Chevrolet 5.7L Corvette 2004 Shop Manual
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Chevrolet 5.7L Corvette 2004 Shop Manual

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Table of Contents

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SPECIFICATIONS

FASTENER TIGHTENING SPECIFICATIONS
Fastener Tightening Specifications
Accessory Drive Belt Idler Pulley Bolt
Accessory Drive Belt Tensioner Bolt
Air Conditioning (A/C) Compressor and Condenser Hose Bolt
A/C Drive Belt Idler Pulley Bolt
A/C Drive Belt Tensioner Bolt
Air Injection Reaction (AIR) Pipe-to-Exhaust Manifold Bolts
AIR Right Side Pipe Bracket-to-Cylinder Head Bolt
Automatic Transmission Fluid Cooler Line Clamp Bolt - at Oil Pan
Automatic Transmission Fluid Cooler Line Clamp Bolt - at Right Transmission Cover
Automatic Transmission Fluid Cooler Pipe
Camshaft Retainer Bolts
Camshaft Sensor Bolt
Camshaft Sprocket Bolts
Connecting Rod Bolts - First Pass
Connecting Rod Bolts - Final Pass
Coolant Temperature Gage Sensor
Crankshaft Balancer Bolt - Installation Pass-to Ensure the Balancer is Completely
Installed
Crankshaft Balancer Bolt - First Pass - Install a NEW Bolt After the Installation Pass
and Tighten as Described in the First and Final Passes
Crankshaft Balancer Bolt - Final Pass
Crankshaft Bearing Cap Bolts - Inner Bolts - First Pass in Sequence
Crankshaft Bearing Cap Bolts - Inner Bolts - Final Pass in Sequence
Crankshaft Bearing Cap Side Bolts
Crankshaft Bearing Cap Studs - Outer Studs - First Pass in Sequence
Crankshaft Bearing Cap Studs - Outer Studs - Final Pass in Sequence
Crankshaft Oil Deflector Nuts
Crankshaft Position Sensor Bolt
Crossmember Nut
2004 ENGINE PERFORMANCE
Engine Mechanical (Introduction) - 5.7L - Corvette
Application
Specification
Metric English
50 N.m 37 lb ft
50 N.m 37 lb ft
27 N.m 20 lb ft
50 N.m 37 lb ft
25 N.m 18 lb ft
20 N.m 15 lb ft
20 N.m 15 lb ft
106 lb
12 N.m
in
2.2
19 lb in
N.m
25 N.m 18 lb ft
25 N.m 18 lb ft
25 N.m 18 lb ft
35 N.m 26 lb ft
20 N.m 15 lb ft
75 degrees
20 N.m 15 lb ft
330
240 lb ft
N.m
50 N.m 37 lb ft
140 degrees
20 N.m 15 lb ft
80 degrees
25 N.m 18 lb ft
20 N.m 15 lb ft
53 degrees
25 N.m 18 lb ft
25 N.m 18 lb ft
81 lb ft
110

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Summary of Contents for Chevrolet 5.7L Corvette 2004

  • Page 1: Specifications

    2004 ENGINE PERFORMANCE Engine Mechanical (Introduction) - 5.7L - Corvette SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Fastener Tightening Specifications Specification Application Metric English Accessory Drive Belt Idler Pulley Bolt 50 N.m 37 lb ft Accessory Drive Belt Tensioner Bolt 50 N.m 37 lb ft Air Conditioning (A/C) Compressor and Condenser Hose Bolt 27 N.m 20 lb ft A/C Drive Belt Idler Pulley Bolt...
  • Page 2 Cylinder Head Bolts - First Design - First Pass all M11 Bolts in Sequence 30 N.m 22 lb ft Cylinder Head Bolts - First Design - Second Pass all M11 Bolts in Sequence 90 degrees Cylinder Head Bolts - First Design - Final Pass all M11 Bolts in Sequence - Excluding 90 degrees the Medium Length Bolts at the Front and Rear of Each Cylinder Head Cylinder Head Bolts - First Design - Final Pass M11 Medium Length Bolts at the...
  • Page 3 Exhaust Manifold Bolts - Final Pass 25 N.m 18 lb ft Exhaust Manifold Heat Shield Bolts 9 N.m 80 lb in Flywheel Housing Bolt 50 N.m 37 lb ft Fuel Injection Fuel Rail Bolts 10 N.m 89 lb in Generator Bracket Bolt 50 N.m 37 lb ft 106 lb Ignition Coil Bracket-to-Valve Rocker Arm Cover Bolts...
  • Page 4 Spark Plugs - Cylinder Heads - New 20 N.m 15 lb ft Spark Plugs - all Subsequent Installations 15 N.m 11 lb ft Steering Knuckle Nut - First Pass 20 N.m 15 lb ft Steering Knuckle Nut - Second Pass 50 degrees Steering Knuckle Nut - Final Pass 55 N.m 41 lb ft...
  • Page 5 Block 59.08-59.13 mm 2.325-2.327 in Camshaft Bearing Bore 1 and 5 Diameter - First Design 58.83-58.88 mm 2.316-2.318 in Camshaft Bearing Bore 2 and 4 Diameter - First Design 58.58-58.63 mm 2.306-2.308 in Camshaft Bearing Bore 3 Diameter - First Design Camshaft Bearing Bore 1 and 5 Diameter - Second 59.58-59.63 mm 2.345-2.347 in...
  • Page 6 Service 0.006 mm 0.00023 in 0.11-0.51 mm 0.00433-0.02 in Connecting Rod Side Clearance Crankshaft 53.318-53.338 2.0991-2.0999 in Connecting Rod Journal Diameter - Production 53.308 mm 2.0987 in Connecting Rod Journal Diameter - Service 0.005 mm 0.0002 in Connecting Rod Journal Out-of-Round - Production 0.01 mm 0.0004 in Connecting Rod Journal Out-of-Round - Service...
  • Page 7 0.22 mm 0.008 in Surface Flatness - Exhaust Manifold Deck 0.22 mm 0.008 in Surface Flatness - Intake Manifold Deck Intake Manifold 0.5 mm 0.02 in Surface Flatness - Measured at Gasket Sealing Surfaces Lubrication System 6.151 Liters 6.5 Quarts Oil Capacity - with Filter 5.678 Liters 6.0 Quarts...
  • Page 8 -0.008 to +0.176 -0.0003 to +0.0069 Piston Ring to Groove Clearance - Oil Control Ring - Production -0.008 to +0.176 -0.0003 to +0.0069 Piston Ring to Groove Clearance - Oil Control Ring - Service Pistons and Pins 98.969-98.987 Piston - Piston Diameter- Non Coated Skirt - at Size 3.8964-3.8997 in Point 98.984-99.027...
  • Page 9 11.79 mm 0.464 in Valves - Valve Lift - Intake 12.16 mm 0.479 in Valves - Valve Lift - Exhaust 46 degrees Valves - Valve Seat Angle 0.05 mm 0.002 in Valves - Valve Seat Runout 1.78 mm 0.07 in Valves - Valve Seat Width - Exhaust 1.02 mm 0.04 in...
  • Page 10 Compression Ratio 1-8-7-2-6-5-4-3 Firing Order 1.016 mm 0.04 in Spark Plug Gap Block 59.08-59.13 mm 2.325-2.327 in Camshaft Bearing Bore 1 and 5 Diameter - First Design 58.83-58.88 mm 2.316-2.318 in Camshaft Bearing Bore 2 and 4 Diameter - First Design 58.58-58.63 mm 2.306-2.308 in Camshaft Bearing Bore 3 Diameter - First Design...
  • Page 11 Connecting Rod Bore Diameter - Bearing End 0.006 mm 0.00023 in Connecting Rod Bore Out-of-Round - Bearing End Connecting Rod Bore Out-of-Round - Bearing End - 0.006 mm 0.00023 in Service 0.11-0.51 mm 0.00433-0.02 in Connecting Rod Side Clearance Crankshaft 53.318-53.338 2.0991-2.0999 in Connecting Rod Journal Diameter - Production...
  • Page 12 mm (6.0 in) Area Surface Flatness - Block Deck - Measuring the Overall 0.1 mm 0.004 in Length of the Cylinder Head 0.22 mm 0.008 in Surface Flatness - Exhaust Manifold Deck 0.22 mm 0.008 in Surface Flatness - Intake Manifold Deck Intake Manifold 0.5 mm 0.02 in...
  • Page 13 Piston Ring to Groove Clearance - Second Compression 0.05-0.088 mm 0.002-0.0034 in Ring - Production Piston Ring to Groove Clearance - Second Compression 0.05-0.088 mm 0.002-0.0034 in Ring - Service -0.008 to +0.0176 -0.0003 to +0.0069 Piston Ring to Groove Clearance - Oil Control Ring - Production -0.008 to +0.0176 -0.0003 to +0.0069...
  • Page 14 45 degrees Valves - Valve Face Angle 1.25 mm 0.05 in Valves - Valve Face Width Net Lash - No Adjustment Valves - Valve Lash 14.02 mm 0.552 in Valves - Valve Lift - Intake 13.92 mm 0.548 in Valves - Valve Lift - Exhaust 46 degrees Valves - Valve Seat Angle 0.05 mm...
  • Page 15 Engine Flywheel Bolt Threads Threadlock 12345382 10953489 Engine Oil 5W-30 Synthetic Oil 12345885 10953468 Engine Oil Supplement Fluorescent Dye 12345795 10953470 Exhaust Manifold Bolt Threads Threadlock 12345493 10953488 Fuel Rail Bolt Threads Threadlock 12345382 10953489 Ignition Coil and Bracket Assembly Bolts Threadlock 12345382 10953489...
  • Page 16 Engine Block - Front View Drill Depth - Tap Depth - Thread Counterbore Maximum mm Maximum mm Hole Size Insert Drill Tool Driver (in) (in) M8 x 42385- 42385- J 42385-207 42385- 42385- 22.5 (0.885) 17.5 (0.688) 1.25 M10 x 42385- 42385- J 42385-212...
  • Page 17 Fig. 2: Engine Block Bolt Holes Component View - Rear View Courtesy of GENERAL MOTORS CORP. Engine Block - Rear View Drill Depth - Tap Depth - Thread Counterbore Maximum mm Maximum mm Hole Size Insert Drill Tool Driver (in) (in) M10 x 42385-...
  • Page 18 M8 x 42385- 42385- J 42385-207 42385- 42385- 22.5 (0.885) 17.5 (0.688) 1.25 Engine Block - Left Side View Fig. 3: Engine Block Bolt Holes Component View - Left Side View Courtesy of GENERAL MOTORS CORP. Engine Block - Left Side View Tap Depth - Thread Counterbore...
  • Page 19 M11 x 2.0 First 124.0 (4.88) 115.0 (4.52) Design M11 x 2.0 Second 69.0 (2.72) 60.0 (2.36) Design M11 x 2.0 69.0 (2.72) 60.0 (2.36) Bolt holes 7, second design, and 8 have a 30 mm (1.18 in) counterbore included in the 69.0 mm (2.72 in) drill depth.
  • Page 20 J 42385 M28 x 1.25 22.5 (0.885) 17.5 (0.688) M8 x 1.25 26.5 (1.04) 19.0 (0.784) M11 x 2.0 69.0 (2.72) 60.0 (2.36) M10 x 1.25 29.0 (1.141) 23.0 (0.905) M10 x 1.5 27.0 (1.062) 21.5 (0.846) M16 x 1.5 N/A N/A N/A N/A M11 x 2.0...
  • Page 21 Fig. 5: Engine Block Bolt Holes Component View - Bottom View Courtesy of GENERAL MOTORS CORP. Engine Block - Bottom View Drill Depth - Tap Depth - Thread Counterbore Maximum mm Maximum mm Hole Size Insert Drill Tool Driver (in) (in) M10 x 42385-...
  • Page 22 M10 x 42385- 42385- 42385- 42385- 53.5 (2.10) 44.0 (1.73) M10 x 42385- 42385- 42385- 42385- 31.0 (1.22) 25.5 (1.0) M8 x 42385- 42385- J 42385-207 42385- 42385- 22.5 (0.885) 17.5 (0.688) 1.25 M10 x 42385- 42385- 42385- 42385- 53.5 (2.10) 44.0 (1.73) M10 x 42385-...
  • Page 23 M10 x 42385- 42385- 42385- 42385- 53.5 (2.10) 44.0 (1.73) M10 x 42385- 42385- 42385- 42385- 31.0 (1.22) 25.5 (1.0) M8 x 42385- 42385- J 42385-207 42385- 42385- 22.5 (0.885) 17.5 (0.688) 1.25 Bolt holes 2, 5, 10, 11, 18, 21, 24, 28, 29, and 34 have a 20.5 mm (0.807 in) counterbore included in the 53.5 mm (2.10 in) drill depth.
  • Page 24 Engine Block - Top View Drill Depth - Tap Depth - Thread Counterbore Maximum mm Maximum mm Hole Size Insert Drill Tool Driver (in) (in) M8 x 42385- 42385- J 42385-207 42385- 42385- 26.5 (1.04) 19.0 (0.784) 1.25 M16 x M8 x 42385- 42385-...
  • Page 25 Drill Depth - Tap Depth - Thread Counterbore Maximum mm Maximum mm Hole Size Insert Drill Tool Driver (in) (in) M8 x 42385- 42385- J 42385-207 42385- 42385- 26.5 (1.04) 19.0 (0.784) 1.25 6-9 M6 x 1.0 42385- 42385- J 42385-202 42385- 42385- 20.05 (0.789)
  • Page 26 M10 x 42385- 42385- 42385- 42385- J 42385-212 28.0 (1.10) 20.0 (0.787) M10 x 42385- 42385- J 42385-212 42385- 42385- 28.0 (1.10) 20.0 (0.787) M10 x 42385- 42385- J 42385-212 42385- 42385- 28.0 (1.10) 20.0 (0.787) Cylinder Head - Exhaust Manifold Deck View Fig.
  • Page 27 M14 x 1.25 M8 x 42385- 42385- J 42385-207 42385- 42385- 21.0 (0.826) 16.0 (0.629) 1.25 M14 x 1.25 M8 x 42385- 42385- J 42385-207 42385- 42385- 21.0 (0.826) 16.0 (0.629) 1.25 M14 x 1.25 M8 x 42385- 42385- J 42385-207 42385- 42385- 21.0 (0.826)

  • Page 28: Component Locator

    Hole Size Insert Drill Tool Driver (in) (in) 1-2 M6 x 1.0 42385- 42385- J 42385-202 42385- 42385- Thru Thru 3-4 M6 x 1.0 42385- 42385- J 42385-202 42385- 42385- 22.5 (0.885) 15.0 (0.688) 5-7 M6 x 1.0 42385- 42385- J 42385-202 42385- 42385-...
  • Page 29 Fig. 11: Intake Manifold/Upper Engine Component View Courtesy of GENERAL MOTORS CORP. Callouts For Fig. 11 Callout Component Name Engine Coolant Air Bleed Pipe Engine Coolant Air Bleed Pipe/Cover Gasket Engine Coolant Air Bleed Pipe/Cover Gasket Engine Coolant Air Bleed Pipe Stud Engine Coolant Air Bleed Hose Clamp...
  • Page 30 Engine Coolant Air Bleed Hose Engine Coolant Air Bleed Cover Bolt Engine Coolant Air Bleed Cover Intake Manifold Valley Cover Bolt Throttle Body Bolt Throttle Body Throttle Body Gasket Fuel Rail with Injectors Fuel Rail Bolt Intake Manifold Bolt Intake Manifold Insulator Intake Manifold Gaskets Knock Sensor Oil Seals Fuel Rail Ground Strap...
  • Page 31 Fig. 12: Cylinder Head/Upper Engine Component View Courtesy of GENERAL MOTORS CORP. Callouts For Fig. 12 Callout Component Name Valve Lifter Valve Lifter Guide Valve Lifter Guide Bolt Pushrod Rocker Arm Rocker Arm Bolt Rocker Arm Pedestal Expansion Plug Cylinder Head Gasket...
  • Page 32 Cylinder Head Cylinder Head Bolt - M8 Short Cylinder Head Bolt - M11 Medium Cylinder Head Bolt - M11 Long - First Design Valve Stem Oil Seal and Shim Valve Stem Oil Seal and Shim Valve Spring Valve Spring Valve Spring Cap Valve Spring Cap Valve Stem Key Expansion Plug...
  • Page 33 Coolant Temperature Sensor Spark Plug Fig. 13: Front Of Engine Component View Courtesy of GENERAL MOTORS CORP. Callouts For Fig. 13 Callout Component Name Engine Block Crankshaft Balancer Crankshaft Balancer Bolt Crankshaft Front Oil Seal Balance Weight - Manual Transmission Camshaft Camshaft Bearings Camshaft Sprocket Locating Pin...
  • Page 34 Camshaft Retainer Plate Bolt Camshaft Sprocket Camshaft Sprocket Bolt Crankshaft Sprocket Timing Chain Timing Chain Guide Bolt Timing Chain Guide Water Pump Water Pump Bolt Thermostat Housing Bolt Thermostat Housing O-Ring Thermostat Water Pump Gaskets Crankshaft Oil Deflector Nut Oil Pump Screen Bolt Oil Pump Screen O-Ring Oil Pump Screen Oil Pump Cover Bolt...
  • Page 35 Fig. 14: Rear Of Engine Component View Courtesy of GENERAL MOTORS CORP. Callouts For Fig. 14 Callout Component Name Engine Block Clutch Pilot Bearing - Manual Transmission Flywheel - Automatic Transmission Flywheel Bolt Flywheel - Manual Transmission Clutch Disc - Manual Transmission Pressure Plate - Manual Transmission Pressure Plate Bolt - Manual Transmission Crankshaft Rear Oil Seal...
  • Page 36 Fig. 15: Lower Engine Assembly Component View Courtesy of GENERAL MOTORS CORP. Callouts For Fig. 15 Callout Component Name Engine Block Connecting Rod Bolt Connecting Rod Cap Connecting Rod Bearings Connecting Rod Piston Pin Piston...
  • Page 37 Piston Rings Piston Pin Clip - Second Design with Full Floating Pin Crankshaft Thrust Bearing Crankshaft Thrust Bearing Crankshaft Main Bearing Crankshaft Main Bearing Crankshaft Sprocket Key Clutch Pilot Bearing - Manual Transmission Crankshaft Bearing Cap Bearing Cap Side Bolt Bearing Cap Bolt/Stud Bearing Cap Bolt Oil Pan...
  • Page 38 Fig. 16: Engine Block Plugs/Sensors Component View Courtesy of GENERAL MOTORS CORP. Callouts For Fig. 16 Callout Component Name Engine Block Engine Block Front Oil Gallery Plug Engine Block Rear Oil Gallery Plug O-Ring Engine Block Rear Oil Gallery Plug O-Ring Engine Block Rear Oil Gallery Plug Engine Block Rear Oil Gallery Plug Oil Gallery Plug...
  • Page 39 Coolant Heater Coolant Heater Washer Oil Gallery Plug Oil Gallery Plug Washer Transmission Housing Locating Pin Coolant Drain Plug Washer - Right Coolant Drain Plug - Right Crankshaft Position Sensor Bolt Crankshaft Position Sensor Crankshaft Position Sensor O-Ring Camshaft Position Sensor Camshaft Position Sensor O-Ring Camshaft Position Sensor Bolt Oil Pressure Sensor...

  • Page 40: Engine Identification

    Callout Component Name Cover Bolt Cover Drive Gear Driven Gear Oil Pump Pressure Relief Valve Pressure Relief Valve Spring Plug ENGINE IDENTIFICATION...

  • Page 41: Diagnostic Information And Procedures

    Fig. 18: Vehicle Identification Number (VIN) At Left Side Rear Of Engine Block Courtesy of GENERAL MOTORS CORP. The vehicle identification number (VIN) is located on the left side rear of the engine block (1 or 2) and is typically a nine digit number stamped or laser-etched onto the engine at the vehicle assembly plant. The first digit identifies the division.
  • Page 42 ambient temperature, engine temperature, amount of engine warm-up time, and other specifics. Compare the engine sounds, if applicable, to a known good engine and make sure you are not trying to correct a normal condition. Intermittent Test the vehicle under the same conditions that the customer reported in order to verify the system is operating properly.
  • Page 43 Base Engine Misfire without Internal Engine Noises Cause Correction Abnormalities, such as severe cracking, bumps, or missing Replace the drive belt. Refer to Drive Belt areas in the accessory drive belt Replacement - Accessory . Abnormalities in the accessory drive system and/or components may cause engine RPM variations and lead to a misfire DTC.
  • Page 44 excessive valve lifter pump-up and loss of compression. Testing . Repair or replace the oil pump as required. Faulty cylinder head gaskets and/or cracking or other Inspect for spark plugs saturated by damage to the cylinder heads and engine block cooling coolant.
  • Page 45 Base Engine Misfire with Abnormal Internal Lower Engine Noises Cause Correction Abnormalities, such as severe cracking, bumps or missing Replace the drive belt. Refer to Drive areas in the accessory drive belt Belt Replacement - Accessory . Abnormalities in the accessory drive system and/or components may cause engine RPM variations, noises similar to a faulty lower engine and also lead to a misfire condition.

  • Page 46: Engine Noise On Start-Up, But Only Lasting A Few Seconds

    the top of the piston shows valve contact, replace the piston and pin assembly. Stuck valves Repair or replace as required. Carbon buildup on the valve stem can cause the valve not to close properly. Excessively worn or mis-aligned timing Replace the timing chain and sprockets as required.

  • Page 47: Upper Engine Noise, Regardless Of Engine Speed

    Engine Noise on Start-Up, but Only Lasting a Few Seconds Cause Correction Incorrect oil filter without anti-drainback Install the correct oil filter. feature Incorrect oil viscosity 1. Drain the oil. 2. Install the correct viscosity oil. High valve lifter leak down rate Replace the lifters as required.

  • Page 48: Lower Engine Noise, Regardless Of Engine Speed

    The valve rocker arm The valve push rod The valve lifter The oil filter bypass valve The oil pump and pump screen The engine block oil galleries Broken valve spring Replace the valve spring. Loose or broken valve lifter guide Repair or replace as required.

  • Page 49: Engine Noise Under Load

    flywheel. Repair or replace as required. Loose or damaged flywheel Repair or replace the flywheel. Oil pump screen loose, damaged or restricted Inspect the oil pump screen. Repair or replace as required. Excessive piston-to-cylinder bore clearance Inspect the piston and cylinder bore. Repair as required.

  • Page 50: Engine Will Not Crank - Crankshaft Will Not Rotate

    Detonation or spark knock Verify the correct operation of the ignition controls. Refer to Detonation/Spark Knock in Engine Controls - 5.7L. Loose torque converter bolts Inspect the torque converter bolts and flywheel. Repair as required. Cracked flywheel - automatic Inspect the flywheel bolts and flywheel. transmission Repair as required.

  • Page 51: Coolant In Combustion Chamber

    Inspect the timing chain and gears. Repair or replace the components as required. Seized timing chain or timing gears Inspect the timing chain and gears for foreign material or a seized chain. Repair or replace the components as required. Seized or broken camshaft Inspect the camshaft and the camshaft bearings.

  • Page 52: Coolant In Engine Oil

    DEFINITION: Excessive white smoke and/or coolant type odor coming from the exhaust pipe may indicate coolant in the combustion chamber. Low coolant levels, an inoperative cooling fan, or a faulty thermostat may lead to an "overtemperature" condition which may cause engine component damage. 1.

  • Page 53: Engine Compression Test

    Compression Test . Faulty external engine Replace the components as required. oil cooler Faulty cylinder head Replace the head gasket and components as required. Refer to Cylinder Head gasket Cleaning and Inspection , Cylinder Head Replacement - Left and Cylinder Head Replacement - Right .

  • Page 54: Cylinder Leakage Test

    applications, the flywheel, clutch, and pressure plate is also a balanced assembly. During the powertrain build process, balance weights may be added to the crankshaft balancer and/or flywheel as required. In order to maintain engine/clutch assembly balance, it may be necessary to install or remove balance weights as detailed below: Crankshaft Balancer Existing balancer onto existing engine:...
  • Page 55 Tools Required J 35667-A Cylinder Head Leakdown Tester or equivalent. See Special Tools and Equipment . CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices. IMPORTANT: A leakage test may be performed in order to measure cylinder/combustion chamber leakage. High cylinder leakage may indicate one or more of the following: Worn or burnt valves Broken valve springs...

  • Page 56: Oil Consumption Diagnosis

    damaged cylinder head. Air bubbles in the cooling system may indicate a damaged cylinder head or a damaged cylinder head gasket. 7. Perform the leakage test on the remaining cylinders and record the values. OIL CONSUMPTION DIAGNOSIS Oil Consumption Diagnosis Checks Causes DEFINITION: Excessive oil consumption, not due to leaks, is the use of 0.95 liters (1.0 qt) or more of...
  • Page 57 Fig. 19: J 42907, J 21867 & Engine Courtesy of GENERAL MOTORS CORP. 1. With the vehicle on a level surface, run the vehicle for a few minutes, allow adequate drain down time of 2-3 minutes and measure the oil level. 2.

  • Page 58: Oil Leak Diagnosis

    7. Install J 21867 or equivalent to the. See Special Tools and Equipment . J 42907 . 8. Run the engine and measure the engine oil pressure. 9. Compare the readings to Engine Mechanical Specifications (LS1) or Engine Mechanical Specifications (LS6) . 10.
  • Page 59 1. Operate the vehicle until it reaches normal operating temperature. 2. Park the vehicle on a level surface, over a large sheet of paper or other clean surface. 3. Wait 15 minutes. 4. Check for drippings. Go to System Are drippings present? Step 2 Go to Can you identify the type of fluid and the approximate location of the leak?
  • Page 60 4. Identify the type of fluid, and the approximate location of the leak, from the discolorations in the powder surface. Go to Step Go to Can you identify the type of fluid and the approximate location of the leak? Step 7 1.
  • Page 61 11 Does the engine still leak oil? Step 1 CRANKCASE VENTILATION SYSTEM INSPECTION/DIAGNOSIS Crankcase Ventilation System Inspection/Diagnosis Concern Action External oil leak Inspect for any of the following conditions: Plugged positive crankcase ventilation (PCV) valve Plugged or kinked PCV hose(s) Damaged or incorrectly installed PCV valve or hose(s) Excessive crankcase pressure Rough Idle...
  • Page 62 2: The chirping noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further in this table. 3: The noise may be an internal engine noise. Remove the drive belt(s) and operate the engine for a few seconds, this will verify if the chirping noise is related to the drive belt(s) or not.
  • Page 63 Go to Engine Noise on Start-Up, but 2. Operate the engine for no longer Only Lasting a Few Seconds , Upper than 30 to 40 seconds. Engine Noise, Regardless of Engine Speed , or Lower Engine Noise, Does the chirping noise still exist? Regardless of Engine Speed Go to Step 4 Inspect for severe drive belt pilling...
  • Page 64 Replace the bent accessory drive pulley (s). Was the bent accessory drive pulley(s) replaced? Go to Step 15 Replace the drive belt(s). Refer to Drive Belt Replacement - Accessory or Drive Belt Replacement - Air Conditioning . Was the drive belt(s) replaced? Go to Step 15 1.
  • Page 65 tensioner(s) from operating properly. Also if the incorrect length drive belt(s) was installed, it may not be routed correctly and may be turning an accessory drive component in the incorrect direction. 7: Misalignment of the accessory drive pulley(s) may be caused from improper mounting or incorrect installation of a accessory drive component, or the pulley is bent inward or outward from a previous repair.
  • Page 66 Did you find and correct the condition? Go to Step 9 Go to Step 6 Check for the correct length drive belt. Did you find and correct the condition? Go to Step 9 Go to Step 7 Inspect for misaligned pulley. Did you find and correct the condition? Go to Step 9 Go to Step 8...
  • Page 67 NOTE: Refer to Belt Dressing Notice in Cautions and Notices. DEFINITION: A high pitched continuous noise that may be caused by an accessory drive component failed bearing. Did you review the Symptoms - Engine Go to Mechanical diagnostic information, and Symptoms - perform the necessary inspections? Engine...
  • Page 68 the only repair for the symptom. If after replacing the drive belt(s) and completing the diagnostic table, the noise is only heard with the drive belt (s) installed, there might be an accessory drive component failure. Varying the load on the accessory drive component(s) may aid in identifying which accessory drive component is causing the rumbling noise.
  • Page 69 noise? Go to Step 3 Aids 1. Remove the drive belt(s). Refer to Drive Belt Replacement - Accessory or Drive Belt Replacement - Air Conditioning . Go to Engine Noise on Start-Up, but 2. Operate the engine for no longer Only Lasting a Few Seconds , Upper than 30 to 40 seconds.
  • Page 70 Test Description The number(s) below refer to the steps) in the diagnostic table. 2: This test is to verify that the vibration is present during diagnosing. Other vehicle components may cause a similar symptom such as the exhaust system, or the drivetrain. 3: This test is to verify that the drive belt(s) or accessory drive components may be causing the vibration.
  • Page 71 Does the engine still make the vibration? Diagnosis and Correction Go to Step 4 Inspect the drive belt(s) for wear, damage, debris build-up and missing drive belt ribs. Were any of these conditions found? Go to Step 5 Go to Step 6 Install a new drive belt.
  • Page 72 2: This inspection is to verify the condition of the drive belt(s). Damage may have occurred to the drive belt(s) when the drive belt(s) fell off the pulley. Inspect the drive belt(s) for cuts, tears, sections of ribs missing, or damaged belt plys. 4: Misalignment of the accessory drive pulley(s) may be caused from improper mounting or incorrect installation of a accessory drive component, or the pulley may bent inward or outward from a previous repair.
  • Page 73 Test the drive belt tensioner for correction operation. Refer to Drive Belt Tensioner Diagnosis . Go to Does the drive belt tensioner operate correctly? Step 11 Go to Step 10 Replace the drive belt tensioner. Refer to Drive Belt Replacement - Accessory or Drive Belt Replacement - Air Conditioning .

  • Page 74: Drive Belt Tensioner Diagnosis

    Did you review the Symptoms - Engine Mechanical diagnostic Go to Go to Symptoms - information and perform the necessary inspections? Step 2 Engine Mechanical Inspect the drive belt(s) for the proper installation. Refer to Drive Belt Replacement - Accessory or Drive Belt Replacement - Air Conditioning .

  • Page 75: Drive Belt System Description

    passed through a crankcase ventilation valve and into the intake manifold. The primary component in the positive crankcase ventilation (PCV) system is the PCV valve, the valve meters the flow of blow-by vapors at a certain rate depending on manifold vacuum. To maintain idle quality, the PCV valve restricts the vapor flow when manifold vacuum is high.

  • Page 76: Engine Component Description

    The crankshaft balancer pulley The accessory drive component mounting brackets The accessory drive components The power steering pump, if belt driven The generator The A/C compressor, if equipped The engine cooling fan, if belt driven The water pump, if belt driven The vacuum pump, if equipped The air compressor, if equipped The drive belt system may use 1 belt or 2 belts.
  • Page 77 Fig. 20: 5.7 Liter V8 Engine Courtesy of GENERAL MOTORS CORP. The 5.7 Liter V8 engine is identified as RPO LS1 (VIN G) and RPO LS6 (VIN S). Camshaft and Drive System A billet steel 1-piece camshaft is supported by 5 bearings pressed into the engine block. The camshaft has a machined camshaft sensor reluctor ring incorporated between the fourth and fifth bearing journals.
  • Page 78 crankshaft position reluctor ring is mounted at the rear of the crankshaft. The reluctor ring is not serviceable separately. Cylinder Heads The cylinder head assemblies are cast aluminum and have pressed in place powdered metal valve guides and valve seats. Passages for the vapor ventilation system are at the front of each cylinder head. There are no exhaust gas passages within the cylinder head.
  • Page 79 Piston and Connecting Rod Assemblies The pistons are cast aluminum. The pistons use 2 compression rings and a 3-piece oil control ring assembly. The piston is a low friction, lightweight design with a barrel shaped skirt. All applications use pistons with graphite-coated skirts.

  • Page 80: Lubrication Description

    medium length 100 mm (3.94 in) and long 155 mm (6.1 in) M11 cylinder head bolts. Second design engine blocks use only the medium length 100 mm (3.94 in) bolt with a common torque/angle specification. Certain fasteners should not be used again. Bolts, studs, or other fasteners that must be replaced will be called out in the specific service procedure.
  • Page 81 Fig. 21: Lubrication Flow Schematic Courtesy of GENERAL MOTORS CORP. Engine lubrication is supplied by a gerotor type oil pump assembly. The pump is mounted on the front of the engine block and driven directly by the crankshaft sprocket. The pump gears rotate and draw oil from the oil pan sump through a pick-up screen and pipe.

  • Page 82: Cleanliness And Care

    Fig. 22: Oil Pump Assembly Schematic Courtesy of GENERAL MOTORS CORP. Callouts For Fig. 848 Callout Component Name Cover Bolt Cover Drive Gear Driven Gear Oil Pump Pressure Relief Valve Pressure Relief Valve Spring Plug CLEANLINESS AND CARE Throughout this section, it should be understood that proper cleaning and protection of machined surfaces and friction areas is part of the repair procedure.

  • Page 83: Separating Parts

    order for reassembly. Refer to Separating Parts . At the time of installation, components should be installed in the same location and with the same mating surface as when removed. An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in millimeters or thousandths of an inch.

  • Page 84: Replacing Engine Gaskets

    REPLACING ENGINE GASKETS Tools Required J 28410 Gasket Remover. See Special Tools and Equipment . Gasket Use and Applying Sealants Do not use any gasket again unless specified. Gaskets that can be used again are identified in the service procedure. Do not apply sealant to any gasket or sealing surface unless called out in the service information.

  • Page 85: Use Of Room Temperature Vulcanizing (Rtv) And Anaerobic Sealer

    USE OF ROOM TEMPERATURE VULCANIZING (RTV) AND ANAEROBIC SEALER Pipe Joint Compound IMPORTANT: 3 types of sealer are commonly used in engines. These are room temperature vulcanizing (RTV) sealer, anaerobic gasket eliminator sealer, and pipe joint compound. The correct sealer and amount must be used in the proper location to prevent oil leaks.

  • Page 86: Special Tools And Equipment

    Anaerobic gasket eliminator hardens in the absence of air. This type sealer is used where 2 rigid parts, such as castings, are assembled together. When 2 rigid parts are disassembled and no sealer or gasket is readily noticeable, the parts were probably assembled using a gasket eliminator. Follow all safety recommendations and directions that are on the container.
  • Page 87 Special Tools Illustration Tool Number/Description J 3049-A Valve Lifter Remover J 6125-1B Slide Hammer J 7872 Magnetic Base Dial Indicator Set J 8037 Piston Ring Compressor...
  • Page 88 J 8062 Valve Spring Compressor J 8087 Cylinder Bore Gage J 8089 Carbon Removing Brush J 8433-1 Puller Bar...
  • Page 89 J 8520 Cam Lobe Lift Indicator J 9666 Valve Spring Tester J 21867 Pressure Gage...
  • Page 90 J 22794 Spark Plug Port Adapter J 24086-C Piston Pin Remover/Installer Set J 24270 Cylinder Bore Ridge Reamer J 25033-C Power Steering Pump Pulley Installer J 25034-C Power Steering Pump Pulley Remover...
  • Page 91 J 28410 Gasket Remover J 28428-E Leak Detector Kit J 33049 Camshaft Bearing Service Set...
  • Page 92 J 35667-A Cylinder Leakdown Tester J 36221 Hydraulic Clutch Line Separator J 37378-1 Valve Guide Reamer J 38606 Valve Spring Compressor - Head On-Vehicle...
  • Page 93 J 38836 Pilot Bushing Installer/Clutch J 39580 Engine Support Table J 39580-500 Engine Support Table Top...
  • Page 94 J 41476 Front and Rear Cover Alignment - at Crankshaft Seal Area J 41478 Crankshaft Front Oil Seal Installer J 41479 Crankshaft Rear Oil Seal Installer J 41480 Front and Rear Cover Alignment - at Oil Pan Surface J 41556 Connecting Rod Guide...
  • Page 95 J 41558 Crankshaft Sprocket Remover J 41665 Crankshaft Balancer and Sprocket Installer J 41712 Oil Pressure Switch Socket J 41798 Engine Lifting Brackets J 41816 Crankshaft Balancer Remover...
  • Page 96 J 41816-2 Crankshaft End Protector J 41818 Crankshaft Bearing Cap Remover J 42188 Ball Joint Separator J 42203 Driveline Support...
  • Page 97 J 42385-100 Head/Main Bolt Thread Repair Kit J 42385-200 Common Thread Repair Kit J 42385-300 Fixtures and Hardware Kit...
  • Page 98 J 42386-A Flywheel Holding Tool J 42907 Oil Pressure Testing Tool J 43276 Clutch Pilot Bearing Remover...
  • Page 99 J 43690 Rod Bearing Checking Tool J 43690-100 Rod Bearing Checking Tool - Adapter Kit J 45059 Angle Meter...
  • Page 100 J 45299 Engine Preluber...

  • Page 101: Engine Performance

    2004 ENGINE PERFORMANCE Engine Mechanical (Repair Instructions 1 Of 3) - 5.7L - Corvette REPAIR INSTRUCTIONS DRIVE BELT REPLACEMENT - ACCESSORY Removal Procedure Fig. 1: Accessory Drive Belt Courtesy of GENERAL MOTORS CORP. 1. Remove the air intake duct, if necessary. Refer to Air Cleaner Assembly Replacement in Engine Controls - 5.7 L.
  • Page 102 2. Install a breaker bar with hex-head socket to the drive belt tensioner bolt. 3. Rotate the drive belt tensioner clockwise in order to relieve tension on the accessory drive belt. 4. Remove the accessory drive belt from the pulleys and tensioner. 5.
  • Page 103 3. Rotate the drive belt tensioner clockwise in order to relieve tension on the drive belt tensioner. 4. Install the accessory drive belt under the water pump pulley. 5. Install the accessory drive belt onto the drive belt tensioner. 6. Slowly release the tension. 7.
  • Page 104 3. Rotate the A/C drive belt tensioner clockwise in order to relieve tension on the drive belt. 4. Remove the A/C drive belt from the pulleys. 5. Slowly release tension on the A/C drive belt tensioner. 6. Remove the breaker bar and socket from the A/C drive belt tensioner bolt. 7.
  • Page 105 7. Remove the breaker bar and socket from the A/C drive belt tensioner bolt. 8. Inspect the A/C drive belt for correct alignment. 9. Install the accessory drive belt. Refer to Drive Belt Replacement - Accessory . DRIVE BELT IDLER PULLEY REPLACEMENT - ACCESSORY Removal Procedure Fig.
  • Page 106 Installation Procedure Fig. 6: Accessory Drive Belt Idler Pulley Bolt Courtesy of GENERAL MOTORS CORP. IMPORTANT: Ensure that the idler pulley and dust shield are fully seated against the shoulder on the bracket before tightening the bolt. 1. Install the accessory drive belt idler pulley bolt until snug. 2.
  • Page 107 3. Tighten the accessory drive belt idler pulley bolt. Tighten: Tighten the accessory drive belt idler pulley bolt to 50 N.m (37 lb ft). DRIVE BELT IDLER PULLEY REPLACEMENT - AIR CONDITIONING Removal Procedure Fig. 7: A/C Drive Belt Idler Pulley Courtesy of GENERAL MOTORS CORP.
  • Page 108 Installation Procedure Fig. 8: A/C Drive Belt Idler Pulley Courtesy of GENERAL MOTORS CORP. 1. Install the idler pulley bolt. 2. Install the A/C drive belt idler pulley bolt until snug. IMPORTANT: Ensure that the idler pulley is fully seated against the shoulder on the bracket before tightening the bolt.
  • Page 109 4. Tighten the A/C drive belt idler pulley bolt. Tighten: Tighten the A/C drive belt idler pulley bolt to 50 N.m (37 lb ft). DRIVE BELT TENSIONER REPLACEMENT - ACCESSORY Removal Procedure Fig. 9: Accessory Drive Belt Tensioner & Bolts Courtesy of GENERAL MOTORS CORP.
  • Page 110 Fig. 10: Accessory Drive Belt Tensioner & Bolts Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Fastener Notice in Cautions and Notices. 1. Install the accessory drive belt tensioner. 2. Install the accessory drive belt tensioner bolts. Tighten: Tighten the accessory drive belt tensioner bolts to 50 N.m (37 lb ft) starting with the lower bolt first.
  • Page 111 Fig. 11: A/C Drive Belt Tensioner Courtesy of GENERAL MOTORS CORP. 1. Remove the air conditioning (A/C) drive belt. Refer to Drive Belt Replacement - Air Conditioning . 2. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 3.
  • Page 112 Fig. 12: A/C Drive Belt Tensioner Courtesy of GENERAL MOTORS CORP. 1. Install the A/C drive belt tensioner. NOTE: Refer to Fastener Notice in Cautions and Notices. 2. Tighten the A/C drive belt tensioner bolt. Tighten: Tighten the A/C drive belt tensioner bolt to 50 N.m (37 lb ft). 3.

  • Page 113: Engine Mount Inspection

    ENGINE MOUNT INSPECTION NOTE: Broken or deteriorated mounts can cause misalignment and destruction of certain drive train components. When a single mount breaks, the remaining mounts are subjected to abnormally high stresses. NOTE: When raising or supporting the engine for any reason, do not use a jack under the oil pan, any sheet metal, or the crankshaft pulley.
  • Page 114 Fig. 13: Left Engine Mount Bracket & Bolts Courtesy of GENERAL MOTORS CORP. 1. Remove the left engine mount. Refer to Engine Mount Replacement - Left . 2. Remove the engine mount bracket bolts. 3. Remove the engine mount bracket. Installation Procedure...
  • Page 115 Fig. 14: Left Engine Mount Bracket & Bolts Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Fastener Notice in Cautions and Notices. 1. Install the engine mount bracket. 2. Install the engine mount bracket bolts. Tighten: Tighten the engine mount bracket bolts to 50 N.m (37 lb ft). 3.
  • Page 116 Fig. 15: Right Engine Mount Bracket & Bolts Courtesy of GENERAL MOTORS CORP. 1. Remove the right engine mount. Refer to Engine Mount Replacement - Right . 2. Remove the engine mount bracket bolts. 3. Remove the engine mount bracket. Installation Procedure...
  • Page 117 Fig. 16: Right Engine Mount Bracket & Bolts Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Fastener Notice in Cautions and Notices. 1. Install the engine mount bracket. 2. Install the engine mount bracket bolts. Tighten: Tighten the engine mount bracket bolts to 50 N.m (37 lb ft). 3.
  • Page 118 Removal Procedure Fig. 17: Engine Mount-To-Engine Mount Bracket & Nuts Courtesy of GENERAL MOTORS CORP. 1. Remove the front suspension crossmember. Refer to Crossmember Replacement - Front Suspension in Front Suspension.
  • Page 119 2. Remove the engine mount-to-engine mount bracket nut. 3. Remove the engine mount. 4. Remove the engine mount heat shield from the engine mount, if necessary. Installation Procedure Fig. 18: Engine Mount-To-Engine Mount Bracket & Nuts...
  • Page 120 Courtesy of GENERAL MOTORS CORP. 1. Install the engine mount heat shield to the engine mount, if necessary. 2. Install the engine mount. NOTE: Refer to Fastener Notice in Cautions and Notices. 3. Install the engine mount-to-engine mount bracket nut. Tighten: Tighten the nut to 65 N.m (48 lb ft).
  • Page 121 Fig. 19: Engine Mount-To-Engine Mount Bracket & Nuts Courtesy of GENERAL MOTORS CORP. 1. Remove the front suspension crossmember. Refer to Crossmember Replacement - Front Suspension in Front Suspension. 2. Remove the engine mount-to-engine mount bracket nut. 3. Remove the engine mount (left side shown, right side similar).
  • Page 122 4. Remove the engine mount heat shield from the engine mount, if necessary. Installation Procedure Fig. 20: Engine Mount-To-Engine Mount Bracket & Nuts Courtesy of GENERAL MOTORS CORP.
  • Page 123 1. Install the engine mount heat shield to the engine mount, if necessary. IMPORTANT: When installing the engine mount be sure to have the locating dowel in the correct position. NOTE: Refer to Fastener Notice in Cautions and Notices. 2. Install the engine mount (left side shown, right side similar). 3.
  • Page 124 1. Remove the positive crankcase ventilation (PCV) tube from the right rocker arm cover and intake manifold, if necessary. Fig. 22: Left Rocker Arm Cover & PCV Valve Pipe Courtesy of GENERAL MOTORS CORP. 2. Remove the PCV valve pipe from the left rocker arm cover.
  • Page 126 Fig. 23: Right Rocker Arm Cover & PCV Valve Pipe Courtesy of GENERAL MOTORS CORP. 3. Remove the PCV valve pipe strap nut. 4. Remove the PCV valve pipe from the right rocker arm cover and intake manifold. 5. Remove the PCV valve from the valve pipe. Installation Procedure...
  • Page 128 Fig. 24: Right Rocker Arm Cover & PCV Valve Pipe Courtesy of GENERAL MOTORS CORP. 1. Install the PCV valve to the valve pipe. 2. Install the PCV valve pipe to the right rocker arm cover and intake manifold. NOTE: Refer to Fastener Notice in Cautions and Notices.
  • Page 129 Fig. 25: Left Rocker Arm Cover & PCV Valve Pipe Courtesy of GENERAL MOTORS CORP. 4. Install the PCV valve pipe to the left rocker arm cover.
  • Page 130 Fig. 26: PCV Tube & Rocker Arm Cover Courtesy of GENERAL MOTORS CORP. 5. Install the PCV tube to the right rocker arm cover and intake manifold, if necessary. POSITIVE CRANKCASE VENTILATION (PCV) VALVE REPLACEMENT (LS6 ENGINE) Removal Procedure...
  • Page 131 Fig. 27: PCV Valve Hose Courtesy of GENERAL MOTORS CORP. 1. Remove the positive crankcase ventilation (PCV) valve hose (1) from the intake manifold. 2. Remove the positive crankcase ventilation (PCV) valve hose (1) from the valley cover. 3. Remove the PCV valve from the valve hose. Installation Procedure...
  • Page 132 Fig. 28: PCV Valve Hose Courtesy of GENERAL MOTORS CORP. 1. Install the PCV valve to the valve hose. 2. Install the PCV valve hose (1) to the valley cover. 3. Install the PCV valve hose (1) to the intake manifold. CRANKCASE VENTILATION HOSES/PIPES REPLACEMENT Removal Procedure...
  • Page 133 Fig. 29: PCV Tube & Rocker Arm Cover Courtesy of GENERAL MOTORS CORP. 1. Remove the throttle position (TP) sensor harness clip from the positive crankcase ventilation (PCV) tube. 2. Remove the PCV tube from the right rocker arm cover and throttle body, if necessary.
  • Page 134 Fig. 30: Left Rocker Arm Cover & PCV Valve Pipe Courtesy of GENERAL MOTORS CORP. 3. If equipped with the regular production option (RPO) LS1 engine, remove the PCV valve pipe from the left rocker arm cover.
  • Page 136 Fig. 31: Right Rocker Arm Cover & PCV Valve Pipe Courtesy of GENERAL MOTORS CORP. 4. If equipped with the RPO LS1 engine, remove the PCV valve pipe strap nut. 5. Remove the PCV valve pipe from the right rocker arm cover and intake manifold. 6.
  • Page 137 Fig. 33: PCV Valve Hose Courtesy of GENERAL MOTORS CORP. 1. If equipped with the RPO LS6 engine, install the PCV valve to the hose, if necessary. 2. Install the PCV valve hose (1) to the valley cover and intake manifold.
  • Page 139 Fig. 34: Right Rocker Arm Cover & PCV Valve Pipe Courtesy of GENERAL MOTORS CORP. 3. If equipped with the RPO LS1 engine, install the PCV valve to the valve pipe, if necessary. 4. Install the PCV valve pipe to the right rocker arm cover and intake manifold. NOTE: Refer to Fastener Notice in Cautions and Notices.
  • Page 140 Fig. 35: Left Rocker Arm Cover & PCV Valve Pipe Courtesy of GENERAL MOTORS CORP. 6. If equipped with the RPO LS1 engine, install the PCV valve pipe to the left rocker arm cover.

  • Page 141: Intake Manifold Replacement

    Fig. 36: PCV Tube & Rocker Arm Cover Courtesy of GENERAL MOTORS CORP. 7. Install the PCV tube to the right rocker arm cover and throttle body, in necessary. 8. Install the TP sensor harness clip to the PCV tube. INTAKE MANIFOLD REPLACEMENT Removal Procedure IMPORTANT: The intake manifold, throttle body, fuel injection rail, and injectors may be...
  • Page 142 Fig. 37: Right Fuel Injection Rail Cover Courtesy of GENERAL MOTORS CORP. 1. Drain the cooling system. Refer to Draining and Filling Cooling System in Engine Cooling. 2. If replacing the intake manifold, perform the following: Remove the throttle body. Refer to Throttle Body Assembly Replacement in Engine Controls - 5.7 L.
  • Page 143 Fig. 38: Left Fuel Rail Cover Courtesy of GENERAL MOTORS CORP. 4. Remove the left fuel rail cover.
  • Page 144 Fig. 39: EVAP Canister Purge Tube Courtesy of GENERAL MOTORS CORP. 5. Remove the fuel feed hose. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls - 5.7 L. 6. Disconnect the evaporative emission (EVAP) canister purge tube from the intake manifold. 7.
  • Page 145 Fig. 40: Fuel Feed Pipe Courtesy of GENERAL MOTORS CORP. 9. Disconnect the EVAP canister purge tube from the EVAP canister purge solenoid valve. 10. Disconnect the EVAP canister purge tube from the fuel feed pipe. 11. Remove the EVAP canister purge tube.
  • Page 146 Fig. 41: TP Sensor Electrical Connector Courtesy of GENERAL MOTORS CORP. 12. Disconnect the throttle position (TP) sensor electrical connector. 13. Remove the coolant air bleed hose. Refer to Coolant Air Bleed Hose Replacement in Engine Cooling.
  • Page 147 Fig. 42: Throttle Body Heater Outlet Hose & Clamp Courtesy of GENERAL MOTORS CORP. 14. Reposition the throttle body heater outlet hose clamp at the throttle body. 15. Remove the throttle body heater outlet hose from the throttle body. 16. Remove the throttle body heater outlet hose.
  • Page 148 Fig. 43: Electrical Connectors Courtesy of GENERAL MOTORS CORP. 17. Disconnect all the fuel injector electrical connectors (1). 18. Disconnect the EVAP canister purge solenoid valve electrical connector (2). 19. Disconnect the electronic throttle control (ETC) electrical connector (3).
  • Page 149 Fig. 44: EVAP Canister Purge Solenoid Valve & Bracket Courtesy of GENERAL MOTORS CORP. 20. Remove the EVAP canister purge solenoid valve from the bracket. 21. Disconnect the harness clips at the fuel rails. 22. Reposition the intake manifold branches of the wiring harness.
  • Page 150 Fig. 45: Vacuum Booster Hose Courtesy of GENERAL MOTORS CORP. 23. Disconnect the power brake booster vacuum hose at the booster.
  • Page 151 Fig. 46: Knock Sensor Wire Harness Clip & Fuel Rail Stop Bracket Courtesy of GENERAL MOTORS CORP. 24. Remove the knock sensor wire harness (1) clip from the fuel rail stop bracket (2).
  • Page 152 Fig. 47: TP Sensor Harness Clip & PCV Tube Courtesy of GENERAL MOTORS CORP. 25. Remove the TP sensor harness clip from the positive crankcase ventilation (PCV) tube. 26. Remove the PCV tube from the right rocker arm cover and throttle body.
  • Page 153 Fig. 48: Left Rocker Arm Cover & PCV Valve Pipe Courtesy of GENERAL MOTORS CORP. 27. If equipped with the regular production option (RPO) LS1 engine, remove the PCV valve pipe from the left rocker arm cover.
  • Page 155 Fig. 49: Right Rocker Arm Cover & PCV Valve Pipe Courtesy of GENERAL MOTORS CORP. 28. If equipped with the RPO LS1 engine, remove the PCV valve pipe strap nut. 29. Remove the PCV valve pipe from the right rocker arm cover and intake manifold. Fig.
  • Page 156 Fig. 51: Intake Manifold Bolts & Fuel Rail Stop Bracket Courtesy of GENERAL MOTORS CORP. 31. Remove the intake manifold bolts (1) and fuel rail stop bracket (2). 32. Position the intake manifold forward.
  • Page 157 Fig. 52: MAP Sensor Vacuum Hose & MAP Sensor Electrical Connector Courtesy of GENERAL MOTORS CORP. 33. Disconnect the manifold absolute pressure (MAP) sensor vacuum hose. 34. Disconnect the MAP sensor (3) electrical connector.
  • Page 158 Fig. 53: Intake Manifold Courtesy of GENERAL MOTORS CORP. 35. Remove the intake manifold.
  • Page 159 Fig. 54: Intake Manifold Gaskets Courtesy of GENERAL MOTORS CORP. 36. Remove the intake manifold gaskets (1). Discard the old gaskets. 37. Clean and inspect the intake manifold. Refer to Intake Manifold Cleaning and Inspection . Installation Procedure IMPORTANT: DO NOT reuse the intake manifold gaskets. Install NEW intake manifold gaskets.
  • Page 160 Fig. 55: Intake Manifold Gaskets Courtesy of GENERAL MOTORS CORP. 1. Install NEW intake manifold gaskets (1) to the manifold.
  • Page 161 Fig. 56: Intake Manifold Courtesy of GENERAL MOTORS CORP. 2. Install intake manifold. 3. Position the intake manifold forward.
  • Page 162 Fig. 57: MAP Sensor Vacuum Hose & MAP Sensor Electrical Connector Courtesy of GENERAL MOTORS CORP. 4. Connect the MAP sensor vacuum hose. 5. Connect the MAP sensor (3) electrical connector. 6. Position the intake manifold into place.
  • Page 163 Fig. 58: Intake Manifold Bolts & Fuel Rail Stop Bracket Courtesy of GENERAL MOTORS CORP. CAUTION: The fuel rail stop bracket must be installed onto the engine assembly. The stop bracket serves as a protective shield for the fuel rail in the event of a vehicle frontal crash. If the fuel rail stop bracket...
  • Page 164 is not installed and the vehicle is involved in a frontal crash, fuel could be sprayed possibly causing a fire and personal injury from burns. 7. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489), or equivalent to the threads of the intake manifold bolts (1).
  • Page 165 2. Tighten the intake manifold bolts a final pass in sequence to 10 N.m (89 lb in). Fig. 60: PCV Valve Hose Courtesy of GENERAL MOTORS CORP. 11. If equipped with the RPO LS6 engine, install the PCV valve hose (1) to the valley cover and intake manifold.
  • Page 167 Fig. 61: Right Rocker Arm Cover & PCV Valve Pipe Courtesy of GENERAL MOTORS CORP. 12. If equipped with the RPO LS1 engine, install the PCV valve pipe to the right valve rocker arm cover and intake manifold. 13. Install the PCV pipe strap nut. Tighten: Tighten the PCV pipe strap nut to 12 N.m (106 lb in).
  • Page 168 Fig. 62: Left Rocker Arm Cover & PCV Valve Pipe Courtesy of GENERAL MOTORS CORP. 14. If equipped with the RPO LS1 engine, install the PCV valve pipe to the left rocker arm cover.
  • Page 169 Fig. 63: TP Sensor Harness Clip & PCV Tube Courtesy of GENERAL MOTORS CORP. 15. Install the PCV tube to the right rocker arm cover. 16. Install the TP sensor harness clip to the PCV tube.
  • Page 170 Fig. 64: Knock Sensor Wire Harness Clip & Fuel Rail Stop Bracket Courtesy of GENERAL MOTORS CORP. 17. Install the knock sensor wire harness (1) to the fuel rail stop bracket (2).
  • Page 171 Fig. 65: Vacuum Booster Hose Courtesy of GENERAL MOTORS CORP. 18. Connect the power brake booster vacuum hose to the booster.
  • Page 172 Fig. 66: EVAP Canister Purge Solenoid Valve & Bracket Courtesy of GENERAL MOTORS CORP. 19. Position the intake manifold branches of the wiring harness. 20. Connect the harness clips at the fuel rails. 21. Install the EVAP canister purge solenoid valve from the bracket.
  • Page 173 Fig. 67: Electrical Connectors Courtesy of GENERAL MOTORS CORP. 22. Connect the ETC electrical connector (3). 23. Connect the EVAP canister purge solenoid valve electrical connector (2). 24. Connect all the fuel injector electrical connectors (1).
  • Page 174 Fig. 68: Throttle Body Heater Outlet Hose & Clamp Courtesy of GENERAL MOTORS CORP. 25. Install the throttle body heater outlet hose. 26. Install the throttle body heater outlet hose to the throttle body. 27. Position the throttle body heater outlet hose clamp at the throttle body. 28.
  • Page 175 Fig. 69: TP Sensor Electrical Connector Courtesy of GENERAL MOTORS CORP. 29. Connect the TP sensor electrical connector.
  • Page 176 Fig. 70: Fuel Feed Pipe Courtesy of GENERAL MOTORS CORP. 30. Install the EVAP canister purge tube. 31. Connect the EVAP canister purge tube to the fuel feed pipe. 32. Connect the EVAP canister purge tube to the EVAP canister purge solenoid valve.
  • Page 177 Fig. 71: EVAP Canister Purge Tube Courtesy of GENERAL MOTORS CORP. 33. Install the EVAP canister purge tube. 34. Connect the EVAP canister purge tube to the EVAP canister purge solenoid valve. 35. Connect the EVAP canister purge tube to the intake manifold. 36.
  • Page 178 Fig. 72: Left Fuel Rail Cover Courtesy of GENERAL MOTORS CORP. 37. Install the left fuel rail cover.
  • Page 179 Fig. 73: Right Fuel Injection Rail Cover Courtesy of GENERAL MOTORS CORP. 38. Install the right fuel rail cover. 39. If replacing the intake manifold, perform the following: Install the throttle body. Refer to Throttle Body Assembly Replacement in Engine Controls - 5.7 Install the fuel injectors.
  • Page 180 Fig. 74: View Of Knock Sensor Wire Harness Courtesy of GENERAL MOTORS CORP. 1. Remove the intake manifold. Refer to Intake Manifold Replacement . 2. Gently pry up the rubber grommets. 3. Disconnect the knock sensor wire harness electrical connectors.
  • Page 181 Fig. 75: View Of Knock Sensors Courtesy of GENERAL MOTORS CORP. 4. Remove the knock sensors.
  • Page 182 Fig. 76: View Of Engine Valley Cover, Gasket & LS1 Engine Courtesy of GENERAL MOTORS CORP. 5. If equipped with the 5.7 L, regular production option (RPO) LS1 engine, remove the engine valley cover bolts.
  • Page 183 Fig. 77: Engine Valley Cover, Gasket, Bolts & LS6 Engine Courtesy of GENERAL MOTORS CORP. 6. If equipped with the 5.7 L, RPO LS6 engine, remove the engine valley cover bolts. 7. Remove the engine valley cover and gasket. 8. Discard the engine valley cover gasket.
  • Page 184 Fig. 78: View Of Knock Sensor Oil Seals & Cover Courtesy of GENERAL MOTORS CORP. 9. Remove the knock sensor oil seals (1) from the cover (2). 10. Clean and inspect the engine valley cover. Refer to Engine Valley Cover Cleaning and Inspection . Installation Procedure IMPORTANT: All gasket surfaces should be free of oil or other foreign material during assembly.
  • Page 185 Fig. 79: View Of Knock Sensor Oil Seals & Cover Courtesy of GENERAL MOTORS CORP. 1. Install NEW knock sensor oil seals (1) into the valley cover (2). Lubricate the seal surfaces with clean engine oil.
  • Page 186 Fig. 80: Engine Valley Cover, Gasket, Bolts & LS6 Engine Courtesy of GENERAL MOTORS CORP. 2. If equipped with the 5.7 L, RPO LS6 engine, install the engine valley cover and a NEW gasket.
  • Page 187 Fig. 81: View Of Engine Valley Cover, Gasket & LS1 Engine Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Fastener Notice in Cautions and Notices. 3. If equipped with the 5.7 L, RPO LS1 engine, install the engine valley cover and NEW gasket. 4.
  • Page 188 Fig. 82: View Of Knock Sensors Courtesy of GENERAL MOTORS CORP. 5. Install the knock sensors. Tighten: Tighten the knock sensors to 20 N.m (15 lb ft).
  • Page 189 Fig. 83: View Of Knock Sensor Wire Harness Courtesy of GENERAL MOTORS CORP. 6. Connect the knock sensor wire harness electrical connectors. 7. Install the rubber grommets into the valley cover. 8. Install the intake manifold. Refer to Intake Manifold Replacement . VALVE ROCKER ARM COVER REPLACEMENT - LEFT Removal Procedure...
  • Page 190 Fig. 84: Engine Wiring Harness Generator Lead Nut & Generator Electrical Connector Courtesy of GENERAL MOTORS CORP. 1. Remove the fuel feed hose. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls - 5.7 L. 2. Disconnect the generator electrical connector (1). 3.
  • Page 191 Fig. 85: AIR Hose Clamp & Check Valve Courtesy of GENERAL MOTORS CORP. 4. Remove the secondary air injection (AIR) hose clamp. 5. Disconnect the AIR hose (3) from the check valve.
  • Page 192 Fig. 86: Left Rocker Arm Cover & PCV Valve Pipe Courtesy of GENERAL MOTORS CORP. 6. If equipped with the regular production option (RPO) LS1 engine, remove the positive crankcase ventilation (PCV) valve pipe from the left rocker cover.
  • Page 193 Fig. 87: Spark Plug Wire Courtesy of GENERAL MOTORS CORP. 7. Disconnect the spark plug wires from the ignition coils. Twist the spark plug wire boot 1/2 turn. Pull only on the boot in order to remove the wire from the ignition coil. 8.
  • Page 194 Fig. 88: EVAP Canister Purge Tube Courtesy of GENERAL MOTORS CORP. 9. Remove the evaporative emission (EVAP) canister purge tube from the intake manifold. 10. Remove the EVAP canister purge tube from the EVAP canister purge solenoid valve. 11. Remove the EVAP canister purge tube.
  • Page 195 Fig. 89: Fuel Feed Pipe Courtesy of GENERAL MOTORS CORP. 12. Disconnect the EVAP canister purge tube from the EVAP canister purge solenoid valve. 13. Disconnect the EVAP canister purge tube from the fuel feed pipe. 14. Remove the EVAP canister purge tube.
  • Page 196 Fig. 90: Electrical Connectors Courtesy of GENERAL MOTORS CORP. 15. Disconnect the EVAP canister purge solenoid valve electrical connector (2).
  • Page 197 Fig. 91: EVAP Canister Purge Solenoid Valve & Bracket Courtesy of GENERAL MOTORS CORP. 16. Remove the EVAP canister purge solenoid valve from the bracket.
  • Page 198 Fig. 92: Ignition Coil Bracket & Studs Courtesy of GENERAL MOTORS CORP. 17. Remove the ignition coil bracket studs. 18. Remove the ignition coil bracket.
  • Page 199 Fig. 93: Valve Rocker Arm Cover & Bolts Courtesy of GENERAL MOTORS CORP. 19. Loosen the valve rocker arm cover bolts. 20. Remove the valve rocker cover.
  • Page 200 Fig. 94: Rocker Arm Cover & Gasket Courtesy of GENERAL MOTORS CORP. 21. Remove the gasket (1) from the rocker cover. Discard the OLD gasket. 22. Clean and inspect the rocker arm cover. Refer to Valve Rocker Arm Cover Cleaning and Inspection . Installation Procedure IMPORTANT: All gasket surfaces should be free of oil and other foreign material during...
  • Page 201 If the PCV valve grommet has been removed from the rocker arm, install a NEW grommet during assembly. Fig. 95: Rocker Arm Cover & Gasket Courtesy of GENERAL MOTORS CORP. 1. Install a NEW rocker cover gasket (1) into the valve rocker cover lip.
  • Page 202 Fig. 96: Valve Rocker Arm Cover & Bolts Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Fastener Notice in Cautions and Notices. 2. Install the valve rocker arm cover. 3. Tighten the valve rocker cover bolts. Tighten: Tighten the valve rocker arm cover bolts to 12 N.m (106 lb in).
  • Page 203 Fig. 97: Ignition Coil Bracket & Studs Courtesy of GENERAL MOTORS CORP. 4. Install the ignition coil bracket. 5. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489), or equivalent to the threads of the ignition coil bracket studs. 6. Install the ignition coil bracket studs. Tighten: Tighten the ignition coil bracket studs to 12 N.m (106 lb in).
  • Page 204 Fig. 98: EVAP Canister Purge Solenoid Valve & Bracket Courtesy of GENERAL MOTORS CORP. 7. Remove the EVAP canister purge solenoid valve from the bracket.
  • Page 205 Fig. 99: Electrical Connectors Courtesy of GENERAL MOTORS CORP. 8. Connect the EVAP canister purge solenoid valve electrical connector (2).
  • Page 206 Fig. 100: Fuel Feed Pipe Courtesy of GENERAL MOTORS CORP. 9. Disconnect the EVAP canister purge tube from the EVAP canister purge solenoid valve. 10. Disconnect the EVAP canister purge tube from the fuel feed pipe. 11. Remove the EVAP canister purge tube.
  • Page 207 Fig. 101: EVAP Canister Purge Tube Courtesy of GENERAL MOTORS CORP. 12. Remove the EVAP canister purge tube from the intake manifold. 13. Remove the EVAP canister purge tube from the EVAP canister purge solenoid valve. 14. Remove the EVAP canister purge tube.
  • Page 208 Fig. 102: Spark Plug Wire Courtesy of GENERAL MOTORS CORP. 15. Connect the ignition coil wire harness main electrical connector. 16. Install the spark plug wires to the ignition coils.
  • Page 209 Fig. 103: Left Rocker Arm Cover & PCV Valve Pipe Courtesy of GENERAL MOTORS CORP. 17. If equipped with the RPO LS1 engine, install the PCV valve pipe to the left rocker cover.
  • Page 210 Fig. 104: AIR Hose Clamp & Check Valve Courtesy of GENERAL MOTORS CORP. 18. Connect the AIR hose (3) to the check valve. 19. Install the AIR hose clamp.
  • Page 211 Fig. 105: Engine Wiring Harness Generator Lead Nut & Generator Electrical Connector Courtesy of GENERAL MOTORS CORP. 20. Connect the generator electrical connector (1). 21. Install the engine wiring harness generator lead and nut (3). Tighten: Tighten the engine wiring harness generator lead nut to 13 N.m (115 lb in). 22.
  • Page 212 Removal Procedure Fig. 106: Right Fuel Injection Rail Cover Courtesy of GENERAL MOTORS CORP. 1. Remove the right fuel rail cover.
  • Page 213 Fig. 107: AIR Hose Clamp & Check Valve Courtesy of GENERAL MOTORS CORP. 2. Remove the secondary air injection (AIR) hose clamp. 3. Remove the AIR hose (1) from the check valve.
  • Page 214 Fig. 108: AIR Pipe & Bolts Courtesy of GENERAL MOTORS CORP. 4. Remove the AIR pipe bolts at the exhaust manifold.
  • Page 215 Fig. 109: AIR Pipe Gasket, Exhaust Manifold & Bolts Courtesy of GENERAL MOTORS CORP. 5. Loosen, DO NOT remove the AIR pipe bolt at the rear of the left cylinder head. 6. Slide the AIR pipe up and out from behind the bolt. 7.
  • Page 216 Fig. 110: PCV Tube & Rocker Arm Cover Courtesy of GENERAL MOTORS CORP. 9. Remove the throttle position (TP) sensor harness clip from the positive crankcase ventilation (PCV) tube. 10. Remove the PCV tube from the throttle body and rocker arm cover.
  • Page 218 Fig. 111: Right Rocker Arm Cover & PCV Valve Pipe Courtesy of GENERAL MOTORS CORP. 11. If equipped with the regular production option (RPO) LS1 engine, remove the PCV valve pipe strap nut. 12. Remove the PCV valve pipe from the right rocker arm cover and intake manifold. Fig.
  • Page 219 Pull only on the boot in order to remove the wire from the ignition coil. 14. Disconnect the ignition coil wire harness main electrical connector. Fig. 113: Ignition Coil Bracket & Studs Courtesy of GENERAL MOTORS CORP. 15. Remove the ignition coil bracket studs.
  • Page 220 16. Remove the ignition coil bracket. Fig. 114: View Of Valve Rocker Arm Cover & Bolts (Right) Courtesy of GENERAL MOTORS CORP. 17. Loosen the valve rocker arm cover bolts. 18. Remove the valve rocker arm cover.
  • Page 221 Fig. 115: Rocker Arm Cover & Gasket Courtesy of GENERAL MOTORS CORP. 19. Remove the gasket (1) from the rocker cover. Discard the OLD gasket.
  • Page 222 Fig. 116: View Of Oil Fill Tube Courtesy of GENERAL MOTORS CORP. 20. Remove the oil fill cap from the oil fill tube. 21. Remove the oil fill tube, if required. 22. Discard the oil fill tube.
  • Page 223 23. Clean and inspect the valve rocker arm cover. Refer to Valve Rocker Arm Cover Cleaning and Inspection . Installation Procedure IMPORTANT: All gasket surfaces should be free of oil and other foreign material during assembly. DO NOT reuse the valve rocker arm cover gasket. The valve rocker arm cover bolt grommets may be reused.
  • Page 224 Fig. 117: View Of Oil Fill Tube Courtesy of GENERAL MOTORS CORP. 1. Lubricate the O-ring seal of the NEW oil fill tube with clean engine oil. 2. Insert the NEW oil fill tube into the rocker arm cover. Rotate the tube clockwise until locked in the proper position.
  • Page 225 3. Install the oil fill cap into the tube. Rotate the cap clockwise until locked in the proper position. Fig. 118: Rocker Arm Cover & Gasket Courtesy of GENERAL MOTORS CORP. 4. Install a NEW gasket (1) into the valve rocker cover lip.
  • Page 226 Fig. 119: View Of Valve Rocker Arm Cover & Bolts (Right) Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Fastener Notice in Cautions and Notices. 5. Install the valve rocker arm cover onto the cylinder head. 6. Tighten the rocker arm cover bolts. Tighten: Tighten the valve rocker arm cover bolts to 12 N.m (106 lb in).
  • Page 227 Fig. 120: Ignition Coil Bracket & Studs Courtesy of GENERAL MOTORS CORP. 7. Install the ignition coil bracket. 8. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489), or equivalent to the threads of the bracket studs. 9. Install the ignition coil bracket studs.
  • Page 228 Tighten: Tighten the ignition coil bracket studs to 12 N.m (106 lb in). Fig. 121: Spark Plug Wire Courtesy of GENERAL MOTORS CORP. 10. Connect the ignition coil wire harness main electrical connector. 11. Install the spark plug wires to the ignition coils.
  • Page 230 Fig. 122: Right Rocker Arm Cover & PCV Valve Pipe Courtesy of GENERAL MOTORS CORP. 12. If equipped with the RPO LS1 engine, install the PCV valve pipe to the right rocker arm cover and intake manifold. 13. Install the PCV valve pipe strap nut. Tighten: Tighten the PCV valve strap nut to 12 N.m (106 lb in).
  • Page 231 Fig. 124: AIR Pipe Gasket, Exhaust Manifold & Bolts Courtesy of GENERAL MOTORS CORP. 16. Position the AIR pipe into place. 17. Slide the AIR pipe behind the bolt on the rear of the left cylinder head.
  • Page 232 Fig. 125: AIR Pipe & Bolts Courtesy of GENERAL MOTORS CORP. 18. Install the AIR pipe gasket to the exhaust manifold. 19. Install the AIR pipe to the exhaust manifold. 20. Install the AIR pipe bolts at the exhaust manifold. 21.
  • Page 233 Fig. 126: AIR Hose Clamp & Check Valve Courtesy of GENERAL MOTORS CORP. 22. Connect the AIR hose (1) to the check valve. 23. Install the AIR hose clamp.
  • Page 234 Fig. 127: Right Fuel Injection Rail Cover Courtesy of GENERAL MOTORS CORP. 24. Install the right fuel injection rail cover. VALVE ROCKER ARM AND PUSH ROD REPLACEMENT Removal Procedure...
  • Page 235 Fig. 128: View Of Valve Rocker Arms & Bolts Courtesy of GENERAL MOTORS CORP. IMPORTANT: Place the valve rocker arms, valve pushrods, and pivot support, in a rack so that they can be installed in the same location from which they were removed.
  • Page 236 Fig. 129: View Of Valve Rocker Arm Pivot Support Courtesy of GENERAL MOTORS CORP. 4. Remove the valve rocker arm pivot support.
  • Page 237 Fig. 130: View Of Pushrods Courtesy of GENERAL MOTORS CORP. 5. Remove the pushrods. 6. Clean and inspect the valve rocker arms and pushrods. Refer to Valve Rocker Arm and Push Rods Cleaning and Inspection . Installation Procedure IMPORTANT: When reusing the valvetrain components, always install the components to the original location and position.
  • Page 238 Fig. 131: View Of Valve Rocker Arm Pivot Support Courtesy of GENERAL MOTORS CORP. 1. Lubricate the valve rocker arms and pushrods with clean engine oil. 2. Lubricate the flange of the valve rocker arm bolts with clean engine oil. Lubricate the flange or washer surface of the bolt that will contact the valve rocker arm.
  • Page 239 Fig. 132: View Of Pushrods Courtesy of GENERAL MOTORS CORP. IMPORTANT: Make sure that the pushrods seat properly to the valve lifter sockets. 4. Install the pushrods.
  • Page 240 Fig. 133: View Of Valve Rocker Arms & Bolts Courtesy of GENERAL MOTORS CORP. IMPORTANT: Make sure that the pushrods seat properly to the ends of the rocker arms. 5. Install the rocker arms and bolts. DO NOT tighten the rocker arm bolts at this time.
  • Page 241 Fig. 134: View of Crankshaft Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Fastener Notice in Cautions and Notices.
  • Page 242 6. Rotate the crankshaft until the number one piston is at top dead center (TDC) of the compression stroke. In this position, cylinder number one rocker arms will be off lobe lift, and the crankshaft sprocket key will be at the 1:30 position. The engine firing order is 1,8,7,2,6,5,4,3.
  • Page 243 Fig. 135: Spark Plug Wire Courtesy of GENERAL MOTORS CORP. 1. Remove the valve rocker arms. Refer to Valve Rocker Arm and Push Rod Replacement . 2. Remove the spark plug wire from the spark plug for the cylinder to be serviced. Twist the plug wire 1/2 turn.
  • Page 244 Fig. 136: View Of Spark Plug Courtesy of GENERAL MOTORS CORP. IMPORTANT: Remove the spark plugs from the cylinder head with the engine at room temperature. 3. Loosen the spark plug 1 or 2 turns. 4. Brush or use compressed air to remove any dirt or debris around the spark plug. 5.
  • Page 245 Fig. 137: Install/Remove J 22794 Spark Plug Hole Courtesy of GENERAL MOTORS CORP. 6. Install the J 22794 into the spark plug hole. 7. Attach an air hose to J 22794 . 8. Tap the end of the valve stem with a plastic face hammer in order to loosen any varnish on the valve stem keys.
  • Page 246 Fig. 138: J 38606, J 5892-D & Valve Spring Courtesy of GENERAL MOTORS CORP. 9. Use the J 38606 in order to compress the valve spring.
  • Page 247 Fig. 139: Valve Stem Keys Courtesy of GENERAL MOTORS CORP.
  • Page 248 10. Remove the valve stem keys (3). 11. Carefully release the valve spring tension. 12. Remove the J 38606 . 13. Remove the valve spring cap (4). 14. Remove the valve spring (5). IMPORTANT: A second design valve stem oil seal and shim may be used on later engines.
  • Page 249 Fig. 140: Valve Stem Keys Courtesy of GENERAL MOTORS CORP.
  • Page 250 1. Clean the cylinder head valve spring seat and/or shim area. 2. Install the valve spring shim (7) (first design). 3. Install the valve stem oil seal and shim (2) (second design). The J 42078 is not required for installation of the second design seal and shim.
  • Page 251 Fig. 141: J 42078, Valve Stem Oil Seal & Bolt Courtesy of GENERAL MOTORS CORP. IMPORTANT: The valve stem oil seal alignment and position on the valve guide is critical. An improperly installed valve stem oil seal may lead to excessive oil consumption, and increased vehicle emissions.
  • Page 252 Fig. 142: Measuring Valve Stem Oil Seal For Properly Installed Height Courtesy of GENERAL MOTORS CORP. 5. Measure the valve stem oil seal (first design) for the properly installed height. There should be a 18.1-19.1 mm (0.712-0.752 in) gap between the top edge of the oil seal body and the valve spring shim surface.
  • Page 253 Fig. 144: Valve Stem Keys Courtesy of GENERAL MOTORS CORP.
  • Page 254 9. Install the valve spring cap (4). 10. Install the valve stem keys (3). Use grease to hold the keys (3) in place and remove J 38606 . Make sure the keys (3) seat properly in the groove of the valve stem. Carefully release the valve spring pressure, making sure the valve keys stay in place.
  • Page 255 Fig. 146: Measuring Valve Spring Installed Height Courtesy of GENERAL MOTORS CORP. 13. Measure the valve spring installed height using a ruler. Measure from the base of the valve spring to the top of the valve spring. If the installed height exceeds 46.25 mm (1.82 in), install a valve spring shim of approximately 0.5 mm (0.02 in) thick.
  • Page 256 Fig. 147: View Of Spark Plug Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Fastener Notice in Cautions and Notices. 15. Instal the spark plug by hand until snug. 16. Tighten the spark plug. Tighten: Tighten the spark plugs to 15 N.m (11 lb ft).
  • Page 257 Fig. 148: Spark Plug Wire Courtesy of GENERAL MOTORS CORP. 17. Install the spark plug wire to the spark plug. 18. Install the valve rocker arms. Refer to Valve Rocker Arm and Push Rod Replacement . OIL LEVEL INDICATOR AND TUBE REPLACEMENT Removal Procedure...
  • Page 258 Fig. 149: Oil Level Indicator Courtesy of GENERAL MOTORS CORP. 1. Remove the oil level indicator.
  • Page 259 Fig. 150: Oil Level Indicator Tube & Bolt Courtesy of GENERAL MOTORS CORP. 2. Remove the oil level indicator tube bolt. 3. Remove the oil level indicator tube. IMPORTANT: Inspect the O-ring seal for cuts or damage. The O-ring seal may be reused...
  • Page 260 if not cut or damaged. 4. Remove the O-ring from the oil level indicator tube, if required. Installation Procedure Fig. 151: Oil Level Indicator Tube & Bolt Courtesy of GENERAL MOTORS CORP.
  • Page 261 1. Lubricate the O-ring seal with clean engine oil. 2. Install the oil level indicator tube into position. 3. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 4. Insert the oil level indicator tube into the engine block until the collar is flush with the block. 5.
  • Page 262 Fig. 152: Oil Level Indicator Courtesy of GENERAL MOTORS CORP. 7. Install the oil level indicator. 8. Check the oil level and add if necessary. CYLINDER HEAD REPLACEMENT - LEFT Tools Required...
  • Page 263 J 42385-100 Thread Repair Kit (Cylinder Head/Main Bearing Bolt) J 45059 Angle Meter Removal Procedure Fig. 153: MAP Sensor Vacuum Hose & MAP Sensor Electrical Connector Courtesy of GENERAL MOTORS CORP. 1. Remove the valve rocker arms and pushrods. Refer to Valve Rocker Arm and Push Rod Replacement . 2.
  • Page 264 3. Remove the generator bracket. Refer to Generator Bracket Replacement in Engine Electrical. 4. Remove the exhaust manifold. Refer to Exhaust Manifold Replacement - Left in Engine Exhaust. 5. Remove the engine wiring harness ground bolt (5) from the rear of the left cylinder head. 6.
  • Page 265 7. Remove the cylinder head bolts. 8. Remove the cylinder head. Fig. 155: View Of Cylinder Head Gasket (Left) Courtesy of GENERAL MOTORS CORP. 9. Remove the cylinder head gasket. 10. Discard the gasket. 11. Discard the M11 cylinder head bolts. 12.
  • Page 266 Fig. 156: View Of 100 mm & 155 mm Bolts Courtesy of GENERAL MOTORS CORP. CAUTION: Refer to Safety Glasses Caution . NOTE: Clean all dirt, debris, 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 components.
  • Page 267 bolts during assembly. Do not use any type sealant on the cylinder head gasket, unless specified. The cylinder head gaskets must be installed in the proper direction and position. 1. Clean the engine block cylinder head bolt holes, if required. Thread repair tool J 42385-107 may be used to clean the threads of old threadlocking material.
  • Page 268 Fig. 157: View Of 100 mm & 155 mm Bolts Courtesy of GENERAL MOTORS CORP. IMPORTANT: First design engine blocks have different drill and tap depths using both medium length 100 mm (3.94 in) and long 155 mm (6.1 in) M11 cylinder head bolts.
  • Page 269 Fig. 158: View Of Cylinder Head Gasket Displacement Markings Courtesy of GENERAL MOTORS CORP. 6. Inspect the displacement markings (1) on the gasket, for proper usage.
  • Page 270 Fig. 159: View Of Cylinder Head Gasket (Right) Courtesy of GENERAL MOTORS CORP. IMPORTANT: When properly installed, the tab on the right cylinder head gasket will be located right of center or closer to the front of the engine. 7. Install the NEW cylinder head gasket onto the locating pins.
  • Page 271 Fig. 160: View Of Cylinder Head & Bolts Courtesy of GENERAL MOTORS CORP. 8. Install the cylinder head onto the locating pins and the gasket. 9. Install the NEW cylinder head bolts.
  • Page 272 Fig. 161: Cylinder Head Bolt Tightening Sequence (Right) Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Fastener Notice . 10. Tighten the first design cylinder head bolts. Tighten: 1. Tighten the first design M11 cylinder head bolts a first pass in sequence to 30 N.m (22 lb ft). 2.
  • Page 273 12. Install the wiring harness to the clip at the rear of the cylinder head. Fig. 162: MAP Sensor Vacuum Hose & MAP Sensor Electrical Connector Courtesy of GENERAL MOTORS CORP. 13. Position the engine wire harness ground strap (6) against the cylinder head. 14.
  • Page 274 16. Install the generator bracket. Refer to Generator Bracket Replacement in Engine Electrical. 17. Install the engine coolant air bleed pipe. Refer to Coolant Air Bleed Pipe Assembly Replacement in Engine Cooling. 18. Install the valve rocker arms and pushrods. Refer to Valve Rocker Arm and Push Rod Replacement . CYLINDER HEAD REPLACEMENT - RIGHT Tools Required J 42385-100 Thread Repair Kit (Cylinder Head/Main Bearing Bolt)
  • Page 275 Fig. 163: Oil Level Indicator Tube & Bolt Courtesy of GENERAL MOTORS CORP. 1. Remove the valve rocker arms and pushrods. Refer to Valve Rocker Arm and Push Rod Replacement . 2. Remove the engine coolant air bleed pipe and covers. Refer to Coolant Air Bleed Pipe Assembly Replacement in Engine Cooling.
  • Page 276 4. Remove the oil level indicator tube bolt. 5. Reposition the oil level indicator tube, if necessary. 6. Remove the wiring harness from the clip at the rear of the cylinder head. Fig. 164: View Of Cylinder Head & Bolts Courtesy of GENERAL MOTORS CORP.
  • Page 277 7. Remove the cylinder head bolts. 8. Remove the cylinder head. Fig. 165: View Of Cylinder Head Gasket (Right) Courtesy of GENERAL MOTORS CORP. 9. Remove the cylinder head gasket. 10. Discard the gasket. 11. Discard the cylinder head bolts. 12.
  • Page 278 Fig. 166: View Of 100 mm & 155 mm Bolts Courtesy of GENERAL MOTORS CORP. CAUTION: Refer to Safety Glasses Caution . NOTE: Clean all dirt, debris, 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 components.
  • Page 279 bolts during assembly. Do not use any type sealant on the cylinder head gasket, unless specified. The cylinder head gaskets must be installed in the proper direction and position. 1. Clean the engine block cylinder head bolt holes, if required. Thread repair tool J 42385-107 may be used to clean the threads of old threadlocking material.
  • Page 280 Fig. 167: View Of 100 mm & 155 mm Bolts Courtesy of GENERAL MOTORS CORP. IMPORTANT: First design engine blocks have different drill and tap depths using both medium length 100 mm (3.94 in) and long 155 mm (6.1 in) M11 cylinder head bolts.
  • Page 281 Fig. 168: View Of Cylinder Head Gasket Displacement Markings Courtesy of GENERAL MOTORS CORP. 6. Inspect the displacement markings (1) on the gasket, for proper usage.
  • Page 282 Fig. 169: View Of Cylinder Head Gasket (Right) Courtesy of GENERAL MOTORS CORP. IMPORTANT: When properly installed, the tab on the right cylinder head gasket will be located right of center or closer to the front of the engine. 7. Install the NEW cylinder head gasket onto the locating pins.
  • Page 283 Fig. 170: View Of Cylinder Head & Bolts Courtesy of GENERAL MOTORS CORP. 8. Install the cylinder head onto the locating pins and the gasket. 9. Install the NEW cylinder head bolts.
  • Page 284 Fig. 171: Cylinder Head Bolt Tightening Sequence (Right) Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Fastener Notice . 10. Tighten the first design cylinder head bolts. Tighten: 1. Tighten the first design M11 cylinder head bolts a first pass in sequence to 30 N.m (22 lb ft). 2.
  • Page 285 12. Install the wiring harness to the clip at the rear of the cylinder head. Fig. 172: Oil Level Indicator Tube & Bolt Courtesy of GENERAL MOTORS CORP. 13. Position the oil level indicator tube into place. 14. Install the oil level indicator tube bolt.

  • Page 286: Valve Lifter Replacement

    Tighten: Tighten the oil level indicator tube bolt to 25 N.m (18 lb ft). 15. Install the exhaust manifold. Refer to Exhaust Manifold Replacement - Right in Engine Exhaust. 16. Install the engine coolant air bleed pipe. Refer to Coolant Air Bleed Pipe Assembly Replacement in Engine Cooling.
  • Page 287 Fig. 173: Valve Lifter Guide & Bolts Courtesy of GENERAL MOTORS CORP. 1. Remove the cylinder head. Refer to Cylinder Head Replacement - Left or Cylinder Head Replacement - Right . 2. Remove the valve lifter guide bolts (1). 3. Remove the valve lifters and guide.
  • Page 288 Fig. 174: Using J 3049-A To Remove Stuck Valve Lifters Courtesy of GENERAL MOTORS CORP. IMPORTANT: Some valve lifters may be stuck in their bores because of gum or varnish deposits. 4. Use the J 3049-A or equivalent in order to remove the valve lifters (if required).
  • Page 289 Fig. 175: View Of Valve Lifters & Guide Courtesy of GENERAL MOTORS CORP. 5. Remove the valve lifters from the guide. 6. Organize or mark the components so that they can be installed in the same location from which they were removed.
  • Page 290 Fig. 176: View Of Valve Lifters & Guide Courtesy of GENERAL MOTORS CORP. 1. Lubricate the valve lifters and engine block valve lifter bores with clean engine oil. 2. Insert the valve lifters into the lifter guides. Align the flat area on the top of the lifter with the flat area in the guide bore. Push the lifter completely into the guide bore.
  • Page 291 Fig. 177: Valve Lifter Guide & Bolts Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Fastener Notice in Cautions and Notices. 3. Install the valve lifters and guide to the engine block. 4. Install the valve lifter guide bolt (1). Tighten: Tighten the valve lifter guide bolt to 12 N.m (106 lb in).

  • Page 292: Crankshaft Balancer Replacement

    CRANKSHAFT BALANCER REPLACEMENT Tools Required J 41816 Crankshaft Balancer Remover J 41816-2 Crankshaft End Protector J 42386-A Flywheel Holding Tool J 41665 Crankshaft Balancer and Sprocket Installer J 36660-A Torque Angle Meter Removal Procedure...
  • Page 293 Fig. 178: Right Transmission Cover & Bolt Courtesy of GENERAL MOTORS CORP. 1. Remove the air conditioning (A/C) drive belt. Refer to Drive Belt Replacement - Air Conditioning . 2. Remove the power steering gear. Refer to Power Steering Gear Replacement in Power Steering System.
  • Page 294 Fig. 179: J 42386-A & Bolts Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Fastener Notice in Cautions and Notices. IMPORTANT: Make sure that the teeth of the flywheel holding tool mesh with the teeth of the engine flywheel. 5. Install the J 42386-A and bolts. Use one M10-1.5 x 120 mm and one M10-1.5 x 45 mm bolt for proper tool operation Tighten: Tighten the J 42386-A bolts to 50 N.m (37 lb ft).
  • Page 295 Fig. 180: Identifying Harmonic Balancer Bolt Courtesy of GENERAL MOTORS CORP. 6. Remove the crankshaft balancer bolt. Do not discard the crankshaft balancer bolt. The balancer bolt will be used during the balancer installation procedure.
  • Page 296 Fig. 181: J 42386-A, Crankshaft Balancer & Bolt Courtesy of GENERAL MOTORS CORP. IMPORTANT: For manual transmission applications, note the position of the crankshaft balancer before removal. The balancer does not use a key or keyway for positioning. Mark or scribe the end of the crankshaft and the balancer before removal.
  • Page 297 Note the balancer installed position on the crankshaft for assembly. Refer to Engine Balancing Fig. 182: View Of J 41816 & J 41816-2 Courtesy of GENERAL MOTORS CORP. 8. Use the J 38416-B and the J 41816-2 in order to remove the crankshaft balancer. 9.
  • Page 298 Fig. 183: Crankshaft Balancer Weights Courtesy of GENERAL MOTORS CORP. 10. Not the position of any crankshaft balancer weights (if applicable). 11. Clean and inspect the crankshaft balancer. Refer to Crankshaft Balancer Cleaning and Inspection in the Engine Unit Repair Manual. Installation Procedure IMPORTANT: The used crankshaft balancer bolt will be used only during the first pass...
  • Page 299 The crankshaft balancer installation and bolt tightening involves a four stage tightening process. The first pass ensures that the balancer is installed completely onto the crankshaft. The third, and fourth passes tighten the new bolt to the proper torque. Fig. 184: Crankshaft Balancer Weights Courtesy of GENERAL MOTORS CORP.
  • Page 300 Refer to Crankshaft Balancer Cleaning and Inspection Fig. 185: Identifying Harmonic Balancer Bolt Courtesy of GENERAL MOTORS CORP. IMPORTANT: Align the scribe mark on the balancer with the scribe mark on the crankshaft. The balancer should be positioned onto the end of the crankshaft as straight as possible prior to tool installation.
  • Page 301 Fig. 186: J 41665 & Crankshaft Balancer Courtesy of GENERAL MOTORS CORP. 4. Use the J 41665 in order to install the crankshaft balancer. 1. Assemble the threaded rod, nut, washer and installer. Insert the smaller end of the installer into the front of the balancer. 2.
  • Page 302 Position the larger end of the installer against the front of the balancer. 5. Use a wrench and hold the hex end of the threaded rod. 6. Use a second wrench and rotate the installation tool nut clockwise until the balancer is installer onto the crankshaft.
  • Page 303 Fig. 187: View Of Balancer Proper Installation Position Courtesy of GENERAL MOTORS CORP. 5. Install the used crankshaft balancer bolt. Tighten: Tighten the used crankshaft balancer bolt to 330 N.m (240 lb ft).
  • Page 304 6. Remove the used crankshaft balancer bolt. IMPORTANT: The nose of the crankshaft should be recessed 2.40-4.48 mm (0.094-0.176 in) into the balancer bore. 7. Measure for a correctly installer balancer. If the balancer is not installed to the proper dimensions, install the J 41665 and repeat the installation procedure.
  • Page 305 1. Tighten the new crankshaft balancer bolt a first pass to 50 N.m (37 lb ft). 2. Tighten the new crankshaft balancer bolt a second pass to 140 degrees using the J 36660-A . Fig. 189: J 42386-A, Crankshaft Balancer & Bolt Courtesy of GENERAL MOTORS CORP.
  • Page 306 Fig. 190: Right Transmission Cover & Bolt Courtesy of GENERAL MOTORS CORP. 10. Install the right transmission cover and bolt. Tighten: Tighten the right transmission cover bolt to 12 N.m (106 lb in). 11. Install the starter motor. Refer to Starter Motor Replacement in Engine Electrical. 12.
  • Page 307 Variation Learn Procedure in Engine Controls - 5.7 L. CRANKSHAFT FRONT OIL SEAL REPLACEMENT Tools Required J 41478 Crankshaft Front Oil Seal Installer Removal Procedure Fig. 191: Front Cover & Oil Seal Bore Courtesy of GENERAL MOTORS CORP.
  • Page 308 1. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement . 2. Gently pry the crankshaft oil seal (1) from the front cover. Installation Procedure IMPORTANT: Do not lubricate the oil seal sealing surface. Do not reuse the crankshaft oil seal. Fig.
  • Page 309 1. Lubricate the outer edge of the oil seal (1) with clean engine oil. 2. Lubricate the front cover oil seal bore with clean engine oil. Fig. 193: J 41478 & Crankshaft Front Oil Seal Courtesy of GENERAL MOTORS CORP. 3.

  • Page 310: Engine Front Cover Replacement

    3. Remove the tool. 4. Inspect the oil seal for proper installation. The oil seal should be installed evenly and completely into the front cover bore. 6. Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement . ENGINE FRONT COVER REPLACEMENT Tools Required J 41476 Front and Rear Cover Alignment (Crankshaft Oil Seal Area) J 41478 Crankshaft Front Oil Seal Installer...
  • Page 311 Courtesy of GENERAL MOTORS CORP. 1. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement . 2. Remove the water pump. Refer to Water Pump Replacement in Engine Cooling. 3. Remove the oil pan-to-front cover bolts (2). Fig. 195: Front Cover Gasket & Bolts Courtesy of GENERAL MOTORS CORP.
  • Page 312 IMPORTANT: Do not reuse the crankshaft oil seal or front cover gasket. Do not apply any type sealant to the front cover gasket (unless specified). The special tool in this procedure is used to center the crankshaft front oil seal. All gasket surfaces should be free of oil or other foreign material during assembly.
  • Page 313 1. Apply a 5 mm (0.20 in) bead of sealant GM P/N 12378190, or equivalent 20 mm (0.80 in) long to the oil pan to engine block junction. 2. Install the front cover gasket and cover. 3. Install the front cover bolts until snug. Do not overtighten. Fig.
  • Page 314 Fig. 198: J 41476 & Front Cover Courtesy of GENERAL MOTORS CORP. 5. Install the J 41476 to the front cover. 6. Align the tapered legs of the J 41476 with the machined alignment surfaces on the front cover. NOTE: Refer to Fastener Notice in Cautions and Notices.
  • Page 315 7. Install the crankshaft balancer bolt until sung. Do not overtighten. Tighten: 1. Tighten the oil pan-to-front cover bolts to 25 N.m (18 lb ft). 2. Tighten the engine front cover bolts to 25 N.m (18 lb ft). 8. Remove the J 41476 . Fig.
  • Page 316 IMPORTANT: Do not lubricate the oil seal sealing surface. Do not reuse the crankshaft oil seal. 9. Lubricate the outer edge of the oil seal (1) with clean engine oil. 10. Lubricate the front cover oil seal bore with clean engine oil. Fig.

  • Page 317: Crankshaft Rear Oil Seal Replacement

    13. Use the J 41478 in order to install the oil seal into the cover bore. Use a wrench and hold the hex on the installer bolt. Use a second wrench and rotate the installer nut clockwise until the seal bottoms in the cover bore. Remove the tool.
  • Page 318 Fig. 201: View Of Crankshaft Rear Oil Seal Courtesy of GENERAL MOTORS CORP. 1. Remove the engine flywheel. Refer to Engine Flywheel Replacement . 2. Gently pry the crankshaft rear oil seal (1) from the rear cover. Installation Procedure IMPORTANT: Do not lubricate the oil seal inside diameter (ID) of the crankshaft surface.
  • Page 319 Fig. 202: View Of Crankshaft Rear Oil Seal Courtesy of GENERAL MOTORS CORP. 1. Lubricate the outside diameter (OD) of the oil seal (1) with clean engine oil. DO NOT allow oil or other lubricants to contact the seal surface. 2.
  • Page 320 Fig. 203: J 41479, Cone & Rear Crankshaft Courtesy of GENERAL MOTORS CORP. 3. Install the J 41479 cone (2) and bolts onto the rear of the crankshaft. 4. Tighten the bolts until snug. Do not overtighten. 5. Install the rear oil seal onto the tapered cone (2) and push the seal to the rear cover bore. 6.
  • Page 321 Tools Required J 41476 Front and Rear Cover Alignment (Crankshaft Oil Seal Area) J 41479 Crankshaft Rear Oil Seal Installer Removal Procedure Fig. 204: Oil Pan-To-Front Cover Bolts & Oil Pan-To-Rear Cover Bolts Courtesy of GENERAL MOTORS CORP. 1. Remove the engine flywheel. Refer to Engine Flywheel Replacement . 2.
  • Page 322 Fig. 205: Rear Cover Gasket & Bolts Courtesy of GENERAL MOTORS CORP. 3. Remove the rear cover bolts. 4. Remove the rear cover and gasket. 5. Discard the rear cover gasket. 6. Clean and inspect the engine rear cover. Refer to Engine Rear Cover Cleaning and Inspection . Installation Procedure IMPORTANT: Do not reuse the crankshaft oil seal or rear cover gasket.
  • Page 323 crankshaft. The crankshaft rear oil seal will be installed after the rear cover has been installed. An improperly aligned rear cover may cause premature rear oil seal wear and/or engine assembly oil leaks. Fig. 206: Rear Cover Gasket & Bolts Courtesy of GENERAL MOTORS CORP.
  • Page 324 Fig. 207: Oil Pan-To-Front Cover Bolts & Oil Pan-To-Rear Cover Bolts Courtesy of GENERAL MOTORS CORP. 3. Install the oil pan-to-rear cover bolts (1) until snug. Do not overtighten.
  • Page 325 Fig. 208: J 41476 & Bolts Courtesy of GENERAL MOTORS CORP. IMPORTANT: The tapered legs of the alignment tool must enter the rear cover oil seal bore. 4. Rotate the crankshaft until 2 opposing flywheel bolt holes are parallel to the oil pan surface. 5.
  • Page 326 1. Tighten the oil pan-to-rear cover bolts to 12 N.m (106 lb in). 2. Tighten the engine rear cover bolts to 25 N.m (18 lb ft). 7. Remove the J 41476 . Fig. 209: View Of Crankshaft Rear Oil Seal Courtesy of GENERAL MOTORS CORP.
  • Page 327 8. Lubricate the outside diameter (OD) of the oil seal (1) with clean engine oil. Do not allow oil or other lubricants to contact the seal surface. 9. Lubricate the rear cover oil seal bore with clean engine oil. Do not allow oil or other lubricants to contact the crankshaft surface. Fig.

  • Page 328: Oil Filter Adapter Replacement

    13. Thread the J 41479 threaded rod into the tapered cone (2) until the tool (1) contacts the oil seal. 14. Align the oil seal onto the tool (1). 15. Rotate the handle of the J 41479 clockwise until the seal enters the rear cover and bottoms into the cover bore.
  • Page 329 Fig. 211: Oil Filter Courtesy of GENERAL MOTORS CORP. 1. Drain the engine oil. 2. Remove the oil filter.
  • Page 330 Fig. 212: Oil Filter Adapter & Oil Filter Bypass Valve Courtesy of GENERAL MOTORS CORP. 3. Remove the oil filter adapter (1). Installation Procedure...
  • Page 331 Fig. 213: Oil Filter Adapter & Oil Filter Bypass Valve Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Fastener Notice in Cautions and Notices. 1. Install the oil filter adapter (1). Tighten: Tighten the oil filter adapter to 55 N.m (40 lb ft).
  • Page 332 Fig. 214: Oil Filter Courtesy of GENERAL MOTORS CORP. 2. Install the oil filter. Tighten: Tighten the oil filter to 30 N.m (22 lb ft).
  • Page 333 3. Refill the engine oil. OIL FILTER BYPASS VALVE REPLACEMENT Removal Procedure...
  • Page 334 Fig. 215: Oil Filter Courtesy of GENERAL MOTORS CORP. 1. Drain the engine oil. 2. Remove the oil filter. Fig. 216: Oil Filter Adapter & Oil Filter Bypass Valve Courtesy of GENERAL MOTORS CORP. 3. Remove the oil filter adapter 1. 4.
  • Page 335 Installation Procedure Fig. 217: Oil Filter Adapter & Oil Filter Bypass Valve Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Fastener Notice in Cautions and Notices. 1. Install the oil filter bypass valve 2. 2. Install the oil filter adapter 1. Tighten: Tighten the oil filter adapter to 55 N.m (40 lb ft).
  • Page 336 Fig. 218: Oil Filter Courtesy of GENERAL MOTORS CORP. 3. Install the oil filter. Tighten: Tighten the oil filter to 30 N.m (22 lb ft).
  • Page 337 4. Refill the engine oil. OIL PAN COVER REPLACEMENT Removal Procedure...
  • Page 338 Fig. 219: Oil Filter Courtesy of GENERAL MOTORS CORP. 1. Drain the engine oil. 2. Remove the oil filter. Fig. 220: Oil Pan Cover Bolts, Cover & Gasket Courtesy of GENERAL MOTORS CORP. 3. Remove the oil pan cover bolts, cover, and gasket. 4.
  • Page 339 Fig. 221: Oil Pan Cover Bolts, Cover & Gasket Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Fastener Notice in Cautions and Notices. 1. Install a new gasket, the cover, and bolts. Tighten: Tighten the oil pan cover bolts to 12 N.m (106 lb in).
  • Page 340 Fig. 222: Oil Filter Courtesy of GENERAL MOTORS CORP. 2. Install the oil filter. Tighten: Tighten the oil filter to 30 N.m (22 lb ft).

  • Page 341: Oil Pan Replacement

    3. Refill the engine oil. OIL PAN REPLACEMENT Removal Procedure Fig. 223: Oil Pan Drain Plug Courtesy of GENERAL MOTORS CORP. 1. Remove the front suspension crossmember. Refer to Crossmember Replacement - Front Suspension in Front Suspension. 2. Remove the oil pan drain plug and allow the oil to drain. 3.
  • Page 342 If the oil pan (lower) gasket replacement is required proceed to the next step. Fig. 224: Lower Oil Pan Bolt (1-15) Courtesy of GENERAL MOTORS CORP. 5. If replacement of the oil pan (lower) gasket is needed, perform the following: 6.
  • Page 344 Fig. 225: Lower Oil Pan, Gasket, Oil Pan & Bolts Courtesy of GENERAL MOTORS CORP. 7. Separate the oil pan (lower) (3) from the oil pan (1). 8. Remove the oil pan (lower) gasket (2). 9. Clean the oil pan (lower) gasket surface. For the oil pan (lower) installation, refer to step 13 in the installation procedure.
  • Page 345 Fig. 226: Left Transmission Cover & Bolt Courtesy of GENERAL MOTORS CORP. 10. Remove the starter motor. Refer to Starter Motor Replacement in Engine Electrical. 11. Remove the left transmission cover bolt and cover.
  • Page 346 Fig. 227: Engine Oil Filter Courtesy of GENERAL MOTORS CORP. 12. Remove the engine oil filter and allow the oil to drain. 13. Re-install the engine oil filter until snug.
  • Page 347 Fig. 228: Automatic Transmission Fluid Cooler Line Clamp & Bolt Courtesy of GENERAL MOTORS CORP. 14. Remove the automatic transmission fluid cooler line clamp bolt at the right transmission cover, if equipped.
  • Page 348 Fig. 229: Automatic Transmission Fluid Cooler Line & Oil Pan Courtesy of GENERAL MOTORS CORP. 15. Remove the automatic transmission fluid cooler line clamp bolt at the oil pan, if equipped.
  • Page 349 Fig. 230: Right Transmission Cover & Bolt Courtesy of GENERAL MOTORS CORP. 16. Remove the right transmission cover bolt and cover.
  • Page 350 Fig. 231: Bottom Flywheel Housing-To-Oil Pan & Bolts Courtesy of GENERAL MOTORS CORP. 17. Remove the bottom 2 flywheel housing-to-oil pan bolts.
  • Page 351 Fig. 232: Engine Oil Level Sensor Electrical Connector & CKP Sensor Electrical Connector Courtesy of GENERAL MOTORS CORP. 18. Disconnect the engine oil level sensor electrical connector (2).
  • Page 352 Fig. 233: Engine Oil Temperature Sensor Electrical Connector & Ground Straps Courtesy of GENERAL MOTORS CORP. 19. Disconnect the engine oil temperature sensor (3) electrical connector.
  • Page 353 Fig. 234: Oil Pan Gasket & Engine Block Courtesy of GENERAL MOTORS CORP. IMPORTANT: The original oil pan gasket is retained and aligned to the oil pan by rivets. When installing a new gasket, it is not necessary to install new oil pan gasket rivets.
  • Page 354 20. Remove the oil pan bolts. 21. Lower the oil pan, rotate the pan until it can be removed from around the oil pump screen. 22. Remove the engine oil filter. 23. Clean and inspect the engine oil pan. Refer to Oil Pan Cleaning and Inspection . Installation Procedure IMPORTANT: All gasket surfaces should be free of oil or other foreign material during assembly.
  • Page 355 Fig. 235: View Of Sealant Applied To Front Oil Pan-To-Engine Block Junction Courtesy of GENERAL MOTORS CORP. 1. Apply a 5 mm (0.20 in) bead of sealant GM P/N 12378190, or equivalent 20 mm (0.80 in) long to the engine block. Apply the sealant directly onto the tabs of the front cover gasket that protrude into the oil pan surface.
  • Page 356 Fig. 236: View Of Sealant Applied To Rear Oil Pan-To-Engine Block Junction Courtesy of GENERAL MOTORS CORP. 2. Apply a 5 mm (0.20 in) bead of sealant GM P/N 12378190, or equivalent 20 mm (0.80 in) long to the engine block. Apply the sealant directly onto the tabs of the rear cover gasket that protrude into the oil pan surface.
  • Page 357 Fig. 237: Oil Pan Gasket & Engine Block Courtesy of GENERAL MOTORS CORP. IMPORTANT: Be sure to align the oil gallery passages in the oil pan and engine block properly with the oil pan gasket. 3. Pre-assemble the oil pan gasket to the pan. 1.
  • Page 358 3. Install the oil pan, gasket and bolts to the engine block. 4. Tighten the oil pan bolts until snug. Do not overtighten. Fig. 238: Bottom Flywheel Housing-To-Oil Pan & Bolts Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Fastener Notice in Cautions and Notices. 4.
  • Page 359 3. Tighten the flywheel housing bolts to 50 N.m (37 lb ft). Fig. 239: Engine Oil Temperature Sensor Electrical Connector & Ground Straps Courtesy of GENERAL MOTORS CORP. 6. Connect the engine oil temperature sensor (3) electrical connector.
  • Page 360 Fig. 240: Engine Oil Level Sensor Electrical Connector & CKP Sensor Electrical Connector Courtesy of GENERAL MOTORS CORP. 7. Connect the engine oil level sensor electrical connector (2).
  • Page 361 Fig. 241: Right Transmission Cover & Bolt Courtesy of GENERAL MOTORS CORP. 8. Install the right transmission cover and bolt. Tighten: Tighten the right transmission cover bolt to 12 N.m (106 lb in).
  • Page 362 Fig. 242: Automatic Transmission Fluid Cooler Line & Oil Pan Courtesy of GENERAL MOTORS CORP. 9. Install the automatic transmission fluid cooler line clamp bolt-at-the oil pan, if equipped. Tighten: Tighten the automatic transmission fluid cooler line clamp bolt-at-the oil pan to 12 N.m (106 lb in).
  • Page 363 Fig. 243: Automatic Transmission Fluid Cooler Line Clamp & Bolt Courtesy of GENERAL MOTORS CORP. 10. Install the automatic transmission fluid cooler line clamp bolt-at-right transmission cover, if equipped. Tighten: Tighten the automatic transmission fluid cooler line bolt-at-right transmission cover to 2.5 N.m (22 lb in).
  • Page 364 Fig. 244: Left Transmission Cover & Bolt Courtesy of GENERAL MOTORS CORP. 11. Install the left transmission cover and bolt. Tighten: Tighten the left transmission cover bolt to 12 N.m (106 lb in). 12. Install the starter motor. Refer to Starter Motor Replacement in Engine Electrical.
  • Page 366 Fig. 245: Lower Oil Pan, Gasket, Oil Pan & Bolts Courtesy of GENERAL MOTORS CORP. 13. Install the oil pan (lower) (3) and gasket (2) to the oil pan (1). 14. Install the oil pan bolts (4). Fig. 246: Lower Oil Pan Bolt (1-15) Courtesy of GENERAL MOTORS CORP.
  • Page 367 Fig. 247: Engine Oil Filter Courtesy of GENERAL MOTORS CORP. 16. Install a NEW engine oil filter. Tighten: Tighten the engine oil filter to 30 N.m (22 lb ft).
  • Page 368 Fig. 248: Oil Pan Drain Plug Courtesy of GENERAL MOTORS CORP. 17. Install the oil pan drain plug. Tighten: Tighten the oil pan drain plug to 25 N.m (18 lb ft). 18. Install the front suspension crossmember to the vehicle. Refer to Crossmember Replacement - Front Suspension in Front Suspension.
  • Page 369 J 41712 Oil Pressure Sensor Socket Removal Procedure Fig. 249: MAP Sensor Vacuum Hose & MAP Sensor Electrical Connector Courtesy of GENERAL MOTORS CORP. 1. Remove the intake manifold. Refer to Intake Manifold Replacement . 2. Disconnect the oil pressure sensor electrical connector (2). IMPORTANT: Clean the area around the sensor before removal.
  • Page 370 Fig. 250: J 41712 & Oil Pressure Sensor Courtesy of GENERAL MOTORS CORP. 3. Use J 41712 to remove the oil pressure sensor from the engine block. Installation Procedure...
  • Page 371 Fig. 251: J 41712 & Oil Pressure Sensor Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Fastener Notice in Cautions and Notices. 1. If installing the old sensor, apply thread sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent. 2. Use J 41712 to install the oil pressure sensor to the engine block. Tighten: Tighten the engine oil pressure sensor to 20 N.m (15 lb ft).
  • Page 372 Fig. 252: MAP Sensor Vacuum Hose & MAP Sensor Electrical Connector Courtesy of GENERAL MOTORS CORP. 3. Connect the oil pressure sensor electrical connector (2). 4. Install the intake manifold. Refer to Intake Manifold Replacement . ENGINE OIL LEVEL SENSOR AND/OR SWITCH REPLACEMENT Removal Procedure...
  • Page 373 Fig. 253: Engine Oil Level Sensor Electrical Connector Courtesy of GENERAL MOTORS CORP. 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 2. Remove the oil pan drain plug. 3. Completely drain the engine oil. 4.
  • Page 374 Fig. 254: Engine Oil Level Sensor Electrical Connector Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Fastener Notice in Cautions and Notices. 1. Install the drain plug to the oil pan. Tighten: Tighten the drain plug to 25 N.m (18 lb ft). 2.
  • Page 375 Removal Procedure Fig. 255: Engine Oil Temperature Gage Sensor Courtesy of GENERAL MOTORS CORP. 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 2. Remove the engine oil temperature gage sensor.
  • Page 376 Installation Procedure Fig. 256: Engine Oil Temperature Gage Sensor Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Fastener Notice in Cautions and Notices. 1. Install the engine oil temperature gage sensor.
  • Page 377 Tighten: Tighten the engine oil temperature gage sensor to 23 N.m (17 lb ft). 2. Lower the vehicle. OIL PUMP, PUMP SCREEN AND DEFLECTOR REPLACEMENT Removal Procedure Fig. 257: O-Ring Seal, Oil Pump Screen & Bolt Courtesy of GENERAL MOTORS CORP. 1.
  • Page 378 5. Remove the O-ring seal from the pump screen. 6. Discard the O-ring seal. Fig. 258: Crankshaft Oil Deflector & Nuts Courtesy of GENERAL MOTORS CORP. 7. Remove the remaining crankshaft oil deflector nuts. 8. Remove the crankshaft oil deflector.
  • Page 379 Fig. 259: View Of Oil Pump & Bolt Courtesy of GENERAL MOTORS CORP. IMPORTANT: Do not allow dirt or debris to enter the oil pump, cap the ends as necessary. 9. Remove the oil pump bolts. 10. Remove the oil pump. 11.
  • Page 380 Fig. 260: View Of Oil Pump & Bolt Courtesy of GENERAL MOTORS CORP. 1. Align the splined surfaces of the crankshaft sprocket and the oil pump drive gear and install the oil pump. 2. Install the oil pump onto the crankshaft sprocket until the pump housing contacts the face of the engine block.
  • Page 381 Fig. 261: Crankshaft Oil Deflector & Nuts Courtesy of GENERAL MOTORS CORP. 4. Install the crankshaft oil deflector. 5. Install the crankshaft oil deflector nuts. Tighten: Tighten the crankshaft oil deflector nuts to 25 N.m (18 lb ft).
  • Page 382 Fig. 262: O-Ring Seal, Oil Pump Screen & Bolt Courtesy of GENERAL MOTORS CORP. 6. Lubricate a NEW oil pump screen O-ring seal with clean engine oil. 7. Install the NEW O-ring seal onto the oil pump screen. IMPORTANT: Push the oil pump screen tube completely into the oil pump prior to tightening the bolt.
  • Page 383 Tighten the oil pump screen bolt to 12 N.m (106 lb in). Tighten the oil pump screen nut to 25 N.m (18 lb ft). 10. Install the engine oil pan. Refer to Oil Pan Replacement . 11. Install the engine front cover. Refer to Engine Front Cover Replacement . TIMING CHAIN AND SPROCKETS REPLACEMENT Tools Required J 8433 Pulley Puller...
  • Page 384 Fig. 263: View Of Camshaft Sprocket, Bolt & Timing Chain Courtesy of GENERAL MOTORS CORP. 1. Remove the oil pump. Refer to Oil Pump, Pump Screen and Deflector Replacement . 2. Remove the camshaft sprocket bolts. 3. Remove the camshaft sprocket and timing chain.
  • Page 385 Fig. 264: View Of J 8433-1, J 41816-2 & J 41558 Courtesy of GENERAL MOTORS CORP. 4. Use the J 8433 , J 41816-2 and J 41558 in order to remove the crankshaft sprocket.
  • Page 386 Fig. 265: View Of Crankshaft Sprocket Courtesy of GENERAL MOTORS CORP. 5. Remove the crankshaft sprocket.
  • Page 387 Fig. 266: View Of Crankshaft Sprocket Key Courtesy of GENERAL MOTORS CORP. 6. Remove the crankshaft sprocket key (if required). 7. Clean and inspect the timing chain and sprockets. Refer to Timing Chain and Sprockets Cleaning and Inspection . Installation Procedure...
  • Page 388 Fig. 267: View Of Crankshaft Sprocket Key Courtesy of GENERAL MOTORS CORP. 1. Install the key into the crankshaft keyway (if previously removed).
  • Page 389 Fig. 268: View Of Crankshaft Sprocket Key Installation Position Courtesy of GENERAL MOTORS CORP. 2. Tap the key (1) into the keyway until both ends of the key bottom onto the crankshaft.
  • Page 390 Fig. 269: View Of Crankshaft Sprocket Courtesy of GENERAL MOTORS CORP. 3. Install the crankshaft sprocket onto the front of the crankshaft. Align the crankshaft key with the crankshaft sprocket keyway.
  • Page 391 Fig. 270: Installing Crankshaft Sprocket Using J 41665 Courtesy of GENERAL MOTORS CORP. 4. Use the J 41665 in order to install the crankshaft sprocket. Install the sprocket onto the crankshaft until fully seated against the crankshaft flange. 5. Rotate the crankshaft sprocket until the alignment mark is in the 12 o'clock position.
  • Page 392 Fig. 271: View Of Camshaft Sprocket, Bolt & Timing Chain Courtesy of GENERAL MOTORS CORP. IMPORTANT: Properly locate the camshaft sprocket locating pin with the camshaft sprocket alignment hole. The sprocket teeth and timing chain must mesh. The camshaft and the crankshaft sprocket alignment marks MUST be aligned correctly.
  • Page 393 position. 6. Install the camshaft sprocket and timing chain. Fig. 272: Crankshaft Sprocket Courtesy of GENERAL MOTORS CORP.

  • Page 394: Camshaft Replacement

    NOTE: Refer to Fastener Notice in Cautions and Notices. 7. If necessary, rotate the camshaft or crankshaft sprockets in order to align the timing marks. 8. Install the camshaft sprocket bolts. Tighten: Tighten the camshaft sprocket bolts to 35 N.m (26 lb ft). 9.
  • Page 395 Fig. 273: Oil Pan-To-Front Cover Bolts & Oil Pan-To-Rear Cover Bolts Courtesy of GENERAL MOTORS CORP. 1. Remove the engine assembly. Refer to Engine Replacement . 2. Remove the crankshaft balancer. Refer to Crankshaft Balancer Removal . 3. Remove the oil level indicator tube. Refer to Oil Level Indicator and Tube Removal . 4.
  • Page 396 10. Remove the left and right cylinder heads. Refer to Cylinder Head Removal - Left and Cylinder Head Removal - Right . 11. Remove the valve lifters. Refer to Valve Lifter Removal . 12. Remove the oil pan-to-front cover bolts (2). Fig.
  • Page 397 Fig. 275: Crankshaft Sprocket Courtesy of GENERAL MOTORS CORP. 15. Rotate the engine in order to align the timing marks.
  • Page 398 Fig. 276: View Of Camshaft Sprocket, Bolt & Timing Chain Courtesy of GENERAL MOTORS CORP. 16. Remove the camshaft sprocket bolts. 17. Remove the timing chain from the camshaft sprocket, and allow the timing chain to rest on the crankshaft sprocket.
  • Page 399 Fig. 277: Oil Pan-To-Front Cover Bolts & Oil Pan-To-Rear Cover Bolts Courtesy of GENERAL MOTORS CORP. IMPORTANT: Rear cover removal is not required, if the camshaft bearings are not being replaced. 20. If the camshaft bearings need to be replaced, remove the oil pan-to rear cover bolts (1).
  • Page 400 Fig. 278: View Of Rear Cover, Bolts & Gasket Courtesy of GENERAL MOTORS CORP. 21. Remove the rear cover bolts. 22. Remove the rear cover and gasket. Discard the gasket. 23. Remove the camshaft bearings, if required. Refer to Camshaft Bearing Removal . Installation Procedure...
  • Page 401 Fig. 279: View Of Sealant On Engine Rear Cover Gasket Tabs Courtesy of GENERAL MOTORS CORP. 1. Install NEW camshaft bearings, if required. Refer to Camshaft Bearing Installation . 2. Apply a 5 mm bead of sealant GM P/N 12378190, or equivalent 20 mm (0.8 in) long to the oil pan to engine block junction, if required.
  • Page 402 Fig. 280: View Of Rear Cover, Bolts & Gasket Courtesy of GENERAL MOTORS CORP. 3. Install the rear cover and a new gasket, if required. 4. Install the rear cover bolts until snug, if required.
  • Page 403 Fig. 281: Oil Pan-To-Front Cover Bolts & Oil Pan-To-Rear Cover Bolts Courtesy of GENERAL MOTORS CORP. 5. Install the oil pan-to-rear cover bolts (1) until snug, if required.
  • Page 404 Fig. 282: J 41476 & Bolts Courtesy of GENERAL MOTORS CORP. 6. Rotate the crankshaft as required until two opposing flywheel bolt holes are parallel to the oil pan surface, if required. NOTE: Refer to Fastener Notice in Cautions and Notices. IMPORTANT: The tapered legs of the alignment tool must enter the rear cover oil seal bore.
  • Page 405 1. Tighten the oil pan-to-rear cover bolts to 12 N.m (106 lb in). 2. Tighten the engine rear cover bolts to 25 N.m (18 lb ft). 8. Remove the J 41476 . 9. Install a NEW crankshaft rear oil seal, if required. Refer to Crankshaft Rear Oil Seal Installation .
  • Page 406 Fig. 283: Crankshaft Sprocket Courtesy of GENERAL MOTORS CORP. 10. Install the camshaft. Refer to Camshaft Installation . 11. Align the camshaft sprocket alignment mark in the 6 o'clock position. Fig. 284: View Of Camshaft Sprocket, Bolt & Timing Chain Courtesy of GENERAL MOTORS CORP.
  • Page 407 Tighten: Tighten the camshaft sprocket bolts to 35 N.m (26 lb ft). Fig. 285: View Of Sealant Applied To Front Oil Pan-To-Engine Block Junction Courtesy of GENERAL MOTORS CORP. 14. Apply a 5 mm (0.2 in) bead of sealant GM P/N 12378190, or equivalent 20 mm (0.8 in) long to the oil pan to engine block junction.
  • Page 408 Fig. 286: Front Cover Gasket & Bolts Courtesy of GENERAL MOTORS CORP. 15. Install the front cover and a new gasket. 16. Install the front cover bolts until snug.
  • Page 409 Fig. 287: Oil Pan-To-Front Cover Bolts & Oil Pan-To-Rear Cover Bolts Courtesy of GENERAL MOTORS CORP. 17. Install the oil pan-to-front cover bolts (1) until snug.
  • Page 410 Fig. 288: J 41476 & Front Cover Courtesy of GENERAL MOTORS CORP. 18. Install the J 41476 and crankshaft balancer bolt to the front cover. 19. Align the tapered legs of the J 41476 with the machined alignment surfaces on the front cover. 20.
  • Page 411 1. Tighten the oil pan-to-front cover bolts to 25 N.m (18 lb ft). 2. Tighten the engine front cover bolts to 25 N.m (18 lb ft). 21. Remove the J 41476 . 22. Install a NEW crankshaft front oil seal. Refer to Crankshaft Front Oil Seal Installation . 23.
  • Page 412 tightening process. DO NOT remove the prop shaft hub or flex plate from the automatic transmission engine flywheel. The flywheel, prop shaft hub, and flex plate are balanced as an assembly. If service is required, the entire flywheel assembly should be replaced.
  • Page 413 Fig. 289: Mark End Of Crankshaft & Manual Transmission Flywheel Courtesy of GENERAL MOTORS CORP. 1. Remove the catalytic converter. Refer to Catalytic Converter Replacement in Engine Exhaust. 2. Remove the driveline support, if equipped with a automatic transmission. Refer to Driveline Support Assembly Replacement (Automatic Transmission) or Driveline Support Assembly Replacement (Manual Transmission) in Propeller Shaft.
  • Page 414 Fig. 290: Automatic Transmission Engine Flywheel & Bolts Courtesy of GENERAL MOTORS CORP. 5. If equipped with an automatic transmission, remove the engine flywheel bolts. Fig. 291: Manual Transmission Engine Flywheel & Bolts Courtesy of GENERAL MOTORS CORP. 6. If equipped with a manual transmission, remove the engine flywheel bolts. 7.
  • Page 415 engine flywheel before removal. The flywheel does not use a locating pin for alignment. Mark or scribe the end of the crankshaft and the flywheel before component removal. The engine flywheel must be reinstalled to the original position and direction. The engine flywheel will not initially seat against the crankshaft flange, but will be pulled onto the crankshaft by the engine flywheel bolts.
  • Page 416 1. If equipped with a manual transmission, align the mark or scribe on the crankshaft with the mark or scribe on the existing flywheel. Refer to Engine Balancing Fig. 293: Automatic Transmission Engine Flywheel & Bolts Courtesy of GENERAL MOTORS CORP. 2.
  • Page 417 Fig. 294: Flywheel Bolt Tightening Sequence Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Fastener Notice in Cautions and Notices. 3. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489), or equivalent to the threads of the flywheel bolts. 4. Install the engine flywheel bolts until snug. Tighten: 1.

  • Page 418: Engine Replacement

    2. Tighten the engine flywheel bolts a second pass in sequence to 50 N.m (37 lb ft). 3. Tighten the engine flywheel bolts a final pass in sequence to 100 N.m (74 lb ft). 5. Install the driveline support, if equipped with a automatic transmission. Refer to Driveline Support Assembly Replacement (Automatic Transmission) or Driveline Support Assembly Replacement (Manual Transmission) in Propeller Shaft.
  • Page 419 Fig. 295: Right Fuel Injection Rail Cover Courtesy of GENERAL MOTORS CORP. 1. Recover the air conditioning (A/C) refrigerant. Refer to Refrigerant Recovery and Recharging in Heating, Ventilation and Air Conditioning. 2. Remove the radiator. Refer to Radiator Replacement in Engine Cooling. 3.
  • Page 420 Fig. 296: Radiator Hoses & Water Pump Courtesy of GENERAL MOTORS CORP. IMPORTANT: Cap the hoses and inlets when separating the cooling system components, this prevents dirt and other contaminants from entering the cooling system. 10. Remove the radiator hoses from the water pump.
  • Page 421 Fig. 297: Heater Hoses & Water Pump Courtesy of GENERAL MOTORS CORP. 11. Remove the heater hoses from the water pump.
  • Page 422 Fig. 298: Electrical Connectors Courtesy of GENERAL MOTORS CORP. 12. Disconnect the following electrical connectors from the engine: The fuel injectors (1) The ignition coil main harness connectors The evaporative emission (EVAP) solenoid (2) The electric throttle motor (3) The throttle position (TP) sensor The engine coolant temperature (ECT) sensor The A/C compressor...
  • Page 423 13. Remove the generator. Refer to Generator Replacement in Engine Electrical. Fig. 299: Vacuum Booster Hose Courtesy of GENERAL MOTORS CORP. 14. Remove the power brake booster vacuum hose.
  • Page 424 Fig. 300: Intermediate Steering Shaft & Bolt Courtesy of GENERAL MOTORS CORP. 15. Remove the intermediate steering shaft bolt (to steering gear). 16. Remove the intermediate steering shaft from the steering gear and position it to the left onto the frame rail.
  • Page 425 Fig. 301: AIR Pump Hose & AIR Pipe Courtesy of GENERAL MOTORS CORP. 17. Disconnect the secondary air injection (AIR) pump hose from the AIR pipe. 18. Remove the front tires and wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  • Page 426 Fig. 302: Driveline Tunnel Close-Out Panel & Bolts Courtesy of GENERAL MOTORS CORP. 20. Remove the driveline tunnel close-out panel bolts. 21. Remove the driveline tunnel close-out panel. 22. Remove the starter motor. Refer to Starter Motor Replacement in Engine Electrical.
  • Page 427 Fig. 303: Engine Oil Level Sensor Electrical Connector & CKP Sensor Electrical Connector Courtesy of GENERAL MOTORS CORP. 23. Disconnect the crankshaft position (CKP) sensor electrical connector (1). 24. Disconnect the oil level sensor electrical connector (2). 25. Disconnect the right heated oxygen sensor (HO2S) electrical connector.
  • Page 428 Fig. 304: A/C Compressor & Condenser Hose & Bolt Courtesy of GENERAL MOTORS CORP. 26. Remove the A/C compressor and condenser hose bolt (at compressor). 27. Separate the A/C compressor and condenser hose from the A/C compressor.
  • Page 429 Fig. 305: Engine Oil Temperature Sensor Electrical Connector & Ground Straps Courtesy of GENERAL MOTORS CORP. 28. Disconnect the engine oil temperature sensor (3) electrical connector. 29. Disconnect the left HO2S electrical connector. 30. Remove the ground strap bolt. Remove the ground straps (1 and 2) from the engine block.
  • Page 430 Fig. 306: Transmission Wire Harness & Electrical Connectors Courtesy of GENERAL MOTORS CORP. 31. Disconnect the wheel speed sensor electrical connectors. 32. If equipped with real time damping (RTD) disconnect the following electrical connectors: Shock absorber damper Position sensor pigtail 33.
  • Page 431 Fig. 307: Transmission Wire Harness & Engine Wire Harness Courtesy of GENERAL MOTORS CORP. 35. Remove the transmission harness clip bolts from the engine block. 36. Unclip the transmission wire harness from the engine wire harness. 37. Remove the stabilizer shaft. Refer to Stabilizer Shaft Replacement in Front Suspension.
  • Page 432 Fig. 308: J 42188, Steering Knuckle & Lower Control Arm Ball Stud Courtesy of GENERAL MOTORS CORP. 38. Loosen, do not remove, the steering knuckle nut (2) from the lower control arm ball stud. 39. Install theJ 42188 between the steering knuckle and the lower control arm ball stud. 40.
  • Page 433 Fig. 309: Automatic Transmission Fluid Cooler Line & Oil Pan Courtesy of GENERAL MOTORS CORP. 43. Disconnect the automatic transmission fluid cooler pipe clip from the front of the engine oil pan (if equipped).
  • Page 434 Fig. 310: Automatic Transmission Fluid Cooler Line Clamp & Bolt Courtesy of GENERAL MOTORS CORP. 44. Disconnect the front automatic transmission fluid cooler pipes from the rear pipes. 45. Disconnect the automatic transmission cooler pipe clip at the right transmission cover (if equipped).
  • Page 435 Fig. 311: Driveline Support Plug & Bolts Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Fastener Notice in Cautions and Notices. IMPORTANT: Failure to use the minimum fastener length specified will prevent proper retention of the propeller shaft during disassembly. 46.
  • Page 436 Tighten: Tighten the M10 bearing support bolts to 35 N.m (26 lb ft). Fig. 312: Flywheel Housing Plug Courtesy of GENERAL MOTORS CORP. 47. If equipped with a automatic transmission, remove the flywheel housing plug.
  • Page 437 Fig. 313: Prop Shaft Hub Collar & Bolt Courtesy of GENERAL MOTORS CORP. 48. If equipped with a automatic transmission perform the following: 1. Orientate the prop shaft hub clamp for access to the bolt (1). 2. Position the clamp bolt (1) facing downward. 3.
  • Page 438 Fig. 314: Transmission Wire Harness Bracket & Bolts Courtesy of GENERAL MOTORS CORP. 49. Remove bolts attaching the transmission wire harness bracket to the flywheel housing. 50. Remove the transmission wire harness from its mounting location, rearward toward the driveline support. 51.
  • Page 439 Fig. 315: J 42203, Close-Out Panel Flange & Bolts Courtesy of GENERAL MOTORS CORP. IMPORTANT: The weight of the engine should never be supported by the J 42203 . 52. Install the J 42203 to the close-out panel flange.
  • Page 440 Fig. 316: Identifying White Circular Release Ring On The Actuator Hose Courtesy of GENERAL MOTORS CORP. 53. If equipped with a manual transmission perform the following: 1. Unclip the clutch actuator hose from the clutch actuator hose clip. 2. Using the J 36221 , depress the white circular release ring on the actuator hose and simultaneously pull lightly on the master cylinder hose to disconnect.
  • Page 441 Fig. 317: J 42203, Close-Out Panel Flange & Bolts Courtesy of GENERAL MOTORS CORP. IMPORTANT: The weight of the engine should never be supported by the J 42203 . 54. Install the J 42203 to the close-out panel flange. 55. Slowly lower the vehicle onto the J 39580 and the J 39580-500 . 56.
  • Page 442 Fig. 318: Front & Rear Crossmember Nuts Courtesy of GENERAL MOTORS CORP. 57. Using HAND TOOLS ONLY, remove the front and rear crossmember nuts. 58. Partially raise the vehicle.
  • Page 443 Fig. 319: AIR Pipe & Bolts Courtesy of GENERAL MOTORS CORP. 59. Remove the AIR pipe bolts from the right exhaust manifold.
  • Page 444 Fig. 320: AIR Pipe Gasket, Exhaust Manifold & Bolts Courtesy of GENERAL MOTORS CORP. 60. Remove the AIR pipe bracket bolt (at the rear of the cylinder head). 61. Remove the AIR pipe (with check valve) and gasket.
  • Page 445 Fig. 321: MAP Sensor Vacuum Hose & MAP Sensor Electrical Connector Courtesy of GENERAL MOTORS CORP. 62. Remove the ground strap bolt (5). 63. Remove the ground strap (6) from the left rear cylinder head. 64. Disconnect the following electrical connectors from the back of the engine: The knock sensor wire harness (1) The engine oil pressure sensor (2) The manifold absolute pressure (MAP) sensor (3)
  • Page 446 65. Disconnect the vacuum hose from the MAP sensor. Fig. 322: Driveline Support & Bolts Courtesy of GENERAL MOTORS CORP. 66. Remove the driveline support bolts.
  • Page 447 Fig. 323: Inserting Flat Tool Separating Flywheel Housing & Driveline Support Courtesy of GENERAL MOTORS CORP. IMPORTANT: Visually inspect the transmission wiring harness to ensure detachment from the engine. 67. Insert a flat bladed screwdriver, or similar tool, between the edge of the driveline support and the flywheel housing, then separate the flywheel housing from the driveline support.
  • Page 448 Fig. 324: Power Steering Pump Pulley & Courtesy of GENERAL MOTORS CORP. IMPORTANT: Visually inspect the wiring harness clearances while raising the vehicle. 71. Raise the vehicle completely off of the engine and crossmember. 72. Remove the power steering pump pulley hub cap, if necessary. 73.
  • Page 449 Fig. 325: Power Steering Pump, Generator Bracket & Bolts Courtesy of GENERAL MOTORS CORP. IMPORTANT: It is not necessary to open the power steering system during the engine removal procedure. 74. Remove the power steering pump bolts. 75. Remove the power steering pump brace. 76.
  • Page 450 Fig. 326: Generator Bracket & Bolts Courtesy of GENERAL MOTORS CORP. 78. Remove the generator bracket bolts. 79. Remove the generator bracket and power steering pump bracket.
  • Page 451 Fig. 327: AIR Pipe Bolts, Exhaust Manifold & Bolts Courtesy of GENERAL MOTORS CORP. 80. Remove the AIR pipe bolts from the left exhaust manifold. 81. Remove the AIR pipe and gasket. 82. Install the J 41798 to the engine. 83.
  • Page 452 Fig. 328: Engine Mount & Nuts Courtesy of GENERAL MOTORS CORP. 84. Remove the engine mount nuts. 85. Using a engine hoist and the J 41798 slowly raise the engine. 86. Remove the engine from the crossmember.
  • Page 453 Fig. 329: Bottom Flywheel Housing-To-Oil Pan & Bolts Courtesy of GENERAL MOTORS CORP. 87. Remove the flywheel housing bolts. 88. Remove the flywheel housing from the engine block. 89. Install the engine onto an engine stand and prepare for disassembly. Refer to Engine Balancing . 90.
  • Page 454 The steps in the following procedure are in a specific order. Follow these steps in this order and ignore no details. 1. Prepare the engine for installation. Refer to Engine Prelubing and Engine Balancing . Fig. 330: Bottom Flywheel Housing-To-Oil Pan & Bolts Courtesy of GENERAL MOTORS CORP.
  • Page 455 4. Install the J 41798 to the engine. 5. Using a engine hoist and the J 41798 raise the engine slightly. 6. Remove the engine from the engine stand. 7. Install the flywheel housing to the engine block. 8. Install the flywheel housing bolts. Tighten: Tighten the flywheel housing bolts to 50 N.m (37 lb ft).
  • Page 456 Courtesy of GENERAL MOTORS CORP. 10. Install the engine mount nuts. Tighten: Tighten the engine mount nuts to 65 N.m (48 lb ft). 11. Install the spark plugs. Refer to Spark Plug Replacement in Engine Controls - 5.7 L. 12. Remove the J 41798 from the engine. Fig.
  • Page 457 Tighten: Tighten the AIR pipe bolts to 20 N.m (15 lb ft). 16. Install the A/C compressor bracket. Refer to Compressor Mounting Bracket Replacement in Heating, Ventilation, and Air Conditioning. Fig. 333: Generator Bracket & Bolts Courtesy of GENERAL MOTORS CORP. 17.
  • Page 458 Fig. 334: Power Steering Pump, Generator Bracket & Bolts Courtesy of GENERAL MOTORS CORP. 20. Install the power steering pump (with reservoir) to the generator bracket. 21. Install the power steering pump brace. 22. Install the power steering pump bolts. Tighten: Tighten the power steering pump bolts to 25 N.m (18 lb ft).
  • Page 459 Fig. 335: J 25033-C & Power Steering Pump Pulley Courtesy of GENERAL MOTORS CORP. 23. Using the J 25033-C install the power steering pump pulley. 24. Install the power steering pump pulley hub cap, if necessary. 25. Roll the engine and crossmember underneath the vehicle. 26.
  • Page 460 Fig. 336: MAP Sensor Vacuum Hose & MAP Sensor Electrical Connector Courtesy of GENERAL MOTORS CORP. 27. Install the ground strap (6) and ground strap bolt (5) to the rear of the left cylinder head. Tighten: Tighten the ground strap bolt (5) to 32 N.m (24 lb ft). 28.
  • Page 461 The CMP sensor (4) 29. Connect the vacuum hose to the MAP sensor. Fig. 337: AIR Pipe & Bolts Courtesy of GENERAL MOTORS CORP. 30. Clean the exhaust manifold AIR gasket flange, if necessary. 31. Install a NEW AIR pipe gasket and the pipe (with check valve) to the right exhaust manifold. 32.
  • Page 462 Fig. 338: AIR Pipe Gasket, Exhaust Manifold & Bolts Courtesy of GENERAL MOTORS CORP. 33. Install the AIR pipe bracket bolt (at the rear of the cylinder head). Tighten: Tighten the AIR pipe bolts to 20 N.m (15 lb ft).
  • Page 463 Fig. 339: Propeller Input Shaft & Clutch Driven Plate Hub Courtesy of GENERAL MOTORS CORP. 34. Vehicles equipped with a manual transmission, slide the engine and crossmember rearward. Do not force the engine onto the propeller spline. 35. Position the engine to the proper height and angle in order to install the propeller input shaft. 36.
  • Page 464 Fig. 340: Identifying White Circular Release Ring On The Actuator Hose Courtesy of GENERAL MOTORS CORP. 37. Slowly seat the flywheel housing to the driveline. 38. Install the driveline support bolts. Tighten: Tighten the driveline support bolts to 50 N.m (37 lb ft). 39.
  • Page 465 Fig. 341: Driveline Support & Bolts Courtesy of GENERAL MOTORS CORP. IMPORTANT: Do not tighten the flywheel hub collar bolt at this time. 41. Vehicles equipped with an automatic transmission, slide the engine and crossmember rearward. Do not force the engine onto the propeller spline. 42.
  • Page 466 Fig. 342: Front & Rear Crossmember Nuts Courtesy of GENERAL MOTORS CORP. IMPORTANT: Use only hand tools when tightening or torquing crossmember nuts. 46. By HAND, install new crossmember nuts until snug. Tighten: Tighten the crossmember nuts to 110 N.m (81 lb ft). 47.
  • Page 467 Fig. 343: Transmission Wire Harness Bracket & Bolts Courtesy of GENERAL MOTORS CORP. 50. Route the transmission wire harness into place. 51. Install the transmission wire harness bracket bolts. Tighten: Tighten the transmission wire harness bracket bolts to 50 N.m (37 lb ft).
  • Page 468 Fig. 344: Driveline Support Plug & Bolts Courtesy of GENERAL MOTORS CORP. 52. Vehicles equipped with an automatic transmission, remove the previously installed M10-1.5 x 55 mm bolts from the front of the driveline support. 53. Install 2 plugs in the driveline support. Tighten: Tighten the driveline support plugs to 50 N.m (37 lb ft).
  • Page 469 Fig. 345: Automatic Transmission Fluid Cooler Line Clamp & Bolt Courtesy of GENERAL MOTORS CORP. 54. Connect the front automatic transmission fluid cooler pipes to the rear pipes, if equipped. Tighten: Tighten the automatic transmission fluid cooler pipes to 25 N.m (18 lb ft). 55.
  • Page 470 Fig. 346: Automatic Transmission Fluid Cooler Line & Oil Pan Courtesy of GENERAL MOTORS CORP. 56. Install the automatic transmission fluid cooler pipe clamp bolt (at the oil pan), if equipped. Tighten: Tighten the automatic transmission fluid cooler pipe clamp bolt (at the oil pan) to 12 N.m (106 lb in).
  • Page 471 Fig. 347: Lower Control Arm Stud, Steering Knuckle & Nut Courtesy of GENERAL MOTORS CORP. 58. Install the lower control arm stud to the steering knuckle. 59. Install a NEW steering knuckle nut. Tighten: 1. Tighten the steering knuckle nut to 20 N.m (15 lb ft) to seat the ball joint stud. 2.
  • Page 472 Fig. 348: Transmission Wire Harness & Engine Wire Harness Courtesy of GENERAL MOTORS CORP. 62. Clip the transmission wire harness the engine wire harness (at the white tape). 63. Install the transmission wire harness clip bolts to the engine block. Tighten 1.
  • Page 473 Fig. 349: Transmission Wire Harness & Electrical Connectors Courtesy of GENERAL MOTORS CORP. 65. Clip the transmission wire harness to the crossmember. 66. If equipped with RTD connect the following electrical connectors: Position sensor pigtail Shock absorber damper...
  • Page 474 Fig. 350: Engine Oil Temperature Sensor Electrical Connector & Ground Straps Courtesy of GENERAL MOTORS CORP. 67. Position the ground straps (1 and 2) to the engine block. 68. Install the engine ground strap bolt. Tighten: Tighten the engine wire harness ground bolt to 32 N.m (23 lb ft). 69.
  • Page 475 Fig. 351: A/C Compressor & Condenser Hose & Bolt Courtesy of GENERAL MOTORS CORP. 71. Install the AC compressor and condenser hose to the A/C compressor. 72. Install the A/C compressor and condenser hose bolt (at compressor). Tighten: Tighten the A/C compressor and condenser hose bolt (at compressor) to 27 N.m (20 lb ft).
  • Page 476 Fig. 352: Engine Oil Level Sensor Electrical Connector & CKP Sensor Electrical Connector Courtesy of GENERAL MOTORS CORP. 73. Connect the right front HO2S sensor electrical connector. 74. Connect the oil level sensor (2) electrical connector. 75. Connect the CKP sensor (1) electrical connector. 76.
  • Page 477 Fig. 353: Driveline Tunnel Close-Out Panel & Bolts Courtesy of GENERAL MOTORS CORP. 77. Install the driveline close-out panel. 78. Install the driveline close-out panel bolts. Tighten: Tighten the driveline close-out panel bolts to 12 N.m (106 lb in). 79. Install the catalytic converter. Refer to Catalytic Converter Replacement in Engine Exhaust. 80.
  • Page 478 Fig. 354: AIR Pump Hose & AIR Pipe Courtesy of GENERAL MOTORS CORP. 82. Connect the AIR pump hose to the AIR pipe.
  • Page 479 Fig. 355: Intermediate Steering Shaft & Bolt Courtesy of GENERAL MOTORS CORP. 83. Install the intermediate steering shaft to the steering gear. 84. Install the intermediate steering shaft bolt. Tighten: Tighten the intermediate steering shaft bolt to 48 N.m (35 lb ft).
  • Page 480 Fig. 356: Vacuum Booster Hose Courtesy of GENERAL MOTORS CORP. 85. Install the power brake booster vacuum hose. 86. Install the generator. Refer to Generator Replacement in Engine Electrical.
  • Page 481 Fig. 357: Electrical Connectors Courtesy of GENERAL MOTORS CORP. 87. Connect the following electrical connectors to the engine: The fuel injectors (1) The ignition coil main harness connectors The EVAP solenoid (2) The electric throttle motor (3) The TP sensor The ECT sensor The A/C compressor...
  • Page 482 Fig. 358: Heater Hoses & Water Pump Courtesy of GENERAL MOTORS CORP. 88. Install the heater hoses to the water pump.
  • Page 483 Fig. 359: Radiator Hoses & Water Pump Courtesy of GENERAL MOTORS CORP. 89. Install the radiator hoses to the water pump. 90. Install the fuel feed hose. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls - 5.7 L. 91.
  • Page 484 Fig. 360: Right Fuel Injection Rail Cover Courtesy of GENERAL MOTORS CORP. 92. Install the right fuel injection rail cover. 93. Install the accessory drive belt. Refer to Drive Belt Replacement - Accessory . 94. Install the BPMV bracket. Refer to Brake Pressure Modulator Valve (BPMV) Bracket Replacement in Antilock Brake System.
  • Page 485 Fluid and Fluid and Lubricant Recommendations in Maintenance and Lubrication. 101. Disable the ignition system. 102. Crank the engine several times. Listen for any unusual noises or evidence that parts are binding. 103. Enable the ignition system. 104. Start the engine and listen for unusual noises. 105.
  • Page 486 Fig. 361: Prop Shaft Hub Collar & Bolt Courtesy of GENERAL MOTORS CORP. 109. With automatic transmission vehicles perform the following steps: 1. Shut off the engine. 2. Allow engine to cool to room temperature. 3. Raise the vehicle. 4. Tighten the prop shaft hub collar bolt (1). Tighten: Tighten the propeller shaft hub collar bolt to 125 N.m (92 lb ft).
  • Page 487 ENGINE OIL AND OIL FILTER REPLACEMENT Removal Procedure Fig. 363: Oil Pan Drain Plug Courtesy of GENERAL MOTORS CORP. 1. Open the hood. 2. Remove the oil fill cap. 3. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 4.
  • Page 488 Fig. 364: Engine Oil Filter Courtesy of GENERAL MOTORS CORP. IMPORTANT: Check the old oil filter to ensure that the filter seal is not left on the engine block.
  • Page 489 6. Remove the engine oil filter from the engine block. 7. Empty the oil filter into the drain pan. 8. Allow sufficient time for the oil to drain from the oil filter opening. 9. Wipe the excess oil from the oil filter mounting. Installation Procedure...
  • Page 490 Fig. 365: Engine Oil Filter Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Fastener Notice in Cautions and Notices. 1. Wipe any excess oil from the oil filter mounting.
  • Page 491 IMPORTANT: Lightly oil the engine oil filter gasket, using CLEAN oil. 2. Install the oil filter to the engine block. Tighten: Tighten the engine oil filter to 30 N.m (22 lb ft). Fig. 366: Oil Pan Drain Plug Courtesy of GENERAL MOTORS CORP. 3.

  • Page 492: Draining Fluids And Oil Filter Removal

    6. Fill the engine with the appropriate amount and type of engine oil. Refer to Capacities - Approximate Fluid and Fluid and Lubricant Recommendations in Maintenance and Lubrication. 7. Run the engine for 3 minutes. 8. Raise the vehicle. 9. Thoroughly inspect the oil filter and the oil pan drain plug areas for leaks. 10.
  • Page 493 Fig. 367: Oil Pan Drain Plug Courtesy of GENERAL MOTORS CORP. IMPORTANT: In order to completely drain the oil from the oil pan internal baffling, the bottom of the oil pan must be level during the oil drain procedure. 1. Remove the oil pan drain plug and allow the oil to drain.
  • Page 494 Fig. 368: Engine Oil Filter Courtesy of GENERAL MOTORS CORP. 2. Remove the engine oil filter.
  • Page 495 Fig. 369: Right Rear Engine Block Coolant Drain Plug Courtesy of GENERAL MOTORS CORP. 3. Remove the right rear engine block coolant drain plug and allow the coolant to drain.
  • Page 496 Fig. 370: View Of Engine Block Left Rear Coolant Drain Hole Plug Courtesy of GENERAL MOTORS CORP. 4. Remove the left front engine block coolant drain plug, if applicable, and allow the coolant to drain.
  • Page 497 Fig. 371: Engine Block Coolant Heater Courtesy of GENERAL MOTORS CORP. 5. Remove the engine block coolant heater, if applicable, and allow the coolant to drain.
  • Page 498 Fig. 372: J 41712 & Oil Pressure Sensor Courtesy of GENERAL MOTORS CORP. 6. Use the J 41712 or equivalent in order to remove the oil pressure sensor. CRANKSHAFT BALANCER REMOVAL Tools Required J 41816 Crankshaft Balancer Remover J 41816-2 Crankshaft End Protector J 42386-A Flywheel Holding Tool...
  • Page 499 Fig. 373: J 42386-A, Crankshaft Balancer & Bolt Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Fastener Notice in Cautions and Notices. IMPORTANT: For manual transmission applications, note the position of the crankshaft balancer before removal. The balancer does not use a key or keyway for positioning.
  • Page 500 new crankshaft balancer, if applicable. Crankshaft balancer weights must be installed into the new balancer in the same location as the old balancer. A properly installed balance weight will be either flush or below flush with the face of the balancer. Do not use the crankshaft balancer bolt again.
  • Page 501 Fig. 374: Identifying Harmonic Balancer Bolt Courtesy of GENERAL MOTORS CORP. 2. Remove the crankshaft balancer bolt. Do not discard the crankshaft balancer bolt. The balancer bolt will be used during the balancer installation procedure. Fig. 375: Mark Crankshaft Balancer & End Of Crankshaft Courtesy of GENERAL MOTORS CORP.
  • Page 502 Note the balancer installed position on the crankshaft for assembly. Refer to Engine Balancing . Fig. 376: View Of J 41816 & J 41816-2 Courtesy of GENERAL MOTORS CORP. 4. Use the J 41816 and the J 41816-2 in order to remove the crankshaft balancer. 5.

  • Page 503: Engine Flywheel Removal

    Fig. 377: Crankshaft Balancer Weights Courtesy of GENERAL MOTORS CORP. 6. Note the position of crankshaft balancer weights, if applicable. Refer to Crankshaft Balancer Cleaning and Inspection . ENGINE FLYWHEEL REMOVAL...
  • Page 504 Fig. 378: Mark End Of Crankshaft & Manual Transmission Flywheel Courtesy of GENERAL MOTORS CORP. IMPORTANT: For manual transmission applications, note the position and direction of the engine flywheel before removal. The flywheel does...
  • Page 505 not use a locating pin for alignment. Mark or scribe the end of the crankshaft and the flywheel before component removal. The existing manual transmission engine flywheel must be installed to the original position and direction. The engine flywheel will not initially seat against the crankshaft flange, but will be pulled onto the crankshaft by the engine flywheel bolts.
  • Page 506 2. Remove the manual transmission engine flywheel and bolts. Fig. 380: Automatic Transmission Engine Flywheel & Bolts Courtesy of GENERAL MOTORS CORP. 3. Remove the automatic transmission engine flywheel and bolts. CLUTCH PILOT BEARING REMOVAL Tools Required J 43276 Clutch Pilot Bearing Remover...
  • Page 507 Fig. 381: Clutch Pilot Bearing & J 43276 Courtesy of GENERAL MOTORS CORP. NOTE: When using the J 43276 Clutch Pilot Bearing Remover, always secure the J 43276-1 Clutch Pilot Bearing Remover tool body using a wrench. Do not allow the J 43276-1 tool body to rotate. Failing to do so causes damage to the J 43276-1 tool body.

  • Page 509: Oil Level Indicator And Tube Removal

    Fig. 382: Pilot Bearing Courtesy of GENERAL MOTORS CORP. 2. Discard the pilot bearing. OIL LEVEL INDICATOR AND TUBE REMOVAL Fig. 383: Oil Level Indicator Tube Courtesy of GENERAL MOTORS CORP. 1. Remove the oil level indicator from the tube. 2.
  • Page 510 3. Remove the oil level indicator tube from the engine block. IMPORTANT: Inspect the O-ring seal for cuts or damage. The O-ring seal may be used again if it is not cut or damaged. 4. Remove the O-ring seal from the tube, if required. EXHAUST MANIFOLD REMOVAL - LEFT Fig.
  • Page 511 Do not remove the oxygen sensor from the exhaust manifold unless service is required. 1. Remove the AIR pipe, with check valve, bolts, and gasket from the left exhaust manifold. Fig. 385: Spark Plug Wires & Oxygen Sensor Courtesy of GENERAL MOTORS CORP. 2.
  • Page 512 Fig. 386: Exhaust Manifold, Bolts & Gasket Courtesy of GENERAL MOTORS CORP. 4. Remove the exhaust manifold, bolts, and gasket. 5. Discard the gasket. 6. Remove the heat shield and bolts, if required. EXHAUST MANIFOLD REMOVAL - RIGHT...
  • Page 513 Fig. 387: AIR Pipe, Oxygen Sensor & Bolt Courtesy of GENERAL MOTORS CORP. IMPORTANT: Do not remove the check valve from the air injection reaction (AIR) pipe unless service is required. Do not remove the oxygen sensor from the exhaust manifold unless service is required.
  • Page 514 Fig. 388: Air Pipe, Bolts, Gasket & Right Exhaust Manifold Courtesy of GENERAL MOTORS CORP. 2. Remove the AIR pipe, with check valve, bolts, and gasket from the right exhaust manifold.
  • Page 515 Fig. 389: Exhaust Manifold, Bolts & Gasket Courtesy of GENERAL MOTORS CORP. 3. Remove the spark plug wires from the spark plugs. Do not remove the spark plug wires from the ignition coils unless required. 4. Remove the oxygen sensor from the manifold. 5.

  • Page 516: Water Pump Removal

    WATER PUMP REMOVAL Fig. 390: Water Pump, Gaskets & Bolts Courtesy of GENERAL MOTORS CORP. 1. Remove the water pump bolts. 2. Remove the water pump and gaskets. 3. Discard the water pump gaskets.

  • Page 517: Engine Performance

    2004 ENGINE PERFORMANCE Engine Mechanical (Repair Instructions 2 Of 3) - 5.7L - Corvette REPAIR INSTRUCTIONS THROTTLE BODY REMOVAL Fig. 1: Throttle Body & Bolts Courtesy of GENERAL MOTORS CORP. IMPORTANT: The intake manifold, throttle body, fuel injection rail and fuel injectors may be removed as an assembly.
  • Page 518 NOTE: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type.
  • Page 519 assembly. 6. Discard the gasket. FUEL RAIL AND INJECTORS REMOVAL...
  • Page 520 Fig. 3: Fuel Rail Ground Strap Courtesy of GENERAL MOTORS CORP. IMPORTANT: The intake manifold, throttle body, fuel injection rail and fuel injectors...
  • Page 521 may be removed as an assembly. If not servicing the individual components, remove the intake manifold as a complete assembly. 1. Note the location of the fuel rail ground strap (550) on the intake manifold. The fuel rail ground strap must be installed during assembly. Fig.

  • Page 522: Intake Manifold Removal

    CAUTION: Refer to Fuel Rail Stop Bracket Installation Caution in Cautions and Notices. 2. Remove the fuel rail bolts. IMPORTANT: Do not separate the fuel injectors from the fuel rail unless component service is required. Use cleanliness and care when handling the fuel system components.
  • Page 523 Fig. 5: MAP Sensor Courtesy of GENERAL MOTORS CORP. IMPORTANT: The intake manifold, throttle body, fuel injection rail, and fuel injectors may be removed as an assembly. If not servicing the individual components, remove the manifold as a complete assembly. DO NOT use the intake manifold-to-cylinder head gaskets again.
  • Page 524 Fig. 6: Knock Sensor Wire Harness Connector & Fuel Rail Stop Bracket Courtesy of GENERAL MOTORS CORP. 2. Disconnect the knock sensor wire harness connector (1) from the fuel rail stop bracket (712).
  • Page 525 Fig. 7: PCV Dirty Air Pipe, Valley Cover & Intake Manifold Courtesy of GENERAL MOTORS CORP. 3. Remove the positive crankcase ventilation (PCV) pipe - dirty air (716) from the valley cover and intake manifold.
  • Page 526 Fig. 8: Intake Manifold Bolts & Fuel Rail Stop Bracket Courtesy of GENERAL MOTORS CORP. CAUTION: Refer to Fuel Rail Stop Bracket Installation Caution in Cautions and Notices.
  • Page 527 4. Remove the intake manifold bolts (713) and fuel rail stop bracket (712). Fig. 9: Fuel Rail Ground Strap Courtesy of GENERAL MOTORS CORP.
  • Page 528 5. Note the location of the fuel rail ground strap (550) on the intake manifold. The fuel rail ground strap must be installed during assembly. Fig. 10: Engine Coolant Air Bleed Pipe Hose & Throttle Body Courtesy of GENERAL MOTORS CORP. 6.
  • Page 529 Fig. 11: Manifold-To-Cylinder Head Gaskets Courtesy of GENERAL MOTORS CORP. 8. Remove the manifold-to-cylinder head gaskets (514) from the intake manifold. 9. Discard the intake manifold gaskets. COOLANT AIR BLEED PIPE REMOVAL...
  • Page 530 Fig. 12: Engine Coolant Air Bleed Pipe Studs, Pipe & Gaskets Courtesy of GENERAL MOTORS CORP. 1. Remove the engine coolant air bleed pipe studs (309). 2. Remove the pipe (307) and gaskets (308).
  • Page 531 Fig. 13: View Of Engine Coolant Air Bleed Cover & Bolts Courtesy of GENERAL MOTORS CORP. 3. Remove the engine coolant air bleed cover bolts (312) and covers (313).
  • Page 532 Fig. 14: View Of Pipe, Cover & Gasket Courtesy of GENERAL MOTORS CORP. 4. Remove the gaskets from the pipe and covers. 5. Discard the gaskets.
  • Page 533 Fig. 15: Hose, Clamps & Pipe Courtesy of GENERAL MOTORS CORP. 6. Remove the hose (311) and clamps (310) from the pipe (307). ENGINE VALLEY COVER REMOVAL...
  • Page 534 Fig. 16: View Of Knock Sensor Wire Harness Courtesy of GENERAL MOTORS CORP. 1. Remove the knock sensor wire harness.
  • Page 535 Fig. 17: View Of Knock Sensors Courtesy of GENERAL MOTORS CORP. 2. Remove the knock sensors.
  • Page 536 Fig. 18: Valley Cover Gasket & Bolts Courtesy of GENERAL MOTORS CORP. 3. Remove the valley cover bolts. 4. Remove the valley cover and gasket. 5. Discard the valley cover gasket.
  • Page 537 Fig. 19: Knock Sensor Oil Seals & Cover Courtesy of GENERAL MOTORS CORP. 6. Remove the knock sensor oil seals (520) from the cover (555). VALVE ROCKER ARM COVER REMOVAL - LEFT...
  • Page 538 Fig. 20: Ignition Coil, Bracket Assembly & Bolts Courtesy of GENERAL MOTORS CORP. IMPORTANT: Do not remove the positive crankcase ventilation (PCV) valve grommet from the cover unless service is required. If the grommet has been removed from the cover, a NEW grommet must be installed.
  • Page 539 1. Remove the ignition coil and bracket assembly and bolts. Fig. 21: Valve Cover To Cylinder Head View Courtesy of GENERAL MOTORS CORP. 2. Remove the valve rocker arm cover bolts. 3. Remove the valve rocker arm cover.
  • Page 540 Fig. 22: View Of Valve Rocker Arm Cover Gasket Courtesy of GENERAL MOTORS CORP. 4. Remove the gasket (504) from the cover. 5. Discard the gasket. The bolt grommets may be used again, if not damaged.
  • Page 541 Fig. 23: View Of Left Ignition Coils & Bolts Courtesy of GENERAL MOTORS CORP. 6. Remove the ignition coils, wire harness, and bolts from the bracket, if required. VALVE ROCKER ARM COVER REMOVAL - RIGHT...
  • Page 542 Fig. 24: View Of Right Ignition Coils & Bolts Courtesy of GENERAL MOTORS CORP. IMPORTANT: Do not remove the oil fill tube from the cover unless service is required. If the oil fill tube has been removed from the cover, install a NEW tube during assembly.
  • Page 543 1. Remove the ignition coil and bracket assembly and bolts. Fig. 25: View Of Valve Rocker Arm Cover & Bolts (Right) Courtesy of GENERAL MOTORS CORP. 2. Remove the valve rocker arm cover bolts. 3. Remove the valve rocker arm cover.
  • Page 544 Fig. 26: View Of Oil Fill Tube Courtesy of GENERAL MOTORS CORP. 4. Remove the oil fill cap from the oil fill tube. 5. Remove the oil fill tube, if required. 6. Discard the oil fill tube.
  • Page 545 Fig. 27: View Of Valve Rocker Arm Cover Gasket Courtesy of GENERAL MOTORS CORP. 7. Remove the gasket (504) from the cover. 8. Discard the gasket. The bolt grommets may be used again, if not damaged.

  • Page 546: Valve Rocker Arm And Push Rod Removal

    Fig. 28: View Of Left Ignition Coils & Bolts Courtesy of GENERAL MOTORS CORP. 9. Remove the ignition coils, wire harness, and bolts from the bracket, if required. VALVE ROCKER ARM AND PUSH ROD REMOVAL IMPORTANT: Place valve rocker arms, valve pushrods, and pivot support, in a rack so that they can be installed in the same location from which they were removed.
  • Page 547 Fig. 29: View Of Valve Rocker Arms Courtesy of GENERAL MOTORS CORP. 1. Remove the valve rocker arm bolts. 2. Remove the valve rocker arms.
  • Page 548 Fig. 30: View Of Valve Rocker Arm Pivot Support Courtesy of GENERAL MOTORS CORP. 3. Remove the valve rocker arm pivot support.
  • Page 549 Fig. 31: View Of Pushrods Courtesy of GENERAL MOTORS CORP. 4. Remove the pushrods. CYLINDER HEAD REMOVAL - LEFT...
  • Page 550 Fig. 32: View Of Cylinder Head & Bolts (Left) Courtesy of GENERAL MOTORS CORP. 1. Remove the spark plugs from the cylinder head. IMPORTANT: The cylinder head bolts can NOT be used again. Install NEW cylinder head bolts during assembly. 2.
  • Page 551 3. Remove the cylinder head. Fig. 33: View Of Cylinder Head Gasket (Left) Courtesy of GENERAL MOTORS CORP. 4. Remove the gasket. 5. Discard the gasket. 6. Discard the cylinder head bolts. CYLINDER HEAD REMOVAL - RIGHT...
  • Page 552 Fig. 34: View Of Cylinder Head & Bolts Courtesy of GENERAL MOTORS CORP. 1. Remove the spark plugs from the cylinder head. IMPORTANT: The cylinder head bolts can NOT be used again. Install NEW cylinder head bolts during assembly. 2. Remove the cylinder head bolts. NOTE: After removal, place the cylinder head on two wood blocks to prevent damage to the sealing surfaces.

  • Page 553: Valve Lifter Removal

    3. Remove the cylinder head. Fig. 35: View Of Cylinder Head Gasket (Right) Courtesy of GENERAL MOTORS CORP. 4. Remove the gasket. 5. Discard the gasket. 6. Discard the cylinder head bolts. VALVE LIFTER REMOVAL Tools Required J 3049-A Valve Lifter Remover...
  • Page 554 Fig. 36: View Of Valve Lifter & Guide Bolts Courtesy of GENERAL MOTORS CORP. 1. Remove the valve lifter guide bolts (211). 2. Remove the valve lifters and guide.
  • Page 555 Fig. 37: Using J 3049-A To Remove The Stuck Valve Lifters Courtesy of GENERAL MOTORS CORP. IMPORTANT: Some valve lifters may be stuck in their bores because of gum or varnish deposits. 3. Use the J 3049-A or equivalent in order to remove the valve lifters, if required.
  • Page 556 Fig. 38: View Of Valve Lifters Removed From Guide Courtesy of GENERAL MOTORS CORP. 4. Remove the valve lifters from the guide. 5. Organize or mark the components so that they can be installed in the same location from which they were removed.
  • Page 557 Fig. 39: Oil Filter Courtesy of GENERAL MOTORS CORP. 1. Remove the oil filter.
  • Page 558 Fig. 40: Oil Temperature Sensor, Oil Pan Cover, Bolts, And Gasket Courtesy of GENERAL MOTORS CORP. 2. Remove the oil temperature sensor from the oil pan cover. 3. Remove the oil pan cover, bolts, and gasket. 4. Discard the gasket.

  • Page 559: Oil Pan Removal

    Fig. 41: View Of Oil Filter Fitting & Valve Courtesy of GENERAL MOTORS CORP. 5. Remove the oil filter fitting (438) and valve (436), if required. OIL PAN REMOVAL...
  • Page 560 Fig. 42: View Of Left Closeout Cover & Bolt Courtesy of GENERAL MOTORS CORP. IMPORTANT: It is not necessary to remove the oil pan - lower - in order to remove the oil pan assembly. The original oil pan gasket is retained and aligned to the oil pan by...
  • Page 561 rivets. When installing a new gasket, it is not necessary to install new oil pan gasket rivets. DO NOT use the oil pan gaskets again. When installing the oil pan, install NEW oil pan gaskets. 1. Remove the left closeout cover and bolt. Fig.
  • Page 562 Fig. 44: Oil Level Sensor & Oil Pan Courtesy of GENERAL MOTORS CORP. IMPORTANT: It is not necessary to remove the oil level sensor prior to oil pan removal. Remove the oil level sensor if service is required. 3. Remove the oil level sensor from the oil pan, if required.
  • Page 563 Fig. 45: Oil Pan - Lower - Bolts Courtesy of GENERAL MOTORS CORP. IMPORTANT: It is not necessary to remove the oil pan - lower - to remove the oil pan assembly. 4. Remove the oil pan - lower - bolts (1-15), if required.
  • Page 564 Fig. 46: Lower Oil Pan Courtesy of GENERAL MOTORS CORP. 5. Removal of the oil pan - lower - will not provide access to the crankshaft oil deflector, crankshaft, or other internal engine components.
  • Page 565 Fig. 47: Oil Pan - Upper, Gasket, Oil Pan - Lower & Bolts Courtesy of GENERAL MOTORS CORP. 6. Separate the oil pan (400) - upper, gasket (453), oil pan (454) - lower, and bolts (455), if required.
  • Page 567 Fig. 48: Oil Pan & Gasket Courtesy of GENERAL MOTORS CORP. 7. Remove the oil pan bolts. 8. Remove the oil pan. Fig. 49: Drill, Gasket & Oil Pan Gasket Retaining Rivets Courtesy of GENERAL MOTORS CORP. IMPORTANT: DO NOT allow foreign material to enter the oil passages of the oil pan.

  • Page 568: Engine Front Cover Removal

    Use care not to gouge, score, or damage the oil pan sealing surface. 9. Drill (2) out the oil pan gasket retaining rivets (1), if required. 10. Remove the gasket (426) from the pan - upper. 11. Discard the gasket and rivets. ENGINE FRONT COVER REMOVAL Fig.
  • Page 569 Fig. 51: View Of Crankshaft Front Oil Seal Courtesy of GENERAL MOTORS CORP. 4. Remove the crankshaft front oil seal (140) from the cover. ENGINE REAR COVER REMOVAL...
  • Page 570 Fig. 52: View Of Rear Cover, Bolts & Gasket Courtesy of GENERAL MOTORS CORP. 1. Remove the rear cover bolts. 2. Remove the rear cover and gasket. 3. Discard the rear cover gasket.
  • Page 571 Fig. 53: View Of Crankshaft Rear Oil Seal Courtesy of GENERAL MOTORS CORP. 4. Remove the crankshaft rear oil seal (141) from the cover. OIL PUMP, PUMP SCREEN AND DEFLECTOR REMOVAL...
  • Page 572 Fig. 54: View Of Oil Pump Screen, Nuts & Bolts Courtesy of GENERAL MOTORS CORP. 1. Remove the oil pump screen bolt and nuts. 2. Remove the oil pump screen with O-ring seal. 3. Remove the O-ring seal from the pump screen. 4.
  • Page 573 Fig. 55: Crankshaft Oil Deflector Courtesy of GENERAL MOTORS CORP. 5. Remove the remaining crankshaft oil deflector nuts. 6. Remove the crankshaft oil deflector.
  • Page 574 Fig. 56: Oil Pump & Bolts Courtesy of GENERAL MOTORS CORP. 7. Remove the oil pump bolts. IMPORTANT: Do not allow dirt or debris to enter the oil pump assembly. Cap ends as necessary. 8. Remove the oil pump. TIMING CHAIN AND SPROCKETS REMOVAL Tools Required J 8433-1 Puller Bar J 41558 Crankshaft Sprocket Remover...
  • Page 575 Fig. 57: Camshaft Sprocket, Timing Chain & Bolts Courtesy of GENERAL MOTORS CORP. NOTE: Do not turn the crankshaft assembly after the timing chain has been removed in order to prevent damage to the piston assemblies or the valves. 1. Remove the camshaft sprocket bolts. 2.
  • Page 576 Fig. 58: Chain Dampener & Bolts Courtesy of GENERAL MOTORS CORP. 3. Remove the chain dampener (232) and bolts (231).
  • Page 577 Fig. 59: View Of J 8433-1, J 41816-2 & J 41558 Courtesy of GENERAL MOTORS CORP. 4. Use the J 8433-1 , the J 41816-2 , and the J 41558 in order to remove the crankshaft sprocket.
  • Page 578 Fig. 60: View Of Crankshaft Sprocket Courtesy of GENERAL MOTORS CORP. 5. Remove the crankshaft sprocket.

  • Page 579: Camshaft Removal

    Fig. 61: View Of Crankshaft Sprocket Key Courtesy of GENERAL MOTORS CORP. 6. Remove the crankshaft sprocket key, if required. CAMSHAFT REMOVAL...
  • Page 580 Fig. 62: View Of Camshaft Sensor & Bolt Courtesy of GENERAL MOTORS CORP. 1. Remove the camshaft position (CMP) sensor bolt and the sensor.
  • Page 581 Fig. 63: View Of Camshaft Retainer & Bolts Courtesy of GENERAL MOTORS CORP. 2. Remove the camshaft retainer bolts and the retainer.

  • Page 582: Piston, Connecting Rod, And Bearing Removal

    Fig. 64: 3 M8 - 1.25 X 100 mm Bolts & Camshaft Front Bolt Holes Courtesy of GENERAL MOTORS CORP. NOTE: 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.
  • Page 583 J 24270 Cylinder Bore Ridge Reamer J 41556 Connecting Rod Guide Fig. 65: Cylinder Ridge & J 24270 Courtesy of GENERAL MOTORS CORP. IMPORTANT: The connecting rods and the bearing caps are NOT interchangeable. 1. Use the J 24270 in order to remove the cylinder bore ring ridge, if required. 1.
  • Page 584 Fig. 66: View Of Connecting Rod Cap & Bolts Courtesy of GENERAL MOTORS CORP. IMPORTANT: Using a paint stick or etching tool, place matchmarks or numbers on the connecting rods and the connecting rod caps. The connecting rods and caps MUST be assembled to their original position and direction.
  • Page 585 A stamping mark on the side of the connecting rod, at the crank journal, may effect component geometry. Mark the top of the piston to the specific cylinder bore. 2. Remove the connecting rod bolts. IMPORTANT: Mark, sort, or organize the connecting rod bearings so they may be installed to their original position and location.
  • Page 586 4. Install the J 41556 to the connecting rod. Fig. 68: View Of Piston, Cylinder Bore & Connecting Rod Assembly Courtesy of GENERAL MOTORS CORP. 5. Use a hammer and tap lightly on the end of the J 41556 in order to remove the piston and connecting rod assembly from the cylinder bore.
  • Page 587 Fig. 69: View Of Connecting Rod Cap & Bolts Courtesy of GENERAL MOTORS CORP. 6. Upon removal of the piston and connecting rod assembly, assemble the connecting rod cap and bolts onto the matching connecting rod. CRANKSHAFT AND BEARINGS REMOVAL...
  • Page 588 Tools Required J 6125-1B Slide Hammer J 41818 Crankshaft Bearing Cap Remover Fig. 70: View Of CKP Sensor & Bolt Courtesy of GENERAL MOTORS CORP. IMPORTANT: The crankshaft bearing caps are machined with the engine block, for the proper clearances. Mark or identify each crankshaft bearing cap location and direction before removal.
  • Page 589 1. Remove the crankshaft position (CKP) sensor bolt. 2. Remove the CKP sensor. Fig. 71: View Of Bearing Cap Bolts & Studs Courtesy of GENERAL MOTORS CORP. 3. Remove the crankshaft bearing cap M8 bolts. 4. Remove the bearing cap M10 bolts and studs.
  • Page 590 Fig. 72: View Of J 6125-1B & J 41818 Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Fastener Notice in Cautions and Notices. 5. Install the J 41818 . Tighten: Tighten the J 41818 bolts to 11 N.m (100 lb in). 6.
  • Page 591 Fig. 73: View Of Bearing Caps Courtesy of GENERAL MOTORS CORP. 7. Remove the bearing caps.
  • Page 592 Fig. 74: View Of Crankshaft Courtesy of GENERAL MOTORS CORP. 8. Remove the crankshaft.
  • Page 593 Fig. 75: CKP Reluctor Ring Lobes Courtesy of GENERAL MOTORS CORP. IMPORTANT: Use care when handling the crankshaft. Avoid damage to the crankshaft position sensor reluctor ring teeth. Nicks, burrs or other damage to the teeth may effect On-Board Diagnostics (OBD) II system performance. 9.
  • Page 594 Fig. 76: View Of Crankshaft Bearings & Bearing Caps Courtesy of GENERAL MOTORS CORP. 10. Remove the crankshaft bearings from the bearing caps and the engine block. 11. Mark, sort, or organize the crankshaft bearings so they may be installed to their original position and location.
  • Page 595 Tools Required J 41712 Oil Pressure Switch Socket Fig. 77: Remove J 41712 Oil Pressure Sensor Courtesy of GENERAL MOTORS CORP. IMPORTANT: Do not remove the engine block front oil gallery plug unless service is required. If the front oil gallery plug is removed for service, a NEW oil gallery plug must be installed.
  • Page 596 1. Use the J 41712 or equivalent in order to remove the oil pressure sensor, if not previously removed. Fig. 78: Identifying Plug Location On Underside Of Block Courtesy of GENERAL MOTORS CORP. 2. Remove the engine block right side coolant drain hole plug.
  • Page 597 Fig. 79: View Of Engine Block Coolant Heater Courtesy of GENERAL MOTORS CORP. 3. Remove the engine block coolant heater, if applicable.
  • Page 598 Fig. 80: View Of Engine Block Left Rear Coolant Drain Hole Plug Courtesy of GENERAL MOTORS CORP. 4. Remove the engine block left side coolant drain hole plug, if applicable.
  • Page 599 Fig. 81: Engine Block Left Front Oil Gallery Plug Courtesy of GENERAL MOTORS CORP. 5. Remove the engine block left front oil gallery plug.
  • Page 600 Fig. 82: Engine Block Left Rear Oil Gallery Plug Courtesy of GENERAL MOTORS CORP. 6. Remove the engine block left rear oil gallery plug. 7. Inspect the block plug sealing washers. If the block plug and coolant heater sealing washers are not damaged, they may be used during assembly.
  • Page 602 Fig. 83: Engine Block Rear Oil Gallery Plug Courtesy of GENERAL MOTORS CORP. 8. Remove the engine block rear oil gallery plug. 9. Inspect the O-ring seal of the rear oil gallery plug. If the O-ring seal is not cut or damaged, the plug and O-ring seal may be used during assembly. Fig.
  • Page 603 be installed. 10. Remove the engine block front oil gallery plug. ENGINE BLOCK CLEANING AND INSPECTION Tools Required J 8087 Cylinder Bore Gage J 42385-100 Head/Main Bolt Thread Repair Kit 1. Clean the following areas: NOTE: Do not use a caustic solution to clean the aluminum engine block. IMPORTANT: When cleaning an engine block in a thermal type oven, do not exceed 232°C (450°F).
  • Page 604 The gasket sealing surfaces for excessive scratches or gouging Refer to Replacing Engine Gaskets . The oil galleries for restrictions All threaded bolt holes for damage 3. Measure the cylinder bores for oversize. Measuring the Cylinder for Oversize Fig. 85: Measuring The Micrometer & Bore Gauge Dial Using J 8087 Courtesy of GENERAL MOTORS CORP.
  • Page 605 2. Insert the J 8087 into the micrometer and zero the bore gauge dial. Fig. 86: Determining The Cylinder Bore Out-Of-Round Using J 8087 Courtesy of GENERAL MOTORS CORP. 3. Use a bore gage and measure the cylinder bore for oversize. Slide the bore gage up and down throughout the length of the cylinder bore.

  • Page 606: Cylinder Boring And Honing

    and perpendicular to the centerline of the crankshaft. A cylinder that measures 99.0-99.018 mm (3.897-3.898 in) may be honed and serviced with a standard size piston. A cylinder bore that exceeds the maximum diameter must be serviced with an oversized piston. CYLINDER BORING AND HONING Boring Procedure 1.
  • Page 607 Fig. 87: Cylinder Bore Cross Hatch Pattern Courtesy of GENERAL MOTORS CORP. 1. When honing the cylinders, follow the manufacturer's recommendations for equipment use, cleaning, and lubrication. Use only clean, sharp stones of the proper grade for the amount of material you remove. Dull, dirty stones cut unevenly and generate excessive heat.
  • Page 608 A 240 grit stone is preferred for final honing. If a 240 grit stone is not available, a 220 grit stone may be used as a substitute. 5. When honing to eliminate taper in the cylinder, make full strokes the complete length of the bore. Repeatedly check the measurement at the top, the middle, and the bottom of the bore.
  • Page 609 Fig. 88: Deglazing The Cylinder Bore Courtesy of GENERAL MOTORS CORP. Using a ball type or self centering honing tool, deglaze the cylinder bore lightly. Deglazing should be done only to remove any deposits that may have formed. Use a 240 grit stone of silicone carbide or equivalent material when preforming the deglazing procedure.
  • Page 610 J 45059 Angle Meter Cleaning Procedure Fig. 89: CKP Reluctor Ring Lobes Courtesy of GENERAL MOTORS CORP. IMPORTANT: Use care when handling the crankshaft. Avoid damage to the bearing surfaces or the lobes of the crankshaft position reluctor ring. Damage to the teeth of the crankshaft position reluctor ring may effect On-Board Diagnostics (OBD) II system performance.
  • Page 611 Fig. 90: CKP Reluctor Ring Lobes Courtesy of GENERAL MOTORS CORP. IMPORTANT: The reluctor ring teeth should not have imperfections on the rising or falling edges. Imperfections of the reluctor ring teeth may effect OBD II system performance. 1. Perform a visual inspection of the crankshaft for damage. 2.
  • Page 612 Fig. 91: Crankshaft Inspection Areas (1-4) Courtesy of GENERAL MOTORS CORP. 3. Inspect the crankshaft journals for wear (1). Journals should be smooth with no signs of scoring, wear, or damage. 4. Inspect the crankshaft journals for grooves or scoring (2). 5.
  • Page 613 Fig. 92: View Of Crankshaft Key, Keyway & Threaded Hole Courtesy of GENERAL MOTORS CORP. 7. Inspect the crankshaft key (122), keyway (1), and threaded hole (2) for damage.
  • Page 614 Fig. 93: Measuring The Crankpins For Out-Of-Round & Taper Courtesy of GENERAL MOTORS CORP. 8. Measure the crankpins for the out-of-round. 9. Measure the crankpins for taper.
  • Page 615 Fig. 94: Measuring The Crankshaft Thrust Wall Width Courtesy of GENERAL MOTORS CORP. 10. Measure the crankshaft thrust wall width. A crankshaft with a thrust wall width in excess of 26.2 mm (1.0315 in) must be replaced.
  • Page 616 Fig. 95: Measuring The Crankshaft Runout Using J 7872 Courtesy of GENERAL MOTORS CORP. 11. Measure the crankshaft runout. Use wooden V blocks or a fixture to support the crankshaft on the front and rear journals. 12. Use the J 7872 in order to measure the crankshaft runout at the front and rear intermediate journals. 13.
  • Page 617 Fig. 96: Crankshaft Rear Oil Gallery Plug Courtesy of GENERAL MOTORS CORP. IMPORTANT: A loose or damaged crankshaft oil gallery plug must be replaced.
  • Page 618 15. Inspect the crankshaft rear oil gallery plug for a loose fit or leaking. Fig. 97: Inspecting Bearings For Craters Or Pockets Courtesy of GENERAL MOTORS CORP. 16. Inspect crankshaft bearings for craters or pockets. Flattened sections on the bearing halves also indicate fatigue.
  • Page 619 Fig. 98: Inspecting The Crankshaft Rod Bearings For Excess Scoring Or Discoloration Courtesy of GENERAL MOTORS CORP. 17. Inspect the crankshaft bearings for excessive scoring or discoloration. 18. Inspect the crankshaft bearings for dirt or debris imbedded into the bearing material.
  • Page 620 Fig. 99: Inspect The Crankshaft Bearings For Improper Seating Courtesy of GENERAL MOTORS CORP. 19. Inspect the crankshaft bearings for improper seating indicated by bright, polished sections of the bearing. If the lower half of the bearing is worn or damaged, both upper and lower halves should be replaced. Generally, if the lower half is suitable for use, the upper half should also be suitable for use.
  • Page 621 Fig. 100: View Of Bearing Cap Bolts & Studs Courtesy of GENERAL MOTORS CORP. IMPORTANT: The crankshaft main bearings are a precision insert type. Main bearing caps are machined with the engine block, for proper clearance, and cannot be shimmed or filed for bearing fit. If the clearances are found to be excessive, new bearings and/or engine block and cap repair or replacement may be required.
  • Page 622 Fig. 101: View Of Bearing Caps Courtesy of GENERAL MOTORS CORP. 2. Remove the bearing cap M10 bolts and studs.
  • Page 623 Fig. 102: View Of J 6125-1B & J 41818 Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Fastener Notice in Cautions and Notices. 3. Install the J 41818 to the bearing cap. Tighten: Tighten the J 41818 bolts to 11 N.m (100 lb in). 4.
  • Page 624 Fig. 103: View Of Crankshaft Bearings & Bearing Caps Courtesy of GENERAL MOTORS CORP. 5. Remove the bearing cap and lower bearing.
  • Page 625 Fig. 104: View Of Gaging Plastic & Crankshaft Journal Courtesy of GENERAL MOTORS CORP. 6. Install gaging plastic onto the crankshaft journal. Install the gaging plastic the full width of crankshaft bearing journal.
  • Page 626 Fig. 105: Main Cap Bolt Hole Tightening Sequence Courtesy of GENERAL MOTORS CORP. 7. Install the bearing, bearing cap, bolts and studs. Tighten: 1. Tighten the M10 bolts (1-10) a first pass in sequence to 20 N.m (15 lb ft). 2.
  • Page 627 Fig. 106: View Of Bearing Cap Bolts & Studs Courtesy of GENERAL MOTORS CORP. IMPORTANT: Remove the bearing cap side bolts prior to cap removal. 8. Remove the bearing cap M8 bolts.
  • Page 628 Fig. 107: View Of Bearing Caps Courtesy of GENERAL MOTORS CORP. 9. Remove the bearing cap M10 bolts and studs.
  • Page 629 Fig. 108: View Of J 6125-1B & J 41818 Courtesy of GENERAL MOTORS CORP. 10. Use the J 41818 and the J 6125-1B in order to remove the bearing cap.
  • Page 630 Fig. 109: Measuring The Gaging Plastic On Crankshaft Courtesy of GENERAL MOTORS CORP. 11. Measure the gaging plastic at its widest area using the scale supplied with the plastic gaging kit. If the gaging plastic shows irregularity in the journal exceeding 0.025 mm (0.001 in), remove the crankshaft and measure the journal with a micrometer.
  • Page 631 Fig. 110: Measuring Crankshaft End Play Courtesy of GENERAL MOTORS CORP. 12. Measure the crankshaft end play. 1. Thrust the crankshaft forward or rearward. 2. Insert a feeler gage between the center crankshaft bearing and the bearing surface of the crankshaft and measure the bearing clearance.
  • Page 632 Fig. 111: View Of Connecting Rod Cap & Bolts Courtesy of GENERAL MOTORS CORP. IMPORTANT: Connecting rod bearings are a precision insert type. Connecting rods are of a powdered metal design and cannot be shimmed or filed for bearing fit. If clearances are found to be excessive, a new bearing and/or connecting rod are required.
  • Page 633 Do not rotate the crankshaft while gaging plastic is between the crankshaft journal and the bearing surface. 1. Remove the bearing cap, bearing half and bolts. Fig. 112: View Of Gaging Plastic & Crankshaft Journal Courtesy of GENERAL MOTORS CORP. 2.
  • Page 634 Fig. 113: View Of Connecting Rod Cap & Bolts Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Fastener Notice in Cautions and Notices. 3. Install the bearing cap, bearing, and bolts.
  • Page 635 Tighten: 1. Tighten the connecting rod bolts first pass to 20 N.m (15 lb ft). 2. Tighten the connecting rod bolts final pass to 75 degrees using the J 45059 . 4. Remove the bearing cap, bearing, and bolts. Fig. 114: Measuring The Gaging Plastic On Crankshaft Courtesy of GENERAL MOTORS CORP.
  • Page 636 J 43690 and J 43690-100 have been developed as a more accurate method to measure connecting rod bearing clearances. The instructions below provide an overview of tool set-up and usage. For more detailed information, refer to the tool instruction sheets as supplied by the tool manufacturer. Fig.
  • Page 637 J 43690-5, -6 Handle (4) J 43690-10, -11 Foot (5) 280307 Screw (6) J 43690-1 Pivot Arm Assembly (7) J 43690-3, -7, -8 Screws (8) 280319 Screw (9) 280311 Screw (10) J 43690-17, -18 Adapter (11) 280310 Pin (12) Fig. 116: View Of J 43690-100 & Components...
  • Page 638 Courtesy of GENERAL MOTORS CORP. J 43690-100 J 43690-104 Spacer (1) J 43690-105 Retainer Plate (2) 505478 Bolt (3) 511341 Bolt (4) J 43690-106 Retainer Plate (5) J 43690-107 Cap (6) J 43690-102 Foot (7) J 43690-101 Pivot Arm Assembly (8) J 43690-103 Adapter (9) 505439 Adapter (10)
  • Page 639 Fig. 117: View OF Bearing Cap Bolt & Bearing Half Courtesy of GENERAL MOTORS CORP. IMPORTANT: The crankshaft must be secure with no movement or rotation in order to obtain an accurate reading. 1. Rotate the crankshaft until the journal/connecting rod to be measured is in the 12 o'clock position. 2.
  • Page 640 4. Insert a piece of paper card stock onto the crankshaft journal. 5. Install the bearing half (2) and cap and bolts (1). Refer to Fastener Tightening Specifications . Fig. 118: View Of J 43690-2, J 43690-3, J 43690-101, 280310 & J 43690-5 Courtesy of GENERAL MOTORS CORP.
  • Page 641 4. 280310 (3) 5. J 43690-5 (1) Fig. 119: Swivel Base & Dial Indicator Courtesy of GENERAL MOTORS CORP. 7. Install the swivel base (1) and dial indicator (2). 8. Adjust per the manufacturers instructions and measure the connecting rod bearing clearance. A connecting rod with a clearance in excess of 0.076 mm (0.003 in) is considered excessive.
  • Page 642 Fig. 120: Crankshaft Balancer Courtesy of GENERAL MOTORS CORP. 1. Clean the crankshaft balancer in solvent. 2. Clean the belt grooves of all dirt or debris with a wire brush. 3. Dry the crankshaft balancer with compressed air. 4. Inspect the crankshaft balancer for the following: Loose or improperly installed balance weights, manual transmission applications A properly installed balance weight should be installed until flush or below flush with the face of the balancer.
  • Page 643 A crankshaft balancer hub seal surface with excessive scoring, grooves, rust or other damage must be replaced. Minor imperfections on the hub seal surface may be removed with polishing compound or fine grade emery cloth. IMPORTANT: In order for the belt to track properly, the belt grooves should be free of all dirt or debris.
  • Page 644 Fig. 121: Crankshaft Balancer Courtesy of GENERAL MOTORS CORP. IMPORTANT: The position of the crankshaft balancer must be marked before removal, relative to the crankshaft. The balancer does not use a key or keyway for positioning. Mark or scribe the end of the crankshaft and the balancer before removal.
  • Page 645 CAUTION: Refer to Safety Glasses Caution in Cautions and Notices. 2. Use a punch and position the balance weights to the bottom of the weight holes. 3. With a marking crayon, note the weight holes containing balance weights. 4. Lay the old crankshaft balancer on a bench or flat table. Rotate the old balancer until one of the marked balance weight holes is in the 12 o'clock position.
  • Page 646 Fig. 122: Flywheel Weights (Manual Transmission) Courtesy of GENERAL MOTORS CORP. IMPORTANT: In order to maintain the proper component balance, contact surface taper, and heat transfer, manual transmission flywheels are NOT to be machined.
  • Page 647 1. Clean the flywheel in solvent. CAUTION: Refer to Safety Glasses Caution in Cautions and Notices. 2. Dry the flywheel with compressed air. 3. Inspect the manual transmission flywheel for loose or improperly installed balance weights. A properly installed balance weight should be installed until flush or below flush with the face of the flywheel.
  • Page 648 Fig. 123: Flywheel Inspection Areas (Manual Transmission) Courtesy of GENERAL MOTORS CORP. 4. Inspect the manual transmission flywheel for the following: Pitted surface (1) Grooved or scored surface (2) Rusted surface (3) Damaged ring gear teeth (4) Loose or improperly positioned ring gear The ring gear has an interference fit onto the flywheel and should be positioned completely against the flange of the flywheel.

  • Page 649: Piston And Connecting Rod Disassemble

    Fig. 124: Automatic Transmission Flywheel Courtesy of GENERAL MOTORS CORP. 5. Inspect the automatic transmission flywheel for the following: Damaged ring gear teeth Stress cracks around the flywheel-to-crankshaft bolt hole locations Worn prop shaft drive hub splines Loose prop shaft drive hub IMPORTANT: Do not attempt to repair the welded areas that retain the ring gear to the flywheel plate.
  • Page 650 Tools Required J 24086-C Piston Pin Remover/Installer Set Fig. 125: View Of Piston, Connecting Rod & Components Courtesy of GENERAL MOTORS CORP. IMPORTANT: Disassembly of the piston, press-fit design piston pin, and connecting rod may create scoring or damage to the piston pin and piston pin bore.
  • Page 651 purposes only. 1. Remove the connecting rod bearings (3) from the rod (2) and cap (4). Fig. 126: Piston Rings & Piston Courtesy of GENERAL MOTORS CORP. 2. Using piston ring pliers, remove the piston rings from the piston.
  • Page 652 Fig. 127: View Of J 24086-920A & J 24086-10 Courtesy of GENERAL MOTORS CORP. 3. Install fork insert J 24086-920A into J 24086-10 .
  • Page 653 Fig. 128: J 24086-88A & J 24086-107 Courtesy of GENERAL MOTORS CORP. 4. Install the piston and connecting rod assembly onto J 24086-10 . 5. Install J 24086-107 to the piston pin. 6. Install J 24086-88A through the fixture and to the J 24086-107.
  • Page 654 Fig. 129: Pressing Piston Pin From Piston & Connecting Rod Assembly Courtesy of GENERAL MOTORS CORP. NOTE: After the installer hub bottoms on the support assembly, do not exceed 35 000 kPa (5,000 psi) pressure, this could cause damage to the tool.
  • Page 655 7. Press the piston pin from the piston and connecting rod assembly. Full-Floating Piston Pin Fig. 130: View Of Piston, Connecting Rod & Components Courtesy of GENERAL MOTORS CORP. 1. Remove the connecting rod bearings (3) from the rod (2) and cap (4).
  • Page 656 Fig. 131: Piston Rings & Piston Courtesy of GENERAL MOTORS CORP. 2. Using piston ring pliers, remove the piston rings from the piston.
  • Page 657 Fig. 132: Cutout Area Of Pin Bore Courtesy of GENERAL MOTORS CORP. 3. Rotate the piston pin retaining clips until the ring end gap is positioned in the cutout area (1) of the pin bore.
  • Page 658 Fig. 133: Removing Clips Starting In Cutout Area Courtesy of GENERAL MOTORS CORP. 4. Remove the clips starting in the cutout area of the pin bore.
  • Page 659 Fig. 134: Pin, Piston & Connecting Rod Courtesy of GENERAL MOTORS CORP. 5. Remove the pin from the piston and connecting rod. 6. The piston and pin are a matched set and are not to be serviced separately. Mark, sort, or organize the piston and the matching piston pin. PISTON, CONNECTING ROD, AND BEARINGS CLEANING AND INSPECTION Piston, Pin, and Piston Rings...
  • Page 660 Fig. 135: View Of Piston, Connecting Rod & Components Courtesy of GENERAL MOTORS CORP. IMPORTANT: Replace pistons, pins, and connecting rods that are damaged or show signs of excessive wear. The first design press-fit piston, pin, and connecting rod are to be serviced as an assembly.
  • Page 661 1. Clean the varnish and carbon from the piston (1) using cleaning solvent. CAUTION: Wear safety glasses in order to avoid eye damage. 2. Dry the components with compressed air.
  • Page 662 Fig. 136: Cleaning The Piston Ring Grooves With Suitable Ring Groove Cleaning Tool Courtesy of GENERAL MOTORS CORP. 3. Clean the piston ring grooves with a suitable ring groove cleaning tool. 4. Clean the oil lubrication holes and slots.
  • Page 663 Fig. 137: Inspecting Piston For Damage Courtesy of GENERAL MOTORS CORP. 5. Inspect the piston for the following conditions: Cracks in the piston ring lands, the piston skirt, or pin bosses Piston ring grooves for nicks, burrs, or warpage which may cause the piston ring to bind MINOR imperfections may be removed from the piston with a fine file.
  • Page 664 Scoring to the full-floating design piston pin bore (3) or piston pin Fig. 138: View Of Upper/Lower Compression Rings & Marks Courtesy of GENERAL MOTORS CORP. 6. Identify the NEW upper and lower compression rings. The upper compression ring can be identified by a paint mark (3) located 180 degrees from the end gap.
  • Page 665 Fig. 139: Inserting Piston Ring-To-Piston Ring Groove Side Courtesy of GENERAL MOTORS CORP. 7. Insert the edge of the piston ring into the piston ring groove. Roll the piston ring completely around the piston. If binding is caused by distorted ring groove, MINOR imperfections may be removed with a fine file.
  • Page 666 Fig. 140: Measuring The Piston Ring Side Clearance With Feeler Gauge Courtesy of GENERAL MOTORS CORP. 8. Measure the piston ring side clearance with a feeler gauge. If side clearance is not within specifications, try another piston ring. If the proper ring-to- groove clearance cannot be obtained, replace the first design press-fit piston, pin, and connecting rod assembly.
  • Page 667 Fig. 141: Measuring The Piston Pin Diameter Courtesy of GENERAL MOTORS CORP. 9. To determine piston pin-to-bore clearance, use a micrometer and measure the piston pin outside diameter (OD).
  • Page 668 Fig. 142: Measuring The Piston Pin Bore Courtesy of GENERAL MOTORS CORP. 10. To determine the piston pin-to-bore clearance, use an inside micrometer and measure the piston pin bore inside diameter (ID). 11. Subtract the piston pin OD measurement from the piston pin bore ID measurement to determine pin-to- bore clearance.
  • Page 669 Fig. 143: View Of Upper/Lower Compression Rings & Marks Courtesy of GENERAL MOTORS CORP. IMPORTANT: Do not attempt to file the end of the piston ring to achieve the proper end gap clearance. Measure the piston ring in the cylinder in which it will be used. 1.
  • Page 670 Fig. 144: Measuring The Piston Compression Ring End Gap Courtesy of GENERAL MOTORS CORP. 2. Place the piston ring into the cylinder bore 6.5 mm (0.25 in) below the top of the ring travel area. 3. Insert a feeler gage and measure the piston ring end gap. Refer to Engine Mechanical Specifications (LS1) or Engine Mechanical Specifications (LS6) .
  • Page 671 Connecting Rod and Bearings Fig. 145: View Of Piston, Connecting Rod & Components Courtesy of GENERAL MOTORS CORP. IMPORTANT: The powdered metal connecting rod and cap are machined for proper clearances. The connecting rod and cap must be used as an assembly with no repair or modifications to either mating surface.
  • Page 672 1. Clean the connecting rod (2) and cap (4) in solvent. CAUTION: Wear safety glasses in order to avoid eye damage. 2. Dry the components with compressed air.
  • Page 673 Fig. 146: Inspecting The Connecting Rod For Damage Courtesy of GENERAL MOTORS CORP. 3. Inspect the connecting rod for the following conditions: Twisting (1) Proper fit of the connecting rod and cap mating surfaces (2)
  • Page 674 Nicks or gouges in the bearing bore (3) Damage to the bearing locating slots (4) Fig. 147: Measuring The Connecting Rod Bearing Bore For Out-Of-Round Condition Courtesy of GENERAL MOTORS CORP.
  • Page 675 4. Measure the connecting rod bearing bore (1) for an out-of-round condition. Refer to Engine Mechanical Specifications (LS1) or Engine Mechanical Specifications (LS6) . Fig. 148: Measuring The Piston Pin Diameter Courtesy of GENERAL MOTORS CORP. 5. To determine piston pin-to-connecting rod bore clearance, use a micrometer and measure the piston pin outside diameter (OD).
  • Page 676 Fig. 149: Measuring The Connecting Rod Pin Bore Inside Diameter Courtesy of GENERAL MOTORS CORP. 6. To determine piston pin-to-connecting rod bore clearance, use a micrometer and measure the connecting rod pin bore (1) inside diameter (ID). 7. Subtract the piston pin OD measurement from the connecting rod pin bore ID measurement to determine...
  • Page 677 pin-to-bore clearance. Refer to Engine Mechanical Specifications (LS1) or Engine Mechanical Specifications (LS6) . Fig. 150: Inspecting Bearings For Damage Courtesy of GENERAL MOTORS CORP. 8. Inspect the connecting rod bearings for craters or pockets. Flattened sections on the bearing halves indicate fatigue.
  • Page 678 Fig. 151: Inspecting Connecting Rod Bearings For Excess Scoring Or Discoloration Courtesy of GENERAL MOTORS CORP. 9. Inspect the connecting rod bearings for excessive scoring or discoloration. 10. Inspect the connecting rod bearings for dirt or debris imbedded into the bearing material.

  • Page 679: Piston And Connecting Rod Assemble

    Fig. 152: Inspecting Bearings For Improper Seating Courtesy of GENERAL MOTORS CORP. 11. Inspect the connecting rod bearings for improper seating indicated by bright, polished sections of the bearing surface. PISTON AND CONNECTING ROD ASSEMBLE Tools Required J 24086-C Piston Pin Remover/Installer Set...
  • Page 680 Fig. 153: View Of J 24086-920 & J 24086-10 Courtesy of GENERAL MOTORS CORP. IMPORTANT: Disassembly of the piston, press-fit design piston pin, and connecting rod may create scoring or damage to the piston pin and piston pin bore. If the piston, pin, and connecting rod have been disassembled, replace the components as an assembly.
  • Page 681 The assembly procedure, as shown, is to be used for diagnostic purposes only. 1. Install fork insert J 24086-920 into J 24086-10 . Fig. 154: Connecting Rod, Positioning Tab & Flat Flange Courtesy of GENERAL MOTORS CORP. CAUTION: Avoid contact with HOT components. Wear safety glasses and protective gloves to avoid personal injury.
  • Page 682 temperature the end of the connecting rod will turn a straw color upon visual inspection. 2. Use a torch and apply MILD heat to the pin end of the connecting rod. Mild heating of the connecting rod will ease in piston and pin assembly. 3.
  • Page 683 Fig. 156: J 24086-9 Courtesy of GENERAL MOTORS CORP. 5. Adjust the J 24086-9 to I 8.
  • Page 684 Fig. 157: J 24086-9 Courtesy of GENERAL MOTORS CORP. 6. Install the piston, connecting rod, piston pin, and J 24086-16A to the J 24086-10 .
  • Page 685 Fig. 158: View Of Piston, Pin & Connecting Rod Proper Assembly Courtesy of GENERAL MOTORS CORP. NOTE: After the installer hub bottoms on the support assembly, do not exceed 35 000 kPa (5,000 psi) pressure, this could cause damage to the tool. 7.
  • Page 686 Fig. 159: View Of Upper/Lower Compression Rings & Marks Courtesy of GENERAL MOTORS CORP. 10. Identify the compression and oil control rings for proper installation. The upper compression ring can be identified by a paint mark (3) located 180 degrees from the end gap. The lower compression ring can be identified by a paint mark (3) located 90 degrees from the end gap.
  • Page 687 Fig. 160: Piston Rings & Piston Courtesy of GENERAL MOTORS CORP. IMPORTANT: When installing piston rings, use a ring expander plier type tool. Do not roll the rings into the grooves of the piston. Use caution and care to expand the rings only slightly larger than the outside diameter (OD) of the piston.
  • Page 688 Fig. 161: View Of Piston, Connecting Rod & Components Courtesy of GENERAL MOTORS CORP. 14. Install the connecting rod bearings (3) to the rod (2) and cap (4). Full-Floating Piston Pin...
  • Page 689 Fig. 162: Installing Retaining Clip In Groove Of Pin Bore Courtesy of GENERAL MOTORS CORP. 1. Install the retaining clip. The clip should be seated in the groove of the pin bore.
  • Page 690 Fig. 163: Pin, Piston & Connecting Rod Courtesy of GENERAL MOTORS CORP. 2. Install the piston pin to the piston and connecting rod. 3. Install the retaining clip. The clip should be seated in the groove of the pin bore.
  • Page 691 Fig. 164: View Of Upper/Lower Compression Rings & Marks Courtesy of GENERAL MOTORS CORP. IMPORTANT: When installing piston rings, use a ring expander plier type tool. Do not roll the rings into the grooves of the piston. Use caution and care to expand the rings only slightly larger than the outside diameter (OD) of the piston.
  • Page 692 Fig. 165: Piston Rings & Piston Courtesy of GENERAL MOTORS CORP. 5. Using piston ring pliers, install the piston rings onto the piston. 6. Position the oil control ring end gaps a minimum of 25 mm (1.0 in) from each other. 7.

  • Page 693: Camshaft Bearing Removal

    Fig. 166: View Of Piston, Connecting Rod & Components Courtesy of GENERAL MOTORS CORP. 8. Install the connecting rod bearings (3) to the rod (2) and cap (4). CAMSHAFT BEARING REMOVAL Tools Required J 33049 Camshaft Bearing Service Set...
  • Page 694 Fig. 167: View Of Camshaft Bearings Courtesy of GENERAL MOTORS CORP. IMPORTANT: A loose camshaft bearing may be caused by an enlarged, out of round or damaged engine block bearing bore. 1. Prior to bearing removal, inspect the camshaft bearings for loose fit in the engine block bearing bores. Refer to Camshaft and Bearings Cleaning and Inspection .
  • Page 695 Fig. 168: J 33049 Camshaft Bearing Service Kit Components Courtesy of GENERAL MOTORS CORP. 3. Select the expanding driver (4-8) and washer (2 or 3) from the tool usage information. 4. Assemble the J 33049 . 5. Insert the tool through the front of the engine block and into the bearing.
  • Page 696 6. Tighten the expander assembly (15) nut until snug. 7. Push the guide cone (1) into the front camshaft bearing to align the tool. Fig. 169: Bearing & Block Bore Courtesy of GENERAL MOTORS CORP. 8. Drive the bearing from the block bore. IMPORTANT: To remove the front camshaft bearing, operate the tool from the rear of the block using the guide cone in the rear camshaft bearing bore.
  • Page 697 Fig. 170: J 33049 Camshaft Bearing Service Kit Components Courtesy of GENERAL MOTORS CORP. The tool consists of a guide cone (1), driving washers (2 or 3), expander bearing drivers (4-8), driver bars (9 or 10), expander jaws (11), expander sleeve (12), expander cone (13), expander shaft (14), and expander assembly (15).
  • Page 698 Expander bearing driver number one inside diameter is 28.575-37.465 mm (1.125-1.475 in) and is used with the expander assembly and the small washer. Expander bearing driver number 2 inside diameter is 37.465-43.18 mm (1.475-1.7 in) and is used with number 1 expanding driver and the small washer. Expander bearing driver number 3 inside diameter is 43.18-48.895 mm (1.7-1.925 in) and is used with number 2 expanding driver and the large washer.
  • Page 699 Fig. 171: Inner Camshaft Bearing & Snug Courtesy of GENERAL MOTORS CORP. 7. Insert the tool into a inner camshaft bearing and tighten until snug. Operate the tool from the front or rear of the engine block. On some engine blocks, the nut on the expander assembly is inaccessible except from either end. In this case you must use a socket and extension to enlarge and reduce the expander assembly.
  • Page 700 10. Repeat the procedure for the additional inner bearings. Fig. 172: Bearing & Block Bore Courtesy of GENERAL MOTORS CORP. 11. For the 2 end bearings, front and rear, remove the nylon cone and driver bar extension. 12. Drive the bearings out of or into the engine block. CAMSHAFT AND BEARINGS CLEANING AND INSPECTION Tools Required J 7872 Magnetic Base Dial Indicator Set...
  • Page 701 Fig. 173: Inspecting The Camshaft Bearing Journals, Threaded Bolt Holes, Camshaft Valve Lifter Lobes & Camshaft Sprocket Pin For Damage Courtesy of GENERAL MOTORS CORP. 1. Clean the components in solvent. CAUTION: Refer to Safety Glasses Caution in Cautions and Notices. 2.
  • Page 702 Fig. 174: View Of Camshaft Retainer & Bolts Courtesy of GENERAL MOTORS CORP. 8. Inspect the camshaft retainer plate for wear or a damaged sealing gasket. If the camshaft retainer plate sealing gasket is not cut or damaged, it may be used again.
  • Page 703 Fig. 175: View Of Camshaft Bearings Courtesy of GENERAL MOTORS CORP. 9. Inspect the camshaft bearings for proper fit in the engine block. The camshaft bearings have an interference fit to the engine block and should not be loose in their engine block bearing bores. 10.
  • Page 704 Fig. 176: Measuring The Camshaft Journals For Wear & Out-Of-Round Courtesy of GENERAL MOTORS CORP. 11. Measure the camshaft journals for wear and out-of-round with a micrometer. A camshaft with bearing journals that measure more than 0.025 mm (0.001 in) out-of-round, must be replaced.
  • Page 705 Fig. 177: Measuring The Camshaft Lobes For Wear Courtesy of GENERAL MOTORS CORP. 12. Measure the camshaft lobes for wear with a micrometer. An LS1 camshaft with an intake lobe that measures 46.31 mm (1.823 in) or less, must be replaced. An LS1 camshaft with an exhaust lobe that measures 46.31 mm (1.823 in) or less, must be replaced.
  • Page 706 Fig. 178: Measuring The Camshaft Runout Using Courtesy of GENERAL MOTORS CORP. 13. Measure the camshaft runout. 1. Mount the camshaft in wooden V-blocks or between centers on a fixture. 2. Check the runout of the intermediate camshaft bearing journals using the J 7872 . 3.

  • Page 708: Camshaft Bearing Installation

    Fig. 179: Measuring Camshaft Lobe Lift Using Courtesy of GENERAL MOTORS CORP. IMPORTANT: Measuring camshaft lobe lift is a procedure used to determine if the camshaft lobes have worn. This test is to be performed prior to engine disassembly and with the camshaft and valve train components installed in the engine.
  • Page 709 Fig. 180: Measuring The Engine Block Camshaft Bearing Bores (1-5) Courtesy of GENERAL MOTORS CORP. IMPORTANT: The engine block camshaft bearing bores are machined for 3 different OD size bearings. Positions 1 and 5 are the largest diameter bores. Position 3 is the smallest diameter bore.
  • Page 710 (LS6) . Fig. 181: J 33049 Camshaft Bearing Service Kit Components Courtesy of GENERAL MOTORS CORP. 2. Select the expanding driver (4-8) and washer (2 or 3) from the J 33049 . Refer to Camshaft Bearing...
  • Page 711 Removal . 3. Assemble the tool. Fig. 182: Bearing & Block Bore Courtesy of GENERAL MOTORS CORP. 4. Insert the tool through the front of the engine block and into the bearing. 5. Tighten the expander assembly nut until snug. 6.
  • Page 712 1. Clean the components with cleaning solvent. CAUTION: Refer to Safety Glasses Caution in Cautions and Notices. 2. Dry the components with compressed air.
  • Page 713 Fig. 183: View Of Camshaft & Crankshaft Sprockets Aligned Courtesy of GENERAL MOTORS CORP. 3. Inspect the timing chain for binding or wear.
  • Page 714 Fig. 184: Inspecting Camshaft & Crankshaft Sprockets For Damage Courtesy of GENERAL MOTORS CORP. 4. Inspect the camshaft and crankshaft sprockets for: Worn teeth (1) Damaged teeth (2) Chipped teeth (3) Worn valleys between the sprocket teeth...
  • Page 715 Fig. 185: View Of Crankshaft Sprocket Courtesy of GENERAL MOTORS CORP. 5. Inspect the crankshaft sprocket keyway for wear. 6. Inspect the crankshaft sprocket oil pump drive splines for wear.
  • Page 716 Fig. 186: Inspecting Chain Dampener For Damage Courtesy of GENERAL MOTORS CORP. 7. Inspect the chain dampener (232) for the following conditions: Loose metal inserts (1) Cracking (2) in the chain contact area Excessive grooves (3) in the chain contact area Grooves 1 mm (0.040 in) or less in depth are to be considered normal wear.
  • Page 717 Fig. 187: View Of Valve Stem Mating Surfaces, Valve Rocker Arms Bearing & Pushrod Sockets Courtesy of GENERAL MOTORS CORP. IMPORTANT: Parts that are to be used again must be marked, sorted or organized for assembly. 1. Mark, sort, or organize the components for assembly. Refer to Separating Parts . 2.
  • Page 718 3. Dry the components with compressed air. 4. Inspect the valve rocker arms bearings (2) for binding or roughness. 5. Inspect the valve rocker arm pushrod sockets (3) and valve stem mating surfaces (1). These surfaces should be smooth with no scoring or exceptional wear. Fig.
  • Page 719 Fig. 189: View Of Valve Rocker Arm Pivot Support Courtesy of GENERAL MOTORS CORP. 9. Inspect the pivot supports for cracks, wear, or other damage. VALVE LIFTERS AND GUIDES CLEANING AND INSPECTION...
  • Page 720 Fig. 190: Inspecting The Valve Lifters For Damage Courtesy of GENERAL MOTORS CORP. IMPORTANT: Components that are to be used again must be marked, sorted or organized for assembly. 1. Mark, sort, or organize the components for assembly. Refer to Separating Parts . 2.
  • Page 721 3. Dry the components with compressed air. 4. Inspect the valve lifters for the following conditions: Bent or broken clip (1) Worn pushrod socket (2) Scuffed or worn sides (3) If the valve lifter shows wear, inspect the engine block lifter bores for wear or damage. Flat spots on the roller (4) Loose or damaged pin (5) Plugged oil hole (6)

  • Page 722: Cylinder Head Disassemble

    For cracks or damage Excessive wear in the lifter mounting bores CYLINDER HEAD DISASSEMBLE Tools Required J 8062 Valve Spring Compressor...
  • Page 723 Fig. 192: View Of Cylinder Head Components Courtesy of GENERAL MOTORS CORP.
  • Page 724 IMPORTANT: Remove the spark plugs from the cylinder head with the components at room temperature. Mark, organize, or sort the cylinder head components for assembly. Return the components to their original location during assembly. Do not remove the cylinder head expansion plugs (226) unless service is required.
  • Page 725 Fig. 193: Compressing The Valve Spring Using J 8062 Courtesy of GENERAL MOTORS CORP. 2. Use the J 8062 in order to compress the valve spring.
  • Page 726 Fig. 194: View Of Cylinder Head Components Courtesy of GENERAL MOTORS CORP.
  • Page 727 3. Remove the valve stem keys (225). 4. Remove the valve spring cap (224). 5. Remove the valve spring (223). 6. Remove the valves (227 and 228). 7. Remove the valve stem oil seal (222). Refer to Separating Parts . Fig.
  • Page 728 Fig. 196: View Of Coolant Temperature Sensor (Left Cylinder Head) Courtesy of GENERAL MOTORS CORP. 9. Remove the coolant sensor from the left cylinder head.

  • Page 729: Cylinder Head Cleaning And Inspection

    Fig. 197: View Of Coolant Plug (Right Cylinder Head) Courtesy of GENERAL MOTORS CORP. 10. Remove the coolant plug from the right cylinder head. CYLINDER HEAD CLEANING AND INSPECTION Tools Required J 8089 Carbon Removing Brush J 9666 Valve Spring Tester...
  • Page 730 Fig. 198: Cleaning The Carbon From Combustion Chambers Using J 8089 Courtesy of GENERAL MOTORS CORP. CAUTION: Refer to Safety Glasses Caution in Cautions and Notices. IMPORTANT: When cleaning a cylinder head in a thermal type oven, do not exceed 204° C (400°F).
  • Page 731 Use the J 8089 in order to remove the carbon from the combustion chambers. Gasket surfaces Refer to Replacing Engine Gaskets . Valve stems and heads on a buffing wheel Bolt hole threads Remove all dirt, debris, or threadlocking material from the bolt holes.
  • Page 732 Fig. 199: View Of Cylinder Head Components Courtesy of GENERAL MOTORS CORP.
  • Page 733 2. Inspect for the following conditions: 1. The cylinder head (218) for cracks in the exhaust ports and combustion chambers 2. The cylinder head for external cracks in the water chambers 3. The gasket surfaces for excessive scratches or gouging Refer to Replacing Engine Gaskets .
  • Page 734 Fig. 201: Inspecting Valve Spring For Squareness Courtesy of GENERAL MOTORS CORP. 4. Inspect the valve springs for squareness.

  • Page 735: Valve Guide Reaming/Valve And Seat Grinding

    Fig. 202: Measuring The Valve Spring Using J 9666 Courtesy of GENERAL MOTORS CORP. 5. Use the J 9666 in order to measure the valve spring tension. Replace the LS1 spring if the spring tension is less than 310 N (70 lb) at 45.75 mm (1.80 in). Replace the LS6 spring if the spring tension is less than 400 N (90 lb) at 45.75 mm (1.80 in).
  • Page 736 Tools Required J 37378-1 Valve Guide Reamer Fig. 203: Measuring The Valve Stem-To-Guide Clearance Using Dial Indicator Courtesy of GENERAL MOTORS CORP.
  • Page 737 IMPORTANT: Excessive valve stem-to-guide clearance may cause a noisy valve train, premature valve stem oil seal wear, component damage, and/or excessive engine oil consumption. Insufficient valve stem-to-guide clearance will result in noisy or sticking valves. Valves that are too tight may disturb engine smoothness or lead to component damage.
  • Page 738 Fig. 204: Valve Stem & Guide Courtesy of GENERAL MOTORS CORP. 2. A valve stem (1) and guide (2) with clearance in excess of 0.093 mm (0.0037 in) must be repaired or the components replaced.
  • Page 739 Fig. 205: Inspecting Valves For Damage Courtesy of GENERAL MOTORS CORP. 3. Inspect the valve stems for excessive scoring, wear, or warpage. A valve stem that has excessive scoring (3 or 4) or wear (4 or 6) must be replaced. A valve guide that is worn and has excessive stem-to-guide clearance should be reamed and valves with oversize stems installed.
  • Page 740 If the valve stem diameter is within specifications, and the stem-to-guide clearance is excessive, the valve guide must be reamed oversize and a valve with oversize stem installed. Fig. 206: Reaming The Valve Guide Using J 37378-1 Courtesy of GENERAL MOTORS CORP. 5.
  • Page 741 Fig. 207: View Of Valve & Cylinder Head Courtesy of GENERAL MOTORS CORP. 7. Install the valve (227 and 228), with oversize stem, into the cylinder head (218). 8. Inspect the valve for proper fit.
  • Page 742 Move the valve back and forth in the guide. The valve should move freely with no resistance or drag. Valve and Seat Grinding Fig. 208: Inspecting Valves For Damage Courtesy of GENERAL MOTORS CORP. IMPORTANT: Reconditioning the valve seats is very important. The seating of the valves must be perfect for the engine to deliver optimum power and...
  • Page 743 performance. Several different types of equipment are available for grinding valve seats. Another important factor is the cooling of the valve head. Good contact between the valve and the seat will ensure that heat will be properly dissipated. The recommendations of the manufacturer of the equipment should be followed carefully to obtain the proper results.
  • Page 744 Fig. 209: Inspecting Valve Face For Damage Courtesy of GENERAL MOTORS CORP. 2. Inspect the valve face for the following conditions: Worn or no margin (1 or 4) Pitted surfaces (2) Burnt or eroded areas (3)
  • Page 745 Fig. 210: Inspecting The Valve Margin Courtesy of GENERAL MOTORS CORP. 3. Inspect the valve margin. The exhaust valve may be refaced if the margin is greater than 1.25 mm (0.05 in) thick before grinding.
  • Page 746 4. Reface pitted exhaust valves on a suitable valve refacing machine. 5. Replace the valve if the margin is less than 1.25 mm (0.05 in) thick after grinding. 6. If the valve face has been ground, it may be necessary to shim the valve spring to obtain the proper spring installed height.
  • Page 747 Fig. 211: View Of Cylinder Head Components Courtesy of GENERAL MOTORS CORP.

  • Page 748: Cylinder Head Assemble

    7. Inspect for a loose valve seat in the cylinder head (218). The valve seat has an interference fit to the cylinder head. 8. Clean the valve guide bores with a suitable tool. Remove all carbon or dirt from the bores. The valve guide must be clean for the seat grinding tool to obtain proper results.
  • Page 749 Fig. 212: View Of Cylinder Head Components Courtesy of GENERAL MOTORS CORP.
  • Page 750 1. Clean the cylinder head valve spring shim area. IMPORTANT: When using the valves and related components again, install the parts to their original location. 2. Install the valves (227 and 228) into the proper port. Refer to Separating Parts . IMPORTANT: The valve stem oil seal alignment and position on the valve guide is critical.
  • Page 751 Fig. 213: Compressing The Valve Spring Using J 8062 Courtesy of GENERAL MOTORS CORP. 6. Compress the valve spring using the J 8062 . 7. Install the valve stem keys. 1. Use grease to hold the keys in place and remove the J 8062 . 2.
  • Page 752 3. Tap the end to the valve stem with a plastic faced hammer to seat the keys, if necessary. Fig. 214: Measuring Valve Spring Installed Height Courtesy of GENERAL MOTORS CORP. 8. Measure the valve spring installed height using a ruler. Measure from the base of the valve spring to the top of the valve spring.
  • Page 753 Do not assemble the components without a spring shim on the cylinder head. 9. Install the remaining valves, springs, and other components. Fig. 215: View Of Coolant Temperature Sensor (Left Cylinder Head) Courtesy of GENERAL MOTORS CORP. 10. Install sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the threads of the coolant sensor.
  • Page 754 Fig. 216: View Of Coolant Plug (Right Cylinder Head) Courtesy of GENERAL MOTORS CORP. 12. Install the coolant plug to the right cylinder head. Tighten: Tighten the coolant plug to 20 N.m (15 lb ft).

  • Page 755: Oil Pump Disassemble

    Fig. 217: View Of Cylinder Head Expansion Plugs Courtesy of GENERAL MOTORS CORP. 13. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the sides of the cylinder head expansion plugs (226). 14. Install the expansion plugs into the cylinder head. A properly installed plug should be installed 2.5 mm (0.1 in) below the end face of the head.
  • Page 756 Fig. 218: View Of Oil Pump Cover & Bolts Courtesy of GENERAL MOTORS CORP. IMPORTANT: The internal parts of the oil pump assembly are not serviced separately, excluding the spring. If the oil pump components are worn or damaged, replace the oil pump as an assembly. 1.
  • Page 757 Fig. 219: View Of Oil Pump & Cover Courtesy of GENERAL MOTORS CORP. 2. Remove the oil pump cover.
  • Page 758 Fig. 220: View Of Oil Pump Drive Gear Splines Courtesy of GENERAL MOTORS CORP. IMPORTANT: Mark or identify the gears for assembly. Refer to Separating Parts . 3. Remove the drive gear.
  • Page 759 Fig. 221: View Of Oil Pump Driven Gear Courtesy of GENERAL MOTORS CORP. 4. Remove the driven gear.
  • Page 760 Fig. 222: View Of Oil Pump Pressure Relief Valve Plug Courtesy of GENERAL MOTORS CORP. 5. Remove the pressure relief valve plug.
  • Page 761 Fig. 223: View Of Oil Pump Pressure Relief Valve Spring Courtesy of GENERAL MOTORS CORP. 6. Remove the pressure relief valve spring.
  • Page 762 Fig. 224: View Of Oil Pump Pressure Relief Valve Courtesy of GENERAL MOTORS CORP. 7. Remove the pressure relief valve. 8. Inspect the oil pump components. Refer to Oil Pump Cleaning and Inspection . OIL PUMP CLEANING AND INSPECTION IMPORTANT: The internal parts of the oil pump assembly are not serviced separately, excluding the spring.
  • Page 763 The oil pump pipe and screen are to be serviced as an assembly. Do not attempt to repair the wire mesh portion of the pump and screen assembly. 1. Clean the parts in solvent. CAUTION: Refer to Safety Glasses Caution in Cautions and Notices. 2.
  • Page 764 Fig. 226: View Of Oil Pump Pressure Relief Valve Plug Courtesy of GENERAL MOTORS CORP. 6. Inspect the relief valve plug and plug bore for damaged threads. 7. Inspect the oil pump internal oil passages for restrictions.
  • Page 765 Fig. 227: View Of Oil Pump Driven Gear Courtesy of GENERAL MOTORS CORP. 8. Inspect the drive gear and driven gear for chipping, galling or wear. Minor burrs or imperfections on the gears may be removed with a fine oil stone.
  • Page 766 Fig. 228: View Of Oil Pump Drive Gear Splines Courtesy of GENERAL MOTORS CORP. 9. Inspect the drive gear splines for excessive wear.
  • Page 767 Fig. 229: View Of Oil Pump Pressure Relief Valve Courtesy of GENERAL MOTORS CORP. 10. Inspect the pressure relief valve and bore for scoring or wear. The valve must move freely in the bore with no restrictions.

  • Page 768: Oil Pump Assemble

    Fig. 230: View Of Oil Pump Screen, Nuts & Bolts Courtesy of GENERAL MOTORS CORP. 11. Inspect the oil pump screen for debris or restrictions. 12. Inspect the oil pump screen for broken or loose wire mesh. OIL PUMP ASSEMBLE...
  • Page 769 Fig. 231: View Of Oil Pump Driven Gear Courtesy of GENERAL MOTORS CORP. IMPORTANT: Prior to assembling the oil pump, coat all wear or internal surfaces with clean engine oil. 1. Install the driven gear into the pump housing. Install the driven gear with the orientation mark facing the pump cover.
  • Page 770 Fig. 232: View Of Oil Pump Drive Gear Splines Courtesy of GENERAL MOTORS CORP. 2. Install the drive gear into the pump housing.
  • Page 771 Fig. 233: View Of Oil Pump & Cover Courtesy of GENERAL MOTORS CORP. 3. Install the oil pump cover.
  • Page 772 Fig. 234: View Of Oil Pump Cover & Bolts Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Fastener Notice in Cautions and Notices. 4. Install the pump cover bolts. Tighten: Tighten the oil pump cover bolts to 12 N.m (106 lb in).
  • Page 773 Fig. 235: View Of Oil Pump Pressure Relief Valve Courtesy of GENERAL MOTORS CORP. 5. Install the regulator valve.
  • Page 774 Fig. 236: View Of Oil Pump Pressure Relief Valve Spring Courtesy of GENERAL MOTORS CORP. 6. Install a NEW regulator valve spring.
  • Page 775 Fig. 237: View Of Oil Pump Pressure Relief Valve Plug Courtesy of GENERAL MOTORS CORP. 7. Install the pressure relief valve plug. Tighten: Tighten the pressure relief valve plug to 12 N.m (106 lb in). 8. Inspect the oil pump for smooth operation by rotating the drive gear. ENGINE FRONT COVER CLEANING AND INSPECTION...
  • Page 776 Fig. 238: View Of Crankshaft Front Oil Seal Courtesy of GENERAL MOTORS CORP. IMPORTANT: Do not use the crankshaft oil seal again. Install a NEW crankshaft oil seal during assembly. Do not use the front cover-to-engine block gasket again. Install a...
  • Page 777 NEW gasket during assembly. 1. Remove the crankshaft oil seal (140) from the front cover. 2. Clean the cover in solvent. Remove the sealant from the cover oil pan surface. Refer to Replacing Engine Gaskets . CAUTION: Refer to Safety Glasses Caution in Cautions and Notices. 3.
  • Page 778 Fig. 239: View Of Crankshaft Rear Oil Seal Courtesy of GENERAL MOTORS CORP. IMPORTANT: Do not use the crankshaft oil seal again. Install a NEW crankshaft oil seal during assembly. Do not use the rear cover-to-engine block gasket again. Install a NEW gasket during assembly.
  • Page 779 CAUTION: Refer to Safety Glasses Caution in Cautions and Notices. 3. Dry the cover with compressed air. 4. Inspect the gasket sealing surfaces for excessive scratches or gouging. 5. Inspect the cover-to-oil pan threaded bolt holes for damaged threads or debris. 6.
  • Page 780 1. Remove the knock sensor oil seals (520) from the valley cover (555). Fig. 241: Bolts, Baffle Cover, Baffle & Valley Cover Courtesy of GENERAL MOTORS CORP. 2. Remove the bolts (1), baffle cover (2), and baffle (3) from the valley cover (555). 3.
  • Page 781 5. Inspect the gasket sealing surfaces for excessive scratches or gouging. 6. Inspect the oil seal bores for excessive scratching or gouging. 7. Inspect the ventilation tube for a loose fit or restrictions. NOTE: Refer to Fastener Notice in Cautions and Notices. 8.
  • Page 782 Fig. 242: Ignition Coil, Bracket Assembly & Bolts Courtesy of GENERAL MOTORS CORP. IMPORTANT: Do not use the valve rocker arm cover gasket again. Install a NEW gasket during assembly. Remove the ignition coils from the bracket before cleaning the bracket in solvent.
  • Page 783 Do not remove the oil fill tube from the cover unless service is required. If the oil fill tube has been removed from the rocker arm cover, install a NEW tube during assembly. 1. Remove the ignition coil and bracket assembly and bolts from the rocker cover, if required. Fig.
  • Page 784 2. Remove the ignition coils and bolts from the bracket, if required. Fig. 244: View Of Oil Fill Tube Courtesy of GENERAL MOTORS CORP. 3. Inspect the tube for a loose fit or damage.
  • Page 785 4. Remove the oil fill cap and tube from the right cover, if required. Fig. 245: View Of Valve Rocker Arm Cover Gasket Courtesy of GENERAL MOTORS CORP. 5. Remove the gaskets (504) from the covers. 6. Remove the cover mounting bolts, with grommets. Cover mounting bolts and grommets that are not damaged may be used again during assembly.
  • Page 786 Fig. 246: Valve Cover To Cylinder Head View Courtesy of GENERAL MOTORS CORP. CAUTION: Refer to Safety Glasses Caution in Cautions and Notices. 8. Dry the components with compressed air. 9. Inspect the ventilation system passages for restrictions. 10. Inspect the gasket grooves for damage. 11.
  • Page 787 Fig. 247: View Of Left Ignition Coils & Bolts Courtesy of GENERAL MOTORS CORP. 12. Inspect the coil mounting brackets for cracking, stripped bolt hole threads, or other damage. 13. Inspect the ignition coils for exterior damage and bent or broken connector pins. OIL PAN CLEANING AND INSPECTION...
  • Page 788 Fig. 248: Oil Level Sensor & Oil Pan Courtesy of GENERAL MOTORS CORP. IMPORTANT: Do not use the oil pan gaskets again. Install NEW gaskets during assembly. When installing a NEW oil pan gasket, it is not necessary to install the rivets that retain the NEW gasket to the pan.
  • Page 789 Fig. 249: Oil Temperature Sensor, Oil Pan Cover, Bolts, And Gasket Courtesy of GENERAL MOTORS CORP. 2. Remove the oil temperature sensor, oil pan cover, gasket, and bolts.
  • Page 790 Fig. 250: Oil Pan Drain Plug & O-Ring Seal Courtesy of GENERAL MOTORS CORP. 3. Remove the oil pan drain plug and O-ring seal.
  • Page 791 Fig. 251: Drill, Gasket & Oil Pan Gasket Retaining Rivets Courtesy of GENERAL MOTORS CORP. 4. Drill (2) out the oil pan gasket retaining rivets (1), if required. 5. Remove the oil pan gasket (426). 6. Discard the gasket.
  • Page 792 Fig. 252: Oil Pan - Lower - Bolts Courtesy of GENERAL MOTORS CORP. 7. Remove the oil pan - lower - bolts (1-15).
  • Page 793 Fig. 253: Oil Pan - Upper, Gasket, Oil Pan - Lower & Bolts Courtesy of GENERAL MOTORS CORP. 8. Separate the oil pan (400) - upper, gasket (453), oil pan (454) - lower, and bolts (455).
  • Page 794 9. Discard the oil pan gasket. Fig. 254: Oil Pan - Lower - To Crankshaft Oil Deflector, Crankshaft, Or Other Internal Engine Components Courtesy of GENERAL MOTORS CORP. 10. Clean the oil pan halves in solvent. Be sure to thoroughly clean all of the oil passages and recesses of dirt and debris.
  • Page 795 CAUTION: Refer to Safety Glasses Caution in Cautions and Notices. 12. Dry the oil pan with compressed air. 13. Inspect the gasket sealing surfaces for excessive scratches or gouging. Refer to Replacing Engine Gaskets . Fig. 255: Oil Level Sensor & Oil Pan Courtesy of GENERAL MOTORS CORP.
  • Page 796 Fig. 256: Oil Pan Drain Plug & O-Ring Seal Courtesy of GENERAL MOTORS CORP. 15. Inspect the oil pan drain plug and threaded drain hole for damaged threads. The drain plug O-ring seal may be used again if it is not cut or damaged.
  • Page 797 Fig. 257: Oil Temperature Sensor, Oil Pan Cover, Bolts, And Gasket Courtesy of GENERAL MOTORS CORP. 16. Inspect the oil filter and pan cover sealing surface for scratches or gouging. 17. Inspect the oil passages for restrictions.

  • Page 798: Intake Manifold Cleaning And Inspection

    Fig. 258: View Of Oil Filter Fitting & Valve Courtesy of GENERAL MOTORS CORP. 18. Inspect the oil filter fitting (438) for a loose fit or damaged threads. 19. Inspect the oil filter bypass valve (436) for proper operation. Lightly push the bypass valve into the bore. The valve spring should seat the valve to the proper position. INTAKE MANIFOLD CLEANING AND INSPECTION Cleaning Procedure...
  • Page 799 Fig. 259: MAP Sensor Courtesy of GENERAL MOTORS CORP. 1. Remove the manifold absolute pressure (MAP) sensor from the rear of the intake manifold. The MAP sensor is to be installed upon completion of the cleaning and inspection procedures. 2. Inspect the sealing grommet on the MAP sensor. The grommet should not be torn or damaged.
  • Page 800 Fig. 260: Throttle Body & Bolts Courtesy of GENERAL MOTORS CORP. 3. Remove the throttle body.
  • Page 801 Fig. 261: Throttle Body Gasket Courtesy of GENERAL MOTORS CORP. 4. Remove the throttle body gasket (509). 5. Discard the gasket.
  • Page 802 Fig. 262: Fuel Rail & Bolts Courtesy of GENERAL MOTORS CORP. 6. Remove the fuel rail with injectors.
  • Page 803 Fig. 263: Manifold-To-Cylinder Head Gaskets Courtesy of GENERAL MOTORS CORP. 7. Remove and discard the intake manifold-to-cylinder head gaskets (514). 8. Clean the intake manifold in solvent. Clean the intake manifold gasket grooves. Clean the intake manifold vacuum passages at the rear of the intake. CAUTION: Refer to Safety Glasses Caution in Cautions and Notices.
  • Page 804 Fig. 264: Throttle Body & Bolts Courtesy of GENERAL MOTORS CORP. 1. Inspect the throttle body bolt inserts for looseness or damaged threads.
  • Page 805 Fig. 265: Fuel Rail & Bolts Courtesy of GENERAL MOTORS CORP. 2. Inspect the fuel rail bolt inserts for looseness or damaged threads. 3. Inspect the intake manifold vacuum passages for debris or restrictions.
  • Page 806 Fig. 266: MAP Sensor Courtesy of GENERAL MOTORS CORP. IMPORTANT: The manifold absolute pressure (MAP) sensor housing is retained to the intake manifold by push-in-place snap lock design. The MAP sensor housing is sealed at the intake manifold by an O- ring seal.
  • Page 807 5. Inspect the composite intake manifold assembly for cracks or damage. Inspect the areas between the intake runners. 6. Inspect all the gasket sealing surfaces and grooves for cracking or damage. Fig. 267: Fuel Rail & Bolts Courtesy of GENERAL MOTORS CORP.
  • Page 808 7. Inspect the fuel injector bores for excessive scoring or damage. 8. Inspect the intake manifold cylinder head deck for warpage. 1. Locate a straight edge across the intake manifold cylinder head deck surface. 2. Insert a feeler gauge between the intake manifold and the straight edge. A intake manifold with warpage in excess of 0.5 mm (0.02 in), must be replaced.
  • Page 809 Fig. 268: Exhaust Manifold Air Injection Reaction Courtesy of GENERAL MOTORS CORP. IMPORTANT: Do not use the exhaust manifold-to-cylinder head gaskets again. Upon installation of the exhaust manifold, install a NEW gasket. An improperly installed gasket or leaking exhaust system may effect On-Board Diagnostics (OBD) II system performance.
  • Page 810 Fig. 269: Inspecting The Take Down Studs For Damaged Threads Courtesy of GENERAL MOTORS CORP. 9. Inspect the take down studs for damaged threads.
  • Page 811 Fig. 270: Measuring The Exhaust Manifold Cylinder Head For Warpage Courtesy of GENERAL MOTORS CORP. 10. Using a straight edge and a feeler gage, measure the exhaust manifold cylinder head deck for warpage. A exhaust manifold deck with warpage in excess of 0.25 mm (0.01 in), may cause an exhaust leak and may effect OBD II system performance.
  • Page 812 Fig. 271: View Of Pipe, Cover & Gasket Courtesy of GENERAL MOTORS CORP. IMPORTANT: Do not use the engine coolant air bleed pipe and cover gaskets again. Upon installation of the pipe and covers, install NEW gaskets. 1. Remove the sealing gaskets from the pipe. 2.
  • Page 813 Fig. 272: Hose, Clamps & Pipe Courtesy of GENERAL MOTORS CORP. 3. Clean the pipe (307), hose (311), and covers in solvent. CAUTION: Refer to Safety Glasses Caution in Cautions and Notices. 4. Dry the pipe and covers with compressed air. 5.

  • Page 814: Water Pump Cleaning And Inspection

    2004 ENGINE PERFORMANCE Engine Mechanical (Repair Instructions 3 Of 3) - 5.7L - Corvette REPAIR INSTRUCTIONS WATER PUMP CLEANING AND INSPECTION Fig. 1: Old Gasket & Water Pump Sealing Courtesy of GENERAL MOTORS CORP. 1. Remove the old gasket from the water pump sealing surfaces. Refer to Replacing Engine Gaskets . 2.

  • Page 815: Thread Repair

    Excessive side-to-side play in the pulley shaft A loose belt pulley or a pulley with excessive wear or scoring on the belt tracking area Leakage at the water outlet housing or rear cover gasket Leakage at the water pump vent hole A stain around the vent hole is acceptable.
  • Page 816 Fig. 2: View Of Bushing Type Insert & Base Material Courtesy of GENERAL MOTORS CORP. The thread repair process involves a solid, thin walled, self-locking, carbon steel, bushing type insert (1). During the bushing installation process, the driver tool expands the bottom external threads of the insert into the base material (2).
  • Page 817 Fig. 3: Removing Damaged Threads Courtesy of GENERAL MOTORS CORP. CAUTION: Refer to Safety Glasses Caution in Cautions and Notices. IMPORTANT: The use of a cutting type fluid GM P/N 1052864 (Canadian P/N 992881), WD 40(R), or equivalent is recommended when performing the drilling, counterboring, and tapping procedures.
  • Page 818 The tool kits are designed for use with either a suitable tap wrench or drill motor. 1. Drill out the threads of the damaged hole (1). M6 inserts require a minimum drill depth of 15 mm (0.59 in). M8 inserts require a minimum drill depth of 20 mm (0.79 in). M10 inserts require a minimum drill depth of 23.5 mm (0.93 in).
  • Page 819 Fig. 4: View Of Counterbore Drill Courtesy of GENERAL MOTORS CORP. 3. Counterbore the hole to the full depth permitted by the tool (1). 4. Using compressed air, clean out any chips.
  • Page 820 Fig. 5: Removing Damaged Threads Courtesy of GENERAL MOTORS CORP. 5. Using a tap wrench (2), tap the threads of the drilled hole. M6 inserts require a minimum tap depth of 15 mm (0.59 in). M8 inserts require a minimum tap depth of 20 mm (0.79 in). M10 inserts require a minimum tap depth of 23.5 mm (0.93 in).
  • Page 821 Fig. 6: Lubricating Installer Tool Using Driver Oil Courtesy of GENERAL MOTORS CORP. IMPORTANT: Do not allow oil or other foreign material to contact the outside diameter (OD) of the insert. 9. Lubricate the threads of the installer tool (2) with the driver oil (1).
  • Page 822 Fig. 7: View of Bushing Type Insert Courtesy of GENERAL MOTORS CORP. 10. Install the insert (2) onto the driver tool (1).
  • Page 823 Fig. 8: Applying Threadlock LOCTITE(tm) 277, J 42385-109 To Insert Courtesy of GENERAL MOTORS CORP. 11. Apply threadlock LOCTITE(tm) 277, J 42385-109 (1), or equivalent to the insert OD threads (2).
  • Page 824 Fig. 9: Installing Insert Into Bolt Hole Using Installer Tool Courtesy of GENERAL MOTORS CORP. 12. Install the insert (2) into the hole. Install the insert until the flange of the insert contacts the counterbored surface. Continue to rotate the installer tool (1) through the insert.
  • Page 825 The installer tool will tighten up before screwing completely through the insert. This is acceptable. You are forming the bottom threads of the insert and mechanically locking the insert to the base material threads. Fig. 10: View Of Bushing Type Insert & Base Material Courtesy of GENERAL MOTORS CORP.
  • Page 827 Fig. 11: View Of Cylinder Head Bolt Hole Thread Repair Kit Courtesy of GENERAL MOTORS CORP. 1. The cylinder head bolt hole thread repair kit consists of the following items: The drill (1) The tap (2) The installer (3) The sleeve (4) The alignment pin (5) The bushing (6) The bolts (7)
  • Page 828 Fig. 13: View Of Fixture Plate, Bolts, Bushing & Cylinder Hole Courtesy of GENERAL MOTORS CORP. CAUTION: Refer to Safety Glasses Caution in Cautions and Notices. IMPORTANT: The use of a cutting type fluid GM P/N 1052864 (Canadian P/N 992881), WD 40(R), or equivalent is recommended when performing the drilling and tapping procedures.
  • Page 829 3. Install the fixture plate (3), bolts (1), and bushing (2) onto the engine block deck. Position the fixture plate and bushing over the hole that is to be repaired (4). Fig. 14: View Of Alignment Pin & Fixture Retaining Bolt Courtesy of GENERAL MOTORS CORP.
  • Page 830 Fig. 15: Installing Sleeve Onto Drill Courtesy of GENERAL MOTORS CORP. 7. Install the sleeve (2) onto the drill (1), if required.
  • Page 831 Fig. 16: Drilling Cylinder Head Bolt Hole Courtesy of GENERAL MOTORS CORP. IMPORTANT: During the reaming process, it is necessary to repeatedly remove the drill and clean the chips from the hole. 8. Drill out the threads of the damaged hole. Drill the hole until the stop collar of the drill bit or the sleeve contacts the bushing.
  • Page 832 Fig. 17: Tapping Cylinder Head Drilled Hole Using Tap Wrench Courtesy of GENERAL MOTORS CORP. 10. Using a tap wrench, tap the threads of the drilled hole.
  • Page 833 Fig. 18: View Of Tap Upper & Lower Marks, Fixture Plate Bushing Courtesy of GENERAL MOTORS CORP. 11. In order to tap the new threads to the proper depth, rotate the tap into the hole until the marks (1 or 4) on the tap align with the top of the drill bushing (3).
  • Page 834 the top of the drill bushing. 12. Remove the fixture plate (2), bushing (3), and bolts. 13. Using compressed air, clean out any chips. 14. Spray cleaner GM P/N 12346139 (Canadian P/N 10953463), GM P/N 12377981 (Canadian P/N 10953463) or equivalent into the hole. 15.
  • Page 835 16. Lubricate the threads of the installer tool (2) with the driver oil (1). Fig. 20: View of Bushing Type Insert Courtesy of GENERAL MOTORS CORP. 17. Install the insert (2) onto the driver tool (1).
  • Page 836 Fig. 21: Applying Threadlock LOCTITE(tm) 277, J 42385-109 To Insert Courtesy of GENERAL MOTORS CORP. 18. Apply threadlock LOCTITE(tm) 277, J 42385-109 (1), or equivalent to the insert OD threads (2).
  • Page 837 Fig. 22: Installing Insert & Driver Into Cylinder Bolt Hole Courtesy of GENERAL MOTORS CORP. 19. Install the insert and driver (1) into the hole. Rotate the driver tool until the mark on the tool aligns with the deck surface of the engine block. The installer tool will tighten up before screwing completely through the insert.
  • Page 839 Fig. 23: Exploded View Of Main Cap Bolt Hole Thread Repair Kit Courtesy of GENERAL MOTORS CORP. 1. The main cap bolt hole thread repair kit consists of the following items: The drill (1) The tap (2) The installer (3) The fixture plate (4) The long bolts (5) The short bolts (6)
  • Page 840 Fig. 24: View Of Fixture Plate, Bolt & Bushing Courtesy of GENERAL MOTORS CORP. 2. Install the fixture plate, bolt, and bushing, onto the engine block. Position the fixture plate and bushing over the hole that is to be repaired. 3.
  • Page 841 Fig. 25: Main Cap Bolt Hole Tightening Sequence Courtesy of GENERAL MOTORS CORP. 4. Drill out the damaged hole. The outer bolt hole locations (11-20) have the shallower counterbores. Use sleeve J 42385-316 with the drill. Drill until the stop collar of the drill bit or the sleeve contacts the bushing. 5.
  • Page 842 Fig. 26: View Of Tap Upper & Lower Marks, Fixture Plate Bushing Courtesy of GENERAL MOTORS CORP. 6. Using a tap wrench, tap the threads of the drilled hole. In order to tap the new threads to the proper depth, rotate the tap into the hole until the mark on the tap aligns with the top of the bushing.
  • Page 843 For the shallower main cap holes (11-20), rotate the tap until the lower mark (1) on the tap aligns with top of the bushing (3). 7. Using compressed air, clean out any chips. 8. Spray cleaner GM P/N 12346139 (Canadian P/N 10953463) or equivalent into the hole. 9.
  • Page 844 10. Lubricate the threads of the installer tool (2) with the driver oil (1). Fig. 28: View of Bushing Type Insert Courtesy of GENERAL MOTORS CORP. 11. Install the insert (2) onto the driver tool (1).
  • Page 845 Fig. 29: Applying Threadlock LOCTITE(tm) 277, J 42385-109 To Insert Courtesy of GENERAL MOTORS CORP. 12. Apply threadlock LOCTITE(tm) 277, J 42385-109 (1), or equivalent to the insert OD threads (2).
  • Page 846 Fig. 30: Insert & Driver, Driver Tool & Top Of Bushing Courtesy of GENERAL MOTORS CORP. IMPORTANT: The fixture plate and bushing remains installed onto the engine block during the insert installation procedure. 13. Install the insert and driver (1) through the fixture plate and bushing and into the hole. Rotate the driver tool until the mark on the tool (3) aligns with the top of the bushing (2).
  • Page 847 The installer tool will tighten up before screwing completely through the insert. This is acceptable. You are forming the bottom threads of the insert and mechanically locking the insert to the base material threads. SERVICE PRIOR TO ASSEMBLY Dirt or debris will cause premature wear of the rebuilt engine. Clean all the components. Refer to Cleanliness and Care .
  • Page 848 Fig. 31: Engine Oil Filter Courtesy of GENERAL MOTORS CORP. IMPORTANT: A constant and continuous flow of clean engine oil is required in order to properly prime the engine. Be sure to use an approved engine oil as specified in the owners manual. 1.
  • Page 849 3. Locate the engine block left front oil gallery plug (116). 4. Install the M16 x 1.5 adapter P/N 509375. Fig. 32: Flexible Hose, Adapter & Gallery Plugs Courtesy of GENERAL MOTORS CORP.
  • Page 850 5. Install the flexible hose to the adapter and open the valve. 6. Pump the handle on the J 45299 in order to flow a minimum of 1-1.9 liters (1-2 quarts) engine oil. Observe the flow of engine oil through the flexible hose and into the engine assembly. 7.
  • Page 851 Fig. 33: View Of Engine Block Coolant Heater Courtesy of GENERAL MOTORS CORP. IMPORTANT: Engine block plug, including oil gallery, and coolant, and coolant heater, sealing washers may be used again if not bent, scored or otherwise damaged. Apply the proper amount and type of sealant to the sealing washer as recommended in the service procedure.
  • Page 852 2. Install the engine block coolant heater to the engine block, if applicable. Tighten: Tighten the block coolant heater to 40 N.m (30 lb ft). Fig. 34: View Of Engine Block Left Rear Coolant Drain Hole Plug Courtesy of GENERAL MOTORS CORP. 3.
  • Page 853 Fig. 35: Identifying Plug Location On Underside Of Block Courtesy of GENERAL MOTORS CORP. 5. Apply a 3.175 mm (0.125 in) bead of sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the engine block right side coolant drain hole plug sealing washer. 6.
  • Page 854 Fig. 36: View Of Engine Block Left Front Oil Gallery Plug Courtesy of GENERAL MOTORS CORP. 7. Apply a 3.175 mm (0.125 in) bead of sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the engine block left front oil gallery plug sealing washer. 8.
  • Page 855 Fig. 37: View Engine Block Left Rear Oil Gallery Plug Courtesy of GENERAL MOTORS CORP. 9. Apply a 3.175 mm (0.125 in) bead of sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the engine block left rear oil gallery plug sealing washer. 10.
  • Page 857 Fig. 38: View Of Engine Block Rear Oil Gallery Plug Courtesy of GENERAL MOTORS CORP. 11. Inspect the engine block rear oil gallery plug and O-ring seal. If the O-ring seal on the plug is not cut or damaged, the rear oil gallery plug may be used again. 12.
  • Page 858 14. Apply sealant GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the sides of the NEW front oil gallery plug. 15. Install a NEW engine block front oil gallery plug, if required. Install the front oil gallery plug into the oil gallery bore 2.2-2.8 mm (0.0086-0.011 in) below flush.
  • Page 859 17. Use the J 41712 or equivalent in order to install the oil pressure sensor, if required. Tighten: Tighten the oil pressure sensor to 20 N.m (15 lb ft). CRANKSHAFT AND BEARINGS INSTALLATION Tools Required J 45059 Angle Meter...
  • Page 860 Fig. 41: View Of Crankshaft Bearings & Bearing Caps Courtesy of GENERAL MOTORS CORP. IMPORTANT: Crankshaft bearing clearances are critical. Excessive crankshaft bearing clearance may effect crankshaft position (CKP) sensor signals and/or On-Board Diagnostics (OBD) II system performance. Crankshaft bearing caps must be installed to the proper location and direction.
  • Page 861 Fig. 42: View Of Crankshaft & Engine Block Courtesy of GENERAL MOTORS CORP. NOTE: To maintain proper crankshaft end play, use extreme care during crankshaft installation. Avoid scoring or damaging the thrust bearing. 4. Install the crankshaft.
  • Page 862 Fig. 43: View Of Bearing Caps Courtesy of GENERAL MOTORS CORP. IMPORTANT: The bearing caps must be installed in the proper location and direction. 5. Install the crankshaft bearing caps, with bearings, into the engine block. 6. Start the M10 bolts and studs. 7.
  • Page 863 Fig. 44: View Of Bearing Cap Bolts & Studs Courtesy of GENERAL MOTORS CORP. 8. Install the NEW M8 bearing cap side bolts.
  • Page 864 Fig. 45: Main Cap Bolt Hole Tightening Sequence Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Fastener Notice in Cautions and Notices. 9. Tighten the bearing cap M10 bolts and studs. Tighten: Tighten the M10 bolts (1-10) a first pass in sequence to 20 N.m (15 lb ft). IMPORTANT: To properly align the crankshaft thrust bearings, the final thrust of the crankshaft MUST be in the forward direction.
  • Page 865 Tighten the bolt on one side of the bearing cap and then tighten the bolt on the opposite side of the same bearing cap. Fig. 46: View Of CKP Sensor & Bolt Courtesy of GENERAL MOTORS CORP. 11. Install the CKP sensor. 1.

  • Page 866: Piston, Connecting Rod, And Bearing Installation

    Fig. 47: Measuring Crankshaft End Play Courtesy of GENERAL MOTORS CORP. 12. Measure the crankshaft end play. 1. Thrust the crankshaft forward or rearward. 2. Insert a feeler gage between the center crankshaft bearing and the bearing surface of the crankshaft and measure the bearing clearance.
  • Page 867 Piston Selection Fig. 48: Measuring Piston Courtesy of GENERAL MOTORS CORP. IMPORTANT: Measurements of all components should be taken with the components at normal room temperature. For proper piston fit, the engine block cylinder bores must not have excessive wear or taper. A used piston, pin, and connecting rod assembly may be installed if, after inspection is within specifications.
  • Page 868 Fig. 49: Measuring J 8087 Dimension Courtesy of GENERAL MOTORS CORP. 3. Adjust the micrometer to the recorded piston OD. 4. Insert the J 8087 into the micrometer and zero the gage dial.
  • Page 869 Fig. 50: Determining The Cylinder Bore Out-Of-Round Using J 8087 Courtesy of GENERAL MOTORS CORP. 5. Using the J 8087 , measure the cylinder bore inside diameter (ID). Measure at a point 64 mm (2.5 in) from the top of the cylinder. 6.
  • Page 870 Engine Mechanical Specifications (LS1) or Engine Mechanical Specifications (LS6) . 8. If the proper clearance cannot be obtained, select another piston, pin, and connecting rod assembly and again measure the clearances. If the proper fit cannot be obtained, the cylinder bore may require honing for an oversize piston.
  • Page 871 Piston rings Cylinder bore Bearings (3) and bearing surfaces 2. Position the oil control ring end gaps a minimum of 25 mm (1.0 in) from each other. 3. Position the compression ring end gaps 180 degrees opposite each other. Fig. 52: View Of J 41556 & Connecting Rod Courtesy of GENERAL MOTORS CORP.
  • Page 872 Fig. 53: Installing Piston Using J 8037 Courtesy of GENERAL MOTORS CORP. 5. Install the J 8037 onto the piston and compress the piston rings. IMPORTANT: The piston alignment mark MUST face the front of the engine block. 6. Install the piston, pin, and connecting rod assembly into the cylinder bore. Hold the piston ring compressor firmly against the engine block.
  • Page 873 Fig. 54: View Of J 41556 Courtesy of GENERAL MOTORS CORP. 7. Use the J 41556 to guide the connecting rod onto the crankshaft journal. 8. Remove the J 41556 from the connecting rod.
  • Page 874 Fig. 55: View Of Connecting Rod & Bolts Courtesy of GENERAL MOTORS CORP. NOTE: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure.
  • Page 875 lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  • Page 876: Camshaft Installation

    Courtesy of GENERAL MOTORS CORP. 10. Measure the connecting rods for the proper side clearance. Refer to Engine Mechanical Specifications (LS1) or Engine Mechanical Specifications (LS6) . CAMSHAFT INSTALLATION Fig. 57: View Of Bolts installed In Camshaft Front Bolt Holes Courtesy of GENERAL MOTORS CORP.
  • Page 877 NOTE: 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. 3. Using the bolts as a handle, carefully install the camshaft into the engine block. 4.
  • Page 878 The gasket surface on the engine block should be clean and free of dirt or debris. 5. Install the camshaft retainer and the bolts. Tighten: Tighten the camshaft retainer bolts to 25 N.m (18 lb ft). 6. Inspect the camshaft sensor O-ring seal. If the O-ring seal is not cut or damaged, it may be used again. 7.
  • Page 879 8. Install the camshaft position (CMP) sensor and bolt. Tighten: Tighten the CMP sensor bolt to 25 N.m (18 lb ft). TIMING CHAIN AND SPROCKETS INSTALLATION Tools Required J 41665 Crankshaft Balancer and Sprocket Installer Fig. 60: View Of Crankshaft Sprocket Key Courtesy of GENERAL MOTORS CORP.
  • Page 880 Fig. 61: View Of Installed Crankshaft Key Courtesy of GENERAL MOTORS CORP. 2. Tap the key (122) into the keyway until both ends of the key bottom onto the crankshaft.
  • Page 881 Fig. 62: View Of Crankshaft Sprocket Courtesy of GENERAL MOTORS CORP. 3. Install the crankshaft sprocket onto the front of the crankshaft. Align the crankshaft key with the crankshaft sprocket keyway.
  • Page 882 Fig. 63: Installing Crankshaft Sprocket Using J 41665 Courtesy of GENERAL MOTORS CORP. 4. Use the J 41665 in order to install the crankshaft sprocket. Install the sprocket onto the crankshaft until fully seated against the crankshaft flange. 5. Rotate the crankshaft sprocket until the alignment mark is in the 12 o'clock position.
  • Page 883 Fig. 64: Chain Dampener & Bolts Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Fastener Notice in Cautions and Notices. 6. Install the chain dampener (232) and bolts (231). Tighten: Tighten the bolts to 35 N.m (26 lb ft).
  • Page 884 Fig. 65: Chain Dampener & Heads Of Bolts Courtesy of GENERAL MOTORS CORP. 7. With the chain dampener properly installed, the heads of the bolts (231) should install to flush or below the face of the dampener (232).
  • Page 885 Fig. 66: Camshaft Sprocket & Timing Chain Courtesy of GENERAL MOTORS CORP. IMPORTANT: Properly locate the camshaft sprocket locating pin with the camshaft sprocket alignment hole. The sprocket teeth and timing chain must mesh. The camshaft and the crankshaft sprocket alignment marks MUST be aligned properly.
  • Page 886 8. Install the camshaft sprocket and timing chain. Fig. 67: View Of Camshaft & Crankshaft Sprockets Aligned Courtesy of GENERAL MOTORS CORP. 9. If necessary, rotate the camshaft or crankshaft sprockets in order to align the timing marks.
  • Page 887 10. Install the camshaft sprocket bolts. Tighten: Tighten the camshaft sprocket bolts to 35 N.m (26 lb ft). OIL PUMP, PUMP SCREEN AND DEFLECTOR INSTALLATION Fig. 68: Crankshaft Sprocket & Oil Pump Drive Gear Courtesy of GENERAL MOTORS CORP. IMPORTANT: Inspect the oil pump and engine block oil gallery passages. These surfaces must be clear and free of debris or restrictions.
  • Page 888 NOTE: Refer to Fastener Notice in Cautions and Notices. 3. Install the oil pump bolts. Tighten: Tighten the oil pump bolts to 25 N.m (18 lb ft). Fig. 69: Crankshaft Oil Deflector Courtesy of GENERAL MOTORS CORP. 4. Install the crankshaft oil deflector. 5.
  • Page 889 Fig. 70: View Of Oil Pump Screen Courtesy of GENERAL MOTORS CORP. IMPORTANT: Push the oil pump screen tube completely into the oil pump prior to tightening the bolt. Do not allow the bolt to pull the tube into the pump.
  • Page 890 1. Tighten the oil pump screen bolt to 12 N.m (106 lb in). 2. Tighten the crankshaft oil deflector nuts to 25 N.m (18 lb ft). ENGINE REAR COVER INSTALLATION Tools Required J 41480 Front and Rear Cover Alignment - Oil Pan Surface J 41476 Front and Rear Cover Alignment Tool - Crankshaft Oil Seal Area...
  • Page 892 Fig. 71: View Of Engine Block Rear Oil Gallery Plug Courtesy of GENERAL MOTORS CORP. IMPORTANT: Do not use the crankshaft rear oil seal or the engine rear cover gasket again. Do not apply any type sealant to the rear cover gasket, unless specified.
  • Page 893 Fig. 72: View Of Rear Cover, Bolts & Gasket Courtesy of GENERAL MOTORS CORP. 2. Install the rear cover gasket, rear cover and bolts. 3. Tighten the bolts finger tight. Do not overtighten.
  • Page 894 Fig. 73: View Of J 41480 & Bolts Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Fastener Notice in Cautions and Notices. IMPORTANT: Start the J 41480 tool-to-rear cover bolts. Do not tighten the bolts at this time. 4. Install the J 41480 and bolts.
  • Page 895 Tighten: Tighten the tool-to-engine block bolts to 25 N.m (18 lb ft). Fig. 74: View Of J 41480 & J 41476 Removed Courtesy of GENERAL MOTORS CORP. IMPORTANT: To properly align the rear cover, the J 41476 must be installed onto the rear of the crankshaft with the tool mounting bolts parallel to the oil pan surface.
  • Page 896 Fig. 75: View Of J 41480 & J 41476 Installed Courtesy of GENERAL MOTORS CORP. IMPORTANT: The tapered legs of the alignment tool must enter the rear cover oil seal bore. 6. Install the J 41476 and bolts onto the rear of the crankshaft. Tighten: 1.
  • Page 897 7. Remove the tools. Fig. 76: Measuring The Rear Cover-To-Engine Block Oil Pan Surface For Flatness Courtesy of GENERAL MOTORS CORP.

  • Page 898: Crankshaft Rear Oil Seal Installation

    8. Measure the rear cover-to-engine block oil pan surface for flatness. 1. Place a straight edge onto the engine block and rear cover oil pan sealing surfaces. Avoid contact with the portion of the gasket that protrudes into the oil pan surface. 2.
  • Page 899 Fig. 77: View Of Crankshaft Rear Oil Seal Courtesy of GENERAL MOTORS CORP. IMPORTANT: Do not lubricate the oil seal inside diameter (ID) or the crankshaft surface. Do not use the crankshaft rear oil seal again. 1. Lubricate the outside diameter (OD) of the oil seal (141) with clean engine oil. DO NOT allow oil or other lubricants to contact the seal surface.

  • Page 900: Engine Front Cover Installation

    DO NOT allow oil or other lubricants to contact the crankshaft surface. Fig. 78: View Of J 41479 Courtesy of GENERAL MOTORS CORP. 3. Install the J 41479 cone (2) and bolts onto the rear of the crankshaft. 4. Tighten the bolts until snug. Do not overtighten. 5.
  • Page 901 Tools Required J 41480 Front and Rear Cover Alignment - Oil Pan Surface J 41476 Front and Rear Cover Alignment Tool - Crankshaft Oil Seal Area Fig. 79: View Of Front Cover & Gasket Courtesy of GENERAL MOTORS CORP. IMPORTANT: Do not use the crankshaft oil seal or the engine front cover gasket again.
  • Page 902 All gasket surfaces should be free of oil or other foreign material during assembly. The crankshaft front oil seal MUST be centered in relation to the crankshaft. The oil pan sealing surface at the front cover and engine block MUST be aligned within specifications. An improperly aligned front cover may cause premature front oil seal wear and/or engine assembly oil leaks.
  • Page 903 Fig. 80: View Of J 41480 Installed Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Fastener Notice in Cautions and Notices. IMPORTANT: Start the tool-to-front cover bolts. Do not tighten the bolts at this time. 3. Install the J 41480 .
  • Page 904 Tighten: Tighten the tool-to-engine block bolts to 25 N.m (18 lb ft). Fig. 81: View Of J 41476 & J 41480 Installed Courtesy of GENERAL MOTORS CORP. IMPORTANT: Align the tapered legs of the tool with the machined alignment surfaces on the front cover.
  • Page 905 Tighten: 1. Tighten the crankshaft balancer bolt by hand until snug. Do not overtighten. 2. Tighten the J 41480 . 3. Tighten the engine front cover bolts to 25 N.m (18 lb ft). 6. Remove the tools.
  • Page 906 Fig. 82: Measuring The Oil Pan Surface Flatness, Front Cover-To-Engine Block Courtesy of GENERAL MOTORS CORP. 7. Measure the oil pan surface flatness, front cover-to-engine block.
  • Page 907 1. Place a straight edge across the engine block and front cover oil pan sealing surfaces. Avoid contact with the portion of the gasket that protrudes into the oil pan surface. 2. Insert a feeler gage between the front cover and the straight edge tool. The cover must be flush with the oil pan surface or no more than 0.5 mm (0.02 in) below flush.
  • Page 908 Fig. 83: View Of Crankshaft Front Oil Seal Courtesy of GENERAL MOTORS CORP. IMPORTANT: Do not lubricate the oil seal sealing surface. Do not use the crankshaft front oil seal again.
  • Page 909 1. Lubricate the outer edge of the oil seal (140) with clean engine oil. 2. Lubricate the front cover oil seal bore with clean engine oil. Fig. 84: View Of J 41478 Courtesy of GENERAL MOTORS CORP. 3. Install the crankshaft front oil seal onto the J 41478 guide. 4.

  • Page 910: Oil Pan Installation

    3. Remove the tool. 4. Inspect the oil seal for proper installation. The oil seal should be installed evenly and completely into the front cover bore. OIL PAN INSTALLATION Fig. 85: Front Cover Gasket That Protrude & Oil Pan Surface Courtesy of GENERAL MOTORS CORP.
  • Page 911 transmission alignment, it is important that the rear of the block and the rear of the oil pan are flush or even. The rear of the oil pan must NEVER protrude beyond the engine block and transmission housing plane. DO NOT use the oil pan gaskets again. It is not necessary to rivet the NEW gasket to the oil pan.
  • Page 912 Courtesy of GENERAL MOTORS CORP. 2. Apply a 5 mm (0.2 in) bead of sealant GM P/N 12378190 or equivalent 20 mm (0.8 in) long to the engine block. Apply the sealant directly onto the tabs of the rear cover gasket that protrude into the oil pan surface.
  • Page 914 Fig. 87: Oil Pan, Upper Gasket, Bolts & Engine Block Courtesy of GENERAL MOTORS CORP. IMPORTANT: Be sure to align the oil gallery passages in the oil pan and engine block properly with the oil pan gasket. 3. Pre-assemble the oil pan gasket to the pan, upper. 1.
  • Page 915 Fig. 88: Measuring The Oil Pan-To-Engine Block Alignment Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Fastener Notice in Cautions and Notices. 7. Align the oil pan - upper - until the rear of engine block and rear of oil pan are flush or even. Tighten: 1.
  • Page 916 Fig. 89: Oil Pan, Lower & Gasket Courtesy of GENERAL MOTORS CORP. 9. Install the oil pan, lower (454), and gasket (453).
  • Page 917 Fig. 90: Oil Pan & Lower Bolts Courtesy of GENERAL MOTORS CORP. 10. Install the oil pan, lower bolts (1-15). Tighten: Tighten the oil pan, lower bolts to 12 N.m (106 lb in). Tighten the bolts in a crossing pattern, alternating from side to side.
  • Page 918 Fig. 91: Oil Level Sensor Courtesy of GENERAL MOTORS CORP. 11. Install the oil level sensor. Tighten: Tighten the oil level sensor to 13 N.m (115 lb in).
  • Page 919 Fig. 92: View Of Left Closeout Cover & Bolt Courtesy of GENERAL MOTORS CORP. 12. Install the left closeout cover and bolt. Tighten: Tighten the closeout cover bolt to 12 N.m (106 lb in).
  • Page 920 Fig. 93: View Of Right Closeout Cover & Bolt Courtesy of GENERAL MOTORS CORP. 13. Install the right closeout cover and bolt. Tighten: Tighten the closeout cover bolt to 12 N.m (106 lb in). OIL FILTER, ADAPTER, PAN COVER INSTALLATION...
  • Page 921 Fig. 94: Oil Pan Cover Gasket & Oil Temperature Sensor Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Fastener Notice in Cautions and Notices. 1. Install a NEW oil pan cover gasket, the transfer cover and the bolts. Tighten: Tighten the oil pan cover bolts to 12 N.m (106 lb in).
  • Page 922 2. Install the oil temperature sensor. Tighten: Tighten the oil temperature sensor to 20 N.m (15 lb ft). Fig. 95: View Of Oil Filter Fitting & Bypass Valve Courtesy of GENERAL MOTORS CORP. 3. Install a new oil filter bypass valve (436) into the oil pan, if required. 4.
  • Page 923 Fig. 96: Oil Filter Courtesy of GENERAL MOTORS CORP. 5. Install the oil filter. Tighten: Tighten the oil filter to 30 N.m (22 lb ft).

  • Page 924: Valve Lifter Installation

    Fig. 97: Oil Pan Drain Plug Courtesy of GENERAL MOTORS CORP. 6. Install the oil pan drain plug. Tighten: Tighten the oil pan drain plug to 25 N.m (18 lb ft). VALVE LIFTER INSTALLATION...
  • Page 925 Fig. 98: View Of Valve Lifters Removed From Guide Courtesy of GENERAL MOTORS CORP. IMPORTANT: When using the valve lifters again, install the lifters to their original locations. If camshaft replacement is required, the valve lifters must also be replaced. 1.
  • Page 926 Fig. 99: View Of Valve Lifters, Guide & Guide Bolts Courtesy of GENERAL MOTORS CORP. 3. Install the valve lifters and guide assembly to the engine block. NOTE: Refer to Fastener Notice in Cautions and Notices. 4. Install the valve lifter guide bolt (211). Tighten: Tighten the valve lifter guide bolt to 12 N.m (106 lb in).
  • Page 927 Tools Required J 42385-100 Head/Main Bolt Thread Repair Kit J 45059 Angle Meter Fig. 100: View Of 100 mm & 155 mm Bolts Courtesy of GENERAL MOTORS CORP. CAUTION: Refer to Safety Glasses Caution in Cautions and Notices.
  • Page 928 NOTE: Clean all dirt, debris, 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 components. IMPORTANT: Do not use the cylinder head bolts again. Install NEW cylinder head bolts during assembly.
  • Page 929 Fig. 101: View Of Cylinder Head Locating Pins Installation Position Courtesy of GENERAL MOTORS CORP. 5. Check the cylinder head locating pins for proper installation.
  • Page 930 Fig. 102: View Of Cylinder Head Gasket (Left) Courtesy of GENERAL MOTORS CORP. 6. Install the NEW left cylinder head gasket onto the locating pins.
  • Page 931 Fig. 103: Left Cylinder Head Gasket Courtesy of GENERAL MOTORS CORP. IMPORTANT: When properly installed, the tab on the left cylinder head gasket is located left of center, or closer to the front of the engine, and the words "This Side Up", and the engine displacement, is visible.
  • Page 932 Fig. 104: View Of Cylinder Head & Bolts (Left) Courtesy of GENERAL MOTORS CORP. 8. Install the cylinder head onto the locating pins and the gasket. 9. Install the NEW cylinder head bolts.
  • Page 933 Fig. 105: Cylinder Head Bolt Tightening Sequence (Right) Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Fastener Notice in Cautions and Notices. 10. Tighten the first design cylinder head bolts. Tighten: 1. Tighten the first design M11 cylinder head bolts a first pass in sequence to 30 N.m (22 lb ft). 2.
  • Page 934 CYLINDER HEAD INSTALLATION - RIGHT Tools Required J 42385-100 Head/Main Bolt Thread Repair Kit J 45059 Angle Meter Fig. 106: View Of 100 mm & 155 mm Bolts Courtesy of GENERAL MOTORS CORP. CAUTION: Refer to Safety Glasses Caution in Cautions and Notices.
  • Page 935 NOTE: Clean all dirt, debris, 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 components. IMPORTANT: Do not use the cylinder head bolts again. Install NEW cylinder head bolts during assembly.
  • Page 936 Fig. 107: View Of Cylinder Head Locating Pins Installation Position Courtesy of GENERAL MOTORS CORP. 5. Check the cylinder head locating pins for proper installation.
  • Page 937 Fig. 108: View Of Cylinder Head Gasket (Right) Courtesy of GENERAL MOTORS CORP. 6. Install the NEW right cylinder head gasket onto the locating pins.
  • Page 938 Fig. 109: Right Cylinder Head Gasket Courtesy of GENERAL MOTORS CORP. IMPORTANT: When properly installed, the tab on the right cylinder head gasket is located right of center, or closer to the front of the engine, and the words "This Side Up", and the engine displacement is visible. 7.
  • Page 939 Fig. 110: View Of Cylinder Head & Bolts Courtesy of GENERAL MOTORS CORP. 8. Install the cylinder head onto the locating pins and the gasket. 9. Install the NEW cylinder head bolts.
  • Page 940 Fig. 111: Cylinder Head Bolt Tightening Sequence (Right) Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Fastener Notice in Cautions and Notices. 10. Tighten the first design cylinder head bolts. Tighten: 1. Tighten the first design M11 cylinder head bolts (1-10) a first pass in sequence to 30 N.m (22 lb ft). 2.

  • Page 941: Valve Rocker Arm And Push Rod Installation

    VALVE ROCKER ARM AND PUSH ROD INSTALLATION Fig. 112: View Of Valve Rocker Arm Pivot Support Courtesy of GENERAL MOTORS CORP. IMPORTANT: When using the valve train components again, always install the components to the original location and position. Valve lash is net build, no valve adjustment is required. 1.
  • Page 942 3. Install the valve rocker arm pivot support. Fig. 113: View Of Pushrods Courtesy of GENERAL MOTORS CORP. IMPORTANT: Ensure that the pushrods seat properly to the valve lifter sockets. 4. Install the pushrods.
  • Page 943 Fig. 114: View Of Valve Rocker Arms Courtesy of GENERAL MOTORS CORP. IMPORTANT: Ensure that the pushrods seat properly to the ends of the rocker arms. DO NOT tighten the rocker arm bolts at this time. 5. Install the rocker arms and bolts.
  • Page 944 Fig. 115: View of Crankshaft Courtesy of GENERAL MOTORS CORP. 6. Rotate the crankshaft until number one piston is at top dead center of compression stroke. In this position, cylinder number one rocker arms will be off lobe lift, and the crankshaft sprocket key...
  • Page 945 will be at the 1:30 position. If viewing from the rear of the engine, the additional crankshaft pilot hole, non-threaded, will be in the 10:30 position. The engine firing order is 1, 8, 7, 2, 6, 5, 4, 3. Cylinders 1, 3, 5 and 7 are left bank. Cylinders 2, 4, 6, and 8 are right bank.
  • Page 946 Fig. 116: View Of Valve Rocker Arm Cover Gasket Courtesy of GENERAL MOTORS CORP. IMPORTANT: All gasket surfaces should be free of oil or other foreign material during assembly. DO NOT use the valve rocker arm cover gasket again. The valve rocker arm cover bolt grommets may be used again. 1.
  • Page 947 Fig. 117: Valve Cover To Cylinder Head View Courtesy of GENERAL MOTORS CORP. 2. Install the valve rocker arm cover onto the cylinder head. NOTE: Refer to Fastener Notice in Cautions and Notices. 3. Install the cover bolts with grommets. Tighten: Tighten the valve rocker arm cover bolts to 12 N.m (106 lb in).
  • Page 948 Fig. 118: View Of Ignition Coils Courtesy of GENERAL MOTORS CORP. 4. Install the ignition coils, wire harness, and bolts onto the mounting bracket. Tighten: Tighten the ignition coil bolts to 12 N.m (106 lb in).
  • Page 949 Fig. 119: Ignition Coil Bracket Bolts & Rocker Cover Courtesy of GENERAL MOTORS CORP. 5. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the threads of the bracket bolts. 6. Install the ignition coils and bracket assembly and bolts onto the rocker cover. Tighten: Tighten the ignition coil bracket bolts to 12 N.m (106 lb in).
  • Page 950 7. Install the crankcase ventilation hose. VALVE ROCKER ARM COVER INSTALLATION - RIGHT Fig. 120: View Of Oil Fill Tube Courtesy of GENERAL MOTORS CORP.
  • Page 951 IMPORTANT: All gasket surfaces should be free of oil or other foreign material during assembly. DO NOT use the valve rocker arm cover gasket again. The valve rocker arm cover bolt grommets may be used again. If the oil fill tube has been removed from the valve rocker arm cover, install a NEW oil fill tube during assembly.
  • Page 952 Fig. 121: View Of Valve Rocker Arm Cover Gasket Courtesy of GENERAL MOTORS CORP. 4. Install a NEW gasket (504) into the valve rocker arm cover. Fig. 122: View Of Valve Rocker Arm Cover & Bolts (Right) Courtesy of GENERAL MOTORS CORP. 5.
  • Page 953 6. Install the cover bolts with grommets. Tighten: Tighten the valve rocker arm cover bolts to 12 N.m (106 lb in). Fig. 123: View Of Ignition Coils Courtesy of GENERAL MOTORS CORP. 7. Install the ignition coils, wire harness, and bolts onto the mounting bracket. Tighten: Tighten the ignition coil bolts to 12 N.m (106 lb in).
  • Page 954 Fig. 124: Ignition Coil Bracket Bolts & Rocker Cover Courtesy of GENERAL MOTORS CORP. 8. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the threads of the bracket bolts. 9. Install the ignition coils and bracket assembly and bolts to the rocker cover. Tighten: Tighten the ignition coil bracket bolts to 12 N.m (106 lb in).
  • Page 955 10. Install the crankcase ventilation hoses to the cover. ENGINE VALLEY COVER INSTALLATION Fig. 125: Knock Sensor Oil Seals & Valley Cover Courtesy of GENERAL MOTORS CORP. IMPORTANT: All gasket surfaces should be free of oil or other foreign material during assembly.
  • Page 956 Fig. 126: Valley Cover & Gasket Courtesy of GENERAL MOTORS CORP. 2. Install the valley cover and NEW gasket. NOTE: Refer to Fastener Notice in Cautions and Notices. 3. Install the valley cover bolts. Tighten: Tighten the valley cover bolts to 25 N.m (18 lb ft).
  • Page 957 Fig. 127: View Of Knock Sensors Courtesy of GENERAL MOTORS CORP. 4. Install the knock sensors. Tighten: Tighten the knock sensors to 20 N.m (15 lb ft).
  • Page 958 Fig. 128: View Of Knock Sensor Wire Harness Courtesy of GENERAL MOTORS CORP. 5. Install the knock sensor wire harness. COOLANT AIR BLEED PIPE INSTALLATION...
  • Page 959 Fig. 129: View Of Pipe & Cover Gasket Courtesy of GENERAL MOTORS CORP. IMPORTANT: Install the pipe gaskets properly onto the pipe and covers. Position the gasket O-ring seal onto the nipple portion of the pipe. 1. Install the gaskets onto the engine coolant air bleed pipe and covers.
  • Page 960 Fig. 130: Pipe, Gaskets & Cylinder Heads Courtesy of GENERAL MOTORS CORP. 2. Install the pipe (307) and gaskets (308) onto the cylinder heads. NOTE: Refer to Fastener Notice in Cautions and Notices. 3. Install the pipe studs (309). Install the two pipe studs to the front of the engine. Tighten: Tighten the pipe studs to 12 N.m (106 lb in).
  • Page 961 Fig. 131: View Of Engine Coolant Air Bleed Cover, Gasket & Bolts Courtesy of GENERAL MOTORS CORP. 4. Install the covers (313), gaskets (308), and bolts (312) onto the rear of the engine. Tighten: Tighten the cover bolts to 12 N.m (106 lb in).

  • Page 962: Intake Manifold Installation

    Fig. 132: Hose, Clamps & Pipe Courtesy of GENERAL MOTORS CORP. 5. Install the hose (311) and clamps (310) onto the pipe (307). INTAKE MANIFOLD INSTALLATION...
  • Page 963 Fig. 133: Manifold-To-Cylinder Head Gaskets Courtesy of GENERAL MOTORS CORP. IMPORTANT: The intake manifold, throttle body, fuel injection rail and fuel injectors may be removed as an assembly. If not servicing the individual components, install the intake manifold as a complete assembly.
  • Page 964 Fig. 134: Intake Manifold & Engine Courtesy of GENERAL MOTORS CORP. 2. Install the intake manifold to the engine.
  • Page 965 Fig. 135: Fuel Rail Stop Bracket Courtesy of GENERAL MOTORS CORP. 3. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the threads of the intake manifold bolts (713). Refer to Sealers, Adhesives, and Lubricants . 4. Install the fuel rail stop bracket (712).
  • Page 966 Fig. 136: Intake Manifold Bolt Tightening Sequence Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Fastener Notice in Cautions and Notices. 5. Install the manifold bolts. Tighten: 1. Tighten intake manifold bolts a first pass in sequence to 5 N.m (44 lb in). 2.
  • Page 967 Fig. 137: Knock Sensor Wire Harness Connector & Fuel Rail Stop Bracket Courtesy of GENERAL MOTORS CORP. 6. Install the knock sensor wire harness connector (1) onto the fuel rail stop bracket (712).
  • Page 968 Fig. 138: Fuel Rail Ground Strap & Intake Manifold Courtesy of GENERAL MOTORS CORP. 7. Note the location of the fuel rail ground strap (550) on the intake manifold.
  • Page 969 The fuel rail ground strap must be installed during assembly. Fig. 139: Manifold Absolute Pressure (MAP) Sensor Courtesy of GENERAL MOTORS CORP. 8. Install the manifold absolute pressure (MAP) sensor, if previously removed.
  • Page 970 Fig. 140: PCV Dirty Air Pipe, Valley Cover & Intake Manifold Courtesy of GENERAL MOTORS CORP. 9. Install the positive crankcase ventilation (PCV) pipe - dirty air (716) to the valley cover and intake manifold. FUEL RAIL AND INJECTORS INSTALLATION...
  • Page 971 Fig. 141: Fuel Rail Ground Strap & Intake Manifold Courtesy of GENERAL MOTORS CORP. IMPORTANT: DO NOT use fuel injector O-ring seals again. Install NEW fuel injector O-...
  • Page 972 ring seals during assembly. 1. Lubricate the NEW fuel injector O-ring seals with clean engine oil. 2. Install the O-ring seals onto the fuel injectors. 3. Note the location of the fuel rail ground strap (550) on the intake manifold. The fuel rail ground strap must be installed during assembly.

  • Page 973: Throttle Body Installation

    Fig. 142: Fuel Rail To Intake Mounting View Courtesy of GENERAL MOTORS CORP. 4. Install the fuel rail, with fuel injectors, into the intake manifold. Press evenly on both sides of the fuel rail until all of the injectors are seated in their bores. 5.
  • Page 974 Fig. 143: Throttle Body Gasket & Intake Manifold Courtesy of GENERAL MOTORS CORP. NOTE: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components.

  • Page 975: Water Pump Installation

    Fig. 144: View Of Throttle Body Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Fastener Notice in Cautions and Notices. 2. Install the throttle body and bolts. Tighten: Tighten the throttle body bolts to 12 N.m (106 lb in). 3. Install the engine coolant air bleed hose and clamp. WATER PUMP INSTALLATION...
  • Page 976 Fig. 145: Old Gasket & Water Pump Sealing Courtesy of GENERAL MOTORS CORP. NOTE: DO NOT use cooling system seal tabs, or similar compounds, unless otherwise instructed. The use of cooling system seal tabs, or similar compounds, may restrict coolant flow through the passages of the cooling system or the engine components.
  • Page 977 Tighten: 1. Tighten the water pump bolts a first pass to 15 N.m (11 lb ft). 2. Tighten the water pump bolts a final pass to 30 N.m (22 lb ft). EXHAUST MANIFOLD INSTALLATION - LEFT Fig. 146: Exhaust Manifold Gasket & Bolts Courtesy of GENERAL MOTORS CORP.
  • Page 978 equivalent to the threads of the exhaust manifold bolts. 2. Install the exhaust manifold and NEW exhaust manifold gasket. NOTE: Refer to Fastener Notice in Cautions and Notices. 3. Install the exhaust manifold bolts. Tighten: 1. Tighten the exhaust manifold bolts a first pass to 15 N.m (11 lb ft). Tighten the exhaust manifold bolts beginning with the center 2 bolts.
  • Page 979 Fig. 147: AIR Pipe & Exhaust Manifold Bolts Courtesy of GENERAL MOTORS CORP. 6. Install the air injection reaction (AIR) pipe, with check valve, NEW gasket, and bolts. Tighten: Tighten the AIR pipe to exhaust manifold bolts to 20 N.m (15 lb ft).
  • Page 980 Fig. 148: Oxygen Sensor & Intake Manifold Courtesy of GENERAL MOTORS CORP. 7. Install the oxygen sensor into the intake manifold. Tighten: Tighten the oxygen sensor to 42 N.m (30 lb ft). EXHAUST MANIFOLD INSTALLATION - RIGHT...
  • Page 981 Fig. 149: Exhaust Manifold Gasket & Exhaust Manifold Courtesy of GENERAL MOTORS CORP. IMPORTANT: Tighten the exhaust manifold bolts as specified in the service procedure. Improperly installed and/or leaking exhaust manifold gaskets may effect vehicle emissions and/or On-Board Diagnostics (OBD) II system performance. The cylinder head exhaust manifold bolt hole threads must be clean and free of debris or threadlocking material.
  • Page 982 equivalent to the threads of the exhaust manifold bolts. 2. Install the exhaust manifold gasket and exhaust manifold. NOTE: Refer to Fastener Notice in Cautions and Notices. 3. Install the exhaust manifold bolts. Tighten: 1. Tighten the exhaust manifold bolts first pass to 15 N.m (11 lb ft). Tighten the exhaust manifold bolts beginning with the center 2 bolts.
  • Page 983 Fig. 150: Air Pipe, Check Valve, Gasket & Bolts Courtesy of GENERAL MOTORS CORP. 6. Install the air injection reaction (AIR) pipe, with check valve, NEW gasket, and bolts.

  • Page 984: Oil Level Indicator And Tube Installation

    Fig. 151: AIR Tube Bolt To Left Rear Cylinder Head Courtesy of GENERAL MOTORS CORP. 7. Install the AIR tube bolt to the left rear cylinder head. Tighten: 1. Tighten the AIR pipe to exhaust manifold bolts to 20 N.m (15 lb ft). 2.
  • Page 985 Fig. 152: O-Ring Seal, Oil Level Indicator Tube & Engine Block Courtesy of GENERAL MOTORS CORP. 1. Inspect the O-ring seal for cuts or damage. If the oil level indicator tube O-ring seal is not cut or damaged, it may be used again. 2.
  • Page 986 Tighten: Tighten the oil level indicator tube bolt to 16 N.m (12 lb ft). 6. Install the oil level indicator into the tube. CLUTCH PILOT BEARING INSTALLATION Tools Required J 38836 Pilot Bushing Installer/Clutch Fig. 153: 5/8 Inch Washer, Pilot Bearing & Courtesy of GENERAL MOTORS CORP.
  • Page 987 Fig. 154: J 38836 & Pilot Bearing Courtesy of GENERAL MOTORS CORP. 3. Install the new pilot bearing into the crankshaft using the J 38836 .

  • Page 989: Engine Flywheel Installation

    Fig. 155: Clutch Pilot Bearing & Rear Face Of Crankshaft Courtesy of GENERAL MOTORS CORP. 4. Inspect the clutch pilot bearing for proper installation. A properly installed clutch pilot bearing will be installed until flush to the rear face of the crankshaft. ENGINE FLYWHEEL INSTALLATION Fig.
  • Page 990 original position and direction. The engine flywheel will not initially seat against the crankshaft flange, but will be pulled onto the crankshaft by the engine flywheel bolts. This procedure requires a three stage tightening process. DO NOT remove the propshaft hub or flexplate from the automatic transmission engine flywheel.
  • Page 991 Fig. 158: Flywheel Bolt Tightening Sequence Courtesy of GENERAL MOTORS CORP. 3. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the threads of the flywheel bolts. NOTE: Refer to Fastener Notice in Cautions and Notices. 4. Install the engine flywheel bolts. Tighten:...
  • Page 992 1. Tighten the engine flywheel bolts first pass in sequence to 20 N.m (15 lb ft). 2. Tighten the engine flywheel bolts second pass in sequence to 50 N.m (37 lb ft). 3. Tighten the engine flywheel bolts final pass in sequence to 100 N.m (74 lb ft). CRANKSHAFT BALANCER INSTALLATION Tools Required J 41665 Crankshaft Balancer and Sprocket Installer...
  • Page 993 Fig. 159: Install J 42386 Crankshaft Balancer Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Fastener Notice in Cautions and Notices. IMPORTANT: Note the position of the crankshaft balancer before removal, on manual transmission applications. The balancer does not use a key or keyway for positioning.
  • Page 994 Fig. 160: Balance Weights Courtesy of GENERAL MOTORS CORP. 2. Using the old balancer as a reference, mark or scribe the NEW balancer in the same location, if required. Install balance weights into the NEW balancer, if required. Refer to Engine Balancing and Crankshaft Balancer Cleaning and Inspection .
  • Page 995 Fig. 161: Identifying Harmonic Balancer Bolt Courtesy of GENERAL MOTORS CORP. IMPORTANT: Align the scribe mark on the balancer with the scribe mark on the crankshaft. The balancer should be positioned onto the end of the crankshaft, as straight as possible, prior to tool installation. 3.
  • Page 996 Fig. 162: View Of J 41665 Courtesy of GENERAL MOTORS CORP. 4. Use the J 41665 in order to install the balancer. 1. Assemble the threaded rod, nut, washer and installer. Insert the smaller end of the installer into the front of the balancer. 2.
  • Page 997 Position the larger end of the installer against the front of the balancer. 5. Use a wrench and hold the hex end of the threaded rod. 6. Use a second wrench and rotate the installation tool nut clockwise until the balancer is installed onto the crankshaft.
  • Page 998 Fig. 163: View Of Balancer Proper Installation Position Courtesy of GENERAL MOTORS CORP. 5. Install the used crankshaft balancer bolt. Tighten: Tighten the crankshaft balancer bolt to 330 N.m (240 lb ft).
  • Page 999 6. Remove the used crankshaft balancer bolt. IMPORTANT: The nose of the crankshaft should be recessed 2.40-4.48 mm (0.094-0.176 in) into the balancer bore. 7. Measure for a correctly installed balancer. If the balancer is not installed to the proper dimensions, install the J 41665 and repeat the installation procedure.
  • Page 1000 1. Tighten the crankshaft balancer bolt a first pass to 50 N.m (37 lb ft). 2. Tighten the crankshaft balancer bolt a second pass to 140 degrees using the J 45059 . 9. Remove the J 42386-A .

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