GM 8.1 L
GM 8.1 L
GM 8.1 L
Service Manual
8.1L
L510003
Engine
Metric
25 Nm
12 Nm
50 Nm
English
19 lb ft
106 lb in
37 lb ft
12 Nm
12 Nm
12 Nm
30 Nm
30 Nm + 90 Degrees
106 lb in
106 lb in
106 lb in
22 lb ft
22 lb ft + 90 Degrees
60 Nm
20 Nm
255 Nm
44 lb ft
15 lb ft
189 lb ft
30 Nm
22 lb ft
90 Degrees
30 Nm
22 lb ft
80 Degrees
50 Nm
12 Nm
37 lb ft
106 lb in
30 Nm
22 lb ft
30 Nm + 120 Degrees 22 lb ft + 120 Degrees
60 Degrees
45 Degrees
30 Degrees
23 Nm
17 lb ft
50 Nm
37 lb ft
30 Nm
22 lb ft
30 Nm
22 lb ft
30 Nm
22 lb ft
50 Nm
37 lb ft
30 Nm
22 lb ft
12 Nm
106 lb in
20 Nm
15 lb ft
50 Nm
37 lb ft
35 Nm
26 lb ft
2001 Marine/Industrial
Engine
Metric
16 Nm
20 Nm
English
12 lb ft
15 lb ft
25 Nm
25 Nm
100 Nm
12 Nm
19 lb ft
19 lb ft
74 lb ft
106 lb in
67 Nm
60 Nm
12 Nm
12 Nm
12 Nm
12 Nm
12 Nm
20 Nm
12 Nm
50 Nm
12 Nm
23 Nm
12 Nm
38 Nm
66 Nm
50 lb ft
44 lb ft
106 lb in
106 lb in
106 lb in
106 lb in
106 lb in
15 lb ft
106 lb in
37 lb ft
106 lb in
17 lb ft
106 lb in
12 lb ft
49 lb ft
30 Nm
30 Nm
30 Nm
20 Nm
18 Nm
14 Nm
25 Nm
28 Nm
30 Nm
75 Nm
12 Nm
25 Nm
10 Nm
20 Nm
30 Nm
22 lb ft
22 lb ft
22 lb ft
15 lb ft
13 lb ft
10 lb ft
18 lb ft
21 lb ft
22 lb ft
56 lb ft
106 lb in
19 lb ft
88 lb in
15 lb ft
22 lb ft
10 Nm
12 Nm
88 lb in
106 lb in
Engine
Application
Transmission Converter Cover Bolts
Valve Lifter Guide Retainer Bolt
Valve Rocker Arm Cover Bolt
Valve Rocker Arm Nut
Valve Rocker Arm Stud
Water Crossover Pipe Bolt
Water Pump Bolt
Water Pump Pulley Bolt
Metric
12 Nm
25 Nm
12 Nm
25 Nm
50 Nm
50 Nm
50 Nm
25 Nm
English
106 lb in
19 lb ft
106 lb in
19 lb ft
37 lb ft
37 lb ft
37 lb ft
19 lb ft
2001 Marine/Industrial
Engine
Engine Mechanical Specifications
Specification
Application
Metric
English
General Data
Engine Type
V-8
RPO
L18
Displacement
8.1L
496 CID
Bore
107.950 mm
4.250 in
Stroke
111.00 mm
4.370 in
Compression Ratio
9.1:1
Firing Order
Spark Plug Gap
1-8-7-2-6-5-4-3
1.52 mm
0.060 in
Cylinder Head
Surface Flatness
0.050 mm
0.002 in
0.3048 mm
0.012 in
0.254 mm
0.010 in
Exhaust Manifold
Surface Flatness
Lubrication System
Oil Capacity without Filter Change
10 psi @ 2,000RPM
Full Flow
Gear Driven
Cylinder Bore
Diameter - Production
Diameter - Service
Out-of-Round Production (Maximum Minus Minimum Bore Diameter)
107.950-107.968 mm
4.2500-4.2507 in
107.940-107.990 mm
4.2496-4.2516 in
0.0180 mm (Maximum)
0.0007 in (Maximum)
0.050 mm (Maximum)
0.002 IN (Maximum)
Taper Production
0.0180 mm (Maximum)
0.0007 in (Maximum)
0.050 mm (Maximum)
0.002 in (Maximum)
0.050 mm (Maximum)
0.002 in (Maximum)
74.6060-74.6220 mm
2.9372-2.9379 in
21.417-21.443 mm
0.843-0.844 in
259.875-260.125 mm
10.231-10.241 in
0.100 mm
0.004 in
0.050 mm
0.002 in
Not Measurable
Not Measurable
Piston
Piston Diameter (Coated Piston)
Clearance Prodution
0.031-0.074 mm
0.0012-0.0029 in
0.031-0.074 mm
0.0012-0.0029 in
0.300-0.450 mm
0.012-0.018 in
0.450-0.675 mm
0.018-0.027 in
0.450-0.650 mm
0.017-0.025 in
0.675-0.975 mm
0.026-0.039 in
0.051-0.203 mm
0.002-0.008 in
Production Gap
0.249-0.759 mm
0.0098-0.0299 in
0.373-1.138 mm
0.015-0.045 in
Piston Pin
Diameter
Fit in Connecting Rod
2001 Marine/Industrial
26.416-26.419 mm
1.0400-1.0401 in
0.049-0.020 mm
0.00019-0.0007 in
Interference
Interference
Engine
Crankshaft
Crankshaft Main Journal Runout - Production
0.0380 mm (Maximum)
0.0015 in (Maximum)
0.0510 mm (Maximum)
0.0020 in (Maximum)
69.805-69.822 mm
2.7482-2.7489 in
0.0102 mm (Maximum)
0.0004 in (Maximum)
0.0102 mm (Maximum)
0.0004 in (Maximum)
0.022-0.052 mm
0.0008-0.0020 in
0.035-0.067 mm
0.0014-0.0026 in
0.022-0.089 mm
0.0008-0.0035 in
0.035-0.102 mm
0.0014-0.0040 in
0.127-0.279 mm
0.0050-0.0110 in
Crankpin Diameter
Crankpin Taper Production
Crankpin Taper Service Limit
Crankpin Out-of-Round Production
Crankpin Out-of-Round Service Limit
55.854-55.870 mm
2.1990-2.1996 in
0.0102 mm (Maximum)
0.0004 in (Maximum)
0.0102 mm (Maximum)
0.0004 in (Maximum)
0.021-0.064 mm
0.0008-0.0025 in
0.021-0.081 mm
0.0008-0.0032 in
0.384-0.686 mm
0.0151-0.0270 in
Camshaft
Camshaft Runout - Production
0.051 mm (Maximum)
0.003 in (Maximum)
0.076 mm (Maximum)
0.002 in (Maximum)
6.924-7.026 mm
0.2726-0.2766 in
6.973-7.075 mm
0.2745-0.2785 in
Journal Diameter
49.472-49.522 mm
1.9477-1.9479 in
49.5480-49.5730 mm
1.9507-1.9517 in
1.70:1
Net Lash
Net Lash
45 degrees
46 degrees
0.050 mm (Maximum)
0.002 in (Maximum)
0.800-1.200 mm
0.030-0.060 in
1.651-2.159 mm
0.060-0.095 in
0.025-0.0740 mm
0.0010-0.0029 in
0.030-0.079 mm
0.0012-0.0031 in
381-419 N@
45.923 mm
86-94 lb@1.808 in
962-1058 N@
33.985 mm
216-236 lb@1.338 in
45.923-46.685 mm
1.808-1.838 in
56.35 mm
2.218 in
55.63 mm
2.19 in
43.69 mm
1.72 in
9.436-9.454 mm
0.3715-0.3722 in
9.431-9.449 mm
0.3713-0.3720 in
2001 Marine/Industrial
Engine
0.726 mm
0.030 in
0.726 mm
0.030 in
1.524 mm
0.060 in
Camshaft
0.519
Camshaft Sprocket
0.736
0.724
Crankshaft
0.646
0.096
Crankshaft Sprocket
0.728
Connecting Rod
0.603
Cylinder Head
0.269
0.289
2.363
3.670
3.680
Exhaust Manifold
3.601
3.270
0.206
0.207
3.265
Oil Filter
1.836
1.516
Oil Pan
1.426
1.429
1.723
1.724
1.652
0.643
Spark Plug
2.270
Valve Lifter
0.459
Thermostat
1.246
Valve Pushrod
0.426
0.333
0.423
1.069
2001 Marine/Industrial
Engine
Type of Material
GM Part Number
Sealant
12346004
Sealant
12377901
Sealant
12346004
Thread Adhesive
12345493
Sealant
1052942
Sealant
12346004
Sealant
12346004
Sealant
12346004
Sealant
12346286
Lubricant
1051396
Thread Adhesive
12345382
Sealant
12346004
Lubricant
9985770
Sealant
12346004
Sealant
12346286
Sealant
12346004
Thread Adhesive
12345493
Lubricant
1052367
Sealant
12346004
2001 Marine/Industrial
Engine
Action
Engine Performance diagnosis procedures are covered in Engine Controls and should be consulted for diagnosis of any
Drivability, Emissions or Malfunctioning Indicator Lamp (MIL) concerns.
The following diagnosis covers common concerns and possible causes.
When the proper diagnosis is made, the concern should be corrected by adjustment, repair or replacement as required.
Refer to the appropriate section of the service manual for each specific procedure.
This diagnostic table will assist in engine misfire diagnosis due to a mechanical concern such as a faulty engine camshaft,
worn or damaged bearings or bent valve pushrod.
Thsi table will not isolate a crossed fuel injector wire, faulty fuel injector or any other drivability component failure that may
cause a misfire.
The Powertrain On-Board Diagnostic System checks must be performed first.
When using this table to make a Base Engine Misfire diagnosis, begin with the preliminary information below and then
proceed to the specific category.
Preliminary
1. Perform DTC P0300 before proceeding with Base Engine Misfire Diagnosis
information.
DTC P0300 will assist in determining which cylinder or cylinders are misfiring.
2. Perform a visual inspection of the following:
A loose or improperly isnstalled engine flywheel or crankshaft balancer
Worn, damaged or misaligned accessory drive system components
3. Listen to the engine for any abnormal internal engine noises.
4. Inspect the engine for acceptable oil pressure.
5. Verify if the engine has excessive oil consumption.
6. Verify if the engine has excessive coolant consumption.
7. Perform a compression test on the engine.
Coolant Consumption
Oil Consumption
2001 Marine/Industrial
Engine
Action
1. Start the engine and determine if the noise is timed to the engine camshaft speed or
the crankshaft speed.
2. Using a timing light, two knocks per flash is the crankshaft speed and one knock
per flash is the engine camshaft speed.
3. If the noise is timed to the engine camshaft speed, inspect the following:
Missing or loose valve train components
Worn or loose valve rocker arms
Worn or bent valve pushrods
Faulty valve springs
Bent or burnt valves
Worn engine camshaft lobes
Worn or damaged camshaft timing chain and/or sprockets
Important: A slight COLD knock or piston slapping noise could be considered normal
if not present after the engine has reached normal operating temperatures.
If the knock is timed to the crankshaft speed, inspect the following:
Worn crankshaft or connecting rod bearings
Piston ro cylinder damage
Worn piston or piston pin
Faulty connecting rod
Excessive carbon build-up on the top of the piston
1. Inspect for a worn or improperly installed camshaft timing chain and/or sprockets.
2. Remove the valve rocker arm cover on the side of the engine with the cylinder that
is misfiring.
3. Inspect for the following:
Loose valve rocker arm studs
Bent valve push rods
Faulty valve springs
Faulty valve lifters (bleeding down)
Worn or improperly seated valves
Worn engine camshaft lobes
Engine
Engine Noise Diagnosis
Symptoms
Cause
When diagnosing engine noisee complaints, use the following steps to isolate the source of the engine noise:
Determine the type of noise
For example, is the noise a light rattle/tapping or a low rumble/knocking?
The exact operating condition under which the noise exists
Note factors such as ambient temperature, the amount of engine warm-up time, the engine temperature, the engine
RPM and other specifics.
At what rate the noise occurs, and at what location on the engine
Engine noises are generally synchronized to either engine speed (crankshaft, engine flywheel, connecting rods,
crankshaft balancer or pistons and related components) or one-half engine speed (valve train noise such as valve
rocker arms, valve lifters and camshaft timing chain). Determine the rate at which the noise is occurring.
Compare the engine sounds to other engines, and make sure you are not trying to correct a normal condition.
Noise on Start-Up but Only Lasts a
Few seconds
Improper oil viscosity. Install the recommended oil viscosity for the expected
temperatures.
Worn or dirty valve lifters
Excessive piston-to-cylinder bore clearance
Excessive piston pin-to-bore clearance
Excessive crankshaft bearing clearance
Improper oil viscosity. Install the recommended oil viscosity for the expected
temperatures.
Lower than specified oil pressure
Install an oil pressure gauge and measure the engine oil pressure.
Dirty or worn valve lifter
Knocks Hot at
Idle (Rumble/Knocking)
Exhaust system noise and/or leakage may be caused by the following conditions:
Improperly installed or misaligned exhaust system components
A cracked or broken exhaust manifold
Damaged or worn exhaust manifold gaskets and/or seals
Burnt or rusted out exhaust system components
Broken or loose exhaust clamps and/or brackets
2001 Marine/Industrial
Engine
Cause
A light tapping noise at 1/2 engine speed, or any varying frequency, may indicate a valve train problem.
Tapping noises will typically increase with increased engine speed.
Before attempting to diagnose a valve train noise, check for the proper engine oil level and then allow the engine to
obtain normal operating temperature.
Following this procedure will bring all engine components to a normal state of expansion.
Sit in the drivers seat, then operate the engine at various speeds and listen for any abnormal engine noise.
Valve Train Noise
Diagnostic Table
Step
Action
Value(s)
Yes
No
Go to Step 2
System OK
Go to Step 3
Go to Step 4
System OK
Go to Step 6
Check for a low engine oil level. An engine with the engine
oil level below the ADD mark on the oil level indicator may
allow the oil pump to pump air at high engine RPM.
Is the engine oil level below the ADD mark on the oil level
indicator?
Go to Step 5
Go to Step 6
System OK
Go to Step 6
Go to Step 11
Go to Step 7
DEFINITION: A light tapping noise at 1/2 engine speed, or any varying frequency.
1
engine oil into foam. When the foamy engine oil is pumped
into the valve lifters, the valve lifters become noisy. A solid
column of engine oil ensures proper valve lifter operation.
Is the engine oil level too high?
41.4 kPa
(6 psi)
2001 Marine/Industrial
Engine
Diagnostic Table (contd)
Step
Action
Value(s)
Yes
No
Go to Step 8
Go to Step 9
System OK
Go to Step 9
Go to Step 10
Go to Step 11
Repair as required.
Is the tapping noise gone?
System OK
Go to Step 11
Go to Step 12
Go to Step 13
System OK
Go to Step 13
Go to Step 15
Go to Step 14
14
System OK
Go to Step 13
15
Go to Step 17
Go to Step 16
16
System OK
Go to Step 17
17
System OK
Go to Step 11
System OK
Check the oil pump screen for damage or a loose fit to the
7
oil pump.
Is the oil pump screen loose or is the oil pump screen
damaged?
Repair as required.
Is the tapping noise gone?
Check for a damaged oil pump or loose bolts.
10
12
13
18
2001 Marine/Industrial
Engine
Excessive oil consumption (not due to leaks) is the use
1.9 liters (2 quarts) of engine oil within 3,200 kilometers
(2,000 miles). However, during initial engine break-in
periods 4,828-6,437 kilometers (3,000-4,000 miles) oil
consumption may exceed 1.9 liters (2 quarts) or more.
The causes of excessive oil consumption include the
following conditions:
External oil leaks. Tighten the bolts and/or
replace gaskets and oil seals as necessary.
Incorrect oil level or improper reading of oil
level indicator. With the vehicle on a level
surface, allow adequate drain down time and
check for the correct oil level.
Improper oil viscosity. Use a recommended
SAE viscosity for the prevailing temperatures.
Continuous high speed operation and/or
severe usage.
Crankcase ventilation system restrictions or
malfunctioning components. Possible improper
PCV valve.
Valve guides and/or valve stem oil seals worn,
damaged or the seal omitted. Ream the valve
guides and install oversize service valves and/
or new valve stem oil seals.
Piston rings broken, improperly installed, worn
or not seated properly. Allow adequate time for
the piston rings to seat. Replace broken or
worn piston rings as necessary.
Piston improperly installed or mis-fitted.
2001 Marine/Industrial
Engine
Oil Leak Diagnosis
Step
Action
Value(s)
Yes
No
Important: You can repair most fluid leaks by first visually locating the leak, repairing or replacing the component, or
by resealing the gasket surface. Once the leak is identified, determine the cause of the leak. Repair the cause of the
leak as ewll as the leak itself.
1. Operate the vehicle until it reaches normal operating
1
temperature.
2. Park the vehicle on a level surface, over a large
Go to Step 2
System OK
Go to Step 10
Go to Step 3
Go to Step 10
Go to Step 4
Go to Step 10
Go to Step 5
Go to Step 10
Go to Step 6
Sealing surfaces
Fittings
Cracked or damaged components
Can you identify the type of fluid and the approximate
Sealing surfaces
Fittings
Cracked or damaged components
Can you identify the type of fluid and the approximate
location of the leak?
1. Completely clean the entire engine and surrounding
components.
2. Apply an aerosol-type powder (baby powder, foot
2001 Marine/Industrial
Engine
Step
6
Action
Value(s)
Yes
No
Go to Step 10
Go to Step 4
Go to Step 10
Go to Step 8
Go to Step 10
Go to Step 9
Go to Step 10
System OK
Go to Step 11
System OK
Go to Step 1
Sealing surfaces
Fittings
Cracked or damaged components
Can you identify the type of fluid and the approximate
location of the leak?
Use J 28428-E, Dye and Light Kit, in order to identify the
type of fluid and the approximate location of the leak.
Sealing surfaces
Fittings
Cracked or damaged components
Can you identify the type of fluid and the approximate
location of the leak?
1. Inspect the engine for mechanical damage. Special
attention should be shown to the following areas:
Higher than recommended fluid levels
Higher than recommended fluid pressures
Plugged or maalfunctioning fluid filters or pressure
bypass valves
Plugged or malfunctioning engine ventilation
system
10
11
2001 Marine/Industrial
Visual/Physical Inspection
Inspect for aftermarket devices which could
affect the operation of the drive belts.
Inspect the easily accessible or visible system
components for obvious damage or conditions
which could cause the symptom.
Inspect the drive belt for excessive wear,
shredding or missing sections.
Inspect the drive belt for contamination of
excessive dirt, oil, coolant or other substances
that may affect the drive belt operation.
Intermittent
Engine
failure of an accessory drive component.
Drive belt symptoms may occur from changes in load of
the accessory drive components.
. Ambient temperatures, moisture or engine operating
temperature can affect the drive belt operation.
Symptoms List
Refer to a symptom diagnostic procedure from the following list
in order to diagnose the symptom:
Drive Belt Chirping Diagnosis
Drive Belt Squeal Diagnosis
Drive Belt Whine Diagnosis
Drive Belt Rumbling Diagnosis
Drive Belt Vibration Diagnosis
Drive Belt Falls Off Diagnosis
Drive Belt Excessive Wear Diagnosis
Test Description
The number(s) below refer to the step number(s) on
the diagnostic table.
2. The 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 with this table.
3. The noise may be an internal engine noise.
Removing the drive belt and operating the
engine for a brief period will verify the noise is
related to the drive belt. When removing the
drive belt(s), the water pump may not be
operating and the engine may overheat. Also
DTCs may set when the engine is operating
with the drive belt removed.
4. Inspect all drive belt pulleys for pilling. Pilling is
the small balls or pills or it can be strings in the
drive belt grooves from the accumulation of
rubber dust.
2001 Marine/Industrial
Engine
Step
Action
Value(s)
Yes
No
Go to Symptoms -
Go to Step 2
Drive Belt
Go to
Go to Step 3
Diagnostic Aids
Go to Engine
Noise Diagnosis
Go to Step 4
Inspect for severe pilling exceeding 1/3 of the belt groove depth.
Does the belt grooves have pilling?
Go to Step 5
Go to Step 6
Go to Step 15
Go to Step 6
Go to Step 7
Go to Step 8
Go to Step 15
Go to Step 8
Go to Step 9
Go to Step 10
Go to Step 15
Go to Step 10
10
Go to Step 11
Go to Step 12
Go to Step 15
Go to Step 12
12
Go to Step 13
Go to Step 14
13
Go to Step 15
Go to Step 14
14
Go to Step 15
Go to
Diagnostic Aids
15
System OK
Go to Step 3
4
5
Tightening Specifications.
2001 Marine/Industrial
Engine
5.
6.
Test Description
The number(s) below refer to the step number(s) on
the diagnostic table.
2. The 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 with this table.
3. The noise may be an internal engine noise.
Removing the drive belt and operating the
engine for a brief period will verify the noise is
related to the drive belt. When removing the
drive belt(s), the water pump may not be
operating and the engine may overheat. Also
DTCs may set when the engine is operating
with the drive belt removed.
4. This test is to verify that an accessory drive
component does not have a seized bearing.
With the belt removed, test the bearings in the
7.
8.
Action
Value(s)
Yes
No
Go to Symptoms -
Go to Step 2
Drive Belt
Go to
Go to Step 3
Diagnostic Aids
Go to Engine
Noise Diagnosis
Go to Step 4
Go to Step 9
Go to Step 5
2001 Marine/Industrial
Engine
Step
Action
Value(s)
Yes
No
Go to Step 9
Go to Step 6
Inspect for the correct drive belt length. Refer to Drive Belt
Replacement.
Did you find and correct the condition?
Go to Step 9
Go to Step 7
Go to Step 9
Go to Step 8
Go to Step 9
Go to
Diagnostic Aids
System OK
Go to Step 3
Test the drive belt tensioner for proper operation. Refer to Drive
5
Test Description
The number(s) below refer to the step number(s) on
the diagnostic table.
3. This test is to verify that the noise is being
Action
Value(s)
Yes
No
Did you review the Drive Belt Symptom operation and perform
the necessary inspections?
Go to Step 2
Go to SymptomsDrive Belt
Go to Step 3
Go to
Diagnostic Aids
Go to Engine
Noise Diagnosis
Go to Step 4
Go to Step 5
Go to
Diagnostic Aids
System OK
2001 Marine/Industrial
Engine
Test Description
The number(s) below refer to the step number(s) on
the diagnostic table.
Action
Value(s)
Yes
No
Did you review the Drive Belt Symptom operation and perform
the necessary inspections?
Go to Step 2
Go to SymptomsDrive Belt
Go to Step 3
Go to
Diagnostic Aids
Go to Engine
Noise Diagnosis
Go to Step 4
Go to Step 7
Go to Step 5
Inspect for severe pilling of more than 1/3 of the drive belt
pulley grooves.
Did you find severe pilling?
Go to Step 6
Go to Step 7
Go to Step 8
Go to Step 7
2001 Marine/Industrial
Engine
Step
Action
Value(s)
Yes
No
Go to Step 8
System OK
Go to
Diagnostic Aids
Test Description
The number(s) below refer to the step number(s) on
the diagnostic table.
2. This test is to verify that the symptom 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. When removing the drive belt the
water pump may not be operating and the
engine may overheat. Also, DTCs may set
when the engine is operating with the drive belt
removed.
Action
Value(s)
Yes
No
Did you review the Drive Belt Symptom operation and perform
the necessary inspections?
Go to Step 2
Go to SymptomsDrive Belt
Go to Step 3
Go to
Diagnostic Aids
Go to Engine
Related Vibration
in Vibration and
Diagnosis
Go to Step 4
Go to Step 5
Go to Step 6
Inspect the drive belt(s) for wear, damage, debris build-up and
missing drive belt ribs.
Did you find any of these conditions?
2001 Marine/Industrial
Engine
Action
Value(s)
Yes
No
Go to Step 11
Go to Step 5
Go to Step 6
Go to Step 11
Inspect for damaged fan blades or bent fan clutch shaft, if the
fan is belt driven. Refer to Fan Clutch Replacement in Engine
Cooling.
Did you find and correct the condition?
Go to Step 11
Go to Step 9
Inspect for bent water pump shaft, if the water pump is belt
driven. Refer to Water Pump Replacement (4.3L Engine)
in Engine Cooling.
Did you find and correct the condition?
Go to Step 11
Go to Step 10
10
Go to Step 11
Go to
Diagnostic Aids
11
System OK
Go to Step 3
Test Description
The number(s) below refer to the step number(s) on
the diagnostic table.
2. This inspection is to verify the condition of the
drive belt. Damage may of occured to the drive
belt when the drive belt fell off. The drive belt
may of been damaged, which caused the drive
belt to fall off. Inspect the belt for cuts, tears,
sections of ribs missing or damaged belt plys.
4. Misalignment of the pulleys may be caused
from improper mounting of the accessory drive
2001 Marine/Industrial
Engine
Step
Action
Value(s)
Yes
No
Did you review the Drive Belt Symptom operation and perform
the necessary inspections?
Go to Step 2
Go to SymptomsDrive Belt
Go to Step 3
Go to Step 4
Go to Step 4
System OK
Go to Step 12
Go to Step 5
Go to Step 12
Go to Step 6
Go to Step 12
Go to Step 7
Go to Step 8
Go to Step 9
Go to Step 9
System OK
Go to Step 11
Go to Step 10
Go to Step 11
System OK
Inspect for failed drive belt idler and drive belt tensioner pulley
bearings.
Did you find and repair the condition?
Go to Step 12
Go to
Diagnostic Aids
System OK
Go to Step 2
10
11
12
Test Description
The number(s) below refer to the step number(s) on
the diagnostic table.
2001 Marine/Industrial
Engine
Action
Value(s)
Yes
No
Did you review the Drive Belt Symptom operation and perform
the necessary inspections?
Go to Step 2
Go to SymptomsDrive Belt
Go to Step 5
Go to Step 3
Go to Step 5
Go to Step 4
Go to Step 6
Go to
Diagnostic Aids
Go to Step 6
System OK
374176
Engine
2001 Marine/Industrial
Engine
Component Locator
Dissassembled Views
Engine Flywheel and Flywheel Housing Components
638592
Legend
(1) Flywheel Housing Adapter, Medium Duty with
Manual Transmission
(2) Flywheel Adapter Bolt
(3) Flywheel - C/K/C3500HD with Manual
Transmission
(4) Flywheel Bolt
(5) Flywheel - Automatic Transmission
(6) Flywheel Bolt
(7) Flywheel Bolt
2001 Marine/Industrial
Engine
638596
Legend
(1) Valve Rocker Arm Cover
(2) Valve Rocker Arm Cover Gasket
(3) Intake Valve Push Rod
(4) Exhaust Valve Push Rod
(5) Valve Rocker Arm Nut
(6) Valve Rocker Arm Ball
(7) Valve Rocker Arm
(8) Valve Rocker Arm Stud
(9) Push Rod Guide
(10) Cylinder Head Bolt
(11) Engine Coolant Temperature (ECT) SensorRight Cylinder Head
(12) Coolant Hole Plug-Left Cylinder Head
(13) Exhaust Manifold Stud
(14) Exhaust Manifold Gasket
(15) Exhaust Manifold - C/K/C3500HD
(16) Exhaust Manifold Bolt
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
Engine
Intake Manifold and Components
Legend
(1) Fuel Rail Bolts
(2) Fuel Rail Nuts
(3) Fuel Pressure Regulator Vacuum Hose
(4) Purge Solenoid Vacuum Hose
(5) MAP Sensor Retaining Bolt
(6) MAP Sensor
(7) EGR Valve Nuts
(8) EGR Valve (C/K/C3500HD/Medium Duty)
(9) EGR Valve Gasket
(10) EGR Valve Nuts
(11) EGR Valve (G Van)
(12) EGR Valve Gasket (G Van)
(13) EGR Adapter Nuts
(14) EGR Adapter (C/K/C3500HD/Medium Duty)
2001 Marine/Industrial
638602
Engine
638608
Legend
(1) Oil Pump Screen
(2) Oil Pump Bolt
(3) Oil Pump
(4) Oil Pump Driveshaft Retainer
(5) Oil Pump Locating Pins
(6) Oil Pump Driveshaft
(7) Crankshaft Thrust Bearing Cap
(8) Lower Crankshaft Thrust Bearing
(9) Rear Crankshaft Seal
(10) Upper Crankshaft Thrust Bearing
(11) Connecting Rod Nut
(12) Connecting Rod Cap
(13) Connecting Rod Bearings
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
Engine
Legend
(1) Top Oil Gallery Plug
(2) Valve Lifter Guide Retainer
(3) Valve Lifter Guide Retainer Bolt
(4) Oil Pump Drive Bolt
(5) Oil Pump Drive
(6) Valve Lifter Guide
(7) Valve Lifter
(8) Crankshaft Position Sensor Bolt
(9) Crankshaft Position Sensor
(10) Cylinder Head Locating Pin
(11) Engine Block
(12) Left Oil Gallery Plug
(13) Left Knock Sensor Shield - C/K/C3500HD
(14) Left Knock Sensor Shield Bolt
(15) Oil Filter Adapter
(16) Oil Filter
(17) Left Knock Sensor - C/K/C3500HD
(18) Coolant Drain Plug
2001 Marine/Industrial
638616
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
Engine
Engine Identification
677764
2001 Marine/Industrial
Engine
Repair Instructions
Draining Fluids and Oil Filter Removal
1.
2.
3.
4.
470515
470799
640013
2001 Marine/Industrial
Engine
640014
6.
7.
8.
9.
640015
2001 Marine/Industrial
Engine
Crankshaft Balancer Removal (Medium Duty)
Tools Required
J 24420-C Harmonic Balancer Puller
J 42847 Flywheel Holding Tool
Notices: Refer to Fastener Notice in Cautions and Notices.
Important: Make sure the teeth of the flywheel holding tool
engage the engine flywheel teeth.
1. Install the J 42847 to the starter bolt holes.
Tighten
Tighten the J 42847 bolts to 50 N.m (37 lb ft).
2. Remove the crankshaft balancer bolt and washer.
470799
677814
470572
2001 Marine/Industrial
Engine
470576
470579
679414
2001 Marine/Industrial
Engine
Engine Flywheel Housing Removal (Medium
Duty with AT)
1.
2.
3.
4.
470599
470612
2001 Marine/Industrial
Engine
373133
2001 Marine/Industrial
Engine
Clutch Pilot Bearing Removal (Medium Duty)
Tools Required
J 23907 Slide Hammer
Caution: Wear safety glasses in order to avoid eye
damage.
1. Remove the clutch pilot bearing using the J 23907.
2. Discard the clutch pilot bearing.
3. Inspect the engine flywheel clutch pilot bearing bore for
servicability.
375105
470627
2. Remove the oil level indicator tube bracket nut from the
exhaust manifold stud.
3. Remove the oil level indicator tube bracket from the
exhaust manifold stud.
4. Remove the oil level indicator tube from the oil pan.
5. Remove the O-ring seal from the oil level indicator
tube.
470630
2001 Marine/Industrial
Engine
470639
470666
2001 Marine/Industrial
Engine
2. Remove the left exhaust manifold heat shield nuts.
3. Remove the left exhaust manifold heat shield.
470678
470686
2001 Marine/Industrial
Engine
470690
470683
2001 Marine/Industrial
Engine
Exhaust Manifold Removal - Right
Important: Twist the spark plug boot one-half turn in order to
release the boot. Pull on the spark plug boot only. Do not pull
on the spark plug wire or the wire could be damaged.
1. Remove the left spark plug wires from the spark plugs
and ignition coils.
470704
470737
2001 Marine/Industrial
Engine
470708
470725
470727
2001 Marine/Industrial
Engine
12. Remove the exhaust manifold studs, if necessary.
470723
470789
470698
2001 Marine/Industrial
Engine
470698
635643
2001 Marine/Industrial
Engine
Water Pump Removal
1. Remove the water pump bolts.
2. Remove the water pump.
3. Remove the water pump gaskets.
470792
470770
470774
2001 Marine/Industrial
Engine
470775
470779
470783
2001 Marine/Industrial
Engine
Important: The splash shield is secured using a snap-fit. Do
not distort the splash shield. The splash shield is reusable.
8. Remove the splash shield.
470786
470890
470897
2001 Marine/Industrial
Engine
470899
Important: The exhaust valve push rods (2) are longer than
the intake valve push rods (1).
2. Remove the valve push rods.
470903
470906
2001 Marine/Industrial
Engine
Cylinder Head Removal - Left
1. Remove and discard the eighteen cylinder head bolts
(1,2,3).
470914
470916
470974
2001 Marine/Industrial
Engine
470989
470991
470992
2001 Marine/Industrial
Engine
Valve Lifter Removal
Tools Required
J 3049-A Valve Lifter Remover
Important: Mark, organize and sort the cylinder head
components for return to their original location during
assembly.
1. Remove the valve lifter guide retainer bolts and
retainer.
470994
470996
719128
2001 Marine/Industrial
Engine
470910
635651
635654
2001 Marine/Industrial
Engine
Oil Pump, Pump Screen and Deflector
Removal
1. Remove the bolt that attaches the oil pump to the rear
crankshaft bearing cap.
2. Remove the oil pump, driveshaft and retainer from the
rear crankshaft bearing cap.
3. Separate the oil pump, driveshaft and retainer.
4. Discard the driveshaft retainer.
635701
635703
470803
2001 Marine/Industrial
Engine
470805
470814
639535
2001 Marine/Industrial
Engine
Camshaft Removal
1. Remove the camshaft retainer bolts.
2. Remove the camshaft retainer.
470998
471002
2001 Marine/Industrial
Engine
11497
639084
2001 Marine/Industrial
Engine
4. Install rubber fuel line onto the connecting rod bolts.
639533
639536
639532
2001 Marine/Industrial
Engine
655276
655278
655279
2001 Marine/Industrial
Engine
Crankshaft and Bearings Removal
Important: The crankshaft position sensor is designed to
contact the reluctor wheel of the crankshaft. Wear may be
noticeable on the end of the sensor.
1. Remove the crankshaft position sensor bolt.
2. Apply penetrating oil to the crankshaft position sensorto-engine block mating surface. Allow the penatrating
oil to soak for several minutes, to help loosen the Oring from the engine block.
3. Remove the crankshaft position sensor.
4. Inspect both crankshaft position sensor O-rings for
cuts, cracks, tears or damage. Replace the O-rings as
needed.
470801
471055
2001 Marine/Industrial
Engine
471044
471047
471041
2001 Marine/Industrial
Engine
Oil Filter Adapter Removal
1. Loosen the oil filter fitting using a hex wrench.
452375
471026
471143
2001 Marine/Industrial
Engine
471089
471118
471100
2001 Marine/Industrial
Engine
5. Remove the left side knock sensor.
471081
471076
471126
2001 Marine/Industrial
Engine
471134
471133
471138
2001 Marine/Industrial
Engine
11. Remove the top oil gallery plugs.
471137
635657
2001 Marine/Industrial
Engine
635660
719139
2001 Marine/Industrial
Engine
Important: A loose camshaft bearing may be caused by an
enlarged, out-of-round or damaged engine block bearing
bore.
2. Prior to bearing removal, inspect the camshaft
bearings for loose fit in the engine block bearing bores
(positions 1-5).
639523
66100
64183
2001 Marine/Industrial
Engine
63219
635662
Engine
35209
719134
2001 Marine/Industrial
Engine
186747
Engine
3. When honing to eliminate taper in the cylinder, make
full strokes of the hone in the cylinder. Repeatedly
check the measurement at the top, the middle and the
bottom of the bore.
639519
2001 Marine/Industrial
Engine
677825
639543
677772
2001 Marine/Industrial
Engine
6. Measure the crankshaft main journals and the
crankpins to out-of-round and taper.
35207
677818
639520
2001 Marine/Industrial
Engine
52051
52053
52056
2001 Marine/Industrial
Engine
Crankshaft and Connecting Rod Bearing
Clearance Measurement
The crankshaft and connecting rod bearings are of the
precision insert type and do not use shims for adjustment. If
the clearances are excessive, the new upper and the lower
bearings will be required. The service bearings are available
in the standard size and an undersize.
The selective fitting of the bearings are necessary in
production in order to obtain close tolerances. For this reason,
in one journal bore you may use one-half of a standard
bearing with one-half of an undersize bearing.
In order to determine the correct replacement bearing size,
the bearing clearance must be measured accurately. Either
the micrometer or plastic gauge method may be used,
however, the micrometer method gives more reliable results
and is preferred.
35207
639521
2001 Marine/Industrial
Engine
7. Compare the crankshaft bearing clearance to the
specifications. Refer to Engine Mechanical
Specifications.
8. If the crankshaft bearing clearances exceeds
specifications, install the new crankshaft bearings.
9. Measure the new crankshaft bearing inside diameter
(ID) using an inside micrometer.
10. Replace or repair the crankshaft if the proper
clearances cannot be obtained.
Micrometer Method for Connecting Rod Bearings
Tools Required
J 36660-A Electronic Torque Angle Meter
1. Measure the crankpin diameter with a micrometer in
several places along the length approximately 90
degrees apart, (minimum of 4 places), and average the
measurements.
2. Determine the taper and the out-of-round. Refer to
Engine Mechanical Specifications.
Notice: Do not shim, scrape or file bearing inserts. Do not
touch the bearing surface of the insert with bare fingers. Skin
oil and acids will etch the bearing surface.
3. Install the connecting rod bearings into the connecting
rod cap and the connecting rod.
Notice: Refer to Fastener Notice in Cautions and Notices.
Important: Use the original connecting rod nuts for clearance
measurement. During final assembly, new connecting rod
nuts must be used to obtain correct fastener tightening.
4. Install the connecting rod cap and the original (used)
nuts.
Tighten
Tighten the connecting rod nuts to 30 N.m (22 lb ft).
Using the J 3660-A, tighten the connecting rod nuts an
additional 90 degrees.
5. Measure the connecting rod bearing inside diameter
(ID) using an inside micrometer.
6. Compare the connecting rod bearing clearance
specifications. Refer to Engine Mechanical
Specifications.
7. If the connecting rod bearing clearance is within
specifications, the connecting rod bearing is
satisfactory.
35207
2001 Marine/Industrial
Engine
Plastic Gauge Method for Main Bearings
Important: When bearings are removed, NEW bearings
must be installed during reassembly.
1. Install the crankshaft and crankshaft bearings into the
engine block, making sure not to damage the reluctor
rings of the crankshaft.
639522
4980
2001 Marine/Industrial
Engine
7.
8.
9.
10.
11.
12.
4981
2001 Marine/Industrial
Engine
Plastic Gauge Method for Connecting Rod Bearings
Tools Required
J 36660-A Electronic Torque Angle Meter
Important: When bearings are removed, NEW bearings
must be installed during reassembly.
1. Install the connecting rod bearings into the connecting
rod and connecting rod cap.
2. Using rubber fuel line over the connecting rod bolts,
install the piston and connecting rod assembly onto the
crankpin journal.
635669
4980
639084
2001 Marine/Industrial
Engine
6. On the edge of the gauging plastic envelope, there is a
graduated scale. Without removing the gauging plastic,
measure the compressed width at the widest point.
If the flattened gauging plastic tapers toward the middle
or the ends, there may be a difference in clearance
indicating taper, low spot or other irregularity of the
crankshaft bearing or the crankshaft journal.
7. Normally, the crankshaft journals wear evenly and
are not out-of-round. However, if a connecting rod
bearing is being fitted to an out-of-round 0.0254 mm
(0.001 in maximum) crankpin journal, be sure to fit to
the maximum diameter of the crankpin journal. If the
connecting rod bearing is fitted to the minimum
diameter and the crankpin journal is excessively out-ofround, the interference between the onnecting rod
bearing and the crankpin journal will result in rapid
connecting rod bearing failure.
8. Compare the connecting rod bearing clearance to the
specifications. Refer to Engine Mechanical
Specifications.
9. If the connecting rod bearing clearances exceed
specifications, install undersize connecting rod
bearings to achieve the correct clearance.
10. A standard or undersize connecting rod bearing
combination may result in the proper clearance. If the
proper clearance cannot be achieved using the
standard or the undersize connecting rod bearings, it
may be necessary to repair or replace the crankshaft
or connecting rod.
11. Remove the flattened gauging plastic.
12. Measure the remaining crankpin journals.
4981
677804
2001 Marine/Industrial
Engine
4. If the correct end play cannot be obtained, inspect for
the following conditions:
2001 Marine/Industrial
Engine
635666
2001 Marine/Industrial
Engine
Engine Flywheel Clean and Inspect (M/T)
1. Clean the engine flywheel in solvent.
Caution: Wear safety glasses in order to avoid eye
damage.
2. Dry the engine flywheel with compressed air.
3. Inspect the manual transmission engine flywheel for
the following:
188086
635669
2001 Marine/Industrial
Engine
635669
4977
639530
2001 Marine/Industrial
Engine
7. Measure the piston ring-to-piston ring groove side
clearance. Refer to Engine Mechanical Specifications.
7.1. Insert the edge of the piston ring into the piston
ring groove.
Roll the piston ring completely around the piston.
7.2. If binding is caused by a distorted piston ring
groove, MINOR imperfections may be removed
with a fine file.
7.3. If binding is caused by a distorted piston ring,
replace the piston ring.
4969
639528
639526
2001 Marine/Industrial
Engine
639524
4968
2001 Marine/Industrial
Engine
Piston and Connecting Rod Assemble
Notice: Use a piston ring expander to install the piston rings.
The rings may be damaged if expanded more than
necessary.
1. Install the lower oil control piston ring spacer onto the
piston.
562836
2. Install the lower oil control piston ring onto the piston
(1).
562842
3. Install the upper oil control piston ring onto the piston
(1).
562839
2001 Marine/Industrial
Engine
562848
562823
562819
2001 Marine/Industrial
Engine
Camshaft and Bearings Clean and Inspect
Tools Required
J 7872 Magnetic Base Dial Indicator
1. Clean the camshaft in solvent.
Caution: Wear safety glasses in order to avoid eye
damage.
2. Dry the camshaft with compressed air.
3. Inspect the camshaft retainer plate for damage.
4. Inspect the camshaft for the following:
188095
35212
2001 Marine/Industrial
Engine
639523
639523
2001 Marine/Industrial
Engine
1. Assemble the tool handle (10), expanding driver (4-8)
and washer (2 or 3).
66100
4985
66100
2001 Marine/Industrial
Engine
6. Insert the J 33049 tool through the front of the engine
block and to the inner bearing bores (positions 2-4).
7. Install the bearing onto the expanding driver (4-8).
8. Tighten the expander assembly nut (15) until the tool is
snug in the bearing.
Important: The camshaft bearing oil holes must align with
the oil galleries in the engine block.
After installation of the camshaft bearings, inspect the
camshaft bearing oil holes for proper alignment with the oil
galleries.
An improperly aligned camshaft bearing oil gallery hole will
restrict oil flow to the bearing and the camshaft journal.
9. Align the oil lubrication hole in the bearing with the oil
galleries in the engine block.
10. Push the guide cone (1) into the front camshaft bearing
bore to align the tool.
11. Drive the bearing into the bore.
64183
677756
2001 Marine/Industrial
Engine
Important: If the sprocket(s) must be replaced, replace both
sprockets to ensure that timing chain centerline alignment is
maintained.
4. Inspect the camshaft and crankshaft sprockets for the
following:
188097
470899
470903
2001 Marine/Industrial
Engine
635671
Wear between the push rod and the push rod guide
(1)
635675
2001 Marine/Industrial
Engine
Valve Lifters and Guides Clean and Inspect
Important: Parts that are to be reused must remain sorted or
organized in order to return them to their original locations.
Important: Disassembly of the valve lifter(s) is not
recommended.
1. Clean the components in solvent.
Caution: Wear safety glasses in order to avoid eye
damage.
2. Dry the components with compressed air.
3. Inspect the valve lifters for the following:
173176
173193
2001 Marine/Industrial
Engine
196664
2.
3.
4.
5.
6.
677748
2001 Marine/Industrial
Engine
9. Disconnect the Engine Coolant Temperature (ECT)
sensor from the bracket.
10. Remove the ECT sensor from the right cylinder head.
11. Remove the ECT sensor bracket and bolt.
470744
12. Remove the cylinder head coolant plug from the left
cylinder head.
635678
677748
2001 Marine/Industrial
Engine
35201
64318
2001 Marine/Industrial
Engine
Valve Inspection Procedure
1. Inspect the valves for the following:
677854
156173
4960
2001 Marine/Industrial
Engine
677797
719136
4956
2001 Marine/Industrial
Engine
Valve Reconditioning Procedure
1. Replace the valve if the valve stem shows excessive
wear or is warped.
Important: Several different types of equipment are available
for reconditioning valves. Use the manufacturers
recommendations of equipment to attain proper results.
2. Reface pitted valves on a valve refacing machine in
order to ensure the correct relationship between the
head and the valve stem.
3. Replace the valve if the edge of the head is less than
0.79 mm (0.031 in) thick after grinding.
57502
53234
2001 Marine/Industrial
Engine
635681
Valve Installation
Caution: Wear safety glasses in order to avoid eye
damage.
Caution: Compressed valve springs have high tension
against the valve spring compressor. Valve springs that
are not properly compressed by or released from the
valve spring compressor can be ejected from the valve
spring compressor with intense force. Use care when
compressing or releasing the valve spring with the valve
spring compressor and when removing or installing the
valve stem keys. Failing to use care may cause personal
injury.
1. Lubricate the valve stems (6) with clean engine oil.
2. Insert the valves into their proper locations.
3. Install the necessary valve spring shims onto the
cylinder head.
4. Lubricate the rotators (5) with clean engine oil.
5. Install the rotators over the guide and onto the valve
spring shims, if applicable.
677779
2001 Marine/Industrial
Engine
Important: When installing valve stem oil seals onto the
valve guides, be careful not to tear the seal lip.
Important: When installing valve seals, J 43105 must be
used to achieve correct installation. Failure to use J43105
may cause excessive oil consumption.
6. Lubricate the valve stem seal and the outside diameter
of the valve guide with clean engine oil.
7. Install the valve stem oil seals (2) over the valve tip and
onto the valve guides using J 43105. Tap the valve
stem seal onto the valve guide until the J 43105 fully
seats the seal.
719126
677779
196664
2001 Marine/Industrial
Engine
470744
16. Install the cylinder head coolant hole plug (1) into the
left cylinder head.
Tighten
Tighten the cylinder head coolant hole plug to 23 N.m
(17 lb ft).
635678
427935
2001 Marine/Industrial
Engine
2. Remove the oil pump cover bolts.
678105
678106
678107
2001 Marine/Industrial
Engine
427947
678109
2001 Marine/Industrial
Engine
Oil Pump Assemble
Tools Required
J 21882 Oil Suction Pipe Installer
Important: Replace the pressure relief valve spring when
reusing the oil pump.
1. Install the following items:
1.1. The pressure relief valve
1.2. The pressure relief spring
1.3. The retaining pin
427947
2. Coat the drive gear, the driven gear and the housing
gear surfaces with clean engine oil.
3. Install the drive gear and the driven gear into the pump
body. Align the matching marks on the gears. Install the
smooth side of the gear toward the pump cover.
678107
678106
2001 Marine/Industrial
Engine
678105
427935
2001 Marine/Industrial
Engine
Oil Pump Drive Clean and Inspect
Caution: Wear safety glasses in order to avoid eye
damage.
1. Clean the oil pump drive in cleaning solvent.
2. Dry the oil pump drive with compressed air.
3. Inspect the oil pump drive for the following:
470659
2001 Marine/Industrial
Engine
470887
470897
470887
2001 Marine/Industrial
Engine
12. Install and secure the ignition coil wiring harness into
the two wiring harness retainers.
13. Install the ignition coil wiring harness retainer bolts.
Tighten
Tighten the ignition coil wiring harness retainer bolts to
12 N.m (106 lb in).
14. Connect the ignition coil wiring harness to the ignition
coils, making sure the connectors for cylinders one and
three, and cylinders six and eight are connected to the
corresponding ignition coils.
15. Install the white wiring harness clip locks.
470659
635649
470760
2001 Marine/Industrial
Engine
471023
471008
471009
2001 Marine/Industrial
Engine
9. Remove the purge solenoid vacuum hose.
471013
471015
2001 Marine/Industrial
Engine
471015
471013
2001 Marine/Industrial
Engine
6. Install the EGR adapter gasket.
7. Install the EGR adapter.
8. Install the EGR adapter nuts.
Tighten
Tighten the EGR adapter nuts to 30 N.m (22 lb ft).
471009
471008
471023
2001 Marine/Industrial
Engine
470760
66607
2001 Marine/Industrial
Engine
Water Crossover Clean and Inspect
Cleaning Procedure
1. Clean the water crossover (3) and thermostat housing
(1) in solvent.
Caution: Wear safety glasses in order to avoid eye
damage.
2. Dry the water crossover and thermostat housing with
compressed air.
635646
Inspection Procedure
1. Inspect the water crossover (3) for the following:
635646
2001 Marine/Industrial
Engine
635691
635640
2001 Marine/Industrial
2001 Marine/Industrial
Engine
14.2. Screw the insert on the mandrel of the
installation tool until the driving tang is fully
engaged in the driving contour.
14.3. Coat the insert with spray machining oil.
14.4. Install the insert as follows:
14.4.1. Slide the prewinder over the mandrel and
insert.
14.4.2. Rotate the mandrel clockwise until 1 or 2
threads of the insert are threaded into the
prewinder.
14.4.3. Place the insert in position on the
threaded hole being repaird.
14.4.4. Rotate the mandrel clockwise until the
insert is flush with the top surface of the
threaded hole.
14.4.5. Remove the prewinder except when
repairing cylinder head bolts.
14.4.6. Continue to install the insert until
reaching the original thread depth.
14.4.7. Remove the mandrel.
14.5. Remove the driving tang from the thread
insert as follows. The tang must be removed
in order to allow passage of the fastener
through the insert.
14.5.1. Place the square end of the punch, no
chamfer, on the tang after installation.
14.5.2. Strike the punch sharply with the hammer.
The tang will break off at the notch.
15. Clean the hole using compressed air. Take
appropriate steps to assure that the chips are not
blown into the engine.
Engine
2001 Marine/Industrial
Engine
Engine Block Plug Installation
Tools Required
J 41712 Oil Pressure Sending Unit Socket
Notice: Refer to Fastener Notice in Cautions and Notices.
1. Apply sealant GM P/N 12346004 or equivalent to the
threads of the coolant hole plug.
2. Install the engine coolant hole plug into the block.
Tighten
Tighten the engine coolant hole plug to 60 N.m (40 lb
ft).
635657
635660
471137
2001 Marine/Industrial
Engine
471138
471133
471134
2001 Marine/Industrial
Engine
13. Apply sealant GM P/N 12346004 or equivalent to the
threads of the engine block oil cooler hose fittings (with
oil cooler).
14. Install the engine block oil cooler hose fittings (with oil
cooler).
Tighten
Tighten the engine block oil cooler hose fittings to 23
N.m (17 lb ft).
471126
471081
2001 Marine/Industrial
Engine
471100
471076
2001 Marine/Industrial
Engine
19. Apply sealant GM P/N 12346004 or equivalent to the
threads of the engine block coolant drain hole plugs.
20. Install the engine block coolant drain hole plugs.
Tighten
Tighten the engine coolant drain hole plugs to 20 N.m
(15 lb ft).
470568
471118
471122
2001 Marine/Industrial
Engine
471089
471143
471026
2001 Marine/Industrial
Engine
Crankshaft and Bearings Installation
Tools Required
J 8001 Dial Indicator Set
J 36660-A Electronic Torque Angle Meter
Important:
471041
471044
471047
2001 Marine/Industrial
Engine
647705
679831
471055
2001 Marine/Industrial
Engine
7. Measure the crankshaft end play as follows:
7.1. Install the J 8001 or equivalent to the cylinder
block, with the dial indicator plunger against one
of the counterweights of the crankshaft.
7.2. Firmly thrust the crankshaft first rearward, then
forward. This will line up the rear crankshaft
bearing and the crankshaft thrust surfaces
7.3. With the crankshaft pushed forward, zero the dial
indicator. Move the crankshaft rearward, and read
the end play measurement on the dial indicator.
An optional method is to insert a feeler gauge
between the crankshaft and the bearing surface
and measure the clearance. Refer to Engine
Mechanical Specifications.
7.4. If the correct end play cannot be obtained, inspect
for the following conditions:
677804
Damaged bearing
Improper size bearing
2001 Marine/Industrial
Engine
Important: Ensure that the crankshaft position sensor is fully
seated against the crankshaft reluctor ring. The upper flange
on the sensor MAY NOT seat against the engine block. The
sensor is designed to wear to zero tolerance against the
reluctor ring. The sensor is designed to be removed and
installed three times. Exceeding three installations with the
same sensor may result in engine driveability problems or a
possible no-start.
Important: The crankshaft position sensor bolt has a thread
sealant applied to the threads. The thread sealant may have
come off during the removal of the bolt. Ensure that the bolt
holes is clean of any debris before installing the crankshaft
sensor bolt.
8. Inspect both crankshaft position sensor O-rings for
cuts, cracks, tears or damage. Replace the O-rings as
needed. Lubricate the crankshaft position sensor Orings with clean engine oil.
9. Install the crankshaft position sensor into the engine
block.
There may be a slight resistance as the O-rings seat
into the engine block.
10. Apply thread sealer GM P/N 12345493 or equivalent to
the crankshaft position sensor bolt.
11. Install the crankshaft position sensor bolt.
Tighten
Tighten the crankshaft position sensor bolt to 12 N.m
(106 lb in).
470801
640011
2001 Marine/Industrial
Engine
Piston, Connecting Rod and Bearing
Installation
4972
Piston Selection
Tools Required
J 8037 Piston Ring Compressor
J 8087 Cylinder Bore Checking Gauge
Important: The coating on the piston allows for an
interference fit between the cylinder and the bore. The piston
diameter can NOT be measured accurately because the
piston coating is not a consistent thickness. Do NOT
measure the piston diameter.
To select the correct piston for installation, the cylinder bore
must be measured. If the cylinder bore diameter is within
service specifications, install the original piston/connecting
rod assembly. A used piston/connecting rod assembly may
be reinstalled if, after cleaning and inspection, the piston is
not damaged. If the cylinder bore is NOT within
specifications, the cylinder must be resized to accept a new,
oversized piston.
For proper piston fit, the engine block cylinder bores should
not have excessive wear or taper.
1. Inspect the engine block cylinder bore. Refer to
Cylinder Boring and Honing.
2. Inspect the piston/connecting rod assembly for
damage. Refer to Piston, Connecting Rod and
Bearings Clean and Inspect.
3. Use the J 8087 in order to measure the cylinder bore
diameter. Refer to Engine Block Clean and Inspect.
4974
2001 Marine/Industrial
Engine
2001 Marine/Industrial
Engine
Piston Installation
1. Coat the following components with clean engine oil:
The piston
The piston rings
The cylinder bore
The bearing surfaces
639532
Important: The mark on the top of the piston must face the
front of the engine block. When assembled, the flanges on
the connecting rod and cap should face to the front of the
block on the left bank and to the rear of the block on the right
bank.
3. Install the piston, connecting rod and upper connecting
rod bearing through the top of the engine block.
639536
5159
2001 Marine/Industrial
Engine
639533
639084
639084
2001 Marine/Industrial
Engine
11. Once the piston and connecting rod assemblies have
been installed, lightly tap each connecting rod
assembly (parallel to the crankpin) in order to make
sure that they have side clearance.
12. Use a feeler gauge or a dial indicator to measure the
side clearance between the connecting rod caps. The
connecting rod side clearance should be 0.384-0.686
mm (0.0151-0.0270 in).
677801
Camshaft Installation
1. Lubricate the following components with clean engine
oil, engine supplement GM P/N 1052367 or equivalent:
471002
470998
2001 Marine/Industrial
Engine
65850
470814
677756
2001 Marine/Industrial
Engine
Engine Front Cover Installation
Tools Required
J 42851 Front Cover Oil Seal Installer
1. Install the NEW crankshaft front oil seal using the J
42851.
2. Lubricate the sealing surface of the crankshaft front oil
seal with clean engine oil.
Important: The front cover must be installed and the
fasteners tightened while the sealant is still wet to the touch.
3. Apply the sealant GM P/N 12346286 or equivalent in
two sealant points (1) on the engine block where the
front cover meets the oil pan.
470807
719124
677874
2001 Marine/Industrial
Engine
635703
471060
2001 Marine/Industrial
Engine
Oil Pan Installation
Important: The oil pan must be installed within five minutes
of the sealer being applied or the sealer will begin to cure,
causing an inadequate seal.
1. Apply sealant GM P/N 12346286 or equivalent to the
side of the front (1) and rear (2) crankshaft bearing
caps, on both the left and right sides (four locations
total).
677833
2. Install the new oil pan gasket (2) into the pan groove.
3. Install the oil pan (1).
635654
2001 Marine/Industrial
Engine
677869
635648
2001 Marine/Industrial
Engine
Oil Pump Drive Installation
1. Apply grease to the oil pump drive gear for ease of
assembly.
Important: Correct alignment of the oil pump drive and oil
pump drive shaft is critical. Make sure both components mate
correctly, or engine damage may occur.
2. Line up the oil pump drive gear with the oil pump drive
shaft.
3. Install the oil pump drive, making sure that the oil pump
drive is fully seated in the engine block.
Notice: Refer to Fastener Notice in Cautions and Notices.
4. Install the oil pump drive bolt.
Tighten
Tighten the oil pump drive bolt to 25 N.m (18 lb ft).
470910
470996
2001 Marine/Industrial
Engine
470994
470974
2001 Marine/Industrial
Engine
Important: Guide the cylinder head carefully into place over
the locating pins and the cylinder head gasket.
2. Install the cylinder head to the engine block.
470916
470914
470987
2001 Marine/Industrial
Engine
470992
470991
470989
2001 Marine/Industrial
Engine
470987
470906
2001 Marine/Industrial
Engine
470903
4. Coat the valve rocker arm and valve rocker arm ball
bearing surfaces with prelube GM P/N 1052367 or
equivalent.
5. Install the valve rocker arms, the valve rocker arm balls
and the valve rocker arm nuts.
Tighten
Tighten the valve rocker arm nuts slowly, to 25 N.m (18
lb ft), while guiding the tips of the rocker arms over the
tips of the halves.
470899
2001 Marine/Industrial
Engine
Intake Manifold Installation
1. Install the splash shield.
470786
413867
470783
2001 Marine/Industrial
Engine
470779
470778
470775
2001 Marine/Industrial
Engine
640010
470774
2001 Marine/Industrial
Engine
470770
2001 Marine/Industrial
Engine
Valve Rocker Arm Cover Installation - Left
Important: If the valve rocker arm cover gasket was removed
from the valve rocker arm cover, install a NEW valve rocker
arm cover gasket.
1. Install the valve rocker arm cover with gasket.
2. Install the valve rocker arm cover bolts.
470890
677858
2001 Marine/Industrial
Engine
470897
677858
2001 Marine/Industrial
Engine
Water Pump Installation
1. Place the water pump gaskets and the water pump into
position.
Notice: Refer to Fastener Notice in Cautions and Notices.
2. Install the water pump bolts.
Tighten
Tighten the water pump bolts to 50 N.m (37 lb ft).
470792
635643
470698
2001 Marine/Industrial
Engine
470692
470789
2001 Marine/Industrial
Engine
Exhaust Manifold Installation - Left
Notice: Refer to Fastener Notice in Cautions and Notices.
1. Install the exhaust manifold studs into the cylinder
head (if necessary).
Tighten
Tighten the exhaust manifold studs to 20 N.m (15 lb ft).
470683
470686
470678
2001 Marine/Industrial
Engine
470690
470666
470659
2001 Marine/Industrial
Engine
Exhaust Manifold Installation - Right
Notice: Refer to Fastener Notice in Cautions and Notices.
1. Install the exhaust manifold studs into the cylinder
head (if necessary).
Tighten
Tighten the exhaust manifold studs to 20 N.m (15 lb ft).
470723
470725
470708
2001 Marine/Industrial
Engine
470727
470704
470737
2001 Marine/Industrial
Engine
Oil Level Indicator and Tube Installation
1. Install a NEW O-ring seal onto the oil level indicator
tube.
2. Install the oil level indicator tube into the oil pan.
3. Install the oil level indicator tube bracket to the exhaust
manifold stud.
Notice: Refer to Fastener Notice in Cautions and Notices.
4. Install the oil level indicator tube bracket nut to the
exhaust manifold stud.
Tighten
Tighten the oil level indicator tube bracket nut to 25
N.m (18 lb ft).
470630
5. Install the oil level indicator into the oil level indicator
tube.
470627
2001 Marine/Industrial
Engine
470617
470620
375107
2001 Marine/Industrial
Engine
Engine Flywheel Housing Installation
(Medium Duty with AT)
1. Install the transmission converter covers.
2. Install the transmission converter cover bolts.
Tighten
Tighten the transmission converter cover bolts to 12
N.m (106 lb in).
3. Install the engine flywheel housing.
Notice: Refer to Fastener Notice in Cautions and Notices.
4. Install the engine flywheel housing bolts.
Tighten
Tighten the engine flywheel housing bolts to 67 N.m
(49 lb ft).
470599
470612
2001 Marine/Industrial
Engine
470572
470576
2001 Marine/Industrial
Engine
Engine Flywheel Installation (Medium Duty
with AT)
Important: Make sure the flywheel is installed correctly.
Engine Side is stamped on the flywheel to assist with
installation.
1. Install the engine flywheel.
Notice: Refer to Fastener Notice in Cautions and Notices.
2. Install the engine flywheel bolts.
Tighten
2.1. Tighten the engine flywheel bolts to 80 N.m (59 lb
ft) on the first pass.
2.2. Tighten the engine flywheel bolts to 100 N.m (74
lb ft) on the final pass.
470579
679414
2001 Marine/Industrial
Engine
639537
639539
639542
2001 Marine/Industrial
Engine
6. Install the crankshaft balancer washer and bolt.
Tighten
Tighten the crankshaft balancer bolt to 225 N.m (188 lb
ft).
7. Remove the J 42847.
470799
2001 Marine/Industrial
Engine
639544
Cylinder Block
The engine block is made of cast iron and it has eight
cylinders arranged in a V shape with four cylinders in each
bank. The engine block is a one piece casting with the
cylinders encircled by coolant jackets.
Cylinder Head
The cylinder heads are made of cast iron and have parent
metal intake valve guides and intake valve seats. The cast
iron exhaust valve guides and powdered metal valve seats
are pressed into the exhaust ports. A spark plug is located
between the valves in the side of the cylinder head. The
water crossover pipe attaches to the front of each cylinder
head.
Camshaft
A steel camshaft is supported by five bearings pressed
into the engine block. The camshaft sprocket is mounted
to the front of the camshaft and is driven by the crankshaft
sprocket through a camshaft timing chain.
Motion from the camshaft is transmitted to the valves by
hydraulic roller valve lifters, valve pushrods and ball-pivot
type rocker arms. A spiral gear machined into the
camshaft near the rear journal drives a shaft assembly
which operates the oil pump driveshaft assembly.
Crankshaft
The crankshaft is made of cast nodular iron. The
crankshaft is supported by five crankshaft bearings. The
crankshaft bearings are retained by the crankshaft
bearing caps. The crankshaft bearing caps are machined
with the engine block for proper alignment and clearance.
The crankshaft bearing caps are retained by two bolts and
2001 Marine/Industrial
2001 Marine/Industrial
Engine
New Special Tools Required
A variety of new tools have been developed to assist in
engine disassembly, assembly and on-vehicle service.
Refer to Special Tools.
A Component Comparison from the Previous Year
The 8.1 liter, L18 engine has replaced the 7.4 liter,
L29/LP4/L21 engines.
Engine
Lubrication Description
677884
677880
677891
2001 Marine/Industrial
Engine
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.
This is considered standard shop practice even if not
specifically stated.
If both the oil filter and the oil cooler are plugged, the
pressurized oil is routed around the top of the oil filter,
through the oil filter bypass valve (2), through the oil cooler
bypass valve (1) and directly into the engine oil passages.
Lubrication still occurs, but the oil is not filtered or directed
through the oil cooler.
Separating Parts
Important: Many internal engine components will develop
specific wear patterns on their friction surfaces.
When disassembling the engine, internal components
MUST be separated, marked or organized in a way to
ensure reinstallation to the original location and position.
Separate, mark or organize the following components:
2001 Marine/Industrial
Engine
Do not use abrasive pads, sand paper or power
tools to clean the gasket surfaces.
2001 Marine/Industrial
2001 Marine/Industrial
Engine
Important: Do not allow the pipe sealant to enter any blind
threaded holes, as the pipe sealant may prevent the
fasteners from clamping properly, seating properly or
cause damage when the fastener is tightened.
Engine
Illustration
J 3049-A
Hydraulic Lifter Remover
J 7872
Magnetic Base Dial
Indicator
J 8001
Dial Indicator Set
Illustration
Tool Number/Description
J 8087
Cylinder Bore
Checking Gauge
J 8358
Carbon Removal Brush
J 9666
Valve Spring Tester
J 8037
Piston Ring Compressor
J 22102
Crankshaft Sprocket
Installer
J 8062
Valve Spring Compressor
(Cylinder Head Off)
J 24270
Cylinder Bore Ridge
Reamer
2001 Marine/Industrial
Tool Number/Description
Illustration
Tool Number/Description
J 24420-C
Harmonic Balancer Puller
J 42845
Crankshaft Balancer
Installer
J 33049
Camshaft Bearing
Service Set
J 42846
Crankshaft Protector
Button
J 36660
Electronic Torque
Angle Meter
J 42847
Flywheel Holding Tool
J 41240
Fan Clutch Wrench
J 42849
Crankshaft Rear
Seal Installer
J 41712
Oil Pressure Sending
Unit Socket
2001 Marine/Industrial
Engine
J 42851
Front Cover Oil Seal
Installer
Engine
Illustration
J 43105
Valve Stem Seal nstaller
J 43320
Crankshaft Rear
Seal Puller
2001 Marine/Industrial