Page 1 Service Engine Engine Model: General Motors 4.3 L Powertrain Generator Models: 30--45 kW TP-6103 1/01...
Page 2: Caution
CAUTION Caution: In order to reduce the chance of personal injury and/or property damage, carefully observe the instructions that follow. The service manual of General Motors Powertrain is intended for use by professional, qualified technicians. Attempting repairs or service without the appropriate training, tools, and equipment could cause injury to you or others, damage the equipment, or cause the equipment to operate improperly.
Page 3: Table Of Contents
Table of Contents Caution ..............Inside Front Cover Introduction .
Page 4 Table of Contents, continued Crankshaft Rear Oil Seal Removal ........... 6-59 Crankshaft and Bearings Removal .
Page 5 Table of Contents, continued Valve Rocker Arm and Push Rod Installation ......... 6-157 Intake Manifold Installation .
Page 6 Table of Contents, continued TP-6103 1/01...
Page 7: Introduction
Introduction This service manual provides the service technician This manual has been reprinted by the generator set with information to service the General Motors manufacturer with the permission of General Motors Powertrain engines. Powertrain. In general, this manual covers the service of the engine This manual is a reproduction of a General Motors and associated standard equipment.
Page 8 Notes Introduction TP-6103 1/01...
Page 9: Cautions And Notices
Cautions and Notices Definition of Caution, Notice, and Notice Defined Important Notices call special attention to a necessary action or to a prohibited action. If a Notices not heeded, the The diagnosis and repair procedures in the GM following consequences may occur: Powertrain Service Manual contain both general and specific Cautions, Notices, and Importants.
Page 10 Moving Parts and Hot Surfaces Caution Fastener Notice Caution: Avoid contact with moving parts and hot Notice: Use the correct fastener in the correct location. surfaces while working around a running engine in order Replacement fasteners must be the correct part number to prevent physical injury.
Page 11: Fastener Tightening Specifications
Engine Marine/Industrial 4.3L 6-1 Engine Mechanical - 4.3L Specifications Fastener Tightening Specifications Specification Application Metric English Accelerator Control Cable Bracket Nut to Stud 12 N•m 106 lb in Accelerator Control Cable Bracket Nut to Throttle Body 9 N•m 80 lb in Accelerator Control Cable Bracket Stud to Intake Manifold 6 N•m 53 lb in...
Page 12 6-2 Marine/Industrial 4.3L Engine Fastener Tightening Specifications (cont’d) Specification Application Metric English EGR Valve Inlet Pipe Clamp Bolt 25 N•m 18 lb ft EGR Valve Inlet Pipe Nut at Intake Manifold 25 N•m 18 lb ft EGR Valve Inlet Pipe Nut at Exhaust Manifold 30 N•m 22 lb ft Engine Block Left Side Oil Gallery Plug...
Page 13 Engine Marine/Industrial 4.3L 6-3 Fastener Tightening Specifications (cont’d) Specification Application Metric English Generator and Drive Belt Tensioner Bracket Stud Nut 41 N•m 30 lb ft Ground Wire Bolt to Rear of Left Side Cylinder Head 16 N•m 12 lb ft Ground Wire Nut to Rear of Right Side Cylinder Head 16 N•m 12 lb ft...
Page 14: Engine Mechanical Specifications
6-4 Marine/Industrial 4.3L Engine Fastener Tightening Specifications (cont’d) Specification Application Metric English Water Outlet Stud 25 N•m 18 lb ft Water Pump Bolt 45 N•m 33 lb ft Engine Mechanical Specifications Specification Application Metric English General Data Engine Type Regular Production Option (RPO) Code L35 VIN Code W Displacement 4.3L 262 CID...
Page 15 Engine Marine/Industrial 4.3L 6-5 Engine Mechanical Specifications (cont’d) Crankshaft Journal Diameter (Journal #4) 62.179-62.203 mm 2.4480-2.4489 in Crankshaft Journal Out-of-Round (Production) 0.005 mm (Maximum) 0.0002 in (Maximum) Crankshaft Journal Out-of-Round (Service) 0.025 mm (Maximum) 0.0010 in (Maximum) Crankshaft Journal Taper (Production) 0.007 mm (Maximum) 0.0003 in (Maximum) Crankshaft Runout...
Page 16: Gm Spo Group Numbers
6-6 Marine/Industrial 4.3L Engine Engine Mechanical Specifications (cont’d) Valve Seat Width (Intake) 1.016-1.651 mm 0.040-0.065 in Valve Spring Free Length 51.3 mm 2.02 in Valve Spring Installed Height (Exhaust) 42.92-43.43 mm 1.670-1.700 in Valve Spring Installed Height (Intake) 42.92-43.43 mm 1.670-1.700 in Valve Spring Pressure (Closed) 338-374 N at 43.2 mm...
Page 17 Engine Marine/Industrial 4.3L 6-7 GM SPO Group Numbers (cont’d) Application GM SPO Group Number Drive Belt Tensioner 1.060 EGR Valve 3.670 EGR Valve Gasket 3.680 EGR Valve Inlet Pipe 3.675 Evaporative Emission Canister Purge Solenoid Valve 3.130 Evaporative Emission Canister Purge Solenoid Valve Harness 3.145 Engine Block N.S.
Page 18 6-8 Marine/Industrial 4.3L Engine GM SPO Group Numbers (cont’d) Application GM SPO Group Number Oil Level Indicator 1.516 Oil Level Indicator Tube 1.516 Oil Pan 1.426 Oil Pan Drain Plug 1.453 Oil Pan Drain Plug Seal (O-ring) 1.456 Oil Pan Gasket 1.429 Oil Pump 1.652...
Page 19: Sealers, Adhesives And Lubricants
Engine Marine/Industrial 4.3L 6-9 GM SPO Group Numbers (cont’d) Application GM SPO Group Number Water Outlet 1.153 Water Pump Gaskets 1.079 Water Pump Inlet Hose 1.097 Water Pump Kit (with Gaskets) 1.069 Sealers, Adhesives and Lubricants Application Type of Material GM Part Number Balancer Shaft Driven Gear Bolt Threadlock...
Page 20: Diagnostic Information And Procedures
6-10 Marine/Industrial 4.3L Engine Diagnostic Information and Procedures Base Engine Misfire Diagnosis Checks Action Engine Performance diagnosis procedures are covered in Engine Controls and should be consulted for diagnosis of any Drivability, Emissions or Malfunctioning Indicator Lamp (MIL) concerns. The following diagnosis covers common concerns and possible causes. When the proper diagnosis is made, the concern should be corrected by adjustment, repair or replacement as required.
Page 21: Engine Compression Test
Engine Marine/Industrial 4.3L 6-11 Base Engine Misfire Diagnosis (cont’d) Checks Action Abnormal Internal Engine Noises 1. Start the engine and determine if the noise is timed to the engine camshaft speed or the crankshaft speed. 2. Using a timing light, two knocks per flash is the crankshaft speed and one knock per flash is the engine camshaft speed.
Page 22: Engine Noise Diagnostic
6-12 Marine/Industrial 4.3L Engine Engine Noise Diagnosis Symptoms Cause When diagnosing engine noisee complaints, use the following steps to isolate the source of the engine noise: Determine the type of noise For example, is the noise a light rattle/tapping or a low rumble/knocking? The exact operating condition under which the noise exists Note factors such as ambient temperature, the amount of engine warm-up time, the engine temperature, the engine RPM and other specifics.
Page 23: Valve Train Diagnosis
Engine Marine/Industrial 4.3L 6-13 Valve Train Diagnosis General Information Symptoms Cause A light tapping noise at 1/2 engine speed, or any varying frequency, may indicate a valve train problem. Tapping noises will typically increase with increased engine speed. Before attempting to diagnose a valve train noise, check for the proper engine oil level and then allow the engine to obtain normal operating temperature.
Page 24 6-14 Marine/Industrial 4.3L Engine Diagnostic Table (cont’d) Step Action Value(s) Check the oil pump screen for damage or a loose fit to the oil pump. Is the oil pump screen loose or is the oil pump screen — Go to Step 8 Go to Step 9 damaged? Repair as required.
Page 25: Excessive Oil Consumption
Engine Marine/Industrial 4.3L 6-15 Excessive oil consumption (not due to leaks) is the use 4. Remove the oil pressure gauge sensor or 1.9 liters (2 quarts) of engine oil within 3,200 kilometers another engine block oil gallery plug. (2,000 miles). However, during initial engine break-in 5.
Page 26: Oil Leak Diagnosis
6-16 Marine/Industrial 4.3L Engine Oil Leak Diagnosis Step Action Value(s) Important: You can repair most fluid leaks by first visually locating the leak, repairing or replacing the component, or by resealing the gasket surface. Once the leak is identified, determine the cause of the leak. Repair the cause of the leak as ewll as the leak itself.
Page 27 Engine Marine/Industrial 4.3L 6-17 Oil Leak Diagnosis (cont’d) Step Action Value(s) Can you identify the type of fluid and the approximate location of the leak? — Go to Step 10 Go to Step 4 1. Visually inspect the suspected area. Use a small mirror to assist in looking at hard to see areas.
Page 28: Drive Belts
6-18 Marine/Industrial 4.3L Engine Symptoms - Drive Belt failure of an accessory drive component. • Drive belt symptoms may occur from changes in load of Important: Review the system operation in order to the accessory drive components. familiarize yourself with the system functions. Refer to Drive Belt System Description.
Page 29 Engine Marine/Industrial 4.3L 6-19 Drive Belt Chirping Diagnosis Step Action Value(s) Notice : Refer to Belt Dressing Notice in Cautions and Notices. DEFINITION: The following items are indications of chirping: • A high pitched noise that is heard once per revolution of the drive belt or a pulley. •...
Page 30 6-20 Marine/Industrial 4.3L Engine Drive Belt Squeal Diagnosis accessory drive components for turning smoothly. Also test the accessory drive Diagnostic Aids components with the engine operating by A loose or improper installation of a body component, varying the load on the components to verify a suspension component or other items of the vehicle that the components operate properly.
Page 31: Drive Belt Squeal
Engine Marine/Industrial 4.3L 6-21 Drive Belt Squeal Diagnosis (cont’d) Step Action Value(s) Test the drive belt tensioner for proper operation. Refer to Drive Belt Tensioner Diagnosis. Did you find and correct the condition? — Go to Step 9 Go to Step 6 Inspect for the correct drive belt length.
Page 32 6-22 Marine/Industrial 4.3L Engine Drive Belt Rumbling Diagnosis 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components Diagnostic Aids may cause a similar symptom. Vibration from the engine operating may cause a 3. This test is to verify that the drive belt(s) is body component or another part of the vehicle to causing the rumbling noise.
Page 33: Drive Belt Rumbling
Engine Marine/Industrial 4.3L 6-23 Drive Belt Rumbling Diagnosis (cont’d) Step Action Value(s) Install a new drive belt. Refer to Drive Belt Replacement. Did you complete the replacement? — Go to Step 8 — Operate the system in order to verify the repair. Go to Did you correct the condition? —...
Page 34: Drive Belt Vibration
6-24 Marine/Industrial 4.3L Engine Drive Belt Vibration Diagnosis (cont’d) Step Action Value(s) Install a new drive belt. Refer to Drive Belt Replacement. Did you complete the replacement? — Go to Step 11 — Inspect for improper, loose or missing fasteners. Did you find any of these conditions? —...
Page 35: Drive Belt Excessive Wear
Engine Marine/Industrial 4.3L 6-25 Drive Belt Falls Off Diagnosis Step Action Value(s) Notice: Refer to Belt Dressing Notice in Cautions and Notices. DEFINITION: The drive belt falls off the pulleys or may not ride correctly on the pulleys. Go to Symptoms- Did you review the Drive Belt Symptom operation and perform the necessary inspections? —...
Page 36: Drive Belt Tensioner
6-26 Marine/Industrial 4.3L Engine Drive Belt Excessive Wear Diagnosis Step Action Value(s) Notice: Refer to Belt Dressing Notice in Cautions and Notices. DEFINITION: Wear at the outside ribs of the drive belt due to an incorrectly installed drive belt. Go to Symptoms- Did you review the Drive Belt Symptom operation and perform the necessary inspections? —...
Page 37 Engine Marine/Industrial 4.3L 6-27 2000 Marine/Industrial...
Page 38: (14) Intake Manifold
6-28 Marine/Industrial 4.3L Engine Visual Identification Dissassembled Views Upper and Lower Intake Manifold View 334238 Legend (11) Upper Intake to Lower Intake Manifold Gasket (1) Fuel Pipe Retainer Bracket Nut (12) Fuel Meter Body Seal (O-ring) (2) Fuel Pipe Retainer (13) Fuel Meter Body (3) Fuel Pipe (14) Intake Manifold...
Page 39 Engine Marine/Industrial 4.3L 6-29 Upper Engine View 1 480498 Legend (1) Distributor Bolt (10) Water Outlet Stud (2) Distributor (11) Engine Coolant Thermostat (3) Intake Manifold Bolt (Lower) (12) Accelerator Control Cable Bracket (13) Accelerator Control Cable Bracket Stud (4) Intake Manifold Gasket (Lower) (14) Ignition Coil (5) Intake Manifold Assembly (15) Ignition Coil Stud...
Page 40 6-30 Marine/Industrial 4.3L Engine Upper Engine View 2 480513 Legend (10) Spark Plug Wire Shields (1) Valve Rocker Arm Cover (2) Valve Rocker Arm Cover Gasket (11) Exhaust Manifold Gasket (3) Valve Rocker Arm Assembly (12) Valve Lifter (4) Valve Rocker Arm Support (13) Valve Lifter Pushrod Guide (5) Spark Plug Wire Support (14) Valve Pushrod...
Page 41 Engine Marine/Industrial 4.3L 6-31 Lower Engine View 1 569262 Legend (1) Oil Level Indicator Tube Bolt (14) Oil Filter Fitting (2) Oil Level Indicator (15) Oil Filter Bypass Valve (3) Oil Level Indicator Tube (16) Engine Coolant Drain Hole Plug (4) Engine Oil Pressure Sensor Fitting (17) Engine Block Core Hole Plug (5) Balance Shaft Bearing (Rear)
Page 42 6-32 Marine/Industrial 4.3L Engine (29) Camshaft Timing Chain (37) Piston (30) Camshaft Sprocket Bolt (38) Piston Pin (31) Balance Shaft Gear Bolt (39) Connecting Rod Bolt (32) Balance Shaft Driven Gear (40) Connecting Rod (33) Balance Shaft Retainer Bolt (41) Connecting Rod Bearings (34) Balance Shaft Retainer (42) Connecting Rod Cap (35) Balance Shaft...
Page 43 Engine Marine/Industrial 4.3L 6-33 Lower Engine View 2 480518 Legend (13) Oil Pan (1) Crankshaft Rear Oil Seal Housing Retainer Stud (14) Oil Pan Bolt (2) Crankshaft Rear Oil Seal Housing Nut (15) Oil Pan Gasket (3) Flywheel Locator Pin (16) Crankshaft Bearing Cap Bolt (4) Crankshaft Rear Oil Seal Housing Bolt (17) Crankshaft Bearing Cap...
Page 44: Draining Fluids And Oil Filter Removal
6-34 Marine/Industrial 4.3L Engine Draining Fluids and Oil Filter Removal 1. Remove the oil pan drain plug and allow the engine oil to drain into a suitable container. 188048 2. Remove the oil filter (if applicable). 3. Discard the oil filter (if applicable). 188050 4.
Page 45: Engine Flywheel Removal
Engine Marine/Industrial 4.3L 6-35 Engine Flywheel Removal 1. Remove the engine flywheel bolts. 2. Remove the engine flywheel (automatic transmission) (1), if applicable. 3. Remove the engine flywheel (manual transmission) (2), if applicable. 188129 Important: If replacing the engine flywheel (manual transmission), then NEW flywheel weights must be installed into the NEW engine flywheel in the same location as the old flywheel weights in the old engine flywheel.
Page 46: Exhaust Manifold Removal
6-36 Marine/Industrial 4.3L Engine 1.2. Using a wrench secure the J 43276-1 tool body. 1.3. Insert the J 43276-2 forcing screw into the J 43276-1 tool body. 1.4. Rotate the J 43276-2 forcing screw clockwise into the J 43276-1 tool body until the clutch pilot bearing is completely removed from the crankshaft.
Page 47: Oil Level Indicator And Tube Removal
Engine Marine/Industrial 4.3L 6-37 Exhaust Manifold Removal (Right) Notice: Twist the spark plug boot one-half turn in order to release the boot. Pull on the spark plug boot only. Do not pull on the spark plug wire or the wire could be damaged. 1.
Page 48: Water Pump Removal
6-38 Marine/Industrial 4.3L Engine 2. Remove the oil level indicator tube bolt. 3. Remove the oil level indicator tube from the engine block. 188047 Water Pump Removal Tools Required J 41240 Fan Clutch Remover and Installer 1. Remove the bolts and the fan and water pump pulley using the J 41240.
Page 49: Crankshaft Balancer Removal
Engine Marine/Industrial 4.3L 6-39 3. Remove the water pump bolts. 4. Remove the water pump. 5. Remove the water pump gaskets. 6. Discard the water pump gaskets. 188054 Crankshaft Balancer Removal Tools Required J 23523-F Balancer Remover and Installer 1. Remove the crankshaft balancer bolt and washer. 173172 2.
Page 50: Valve Rocker Arm Cover Removal
6-40 Marine/Industrial 4.3L Engine Notice: Refer to Fastener Notice in Cautions and Notices. 3. Use the J23523-F in order to remove the crankshaft balancer. 3.1. Install the J 23523-F plate and bolts onto the crankshaft balancer. Tighten Tighten the bolts to 25 N•m (18 lb ft). 3.2.
Page 51 Engine Marine/Industrial 4.3L 6-41 4. Remove the valve rocker arm cover. 480519 5. Remove the valve rocker arm cover gasket. 6. Discard the valve rocker arm cover gasket. 328573 Valve Rocker Arm Cover Removal (Right) 1. Remove the valve rocker arm cover bolts. 2.
Page 52: Distributor Removal
6-42 Marine/Industrial 4.3L Engine 4. Remove the valve rocker arm cover. 480524 5. Remove the valve rocker arm cover gasket. 6. Discard the valve rocker arm cover gasket. 328573 Distributor Removal 1. Remove the ignition coil wire harness from the ignition coil and distributor cap.
Page 53: Intake Manifold Removal
Engine Marine/Industrial 4.3L 6-43 2. Remove the distributor clamp bolt. 3. Remove the distributor and the distributor clamp. 569265 4. Remove the distributor gasket and discard. 523516 Intake Manifold Removal 1. Remove the evaporitive emission (EVAP) canister purge solenoid valve harness. 1.1.
Page 54: Valve Rocker Arm And Push Rod Removal
6-44 Marine/Industrial 4.3L Engine 2. Remove the engine coolant temperature (ECT) sensor wire connector (if equipped) from the engine wiring harness bracket. 3. Remove the lower intake manifold bolts. Important: The intake manifold may be removed as an assembly. Do not remove the specific intake manifold components unless component service is required.
Page 55: Cylinder Head Removal
Engine Marine/Industrial 4.3L 6-45 2. Remove the valve pushrods. 480529 Cylinder Head Removal (Left) 1. Remove the engine coolant temperature sensor (if applicable). 387769 2. Remove the engine coolant temperature gauge sensor (if applicable). 387767 2000 Marine/Industrial...
Page 56 6-46 Marine/Industrial 4.3L Engine 3. Remove the spark plugs. 328582 4. Remove the bolts and the spark plug wire support. 328588 5. Remove the cylinder head bolts. 480533 2000 Marine/Industrial...
Page 57 Engine Marine/Industrial 4.3L 6-47 Notice: After removal, place the cylinder head on two wood blocks to prevent damage. 6. Remove the cylinder head. 480536 7. Remove and discard the cylinder head gasket. 334299 8. Remove the dowel pins (cylinder head locator) (if required). 330548 2000 Marine/Industrial...
Page 58 6-48 Marine/Industrial 4.3L Engine Cylinder Head Removal (Right) 1. Remove the spark plugs. 328586 2. Remove the bolts and the spark plug wire support. 328590 3. Remove the cylinder head bolts. 480537 2000 Marine/Industrial...
Page 59 Engine Marine/Industrial 4.3L 6-49 Notice: After removal, place the cylinder head on two wood blocks to prevent damage. 4. Remove the cylinder head. 480538 5. Remove and discard the cylinder head gasket. 334312 6. Remove the dowel pins (cylinder head locator) (if required). 330553 2000 Marine/Industrial...
Page 60: Valve Lifter Removal
6-50 Marine/Industrial 4.3L Engine Valve Lifter Removal Tools Required J 3049-A Valve Lifter Remover Important: Place the components in a rack so that the components can be reinstalled to their original location. 1. Remove the bolts and the valve lifter pushrod guide. 328592 Important: Place the valve lifters in the rack in the upright position in order to maintain the oil inside the valve lifters.
Page 61: Oil Pan Removal
Engine Marine/Industrial 4.3L 6-51 Oil Pan Removal 1. Remove and discard the engine oil level sensor (if applicable). 387460 2. Remove the oil pan bolts and nuts. 330559 3. Remove the oil pan. 330568 2000 Marine/Industrial...
Page 62: Oil Pump Removal
6-52 Marine/Industrial 4.3L Engine 4. Remove the oil pan gasket. 5. Discard the oil pan gasket. 387757 Oil Pump Removal 1. Remove the oil pump bolt. 330572 2. Remove the oil pump. 330576 2000 Marine/Industrial...
Page 63: Engine Front Cover Removal
Engine Marine/Industrial 4.3L 6-53 3. Inspect the pins (oil pump locator) for damage, and replace the pins if required. 330578 Engine Front Cover Removal 1. Remove the crankshaft position sensor bolt. 2. Remove the crankshaft position sensor. 11485 3. Remove the crankshaft position sensor seal (O-ring). 4.
Page 64: Timing Chain And Sprockets Removal
6-54 Marine/Industrial 4.3L Engine 5. Remove the engine front cover bolts. Important: After the composite engine front cover is removed, do not reinstall the engine front cover. Always install a NEW engine front cover. 6. Remove the engine front cover. 7.
Page 65 Engine Marine/Industrial 4.3L 6-55 3. Remove the camshaft sprocket bolts. 480544 4. Remove the camshaft sprocket and the camshaft timing chain. 480546 Caution: Refer to Safety Glasses Caution in Cautions and Notices. 5. Remove the crankshaft sprocket using the J 5825-A. 480547 2000 Marine/Industrial...
Page 66: Balance Shaft Removal
6-56 Marine/Industrial 4.3L Engine 6. Remove the crankshaft balancer key. 387761 Balance Shaft Removal 1. Remove the balancer shaft drive gear. 9847 Important: The balance shaft drive and balance shaft driven gears are serviced as a set. The set includes the balance shaft driven gear bolt.
Page 67: Camshaft Removal
Engine Marine/Industrial 4.3L 6-57 4. Remove the bolts and the balance shaft retainer. 188031 Important: The balance shaft and the balance shaft front bearing are serviced only as a package. Do not remove the balance shaft front bearing from the balance shaft. 5.
Page 68: Piston, Connecting Rod, And Bearing Removal
6-58 Marine/Industrial 4.3L Engine Notice: All camshaft journals are the same diameter, so care must be used in removing or installing the camshaft to avoid damage to the camshaft bearings. 2. Remove the engine camshaft. 2.1. Install the three 5/16-18 x 4.0 inch bolts into the engine camshaft front bolt holes.
Page 69 Engine Marine/Industrial 4.3L 6-59 4. Use the J 5239 in order to protect the crankshaft journals and remove the connecting rod and the piston out of the top of the engine block. 31373 Important: Always assemble the connecting rod caps to the matching connecting rods.
Page 70 6-60 Marine/Industrial 4.3L Engine 4. Remove the crankshaft rear oil seal housing nut and bolts. 5. Remove the crankshaft rear oil seal housing. 334317 6. Remove the crankshaft rear oil seal housing gasket. 7. Discard the crankshaft rear oil seal housing gasket. 334319 8.
Page 71: Crankshaft And Bearings Removal
Engine Marine/Industrial 4.3L 6-61 Crankshaft and Bearings Removal 1. Mark or identify the crankshaft bearing cap locations, direction and positions for assembly. 2. Remove the crankshaft bearing cap bolts. 3. Remove the crankshaft bearing caps. 334329 4. Remove the crankshaft. 334336 5.
Page 72: Engine Block Plug Removal
6-62 Marine/Industrial 4.3L Engine 6. Remove the crankshaft bearings from the engine block. 334338 Engine Block Plug Removal Tools Required J 41712 Oil Pressure Switch Socket Caution: Refer to Safety Glasses Caution in Cautions and Notices. 1. Remove the knock sensor from the engine block. 10793 2.
Page 73 Engine Marine/Industrial 4.3L 6-63 3. Remove the engine oil pressure sensor fitting. 188020 4. Remove the dowel straight pins (transmission locator) (if required). 334350 5. Remove the engine block left side oil gallery plug. 6. Remove the engine block left rear oil gallery plug. 7.
Page 74 6-64 Marine/Industrial 4.3L Engine 8. Remove the expansion cup plug (camshaft rear bearing hole) and discard. 334364 9. Remove the expansion cup plug (balance shaft rear bearing hole) and discard. 334366 10. Remove the spring type S pin (crankshaft rear oil seal housing locator) (if required).
Page 75 Engine Marine/Industrial 4.3L 6-65 11. Remove the front oil gallery plugs or balls from the front of the engine block and discard. 12. Insert a 3/8 x 26 in. rod into the rear oil gallery holes in order to drive out the front oil gallery plugs or balls. 5270 13.
Page 76: Engine Block Clean And Inspect
6-66 Marine/Industrial 4.3L Engine Engine Block Clean and Inspect Tools Required J 8087 Cylinder Bore Gauge Caution: Refer to Safety Glasses Caution in Cautions and Notices. 1. Clean all the remaining sealing or gasket material from the sealing surfaces. 2. Clean the engine block with cleaning solvent. 3.
Page 77: Cylinder Boring And Honing
Engine Marine/Industrial 4.3L 6-67 10. Measure the cylinder bores for taper and out-of-round. 10.1. Depress the plunger on the J 8087 7 mm (0.275 in) or until the J 8087 enters the cylinder bore. 10.2. Center the J 8087 in the cylinder bore and turn the indicator dial to 0.
Page 78: Boring Procedure
6-68 Marine/Industrial 4.3L Engine 5. By measuring the selected piston at the sizing point and then by adding the average of the clearance specification, the final cylinder bore honing dimension required can be determined. 6. When finished, the reconditioned cylinder bores should have less than or meet the specified out-of-round and taper requirements.
Page 79: Piston And Connecting Rod Disassemble
Engine Marine/Industrial 4.3L 6-69 Piston and Connecting Rod Disassemble Tools Required J 24086-C Piston Pin Remover/Installer Caution: Refer to Safety Glasses Caution in Cautions and Notices. 1. Remove the piston rings from the pistons. 4967 2. Press the piston pin from the connecting rod using the J 24086-C.
Page 80: Piston, Connecting Rod And Bearings Clean/Inspect
6-70 Marine/Industrial 4.3L Engine Piston, Connecting Rod and Bearings Clean/ Inspect Important: Measurement of all components should be taken with the components at room temperature. Do not use a wire brush in order to clean any part of the piston. Caution: Refer to Safety Glasses Caution in Cautions and Notices.
Page 81 Engine Marine/Industrial 4.3L 6-71 7. Measure the piston ring-to-piston ring groove side clearance. 7.1. Insert the edge of the piston ring into the piston ring groove. 7.2. 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.
Page 82 6-72 Marine/Industrial 4.3L Engine 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 Engine Mechanical Specifications. 4975 15.
Page 83: Piston Selection
Engine Marine/Industrial 4.3L 6-73 17. Inspect the connecting rod for twisting. 18. Inspect the connecting rod for damage to the bearing cap and bolt threads. 156169 19. Measure the piston compression ring end gap. Important: Fit each compression ring to the cylinder in which it will be used.
Page 84: Piston And Connecting Rod Assemble
6-74 Marine/Industrial 4.3L Engine 2. Measure the J 8087 with a micrometer and record the reading. 4974 3. With a micrometer or caliper at a right angle to the piston pin bore, meausre the piston 11 mm (0.433 in) from the bottom of the skirt.
Page 85 Engine Marine/Industrial 4.3L 6-75 Important: When assembling the piston and connecting rod, the mark on the top of the piston must point to the front of the engine block. The left bank connecting rods should have the flange face toward the front of the engine block. The right bank connecting rods should have the flange face toward the rear of the engine block.
Page 86: Crankshaft And Bearings Clean And Inspect
6-76 Marine/Industrial 4.3L Engine 3. Space the compression piston ring end gaps 120 degrees apart. 4. Space the oil control piston ring end gaps a minimum of 90 degrees apart. 4967 Crankshaft and Bearings Clean and Inspect Tools Required J 7872 Magnetic Base Dial Indicator J 36660 Electronic Torque Angle Meter Caution: Refer to Safety Glasses Caution in Cautions and Notices.
Page 87 Engine Marine/Industrial 4.3L 6-77 5. Inspect the crankshaft for the following: • Crankshaft journals (1) should be smooth with no evidence of scoring or damage. • Deep grooves (2) • Scratches or uneven wear (3) • Pitted surfaces (4) • Wear or damage to the thrust journal surfaces •...
Page 88 6-78 Marine/Industrial 4.3L Engine 8. Use a suitable support to support the crankshaft on the front and rear journals. 9. Use the J 7872 in order to measure the crankshaft journal runout. The crankshaft runout should not exceed 0.025 mm (0.0010 in).
Page 89 Engine Marine/Industrial 4.3L 6-79 11. Inspect the crankshaft bearings for craters or pockets. Flattened sections on the crankshaft bearing halves also indicate fatigue. 52051 12. Inspect the crankshaft bearings for excessive scoring or discoloration. 13. Inspect the crankshaft bearings for dirt or debris imbedded into the crankshaft bearing material.
Page 90: Bearing Clearance Measuring Procedure
6-80 Marine/Industrial 4.3L Engine Bearing Clearance Measuring Procedures The crankshaft bearings are of the precision insert type and do not use shims for adjustment. If the clearances are excessive, then new upper and lower crankshaft bearings will be required. The service crankshaft bearings are available in the standard size and an undersize.
Page 91 Engine Marine/Industrial 4.3L 6-81 4. Install the crankshaft bearings into the crankshaft bearing caps. 334342 5. Install the crankshaft bearing caps in the original positions and with the arrow on the crankshaft bearing caps in the direction of the front of the engine block. Notice: Refer to Fastener Notice in Cautions and Notices.
Page 92 6-82 Marine/Industrial 4.3L Engine Micrometer Method for Connecting Rod Bearings Notice: Do not shim, scrape or file bearing inserts. Do not touch the bearing surface of the insert with bare fingers. Skin oil and acids will etch the bearing surface. 1.
Page 93 Engine Marine/Industrial 4.3L 6-83 Plastic Gauge Method for Crankshaft Bearings 1. Install the crankshaft bearings into the engine block. 334338 2. Install the crankshaft. 334336 3. Install the gauging plastic the full width of the journal. 500655 2000 Marine/Industrial...
Page 94 6-84 Marine/Industrial 4.3L Engine 4. Install the crankshaft bearings into the crankshaft bearing caps. 334342 5. Install the crankshaft bearing caps in the original positions and with the arrow on the crankshaft bearing caps in the direction of the front of the engine block. Notice: Refer to Fastener Notice in Cautions and Notices.
Page 95 Engine Marine/Industrial 4.3L 6-85 • If the crankshaft bearing clearance is within specifications, the crankshaft bearing is satisfactory. If the clearance is not within specifications, replace the crankshaft bearing. Always replace both the upper and lower crankshaft bearings as a unit. •...
Page 96: Crankshaft Balancer Clean And Inspect
6-86 Marine/Industrial 4.3L Engine Crankshaft Balancer Clean and Inspect Caution: Refer to Safety Glasses Caution in Cautions and Notices. 1. Clean the crankshaft balancer in cleaning solvent. 2. Dry the crankshaft balancer with compressed air. 3. Inspect the crankshaft balancer for the following: •...
Page 97 Engine Marine/Industrial 4.3L 6-87 3. Inspect the engine flywheel (automatic transmission) (if equipped) for the following: • Stress cracks around the engine flywheel-to-torque converter bolt hole locations (1) • Missing balance weights • Stress cracks around the engine flywheel-to-crankshaft bolt hole locations (2) or (3) Important: Do not attempt to repair the welded areas (if present) that retain the ring gear to the engine flywheel plate.
Page 98: Camshaft And Bearings Clean And Inspect
6-88 Marine/Industrial 4.3L Engine Camshaft and Bearings Clean and Inspect Tools Required J 7872 Magnetic Base Dial Indicator Caution: Refer to Safety Glasses Caution in Cautions and Notices. 1. Clean the engine camshaft in cleaning solvent. 2. Dry the engine camshaft with compressed air. 3.
Page 99: Camshaft Bearing Removal
Engine Marine/Industrial 4.3L 6-89 7. Measure the engine camshaft journals with a micrometer. If the camshaft journals are more than 0.025 mm (0.0010 in) out-of-round, then replace the engine camshaft. 188014 8. Measure for a bent engine camshaft or excessive engine camshaft runout using the J 7872.
Page 100 6-90 Marine/Industrial 4.3L Engine Important: A loose camshaft bearing may be caused by an enlarged, out-of-round or damaged engine block camshaft bearing bore. Important: Always remove the camshaft inner bearings #2 and #3 first. The camshaft outer bearings #1 and #4 serve as a guide for the J 33049.
Page 101: Camshaft Bearing Installation
Engine Marine/Industrial 4.3L 6-91 Camshaft Bearing Installation Tools Required J 33049 Camshaft Bearing Service Kit Important: When installing the camshaft bearings, always look in order to ensure that the camshaft bearing lubrication hole is located above the 3 o’clock position (1) or the 9 o’clock position (2).
Page 102 6-92 Marine/Industrial 4.3L Engine Caution: Refer to Safety Glasses Caution in Cautions and Notices. Important: The camshaft bearings vary in size. When ordering the new camshaft bearings, be sure to order the correct camshaft bearings for the application to be serviced. Always install the camshaft outer bearings #1 and #4 first.
Page 103: Balance Shaft Bearing And/Or Bushing Removal
Engine Marine/Industrial 4.3L 6-93 4. Install the NEW camshaft inner bearings #3 and #2. 4.1. Install the NEW camshaft inner bearing #3 onto the J33049 expander assembly. 4.2. Tighten the J 33049 expander assembly nut until snug. 4.3. Align the lubrication hole of the camshaft inner bearing #3 above the 3 o’clock position or the 9 o’clock position of the camshaft inner bearing bore #3 of the engine block.
Page 104: Balance Shaft Clean And Inspect
6-94 Marine/Industrial 4.3L Engine 1.4. Slide the J 38834-2 onto the J 38834-1 and into the balance shaft bore of the engine block. 1.5. Install the J 38834 bearing, washer and nut onto the J 38834-1. 1.6. Using a wrench, secure the J 38834-1 and then rotate the J 38834 nut clockwise until the balance shaft rear bearing is removed from the engine block.
Page 105: Balance Shaft Bearing And/Or Bushing Installation
Engine Marine/Industrial 4.3L 6-95 8. Inspect the driven gear bolt (5) for damaged threads. 9. Inspect the balance shaft drive gear for the following: • Excessive wear or damage • Nicks, burrs or scoring 9848 Balance Shaft Bearing and/or Bushing Installation Tools Required J 38834 Balance Shaft Service Kit...
Page 106: Timing Chain And Sprockets Clean And Inspect
6-96 Marine/Industrial 4.3L Engine Timing Chain and Sprockets Clean and Inspect Caution: Refer to Safety Glasses Caution in Cautions and Notices. 1. Clean the components with cleaning solvent. 2. Dry the components with compressed air. 3. Inspect the camshaft timing chain for binding or wear. 480575 4.
Page 107 Engine Marine/Industrial 4.3L 6-97 5. Inspect the valve push rods for the following: • Restriction of the oil passage (1) • Wear or scoring of the end contact surfaces (2). The end contact surfaces must be smooth with no scoring or excessive wear.
Page 108: Valve Lifters And Guides Clean And Inspect
6-98 Marine/Industrial 4.3L Engine Valve Lifters and Guides Clean and Inspect Important: Parts that are to be reused must be marked, sorted and organized for assembly. 1. Mark, sort and organize the components for assembly. Caution: Refer to Safety Glasses Caution in Cautions and Notices.
Page 109: Cylinder Head Disassemble
Engine Marine/Industrial 4.3L 6-99 Cylinder Head Disassemble Tools Required J 8062 Valve Spring Compressor Caution: Compressed valve springs have high tension against the valve spring compressor. Valve springs that are not properly compressed by or released from the valve spring compressor can be ejected from the valve spring compressor with intense force.
Page 110 6-100 Marine/Industrial 4.3L Engine 3. Dry the components with compressed air. 4. Use the J 8089 to clean the carbon from the cylinder head combustion chambers. Be careful not to scuff the combustion chambers. 5. Inspect the cylinder head for the following: •...
Page 111 Engine Marine/Industrial 4.3L 6-101 7. Use the J 9666 in order to measure the valve spring. Replace the valve spring if the valve spring tension is less than 338 N (76 lb) at 43.2 mm (1.70 in). 4960 8. Inspect the valve springs for squareness. 40075 9.
Page 112: Valve Guide Reaming/Valve And Seat Grinding
6-102 Marine/Industrial 4.3L Engine 10. Measure the valve stem-to-guide clearance. Excessive valve stem-to-guide clearance may cause an excessive oil consumption and may also cause a valve to break. Insufficient clearance will result in noisy and sticky functioning of the valve and will disturb the engine assembly smoothness.
Page 113 Engine Marine/Industrial 4.3L 6-103 2. Improper valve stem (1) to valve guide (2) clearance may cause excessive oil consumption. 156172 Caution: Refer to Safety Glasses Caution in Cautions and Notices. Important: Exhaust valves with excessive valve stem-to-guide clearance must be replaced with the available service valve that has an 0.0774 mm (0.0305 in) oversize valve stem.
Page 114: Cylinder Head Assemble
6-104 Marine/Industrial 4.3L Engine 6. Inspect the valve contact surface for the following: • Undersized margin (1) • Pitted surfaces (2) • Burnt or eroded areas (3) • Acceptable edge (margain) (4) Valves with excessive damage must be replaced. Minor imperfections of the valve or valve seat may be repaired.
Page 115 Engine Marine/Industrial 4.3L 6-105 4. Assemble the valve stem oil seal onto the valve stem. Caution: Refer to Safety Glasses Caution in Cautions and Notices. 5. Install the valve stem oil seal onto the valve guide using the J 42073. Tap the valve stem oil seal onto the valve guide until the J 42073 bottoms against the valve spring seat.
Page 116: Oil Pump Disassemble
6-106 Marine/Industrial 4.3L Engine Caution: Compressed valve springs have high tension against the valve spring compressor. Valve springs that are not properly compressed by or released from the valve spring compressor can be ejected from the valve spring compressor with intense force. Use care when compressing or releasing the valve spring with the valve spring compressor and when removing or installing the valve stem keys.
Page 117 Engine Marine/Industrial 4.3L 6-107 2. Remove the oil pump screen (if necessary). • The oil pump screen has a press fit into the oil pump cover. • DO NOT remove the oil pump screen from the pipe. The pipe and oil pump screen are serviced as a complete assembly.
Page 118: Oil Pump Clean And Inspect
6-108 Marine/Industrial 4.3L Engine 5. Remove the oil pump drive gear and the oil pump driven gear. 6. Matchmark the gear teeth for assembly. 5278 Caution: Refer to Safety Glasses Caution in Cautions and Notices. 7. Remove the following items: 7.1.
Page 119: Oil Pump Assemble
Engine Marine/Industrial 4.3L 6-109 • Damaged bolt hole threads • Worn oil pump driveshaft bore • Damaged or sticking oil pump pressure relief valve (minor imperfections may be removed with a fine oil stone) • Collapsed or broken oil pump pressure relief valve spring 4.
Page 120 6-110 Marine/Industrial 4.3L Engine 4. Install the oil pump cover. 5277 Notice: Refer to Fastener Notice in Cautions and Notices. 5. Install the oil pump cover bolts. Tighten Tighten the bolts to 12 N•m (106 lb in). 6. Inspect the oil pump for smoothness of operation by turning the oil pump driveshaft by hand.
Page 121: Valve Rocker Arm Cover Clean And Inspect
Engine Marine/Industrial 4.3L 6-111 Important: Install a NEW oil pump driveshaft retainer during assembly. 8. Install the oil pump driveshaft and the NEW oil pump driveshaft retainer. 5274 Valve Rocker Arm Cover Clean and Inspect Caution: Refer to Safety Glasses Caution in Cautions and Notices.
Page 122: Oil Pan Clean And Inspect
6-112 Marine/Industrial 4.3L Engine Oil Pan Clean and Inspect 1. Remove the oil pan baffle bolts and the oil pan baffle. 387763 Caution: Refer to Safety Glasses Caution in Cautions and Notices. 2. Clean the oil pan and the oil pan baffle in cleaning solvent. 3.
Page 123: Intake Manifold Disassemble
Engine Marine/Industrial 4.3L 6-113 Intake Manifold Disassemble 1. Remove the nuts, the studs and the accelerator control cable bracket. 374902 2. Remove the throttle body attaching studs. 12852 3. Remove the throttle body. 4. Remove the throttle body to upper intake manifold gasket. 5.
Page 124 6-114 Marine/Industrial 4.3L Engine 6. Remove the water outlet studs. 7. Remove the water outlet (1) or (2). 8. Remove the engine coolant thermostat. 480559 Important: Note the position and direction of the exhaust gas recirculation (EGR) valve before removal. It is possible to improperly install the EGR valve 180 degrees from the original position.
Page 125 Engine Marine/Industrial 4.3L 6-115 12. Remove the engine coolant temperature (ECT) sensor plug (1) or the ECT sensor (2) from the front of the lower intake manifold (if equipped). 480566 13. Remove the studs and the ignition coil. 480561 14. Remove the manifold absolute pressure (MAP) sensor. 15.
Page 126 6-116 Marine/Industrial 4.3L Engine 17. Remove the fuel pipe bolt (4). 18. Remove the fuel pipe retainer nuts (1). 19. Remove the fuel pipe retainer (2). 20. Remove the fuel pipe (3). 21. Remove and discard the fuel seal retainers (5). 22.
Page 127: Intake Manifold Clean And Inspect
Engine Marine/Industrial 4.3L 6-117 31. Remove the fuel meter body seal and discard. 32. Remove the 6 poppet nozzles from the lower intake manifold bores. 33. Remove the fuel meter body. 34. Remove the bolt and the fuel meter body bracket. 523513 Intake Manifold Clean and Inspect Caution: Refer to Safety Glasses Caution in Cautions and...
Page 128: Intake Manifold Assemble
6-118 Marine/Industrial 4.3L Engine 5. Inspect the upper intake manifold for the following: • Cracks or other damage to the exterior (1) • Cracking or damage in the gasket grooves (2) and (3) • Damage to the throttle body mounting surface (4) •...
Page 129 Engine Marine/Industrial 4.3L 6-119 6. Install a NEW fuel meter body seal into the groove of the fuel meter body. 7. Install NEW upper intake manifold to lower intake manifold gasket into the groove of the upper intake manifold. 8. Install the upper intake manifold onto the lower intake manifold.
Page 130 6-120 Marine/Industrial 4.3L Engine 13. Install the engine wiring harness bracket and nut. Tighten Tighten the engine wiring harness bracket nut to 12 N•m (106 lb in). 14. Install the NEW fuel seals (8) (black O-rings) into the fuel meter body. 15.
Page 131 Engine Marine/Industrial 4.3L 6-121 26. Install the ignition coil and studs. Tighten Tighten the ignition coil studs to 12 N•m (106 lb in). 480561 27. If reusing the engine coolant temperature (ECT) sensor plug (1) or the ECT sensor (2) (if equipped), apply sealant GM P/ N 12346004 or equivalent to the threads of the ECT sensor plug (1) or the ECT sensor (2).
Page 132 6-122 Marine/Industrial 4.3L Engine 30. Install the EGR valve bolts. Tighten 30.0. Tighten the EGR valve bolts on the first pass to 7 N•m (62 lb in). 30.1. Tighten the EGR valve bolts on the final pass to 30 N•m (22 lb ft). 480563 31.
Page 133: Exhaust Manifold Clean And Inspect
Engine Marine/Industrial 4.3L 6-123 36. If reusing the fasteners, apply threadlock GM P/N 12345382 or equivalent to the threads of the throttle body attaching studs. 37. Install the throttle body attaching studs. Tighten Tighten the throttle body attaching studs to 9 N•m (80 lb in). 12852 38.
Page 134: Water Pump Clean And Inspect
6-124 Marine/Industrial 4.3L Engine 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. 334528 Water Pump Clean and Inspect Caution: Refer to Safety Glasses Caution in Cautions and...
Page 135: Thread Repair
Engine Marine/Industrial 4.3L 6-125 Thread Repair General purpose thread repair kits are available commercially. Caution: Refer to Safety Glasses Caution in Cautions and Notices. Important: Refer to the thread repair kit manufacturer’s instructions regarding the size of the drill and which tap to use. Always avoid any buildup of chips.
Page 136: Service Prior To Assembly
6-126 Marine/Industrial 4.3L Engine Service Prior to Assembly • When the components are re-installed into an engine, return the components to the original location, • Dirt will cause premature wear of the rebuilt position and direction. engine. Clean all the components. •...
Page 137 Engine Marine/Industrial 4.3L 6-127 This page left intentionally blank 2000 Marine/Industrial...
Page 138: Engine Block Plug Installation
6-128 Marine/Industrial 4.3L Engine Engine Block Plug Installation Tools Required J 41712 Oil Pressure Switch Socket Caution: Refer to Safety Glasses Caution in Cautions and Notices. 1. Install a NEW oil filter bypass valve. 1.1. Install the oil filter bypass valve into the oil gallery bore until slightly below flush with the surface of the engine block.
Page 139 Engine Marine/Industrial 4.3L 6-129 6. Install the spring type S pin (crankshaft rear oil seal housing locator) (if required). 334546 7. Apply sealant GM P/N 12346004 or equivalent to the outside diameter of the NEW expansion cup plug (balance rear bearing hole). 8.
Page 140 6-130 Marine/Industrial 4.3L Engine 11. Apply sealant GM P/N 12346004 or equivalent to the threads of the engine block right rear oil gallery plug, the engine block left rear oil gallery plug and the engine block left side oil gallery plug. Tighten 11.1.
Page 141 Engine Marine/Industrial 4.3L 6-131 15. Install the right side dowel pins (cylinder head locator) (if required). 334314 16. Apply sealant GM P/N 12346004 or equivalent to the threads of the engine block coolant drain hole plugs. 17. Install the engine block coolant drain hole plugs. Tighten Tighten the engine block coolant drain hole plugs to 20 N•m (15 lb ft).
Page 142: Crankshaft And Bearings Installation
6-132 Marine/Industrial 4.3L Engine 21. If reusing the engine oil pressure gauge sensor, apply sealant GM P/N 12346004 or equivalent to the threads of the engine oil pressure gauge sensor. 22. Install the engine oil pressure gauge sensor using the J 41712.
Page 143 Engine Marine/Industrial 4.3L 6-133 3. Apply clean engine oil to the crankshaft bearing journals. 4. Install the crankshaft. 334336 5. Install the crankshaft bearings into the crankshaft bearing caps. 6. 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.
Page 144: Crankshaft Rear Oil Seal And Housing Installation
6-134 Marine/Industrial 4.3L Engine 11.2. Tighten the crankshaft bearing cap bolts on the final pass an additional 73 degrees using the J 36660. 12. Measure the crankshaft end play. 12.1. Firmly thrust the crankshaft rearward, and then forward. This will align the crankshaft rear bearing thrust surfaces.
Page 145 Engine Marine/Industrial 4.3L 6-135 Important: Always use a NEW crankshaft rear oil seal housing gasket when installing the crankshaft rear oil seal housing. 2. Install the NEW crankshaft rear oil seal housing gasket. 334319 3. Install the crankshaft rear oil seal housing onto the crankshaft rear oil seal housing retainer stud.
Page 146: Piston, Connecting Rod And Bearing Installation
6-136 Marine/Industrial 4.3L Engine 10. Remove the sleeve from the crankshaft rear oil seal. 11. Apply a small amount (2 to 3 drops) of clean engine oil to the outside diameter of the crankshaft rear oil seal. 12. Install the crankshaft rear oil seal onto the J 35621-B. 13.
Page 147 Engine Marine/Industrial 4.3L 6-137 3. Install the J 8037 onto the piston and compress the piston rings. 480573 Important: The mark on the top of the piston must face the front of the engine block. When assembled, the flanges on the connecting rod and connecting rod cap should face to the front of the engine block on the left bank, and to the rear of the engine block on the right bank.
Page 148 6-138 Marine/Industrial 4.3L Engine 6. Remove the J 5239. 31373 Notice: Refer to Fastener Notice in Cautions and Notices. 7. Install the connecting rod caps, bearings and nuts. Tighten 7.1. Tighten the nuts evenly on the first pass to 27 N•m (20 lb ft).
Page 149: Balance Shaft Installation
Engine Marine/Industrial 4.3L 6-139 Camshaft Installation 1. Apply clean engine oil GM P/N 12345610 or equivalent, or engine oil supplement GM P/N 1052367 or equivalent to the following components: • The engine camshaft lobes • The camshaft bearing journals • The camshaft bearings 2.
Page 150 6-140 Marine/Industrial 4.3L Engine Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the balance shaft retainer and bolts. Tighten Tighten the balance shaft retainer bolts to 12 N•m (106 lb in). 188031 4. Install the balance shaft driven onto the balance shaft. 5.
Page 151 Engine Marine/Industrial 4.3L 6-141 9. Install the balance shaft drive gear. DO NOT install the camshaft sprocket bolts at this time. 9847 10. Rotate the engine camshaft so that the timing mark on the balance shaft drive gear is in the 12 o’clock position. 9848 11.
Page 152: Timing Chain And Sprockets Installation
6-142 Marine/Industrial 4.3L Engine 12. Rotate the balance shaft so that the timing mark on the balance shaft driven gear is in the 6 o’clock position. 9849 13. Position the balance shaft drive gear onto the engine camshaft. 14. Look to ensure that the balance shaft drive gear and the balance shaft driven gear timing marks are aligned.
Page 153 Engine Marine/Industrial 4.3L 6-143 2. Align the keyway of the crankshaft sprocket with the crankshaft balancer key. Caution: Refer to Safety Glasses Caution in Cautions and Notices. 3. Use the J 5590 in order to install the crankshaft sprocket. 480574 4.
Page 154: Engine Front Cover Installation
6-144 Marine/Industrial 4.3L Engine Notice: Refer to Fastener Notice in Cautions and Notices. Important: Do not use a hammer to install the camshaft sprocket onto the camshaft. To do so may dislodge the expansion cup plug (camshaft rear bearing hole). 7.
Page 155: Oil Pump Installation
Engine Marine/Industrial 4.3L 6-145 Important: DONOT reuse the original crankshaft position sensor seal (o-ring). When installing the crankshaft position sensor, be sure the crankshaft position sensor is fully seated and held stationary in the engine front cover crankshaft position sensor bore.
Page 156: Oil Pan Installation
6-146 Marine/Industrial 4.3L Engine Important: DO not reuse the oil pump driveshaft retainer. During assembly, install a NEW oil pump driveshaft retainer. 2. Install the oil pump. 3. Position the oil pump onto the pins. 330576 Notice: Refer to Fasteners Notice in Cautions and Notices. 4.
Page 157 Engine Marine/Industrial 4.3L 6-147 2. Apply a 5 mm (0.197 in) wide and 25 mm (1.0 in) long bead of adhesive GM P/N 12346141 or equivalent to both the right and left sides of the crankshaft rear oil seal housing to engine block junction at the oil pan sealing surfaces.
Page 158 6-148 Marine/Industrial 4.3L Engine Notice: Refer to Fastener Notice in Cautions and Notices. 6. Install the oil pan bolts and nuts, but do not tighten. 7. Measure the pan-to-transmission housing clearance using a feeler gauge and a straight edge. Use a feeler gauge to check the clearance between the oil pan-to-transmission housing measurement points.
Page 159: Crankshaft Balancer Installation
Engine Marine/Industrial 4.3L 6-149 12. Install the NEW engine oil level sensor (if applicable). Tighten Tighten the engine oil level sensor to 13 N•m (115 lb in). 387460 Crankshaft Balancer Installation Tools Required J 23523-F Balancer Remover and Installer 1. Look to ensure that the front groove pin (crankshaft balancer) is installed in the proper location (if applicable).
Page 160 6-150 Marine/Industrial 4.3L Engine 5. Use the J 23523-F in order to press the crankshaft balancer onto the crankshaft. 5.1. Install the J 23523-F plate and bolts onto the front of the crankshaft balancer. Tighten Tighten the J 23523-F plate bolts to 25 N•m (18 lb ft). 5.2.
Page 161: Valve Lifter Installation
Engine Marine/Industrial 4.3L 6-151 9. Install the crankshaft balancer washer and the bolt. Tighten Tighten the crankshaft balancer bolt to 95 N•m (70 lb ft). 173172 Valve Lifter Installation 1. Apply lubricant GM P/N 12345501 or equivalent to the valve lifter rollers.
Page 162: Cylinder Head Installation
6-152 Marine/Industrial 4.3L Engine Cylinder Head Installation (Left) Tools Required J 36660 Electronic Torque Angle Meter 1. Clean the cylinder head gasket surfaces on the engine block. 2. Inspect the dowel pins (cylinder head locators) for proper installation. 3. Clean the cylinder head gasket surfaces on the cylinder head.
Page 163 Engine Marine/Industrial 4.3L 6-153 6. Apply sealant GM P/N 12346004 or equivalent to the threads of the cylinder head bolts. Notice: Refer to Fastener Notice in Cautions and Notices. 7. Install the cylinder head bolts finger tight. 480533 8. Tighten the cylinder head bolts in sequence on the first pass.
Page 164 6-154 Marine/Industrial 4.3L Engine 11. Measure the NEW spark plugs for the proper gap. Adjust the spark plug gap if necessary. Specification Spark plug gap to 1.52 mm (0.060 in) 12. Install the spark plugs. Tighten • Tighten the spark plugs for a USED cylinder head to 15 N•m (11 lb ft) •...
Page 165 Engine Marine/Industrial 4.3L 6-155 Cylinder Head Installation (Right) Tools Required J 36660 Electronic Torque Angle Meter 1. Clean the cylinder head gasket surfaces on the engine block. 2. Inspect the dowel pins (cylinder head locators) for proper installation. 3. Clean the cylinder head gasket surfaces on the cylinder head.
Page 166 6-156 Marine/Industrial 4.3L Engine 6. Apply sealant GM P/N 12346004 or equivalent to the threads of the cylinder head bolts. Notice: Refer to Fastener Notice in Cautions and Notices. 7. Install the cylinder head bolts finger tight. 480537 8. Tighten the cylinder head bolts in sequence on the first pass.
Page 167: Valve Rocker Arm And Push Rod Installation
Engine Marine/Industrial 4.3L 6-157 12. Measure the NEW spark plugs for the proper gap. Adjust the spark plug gap if necessary. Specification Spark plug gap to 1.52 mm (0.060 in) 13. Install the spark plugs. Tighten • Tighten the spark plugs for a USED cylinder head to 15 N•m (11 lb ft) •...
Page 168 6-158 Marine/Industrial 4.3L Engine 3. Apply prelube GM P/N 12345501 or equivalent to the following valve rocker arm contact surfaces: • Valve pushrod socket (1) • Roller pivot (2) • Valve stem tip (3) 480551 Notice: Refer to Fastener Notice in Cautions and Notices. 4.
Page 169: Intake Manifold Installation
Engine Marine/Industrial 4.3L 6-159 Intake Manifold Installation Notice: Applying excessive amounts of sealant may prohibit the intake manifold gaskets from sealing properly. 1. Apply a 4.0 mm (0.157 in) patch of adhesive GM P/N 12346141 or equivalent to the cylinder head side of the lower intake manifold gasket at each end.
Page 170 6-160 Marine/Industrial 4.3L Engine 5. Install the lower intake manifold onto the engine block. Notice: Refer to Fastener Notice in Cautions and Notices. 6. If reusing the fasteners, apply threadlock GM P/N 12345382 or equivalent to the threads of the lower intake manifold bolts.
Page 171: Distributor Installation
Engine Marine/Industrial 4.3L 6-161 Distributor Installation Important: The engine front cover has 2 alignment tabs and the crankshaft balancer has 2 alignment marks (spaced 90 degrees apart) which are used for positioning number 1 piston at Top Dead Center (TDC). With the piston on the compression stroke and at top dead center, the crankshaft balancer alignment mark (1) must align with the engine front cover tab (2) and the crankshaft balancer alignment mark (4) must align with the engine front cover...
Page 172 6-162 Marine/Industrial 4.3L Engine 4. Align the indent hole on the driven gear with the paint mark on the distributor housing. 5. Ensure that the distributor rotor segment points to the cap hold area. 492137 6. Align the slotted tang in the oil pump driveshaft with the distributor driveshaft.
Page 173 Engine Marine/Industrial 4.3L 6-163 9. Once the distributor is fully seated, align the distributor rotor segment with the number 6 pointer (1) that is cast into the distributor base. If the distributor rotor segment does not come with a few degrees of the number 6 pointer (1), the gear mesh between the distributor and camshaft may be off a tooth or more.
Page 174: Valve Rocker Arm Cover Installation
6-164 Marine/Industrial 4.3L Engine 12. Install the ignition coil wire harness. 387772 Valve Rocker Arm Cover Installation (Left) Important : Do not reuse the valve rocker arm cover gasket or the valve rocker arm cover grommets. 1. Install the NEW valve rocker arm cover gasket into the groove of the valve rocker arm cover.
Page 175 Engine Marine/Industrial 4.3L 6-165 Notice: Refer to Fastener Notice in Cautions and Notices. 4. Install the valve rocker arm cover bolts. Tighten Tighten the valve rocker arm cover bolts to 12 N . m (106 lb in). 328566 Valve Rocker Arm Cover Installation (Right) Important: Do not reuse the valve rocker arm cover gasket or the valve rocker arm cover bolt grommets.
Page 176: Oil Level Indicator And Tube Installation
6-166 Marine/Industrial 4.3L Engine Notice: Refer to Fastener Notice in Cautions and Notices. 4. Install the valve rocker arm cover bolts. Tighten Tighten the valve rocker arm cover bolts to 12 N . m (106 lb in). 328568 Oil Level Indicator and Tube Installation 1.
Page 177: Water Pump Installation
Engine Marine/Industrial 4.3L 6-167 Water Pump Installation Tools Required J 41240 Fan Clutch Remover and Installer 1. If reusing the fasteners, apply sealant GM P/N 12346004 or equivalent to the threads of the water pump bolts. 2. Install the water pump and the NEW water pump gaskets. Notice: Refer to Fastener Notice in Cautions and Notices.
Page 178: Exhaust Manifold Installation
6-168 Marine/Industrial 4.3L Engine Exhaust Manifold Installation (Left) 1. Install the NEW exhaust manifold gaskets. 328540 2. Install the exhaust manifold. 3. Install the spark plug wire shields. Notice: Refer to Fastener Notice in Cautions and Notices. 4. If reusing the fasteners, apply threadlock GM P/N 12345493 or equivalent to the threads of the exhaust manifold bolts and stud.
Page 179: Clutch Pilot Bearing Installation
Engine Marine/Industrial 4.3L 6-169 2. Install the exhaust manifold. 3. Install the spark plug wire shields. Notice: Refer to Fastener Notice in Cautions and Notices. 4. If reusing the fasteners, apply threadlock GM P/N 12345493 or equivalent to the threads of the exhaust manifold bolts and stud.
Page 180 6-170 Marine/Industrial 4.3L Engine 1. Install the engine flywheel (1) or (2) to the crankshaft. Align the engine flywheel locator hole to the flywheel locator pin. 188129 Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the engine flywheel bolts. Tighten Tighten the engine flywheel bolts in sequence (1-6) to 100 N•m (74 lb ft).
Page 181: Engine Setup And Testing
Engine Marine/Industrial 4.3L 6-171 Engine Set-Up and Testing After overhaul, the engine must be tested before it is installed in the vehicle. If a suitable test stand is not available, the following procedures can be used after the engine is installed in the vehicle. 1.
Page 182: Description And Operation
6-172 Marine/Industrial 4.3L Engine the upper manifold. The lower manifold has an exhaust gas Description and Operation recirculation (EGR) port cast into the manifold for mixture. The (EGR) valve bolts into the lower intake manifold. The Engine Component Description Central Sequential Multiport Fuel Injection system uses Balance Shaft multiple fuel injectors to meter and distribute fuel to each The cast iron balance shaft is mounted in the crankcase...
Page 183: New Product Information
Engine Marine/Industrial 4.3L 6-173 The drive belt system may use one belt or two belts. The • Cylinder head bolts, the crankshaft bearing cap drive belt is thin so that it can bend backwards and has bolts, the connecting rod bolts and balance shaft several ribs to match the grooves in the pulleys.
Page 184 6-174 Marine/Industrial 4.3L Engine Engine Identification • The Vehicle Identification Number (VIN) Derivative is located on the left side rear of the engine block (1) or on the right side rear (2) and typically is a nine digit number stamped or laser etched onto the engine at the vehicle assembly plant.
Page 185: Lubrication
Engine Marine/Industrial 4.3L 6-175 Lubrication Engine Lubrication and piston pins are lubricated by oil splash. Full pressure lubrication, through a full-flow oil filter is supplied by a gear-type oil pump. Oil is drawn up through the oil pump Cleanliness and Care screen and passes through the pump to the oil filter.
Page 186: Replacing Engine Gaskets
6-176 Marine/Industrial 4.3L Engine • or oil. At the time of installation, the components should be installed in the same location and with the same • Specific components such as crankshaft oil seals or mating surface as when removed. valve stem oil seals may require lubrication during •...
Page 187: Separating Parts
Engine Marine/Industrial 4.3L 6-177 clamping properly or cause damage when the fastener is • The threaded surfaces must be clean and dry. tightened. • Apply the threadlock sealant as specified on the The surfaces to be sealed must be clean and dry. threadlock sealant container.
Page 188: Tools And Equipment
6-178 Marine/Industrial 4.3L Engine • quickly and safely accomplish the operations for which the Piston and the piston pin tools are intended. The use of special tools will also minimize • Piston to the specific cylinder bore possible damage to engine components. Some precision •...
Page 189: Special Tools And Equipment
Engine Marine/Industrial 4.3L 6-179 Special Tools and Equipment Illustration Illustration Tool Number/Description Tool Number/Description J 3049-A J 5892-D Valve Lifter Remover Valve Spring Compressor J 5239 J 7872 Connecting Rod Bolt Magnetic Base Dial Guide Set Indicator J 5590 J 8001 Installer Dial Indicator Set J 5825-A...
Page 190 6-180 Marine/Industrial 4.3L Engine Illustration Illustration Tool Number/Description Tool Number/Description J 8087 J 22794 Cylinder Bore Gauge Spark Plug Port Adapter J 8089 J 23523-F Carbon Removing Brush Balancer Remover and Installer J 8092 J 24086-C Universal Driver Handle Piston Pin Remover/Installer J 9666 J 24270 Valve Spring Tester...
Page 191 Engine Marine/Industrial 4.3L 6-181 Illustration Illustration Tool Number/Description Tool Number/Description J 28428-E J 36996 High Intensity Black Balance Shaft Installer Light Kit J 33049 J 38606 Camshaft Bearing Valve Spring Compressor Service Kit J 35468 J 38834 Cover Aligner/Seal Installer Balance Shaft Service Kit J 35621-B J 39580...
Page 192 6-182 Marine/Industrial 4.3L Engine Illustration Tool Number/Description J 41427 Engine Lift Bracket J 41602 Body Protection Hoist Adapter Set J 41712 Oil Pressure Switch Socket J 42073 Valve Stem Seal Installer J 43276 Clutch Pilot Bearing Remover 2000 Marine/Industrial...
Page 193 Notes...
Page 194 Notes...
Page 195 Notes...
Page 196 TP-6103 1/01...

GMC Powertrain 4.3 L Service Manual

Quick Links

Need help?

Questions and answers

Related Manuals for GMC Powertrain 4.3 L

Summary of Contents for GMC Powertrain 4.3 L

Table of Contents