Professional Documents
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Volvo Penta 3.0 GS, 4.3 GL-GS-Gi, 5.0 GL-Gi, 5.7 GS-GSi, 7.4 Gi-GSi, 8.2 GSi 2-3 SEZ4
Volvo Penta 3.0 GS, 4.3 GL-GS-Gi, 5.0 GL-Gi, 5.7 GS-GSi, 7.4 Gi-GSi, 8.2 GSi 2-3 SEZ4
Table of Contents
Safety Warnings
Before working on any part of the engine, read the Safety section
at the end of this manual.
Always use the correct fastener in the proper location. When you
replace a fastener, use ONLY the exact part number for that appli-
cation. The text will call out those fasteners that require replace-
ment after removal. The text will also call out the fasteners that
require thread lockers or thread sealant.
UNLESS OTHERWISE SPECIFIED, do not use supplement coatings
(paints, greases, or other corrosion inhibitors) on threaded fas-
teners or fastener joint interfaces. Generally, such coatings ad-
versely affect the fastener torque and the joint clamping force,
and may damage the fastener.
When you install fasteners, use the correct tightening sequence
and tightening specifications. Following these instructions can
help you avoid damage to parts and systems.
Engine/eng 4-1
General Description
Engine Construction
Cylinder Block
The cylinder block has 6 cylinders arranged in a “V” shape with 3 cyl-
inders in each bank. Starting at the front of the engine, cylinders in the
right bank are numbered 1-3-5 and cylinders in the left bank are num-
bered 2-4-6 (when viewed from the front). The firing order of the cylin-
ders is 1-6-5-4-3-2. The cylinders are encircled by coolant jackets.
Cylinder Heads
The cylinder heads have one intake and one exhaust valve for each
cylinder. A spark plug is located between the valves in the side of the
cylinder head. The valve guides are integral and the valve rocker arms
are retained on individual threaded studs.
Crankshaft
Camshaft
Balance Shaft
4-2 Engine/eng
Valve Train
The valve train is a ball-pivot type. Motion is transmitted from the cam-
shaft through the valve lifter and valve push rod to the valve rocker arm.
The valve rocker arm pivots on its ball and transmits the camshaft mo-
tion to the valve. The valve lifters with roller followers keep all parts of
the valve train in constant contact. Each lifter acts as an automatic ad-
juster and maintains zero lash in the valve train. This eliminates the
need for periodic valve adjustment.
Intake Manifold
Material Required
Engine/eng 4-3
Accessories
The various procedures in this manual assume that the engine acces-
sories have been removed. These accessories include all of the fol-
lowing:
Cleaning
Remove the engine accessories before cleaning to provide better ac-
cess to the engine’s exterior surfaces. After removing the distributor,
accessory brackets, etc., cover the openings with tape to prevent the
entry of contaminants.
Methods used to clean the engine will depend on the means which are
available. Steam cleaning, pressure washing, or solvent cleaning are
some of the acceptable methods. Allow the engine to dry thoroughly
before beginning any work.
It is important that the engine be as clean as possible to prevent dirt,
water, or any other contaminants from entering critical areas during
disassembly.
4-4 Engine/eng
1
DRC6583
Engine Lubrication
1 Full pressure lubrication, through a full-flow oil fil- Filtered oil flows into the main gallery and then to the
ter is supplied by a gear-type oil pump. Oil is drawn up camshaft, balance shaft, rear bearing, and crankshaft
through the oil pump screen and passes through the bearings. The valve lifter oil gallery supplies oil to the
pump to the oil filter. The oil filter is a full-flow paper valve lifters. Oil flows from the valve lifters through the
element unit with an anti-drain back valve. An oil filter hollow valve push rods to the valve rocker arms. Oil
bypass valve is used to ensure adequate oil supply, in drains back to the crankcase through oil drain holes in
the event the filter becomes plugged or develops ex- the cylinder head. The camshaft timing chain is drip
cessive pressure drop. fed from the front camshaft bearing. The pistons and
piston pins are lubricated by oil splash.
Engine/eng 4-5
Exhaust Manifold
Removal
Inspection
Installation
2. Install a new gasket and high rise elbow to manifold. Tighten bolts
to 12-18 ft. lb. (16-24 N m).
•
6
28546
7
25140
Install or Connect:
take.
b. Bolts to 106 in. lb. (12 N m). •
4
DRC6593
4-8 Engine/eng
d. Distributor with rotor and aligned exactly as marked during re-
moval.
If engine was cranked while distributor was out, complete igni-
tion timing procedure must be followed. See the appropriate Ignition
Circuit in Electrical/Ignition/Fuel Systems Service Manual.
e. Alternator with mounting bracket.
f. Distributor cap and high tension leads. See the General In-
formation section in Electrical/Ignition/Fuel Service Manual
for correct firing order and spark plug wire routing.
g. Oil pressure sending unit.
3. Connect:
a. All electrical connections. Apply black neoprene dip, or
equivalent, on all exposed connections.
b. Fuel lines to carburetor and fuel pump or throttle body and
fuel pump/vapor separator.
c. Throttle cable.
d. All water hoses, and close all drain petcocks.
e. Both crankcase ventilation hoses.
f. Battery cables.
g. Start engine. Check ignition timing, carburetor idle speed and
mixture. Check for leaks.
5 Remove or Disconnect:
1. Valve rocker arm cover bolts.
2. Valve rocker arm cover.
3. Gasket.
5
DRC6584
1 Install or Connect: 1
DRC6584
1. New gasket.
2. Valve rocker arm cover.
3. Valve rocker arm cover bolts.
Tighten:
Valve rocker arm cover bolts to 106 in. lb. (12 N m).
•
Valve Train
Removal 2
DRC6585
4
DRC6586
4-10 Engine/eng
Clean:
Valve Lifters
This engine uses hydraulic valve lifters. Valve lifters are serviced only
as an assembly. No internal parts are available. Service is limited to a
disassembly and cleaning. Discard valve lifters that are excessively worn
or damaged.
Installation
Important Replace all valve roller lifters, change the engine oil
and filter, and add GM Engine Oil Supplement, P/N 1052367, or equiva-
lent to the engine oil whenever a new camshaft is installed.
Lubricate the valve lifter bodies and roller with GM Engine Oil
Supplement, P/N 1052367, or equivalent.
Install or Connect:
3 1. Valve lifters to the block.
3 2. Valve lifter guide.
! Note previously made mark on valve lifter guide. Refer-
ence mark should be pointing toward front of engine.
Engine/eng 4-11
Tighten:
Bolts to 12 ft. lb. (16 N m). •
Cylinder Head 2
DRC6589
Remove or Disconnect:
1. Spark plugs.
2. Cylinder head bolts.
3. Cylinder heads.
4. Head gaskets.
7. Valves 5 and 6 .
Place the valves in an organizer rack so they can be replaced in their
original position at reassembly.
4-12 Engine/eng
Cleaning, Inspection, and Measurement
Engine/eng 4-13
1 d. Release the compressor tool J 8062, making sure the valve
keys 1 stay in place.
e. Repeat the preceding steps on the remaining valves.
Measure:
Refer to General Engine Mechanical section in this manual for
valve spring installed height.
Clean:
Gasket surfaces on the block and cylinder head. 1
DRC6595
4-14 Engine/eng
Crankshaft Balancer
Removal
size must be installed on the new balancer in the same location as the
old balancer.
Installation
Engine/eng 4-15
6. Crankshaft balancer bolt and washer.
Tighten:
Bolt to 74 ft. lb. (100 N m).
•
Oil Pan
Removal
1 Remove or Disconnect:
1. Oil pan nuts.
2. Oil pan bolts.
3. Oil pan.
4. Gasket.
Clean:
Important The alignment between the rear of the oil pan and
rear of the block flange is critical. The two surfaces must be flush to 2
DRC6639
provide a rigid engine-to-transom bracket alignment.
Install or Connect:
2 3 Apply GM Adhesive, P/N 12346141, or equivalent to the
engine front cover to block joint and to the rear crankshaft housing to
block joint. Apply the sealant about 1.00 in. (25,4 mm) in both direc-
tions from each of the four corners.
1. Oil pan gasket onto pan.
3
DRC6640
4-16 Engine/eng
4 2. Oil pan against cylinder block.
5 3. Slide oil pan back against straight edge using J 34673 or equiva-
lent.
4. Oil pan bolts and nuts but do not tighten.
Measure:
5 Use a feeler gauge to check the clearance between the three oil
pan-to-transmission bell housing contact points as shown. If clearance
exceeds 0.010 in. (0,254 mm) at any of the three points repeat steps 2 4
DRC6642
and 3 until the clearance is within specification.
If the clearance is more than 0.010 in. (0,254 mm), powertrain
durability may be affected.
6 Tighten:
! Bolts to 18 ft. lb. (25 N m) in the sequence shown.
•
Measure:
Oil Pump
Removal
7 Remove or Disconnect:
1. Bolt from oil pump to crankshaft bearing cap.
2. Oil pump assembly.
6
DRC6645
7
DRC6643
Engine/eng 4-17
1 Disassemble:
1. Driveshaft 9 and retainer 8 .
Do not remove the oil pump screen unless replacement is re-
quired. The oil pump screen has a press fit in to the pump cover. Do
not remove the screen from the pipe 6 . The oil pump screen is ser-
viced as a complete assembly only.
2. Oil pump screen pickup 6 .
3. Bolts 5 .
4. Pump cover 4 .
Mark where the idler gear and drive gear and shaft mesh to-
gether, so they can be reinstalled with the same gear teeth indexed.
5. Idler gear and drive gear and shaft 7 .
6. Retaining pin 1 .
7. Pressure regulator spring 2 .
8. Pressure regulator valve 3 .
Clean: 1
DRC6624
All parts in clean solvent and dry them with compressed air.
1 Inspect:
Important The pump gears, cover, and body are not serviced
separately. If any of the parts are damaged or worn, the entire oil pump
assembly must be replaced.
4-18 Engine/eng
Assemble
1 Install or Connect:
1. Pressure regulator valve 3 into the pump cover 4 .
2 Install or Connect:
1. Oil pump screen pickup 6 .
a. The oil pump screen assembly 6 should be replaced with a
new part. Loss of press fit condition could result in an air leak
and loss of oil pressure.
b. Mount the oil pump in a soft jawed vise.
c. Apply sealer to the end of the pipe.
d. Tap the pickup screen and pipe into place, using J 21882 and
a hammer.
e. The oil pump screen must be parallel with the bottom of the oil
pan when installed.
1 2. Oil pump driveshaft 9 and retainer 8 .
2
DRC6625
Engine/eng 4-19
Oil Pump Installation
1 Install or Connect:
1. Oil pump to the engine.
a. Align the slot in the oil pump shaft with the tang on the dis-
tributor shaft.
b. The oil pump should slide easily into place.
c. No gasket is used.
1
2. Oil pump and bolt onto crankshaft bearing cap. DRC6643
Tighten:
Bolt to 66 ft. lb. (90 N m).
•
Installation
Install or Connect:
1. Engine front cover to engine.
2. Engine front cover bolts.
Tighten:
Bolts to 106 in. lb. (12 N m).
•
4-20 Engine/eng
Timing Chain and Sprockets
Tool Required: J 5825-A Crankshaft Sprocket Puller
Measure:
Check camshaft timing chain free play. If the camshaft timing chain can
be moved back and forth in excess of 0.625 in. (16 mm), make a note
that the camshaft timing chain should be replaced during assembly.
Removal
2
2 Remove or Disconnect: DRC6633
Engine/eng 4-21
Inspect:
1. Sprockets for chipped teeth and wear.
Excessively worn sprockets will rapidly wear a new chain.
2. Camshaft timing chain for damage.
An excessively worn chain will rapidly wear a new set of sprock-
ets.
Installation
1
DRC6694
Tool Required: J 5590 Crankshaft Sprocket Installer
Install or Connect:
1. Crankshaft key (if removed).
1 2. Crankshaft sprocket using J 5590.
3. Balance shaft drive gear.
4. Camshaft sprocket and camshaft timing chain.
Camshaft
Removal
3
Remove or Disconnect: DRC6633
4
DRC6635
4-22 Engine/eng
Measure:
Camshaft Journals. Refer to General Engine Mechanical section in
this manual.
Bearings
Installation
Install or Connect:
Coat the camshaft lobes and journals with a high quality GM
Engine Oil Supplement , P/N 1052367, or equivalent. Apply GM Engine
Oil Supplement, P/N 1052367, or equivalent to all the teeth on the dis-
tributor drive gear.
4 1. Two or three 5/16 - 18 (4.0 in.) long bolts into the camshaft
threaded holes. Use these bolts to handle the camshaft.
4 2. Camshaft into the engine. Handle the camshaft carefully to pre-
vent damage to the camshaft bearings.
3. Camshaft retainer and retainer bolts.
Balance Shaft
Removal
7
DRC6618
Engine/eng 4-23
Inspect:
4-24 Engine/eng
5 • Turn the camshaft with the balance shaft drive gear tem-
porarily installed. The timing mark on the drive gear must
be straight up.
5 • With the balance shaft drive gear removed, turn the bal-
ance shaft so the timing mark on the driven gear points
straight down.
6. Balance shaft drive gear onto camshaft.
Important Make sure the timing marks on the balance shaft drive 5
DRC6632
gear and driven gear line up.
Engine/eng 4-25
4. Connecting rod and piston.
1 a. Attach J 5239 to the connecting rod bolts.
1 b. Use the long guide rod J 5239 to push the connecting rod
and piston out of the bore.
Disassembly
Assembly
Bearing Selection
Piston Selection
3
DRC6514
4-26 Engine/eng
Measure piston diameter at 70 degrees F (20 degrees C).
3. Subtract the piston diameter from the cylinder bore diameter to de-
termine piston to bore clearance.
4. Locate the piston-to-bore clearance, refer to Engine Specifications.
Determine if the piston-to-bore clearance is within the acceptable range.
Installation
Engine/eng 4-27
4. Piston and connecting rod into the proper bore.
1 a. With the connecting rod cap removed, install J 5239 onto the
connecting rod bolts.
2 b. Locate the piston ring end gaps. Lubricate the piston and
rings with engine oil.
3 c. Without disturbing the ring end gap location, install J 8037
over the piston and compression rings.
2 d. The piston must be installed so that the notch in the piston
faces the front of the engine.
1 e. Place the piston in its matching bore. The connecting rod bear-
ing tang slots must be on the side opposite the camshaft.
Using light blows with a hammer handle, tap the piston down
into its bore. At the same time, from beneath the engine, guide
the connecting rod on to the crankpin with J 5239. Hold the
ring compressor against the block until all rings have entered
the cylinder bore.
1 f. Remove J 5239 from the connecting rod bolts.
1
Important Each connecting rod and bearing cap should be
DRC6619
marked, beginning at the front of the engine. Cylinders 1, 3, and 5 are FORWARD
the right bank and 2, 4, and 6 are the left bank (when viewed from the
B
front). The numbers on the connecting rod and bearing cap must be
on the same side when installed in the cylinder bore. If a connecting C A D
rod is ever transposed from one block or cylinder to another, new con-
necting rod bearings should be fitted and the connecting rod should B
be numbered to correspond with the new cylinder number. A - POSITION OF THE GAP FOR THE
SPACER OF THE OIL RING
B - POSITION OF THE GAP FOR THE
5. Connecting rod cap with crankshaft bearing. OIL RING
C - POSITION OF THE GAP FOR THE
LOWER COMPRESSION RING
J 8037
3
DRC6628
4-28 Engine/eng
Crankshaft Rear Oil Seal
Removal
Take care when removing the rear crankshaft oil seal so as not
to damage the crankshaft sealing surface.
Remove or Disconnect:
4 Insert a screwdriver into the notches provided in the seal retainer
and pry the seal out.
4
DRC6658
Installation
engine oil.
2. Install the oil seal on J 35621.
3. Position J 35621 against the crankshaft. Thread the attaching
screws into the tapped holes in the crankshaft.
5
4. Tighten the screws securely with a screwdriver. This will en- DRC6626
6 Remove or Disconnect:
1. Bolts and nuts. 6
DRC6657
Engine/eng 4-29
Installation
1 Install or Connect:
1. New gasket to the block.
It is not necessary to use sealant to hold the gasket in place.
2. Oil seal retainer.
3. Screws and nuts.
Tighten:
1
DRC6657
Screws and nuts to 11 ft. lb. (15 N m).
•
The crankshaft need not be removed for replacement of the rear oil
seal or crankshaft bearings. Those procedures are covered in other
parts of this section.
Installation
Install or Connect:
1. Upper crankshaft bearing to the block.
4-30 Engine/eng
Measure:
Refer to General Engine Mechanical section in this manual for
crankshaft bearing clearance procedures.
4. Apply engine oil to the crankshaft bearings. Install crankshaft bear-
ing caps (except rear cap) and bolts to the block.
Tighten:
Crankshaft bearing cap bolts to 77 ft. lb. (105 N m). •
5. Rear crankshaft bearing cap. Apply engine oil to the crankshaft bear-
ings.
6. Rear crankshaft bearing cap bolts.
Tighten:
Rear crankshaft bearing cap bolts to 124 in. lb. (14 N m). •
Measure:
Refer to General Engine Mechanical section in this manual for
crankshaft end play procedure.
Tighten:
Finally tighten rear crankshaft bearing cap bolts to 77 ft. lb. (105
N m).
•
Cylinder Block
Disassembly
Remove or Disconnect:
1. Coolant drain fittings.
2. Camshaft and balance shaft cup plugs.
2 3. Front oil gallery cup plugs.
2
DRC6623
4
DRC6622
Engine/eng 4-31
3. Cylinder bores.
4. Threaded holes.
5. Oil galleries and passages.
6. Scale deposits from coolant passages.
7. Spray or wipe cylinder bores and machined surfaces with engine
oil.
Inspect:
1. All block core plugs for lack of fit or leakage.
2. Camshaft lifter bores for deep scratches and deposits.
3. Cracks in the block
! Cylinder walls.
! Water jackets.
! Engine mount bosses.
! Crankshaft bearing webs.
! Crankshaft bearing bores and caps.
! All crankshaft bearing bores should be rounded and
uniform in inside diameter (I.D.) at all of the bearing
supports.
! The area where the crankshaft bearings contact the
crankshaft bearing bore should be smooth.
! If a crankshaft bearing cap is found to be damaged,
replace the cap and line bore the block.
1 4. Cylinder block head mounting surface for flatness, using a pre-
cision straight edge and feeler gauge.
a. Set the straight edge on the sealing surface to be inspected.
b. Take the feeler gauge and at various locations, check the
gap between the straight edge and the sealing surface.
c. If the gap is found to be greater than 0.004 in. (0,1016 mm)
within 5.984 in. (152 mm) at any sealing location, the block
must be replaced.
1
DRC6620
4-32 Engine/eng
d. If the gap is found to be less than 0.004 in. (0,1016 mm) within 5.984
in. (152 mm) at any sealing location and a cause for leakage is sus-
pected, then the minor irregularities may be carefully machined from
the block.
Inspect:
Cylinder bores for scoring or other damage. Refer to General Engine
Mechanical section in this manual.
Measure:
Cylinder bore taper and out-of-round. Refer to General Engine Me-
chanical section in this manual.
Measure:
Refer to General Engine Mechanical section in this manual.
Install or Connect:
1. Front oil gallery plugs. Coat plug outside diameter with GM Sealant,
P/N 12346004, or equivalent.
2 3 4 2. Rear oil gallery plugs.
Tighten:
3. Camshaft and balance shaft cup plugs to proper depth. Coat bore
inside diameter with GM Sealant , P/N 12346004, or equivalent.
3
DRC6621
4
DRC6622
Engine/eng 4-33
Circulating Pump
Description
Inspection
1. Drain water from block and disconnect water hose from circulating
pump.
2. Remove pulley. Remove circulating pump bolts, pump and gaskets.
3. Use new pump to block gaskets and sealer. Install new pump as-
sembly on cylinder block and tighten bolts as specified.
4. Install pulley. Install alternator and power steering belts, then adjust
tension.
5. Install hose to circulating pump.
6. Lake or tank test unit and check for leaks.
4-34 Engine/eng
Front Engine Mounts
Removal
1 1. Remove two lag screws A and washers from mounts.
2. Lift engine with a hoist capable of lifting at least 1500 lb.
(680 kg) to allow removal of front mount and bracket.
2 3. Remove three mount screws and lock washers B . Note screw
lengths and location.
1
3 Prior to disassembly of front mount assembly, measure 25929
Disassembly
3
11980
4
11979
5
11978
163 N m).
•
Installation
Height Adjustment 2
11979
5 1. To change engine height, tighten or loosen nuts F and G as
required.
2. Lift engine with a hoist capable of lifting at least 1500 lb.
(680 kg). Position engine at desired height.
5 3. After setting mount position, turn nut G up against underside
of engine bracket and hold nut with a wrench. Tighten nut F to 100-
120 ft. lb. (136-163 N m).
•
4
21929
5
2953
Safety Related 4-36 Engine/eng
High-Rise Exhaust Elbow Replacement
Removal
6 1. Loosen two clamps securing upper hose to elbow. Lubricate
inside of hose with a soapy water solution.
7 2. Starboard Elbow: Remove four screws, flat washers, and lock
washers mounting high-rise elbow. Remove circuit breaker bracket H
and set aside.
3. Port Elbow - EFI Models Only: Remove fuel reservoir water hose
6
34719
and set aside. Remove four screws, flat washers, and lock washers
mounting high-rise elbow.
8 9 4. Use a soft hammer to free elbow from manifold. Use a
twisting motion to pull elbow from hose. Remove and discard the elbow
gasket.
Installation
8
34718
9
34716
10
34717
Engine/eng 4-37
1 3. Position elbow on manifold. Secure elbows and brackets with
four screws, flat washers, and lock washers. Tighten screws to 12-18
ft. lb. (16-24 N m). Starboard Elbow: Install circuit breaker bracket
•
A . Port Elbow: Install fuel reservoir water hose. Tighten clamp se-
curely.
2 4. Slide clamps B up onto hose and position them in the
two surface channels. Tighten clamps securely.
Removal
pipe.
3
32374
4
32375
5
32363
Safety Related 4-38 Engine/eng
Installation
6 1. Lubricate inside diameter of 3.5 in. (8.89 cm) I.D. lower hose
with a soapy water solution. Slide it all the way onto the exhaust Y-pipe.
7 The inside diameter of both the upper and lower hoses
has a step E 1.5 in. (3.81 cm) from one end. The stepped end of the
hose must face the intermediate pipe when installed.
2. Slide hose onto high-rise elbow until it seats.
If hose is not properly positioned, it will not completely engage 6
the high-rise elbow or allow secure attachment. 32370
9
19085
Installation
4 1. Install coupler and secure with six locknuts. Use a suitable adap-
tor and tighten to 40-45 ft. lb. (54-61 N m).
•
3
6712
4
6714
5
19996
4-40 Engine/eng
Torque Specifications
Balance Shaft Driven Gear Bolt ............................................................................ 15 ft. lb. (20 N m) (Plus 35 degrees)
•
Bell Housing Nuts and Bolts ....................................................................................................... 32-40 ft. lb. 43-54 N m) •
Block Oil Gallery Plug, Left Rear ......................................................................................................... 15 ft. lb. (20 N m) •
Block Oil Gallery Plug, Right Rear ...................................................................................................... 18 ft. lb. (25 N m) •
Block Oil Gallery Plug, Left Side Rear ................................................................................................. 15 ft. lb. (20 N m) •
Crankshaft Rear Oil Seal Housing Nut and Bolt ................................................................................. 11 ft. lb. (15 N m) •
Engine/eng 4-41
Torque Specifications
High Rise Elbow Nuts ................................................................................................................ 12-18 ft. lb. (16-24 N m) •
Oil Pan
Nuts ................................................................................................................................................. 17 ft. lb. (23 N m)
•
Spark Plugs
Cylinder Head (New) ...................................................................................................................... 22 ft. lb. (30 N m) •
Valve Rocker Arm Cover Bolts .......................................................................................................... 106 in. lb. (12 N m) •
4-42 Engine/eng
Engine Specifications
ENGINE
Type ....................................................................................................................................................... 90 Degree V6
Displacement ....................................................................................................................................... 4.3L (262 CID)
Bore .............................................................................................................................................. 4.00 in. (101.6 mm)
Stroke ......................................................................................................................................... 3.480 in. (88.39 mm)
Compression Ratio .............................................................................................................................................. 9.2:1
Firing Order ............................................................................................................................................... 1-6-5-4-3-2
LUBRICATION SYSTEM
Oil Capacity
Without Filter Change ..................................................................................................................... 4 Qt. (3.75 Liters)
With Filter Change Add............................................................................................................ 0.42 Qt. (0.398 Liters)
Oil Pressure (Minimum Hot) ....................................................................... 6.0 PSI (41.4 kPa) at 1,000 engine RPM
18.0 PSI (24.1 kPa) at 2,000 engine RPM
24.0 PSI (165.5 kPa) at 4,000 engine RPM
CYLINDER BORE
Diameter .............................................................................................. 4.0007 - 4.0017 in. (101.618 - 101.643 mm)
Out-of-Round ................................................................................................................ 0.002 in. (0.0508 mm) MAX.
Taper .............................................................................................................................. 0.001 in. (0.0254 mm) MAX.
PISTON
Piston Bore Clearance .............................................................................................. 0.0024 in. (0.06096 mm) MAX.
PISTON RINGS
Piston Compression Ring
Groove Clearance ............................................................................................................... 0.0042 in. (0.10668 mm)
Gap .................................................................................................................................. 0.035 in. (0.889 mm) MAX.
OIL PAN
Engine Block Clearance
Tolerance ......................................................................................................................... 0.010 in. (0.254 mm) MAX.
Engine/eng 4-43
Engine Specifications
PISTON PIN
Diameter ...................................................................................................... 0.927 - 0.926 in. (23,545 - 23,548 mm)
Clearance in Piston ..................................................................................................... 0.001 in. (0,0254 mm) MAX.
Fit In Connecting Rod .................................................. 0.0008 - 0.0016 in. (0,02032 - 0,04064 mm) Interference
INTAKE MANIFOLD
Surface Flatness ............................................................................................................ 0.010 in. (0.254 mm) MAX.
CYLINDER HEAD
Surface Flatness .......................................................................................................... 0.004 in. (0.1016 mm) MAX.
CRANKSHAFT
Crankshaft Journal
Diameter #1 ............................................................................................ 2.4488 - 2.4495 in. (62.199 - 62.217 mm)
Diameter #2, #3 ...................................................................................... 2.4485 - 2.4494 in. (62.192 - 62.215 mm)
Diameter #4 ........................................................................................... 2.4480 - 2.4489 in. (62.180 - 62.202 mm)
Taper ............................................................................................................................ 0.001 in. (0.0254 mm) MAX.
Out-of-Round ............................................................................................................. 0.0010 in. (0.0254 mm) MAX.
Crankshaft End Play ....................................................................................... 0.002 - 0.008 in. (0.0508 - 0.2032 mm)
CONNECTING ROD
Connecting Rod Journal
Diameter .................................................................................................. 2.2487 - 2.2497 in. (57.117 - 57.142 mm)
Taper ............................................................................................................................ 0.001 in. (0.0254 mm) MAX.
Out-of-Round ............................................................................................................... 0.001 in. (0.0254 mm) MAX.
Rod Bearing Clearance .......................................................................... 0.0010 - 0.0030 in. (0.0254 - 0.0762 mm)
Rod Side Clearance .................................................................................. 0. 006 - 0.017 in. (0.1524 - 0.4318 mm)
CAMSHAFT
Journal Diameter ......................................................................................... 1.8677 - 1.8697 in. (47.440 - 47.490 mm)
BALANCE SHAFT
Front Bearing Journal Diameter ............................................................ 2.1648 - 2.1654 in. (55.985 - 55.001 mm)
Rear Bearing Journal Diameter ............................................................... 1.4994 - 1.500 in. (38.084 - 38.100 mm)
Rear Bearing Journal Clearance ........................................................... 0.001 - 0.0036 in. (0.0254 - 0.09144 mm)
4-44 Engine/eng
Engine Specifications
VALVE SYSTEM
Valve Lifter ........................................................................................................................................ Hydraulic Roller
Valve Rocker Arm Ratio ................................................................................................................................... 1.50:1
Valve Lash Net Lash .......................................................................................................................... No Adjustment
Face Angle ................................................................................................................................................. 45 degree
Seat Angle .................................................................................................................................................. 46 degree
Seat Runout ................................................................................................................. 0.002 in. (0.0508 mm) MAX.
Seat Width
Intake ............................................................................................................... 0.040 - 0.065 in. (1.016 - 1.651 mm)
Exhaust ........................................................................................................... 0.065 - 0.098 in. (1.651 - 2.489 mm)
Stem Clearance
Intake .............................................................................................. High Limit Production + 0.001 in. (0.0257 mm)
Exhaust .......................................................................................... High Limit Production + 0.002 in. (0.0508 mm)
Valve Spring
Free Length ...................................................................................................................................... 2.03 in. (52 mm)
Installed Height ............................................................................................... 1.690 - 1.710 in. (42.92 - 43.43 mm)
Spring Pressure
Closed ............................................................................................... 76 - 84 lb. at 1.70 in. (338 - 374 N at 43 mm)
Open .............................................................................................. 832 - 187 - 203 lb. at 1.27 in. (903 N at 32 mm)
Valve Lift
Intake ......................................................................................................................................... 0.414 in. (10.51 mm)
Exhaust ..................................................................................................................................... 0.428 in. (10.87 mm)
Engine Lubrication:
Oil Grade Recommended
32° F (0° C) and Above ............................................................................................................................ SAE 30
0° F to 32° F (-18° C to 0° C) ......................................................................................................... SAE 20W-20
Below 0° F (-18° C) .............................................................................................................................. SAE 10W
Engine/eng 4-45
GM Special Tools
1 2 3
DRC6596 DRC6597 DRC6598
4 5 6
DRC6599 DRC6600 DRC6601
8
DRC6603
4-46 Engine/eng
GM Special Tools
1 2 3
DRC6604 DRC6605 DRC6606
4 5 6
DRC6607 DRC6608 DRC6609
8
DRC6611
Engine/eng 4-47