Vortec V6 4.3L

Oil Leak Diagnosis
-22-
Oil Leak Diagnosis, continued
-23-
Drive Belt Tensioner Diagnosis
-24-
Engine Lubrication
44610
Full pressure lubrication, through a full-flow oil filter, balance shaft, rear bearing, and crankshaft bearings.
is supplied by a gear-type oil pump. Oil is drawn up The valve lifter oil gallery supplies oil to the valve
through the oil pump screen and passes through the lifters. Oil flows from the valve lifters through the
pump to the oil filter. The oil filter is a full-flow paper hollow valve pushrods to the valve rocker arms. Oil
element unit with an anti-drain back valve. An oil drains back to the crankcase through the oil drain
filter bypass valve is used to ensure adequate oil holes in the cylinder head. The camshaft timing
supply in the event the filter becomes plugged or chain is drip fed from the front camshaft bearing.
develops excessive pressure drop. Filtered oil flows The pistons and piston pins are lubricated by oil
into the main gallery and then to the camshaft, splash.
-25-
-26-
Lower Engine View 1
Legend
(1) Oil Level Indicator Tube Bolt (25) Water Pump
(2) Oil Level Indicator (26) Water Pump Bolt
(3) Oil Level Indicator Tube (27) Front Oil Gallery Plug
(4) Engine Oil Pressure Sensor Fitting (28) Camshaft Bearings
(5) Balance Shaft Bearing (Rear) (29) Engine Camshaft
(6) Knock Sensor (30) Camshaft Retainer
(7) Expansion Cup (Balance Shaft Rear Bearing Hole) (31) Camshaft Retainer Bolt
(8) Engine Block Rear Oil Gallery Plug (32) Balance Shaft Drive Gear
(9) Expansion Cup Plug (Camshaft Rear Bearing Hole) (33) Camshaft Sprocket
(10) Engine Block (34) Camshaft Timing Chain
(11) Dowel Straight Pin (Transmission Locator) (35) Camshaft Sprocket Bolt
(12) Left Side Oil Gallery Plug (36) Balance Shaft Gear Bolt
(13) Oil Filter Adapter Gasket (37) Balance Shaft Driven Gear
(14) Oil Filter Adapter Seal (O-ring) (38) Balance Shaft Retainer Bolt
(15) Oil Filter Adapter (Typical) (39) Balance Shaft Retainer
(16) Oil Filter Adapter Bolt (40) Balance Shaft
(17) Oil Filter (41) Piston Ring Set
(18) Oil Filter Fitting (42) Piston
(19) Oil Filter Adapter Bolt (43) Piston Pin
(20) Oil Filter Bypass Valve (44) Connecting Rod Bolt
(21) Engine Coolant Drain Hole Plug (45) Connecting Rod
(22) Engine Block Core Hole Plug (46) Connecting Rod Bearings
(23) Dowel Pin (Cylinder Head Locator) (47) Connecting Rod Cap
(24) Water Pump Gasket -27- (48) Hex Nut
-28-
Intake Manifold
Removal and Installation
Torque Specifications
N First pass: .31 kgf•m (27 lb•in) [3 N•m]
Second pass: 1.22 kgf•m (106 lb•in) [12 N•m]
Third pass: 1.52 kgf•m (11 lb•ft) [15 N•m]
Removal steps
1. Cover - Thermostat N
2. Gasket
3. Thermostat
➧B➧ 4. Manifold
➧A ➧ 5. Gasket
-29-
Intake Manifold Removal 9. Remove the intake manifold.
NOTE
Important: Make sure the ends of the fuel system
lines are properly sealed. Do not allow dirt or debris
to enter the fuel system.
1. Drain the engine coolant.

2. Remove the distributor clamp and bolt.
3. Remove the distributor.
31510
10. Remove and discard the intake manifold
Intake Manifold Clean and Inspect

1. Clean the intake manifold in cleaning solvent.
2. Dry the intake manifold with compressed air.
3. Inspect the intake manifold for the following:
• Damage to the gasket sealing surfaces (1), (2)
34403 • Restricted exhaust gas recirculation system
passages
4. Remove the air inlet duct.
• Restricted cooling system passages (3)
5. Remove the throttle linkage.
• Cracks or damage
6. Remove the ignition coil.
7. Remove PCV valve and vacuum hoses.
8. Remove the intake manifold bolts.
NOTE
Important: The intake manifold may be removed as
an assembly. Do not remove the intake manifold
components unless component service is required.
480570
-30-
➧A Intake Manifold Installation 3. Apply a 5 mm (0.197 in.) bead of sealant MCF
P/N A000000165 (GM P/N 12346141) or
NOTE equivalent to the front and rear top of the
engine block intake mounting surface.
Important: Applying excessive amounts of sealant a. Extend the sealant bead 13 mm (0.50 in.)
may prohibit the intake gasket from sealing onto the intake manifold gasket. Front and
properly. rear of the engine block.
1. Apply a 4.0 mm (0.157 in.) patch of adhesive

patch of sealant P/N A000000165 (GM
12346141) or equivalent to the cylinder head
side of the lower intake manifold gasket at each
end front top of the engine block.
NOTE
Important: The intake manifold must be installed
and the fasteners tightened while the adhesive is
still wet to the touch.
2. Install the lower intake manifold gasket onto the b. Install the intake manifold on to engine block.
cylinder head. Use the gasket locator pins to c. Apply threadlock (GM P/N 12345382) or
properly seat the intake manifold gasket on the equivalent to the threads of the intake
cylinder head. manifold bolts.
4. Install the intake manifold bolts in sequence
NOTE and torque in the 3 step method.
Note: 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.
31510
-31-
NOTE
Important: Proper manifold fastener tightening

sequence and torque are critical. Always follow the
tightening sequence and torque the intake manifold
bolts using the three (3) step method. Failing to do
so may distort the crankshaft bearing bore
alignment and cause damage to the crankshaft
bearings.
5. Tighten the manifold bolts as shown below.
1st pass
.31 Kgf•cm (27 lbf.in) [3 N•m]
Tightening torque 2nd pass
for intake 1.22 Kgf•cm (106 lbf.in) [12 N•m]
manifold Final pass
1.52 Kgf•cm (11 lbf.ft) [15 N•m]
-32-
Exhaust Manifold
Torque Specifications:
First pass: 1.52 kgf•m (11 lb•ft) [15 N•m]
Final pass: 3.05 kgf•m (22 lb•ft) [30 N•m]
New
6
4
3
5
Removal steps
➧A➧ 1. Gauge - Oil

➧B ➧ 2. Tube - Level Gage
3. Shield - Exhaust
4. Shield - Spark Plug
5. Shield - Spark Plug
6. Manifolds - Exhaust
-33-
Oil Level Indicator and Tube Removal Exhaust Manifold Clean and Inspect
1. Remove oil level indicator from the tube.
2. Remove the oil level indicator tube bolt from the ! CAUTION
right cylinder head.
Refer to Safety Glasses Caution in Cautions
3. Remove the oil level indicator tube from the
and Notices.
engine block.
1. Clean the exhaust manifolds in cleaning solvent.
2. Dry the components with compressed air.
3. Inspect the exhaust manifolds for the following:
• Damage to the gasket sealing surfaces (1)
• Damage to the exhaust gas recirculation
(EGR) pipe fitting (2) (left manifold)
• Damage to the threaded holes (3)
• Restrictions within exhaust passages
• Broken or damaged exhaust manifold heat
shields (4) (if applicable)
• Broken or damaged exhaust manifold
11472
➧ B ➧ Exhaust Manifold and Heat Shields

Removal
1. Remove the studs and bolts from the
exhaust manifold and heat shields.
2. Remove the exhaust manifold and heat shields.
4. Measure the alignment or surface flatness of

the exhaust manifold flanges using a straight
edge and a feeler gauge.
Refer to Engine Mechanical Specifications.
If the surface flatness is not within the
specifications, the exhaust manifold is warped
and must be replaced.
3. Remove and discard the exhaust manifold

gaskets.
-34-
Exhaust Manifold and Heat Shields ➧ B ➧ Oil Level Indicator and Tube
Installation Installation
1. Install NEW exhaust manifold gaskets. 1. Clean and inspect the tube and indicator for
damage or serviceability.
2. Apply a sealer MCF P/N 2I4256
(GM P/N 12346004) or equivalent around the oil
level indicator tube 13 mm (0.5 in.) below the
bead.
328540
2. Install the exhaust manifold.

3. Install the spark plug heat shields.
4. Use Locktite (G/M P/N 12345382) or
equivalent to the threads of the exhaust manifold
bolts and stud.
5. Install the exhaust manifold bolts and stud and
torque to the specified torque.
188009
Tightening torque 1st 1.52 Kgf•m
pass exhaust (11 lb•ft) [15 N•m] 3. Install the oil level indicator tube into the engine
manifold bolts block. Rotate the tube into position.
4. Install the oil level indicator tube bolt to the
Tightening torque 3.05Kgf•m
cylinder head.
final pass (22 lb•ft) [30 N•m]
exhaust manifold bolts
Tightening torque
oil level indicator 1.22 Kgf•m (106 lb•in) [12 N•m]
tube bolt
5. Install the oil level indicator into the tube.
188045
6. Install the spark plug wires to the spark plug

wire retainers.
7. Install the spark plug wires onto the spark
-35-
-36-
Cylinder Head and Valves
Removal steps
1. Rocker Arm Cover
2. Bolts
➧ A ➧ 3. Cylinder Head Assy
➧ B ➧ 4. Gasket
5. Nut
6. Rocker Arm
7. Rocker Arm Support
8. Key
9. Cap 1
10. Spring
11. Seal
12. Valves
Torque Specifications For

Cylinder Head Bolts:
All bolts first pass in sequence
T=2.49 kgf•m (18 lb•ft) [25 N•m] 3.05 kgf•m (22 lb•ft) [30N•m]
Long Bolts final pass in
sequence 75 degrees
Medium Bolts final pass in
8 sequence 65 degrees
Short Bolts final pass in
9 5 3 sequence 55 degrees
2
ng
10
Lo
6
m
iu
11
ed
M
t
or
Sh
N 12
T=4.16 kgf•m (30 lb•ft) [40 N•m]
-37-
Valve Rocker Arm Cover Removal (Left) 7. Remove the valve rocker arm cover gasket.
1. Disconnect the negative battery cable. 8. Discard the valve rocker arm cover gasket.
2. Remove the ignition coil.
3. Disconnect the spark plug wires from the spark
plugs.
4. Remove the PCV valve and tube.
5. Remove the rocker arm cover bolts. Discard the
grommets from the rocker arm valve cover and
replace with new grommets.
328573
Valve Rocker Arm Cover Removal (Right)

1. Disconnect the negative battery cable.
2. Disconnect the spark plug wires from the spark
plugs.
3. Remove the crankcase vent tube.
4. Remove the starter relay.
5. Remove the oil level indicator tube.
6. Remove the valve rocker arm cover bolts.
328566
7. Remove the valve rocker arm cover bolt
6. Remove the valve rocker arm cover. grommets. Discard the valve rocker arm bolt
grommets and replace with new grommets.
4042
328568
-38-
8. Remove the valve rocker arm cover. 3. Inspect the valve rocker arm cover for the
following:
• Damage to the PCV valve grommet (1)
• Damage to the bolt holes (2)
A damaged valve rocker arm cover may
interfere with the valve rocker arms.
• Damage to the exterior of the valve rocker
arm cover (3)
• Gouges or damage to the sealing surface (4)
• Damage to the oil fill tube grommet (5)
• Restrictions to the ventilation system passages
480524
9. Remove the valve rocker arm cover gasket.

10. Discard the valve rocker arm cover gasket.
334508
Valve Rocker Arm and Push Rod Removal

Note: Mark, sort and organize all the components
for assembly.
1. Remove the rocker arm cover.
• For the right side of the truck, refer to Valve
328573 Rocker Arm Cover Replacement (Left).
• For the left side of the truck, refer to Valve
Rocker Arm Cover Replacement (Right).
2. Remove the following components from the
Valve Rocker Arm Cover Clean and cylinder head and place in a part’s rack so they
Inspect can be reinstalled to their original location.
• The valve rocker arm nuts (former style)
! CAUTION • The valve rocker arm balls (former style)
Safety glasses must be worn or eye injury may occur. • The valve rocker arms
1. Clean the valve rocker arm cover in cleaning
solvent.
2. Dry the valve rocker arm cover with compressed
air.
-39-
5. Place the following parts in a rack so they can
(Former Style) be reinstalled in their original locations:
• The valve pushrods
• The valve rocker arms
4045
2a. Remove the valve rocker arms (new style).
(New Style)
4047
Valve Rocker Arm and Push Rods Clean

and Inspect
Important: Parts that are to be reused must be
marked, sorted and organized for assembly.
480526 1. Mark, sort and organize the components for
3. Remove the valve rocker arm stud (former style). assembly.
! CAUTION
(Former Style)
and Notices.
2. Clean the components with cleaning solvent.
4. Inspect the valve rocker arm components for
the following:
• Valve rocker arm valve push rod socket
contact surface (1). The contact surface must
4081 be smooth with no scoring or excessive wear.
• Valve rocker arm pivot for binding or damage (2)
3a. Remove the valve rocker arm supports (new style) • Valve rocker arm valve stem contact surface (3)
• Valve rocker arm bolt threads for damage (4)
(New Style)
480527
4. Remove the valve pushrods.

-40-
Important: Place the components in a rack so that
the components can be reinstalled to their original
location.
2. Remove the valve lifters.
4578
NOTE
Important: Some valve lifters may be stuck in their
bores because of gum or varnish deposits. Use the
J 3049 or the J 9290-01 to remove these valve
lifters.
3. Use the J 3049 pliers to remove the valve lifters.
Valve Lifter Removal

Tools Required
• J 3049 Valve Lifter Remover (Plier Type)
• J 9290-01 Valve Lifter Remover (Slide
Hammer Type)
Important: Place the components in a rack so that
the components can be reinstalled to their original
location.
1. Remove the bolts and the valve lifter push rod
guide.
31350
4. If the valve lifters cannot be removed with the

J3049, use the J 9290-01 to remove the valve
lifters.
4577
-41-
Valve Stem Oil Seal and Valve Spring
Removal
Tools Required
• J 23590 Spark Plug Adapter
• J 5892-D Valve Spring Compressor
• J 38606 Valve Spring Compressor
34571

7. Inspect the valve lifter pushrod guides for
excessive wear. 4041
8. Inspect the valve lifter pushrod guides for cracks

or damage. 1. Remove the valve rocker arm cover.
9. Inspect the valve lifter for the following: 2. Remove the valve rocker arms.
• Broken or damaged clip (1) 3. Remove the spark plugs.
• Worn pushrod socket (2) 4. Install the J 23590.
• Scuffed or worn lifter body (3) 5. Apply compressed air to hold the valves in
If the valve lifter shows scuffing or wear,
inspect the engine clock valve lifter bores for
wear.
• Worn roller (4)
• Loose or damaged pin (5)
• Plugged oil hole (6)
4048
6. Install the valve rocker arm nut.

7. Use the J 5892-D valve springs compressor.
178485
1964
-42-
8. Use the J 38606 if clearance does 3. Remove the following components from the left
not permit use of J 5892-D. cylinder head:
• The electrical connector at the coolant
temperature sensor
• Spark plugs
J 38606
31730
9. Remove the valve keys. 31868

10. Carefully release the valve spring tension.
11. Remove the J 5892-D or J 38606.
12. Remove the cap, rotator, and spring. 4. Remove the alternator and bracket from the
13. Remove the valve seal. right cylinder head.
5. Remove valve rocker arm cover.
Cylinder Head Removal

1. Remove the intake manifold.
4041
2. Remove the exhaust manifold.
-43-
6. Remove the cylinder head bolts. 8. Remove and discard the cylinder head gasket.
5131
4047
NOTE 9. Remove the dowel pins (cylinder head locator)

(if required).
After removal, place the cylinder head on two wood
blocks to prevent damage.
7. Remove cylinder head.
330548
5130
-44-
Cylinder Head Disassembly and Assembly
Disassembly
Tools Required
• J 8062 Valve Spring Compressor
! CAUTION
Compressed valve springs have high
tension against the valve spring compressor.
Valve springs that are not properly compressed
by or released from the valve spring compressor
can be ejected from the valve spring compressor
with intense force. Use care when compressing
or releasing the valve spring with the valve
31715
spring compressor and when removing or
installing the valve stem keys. Failing to use care (1) Key (3) Seal (5) Valve
may cause personal injury. (2) Cap (4) Spring (6) Valve
Assembly
! CAUTION
Tools Required
Refer to Safety Glasses Caution in Cautions • J 8062 Valve Spring Compressor
and Notices.
• J 42073 Valve Stem Oil Seal
Installer
1. Use J 8062 to compress the valve springs. 1. Clean the valve spring seat area.
2. Install the valve into the proper port.
NOTE
J 8062 Important: In order for tool J 42073 to work
properly, the valve is installed into the cylinder head.
3. Lubricate guide and valve stem oil seals (3) with
clean engine oil.
NOTE
Important: Install the valve stem oil seal (3) onto
the valve stem (5 or 6). Push the seal down until the
seal contacts the valve guide (2).
34468 4. Valve stem oil seal alignment onto the valve

guide is critical.
2. Remove the valve stem keys (1).
3. Remove the cap (2) from the valve (5 or 6).
4. Remove the valve spring (4).
5. Remove the valve stem oil seal (3).
6. Remove the valve (5 or 6). Place the valves in a
rack in the proper sequence so you can install
them in the same order.
36371
-45-
5. Place the J 42073 over the valve stem and oil
seal. Lightly tap on the J 42073 until the tool
bottoms out against the valve spring seat. J 8062
6. Install the valve spring (4).
NOTE
Important: A correctly installed seal should not
bottom against the valve guide. There should be a
1-2 mm (0.03937-0.07874 in.) gap (2) between the
bottom edge of the seal (5) and the valve guide (4).
34468
Cylinder Head Clean and Inspect

Tools Required
• J8089 Carbon Removing Brush
• J 9666 Valve Spring Tester
• J 8001 Dial Indicator Set
1. Clean the valve stems and cylinder heads on a
buffing wheel.
2. Clean the following components in cleaning solvent:
• Valve stem keys
• Valve spring cap
• Valve spring
36373
• Cylinder head
7. Install the cap (2) on the valve stem. 4. Use the J 8089 to clean the carbon from the
8. Use the valve spring compressor J 8062 to combustion chambers and the valve area. Be
compress the valve spring. careful not to scuff the chamber.
9. Install the valve stem keys (1).
• Use grease to hold the keys in place while
disconnecting the valve spring compressor ! CAUTION
J 8062.
• Make sure the keys seat properly in the Safety glasses must be worn or eye injury may occur.
upper groove of the valve stem.
• Tap the end of the stem with a plastic-faced
hammer to seat the keys if necessary.
J 8089
10. Measure the valve spring installed height from
the valve spring seat to the locating surface on
the cap.
-46-
5. Inspect the cylinder head for the following: 9. Valve stems (1) with excessive valve guide (2)
• Damage to the gasket surfaces clearance must be repaired or the cylinder head
• Damage to the threaded bolt holes replaced.
• Burnt or eroded areas in the combustion
chambers
• Cracks in the exhaust ports and combustion
chambers
• External cracks in the water chambers
• Restrictions in the intake or exhaust passages
• Restrictions in the cooling system passages
• Rusted, damaged or leaking core plugs
6. Measure the cylinder head for warpage with a
straight edge and feeler gauge.
• A cylinder head block deck with warpage in
excess of 0.10 mm (0.004 in) withing a 152.4
mm (6.0 in) area must be repaired or replaced.
• A cylinder head exhaust manifold deck with
warpage in excess of 0.05 mm (0.002 in)
withing a 152.4 mm (6.0 in) area must be
repaired or replaced. 156172
• A cylinder head intake manifold deck with 10. Measure the valve stem-to-bore clearance.
warpage in excess of 0.10 mm (0.004 in) Excessive valve stem-to-bore clearance may
withing a 152.4 mm (6.0 in) area must be cause excessive oil consumption and may
repaired or replaced. cause a valve to break. Insufficient clearance
7. Use the valve spring tester J 9666 to measure will result in noisy and sticky functioning of
the valve spring. the valve and will disturb the engine
• Replace the intake valve spring if the spring assembly smoothness.
tension is less than 360 N (81 lb) at 45.2 mm a. Clamp the dial indicator J 8001 on the
(1.78 in.). exhaust port side of the cylinder head.
• Replace the exhaust valve spring if the spring b. Locate the indicator so the movement of the
tension is less than 425 N (96 lb) at 45.2 mm valve stem from side to side (crosswise to the
(1.78 in.). cylinder head) will cause a direct movement
of the indicator stem. The indicator stem
must contact the side of the valve stem just
above the valve guide.
c. Drop the valve head about 1.6 mm (0.064 in.)
off the valve seat.
d. Use light pressure when moving the valve stem
J 9666 from side to side to obtain clearance reading.
4960
8. Inspect the valve spring for squareness.
J 8001
40075
35214
-47-
Valve Guide Reaming / Valve and Seat
Grinding ! CAUTION
Tools Required Safety glasses must be worn or eye injury may occur.
• J 8001 Dial Indicator Set
• J 5830-02 Valve Guide Reamer Set NOTE
1. Measure the valve stem-to-guide clearance. Important: Exhaust valves with excessive valve
Refer to Cylinder Head Clean and Inspect. stem-to-guide clearance must be replaced with the
available service valve that has an 0.0774 mm
(0.0305 in) oversize valve stem. The intake valves
are NOT available with oversize valve stems.
Replace the cylinder head if after using a NEW
intake valve and in order to measure the valve
stem-to-guide clearance, the valve stem-to-guide
clearance is not within specifications.
3. Use the J 5830-3 in order to ream the exhaust
valve guide in order to achieve the correct valve
stem-to-guide clearance.
4. Always recondition the exhaust valve seat after
reaming the exhaust valve guide bores and
installing new exhaust valves.
J 8001
35214
2. Improper valve stem (1) to valve guide (2)

clearance may cause excessive oil
consumption.
480556
5. Inspect the valves for the following:

• Burnt or damaged areas (1)
• Undersize margain (2)
• Bent stem (3)
• Scoring or other damage to the stem (4)
• Worn key groove (5)
• Worn stem tip (6)
156172
-48-
• Reface pitted valves on a valve refacing
machine in order to ensure the correct
relationship between the valve head and the
valve stem.
Replace the valve if the valve stem is
excessively worn or wrapped.
Replace the valve if the edge margain (4) of
the valve head is less than 0.79 mm (0.031 in)
thick after grinding.
• Several different types of equipment are
available for reconditioning valves and valve
seats. Follow the equipment manufacturer’s
156174 recommendations for equipment use to attain
the proper results.
6. Inspect the valve contact for the following:
• Undersize margain (1)
• Pitted surfaces (2)
• Burnt or eroded areas (3) Cylinder Head Assemble
• Acceptable edge (margain) (4) Tools Required
Valves with excessive damage must be • J 8062 Valve Spring Compressor
replaced. Minor imperfections of the valve or • J 42073 Valve Stem Seal Installer
valve seat may be repaired. Important: The exhaust valve oil stem seal has the
letters EX (1) molded into the top of the seal. The
exhaust valve oil stem seal material is brown in
color (2) with a white stripe (3) painted onto the out-
side diameter of the seal, or the material may be
red in color (2) with no paint stripe. The intake valve
oil seal is black in color.
1. Assemble the valve into the proper valve guide.
2. Select the proper valve stem oil seal for the
specific valve guide.
3. Lubricate the valve stem oil seal and the outside
diameter of the valve guide with clean engine oil.
156173
7. Reconditioning of the valves and valve seats:

• The valves must seat perfectly for the engine
to deliver optimum power and performance.
• Cooling the valve heads is another important
factor. Good contact between each valve and
valve seat in the cylinder head is necessary to
insure that the heat in the valve head is
properly carried away.
• Regardless of what type of equipment is used,
it is essential that the valve guide bores are
free from carbon or dirt in order to ensure the
proper centering of the pilot in the valve guide.
The valve seats should be concentric to
within 0.05 mm (0.002 in) total indicator 4. Assemble the valve stem oil seal onto the valve
reading. stem.
-49-
9. Use the valve spring compressor J 8062 in
! CAUTION order to compress the valve springs.
Safety glasses must be worn or eye injury may occur. 10. Install the valve stem keys.
10.1 Use grease in order to hold the valve stem
5. Install the valve stem oil seal onto the valve keys in place while disconnecting the
guide using the valve stem seal installer J 42073. valve spring compressor J 8062.
Tap the valve stem oil seal onto the valve guide 10.2 Look to ensure that the valve stem keys
until the valve stem seal installer J 42073 seat properly in the upper groove of the
bottoms against the valve spring seat. valve stem.
6. Inspect the valve stem oil seal. The valve stem 10.3 Tap the end of the valve stem with a
oil seal should not be bottomed against the plastic-faced hammer in order to seat the
valve guide. valve stem keys, if necessary.
J 8062
36373
Valve Lifter Installation
7. Install the valve spring (3).
8. Install the valve spring cap (2) onto the valve NOTE
spring (3) and over the valve stem. Parts that are to be reused must be marked, sorted
and organized for assembly. If reusing the valve
lifters, install the valve lifters in the original positions.
1. Apply engine oil to the valve lifter rollers.
2. Install the valve lifters.
3. Install the valve lifter pushrod guides.
480555
! CAUTION
Compressed valve springs have high tensions
against the valve spring compressor. Valve
springs that are not properly compressed by or
released from the valve spring compressor can
be ejected from the valve spring compressor Tightening torque 1.66 Kgf•m
with intense force. Use care when compressing for valve lifter (12 lb ft)
or releasing the valve spring with the valve pushrod guide bolts [16 N•m]
spring compressor and when removing or
installing the valve stem keys. Failing to use
care may cause personal injury. -50-
Cylinder Head Installation 5. Install the cylinder head onto the engine block.
Tools Required Guide the cylinder head carefully into place over
the dowell pins and the cylinder head gasket.
• J 36660 Electronic Torque Meter
1. Clean the cylinder head gasket surfaces on the

engine block.
2. Inspect the dowel pins (cylinder head locators)
for proper installation.
3. Clean the cylinder head gasket surfaces on the
cylinder head.
480536
6. Apply sealant P/N 2I4256, GM P/N

12346004 or equivalent to the threads of the
cylinder head bolts.
7. Install the cylinder head bolts finger tight.
334303
NOTE
Do not use any type of sealer on the cylinder head
gasket (unless specified).
4. Install the NEW cylinder head gasket in position 480533
over the dowel pins (cylinder head locators). 8. Tighten the cylinder head bolts in sequence
and use the two step method.
First Pass
Tightening torque 3.05 Kgf•m (22 lb ft) [30 N•m]
for cylinder Final Pass
head bolts Long bolts 75 degrees
Medium bolts 65 degrees
Short bolts 55 degrees
9. Use the electronic torque meter J 36660 to tighten

the cylinder head bolts in sequence on the final
pass.
• Tighten the long bolts (1,4,5,8 and 9) on the
final pass in sequence to 75 degrees.
• Tighten the medium bolts (12 and 13) on
334299 the final pass in sequence to 65 degrees.
• Tighten the short bolts (2,3,6,7,10 and 11)
on the final pass in sequence to 55 degrees.
-51-
13. If reusing the engine coolant temperature gauge
sensor (if applicable), apply sealant GM P/N
engine coolant temperature gauge sensor.
14. Install the engine coolant temperature gauge
sensor (if applicable).
Tightening torque 2.07 Kgf•m (15 lb ft)

for coolant [20 N•m]
temperature gauge
5132
10. Install the spark plug wire support and bolts.
Tightening torque
for wire support 1.22 Kgf•m (106 lbf.in) [12 N•m]
and bolts
15. If reusing the engine coolant temperature

sensor (if applicable), apply sealant GM P/N
328588 engine coolant temperature sensor.
16. Install the engine coolant temperature sensor
11. Measure the NEW spark plugs for the proper (if applicable).
gap. Adjust the spark plug gap if necessary.
Specification
Spark plug gap to .889 mm (0.035 in). for coolant [20 N•m]
12. Install the spark plugs. temperature sensor
Tightening torque
for spark plugs 3.05 Kgf•m (22 lb ft) [30 N•m]
NEW
USED PLUGS 1.52 Kgf•m (11 lb ft) [15 N•m]
328582
-52-
Valve Rocker Arm and Push Rod 4. Install the valve rocker arm assemblies as follows:
Installation 4.1 Finger start the bolt at location (1)
Important: Be sure to keep parts in order. Parts must 4.2 Finger start the bolt at location (2)
be reinstalled into the original location and position. 4.3 Finger start the bolt at location (3)
4.4 Finger start the remaining valve rocker arm bolts.
1. Install the valve pushrods.
480529
NOTE
480580
Be sure that the arrow on the valve rocker arm
support is in the up position.
2. Install the valve rocker arm supports. 5. Rotate the crankshaft balancer to position the
crankshaft balancer alignment mark (1) 57-63
degrees clockwise or counterclockwise from
the engine front cover alignment tab (2).
3. Apply prelube GM P/N 12345501 or equivalent

to the following valve rocker arm contact
surfaces: 334551
• Valve pushrod socket (1)
• Roller pivot (2)
• Valve stem tip (3) NOTE
Once the valve rocker arm assemblies are installed
and properly torqued, no additional valve lash
adjustment is required.
6. Tighten the valve rocker arm bolts.
Tightening torque
for valve rocker 3.05 Kgf•m (22 lb ft) [30 N•m]
arm bolts
-53-
Valve Rocker Arm Cover Installation 4. Install the valve rocker arm cover bolts and
(Left) torque to the specified torque.
Important: Do not reuse the valve rocker arm cover
gasket or the valve rocker arm cover grommets. Tightening torque
1. Install the NEW valve rocker arm cover gasket for valve rocker 3.05 Kgf•m (22 lbf.ft) [ 30 N•m]
into the groove of the valve rocker arm cover. arm bolts
2. Install the NEW valve rocker arm cover bolt
grommets into the valve rocker arm cover.
4041
328573
3. Install the valve rocker arm cover onto the 5. Install PCV valve and tube.
cylinder head. 6. Connect the spark plug wires to the spark plugs
and route the wires so that they do not touch
the engine or exhaust system.
7. Install the ignition coil.
8. Connect the negative battery cable.
480519
31868
-54-
Valve Rocker Arm Cover Installation 4. Install the valve rocker arm cover bolts and
(Right) torque to the specified torque.
Important: Do not reuse the valve rocker arm cover
gasket or the valve rocker arm cover bolt grommets.
Tightening torque
1. Install the NEW valve rocker arm cover gasket for valve rocker 3.05 Kgf•m (22 lbf.ft) [ 30 N•m]
into the groove of the valve rocker arm cover. arm bolts
2. Install the NEW valve rocker arm cover bolt
grommets into the valve rocker arm cover.
328573
328568
3. Install the valve rocker arm cover onto the
cylinder head.
480524
-55-
-56-
Oil Pan, Pump and Filter
Removal steps
1. Plug
2. Pan
3. Gasket
4. Bolt
5. Pump
6. Retainer
7. Shaft
8. Pin N
9. Pin
10. Cover
11. Screen
12. Plug
13. Valve
14. Spring
15. Filter
16. Fitting
17. Valve
18. Adapter, Oil Filter
19. Gasket
20. Connector, Cooler
21. Gasket
-57-
Oil Pan Removal 5. Remove oil filter adapter bolts.
1. Remove the water pump. 6. Remove oil filter adapter gasket.
2. Remove crankshaft balancer. 7. Remove oil filter adapter O-ring seal, if equipped.
4555
8. Remove the oil pan.

42882
3. Drain the engine oil.

4. Remove the following fasteners from the oil pan:
• The bolts
• The nuts
330568
9. Remove the oil pan gasket.

10. Discard the oil pan gasket and replace with
NEW at reassembly.
NOTE
Important: Discard old oil pan gasket.
330559
387757
-58-
Oil Pump Removal Oil Pan Clean and Inspect
1. Remove the bolt that attaches the oil pump to 1. Remove the oil pan baffle bolts and the oil pan
the rear crankshaft bearing cap. baffle.
4548
2. Remove the oil pump driveshaft and the

387763
! CAUTION
Safety glasses must be worn or eye injury may occur.
2. Clean the oil pan and the oil pan baffle in

cleaning solvent.
3. Dry the oil pan and the oil pan baffle with
compressed air.
4. Inspect the oil pan for the following:
• Gouges or damage to the oil pan sealing
surfaces (1)
• Damage to the threaded holes (2)
• Damaged oil pan drain hole threads (3)
• Damage to the oil pan baffle
4549
• Damage to the exterior of the oil pan
3. Inspect the pins (oil pump locator) for damage, A damaged oil pan may interfere with the
and replace the pins if required. proper position of the oil pump screen, or
may not distribute oil properly in the oil pan
sump area.
330578
4554
-59-
5. Install the oil pan baffle and the bolts. 2. Remove the oil filter adapter and gasket.
Tightening torque
for oil pan baffle 1.22 Kgf•m (106 lb in) [12 N•m]
bolts
4555
3. Remove the seal.
387763
Oil Filter Adapter Removal

1. Remove the oil filter adapter bolts.
4556
Oil Pump Disassemble

1. Remove the oil pump drive shaft and oil pump
driveshaft retainer.
4554
5274
-60-
2. If necessary, remove the oil pump screen. 5. Remove the drive gear and the driven gear.
• The oil pump screen has a press fit into the 6. Matchmark the gear teeth for assembly.
pump cover.
• Do not remove the screen from the pipe.
The pipe and screen are serviced as a
complete assembly
5278
7. Remove the following items:

a. The oil pump pressure relief valve spring
straight pin.
b. The oil pump pressure relief spring
5275
c. The oil pump pressure relief valve
3. Remove the oil pump cover bolts.
30401
Oil Pump Clean and Inspect

1. Clean the oil pump components in cleaning solvent.
5276
4. Remove the pump cover. 3. Inspect the oil pump for the following
conditions:
• Scoring gears (2) for the following:
• Damaged gears (2) for the following:
❍ Chipping ❍ Gailing ❍ Wear
• Scoring, damage or casting imperfections

to the body (3)
• Damaged or scored gear shaft (4)
• Damaged or scored gear shaft (5)
• Damaged bolt hole threads
• Worn oil pump driveshaft bore
• Damaged or sticking oil pump pressure
relief valve (minor imperfections may be
5277 removed with a fine oil stone)
• Collapsed or broken oil pump relief valve
spring
-61-
3. Coat the drive gear, the driven gear and the
housing gear surfaces with clean engine oil.
4. Install the drive gear and the driven gear into the
pump body.
a. Align the matchmarks on the gears.
b. Install the smooth side of the gear toward
the pump cover.
186750
4. If the oil pump is to be reused, install a NEW oil

pump pressure relief valve spring.
5. During oil pump installation, install a NEW oil pump
5278
Oil Pump Assemble
5. Install the pump cover.
Tools Required
• J 21882 Oil Pump Screen Installer.
NOTE
Important: Replace the pressure relief valve spring
when you reuse the oil pump.
1. Apply clean engine oil to the oil pump pressure
relief valve, oil pump pressure relief valve spring
and oil pump body.
2. Install the following items:
a. The oil pump pressure relief valve
b. The oil pump pressure relief valve spring
c. The oil pump pressure relief valve spring
5277
straight pin
6. Install the cover bolts.
Tightening torque
for cover bolts 1.22 Kgf•m (106 lb•in) [12N•m]
7. Inspect the pump for smoothness of operation

by turning the oil pump driveshaft by hand.
30401
-62-
9. Install the oil pump drive shaft and the NEW oil
pump drive shaft retainer.
5276
5274
8. Install the oil pump screen.
a. If removed, replace the oil pump screen. The
oil pump screen must have a good press fit Oil Filter Adapter Installation
into the oil pump body. 1. Install the seal.
b. Mount the oil pump in a soft jawed vise.
c. Apply sealant MCF P/N 2I4256 GM P/N
12346004 or equivalent to the end of the oil
pump screen pipe.
d. Use the oil pump screen installer J 21882 and
a soft-faced hammer to tap the oil pump
screen into the pump body. The screen must
align parallel with the bottom of the oil pan
when it is installed.
4556
2. Install the oil filter adapter and gasket.
J 21882
5280
NOTE
Install a NEW oil pump driveshaft retainer during
assembly.
4555
-63-
3. Install the oil filter adapter bolts.
4554
330576
4. Install the oil pump bolt attaching the oil pump to

Oil Pump Installation the rear crankshaft bearing cap. Tighten to the
specified torque.
1. Inspect for properly installed pins (oil pump
locator).
Tightening torque for
Oil pump bolts 9.14 Kgf•m (66 lb ft) [90 N•m]
330572
330578
Important: DO NOT reuse the oil pump driveshaft

retainer. During assembly, install a NEW oil pump
2. Install the oil pump.
3. Position the oil pump onto the pins.
-64-
Oil Pan Installation Important: Always install a NEW oil pan gasket.
1. Apply a 5 mm (0.197 in) wide and 25 mm (1.0 in) The oil pan gasket and oil pan must be installed
long bead of PERMATEX® Gasket Maker P/N and the fasteners tightened while the adhesive is
A000000165 GM P/N 12346141 or equivalent still wet to the touch.
to both the right and left sides of the engine 3. Install the NEW oil pan gasket into the groove in
front cover to engine block junction at the oil the oil pan.
pan sealing surfaces.
317310
387757
2. Apply a 5 mm (0.197 in) wide and 25 mm (1.0 in)
long bead of PERMATEX® Gasket Maker P/N Important: The oil pan alignment must always be
A000000165, GM P/N 12346141 or equivalent flush or forward no more than 0.3 mm (0.011 in)
to both the right and left sides of the crankshaft from the rear face of the engine block.
rear oil seal housing to engine block junction at 4. Install the oil pan onto the engine block.
the oil pan sealing surfaces. Press the oil pan gasket into the grooves of the
engine front cover and crankshaft rear oil seal
housing.
5. Slide the oil pan back against a suitable straight
edge.
317313
330568
-65-
6. Install the oil pan bolts and nuts, but do not 10. Install a NEW oil pan drain plug seal (O-ring)
tighten. onto the oil pan drain plug.
7. Measure the pan-to-transmission housing 11. Install the oil pan drain plug into the oil pan.
clearance using a feeler gauge and a straight
edge.
Use a feeler gauge to check the clearance Tightening torque
between the oil pan-to-transmission housing for oil pan 2.49 Kgf•m (18 lb•ft) [25N•m]
measurement points. If the clearance exceeds drain plug
0.3 mm (0.011 in) at any of the 3 oil pan-to-
transmission housing measurement points (1),
then repeat the step until the oil pan-to-
transmission housing clearance is within the
specification. The oil pan must always be
forward of the rear face of the engine block.
188048
12. Install the NEW engine oil level sensor

(if applicable).
38496
Tightening torque 13.2 kgf•m (115 lb in)
for oil level sensor [13N•m]
Notice: If the clearance is more than 0.3 mm
(0.011 in), powertrain durability may be reduced.
8. Tighten the oil pan bolts and nuts in sequence
(1-12).
9. Measure the clearance between the 3 oil pan-
to-transmission housing measurement points in
order to ensure proper alignment.
Tightening torque
for oil pan nuts 2.49 Kgf•m (18 lb•ft) [25N•m]
and bolts
38481
-66-
Front Cover, Timing Chain, and Crankshaft Balancer
8
7
3
4
9
5 Removal steps
1. Cover
2 1 2. Seal
3. Bolt
4. Sprocket
5. Chain
6. Drive Gear
7. Bolt
8. Gear
9. Sprocket
-67-
Engine Front Cover Removal Engine Front Cover Oil Seal Removal
1. Remove the crankshaft balancer. 1. Disconnect the negative battery cable.
2. Remove the water pump. 2. Remove the crankshaft balancer.
3. Remove the crankshaft position sensor bolt. 3. Remove the crankshaft front seal.
4. Remove the crankshaft position sensor.
Timing Chain and Sprockets Removal

Tools Required
• J 23523-F Crankshaft Balancer
Remover and Installer
• J 5825-A Crankshaft Sprocket Puller
NOTE
Check the camshaft timing chain free play. Replace
the camshaft timing chain if it can be moved back
and forth in excess of 16 mm (0.625 in.).
5. Remove the crankshaft position sensor seal (O-ring). 1. Remove the engine front cover.
6. Discard the crankshaft position sensor seal (O-ring). 2. Check the camshaft timing chain free play.
2.1. Rotate the camshaft sprocket (1)
counterclockwise until all slack is removed
from the camshaft timing chain (2).
2.2. Measure the free play on the slack side (3)
of the camshaft timing chain.
If the camshaft timing chain can be moved
side to side in excess of 11 mm (0.43 in),
replacement of the camshaft timing chain
and the sprockets is recommended during
assembly.
7. Remove the engine front cover bolts.

8. Remove the engine front cover.
9. Discard the engine front cover.
NOTE
Do not reuse the engine front cover. Always install a
new engine front cover.
480542
-68-
3. Remove the crankshaft position sensor reluctor 6. Remove the crankshaft sprocket using the
ring. crankshaft sprocket puller J 5825-A.
J 5825 - A
480541
7. Remove the camshaft balancer key.

4. Remove the camshaft sprocket bolts.
387761
480544 Timing Chain and Sprockets Clean and

Inspect
5. Remove the camshaft sprocket and the camshaft
timing chain. ! CAUTION
and Notices.
3. Inspect the camshaft timing chain for binding or wear.
480546
! CAUTION
Safety Glasses must be worn or eye injury
may occur.
-69-
4. Inspect the camshaft sprocket and the 3. Use the balancer remover and installer J23523-F
crankshaft sprocket for the following: in order to remove the crankshaft balancer.
• Broken teeth (1) a. Install the balancer remover and installer
• Damaged teeth (2) J23523-F plate and bolts onto the crankshaft
• Chipped teeth (3) balancer and tighten.
• Worn teeth
• Uneven wear on the edge of the teeth
• Worn valleys between the sprocket teeth Tightening torque for
Balancer bolts 2.49 Kgf•m (18 lb ft) [25 N•m]
• Crankshaft sprocket keyway for wear
b. Install the balancer remover and installer

J23523-F forcing screw into the plate.
c. Rotate the balancer remover and installer
J23523-F forcing screw clockwise in order to
remove the crankshaft balancer.
4. Remove the balancer remover and installer
J23523-F from the crankshaft balancer.
J 23523-F
Crankshaft Balancer Removal
Tools Required
• J 23523-F Balancer Remover and Installer
1. Remove the crankshaft balancer bolt and washer.
4059
Important: If replacing the crankshaft balancer,

NEW weights must be installed into the NEW
crankshaft balancer, in the same location as the old
weights in the old balancer.
173172
5. Note the position and length of any crankshaft
2. Remove the bolts and the crankshaft pulley. balancer front groove pins, if applicable.
334258
188055
-70-
Crankshaft Balancer Installation b. Install the J 23523-F screw into the end for
Tools Required the crankshaft.
• J 23523-F Crankshaft Balancer Remover and c. Install the J 23523-F bearing, the washer and
Installer the nut onto the J 23523-F screw.
1. Look to ensure that the front groove pin d. Rotate the J 23523-F nut clockwise until the
(crankshaft balancer) is installed in the proper crankshaft balancer hub is completely seated
location (if applicable). against the crankshaft position sensor
reluctor ring.
6. Remove the J 23523-F.
J 23523–F
334258
4065
Important: The inertial weight section of the crank-
shaft balancer is assembled to the hub with a rub- 7. Install the crankshaft pulley and bolts.
ber type material. The correct installation proce-
dures (with the proper tool) must be followed or
movement of the inertial weight section of the hub Tightening torque for
will destroy the tuning of the crankshaft balancer. Crankshaft pulley bolts 5.94 Kgf•m (43 lb ft) [58 N•m]
2. Apply a small amount of adhesive A000000165, 8. Ensure that the crown of the crankshaft balancer
GM P/N 12346141 or equivalent onto the washer (2) is faced away from the engine.
crankshaft balancer keyway in order to seal the
crankshaft balancer keyway and crankshaft joint.
3. Align the keyway of the crankshaft balancer with
the crankshaft balancer key. 1
4. Install the crankshaft balancer onto the end of
the crankshaft.
342203
9. Install the crankshaft balancer washer and the

bolt, tighten to the specified torque.
Tightening torque
for Crankshaft 9.67 Kgf•m (70 lb•ft) [95N•m]
Balancer bolt
188059
5. Use the J 23523-F in order to press

the crankshaft balancer onto the crankshaft.
a. Install the J 23523-F plate and bolts onto the
front of the crankshaft balancer and tighten to
the specified torque.
Tightening torque for

Balancer bolts 2.49 Kgf•m (18 lb ft) [25 N•m]
-71-
Timing Chain and Sprockets Installation 4. Rotate the crankshaft until the crankshaft
Tools Required sprocket is at the 12 o’clock position.
• J 5590 Crankshaft Sprocket Installer Important: Install the crankshaft sprocket with the
alignment mark at the 6 o’clock position.
1. Install the key into the crankshaft keyway.
The crankshaft balancer key should be parallel 5. Install the crankshaft sprocket and the camshaft
to the crankshaft or with a slight incline. timing chain.
387766
2. Align the keyway of the crankshaft sprocket with

the crankshaft balancer key.
3. Use the crankshaft sprocket installer J 5590 to
install the crankshaft sprocket. 480546
6. Look to ensure that the crankshaft sprocket is

aligned at the 12 o’clock position and the
camshaft sprocket is aligned at the 6 o’clock
position.
J 5590
480574
480575
-72-
Important: Do not use a hammer to install the Engine Front Cover Oil Seal Installation
camshaft sprocket onto the camshaft. To do so Tools Required
may dislodge the expansion cup plug (camshaft
rear bearing hole). • J 35468 Crankshaft Seal Installer and
Centering Tool
7. Install the camshaft sprocket bolts. 1. Install the crankshaft front seal.
2. Install the crankshaft balancer.
Tightening torque
for camshaft 2.49 Kgf•m (18 lb•ft) [25N•m]
Engine Front Cover Installation
sprocket bolts
NOTE
Once the composite engine front cover is removed
DO NOT reinstall the engine front cover. Always
install a new engine front cover.
Tightening torque
for front cover 1.22 Kgf•m (106 lb•in) [12 N•m]
bolts
1. Install the NEW engine front cover.

2. Install the front cover bolts.
480544
8. Install the crankshaft position sensor reluctor ring.

a. Align the keyway on the crankshaft position
sensor reluctor ring with the crankshaft
balancer key in the crankshaft.
b. Use the crankshaft sprocket installer J 5590 to
push the crankshaft position sensor reluctor
ring onto the crankshaft until completely
seated against the crankshaft sprocket.
4068
J 5590
480574
-73-
Important: Do not reuse the original crankshaft Water Pump Removal
position sensor seal (o-ring). When installing the Tools Required
crankshaft position sensor, be sure the crankshaft
• J 41240 Fan Clutch Remover and Installer
position sensor is fully seated and held stationary in
the engine front cover crankshaft position sensor 1. Remove the bolts and the fan and water pump
bore. A crankshaft position sensor that is not pulley using the J 41240.
completely seated will cock in the engine front
cover and may result in erratic engine operation.
3. Lubricate the NEW crankshaft position sensor
seal (o-ring) with clean engine oil.
4. Install the NEW crankshaft position sensor seal
(o-ring) onto the crankshaft position sensor.
2. Remove the clamps and water pump inlet hose.
5. Install the crankshaft position sensor until fully

seated into the engine front cover.
6. Install the crankshaft position sensor bolt.
Tightening torque .82 Kgf•m (71 lb ft)

for crankshaft [8 N•m]
position bolt
3. Remove the water pump bolts.

4. Remove the water pump.
5. Remove the water pump gaskets.
6. Discard the water pump gaskets.
-74-
Water Pump Clean and Inspect Water Pump Installation
Tools Required
! CAUTION • J 41240 Fan Clutch Remover and Installer
Refer to Safety Glasses Caution in Cautions 1. If reusing the fasteners, apply sealant GM P/N
and Notices. 12346004 or equivalent to the threads of the
water pump bolts.
1. Remove all the old gasket material from the 2. Install the water pump and the NEW water
water pump sealing surfaces. pump gaskets.
2. Clean all the dirt and any debris from the water 3. Install the water pump bolts.
pump.
3. Inspect the water pump for the following:
• Leakage or damage to the housing cover or Tightening torque 4.56 Kgf•m (33 lb ft)
for [45 N•m]
gasket (1)
water pump bolts
• Excessive scratches or grouping to the gasket
sealing surfaces (2)
• Leakage from the water pump vent hole (3)
A stain around the vent hole is acceptable. If
leakage occurred (dripping) with the engine
operating and the cooling system pressurized,
then replace the water pump.
• Damaged bolt hole threads (4)
• Excessive side-to-side movement of the water
pump shaft (5)
• Leakage around the water inlet pipe (6)
• Leakage around the heater hose pipe (7)
• Restrictions within the internal coolant passages
Important: After final assembly, the water pump

inlet hose clamp tangs (water pump end) must
point forward and the upper tang should be level
with the outside diameter of the water pump inlet
hose.
4. Install the water pump inlet hose and the water
pump inlet hose clamps.
-75-
5. Install the fan and water pump pulley and bolts
using the J 41240.

for water pump [25 N•m]
pulley bolts
-76-
Balancer and Camshaft
12 13
11
7
10
6
4 Removal steps
1. Rod
8 2. Guide
3. Lifter
4. Camshaft Gear
5. Gear Kit
6. Retainer
7. Retainer
8. Camshaft
9. Balancer
10. Bearing Kit - Camshaft
11. Bearing
12. Bearing
13. Plug
-77-
Balance Shaft Removal NOTE
Tools Required
• J 23523-F Crankshaft Balancer Remover and Important: The balance shaft drive and driven
Installer gears are serviced as a set. The set includes the
• J 38834 Balancer Shaft Bearing Service Kit balance shaft driven gear bolt.
1. Remove the balance shaft drive gear. Inspect
the sprockets for chipped teeth and wear. Worn
sprockets will wear a new chain.
5135
2. Remove the bolt and the balance shaft driven

gear. Inspect the balance shaft drive and driven
gears for nicks and burrs.
a. Use a wrench in order to secure the balance
9847 shaft. Place the wrench onto the balance
shaft near to the balance shaft front bearing.
b. Remove the balance shaft bolt.
c. Remove the wrench from the balance shaft
3. Remove the balance shaft driven gear from
the balance shaft.
5136
-78-
4. Remove the bolts and the balance shaft retainer. c. Install the J 38834-1 into the J 26941.
d. Slide the J 37734-2 and into the balance
shaft bore of the engine block.
e. Install the J 38834 bearing, washer and nut
onto the J 38834-1.
f. Using a wrench, secure the J 38834-1 and
then rotate the J 37734 nut clockwise until
the balance shaft rear bearing is removed
from the engine block.
g. Remove the J 26941 from the balance shaft
rear bearing.
7. Discard the balance shaft rear bearing.
J 38834-1
5137
NOTE
Important: The balance shaft and the front bearing
are serviced only as a package. Do not remove the
front bearing from the balance shaft.
5. Use a soft-faced hammer to remove the balance

shaft from the engine block.
J 38834-2 J 26941
5139
5139
6. Use the balancer shaft bearing service kit J 38834

and the crankshaft balancer remover and
installer J 26941 in order to remove the
balance shaft rear bearing.
a. Install the crankshaft balancer remover and
installer J 26941 legs behind the balance shaft
rear bearing and secure.
b. Install the balancer shaft bearing service kit
J 38834 with the short threaded end through
the balance shaft bore in the front of the
engine block.
-79-
Camshaft Removal Camshaft Bearing Removal
Tools Required Tools Required
• J23523-F Crankshaft Balancer Remover/Installer • J 33049 Camshaft Bearing Replacer
1. Remove the camshaft retainer bolts and retainer.
NOTE
Important: A loose camshaft bearing may be
caused by an enlarged, out-of-round or damaged
engine block camshaft bearing bore.
NOTE
Important: Always remove the camshaft inner
bearings #2 and #3 first. The camshaft outer bear-
ings #1 and #4 serve as a guide for the camshaft
bearing replacer J 33049.
1. Select the cone (1), the handle (10), the expanding

driver (4-8), the washer (2 or 3) and the expander
assembly (15) from the J 33049
2. Assemble the J 33049.
5146
Notice: All camshaft journals are the same diameter,

so care must be used in removing or
installing the camshaft to avoid damage to
the camshaft bearings.
2. Remove the camshaft.
a. Install the three 6/16 x 4.0 inch bolts in the
camshaft front bolt holes.
b. Carefully rotate and pull the camshaft out of
the bearings.
66100
5147
-80-
3. Remove the camshaft inner bearings #2 and #3. 4. Remove the camshaft bearing replacer J 33049
a. Insert the camshaft bearing replacer J 33049 from the engine block.
through the front of the engine block and into 5. Remove the camshaft outer bearing #1 and #4.
the camshaft inner bearing #2. a. Insert the J 33049 into the camshaft outer
b. Tighten the J 3304) expander assembly nut bearing #1.
until snug. b. Tighten the J 33049 expander assembly nut
c. Push the J 33049 guide cone into the until snug.
camshaft front bearing in order to align the c. Drive the camshaft outer bearing #1 from the
J 33049. camshaft outer bearing bore #1.
d. Drive the camshaft inner bearing #2 from the d. Loosen the J 33049 expander assembly nut.
camshaft inner bearing bore #2. e. Remove the camshaft outer bearing #1 from
e. Loosen the J 33049 expander assembly nut. the J 33049 expander assembly.
f. Remove the camshaft inner bearing #2 from f. Remove the J 33049 from the engine block.
the J 33049 expander assembly. g. Insert the J 33049 expander assembly into the
g. Insert the J 33049 expander assembly into the camshaft outer bearing #4.
camshaft inner bearing #3. h. Tighten the J 33049 expander assembly nut
h. Tighten the J 33049 expander assembly nut until snug.
until snug. i. Drive the camshaft outer bearing #4 from the
i. Push the J 33049 guide cone into the camshaft inner bearing #4.
camshaft front bearing in order to align the j. Loosen the J 33049 expander assembly nut.
J 33049.
k. Remove the camshaft outer bearing #4 from
j. Drive the camshaft inner bearing #3 from the the J 33049 expander assembly.
camshaft inner bearing bore #3.
6. Remove the camshaft bearing replacer J 33049
k. Loosen the J 33049 expander assembly nut. from the engine block.
l. Remove the camshaft inner bearing #3 from 7. Discard the camshaft bearings.
the J 33049 expander assembly.
J 33049
4985 J 33049
63219
-81-
Camshaft and Bearings Clean and 7. Measure the engine camshaft journals with a
Inspect micrometer. If the camshaft journals are more
Tools Required than 0.025 mm (0.0010 in) out-of-round, then
replace the engine camshaft.
• J 7872 Magnetic Base Indicator Set
1. Clean the engine camshaft in cleaning solvent.
2. Dry the engine camshaft with compressed air.
3. Inspect the camshaft retainer plate for damage.
If the camshaft retainer plate is damaged, replace
as necessary.
4. Inspect the camshaft bearings for correct fit into
the engine block camshaft bearings bores.
The camshaft bearings have an interference fit to
the engine block camshaft bearing bores and
must not be loose in the engine block camshaft
bearing bores.
188014
8. Measure for a bent engine camshaft or excessive

engine camshaft run out using the magnetic base
indicator J7872.
• Mount the engine camshaft in a suitable stand
334499
between centers.
• Use the magnetic base indicator J7872 to check
NOTE the intermediate engine camshaft journals.
Important: If any camshaft bearing is excessively 9. Measure the engine camshaft lobe lift using the
worn or scored, replace all the camshaft bearings. magnetic base indicator J7872.
• Place the engine camshaft on the V-blocks.
5. Inspect the camshaft bearings for excessive wear • Use the magnetic base indicator J7872 to
or scoring. measure the engine camshaft lobe lift.
6. Inspect the engine camshaft for the following: 10. Replace the engine camshaft if the engine
• Worn, scored or damaged bearing journals (1) camshaft lobe lift is not within specifications.
• Worn engine camshaft lobes (2) Refer to General Specifications.
• Damaged bolt hole threads (3)
• Damaged camshaft sprocket locator pin (4)
188095
-82-
Camshaft Bearing Installation NOTE
Tools Required
• J 33049 Camshaft Bearing Service Kit Important: The camshaft bearings vary in size.
When ordering the new camshaft bearings, be sure
to order the correct camshaft bearings for the
NOTE application to be serviced.
Always install the camshaft outer bearings #1 and
Important: When installing the camshaft bearings, #4 first. The camshaft outer bearings serve as a
always make sure that the camshaft bearing lubri- guide for the camshaft bearing service kit J 33049
cation hole is located above the 3 o’clock position and help center the camshaft inner bearings during
(1) or the 9 o’clock position (2). The proper posi- the installation process.
tioning of the camshaft bearing lubrication hole is in
order to ensure the best lubrication of the engine 3. Install the NEW camshaft outer bearings #4 and #1.
camshaft journals. a. Install the NEW camshaft outer bearing #4 onto
the J33049 expander assembly.
b. Tighten the J 33049 expander assembly nut
until snug.
c. Align the lubrication hole of the camshaft outer
bearing #4 above the 3 o’clock position or the
9 o’clock position of the camshaft outer bearing
bore #4 at the rear of the engine block.
d. Drive the camshaft outer bearing #4 into the
camshaft outer bearing bore #4 at the rear of
the engine block.
e. Loosen the J 33049 expander assembly nut.
f. Remove the camshaft outer bearing #4 from
the J 33049 expander assembly.
g. Install the NEW camshaft outer bearing #1 onto
594647
h. Tighten the J 33049 expander assembly nut
1. Select the handle (10), the expanding driver (4-8), until snug.
the washer (2 or 3) and the expander assembly
i. Align the lubrication hole of the camshaft outer
(15) from the camshaft bearing service kit J 33049.
2. Assemble the camshaft bearing service kit 9 o’clock position of the camshaft outer bearing
J 33049. bore #1 at the front of the engine block.
j. Drive the camshaft outer bearing #1 into the
camshaft outer bearing bore #1 at the front of
the engine block.
k. Loosen the J 33049 expander assembly nut.
l. Carefully slide the J 33049 into the engine
block until the J 33049 expander assembly is
positioned between the camshaft inner
bearing bores.
66100
-83-
g. Install the NEW camshaft inner bearing #2 onto
h. Tighten the J 33049 expander assembly nut
until snug.
i. Align the lubrication hole of the camshaft inner
9 o’clock position of the camshaft inner bearing
bore #2 of the engine block.
j. Push the J 33049 guide cone into the
camshaft front bearing bore #1 in order to
align the J 33049.
k. Drive the camshaft inner bearing #2 into the
camshaft inner bearing bore #2 of the engine
block.
J 33049
l. Loosen the J 33049 expander assembly nut.
5. Carefully remove the J 33049 from the engine
63219 block.
6. Install a new camshaft rear bearing hole plug. Coat
the outside diameter of the plug with MCF P/N
2I4256 (GM P/N 12346004) sealant or equivalent.
J 33049 a. Install the plug flush to 0.80 mm (1/32 in.)
b. Install the plug while RTV is still wet.
Camshaft Installation
1. Apply clean engine oil or equivalent, to the
following components:
• The engine camshaft lobes
• The camshaft bearing journals
• The camshaft bearings
2. Install three 5/16-18 x 4.0 in. bolts into the
4985 engine camshaft front bolt holes.
4. Install the NEW camshaft inner bearings #3 and #2.
a. Install the NEW camshaft inner bearing #3 onto NOTE
b. Align the lubrication hole of the camshaft inner Important: All camshaft journals are the same
bearing #3 above the 3 o’clock position or the diameter, so care must be used in removing or
9 o’clock position of the camshaft inner bearing installing the camshaft to avoid damage to the
bore #3 of the engine block. camshaft
c. Push the J 33049 guide cone into the
camshaft front bearing bore #1 in order to
align the J 33049.
d. Drive the camshaft inner bearing #3 into the
camshaft inner bearing bore #3 of the engine
block.
e. Loosen the J 33049 expander assembly nut.
f. Carefully slide the J 33049 until the J33049
expander assembly is positioned between the
camshaft inner bearing bore #2 and the
camshaft outer bearing bore #1.
5147
-84-
3. Use the bolts as a handle in order to install the Balance Shaft Clean and Inspect
engine camshaft. Important: The balance shaft and the balance shaft
4. Remove the 3 bolts from the front of the engine front bearing are serviced only as an assembly. Do
camshaft. not remove the balance shaft front bearing from the
5. If reusing the fasteners, apply thread lock GM balance shaft.
P/N 12345382 or equivalent to the threads of the
camshaft retainer bolts.
6. Install the camshaft retainer and bolts.
188106
1. Clean the following components in cleaning solvent.

• The balance shaft (1)
• The balance shaft retainer (2)
188030 • The balance shaft rear bearing
• The balance shaft driven gear (4)
Tightening torque • The balance shaft drive gear
for Camshaft 1.22Kgf•m (106 lb•in) [12N•m] 2. Dry the following components with compressed air.
Retainer bolts • The balance shaft (1)
• The balance shaft retainer (2)
• The balance shaft rear bearing
• The balance shaft driven gear (4)
• The balance shaft drive gear
3. Inspect the balance shaft bearings for the following:
• Front ball bearing for damage or wear
• Front ball bearing for smoothness of operation
• Rear sleeve bearing for wear, scoring or other
damage.
4. Inspect the balance shaft (1) for the following:
• Wear or scoring on the rear bearing journal
• Damaged bolt hole threads
• Damage to the balance shaft driven gear
locator pin
5. Inspect the balance shaft retainer (2) for wear or
damage
6. Inspect the balance shaft retainer bolts (3) for
damaged threads.
7. Inspect the driven gear (4) for the following:
• Excessive wear or damage
• Nicks, burns or scoring
-85-
8. Inspect the driven gear bolt (5) for damaged 2. Remove the J 38834.
threads.
9. Inspect the balance shaft drive gear for the following:
• Excessive wear or damage J 38834-1
• Nicks, burns or scoring
J 38834-3
J 38834-2
340085
9848 Balance Shaft Installation

Tools Required
Balance Shaft Bearing and/or Bushing
Installation • J 36996 Balance Shaft Installer.
Tools Required
• J 8092 Universal Driver Handle.
• J 38834 Balance Shaft Service Kit • J 36660 Torque / Angle Meter.
1. Use the J 38834 in order to install the balance Important: The balance shaft and the balance shaft
shaft rear bearing. front bearing are serviced only as an assembly. Do
not remove the balance shaft front bearing from the
a. Install the J 38834-3 onto the short threaded
balance shaft.
end of the J 38834-1.
b. Install the J 38834 nut, the washer and the 1. Apply clean engine oil or equivalent to the
bearing on the long threaded end of the balance shaft front bearing.
J 38834-1. 2. Use the balance shaft installer J 36996 and the
c. Install the J 38834-2 onto the J 38834-1 so universal drive handle J 8092 in order to install
that the smaller diameter of the J 38834-2 will the balance shaft.
be facing the front of the engine block.
d. Install the J 38834-2 on the inside of the
balance shaft front bearing bore.
e. Lubricate the NEW balance shaft rear bearing
with clean engine oil.
f. Install the balance shaft rear bearing onto the
J 38834-2.
g. Align the balance shaft rear bearing for
installation.
h. Using a wrench, secure the J 38834- into place.
i. Rotate the J 38834 until the balance shaft rear
bearing is properly and completely pushed
into the balance shaft rear bearing bore.
J 8092 J 36996
5141
-86-
3. Install the balance shaft retainer and bolts. 7. Remove the wrench from the balance shaft.
8. Rotate the balance shaft by hand in order to
Tightening Torque ensure that there is clearance between the
for Balance 1.22Kgf•m (106 lb•in) [12N•m] balance shaft and the valve lifter pushrod guide.
Shaft bolts If the balance shaft does not rotate freely, check
to ensure that the retaining ring on the balance
shaft front bearing is seated on the case.
188031
5136
4. Install the balance shaft driven onto the balance
shaft.
5. If reusing the fastener, apply thread lock MCF P/N 9. Install the balance shaft drive gear. DO NOT
2I4264, GM P/N 12345382 or equivalent to the install the camshaft sprocket bolts at this time.
threads of the balance shaft driven gear bolt.
6. Install the balance shaft driven gear bolt.
a. Use a wrench to secure the balance shaft.
b. Place the wrench onto the balance shaft near
to the balance shaft front bearing.
c. Install the balance shaft driven gear bolt.
Tightening Torque
for Balance Shaft 2.08 Kgf•m (15 lb ft) [20N•m]
Driven gear bolt
First Pass
Tightening Torque
for Balance Shaft 35°
Driven gear bolt
Final Pass
9847
-87-
10. Rotate the engine camshaft so that the timing 12. Rotate the balance shaft so that the timing mark
mark on the balance shaft drive gear is in the on the balance shaft driven gear is in the
12 o’clock position. 6 o’clock position.
9848
9849
11. Remove the balance shaft drive gear.

13. Position the balance shaft drive gear onto the
engine camshaft.
14. Look to ensure that the balance shaft drive gear
and the balance shaft driven gear timing marks
are aligned.
9847
5144
-88-
Crankshaft, Flywheel, Rear Seal, and Bearings
Removal Steps
1. Bolt
2. Bushing - Flywheel
3. Flywheel Assy
4. Housing
5. Seal
6. Gasket
7. Hub
8. Bolt
9. Balancer
10. Crankshaft Bearing Cap
11. Lower Bearing Kit
12. Crankshaft
13. Upper Bearing Kit
-89-
Engine Flywheel Removal Crankshaft Rear Oil Seal and Housing
1. Remove the flywheel bolts. Removal
2. Remove the flywheel. 1. Remove the crankshaft rear oil seal housing nuts
and bolts.
2. Remove the crankshaft rear oil seal housing, seal,
and gasket.
4078
Engine Flywheel Clean and Inspect

1. Clean the engine flywheel in cleaning solvent.
11479
2. Dry the engine flywheel with compressed air.
3. Inspect the engine flywheel for the following: 3. Remove the crankshaft rear oil seal from the
crankshaft rear oil seal housing. Insert a screw
• Stress cracks around the engine flywheel-to-
driver into the notches provided in the rear seal
torque converter bolt hole locations (1)
retainer and pry out the seal.
• Missing balance weights
4. Discard the crankshaft oil seal.
• Stress cracks around the engine flywheel-to-
crankshaft bolt hole locations (2) or (3)
NOTE
Important: Do not attempt to repair the welded
areas (if present) that retain the ring gear to the
engine flywheel plate. Always install a NEW engine
flywheel.
• Welded areas that retain the ring gear onto the
engine flywheel for cracking (4) (if present)
• Damaged ring gear teeth (5)
31379
381965
-90-
Crankshaft and Bearings Removal 5. Remove the crankshaft bearings from the
1. Mark or Identify the crankshaft bearing cap crankshaft bearing caps
locations, direction and positions for assembly.
2. Remove the crankshaft bearing cap bolts.
3. Remove the crankshaft bearing caps.
334342
6. Remove the crankshaft bearings from the engine

block.
334329
4. Remove the crankshaft.
334338
Crankshaft and Bearings Clean and

Inspect
Tools Required
• J 7872 Magnetic Base Dial Indicator
334336
• J 36660 Electronic Torque Angle Meter
! CAUTION
Safety glasses must be worn or eye injury may occur.
-91-
Important: Use care when handling the crankshaft. 5. Inspect the crankshaft for the following:
Avoid damage to the crankshaft bearing surfaces. • Crankshaft journals (1) should be smooth
1. Clean the crankshaft in cleaning solvent. with no evidence of scoring or damage.
Remove all sludge or restrictions from the oil • Deep grooves (2)
passages. • Scratches or uneven wear (3)
2. Dry the crankshaft with compressed air. • Pitted surfaces (4)
• Wear or damage to the thrust journal surfaces
• Scoring or damage to the rear seal surface
• Restrictions to the oil passages
• Damage to the threaded bolt holes
334383
156170
3. Clean the crankshaft bearings in cleaning solvent.

Wipe the crankshaft bearings clean with a soft 6. Inspect the crankshaft balancer key (1), the
cloth, do not scratch the crankshaft bearing keyway (2) and the threaded hole (3) for
surface. damage. Repair or replace the crankshaft as
necessary.
4. Dry the crankshaft bearings with compressed air.
188090
7. Measure the crankpins for out-of-round and

334386
taper. Refer General Specifications.
188015
-92-
8. Use a suitable support to support the crankshaft
on the front and rear journals.
9. Use the magnetic dial indicator J 7872 to
measure the crankshaft journal run out. The
crankshaft run out should not exceed 0.025 mm
(0.0010 in).
188467
11. Inspect the crankshaft bearings for craters or

pockets. Flattened sections on the crankshaft
bearing halves also indicate fatigue.
35210
10. Measure the crankshaft end play.

Important: In order to properly measure the
crankshaft end play, the crankshaft, the crankshaft
bearings and the crankshaft bearing caps, the
crankshaft bearing cap bolts must be installed into
the engine block and the bolts tightened to
specifications. 52051
• Firmly thrust the crankshaft first rearward, 12. Inspect the crankshaft bearings for excessive
then forward. This will align the crankshaft scoring or discoloration.
rear bearings and the crankshaft thrust
13. Inspect the crankshaft bearings for dirt or debris
surfaces.
imbedded into the crankshaft bearing material.
• With the crankshaft pushed forward, insert a
feeler gauge between the crankshaft and the
crankshaft bearing surface and then measure
the clearance. Refer to General Specifications.
• If the correct end play cannot be obtained,
verify that the correct size crankshaft bearing
has been installed. Refer to General
Specifications.
• Inspect the crankshaft for binding. Turn the
crankshaft to check for binding. If the
52053
crankshaft does not turn freely, then loosen
the crankshaft bearing cap bolts, one bearing 14. Inspect the crankshaft bearings for improper
cap at a time, until the tight crankshaft bearing seating indicated by bright, polished sections of
is located. the crankshaft bearings.
Burrs on the crankshaft bearing cap, foreign • If the lower half of the crankshaft bearing is
matter between the crankshaft bearing and worn or damaged, both the upper and lower
the engine block or crankshaft bearing cap halves of the crankshaft bearing should be
or a faulty crankshaft bearing could cause a replaced.
lack of clearance at the crankshaft bearing. • Generally, if the lower half of the crankshaft
bearing is suitable for use, the upper half of
the crankshaft bearing should also be suitable
for use.
-93-
Service Prior to Assembly 5. Install the crankshaft bearings into the crankshaft
Dirt will cause premature wear of the rebuilt engine. bearing caps.
During assembly, lubricate all moving parts lightly 6. Apply clean engine oil to the crankshaft bearings.
with engine oil or engine assembly lubricant (unless
otherwise specified.) This will provide initial lubrica-
tion when the engine is started.
Crankshaft and Bearings Installation

Tools Required
• J 36660 Electronic Torque Angle Meter
1. Install the crankshaft bearings into the engine
block.
2. Apply clean engine oil to the crankshaft bearings.
334342
7. Install the crankshaft bearing caps in the original

position and with the arrow on the crankshaft
bearing caps in the direction of the front of the
engine block.
8. Install the crankshaft bearing cap bolts until snug.
334338
3. Apply clean engine oil to the crankshaft bearing

journals.
4. Install the crankshaft.
334329
9. Thrust the crankshaft rearward in order to set and

align the crankshaft thrust bearings and the
crankshaft bearing caps.
334336
-94-
10. Thrust the crankshaft forward in order to align • In order to determine the correct replacement
the rear faces of the crankshaft thrust bearings. crankshaft bearing size, the crankshaft bear-
11. Tighten the crankshaft bearing cap bolts. ing clearance must be measured accurately.
a. Tighten the crankshaft bearing cap bolts to Either the micrometer or plastic gauge
2.08 Kgf•m (15 lb•ft) [20N•m] on the first pass. method may be used; however, the microme-
ter method gives more reliable results and is
b. Tighten the crankshaft bearing cap bolts on
preferred. When checking connecting rod
the final pass an additional 73 degrees using bearing clearances, the plastic gauge method
the electronic torque angle meter J 36660. will result in unreliable measurements. The
Tightening torque 1st pass use of J 43690 is preferred.
for Crankshaft 2.08 Kgf•m (15 lb•ft) [20N•m] • Normally the crankshaft bearing journals wear
Bearing Cap Final pass evenly and are not out-of-round. However, if
a crankshaft bearing is being fitted to an out-
Bolts 73 degrees
of-round crankshaft bearing journal, be sure
12. Measure the crankshaft end play. to fit to the maximum diameter of the crank-
shaft bearing journal. If the crankshaft bear-
a. Firmly thrust the crankshaft rearward, and ing is fitted to the minimum diameter and the
then forward. This will align the crankshaft crankshaft bearing journal will result in rapid
rear bearing thrust surfaces. crankshaft bearing failure.
b. With the crankshaft pushed forward, insert a • If the crankshaft bearing clearance is within
feeler gauge between the crankshaft and the specifications, the crankshaft bearing is satis-
crankshaft rear bearing thrust surface to factory. If the clearance is not within specifi-
measure the clearance. cations, replace the crankshaft bearings.
Always replace both the upper and lower
Specification crankshaft bearings as a set.
Crankshaft end play 0.05-0.20 mm (0.002-0.008 in) • A standard or oversize crankshaft bearing
combination may result in the proper clearance.
13. Rotate the crankshaft in order to check for
If the proper crankshaft bearing clearance
binding. A bent crankshaft or lack of proper
cannot be achieved using the standard or the
crankshaft bearing clearance may cause binding.
undersize crankshaft bearings, it may be nec-
14. If the crankshaft does not turn freely, loosen the essary to repair or replace the crankshaft.
crankshaft bearing cap bolts on 1 crankshaft
bearing cap at a time in order to determine the
location of the binding. A lack of proper
crankshaft bearing clearance may be caused
by the following:
• Burrs on the crankshaft bearing cap
• Foreign material between the crankshaft
bearing and the engine block 188015
• Foreign material between the crankshaft

bearing and the crankshaft bearing cap Micrometer Method for Crankshaft
• Damaged crankshaft bearing Bearings
• Improper size crankshaft bearing 1. Measure the crankshaft journal diameter with a
micrometer in several places, approximately 90
Measure Crankshaft Bearing Clearances degrees apart, and then average the measurements.
2. Determine the taper and the out-of-round of the
• The crankshaft bearings are of the precision
crankshaft journal. Refer to General Specifications.
insert type and do not use shims for adjust-
3. Install the crankshaft bearings into the engine block
ment. If the clearances are excessive, then
or connecting rod assembly.
new upper and lower crankshaft bearings will
be required. The service crankshaft bearings
are available in the standard size and an
undersize.
• The selective fitting of the crankshaft bear-
ings are necessary in production in order to
obtain close tolerances. For this reason, in
one journal bore you may use one-half of a
standard crankshaft bearing with one-half of
a undersize crankshaft bearing.
334338
-95-
4. Install the bearing cap bolts and tighten to 10. If the crankshaft bearing clearances exceeds
specifications. specifications, install new crankshaft bearings
as follows:
a. Measure the crankshaft bearing inside
diameter (ID) at the top and the bottom
using an inside micrometer.
b. Compare the crankshaft bearing clearance
to the specifications. Refer to General
Specifications.
11. Replace or repair the crankshaft if the proper
clearances cannot be obtained.
Micrometer Method for Connecting Rod

Bearings
Important: Do not shim, scrape or file bearing
353070 inserts. Do not touch the bearing surface of the
insert with bare fingers. Skin oil and acids will etch
5. Install the crankshaft bearing caps in the original the bearing surface.
positions and with the arrow on the crankshaft 1. Measure the crankpin diameter with a micrometer
bearing caps in the direction of the front of the in several places, approximately 90 degrees
engine block. apart, and then average the measurements.
6. Install the crankshaft bearing cap bolts and 2. Determine the taper and the out-of-round. Refer
tighten to the specified torque using a two step to General Specifications.
method. 3. Install the connecting rod bearings into the
connecting rod cap and the connecting rod.
Tightening torque
4. Install the connecting rod caps and the nuts and
for Crankshaft 2.08 Kgf•m (15 lb ft) [20 N•m] tighten to the specified torque by a two step
Bearing Cap
method. Torque all nuts to the specified torque
bolts First Pass
on the first pass. Tighten the nuts on the final
Tightening torque pass an additional 70 degrees using the
for Crankshaft electronic torque angle meter J-36660.
Additional 73°
Bearing Cap
bolts Final Pass Tightening torque for Connecting 2.77 Kgf•m
Rod Cap Nuts First Pass (20 lb ft) [27 N•m]
7. Measure the bearing inside diameter (ID) at two
points 90 degrees apart. Tightening torque for Connecting Additional 70°
8. In order to determine the crankshaft bearing Rod Cap Nuts Final Pass
clearance, subtract the average journal diameter 5. Measure the connecting rod bearing inside
from the average bearing inside diameter. diameter (ID) at the top and the bottom using an
9. Compare the crankshaft bearing clearance to inside micrometer.
the specifications. Refer to General Specifications. 6. Compare the connecting rod bearing clearance
to the specifications. Refer to General
Specifications.
7. If the connecting rod bearing clearance is within
specifications, the connecting rod bearing is
satisfactory.
• Replace the connecting rod bearing if the
clearance is not within specifications.
• Always replace both the upper and the lower
connecting rod bearings as an assembly.
8. A standard or undersize connecting rod bearing
combination may result in the proper clearance.
If the proper connecting rod bearing clearance
cannot be achieved using the standard or the
undersize connecting rod bearings, it will be neces-
-96- sary to replace or repair the crankshaft.
Measuring Connecting Rod Bearing 5. Install the foot (1) and bolt (2) to the pivot arm
Clearances J43690 Method assembly (3). Tighten the bolt until snug.
1. Remove the oil pan and other necessary compo-
nents to gain access to the connecting rods.
Remove the oil pump, screen and deflector
(when applicable).
2. Rotate the crankshaft until the crankshaft jour-
nal/connecting rod to be measured is in the
10 o’clock position.
Important: The crankshaft must be secure with no
movement or rotation in order to obtain an accurate
reading. Remove an intermediate bearing cap (as
required) in order to secure the crankshaft and allow
measurement of connecting rod bearing clearances.
3. Remove the bearing cap bolts (1), cap (2) and
bearing half.
Notice: Refer to Fastener Notice in Cautions and
Notices.
6. Install the screw (1 or 3) to the pivot arm
4. Insert a piece of paper card stock onto the assembly (2).
crankshaft journal. Install the bearing half, bearing
cap and bolts. Refer to Fastener Tightening
Specifications.
7. Install the pivot arm assembly (1) onto the

connecting rod.
-97-
8. Position the foot of the pivot arm assembly 11. Align the center of the base (1) with the screw
over the large end of the connecting rod bolt. (3) of the pivot arm assembly. Tighten the bolt
9. Position the screw (1) onto the small end of the (2) until snug.
connecting rod bolt and tighten securely.
12. Align the link (1) of the pivot arm assembly on a

plane (3) equal to that of the connecting rod
10. Install the base (1) and bolt (2) to the oil pan rail.
beam (2).
-98-
13. With the link of the pivot arm assembly aligned Important: The clamp of the swivel base and the
to the beam of the connecting rod, position the shaft of the indicator should be free of oil or other
pivot arm to the base and insert the pin (1). debris. A loose or improperly clamped indicator may
indicate incorrect readings.
16. Install the indicator (2) to the swivel base (1).
Tighten the clamp of the baser until snug.
14. Install the handle (1) to the pivot arm assembly.
17. Install the swivel base (1) to the oil pan rail of
the engine block. Tighten until snug.
15. Select the adapter (2) (as required) and install

to the swivel base (1). Tighten until snug.
-99-
18. Adjust the swivel base as required and position 21. Lightly actuate the handle of the pivot arm
the indicator tip slightly above the connecting assembly (multiple items in both directions) to
rod cap. Lock the swivel base in position by ensure the oil film is removed from the journal.
rotating the locking lever (1). Do not allow the
tip of the indicator to contact the connecting
rod at this time.
19. The tip of the indicator should be positioned

above and NOT in contact with the cap end of 22. Load the handle in the forward position and
the connecting rod. zero the dial indicator. Load the handle multiple
times in both directions and record the reading.
Important: During this procedure, card stock may
enter the crankshaft journal oil galleries. Be sure to
remove all card stock from the bearing journal and
oil galleries prior to reassembly.
23. Remove the bearing cap bolts, cap and paper
stock.
24. Replace the bearing halves as required to
obtain the proper bearing clearance.
20. Rotate the fine adjustment knobs on the dial

indicator end of the swivel base to position the tip
of the indicator in contact with the connecting rod.
-100-
Plastic Gauge Method for Crankshaft 4. Install the crankshaft bearings into the crankshaft
Bearings bearing caps.
1. Install the crankshaft bearings into the engine
block.
334342
334338 5. Install the crankshaft bearing caps in the original

2. Install the crankshaft. positions and with the arrow on the crankshaft
bearing caps in the direction of the front of the
engine block.
6. Install the crankshaft bearing cap bolts and
tighten in a two step method. First pass tighten
to the specified torque and the final pass tighten
an additional 73 degrees using the electronic
torque angle meter J 36660.
Tightening Torque
for Crankshaft 2.08 Kgf•m (15 lb ft) [20 N•m]
Bearing Cap
Bolts First Pass
Tightening Torque
for Crankshaft Additional 73°
Bearing Cap
Bolts Final Pass
334336
3. Install the gauging plastic the full width of the

journal. 7. Remove the crankshaft bearing cap bolts.
8. Remove the crankshaft bearing caps. The
gauging plastic may adhere to either the
crankshaft bearing journal or the crankshaft
bearing surface.
334336
-101-
9. Without removing the gauging plastic, measure Connecting Rod Side Clearance
the compressed width at the widest point using Measuring Procedure
the graduated scale on the edge of the gauging
plastic envelope. 1. Insert a feeler gauge between the connecting
If the flattened gauging plastic tapers toward the rod caps and measure the connecting rod side
middle or the ends, there may be a difference in clearance. Refer to General Specifications.
clearance indicating taper, low spot or other 2. Connecting rod side clearances may also be
irregularity of the crankshaft bearing or the measured with a dial indicator set.
crankshaft bearing journal.
• Normally the crankshaft bearing journals wear
evenly and are not out-of-round. However, if
a crankshaft bearing is being fitted to an out-
of-round 0.0254 mm (0.0010 in) (maximum)
crankshaft bearing journal, be sure to fit to
the maximum diameter of the crankshaft
bearing journal. If the crankshaft bearing is
fitted to the minimum diameter and the
crankshaft bearing journal is excessively out-
of-round, the interference between the crank-
shaft bearing and the crankshaft bearing jour-
nal will result in rapid crankshaft bearing failure.
• If the crankshaft bearing clearance is within
specifications, the crankshaft bearing is
satisfactory. If the clearance is not within 5163
specifications, replace the crankshaft bearing.

Always replace both the upper and lower Crankshaft Balancer Clean and Inspect
crankshaft bearings as a unit.
• A standard or undersize crankshaft bearing
combination may result in the proper clear- ! CAUTION
ance. If the proper crankshaft bearing clear-
ance cannot be achieved using the standard Refer to Safety Glasses Caution in Cautions
or the undersize crankshaft bearings, it may be and Notices.
necessary to repair or replace the crankshaft. 1. Clean the crankshaft balancer in cleaning solvent.
Important: Do not shim, scrape or file bearing 2. Dry the crankshaft balancer with compressed air.
inserts. Do not touch the bearing surface of the 3. Inspect the crankshaft balancer for the following:
insert with bare fingers. Skin oil and acids will etch
• Loose or improperly installed front groove
the bearing surface.
pin (1) (crankshaft balancer)
10. Remove the flattened gauging plastic.
A properly installed front groove pin should
11. Measure the remaining crankshaft bearing be installed until flush or below flush with
journals. the face of the crankshaft balancer.
Important: A crankshaft front oil sealing surface
with excessive scoring, grooves, rust or other dam-
age must be replaced.
• Worn, grooved or damaged crankshaft front
oil sealing surface (2)
Minor imperfections on the crankshaft
balancer crankshaft front oil seal surface
may be removed with a polishing compound
or fine grade emery cloth.
• Worn, chunking or deteriorated rubber (3)
between the hub and the outer ring
• Worn or damaged keyway (4)
• Worn or damaged bolt hole threads (5)
-102-
Important: Always use a NEW crankshaft rear oil
seal housing gasket when installing the crankshaft
rear oil seal housing.
2. Install the NEW crankshaft rear oil seal housing
gasket.
Crankshaft Rear Oil Seal and Housing

Installation
Tools Required
• J 35621-B Rear Main Seal Installer
3. Install the crankshaft rear oil seal housing onto
Notice: Refer to Fastener Notices in Cautions and the crankshaft rear oil seal housing retainer stud.
Notices. 4. Install the crankshaft rear oil seal housing nut
1. Install the crankshaft rear oil seal housing and bolts.
retainer stud.
Tightening torque for 1.22 Kgf•m
crankshaft rear oil seal (106 lb ft)
Tightening torque for 1.22 Kgf•m
housing nut and bolts [12 N•m]
crankshaft rear oil seal (53 lb ft)
housing retainer stud [6 N•m]
-103-
5. Apply a small amount (2 to 3 drops) of clean 14. Install the crankshaft rear oil seal onto the
engine oil to the bore of the crankshaft rear oil crankshaft and into the crankshaft rear oil seal
seal housing. housing.
6. Apply a small amount (2 to 3 drops) of clean a. Turn the J 35621-B wing nut clockwise
engine oil to the outside diameter of the engine until the crankshaft rear oil seal is installed
flywheel pilot flange. near to flush and square to the crankshaft
7. Apply a small amount (1 drop) of clean engine oil rear oil seal housing.
to the outside diameter of the flywheel locator pin. Increased resistance will be felt when the
crankshaft rear oil seal has reached the
8. Apply a small amount (2 to 3 drops) of clean
bottom of the crankshaft rear oil seal
engine oil to the crankshaft seal surface.
housing bore.
9. Inspect the J 35621-B flange for imperfections b. Turn the J 35621-B wing nut counterclock-
that may damage the crankshaft rear oil seal. wise to release the J 35621-B from the
Minor imperfections may be removed with a fine crankshaft rear oil seal.
grade emery cloth.
15. Remove the J 35621-B from the crankshaft.
Important: DO NOT allow oil or any other lubricants
16. Wipe off any excess engine oil with a clean rag.
to contact the seal lip of the crankshaft rear oil seal.
Engine Flywheel Clean and Inspect
! CAUTION
and Notices.
1. Clean the engine flywheel(1) or (2) in cleaning
solvent.
2. Dry the engine flywheel with compressed air.
10. Remove the sleeve from the crankshaft rear oil

seal.
11. Apply a small amount (2 to 3 drops) of clean
engine oil to the outside diameter of the
crankshaft rear oil seal.
12. Install the crankshaft rear oil seal onto the
J 35621-B.
13. Install the J 35621-B onto the rear of the
crankshaft and hand tighten the tool bolts
until snug.
Notice: Proper alignment of the crankshaft rear oil
seal is critical. Install the crankshaft rear oil seal near 3. Inspect the engine flywheel (automatic transmis-
to flush and square to the crankshaft rear oil seal sion) (if equipped) for the following:
housing. Failing to do so may cause the crankshaft • Stress cracks around the engine flywheel-
rear oil seal or the crankshaft rear oil seal installation to-torque converter bolt hole locations (1)
tool to fail. • Missing balance weights
• Stress cracks around the engine flywheel-
to-crankshaft bolt hole locations (2) or (3)
-104-
Important: Do not attempt to repair the welded areas 5. Inspect the engine flywheel (manual transmis-
(if present) that retain the ring gear to the engine fly- sion) (if equipped) for the following:
wheel plate. Always install a NEW engine flywheel. • Pitted friction surface (1)
• Welded areas that retain the ring gear onto • Scoring or grooves (2)
the engine flywheel for cracking (4) (if present). • Damaged ring gear teeth (4)
• Damaged ring gear teeth (5) • Loose or improperly positioned ring gear
The ring gear has an interference fit onto the
engine flywheel and the ring gear should be
positioned completely flat against the flange
of the engine flywheel.
4. Inspect the engine flywheel (manual transmis-

sion) (if equipped) for loose or improperly
installed flywheel weights (if applicable).
A properly installed flywheel weight should be
installed until flush or below flush with the face
of the engine flywheel.
Engine Flywheel Installation

1. Install the engine flywheel to crankshaft.
2. Align the locator hole to the pin.
3. Install the engine flywheel bolts.
Tightening torque
for engine 10.25 Kgf•m (74 lb•ft) [100 N•m]
flywheel bolts
4078
-105-
Clutch Pilot Bearing Installation
! CAUTION
and Notices.
1. Install the NEW clutch pilot bearing using a
suitable clutch pilot bearing installation tool.
2. Measure to ensure the proper installation depth
is obtained.
-106-
Cylinder Block
Cleaning and Inspection
Disassembly steps
1. Engine support (R.H.)
2. Engine support (L.H.)
3. Cylinder block
7EN0035
-107-
Engine Block Plug Removal 3. Remove the engine oil pressure sensor fitting.
Tools Required
• J 41712 Oil Pressure Switch Socket
1. Remove the knock sensor from the engine block.
188020
4. Remove the dowel straight pins (transmission

locator) (if required).
10793
2. Remove the engine oil pressure gauge sensor

using the oil pressure switch socket J41712.
334350
5. Remove the engine block left side oil gallery plug.

6. Remove the engine block left rear oil gallery plug.
7. Remove the engine block right rear oil gallery plug.
J 41712
188018
5271
-108-
8. Remove the expansion cup plug (camshaft rear 10. Remove the spring type S pin (crankshaft rear
bearing hole) and discard. oil seal housing locator) (if required).
334323
11. Remove the front oil gallery plugs or balls from

the front of the engine block and discard.
12. Insert a 3/8 x 26 in. rod into the rear oil gallery
334364 holes in order to drive out the front oil gallery
plugs or balls.
9. Remove the expansion cup plug (balance shaft
rear bearing hole) and discard.
5270
13. Remove the engine block core hole plugs.

a. Use a suitable tool in order to drive the engine
block core hole plugs into the coolant jacket.
b. Use a suitable tool in order to pull the engine
block core hole plugs from the coolant jacket.
c. Discard the engine block core hole plugs.
334366
480550
-109-
14. Remove the oil filter bypass valve and discard. 1. Clean all the remaining sealing or gasket material
from the sealing surfaces.
2. Clean the engine block with cleaning solvent.
3. Flush the engine block with clean water or steam.
4. Clean the cylinder bores.
5. Clean the oil galleries and the oil passages.
6. Clean the scale and the deposits from the
coolant passages.
Notice: Clean all debris, dirt and coolant from the
engine block cylinder head bolt holes. Failure to
remove all foreign material may result in damaged
threads, improperly tightened fasteners or damage
to the components.
7. Clean the engine block cylinder head bolt holes.
8. After cleaning the engine block, spray or wipe the
cylinder bores and the machined surfaces with
188026 clean engine oil.
9. Inspect the following areas:
• Coolant jackets (1) for cracks
Engine Block Clean and Inspect • Cylinder bores (2) for scratches or gouging
Tools Required • Valve lifter bores (3) for excessive scoring or wear
• J 8087 Cylinder Bore Gauge • Threaded holes (4) for damage
• Crankshaft bearing webs (5) for cracks
• Crankshaft bearing caps (6) and the crankshaft
! CAUTION bearing bores (7) for damage
■ The crankshaft bearing bores should be
Safety Glasses must be worn or eye injury may occur. round and uniform when measuring the
inside diameter (ID).
■ The surface where the crankshaft bearings
contact the crankshaft bearing bore should

be smooth.
■ If a crankshaft bearing cap is damaged and
requires replacement, replace the crankshaft

bearing cap first, then rebore the engine
block crankshaft bearing bores and check
for proper alignment. Finally, check the
crankshaft for the proper clearances.
• Engine block core hole plug bores (8) for damage
• Engine block (9) for cracks or damage
• Engine mount bosses (10) for damage
10. Measure the cylinder bores for taper and out-of-
round.
a. Depress the plunger on the cylinder bore guage
J 8087 7 mm (0.275 in) or until the J 8087
enters the cylinder bore.
b. Center the cylinder bore guage J 8087 in the
cylinder bore and turn the indicator dial to 0.
c. Move the cylinder bore guage J 8087 up and
down the cylinder bore to determine the
cylinder bore taper. Refer to General
Specifications.
d. Turn the J8087 to different points around the
cylinder bore to determine the cylinder bore
334378 out-of-round condition. Refer to Engine
Mechanical Specifications.
-110-
Cylinder Boring and Honing
Honing Procedure
1. When honing the cylinder bores, follow the
manufacturer’s recommendations for equipment
use, cleaning and lubrication.
J 8087
• Use only clean sharp stones of the proper
grade for the amount of material to be removed.
• Dull, dirty stones cut unevenly and generate
excessive heat.
• DO NOT hone to a final grade with a coarse or
medium- grade stone.
• Leave sufficient metal so that all the stone
marks will be remove with the fine grade stones.
• Perform the final honing with a fine-grade
stone and hone the cylinder bore in a cross-
hatch pattern at 45-65 degrees to obtain the
NOTE proper clearance.
Caution: Do not grind the mating surfaces of the
cylinder block and cylinder head beyond 0.2 mm
(0.008 in.) of total grinding limit.
186747
7EN266 2. During the honing operation, thoroughly check

the cylinder bore.
11. Check the Cylinder head mounting surface for • Repeatedly check the cylinder bore fit with the
flatness, using a precision straight edge and selected piston.
feeler gauge.
• All measurements of the piston or cylinder bore
• Set the straight edge on the sealing surface to should be made with the components at
be inspected. normal room temperature.
• Put the feeler gauge at various locations; 3. When honing to eliminate taper in the cylinder
check the gap between the straight edge and bore, use full strokes the complete length of the
the sealing surface. cylinder bore.
• If the gap is greater than 0.05 mm (0.002 in.) 4. Repeatedly check the measurement at the top,
within 152 mm (6 in.) at any sealing location,
the middle and the bottom of the cylinder bore.
the block must be replaced.
• The finish marks should be clean but not sharp.
• If the gap is found to be less than 0.05 mm
(0.002 in.) at any sealing location and a cause
• The finish marks should be free from imbedded
particles or torn or folded material.
for leakage is suspected, then the minor
irregularities may be carefully machined from 5. By measuring the selected piston at the sizing
the block. point and then by adding the average of the
clearance specification, the final cylinder bore
12. Check the Oil pan, timing cover and intake
honing dimension required can be determined.
manifold mounting surfaces for nicks. Minor
irregularities may be cleaned up with a flat file.
-111-
6. When finished, the reconditioned cylinder bores 3. From the piston O.D. measurement, calculate
should have less than or meet the specified out- the valve of the cylinder bore to which every
of-round and taper requirements. cylinder is to be rebored.
7. After the final honing and before the piston is Rebore diameter = Piston O.D. + 0.02 mm
checked for fit, clean the cylinder bore with hot (8 x 10-4 in.) to 0.04 mm (1.6 x 10-3 in.)
water and detergent. (Cylinder-to-piston clearance) - 0.02 mm
• Scrub the cylinder bores with a stiff bristle brush. (8 x 10-4 in.) (honing allowance)
• Rinse the cylinder bores thoroughly with clean 4. Rebore all cylinders to the calculated diameter.
hot water.
• Dry the cylinder bores with a clean rag. NOTE
• Do not allow any abrasive material to remain
in the cylinder bores. Reboring should be made in the order of the
■ Abrasive material may cause premature
cylinders numbers to prevent warping due to
wear of the new piston rings and the excessive temperature.
cylinder bores.
■ Abrasive material will contaminate the
5. With a hone,
engine oil and may cause premature wear a. Recondition the cylinders that have less than
of the bearings. 0.025 mm (0.0010 in.) wear or taper.
8. Perform final measurements of the piston and b. Bore and hone the cylinders that have more
the cylinder bore. than 0.025 mm (0.0010 in.) of wear or taper to
9. Permanently mark the top of the piston for the the smallest oversize piston that will permit
specified cylinder to which it has been fitted. complete resurfacing of all the cylinders.
10. Apply clean engine oil to each cylinder bore in 6. Hone the cylinders to the finished size (piston O.D.
order to prevent rusting. + piston-to-cylinder clearance).
• During the honing operations occasionally:
– Clean the cylinder bore.
– Measure the cylinder bore for a proper piston fit.
Reboring the Cylinders
NOTE Boring Procedure

Important: Handle the pistons with care. Do not
force the pistons through the cylinders until you ! CAUTION
hone the cylinder to the correct size. The piston
Safety Glasses must be worn or eye injury may occur.
can be distorted through careless handling.
1. Before starting the honing or reboring operation,
1. To determine the size of the oversize piston to be
measure all the new pistons with the micrometer
used in all cylinders, choose the cylinder that
contacting at points exactly 90 degrees from the
requires the largest amount of reboring and use
piston pin centerline.
its size as the basis for all piston sizes.
2. Two kinds of oversize pistons are available;
0.50 mm (0.02 in.) O.S. and 1.00 mm (0.039 in.)
O.S. Those oversizes are based on the piston
skirt O.D. measured along the datum line as
shown in the figure. For all cylinders, select
oversize pistons with the same diameter.
7EN268 188016
-112-
2. File the top of the cylinder block in order to 2. Apply sealant MCF P/N 2I4256 GM P/N
remove any dirt or burrs before using any type of 12346004 or equivalent to the outside diameter
boring bar. of the new front engine oil gallery plugs.
3. Follow the instructions furnished by the 3. Install the new front engine block oil gallery
manufacturer regarding the use of the boring plugs. A properly installed front engine oil gallery
equipment. plug must be installed slightly below flush with
4. When reboring the cylinders, make sure all the the front face of the engine block.
crankshaft bearing caps are installed in the
original position and direction.
5. Tighten the crankshaft bearing caps to the proper
torque specifications in order to avoid distortion
of the cylinder bores in the final assembly.
6. When making the final cut with the boring bar,
leave 0.03 mm (0.001 in) on the cylinder bore
diameter for finish honing. This gives the required
position to the cylinder clearance specifications.
(Carefully perform the honing and boring
operation in order to maintain the specified
clearances between the pistons, the piston rings
and the cylinder bores). 5270
7. Check each cylinder for proper cylinder-to-piston

clearance. 4. Apply threadlock GM P/N 12345382 or
equivalent to the outside diameter of the NEW
engine block core hole plugs.
Engine Block Plug Installation
5. Install the NEW engine block core hole plugs.
Installation Procedure
Properly installed engine block core hole plug
Tools Required must be installed flush with the bottom of the
• J 41712 Oil Pressure Switch Socket chamfer (1) of the engine block core hole.
! CAUTION
Wear safety glasses in order to avoid eye damage.
1. Install a new oil filter bypass valve.
a. Install the oil filter bypass valve into the oil
gallery bore until slightly below flush with the
surface of the engine block.
b. Using a pointed punch, stake the engine block
area around the oil filter bypass valve. Stake in
3 locations 120 degrees apart.
6. Install the spring type S pin (crankshaft rear oil

seal housing locator) (if required).
188023
-113-
11. Apply sealant MCF P/N 2I4256 GM P/N
engine block right rear oil gallery plug, the
engine block left rear oil gallery plug, and the
engine block left side oil gallery plug.
Tightening torque
for left and right 2.08 Kgf•m (15 lb•ft) [20N•m]
side rear oil
gallery plugs
Tightening torque
for left rear 3.05 Kgf•m (22 lb•ft) [30 N•m]
oil gallery plug
334546
7. Apply sealant MCF P/N 2I4256/GM P/N

12346004 or equivalent to the outside diameter
of the new expansion cup plug (balance rear
bearing hole).
8. Install the new expansion cup plug (balance shaft
rear bearing hole).
182841
12. Install the dowel straight pins (transmission

334540

12346004 or equivalent to the outside diameter
of the new expansion cup plug (camshaft rear
bearing hole).
10. Install the new expansion cup plug (camshaft
rear bearing hole).
334548
-114-
13. Install the left side dowel pins (cylinder head 16. Install the engine block coolant drain hole plug.
Tightening torque
for engine block 2.08 Kgf•m (15 lb•ft) [20N•m]
coolant drain
hole plug
188052
334303
14. Install the right side dowel pins (cylinder head 17. Apply sealant MCF P/N 2I4256/GM P/N
locator) (if required). 12346004 or equivalent to the threads of the
engine oil pressure sensor fitting.
NOTE
Important: Do not loosen the engine oil pressure
fitting after the initial torque has been obtained.
Tightening torque
for engine oil 1.52 Kgf•m (11 lb•ft) [15 N•m]
pressure sensor
fitting
334314

engine block coolant drain hole plug.
-115-
18. Install the engine oil pressure sensor fitting. 23. Install the knock sensor.
NOTE
Tightening torque
Important: Do not rotate the engine oil pressure for 2.08 Kgf•m (15 lbf•ft) [20 N•m]
fitting clockwise more than 359 degrees after the knock sensor
initial torque has been obtained.
19. Rotate the engine oil pressure sensor fitting
clockwise to the proper position (1) 50 degrees
from the centerline.
10793
20. Apply sealant MCF P/N 2I4256/GM P/N 12346004

or equivalent to the threads of the engine oil
pressure gauge sensor.
21. Install the engine oil pressure gauge sensor
using the oil pressure switch socket J 41712.
22. Apply sealant MCF P/N 2I4256/GM P/N 12346004
or equivalent to the threads of the knock
sensor.
Tightening torque
for engine oil 3.05 Kgf•m (22 lb•ft) [30 N•m]
pressure gauge
sensor
J 41712 188018
-116-
Piston and Connecting Rod
Removal steps
1. Nut
2. Rod Cap
3. Bearing
4. Bearing
5. Piston and Connecting Rod Assy
6. Pin
7. Rod - Connecting
8. Piston
9. Ring Kit
-117-
Piston, Connecting Rod, and Bearing NOTE
Removal
Tools Required Important: Place matchmarks or numbers on the
connecting rods and the connecting rod caps.
• J 24270 Cylinder Bore Ridge Reamer Assemble the connecting rod caps to the matching
• J 5239 Guide Set connecting rods.
1. Use the cylinder boer ridge reamer J 24270 to 2. Remove the connecting rod nuts.
remove the cylinder ring ridge. 3. Remove the connecting rod cap.
a. Turn the crankshaft until the piston is at the 4. Remove the connecting rod bearings.
bottom of the stroke. • Keep the bearings with the original connecting
b. Place a cloth on top of the piston. rod and connecting rod cap.
c. Use a ridge reamer to remove cylinder ring ridge. • Wipe the oil from the bearings.
d. Turn the crankshaft so the piston is at the top • Wipe the oil from the crankpins.
of the stroke.
e. Remove the cloth.
f. Remove the cutting debris.
480549
11497
5. Use the guide set J 5239 to protect the crankshaft
vournals and to remove the connecting rod and
the piston out of the top of the engine block.
31373
-118-
Piston and Connecting Rod Disassemble 4. Mark, separate and organize the parts for
Tools Required assembly.
• J 24086 Piston Pin Remover/Installer
NOTE
Important: Mark the piston for installation to the
proper cylinder.
1. Remove the piston rings from the pistons.
34671
Piston, Connecting Rod and Bearings

Clean and Inspect
Important: Measurement of all components should
be taken with the components at room temperature.
Do not use a wire brush in order to clean any part of
the piston.
! CAUTION
4967
2. Press the piston pin from the connecting rod

Safety Glasses must be worn or eye injury may occur.
using the piston pin remover/installer J 24086-C.
3. The piston pin has an interference fit into the 1. Clean the piston and connecting rod in solvent.
connecting rod, and is full floating in the piston. 2. Dry the components with compressed air.
J 24086-C
4965 34671
-119-
3. Clean the piston ring grooves with a suitable ring 6. Inspect the piston pin for scoring, wear or other
groove cleaning tool. damage.
7. Measure the piston ring-to-piston ring groove side
clearance.
a. Insert the edge of the piston ring into the piston
ring groove.
b. Roll the piston ring completely around the piston.
■ If binding is caused by a distorted piston
ring groove, MINOR imperfections may be
removed with a fine file.
■ If binding is caused by a distorted piston
ring, replace the piston ring.
4977
4. Clean the piston oil lubrication holes and slots.

5. Inspect the piston for the following:
• Eroded areas (1) on the top of the piston
• Scuffed or damaged skirt (2)
• Damage to the pin bore (3)
• Cracks in the piston ring lands, the piston skirt
or the pin bosses
4969
• Piston ring grooves for nicks, burrs or other
warpage which may cause the piston ring to 8. Measure the piston ring side clearance with a
bind feeler gauge.
9. If the side clearance is too small, try another
piston ring set.
10. If the proper piston ring-to-piston ring groove
clearance cannot be achieved, replace the pis-
ton and pin assembly.
11. To determine the proper piston ring side clearance,
refer to General Specifications.
156168
22934
-120-
12. To determine piston pin-to-bore clearance, use
a micrometer and measure the piston pin.
188016
16. Inspect the connecting rod for an out-of-round

bearing bore. Refer to General Specifications.
4976
13. To determine piston pin-to-bore clearance, use

an inside micrometer and measure the piston
pin bore.
14. To determine the piston pin-to-bore clearance,
subtract the piston pin diameter from the piston
pin bore diameter. Refer to General
Specifications.
156167
17. Inspect the connecting rod for twisting.

18. Inspect the connecting rod for damage to the
bearing cap and bolt threads.
4975
15. Measure the piston with a micrometer at a right

angle to the piston pin bore, measure the piston
at 11 mm (0.433 in) from the bottom of the
skirt. Refer to General Specifications. If the pis-
ton is not within specifications, replace the pis-
ton and pin as an assembly.
156169
-121-
19. Measure the piston compression ring end gap. 2. Measure the cylinder bore guage J 8087 with a
Important: Fit each compression ring to the cylinder micrometer and record the reading.
in which it will be used.
20. Place the compression ring into the cylinder bore.
a. Push the compression ring into the cylinder J 8087
bore to approximately 6.5 mm (0.25 in) above
the ring travel. The ring must be square to
the cylinder wall.
b. Use a feeler gauge in order to measure the
end gap.
c. Select another size ring set if the end gap
exceeds specifications. Refer to General
Specifications.
4974
3. With a micrometer or caliper at a right angle to

the piston pin bore, measure the piston 11 mm
(0.433 in) from the bottom of the skirt.
4. Subtract the piston diameter from the cylinder
Piston Selection bore diameter in order to determine piston-to-
Tools Required bore clearance. Refer to General Specifications.
• J 8087 Cylinder Bore Gauge 5. If the proper clearance cannot be obtained, then
select another piston and measure the clearances.
Important: Measurements of all components should If the proper fit cannot be obtained, the cylinder
be taken with the components at normal room tem- bore may require honing or boring.
perature. 6. When the piston-to-cylinder bore clearance is
For proper piston fit, the engine block cylinder bores within specifications, permanently mark the top
should not have excessive wear or taper. of the piston for installation into the proper cylinder.
A used piston and piston pin set may be reinstalled
if, after cleaning and inspection, the piston and pis-
ton pin are within specifications.
1. Use the cylinder bore guage J 8087 to measure
the cylinder bore diameter. Measure at a point
64 mm (2.5 in) from the top of the cylinder bore
and 90 degrees to the crankshaft centerline.
J 8087
188016
4972
-122-
Piston, Connecting Rod and Bearing Important: The mark on top of the piston must face
Installation the front of the engine block. When assembled, the
Tools Required flanges on the connecting rod and connecting rod
cap should face the front of the engine block on the
•J 5239 Guide Set left bank, and to the rear of the engine block on the
•J 8037 Piston Ring Compressor right bank.
•J 36660 Torque Angle Meter
4. Install the piston and connecting rod assembly,
1. Coat the following components with clean and the piston ring compressor J 8037 into the
engine oil: proper cylinder bore.
• The piston
• The piston rings
• The cylinder bore
• The bearing surfaces
2. Install the guide set J 5239 onto the connecting
rod bolts.
J 5239
J 8037
492144
5. Use the piston ring compressor J 8037 and the

guide set J 5239 to lightly tap the top of the
piston with a wooden hammer handle.
387765 a. Hold the piston ring compressor J 8037 firmly
against the engine block until all of the piston
3. Install the piston ring compressor J 8037 onto the rings enter
piston and compress the piston rings.
J 8037
J 8037
480573 5159
-123-
b. Use the guide set J 5239 to guide the 8. After the piston and connecting rod assemblies
connecting rod onto the crankshaft journal. have been installed, then lightly tap each
6. Remove the piston ring compressor J 5239. connecting rod assembly (parallel to the crankpin)
in order to insure that the connecting rods have
side clearance.
J 5239
5163
9. Use a feeler gauge or a dial indicator to measure

the connecting rod side clearance between the
31373 connecting rod caps. The connecting rod side
clearance should be 0.16-0.44 mm (0.006-0.017 in.).
7. Install the connecting rod cap, bearings and nuts.
Tightening torque 1st pass

for rod cap nuts 2.77 Kgf•m (20 lbf•ft) [27 N•m] Piston and Connecting Rod Assemble
Tools Required
• On the final pass, use the electronic torque • J 24086-C Piston Pin Remover/ Installer
angle meter J 36660 to tighten the nuts an
additional 70 degrees.
! CAUTION
Tightening torque Final pass Avoid contact with HOT components. Wear
for rod cap nuts Additional 70° safety glasses and protective gloves to avoid
personnel injury.
NOTE
Important: Applying excessive heat to the connect-
ing rod may damage or distort the rod. Rod temper-
ature SHOULD NOT exceed 315°C (600°F). At this
temperature, the end of the connecting rod will turn
a straw color upon visual inspection.
NOTE
Important: After the MCF-1083 (J 24086-C)
installer hub bottoms on the support assembly, DO
NOT exceed 35,000 kPa (5,000 psi) or the tool may
be damaged.
480545
-124-
2. Install the piston rings onto the piston.
NOTE a. Install the oil control piston ring spacer.
Important: When assembling the piston and b. Install the lower oil control piston ring.
connecting rod, the mark on the top of the piston c. Install the upper oil control piston ring.
must point to the front of the engine block. The left d. Install the lower compression piston ring. The
bank connecting rods should have the flange face mark on the side of the piston ring should face
toward the front of the engine block. The right bank the top of the piston.
connecting rods should have the flange face toward e. Install the upper compression piston ring. The
the rear of the engine block. mark on the side of the piston ring should face
The piston pin has an interference fit into the the top of the piston.
connecting rod and is full floating in the piston.
1. Install the piston pin and connecting rod assembly.

a. Lubricate the piston holes in both the piston
and the connecting rod assembly with clean
engine oil.
b. Use a torch and apply MILD heat to the piston
pin end of the connecting rod.
c. Press the piston pin into the piston and
connecting rod assembly using the piston pin
remover/installer J 24086-C.
d. Inspect for proper installation of the piston
and piston pin. The piston must move freely on
the piston pin with no binding or interference.
490763
J 24086-C 3. Space the compression piston ring end gaps

120 degrees apart.
4. Space the oil control piston ring end gaps a
minimum of 90 degrees apart.
4965
NOTE
Important: Use a piston ring expander to install the
piston rings. The rings may be damaged if expand-
ed more than necessary.
-125-
-126-
Gasoline Carburetor
1. Carburetor
2. Fuel Inlet
3. Intake Air Connector
4. Accelerator Cable
5. Carburetor Connector
6. Gasket
7. Adapter
8. Gasket
-127-
Carburetor Assembly Removal Procedure
1. Remove Intake Air Connector.
2. Disconnect Accelerator Cable from Carburetor.
3. Disconnect Carburetor Connector.
NOTE
Important: Mark and organize all hoses for assembly.
4. Disconnect the Following Hoses:

• Fuel inlet hose
• Emmision control hoses
• Vacuum Lines
5. Remove the four carburetor mounting nuts. PO5026
6. Lift out the carburetor.
7. Cover the inlet hole of the intake manifold with a
cloth.
PO5024
PO5034
-128-
Carburetor Assembly (Upper)
7
1
15
2
27 28
29
34
6
4
33 36 3
32 35
31
30 5
38
37
39 40
26 16
24
23 18
25
Disassembly steps 22 17
1. Stud bolt 21. Power piston

2. Nipple union 22. Spring 21
20 14
3. Pivot bolt 23. Primary upper slow jet
4. Acceleration pump arm 24. Screw 19
5. FICB link 25. Coil housing
6. Air Horn 26. Gasket
7. Wire clamp 27. Screw 13
8. Pivot pin 28. Cover
9. Wire 29. Spring 12
10. Float 30. E-ring 11
11. Plunger 31. Stopper
12. Spring 32. Spring
10 9
13. Needle valve 33. Collar 8
14. Acceleration pump plunger 34. Diaphragm
15. Plunger boot 35. Solenoid Valve
16. Air horn gasket 36. Gasket
17. Needle valve seat 37. Screw
18. Gasket 38. Choke lever
19. Screw 39. Screw
20. Retainer 40. Thermostat housing
-129-
-130-
Carburetor Assembly (Lower)
1 7 4
19 5
13 6
18
14
2
3
20 5
15
16
17
8
21 11
9
12 10
Disassembly steps
1. Discharge weight
2. Spring
3. Check ball
24
4. Plunger spring
5. Retainer
6. Check ball 27 28
7. Primary slow jet
8. Plug
9. Spring
10. Ball 25
11. Plug
12. Ball 23
13. Power valve 30
14. Passage plugs 22
15. Gaskets
16. Primary main jet
17. Gasket
18. Passage ring
19. Screw
20. Primary small venturi
21. Gasket
22. Snap ring
23. Screw
24. Fast idle cam breaker (FICB)
25. Fast idle cam
26. Passage screw
29
27. Bolt 26
28. Carburetor Body
29. Carburetor flange
30. Insulator
-131-
Carburetor Disassembly 3. Disconnect Fast Idle Cam Breaker (FICB) Link.
Hint: The following instructions are organized to
allow work on only one component group at a time.
This will help avoid confusion between similar
looking parts from different subassemblies that are
on the workbench at the same time.
1. To facilitate reassembly, arrange parts in order.

2. Be careful not to mix up or lose balls, clips or
springs.
Air Horn Disassembly PO5033

1. Remove Carburetor Stud Bolt and Nipple Union.
4. Remove Air Horn Assembly.
a. Remove the seven screws and following parts:
• Number plate (1)
• Wire clamps (2)
• Switch harness clamp (3)
• Coil housing and solenoid valve harness
clamp (4)
b. Lift off the air horn assembly together with the
air horn gasket.
PO4859
2. Remove Acceleration Pump Arm.

a. Remove the snap ring from the pump
connecting link.
b. Remove the pivot bolt.
c. Disconnect the pump arm from the pump
plunger.
PO5522
d. Disconnect the pump connecting link from the
throttle lever and remove the pump arm and 5. Remove Float and Needle Valve. Remove the
pump connecting link. float pivot pin, float and needle valve subassembly.
PO5109
PO5035
-132-
6. Remove Acceleration Pump Plunger. 9. Remove Primary Upper Slow Jet.
a. Remove the pump plunger and boot.
b. Remove air horn gasket.
PO5082
PO4976
10. Disconnect Wires from Carburetor Connector.
a. Pry up the locking lugs with a screwdriver
7. Remove Needle Valve Seat. and pull out the terminal.
a. Remove the needle valve seat and gasket. 11. Remove Coil Housing.
a. Remove the three screws, retainer, coil
housing and gasket.
PO5083
8. Remove Power Piston.

PO4723
a. Remove the screw, retainer, power piston and
spring. 12. Remove Choke Breaker (CB).
a. Remove the three screws, cover and spring.
PO4721 PO4722
-133-
b. Remove the E-ring, stopper, spring collar and b. Remove the two screws and thermostat
diaphragm. housing.
PO4725 PO4853
13. Remove Fuel Cut Off Solenoid Valve. 15. Remove Fast Idle Cam Breaker (FICB) Link.
a. Remove the solenoid valve and gasket. a. Remove the screw and FICB link.
PO4724 PO4977
14. Remove Thermostat Housing.

a. Remove the screw and choke lever.
Carburetor Body Disassembly
1. Remove Check Balls for Acceleration Pump.
a. Remove the pump discharge weight, spring
and large ball.
b. Remove the plunger spring.
PO4727
PO4719
-134-
c. Using tweezers, remove the ball retainer. 4. Remove Power Valve.
d. Remove the small ball.
PO4890
PO5036
5. Remove Primary Main Jets.
2. Remove Slow Jets. a. Remove the two passage plugs and gaskets.
a. Remove the primary slow jet.
PO4718
PO4926
b. Remove the primary main jets and gaskets.
3. Remove Check Balls for Auxiliary Acceleration
Pump (AAP).
a. Remove the plug, spring and ball (a).
b. Remove the plug and ball (b).
PO4949
PO4944
-135-
6. Remove Small Venturies. 8. Remove Fast Idle Cam.
a. Remove the passage ring.
PO4714
PO4858 9. Separate Carburetor Body and Flange.

a. Remove the passage screw and spring washer.
b. Remove the two screws, primary small venturi
and gasket.
PO5019
PO5509
7. Remove Fast Idle Cam Breaker (FICB). b. Remove the two bolts.
a. Remove the snap ring. c. Separate the body and flange.
b. Remove the two screws. d. Remove the insulator.
c. Disconnect the link, and remove the FICB.
PO4733 PO4712
-136-
General Cleaning Procedure 2. Inspect Power Piston.
1. Clean Disassembled Parts Before Inspection. a. Check that the power piston moves smoothly.
a. With a soft brush, wash and clean the cast
parts in carburetor cleaner.
b. Clean the carbon around the throttle valve.
c. Thoroughly wash the other parts in carburetor
cleaner.
d. Blow all dirt and other foreign material from the
jets, fuel passages and restrictions in the body.
PO4893
3. Inspect Power Valve.

a. Check for faulty opening and closing action.
PO4975
Carburetor Inspection
1. Inspect Float and Needle Valve.
a. Inspect the pivot pin (1) for scratches and
excessive wear.
PO4740
b. Inspect the float (2) for broken lips and wear in
the pivot pin holes. 4. Inspect Fuel Cut Off Solenoid Valve.
c. Inspect the spring (3) for breaks and a. Connect the connector terminals to the battery
deformation. terminals.
d. Inspect the needle valve (4) and plunger (5) for b. You should feel a “click” from the solenoid
wear or damage. valve when the battery power is connected
e. Inspect the strainer (6) for rust and breaks. and disconnected. If the solenoid valve is not
operating properly, replace it.
PO4739 PO4741
-137-
5. Inspect Choke Heater (Coil Housing). 2. Install Fast Idle Cam.
a. Using an ohmmeter, measure the resistance
between the terminals.
Resistance (Cold): 17.3 - 18.7 Ω at 20°C (68°F)
If a problem is found, replace the choke heater.
PO4714
3. Install Fast Idle Cam Breaker (FICB).

PO4742 a. Connect the link, and install the FICB with
the two screws.
b. Secure the link with the snap ring.
Carburetor Assembly
Hint: Use new gaskets and O-rings throughout.
1. Assemble Carburetor Body and Flange.
a. Assemble the flange and body together with a
new insulator.
b. Install the two bolts.
PO4733
4. Install Small Venturies.

a. Install a new gasket and the primary venturi
with the two screws.
PO4712
c. Install the passage screw together with the

spring washer.
PO4946
PO5509
-138-
b. Install the passage ring. 6. Install Power Valve.
PO4858 PO4890
5. Install Primary Main Jets. 7. Install Primary Slow Jet.

a. Install the primary main jets with new
PO4873
PO4871
8. Install Check Balls for Acceleration.
b. Install the primary passage plugs with new a. Install the plunger small ball.
gaskets.
b. Using tweezers, install the ball retainer.
PO4718 PO5036
-139-
c. Install the plunger spring (c). b. Install the choke lever with the screw.
d. Install the pump discharge large ball, spring
and weight (d).
PO4727
3. Install Fuel Cut Off Solenoid Valve.

PO4891
a. Install a new O-ring to the solenoid valve.
b. Install the solenoid valve together with a new
gasket.
Air Horn Assembly
1. Install Fast Idle Cam Breaker (FICB) Link.
Install the FICB link with the screw.
PO4724
4. Install Choke Breaker (CB).

a. Install the diaphragm into the thermostat
PO4977 case, and install the collar, spring and
stopper with the E-ring.
2. Install Thermostat Housing.
b. Insert the shaft of the diaphragm into the
a. Install the thermostat housing with the two
hole of the thermostat case.
screws.
PO4853 PO4725
-140-
c. Install the following parts with the three b. Pull on the wire to check that it is securely
screws: locked.
• Spring
PO4738
7. Install Primary Upper Slow Jet.

PO5425
5. Install Coil Housing.

a. Install the gasket to the thermostat case.
b. Align the bi-metal spring with the wire spring
and install the coil housing, aligning the
choke lever as shown in the illustration.
PO5082
8. Install Power Piston.

a. Install the spring and power piston with the
retainer and screw.
PO5060
c. Align the scale center line of the thermostat

case with the coil housing line, and install the
plate with the three screws.
d. Check the choke valve action.
6. Connect Wires to Connector.
a. Push in the terminal until it is securely locked
in the connecting lug.
PO4919
PO4730
-141-
9. Install Needle Valve Seat. c. Allow the float to hang down by its own weight.
a. Install the valve seat together with a new Measure the clearance between the float tip
gasket. and air horn. Float level (Raised position):
7.0 mm (0.276 in.). Hint: This measurement
should be made without a gasket on the air
horn.
PO5083
10. Adjust Float Level.

a. Insert the needle valve, spring and plunger
into the needle valve seat. PO4889
Hint: After adjusting the float level, install the d. Adjust by bending the portion of the float lip
clip onto the needle valve. marked A.
PO4857
PO4735
b. Install the float with the pivot pin.
e. Lift up the float. Measure the clearance
between the needle valve plunger and float
tip. Float level (lowered position):
0.9 - 1.1 mm (0.035 - 0.043 in.)
PO4860
PO4736
-142-
f. Adjust by bending the position of the float lip 13. Install Needle Valve and Float.
marked B. a. Hook the needle valve clip to the lip portion
g. After adjusting the float level, remove the of the float.
float, plunger, spring and needle valve.
PO4973
PO4737
h. Assemble the clip onto the needle valve. b. Install the float and secure it with the pivot
PO4720
PO5035
11. Install New Air Horn Gasket.
14. Install Air Horn Assembly.
a. Place the air horn gasket on the air horn.
a. Install the wire clamp in position.
12. Install Acceleration Pump Plunger.
a. Install a new boot and the pump plunger.
PO5037
PO4976
-143-
b. Place the air horn in the carburetor body. 17. Install Nipple Union.
c. Install the following parts with the seven a. Install a new gasket and nipple union.
screws: 18. Check for Smooth Operation of Each Part.
• Number plate (1)
• Wire clamps (2)
• Switch harness clamp (3)
• Coil housing and solenoid valve harness
clamp (4)
PO4974
Carburetor Adjustment
PO5522 1. Check and Adjust Throttle Valve Opening.
a. Check the full opening angle of the primary
15. Connect Fast Idle Cam Breaker (FICB) Link. throttle valve.
Standard angle: 90° from horizontal
PO5033
16. Install Acceleration Pump Arm. PO5032
a. Connect the pump connecting link to the b. Adjust by bending the primary throttle stop lever.
throttle lever.
b. Connect the pump arm to the pump plunger.
c. Install the pump arm with the pivot bolt.
d. Secure the link with the snap ring.
PO5113
PO5109
-144-
2. Set Automatic Choke. b. Check the primary throttle valve angle.
a. Set the coil housing line so that it is aligned Standard angle: 23.3° - 25.3° from horizontal
with the center line of the thermostat housing.
Hint: The choke valve becomes fully closed
when the atmospheric temperature reaches
30°C (86°F).
PO5074
c. Adjust by turning the fast idle adjusting screw.
PO5039
b. Depending on truck operating conditions,

turn the coil housing and adjust the engine
starting mixture.
If too rich ........ Turn clockwise.
If too lean ....... Turn counterclockwise.
PO5077
4. Check and Adjust Unloader.

a. With the primary throttle valve fully opened,
check the choke valve angle.
Standard angle: 35° - 39° from horizontal
PO5088
3. Check and Adjust Fast Idle Setting.

a. Position the fast idle lever onto the 1st step as
shown.
PO5068
PO4909
-145-
b. Adjust by bending the unloader lever. b. Apply vacuum to the FICB and release it.
c. Check that the choke linkage moves, and that
the fast idle cam is released to the 3rd step.
PO5078
5. Check and Adjust Fast Idle Cam Breaker (FICB).

a. Set the fast idle cam: PO5511
• While holding the throttle slightly open, push
the choke valve closed, and hold it closed as d. Adjust by bending the FICB lever.
you release the throttle valve.
PO5090
6. Check and Adjust Choke Breaker (CB).

PO5028
a. Set the fast idle cam.
• Check that the fast idle lever is set in the 1st b. Apply vacuum to the CB.
step of the fast idle cam as shown. c. Check the choke valve angle.
Standard angle: 43.5° - 44.5° from horizontal
PO4913 PO5067
-146-
d. Adjust by turning the CB adjusting screw. c. Adjust turning the idle speed adjusting screw.
PO5485 PO5087
7. Check and Adjust Acceleration Pump. 9. Preset Idle Mixture Adjusting Screw. If the idle
a. Apply vacuum to fast idle cam breaker (FICB). mixture adjusting screw has been removed,
b. Rotate the throttle shaft and check the length fully screw it in and then unscrew it the follow-
of the stroke. ing amount:
Standard stroke: 10.9 mm (0.429 in.). Standard:
c. Adjust the pump stroke by bending the Return 2 3/4 turns from fully closed position.
connecting link.
NOTE
Use care not to screw it in too tightly and damage
the screw tip.
PO5021
8. Preset Idle Speed Adjusting Screw.

a. Apply vacuum to fast idle cam breaker (FICB).
b. Check the primary throttle valve angle.
PO5086
Standard angle: 16° from horizontal
10. Check for smooth operation of each part.
11. Install carburetor stud bolt.
Operational Adjustments
1. Start engine.
2. Allow engine to reach operating temperature.
3. Install tachometer.
4. Idle speed adjustment.
5. Idle mixture adjustment.
Adjust by using the following tools:
1. Tachometer
2. Exhaust Gas Analyzer
3. Vacuum Gauge
PO5075
-147-
Carburetor Installation 3. Connect Carburetor Connector.
1. Install Carburetor. 4. Connect and Adjust Accelerator Cable.
a. Place the insulator and new gaskets on the a. Loosen the locknut of the Adjusting Nut at
intake manifold. carburetor and rotate the Adjusting Nut until
all slack from the accelerator cable is
removed. Do not set cable so tight as to pull
the accelerator pedal.
b. Adjustment of the accelerator pedal is required
to obtain correct low idle setting. This
requires the installation of the floor plate and
the engine cover open in order to view the
movement of the mechanical throttle body
bell crank.
c. Adjust the throttle cable tension at the throttle
position sensor to 0-2 mm of free play at
accelerator pedal before the throttle position
PO5025
sensor starts to move. The clevis at both
b. Place the carburetor on the insulator. ends of the cable should not be slack.
c. Install the four carburetor mounting nuts. d. Loosen the locking nut on the accelerator
pedal stop bolt to allow adjustment of the
Tightening torque accelerator pedal stop bolt.
for carburetor 130 Kgf•m (9 lb•ft) [13 N•m] e. Depress the accelerator pedal while viewing
mounting nuts the throttle body bell crank. The bell crank
will rotate as the accelerator pedal is
depressed.
f. Set the stop bolt height so the bell crank
moves the full range of motion within 0-1
mm from stop plate at carburetor. Tighten
the locknut to secure the accelerator stop
bolt once adjustment is obtained.
g. Start the engine but do not make adjustment
until the engine is at operating temperature
and the vacuum switch has opened to pull
the choke to the off position.
h. Slowly depress and release the Accelerator
PO5034 Pedal a few times. Check that there is no
2. Connect the Following Hoses. slack in the cable when the stepping motor
a. Emission control hoses. lever is not in motion. The cable will be loose
b. Fuel inlet hose. while choke is ON and the cable will be tight
c. Outer vent control hose. when the choke is OFF. Readjust as neces-
d. Vacuum lines. sary.
i. Install Intake Air Connector.
j. Adjust Idle Speed (750 + - 50) and Idle Mixture.
k. High RPM cannot be adjusted. It is controlled
by the ECU.
l. Adjust Choke.
m. Check torque converter stall speed per
chassis service manual.
-148-

Vortec V6 4.3L

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Vortec V6 4.3L

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Oil Leak Diagnosis

1. Drain the engine coolant.

10. Remove and discard the intake manifold

Intake Manifold Clean and Inspect

1. Apply a 4.0 mm (0.157 in.) patch of adhesive

Note: Care must be used to apply the correct

Important: Proper manifold fastener tightening

➧A➧ 1. Gauge - Oil

➧ B ➧ Exhaust Manifold and Heat Shields

4. Measure the alignment or surface flatness of

3. Remove and discard the exhaust manifold

2. Install the exhaust manifold.

5. Install the oil level indicator into the tube.

6. Install the spark plug wires to the spark plug

Torque Specifications For

T=4.16 kgf•m (30 lb•ft) [40 N•m]

Valve Rocker Arm Cover Removal (Right)

9. Remove the valve rocker arm cover gasket.

Valve Rocker Arm and Push Rod Removal

2a. Remove the valve rocker arms (new style).

Valve Rocker Arm and Push Rods Clean

4. Remove the valve pushrods.

2. Remove the valve lifters.

Valve Lifter Removal

4. If the valve lifters cannot be removed with the

5. Clean the components with cleaning solvent.

8. Inspect the valve lifter pushrod guides for cracks

6. Install the valve rocker arm nut.

9. Remove the valve keys. 31868

Cylinder Head Removal

2. Remove the exhaust manifold.

NOTE 9. Remove the dowel pins (cylinder head locator)

7. Remove cylinder head.

34468 4. Valve stem oil seal alignment onto the valve

Cylinder Head Clean and Inspect

8. Inspect the valve spring for squareness.

2. Improper valve stem (1) to valve guide (2)

5. Inspect the valves for the following:

7. Reconditioning of the valves and valve seats:

1. Clean the cylinder head gasket surfaces on the

6. Apply sealant P/N 2I4256, GM P/N

4. Install the NEW cylinder head gasket in position 480533

9. Use the electronic torque meter J 36660 to tighten

Tightening torque 2.07 Kgf•m (15 lb ft)

10. Install the spark plug wire support and bolts.

15. If reusing the engine coolant temperature

USED PLUGS 1.52 Kgf•m (11 lb ft) [15 N•m]

3. Apply prelube GM P/N 12345501 or equivalent

8. Remove the oil pan.

3. Drain the engine oil.

9. Remove the oil pan gasket.

2. Remove the oil pump driveshaft and the

2. Clean the oil pan and the oil pan baffle in

3. Remove the seal.

Oil Filter Adapter Removal

Oil Pump Disassemble

7. Remove the following items:

Oil Pump Clean and Inspect

• Scoring, damage or casting imperfections

4. If the oil pump is to be reused, install a NEW oil

7. Inspect the pump for smoothness of operation

2. Install the oil filter adapter and gasket.

4. Install the oil pump bolt attaching the oil pump to

Important: DO NOT reuse the oil pump driveshaft