TMCorrosion Shield P/N
362002-8or equivalent. Replacethe rotor and cap.
3. Cleanthe battery terminals. With the ignition switch in the "OFF"position,

install the battery and attach the battery cables. Sprayterminals with
DuraPlusTM Corrosion Shield P/N 362002-8.
~4. Openthe fuel shut-off valve (if so equipped)and checkall fuel line
connectionsfor leaks.
~5. Checkthe flame arrestor and clean if necessary. Reinstall, make

sure all parts are in place andtighten nut securely.
6. Makea thorough checkof the boat and enginefor loose or missing nuts
and screws. Pumpthe bilge dry and air out the engine compartment.
~SafetyWarning
To prevent a possible explosion, operate the blower as

recommended by the boat manufacturer before starting
engine, if the boat is not equippedwith a bilge blower,
openengine cover or hatch prior to starting andleave
openuntiP, after engineis running.
® if operatingboat in water, tie boat securelyto dockto

prevent forward or backwardmovement.
Whenusing a flushing adaptor, removethe propeller

before starting engineto prevent accidental contact
with rotating propeller.
7. Test run engine: Launchboat or use a flushing adaptorinstalled on

vertical drive.
~] Do not start engine out of water unless using a flushing adaptor.

Atwaysturn water on before starting engine. Control water pressureas full
water pressure maycause dam~_geto supply pumpand engine.
~8. With engine compartmentopen, start the engine. Monitor the

voltmeter, oil pressureand water temperaturegaugesfrequently to be sure
all systemsare operating properly. Checkfor fuel, oil, andwaterleaks,
Safety Related 1-20 Englne/eng

EngineBreak=in
All VolvoPentaSterndrive engineshavebeenrun for a short period of time:
as a final test at the factory. Youmustfollow the EngineBreak-Inprocedure
during the first 20 hours of operation to ensure maximum performanceand
Ioiflgest enginehfe.
E~-JO-~To ensureproper lubrication during the break-in period, do not

removefactory break-in oil until after the 20-hourbreak-in is completed.
For the first five to ten minutesof operation,operateengineat a fast idle

(above 1500 RPM).After engine has reachedoperating temperature,
momentarilyreduce engine speed,then increase engine speed, .to assist
br0~ak=inof rings andbearings.
Duringthe remainingfirst two hoursof operation, accelerateto bring boat

onto plane quickly andbring throttle backto maintaina planing attitude.
During this period, vary the enginespeedfrequently by accelerating to
approximatelythree-fourths throttle for two to three minutes,then backto
n’finimumplaning speed.Maintainplaning attitude to avoid excessiveengine
load.
DO NOT RUN ENGINE! AT A CONSTANTRPM FOR PROLONGED

PERIODS OFTIME DURING THE BREAKqNPERnOD.
During next eight hours, continue to operate at approximately three-fourths

throttle or less (minimumplaning speed). Occasionally reduce throttle to idle
speedfor a cooling period. Duringthis eight hoursof operationit is permis-
sible to operateat full throttle for periodsof less than two minutes.
DO NOT RUN ENGINE: AT A CONSTANTRPM FOR PROLONGED

PERI-
ODS OF TIME DURINGTHE BREAK-IN PERIOD.
During the final ten hoursof break°in, after warmingengineto operating

temperature,it is permissibleto operateat full throttle for five to ten minutes
al a time. Momentarilyreducethen increase enginespeedto assist break-in
ot rings and bearings. Occasionallyreduceenginespeedto idle to provide
cooling periods.
Eng,ne/eqg 1-21
DO NOT RUN ENGINE AT A CONSTANTRPlVl FOR PROLONGED
PERIODSOF TIME DURINGTHE BREAK-INPERIOD.
During break-in period, be particularly observant during initial

running of engine, as follows:
1. Checkcrankcaseoil levek frequently. Maintain oil level in safe

range, between "add" and "full" marks on dipstick.
If you have a problemgetting a good oil level reading on

dipstick, rotate dipstick 180° in tube.
2. Watchoil pressure gauge. If indicator fluctuates wheneverboat

attitude (i.e. turning, climbing on plane, etc.) is changed,it may
be the oil pickup screen is not covered with oil. Checkcrankcase
dipstick, and add oil to crankcaseif required. DONOTOVERFILL.
If oil level is correct and condition still exists, checkfor possibne
gauge or oil pumpmalfunction.
Oil pressure will rise as RPMincreases, and fall as RPM

decreases. In addition, cold oil will generally showhigher oil
pressure for any specific RPMthan hot oil. Both of these condi-
tions reflect normal engine operation.
3. Watchengine temperature indicator to be sure there is proper

water circulation.
Failure to follow the break-in procedure will void the

engine warranty.
At end of break-in period (20 hours), removemotor oil and replace

oil filter. Fill crankcasewith recommended 4-cycle motor oil.
OperationAfter Break-In
After break-in, the engine can be operated at any RPMfrom idle to

full throttle. However,cruising at 3600 RPMor less saves fuel,
reduces noise, and prolongs engine life.
Whenstarting a cold engine, aBwaysallow engine to warm up

gradually. Never run engine at full throttle until engine is thor-
oughly warmedup. Be sure to check oil level frequently during
the first 50 hours of operation, since oil consumptionwill be high
until piston rings are properly seated.
1-22 Engme/eng
SubmergedEngine
Remove
engine from water as quickly as possible.
Bt is imperative that your dealer removeall water from the engineand

immediatelyrelubricate all internal parts. All electrical devicesmustalso be
dried and inspected for water damage.Delay in completing these actions
mayallow extensive engine damage.
Frequently check engine compartmentfor gasoline fumes and excessive

water accumulation;water depth in bilge should be kept well belowflywheel
housing.
Volvo Penta Dealer Service = 20-Hour Check

1. Change
engineoil and oil filter.
2. Checkfuel filter/water separator.
3 Checkpowertrim/tilt reservoir for properfluid level.
4 3.0 GSOnly: Cleanand inspect the ceramicfilter rocated under the fuel’
pump.
5. All ModelsExcept 3.0 GS: Change

fuel filter/water separator.
~/~6. Checkflame arrestor for proper mounting.
~=~W~
7, Start engineandcheckcompletefuel systemfor aeaks.
~8. Lubricate steering cable ram with Volvo Penta GreaseP/N 828250-
1. On modelsequipped with powersteering, check power steering pump
reservoir for correct fluid level. FaiRureto properly nubricatethe steering
system could lead to Hossof steering control
L’~._~ 9. Checkshift system for proper adjustmentand operation.
~. 10. Inspect exhaust system. Tighten all hose clamps, and check
for leaks.
1 ~. Checktensionon all drive belts~
12, Checkall enginemountscrewsfor tightness.
13. Checkbaseignition timing.
14. CarburetedModels:Checkand adjust carburetor for correct idle

m;,xture and idle RPM.
15, Checkfor defencies, malfunctions, signs of abuse,etc.
TM GL-
16.Checkoil level in sterndrive and add as necessarywith DuraPlus
5 Synthetic GearLubricant.
17. Checkengine can achieve maximum

rated RPM.See engine specifica-
tions.
E,~,,~,o,~ //~ Safety Related 1-23

Belt Tension
o 3.0 GS Models E~
o 4.3, 5.0, 5.7, 7.4, and 8.2 ModelsE~

e 3.0 GSNon power steering Models [~
® 4.3 PJX Models [~
(~) PowerSteering PumpBeLt

(~) AlternatorBelt
(~) Raw-waterPumpBelt
[~m,~,,[~ With engine stopped, belts should be tight enough so
that it will deflect 1/4" to 1/£, (6 - 13 mm)whenpressedwith a finger
the point indicated. Alternate method,use Volvo Pentaspecial tool
1159660=8 and tighten beets to 20 - 25 kg (44 - 55 Ibs.). If belts are
too tight, excessivebelt and bearing wearcan occur. If they are too
loose, slippage can occur, resulting in excessivebeat wear, poor cir-
culation pump, raw-water pump,and or power steering performance.
Tensionof a newbelt should be checkedafter 10 hours of service
and every 50 hours thereafter.
4
1-24 Engine/eng
Alternator Belt Adjustment
® 3.0 GS Models [~
¯ 3.0 GS NPSModels E~]
o 4.3, 5.0, 5.7 GL, GS, and Gi Models[~
® 4.3 PJX Models DE]
o 7.4, 8.2 GL, Gi and GSi ModelsE~]
10 CrankshaftPulley
(~) Circulating Pump Pulley
~ AlternatorPulley
(4~1/4" to 1/2"(6- 13ram)Deflection
(~, Raw-waterPumpPulley
[~="==~[~ Checkalternator belt tension (~) midwaybetweenthe

circulating pump
pulley (~) andthe alternator pulley
1. Loosenalternator mountingscrewsand nuts, pivot alternator awayfrom

engineto increasebelt tension. DRC43344
2. Whilemaintainingtensionon alternator belt, tighten top screw,bottom

screwandnut. Recheck belt tension.
[~ot~ Thebelts usedfor the alternator, circulating pump,and power

steering pumpare heavy-duty. DONOTreplace with automotivebelts.
Raw-WaterPumpBelt Adjustment
EJ~~ Check raw-water pump belt tension midway between the
circulating pumppulley (~ andthe raw-waterpumpputley ®.
21815
Loosenmountingbracket to raw-waterpumpscrews, pry raw-waterpump

awayfromengineto increasebelt tension. Whilemaintainingpressureon
raw-waterpump,retighten top andbottomscrews.Recheck belt tension.
©
Engirie/eng 1 - 25
®
DR4933 DRC4334,4 16067
PowerSteering Pump8eit Adjustment
® 3.0 GS Models [~
® 4.3, 5.0, 5.7, 7.4 and 8.2 Liter Models[~
(~ PowerSteering PumpPulley
(~ Circulating Pump Pulley 23910
(~ V4"to 1/£, (6 - 13ram)Deflection
~-] Improperpowersteering belt adjustmentwilt causea loss of power

steeringassist, resulting in hardsteering.
[~=~[~] Checkpower steering belt tension (~) midwaybetweenthe
circulating pumppulley (~ andthe powersteering pumppulley O.
[~ [~ To increase belt tension: Loosennut on lower pivot bolt, and 24278

loosenscrewon bracebehindpulley. Placea Y2" breakerbar into the
squarehole in the pumpmountingbracket, and pivot pumpawayfrom
engineas shown.Whilemaintainingpressureon pump,retighten all
mountingscrews. Recheckbelt tension. Neverpry against the pump
reservoiror pull ~ier neck.
[~ To increase belt tension: Loosenpumpmountingbracket

screws,insert a I/2 in. breakerbar into squarehole in the pumpmounting
bracket, and pivot pumpawayfrom engineas shown.White maintaining
pressureon pump,retighten all mountingscrews.Recheck belt tension.
Neverpry againstthe pump reservoiror pu|mfiller neck.
[~ To increase belt tension: Loosenpumpmountingbracket

screws.Witha long pry-bar, pry againstcornerof timing chain coverand
tab on pumpmountingbracket. While maintainingpressureon bracket,
tighten screwclosest to tab. Tightenthe remainingscrews.Recheckbelt
tension.
1-26 Ertgine/eng
¯ roubieshooting - System Isolation
The following is to help you isolate a maffunction of one or possibRyseveral systems. After determining
which systemsare related to the malfunction, refer to the individual systemtroubleshooting charts to
isolate the specific cause.
Engine should (:rank at specified RPM.If not, check

for:
Cranking
System 1. Discharged or dead battery
2. Loose or corroded connections
3. Cranking System Troubleshooting Chart in the
Electrical Service Manual
Must have good spark at spark plugs, ff not, check the:
Engine ignition 1. Distributor cap and rotor

Does Not System 2. Coil and spark plug leads
Run 3. ignition timing
4. Automatic spark advance
5. Appropriate ignition Troubleshooting Chart
in the ignition Service Manual
6. EFi Modelsrefer to Diagnostic
Service Manual
EFi Models: Refer to Diagnostic Service Manual
Non-EF! Models: Carburetor accelerator pumpshould

squirt fuel into venturi whenthrottle is advanced.If not,
check the:
Fuel
System 1. Fuel tank, valves, and lines
2. Fuel pumpand fiater
3. Carburetor and filter
=
Check the following:
1. Compression
2. Ignition system
3. Fuel and carburetor/injector system
Engine Runs 4. Lubrication system
Improperly 5. Cooling system
6. Vertical drive and propeller
7. Vertical drive gear ratio and installation
8. Engine Troubleshooting Guides
Engine Troubleshooting Guides
EFi EnginesOnly: Refer to EFI Diagnostic Service Manual.
These guides were written to help you trace the symptomsof the
trouble to the source, without having to read through and prove
every possibility. Muchof the information here will be familiar to
well informed mechanics.
Also, manyfactors will seeminsignificant but whenyou think of

it, usually the toughest problemto troubleshoot is causedby the
smallest error. The greatest aid to solving a service problemis
information. Start gathering information from the boat operator
and write it on his job card or workticket. Find out pertinent facts,
such as:
¯ Whendid this trouble start?

¯ Howwas the boat loaded?
¯ Did the trouble occur suddenly, or start gradually?
Analyzethis information and try to matchit to siminar situations

you have experienced in the past. Keepin mind the fundamental
rules:
1. COMPRESSION
- Mixture inducted into cylinder and com-
pressed.
2. SPARK
- Proper intensity at the proper time.
3. FUEL-Proper mixture of air and fuel.
Theseare very oUdrules, but necessaryfor the engine to run. Use

these charts and the service information they refer to. Do not try
to remembertonerances, settings, measurements,etc., as they
are written in the service manual.Leaveyour mind free to analyze
the probiem.
Following is a list of the troubleshooting guides which maybe

found on the pages indicated.
Title .......................................... Page
1. Engine Will Not Crank .......................... 1-29

2. Engine Cranks, But Will Not Start ................. 1-29
3. Hard Starting - CoDdEngine ...................... 1-30
4. Hard Starting - Hot Engine ...................... 1-30
5. Engine Runs Rough ............................ 1-31
6. Engine Noises and Vibrations .................... 1-31
7. Engine Overheats ............................. 1-32
8. Engine Dies Out ............................... 1-33
9. Engine Won’t Reach Operating RPM............... 1-33
10. Defective Engine Lubricating System .............. 1-34
11. Low Battery Voltage After Short Storage ........... 1-34
1-28
Engine Will Not Crank
¯ Battery condition: weak, dead, sulfated, bad cells

¯ Battery cables for loose or corroded connections
e Shorted or open ignition switch
e Starter motor and solenoid for shorts, grounds or open
circuits
¯ Starter assist solenoid/starter relay
¯ Circuit breakers
¯ Wiring from battery to ignition switch
¯ See Electrical/Ignition Service Manual
EngineCranks, But Will Not Start
e Primary circuit wiring from ignition switch to ignition

coil/ignition module
¯ Secondarycircuit wiring from coil to spark plug
e Spark plugs for proper gap, fouling, burned electrodes,
cracked or dirty insulator
¯ See Electrical/Ignition Service Manual
¯ Ignition circuit breaker
¯ Low battery voltage
¯ Quantity and condition of fuel in boat tank

¯ Operation and flow capacity of boat anti-siphon valve
e Fuel tank vent is unrestricted
e Fuel tank pick-up screen is clean
e Correct diameter/unrestricted boat fuel lines
e Fuel shutoff and multiple tank valves
¯ Fuel pump/relay/circuit breaker operation
¯ Fuel filter canister and carburetor filter
¯ Carburetor accelerator pump
¯ Vaporseparator~fuel reservoir (EFI)
¯ See Fuel SystemService Manual
0 "~
0_’__ ~ 0 "
¯ Conduct test following procedure in this section, and

compare readings to CompressionLimit Chart
Eng,ne/eng 1-29
Hard Starting - Cold Engine
Ask these questions first:
m e " ’ __, eo ° _--- " __
¯ Carburetor choke operation and adjustment

¯ Fuel lines for obstructions
e For debris inside fuel tank
e See Fuel System Service Manual
¯ For clean external canister and carburetor fuel filters

® Emptycarburetor float bowl due to evaporation
¯ Water in fuel due to condensation
® Fuel quality deterioration
¯ See Fuel System Service Manual
I A = oe® ¯

® Carburetor accelerator pump
¯ Fuel systemfor leaks, dirt, or obstructions
¯ Engine timing and ignition system
¯ See Electrical/Ignition and Fuel System Service Manu-
ares
Hard Starting - Hot Engine

Ask these questions first:
--I _ = A
e = D 0 _" -
_ "
e Carburetor choke operation and adjustment

A a e 0 e °
¯ Brand, type or octane of fuel

e Spark plugs
e Water in fuel
¯ Condition of battery and cables
¯ Starter motor for overheat damage
e Ignition systemprimary circuit

¯ ignition coil/ignition module
¯ Engine timing
¯ See ElectricaUIgnition and Fuel SystemService Manu-
els
1-30 Engme/eng
Engine Runs Rough
® Idle speed and idle mixture

¯ Engine timing and spark plugs
® Fuel pump pressure
® Water or contaminants in fuel
¯ Carburetor or manifold vacuumleak
¯ nnternal carburetor fuel leak
® See Fuel SystemService Manual
& e O= ° e "
® Air leak on suction side of fuel system

® Too low octane fuel
® Ignition systemsecondarycircuit
® Engine timing
® Wrongmodel or size carburetor, improper main jets or
powervalve, defective secondaryfuel circuit, secondary
vacuum diaphragm failure
¯ External canister and carburetor fuel filters
® Fuel pump pressure
® Engine compression
® Water or contaminantsin fuel, water in cylinders
¯ See General information section and Electrical/Ignition
and FuemSystemService Manuals
Engine Noises and Vibrations
¯ RappingonJy whenstarting (oil too heavy for prevailing

weather, varnish on lifter, oil needsto be changed)
¯ Untermittent rapping (Deakageat lifter checkball)
¯ Idle noise (excessive leak downrate, faulty check ball
seat)
® Generally =noisy (excessive oil in crankcase,stuck lifter
plunger)
® Loudnoise at operating temperature(scored lifter plung-
er, fast leak downrate, oil viscosity too light for prevail-
ing weather or operating temperatures)
® See appropriate Engine section
~-~,,j,o~,/eog 1-31
EngineNoises and Vibrations, Cont,
¯ Improper tuning
® Incorrect spark plug wire routing
¯ Use higher octane fuel
® See Electrical/Ognition Service ManuaB
e Supply pump
e Loosebelts, pulleys
e See Cooling System section
¯ Loose, broken or worn engine mounts

® Loose lag screws hotding mounts to stringer
¯ . ~. ¯ " e °#]
e Loosebolt(s)
Loose pulley, worn bearings

Loose mounting bolts
Failed U-joints or gimbal bearing

Damagedinternal drive components
Worn, bent or broken propeller hub or blades
e Loose, worn or damagedengine coupler
EngineOverheats- Check"
¯ Actual engine temperature by verifying with an accurate
thermometer
¯ Gaugeoperation and wiring circuit
¯ Sending unit operation and wiring circuit
¯ Supply pump, circulating pumpand belts
® Water intake screens for blockage
¯ Thermostat
¯ Water supply hoses
¯ Engine timing
¯ Water leaks on pressure side of supply pump
o Air leaks on suction side of supply pump
e Engine compression
1-32 Englne/eng
Engine Dies Out .............
, ® -0 e e - -___
¯Fuel gauge operation and wiring
¯Fuel level in tank
¯ ’Water or debris in fuel
¯ Fuel pickup tube and screen blockage
e Fuel tank vent blockage
e Pluggedexternal canister or carburetor fuel filters
¯ Air leak on suction side of fuel system
e Fuel leak on pressure side of fuel system
¯ Inoperative, restricted or incorrectly sized anti-siphon
valve
® Boat fuel lines too small in diameter
o Fuel pumppressure and suction
¯ Carburetor cleanliness and operation
¯ Primary and secondaryignition circuits

® Ignition switch
¯ Circuit breakers
¯ Wiring between engine and dash
® Main engine harness wiring
® See ElectricaN/|gnition Service Manual
¯ Vertical drive for internal damage

¯ Oil pressure gauge and crankcase oil level
¯ Temperature gauge and cooling system operation
¯ Internal engine componentsas required
Engine Won’t Reach Operating FIPNi - Check: ,,,=,,,~

e Fuel type or octane
o Propeller pitch or diameter, damagedblades, slipping
hub
o Crankcase oil volume
e Marine growth on hull and drive
e Wrongvertical drive gear ratio
¯ Operating at high altitude
® Restricted carburetor air intake
® Restricted e×haust outlets in engine, transombracket or
drive
® Poor cylinder compression
® Carburetor size and type correct for engine
® Fuel pump pressure and vacuum
® Boat overloaded, or load improperly placed
¯ Engine overheating
® Engine timiing and ignition system operation
¯ Remotecontrol cables and linkage for proper attachment
and travel
Engme/eng 1-33
Defective EngineLubricating System
¯ Cloggedor incorrect oil filter

® Worn oil pumpgears, cover or shaft
¯ Wornor collapsed oil pumprelief valve spring, or foreign
material caught on valve seat
® Oil pumprelief valve plunger loose in cover
¯ Damagedfilter bypass grommet
® Cloggedoil pickup screen, broken tube or housing
® Pluggedcrankshaft or blocked oil galneys
® Dirty or defective hydraulic lifters, clogged push rod
passages
® Poor quality, incorrect viscosity or quantity of oil
¯ Incorrect hose routing on remote filter systems
¯ Water in crankcase oil from condensation, defective head
gasket, oil cooler, or cracked manifold/block water pas-
sages
o Oil gauge/warning horn operation and wiring

o Engine temperature
o Oil pressure gauge and warning horn sender operation
and wiring
LowBattery Voltage After Short Storage
¯ All electrical accessoriesincluding ignition circuit off

¯ Disconnect main battery negative cable from battery
¯ Connect ammeteror voltmeter in series between nega-
tive battery cable and negative battery post
1. Meter reading of "0’" indicates no draw, test battery
and charging system
2. Meter movementno matter how slight indicates draw
from battery
® Disconnect main engine harness 10-Pin Connector
1. Meter drops back to "0", problem caused by boat
system, continue to isolate each boat electrical acces-
sory until problem is found
2. Meter does not drop back to "0", problem caused by
engine electrical system, continue to isolate each
engine electrical accessory until problem is found
® Repair or replace componentsas necessary
1-34 Engine/eng
Tune-upSpecifications
EngineFiring Order
3.0 liter ................................................... 1-3-4-2

4..3 alter ............................................... 1-6-5-4-3-2
5.0 and 5.7 liter ..................................... 1-8-4-3-6-5-7-2
7.4 and 8.2 liter ..................................... 1-8=4=3-6-5-7-2
Fuel PumpPressure
Carbureted Models ..................................... 5.75- 7 psi
(40- 48 kPa)
at idle RPM
Fuel Injecected Models .................. See GMEFI Diagnostic Service
Manual
CrankcaseCapacities
Model LessFilter WithFiater
3.0GS 3.5qts. (3,3liters) 4.0qts. (3,8liters)
4.3GL, GS,Gi 4.0qts. (3,8liters) 4.5qts. (4,3liters)
5.0GLand Gi 5.0qts. (4,7liters) 8.0qts. (5,7liters)
5.7GSand GSi 5.0qts.(4,7liter.,;) 8.0qts. (5,7liters)
7.4GL,Gi, GSi 8.0qts.(7,5liter.,;) 9.0 qts. (8,5liters)
8.2GSi 8.0qts. (7,5liters) 9.0 qts. (8,5liters)
DPX300 5.0qts.(4,7liter.,;) 6.0 qts. (5,7liters)
DPX385, DPX415,DPX500 8.0qts.(7,5liters.) 9.0 qts. (8,5liters)
Tune=up
Specifications
Idle* and OperatingRPM
3.0 GS
Idle ....................................... 650-750 RPM
WOT.................................... 4200-4600 RPM
4.3 GL
Idle ....................................... 550-650 RPM
WOT.................................... 4200-4600 RPM
4.3 GS
Idle ....................................... 550-650 RPM
WOT.................................... 4400-4800 RPM
4.3 Gi
Idle ............................. 600 RPM- Not Adjustable
WOT.................................... 4400-4800 RPIVI
5.0 GL
Idle ....................................... 550-650 RPM
WOT.................................... 4400-4800 RPM
5.0 Gi
WOT.................................... 4600-5000 RPM
5.7 GS
Idle ....................................... 550-650 RPM
WOT.................................... 4400-4800 RPM
5.7 GS~
WOT.................................... 4600-5000 RPM
7.4 Gi
WOT........................................ 4200-4600
7.4 GSi
WOT........................................ 4800-5200
8.2 GSi
Idte ............................. 600 RPM- Not Adjustable
WOT................................... 4600 - 5000 RPM
DPX385
WOT........................................ 4800-5200
DPX415
WOT................................... 4600 - 5000 RPM
* In Forward Gear
WOT= Wide Open Throttle
1-36 Engine/eng
Tune-up
Specifications
Oil Pressure-All IViodels
800RPM.............................. 103-207
kPa(15-30
psi)[
2000RPM............................
.276-414
I’ kea(40-60
psi)
Timing and Fuel Requirements
3.0GS ......................... 2° ATDC

- w/87AKI or higher
Volvo Penta885163=6
shunt required
4.3GL, GS .................... 6° BTDC

- w/89AKI or higher
1 o BTDC- w/87AKI
VolvoPenta885163-6shunt required
4.3Gi ........................ 8° 6TDC

- w/87AKBor higher
Service Moderequired
5.0GL ....................... 10° BTDC

- w/86 AKI or higher
5.0Gi ........................ 8° BTDC

5.7GS ........................ 8° BTDC

5.7GSi ....................... 8° BTDC

7.4 Gi ....................... 10° BTDC

7.4 GSi ...................... 10° BTDC

- w/87 AKt or higher
8.2 GSi ...................... 10° BTDC

- vv/87AKI or higher
DPX385, DPX415............. 10° BTDC

NI timingset at idle RPM
Englne/eng
1 -37
Tune-upSpecifications =
Spark Plugs
3.G GS
Spark Plug ..................... VP-3851857-7, AC-MR43LTS, CH-RS12YC

Gap ............................................. 0.045" (1,143ram)
Torque .............................................. 20ft. Ib. (27Nm)
4.3 GL, GS, Gi
Spark Plugs .................... VP-3856756-0, AC-MR43LTS, CH-RS12YC
Gap ............................................. 0.045" (1,143ram)
Torque .............................................. 20ft. lb. (27Nm)
5.0 GL
Spark Plugs ..................... VP-3851859-3, AC-MR43T,CH-RV15YC4
Gap ............................................... 0.035" (0.89ram)
Torque .............................................. 20ft. lb. (27Nm)
t5.0 Gi
Spark Plugs ................................ VP-3854399-7, CH-RS12YC
Gap ............................................. 0.045"(1,143 ram)
Torque .............................................. 20ft. lb. (27Nm)
5.7 GS
Gap ............................................... 0.035" (0.89ram)
Torque .............................................. 20ft. lb. (27Nm)
5.7GSi
Spark Plugs .................... VP-3856756-0, AC-MR43LTS, CH=RS12YC
Gap ............................................. 0.045" (1,143 mm)
Torque .............................................. 20ft. lb. (27Nm)
7.4 GL
Spark Plugs ..................... VP=3851861-9,AC-MR43T,CH-RVl5YC4
Gap ............................................. 0.045" (1,t43 mm)
Torque .............................................. 20ft. lb. (27Nm)
7.4 Gi
Spark Plugs ..................... VP-3851862-1, AC-R43TS,CH-RV15YC4
Gap ............................................. 0.045" (1,143 mm)
Torque .............................................. 20 ft. lb. (27Nm)
7.4 GSi

Gap ............................................. 0.045" (1,143 mm)
Torque .............................................. 20 ft. lb. (27Nm)
8.2 GSi
Spark Plugs ..................... VP=3851861-9,AC-MR43T,CH-RV15YC4
Gap ............................................. 0.045" (1,143 mm)
Torque .............................................. 20ft. lb. (27Nm)
VP = Volvo Penta CH= Champion
AC= ACDelco
,~CAUTIONWhenreplacing spark plugs, use only VP# 3854399-7 or

ChampionRS12YC.Failure to use the correct spark plug mayresult in engine
failure and is not coverdunder ’volvo Penta’s Limited warranty.
1-38 Englne/eng
GeneralTorqueSpecifications
T,hefollowing specificationsare for nut andscrewsizes not havingspecific torquerecommendations.
Screw Size Ft. Lb. in. Lb. Nm Screw Size Ft. Lb. In. lb. Nm
No. 6 9.7 - 14 1,1- 1,6 M-6 6-9 72-108 8-12
No=8 19.4- 24.7 2,2- 2,8 M-8 14-21 168-252 19-28
No. 10 2- 3 25 - 35 3-4 M-10 2840 336-480 38-54
No. 12 3- 4 35 - 45 4- 5 M-12 50-71 600-852 68-98
1/4-20 5- 7 60 - 80 6,8 - 9,5 M-14 80-114 960-1368 108-155
5/16-18 12 - 14 144- 168 14- 16
3/8-16 20 - 25 240 - 300 24 - 27
7/16-14 3240 384480 43 - 54
Pound-inchesx 0.11298= NewtonMeters (N*m)
Pound-feetx 1.3558== NewtonMeters(N.m)
Battery Cable Requirements

Thebattery shouldbe mounted
as closeto the engineas practical to cut downon battery cabaelengths. Followthe
recommendations below.
0-10 feet 1AWG
10-15feet 2.0 AWG
15-20 feet 4/0AWG

LNo-~Thesespecifications do not apply to aluminum
battery cabtes. Volvo Pentadoesnot recommend
the useof
aluminum
battery cables.
L/~Toprevent the possibility of fire or explosion, do not substitute automotiveparts for the foJJowingmarine
components:
o Alternator
Carburetorand related parts
Distributorandrelatedignition parts
Fuel pump
Fuelfilter canister
,, Solenoids
Spark plug leads
* Starter
Tilese componentsIlave beenspecifically designedto meetU.S. CoastGuardregulationsnot to emit fuel

vaporsor to causeignition of fuel vaporsin the bilge.
E,,~,.~/~.g ~ Safety Related 1-39

METRIC CONVERSIONCHART
inches X 25.4 = millimetres (mm) foot-pounds X 1.3558 = joules (j)

feet X 0.3048 = metres (m) calories X 4.187 = joules (j)
yards X 0.9144 = metres (m) Btu X 1055 = joules (j)
miles X 1.6093 = kilometres (km) watt-hours X 3500 = joules (j)
inches X 2.54 = centimetres (cm) kilowatt - hrs X 3.600 = megajoules (M J)
2
inches X 645.16 = millimetres 2 2)(mm mines/gal X 0.42514 = kilometres/litre (km/I)
2
inches X 6.452 = centimetres 2 2)
(cm
2
feet X 0.0929 = metres2 s)
(m N ore:
2
yards X 0.8361 = metres2 2)
(m 235.2/(mi/gal) = litres/100
acres X 0.4047 = hectares (104 s) 235.2/(litres/100 kin) = mi/gal
(ha)
2
miles X 2.590 = kilometres 2 2)
(km
footcandles X 10.76 = lumens/metre 2 2)

(Im/m
3
inches X 16387 = millimetres 3 3)
(ram
3
inches X 16.387 = centimetres3 3)(cm
3
inches X 0.01639 = litres (I)
quarts X 0.94635 = litres (I)
gallons X 3.7854 = litres (I) inches HG(60°F) X 3.377 = kilopascals (kPa)
3
feet X 28.317 = litres (I) pounds/sq in X 6.895 = kilopasca~s (kPa)
3
feet X 0.02832 = metres3 3) (m inches H20 (60°F) X 0.2488 = kilopascals (kPa)
fluid oz X 29.57 = millilitres (ml) bars X 100 = kilopascals (kPa)
3
yards X 0.7646 = metres3 (m 3) pounds/sq ft X 47.88 = pascals (Pa)
ounces (av) X 28.35 = grams (g) horsepower X 0.746 = kilowatts (kW)

pounds (av) X 0.4536 = kilograms (kg) ft-lbf/min X 0.0226 = watts (W)
tons (2000 Ib) X 907.18 = kilograms (kg)
tons (2000 Ib) X 0.90718 = metric tons (t)
°Celsius = 0.556 X (°F -32)

ounces- f (av) X 0.278 = newtons (N) °Fahrenheit = (1.8 X °C) +32
pounds- f (av) X 4.448 = newtons (N)
kilograms - f X 9.807 = newtons (N)
pound-inches X 0.11299 = newton-metres (N.m)

2
feet/sec X 0.3048 = metres/sec2 2)
(m/S pound-feet X 1.3558 = newton-metres (N.m)
2
inches/sec X 0.0254 = metres/sec2 {m/S
2)
miles/hour X 1.6093 = kilometres/hour (km/h)

feet/sec X 0.3048 = metres/sec (m/s)
kilometres/hr X 0.27778 = metres/sec (m/s)
miles/hour X 0.4470 = metres/sec (m/s)
1-40 Engine/eng
Drill Size ConversionChart
SHOWINGMILLIMETER SIZES, FRACTIONALAND
DECIMALINCH SIZES AND NUMBERDRILL SIZES
Milh- Dec. Frac- Num- Milli- Dec. Frac= Num- Mdh- Dec. Frac- Num- MILE== Dec. Frac- Num- Milli- Dec. Frac-
Meter Equiv. tional ber Meter Equiv. tional ber Meter Equiv. tional ber Meter Equiv. tional ber Meter Equw tionai
.1 .0039 1.75 .0689 .... 1570 22 6.8 .2677 10.72 .4219 2%4
.15 .0059 .... 0700 50 4.0 .1575 6.9 .2716 11.0 .4330
,2 .0079 1.8 .0709 .... 1590 2I .... 2720 I 11.11 .4375 ¾6
.25 .0098 1.85 .0728 .1610 20 7.0 .2756 11.5 .4528
.3 .0t18 .... 073O 49 4.1 .1614 .... 2770 J 11.51 .4531 2%4
.... 0135 80 1.9 .0748 4.2 .1654 7.1 .2795 11.91 .4687 1%2
.35 .0138 .... 0760 48 .... 1660 19 .... 2811 K 12.0 ,4724
.... 0415 79 1.95 .0767 4.25 .1673 7.14 2812 %2 .. 12.30 .4843 3~4
.39 .0156 1/s4 ... 1,98 .0781 %4 ... 4.3 .1693 7.2 .2835 12,5 .4921
.4 .0157 .... 0785 47 .... 1695 18 7.25 .2854 12.7 .5000 1~
.0160 78 2.0 .0787 4,37 .1719 1~4 7.3 .2874 13.0 .5118
.4; .0177 2.05 .0807 .... 1730 1"7’ .... 2900 L 13.10 .5156 3%4
.0180 77 .... 0810 46 4.4 .1732 7,4 .2913 13.49 .5312 1%2
.5’ .0197 .... 0820 45 .1770 16 .... 2950 M 13.5 .5315
.. .0200 76 2.1 .0827 4.5’ .1771 7,5 .2953 13.89 ,5469 3%4
.0210 75 2.15 .0846 .1800 15 7.54 .2968 19/64 .. 14.0 .5512
.5i .0217 .... 0860 44 4.6’ .1811 7.6 .2992 14.29 .5624 ~6
.... 0225 74 2.2 .0866 .... 1820 14 .... 3020 N 14.5 .5709
.6 .0236 2.25 .0855 4.7 .1850 13 7.7 .3031 14.68 .5781 3%4
.... 0240 73 .... 0890 43 4.75 .1870 7.75 .305I 15.0 .5906
.... 0250 72 2.3 .0905 4,76 .1875 ¾6 7.8 .3071 15.08 .5937 ~%2
.65 .0256 2.35 .0925 4.8 .1890 12 7.9 3110 15.48 .6094 3%4
.... 0260 71 .... 0935 42 .... 1910 11 7.94 .3125 ~5/16 .. 15.5 ,6102
.... 0280 70 2.38 .0937 %2 ... 4.9 .1929 8.0 .3150 15.88 .6250 %
.7 .0276 2,4 .0945 .... 1935 10 .... 3160 0 16.0 .6299
.... 0292 69 .... 0960 41 ... 1960 9 8.1 .3189 16.27 .6406 41/~
.75 .0295 2.45 .0964 5.0 .1968 8.2 .3228 16.5 .6498
.... 0310 68 .... 0980 40 .... 1990 8 .... 3230 P 16.67 .6562 21A2
.79 .0312 1~2 . . 2.5 .0984 5.1 .2008 8.25 .3248 17.0 .6893
.8 .0315 .... 0£95 39 .... 2010 7 8.3 .3268 17.06 .6719 4%4
.... 0320 67 .... 1015 38 5.16 .2031 13/e4 8.33 .3281 ~J/64 .. 17.46 .6875 u48
.... 0330 66 2.6 .1024 .... 2040 i 8.4 .3307 17.5 .6890
.85 .0335 .... 1040 37 5.2 .2047 .... 3320 Q 17.86 .7031 4~4
.... 0350 65 2.7 .1063 .... 2055 5 8.5 .3346 18.0 .7087
.9 .0354 .... 1065 36 5.25 .2067 8.6 .3386 i18.26 .7187 2¾2
.... 0360 64 2.75 .1082 5.3 .2086 .... 3390 R ;18.5 .7283
.... 0370 63 2.78 .1094 %4 ........ 2090 4 8.7 .3425 18.65 .7344 4~4
.95 .0374 .... 1100 35 5.4 .2126 8.73 .3437 W32 .. 19.0 .7480
.. .0380 62 2.8 .1102 .... 2130 3 8.75 .3445 19.05 .7500 ¾
.039o 61 .. .1110 34 5.5 .2165 8.8 .3465 19.45 .7656 49/64
1.0 .0394 .... 1130 33 5.56 .2187 7/32 .... 3480 S 19.5 .7677
.. ,0400 60 2.9 .1141 56 .2205 8.9 .3504 19.84 .7812 2~2
.0410 59 .... 1160 32 .... 2210 2 9.0 .3543 20.0 .7874
1’.05 .0413 3.0 .1181 5.7 .2244 .... 3580 T 20.24 .7969 5~4
.... 0420 58 .... 1200 31 5.75 .2263 9.1 .3583 20.5 .8071
.... 0430 57 3.1 .1220 .... 2280 1 9.13 .3594 23/64 .. 20.64 .8125 1¾6
1.1 .0433 3.18 .1250 ~ ... 5.8 .2283 9.2 .3622 21.0 .8268
1.15 .0452 3.2 .1260 5.9 .2323 9.25 .3641 21.04 .8218 s~4
.... 0465 56 3.25 .1279 .... 2340 A 9,3 .3661 21.43 3437 2%2
1.19 .0469 %4 ........ 1285 3O 5.95 .2344 15/64 .... 3680 U 21.5 .8465
1.2 .0472 3.3 .1299 6.0 .2362 9.4 .3701 21.83 ,8594 ~%4
1.25 .O492 3.4 .1338 .... 2380 B 9.5 .3740 22.0 .8661
1,3 .0512 .... 1360 29 6.1 .2401 9.53 .3750 3/8 22.23 .8750
.... 0520 55 3.5 ,1378 .... 2420 C .... 3770 ’V 22.5 .8858
1.35 ,0513 .... 1405 28 6.2 .2441 9.6 3780 22.62 ,8906 s%4
.... 0550 54 3.57 .1406 %4 ... 6.25 .2460 D 9.7 .3819 23.0 .9055
1.4 .0551 3.6 .1417 6.3 .2480 9.75 .3838 23.02 ,9062 2%2
1.45 .0570 .... 1440 27 6.35 .2500 ¼ E 9.8 .3858 23.42 ,9219 6%4
1.5 .0591 3.7 ,1457 6.4 .2520 .... 3860 W 23.5 .9252
.... 0595 53 .... 1470 26 6.5 .2559 9.9 .3839 23.81 ,9375 1~6
1.55 .0610 3.75 .1476 .... 2570 F 9.92 .3906 2~/64 .. 24.0 .9449
1.59 .0625 ½6 ... .... 1495 25 6.6 .2598 10.0 .3937 24.21 .9531 6~4
1.6 ,0629 3.8 .1496 .... 2610 G .... 3970 X 24.5 ,9646
.... 0635 52 .... 1520 24 6.7 .2638 .... 4040 Y 24.61 .9687 3½2
1.65 .0649 3.9 .1535 6,75 .2657 1%4 10.32 .4062 13/32 25.0 .9843
1.7 .0669 .... 1540 23 6.75 .2657 .... 4130 "Z 25,03 .9844 6~4
.... 067O 51 3.97 .1562 ~/32 ... .... 2660 H 10.5 4134 25,4 1,0000 1
DR2949-ENG
Engme/eng 1-41
Symbols
Certainsymbolsor combinationsof symbolsmayappearon your VolvoPentaSterndriveor on their accessories.It is
very importantthat youunderstand
the!r meaning
or purpose.If anysymbolis not clearly understood,
seeyour Dealer.
"Safety Warning" Symbols
A " Risk of serious injury ~ ~,
o,soooo
Contents Under Pressure
"Position indicator" Symbois

Shift Positions
NEUTRAL
-4’-
Raise Lower FORWARD REVERSE
"Condition" Symbols
(~ Hour Meter ® Ammeter

f o Voltmeter
Tachometer
~ Vo,tmeter
~ OH Fi,ter @ FuelFilter
Water Temperature ~ Emergency Stop ~1~(~ Oil Pressure
instructional Symbols
1-42 Engme/eng
Periodic MaintenanceChart
Items marked//~Safety Warningare safety related service points to preventmechanicalfailures, fire and explosion.
Makesure the safety related service is performed
at thesepointsandat the intervals specified.
[ServicePoint Every25 Hours

or AsSpecified Every50 Hours
or AsSpecified Recommendations
IAIternator
Belt, Check
belt for tensionand Adjustto specifications.
Replace
!PowerSteeringPump
Belt deterioration, deteriorated
belts. Keepspareon
board.
FlameArrestor Checkfor damage to grill area. Seasonallyclean and inspect. If damaged,replace with specified
Must be firmly attached. Damaged unit mayallow backfire VolvoPentaparts, tf dirty, cleanin
flame to enter engine compartment, solvent, air dry beforeinstallation.
Crankcase Checkoil level daily. Drain and refill every 50 hours or SeeSpecifications.
every 6 months, whichever occurs
first.
Engine Alignment Seasonally. Checkengine alignment.
Oil Filter Replace. SeeSpecifications.
Service Point Every 25 Hoursor As Specified Every 50 Hoursor As Specified Recommendations
Power Steering Pump Checkresovoir fluEd level. Use DuraPlus PowerTrirrVTilt &
SteeringFluid.
Steering Cable Ram Lubricate every 50 hours or every Use Volvo Penta Grease P/N
60 days, whichever comesfirst 828250-1.
Service Point Every 25 Hoursor As Specified Every 50 Hours or As Specified Recommendations
Engine Checkfor leaks. CPleckbelts for Seasonally check for hose Drain after operation in freezing
correct tension, deterioration, Checksupply pump temperatures, or during seasonal
operat=on.Repair as requ=red, lay-up. -Rghtenconnections.
Replace supply pumpevery 2
years.
TransomShietd Seasonally check for hose Drain after operation in freezJng

deterioration. temperatures, or during seasonal
lay=up.
Sterndrive Check water pickup screens for Drain after operation m free;ang
obstructions. temperatures, or during seasonal
lay- up.
Periodic MaintenanceChart - Continued
ServicePoint Every25 Hoursor As Specified Every 50 Hoursor As Specified Recommendations
ControlLinkage Checkoperation.Check
adjustment Adjustas required. UseVolvoPenta
andlubricate GreaseP/N 828250-1.
Shift System Check for smooth

shifting into and Seasonallyor every100hours, Replace
shift cableif necessary.
out of gear. checkcablefor properrouting and
operation.
r ServicePoint Every25 Hoursor AsSpecified Every50 Hoursor As Specified Recommendations
Bilge Area Checkfor gas fumesandleaks. Repairor replacedefective

components.
Hull Checkfor marinegrowth. Cleanboat bottom.
Preparationfor boating season SeePreparationfor Boating.
Safety Equipment Checkremotecontrol and shouldbe Besure U.S.C.G.required

All boat safety equipment
emergency
stopswitch, if installed, checkedfor conditionandproper equipmentaboard(check Coast
for properoperation, operation. Guardregulations).
Trailer(if applicable) Seasonallyrepackwheelbearings. UseMarine E/P wheel bearing

grease.
1-44 Engine/eng
NOTES
1-45
NOTES
1-46
Section 2
General Engine Mechanical
V6 and V8 iVlodels
Table of Contents,
AssemblingPiston and ConnectingRod...... 2=10 Cylinder

Head ................................................... 2=15
Camshaft Assembly...................................................... 2=18
Bearings....................................................... 2-13 Cleaning andInspection ............................. 24 5
Bearinginstallation ..................................... 2-14 Disassembly ................................................. 2-15
BearingRemoval ......................................... 2-13 Reaming Valve Guides ................................ 2-17
Cleaning andinspection ............................. 2-13 Repair
............................................................2=17
Measurements ............................................. 2=14 Valve
Grinding ............................................. 2-17
Cleanliness
andCrate ........................................ 2-2 ValveSeatGrinding ..................................... 2=17
Crankshaft and ConnectingRodBearings ... 2=18 EngineGaskets, Replacing ............................... 2-4
Cleaning andinspection ............................. 24 8 General
Description ........................................... 2-2
Connecting RodSideClearance ................ 2-21 PistonandConnecting Rod.............................. 2=8
Crankshaft End Play.................................... 2-21 Measuring Pistonto Pin Clearance ................. 2=9
Crankshaft Runout ...................................... 2-21 Piston Rings
Measuring BearingClearance .................... 2=19 Assembly...................................................... 2-12
Cylinder
Bores ................................................... 2-4 inspecting ..................................................... 2-12
Boring
............................................................. 2=6 installing
....................................................... 2=11
Honing
............................................................ 2-7 Piston
Selection ............................................... 240
Measuring TaperandOut-of-Round ............ 2=4 RTVSealer / AnaerobicGasketEliminator ..... 2-2
Reconditioning .............................................. 2-5 Special
Tools .................................................... 2=23
Removing Ridge ............................................ 2-5 Thread
Repair ................................................... 2=22
Z~ Safety Warnings
Beforeworkingon any part of the engine,readthe section called Safety
at the endof this manual.
Alwaysuse the correct fastener in the properlocation. When you replace
a fastener, useONLY the exactpart number for that application. Thetext
will call out thosefastenersthat requrereplacement after removal.The
text will also call out the fastenersthat requirethreadlockersor thread
sealant.
UNLESS OTHERWISE SPECIFIED,do not use supplement coatings
(paint, grease,or other corrosioninhibitors) on threadedfasteners
fastenerjoint interfaces. Generally,suchcoatingsadverselyaffect the
fastener torque andthe joint clampingforce, andmaydamage the fas-
tener.
When you install fasteners, use the correct tightening sequenceand
tighteningspecifications. Followingtheseinstructionswill help youavoid
damage to parts and systems.
Enc.lne/eng 2-1
Generai Description
The engine repair information described in this section explains
how to clean, inspect, and measurecertain engine components.
Use this section along with the proper engine repair section for
the correct disassembly and assembly procedures. Engine speci-
fications are found in the back of each engine repair section and
wild be referred to often in this section.
Cleanliness and Care

An engine is a combination of manymachined, honed, polished,
and lapped surfaces with very close tolerances. Whenevervalve
train, cylinder head, crankshaft, piston, and connecting rod com-
ponentsare removedfor service, they should be installed in their
original location.
Anytime the flame arrestor is removed, the intake opening must

be covered. This will protect against the entrance of foreign
materiaD which could follow the intake passageinto the cylinder
and cause extensive damagewhenthe engine is started.
Whenany internal engine parts are serviced, care and cleanliness

are important. Apply a liberal coating of engine oil to friction
areas during assembly to protect and lubricate the surfaces
during initial operation.
Throughout this section, it should be understood that proper

cleaning and protection of machinedsurfaces and friction areas is
part of the repair procedure. This is considered standard shop
practice evenif not specifically stated.
Use of RTVSealer and Anaerobic Gasket

Eliminator
Twotypes of sealants are commonlyused in the engines covered
by this manual. These are RTVsealer and anaerobic "gasket
eliminator" sealer.
It is important that these sealers be applied properly and in the

proper place to prevent oil leaks. THETWOTYPESOF SEALER
ARE NOT INTERCHANGEABLE. Use the sealer recommended in
the procedure.
® RTV (Room Temperature Vulcanizing) sealer is used

where a non-rigid part is assembled to a rigid part.
Commonexamples are oil pans and valve rocker arm
covers.
Anaerobic gasket eliminator hardens in the absence of

air. This sealer is used where two rigid parts (such as
castings) are assembledtogether. Whentwo rigid parts
are disassembled and no sealer or gasket is readily
noticeable, the parts were probably assembled using
gasket eliminator.
2-2 Engme,’eng
Using RTVSealer
1. Do not use RTV in areas where extreme temperatures are

expected, such as exhaust manifold or head gaskets, or where
gasket eliminator is specified.
2. Use a rubber mallet to separate componentssealed with RTV.

Bumpthe part sideways to shear the RTVsealer. Bumpingshould
be done at bends or reinforced areas to prevent distortion of
parts. RTVis weaker in shear (lateral) strength than in tensiJe
{vertical) strength.
[~ Attempting to pry or pull componentsapart may result in

damageto the part.
3. Removeall gasket material from the part using a plastic or

wood scraper. Use Loctite brand "Chisel Gasket Remover", P/N
79040, or Permatex brand "Gasket Remover", P/N 4MA, or
equivalent. Follow all safety recommendationsand directions
that are on the can. Do not use any other methodor technique to
removegasket material from a part.
[~ Do not use abrasive pads, sand paper or power tools to
clean gasket surfaces. These methods of cleaning can damage
the part. Abrasivepadsalso producea fine grit that the oil filter
cannot removefrom the oil. This grit is abrasive and has been
knownto cause internal engine damage.
4. Apply RTVto one of the clean surfaces. Use a bead size as

specified in the procedure. Runthe bead to the inside of any bolt
holes. Do not allow the seaner in any blind threaded holes, as it
may prevent the bolt from seating properly or cause damage
whenthe bolt is tightened.
5. Assemblecomponentswhile RTVis still wet (within 3 minutes).

Do not wait for RTVto skin over.
6. Torquebolts to specifications. Do not overtighten.
Using AnaerobicGasket Eliminator
1. Removeall gasket material from the part using a pJastic or

wood scraper. Use Loctite brand "Chisel Gasket Remover", P/N
79040, or Permatex brand "Gasket Remover", P/N 4MA, or
equivalent. Follow all safety recommendationsand directions
that are on the can. Do not use any other methodor technique to
removegasket material from a part.
r~ Do not use abrasive pads, sand paper or power tools to
c, lean gasket surfaces. These methods of cleaning can damage
the part. Abrasivepadsalso producea fine grit that the oil filter
cannot removefrom the oil. This grit is abrasive and has been
knownto cause internal engine damage.
Engme/eng 2-3
2. Apply a continuous bead of gasket eliminator to one flange.
Surfaces to be resealed must be cmeanand dry.
3. Spread the bead evenly with your finger to get a uniform

coating on the complete flange.
4. Assembleparts in the normal mannerand torque immediately

ecifications.
~ important: Anaerobic sealed joints that are partially
torqued and allowed to cure morethan five minutes mayresult in
incorrect shimmingof the joint. ~C6507
Replacing Engine Gaskets

Composite-type head gaskets and intake manifold gaskets
are used in the engine assembly. The head gaskets have a thin
metal core. Someengine applications use a thin metal core for
intake manifold gaskets. Use caution whenremovingor handling
gasketsto help avoid personalinjury.
Cylinder Bores
MeasuringCylinder Bore Taper and Out-of-Round
[~ Took Required: J 8087 Cylinder Bore Gauge
If one or more cylinder bores are rough, scored or worn

beyondlimits, it will be necessaryto smoothor true up
such bores to fit newpistons.
No attempt should be madeto cut downoversize pistons

to fit cylinder bores as this wiia destroy the surface
treatment and affect the weight. The smallest possible
oversize service pistons should be used and the cylinder
bores shouUdbe honed to size for proper cmearances.
1. Refer to EngineSpecifications in the proper engine repair

section for cylinder bore tolerances.
[~] 2. Depressplunger on tool 0.03 in. (0,76 ram) or until tool

enters cylinder bore.
[~ 3. Center the gaugein the cylinder and turn the dial to "0".
Safety Related 2-4 Engme/eng

~-~ 4. Carefully work the gauge up and down the cylinder to
determinetaper and turn it to different points aroundthe cylinder
wall to determine the out-of-round condition. Measurethe bore
both paralleD to and at right angles to the engine centerline.
Measureat the top, middle, and bottom of the bore and note the
readings.
5. Recondition the cylinder bore as necessary. Refer to Cylinder

-®®__l---
BoreReconditioningin this section.
Cylinder Bore Reconditioning

DRC6508
Measure:
1. Cylinder bore for out-of-round and taper.

~=~ 2. Wearat the top of the bore ~ and the bottom (~. Refer to
Engine Specifications in the proper engine repair section for
cylinder bore tolerances.
F~D Cylinder bores can be measured by setting the cylinder
gaugedial at zero in the cylinder at the point of desired measure-
ment. Lock the dial indicator at zero before removingit from the
cylinder, and measureacross the gauge contact points with an
DRC6509
outside micrometer, with the gauge at the same zero setting
when removed from the cylinder.
If cylinder bore taper or wearexceedspecification, the cylinder,,;

must be bored and honed to the smallest oversize. Refer to
Engine Specifications in the proper repair section.
Fh~evertical scratches madeby ring endswill not, by themselves,

cause excessive oil consumption; therefore, honing to remove
them is unnecessary.
If the bore is glazed but otherwise serviceable, break the glaze

lightly with a honeand replace the piston rings. Refer to Honingin
this section.
if honing is not required, the cylinder bores should be cleaned
with a hot water and detergent wash.Apply clean engine oil to the.
bore after cleaning.
Engme/eng 2=5
RemovingCylinder Bore Ridge
E! Tool Required: J 24270 Ridge Reamer

[~ important: Do NOT remove excessive material from the
cylinder bore. Excessive removal of material mayrequire cylinder
boring to the next oversize.
1. Rotate the crankshaft unti~ the piston is at BDC.
2. Place a cloth on top of the piston.

DRC6510
[~] 3. Performthe cutting operation with a J 24270ridge reamer.
Refer to the manufacturer’s instructions before using J 24270.
4. Remove
J 24270and rotate the crankshaft until the piston is at
-rDC.
5. Remove
the cloth and cuttings.
6. Repeatthis procedure for each piston.
Boring
[~ important: Refer to Engine Specifications in the proper
enginerepair section for additional information.
1. Before the honing or reboring operation is started, measureall

new pistons with the micrometer contacting at points exactly 90
degrees from the piston pin centerline. Somepistons must be
measuredat a specified distance from the piston crown. Refer to
the proper section for additional instructions. Then select the
smallest piston for the first fitting. Theslight variation usually
found betweenpistons in a set mayprovide for correction in case
the first piston is fitted too loose.
2. Before using any type of boring bar, the top of the cylinder
baock should be filed to removeany dirt or burrs. This is very
important. If not checked, the boring bar maybe tilted which
wouldresult in the rebored cylinder wall not being at right angles
to the crankshaft.
3. The instructions furnished by the manufacturer of the equip-

ment being used should be carefully followed.
4. Whenreboring cylinders, all crankshaft bearing caps mustbe in

place and tightened to the proper torque to avoid distortion of
bores in the final assembly.
2-6 Eng=neJeng
5. Whentaking the final cut with a boring bar, leave 0.001 in.
(0,025 ram) on the diameter for finish honing to give the required
position to the cylinder clearance specifications. (The honing or
boring operation must be done carefully so the specified clear-
ance betweenpistons, rings, and cylinder bores is maintained).
Honing
1. Whenhoning the, = cylinders, follow the hone manufacturer’,,;

recommendationsfor use, cleaning, and lubrication during hon-
ing. Use only clean, sharp stones of the proper grade for the;
amountof material to be removed.Dull, dirty stones cut unevenly
and generate excessive heat. Whenusing coarse or medium
grade stones, use care to leave sufficient metal so that all stone
marks maybe removedwith the fine stones used for finishing to
provide proper clearance.
2. Occasionally, during the honing operation, the cylinder bore

should be thoroughly cleaned, and the piston selected for the
individual cylinder checkedfor correct fit.
3. Whenhoning to eliminate taper in the cylinder, makefull

strokes of the hone in the cylinder. Also check measurementat
the top, middle, and bottom of the bore repeatedly.
Handle the pistons with care and do not attempt to force

them through the cylinder until the cylinder has been honed to
the correct size. The piston can be easily distorted through
careless handling.
4. Whenfinish honing a cylinder bore to fit a piston, movethe

hone up and down at a sufficient speed to obtain very fine
uniform surface finish marks in a cross-hatch pattern at the
specified angle (45 to 65 degrees).
5. The finish marks should be clean but not sharp, free from
embeddedparticles and torn or folded metal.
6. By measuring the piston to be installed at the sizing point

specified in the proper section, and adding the average of the
clearance specification, the finish hone cylinder measurement
can be determined. IL is important that both the block and piston
be measuredat normal room temperature.
7. Refer to Engine Specifications in the proper engine repair

section.
8o It is of the greatest importancethat refinished cylinder bores

are trued up to haveless than the specified out-of-round or taper.
Eachbore must be final honedto removeall stone or cutter marks
and provide a smooth surface.
Eng,ne;eng 2-7
9. After final honingand before the piston is checkedfor fit, clean
the bores with hot water and detergent. Scrubwith a stiff bristle
brush and rinse thoroughly with hot water. It is essentian that a
good cleaning operation be performed. If any of the abrasive
material is allowed to remainin the cylinder bores, it will wearthe
newrings, cyJinder bores, and bearings bubricated by the contam-
inated oil. After washing, the dry bore should be brushed clean
with a power-driven fiber brush.

section.
DRC6511
11. Permanentlymark the piston for the cylinder to which it has
beenfitted.
J 24086-C
12. Apply clean engine oil to each bore to prevent rusting.
Piston and ConnectingRod

Tools Required: J 24086-CPiston Pin Removaland Installation Set
E~ Disassemble:
[~ 1. Piston rings. In most cases the rings should be discarded

and replaced with new rings at assembly.
2. Connectingrod bearings. If the bearings are to be reused, place

them in a rack so they may be reinstalled with the original
connecting rod and cap.
3. Piston pin.
a. Place the piston/connecting rod on support fixture J

24086-C. Makesure the connecting rod is fully supported.
b. Place removerJ 24086-Con the support fixture. DRC65~5
c. Pressout the piston pin.
2-8 Engine/eng
Cleaning and Inspection
[~ C|ean: Piston
o Removeall varnish and carbon deposits. DO NOTUSEA

WIRE BRUSH.
¯ Use an approved cleaning solution to remove carbon
build-up.
¯ Removethe carbon from the ring grooves. Use a ring
groove cleaning tool.
e Oil-control ring groove holes.
EL~ Inspect:
t. Piston pin bore and connectingrod bore for scuffing and burr,,;.
2. Connecting rod for cracks, nicks, etc. If a suitable jig is

available, check the connecting rod for a bent or twisted condi-
tion.
3. Connectingrod bearings for scratches or deep pitting~
4. Piston for:
¯ Scratches, scuffing, and burrs

¯ Ring land for cracking and wear
¯ Ring grooves for burrs and nicks
® Skirts and loin bossesfor cracking
¯ Skirts for scuffing
MeasuringPiston Pin to Piston Clearance

E~
Measure:
[~] 1. Piston pin diameter. Checkagainst Engine Specifications DRC6512
in the proper engine, repair section.
2u Piston pin to piston clearance.
a. Measurethe piston pin hole diameter.
b. Subtract the piston pin diameter from the piston pin hole
diameter to obtain the clearance.
c. Replacethe pL,;ton and piston pin if the clearance exceeds i

specifications. Thepiston and piston pin are a matchedset and
not available separately. DRC6513
Engme/eng 2-9
Piston Selection
Checkthe used piston to cylinder bore clearance.
r~ Measure:
1. Cylinder bore diameter. Use a telescoping bore gauge,

located 2.56 in. (65 mm)below the top of the cylinder bore.
[~ 2. Piston diameter= Measurethe piston skirt at a right angle
to the piston pin, at the centerline of the piston pin.
DRC6507
3. Subtract the piston diameter from the cylinder bore diameter to

determine piston to bore clearance.

section to determine if piston clearance is within the acceptable
range.
If the usedpiston is not acceptable, determineif a newpiston will

fit the cylinder bore. If a newpiston doesnot bring the cJearance
within tolerances, the cylinder bore must be reconditioned. Mark
the piston to identify the cylinder for whichit wasfitted.
DRC6514
Assemblingthe Piston and ConnectingRod
J 24086-C
Tool Required: J 24086-CPiston Pin Removaland Installa-
tion Set
Assemble:
1. Piston and connecting rod.
a. The alignment mark on the top of the piston must face the
front of engine block. Connectingrod must be installed in the
correct orientation. Refer to the proper engine repair section
for piston and connecting rod installation.
b. Lubricate the piston pin holes in the piston and connecting

rod with engine oil.
DRC65!5
2-10 Engme/eng
c. Install the pin guide. Hold the piston and connecting rod
together. Be sure to use the proper pin guide. Refer to the
instructions supplied with the tool.
2. Piston pin:
a. Insert the piston pin into the piston pin hole.
~] b. Place the assembly on the support fixture.
~] c. Adjust the piston pin installer (J 24086-C)to the correct

length, using the letter-number scale on the installer adjuster.
This is necessaryto ensure the piston pin is pressed into the
piston to the correct depth. Refer to the instructions supplied
with the tool for the proper setting.
d. Lock the adjuster in place with the lock ring.

~ot~ After the installer hub bottoms on the support assembly,
do not exceed5000PSI (35,000 kPa} pressure, as this could cause
damageto the tool.
e. Place the adjuster in the supportfixture. Pressthe piston pin

into place (until the adjustable installer bottomsin the support
fixture).
f. Removethe piston and connecting rod assembly from the

tool and check the piston for freedom of movementon the
piston pin.
installing the Piston Rings

Measure:
~’~ Ring end gap as follows:

DRC6516
1. Select rings comparablein size to the piston being used.
2. Slip compressionring into the cylinder bore.
3. Use piston to square ring in cylinder wall.
~’~ Insert piston without rings upside down and guide the
compressionring into the cylinder bore until ring is downabout
1.499 in. (38,1 mm)below ring travel.
[~’~ 4. Spaceor gap betweenthe ends of the ring with a feeler

gauge.
Engme/eng 2-11
5. Refer to EngineSpecificatiens in the proper engine repair
section for correct gap.
6. if the gap betweenthe ends of the ring is not as specified,

removethe ring and try another for fit.
mnspect:
Ring fit as follows:
1. Fit each compressionring to the piston on which it is going to

be used. 10755
[~ 2. Slip the outer surface of the top and second compression

ring into the respective piston ring groove, to makesure the ring
is free. Lf binding occurs at any point, the cause should be
determined. If binding is causedby the ring groove, correct it by
dressing the groovewith a fine cut file. If the binding is causedby
a distorted ring, try a newring.
~] Assemble:
Refer to Piston Assemblyin the proper engine repair section.
ARI compressionrings are markedon the upper side of the ring.

Wheninstalling the compression rings, make sure the MARKED
SiDE IS TOWARD THE TOP OF THE PISTON.
The oil control rings are 3-piece assemblies, consisting of two

rails and an expander.
¯ Expander
¯ Lowerrail
¯ Upperrail
¯ Lower compression ring
¯ Upper compression ring
F}ex all rings to makesure they are free. If binding occurs at any
point the cause should be determined. If binding is causedby the
ring groove,correct it by dressingthe groovewith a fine cut file. If
binding is causedby a distorted ring, try a newring.
¯ Ring gaps must be 180 degrees apart

¯ Rail gaps must be 180 degrees apart
2-12 Engine/eng
L==~ Measure:
E2-~ 1. Ring clearance. Use a feeler gauge.
2 Compare with Engine Specifications in the proper engine

repair section.
CamshaftBearings
Camshaft Bearing Removal
E-~ Disassemble,: DRC6517
~3~ Tool Required: J 33049 Camshaft Bearing Removal and J33049

installation Set
1. Rear camshaft plug.
D~ 2. All camshaft bearings. Use J 33049.
a. hsert the tool with the correct collet into the camshaft
bearing you want to replace.
b. Turn the tool until the collet has tightened in the bearing. DRC6518
c. Push the center cone against the block and into the first
bearing bore to center the tool.
d. Drive the bearing from the block.
e. Repeat this procedure to remove the remaining inneF

camshaft bearings. Note that the rear bearing must be re.-
movedfrom the front of the block and the front bearing should
be removed from the rear. This allows the tool to remain
centered.
CJeaningand inspection
Clean:
¯ Camshaftbearing bores in the block.
~o~ Inspect:
® Camshaftbearingsfor scratches, pits, or loose fit in their

bores. Replace the camshaft bearings if necessary.
¯ Camshaftlobes and journals for scratches, pitting, scor-

ing, and wear. Minor irregurarities maybe cleaned up
with emery cloth.
Engme/eng 2-13
Camshaft Measurements
m Tool Required: J 7872 Dial Indicator or Equivalent
Important: Wheneverthe camshaft needs to be replaced, a

new set of valve roller lifters mustalso be installed.
Measure:
m 1. Camshaftjournal diameters using a micrometer. Compare

with EngineSpecificatiens in the proper engine repair section.
DRC651g
[~ 2. Camshaft runout. Mount the camshaft in V-blocks or
between centers. Using J 7872, check the intermediate camshaft
journal. Comparecamshaft runout specifications in the proper
engine repair section. If the camshaftis excessively bent, replace
the camshaft and camshaft bearings.
CamshaftBearing Installation
Tool Required: J 33049 Camshaft Bearing Removal and
Installation Set
The outer camshaft bearings must be installed first. Thesebear- DRC6520

ings serve as guides for the tool, and help center the inner
bearings during the installation process. 333049
Makesure to fit the correct cambearing into the bore. The cam
bearing bores mayvary in size.
[~ Assemble:
[~ 1. Rear camshaft bearings. Drive the bearings into place

using J 33049 from front of engine.
E~ Important: Make sure the camshaft bearing lubrication
DRC6518
hole (or holes) align with the oil gallery hole (or holes) in
block. On someengines, the oil holes maybe difficult to see.
Verify the holes are lined up.
2. Front camshaft bearing using tool J 33049.

[~ important: Make sure the camshaft bearing lubrication
hole (or holes) align with the oil hole (or holes) in the block.
2=14 Eqgmeleng
[-3~ 3. Inner camshaft bearings using J 33049. Reverseof remov-
a~ procedure.
4. Camshaftrear plug.
a. Coat a newcamshaft plug with GMSealer, P/N 12345493,or

equivalent.
b. Install the plug. The plug must be installed deepenoughin

camshaft bore. Refer to the proper engine repair section for
camshaftplug installation.
Cylinder Head
E~]
Disassemble:
Valves and components.Refer to the proper engine repair section.
E4~] Tools Required" J 8089 Wire Brush
Clean:
DR3123
E4~ 1. Carbon from the combustion chambers, using J 8089.
2. Valve stems and heads on a wire wheel.
3. Carbonand old gasket from the cylinder head gasket surface.

~-~ 4. Valve guides using a valve guide cleaner.
[~ inspect:
1. Cylinder head for cracks in the exhaust ports, combustion

chambers, or external cracks to the coolant chamber. Gasket
DR3124
surfaces should be free of damage.
2. Valves for burning, pitting, or warpage. Grind or replace as

needed. Refer to Valve Grinding in this section. Checkthe valve
stems for scoring or excessive wear. Stemsmust not be bent.
3. Valve rocker arm studs for wear, damage,or improper fit.
4.. Valve seats for pitting or other damage.Grind or reface as

Peeded.
5. Rotators (if used). The rotators should rotate smoothly without

binding.
Engrne/eng 2-15
[~ 6. Cylinder head for surface flatness.
[~ Measure:
~]’~[~ Tools Required: J 8001 Dial Indicator or equivalent

J 9668 Valve Spring Tester
1. VaBvestem to guide bore ckearance.
Excessive valve stem to guide bore clearance will cause

excessive oil consumption and may damagecomponents.Insuffi-
cient clearance wiII result in noisy and sticky functioning of the DRC6521
valve and interfere with engine smoothness.
a. Clampa dial indicator J 8001or equivalent on one side

of the cylinder headvalve rocker armcover gasket rail.
[~ b. Observe dial indicator movementwhile moving valve

from side to side (crosswise to the head). The dial indicator
measurementmust be taken just above the valve guide bore.
c. Drop the valve head about 0°063 in. (1,8 mm)off the valve
seat.
DR2101
d. Movethe stem of the valve from side to side using light
pressure to obtain a clearance reading. If clearance exceeds
specifications, it will be necessary to ream the valve guide
bores for oversize valves as outlined later.
2. Valve spring tension, using J 9666or equivalent.
E~ a. Compressthe valve springs to the specified height.

Check valve spring height in Engine Specifications in the
proper engine repair section. Valve springs should be replaced
if not within specification.
[~ b. Valve spring length. Replace the valve spring if valve DR3122
spring length exceedsspecifications. Refer to Engine Specifi-

cations in the proper engine repair section.
DRCb’522
2-16 Eng,ne/eng
Repair
Valve Grinding
~
E~-5~] Pitted valves must be refaced to the proper angle. Valw.
stems that show excessive wear, or valves that are warped
=
excessiveb/must be replaced. Whenan excessively warpedvalw.
head is refaced, a sharp or thin valve margin mayresult because
of the amount of metal that must be removed. Undersize valve
margins lead to breakage, burning, or preignition due to heat
localizing on this edge. Refer to Engine Specifications in the
proper engine repair section.
Several different types of equipmentare available for refacing

valves. The manufacturer’s instructions for howto use the equip-
ment should be carefully followed to achieve proper results. Refer NEWVALVE WORNVALVE
to Engine Specifications in the proper engine repair section for 2(}4 VALVETIP 207 STEM-MOSTWORN
2(}5 KEY GROOVE SECTION
vaUveface angle specifications. 2(}6 STEM=LEASTWORN 208 FACE
SECTION 209 MARGIN
Valve Seat Grinding
Reconditioning the valve seats is very important, because the

seating of the valve.,; mustbe perfect for the engineto deliver the
power and performance it was designed to produce. DRC6523
Another important factor is the cooling of the valve head. Good

contact betweeneach valve and its seat ensuresthat heat will be
carried awayproperly.
Several different types of equipmentare available for resurfacing

valve seats. Carefullly follow the recommendationsof the manu-
facturer of the equipmentbeing used to attain proper results.
Regardlessof what type of equipmentis used, it is essential that

valve guide bores be free from carbon or dirt to ensure proper
centering of the pilot in the guide. Refer to EngineSpecification.,}
DRC8524
in the proper engine repair section for valve seat angle specifica-
tions.
Reaming Valve Guides
The valve guides used in engines covered by this manual are

simply holes bored into the cylinder head. The valve guides are
not replaceable.
If the valve stem-to-bore clearance as previously measuredis

excessive, the valve guides should be reamedand a valve with an
oversize stem installed. Oversize valves are available. Refer to
Engine Specifications in the proper engine repair section.
E~ Select a reamer that will provide a straight, clean bore

through the entire length of the valve guide.
Eng~ne/eng 2-17
Assembly
Valves and components.Refer to the proper engine repair section. ®
~] Measure:
Valve spring installed height of each valve spring as follows:
[~] 1. Valve installed height using a narrowthin scale. A cutaway

scabe ~ may be helpful
[~ 2. Spring seat in the cylinder head to the top of the valve DRC6667
spring cap.
E~ 3. Certain engine applications use valve spring shims to

adjust valve spring installed height. If measurement® exceeds
the amountshownin EngineSpecifications in the proper engine
repair section, install valve spring seat shimsof sufficient thick-
ness (between the spring and cylinder head) to obtain desired
measurement.NEVER shim the spring so as to give an installed
height under the specified amount.
Crankshaftand ConnectingRodBearings
@
DRC6668
Cleaning and inspection
[~ Clean:
1. Crankshaft with solvent.
¯ Do not scratch the bearing journals

¯ Removeall sludge from the oil passages with com-
pressed air
2. Crankshaft bearings.
e Wipefree of oil with a soft cloth.

[~ inspect:
Crankshaft for cracks.

¯ Use the magnaflux methodif available.
e Crankshaft, crankshaft bearing journals, and thrust sur-

faces for scoring, nicks, or damagecaused by lack of
lubrication.
2-18 Engtne/eng
Crankshaft: bearings for scoring or other damage.Jn
general, the lower crankshaft bearings (except the #1
bearing) showthe greatest wear and distress from fa-
tigue. Uponinspection, if a lower crankshaft bearing is
suitable for reuse, it can be assumedthat the upper
crankshaft bearing is also satisfactory. If a lower crank-
shaft bearing shows evidence of wear or damage,both
the upper and lower crankshaft bearings must be re-
placed.
MeasuringBearing Clearance
DRC6525
Crankshaft bearings are of the precision insert type and do not
use shims for adjustment. If clearances are excessive, newupper
and lower bearings with be required. Service bearings are avaiF
able in standard size and undersize. Refer to Crankshaft arid
Bearing Installation in the proper engine repair section.
Selective fitting of crankshaft bearings are necessaryin produc-

tk~n to obtain close tolerances. For example, you may find
one-half of a standard crankshaft bearing with one-half of an
undersize crankshaft bearing.
To determine the correct replacement bearing size, the bearing

clearance must be measuredaccurately. Either of the following
two methods may be used, however, the micrometer method
£~ives morereliable results and is preferred.
Micrometer Method
~ 1. Measurethe crankshaft journal diameter with a microme-
ter in several places, approximately 90 degreesapart, and aver-
age the measurements.
2. Computetaper and runout. Refer to Engine Specifications in

the proper engine repair section for allowable limits.
3. Install crankshaft bearings into the crankshaft cap and engine

block.
4. Install crankshaft caps and bolts. Tighten bolts to the Torque

Specifications in the proper engine repair section.
5. Bearing inside diameter (I.D.) using an inside micrometer.
6. Comparecrankshaft bearing clearance specifications using

Engine Specifications in the proper engine repair section.
7. If bearing clearancesexceedsspecifications, install newcrank-

shaft bearings.
a. Measureinside diameter with an inside micrometer. Place

the micrometerat 90 degreesto the split line of the crankshaft
bearing.
Englne/eng 2-19
b. Subtract journal diameter from bearing inside diameter to
obtain bearing clearance. Refer to EngineSpecifications in the
proper engine repair section for bearing inside clearance.
Replaceor repair the crankshaft if clearanceexceedsspecifica-
tions.
Plastic GaugeMethod
/
[~ 1. Install all crankshaft bearings and crankshaft into block.
[~ Install the crankshaft bearing caps and torque them to

specifications. Removethe bearing caps and check the amount DRC6526
the gauging plastic has been compressed. Gauging plastic may
adhere to either the crankshaft bearing or crankshaft journal.
2. On the edge of the gauging plastic envelope there is a

graduated scale. Without removing the gauging plastic, measure
its compressedwidth (at the widest point). t
3. If the flattened gauging plastic tapers toward the middle or

ends, there is a difference in clearanceindicating taper, nowspot
or other irregularity of the bearing or journal.
4. Normally crankshaft bearing journals wear evenly and are not

DRC6527
out-of-round. However,if a bearing is being fitted to an out-of-
round 0.001 in. (0,0254 mm)maximum journal, be sure to fit
the maximum diameterof the journal. If the bearing is fitted to the
minimumdiameter and the journal is excessively out-of-round,
interference betweenthe bearing and the journaB will result in
rapid bearing failure.
5. If the bearing clearanceis within specifications, the bearing is

satisfactory, if the clearanceis not within specifications, replace
the bearing. Always replace both upper and lower bearings as a
unit.
6. A standard or undersize bearing combination mayresult in the

proper clearance. If the proper bearing clearance cannot be
achieved using standard or undersize bearings, it will be neces-
sary to replace the crankshaft.
Crankshaft bearings must not be shimmed, scraped or

filed. Do not touch the bearing surface with bare fingers. Skin oil
and acids wild etch the bearing surface.
7. Remove
the flattened gaging plastic.
8. Measureremaining journals.
2-20 Englne/eng
Crankshaft Runout
Tools Required: J 7872 Magnetic Base Dial Indicator
MeasureCrankshaft:
E3~] 1. Mountthe crankshaft in V-blocks at crankshaft journals 1
and 5.
2. Position a dial indicator pointer on the center mainbearing

and rotate crankshaft.
DRC6528
3, Refer to Engine, Specifications in the proper engine repair

section for crankshaft runout specifications,
C, onnectingRodSide Clearance
~-~ Measure:
E’$-’=] Connectingrod side clearance. Refer to Engine Specifica-

tions in the proper engine repair section for clearances
Crankshaft End Play

DRC652
L~
Measure:
Crankshaft end play, as follows:
I. Firmly thrust the end of the crankshaft first rearward then

forward. This will line up the rear crankshaft bearing and crank-
shaft thrust surfaces.
ES~2. With crankshaft wedgedforward, measureat the front end
of the crankshaft bearing(thrust side) with a feeter gauge.Refer
Engine Specifications in the proper engine repair section for
crankshaft end play clearance. DRC6530
3 If correct end play cannot be obtained, be certain that the

correct size crankshaft bearing has been installed. Someproduc-
tion engines mayuse crankshaft bearings that are wider across
the thrust faces than standard size bearings. Refer to Engine
Specifications in the proper engine repair section for available
bearing sizes.
Engme/eng 2-21
[~ Inspect:
Crankshaftfor binding. Turn crankshaft to checkfor binding. If the

crankshaft does not turn freely, loosen the crankshaft bearing
bolts, onepair at a time, until the tight bearingis located. Burrs on
the bearing cap, foreign matter between the bearing and the
block or the bearing cap, or a faulty bearing could causea lack of
clearance at the bearing.
Thread Repair
Damaged threads may be reconditioned by drilling out, DRC6572
rethreading, and installing a suitable thread insert.
Z~ Wearsafety gUassesto avoid eye damage.
1. Determinesize, pitch, and depth of damaged thread. If neces-

, adjust stop collars on cutting too[ and tap to required depth.
~ Important: Refer to the kit manufacturer’s instructions
regarding the size of drill and tap to be used.
IT] 2. Drill out damagedthread. Clean out chips.
DRC6573
[~] 3. Lubricate tap with light engine oil. Tap hole. Clean the
thread.
[-~ Important: Avoid buildup of chips. Sack out the tap every
few turns and removechips.
4. Threadthe thread insert onto the mandrelof the instalBer.

Engagethe tang of the insert onto the end of the mandrel.
[~ 5. Lubricate the insert with light engine oil (except when

installing in aluminum)and install.
~’~ Important: Whencorrectly installed, the insert should be DRC6574
flush to one turn below the surface.
6. If the tang of the insert doesnot break off whenbackingout the

installer, breakthe tang off with a drift.
DRC6575
2-22 Engme/eng
J 8087 1
J 24086-C
DRC6576 DRC6579 DRC6577
Special Tools
E~ Cylinder Bore Gauge
E~ Piston Pin Replacer Set

J 8089
E~==1 CamshaftBearing Remover
/ Installer
DRC6580
E~ Wire Brush
[==9~Dial indicator
~ Valve Spring Tester
[~ Ridge
Reamer
DRC6578
DRC6581
J 24270
DRC6582
2-23
NOTES
2-24 Eng,ne/eng
Section 3
3.0 GSEngines
Table of Contents
Camshaft .......................... 3-14 General Motors Tools ................. 3-2

Camshaft Bearings .................. 3-16 High-Rise Exhaust Elbow RepJacernent... 3-37
Circulating Pump.................... 3-32 Hydraulic Valve Lifter ................. 3-4
Connecting Rod Bearings ............. 3-19 Intake~Exhaust Manifold .............. 3-3
Crankshaft ......................... 3-18 OU Fi0ter Bypass Valve ................ 3-35
Crankshaft Bearings ................. 3-20 Oil Pan Replacement ................. 3-32
Cylinder Block ...................... 3-27 Oil Pump .......................... 3-33
Cylinder Head Assembly .............. 3-6 Oil Seal Replacement, Rear Main Bearing 3-23
Distributor Lower Bearing ............. 3-31 Oil Seal Retainer Replacement ......... 3-23
Engine Coupler Replacement ........... 3=40 Piston Rings ........................ 3-25
Engine Specifications ................. 3-42 Piston a~d Connecting Rod ............ 3-23
Exhaust (Flapperl Valve Replacement.... 3-39 Timing Gear Cover ................... 3-12
Exhaust Hose Replacement ............ 3-38 Torque Specifications ................. 3-45
Front Engine MmJnt .................. 3-35 Valve Lash Adjustment ............... 3-5
Height Adjustment ................. 3-37 Valve Spring and Seal Repair ........... 3-5
Before removing cooling system hoses, it may be neces=

sary to removeboat from water to prevent flooding boat.
Safety Warnings
Before working or= any part of the engine, read the section called
Safety at the end of this manual.
Unless instructed otherwise, always disconnect the battery

cables from the battery before working on electrical system to
prevent possible sparks or arcing in the engine compartment.
Before starting engine after repair or maintenanceprocedures,

always makesure engine compartmentis free of fuel vapors to
prevent possible fire and explosion.
Whenworking on an engine that is running or being cranked, use

extreme care to avoid getting hands, fingers or clothing caught
in the a0ternator, power steering, supply pumpand circulating
pumpbelts, pulleys and other moving parts.
Engme/eng 3-1
Genera/Motors Tools
Part
Number
Air Line Adaptor ........................................... J-23590

Bolt Guide Set ........................................... J-6305-01
CamLobe Lift Indicator ....................................... J-8520
Camshaft Bearing Removerand Installer ...................... J-6098-01
Carbon Remover Brush ...................................... J-8089
Crankshaft Gear Installer ..................................... J-5590
Cylinder Bore Checker ....................................... J-8087
Distributor Bearing Installer ................................... J-9535
Distributor Bearing Remover................................ J-9534-01
Piston Pin Tool ............................................. J-24086
Piston Ring Tool ............................................ J-8037
Rear Crankshaft Seal Installer ................................ J-35621
Rocker Arm Stud Hole Reamer(0.003 Oversize) .................. J-5715
Rocker Arm Stud Hole Reamer(0.013 Oversize) .................. J-6036
Rocker Arm Stud Installer ..................................... J-6880
Rocker Arm Stud Remover ................................. J-5802-01
Timing Cover Tool .......................................... J-23042
Valve Guide Cleaner ......................................... J-8101
Valve Guide ReamerSet ................................... J-5830-02
Valve Seal Tester ........................................... J-23994
Valve Spring Compressor ..................................... J-5892
Valve Spring Tester .......................................... J-8056
Vibration Damperand Crankshaft Gear Remover................ J-6978-E
Order Directly from:
Kent-MooreTool Division
28635 Mound Road
Warren, M148092800-345-2233
Price and ordering information are available from Kent-Moore

Tool Division.
Material Required
Molykote Lubricant
Volvo Penta Gasket Sealing CompoundP/N 1161231-4
Permatex~ No. 2
GMSuperEngine Oil Supplement
PlastigageTM(G teen)
DuraPlusTM SAE30 HeavyDuty Synthetic Motor Oil
For additional service information not coveredin this manual,obtain the

appropriate ChevroletEngineService Manualfrom:
HelmInc.
P.O.Box 07130
Detroit, M148207
3-2 Eng[neleng
Intake/E×haust Manifold
Removal
1. Disconnect battery cables at battery. Removethrottle

cable from anchor block and actuating bracket.
2. Drain water from block and exhaust manifold (see Cooling

SystemSection in this manual).
3. Removecarburetor from intake manifold. FolBowthe instruc-.

tions in Fuel SystemsService Manual.
EI~ 4. Disconnect water hose (~ running between manifold end

cap and thermostat housing.
E2~ 5. Removealternator and mounting bracket ®.
E3~] 6. Loosen upper hose clamps © securing exhaust hose to

high rise elbow. Loosen and remove screws and lock washers @
securing elbow to manifold and removethe throttle linkage plate
and elbow.
7. Removefour bolts, two nuts and lock washers securing 45375

manifold to cylinder head, then pull manifold off of head. Discard
gasket.
8. Clean all gasket surfaces of cylinder head and manifold and

check for cracks on the manifold casting.
Installation
1. Position a newgasket over the manifold studs on the head. Use

a gasket sealer if leakage has occurred. Carefully install the
manifold in posith)n making sure that the gasket is correct,ly
placed. 34727
2. Install nuts, bolts and washerswhile holding the manifold iin

place. Tighten borers and nuts finger tight, then alternately tighten
to 20-25 ft. Ibs. (27-34 N.m) working from the center towards the
ends.
3. Apply gasket sealer to a newelbow gasket and place it on the

manifold. Pushthe eJbowinto the exhaust hose, then install the
elbow, throttle linkage plate, lock washers, and screws. Tighten
tlhe screwsto 12-14 ft. Ibs. (16-19 N.m).
[~ 4. Install carburetor using a new mounting gasket following

the instructions in Fuel SystemsService Manual. Install water
hose from thermostat housing to manifold ~.
[~ 5. Install aPternator with mounting bracket ~. Tighten
screws ® to 26-30 ft. Ibs= (35-41 N.m).. Reset belt tension
following the procedures found in the General mnformationsec-
tion of this manual. Tighten the alternator screws© to 26-30 ft.
Ibs. (35-41 N.m).
6. Reconnect throttle cable to anchor block and actuating

bracket. Securewith cotter pin.
Z~ 7. Connectbattery cables. Start engine and check for fuel

leaks.
45376
HydraulicValve Lifter
RemovaU
1. With air hose and cloths, clean dirt from cylinder head and
adjacent parts to avoid getting dirt into engine, it is extremely
important that no dirt gets into the valve Bifters.
2. Disconnect ventilation hose, fuel line, and fuel pumpoverflow

hose. Removecircuit breaker bracket. Removerocker arm cover.
3. Loosenrocker arm nuts and pivot the rocker arms free of the
push rods.
4. Disconnect spark plug wires at plugs. Remove

high tension lead
from coil. Removeboth connectors from coil. Removecoil and
mounting bracket from cylinder head.
[~ 5. Removeboth connectors at distributor. Take off cap, note
ROTATING
- NORMAL,
OK- NOTROTATING
distributor rotor position and removedistributor. (Mark distribu-
tor housing and block with chaUkat point of rotor.)
6. Fromrear of block, take out screwsthat mountthe shift bracket

assembly and move bracket away from push rod cover.
7. Removepush rod cover and gasket.
8. Remove pushrods and lift out vaBvelifters that require service.

Place lifters in a woodenblock having numberedholes, or use GALLED
- SHOULD
8E REPLACED
- SOFT,WORN
other suitable meansof identifying them according to original

position in the engine.
9. If less than a completeset of lifters is being removed,immedi-

ately disassembleand inspect one or two for presence of dirt or
varnish. If lifters contain dirt or varnish, it is advisableto replace
all lifters. Otherwise,it will be satisfactory to service only those 860000
lifters that are not operating properly.
[~ 10. Examinethe cam contact surface at lower end of lifter

body. If this surface is excessively worn, galled or otherwise
damaged,discard the lifter assembly. In this case, also examine
the mating camshaft lobe for excessive wear or damage.
SafetyRelated 3-4 Englne/eng

I:nstallation
["~ Before installing any new lifters, coat the bottom of each
lifter with Molykoteor its equivalent.
1. Rnstall valve lifters in cylinder block, if anynewlifters or a new

camshaft has been installed, an additive containing EPlubricant
such as GMEngine Oil Supp/ement must be added to the
crankcaseoil for break-in.
2. Install pushrods onto lifters and install pushrod cover with a

new gasket.
3. Install distributor {position rotor to markon housingandblock).

install coil and bracket. Connectboth connectorsto coil. Install
distributor cap and attach spark plug and coil wires. Connectbol:h
connectorsto distributor.
4. Install shift bracket assembly.
5. Pivot rocker arms in place and turn adjusting nuts the amount
necessaryto elimh~ate lash.
Valve Lash Adjustment

Adjust valve lash whenlifter is on basecircle of camas follow,J:
1+ Remove distributor cap and crank engine until distributor rotor

points to numberone cyninder terminal. In this position the piston
in numberone cylinder is at top center on compressionstroke.
Both lifters are on base circle of cam and both valves can be
adjusted.
E3~] 2. Turn adjusting nut until all lash is removedfrom valve

train. This can be determined by checking push rod side play by
hand while turning nut slowly. At this point, turn adjusting nut
one moreturn to place the lifter plunger in center of its travel.
3. Follow steps 1 and 2 for each cylinder following firing order

sequenceand adjust remaining valve one cylinder at a time. No
further adjustment is necessary.
ENo-~Do not attempt to turn the adjusting nut one full turn while
the engine is operating. Adjustmentin this mannerwill not allow
the lifters to bleed down.This wouldresult in valve train damage,
probably bent push rods. For those whoprefer to adjust the valve
lash while the engine is running, the preferred methodwould be
to find the "zero lash" point as described aboveand then slowly
1urn the adjusting nut V+ turn. Wait for the lifter to bleed down
(several engine revolutions) and again turn adjusting nut V+ turn.
Continuethis adjust-and-wait cycle until nut is one completeturn
down from "zero lash" point. Repeat sequence on remaining
V;3[ves.
En ~,ne/eng 3-5
4. Install rocker cover gasket and cover. Connectfuel line and fuel
pumpoverflow hose to carburetor.
5. Install circuit breaker bracket. Connectcrankcaseventilation

hose.
Z~ 6. Start engineand checkfor oil or fuel leaks and Jisten for

lifter noise. Checkenginetiming.
Valve Spring and Seal Repair

Refer to 5.7 GL, GSand Gi EngineSection for procedure.
Cylinder Head Assembly
The condition of the cylinder head and va6ve mechanismsignifi-

cantly determines the power, performance and economyof the
valve-in-head engine. Extreme care should be exercised when
conditioning the cylinder head and valves. Maintain correct valve
stem to guide clearance, correctly grind valves and valve seats,
and properly adjust valves.
Removal
1. Removeintake and exhaust manifold as described under

heading Intake/E×haust Manifold.
2. Disconnect coolant hoses at thermostat housing. Disconnect

spark plug wires and removespark plugs.
3. Disconnect fueN line retaining clips at thermostat housing and

cylinder head. Disconnect wire harness from the temperature
sending unit, leaving harness clear of clips on rocker arm cover.
Removethermostat housing assembly from front of cylinder
head. Disconnect fuel line at the fuel pumpand remove.
4. Removethe rocker arm cover. Next, back off the rocker arm
nuts and pivot the rocker arms to clear the push rods. Remove
the
push rods. 860002
5. Remove
the ignition coil and bracket.
6. Removethe cylinder head bolts, cyRinder head, and gasket.

Place the cylinder head on two blocks of woodto prevent damage
to the head.
Disassembly
E~ 1. Removerocker arms nuts, ball seats and rocker arms. Use

tool J-8062, compressthe valve springs and removevalve stem
keys. Release the spring compressor tool and remove exhaust
valve rotator or intake valve cap, shield, spring and seals.
SafetyRelated 3-6 Engme/eng

2. Removevalves from bottom of cylinder head and place them in
a rack in their proper sequenceso they can be assembledin their
original positions.
"....
Cleaning
[i~ 1. Clean aH carbon from combustion chambers and varv’e

ports using tool J-8089. inspect the cylinder headfor cracks in the
exhaust ports, combustion chambers, or external cracks to the
water chamber. Clean carbon deposits from head gasket mating
surfaces.
[-3~ 2. Thoroughly clean the valve guides using tool J-810’1.
N 860003
Clean all carbon and sludge from push rods and rocker arms.
:3. Clean valve stems and heads on a buffing wheel. Inspect the
valve for burned head, worn seat, cracked faces, or damaged
stems.
4. Washall parts in cleaning solvent and dry them thoroughly.

Checkfit of valve stemsin their respective bores.
5. Measurevalve stem clearance as follows: Clampa dial

indicator on one side of the cylinder headrocker armcover gasket
rail, locating the indicator so that movementof the valve stem
from side to side (crosswise to the head} will cause a direct
movementof the indicator stem. The indicator stem must contact
the side of the valve stem just above the valve guide. With the
valve headdroppedabout 1/10 in. offthe valve seat; movethe stem
of the valve from side to side using light pressure to obtain a
clearance reading. If clearance exceedsspecifications it will be 860004
necessaryto reamvalve guides for oversize valves as outlined.
Excessive valve stem to bore clearance will cause lack of

power, oil consumption, rough idling and noisy valves, and may
cause valve breakage. Insufficient clearance will result in noisy
and sticky functioning of the valves and disturb engine smooth-
ness of operation. Intake and exhaust valve stem to bore clear-
ance should be 0.001-0.0027 in. (0,025-0,007 ram). By using
micrometer and a suitable hole gauge, check the diameter of the
valve stem in three, places; top, center and bottom. Unsert hole
gauge in valve guide bore, measuring at the center. Subtract
highest reading of valve stem diameter from valve guide bore
center diameter to obtain valve to valve guide clearance. If
clearance is not within limits use next oversize valve and ream
bore to fit using suitable reamer.
[]~ 6. Checkvalve spring tension with tool J-8056 spring tester.

86OOO5
[~tet~ Onall models, springs should be compressed
to 12V32in. at \
which height it should check 78-86 pounds(35,5-39,0 kg). Weak
springs affect power and economyand should be replaced if
below 70 pounds. (31,8 kg)
86(}O06
En§jme/eng 3-7
7. Checkvalve Jifters for free fit in block. Theendthat contactsthe
camshaft should be smooth. If this surface is worn or rough, the
lifter should be replaced. If lifter is damaged,check the corre-
sponding camshaft lobe for damage.
Repair
[~ 1. Valve Guide Bore:
Valves with oversize stems are available for inlet and exhaust
valves in the following sizes: 0.0003 in., 0.015 in., and 0.030 in.
Use the 11/32 in. diameter reamer sizes from reamer tool set
J-5830-02 which are: J-4822 standard; J-5830-1,0.003in oversize,
J-5830-2, 0.015 in. oversize and J-5830-3, 0.030 in. oversize to
ream the bores for the new valves.
2. Rocker Arm Studs f l

Rocker arm studs that have damagedthreads may be replaced
with standard studs. If the studs are loose in the head, oversize
studs (available in .003 in. or .013 in. oversize) maybe installed
after reaming the holes as follows: 860007
Do not attempt to install oversize stud without reaming

stud hole.
Removeold stud by placing tool J-5802-01 over the stud.

InstaUb nut and flat washer, and removestud by turning
nut.
b. Reamhole for oversize stud. Use tool J-5715 for 0.003 in.
oversize and tool J-6036 for 0.013 in. oversize.
E~ C. Coat press-fit area of stud with a hypoid axle Jubr[cant.
Install newstud using tool J-6880. Tool should bottom
on head.
3. Valve Seats:

seating of the valve must be perfect for the engine to deliver the
powerand performancebuilt into it.
Another important factor is the cooling of the valve heads. Good

contact betweeneach valve and its seat in the head is imperative 86OOO8
to ensure that the heat in the valve headwill be properly carried
away.
Several different types of equipmentare available for reseating

valve seats; the recommendations of the manufacturer of the
equipment being used should be carefully followed to attain
proper results.
860009
3-8 Engme/eng
Regardless of what type of equipment is used, however, it is
essential that valve guides be free from carbon or dirt to ensure
proper centering of pilot in the guide.
a. lnstall expanding pilot in the valve guide bore and

expandpilot by tightening nut on top of pilot.
bo Place roughing stone or forming stone over pilot and just
clean up the valve seat. Usea 46° stone for both the inlet
and exhaust valve seats.
Removeroughing stone or forming stone from pilot, 860010

install finishing stone on pilot and cut just enoughmetal
from the seat to provide a smoothfinish.
d. Narrowdownthe valve seats to the proper width for the

intake and exhaust. See Engine Specifications.
°This operation is doneby grinding the port side with a 30
stone to lower seat: and a 60° stone to raise seat.
e. Removeexpanding pilot and clean cylinder head care-

fully to remove all chips and grindings from above
operations.
Eh~ ~ Valve seats should be concentric to within 0.002 in.

total indicator reading.
4. Valves:
Valves that are pitted can be refaced to the proper angle, ensuring
correct relation between the head and stem on a valve refacing
machine. Valve sterns which showexcessive wear, or valves that
are warped excessively should be replaced. Whena valve head 8600~1
which is warped excessively is refaced, a knife edge will be
groundon part or a[ll of the valve headdue to the amountof metal
that must be removedto completely reface. Knife edges lead to
breakage, burning or pre-ignition due to heat localizing on this
k~[fe edge. If the edgeof the valve headis less than 1/32 in. thick
after grinding, replace the valve.
a. If necessary, dress the valve refacing machinegrinding

°wheelto makesure it is smoothand true. Set chuck at45
mark for grinding valves.
b. Clampthe valve stem in the chuck of the machine.
c. Start the grinder and movethe valve head out in line

with the grinder wheelby movingthe lever to the left.
d. Turn the feed screw until the valve head just contacts
wheel. Movevalve back and forth across the wheel and
regulate the feed screw to provide light valve contact.
Er,~;me/eng 3=9
e. Continuegrinding until the valve face is true and smooth
all around valve. If this makesthe valve thin the valve
must be replaced as the valve will overheat and burn. ®
f. Removevalve from chuck and place stem in "V" block.
Feedvalve squarely against grinding wheel to grind any
pit from rocker arm end of stem.
Only the extreme end of the valve stem is hardened to

resist wear. Do not grind end of stem excessively.
g. After cleaning valve face and cyDinder head valve seat of 860012
grinding particles, makepencil marksabout 1/4 in. apart
across the valve face, place the valve in cylinder head
and give the valve one-half turn in each direction while
exerting firm pressure on face of valve.
Remove valve and checkface carefully. If all pencil marks

have not been removedat the point of contact with the
valve seat, it will be necessary to repeat the refacing
operation and again recheck for proper seating.
i. Grind and check remaining valves in the samemanner.

860013
Assembly
[~ 1. Starting with number one cylinder, place the exhaust
valve in the port, and place the valve spring (~) and cap ®
position. Place spring and cap on exhaust valves. Then, using tool
J-8062, compressthe spring and install the oil seal @and valve
keys @.Seethat the seal is flat and not twisted in the valve stem
groove and that the keys seat properly in the valve stem groove.
Place valve springs in position with the closed coil end

toward the cylinder head.
2. Assemblethe remaining valve, valve springs, spring caps, oil 860014
seals and valve keys in the cylinder headusing tool J-8062. Check
seals by placing a vacuumcup over valve stem and cap, squeeze
vacuumcup to makesure no oil leaks past oil seal.
[~ 3. Check the installed height of the valve springs using a

narrow, thin scale to measurefrom the top of the shim or spring
seat in the head, to the top of the valve spring shield. If this is
found in excess of 12s/s2 in., install a valve spring seat shim,
approximately 1/16 in. thick. At no time should the spring be
shimmed to give an installed height of less than 121/32 inch.
If springs are to be changedwith cylinder head installed, 860015
refer to Valve Spring and Seal Repair, in 5.7 GL, GSand Gi Engine
Section.
3-10 Engme/eng
REAR
I. Thegasket surface,,; of both the headand the block mustbe clean and
free of any foreign matter, andfree of nicks or heavyscratches.
2. Cylinder headbolt threads in the block mustbe cleanedas well as the

threadson the cylinder headbolts. Dirt will affect bolt torque.
E3--’] 3. Placea newcylinder headgasketin position over the dowelpins in

the cylinder block. Onengineswith a steel gasket coat both sides of a new
gasket with a thin, even coat of Volvo Penta Gasket Sealing Compound P/N
1161231-4.Too muchseater will hold the beadsof the gasket awayfrom the
block or head.
[_No~~The 3.0 Litre engine has a specia, marine head gasket. Do not
substitute an automotiveheadgasket.
E~ 4. Carefully guide cylinder headinto place over dowel pins and gasket.
Coat threads of cylinder headbolts with PermatexNo. 2 P/N 910032.Install
the bolts and run themdownto the block.
ES-~5. Tighten the cylinder headbolts, with a torque wrench,in three

progressive steps following the sequenceshown.
¯ Step 1 -35ft. Ibs. (47 N m)
® Step 2 - 65 ft. Ibs. (88 N.m)
® Step3 - 95 ft. Ibs. (129N.m)
6. Install valve push rods downthrough openingsin the cylinder headand

seat themin lifter sockets.
E~7. Install rocker arms, balls and nuts and tighten rocker arm nuts until
all pushrod play is taken up.
8. Install thermostathousingusing a newgasket. Attach coolant hoses.

FRONT
9. Cleanall spark plugs with abrasive-typecleaner, inspect for damage
860016
(replace if necessary)and set the gap at 0.045 in. (1,14 mm)using a
gauge.Install the sparkplugs. Tightenspark plugsto 20 ft. Ibs. (27 N.m).
10. Install coil andconnectboth connectorsto coil. Connectwire to terr-

perature sendingunit.
11. Cleanmanifold gasket surfaces and install newgasket over manifold

studs, Position manifoldand slide it into placeover the studs, makingsure it
seats against the gasket. Install bolts and nuts and tighten as described
under heading lntake/Fxhaust Mar=ifond.
’,..LC4
860017
Eng,ne/eng 3-11
12. Adjust valve lash as outlined under heading Valve Lash
Adjustment. JnstaJl rocker arm cover and gasket. Tighten screws
to 65 in. Ibs. (7,3 N.m)=
13. Connectthrottle linkage and adjust.
14. Connectfuel line and overflow hose to carburetor and install

fuel line support clamps(two). Clean and install flame arrestor.
Z~ 15. Start engine and check for fuel, coolant, and exhaust
leaks.
Timing Gear Cover

Removal
1. Drain coolant from block and exhaust manifold.
Z~ 2. Securely support engine and removefront engine mount.
3. Removealternator and power steering beJts. Next remove

harmonic balancer and pulley assembly from pulley hub.
860019
[~ 4. Install puller tool J-6978-Eto pulley hub with three 3/8-24 x
2 in. bolts and removehub. Removepuller tool.
5. Removecirculating pumppuIRey.
6. Removecrankcase oil drain tube cap and withdraw oil with a

suction pump. Disconnect oi~ drain tube and removeoil pan.
7. Removetiming gear cover attaching screws. Removecover and

gasket.
OiR Seal Replacement
1. After removingtiming gear cover, pry oil seal out of cover from
front with a large screwdriver.
E~2. Install newlip seal with tip (open side of seal) facing inside
of cover, and drive or press seal into place with tool J-23042.
860O2O
Oil Nozzle Repmacement
E~] Removeold nozzne with pliers. Drive new nozzle in place
using a suitable 6ight plastic or rubber hammer.
SafetyReJated 3-12 Englne/eng

TimingGear Coverinstallation
1. Clean gasket surface on block and cover.
2. Install centering tool J-23042over end of crankshaft.
3. Coat both sides of a newgasket with a light grease, and stick

gasket in position on block.
[~4~ 4, Place cover over centering tool and install cover screws.
Tighten screws to 80 in. Ibs. (9 N.m) and removecentering tool.
868022
5. Install oil pan using newgaskets. Tighten 1/4-20 inch screwsto
80 in. Ibs. (9 N.m). Tighten s/i6-18 inch screwsto 165 in Ibs. (18,6
N,m).
6. Connectoil drain tube to oil pan.
HarmonicBalancer instagation
~ [~ I. Coat oil seal contact area on harmonic balancer with

engine oil. Position hub over crankshaft and key, and start hub
fi
into position with a mallet. Using tool J-5590, drive hub onto
crankshaft until it bottomsagainst crankshaft gear.
[~.ot----~ Crankshaftextendsslightly through hub and a hollow tool
is necessary to driw~ hub completely into bottomedposition.
FN°t~ 2. There are two 3/8 in. holes and one %6in. hole that must
be matchedon hub in order to properly position timing mark.
3, Install circulating pumppulley.
4. install alternator’ and power steering belts and adjust to

specifications.
5.. Install front enginemount. 860023
6, Fill engine crankcasewith proper amountof oil.
7rr Lakeor tank test unit and checkfor leaks°
860024
Engme/eng 3-13
Camshaft
MeasuringCamshaftLift
Removeboth connectors from ignition coin.
If improper valve operation is indicated, measurethe lift of each

push rod in consecutive order and record the readings.
1. Removevalve cover and rocker arms.

[~ 2. Position indicator with bali socket adapter (Tool J-8520)
push rod.
3. Rotate crankshaft slowly in the direction of rotation until the

lifter is on the heel of the camlobe. At this point, the pushrod will
be in its lowest position.
4. Set dial indicator on zero. Rotate the crankshaft slowly, or

attach an auxiliary starter switch and "bump" the engine over,
until the pushrod is in the fully raised position.
5. Comparethe total lift recorded from the dial indicator with

specifications. Thecorrect nift is 0.253 inch - 0.005 inch (6,426
0,127 ram).
6. Continueto rotate the crankshaft until the indicator reads zero.

This "will be a check on the accuracy of the original indicator
reading. 860028
7. If camshaft readings for all lobes are within specifications,

removedial indicator assembJy.Install and adjust valve mecha-
nism.
Removal
1. Withdraw oil from crankcase. Drain coolant from block and

exhaust manifoBd.
2. Removevalve cover and gasket. Loosenvalve rocker arm nuts

and pivot rocker arms clear of push rods.
3. After noting position of rotor, removedistributor.
4. Removecoil, side cover, and gasket. Removepush rods and

valvelifters.
5. Removecrankshaft pulley and hub. Disconnect oil drain tube.

Removeoil pan and timing gear cover.
[~J 6. Removetwo camshaft thrust plate screws by working
through holes in camshaft gear.
860027
3-14 ~Q,o~en~
7. Removethe camshaft and gear assembly by pulling it out
through the front of the block.
Support shaft carefully when removing so as not to

damagecamshaft bearings.
inspection
The camshaft has three bearings, all with the same journal
diameter of 1.8692 in. to 1.8682 in. (4,7478 to 4,7452 cm). These
dimensions should be checked with a micrometer for an out-of-
round condition. If the journals exceed 0.001 in. (0,025 mm)
out-of-round, the camshaft should be replaced.
The camshaft should also be checked for alignment. The best

methodis by use of "V" blocks and a dial indicator. The dial
indicator will indicate the exact amountthat the camshaftis out of
true. If it is out morethan 0.002 in. (0,051 ram) dial indicator
reading, the camshaft shound be replaced. Whenchecking, the
h:gh reading of the dial indicator indicates the high point of the
shaft. Examinethe camshaft bearings and if any bearing needs
replacement, repnaceaIB bearings.
Gear and Thrust Plate

r~]~] If the inspection indicated that the camshaft,gear and thrust
plate were in good condition, the camshaft end play should be
checked.This clearanceshould be 0.001 in. to 0.005 in. (0,025 to
0,127 ram).
Disassembly
E4~if the inspectiotn indicated that the shaft, gear or plate should
be replaced, the gear must be removedfrom the shaft. Support
the camshaft gear and press shaft out of gear.
[~ot~ Thrust plate must be positioned so that woodruff key in 860028
shaft doesnot damageit whenshaft is pressed out of gear. Also,

support the hub of the gear orthe gear will be seriously damaged.
Assembly
T(:~ assemblecamshaftgear, thrust plate and gear spacer ring to

camshaft, proceed as follows:
1. Firmly support shaft at back of front journal in an arbor press.

Place gear spacer ring and thrust plate over end of shaft, and
install woodruff key in shaft keyway.
2. Install camshaftgear and press it onto the shaft until it bottoms

against the gear spacer ring. Theend clearanceof the thrust plate
should be 0.001-0.005 in. (0,025-0,127 mm)
Engrt3e/eng 3-15
CamshaftBearings
RemovaJ
Camshaftbearings can be replaced while the engine is disassem-

bled for overhaul, or without compUetedisassembly of the engine
after camshaft and flywheel have been removed. Operation is
easier if crankshaft is also removed. See Crankshaft in this
section.
1. With camshaft and flywheel removed,drive out expansion plug

for rear cambearing by driving from inside. 860030
2. Position bearing pilot in inner bearing, install nut on puler

screw far enoughso puller screw can be threaded into pilot while
nut extends out front of block.
3. Install removersection onto puller screw, and then install screw

through cambore and thread it into pilot.
[~ 4. Using two wrenches, hold screw shaft and turn puller nut
to removebearing. v
r"-R~
5. Removepilot from shaft and install on drive handle with
shoulder to handle. Drive out front and rear bearings from outside
to inside of block.
|nstalation
860031
Inner bearing should be installed first to prevent damagingend
bearing with screw shaft.
Bearing O.D.’s for number one and number two are

1.999-2.001 in. (5,077-5,083 cm) and numberthree is 2.009-2.011
in. (5,103-5,108cm).
1. Remove
handle from pilot, install inner bearing on pilot.
2. Position inner bearing and pilot to rear of inner bearing bore=

Install screw shaft (with removeradapter on it) through the block
from front of engine into pilot. C.- E
¯ <Y 17
.,o . //
3. Align oil hole on bearing with ol hole from oii gallery. Snug
puller nut against adapter. ’~
.... IL. !
[~ 4. Using two wrenches, hold screw shaft and turn puller nut
to pull bearing into place.
Oil hole is on top side of bearing and cannot be seen 860032
during instalation. First align bearing oil hole with oil hole in
bore, and mark opposite side of bearing and block at bore to
easily index oil hole during installation.
3-16 Engme/eng
5. Attach drive handle to pilot, then place new number one
beating on pilot.
[~ 6. Align oil hoh~on bearing with oil hole from oil gallery and
drive bearing in from front of engine.
I-~Z] ~ The front bearing must be driven approximately 1/8 in.
behindfront of cylinder block to uncoveroil hole to timing gear oil
nozzle.
7. Repeatstep (5) and (6) aboveto drive rear bearing into position
from rear of block. 860033
I~_°t~i Rearbearing installed position is flush with inner edgeof

rear cambearing bore.
8. Install a newexpansionplug at rear beating.
CamshaftInstallation
1. if crankshaft has been removed,instaU it at this time. Follow

procedures under the title Crankshaft in this section. If a new
camshaft is to be installed, coat cam lobes with G.M. Super
Engine OilSupplement(G.M. P/N 1051858) and add rest of can to
880034
crankcaseoil.
2. install the camshaftassemblyin the engine block, being careful

not to damagebearings or cam.
[~] 3. Turn crankshaft and camshaft so that the valve timing
marks on the gear teeth will line up, then push camshaft into
position. Install camshaftthrust plate to block screwsand tighten
themto 72-90 in. Ibs. {8-10 N.m).
E~-] 4. Check camshaft and crankshaft gear runout with a dial
indicator. The camshaft gear runout should not exceed 0.004 in.
(0,102 mm)and the, crankshaft gear runout should not exceecl 880035
0.003 in. (0,076 mm).
5.. If gear runout is excessive, the gear will haveto be removed,

and any burrs cleaned from the shaft or the gear replaced.
[~] 6. Check the backlash betweenthe timing gear teeth with a

narrow feeler gaugeor dial indicator. The backlash should not be
less than 0.004 in. (0,102 mm)nor morethan 0.006 in. (0,152 ram).
7. hstall timing gear cover with newgaskets. Install oil pan with
newgaskets and sealer. Connectoil drain tube.
860036
8. Install harmonicbalanceras describedundertitle TimingGear
Coverin this section.
Engtr~e/er~g 3-17
9. Install valve lifters and pushrods. Install side cover with a new
gasket and sealer. Attach coil and wires. Install distributor,
positioning rotor to reference mark.
10. Pivot rocker arms over push rods. Adjust valve lash as
outlined under heading Valve Lash Adjustment.
11. Add oil to engine, install the alternator and power steering
belts, then adjust tension. Checkand adjust timing.
Crankshaft
Removaland Unstallation
1. Removemain bearing caps and connecting rod caps and lift

crankshaft out of cylinder block. Pushpistons to top of bores.
2. Inspect the crankshaft:
Main bearing journals are ground to 2.2983-2.2993 in. (5,8377-

5,8402 cm).
Crankpin journals are ground to 2.099-2.100 in. (5,331-5,334 cm).
These dimensions should be checked with a micrometer for

out-of-round, taper or undersize. If the journals exceed0.001 in.
(0,025 mm)out-of-round or taper, the crankshaft should
replaced or reconditioned to an undersize figure that will enable
the installation of undersize precision type bearings.
The crankshaft should also be checkedfor runout. To perform this

operation, support the crankshaft at the front and rear main
bearing journals in "V" blocks, and indicate the runout of both the
front center and rear center journals using a dial indicator. The
runout limit of eachof thesejournals is 0.002in. (0,051 ram). If the
runout exceeds 0.002 in. (0,051 mm), the crankshaft must
repaired or replaced.
3. Removerear main bearing oil seal.
4. Removeold bearings from cylinder block and caps. hstall new

bearings in the cylinder block and caps.
[~ Main bearings with oil holes are the upper halves of the
bearings and are inserted between the crankshaft and cylinder
block.
5. Oil crankshaft journals and carefully place the crankshaft in the

bearings.
3-18 Engme/eng
& InstaIB all bearing caps and bolts. Tighten all mainbearing cap
bolts, except the rear mainbearing, to 60-70ft. Ibs. (81-95 N.m).
Whentightening rear main bearing cap, tighten botts to 10-12 ft.
Ibs. (14-18 N.m)first, then tap end of crankshaft rearward with
lead hammer(this will locate bearing cap and bearing). Thenta0
crankshaft forward (this will line up both upper and lower
crankshaft bearing thrust surfaces). Proceedwith final tightening
of rear main bearing cap bolts to 60-70 ft. Ibs. (81-95 N.m).
7. Checkmain bearing clearance and crankshaft end play. Install

newrear bearing oil seal. Unstall connecting rod bearings and
caps.
Connecting Rod Bearings

Connecting rod bearings are available in standard sizes and
undersizesof 0.001 in., 0.002 in., 0.010 in. and 0.020 in. (0,025,
0,,051, 0,254, 0,508 mm). These bearings are not shimmedand
when clearances becomeexcessive the next undersize bearing
should be used.
~ Do not file rod or rod caps.
Removaland Inspection
1. Withdrawoil, disconnect oil drain tube and removeoil pan.
2. Removethe connecting rod bearing cap. Wipe bearing and

crankpin clean of oil.
860037
D=] 3. Place a piece of Plastigage gaugingplastic the full width of
the bearing on crankp[n (parallel to the crankshaft).
4. Reinstall the bearing cap and evenly tighten the retaining nuts
to 35 ft. Ibs. (47 N.rn).
~ot-~ Do not turn crankshaft with the gauging plastic installed.
E~ 5. Remove the bearing cap and, without removing the

gauging plastic, check its width at the widest point with the
PI astigagescale.
~=ot~ If the crankpin is out-of-round be sure to fit the bearing to
the maximum diameter of the crankpin. If the flattened plastic is
not uniform from end to end in its width, the crankpin or bearing
is tapered, has a low spot or someother irregularity. Checkthe
crankpin with a micrometer for taper if the flattened gauging
plastic indicates morethan 0.001 in. (0,025 ram) difference.
860038
Engme/eng 3-1g
6. If the readingis not over 0.0009in. (0,0229ram) or not less than
0.0014 in. (0,0356 ram) the fit is satisfactory, tf however, the
clearances are not within these limits, replace the bearing with
the proper undersize bearing.
The bearings are not adjustable and no attempt should be

madeto adjust by filing or shimmingthe bearing caps.
Installation
Newbearing clearance should be 0.00085-0.00135 in. (0,02159-

0,03429 ram).
1. Rotate the crankshaft after bearing adjustment to be sure the

bearings are not too tight.
EEl 2. Check connecting rod end clearance between connecting

rod cap and side of crankpin. See Engine Specifications for
clearance.
3. Install oil pan with newgaskets and seals. Connectoil drain

tube. Refill with engineoil.
Crankshaft Bearings
The main bearings are of the precision insert type and do not
utilize shims for adjustment, ff the clearances are found to be
excessive, a new standard or oversize bearing, both upper and
lower halves, wiJl be required.
[~ if, for any reason, main bearing caps are replaced, shim-
ming may be necessary. Laminated shims for each cap are
available for service. Shim requirements will be determined by
bearing clearance.
The clearance may be checked by using Piastigage gauging

plastic. Whenone bearing is being checked, all the other main
bearing caps must be in place and tightened to specifications.
The main bearings used as service replacement are of high

qua(ity with close tolerances of fit and will not require line
reaming on installations. The close dimensional tolerances en-
sure an equalized bearing surface at all points on the crankshaft
whenreplaced in sets.
Main bearings may be replaced without removing the

crankshaft.
1. Withdraw oil from crankcase. Disconnect oil drain tube. Re-

movethe oil pan.
3-20 Engme/eng
2. Removethe spark plugs.
3o Removecap on main bearing requiring replacement and

remove bearing from cap. Install a main bearing removing and
installing tool in the oil hole in the crankshaft.
~ot~ Usetool J-6098-01. ff such a tool is not available, a cotter
pin maybe bent as required to do the job.
4. Rotate the crankshaft clockwise as viewedfrom the front of the

engine. This will roll upper bearing out of engine.
5. Oil newupper bearing and insert plain (unnotched) end of the

bearing betweencrankshaft and indented or notched side. Rotate
the bearing into place.
6. Install new bearing in bearing cap. The rear main bearing

journal has no oil hole drilling. To removethe upper bearing half
proceed as follows after cap is removed:
a. Use a small drift punch and hammerto start the bearing

rotating out of block.
E~ b. Usea pair of pliers to hold the bearing thrust surface to

the oil slinger, and rotate the crankshaft to pull bearing
out.
C, To install, start the bearing (side not notched) into

notchedside of block by hand, then use pliers as before
to turn bearing half into place.
d® Thelast 1/4 in. movement maybe done by holding just the

slinger with pliers (taped jaws) or tap in place with a drift
punch.
7. Check bearing clearance per paragraph below.
Main Bearing Clearance
Plastigage gaugingplastic is a wax-like plastic material which will

compress evenly between the bearing and journal surfaces
without damaging either surface. To obtain the most accurate
results with gauging plastic, certain precautions should be ob-.
served, ff the engine is upside down, the crankshaft will rest on
the upper bearings and it can be assumedthat the total clearance 860040
can be measuredbetween the cap bearing and journal.
~__°t-"~l To ensure the proper seating of the crankshaft, the rear

main bearing oil seal should be removedand all bearing cap bolts,
should be at their specified torque, in addition, preparatory to
checkingfit of bearings, the surface of the crankshaft journal and
bearing should be wiped clean of oil.
1. Starting with the rear main bearing, removebearing cap.
[~ Wipe oil from journal and bearing cap before applying

gauging plastic.
E..i,~/~.~ 3-21
2. Place a piece of gauging plastic the full width of the
bearing (parallel to the crankshaft) on the journal.
Do not rotate the crankshaft while the gauging plastic is

between the bearing and journal. \
3. Install the bearing cap and evenly tighten the retaining bolts to
60-70ft. Ibs. (81-95 N.m).
4. Removebearing cap. The flattened gauging plastic will be

found adhering to either the bearing or journal. Onthe edge of
gauging plastic packing envelope there is a graduated scale 860041
measuring in thousandths of an inch.
[~ 5. Without removing the gauging plastic, check its com-

pressed width (at the widest point) with the graduations on the
gauging plastic envelope.
[~ Normally, main bearing journals wear evenly and are not

out-of-round. However,if a bearing is being fitted to an out-of-
round journaB be sure to fit to the maximumdiameter of the
journal. If the bearing is fitted to the minimumdiameter of the
journal, and the journal is out-of-round 0.001 in. (0,025 mm)
more, interference betweenthe bearing and journal will result in
rapid bearing failure. If the flattened gauging plastic tapers
toward the middle or ends, there is a difference in clearance
indicating a taper, low spot, or other irregularity of the bearingor
iournal. Be sure to check the journal with a micrometer if the
flattened gauging plastic indicates more than 0.001 in. (0,025
ram) difference.
6. If the bearing clearance is not over 0.0035 in. (0,0889 ram}

(worn) or 0.003 in. (0,076 ram) (new), or less than 0.001 in.
mm),the bearing is satisfactory, ff the clearance is not within
these limits replace the bearing.
[~ If a new bearing cap is being installed and clearance is less

than 0.001 in. (0,025 mm),check for burrs or nicks; if none are
found then install shims as required.
7. A 0.002 in. (0,051 ram) undersize bearing mayproduce the

proper clearance, if not, it will be necessary to regrind the
crankshaft journal for use with the next undersize bearing.
Bearings are available in standard sizes and various under-

sizes. See your parts catalog.
8. Oil newbearings with engine oil prior to installing end caps.

Proceed to the next bearing. After all bearings have been
checked, rotate the crankshaft to see that there is no excessive
drag.
3-22 Eng,ne/eng
L~3---~ 9. Checkthe end play by forcing the crankshaftto its extreme t
,o"
front position. Checkat the front side of the rear main bearing
with a feeler gauge.. This clearanceshould be from 0.002-0.006in.
(0,051-0,152 mm).
’10. Installa newrear mainbearing oil seal in the cylinder block

and main bearing oil cap as described below.
Rear Main Bearing Oil Seal Replacement

~o-’~ Care should be taken when removing the rear crankshaft
oil seal so as not to nick the crankshaft seaning surface.
[-4--1 1.Insert a screwdriver into the notchesprovided in the seal
retainer and pry the seal out. Take care not to damagethe
crankshaft seaning surface. 860043
2. Inspect chamferon crankshaft for grit, nooserust, and burrs.

Clean seal running surface on the crankshaft with a non-abrasive
cleaner.
[~5~ 3. Lubricate the inner and outer diameter of newseal with
engine oil. Install the seal on J-35621. Position J-35621against
the crankshaft. Threadthe attaching screws into the tapped holes
i~b the crankshaft.
4. Tighten screws securely. This will ensure the seal is installed

squarely over the crankshaft. Turn handle until it bottoms then
remove J-35621.
OiR Seal Retainer Replacement

1. RemoveFlywheel and oil pan. Removescrews, nuts and seal
retainer. Remove
gasket. DR1878
2. Remove rear crankcase oil seal as previously stated and clean

gasket surfaces on block and seal retainer.
/,wl
iii
Wheneverseal retainer is removed,a new retainer gasket
and rear crankshaft oil seal mustbe installed. 1// [ ! "\ i!
31. Attach gasket to block. No sealer is required. Install seal
retainer, screwsand nuts. Tighten to 135 in. Ibs. (15,3 N.m).
4. Install oil pan. Install rear crankshaft oil seal as outlined

previously. Install flywheel.
DR1879
Piston and ConnectingRod

P~ston and Rod Removal
1. Withdrawcrankcaseoil. Disconnect oil drain tube. Remove

oil
pan.
2. Drain coolant from block and exhaust manifold, then remow;

cylinder head.
E,g,,~’~,9 3-23
3. Removeanyridge and/ordepositsfromthe upperendof the cylinder
boreswith a ridge reamer.
~Movepiston to the bottomof its travel and place a cloth on top of

pistonto collect the cuttings. After ridge and/ordepositsare removed,
turn
crankshaftuntil pistonis at the top of its strokeandcarefully remove
cloth
with the cuttings.
4. Checkconnectingrods andpistonsfor cylinder number

identification and
if necessary,markthem.
5. Removeconnectingrod cap nuts andcaps. Pushthe rods awayfrom the

crankshaftandinstall capsandnuts looselyto their respectiverods.
6. Pushpiston androd assembliesawayfrom crankshaftandout of the

cylinders.
Note1It will be necessary

to turn the crankshaftslightly to disconnect
some
of the rods andpushthemout of the cylinder.
Piston and RodDisassembly
1. Install pilot of pistonpin removing

andinstalling tool J-24086
onpiston
pin.
2. Install piston andconnectingrod assemblyon supportandplace

assemblyin an arbor press. Presspin out of connectingrod.
3. Remove
assemblyfrom press. Remove
piston pin from support and
remove
tool frompiston androd.
4. Pistonpins are a matched

fit to the pistonandnot availableseparately.
Piston pins will not becomelooseenough to causea knockor tappinguntil
after prolongeduse. In suchcasesa newpiston and pin assemblyshouldbe
installed.
Pistonpins shouldbe capableof supportingtheir ownweightin either pin

bosswhencoatedwith light engineoil at 60° R Higheror lower temperatures
will causefalse indications. Pistonsandpins are servicedas assemblies.
Checkfit of usedpiston pins. Usea dial boregaugeor telescopingsnap GR970257
gaugefor the bore,anda micrometerfor the pin. Wearlimit on piston pin is

productionclearanceplus 0.001in. (0,025mm).Replacepiston andpin
assemblyif wearis excessive.
Cleaning and |nspection
Cleanvarnish frompiston skirts andpins with a cleaningsolvent. DONOT

WIREBRUSH, ORSAND BLASTTHEPISTONSKIRT. Particles of the wire
brushor sandwill become embedded in the surface of the piston and cause
severecylinder wear.Cleanthe ring grooveswith a groovecleaner,and
makesureoil ring holesandslots are clean.
3-24 Engine/eng
Inspect the piston for cracked ring lands, skirts or pin bosses,
wavy worn ring lands, scuffed or damaged skirts, or eroded areas
at top of the piston. Replace pistons that are damagedor
otherwise showsigns of excessive wear.
Piston and Rod Assembly
1. Lubricate piston pin holes in piston and connecting rod to

facilitate installation of pin.
2. Position connectingrod in its respective piston so that flange or

heavy side of rod at the bearing end will be towards front of
piston (cast depressionin top of piston head).
~D 3. Install piston pin @on installer ® and pilot spring © and

pilot @in support(E~.
4. Install piston and rod on support, indexing pinot through piston

and rod.
®®
5. Place support on arbor press, start pin into piston and press on
installer until pin pilot bottoms.
6. Removeinstaller and support assembly from piston and

860047
connecting rod assembly. Checkpiston pin for freedom of move-
ment in piston bore.
PistonRings
Piston rings are furnished in standard sizes as well as several
oversizes. See your parts catalog.
Oil control rings used on all engines consist of two segments

(rails) and a spacer.
Compressionrings in all engines are the deep section twist type,

0.0775-0.0780in. (1,969-1,981 ram) wide.
This type compressionring takes its name, twist type, from its
installed position which is cocked or twisted. It assumesand
maintains this position for life becausethe upper edge of its
diameter is chamfered, making the ring unbalanced in cross
section.
EN=°=~All compression rings are marked with the letter "GM"
cast in the upper side of the ring. Wheninstalling compression
rings, makesure the side marked"GM" is toward the top of the
piston.
Removal
1. Removepiston rings by expanding them and sliding them off

the ends of the piston. Tool No. J-8037 is available for this
purpose.
Eng’,ne/eng 3-25
2. Checkpiston ring groovesby carefully removingall particles of
carbon. Also check for burrs or nicks that might cause rings to
hang up.
Installation
1. Select rings comparablein size to the piston being used.
It is important that each ring be fitted to its individuaR

cytinder for proper gap spacing and to its individual piston and
groove for proper clearance.
2. Slip the ring in the cylinder bore; then, using the head of a
piston, press the ring down into the cylinder bore about two
inches.
Using a piston in this way will place the ring square with
the cylinder walls.
[~ 3. Checkthe space or gap betweenthe ends of the ring with a

feeler gauge.
p ,
4. If the gap betweenthe endsof the ring is belowspecifications,

removethe ring and try another for fit. 1-3 860048
5. Fit eachring separatelyto the cyninder in whichit is going to be

used.
6. New pistons, rings and cylinder bores wear considerably

during seating and gaps widen quickly; however, engine opera-
tion wil~ not becomeseriousRyaffected if ring gapsdo not become
greater that %2in.
I~ 7. Slip the outer surface of the compression ring into the

piston ring groove. Roll the ring entirely around the groove to
makesure that the ring is free and does not bind in the groove at
any point. If binding occurs, the cause should be determined and 860049
removedby carefully dressing with a fine cut file. However,if the

binding is causedby a distorted ring, install a newring.
I
8. Install the oil ring spacerin the oil ring grooveand position gap
in line with piston hole. Hold spacer endsbutted and install steel
rail on top side of spacer. Position gap at least oneinch to left of
spacer gap, then install second rail on lower side of spacer.
Position gap at least one inch to right of spacer gap.
g. Flex the oil ring assemblyin its grooveto makesure ring is free
and doesnot bind in the grooveat any point. If binding occurs, the
cause should be determined and removedby carefully dressing 860050
with a fine cut file. However, if the binding is caused by a

distorted ring, install a newring.
3-26 Englne/eng
E~3--7 10. Proper clearance of the piston ring in its piston ring
groove is very important in maintaining engine performanceand
in preventing excessive oil consumption. Therefore, whenfitting
new rings, the clearances betweenthe top and bottom surfaces of
the ring grooves should be inspected.
E~ 11. The compression rings should be fitted so that the

cbearanceis 0.0020.-0.0035in. (0,051-0,089 ram).
12. Assemblethe rhlgs to the pistons as they are fitted and makea
final test of the ring fit in the groovesby repeating the fitting
procedure given above.
Expanderends must not align with the ring gap.
Piston and Rodinstallation
t r Lightly coat pistons, rings and cylinder walls with light engine
oil.
E4~] 2. With bearing caps removed, install tool J-6305-01 on
bearing cap bolts.
E4~] ~ 3. Install each piston in its respective bore, using tool

J-.8037 on each assembly. The side of the piston with the cast
depressionin the headshould be to the front of the cylinder block
and the oil hole on connecting rod toward the camshaft side of
the engine. Guide the connecting rod bearing into place on the
crankshaft journals with the long detail of tool J-6305-01. Use
J-8037 to compresspiston rings.
4. Oil bearings and install bearing caps. Install cap retaining

screws and nuts. Tighten nuts to 35 ft. Ibs. (47 N.m). Checkthe
bearing clearance as described previously.
860051
5. Install oil pan gaskets, seals and oil pan. SeeOiB Pan. Connect V
oil drain tube.
6. Install cylinder head gasket and head. See Cylinder Head

Installation.
7. Refill crankcaseand checkfor leaks. Lakeor tank test unit and

checkfor coolant leaks.
Cylinder Block
I,nspection
1, Checkthe cylinder block for cracks in the cylinder walls, water

jacket and main bearing webs.
860052
Enq,ne/eng 3-27
[~ 2. Checkthe cylinder walls for taper, out-of-round or exces-
sive ridge at top of ring travel. This should be done with a dial
indicator (use "Fool J-8087). Set the gaugeso that the thrust pin
must be forced in about 1/4 in. to enter gauge in cylinder bore.
Center gauge in cylinder and turn dial to "O". Carefully work
gauge up and down cylinder to determine taper and turn it to
different points around cylinder wall to determine the out-of-
round condition. Bf cylinders were found to have morethan 0.002
in. (0,051 mm)out-of-round, boring will be necessary.
Repair
The performanceof the following operations is contingent upon

engine condition at time of repair.
If the cylinder block inspection indicated that the block was

suitable for continued use except for out-of-round or tapered
cylinders, they can be conditioned by honing, or boring and
honing.
860053
If the cylinders were found to haveless than 0.005 in. (0,127 mm)
taper or wear, they can be conditioned with a honeand fitted with
0.001 in. (0,025 ram) oversize pistons. A cylinder bore of less than
0.005 in. (0,127 mm)wear or taper maynot entirely clean up when
fitted to a 0.001 in. (0,025 mm)oversize piston. If it is desired
entirely clean up the bore in these cases, it will be necessaryto
rebore for an oversize piston, ff morethan 0=005in. taper or wear
exists, they should be bored and honed to the smallest oversize
that will permit completeresurfacing of all cyJinders.
Piston Selection
Replacementpistons are available in two sizes, see the appropri-

ate parts catalog for part numbers.The size identification of the
piston is markedin ink on the piston top.
To determine the correct size of piston needed, measure the

cylinder bore with a telescope gauge and micrometer, and
subtract the base cylinder bore diameter, 4.000 in. (10,160 cm)
from the measureddiameter. Next locate this dimension on the
Piston Selection Chart. The numbershownon the chart in the box
above the dimension is the marking on the piston which should
be used.
3-28 Enome/eng
Cylinder Bore Measurement 4.002 in. (10,165 cm) (WornBore)
Base Cylinder Bore
Diameter 4.000 in. (10,160 cm)
Difference 0.002 in. (0,051 mm)
The numberin the box above 0.002 (0,051 mm)in is $7. There-.
fore, in this case a 0.001 in. (0,025 mm)oversize piston marked
would be used.
Example"’B":
CyMinder Bore Measurement 4.032 in. (10,241 cm) (Bored Out Bore)
Base Cylinder Bore
Diameter 4=000in. (10,180 cm)
Difference 0.032 in. (0,813 mm)
The numberin the box above 0.032 in. (0,813 mm)is 4. In this
example, a 0.030 in. (0,762 mm)oversize piston marked4 would
be used.
SERVICE PISTON MARKING
¯ o o o o o o o
£) o o o
DR4649
Boring
1’,. Before using any type boring bar, the top of the cylinder block
should be dressed to remove any dirt or burrs. This is very
important. Otherwise, the boring bar maybe tilted which would
result in the reboredcylinder wall not being at right angles to the
crankshaft.
2. The piston to be fitted should be checkedwith a micrometer-,

measuringjust below the lower ring groove and at right angles to
the piston pin= The cylinder should be bored to the samediameter
as the piston and honedto give a clearance of 0.0025-0.0035in.
(0,064-0,089 mm).
3, The instructions furnished by the manufacturer of the equip-

ment being used should be carefully followed.
E~,~,oe/eoQ 3-29
Honingand Piston Fit
1. Whenthe cylinders are to be honedonly for use of a standard

piston or for final finishing after they havebeenreboredto within
0.002 in. (0,053 mm)of the desired size, they should be finished
with a hone. Roughstones maybe used at first and fine stones for
the final operation.
2. Place the hone into a cylinder bore and expandthe stones until
the honecan just be turned by hand. Connecta 1/2 in. (0,217 ram)
electric drill to the hone and drive hone at drill speed while
moving hone up and down entire length of cylinder until hone
begins to run free. During this operation a liberal amountof
keroseneshould be used as a cutting fluid to keep the stones of
the hone clean. Move hone snowly up and down with rough
stones, but movehone up and downrapidly enoughwith the fine
stones to producea final bore finish of very fine surface scratches
in a cross-hatch pattern of approximately 45° to 60°. The marks
should be clean but not sharp, and free from embedded particles
or torn or folded metal.
3. Expandthe stones against the cylinder bore and repeat the

honing operation until the desired bore diameter is obtained.
4. Occasionaimyduring the honing operation, the cylinder bore

should be thoroughly cleaned and the piston selected for the
individual cylinder checkedfor correct fit.
5. Checkfit of the aluminumpistons in the following manner:
Thoroughly clean cylinder bores with soap and hot water

to removeanl grit particles.
Measure the cylinder bore diameter with a telescope

gauge and micrometer 21/2 inches (6,35 cm) from top
cylinder bore at gO° from crankshaft axis.
b, Next measurethe diameter of the piston skirt just betow

the lower ring groove and at right angles to the piston
pin.
if the difference is greater than the maximum allowable

(see Boring, step 2), try another piston or lightly honethe
cylinder bore to obtain the proper fit.
d, Should the difference be less than the minimumallowa-

ble (see Boring, step 2), try another piston. If proper fit
cannot be obtained, it will be necessary to rebore the
cylinder to the next oversize piston.
e. Mark each piston after fitting to correspond with the

cylinder to which it has been fitted. Proceed to hone
cylinders and fit the remaining pistons.
3-30 Engme/eng
~Jot’~ Handle the pistons with care and do not attempt to force
them through the cylinder until the cylinder has been bored to
correct size. This type piston can be distorted through careless
handling.
6. Thoroughly clean the cylinder bores with hot water and soap.
Scrubwell with a stiff bristle brush and rinse thoroughly with hot
water. It is extremely essential that a goodcleaning operation be
performed°if any of the abrasive material is allowed to remain in
the cylinder bores, it will rapidly wearthe newrings and cylinder
bores. In addition, the bearing will be lubricated by the contamii-
nated oil The bores should be swabbedseveral times with light
engine oil and a clean cloth and then wipedwith a clean dry cloth.
Cylinder should not be cleaned with kerosene or gasoline. Clean
the remainderof the cylinder block to removethe excess material
spread during the honing operation.
Distributor LowerBearing
\-
The distributor lower bearing is a bronze bushing pressed into the

lower side of the engineblock. Its upperinside diameterpilots the
distributor shaft, and the outside diameter extending below the
block pilots the oil pump.
Someengines have a thrust washer at the upper end of the

bushing bore. The thrust washer, whereused, maybe replaced a~t
the sametime the bushing is replaced.
Thelower bushing will ordinarily require only a clearance or wear

check during engine overhaul. Whendistributor shaft-to-bushing 860655
clearance exceeds 0.0035 in. (0,0889 mm)the bushing shoukt

replaced as follows with oil pumpand distributor removed:
E1-’] 1. Install tool J-9534-01 into bushing and using a slide

hammer, remove the bushing.
Protect your eyes from fragrnents. Wearsafety glasses whe=~

striking these tools, handles, drivers, etc. Tool end may mush,-
room after being repeatedly struck. Alwaysgrind off any rolled
edges before using tool. Use soft face hammerswhenever
possible.
r~&=-1
L_"£J 2. Using a drift upthroughbushing bore, drive thrust washer
(if installed) out of bore and removefrom block.
3. Clean bushing bore in block and check for burrs or damage.

[~3~ 4. If thrust washer was removed, start new washer in
position in bore and drive into place using toot J-9534-01.
5. Usingtool J-9535with driver-bolt in driver handle, install driver

into new bushing from large inside diameter.
860056
E,,~,~,~ Z~ Safety Related 3-31
E~] 6. Place bushingand driver on block and drive the bushingin position.
Depthis determinedby tool bottomingagainst the block.
7. Remove tool from bushing. It is possible that the bushingwith minimum

I.D. will collapseenough,duringinstallation, to slightly seizethe installer
arbor. If this happens,removeinstaller tool using slide hammer in driver bolt
hole of driver handle.
[--~-~ This will not damage

the bushingand the tool is designedfor this
purpose,shouldit occur.
Circulating Pump
Removal
1. Openpetcocks on port side and drain coolant from block and exhaust
manifold. Disconnectwater hose from circulating pump.
2. Loosenfour screwsholding circulating pumppulley to circulating pump.
3. Loosenalternator bracket bolts and removealternator belt. Remove

circulating pumppulley and bolts. Unscrewbolts and removethe circulating
860057
pumpfrom the engine.
~Pull the pumpstraight out of the block first, to avoid damageto

impeller.
Inspection
If the seal is leaking replacethe pump.If the bearingis roughor allows

excessivesidewaysmovement of the shaft, replace the pump.If the impeller
has excessive erosion replace the pump.
Installation
~This pumphas a special shaft and bearing assembly and a special

seal assemblyintendedfor marineservice. Donot substitute with an "
automotive pump.
1. Apply Volvo Penta Gasket Sealing Compound P/N 1161231-4to a new

pumpto block gasket. Install pumpassemblyon cylinder block and tighten
bolts securely.
2. Install circulating pump

pulley. Attachalternator belt andadjust. Referto
GeneralInformationsection for specifications.
3. Connectcoolant hosesto circulating pump.Lakeor tank test unit and

checkfor leaks.
Oil Pan Replacernent

Removal
1. Remove
oil using a suction pump.
3-32 Eo.~
ne/eng
2. Removeoil witlhdrawal tube. Removescrews, oil pan and
gasket.
kestaHation
I. Thoroughlyclean all gasket sealing surfaces. Apply RTVsealer

to the front and rear of the block.
2. Install gasket on the block, install oil pan. Tighten1/4x20screws

to 80 in. Ibs. (g N.m)and5/16x18screwsto 165in. Ibs. (18,6 N.m).
Install oil drain tube and fill crankcasewith engineoil.
Oil Pump
EEl The oil pumpconsists of two gears (~ and a pressure relief
valve ® enclosed in a two-piece housing @. The pumpis driven
from the distributor driveshaft which in turn is driven by a helix
gear on the camshaft.
The oil pumpis flange mountedto the cylinder block with two
bolts, and piloted on the outside of the lower distributor bronze
bearing. Oil pressure passes through an opening in the mounting
flange to the cylinder block, then into the full flow oil filter. The
pumpcover is equipped with the pressure regulator valve that
regulates oil pressure at approximately 40-60 PSI (135,1-202,6
kPa) at 2000 RPM.The pumpintake is of the fixed screen type.
meshscreen @filters out smalKparticles of dirt and sludge which
maybe present.
[~o-~ A baffle incorporated on the intake screen has been
designed to eliminate pressure loss due to suddensurging stops,
turns, and acceleration.
In the event that a screen becomesplugged a steel grommet

opens and bypasses oil to the pump.
Removanand Disassembly
1. Withdrawoil. Disconnect oil withdrawal tube. Removescrews,

oil pan and gasket.Removeoil withdrawal tube fitting from oil
pan°
2. Removeoil pickup tube clamp bolt. Removetwo flange

mounting bolts. Removepump and screen as an assembly. 860058
3. Remove four cover attaching screws, cover, gasket, idler gear,

and drive gear and shaft.
4 Remove pressure regulator valve and valve parts. If necessary,

removeoil pumpsuction pipe and screen by pulling from pump
housing.
Engme/eng 3-33
[~ Do not disturb oin pickup pipe on screen. This pipe is
located at assembly.
5. Washall parts in cleaning solvent and dry using compressed

air.
Inspection
Should any of the following conditions be found during inspec-

tion operations, the defective parts should be replaced.
1. Inspect pumpbody for cracks and excessive wear. Inspect oil

pumpgears for excessive wear or damage.
2. Checkshaft for Boosenessin the housing. Checkinside of cover

for wearthat would permit oil to leak past the endsof gears.
3. Checkthe oil pick-up screen for damageto screen or relief

grommet.
4. Checkpressure regulator valve plunger for fit in cover.
Assemblyand Installation
1. Place drive gear and shaft in pumpbody. Install idler gear so

that smoothside of gear will be toward the cover.
2. Unstall a new pumpto cover gasket to ensure correct end

clearance of the gears.
3. Install suction pipe and screen assembly to pumpbody and

instaBI cover and attaching screws. Tighten screwsto 65-75in. Rbs.
(7-8 N.m) and check to see that shaft turns freely.
4. Install regulator valve plunger, spring, retainer and pin.
5. Align oil pumpdriveshaft slot to matchwith distributor tang.

Install oil pumpto block, positioning flange over distributor lower
bushing. Use no gasket.
Oil pumpshould slide easily into place. If not, removeand

reJocate slot or determine other problem.
6. Attach and tighten oil pickup tube clamp.
7. Install oil pan using newgaskets and seals.

E~ 8. Install withdrawal tube fitting to pan; leave screw boose.
Orient fitting and attach withdrawal tube. Then tighten both 31576
fitting screwandflare nut to 15-18ft. Ibs. (20-24 N.m).
9. Fill crankcasewith oil.
3-34 Engme/eng
Oil Filter BypassValve
inspection
Removethe oil filter and check the spring and fiber valve for
operation. Checkfor a cracked or broken valve.
Replacement
If repHacement
is necessary:
1. Remove
the valve by prying it out with a screwdriver. 2888
2. Install a newvalve and seat it by tapping into place using a g/t6

ir~. thin wall deep socket and hammer.
3. Install oil filter accordingto manufacturer’sinstructions.
Front Engine Mount

Removal
E2~1. Removetwo lag screws and washers from mounts. 34732
~ 2, Lift enginewith hoist capableof lifting at aeast 1000 lb.

(454 kg} minimumcapacity hoist to allow removalof front mou~,t
and bracket.
E,~ 3. Removefour mount screws and lock washers. Remove
front engine mount and spacer (port side) from engine.
Disassembly
r~ 4--’-1 ~ Prior to disassembly of front mount assembly, mea-
sure distance betwe, en large washer on bracket and small washer
on lower mount and record for reference during reassembly.
ES~ ~-] 1. Put w,rench on flat of trim adjustment shaft and
socket on top nut, and removeengine bracket and spacer.
22687
16383
22656 16351 22654
[~ 2. Removetwo bolts from engine bracket and remove rubber

mount assembly.
/
3. Removelower nut and washer on shaft and removeshaft
from lower mount.
4. Upon complete disassembly, check pieces and replace

where necessary.
ReassembUy
16383
z~ 1. Place one nut and washer on trim shaft, then set trim
adjustment shaft in lower mount, install remaining washer, and
screwon lower nut. Makesure at Ueastthree shaft threadsextend
through nut. Tighten nuts finger tight, do not tighten at this time.
E~ 2. Place engine bracket spacer on shaft.
[~ 3. Attach rubber mount to engine bracket with two bolts and

tighten to 30-35ft. Ibs. (41-47 N-m).
4. Place engine bracket assembly on shaft with large and

small washerand tighten nut to 50-60 ft. Ibs. (68-81 N.m).
22653
Installation
1. Attach engine bracket and port side spacer to the engine

with two long bobts and lock washers (port side) and two short
bolts and lock washers(starboard side). Tighten long port side
bolts to 48-56ft. Ibs, (65-76 N.m)and starboard bolts to 32-40 ft.
Ibs. (43-54 N.m).
[~ ~ 2. To reset engine height to original position, refer to
measurementpoints and dimension recorded in Step 4 of Remov-
aL Loosen nuts to adjust shaft and mount position to desired
height° Hold one nut and tighten the other to 115-140 ft. Ibs. 16382
(156-190 N.m).
34731
3-36 Eng,ne/eng
[~ L~ 3. Install lag screwsand tighten securely.
Front MountHeight Adjustment

[_1~ 1. Supportengine with a hoist capableof lifting at least 1000lb.
(454 kg).
[2~] [~ L~ 2. Removeboth lag screws from lower front mount.
:3. Loosennuts securing lower mountto trim shaft. Reposition lower mount
to desiredposition, then retighten lower mountnuts to 115-140ft. Ibs.
(156-190 N m). 16367
[~ L~ 4. Install two lag screws in Jower mount and tighten securely.
High-Rise Exhaust Elbow Replacement

Removal
1. Loosenall four hose clamps. Lubricate exhaustpipe with a soapywater

solution, and slide hose downoff exhaustelbow.
2’.. Loosenhose clampand disconnectcooling hose from inside of exhaust

elbow. Thenremovehosefitting. 2972
[~ 3. Removethe two screws - and swing anchor bracket out of the way.
Thenremovethe two nuts and lock washers(id.
1~14. Loosenthe elbowwith a soft hammer,

then lift it off the manifold.
Remove and discard the elbow gasket.
Installation
1. Thoroughlyclean the manifold and elbowgasket surfaces. Apply Volvo

Penta Gasket Sealing Compound P/N 1161231-4to both sides of a new
gasket, and place it on the manifold. 2888
34729
Eng[ne/eng 22649
3=37
[~ 2. Mount the elbow on the manifond. {nstall the throttle
anchor bracket, and secure with the two screws Q and the two
nuts and lock washers®.Tighten all four to t2-14 ft. Ibs. (16-19
N.m). Slide the exhaust hose all the way onto the elbow.
3. Install hose fitting on the inside of elbowand connect cooling

hose.
4. Position the upper clamps in the top two channels and

tighten them securely. Position the two lower clamps in the
channels and tighten them securely.
34728
Z~ 5. Reconnectthrottle cable to carburetor and throttle Dinkage
plate. Securewith cotter pin.
Exhaust Hose Replacement

Removal
1. Removehigh rise exhaust elbow following procedure in

High-Rise Exhaust EabowReplacement.
[~ 2. Removeclamps and slide hose off exhaust pipe. 34727
Installation
E~ ~ One end of exhaust hose has two ribs @ around the

circumference. Position this end up when installing hose to
ensure secure attachment.
1. Place two No. 64 hose clamps over exhaust pipe if they were
removed.
E~ 2. For ease of installation lubricate inside diameter of hose

with a soapy water solution, and slide hose all the way onto
22647
exhaust pipe. Place two No. 64 clamps around top section of
hose.
3. Complete hose and high-rise elbow installation following

procedure in High=Rise Exhaust Elbow Replacement
16350
Exhaust (Flapper)Valve Replacement
Removal
1. Theexhaustvalve is at the upper end of the exhaustpipe. Remove

exhaust elbow and exhaust hose.
E~ 2. Using a small drift or punch@,push the exhaust valve pin (~ out

of the exhaustpipe.
E~ [~ 3. Removepin and valve. Push out two rubber bushings.

6373
installation
ES~1. Apply 3Ms Scotch Grip RubberAdhesive 1300 to two new rubber
bushingsand push into exhaust pipe.
~_~3~J~ 2. Lightly lubricate exhaustvaive pin with oil. Position valve in

exhaustpipe with Pongside of valve down. Pushpin through bushingand
exhaustvalve until flush with both sides of pipe. Checkexhaustvalve for
freedom of movement.
E~If the valve is ,lot positioned properly (long lip down),it will restrict
exhaustflow and fail to prevent water from backingup into exhaustsystem. 6375A
Boat performancecould be adversely affected, and major powerhead
damagecould occur.
3. Install exhausthose and elbow.
6376
6377
6378
En’.},ne/eng 3-39
6675
Engine Coupler Replacement

Removal
1. Removeengine from boat following instructions in Engine

Removal
and installation section.
If coupler is being replaced due to coupler failure (rubber

hub of sp~ined hubl, check engine alignment after installing new
coupler. See Engine AJignment in EngineRemovaland installa-
tion section.
2. Cut tie strap holding flywheeJ housing drain hose to starter

motor.
[~ [~ 3. Take out screws holding flywheel housing cover (~),

then slide out cover.
[~ 4. Removenut, lock washer, and ground leads from ground
stud. Removeinner nut, lock washer and washer. Removesimilar
ground stud hardware on opposite side of block,
5. Removescrews and washers holding 10 pin connector and 6712

relay, and movebracket aside.
6. Unscrewremaining flywheel housing bolts, lock washers and

washers. Note position of clamps so they can be installed in
original position.
[~ 7. Lift flywheel housing off engine block and set aside.
[~ 8. Unscrewsix Iocknuts, then pull coupler off flywheel.
3-40 Eng,ne/eng
~nstallation
[6-] 1. Slide coupEeronto crankshaftstuds. Install Iocknuts. Usea crowfoot

wrenchand tighten nuts to 50-55ft. lb. (54-61N*m)applied in a "star"
sequence. Repeat torque procedure once more.
ET~2. Install flywheeL housing.Placeclampsin their original positions, and

attach 10 pin connectorand relay bracket. Tightenscrewsto 28-36ft. Ibs.
(38-49 N-m).
~3. Place washer, lock washerand nut on ground stud. Tighten inner nut
6711A
to 35-40ft. Ibs. (47-54N®m).
Attachelectrical leadsto groundstud. Install
lock washerand tighten outer nut securely. Install groundstud hardwareon
oppositeside of block.
EB~]4. Slide flywheel cover up into place. Install screwsand tighten themto
60-84in. Ibs. (7-9 N-m).
~9~] 5. Attach flywheel housingdrain hose® to starter motor with tie strap.
6. Install enginein boatfollowinginstructionsin EngineRemoval

and
Installation section.
20034
14704
Eo,~,r,o/on~ Z~ Safety Related 3-41

EngineSpecifications
1. GeneralSpecifications
Type - No. of Cylinder ..................... 4 - In-line

Bore and Stroke .......................... 4.000in. x 3.60 in.
Piston Displacement ....................... 181Cu. In. (3.0 Litre)
Cylinder No. (front to rear) .................. 1- 2- 3- 4
Firing Order ............................. 1 - 3 - 4- 2
Compression Ratio ........................ 9.3 to 1
Thermostat Opens at ...................... 160° F
Full Throttle Operating Range ............... 4200-4600 RPM
2. EngineDimensions,Fits and Adjustments
Pistons:
Type ................................ Flat Hea::l
Clearance Limit at Top Land .............. 0.0255 - 0.0345 in.
Clearance Limit at Skirt .................. 0.0025 - 0.0035 in.
Compression Ring Groove Depth .......... 0.209 - 0.211 in.
Oil Ring Groove Depth .................. 0.190 - 0.199 in.
Piston Rings:
Compression Ring
Material ......................... Cast Iron
Type ............................ Radius Face (Upper)
Tape Face (Lower)
Coating - Upper Ring ............... Molybdenum
Coating - Lower Ring ............... Wear Resistant
Width ........................... 0.0775 - 0.0780 in.
Gap ............................ 0.010 - 0.020 in, (Upper)
0.013 - 0.025 in. (Lower)
Oil ring
Material ......................... Flat Spring Steel
Type ............................ Multi-piece Rail Expanderand Spacer
Coating (rail) ..................... Chrome
Width (Piston Groove) .............. 0.188 - 0.189 in.
Gap (Ring) ....................... 0.015 - 0.055 in.
Width (Ring) ...................... 0,154 - 0.160 in.
Expanders ....................... One-Piece Expander-Spacer
Piston Pins:
Length .............................. 2.990 - 3.010 in.
Diameter ............................. 0.9270- 0.9273in.
Clearance in Piston (new) ................ 0.0003- 0.0004in.
Wear Limit in Piston .................... 0.001in,
Clearance in Rod ....................... 0.0008- 0.0021in.
3-42 Engme/eng
Connecting Rods:
Material ............................. Drop Forged Steel
Length CL to CL ....................... 5.700in.
Connecting Rod Bearing
Material ......................... M400
Effectiw ~. Length ................... 0.792 - 0.822 in.
Clearance ........................ 0.00085- 0.00135in.
End Play ......................... 0.008 - 0.015 in.
Crankshaft:
Material .............................. Nodular Cast Iron
End Play .............................. 0.002 - 0.006 in.
End Thrust Taken By .................... Rear Main Bearing
Crankpin Journaa Diameter ............... 2.099- 2.11)0in.
Main Bearing
Type ............................ Precision Removable
Journal Diameter .................. 2.2983- 2.2993in.
Length .......................... 0.822in. (rear}
0.830 in. (others}
Clearance ........................ 0.0003- 0.{)029 in.
Camshaft:
Camshaft Bearing
Material ......................... Steel BackedBabbitt
Journal Diameter x Bearing Length .... 1.8692in. x .860 in.
Bearing Outer Diameter- Nos. 1 and 2 . 1.999 - 2.001 in.
Bearing Outer Diameter - No. 3 ....... 2.009- 2.011in.
Type of Drive ......................... Gear
Crankshaft Gear Material ................ Helical Cut Nodular Cast Iron
Camshaft Gear Material ................. Helical Cut Bakelite and Fabric Composition
Lobe Lift ............................. 0.253 in. +- 0.005 in.
Valve Systems:
Lifter Type ........................... Hydraulic
Rocker Arm Ratio ...................... 1.75 to 1
Valve Lash Adjustment -
mntake and Exhaust (hot) ............ 3/4 to 1 Turn DownFrom "Zero Lash" Point
Valve Face Angle ...................... °45
Valve Seat Angle ....................... °46
Stemto Guide Clearance -
Intake Valve ...................... 0.0010- 0.0027in.
Stemto Guide Clearance -
Exhaust Valve .................... 0.0010- 0.0027in.
RecommendedValve Seat Width
Intake ........................... 1/3~in. to 1/~ in.
Exhaust ......................... 1/~6in. to 3/3~_
in.
Valve Systems(cont.):
Outer Valve Spring Free Length ................................ 2.08 in.

Outer Valve Spring Pressure
Lb. @In ......................................... 78-86 @1.66 in.
EngineLubrication:
Type Oil Pump............................................... Gear

Normal Oil Pressure ........................... 40-60 PSI @2000 RPM
Crankcase Capacity ....................... 31/2qts. (4 qts. with newfilter)
Oil Grade Recommended:
Service SG-IVleeting GMSpec 6094
32° F. and Above ........................................... SAE 30
0° R to 32° F .......................................... SAE 20W-20
Below 0° F ............................................... SAE 10W
Werecommend DuraPlusTM SAE30 HeavyDuty Synthetic Motor Oil which is specially formulated for heavy duty marine
TM
use. DuraPlus SAE30 HeavyDuty Synthetic Motor Oil provides superior anti-wear qualities, especially important
during prolongedhigh speedoperation. It also neutralizes acids created in all internal combustionengines.This motoroil
is formulatedto offer superior protection against corrosion and to resist oxidation and high temperaturesludge forma-
tion.
[~ The use of multi-viscosity oils is not recommended.Disregard any reference to multi-viscosity oil printed on
engine. Suchreference is intended for automotiveuse only, not marineuse.
Fuel Grade Recommendation............ See General Information section
3-44 Eng,ne/eng
TorqueSpecifications
Usea reliable torque wrenchto tighten the parts listed to prevent straining or distorting the parts or
possibly damagingthe threads. Thesespecifications are for clean threads only. Dirty threads produce
friction which prevents accurate measurement
of tightness. It is important that these torque specifica-
tions be strictly observed. Overtightening to any extent maydamagethreads, thus preventing proper
torque from being obtained, requiring replacement or repair of the damagedpart.
Adaptor -Oil Pressure Sender 10-14 14-19

Alternator- Bracket to Engine 26-30 35-41
Camshaft Thrust Plate 72-90 8-10
Circulating Pump 13-17 18-23
Crankshaft Oil Seal Retainer 135 15,3
Distributor Clamp 20 27
Exhaust Elbow 12-14 16-19
Flywheel Bei[housing 28-36 38-49
Flywheel Cover 60-84 7-g
Front Mount - Port 48-56 65-76
Front Mount - Starboard 32-40 43-54
Oil Pan(1/4 x 20) 80 9
Oil Pan(5/16 x 18) - 165 18,6
Oil PumpCover - 65-75 7-8
Oil Withdrawal TubeFitting 15-18 20-24
Power Steering PumpBracket 26-30 35-41
Starter Motor 30-38 41-49
Starter Motor Bracket 16-19 22-26
Supply PumpBracket 13-17 18-23
Thermostat Housing 12-16 16-22
Timing Chain Cover - 80 9
Valve Cover - 65 7,3
TorqueSpecifications= (Cont.) . _
LFT. LBS.I I IN. LBS.]
Connecting Rod Cap 35 47

Crankshaft Oil Seal Retainer 135 15,3
FlameArrestor Cover 30-40 3,4-4,5
Flare - Oil WithdrawalTube 15-18 20-24
Flywheel and Coupler 50-55 54-61
Flywheel Belihousing 35-40 47-54
Intake/Exhaust Manifold 20-25 27-34
Cylinder Head
Step 1 35 47
Step 2 65 88
Step 3 95 129
Intake/Exhaust Manifold 20-25 27-34
Main Bearing Cap(exe. rear) 60-70 81-95
Main Bearing Cap, Rear
Step 1 10-12 14-16
Step 2 60-70 81-95
Oil Pump 110-120 12-14
FlameArrestor to Carburetor 65-80 7-9

Oil Filter Oneturn after contact

Retainer - Oil PanDrain 15-18 20-24
Sender, OiE Pressure 10-14 14-19
Sender, Water Temperature 18-22 24-30
Spark Plugs 2O 27
3-46 Engine/eng
NOTES
3-47
NOTES
3-48
Section 4
4.3 GL, GS and Gi Engine
Table of Contents
Accessories ......................... 4-4 Generan Description ................... 4=2

Balance Shaft ...................... 4-23 intake Mar|ifold ...................... 4-7
Balancer, Crankshaft ................. 4-15 intermediate Pipe Replacement ......... 4-38
Camshaft .......................... 4-22 Oil Pan ............................ 4-16
Cleaning ........................... 4-4 Oil Pump .......................... 4-17
Circulating Pump.................... 4-34 Pistons and Connecting Rods .......... 4=25~
Crankshaft and Bearings .............. 4-30 Rear OiJ Seal, Crankshaft .............. 4=29~
Cylinder BBock ...................... 4-31 Rear Oin Seal Housing ................ 4-29~
CyUinder Head ...................... 4-12 Rocker Arm Cover .................... 4-9
Engine Rocker Arm Stud Replacement ......... 4-13
Coupler Replacement ............... 440 Special Tools - GM................... 4-47
Draining .......................... 4°4 Specifications
Front Cover ....................... 4-20 Engine .......................... 4-44
Front Mount ...................... 4-35 Torque .......................... 4-42
Lubrication ........................ 4=5 Timing Chain and Sprockets ........... 4-21
Exhaust Tools and Shop Equipment ............. 4-3
(Flapper) Valve Replacement ......... 4-39 Valve Train ......................... 4-10
Manifold .......................... 4-6
High-Rise Elbow Replacement ........ 4-37
Hose Replacement ................. 4-38
Safety Warnings
Before working on any part of the engine, read the section called
Safety at the end of this manual
Alwaysuse the correct fastener in the proper location. Whenyou

replace a fastener, use ONLYthe exact part number for that
application. The text will call out those fasteners that require
replacementafter removal. The text will also |:all out the fasten-
ers that require thread lockers or thread seahmt.
UNLESSOTHERWISE SPECiFiED, do not use supplement coat-

ings (paints, greases, or other corrosion inhibitors) on threaded
fasteners or fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joiint clampingforce,
and may damagethe fastener.
Whenyou install fasteners, use the correct tightening sequence

and tightening specifications. Following these instructions can
help you avoid damageto parts and systems=
Eng,ne/eng 4-
General Description
Engine Construction
The 4.3L engine is a biquid-cooled 90 degree V6 type with

overheadvalves, a balance shaft, and cast-iron block and cylinder
heads.
Cylinder Block
The cylinder block has 6 cylinders arranged in a "V" shapewith 3

cylinders in each bank. Starting at the front of the engine,
cylinders in the right bank are numbered1-3-5 and cylinders in
the left bank are numbered2-4-6 (when viewed from the front).
Thefiring order of the cylinders is 1-6-5-4-3-2. The cylinders are
encircled by coolant jackets.
Cylinder Heads
The cylinder heads have one intake and one exhaust valve for
each cylinder. A spark plug is located betweenthe valves in the
side of the cylinder head. The valve guides are integral and the
valve rocker arms are retained on individual threaded studs.
Crankshaft
The crankshaft is supported by four crankshaft bearings. The

numberfour bearing at the rear of the engine is the end thrust
bearing. The bearings are retained by bearing caps that are
machinedwith the block for proper alignment and clearances.
Camshaft
The camshaft is supported by four full round, sleeve-type bear-

ings. A sprocket on the crankshaft drives a camshaft timing chain
which in turn drives the camshaft through a sprocket.
Pistons and ConnectingRods
The pistons are madeof cast-aluminum alloy using two compres-

sion rings and one oil control ring assembly.Piston pins are offset
0.0354 in. (0,9 ram) toward the major thrust side (right side)
reduce piston slap as the connecting rod travels from one side of
the piston to the other side after a stroke. Thepins are a press fit
in the connectingrod and a floating fit in the piston.
Balance Shaft
The cast-iron balance shaft is mountedin the crankcase above

and inline with the camshaft. A camshaft gear drives the gear
attached to the balanceshaft. Thefront end of the balance shaft is
supported by a ball-type bearing. The rear end of the balance
shaft uses a sleeve-type bearing.
4-2 Engm~eng
Valve Train
Thevalve train is a ball-pivot type. Motion is transmitted from the

camshaftthrough the valve lifter and valve push rod to the valve
rocker arm. Thevalve rocker arm pivots on its ball and transmits
the camshaft motion to the valve. The valve lifters with roller
followers keepall parts of the valve train in constant contact. Each
lifter acts as an automaticadjuster and maintains zero lash in the
valve train. This eliminates the need for periodic valve adjust-
ment.
intake Manifold
The intake manifold assembly is a two-piece design. The upper

portion is madefrom a composite material and lower portion is
cast-aluminum. The throttle body attaches to the upper manifold.
Tools and Shop Equipment

A clean, well-lit, work area should be available° Other necessary
equipment includes: a suitable parts cleaning tank, compressed
air supply, trays to keep parts and fasteners organized, and an
adequateset of hand tools. An approvedengine repair stand will
help aid with the work and help prevent personal injury or
component damage.
Special tools are listed and illustrated throughout this section

with a completelisting at the end of the section. Thesetools (or
their equivalents) are specially designed to quickly and safely
accomplishthe operations for which they are intended. The use of
these special tools will also minimize possible damageto engine
components. Someprecision measuring tools are required for
in,;pection of certain critical components.Torque wrenchesare
necessaryfor the correct assemblyof various parts.
Eng,ne/eng 4-3
Accessories
The various procedures in this manual assumethat the engine

accessories have been removed.These accessories include all of
the following:
¯ Power Steering Pump

¯ A~ternator
¯ Distributor
¯ Water Supply Pump
® Accessory Brackets and Electrical Wiring
¯ Starter Motor
Cleaning
Removethe engine accessories before cleaning to provide better
access to the engine’s exterior surfaces. After removing the
distributor, accessorybrackets, etc., cover the openingswith tape
to prevent the entry of contaminants.
Methods used to clean the engine will depend on the means

which are available. Steamcleaning, pressure washing, or sol-
vent cleaning are some of the acceptable methods. Allow the
engine to dry thoroughly before beginning any work.
It is important that the engine be as clean as possible to prevent

dirt, water, or any other contaminantsfrom entering critical areas
during disassembBy.
Draining The Engine

Follow the procedures in Section 1, General Information of this
manua~to drain crankcase engine oil and the cooling system.
4-4 Ei~gme;eng
r
==
-.%= | m
DRC6583
Engine Lubrication
Full pressurelubrication, through a full-flow Filtered oil flows into the main ganlery and then
oil filter is suppliedby a gear-typeoil pump.Oil is to the camshaft, balance shaft, rear bearing, and
drawn up through the oil pump screen and crankshaft bearings. The valve lifter oil gallery
passesthrough the pumpto the oil filter. Theoil supplies oit to the valve lifters. Oil flows from the
filter is a full-flow paper element unit with an valve lifter.,; through the hollow valve pushrods
anti-drain backvalve. An oil filter bypassvalve is to the valve rocker arms. Oil drains back to the
used to ensure adequateoil supply, in the event crankcasethrough oil drain holes in the cylinder
the filter becomesplugged or develops excessive head. The camshaft timing chain is drip fed from
pressure drop. the front camshaft bearing. The pistons and
piston pins are lubricated by oil splash.
Engme/eng 4-5
ExhaustManifold
Removal
1. Drain waterfromexhaustmanifolds.
2, Disconnectwaterhosefrommanifold.
3. Loosenupperexhausthoseclamps,then removehigh rise elbow.
4. Remove
manifoldattaching nuts and washers.Discardnuts.
Inspection
1. Inspectfor cracks.
07 2. Topressurecheckmanifold, fabricate a plate suchas pictured (~)

anda newelbowgasket(~) to seal waterpassage in manifold. Besure
applyseater to gasket.Install rubberdrain capsto manifoldandsecurewith
clamps. Attach a GearcasePressureTester © (such as StevensCompany
S-34)to the waterinlet hose. A bushingcanbe madeto securepressure
tester to hose.With the pressuretester attachedto the manifold,submerge
manifoldin water. Pressurizethe manifoldto 10-15PSI(22-25kPa) and
checkfor leaks. Manifoldshouldnot leak aroundclampsandplate. If so, dr2642
retighten clampsor reseal plate. Nodropin pressureshouldbe realized.
installation
[~] 1 Cleanmatingsurfaces on manifold andhead. Install newexhaust

gasket,then install manifoldandsecurewith bolts. Tightenbolts @to 20-26
ft. Ibs. (27-35N.m).
2. Install a newgasketandhighrise elbowto manifold.Tightenbolts to

12-18ft. Ibs. (16-24Nm).
3. Install exhausthoseandsecurewith clamps. 28287
4. Connect
waterhose.Install andtighten drain petcocks.
/~5. Start engineandcheckfor fueB leaks.
4-6 Engine/eng
intake Manifold
Removal
[==3~~ 1. Draincoolantfrommanifolds
andbothsidesof block.
;.L Disconnect:
a. Batterycablesfrombattery.
b. Coolanthosesat thermostathousing.
C. Throttle cablefromcarburetorandanchorblock.
d. Crankcase
ventilation hosefromrocker armcovers(both
sides).
e. Wireat temperaturegaugesenderunit andenginewiring

harnessfromalternator.
f. Distributorhightensionandignition primaryleadsfromcoil.
3. Remove:
a. Distributor capand markthe position of the rotor on the

housing. Scribe a line on distributor housingandintake
manifotd for reassemblyin the sameposition. Remove
the distributor.
b. Alternator andalternator mounting bracketfromengine.
c. Carburetorfuel line fromcarburetorandfuel pumpor fuel

lines fromthrottle bodyandfuel pump/vapor separator.
d. Oil pressuresendingunit.
e. Manifoldattachingbolts andsolenoidbracket.Lift manifold

fromengine.Discardfront andrear sealsandgaskets.
If manifold
is to bereplaced,transfer: carburetor
or throttle
bodyand ECMbracket, thermostatand housing(use new
gasket),throttle cableanchorblockassembly, distributor
clampandtemperature sendingunit. Transferadditional
hardwareas required.
Eng[ne/eng
4-7
¯ Old pieces of gasket or RTVfrom the gasket surfaces.
e Excessive carbon build-up in the intake passagesof the
intake manifold.
o Scale and deposits from the coolant passages of the
intake manifold.
installation
[~ important: Do NOTreuse intake manifold gaskets.
DRC8590
E~] Install or Connect: 12.7 mm

(0.499 IN.) o ~
1. Sealant to the intake manifold gasket, cylinder head side.
[~ Care must be used to apply the correct amount of sealant

onto the gaskets. Applying excessive amounts of sealant may
prohibit the intake gaskets from sealing properly.
2. Gaskets onto the cylinder head. -, %

a. Use gasket Iocator pins to properly seat gasket on cyninder
head.
~ b. Apply a 0.499 in. (13 mm)bead of GMSealant, P/N
12346141,or equivalent to the front and rear block sealant
areas.
c. Extend the sealer bead 0.157 in. (4 ram) onto each gasket.
3. GMThreadlocking Sealant, P/N 12345382,or equivagent to the

threads of the eight lower intake mounting bolts.
4. Lower intake manifold onto engine block.

DRC6592
5. Lowerintake manifold bolts.

8
[~ Tighten:
4~
I~ Bolts in three steps, using the following sequence:
a. Snugall bolts to 27 in. lb. (3 N-rn) to minimizeshifting

intake.
b. Bolts to 106 in. lb. (12 N-m).

6
c. Bolts to 11 ft. Ibo (15 N.m). DRC6593
4-8 Engme./eng
d. Distributor with rotor andaligned exactly as markedduring
removal.
~NO-O-~
If enginewascrankedwhile distributor wasout, completeignition
timing proceduremust be followed. Seethe appropriate Ignition Circuit in
Electricallfgnition SystemsService Manual.
e. Alternator with mountingbracket.
f. Distributor cap and high tension leads. Seethe General

Informationsection in Electrical/Ignition ServiceManua~
for
correct firing order and sparkplug wire routing.
g. Oil pressuresendingunit.
3. Connect:
a. All electrical connections. Apply Black NeopreneDip, on

all exposedconnections.
b. Fuel lines to carburetor and fuel pumpor throttle bodyand

fuel pump/vaporseparator.
c. Throttle cable.
d. All water hoses, and close all drain petcocks.
e. Both crankcaseventilation hoses.
f. Battery cables.
g. Start engine.Checkignition timing, carburetor idle speed

and mixture. Checkfor leaks.
Rocker ArmCover
Removal
~5=~ Remove or Disconnect:
1. Valverocker armcover botts.
2. ’Valve rocker armcover.
3. ,Gasket.
DRC6584
Eqgme/eng 4-9
Clean:
o Parts in solvent. Removeall sludge and varnish.

e Old gaskets from the gasket surfaces.
inspect:
® Gasket flanges for bending or damage.

® Rubber grommetsand parts for deterioration.
Rnstallation
DRC6584
i~ Install or Connect:
1. Newgasket. J
2. Valve rocker arm cover.
3. Valve rocker arm cover bolts.
Tighten:
Valve rocker armcover bolts to 106 in. lb. (12 N.m).

DRC6585
ValveTrain
Removal
~] Important: Store all reusable components in an exact
order, so they can be reassembled in the samewear pattern
location from which they were removed.Mark the front end of
the retainer.
E~ Remove or Disconnect:
DRC6588
I~ 1. Valve rocker arm nuts, bails, and vaJve rocker arms.
[~ 2. Valve push rods.
[~ 3. Bolts and valve lifter retainer.
[~ 4. Valve lifters.
Removethe lifters one at a time using J 9290-01/J 3049 or

equivalent and place them in an organizer rack.
EEl Urnportant: Store all reusabae components in an exact
order, so they may be reassembled in the same wear pattern DRC6586
location from ,which they were removed.
4-10 Erlgine/eng
¯ AIB parts in clean solvent and dry them with compressed
air.
¯ Makesure oil passagesin valve push rods are clear.

[~ Inspect:
e Valve rocker arms and baBIs at their mating surfaces.

These surfaces should be free from wear or any damage.
0 Valve rocker arm areas that contact the valve stems and
the socket areas that contact the ends of the valve push
rods. These areas should be free of damageor wear.
¯ Valve rocker arm nuts.
e Valve push rod ends for scoring, roughness, or bends.

[~et-~ Roll the valve push rod on a flat surface to determine its
straightness. If the rod is bent, the rod will not roll freely. Replace
if necessary.
Vamve
Lifters
This engineuses hydraulic valve lifters. Valve lifters are serviced

only as an assembly. No internal parts are available. Service is
limited to a disassemblyand cleaning. Discard valve lifters that
are excessively worn or damaged.
E~ important: Whenever the camshaft needs to be re=
placed, a newset of valve lifters mustalso be installed.
Instagation
[~ important: Replace all valve roller lifters, change the
engine oil and filter, and add GMEngine Oil Supplement,P/N
1052367, or equrivalent to the engine oil whenever a new
camshaftis installed.
Lubricate the valve lifter bodies and roller with GM

Engine Oil Supplement,P/N 1052367, or equivalent.
E3 Instal| or Co,,nect:
~ 1. Valve lifters to the block=

~ 2. Valve lifter guide.
¯ Note previously mademark on valve lifter guide. Refer-

ence mark should be pointing toward front of engine.
Eo~
......g 4-11
Tighten:
Bolts to 12 ft. lb. (16 N-m).

[~ 3. Valve push rods.
a. Seat the valve pushrods into the socket of the valve Uifters.
b. Coat the mating surfaces of the valve rocker arms and balls
with GMEngine Oil Supplement, P/N 1052365, or equivalent.
J~ 4. Valve rocker arms with balls on to the proper stud.
DRC6588
J~ 5. Valve rocker arm nuts onto the studs.
o Align the vaPvepush rod into the valve rocker arm while
tightening valve rocker arm nut.
[~ Important: No Bash adjustment is needed. These mod-
els use screw-in rocker arm studs with positive stop shoulders.
J~ Tighten:
Valve rocker arm nuts to 20 ft. lb. (27 N.m). DRC658g
Cylinder Head
Cylinder Head Removal
Removeor Disconnect:
1. Spark pnugs.
2. Cyninder head bolts.
3. Cylinder heads.
4. Headgaskets.
Cylinder HeadDisassembmy
Tool Required: J 8062 Valve Spring Compressor ~3
[~] [~ ~ Remove or Disconnect:
1. Compressthe springs with J 8062.

2. Keys Q.
3. Tool J 8062. DRC6595
4. Valve spring cap (~.

5. Spring (~.
6. Seal ~).
7. Valves ~ and (~.
Place the valves in an organizer rack so they can be replaced in

their original position at reassembly.
4= 1 2 Engme/eng
Cmeaning, inspection, and Measurement
Refer to General Engine MechanicaUsection in this manual.
Rocker Arm Stud Replacement

Valve rocker arm stud by unscrewing.
Install or Connect:
Screwvalve rocker arm stud into cylinder head.
Tighten:
Valve rocker armstud to 35 ft. lb. (47 N.m).
CyJinder Head Assembly
Tools Required: J 8062 Valve Spring Compressor
Install or Connect:
E~E] 1. Valves ~ and ~.
a. Lubricate the valve stemswith clean engine oil.
b. Insert the valves into the proper valve guides until the face
of the valve contacts the valve seat.
2.Seal
®.
a= Install the seal over the valve stem.
b. Hold the valve against the valve seat.
c. Push the seal down the valve stem until it bottoms out
against the head[.
[~4~ 3. Springs (~.
[~ 4. Valve spring cap (~.
a. Compressthe valve spring using J 8062, enoughso the

lower valve stern groove can be seen clearly.
b. Apply a small amountof grease to the area of the upper

valve stem groove.
[~ c. Assemble the two valve keys O into the upper groove

using the grease, to hold them in place.
En!~,ne/eng 4-13
[~ d. Release the compressor tool J 8062, making sure the
valve keys O stay in place.
e. Repeat the preceding steps on the remaining valves.

r~ Measure:
Refer to General Engine Mechanicalsection in this manualfor

valve spring installed height.
Clean:
DRC6595
Gasketsurfaces on the block and cyninder head.
Cylinder Headinstallation
Tool Required: J 36660 Torque/Angle Meter
3 install or Connect:
1. Headgasket.
¯ Do not use sealer on head gaskets.

¯ Place the gasket over the block dowel pins with the head
DRC6587
up.
2. Cylinder head. Carefully guide the cylinder headinto place over

the dowel pins and gasket.
3. Cylinder head bolts. Coat threads of the cylinder head bolts

with GMSeating Compound,P/N 12346004, or equivalent and
install fi[~r-tig ht.
[~ ~ Tighten:
a. Bolts in sequenceto 22 ft. lb. (30 N-m).
b. Bolts in sequenceusing J 36660to:
¯ Short length bolt (11, 7, 3, 2, 6, 10) 55 degrees.

e Mediumlength bolt (12, 13) 65 degrees.
¯ Long length bolt (1, 4, 8, 5,9) 75 degrees.
4. ~k plugs.
Tighten:
a. Spark plug into newcylinder headto 22 ft. lb. (30 N.m).
b. All other subsequentinstallations to 15 ft. lb. (20 N.m).
4-14 Engine/eng
Crankshaft Balancer
Removal
-tool Required: J 39046 Crankshaft Balancer Remover
The inert[at weight section of the crankshaft balancer is

assembledto the hub with a rubber sleeve. The removal proce-
dures must be followed (with the proper tools) or movement
the inertial weight section of the hub will destroy the tuning of the
crankshaft balancer and the engine timing reference.
.emo..,
o,Di,co°.ect:
t Crankshaft balancer bolt and washer.
2. Crankshaft balancer using J 39046. J 3g046
3. Crankshaftkey, (if necessary).

~--~ Inspect:
Crankshaft balancer weight for signs of shifting on the hub.

Replace as needed. The area of the crankshaft hub shaft that DRC6641
contacts the front crankshaft seal for roughnessor nicks. Replace
the balancer if this condition exists. If balancer is replaced, new
balance weights of the samesize must be installed on the new
balancer in the samelocation as the old balancer.
Installation
J 39046
-[i~ol Ree~uired: J 39046CrankshaftBalancerInstaller \

1. Apply GMRTVSea~ant, P/N 12345739,or equivalent to crank- DRC6~4
shaft keyway.
2. Crankshaft key (if removed).

[~o~ The inertial weight section of the crankshaft balancer is
assembled to the hub with rubber type material. The correct
installation procedures(with the proper tool) must be followed
movementof the inertial weight section of the hub will destroy
the tuning of the crankshaft balancer.
3. Stud (part of J 39046)to the crankshaft. Threadstud fully into

the tapped hole in Lhe crankshaft.
4. Crankshaft balancer over the end of the stud. Align the keyway
in the crankshaft balancer shaft with the crankshaft key.
Englne/eng 4-15
5. Bearing, washer, and nut.
a. Turn the nut to pull the crankshaft baRancerinto place.
b. Removethe tool.
6. Crankshaft balancer boRt and washer.

[~ Tighten:
Bolt to 74 ft. lb. (100 N.m).
Removal
[~ B Remove or Disconnect:
% ,
1. Oil pan nuts.
2. Oil panbolts.
3. Oil pan. DRC6642
4. Gasket.
[~ Clean:
® Parts in solvent. Removeall sludge and varnish.

® Old gaskets and RTVsealant from the gasket surfaces.
® Inspect:
¯ Gasket flanges for bending or damage.

¯ Oil pan for damageor cracks.
¯ Oil pandeflector for lack of fit.
® Drain plug threads for stripping.
Installation
Tool Required: J 34673 Straight Edgeor Equivalent

E~ Important: The alignment between the rear of the oil pan
and rear of the block flange is critical. The two surfaces must be
flush to provide a rigid engine-to-transom bracket alignment.
DRC6539
4-16 Englne/eng
~ Install or Connect:
~.~ [] Apply GMRTVSealant, P/N 12346141, or equivalent to

the engine front cover to block joint and to the rear crankshaPt
housing to block joint. Apply the sealant about 1.00 in. (25,4 mm)
in both directions from each of the four corners.
1. Oil pan gasket onto pan.
E4-’] 2. Oil pan against cylinder block.

25.4 turn
(1,00IN.)
[~5~ 3. Slide oil pan back against straight edge using J 34673or DRC6640
equivalent.
4. O~anbolts and nuts but do not tighten.
N~3~N
Measure:
[~ Use a feeler gauge to check the clearance between the
three oil pan-to-transmission bell housing contact points as
shown,if clearanceexceeds0.010 in. (0,254 mm)at any of th,
three points repeat steps 2 and 3 until the clearance is within
specification.
DRC6642
[~ If the clearance is more than 0.010 in. (0,254 mm),
powertrain durability maybe affected.
[~ ~ Tighten:
e Bolts to 18 ft. lb. (25 N.m) in the sequenceshown.

¯ Nuts to 17 ft. lb. (23 N.m).
Measure:
¯ Clearance betweenthe three oil pan-to-transom bracket

contact points to verify proper alignment. DRC6648
5. Lubricate newoil filter seal with cneanengineoil. ® ®
6. Newoil filter. ®
®
Oil Pump
Removal ®
[7~ [~ Remove or Disconnect: ® @

DRC6645
1. Bolt from oil pumpto crankshaft bearing cap.
2. Oil pump assembly.
3. Driveshaft and retainer
DRC6643
Engnne/eng 4-17
FT] ~ Disassemble:
1. Driveshaft ~ and retainer (~.

[~ Do not remove the oil pump screen unless replacement
is required. The oil pumpscreen has a press fit in to the pump
cover. Do not remove the screen from the pipe (~. The oil
pumpscreen is serviced as a complete assembly only.
2. Oil pumpscreen pickup ~.
3. Bolts (~.
4. Pumpcover (~.
Mark where the idler gear and drive gear and shaft (~
meshtogether, so they can be reinstalled with the samegear
teeth indexed.
5. Idler gear and drive gear and shaft O.
6. Retaining pin Q.
7. Pressure regulator spring (~.

DRC6624
8. Pressureregulator valve (~).

r~ Clean:
All_~rts in clean solvent and dry them with compressedair.
[~][I~[~L~.j inspect:
~-~ important: The pump gears, cover, and body are not
serviced separately. If any of the parts are damaged
or worn,
the entire oil pumpassembly must be replaced.
¯ Pumpbody ~ for cracks, wear, or other damage.
¯ Inside of the cover (~) for cracks and wear that would
permit oil to leak past the endsof the gears.
¯ nd[er and drive gear (~ for wear.
¯ Drive gear and shaft for lack of fit in the pumpbody.
¯ Oil pumpscreen for damageto the screen or loose fit of

the pipe.
¯ Pressure regulator valve (~) for fit. The regulator valve

should slide freely in its bore without sticking or binding.
4-18 Engme/eng
Assemble
J 21882
[~ ~ instalm or Connect:
1, Pressure regulator valve ® into the pumpcover Q.

[~ important: Replace the pressure relief valve spring ~
when reusing the oil pumpassembly,
2, Pressureregulator spring (~) into the pumpcover (~).
3, Retaining pin O into the pumpcover Q. DRC6625
4. Drive gear and shaft O into the pumpbody ~.
5, Idler gear Q into the pumpbody [~.
[~ Match together the index marks on the two gears made

during disassembly.
6, Pumpcover (~.
7, Bolts (~).
Tighten:
Bolts (~)to 106 in. lb. (12 N.m).
With the driveshaft (~) installed on the pump,turn the driveshaft

by hand to check for smooth operation.
~o-~ Be careful of twisting, shearing, or collapsing the pipe
wheninstalling it to the pump.A damaged pipe can cause lack of
lubrication and engine failure.
Oil Pu~.~ScreenInstallation
E2~ ~ install or Connect:
1, Oil pumpscreen pickup (~).
a. The oil pumpscreen assembly @should be replaced with a

newpart. Lossof press fit condition could result in an air leak
and loss of oil pressure.
b. Mount the oil pumpin a soft jawed vise.
c. Apply sealer to the end of the pipe.
d. Tapthe pickup screen and pipe into place, using J 21882and

a hammer.
e. The oil pumpscreen must be parallel with the bottom of the

oil pan wheninstalled.
E1=-] 2. Oil pumpdriveshaft (~)and retainer
Engme/eng 4-19
~ P~ Instal|ation
Install or Connect:
1. Oil pumpto the engine.
a. Align the slot in the oil pumpshaft with the tang on the
distributor shaft.
b. Theoil pumpshould slide easily into pnace.
c. No gasket is used. DRC6643
2. ~umpand bolt onto crankshaft bearing cap.

I,~)!
Tighten:
Bolt to 66 ft. lb. (90 N.m)=
Engine Front Cover

Removal
[~ important: Once the composite engine front cover is
removedDONOTreinstall it. Alwaysinstall a newengine front
cover.
[~ Remove or Disconnect:
1. Enginefront cover bomts.
2. Enginefront cover.
Installation
E~ Important: Once the composite engine front cover is
removedDONOTreinstall it. Alwaysinstall a newengine front
cover°
Do not reuse the original O-ring seal wheninstalling onto crank-

shaft sensor body. Lubricate new O-ring seal with engine oil.
Wheninstalling crankshaft position sensor be sure the sensor is
fully seated and held stationary in the engine front cover bore.
Torquehold downbolt to the specification shownbelow. A sensor
that is not seated will cock in the engine front cover bore and may
result in erratic engine operation.
4-20 Eng,ne/eng
E~’~ Install or Connect:
1. Enginefront cover to engine.
2. E~nefront cover bolts.

b’
B~)U
Tighten:
Bolts to 106 in. ab. (12 N.m).
Timing Chain and Sprockets

DRC6633
Tool Required: J 5825-A Crankshaft Sprocket Puller
Measure: J 5825-A
Checkcamshaft timing chain free pnay. If the camshaft timing

clhain can be movedback and forth in excessof 0°625in. (16 ram),
makea note that tile camshaft timing chain should be replaced
during assembly.
Removal
E2~ E~ Remove or Disconnect: DRC6615
1, Camshaftsprocket bolts Q.
2. Camshaftsprocket (~ and camshaft timing chain (~ together.
The sprocket has a light interference fit on the carn-

shaft. Tapthe sprocket on its lower edge to loosen it.
3. Balanceshaft drive gear.
E2-~ [~ 4. Crankshaft sprocket (~ using J 5825-A.
5, Key ~ (if damaged).
Englne/eng 4-21
inspect:
1. Sprockets for chipped teeth and wear.
Excessively worn sprockets will rapidly wear a new

chain.
2. Camshafttiming chain for damage.
An excessively worn chain will rapidly wear a new set

of sprockets.
DRC6694
installation
Tool Required: J 5590 Crankshaft Sprocket Installer

[~ Instag or Connect:

[~ 2. Crankshaft sprocket using J 5590.
3. Balanceshaft drive gear, View A
DRC6634
4. Camshaftsprocket and camshaft timing chain.
[~ E~ important: Line up the sprocket alignment marks
® on the camshaft sprocket and crankshaft sprocket.
[~ The number 4 cylinder is at top dead center of the
compression
stroke with the timing marksin this position.
5. Camshaftsprocket bolts (~). 4
[’~ Tighten:
Bolts 21 ft. lb. (28 N.m). DRC6633
Camshaft
Removal
1. Camshaftretainer bolts and camshaft retainer,
2. Camshaft.
DRC6635
[~ a. Install three 5/16 - 18 (4.0 in.) long into the camshafts
threaded holes. Use these bolts to handle the camshaft.
[~ b. PulD the camshaft out from the block being careful to
prevent damageto the camshaft bearings.
4-22 Enome/eng
E~ Measure:
CamshaftJournals.. Refer to General Engine Mechanical section

in this manual.
Bearings
Refer to General Engine Mechanical section in this manual for

camshaft bearing disassembly, cleaning, inspection, and assem-
bly.
Instagation
E3 install or Connect:
Coat the camshaft lobes and journals with a high

quality GMEngine Oil Supplement, P/N 1052367, or equiva-
lent. Apply GMEngine Oil Supplement, P/N 1052367, or
equivalent to all the teeth on the distributor drive gear.
~,4~] 1. Twoor three 5/16 - 18 (4.0 in.) bolts long into the camshaft
E4~ 2. Camshaftinto the engine. Handle the camshaft carefully
to prevent damageto the camshaft bearings.
4
3. Camshaftretainer and retainer bolts.
¯ Coat camshaft retainer plate with GMEngine Oil Supple-

ment, P/N 1052367,or equivalent.
[~ Tighten:
Bolts to 124 in. lb. (14 N.m).
Balance Shaft 0RC6631
Removal
Tools Required: J 38834 Balance Shaft Bearing Service Kit

p...=,.~
J 26941 Rear Balance Shaft Bearing Remover
ES~ ~ Remove or Disconnect:
1. Bolt Q.
2. Drivengear (~).
DRC6617
3. Retainer bolts ®.
J 388~ °~
4. Retainer (~.
EsZ] ~ 5. Balance shaft (~ using a soft faced hammer.
E~ 6. Balance shaft rear bearing using J 38834 and J 26941. .

DRC6618
En(jine/eng 4-23
[~ inspect:
Balanceshaft front roller bearing and rear sleeve bearing

for damageor excessive wear. The bearings are serviced
as an assembly.Use the proper tools for properly servic-
ing the bearings.
e Balanceshaft drive and driven gears for nicks or burrs.

Replace gears that are damaged.
Front and rear bearing journal diameters. Replace the

balance shaft if the diameter exceedsthe specifications. DRC6629
Refer to Specifications in this section.
’~J 36996
Rear sleeve bearing journal clearance. Replace the bal- J 38
ance shaft if the clearance exceeds the specification. /
Refer to Specifications in this section.
installation
Tools Required" J 38834 Balance Shaft Bearing Service Kit

J 36996 BalanceShaft Installer
J 8092 Driver Handle
J 36660 Torque/Angle Meter
DRC6618
E~ Install or Connect:
1. Dip bearing in clean engineoil before installation.

EEl [~ 2. Balance shaft rear bearing using J 38834.
EEl 3. Balance shaft into block using J 36996 and J 8092.

J 8092
J 6996
a. Dip the front balance shaft bearing into clean engine oil
before assembly.
b. Retaining ring on balance shaft front bearing must be seated DRC6630
on case. 4
[~ 4. Install balance shaft bearing retainer (~) and bolts (~). 2
Tighten:
[~E] Balanceshaft retainer bolts (~) to 124 in. lb. (14 N.m).
[~ 5. Balance shaft driven gear (~ and bolt Q.
’I
[~ Tighten:
DRC6631
EEl Balanceshaft driven gear bolt Q to 15 ft. lb. (20 N.m)
plus an additional turn of 35 degreesusing J 36660.
i~ i~ Rotate balance shaft (~) by hand to make sure

there is clearance betweenthe balance shaft and retainer. If
balance shaft does not rotate freely, check to be sure
retaining ring on front bearing is seated in case.
4-24 Engme/eng
e Turn the camshaft with the balance shaft drive gear
temporarily installed. The timing mark on the drive gear
must be straight up.
o With the balance shaft drive gear removed, turn the

balance shaft so the timing mark on the driven ge~ir
points straight down.
6. Balanceshaft drive gear onto camshaft.

E~ important: Make sure the timing marks on the balance
shaft drive gear and driven gear aine up. DRC6632

Removal
Tool Required" J 5239 Guide Set

B Remove or Disconnect:
Before attempting to remove piston, refer to General

Engine Mechanicalsection in this manualfor cylinder bore ridge
reamer procedures.
1. Mark the cylinder numberson the tops of each piston. Mark

them from the front to the rear, with the engine in an upright
position and viewed from the front.
e The right bank is numbered1=3-5

e The left bank is numbered2-4-6
2. Checkthe connecting rod and cap for identification marks. If

reusing the connecting rods, mark the parts in the sameway as
istons.
~ important: Store the connecting rod and cap together as
mating parts, so they may be reassembled in the same wear
pattern and balance in which they were removed.
3.. Connectingrod nuts, cap and bearings.
important: If reusing bearings, keep bearings with their

original connecting rod and cap.
E.,~i.~le.g 4-25
4. Connecting rod and piston.
a. Attach J 5239 to the connecting rod bolts.

[~ b. Use the long guide rod J 5239 to push the connecting
rod and piston out of the bore.
Disassembly

piston and connecting rod disassembly.
Assembly
Refer to GeneramEngine Mechanical section in this manual for

piston and connecting rod assembly.
Bearing Selection
[~ important: Connecting rod bearings are of the precision
insert type and do not use shims for adjustment. DONOTFiLE
RODSOR ROD CAPS.
If clearances are excessive, install a newbearing. Service bear- DRC6619

ings are available in standardsize 0o001in. (0,0254 ram) and 0.002
in. (0,0508 ram) undersize for use with new and used standard
size crankshafts. For reconditioned crankshafts 0.010 in. (0,254
ram) and 0.020 in. (0,508 mm)undersize bearings are available.
Piston Selection
Measuringthe Piston
Checkthe used piston to cylinder bore clearance, as follows:
1. Cylinder bore diameter. Use a telescoping bore gauge,

located 2.5 in. (65 ram) below the top of the cylinder bore. DRC8507
[~] 2. Piston diameter. Measurethe skirt at a right angle to the

piston pin hole, 1.0 in. (25 ram) belowthe oil ring groove.
DRC6514
4-26 Engme/eng
ENe-~ Measurepiston diameter at 70 degrees F (20 degrees C).
3. Subtract the piston diameter from the cylinder bore diameter 1:o
4, Locate the piston-to-bore c;earance, refer to EngineSpecifica-

tions. Determine if the piston-to-bore clearance is within the
acceptable range.
Piston Ring End Gapand Fit
Refer to General Engine Mechanical section in this manual.

[~ Important:
The numberson the connecting rod and bearing cap must be on

the sameside wheninstalled in the cyainder bore. If a connecting
rod is ever transposedfrom one block or cylinder to another, new
connecting rod bearings should be fitted and the connecting rod
should be renumbered to correspond with the new cylinder
number.
Tools Required: J 5239 Connecting Rod Bolt Guide Set

J 8037 Ring Compressor
E3 Install or Connect:
1. Lubricate the cylinder walls lightly with engineoil.
2. Makesure the piston is installed in the matchingcylinder.
3. Connecting rod bearings.
a. Makesure the crankshaft bearings are the proper size.
b. Install the crankshaft bearings in the connecting rod and

connecting rod cap.
c. Lubricate the bearings with engine oil.

4. Piston and connecting rod into the proper bore.
a. With the connecting rod cap removed, install J 5239

onto the connecting rod bolts.
[~] b. Locate the piston ring end gaps. Lubricate the piston
and rings with engine oil. J 5239
[~ c. Without disturbing the ring end gap location, install J

8037 over the piston and compression rings.
d. The piston must be installed so that the notch in the

piston faces the front of the engine.
[~ e. PEacethe piston in its matching bore. The connecting
rod bearing tang slots must be on the side opposite the
camshaft. Using light blows with a hammerhandle, tap the
piston downinto its bore. At the sametime, from beneath the
engine, guide the connecting rod on to the crankpin with J
5239. Hold the ring compressoragainst the block until all rings
have entered the cylinder bore.
[~ f. RemoveJ 5239 from the connecting rod bolts°
[~ important: Each connecting rod and bearing cap should be DRC6619
marked,beginningat the front of the engine. Cylinders 1, 3, and 5 ENG}NELEFT ENGINE FRONT ENGINE RIGHT
are the right bank and 2, 4, and 6 are the left bank (whenviewed
from the front). The numberson the connecting rod and bearing
cap must be on the sameside wheninstaIRed in the cylinder bore.
If a connecting rod is ever transposed from one block or cylinder
to another, new connecting rod bearings should be fitted and the
i ’~ -=--- A, D
connecting rod shouUdbe numberedto correspond with the new A OIL RING SPACERGAP
(TANGIN HOLEOR SLOTWITHINARC)
cylinder number. 8 OIL RiNGRAILGAPS
C 2NO COMPRESSION RING GAP
0 TOP COMPRESSIONRING CAP
5. Connecting rod cap with crankshaft bearing.
6. Connecting rod bolt nuts. DRC6627
[~ Tighten:
o Connectingrod bolt nuts to 20 ft. lb. (27 N-m).

J 8037
e Connecting rod bolt nuts an additional 70 degrees using
J 36660.
[~ Measure:

connecting rod side clearance procedure. DRC6628
4=28 Eng,neleng
CrankshaftRear Oil Seal
P, emoval
Take care whenremovingthe rear crankshaft oil seal so

as not to damagethe crankshaft sealing surface.
F=...I
[+=~J Removeor Disconnect:
E4:~] hsert a screwdriver into the notches provided in the seal
retainer and pry the seal out.
DRC6858
Installation
"[bol Required: J 35621Crankshaft Rear Oil Seal Instatler

I-H-I
F_=~LL.LJ Install or Connect:
1. Lubricate the inner and outer diameter of the oil seaBwith

clean engine oil.
2. Install the oil seal on J 35621.

J 35621
3. Position J 35621 against the crankshaft. Thread the at- DRC6626
taching screws into the tapped holes in the crankshaft.
4. Tighten the screws securely with a screwdriver. This will

ensure that the seal is installed squarely over the crankshaft,
5. Turn the handle until it bottoms.
6. RemoveJ 35621.
C oankshaftReanrOil Seal Housing

DRC6657
Remevan
E~] ~ Remove or Disconnect:
1. Bolts and nuts.
2. Oil seal housing.
3. Gasket=
Gasketsurfaces on the block and seal retainer.
Eo~
........
g 4-29
installation
1. Newgasket to the block.
It is not necessary to use sealant to hold the gasket in

place.
2. Oil seal retainer.
3. Screws and nuts. DRC6657
[~ Tighten:
Screwsand nuts to 11 ft. lb. (15 N.m).
Crankshaft And Bearings

Removal
The crankshaft need not be removedfor replacement of the rear

oil seal or crankshaft bearings. Those proceduresare covered in
oth~=~arts of this section.
ITI
i=.t--! Irnportant: Checkthe crankshaft bearing caps for loca-
tion markings. Mark the caps if necessary. The caps must be
returned to their original locations during assembly.
1. Crankshaft bearing cap bolts.
2. Crankshaft bearing caps and lower crankshaft bearings.
3. Crankshaft from the cylinder block with extreme care, taking

care to avoid damageto crankshaft journals and thrust flange
surfaces.
4. Uppercrankshaft bearings.
Refer to General Engine Mechanical section in this manual

for cleaning, inspection, and measurements.
InstaUation
[~ Install or Connect:
1. ~,~er crankshaft bearing to the block.
Urnportant: if any undersized bearings are used, they

mustbe fitted to the proper journals.
2. Crankshaft.
3. Lower crankshaft bearings to the crankshaft bearing caps.
4-30 Engme/eng
Measure:

for crankshaft bearing clearance procedures.
4, Apply engine oil to the crankshaft bearings, Instalt crankshaft

be~ caps (except rear cap) and bolts to the block.
Tighten:
Crankshaftbearing cap bolts to 77 ft. lb. (105 N.m}.
5, Rear crankshaft bearing cap. Apply engine oil to the crankshaft

bearings°
6, Rear crankshaft bearing cap bolts.
Tighten:
Rear crankshaft bearing cap bolts to 124 in. lb. (14 N.m).
Measure:

for crankshaft end play procedure.
[~ Tighten:
Finally tighten rear crankshaftbearingcap bolts to 77 fto lb.

(105 N.m)
Cylinder Block
Disassembly
F--=I
DRC6623
E’~=..J Remove
or Disconnect:
1, Coolantdrain fittings.
2.. Camshaftand balance shaft cup plugs.
~_~3. Front oil gallery cup plugs.
~ 4. Port side oil galaery plugs.
~ 5= Rear oil ganlery plugs.

~=~ Clean: DRC6621
1. Sealing material from mating surfaces.
2r. Boil cylinder bnockin caustic solution.
o Flush with clean water or steam.
DRC6622
Engme/eng 4-31
3. Cylinder bores.
4. Threaded holes¯
5. Oil galleries and passages.
6. Scale deposits from coolant passages.
7. Spray or wipe cylinder bores and machined surfaces with

neoil.
~ Inspect:
1. All block core plugs for lack of fit or leakage.
2. Camshaftlifter bores for deep scratches and deposits¯
3. Cracksin the block

¯ Cylinder walls.
¯ Water jackets.
¯ Engine mount bosses.
¯ Crankshaft bearing webs.
¯ Crankshaft bearing bores and caps.
¯ All crankshaft bearing bores should be rounded and

uniform in inside diameter (I.D.} at all of the bearing
supports.
e The area where the crankshaft bearings contact the

crankshaft bearing bore should be smooth.
¯ If a crankshaft bearing cap is found to be damaged,

replace the cap and line bore the block.
[~ 4. Cylinder block head mountingsurface for flatness, using a
precision straight edge and feeler gauge.
a. Set the straight edgeon the sealing surface to be inspected.
b. Takethe feeler gaugeand at various locations, checkthe gap

betweenthe straight edge and the sealing surface.
c. If the gap is found to be greater than 0.004 in. (0,1016 mm)

within 5.984 in. (152 ram) at any sealing location, the block DRC6620
must be replaced.
4-32 Engme/eng
d. If the gap is found to be less than 0.004 in. (0,1016 mm)
within 5.984 in. (152 mm)at any seabing location and a cause
for leakage is suspected, then the minor irregularities maybe
carefully machinedfrom the block.
¯ Oil pan and intake manifold mountingsurfaces for nicks.

Minor irregularities maybe cleaned up with a flat file.
nder Bore
~ Inspect:
Cylinder boresfor scoringor other damage.Refer to Generz~!

EngineMechanicalsection in this manual.
Measure:
Cylinder bore taper and out-of-round. Refer to General Engine

Mechanicalsection in this manual.
nder Bore Reconditioning
~ Measure:
nder Block Assembly

1. Front oil gallery plugs. Coat pnug outside diameter with GM

Sealant, P/N 12346004,or equivalent.
~-] [~ ~ 2. Rear oil gallery plugs.
Tighten:
DRC6623
¯ Left rear plug to 15 ft. lb. (20 N.m).
¯ Right rear plug to 18 ft. lb. (25 N.m).
¯ Left side plug to 15 ft. lb. (20 N.m).
3. :Camshaft and balance shaft cup plugs to proper depth. Coat

bo~re inside diameter with GMSealant, P/N 12346004,or equiva-
lent.
[=~] important: Do not allow residue on camshaft bear-
ing or seizure mayresult. DRC6621
DRC6622
Engine/eng 4-33
Circulating PumpDescription
TheVoLvoPentacirculating pumpis manufacturedspecially for marineuse.
It is serviced only as an assembly.Donot replace with an automotive
circulating pump.
Inspection
1. Remove
alternator and powersteering belts.
2. Graspcirculating pumppulley and checkend and side play. Turn pulley to

checkfor drag.
3. Look for water leaking from indicator hole beneathpumpshaft behind

pulley. Replacepumpif play, drag, or leakageare evident.
Removaland Installation
1. Drain water from block and disconnectwater hose from circulating pump.
2. Remove
pulley. Remove
circulating pumpbolts, pumpand gaskets.
3. Usenewpumpto block gaskets and sealer. Install newpumpassembly

on cyFinderblock and tighten bolts as specified.
4. Install pulley. Install alternator andpowersteering be~ts, then adjust

tension.
5. Install hoseto circulating pump.
6. Lakeor tank test unit and checkfor leaks.
4-34 Engme/eng
Front Engine Mounts
Removal
LTJ 1. Removetwo lag screws (~ and washers from mounts.
2. Lift engine with a hoist capableof lifting at least 1500lb.

(680 kg) to allow removalof front mount and bracket.
~=~ 3. Removethree mount screws and lock washers ®. Note

sc.rew lengths and location.
25929
I~ Prior to disassembly of front mount assembly, mea-
sure distance and record measurement between large washer
and flat on upper mount bracket.
Disassembly
~ 1. Removethree nuts © and engine mount bracket @ from

mount bolt while holding bolt secure with socket (~.
~] 2. Removetwo fiat washers, one large ® and one smaller @.

Removelock washer ®, and engine mount bolt (D from mount.
25917
11980
11979
’®’® 11978
Reassembly
~]] 1. Place small washer(~) on mountbolt and insert bolt up through

mount.Install large washerand securewith nut (~). Tightento 60-75ft. Ibs.
(81-102Nora).
2. Install upper inner nut and place engine mountbracket on engine

mountbolt.
~ Measure distance between large washer and flat on upper mount

bracket. Adjust distance to recorded measurement.
11983
3. Install lock washerand top nut.Tightennut to 100-120ft. Ibs. (138-163
N®m).
Instalmation
[~ 1. Spray the engine mountscrew threads with Loctite ~ Primer N and

allow to air dry. Apply Volvo Penta TreadSealing AgentP/N 1161053-6to
the screws. Attach engine mountassemblyto engine with three screws and
washers(~). Tighten to 32-40ft. Ibs. (43-54N
[~ 2. Install washersand lag screws(~) and tighten securely.

11979
Height Adjustment
[~ 1. To changeengine height, tighten or loosen nuts (~) and ~)

required.
Z~2. Lift enginewith a hoist capableof lifting at least 1500lb. (68(}

kg). Position engineat desired height.
3. After setting mountposition, turn nut (~) up against undersideof engine

bracketand hold nut with a wrench.Tighten nut (~ to 100-120ft. Ibs.
(136-163 N°m).
25917
~Any large adjustments to engine height should be followed by a
checkof enginealignment. Failure to checkalignmentcould result in rapid
enginecoupler failure. SeeDrive Removaland Installation section of the
Sterndrivefrransom Bracket Service Manualfor alignment procedures.
21929
2953
4-36 Eng=ne/eng
High-Rise Exhaust Elbow RepJacernent
RemovaJ
E~ 1. Loosentwo dampssecuring upper hose to elbow, lubricate inside

of hose with a soapywater solution=
E~2oStarboard Elbow: Removecircuit breaker bracket 3 and set aside.

Remove four screws, flat washers, and lock washersmountinghigh-rise
elbow.
E~ [~ 3. Use a soft hammerto free elbow from manifold. Usea twisting 34719
motion to pull elbow from hose, Remove
and discard the elbow gasket.
Installation
1. Thoroughlyclean manifold gasket surface. Apply Volvo PentaGasket

Sealing Compound P/N 1161231-4to both sides of a newmanifold gasket
and place it on the exhaustmanifold.
EgZ] ~ 2. Lubricate the inside of the exhaust hose with a soapy water
solution. Insert the high-rise elbowinto the hosewith a twisting motion,and
pushit into hoseas far as it will go.
3472q
34718
34718
34717
Eng,ne/eng 4-37
[~ 3. Position elbow on manifold. Secure eUbowsand brackets
with four screws, flat washers, and lock washers. Tighten screws
to 12-18 ft. Ibs. (16-24 N.m). Starboard Elbow: Install circuit
breaker bracket @.
Z~ 4. Slide caamps®up onto hose and position them in the
two surface channels. Tighten clamps securemy.
Exhaust Hose and intermediate Pipe

Replacement
34720
Removaa
[~ 1. Loosen eight clamps that secure the upper @and lower @
exhaust hoses.
[~ 2. Lubricate inside of lower hose with a soapy water solu-
tion, and slide lower hose downonto exhaust Y-pipe.
3. Twist intermediate pipe out of upper hose. Lubricate

inside of upper hose if necessary to ease removal.
4. Slide upper hose off high-rise elbow. Slide lower hose off 32371
exhaust Y-pipe.
32374
32375
32363
Z~ Safety Related 4-38 Engine/~;ng
Installation
1. Lubricate inside diameter of 3.5 in. (8,89 cm) i.D. lower

hose with a soapy water solution. Slide it aJl the way onto the
exhaust Y-pipe.
I~] ~ The inside diameter of both the upper and lower

hoses has a step (~ 1=5 in. (3,81 cm) from one end. The stepped
end of the hose must face the intermediate pipe wheninstalled.
2. Slide hoseonto high-rise elbowuntil it seats.

32370
If hoseis not properly positioned, it will not completely
engagethe high-rise elbow or allow secure attachment.
~=j EEl/~ 3. Place four No. 68 clamps on upper hose. With a
twisting motion, insert intermediate pipe all the way into the
upper hose. Place four No. 64 clampson lower hose. Align lower’
end of pipe with exhaustY-pipe, then slide lower hoseup until it’s;
halfway onto the intermediate pipe. Position dampsin channels,
and tighter= clampssecurely.
Exhaust (Flapper) Valve Replacement 32366
Removal
1. Removethe intermediate exhaust pipe following the procedure

under Exhaust Hoseand Intermediate Pipe Replacement.
~’~ 2. Smidethe lower hose downfar enoughto expose the valve

pivot pin. Hold the valve while pulling out the pin, then lift out the.
vaJve.
EEl 3. Inspect the two rubber bushings inside the pipe. Replace:
them as necessary.
32367
32368
Engme/eng ~ Safety Related 4-39

Installation
1= If installing newrubberbushings,apply3M ® ScotchGrip Rubber

Adhesive
1300to outsideof tips, andinsert into insideof exhaust
pipe.
~2. Positionvalvewith longestlip pointingdown,andinsert into pipe.

Pushpivot pin throughbushings
andvalveuntil pin endis flush with outside
of pipe. Checkexhaustvalvefor freedomof movement.
[~lf valveis not positionedproperly(long lip down),it will restrict

exhaustflow andfail to preventwaterbackingup into engine.Boatperfor-
mance wouldbe adverselyaffected, andenginemaysuffer water damage. 32368
3. Install intermediatepipe following procedure

underExhaustHoseand
Pipe Replacement.
EngineCoupler Replacement
Removel
1. Remove
enginefrom boat.
If coupleris beingreplaceddueto couplerfailure (rubberhubof splined

hub), checkenginealignmentafter installing newcoupler.SeeDrive 32369
Removal andInstallation section of the Sterndrive/Transom Bracket
ServiceManual.
2. Disconnect
all wires, lines andconnectors
frombellhousing.
[~ ~] 3. Remove
screwssecuring belihousing cover, and slide cover
out.
20034
~9085
4-40 Engine/eng
ES~4. Pull drain hoseout of bellhousing.
E~ 5. Unscrewbolts and nuts retaining beflhousing. Disconnect ground

wires. Removepowersteering cooler bracket.
6 Remove
belihousing from engine bfock.
LT~’-j 7. Unscrewsix nuts securing coupler and removecoupler from studs.
8. Remove
old gasketfrombellhousingcover. Cleangasketsurfacethor-
oughly.
19842
Instalmatiort
ES~1. Install couplerand secure’with six Iocknuts. Usea suitable adaptor

andtighten to 40-45ft, Ibs. (54-61N=m).
E’~2. Install belihousing and attach powersteering cooler. Tighten nuts

and bolts to 32-40ft. Ibs. (43-54 N,m). Attach groundwires and tighten nuts
to 15-20ft. Ibs, (20-27Nom).
3. Pushdrain hoseinto belihousing.
4. Apply Vo0voPenta Gasket Sealing Compound P/N 116t 231-4 to both

6710
sides of a newbelihousinggasket and position it on cover.
~.~ 5. Cleansevenself-tapping screwswith a wire brush, install

bellhousing cover and screws.Tighten to 60-84in. Ibs. (7-9 N.m).
6. Connectall wires, Einesand connectorsto bellhousing.
7. Install enginein boat.
6712
8714
18996
4-41
Balance Shaft Driven Gear Bolt ......................... 15 ft. Ibs. (20 N.m)(Plus 35 degrees)
Balance Shaft Retainer Bolts ........................................ 124 in. Ibs. (14 N.m}
Bell Housing Cover Screws ....................................... 60-84 in. Ibs. (7-g N-m)
Bell Housing Nuts and Borers ..................................... 32-40 ft. Ibs. 43-54 N-m)
Block Drain Plug .................................................. 15 ft. lbs. (20 N-m)
Block Oil Gallery Plug, Left Rear ...................................... 15 ft. Ibs. (20 N.m)
Block Oil Gallery Pmug, Right Rear ..................................... 18 ft. Ibs. (25 N.m)
Bkock OiR Gallery Plug, Left Side Rear .................................. 15 ft. Ibs. (20 N.m)
Camshaft Retainer Bolt ............................................ 124 in. Ibs. {14 N.m}
Camshaft Sprocket Bolts ............................................ 21 ft. Ibs. (28 N.m)
Connecting Rod Nut .................................. 20 ft. Ubs. (27 N.m)(Plus 70 degrees)
Crankshaft Balancer Bolt ........................................... 74 ft. Ibs. (100 N.m)
Crankshaft Bearing Cap Bolt ........................................ 77 ft. Ibs. (105 N.rn)
Crankshaft Rear Oin Seal Housing Nut and Bolt ........................... 11 ft. Ibs. (15 N.m)
Cylinder HeadBolt
First Pass ...................................................... 22 ft. Ubs. (30 N.m)
SecondPass Torque Angle all Bolts in Sequence:

Short Length Bolt ................................................... 55 degrees
Medium Length Bolt ................................................. 65 degrees
Long Length Bolt ................................................... 75 degrees
Engine Coupler Nuts .......................................... 40-45 ft. Ibs. (54-61 N.m)
Engine Mount Screws ......................................... 32-40 ft. lbs. (43-54 N.m)
Exhaust Manifold Nuts ......................................... 20-26 ft. Ibs. (27-35 N-m)
Front Cover BoUt ................................................. 106 in. Ibs. (12 N.m)
Front Mount Nut

Lower ................................................... 60-75 ft. Ibs. (81-102N.m)
Upper ................................................ 100-120ft. Ibs. (136-163N.m)
4-42 Engme/eng
"[brqueSpecifications
High Rise Elbow Nuts .......................................... 12-18 ft. Ibs. (16-24 N.m}
intake Manifold Boats

First Pass ...................................................... 27 in. Ibs. (3 N.m)
Second Pass .................................................. 106 in. Ibs. (12 N.m)
Final Pass ..................................................... 11 ft. Ibs. (15 N=m)
Oil Pan
Nuts ......................................................... 17 ft. Ibs. (23 N.m)
Bolts ......................................................... 18 ft. Ibs, (25 N.m)
Studs in Engine Block ............................................. 18 ft. Ibs, (25 N.m)
Oil Pump Bolt ..................................................... 66 ft. Ibs. (90 N.m)
Oil Pump Cover Bolt .............................................. 106 in. nbs. (12 N.m}
Spark Plugs
Cylinder Head (New) .............................................. 22 ft. Ibs. (30 N.m}
Cylinder Head (All Subsequent Installation} ............................ 15 ft. Ibs. (20 N.m}
Valve Lifter Guide Retainer Bolt ....................................... 12 ft. Ibs. (16 N.m)
Valve Rocker Arm Cover Bolts ....................................... 106 in. Ibs. (12 N.m}
Valve Rocker Arm Nut .............................................. 20 ft. Rbs. (27 N.m}
W~lve Rocker Arm Stud ............................................. 35 ft. nbs. (47 N.m}
E,~,,,,e;oog 4-43
Type ............................................................. 90 Degree V6

Dispbacement ...................................................... 4.3L (262 CID}
Bore ......................................................... 4.00 in. (101,6 ram}
Stroke ....................................................... 3.480 in. (88,39 ram}
Compression Ratio ......................................................... 9.2:1
Firing Order .......................................................... 1-6-5-4-3-2
OUCapacity
Without Filter Change ............................................ 4 Qts=(3,75 Litres)
With Filter Change Add ........................................ 0.42 Qts. (0,398 Litres)
OiJ Pressure (Minimum Hot) .......................... 6.0 PSm(41,4 kPa) at 1,000 engine RPM
18.0 PSi (24,1 kPa) at 2,000 engine RPM
24.0 PSI (165,5 kPa) at 4,000 engine RPM
Oil Fi|ter System .......................................................... Full Flow

OH Pump Type ......................................................... Gear Driven
Diameter .................................... 4.0007 -4.0017 in. (101,618 - 101,643 mm)

Out-of-Round ........................................... 0.002 in. (0,0508 ram) MAX.
Taper .................................................. 0.001 in. (0,0254 ram) MAX.
Piston Bore Clearance ................................... 0.0024 in. (0,06096 ram} MAX.
Piston CompressionRing
Groove Clearance ........................................... 0.0042 in= (0,10668 ram)
Gap ................................................... 0.035 in. (0,889 ram) MAX.
Piston Oil Ring

Groove Clearance ........................................ 0.008 in. (0,2032 ram) MAX.
Gap ........................................................ 0.065 in. (1,651 ram)
4-44 Eng,ne/eng
Engine Block Clearance

Tolerance ............................................... 0.010 in. (0,254 ram) MAX.
Diameter ....................................... 0.927 - 0.926 in. (23,545 - 23,548 ram)

Clearance in Piston ....................................... 0.001 in. (0,0254 ram) MAX.
Fit In Connecting Rod ................ 0.0008 - 0.0016 in. (0,02032 - 0,04064ram) Interference
Surface Flatness .......................................... 0.010 in. (0,254 ram) MAX.
Surface Flatness ......................................... 0.004 in. (0,1016 ram) MAX.
Crankshaft Journal
Diameter #1 ................................... 2.4488 - 2.4495 in. (62,199 - 62,217 mm)
Diameter #2, #3 ............................... 2.4485 - 2.4494 in. (62,192 - 62,215 ram)
Diameter #4 ................................... 2.4480 - 2.4489 in. (62,180 - 62,202 ram)
Taper .................................................. 0.001 in. (0,0254 ram) MAX.
Out-of-Round .......................................... 0.0010 in. (0,0254 ram) MAX.
Crankshaft Bearing Clearance

Bearing #1 .................................... 0.0010 - 0.0015 in. (0,0254 o 0,0381 ram)
Bearings #2, #3 ................................ 0.0010 - 0.0025 in. (0,0254 - 0,0635 ram)
Bearing #4 .................................... 0.0025 - 0.0035 in. (0,0635 - 0,0889 ram)
Crankshaft End Play ................................. 0.002 - 0.008 in. (0,0508 - 0,2032 ram)
Connecting Rod Journal

Diameter ..................................... 2.2487- 2.2497in. (57,11-7 - 57,142 ram)
Taper .................................................. 0.001 in. (0,0254 ram) MAX.
Out-of-Round ........................................... 0.001 in. (0,0254 ram) MAX.
Rod Bearing Clearance ........................... 0.0010 - 0.0030 in. (0,0254 - 0,0762 ram)
Rod Side Clearance ............................... 0.006 - 0.017 in. (0,1524 - 0,4318 ram)
Journal Diaraeter ................................. 1.8677 - 1.8697 in. (47,440 - 47,490 mra)

End Pnay .......................................... 0.001 - 0.009 in. (0,0254 - 0,2286 mra)
Lobe Lift ................................................... - 0.002 in. (--- 0,051 ram)
intake ..................................................... 0.2763 in. (0,7180 mm)
Exhaust .................................................... 0.2855 in. (0,7252 mm)
Front Bearing Journal Diameter .................... 2.1648 - 2.1654 in. (55,985 - 55,001 mm)
Rear Bearing Journal Diameter ..................... 1.4994 - 1.500 in. (38,084 - 38,100 mm)
Rear Bearing Journal Clearance .................... 0.001 - 0.0036 in. (0,0254 - 0,09144mra)
Valve Lifter ...................................................... Hydraulic Roller

Valve Rocker Arm Ratio ..................................................... 1.50:1
Valve Lash Net Lash ................................................ No Adjustment
Face Angle ........................................................... 45 degree
Seat Angle ........................................................... 46 degree
Seat Runout ............................................ 0.002 in. (0,0508 mm)MAX.
Seat Width
Intake ............................................ 0.040 - 0.065 in. (1,016 - 1,651 mm)
Exhaust .......................................... 0.065 - 0.098 in. (1,651 - 2,489 ram)
Stem Clearance
intake ................................... High Limit Production + 0.001 in. (0,0257 mra)
Exhaust ................................. High Limit Production + 0.002 in. (0,0508 rata)
Valve Spring
Free Length ...................................................... 2.03 in. (52 tara)
Installed Height .................................... 1.690 - 1.710 in. (42,92 -43,43 rata)
Spring Pressure
Closed .................................... 76 - 84 lb. at 1.70 in. (338 - 374N at 43 tara)
Open ................................... 832 - 187 - 203 lb. at 1.27 in. (903 N at 32 mm)
ValveLift
intake ....................................................... 0.414 in. (10,51 ram)
Exhaust ..................................................... 0.428 in. (10,87 ram)
4-46 Engme/eng
GM Special Tools ~_~~
J 3049 J 5239 J 5590

DRC6596 DRC6597 DRC6598
J 5825-A -5-7 j 8001 J 8037

DRC6599 DRC6600 DRC6601
E~ Pliers, Valve Lifter Remover
E2~ ConnectingRod Bolt Guide Set
E3~ CrankshaftSprocketinstaller
~ Crankshaft Sprocket Remover
~ Dial indicator Set

J 8062
[~ Piston Ring Compressor DRC6602
Valve Spring Compressor
[8~ Driver Handle
J 8092
DRC6603
E rlgme/eng 4-47
Girl Special Tools
J 9290-1
J 21882
DRC6604 DRC6605 DRC6606
J 35621 5~ J 36660 J 36996

DRC6607 DRC6608 DRC6609
Hydraulic Valve Lifter Remover
Oil Suction Pipe Installer
Straight Edge
Rear Main Seal Installer J 38834

Torque/Angle Meter
BalanceShaft installer DRC6610
Balance Shaft Bearing Service Kit
Harmonic Balancer Remover/Instaler
8-7 J 39046 DRC6611
4-48 Engme/eno
Section 5
5.0GL and Gi
5.7GS and GSi
Table of Contents
Accessories ............................... 5=6 Front Mounts ............................. 5-39

Crankshaft GeneramDescription ........................ 5-2
And Bearings .......................... 5-31 Special Tools ............................. 5-54
Balancer .............................. 5-17 intake Manitold ............................. 5=6
Rear Oim Seal ........................... 5-30 intermediate Pipe Replacement.............. 5=41
Rear Oil Seal Housing ................... 5-31 Oil Filter ................................. 5-20
Camshaft ................................ 5-25 Oil Pan .................................. 5-18
Circulating Pump.......................... 5-38 Oil Pump................................. 5-2(}
Cleaning .................................. 5-4 Oil Seal, Rear, Crankshaft ................... 5-3G
Cylinder Block ............................ 5-35 Oil Seal Housing, Rear, Crankshaft ........... 5-31
Cylinder Head ............................ 5-14 PCV System .............................. 5-45
Engine Pistons and Connecting Rods ............... 5-27
Coupler Replacement.................... 5-43 Rocker Arm Cover ......................... 5-10
Draining ................................ 5-6 Rocker Arm Stud Replacement.............. 5-15
Lubrication ............................. 5-4 Specifications
Exhaust Engine ................................ 5=48
High-Rise Elbow Replacement............ 5-40 Torque ................................ 5=48
Hose Replacement ...................... 5-41 Timing Chaiin and Sprockets ................ 5-24
(Flapper) Valve Replacement.............. 5-42 Tools and Shop Equipment .................. 5=6
Manifold ................................ 5-7 Valve Train ............................... 5-11
Front Cover .............................. 5-23
Safety Warnings
Before workingon any part of the engine, read the section called Safety
Alwaysuse the correct fastener in the proper location. Whenyou replace

a fastener, use ONLY the exact part numberfor that application. Thetext
will call out those fasteners that requre replacementafter removal.The
text will also cal~ out the fastenersthat require thread rockersor thread
sealant.
UNLESSOTHERWISE SPECiFiED, do not use supplement coatings

(paint, grease,or other corrosion inhibitors) on threadedfasteners
fastener joint interfaces. Generally, suchcoatings adverselyaffect the
fastener torque and the joint clampingforce, and maydamage the fas-
tener.
Whenyou install fasteners, use the correct tighter~ing sequenceand

tightening specifications. Followingthese instructions will help youavoid
damageto parts and systems.
5-1
Engine/eng
General Description
Cylinder Block
The engine bnock is madeof cast iron and has eight cylinders
arranged in a "V" shape with four cyUinders in each bank. Wsa
one piece casting with the cylinders encircled by coolant jackets.
Cyainder Head
The cylinder heads are cast iron and have powderedmetal valve
guides and valve seats pressed into the intake and exhaust ports.
The spark plugs are located between the intake and exhaust
ports.
Camshaft
A steel camshaft is supported by five bearings pressed into the

engine block. The camshaft sprocket, mountedto the front of the
camshaft is driven by the crankshaft sprocket through a camshaft
timing chain. Motion from the camshaft is transmitted to the
valves by hydraulic roiaer vamvelifters, vamvepush rods, and
ball-pivot type rocker arms.
Crankshaft
Thecrankshaft is madeof cast nodular iron. It is supportedby five

crankshaft bearings that are retained by crankshaft bearing caps
which are machined with the bJock for proper aJignment and
clearances. Light duty 5.7L engines have two bolts per cap. Heavy
duty 5.7L engines have four bolts per cap on caps two, three, and
four. Thenumberfive crankshaft bearing at the rear of the engine
is the end thrust bearing. Four connecting rod journals (two rods
per journal) are spaced90 degrees apart.
5=2 Engine/eng
The pistons are cast aluminumthat use two compression rings

and one oil control ring assembly, The piston is a low-friction,
lightweight design with a flat top and barrel-shaped skirt. The
piston pins are chromiumsteel. They have a floating fit in the
piston and are retained by a press fit in the connecting rod
assembly. The connecting rods are madeout of either forged
powderedmetal or forged steel. They are machinedwith the rod
cap installed for proper clearances and alignment.
Lubrication
The gear-type oil pumpis driven through an extension driveshaft.

The extension driveshaft is driven by the distributor which is gear
driven by the camshaft. The oil is drawnfrom the oil pan through
a pickup screen and tube. Pressurized oil is delivered through
internal passagesto lubricate camshaft and crankshaft bearings
and to provide valve lash control in the hydraulic valve lifters. Oil
is metered from the valve lifters through the valve push rods to
lubricate the valve rocker armsand ball pivots. Oil returning to the
oil pan from the cylinder heads and the front camshaft bearing,
Lubricates the camshaft timing chain and crankshaft and cam-
shaft sprockets.
V~alveTrain
TIhe valve train is a ball pivot type. Motionis transmitted from the
camshaftthrough hydraulic roller valve lifter,,; and tubular valve
push rods to the valve rocker arms. The valw; rocker arm pivots
on a ball to openthe valve. Thehydraulic roller valve lifters keep
all parts of the valve train in constant contact.
The valve rocker armball is retained on the valve rocker arm stud
with a locking nut. Thevalve rocker armstuds are pressedinto the
cylinder head.
intake Manifold
The intake manifold is a single piece design. It supports either a

thrott!e bodyor multiple iniectors to meter and distribute fuel to
each engine cylinder.
Engtne/eng 5-3
Cleaning
Before cleaning the engine, remove the engine accessories to
provide better access to the engine’s exterior surfaces. After
removingthe throttle body, distributor, etc., cover the openings
with tape to prevent the entry of cooaant, solvent, or dirt.
Methodsused to cnean the engine will dependon what equipment

is available. Steamcleaning, pressure washing, or solvent clean-
ing are someacceptable methods. ARIowthe engine to dry before
beginning the work.
It is important that the engine be as clean as possible to prevent

dirt from entering critical areas during disassembly.
EngineLubrication
"~ Full pressure lubrication, through a full-flow oil filter
is supplied by a gear-type oil pump. Oil is drawn up through the
oi~ pumpscreen and passesthrough the pumpto the oil fieter. The
oil filter is a ruin-flow paper elementunit with an anti-drain back
valve. An oil filter bypass vaUveis used to ensure adequateoil
supply, in the event the filter becomesplugged or develops
excessive pressure drop.
Filtered oil flows into the maingallery and then to the camshaft,
rear bearing, and crankshaft bearings. Thevalve ~ifter oil gallery
supplies oil to the valve lifters. Oil flows from the valve lifters
through the hollow valve push rods to the valve rocker arms. Oil
drains back to the crankcase through oil drain holes in the
cylinder head. The camshaft timing chain is drip fed from the
front camshaftbearing. The pistons and piston pins are lubricated
by oil spmash.
5-4 Engine/eng
o@
; s,-cT,oN
c-c
I
Front View Rear View
__ "---’-- i
Side View
Engmne/eng
5-5
Tools and Shop Equipment
A clean, well lit work area should be available. Other necessary

equipment includes: a suitable parts cleaning tank, compressed
adequateset of hand tools.
An approvedengine repair stand will help prevent personal injury

or damageto engine components.
Special tools are illustrated throughout this section and listed at

its end. Thesetools (or their equivalents) are specially designed
quickly and safely accomplish the operations for which they are
intended. The use of these tools will also minimize possible
damageto engine components.
Someprecision measuring tools are required for inspection of

certain critical components.Torquewrencheswill be necessaryto
correctly tighten various fasteners. Thosefasteners will be called
out within this section.
Accessories
This manuaRassumes that the engine accessories have been
removed. These accessories may include one or more of the
following:
o Power Steering Pump

o Alternator
e Distributor
o Water Supply Pump
o Accessory Brackets and Electrical Wiring
o Starter Motor
It is beyondthe scopeof this section to detail the manydifferent

accessory installations. Refer to the proper Service Manualfor
this information. Diagrams of vacuumhose routing, wiring har-
ness routing, accessory drive belt layout, etc., should be made
before removing these components.
Draining The Engine

Follow the procedures in Section 1, General information of this
manualto drain crankcase engine oil and the cooling system.
ExhaustManifold
Removal
1. Drain waterfrom exhaustmanifolds.
2. DisconnectwaterhosefrommanifoSd.
3. Loosenupperexhausthoseclamps,then removehigh rise elbow.
4. Remove
manifoldattaching nuts and washers.Discardnuts.
inspection
1. Inspectfor cracks.
E~2. To pressurecheckmanifold, fabricate a plate (~) as shown,and

newelbowgasket(~) to seal waterpassage in manifold.Be sure to apply
sealerto gasket.Install rubberdrain capsto manifoldandsecurewith
clamps. Attach a GearcasePressureTester © (such as StevensCompany
S-34)to the waterinlet hose.A bushingcanbe madeto securepressure
tester to hose.Withthe pressuretester attachedto the manifold,submerge
manifoldin water. Pressurizethe manifoldto 10-15PSI(22-25kPa) and
checkfor leaks. Manifoldshouldnot leak aroundclampsandplate. If so,
retightenclampsor resealplate. Nodropin pressureshouldbe realized.
Installation
r~ 1. Cleanmatingsurfaces on manifold and head. Install newexhaust

gasket, then install manifoldandsecurewith newIocknutsandwashers.
Tightennuts @to 20-26ft. Ibs. (27-35N,m).
2. Install a newgasketandhighrise elbowto manifold.Tightenbolts to

12-18ft. Ibs. (16-24N,m).
3. Install exhausthoseandsecurewith clamps.
4. Connect
waterhose.Install andtighten drain petcocks.
L~ 5. Start engineandcheckfor fuel leaks.
Englne/eng
5-7
intakeIVlanifoid
Removal
~ 1. Drain coolant from manifoldsand both sides of block.
2. Disconnect:
a. Battery cables from battery.
b. Coolanthosesat thermostathousing.
c. Throttle cable fromcarburetorandanchorblock.
d. Crankcase
ventilation hosefrom rocker armcovers(both
sides).
e. Wire at temperaturegaugesenderunit andenginewiring

harnessfromalternator.
f. Distributor hightensionandignition primaryleadsfromcoil.
3. Remove:
a. Distributor cap andmarkthe position of the rotor on the

housing. Scribe a line on distributor housingand intake
manifold for reassemblyin the sameposition. Remove
the distributor.
b. Alternator andalternator mountingbracketfromengine.
c. Carburetorfuel line fromcarburetorandfuel pump

or fuel
lines fromthrottle bodyandfuel pump/vaporseparator.
d. Oil pressuresendingunit.
e. Manifoldattachingbolts andsolenoidbracket.Lift manifold

fromengine.Discardfront andrear seals andgaskets.
If manifoldis to be replaced,transfer: carburetoror throttle

body and ECMbracket, thermostat and housing (use new
gasket),throttle cableanchorblockassembly, distributor
clampandtemperaturesendingunit. Transferadditional
hardwareas required.
5-8
Engme/eng
® Old pieces of gasket or RTVfrom the gasket surfaces.
¯ Excessive carbon build-up in the intake passagesof the
intake manifold.
o Scale and deposits from the coolant passages of the
intake manifold.
Instaffation
[~] Important: Do NOTreuse intake manifold gaskets.
DRC6591
E3 nnstall or Connect:
1. Sealant to the intake manifold gasket, cylinder head side.
Care must be used to apply the correct amountof sealanl;

onto the gasket. Applying excessive amounts of sealant may
prohibit the intake gasket from sealing properly.
2. Gasketsonto the cylinder head.
a. Use gasket Iocator pins to properly seat gasket on the

DRC6592
cylinder head.
[~] ~ b. Apply a 0.499 in. (13 ram) bead of GMSealant,P/N

12346141,or equivalent to the front and rear block sealant
areas.
c. Extend the sealer bead 0.157 in. (4 ram) onto each

gasket. 4 0 rnrn
0.157IN }
3. GMThreadLocking Sealant, P/N 12345382,or equivalent to the

threads of the eight Jower intake mounting bolts.
4. Lower intake manifold onto engine block. DRCb"59g
5. Lowerintake manifold bolts. 8 7

4 ’1
Tighten:
[=6~ Bolts in three steps, using the following sequence.
a. The first pass to 27 in. lb. (3 N.m). Snugall bolts

minimize shifting of the intake.
b. Thesecondpass to 106 in. Kb. (12 N.m).

DRC6593
c. Final passto 11 ft. Ib. (15 Nora).
EngIne/eng 5-9
d. Distributor with rotor and aligned exactly as markedduring
removal.
~lf engine was cranked while distributor was out, complete ignition
timing proceduremustbe followed. Seethe appropriate Ignition Circuit in
Electrical/Ignition SystemsService Manual.
e. Alternator with mounti ng bracket.
Distributor cap and high tension leads. Seethe General

Informationsection in Electrical/Ignition Service Manualfor
correct firing order and spark plug wire routing.
g. Oil pressuresendingunit.
6. Connect:
a. AHelectrical connections. Apply Black NeopreneDip, on

all exposedconnections.
b. Fuel lines to throttle body and fuel pump/vapor

separator.
c. Throttle cable.
d. All water hoses, and ciose all drain petcocks.
e. Both crankcaseventilation hoses.
f. Battery cables.
9. Start engine. Checkignition timing. Checkfor leaks.
Rocker Arm Cover

Removal
1. Valverocker armcover bolts.
2. Valverocker armcover.
3. Gasket.
DRC6647
5-10 Engme/eng
Cnean:
¯ Parts in solvent. Removeall snudgeand varnish.

¯ Old gaskets from the gasket surfaces.
[~ inspect:
¯ Gasket flanges for bending or damage.

¯ Rubber grommetsand parts for deterioration.
installation
E~ 53 Install.or Connect:
1. Newgasket=
2. Valve rocker arm cover.
3 Valve rocker arm cover bolts.

[~ Tighten: bolts to:
106 in= Lb. (12 N-m)
ValveTrain
Removal
important: Store all reusable componentsin an exact

order, so they can be reassembnedin the samewear pattern
location from which they were removed.Mark the front end c:f
the retainer.
E3 Remove or Disconnect:
Tools Required:J 3049-AValve Lifter Removal(Plier Type)

J 9290-01 Valve Lifter Removal (Slide Hammer /
Type)
Every effort should be madeto ensure that the mating parts are
installed in their original nocations during assembly. A simple
valve train componentorganizer rack can be madefrom a piece of
wood.
[=~ 1. Valve rocker arm nuts, balls, and valve rocker arms.
E’~ 2. Valve push rods.
DRCG648
DRC6850
[~] 3. Valve lifter guide retainer and bolts.
E~] 4. Valve lifter guides.
5. Valvelifters.
Removethe valve lifters one at a time using a magnet.Place the

valve lifters in the organizer rack, or tag themin a way to ensure
they can be returned to the valve lifter bore from which they were
removed.
[~] ~ Somevalve lifters may be stuck in their bores due to DRC~49
gum or varnish deposits. These valve lifters can be removed
using either J 3049-Aor J 9290-01.
[~ Clean:
¯ Parts in solvent. Blow dry with compressedair.

o Makesure the oil passagesin the valve push rods are
clear.
[~ |nspect:
o Valve rocker arms and balls at their mating surfaces. DRC6651

These surfaces should be smooth and free from scoring
or other damage.
¯ Valve rocker arm areas that contact the valve stems and
the sockets that contact the valve pushrods. Theseareas
should be smooth and free of damageand wear.
¯ Valve rocker arm nuts or bolts.
~ J9290-1
/
["~ Important:
All enginesuse prevaiUingtorque nuts. At least 55 in. lb. (6,2 N.m)

of torque should be required to thread the nuts onto the valve DRC6586
rocker armstuds, if not, it is possible that the nut(s) could backoff
during engine operation causing a loss of lash and create valve
train noise.
5-12 Engine/er~g
Installation
important: Replace all valve roller lifters, changethe

engine oil and filter, and add GMEngine Oil Supplement,P/N
1052367, or equivalent to the engine oil whenever a new
camshaftis installed.
Lubricate the valve lifter bodies and roller with GM

Engine Oil Supplement, P/N 1052387, or equivalent.
3 Install or Connect:
I~ Valve lifters in samelocation from which they were removed.
EI~ 2. Valve lifter guides, valve lifter guide retainer and valve
lifter guideretainer bolts.
Vamvelifter guide retainer must contact a01 valve lifter

guides. If valve lifter guide retainer is bent it mustbe replaced.
Tighten:
bolts to 18 ft. lb. (25 N.m).
3. Coat valve rocker armand rocker arm ball bearing surfaces with
prelube, GMEngine Oil Supplement,P/N 1052367,or equivalent:,
when installing. Keep these componentsand valve push rods in
samesequenceto ensure their return to the originaB position from
which they were removed.
=
E~ 4. Valve push rods. Makesure valve push rods seat in valw,
lifter sockets.
~ 5. Valve rocker arms, balls, and nuts.
Valve Adjustment
DRC6650
~] Adjust: Valve rocker arm nuts until all lash is eliminated.
1. Turn crankshaft until cast arrow on crankshaft balancer hub i,¢

in 12 o’clock position and number1 cylinder is in firing position
(top dead center).
¯ Watchnumber1 cylinder valves as crankshaft balance~"

=
hub arrow approaches 12 o’clock position, if a valw,
movesas arrow movesto position, engine assemblyis in
number6 cylinder firing position. Crankshaft must then
be turned one more time to reach number 1 cylindefr
firing position. 0RC6648
Eng,ne/eng 5-13
2. With engine assembly in number1 cylinder firing position,
following valves can be adjusted:
¯ Exhaust1, 3, 4, 8
¯ intake 1, 2, 5, 7
3. E}ackoff valve rocker armnut until lash is felt in valve push

rod. Thentighten valve rocker armnut until all lash is removed.
Zero lash can be felt by moving valve push rod up and down
between thumb and forefinger until there is no more movement.
4. Whenall free play has been removed,tighten valve rocker arm DRC6673
nut one additional turn (360 degrees).
5. Turn crankshaft one revolution until hub arrow is again at 12

o’cnock position. This is number6 cylinder firing position. Follow-
ing valves can now be adjusted"
o Exhaust2, 5, 6, 7
¯ intake 3, 4, 6, 8
Cylinder Head
nder Head Removal
~ Removeor Disconnect:
1. Spark plugs,
2. Cylinder head bolts.
3. Cylinder heads.
4. Headgaskets.
i~ Important: Use care when handling the cylinder heads, to
prevent damageto the gasket sealing surfaces. DRC6595
nder Head Disassembly

J 8062
Tool Required: J 8062 Valve Spring Compressor
~ 1. Valve keys. Compressthe valve springs with J 8082.

Removethe valve keys and tool J 8062.
5-14 Engine/eng
~ 2. Caps and springs.
3. Valve stem oil seals, valves, and components.Place them in a

rack so they can be returned to their original position at assembly.
Cleaning, Inspection, and Measurement
Refer to GeneralEngineMechanicalsection in this manual.
Rocker Arm Stud Replacement
Tools Required: J 5802-01 Valve Rocker Arm Stud Removal DRC6664

J 5715 Reamer0.003 in. (0,0762 mm)oversize)
J 6036 Reamer0.013 in. (0,3302 mm)oversize)
J 6880 Valve Rocker Arm Stud Installation
Valve rocker arm studs that have damagedthreads or are loose in

cylinder heads should be replaced. Newstuds are available in
0°003 in. (0,0762 mm)and 0.013 in. (0,3302 mm)oversize.
r47 1. Place J 5802..01 over the stud to be removed.Install a nut
and flat washer. Removethe stud by turning the nut.
~] 2. Reamthe hole to the proper size for the replacement

DRC6665
oversize stud. UseJ 5715for 0.003 in. (0,0762 mm)oversize studs,
J 6036 for 0.013 in. I0,3302 mm)oversize studs.
3. Coat lower end (press-fit area} of stud with hypoid axle

lubricant. Drive the stud into place with a hammerand J 6880.
Stud is installed to proper depth whenthe tool bottoms on the
cyllinder head.
Cylinder Head Assembly
Tools Required" J 8062 Valve Spring Compressor

J 6880
E~ Instag or Connect:
1. Valves.
¯ Lubricate the valve stems with clean engine oil.

¯ insert the valves into their proper location.
2. Oil seals. Install the oil seals over the valve stemsand seat them
against the cylinder head.
3. Valve springs.
DRC6666
Eng,ne/eng 5-15
4. Caps.
J 8062
a. Compressthe vane spring, using J 8062. Compressthe
spring enoughso the Uowervalve stem grooves can be clearly
seen.
b. Apply a smaln amountof grease to the area of the upper

vane stem groove. Assemble the two valve keys using the
grease to hold the keys in place. Makesure the keys seat
properly in the valve stem grooves.
c. Release the compressortool. Makesure the valve keys stay DRC6663

in place.
d. Repeat the preceding steps on the remaining valves.

[~ [~] Measure: Valve spring installed height of each
valve spring as follows"
1. Use a narrow, thin scale. A cut awayscale @maybe helpful.
2. Measurefrom the cylinder head spring seat to the top of the

cap.
DRC6667
Cy0inderHeadinstallation
Tool Required: J 36660 Torque/Angle Meter

1~ C|ean:
® Gasket surfaces on block and cylinder head.
Bnstall or Connect:
1. Headgasket onto engine block.
2. PLacethe gasket in position over the cylinder head dowel pins DRC6668
aligning the gasket locating mark facing up.
3. Cylinder headonto bBock. Carefully guide the cylinder headinto

place over the dowel pins and head gasket.
5= ~ 6 Engme/eng
4. Coat threads of cylinder head bolts with GMSealing Com-
pound, P/N 12346004,or equivalent.
5. ~der head boJts.

133)|
L~J Tighten:
[~ 1. in sequencefirst pass to 22 ft. lb. (30 N-m).
E~] 2. in sequencefinal pass using J 36660 to"
Short bolts -{3,4,7,8,11,12,15,16) 55 degrees.

Mediumbolts - (14,17) 65 degrees.
Longbolts - (1,2,5,6,9,10,13) 75 degrees.
Crankshaft Balancer
RemovaJ
16 12 8 4 3 7 11 15
ToolRequired: J 39.046 Crankshaft Balancer Remover
The inertial weight section of the crankshaft balancer is DRC6672

assembledto the hub with a rubber sleeve. The removal proce-
dures must be followed (with the proper tools) or movement
the inertial weight section of the hub witi destroy the tuning of the
crankshaft balancer and the engine timing reference.
J 35’(}46
1. Crankshaft balancer bolt and washer. \

D~ 2. Crankshaft balancer using J 39046.
3. Crankshaftkey, (if necessary).

DRC6671
~==’~ Inspect:
Crankshaft balancer weight for signs of shifting on the hub.

Replace as needed.. The area of the crankshaft hub shaft that
contacts the front crankshaft seal for roughnessor nicks. Repnace
the balancer if this condition exists. If balancer is replaced, new
balance weights of the samesize must be installed on the new
balancer in the samelocation as the old baaancer.
|nstallatien
Tool Required: J 39046 Crankshaft Balancer Installer

E~ install or Connect:
J 39046
The inertial weight section of the crankshaft batancer is \\

assembledto the hub with a rubber type material. The correct
installation procedures(with the proper tool) mustbe followed
movementof the inertial weight section of the hub will destroy
the tuning of the crankshaft balancer.
DRC$671
1. Use a small amountof RTVsealant to seal the ba[ancer keyway
to crankshaftjoint.
[~ 2. Crankshaft balancer hub, until completeKy seated against
the crankshaft position sensor reluctor ring using J 39046.
3= Removetool J 39046.
4. Bolt and washerinto front of crankshaft.
Tighten: bolt to specifications:
74 ft. lb. (100 N-m).
Oil Pan =f
Removal
1. Oil pan bolts, nuts, and studs.

DRC6637
2. Oil pan reinforcements.
3. Oil pan.
4. Oil pan gasket.
Clean:
o Parts in solvent. Removeall sludge and varnish.

¯ Old gaskets and RTVsealant from the gasket surfaces.
5-1 8 Engme/eng
inspect:
® Gasket flanges for bending or damage.

¯ Oil pan for damageor cracks.
¯ Drain plug threads for stripping.
Installation
E~ Install or Connect:
E3-] I~ 1. Apply a small amount of GMSealer, P/N 12346141,

DRC6639
or equivalent, to engine front cover and engine block junction,
and to crankshaft rear oil seal housing and engine block junction.
Apply sealer 1.0 in. (25 mm)in either direction of radius cavity %
junctions.
2. Oil pan gasket, oil pan and reinforcements.
3. Oil pan nuts, bolts and studs.

~ Tighten:
25.4 mm
(1,OOIN.}
Cornerbolts or stud, and nuts to 15 ft. lb. (20 N.m).
DRC6640
Remainderof bolts and studs to 106 in. lb. (12 N.m).
4. Organ drain plug and gasket.

Tighten:
Oil pan drain plug to 18 ft. lb. (25 N.m).
Engme/eng 5-1 9
OUFilter
Removal
[~ ~[~ Remove or Disconnect:
1. Oil filter,
2. Oil filter adapter bolts and washers.
3. Oil filter adapterand oil filter adaptergasket.

[~ |nspect:
® Oil filter adapter bypassvalve and spring for operation.

¯ For cracked or broken bypass valve.
installation
Oil filter adapter and bypassvalve must be replaced as a

unit.
[~ ~] Install or Connect:
DRC6638
1. Oil filter adapterandoit filter adaptergasket.
2. Oil filter adapter bolts and washers.
Tighten:
Oil filter adapterbolts to 20 ft° lb. (26 N.m).
3. Oil filter.
Tighten:
Oil filter to 12 ft. lb. (16 N.m).
Oil Pump
Removal
[] B Remove or Disconnect:
1. Crankshaftoil deflector nuts.
2. Crankshaftoil deflector. DRC6654
5-20 Engme/eng
3. Bolt attaching oil pumpto rear crankshaft bearing cap.
4. Oil pump,retainer, and driveshaft from rear crankshaft bearing
Disassemble:
1. Driveshaft ~ and retainer (~).
Do not removethe oil pumpscreen unless replacement

is required. Theoil pumpscreen has a press fit in to the pump
cover. Do not removethe screen from the pipe (~). The oil 3 j~7 ,tl
pumpscreen is serviced as a complete assembly only.
2. Oil pumpscreen pickup (~).
3, Borers (~ and pumpcover (~.

Mark where the idler gear and drive gear and shaft C)
meshtogether, so they can be reinstalled with the samegear
teeth indexed.
DRC6624
4. Idler gear and drive gear and shaft O.
5. Retaining pin 0.
6. Pressureregulator spring (&) and valve (~).

[~ Clean:
AIl~,,~rts in clean solvent and dry them with compressedair.
~3~II~m~ inspect:
E~ important: The pump gears, cover, and body are not
serviced separately. Thepressurerelief valve spring is the only
serviceable component. If any of the parts are damagedor
worn, the entire oil pumpassembly must be replaced.
¯ Pumpbody ~ for cracks, wear, or other damage.
¯ Inside of the cover (~) for cracks and wear that would
permit oil to leak past the endsof the gears.
e idler and drive gear Q for wear.
® Drive gear and shaft for lack of fit in the pumpbody.
e Oil pumpscreen for damageto the screen or loose fit of

the pipe.
¯ Pressure regulator valve ® for fit. The regulator valve

shouldslide freely in its bore without sticking or binding.
E,~,n~/ong 5-21
Assemble:
r~ ~ Install or Connect:
1. Pressure regulator valve (~ into the pumpcover (~.
important: Replace the pressure relief valve spring (~

when reusing the oil pumpassembBy.
2. Pressure regulator spring (~ into the pumpcover (~.
3. Retaining pin (~ into the pumpcover (~).
4. Drive gear and shaft O into the pumpbody ~.
5. Idler gear O into the pumpbody ~.
Match together the index marks on the two gears made

during disassembly.
6. Pumpcover (~.
7. Bolts (~.
[~ Tighten: to 106 in. lb. {12 N-m).
J 21882
With the ddveshaft ~) instalned on the pump, turn the ddveshaft
by hand to check for smoothoperation.
Be careful of twisting, shearing, or collapsing the pipe

wheninstalling it to the pump.A damaged pipe can cause lack of
lubrication and enginefailure.
Oi| PumpScreeninstallation
DRC6525
1. Oil pumpscreen pickup.
a. The oil pumpscreen assembly shoutd be replaced with a

newpart. Loss of press fit condition could result in an air leak
and loss of oil pressure.
b. Mount the oil pumpin a soft jawed vise.
c. Apply sealer to the end of the pipe.
d. Tap the pickup screen and pipe into place, using J 21882and
a hammer.
e. The oil pumpscreen must be parallel with the bottom of the

oil pan wheninstalled.
5-22 Engme/eng
Oil Pump
installation
~ install or Connect:
[~1~] 1. Oil pump

driveshaft ® andretainer ®.
E3~2. Oil pumpto engine.
a. Align the slot in the oil pump

shaftwith the tangonthe distributorshaft.
b. Theoil pump
shouldslide easily into place.
c. Nogasketor sealeris used.
E~3. Oil pumpand bolt onto crankshaftbearingcap.
~ Tighten:
Boltto 66ft. lb. (£0N-m).

Engine Front Cover
~Ot~Thecompositetiming chain cover and comeswith an integrated

gasket and is NOTREUSABLE!
Oncethe cover is remove,a newcover
mustbe installed.
E~1. Enginefront cover bolts.
2. Enginefront cover.
~ install or Connect:
[NOt~A newcompositeenginefront cover mustbe usedon all "BY" model
5~0and5.7 engines.Donot reusethe composite enginefront cover
, Lubricate
thesealingsurface
of thecranksha/t
frontoil sealwithcleanengine
oil.
L=4J1. Enginefront cover.
2. Enginefront coverbolts.
To108in. lb. (12N®m).
5-23
Eng~ne/e.g
Timing Chain and Sprockets
ToolRequired"
J 5825-A Crankshaft Sprocket Puller
Removal
[~ To prevent damageto pistons or valves, do not turn the
crankshaft after the camshaft timing chain has been removed.
p=.....~
~ Remove or Disconnect: D~C6656
1. Camshaftsprocket bolts.
~ J 5825-A
2. Camshaftsprocket and camshaft timing chain together.
The sprocket has a light interference fit on the cam=

shaft. Tapthe sprocket on its lower edgeto loosen it.
~-~ 3. Crankshaft sprocket using J 5825-A.
4. Key (if damaged).

DRC6615
inspect:
1. Sprockets for chipped teeth and wear.
Excessively worn sprockets will rapidly wear a new

chain.
2. Camshafttiming chain for damage.
[~ An excessively worn chain will rapidly wear a new set

of sprockets.
3. Crankshaft sprocket for wear in the keywayarea.
4. Crankshaft sprocket key for wear.
5-24 Engme/eng
Installation
Tool Required:
J 5590 Crankshaft Sprocket Installer
53 Install or Connect:

~__4~2. Crankshaft sprocket using J 5590.
[~ Bmportant: Make sure the sprocket alignment mark faces

away from the engine block. Make sure the sprocket is fully
seated against the crank shoumder.
ES~] 3. Camshaftth~ing chain to the camshaft sprocket.
4, Camshaftsprocket and camshaft timing chain to the front

of camshaft.
important:
DRC6633
E~ ¯ Makesure’that camshaft and crankshaft timing marks (~)
align.
The number6 cylinder is at top dead center of the
compression
stroke with the timing marksin this position.
e Makesure the camshaft dowenpin and camshaft sprock-

et hole are properly aligned
¯ Gears and chain mesh.
5. Camshaftsprocket bolts. Use the bolts to draw the camshaft

sprocket onto the camshaft. DONOTATTEMPT TO HAMMER THE:.
CAMSHAFTSPROCKETONTOTHE CAMSHAFT. TO DO SO MAY DRC6670
DqSLODGETHE REAR CAMSHAFTPLUG AND/OR DAMAGETHE:.
CAMSHAFT.
Tighten:
bolts to 21 ft. lb. (28 N.m).
Camshaft
Re.oval
R,====I
EJRemove
Disconnect:
~=ot~] All camshaft journals are the samediameter so care must
be used in removing the camshaft to avoid damage to the
bearings.
En~=ne/eng 5-~5
1. Camshaftretainer bolts and camshaft retainer.
2. Camshaft.
EEl a. Install three 5/16 - 18 (4.0 in=) long into the camshafts
t~ b. Pull the camshaft out from the bmockbeing careful to
revent damageto the camshaft bearings.
[~ Measure:
DRC6636
CamshaftJournals. Refer to General Engine Mechanical section
in this manual.Do not attempt to repair the camshaft. Replacethe
camshaft if damaged. Whenever the camshaft needs to be
replaced, a newset of valve lifters must also be installed.
Bearings
Refer to General EngineMechanicalsection in this manual for

camshaft bearing disassembly, cleaning, inspection, and assem-
bly.
Installation
install or Connect:
Coat the camshaft lobes and journals with a high

quality GMEngine Oil Supplement, P/N 1052367, or equiva-
lent. Apply GMEngine Oil Supplement, P/N 1052367, or
equivalent to all the teeth on the distributor drive gear.
1. Twoor three 5/16 - 18 (4.0 in.) bolts long into the camshaft
[~ 2. Camshaft into the engine. Handle the camshaft carefully
to prevent damageto the camshaft bearings.
3. Camshaftretainer and retainer bolts.
¯ Coat camshaft retainer plate with GMEngine Oil

Supplement,P/N 1052367, or equivalent.
Tighten:
106 ft. lb. (12 N.m).
5-26 Eng,ne/eng
Pistons and Connecting Rods
Removal
"Fool Required" J 5239 Guide Set
F.==t
[~.J Removeor Disconnect:
11. Before attempting to removepiston, remove cylinder bore

ridge as necessary.
~ Refer to General Engine Mechanical section in this manual

for cylinder bore ridge reamerprocedures.
2. Mark the cylinder numberson the tops of each piston. Mark

them from the front to the rear, with the engine in an upright
position and viewed from the front.
¯ The right bank is numbered1-3=5-7

® The left bank is numbered2-4-6-8
3. Checkthe connecting rod and cap for identification marks. If

none, place match marks or numbers on connecting rods and
caps. Markthe parts from the front to the rear, with the engine in
an upright position and viewed from the front. Connecting rod
s must be assembledto their original connecting rods.
~ Important: Store the connecting rod and cap together as
mating parts, so they may be reassembled in the same wear
pattern and balance in which they were removed.
4. Connecting rod nuts, cap and bearings.
|mportant: if reusing bearings, keep bearings with their

original connecting rod and cap.
¯ Wipeoil from bearings and crank pins.
5. Connecting rods and pistons.
a. Attach J 5239 to the connecting rod bolts.
b. Use the long guide rod J 5239 to push the connecting

rods and pistons out of the top of the engine block.
Disassembly
R~;fer to General Engine Mechanical section in this manualfor

pi.ston and connecting rod disassembly.
Assembly

pi~ton and connecting rod assembly.
Piston Selection
Measuringthe Piston
Checkthe used piston to cylinder bore clearance, as follows:
[~ 1. Cylinder bore diameter. Use a tenescoping bore gauge,

located 2.5 in. (65 ram) belowthe top of the cylinder bore.
I~] 2. Piston diameter. Measurethe skirt at a right angle to the

piston pin hole, 1.0 in. (25 ram) belowthe o[I ring groove.
DRC6507
[~ Measure piston diameter at 70 degrees F (20 degrees C).
3. Subtract the piston diameter from the cylinder bore diameter to

4. Locate the piston-to-bore clearance, refer to Engine Specifica-

tions. Determine if the piston-to-bore clearance is within the
acceptable range.
Piston Ring EndGapand Fit
Refer to General EngineMechanicalsection in this manual.

DRC6514
[~ Important:
The numberson the connecting rod and bearing cap must be on

the sameside wheninstamnedin the cylinder bore. If a connecting
rod is ever transposed from one block or cylinder to another, new
connecting rod bearings should be fitted and the connecting rod
should be renumbered to correspond with the new cylinder
number.
Installation
Tools Required: J 5239 Connecting Rod Bolt Guide Set

J 8037 Ring Compressor
!~ |nstall or Connect:
1. Lubricate the cyninder walls lightny with engineoil.
2. Makesure the piston is installed in the matchingcylinder.
3. Connecting rod bearings.
a. Makesure the crankshaft bearings are the proper size.
b. Install the crankshaft bearings in the connecting rod and

cap.
c. Lubricate the bearings with engine oil.
5-28 Eng,ne/eng
4. Piston and connecting rod into the proper bore. }
a. With the connecting rod cap removed, install J 5239

onto the connecting rod bolts.
b. Locate the piston ring end gaps. Lubricate the piston

and rings with engine oil.
[~ c. Without disturbing the ring end gap location, install ,J

8037 over the piston and compressthe rings.
d. Place the piston in its matching bore. The connecting rod D1~(~10
bearing tang slots must be on the side opposite the camshaft.
Using light blows with a hammerhandle, tap the piston down ENGINELEFT ENGINEFRONT ENGINERIGHT
into its bore. At the sametime, from beneaththe engine, guide
the connecting rod onto the crankpin with J 5239. Hold the ring
compressoragainst the block until all rings have entered the ..~-- A, D
cylinder bore.
A OIL RINGSPACER GAP
e. RemoveJ 5239 from the connecting rod bolts. (TANGrN HOLEORSLOTWITHINARC)
B OIL RINGR/UL GAPS
C 2NOCOMPRESSION RING GAP
E~ important: Each connecting rod and bearing cap should be 0 TOPCOMPRESSION RINGGAP
rnarked, beginningat the front of the engine. Cylinders 1, 3, and 5

are the right bank and 2, 4, and 6 are the left bank (whenviewed
DRC6627
from the front). The numberson the connecting rod and bearing
cap must be on the sameside wheninstalled in the cylinder bore.
if a connecting rod is ever transposedfrom one block or cylinder
to another, newconnecting rod bearings should be fitted and the
connecting rod should be numberedto correspond with the new
cylinder number. J 8037
5. Connecting rod cap with crankshaft bearing.
6o Connectingrod bolt nuts.

[~ Tighten:
DRC6628
20 ft. lb. (27 N.mj plus an additional 55 degreesusing J 36660.

L=~"3 Measure:

connecting rod side cUearanceprocedure.
Engme/eng 5=29
CrankshaftRear Oil Seal
Removal
[~ Take care whenremoving the rear crankshaft oil seal so

as not to damagethe crankshaft sealing surface=
[~ Insert a screwdriver into the notches provided in the oin seal

housing and removethe oil seal.
DRC6658
Installation
TooJRe~_~uired:
J 35621CrankshaftRearOia Seal Installer
[~i’~’~L=LJ |nstail or Connect:
1. Lubricate the inner and outer diameterof the oil seal with clean
engineoil.
2. InstalB the oil seal on J 35621.

J 35621
3. Position J 35621against the crankshaft. Threadthe attaching
screws into the tapped holes in the crankshaft.
4. Tighten the screws secureny with a screwdriver. This will

ensure that the seal is installed squarely over the crankshaft.
6. RemoveJ 35621.
5-30 Englne/er~g
Crankshaft Rear Oil Seal Housing
Removal
E3~ B Remove or Disconnect:
1. Bolts and nuts.
2. Oil seal housing.
3. Gasket.
DRC6657
Clean:
Gasketsurfaces on the block and seal retainer.
Instai|ation
[3~ ~ Install or Connect:
® Always use new crankshaft rear oil seal and newhousing

gasket during installation of rear oil seal housing.
1, Newgasket to the block.
It is not necessary to use sealant to hold the gasket in

place.
2. Oil sear retainer.
3 Screws and nuts.

[~ Tighten: to 11 ft. lb. (15 N.m).
Crankshaft And Bearings

Removal
The crankshaft need not be removedfor replacement of the rear

oil seal or crankshaft bearings. Thoseproceduresare covered in
othr~arts of this section.
!¥1
LtJ Important: Check the crankshaft bearing caps for aoca-
tion markings, Mark the caps if necessary, The caps must be
returned to their original locations during assembly,
Engme/eng 5-31
B Remove or Disconnect:
[~ 1. Crankshaft bearing cap bolts and studs.
2. Crankshaft bearing caps and lower crankshaft bearings.
3. Crankshaft from the cylinder block with extreme care, taking

care to avoid damageto crankshaft journals and thrust flange
surfaces.
4. Upper crankshaft bearings.
Cleaning, inspection, and Repair
Refer to GeneralEngineMechanicalsection in this manual

for cleaning, inspection, and measurements.
The following is the recommended

gasket cleaning procedure for
General Motors engine components:
Carefully removeaH gasket material from the part using a plastic

or woodscraper. Use Loctite brand "Chisel Gasket Remover"(P/N
4MA)or equivalent. Do not use any other methodor technique to
removegasket material from a part. Do not use abrasive pads,
DRC6659
sand paper or power tools to ctean gasket surfaces. These
methods of cleaning can damagethe part. Abrasive pads also
producea fine grit that the oil filter cannot removefrom the oil.
This grit is abrasive and has been knownto cause internal engine
damage.
mf the engine is damaged internally and needsto be rebuilt, make

sure all foreign material is completely flushed out of the cooling
and lubrication systems. Failure to rid the oil or cooaing systems
of debris can result in damageto the rebuilt engine.
Measure:
Crankshaft bearing vertical inside diameter (ID). Use an inside

micrometer. This dimension should be the same as the other
crankshaft bearing bore vertical diameters.
[~ Clean:
[~ Use care not to scratch crankshaft journams.
¯ Crankshaft with solvent.

¯ Blow all debris from the oil passageswith compressed
air.
¯ Crankshaftbearings. Wipefree of oil with a soft cloth.
¯ Oil seal surfaces with a non-abrasive cleaner.
5-32 Engme/eng
hstallation
[~ important:
Crankshaft bearings are the precision insert type and do not use
shims for adjustment. If clearances are excessive, a newbearing
will be required. Service bearings are available in standard size
and 0.001 in. (0,0254 mm},0.002 in. (0,0508 mm),0.010 in. (0,2540
ram), and 0.020 in. (0,5080 mm)undersize. Also a 0.009 in. (0,2286
ram) is avaiJable for 5.7L enginesonly.
Selective fitting of both connectingrod and crankshaft bearings is

necessary to obtain close tolerances. For this reason you may
use, for example, one half of a 0.001 in. (0,0254 mm}undersize
bearing which will decreasethe clearance 0.0005 in. (0,0127 mm)
from using a full standard bearing.
Undersize Crankshaft Journals
Whena production crankshaft cannot be precision fit by the

methoddescribed previousUy, it is then ground 0.009 in. (0,2286
ram) undersize. GRIND ONLY THOSECRANKSHAFT JOURNALS
THAT CANNOTBE PROPERLYFITTED. ALL JOURNALSWILL NOT
NECESSARILYBE GROUND.
A 0.009 in. (0,2286 ram} undersizebearing or 0.010 in. (0,254 ram)

undersize bearing will then be used for precision fitting in the
samemanner as previously described.
Oversize Rear Crankshaft Bearing Thrust Faces
Someproduction engines mayhave rear crankshaft bearings that

are 0.008 in. (0,2032 ram) wider than standard across the thrust
faces. Thecrankshaft on these enginescan be identified by "’.008’"
stampedon the rear counterweight. If the rear crankshaft bear-
ings are replaced, they must have the proper distance between
thrust faces to obtain correct crankshaft end play.
~2=~ ~3 install or Connect:
er crankshaft bearing to the block.

=
~] important: if any undersized bearings are used, they
mustbe fitted to the proper journals.
2. Crankshaft.
3. Lowercrankshaft bearings to the crankshaft bearing caps.
Measure:,
Refer to GeneraUEngine Mechanical section in this manu~al

for crankshaft bearing clearance procedures.
E~,oe’~.. 5-33
4. Apply engine oil to the crankshaft bearings. Install crankshaft
bearing caps and bolts to the baock. DONOTinstall the rear
crankshaft bearing cap at this time.
[~E] In order to prevent the possibitity of cylinder block and/or

crankshaft bearing cap damage,the crankshaft bearing caps are
to be lightly tapped into their cylinder block cavity using a brass
or leather mallet before attaching bolts are installed. DONOT
USE ATTACHINGBOLTSTO PULL CAPS INTO THEIR SEAT.
IT] Important: The arrows on the crankshaft bearing caps
mustbe facing the front of the engine.
[~ Tighten:
Crankshaft main bearing cap bolts to specifications.
All inboardbolts 74 ft. lb. (100 N.m).

Outboardbolts (four bolt caps} 67 ft. lb. (90 N.m).
5. Rearcrankshaft bearing cap and bolts to the baock.
[~ Tighten: bolts temporarily to 35 in. lb. (4 N.m).
I~ Measure:
Crankshaft end play, as follows:
EEl 1. Firmly thrust the crankshaft first rearward then forward.

This will line up the rear crankshaft bearing and crankshaft thrust
surfaces.
[~ Tighten:
Rear crankshaft bearing cap bolts to specifications"
74 ft. lb. (100 N.m}. DRC$530
5-34 Engineieng
2. With the crankshaft wedgedforward, measureat the front end
of the rear crankshaft bearing with a feeler gauge. The proper
c’iearance is 0.002 - 0.006 in. (0,0508 - 0,1524ram).
3. If correct end play cannot be obtained, makesure the correct

size rear crankshaft bearing has been installed. Production en-
gines mayhaverear crankshaft bearings that are 0.008 in. (0,2032
ram) wider across the thrust faces than standard, as expnained
~ iousJy.
|nspect:
Crankshaft for binding° Try turning the crankshaft to check for

binding. If the crankshaft doesnot turn freely, loosen the crank-
shaft bearing cap bolts on one cap at a time until the tight bearing
is located. Burrs on the bearing cap, foreign matter betweenthe
bearing and the block or the bearing cap, or a faulty bearing could
cause a lack of clearance at the bearing.
¯ A bent crankshaft could cause binding. Makesure the

steps outlined in GeneramEngine Mechanical section
have been performed when checking for a bent crank=
shaft.
DRC6661
Cylinder Block
Disassembly
~] Remove or Disconnect:
1. Coolantdrain fittings,
2. CooUingjacket plugs.
DRC6662
Obtain a suitable self-threading screw. Drill a hole into the pSug

and install the self-threading screw. Remove jacket plugs.
3. Oil gallery plugs.

[~ Clean:
1. Sealing material from mating surfaces.
2. Boil cylinder block in caustic solution.
o Flush with clean water or steam.
3. CyUinderbores.
4° Threadedholes.
Englne/eng 5-35
5. OHgalleries and passages.
6. Scale deposits from coolant passages.
7. Spray or wipe cylinder bores and machined surfaces with

neoil.
~ |nspect:
1. All block core plugs for lack of fit or leakage.
2. Camshaftlifter bores for deep scratches and deposits.
3. Cracksin the b~ock
a. Cylinder walls.
b. Waterjackets.
c. Engine mount bosses.
d. Crankshaft bearing webs.
e. Crankshaft bearing bores and caps.
¯ All crankshaft bearing bores should be rounded and
uniform in inside diameter (i.D.) at all of the bearing
supports.
¯ The area where the crankshaft bearings contact the
crankshaft bearing bore should be smooth.
® If a crankshaft bearing cap is found to be damaged,

repRacethe cap and line bore the block.
[~ 4. Cylinder block head mounting surface for flatness, using a

precision straight edge and feeler gauge.
a. Set the straight edgeon the sealing surface to be inspected.

DRC6521
b. Takethe feeler gaugeand at various locations, checkthe gap

betweenthe straight edge and the sealing surface.
c. If the gap is found to be greater than 0.004 in. (0,1016 ram)

within 5.984 in. (152 ram) at any sealing location, the block
must be replaced.
d. if the gap is found to be less than 0.004 in. (0,1016 mm)

within 5.984 in. (152 mm}at any sealing location and a cause
for leakage is suspected, then the minor irregularities maybe
carefully machinedfrom the block.
¯ Oil pan and intake manifold mountingsurfaces for nicks.

Minor irregularities maybe cleaned up with a fiat file.
5-36 Englne/eng
Cylinder Bore
[~ inspect:
Cylinder bores for scoring or other damage.Refer to General

Engine MechanicaUsection in this manual.
~] Measure:
Cylinder bore taper and out-of-round. Refer to General Engine

Mechanicansection in this manual.
DRC6660
C~nder Bore Reconditioning

Measure:
Refer to General Engine Mechanical section in this manual,
Cylinder Block Assembly
Instal| or Connect:
1. Oil gallery plugs. Coat plug outside diameter with GM

DRC6661
2, Camshaftcup plugs to proper depth. Coat bore inside diameter

with GMSealant, P/N 12346004,or equivalent.
important: Do not allow residue on camshaft bear-

ing or seizure mayresuJt.
3, Coolantdrain fittings.
DRC6662
En;ime/eng 5-37
Circulating Pump
Description
The Volvo Pentacirculating pumpis manufactured specially for marine use.

It is serviced only as an assembly.Donot replace with an automotive
circulating pump.
inspection
1. Remove
alternator and powersteering belts.
2. Graspcirculating pumppulley and checkend and side play. Turn pulley to

checkfor drag.
3. Look for water leaking from indicator hole beneathpumpshaft behind

pulley. Replacepump if play, drag, or leakageare evident.
Removaland installation
1. Drain water from block and disconnectwater hose from circulating pump.
2. Remove
pulley. Remove
circulating pumpbolts, pumpand gaskets.
3. Usenewpumpto block gaskets and sealer. Install newpumpassembly

on cylinder block and tighten bolts as specified.
4. Install pulley. Install alternator andpowersteering belts, then adjust

tension.
5. Install hoseto circulating pump.
6. Lakeor tank test unit and checkfor leaks.
5=38 Engme/eng
25829 25917 11980
Front Engine Mounts

Removal
E1-=] 1. Removetwo lag screws ~) and washers from mounts.
,~’~ 2. Lift enginewith a hoist capableof lifting at least 1500lb.

(880 kg) to aJlow removalof front mountand bracket.
[=2--] 3. Removethree mount screws and lock washers ®. Note
screwlengths and IIocation. 11979
[~ Prior to disassembly of front mount assembly, me~,-

sure distance and record measurement between large washer
and flat on upper mount bracket.
O
Disassembly
[:’~ 1. Removethree nuts © and engine mount bracket @from

mountbolt while h onding bolt secure with socket ~.
~-~ 2. Removetwo flat washers, one large O and one smaller @.

Removelock washer ®, and engine mount bolt (~ from mount.
"®’@ 11978
Reassembly
~B--’] 1. Place small washer@on mountbolt and insert bolt Ul;)
through mount, install large washer and secure with nut ©.
Tighten to 60-75ft. Ibs. (81-102 N.m).
E4~2. Install upper inner nut and place engine mount bracket ~
on engine mount bolt.
Measuredistance between large washer and fiat on upper

mount bracket. Adjust distance to recorded measurement.
11983
3. Install lock washerand top nut. Tighten nut to 100-120ft. Ibs.

(136-163 N-m).
E.,~,.~/~.~ Z~ Safety Related 5-39

25817 25929 2953
installation
~1 Spray the engine mountscrew threads with Loctite ~ Primer N and

allow to air dry. Apply Volvo PentaTreadSealing Agent P/N 1161053-6to
the screws. Attach engine mountassemblyto engine with three screwsand
washers.Tighten to 32-40ft. Ibs. (43-54N,m).
[~ 2. Install washersand lag screwsand tighten securely.
Height Adjustment
34719
E~ 1 To changeengine height, tighten or loosen nuts (~ and @required.
~2. Lift engine with s hoist capable of lifting at least 1500lb. (680
kg). Position engineat desired height.
E~ 3. After setting mountposition, turn nut @up against undersideof

enginebracket and hold nut with a wrench.Tightennut (~ to 100-120ft. Ibs.
(136-163 Nom).
~Any large adjustments to engine height should be followed by a

checkof enginealignment.Failure to checkalignmentcould result in rapid
engine coupler failure. SeeDrive Removaland Instamlation section of the 34720
SterndrivefrransomBracket Service Manualfor alignment procedures.
High-Rise ExhaustElbowReplacement
Removal
~1. Loosentwo clamps securing upper hose to elbow. Lubricate inside

of hosewith a soapywater solution.
E~ 2~ Starboard Elbow: Removecircuit breaker bracket (E) and set aside.

Remove four screws, flat washers,and lock washersmountinghigh-rise
elbow. 34718
[~ E~ 3. Usea soft hammerto free elbow from manifold. Use a twisting

motion to pull elbow from hose. Remove
and discard the elbow gasket.
34716
5-40 Engme/eng
1. Thoroughlyclean manifold gasket surface. Apply Volvo Penta Gasket
Sealing Compound P/N 1161231-4to both sides of a new manifold gasket
and place it on the exhaustmanifold.
E~ [~ 2. Lubricate the inside of the exhaust hose with a soapy water

solution. Insert the high-rise elbowinto the hosewith a twisting motion,and
pushit into hoseas far as it will go.
E~ 3. Position elbow on manifold. Secureelbowsand brackets with four

screws,flat washers,and lock washers.Tighten screwsto 12-18ft. Ibs.
(16-24 N®m}.StarboardElbow:Install circuit breakerbracket (~.
Eg--] ~ 4. Slide clamps (~ up onto hose and position them in the two
surface channels. Tighten clamps securemy.
Exhaust Hose and intermediate Pipe Replacement

Removal
[~r~ 1. Looseneight clamps that secure the upper © and lower exhaust
hoses®.
32371
[] 2. Lubricate inside of lower hose with a soapywater solution, and slide
lower hose downonto exhaust Y-pipe.
[~"~ 3. Twist intermediatepipe out of upper hose. Lubricate inside of upper

hose if necessaryto ease removal.
4. Slide upperhoseoff high-rise elbow.Slide lower hoseoff exhaustY-pipe.
32374
32375
32363
Eng,ne/eng 5-41
32370 32366 32363
anstaIiation
~] 1. Lubricate inside diameter of 3.5 in. (8,89 cm) I.Do lower

hose with a soapy water solution. Slide it all the way onto the
exhaust Y-pipe.
[~ ~ The inside diameter of both the upper and lower

hoses has a step (~ 1.5 in. (3,81 cm) from one end. The stepped
end of the hose must face the intermediate pipe wheninstalled.
2. Slide hoseonto high-rise elbowuntil it seats. 32374
ff hose is not properly positioned, it will not completely

engagethe high-rise elbow or allovv secure attachment.
[~ [~ L~ 3. Place four No. 68 clamps on upper hose. With a
twisting motion, insert intermediate pipe all the way into the
vpper hose. Place four No. (]4 clampson lower hose. Align lower
end of pipe with exhaustY-pipe, then slide lower hoseup until it’s
hatfway onto the intermediate pipe. Position clampsin channels
and tighten cOamps secureOy.
Exhaust {Flapper) Valve Replacement 32367
Removal

under Exhaust Hose and Intermediate Pipe Repmacement.
2. Slide the lower hose downfar enoughto expose the valve

pivot pin. Hold the valve while pulling out the pin, then lift out the
valve.
[~ 3. Inspect the two rubber bushings inside the pipe. Replace
32368
them as necessary.

Installation
E6=71. If installing newrubber bushings, apply 3M® ScotchGrip Rubber

Adhesive1300to outside of tips, and insert into inside of exhaustpipe.
[~7~2. Position valve with longestlip pointing down,andinsert into pipe.

Pushpivot pin throughbushingsandvalve until pin endis flush with outside
of pipe. Checkexhaust valve for freedomof movement.
[~ If valve is not positioned properly (long lip down),it will restrict

exhaustflow and fail to preventwater backingup into engine. Boat perfor-
mancewould be adversely affected, and engine maysuffer water damage. 32369
3. Install intermediate pipe following procedureunder ExhaustHoseand

Pipe Replacement.

Removal
1. Remove
engine from boat.
ENO-~if coupler is being replaced due to coupler failure (rubber hub of

splined hub), checkengine alignmentafter installing newcoupler. SeeDrive 20034
Removaland installation section of the Sterndrive/TransomBracket
Service Manual.
2. Disconnectall wires, lines and connectorsfrom bellhousing.
[] ~ 3. Removescrews securing bellhousing cover, and slide cover

out.
19085
Er,.£,ne/eng 5-43
[~ 4. Pull drain hose out of bellhousing.
[~] 5, Unscrewbolts and nuts retaining bellhousing. Disconnectground

wires. Removepowersteering cooler bracket.
6. Remove
bellhousing from engine block.
[~7. Unscrewsix nuts securing coupler and removecoupter from studs,
8. Remove
old gasket from bellhousing cover. Clean gasket surface thor-
oughly.
1%842
installation
E~I. Install coupler and secure with six Iocknuts. Usea suitable adaptor
andtighten to 40-45ft. Ibs. (54-61N®m).
[~ 2. mnstall bellhousing and attach powersteering cooler. Tighten nuts

and bolts to 32-40ft. Ibs. (43-54 N.m). Attach groundwires and tighten nuts
to 15-20ft. ~bs. (20-27N,m).
3. Pushdrain hoseinto bellhousing.
4. Apply Volvo Penta Gasket Seating Compound P/N 1161231-4to both 6710
sides of a newbellhousing gasketand position it on cover.
[~] 5. Cleansevenself-tapping screwswith a wire brush. Install

beflhousingcover and screws.Tightento 60-84in. robs. (7-9 N,m).
6. Connectall wires, lines and connectorsto bellhousing.
7. Install enginein boat.
6712
6714
19996
5-44 Engme/eng
Positive Closed-TypeVentilation System
A malfunctioning closed crankcase ventilation system may be
indicated by loping or rough engine idle. Do not attempt to
compensatefor this idle condition by disconnecting the crank-
c, ase ventilation systemand makingcarburetor adjustments. The
removal of the crankcaseventilation systemfromthe enginewilll
adverseUyaffect fuel economy and engineventilation with resul’-
rant shortening of engine life. To determine whether loping or
rough idle condition is caused by a malfunctioning crankcase
ventilation system, perform the following tests.
1. RemovePCVvalve from its mounting, but leave vacuuminlet

side connectedto hose. If the valve is functioning properly and
not plugged, a hissing noise will be heard as air passesthrough
valve. A strong vacuumwill be felt whena finger is placed over
valve inlet. Check for vacuumleaks in hose line and at all
connections.
2. Reinstall PCVvalve, then removecrankcase air inlet hose at

flame arrestor connection. Loosely hold a small piece of stiff
p~lper (such as a 3 x 5 memocard or parts tag card) over opening
at end of inlet hose. After a minute or so, (to allow crankcase
pressure to lower) the piece of paper should be sucked against
hose opening with a noticeable force.
-__ o,-,=
RemovePCVvalve from its mounting and shake it. A metallic
clicking noise should be heard, indicating that valve parts are
free, andnot sticking.
if ventilation systempassesthese two tests, it can be considered

functionally OK,andno further service is required. If it fails either
test, replace PCVvalve and repeat Engine idling Test.
If ..system still doesnot pass test, clean ventilation systemhoses

ar, d all passagesto induction systemin accordancewith estab-.
lished procedures.
Servicing PCVValve
Donot attempt to c~eancrankcaseventilation regulator valve, it

should be replaced. Clean crankcase ventilation system connec-
tion(s) on intake manifold by probingwith a flexible wire or bottle.
brush. Clean hoses, tubes and associated hardware with a Iow-
w31atility, petroleum-basesolvent and dry ,with compressedair.
E rl(ll ne/eng 5-45

Metric English
Camshaft
CamshaftRetainer Bolt ...................................... 12N,m 106in Ib
CamshaftSprocketBolt ...................................... 25 N,m 18ft Ib
Valve Lifter GuideRetainer Bolt ................................ 25 N,m 18ft Ib
Crankshaft
Connecting Rod Nut .........................................
First Pass ................................................. 27 Nora 20ft Ib
Second Pass .............................................. 55 Degrees
Crankshaft Balancer Bolt ..................................... 95 N-m 70ft lb.
CrankshaftBearingCapBolt and Stud
First Pass (Two Bolt Bearing Cap) .............................. 20 N,m 15ft Ib
SecondPass (Two Bolt Bearing Cap) ........................... 73 Degrees
First Pass (Four Bolt Bearing Cap) ............................. 20 N,m 15ft Ib
Final PassOutboardBolt (Four Bolt Bearing Cap) ................. 43 Degrees
Final PassInboard Bolt and Stud (Four Bolt BearingCap)........... 73 Degrees
Crankshaft Pulley Bolt ....................................... 58 Nora 43ft Ib
Crankshaft RearOil Seal HousingNut and Bolt .................... 12 N,m 106in Ib
Crankshaft Rear Oil Seal HousingRetainer Stud .................. 6 N,m 53in Ib
Engine Coupler Nuts (SX/DP-S) ............................... 56 N,m 43ft Ib
Engine Flywheel Bolt (DP-D/DP-E)............................. 100 N®m 74ft Ib
Windage Tray Nut .......................................... 40 N,m 29ft Ib
Cylinder Head
Cylinder HeadBolt
All Bolts First Pass( In Sequence).............................. 30 N,m 22ft Ib
Long Bolt Final Pass (In Sequence)............................ 75 Degrees
MediumBolt Final Pass (In Sequence).......................... 65 Degrees
Short Bolt Final Pass (In Sequence)............................ 55 Degrees
Cylinder HeadCore Hole Plug ................................. 20 N,m 15ft Ib
Distributor CapBoEt ......................................... 2.4 Nora 21in Ib
Distrubutor ClampHold DownBolt .............................. 25 N,m 18ft Ib
ExhaustManifoldBolts
First Pass ................................................. 15 N°m 11ftlb
Final Pass ................................................ 30 N,m 22ft Ib
Rocker Arm Cover Bolt ....................................... 12 N,m 106in lb
5-46
EngineJeng
Metric English
Engine Block
Circulating Water PumpBolt .................................. 45 N.m 33ft Ib
Engine Block Coolant Drain Plug ............................... 20 N®m 15ft Ib
Engine Block Oil Galley Plug .................................. 20 N,m 15ft Ib
Engine Coolant Temperature(ECT) GaugeSensor................. 20 N°m 15ft Ib
Engine Front Cover Bolt ...................................... 12 Nom 106in Ib
Engine Oil Pressure GaugeSensor ............................. 15 N,m 11ft Ib
Front Mount
Lower Nut ................................................. 81-102 N®m 60-75ft Ib
Upper Nut ................................................. 136-163 N®m 100=120 ft Ib
KnockSensor(fuel injected models) ............................ 20 N,m 15ft Ib
SquareSocket Plug (Engine Block Oil Galley) .................... 20 N,m 15ft Ib
Oil Pan
Oil Pan Drain Plug .......................................... 25 N,m 18ft Ib
Oil Pan Stud (Fronl) ......................................... 6 N,m 53in Ib
Oil Pan Stud Nut ............................................ 25 N,m 18ft Ib
Oil Pan Bolt or Stud Bolt ..................................... 12 N.m 106in Ib
Oiil Filter .......................................... 16 N-m t2 ft Ib
Oil Filter BypassValve Bolt ................................... 26 N,m 20ft Ib
Oil Pump
Oil PumpBolt to RearCrankshaft Bearing Cap.................... 90 N,m 66ft Ib
Oil PumpCover Bolt ......................................... 12 N,m 106in Ib
Spark Plug ................................................
Initial Installation (NewCylinder Head).......................... 30 N-m 22ft Ib
All Subsequentinstallations ................................... 15 Nom 11ft lb
#1take Manifold
First Pass (in sequence) ..................................... 3 N,m 27in Ib
SecondPass (in sequence) ................................... 12 N,m 106in Ib
Final Pass (in sequence)..................................... 15 N,m 11ftlb
Final Pass (in sequence)..................................... 15 N,m 11ftlb
Engfne/eng
5-47
5.0GLand Gi EngineSpecifications
Metric English
Engine
Engine Type .......................................... V8
Displacement ......................................... 5.0 L 305 CID
Bore ................................................ 94.89mm 3.736in
Stroke ............................................... 88.39mm 3.480in
CompressionRatio ..................................... 9.4:1
Firing Order .......................................... 1-8-4-3-6-5-7-2
Spark Plug Gap ....................................... 1.52mm 0.060in
Oil Pressure(min. hot) .................................. 41.4 kPa@1000 r/m 6.0 psig @1,000 r/m
(rain, hot) ..................................
Oil Pressure 124 kPa @2,000 r/m 18.0 psig @2,000 r/m
(rain. hot) ..................................
Oil Pressure 165 kPa@4,000r/m 24.0 psig @4,000 r/m
Camshaft
End Play ............................................. 0.11 - 0.30mm 0.004- 0.012in
Journal Diameter ...................................... 47.440 - 47.490 mm 1.8677- 1.8697in
Lobe Lift (Exhaust) ..................................... 7.20 - 7.30 mm 0.283- 0.287in
Lobe Lift (intake) ...................................... 6.97 - 7.07 mm 0.274- 0.278in
ConnectingRod
Bearing Clearence(Production) ........................... 0.033 - 0.078 mm 0.0013- 0.0031in
Bearing Clearence (Service) ............................. 0.025 - 0.063 mm 0.0010- 0.0025in
Connecting RodJournal Diameter ......................... 53.304 - 53.334 mm 2.0986- 2.0998in
ConnectingRodJournal Taper (Production) ................. 0.007 mmMax. 0.0003in Max.
ConnectingRodJournal Taper (Service) .................... 0.025 mmMax. 0.0010in Max.
ConnectingRodJournal Out-of-Round(Production) ........... 0.007 mmMax. 0.0003in Max.
ConnectingRodJournal Out-of=Round(Service) .............. 0.025 mmMax. 0.0010in Max.
Connecting rod Side Clearence ........................... 0.15 - 0.68 mm 0.006- 0.027in
Crankshaft
CrankshaftBearing Clearence#1 (Production) ............... 0.018- 0.053 mm 0.0007- 0.0021in
CrankshaftBearingClearence#2,#3, and #4 (Production) ...... 0.030 - 0.068 mm 0.0012- 0.0027tn
CrankshaftBearing Clearence#5 (Production) ............... 0.020 - 0.060 mm 0.0008- 0.0024in
CrankshaftBearing Clearence#1 (Service) .................. 0.025 - 0.051 mm 0.0010- 0.0020 m
CrankshaftBearingClearence#2,#3, and #4 (Service) ......... 0.025 - 0.064 mm 0.0010- 0.0025in
CrankshaftBearing Clearence#5 (Service) .................. 0.038 - 0.063mm 0.0015- 0.0025=n
CrankshaftEnd Play ................................... 0.05 - 0.20 mm 0.002- 0.008in
CrankshaftJournal Diameter #1 and #5 ..................... 62.189 - 62.212 mm 2.4484- 2.4493in
CrankshaftJournal Diameter#2, #3 and #4 .................. 62.181 - 62.207 mm 2.4481- 2.4491in
CrankshaftJournal Taper(Production) ...................... 0.005 mmMax. 0.002 in Max.
CrankshaftJournal Out-of-Round(Priduction) ................ 0.005 mmMax. 0.002in Max.
CrankshaftRunout at Rear Flange ......................... 0.038 mm 0~0015 in
5"48
Eng~ne/eng
....... .............. 5.0GL and Gi EngineSpecifications
Metric English
Cylinder Bore
Diameter ............................................. 94.876 - 94.929 mm 3.7353- 3.734in
Out-of-Round (Production) ............................... 0.025 mm 0.001in
Out-of-Round (Service) ................................. 0.05 mm 0.002in
Taper (Production - Relief Side) ........................... 0.025 mm 0.0010in
Taper(Production .1 Thrust Side) ........................... 0.012 mm 0.0005in
Service Limit ........................................... 0.025 mm 0.0010in
Cylinder Head
Surface Flatness (Engine Block Deck) ...................... 0.10 mm 0.004in
Surface Flatness (Exhaust Manifold Deck) .................. 0.05 mm 0.002in
Surface Flatness (intake Manifold Deck).................... 0.10 mm 0.004in
Pi,~ton
Piston Bore Cleare~qce(Production) ........................ 0.018 - 0.053 mm 0.0007- 0.002in
Piston Bore Clearence(Service) .......................... 0.018- 0,068 0.0007- 0.0026in
Piston Pin
Clearencein Piston (Production) .......................... 0.010 - 0.020 mm 0.0004- 0.0008in
Clearencein Pistor, (Service) ............................. 0.013- 0.025 mm 0.0005- 0.0010in
Diameter ............................................. 23,545 - 23.548 mm 0.9270- 0.9271in
Interfearence Fit in ConnectingRod........................ 0.021 - 0.040 mm 0.0008- 0.0016in
Piston Rings (End GapsMeasuredin Cylinder Bore)
Piston Compression Ring GrooveClearence
(Production - Top Groove) ............................... 0.030 - 0.070 mm 0.0012- 0.0027in
(Production - 2rid Groove)............................... 0.040 - 0.080 mm 0.0015- 0.003in
(Service - Top Groove) .................................. 0.030 - 0.090 mm 0.0012- 0.0035in
(Service ° 2nd Groove) .................................. 0.040 -0.100 mm 0.0015- 0.0040in
Piston Compression Ring Gap(Production - TopGroove)....... 0.25 - 0,51 mm 0.010- 0.020in
Piston CompressionRing Gap(Production - 2nd Groove)...... 0.46 = 0.66 mm 0.018- 0.026in
Piston CompressionRing Gap(Service - Top Groove)......... 0.25 - 0.65 mm 0.010- 0.025in
Piston CompressionRing Gap(Service- 2nd Groove)......... 0.46- 0.90 mm 0.18- 0.035in
Piston Oil Ring GrooveClearence(Production) ............... 0.051 - 0.17 mm 0,002- 0.006in
Piston Oil Ring GrooveClearence(Service) ................. 0.051 - 0.22 mm 0.002- 0.009in
Piston Oil Ring Gap(Production) .......................... 0.25 - 0.76 mm 0.010- 0.30in
PistonOil Ring Gap(Service) ............................ 0.25- 0.89 mm 0.010- 0.35in
Engirm/eng
5-49
5,0GL and Gi Engine Specifications
Metric English
Valve System
Valve Lifter ........................................... HydrauticRoller
Valve Roker Arm Ratio .................................. 1.5"1
Valve Lash ........................................... Rotate Valve RockerArmNut Clockwise360
degrees(1 Turn) fromzero lash
Valve Face Angne...................................... 45 Degrees
Valve Seat Angle ...................................... 46 Degrees
Valve Seat Runout ..................................... 0.05 mmMax. 0.002 in Max.
Valve Seat Width (Exhaust) .............................. 1.65 - 2.49 mm 0.065- 0.098in
Valve Seat Width (Exhaust - HeavyDuty) ...................
Valve Seat Width (intake) ................................ 1.14 - 1.78 mm 0.045- 0.070in
Valve Spring Free Length ................................ 51.3 mm 2.02in
Valve Spring Installed Height (Exhaust) ..................... 42.92 - 43.43 mm 1.67- 1.70in
Valve Spring installed Height (Intake) ...................... 42.92 - 43.43 mm 1.67- 1,70in
Valve Spring Pressure (Closed) ........................... 338 - 374 N @43.2 mm76 - 84 Ib @1.70 in
Valve Spring Pressure (Open) ............................ 832 - 903 N @32.2 mm187 - 203 Ib @1.27 in
Valve StemClearenceExhaust(Production) ................. 0.025 - 0.069 mm 0 0010- 0.0027in
Valve Stern Clearenceintake (Production) .................. 0,025 - 0.069 mm 0 0010- 0.0027in
Valve StemC~earneceExhaust(Service) ................... 0.025 - 0.094 mm 0.0010- 0.0037in
Valve StemCJearenceIntake (Service) ..................... 0.025 - 0.094 mm 0.0010- 0.0037in
5-50
Engineteng
5.7GS and GSi Engine Specifications
Metric English
Engine
Engine Type .......................................... V8
Displacement ......................................... 5.7 L 350 CID
Bore ................................................ 101.63 mm 4.0012in
Stroke ............................................... 88.39 mm 3.480in
CompressionRatio ..................................... 9.4:1
Firing Order .......................................... 1-8-4-3-6=5-7-2
Spark Plug Gap....................................... t .52mm 0.060in
Oil Pressure(min. hot) .................................. 41.4 kPa@1000 dm 6.0 psig @1,000 r/m
Oil Pressure(min. hot) .................................. 124 kPa @2,000 r/m 18.0 psig @2,000 r/m
Oil Pressure(min. hot) .................................. 165 kPa@4,000r/m 24.0 psig @4,000 dm
Camshaft
End Play ............................................. 0.11 - 0.30ram 0.004- 0.012in
Journal Diameter ...................................... 47.440 - 47.490 mm 1.8677o 1.8697in
Lobe Lift (Exhaust) ..................................... 7.20 - 7.30 mm 0~283- 0.287in
Lobe Lift (intake) ...................................... 6.97- 7.07 mm 0.274- 0.278in
Connecting Rod
Bearing Clearence (Production) ........................... 0.033 - 0.078 mm 0.0013- 0.0031in
Bearing Clearence (Service) ............................. 0.025 - 0.063 mm 0.0010- 0.0025in
Connecting Rod Journal Diameter ......................... 53304 - 53.334 mm 2.0986- 2.0998in
ConnectingRodJournal Taper(Production) ................. 0.007 mmMax. 0.0003in Max.
ConnectingRodJournal Taper (Service) .................... 0.025 mmMax. 0.0010in Max.
,ConnectingRodJournal Out-of-Round(Production) ........... 0.007 mmMax. 0.0003in Max.
,ConnectingRodJournal Out-of-Round(Service) .............. 0.025 mmMax. 0.0010in Max.
Connecting rod Side Clearence ........................... 0.15- 0.68turn 0.006= 0.027in
Crankshaft
,CrankshaftBearing Clearence#1 (Production) ............... 0.018 - 0.053 mm 0.0007- 0.0021m
CrankshaftBearingClearence#2,#3, and #4 (Production) ...... 0.030 - 0.068 mm 0.0012- 0.0027in
CrankshaftBearing Clearence#5 (Production) ............... 0.020 - 0.060 mm 0.0008- 0.0024=n
CrankshaftBearing Clearence#1 (Service) .................. 0.025- 0.051 mm 0.0010- 0.0020in
CrankshaftBearingClearence#2,#3, and #4 (Service) ......... 0.025 - 0.064 mm 0.0010- 0.0025In
CrankshaftBearing Clearence#5 (Service) .................. 0.038 - 0.063mm 0.0015- 0.0025in
CrankshaftEnd Play ................................... 0.05 - 0.20 mm 0.002- 0.008in
CrankshaftJournal Oiameter #1 and #5 ..................... 62.t89 - 62.212 mm 2.4484- 2.4493in
Crankshaft Journal Diameter#2, #3 and #4 .................. 62.181 - 62°207mm 2.4481- 2.4491in
Crankshaft Journal Taper(Production) ...................... 0.005turn Max. 0.002 in Max.
CrankshaftJournal Out-of-Round(Priduction) ................ 0.005 mmMax. 0.002 in Max.
Crankshaft Runout at Rear Flange ......................... 0.038 mm 0.0015in
5.7GS and GSi Engine Specifications_
Metric English
Cylinder Bore
Diameter ............................................. 101.618- 101.643mm 4.0007- 4.0017in
Out-of-Round (Production) ............................... 0.025 mm 0.001in
Out-of-Round (Service) ................................. 0.05 mm 0.002in
Taper(Production - Relief Side) ........................... 0.025 mm 0.0010in
Taper (Production - Thrust Side) .......................... 0.012 mm 0.0005in
Service Limit .......................................... 0.025 mm 0.0010in
Cylinder Head
Surface Flatness (Engine Block Deck) ...................... 0.10 mm 0.004in
Surface Flatness (Exhaust Manifold Deck) .................. 0.05 mm 0.002in
Surface Flatness (Intake Manifold Deck).................... 0.10 mm 0.004in
Piston
Piston Bore Clearence(Production) ........................ 0.018 - 0.053 mm 0.0007- 0.002in
Piston Bore Clearence (Service) .......................... 0.018 -0.068 0,0007- 0.0026in
Piston Pin
Clearencein Piston (Production) .......................... 0.013 - 0.023mm 0.0005- 0.0009in
Clearencein Piston (Service) ............................. 0.013 - 0.025 mm 0.0005- 0.0010in
Diameter ............................................. 23.545 - 23.548 mm 0.9270- 0.9271in
Interfearence Fit in ConnectingRod........................ 0.021 - 0.040 mm 0.0008- 0.0016in
Piston Rings (End GapsMeasured in Cylinder Bore)
Piston CompressionRing GrooveClearence
(Production - Top Groove) ............................... 0.030 - 0.070 mm 0.0012- 0.0027in
(Production - 2nd Groove) ............................... 0.040 - 0.080 mm 0.0015- 0.003in
(Service - Top Groove) .................................. 0.030 - 0.090 mm 0.0012- 0.0035in
(Service - 2nd Groove) .................................. 0.040- 0.100 mm 0.0015- 0.0040in
Piston Compression
Ring Gap(Production - Top Groove)....... 0.25 - 0.40 mm 0.098- 0.015in
Piston CompressionRing Gap(Production - 2nd Groove)...... 0.46 - 0.66 mm 0.018- 0.025in
Piston CompressionRing Gap(Service - Top Groove)......... 0.25- 0.50 mm 0.009- 0.019in
Piston CompressionRing Gap(Service- 2nd Groove)......... 0.46 - 0.80 mm 0.018- 0.031in
Piston Oil Ring GrooveClearence(Production) ............... 0.046 - 0.096 mm 0.0018- 0.0037in
Piston Oil Ring GrooveClearence(Service) ................. 0,046 - 0.100 mm 0,0018- 0.0039in
Piston Oil Ring Gap(Production) .......................... 0.25 - 0.76 mm 0.010- 0.30in
Piston Oil Ring Gap(Service) ............................ 0.25 - 0.90 mm 0.010- 0.35in
5-52 Engineleng
5.7GSandGSi EngineSpecifications
Metric English
valve System
Valve Lifter ........................................... HydraulicRoller
Valve Roker Arm Ratio .................................. 1.5:1
’valve Lash ........................................... Rotate Valve RockerArmNut Clockwise
360degrees(1 Turn) from zero lash
Valve Face Angle ...................................... 4!5 Degrees
Valve Seat Angle ...................................... 46 Degrees
Valve Seat Runout ..................................... 0.05 mmMax. 0.002in Max.
Valve Seat Width (Exhaust) .............................. 1.65 - 2.49 mm 0.065- 0~098in
Valve Seat Width (Exhaust - HeavyDuty) ................... 1.50 ° 2.56 mm 0.059- 0.101in
Valve Seat Width (I, ntake) ................................ 1.02 - 1.65 mm 0.040- 0.065in
Valve Spring Free Length ................................ 51.3 mm 2.02in
Valve Spring Installed Height (Exhaust) ..................... 42.92 - 43.43 mm 1.67- 1.70in
ValveSpring Installed Height (Intake) ...................... 42.92 - 43.43 mm 1.67- 1.70in
ValveSpring Pressure (Closed) ........................... 338 - 374 N @43.2 mm76 - 84 Ib @1.70in
ValveSpring Pressure (Open) ............................. 832 - 903 N @32.2 mm187- 203Ib @1.27 in
ValveStemClearenceExhaust (Production) ................. 0.025 - 0.069 mm 0 0010- 0.0027in
ValveStemClearenceIntake (Production) .................. 0.025 - 0.069 mm 0 0010- 0.0027in
ValveStemClearnece Exhaust (Service) ................... 0.025 - 0.094 mm 0.0010- 0.0037in
ValveStemClearenceIntake (Service) ..................... 0.025 - 0.094 mm 0.0010- 0.0037in
5-53
Eng~ne/eng
GIVI SpecialTools
J 5715 J 5802-01
2~ J 6036
DRC6674 DRC6675 DRC6676
4-~ J 6880 5~ J 24086-C "~ J 24270

DRC66"/7 DRC657S DRC6582
®
J 35468 J 35621 J 36660
DRC6678 DRC6~07 DRC6608
RockerArmStud Bore Reamer0.003 in. (0,0762 ram) O.S.

[~ RockerArmStud Bore Reamer0.013 in. (0,3302 ram) O.S.
[~ Rocker Arm Stud Remover
[~ RockerArmStudInstaller)
[~ Piston Pin Remover/ Instanler
I~ Cylinder Bore Ridge Reamer
J 39046
Front CoverAligner / Oil Sealinstaller
[~ CrankshaftRearOil Seal installer DRC6611
Torque Angle Meter

[~ CrankshaftBalancer Remover/ Installer
Engine;eng 5-54
GMSpecial Tools
J 3049 J 5239 J 5590

DRC6596 Df~6597 DRC6598
_-~ J 5825-A J 8037 3 8062

DRC$Sg9 DRCSS01 DRC6802
J 38834
J 8358 J 9290-01 J 21882

DRC6680 D~C6610 DRC6605
E~ VaJve Lifter Remover (plier type)

E~] Connecting Rod Guide Tool
~D Crankshaft Sprocket Unstaller
~D Crankshaft Sprocket Remover
~ Piston Ring Compressor
~-~ Valve Spring Compressor
J 23738-A
E/~ Carbon Removal Brush
~ Valve Lifter Remover(slide hammertype) DRC6681
Oil PumpScreen installer

~ Vacuum Pump
5-55 Engme/eng
NOTES
5-56
Section 6
7A Gi Engines
Table of Contents
Camshaft GeneralMotorsSpeciaR Tools........................ 6-42
installation................................................. 6-24 High-RiseExhaustElbowReplacement ....... 632
Removal
..................................................... 6-10 intake Manifold
Circulating
Pump ............................................ 6-31 Installation................................................. 6-29
Crankshaft Removal
....................................................... 6=7
BalancerInstallat:ion ................................. 6-30 Service
....................................................... 6.16
BalancerRemoval ....................................... 6-7 intermediate PipeReplacement ................... 6.34
BearingCapandBearingRemoval ......... 6=12 Lubrication
System ......................................... 6=18
8earinginstallation ................................... 6.21 Oil Pan
RearOil SealInstallation.......................... 6=23 installation
................................................. 6-26
Cylinder Block Removal
....................................................... 6.9
Assembly................................................... 6-14 Oil Pump
Cleanandinspect ..................................... 6-13 Instalhition
................................................. 6=26~
Disassembly............................................... 6.12 Removal
....................................................... 6=91~
Cylinder Head Service
....................................................... 6.18
installation
.................................................. 6.27 Piston, ConnectingRod, and Bearing
Removan
........................................................ 6-9 installation................................................. 6-23
Service
....................................................... 6.20 Removal
..................................................... 6.11
Engine Coupler Replacement ........................ 6-35 PistonSelection.............................................. 6-14
Engine Front Cover Timing Chain and Sprockets
Cleanandinspect ..................................... 6.15 InstaUlation................................................. 6-25
|nstaliation................................................. 6.26 Removal..................................................... 6.10
Removal
....................................................... 6-9 TorqueSpecifications ..................................... 6=40
EngineSpecifications ..................................... 6.37 Valve Rocker Arm Cover
Exhaust installation................................................. 6-29
(Flapper)VaJve Replacement .................. 6-34 Removal
....................................................... 6.7
Hose Replacement ................................... 6.34 Valve Rocker Arm and Push Rod
Manifo|d Replacement ................................ 6.6 Installation................................................. 6-28
Front EngineMountReplacement ................ 6-31 Removal
..................................................... 6-10
General
Description .......................................... 5=2 ValveTrainComponents ................................ 6-19
Safety Warnings
Before workingon any part of the engine, read the section calRed
Safety at the end of this manual.
Alwaysuse the correct fastener in the proper location. Whenyou

replace a fastener, use ONLYthe exact part numberfor that
application. The text wUl call out those fasteners that require
replacement8fter removal. The text will also call out the fasten-
ers that require thread lockers or thread sealant.
UNLESSOTHERWISE SPECIFIED, do not use supplement coat-

ings (paints, greases, or other corrosioninhibitorsl on threaded
fasteners or fastener joint interfaces. Generally, suchcoatings
adverselyaffect the fastener torque and the joint clampingforce,
and may damagethe fastener.
Whenyou install fasteners, use the correct tightening sequence

and tightening specifications. Following these instructions can
help you avoid damageto parts and systems.
General Description
Cylinder Block
The engine block is madeof cast iron and has eight cylinders
arranged in a "V" shape with four cylinders in each bank. it is a
one piece casting with the cylinders encircled by coolant jackets.
Cylinder Head
The cylinder heads are cast iron and have parent metal inlet valve
guides and inlet valve seats. Cast iron exhaust valve guides and
powered metal valve seats are pressed into the exhaust ports.
Camshaft
A steel camshaft is supported by five bearings pressed into the

engine block. The camshaft sprocket, mountedto the front of the
camshaft, is driven by the crankshaft sprocket through a cam-
shaft timing chain. Motion from the camshaft is transmitted to the
valves by hydraulic roller valve lifters, valve push rods, and
ball-pivot type rocker arms.
6-2 Engme/eng
Crankshaft
]’he crankshaft is madeof cast nodular iron. The crankshaft is

supported by five crankshaft bearings. The crankshaft bearings
are retained by the crankshaft bearing caps which are machined
with the block for proper alignment and clearances. The engine
crankshaft bearing caps are retained by four boEts each. The
numberfive crankshaft bearing at the rear of the engine is the end
thrust bearing. Four connecting rod journals (two rods per jour-
na0 are spaced 90 degrees apart.
Pistons and Connecting Reds
]’he pistons are cast aluminum that use two compression rings
and one oil control ring assembly.The piston pins are a floating fit
i,n the pistons and are retained by a press fit i~n the connectingrod
assembly. Connecting rods are forged steel, with precision type
insert crankpin bearings.
Lubrication
The gear-type oil pumpis driven through an extension driveshaft.

The extension ddveshaft is driven by the distributor which is gear
driven by the camshaft. The oil is drawn from the oil pan through
a pickup screen and tube. Pressurized oiR is delivered through
internal passages to gubricate camshaft and crankshaft bearings
and to provide valve lash control in the hydraulic valve lifters. Oil
is metered from the valve lifters through the valve push rods to
lubricate the valve rocker armsand ball pivots. Oil returning to the
oil pan from the cylinder heads and the front camshaft bearing,
lubricates the camshaft timing chain and c;rankshaft and cam-
s haft sprockets.
Valve Train
"[’he valve train is a ball pivot type. Motionis transmitted from the
camshaft through hydraulic roller valve lifters and tubular valve
push rods to the valve rocker arms. The valve rocker arm pivots
on a ball to openthe valve. Thehydraulic roller valve lifters keep
all parts of the valve train in constant contact. The valve rocker
arm and balls are retained by bolts.
Englne/eng 6-3
DRC6932
EngineLubrication Cleaning
EEl Full pressure lubrication, through a full-flow Before cleaning the engine, remove the engine
oil filter is suppliedby a gear-typeoil pump.OiEis accessories to provide better access to the en-
drawn up through the oil pump screen and gine’s exterior surfaces. After removing the
passesthrough the pumpto the oil filter. The oil throttle body, distributor, etc., cover the open-
filter is a full-flow paper e~ementunit with an ings with tape to prevent the entry of coolant,
anti-drain back valve. An oil filter bypassvalve is solvent, or dirt.
used to ensure adequateoil supply, in the event
the filter becomesplugged or develops excessive Methods used to clean the engine wial dependon
pressure drop. what equipment is available. Steam cleaning,
pressure washing, or solvent cleaning are some
Filtered oil flows into the main gallery and then acceptable methods. Allow the engine to dry
to the camshaft, rear bearing, and crankshaft before beginning the work.
bearings. The valve lifter oil gallery supplies oil
to the valve lifters. Oil flows from the valve lifters It is important that the engine be as clean as
through the hollow valve push rods to the valve possible to prevent dirt from entering critican
rocker arms. Oil drains back to the crankcase areas during disassembly.
through oil drain holes in the cyUinder head. The
camshaft timing chain is drip fed from the front
camshaft bearing. The pistons and piston pins
are lubricated by oit splash.
-4 Eng[neleng
Too|s and Shop Equipment
A clean, wenl lit work area should be available. Other necessary

equipment incaudes: a suitable parts cleaning tank, compressed
adequate set of hand tools.
An approvedengine repair stand will help prevent personal injury

or damageto engine components.
Special tools are illustrated throughout this section and listed at

its end. Thesetools (or their equivalents) are specially designed
quickly and safely accomplish the operations for which they are
intended. The use of these tools will also minimize possible
damage to engine components.
Someprecision measuring toons are required for inspection of

c, ertain critical components.Torquewrencheswill be necessaryto
correctly tighten various fasteners. Thosefasteners will be called
out within this section.
Accessories
]’his manual assumes that the engine accessories have been

removed. These accessories may include one or more of the
following:
¯ Power Steering Pump

¯ Alternator
e Distributor
¯ Water Supply Pump
e Accessory Brackets and Electrical Wiring
e Starter Motor
It is beyondthe scopeof this section to detail the manydifferent

accessory instaltations. Refer to the proper Service Manual for
this information. Diagrams of vacuumhose routing, wiring har-
ness routing, accessory drive belt layout, etc., should be made
before removing these components.
Draining The Engine
Follow the procedures in Section 1, GeneraRinformation of this

manual to drain crankcase engine oil and the cooling system.
Errglne/eng 6-5
Exhaust Manifold Replacement
Removal
~ Drain water from respective exhaust manifold before beginning

procedure.
1. Remove
high-rise exhaustelbowfollowing procedureunderHigh-Rise
ExhaustElbow Replacement.
2. Carefullypull wiresoff sparkplugs.
3. Loosenhoseclampat front of manifold,andpull off waterhose.
4. Remove
manifoldattaching screws,nuts andwashers.Discardnuts.
Removemanifold and discard manifold gasket.
Cleaning
Cleanmatingsurfaceson manifold andcylinder head.Cleanthe threadson

the exhaustmanifoldbolts.
Inspection
Inspectfor cracks.Topressurecheckmanifold,fabricate a plate (~)

shownand a newelbowgasket ® to seal water passagein manifold. Be
sure to applyseafer to gasket.Install rubberdrain capsto the manifoldand
securewith clamps.Attach a gearcasepressuretester (such as Stevens
Company S-34) to the plate. An adaptorbushingcan be usedto secure
pressuretester to the plate. Withthe pressuretester attachedto the
manifold, submerge manifoldin water. Pressurizethe manifoldto 10-15PSi
(22-25kPa) andcheckfor leaks.
Installation
1. Install a newexhaustmanifoldgasket.
B[]E~2. Install manifold and securewith bolts, washersand new

Iocknuts.Tightennutsto 20-26ft. Ibs. (27-35N,m).Tightenbolts to 24=28
ft. Ibs. (33-38N,m).
3. Attachwaterhoseto nipple at front of manifoldandtighten clamp
4. Attachsparkplug wiresto plugs. Makesurefiring orderis correct.
5. Install high-rise exhaustelbowfollowing procedureunderHigh-Rise

Exhaust Elbow Replacement
~6. Start engine and checkfor water and exhaustleaks,
6-6 Engtne/ertg
Crankshaft Baiancer Removal
Tools Required: J 23523-F Crankshaft Balancer Remover/hstaller \
\
J 23523 -
1. Crankshaft balancer retaining bolt and washer.
~4~ 2= Crankshaft balancer using Special Tool P/N J 23523-F
Crankshaft BaJancer Remover/InstaLler.
DRC6913
Intake Manifold Removal
5~ 1. Upper intake manifold bolts.
2. Upper intake manifold and gaskets. Discard the gaskets.
3, Lower intake manifold bolts.
Do not attempt to loosen the manifoJd by

prying under the gasket surface with any tool. The lower intake DRC6891
manifold gaskets are reusabRe,
4. Lower intake manifold by pulling up on the manifold.
5. Lower intake manifold gaskets and seals,
Valve Rocker Arm Cover Removal

1. Valve rocker arm cover bolts. DRC6893
2. Valve rocker arm cover and gasket. Discard the gasket.
DRC6895
Engme/eng 6=7
Valve Rocker Arm and Push Rod Removal
Tools Requited: J 3049-A Valve Lifter Removal(Plier Type)
J 9290-01 Valve Lifter Removal (Slide Hammer
Type)
{]~~~ Every effort should be made to ensure that the
mating parts are installed in their original locations during
assembly.
DRC6898
I~ 1. Valve rocker arm bolts, balls, rocker arms and push rod
guides.
I~ 2. Valve push rods. Note: The exhaust valve push rods are
longer than the intake valve push rods.
EE] 3. Splash shield.
EE] 4. valve lifter guide retainer bolts and retainer.
EEl 5. Lifter guides.

DRC6897
6. Valvelifters
a. Usea magnetin order to removethe valve lifters one at a

time.
b.Tag the valve lifters in a way to ensure they can be
returned to the valve lifter bore from which they were
removed.
c. Somevalve lifters maybe stuck in their bore due to gum
or varnish deposits. These valve lifters can be removed
by using either J 3049-A Valve Lifter Removal (Plier
Type), or J 9290-01 Valve Lifter Removal(Slide Hammer
DRC5914
Type).
DRC6915
DRC6916
6-8 EnglneJeng
Cylinder Head Removal
1, Cylinder headbolts.
2, Cylinder Head. Note: Handle the cylinder heads carefully to

prevent damageto the gasket sealing surfaces.
3. Cylinder head gasket. Discard the gasket.
DRC6907
C)il Pan Removal

ET~1. Oil pan bolts,
2. Oil pan.
3. Oil pan gasket. Discard the gasket.
Oil PumpRemoval DRC6909
1. Bolts that attach the oil pumpto the rear crankshaft

bearing cap.
o
2. Oi~ pump, the retainer, and the driveshaft from the rear
crankshaft bearing cap.
Engine Front Cover Removal

DRC6910
EEl 1. Engine front cover bolts. ¢
2. Engine front cover and gasket. Note: The engine front cover b= I
gasket is reusable.
~C6901
E,~g,ne/eng 6-g
riming Chain and Sprockets Removal
Tools Required: J 28509-A Crankshaft Sprocket Remover
Measure:Thecamshafttiming chain free play, if the chain can be

movedback and forth in excessof 0.825 in. (16 ram), makea note
that the camshaft timing chain and sprockets must be repJaced
during assembly.
FT] 1. Camshaft sprocket bolts. DRC6903
2. Camshaft sprocket and camshaft timing chain.
3. Crankshaft sprocket using J 28509-A Crankshaft Sprocket

Remover.
4, Crankshaft key, if necessary.
Camshaft Removal
[~ Removeor Disconnect:
1. Camshaftretainer bolts and camshaft retainer.
2. Install three 5/1e - 18 x 4 in. bolts in the camshaftfront bolt holes.
3. Carefully rotate and pull the camshaft out of the engine block.
DRC6906
6-10 Englne/eng
Piston, Connecting Rod, and Bearing RemovaJ
Tools Required: J 24270 Ridge Reamer
J 5239 Connecting Rod Guide Tool
~D,o not remove excessive material from the
cylinder bore. Excessive removal of material mayrequire cylinder
boring to the next oversize.
~_~ 1. Cylinder bore ridge as necessary.
a. Rotate the crankshaft until the piston is at BDC=

b. Place a cloth on top of the piston.
/
c. Perform the cutting operation using J 24270 Ridge
Reamer.Refer to the manufacturer’s instructions before
using the tool.
d. Removethe special tool
e. Rotate the piston to TDC and remove the cloth and
cuttings
f. Repeatthe; procedure for the remaining pistons. DRC6510
~Place the match marks or numbers on the

connecting rods and the connecting rod caps. The rod caps must
be assembledto their original connecting rods.
2. Connecting rod nuts.

~lf reusing keep the bearings with their orighlal
connecting rods and rod caps. Wipe the oil from the bearings and
crank pins.
3, Connecting rod caps and bearings. DRC6619
E-~ 4. Connecting rod and piston out of the top of the engine
biock using J 5239 Connecting Rod Guide Tool,
5. Remaining piston and connecting rod assemblies from the

engine block.
Engme/eng 6-11
Crankshaft Bearing Cap and Bearing Removal
~ Check the crankshaft bearing caps for location
markings. Mark the caps if necessary. The caps must be returned
to the original nocations with the arrow pointing forward during
assembly.
E~ 1. Crankshaft bearing cap bolts.
2. Crankshaft bearing caps. DRC6917
3. Crankshaft.
4. Crankshaft upper bearings from the engine block.
5. Crankshaft lower bearings from the crankshaft bearing caps.
6= Rear crankshaft oil seal from the crankshaft. Discard the seal.
Cylinder Block Disassembly

[~ 1. Cooling jacket plugs by using the following procedure:
a. Obtain a suitable self-threading screw.

b. Drill a hole into the pJug.
c. Install the serf-threading screw.
d. Removethe jacket plug
2. Oil gallery plugs.

DRC6918
3. Oil pumpswitch.
4. Knock Sensor.
5. Oil bypass valves. Discard the valves.
6-12 Englne/eng
Cylinder Block Clean and inspect
Clean:
1, Sealing material from the mating surfaces,
2. Boil the cylinder" block in a caustic solution.
3. Flush the cylinder block with clean water or steam.
4. Cylinder bores.
5. Oil galleries and the passages.
6. Scale deposits from the cooling system passages,
7. After cleaning the engine block, spray or wipe the cylinder

bores and machinedsurfaces with clean engine oil.
|nspect:
t. VaNenifter bores for deep scratches and varnish deposits.
2. Checkthe bores, for cracks.
3. Cylinder walls for scoring.
4. Cooling jackets.
5. Crankshaft bearing webs.
6. Engine mounting bosses.
7. Crankshaft bearing bores and the crankshaft bearing caps for

the following:
8. All crankshaft bearing bores must be round and uniform in

inside diameter (ID) at all the bearing supports.
a. The area where the crankshaft bearings contact the
crankshaft bearing bore must be smooth.
b. Note if a crankshaft bearing cap is damagedand requires b ..
replacement. Refer to Crankshaft and Bearings Ch,~an
and inspect
E.3_~__9. Checkcylinder head gasket surfaces for flatness using a

straight edge and a feeler gauge. The surface must be flat within
0,004 in. (0,10 mm).
DRC6620
E’~glne/eng {3-13
Cylinder Block Assembly
Tools Required: J 35748 Fuel Pump/Oil Pressure Switch Installa-
tion Socket
install or Connect:
1. Newoil bypass valves.
2. Knock Sensor into cylinder block after applying a water base

caulk to the sensor threads.
Tighten:
KnockSensorto 14 ft. Ibs. (19 N.m).
3. Oil pressure switch using J 35748 Fuel Pump/Oil Pressure

Switch Installation Socket.
[~ 4. Oil gallery plugs.
Tighten:
Oil gallery plugs to 15 ft. Ibs. (20 N.m).
5. Cooling jacket plugs.
6. Cylinder block cooling drain plugs.
Tig hten:
Cylinder block drain plugs to 15 ft. Ibs. (20 N.m).
Piston Selection
DRC6918
Measure:
Checkthe used piston-to cylinder bore clearance in the following

manner:
[~ 1. Using a telescoping bore gauge located 2.5 in. (65 ram)

below the top of the cylinder bore, measure the cylinder bore
diameter.
[~ 2. Piston diameter at 70° F (20° C)0
3. Skirt at a right angle to the piston pin hole, 1 in. (25 mm)below
DRC6507
the oil ring groove.
~---~
DRC6514
6-14 Engme/eng
4. Subtract the piston diameter from the cylinder bore diameter in
order to determine the piston-to-bore clearance.
5. Determineif the piston-to-bore clearance is within the accepta-

ble range. Refer to Specifications found elsewherein this section.
6. if the used piston is not acceptable, determine if a newpiston

will fit the cylinder bore.
7. If the newpiston will not bring the clearance within tolerances,

the cylinder must be reconditioned. Refer to Cylinder Boring and
Honing found in tile General Engine Mechanical section in this
manual
8. Markthe piston to identify the cylinder for which it was fitted.
EngineFront Cover - Clean and Inspect

Disassemble:
E4-=~Remove the crankshaft front oil seal. Drive the seal out with
multiple hits on the inside of the seal from the inside of the cover.
Caean:
Sealer from the front cover and engine case.
Inspect:
1. Timing tab marker.
2. Front cover.
Assembly:
DRC6921
Tools Required: J 22102 Crankshaft Seal Installer
5~ 1. Coat the seal lips with grease. J 22162
:2. Place the open end of the seal toward the inside of the front
cover. Use J 22102Crankshaft Seal Installer to install the seal.
DRC6900
Englne/eng 6-15
intake Manifold Service
Upper intake Manifold Disassembly
[~ 1. Throttle body nuts.
E~ 2. Throttle body.
E~ 3. Throttle body gasket and studs.

DRC6922
Lower intake Manifold Disassembly
Removeor Disconnect: %
1. MAPSensor nut, retainer and the MAPSensor.
2. Fuel rail bolts and stud.
E~ 3. Fuel rail.
4. Coolant housing bolts, coolant housing, and thermostat from

lower intake manifold. DRC6923
5. CoomantTemperature Sensor from the lower intake manifold.
Cmeanand inspect:
1. Gasketsurfaces.
2. Intake passagesof the intake manifold.
3. Coolant passagesof the intake manifold.
Lower intake Manifold Assembly

[]~~~ Do not install the thermostat without the rubber
O-ring seal. Omitting the rubber O-ring seal may result in poor
engine warm-up.
Install or Connect:
1. Thermostat, coolant housing and bolts to lower intake mani-

fold.
Tighten:
DRC6925
Bolts to 30 ft. Ibs. (40 N-m).
N
i ..........
DRC6926
6-16 Engine/eng
2. Coolant Temperaturesensor to Rowerintake manifold.
Tighten:
Sensorto 15 ft. Ibs. (20 N.m).

~ L.ubricate the injector O-ring seals with dean
engine oil and instaUl on the spray tip end of each injector.
L-~ 3. Fuel rail assembly in the intake manifoJd. Tilt the rail
assemblyto install the injectors.
E4~4. FueJ rail attaching bolts and stud.
Tighten:
Bolts to 89 in. Ibs. (10 N.m)

Stud to 18 ft. Ibs. (25 N.m).
5, MAPSensor, retainer, and nut to the lower intake manifold.
Tighten:
Nut to 18 ft. Ibso (25 N.m).
Upper intake Manifold Assembly
Install or Connect:
E3-=] 1. Throttle bodystuds.
Tighten:
Studs to 106 in. tbs. (12 N-m).
2. ThrottJe body gasket.

~2:~ 3. Thrott}e body.
EI:~] 4. Throttle body nuts.
Tighten:
Nuts to 89 in. Jbs. (10 N.m).
Eng,ne/eng 6-17
Oil PumpService
Disassembly
~J~~ Do not remove the pick up screen and pipe.
They are only serviced as part of the oil pump.
[~ 1. Oil pumpshaft and retainer.
2. Oil pumpbody screws. DRC6927
3. OiL pumpbody cover.

~Mark the gear teeth so the pump can be in-
stalled with the samegear teeth indexed.
4. Drive gear and shaft.
5. Idler gear.
6. Pressure relief valve spring retaining pin.
7. Pressurerelief valve spring.
8. Pressurerelief valve.
Clean and Inspect:

~The oiD pump is serviced as an assembly. Do
not attempt to service the individual components. The pressure
relief valve spring is the only serviceable component.Replacethe
pumpif any wear to the pumpgears or housing exists.
1. Oil pump housing and cover for cracks, scoring, casting

imperfections and damagedthreads.
2. Drive gear shaft, ff the shaft is loose in the pumphousing,

replace the oil pump.
3. Pressure relief valve for scoring and sticking Burrs may be

removedwith a fine stone.
4. Oil pumpscreen for broken wire meshor looseness.
5. Gears for chipping, galling and wear.
6- "1 8 Engme/eng
Assembly
Instal| or Connect:
1~ Pressurerelief valve.
2, Pressurerelief valve spring.
3. Pressurerelief valve spring retaining pin.
4. Drive gear and shaft.
5. idler gear.
& Oil pump body cover=
7. Oil pumpbody screws.
Tig hten:
Oil pumpbody screws to 106 in. Ibs. (12 N.m).
8. Oil pumpdriveshaft and retainer. Turn the driveshaft by hand

to check for smooth operation.
Valve Train Components

C~ean:
1, All parts in solvent.
2. Blow dry the parts with compressedair.
Inspect:
1. Valve rocker arms and balls at the mating surfaces. Theseparts

should be smooth and free from scoring or other damage.
2. Valve rocker arm areas that contact the valve stems and the
sockets that contact the push rods. These areas should be smooth
and free of damage,and wear.
3. Valve rocker are bolts for signs of cracking at the bolt shoulder.
Replace as necessary.
4. Valve push rods for bending. Roll the push rod on a flat surface
in order to determine if it is bent. Replaceas necessary.
5. Ends of the valve push rods for scoring or roughness.
6. Valve push rod oil passagefor restrictions.
Ertglne/eng 6-19
Cylinder HeadService
J 8062
Disassembly
[~ [-~ Removeor Disconnect:
1, Spark plugs.
2. Valve keys 0 as follows:

DRC6863
a. Compressthe valve springs using J 8062 Valve Spring
Compressor
b. Removethe valve keys.
c. Removethe valve spring compressor.
E~] 3. caps (~, springs (~) and rotators.
4. Valve stem oil seals @.
5. Valves ~. Place valves in a rack to ensure that they ’will be

returned to their original locations at assembly. DRC6595
6. Remaining valves and components.
Cleaning, Inspection, and Measurement
Assembay
1. Lubricate the valve stem with clean engine oil.
2. Valves(~)(~) into their proper location.
3. Oil seals (~) over the valve stems.
4. Rotators.
5. Valve springs (~).
6-20 Eng,ne/eng
6. Valve keys as follows:
a, Compress the valve spring using J 8062 Valve Spring

Compressor. Compressthe spring enough to clearly see
the valve stem groove.
b, Apply a small amountof grease to the valve keys to hold

them in ph]ce. Makesure the keys are properly seated in
the valve stem grooves.
c. Removethe compressor tool. Make sure the valve keys

stay in place.
d. Repeat the procedure on the remaining valves.
~ 7. Measure the installed height of each valve spring using

the following procedure:
a. Use a narrow, thin scale. A cut away scale may be

helpful.
b. Measurefrom the cylinder head spring seat to the top of

the cap. If this measurementexceeds the amount giw~n
under Specifications found in this manual, install the
DRC6668
valve spring shims of sufficient thickness between the
rotator and the cylinder headin order to give the desired
measurement.
~ Never shim the spring so as to give an
installed height under the specified amount~
CrankshaftBearing installation
~J~~ If undersized bearings are used, ensure that the
bearings are fitted to the proper journals.
DRC6667
install or Connect:
~5,-] 1. Uppercrankshaft bearingsto the block.
2 Lower crankshaft bearings to the crankshaft bearing caps.
3 Lubricate the crankshaft bearings with clean engine oil.
4 Crankshaft.
r~t~ In order to prevent the possibility of cylinder block or
crankshaft bearing cap damage,the crankshaft bearing caps are DRC6917
tapped into the cylinder block cavity using a brass, lead, or a

leather mallet before the attaching bolts are installed. Donot use
the attaching boffs to pull the crankshaft bearing caps into the
seats. Failure to observe this information maydamagea cylinder
block or a bearing cap.
Engl ~e/eng 6-21

[~ 5. Crankshaft bearing caps and the boKts. Ensure that the
arrows on the crankshaft bearing caps are facing the front of the
engine. Donot install the rear crankshaft bearing cap at this time.
~ Tighten the inside bearing cap bolts first and

the outside bearing cap bolts last.
Tighten:
Crankshaft bearing cap bolts to 100 ft. Ibs. (135 N-m).
DE] 6. Apply anaerobic sealing compoundto the rear bearing DRC6917

cap sealing face or to the rear bearing cap channel of the engine
block, from the corner of the rear thrust bearing pocket to the
edge of the channel.
7. Rear crankshaft bearing cap and bolts to the rear of the engine
block. Temporarily tighten the bolts to 35 in. Ibs. 94 N.m).
[~ 8. Measure the crankshaft end play as follows:
a. Firmly thrust the crankshaft first rearward then forward.

This will line up the rear crankshaft thrust surfaces.
DRC6929
~ Tighten the inside bearing cap bolts first and
the outside bearing cap bo~ts last.
Tighten:
Rear crankshaft bearing cap bolts to 100 ft. Ibs. (135 N.m).
b.With the crankshaft wedged forward, measure at the

front end to the rear crankshaft bearing with a feeler
gauge, the proper clearance is 0.002-0.010 in. (0,0508-
0,2540 mm).
DRC6530
9. Inspect the crankshaft for binding as follows:
a. Try turning the crankshaft to check for binding.
If the crankshaft does not turn freely, loosen the crank-

shaft bearing cap bolts on one cap at a time until the tight
bearing is located.
c.A bent crankshaft or a lack of bearing clearance could

cause binding.
10. A lack of bearing clearance maybe caused by the following

conditions:
® Burrs on the bearing cap.

¯ Foreign matter between the bearing and the block.
o Foreign matter between the bearing and the bearing
cap.
6-22 Engme/eng
CrankshaftRear Oil Seal Installation
Tool Required" J 38841 Crankshaft Rear Oil Seal Installer
1. Makesure the crankshaft rear chamferis free of grit, loose rust,

and burrs. Correct as needed.
2. Lubricate the inner and outer diameter of the seal with engine
oil.
[~ 3. Install the seal on J 38841 Crankshaft Rear Oil Seal

Installer.
4. Position J 38841Crankshaft Rear Oil Seal Installer against the

crankshaft.Thread the attaching screws into the tapped ho~es in
the crankshaft.
5. Tighten the screws securely with a screwdriver in order to

ensure that the seal is installed squarely over the crankshaft.
7. RemoveJ 38841 Crankshaft Rear Oil Seal Installer.

DRC6939
Piston, ConnectingRod, and Bearing installation

J~239
Tools Required: J 5239 Connecting Rod Guide Tool

J 8037 Piston Ring Compressor
In order to determine the correct replacement bearing size, the

bearing clearance must be measuredaccurately. Either the mi-
crometer or plastic gauge method may be used, however the
micrometer methodgives more reliable results and is preferred.
Refer to Crankshaft and ConnectingRod Bearings, Cleaning and
inspection found in this manualfor either procedure. DRC661g
Do not shim, scrape, or file bearing inserts. Do not touch ENG,NE LEFT ENGINE FRONT ENGiN.~E RIGHT
the bearing surface of the insert with bare fingers. Skin oil and
acids will etch the bearing surface.
hstall or Connect:
A OiL RING SPACERGAP
1. Connecting rod bearings to the connecting rods and connect- ,[TANGIN HOLEOR SLOT WITHINARC)
i~g rod caps. O,L RING RNL GAPS
C 2ND COMPRESSIONRING C, AP
D TOp COMPRESSION RINGGAP
2. Lubricate the cylinder walls lightly with engine oil.

DRC6627
D~ 3. J 5239 Connecting Rod Guide Tool onto the connecting
rod bolts.
~ 4. Align the piston ring end gaps.
En,q....... g 6-23
5. Lubricate the piston and the rings with engine oil.
FT] 6. J 8037 Piston Ring Compressorover the piston and rings
assembly without disturbing the eng gap locations°
J 8037
7. Compressthe piston rings.
\
EEl 8. Ensurethat the dimple faces the front of the block.
U~]~I~ Each connecting rod and bearing cap should be

markedfor proper location and orientation. Cylinder 1,3, 5, and 7
are the right bankand 2, 4, 6, and 8 are the left bank(whenviewed DRC6628
from the front of the engine). The numberson the connecting rod
and bearing cap must be on the sameside when installed in the
cylinder bore. If a connecting rod is ever transposed from one
block or cylinder to another, new connecting rod bearings should
be fitted and the connecting rod should be numberedto corre-
spond with the new cylinder number.
EEl 9. Piston and connecting rod into proper cylinder bore.
10. Use a hammerto lightly tap the piston downinto the cylinder <;=
bore.
DRC6919
11. Guide the connecting rod into position on the crankpin, while
tapping the piston into the bore.
12. Coat the connecting rod bearings with clean engine oil.
13. Coat the crankpin with clean engine oil.
14. Connecting rod cap with the bearing and connecting rod nuts.
Tighten:
Connectingrod nuts to 45 ft. Ibs. (61 N.m).

DRC6906
CamshaftInstallation
install or Connect
1. Camshaftas follows:
a. Install three 5/18 - 19 X 4 in. bolts into the camshaftfront

bolt holes in order to handle the camshaft.
b. Use care to avoid damagingthe camshaft bearings.
c. Remove
the three bolts after the camshaft is installed.
6-24 Engme/eng
2. Camshaftretainer and bolts.
Tighten:
Camshaftretainer bolts to 10 ft. Ibs. (14 N.m).
TimingChainandSprocketsinstallation
Tools Required: J 22102 Crankshaft Sprocket Installer
install or Connect
1. Crankshaft key, as necessary.
~ Ensure that the sprocket alignment mark faces

away from the engine block. Ensure that the sprocket is fully
seated against the crank shoulder.
~-] 2. Crankshaft sprocket using J 22102 Crankshaft Sprocket

Installer.
~ Ensure the following conditions exist:
a. The camshaft and crankshaft timing marks are aligned.
b. The camshaft dowel pin and camshaft sprocket hole are

properly aligned.
.Z_
c, The gears and timing chain mesh.
3. Camshaft timing chain to the camshaft sprocket.

~~J 22102
7
[~5~ 4. Camshaft sprocket and the camshaft timing chain to the
front of the camshaft.
IN’°t~ Do not hammerthe camshaft sprocket onto the camshaft. DRC6905
To do so may dislodge the rear camshaft plug and damagethe

camshaft.
5, Camshaft sprocket bolts. Use the bolts to draw the camshaft

sprocket onto the camshaft.
Tighten:
Camshaftsprocket bolts to 25 ft. lbs. (34 N.m).
DRC6902
EngineFront Coverinstallation
Install or Connect:
[~ 1. Lubricate the sealing surface of the crankcasefront oil seal

with clean engine oil.
2. Apply GMR-I’V Sealer, P/N 12345739,or the equivalent in two

places where the front cover meetsthe oia pan rail.
3. Engine front cover.

DRC6921
4= Engine front cover screws.
Tighten:
Engine front cover screws to 106 in. Ibs. (12 N.m).
Oil PumpInstallation
Instal| or Connect:
[~ 1. Oil pumpdriveshaft and retainer.
2. Oil pump.
3. Oil pumpbolt.
Tig hten:
Oil pumpbout to 65 ft. Ibs. (90 N.m}.
Oil PanInstallation
DRC6910
Install the oil pan within 10 minutes of the RTV
application,
install or Connect:
1. Appny GMRTVSealer, P/N 12345739, or the equivalent in

four pBaceswherethe front and rear crankshaft bearing caps meet
the engine block.
2. Oil pan gasket to the engine block.
DRC6909
6-26 EngineJeng
3, Oil pan. Ensurethat the oil pan gasket stays in place.
4. Oil pan bonts.
Tighten:
Oil pan bolts to 18 ft. Ibs. (25 N.m).
5. Oil pan drain plug.
Tighten:
Oil pan drain plug to 20 ft. Ibs. (28 N-m}.
Cylinder HeadInstallation
install or Connect
1. Cylinder head gasket onto the engine block. /

~Do not use sealer on any engines that use a
composition gasket. ¯ ¯
2. Align the gasket locating mark to face up.
3. Cylinder head onto the block. Guide the cylinder head carefulily
into place over the dowel pins and head gasket.
4. Coat the threads of the cylinder head boffs with GMSealing

Compound,P/N 12346004, or equivalent.
5. Cylinder head bolts and tighten in the following three

sequential steps:
Tighten:
DRC6908
a. First pass to 30 ft. Ibs. (40 N.m).
b. Secondpass to 60 ft. Ibs. (80 N.m).
c. Third pass to 85 ft. Ibs. (115 N-m).
6 Spark plugs.
Tighten:
¯ Newcylinder headsto 22 ft. Ibs. (30 N.m).

¯ Subsequentinstallations to 15 ft. Ibs. (20 N.m).
Eng,~e/eng 6-27
Valve RockerArmandPushRodinstallation
,~J~~ If a new camshaft is installed, repJace all the
valvelifters.
install or Connect:
1. Coatthe valve lifter rollers andinside of the valve lifter guides

with GMPrelube, P/N 1052367, or equivaHent.
EEl 2. valve lifters in the samelocation from which they were

removed. DRC6916
3. Valve lifter guides.

I~~1=~1~ The vaDve lifter guide retainer must contact all
of the valve lifter guides=If the valve lifter guide retainer is bent,
the valve lifter guide must be replaced.
EEl 4. valve lifter guide retainer.
5. Valve lifter guide retainer bolts.
Tighten: DRC6915
Bolts to 20 ft. Ibs. (26 N.m).
The 7.4 L engine uses different length intake and exhaust valve
push rods.The exhaust valve push rods are longer than the intake
valve push rods.
EEl 6. Valve push rods. Be sure that the valve push rods seat in
the valve lifter sockets.
7. Valve rocker arms, balls and the bouts.

DRC8897
Tighten:
Bolts to 45 ft. Ibs. (61 N.m).
I~ 8. Splash shield.
DRC6914
6-28 Engme/eng
Valve RockerArmCoverInstallation
Install or Connect:
D~ 1. Valve rocker arm cover and gasket.
2. Valve rocker arm cover bolts.
Tighten:
Valve rocker arm cover bolts to 72 in. Ibs. (8 N.m).

DRC689
intake Manifoldinstallation
install or Connect
~=~ 1. Seals on the cylinder block.
2. Gasket onto the cylinder head.
3. Lower intake manifold onto the engine block.
4. Coat the lower intake manifold bolts with GMThread Locking DRC6893
1
12 8 3 5 9
~/~ 5. Lower intake manifold bolts.
Tighten:
Bolts in sequenceto 30 ft. Ibs. (40 N.m).
E~=~6. upper intake manifold gaskets. 7 4 2 6 10
7. Upper intake manifold.

7--77 <~
DRC6694
8. Cover a minimumof eight threads of the upper intake manifond
bolts with GMThread Locking Sealant, P/N 12345493, or equiva-
lent.
DRC689I
Engme/eng 6-29
E~] 9. Upper intake manifold bolts and tighten in the following
two sequential steps:
Tighten:
a. First passto 72 in. Ibs. (8 N-m).
b. Secondpass to 10 ft. Ibs. (14 N.m)o
CrankshaftBalancerinstallation
DRC6892
Tools Required: J 23523-F Crankshaft Balancer Installer
Inspect: J 23523 - F
1.Crankshaft balancer weight for signs of shifting on the hub.

Replace the crankshaft balancer if the weight has shifted.
2. Crankshaft balancer hub sealing surfaces for grooves, nicks, or

damage. Replace the crankshaft balancer if any of the above
conditions exist.
~The inertial weight section of the crankshaft DRC6982
balancer is assembled to the hub with a rubber material. You
must follow the installation procedurescarefully, using the prop-
er tool, or movement of the inertial weight section of the hub will
destroy the tuning of the crankshaft balancer.
|nstall or Connect:
3. Use a smanl amountof RTVsealant to seal the balancer key to

the crankshaft ke/way groove.
4. Key into the crankshaft keyway, if the key has been removed.
5. Crankshaft balancer hub, until the hub is completely

seated against the crankshaft ridge using J 23523-F Crankshaft
BalancerInstaller.
& Removethe J 23523-F Crankshaft Balancer Installer.
7. Bolt and washerinto the front of the crankshaft.
Tighten:
Bolt to 110 ft. Ibs. (149 N.m).
6-30 Englne/eng
Circulating Pump
E~O=-~TheVolvoPentacirculating pumpis manufactured specially for
marineuse. It is servicedonly as an assembly.
Donot replacewith an
aL~tomotivecirculating pump.
In,spection
Remove alternator and powersteering belts. Graspcirculating pumppu;ley

andcheckendandside play. Turnpulley to checkfor drag. Lookfor water
leaking from indicator hole beneathpump shaft behindpulley. Replace
pumpif play, drag, or leakageare evident. 11982
Removal
and installation
1. Drain waterfrom block anddisconnectwaterhosefromcirculating pump.

Remove pulley. Remove circulating pumpbolts, pumpandgaskets.
2. Usenewpumpto block gasketsand sealer. Install newpumpassembly

on cylinderblockandtightenbolts as specified.Install pulley. Install alter-
nator andpowersteering belts, then adjust tension. Connect hoseto
circulating pump.Lakeor tank test unit andcheckfor leaks.
Front Engine MountReplacement 11981
RemovaJ
~-~ 1. Remove
two lag screws(~) and washersfrom mounts.
~’~/~ 2. Lift engine with 1500 lb. (680 kg) minimumcapacity hoist
to allow removamof front mountandbracket. Remove three mount
screws and lock washers®.
E,~ ~ Prior to disassembly of front mount assembly, measure
distance betweenlarge washerand flat on uppermountbracket.
11989
Disassembly
!. Removethree nuts ©, one Iockwasher,and engine mountbracket

@from mountbolt @while holding bolt securewith socket.
11979
Engine/eng
6-31
E!] 2. Remove one large washer® one small washer @and engine
mountbolt (~ from mount.
Reassembly
E~1. Place small washer@on mountbolt and insert bolt up through

mount.Install large washer® and securewith nut @.Tightento 60-75ft.
Ibs. (81-102N-m).
E~2. Install upperinner nut and place enginemountbracket on engine

mountbolt.
11978
3. Install lock washerandlowernut. Tightennut to 50-70ft. Ibs, (68-95
N,m).
Instalmation
1. Spraythe enginemountscrewsthreadswith Loctite~ Primer N andallow

to air dry. ApplyVolvo PentaTreadSealingAgentP/N1161053-6 to the
screws. Attach enginemountassemblyto enginewith three screwsand
washers.Tightento 32-40ft. Ibs. (43-54N,m).
2. Install lag screwsandtighten securely.

11983
Height Adjustment
E~] 1 To changeengineheight, tighten or loosen nuts (~) and(~
required.
~2. Lift enginewith 1500 Ib.(680 kg) minimum

capacity hoist.
Positionenginest desiredheight.
[~] 3. After setting mountposition, turn nut (i) up againstunderside

enginebracket and hold nut with a wrench.Tightenuppernut ® to
100-120ft. Ibs. (136-163N.m).
2953
High-Rise Exhaust EBbowReplacement
Removal
[~ Drain water from respective exhaustmanifold.
1. Loosentwo clampssecuring upperhoseto elbow.
8- 3 2 Engine/eng
2. Port Elbow- Remove four thru-bolts, lock washers,and washers.Move /
remote
oil filter aside.
E4~3. StarboardElbow-Remove two thru-bolts (~), lock washers,and

washersattaching circuit breakerbracket. Set bracketassembly
aside.
[~ 4. Lubricate inside of exhausthosewith a soapywatersolution, then
remove remainingelbowbolt. Tapelbowwith a soft hammerto free it, then
twist it out of the hose.Removeanddiscard the manifoldgasket.
Ir=stailation DR6451
EsZ] 1. Apply Volvo PentaGasketSeating Compound P/N 1161231-4to

both sides of a newgasket@~andplace it on the manifold. Lubricate
inside of exhausthosewith a soapywatersolution to easeelbowinstalla-
tion.
2. Twist elbowinto hoseandpositionit on the gasket.Install the outer rear

thru-bolt, washer,andlock washer,andturn it in finger tight.
3. Port Elbow- Positionremoteoil filter at front of elbow.
4. Install four thru-bolts, washers,

andlock washers
finger tight.
E4--’~ 5. StarboardElbow-Position circuit breakerassemblyat front of

elbowInstall twothru-.bolts (~, washers,andlock washers
finger tight.
6~ Tightenall elbowthru-boltsto 12-18ft. Ibs. (16-24N.m).

~7. Properly position the two exhaust hoseclampsand tighten them
securely.
Exhaust Hose and intermediate Pipe
Replacement
Removal
1. Loosen eight cJampsthat attach the upper and lower exhaust

hoses, and slide clamps down onto exhaust Y-pipe.
2. Lubricate inside of lower hose with a soapy water solu-

tion, and push lower hose down onto exhaust Y-pipe.
3. Twist intermediate pipe out of upper hose. Lubricate

inside of upper hose with a soapy water solution for ease of
removal
4. Slide upper hose off high-rise elbow. Slide lower hose off
exhaust Y-pipe.
installation
1. Lubricate inside diameter of 3.5 in. (8,89 cm) I.D. lower hose
with a soapy water solution. Slide it all the way onto the exhaust
Y-pipe.
28264
2. Onthe inside ofthe 4 in. (10,16 cm) I.D. upper hose, there
is e circular rib 1.5 in. (3,81 cm) from one end. Theribbed end
the hose must face the intermediate pipe (rearward) when it’s
installed. Slide hose onto high-rise elbow until it seats. NOTE:If
hose is not properly positioned, it will not completely engagethe
high-rise elbow or anlow secure attachment.
[~ 3. With a twisting motion, insert intermediate pipe all the

way into the upper hose. Slide the lower hose up until it’s halfway
onto the intermediate pipe.
Z~ 4. Sfidefour No. 88clamps up onto the upper hose. Slide four 16041
No. 64 clamps up onto lower hose. Position champs in their
proper channels and tighten them securely.
Exhaust (Flapper) Valve Replacement
Removal

under Exhaust Hose and Intermediate Pipe Replacement.
[~ 2. Slide the lower hose down far enoughto expose the valve
pivot pin. Hold the valve while pulling out the pin, then lift out the
valve.
[~ 3. Inspect the two rubber bushings inside the pipe, and

replace them as necessary.
19444
Z~ Safety ReBated 6-34 Engme/eng
Installation
I. If installing newrubberbushings,apply 3M e ScotchGrip Rrubber

Adhesive1300to outsideof tips, andinsert into inside of exhaustpipe.
E6~2. Positionvalvewith longestlip pointing downandinsert into pipe.

Pushpivot pin throughbushingsandvalveuntil pin endis flush with
outsideof pipe.
~No--~If valveis not positionedproperly(long lip down),it will restrict
exhaustflow andfail to preventwaterbackingup into engine.Valvemu,,~t
also movefreely and not bind. Boat performance wouldbe adversely 19443
affected, and enginemaysuffer water damage.
3. Install intermediatepipe following procedureunderExhaustHoseand

intermediate Pipe Replacement.

Removal
1. Remove
engine from boat.
2. Disconnectall wires, lines andconnectors

frombellhousing. 20034
E~3. Remove
sevenscrewssecuring bellhousing cover and slide
coveroff.
19996
~,~i,e/e,g 6-35
[~ 4. Pull drain hoseout of bellhousingif equipped,
5. Removebolts andnuts retaining bellhousing. Disconnectgroundwires

andoil coolerbracket.Noteoil coolerorientation.
6. Remove
bellhousing.
E~7. use an offset box end wrenchto removethe six nuts securing the
coupler,andslide coupleroff studs.
8. Remove
old gasketfrom bellhousingcover. Cleangasketsurface thor-
oughly.
Instamlation
1. Install couplerandattach six Iocknuts,Usea suitable adaptorand

tighten nutsto 40-45ft. Ibs. (54-81N.m).
2. Install bell housing.Attachoil coolerwith sameorientationas notedin a

previousstep. Tightennutsandbolts to 32-40ft. Ibs. (43-54N.m).Attach
groundwires andtighten nuts to 15-20ft. Ibs. (20-27N,m).
3. Pushdrain hoseinto bellhousing,if equipped.

6712
4. Apply Volvo PentaGasketSealing Compound P/N 1161231-4to both
sidesof a newbellhousinggasketandposition it on cover.
~] 5. Cleansevenself-tapping screwswith a wire brush. Install belthous-

ing coverandscrewsandtighten to 60-84in. Ibs. (7-9 N-m).
6. Connect
to bellhousing.Install enginein
boat.
8714
19083
- 3 ~ Engine/eng
7.4Gi EngineSpecifications
Metric English
Engine Type ..................................... V-8
Displacement .................................... 7.4L 454 CID
Bore ........................................... 107.95 mm 4.25 in
Stroke .......................................... 101.6 mm 4.00in
CompressionRatio ............................... 9.0:1
Firing Order ..................................... 1-8-4-3-6-5-7-2
Spark Plug Gap .................................. 0.8890 mm 0.060in
Cylinder Head
Surface Flatness ................................. 0.0762 mm 0.003in
MaximumCylinder head block deck resurfacing ........ 0.3048 mm 0.012in
Exhaust Manifold ................................. 0.251 mm 0.010in
Lubrication System
Oil Capacitywithout filter ........................... 5.7liters 6.0 quarts
Oil pressure
(hot oil) 68.65 kPa @600 r/m 172.37 kPa@2,000 r/m
10 psi @600 r/m 25 psi @2,000 r/m
Oil Filter System.................................. Full Flow
Oil PumpType ................................... GearDriven
Cylinder Bore
Diameter ....................................... 107.950- 107.968mm 4.2500- 4.2507in
Out-of-Round (Production) ......................... 0.0254 mm(maximum) 0.001 in (maximum)
Out-of=Round(Service) ............................ 0.051 mm(maximum) 0.002 in (maximum)
Cylin-
der Taper- Thrust side (Production) .................. 0.0127 mm(maximum) 0.0005 in (maximum)Cylin-
der Taper- Relief side (Production) ................... 0.0254 mm(maximum) 0.001 in (maximum)
Cylin-
der Tapoer (Service) .............................. 0,0254 mm(maximum) 0.001 in (maximum)
Piston
Piston Diameter .................................. 1.07891- 1.07904 mm 4.2477- 4.2482in
Clearence (Production) ............................ 0.0457 = 0.0762 mm 0.0018- 0.0030in
Clearence (Service Limit) .......................... 0,0457 - 0.219 mm 0.0018- 0.0048in
Piston Ring - Compression.........................
Top GroovePriduction Ciearence .................... 0.031 - 0.074 mm 0.0012- 0.0029in
SecondGroove Production Clearence ................ 0.031 = 0.074 mm 0.0012- 0.0029in
Service Limit GrooveClearence ..................... 0.305 - 0.0991 mm 0.0012- 0.0039in
Top Ring Gap(Production) ......................... 0.254 - 0.457 mm 0.010- 0.018in
Top Ring Gap(Service) ............................ 0.254 - 0.711 mm 0.010- 0.028in
SecondRing Gap(Porduction) ...................... 0.408 - 0.609 mm 0.016- 0.024in
SecondRing Gap(Service) ......................... 0.406 - 0.863 mm 0.016- 0.034in
Metric English
Oil Ring
Production GrooveClearence ....................... 0.127 - 0.165 mm 0.0050- 0.0065in
Service Limit GrooveClearence ..................... 0.127 - 0.191 mm 0.0050- 0.0075in
Production Gap.................................. 0.254 - 0.762 mm 0.010- 0.030in
Serivece Limit Gap................................ 0.254 - 1.016 mm 0.010- 0.040in
PistonPin
Diameter ....................................... 25.132 - 25.137 mm 0.98945- 0.98965in
Clearencein Piston Production ...................... 0.005 - 0.017 mm 0.0002- 0.0007in
Clearencein Piston Service limit ..................... 0.005 - 0.025 mm 0.0002- 0.0010in
Fit in Connecting Rod ............................. 0.078 - 0.053 mm 0.0021- 0.0031in
Crankshaft
Crankshaft Run Out ............................... 0.051 mm(maximum) 0.002 in (maximum)
CrankshaftJournal Diameter#1, #2, #3, #4, #5 ......... 69.804 - 69.822 mm 2.7482- 2.7489in
Crankshaft Journal Taper (Production) ................ 0.010 mm(maximum) 0.0004 in (maximum)
Crankshaft Journal Taper (Service) ................... 0.025 mm(maximum) 0.0010 in (maximum)
CrankshaftJournal Out-of-Round(production) .......... 0.010 mm(maximum) 0.0004 in (maximum)
CrankshaftJournal Out-of-Round(service) ............. 0.025 mm(maximum) 0.0010 in (maximum)
CrankshaftBearing Clearence#1 (production) .......... 0.043 - 0.076 mm 0.0017- 0.0030in
CrankshaftBearingClearence#2, #3, #4 (production) .... 0.028 - 0.061 mm 0.0011- 0.0024in
CrankshaftBearingClearence#2, #3, #4 (service limit) ... 0.025 - 0.076 0.0010- 0.0030in
Crankshaft End Play .............................. 0.127- 0.279 mm 0.005- 0.011in
Crankshaft Thrust Wall Width ........................ 46.1391 - 46.2153mm 1.8165- 1.8195 in
Crankshaft Thrust Walt Maximum Run Out ............. 0.025 mm 0.001in
Crankpin Diameter ................................ 55.854 - 55-896 mm 2.1990- 2.1996in
Crankpin Taper (production) ........................ 0.0127turn 0.0005in
Crankpin Taper(service limit) ....................... 0.025 mm 0.0010in
Crankpin Out-of-Round(production) .................. 0.013 mm 0.0005in
CrankpinOut-of-Round(service limit) ................. 0.025 mm 0.0010in
RodBearing Clearence (production) .................. 0.028 - 0.074 mm 0.0011- 0.0029in
RodBearingCiearence(service limit) ................. 0.028 - 0.099 mm 0.0011- 0.0039in
Connecting Rod Side Clearence ..................... 0.033 -.0584 mm 0.0013- 0.0230in
6-3 8 Engine/en
Metric English
Camshaft
Camshaft Run out ................................ 0.051 rnm (maximum) 0.002 in (maximum)
Lobe Lift (Intake) ................................. 7.115 - 7.216 mm 0.2801- 0.2841in
Lobe Lift (Exhaust) ................................ 7.170 - 7.272 mm 0.2823- 0.2863in
Journal Diameter ................................. 49.471 - 49.522 mm 1.9477- 19497in
Valve System
Lifter ........................................... HydraulicRoller Followers
Rocker Arm Ratio ................................. 1.70:1
Valve Lash Intake ................................. Net Lash
Valve Lash Exhaust ............................... Net Lash
Face Angle (Intake & Exhaust) ...................... 45 Degrees
Seat Angle (Intake & Exhaust) ....................... 46 degrees
Seat Runout (intake & Exhaust) ..................... 0.051 mm(maximum) 0.002 in (maximum)
Seat Width (Intake.) ............................... 0.762 - 1.524 mm 0.030- 0.060in
Seat Width (Exhaust) .............................. 1.524 - 2.413 mm 0.060- 0.095in
StemClearenceIntake (production) .................. 0.025 - 0.0737 mm 0.0010- 0.0029in
StemClearenceExhaust (production) ................. 0.030 - 0.079 mm 0.0012- 0.0031in
StemClearenceIntake (service limit) ................. 0.025 - 0.094 mm 0.0010- 0.0037in
StemClearenceExhaust(service limit) ................ 0.030 - 0.124 mm 0.0012- 0.0049in
Varve Sping Pressure Closed ....................... 316 - 3!51 N @46.685mm71 - 79 Ib @1.838 in
Vafve Spring Pressure Open........................ 1059 - 1165 N @34.213 mm238 - 262 Ib @1.347
in ............................................. Valve Spring Installed Height 46.685 - 47.479 mm
1,838 - 1.869 in ..................................
Maximum Valve Spring installed Height Shim........... 0.726 mm 0.030in
Maximum Valve Spring Tension Shim ................. 0.726 rnm 0.030in
Maximum CombinedValve Spring
Installed Height and Valve TensionShim.............. 1.542 rnm 0.060in
Oil Recommendation
32° F (0° C) and above ................................. S AE30
0° F (-17° C) to 32° F (0° C) .............................. SAE 20W-20
0(; F (-17 ° C) and below ................................. SAE 10W
Werecommend TM Synthetic MotorOil, whichis specially formulatedfor heavyduty marine

Volvo PentaDuraPlus
use, andideal for VolvoPentaEngines.It providesbetter anti-wearqualities, especiallyduring long high speed
operation,tn addition, it neutralizesacidscommon to all internal combustion
engines,offers superiorcorrosion
protection, andis lormulatedto offer better resistanceto oxidationandhigh temperature sludgeformation.
Fuel Recommendation.................................. See General|nforrnation Section

7.4Gi TorqueSpecifications
Metric English
Camshaft
CamshaftRetainer Bolt ...................................... 12 N.m 106in Ib
CamshaftSprocket BoJt ...................................... 30 N,m 22ft Ib
Valve Lifter Guide Retainer Bolt ................................ 25 N,m 18ft Ib
Crankshaft
Connecting Rod Nut
First Pass ................................................. 64 N°m 47ft Ib
Crankshaft Balancer Bolt ..................................... 149 Nom 1lOft lb.
Crankshaft Bearing Cap Bolt and Stud .......................... 138 N.m 102ft Ib
Engine Coupler Nuts (SX/DP-S) ............................... 56 N°m 43ft Ib
Engine Flywheel Bolt (DP-D/DP-E/DPX) ......................... 88 N,m 65ft Ib
WindageTray Nut ........................................... 40 N,m 29ft lb
Cylinder Head
Cylinder HeadBolt
All Bolts First Pass ( In Sequence)............................. 50 Nora 37ft Ib
SecondPass (In Sequence) .................................. 60 Degrees
Final Pass Long Bolt (In Sequence)............................ 90 Degrees
Finar Pass Short Bolt (In Sequence)............................ 30 Degrees
Distributor Cap Bolt ......................................... 2.4 N.m 21 in lb
Rocker Arm Cover Bolt ...................................... 12 N.m 106in Ib
Rocker Arm Bolt ............................................ 54 N°m 40ft Ib
Engine Block
Circulating Water PumpBolt .................................. 40 N,m 30ft Ib
Circulating Water PumpPulley Bolt ............................. 25 N-m 18ft Ib
Engine Block Coolant Drain Plug ............................... 20 N.m 15ft Ib
Engine Block Oil Galley Front Plug ............................. 20 N-m 15ft Ib
Engine Block Oil Galley Left Side Plug .......................... 20 N-m 15ft Ib
Engine Block Qil Galley Rear Plug ............................. 20 N-m 15ft Ib
Engine Block Oil Galley Top Plug ............................... 20 N,m 15ft Ib
Engine Coolant Temperature(ECT) GaugeSensor ................ 20 N.m 15ft Ib
Engine Front Cover Bolt ...................................... 10 N,m 89in Ib
Engine Oil Pressure GaugeSensor ............................. 15 N-m 11ft Ib
Flywheel Housing Bolt ....................................... 40 N.m 30ft Ib
PowerSteering PumpBracket ................................. 38 N°m 31ft Ib
ExhaustManifold Bolts
First Pass ................................................. 15 N,m 11ft Ib
Final Pass ................................................ 30 N,m 22ft Ib
High Rise Elbow ............................................ 20 N,m 14ft Ib
Front Mount
Lower Nut ................................................. 81-102 N-m 60-75ft {b
Upper Nut ................................................. 136-163 N.m 100-120 ft Ib
8- 40 Engme/eng
Im 7.4Gi TorqueSpecifications
Metric English
Oil Pan
Oil Pan Drain Plug .......................................... 25 N.m 18ft Ib
Oil Pan Stud (Front) ......................................... 6 N,m 53in Ib
Oil Pan Stud Nut ........................................... 25 N.m 18ft Ib
Oil Pan Bolt or Stud Boat ..................................... 12 N®m 108in Ib
Oil Pump.................................................
Oil PumpBolt to Rear Crankshaft Bearing Cap................... 90 N.m 66ft Ib
Oil PumpCover BoLt ......................................... 12 N,m 106in Ib
Spark Plug
Initial Installation (NewCylinder Head).......................... 30 N°m 22ft Ib
All SubsequentInstallations ................................... 15 N,m 11ft fb
Intake Manifold
Distrubutor ClampHold DownBolt ............................. 33 N°m 24ft Ib
Flame Arrestor ............................................. 3.4 N,m 30in Ib
Fuel Rail .................................................. 25 N-m 18ft Ib
Lower Intake Manifold ....................................... 40 Nora 30ft Ib
Map Sensor Nut ............................................ 25 N°m 18ft Ib
Thermostat Housing ........................................ 40 N°m 30ft Ib
Throttle Body Nut ........................................... 10 N°m 89 in Ib
Throttle Body Stud .......................................... 12 N°m 106in Ib
UpperIntake ManifoldBolt (in sequence)
First Pass ................................................. 8 N,m 71 in Ib
Final Pass ................................................ 18 N.m 13ft Ib
Engineleng
6-41
GMSpecial Tools
J 3049 J 5239
DRC6596 DRC6597 DRC6601
J 8062 J 8358 J 9290-1

DRC6602 DRC6680 DRC6604
8-~ J 24270
DRC6936 DRC6582 DRC6938
~L] Valve Lifter Remover(Plier Type)

Connecting Rod Guide Tool
Piston Ring Compressor
~=] Valve Spring Compressors
DE] Carbon Remover Brush
’valve Lifter Remover(Slide HammerType)
[~ Crankshaft Oil Seal and Sprocket Installer
[~ Cylinder Ridge Remover DRC6939
[~ Crankshaft Sprocket Remover

~] Crankshaft Rear Main Seal installer
6-42 Eng,rJe/eng
Section 7
7.4GSi and 8.2GSi
Table of Contents
Camshaft
........................................................... 7-15 intake
Manifold ................................................... 7-3
Camshaft LobeLift, Measuring ...................... 7-19 Intermediate PipeReplacement .................... 7-27
Circulating
Pump ............................................. 7-24 LubricationSystem .......................................... 7-15
ConnectingRodBearing Replacement ......... 7-21 OilPan
...............................................................7-17
Crankshaft
......................................................... 7-20 OilPump
........................................................... 7-17
Cylinder
Bnock .................................................. 7-23 Oil Seal Replacement,RearMainBearing .... 7-19
Cylinder
Head ..................................................... 7-9 Piston,RingandConnecting Rod.................. 7-22
EngineCoupler Replacement ......................... 7-28 RemoteEngine Oil Filter ................................. 7-16
Engine
Specifications ...................................... 7-30 Sealants,Lubricants,andAdhesives .............. 7-2
ExhaustHose Replacement ........................... 7-27 Special
Tools ...................................................... 7-2
ExhaustManifoldReplacement ........................ 7-5 TimingChain,Cover,andSeal....................... 7=12
Exhaust(Flapper) ValveReplacement .......... 7-27 Torque
Specifications ...................................... 7=34
Front EngineMountReplacement ................. 7-24 Valve
Lifter,Hydraulic ....................................... 7-5
High-RiseExhaustElbowReplacement ........ 7-25 ValveSpringandSealRepair........................... 7-8
Safety Warnings
Beforeworkingonanypart of the engine,readthe sectioncalledSafetyat the
end of this manual.
Unlessinstructedotherwise,alwaysdisconnectthe batterycablesfromthe bat-

tery beforeworking
on electrical system
to preventpossiblesparksor arcingin
the enginecompartment.
Beforestarting engineafter repairor maintenance

procedures, alwaysmakesure
enginecompartment
is free of fuel vapors
to preventpossiblefire andexplosion.
Whenworkingonan enginethat is runningor beingcranked,useextremecareto

avoidgettinghands,
fingersor clothingcaughtin thealternator,power
steering
pump,raw-water
pumpandcirculatingpump belts, pulleysandothermovingparts.
Engine/eng 7-1
General Motors Tools
item Part
Number
Air Line Adaptor ........................................... J-23590

Crakshaft Seal/Sprocket mnstaller .............................. J-22102
Crakshaft Sprocket Puller ..................................... J-1819
Dial Indicator Set ............................................ J-8520
Hydraulic Lifter Remover.................................. J-9290-01
Hydraulic Lifter Remover................................... J-3049-A
Main Bearing Replacer ....................................... J-8080
Ring Compressor ........................................... J-8037
Seal Installer .............................................. J-35468
Seal Installer .............................................. J-38841
Stud Protector .............................................. J-5239
Valve Spring Compressor ................................... J-5892-C
Torsional DamperPuller ................................... J-23523-E
Order D}rectly from:
Kent-MooreTool Division
28835 Mound Road
Warren, M148092800-345-2233
Price and ordering information are available from Kent-Moore

Tool Division.
Varsoi or Equivilent CleaningSolvent

Molykote Lubricant
Volvo Penta Gasket Sealing CompoundP/N 1161231-4
Permatexe No. 2
GMSuperEngine Oil Supplement
GMSilicone RubbverSealer, P/N 1052366
Plastigage TM(Green)
DuraPlusT# SAE30 HeavyDuty Synthetic Motor Oil
Black NeopreneDip
For additional service information not coveredin this manual,obtain the

appropriate Chevrolet EngineService Manualfrom:
HelmInc.
P.O.Box 07130
Detroit, M148207
7-2 Engine/eng
intake Manifol,d
Removam
SeeOn-BoardServicesection of GMEFI DiagnosticsManualfor removalof

components
from intake manifold.
E~ ~ Disconnectbattery cablesat battery, and drain coolant

from both sidesof blockandmanifolds.
2. Removealternator. If electrical leadsare not disconnected,

tie alternator 19846
to oil hosesto prevenlalternator weightdamaging leads.
3. Remove
thermostathousing.
4. Remove mainelectrical harnessfrom clampson port side of manifoldand

at front of manifold.Disconnect
other wire connections
as necessary.
E~5.Remove distributor cap andmarkthe position of the rotor on the

housing.Scribea line onthe distributor housingandintake manifoldfor
reassemblyin the sameposition. Remove the distributor.
6. Unscrew
attaching bolts andremoveintake manifold.
ENO---~If necessaryto pry manifoldawayfromcylinder heads,do not

damagegasket sealing surfaces.
7. Remove
anddiscard intake manifoldgasketsandseals.
CReaning
FIemoveall gasketmaterialandclean the sealingsurfacesof the manifold,

block and thermostathousing. Remove excessivecarbondeposits from
exhaustpassages,scale anddepositsfrom cooling passages.Cleanthe
manifoldin a suitablesolventanddry it with compressed
air. 25140e
inspection
Inspectthe manifoldfor cracks, damaged gasketsurfaces, or other defects

tt~at wouldmakeit unfit for further service.Replaceall studsthat are
stripped or otherwisedamaged. Remove all filings andforeignmatterthat
mayhaveenteredthe manifoldas a result of repairs.
Engine/eng 7- 3
Installation
1. Install newmanifold seals on block, and newgasketson cyPinderheads.

Useonly side gaskets having metal inserts covering the center exhaust
passage.Usesealer at water passagesand whereseals butt to gaskets.
~2. Install intake manifold. Tighten bolts in the sequenceshown.See

TorqueSpecifications at end of section for torque figure.
~ Check torque of the intake manifold screws annually. The center

screws can becomeloose under normal usage.
3. Install distributor with rotor and align exactly as markedduring removal.

Install clampand tighten screwto 25 ft. Ibs. (34 N-m).
~N---ot-~ If enginewascrankedwhile distributor wasout, completeignition

timing proceduremust be followed.
4. Install distributor capandhigh tensionleads.
5. Place main wire harnessunder clampson port side of manifold and at

front of manifold. Makeother wire connectionsas necessary.
6. Attach throttle cabFeto carburetor and anchorblock. DR6351
7. Connectpurple/whitestripe wire to chokehousing.Attach fuel line to

carburetor.
~8. Apply Volvo Penta Gasket Sealing CompoundP/N 1161231-4 to

both sides of a newthermostat housinggasket and place it on manifold.
Placelifting eye on long bolt, then instam8and tighten both bolts to 12-16
ft. Ibs. (16=22N*m).
9, Install alternator and properly tension belt. Tighten mountingscrews

securely.
10. Install flamearrestor andtighten nut to 25-35ft. Ibs. (2,8-4,0 Nom).

Install flamearrestor coverand tighten nut 30-35ft. Ibs. (3,4-4,0 N°m).
//~11. Attach battery cables at battery. Start engineandcheckfor fuel

and water leaks.
7-4 Engme/eng
ExhaustManifold Replacement
Removal
[~ Drain water from respective exhaust manifold before beginning

procedure.
1. Removehigh-rise exhaust eBbowfollowing procedureunder High-Rise

Exhaust Elbow Replacement.
2. Carefully pull wires off sparkplugs.
3. Loosenhoseclampat front of manifold, and pult off water hose.
4. Remove
manifold altaching screws, nuts and washers.Discard nuts.
Removemanifold and discard manifold gasket.
Cleaning
Ctean mating surfaces on manifold and cylinder head. Clean the threads on
the exhaustmanifoldbolts.
inspection
DR2875
E~ Inspect for cracks. To pressurecheckmanifold, fabricate a plate (~)
shownand a newelbow gasket (~) to seal water passagein manifold.
sure to apply sealer to gasket. Install rubberdrain cap to manifoldand
secure with clamp. Attach a gearcasepressure tester © (such as Stevens
Company S-34) to the water inlet hose. A bushing can be madeto secure
pressuretester to hose. With the pressuretester attachedto the manifold,
submergemanifold in water. Pressurize the manifold to 10-15 PSI (22-25
kPa) and checkfor leaks.
Bnstallation
1. Install a newexhaustmanifoldgasket.
E3-’=l [] 2. Install manifold and secure with screws, washersand new

Iocknuts. Tighten nuts to 20-26 ft. Ibs. (27-35 N®m).Tightenscrewsto 24°28
ft. Ibs. (33-38N®m).
3. Attach water hoseto nipple at front of manifoldand tighten clamp
4~ Attach spark plug wires to plugs. Makesure firing order is correct.
5. Install h{gh-rise exhaustelbowfollowing procedureunder High-Rise

Exhaust Elbow Replacement
,~/.~ 6. Start engine and check for water andexhaustleaks. 18944
E ng,ne/eng 7-5
Hydraulic Valve Ufter
CheckingHydraulic Valve Lifter
When checkinghydraulic valve lifters, remember that grit, sludge, varnish,

or other foreign matterwill seriously affect their operation.If anyforeign
substanceis foundin the lifters or enginewhereit maybe circulated by the
lubrication system, a thoroughcleaning job must be doneto avoid a repeti-
tion of lifter trouble.
To help preventlifter trouble, the engineoil and oil filter mustbe changed as
recommended in Generalinformationsection. The engine oil must be
heavy-dutytype (for Service SG)and must also conformto General Motors
Specification 6094Mto avoid detrimental formation of sludge and varnish.
WerecommendDuraPluszi SAE30 Heavy Duty Synthetic Motor Oil. The
boat ownershould be specifically advised of these requirementswhenthe
unit is delivered. Faulty valve lifter operationusually appearsunderone of
the following conditions:
1. Rapping Noise Only WhenEngine is Started:
Whenthe engine is stopped, any lifter on a camshaftlobe is under pressure

of the valve spring; therefore, leak downor escapeof oil from the lower
chambercan occur. Whenthe engine is started, a few secondsmaybe
requiredto fill the lifter, particularly in colderweather.If noiseoccursonly
occasionally, it maybe considerednormal, requiring no correction. If noise
occursfrequently, however,checkfor either oil too heavyfor prevailing
temperatures,or excessivevarnish in lifters.
2. Intermittent RappingNoise:
An intermittent rapping noise that appearsand disappearsevery few

secondindicates leakageat checkball seat due to foreign particles, var-
nish, or defective surfaceof checkball or seat. Replacelifters as necessary.
3. Noise at Idle and LowSpeed:
If one or morevalve lifters are noisy at idle speedand up to approximately

1200RPM,but quiet at high speeds,it indicates excessiveleak downrate
or fautty checkball seat or plunger. Withengineidling, lifters with excessive
leak downrate maybe spotted by pressing downon each rocker arm above
the pushrod with equal pressure. Reconditionor replacenoisy lifters.
7-6 Engmeleng
4, GenerallyNoisyat: All Speeds:
Check for low or highoil level in crankcase.Highoil levels will causeoil

foaming fromthe crankshaft andwill force air bubbles into the lifters. Lowoil
levels allow pump to pumpair at highspeed.Withengineidling, strike each
rocker armabovethe pushrod severalsharpblowswith a mallet; if noise
disappears,it indicates that foreign materialwaskeepingcheckball from
seating. Stopengineandplacelifters oncamshaft basecircle. If there is
lash clearance in anyvalvelinkage,it indicatesa stucklifter plunger,worn
lifter roller, or worncamshaft lobe.
5. LoudNoiseat Norrr|a| OperatingTemperature

Only: 11508
If a lifter develops a loudnoisewhenthe engineis at normaloperating

temperature,but is quiet whenengineis belownormaltemperature,it
indicatesan excessivelyfast leak downrate of scoredlifter plunger.Recon-
ditionor replacelifter.
Removam
1. Withair hoseandcloths, cleandirt fromcylinder headsandadjacent
partsto avoidgettingdirt into engine.It is extremely
importantthat nodirt
getsinto the valvelifters.
11509
2. Remove
intake manifold, Remove
exhaustmanifolds.
3. Removerocker armcovers.Donot pry. If coversstick userubbermallet

andstrike coverendto jar loose. Loosenrocker armnutsandpivot the J 3049 A
rockerarmfree of the pushrods.
EI~ [~ 4. Remove pushrods. Remove the hydraulic lifter guides and

lifters that requireserviceoneat a timeandplacethemin an organizerrack.
Thelifters mustbe installed in the sameborefromwhichthey werere-
moved.
E~[~ A stuck hydraulic lifter can be removed

using Tool J-3049-A(plier D
31350
type) orToolJ-9290-01(slide hammer type).
5. If less thana complete set of lifters is beingremoved, immediately

is
assembleoneor twofor presence of dirt or varnish.If lifters containdirt or
varnish,it is advisableto removeall lifters for replacement. Otherwise,
it will
besatisfactoryto serviceonly thoselifters that are not operatingproperly.
’E~ 6. Examine
the camroller (4) of the lifter. If this surfaceis excessively
worn,galled or otherwisedamaged, discardthe lifter assembly. In this case,
also examinethe matingcamshaftlobe for excessivewearor damage.
UnstaHation
[.~O--0~Beforeinstalling anynewlifters, coatthe bottomof the lifter with
Molykoteor its equivalent.
//3
T~5-
Engineteng
7-7
1. Install valve Fifters in cyRinderblock. If any newlifters or a new
camshaft has been installed, an additive containing EPlubricant
such as G.M. Engine Oil Supplement must be added to the
crankcaseoil for break-in.
2. Install pushrods onto lifters. Install intake manifold.
3. Pivot rocker armsin place and install rocker armbolts. Tighten

bolts to 40 ft. abs. (54 N.m).
4. Install rocker arm covers, using G.M. Sealer No. 1052289,and

tighten nuts to 115 in. Ibs. (13 N-m).
5. Install exhaustmanifold. Start engine and checkfor oil leaks at

rocker arm covers.
Valve Spring and Sear Repair
RernovaJ
r~l. Remove rocker arm cover.
2. Remove spark plug, rocker arm, and push rod on the cylinder(s)
to be serviced.
[~ 3. Install Air Line Adapter tool J-23590to spark plug port and
apply compressedair to hold the valves in place.
[~ 4. Using tool J-5892-C, compress the valve spring and
removethe valve locks. Release and removetool. Removevaave
cap and shield, and valve spring and damper.
5. Remove
the valve stem oil seal.
installation
DR3796
1. Install seal over valve stem and seat against head.

J 5892-C .... ~ ~.
2. Set the valve spring and damper,valve shield and valve cap in
place. Compress the spring with tool J-5892-Cand install oil seal \y
in the lower groove of the stem, makingsure the seal is flat and
not twisted. NOTE:A light coat of oil on the seal will help prevent
twisting.
3. ~nstal} the valve locks and re~easethe compressortool making /

sure the locks seat properly in the upper groove of the vanvestem.
NOTE:Grease may be used to hold the locks in place while
releasing the compressortool DR3794
4. Install spark plug and torque to 20 ft. lb. (27 N.m).
5. Install rocker armcover. Tightennuts to 115 in. Ibs. (13,0 N.m).
7-8 Engine/eng
Cylinder Head
Removal
1, Drain water from block and exhaust manifolds. Removeintake

and exhaust manifolds.
2. Removevalve covers and spark plugs.

=
3. Loosenrocker arm bolts and turn rocker arms aside. Remow,
pushrods. If lifters are to be serviced, removethemat this poinl.
Otherwise protect the lifters and the camshaft from the entrance
of dirt by covering the area with clean cloths.
4. Removecylinder head bolts, cylinder heads and gasket. Place

cylinder heads on bench, supporting them at each end on blocks
of wood to prevent damageto gasket faces of heads.
Disassembly
1. Remove
rocker arm bolts, ball seats and rocker arms.
2. Using tool J-8062, compressthe valve springs and remove

the valve keys. Releasethe compressortool, and removerotators, DR3125
springs and spring dampers,then removeoil seals.
3. Removevalve from bottom of cylinder heads and place them

and their respective valve springs in a rack in their proper
sequenceso they can be assembledin their original positions.
CHeaningand inspection

cylinder head cleaning and inspection.
Repair
1. ValveSeats:

seating of the valve must be perfect for the engine to deliver the
power and performancebuilt into it.
Another important factor is the cooling of the valve heads. Good

contact betweeneachvalve and its seat in the head is imperative
to ensure that the heat in the valve head will be properly carried
away.
Eng,ne/eng 7-9
Several different types of equipmentare available for reseating
valve seats; the recommendationsof the manufacturer of the
equipment being used should be carefully followed to attain
proper results.
Regardless of what type of equipment is used, however, it is

essential that valve guides be free from carbon or dirt to ensure
proper centering of pilot in the guide.
a. lnstall expanding pilot in the valve guide bore and

expandpilot by tightening nut on top of pilot.
b. Place roughing stone or forming stone over pilot and just

clean up the valve seat. Usea 46° stone for both the inlet
and exhaust valve seats.
Removeroughing stone or forming stone from pilot,

install finishing stone on pilot and cut just enoughmetal
from the seat to provide a smoothfinish.
d, Narrowdownthe valve seats to the proper width for the

intake and exhaust. SeeSpecifications at the end of this
section.
°This operation is done by grinding the port side with a 30
stone to lower seat and a 60° stone to raise seat.
e. Removeexpanding piJot and clean cylinder head care-

fully to remove all chips and grindings from above
operations.
E~] ~ Valve seats should be concentric to within 0.002 in.

total indicator reading.
2. Valves:
Valves that are pitted can be refaced to the proper angle, ensuring
correct relation between the head and stem on a valve refacing
machine. Valve stems ,which showexcessive wear, or valves that
are warped excessively should be replaced. Whena valve head
which is warped excessively is refaced, a knife edge will be
groundon part or aH of the valve head due to the amountof metal
that must be removedto completely reface. Knife edges lead to
breakage, burning or pre-ignition due to heat localizing on this
10425
1
knife edge. If the edgeof the valve headis less than ½2in. thick
after grinding, replace the valve.
7-10 Engme/eng
a° If necessary, dress the vaUverefacing machinegrinding
°wheelto makesure it is smoothand true. Set chuckat 45
mark for grinding valves.
b. Clampthe valve stem in the chuck of the machine.
c. Start the grinder and movethe valve head out in line

with the grinder wheenby movingthe lever to the left.
d= Turn the feed screw until the valve head just contacts
wheel. Movevalve back and forth across the wheel and
regulate the feed screw to provide light valve contact.
Continue grinding until the valve face is true and smooth

¯all aroundvalve. If this makesthe valve thin, the valw,
must be replaced as the valve will overheat and burn.
f. Removevalve from chuck and place stem in "V" block.

Feed valve squarely against grinding wheel to grind any
pit from rocker arm end of stem. NOTE:Onnythe extreme
end of the valve stem is hardenedto resist wear. Do not
grind end of stem excessively.
g°After cleaning vaave face and cylinder head valve seat of

grinding partic6es, makepencil marksabout 1/4 in. apart
across the valve face, place the valve in cylinder head
and give the valve one-half turn in each direction while
exerting firm pressure on face of valve. @@
Remove valve and checkface carefully. If all pencil marks

have not been removedat the point of contact with the
valve seat, it will be necessary to repeat the refacing
operation and against recheck for proper seating.
i. Grind and check remaining valves in the samemanner.
Assembly
~’et-~ Whenreplacing valve springs, refer to the latest part,,;
catalog for ordering information.
~] Starting with number 1 cylinder, place the valves in the
designated ports and assembleall but the seal and locks. Then,
using tool J-5892-C,compressthe spring (~) and install the seal
and locks ©. Seethat the seal is flat and not twisted in the valve
stem groove, and that the locks seat properly in the valve stem
groove.
DR3795
~ Place valve spring in position with the closed coil end toward the
cylinder head.
Installation
1. Wipeoff engineblock gasket surface and be certain no foreign material

hasfallen into the cylinder bores,bolt holes, or the valve lifter area.It is
goodpractice to clean out bolt holes with an air hose.
~This engine has special marine head gaskets. Do not substitute

automotive head gaskets.
2. Install newheadgasketon cylinder block. Dowelsin the block will hold

the gasket in position. Alwayshandlegasketscarefully to avoid kinking or
damage to the surface treatment of the gaskets. DONOTuse any type of
sealing material on headgaskets. Thegaskets are coatedwith a special
lacquer to provide a goodseal, once the parts have warmedup.
3. Carefully set in place on the engineblock dowelpins.
4. Clean and lubricate the headbolts with VolvoPentaGasketSealing

Compound P/N 1161231-4.Install bolts.
5. Tighten the headbolts with a torque wrench,in three progressive

steps, following the sequenceshown.
Step1 - 35 ft. Ibs. (47 N®m)
Step2 - 65 ft. Ibs. (88 N®m)

® ® ® @
Step3 - 85 ft. Ibs. (115Nom)
~ Damage to the cylinder block threads can result if bolts are not
lubricated with VoRvoPenta Gasket Sealing Compound P/N 1161231-4
prior to installation or if the bolts are tightenedexcessively.Usean accurate
torque wrenchwheninstalling headbolts and do not overtighten. Uneven
DR2905
tightening of the cylinder headbolts candistort the cylinder bores, causing
compressionloss and excessive oil consumption.
Timing Chain, Cover and Seal

Harmonic Balancer Removam
1. Remove
alternator and powersteering belts, and crankshaft pulley.
\
[~ 2. Attach tool J-23523-Eto baEancer,and turn puller screw to remove
balancer from crankshaft.
DR3573
Oil Seal Replacement
~-~ Cover need not be removedto replace the craknkshaft seal.
1. Pry oil seal out of front of coverusinga large screwdriver.
7-12 Eng,ne/eng
L_,LJ 2. Coat seal lips with engine oil. Install newseal with lip
toward inside of cover. Use too} J-35468 to drive seal into
position.
11
Timing Chain Covet" Removal
1. RemovecircuBating pumppulley, aUternator brace, and power

steering pump.
2. Drain cooling system and remove hose at circulating pump.

Disconnect temperature sender wire, then remove circulating
pumpand discard gaskets. 787
3. Remove
oil pan. See Oil Pan in this section.
4, Removethe front cover-to-block attaching screws. Remove

front cover and gasket.
Timing Chain and Sprocket Replacement

~ 1. Crank engine until "0’" marks on camshaft and crankshaft
sprocketsare in alignment,in this position, engineis timed to firE:
No. 6 cylinder.
DR3579
2. Removecamshaft sprocket bolts. Removesprocket and timing
chain together. Sprocketis a slight press-fit for approximately1/i~
inch. If sprocket does not comeoff easily, a light blow with a
plastic-faced hammeron the lower edge of the camshaft sprocket
should dislodge it.
3. If crank sprocket requires replacement,use a two or three

jaw puller such as J-1619 that pilots on end of crankshaft to pull
off sprocket.
E~ 4. Install crank sprocket using tool J=22102to drive it into

place over keyway.
DR3574
[~ 5. Install timing chain on camshaft sprocket. Hold the sprock-

et vertical with the chain hanging below. Align the camand crank
sprocket timing marks, and attach the chain to the crank sprocket.
DR3577
/// ~ //’x-’~,¢"
/’ ,
DR3571
6. Align dowelin camshaftwith dowelhole in sprocket and install
sprocket on camshaft.
De not hammersprocket onto camshaft. This may loosen

rear camshaft welsh plug.
7. Drawsprocket onto camshaft using the mounting bolts. Lubri-

cate the timing chain with engine oil.
TimingChain CoverInstallation
1. Clean gasket surface on block and crankcasefront cover.
2. Install new oil pan gasket and oil pan. See Oil Pan in this
section.
3. Coat the gasket with sealer and place in position on cover.

Apply a 1/8 inch bead of GMSilicone RubberSealer, P/N 1052366
(or equivalent), to the joint formed at the oil pan and cylinder
block.
4. Position crankcase front cover over crankshaft. Press cover

downward against oil pan until cover is aligned and installed over
dowel pins on block.
5. Install the front cover-to-block attaching screws.
6. Tighten front cover to block bolts. See TorqueSpecifications at

the end of this section for the torque figure.
Harmonic Balancer lnstaBatien
1. Coat machinedouter surface of balancer hub with engine oil.

Align keywayand start balancer onto crankshaft.
[~ 2. Using appropriate end of tool J-23523-E threaded into

crankshaft, or a large washerand a 7/16-20 x 4 in. bolt and nut DR3576
threaded into center hole in crankshaft, tighten nut to seat

harmonic balancer on crankshaft.
[~E} 3. Removeinstalling tooi. Install crankshaft puiley and
tighten screws securely. Thread 7/16-20 x 2 in. bolt and thick
washer into crankshaft and tighten. See Torque Specifications at
4. Install circulating pumpand pulley, and tighten screws se-

curely. Attach water hose to pump=
5. Install alternator and power steering pumpbrackets. Install 24965

alternator and powersteering belts and adjust tension to specifi-
cations.
7-14 Eng,ne/eng
Camshaft
Removal
[::3~ 1. Remove
distributor (~. Remove
intake manifold and circu-
lating pump.
2. Removerocker arm covers, loosen rocker arms, then remove

pushrods and valve lifters.
3. Removecrankshaft pulley, harmonic balancer, timing chain

cover, timing chain, and camshaft sprocket. 28257
E4--’~ 4. Install two or three 5/16-18x 4 in. bolts in camshaftsprocket

bolt holes and carefully pull out camshaft. Use care not to
damagecamshaft bearings.
Measure:
Camshaft Journals. Refer to General Engine Mechanical section

in this manual.Do not attempt to repair the camshaft. Replacethe
c~]mshaft if damaged. Whenever the camshaft needs to be
replaced, a newset: of valve lifters mustalso be installed.
DR3790
Bearings

camshaft bearing disassembly, cleaning, inspection, and assem,-
b!y.
Installation
1. Lubricate camshaftjournals with engine oil.

~ot~ Whenevera new camshaft is installed, lubricate the cam-
shaft lobes with Molykote or its equivalent. Also add one can cf
G.M. Engine Oil Supplementto crankcase oil.
2. Install three 5/lS-18 x 4 in. bolts in camshaftbolt holes, install

camshaft, being careful not to damagebearings.
3. Install camsprocket (making sure timing marksface outward),,

timing chain, and timing chain cover.
4. Install harmonicbalancer andcrankshaft pulley. Install circulat-

ing pumpand connect coolant hose.
5. Install valve lifters, push rods, rocker arms, and intake mani-
fold. Install rocker armcovers.
6. Install distributor andset initial timing.

Lubrication System
Description and Operation
The oil pumpconsists of two gears and a pressure relief valve

enclosed in a two-piece housing, and is driven by the distributor
driveshaft which in turn is driven by a helix gear on the camshaft.
The pumpis flange mountedto the cylinder block with two bolts.
The pumpcover is equipped with a pressure regulator valve that

regulates oil pressure at approximately 40-60 PSnat 2000 RPM.
Thepumpintake is of the fixed screen type. A meshscreen filters
out small particles of dirt and sludge which maybe present.
A baffle incorporated in the intake screen has been de-

signed to eliminate pressure toss due to suddensurging stops. In
the event that a screen becomesplugged, a steel grommetopens
and bypasses oil to the pump. Oil passes through an opening in
the mountingflange to the cylinder block, then into an oil filter
adapter.
The mainoil galleries run the full Dengthof the crankcaseand cut
into the valve lifter guide holes to supplyoil at full pressureto the
lifters. The rocker arms and valves are lubricated by an oi0
channel in each pushrod. Excessoi6 drains off and returns to the
oil pan through passagesin the cylinder head and block.
Connecting passagesdrilled in the crankcase permit delivery of

oil at full pressure to all crankshaft and camshaft bearings,
distributor drive gear, and shaft, and the timing chain.
Holes drilled in the crankshaft carry oil from the crankshaft

bearings to the connecting rod bearings. Pistons and cylinder
walls are lubricated by oil forced through a small notch in the
bearing parting surface on the connecting rod, ,which registers
with the hole in the crankpin once every revolution. Piston pins
28256
are lubricated by splash.
RemoteEngineOil Filter
tIT [~ A full flow oil filter ~ is mountedto a bracket attached
to the port exhaust elbow. Twohoses connect it to an oil cooler
and an engine block adaptor ®.
[~ [~ Oil exits the block through the rear opening © of the
adaptor, andtravels througha hoseto the rear oil cooler fitting. It
leaves the front cooler fitting, and travels through a hose that
19~6A
connectsto the filter bracket inner (starboard) opening@. Return
oil leavesthe filter bracket at the outer (port) opening(~), travels
through a hose and re-enters the engine at the forward opening
(~) of the adaptor.
If hosesare improperly attached at adaptor or filter brack-

et, oil flow will be reversed. Oil pressure wilt drop and engine
damagemay result.
7-16 Engme/eng
[~ Normally, all engine oil passes from the bJock through an
OEMfilter adapter @. If the remote oil filter or lines become ©
restricted, a spring loaded bypass vaBve ® opens in the adaptor
and circuJates oil back into the block.
E’3~ Inspect bypass valve spring and valve disc ® for proper
operation or damage.If repmacementof bypass valve is neces-
sary, removebolts and adaptor. Clean valve chamberin block and
replace adaptor.
DR2906
Removal
1. Removetiming chain cover. See Timing Chain, Cover and Seal

in this section.
2. Removeoil dipstick and withdraw oil using a suction pump.
3. Removeoil dipstick tube. Removescrews, oil pan and gasket.
4. Remove
oil dipstick tube fitting from oil pan.
DR3788
installation
1. Thoroughlyclean all gasket sealing surfaces.

~-] 2. Apply RTVsealer to the front and rear corners of the block.
3. Attach gasketto block. Install rear portion of oil panseal in

groove in rear main bearing cap.
~ 4. Install front portion of oil pan seal by pressing the corner,,;
im.o sealer applied to block.
31576
5. install oil pan and tighten screws. SeeTorqueSpecifications al:
[~ 6. Install dipstick tube fitting to pan; leave screw loose..
Orient fitting and attach dipstick tube. Thentighten fitting screw
and flare nut. SeeTorqueSpecifications at the endof this sectiorT:
for the torque figure.
7. Fill crankcasewith specified engine oil. See CrankcaseOil in

the General information Section.
Oiil Pump DR3580
Removal and Disassembly
1. Removeoil pan.
[~] 2. Removepumpto rear main bearing cap bolt, and remove

pump,extension shaft, and collar. NOTE:Baffle nuts have to be
loosened.
Englrle/eng 7-17
3. Disconnect pump shaft from extension. Removefour cover
attaching screws, cover, gasket, idler gear and drive gear, and
shaft.
4. Removepressure reguKator valve and valve parts°
5. If the pickup screen or pipe needreplacing, replace the entire

pump and pickup screen assembly.
6. Washall parts in cleaning solvent and dry using compressed

air.
inspection
Should any of the following conditions be found during inspec-

tion operations, the pumpand pickup screen assembly should be
replaced.
1. Inspect pumpbody for cracks or excessive wear. Inspect oil

pumpgears for excessive wear or damage.
2. Checkshaft for looseness in the housing. Checkinside of cover

for wearthat would permit oil to leak past the endsof gears.
3. Check the oil pickup screen for damageto screen or reBief

grommet.Checkfor oil in the air chamber.
4. Checkpressure regulator valve plunger for fit in cover.
Assemblyand installation
1. Place drive gear and shaft in pumpbody. Install idler gear so

that smoothside of gear will be toward the cover.
2. Install a new pumpto cover gasket to ensure correct end

clearance of the gears.
3. install cover and attaching screws. Tighten screwsto 80 in. Ibs.

(9 N.m), and check to see that shaft turns freely.
4. Install regulator valve plunger, spring, retainer, and pin.
5. Assemble collar end of extension shaft assembly over pump

driveshaft, aligning tang of extension shaft with slot in end of
pumpdriveshaft.
6. Assemblepumpand extension shaft to rear main bearing cap,

aligning slot on top end of extension shaft with drive tang on
lower end of distributor shaft. NOTE:Oil pumpshould slide easily
into place. If not, remove and relocate slot or locate other
problem. Install mounting screws and tighten. See Torque Speci-
fications at the end of this section for the torque figure.
7. Tightenbaffle nuts.
8. Install oil pan using newgasket. Connectoil drain tube.
7-18 Englne/eng
MeasuringCamshaftLobeLift
E~ 1. Removerocker arm covers. Loosen rocker arms and pivot
awayfrom push rods. Position indicator with ball socket adapter
(]bol J-8520) on push rod. Makesure push rod is in the lifter
socket.
2. Rotate the crankshaft slowly in the direction of rotation until the

lifter is on the heel of the camlobe. At this point, the pushrod will
be in its lowest position.
3. Set dial indicator on zero, then rotate the crankshaft stowly, or DR3791
attach an auxiliary starter switch and "bump" the engine over,

until the pushrod is fully raised position.
Wheneverthe engine is cranked:
Removegray and black connectors from ignition coil to

preventaccidental starting ef engine.
4. Comparethe total lift recorded from the dial indicator with

specifications. If camshaftreadingsfor all lobes are ,within specifi-
cations, removedial indicator assembly.
DR5555
5. Install valve mechanismas outlined. Install rocker arm covers.
Rear Main Bearing Oil Seal Replacement
Pry out rear crankcase oil seal. NOTE:Care should be taken when
removing the rear crankcase oil seal so as not to nick tl~e
crankcase seal surface.
Clean sealing surface on crankshaft with a non-abrasive cleaner.

Inspect chamfer on crankshaft for grit, loose rust, and burrs.
Correct as necessary.
Rnstaliation
1. Lubricate the inner and outer diameter of the seal with engine
oil
D~ 2. Position the seal onto tool J-38841(~ so seal lip will face
the block.
~ 3. Position tool J-38843 against the crankshaft. Thread the
attaching screws into the tapped holes in the crankshaft and
tighten securely. This will ensure that the seal ® is installed
squarely over the crankshaft. Turn the handle until it bottomsthen
removethe tool.
Eog,o~;~.g ~ Safety Related 7-19

Crankshaft
Description
Main bearings are of the precision insert type and do not utilize
shims for adjustment. If clearances are found to be excessive, a
new bearing, both upper and lower halves, will be required.
Bearings are available in standard size and 0.001 in. (0,0254 ram),
0.002 in. (0,0508 mm), 0.010 in. (0,245 ram) and 0.020 in. (0,508
mm)undersize.
Selective fitting of both rod and main bearing inserts is necessary

in production in order to obtain close tolerances. For this reason
you mayfind one-haft of a standard insert with one-half of a 0.001
in. (0,0254 mm)undersize insert which ,will decrease the clear-
ance 0.0005 in. (0,0127 mm)from using a full standard bearing.
Whena production crankshaft cannot be precision fitted by this

method,it is then ground 0.009 in. (0,2286 mm)undersize on only
those main journals that cannot be properly fitted. All journals
will not necessarily be ground undersize. A 0.009 in. (0,2286 ram)
undersize bearing and 0.010 in. (0,245 ram) undersize bearing
maybe used for precision fitting in the samemanneras previ-
ously described.
if, for any reason, main bearing caps are replaced, shim-
ming may be necessary. Laminated shims for each cap are
available for service. Shim requirement will be determined by
bearing clearance.
Cleaning, Inspection and Repair
[~ Refer to General Engine Mechanical section in this manual

for cUeaning, inspection, and measurements.
in general, (except No. 1 bearing) the lower half of the bearing

showsa greater wear and the most distress from fatigue, ff upon
inspection the lower half is suitable for use, it can be assumed
that the upper half is also satisfactory. If the lower half shows
evidence of wear or damage,both upper and lower halves should
be replaced. Never replace one half without replacing the other
half.
These dimensions should be checked with a micrometer for

out-of-round, taper or undersize. If the journals exceed0.001 in.
(0,0254 mm)out-of-round, or taper, the crankshaft should
replaced or reconditioned to an undersize figure that will enable
the installation of undersize precision type bearings.
The crankshaft should also be checkedfor runout. To perform this

operation, support the crankshaft at the front and rear main
bearing journals in "V" blocks, and indicate the runout of both the
rear intermediate and front intermediate journals, using a dial
indicator. The runout limit of each of these journals is 0.002 in.
(0,0508 ram). if the runout exceeds 0.002 in. (0,0508 ram),
crankshaft must be repaired or replaced.
7-20 Engme/eng
Main Bearing Replacement
[~ 1. Install a main bearing removing and installing tool 3-8080

~) in oiE hole in crankshaft journal. NOTE:If such a tool is not
available, a cotter pin maybe bent as required to do the job.
2. Rotate the crankshaft clockwise as viewed from the front of

engine. This will roll upper bearing out of block.
3. Oil new selected size upper bearing and insert plain (un-
notched) end between crankshaft and indented or notched side of
brock. Rotate the bearing into place, and removetool from oiE hole DR2£1
in crankshaft journal.
4. Oil new Jower bearing and install in bearing cap. Install main
bearing cap with arrows pointing toward front of engine. Torque
main bearing cap bolts to specifications.
Measure:
Refer to General Engine Mechanicansection in this manual for

crankshaft bearing clearance procedures.
Connecting Rod Bearing Replacement

Connecting rod bearings are of the precision insert type and do
not utilize shims for adjustment. DO NOTFILE RODSOR ROD
CAPS,If clearances are found to be excessive a newbearing will
be required. Bearings are available in standard size and 0.001 in.
undersize for use with standard size crankshafts.
1, With o[I pan and oil pumpremoved, removethe connecting rod

cap and bearing.
2. Wipethe bearings and crankpin clean of oil. Inspect the bearing

for evidence of wear or damage.
3. Measurethe crankpin for out-of-round or taper with a microme-

ter. ff not within specifications, replace or recondition the crank-
shaft. If within specifications and a newbearing is to be installed,
measure the maximumdiameter of the crankpin to determine
new bearing size required.
4. If within specifications, measurenew or used bearing clear-

ances with Plastigage or its equivalent.
[~ If a bearing is being fitted to an out-of-round crankpin, be

sure to fit to the maximum diameter of the crankpin. If the bearing
is fitted to the minimumdiameter and the crankpin is out-of-
round 0.001 in., interference between the bearing and crankpin
will result in rapid bearing failure.
a. Place a piece of gauging plastic the full width of ttne

crankpin parallel to the crankshaft. (Note: Surfaces must
be free from oil.)
Englne/eng 7-21
b. Install the bearing in the connecting rod and cap.
c. Install the bearing cap and evenly tighten nuts to specifi-

cations.
[~ Do not turn the crankshaft with the gauging plastic

insta||ed.
d. Removethe bearing cap and using the scale on the

gauging plastic envelope, measurethe gauging plastic
width at the widest point.
5. If the clearanceexceedsspecifications select a new, correct size

bearing and remeasure the clearance.
6. Coat the bearing surface with oil, install the rod cap and tighten
nuts to specifications.
7. Whenall connecting rod bearings have been installed tap each

rod lightly (parallel to the crankpin) to makesure they have
clearance.
[~ 8. Measureall connecting rod side clearances (see Specifica-

tions at end of this section), betweenconnecting rod caps.
47427
Piston, Ring and Connecting Rod

Piston and Rod Removal
1. Removeoil pan, oil pump, and cylinder head. Turn crankshaft

until piston is at bottomof stroke. Place a cloth on top of piston to
collect cuttings.
2. Before attempting to remove piston, remove cylinder bore

ridge as necessary.
DR3792
Refer to GeneralEngineMechanicalsection in this manual

for cylinder bore ridge reamer procedures.
3. Inspect connecting rods and connecting rod caps for cylinder

identification. If necessarymark them.
DE] 4. Removeconnecting rod cap and install tool J-5239 on

studs. Push connecting rod and piston assembly out of top of
cylinder block.
[~ It will be necessary to turn the crankshaft slightly to

disconnect some of the connecting rod and piston assemblies
and push them out of the cylinder.
Disassembly
Refer to General Engine Mechanicalsection in this manual for

piston and connecting rod disassembly.
7-22 Engine/eng
Assembly
Referto GeneralEngineMechanical
section in this manualfor piston and
connectingrod assembly.
PistonandRodUnstallation
1. Lightlycoatpistons,rings andcylinderwarlswith light engineoil.
2. Withbearingcapsremoved,
install tool J-5239on bearingcapbolts.
[~o-0-t-~ Checkposition of ring endgaps.Theymustbe alignedwith each

().’.her as describedpreviously.SeeGeneralEngineMechanical.
3 Install eachpiston in its respectivebore, usingtool J-5239on each
assembly. For valveclearance,the teardropin the piston facesup andthe
oil holeon the connecting rod shouldbe to the centerof the cylinderbtock.
Guidethe connectingrod into placeon the crankshaftjournals with the long
detail of tool J-5239.
E3~]4. Usetool J=8037to compress
the piston rings.
5. Install bearingcapsandcheckthe bearingclearance.Referto General
EngineMechanical section in this manualfor connectingrod side clearance
procedure.
Cylinder Block
C~,linderBore
[~ Inspect: J 8037~
Cylinderboresfor scoringor other damage.

Referto GeneralEngineMe- \
chanicalsectionin this manual.
[~_~ Measure:
Cylinderbore taper andout-of-round.Referto GeneralEngineMechanical 5159
sectionin this manual.
C, ylinder BoreReconditioning
[~ Measure:
Referto GeneralEngineMechanical
section in this manual.
Piston Selection
1. CheckUSED
piston to cylinder bore clearanceas follows:
a. MeasL,re the "CylinderBoreDiameter"with a telescope
gauge21/2in. (64 mm)fromtop of cylinderbore.
b. Mesurethe "PistonDiameter"(at skirt acrosscenterlineof
pistonpin).
c. Subtractpiston diameterfrm cylinder borediameterto
determine"Piston to CylinderCtearence.."
d. Calculatepiston diameterfrom cylinder clearenceand
determineif pistonto cylinderwall clearence
is within
servicelimits.
2. If usedpiston is not acceptable,checkif a newpiston maybe usedto fit
cyinderborewithin servicelimits.
Engine/eng
7-23
3. If cylinder boremustbe reconditioned,measure newpiston diameter
(acrosscenterlineof piston pin), thenhonecylinderboreto correct clear-
ancePreferablerange).Markthe piston to identify the cylinderfor whichit
wasfitted.
Handlethe pistons with care, anddo not attemptto force themthroughthe

cylinderuntil the cylinder hasbeenboredto correct size as this typepiston
canbe distorted throughcarelesshandling.
Circulating Pump
~TheVolvo Penta circulating pumpis manufacturedspecially for
marineuse. It is servicedonly as an assembly.Donot replacewith an
automotivecirculating pump.
inspection
Remove alternator andpowersteering belts. Graspcirculating pumppulley

andcheckendandside play. Turnpulley to checkfor drag. Lookfor water
leaking from indicator hole beneathpumpshaft behindpulley. Replace
pump if play, drag, or leakageare evident.
Removal
and Installation
1. Drain waterfrom block anddisconnectwaterhosefrom circulating pump.

Remove pulley. Remove circulating pumpbolts, pumpand gaskets.
2. Usenewpumpto block gasketsand sealer, install newpumpassembly

oncylinderblockandtightenbolts as specified.Install pulley. Install alter-
nator andpowersteering belts, then adjust tension. Connecthoseto
circulating pump.Lakeor tank test unit andcheckfor leaks.
Front Engine MountReplacement

Removal
E~ 1. Removetwo lag screws @and washersfrom mounts.
Z~ 2. Lift engine with 1500lb. (680 kg) minimum

capacityhoist
to allow removalof front mountand bracket. Remove three mount
screwsand lock washers(E).
11982
11981
7-24 Engineleng
E3~~ Prior to disassembly of front mount assembly, measure
d,stance betweenlarge washerandflat on uppermountbracket.
Disassembly
[~] t. Remove
three nuts ©; one Iockwasher,and engine mountbracket
@from mountbolt ~:) while holding bolt securewith socket.
L-~ 2. Remove one large washer ®, one small washer @and engine
mountbolt (~) from mount. \
11980
Reassembly
1. Pfacesmall washer@on mountbolt andinsert bolt up through

mount.Install large washer® andsecurewith nut @.Tightento 80-75ft.
Ibs. (81-102N.m).
E~2. Install upperinner nut and place enginemountbracket @on

enginemountbolt.
E~ Measuredistance betweenlarge washer and flat on upper mount

bracket. Distancemustbe the sameas that prior to disassembly.
11879
3. Install lock washer

andlowernut. Tightennut to 50-70ft. Ibs. (68-95
N,m).
installation
1. Spraythe enginemountscrewsthreadswith Loctite~ PrimerN and

allow to air dry. ApplyVolvoPentaTreadSealingAgentP/N1161053-6 to
the screws. Attach enginemountassemblyto enginewith three screwsand
washers.Tightento 32-40ft. Ibs. (43=54N-m).
2. Install lag screwsandtighten securely. m

11978
Height Adjustment
~T~1. To changeengineheight, tighten or loosen nuts (~ andC)
required.
L~2 Lift enginewith 1500 ib.1680 kg) minimum
capacity hoist.
Positionengineat desiredheight.
[~7~3. After setting mountposition, turn nut C) up against undersideof
enginebracket andhold nut with a wrench.Tightenuppernut ® to 100-
120ft. tbs. (138-163N-m).
11983
High-Rise ExhaustElbowReplacernent
Removal
I~O-~ Drain water from respective exhaustmanifold.
1, Loosentwo clampssecuring upperhoseto elbow.
2953
Engine/eng
7-25
Ei=] 2. Port Elbow- Remove
four thru-bolts and lock wahsers@. Move
the remotefilter aside
3. StarboardElbow- Remove four thru-bolts lock washers,and

washersattaching high rise elbowandcircuit breakerbracket ®. Set
bracket assemblyaside.
[~ 4. Lubricate inside of exhausthosewith a soapywatersolution, then

removeremainingelbowbolts. Tapelbowwith a soft hammer to free it,
then twist it out of the hose.Remove
anddiscardthe manifoldgasket.
28~67
Installation
1. Apply VolvoPentaGasketSealing Compound P/N 1161231-4to

both sides of a newgasket©, andplace it on the manifold. Lubricate
inside of exhausthosewith a soapywatersolution to easeelbowinstalla-
tion.
3. Twist elbowinto hoseandposition it on the gasket.Install the outerrear

thru-bolt, washer,andlock washer,
andturn it in finger tight.
[~ 4. Port Elbow- Positionremoteoil filter at front of elbowandalign the

ECM/throttlelinkagebracketwith the bolt holesof the high rise elbow. 37349
Install four thru-bolts, washers,
andlock washers finger tight.
CAUTION
Do not damageor bind throttle linkage during reassembly.
E~5. StarboardElbow- Position circuit breakerassemblyat front of
elbowInstall twothru-bolts (~, washers,andlock washers
finger tight.
6.Tightenall erbowthru-bolts to 12-18ft. Ibs. (16-24N.m).

/t~7. Properly position the two exhausthoseclampsand tighten them
secureJy.
28265
28266
7- 2 6 Engine/eng
Exhaust Hoseand intermediate Pipe
RepUacement
1. Loosen eight dampsthat attach the upper and lower exhaust

hoses, and slide cramps down onto exhaust Y-pipe=
[~6---’] 2. Lubricate inside of lower hosewith a soapywater solu-
tion, and push lower hose down onto exhaust Y-pipe0
ETml 3. Twist intermediate pipe out of upper hose. Lubricate 19377A
inside of upper hose with a soapy water solution for ease of

removal.
4. SJide upper hose off high-rise elbow. Slide lower hose off
exhaust Y=pipe.
Installation
1. Lubricate inside diameter of 3.5 in. (8,89 cm) I.D. lower hose
with a soapywater solution. Slide it all the wayonto the exhaust
Y=pipe.
28264
ES-=-I 2. Onthe inside of the 4 in. (10,16 cm)i.D. upperhose, there
is a circular rib 1.5 in. (3,81 cm) from one end. Theribbed end
the hose must face the intermediate pipe (rearward) whenit’s
installed. Slide hoseonto high-rise elbowuntil it seats. NOTE:If
hoseis not properly positioned, it will not completely engagethe
high-rise elbow or allow secure attachment.
EThEl3. With a twisting motion, insert intermediate pipe aln the

wayinto the upper hose. Slide the lower hoseup until it’s halfway
onto the intermediate pipe.
L~ 4. Slide four No. 68 clampsup onto the upper hose. Slide four
No. 64 clamps up onto lower hose. Position clamps in theiir
proper channels and tighten them securely.
Exhaust {Flapper) Valve Replacement

under E×haust Hose and intermediate Pipe Replacement.
Eg~2. Slide the Rowerhose downfar enoughto expose the valve I g445
pivot pin= Hold the valve while pulling out the pin, then lift out the
valve.
EIO~] 3. Inspect the two rubber bushings inside the pipe, and
replace them as necessary.
installation
1. If installing newrubberbushings,apply3/t,P ScotchGripRrubberAdhe-

sive 1300to outsideof tips, andinsert into inside of exhaustpipe.
[~ 2. Positionvalvewith longestlip pointing downandinsert into pipe.

Pushpivot pin throughbushingsandvalveuntil pin endis flush with outside
of pipe.
If valveis not positioned

properly(longlip down),it will restrict
exhaustflow andfail to preventwaterbackingup into engine.Valvemust
also movefreely andnot bind. Boatperformance wouFd
be adverselyaf- 19443
fected, and enginemaysuffer water damage.
3. Install intermediatepipe following procedureunderExhaustHoseand

intermediatePipe Replacement.

Removal
1. Remove
enginefrom boat.
20834
2. Disconnect
frombellhousing.
E~] [~] 3. Remove

sevenscrewssecuring bellhousing cover and slide
coveroff.
7- 2 8 Engine/eng
E4~]4. Pull drain hoseout of bellhousingif equipped.
5. Remove bolts andnuts retaining belthousing.Disconnectgroundwires and

oil coolerbracket.Noteoil coolerorientation.
6. Remove
bell housing.
LT~7. usean offset boxendwrenchto removethe six nuts securingthe

coupler,andslide coupleroff studs.
8 Removeold gasketfrombellhousingcover. Cleangasketsurfacethor-.

oughly. 19842
Installation
[:6-~ 1. install couplerandattachsix Iocknuts.Usea suitable adaptorand
tightennutsto 40-45ft. nbs.(54-61N,m).
2 Install bell housing.Attachoil coolerwith same

orientationas notedin a
previousstep. Tightennutsandbolts to 32-40ft. Ibs. (43-54N-m).Attach
groundwiresandtighten nutsto 15-20ft. Ibs. (20-27N,m).
3 Pushdrain hoseint,o bellhousingif equipped.

6712
4. Apply Volvo PentaGasketSealing Compound P/N 1161231-4to both
sidesof a newbellhousinggasketandposition it on cover.
ET~5. Cleansevenself-tappingscrewswith a wire brush. Install bellhous-

ing coverandscrewsandtighten to 60-84in. lbs. (7-9 N,m).
6 Connect
to bellhousing.Install enginein
boat.
Er~gme;eng
7-29
7.4 and 8.2GSi EngineSpecifications
Type - No. of Cylinder .................................. 90° - V-8

Valve Arrangement .............................. OverheadValves
Bore and Stroke:

7.4 models ................. 4.250 x 4.000 in. (107,95 x 101,6 ram)
8.2 models ................. 4.468 x 4.000 in. (113,48 x 101,6 ram)
Piston Displacement
7.4 models ......................... 454 Cubic Inches (7.4 Liters)
8.2 models ......................... 502 Cubic Inches (8.2 Liters)
Cylinder Numbers- Front to Rear

Starboard ............................................. 2-4-6-8
Port .................................................. 1-3-5-7
Firing Order .................................... 1-8-4-3-6°5-7-2
Compression Ratio
7.4 GSi ................................................. 8.6:1
8.2 GSi ................................................. 8.8:1
Water Temperature Control ........................... Thermostat
Thermostat Opens @ .............................. 160°F(71 °C)
Fu|! Throttle Operating Range

7.4 GSi ...................................... 4800 - 5200 RPM
8.2 GSi ...................................... 4400 - 4800 RPM
Pistons:
Production Clearance
7.4 Models ................. 0.003 - 0.004 in. (0,0762 - 0,1016 ram)
8.2 Models ................. 0.004 - 0.005 in. (0,1016 - 0,1270 ram)
Service Limit .............................. 0.005 in. (0,127 ram)
Piston Rings:
Top GrooveClearance..... 0.0012 - 0.0029 in. (0,0304 - 0,0736 ram)

SecondGrooveClearance . .0.0012 - 0.0029 in. (0,0304 - 0,0736 ram)
Third Ring Groove Clearance .0.005-0.0065in.(0,127-0,1651 ram)
Service Limit ........................... +0.001 in. (+0,0254 ram)
Top Ring Gap ................. 0.010 - 0.018 in. (0,254 = 0,457 mm)
Second Ring Gap ............. 0.016 - 0.024 in. (0,406 - 0,609 ram)
Third Ring Gap ............... 0.010 - 0.030 in. (0,254 = 0,762 ram)
Service Limit ............................. +0.010 in. (0,254 mm)
7-30 Engine/eng
7.4 and 8.2GSi Engine Specifications =
Piston Pins:
Diameter ................. 0.9895 - 0.9897 in. (2,5133 - 2,5138 mm)

Clearance
Production ............... 0.0002 -0.0007 in. (0,0050 - 0,0177 mm)
Service Limit .............................. 0.001 in (0,0254 mm)
RodFit, interferencefit ..... 0.0031 - 0.0021 in. (0,0787 - 0,0533 mm)
Connecting Rod:
Bearing Clearance, New...0.0011 - 0.0029 in. (0.0279 - 0.07366 mm)

Bearing Clearance, Service Limit ............ 0.003 in. (0,0762 ram)
Side Clearance............ 0.0013 - 0.023 in. (0,0330 - 0,5842 ram)
Crankshaft:
Thrust ...................... 0.006 - 0.010 in.( 0,1524 - 0,254 mm)
Main Journal O
No.l, 2, 3, 4, 5 ......... 2.7482 - 2.7489 in. (89.8042 - 69.8220 mm)
Taper
Production .......................... 0.0002 in. (0.0051 ram) Max
Service Limit ......................... 0.001 in. (0.0254 mm)Max
Out-of-round
Production .......................... 0.0002 in (o.0051 mm)Max
Service Limit .......................... 0.001 in (0.0254 ram) Max
Main Bearing Clearance, Production

No.l, 2, 3, 4 .............. 0.0017 - 0.0030 in. (0,0432 - 0,0762 mm)
No. 5 .................... 0.0025 - 0.0040 in. (0,0635- 0,0965 mm)
Main Bearing Clearance, Service Limit

No. 1, 2, 3, 4 ............. 0.0010 - 0.0030 in. (0,0254 - 0,0762 ram)
No. 5 .................... 0.0025 - 0=0040in. (0,0635 - 0,1016 mm)
Crankpin Diameter
7.4 GSi .................. 2.199 - 2.1996 in. (55,854 -55,8698 mm)
8.2 GSi .................................... 2.20 in. (55.88 mm)
Taper and Out-of-Round, New.............. 0.0005 in. (0,0127 mm)
Taper and Out-of-Round, Service Limit ....... 0.001 in. (0,0254 mm)
Camshaft:
CamshaftBearing Journal E~ .. 1.9497 - 1.9477 in. (49,5224 - 49,4716

mm)
Lift, Intake ................ 0.284 + 0.002 in. (7.2136 + 0,0508 mm)
Lift, Exhaust............... 0.284 + 0.002 in. (7.2136 + 0,0508 mm)
Engine/eng
7- 31
7.4 and8.2GSiEngineSpecifications
Valve Systems:
Lifter Type ...................................... Hydraulic Roller
Rocker Arm Ratio

7.4, 8.2GSi .............................................. 1.7:1
Valve Adjustment ............................ zero lash + one turn
Valve Angle .............................................. °45
Seat Angle ............................................... °46
Valve Seat Run-out ............... +0.002 in (0.0508 mm)Maximum
Valve Stem Clearance

Intake, New.............. 0.0010 - 0.0027 in. (0.0254 - 0,0270 mm)
Exhaust, New............. 0.0012 - 0.0029 in. (0,0304 - 0,0736 ram)
Intake, Service Limit ...................... +0.001in. (0,0254 ram)
Exhaust, Service Limit .................... +0.002 in. (0,0508 mm)
Valve Seat Width, Intake ....... 1/32 to 1/16 in. (0,794 to 1,587 mm)
Valve Seat Width, Exhaust ...... 1/16 to 3/32 in. (1,587 to 2,381 mm)
Valve Spring Length ......................... 2.15 in. (54,41 mm)
Valve Spring Installed Height, Installed ...... 1 51/64 in. (45,641 mm)
Valve Spring Pressure

Ibso @in. (kg @mm)compressed..74-86@1.80 in. (33,5-39@45.72)
Ibs. @in. (kg @mm)compressed.......... 195-215@1.40in.(88.4-
97.5@35.56)
Installed Height ............................ + 1/32 in. (0,794 mm)
Valve Spring Fit In Damper....... 0.042 - 0.094 in. (1,06 - 2,38 ram)
Engine Lubrication:
Type Oil Pump............................................. Gear
Normal Oil Pressure, WarmEngine ..... 10 psi (70,3 kPa) @500 RPM
40-60 psi (281-422kPa) @2000 RPM
Crankcase Capacity
8 qts (7,57 liters); 9 qts (8,51liters) w/filter
Oil Grade Recommended

32° F (0 ° C) and above .................................. SAE 30
0° F (-17 ° C) to 32~’ F (0 ° C) ........................ SAE 20W-20
0° F (-17 ° C) and below ............................... SAE 10W
Werecommend Volvo PentaDuraPlus TMSynthetic MotorOil. which is specially

formulatedfor heavyduty marineuse, andideal for VolvoPentaEngines.It pro-
videsbetter anti-wearqualities, especially during long high speedoperation.In
addition, it neutralizes acids common
to all internal combustion engines,offers
superiorcorrosionprotection,andis formulatedto offer better resistanceto oxida-
tion andhigh temperaturesludgeformation.
Fuel Recommendation............ See General Information Section
7- 3 2 EngineJeng
NOTES
7-33
Usea reliable torque wrenchto tighten the parts listed to prevent straining or distorting the parts or
possibly damagingthe threads. Thesespecifications are for clean threads only. Dirty threads produce
friction which prevents accurate measurementof tightness. It is important that these torque specifica-
tions be strictly observed. Overtightening to any extent maydamagethreads, thus preventing proper
torque from being obtained, requiring replacement or repair of the damagedpart.
Camshaft Sprocket 2O 27
Circulating Pump 3O 40
Distributor Clamp 25 34
Dipstick -[ijbe Fitting 15-18 20-24
Flywheel BeHhousing 32-40 43-54
Flywheel Cover 60-84 7-9
Front Mount Bracket to Block 32-40 43-54
Oil Filter BypassValve 20 27
Oil Pan to Block 160 18,1
Oil Pan to Front Cover 70 7,9
Oil PumpCover 80 9
Rocker Arm Cover 60-90 7-10
Starter Motor 30-38 41-49
Thermostat Housing 12-16 16-22
Timing Chain Cover 96 10,8
7-34 Engme/eng
lbrque Specifications(cont.)
m
Connecting Rod Cap 48 65
Exhaust Manifold 20-26 27-35
Flame Arrestor 25-35 2,8-4,0
Flame Arrestor Cover (GL Models) 30-35 3,4-4,0
Flare-Dipstick Tube 15-18 20-24
Flywheel Bellhousing 32-40 43-54
Front Mount (lower) 50-70 68-95
Front Mount (upper) 100-120 136-163
Cylinder Head
Step I 35 47
Step 2 65 88
Step 3 85 115
Exhaust Manifold 24-28 33-38
Front Mount 65-75 81-102
Harmonic Balancer 85 115
High-Rise Elbow 12-18 16-24
Intake Manifold 30 - 40
Main Bearing Cap (All) 100 - 135
Oil Pump 65 - 90
RemoteOil Filter Adaptor (to block) 20-25 - 27-34
Rocker Arm 40 - 54
Sensor and Cover 48-60 5-7
Flywheel and Coupler 10-15 - 14-20
Oil Filter one turn after contact

Spark Plugs 22 30
Er, gme/eng 7-35

NOTES
7-36 Eng,neieng
Section 8
Steering System
Table of Contents
Mechanical (Non-power) Steering PowerSteering System(cont.)
System ................................ 8=2 Extemai Leakage ....................... 8-18
Cable installation ........................ 8=2 Feedback To Helm ...................... 8-21
Cable Removal .......................... 8-2 Hoses ................................ 8-14
Lubrication ............................. 8=3 Hydraulic Fluid .......................... 8=9
Sealants, Lubricants and Adhesives ........ 8-1 Lubrication ............................ 8-14
Steering Tube Replacement................ 8-3 Pumpi=~staHation ........................ 8=8
Trim Tab Adjustment .................... 8=15 PumpLeakage ......................... 8=19
Power Steering System ...................... 8-4 PumpOperation ......................... 8-5
Belt Adjustment ........................ 8-10 PumpPressure Test ..................... 8=19
Cable Installation ....................... 843 PumpRemoval ........................... 8=8
Cable Installation Problems .............. 8-20 Purging Air FromSteering System.......... 8-9
CheckingFluid Level ..................... 8=9 Sealants, Lubricants, and Adhesives........ 8-1
Cylinder Installation ..................... 8-12 Special Tools ............................ 8=1
Cylinder Removal........................ 8-11 Specifications - Torque .................. 8=21
Cylinder Servicing ...................... 842 Steering Without PowerAssist ............. 8-7
Description ............................. 8-4 SystemDiagnosis ....................... 8=14
Diagnosis Chart ......................... 8=16 SystemOperation ........................ 8-8
Special Tools Required: Materials Required:

CrowfootWrench(steering cable anchornut) Volvo PentaGrease
P/N 9995443-08.2 GLPumpPulley Remover VolvoPentapowertrim/tilt & steeringfluid or
P/N 9995444-8
8.2 GLPumpPulley installer GMPowerSteering Fluid
P/N 3854367-4
Volvo PentaHydraulic Cylinder Rod Dexron,or DexronII
H older
Ax Safety Warnings
Beforeworkingon anypart of the engine,read1hesection called
Safetyat the endof this manual.
Unlessinstructed otherwise,alwaysdisconnectthe battery cablesfrom

the battery beforeworkingon electrical systemto preventpossible
sparksor arcing in the enginecompartment.
Beforestarting engineafter repair or maintenance

procedures,always
makesure enginecompartment is free of fuel vaporsto prevent
possiblefire andexplosion.
When workingon an enginethat is runningor beingcranked,use

extreme care to avoidgetting hands,fingers or clothing caughtin the
alternator, powersteering pump,supplypump,andcirculating pump
belts, pulleys andother movingparts.
8 =1
Engine/eng
®
CO2740 18638
Mechanical(Non-power)Steering System
Description
The mechanicalsteering system consists of a helm assembly(~, the

steering cable (~), and attaching hardware© that connectthe steering
systemto the inner transombracket and steering arm.
Steering Cable Removal
The steering cable is serviced as an assembly. 6825
[~ I’~ 1 To removethe steering cable, removethe cotter pin (~) and

steering arm pin ~) securing the cable ram to the steering arm(E). Remove
both steering arm bushings@.
2. Turnthe helmto the port full lock position.
3. Loosenthe cabie anchor nut ®, and removethe cable.
SteeringCable Installation
~ Steering tube position in the anchor block is preset at the factory 31837
for proper centering of the steering system.Donot loosen the jam nut or
changethe position of the steering tube.
EEl//~1. Turn the steering wheelto fully extend the steering cable ram to
its maximumextension. Lubricate the full ~engthof the steering cable ram
with Volvo Penta GreaseP/N 828250-1o
2. Install the steering cable ramthroughthe steering tube.
3. Whileholding the steering cable in the steering tube, thread the steering
cable anchornut onto the steering tube until the steering cable anchornut
bottomson the end of the steering tube. 2921
//~ 4. Attach a crowfoot wrench~) at a 90° angle to the torque

wrench.Tightenthe steering cable anchornut to 120 in. Ibs. (14 N,m).
18653
8-2 Eng,ne;eng
E2-7 E~5. Insert bushings@into steering arm. Install the steering arm
pin (~) throughthe top hole in the steering armand throughthe hole of the
steering cable ram.
L~ ~ 6. Install the: cotter pin @through the steering arm pin and
secureby spreadingthe ends of the cotter pin.
L~7. Turn the steering wheelto fully extendand retract the steering cable
ram @.The steering arm should movefrom stop to stop as the steering
rammovesfrom fully retracted to fully extended.Steering armmustnot
contact inside of transomcutout in either direction. Checkfor equal clear-
ance of steering arm. Centerthe steering wheeland checkcentering of 3253
steering arm. Readjust as necessary.
Steering SystemLubrication
[~] Z~ Lubricate the steering ram with Volvo Penta Grease P/N
828250-1every 50 hoursor 60 days, whichever comesfirst.
E~ Due to local conditions, it maybe necessary to lubricate your

steering ramat morefrequent intervals.
Steering Tube Replacement

DR172
1. Loosenthe jam nut and screwthe steering tube out of the anchorblock.
Removethe jam nut from the steering tube.
E9--’1 2. Screwthe jamnut (~ alJ the wayonto a newsteering tube. ®

E~9~3. Measure3¼in, (8,26 cm) @in from the end of the steering tube.
Cleanthe following 11Ain. (3,18 cm) of thread (~ with Loctite~ PrimerN and
allow to air dry. Apply Volvo PentaTreadSealing AgentP/N 1181053-6to
the 1¼in. (3,18 cm) thread area (~).
~4. Screwthe anchor block onto the steering tube until the block is
35/32in. (8,02 cm) (~ "romthe end. This dimensionpositions the steering DR1727
tube for accurate centering of the steering system,
5, Screwthe jamnut up against the anchorblock and tighten to 35-40ft. Ibs.

(47-54 N=m).Donot disturb the anchorblock position while tightening the
nut.
B~ ~ ~ 6. If the anchor block was removedfrom the transom plate,

apply a small mountof VolvoPenta GreaseP/N 828250-1to both bushings.
Install the block with the original screw&Tightenbothto 40-45ft. Ibs.
(54-61 N~m). Secure screws with two cotter pins.
[~ Filling the bushing pockets with grease can cause the screws to
8012
hydraulically lock and break the transomplate whentightened.
8011
Englne/eng 8-3
®
©
-®
DR2959
Power Steering System ¯ The oil cooler © is a heat exchangerthat uses

engine cooling water to keep the hydraulic fluid
Description cool.
]’he power steering system consists of a mechan- ¯ A high pressure hydraulic hose (~) carries fluid
ical cable from the helm to the inner transom from the pump to the control valve, and low
plate, an engine mounted pump, and a power pressure hoses ~ and ® carry the fluid from the
cylinder to movethe vertical drive steering arm. valve to the o[I cooler, and back to the reservoir.
e The steering cable casing @attaches to the

[~The hydraulic pump ~) is mounted on the
front of the engine and is belt driven by the steering cylinder valve.
crankshaft pulley. The reservoir fill cap has a
dipstick attached. ¯ The cable ram passes thru the valve and
attaches to the cnevis ®. ]’he drive steering arm
® Thecontrol valve and cylinder ® is a single unit is also attached to the clevis.
mountedto the inner transom bracket.
8-4 CobrEng/eng
® ®
P-@
DR3067 DR3008
PumpOperation
E2~ During normal operation, fluid is drawn into dual pump
intake ports @from the reservoir CK~.Thereservoir is supplied by
a low pressure return line (~) from the powersteering oil cooler.
The pumpoutput is thru ports ~). The vanes (~ are held ou:t
against the pumpbore by pressure behind the vanes. The pum13
has sufficient output @to allow quick boat maneuverseven ~t
engine idle RPM.The pumpoutput at high RPMis limited to about
2.3 gallons per minute by a flow restriction orifice ®.
The pumpoutput pressure is determinedby the resistance to flow

of the system. Whenno steering changes are being made, the
pressure will be about 50-100 PSI. Whenthere is steering input,
the pressure will be higher and will dependon the steering forces
required due to the boat attitude, drive trim position, throttle
position and quickness of the maneuver.
~3~] The pump is protected from very high pressures by a
pressure relief valve @that is located in the pumpbody. If the
steering load becomesextremely high, the relief valve will open
and limit the output pressure ® to about 1,000-1,100 PSI.
~ot-~ Internal damageto the pumpwill occur if the system is
operated at relief valve pressure for more than a few seconds.
E~ The pumphas a metric output fitting. Use only a hose with a

metric fitting.
2635
Eng,ne/eng 8-5
STARBOARD PORT STARBOARD PORT
-®
’S
DR3508 DR3506
SystemOperation Steering To Port - Steering WheelTurning To

Left
No Steering input - Steering WheelNot
~-~ Whenthe helm is turned to port (either
Turning
turning boat to left or straightening from a right
~-~ Whenthere is no steering input from the turn) the steering armis pulled to starboard. The
helm, the spring @in the control valve keeps the steering cable casing pushes the valve spool (~
spool ® centered. Fluid from the pumpenters tO port. Fluid from the pumpenters the valve at
the control valve thru the pressure port ©, flows ©, is routed to the rod-end outlet (~, and to the
past both cylinder ports @and (~) with titt{e low volume side end of the cylinder ®. The pump
restriction, then thru the return port ~ and back pressure movesthe piston and steering arm to
to the reservoir. There is a small equal force at starboard. Fluid in the high volume side of the
both ends @ and ® of the cylinder and the cylinder @is forced out thru the valve from @to
cylinder does not move. return port ® and back to the reservoir. As long
as the helmis turning to port this motion contin-
With no steering input, the outdrive is held in one ues, swinging the outdrive to port.
position and the boat movesin a constant turn or
in a straight line. Whenthe helm input stops (steering wheel not
turning}, the steering cable stops pulling the
steering arm to starboard, and the steering cas-
ing stops pushing the valve spool to port. When
the spring @moves the valve spool to a "cen-
tered" position, hydraulic fluid is again routed
past both cylinder outlets. The steering cylinder
has an equal force at both ends and stops mov-
ing. The steering system is then back to the No
Steering input condition described previously=
8-6 Englne/eng
STARBOARD PORT STARBOARD PORT
DR3509 DR3507
Steering To Starboard - Steering Wheem Steering Without PowerAssist

TurningTo Right
[~] If the steering systemis not providing pow-
D-’] Whenthe helm is turned to starboard (either er assist, the operator maystill steer the boat.
turning boat to right or straightening from a left Turning the steering wheel to port causes the
turn), the steering arm is pushed to port. The steering cable to pull the steering arm to star-
steering cable casing puJls the valve spooJ ® to board. This causes the cable casing to push the
starboard. Fluid from the pumpenters the valve valve spool ® to port against the stop about
at © and is routed to the piston-end outlet @and 0.125 in. (3,18 mm). The steering cable then
to the high volume side of the cylinder @. The transmits the full manualeffort to pull the steer-
pump pressure moves the piston and steering ing arm.
arm to port. Fluid at the low volume side of the
cylinder ®is forced out and thru the valve from The fluid ~.~ aheadof the piston is forced out of
to return port (~) and backto the reservoir. the cylinder thru outlet @into the valve, and thru
long as the helm is turning to starboard this return port ® back to the reservoir. Additional
motion continues, swinging the outdrive to star- fluid is drawnout of the reservoir thru the pres-
board. sure inlet (9 and (~) to the opposite side of
piston ®.
Whenthe helm input stops (steering wheel not
turning), the steering cable stops pushing the Moresteering effort is required since aN of the
steering arm to port, and the steering casing power required to steer the boat must be sup-
stops pulling the valve spool to starboard. When plied by the operator, and additional force is
the spring ~) movesthe valve spool to a "cen- required to movethe fluid through the system
tered" position, hydraulic fluid is again routed when the pumpis not operating.
past both cylinder outlets. Thesteering cylinder
has an equal force at both ends and stops mov-
ing. The steering system is then back at the No
Steering Input condition described previously.
STARBOARDSTARBOARD
PORT PORT
Eng~ne/eng 8-7 /
/
Pump Removal
E~I. Place an oil drain pan under pump.Disconnect high pressure hose
(~) and return hose® at pump.Donot lose O-ring on pressurehosefitting.
Securehoseendsin a raised position to prevent fluid draining from hoses.
Capor tape ends of hoses to keep out dirt. Drain pumpcompletelybefore
removing.
[~] ~ [~] 2. Loosen pump bracket mounting screws and remove

drive belt.
20497
® 3.0 Models ~]
¯ 4.3 and 5.7 Models
® 7.4, 8.2 Models ~]
3. Take out mounting screws and removepumpfrom engine.
Lg__l 4. Removepumppulley using a pulley remover, then remove

mountingbracket.
23916A
Pumplnsta|lation
[~1. Attach mountingbracket to pump.Attach pulley using a pulley
installer.
2. Mountpumpbracket loosely on the engine.
E~ 3. Makesure O-ring is in place and in goodcondition, then connect

high pressurehosefitting (~). Tightenfitting to 15-26ft. Ibs. (20-35N*m).
E~ 4. Connectreturn hose (~) to reservoir.Tighten hose clampto 12-17 in.

Ibs. (1,4-2,0 N°m). 20495A
5. Fill pumpreservoir with VolvoPentapowertrim~tilt & steering fluid. Bleed

pump,hoses, and valve by turning pulley clockwise(as viewedfrom front of
engine)until reservoir no longer showsair bubbles.Keepreservoir filled
while purging air from system.
6. Install drive belt andadjust belt tension as describedunderBelt Adjust-

mentin this section. Do not pry against pumpreservoir while tightening
belt,
7. Bleedentire systemas outlined underPurgingAir FromSteering

System. 20510
8-8 Engme/eng
HydraulicFluid
TM PowerTrim/Tilt &
Usean approvedpowersteering fluid such as DuraPlus
SteeringFluid or GMFbwerSteeringFluid. If these fluids are not available,
arty automatictransmission fluid labeled Dexronor DexronII maybe used.
CheckingFluid Level
Eta1. Runengine and rotate steering wheel Iock4oqockfor a reasonably
long period of time to warmup steering fluid, then shut engineoff. Remove
reservoir filler capandcheckif fluid level is at "HOT"markon dipstick.
E~] 2. if fluid level is k~w,add recommended

hydraulic fluid to bring fluid up
to "HOT"markon dipstick. Replacefiller cap.
Eel Donot over-flit a cold reservoir. Fluid could overflow whensystem

reaches operating temperature.
Purging Air FromSteering System

Whensystem componentshave been serviced, pumpmust be refilled with
fluid before engineis started. Performthe following steps to purgeair from
the steering system.
28846
E~Ot--~Do not run pumpeven momentarilywithout fluid. Pumpwill be

ruined or severely damaged.
1. With engine"OFF,"turn helmall the wayto port. Addpowersteering fluid

to bring fluid level to "COLD"
markon dipstick.
2. Start engine,run mornentarilyand shut off engine. Recheck

fluid level
ancl fill to "COLD"mark.Repeatthis step as necessaryuntil systemno
Ior~gerrequiresadditionalfluid.
3. {Completepurging of air from systemby starting engineand turning wheel

20509
slowly lock-to-lock. Maintainfluid level abovepumpbodyin reservoir.
4. Returningfluid with air in it will often be in the formof foamandwill have

a light tan or red appearance. Maintainfluid level high enoughso foamis not
drawninto pumpinlet. All air mustbe eliminated from fluid before normal
steering action can be obtained. If excessivefoamaccumulatesin reservoir
it must be removed,or let unit stand for an hour and repeat steps above.
5. After all air has beenpurged,return wheelto centeredposition. Continue

to run enginefor several minutesand then shut engineoff.
31839
Eng,rie/eng 8=~
6. With engine"OFF"and with fluid at normaloperatiing temperature,
recheckto makesure fluid level is at "HOT"markon the dipstick.
7. Watertest the boat to makesure the steering functions normallyand is

free fromnoise.
Power Steering PumpBelt Adjustment

[~ ~ ~ With engine stopped, the belt should be tight enough.so
that it will deflect ¼" to V2"(6-13 mm)whenpressedwith the finger at the
point indicated(~). tf the belt is too tight, excessivebelt wearcanoccur. If
is too loose, slippage can occur, resulting in belt wearand poor power 23910
steering operation. Belt tension should be checkedafter 10 hours of

service and every 50 hoursthereafter.
PowerSteering PumpPulley
Circulating PumpPuJley
1,4"- 1/2" (6-13 mm)Deflection
Checkpowersteering pumpbelt tension (~) midwaybetweenthe circulating

pumppulley (~) and the powersteering pumppulley (~. Retighten newbelt,
or checkold belt after 10 hoursof service and every 50 hours thereafter.
DR4933
~Whenadjusting a power steering pump belt, never pry against
the pump
reservoir or pull againstthe filler neck.
3.0 Models
|____Z____l
~ To increasebelt tension: - Loosennut on lower pivot bolt,
and loosen screwon bracebehindpulley. Place 1/2" breaker bar into the
square hole in the pumpmountingbracket, and pivot pumpawayfrom
engine as shown.While maintaining pressure on pump,retighten all
mountingscrews. Recheckbelt tension. 24278
4.3 and5.7 Models

|4J [~]To increase bert tension: - Loosen pumpmounting bracket
screws, insert a V2" breaker bar into the squarehole in the pumpmounting
bracket, and pivot pumpawayfrom engine as shown. While maintaining
pressureon pump,retighten all mountingscrews. Recheckbelt tension.
7.4 and8.2 Models

E~ ~ ~ To increase belt tension: - Loosen mounting screws.
Rotate bottom of pumpoutward by prying betweenthe harmonic balancer DR4935
and the bottom tab of the powersteering pumpsupport bracket.
20510
8-10 Er,g,ne./eng
©
16067 DR2959 20572
Steering Cylinder
The steering cylinder assembly is a combination power
cylinder and control valve. A piston rod clevis (~ provides the
attachment to the steering arm and steering cable ram. The
steering cable casing attaches to the threaded valve ®.
Cylinder Removal
D~ 1. Turn helmto port fuln lock position. Remove

the cotter pin
© and the steering cable pin @. 20606
2. Hold steering tube with wrench. Loosen steering cable

anchor nut ® and punl steering cable out of valve.
[~0~ 3. Removecotter pin, then pull pin ~ out of clevis and
steering arm.
[~ 4. Removeboth hose fittings @from the valve. Raise hose,,;

and cover the endsto keep out dirt.
Z~ Do not movecylinder rod in or out untiJ cylinder has been

drained completely. A dangerousspray of fluid can discharge 205O4
from the cylinder ports if the rod is movedin or out.
20583
Eng....... g ~ Safety ReBated 8-1 1

®
20503 20580 20579
~J 5. Remove cotter pins (~) and loosen both anchor screws 3 until
steering cylinder assembly can be removed.
Cylinder Servicing
[~ 1 Pry out steering pivot bushings@if they are to be replaced. If

necessarythey maybe carefully drilled in two placeswith a ~/16in. (1,5
ram) drill bit and then removed.
2. Newbushingsshould be lubricated and pushedinto place.

20576
[~] 3. The cytinder rod should be wrappedwith heavy paper or pasteboard
and held in a vise with Holder, P/N 3854367-4@.To removethe clevis (~,
unscrewthe 19 mmIocknut (~.
~ 4. To reinstall clevis, tighten piston rod Iocknut(~ to 23=28ft.

ibs. (31-38 N-m).
Cylinderinstallation
[~ 1. lnstatf anchorscrews(~ flush with inside of inner transombracket.
~2. Apply Vo|vo Penta Grease P/N 828250-1 to both bushings.

31842
~] Filling the bushing pockets with grease can cause the screws to
hydraulically lock and break the transomplate whentightened.
~ 3. Position steering cylinder assemblyon inner transombracket.

ALign bushingsof steering cylinder with screws. Handstart both anchor
screws to ensure alignment and engagementinto bushings. Tighten anchor
screwsto 40-45ft. Ibs. (54-81N m).
[~ ~ 4. Install cotter pins (~ through holes in transom bracket from

transom side. Spreadendsof cotter pins to secure.
20574
(~ Do not movecylinder rod if cylinder containsany fluid. A danger-
ous spray of fluid maydischargefrom the ports.
20573
Englne/eng 8-12
®
20504 31837 20570
E7==j 5. Connecthosesto cylinder. Start eachfitting by hand.Tighten

pressurefitting @to 10-12ft. Ibs. (-4-16 N,m).Tightenreturn fitting (~
15-17ft. Ibs. (2--23 N,m).
~ 6. Pull steering arm(~ into hydraulic cylinder clevis @.Align

holes and install large pin ® from top of arm. Securelarge pin by install-
ing andspreadingendsof cotter pin.
Cableinstallation
~ 1. Turn the steering wheeEto fully extend the steering cable ram 20506
to its maximum
extension. Lubricatethe full length of the steering cable
ram with Volvo Penta Grease,
[~0~ 2. Retract steering cable ram (~ and insert ram through valve @.
[~1~] 3. Hold steering cable anchor nut backon cable casing to makecertain
the steering cable is completelyseatedin end of valve.
[~2~4. Whileholding steering cable tight against valve, thread steering

cable anchornut (~ onto valve until snug.
20606
[~ ~ 5. Hold cable tube with a 22 mmwrench on the flat @.
Attach a crowfoot wrenchat 90° to a torque wrench® and tighten the
steering cable anchornut to a torqueof 126 in. Ibs. (14 N.m).
[~4~] ,/~ 6. Align cable ram @with steering cylinder clevis ® and install
small pin from top of clevis. Securesmall pin by installing and spreading
endsof cotter pin.
7. !=ill systemwith fluid and removeall air. SeePurgingAir FromSteering

System.
20605
20507
Eng,ne/eng 8-13
Lubrication
~] Z~ Every 60 days, grease the steering ram with Volvo Penta
Grease P/N 828250-1
~Dueto local conditions, it maybe necessary to lubricate your

engineat morefrequent intervals.
Hoses
~Do not start engine with any power steering hose disconnected.
31837
The pumpoutput fitting has metric threads. Do not attach a hosewith

SAEthreads to the pumpfitting,
After connecting powersteering hoses, makesure that there’s ample

clearance betweenthe hoses and drive belts and other components.Hoses
installed out of position mayrub during operation and be damaged.
If fluid return hoseis removedat pump,be sure to use a "wormdrive" clamp

whenreinstalling it.
System Diagnosis
Complaintsof faulty steering are frequently the resurt of problemsother
than the steering cylinder assembtyor pump.Conditions such as hard or
loose steering, or vibrations, are often related to suchfactors as the drive
belt; pumpandcylinder mounting;fluid level; or incorrect installation of the
steering cable. Thesefactors should be checkedand corrected before
disassemblingor replacing parts of the steering system.
System Checks
Manyfactors affect poweroperation of the steering system. Someof the

most commonproblem areas are:
= Fluid level.
= Looseor worndrive belt, or oiFy belt.
¯ Steering cable jammedagainst somethingin boat at stern.

¯ Steering cable too short or steering cable too long.
o Loosely mountedcomponents.
® Loose pumppulley.
8-14 Engme/eng
After the problem has been found, determine the cause. For
example,if the fluid level in the reservoir is foundto be low, refilP
and bleed the system and check the entire hydraulic system for
leaks. Just refilling the reservoir will makethe unit operate, but
will not correct the condition that causedthe problem.
Trim Tab Adjustment
Models With Power Steering
EI~ Most power steering models are not equipped with trim
tabs. If equipped,trim tab adjustmentis not required. Thetrim tab
should be preset to dimension (~ 31/4 in. (83 ram), ° ® for
left-hand rotation) and dimension© 21/4 in. (57 mini, (30° @fo:
riqht-hand rotation). They should remain at this setting for all
applications.
If the trim tab is NOTset correctny, movetrim tab to the correct

position. Tighten the trim tab screwto a torque of 34-16 ft. Ibs.
119°22N.m).
Models Without Power Steering

DR4931
The boat maybe slightly easier to steer in one direction or the
other due to steering forces or other reasons. To adjust, preset the
trim to the dimensions above for models with power steering.
Thencheck by running the boat in a straight line with a balanced
load in an area where current and wind will not be a factor. To
obtain equal steering effort, adjust the trim tab as follows:
~.L~ Safety Warning: Improper trim tab adjustment can cause

difficult steering.
1. Turn the steering wheel in both directions to determine Lhe

direction that requires the least amountof steering effort.
2. Loosenthe trim tab bolt and if tess steering effort is required to=
port, movethe trim tab slightly to port. If less steering effort is:
required to starboard, movethe trim tab slightly to starboard.
Twin engine installations require both trim tabs be movedan
equal amountin the samedirection.
3. For twin engine installations wheretrim tabs are used, set both
trim tabs to the sameposition.
4. Retighten trim tab bolt and recheck steering effort in both

directions. Repeatprocedureuntil steering effort is equal in both
directions.
5. After final adjustment,retighten the trim tab screwto 14-16 ft.

ibm;. (19-22N.m).
EnGr,~e/eng ~ Safety Related 8-15

Power Steering SystemDiagnosis Chart
Condition Possible Cause Correction
SYSTEMNOISE:
Pumpnoise "chirp=" Loosebelt. Adjust belt tension to specification.
Belt squeal. Loosebelt. Adjust belt tension to specification.
"Hissing" sound. Somenoise exists in all power None; a slight "hiss" is normal and
steering systems. "Hiss"may be in no wayaffects steering.
expected whenturning the steering
wheel, particularly at low speed=
RattJe Pressure hose touching other parts Adjust hose position.

of powerhead.
Rattle or chuckle. Steering system looseness. Checkcable nut and cylinder pivot
points for wear or looseness.
Replace bushings if necessary.
Groan Lowfluid level. Find and repair leak. Fill reservoir and
bleed system.
Air in fluid. Fill reservoir, find and repair leak.
Check connections, bleed system.
Growl Excessive back pressure caused by Locate restriction and correct. Replace
hoserestriction, part if necessary.
Pumpgrowl. Incorrect steering cable adjustment. Adjust cable per procedure. Eliminate
Cable to boat interference, interference.
Whine in pump. Pumpshaft bearing scored. Flush system, replace pump.
SYSTEMOPERATION:
Excessive wheel kickback Steering cable attachment loose. Replace pin. Tighten steering cable
or loose steering (not boat anchor nut.
wander).
Air in system. Add fluid to pumpreservoir and bleed
system. Checkall connections.
Steering wheel surges or Loose pumpbelt. Adjust tension to specification.

jerks whenturning with
engine running, especially Air in fluid. Fill reservoir, find andrepair leak.
during slow speed Bleed system.
operation. Insufficient pumppressure. Replace pumpif defective.
Momentaryincrease in Pumpbelt slipping. Tightenor replacebelt. If oily, fix

effort whenturning wheel leak.
fast to right or left. Lowfluid level. Fill reservoir and bleed system.
High internal leakage. Replace pumpif defective.
8-16 CobrEng/eng
Condition Possible Cause Correction
Hard steering or lack of High internal leakage. (Power Replace pumpif defective.
assist. cylinder or pump.) Replacecylinder if defective.
Cable jacket movementrestricted Do not clamp cable tight near

(bulkhead, fuel tank, jammed output end. Eliminate interference.
against inside of hull}.
Loose pumpbelt. Adjust belt tension to specification.
Lowfluid level in reservoir. Fill to properlevel, if excessivelylow,

checkall lines and joints for evidence
of external leakage, torque to specs.
Lack of lubricant in lube points. Lubricate, relubricate at proper

intervals.
Excessivefriction in steering linkage. Find reason for excessivefriction;

relubricate or repair.
Cable has too tight a radius at output Eliminate small radius.

end.
Cabnemovementrestricted by tie Remove all cable anchors, tie straps,

straps, anchors, attached wires, etc. etc. on cable betweenlast bend and
valve attachment point.
Insufficient fluid pressure. Repmace

pumpif defective.
Hard steering to starboard. Cable too long or movement Replacecable, or eliminate restriction.
restricted by bulkhead, etco
Hard steering to port. Cable too short or movement Replacecable, or eliminate restriction.
restricted by bulkhead, etc.
Low fluid pressure due to Checkfor kinks in hoses. Removekink.

restriction in hoses.
Foreign object stuck in hose. Removerestricting object or replace
hose.
Low fluid pressure due to Pressure loss in cylinder due to worn Replace cylinder assembly.
steering cylinder, piston ring or scored housing bore.
Low fluid pressure due to Loosebelt. Adjust tension to specification.

steering pump.
Lowfluid level. Find and repair leak. Fill reservoir
and bleed system.
Air in fluid. Fill reservoir, tighten fittings
and hose clamps. Bleed system.
Defective hoses. Correct as necessary.
Pump worn or damaged Flush system, replace pump.
Foaming milky power Air in fluid and loss of fluid due Checkfor leak and correct. Bleed
steering fluid, low level to internal pumpleakage causing system. Keep fluid level up whenvery
and possible low pressure. foaming and overflow. cold. Bf fluid level is correct and pump
still foams, replace pump.
Col:,rEng/eng 8-1 7
External Leakage
General Procedure
1. Wipesuspected area dry.
2. Checkfor over-filled reservoir.
3. Checkfor fluid aeration and overflow.
4. Checkhose connections - tighten if necessary.
5. Determineexact point of leakage.
6. Whenservice is required, replace component.
Leakage Checks
Although someleaks are easily found, seepagetype leaks maybe

difficult to pinpoint. Locate seepageleaks as follows:
1. With the engine off, wipe the complete power steering

system dry (pump, hoses, and connections).
2. Checkthe fluid level in the pumpreservoir and adjust as

directed.
3. Start the engine and turn the steering wheel from stop=to-
stop several times.
4. Find the exact area of leakage.
Easily Fixed Leaks
1. Loose clamp on pumpreturn hose.
2. Loosepumpor cylinder hosefitting, tf fittings are not

cross-threaded, tighten to correct torque. See Torque
Specifications.
3. Damaged
O-ring on pumppressure fitting. Replace O-ring.
4. External leakage of power cylinder. Replace power cylinder.
5. Leakageof fluid in cooling water. Replaceoil cooler.
6. Damageor cracked hose. Replace hose.
if the return hose is removed,the clamp must be replaced with a

wormdrive clamp. Replace leaky hoses.
@
®
DR3009 DR1443
PumpLeakage 2. Removefiller cap from pump reservoir and

checkfluid level. Fill pumpreservoir to full mark
[7-] 1. An over-filled pumpreservoir can causea an dipstick. Start engine, momentarily hold
leak. Thefluid in the steering systemexpandsas steering wheel against stop, and check connec-
it heats up during normal usage and fluid level tions at Tool J-5176 for leakage.
rises in reservoir. Excessfluid is forced through
the breather cap hole where it maybe sprayed 3. Bleed system as outlined under Purging Air
over the engine by the drive belt. From Steering System.
r T"I 2. install new()-ring. Tightenhosefitting (~) 4. Insert thermometer Kent-Moore Tool J-5421
to 15-26ft. Ibs. (20--32 N.m). If leakagepersists, into reservoir filler opening. Start the engineand
replace pumpor hose as required. movesteering wheel from stop-to-stop several
times until thermometerindicates that hydraulic
E~ 3. Check torque on fitting (~). Tighten fluid has reached its normal operating tempera-
37-75ft. Ibs. (50-102N.m).If fitting is not loose, ture of approximately150° to 190° F (65° to 88° C).
replace pump.
5. Checkfluid level; add fluid if required. When
I~ 4. Check fluid level ©. If leakage persists engine is at normal operating temperature, the
wiith fluid at correct: levemand cap tight, replace pressure reading on the gauge (valve open)
cap or pump. should be i’n the 50-100 PSi (345-690kPa) range.
If pressure exceeds specifications, check the
Ell 5. Somenon-repairable pumpleakage areas hosesfor restrictions.
are markedwith the oil-drop symbol. If leakage
occurs in these areas, replace pump. Z~ 6. Pumprelief valve pressure can be checked
by momentarily closing the shutoff valve. Do not
leave valve closed longer than it takes to read
PumpPressure Test gauge; high hydraulic pressuresare developed.
Relief valve pressure is approximately 1000-1100
~ 1. With engine off, disconnect high pressure PSI (6895-7584kPa).
(output) hose at pump. Use a spare pressure
Replace pumpif fluid pressures or temperature
hose @to install Kent-Moore Tool J-5176
between pump and steering cylinder pressure do not meet specifications.
hose (~. Gauge must be positioned between
shut-off valve and pump. Connectsteering cylin-
der pressurehose to shut-off valve. Openshut-off
va lye.
8-19
DR1451 DR~452
Cable Installation Problems

The hydraulic valve reacts to steering cable casing movement.
Total valve movementis about 1/4 inch. This small motion is
sufficient to operate the vanveand direct hydraulic pressureto the
appropriate side of the steering cylinder. Any restriction of
movement of the steering cable casing at the stern of the boat will _L
limit or restrict the movement of the valve and will result in hard
steering in one or both directions.
Whenreplacing the steering cable, the following points must be DR1453
followed for proper power steering system operation:
1. Do not install a cable that is too short. Inadequatelength

will put tension on the cable casing, and cause binding of the
steering cable. This will restrict valve movement,cause hard
steering to port and a tendencyto self steer to starboard.
[~ 2. Do not install a cable that is too long. Excessivelength will
push on the cable casing, and cause binding of the steering cable.
This will restrict valve movement,cause hard steering to star-
board and a tendencyto self steer to port.
DR56,~
3. Donot position steering cable in a sharp bendof less than 6 in.
radius. Tight bends will cause binding and limit control valve
movement.This vviH contribute to hard or uneven steering, or
rough steering wheel movement.
’ ° I (~
4. Do not jam anything against cable at the engine end. Do
not bind cable against inside of boat or against fuel tanks, battery
boxesor flotation blocks. Jamming the steering cable will restrict
steering cable movementand cause hard steering.
[~] 5. Do not interfere with or restrict steering cable movement

through the last 90° of bendto the engine. Cableretainers, clips, DR5644
clamps or tie straps should not be used in a mannerthat witl
restrict the cable movement near the engine. Do not attach wiring
harnessor control cables to this end of the steering cable.
Do not restrict steering cable casingmovement. Any restric-

tion of the cable also restricts the valve movement.
This will limit
or stop hydraulic assist, or mayhold the valve in one steering
mode.

FeedbackTo The Helm If the steering wheel turns to both starboard and
port, then helm friction must be increased
The steering system requires at least a little slightly. This will allow the powersteering sys-
friction in the helm (and cable) to prevent hydro- tem to hold the desired steering position.
dynamic forces on the gearcase from feeding
back and turning the steering wheel without the EEl if the helm always turns in one direc-
operator activating the powerassist system. This tion (when it turns), it may be caused by
mayhappenon singne engine installations (or on steering cable that is too short, too long, or has
twin engines having both drives rotating in the restricted movement. See Cable Bnstallation
samedirection). Problems. Twin engine problems may be cor-
rected by adjusting the tie bar for "toe-in" (~ or
Runthe boat in a straight line in opposite direc- for "toe-out" (~ of the vertical drives.
tions at normal cruising speed with the drive
trimmed in both a "bow up" position and in a
"bow down" position, in each trim position,
momentarilyrelease the steering wheel to see if
the wheel is turned by the gearcase, and in which
direction.
Specifications
PowerSteering PumpRelief Valve Pressure .................... 1000-1100psi (6895=7584kPa).
=TorqueSpecifications
Component Torque
Anchor Screw - Cylinder assy. to TransomPlate 40-45 ft. Ibs. (54-61 N.m)
Bolts - Power Steering PumpMounting Bracket 25 ft. Ibs. (34 N.m)
Bolts - Power Steering PumpMounting 25 ft. Ibs. (34 N.m)
Fitting- Power Steering Pump 37,-75 ft. Ibs. (50-102N-m)
Fitting - Power Steering PumpHose 15,-26 ft. Ibs, (20-35N.m)

Fitting - Inlet Control Valve Hose 10.-12 ft. Ibs. (14-16N.m)
Fitting - Outlet Control Valve Hose 15-17ft. Ibs. (20-23 N.m)
Hose Clamps - Oil Cooler and Power Steering Pump 12-17in. Ibs. (1,4-2,0 N.m)
Jam Nut - Anchor Block 35-40ft. Ibs. (47-54 N.m)
Locknut - Piston Rod To Clevis 23,-28 ft. Ibs. (31-38N.m}
Nut - Steering Cable Anchor 120 in. Ibs. (14 N.m)
Screw - Trim Tab 14-16 ft. Ibs. (19-22 N.m)
Engme/eng 8-21
NOTES
Section 9
Throttle andShift Control Systems
Contents
Throttle and Shift Control Systems............................. 9-1
Shift andThrottle Cable Routing ............................... 9-2
Installation of SAECablesto Engine/Drive...................... 9-3
Shift Cableto Drive Unit installation ............................ 9-3
Twin Engine SX ModelsOnly ................................. 9-4
Throttle Cableto EngineInstallation ........................... 9.4
CheckRemoteControl Shift Cable Stroke ....................... 9-8
Materials Required
VolvoPentaGreaseP/N 828250-1
MolybdenumGrease
Z~ Safety Warnings
Beforeworkingon anypart of the engineorrelated systems,read the section
called Safetyat the endof this manual.
Unlessinstructed otherwise,alwaysdisconnectthe battery cablesfromthe
battery beforeworkingon electrical systemto prew.~ntpossiblesparksor arcing
in the enginecompartment.
Beforestarting engineafter repair or maintenance procedures,alwaysmake
sure enginecompartment
is free of fuel vaporsto preventpossiblefire and
explosion.
Whenworkingon an enginethat is runningor being cranked,use extremecare
to avoidgetting hands,fingers or clothing caughtin the alternator, power
steering pump,supplypump,andcirculating pumpbelts, pulleys andother
movingparts.
Engine/eng 9-1
Shift and Throttle Cable Routing
1. If the remotecontrol shift andthrottle cablesare installed in the remote

controls, proceed to CheckRemoteControl Shift Cable Stroke.
2. If the remotecontrol shift andthrottle cableshavenot beeninstalled, the
/
following procedurewill permit you to order the correct length remote
control shirt andthrottle cables.
3. Measurethe proposedroute of the remotecontrol shift and throttle

cables. All bendsmusthave a radius greater than 6 inches (15,2 cm).
* Remote control shift cable: Add(~)+~) plus 20 in. (50,8

cm), round up to next cable length. T
= Remotecontrol throttle cable: Add(~)+(~)+@plus 4

(10,1 cm), (© is to center of throttle armpin). Roundup
next cable length.
~-~ Whenremoving shift and throttle cables from the packing box, DO ®
NOTbendthe cables tighter than a 6 inch radius.
___t_
-2 Englne/eng
® ®
\
34045 34044 34041

installation of SAECablesto EnginelDrive
Shift Cableto Drive Unit installation
~i"O-tel] Remote
control shift and throttle cables mustbe SAEtype cables,
f .~Ot~1. If the throttle cableis attachedto the throttle armand anchor

block, removeit from both. Thethrottle cable mustbe disconnectedfrom
the throttle armprior to shift cableinstallation and adjustmentto prevent
"loading" the control boxand adverselyaffecting shift adjustments.
2. Notethe position of small seal (~) andlarge seat (~) on the shift 34039
cable. Removeand retain jam nut, small seal, and large seal from the shift
cable.
~]3. Apply a light coating of Volvo PentaGreaseto the end of the remote
control shift cablecasing. Slide shift cablethroughshift cabletube until it
appearson the outside of the transom.
4. For easeof installation of shift cable, turn drive unit to port. Rein-
stall the retained large seal ~) andsmall seal (~ onto the shift cablein the
sameposition as notedin step 2.
E4~] 5. Loosencable clamp screw © and pull clamp out.

34037
~=’J6. Slide shift cable throughpivot housingandfrive unit.
E~ 7. Slide clampin fully, engagingthe shift cable anchorgroove.
,~,CAUTION:Tighten clamp screw securely.
34038
E~ [~ 8. Rotate shift lever to extendbellcrank @.Remove
cotter pin,
fiat washer,andanchorpin (~).
9. Threadanchorpin halfwayonto remotecontrol cable end.
[~] 10. Rotateshift lever backto neutral detent position, then move
remotecontrol handleto its neutral detentposition. Turnanchorpin IN or
OUT until it alignswith centerof bellcrankslot (~.
[~ ~ 11. Install fiat washerand cotter pin. Secureby spreading end
of cotter pin Install jam nut @and tighten securely against cotter pin.
E~ 12. Reinstaaa rear cover and secure with screws®. Tighten to 108
- 132in Ibs. (12 - 15 N.m).
Twin EngineSX ModelsOnly
13. For left handrotation propei|ers: the control cable mustbe reversed
at the remotecontrol.
Throttle Cableto Engineinstallation

I-N--~ Moveremotecontrol handle to NEUTRAL detent position. Turn
propeller shaft andshift into the FORWARD gear detent position, then pull
HALFWAY BACKtowards NEUTRAL. This positions the control for proper
throttle cableadjustment.Failure to follow this procedurecanbindthe shift
linkagein the control, andproduce "hardshifting."
E~1. Atign internal boss(~ of trunnionwith throttle cable groove®.

Presstrunnionon throttle cableuntil seated.
EEl ®
9- 4 Engine/eng
F~
Lm~V_.~.~_J CarburetedModelsOnly: Engineanchorbracket mayhavetwo
sets of anchorblock holes. Thetop set (marked)is for the 4Vcarburetor
models,andthe bottomset is for the 2V carburetedmodels.
[8~ ~ 2. Install openend © of trunnion in anchorblock. Install screw

(A~ in anchorblock(~) andposition throttle cableassembly
in selected
of holes. Nut @must be against the anchorbracket, tighten securely.
[~ Z~ 3. Throttle arm connector Q must have a minimumof 9 fu,

turns or 1A in. (6.4ram)of throttle cable threadengagement. Install
throttle armconnectoronto the throttle cable. Pull connectorforwardto
remove all free play fromthe throttle cable, thenturn the connector in until
holealignswith the top throttle lever pin. Thetop throttle leverpin is for
"Pull-to-Open"throttle operation.
E~if throttle armconnectorhole cannotbe adjusted to align with the

throttle arm,checkfor propercableinstallation in remotecontrol.
[~ ~ 4. Install connectoronto appropriatethrottle lever pin. Install

washerand cotter pin @, and secure by spreading end of cotter pin.
Tighten Iocknut ® against connector.
o 7.4 Gi Models [~]
. 7.4GSi, 8.2GSi, DPX385,and DPX415[~
~:ngine/eng 9=5
NOTES
Engine/eng 9-6
NOTES
9-7
CheckRemoteControl Shift Cable Stroke
Control cable should "PULL" for forward gear.
r’~ 1. Moveremote control handle into the forward gear, wide
open throttle position. Pull out cable core wire to removeend
play. Mark cable core wire at end of casing.
2. Return remote control shift handle to the neutral detent

position. Measureand record the distance betweenmark (~) and
end of casing. This dimensionis the shift cable stroke for forward
gear. 36560
I~ 3. Mark cable core wire at end of casing with control in the

neutral detent position.
I-4] 4. Movethe remote control handle into the reverse gear,
wide open throttle position. Pushin on cable core wire to remove
end play. Measureand record the distance between mark ® and
end of casing. This dimensionis the shift cable stroke for reverse
gear.
e The distance between forward and neutral must be no

less than 11/4 in. (31,8 turn) andno greater than 13/8 in. 36561
(35,0 rnrn).
e The distance between neutral and reverse must be no
less than 11/4 in. (31,8 ram) and no greater than 1%in.
(35,0 turn).
Checkyour remotecontrol installation instructions, if your

measurements are not within these specifications. Makesure the
cables are attached correctly inside the control box before contin-
uing. All control boxes must meet these minimumand maximum
specifications in order for the shift systemto function properly.
Should it becomenecessary to remove or replace the 36562

remote control cables, the attachment at the engine and vertical
drive is very important. Follow these steps for removal and
installation of remotecontrol cables.
36563
//~ Safety Related 9-8 Engine/ertg

Section 10
Cooling System
Table of Contents
Components Water Flow Diagrams

Circulating Pump - Engine ..................... 10-18 DriveUnit andTransom Bracket ............. 10-8
Hoses,Clamps andDrainPlugs............ 10-17 3.0GS
..........................................................10-9
ManifoldandElbows .............................. 10-18 4.3GL,and GS ......................................... 10-10
Thermostat
............................................... 10-17 4.3Gi
.........................................................10-11
RawWaterPump ..................................... 10-19 5.0GLand5.7GS ..................................... 10-12
Description
................................................ 10-2 5.0Giand5.7GSi ...................................... 10-13
Draining 7.4Gi,7.4GSi and8.2GSi ........................ 10-14
EngineBlock or Exhaust Manifold........ 10-20 V-6 and V-8 Carbureted Closed
PivotHousing.......................................... 10-23 CoolingSystem ....................................... 10-15
PowerSteering Coolers ......................... 10-22 V-6 and V-8 EFi ClosedCooling
Supply
Pump........................................... 10-19 System
..................................................... 10-16
Thermostat Replacement ....................... 10-23
Troubleshooting
Isolating
Problem ...................................... 10-4
Possibilitiesto Consider .......................... 10-4
ProblemCheckpoints ............................... 10-6
QuiztheCustomer .................................... 10-3
Safety Warnings U
Beforeworkingon anypart of the engine, readthe section called Safety
Unlessinstructed otherwise,alwaysdisconnect:the battery cablesfrom
the battery beforeworkingon electrical systemto preventpossible
sparksor arcing in the enginecompartment.
Beforestarting engineafter repair or maintenanceprocedures,always
makesure enginecompartment is free of fuel vaporsto preventpossible
fire andexplosion.
When workingon an enginethat is running or being cranked,use ex-
tremecare to avoidgetting hands,fingers or clothing caughtin the
alternator, powersteering pump,supplypump,andcirculating pump
belts, pulleys andother movingparts.
Engir~/eng 1O-1
Description All Models: The circulating pumpis mountedon
the front of the cyainder block, it has a pulley
Water is supplied to the engine by meansof an bolted to the pumpshaft hub at its forward end.
impeller type pump (supply pump). The water This in turn is driven by meansof a belt from the
supply pump is mounted on the engine. Water crankshaft pulley. The pumpshaft and bearing
supplied to the engine is circulated in the engine assembly is pressed in the water pumphousing.
by meansof a centrifugal type pump(circulating The bearing is permanently lubricated during
pump). manufactureand sealed to prevent loss of lubri-
cant and entry of dirt. Thepumpis sealed against
The supply pump used on aH models is a self coolant leakage by a non-adjustable sean assem-
priming impelUer type pump, mounted on the bly pressed into the pumpcover.
engine and belt driven. During low speed opera-
tion the impeller functions as a positive displace- Cooling water for the engine is picked up at the
ment pump. At higher speeds it functions as a water intakes on both sides of the lower gear-
combination centrifugal and positive displace- case. Water is pulled upward thru the Jower
ment pump. gearcaseuntil it enters a water tube that transfers
it to the upper gear housing.
The shape of the housing and liner cause an
eccentric action of the impeller blades during Water is pulled through the upper gear housing
engine operation. During periods of high speed water passage where it meets a nipple and hose
operation, the resistance of the water on its way attached to the pivot housing. Water is routed
through the pumpis sufficient to prevent the through the transom mount assembly to a tube
ends of the impeller blades from making contact that’s mountedon the inside of the gimbal hous-
and following the inside perimeter of the pump ing. From this tube the water is drawnthrough a
housing. The blades merely flex in toward the supply hose that’s connectedto the inside nipple
center of the impeller to perform as a combina- of the supply pump. Water exits the outside
tion centrifugal and positive displacement pump. nipple of the supply pump under pressure and
carried through a hose to the inlet nipple of the
thermostat housing.
’1 0-2 Engine/eng
All Models: The water is now carried downward In the event the engine cooling water is cold, as
through the thermostat housing where it enters in first starting up, the thermostatwill be closed
the flexible hosewlnich attaches to the inlet pipe and will not allow any of the water to pass
of the circulating pump.This inlet pipe is a part of through for eventual discharge overboard, h-
the pumpcover and feeds the coolant into a low stead, the water will be carried via the flexible
pressure area located at the axis of the impeller. hose back to the circulating pumpfor recircula-
Vaneson the rotathlg impeller cause the coolant tion within the block. While the water within the
to be thrown outwardand into the cylinder block. block is recirculating, the supply pumpis pump-
ing water to the block.
The cooling water flows rearward through the
water jacket which surrounds each cylinder and Since this water is not able to enter the cylinder
extends below the lower limit of piston ring block, it is necessary to provide a method of
traveH. After flowing the full length of the cylinder discharge. This is provided by the bypass pas-
b;ock, the water is forced upward through two sage within the thermostat housing, if this were
passagesand into the cylinder head(s). The wa- not provided, the resulting water pressure would
ter now flows forward in the cylinder head(s) be enoughto force the thermostat off its seat,
cool the combustion chamberareas. resulting in a greatly increased warm-upperiod.
At the forward end of the cylinder head(s), the

water enters the thermostat housing, ff the water Cooling SystemTroubleshooting
within the block is sufficiently warmedup, the
thermostat will be open and a portion of the 1. Quiz Customerfor the Foliowing
water will be pumpedupward past the thermo- information:
stat. The remainder will be returned via the
flexible hose to the water pumpfor recirculation a. How old is unit, how many hours of
within the powerhead. The water which ,was operation? (Wear and corrosion.)
pumpedupward past the thermostat will enter
the hose(s) connectedto the thermostat housing b. Howlong has problem existed? {Gradu-
outlet(s) and travel to the manifold(s). al or sudden.)
At this point the water flows rearward through Whatwere the operating conditions pri-
the manifold passages and into the high-rise or to problem?(Fresh or salt water, silty
elbow. All of the water that enters the high-rise or sandy water.)
elbow is mixed with the exhaust gases prior to
entering the exhaust pipe(s} and hose(s). This Wihat previous repairs and service have
mixture of exhaust gases and water then enters been madeon unit? (Tune-ups, impeller
the exhaust passages of the gimbal housing, replacement, etc.)
pivot housing and vertical drive whereit is dis-
charged under water. e. At what RPIVI does problem occur? (Low,
high.)
Englne/eng 10-3
2. Possibilities To Consider:
a. Temperature GaugeMalfunction.
¯ improper or defective sender unit

¯ Malfunctioning gauge- Checkground wire - substitute
good gauge.
b. Engine Water Circulation PumpMalfunction.
¯ Loosealternator belt
¯ Impeller vanes worn - replace pump.
¯ Impeller shaft seamfailure - replace pump.
c. Water Intake ScreensBJocked.
d. Ventilation - Marinegrowthon keel, hull deformities, etc.
e. Ignition Timing
¯ Running with retarded timing - Checktiming.
3. Isolating CoolingProblem:
a. Procedure- Replace water hose between thermostat

housing and the supply pumpwith clear plastic hose.
Operateunit in test tank or boat in water at RPMat which
overheat occurs.
[~ If operating unit in test tank, run motor in neutral. Some
test tanks maynot have sufficient water volumeto allow running
engine in gear without creating turbulence. This can be picked up
by the water intake and misconstrued as evidence of a cooling
problem.
b. Results and Conclusions - No bubbles in hose, air/

exhaust is not entering cooling water. Bubblesin hose,
air/exhaust is entering cooling water.
c.Check for - Defective lower gearcase water tube guide

and seals; damagedwater tube grommet; leaking water
passagecover gasket or adaptor-to-gear housing gasket.
10-4 Engine/erie
a. Procedure- Disconnect water suppDyhose from transonq
bracket at thermostat housing. Operateengine at speci-
fied idle RPM.Hold end of hose level with the top of the
flame arrestor.
b, Resultsand Conclusions - A 1 inch (2,5 cm) head of water
discharge, water supply is good. If less than 1/2 inch (1.2
cm), look for source of water loss.
Checkfor - Blocked intake screens; damagedimpeller

housing O-ring or impeller plate gasket; broken or worn
impeller; defective pivot housing water passageO-ring
or water drain screw seal; loose pivot housing-to-gimbal
housing water hose clamps.
|ii|~]|i|[oT.’i~Ini~||ilr,[oi~o]il - overheatingor slowwarm-up:
a. Procedure- Operate engine until indicated temperature

exceeds 160° . Touch hoses between thermostat and
exhaust manifolds.
b.Results and Conclusions- Hoses cold, thermostat is

stuck closed. Hoseswarmor hot, thermostat is good.
c. Checkfor -- Thermostatstuck open or closed, defective

thermostat O-ring, correct thermostat style for engine
type, clear thermostat housing bypass passage.
|~JL,~=l-m[~.~ll[ml:~.[,_~r~ I - overheating or hard starting

(water in cylinders):
a. Procedure.- Allow engine to cool. Replacewater hose(s)

between thermostat housing and exhaust manifold(s)
with clear plastic hose. Operate unit at RPMat which
overheat occurs.
b, Results and Conclusions - No bubbles evident, head
gaskets not leaking. Bubblesevident, head gaskets leak-
ing.
Checkfor - Cylinder compression using appropriate

tester, water in engineoil, water in cylinders, spark plugs
wet with water.
Problem Checkpoints:
Numbersrefer to Cooling System Flow Diagrams.
O Intake Screen - Blocked with debris.
(~ Water Tube Guide and Seal - Improperly sealed.
® Water Tube - Plugged with debris.
Grommet- Deteriorated, improperly seated.
(~ Upper Gear Housing - Debris blocking passage, freeze

damaged.
(~)Pivot Housing Seal - Damaged,out of position, improperly

sealed.
O Nipple O-ring - Out of position, improperly sealed, dam-

aged.
(~) Nipple - Blockedby debris, freeze cracked.
(~)Water Hose and Clamps - Clamps loose, hose collapsed or

leaking.
(~ TransomMount Water Tube - Blocked by debris.
Supply Pump(Engine Mounted) - Failed seal, corroded

bad bearings, eroded impeller, leaking mounting gaskets or
backing plate.
Thermostat Housing - Corroded, restricted, or leaking gas-

ket.
I~) Thermostat - Defective thermostat, or wrong type for en-

gine; improperly seated or damagedO-ring.
Belts - Loose, or worn and slipping.
Circulating Pump(Engine) - Failed seal, corroded or bad

bearings, eroded impeller, leaking mounting gaskets or
backing plate.
10-6 EngmeJeng
~} Cylinder Block Water Passages- Corrosion, slag, blocked passages,or leaking core
plugs.
Cylinder Head- Corrosion, slag, blocked passagesor leaking gaskets.
ExhaustManifold, Elbows,Gaskets, and Hoses- Gasketsimproperly installed;

corrosion, sand, or sJag in manifold and elbows; hosescollapsed, burnedthrough, or
Jeaking.
ExhaustPipe and Seal - Improperlysealed or installed, leaking.
Bellows, Clamp,and Retainer - LoosecJamp,detachedor torn bellows.
{~ PowerSteering Cooler - Restricted, or crackedand leaking.
Intake Manifold- Crackedcasting, or leaking gasket(s).
[] EngineOil Cooler - Restricted, or crackedand leaking.
[] 7.4Gi, GSi, and 8.2GSi Models: CheckValve - Water By-passHose- Pluggedwith

debris.
In addition, check:
¯ Ignition Timing
¯ BoatHull - Condition of hull, marinegrowth, or underhulJequipment.
[~Ot~ Fittings protruding through hull maycause air bubble streams which can be picked
up by the lower gearcaseand mixed with incoming cooling water to causean overheat
condition.
Englne/eng 10-7
(~) Water
(~)To Thermostat Housing
©Return From Exhaust Pipe
(~ Exhaust and Water Out
Vertical Drive and TransomBracket
A[[ Models
DR6252
1 0-8 Eng,ne/eng
Warm water
C Bypass
e
Cold Water er in driv
Exhaust Water 21 Wat Stern
A from
11
9
9 13
18
12
19
18
22 17
Cold Engine
12
C
16
15
B
Warm Engine
14
3.0GS Models D
GR970388
Engine/eng
10-9
Warm water
Bypass A
C
Cold Water 11
Exhaust Water
21
9
9
9
18
13
12 22
9
19
17
B
15
16 D
GR970389
14
4.3GL and GS Models
10-10 Engine/eng
Warm water A
C Bypass
Cold Water
11
Exhaust Water
9
21
9
18
13
12 22
9
19
17
15
B
C
16
D
14 4.3Gi Models GR970390
Engine/eng
10-11
C
Warm water
Bypass 11 A
Cold Water
Exhaust Water
9
21
9
18
9
12
13
22
19
17
9
15
B
14
C
16
D
GR970392
5.0GL and 5.7GS Models
10-12 Engine/eng
Warm water
Bypass
C
Cold Water 11 A
Exhaust Water
9
21
9
9
18
12
13
22 19
17
9
15 B
14
C
16
D
GR970391
5.0Gi and 5.7GSi Models
Engine/eng
10-13
Warm water
C Bypass
Cold Water
Exhaust Water
9
24
9
21
9
21
18
12
9
13
22
19
17
9
15 B
14
C
16
D
GR970393
7.4Gi, 7.4GSi and 8.2GSi Models
10-14 Engine/eng
Warm water
C Bypass
Cold Water A
Exhaust Water 11
Raw Water
Air Vent
21
9
9
9
18
9
13
12
9 22 19
9
17
16
14 15
GR970433
V6 and V8 Carbureted Models with Closed Cooling System
Engine/eng
10-15
Warm water
C Bypass
Cold Water
Exhaust Water
Raw Water
Air Vent A
9
9 24
21
21
18
13 9
19
12
22
17
14
16
GR970437
15
V6 and V8 EFI Models with Closed Cooling System
10-16 Engine/eng
Cooling System Components
For all models.Nospecialtools required.
~nspectionProcedure:Examineall external cooling systemcomponents

for Veaks,wear,deterioration, anddamage.Checkall connectionsfor
tightness. Inspecthosesfor cracks,checkingor deterioration.
Repair Procedure:Repairor replace as required.
E~ Water supply hoses used for replacement must conform to S.A.E.

20R3,class D-2.
¯ All ModelsExcept7.4Gi, GSi and8.2GSi:A

180° F (71 ° C) thermostatis standard.
¯ 7.4Gi, GSiand 8.2GSiModels:A 140° F
(60° C) thermostatis standard.
¯ All modelswith closedcooling systems:A
158° I-- (70° C)is standard.
InspectionProcedure:
Checkfor properrating andstyle, corrosion,
restricted movement,
or brokenspring.
Test
Procedure-
A.Models
Except
7.4G, Gsi
a.d8.2Gsi:
Immerse the thermostatanda thermometer in a container of water. Heat
water. Thermostat should start to openbetween157-163 ° F. and should
opento 5/32 in. (3,96 ram)minimum ~) at ° F.
~ Test Procedure: 7.4 Gi, GSi and 8.2GSi: Immersethe thermosta!

anda thermometer in a containerof water. Heatwater. Thermostat
should
start to openbetween138-142° F. andshouldopento 5/32 in. (3,96 mm)
minimum (~ at 162° F.
¯ 3.0 GSModelsr-~
¯ All V-6 and V-8 Models[~
Repair Procedure:None,replace unit.

For all models.Nospecial tools required.
inspectionProcedure:Pressure check componentsfor leaks. Disas-

sembleand inspect for corrosion or accumulationof foreign materia I.
Repair Procedure:Rodout any accumulationof foreign matter built up in

water passages.If evidence of porosity betweenwater passagesand
exhaustchambersor exterior is found, replace component.Install new
gaskets on reassembly.
For all models.Nospecial tools required.
InspectionProcedure:Makesure belt tension is correct. With the engine

running, observethe rotation of the circulating pumppulley. If the pulley
does not run true it can causeexcessivedrive belt wear and damage to the
circuaatingpump itself.
If the leakageof water occursat the circulating pumpwhile the engineis in

operation, the pumpmaybe loosely mountedto the engine, the shaft seal in
front of the pumpmaybe bad, the backing plate gasket maybe defective, or
the circulating pumpmountinggaskets are leaking.
If the aboveinspections do not detect any defect, the pumpmustbe re-

movedand inspected for internal corrosion, blockage, or damage.Inspect
impe{lerfor erosion.
Repair Procedure: None, replace the pump.
~ Volvo Penta marine engines have a special circulating water pump

with stainless steel components
and a special marine shaft seal assembly.
Donot replace with an automotivewater pump.
1 O-18 Eng,ne/eng
Removal
1. Drain engine, refer to DrainingEngineBlockor ExhaustManifold.
E~2. Loosen hose clamps and remove hoses from supply pump.
E~ The inside hose (~) is the inlet hose.
3. Loosenpumpto bracket mountingscrews~) and removedrive belt.

Removemounting screws and remove pumpassembly. 45330
impeller Removal
E~ 1. Removethe three screws © securing the end cover.
[~]2. Removeand discard gasket.
[] 3. Graspimpeller securely and pull from housing.
C~eaningand inspection
1. Cleanall parts with solvent andblow dry thoroughly.

42864
2. Remove any old gasket from end cover and housing. C~eansealing
surfaces.
3. Inspect impelrer housingand camfor wear, and housingfor cracks and

distortion causedby freezing. Replaceif necessary.Donot removecamif
not required.
4. mnspectend cover; checkimpeller contact surfacefor wear, scoring, or

distortion causedby freezing. Replaceif necessary.
5. Inspectimpeller; if bladesare set in a bent position, cracked,or broken,

or showflat instead of roundededgeson the housingcontact surfaces, 39149
replacethe impeller.
6. Checkbearings for smoothoperation.
39150
39151
10-19 Englne/eng
39152 39155
impeller installation - V-6 andV=8Models
1. Apply a light coat of VolvoPentaGreaseP/N 828250-1to impeller

surfaces,install impelleruntil flush with surface.
[~2. install newgasket without sealant.
[~ 3. Install end cover and secure with screws. Tighten screwssecurely.
Installation
42865
~] 1. Orient pumpassemblyto the pumpbracket with the camscrew (~)
up. mnstall mountingscrewsand belt. Refer to Supply PumpBelt Adjust=
ment in the General information Section.
2. Attach the inlet hoseto the inside nipple andthe outlet hoseto the
outside nipple. Tighten hose clampssecurely.
Draining EngineBlock or ExhaustManifold

Someservice work performed on the engine block and exhaust manifold
mayrequire the comptetedrainage of those components.
3.0 Modens
1. Remove the long supply hose at thermostat housing (~. Lowerit

alongsidethe cylinder block and drain it completely.
2. Disconnect and drain large hose ® at water pump.
3. Remove
the drain plugs from cylinder block port side ~) and
exhaustmanifold (~. Clear holes with a small wire to ensure complete
drainage.
23907
23913
Eng,ne/eng ~0-20
4.3 Gi Models
L~ 1. Disconnectthe small water bypasshose@at the top of the

thermostathousing.
~L~2. Disconnecttl~e water dischargehose® at the port side exhaust

elbownipple. Lowerthe hosebelowthe level of the vaporseparator. Blow
out anytrappedwaterin the vaporseparatorandlines by applyingair to
the bypasshose.
AH4.3 Models
10204
[~ 1. Remove the long water supply hoseat the thermostathousing
@.Lowerit alongsidethe engineblock anddrain completely.
ET~2. Disconnectand drain the large hoseat the circulation waterpump

@.
E~ 3. Remove the drain plugs (~ from the port and starboard exhaust
manifolds. Removedrain plugs ® on the port andstarboardside of the
engineblock. Clear holes with a small wire to ensurecompletedrainage.
5.0Gi and 5.7GSi Models
[[~ 1. Disconnectthe small water bypasshose@at the top of the

thermostathousing.
L~ 2. Disconnectthe water dischargehose® at the port side exhaust

elbownippfe. Lowerthe hosebelowthe level of the vaporseparator.Blow
out anytrappedwaterin the vaporseparatorandlines by applyingair to
the bypasshose.
All 5.7 Models
1. Remove the tong water supplyhoseat the thermostathousing0.

Lowerit alongsideblock anddrain completely.
[_4_~_2. Disconnect
anddrain the large hoseat the circulating waterpump
@.
1020-5
Fngine/eng
10-21
1021-6 42863
All 5,7 Models (continued)
[~ 3. Remove plug ® at rear of eachexhaust manifold, and

remove drain piugs (~ on both sides of the cylinder block, Clearholes
with a small wire to ensurec0mpletedrainage.
All 7.4 and 8.2 Models
[~ 1. Remove the long water supply hoseat the thermostat housing

~). Lowerit alongsideblockanddrain it completely.
[~ 2. Disconnectand drain the large hoseat the water pump(~), 1021o9
[~ ~ 3. Remove hose (~ at front of each port and starboard

exhaustmanifold, and removedrain plugs ® on both sides of the
cylinder block. Clear holeswith a small wire to ensurecomplete
drainage.
7.4 Gi, GSi and 8.2GSi Models
DE] Drain the small water by-passhose@betweenfuel reservoir

andthe top of thermostathousing.Disconnecthoseat the reservoir
side of the checkvalve. Blowout waterin both directions. ~nspect
1021-10
checkvalve for debris, then reassemble.
Draining PowerSteering Coolers

[~] Remove the lowest water hosefrom the powersteering oil
cooler. If cooler is mountedhorizontally, removeonewater hose®
from the cooler, loosencooler mountingbolt and tip cooler downward
to drain.
Draining Supply Pump

[~1. Loosenand slide hose clampsback. Remove
hoses from the
rear of pumpanddrain.
2. Crank the engine no morethan 2 seconds(DONOTSTART)

expel anywater trapped in waterpump.Reattachhoses.
10-22
34087 45332 45333
Draining Pivot Housing

EI~ 1. Tilt vertical drive to the full tilt up position and removethe
water drain plug @from the port side of the pivot housing.
2. Tilt the verticaR drive to the full tilt downposition. Allow unit to
drain. After unit has completely drained, replace pivot housing
plug.
Failure to ensure complete drainage of the cooling system

mayresult in serious damageto the engine and/or drive unit if 45334
temperature should drop below freezing.
Thermostat RepUacement
3.0 GS Models
E2~ 1. Removeall hoses ® from the thermostat housing.
the=, engine coolant temperature sender nut, lead

E3~] 2. Remove
and washers @from the sender.
45335
L~ 3. Loosen the alternator adjusting screw. Removescrew
securing alternator bracket @to the thermostat housing. Pivot the
bracket out of the way.
E~ 4. Removetwo screws (~ securing thermostat housing to the

cylinder head, Renqovethe housing from the head. Clean all
gasket surfaces.
E6=-] 5. Removethermostat O-ring ® and thermostat @from the

housing.
®
45354
10-23 Engme/eng
t/L
45355 45356 45357
[~ [~] 6. Install thermostat ~ into the thermostat housing

with the pointed end ® facing into the housing. Place the O-ring
® into position in the O-ring groove to retain the thermostat.
[~ 7. Place a newgasket (~ into position at the front of the head.
No sealer is required with this gasket.

[~ 8. Install the thermostat housing into position and secure
with two screws ~. Tighten the screws to 12-16 ft. Ibs. (16-22
N.m). 45358
[~ 9. Install the alternator bracket on the engine. Set alternator

bett tension following the procedures in the General Information
section. Tighten both screwsQ to 26-30 ft. Ibs. (35-41 N.m),
[~] 10. Attach the engine coonant temperature sender washers,
lead and nut © to the sender. Tighten the nut securely.
11. Install all hoses ® and secure with clamps. Tighten the
clamps securely.
45345
Englne/eng 10-24
V=6 and V-8 Models
[1~] ~]1 Removeall water hoses from the thermostat housing.
® Carburetor Models: four hoses ~) [~
" EFt Models: five hoses ~ [~
2. Note position of lifting eye @.Remove

two screws(~ then remove
lifting eye andthermostathousing.
28546
L’~ 3. Thethermostat(g) is held in place by an O-ring. Pry the O-ring out
of its groove,then lift the thermostatout of the housing.
4. Discard the housing gasket and O-ring. Thoroughlyclean the housing

and manifold gasket surfaces.
E4~5. PLacethe thermostat in the housing. Thetemperaturesensing

element(3 mustface you wheninstalled. Install a newO-ring to seal
thermostatin housing.Makesure O-ring is completelyseatedin its groow,=.
E,.~ 6. Coat both sides of a newgasket with Volvo Penta GasketSealing

Compound P/N 1161231-4and place it on the manifold. Position thermoslat 38259
housingand lifting eye; on engineadapteras notedin Step2. Install two
lock washersand screws@.Tighten the screwsto 20-25 ft. Ibs. (27-34
N.m).
7. Connectthe water supply hose to nipple ® and tighten hose clamp

securely. Connectthe three remainingwater hosesand tighten hose
clampssecurely. Makesure lifting eye @is positioned as shown.
[~ If the water supply hose is attached to the wrongnipple, the engine

will overheat.
28548
28547
10-25 Engme/eng
NOTES
10-26
Section 11
EngineRemoval
andinstallation
Table of Contents
Engine
Alignment ................................................. 11-7
Installation ................................................ 11-6
Removal .................................................. 11-2
Determining MinimumEngine Height ......................... 11-12
Engine Mounts, Rear ........................................ 11-11
Exhaust Pipe Replacement ................................... 11-6
Volvo PentaSpecial TooRs
PIN Description
3851083-0 Volvo Penta Alignment Tool

3850609-3 Volvo Penta Drive Handle
Sealants, Lubricants and Adhesives

Volvo Penta Grease
3M adhesive or equivalent
Gasket Sealing Compound
Z~ Safety Warnings
BeforE.= beginning work in this section, read Safety chapter at end of this
manual.
Proper installation is important for the safe, reliable operation of all me-
chanical products. The procedures we recommendand describe in these
instructions are effective methodsto be followed wheninstalling Volvo
Penta sterndrive products. Someof these methodsrequire the use of tools
specially designed for the purpose. The special tools should be used when
and as recommended.
Englne/eng 1 1-1
Engine Removal
Before removing engine, check engine height. See Deter-
mining Minimum Engine Height.
Check engine clearance between front of engine and engine

compartmentbulkhead prior to starting work° If clearance is less
than 8 in. (15,2 cm), the vertical drive must be removed
disengageU-joint shaft from engine coupler. See Vertical Drive
and TransomBracket Service Manual
Whenengine clearance is more than 6 in. (15,2 cm), the engine 22703
can be pulled forward to disengage the U-joint shaft from the
flywheel coupler, and be removedfrom the engine compartment.
The vertical drive can remain installed only if engine

removaldoes not require re-alignment of the engine. If the engine
mounts, boat stringers, or engine coupler are being repaired or
replaced, removethe vertical drive for engine alignment.
Z~ To prevent possible fire and explosioncausedby ignition of
fuel vapors which may be present in the engine compartment,
removethe positive and negative cables from the battery.
22704
DisconnectBattery
Z~ AHswitches must be in the "OFF"position prier to discon-

necting the red (positive) and black {negative) cables from
battery. This will safeguard against permanentdamage to elec-
trical components.
Disconnect PowerSteering Lines

[~ 1. Disconnect both power steering lines at the steering
cylinder.
22706
[~ ~ 2. If original steering line connector, P/N 914728, is
available, useit to [ink both steering lines together. If Connectoris
not used, cover both steering cylinder openingsand line fittings
to prevent fluid loss and entry of contaminants. Tie lines onto
engine higher than power steering pumpto prevent damageand
loss of oil during engine removal.
Disconnect Fuel Supply
[~ Z~ Disconnectboat fuel line at the fuel filter inlet. Seal end

of fuel line and inlet opening.
DisconnectElectrical Cables 2913
1. Disconnectthe plastic two-wire trim/tilt motor connector

®.
38277
11-2 Eng,ne/eng
[6~] 2. Removewire retainer (~ andunplugrubbertwo-wiretrim/tilt sender
connector.Cut tie strap © securingsendercable, if required.
[~ 3. Unscrewclamp@and disconnectlarge rubber instrument cable

connector(~). Unplugrubberthree-wiretrim/tilt cableconnector
T’hrottJe Cab|eDisconnection
[i~ Prior to disconnectingthe remotecontrol throttle cabre, note wheter

you havea "Push=To-Open" or "Pull-To-Open"throttle armattachment.
~ ~ 1. Remove
cotter pin and flat washer@from throttle arm. 24288
~ ~ 2. Loosenanchor retainer nut (~) and rotate retainer (~ away

fromcable trunnion. Remove
throttle cable fromthrottle armandanchor
bracket.
, All Models(except 7.4Gi, GSi and 8.2GSi) E~
, 7.4Gi, Models E~
. 7.4GSiand8.2GSi Modeas [~ 33727

DisconnectExhaustHose- 3.0 Models
[~ 1. Loosen four hose clamps.
[~ 2. For ease of moving hose, lubricate exhaust pipe.
I~ 3. To free exhaust hose from elbow, pry or twist hose. Slide

hose down onto exhaust pipe.
DisconnectExhaustHose- All V-6 and V-8 Models

E~ 1. Loosen four clamps ® on lower exhaust hose. For ease of 6361
moving lower hose, lubricate exhaust pipe.
[~ 2. To free lower hose from intermediate pipe, pry or twist
hose. Slide hose down onto exhaust pipe ®.
6362
6363
17370
17371
11-4 Eng,ne/eng
Disconnect Water Hose
Loosen clamp and pult water supply hose off transom

bracket water tube.
Separate Engine Mounts
~-~ Z~ 1. Attach a hoist to lifting brackets of engine. Hoist must

havea lifting capacity of at least 1500Ibs. (680 kg).
ES~2. Removeand retain both lock nuts © and both flat washers
~ from rear engine mounts. 22698
L-~ [~] 3. Removeand retain lag screws from front engine

mo u nts.
® 3.0 Models
® All V-6 and V-8 Models
4. ffvertical drive wasremoved,lift engine out of engine compart-

ment. If vertical drive was not removed,lift engine slightly and
pull it forward to disengageU-joint shaft and flywheel coupler.
With U-joint shaft clear of flywheel coupler, lift engine out of
31444
compartment.
12211
2888
2933
En;lme/eng 1 1-5
Exhaust Pipe Replacement
Removal
1. Remove
engine following previous procedure.
[~ 2. Removeand retain four exhaust pipe screws. Remove exhaust pipe

and discard seal (~. Cleanall material from transomshield and exhaust
pipe seal surfaces.
NoteExhaust pipe mountingholes have locking Hefi-CoiP inserts. Do

not clean screwholes with a thread tapping tool, otherwiselocking feature ?.2780
will be destroyedandHeft-Coil will haveto be replaced.
mnstalmatien
1 Coat a newseal with 3Madhesiveor equivalent and place in tran-

somshield groove (~.
[~ 2. Apply VomvePenta Gasket Sealing Compound

P/N 1161231-4to the
four exhaust pipe mounting screws @.
3. Secureexhaustpipe (~) to transomshield with four screws.Tighten

to 20-25 ft. Ibs. (27-34 N.m). Slide exhausthosesand caamps(~ onto 15048
exhaust pipes if they were removed.
4. install engine.
EngineInstallation
Engine Mount Attachment
1. Lowerengine into engine compartment:
If drive unit wasnot removedand engine

crankshaft wasnot rotated, engageU-jo nt 15047
shaft with engine coupler and slide engine

back onto rear mounts.If coupler and U-
joint shaft will not align, either the engineor
U-joint shaft will haveto be rotated to allow
engagement.If engine mountheight was
disturbed, engine must be realigned as
describedlater.
L.~ ¯ If drive unit has beenremoved,lower

engine onto rear mounts.
12212
[~ 2. nnstall flat washers~ into recesses of engine bracket and secure
engineto mountwith lock nuts (~). Tightenlock nuts to 28-30ft. Ibs. (38-40
N,m).
12211
11-6 E,~,n~on~
L_Vj ~ 3. install forward engine mountUagscrews and tighten them
securely.
. 3.0 Models E~
, AJJ V-6 and V-8 Models E~
If the sterndrive wasnot removed,go to ExhaustHoseAttachment.If the;

stemdrive was removed, continue with Engine Alignment section.
EngineAlignment 2988
~-_N~Correct enginealignmentis essential to long enginedrivetrain life.

The front engine mountsmayneed adjustment UPor DOWN to produce
correct engine alignment. UseVolvo Penta Alignment Tool P/N 3851083-0
with Volvo Penta Drive HandleP/N 3850609-3to check engine alignment.
1. Slide aJignmenttool ~) throughdriveshaft gimbal bearing (~. The

alignmenttool must slide throughthe gimbal bearing and into engine
couplerwith ease. If the alignmenttool binds going into enginecoupler,
makesure the gimbal bearing is properly aligned. If gimbal bearing align-
mentis correct, the front enginemountsmust be adjusted either UPor 2933
DOWN,as required, until alignmenttoomslides easily in and out of engine

coupler.
DE] [~ 2. To changeengine height, tighten or loosen nuts @and ® as

required. See respective engine section, Front MountHeight Adjustment.
* 3.0 Mode|s E~
¯ All V-6 and V-8 Models [~
3. After correct alignment has beenmade,the front mount(s)must 34068
tightened to maintainalignment.
3.0 Models- While holding one nut with an

open-endwrench, tighten the second
adjustingnut to a torqueof t 15-140ft. Ibs.
(156-190 N®m).
V-6 and V-8 ModeJs- While holding one #
nut with an open-endwrench,tighten the

secondadjusting nut to 100-120ft. Ibs.
......!;,¯
(136-163 N®m). 2972
2953
Eo~,o~/ong 1 1-7
Connect Exhaust Hose
[~ 3.0 Models- Slide exhaust hose (~) up onto high-rise exhaust elbow
®.
[~ V-6 and V-8 Models - Push lower hoses © up onto intermediate
exhaust pipes (~.
E~ Position and tighten all hose clampssecurely betweenribs of exhaust

hose(s) as shown.
Z~ DONOTinstall hose clamps in expandedarea (~) of hose(s).

Coolingwill be restricted and engine damage
will occur,
ConnectThrottle Cabme
[~ Determine whether you have a "pull-to-open" or "push-to-open"

remotecontrol throttle cable. Position remotecontrol handlein neutral,
propeller shouldrotate freely. Turn propeller shaft andshift into the forward
gear detent position, then pu~l handle HALFWAY BACKtowards NEUTRAL.
This positions the control for properthrottle adjustment.Failure to follow this
procedurecanresult in "hard shifting" out of neutral.
E~ 1. Align internal bosses® of trunnion with throttle cable groove @. ~7372A

Presstrunnion on throttle cable until seated.
[~ ~ 4.3 GL and GS Models Only: Engine anchor bracket may

havetwo sets of anchorblock holes. Thetop set (~ is for GSmodelsonly.
The bottom set (~ is for GLmodelsonly.
[~ ~ 2. Install openend @of trunnion in anchor block. Instalt screw in

anchorblock and position throttle cable assemblyin selected set of holes.
Nut mustbe against the anchorbracket, tighten it securely.
~] ~ 3. Throttle arm connector ® must have a minimumof 9 full

turns or 1,~ in. of throttBecable threadengagement. Install throttle arm 17370A
connectoronto the throttle cable. Pull connectorforward ® to removeall
end play from throttle cable, then turn the connectorin until hote aligns with
the "pull-to open"(~ throttle armstud. ®
~lf throttle arm connector hole cannot be adjusted to align with the
throttle arm, checkfor propercable installation in the remotecontrol box.
34751
DR4977
11-8 Engmelerlg
DR4978 DR4979 22698
~ 4. install connectoronto throttle arm. Install washerandcotter

pin (~, and spreadcotter pin prongs.Tightenjam nut @against
connector.
El~_~For throttle andshift cable adjustmentprocedures,see Throttle

and Shift Control Sy.,~temssection.
Water HoseInstallation
E~ 1. Slide hose damp® onto water inlet hose. Lightly lubricate inside of
water inlet hose and push hose onto water inlet tube @. 15864
E~9~3 2. if inlet hoseis not installed properly, undersideof hosemaycol-

lapse. Checkundersideof hosefor proper installation and adjust hoseas
required. Tighten hose clampsecurely.
~ Failure to install water inlet hose correctly can result in engine

damage from blockageof water circulation.
PowerSteering Line installation
1, Removetape or protective cover from small hydraulic hosefitting (or

unscrewsteering line connector)and small steering cylinder opening. 22702
rlo-~ 2. install smallhosefitting into steeringcylinder andtighten to 10-12ft.

Ibs. (14-16 N®m).
3. Remove tape or protective cover from large hydraulic hosefitting and

large steering cylinder opening.
~--~4. install large hosefitting into steering cylinder andtighten to 15-17fl.

Ibs. (20-23N.m).
22701
Encjtne/eng 11-9
Electrical Cabie Connections
E~1. Connectplastic two=wireplug of engineharnessto two-wirerecep-
tacle @of trim/tilt motor.Connectors
shouldlock together.
~2. Connectrubbertwo-wire trim/tilt senderplug to two-wire receptacle

of instrumentharness.Secureconnectorswith wire retainer andcable
with a tie strap @.
3. Routethe instrumentcable plug to join enginecablereceptacleon

engine.
~ Ensure cable is routed to prevent cutting or chafing on any

sharpor hot object. This could resumtin an electricaJ short, and
contribute to fire and explosion in the engine compartment.
~] 4. Apply a light coat of Volvo PentaGreaseP/N 828250-1around

large engineplug @.
[~ 5. Slide hoseclampover large enginereceptacle. Align the two large

terminals on plug and receptacle ® and press together. Slide hosedamp
over receptacleandtighten securely.
Z~6. Modelswith Starter Solenoids: Position the red cable protec=
tor over solenoid terminal.
~7. All switches must be in the "OFF" position prior to connect-
ing the battery cablesto the battery. Besure polarity is observed;
positive (+) cableto the positive terminal, andnegative(--) cableto
negativeterminal.
1 1 - 10 Engine/eng
ConnectFuel Supply
L~ Attachboat’s fiJel supplyhoseto fuel filter canister. Tighten

connectionsecurelyo Checkfor fuea leaks whentesting engine,
and repair any leaks that mightoccur.
Rear Engine Mounts

Removaa
11. Remove
engine as previously described in this section. 6678
ES~2= Unscrewtwo screws and washers, then Pift mount assem-

bly off transomplate.
Disassembly
Hold square nut and remove screw. Mount assembly will

break downinto componentsshown. Pay particular attention to
the two mountwashers; their thickness, their shape (concave or
flat), and their position in the assembly (above or below the
rubber mount).
16348
Assembly
~--~ 1. Slide lower washer ® onto mount bolt; makesure you
choose the correct washer (as determined during the mount
disassembly)for this position, insert bolt into bottom(flat) side
rubber mount assembly, and install remaining washer and
square nut. Do not tighten nut at this time.
if top and bottomwashersare not installed in their original

positions, mount maytransmit excessive engine vibrations into
boat and cause undesirable operating conditions.
6880
2. -Pdrn mount assembly upside downand clamp square nut
in vise. Rotate rubber mount until mountingholes are positioned
at 90° to any side of square nut. Hold mountin this position and
tighten center bolt to 44-52 ft. Ibs. (60-71 N.m).
~ot~ ff 90° relationship between nut and mounting holes is not
maintained, slot of engine mount pad cannot engagerear mount
during installation.
Installation
~’ 1. Place mount assembly on transom plate. Install two
screws and washers, and tighten them to 20-25 ft. Ibs. (27-34 6677
N~m).
~--~ 2. Install engine as previously described in this section.
Makesure mount pad slot engagessquare nut. Install both flat
washersand lock nuts, then tighten lock nuts to 28-30 ft. Ibs.
(38-41 N.m).
12212
E.g,.e~ng 1 1-11
®
Determining MinimumEngine Height

[~ 1. To determine minimum engine height, use a level (~)
placed on top of the transom, measurefrom bottom of level to top
of elbow (~) and record distance=
[~ 2. Measurefrom bottom of level to static water line © and

record distance.
[~ 3. Subtract dimension (~) from dimension © and record

result. See engine height requirements below:
¯ 3.9 Models - Measurement © minus ~) should not be

less than g in. (22,8 cm).
® V-6 Models - Measurement © minus (~ should not be

less than 13 in. (33 cm).
¯ V-8 Models - Measurement © minus ~) should not be

less than 14 in. (35,6 cm).
4. Whenengine installations do net meet these specifications, an

exhaust elbow high-rise kit must be installed.
An installation that permits water to enter the engine

through the exhaust manifolds(s) wilJ not be covered by warran-
ty, unless damageis due to defective part(s).
11-12 Engine/eng
Safety Section
Part A
Marine Products and Safety of People Who Use Them . . . . . . . . . S-2
Sterndrive Shift System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-3
Sterndrive Throttle Control System . . . . . . . . . . . . . . . . . . . . . . . . S-4
Sterndrive Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-5
Sterndrive Fuel, Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . S-7
Part B
Marine Products and Safety of People Who Fix Them . . . . . . . . S-11
Handling Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-11
Handling Lead Acid Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-12
Gasoline! Handle with Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-13
Hazardous Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-14
Safety
S-1
Part A - Marine Products and safety of
People Who Use Them
Enjoyable boating is the goal of people who design and build marine products. To reach this goal, manufacturers are
careful to make sure...
Product User is informed. . .
Products are safe and reliable. . .
It's up to you, the People who. . .
Install accessories. . .
Service and Maintain the boat. . .

Service and maintain the sterndrive. . .
. . . to keep the products safe and reliable.
This section talks about safe boating and how you can help keep it safe. Some things you may know
. . . but others you may not.
First!
A word about fasteners . . . plain . . . special . . . all screws, nuts, washers and bolts.
Do Not Substitute Fasteners
They look the same, but . . . are they?
The Same Size?

The Same Strength?
The Same Material?
The Same Type?
Standard or Metric Thread?
Don't substitute unless you know they are the same in all characteristics.
Second!
Special locking screws and nuts are often used to attach steering, and remote control components to
the sterndrive.
When you remove any part from the sterndrive, keep track of special screws and nuts. Don't mix with
other parts
When reassembling the sterndrive, use only the special screws and nuts intended to hold steering, and
control cables, plus related parts.
Service with parts of known quality that meet Marine Industry (BIA/ABYC) Standard.
S-2 Safety
Sterndrive Shift System
The Shift System starts

here at the remote control lever. . .
. . . and ends here at the propeller.
What's Most Important?
When the control lever is in Forward,

Neutral or Reverse position . .
. . . Shift mechanism must match

control lever position.
What Could Happen?
If . . . Neutral If . . . Forward
Forward
or
Reverse
Reverse
. . . Propeller is still powered (turning) . . . boat will move opposite

unknown to operator, or engine will to direction intended by operator.
start in gear, boat will move unexpectedly.
How Can Loss of Shift Control be Minimized? In pre-delivery inspection and when servicing . . .
Read, understand and follow manufacturers instructions.
Closely follow the warnings marked with ...
Assemble parts and make adjustments carefully . . .
Test your work. Don't guess. Make sure propeller does what the operator wants and
nothing else.
Safety
S-3
Sterndrive Throttle Control System
The throttle Control System starts

here and the remote control lever . . .
. . . and ends
here on the engine.
When the control lever is moved from

Forward (or Reverse) to Neutral . . .
. . . engine speed must slow to idle
RPM and allow operator to shift into
Neutral.
Operator must be able to stop propeller.
What Could Happen?
If operator cannot slow the engine to idle RPM and shift into neutral, (stop propeller), operator could panic and lose control
of boat.
How Can Loss of Throttle Control be Minimized? In pre-delivery inspection and when servicing . . .
Read, understand, and follow manufacturers instructions.
Assemble parts and make adjustments carefully . . .
Test your work. Don't guess. Make sure engine throttle response is smooth.
Make sure full throttle operating RPM can be reached so operator won't overload engine
S-4 Safety
Sterndrive Steering System
The Steering System starts

here at the helm . . .
The Steering System . . .

. . . and ends here at the propeller
on the sterndrive
must be installed properly
must be adjusted properly
must be lubricated
What Could Happen?
. . . if steering system comes apart, boat would turn suddenly and circle . . . passengers and/or operator
may be thrown into water and could be hit.
. . . if steering jams, operator may not be able to avoid obstacles. Operator could panic.
. . . if steering is loose, operator may not be able to maintain a true course, and could result in loss of
boat control.
Safety
S-5
How Can Loss of Steering Control be Minimized?
In pre-
use steering components which meet marine industry (BIA/ABYC) standards . . .
delivery Read, understand, and follow manufacturer's instructions.
inspection Assemble parts and make adjustments carefully . . .
and when Closely follow the warnings marked with ...
servicing Keep parts moving freely . . . lubricate parts as soon as shown in manuals
Use bolts, nuts, and washers supplied with steering attachment kits
When power assisted or mechanical steering systems are used, check to uncover possible trouble!
Cable housing in this area

must not be restricted Steering components must not
bind
Why? Unit may go to full turn without
Why? Possible jamming of steering
turning steering wheel (Power
system.
assist models)
Engine stringer must not interfere

with power steering pump and pul-
ley
Maintain proper belt tension.
Power steering parts and push/pull cable

must be free to move in order to actuate
power steering valve when operator
turns steering wheel
Check for damaged parts . . . impacts to the sterndrive like this
or this . . . or ? ? ?
can put stress on steering components. Look for . . .
Cracked parts
Bent parts
Loose fasteners
Replace damaged parts. If weakened, parts could fail later . . . on the water
. . . when least expected.
S-6 Safety
Sterndrive Fuel and Electrical Systems
The electrical System begins

here at the battery . . .
. . . and ends here
at the carburetor or fuel injectors
The fuel system

starts here at the fuel tank . . . . . . and ends
here on the en-
gine.
What's Important?
Fuel leakage must be prevented.

Electric sparks must not happen.
What Could Happen?
Gasoline can explode and/ or burn easily:
When boating, fuel leaking in the engine compartment could be ignited by a spark from a loose wire
connection, or a damaged or deteriorated electrical component.
How Can Fire and Explosion Be Minimized?
Read, understand and follow manufacturers instructions.
Do not substitute fuel or electrical parts with other parts which may look the same. These parts are
designed and manufactured to meet special U. S. Coast Guard safety regulations to prevent fire and
explosion.
If you work on marine engines, you must understand these U.S. Coast Guard requirements. If you don't have them, write
to . . .
---------
---------
---------
National Technical Information Service
Springfield, Virginia 22161
. . . and ask for copies of:
(1) Electrical System Compliance Guideline (AD/A-049-638)

(2) Fuel System Compliance Guideline (AD/A-047-767)
These are concise guidelines - easy to read and understand. They explain what must be done to prevent fire and explo-
sions.
Safety
S-7
Always use replacement parts specified by the manufacturer. They meet the U.S. Coast Guard require-
ments. Most automotive parts do not, especially electrical components that must meet ignition protec-
tion requirements of the U.S. Coast Guard regulations.
When nonmetallic parts look to be in poor shape . . . replace them!
Torn Boots!
Wires Cracked!
Cracked Fuel Lines!
Using parts which meet U.S. Coast guard requirements is only half the job. The other half is your job . . .
It's time for replacement BEFORE sparks and/or fuel leaks occur.
Replace parts carefully. Make sure nuts and bolts are tight especially when they anchor electrical wires
(to prevent sparking). If lock washers are specified - use them. No short cuts or missing parts with
either of these CRITICAL safety related systems.
When refueling, always ground fuel nozzle to the inlet fitting on the boat to prevent the buildup of
electrostatic sparks. If you use a funnel, make sure it's metal and ground the fuel nozzle to the funnel.
If you smell gasoline in the engine compartment . . .

STOP find its source and stop the leakage.
S-8 Safety
Follow "Starting Procedure" outlined in the operator's manual.
Always make sure there are no gasoline fumes in the engine compartment before starting the
engine. Open the compartment and use your nose. Don't gamble.
Backfire flame arrestor must be in place and securely attached to the air intake.
Do not alter the backfire flame arrestor.
If loose, damaged, or altered, an engine "backfire" may pass through the flame arrestor assembly into the engine compart-
ment. If fumes are present in compartment, fire and explosion could result.
Safety
S-9
Summing Up
Now you know some things that can take the joy out of enjoyable boating.
No doubt about it . . . it takes time!
Reading and understanding instructions.
Reading and understanding warnings marked with ...
Putting parts together correctly . . .
Making correct adjustments . . .
Testing you work.
and making sure
Worn or damaged parts are replaced,
Replaced parts are like originals . . . in every way.
Customer is told of things which need attention . . .
But do you really want the alternative?
S-10 Safety
Part B - Marine Products and Safety of
People* Who Fix Them
Part A talked about safe boating and how you, the mechanic, can help keep it safe for the boater. But what about you?
Mechanics can be hurt while . . .
Servicing boats
Servicing sterndrives
Troubleshooting problems
Testing their work
Some items you'll know . . . others you may not.
When Lifting Engines
If hoist is poor shape . . . or too small for the job
Engine may drop suddenly
DR3471 DR3469
Make sure shop aids have extra capacity — and keep them in good repair!
When Running Engine with Engine Compartment Cover Removed
The engine compartment cover is a guard. When you remove the cover / guard to work on the engine, remember:
Loose clothing (open shirt sleeves, neckties), long hair, jewelry (rings, watches, bracelets), hands,
arms, belts can be caught by moving belts or spinning pulleys
Handle high voltage ignition components carefully. They can shock you and may cause you to recoil into
moving parts.
Two people working together on a running engine must look out for each other. Never, ever, hit the key to start the
engine before signalling to your partner. (He may be leaning over the engine with his hands on a belt, or a "hot" electri-
cal part, near the propeller, etc.)
*Mechanics, technicians, backyard do-it-yourselfers.
Safety
S-11
Exhaust gasses of running engines contain carbon monoxide. . . you can't see it. . . you can't smell it. . .
you can't taste it. . . but it's there whenever an engine runs. . . and it's deadly!
When you smell the other gasses in the exhaust, you are inhaling carbon monoxide. Run engines only in well ventilated
areas.
Eyes Need help
Grinding Sprayed
Cleaners,
Paints
End of Cables Acid
Chiseling
(steel on steel)
(Tip: Use plastic or brass type hammers.
They don't chip off as easily as steel hammers.)
Handling Lead Acid Batteries
If spilled or splashed on
any part of body..
Wash with lots

If solution gets
of water. . .
into eyes. . .
Wash. . . and see a Doctor, fast!
Charging Lead Acid Batteries
Attach and remove these cables

with charger unplugged from 110 volt wall
socket. (Prevents shocks if the charger
is defective.)
Observe correct polarity when con-

necting these charger leads.
Always charge in a well ventilated

area. Charging causes acid solution to
give off hydrogen gas through the vents
in the caps. . . Make sure vents are open.
If clogged, pressure inside may build. . .
battery may explode.
S-12 Safety
Never yank cables off
Battery gas is explosive! battery posts. . . it's a sure
While charging or discharging, way to make lots of
remember. . . sparks. . .surrounded by battery gas
No Smoking
No Flames
No Sparks
Don't check battery condition After Charging. . .

by placing metal objects
across posts. Shut off charger
You're sure to make sparks Remove charger plug from wall socket
Then. . .
and serious burns are
possible. Take charger cable off battery posts
Gasoline! Handle With Care

When you smell any odor of gasoline,
explosion is possible
Gasoline fumes are heavier than air and will sink

to the lowest point in the boat or room,
and will stay there. . . waiting
Gasoline explodes easily and violently when

If the air around you is quiet . . . the pilot light in mixed with air
the heater may
ignite the heavy fumes 5 Parts
before your nose ever Gasoline
smells the fumes . .
100 Parts
Air
What Can you Do?
Store properly . . .
Fill portable tanks outside boat to prevent spillage in
boat
Use fuel for fuel . . . not for a solvent
If fumes are smelled (in shop, basement, garage), immediately:
Store in sturdy, Put out open flames, cigarettes, sparking devices
sealed gas can Wipe up spill or leak; get towels, rags outside fast
. . .and . . . Check lowest area for fumes; open doors or win-
keep outside dows
Safety
S-13
Know items in and around repair area which can ignite gasoline fumes . . . Control them if fumes are smelled.
Matches, cigarettes, torches, welders

Electric motors (with unsealed cases)
Electric generators (with unsealed cases)
Light switches
Appliance pilot lights (furnace, dryer, water heater)
?????????
How many of these are in your area?
Hazardous Products
Read the container label. It tells you . . .
"How, and where, to use,"

"How to give First Aid," and have "recommended" first aid materials on hand- should an
emergency arise
"How to dispose of can,"
Remember: Little children are very curious and will try to taste everything, so . . .
. . . yummmmmmmmmmm Keep containers away

from children
S-14 Safety
VOLVOPENTAMODELiDENTiFiCATiON
Engine Modelidentification is located on the engine valve cover for four cylinder (in-line) models,
on the inside of the port valve cover for V6 & V8 models, or on the Thick Film Ignition (TFI}
module bracket for Ford fuel injection models. The identification numbersmust correspond with
the transom shield and drive unit numbers. See below.
E] Engine Model Number(GL, GS, and Gi Models)
Engine Model Number
SX MODELS:
E] Transom Shield Model Number
r~ Drive Unit Model Number
DP & DPX MODELS:
Nunber plate for drive unit andtransomshield.

Onlyfields 2 and3 are filled for transom
shield.
1
3 [ 1
1. Product Designation
4
2. Model Number
3. Serial Number
4. ReductionRatio
07-1998
®
English
Volvo Penta of the Americas, Inc.

1300 Volvo Penta Drive
Chesapeake, Virginia 23320
U.S.A.
7797451

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Workshop Manual C

Engine Components 2(0)

This Workshop IVlanual will alert you to certain proceduresthat

® injure yourself or people around you

Understand the following symbols before proceeding:

Alerts you to the possibility of dangerand

Appearsnext to information that controls

This WorkshopManual is ,written for qualified, factory trained

This Workshop Manual tells you how to correctly maintain and

WhenVolvo Penta special tools are called for, use them.

If you use service proceduresor service tools that are not

General information .................................... ~ii~

General Engine Mechanical- V6 and V8 Models ..........

3.0GS Engine .......................................... ~

4.3GL, 4.3GS and 4.3Gi Engines ......................... ~

5.0GL, 5.0Gi, 5.7GS and 5.7GSi Engines .................. ~

7.4Gi Engines ......................................... ~;~

70.4GSi and 8.2GSi Engines .............................. ~/

Steering Systems g m aa m~ m ~= w = = m [] Eim m m ~ = m [] ~ ¯ m E [] [] == [] ! m~ B es m B ea m~ m o m :~

Throttle and Shift Control Systems ...................... =-~

Engine Removal and Installation ......................... ~ml

Safety Section ......................................... ~

© 1998VolvoPentaof the Americas,Inc, All rights reserved.

Engine Steering Model Number TransomShield Drive Unit

3.0 GS Manual 30GSMBYCCE 3868844 3865895 (1.97:1) SX-M

4.3 GL Power 43GLPBYC 3868844 3868892 (1.66:1) SX-M

Power 43GSJBYA 3868694 PJX-C1

4,3 Gi Power 43GIJBYA m= 3868694 PJX-C1

5.0 GL Power 50GLPBYC 3868844 3868891(1 .60:1 SX-M

Engine Steering Model Number TransomShiend Drive Unit

5.0 Gi Power 50GIPBYCCE 3868844 3868891(1 .60:1 SX-M

5.7 GS Power 57GSPBYC 3868844 3868889(1 .43:1 SX-M

5.7 GSi Power 57GSIPBYCCE 3868844 3868889 (1.43:1 SX-M

7.4 Gi Power 74GIPBYCCE 3868844 3868889 (1.43:1) SX-M

7.4 GSi Power 74GSIPBYCCE 3868850 3868911 (1.68:1)DP-SM

8.2 GSi Power 82GSIPBYCCE 3868850 3868911 (1.68:1) DP-SM

DPX 385 Xact DPX385XBYDCE 3868289 3868637 1.59:1) DPX-S1

DPX 415 Xact DPX415XBYDCE 3868289 3868637 1.59:1) DPX-S1

¯ Engine Model Number [~ [~ DRl14!

® Transom Bracket Model Number E~

o Sterndrive Model Number E~

Battery Cable Requirements .................................. 1 -3g

Service required for Volvo PentaSterndrivesis generally one of three ki

Normalcare and maintenance - which includes putting a

Operating malfunctions - due to improper engine or drive

Complete disassemblyand overhau| - such as major

It is importantto determinebefore disassemblyjust what the trouble is and

Whenrepairing an assembly,the most reliabJe wayto ensure a goodjob is

~Do not operate engine out of water even momentarily. If

~Useproper lifting and handling equipment. Workingon sterndrive~==

Alwaysuse clean fresh fuel whentesting engines. Troublescan often be

Whetherwithin or following the warranty period, Volvo Pentahas a constant

It is an Volvo Pentapolicy to providedealers with service knowledge so they

Parts Catalogsare a goodsourceof information for ordering parts. They

Special Service Tools

Volvo Pentahas specially designedtools to simplify someof the disas-

ProductReferences,illustrations & Specifications

Volvo Pentaof the Americas,Inc. reserves the right to makechangesat

All photographsand illustrations usedin this manualmaynot depict actuat

//~ Safety Related

Economical,dependableoperation can be ensuredif a completetune up is

Proceduresfor performinga completeengine tune-up will be covered in

~Use extreme care around engine while running or cranking. Remove;