Section 4

4.3 GL and Gi Engine

Table of Contents

Accessories .............................................................. 4-4 General Description ................................................. 4-2

Balance Shaft ......................................................... 4-23
Balancer, Crankshaft .............................................. 4-15
Camshaft ................................................................. 4-22
Cleaning .................................................................... 4-4
Circulating Pump .................................................... 4-34
Crankshaft and Bearings ....................................... 4-30
Cylinder Block ........................................................ 4-31
Bylinder head .......................................................... 4-12
Engine
Coupler Replacement ......................................... 4-39
Draining ................................................................. 4-4
Front Cover .......................................................... 4-20
Front Mount ......................................................... 4-35
Lubrication ............................................................ 4-5
Exhaust
Manifold ................................................................. 4-6
High-Rise Elbow Replacement........................... 4-37
Hose Replacement .............................................. 4-38
Intake Manifold ......................................................... 4-7
Intermediate Pipe Replacement ............................ 4-38
Materials Required ................................................... 4-3
Oil Pan ..................................................................... 4-16
Oil Pump ................................................................. 4-17
Pistons and Connecting Rods .............................. 4-25
Rear Oil Seal, Crankshaft ...................................... 4-29
Rear Oil Seal Housing ............................................ 4-29
Rocker Arm Cover .................................................... 4-9 4
Rocker Arm Stud Replacement ............................. 4-13
Special Tools - GM ................................................. 4-46
Specifications
Engine .................................................................. 4-43
Torque .................................................................. 4-41
Timing Chain and Sprockets ................................. 4-21
Tools and Shop Equipment ..................................... 4-3
Valve Train .............................................................. 4-10

Safety Warnings
Before working on any part of the engine, read the Safety section
at the end of this manual.
Always use the correct fastener in the proper location. When you
replace a fastener, use ONLY the exact part number for that appli-
cation. The text will call out those fasteners that require replace-
ment after removal. The text will also call out the fasteners that
require thread lockers or thread sealant.
UNLESS OTHERWISE SPECIFIED, do not use supplement coatings
(paints, greases, or other corrosion inhibitors) on threaded fas-
teners or fastener joint interfaces. Generally, such coatings ad-
versely affect the fastener torque and the joint clamping force,
and may damage the fastener.
When you install fasteners, use the correct tightening sequence
and tightening specifications. Following these instructions can
help you avoid damage to parts and systems.

Engine/eng 4-1
General Description
Engine Construction

The 4.3L engine is a liquid-cooled 90 degree V6 type with overhead

valves, a balance shaft, and cast-iron block and cylinder heads.

Cylinder Block

The cylinder block has 6 cylinders arranged in a “V” shape with 3 cyl-
inders in each bank. Starting at the front of the engine, cylinders in the
right bank are numbered 1-3-5 and cylinders in the left bank are num-
bered 2-4-6 (when viewed from the front). The firing order of the cylin-
ders 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 between the 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 number

four bearing at the rear of the engine is the end thrust bearing. The
bearings are retained by bearing caps that are machined with the block
for proper alignment and clearances.

Camshaft

The camshaft is supported by four full round, sleeve-type bearings. A

sprocket on the crankshaft drives a camshaft timing chain which in
turn drives the camshaft through a sprocket.

Pistons and Connecting Rods

The pistons are made of cast-aluminum alloy using two compression

rings and one oil control ring assembly. Piston pins are offset 0.0354
in. (0,9 mm) toward the major thrust side (right side) to reduce piston
slap as the connecting rod travels from one side of the piston to the
other side after a stroke. The pins are a press fit in the connecting rod
and a floating fit in the piston.

Balance Shaft

The cast-iron balance shaft is mounted in the crankcase above and

inline with the camshaft. A camshaft gear drives the gear attached to
the balance shaft. The front end of the balance shaft is supported by a
ball-type bearing. The rear end of the balance shaft uses a sleeve-
type bearing.

4-2 Engine/eng
 Valve Train

The valve train is a ball-pivot type. Motion is transmitted from the cam-
shaft through the valve lifter and valve push rod to the valve rocker arm.
The valve rocker arm pivots on its ball and transmits the camshaft mo-
tion to the valve. The valve lifters with roller followers keep all parts of
the valve train in constant contact. Each lifter acts as an automatic ad-
juster and maintains zero lash in the valve train. This eliminates the
need for periodic valve adjustment.

Intake Manifold

The intake manifold assembly is a two-piece design. The upper portion

is made from 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 equip-
ment includes: a suitable parts cleaning tank, compressed air supply,
trays to keep parts and fasteners organized, and an adequate set of
hand tools. An approved engine 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
complete listing at the end of the section. These tools (or their equiva-
lents) are specially designed to quickly and safely accomplish the op-
erations for which they are intended. The use of these special tools will
also minimize possible damage to engine components. Some precision
measuring tools are required for inspection of certain critical compo-
nents. Torque wrenches are necessary for the correct assembly of vari-
ous parts.

Material Required

DuraPlusTM Synthetic Motor Oil

Volvo Penta Gasket Sealing Compound
Volvo Penta Thread Sealing Agent
3M Scotch Grip Rubber Adhesive 1300
GM Adhesive, P/N 12346141
GM Engine Oil Supplement, P/N 1052367
GM Sealant, P/N 12346004
GM Threadlock, P/N 12345382
Loctite Primer
Black Neoprene Dip

Engine/eng 4-3
Accessories
The various procedures in this manual assume that the engine acces-
sories have been removed. These accessories include all of the fol-
lowing:

! Power Steering Pump

! Alternator
! Distributor
! Water Supply Pump
! Accessory Brackets and Electrical Wiring
! Starter Motor

Cleaning
Remove the engine accessories before cleaning to provide better ac-
cess to the engine’s exterior surfaces. After removing the distributor,
accessory brackets, etc., cover the openings with tape to prevent the
entry of contaminants.
Methods used to clean the engine will depend on the means which are
available. Steam cleaning, pressure washing, or solvent 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 contaminants from entering critical areas during
disassembly.

Draining The Engine

Follow the procedures in Section 1, General Information of this
manual to drain crankcase engine oil and the cooling system.

4-4 Engine/eng
 1
Engine Lubrication
1 Full pressure lubrication, through a full-flow oil fil-
ter is supplied by a gear-type oil pump. Oil is drawn up
through the oil pump screen and passes through the
pump to the oil filter. The oil filter is a full-flow paper
element unit with an anti-drain back valve. An oil filter
bypass valve is used to ensure adequate oil supply, in
the event the filter becomes plugged or develops ex-
cessive pressure drop.
Engine/eng
DRC6583
Filtered oil flows into the main gallery and then to the
camshaft, balance shaft, rear bearing, and crankshaft
bearings. The valve lifter 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 camshaft bearing. The pistons and
piston pins are lubricated by oil splash.
4-5
Exhaust Manifold
Removal

1. Drain water from exhaust manifolds.

2. Disconnect water hose from manifold.
3. Loosen upper exhaust hose clamps, then remove high rise elbow.
4. Remove manifold attaching screws, then remove the manifold.

Inspection

1. Inspect for cracks. A

1 2. To pressure check manifold, use a plate such as pictured, A
B
and a new elbow gasket B
to seal water passage in manifold. Be sure
to apply sealer to gasket. Install rubber drain caps to manifold and C
secure with clamps. Attach a Gearcase Pressure Tester C (such as
Stevens Company S-34) to the water inlet hose. A bushing can be
made to secure pressure tester to hose. With the pressure tester at-
tached to the manifold, submerge manifold in water. Pressurize the
manifold to 10-15 PSI (22-25 kPa) and check for leaks. Manifold should
not leak around clamps and plate. If so, retighten clamps or reseal
1
DR2642
plate. No drop in pressure should be realized.

Installation

2 1. Clean mating surfaces on manifold and head. Install new ex-

haust gasket, then install manifold and secure with screws. Tighten
screws D to 20-26 ft. lb. (27-35 N m).
•

2. Install a new gasket and high rise elbow to manifold. Tighten bolts
to 12-18 ft. lb. (16-24 N m).
•

3. Install exhaust hose and secure with clamps.

2
4. Connect water hose and secure with clamp. 28287A

5. Start engine and check for fuel leaks.

Safety Related 4-6 Engine/eng

Intake Manifold
Removal
3 5 1. Drain coolant from manifolds and both sides of block.
6 2. Remove intake manifold drain plug E from front of intake mani-
fold.
3. Disconnect:
a. Battery cables from battery. 3
34091A
b. Coolant hoses at thermostat housing.
c. Throttle cable from carburetor and anchor block.
d. Crankcase ventilation hose from rocker arm covers (both
sides).
e. Wire at temperature gauge sender unit and engine wiring har-
ness from alternator.
f. Distributor high tension and ignition primary leads from coil.
4. Remove:
4
7 a. Distributor cap and mark the position of the rotor on the hous- 34102A

ing. Scribe a line on distributor housing and intake manifold

for reassembly in the same position. Remove the distributor.
b. Alternator and alternator mounting bracket from engine.
c. Carburetor fuel line from carburetor and fuel pump or fuel lines
from throttle body and fuel pump/vapor separator.
d. Oil pressure sending unit.
e. Manifold attaching bolts and solenoid bracket. Lift manifold
from engine. Discard front and rear seals and gaskets.
5
49459
f. If manifold is to be replaced, transfer: carburetor or throttle
body and ECM bracket, thermostat and housing (use new gas-
ket), throttle cable anchor block assembly, distributor clamp
and temperature sending unit. Transfer additional hardware
as required.

6
28546

7
25140

Engine/eng Safety Related 4-7

Clean:

! Old pieces of gasket or RTV from the gasket surfaces.

! Excessive carbon build-up in the intake passages of
the intake manifold.
! Scale and deposits from the coolant passages of the
intake manifold.
Installation
1
Important Do NOT reuse intake manifold gaskets. DRC6590

Install or Connect:

1 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 3 2. Gaskets onto the cylinder head.
a. Use gasket locator pins to properly seat gasket on cylinder
head.
2
DRC6591

b. Apply a 0.499 in. (13 mm) bead of GM Adhesive , P/N

12346141, or equivalent to the front and rear block sealant
areas.
c. Extend the sealer bead 0.157 in. (4 mm) onto each gasket.
3. GM Threadlock, P/N 12345382, or equivalent to the threads of the
eight lower intake mounting bolts.
4. Lower intake manifold onto engine block.
5. Lower intake manifold bolts.
3
Tighten: DRC6592

4 Bolts in three steps, using the following sequence:

a. Snug all bolts to 27 in. lb. (3 N m) to minimize shifting of in-
•

take.
b. Bolts to 106 in. lb. (12 N m). •

c. Bo Its to 11 ft. Ib. (15 N m).

•

4
DRC6593

4-8 Engine/eng
 d. Distributor with rotor and aligned exactly as marked during re-
moval.
If engine was cranked while distributor was out, complete igni-
tion timing procedure must be followed. See the appropriate Ignition
Circuit in Electrical/Ignition/Fuel Systems Service Manual.
e. Alternator with mounting bracket.
f. Distributor cap and high tension leads. See the General In-
formation section in Electrical/Ignition/Fuel Service Manual
for correct firing order and spark plug wire routing.
g. Oil pressure sending unit.
3. Connect:
a. All electrical connections. Apply black neoprene dip, or
equivalent, on all exposed connections.
b. Fuel lines to carburetor and fuel pump or throttle body and
fuel pump/vapor separator.
c. Throttle cable.
d. All water hoses, and close all drain petcocks.
e. Both crankcase ventilation hoses.
f. Battery cables.
g. Start engine. Check ignition timing, carburetor idle speed and
mixture. Check for leaks.

Rocker Arm Cover

Removal

5 Remove or Disconnect:
1. Valve rocker arm cover bolts.
2. Valve rocker arm cover.
3. Gasket.

5
DRC6584

Engine/eng Safety Related 4-9

Clean:

Parts in solvent. Remove all sludge and varnish.

Old gaskets from the gasket surfaces.
Inspect:

Gasket flanges for bending or damage.

Rubber grommets and parts for deterioration.
Installation

1 Install or Connect: 1
DRC6584

1. New gasket.
2. Valve rocker arm cover.
3. Valve rocker arm cover bolts.
Tighten:
Valve rocker arm cover bolts to 106 in. lb. (12 N m).
•

Valve Train
Removal 2
DRC6585

Important Store all reusable components in an exact order,

so they can be reassembled in the same wear pattern location from
which they were removed. Mark the front end of the retainer.
Remove or Disconnect:
2 1. Valve rocker arm nuts, balls, and valve rocker arms.
3 2. Valve push rods.
3 3. Bolts and valve lifter retainer.
4 4. Valve lifters. 3
DRC6588

Remove the lifters one at a time using J 9290-01/J 3049 or equivalent

and place them in an organizer rack.

Important Store all reusable components in an exact order,

so they may be reassembled in the same wear pattern location from
which they were removed.

4
DRC6586

4-10 Engine/eng
 Clean:

! All parts in clean solvent and dry them with compressed

air.
! Make sure oil passages in valve push rods are clear.
Inspect:

! Valve rocker arms and balls at their mating surfaces.

These surfaces should be free from wear or any dam-
age.
! 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 damage or wear.
! Valve rocker arm nuts.
! Valve push rod ends for scoring, roughness, or bends.
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.

Valve Lifters

This engine uses hydraulic valve lifters. Valve lifters are serviced only
as an assembly. No internal parts are available. Service is limited to a
disassembly and cleaning. Discard valve lifters that are excessively worn
or damaged.

Important Whenever the camshaft needs to be replaced, a new

set of valve lifters must also be installed.

Installation

Important Replace all valve roller lifters, change the engine oil
and filter, and add GM Engine Oil Supplement, P/N 1052367, or equiva-
lent to the engine oil whenever a new camshaft is installed.
Lubricate the valve lifter bodies and roller with GM Engine Oil
Supplement, P/N 1052367, or equivalent.

Install or Connect:
3 1. Valve lifters to the block.
3 2. Valve lifter guide.
! Note previously made mark on valve lifter guide. Refer-
ence mark should be pointing toward front of engine.

Engine/eng 4-11
Tighten:
Bolts to 12 ft. lb. (16 N m). •

1 3. Valve push rods.

a. Seat the valve push rods into the socket of the valve lifters.
b. Coat the mating surfaces of the valve rocker arms and balls
with GM Engine Oil Supplement , P/N 1052365, or equiva-
lent.
2 4. Valve rocker arms with balls on to the proper stud. 1
DRC6588
2 5. Valve rocker arm nuts onto the studs.
! Align the valve push rod into the valve rocker arm while
tightening valve rocker arm nut.
Important
No lash adjustment is needed. These models use
screw-in rocker arm studs with positive stop shoulders.
Tighten:
Valve rocker arm nuts to 20 ft. lb. (27 N m).
•

Cylinder Head 2
DRC6589

Cylinder Head Removal

Remove or Disconnect:
1. Spark plugs.
2. Cylinder head bolts.
3. Cylinder heads.
4. Head gaskets.

Cylinder Head Disassembly 3

DRC6594

Tool Required: J 8062 Valve Spring Compressor

3 4 Remove or Disconnect:
1. Compress the springs with J 8062.
2. Keys 1 .
3. Tool J 8062.
4. Valve spring cap 2 .
5. Spring 4 .
3
4
6. Seal . DRC6595

7. Valves 5 and 6 .
Place the valves in an organizer rack so they can be replaced in their
original position at reassembly.

4-12 Engine/eng
Cleaning, Inspection, and Measurement

Refer to General Engine Mechanical section in this manual.

Rocker Arm Stud Replacement

Remove or Disconnect:
Valve rocker arm stud by unscrewing.
Install or Connect:
Screw valve rocker arm stud into cylinder head.
Tighten:
Valve rocker arm stud to 35 ft. lb. (47 N m).
•

Cylinder Head Assembly

Tools Required: J 8062 Valve Spring Compressor
Install or Connect:
4 1. Valves 5 and 6 .
a. Lubricate the valve stems with clean engine oil.
b. Insert the valves into the proper valve guides until the face of
the valve contacts the valve seat.
4 2. Seal 3 .
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 .
4 4. Valve spring cap 2 .
3 a. Compress the valve spring using J 8062, enough so the lower
valve stem groove can be seen clearly.
b. Apply a small amount of grease to the area of the upper valve
stem groove.
4 c. Assemble the two valve keys 1 into the upper groove using
the grease to hold them in place.

Engine/eng 4-13
 1 d. Release the compressor tool J 8062, making sure the valve
keys 1 stay in place.
e. Repeat the preceding steps on the remaining valves.
Measure:
Refer to General Engine Mechanical section in this manual for
valve spring installed height.
Clean:
Gasket surfaces on the block and cylinder head. 1
DRC6595

Cylinder Head Installation

Tool Required: J 36660 Torque/Angle Meter or equivalent
Install or Connect:
1. Head gasket.

! Do not use sealer on head gaskets.

! Place the gasket over the block dowel pins with the
head up.
2. Cylinder head. Carefully guide the cylinder head into place over the 2
DRC6587
dowel pins and gasket.
3. Cylinder head bolts. Coat threads of the cylinder head bolts with
GM Sealant , P/N 12346004, or equivalent and install fingertight.
2 Tighten:
a. Bolts in sequence to 22 ft. lb. (30 N m).
•

b. Bolts in sequence using J 36660 or equivalent to:

! Short length bolt (11, 7, 3, 2, 6, 10) 55 degrees.

! Medium length bolt (12, 13) 65 degrees.
! Long length bolt (1, 4, 8, 5, 9) 75 degrees.
4. Spark plugs.
Tighten:
a. Spark plug into new cylinder head to 22 ft. lb. (30 N m). •

b. All other subsequent installations to 15 ft. lb. (20 N m).

•

4-14 Engine/eng
Crankshaft Balancer
Removal

Tool Required: J 39046 Crankshaft Balancer Remover

The inertial weight section of the crankshaft balancer is as-
sembled to the hub with a rubber sleeve. The removal procedures must
be followed (with the proper tools) or movement of the inertial weight
section of the hub will destroy the tuning of the crankshaft balancer and
the engine timing reference.
3 Remove or Disconnect:
1. Crankshaft balancer bolt and washer.
2. Crankshaft balancer using J 39046.
3. Crankshaft key, (if necessary).
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 roughness or nicks. Replace the balancer if this con- 3
dition exists. If balancer is replaced, new balance weights of the same DRC6641

size must be installed on the new balancer in the same location as the
old balancer.

Installation

Tool Required: J 39046 Crankshaft Balancer Installer

4 Install or Connect:
1. Apply GM Adhesive , P/N 12346141, or equivalent to crankshaft key-
way.
2. Crankshaft key (if removed). 4
DRC6644
The inertial weight section of the crankshaft balancer is as-
sembled to the hub with rubber type material. The correct installation
procedures (with the proper tool) must be followed or movement of the
inertial weight section of the hub will destroy the tuning of the crank-
shaft balancer.
3. Stud (part of J 39046) to the crankshaft. Thread stud fully into the
tapped hole in the crankshaft.
4. Crankshaft balancer over the end of the stud. Align the keyway in the
crankshaft balancer shaft with the crankshaft key.
5. Bearing, washer, and nut.
a. Turn the nut to pull the crankshaft balancer into place.
b. Remove the tool.

Engine/eng 4-15
6. Crankshaft balancer bolt and washer.
Tighten:
Bolt to 74 ft. lb. (100 N m).
•

Oil Pan
Removal

1 Remove or Disconnect:
1. Oil pan nuts.
2. Oil pan bolts.
3. Oil pan.
4. Gasket.
Clean:

! Parts in solvent. Remove all sludge and varnish.

! Old gaskets and sealant from the gasket surfaces.
Inspect:
1
DRC6642
! Gasket flanges for bending or damage.
! Oil pan for damage or cracks.
! Oil pan deflector for lack of fit.
! Drain plug threads for stripping.
Installation

Tool Required: J 34673 Straight Edge or Equivalent

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 2
DRC6639
provide a rigid engine-to-transom bracket alignment.
Install or Connect:
2 3 Apply GM Adhesive, P/N 12346141, or equivalent to the
engine front cover to block joint and to the rear crankshaft housing to
block joint. Apply the sealant about 1.00 in. (25,4 mm) in both direc-
tions from each of the four corners.
1. Oil pan gasket onto pan.

3
DRC6640

4-16 Engine/eng
 4 2. Oil pan against cylinder block.
5 3. Slide oil pan back against straight edge using J 34673 or equiva-
lent.
4. Oil pan bolts and nuts but do not tighten.
Measure:
5 Use a feeler gauge to check the clearance between the three oil
pan-to-transmission bell housing contact points as shown. If clearance
exceeds 0.010 in. (0,254 mm) at any of the three points repeat steps 2 4
DRC6642
and 3 until the clearance is within specification.
If the clearance is more than 0.010 in. (0,254 mm), powertrain
durability may be affected.
6 Tighten:
! Bolts to 18 ft. lb. (25 N m) in the sequence shown.
•

! Nuts to 17 ft. lb. (23 N m).

•

Measure:

! Clearance between the three oil pan-to-transom bracket 5

contact points to verify proper alignment. DRC6646

5. Lubricate new oil filter seal with clean engine oil.

6. New oil filter.

Oil Pump
Removal
7 Remove or Disconnect:
1. Bolt from oil pump to crankshaft bearing cap.
2. Oil pump assembly.
6
DRC6645

3. Driveshaft and retainer.

7
DRC6643

Engine/eng 4-17
 1 Disassemble:
1. Driveshaft 9 and retainer 8 .
Do not remove the oil pump screen unless replacement is re-
quired. The oil pump screen has a press fit in to the pump cover. Do
not remove the screen from the pipe 6 . The oil pump screen is ser-
viced as a complete assembly only.
2. Oil pump screen pickup 6 .
3. Bolts 5 .
4. Pump cover 4 .
Mark where the idler gear and drive gear and shaft mesh to-
gether, so they can be reinstalled with the same gear teeth indexed.
5. Idler gear and drive gear and shaft 7 .
6. Retaining pin 1 .
7. Pressure regulator spring 2 .
8. Pressure regulator valve 3 .
Clean: 1
DRC6624
All parts in clean solvent and dry them with compressed air.
1 Inspect:

Important The pump gears, cover, and body are not serviced
separately. If any of the parts are damaged or worn, the entire oil pump
assembly must be replaced.

! Pump body 10 for cracks, wear, or other damage.

! Inside of the cover 4

for cracks and wear that would
permit oil to leak past the ends of the gears.

! Idler and drive gear 7 for wear.

! Drive gear and shaft for lack of fit in the pump body.
! Oil pump screen for damage to the screen or loose fit
of the pipe.

! Pressure regulator valve 3

for fit. The regulator valve
should slide freely in its bore without sticking or bind-
ing.

4-18 Engine/eng
Assemble

1 Install or Connect:
1. Pressure regulator valve 3 into the pump cover 4 .

Important Replace the pressure relief valve spring 2 when re-

using the oil pump assembly.
2. Pressure regulator spring 2 into the pump cover 4 .
3. Retaining pin 1 into the pump cover 4 .
4. Drive gear and shaft 7 into the pump body 10 .
5. Idler gear 7 into the pump body 10 .
Match together the index marks on the two gears made during
disassembly.
6. Pump cover 4 .
7. Bolts 5 .
Tighten:
Bolts 5 to 106 i n. Ib. (12 N•m).
With the driveshaft 9 installed on the pump, turn the driveshaft by hand
to check for smooth operation.
Be careful of twisting, shearing, or collapsing the pipe when
installing it to the pump. A damaged pipe can cause lack of lubrication
and engine failure.

Oil Pump Screen Installation

2 Install or Connect:
1. Oil pump screen pickup 6 .
a. The oil pump screen assembly 6 should be replaced with a
new part. Loss of press fit condition could result in an air leak
and loss of oil pressure.
b. Mount the oil pump in a soft jawed vise.
c. Apply sealer to the end of the pipe.
d. Tap the pickup screen and pipe into place, using J 21882 and
a hammer.
e. The oil pump screen must be parallel with the bottom of the oil
pan when installed.
1 2. Oil pump driveshaft 9 and retainer 8 .
2
DRC6625

Engine/eng 4-19
Oil Pump Installation

1 Install or Connect:
1. Oil pump to the engine.
a. Align the slot in the oil pump shaft with the tang on the dis-
tributor shaft.
b. The oil pump should slide easily into place.
c. No gasket is used.
1
2. Oil pump and bolt onto crankshaft bearing cap. DRC6643

Tighten:
Bolt to 66 ft. lb. (90 N m).
•

Engine Front Cover

Removal

Important Once the composite engine front cover is removed

DO NOT reinstall it. Always install a new engine front cover.
Remove or Disconnect:
1. Engine front cover bolts.
2. Engine front cover.

Installation

Install or Connect:
1. Engine front cover to engine.
2. Engine front cover bolts.
Tighten:
Bolts to 106 in. lb. (12 N m).
•

4-20 Engine/eng
Timing Chain and Sprockets
Tool Required: J 5825-A Crankshaft Sprocket Puller
Measure:
Check camshaft timing chain free play. If the camshaft timing chain can
be moved back and forth in excess of 0.625 in. (16 mm), make a note
that the camshaft timing chain should be replaced during assembly.

Removal
2
2 Remove or Disconnect: DRC6633

1. Camshaft sprocket bolts 1 .

2. Camshaft sprocket 2 and camshaft timing chain 3 together.
The sprocket has a light interference fit on the camshaft. Tap
the sprocket on its lower edge to loosen it.
3. Balance shaft drive gear.
2 3 4. Crankshaft sprocket 4 using J 5825-A.
5. Key 5 (if damaged).
3
DRC6615

Engine/eng 4-21
Inspect:
1. Sprockets for chipped teeth and wear.
Excessively worn sprockets will rapidly wear a new chain.
2. Camshaft timing chain for damage.
An excessively worn chain will rapidly wear a new set of sprock-
ets.

Installation
1
DRC6694
Tool Required: J 5590 Crankshaft Sprocket Installer
Install or Connect:
1. Crankshaft key (if removed).
1 2. Crankshaft sprocket using J 5590.
3. Balance shaft drive gear.
4. Camshaft sprocket and camshaft timing chain.

2 Important Line up the sprocket alignment marks on the

camshaft sprocket and crankshaft sprocket. 2
DRC6634
The number 4 cylinder is at top dead center of the com-
pression stroke with the timing marks in this position.
3 5. Camshaft sprocket bolts 1 .
Tighten:
Bolts 21 ft. lb. (28 N m).
•

Camshaft
Removal
3
Remove or Disconnect: DRC6633

1. Camshaft retainer bolts and camshaft retainer.

2. Camshaft.
4 a. Install three 5/16 - 18 (4.0 in.) long into the camshafts threaded
holes. Use these bolts to handle the camshaft.
4 b. Pull the camshaft out from the block being careful to prevent
damage to the camshaft bearings.

4
DRC6635

4-22 Engine/eng
Measure:
Camshaft Journals. Refer to General Engine Mechanical section in
this manual.

Bearings

Refer to General Engine Mechanical section in this manual for cam-

shaft bearing disassembly, cleaning, inspection, and assembly.

Installation

Install or Connect:
Coat the camshaft lobes and journals with a high quality GM
Engine Oil Supplement , P/N 1052367, or equivalent. Apply GM Engine
Oil Supplement, P/N 1052367, or equivalent to all the teeth on the dis-
tributor drive gear.
4 1. Two or three 5/16 - 18 (4.0 in.) long bolts into the camshaft
threaded holes. Use these bolts to handle the camshaft.
4 2. Camshaft into the engine. Handle the camshaft carefully to pre-
vent damage to the camshaft bearings.
3. Camshaft retainer and retainer bolts.

! Coat camshaft retainer plate with GM Engine Oil Supple-

ment, P/N 1052367, or equivalent.
Tighten:
Bolts to 124 in. lb. (14 N m). •

Balance Shaft
Removal

Tools Required: J 38834 Balance Shaft Bearing Service Kit 5

DRC6631
J 26941 Rear Balance Shaft Bearing Remover
5 Remove or Disconnect:
1. Bolt 1 .
2. Driven gear 2 .
3. Retainer bolts 5 .
4. Retainer 3 .
5 6 5. Balance shaft 4 using a soft faced hammer.
7 6. Balance shaft rear bearing using J 38834 and J 26941. 6
DRC6617

7
DRC6618

Engine/eng 4-23
Inspect:

! Balance shaft front roller bearing and rear sleeve bear-

ing for damage or excessive wear. The bearings are
serviced as an assembly. Use the proper tools for prop-
erly servicing the bearings.
! Balance shaft 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 exceeds the specifications.
1
DRC6629
Refer to Specifications in this section.
! Rear sleeve bearing journal clearance. Replace the bal-
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 Balance Shaft Installer
J 8092 Driver Handle 2
DRC6618
J 36660 Torque/Angle Meter or equivalent
Install or Connect:
1. Dip bearing in clean engine oil before installation.
1 2 2. Balance shaft rear bearing using J 38834.
3 3. Balance shaft into block using J 36996 and J 8092.
a. Dip the front balance shaft bearing into clean engine oil be-
fore assembly.
b. Retaining ring on balance shaft front bearing must be seated
on case.
3
DRC6630

4 4. Install balance shaft bearing retainer 3 and bolts 5 .

Tighten:
4 Balance shaft retainer bolts 5 to 124 in. lb. (14 N m). •

4 5. Balance shaft driven gear 2 and bolt 1 .

Tighten:
4 Balance shaft driven gear bolt 1
to 15 ft. lb. (20 N m) plus an
•

additional turn of 35 degrees using J 36660 or equivalent.

4 Rotate balance shaft 4 by hand to make sure there is
4
DRC6631
clearance between the 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 Engine/eng
 5 • Turn the camshaft with the balance shaft drive gear tem-
porarily installed. The timing mark on the drive gear must
be straight up.

5 • With the balance shaft drive gear removed, turn the bal-
ance shaft so the timing mark on the driven gear points
straight down.
6. Balance shaft drive gear onto camshaft.

Important Make sure the timing marks on the balance shaft drive 5
DRC6632
gear and driven gear line up.

Pistons and Connecting Rods

Removal

Tool Required: J 5239 Guide Set

Remove or Disconnect:
Before attempting to remove piston, refer to General Engine
Mechanical section in this manual for cylinder bore ridge reamer pro-
cedures.
1. Mark the cylinder numbers on 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 numbered 1-3-5

! The left bank is numbered 2-4-6
2. Check the connecting rod and cap for identification marks. If reusing
the connecting rods, mark the parts in the same way as the pistons.

Important Store the connecting rod and cap together as mating

parts, so they may be reassembled in the same wear pattern and bal-
ance in which they were removed.
3. Connecting rod nuts, cap and bearings.

Important If reusing bearings, keep bearings with their original

connecting rod and cap.

Engine/eng 4-25
4. Connecting rod and piston.
1 a. Attach J 5239 to the connecting rod bolts.
1 b. Use the long guide rod J 5239 to push the connecting rod
and piston out of the bore.

Disassembly

Refer to General Engine Mechanical section in this manual for piston

and connecting rod disassembly.

Assembly

Refer to General Engine 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. DO NOT FILE RODS OR
ROD CAPS.
If clearances are excessive, install a new bearing. Service bearings 1
DRC6619
are available in standard size 0.001 in. (0,0254 mm) and 0.002 in.
(0,0508 mm) undersize for use with new and used standard size crank-
shafts. For reconditioned crankshafts 0.010 in. (0,254 mm) and 0.020
in. (0,508 mm) undersize bearings are available.
J 8087

Piston Selection

Measuring the Piston

Check the used piston to cylinder bore clearance, as follows:

2 1. Cylinder bore diameter. Use a telescoping bore gauge, located
2.5 in. (65 mm) below the top of the cylinder bore. 2
DRC6507
3 2. Piston diameter. Measure the skirt at a right angle to the piston
pin hole, 1.0 in. (25 mm) below the oil ring groove.

3
DRC6514

4-26 Engine/eng
 Measure piston diameter at 70 degrees F (20 degrees C).
3. Subtract the piston diameter from the cylinder bore diameter to de-
termine piston to bore clearance.
4. Locate the piston-to-bore clearance, refer to Engine Specifications.
Determine if the piston-to-bore clearance is within the acceptable range.

Piston Ring End Gap and Fit

Refer to General Engine Mechanical section in this manual.

Important The numbers on the connecting rod and bearing cap

must be on the same side when installed in the cylinder bore. If a con-
necting 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
J 36660 Torque/Angle Meter or equivalent
Install or Connect:
1. Lubricate the cylinder walls lightly with engine oil.
2. Make sure the piston is installed in the matching cylinder.
3. Connecting rod bearings.
a. Make sure the crankshaft bearings are the proper size.
b. Install the crankshaft bearings in the connecting rod and con-
necting rod cap.
c. Lubricate the bearings with engine oil.

Engine/eng 4-27
4. Piston and connecting rod into the proper bore.
1 a. With the connecting rod cap removed, install J 5239 onto the
connecting rod bolts.
2 b. Locate the piston ring end gaps. Lubricate the piston and
rings with engine oil.
3 c. Without disturbing the ring end gap location, install J 8037
over the piston and compression rings.
2 d. The piston must be installed so that the notch in the piston
faces the front of the engine.
1 e. Place the piston in its matching bore. The connecting rod bear-
ing tang slots must be on the side opposite the camshaft.
Using light blows with a hammer handle, tap the piston down
into its bore. At the same time, from beneath the engine, guide
the connecting rod on to the crankpin with J 5239. Hold the
ring compressor against the block until all rings have entered
the cylinder bore.
1 f. Remove J 5239 from the connecting rod bolts.
1
Important Each connecting rod and bearing cap should be
DRC6619

marked, beginning at the front of the engine. Cylinders 1, 3, and 5 are FORWARD

the right bank and 2, 4, and 6 are the left bank (when viewed from the
B
front). The numbers on the connecting rod and bearing cap must be
on the same side when installed in the cylinder bore. If a connecting C A D
rod is ever transposed from one block or cylinder to another, new con-
necting rod bearings should be fitted and the connecting rod should B

be numbered to correspond with the new cylinder number. A - POSITION OF THE GAP FOR THE
SPACER OF THE OIL RING
B - POSITION OF THE GAP FOR THE
5. Connecting rod cap with crankshaft bearing. OIL RING
C - POSITION OF THE GAP FOR THE
LOWER COMPRESSION RING

6. Connecting rod bolt nuts. 2 D - POSITION OF THE GAP FOR THE

UPPER COMPRESSION RING
DRC6627
Tighten:

! Connecting rod bolt nuts to 20 ft. lb. (27 N m).

•

J 8037

! Connecting rod bolt nuts an additional 70 degrees us-

ing J 36660 or equivalent.
Measure:
Refer to General Engine Mechanical section in this manual for con-
necting rod side clearance procedure.

3
DRC6628

4-28 Engine/eng
Crankshaft Rear Oil Seal
Removal

Take care when removing the rear crankshaft oil seal so as not
to damage the crankshaft sealing surface.
Remove or Disconnect:
4 Insert a screwdriver into the notches provided in the seal retainer
and pry the seal out.
4
DRC6658
Installation

Tool Required: J 35621 Crankshaft Rear Oil Seal Installer

5 Install or Connect:
1. Lubricate the inner and outer diameter of the oil seal with clean J 35621

engine oil.
2. Install the oil seal on J 35621.
3. Position J 35621 against the crankshaft. Thread the attaching
screws into the tapped holes in the crankshaft.
5
4. Tighten the screws securely with a screwdriver. This will en- DRC6626

sure that the seal is installed squarely over the crankshaft.

5. Turn the handle until it bottoms.
6. Remove J 35621.

Crankshaft Rear Oil Seal Housing

Removal

6 Remove or Disconnect:
1. Bolts and nuts. 6
DRC6657

2. Oil seal housing.

3. Gasket.
Clean:
Gasket surfaces on the block and seal retainer.

Engine/eng 4-29
Installation

1 Install or Connect:
1. New gasket to the block.
It is not necessary to use sealant to hold the gasket in place.
2. Oil seal retainer.
3. Screws and nuts.
Tighten:
1
DRC6657
Screws and nuts to 11 ft. lb. (15 N m).
•

Crankshaft and Bearings

Removal

The crankshaft need not be removed for replacement of the rear oil
seal or crankshaft bearings. Those procedures are covered in other
parts of this section.

Important Check the crankshaft bearing caps for location mark-

ings. Mark the caps if necessary. The caps must be returned to their
original locations during assembly.
Remove or Disconnect:
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 damage to crankshaft journals and thrust flange surfaces.
4. Upper crankshaft bearings.
Refer to General Engine Mechanical section in this manual
for cleaning, inspection, and measurements.

Installation

Install or Connect:
1. Upper crankshaft bearing to the block.

Important If any undersized bearings are used, they must be

fitted to the proper journals.
2. Crankshaft.
3. Lower crankshaft bearings to the crankshaft bearing caps.

4-30 Engine/eng
Measure:
Refer to General Engine Mechanical section in this manual for
crankshaft bearing clearance procedures.
4. Apply engine oil to the crankshaft bearings. Install crankshaft bear-
ing caps (except rear cap) and bolts to the block.
Tighten:
Crankshaft bearing cap bolts to 77 ft. lb. (105 N m). •

5. Rear crankshaft bearing cap. Apply engine oil to the crankshaft bear-
ings.
6. Rear crankshaft bearing cap bolts.
Tighten:
Rear crankshaft bearing cap bolts to 124 in. lb. (14 N m). •

Measure:
Refer to General Engine Mechanical section in this manual for
crankshaft end play procedure.
Tighten:
Finally tighten rear crankshaft bearing cap bolts to 77 ft. lb. (105
N m).
•

Cylinder Block
Disassembly

Remove or Disconnect:
1. Coolant drain fittings.
2. Camshaft and balance shaft cup plugs.
2 3. Front oil gallery cup plugs.
2
DRC6623

3 4. Port side oil gallery plugs.

4 5. Rear oil gallery plugs.
Clean:
1. Sealing material from mating surfaces.
2. Boil cylinder block in caustic solution.

! Flush with clean water or steam.

3
DRC6621

4
DRC6622

Engine/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 engine
oil.
Inspect:
1. All block core plugs for lack of fit or leakage.
2. Camshaft lifter bores for deep scratches and deposits.
3. Cracks in 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.
! 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.
1 4. Cylinder block head mounting surface for flatness, using a pre-
cision straight edge and feeler gauge.
a. Set the straight edge on the sealing surface to be inspected.
b. Take the feeler gauge and at various locations, check the
gap between the 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 mm) at any sealing location, the block
must be replaced.

1
DRC6620

4-32 Engine/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 sealing location and a cause for leakage is sus-
pected, then the minor irregularities may be carefully machined from
the block.

! Oil pan and intake manifold mounting surfaces for nicks.

Minor irregularities may be cleaned up with a flat file.
Cylinder Bore

Inspect:
Cylinder bores for scoring or other damage. Refer to General Engine
Mechanical section in this manual.
Measure:
Cylinder bore taper and out-of-round. Refer to General Engine Me-
chanical section in this manual.

Cylinder Bore Reconditioning

Measure:
Refer to General Engine Mechanical section in this manual.

Cylinder Block Assembly

Install or Connect:
1. Front oil gallery plugs. Coat plug outside diameter with GM Sealant,
P/N 12346004, or equivalent.
2 3 4 2. Rear oil gallery plugs.
Tighten:

! Left rear plug to 15 ft. lb. (20 N m).

•

! Right rear plug to 18 ft. lb. (25 N m).

•
2
DRC6623
! Left side plug to 15 ft. lb. (20 N m).
•

3. Camshaft and balance shaft cup plugs to proper depth. Coat bore
inside diameter with GM Sealant , P/N 12346004, or equivalent.

Important Do not allow residue on camshaft bearing or seizure

may result.

3
DRC6621

4
DRC6622

Engine/eng 4-33
Circulating Pump
Description

The circulating pump is manufactured specially for marine use. It is

serviced only as an assembly. Do not replace with an automotive cir-
culating pump.

Inspection

1. Remove alternator and power steering belts.

2. Grasp circulating pump pulley and check end and side play. Turn
pulley to check for drag.
3. Look for water leaking from indicator hole beneath pump shaft be-
hind pulley, Replace pump if play, drag, or leakage are evident.

Removal and Installation

1. Drain water from block and disconnect water hose from circulating
pump.
2. Remove pulley. Remove circulating pump bolts, pump and gaskets.
3. Use new pump to block gaskets and sealer. Install new pump as-
sembly on cylinder block and tighten bolts as specified.
4. Install pulley. Install alternator and power steering belts, then adjust
tension.
5. Install hose to circulating pump.
6. Lake or tank test unit and check for leaks.

4-34 Engine/eng
Front Engine Mounts
Removal
1 1. Remove two lag screws A and washers from mounts.
2. Lift engine with a hoist capable of lifting at least 1500 lb.
(680 kg) to allow removal of front mount and bracket.
2 3. Remove three mount screws and lock washers B . Note screw
lengths and location.
1
3 Prior to disassembly of front mount assembly, measure 25929

distance and record measurement between large washer and flat on

upper mount bracket.

Disassembly

4 1. Remove three nuts C and engine mount bracket D from mount

bolt while holding bolt secure with socket E .
5 2. Remove two flat washers, one large F and one smaller G .
Remove lock washer H, and engine mount bolt I from mount.
2
25917

3
11980

4
11979

5
11978

Engine/eng Safety Related 4-35

Reassembly

1 1. Place small washer A

on mount bolt and insert bolt up through
mount. Install large washer and secure with nut B . Tighten to 60-75 ft.
lb. (81-102 N m).
•

2 2. Install upper inner nut and place engine mount bracket C on

engine mount bolt.
Measure distance between large washer and flat on upper
mount bracket. Adjust distance to recorded measurement.
1
3. Install lock washer and top nut. Tighten nut to 100-120 ft. lb. (136- 11983

163 N m).
•

Installation

3 1. Spray the engine mount screw threads with Loctite Primer N

and allow to air dry. Apply Volvo Penta Thread Sealing Agent P/N
1161053 to the screws. Attach engine mount assembly to engine with
three screws and washers D . Tighten to 32-40 ft. lb. (43-54 N m).•

4 2. Install washers and lag screws E and tighten securely.

Height Adjustment 2
11979
5 1. To change engine height, tighten or loosen nuts F and G as
required.
2. Lift engine with a hoist capable of lifting at least 1500 lb.
(680 kg). Position engine at desired height.
5 3. After setting mount position, turn nut G up against underside
of engine bracket and hold nut with a wrench. Tighten nut F to 100-
120 ft. lb. (136-163 N m).
•

Any large adjustments to engine height should be followed by

a check of engine alignment. Failure to check alignment could result in 3
rapid engine coupler failure. See Drive Removal and Installation sec- 25917

tion of the Vertical Drive/Transom Bracket Service Manual for align-

ment procedures.

4
21929

5
2953
Safety Related 4-36 Engine/eng
High-Rise Exhaust Elbow Replacement
Removal
6 1. Loosen two clamps securing upper hose to elbow. Lubricate
inside of hose with a soapy water solution.
7 2. Starboard Elbow: Remove four screws, flat washers, and lock
washers mounting high-rise elbow. Remove circuit breaker bracket H
and set aside.
3. Port Elbow - EFI Models Only: Remove fuel reservoir water hose
6
34719
and set aside. Remove four screws, flat washers, and lock washers
mounting high-rise elbow.
8 9 4. Use a soft hammer to free elbow from manifold. Use a
twisting motion to pull elbow from hose. Remove and discard the elbow
gasket.

Installation

1. Thoroughly clean manifold gasket surface. Apply Volvo Penta Gas-

ket Sealing Compound to both sides of a new manifold gasket and place
it on the exhaust manifold. 7
49464
9 10 2. Lubricate the inside of the exhaust hose with a soapy wa-
ter solution. Insert the high-rise elbow into the hose with a twisting mo-
tion, and push it into hose as far as it will go.

8
34718

9
34716

10
34717

Engine/eng 4-37
 1 3. Position elbow on manifold. Secure elbows and brackets with
four screws, flat washers, and lock washers. Tighten screws to 12-18
ft. lb. (16-24 N m). Starboard Elbow: Install circuit breaker bracket
•

A . Port Elbow: Install fuel reservoir water hose. Tighten clamp se-
curely.
2 4. Slide clamps B up onto hose and position them in the
two surface channels. Tighten clamps securely.

Exhaust Hose & Intermediate Pipe 1

Replacement 49464

Removal

3 1. Loosen eight clamps that secure the upper C and lower D

exhaust hoses.
4 2. Lubricate inside of lower hose with a soapy water solution, and
slide lower hose down onto exhaust Y-pipe.
5 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 exhaust Y-
2
32371

pipe.

3
32374

4
32375

5
32363
Safety Related 4-38 Engine/eng
Installation
6 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.
7 The inside diameter of both the upper and lower hoses
has a step E 1.5 in. (3.81 cm) from one end. The stepped end of the
hose must face the intermediate pipe when installed.
2. Slide hose onto high-rise elbow until it seats.
If hose is not properly positioned, it will not completely engage 6
the high-rise elbow or allow secure attachment. 32370

3 5 3. Place four No. 68 clamps on upper hose. With a twist-

ing motion, insert intermediate pipe all the way into the upper hose.
Place four No. 64 clamps on lower hose. Align lower end of pipe with
exhaust Y-pipe, then slide lower hose up until it’s halfway onto the inter-
mediate pipe. Position clamps in channels and tighten clamps se-
curely.

Engine Coupler Replacement

Removal 7
32366
1. Remove engine from boat.
If coupler is being replaced due to coupler failure (rubber hub of
splined hub), check engine alignment after installing new coupler. See
Drive Removal and Installation section of the Vertical Drive/Tran-
som Bracket Service Manual.
2. Disconnect all wires, lines and connectors from bellhousing.

8 9 3. Remove screws securing bellhousing cover, and slide cover

out. 8
20034

9
19085

Engine/eng Safety Related 4-39

 1 4. Pull drain hose out of bellhousing if equipped.

2 5. Unscrew bolts and nuts retaining bellhousing. Disconnect ground

wires. Remove power steering cooler bracket.
6. Remove bellhousing from engine block.

3 7. Unscrew six nuts securing coupler and remove coupler from

studs.
8. Remove old gasket from bellhousing cover. Clean gasket surface 1
19842
thoroughly.

Installation

4 1. Install coupler and secure with six locknuts. Use a suitable adap-
tor and tighten to 40-45 ft. lb. (54-61 N m).
•

5 2. Install bellhousing and attach power steering cooler. Tighten

nuts and bolts to 32-40 ft. lb. (43-54 N m). Attach ground wires and
•

tighten nuts to 15-20 ft. lb. (20-27 N m).

•

3. Push drain hose into bellhousing if equipped. 2

6710
4. Apply Volvo Penta Gasket Sealing Compound P/N 591247 to both
sides of a new bellhousing gasket and position it on cover.

5 5. Clean seven self-tapping screws with a wire brush. Install

bellhousing cover and screws. Tighten to 60-84 in. lb. (7-9 N m).
•

6. Connect all wires, lines and connectors to bellhousing.

7. Install engine in boat.

3
6712

4
6714

5
19996

4-40 Engine/eng
Torque Specifications
Balance Shaft Driven Gear Bolt ............................................................................ 15 ft. lb. (20 N m) (Plus 35 degrees)
•

Balance Shaft Retainer Bolts ............................................................................................................ 124 in. lb. (14 N m) •

Bell Housing Cover Screws .......................................................................................................... 60-84 in. lb. (7-9 N m) •

Bell Housing Nuts and Bolts ....................................................................................................... 32-40 ft. lb. 43-54 N m) •

Block Drain Plug ................................................................................................................................... 15 ft. lb. (20 N m)

•

Block Oil Gallery Plug, Left Rear ......................................................................................................... 15 ft. lb. (20 N m) •

Block Oil Gallery Plug, Right Rear ...................................................................................................... 18 ft. lb. (25 N m) •

Block Oil Gallery Plug, Left Side Rear ................................................................................................. 15 ft. lb. (20 N m) •

Camshaft Retainer Bolt ..................................................................................................................... 124 in. lb. (14 N m) •

Camshaft Sprocket Bolts ...................................................................................................................... 21 ft. lb. (28 N m) •

Connecting Rod Nut ............................................................................................... 20 ft. lb. (27 N m) (Plus 70 degrees)

•

Crankshaft Balancer Bolt .................................................................................................................... 74 ft. lb. (100 N m) •

Crankshaft Bearing Cap Bolt .............................................................................................................. 77 ft. lb. (105 N m) •

Crankshaft Rear Oil Seal Housing Nut and Bolt ................................................................................. 11 ft. lb. (15 N m) •

Cylinder Head Bolt

First Pass ........................................................................................................................................ 22 ft. lb. (30 N m)
•

Second Pass 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. lb. (54-61 N m) •

Engine Mount Screws ................................................................................................................ 32-40 ft. lb. (43-54 N m) •

Exhaust Manifold Screws .......................................................................................................... 20-26 ft. lb. (27-35 N m) •

Front Cover Bolt ................................................................................................................................. 106 in. lb. (12 N m)•

Front Mount Nut

Lower .................................................................................................................................. 60-75 ft. lb. (81-102 N m)
•

Upper ........................................................................................................................... 100-120 ft. lb. (136-163 N m) •

Engine/eng 4-41
Torque Specifications
High Rise Elbow Nuts ................................................................................................................ 12-18 ft. lb. (16-24 N m) •

Intake Manifold Bolts

First Pass ......................................................................................................................................... 27 in. lb. (3 N m)
•

Second Pass ................................................................................................................................ 106 in. lb. (12 N m) •

Final Pass ....................................................................................................................................... 11 ft. lb. (15 N m)

•

Oil Pan
Nuts ................................................................................................................................................. 17 ft. lb. (23 N m)
•

Bolts ................................................................................................................................................ 18 ft. lb. (25 N m)

•

Studs in Engine Block .................................................................................................................... 18 ft. lb. (25 N m) •

Oil Pump Bolt ........................................................................................................................................ 66 ft. lb. (90 N m)•

Oil Pump Cover Bolt .......................................................................................................................... 106 in. lb. (12 N m) •

Spark Plugs
Cylinder Head (New) ...................................................................................................................... 22 ft. lb. (30 N m) •

Cylinder Head (All Subsequent Installation) ................................................................................. 15 ft. lb. (20 N m) •

Valve Lifter Guide Retainer Bolt ........................................................................................................... 12 ft. lb. (16 N m) •

Valve Rocker Arm Cover Bolts .......................................................................................................... 106 in. lb. (12 N m) •

Valve Rocker Arm Nut ........................................................................................................................... 20 ft. lb. (27 N m) •

Valve Rocker Arm Stud ......................................................................................................................... 35 ft. lb. (47 N m) •

4-42 Engine/eng
Engine Specifications
ENGINE
Type ....................................................................................................................................................... 90 Degree V6
Displacement ....................................................................................................................................... 4.3L (262 CID)
Bore .............................................................................................................................................. 4.00 in. (101.6 mm)
Stroke ......................................................................................................................................... 3.480 in. (88.39 mm)
Compression Ratio .............................................................................................................................................. 9.2:1
Firing Order ............................................................................................................................................... 1-6-5-4-3-2

LUBRICATION SYSTEM
Oil Capacity
Without Filter Change ..................................................................................................................... 4 Qt. (3.75 Liters)
With Filter Change Add............................................................................................................ 0.42 Qt. (0.398 Liters)

Oil Pressure (Minimum Hot) ....................................................................... 6.0 PSI (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 Filter System ............................................................................................................................................... Full Flow

Oil Pump Type ............................................................................................................................................. Gear Driven

CYLINDER BORE
Diameter .............................................................................................. 4.0007 - 4.0017 in. (101.618 - 101.643 mm)
Out-of-Round ................................................................................................................ 0.002 in. (0.0508 mm) MAX.
Taper .............................................................................................................................. 0.001 in. (0.0254 mm) MAX.

PISTON
Piston Bore Clearance .............................................................................................. 0.0024 in. (0.06096 mm) MAX.

PISTON RINGS
Piston Compression Ring
Groove Clearance ............................................................................................................... 0.0042 in. (0.10668 mm)
Gap .................................................................................................................................. 0.035 in. (0.889 mm) MAX.

Piston Oil Ring

Groove Clearance ......................................................................................................... 0.008 in. (0.2032 mm) MAX.
Gap ............................................................................................................................................. 0.065 in. (1.651 mm)

OIL PAN
Engine Block Clearance
Tolerance ......................................................................................................................... 0.010 in. (0.254 mm) MAX.

Engine/eng 4-43
Engine Specifications
PISTON PIN
Diameter ...................................................................................................... 0.927 - 0.926 in. (23,545 - 23,548 mm)
Clearance in Piston ..................................................................................................... 0.001 in. (0,0254 mm) MAX.
Fit In Connecting Rod .................................................. 0.0008 - 0.0016 in. (0,02032 - 0,04064 mm) Interference

INTAKE MANIFOLD
Surface Flatness ............................................................................................................ 0.010 in. (0.254 mm) MAX.

CYLINDER HEAD
Surface Flatness .......................................................................................................... 0.004 in. (0.1016 mm) MAX.

CRANKSHAFT
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 mm)
Diameter #4 ........................................................................................... 2.4480 - 2.4489 in. (62.180 - 62.202 mm)
Taper ............................................................................................................................ 0.001 in. (0.0254 mm) MAX.
Out-of-Round ............................................................................................................. 0.0010 in. (0.0254 mm) MAX.

Crankshaft Bearing Clearance

Bearing #1 ............................................................................................... 0.0010 - 0.0015 in. (0.0254 - 0.0381 mm)
Bearings #2, #3 ...................................................................................... 0.0010 - 0.0025 in. (0.0254 - 0.0635 mm)
Bearing #4 ............................................................................................... 0.0025 - 0.0035 in. (0.0635 - 0.0889 mm)

Crankshaft End Play ....................................................................................... 0.002 - 0.008 in. (0.0508 - 0.2032 mm)

CONNECTING ROD
Connecting Rod Journal
Diameter .................................................................................................. 2.2487 - 2.2497 in. (57.117 - 57.142 mm)
Taper ............................................................................................................................ 0.001 in. (0.0254 mm) MAX.
Out-of-Round ............................................................................................................... 0.001 in. (0.0254 mm) MAX.
Rod Bearing Clearance .......................................................................... 0.0010 - 0.0030 in. (0.0254 - 0.0762 mm)
Rod Side Clearance .................................................................................. 0. 006 - 0.017 in. (0.1524 - 0.4318 mm)

CAMSHAFT
Journal Diameter ......................................................................................... 1.8677 - 1.8697 in. (47.440 - 47.490 mm)

End Play ........................................................................................................... 0.001 - 0.009 in. (0.0254 - 0.2286 mm)

Lobe Lift ................................................................................................................................. ± 0.002 in. (± 0.051 mm)

Intake .................................................................................................................................... 0.2763 in. (0.7180 mm)
Exhaust ................................................................................................................................ 0.2855 in. (0.7252 mm)

BALANCE SHAFT
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 - 0.09144 mm)

4-44 Engine/eng
Engine Specifications
VALVE SYSTEM
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 mm)

Stem Clearance
Intake .............................................................................................. High Limit Production + 0.001 in. (0.0257 mm)
Exhaust .......................................................................................... High Limit Production + 0.002 in. (0.0508 mm)

Valve Spring
Free Length ...................................................................................................................................... 2.03 in. (52 mm)
Installed Height ............................................................................................... 1.690 - 1.710 in. (42.92 - 43.43 mm)

Spring Pressure
Closed ............................................................................................... 76 - 84 lb. at 1.70 in. (338 - 374 N at 43 mm)
Open .............................................................................................. 832 - 187 - 203 lb. at 1.27 in. (903 N at 32 mm)

Valve Lift
Intake ......................................................................................................................................... 0.414 in. (10.51 mm)
Exhaust ..................................................................................................................................... 0.428 in. (10.87 mm)

Engine Lubrication:
Oil Grade Recommended
32° F (0° C) and Above ............................................................................................................................ SAE 30
0° F to 32° F (-18° C to 0° C) ......................................................................................................... SAE 20W-20
Below 0° F (-18° C) .............................................................................................................................. SAE 10W

We recommend DuraPlusTM Synthetic Motor Oil, which is specially for-

mulated for heavy duty marine use, and ideal for stern drive engines. It
provides better antiwear qualities, especially during long high speed
operation. In addition, it neutralizes acids caused in all internal com-
bustion engines, offers superior corrosion protection, and is formulated
to offer better resistance to oxidation and high temperature sludge for-
mation.

Fuel Recommendation ................... See General Information Section

Engine/eng 4-45
GM Special Tools

1 2 3
DRC6596 DRC6597 DRC6598

4 5 6
DRC6599 DRC6600 DRC6601

1 Pliers, Valve Lifter Remover

2 Connecting Rod Bolt Guide Set
3 Crankshaft Sprocket Installer
4 Crankshaft Sprocket Remover
5 Dial Indicator Set
6 Piston Ring Compressor
7 Valve Spring Compressor
7
8 Driver Handle DRC6602

8
DRC6603

4-46 Engine/eng
GM Special Tools

1 2 3
DRC6604 DRC6605 DRC6606

4 5 6
DRC6607 DRC6608 DRC6609

1 Hydraulic Valve Lifter Remover

2 Oil Suction Pipe Installer
3 Straight Edge
4 Rear Main Seal Installer
5 Torque/Angle Meter or equivalent
6 Balance Shaft Installer
7 Balance Shaft Bearing Service Kit
7
8 Harmonic Balancer Remover/Installer DRC6610

8
DRC6611

Engine/eng 4-47