4.3L V6 2002 Service Manual PDF

Engine Engine Mechanical - 4.
3L 6-1
Engine Mechanical - 4.3L

Specifications
SIE-ID = 645451
Fastener Tightening Specifications (G Van)

Specification
Application Metric English
Accelerator Control Cable Bracket Nut 12 N·m 106 lb in
Accelerator Control Cable Bracket Stud to Intake Manifold 6 N·m 53 lb in
Accelerator Control Cable Bracket Stud to Throttle Body 12 N·m 106 lb in
Air Cleaner Adapter Stud 8 N·m 71 lb in
Balance Shaft Driven Gear Bolt
First Pass 20 N·m 15 lb ft
Final Pass 35 degrees
Balance Shaft Retainer Bolt 12 N·m 106 lb in
Battery Negative Cable Bolt to Engine 25 N·m 18 lb ft
Belt Idler Pulley Bolt 50 N·m 37 lb ft
Camshaft Retainer Bolt 12 N·m 106 lb in
Camshaft Sprocket Bolt 25 N·m 18 lb ft
Connecting Rod Nut
Crankshaft Balancer Bolt 95 N·m 70 lb ft
Crankshaft Bearing Cap Bolt – Preferred Method
Crankshaft Bearing Cap Bolt – Optional Strategy 105 N·m 77 lb ft
Crankshaft Position Sensor Bolt 9 N·m 80 lb in
Crankshaft Pulley Bolt 58 N·m 43 lb ft
Crankshaft Rear Oil Seal Housing Bolt and Nut 12 N·m 106 lb in
Crankshaft Rear Oil Seal Housing Retainer Stud 6 N·m 53 lb in
Cylinder Head Bolt – Preferred Method
All Bolts First Pass in Sequence 30 N·m 22 lb ft
Long Bolts Final Pass in Sequence 75 degrees
Medium Bolts Final Pass in Sequence 65 degrees
Short Bolts Final Pass in Sequence 55 degrees
Cylinder Head Bolt – Optional On-Vehicle Strategy
First Pass in Sequence 35 N·m 26 lb ft
Second Pass in Sequence 60 N·m 44 lb ft
Final Pass in Sequence 90 N·m 66 lb ft
Cylinder Head Core Hole Plug 20 N·m 15 lb ft
Distributor Cap Bolt 2.4 N·m 21 lb in
Distributor Clamp Bolt 25 N·m 18 lb ft
Drive Belt Tensioner Bolt 50 N·m 37 lb ft
EGR Valve Bolt
First Pass 7 N·m 62 lb in
Final Pass 30 N·m 22 lb ft
EGR Valve Inlet Pipe Clamp Bolt 25 N·m 18 lb ft
EGR Valve Inlet Pipe Nut at Exhaust Manifold 30 N·m 22 lb ft
2002 - Unit Repair (May 24, 2001)

6-2 Engine Mechanical - 4.3L Engine
Fastener Tightening Specifications (G Van) (cont’d)
Specification
EGR Valve Inlet Pipe Nut at Intake Manifold 25 N·m 18 lb ft
Engine Block Coolant Drain Hole Plug 20 N·m 15 lb ft
Engine Block Left Rear Oil Gallery Plug 30 N·m 22 lb ft
Engine Block Left Side Oil Gallery Plug 20 N·m 15 lb ft
Engine Block Oil Gallery Plug 20 N·m 15 lb ft
Engine Block Right Rear Oil Gallery Plug 20 N·m 15 lb ft
Engine Coolant Heater Bolt/Screw 2 N·m 18 lb in
Engine Coolant Temperature (ECT) Sensor 20 N·m 15 lb ft
Engine Flywheel Bolt 100 N·m 74 lb ft
Engine Front Cover Bolt 12 N·m 106 lb in
Engine Lift Front Bracket Stud 35 N·m 26 lb ft
Engine Mount Bolt to Engine Mount Bracket – Frame Side 58 N·m 43 lb ft
Engine Mount Bracket Bolt to Engine 54 N·m 40 lb ft
Engine Mount Bracket Bolt to Frame 45 N·m 33 lb ft
Engine Mount Bracket Nut to Engine Mount Bracket Bolt – Through-bolt 68 N·m 50 lb ft
Engine Mount Heat Shield Bolt 6 N·m 53 lb in
Engine Oil Pressure Gage Sensor 30 N·m 22 lb ft
Engine Oil Pressure Gage Sensor Fitting – Plus Required Angle 15 N·m 11 lb ft
Engine Wiring Harness Retainer Nut to Transmission to Engine Stud 10 N·m 89 lb in
Evaporative Emission (EVAP) Canister Purge Solenoid Valve Nut to
10 N·m 89 lb in
Intake Manifold
Exhaust Manifold Bolt/Stud
Fan and Water Pump Pulley Bolt 25 N·m 18 lb ft
Fuel Meter Body Bracket Bolt 10 N·m 89 lb in
Fuel Pipe Bracket Bolt 6 N·m 53 lb in
Fuel Pipe Retainer Nut 3 N·m 27 lb in
Generator and Drive Belt Tensioner Bracket Bolt to Engine 41 N·m 30 lb ft
Generator and Drive Belt Tensioner Bracket Stud Nut 41 N·m 30 lb ft
Generator and Drive Belt Tensioner Bracket Stud to Engine 20 N·m 15 lb ft
Ground Wire Bolt to Rear of Left Cylinder Head 10 N·m 89 lb in
Ground Wire Nut to Water Outlet Stud 10 N·m 89 lb in
Ground Wire Stud to Rear of Right Cylinder Head 10 N·m 89 lb in
Heater Inlet and Outlet Hose Bracket Bolt to Oil Fill Tube Lower
5 N·m 44 lb in
Support
Ignition Coil Stud 12 N·m 106 lb in
Knock Sensor 25 N·m 18 lb ft
Lower Intake Manifold Bolt
First Pass in Sequence 3 N·m 27 lb in
Second Pass in Sequence 12 N·m 106 lb in
Oil Fill Tube to Oil Fill Tube Lower Support Bolt 5 N·m 44 lb in
Oil Fill Tube Lower Support Bolt and Stud 25 N·m 18 lb ft
Oil Fill Tube Nut 12 N·m 106 lb in
Oil Filter Adapter Bolt 21 N·m 15 lb ft
Oil Filter Fitting 55 N·m 41 lb ft
2002 - Unit Repair (May 24, 2001)

Engine Engine Mechanical - 4.3L 6-3
Fastener Tightening Specifications (G Van) (cont’d)
Specification
Oil Level Indicator Tube Bolt 12 N·m 106 lb in
Oil Level Indicator Tube to Oil Fill Tube Lower Support Bolt 5 N·m 44 lb in
Oil Pan Baffle Bolt 12 N·m 106 lb in
Oil Pan Bolt and Nut 25 N·m 18 lb ft
Oil Pan Drain Plug 25 N·m 18 lb ft
Oil Pump Bolt to Rear Crankshaft Bearing Cap 90 N·m 66 lb ft
Oil Pump Cover Bolt 12 N·m 106 lb in
Power Steering Pump Bolt 50 N·m 37 lb ft
Power Steering Pump Bracket Bolt to Engine 41 N·m 30 lb ft
Power Steering Pump Bracket Stud Nut 41 N·m 30 lb ft
Power Steering Pump Bracket Stud to Engine 20 N·m 15 lb ft
Power Steering Pump Rear Bracket Nut to Engine 41 N·m 30 lb ft
Power Steering Pump Rear Bracket Nut to Power Steering Pump 50 N·m 37 lb ft
Spark Plug
Initial Installation – NEW Cylinder Head 30 N·m 22 lb ft
All Subsequent Installations 15 N·m 11 lb ft
Spark Plug Wire Support Bolt 12 N·m 106 lb in
Starter Motor Wiring Harness/Transmission Cooler Pipe Bracket Bolt to
9 N·m 80 lb in
Oil Pan
Throttle Body Stud 9 N·m 80 lb in
Transmission Bolt to Oil Pan 47 N·m 35 lb ft
Transmission Control Cable Bracket Bolt 40 N·m 30 lb ft
Transmission Cover Bolt 12 N·m 106 lb in
Transmission Fluid Fill Tube Bolt to Rear of Engine 10 N·m 89 lb in
Upper Intake Manifold Stud
Final Pass 9 N·m 80 lb in
Vacuum Brake Booster Hose Bracket Nut 11 N·m 97 lb in
Valve Lifter Pushrod Guide Bolt 16 N·m 12 lb ft
Valve Rocker Arm Bolt 30 N·m 22 lb ft
Water Outlet Stud 25 N·m 18 lb ft
Water Pump Bolt 45 N·m 33 lb ft
SIE-ID = 645455
Fastener Tightening Specifications (S/T Truck)

Specification
Accelerator Control Cable and Cruise Control Cable Bracket Nut 9 N·m 80 lb in
2002 - Unit Repair (May 24, 2001)

Fastener Tightening Specifications (S/T Truck) (cont’d)
Specification
Connecting Rod Nut
Long Bolt Final Pass in Sequence 75 degrees
Medium Bolt Final Pass in Sequence 65 degrees
Short Bolt Final Pass in Sequence 55 degrees
EGR Valve Bolt
Engine Mount Bolt – Through-bolt 74 N·m 55 lb ft
Engine Mount Bolt to Engine 54 N·m 40 lb ft
Engine Mount Bracket Bolt to Frame 45 N·m 33 lb ft
2002 - Unit Repair (May 24, 2001)

Specification
Engine Mount Nut – Through-bolt 63 N·m 46 lb ft
Engine Oil Cooler Pipe Clip Bolt to Oil Pan 9 N·m 80 lb in
Engine Wiring Harness Bracket Bolt to Generator and Drive Belt
25 N·m 18 lb ft
Tensioner Bracket
Engine Wiring Harness Bracket Bolt to Rear of Cylinder Head 35 N·m 26 lb ft
Engine Wiring Harness Bracket Nut to Intake Manifold 12 N·m 106 lb in
10 N·m 89 lb in
Intake Manifold
Fuel Pipe Bracket Bolt to Rear of Cylinder Head 30 N·m 22 lb ft
Fuel Supply Pipe Nut – Fuel Tank Side 30 N·m 22 lb ft
Ground Wire or Strap Bolt to Rear of Cylinder Head 35 N·m 26 lb ft
Heater Inlet Hose Fitting 25 N·m 18 lb ft
Oil Pan Bolt and Nut in Sequence 25 N·m 18 lb ft
Power Steering Fluid Reservoir Filler Neck Bolt to Power Steering
20 N·m 15 lb ft
Pump Bracket
Power Steering Pump Nut to Engine 41 N·m 30 lb ft
Power Steering Pump Rear Bracket Nut to Engine Stud 41 N·m 30 lb ft
Radiator Inlet Hose Support Bracket Nut to Exhaust Manifold Stud 36 N·m 27 lb ft
2002 - Unit Repair (May 24, 2001)

Specification
Remote Oil Filter Adapter Mounting Bracket Bolt 30 N·m 22 lb ft
Remote Oil Filter Adapter Nut 25 N·m 18 lb ft
Remote Oil Filter Inlet and Outlet Hose Clip Bolt 10 N·m 89 lb in
Remote Oil Filter Inlet and Outlet Hose to Remote Oil Filter
35 N·m 26 lb ft
Adapter Bolt
Remote Oil Filter Inlet and Outlet Hose to Remote Oil Filter Pipe
35 N·m 26 lb ft
Adapter Bolt
Remote Oil Filter Pipe Clip Bolt to Oil Pan 9 N·m 80 lb in
Secondary Air Injection (AIR) Check Valve Pipe Bracket Bolt to Engine 40 N·m 29 lb ft
Secondary Air Injection (AIR) Check Valve Pipe Stud Nut 25 N·m 18 lb ft
Spark Plug
9 N·m 80 lb in
Oil Pan
Valve Rocker Arm Cover Bolt 12 N·m 106 lb in
SIE-ID = 645458
Fastener Tightening Specifications (C/K 800 Truck)

Specification
Accelerator Control Cable Bracket Nut to Stud 12 N·m 106 lb in
Accelerator Control Cable Bracket Nut to Throttle Body 9 N·m 80 lb in
Battery Cable Bracket Bolt to Oil Pan 12 N·m 106 lb in
Battery Positive Cable Junction Block Bracket Bolt 25 N·m 18 lb ft
Connecting Rod Nut
2002 - Unit Repair (May 24, 2001)

Fastener Tightening Specifications (C/K 800 Truck) (cont’d)
Specification
Crankshaft Bearing Cap Bolt 105 N·m 77 lb ft
EGR Valve Bolt
Engine Mount Bolt to Engine Bracket 50 N·m 37 lb ft
Engine Mount Engine Bracket Bolt to Engine 50 N·m 37 lb ft
Engine Mount Frame Bracket Through-bolt 75 N·m 55 lb ft
Engine Mount Frame Side Mount Bolt 65 N·m 50 lb ft
Engine Oil Level Sensor 13 N·m 115 lb in
Engine Wiring Harness Bracket Bolt to Battery Positive Cable Junction
9 N·m 80 lb in
Block Bracket
25 N·m 18 lb ft
Tensioner Bracket
2002 - Unit Repair (May 24, 2001)

Specification
Engine Wiring Harness Bracket Bolt to Rear Right Side Cylinder Head 25 N·m 18 lb ft
Engine Wiring Harness Bracket Nut to Evaporative Emission (EVAP)
9 N·m 80 lb in
Canister Purge Solenoid Valve Stud
Engine Wiring Harness Bracket Nut to Intake Manifold Stud 12 N·m 106 lb in
Evaporative Emission (EVAP) Canister Purge Solenoid Valve Stud to
10 N·m 89 lb in
Intake Manifold
Exhaust Manifold Heat Shield Bolt 9 N·m 80 lb in
Frame Cross Bar Bolt 100 N·m 74 lb ft
Ground Wire Bolt to Rear of Left Side Cylinder Head 16 N·m 12 lb ft
Ground Wire Nut to Rear of Right Side Cylinder Head 16 N·m 12 lb ft
Heater Hose Bracket Bolt to Generator and Drive Belt Tensioner
25 N·m 18 lb ft
Bracket
Oil Cooler Pipe Bracket to Oil Pan Bolt 12 N·m 106 lb in
Oil Pan Skid Plate Bolt 20 N·m 15 lb ft
Power Steering Pump Nut to Engine – Rear Bracket to Engine 41 N·m 30 lb ft
Power Steering Pump Rear Bracket Nut 50 N·m 37 lb ft
Secondary Air Injection (AIR) Check Valve Pipe Bracket Bolt to Exhaust
10 N·m 89 lb in
Manifold
Secondary Air Injection (AIR) Check Valve Pipe Stud Nut 25 N·m 18 lb ft
Spark Plug
2002 - Unit Repair (May 24, 2001)

Specification
Starter Motor Wiring Harness/Transmission Cooler Pipe Bracket to Oil
9 N·m 80 lb in
Pan Bolt
Transmission to Oil Pan Bolt 47 N·m 35 lb ft
Valve Rocker Arm Cover Bolt 12 N·m 106 lb in
SIE-ID = 645459
Fastener Tightening Specifications (M/L Van)

Specification
Air Conditioning (A/C) Compressor Side Brace Bolt 25 N·m 18 lb ft
Air Conditioning (A/C) Hose Bracket Nut to Intake Manifold 5 N·m 44 lb in
Air Conditioning (A/C) Pipe Bracket Nut to Rear of Left Cylinder Head 35 N·m 26 lb ft
Body Bolt
First Pass in Sequence – All Bolts 35 N·m 26 lb ft
Final Pass in Sequence – Center Bolts 155 N·m 114 lb ft
Final Pass in Sequence – Front and Rear Bolts 90 N·m 66 lb ft
Connecting Rod Nut
2002 - Unit Repair (May 24, 2001)

Fastener Tightening Specifications (M/L Van) (cont’d)
Specification
EGR Valve Bolt
Engine Mount Bolt to Frame (4WD) 59 N·m 44 lb ft
Engine Mount Bolt to Frame (RWD) 47 N·m 35 lb ft
Engine Mount Bracket Bolt to Engine 64 N·m 47 lb ft
Engine Mount Bracket to Frame Bolt (RWD) 47 N·m 35 lb ft
Engine Mount Bracket to Frame Nut (RWD) 42 N·m 31 lb ft
Engine Mount Frame Bracket Through-bolt 68 N·m 50 lb ft
Engine Mount Nut to Frame (RWD) 42 N·m 31 lb ft
25 N·m 18 lb ft
Tensioner Bracket
Engine Wiring Harness Bracket Nut to Evaporative Emission (EVAP)
8 N·m 71 lb in
Canister Purge Solenoid Valve
Engine Wiring Harness Bracket Nut to Intake Manifold 12 N·m 106 lb in
2002 - Unit Repair (May 24, 2001)

Specification
Engine Wiring Harness Retainer Bolt to Rear of Right Cylinder Head 36 N·m 27 lb ft
10 N·m 89 lb in
Intake Manifold
Fuel Pipe Bracket Stud to Rear of Cylinder Head 33 N·m 24 lb ft
Ground Wire Bolt to Rear of Cylinder Head 35 N·m 26 lb ft
Ground Wire Nut to Water Outlet Stud 19 N·m 14 lb ft
Negative Battery Cable Stud 40 N·m 30 lb ft
Oil Cooler Pipe Bracket Bolt to Oil Pan 10 N·m 89 lb in
Oil Fill Tube Bolt 25 N·m 18 lb ft
Oil Level Indicator Tube Bolt to Transmission Fluid Fill Tube 12 N·m 106 lb in
Park Brake Bracket Bolt to Frame 24 N·m 18 lb ft
Power Steering Pump Rear Bracket Nut to Engine 41 N·m 30 lb ft
Spark Plug
2002 - Unit Repair (May 24, 2001)

Specification
10 N·m 89 lb in
Oil Pan
Transmission Fluid Fill Tube Bolt to Accelerator Control Cable Bracket 6 N·m 53 lb in
Upper Radiator Hose Support Bracket Nut to Exhaust Manifold Stud 36 N·m 27 lb ft
SIE-ID = 506832
Engine Mechanical Specifications

Specification
General Data
Engine Type V6
RPO Code L35
VIN Code W
Displacement 4.3 L 262 CID
Bore 101.60 mm 4.012 in
Stroke 88.39 mm 3.480 in
Compression Ratio 9.2:1
Firing Order 1–6–5–4–3–2
Spark Plug Gap 1.52 mm 0.060 in
42 kPa at 1,000 RPM 6 psig at 1,000 RPM
Oil Pressure – Minimum – at Normal Operating Temperature 125 kPa at 2,000 RPM 18 psig at 2,000 RPM
166 kPa at 4,000 RPM 24 psig at 4,000 RPM
Balance Shaft
Rear Bearing Journal Clearance 0.050–0.088 mm 0.0020–0.0035 in
Rear Bearing Journal Diameter 38.085–38.100 mm 1.4994–1.500 in
Camshaft
End Play 0.0254–0.2286 mm 0.0010–0.0090 in
Journal Diameter 47.440–47.490 mm 1.8677–1.8696 in
Journal Diameter Out-of-Round 0.025 mm – Maximum 0.0010 in – Maximum
Lobe Lift – Exhaust 7.20–7.30 mm 0.283–0.287 in
Lobe Lift – Intake 6.97–7.07 mm 0.274–0.278 in
Runout 0.065 mm 0.0026 in
Connecting Rod
Connecting Rod Bearing Clearance – Production 0.038–0.078 mm 0.0015–0.0031 in
Connecting Rod Bearing Clearance – Service 0.025–0.063 mm 0.0010–0.0025 in
Connecting Rod Journal Diameter 57.116–57.148 mm 2.2487–2.2497 in
Connecting Rod Journal Out-of-Round – Production 0.007 mm – Maximum 0.0002 in – Maximum
Connecting Rod Journal Out-of-Round – Service 0.025 mm – Maximum 0.0010 in – Maximum
2002 - Unit Repair (May 24, 2001)

Engine Mechanical Specifications (cont’d)
Specification
0.00508 mm –
Connecting Rod Journal Taper – Production 0.00030 in – Maximum
Maximum
Connecting Rod Journal Taper – Service 0.025 mm – Maximum 0.0010 in – Maximum
Connecting Rod Side Clearance 0.15–0.44 mm 0.006–0.017 in
Crankshaft
Crankshaft Bearing Clearance – Journal #1–Production 0.02–0.508 mm 0.0008–0.0020 in
Crankshaft Bearing Clearance – Journal #2, #3, and #4–Production 0.028–0.058 mm 0.0011–0.0023 in
Crankshaft Bearing Clearance – Journal #1–Service 0.0254–0.05 mm 0.0010–0.0020 in
Crankshaft Bearing Clearance – Journal #2, #3, and #4–Service 0.025–0.063 mm 0.0010–0.0250 in
Crankshaft End Play 0.050–0.20 mm 0.002–0.008 in
Crankshaft Journal Diameter – Journal #1 62.199–62.217 mm 2.4488–2.4495 in
Crankshaft Journal Diameter – Journal #2 and #3 62.191–62.215 mm 2.4485–2.4494 in
Crankshaft Journal Diameter – Journal #4 62.179–62.203 mm 2.4480–2.4489 in
Crankshaft Journal Out-of-Round – Production 0.005 mm – Maximum 0.0002 in – Maximum
Crankshaft Journal Out-of-Round – Service 0.025 mm – Maximum 0.0010 in – Maximum
Crankshaft Journal Taper – Production 0.007 mm – Maximum 0.0003 in – Maximum
Crankshaft Runout 0.025 mm – Maximum 0.0010 in – Maximum
Cylinder Bore
Diameter 101.618–101.643 mm 4.0007–4.0017 in
Out-of-Round – Production 0.0127 mm – Maximum 0.00050 in – Maximum
Out-of-Round – Service 0.05 mm – Maximum 0.002 in – Maximum
Taper – Production Relief Side 0.025 mm – Maximum 0.0010 in – Maximum
Taper – Production Thrust Side 0.012 mm – Maximum 0.0005 in – Maximum
Taper – Service 0.025 mm – Maximum 0.0010 in – Maximum
Cylinder Head
Surface Flatness 0.10 mm – Maximum 0.004 in – Maximum
Exhaust Manifold
Surface Flatness – Flange to Flange 0.25 mm – Maximum 0.010 in – Maximum
Surface Flatness – Individual Flange 0.05 mm – Maximum 0.002 in – Maximum
Intake Manifold
Surface Flatness 0.10 mm – Maximum 0.004 in – Maximum
Oil Pan
Oil Pan Alignment at Rear of Engine Block 0.3 mm – Maximum 0.011 in – Maximum
Piston
Piston Bore Clearance – Production 0.018–0.061 mm 0.0007–0.0024 in
Piston Bore Clearance – Service 0.075 mm – Maximum 0.0029 in – Maximum
Piston Pin
Clearance in Piston – Production 0.013–0.023 mm 0.0005–0.0009 in
Clearance in Piston – Service 0.025 mm – Maximum 0.0010 in – Maximum
Diameter 23.545–23.548 mm 0.9270–0.9271 in
0.012–0.048 mm – 0.0005–0.0019 in –
Fit in Connecting Rod
Interference Interference
Piston Rings – End Gap Measured in Cylinder Bore
Piston Compression Ring Gap – Production–Top Groove 0.25–0.40 mm 0.010–0.016 in
Piston Compression Ring Gap – Production–2nd Groove 0.38–0.58 mm 0.015–0.023 in
Piston Compression Ring Gap – Service–Top Groove 0.25–0.50 mm 0.010–0.020 in
Piston Compression Ring Gap – Service–2nd Groove 0.38–0.80 mm 0.015–0.031 in
2002 - Unit Repair (May 24, 2001)

Engine Mechanical Specifications (cont’d)
Specification
Piston Compression Ring Groove Clearance – Production–Top
0.030–0.070 mm 0.0012–0.0027 in
Groove
Piston Compression Ring Groove Clearance – Production–
0.040–0.080 mm 0.0015–0.0031 in
2nd Groove
Piston Compression Ring Groove Clearance – Service 0.030–0.085 mm 0.0012–0.0033 in
Piston Oil Ring Gap – Production 0.25–0.76 mm 0.010–0.029 in
Piston Oil Ring Gap – Service 0.005–0.090 mm 0.0002–0.0035 in
Piston Oil Ring Groove Clearance – Production 0.046–0.196 mm 0.0018–0.0077 in
Piston Oil Ring Groove Clearance – Service 0.046–0.200 mm 0.0018–0.0079 in
Valve System
Valve Face Angle 45 degrees
Valve Head Edge Margin 0.79 mm – Minimum 0.031 in – Minimum
Valve Lash Net Lash—No Adjustment
Valve Lift – Exhaust 10.879 mm 0.4280 in
Valve Lift – Intake 10.527 mm 0.4140 in
Valve Lifter Hydraulic Roller Type
Valve Rocker Arm Roller Pivot Type
Valve Rocker Arm Ratio 1.5:1
Valve Seat Angle 46 degrees
Valve Seat Runout 0.05 mm – Maximum 0.002 in – Maximum
Valve Seat Width – Exhaust 1.651–2.489 mm 0.065–0.098 in
Valve Seat Width – Intake 1.016–1.651 mm 0.040–0.065 in
Valve Spring Free Length 51.3 mm 2.02 in
Valve Spring Installed Height – Exhaust 42.92–43.43 mm 1.670–1.700 in
Valve Spring Installed Height – Intake 42.92–43.43 mm 1.670–1.700 in
Valve Spring Pressure – Closed 338–374 N at 43.2 mm 76–84 lb at 1.70 in
Valve Spring Pressure – Open 832–903 N at 32.3 mm 187–203 lb at 1.27 in
Valve Stem Clearance – Exhaust–Production 0.025–0.069 mm 0.0010–0.0027 in
Valve Stem Clearance – Exhaust–Service 0.025–0.094 mm 0.0010–0.0037 in
Valve Stem Clearance – Intake–Production 0.025–0.069 mm 0.0010–0.0027 in
Valve Stem Clearance – Intake–Service 0.025–0.094 mm 0.0010–0.0037 in
Valve Stem Oil Seal Installed Height – Measured from the Top of the
Large Diameter Valve Guide Bevel to the Bottom of the Valve Stem 1–2 mm 0.03937–0.07874 in
Oil Seal
SIE-ID = 506836
Sealers, Adhesives, and Lubricants

GM Part Number
Application Type of Material United States Canada
Balancer Shaft Driven Gear Bolt Threadlock 12345382 10953489
Camshaft Retainer Bolt Threadlock 12345382 10953489
Crankshaft Balancer Keyway Adhesive 12346141 10953433
Cylinder Head Bolt Sealant 12346004 10953480
Engine Block to the Crankshaft Rear Oil Seal Housing
Adhesive 12346141 10953433
Junction at the Oil Pan Sealing Surfaces
Engine Block to the Engine Front Cover Junction at the Oil
Adhesive 12346141 10953433
Pan Sealing Surfaces
Engine Block at the Lower Intake Manifold Sealing
Adhesive 12346141 10953433
Surfaces
2002 - Unit Repair (May 24, 2001)

Sealers, Adhesives, and Lubricants (cont’d)
GM Part Number
Application Type of Material United States Canada
Engine Block Coolant Drain Hole Plug Sealant 12346004 10953480
Engine Block Core Hole Plug Threadlock 12345382 10953489
Engine Block Oil Gallery Plug Sealant 12346004 10953480
Engine Coolant Temperature (ECT) Gage Sensor Sealant 12346004 10953480
Engine Coolant Temperature (ECT) Sensor Sealant 12346004 10953480
Engine Oil SAE 5W-30 Oil 12345610 993193
Engine Oil Pressure Sensor Sealant 12346004 10953480
Engine Oil Pressure Sensor Fitting Sealant 12346004 10953480
Engine Oil Supplement Lubricant 1052367 992367
Evaporative Emission (EVAP) Canister Purge Solenoid
Threadlock 12345382 10953489
Valve Stud
Exhaust Manifold Bolt/Stud Threadlock 12345493 10953488
Expansion Cup Plug – Balance Shaft Rear Bearing Hole Sealant 12346004 10953480
Expansion Cup Plug – Camshaft Rear Bearing Hole Sealant 12346004 10953480
Fuel Meter Body Bracket Bolt Threadlock 12345382 10953489
Fuel Pipe Bolt Threadlock 12345382 10953489
Lower Intake Manifold Bolt Threadlock 12345382 10953489
Oil Level Indicator Tube Sealant 12346004 10953480
Oil Pump Screen Tube Sealant 12346004 10953480
Throttle Body Stud Threadlock 12345382 10953489
Upper Intake Manifold Stud Threadlock 12345382 10953489
Valve Train Component Prelube Lubricant 12345501 992704
Water Pump Bolt Sealant 12346004 10953480
2002 - Unit Repair (May 24, 2001)

Component Locator
Disassembled Views (M/L Van and G Van)
SIE-ID = 645467
Upper and Lower Intake Manifold View SIO-ID = 356346
334238
Legend
(1) Fuel Pipe Retainer Bracket Nut (11) Upper Intake to Lower Intake Manifold
(2) Fuel Pipe Retainer Gasket
(3) Fuel Pipe (12) Fuel Meter Body Seal (O-ring)
(4) Fuel Pipe Bolt (13) Fuel Meter Body
(5) Fuel Seal Retainer (14) Intake Manifold
(6) Upper Fuel Seal (Yellow O-ring) (15) Throttle Body to Upper Intake Manifold
(7) Spacer Ring (Metal Flat Washer) Gasket
(8) Lower Fuel Seal (Black O-ring) (16) Throttle Body
(9) Upper Manifold Attaching Stud (17) Throttle Body Attaching Stud
(10) Upper Intake Manifold
2002 - Unit Repair (May 24, 2001)

Upper Engine View 1 SIO-ID = 519804
480504
Legend
(1) Distributor Bolt (10) Water Outlet Stud
(2) Distributor (11) Engine Coolant Thermostat
(3) Intake Manifold Bolt (Lower) (12) Accelerator Control Cable Bracket
(4) Intake Manifold Gasket (Lower) (13) Accelerator Control Cable Bracket Stud
(5) Intake Manifold Assembly (14) Ignition Coil
(6) EGR Valve (15) Ignition Coil Stud
(7) EGR Valve Bolt (16) EVAP Canister Purge Solenoid Valve Stud
(8) EGR Valve Gasket (17) EVAP Canister Purge Solenoid Valve
(9) Water Outlet
2002 - Unit Repair (May 24, 2001)

480513
Legend
(1) Valve Rocker Arm Cover (10) Spark Plug Wire Shields
(2) Valve Rocker Arm Cover Gasket (11) Exhaust Manifold Gasket
(3) Valve Rocker Arm Assembly (12) Valve Lifter
(4) Valve Rocker Arm Support (13) Valve Lifter Pushrod Guide
(5) Spark Plug Wire Support (14) Valve Pushrod
(6) Spark Plug Wire Support Bolt (15) Cylinder Head Gasket
(7) Exhaust Manifold Gasket (16) Engine Lift Front Bracket
(8) Exhaust Manifold (17) Cylinder Head Bolt
(9) Exhaust Manifold Bolt (18) Cylinder Head
2002 - Unit Repair (May 24, 2001)

Lower Engine View 1 SIO-ID = 502236
480515
Legend
(1) Oil Level Indicator Tube Bolt (15) Oil Filter Adapter (Typical)
(2) Oil Level Indicator (16) Oil Filter Adapter Bolt
(3) Oil Level Indicator Tube (17) Oil Filter
(4) Engine Oil Pressure Sensor Fitting (18) Oil Filter Fitting
(5) Balance Shaft Bearing (Rear) (19) Oil Filter Adapter Bolt
(6) Knock Sensor (20) Oil Filter Bypass Valve
(7) Expansion Cup Plug (Balance Shaft Rear (21) Engine Coolant Drain Hole Plug
Bearing Hole) (22) Engine Block Core Hole Plug
(8) Engine Block Rear Oil Gallery Plug (23) Dowel Pin (Cylinder Head Locator)
(9) Expansion Cup Plug (Camshaft Rear (24) Water Pump Gasket
Bearing Hole) (25) Water Pump
(10) Engine Block (26) Water Pump Bolt
(11) Dowel Straight Pin (Transmission Locator) (27) Front Oil Gallery Plug
(12) Left Side Oil Gallery Plug (28) Camshaft Bearings
(13) Oil Filter Adapter Gasket (29) Engine Camshaft
(14) Oil Filter Adapter Seal (O-ring) (30) Camshaft Retainer
2002 - Unit Repair (May 24, 2001)
(31) Camshaft Retainer Bolt (40) Balance Shaft
(32) Balance Shaft Drive Gear (41) Piston Ring Set
(33) Camshaft Sprocket (42) Piston
(34) Camshaft Timing Chain (43) Piston Pin
(35) Camshaft Sprocket Bolt (44) Connecting Rod Bolt
(36) Balance Shaft Gear Bolt (45) Connecting Rod
(37) Balance Shaft Driven Gear (46) Connecting Rod Bearings
(38) Balance Shaft Retainer Bolt (47) Connecting Rod Cap
(39) Balance Shaft Retainer (48) Hex Nut
2002 - Unit Repair (May 24, 2001)

480518
Legend
(1) Crankshaft Rear Oil Seal Housing (14) Oil Pan Bolt
Retainer Stud (15) Oil Pan Gasket
(2) Crankshaft Rear Oil Seal Housing Nut (16) Crankshaft Bearing Cap Bolt
(3) Flywheel Locator Pin (17) Crankshaft Bearing Cap
(4) Crankshaft Rear Oil Seal Housing Bolt (18) Crankshaft Bearings (Lower)
(5) Crankshaft Rear Oil Seal Housing (19) Crankshaft Sprocket
(6) Crankshaft Rear Oil Seal Housing Gasket
(20) Crankshaft Position Sensor Reluctor Ring
(7) Crankshaft
(21) Engine Front Cover
(8) Oil Pump Drive Shaft
(22) Crankshaft Front Oil Seal
(9) Oil Pump Locator Pin
(23) Crankshaft Balancer
(10) Oil Pump Drive Shaft Retainer
(24) Crankshaft Balancer Bolt
(11) Oil Pump
(25) Crankshaft Balancer Key
(12) Oil Pump Bolt
(26) Crankshaft Bearings (Upper)
(13) Oil Pan
2002 - Unit Repair (May 24, 2001)

Disassembled Views (S/T Truck)
SIE-ID = 645469
334238
Legend
2002 - Unit Repair (May 24, 2001)

480498
Legend
(9) Water Outlet
2002 - Unit Repair (May 24, 2001)

480511
Legend
(1) Valve Rocker Arm Cover (10) Exhaust Manifold Gasket
(2) Valve Rocker Arm Cover Gasket (11) Valve Lifter
(3) Valve Rocker Arm Assembly (12) Valve Lifter Pushrod Guide
(4) Valve Rocker Arm Support (13) Valve Pushrod
(5) Spark Plug Wire Support (14) Cylinder Head Gasket
(6) Spark Plug Wire Support Bolt (15) Engine Lift Front Bracket
(7) Exhaust Manifold Gasket (16) Cylinder Head Bolt
(8) Exhaust Manifold (17) Cylinder Head
(9) Exhaust Manifold Bolt
2002 - Unit Repair (May 24, 2001)

480515
Legend
(1) Oil Level Indicator Tube Bolt (15) Oil Filter Adapter (Typical)
(2) Oil Level Indicator (16) Oil Filter Adapter Bolt
(3) Oil Level Indicator Tube (17) Oil Filter
(4) Engine Oil Pressure Sensor Fitting (18) Oil Filter Fitting
(5) Balance Shaft Bearing (Rear) (19) Oil Filter Adapter Bolt
(6) Knock Sensor (20) Oil Filter Bypass Valve
(7) Expansion Cup Plug (Balance Shaft Rear (21) Engine Coolant Drain Hole Plug
Bearing Hole) (22) Engine Block Core Hole Plug
(8) Engine Block Rear Oil Gallery Plug (23) Dowel Pin (Cylinder Head Locator)
(9) Expansion Cup Plug (Camshaft Rear (24) Water Pump Gasket
Bearing Hole) (25) Water Pump
(10) Engine Block (26) Water Pump Bolt
(11) Dowel Straight Pin (Transmission Locator) (27) Front Oil Gallery Plug
(12) Left Side Oil Gallery Plug (28) Camshaft Bearings
(13) Oil Filter Adapter Gasket (29) Engine Camshaft
(14) Oil Filter Adapter Seal (O-ring) (30) Camshaft Retainer
2002 - Unit Repair (May 24, 2001)
(31) Camshaft Retainer Bolt (40) Balance Shaft
(32) Balance Shaft Drive Gear (41) Piston Ring Set
(33) Camshaft Sprocket (42) Piston
(34) Camshaft Timing Chain (43) Piston Pin
(35) Camshaft Sprocket Bolt (44) Connecting Rod Bolt
(36) Balance Shaft Gear Bolt (45) Connecting Rod
(37) Balance Shaft Driven Gear (46) Connecting Rod Bearings
(38) Balance Shaft Retainer Bolt (47) Connecting Rod Cap
(39) Balance Shaft Retainer (48) Hex Nut
2002 - Unit Repair (May 24, 2001)

480518
Legend
(7) Crankshaft
(11) Oil Pump
(12) Oil Pump Bolt
(13) Oil Pan
2002 - Unit Repair (May 24, 2001)

Disassembled Views (C/K 800 Truck)
SIE-ID = 645471
334238
Legend
2002 - Unit Repair (May 24, 2001)

480498
Legend
(9) Water Outlet
2002 - Unit Repair (May 24, 2001)

480513
Legend
(1) Valve Rocker Arm Cover (10) Spark Plug Wire Shields
(2) Valve Rocker Arm Cover Gasket (11) Exhaust Manifold Gasket
(3) Valve Rocker Arm Assembly (12) Valve Lifter
(4) Valve Rocker Arm Support (13) Valve Lifter Pushrod Guide
(5) Spark Plug Wire Support (14) Valve Pushrod
(6) Spark Plug Wire Support Bolt (15) Cylinder Head Gasket
(7) Exhaust Manifold Gasket (16) Engine Lift Front Bracket
(8) Exhaust Manifold (17) Cylinder Head Bolt
(9) Exhaust Manifold Bolt (18) Cylinder Head
2002 - Unit Repair (May 24, 2001)

569262
Legend
(1) Oil Level Indicator Tube Bolt (15) Oil Filter Bypass Valve
(2) Oil Level Indicator (16) Engine Coolant Drain Hole Plug
(3) Oil Level Indicator Tube (17) Engine Block Core Hole Plug
(4) Engine Oil Pressure Sensor Fitting (18) Dowel Pin (Cylinder Head Locator)
(5) Balance Shaft Bearing (Rear) (19) Water Pump Gasket
(6) Knock Sensor (20) Water Pump
(7) Expansion Cup Plug (Balance Shaft Rear (21) Water Pump Bolt
Bearing Hole) (22) Front Oil Gallery Plug
(8) Engine Block Rear Oil Gallery Plug (23) Camshaft Bearings
(9) Expansion Cup Plug (Camshaft Rear (24) Engine Camshaft
Bearing Hole) (25) Camshaft Retainer
(10) Engine Block (26) Camshaft Retainer Bolt
(11) Dowel Straight Pin (Transmission Locator) (27) Balance Shaft Drive Gear
(12) Left Side Oil Gallery Plug (28) Camshaft Sprocket
(13) Oil Filter (29) Camshaft Timing Chain
(14) Oil Filter Fitting (30) Camshaft Sprocket Bolt
2002 - Unit Repair (May 24, 2001)
(31) Balance Shaft Gear Bolt (38) Piston Pin
(32) Balance Shaft Driven Gear (39) Connecting Rod Bolt
(33) Balance Shaft Retainer Bolt (40) Connecting Rod
(34) Balance Shaft Retainer (41) Connecting Rod Bearings
(35) Balance Shaft (42) Connecting Rod Cap
(36) Piston Ring Set (43) Hex Nut
(37) Piston
2002 - Unit Repair (May 24, 2001)

480518
Legend
(7) Crankshaft
(11) Oil Pump
(12) Oil Pump Bolt
(13) Oil Pan
2002 - Unit Repair (May 24, 2001)

Engine Identification − The second and third digits (2) are the month
of build.
SIE-ID = 645479
SIO-ID = 502239 − The forth and fifth digits (3) are the date
of build.
− The sixth, seventh, and eighth digits (4) are
the broadcast code.
SIO-ID = 502239
569359
• The Vehicle Identification Number (VIN) Derivative

is located on the left side rear of the engine block
(1) or on the right side rear (2) and typically is
a nine digit number stamped or laser etched onto 195339
the engine at the vehicle assembly plant. • Engines built at the Romulus engine plant have
− The first digit identifies the division. the engine identification number located at the
− The second digit identifies the model year. right front top of the engine block.
− The third digit identifies the assembly plant. − The first digit (1) is the source code.
− The fourth through ninth digits are the − The second and third digits (2) are the month
last six digits of the Vehicle Identification of build.
Number (VIN). − The fourth digit (3) is the hour of the build.
SIO-ID = 502239 − The fifth and sixth digits (4) are the date
of build.
− The seventh, eighth, and ninth digits (5) are
the broadcast code.
195338
• Engines built at the Tonawanda engine plant have

the engine identification number located at the
right front top of the engine block.
− The first digit (1) is the source code.
2002 - Unit Repair (May 24, 2001)

Repair Instructions
Draining Fluids and Oil Filter Removal
SIE-ID = 43083
1. Remove the oil pan drain plug and allow the
engine oil to drain into a suitable container.
188048
2. Remove the oil filter, if applicable.

3. Discard the oil filter, if applicable.
188050
2002 - Unit Repair (May 24, 2001)

4. Remove both the engine block coolant drain hole
plugs and allow the coolant to drain into a suitable
container.
188052
Engine Flywheel Removal (M/L Van and

G Van)
SIE-ID = 645481
1. Remove the engine flywheel bolts.
2. Remove the engine flywheel.
188130
Engine Flywheel Removal (S/T Truck and

C/K 800 Truck)
SIE-ID = 645483
1. Remove the engine flywheel bolts.
2. Remove the engine flywheel (1), automatic
transmission, if applicable.
3. Remove the engine flywheel (2), manual
transmission, if applicable.
188129
2002 - Unit Repair (May 24, 2001)

Important: If replacing the engine flywheel, manual
transmission, NEW flywheel weights must be installed
into the NEW engine flywheel in the same location
as the old flywheel weights in the old engine flywheel.
4. Note the position of any flywheel weights for
assembly, if applicable.
64126
Clutch Pilot Bearing Removal (S/T Truck

and C/K 800 Truck)
SIE-ID = 645487
Tools Required
J 43276 Clutch Pilot Bearing Remover
Caution: Refer to Safety Glasses Caution in
Cautions and Notices.
Notice: SIO-ID = 352829 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 will cause damage to
the J 43276-1 tool body.
1. Remove the clutch pilot bearing using the
J 43276.
1.1. Install the J 43276-1 tool body into the
clutch pilot bearing.
1.2. Using a wrench secure the J 43276-1 353275
tool body.
1.3. Insert the J 43276-2 forcing screw into the
J 43276-1 tool body.
1.4. Rotate the J 43276-2 forcing screw
clockwise into the J 43276-1 tool body
until the clutch pilot bearing is completely
removed from the crankshaft.
1.5. Rotate the J 43276-2 forcing screw
counterclockwise to remove the J 43276-2
forcing screw from the J 43276-1
tool body.
1.6. Remove the J 43276-1 tool body from the
clutch pilot bearing.
2. Discard the clutch pilot bearing.
2002 - Unit Repair (May 24, 2001)

Exhaust Manifold Removal - Left
SIE-ID = 645491
Notice: SIO-ID = 2878 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 spark plug wires from the
spark plugs.
1.1. Rotate the spark plug wire boot
one half turn.
1.2. Pull outward on the spark plug wire boot to
release from the spark plug.
2. Remove the spark plug wires from the spark plug
wire retainers.
3. Remove the exhaust manifold bolts and the stud.
4. Remove the spark plug wire shields, if applicable,
and the exhaust manifold.
188045
5. Remove and discard the exhaust manifold

gaskets.
328540
Exhaust Manifold Removal - Right

SIE-ID = 645493
Notice: SIO-ID = 2878 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 spark plug wires from the
spark plugs.
1.1. Rotate the spark plug wire boot
one half turn.
1.2. Pull outward on the spark plug wire boot to
release from the spark plug.
2. Remove the spark plug wires from the spark plug
wire retainers.
3. Remove the exhaust manifold bolts.
4. Remove the spark plug wire shields and the
exhaust manifold.
188121
2002 - Unit Repair (May 24, 2001)

5. Remove and discard the exhaust manifold
gaskets.
328555
Oil Level Indicator and Tube Removal

SIE-ID = 358529
1. Remove the oil level indicator from the oil level
indicator tube, if required.
330580
2. Remove the oil level indicator tube bolt.

3. Remove the oil level indicator tube from the
engine block.
188047
2002 - Unit Repair (May 24, 2001)

Water Pump Removal
SIE-ID = 358515
Tools Required
J 41240 Fan Clutch Remover and Installer
1. Remove the bolts and the fan and water pump
pulley using the J 41240.
317191
2. Remove the clamps and the water pump

inlet hose.
182853
3. Remove the water pump bolts.

4. Remove the water pump.
5. Remove the water pump gaskets.
6. Discard the water pump gaskets.
188054
2002 - Unit Repair (May 24, 2001)

Crankshaft Balancer Removal
SIE-ID = 358517
Tools Required
J 23523-F Balancer Remover and Installer
1. Remove the crankshaft balancer bolt and washer.
173172
2. Remove the bolts and the crankshaft pulley.
188055
Notice: Refer to Fastener Notice in Cautions and

Notices.
3. Use the J 23523-F in order to remove the
crankshaft balancer.
3.1. Install the J 23523-F plate and bolts onto
the crankshaft balancer.
Tighten
Tighten the bolts to 25 N·m (18 lb ft).
3.2. Install the J 23523-F forcing screw into
the plate.
3.3. Rotate the J 23523-F forcing screw
clockwise in order to remove the crankshaft
balancer.
4. Remove the J 23523-F from the crankshaft
balancer.
4059
2002 - Unit Repair (May 24, 2001)

Important: If replacing the crankshaft balancer, NEW
weights must be installed into the NEW crankshaft
balancer, in the same location as the old weights in the
old balancer.
5. Note the position and length of any crankshaft
balancer front groove pins, if applicable.
334258
Valve Rocker Arm Cover Removal - Left

SIE-ID = 645495
1. Remove the valve rocker arm cover bolts.
2. Remove the valve rocker arm cover bolt
grommets.
3. Discard the valve rocker arm cover bolt grommets.
328566
4. Remove the valve rocker arm cover.
480519
2002 - Unit Repair (May 24, 2001)

5. Remove the valve rocker arm cover gasket.
6. Discard the valve rocker arm cover gasket.
328573
Valve Rocker Arm Cover Removal - Right

SIE-ID = 645499
1. Remove the valve rocker arm cover bolts.
2. Remove the valve rocker arm cover bolt
grommets.
3. Discard the valve rocker arm cover bolt grommets.
328568
4. Remove the valve rocker arm cover.
480524
2002 - Unit Repair (May 24, 2001)

5. Remove the valve rocker arm cover gasket.
6. Discard the valve rocker arm cover gasket.
328573
Distributor Removal
SIE-ID = 358521
1. Remove the ignition coil wire harness from the
ignition coil and distributor cap.
328575
2. Remove the distributor clamp bolt.

3. Remove the distributor and the distributor clamp.
569265
2002 - Unit Repair (May 24, 2001)

4. Remove the distributor gasket and discard.
523516
Intake Manifold Removal

SIE-ID = 358523
1. Remove the evaporative emission (EVAP) canister
purge solenoid valve harness.
1.1. Push the quick disconnect clip and hold
in place.
1.2. Pull outward on the harness elbow.
328579
2. Remove the engine coolant temperature (ECT)

sensor wire connector (if equipped) from the
engine wiring harness bracket.
3. Remove the lower intake manifold bolts.
Important:
• The intake manifold may be removed as an
assembly. Do not remove the specific intake
manifold components unless component service is
required.
• Do not allow dirt or debris to enter the fuel
system. Ensure that the ends of the fuel system
are properly sealed.
• Do not disassemble the Central Sequential Fuel
Injection (SFI) unit, unless service is required.
4. Remove the intake manifold assembly.
5. Remove and discard the lower intake manifold
gaskets.
31510
2002 - Unit Repair (May 24, 2001)

Valve Rocker Arm and Push Rod Removal
SIE-ID = 506855
Important: Mark, sort, and organize all the

components for assembly.
1. Remove the valve rocker arms.
480526
2. Remove the valve rocker arm supports.
480527
3. Remove the valve pushrods.
480529
2002 - Unit Repair (May 24, 2001)

Cylinder Head Removal - Left
SIE-ID = 645503
1. Remove the engine coolant temperature sensor, if
applicable.
387769
2. Remove the engine coolant temperature gage

sensor, if applicable.
387767
3. Remove the spark plugs.
328582
2002 - Unit Repair (May 24, 2001)

4. Remove the bolts and the spark plug wire
support.
328588
5. Remove the cylinder head bolts.
480533
Notice: SIO-ID = 13838 After removal, place the

cylinder head on two wood blocks to prevent damage.
6. Remove the cylinder head.
480536
2002 - Unit Repair (May 24, 2001)

7. Remove and discard the cylinder head gasket.
334299
8. Remove the cylinder head locator dowel pins, if

required.
330548
Cylinder Head Removal - Right

SIE-ID = 645507
1. Remove the spark plugs.
328586
2002 - Unit Repair (May 24, 2001)

2. Remove the rear bolt and the spark plug wire
support.
328590
3. Remove the cylinder head bolts.
480537
Notice: SIO-ID = 13838 After removal, place the

cylinder head on two wood blocks to prevent damage.
4. Remove the cylinder head.
480538
2002 - Unit Repair (May 24, 2001)

5. Remove and discard the cylinder head gasket.
334312
6. Remove the cylinder head locator dowel pins, if

required.
330553
Valve Lifter Removal

SIE-ID = 358526
Tools Required
J 3049 Valve Lifter Remover
Important: Place the components in a rack so that
the components can be reinstalled to their original
location.
1. Remove the bolts and valve lifter pushrod guide.
328592
2002 - Unit Repair (May 24, 2001)

Important: Place the valve lifters in the rack in the
upright position in order to maintain the oil inside the
valve lifters.
2. Remove the valve lifters.
328593
Important: Some valve lifters may be stuck in the

valve lifter bores because of gum or varnish deposits
and may require the use of J 3049 for removal.
3. Use the J 3049 in order to remove the stuck valve
lifters.
31350
Oil Filter Adapter Removal (S/T Truck, M/L

Van and G Van)
SIE-ID = 645510
1. Remove the oil filter adapter bolts.
4554
2002 - Unit Repair (May 24, 2001)

2. Remove the oil filter adapter and the oil filter
adapter gasket.
3. Discard the oil filter adapter gasket.
4555
4. Remove the oil filter adapter seal (O-ring).

5. Discard the oil filter adapter seal (O-ring).
4556
Oil Pan Removal

SIE-ID = 358527
1. Remove and discard the engine oil level sensor (if
applicable).
387460
2002 - Unit Repair (May 24, 2001)

2. Remove the oil pan bolts and nuts.
330559
3. Remove the oil pan.
330568
4. Remove the oil pan gasket.

5. Discard the oil pan gasket.
387757
2002 - Unit Repair (May 24, 2001)

Oil Pump Removal
SIE-ID = 358528
1. Remove the oil pump bolt.
330572
2. Remove the oil pump.
330576
3. Inspect the oil pump locator pins for damage, and

replace the pins if required.
330578
2002 - Unit Repair (May 24, 2001)

Engine Front Cover Removal
SIE-ID = 506867
1. Remove the crankshaft position sensor bolt.
2. Remove the crankshaft position sensor.
11485
3. Remove the crankshaft position sensor seal,

O-ring.
4. Discard the crankshaft position sensor seal,
O-ring.
387759
5. Remove the engine front cover bolts.

Important: After the composite engine front cover is
removed do not reinstall the engine front cover. Always
install a NEW engine front cover.
6. Remove the engine front cover.
7. Discard the engine front cover.
480539
2002 - Unit Repair (May 24, 2001)

Timing Chain and Sprockets Removal
SIE-ID = 506868
Tools Required
J 5825-A Crankshaft Gear Remover
1. Remove the crankshaft position sensor
reluctor ring.
480541
2. Check the camshaft timing chain free play.

2.1. Rotate the camshaft sprocket (1)
counterclockwise until all slack is removed
from the camshaft timing chain (2).
2.2. Measure the free play on the slack side (3)
of the camshaft timing chain.
If the camshaft timing chain can be moved
side to side in excess of 11 mm (0.43 in),
replacement of the camshaft timing
chain and the sprockets is recommended
during assembly.
480542
3. Remove the camshaft sprocket bolts.
480544
2002 - Unit Repair (May 24, 2001)

4. Remove the camshaft sprocket and the camshaft
timing chain.
480546

5. Remove the crankshaft sprocket using the
J 5825-A.
480547
6. Remove the crankshaft balancer key.
387761
2002 - Unit Repair (May 24, 2001)

Balance Shaft Removal
SIE-ID = 358918
1. Remove the balance shaft drive gear.
9847
Important: The balance shaft drive and balance shaft

driven gears are serviced as a set. The set includes
the balance shaft driven gear bolt.
2. Remove the balance shaft driven gear bolt from
the balance shaft.
2.1. Use a wrench in order to secure the
balance shaft.
Place the wrench onto the balance shaft
near to the balance shaft front bearing.
2.2. Remove the balance shaft bolt.
2.3. Remove the wrench from the balance shaft.
3. Remove the balance shaft driven gear from
the balance shaft.
5136
4. Remove the bolts and the balance shaft retainer.
188031
2002 - Unit Repair (May 24, 2001)

Important: The balance shaft and the balance shaft
front bearing are serviced only as a package. Do not
remove the balance shaft front bearing from the
balance shaft.
5. Use a soft-faced hammer in order to remove the
balance shaft from the engine block.
5139
Camshaft Removal
SIE-ID = 42977
1. Remove the camshaft retainer bolts and retainer.
188030
Notice: SIO-ID = 13833 All camshaft journals are the

same diameter, so care must be used in removing or
installing the camshaft to avoid damage to the
camshaft bearings.
2. Remove the engine camshaft.
2.1. Install the three 5/16-18 x 4.0 inch bolts into
the engine camshaft front bolt holes.
2.2. Using the bolts as a handle, carefully rotate
and pull the engine camshaft out of the
camshaft bearings.
2.3. Remove the bolts from the front of the
engine camshaft.
5147
2002 - Unit Repair (May 24, 2001)

Piston, Connecting Rod, and Bearing
Removal
SIE-ID = 42978
Tools Required
• J 5239 Connecting Rod Bolt Guide Set
• J 24270 Cylinder Bore Ridge Reamer
1. Use the J 24270 in order to remove the cylinder
ring ridge.
1.1. Turn the crankshaft until the piston is at the
bottom of the stroke.
1.2. Place a cloth on top of the piston.
1.3. Use the J 24270 to remove all of the
cylinder ring ridge.
1.4. Turn the crankshaft so the piston is at the
top of the stroke.
1.5. Remove the cloth.
1.6. Remove the cutting debris. 11497
Important: Place matchmarks or numbers on the

connecting rods and the connecting rod caps.
2. Remove the connecting rod nuts.
3. Remove the connecting rod cap.
480549
4. Use the J 5239 in order to protect the crankshaft

journals and remove the connecting rod and the
piston out of the top of the engine block.
31373
2002 - Unit Repair (May 24, 2001)

Important: Always assemble the connecting rod caps
to the matching connecting rods.
5. Remove the connecting rod bearings.
• Keep the connecting rod bearings with the
original connecting rod and connecting rod cap.
• Wipe the oil from the connecting rod
bearings.
• Wipe the oil from the crankpins.
188017
Crankshaft Rear Oil Seal and Housing

Removal
SIE-ID = 358535
1. Remove the crankshaft rear oil seal from the
crankshaft rear oil seal housing.
Insert a suitable tool into the access notches and
then carefully pry the crankshaft rear oil seal
from the crankshaft rear oil seal housing.
2. Discard the crankshaft rear oil seal.
31379
3. Remove the crankshaft rear oil seal housing nut

and bolts.
4. Remove the crankshaft rear oil seal housing.
334317
2002 - Unit Repair (May 24, 2001)

5. Remove the crankshaft rear oil seal housing
gasket.
6. Discard the crankshaft rear oil seal housing
gasket.
334319

retainer stud from the engine block.
334326
Crankshaft and Bearings Removal

SIE-ID = 358537
1. Mark or identify the crankshaft bearing cap
locations, direction, and positions for assembly.
2. Remove the crankshaft bearing cap bolts.
3. Remove the crankshaft bearing caps.
334329
2002 - Unit Repair (May 24, 2001)

4. Remove the crankshaft.
334336
5. Remove the crankshaft bearings from the

crankshaft bearing caps.
334342
6. Remove the crankshaft bearings from the

engine block.
334338
2002 - Unit Repair (May 24, 2001)

Engine Block Plug Removal
SIE-ID = 723424
Tools Required
J 41712 Oil Pressure Switch Socket
1. Remove the knock sensor retaining bolt (1).
2. Remove the knock sensor (2).
679284
3. Remove the engine oil pressure gage sensor

using the J 41712.
188018
4. Remove the engine oil pressure sensor fitting.
188020
2002 - Unit Repair (May 24, 2001)

5. Remove the transmission locator dowel straight
pins, if required.
334350
6. Remove the engine block left side oil gallery plug.

7. Remove the engine block left rear oil gallery plug.
8. Remove the engine block right rear oil
gallery plug.
5271
9. Remove the expansion cup plug from the

camshaft rear bearing hole and discard.
334364
2002 - Unit Repair (May 24, 2001)

10. Remove the expansion cup plug from the balance
shaft rear bearing hole and discard.
334366

locator spring type S pin, if required.
334323
12. Remove the front oil gallery plugs or balls from

the front of the engine block and discard.
Insert a 3/8 x 26 inch rod into the rear oil gallery
holes in order to drive out the front oil gallery plugs
or balls.
5270
2002 - Unit Repair (May 24, 2001)

13. Remove the engine block core hole plugs.
13.1. Use a suitable tool in order to drive the
engine block core hole plugs into the
coolant jacket.
13.2. Use a suitable tool in order to pull the
engine block core hole plugs from the
coolant jacket.
13.3. Discard the engine block core hole plugs.
480550
14. Remove the oil filter bypass valve and discard.
188026
2002 - Unit Repair (May 24, 2001)

Engine Block Cleaning and Inspection
SIE-ID = 506873
Tools Required
J 8087 Cylinder Bore Gage
1. Clean all the remaining sealing or gasket material
from the sealing surfaces.
2. Clean the engine block with cleaning solvent.
3. Flush the engine block with clean water or steam.
4. Clean the cylinder bores.
5. Clean the oil galleries and the oil passages.
6. Clean the scale and the deposits from the coolant
passages.
Notice: SIO-ID = 96999 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.
7. Clean the engine block cylinder head bolt holes.
8. After cleaning the engine block, spray or wipe
the cylinder bores and the machined surfaces
with clean engine oil.
9. Inspect the following areas:
• Coolant jackets (1) for cracks
• Cylinder bores (2) for scratches or gouging
334378
• Valve lifter bores (3) for excessive scoring
or wear
• Threaded holes (4) for damage
• Crankshaft bearing webs (5) for cracks
• Crankshaft bearing caps (6) and the crankshaft
bearing bores (7) for damage
− The crankshaft bearing bores should be
round and uniform when measuring the
inside diameter (ID).
− The surface where the crankshaft bearings
contact the crankshaft bearing bore should
be smooth.
− If a crankshaft bearing cap is damaged and
requires replacement, replace the crankshaft
bearing cap first, then rebore the engine
block crankshaft bearing bores and
check for the proper alignment. Finally,
check the crankshaft for the proper
clearances.
• Engine block core hole plug bores (8) for
damage
• Engine block (9) for cracks or damage
• Engine mount bosses (10) for damage
2002 - Unit Repair (May 24, 2001)

10. Measure the cylinder bores for taper and
out-of-round.
10.1. Depress the plunger on the J 8087 to
7 mm (0.275 in) or until the J 8087 enters
the cylinder bore.
10.2. Center the J 8087 in the cylinder bore and
turn the indicator dial to 0.
10.3. Move the J 8087 up and down the cylinder
bore to determine the cylinder bore taper.
Refer to Engine Mechanical
Specifications.
10.4. Turn the J 8087 to different points around
the cylinder bore to determine the cylinder
bore out-of-round condition. Refer to
Engine Mechanical Specifications.
4972
Cylinder Boring and Honing

SIE-ID = 69045
Honing Procedure
1. When honing the cylinder bores, 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 to be
removed.
• Dull, dirty stones cut unevenly and generate
excessive heat.
• DO NOT hone to a final grade with a coarse or
medium-grade stone.
• Leave sufficient metal so that all the stone
marks will be removed with the fine grade
186747
stones.
• Perform the final honing with a fine-grade
stone and hone the cylinder bore in a
cross hatch pattern at 45–65 degrees to obtain
the proper clearance.
2. During the honing operation, thoroughly check the
cylinder bore.
• Repeatedly check the cylinder bore fit with the
selected piston.
• All measurements of the piston or cylinder
bore should be made with the components
at normal room temperature.
3. When honing to eliminate taper in the cylinder
bore, use full strokes the complete length of the
cylinder bore.
Repeatedly check the measurement at the top,
the middle, and the bottom of the cylinder bore.
• The finish marks should be clean but
not sharp.
2002 - Unit Repair (May 24, 2001)

• The finish marks should be free from imbedded
particles or torn or folded metal.
4. When finished, the reconditioned cylinder bores
should have less than or meet the specified
out-of-round and taper requirements.
5. After the final honing and before the piston is
checked for fit, clean the cylinder bore with hot
water and detergent.
5.1. Scrub the cylinder bores with a stiff
bristle brush.
5.2. Rinse the cylinder bores thoroughly with
clean hot water.
5.3. Dry the cylinder bores with a clean rag.
5.4. Do not allow any abrasive material to
remain in the cylinder bores.
• Abrasive material may cause premature
wear of the new piston rings and the
cylinder bores.
• Abrasive material will contaminate the
engine oil and may cause premature
wear of the bearings.
6. Perform final measurements of the piston and the
cylinder bore.
7. Permanently mark the top of the piston for the
specified cylinder to which it has been fitted.
8. Apply clean engine oil to each cylinder bore in
order to prevent rusting.
Boring Procedure
1. Before starting the honing or reboring operation,
measure all the new pistons with the micrometer
contacting at points exactly 90 degrees from
the piston pin centerline.
2. File the top of the cylinder block in order to
remove any dirt or burrs before using any type of
boring bar.
3. Follow the instructions furnished by the
manufacturer regarding use of the boring
equipment.
4. When reboring the cylinders, make sure all the
crankshaft bearing caps are installed in the
original position and direction.
5. Tighten the crankshaft bearing caps to the proper
torque specifications in order to avoid distortion of
the cylinder bores in the final assembly.
6. When making the final cut with the boring bar,
leave 0.03 mm (0.001 in) on the cylinder bore
diameter for finish honing. This gives the required
position to the cylinder clearance specifications.
Carefully perform the honing and boring operation
in order to maintain the specified clearances
between the pistons, the piston rings, and
the cylinder bores.
2002 - Unit Repair (May 24, 2001)

Piston and Connecting Rod Disassemble
SIE-ID = 195087
Tools Required
J 24086-C Piston Pin Remover/Installer
1. Remove the piston rings from the pistons.
4967
2. Press the piston pin from the connecting rod

using the J 24086-C.
The piston pin has an interference fit into the
connecting rod, and is full floating in the piston.
4965
3. Mark, separate, and organize the parts for

assembly.
34671
2002 - Unit Repair (May 24, 2001)

Piston, Connecting Rod, and Bearings
Cleaning and Inspection
SIE-ID = 506875
Important: Measurement of all components should be

taken with the components at room temperature.
Do not use a wire brush in order to clean any part of
the piston.
1. Clean the piston and connecting rod in solvent.
2. Dry the components with compressed air.
34671
3. Clean the piston ring grooves with a suitable ring

groove cleaning tool.
4977
4. Clean the piston oil lubrication holes and slots.

5. Inspect the piston for the following:
• Eroded areas (1) on the top of the piston
• Scuffed or damaged skirt (2)
• Damage to the pin bore (3)
• Cracks in the piston ring lands, the piston skirt,
or the pin bosses
• Piston ring grooves for nicks, burrs, or other
warpage which may cause the piston ring
to bind
6. Inspect the piston pin for scoring, wear or other
damage.
156168
2002 - Unit Repair (May 24, 2001)

7. Measure the piston ring-to-piston ring groove side
clearance.
7.1. Insert the edge of the piston ring into the
piston ring groove.
7.2. Roll the piston ring completely around the
piston.
• If binding is caused by a distorted piston
ring groove, MINOR imperfections may
be removed with a fine file.
• If binding is caused by a distorted piston
ring, replace the piston ring.
4969
8. Measure the piston ring side clearance with a

feeler gauge.
9. If the side clearance is too small, try another
piston ring set.
10. If the proper piston ring-to-piston ring groove
clearance cannot be achieved, replace the
piston and pin assembly.
11. To determine the proper piston ring side
clearance, refer to Engine Mechanical
Specifications.
22934
12. Inspect the connecting rod for an out-of-round

bearing bore. Refer to Engine Mechanical
Specifications.
156167
2002 - Unit Repair (May 24, 2001)

13. Inspect the connecting rod for twisting.
14. Inspect the connecting rod for damage to the
bearing cap and bolt threads.
156169
15. Measure the piston compression ring end gap.

Important: Fit each compression ring to the cylinder
in which it will be used.
15.1. Place the compression ring into the
cylinder bore.
15.2. Push the compression ring into the
cylinder bore to approximately 6.5 mm
(0.25 in) above the ring travel.
The ring must be square to the cylinder wall.
15.3. Use a feeler gage in order to measure the
end gap.
15.4. Select another size ring set if the end gap
exceeds specifications. Refer to Engine
Mechanical Specifications.
4968
Piston and Connecting Rod Assemble

SIE-ID = 195097
Tools Required
J 24086-C Piston Pin Remover/Installer
Caution: SIO-ID = 71607 Avoid contact with HOT
components. Wear safety glasses and protective
gloves to avoid personal injury.
Notice: SIO-ID = 71608 Applying excessive heat to the
connecting rod may damage or distort the rod. Rod
temperature SHOULD NOT exceed 315°C (600°F). At
this temperature the end of the connecting rod will
turn a straw color upon visual inspection.
Notice: SIO-ID = 38775 After the J 24086-C installer
hub bottoms on the support assembly, DO NOT
exceed 35,000 kPa (5,000 psi) or the tool may be
damaged.
4965
2002 - Unit Repair (May 24, 2001)

Important: When assembling the piston and
connecting rod, the mark on the top of the piston must
point to the front of the engine block. The left bank
connecting rods should have the flange face toward
the front of the engine block. The right bank connecting
rods should have the flange face toward the rear of
the engine block.
The new piston pin has an interference fit into the
connecting rod and is full floating in the piston.
1. Install the new piston pin and connecting rod
assembly.
1.1. Lubricate the piston pin bores with clean
engine oil.
1.2. Use a torch and apply MILD heat to the
piston pin end of the connecting rod.
1.3. Use the J 24086-C in order to press the
new piston pin into the piston and
connecting rod assembly.
1.4. Inspect for the proper installation of the
piston and piston pin.
The piston must move freely on the new
piston pin with no binding or interference.
Notice: SIO-ID = 16608 Use a piston ring expander to
install the piston rings. The rings may be damaged if
expanded more than necessary.
2. Install the piston rings onto the piston.
2.1. Install the oil control piston ring spacer.
2.2. Install the lower oil control piston ring.
2.3. Install the upper oil control piston ring.
2.4. Install the lower compression piston ring.
The mark on the side of the piston ring
should face the top of the piston.
2.5. Install the upper compression piston ring.
The mark on the side of the piston ring
should face the top of the piston.
490763
2002 - Unit Repair (May 24, 2001)

3. Space the compression piston ring end gaps
120 degrees apart.
4. Space the oil control piston ring end gaps a
minimum of 90 degrees apart.
4967
Crankshaft and Bearings Cleaning and

Inspection
SIE-ID = 506883
Tools Required
• J 7872 Magnetic Base Dial Indicator
• J 36660-A Torque Angle Meter
• J 43690 Rod Bearing Clearance Checking Tool
Important: Use care when handling the crankshaft.
Avoid damage to the crankshaft bearing surfaces.
1. Clean the crankshaft in cleaning solvent. Remove
all sludge or restrictions from the oil passages.
2. Dry the crankshaft with compressed air.
334383
3. Clean the crankshaft bearings in cleaning solvent.

Wipe the crankshaft bearings clean with a soft
cloth, do not scratch the crankshaft bearing
surfaces.
4. Dry the crankshaft bearings with compressed air.
334386
2002 - Unit Repair (May 24, 2001)

5. Inspect the crankshaft for the following:
• Crankshaft journals (1) should be smooth with
no evidence of scoring or damage.
• Deep grooves (2)
• Scratches or uneven wear (3)
• Pitted surfaces (4)
• Wear or damage to the thrust journal surfaces
• Scoring or damage to the rear seal surface
• Restrictions to the oil passages
• Damage to the threaded bolt holes
156170
6. Inspect the crankshaft balancer key (1), the

keyway (2), and the threaded hole (3) for damage.
Repair or replace the crankshaft as necessary.
188090
7. Measure the crankpins for out-of-round and taper.

Refer to Engine Mechanical Specifications.
188015
2002 - Unit Repair (May 24, 2001)

8. Use a suitable support to support the crankshaft
on the front and rear journals.
9. Use the J 7872 in order to measure the crankshaft
journal runout. The proper crankshaft journal
runout is 0.025 mm maximum
(0.0010 in maximum).
35210
10. Measure the crankshaft end play.

Important: In order to properly measure the crankshaft
end play, the crankshaft, the crankshaft bearings,
the crankshaft bearing caps, and the crankshaft
bearing cap bolts must be installed into the engine
block and the bolts tightened. The proper crankshaft
bearing cap bolt tightening specification is
105 N·m (77 lb ft).
10.1. Firmly thrust the crankshaft first rearward,
then forward. This will align the crankshaft
rear bearings and the crankshaft thrust
surfaces.
10.2. With the crankshaft pushed forward, insert
a feeler gage between the crankshaft and
the crankshaft bearing surface and
then measure the clearance. The proper
crankshaft end play clearance specification
is 0.050–0.20 mm (0.002–0.008 in).
10.3. Turn the crankshaft to check for binding. If
188467
the crankshaft does not turn freely, then
loosen the crankshaft bearing cap
bolts, one crankshaft bearing cap at a
time, until the tight crankshaft bearing is
located.
Burrs on the crankshaft bearing cap or
engine block, foreign matter between the
crankshaft bearing and the crankshaft
bearing cap or the engine block, or a faulty
crankshaft bearing could cause a lack of
clearance between the crankshaft and
crankshaft bearing.
2002 - Unit Repair (May 24, 2001)

11. Inspect the crankshaft bearings for craters or
pockets. Flattened sections on the crankshaft
bearing halves also indicate fatigue.
52051
12. Inspect the crankshaft bearings for excessive

scoring or discoloration.
13. Inspect the crankshaft bearings for dirt or debris
imbedded into the crankshaft bearing material.
52053
14. Inspect the crankshaft bearings for improper

seating indicated by bright, polished sections of
the crankshaft bearings.
• If the lower half of the crankshaft bearing is
worn or damaged, both the upper and
lower halves of the crankshaft bearing should
be replaced.
• Generally, if the lower half of the crankshaft
bearing is suitable for use, the upper half
of the crankshaft bearing should also be
suitable for use.
52056
2002 - Unit Repair (May 24, 2001)

Measuring Crankshaft Bearing Clearances
• The crankshaft bearings are of the precision insert
type and do not use shims for adjustment. If the
clearances are excessive, then new upper
and lower crankshaft bearings will be required.
The service crankshaft bearings are available in
the standard size and an undersize.
• The selective fitting of the crankshaft 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
crankshaft bearing with one-half of an undersize
crankshaft bearing.
• In order to determine the correct replacement
bearing size, the bearing clearance must be
measured accurately. When checking main
bearing clearances, either the micrometer or
plastic gage method may be used; however, the
micrometer method gives more reliable results and
is preferred. When checking connecting rod 188015
bearing clearances, the plastic gage method will
result in unreliable measurements. The use of
J 43690 is preferred.
• Normally the crankshaft bearing journals wear
evenly and are not out-of-round. However, if
a crankshaft bearing is being fitted to an
out-of-round crankshaft bearing journal, be sure to
fit to the maximum diameter of the crankshaft
bearing journal. If the crankshaft bearing is fitted
to the minimum diameter and the crankshaft
bearing journal is excessively out-of-round, the
interference between the crankshaft bearing
and the crankshaft bearing journal will result in
rapid crankshaft bearing failure.
• If the crankshaft bearing clearance is within
specifications, the crankshaft bearing is
satisfactory. If the clearance is not within
specifications, replace the crankshaft bearing.
Always replace both the upper and lower
crankshaft bearings as a set.
• A standard or undersize crankshaft bearing
combination may result in the proper clearance. If
the proper crankshaft bearing clearance cannot
be achieved using the standard or the undersize
crankshaft bearings, it may be necessary to
repair or replace the crankshaft.
Measuring Crankshaft Bearing Clearances –
Micrometer Method
1. Measure the crankshaft journal diameter with a
micrometer in several places, approximately
90 degrees apart. Average the measurements.
2. Determine the taper and out-of-round of the
journal. Refer to Engine Mechanical
Specifications.
2002 - Unit Repair (May 24, 2001)

3. Install the bearings into the engine block or
connecting rod assembly.
334338
4. Install the bearing cap bolts and tighten to

specifications. Refer to Fastener Tightening
Specifications (G Van) or Fastener Tightening
Specifications (S/T Truck) or Fastener Tightening
Specifications (C/K 800 Truck) or Fastener
Tightening Specifications (M/L Van).
5. Measure the bearing inside diameter (ID) at
two points 90 degrees apart. Average the
measurements.
6. In order to determine the bearing clearance,
subtract the average journal diameter from
the average bearing inside diameter.
7. Compare the readings to specifications. Refer to
Engine Mechanical Specifications.
8. Replace bearing halves as required to obtain the
proper bearing clearances.
353070
Measuring Connecting Rod Bearing

Clearances – J 43690 Method
1. Remove the oil pan and other necessary
components to gain access to the connecting rods.
Remove the oil pump, screen, and deflector,
when applicable.
2. Rotate the crankshaft until the crankshaft
journal/connecting rod to be measured is in the
10 o’clock position.
Important: The crankshaft must be secure with no
movement or rotation in order to obtain an accurate
reading. Remove an intermediate bearing cap,
as required, in order to secure the crankshaft and
allow measurement of connecting rod bearing
clearances.
3. Remove the bearing cap bolts, cap and
bearing half.
317268
2002 - Unit Repair (May 24, 2001)

Notices.
4. Insert a piece of paper card stock onto the
crankshaft journal. Install the bearing half, bearing
cap, and bolts. Refer to Fastener Tightening
Specifications (G Van) or Fastener Tightening
Specifications (S/T Truck) or Fastener Tightening
Specifications (C/K 800 Truck) or Fastener
Tightening Specifications (M/L Van).
5. Install the foot (1) and bolt (2) to the pivot arm
assembly (3). Tighten the bolt until snug.
627102
6. Install the screw (1 or 3) to the pivot arm

assembly (2).
627106
2002 - Unit Repair (May 24, 2001)

7. Install the pivot arm assembly (1) onto the
connecting rod.
627108
8. Position the foot of the pivot arm assembly over

the large end of the connecting rod bolt.
9. Position the screw (1) onto the small end of the
connecting rod bolt and tighten securely.
627107
10. Install the base (1) and bolt (2) to the oil pan rail.
627109
2002 - Unit Repair (May 24, 2001)

11. Align the center of the base (1) with the screw (3)
of the pivot arm assembly. Tighten the bolt (2)
until snug.
627115
12. Align the link (1) of the pivot arm assembly on a

plane (3) equal to that of the connecting rod
beam (2).
627113
13. With the link of the pivot arm assembly aligned to

the beam of the connecting rod, position the pivot
arm to the base and insert the pin (1).
627111
2002 - Unit Repair (May 24, 2001)

14. Insert the handle (1) to the pivot arm assembly.
627116
15. Select the adapter (2), as required, and install to

the swivel base (1). Tighten until snug.
627118
Important: The clamp of the swivel base and the

shaft of the indicator should be free of oil or other
debris. A loose or improperly clamped indicator may
indicate incorrect readings.
16. Install the indicator (2) to the swivel base (1).
Tighten the clamp of the base until snug.
627122
2002 - Unit Repair (May 24, 2001)

17. Install the swivel base (1) to the oil pan rail of the
engine block. Tighten until snug.
627124
18. Adjust the swivel base as required and position

the indicator tip slightly above the connecting rod
cap. Lock the swivel base in position by rotating
the locking lever (1). Do not allow the tip of
the indicator to contact the connecting rod at
this time.
627126
19. The tip of the indicator should be positioned

above and NOT in contact with the cap end of the
connecting rod.
627129
2002 - Unit Repair (May 24, 2001)

20. Rotate the fine adjustment knobs on the dial
indicator end of the swivel base to position the tip
of the indicator in contact with the connecting rod.
627132
21. Lightly actuate the handle of the pivot arm

assembly, multiple times in both directions, to
ensure the oil film is removed from the journal.
627141
22. Load the handle in the forward position and

zero the dial indicator. Load the handle multiple
times in both directions and record the reading.
Important: During this procedure, card stock may
enter the crankshaft journal oil galleries. Be sure
to remove all card stock from the bearing journal and
oil galleries prior to reassembly.
23. Remove the bearing cap bolts, cap, and
paper stock.
24. Replace bearing halves as required to obtain the
proper bearing clearances.
25. Install the bearings, cap, and bolts. Refer to
Fastener Tightening Specifications (G Van) or
Fastener Tightening Specifications (S/T Truck) or
Fastener Tightening Specifications (C/K 800
Truck) or Fastener Tightening Specifications
(M/L Van).
627135
2002 - Unit Repair (May 24, 2001)

Measuring Crankshaft Bearing Clearances –
Plastic Gage Method
1. Install the crankshaft bearings into the
engine block.
334338
2. Install the crankshaft.
334336
3. Install the gaging plastic the full width of the

journal.
500655
2002 - Unit Repair (May 24, 2001)

4. Install the crankshaft bearings into the crankshaft
bearing caps.
334342
5. Install the crankshaft bearing caps in the original

positions and with the arrow on the crankshaft
bearing caps in the direction of the front of
the engine block.
6. Install the crankshaft bearing cap bolts.
Tighten
Tighten the crankshaft bearing caps to
105 N·m (77 lb ft).
7. Remove the crankshaft bearing cap bolts.
8. Remove the crankshaft bearing caps. The gaging
plastic may adhere to either the crankshaft
bearing journal or the crankshaft bearing surface.
334329
9. Without removing the gaging plastic, measure the

compressed width at the widest point using the
graduated scale on the edge of the gaging plastic
envelope.
If the flattened gaging 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 bearing journal.
10. Remove the flattened gaging plastic.
11. Measure the remaining crankshaft bearing
journals.
500656
2002 - Unit Repair (May 24, 2001)

Measuring Connecting Rod Bearing Side
Clearance
1. Insert a feeler gage between the connecting rod
caps and measure the connecting rod side
clearance. The proper connecting rod side
clearance specification is 0.15–0.44 mm (0.006–
0.017 in).
2. Connecting rod side clearances may also be
measured with a dial indicator set.
5163
Crankshaft Balancer Cleaning and

Inspection
SIE-ID = 358551

1. Clean the crankshaft balancer in cleaning solvent.
2. Dry the crankshaft balancer with compressed air.
3. Inspect the crankshaft balancer for the following:
• Loose or improperly installed crankshaft
balancer front groove pin (1)
A properly installed front groove pin should be
installed until flush or below flush with the
face of the crankshaft balancer.
Important: A crankshaft front oil sealing surface with
excessive scoring, grooves, rust, or other damage
must be replaced.
• Worn, grooved, or damaged crankshaft front
oil sealing surface (2) 334387
Minor imperfections on the crankshaft balancer

crankshaft front oil seal surface may be
removed with a polishing compound or fine
grade emery cloth.
• Worn, chunking, or deteriorated rubber (3)
between the hub and the outer ring
• Worn or damaged keyway (4)
• Worn or damaged bolt hole threads (5)
2002 - Unit Repair (May 24, 2001)

Engine Flywheel Cleaning and Inspection
SIE-ID = 199436

1. Clean the engine flywheel (1 or 2) in cleaning
solvent.
2. Dry the engine flywheel with compressed air.
188129
Important: Do not attempt to repair the welded areas,

if present, that retain the ring gear to the engine
flywheel plate. Always install a NEW engine flywheel.
3. Inspect the engine flywheel, automatic
transmission, if equipped, for the following:
• Stress cracks around the engine
flywheel-to-torque converter bolt hole
locations (1)
• Missing balance weights
• Stress cracks around the engine
flywheel-to-crankshaft bolt hole
locations (2 or 3)
• Welded areas that retain the ring gear onto the
engine flywheel for cracking (4), if present
• Damaged ring gear teeth (5)
381965
4. Inspect the engine flywheel, manual transmission,

if equipped, for loose or improperly installed
flywheel weights, if applicable.
A properly installed flywheel weight should be
installed until flush or below flush with the face of
the engine flywheel.
64126
2002 - Unit Repair (May 24, 2001)

5. Inspect the engine flywheel, manual transmission,
if equipped, for the following:
• Pitted friction surface (1)
• Scoring or grooves (2)
• Rust or other surface damage (3)
• Damaged ring gear teeth (4)
• Loose or improperly positioned ring gear
The ring gear has an interference fit onto the
engine flywheel and the ring gear should
be positioned completely flat against the flange
of the engine flywheel.
188086
Camshaft and Bearings Cleaning and

Inspection
SIE-ID = 506894
Tools Required
J 7872 Magnetic Base Dial Indicator
1. Clean the engine camshaft in cleaning solvent.
2. Dry the engine camshaft with compressed air.
3. Inspect the camshaft retainer plate for damage.
If the camshaft retainer plate is damaged, replace
as necessary.
4. Inspect the camshaft bearings for correct fit into
the engine block camshaft bearing bores.
The camshaft bearings have an interference fit to
the engine block camshaft bearing bores and
must not be loose in the engine block camshaft
334499
bearing bores.
Important: If any camshaft bearing is excessively
worn or scored, replace all the camshaft bearings.
5. Inspect the camshaft bearings for excessive wear
or scoring.
2002 - Unit Repair (May 24, 2001)

6. Inspect the engine camshaft for the following:
• Worn, scored, or damaged bearing journals (1)
• Worn engine camshaft lobes (2)
• Damaged bolt hole threads (3)
• Damaged camshaft sprocket locator pin (4)
188095
7. Measure the engine camshaft journals with a

micrometer.
If the camshaft journals are more than 0.025 mm
(0.0010 in) out-of-round, then replace the
engine camshaft.
188014
8. Measure for a bent engine camshaft or excessive

engine camshaft runout using the J 7872.
8.1. Mount the engine camshaft in a suitable
stand between centers.
8.2. Use the J 7872 in order to check the
intermediate engine camshaft journals.
If the runout exceeds 0.065 mm (0.0026 in),
the engine camshaft is bent and must be
replaced.
9. Measure the engine camshaft lobe lift using the
J 7872.
9.1. Place the engine camshaft on the V-blocks.
9.2. Use the J 7872 in order to measure the
engine camshaft lobe lift.
10. Replace the engine camshaft if the engine
camshaft lobe lift is not within specifications. Refer
to Engine Mechanical Specifications.
188012
2002 - Unit Repair (May 24, 2001)

Camshaft Bearing Removal
SIE-ID = 199684
Tools Required
J 33049 Camshaft Bearing Service Kit
1. Select the cone (1), the handle (10), the expanding
driver (4–8), the washer (2 or 3), and the expander
assembly (15) from the J 33049.
2. Assemble the J 33049.
66100

Important:
• A loose camshaft bearing may be caused by an
enlarged, out-of-round, or damaged engine
block camshaft bearing bore.
• Always remove the camshaft inner
bearings #2 and #3 first. The camshaft outer
bearings #1 and #4 serve as a guide for the
J 33049.
3. Remove the camshaft inner bearings #2 and #3.
3.1. Insert the J 33049 through the front of the
engine block and into the camshaft inner
bearing #2.
3.2. Tighten the J 33049 expander assembly nut
until snug.
3.3. Push the J 33049 guide cone into the
camshaft front bearing in order to align 4985
the J 33049.
3.4. Drive the camshaft inner bearing #2 from
the camshaft inner bearing bore #2.
3.5. Loosen the J 33049 expander assembly nut.
3.6. Remove the camshaft inner bearing #2
from the J 33049 expander assembly.
3.7. Insert the J 33049 expander assembly into
the camshaft inner bearing #3.
until snug.
camshaft front bearing in order to align
the J 33049.
3.10. Drive the camshaft inner bearing #3 from
the camshaft inner bearing bore #3.
3.12. Remove the camshaft inner bearing #3
4. Remove the J 33049 from the engine block.
2002 - Unit Repair (May 24, 2001)

5. Remove the camshaft outer bearings #1 and #4.
5.1. Insert the J 33049 into the camshaft outer
bearing #1.
until snug.
5.3. Drive the camshaft outer bearing #1 from
the camshaft outer bearing bore #1.
5.5. Remove the camshaft outer bearing #1
5.6. Remove the J 33049 from the engine block.
5.7. Insert the J 33049 into the camshaft
outer bearing #4.
until snug.
5.9. Drive the camshaft outer bearing #4 from
the camshaft outer bearing bore #4.
6. Remove the J 33049 from the engine block.
7. Discard the camshaft bearings.
Camshaft Bearing Installation

SIE-ID = 199692
Tools Required
J 33049 Camshaft Bearing Service Kit
Important: When installing the camshaft bearings,
always look in order to ensure that the camshaft
bearing lubrication hole is located above the 3 o’clock
position (1) or the 9 o’clock position (2). The proper
positioning of the camshaft bearing lubrication hole is
in order to ensure the best lubrication of the engine
camshaft journals.
594647
2002 - Unit Repair (May 24, 2001)

1. Assemble the J 33049 handle (10), the expanding
driver (4–8), the washer (2 or 3), and the expander
assembly (15).
66100

Important: The camshaft bearings vary in size. When
ordering the new camshaft bearings, be sure to
order the correct camshaft bearings for the application
to be serviced.
Always install the camshaft outer bearings #1 and #4
first. The camshaft outer bearings serve as a guide
for the J 33049 and help center the camshaft
inner bearings during the installation process.
2. Install the NEW camshaft outer
bearings #4 and #1.
2.1. Install the NEW camshaft outer bearing #4
onto the J 33049 expander assembly.
until snug.
2.3. Align the lubrication hole of the camshaft
outer bearing #4 above the 3 o’clock
4985
position or the 9 o’clock position of the
camshaft outer bearing bore #4 at the rear
of the engine block.
2.4. Drive the camshaft outer bearing #4 into the
camshaft outer bearing bore #4 at the rear
2.7. Install the NEW camshaft outer bearing #1
until snug.
outer bearing #1 above the 3 o’clock
camshaft outer bearing bore #1 at the front
2002 - Unit Repair (May 24, 2001)

2.10. Drive the camshaft outer bearing #1 into the
camshaft outer bearing bore #1 at the front
2.12. Carefully slide the J 33049 into the engine
block until the J 33049 expander assembly
is positioned between the camshaft
inner bearing bores.
3. Install the NEW camshaft inner
bearings #3 and #2.
3.1. Install the NEW camshaft inner bearing #3
until snug.
inner bearing #3 above the 3 o’clock
camshaft inner bearing bore #3 of the
engine block.
camshaft front bearing bore #1 in order
to align the J 33049.
3.5. Drive the camshaft inner bearing #3 into the
camshaft inner bearing bore #3.
3.7. Carefully slide the J 33049 until the
J 33049 expander assembly is positioned
between the camshaft inner bearing bore #2
and the camshaft outer bearing bore #1.
3.8. Install the NEW camshaft inner bearing #2
until snug.
inner bearing #2 above the 3 o’clock
camshaft inner bearing bore #2 of the
engine block.
camshaft front bearing bore #1 in order
to align the J 33049.
3.12. Drive the camshaft inner bearing #2 into the
camshaft inner bearing bore #2.
4. Carefully remove the J 33049 from the
engine block.
2002 - Unit Repair (May 24, 2001)

Balance Shaft Bearing and/or Bushing
Removal
SIE-ID = 358968
Tools Required
• J 26941 Bushing/Bearing Remover
• J 38834 Balance Shaft Service Kit
1. Use the J 38834 and the J 26941 in order to
remove the balance shaft rear bearing.
1.1. Install J 26941 legs behind the balance
shaft rear bearing and secure.
1.2. Install the J 38834-1 with the short threaded
end through the balance shaft bore in the
front of the engine block.
1.3. Install the J 38834-1 into J 26941.
1.4. Slide the J 38834-2 onto the J 38834-1 and
340081
into the balance shaft bore of the
engine block.
1.5. Install the J 38834 bearing, washer, and nut
onto the J 38834-1.
1.6. Using a wrench secure the J 38834-1 and
then rotate the J 38834 nut clockwise until
the balance shaft rear bearing is removed
from the engine block.
1.7. Remove the J 26941 from the balance shaft
rear bearing.
2. Discard the balance shaft rear bearing.
Balance Shaft Cleaning and Inspection

SIE-ID = 199440

front bearing are serviced only as an assembly. Do not
balance shaft.
1. Clean the following components in cleaning
solvent:
• The balance shaft (1)
• The balance shaft retainer (2)
• The balance shaft rear bearing
• The balance shaft driven gear (4)
• The balance shaft drive gear
2. Dry the following components with
compressed air:
188106
• The balance shaft (1)
• The balance shaft retainer (2)
• The balance shaft rear bearing
• The balance shaft driven gear (4)
• The balance shaft drive gear
3. Inspect the balance shaft bearings for the
following:
• Front ball bearing for damage or wear
2002 - Unit Repair (May 24, 2001)

• Front ball bearing for smoothness of operation
• Rear sleeve bearing for wear, scoring, or
other damage
4. Inspect the balance shaft (1) for the following:
• Wear or scoring on the rear bearing journal
• Damaged bolt hole threads
• Damage to the balance shaft driven gear
locator pin
5. Inspect the balance shaft retainer (2) for wear or
damage.
6. Inspect the balance shaft retainer bolts (3) for
damaged threads.
7. Inspect the driven gear (4) for the following:
• Excessive wear or damage
• Nicks, burrs, or scoring
8. Inspect the driven gear bolt (5) for damaged
threads.
9. Inspect the balance shaft drive gear for the
following:
• Excessive wear or damage
• Nicks, burrs, or scoring
9848
Balance Shaft Bearing and/or Bushing

Installation
SIE-ID = 359018
Tools Required
J 38834 Balance Shaft Service Kit
1. Use the J 38834 in order to install the balance
shaft rear bearing.
1.1. Install the J 38834-3 onto the short threaded
end of the J 38834-1.
1.2. Install the J 38834 nut, the washer, and the
bearing on the long threaded end of the
J 38834-1.
1.3. Install the J 38834-2 onto the J 38834-1 so
that the smaller diameter of the J 38834-2
will be facing the front of the engine block.
340085 1.4. Install the J 38834-2 on the inside of the
balance shaft front bearing bore.
2002 - Unit Repair (May 24, 2001)

1.5. Lubricate the NEW balance shaft rear
bearing with clean engine oil.
1.6. Install the balance shaft rear bearing onto
the J 38834-2.
1.7. Align the balance shaft rear bearing for
installation.
1.8. Using a wrench secure the
J 38834-1 into place.
1.9. Rotate the J 38834 nut until the balance
shaft rear bearing is properly and
completely pushed into the balance shaft
rear bearing bore.
2. Remove the J 38834.
Timing Chain and Sprockets Cleaning and

Inspection
SIE-ID = 507062

1. Clean the components with cleaning solvent.
3. Inspect the camshaft timing chain for binding
or wear.
480575
4. Inspect the camshaft sprocket and the crankshaft

sprocket for:
• Broken teeth (1)
• Damaged teeth (2)
• Chipped teeth (3)
• Worn teeth
• Uneven wear on the edge of the teeth
• Worn valleys between the sprocket teeth
• Crankshaft sprocket keyway for wear
188097
2002 - Unit Repair (May 24, 2001)

Valve Rocker Arm and Push Rods
Cleaning and Inspection
SIE-ID = 507063
Important: Parts that are to be reused must be

marked, sorted, and organized for assembly.
1. Mark, sort, and organize the components for
assembly.
2. Clean the components with cleaning solvent.
4. Inspect the valve rocker arm components for the
following:
• Valve rocker arm valve pushrod socket contact
surface (1)
The contact surface must be smooth with no
scoring or excessive wear.
480551
• Valve rocker arm roller pivot for binding or
damage (2)
• Valve rocker arm valve stem contact
surface (3)
The contact surface should be smooth with no
scoring or excessive wear.
• Valve rocker arm bolt threads for damage (4)
5. Inspect the valve pushrods for the following:
• Restriction of the oil passage (1)
• Wear or scoring of the end contact surfaces (2)
The end contact surfaces must be smooth with
no scoring or excessive wear.
• Shaft for bends (3)
Roll the valve pushrod on a flat surface to
determine if the valve pushrod is bent.
488857
2002 - Unit Repair (May 24, 2001)

6. Inspect the valve rocker support for excessive
wear or damage.
480553
Valve Lifters and Guides Cleaning and

Inspection
SIE-ID = 199444
1. Mark, sort, and organize the components for
assembly.
2. Clean the components in cleaning solvent.
188118
4. Inspect the valve lifter pushrod guides for

excessive wear.
5. Inspect the valve lifter pushrod guides for cracks
or damage.
334500
2002 - Unit Repair (May 24, 2001)

6. Inspect the valve lifter for the following:
• Broken or damaged clip (1)
• Worn pushrod socket (2)
• Scuffed or worn lifter body (3)
If the valve lifter shows scuffing or wear,
inspect the engine block valve lifter bores
for wear.
• Worn roller (4)
• Loose or damaged pin (5)
• Plugged oil hole (6)
178485
Cylinder Head Disassemble

SIE-ID = 507072
Tools Required
J 8062 Valve Spring Compressor
Caution: SIO-ID = 411464 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. Use the J 8062 in order to compress the valve
springs.
480554
Important: Mark, sort, and organize the components

so that the components can be reinstalled in their
original location and position.
2. Remove the valve stem keys (1).
3. Remove the J 8062 from the cylinder head.
4. Remove the valve spring cap (2).
5. Remove the valve spring (3).
6. Remove the valve stem oil seal (4).
7. Discard the valve stem oil seal.
8. Remove the valve.
480555
2002 - Unit Repair (May 24, 2001)

Cylinder Head Cleaning and Inspection
SIE-ID = 507077
Tools Required
• J 8001 Dial Indicator Set
• J 8089 Carbon Removing Brush
• J 9666 Valve Spring Tester
1. Clean the valve stems and cylinder heads on a
buffing wheel.
2. Clean the following components in cleaning
solvent:
• Valve stem keys (1)
• Valve spring cap (2)
• Valve spring (3)
• Cylinder head
3. Dry the components with compressed air. 480555
4. Use the J 8089 to clean the carbon from the

cylinder head combustion chambers.
Be careful not to scuff the combustion chambers.
5. Inspect the cylinder head for the following:
• Damage to the gasket surfaces
• Burnt or eroded areas in the combustion
chamber
• Cracks in the exhaust ports and combustion
chambers
• External cracks in the water chamber
• Restrictions in the intake or exhaust passages
• Restrictions in the cooling system passages
• Rusted, damaged, or leaking core plugs
4957
6. Measure the cylinder head for warpage with a

straight edge and feeler gage.
• A cylinder head block deck with warpage in
excess of 0.10 mm (0.004 in) within a
152.4 mm (6.0 in) area must be repaired or
replaced.
• A cylinder head exhaust manifold deck with
warpage in excess of 0.05 mm (0.002 in)
within a 152.4 mm (6.0 in) area must be
repaired or replaced.
• A cylinder head intake manifold deck with
warpage in excess of 0.10 mm (0.004 in) within
a 152.4 mm (6.0 in) area must be repaired
or replaced.
64318
2002 - Unit Repair (May 24, 2001)
7. Use the J 9666 in order to measure the valve
spring.
Replace the valve spring if the valve spring
tension is less than 338 N (76 lb) at 43.2 mm
(1.70 in).
4960
8. Inspect the valve springs for squareness.
40075
9. Valve stems (1) with excessive valve guide (2)

clearance must be repaired or the cylinder head
replaced.
156172
2002 - Unit Repair (May 24, 2001)

10. Measure the valve stem-to-guide clearance.
Excessive valve stem-to-guide clearance may
cause an excessive oil consumption and may also
cause a valve to break. Insufficient clearance
will result in noisy and sticky functioning of
the valve and will disturb the engine assembly
smoothness.
10.1. Clamp the J 8001 on the exhaust port side
of the cylinder head.
10.2. Position the dial indicator so that the
movement of the valve stem from side to
side, crosswise to the cylinder head,
will cause a direct movement of the dial
indicator stem.
The dial indicator stem must contract the
side of the valve stem just above the
valve guide.
10.3. Drop the valve head about 1.6 mm
(0.063 in) off the valve seat.
35214
10.4. Use light pressure and move the valve
stem from side to side in order to obtain a
valve stem-to-guide clearance reading.
Refer to Engine Mechanical
Specifications.
Valve Guide Reaming/Valve and Seat

Grinding
SIE-ID = 507084
Tools Required
J 5830-02 Valve Guide Reamer Set
1. Measure the valve stem-to-guide clearance. Refer
to Cylinder Head Cleaning and Inspection.
2. Improper valve stem (1) to valve guide (2)
clearance may cause excessive oil consumption.
156172
2002 - Unit Repair (May 24, 2001)

Important: Exhaust valves with excessive valve
stem-to-guide clearance must be replaced with the
available service valve that has an 0.774 mm
(0.0305 in) oversize valve stem. The intake valves are
NOT available with oversize valve stems. Replace
the cylinder head if after using a NEW intake valve in
order to measure the valve stem-to-guide clearance,
the valve stem-to-guide clearance is not within
specifications.
3. Use the J 5830–3 in order to ream the exhaust
valve guide in order to achieve the correct valve
stem-to-guide clearance.
4. Always recondition the exhaust valve seat after
reaming the exhaust valve guide bores and
installing new exhaust valves.
480556
5. Inspect the valves for the following:

• Burnt or damaged areas (1)
• Undersized margin (2)
• Bent stem (3)
• Scoring or other damage to the stem (4)
• Worn key groove (5)
• Worn stem tip (6)
156174
6. Inspect the valve contact surface for the following:

• Undersized margin (1)
• Pitted surface (2)
• Burnt or eroded areas (3)
• Acceptable edge margin (4)
Valves with excessive damage must be
replaced.
Minor imperfections of the valve or valve seat
may be repaired.
7. Reconditioning of the valves and valve seats:
• The valves must seat perfectly for the engine
to deliver optimum power and performance.
• Cooling the valve heads is another important
factor. Good contact between each valve
and valve seat in the cylinder head is
necessary to insure that the heat in the valve
head is properly carried away.
156173
2002 - Unit Repair (May 24, 2001)

• Regardless of what type of equipment is used,
it is essential that the valve guide bores are
free from carbon or dirt in order to ensure the
proper centering of the pilot in the valve guide.
The valve seats should be concentric to
within 0.05 mm (0.002 in) total indicator
reading.
• Reface pitted valves on a valve refacing
machine in order to ensure the correct
relationship between the valve head and the
valve stem.
Replace the valve if the valve stem is
excessively worn or warped.
Replace the valve if the edge margin (4) of the
valve head is less than 0.79 mm (0.031 in)
thick after grinding.
• Several different types of equipment are
available for reconditioning valves and valve
seats. Follow the equipment manufacturer’s
recommendations for equipment use to attain
the proper results.
Cylinder Head Assemble

SIE-ID = 507090
Tools Required
• J 8062 Valve Spring Compressor
• J 42073 Valve Stem Seal Installer
Important: The exhaust valve oil stem seal has the
letters EX (1) molded into the top of the seal. The
exhaust valve oil stem seal material is brown in
color (2) with a white stripe (3) painted onto the outside
diameter of the seal, or the material may be red in
color (2) with no paint stripe. The intake valve oil seal
is black in color.
1. Assemble the valve into the proper valve guide.
2. Select the proper valve stem oil seal for the
specific valve guide.
3. Lubricate the valve stem oil seal and the outside
diameter of the valve guide with clean engine oil.
4. Assemble the valve stem oil seal onto the 480558
valve stem.
2002 - Unit Repair (May 24, 2001)

5. Using the J 42073, install the valve stem oil seal
onto the valve guide.
5.1. Tap the valve stem oil seal onto the valve
guide until the J 42073 bottoms against the
valve spring seat.
5.2. Inspect the valve stem oil seal. The valve
stem oil seal should not be bottomed
against the valve guide.
There should be a 1–2 mm (0.03937–
0.07874 in) gap between the bottom edge
of the valve stem oil seal and the
valve guide.
36373
6. Install the valve spring (3).

7. Install the valve spring cap (2) onto the valve
spring (3), over the valve stem.
480555
Caution: SIO-ID = 411464 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.
8. Use the J 8062 to compress the valve spring.
9. Install the valve stem O-ring seal.
10. Install the valve stem keys.
10.1. Use grease to hold the valve stem keys in
place while disconnecting the J 8062.
10.2. Tap the end of the valve stem with a
plastic-faced hammer to seat the valve
stem keys.
480554
2002 - Unit Repair (May 24, 2001)

10.3. Inspect the valve stem keys to ensure that
they are seated in the upper groove of the
valve stem.
Oil Pump Disassemble

SIE-ID = 195049
1. Remove the oil pump driveshaft and oil pump
driveshaft retainer.
5274
Important: Do not remove the oil pump screen from

the pipe. The pipe and oil pump screen are serviced
as a complete assembly.
2. Remove the oil pump screen, if necessary. The oil
pump screen has a press fit into the oil
pump cover.
5275
2002 - Unit Repair (May 24, 2001)

3. Remove the oil pump cover bolts.
5276
4. Remove the oil pump cover.
5277
5. Remove the oil pump drive gear and the oil pump
driven gear.
6. Matchmark the gear teeth for assembly.
5278
2002 - Unit Repair (May 24, 2001)

7. Remove the following items:
7.1. The oil pump pressure relief valve spring
straight pin
7.2. The oil pump pressure relief spring
7.3. The oil pump pressure relief valve
30401
Oil Pump Cleaning and Inspection

SIE-ID = 35473

1. Clean the oil pump components in cleaning
solvent.
3. Inspect the oil pump for the following conditions:
• Scoring on the top of the gears (1)
• Damaged gears (2) for the following:
− Chipping
− Galling
− Wear
• Scoring, damage or casting imperfections to
the body (3)
• Damaged or scored gear shaft (4)
• Damaged or scored gear shaft (5) 186750
• Damaged bolt hole threads
• Worn oil pump driveshaft bore
• Damaged or sticking oil pump pressure
relief valve
Minor imperfections may be removed with a
fine oil stone.
• Collapsed or broken oil pump pressure relief
valve spring
4. If the oil pump is to be reused, install a NEW oil
pump pressure relief valve spring.
5. During oil pump installation, install a NEW oil
pump driveshaft retainer.
2002 - Unit Repair (May 24, 2001)

Oil Pump Assemble
SIE-ID = 389671
Tools Required
J 21882 Oil Suction Pipe Installer
1. Apply clean engine oil GM P/N United
States 12345610, GM P/N Canada 993193, or
equivalent, to the oil pump pressure relief valve, oil
pump pressure relief valve spring, and oil
pump body.
Important: Replace the oil pump pressure relief valve
spring when you reuse the oil pump.
2. Install the following items:
2.2. The oil pump pressure relief valve spring
30401
spring straight pin
equivalent, to the oil pump drive gear, the oil pump
driven gear, and the oil pump body internal
surfaces.
4. Install the oil pump drive gear and the oil pump
driven gear into the oil pump body.
4.1. Align the matchmarks on the oil pump drive
and driven gears.
4.2. Install the smooth side of the oil pump drive
and driven gears toward the oil pump cover.
5278
5. Install the oil pump cover.
5277
2002 - Unit Repair (May 24, 2001)

Notice: Refer to Fastener Notice in Caution and
Notices.
6. Install the oil pump cover bolts.
Tighten
Tighten the bolts to 12 N·m (106 lb in).
7. Inspect the oil pump for smoothness of operation
by turning the oil pump driveshaft by hand.
5276
8. Install the oil pump screen.

8.1. If removed, replace the oil pump screen.
The oil pump screen must have a good
press fit into the oil pump body.
8.2. Mount the oil pump in a soft jawed vise.
8.3. Apply sealant GM P/N United
States 12346004,
GM P/N Canada 10953480, or equivalent,
to the end of the oil pump screen pipe.
8.4. Use the J 21882 and a soft-faced hammer
in order to tap the oil pump screen into the
pump body.
The oil pump screen must align parallel
with the bottom of the oil pan when the oil
pan is installed.
5280
Important: Install a NEW oil pump driveshaft retainer

during assembly.
9. Install the oil pump driveshaft and the NEW oil
pump driveshaft retainer.
5274
2002 - Unit Repair (May 24, 2001)

Valve Rocker Arm Cover Cleaning and
Inspection
SIE-ID = 358571

1. Clean the valve rocker arm cover in cleaning
solvent.
2. Dry the valve rocker arm cover with
compressed air.
3. Inspect the valve rocker arm cover for the
following:
• Damage to the PCV valve grommet (1)
• Damage to the bolt holes (2)
A damaged valve rocker arm cover may
interfere with the valve rocker arms.
• Damage to the exterior of the valve rocker arm
cover (3)
334508 • Gouges or damage to the sealing surface (4)
• Damage to the oil fill tube grommet (5)
• Restrictions to the ventilation system passages
Oil Pan Cleaning and Inspection

SIE-ID = 358572
1. Remove the oil pan baffle bolts and the oil pan
baffle.
387763
2002 - Unit Repair (May 24, 2001)

2. Clean the oil pan and oil pan baffle in cleaning
solvent.
3. Dry the oil pan and oil pan baffle with
compressed air.
4. Inspect the oil pan for the following:
• Gouges or damage to the oil pan sealing
surfaces (1)
• Damage to the threaded holes (2)
• Damaged oil pan drain hole threads (3)
• Damage to the oil pan baffle
• Damage to the exterior of the oil pan
A damaged oil pan may interfere with the
proper position of the oil pump screen, or may
not distribute oil properly in the oil pan
sump area.
334509

Notices.
5. Install the oil pan baffle and the bolts.
Tighten
Tighten the oil pan baffle bolts to
12 N·m (106 lb in).
387763
Intake Manifold Disassemble

SIE-ID = 507107
1. Remove the nuts, the studs, and the accelerator
control cable bracket.
374902
2002 - Unit Repair (May 24, 2001)

2. Remove the throttle body attaching studs.
12852
3. Remove the throttle body.

4. Remove the throttle body to upper intake manifold
gasket.
5. Discard the throttle body to upper intake manifold
gasket.
12853
6. Remove the water outlet studs.

7. Remove the water outlet (1 or 2).
8. Remove the engine coolant thermostat.
480559
2002 - Unit Repair (May 24, 2001)

Important: Note the position and direction of the
exhaust gas recirculation (EGR) valve before removal.
It is possible to improperly install the EGR valve
180 degrees from the original position.
9. Remove the exhaust gas recirculation (EGR)
valve bolts.
480563
Notice: SIO-ID = 5005 The Linear EGR valve is an

electrical component. DO NOT soak in any liquid
cleaner or solvent because damage may result.
10. Remove the EGR valve and the EGR valve gasket
from the lower intake manifold.
11. Discard the EGR valve gasket.
480565
12. Remove the engine coolant temperature (ECT)

sensor plug (1) or the ECT sensor (2) from the
front of the lower intake manifold, if equipped.
480566
2002 - Unit Repair (May 24, 2001)

13. Remove the studs and the ignition coil.
480561
14. Remove the manifold absolute pressure (MAP)

sensor.
15. Remove the MAP sensor seal from the MAP
sensor.
16. Discard the MAP sensor seal.
480562
17. Remove the fuel pipe bolt (4).

18. Remove the fuel pipe retainer nuts (1).
19. Remove the fuel pipe retainer (2).
20. Remove the fuel pipe (3).
21. Remove and discard the fuel seal retainers (5).
22. Remove and discard the fuel seals (6), yellow
O-rings.
23. Remove and discard the spacer rings (7), flat
washers.
24. Remove and discard the fuel seals (8), black
O-rings.
334517
2002 - Unit Repair (May 24, 2001)

25. Remove the studs and the evaporative
emission (EVAP) canister purge solenoid valve.
26. Remove the nut and the engine wiring harness
bracket.
334511
27. Remove the upper intake manifold attaching studs.

28. Remove the upper intake manifold.
29. Remove the upper intake manifold to lower intake
manifold gasket.
30. Discard the upper intake manifold to lower intake
manifold gasket.
334513
31. Remove the fuel meter body seal and discard.

32. Remove the 6 poppet nozzles from the lower
intake manifold bores.
33. Remove the fuel meter body.
34. Remove the bolt and the fuel meter body bracket.
523513
2002 - Unit Repair (May 24, 2001)

Intake Manifold Cleaning and Inspection
SIE-ID = 358591

1. Clean the upper intake manifold in cleaning
solvent.
2. Dry the upper intake manifold with compressed air.
334515
3. Clean the lower intake manifold in cleaning

solvent.
4. Dry the lower intake manifold with compressed air.
480568
5. Inspect the upper intake manifold for the following:

• Cracks or other damage to the exterior (1)
• Cracking or damage in the gasket grooves (2)
and (3)
• Damage to the throttle body mounting
surface (4)
• Loose or damaged bolt hole thread inserts (5)
480569
2002 - Unit Repair (May 24, 2001)

6. Inspect the lower intake manifold for the following:
• Damage to the gasket sealing surfaces (1), (2)
and (3)
• Restricted exhaust gas recirculation (EGR)
system passages (4)
• Restricted cooling system passages (5)
• Cracks or damage
480570
Intake Manifold Assemble

SIE-ID = 507112
1. If reusing the fastener, apply threadlock
GM P/N United States 12345382,
GM P/N Canada 10953489, or equivalent, to the
threads of the fuel meter body bracket bolt.
Notices.
2. Install the fuel meter body bracket and bolt.
Tighten
Tighten the fuel meter bracket bolt to
10 N·m (89 lb in).
3. Install the fuel meter body into the fuel meter
body bracket.
4. Install the 6 poppet nozzles into the proper lower
intake manifold bores.
5. Inspect the poppet nozzles in order to ensure that
the poppet nozzles are firmly seated and locked 523513
in the lower intake manifold bores.
6. Install a NEW fuel meter body seal into the
groove of the fuel meter body.
2002 - Unit Repair (May 24, 2001)

7. Install a NEW upper intake manifold to lower
intake manifold gasket into the groove of the
upper intake manifold.
8. Install the upper intake manifold onto the lower
intake manifold.
9. If reusing the fasteners, apply threadlock
threads of the upper intake manifold
attaching studs.
10. Install the upper intake manifold attaching studs.
Tighten
10.1. Tighten the upper intake manifold
attaching studs on the first pass to
5 N·m (44 lb in).
10.2. Tighten the upper intake manifold
attaching studs on the final pass to
9 N·m (80 lb in).
334516

threads of the evaporative emission (EVAP)
canister purge solenoid valve studs.
12. Install the EVAP canister purge solenoid valve
and studs.
Tighten
Tighten the EVAP canister purge solenoid valve
studs to 10 N·m (89 lb in).
334511
13. Install the engine wiring harness bracket and nut.

Tighten
Tighten the engine wiring harness bracket nut to
12 N·m (106 lb in).
14. Install the NEW fuel seals (8), black O-rings, into
the fuel meter body.
15. Install the NEW spacer rings (7), flat washers, into
16. Install the NEW fuel seals (6), yellow O-rings, into
17. Install the NEW fuel seal retainers (5) into the fuel
meter body.
18. Install the fuel pipe (3) into the fuel meter body.
19. Install the fuel pipe retainer bracket (2) onto
the fuel pipe.
20. Install the fuel pipe retainer bracket nuts (1).
334517
2002 - Unit Repair (May 24, 2001)

threads of the fuel pipe bolt.
22. Install the fuel pipe bolt (4).
Tighten
22.1. Tighten the fuel pipe bracket nuts to
3 N·m (27 lb in).
22.2. Tighten the fuel pipe bolt to
6 N·m (53 lb in).
23. Install a NEW manifold absolute pressure (MAP)
sensor seal onto the MAP sensor.
24. Apply a small amount, approximately 1 drop, of
clean engine oil to the MAP sensor seal.
25. Install the MAP sensor into the upper intake
manifold.
480562
26. Install the ignition coil and studs.

Tighten
Tighten the ignition coil studs to
12 N·m (106 lb in).
480561
2002 - Unit Repair (May 24, 2001)

27. If reusing the engine coolant temperature (ECT)
sensor plug (1) or the ECT sensor (2), if equipped,
apply sealant GM P/N United States 12346004,
GM P/N Canada 10953480, or equivalent, to
the threads of the ECT sensor plug (1) or the ECT
sensor (2).
28. Install the ECT sensor or plug, if equipped, into
the front of the lower intake manifold.
Tighten
Tighten the ECT sensor or plug to
20 N·m (15 lb ft).
480566
Important: The exhaust gas recirculation (EGR) valve

must be installed in the original orientation.
29. Install a NEW EGR valve gasket and the
EGR valve.
480565
30. Install the EGR valve bolts.

Tighten
30.1. Tighten the EGR valve bolts on the
first pass to 7 N·m (62 lb in).
30.2. Tighten the EGR valve bolts on the final
pass to 30 N·m (22 lb ft).
480563
2002 - Unit Repair (May 24, 2001)

31. Install the engine coolant thermostat.
32. Install the water outlet (1 or 2).
33. Install the water outlet studs.
Tighten
Tighten the water outlet studs to 25 N·m (18 lb ft).
480559
34. Install a NEW throttle body gasket into the groove

in the upper intake manifold.
35. Install the throttle body onto the upper intake
manifold.
12853

threads of the throttle body attaching studs.
37. Install the throttle body attaching studs.
Tighten
Tighten the throttle body attaching studs to
9 N·m (80 lb in).
12852
2002 - Unit Repair (May 24, 2001)

38. Install the accelerator control cable bracket, the
studs, and the nuts.
Tighten
38.1. Tighten the accelerator control cable
bracket stud to the intake manifold to
6 N·m (53 lb in).
bracket nuts to 12 N·m (106 lb in).
bracket stud to the throttle body to
12 N·m (106 lb in).
374902
Exhaust Manifold Cleaning and Inspection

SIE-ID = 507115

1. Clean the exhaust manifolds in cleaning solvent.
3. Inspect the exhaust manifolds for the following:
• Damage to the gasket sealing surfaces (1)
• Damage to the exhaust gas recirculation (EGR)
pipe fitting (2), left manifold
• Damage to the threaded holes (3)
• Restrictions within exhaust passages
• Broken or damaged exhaust manifold heat
shields (4), if applicable
• Broken or damaged exhaust manifold
523519
4. Measure the alignment or surface flatness of the

exhaust manifold flanges using a straight edge
and a feeler gage. Refer to Engine Mechanical
Specifications.
If the surface flatness is not within the
specifications, the exhaust manifold is warped and
must be replaced.
334528
2002 - Unit Repair (May 24, 2001)

Water Pump Cleaning and Inspection
SIE-ID = 358600

1. Remove the old gasket material from the water
pump sealing surfaces.
2. Clean all the dirt and any debris from the
water pump.
3. Inspect the water pump for the following:
• Leakage or damage to the housing cover
or gasket (1)
• Excessive scratches or gouging to the gasket
sealing surfaces (2)
• Leakage from the water pump vent hole (3)
A stain around the vent hole is acceptable.
If leakage occurred (dripping) with the engine
operating and the cooling system pressurized,
then replace the water pump. 480571
• Damaged bolt hole threads (4)
• Excessive side-to-side movement of the water
pump shaft (5)
• Leakage around the water inlet pipe (6)
• Leakage around the heater hose pipe (7)
• Restrictions within the internal coolant
passages
Thread Repair
SIE-ID = 43119
General purpose thread repair kits are available
commercially.
Important: Refer to the thread repair kit
manufacturer’s instructions regarding the size of the
drill and which tap to use.
Always avoid any buildup of chips. Back out the tap
every few turns and remove the chips.
1. Determine the size, the pitch, and the depth of the
damaged thread.
2. Adjust the stop collars on the cutting tool as
needed. Tap the stop collars to the required depth.
3. Drill out the damaged thread.
4. Remove the chips.
5. Apply clean engine oil to the top thread. 4962
6. Use the tap in order to cut new thread.

7. Clean the thread.
2002 - Unit Repair (May 24, 2001)

8. Screw the thread insert onto the mandrel of the
thread insert installer. Engage the tang of the
thread insert onto the end of the mandrel.
Important: The thread insert should be flush to 1 turn
below the surface.
9. Lubricate the thread insert with clean engine oil
(except when installing in aluminum) and install
the thread insert.
10. If the tang of the thread insert does not break off
when backing out the thread insert installer, break
off the tang using a drift punch.
4963
2002 - Unit Repair (May 24, 2001)

Service Prior to Assembly • When the components are re-installed into an
SIE-ID = 43122
engine, return the components to the original
location, position, and direction.
• Dirt will cause premature wear of the rebuilt
engine. Clean all the components. • During assembly, lubricate all the moving parts
• Use the proper tools to measure the components with clean engine oil (unless otherwise specified).
when checking for excessive wear. Components The engine oil will provide the initial lubrication
not within the manufacturer’s specification must be when the engine is first started.
repaired or replaced.
2002 - Unit Repair (May 24, 2001)

Engine Block Plug Installation
SIE-ID = 723426
Tools Required
J 41712 Oil Pressure Switch Socket
1. Install a NEW oil filter bypass valve.
1.1. Install the oil filter bypass valve into the oil
gallery bore until slightly below flush with
the surface of the engine block.
1.2. Using a pointed punch, stake the engine
block area around the oil filter bypass valve.
Stake in 3 locations 120 degrees apart.
188023
2. Apply sealant GM P/N United States 12346004,

outside diameter of the NEW front engine oil
gallery plugs.
3. Install the NEW front engine block oil
gallery plugs.
A properly installed front engine oil gallery plug
must be installed slightly below flush with the front
face of the engine block.
5270
4. Apply threadlock GM P/N United States 12345382,

outside diameter of the NEW engine block
core hole plugs.
5. Install the NEW engine block core hole plugs.
A properly installed engine block core hole plug
must be installed flush or below the bottom of the
chamfer (1) of the engine block core hole.
480572
2002 - Unit Repair (May 24, 2001)

6. Install the crankshaft rear oil seal housing locator
spring type S pin, if required.
334546

outside diameter of the NEW expansion cup plug.
8. Install the NEW expansion cup plug into the
balance shaft rear bearing hole.
334540

outside diameter of the NEW expansion cup plug.
10. Install the NEW expansion cup plug into the
camshaft rear bearing hole.
334543
2002 - Unit Repair (May 24, 2001)

threads of the engine block right rear oil gallery
plug, the engine block left rear oil gallery plug, and
the engine block left side oil gallery plug.
Notices.
12. Install the engine block right rear oil gallery plug,
the engine block left rear oil gallery plug, and the
engine block left side oil gallery plug.
Tighten
• Tighten the engine block left side oil gallery
plug and the engine block right rear oil
gallery plug to 20 N·m (15 lb ft).
• Tighten the engine block left rear oil gallery
plug to 30 N·m (22 lb ft).
5271
13. Install the transmission locator dowel straight pins,

if required.
334548
14. Install the left side cylinder head locator dowel

pins, if required.
334303
2002 - Unit Repair (May 24, 2001)

15. Install the right side cylinder head locator dowel
pins, if required.
334314

threads of the engine block coolant drain
hole plugs.
17. Install the engine block coolant drain hole plugs.
Tighten
Tighten the engine block coolant hole plugs to
20 N·m (15 lb ft).
188052
18. If reusing the engine oil pressure sensor fitting,

the threads of the engine oil pressure sensor
fitting.
Important: Do not loosen the engine oil pressure
fitting after the initial torque has been obtained.
19. Install the engine oil pressure sensor fitting.
Tighten
Tighten the engine oil pressure sensor fitting to
15 N·m (11 lb ft).
Important: Do not rotate the engine oil pressure fitting
clockwise more than 359 degrees after the initial
torque has been obtained.
20. Rotate the engine oil pressure sensor fitting
clockwise to the proper position (1), 50 degrees
from the centerline (2).
334549
2002 - Unit Repair (May 24, 2001)

21. If reusing the engine oil pressure gage sensor,
the threads of the engine oil pressure gage
sensor.
22. Install the engine oil pressure gage sensor using
the J 41712.
Tighten
Tighten the engine oil pressure gage sensor to
30 N·m (22 lb ft).
188018
23. Install the knock sensor (2).

24. Install the knock sensor retaining bolt (1).
Tighten
Tighten the knock sensor to 25 N·m (18 lb ft).
679284
Crankshaft and Bearings Installation

SIE-ID = 358604
Tools Required
J 36660-A Torque Angle Meter
1. Install the crankshaft bearings into the
engine block.
2. Apply clean engine oil to the crankshaft bearings.
334338
2002 - Unit Repair (May 24, 2001)

3. Apply clean engine oil to the crankshaft bearing
journals.
4. Install the crankshaft.
334336
5. Install the crankshaft bearings into the crankshaft

bearing caps.
6. Apply clean engine oil to the crankshaft bearings.
334342
7. Install the crankshaft bearing caps in the original

position and with the arrow on the crankshaft
bearing caps in the direction of the front of
the engine block.
8. Install the crankshaft bearing cap bolts until snug.
9. Thrust the crankshaft rearward in order to set
and align the crankshaft thrust bearings and
the crankshaft bearing caps.
10. Thrust the crankshaft forward in order to align the
rear faces of the crankshaft thrust bearings.
Notices.
11. Tighten the crankshaft bearing cap bolts.
Tighten
11.1. Tighten the crankshaft bearing cap bolts
on the first pass to 20 N·m (15 lb ft).
334329
2002 - Unit Repair (May 24, 2001)

11.2. Tighten the crankshaft bearing cap bolts
on the final pass an additional 73 degrees
using the J 36660-A.
12. Measure the crankshaft end play.
12.1. Firmly thrust the crankshaft rearward, and
then forward.
This will align the crankshaft rear bearing
thrust surfaces.
12.2. With the crankshaft pushed forward, insert
a feeler gage between the crankshaft and
the crankshaft rear bearing thrust
surface to measure the clearance.
Specification
Crankshaft end play 0.05–0.20 mm (0.002–
0.008 in)
13. Rotate the crankshaft in order to check for
binding.
A bent crankshaft or lack of proper crankshaft
bearing clearance may cause binding.
14. If the crankshaft does not turn freely, loosen the
crankshaft bearing cap bolts on 1 crankshaft
188467 bearing cap at a time in order to determine the
location of the binding.
A lack of proper crankshaft bearing clearance may
be caused by the following:
• Burrs on the crankshaft bearing cap
• Foreign material between the crankshaft
bearing and the engine block
• Foreign material between the crankshaft
bearing and the crankshaft bearing cap
• Damaged crankshaft bearing
• Improper size crankshaft bearing
Crankshaft Rear Oil Seal and Housing

Installation
SIE-ID = 358606
Tools Required
J 35621-B Rear Main Seal Installer
Notices.
1. Install the crankshaft rear oil seal housing
retainer stud.
Tighten
Tighten the crankshaft rear oil seal housing
retainer stud to 6 N·m (53 lb in).
334326
2002 - Unit Repair (May 24, 2001)

Important: Always use a NEW crankshaft rear oil seal
housing gasket when installing the crankshaft rear oil
seal housing.
2. Install the NEW crankshaft rear oil seal housing
gasket.
334319
3. Install the crankshaft rear oil housing onto the

crankshaft rear oil seal housing retainer stud.
4. Install the crankshaft rear oil seal housing nut
and bolts.
Tighten
Tighten the crankshaft rear oil seal housing nut
and bolts to 12 N·m (106 lb in).
334317
5. Apply a small amount (2 to 3 drops) of clean

engine oil to the bore of the crankshaft rear oil
seal housing.
engine oil to the outside diameter of the engine
flywheel pilot flange.
7. Apply a small amount (1 drop) of clean engine oil
to the outside diameter of the flywheel locator pin.
engine oil to the crankshaft seal surface.
9. Inspect the J 35621-B flange for imperfections
that may damage the crankshaft rear oil seal.
Minor imperfections may be removed with a fine
grade emery cloth.
Important: DO NOT allow oil or any other lubricants
to contact the seal lip surface of the crankshaft
rear oil seal.
334550
2002 - Unit Repair (May 24, 2001)

10. Remove the sleeve from the crankshaft rear
oil seal.
engine oil to the outside diameter of the
crankshaft rear oil seal.
12. Install the crankshaft rear oil seal onto the
J 35621-B.
13. Install the J 35621-B onto the rear of the
crankshaft and hand tighten the tool bolts
until snug.
Notice: SIO-ID = 348112 Proper alignment of the
crankshaft rear oil seal is critical. Install the crankshaft
rear oil seal near to flush and square to the crankshaft
rear oil seal housing. Failing to do so may cause
the crankshaft rear oil seal or the crankshaft rear oil
seal installation tool to fail.
14. Install the crankshaft rear oil seal onto the
crankshaft and into the crankshaft rear oil
seal housing.
14.1. Turn the J 35621-B wing nut clockwise
until the crankshaft rear oil seal is installed
near to flush and square to the crankshaft
rear oil seal housing.
Increased resistance will be felt when the
crankshaft rear oil seal has reached
the bottom of the crankshaft rear oil seal
housing bore.
14.2. Turn the J 35621-B wing nut
counterclockwise to release the J 35621-B
from the crankshaft rear oil seal.
15. Remove the J 35621-B from the crankshaft.
16. Wipe off any excess engine oil with a clean rag.
Piston, Connecting Rod, and Bearing

Installation
SIE-ID = 645517
Tools Required
• J 5239 Connecting Rod Bolt Guide Set
• J 8037 Ring Compressor
• J 8087 Cylinder Bore Gage
Piston Selection
Important: Measurements of all components should
be taken with the components at normal room
temperature.
For proper piston fit, the engine block cylinder bores
should not have excessive wear or taper.
A used piston and piston pin set may be reinstalled if,
after cleaning and inspection, the piston and piston
4972 pin are within specifications.
1. Use the J 8087 in order to measure the cylinder
bore diameter. Measure at a point 64 mm (2.5 in)
from the top of the cylinder bore and 90 degrees
to the crankshaft centerline.
2002 - Unit Repair (May 24, 2001)

2. Measure the J 8087 with a micrometer and record
the reading.
4974
3. With a micrometer or caliper at a right angle to

the piston pin bore, measure the piston 11 mm
(0.433 in) from the bottom of the skirt.
4. Subtract the piston diameter from the cylinder
bore diameter in order to determine piston-to-bore
clearance. Refer to Engine Mechanical
Specifications.
5. If the proper clearance cannot be obtained, then
select another piston and measure the clearances.
If the proper fit cannot be obtained, the cylinder
bore may require honing or boring.
6. When the piston-to-cylinder bore clearance is
within specifications, permanently mark the top
of the piston for installation into the proper
cylinder.
188016
Installation Procedure
1. Apply clean engine oil to the following
components:
• The piston
• The piston rings
• The cylinder bore
• The bearing surfaces
2. Install the J 5239 onto the connecting rod bolts.
387765
2002 - Unit Repair (May 24, 2001)

3. Install the J 8037 onto the piston and compress
the piston rings.
480573
Important: The mark on the top of the piston must

face the front of the engine block.
When assembled, the flanges on the connecting rod
and connecting rod cap should face to the front of the
engine block on the left bank, and to the rear of the
engine block on the right bank.
4. Install the piston and connecting rod assembly,
and the J 8037 into the proper cylinder bore.
492144
5. Use the J 8037 and the J 5239 and lightly tap the
top of the piston with a wooden hammer handle.
5.1. Hold the J 8037 firmly against the engine
block until all of the piston rings have
entered the cylinder bore.
5.2. Use the J 5239 in order to guide the
connecting rod onto the crankshaft
journal.
5159
2002 - Unit Repair (May 24, 2001)

6. Remove the J 5239.
31373

Notices.
7. Install the connecting rod caps, bearings,
and nuts.
Tighten
7.1. Tighten the nuts evenly on the first pass to
27 N·m (20 lb ft).
7.2. Use the J 36660-A in order to tighten the
nuts on the final pass an additional
70 degrees.
480549
8. After the piston and connecting rod assemblies

have been installed, lightly tap each connecting
rod assembly, parallel to the crankpin, in order to
ensure that the connecting rods have side
clearance.
9. Use a feeler gage or a dial indicator to measure
the connecting rod side clearance between the
connecting rod caps. The connecting rod
side clearance should be 0.15–0.44 mm (0.006–
0.017 in).
5163
2002 - Unit Repair (May 24, 2001)

Camshaft Installation
SIE-ID = 389625
equivalent, or engine oil supplement
following components:
• The engine camshaft lobes
• The camshaft bearing journals
• The camshaft bearings
• The distributor drive gear
2. Install three 5/16–18 x 4.0 inch bolts into the
engine camshaft front bolt holes.
Notice: SIO-ID = 13833 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.
5147
3. Use the bolts as a handle in order to install the
engine camshaft.
4. Remove the 3 bolts from the front of the engine
camshaft.
threads of the camshaft retainer bolts.
Notices.
6. Install the camshaft retainer and bolts.
Tighten
Tighten the camshaft retainer bolts to
12 N·m (106 lb in).
188030
2002 - Unit Repair (May 24, 2001)

Balance Shaft Installation
SIE-ID = 386494
Tools Required
• J 8092 Universal Driver Handle
• J 36996 Balance Shaft Installer
front bearing are serviced only as an assembly. Do not
balance shaft.
equivalent, to the balance shaft front bearing.
2. Use the J 36996 and the J 8092 in order to install
the balance shaft.
5141

Notices.
3. Install the balance shaft retainer and bolts.
Tighten
188031
4. Install the balance shaft driven gear onto the

balance shaft.
threads of the balance shaft driven gear bolt.
6. Install the balance shaft driven gear bolt.
6.1. Use a wrench to secure the balance shaft.
Place the wrench onto the balance shaft
near to the balance shaft front bearing.
6.2. Install the balance shaft driven gear bolt.
Tighten
6.2.1. Tighten the balance shaft driven
gear bolt on the first pass to
20 N·m (15 lb ft).
5136
2002 - Unit Repair (May 24, 2001)

6.2.2. Tighten the balance shaft driven
gear bolt on the final pass using
the J 36660-A an additional
35 degrees.
7. Remove the wrench from the balance shaft.
8. Rotate the balance shaft by hand in order to
ensure that there is clearance between the
balance shaft and the valve lifter pushrod guide. If
the balance shaft does not rotate freely, check
to ensure that the retaining ring on the balance
shaft front bearing is seated on the case.
Important: DO NOT install the camshaft sprocket
bolts at this time.
9. Install the balance shaft drive gear.
9847
10. Rotate the engine camshaft so that the timing

mark on the balance shaft drive gear is in the
12 o’clock position.
9848
2002 - Unit Repair (May 24, 2001)

11. Remove the balance shaft drive gear.
9847
12. Rotate the balance shaft so that the timing mark

on the balance shaft driven gear is in the 6 o’clock
position.
9849
13. Position the balance shaft drive gear onto the

engine camshaft.
14. Look to ensure that the balance shaft drive gear
and the balance shaft driven gear timing marks
are aligned.
5144
2002 - Unit Repair (May 24, 2001)

Timing Chain and Sprockets Installation
SIE-ID = 507123
Tools Required
J 5590 Pinion Bearing Race Installer - Rear
1. Install the crankshaft balancer key into the
crankshaft keyway.
The crankshaft balancer key should be parallel to
the crankshaft or with a slight incline.
387766
2. Align the keyway of the crankshaft sprocket with

the crankshaft balancer key.
3. Use the J 5590 in order to install the crankshaft
sprocket.
480574
4. Rotate the crankshaft until the crankshaft sprocket

alignment mark is at the 12 o’clock position.
Important: Install the camshaft sprocket with the
alignment mark at the 6 o’clock position.
5. Install the camshaft sprocket and the camshaft
timing chain.
480546
2002 - Unit Repair (May 24, 2001)

6. Look to ensure that the crankshaft sprocket is
aligned at the 12 o’clock position and camshaft
sprocket is aligned at the 6 o’clock position.
480575

Notices.
Important: Do not use a hammer to install the
camshaft sprocket onto the camshaft. To do so may
dislodge the expansion cup plug (camshaft rear
bearing hole).
7. Install camshaft sprocket bolts.
Tighten
Tighten the camshaft sprocket bolts to
25 N·m (18 lb ft).
480544
8. Install the crankshaft position sensor reluctor ring.

8.1. Align the keyway on the crankshaft position
sensor reluctor ring with the crankshaft
balancer key in the crankshaft.
8.2. Use the J 5590 in order to push the
crankshaft position sensor reluctor ring onto
the crankshaft until completely seated
against the crankshaft sprocket.
480576
2002 - Unit Repair (May 24, 2001)

Engine Front Cover Installation
SIE-ID = 507165
Important: Once the composite engine front cover is

removed DO NOT reinstall the engine front cover.
Always install a NEW engine front cover.
1. Install the NEW engine front cover.
Notices.
2. Install the engine front cover bolts.
Tighten
480539
Important: DO NOT reuse the original crankshaft

position sensor seal, O-ring. When installing the
crankshaft position sensor be sure the crankshaft
position sensor is fully seated and held stationary in
the engine front cover crankshaft position sensor bore.
A crankshaft position sensor that is not completely
seated will cock in the engine front cover and
may result in erratic engine operation.
3. Lubricate the NEW crankshaft position sensor
seal, O-ring, with clean engine oil.
4. Install the NEW crankshaft position sensor seal,
O-ring, onto the crankshaft position sensor.
387759
5. Install crankshaft position sensor until fully seated

into the engine front cover.
6. Install crankshaft position sensor bolt.
Tighten
Tighten the crankshaft position sensor bolt to
8 N·m (71 lb in).
11485
2002 - Unit Repair (May 24, 2001)

Oil Pump Installation
SIE-ID = 358623
1. Inspect for properly installed oil pump locator pins.
330578
Important: Do not reuse the oil pump driveshaft

retainer.
During assembly, install a NEW oil pump driveshaft
retainer.
2. Install the oil pump.
3. Position the oil pump onto the pins.
330576

Notices.
4. Install the oil pump bolt attaching the oil pump to
the rear crankshaft bearing cap.
Tighten
Tighten the oil pump bolt to 90 N·m (66 lb ft).
330572
2002 - Unit Repair (May 24, 2001)

Oil Pan Installation
SIE-ID = 358625
1. Apply a 5 mm (0.197 in) wide and 25 mm (1.0 in)
long bead of adhesive GM P/N United
equivalent, to both the right and left sides of
the engine front cover to engine block junction at
the oil pan sealing surfaces.
317310
2. Apply a 5 mm (0.197 in) wide and 25 mm (1.0 in)

long bead of adhesive GM P/N United
equivalent, to both the right and left sides of
the crankshaft rear oil seal housing to engine
block junction at the oil pan sealing surfaces.
317313
Important: Always install a NEW oil pan gasket.

The oil pan gasket and oil pan must be installed and
the fasteners tightened while the adhesive is still
wet to the touch.
3. Install the NEW oil pan gasket into the groove in
the oil pan.
387757
2002 - Unit Repair (May 24, 2001)

Important: The oil pan alignment must always be
flush or forward no more than 0.3 mm (0.011 in) from
the rear face of the engine block.
4. Install the oil pan onto the engine block.
Press the oil pan gasket into the grooves of the
engine front cover and crankshaft rear oil
seal housing.
5. Slide the oil pan back against a suitable
straight edge.
330568
6. Install the oil pan bolts and nuts, but do not

tighten.
7. Measure the pan-to-transmission housing
clearance using a feeler gage and a straight edge.
Use a feeler gage to check the clearance
between the oil pan-to-transmission housing
measurement points. If the clearance exceeds
0.3 mm (0.011 in) at any of the 3 oil
pan-to-transmission housing measurement
points (1), then repeat the step until the oil
pan-to-transmission housing clearance is within
the specification. The oil pan must always be
forward of the rear face of the engine block.
38496
Notice: SIO-ID = 41424 The alignment of the mating

components is crucial. An offset greater than 0.30 mm
(0.011 in) between the rear faces of the oil pan and
block is not acceptable. Offsets greater than 0.30 mm
(0.011 in) will affect the alignment between the
engine assembly and the transmission. Mis-alignment
of the engine assembly to the transmission can
lead to internal and external damage to the engine
assembly and/or transmission.
Notices.
8. Tighten the oil pan bolts and nuts in sequence (1–
12).
Tighten
Tighten the oil pan bolts to 25 N·m (18 lb ft).
9. Measure the clearance between the 3 oil
pan-to-transmission housing measurement points
in order to ensure proper alignment.
38481
2002 - Unit Repair (May 24, 2001)

10. Install a NEW oil pan drain plug seal, O-ring, onto
the oil pan drain plug.
11. Install the oil pan drain plug into the oil pan.
Tighten
Tighten the oil pan drain plug to 25 N·m (18 lb ft).
188048
12. Install the NEW engine oil level sensor, if

applicable.
Tighten
Tighten the engine oil level sensor to
13 N·m (115 lb in).
387460
Oil Filter Adapter Installation (S/T Truck,

M/L Van and G Van)
SIE-ID = 645518
1. Install the NEW oil filter adapter seal, O-ring, into
the groove in the oil filter adapter.
4556
2002 - Unit Repair (May 24, 2001)

2. Install the oil filter adapter and NEW oil filter
adapter gasket.
4555

Notices.
3. Install the oil filter adapter bolts.
Tighten
Tighten the oil filter adapter bolts to
21 N·m (15 lb ft).
4554
Crankshaft Balancer Installation

SIE-ID = 358626
Tools Required
J 23523-F Balancer Remover and Installer
1. Look to ensure that the crankshaft balancer front
groove pin is installed in the proper location, if
applicable.
The length and location of the pins must be the
same as the original length and location.
334258
2002 - Unit Repair (May 24, 2001)

Notice: SIO-ID = 16580 The inertial weight section of
the crankshaft balancer is assembled to the hub with
a rubber type material. The correct installation
procedures (with the proper tool) must be followed or
movement of the inertial weight section of the hub
will destroy the tuning of the crankshaft balancer.
2. Apply a small amount of adhesive GM P/N United
equivalent, onto the crankshaft balancer
keyway in order to seal the crankshaft balancer
keyway and crankshaft joint.
3. Align the keyway of the crankshaft balancer with
the crankshaft balancer key.
4. Install the crankshaft balancer onto the end of the
crankshaft.
188059

Notices.
5. Use the J 23523-F in order to press the crankshaft
balancer onto the crankshaft.
5.1. Install the J 23523-F plate and bolts onto
the front of the crankshaft balancer.
Tighten
Tighten the J 23523-F plate bolts to
25 N·m (18 lb ft).
5.2. Install the J 23523-F screw into the end for
the crankshaft.
5.3. Install the J 23523-F bearing, the washer,
and the nut onto the J 23523-F screw.
5.4. Rotate the J 23523-F nut clockwise until the
crankshaft balancer hub is completely
seated against the crankshaft position
sensor reluctor ring.
4065
6. Remove the J 23523-F.
7. Install the crankshaft pulley and bolts.

Tighten
Tighten the crankshaft pulley bolts to
58 N·m (43 lb ft).
188055
2002 - Unit Repair (May 24, 2001)

8. Ensure that the crown of the crankshaft balancer
washer (2) is faced away from the engine.
342203
9. Install the crankshaft balancer washer and

the bolt.
Tighten
Tighten the crankshaft balancer bolt to
95 N·m (70 lb ft).
173172
Valve Lifter Installation

SIE-ID = 358627
1. Apply lubricant GM P/N United States 12345501,
valve lifter rollers.
Important: If reusing the valve lifters, install the valve
lifters in the original positions.
2. Install the valve lifters.
328593
2002 - Unit Repair (May 24, 2001)

Notices.
3. Install the valve lifter pushrod guides.
Tighten
Tighten the valve lifter pushrod guide bolts to
16 N·m (12 lb ft).
328592
Cylinder Head Installation - Left

SIE-ID = 645520
Tools Required
1. Clean the cylinder head gasket surfaces on the
engine block.
2. Inspect the cylinder head locator dowel pins for
proper installation.
cylinder head.
334303
Important: Do not use any type sealer on the cylinder

head gasket, unless specified.
4. Install the NEW cylinder head gasket in position
over the cylinder head locator dowel pins.
334299
2002 - Unit Repair (May 24, 2001)

5. Install the cylinder head onto the engine block.
Guide the cylinder head carefully into place over
the dowel pins and the cylinder head gasket.
480536

threads of the cylinder head bolts.
7. Install the cylinder head bolts finger tight.
480533

Notices.
8. Tighten the cylinder head bolts in sequence on
the first pass.
Tighten
Tighten the bolts in sequence on the first pass to
30 N·m (22 lb ft).
9. Use the J 36660-A in order to tighten the cylinder
head bolts in sequence on the final pass.
Tighten
• Tighten the long bolts (1, 4, 5, 8, and 9) on the
final pass in sequence to 75 degrees.
• Tighten the medium bolts (12 and 13) on the
• Tighten the short bolts (2, 3, 6, 7, 10, and 11)
on the final pass in sequence to 55 degrees.
5132
2002 - Unit Repair (May 24, 2001)

10. Install the spark plug wire support and bolts.
Tighten
Tighten the spark plug wire support bolts to
12 N·m (106 lb in).
328588
11. Measure the NEW spark plugs for the proper gap.
Adjust the spark plug gap if necessary.
Specification
Spark plug gap to 1.52 mm (0.060 in).
12. Install the spark plugs.
Tighten
• Tighten the spark plugs for a USED cylinder
head to 15 N·m (11 lb ft).
• Tighten the spark plugs for the initial
installation of a NEW cylinder head to
30 N·m (22 lb ft).
328582
13. If reusing the engine coolant temperature gage

sensor, if applicable, apply sealant GM P/N United
States 12346004, GM P/N Canada 10953480,
or equivalent, to the threads of the engine coolant
temperature gage sensor.
14. Install the engine coolant temperature gage
sensor, if applicable.
Tighten
Tighten the engine coolant temperature gage
sensor to 20 N·m (15 lb ft).
387767
2002 - Unit Repair (May 24, 2001)

15. If reusing the engine coolant temperature sensor,
if applicable, apply sealant GM P/N United
equivalent, to the threads of the engine coolant
temperature gage sensor.
16. Install the engine coolant temperature sensor, if
applicable.
Tighten
Tighten the engine coolant temperature sensor to
20 N·m (15 lb ft).
387769
Cylinder Head Installation - Right

SIE-ID = 645521
Tools Required
engine block.
2. Inspect the cylinder head locator dowel pins for
proper installation.
cylinder head.
334314
Important: Do not use any type sealer on the cylinder

head gasket, unless specified.
4. Install the NEW cylinder head gasket in position
over the cylinder head locator dowel pins.
334312
2002 - Unit Repair (May 24, 2001)

5. Install the cylinder head onto the engine block.
Guide the cylinder head carefully into place over
the dowel pins and the cylinder head gasket.
480538

threads of the cylinder head bolts.
7. Install the cylinder head bolts finger tight.
480537

Notices.
8. Tighten the cylinder head bolts in sequence on
the first pass.
Tighten
Tighten the bolts in sequence on the first pass to
30 N·m (22 lb ft).
9. Use the J 36660-A in order to tighten the cylinder
head bolts in sequence on the final pass.
Tighten
• Tighten the long bolts (1, 4, 5, 8, and 9) on the
• Tighten the medium bolts (12 and 13) on the
• Tighten the short bolts (2, 3, 6, 7, 10, and 11)
on the final pass in sequence to 55 degrees.
5132
2002 - Unit Repair (May 24, 2001)

10. Install the spark plug wire support and bolts.
Tighten
Tighten only the rear spark plug wire support bolt
to 12 N·m (106 lb in).
11. Remove the front spark plug wire support bolt.
The front spark plug wire support bolt is used to
fasten the oil level indicator tube, and will be
installed within the oil level indicator tube
installation procedure.
328590
12. Measure the NEW spark plugs for the proper gap.
Adjust the spark plug gap if necessary.
Specification
Spark plug gap to 1.52 mm (0.060 in).
13. Install the spark plugs.
Tighten
• Tighten the spark plugs for a USED cylinder
head to 15 N·m (11 lb ft).
• Tighten the spark plugs for the initial
installation of a NEW cylinder head to
30 N·m (22 lb ft).
328586
Valve Rocker Arm and Push Rod

Installation
SIE-ID = 507181
Important: Be sure to keep parts in order. Parts must

be reinstalled into the original location and position.
1. Install the valve pushrods.
480529
2002 - Unit Repair (May 24, 2001)

Important: Be sure that the arrow on the valve rocker
arm support is in the up position.
2. Install the valve rocker arm supports.
480578
3. Apply prelube GM P/N United States 12345501,

following valve rocker arm contact surfaces:
• Valve pushrod socket (1)
• Roller pivot (2)
• Valve stem tip (3)
480551
4. Install the valve rocker arm assemblies as follows:

4.1. Finger start the bolt at location (1)
4.4. Finger start the remaining valve rocker
arm bolts
480580
2002 - Unit Repair (May 24, 2001)

5. Rotate the crankshaft balancer to position the
crankshaft balancer alignment mark (1) 57–
63 degrees clockwise or counterclockwise from
the engine front cover alignment tab (2).
Notices.
Important: Once the valve rocker arm assemblies are
installed and properly torqued, no additional valve
lash adjustment is required.
6. Tighten the valve rocker arm bolts.
Tighten
Tighten valve rocker arm bolts to 30 N·m (22 lb ft).
334551
Intake Manifold Installation

SIE-ID = 358637
Notice: SIO-ID = 41431 Apply the proper amount of the

sealant when assembling this component. Excessive
use of the sealant can prohibit the component
from sealing properly. A component that is not sealed
properly can leak leading to extensive engine
damage.
1. Apply a 4.0 mm (0.157 in) patch of adhesive
cylinder head side of the lower intake manifold
gasket at each end.
Important: The lower intake manifold gasket must be
installed while the adhesive is still wet to the touch.
2. Install the lower intake manifold gasket onto
the cylinder head.
Use the gasket locator pins in order to properly
seat the lower intake manifold gasket on the 38512
cylinder head.
2002 - Unit Repair (May 24, 2001)

Important: The lower intake manifold must be
installed and the fasteners tightened while the
adhesive is still wet to the touch.
3. Apply a 5 mm (0.197 in) bead of adhesive
front top of the engine block.
4. Extend the adhesive bead 13 mm (0.50 in) onto
each lower intake manifold gasket.
26744
5. Apply a 5 mm (0.197 in) bead of adhesive

rear top of the engine block.
6. Extend the adhesive bead 13 mm (0.50 in) onto
each lower intake manifold gasket.
26743
7. Install the lower intake manifold onto the

engine block.
threads of the lower intake manifold bolts.
9. Install the lower intake manifold bolts.
31510
2002 - Unit Repair (May 24, 2001)

Notice: SIO-ID = 382467 Proper lower intake manifold
fastener tightening sequence and torque is critical.
Always follow the tightening sequence, and torque the
intake manifold bolts using the 3 step method.
Failing to do so may distort the crankshaft bearing
bore alignment and cause damage to the crankshaft
bearings.
Notices.
10. Tighten the lower intake manifold bolts.
Tighten
10.1. Tighten the bolts on the first pass in
sequence (1–8) to 3 N·m (27 lb in).
10.2. Tighten the bolts on the second pass in
sequence (1–8) to 12 N·m (106 lb in).
10.3. Tighten the bolts on the final pass in
sequence (1–8) to 15 N·m (11 lb ft).
188150
11. Connect the evaporative emission (EVAP) canister

solenoid valve harness.
11.1. Push the elbow inward until the quick
connect snaps into place.
11.2. Pull the elbow outward in order to ensure
proper connection.
328579
Distributor Installation
SIE-ID = 358641
Important: The engine front cover has 2 alignment

tabs and the crankshaft balancer has 2 alignment
marks (spaced 90 degrees apart) which are used for
positioning number 1 piston at top dead center (TDC).
With the piston on the compression stroke and at
top dead center, the crankshaft balancer alignment
mark (1) must align with the engine front cover tab (2)
and the crankshaft balancer alignment mark (4)
must align with the engine front cover tab (3).
1. Rotate the crankshaft balancer clockwise until the
alignment marks on the crankshaft balancer are
aligned with the tabs on the engine front cover and
the number 1 piston is at top dead center of the
compression stroke.
334551
2002 - Unit Repair (May 24, 2001)

2. Remove the distributor cap bolts and discard.
3. Remove the distributor cap.
301393
4. Install a NEW distributor gasket onto the

distributor.
523516
5. Align the indent hole on the driven gear with the

paint mark on the distributor housing.
6. Ensure that the distributor rotor segment points to
the cap hold area.
492137
2002 - Unit Repair (May 24, 2001)

7. Align the slotted tang in the oil pump driveshaft
with the distributor driveshaft.
Rotate the oil pump driveshaft with a screwdriver
if necessary.
8. Align the flat (1) in the distributor housing toward
the front of the engine.
523746
9. Install the distributor and distributor clamp.

The flat in the distributor housing must point
toward the front of the engine.
310298
10. Once the distributor is fully seated, align the

distributor rotor segment with the number 6
pointer (1) that is cast into the distributor base.
If the distributor rotor segment does not come
within a few degrees of the number 6 pointer (1),
the gear mesh between the distributor and
camshaft may be off a tooth or more. Repeat the
procedure again in order to achieve proper
alignment.
334555
2002 - Unit Repair (May 24, 2001)

Notices.
11. Install the distributor clamp bolt.
Tighten
Tighten the distributor clamp bolt to
25 N·m (18 lb ft).
34403
12. Install the distributor cap and NEW distributor

cap bolts.
Tighten
Tighten the distributor cap bolts to
2.4 N·m (21 lb in).
301393
13. Install the ignition coil wire harness.
387772
2002 - Unit Repair (May 24, 2001)

Valve Rocker Arm Cover Installation - Left
SIE-ID = 645522
Important: Do not reuse the valve cover gasket or the

valve rocker arm cover bolt grommets.
1. Install the NEW valve rocker arm cover gasket
into the groove of the valve rocker arm cover.
2. Install the NEW valve rocker arm cover bolt
grommets into the valve rocker arm cover.
328573
3. Install the valve rocker arm cover onto the

cylinder head.
480519

Notices.
4. Install the valve rocker arm cover bolts.
Tighten
Tighten the valve rocker arm cover bolts to
12 N·m (106 lb in).
328566
2002 - Unit Repair (May 24, 2001)

Valve Rocker Arm Cover
Installation - Right
SIE-ID = 645523
Important: Do not reuse the valve cover gasket or the

valve rocker arm cover bolt grommets.
1. Install the NEW valve rocker arm cover gasket
into the groove of the valve rocker arm cover.
2. Install the NEW valve rocker arm cover bolt
grommets into the valve rocker arm cover.
328573
3. Install the valve rocker arm cover onto the

cylinder head.
480524

Notices.
4. Install the valve rocker arm cover bolts.
Tighten
Tighten the valve rocker arm cover bolts to
12 N·m (106 lb in).
328568
2002 - Unit Repair (May 24, 2001)

Oil Level Indicator and Tube Installation
SIE-ID = 358621
GM P/N Canada 10953480, or equivalent, around
the oil level indicator tube 13 mm (0.5 in) below
the tube bead.
2. Install the oil level indicator tube into the engine
block. Rotate the oil level indicator tube into
position.
Notices.
3. Install the oil level indicator tube bolt.
Tighten
Tighten the oil level indicator tube bolt to
12 N·m (106 lb in).
188009
4. Install the oil level indicator into the oil level

indicator tube, if required.
330580
Water Pump Installation

SIE-ID = 358646
Tools Required
J 41240 Fan Clutch Remover and Installer
1. If reusing the fasteners, apply sealant
threads of the water pump bolts.
2. Install the water pump and the NEW water pump
gaskets.
Notices.
3. Install the water pump bolts.
Tighten
Tighten the water pump bolts to 45 N·m (33 lb ft).
188054
2002 - Unit Repair (May 24, 2001)

Important: After final assembly, the water pump inlet
hose clamp tangs, water pump end, must point
forward and the upper tang should be level with the
outside diameter of the water pump inlet hose.
4. Install the water pump inlet hose and the water
pump inlet hose clamps.
182853
5. Install the fan and water pump pulley and bolts

using the J 41240.
Tighten
Tighten the fan and water pump pulley bolts to
25 N·m (18 lb ft).
317191
Exhaust Manifold Installation - Left

SIE-ID = 645525
1. Install the NEW exhaust manifold gaskets.
328540
2002 - Unit Repair (May 24, 2001)

2. Install the exhaust manifold.
3. Install the spark plug wire shields.
threads of the exhaust manifold bolts and stud.
Notices.
5. Install the exhaust manifold bolts and stud.
Tighten
5.1. Tighten the exhaust manifold bolts and stud
on the first pass to 15 N·m (11 lb ft).
5.2. Tighten the exhaust manifold bolts and stud
on the final pass to 30 N·m (22 lb ft).
6. Install the spark plug wires to the spark plug wire
retainers.
7. Install the spark plug wires onto the spark plugs.
188045
Exhaust Manifold Installation - Right

SIE-ID = 645527
1. Install the NEW exhaust manifold gaskets.
328555
2. Install the exhaust manifold.

3. Install the spark plug wire shields.
threads of the exhaust manifold bolts.
Notices.
5. Install the exhaust manifold bolts.
Tighten
5.1. Tighten the exhaust manifold bolts on the
first pass to 15 N·m (11 lb ft).
5.2. Tighten the exhaust manifold bolts on the
final pass to 30 N·m (22 lb ft).
6. Install the spark plug wires to the spark plug wire
retainers.
188121
2002 - Unit Repair (May 24, 2001)

7. Install the spark plug wires onto the spark plugs.
Clutch Pilot Bearing Installation (S/T

Truck and C/K 800 Truck)
SIE-ID = 645528

1. Install the NEW clutch pilot bearing using a
suitable clutch pilot bearing installation tool.
2. Measure to ensure the proper installation depth is
obtained.
334385
Engine Flywheel Installation (M/L Van and

G Van)
SIE-ID = 645529
1. Install the engine flywheel to the crankshaft.
2. Align the locator hole to the pin.
188130
2002 - Unit Repair (May 24, 2001)

Notices.
3. Install the engine flywheel bolts.
Tighten
Tighten the engine flywheel bolts in sequence to
100 N·m (74 lb ft).
63174
Engine Flywheel Installation (S/T Truck

and C/K 800 Truck)
SIE-ID = 645530
Important: If replacing the engine flywheel, manual

transmission, note the position and length of the
original flywheel weights, if applicable. Flywheel
weights of the same length must be installed into the
new engine flywheel in the same location as the
old flywheel weights were in the old engine flywheel.
1. Note the position of the flywheel weights and
install the NEW flywheel weights as required.
A properly installed flywheel weight will be flush or
slightly below flush with the face of the engine
flywheel.
64126
2. Install the engine flywheel (1 or 2) to the

crankshaft.
Align the engine flywheel locator hole to the
flywheel locator pin.
188129
2002 - Unit Repair (May 24, 2001)

Notices.
3. Install the engine flywheel bolts.
Tighten
Tighten the engine flywheel bolts in sequence to
100 N·m (74 lb ft).
63174
2002 - Unit Repair (May 24, 2001)

Description and Operation
Engine Component Description has an exhaust gas recirculation (EGR) port cast into
the manifold for mixture. The (EGR) valve bolts
SIE-ID = 507196
into the lower intake manifold. The Central Sequential
Balance Shaft Multiport Fuel Injection system uses multiple fuel
The cast iron balance shaft is mounted in the injectors to meter and distribute fuel to each engine
crankcase above and in-line with the camshaft. A cylinder. The Central (SFI) is retained by a bracket
camshaft gear drives the gear attached to the balance bolted to the lower intake manifold. The fuel meter
shaft. The front end of the balance shaft is supported body also houses the pressure regulator. Metal
by a ball-type bearing. The rear end of the balance inlet and outlet fuel lines and nylon delivery tubes
shaft uses a sleeve-type bearing. connect to the Central (SFI) unit. The delivery tubes
independently distribute fuel to each cylinder through
Camshaft nozzles located at the port entrance of each
The steel camshaft is supported by four bearings manifold runner where the fuel is atomized.
pressed into the engine block. The camshaft timing
Piston and Connecting Rod Assemblies
chain sprocket mounted to the front of the camshaft is
driven by the crankshaft sprocket through a camshaft The cast aluminum pistons use two compression rings
timing chain. and one oil control assembly. The piston is a low
friction, lightweight design with a flat top and barrel
Crankshaft shaped skirt. The piston pins are offset 0.9 mm
The cast nodular iron crankshaft is supported by (0.0354 in) toward the major thrust side (right side) to
four crankshaft bearings. The number four crankshaft reduce piston slap as the connecting rod travels
bearing at the rear of the engine is the end thrust from one side of the piston to the other side after a
bearing. The crankshaft bearings are retained stroke. The piston pins have a floating fit in the piston
by bearing caps that are machined with the engine and are retained by a press fit in the connecting
block for proper alignment and clearances. The rod. The connecting rods are forged steel. The
crankshaft position sensor reluctor ring has three lugs connecting rods are machined with the rod cap
used for crankshaft timing and is constructed of installed for proper clearances and alignments.
powdered metal. The crankshaft position sensor
reluctor ring has a slight interference fit onto the
Valve Train
crankshaft and an internal keyway for correct Motion is transmitted from the camshaft through the
positioning. hydraulic roller valve lifters and the tubular valve
pushrods to the roller type valve rocker arms.
Cylinder Heads The roller type valve rocker arm pivots on a needle
The cast iron cylinder heads have one intake and type bearing in order to open the valve. The valve
one exhaust valve for each cylinder. A spark plug is rocker arms for each bank of cylinders are mounted to
located between the valves in the side of the cylinder a one piece valve rocker arm support. Each valve
head. The valve guides and seats are integral to rocker arm is retained on the valve rocker arm support
the cylinder head. The 4.3L heavy duty applications and the cylinder head by a bolt. The hydraulic valve
have pressed in exhaust valve seats. The valve rocker lifters keep all the parts of the valve train in constant
arms are positioned on the valve rocker arm supports contact. Each hydraulic valve lifter acts as an
and retained by a bolt. automatic adjuster and maintains zero lash in the
valve train. This eliminates the need for periodic valve
Engine Block adjustment.
The cast iron engine block has six cylinders arranged
in a V shape with three cylinders in each bank. New Product Information
Starting at the front side of the engine block, the
SIE-ID = 507200
cylinders in the left bank are numbered 1–3–5
and cylinders in the right bank are numbered 2–4–6 The purpose of New Product Information is to highlight
(when viewed from the rear). The firing order of or indicate important product changes from the
the cylinders is 1–6–5–4–3–2. The cylinders are previous model year.
encircled by coolant jackets. Changes may include one or more of the
following items:
Exhaust Manifolds
• A component comparison from the previous year
The cast iron exhaust manifolds direct exhaust gases
from the combustion chambers to the exhaust • Fastener changes
system. The left side exhaust manifold has a port for • Torque values and/or fastener tightening strategies
the EGR valve inlet pipe. • Changed engine specifications
Intake Manifold • New sealants and/or adhesives
The intake manifold is a two-piece design. The upper • Disassembly and assembly procedure revisions
portion is made from a composite material and the
lower portion is cast aluminum. The throttle body • Engine mechanical diagnostic procedure revisions
attaches to the upper manifold. The lower manifold • New special tools required
2002 - Unit Repair (May 24, 2001)

Component Comparison New Sealants and/or Adhesives
• Revised the water pump seal No new sealants or adhesive have been added.
• Revised the engine coolant thermostat Disassembly and Assembly Procedure
• New roller pivot type valve rocker arm assemblies Revisions
using a one piece valve rocker arm support to • Valve rocker arm and pushrod
replace the ball pivot type valve rocker arm system
• Timing chain and sprockets
• Cylinder heads revised using dry holes for the • Discard all used gaskets, seals, or O-ring seals
valve rocker arm bolts unless otherwise indicated.
Torque Values and/or Fastener Tightening Gaskets, seals, or O-ring seals that can be
Strategies reused will be identified in the specific service
• Cylinder head bolts, the crankshaft bearing cap procedure.
bolts, the connecting rod bolts, and balance Engine Mechanical Diagnostic Procedure
shaft bolt apply a torque angle strategy. Revisions
In an on-vehicle situation where a torque angle • Valve Train diagnostic information is now provided
meter may not fit into the vehicle packaging, in table form.
a three step tightening process may be followed Potential or probable causes are supplied for
using a torque wrench. each specific concern.
• Certain fasteners should not be reused. Bolts, • Engine Noise diagnostic information is now
studs, or other fasteners that must be replaced will provided in table form.
be called out in the specific service procedure. Potential or probable causes are supplied for
Changed Engine Specifications each specific concern.
Engine mechanical specifications remain the same as New Special Tools Required
the 1999 products. No new special tools are required.
2002 - Unit Repair (May 24, 2001)

Lubrication Description
SIE-ID = 645531
Engine Lubrication SIO-ID = 41430
44610
Full pressure lubrication, through a full-flow oil filter is chain is drip fed from the front camshaft bearing. The
supplied by a gear-type oil pump. Oil is drawn up pistons and piston pins are lubricated by oil splash.
through the oil pump screen and passes through the
pump to the oil filter. The oil filter is a full-flow Cleanliness and Care
paper element unit with an anti-drain back valve. An
SIE-ID = 19007
oil filter bypass valve is used to ensure adequate
oil supply, in the event the filter becomes plugged or • Throughout this section, it should be understood
develops excessive pressure drop. Filtered oil that proper cleaning and protection of machined
flows into the main gallery and then to the camshaft, surfaces and friction areas is part of the repair
the balance shaft, the rear bearing, and the crankshaft procedure. This is considered standard shop
bearings. The valve lifter oil gallery supplies oil to practice even if not specifically stated.
the valve lifters. Oil flows from the valve lifters through • When any internal engine parts are serviced, care
the hollow valve pushrods to the valve rocker arms. and cleanliness is important.
Oil drains back to the crankcase through the oil
• When components are removed for service, the
drain holes in the cylinder head. The camshaft timing
components should be marked, organized or
retained in a specific order for re-assembly.
2002 - Unit Repair (May 24, 2001)
• At the time of installation, the components should • Apply only the amount of sealant specified in the
be installed in the same location and with the service procedure to a component.
same mating surface as when removed. • Do not allow the sealant to enter into any blind
• An automobile engine is a combination of many threaded holes, as the sealant may prevent
machined, honed, polished and lapped surfaces the fastener from clamping properly or cause
with tolerances that are measured in millimeters or component damage when tightened.
thousandths of an inch. The surfaces should be
Important: Do not overtighten the fasteners.
protected to avoid component damage.
• Tighten the fasteners to the proper specifications.
• Apply a liberal amount of clean engine oil to
friction areas during assembly.
• Proper lubrication will protect and lubricate friction
Use of RTV and Anaerobic Sealer
areas during initial operation. SIE-ID = 411537
Sealant Types
Replacing Engine Gaskets
Important: The correct sealant and amount of sealant
SIE-ID = 66654
must be used in the proper location to prevent oil
Gasket Reuse and Applying Sealant leaks, coolant leaks, or the loosening of the fasteners.
• Do not reuse any gasket unless specified. DO NOT interchange the sealants. Use only the
sealant, or equivalent, as specified in the service
• Gaskets that can be reused will be identified in
procedure.
the service procedure.
• Do not apply sealant to any gasket or sealing The following 2 major types of sealant are commonly
surface unless specified in the service procedure. used in engines:
• Aerobic sealant Room Temperature
Separating Components Vulcanizing (RTV)
• Use a rubber mallet in order to separate the • Anaerobic sealant, which include the following:
components.
− Gasket eliminator
• Bump the part sideways in order to loosen the
components. − Pipe
• Bumping of the component should be done at − Threadlock
bends or reinforced areas of the component Aerobic Type Room Temperature
to prevent distortion of the components.
Vulcanizing (RTV) Sealant
Cleaning Gasket Surfaces Aerobic type Room Temperature Vulcanizing (RTV)
• Use care to avoid gouging or scraping the sealing sealant cures when exposed to air. This type of sealant
surfaces. is used where 2 components, such as the intake
• Use a plastic or wood scraper in order to remove manifold and the engine block, are assembled
all the sealant from the components. together.
Do not use any other method or technique to Use the following information when using RTV
remove the sealant or the gasket material from sealant:
a part. • Do not use RTV sealant in areas where extreme
• Do not use abrasive pads, sand paper, or power temperatures are expected. These areas include:
tools to clean the gasket surfaces. − The exhaust manifold
− These methods of cleaning can cause
− The head gasket
damage to the component sealing surfaces.
− Abrasive pads also produce a fine grit − Any other surfaces where a different type of
that the oil filter cannot remove from sealant is specified in the service procedure
the engine oil. • Always follow all the safety recommendations and
This fine grit is an abrasive and can cause the directions that are on the RTV sealant
internal engine damage. container.
• Use a plastic or wood scraper in order to remove
Assembling Components
all the RTV sealant from the components.
• Assemble components using only the sealant (or
equivalent) that is specified in the service Notice: SIO-ID = 68592 Do not allow the RTV sealant
procedure. to enter any blind threaded hole. RTV sealant that
is allowed to enter a blind threaded hole can cause
• Sealing surfaces must be clean and free of debris hydraulic lock of the fastener when the fastener
or oil. is tightened. Hydraulic lock of a fastener can lead to
• Specific components such as crankshaft oil seals damage to the fastener and/or the components.
or valve stem oil seals may require lubrication Hydraulic lock of a fastener can also prevent the
during assembly. proper clamping loads to be obtained when the
• Components requiring lubrication will be identified fastener is tightened. Improper clamping loads can
in the service procedure. prevent proper sealing of the components allowing
2002 - Unit Repair (May 24, 2001)

leakage to occur. Preventing proper fastener tightening Use the following information when using threadlock
can allow the components to loosen or separate sealant:
leading to extensive engine damage. • Always follow all safety recommendations and
• The surfaces to be sealed must be clean and dry. directions that are on the threadlock sealant
• Use a RTV sealant bead size as specified in container.
the service procedure. • The threaded surfaces to be sealed must be clean
• Apply the RTV sealant bead to the inside of any and dry.
bolt holes areas. • Apply the threadlock sealant as specified on the
threadlock sealant container.
Important: Do not wait for the RTV sealant to
skin over. Important:
• Assemble the components while the RTV sealant • Fasteners that are partially torqued and then the
is still wet to the touch, within 3 minutes. threadlock sealant allowed to cure more than
five minutes, may result in incorrect clamp load of
Important: Do not overtighten the fasteners. assembled components.
• Tighten the fasteners in sequence, if specified, • Do not overtighten the fasteners.
and to the proper torque specifications.
• Tighten the fasteners in sequence, if specified,
Anaerobic Type Gasket Eliminator Sealant and to the proper torque specifications.
Anaerobic type gasket eliminator sealant cures in the Anaerobic Type Pipe Sealant
absence of air. This type of sealant is used where
2 rigid parts, such as castings, are assembled Anaerobic type pipe sealant cures in the absence of
together. When 2 rigid parts are disassembled and no air and remains pliable when cured. This type of
sealant or gasket is readily noticeable, then the sealant is used where 2 parts are assembled together
2 parts were probably assembled using an anaerobic and require a leak proof joint.
type gasket eliminator sealant. Use the following information when using pipe sealant:
Use the following information when using gasket • Do not use pipe sealant in areas where extreme
eliminator sealant: temperatures are expected. These areas
• Always follow all the safety recommendations and include:
directions that are on the gasket eliminator − The exhaust manifold
sealant container. − The head gasket
• Apply a continuous bead of gasket eliminator − Surfaces where a different sealant is
sealant to one flange. specified
The surfaces to be sealed must be clean and dry. • Always follow all the safety recommendations and
Important: the directions that are on the pipe sealant
container.
• Do not allow the gasket eliminator sealant to enter
any blind threaded holes, as the gasket eliminator • The surfaces to be sealed must be clean and dry.
sealant may prevent the fasteners from clamping • Use a pipe sealant bead of the size or quantity
properly, seating properly, or cause damage as specified in the service procedure.
when the fastener tightened. Notice: SIO-ID = 768432 Do not allow the pipe sealant
• Gasket eliminator sealed joint fasteners that are to enter a blind hole. The pipe sealant may prevent
partially torqued and the gasket eliminator the fastener from achieving proper clamp load, cause
sealant allowed to cure more than five minutes, component damage when the fastener is tightened,
may result in incorrect shimming and sealing or lead to component failure.
of the joint. • Apply the pipe sealant bead to the inside of any
• Do not overtighten the fasteners. bolt hole areas.
− Apply the gasket eliminator sealant evenly to • Apply a continuous bead of pipe sealant to
get a uniform thickness of the gasket 1 sealing surface.
eliminator sealant on the sealing surface. Important: Do not overtighten the fasteners.
− Tighten the fasteners in sequence, if • Tighten the fasteners in sequence, if specified,
specified, and to the proper torque and to the proper torque specifications.
specifications.
− After properly tightening the fasteners, Separating Parts
remove the excess gasket eliminator sealant SIE-ID = 507212
from the outside of the joint. Important: Many internal engine components will
Anaerobic Type Threadlock Sealant develop specific wear patterns on their friction
Anaerobic type threadlock sealant cures in the surfaces.
absence of air. This type of sealant is used for When disassembling the engine, internal components
threadlocking and sealing of bolts, fittings, nuts, and MUST be separated, marked and organized in a
studs. This type of sealant cures only when confined way to ensure reinstallation to original location and
between 2 close fitting metal surfaces. position.
2002 - Unit Repair (May 24, 2001)
Mark or identify the following components:
• Piston and the piston pin
• Piston to the specific cylinder bore
• Piston rings to the specific cylinder bore
• Connecting rod to the crankshaft journal
• Connecting rod to connecting rod cap
• Crankshaft bearings and connecting rod bearings
• Engine camshaft and valve lifters
• Valve lifters, valve rocker arms, and valve rocker
arm supports
• Valve to the valve guide
• Valve spring to cylinder head location
• Engine block bearing cap location and direction
• Oil pump drive and driven gears
Tools and Equipment

SIE-ID = 507215
Special tools are listed and illustrated throughout this
section with a complete listing at the end of the
section. The tools (or the equivalents) are specially
designed to quickly and safely accomplish the
operations for which the tools are intended. The use
of special tools will also minimize possible damage
to engine components. Some precision measuring
tools are required for inspection of certain critical
components. Torque wrenches and a torque angle
meter are necessary for the proper tightening of
various fasteners.
To properly service the engine assembly, the following
items should be readily available:
• Approved eye protection and safety gloves
• A clean, well-lit, work area
• A suitable parts cleaning tank
• A compressed air supply
• Trays or storage containers to keep parts and
fasteners organized
• An adequate set of hand tools
• Approved engine repair stand
• An approved engine lifting device that will
adequately support the weight of the components
2002 - Unit Repair (May 24, 2001)

Special Tools and Equipment
SIE-ID = 690670
Illustration Tool Number/ Description Illustration Tool Number/ Description
J 3049-A J 7872
Valve Lifter Remover Magnetic Base Dial Indicator
14487 35463
J 5239
J 8001
Connecting Rod Bolt
Guide Set Dial Indicator Set
3404 2014
J 5590
J 8037
Pinion Bearing Race
Installer - Rear Ring Compressor
3407 3403
J 5825-A J 8062
Crankshaft Gear Remover Valve Spring Compressor
3406 3414
J 5830-02 J 8087
Valve Guide Reamer Set Cylinder Bore Gage
4999 5110
2002 - Unit Repair (May 24, 2001)

J 8089 J 24086-C
Carbon Removing Brush Piston Pin Remover/Installer
35464 14495
J 8092 J 24270
Universal Driver Handle Cylinder Bore Ridge Reamer
2015 3412
J 9666 J 26941
Valve Spring Tester Bushing/Bearing Remover
5112 4862
J 33049
J 21882
Camshaft Bearing
Oil Suction Pipe Installer Service Kit
3416 5118
J 23523-F
J 35621-B
Balancer Remover and
Rear Main Seal Installer
Installer
66168 350498
2002 - Unit Repair (May 24, 2001)

J 36660-A J 42073
Electronic Torque Valve Stem Seal Installer
Angle Meter
3413 38509
J 43276
J 36996
Clutch Pilot Bearing
Balance Shaft Installer
Remover
3411 355040
J 43690
J 38834
Rod Bearing Clearance
Balance Shaft Service Kit Checking Tool
3410 650651
J 41240
Fan Clutch Remover and
Installer
48304
J 41712
Oil Pressure Switch Socket
67136
2002 - Unit Repair (May 24, 2001)

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What are the different types of fasteners mentioned in the document?

What are the different types of fasteners mentioned in the document?

What are some of the engine components that need to be marked or identified?

What are some of the engine components that need to be marked or identified?

Engine Engine Mechanical - 4.

Engine Mechanical - 4.3L

Fastener Tightening Specifications (G Van)

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Fastener Tightening Specifications (S/T Truck)

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Fastener Tightening Specifications (C/K 800 Truck)

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Fastener Tightening Specifications (M/L Van)

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Engine Mechanical Specifications

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Sealers, Adhesives, and Lubricants

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• The Vehicle Identification Number (VIN) Derivative

• Engines built at the Tonawanda engine plant have

2002 - Unit Repair (May 24, 2001)

2. Remove the oil filter, if applicable.

2002 - Unit Repair (May 24, 2001)

Engine Flywheel Removal (M/L Van and

Engine Flywheel Removal (S/T Truck and

2002 - Unit Repair (May 24, 2001)

Clutch Pilot Bearing Removal (S/T Truck

2002 - Unit Repair (May 24, 2001)

Notice: SIO-ID = 2878 Twist the spark plug boot

5. Remove and discard the exhaust manifold

Exhaust Manifold Removal - Right

Notice: SIO-ID = 2878 Twist the spark plug boot

2002 - Unit Repair (May 24, 2001)

Oil Level Indicator and Tube Removal

2. Remove the oil level indicator tube bolt.