Engine Mechanical Page 6A3–1

Page 6A3–1

Section 6A3

Engine Mechanical – GEN III V8

ATTENTION

Before performing any service operation or other procedure described in this Section, refer to Section 00

Warnings, Cautions and Notes for correct workshop practices with regard to safety and/or property damage.

1 General Information ...............................................................................................................................7

1.1 AWD Vehicles......................................................................................................................................................... 7

1.2 Engine Views.......................................................................................................................................................... 8

Engine View Left-hand Side.................................................................................................................................. 8

Lower Front............................................................................................................................................................9

Lower Engine Assembly, Except AWD .............................................................................................................. 10

Lower Engine Assembly, AWD........................................................................................................................... 12

Cylinder Head....................................................................................................................................................... 14

Intake Manifold..................................................................................................................................................... 15

1.3 Engine Serial Number.......................................................................................................................................... 16

1.4 Engine Construction............................................................................................................................................ 17

Cylinder Block...................................................................................................................................................... 17

Cylinder Heads..................................................................................................................................................... 18

Valve Train............................................................................................................................................................ 19

Crankshaft............................................................................................................................................................ 19

Piston and Connecting Rod................................................................................................................................ 20

Camshaft and Drive ............................................................................................................................................. 21

Intake Manifold..................................................................................................................................................... 21

Exhaust Manifold................................................................................................................................................. 22

Oil Pan .................................................................................................................................................................. 23

Excluding AWD Vehicles.................................................................................................................................. 23

AWD Vehicles .................................................................................................................................................. 23

1.5 Engine Lubrication Sy s t em................................................................................................................................. 24

Oil Pump............................................................................................................................................................... 24

Oil Flow................................................................................................................................................................. 25

Oil Seals................................................................................................................................................................ 26

Positive Crankcase Ventilation System............................................................................................................. 26

1.6 Service Notes....................................................................................................................................................... 27

Cleanliness and Care........................................................................................................................................... 27

Replacing Engine Gaskets.................................................................................................................................. 27

Re-using Gaskets and Applying Sealant.......................................................................................................... 27

Cleaning Gasket Surfaces................................................................................................................................ 27

Assembling Components ................................................................................................................................. 27

Room Temperature Vulcanising (RTV) and Anaerobic Sealers....................................................................... 27

Pipe Joint Compound....................................................................................................................................... 28

RTV Sealer....................................................................................................................................................... 28

Anaerobic Sealer.............................................................................................................................................. 28

Separating Components ..................................................................................................................................... 29

Special Tools and Equipment............................................................................................................................. 29

Fasteners.............................................................................................................................................................. 30

Clamp Load...................................................................................................................................................... 30

Torque Angle and Torque to Yield Fasteners................................................................................................... 30

Techline

Engine Mechanical Page 6A3–2

Page 6A3–2

2 Diagnosis ..............................................................................................................................................31

2.1 Engine Diagnosis................................................................................................................................................. 31

Procedure............................................................................................................................................................. 31

2.2 Engine Noise........................................................................................................................................................ 33

Procedure............................................................................................................................................................. 33

2.3 Valve Train Noise................................................................................................................................................. 35

Procedure............................................................................................................................................................. 35

2.4 Oil Consumption.................................................................................................................................................. 36

2.5 Oil Pressure.......................................................................................................................................................... 37

Oil Pressure Check.............................................................................................................................................. 37

Diagnosis.............................................................................................................................................................. 37

2.6 Oil Leaks............................................................................................................................................................... 38

2.7 Compression Check ............................................................................................................................................ 40

Interpreting Compression Readings.................................................................................................................. 40

3 Minor Service Operations....................................................................................................................41

3.1 Air Intake Duct...................................................................................................................................................... 41

Remove................................................................................................................................................................. 41

Reinstall................................................................................................................................................................ 41

3.2 Engine Dress Cover............................................................................................................................................. 42

Remove................................................................................................................................................................. 42

Reinstall................................................................................................................................................................ 42

3.3 Engine Oil and Filter............................................................................................................................................ 43

Oil Level Check.................................................................................................................................................... 43

Oil Change............................................................................................................................................................ 43

Oil Filter and Adapter ......................................................................................................... ................................. 45

Remove............................................................................................................................................................ 45

Reinstall ........................................................................................................................................................... 45

3.4 Oil Pressure Sensor............................................................................................................................................. 46

Remove................................................................................................................................................................. 46

Reinstall................................................................................................................................................................ 46

3.5 Oil Level Indicator and Tube............................................................................................................................... 47

Remove................................................................................................................................................................. 47

Reinstall................................................................................................................................................................ 47

3.6 Engine Drive Belts and Pulleys .......................................................................................................................... 48

Accessory Drive Belt........................................................................................................................................... 48

Remove............................................................................................................................................................ 48

Reinstall ........................................................................................................................................................... 48

Accessory Drive Belt Idler Pulley....................................................................................................................... 48

Remove............................................................................................................................................................ 48

Reinstall ........................................................................................................................................................... 49

Accessory Drive Belt Tensioner......................................................................................................................... 49

Remove............................................................................................................................................................ 49

Reinstall ........................................................................................................................................................... 49

Air Conditioner Drive Belt................................................................................................................................... 50

Remove............................................................................................................................................................ 50

Reinstall ........................................................................................................................................................... 50

Air Conditioner Drive Belt Idler Pulley............................................................................................................... 50

Remove............................................................................................................................................................ 50

Reinstall ........................................................................................................................................................... 51

Air Conditioner Drive Belt Tensioner................................................................................................................. 51

Remove............................................................................................................................................................ 51

Reinstall ........................................................................................................................................................... 51

Engine Mechanical Page 6A3–3

Page 6A3–3

3.7 Intake Manifold Assembly................................................................................................................................... 52

Remove................................................................................................................................................................. 52

Disassemble......................................................................................................................................................... 58

Throttle Body.................................................................................................................................................... 58

Fuel Rail Assembly........................................................................................................................................... 59

Clean and Inspect................................................................................................................................................ 59

Reassemble.......................................................................................................................................................... 60

Fuel Rail Assembly........................................................................................................................................... 60

Throttle Body.................................................................................................................................................... 60

Reinstall................................................................................................................................................................ 61

3.8 Vapour Vent Pipe and Covers............................................................................................................................. 62

Remove................................................................................................................................................................. 62

Reinstall................................................................................................................................................................ 63

3.9 Engine Valley Cover ............................................................................................................................................ 64

Remove................................................................................................................................................................. 64

Disassemble......................................................................................................................................................... 65

Clean and Inspect................................................................................................................................................ 66

Reassemble.......................................................................................................................................................... 66

Reinstall................................................................................................................................................................ 66

3.10 Camshaft Lobe Lift .............................................................................................................................................. 67

Measure ................................................................................................................................................................ 67

3.11 Valve Rocker Arm Cover..................................................................................................................................... 68

Remove................................................................................................................................................................. 68

Clean and Inspect................................................................................................................................................ 71

Reinstall................................................................................................................................................................ 71

3.12 Valve Rocker Arms and Push Rods................................................................................................................... 73

Remove................................................................................................................................................................. 73

Clean and Inspect................................................................................................................................................ 74

Reinstall................................................................................................................................................................ 74

3.13 Valve Stem Oil Seal and Valve Spring................................................................................................................ 76

Remove................................................................................................................................................................. 76

Reinstall................................................................................................................................................................ 78

3.14 Exhaust Manifold................................................................................................................................................. 79

Remove................................................................................................................................................................. 79

Inspect .................................................................................................................................................................. 80

Reinstall................................................................................................................................................................ 81

3.15 Cylinder Head....................................................................................................................................................... 82

Remove................................................................................................................................................................. 82

Disassemble......................................................................................................................................................... 84

Clean..................................................................................................................................................................... 85

Inspect .................................................................................................................................................................. 86

Cylinder Head................................................................................................................................................... 86

Valve Springs................................................................................................................................................... 87

Valves .............................................................................................................................................................. 87

Valve Guides.................................................................................................................................................... 88

Valve Stem Oversize........................................................................................................................................ 89

Valve Seats...................................................................................................................................................... 90

Reassemble.......................................................................................................................................................... 91

Reinstall................................................................................................................................................................ 92

3.16 Hydraulic Valve Lifters........................................................................................................................................ 95

Remove................................................................................................................................................................. 95

Disassemble......................................................................................................................................................... 96

Clean and Inspect................................................................................................................................................ 96

Reassemble.......................................................................................................................................................... 97

Testing Lifter Leak-down Rate............................................................................................................................ 98

Reinstall................................................................................................................................................................ 99

Engine Mechanical Page 6A3–4

Page 6A3–4

3.17 Crankshaft Balancer.......................................................................................................................................... 100

Remove............................................................................................................................................................... 100

Clean and Inspect.............................................................................................................................................. 102

Reinstall.............................................................................................................................................................. 103

3.18 Crankshaft Front Oil Seal.................................................................................................................................. 105

Remove............................................................................................................................................................... 105

Reinstall.............................................................................................................................................................. 105

3.19 Engine Mounts................................................................................................................................................... 106

Inspect ................................................................................................................................................................ 106

Remove............................................................................................................................................................... 106

Reinstall.............................................................................................................................................................. 107

4 Major Service Operations..................................................................................................................108

4.1 Engine Assembly, Except AWD........................................................................................................................ 108

Remove............................................................................................................................................................... 108

Disassemble – Ancillary Equipment ................................................................................................................ 115

Automatic Transmission Vehicles................................................................................................................... 115

Manual Transmission..................................................................................................................................... 117

Reassemble........................................................................................................................................................ 118

Reinstall Set-up and Testing............................................................................................................................. 118

4.2 Engine Assembly, AWD .................................................................................................................................... 119

Remove............................................................................................................................................................... 119

Disassemble – Ancillary Equipment ................................................................................................................ 127

Reassemble........................................................................................................................................................ 130

Reinstall Set-up and Testing............................................................................................................................. 130

4.3 Oil Pan Assembly, Except AWD ....................................................................................................................... 131

Remove............................................................................................................................................................... 131

Disassemble....................................................................................................................................................... 131

Clean and Inspect.............................................................................................................................................. 133

Reassemble........................................................................................................................................................ 133

Reinstall.............................................................................................................................................................. 134

4.4 Oil Pan Assembly, AWD.................................................................................................................................... 137

Remove............................................................................................................................................................... 137

Disassemble....................................................................................................................................................... 138

Clean and Inspect.............................................................................................................................................. 139

Reassemble........................................................................................................................................................ 140

Reinstall.............................................................................................................................................................. 141

4.5 Engine Front Cover............................................................................................................................................ 143

Remove............................................................................................................................................................... 143

Clean and Inspect.............................................................................................................................................. 143

Reinstall.............................................................................................................................................................. 144

4.6 Engine Flywheel and Flexplate......................................................................................................................... 146

Remove............................................................................................................................................................... 146

Clean and Inspect.............................................................................................................................................. 147

Crankshaft...................................................................................................................................................... 147

Flywheel......................................................................................................................................................... 147

Flexplate......................................................................................................................................................... 148

Reinstall.............................................................................................................................................................. 148

4.7 Crankshaft Spigot Bearing................................................................................................................................ 150

Remove............................................................................................................................................................... 150

Reinstall.............................................................................................................................................................. 150

4.8 Engine Rear Cover............................................................................................................................................. 152

Remove............................................................................................................................................................... 152

Clean and Inspect.............................................................................................................................................. 152

Reinstall.............................................................................................................................................................. 153

Crankshaft Rear Main Oil Seal....................................................................................................................... 155

Engine Mechanical Page 6A3–5

Page 6A3–5

4.9 Oil Pump, Pump Screen and Deflector ............................................................................................................ 156

Remove............................................................................................................................................................... 156

Oil Pump Disassemble ...................................................................................................................................... 157

Clean and Inspect.............................................................................................................................................. 158

Oil Pump Reassemble ....................................................................................................................................... 158

Reinstall.............................................................................................................................................................. 159

4.10 Timing Chain and Sprockets............................................................................................................................. 160

Remove............................................................................................................................................................... 160

Clean and Inspect.............................................................................................................................................. 161

Reinstall.............................................................................................................................................................. 162

4.11 Camshaft ............................................................................................................................................................ 164

Remove............................................................................................................................................................... 164

Clean and Inspect.............................................................................................................................................. 165

Reinstall.............................................................................................................................................................. 167

4.12 Piston, Connecting Rod and Bearing............................................................................................................... 168

Remove............................................................................................................................................................... 168

Disassemble....................................................................................................................................................... 169

Clean and Inspect.............................................................................................................................................. 170

Piston and Pin................................................................................................................................................ 170

Connecting Rods and Bearings...................................................................................................................... 173

Measuring Piston Ring End Gap.................................................................................................................... 175

Reassemble........................................................................................................................................................ 175

Piston Selection.............................................................................................................................................. 175

Piston to Connecting Rod............................................................................................................................... 177

Piston Rings................................................................................................................................................... 178

Reinstall.............................................................................................................................................................. 178

4.13 Crankshaft and Bearings .................................................................................................................................. 180

Crankshaft Thrust End Play.............................................................................................................................. 180

Measure......................................................................................................................................................... 180

Remove............................................................................................................................................................... 180

Clean and Inspect.............................................................................................................................................. 183

Main Bearings Inspect.................................................................................................................................... 185

Main Bearing Oil Clearance ........................................................................................................................... 186

Reinstall.............................................................................................................................................................. 189

4.14 Cylinder Block Plugs......................................................................................................................................... 191

Remove............................................................................................................................................................... 191

Reinstall.............................................................................................................................................................. 193

4.15 Cylinder Block.................................................................................................................................................... 195

Cylinder Block Clean, Inspect and Measure.................................................................................................... 195

Clean.............................................................................................................................................................. 195

Inspect............................................................................................................................................................ 195

Cylinder Bore – Measure................................................................................................................................ 195

Cylinder Boring and Honing ............................................................................................................................. 197

Honing Procedure .......................................................................................................................................... 197

Deglazing Procedure...................................................................................................................................... 197

Camshaft Bearings............................................................................................................................................ 198

Remove.......................................................................................................................................................... 198

Reinstall ......................................................................................................................................................... 200

Engine Mechanical Page 6A3–6

Page 6A3–6

5 Thread Repair .....................................................................................................................................201

5.1 General Information........................................................................................................................................... 201

5.2 General Thread Repair ...................................................................................................................................... 202

5.3 Cylinder Head Bolt Hole Thread Repair........................................................................................................... 205

Procedure........................................................................................................................................................... 205

5.4 Main Bearing Cap Bolt Hole Thread Repair.................................................................................................... 209

Procedure........................................................................................................................................................... 209

5.5 Thread Repair Specifications............................................................................................................................ 213

Cylinder Block – Front View.............................................................................................................................. 213

Cylinder Block – Rear View............................................................................................................................... 214

Cylinder Block – Left-hand View ...................................................................................................................... 215

Cylinder Block – Right-hand View.................................................................................................................... 217

Cylinder Block – Bottom View.......................................................................................................................... 219

Cylinder Block – Top View................................................................................................................................ 221

Cylinder Head – Top View................................................................................................................................. 222

Cylinder Head – End View................................................................................................................................. 222

Cylinder Head – Exhaust Manifold Side View.................................................................................................. 223

Cylinder Head – Inlet Manifold Side View........................................................................................................ 224

6 Specifications.....................................................................................................................................225

6.1 Engine................................................................................................................................................................. 225

General ............................................................................................................................................................... 225

Camshaft ............................................................................................................................................................ 225

Connecting Rod................................................................................................................................................. 225

Crankshaft.......................................................................................................................................................... 226

Cylinder Bore ..................................................................................................................................................... 226

Cylinder Head..................................................................................................................................................... 226

Cylinder Block.................................................................................................................................................... 227

Intake Manifold................................................................................................................................................... 227

Oil Pan – Front and Rear Cover Alignment...................................................................................................... 227

Piston.................................................................................................................................................................. 227

Piston Rings....................................................................................................................................................... 228

Valve Train.......................................................................................................................................................... 228

Valve Spring....................................................................................................................................................... 229

Sealants and Adhesives.................................................................................................................................... 229

6.2 Lubrication System............................................................................................................................................ 230

7 Torque Wrench Specifications..........................................................................................................231

7.1 Engine................................................................................................................................................................. 231

7.2 Special Tool Fasteners...................................................................................................................................... 233

8 Special Tools ......................................................................................................................................234

Engine Mechanical Page 6A3–7

Page 6A3–7

1 General Information

The 5.7 litre GEN III V8 engine features an aluminium cylinder block with cast iron sleeves that are cast into the cylinder

block during production. The deep skirt cylinder block also features five main bearings with each main bearing cap being

attached by six bolts.

Each of the two aluminium cylinder heads are attached to the block by 15 bolts, of which 10 are torque to yield bolts that

have their thread bosses loca ted deep into the cylinder block to minimise distortion at the top of the cylinder bore. The

cylinder heads are fitted with powdered metal valve guides and seats.

A five bearing camshaft is machined from a steel billet and is drilled through the centre to reduce weight. A reluctor ring

for the camshaft position sensor is located be tween the fourth and the fifth bearing journals.

The connecting rods are manufactured from forged powdered metal and the rod cap is separated during the

manufacturing process using the fracture method. This manufacturing process creates a stronger, visu ally seamless rod

cap union.

The crankshaft is manufactured from nodul ar cast iron and is drilled through the centre of main bearing journals 2, 3 and

5 to reduce weight. A crankshaft position sensor reluctor ri ng is attached to the rear of the crankshaft and is not serviced.

Extreme care is needed when removing and storing the crankshaft to avoid damage to the reluctor ring.

Cylinder layout for the GEN III V8 is 1, 3, 5, and 7 for the left-han d bank and 2, 4, 6 and 8 for the right-hand bank, with a

firing order of 1-8-7-2-6-5-4-3.

Engine throttle control is achieved using an electronic throttle body, which is controlled through the engine management

system. For further information, refer to Section 6C3 – 1 Powertrain Management – GEN III V8 – General Information.

NOTE

Unless noted otherwise, the information

contained in this Section is appropriate for both

manual and automatic transmission vehicles.

1.1 AWD Vehicles

To accommodate the AWD drivetrain assemblies, a different oil pan assembly is fitted which has a provision for the front

driveshaft. Unique service operations for AWD are included in this Section, specifically those for the oil pan, oi l and filter

change, and engine removal and reinstallation procedures.

Engine Mechanical Page 6A3–8

Page 6A3–8

1.2 Engine Views

Engine View Left-hand Side

Figure 6A3 – 1

Engine Mechanical Page 6A3–9

Page 6A3–9

Lower Front

Figure 6A3 – 2

Legend

1 Oil Level Indicator Tube

2 Oil Level Indicator Tube O-ring

3 Valve Lifter Guide Attaching

Bolt, 4 places

4 Valve Lifter Guide, 4 places

5 Valve Lifter, 16 places

6 Engine Block

7 Crankshaft Rear Oil Seal

8 Engine Rear Cover Attaching

Bolt, 11 places

9 Engine Rear Cover

10 Engine Rear Cover Gasket

11 Engine Block Rear Oil Gallery

Plug

12 Crankshaft Sprocket

13 Camshaft Timing Chain

14 Oil Pump Assembly

15 Oil Pump Assembly Attaching Bolt, 4

places

16 Engine Front Cover Gasket

17 Engine Front Cover

18 Crankshaft Front Oil Seal

19 Crankshaft Balancer

20 Crankshaft Balancer Attaching Bolt

21 Engine Front Cover Attaching Bolt, 10

places

22 Camshaft

23 Camshaft Retainer

24 Camshaft Sprocket

25 Camshaft Sprocket Locating Pin

26 Camshaft Sprocket Attaching Bolt

27 Camshaft Retainer Attaching Bolt, 4

places

28 Camshaft Bearings

29 Coolant Pump

30 Coolant Pump Attaching Bolt, 6 places

31 Carrier Gaskets – Coolant Pump

32 Oil Level Indicator

33 Oil Level Indicator Tube Attaching Bolt

34 Chain Dampener

35 Chain Dampener bolt, 2 places

Engine Mechanical Page 6A3–10

Page 6A3–10

Lower Engine Assembly, Except AWD

Figure 6A3 – 3

Engine Mechanical Page 6A3–11

Page 6A3–11

Legend

1 Camshaft Position Sensor

Attaching Bolt

2 Camshaft Position Sensor

3 Oil Pressure Sensor

4 Cylinder Block

5 Piston Rings

6 Piston and Connecting Rod

Assembly

7 Connecting Rod Bearings

8 Connecting Rod Cap

9 Connecting Rod Attaching Bolt,

2 places

10 Crankshaft Oil Deflector

11 Engine Flywheel – Manual

Transmission.

12 Engine Flexplate – Automatic

Transmission.

13 Oil Pump Pick-up Screen and

Pipe

14 Oil Pump Pick-up to Pump

Attaching Screw

15 Oil Deflector and Oil Pump Pick-

up Attaching Nut

16 Oil Pan Baffle Attaching Bolt

17 Oil Pan Baffle

18 Oil Transfer Tube

19 Oil Transfer Tube Gasket, 2 places

20 Oil Pan Gasket

21 Engine Flywheel/Flexplate Attaching

Bolt, 6 places

22 Oil Pan Closeout Cover Attaching Bolt

(right-hand)

23 Oil Pan Closeout Cover (right-hand)

24 Oil Pan Closeout Cover (left-hand)

25 Oil Pan Closeout Cover Attaching Bolt

(left-hand)

26 Oil Pan Gallery Plug

27 Oil Pan Transfer Tube Attaching Bolt

28 Oil Pan

29 Oil Transfer Cover Stud O-ring, 2 places

30 Oil Transfer Cover Gasket

31 Oil Transfer Cover

32 Oil Transfer Cover Attaching Nut, 2

places

33 Oil Bypass Valve

34 Oil Filter Adaptor

35 Oil Filter

36 Oil Drain Plug

37 Crankshaft Main Bearing Cap Side

Attaching Bolt, 10 places

38 Crankshaft Main Bearing Caps

39 Main Bearing Cap Attaching Stud, 5

places

40 Main Bearing Cap Attaching Bolt, 5

places

41 Crankshaft Main Bearings

42 Crankshaft Main Thrust Bearings

43 Crankshaft Rear Plug

44 Manual Transmission Spigot Bearing

45 Oil Pump Pick-up O-ring

46 Crankshaft

47 Crankshaft Sprocket Key

48 Cylinder Block Front Oil Gallery Plug

49 Cylinder Block Plug, 3 places

Engine Mechanical Page 6A3–12

Page 6A3–12

Lower Engine Assembly, AWD

Figure 6A3 – 4

Engine Mechanical Page 6A3–13

Page 6A3–13

Legend

1 Camshaft Position Sensor

Attaching Bolt

2 Camshaft Position Sensor

3 Oil Pressure Sensor

4 Cylinder Block

5 Piston Rings

6 Piston and Connecting Rod

Assembly

7 Connecting Rod Bearings

8 Connecting Rod Cap

9 Connecting Rod Attaching Bolt,

2 places

10 Crankshaft Oil Deflector

11 Cylinder Block Plug, 3 places

12 Engine Flexplate – Automatic

Transmission.

13 Oil Pump Pick-up Screen and

Pipe

14 Oil Pump Pick-up to Pump

Attaching Screw

15 Oil Deflector and Oil Pump Pick-

up Attaching Nut

16 Oil Deflector and Oil Pump Pick-up

Attaching Stud

17 Cylinder Block Front Oil Gallery Plug

18 Oil Transfer Tube

19 Oil Transfer Tube Gasket, 2 places

20 Oil Pan Gasket

21 Engine Flywheel/Flexplate Attaching

Bolt, 6 places

22 Oil Pan Closeout Cover Attaching Bolt

(right-hand)

23 Oil Pan Closeout Cover (right-hand)

24 Oil Pan Closeout Cover (left-hand)

25 Oil Pan Closeout Cover Attaching Bolt

(left-hand)

26 Oil Pan Gallery Plug

27 Oil Pan Transfer Tube Attaching Bolt

28 Oil Pan

29 Oil Transfer Cover Stud O-ring, 2 places

30 Oil Transfer Cover Gasket

31 Oil Transfer Cover

32 Oil Transfer Cover Attaching Nut, 2

places

33 Oil Bypass Valve

34 Oil Filter Adaptor

35 Oil Filter

36 Oil Drain Plug

37 Crankshaft Main Bearing Cap Side

Attaching Bolt, 10 places

38 Crankshaft Main Bearing Caps

39 Main Bearing Cap Attaching Stud, 5

places

40 Main Bearing Cap Attaching Bolt, 5

places

41 Crankshaft Main Bearings

42 Crankshaft Main Thrust Bearings

43 Crankshaft Rear Plug

44 Manual Transmission Spigot Bearing

45 Oil Pump Pick-up O-ring

46 Crankshaft

47 Crankshaft Sprocket Key

Engine Mechanical Page 6A3–14

Page 6A3–14

Cylinder Head

Figure 6A3 – 5

Legend

1 Valve Rocker Arm Cover Attaching Bolt, 4 places

2 Valve Rocker Arm Cover Grommet, 4 places

3 Cylinder Head Bolt (M8), 5 places

4 Cylinder Head

5 Cylinder Head Attaching Bolt (M11), 10 places

6 Valve Stem Collets

7 Valve Spring Cap

8 Valve Spring

9 Oil Seal Incorporating the Valve Spring Shim

10 Valve

11 Exhaust Manifold Gasket

12 Exhaust Manifold Assembly

13 Exhaust Manifold to Exhaust Pipe Flange Attaching Stud

14 Exhaust Manifold Heat Shield Attaching Bolt

15 Pushrod, 8 places

16 Coolant Temperature Sensor

17 Valve Rocker Arm Attaching Bolt

18 Valve Rocker Arm

19 Valve Rocker Arm Pivot Support

20 Cylinder Head Gasket

21 Valve Rocker Arm Cover Gasket

22 Valve Rocker Arm Cover

23 Oil Fill Tube

24 Oil Fill Tube Cap

25 Ignition Coil and Bracket Assembly

26 Ignition Coil Bracket Assembly Attaching Stud, 7 places

27 Ignition Coil Bracket Assembly Attaching Screw. (Rear on

each side)

28 Exhaust Manifold Attaching Bolt, 6 places

Engine Mechanical Page 6A3–15

Page 6A3–15

Intake Manifold

Figure 6A3 – 6

Legend

1 Fuel Rail to Intake Manifold Attaching Stud, 4 places

2 Fuel Rail Assembly

3 Fuel Rail Stop Bracket (left-hand side only)

4 Throttle Body Gasket

5 Intake Manifold Attaching Bolt, 10 places

6 Intake Manifold Gasket, 8 places

7 Manifold Absolute Pressure (MAP) Sensor

8 Intake Manifold

9 Throttle Body

10 Throttle Body Attaching Bolt, 3 places

11 Valley Cover Gasket

12 Valley Cover

13 Valley Cover Attaching Bolt, 10 places

14 Knock Sensor Oil Seal, 2 places

15 Knock Sensor, 2 places

16 Knock Sensor Wiring Harness

17 Vapour Vent Tube Hose

18 Vapour Vent Tube Stud, 2 places

19 Vapour Vent Tube

20 Vapour Vent Tube Attaching Bolt

21 Vapour Vent Cover, 2 places

22 Vapour Vent Tube Gasket, 2 places

Engine Mechanical Page 6A3–16

Page 6A3–16

1.3 Engine Serial Number

The engine serial number is stamped on the front right-hand

side of the cylinder block. The number is prefixed by two

letters, VF is an example.

The following is a breakdown of the engine numbering

system using VF051904500 a s an example;

• The first two numbers, 05 = 2005 i ndicates the engine

model year.

• The next three numbers, 190 i s the Julian date (day of

the year the engine was manufactured).

• The next four numbers are the daily sequential build

number.

Figure 6A3 – 7

Engine Mechanical Page 6A3–17

Page 6A3–17

1.4 Engine Construction

Cylinder Block

The engine cylinder block is a deep skirt, 90° V

configuration with five crankshaft main bearing caps (1),

which are manufactured from forged powdered metal. The

camshaft is positioned within the block and is supported by

five camshaft bearings that are pressed into the block.

The cylinder block is alumini um with cast-in-place cast iron

cylinder bore liners. The five cross-bolted crankshaft bearing

caps each have four vertical M10 bolts (2 and 3) and two

horizontal M8 (4) mounting bo lts.

Boring of the cylinders is not permitted, althoug h the

cylinders can be honed.

Figure 6A3 – 8

The cylinder block incorporates enclosed valve lifter bores

(1) under each cylinder head.

A structural die-cast aluminium valley cov er (2) is attached

to the block with 10 bolts (3). With the valley area being

closed, this prevents hot oil from contacting the lower

surface of the intake manifold allowing cooler air to enter the

cylinders.

Figure 6A3 – 9

Engine Mechanical Page 6A3–18

Page 6A3–18

Cylinder Heads

The cylinder head assemblies are cast aluminium with

powdered metal valve guides and valve seats pressed into

the cylinder head casting.

The intake and exhaust ports are identica l fo r each cylinder,

ensuring a balanced airflow distribution for balanced

combustion.

The cylinder head is attached to the cylinder block using 10

M11 and five M8 bolts, with the M11 bolts being a deep

threaded arrangement. This arrangement reduces distortion

of the cylinder bore, which then allows low friction pistons

and piston rings to be used for improved fuel consumption.

Cylinder head gaskets are a laminated steel type and

feature stainless steel PTFE coated flang es and lacing.

Legend

• Cylinder Head (1)

• Valve Stem Collets (2)

• Valve Spring Cap (3)

• Valve Spring (4)

• Valve Stem Oil Seal/Shim Combination (5)

• Valve (6)

• Cylinder Head Core Plugs (7)

Figure 6A3 – 10

The additional hei ght of the intake ports are designed to

enhance fuel injector targeting. As the air flows down to the

valve guide, the port narrows then widens to the size of the

intake valve seat.

Figure 6A3 – 11

Engine Mechanical Page 6A3–19

Page 6A3–19

Valve Train

Motion is transmitted from the camshaft (1) to the hydraulic

valve lifters (2) and the tubular pushrod (3) then to the

rocker arms (4), which pivot and in doing so, control the

opening and closing of the valves.

Hydraulic valve lifter guides (5) mounted within the cylinder

block position and retain the hydraulic roller valve lifters

within the cylinder block.

The valve rocker arms for each bank of the cylinders are

mounted on pivot supports. The pivot supports are attached

to the cylinder head by a bolt. Valve lash is adjusted

automatically with oil pressure through each cycle of the

hydraulic valve lifters.

Both the inlet and exhaust valves are angled at 15° to the

cylinder bore centreline. This allows a shallow combustion

chamber and a flat top piston to be used resulting in a

compression ratio of 10.1:1.

Both the exhaust and intake valve seat angle s are at 46°

with an intake valve head diameter of 50.8 mm and exhau st

valve head diameter of 39.4 mm. Figure 6A3 – 12

The valve springs are conical in shap e and are made from chromium silicone spring steel. T he reduced diameter end

coils allow a smaller diameter, lower mass, steel spring retainer to be used with single bead valve stem collets. This

spring design also reduces spring mass and coupled with the increased stiffness in the valve train, results in a reduction

in the valve spring pre-load, thereby reducing friction and valve train noise.

The rocker arms are manufactured from inve stment cast steel and have a ratio of 1.7:1. This allows a lower cam lobe lift

resulting in lower valve train loading and less noise.

The valve rocker arm covers are cast aluminium an d use a pre-moulded silicone gasket for sealing. T here are four

individual ignition coils mounted to each rocker cover. Incorporated into the rocker covers is the oil fill tube and the fitting

for the fresh air hose, which is part of the Positive Crankcase Ventilation (PCV) s ystem.

Crankshaft

The crankshaft (1) is manufactured from nodular cast iro n

and is supported by five main bearings. Each main bearing

cap is attached to the cylinder block by six bol t s, two of

which are attached from the side. The main bearing caps

are machined with the cylinder block for cor rect alignment

and clearance and must be kept in their original location

when servicing.

A 24X reluctor ring (2) is attached to the rear of the number

eight crankshaft counter weight. The reluctor ring is not

serviced separately.

Thrust is controlled by a thrust bearing at the centre (No. 3)

main bearing. This location is used to reduce the expansion

differences between the cast iron crankshaft and the

aluminium cylinder block.

The crankshaft has a 25.4 mm hole drilled through the

centre of the main journals 2, 3, 4 and 5. Apart from a

reduction in crankshaft weight, this also enhances engine

breathing at low speeds.

Figure 6A3 – 13

Engine Mechanical Page 6A3–20

Page 6A3–20

Piston and Connecting Rod

The cast aluminium pistons are fitted with t wo compression

rings (4, 5) and one oil control ring ass embly (1,2,3). The

piston rings are a thin low friction des ign. The top ring is

located close to the top of the piston crown to reduce

hydrocarbon emissions and blow-by. The pistons are a lo w

friction lightweight design with a flat top and a barrel shaped

skirt.

The piston pins are chromium steel and are a floating fit in

the piston and the connecting rod. The piston pin is retained

by a circlip in each side of the piston.

Figure 6A3 – 14

The connecting rods are forged powdered metal. The

connecting rod cap is separated during the manufacturing

process using the fracture method. This creates a stronger

visually seamless rod to cap union. The reassembled rod is

then machined for the correct clearance.

A 0.25 mm oversize piston and piston ring set is available

for service should cylinder honing be re quired. Boring of the

cylinder is not permitted.

Figure 6A3 – 15

Engine Mechanical Page 6A3–21

Page 6A3–21

Camshaft and Drive

The camshaft is machined from a steel billet and is supported by five bearings pressed into the cylinder block. It also has

a machined camshaft sensor reluctor ring incorporated between the fourth and fifth bearing journals and has a 17 mm

hole drilled down its length to reduce weight. The intake and exhaust cam lobes have slow velocity closing ramps to

reduce valve train noise.

The camshaft (1) is driven by a traditional 9.52 mm pitch

roller chain (2) and powdered metal timing sprockets (3)

mounted to the front of the camshaft and crankshaft (4). A

retaining plate (5) mounted to the front of the engine block

maintains the camshaft location.

The crankshaft sprocket is splined internally and drives the

oil pump.

A timing chain dampener (6) is used to red uce chain noise

and resonance and is attached to the eng ine block just

above the crankshaft timing gear.

Figure 6A3 – 16

Intake Manifold

The intake manifold (1) is a one-piece composite design that

incorporates threaded metal inserts (A) for attaching th e fuel

rail (2) and the electronic thrott le body.

The intake manifold is sealed to the cylinder heads by eight

separate non-reusa ble silicone sealing gaskets that are

pressed into the grooves of the intake housing.

The electronic throttle body assembly attaches to the front

of the intake manifold. The throttle bod y is sealed to the

intake manifold using a one piece silicone gasket.

The fuel rail assembly has eight separate fu el injectors (3).

The fuel rail is attached to the intake manifold by four

studs (4). The injectors are seated in their individual

manifold bores with O-ring seals to provide sealing. The fuel

pulsation damper (5) is incorp orated into the fuel rail design.

A fuel rail stop bracket is retained at the rear of the left-hand

fuel rail by the intake manifold mounting bolts (not shown).

A Manifold Absolute Pressure (MAP) sensor is installed in

the snap fit MAP sensor housing that is attached at the rear

of the manifold and sealed by an O-ring seal, refer to

Section 6C3 Powertrain Management – GEN III V8 –

Service Operations.

There are no coolant passage s within the intake manifold.

However, there are two vapour vent hoses that connect to a

fitting located on each lower side of the throttle body.

Figure 6A3 – 17

Engine Mechanical Page 6A3–22

Page 6A3–22

Exhaust Manifold

The exhaust manifolds are one piece, high temperature

silicone molybdenum cast iron manifold.

The exhaust manifolds dir ect the e xhaust gases from the

combustion chambers to the exhaust system.

The exhaust manifolds are attached to each cylinder head

using six M8 bolts.

Figure 6A3 – 18

Each exhaust manifold (1) has an externall y mounted dual

wall heat shield (2) made of aluminised steel that is attached

to the manifold by five M6 bolts (3).

Figure 6A3 – 19

Engine Mechanical Page 6A3–23

Page 6A3–23

Oil Pan

Excluding AWD Vehicles

The cast aluminium oil pan (1) forms a structural part of the

powertrain by providing a 360 ° mounting for the

transmission, whether it be manual or automatic.

Incorporated into the oil pan casting are cast-in dams.

These dams minimise oil migration during braking and

cornering manoeuvres an d assist in guiding oil to the pick-

up screen (2) via the strategically placed openings in the

dam walls.

Also incorporated in the oil p an casting is the oil filter

mounting boss (3), an opening for the drain plug (4) and a

stamped oil pan baffle (5). The oil pan baffle mainta ins an

area around the pick-up screen to prevent oil starvation and

aeration.

A crankshaft oil deflector (6) is attached to the main bearing

caps and controls windage, removes return oil from the

crankshaft and facilitates drain back, thus reducing aeration.

The oil pan gasket (7) is a controlled compression

aluminium carrier gasket with silicone used as the sealing

agent.

Two O-ring seals (8) are fitted to stop oil leaks along the

studs attaching the oil transfer cover to the oil pan.

Figure 6A3 – 20

AWD Vehicles

The engine oil pan fitted to AWD vehicles has undergone an extensive re -design process from the conventional oil pa n.

In addition to providing fixture points for the front final drive and bearing support assemblies, the oil filter a nd the oil

transfer tube have been relocated to the front of the oil pan.

The AWD cast aluminium oil pan (1) is an integra l part of the

powertrain structure that creates a 360° mounting for the

automatic transmission.

The oil filter mounting boss (2) is incorporated into the front

of the oil pan with the oil filter screwing onto the oil filter

adaptor (3).

Internally, the engine oil pan design results in an increased

engine oil capacity with some features retained from the

conventional oil pan.

These include:

• The crankshaft oil deflector is attached to the main

bearing caps and further improves the flow of return oil

by:

• Controlling windage

• Removing return oil from the crankshaft

• Facilitating the return oil drain back into the oil

pan

• Reducing engine oi l aeration

• Controlled compression al uminium carrier oil pan

gasket and is coated with a silicon e materia l as a

sealing agent.

Figure 6A3 – 21

Engine Mechanical Page 6A3–24

Page 6A3–24

1.5 Engine Lubrication System

Oil Pump

A Gerotor type oil pump assembly supplies the engine lubrication, refer to Figure 6A3 – 22. The pump is attached to the

front of the cylinder block and is driven directly by the crankshaft sprocket. The pump gears rotate and draw oil from the

oil pan sump through a pick-up screen and p ipe. Contained within the oil pump assembly is a pressure relief valve that

maintains oil pressure within a specified range.

Pressurised oil is directed thr ough the lower gallery to the full flow oil filter where harmful contaminants are removed.

Incorporated into the oil filter is a bypass valve, which allows oil to flow through the engine in the event the filter becomes

blocked.

The oil is pressurised as it passes through the pump and is then pumped through the cylinder block via the oil galleries,

refer to Figure 6A3 – 23.

Figure 6A3 – 22

Legend

1 Driven Gear

2 Oil Pump Housing

3 Pressure Relief Valve

4 Pressure Relief Valve Spring

5 Plug

6 Drive Gear

7 Cover Bolt, 7 places

8 Cover

Engine Mechanical Page 6A3–25

Page 6A3–25

Oil Flow

Oil is directed to the drilled upper main oil g al leries just above the camshaft assembly at the rear of the cylinder block,

refer to Figure 6A3 – 23. From there, oil is then directe d to the crankshaft and camshaft bear ings. Oil that has entered

the upper main oil galler ies also pressurises the valve lifter assemblies and is then pumped through the pushrods to

lubricate the valve rocker arms and valve stems. The crankshaft oil deflector directs oil returnin g to the pan back to the

sump.

Figure 6A3 – 23

Engine Mechanical Page 6A3–26

Page 6A3–26

Oil Seals

The rear main oil seal is a multiple lip oil seal designed for

long life operation.

The seal includes a Polytetrafluoro ethylene (PTFE) Teflon

centre lip (1) to minimise rear main oil seal leaks. T he anti-

friction property of the PTFE reduces the chances of

choking or build-up of degraded oil on the lip causing the lip

to lift off the shaft resulting in a leak.

Similar to the rear main oil seal, the front crankshaft oil seal

also incorporates a PTFE lip.

The PTFE is actually deposited on the dry crankshaft seal

surface during initial operation by the heat generated from

the rotating shaft. NOTE

Lubricant must not be applied to the PTFE seal

lip or the shaft on which it runs during installatio n

as this will prevent correct break-in of the seal.

The outside of the seal may be lubricated

sparingly for ease of installation.

Figure 6A3 – 24

Positive Crankcase Ventilation System

The crankcase ventilation s ys t em was developed to remove

the engine combustion blow-by vapours and minimise the

following:

• Crankcase pressure build-up

• Oil deterioration

• Oil consumption

• Evaporative/exhaust emissions

During normal idle and part throttle operation, filtered fresh

air is routed from upstream of the throttle body (1) blade to

the front of the right-hand rocker cover via the fresh air inlet

hose (2).

Blow-by gas (oil vapour) in the crankcase valley passes

through the oil separator (3) attached to the valley cover and

then flows through the fixed internal flow-restricting orifice

(4) within the valley cover then via the foul ai r hose (5). The

blow-by gas is directed from the valley cover right-hand

corner to the Intake manifold on the engine side of the

throttle plate.

Under heavy load operation and high engine speeds, a n

acceptable reverse flow condition may occur in the fresh air

inlet hose.

Figure 6A3 – 25

During sustained maximum lateral acceleration (A), the

outboard rocker cover may be overlo aded with oil (1). If the

blow-by gas is dra wn from the rocker cover as in previous

designs, oil may be ingested into the intak e manifo ld.

Instead of the blow-by gas be ing drawn from the rocker

cover, a high efficiency oil separator (2) in conju nction with

an internal flow-restricting orifice (3) is fitted under the valley

cover to draw the blow-by gas from the crankcase (B),

preventing oil from being ingestion during severe vehicle

cornering manoeuvres.

Figure 6A3 – 26

Engine Mechanical Page 6A3–27

Page 6A3–27

1.6 Service Notes

Cleanliness and Care

Throughout this Section, correct cleaning and protection of machined surfaces and friction areas is a vital part of the

service procedure and is considered to be a standard workshop practice even if it is not specifically stated. When any of

the internal engine parts are serviced, care and cleanliness is important.

When components are removed for service, they should be marked, organised or retai ne d in a specific order for

reassembly. Further information, refer to Separating Comp onents. At the time of reinstallation, components should be

installed in the same location and with the same mating surface as when removed.

Any engine is a combination of many machined, honed, po lished an d lapped surfaces with tolerances that are measured

in hundredths of millimetres. These surfaces should be covered or protected to avoid component damage.

A liberal coating of clean engine oil should be applied to all friction areas durin g compo nent assembly. Proper lubrication

of engine components dur ing assembly will protect and lubricate friction surfaces during the initial engine start-up.

Replacing Engine Gaskets

Re-using Gaskets and Applying Sealant

Do not re-use any gasket unless specified in the service procedure. Gaskets that can be re-used will be identified within

the procedure.

Do not apply sealant to any gasket or sealing surface unless instructed in the service procedure and if instructed, use

only the recommended sealant or the equivalent as stated.

Cleaning Gasket Surfaces

Remove all gasket and sealing materials from aluminium components using a plastic or wood scraper. Do not use any

other method or technique to remove sealant or gasket material from a part. Care must be used to avoid gouging or

scraping the sealing surfaces.

Do not use abrasive pads, sand paper, or power tools to clean the gasket surfaces. These methods of cleaning can

cause damage to the component sealin g surfaces. Abrasive pads also produce fine grit the oil filter cannot remove from

the oil. This grit is abrasive and can cause internal engine damage.

Assembling Components

When assembling com ponents, use only the sealant spec ified or equivalent as recommended in the service procedure.

When applying sealant to a component, apply the amount specified in the service proced ure. Do not allow the sealant to

enter into any blind threaded hol es as this can cause the bolt to bottom out and prevent it from clamping properly or

cause component damage when tightened. Sealing surfaces should be clean and free of debris or oil.

Specific components such as valve stem oil seals ma y re quire lubrication during assembly. Components requirin g

lubrication will be identified in the service procedure.

Ensure all fasteners are tightene d to the correct torque specification.

Room Temperature Vulcanising (RTV) and Anaerobic Sealers

NOTE

• A number of sealant types are commonly

used in engines. Examples are; Room

Temperature Vulcanising (RTV) sealer,

anaerobic gasket eliminator sealer, anaerobic

thread sealant and pipe joint compound.

• The correct sealant and am ount must b e us ed

in the specified location to prevent oil and

coolant leaks.

• Do not interchange the different types of

sealers and use only the specified sealer or

equivalent as recommended in the service

procedure.

Engine Mechanical Page 6A3–28

Page 6A3–28

Pipe Joint Compound

Pipe joint compound is a pliable sealer that does not completely harden. This type of sealer is used where two non-rigid

parts (such as pressed steel and machined s urfaces) are assembled together.

Do not use pipe joint compound in areas where extreme temperatures are expected. These areas include exhaust

manifold to cylinder head or other surfaces where a gasket eliminator is specified.

Follow all safety precautions a nd directions for use that are on the container. To remove the sealant or the gasket

material, refer to Replacing Engine Gaskets.

Apply pipe joint compound to a clean and dry surface. Use a bead size or quantity as specified in the procedure and run

the bead to the inside of any bolt holes. Do not allow the sealer to enter any blind threaded holes as it may cause the

fastener to bottom out and prevent the fastener from clamping correctly or cause component damage when the fastener

is tightened. Tighten fasteners to the correct torque specification.

Examples of locations where a pipe sealant type material such as Loctite 565 or equivalent is to be used are:

• Cylinder block coolant an d oil gallery plugs

• Oil pressure sensor threads

• Cylinder block oil pan surface

RTV Sealer

Room Temperature Vulcanising (RTV) sealant hardens when exposed to air. This type of sealer is used where two non-

rigid parts such as the intake manifold and the cylinder head are assembled together.

Do not use RTV sealant in areas where extreme temperatur es are experienced. These areas include exhaust manifol d to

cylinder head or other surfaces where a gasket eliminator is specified.

Follow all safety precautions and directions for use that are on the container.

To remove the sealant or the gasket material, refer to Replacing Engine Gaskets.

Apply RTV to a clean and dry surface and use a bead size as specified in the service procedure. Run the bead to the

inside of any bolt holes. Do not allow the sealer to enter any blind threaded holes as it ma y prevent the fastener from

clamping correctly or cause compo nent damage when the fastener is tightened.

Assemble components and tighten fasteners to the correct torque specification while the RTV is still wet (within 3

minutes at room temperature of 20 to 25 Degrees C). Do not wait for RTV to skin over.

Anaerobic Sealer

Anaerobic gasket elimi nator or thread sealant hardens with the absence of air. T his type of sealer is used where the two

rigid parts (such as castings) are assembled together, where fasteners are subjected to vibration or where the holes are

not blind. When two rigid parts are disassembled and no sealer or gasket is readil y noticeable, the parts were probably

assembled using a gasket eliminator.

Follow all safety precautions and directions for use that are on the container.

To remove the sealant or the gasket material, refer to Replacing Engine Gaskets.

Apply a continuous bead of gasket eliminator to one flange or on the bolt/stud thread. All surfaces must be clean and dry.

Spread the sealer evenly on the sealing surface. Do not allow the sealer to enter any blind threaded holes as it may

prevent the fastener from clamping correctly or cause component damag e when the fastener is tightened.

Incorrect shimming and sealing of the joint

will occur if an anaerobic sealed joint is

partially tightened and the sealer allowed to

cure for more than five minutes before the

final correct torque specification is applied.

Tighten all fasteners to the correct torque specification. After correctly tightening the faste ners, remove any excess

sealer from the outside of the joint.

Examples where thread locking sealant such as Loctite 242, Loctite 272 or equivalent are to be used are:

• Fuel rail attaching studs (Loctite 242)

• Intake manifold attaching bolts (Loctite 242)

• Cylinder head M8 bolts (Loctite 242)

• Exhaust manifold attaching bolts (Loctite 272)

Engine Mechanical Page 6A3–29

Page 6A3–29

Separating Components

Use a rubber mallet or a similar soft-headed hammer to separate components. Gently tap the part sideways to loosen

the components.

NOTE

• Tapping a component loose should be done

at bends or on the reinforce d areas to preve nt

distortion of the parts.

• Do not use screwdrivers or similar between

joints to prise them apart as this will damage

the sealing surfaces.

Many internal engine c omponents will develop specific wear patterns on their friction sur faces. The internal components

when separated, must be marked or organised in a way to ensure they are reinstalled to their original location and

position.

Separate, mark or organise the following compon ents:

• Piston and piston pin

• Piston to the specific cylinder bore

• Piston rings to the specific piston

• Connecting rod to the crankshaft journal

• Connecting rod to the bearing cap

• Crankshaft main and connecti ng rod bearings

• Camshaft and hydraulic valve lifters

• Hydraulic valve lifters, guides, pushrods, pivot supports and rocker arms

• Hydraulic valve to the valve guide

• Hydraulic valve spring and where fitted, the shim to the cylinder head location

• Cylinder block main beari ng cap location and direction

• Oil pump drive gears

Special Tools and Equipment

Special tools are listed and illustrated throughout this Section with a complete listing at the end of this S ection,

refer to 8 Special Tools.

These tools or their equivalents are spec ially designed to quickly and safely accompl ish the operation for which they are

intended. The use of the special tools listed will a lso minimise possible damage to engin e compo nents. Some precision

measuring tools are required for inspection of certain critical components. Torque wrenches and torque angl e tools are

necessary for correct tightening of various fasteners.

To correctly service the engine assemb ly, the following items should be readily available:

• Approved eye protection and appropriate safety gloves

• Clean well lit work area

• Suitable parts cleaning tank

• Compressed air suppl y

• Trays or storage containers to keep parts and fasteners organised

• Adequate set of hand tools

• Approved engine repair stan d such as Tool AU 591

• Approved engine lifting device that will adequately supp ort the weight of the engine and transmission assembly

Engine Mechanical Page 6A3–30

Page 6A3–30

Fasteners

Fasteners are important to the reliable operation of the

engine.

Due to the greater thermal expansion of aluminium, the bolt

threads will change dimension to a greater extent when hot

(A) when compared to cast iron.

It is recommended to allow the engine to cool to at least 50°

Celsius (B) before attempting fastener removal.

If a bolt or other threaded component is remo ved before the

engine is allowed to cool, the threads could be pulled from

the cylinder block or cylinder head.

Do not use impact tools to remove bolts

during engine disassembly. While this may

be a common practice with cast iron engine

components, use of these tools is more likely

to damage the aluminium threads in the

cylinder block or head of the engine. Figure 6A3 – 27

Clamp Load

When torque is applied to a fastener, the fastener stretches

and the joint compresses. The force developed in the

fastener due to its stretch is called tension (A), while the

force applied to the joint is called clamp load (B).

Only a small portion of the applied torque (C) is transferred

to the clamp load (1). Friction under the bo lt head (2) and in

the threads (3) absorbs much of the applied torque.

Typically, only 10% of the torq ue is available to develop

stretch (or tension) in the fastener and clamp load in the

joint. Therefore, a slight variation in friction in the thread or

under the bolt head results in a wide variati on in the clamp

load applied to the joint.

Figure 6A3 – 28

Torque Angle and Torque to Yield Fasten ers

The torque angle method of applying torque to a fastener has been developed to overcome the effects of friction

variations in the fastener application.

The application of the torque angle method does not always mean the fastener has to be replaced after loosening. It is

only when the fastener has been an gle tightened to the extent the yield point of the fastener has been exceeded the

fastener must be replaced.

Examples are the main bearing caps that are angle tightened but the bolts can be re-used, whereas the M11 cylinder

head bolts that are torque to yield fasteners must be replaced when loosened.

Engine Mechanical Page 6A3–31

Page 6A3–31

2 Diagnosis

2.1 Engine Diagnosis

Engine performance diagnosis procedures are covered in

Section 6C3-2 Powertrain Management – GEN III V8 – Diagnostics and s hould be referred to for diagnosis of any

driveability, emissions, or powertrain diagnostic trouble codes (DTC) problems.

The following diagnosis cov ers common problems and possible causes. When the correct diagnosis is made, the cause

should be corrected by adjustment, repair or replacement as required.

Refer to the appropriate Section of the service information for each sp ecific procedure.

This diagnostic table will assist in diagnosis of an engine mechanical fault such as a faulty camshaft, worn or damaged

bearings or bent pushrod.

This diagnostic table will not isolate a crossed injector wire, faulty injector or any other electrical component failure that

may cause a misfire. The Powertrain On-Board Diagnostic System checks must be performed first.

Refer to Section 6C3-2 Powertrain Management – GEN III V8 – Diagnostics.

When using this table to perform the Engine Misfire diagnosis, begin with the preliminary information below and then

proceed to the specific category.

Procedure

Checks Action

Preliminary Perform a visual inspection of the following:

• A loose or incorrectly installed crankshaft balancer and if required check the

flywheel or flexplate for loose or incorrect installation.

• Worn, damaged, or misaligned accessor y dr ive system components.

• Listen to the engine for any abnormal internal engine noises.

• Inspect the engine for acceptable oil pressure. Refer to 2.5 Oil Pressure.

• Verify if the engine has excess ive oil consumption. Refer to 2.4 Oil Consumption.

• Verify if the engine is consuming coola nt.

• Perform a compression test on the engine.

Intake manifold leaks An intake manifold that h as a vacuum leak ma y cause a misfire which is m ore prominent

at idle.

Inspect for the following:

• Incorrectly installed or damag ed vacuum hoses.

• Faulty or incorrectly installed intake manifold and / or gask ets.

• Cracks or damage to the intake manifold, also inspect the areas between the intake

runners.

• Incorrectly installed or damag ed Manifold Absolute Pressure (MAP) sensor or

O-ring seal. The MAP sensor is located at the rear of the intake manifold.

• Incorrectly installed throttle body or damaged gasket.

• Warped intake manifold.

• Warped or damaged cylinder head sealing surface.

Coolant consumption Coolant consumption may or may not cause the engine to overheat. However, an engine

that has been overheated may ca use premature failure of head gaskets and distortion of

gasket surfaces.

Inspect for the following:

• External coolant leaks.

• Faulty cylinder head gasket.

• Distorted cylinder head.

• Cracked or corroded c ylinder head.

• Damaged cylinder block.

• Thermostat operation.

Engine Mechanical Page 6A3–32

Page 6A3–32

Abnormal internal engi ne

noises 1 With the engine running, try to determine the knock speed. That is if the noise is

timed to camshaft speed or crankshaft speed.

NOTE

• Camshaft speed is half the speed of the crankshaft. Use a timing light to

determine the knock spee d. Two knocks per flash is cra nkshaft speed and

one knock per flash is camshaft speed.

• A slight COLD knock or p iston slapping noise could be con sidered normal

if it is not present after the engine has reached normal operating

temperatures.

2 If the noise is timed to camshaft speed, inspect the following:

• Missing or loose valve train components.

• Worn or loose valve rocker arms.

• Worn or bent pushrods.

• Faulty valve springs.

• Bent or burnt valves.

• Worn camshaft lobes.

• Worn or damaged timing chain and/or sprockets.

3 If the knock is timed to crankshaft speed, inspect the following:

• Worn crankshaft main or connecting rod bearings.

• Piston or cylinder damage.

• Worn piston or piston pin.

• Damaged or faulty connecting rod.

• Excessive carbon build-up on the top of the piston.

Engine misfire 1 Remove the valve rocker arm cover on the side of the en gine with the cylinder that

is misfiring.

2 Inspect for the following:

• Loose valve rocker arm bolts.

• Bent push rods.

• Faulty valve springs.

• Faulty valve lifters (bleeding d own).

• Worn or Incorrectly seated valves.

• Worn camshaft lobes.

Engine Mechanical Page 6A3–33

Page 6A3–33

2.2 Engine Noise

There are four steps to diagnosing engine noise that must be determined.:

1 The type of noise.

• Determine if the noise a light rattle/tapping or a low rumble/knocking noise.

2 The exact operating condition under which the noise exists.

• Factors such as the ambient temperature, the amount of engine warm-up time, the engine temperature,

engine speed and load and other specifics.

3 At what rate the noise occurs, and at what location in the engin e.

• Remember, engine noises are generally synchronised to either engine speed (crankshaft, flywheel,

connecting rods, balancer, or pistons and related components) or one-half engine speed (valve train noise

such as rocker arms, valve lifters, and timing chain). Try to determine the r ate at which the noise is occurring.

Use a timing light to assist in determining the knock speed. Two knocks per flash is crankshaft speed and one

knock per flash is camshaft speed.

4 Compare the engine sounds to other engines.

• If possible, compare the engine noise to an other engine as this will verify that you are not trying to correct a

normal condition.

Procedure

Checks Action

Noise on start-up but only lasts a

few seconds 1 This noise condition may be cause d b y:

• Incorrect oil viscosity. Change the engine oil with the recommended

oil viscosity for the expected temper atures.

• Incorrect oil filter without the anti-drain back feature.

• Worn or dirty hydraulic valve lifters.

• Excessive piston to bore clearance.

• Excessive piston pin to piston cleara nce.

• Excessive crankshaft bearing clearance.

Knocks when cold and continues

for 1 to 2 minutes 1 Common causes for a cold start knock are:

• Loose or broken crankshaft bala ncer or accessory drive components.

• Excessive piston to bore clearance.

• Cracked piston.

NOTE

A cold engine knock usually disappears when the specific cylinder's

secondary ignit ion circuit is isolated.

Intermittent noise on idle,

disappearing when the engine

speed is increased

1 Intermittent noises at idle can be caused by:

• Incorrect oil viscosity. Change the engine oil with the recommended

oil viscosity for the expected temper atures.

• Lower than specified oil pressure. Install an oil pressure gauge and

measure the engine oil pressure.

• Dirty or worn hydraulic valve lifter.

Engine Mechanical Page 6A3–34

Page 6A3–34

Checks Action

Valve train noise (rattle/tapping) 1 The following conditions may cause valve train noise:

• Lower than specified oil pres sure.

• Worn or faulty oil pump.

• Loose oil pump to cylinder block bolts.

• Loose or damaged oil transfer tube and/or gaskets.

• Loose valve rocker arm attaching bolt.

• Worn valve rocker arm bearings.

• Worn valve rocker arm and/or pushrod.

• Broken valve spring.

• Sticking valves.

• Worn, dirty, or faulty hydraulic valve lifters.

• Worn hydraulic valve lifter guides.

• Worn camshaft lifter lobes.

• Worn valve guides or valve stems.

• Bent, broken, or damaged timing chain sprocket teeth.

Knocks at idle when hot

(rumble/knocking) 1 The following conditions may cause a knocking noise:

• Malfunctioning accessory dr ive system components.

• Loose or broken crankshaft bala ncer.

• Detonation (Pinging). Check for correct operation of the cooling,

knock, and ignition control compon ents. Refer to diagnostic

information in Section 6C3-2 Powertrain Management – GEN III V8 –

Diagnostics.

• Excessive piston pin to bore clearance.

• Bent connecting rod.

• Excessive connecting rod bearing, crankshaft main or thrust bearing

clearance.

• Loose torque converter and/or fl ywheel/flexplate bolts.

• Cracked or damaged flywheel or flexplate.

• Exhaust leak at the manifold.

Exhaust system noise and/or

leakage 1 Exhaust system noise and/or leakage may be caused by the following

conditions:

• Incorrectly installed or misaligned exhaust system components.

• Cracked or broken exhaust manifold.

• Damaged or worn gaskets.

• Burnt or corroded exhaust system components.

• A broken or loose exhaust clamp and/or br acket.

Engine Mechanical Page 6A3–35

Page 6A3–35

2.3 Valve Train Noise

A light tapping noise at one-half engine speed, or any varying frequency, may indicate a valve train problem. These

tapping noises will typically increase with engine speed.

Before attempting to diagnose valve train noise, check for correct oil level and thoroughly warm up the engine. By doing

this you will bring all engine components to a normal state of expansion.

While sitting in the drivers seat, run the engine at various speeds and listen for any abnormal engine noise.

When diagnosing a valv e lifter noise, always use a listening device such as a stethoscope. Tools such as this will help to

isolate any lifter noise and identify noises that could be mis-diagnosed as lifter noise.

Procedure

Checks Action

Light tapping noise similar to

valve train noise

1 This light type of noise may be caused b y the following:

• Fuel injectors.

• Evaporative emission (EVAP) purge so lenoid.

• Detonation (Pinging).

• Loose heat shields.

Causes of valve train noise 1 Any or a combination of the following can cause valve train noise:

• Loose valve rocker arm attachments caus ing excessive valve lash.

• Worn or damaged valve rocker arm bear ings.

• Worn valve rocker arm and/or pushrod.

• Broken valve spring.

• Sticking valves.

• Worn, dirty, or faulty hydraulic valve lifters

• Broken hydraulic valve lifter guide.

• Camshaft lobes worn.

• Worn valve guides or valve stems.

• Worn, damaged, or missing valve collets.

• Bent pushrods.

• Excessive play in the camshaf t timing chain.

• Bent, broken, or damaged timing chain sprocket teeth.

2 Low engine oil pressure caused by the following:

• Poor oil quality caused by water contamination, aerat ion, or fuel

dilution or incorrect oil viscosity.

• Worn or faulty oil pump.

• A loose oil pump pick-up tube.

• Blocked oil pump pick-up tube screen.

• Loose or damaged oil transfer tube.

Engine Mechanical Page 6A3–36

Page 6A3–36

2.4 Oil Consumption

NOTE

Excessive oil consumption (not due to leaks) is

the use of 0.75 litres or more of engine oil within

2,500 kilometres (3 litres / 10,000 kilometres ).

Checks Action

Preliminary 1 The causes of excessive oil consumption may include the following

conditions:

• External oil leaks. Refer to 2.6 Oil Leaks.

• Incorrect oil level or reading of the oil level indicator. With the vehicle

on a level surface, run the engine for a few minutes, allow adequate

drain down time (2-3 minutes) and check for the correct en gine oil

level.

• Incorrect oil viscosity. Refer to the vehicle Owners Manua l and use

the recommended SAE grade and viscosity for the operating

environment.

• Continuous high speed driving and/or severe usage.

• Crankcase ventilation system restrictions or malfunction.

• Worn valve guides and/or valve stems.

• Worn or incorrectly installed valve stem oil seals.

• Broken, worn or incorrectly seated piston rings. Allow adequate time

for the rings to seat. Replace worn piston rings as necessar y.

• Piston and rings incorrectly installed or incorrectly fitted to the cylinder

bore.

• Excessive piston to bore clearance.

2 Perform a cylinder compression test. Refer to 2.7 Compression Check.

3 If the compression test indicates a worn valve train, inspect for the

following:

• Worn valve guides.

• Worn valve stems.

• Worn or burnt valves or valve seats.

• Worn, brittle, or incorrectly installed valve stem oil seals.

4 If the compression test indicates worn or damaged piston rings, inspect the

following:

• Broken or incorrectly seated piston rings.

• Excessive piston ring end gap.

• Excessive cylinder bor e wear or taper.

• Cylinder damage.

• Piston damage.

Engine Mechanical Page 6A3–37

Page 6A3–37

2.5 Oil Pressure

Oil Pressure Check

1 Ensure the engine is at operating temper ature. Driving

a cold vehicle for a minimum of 15 minutes should be

sufficient to bring the engine to operating temperature.

2 Remove the oil filter, refer to 3.3 Engine Oil and Filter.

3 Install adaptor Tool No. J 42907 to the oil filter

adaptor.

4 On a level surface check the engine oil level, topping

up as required. Refer to 3.3 Engine Oil a nd Filter.

5 Install an accurate oil pressure gauge that is capable

of reading 800 kPa or higher a nd a suitably rated

pressure hose to adaptor Tool No. J 42907.

6 Start the engine and check the oil pressure with the

engine running under a no lo ad condition.

Figure 6A3 – 29

7 Check the oil pressure is within the specifications.

NOTE

If the oil pressure check indicates the oil

pressure is not within specification, refer to

Diagnosis in this Section.

Engine Oil Pressure Specification

Engine Speed (RPM) Oil pressure Reading

1000 45 kPa (Minimum, Hot)

2000 125 kPa (Minimum, Hot)

4000 165 kPa (Minimum, Hot)

Figure 6A3 – 30

8 Switch off the engine and remove the oil pressure gauge and adaptor assembly.

9 Install the oil filter, refer to Oil Filter and Adapter.

10 Top up the engine oil level as required, refer Oil Level Check.

Diagnosis

Checks Action

Oil Pressure Below Specification 1 Inspect the engine for one or more of the following:

• Oil pump worn or dirty.

• Loose oil pump to cylinder block attaching bolts.

• Oil pump pick-up tube screen blocked or damaged.

• Loose oil pump pick-up tub e

• Missing or damaged oil pump pick-up tube O-ring seal.

• Malfunctioning oil pump oi l pressure relief valve.

• Excessive bearing cl earances.

• Cracked, porous or restricted oil galleries.

• Oil gallery plugs leaking, missi ng or incorrectly installed.

• Broken or malfunctioning hydraulic v alve l ifters.

• Worn or damaged hydraulic valve lifters.

Oil Pressure Above Specification 1 Inspect for one or more of the following:

• Blocked or incorrect oil filter fitted.

• Malfunctioning oil by-pass valve.

• Malfunctioning oil pressure gauge or sensor creating a higher reading

than the actual reading.

• Incorrect oil viscosity.

Engine Mechanical Page 6A3–38

Page 6A3–38

2.6 Oil Leaks

NOTE

Most fluid leaks can be repaired by visually

locating the leak, repairing or replacing the

component, tightening fasteners to the correct

torque specification or by resealing the gasket

surface.

Step Action Yes No

1 1 Operate the vehicle until it reaches normal operating tempe rature.

2 Park the vehicle on a level surface, over a large sheet of paper or

other clean surface.

3 Wait for at least 15 minutes.

4 Check for oil drips.

Are oil drips present? Go to Step 2 Go to Step 3

2 1 Identify the type of fluid and the approximate location of the leak.

Can you identify the type of fluid and the approximate l ocation of the leak? Go to Step 8 Go to Step 3

3 1 Visually, inspect the suspected area. Use a small mirror to assist in

looking at hard to see areas.

2 Check for leaks at the following locatio ns:

• Sealing surfaces

• Fittings

• Cracked or damaged components

Can you identify the source of the leak? Go to Step 8 Go to Step 4

4 1 Thoroughly clean the entire engine a nd surrounding components.

2 Operate the vehicle for several kilometres at normal operating

temperature and at varying speeds.

3 Park the vehicle on a level surface, over a large sheet of paper or

another clean surface.

4 Wait for at least 15 minutes.

5 Identify the type of fluid, and the approximate location of the leak.

6 Using a small mirror to assist in looking at hard to see areas, visually

inspect the suspected area.

Can you identify the type of fluid, the source of the leak and the

approximate location ? Go to Step 8 Go to Step 5

5 1 Completely clean the entire engine and surrounding components.

2 Apply an aerosol-type powder (baby powder, foot powder, etc.) to the

suspected area.

3 Operate the vehicle for several kilometres at normal operating

temperature and at varying speeds.

4 Cracked or damaged components.

5 Identify the type of fluid, and the approximate location of the leak,

from the powder surface discolouration.

6 Using a small mirror to assist in looking at hard to see areas, visually

inspect the suspected area.

Can you identify the type of fluid, the source of the leak and the

approximate location ? Go to Step 8 Go to Step 6

Engine Mechanical Page 6A3–39

Page 6A3–39

Step Action Yes No

6 1 Using the Dye and Black Light Kit, Tool J 42220 to assist in identifying

the type of fluid and the approximate location of the leak. Refer to the

manufacturer's instructions when using the tool.

2 Using a small mirror to assist in looking at hard to see areas, visually

inspect the suspected area.

Can you identify the type of fluid, the source of the leak and the

approximate location ? Go to Step 8 Go to Step 7

7 1 Check for the following conditions:

• Higher than recommended fluid levels

• Higher than recommended fluid pr essures

• Blocked or malfunctioning fluid filters or pressure bypass valve

• Blocked or malfunctioning engine ventilation system

• Incorrectly tightened, missing or damaged fasteners

• Cracked or porous componen ts

• Incorrect sealants or gaskets where required

• Improper sealant or gasket installation

• Damaged or worn gaskets or seals

• Damaged or worn sealing sur faces

2 Can you identify the type of fluid, the source of the leak and the

approximate location ?

Repair or

replace all

damaged

components. Go to Step 8

8 1 Check the engine for mechanical damage.

Is there any mechanical damage to the engine?

Repair or

replace all

damaged

components. System OK

Engine Mechanical Page 6A3–40

Page 6A3–40

2.7 Compression Check

1 Before conducting this check inspect the following:

• The battery is at or near a full state of charge

• The throttle plate is held wide open

2 Remove the spark plugs, refer to Section 6C3-3 Powertrain Mana gement – GEN III V8 – Service Operations.

3 With the ignition switched off, disable the ignition

system and fuel injectors, by removing the Engine

Control relay R4 (1), located in the engine

compartment fuse and relay panel assembly.

4 Install an accurate compression tester that has been

reset to zero.

5 Crank the engine through app r oximately four

compression strokes and record the reading. Repeat

for each cylinder, recording the read ing.

6 If a cylinder has low compression, inject abo ut 15 ml

(one tablespoon) of engine o il into the combustion

chamber through the spark plug hole. Cra nk the

engine over for appro x imately four turns to distribute

the oil.

7 Recheck the compression and record the reading.

8 Compare the compression readi ngs, refer to

Interpreting Compression Readings.

Figure 6A3 – 31

Interpreting Compression Readings

The minimum compression in any one cylinder shou ld not be less than 70% of the highest cylinder. For example, if the

highest pressure in any o ne cylinder were 1035 kPa, the lowest allowable pressure for any other cylinder would be 725

kPa. (1,035 x 70% = 725).

NOTE

No cylinder should have a reading less than

690 kPa.

Condition Symptom

Normal Compression builds up q uickl y and evenly to the specified compression for each cylinder.

Worn Piston

Rings (Leaking) Compression is low on the first stroke. Compression then builds up with the following strokes but

does not reach normal. Compression improves considerably when you add oil.

Valves Leaking Compression is low on the first stroke. Compression usuall y does not build up on the following

strokes. Compression does not improve much when you add oil.

Cylinder Head

Gasket Leaking If two adjacent cylinders have lower than normal compression and injecting oil into the cylinders

does not increase the compression.

Engine Mechanical Page 6A3–41

Page 6A3–41

3 Minor Service Operations

ATTENTION

All engine fasteners are important attaching parts as they affect th e performance of vital componen ts and/or

could result in majo r repair expense. Where specified in this Section, fasteners MUST be rep laced with parts

of the same part number or an approved equivalent. Do not use fasteners of an inferior quality or substitute

design.

Torque values must be used as specified during reassembly to ensure correct retention of all components.

Throughout this Section, fastener torque wrench specifications may be accompanied with the following

identification marks:

 Fasten ers must be replaced after loosening .

 Fasteners either have micro encapsulated sealant applied or incorporate a mechanical thread lock and

should only be re-used once. If in doubt, replacement is recommended.

If one of these identification marks is present alongside a fastener torque wrench specification, the

recommendation regarding that fastener must be adhered to.

3.1 Air Intake Duct

LT Section No. — 03–250

Remove

1 Remove the fresh air hose (1) from the air intake duct

(2) and lay it to the side of the engine.

2 Remove the air intake sensor wiring harness

connector (3)

3 Loosen the hose clamps attachin g the intake duct to

the air box and the throttle body and remove the duct

from the engine.

Figure 6A3 – 32

Reinstall

Reinstallation of the air intak e duct is the re verse of the removal procedure ensuring all hose clamps are tightened to the

correct torque specification.

Air intake duct clamp

torque specification.....................................1.5 – 2.5 Nm

Engine Mechanical Page 6A3–42

Page 6A3–42

3.2 Engine Dress Cover

LT Section No. — 00–508

Remove

1 If required, remove the strut tower brace (1), refer to

Section 1A1 Body.

2 Disengage the engine dress cover retaining clips (2)

by pulling upward.

3 Rotate the cover to unlock it from the fuel rail (3) and

remove the cover.

Figure 6A3 – 33

Reinstall

Reinstallation of the engine dress covers is the reverse of the removal procedure ens uring the retaining clips are fully

engaged.

Engine Mechanical Page 6A3–43

Page 6A3–43

3.3 Engine Oil and Filter

LT Section No. — 01–500

Oil Level Check

1 The engine must be at normal operating temperature. This can be achieved by driving the vehicle for minimum of

15 minutes.

2 Park the vehicle on a level surface.

NOTE

Allow sufficient time for the oil to drain back t o the

oil pan after the engine is switched off. A sloping

surface will also affect the accuracy of the

measurement.

3 Remove the oil level indicator and wipe clean.

4 Reinstall the indicator and ensure that it is fully seated. Leave for several seconds and remove slowly to avoid

smearing the oil (level).

5 Hold the indicator horizontally to prevent the oil (level) moving along the indicator.

6 Observe the oil level where it passes over the centre

line of the indicator.

NOTE

As an easy guide for how much oil to add, the

crosshatch area (A) represents 1 litre of oil and

the ADD mark represents 1.6 litres of oil is

required.

7 If the oil level is lower than, or close to the ADD mark,

top-up the engine with enough oil to reach the FULL

mark.

NOTE

Do not fill beyond the FULL mark. If overfilling

occurs drain the excess oil from the engine.

8 Allow several minutes for the added oil to drain down

into the oil pan then recheck the oil level.

Figure 6A3 – 34

Oil Change

While the oil pan is aluminium, it is fitted with a steel thread insert for the drain plug. This is to increase the durability of

the thread and to avoid thread tearing when the drain plug is removed from a hot engine. It is recommended the oil filter

be changed at each engine oil change, refer to Oil Filter and Adapter. A quicker and a more complete draining will occur

if the engine oil is at operating temperature. However, care must be taken to avoid scalding from the hot oil.

Use care when draining the engine oil or

removing the oil filter when the engine oil is

hot. Wear safety glasses and the appropriate

gloves for protection from the hot oil or filter.

Engine Mechanical Page 6A3–44

Page 6A3–44

1 Raise the engine hood and remove the oil fill cap.

NOTE

Ensure the vehicle is level with the floor surface.

This is to ensure complete draining. Refer to

Section 0A General Information.

2 Raise the front and rear of the vehicle and support the vehicl e using safety stands or use a hoist. For hoist pad,

lifting and safety stand locations, refer to Section 0A General Information.

3 Clean any foreign materi al from around the oil pan drain plug (1), refer to Figure 6A3 – 3 5 View A for all vehicles

excluding AWD and View B for AWD vehicles.

4 Place a suitable oil drain tra y beneath the engine.

5 Using a 15 mm ring spanner, remove the drain plug taking care to avoid scalding with the hot waste oil.

6 Inspect and clean the threads and the magnetic end of the drain plug of ferrous material.

NOTE

The drain plug O-ring seal may be re-used if not

cut or damaged, however it is recommended the

seal be replaced when removed.

7 When the oil has drained c ompletely, reinstall the drain plug and tighten the drain plug to the correct torque

specification.

Engine oil pan drain plug

torque specification............................................25.0 Nm

Figure 6A3 – 35

8 Lower the vehicle and fill the crankcase with the correct quantity of the recommended engine oil.

Engine oil viscosity and quantity specifications:

Viscosity..............GF3 5W – 30 SJ or GF3 10W – 30 SJ

Capacity without oil filter change:

Except AWD.......................................................5.7 litres

AWD ..................................................................7.6 litres

Capacity with oil filter change:

Except AWD.......................................................6.2 litres

AWD ..................................................................8.0 litres

9 Start the engine and allo w to run for three to five minutes checking for oil leaks, stop the e ngine, rectify any leaks

and then recheck the oil level topping up as required, refer to Oil Level Check.

Engine Mechanical Page 6A3–45

Page 6A3–45

Oil Filter and Adapter

NOTE

The oil filter should be replaced at the time or

distance intervals specified in the Owner’s

Handbook or whenever the engine oil is changed.

Remove

1 If required, drain the engine oil, refer to Oil Change .

2 Remove the oil filter (1), taking care to avoid being scalded with the hot waste oil, refer to Figure 6A3 – 36 View A

for all vehicles excluding AWD and View B for AWD vehicles.

NOTE

Ensure the vehicle is level with the floor surface.

This is to ensure complete draining. Refer to

Section 0A General Information.

3 If required, remove the oil filter adaptor (2) from the oil filter mounting boss.

Figure 6A3 – 36

Reinstall

1 After checking the oil filter seal has not adhered to the oil filter mounting boss, inspect the oil filter sealing surface

for scratches or other damage and check the oil filter adapto r threads for damage.

2 If removed, reinstall the oil filter adaptor and tighten to the correct torque specification. Refer to Figure 6A3 – 36.

Oil filter adapter

torque specification............................................55.0 Nm

3 Apply a coating of clean engine oil to the new oil filter seal and install the oil filter to the engine.

4 Tighten the oil filter to the correct torque spec ification.

Engine oil filter torque specification....................30.0 Nm

5 Reinstall the drain plug and tighten to the correct torque specification.

Engine oil pan drain plug

torque specification............................................25.0 Nm

6 Lower the vehicle and fill the crankcase with the correct quantity of the recommended engine oil,

refer to Oil Change.

7 Start the engine and allo w to run for three to five minutes checking for oil leaks. Stop the e ngine, rectify any leaks

and then recheck the oil level topping up as required, refer to Oil Level Check.

Engine Mechanical Page 6A3–46

Page 6A3–46

3.4 Oil Pressure Sensor

LT Section No. — 02–000

Remove

1 Release the wiring harness c onnector (1) locking tang

from the oil pressure sensor (2) and remove the

connector from the sensor.

Figure 6A3 – 37

2 Using the oil pressure sensor socket, T ool No. J41712

and suitable 3/8” drive sock et equipment, remove the

oil pressure sensor (1) from the left-hand rear of the

cylinder block.

Figure 6A3 – 38

Reinstall

1 Clean the threads of the oil pressure sensor.

2 Apply Loctite 565 sealant or equiv ale nt to the cleaned oil pressure sensor threads.

3 Reinstall the oil pressure sensor and tighten to the correct torque specification using oil pressure sensor socket

Tool No. J 41712 and suitable 3/8” drive socket equipment.

 Oil pressure sensor

torque specification............................................20.0 Nm

4 Start the engine and check for correct operat ion and leaks.

Engine Mechanical Page 6A3–47

Page 6A3–47

3.5 Oil Level Indicator and Tube

LT Section No. — 00–580

Remove

1 Remove the oil level indicator from the oil level

indicator tube.

2 Remove the oil level indicator tube bracket attaching

bolt (1) from the right hand exhaust manifold.

3 Remove the oil level indicator tube from the engine.

4 Remove the O-ring from the tube and discard .

NOTE

If the oil level indicator tube is not to be

reinstalled immediately, plug the opening to

prevent dirt entry.

Figure 6A3 – 39

Reinstall

1 Clean the oil level indicator tube an d install a new O-ring to the lower end of the tube.

2 Reinstall the oil level indicator tube to the engine and rotate it to the correct position.

3 Reinstall the oil level indicator tube bracket attaching bolt and tighten to the correct torque specification.

Oil level indicator tube attaching bolt

torque specification............................................25.0 Nm

4 Reinstall the oil level indicator to the tube.

Engine Mechanical Page 6A3–48

Page 6A3–48

3.6 Engine Drive Belts and Pulleys

LT Section No. — 01–003

Accessory Drive Belt

Remove

1 Rotate the engine accessory dr ive belt tensioner

pulley attaching bolt (1) in the direction indicated to

reduce belt tension.

2 While holding the tensi on er in the reduced tension

position, remove the accessory drive be lt (2) from the

pulleys, taking note of the belt routing.

3 Clean the accessory drive b elt running surfaces and

inspect the belt for damage, replac e as required.

Figure 6A3 – 40

Reinstall

1 Route the belt around the pull eys except the water pump pulley, ensuring that it is seated correctly in the pulle y

grooves.

2 Rotate the tensioner and then slide th e belt over the water pump pulley and ensure the belt is positioned in the

grooves of the pulleys correctly.

3 Start the engine and check for correct operat ion.

Accessory Drive Belt Idler Pulley

Remove

1 Remove the engine accessory drive belt. Refer to Accessory Drive Belt.

2 Remove the idler pulley attach ing bolt (1) and remove

the pulley (2) from its mounting boss on the gen erator

mounting bracket (3).

Figure 6A3 – 41

Techline

Engine Mechanical Page 6A3–49

Page 6A3–49

Reinstall

1 Install the idler pulley to the mounting boss.

2 Install the idler pulley attach ing bolt and tighten to the correct torque specification.

Accessory belt idler pulley attaching bolt

torque specification............................................50.0 Nm

3 Install the engine accessory dr ive belt. Refer to Accessory Drive Belt.

Accessory Drive Belt Tensioner

Remove

1 Remove the engine accessory drive belt. Refer to Accessory Drive Belt.

2 Remove the two bolts (1) attaching the tensioner

assembly (2) to the engine and remove the tensioner

assembly.

Figure 6A3 – 42

Reinstall

1 Install the tensioner assembly and tighten the two attaching bolts to the correct torque specification.

Accessory belt tensioner attaching bolt

torque specification............................................50.0 Nm

2 If required, reinstall the accessory drive b elt i dler p ulley, refer to Accessory Drive Belt Idler Pulley.

3 Reinstall the engine acc essory drive belt, refer to Accessory Drive Belt.

Engine Mechanical Page 6A3–50

Page 6A3–50

Air Conditioner Drive Belt

Remove

1 Raise the vehicle and suppor t with safety stands. Refer to Section 0A General Information.

2 Remove the accessory drive belt to allow access to air conditioner belt. Refer to Accessory Drive Belt.

3 From under the vehicle, rotate the air conditioner drive

belt tensioner pulley (1) in the directi on of the arrow to

relieve the belt tension.

4 While maintaining the tensioner in the required

position remove the drive belt from the pulleys.

5 Clean the air conditioner drive belt run ni ng surfaces

and inspect the belt for damage, replacing as required.

Figure 6A3 – 43

Reinstall

1 While holding the air conditioner drive belt tensioner in the direction indicated, refer to Figure 6A3 – 43, install the

drive belt over the pulleys routing the belt correctly.

2 Reinstall the accessory drive belt, refer to Accessor y Drive Belt.

3 Inspect the installation to ensure the belt is co rrectly aligned on all pul leys.

4 Start the engine to ensure correct operation.

Air Conditioner Drive Belt Idler Pulley

Remove

1 Remove the air conditioner dri v e belt, refer to Air Conditioner Drive Belt.

2 Remove the bolt (1) attaching the air conditioner drive

belt idler pulley (2) to the mounting boss on the

coolant pump housing and remove the pulley.

Figure 6A3 – 44

Engine Mechanical Page 6A3–51

Page 6A3–51

Reinstall

1 Install the idler pulley (2) to the mounti ng boss. Install the attaching bolt and tighten to the correct torque

specification, refer to Figure 6A3 – 44.

Air conditioner belt idler pulle y attaching bolt

torque specification............................................50.0 Nm

2 Install the air conditioner drive belt, refer to Air Con ditioner Drive Belt.

Air Conditioner Drive Belt Tensioner

Remove

1 Remove the air conditioner drive belt, refer to Air Conditioner Drive Belt.

2 If required, remove the air conditioner tensioner pul ley

attaching bolt (1) and remove the pulley.

3 Remove the bolt (2) attaching the air conditioner drive

belt tensioner to the bracket and then remove the

assembly.

Figure 6A3 – 45

Reinstall

1 Install the tensioner assembly and the attaching bolt (2). Tighten the bolt to the correct torque specification.

Air conditioner belt tensioner attaching bolt

torque specification............................................25.0 Nm

2 If required, reinstall the air conditioner tensi oner pulley and attaching bolt. Tighten the bolt to the correct torque

specification.

Air conditioner tensioner pulley attaching bolt

torque specification............................................50.0 Nm

3 Install the air conditioner drive belt, refer to Air Con ditioner Drive Belt.

Engine Mechanical Page 6A3–52

Page 6A3–52

3.7 Intake Manifold Assembly

LT Section No. — 00–375

NOTE

Unless components such as the throttle body,

fuel injector rail and/or fuel injectors are to be

removed individually, it is recommended the

complete intake manifold be removed from the

engine as an assembly.

Remove

1 Depressurise the fuel system, refer to Section 8A1 Fuel System.

Disconnection of the battery affects certain

vehicle electronic systems. Refer to

Section 00 Warnings, Cautions and Notes

before disconnecting the battery.

2 Disconnect the ground battery cable from the battery.

3 Drain the cooling system, refer to Section 6B3 Engine Cooling – GEN III V8.

4 If required, remove the strut tower brace, refer to Section 1A1 Body.

5 Remove the engine dress covers, refer to 3.2 Engine Dress Cover.

6 Using a small scre wdriver, release the s ecurity lock

(1), at each of the fuel supply hose quick connect

fittings (2).

NOTE

The security lock at the fuel r ail end is fitted with

a tether to prevent loss.

Figure 6A3 – 46

7 Remove the fuel line quick connector (1) from the fuel

rail, refer to Section 6C3-3 Powertrain Management –

GEN III V8 – Service Operations.

8 Disconnect the vapour line connector (2) from the

EVAP purge valve.

NOTE

Cap the fuel line fittings and plug the holes after

separating the fuel lines to prevent fuel leaking

and/or dirt and other foreig n matter from entering

the fuel system.

Figure 6A3 – 47

Engine Mechanical Page 6A3–53

Page 6A3–53

9 Disconnect the electronic throttle body wiring harness

connector (1) from the throttle body.

Figure 6A3 – 48

10 Disconnect the fuel injector wiring harness c onnectors

(1), four places from the right-hand bank of fuel

injectors.

11 Remove the CPA lock (2) from the ignition coil mai n

connector (3) on the right-hand side. Remove the

connector then the harness attaching clips fr om the

fuel rail brackets (4) and set the harness to one sid e.

Figure 6A3 – 49

Engine Mechanical Page 6A3–54

Page 6A3–54

12 Disconnect the fuel injector wiring harness c onnector

(1), four places from the left-hand bank of fuel injectors

by removing the wire attaching clip at the base of the

connector.

13 Remove the CPA lock (2) from the ignition coil mai n

connector (3) on the left-hand side and then remove

the connector.

14 Remove the wiring harness connector from the

canister purge valve (4).

15 Remove the harness attaching clips from the fuel rail

brackets (5) and set the harness to one side.

Figure 6A3 – 50

16 Disconnect the manifold absolute pressure (MAP)

sensor wiring harness connector (1).

17 Disconnect the oil pressure sensor wiring harness

connector (2).

18 Disconnect the knock sensor patch harness connector

(3).

Figure 6A3 – 51

Engine Mechanical Page 6A3–55

Page 6A3–55

19 Remove the fresh air hose (1) from the front fitting of

the rocker cover and the air intake duct.

Figure 6A3 – 52

20 Remove the foul air hose (1) from the throttle body

and the valley cover outlet.

Figure 6A3 – 53

21 Disconnect the engine coolant vapour vent outlet to

radiator hose (1) from the base of the throttle body.

Figure 6A3 – 54

Engine Mechanical Page 6A3–56

Page 6A3–56

22 Disconnect the engine coolant vapour vent outlet to

throttle body hose (1) from the base of the throttle

body.

23 Remove the evaporative (EVAP) canister purge valve

tube (2) from the purge valve (3) and the throttle body.

Figure 6A3 – 55

24 Remove the EVAP canister purge valve and bracket

(1) from the intake manifold.

Figure 6A3 – 56

26 Progressively loosen the intake manifold atta ching bolt

(1), 10 places, while working dia gonally from outside

to inside.

26 Remove the fuel rail stop bracket (2) with the two left

rear bolts and set to one side.

Figure 6A3 – 57

Engine Mechanical Page 6A3–57

Page 6A3–57

27 Carefully, tap the intake manifold assembly (1) with a

rubber mallet to break the gasket seal and lift the

manifold from the engine.

NOTE

Ensure all the attachin g bolts (2) and the fuel rail

stop bracket (3) are removed from the intake

manifold completely.

Figure 6A3 – 58

28 Remove the intake manifold to cylinder head gaskets

(1) and discard. Do not re-use these gaskets.

NOTE

To prevent foreign matter from entering the

cylinder head ports, seal off the ports with

masking tape or a clean lint free shop rag.

Figure 6A3 – 59

Engine Mechanical Page 6A3–58

Page 6A3–58

Disassemble

Throttle Body

1 Remove the MAP sensor, refer to Section 6C3-3 Powertrain Management – GEN III V8 – Service Operations.

2 Remove the throttle body attaching bolt (1), three

places and remove the throttle bod y.

Figure 6A3 – 60

3 Remove the seal (1) and discard. Do not re-use this

seal.

Figure 6A3 – 61

Engine Mechanical Page 6A3–59

Page 6A3–59

Fuel Rail Assembly

1 Remove the stud (1), four places, attaching the fuel

rail (2) and injectors to the intake manifold. Then

carefully remove the fuel rail and injectors as an

assembly.

NOTE

Should further disassembly of the fuel injectors

be required, refer to Section 6C3-3 Powertrain

Management – GEN III V8 – Service Operations.

Figure 6A3 – 62

Clean and Inspect

To avoid personal injury, wear safety glasses

and the appropriate gloves when using

compressed air and cleaning fluids.

1 Clean the intake manifold in a commercially available cleaning fluid and blow dry using compressed air.

2 Ensure the intake manifold gasket grooves a nd vacuum passages in the rear of the intake manifold are all clean

and clear.

3 Inspect the throttle body and fuel rail bolt inserts in the intake manifold for looseness and/or damaged threads.

4 Inspect the intake manifold for cracks or damage includi ng the areas between the intake runners.

5 Inspect the fuel injector bores for excessive scoring or damage.

6 Inspect the intake manifold to cylinder head f aces for warpage as follows:

a Place a straight edge across each of the two surfaces and check for warpage using feeler gauges.

b An intake manifold with warpage in excess of 0.5 mm must be replaced.

Engine Mechanical Page 6A3–60

Page 6A3–60

Reassemble

If removed, reinstall the MAP sensor, refer to Section 6C3-3 Powertrain Management – GEN III V8 – Service Operations.

Fuel Rail Assembly

1 Lubricate the new injector O-ring seals with clean

engine oil.

2 Install the new O-rings to the fuel injectors.

3 Install the fuel rail with the injectors attached (2) into

the intake manifold, pressing evenly on each side until

the injectors are all fully seated in their b ores.

4 Apply a 5 mm bead of thread sealant such as Loctite

242 (or other commercial equivalent) to the cleaned

threads of the fuel rail attaching studs (1) and install

the studs tightening to the correct torque spec ification.

Fuel rail attaching studs

torque specification...................................8.0 – 12.0 Nm

Figure 6A3 – 63

Throttle Body

1 Install a new throttle body seal (1) to the intake

manifold ensuring it is pressed firmly into the groove in

the manifold.

Figure 6A3 – 64

2 Install the throttle body (1) an d attachin g bolt (2), three

places, to the intake manifold and tighten the bolts to

the correct torque specification.

Throttle body attaching bolt

torque specification............................................12.0 Nm

Figure 6A3 – 65

Engine Mechanical Page 6A3–61

Page 6A3–61

Reinstall

Reinstallation of the intake m anifold assembly is the reverse of the removal procedure, noting the following:

1 Remove the masking tape or shop rags sealing the cylinder head ports.

2 Install new intake manifold to cylinder head g askets, refer to Figure 6A3 – 59.

3 Install the intake manifold assembl y (1) by c areful ly

positioning the manifold onto the cylinder head.

4 Apply a 5 mm bead of thread sealant such as

Loctite 242 or equivalent to the clea ned threads of the

intake manifold attaching bolt (2), 10 places.

Do not overlook installing the fuel stop

bracket (3). The stop bracket serves as a

protective shield for the fuel rail in the event

of a vehicle frontal collision. If the fuel stop

bracket is not installed and the vehicle is

involved in a collision, the pressurised fuel

may leak possibly causing a fire and

personal injury from burns.

5 Install all intake manifold bolt, 10 places including the

two at the left hand rear, which also attach the fuel rail

stop bracket. NOTE

The fuel stop bracket is attached by bolts (3

and 9), refer to Figure 6A3 – 67. Figure 6A3 – 66

6 Tighten the intake manifold bolts in two stages in the

sequence shown to the corre ct torque specification.

Intake manifold attaching bolts

torque specification

Stage 1 ................................................................5.0 Nm

Stage 2 .....................................................8.0 – 12.0 Nm

Figure 6A3 – 67

7 Reconnect the electronic thrott le body wiring harness

connector (1).

8 Reconnect the engine coolant vapour vent hoses and

refill the coolant with the recommend ed coolant and to

the correct level,

refer to Section 6B3 Engine Cooling GEN III V8.

Figure 6A3 – 68

Engine Mechanical Page 6A3–62

Page 6A3–62

3.8 Vapour Vent Pipe and Covers

LT Section No. — 00–249

Remove

1 Remove the intake manifold, refer to 3.7 Intake Manifold.

2 If required, remove the attaching bolt (1) from the rear

engine coolant vapour ble ed vent cover (2).

3 Remove the cover and gasket (3) and discard the

gasket. If required, repeat for the other vapour vent

cover.

4 Remove the vapour vent pipe stud (4), t wo places,

attaching the vapour vent pip e (5) togeth er with both

gaskets (6) to the cylinder block. Discard the gaskets.

Figure 6A3 – 69

5 If required, remove the clamp retaining the engine

coolant to vent pipe and remove the hose (1) from the

vent pipe (2).

Figure 6A3 – 70

Engine Mechanical Page 6A3–63

Page 6A3–63

Reinstall

1 Correctly install a ne w vapour pipe gasket by fitting the

O-ring seal section (1) over the pipe fitting ni pple (2).

Figure 6A3 – 71

2 Install the vapour vent pipe (1), vapour vent cover (2)

and gasket (3) to the cylinder heads.

3 Install the vapour vent pipe attaching bolts/studs (5

and 6) and tighten to the correct torque specification.

Vapour vent pipe bolt/stud

torque specification............................................12.0 Nm

4 Reinstall the intake manifold,

refer to 3.7 Intake Manifold.

Figure 6A3 – 72

Engine Mechanical Page 6A3–64

Page 6A3–64

3.9 Engine Valley Cover

LT Section No. — XX–XXX

Remove

1 Remove the vapour vent pipe, refer to 3.8 Vapour Vent Pipe.

2 Carefully lift the knock sensor sealing plug (1), two

places, from the valley cover (2), and release the

knock sensor harness connector locking tabs (3), two

places.

3 Remove the knock sensor wiring harness from the

engine.

Figure 6A3 – 73

Unless a tube socket is used, damage to the

sensor connector will result.

4 Remove the two knock sensors (1) using a 22 mm

tube socket.

Figure 6A3 – 74

Engine Mechanical Page 6A3–65

Page 6A3–65

5 Remove the valley cover attaching bolt (1), 10 places

and remove the valley cover and gasket from the

cylinder block.

Figure 6A3 – 75

Disassemble

1 With the valley cover (1) removed from the engine,

remove the bolt (2), 10 places, attaching the PCV oil

separator (3) to the engine valley c over.

2 Remove the PCV oil separator from the engine valley

cover.

Figure 6A3 – 76

Engine Mechanical Page 6A3–66

Page 6A3–66

3 Remove the two knock sensor oil sea ls (1) from the

valley cover (2).

Figure 6A3 – 77

Clean and Inspect

To avoid personal injury, wear safety glasses

and the appropriate gloves when using

compressed air and cleaning fluid.

1 Clean the valley cover and PCV oil separator in a commercially av ailable cleaning fluid and bl ow dry using

compressed air.

2 Inspect the valley cover sealing surfaces and oil seal bores for excessive scratches or other damage.

3 Ensure the fixed internal flow restricting orifice (1) is

not blocked.

4 Ensure the engine valley cover (2) to PCV oil

separator (3) mating surfaces are free of burrs and

traces of old sealant.

5 Inspect the PCV oil separator for cracks or defects.

Figure 6A3 – 78

Reassemble

1 Apply Loctite 565 sealant or equivalent to the engine valley cover to PCV oil separator mating surfaces.

2 Reinstall the PCV oil separator to the engine valley cover.

3 Reinstall the 10 bolts attaching the PCV oil separator to the engine valley cover and tighten to the correct torque

specification.

PCV oil separator attaching bolt

torque specification...................................6.0 – 10.0 Nm

4 Install new knock sensor oil seals into the valley cover and lightly lubricate the seals with clean engine oil.

5 Install a new gasket to the valley cover and reinsta ll the valley cover to the engine.

Reinstall

1 Reinstall and tighten the 10 valley cover attaching bolts to the correct torque specification.

Valley cover attaching bolt

torque specification............................................25.0 Nm

2 Reinstall the knock sensors and tighten to the correct torque specification.

Knock sensor

torque specification............................................20.0 Nm

3 Reinstall the vapour vent pi pe, refer to 3.8 Vapour Vent Pipe.

Engine Mechanical Page 6A3–67

Page 6A3–67

3.10 Camshaft Lobe Lift

Measuring the camshaft lobe lift is a procedure used to d etermine if the camshaft lobes are worn without removing the

camshaft from the engine. This test is to be performed prior to engine disassembly and with the camshaft, push rods and

valve lifters installed in the engine.

Measure

1 Remove the following:

• The valve rocker arm cover, refer to 3.11 Valve Rocker Arm Cover.

• The valve rocker arms and bolts, refer to 3.12 Valve Rocker Arms and Push Rods.

2 Install an M8 x 1.25 dial indicator mounting stud into the

valve rocker arm bolt hole.

3 Assemble the components of Dial Gauge, Tool No.

J 8520 or an equivalent and position it onto the installe d

stud.

4 Position the shaft of the dial indicator onto the end of

the pushrod.

5 Zero the dial indicator dial.

6 Slowly, rotate the crankshaft clockwise until the dial

indicator obtains its lowest reading and re-zero the dial

indicator gauge.

7 Rotate the crankshaft clockwise until the dial indicator

obtains its highest reading an d record the reading.

8 If required, repeat for all camshaft lobes and ensure the

readings are to the specification.

Camshaft lobe lift specification:

Intake lobe:

Except Coupe ...................................................7.43 mm

Coupe............................................................... 6.96 mm

Exhaust lobe:

Except Coupe ...................................................7.43 mm

Coupe............................................................... 7.13 mm

NOTE

If any of the camshaft lobe readings are not to

the specified limits that particular camshaft lobe

is worn. The camshaft will require replacement.

Refer to 4.11 Camshaft for wear limits. Figure 6A3 – 79

Engine Mechanical Page 6A3–68

Page 6A3–68

3.11 Valve Rocker Arm Cover

LT Section No. — 00–025

Remove

1 Depressurise the fuel system, refer to Section 8A1 Fuel System.

Disconnection of the battery affects certain

vehicle electronic systems. Refer to

Section 00 Warnings, Cautions and Notes

before disconnecting the battery.

2 Disconnect the ground battery cable termi nal from the battery.

3 Remove the strut tower brace, refer to Section 1A1 Body.

4 Remove the engine dress cover, refer to 3.2 Engine Dress Cover.

5 For the right-hand rocker cover, remove the fresh air

hose (1) from the front fitting of the rocker cover and

the air intake duct.

Figure 6A3 – 80

6 Remove the fuel line quick connector (1) from the fuel

rail, refer to Section 6C3-3 Powertrain Management –

GEN III V8 – Service Operations.

7 Disconnect the vapour line connector (2) from the

EVAP purge valve.

NOTE

Cap the fuel line fittings and plug the fuel lines

after separating the fuel lines to prevent fuel

leaking and/or dirt and other foreign matter from

entering the fuel system.

Figure 6A3 – 81

Engine Mechanical Page 6A3–69

Page 6A3–69

Handle the spark plug boot only. Do not pull

on the lead. To remove the lead, twist the

boot first to break the seal and then gently

pull on the boot.

8 Remove the spark plug leads for the entire ba nk for

the cover being removed.

Figure 6A3 – 82

9 Remove the CPA lock (1) from the ignition coil main

connector on the rocker cove r being removed then

remove the wiring harness connector (2).

10 Remove the four bolts and one screw (3) attaching the

ignition coil mounting brack et (4) to the rocke r cover

being removed, then lift the ignition coils, wiring and

bracket from the engine.

NOTE

The rear attaching bolt on each coil mounting

bracket assembly is a conventional screw and

not a stepped stud. Fitment of this screw in the

correct position on reassembly is important to

avoid possible chaffing.

Figure 6A3 – 83

11 Remove the bolt (1), four places, attaching the valve

rocker arm cover (2) to the cylinder head and remove

the cover and gasket.

Figure 6A3 – 84

Engine Mechanical Page 6A3–70

Page 6A3–70

NOTE

Do not remove the oil fill tube from the ri ght h and

valve rocker cover unless replacement is

required as this component will be damaged in

the removal process.

12 If required, remove the oil fill cap (1) and/or fil l tube (2)

from the right-hand valve rocker arm cover (3).

Discard the oil fill tube as this will be perm an ently

damaged when removed.

Figure 6A3 – 85

13 Remove the gasket (1) from the valve rocker cover

and discard.

NOTE

The valve rocker cover attaching bolt grommets

may be re-used if not damaged.

Figure 6A3 – 86

14 If required, remove the eight bolts (1) attaching the

ignition coils to the mounting bracket and remove the

coils and wiring harness.

Figure 6A3 – 87

Engine Mechanical Page 6A3–71

Page 6A3–71

Clean and Inspect

To avoid personal injury, wear safety glasses

and the appropriate gloves when using

compressed air and cleaning fluid.

1 Clean the valve rocker arm cover using commercially available cleaning fluid and dr y off wit h compressed air.

2 Inspect the ventilation system passages for restriction.

3 Inspect the valve rocker cover gasket groove for damage.

4 Inspect the ignition coil mounting boss threads for damage.

Reinstall

Reinstallation of the valve roc k er arm cover is the reverse of the removal procedure, noting the following:

1 If the oil fill tube (1) was removed from the right-hand

rocker cover (2) it must be replaced with a new part.

2 Lubricate the O-ring seal of the new oil fill tube with

clean engine oil.

3 Install the oil fill tube into the rocker cover rot ating the

tube clockwise until locked into the correct position.

4 Install the oil fill cap (3) rotating clockwise until locked

into place.

Figure 6A3 – 88

5 Install a new gasket to the valve rocker arm cover (1).

6 Reinstall the valve rocker cover onto the cylinder head.

7 Install the rocker cover attaching bolt (2), four places

and tighten to the correct torque specification.

Valve rocker cover attaching bolt

torque specification............................................12.0 Nm

Figure 6A3 – 89

Engine Mechanical Page 6A3–72

Page 6A3–72

8 Reinstall the ignition coils and coil wiring harness to

the mounting bracket and tighten the attaching bolts

(1) to the correct torque specification.

Ignition coil attaching screw

torque specification............................................12.0 Nm

NOTE

The rear attaching bolt on each coil mounting

bracket assembly is a conventional screw and

not a stepped stud. Fitment of this screw in the

correct position on reassembly is important to

avoid possible chaffing of the fuel and/or the

EVAP purge valve line.

9 Install the ignition coils and br acket assembly to the

rocker cover and tighten the studs and screw to the

correct torque specification.

Ignition coil bracket attaching stud/screw

torque specification............................................12.0 Nm

10 Install the ignition coil main harness connector then

install the CPA lock ensuring it is fitted securely.

Figure 6A3 – 90

Engine Mechanical Page 6A3–73

Page 6A3–73

3.12 Valve Rocker Arms and Push Rods

LT Section No. — 00–050

Remove

1 Remove the valve rocker arm cover, refer to 3.11 Valve Rocker Arm Cover.

NOTE

Store all removed valve train components in the

same order they were removed. This will ensure

that when they are reinstalled in the same

relationship as on removal.

2 Remove the rocker arm attaching bolt (1) on each

valve rocker arm (2) for the cylinder head being

serviced.

3 Remove the associated valve rocker arm.

Figure 6A3 – 91

4 Remove the valve rocker arm pivot support (1).

NOTE

Mark the rocker arm pivot support orientation in

relation to the cylinder head to ensure it is

reinstalled in the same orientat ion.

Figure 6A3 – 92

Engine Mechanical Page 6A3–74

Page 6A3–74

5 Remove the push rod (1), eight places, ensuring they

are kept in the order removed.

Figure 6A3 – 93

Clean and Inspect

To avoid personal injury, wear safety glasses

and the appropriate gloves when using

compressed air and cleaning fluid.

1 Clean the parts in a commercially available cleaning fluid and blo w dry with compresse d air.

2 Inspect the rocker arms, pivot support and p ushrods for excessive wear and replace as required.

Reinstall

Reinstallation of the valve roc ker arms is the reverse of the removal procedure, noting the following:

1 Remove the spark plugs to reduce the effort required to turn the engine over by hand,

refer to Section 6C3-3 Powertrain Management – GEN III V8 – Service Ope r ations.

2 Lubricate the follo wing parts in clea n engine oil before installation:

• All valve rocker arms and pushrods.

• The flanges of all rocker arm bolts.

3 Install all push rods ensuring that each push rod seats correctly in the hydraulic valve lifter sockets.

4 Install the rocker arm pivot support noting the orie ntatio n as marked in Step 4 of the removal procedure.

5 Install all the rocker arms, bearings and the attaching bolts but do not tighten fully at this time.

Engine Mechanical Page 6A3–75

Page 6A3–75

6 Using a socket and handle on the crankshaft pulley

attaching bolt, rotate the crankshaft until the No. 1

piston is at the Top Dead Centre (TDC) on the

compression stroke.

NOTE

The No.1 piston is at the compression stroke

when the No.6 cylinder inlet and exhaust valves

are rocking, that is when the exhaust valve is at

the end of its upward travel while the intake

valve starts its downward movement.

NOTE

The engine firing order is 1-8-7-2-6-5-4-3.

Cylinder numbers are 1-3-5-7 are on the left

bank and 2-4-6-8 are on the right bank.

Figure 6A3 – 94

7 With No. 1 piston at TDC on the compression stroke, tighte n the following rocker arm bolts to the correct torque

specification.

Rocker arm attaching bolt

torque specification.................................25.0 – 35.0 Nm

Exhaust valve cylinder No's........................ 1, 2, 7 and 8

Intake valve cylinder No's ........................... 1, 3, 4 and 5

8 Rotate the crankshaft 360° and tighten the following rocker arm bolts to the correct torque specification.

Rocker arm attaching bolt

torque specification.................................25.0 – 35.0 Nm

Exhaust valve, cylinder No's....................... 3, 4, 5 and 6

Intake valve, cylinder No's. ......................... 2, 6, 7 and 8

9 Reinstall the rocker cover, refer to 3.11 Valve Rocker Arm Cover.

10 Reinstall the engine dress c over, refer to 3.2 Engine Dress Cover.

Engine Mechanical Page 6A3–76

Page 6A3–76

3.13 Valve Stem Oil Seal and Valve Spring

LT Section No. — 00–075

Remove

NOTE

Valve train components when separated must be

marked or organised in a way to ensure they are

reinstalled to their original loc ation and position.

1 Remove the spark plugs from the cylinder/s being serviced, refer to

Section 6C3-3 Powertrain Management – GEN III V8 – Service Operations.

2 Refer to 3.12 Valve Rocker Arms and Push Rods and remove the following components from the cylinder head

being serviced:

• Valve rocker arms

• Valve rocker arm pivot suppor t

• Pushrods

3 Using a socket and handle on the crankshaft pulley

attaching bolt, rotate the crankshaft until the piston of

the cylinder being servic ed is at the Top Dead Centre

(TDC) on the compression stroke.

NOTE

This operation can be performed with the

cylinder at the bottom of its stroke, however with

the piston at TDC the valve will not fall into the

cylinder if the air supply is accidentally

disconnected during the op eration.

Figure 6A3 – 95

4 Install the Spark Plug Port Adaptor, T ool J 22794 or

equivalent into the spark plug hole of the cylinder

being serviced.

The engine may spin over when the air line is

connected. To avoid being caught by rotating

pulleys and belts, keep clear of the drive

belts and pulleys when connecting the air

line.

5 Using suitable adaptors, attach a compressed air line

to Tool No. J 22794 and appl y a constant supply of

compressed air to the cylinder being service d.

Figure 6A3 – 96

Engine Mechanical Page 6A3–77

Page 6A3–77

6 Compress one of the valve springs using a

commercially available valve spring compressor Tool

No. KD2078. A slight tap on the valve spring cap with

a soft faced hammer may be required to dislodge the

valve spring cap retaining collets.

NOTE

Do not disconnect the airline while the valve

spring is being compressed and/or the valve

spring cap retaining collets are removed.

Figure 6A3 – 97

7 Remove the valve spring cap retaining collets (1) two

places.

NOTE

Valve train components when separate d m ust be

marked or organised in a way to ensure they are

reinstalled to their original loc ation and position.

8 Remove in order, the following:

a Valve spring cap (2).

b Valve spring (3).

c If required, the oil seal and spring sh im

combination (4).

NOTE

Only one cylinder at a time can be done using

this method to remove the valve stem seals

and/or springs.

9 Repeat Steps 3 to 8 to replace the remaining valve

springs and/or valve stem seals in the other cylind ers. Figure 6A3 – 98

Engine Mechanical Page 6A3–78

Page 6A3–78

Reinstall

1 Reinstall a new valve stem oil seal and shim assembly to the valve guide by hand until the shim seats against the

cylinder head.

2 Reinstall the valve spring with the smaller wound coils

facing up then install the spring cap.

3 Compress the spring using spring compressor Tool

No. KD2078 until sufficient space is allo wed for the

valve spring cap retaining collets to be installed.

4 Reinstall both the valve spring retaining collets using

clean grease or petroleum jelly to retain.

5 Release the valve spring com pressor e nsuring that

both valve stem collets are seated correctly.

6 Lightly tap the valve stem with a soft faced hammer to

seat the valve stem collets.

7 Remove the compressed air supp ly.

8 Remove the spark plug adapt or Tool No. J 22794,

refer to Figure 6A3 – 96.

Figure 6A3 – 99

9 If replacing the valve spring or shim, measure the

installed height of the valve spring using a ruler or

vernier calipers. The measure m ent is to be taken from

the base of the valve spring to the top.

10 If the measurement exceeds the specified limit, a

commercially availabl e stainless steel shim must be

installed between the valve stem oil seal/shim

combination and the cylin der head to achieve the

required spring height.

Installed valve spring height.....................45.75 mm Max

NOTE

Do not shim the valve spring to obtain less than

the specified height.

11 Repeat Steps 1 to 10 to replace the remai ning valve

springs and/or valve stem seals in the other cylind ers.

12 Reinstall the spark plug a nd tighten to the correct

torque specification.

Spark plug torque specification:

Used cylinder head............................................15.0 Nm

New cylinder head .............................................20.0 Nm

13 Reinstallation of the remaining components is the

reverse of the removal procedure.

Figure 6A3 – 100

Engine Mechanical Page 6A3–79

Page 6A3–79

3.14 Exhaust Manifold

LT Section No. — 00–450

Remove

Disconnection of the battery affects certain

vehicle electronic systems. Refer to

Section 00 Warnings, Cautions and Notes

before disconnecting the battery.

1 Disconnect the ground battery cable termi nal from the battery.

2 If required, remove the strut tower brace, refer to Section 1A1 Body.

3 Remove the air intake duct, refer to 3.1 Air Intake Duct.

4 Remove the engine dress cover for the side the manifold is t o be removed, refer to 3.2 Engine Dress Cover.

5 Raise the front of the vehicle and place on safety stands. Refer to Section 0A General Information for the location

of jacking and support points.

6 For the left hand side exhaust manifold, remove the

engine coolant temperature sensor (1) from the

cylinder head to avoid possible damage during

exhaust manifold removal.

7 For the right-hand side exhaust manifold, re move the

engine oil level indicator and tube, refer to

3.5 Oil Level Indicator and Tube.

NOTE

Plug the opening of the oil level indicator tube in

the cylinder block to prevent entry of foreign

debris.

8 While not essential, it is recommended the oxygen

sensor/s be removed from the exhaust pipe/s to avoid

accidental damage. Refer to Section 6 C3-3 Powertrain

Management – GEN III V8 – Service Operations.

9 Remove the exhaust manifold to exhaust pipe flange

attaching nuts, refer to Section 8B Exhaust System.

10 Lower the vehicle to the ground.

11 Remove the spark plugs from the cylinder head on the

side the exhaust manifold is being removed. Refer to

Section 6C3-3 Powertrain Management – GEN III V8 –

Service Operations.

Figure 6A3 – 101

Engine Mechanical Page 6A3–80

Page 6A3–80

12 Working from the outside into the centre, progressively

loosen and remove the bolt (1), six pl aces, attaching

the exhaust manifold to the cylinder head.

13 Remove the exhaust manifold and gasket from the

cylinder head.

Figure 6A3 – 102

14 If required, remove the heat shield attaching bolt (1),

five places and the heat shield (2) from the exhaust

manifold (3).

NOTE

While the right-hand side exhaust manifold is

shown, the left-hand side arrangement is the

same.

Figure 6A3 – 103

Inspect

1 Using a straight edge and feeler gauges, check the

cylinder head mounting face of the exhaust manifold

does not exceed the maximum distortion specification.

Distortion limit ............................................0.25 mm Max

NOTE

An exhaust manifold exceeding this maximum

distortion specification must be machined to

within the specification to correct any distortion.

2 Inspect the heat shield for damage.

3 Inspect the exhaust pipe flange stud threads for

damage, replace as required,

refer to Section 8B Exhaust System.

4 Inspect the exhaust manifold to cylinder head

mounting surface for scratches or damage.

Figure 6A3 – 104

Engine Mechanical Page 6A3–81

Page 6A3–81

Reinstall

1 If the heat shield was removed, apply an anti-seize compound such as Caltex Kopr-Kote or equivalent to the

cleaned heat shield bolt threads. Reinstall the heat shield to the exhaust manifold and tighten the attaching bolts to

the correct torque specification.

Exhaust manifold heat shield attaching

bolt torque specification.......................................9.0 Nm

NOTE

Exhaust manifold bolt hole threads must be clean

and free of debris or thread locking compound.

All gaskets, O-rings and seals must be replaced

with new parts on reinstallation.

2 Apply a 5 mm wide band of L octite 272 thread sealant or equivalent to the threads of the exhaust manifold

mounting bolts.

NOTE

Do not apply thread sealant to the first three

threads of any exhaust manifold mounting bolt.

3 Install a new gasket between the e xhaust manifold

and cylinder head, and reinsta ll the manifold and bolts.

4 Tighten the exhaust manifold bolts (1) in two stages to

the correct torque specification. Start with the centre

two bolts and alternate from side to side to the outside

bolts.

Exhaust manifold bolt torque specification

Stage 1 ............................................................. 15.0 Nm

Stage 2 ............................................................. 25.0 Nm

5 Using a suitable size pin pu nch, bend the exposed

edge of the exhaust manifold gasket over at the front

of the right hand cylinder head and the rear of the left-

hand cylinder head.

6 If removed, reinstall the oxygen sens or/s, refer to

Section 8B Exhaust System.

7 Reinstall and tighten the exhaust pipe to the manifold

flange attaching nuts,

refer to Section 8B Exhaust System. Figure 6A3 – 105

8 Apply thread a sealant such a s Loctite 565 or

equivalent, to the cleaned threads of the coolant

temperature sensor (1).

9 Reinstall and tighten the coolant temperature

sensor (1) to the correct torque specification.

Coolant temperature sensor

torque specification............................................20.0 Nm

10 Reinstall the spark plugs a nd tighten to the correct

torque specification and reinstall the spark plug leads.

Spark plug torque specification..........................15.0 Nm

11 Reinstall the engine dress c over and air intake duct in

the reverse of the removal procedure.

Figure 6A3 – 106

Engine Mechanical Page 6A3–82

Page 6A3–82

3.15 Cylinder Head

LT Section No. — 00–075

Remove

1 Remove vapour vent pipe. Refer to 3.8 Vapour Vent Pipe.

2 Remove the valve rocker arms and pus h rods on the cylinder head to be removed.

Refer to 3.12 Valve Rocker Arms and Push Rods.

3 Remove the spark plugs from the cylinder head being removed.

Refer to Section 6C3-3 Powertrain Management – GEN III V8 – Service Operations.

4 Remove the exhaust manifold on the c ylinder head to be removed. Refer to 3.14 Exhaust Manifold.

5 For the right-hand cylinder head, remove th e bolt

attaching the automatic transmission indicator tube

bracket bolt (1) at the rear of the cylinder head.

Figure 6A3 – 107

6 Remove the bolt (1) attaching the powertrain harness

ground strap at the front of the right hand c yli nder

head.

Figure 6A3 – 108

Engine Mechanical Page 6A3–83

Page 6A3–83

7 For the left-hand cylinder head:

a Remove the powertrain wiring harn ess strap (1)

from the bracket at the rear of the cylinder head.

b Remove the bolt (2) attaching the powertrain

harness ground cable at the rear of the cylinder

head.

c Remove the power steering pump. Refer to

Section 9 Steering.

Figure 6A3 – 109

8 Progressively, loosen the M11 (1) and M8 (2) cylinder

head bolts starting with the M8 bolts working from the

outside to the centre.

NOTE

Discard all M11 bolts after removal as these are

torque to yield bolts. The M8 bolts can be re-

used.

9 Remove the cylinder head from the cylinder block and

place on two blocks of wood to avoid scratching the

machined surface.

Figure 6A3 – 110

10 Remove the cylinder head ga sket and discard.

Figure 6A3 – 111

Engine Mechanical Page 6A3–84

Page 6A3–84

Disassemble

NOTE

Do not mix the removed valve train components.

Organise all components in the order they were

removed to ensure that when reinstalled, the y are

fitted to their original locations.

1 Compress the valve spring using a commercially

available valve spring compressor.

NOTE

It may be necessary to tap the valve spring cap

with a soft faced hammer to loosen jammed

valve collets prior to compressing the valve

spring.

Figure 6A3 – 112

2 Remove the following components from the cylinder

head (1):

a Valve spring cap retaining collets (2)

b Valve spring cap (3)

c Valve spring (4)

d Valve stem oil seal and shim assembly (5)

e Valves (6)

NOTE

Do not remove the coolant core plugs (7) unless

servicing is required. These will be damaged on

removal and must be replaced.

Figure 6A3 – 113

Engine Mechanical Page 6A3–85

Page 6A3–85

NOTE

The core plug must not be reused. If the plug is

loosened, it must be replaced wit h a new one.

3 If required, remove the core plug (1) from the right-

hand cylinder head.

Figure 6A3 – 114

Clean

Use the appropriate safety glasses and

protective gloves for the following operation.

1 Clean all carbon deposits from the combusti on

chambers and valve ports using a commerc ially

available rotary wire brush. Do not scuff or damage

the aluminium cylinder head surfaces.

2 Clean any carbon deposits from valve stems and

heads using a wire buffing wheel.

3 Check all the bolt threads for damage and remove any

remaining thread locking compound from both the

threaded holes and bolts.

Figure 6A3 – 115

Engine Mechanical Page 6A3–86

Page 6A3–86

Inspect

Cylinder Head

1 Check the cylinder head deck and the i nlet and

exhaust manifold mating surfaces for distortion. Use a

set of feeler gauges (1) and a straight edge (2). Check

along the length (A), laterall y (B) and diagonally (C).

2 Check the cylinder head to exhaust an d intake

manifold mating surfaces for flatness.

Cylinder head flatness specification:

(measured over the cylinder head length)

Cylinder head to cylinder block surface ............ 0.22 mm

Cylinder head to exhaust manifold surface.......0.22 mm

Cylinder head to intake manifold surface..........0.22 mm

NOTE

If cylinder head to block surface is outside the

specified limit, the cylinder head may be

machined provided th e mi nim um over all he ig ht is

not exceeded.

Figure 6A3 – 116

3 Measure the overall height of the cylinder head (A)

and ensure it is within the specified limit.

Cylinder head height.................................120.2 mm Min

Figure 6A3 – 117

4 Inspect all threaded holes for damage, repairing as required with suitable thread inserts. Refer to 5 Thread Repair

5 Clean any residue of cylinder head attaching bolt thread seala nt from the cylinder block threads using in staller Tool

No. J-42385-107. This tool is part of the thread repair kit Tool No. J-42385.

NOTE

Do not use anything but Tool No. J-4238 5-107 to

clean the cylinder head threads in the cylinder

block.

To avoid personal injury, wear safety glasses

when using compressed air.

6 Use compressed air to clean all residue from the bolt holes.

7 Inspect the coolant jacket coolant core plugs for signs of corrosio n, replace the plugs as required.

NOTE

If replacing the expansion plugs, apply a coating

of Loctite 242 or equivalent around the plug

sealing surface.

8 Inspect the cylinder head for cracks, especially between the valve seats and exhaust ports.

9 Inspect the cylinder block deck surface for distortion, refer to 4.15 Cylind er Block.

10 Clean the M8 cylinder head bolt threads. Replace any bolt that has a suspect thread and repair any damage to the

cylinder head caused b y the i m proper use of tools. NOTE

Discard all M11 bolts after removal, as these are

torque to yield bolts and must be rep lace d.

Engine Mechanical Page 6A3–87

Page 6A3–87

Valve Springs

1 Check all valve springs for dist ortion. There should be

no more than 1.6 mm variance (1) of the spring end

while the spring is being rotat ed on a flat surface.

Replace springs that exceed this specification.

Figure 6A3 – 118

2 Use a commercially available valve spring tester,

measure each valve spring for free height and tension.

3 Measure the valve spring tens ion by compressing the

valve spring and noting the load at the given

compressed spring lengths.

Valve spring specifications:

Free height intake and exhaust......................... 54.9 mm

Valve spring tension specification:

Compressed to 45.75 mm.....................380 – 420 N Min

Compressed to 33.0 mm.....................935 – 1025 N Min

4 Discard any valve spring that does n ot confo rm to

specification. Figure 6A3 – 119

Valves

1 Inspect the valve stems for burrs and scratches. If

minor, these can be removed by polishing with a fine

grade of emery cloth.

2 Valves with excessive stem wear or are warped (1 an d

2), should be replaced.

3 Inspect the valve spring cap retaining collet retaining

groove (3) for wear or damage.

4 Inspect the valve stem end (4) for wear. If required

wear can be corrected by grinding, provided the stem

end is ground at right angles to the valve stem.

NOTE

A commercially availa ble valv e gr inder sho uld be

used to resurface valves faces and stems.

Figure 6A3 – 120

Engine Mechanical Page 6A3–88

Page 6A3–88

5 Check the valve face for:

• Margin (1) of less than 1.25 mm after grinding (4)

• Excessive pitting (2)

• Burnt or corroded areas (3)

6 If an exhaust valve is to be reconditioned, the face can

be ground, using a valve gri nding machine. The valve

seat angle is 45°.

NOTE

• If an exhaust valve face is reground, it may

be necessary to shim the valve spring to

achieve the correct spring installed height.

Refer to 3.15 Cylinder Head.

• Intake valve faces must not be refaced.

Intake valves that are worn or have face

damage must be replaced.

7 The equipment manufacturer’s recommendations must

be carefully follo wed to achieve the required standard

of finish.

8 Measure the valve stem diam eter. A valve stem with a

diameter of less than the specification must be

replaced.

Valve stem diameter...................................7.95 mm Min

Figure 6A3 – 121

Valve Guides

Excessive valve stem to guide clearance may cause noisy valve train operation, premature valve stem oil seal wear,

component damage and/or excess ive oil consumption.

Insufficient valve stem to guide clearance will result in noisy or sticking valves. Valves that are too tight may disturb

engine smoothness or lead to compon ent damage.

Measure the clearance as outlined in the following steps.

1 Insert the valve into its guide.

2 Clamp dial indicator such as Tool No. J 8520 or an

equivalent to a valve rocker arm bolt that has been

temporarily installed. Place the dial gauge in a position

where sideways movement of the valve stem will

cause movement of the indicator needle.

NOTE

To obtain a correct indication of the wear, the

indicator stem must contact the side of the valve

stem, between 8 – 12 mm above the top of the

valve guide and the gauge is to be at right

angles to the valve stem.

3 With the valve head dropped by approximately 2 mm

off its seat, move the stem of the valve side to side

against the dial indicator usin g light force to obtain a

clearance reading.

NOTE

This may need to be done in two directions and

requiring the dial indicator to be repositioned.

4 If the valve stem diameter is within specifica tions and

the valve stem to guide clearance exceeds the

specified limit, either the valve is to be replaced or the

valve guide reamed out and an oversize valve fitted.

Refer to Valve Stem Oversize.

Valve stem to guide clearance..................0.093mm Max

Figure 6A3 – 122

Engine Mechanical Page 6A3–89

Page 6A3–89

Valve Stem Oversize

1 Ream the valve guide us ing reamer, Tool

No. J 37378-1.

2 Clean the valve guide bore of all metal shavings and

debris.

Figure 6A3 – 123

3 Install the oversize valve (2) into the ream ed valve

guide and recheck the clearance as previously

described.

4 The valve should slide freely without resistance or

drag. The clearance must not exc eed specification.

Figure 6A3 – 124

Engine Mechanical Page 6A3–90

Page 6A3–90

Valve Seats

Check the valve seats for any evidence of pitting or damage at the valve contact surface. If pitting is evident, the valve

seats will need to be reconditioned.

Reconditioning the valve seats is a very important process because the seating of the valves must be precise for proper

cooling of the valve head. Good contact between each valve and its seat in the cylinder head is imperative to ensure the

heat in the valve head will be transferred efficiently.

Although there are several different types of equipment available for reconditioning valv e seats, an oscillating type valve

seat grinder is preferred. The manufactur er’s recommendations for the equipment being used should be carefully

followed to attain the correct results.

NOTE

Since the valve guide serves to support and

centre the valve seat grinder, it is essential that

valve guide wear is checked,

refer to Valve Guides.

1 Both the intake and exhaust valve seat angles are ground at 46°and the seat width should not exceed the

specification.

Valve seat width specification:

Intake.........................................................1.02 mm Max

Exhaust......................................................1.78 mm Max

NOTE

New valves must not be lapped to the valve seat

as this will destroy the protective coating on the

valve face.

2 If valve seats are reconditioned and the exhaust valve faces ground, then light lapping of the valve will ensure a

gas tight seal when closed.

3 After refacing an existing valve or installing a new valve, correct seating of the valve must be checked as follows:

a Lightly coat the valve face with Bearing (Prussian) Bl ue.

b Insert the valve and rotate about 1/6th of a turn.

c Remove valve and check its contact with the seat.

d If full contact is indicated, the valve and seat are acceptable. However, if only partial contact is shown,

reinstall the valve and rotate for one full turn. If the bearing blue now indicates a full contact then the valve

must be refaced or replaced. If the bearing blue contact still only shows partial contact then regrind the valve

seat.

e Clean all traces of bearing blue from the valves and seats then clean thoroughly b efore applying clean engine

oil to both surfaces to protect from rusting.

Engine Mechanical Page 6A3–91

Page 6A3–91

Reassemble

NOTE

Ensure that all re-used parts are reinstalled to

their original locations.

1 Lubricate all valve stems, guides and valve faces with

clean engine oil and install th e valves to their correct

ports.

2 Install a new valve stem oil seal and shim assembly by

hand, until the shim seats against the cylinder head.

No special tools are required for this operation.

NOTE

The valve stem oil seal alignment and position

on the valve stem is critical. An improperly

installed valve stem oil seal will lead to excessive

oil consumption and increased exhaust

emissions.

Figure 6A3 – 125

3 Install the valve springs and caps to each valve stem.

4 Compress the valve spring using a commercially

available spring compressor.

5 Install the valve spring cap retainer collets, retaining

with petroleum jelly if required.

6 Ensure that both the collets are correctly located

before releasing the valve spri ng compressor.

7 Tap the end of each installed valve stem, with a soft

faced hammer to seat the collets.

Figure 6A3 – 126

Engine Mechanical Page 6A3–92

Page 6A3–92

8 Measure the installed hei ght of the valve spring using

a ruler or vernier calipers. The measuremen t is to be

taken from the base of the valve spring to the top.

9 If the measurement exceeds the specified limit, a

commercially availabl e stainless steel shim must be

installed between the valve stem oil seal/shim

combination and the cylin der head to achieve the

required spring height.

Installed valve spring height.....................45.75 mm Max

NOTE

Do not shim the valve spring to obtain less than

the specified height.

10 Install the remaining valves, springs and other

components. Checking each v alve spring height as it

is assembled.

11 If the cylinder head core plugs were removed, install

with sealant such as Loctite 565 or equivale nt before

plug installation.

NOTE

If the screw in core plug at the rear of the right-

hand cylinder head has been loosened or

removed, it must be replaced.

Figure 6A3 – 127

Reinstall

NOTE

Discard all used M11 c ylinder head bolts. Alwa ys

use new M11 bolts when installing a cylinder

head. Do not use any sealant on the cylinder

head gasket or threa d l ock compound on the M11

cylinder head bolts.

1 Install the cylinder head locating sleeves and ensure

they are installed to the maximum specification (A).

Dimension (A).............................................8.3 mm max.

Figure 6A3 – 128

Engine Mechanical Page 6A3–93

Page 6A3–93

2 Install a new cylinder head gasket correctly over the

locating sleeves.

The tab (1) on the cylinder head gasket must

be located to the front half of the cylinder

block. This applies with either cylinder head

gasket. The cylinder head gaskets will fit on

either side but installing them incorrectly will

result in vital water jackets being blocked off

causing the engine to overheat. The only

condition is the word FRONT stamped on the

gasket must face the engine front. The tab

should also have 5.7 imprinted on it.

Figure 6A3 – 129

3 Referring to Figure 6A3 – 130:

a Install the cylinder head over the locating sleeves and the previously installed gask et.

b Apply a 5 mm band of thread lock such as Loctite 242 to the threads of the five M8 bolts only (1) and install

the bolts.

c Loosely install 10 new M11 cylinder head bol ts (2).

d Tighten the cylinder head bolts in the sequence shown and to the correct torque specification.

NOTE

Use a torque angle meter such as Tool No.

E 7115 to achieve an accurate turn angle

reading. Bolt numbers 1 to 10 are the M11 bolts

while bolts 11 to 15 are the M8 bolts.

Cylinder head bolt torque specification:

M8 Bolts (11 to 15).............................................30.0 Nm

 M11 Bolts only (1 to 10)

Stage 1 ..............................................................30.0 Nm

Stage 2 ....................................................90° turn angle

Stage 3 .....................................................90° turn angle

Engine Mechanical Page 6A3–94

Page 6A3–94

Figure 6A3 – 130

4 For the remainder of reinstallation procedure, reinstall the following:

a Valve rocker arms and push rods, refer to 3.12 Valve Rocker Arms and Push Rods.

b Valve rocker arm cover, refer to 3.11 Valve Rocker Arm Cover.

c Vapour vent pipe, refer to 3.8 Vapour Vent Pipe.

d Intake manifold, refer to 3.7 Intake Manifold.

e Exhaust manifold, refer to 3.14 Exhaust Manifold.

f Oil level indicator and tube, refer to 3.5 Oil Level Indicator and Tube.

5 Reinstall the spark plugs, refer to Section 6C3-3 Powertrain Management – GEN III V8 – Service Operations.

NOTE

If the cylinder head is replaced, the initial spark

plug torque specification must be adhered to:

Spark plug torque specification:

Used cylinder head............................................15.0 Nm

New cylinder head .............................................20.0 Nm

Engine Mechanical Page 6A3–95

Page 6A3–95

3.16 Hydraulic Valve Lifters

LT Section No. — 00–050

Remove

NOTE

Store all removed valve train components in the

same order they were removed. This will ensure

that when they are reinstalled in the same

relationship as on removal.

1 Remove the cylinder head on the side requiring the hydraulic valve lifter removal. Refer to 3.15 Cylinder Head.

2 Remove the bolt (1), attaching the hydraulic v alve lifter

guide to the cylinder block.

NOTE

There is one bolt and four hydraulic valve lifters

in each guide.

3 Remove the hydraulic valve lifters and the guides.

NOTE

Use care when removing the hydraulic valve

lifter guide as the hydraulic valve lifter may fall

out of the guide while the guide is being

removed.

Figure 6A3 – 131

4 Remove the hydraulic valve lifters from the guides.

Figure 6A3 – 132

Engine Mechanical Page 6A3–96

Page 6A3–96

Disassemble

1 Remove the push rod seat retaining clip (1) by using a

small flat bladed screwdriver and carefully prising the

clip out of the groove in the lifter.

Figure 6A3 – 133

2 Remove in order the following:

• Push rod seat (1).

• Oil metering valve (2).

• Plunger assembly (3).

• Plunger spring (4) from the lifter body (5).

NOTE

If the plunger is stuck in the lifter body, turn the

lifter body upside down and tap the lifter body on

a block of wood. If this is not effective, soak the

lifter assembly in a suitable cleaning fluid.

3 Remove the ball check retainer (6), ball check spring

(7) and ball (8) from the plunger. Figure 6A3 – 134

Clean and Inspect

It is recommended the hydraulic valve lifter be replaced if faulty. However, cleaning of the lifter can remove a build up of

deposits that sometimes can cause the lifter internals to stick causing valve train noise.

To avoid personal injury, wear safety glasses

and the appropriate gloves when using

compressed air and cleaning fluids.

1 Thoroughly cle an all parts in a commercially available cleaning fluid and blow all the parts dr y using com pressed

air.

Engine Mechanical Page 6A3–97

Page 6A3–97

2 Inspect the valve lifters for:

• Bent or broken clip (1).

• Worn pushrod socket (2). If the seat is worn,

inspect the matching push rod and replace the

push rod if worn.

• Scuffed or worn lifter body (3).

NOTE

Inspect the lifter bore in the cylinder block.

• Worn or damaged roller bearing (4). Replace the

lifter if the roller binds or roughness can be felt.

• Loose or damaged pin (5).

• Partially blocked oil hole (6).

NOTE

If the roller bearing on the lifter is worn, inspect

the camshaft for wear.

Refer to 3.10 Camshaft Lobe Lift.

Figure 6A3 – 135

3 Inspect the valve lifter guides for:

• Cracks or damage.

• Excessive wear in the lifter mounting b ores.

Figure 6A3 – 136

Reassemble

NOTE

Do not attempt to recondition a lifter by taking

parts from other unserviceabl e lifters. Cleanliness

is extremely important when handling valve

lifters. Lint or dirt can result in a failed lifter.

1 Place the check ball (1) over the small hole in the

plunger (2).

2 Carefully place the check ball spring (3) and the

retainer (4), over the check ball and press the retainer

into position within the plun ger with a small flat blade

screwdriver.

3 Half fill the valve lifter body with the test fluid SPX No.

E1151 or oil with a viscosity rating of 10W.

Figure 6A3 – 137

Engine Mechanical Page 6A3–98

Page 6A3–98

4 Reinstall the plunger spring into the lifter body.

5 Install the plunger assembly in the body taking care to

align oil feed holes.

6 Using a 1 mm diameter pin punch or similar, unseat

the check ball (1) in the plunger then push the plunger

down to the full extent of its travel.

7 Use Tool 6A24 (or a suitable sized pin punch) to align

the oil feed holes (2) in the body and plunger.

8 Fill the lifter with specified test fluid.

9 Reinstall the oil metering valve, push rod seat (cup

side facing out) and the retaining clip.

Figure 6A3 – 138

Testing Lifter Leak-down Rate

After the hydraulic lifter has been cleaned, in spected and reassembled, it must be tested before being reinstalled. Lifter

test fixture Tool No 6A23 has been designed to test the leak-down rate of the lifter to ensure the lifter will operate as

intended when reinstalled.

1 Ensure the test cup is clean. Install the cup on the

fixture and place the lifter in the cup.

NOTE

Some versions of Tool No. 6A23 may require

modification to hold the base of the lifter inside

the tester cup.

2 Add the test fluid SPX No. E1151 or engine oil with a

viscosity rating of 10W to completely cover the

hydraulic valve lifter when in Tool No 6A23.

3 Place the ball bearing supp lied with the test fixture in

the push rod seat of the hydraulic v alve l ifter.

4 Lower the test fixture ram so it can rest on the ball

bearing.

5 Operate the lifter plunger through its maximum travel

to force all the air out of the lifter by using a vigorous

pumping action on the test fixture weight arm.

Continue the pumping action until considerable

resistance is built up in the lifter and the lifter becomes

solid.

6 Raise the weight arm to allow the lifter plunger to

come up to its retainer then lower the arm to rest on

the ram.

7 Using a stop watch, measure the time required for the

indicator needle on the tester to travel from the Start

position to the 0.125" positi on on the scale and ensure

the lifter is within the specified limit.

Hydraulic valve lifter

bleed down rate specified lim it:

Start to 0.125"......................................10 to 30 seconds

Figure 6A3 – 139

NOTE

A suspect lifter should be tested several times

before being discarded. Cl ean the test fixture cup

and refill with clean test fluid after several lifters

have been tested.

8 Stand the tested lifters in an upright position so the fluid does not drain from the oil holes.

Engine Mechanical Page 6A3–99

Page 6A3–99

Reinstall

1 Check that all hydraulic valve lifter bores and adj acent

areas are clean.

2 Reinstall the valve lifters into the gui des aligning the

flat area at the top of the lifter with the flats in the lifter

guide bore. Ensure the lifter is pushed completely into

the lifter guide bore.

NOTE

Ensure the lifters are reinstalled to their original

locations.

3 Lubricate the hydraulic valv e lifter bodies and their

bores in the cylinder block with Lubrizol 6612 (or

equivalent) then reinstall the lifters and guides into the

block.

4 Reinstall the valve lifters and guide assembly into the

cylinder block.

5 Reinstall each valve lifter guide attaching bolt and

tighten to the correct torque specification.

Hydraulic valve lifter guide attaching bolt

torque specification............................................12.0 Nm

6 Reinstall the cylinder he ad/s.

Refer to 3.15 Cylinder Head.

Figure 6A3 – 140

Engine Mechanical Page 6A3–100

Page 6A3–100

3.17 Crankshaft Balancer

LT Section No. — 00–540

Remove

Disconnection of the battery affects certain

vehicle electronic systems. Refer to

Section 00 Warnings, Cautions and Notes

before disconnecting the battery.

1 Disconnect the ground battery cable termi nal from the battery.

2 Remove the radiator, refer to Section 6B3 Engine Cooling – GEN III V8.

3 Remove the engine accessory and air conditioner drive belts. Refer to 3.6 Engine Drive Belts and Pulleys.

4 Remove the starter motor. Refer to Section 6D3-2 Starting System – GEN III V8.

5 Remove the bolt (1), attaching the right-hand close- out

cover to the cylinder block.

NOTE

The close out covers seal off the area between

the cylinder block and transmission assembly.

Figure 6A3 – 141

NOTE

Ensure the teeth of the holding tool engage

correctly with the ring gear before tightening the

fasteners.

6 Using the two starter motor bolts, install the ring gear

holding Tool No. J 42386-A a nd tighten the bolts to the

correct torque specification.

Ring gear holding tool, Tool NO. J 42386-A

attaching bolt torque specification......................50.0 Nm

Figure 6A3 – 142

Engine Mechanical Page 6A3–101

Page 6A3–101

7 Remove the bolt (1) attaching the crankshaft bal ancer.

NOTE

Do not discard the bolt at this stage, as it will be

required later for the reinstallation process. The

crankshaft bolt is to be replaced during the final

stage of the assembly procedure.

Figure 6A3 – 143

8 Use the crankshaft end protector, T ool No. J 41816-2

and puller, Tool No.J4181 6 or equivalent to remove

the crankshaft balancer.

Figure 6A3 – 144

Engine Mechanical Page 6A3–102

Page 6A3–102

Clean and Inspect

To avoid personal Injury, wear safety glasses

and the appropriate gloves when using

compressed air and cleaning fluids.

1 Clean the crankshaft balancer in a suitable cleaning

fluid and dry the crankshaft bala ncer using

compressed air.

NOTE

Do not use solvent based cleani ng fluids to clea n

the crankshaft balancer as this may damage the

rubber in the balancer.

2 Using a wire brush, clean the belt grooves to remove

all dirt or debris.

3 Inspect the crankshaft balancer for:

• Excessive scoring, grooves or rust on the hub

seal surface. Minor imperfections on the hub

seal surface may be removed with a polishing

compound or a fine grade of em ery cloth.

• Rusted or damaged belt grooves.

• Worn, chunking or deteriorated rubber between

the hub and pulley.

NOTE

The balancer belt grooves should be free of any

nicks, gouges, or other damage that may not

allow the belt to track correctly. For the belt to

track correctly, the belt grooves should be free of

all dirt or debris. Minor imperfections may be

removed with a fine file.

Figure 6A3 – 145

Engine Mechanical Page 6A3–103

Page 6A3–103

Reinstall

NOTE

The crankshaft balancer reinstallation and bolt

tightening involves a multi-stage tightening

process. The first pass uses the used bolt and

ensures the balancer is installed completely onto

the crankshaft. The remaining passes tighten the

new bolt to the correct torque specification.

1 Ensure the teeth of the ring gear locking T ool No. J 42386-A are correctly engaged.

2 Apply a smear of clean engine oil onto th e seal surface of the balancer then install the balancer onto the end of the

crankshaft.

NOTE

The balancer should be positioned onto the end

of the crankshaft as straight as possible before

the tool installation.

3 Use installer, Tool No. J 41665 and instal l the tool to

the crankshaft balancer as follo ws:

a Select the threaded rod, nut, washer and

installer from Tool No. J 41478.

b Insert the installer sleeve, Tool No. J 41665-1

into the front of the balancer and back up with

the plate, Tool No. J 41665-2.

NOTE

Insert the stepped end of sleeve Tool No.

J 41665-1 into the balancer in this initial stage.

4 Use a suitable spanner (1) to hold the hexagonal end

of the threaded rod. Use a second span ner (2) to

rotate the installation tool nut clockwise until the

balancer is started onto the crankshaft.

5 Remove the stepped sleeve of Tool No. J 41665-1 and

reverse it so the larger end of the installer is against

the front of the balancer.

6 Use a suitable spanner to hold the hexagonal end of

the threaded rod. With a second spanner, rotate the

installation tool nut clockwise until the balancer is

installed into the crankshaft.

6 Remove the balancer installation tool.

Figure 6A3 – 146

7 Install the used crankshaft balancer bolt and tighten to

the correct torque specification.

Crankshaft balancer installation

torque specification

Stage 1 ...............................................140.0 – 160.0 Nm

8 Remov e the used balancer bolt and discard.

Figure 6A3 – 147

Engine Mechanical Page 6A3–104

Page 6A3–104

9 Measur e the distance the balancer protrudes from the

crankshaft nose and ensure dimension (A) is to

specification.

Dimension (A)........................................ 2.40 – 4.48 mm

10 If the dimension is not correct, repeat Steps 1 to 8.

Figure 6A3 – 148

11 Install a new crankshaft balancer bolt (1) and tighten

to the correct torque specification in two stages using

a suitable torque wrench and a torque a ngle wrench

Tool No. E 7115 or similar.

 Crankshaft balancer bolt

torque specification

Stage 2 ..............................................................50.0 Nm

Stage 3 ..................................................140° turn angle.

12 Remove the ring gear holding Tool No. J 42386-A.

13 Reinstall the close-out cover and tighten the attaching

bolt to the correct torque specification.

Right-hand close-out cover at taching bolt

torque specification............................................10.0 Nm

14 Reinstall the starter motor, refer to

Section 6D3-2 Starting System – GEN III V8.

15 Reinstall the radiator, refer to

Section 6B3 Engine Cooling – GEN III V8. Figure 6A3 – 149

Engine Mechanical Page 6A3–105

Page 6A3–105

3.18 Crankshaft Front Oil Seal

LT Section No. — 00–325

Remove

1 Remove the crankshaft balancer, refer to 3.17 Crankshaft Balancer.

2 Using Tool No. E308 or e quivalent, carefully prise the

seal from the front engine cover.

NOTE

Use care to avoid scratching the front engine

cover when removing the seal.

Figure 6A3 – 150

Reinstall

NOTE

Do not lubricate the oil seal sealing surface. For

further information refer to

1.5 Engine Lubrication System

1 Lubricate the outer edge of the new oil seal (1) and the

front cover oil seal bore with clean engine oil.

2 Install the crankshaft front oil seal onto the guide of

Tool No. J 41478.

3 Install the threaded rod with the nut, washer, guide,

and oil seal of Tool No. J 41478 into the end of the

crankshaft.

4 Using a suitable spanner, ho ld the head of the installer

bolt. Using a second spanner rotate the installer nut

clockwise until the seal bottoms in the front cover

bore.

5 Remove the tool from the crankshaft.

6 Inspect the oil seal for correct installation. The oil seal

should be installed evenly and completel y into the

front cover.

7 Reinstall the crankshaft bala ncer.

Refer to 3.17 Crankshaft Balancer.

Figure 6A3 – 151

Engine Mechanical Page 6A3–106

Page 6A3–106

3.19 Engine Mounts

LT Section No. — 00–475

Inspect

1 Check the area around the engin e mounts fo r any signs of fluid leakage. If an oi l leak coming from the mount is

visible, the mount is defective.

To protect the aluminium oil pan from damage

when using a floor jack, position a suitable

piece of wood or similar between the oil pan

and the jack.

2 Using a suitable engine lifting crane or a floor jack, raise the engine slightly to remove the weight from the mounts

and to place the rubber slightly in tensio n. Check the mount ing rubber has not deteriorated, split or has separated

from its metal plates.

NOTE

If either fluid is visible or the rubber has

deteriorated or separated the engine mount must

be replaced.

Remove

Disconnection of the battery affects certain

vehicle electronic systems. Refer to

Section 00 Warnings, Cautions and Notes

before disconnecting the battery.

1 Disconnect the ground battery cable termi nal from the battery.

2 If required, remove the strut tower brace, refer to Section 1A1 Body.

3 If required, remove the engine dress covers, refer to 3.2 Engine Dress Cover.

4 Raise the front of vehicle and place on safety stands. For the location of vehicle jacking and support locations,

refer to Section 0A General Information.

5 Remove the exhaust pipe to manifold flange attaching nuts on the side the engine mount is to be removed.

Refer to Section 8B Exhaust System.

6 From under the vehicle, remove the lower mounting to

crossmember attaching nut (1) for both mounts.

7 Lower the vehicle to the ground an d remove the

exhaust manifold on the side the engine mount is to be

removed. Refer to 3.14 Exhaust Manifold.

Figure 6A3 – 152

Engine Mechanical Page 6A3–107

Page 6A3–107

To protect the aluminium oil pan from damage

when using a floor jack, position a suitable

piece of wood or similar between the oil pan

and the jack.

8 Using suitable engine lifting equipment or a floor jack, raise the engine and remove the weight from the engine

mounts.

9 Remove the three bolts (1), attaching the engine

mount bracket to the cylinder block.

10 Lift the engine mount and bracket assembly from the

crossmember and remove it from the vehicle.

11 Using a marker pen or similar, mark the relationship of

the heat shield to the bracket to maintain correct

rotation in the reinstallation pr ocess.

12 With the engine mount and bracket assemb ly removed

from the vehicle, mount the bracket assembly in a vice

and remove the nut (2) attaching the engine mount to

the bracket and separate the heat shield and mount

from the bracket.

NOTE

While the left-hand mount is shown, the

operation is similar for either engine mount with

the exception that for the right-hand engine

mount, the battery harness bracket attachi ng bol t

must be removed before removing the mounting

bracket to the cylinder block bolts. Refer to

Section 12O Fuses, Relays and Wiring

Harnesses.

Figure 6A3 – 153

Reinstall

1 If removed from the bracket, reinstall the engine mount an d heat shiel d then tighten the attaching nut to the correct

torque specification.

 Engine mount and bracket attaching nut

torque specification............................................80.0 Nm

2 Fit the engine mount stud into the crossmember an d install the mounting bracket assembly so the attaching bolts

can be installed.

3 Once all the mounting bracket to cylinder block attaching bolts are installed, tighten the bolts to the correct torque

specification.

Engine mounting bracket and

cylinder block attaching bolt

torque specification............................................50.0 Nm

4 Lower the engine allowing the weight to settle on the crossmember before installing the lower engine mount

attaching nut and tighten to the correct torque specification.

Engine mount to crossmember

attaching nut

torque specification............................................80.0 Nm

5 Reinstall the exhaust manifold, refer to 3.14 Exhaust Manifold.

6 Reinstallation of the remainder of the components removed is the reverse of the removal procedure.

Engine Mechanical Page 6A3–108

Page 6A3–108

4 Major Service Operations

ATTENTION

All engine fasteners are important attaching parts as they affect th e performance of vital componen ts and/or

could result in majo r repair expense. Where specified in this Section, fasteners MUST be rep laced with parts

of the same part number or a GM approved equivalent. Do not use fasteners of an inferior quality or

substitute design.

Torque values must be used as specified during reassembly to ensure proper retention of all engine

components.

Through out this Section, fastener torque wrench specifications may be accompanied with the following

Identification marks:

 Fasteners must be repl aced after loosening.

 Fasteners either have micro encapsulated sealant applied or incorporate a mechanical thread lock and

should only be re-used once. If in doubt, replacement is recommended.

If one of these identification marks is present alongside a fastener torque wrench specification, the

recommendation regarding that fastener must be adhered to.

4.1 Engine Assembly, Except AWD

LT Section No. — 00–500

Remove

Disconnection of the battery affects certain

vehicle electronic systems. Refer to

Section 00 Warnings, Cautions and Notes

before disconnecting the battery.

1 Disconnect the battery ground terminal from the battery.

2 Remove the strut brace, refer to Section 1A1 Body.

3 Remove the hood assembly, refer to Section 1A4 Ho od, Rear Compartment Lid, Liftgate and Endgate.

4 Remove the air intake duct, refer to 3.1 Air Intake Duct.

5 Remove the engine dress covers, refer to 3.2 Engine Dress Cover.

• Do not remove the screw-on radiator

pressure cap while the engine coolant

temperature is above 50° C, as personal

injury could occur.

• Throughout this Section spring type hose

clamps are required to be removed, always

wear eye protection when handling spring

type clamps to avoid possible eye inju ry.

6 Refer to Section 6B3 Engine Cooling – GEN III V8 and remove the following:

• Top and lower radiator hos es from the engi ne and radiator

• Radiator fan and shroud assembl y

• Radiator

7 Remove the accessory and air conditioner drive belts, refer to 3.6 Engine Drive Belts and Pulle ys.

8 Disconnect the suction/discharge hose pad from the air conditioner compressor,

refer to Section 2C HVAC Climate Control (Manual A/C) – Remov al an d Installation.

9 Drain the engine oil into a suit able container and reinstall the drain plug once the oil has drained sufficiently,

refer to 3.3 Engine Oil and Filter.

Engine Mechanical Page 6A3–109

Page 6A3–109

10 Remove the heater hose clamps at the eng ine coolant

pump, taking note of the hose layout. Plug the open

ends to prevent the entry of foreign material.

NOTE

If required, mark the hoses prior to removal with

a paint pen or similar.

11 Remove the ground le ad to the engine cylinder block

and from the left hand engine mount and remove the

positive terminal from the battery and lay the harness

on the engine, refer to

Section 12O Fuses, Relays and Wiring Harnesses.

Figure 6A3 – 154

12 Disconnect the air conditioning pressur e switch and

front wiring harness connector (1) attached to the A/C

condenser pipe (2).

13 Remove the left hand kick pan el trim and

glove box assembly, refer to

Section 1A3 Instrument Panel and Co nsole.

14 Disconnect the Powertrain Interface Module (PIM)

wiring harness connector an d front body harness

connector. Refer to

Section 12O Fuses, Relays and Wiring Harnesses.

15 Release the harness to dash panel grommet and pass

the harness and connectors out into the engi ne bay

and place the powertrain wiring harness on top of the

engine.

Figure 6A3 – 155

16 Referring to Figure 6A3 – 156, remove or disconn ect the following:

a Powertrain wiring harness retaining clips (1) from the engine compartment dash panel.

b Wiring harness connector (2) fr om the theft deterrent horn.

c Cover (3) from the Powertrain Control Module (PCM) (4).

d Two screws (5) retaining the PCM wiring harness connectors to the PCM.

e PCM wiring harness retaining clip (6) from the PCM contain er to free the h arness.

Engine Mechanical Page 6A3–110

Page 6A3–110

Figure 6A3 – 156

17 De-pressurise the fuel system, refer to

Section 8A1 Fuel System.

18 Using a small screwdriver, release the security lock

(1), at each of the fuel supply hose quick connect

fittings (2).

NOTE

The security lock at the fuel rail side is fitted with

a tether to prevent loss.

Figure 6A3 – 157

Engine Mechanical Page 6A3–111

Page 6A3–111

19 Remove the fuel line quick connector (1) from the fuel

rail, refer to Section 6C3-3 Powertrain Management –

GEN III V8 – Service Operations.

20 Disconnect the vapour line connection (2) to the EVAP

purge control valve and place it to one sid e.

NOTE

Plug all openings to prevent fuel leaking and

foreign matter from entering the fuel system.

Figure 6A3 – 158

21 Loosen the low pressure power steering return hose

clamp (1) and the remove the hose (2).

NOTE

Plug the hose ends to prevent an y foreign matter

from entering the system and fluid loss.

22 If required, remove the power steering pump and/or

reservoir, refer to Section 9 Steering.

Figure 6A3 – 159

23 Remove the power steering high press ure line flare

nut (1) and O-ring (2) from the pump outlet fitting.

24 Loosen the low pressure hose clamp (3) and remove

the hose from the pump inlet fitting.

NOTE

Plug the pump and hose fittings to prevent

foreign matter from entering the s ystem and fluid

loss.

Figure 6A3 – 160

Engine Mechanical Page 6A3–112

Page 6A3–112

25 Disconnect the brake booster vacuum hose (1) and

HVAC control vacuum hose (2) from the rear of the

intake manifold.

Handle the spark plug boot only. Do not pull

on the lead. To remove the lead, twist the

boot first to break the seal and then gently

pull on the boot.

26 Remove the No. 3 spark plug lead and plug from the

left-hand bank.

Figure 6A3 – 161

27 Remove the upper left engine mount to engine bracket

attaching nut.

28 Remove the No. 4 spark plug lead and plug from the

right bank.

29 Remove the upper right engine mount to en gine

bracket attaching nut. To improve the removal

process, remove the lower mount attaching nut.

NOTE

To improve access to the upper engine

mount to bracket attaching nuts if

required, remove both exhaust manifolds,

refer to 3.14 Exhaust Manifold.

30 Remove the ignition coil and module for cylinder No. 7.

Refer to Section 6C3-3 Powertrain Manag ement –

GEN III V8 – Service Operations.

NOTE

This step is necessary to gain additional

clearance around the brake vacuum booster,

when the engine is lifted during the removal

process.

Figure 6A3 – 162

31 For manual transmission equipped vehicles, either:

• Remove the clutch master cylinder reservoir bracket attached to the end of the master cylinder,

refer to Section 7A3 Clutch – GEN III V8, or

• Disconnect the clutch slave cylinder h ydr aulic line at the bracket attached to the vehicle s ubframe,

refer to Section 7B2 Manual Transmission – GEN III V8.

NOTE

This step is necessary to reduce the possibi lity of

damage to the reservoir, during the engine

removal procedure.

32 Using a hoist, raise the vehicle or alternatively use a floor jack and support the vehicle on safety stands. For

location of hoist pad, vehicle j ackin g an d support locations, refer to Section 0A General Information.

33 Remove the propeller shaft, refer to Section 4C1 Rear Propeller Shaft and Univers al Joints.

NOTE

If required, use tie wire to secure the sliding yoke

to the rear of the transmission.

Engine Mechanical Page 6A3–113

Page 6A3–113

34 Disconnect the gear shift control from the transmission. Refer to either:

• Section 7B2 Manual Transmission – GEN III V8.

• Section 7C4 Automatic Transmission – 4L60E – On vehicle Servicing.

35 Remove the two bolts (1) attaching the po wer steering,

high pressure hose (2) bracket to the oil pa n.

36 While not essential, it is recommended the oxygen

sensors be removed from the exhaust pipes, to avoid

accidental damage. Refer to Section 6 C3-3 Powertrain

Management – GEN III V8 – Service Operations.

37 If the exhaust manifolds have not been removed,

remove the front exhaust assemblies, refer to

Section 8B Exhaust System.

38 Lower the vehicle enou gh to allow the connection of

the lifting chains but also allo wing th e removal of the

transmission support.

Figure 6A3 – 163

39 Attach a suitable lifting chain and hooks to the engine

lifting brackets located at the left-hand front (1) and

right-hand rear (2) corners of the engi ne.

40 Using a suitable lifting crane, raise the eng in e slightly

to take the weight off the engine mounts.

NOTE

The following step is critical to ensure correct

powertrain alignment on reas sembly. If this is not

carried out, vehicle vibration and/or handling

problems could result.

Figure 6A3 – 164

41 Mark the relationship of the engine rear crossmember (1) to the vehicle underbody to assist with alignment on

reassembly, refer to Figure 6A3 – 165. For further information rel ating to crossmember alignment,

refer to Section 1A2 Body Dimensions.

42 Place a floor jack with a block of wood under the transmission and ra ise the jack slightly to support the weight of

the transmission.

Engine Mechanical Page 6A3–114

Page 6A3–114

43 Referring to Figure 6A3 – 165, remove the bolt (1), four places, attaching the rear crossmember (2) to the vehicle.

NOTE

View A is for Manual Transmission vehicles and

View B is for Automatic transmission vehicles.

44 Remove the rear mount to crossmember attaching nut (3), two places and then remove th e crossmemb er from the

vehicle.

a For vehicles with manual transmission (A), remove the rear mount to transmission bolt (4), four places and

the exhaust resonator bracket base to transmission extension bolt (5) and nut, two places and remove the

exhaust resonator bracket base (6) from the vehicle.

b For vehicles with automatic transmission (B), remove the rear mount to transmission extension housing bolt

(7), two places and nut (8), two places and remove the mount (9) and the exhaust resonator bracket base

(10) from the vehicle.

Figure 6A3 – 165

• Take care when removing the engine and

transmission assembly that no part of the

assembly is allowed to rest on the power

steering rack.

• Do not allow the engine to swing forward

and damage the air conditioning

condenser.

45 Raise the engine and transmission assembly with the front tilted upward and a floor jack supporting the rear of the

transmission assembly.

46 Continue to lift and manoeuvr e the en gine and transmission assembly until it is clear of the engine ba y.

Engine Mechanical Page 6A3–115

Page 6A3–115

Disassemble – Ancillary Equipment

The engine removal and rei nstallation procedures cover the removal and reinstallation of the engine and transmission as

a complete assembly. To perform major engi ne service operations, it is required the engine and transmission be

separated and the ancillary equipment that is attached to the engine be removed. Once a ll ancillary components and the

transmission have been removed, major e ng ine service operations can then be performed, by referring to the appro pri ate

major service operation.

Automatic Transmission Vehicles

1 Remove the wiring harness conn ectors and earth connections from the engine and transmission assembly and

carefully set the wiring harness to one side, refer to Section 12O, Fuses, Rela ys and Wiring Harnesses.

2 Remove the starter motor, refer to Section 6D3 – 2 Starting System – GEN III V8.

3 Remove the right-hand close-out cover (A) and left-hand close out cover (B) attaching bolts (1) and remove the

covers (2). Refer to Figure 6A3 – 166.

Figure 6A3 – 166

4 Remove the three bolts attaching the torque converter to the engine flexplate using the right-hand close -out cover

opening for access to the bolts.

5 Release the lock down lever (1) and remove the

transmission oil level indicator.

6 Remove the bolt (2) attaching the transmissio n filler

tube to the right-hand cylinder head.

7 Release the transmission breat her tube from the filler

tube (3) bracket (arrow).

8 Using a twisting/pulling motio n, remove the filler tu be

from the transmission case seal (4). Set the filler tube

to one side.

9 Plug the filler tube opening in the automatic

transmission to prevent dirt entr y and fluid lea kage.

Figure 6A3 – 167

Engine Mechanical Page 6A3–116

Page 6A3–116

10 Disconnect the transmission cooler lines from the

transmission end, as follows:

a Release the verifier disc (1) by pulling b ack with

your fingertips and slide th e disc back down the

cooler pipe (2).

b Open the cooler line releas e T ool J-41623-B and

slip it over the cooler pipe to be discon nected

from the transmission, ahead of the verifier disc

as shown.

c Slide the release tool alon g the pipe to engage

with the quick-connect fitting.

d While pushing in wards, rotate the tool about one

sixth of a turn clockwise to release the s pring clip

holding the pipe.

e With the release tool held in this position, pull

back on the cooler pipe to release. Repe at this

process with the remaining pipe an d quick-

connect fitting.

f Plug all openings to prevent fl uid loss and/or dirt

entry. Figure 6A3 – 168

11 Remove the transmission housing to engine assembly

attaching bolt (1), eight places in the seq uence shown

and then slide or lift the transmission free from the rear

of the engine.

NOTE

Ensure the torque converter stays with the

transmission when the transmission is being

removed from the engine assembly.

Figure 6A3 – 169

Engine Mechanical Page 6A3–117

Page 6A3–117

12 Remove the three bolts (1), attaching the left-hand

engine mount bracket to the cylinder bl ock and set the

bracket and mount, together with the heat shield, to

one side. Repeat for the remaining engine mount.

13 Mount the engine in a suitable engine stand such as

Tool No AU 591 or similar. Preferab ly, use a stand that

will mount the engine on it from its side using the

engine mount bracket bolt hol es.

14 As required, remove the following:

• Power steering reservoir and pump, refer to

Section 9 Steering.

• Exhaust manifolds, refer to

3.14 Exhaust Manifold.

• Coolant pump, refer to

Section 6B3 Engine Cooling – GEN III V8.

• Ignition coils and bracket assembly, refer to

Section 6C3-3 Powertrain Management –

GEN III V8 – Service Operations.

• Accessory and air conditioner drive belt idler and

tension pulley assemblies, refer to

3.6 Engine Drive Belts and Pulleys.

• Air conditioning compressor, refer to

Section 2C HVAC Climate Control (Manual A/C)

– Removal and Installation.

• Generator and mounting bracket, refer to

Section 6D3-1 Charging System – GEN III V8.

Figure 6A3 – 170

Manual Transmission

1 Remove the wiring harness conn ectors and earth connections from the engine and transmission assembly and

carefully set the wiring harness to one side. For wiring harn ess informati on,

refer to Section 12O, Fuses, Relays and Wiring Harnesses.

2 Remove the starter motor, refer to Section 6D3 – 2 Starting System – GEN III V8.

3 Remove the left and right-hand close-out cover attaching bolts (1) and remove the covers (2).

Refer to Figure 6A3 – 166.

4 Remove the transmission housing to engine assembly attaching bolts (1), refer to Figure 6A3 – 169 and then slide

the transmission free from the rear of the engine.

5 Remove the three bolts (1), attaching the left-hand

hydraulic engine mount bracket to the cylinder block

and set the bracket and mount, together with the heat

shield, to one side. Repeat for the remaining engine

mount.

6 Mount the engine in a suitable engine stand such as

Tool No AU 591 or similar. Preferab ly, use a stand that

will mount the engine from its side usi ng the engine

mount bracket bolt holes.

7 As required, remove the following:

• Clutch assembly, refer to

Section 7A3 Clutch – GEN III V8.

• Power steering reservoir and pump,

refer to Section 9 Steering.

• Exhaust manifolds,

refer to 3.14 Exhaust Manifold.

• Coolant pump, refer to

Section 6B3 Engine Cooling – GEN III V8.

• Ignition coils and bracket assembly, refer to

Section 6C3-3 Powertrain Management –

GEN III V8 – Service Operations.

• Accessory and air conditioner drive belt idler and

tension pulley assemblies, refer to

3.6 Engine Drive Belts and Pulleys.

• Air conditioning compressor, refer to

Section 2C HVAC Climate Control (Manual A/C)

– Removal and Installation.

• Generator and mounting bracket, refer to

Section 6D3-1 Charging System – GEN III V8.

Figure 6A3 – 171

Engine Mechanical Page 6A3–118

Page 6A3–118

Reassemble

Reassembly of the ancillar y c ompo nents for all vehicles is the reverse of the disassemble procedure noting the following:

1 Ensure all fasteners are tightene d to the correct torque specification, refer to 7 Torque Wrench Specifications or

refer to the specific Section for the particular component bei ng installed.

2 Ensure all transmission lines where fitted and power steering lines are free from obstruction and are not rubbing on

any components.

3 Tighten the transmission to engine attach ing bolts to the correct torque specification in the reverse order of the

removal procedure, refer to Figure 6A3 – 1 69.

4 Both close-out covers are installed.

5 The transmission filler tube where fitted is in stalled and sealed in the transmission correctly.

Reinstall Set-up and Testing

Reinstallation of the engine assembly is the reverse of removal procedure, noting the following:

1 Ensure that all fasteners where requ ir ed are either replaced or cleaned, thread seal ant is reapplied and they are

tightened to the correct torque specifications, refer to 7 Torque Wrench Specifications or refer to the specific

Section in the service information for the part icular component.

2 Use only the specified engine lubricant type and quantity.

3 Fill the cooling system with the correct quantity and grade of coolant,

refer to Section 6B3 Engine Cooling – GEN III V8

4 Check and top up the transmission fluid level as required, refer to either:

• Section 7C4 Automatic Transmission – 4L60E – On vehicle Servicing

• Section 7B2 Manual Transmission – GEN III V8

5 Disable the ignition system, refer to 2.7 Compression Ch eck and then crank the engine several times. Listen for

any unusual noises or evidence that parts are binding.

6 Enable the ignition system, start the engine and listen for unusual noises.

7 Check the vehicle oil pressure gauge or warning lamp and confirm the engine has an acceptable oil pressure. If

necessary, install an oil press ure ga uge and measure the engine oil pressure, refer to 2.5 Oil Pressure.

8 Run the engine speed at about 1,000 rpm until the engine has reached normal operating temperature.

9 Listen for sticking lifters and other unusual noises.

10 Check for oil, fuel, coolant and exhaust leak s while the engine is running, stopping the engine and correcting as

required.

11 Perform a final inspection for the correct engine oi l and coolant levels.

12 Reinstall the engine dress c over, refer to 3.2 Engine Dress Cover.

13 If required, ensure the engine hood alignment is correct,

refer to Section 1A4 Hood, Rear Compartment Lid, Liftgate & Endgate.

Engine Mechanical Page 6A3–119

Page 6A3–119

4.2 Engine Assembly, AWD

LT Section No. — 00–500

With the front powertrain components of the AWD system being attached to the oil pan, the preferred method of

removing the engine from the vehicle, is to lower the engine, transmission/transfer case and front crossmember as a

complete assembly below the vehicle.

To perform this operation, it is recommended that a hydraulic scissor lift table with a capacity of 750 Kg or greater be

used. If this approach is used, then the engine hoo d does not need to be removed. However, if a scissor lift is not

available the engine hood will need to be removed to allow suitable overhead lifting equipment to be used to lower the

assembly from the vehicle.

There are many alternative methods for removing and reinstalling the engine, transmissio n/transfer case and

crossmember assembly. However, the procedure describ ed in this Section is the preferred method and allows the

braking system hydraulics to remain intact, eliminating the need to perform lengthy bleeding procedures. This procedure

also eliminates the need for two e xtra people to support the front suspension strut legs during the removal and

reinstallation procedure. The suspension struts once disconnected from the steering arms are supported in the vehicle

using wooden props against the wheelhouse panel. However, if circumstances require the removal of the front

suspension struts from the vehicle, the service procedure described in this Section will need to be modified accordingly

by the technician performing the service operation.

When diverting from the procedures describ ed, refer to the appropriate Section in the service information for the relevant

service procedures. Examples of these Sections would be:

• Section 3 Front Suspension

• Section 5A Service and Park Braking Systems

• Section 5B AWD ABS – TCS

• Section 9 Steering

Disconnection of the battery affects certain

vehicle electronic systems. Refer to

Section 00 Warnings, Cautions and Notes

before disconnecting the battery.

Remove

1 Disconnect the battery ground terminal from the battery.

• Do not remove the screw-on pressure cap

while the engine coolant temperature is

above 50° C, as personal injury could

occur.

• Throughout this Section spring type hose

clamps are required to be removed, always

wear eye protection when handling spring

type clamps to avoid possible eye inju ry.

2 Allow the engine to cool to ambient temperature (less than 50°C) and slowly remove the screw-on pressure cap

from the radiator, refer to Section 6B3 Engine Cooling GEN III V8.

3 Remove the strut tower brace, refer to Section 1A1 Body.

4 Remove the air intake duct, refer to 3.1 Air Intake Duct

5 Remove the engine dress covers, refer to 3.2 Engine Dress Cover.

6 Refer to Section 6B3 Engine Cooling – GEN III V8 and remove the following:

• Top and lower radiator hos es from the engi ne and radiator

• Radiator fan and shroud assembl y

• Radiator

7 Remove the accessory and air conditioner drive belts, refer to 3.6 Engine Drive Belts and Pulle ys.

8 Recover the refrigerant charge and disconnect the suction/discharge hose pad from the air conditioner compressor,

refer to Section 2C HVAC Climate Control (Manual A/C) – Remov al an d Installation.

Engine Mechanical Page 6A3–120

Page 6A3–120

9 Drain the engine oil into a suit able container and reinstall the drain plug once the oil has drained sufficiently.

Refer to 3.3 Engine Oil and Filter.

10 Remove the heater hose clamps at the eng ine water

pump, taking note of the hose layout. Plug the open

ends to prevent the entry of foreign material.

NOTE

If required, mark the hoses prior to removal with

a paint pen or similar.

11 Remove the ground le ad to the engine cylinder block

and from the left hand engine mount and remove the

positive terminal from the battery and lay the harness

on the engine, refer to

Section 12O Fuses, Relays and Wiring Harnesses.

Figure 6A3 – 172

12 Disconnect the air conditioning pressur e switch and

front wiring harness connector (1), which is attached to

the A/C condenser pipe (2).

13 Disconnect the Powertrain Interface Module (PIM)

wiring harness connector an d front body harness

connector. Refer to

Section 12O Fuses, Relays and Wiring Harnesses.

14 Release the harness to dash panel grommet and feed

the harness and connectors out into the engi ne bay

and place the powertrain wiring harness on top of the

engine.

15 Referring to Figure 6A3 – 174, remove or disconn ect

the following:

a Powertrain wiring harness retaining clips (1) from

the engine compartment dash pan el.

b Wiring harness connector (2) from the theft

deterrent horn.

c Cover (3) from the Powertrain Control Module

(PCM) (4).

d Two screws (5) retaining the PCM wiring

harness connectors to the PCM.

e PCM wiring harness retaining clip (6) from the

PCM container to free the harness.

Figure 6A3 – 173

Engine Mechanical Page 6A3–121

Page 6A3–121

Figure 6A3 – 174

16 De-pressurise the fuel line.

Refer to Section 8A1 Fuel System.

17 Using a small screwdriver, release the security lock

(1), at each of the fuel supply hose quick connect

fittings (2).

NOTE

The security lock at the fuel rail side is fitted with

a tether to prevent loss.

Figure 6A3 – 175

Engine Mechanical Page 6A3–122

Page 6A3–122

18 Remove the fuel line quick connector (1) from the fuel

rail, refer to Section 6C3-3 Powertrain Management –

GEN III V8 – Service Operations.

19 Disconnect the vapour line connection (2) to the EVAP

purge control valve and place it to one sid e.

NOTE

Plug all openings to prevent fuel leaking and

foreign matter from entering the fuel system.

Figure 6A3 – 176

20 Disconnect the brake booster vacuum hose (1) and

HVAC control vacuum hose (2) from the rear of the

intake manifold.

If using a hoist during the engine removal

procedure, ensure the vehicle is positioned

correctly so that it remains balanced when

the engine, transmission and crossmember

assembly is remo ved from the vehicle.

Figure 6A3 – 177

21 Raise the vehicle front and rear and su pport on safety stands or ensure the vehicle is positioned correctly on a

hoist. For the location of vehicle lifting and support locations, refer to Section 0A General Information.

22 Remove the front road wheels, refer to Section 10 Wheels and Tyres.

Do not use the tapered side of the wheel nut

as possible damage to the wheel nut and/or

stud may occur.

23 Attach holding Tool KM-468 to the front wheel hub

with two inverted wheel nuts. Support the tool on a

safety stand (1).

24 Using suitable socket equipment, loosen and remove

the driveshaft attaching nut (2) and flat washer.

NOTE

Discard the removed nut as a new nut must be

installed in the reinstallati on procedure.

25 Remove the holding tool and reinstall an inverted nut

to retain the front rotor to the hub assembly. Figure 6A3 – 178

Engine Mechanical Page 6A3–123

Page 6A3–123

26 Remove the front plastic air baffles from the front bumper and front suspension cradle, refer to

Section 6B3 Engine Cooling – GEN III V8.

27 Remove the rear propeller shaft, refer to Section 4C1 Rear Propeller Shaft and Universal Joints.

28 Disconnect the gearshift control cable from the transmission bracket and the selector lever.

Refer to Section 7C4 Automatic Transmission – 4L60E – On Vehicle Servicing.

NOTE

To prevent oil leaking from the front final drive

when the driveshaft is removed, either plug the

seal opening in the front final drive or if required,

drain the lubricant prior to removal of the

driveshaft.

29 Remove both front driveshafts from the vehicle, refer to Section 4B3 Front Final Drive and Driveshafts.

NOTE

The procedure for separating the ball joint is

included within the front driveshaft procedure.

30 With the lower ball joint disconnected, insert a suitable length wooden prop with a 'V' cut out of the outer end to

support the front suspension strut and hub assembly against the inner wheelhouse.

31 Remove the split pin from the outer tie rod end

castellated nut (1) and loosen the nut until it is flush

with the end of the tie rod end stud.

32 Using the tie rod ball joint remover Tool No. 7311 and

a ring spanner (2) separate the outer tie rod end stud

from the steering knuckle. Repeat for the op posite

side.

Figure 6A3 – 179

33 Using a second spanner, hold the stabil iser bar link

inner stud hexagonal (1). With a second spanner,

remove the nut (2) attaching the li nk (3) to the

stabiliser bar (4). Repeat for the remaini ng side.

Figure 6A3 – 180

Engine Mechanical Page 6A3–124

Page 6A3–124

Ensure the ignition key is turned to the lock

position and the key is removed before

disconnecting the steering column coupling.

This will prevent the steering column from

rotating when the coupling is removed and

damaging the clock spring.

34 Remove the lower steering co upling cam bolt retaining

nut (1) and discard.

35 Remove the cam bolt (2) from the lower coupling (3).

36 Pull on the coupling to free it from the steering rack

input shaft (4).

Figure 6A3 – 181

37 From under the vehicle, loosen the power steering

cooler line hose clamps (1) and disconnect both hoses

(2). Plug all openings to prevent fluid loss and/or dirt

entry.

Figure 6A3 – 182

38 Remove the two nuts (1) attaching the exhaust pipe

bracket to each catalytic converter.

39 Remove the two bolts (2) attaching the bracket to the

transfer case adaptor housing and remove the bracket

from the vehicle.

40 Remove the front exhaust assemblies,

refer to Section 8B Exhaust Systems.

Figure 6A3 – 183

Engine Mechanical Page 6A3–125

Page 6A3–125

41 Using a felt tipped pen or similar (e.g. Paint marker),

mark the position of the rear crossmember (1) to the

underbody side rails.

NOTE

This will assist in realigning the crossmemb er on

reinstallation.

42 Remove the four bolts (2) attaching the rear

crossmember to the underbody side rails.

43 Remove the three bolts (3) attaching the rear

crossmember to the transfer case mounting bracket

and remove the crossmember from the vehicle.

NOTE

Support of the transmission is not required at

this stage.

Figure 6A3 – 184

NOTE

A suitable size block of wood may be needed to

help support the rear of the transmission and

keep it level.

44 Using a commercially available hydraulic scissor lift mobile trolley of 750 kg capacity, pos ition the lift centrally under

the engine, transmission and crossmember assembly and support the front suspens ion cradle.

NOTE

If a suitable scissor lift is not available, an

alternative would be to use suitable lifting

equipment to support and lower the engine from

above using the two engine lifting brackets

attached to the cylinder heads. This procedure

requires the removal of the hood, refer to

Section 1A4 Hood, Rear Compartment Lid,

Liftgate and Endgate.

45 With the front suspension cradle, engine and

transmission/transfer case assembly supported,

remove the bolt (1) attaching the transfer case rubber

mount (2) to the transfer case rear mounting bracket

(3).

Figure 6A3 – 185

Engine Mechanical Page 6A3–126

Page 6A3–126

46 Using a felt tipped pen or similar (e.g. paint marker),

mark the position of the transfer case rear mounting

bracket to the vehicle underbody.

NOTE

This will assist in realigning th e mounti ng br acket

on reinstallation.

47 Remove the three bolts (1) attaching the transfer case

rear mounting bracket (2) to the vehicle underbody

and remove the rear mounting bracket from the

vehicle.

Figure 6A3 – 186

48 Mark the location of the front crossmember cradle to

the side rails and remove the four bolts (1 and 2),

attaching the crossmember cradle (3) to the side ra il

members.

NOTE

The engine is not shown in this view to clearly

show the front suspension cradle attaching bolt

locations.

49 Lower and remove the engine, transmission/transfer

case and crossmember assembly from under the

vehicle.

NOTE

During the lowering process ensure that all

wiring harnesses, hoses or other accessories

have been disconnected and are not caught by

the body or the engine, transmission/transfer

case and crossmember assembly. Figure 6A3 – 187

Engine Mechanical Page 6A3–127

Page 6A3–127

Disassemble – Ancillary Equipment

The engine removal and rei nstallation procedures cover the removal and reinstallation of the engine, transmission /

transfer case and front crossmember as a complete assembly. To perform major service operations, the engine and

transmission / transfer case has to be separated and the ancillary equipment that is attached to the engine removed.

Once all ancillary components and the transmission / transfer case have been removed, major e ngine service operations

can be performed by referring to the appropriate major service operation.

1 Remove the wiring harness conn ectors and earth connections from the engine and transmission assembl y and

carefully set the wiring harness to one side. For wiring harn ess informati on,

refer to Section 12O Fuses, Relays and Wiring Harnesses.

2 Remove the front propeller shaft from the transfer case and the front final drive,

refer to Section 4C2 Front Propeller Shaft and Universal Joints.

3 Release the indicator lock down lever (1) and remove

the transmission indicator.

4 Remove the bolt (2) attaching the transmissio n filler

tube to the right-hand cylinder head.

5 Release the transmission breather tube (3) from the

indicator bracket (arrow).

6 Using a twisting/pulling motio n, remove filler tube (3)

from transmission case seal (4). Set the filler tube to

one side.

7 Plug the filler tube opening in the automatic

transmission.

8 Remove the starter motor, refer to

Section 6D3 – 2 Starting System GEN III V8.

Figure 6A3 – 188

9 Disconnect transmission cooler lines from the

transmission end, as follows:

a Release the verifier disc (1) by pulling b ack with

your fingertips and slide th e disc back down the

cooler line (1).

b Open the cooler line releas e T ool J-41623-B and

slip it over the cooler line to be disconnected

from the transmission ahead of the verifier disc

as shown.

c Slide the release tool along the line to engage

with the quick-connect fitting.

d While pushing in wards, rotate the tool about one

sixth of a turn clockwise to release the s pring clip

holding the line.

e With the release tool held in this position, pull

back on the cooler line to release. Repeat this

process with the remaining line and quick-

connect fitting.

f Plug all openings to prevent fl uid loss and/or dirt

entry Figure 6A3 – 189

Engine Mechanical Page 6A3–128

Page 6A3–128

10 Remove the right-hand (A) and left-hand (B) close-out cover attaching bolts (1) and remove the cover (2).

Refer to Figure 6A3 – 190.

Figure 6A3 – 190

11 Remove the three bolts attaching the torque converter to the engine flexplate, using the right-hand side close-out

cover opening for access to the bolts.

12 Remove the bolt (1), eight places, attaching the

transmission housing to the engine assembly and then

slide or lift the transmission/transfer case assembly

free from the rear of the engine.

NOTE

Ensure the torque converter stays with the

transmission when the transmission is being

removed from the engine assembly.

Figure 6A3 – 191

13 Remove the nut (1), two places, attaching the

transmission cooling lines (2) to the power steering

hose bracket (3) and remove the transmission cooling

lines.

14 Remove the two bolts (4) attaching the po wer steering

hose bracket to the oil pan and lower it away from the

oil pan.

Figure 6A3 – 192

Engine Mechanical Page 6A3–129

Page 6A3–129

15 Remove the nut (1) attaching the engine mount to the

front crossmember cradle. Repeat for the other side

engine mount.

Figure 6A3 – 193

NOTE

Using suitable lifting equipment attached to the

engine lifting brackets, ensure the engine is

supported before removing the eng ine mounts.

16 Remove the three bolts (1) attaching the left-hand

engine mount bracket to the cylinder bl ock and set the

bracket and hydraulic mount, together with the heat

shield, to one side. Repeat for the other engine mount.

17 Use suitable lifting equipment fitted to the engine lifting

brackets and lift the engine clear from the front

suspension crossmember cradle

18 Mount the engine in a suitable engine stand such as

Tool No AU 591 or similar. Preferab ly, use a stand that

will mount the engine from its side usi ng the engine

mount bracket bolt holes.

Figure 6A3 – 194

19 As required, remove the following:

• Power steering reservoir and pump, refer to Section 9 Steering .

• Drive shaft bearing support and front final drive, refer to Section 4B3 Front F inal Drive and Drive Shafts.

• Exhaust manifolds, refer to 3.14 Exhaust Manifold.

• Coolant pump, refer to Section 6B3 Engine Cooling – GEN III V8.

• Ignition coils and bracket assembly,

refer to Section 6C3-3 Powertrain Management – GEN III V8 – Service Ope r ations.

• Accessory and air conditioner drive belt idler and tension pulley assembli es,

refer to 3.6 Engine Drive Belts and Pulleys.

• Remove the air conditioning compressor,

refer to Section 2B HVAC Climate Control (Manual A/C) Servicing and Diagnosis.

• Generator and mounting bracket, refer to Section 6D3-1 Charging System GEN III V8.

Engine Mechanical Page 6A3–130

Page 6A3–130

Reassemble

Reassembly of the ancillar y c ompo nents for all vehicles is the reverse of the disassemble procedure noting the following:

1 Ensure all fasteners are tightene d to the correct torque specification, refer to 7 Torque Wrench Specifications or

refer to the specific Section for the particular component bei ng installed.

2 Ensure all transmission lines where fitted and power steering lines are free from obstruction and are not rubbing on

any components.

3 Tighten the transmission to engine attach ing bolts to the correct torque specification in the reverse order of the

removal procedure, refer to Figure 6A3 – 1 91.

4 Both close-out covers are installed.

5 The transmission filler tube where fitted is in stalled and sealed in the transmission correctly.

6 Ensure the front propeller shaft is reinstalled in the correct locatio n as ma rked in the removal procedure.

Reinstall Set-up and Testing

Reinstallation of the engine, transmission/transfer case and front crossmember assembly is the reverse of removal

procedure, noting the follo wing:

1 Ensure that all fasteners where requ ir ed are either, replaced or cleaned, thread sealant is reapplied and they are

tightened to the correct torque specifications, refer to 7 Torque Wrench Specifications or refer to the specific

Section in the service information for the part icular component.

2 Use only the specified engine lubricant type and quantity.

3 Fill the cooling system with the correct quantity and grade of coolant,

refer to Section 6B3 Engine Cooling – GEN III V8

4 Check and top up the transmission fluid level, as required

refer to Section 7C4 Automatic Transmission – 4L60E – On vehicle Servicing.

5 Disable the ignition system, refer to 2.7 Compression Ch eck and then crank the engine several times. Listen for

any unusual noises or evidence that parts are binding.

6 Enable the ignition system, start the engine and listen for unusual noises.

7 Check, the vehicle oil pressure gauge or warning lamp and confirm the engin e has a n acceptable oil pressure. If

necessary, install an oil press ure ga uge and measure the engine oil pressure, refer to 2.5 Oil Pressure.

8 Run the engine speed at about 1,000 rpm until the engine has reached normal operating temperature.

9 Listen for sticking lifters and other unusual noises.

10 Check for oil, fuel, coolant and exhaust leak s while the engine is running, stopping the engine and correcting as

required.

11 Perform a final inspection for the correct engine oi l and coolant levels.

12 Reinstall the engine dress c over, refer to 3.2 Engine Dress Cover.

13 If required, ensure the engine hood alignment is correct,

refer to Section 1A4 Hood, Rear Compartment Lid, Liftgate & Endgate.

Engine Mechanical Page 6A3–131

Page 6A3–131

4.3 Oil Pan Assembly, Except AWD

LT Section No. — 00–275

Remove NOTE

Due to the critical alignment procedures required

for oil pan installation, it is strong ly recommended

the engine assembly be removed from the

vehicle before the oil pan is removed.

1 Remove the engine from the vehicle and if required, mount the engine in an engine stand such as Tool No.

AU 591. Refer to 4.1 Engine Assembly.

2 Remove the flywheel/flexplate, refer to 4.6 Engine Flywheel and Flexplate.

3 Ensure the oil pan has drained completely and if required, place a suitable sized container underneath the engine.

4 Invert the engine assembly.

5 Remove the oil pan attaching bolt (1), 14 places, by

loosening grad ually from the outside and working

inwards toward the centre.

6 Tap the oil pan side ways with a rubber mallet to

dislodge the seal.

Figure 6A3 – 195

Disassemble

Do not allow metal shavings or other foreign

material to enter the oil passages in the oil

pan during gasket removal. Plug all openings

before commencing drilling operations.

1 Use a sharp twist drill (1), drill out each of the oil pan

gasket retaining rivets (2) as required.

2 Remove the oil pan gasket (3) from the oil pan and

discard the gasket and rivets.

NOTE

The original oil pan gasket is retained and

aligned to the oil pan by rivets for production

purposes only. When installing a new gasket as

a service replacement, it is not necessary to

install new oil pan gasket rivets.

Figure 6A3 – 196

Engine Mechanical Page 6A3–132

Page 6A3–132

If the removal of the oil transfer cover

attaching nuts is required while the oil pan is

still installed (e.g. during fitment of an

external oil cooler), the studs must not be

removed. Otherwise, the transfer pipes and

gasket inside the oil pan may become

dislodged.

3 Remove the two oil transfer cover attaching nuts (1),

cover (2), and gasket (3) and discard the gasket.

4 Remove the two O-rings (4) and discard.

Figure 6A3 – 197

5 Remove the bolt (1), two places, attaching the oil filter

transfer tubes.

6 Remove the oil filter transfer tubes (2) and discard the

gaskets (3).

7 If required, remove the oil gallery plug (4).

NOTE

Due to the thread sealant applied to th e threads,

it is recommended the front studs (5) remain

attached to the transfer tube assembly and the

whole assembly withdrawn from inside the oil

pan.

Figure 6A3 – 198

8 Remove the oil pan baffle plat e (1) attaching bolts (2),

six places and remove the baffle.

Figure 6A3 – 199

Engine Mechanical Page 6A3–133

Page 6A3–133

Clean and Inspect

To avoid personal injury, wear safety glasses

and the appropriate gloves when using

compressed air and cleaning fluids.

1 Clean the oil pan in a commercially available cleaning fluid and blow dry using compressed air.

2 Ensure that all oil passages and recesses are thoroughly cleaned.

3 Clean the oil pan gasket surfaces, using a p lastic scraper to avoid scratching or damaging the machined surfaces.

4 Inspect the oil pan for the following:

• Gasket sealing surfaces for excessive scratches or go uging

• Oil pan drain plug an d threaded drain hole for damaged threads

NOTE

The drain plug O-ring seal may be reused if not

cut or damaged.

• Oil filter sealing surface (A) for scratches or

gouging

• Oil filter adaptor (1) for a loose fit or damaged

threads

• Oil passages for restrictions

• Oil filter bypass valve (2) located in the oil filter

flange for correct operation by lightly pushi ng the

bypass valve into the bore, when released the

valve spring should reseat the valve to the

proper position.

5 Inspect the oil transfer tube for damage or restrictions.

Figure 6A3 – 200

Reassemble

1 Install the oil pan baffle plate (1) and the attaching

bolt (2), six places, tightening the bolts to the correct

torque specification.

Oil pan baffle attaching bolt

torque specification............................................12.0 Nm

Figure 6A3 – 201

Engine Mechanical Page 6A3–134

Page 6A3–134

2 If removed, apply thread lock compound s uch as

Loctite 242 or equivalent to the clea ned threads of the

oil gallery plug (1).

3 Tighten the oil galler y plugs to the correct torque

specification.

Oil gallery plug

torque specification............................................25.0 Nm

4 Apply thread lock compound such as Loctite 242 or

equivalent to the cleaned threads of the oil transfer

tube attaching bolt (2), two places.

5 Install the oil filter transfer tubes (3) using new gaskets

(4).

6 Tighten the oil transfer tubes attaching bolts to the

correct torque specification.

Oil transfer tube attaching bolt

torque specification............................................12.0 Nm

Figure 6A3 – 202

7 Install two new oil transfer cover O-rings (1), gasket

(2), cover (3) and the two attaching nuts (4) to the two

oil transfer tube studs (5).

8 Tighten the attaching nuts to the correct torque

specification.

Oil transfer cover attaching nut

torque specification............................................12.0 Nm

9 If removed, install the oil filter adaptor an d tighten to

the correct torque specification.

Oil filter adaptor torque specification..................55.0 Nm

10 If required, install a new oil filter bypass valve using a

suitable size socket and hammer, by tapping the valve

in the oil filter flange to fully seat.

Figure 6A3 – 203

Reinstall

The alignment of the structural oil pan is

critical. The rear bolt hole locations of the oil

pan provide mounting points for the

transmission torque converter housing. To

ensure the rigidity of the powertrain and

correct transmission alignment, it is

important the rear of the cylinder block and

the rear of the oil pan are flush. The rear of

the oil pan must NEVER protrude beyond the

cylinder block and transmission torque

converter housing plane.

NOTE

The original oi l pan gasket is retained and aligned

to the oil pan by rivets for production purposes

only. When installing a new gasket as a service

replacement, it is not necessary to install new oil

pan gasket rivets. Do not reuse the oil pan

gasket.

Engine Mechanical Page 6A3–135

Page 6A3–135

1 Apply a 5 mm wide by 20 mm long bead of sealant (1)

such as Loctite 565 or equiv al ent directly onto the tabs

of the front cover gasket that protrude into the oil pan

surface.

Figure 6A3 – 204

2 Apply a 5 mm wide by 20 mm long bead of sealant (1)

such as Loctite 565 or equiv al ent, directly onto the

tabs of the rear cover gasket that protrude into the oil

pan surface.

Figure 6A3 – 205

Engine Mechanical Page 6A3–136

Page 6A3–136

3 Install a new oil pan gasket to the oil pan.

NOTE

Align the oil gallery passages in the oil pan and

cylinder block correctly with the oil pan gasket.

4 Install the oil pan bolt (1), 14 places to the oil pan and

through the gasket.

5 Install the oil pan, gasket and bolts to the cylinder

block and tighten the bolts finger tight.

6 Place a straight edge across the rear of the cylinder

block and the rear of the oil pan at the transmission

bell housing mounting surfaces.

7 Align the oil pan until the re ar of cylinder block and

rear of oil pan are flush or even.

8 Tighten the oil pan to front cover attaching bolts to the

correct torque specifications.

Oil pan/front cover attaching bolt

torque specification............................................25.0 Nm

Oil pan/rear cover attaching bolt

torque specification............................................12.0 Nm

9 Place a straight edge across the rear of the cylinder

block and the rear of oil pan at the transmission bell

housing mounting surfaces an d recheck the alignment.

Figure 6A3 – 206

10 Insert a feeler gauge between the straight edge and

the oil pan transmission bell housing mounting

surface. Ensure the oil pan is flush to no more than a

0.25 mm gap between the pan and straight edge (A).

NOTE

• The rear of the oil pan must never protrude

beyond the cylinder block and transmission

bell housing mounting surfaces.

• If the oil pan alignment is not within

specification, remove the oil pan and repeat

Steps 3 to 8.

11 Tighten the remaining oil pan to cylinder block

attaching bolts to the correct torque specificat ion.

Oil pan to cylinder block attaching bolt

torque specification............................................25.0 Nm

12 The remainder of the oil pan reinstallation procedure is

the reverse of the removal procedure. Figure 6A3 – 207

Engine Mechanical Page 6A3–137

Page 6A3–137

4.4 Oil Pan Assembly, AWD

LT Section No. — 00–275

Remove

NOTE

Due to the critical alignment procedures required

for oil pan installation, it is strong ly recommended

the engine assembly be removed from the

vehicle before the oil pan is removed.

1 Remove the engine from the vehicle and if required, mount the engine in an engine stand such as Tool No.

AU 591. Refer to 4.1 Engine Assembly.

2 Ensure the oil has drained co mpletely and if required, place a suitable sized container underneath the engine.

NOTE

This procedure will have removed the front final

drive and the driveshaft support bearing

assembly from the engine oil pan.

3 Remove the flexplate, refer to 4.6 Engine Flywheel and F le x plate.

NOTE

Removal of the flexplate is necessary to remove

the engine oil pan.

4 Invert the engine assembly.

5 Remove the engine oil pan attaching bolt (1), 14

places, loosening gra dually from the outside and

working towards the centre.

6 Use a rubber mallet to tap the sides of the engi ne oil

pan to dislodge the seal.

7 Lift the engine oil pan clear of the c ylinder block while

moving oil pan to the rear to clear the oil pick-up pipe

and screen from the baffle.

8 Lift the engine oil pan clear from the c ylinder block.

Figure 6A3 – 208

Engine Mechanical Page 6A3–138

Page 6A3–138

Disassemble

Plug all openings before removal of the

original gasket rivets, to prevent metal

shavings or other foreign material from

entering the oil passages in the oil pan.

NOTE

• The original oil pan gasket is retained and

aligned to the oil pan by pop rivets. When

reinstalling a new gasket as a service

replacement, it is not necessar y to install ne w

oil pan gasket rivets.

• If removal of the oil transfer cover nuts is

required while the o il pan is still installed (e. g.

during the fitment of an external oil cooler),

hold the studs with an E5 Torx bit to prevent

the studs from being loosened or removed. If

the studs are removed, the internal oi l transfer

tube gasket can become dislodged.

1 Use a sharp twist drill (1) to drill out each of the

retaining rivets (2) as required.

2 Remove the oil pan gasket (3) from the oil pan and

discard the gasket and rivets.

Figure 6A3 – 209

3 Remove the two oil transfer cover attaching nuts (1),

cover (2) and gasket (3) from the front of the oil pan.

Discard the removed gasket (3).

4 Remove both oil filter transfer tube studs (4) using an

E5 Torx bit.

NOTE

Removal of the transfer tubes without removing

the two studs is not possible.

Figure 6A3 – 210

Engine Mechanical Page 6A3–139

Page 6A3–139

5 Remove the two oil transfer tube attaching bolts (1).

6 Remove the oil transfer tubes (2) and discard the two

gaskets (3).

7 If required, use an Allen key to remove the oil gallery

plugs (4).

Figure 6A3 – 211

Clean and Inspect

To avoid personal injury, wear safety glasses

and the appropriate gloves when using

compressed air and cleaning fluids.

1 Clean the oil pan in a comme r cially available cleaning fluid and ensur e that all oil passages and recesses are

thoroughly cleaned and blow dry using compressed air.

2 Clean the oil pan gasket surfaces using a plastic scraper to avoid scratching or damaging the machined surfaces.

3 Inspect the oil pan for:

• Gasket sealing surfaces for excessive scratches or go uging.

• Oil pan drain plug and threaded drain hole for damaged threads. T he drain plug O-ring seal may be reused if

it is not cut or damaged.

• Oil filter sealing surface (1) for scratches or

gouging.

• Oil filter adaptor (2) for a loose fit or damaged

threads.

• Oil passages for restrictions.

• Oil filter bypass valve (3) in the oil filter flange for

proper operation Lightly pus h the bypass valve

into the bore. The valve spring should res ea t the

valve to the proper position.

• Check the cup plug installed in drilling (4) is in

place and secure.

4 Inspect the oil transfer tubes for damage or

restrictions.

Figure 6A3 – 212

Engine Mechanical Page 6A3–140

Page 6A3–140

Reassemble

1 If removed, apply thread lock compound s uch as

Loctite 242 or equivalent to the clea ned threads of the

oil gallery plug (1).

2 Use an Allen key and tighten the oil gallery plug to the

correct torque specification.

Oil gallery plug

torque specification............................................25.0 Nm

3 Install two new oil transfer tube gaskets (2) and the oil

transfer tubes (3) to the oil pan.

4 Apply thread lock compound such as Loctite 242 or

equivalent to the cleaned threads of the oil transfer

tube bolts and studs.

5 Install the two oil transfer tube attaching bolts (4) and

studs, tightening to the correct torque specification.

Oil transfer tube bolt

and stud torque specification .............................12.0 Nm

Figure 6A3 – 213

6 Install a new oil pan transfer cover gasket (1), cover

(2) and nuts (3).

7 While holding the studs (4) with an E5 Torx socket,

tighten the nuts to the correct torque specification.

Oil transfer cover nut

torque specification............................................12.0 Nm

8 If removed, reinstall the oil filter adaptor an d tighten to

the correct torque specification.

Refer to Figure 6A3 – 212

Oil filter adaptor

torque specification............................................55.0 Nm

9 If required, install a new oil filter bypass valve, using a

suitable size socket and hammer to fully seat the valve

in the oil filter flange of the oil pan.

Figure 6A3 – 214

Engine Mechanical Page 6A3–141

Page 6A3–141

Reinstall

The alignment of the structural oil pan is

critical. The rear bolt hole locations of the oil

pan provide mounting points for the

transmission torque converter housing. To

ensure the rigidity of the powertrain and

correct transmission alignment, it is

important the rear of the cylinder block and

the rear of the oil pan are flush. The rear of

the oil pan must NEVER protrude beyond the

cylinder block and transmission torque

converter housing plane.

NOTE

The original oi l pan gasket is retained and aligned

to the oil pan by rivets for production purposes

only. When installing a new gasket as a service

replacement, it is not necessary to install new oil

pan gasket rivets.

1 Apply a 5 mm wide bead of sealant (1) such as Loctite

565 or equivalent, 20 mm long to the cylinder block.

Apply the sealant directly onto the tabs of the front

cover gasket that protrude into the oil pan surface.

Figure 6A3 – 215

2 Apply a 5 mm wide bead of sealant (1) such as Loctite

565 or equivalent, 20 mm long, to the cylinder block,

as shown. Apply the sealant directly onto the tabs of

the rear cover gasket that protrude into the oil pan

surface.

Figure 6A3 – 216

Engine Mechanical Page 6A3–142

Page 6A3–142

3 Install a new oil pan gasket to the oil pan.

NOTE

Align the oil gallery passages in the oil pan and

cylinder block properly with the oil pan gasket. It

is not necessary to rivet the new gasket to the oil

pan.

4 Install the oil pan bolt, 14 places to the oil p an and

through the gasket.

5 Install the oil pan, gasket and bolts to the cylinder

block and tighten the bolts finger tight.

6 Place a straight edge across the rear of the cylinder

block and the rear of the oil pan at the transmission

torque converter housing mounting surfaces.

7 Align the oil pan until the re ar of cylinder block and the

rear of oil pan are flush or even.

8 Install the oil pan to front cover bolts and the oil pan to

rear cover bolts, tightening to the correct torque

specification.

Oil pan to front cover attaching bolt

torque specification............................................25.0 Nm

Oil pan to rear cover attaching bolt

torque specification............................................12.0 Nm

Figure 6A3 – 217

NOTE

This preliminary step is needed to avoid oil pan

creep and creating a misalig nment condition.

9 Place a straight edge across the rear of the cylinder

block and the rear of oil pan at the transmission torque

converter housing mounting surfaces and recheck the

alignment.

10 Insert a feeler gauge between the straight edge and

the oil pan transmission bell housing mounting

surface. Ensure the oil pan is flush with no more than

a 0.25 mm gap between the pan and straight edge (A).

11 If the oil pan alignment is not within specification,

remove the oil pan and repeat Steps 5 to 10.

12 Remainder of the reinstallation process is the reverse

of the removal procedure.

Figure 6A3 – 218

Engine Mechanical Page 6A3–143

Page 6A3–143

4.5 Engine Front Cover

LT Section No. — 00–325

Remove

NOTE

Due to critical alignment procedures required for

the reinstallation of the front cover and oil pan, it

is strongly recommended the engine assembly is

removed from the vehicle, before oil pan removal.

1 Remove the coolant pump, refer to Section 6B3 Engine Cooling – GEN III V8.

2 Remove the engine oil pan, refer to 4.3 Oil Pan Assembly, Except AWD or 4.4 Oil Pan Assembly, AWD.

3 Remove the crankshaft balancer, refer to 3.17 Crankshaft Balancer.

4 Remove the bolt (1), eight places, attaching the front

engine cover (2) to the cylinder block.

5 Remove the front cover and gasket (3).

Figure 6A3 – 219

Clean and Inspect

1 Prise the old oil seal from the front cover and discard.

To avoid personal injury, wear safety glasses

and the appropriate gloves when using

compressed air and cleaning fluids.

2 Clean the front cover in a commercially available cleaning fluid and blow dry with compressed air.

3 Inspect the front cover sealing surfaces for excessiv e scra tches and/or gouges.

4 Inspect the front cover gasket for damage to the membrane or distortion to the aluminium carrier.

5 Inspect the front cover to oil pan threaded holes for damaged threads or debris, refer to 5 Thread Repair if

rectification is required.

6 Inspect the front cover crankshaft oil seal bore for damage.

Engine Mechanical Page 6A3–144

Page 6A3–144

Reinstall

Prior to reinstallation of the engine front cover, observe the follo wing:

• Do not reuse the crankshaft oil seal.

• Do not apply any type of sealant to the front cover gasket.

• The special tools in this procedure must be used to correctly align the engine front cover at the oil pan surface and

to centre the crankshaft front oil seal.

• All gasket surfaces should be free of oil or other foreign material during assembly.

• The crankshaft front oil seal must be centred in relation to the crankshaft.

• The oil pan sealing surface at the front cover and cylinder block must also be aligned within specificatio ns.

• An incorrectly aligned front cover may caus e premature front oil seal wear and/or engine assembly oil leaks.

1 Install the front cover attaching bolt (1), eight places,

through the front cover (2) and gasket (3).

2 Install the front cover with the bolts and gasket and

finger tighten the bolts.

Figure 6A3 – 220

3 Assemble alignment Tool No. J 41480 to the front

cover and install the bolts (1) (part of Tool No. J

41480) in the locations shown, but do not tighten.

4 Install the two bolts (2) from alignment Tool No

J 41480 to the cylinder block and tighten to the

correct torque specification.

Front cover alignment tool to cylinder block

attaching bolt torque specification......................25.0 Nm

Figure 6A3 – 221

Engine Mechanical Page 6A3–145

Page 6A3–145

5 Install the centralising Tool J 41476 and hold it in

position by hand. Align the tapered legs of th e tool

with the machined alignment surfaces on the front

cover.

NOTE

Do not tighten the crankshaft balancer bolt to

retain the alignment tool. If the bolt is installed

and over-tightened the alignment tool will be

damaged.

6 Tighten the bolt (1), two places, attaching Tool No.

J 41480 to the front cover to the specified torque.

Alignment tool to front cover

bolt torque specification.....................................25.0 Nm

7 Tighten the engine front cover attaching bolts (2) to

the correct torque specification.

Engine front cover attaching bolt

torque specification............................................25.0 Nm

8 Remove the alignment tools. Figure 6A3 – 222

9 Measure the oil pan surface to front cover for

flatness, as follows:

a Place a straight edge across the cylinder block

and front cover oil pan sealin g surfaces. Avoid

contact with the portion of the gasket that

protrudes into the oil pan surface.

b Insert a feeler gauge between the front cover

and the straight edge tool. T he clear ance

should not exceed 0.25 mm (A).

c If the front cover-to-cylinder block oil pan

surface alignment is not within specifications,

repeat the cover alignment procedure.

10 If the correct front cover to cylinder block alignment

cannot be obtained, replace the front cover.

11 Install crankshaft front oil seal.

Refer to 3.18 Crankshaft Front Oil Seal.

12 Install the crankshaft balancer,

refer to 3.17 Crankshaft Balancer.

13 Reinstall the oil pan. Refer to 4.3 Oil Pan.

Figure 6A3 – 223

Engine Mechanical Page 6A3–146

Page 6A3–146

4.6 Engine Flywheel and Flexplate

LT Section No. — 00–400

Remove NOTE

If replacing a flywheel, note the location of any

existing balance weight pins relative to the

position of the flywheel locating hole. Use a

suitable pin punch and remove the pins from the

old flywheel and then reinstall them in the same

relative location in the replacement part.

Balance weight pins are fitted to the flywheel where they are required to balance the crankshaft/flywheel assembly of

engines that have been dynamically balanced at manufacture. Hence the need to reinstall them to the new flywheel in

the same position.

A correctly installed balance weight pin will be either flush or just below flush with the machined s urface of the flywheel.

NOTE

• Observe the position and direction of the

engine flywheel before removal. The flexplate

does not use a locating pin for alignment.

Mark or scribe the end of the crankshaft and

the flywheel before component removal. The

engine flywheel must be reinstalled to the

original position and direction.

• The flywheel/flexplate will not initially seat

against the crankshaft flange but will be pulled

onto the crankshaft by the attaching bolts as

they are progressively tightened. This

procedure requires a three stage tightening

process.

1 If this operation is to be carried out with the engine installed in the vehicle, remove the transmission and/or clutch

assembly. Refer to:

• Section 7B2 Manual Transmission – GEN III V8 or

• Section 7C4 Automatic Transmission – 4L60E – On vehicle Servicing

2 For manual transmission vehicles, remove the clutch assembl y, refer to Section 7A3 Clutch – GEN III V8.

3 Mark or scribe the end of the crankshaft and the flywheel/flexplate with a marker pen or similar.

4 Remove the bolt (1), six places, attaching either the

engine flywheel or flexplate to the rear of the

crankshaft and then remove the engine

flywheel/flexplate from the crankshaft.

Figure 6A3 – 224

Engine Mechanical Page 6A3–147

Page 6A3–147

Clean and Inspect

Throughout this Section, cleaning fluids and

compressed air are used in the service

procedure. Where compressed air and

cleaning fluids are to be used, wear safety

glasses and the appropriate gloves to avoid

personal injury.

Crankshaft

1 Inspect the threaded holes in the crankshaft for damaged threads. Any damage to the threads will require a

replacement crankshaft.

2 Clean the threads of any remaining thread locking compound using a commercially available cleaning fluid a nd

blow dry using compressed air.

Flywheel

1 Clean the flywheel in a commercially available

cleaning fluid and bl ow dry using compressed air.

2 Inspect the flywheel for loose or incorrectly install ed

balance weights (if applicable). A correctly installed

balance weight should be either flush or below the

machined surface of the flywheel.

3 Inspect the flywheel for the following:

• Damaged ring gear teeth (1)

• Grooves or scoring (2)

• Rusted surface (3)

• Pitted surfaces (4)

• Damaged clutch plate bolt holes

• Loose or incorrectly positioned ring gear. The

ring gear is an interference fit onto the flywheel

and should be positione d completely against the

flange of the flywheel.

• Missing, bent or damaged pre ssure plate

locating pins. The two locating pins are pressed

into the flywheel and are spaced 170° apart.

NOTE

In order to maintain the correct component

balance, contact surface tape r and heat transfer,

the flywheel must not be machined. If the

flywheel is damaged, it must be replaced.

Figure 6A3 – 225

Engine Mechanical Page 6A3–148

Page 6A3–148

Flexplate

1 Inspect the flexplate for the following:

• Damaged ring gear teeth (1)

• Elongation of the crankshaft or torque converter

bolt holes (2)

• Stress cracks around the crankshaft or torque

converter bolt hole locations (3)

• Cracks between pressing holes (4)

• Welded areas that retain the ring gear to the

flexplate for cracks

NOTE

Do not attempt to repair any welded areas that

retain the ring gear to the flexplate. Replace the

flexplate assembly if any welds are cracked or

damage is found.

Figure 6A3 – 226

Reinstall

NOTE

Balance weight pins ar e fitted to the flywheels of

engines that have been dynamically balanced at

manufacture. It is important to reinstall them to

the new flywheel in the same position. A

correctly installed balance weight pin will be

either flush or below flush with the machined

surface of the flywheel.

1 If replacing the flywheel, install any balance weights as

required in the same locations as noted on the old

flywheel.

2 Use the flywheel locating hol e as a reference and

scribe an alignment mark corresponding to the one on

the original flywheel.

3 Clean the threads in the crankshaft and ens ure there

is no remaining encapsul ated sealer remaining in the

holes.

4 Install the flywheel/flexplate aligning the scribed marks

on the crankshaft and the flywheel/fle xplate.

NOTE

Do not reuse the flywheel/flexplate bolts. Only

new bolts are to be used when reinstalling the

flywheel/flexplate.

5 Install new flywheel/flexplate bolts and tig hten to the

correct Stage 1 torque specification.

Refer to Figure 6A3 – 229.

 Flywheel/flexplate torque specification

Stage 1 ..............................................................20.0 Nm

Figure 6A3 – 227

Engine Mechanical Page 6A3–149

Page 6A3–149

6 Install the ring gear holding Tool No. J 4238 6-A, using

the two starter motor attaching bolts. Tighten both

bolts to the correct torque specification.

NOTE

Ensure the teeth of the holding tool engage

correctly with the ring gear teeth, before

tightening the fasteners.

Tool No J 42386-A attaching bolt

torque specification............................................50.0 Nm

Figure 6A3 – 228

7 Continue to tighten the flywheel/flexplate bolts in

sequence in two additional stages to the correct torque

specification.

 Flywheel/Flexplate attaching bolt torque specification

Stage 2 ..............................................................50.0 Nm

Stage 3 ............................................................100.0 Nm

8 Reinstall the clutch and/or transmission, as required.

Refer to either:

• Section 7A3 Clutch – GEN III V8

• Section 7B2 Manual Transmission – GEN III V8

• Section 7C4 Automatic Transmission – 4L60E –

On vehicle Servicing

Figure 6A3 – 229

Engine Mechanical Page 6A3–150

Page 6A3–150

4.7 Crankshaft Spigot Bearing

LT Section No. — 00–200

Remove

Disconnection of the battery affects certain

vehicle electronic systems. Refer to

Section 00 Warnings Cautions and Notes

before disconnecting the battery.

1 Disconnect the ground battery cable termi nal from the battery.

2 Remove the manual transmission and the clutch assembly,

Refer to Section 7B2 Manual Transmission – GEN III V8 and Section 7A3 Clutch – GEN III V8.

3 Using the Tool No. J 23907, (also released as Tool

No. 6A22-2 and the slide hammer Tool No. 7A28) or

equivalent, remove the spigot bearing from the rear of

the crankshaft and discard the removed bea r ing.

Figure 6A3 – 230

Reinstall

1 Check the crankshaft rear oil galler y plug (1) is not a

loose fit, damaged or leaking.

2 If replacement is required, apply sealant such as

Loctite 242 or equivalent, to the sid es of a n ew plug

and install it to the correct depth.

NOTE

Ensure the crankshaft rear oil gallery plug depth

A is fitted to the correct depth of 31.2

to 31.6 mm.

Figure 6A3 – 231

Engine Mechanical Page 6A3–151

Page 6A3–151

3 Using a suitable stepped driver such as Tool J 38836,

install the replacement bearing (1) to the rear of the

crankshaft using a flat washer (2) against the tool to

support the bearing races. Install the bearing until it is

flush with the crankshaft counter-bore.

4 Reinstall the clutch assembly and manual

transmission, refer to

Section 7B2 Manual Transmission – GEN III V8 and

Section 7A3 Clutch – GEN III V8.

5 Reconnect the battery ground lead, refer to

Section 00 Warnings, Cautions and Notes .

Figure 6A3 – 232

Engine Mechanical Page 6A3–152

Page 6A3–152

4.8 Engine Rear Cover

LT Section No. — 00–200

Remove

NOTE

Due to the critical alignment procedures required

for the reinstallation of the rear cover an d oil pan,

it is strongly recommended the engine assembly

be removed from the vehicle before oil pan

removal.

1 Remove the oil pan, refer to 4.3 Oil Pan.

2 Remove the flywheel/flexplate, refer to 4.6 Engine Flywheel and Flexplate.

3 Remove the bolt (1), 12 places, attaching the engi ne

rear cover (2) and remove the rear cover and gasket

(3).

4 Prise the rear main oil seal (4) from the rear cover

taking care not to distort the cover or scratch the oil

seal bore in the cover.

Figure 6A3 – 233

Clean and Inspect

To avoid personal injury, wear safety glasses

and the appropriate gloves when using

compressed air and cleaning fluids.

1 Clean the cover in a commercially available cleaning fluid and blow dry with compressed air.

2 Inspect the gasket sealing surface for e xcessive scratching or gouging.

3 Inspect the gasket for damage to the seal membrane or distortion to the al uminium carrier.

4 Inspect the cover to oil pan threaded h oles fo r debris or damage. Refer to 5 Thread Repair if rectification is

required.

5 Inspect the rear main oil seal bore for damage.

Techline

Engine Mechanical Page 6A3–153

Page 6A3–153

Reinstall

Observe the following prior to reinstallati on:

• Do not reuse the crankshaft rear oil seal.

• Do not apply any type of sealant to the rear cover gasket.

• The special tools in this procedure are used to correctly align the engine rear cover at the oil pan surface and to

centre the crankshaft rear main oil seal.

• All gasket surfaces should be free of oil or other foreign material during assembly.

• The crankshaft rear oil seal must be centred in relation to the crankshaft and is to be installed after the rear cover

installation.

• The oil pan sealing surface at the rear cover and cylinder block must also be aligned within specifications.

• An improperly aligned rear cover may cause premature oil seal wear and/or engine assembly oil leaks.

1 Install the rear cover (2) and gasket (3) to the rear of

the engine.

2 Install the rear cover attaching bolt (1), 12 plac es, and

tighten the rear cover bolts finger tight onl y at this

stage.

NOTE

Do not install the rear main oil seal (4) at this

stage.

Figure 6A3 – 234

3 Assemble the alignment Tool No. J 41480 to the rear

cover and tighten the two attaching bolts (1) finger

tight.

4 Install the attaching bolts (2) to the cylinder block and

tighten to the specified torque.

Rear cover alignment tool to cylinder block

attaching bolt torque specification......................25.0 Nm

Figure 6A3 – 235

Engine Mechanical Page 6A3–154

Page 6A3–154

5 Rotate the crankshaft until two opposing

flywheel/flexplate mounting bolt holes are parallel to

the oil pan surface of the cylin der block.

6 Install the alignment Tool No. J 41476 to the rear of

the crankshaft.

NOTE

The tapered legs of the alignment tool must

enter the rear cover oil seal bore.

7 Install the two screws (1) supplied with Tool No.

J 41476 and tighten firmly with a screwdriver.

Figure 6A3 – 236

8 Tighten the alignment Tool No. J 41480 to the rear

cover to the correct torque specification.

Rear cover alignment tool to rear cover

attaching bolt torque specification......................12.0 Nm

9 Tighten the engine rear cover attaching bolts (1) to the

correct torque specification.

Engine rear cover attaching bolt

torque specification............................................25.0 Nm

10 Remove the alignment tools.

Figure 6A3 – 237

Engine Mechanical Page 6A3–155

Page 6A3–155

11 Measure the oil pan surface to rear cover for flatness

as follows:

• Place a straight edge across the cylinder block

and rear cover oil pan seali ng surfaces. Avoid

contact with the portion of the gasket that

protrudes into the oil pan surface.

• Insert a feeler gauge between the rear cover and

the straight edge tool. The cover must be flush

with the oil pan surface to no more than

0.25 mm (A).

• If the rear cover-to-cylinder block oil pan surface

alignment is not within specification, repeat the

cover alignment procedure.

NOTE

If the correct rear cover to cylinder block

alignment cannot be obtained, replace the rear

cover.

Figure 6A3 – 238

Crankshaft Rear Main Oil Seal

Install

NOTE

Do not lubricate the oil seal inside diameter (ID)

or the crankshaft seal surface.

For further information, refer to

1.5 Engine Lubrication System.

1 Lubricate the outer edge of the oil seal (1) (OD) with

clean engine oil.

2 Lubricate the engine rear c over oil se al bore (2) with

clean engine oil.

3 Install the cone (3) of installation Tool No. J 41479

with bolts, to the rear of the crankshaft. Tighten the

bolts until secure.

4 Install a new oil seal onto the taper of the installation

tool and push the seal to the rear cover bore.

5 Position Tool No. 41479 into the tapered part until the

tool contacts the oil seal.

6 Align the oil seal with the tool then rotate the handle of

the tool clockwise until the seal enters then bottoms

into the rear cover bore.

7 Remove both parts of the installation tool.

8 Reinstall the flywheel.

Refer to 4.6 Engine Flywheel and Flexplate.

9 Reinstall the clutch and/or transmission. Refer to

either:

• Section 7B2 Manual Transmission – GEN III V8

• Section 7A3 Clutch – GEN III V8

• Section 7C4 Automatic Transmission – 4L60E –

On vehicle Servicing

Figure 6A3 – 239

Engine Mechanical Page 6A3–156

Page 6A3–156

4.9 Oil Pump, Pump Screen and Deflector

LT Section No. — 00–251 and 01–500

Remove

NOTE

Due to the critical alignment procedures required

for the reinstallation of the rear cover an d oil pan,

it is strongly recommended the engine assembly

be removed from the vehicle before oil pan

removal.

1 Remove the engine front cover, refer to 4.5 Engine Front Cover.

2 Remove the oil pump pick-up screen and tube

attaching screw (1) and crankshaft oil deflector

attaching nut (2), which also attaches the oil pump

pick-up screen and tube to the cylinder block.

3 Remove the oil pump pick-up screen and tube

assembly and the O-ring seal (3) from the oil pump

bore. Discard the O-ring.

Figure 6A3 – 240

4 Remove the remaining cranks haft oil deflector

attaching nuts, nine places.

5 Remove the crankshaft oil deflector (1), noting the

cover orientation is stamped "REAR" (2) to assist in

the correct installation.

Figure 6A3 – 241

Engine Mechanical Page 6A3–157

Page 6A3–157

6 Remove the bolt (1), four places, attaching the oil

pump to the front of the engine and remove t he oil

pump from the crankshaft.

7 If the oil pump is not being serviced, plug all openings

to avoid the entry of foreign material in the system.

Figure 6A3 – 242

Oil Pump Disassemble

1 Remove the bolt (1), seven places, attaching the oil

pump cover to the pump and remove the cover.

Figure 6A3 – 243

NOTE

Prior to disassembly, mark or identify the

relationship of the gears for reassembly.

2 Remove the inner drive gear (1) and the outer driven

ring (2), from the oil pump body.

Figure 6A3 – 244

Engine Mechanical Page 6A3–158

Page 6A3–158

3 Unscrew the oil pressure relief valve plug (1) and

remove the spring (2), and valve (3) from the oil pump

body.

Figure 6A3 – 245

Clean and Inspect

With the exception of the oil p r essure relief valve spring there are no parts in the oil pump or the oil pump pick-up screen

and pipe that are serviced separately. If either component is found to be worn or damaged the assembly must be

replaced.

To avoid personal injury, wear safety glasses

and the appropriate gloves when using

compressed air and cleaning fluids.

1 Clean all parts in a commerciall y avai lable cleaning fluid and blow dry using compressed air.

2 Inspect the following components:

a Oil pump housing for cracks, excessive wear, scoring or casting imperfections.

b Oil pump housing to cylinder block oil gallery surface for scratches or gouging.

c Inspect the oil pump housing for damag ed bolt hole threads Refer to 5 Thread Repair, if repairs are required.

d Oil pump relief valve plug and bore for scratched or damaged surfaces and the screw thread for damage. The

pressure relief valve must be able to move freely within its bore with no restrictions.

e Oil pump internal oil passages for restrictions.

f Inspect the drive and driven gears for chipping or wear. Minor burrs or imperfections on the gears can be

removed with a fine oil stone.

g Inner gear drive splines for excessive wear.

h Oil pump pick-up screen and pipe assembly and replace if either of the following conditions are observed.

• Oil pump pick-up screen is clogg ed with debris or restriction.

• Screen mesh is broken or has loose stran ds.

Oil Pump Reassemble

Reassembly of the oil pump is the reverse of the disassemble procedure, noting the following:

1 Liberally coat all oil pump components with clean engine oil before assembly.

2 When assembling the oil pump, ensure the relationship of the inner to the outer oil pump gears is matched as

marked in the removal procedure.

3 Tighten the oil pump cover attaching screws to the correct torque specification.

Oil pump cover/pump body attaching bolt

torque specification............................................12.0 Nm

4 Install a new pressure relief valve spri ng.

5 Tighten the pressure relief valv e plug to the correct torque specification.

Oil pump pressure relief plug

torque specification............................................12.0 Nm

6 Rotate the assembled pump checking for smoothness of operation by rotating the inner drive gear.

Engine Mechanical Page 6A3–159

Page 6A3–159

Reinstall

1 Ensure the oil pump and c ylinder block oil gallery

passages are free from any debris or fore ign material.

2 Align the splined surfaces of the crankshaft sprocket

and the oil pump drive gear and install the oil pump

onto the sprocket until the pu m p housing contacts the

face of the cylinder block.

3 Install the two oil pump attaching bolts (1) an d tighten

to the correct torque specification.

Oil pump attaching bolt

torque specification............................................25.0 Nm

Figure 6A3 – 246

4 Install the crankshaft oil deflector (1), ensuri ng the

"REAR" stamping (2) on the deflector is located at the

rear of the engine.

Figure 6A3 – 247

5 Lubricate a new oil pump pic k-up tube O-ring (1) with

clean engine oil and install into the oil pump pick-up

tube (2).

6 Fully install the pick-up tube into the oil p ump housing

aligning the support bracket with the main bearing cap

stud.

7 Install the pick-up tube attaching screw (3) and tighten

to the correct torque specification.

Oil pump pick-up tube attaching screw

torque specification............................................12.0 Nm

NOTE

Ensure the pick-up tube is fully installed before

tightening the attaching screw.

8 Install the crankshaft oil deflector attaching nut (4) 10

places, to the main bearing cap studs and tighten to

the correct torque specification.

Crankcase oil deflector attaching nut

torque specification............................................25.0 Nm

9 Reinstall the front engin e cover,

refer to 4.5 Engine Front Cover.

Figure 6A3 – 248

Engine Mechanical Page 6A3–160

Page 6A3–160

4.10 Timing Chain and Sprockets

LT Section No. — 00–225

Remove

NOTE

Due to the critical alignment procedures required

for the reinstallation of the engine front cover and

oil pan, it is strongly recommended the engine

assembly be removed from the vehicle before oil

pan removal.

1 Remove the harmonic balancer and front engine cover, refer to 4.5 Engine Front Cover.

2 Temporarily install the harmonic balancer bolt and turn

the engine over by hand until the timing marks on the

crankshaft and camshaft sprockets are aligned.

3 Remove the oil pump,

refer to 4.9 Oil Pump, Pump Screen and Deflector.

Figure 6A3 – 249

4 Remove the bolt (1), two places, attaching the timing

chain dampener (2) to the cylinder block.

5 Remove the three camshaft sprocket attaching bolts

(3) and then remove the sprocket (4) and chain (5)

from the camshaft and crankshaft (6).

Figure 6A3 – 250

Engine Mechanical Page 6A3–161

Page 6A3–161

6 Use Tool No’s J 41558, J 41816-2, the b olts from

J 1427-01 and puller J 8433-1 to remove the

crankshaft sprocket from the nose of the crankshaft

7 If required, remove the crankshaft timing sprocket

drive key from the crankshaft nose.

Figure 6A3 – 251

Clean and Inspect

To avoid personal injury, wear safety glasses

and the appropriate gloves when using

compressed air and cleaning fluids.

1 Clean the timing sprockets and timing chain in

commercially available cleaning fluid and blow dry with

compressed air.

2 Inspect the timing chain for binding or wear.

3 Inspect the camshaft and crankshaft sprockets for:

• Worn teeth (1)

• Damaged teeth (2)

• Chipped teeth (3)

• Worn valleys between the sprocket teeth

Figure 6A3 – 252

Engine Mechanical Page 6A3–162

Page 6A3–162

4 Inspect the crankshaft timing sprocket keyway (1) for

wear.

5 Inspect the crankshaft timing sprocket oil pump drive

splines (2) for wear.

NOTE

Replace any worn parts with new components.

Although not mandatory, it is also rec ommended

the timing gears and chain be relaced as a

complete set.

Figure 6A3 – 253

Reinstall

1 If removed, reinstall the crankshaft sprocket drive

keyway into the crankshaft. The key should be tapped

into place until each end bottoms on the crankshaft.

2 Reinstall the crankshaft sprocket onto the cranksh aft

aligning the keyway with the key.

Figure 6A3 – 254

3 Use the installer Tool No. J 41665 to reinsta ll the

crankshaft sprocket, as follows:

a Install the threaded bolt, nut and flat washer from

Tool No. J 41478 through the end plate and

stepped sleeve of Tool No. J 41665-1.

b Screw the threaded bolt into the crankshaft,

using a spanner (1).

c While holding the threade d bo lt with the spanner,

turn the nut with a second set spanner (2),

moving the installer Tool No. J 41665 to fully

install the crankshaft sprocket onto the

crankshaft nose.

d When the crankshaft sprocket has been fully

installed, remove the installation tools.

Figure 6A3 – 255

Engine Mechanical Page 6A3–163

Page 6A3–163

4 If required, temporarily reinstall the harmo nic balancer

bolt and rotate the crankshaft until the cranks haft and

camshaft timing gears are aligned

5 If required, temporarily install the camshaft sprocket

bolts and use a suitable lever to carefully rotate the

camshaft sprocket until the timing mark is correctl y

aligned. Remove the bolts and sprocket.

6 Install the timing chain to the camshaft sprocket. Align

the camshaft peg with the camshaft sprocket hole and

then install the timing chain to the cranksh aft sprocket.

7 Install the camshaft sprocket over the camshaft peg.

8 Before installing the camshaft sprocket attaching bolts,

check the timing marks are aligned. If not, repeat

Steps 4 to 8 above.

Figure 6A4 – 256

9 Install the camshaft sprocket attaching bolts and tighten to the correct torque specification.

Camshaft sprocket attaching bolt

torque specification.................................30.0 – 35.0 Nm

10 Reinstall the timing chain dampener and tighten the two attaching bolts to the correct torque specification.

Timing chain dampener attaching

attaching bolt torque specification...........30.0 – 40.0 Nm

11 Reinstall the oil pump, refer to 4.9 Oil Pump, Pump Screen and Deflector.

12 Reinstall the front cover and harmonic balancer. Refer to 4.5 Engine Front Cover.

Engine Mechanical Page 6A3–164

Page 6A3–164

4.11 Camshaft

LT Section No. — 00–175

Remove

NOTE

• Due to the critical alignment procedures

required for the reinstallation of the engine

front cover and the oil pan, it i s recommended

the engine assembly be removed from the

vehicle before oil pan removal.

• If required, before removing the camshaft

perform a camshaft lobe lift test,

refer to 3.10 Camshaft Lobe Lift.

1 Remove the hydraulic valve lifters, refer to 3.16 Hydraulic Valve Lifters.

2 Remove the front engine cover, refer to 4.5 Engine F ront Cover.

3 Remove the bolt (1), attaching the camshaft sensor

and remove the sensor from the cylinder block by

twisting and applying a slight upward pressure.

4 Remove the oil pump,

refer to 4.9 Oil Pump, Pump Screen and Deflector.

5 Remove the camshaft chain and sprocket.

Refer to 4.10 Timing Chain and Sprock ets .

Figure 6A3 – 257

6 Remove the camshaft retainer attaching bolt (1), four

places and remove the retainer an d gasket.

Figure 6A3 – 258

Engine Mechanical Page 6A3–165

Page 6A3–165

All camshaft bearing journals are the same

size and care must be taken when removing

the camshaft to avoid damaging the

bearings.

7 Install three, M8 x 1.25 x 100 mm bolts (e.g. removed

coolant pump bolts) in the front of the camshaft and

use as a handle to rotate and remove the camshaft

from the cylinder block.

8 Remove the three bolts from the camshaft.

Figure 6A3 – 259

Clean and Inspect

To avoid personal injury, wear safety glasses

and the appropriate gloves when using

compressed air and cleaning fluids.

NOTE

If camshaft replacement is required, the valve

lifters must also be renewed.

1 Clean all components with a commercially available

cleaning fluid and bl ow dry with compressed air.

2 Inspect the camshaft for:

• Scoring or excessive wear to the bearin g

journals (1)

• Nicks or damage to the camshaft position

reluctor ring (2)

• Damaged threads (3) or debris in the threaded

holes

• Damage to the camshaft sprocket pin (4)

• Scoring or excessive wear to the camshaft lobes

Figure 6A3 – 260

Engine Mechanical Page 6A3–166

Page 6A3–166

3 Measure the camshaft journals for wear and out-of-

round using a micrometer. Repl ace the camshaft if

either of these measurements are outsid e th e

specification.

Camshaft journal specifications:

Journal out-of-round.................................0.025 mm Max

Bearing journal diameter...........................54.99 mm Min

Figure 6A3 – 261

4 Measure the camshaft lobes for wear using a

micrometer. Replace the camshaft if any of the

camshaft lobe dimensions are not within spec ification.

Camshaft lobe wear limit:

Intake lobe diameter:

Except Coupe ...........................................46.67 mm Min

Coupe .......................................................46.21 mm Min

Exhaust lobe diameter:

Except Coupe ...........................................46.67 mm Min

Coupe .......................................................46.37 mm Min

Figure 6A3 – 262

5 Mount the camshaft either in Vee blocks or between

centres.

6 Using a suitable dial indicator, rotate the camshaft and

check the runout on the centre bearing journal.

Replace the camshaft if the runout exceeds t he

specification.

Camshaft runout specification....................0.05 mm Max

7 Inspect the camshaft retainer plate for wear or a

damaged sealing gask et. If the gasket is not cut or

damaged, it may be re-used.

Figure 6A3 – 263

Engine Mechanical Page 6A3–167

Page 6A3–167

Reinstall

1 Ensure the cylinder block mating surface is clean and

free of debris.

2 Lubricate the camshaft journals and bearings with

clean engine oil.

3 Install three M8 x 1.25 x 100 mm bolts into the

camshaft front journal (e.g. removed coolant pump

bolts).

All camshaft bearing journals are the same

size and care must be taken when reinstalling

the camshaft to avoid damaging the

bearings.

4 Using the bolts as a handle, carefully reinstall the

camshaft into the cylinder block.

5 Remove the three bolts after camshaft installation. Figure 6A3 – 264

6 Install the camshaft retainer plate with the sealing

gasket facing the cylinder block.

7 Install the camshaft retainer attaching bolt (1 ), four

places, and tighten to the correct torque specificatio n.

Camshaft retainer attaching bolt

torque specification.................................21.0 – 29.0 Nm

Figure 6A3 – 265

8 Inspect the camshaft position sensor O-ring and

replace the O-ring if it is cut or damaged.

9 Lubricate the O-ring with clean en gine oil and install it

to the sensor.

10 Install the camshaft position sensor and the attaching

bolt (1) and tighten to the correct torque specification.

Camshaft position sensor attaching bolt

torque specification............................................25.0 Nm

11 Reinstall the camshaft timing chai n and sprocket.

Refer to 4.10 Timing Chain and Sprock ets .

12 Reinstall the oil pump,

refer to 4.9 Oil Pump, Pump Screen and Deflector.

13 Reinstall the engine front cov er,

refer to 3.17 Crankshaft Balancer.

14 Reinstall the hydraulic valve lifters,

refer to 3.16 Hydraulic Valve Lifters.

Figure 6A3 – 266

Engine Mechanical Page 6A3–168

Page 6A3–168

4.12 Piston, Connecting Rod and Bearing

LT Section No. — 00–550

Remove

NOTE

Due to the critical alignment procedures required

for the reinstallation of the engine front cover and

oil pan, it is strongly recommended the engine

assembly be removed from the vehicle before oil

pan removal.

1 Remove both cylinder heads. Refer to 3.15 Cylinder Head.

2 Remove the oil pan, refer to 4.3 Oil Pan.

3 If required, remove any cylinder ridg e present with the

following procedure:

• Rotate the crankshaft until the piston to be

serviced is at the bottom of its stroke (BDC).

• Place a cloth on top of the piston.

• Use a commercially available cylinder ridge

remover to remove the cylinder ridge.

NOTE

Follow the manufacturer's operating instructions

for the ridge remover being used.

4 Rotate the crankshaft again until the piston is at the

top of its stroke (TDC).

5 Remove the cloth and any metal shavings from the

piston crown.

Figure 6A3 – 267

NOTE

Do not apply a stampin g mark on the side of the

connecting rod and/or cap as this may affect

alignment and the geometry of the assembly.

6 Using a marker pen or etching tool, mark each

connecting rod and its cap. The connecti ng rod caps

must be reassembled to the original position and

direction.

7 Mark the top of each piston to identify its specific bore.

8 Remove the connecting rod b olts loosening

progressively from side to side.

NOTE

Ensure the connecting rod bearings are

organised so the y can be installed in the original

position and location.

9 Remove each connecting rod cap. Figure 6A3 – 268

Engine Mechanical Page 6A3–169

Page 6A3–169

10 Install the guide pins, Tool No. J 41556 to the

connecting rod to be removed.

11 Use a hammer handle, li ghtly tap on the end of the

guide pin and remove the piston and connecting rod

from the cylinder bore.

Figure 6A3 – 269

12 Once removed, assemble the connectin g rod cap,

bearing shells and bolts to the matching connecting

rod.

Figure 6A3 – 270

Disassemble

1 Use a paint or marker pen and mark the orientation of

the piston to the connecting rod and the bore number

from which it was removed.

2 Using a small scre wdriver (1), carefull y prise out the

C clip (2) retaining the piston pin (3). If required,

repeat for the other circlip.

3 Remove the piston pin from the piston and connecting

rod by pushing the pin from the piston by hand.

NOTE

The piston and piston pin are a matched set an d

are not serviced separately. Mark the piston pin

to piston to ensure correct reassembly if the

original parts are to be re-used.

Figure 6A3 – 271

Engine Mechanical Page 6A3–170

Page 6A3–170

Use piston rings pliers and only expand the

piston ring sufficiently to slid e them over the

piston. Excessi ve expansion will permanently

distort the piston ring.

4 Remove the piston rings from the piston by expan din g

the ring at the end gaps in the follo wing order.

a Top compression ring (1).

b Second compression ring (2).

c Oil control upper ring (3).

d Oil control lower ring (4).

e Oil control segment ring (5).

Figure 6A3 – 272

Clean and Inspect

Piston and Pin

To avoid personal injury, wear safety glasses

and the appropriate gloves when using

compressed air and cleaning fluids.

1 Clean any varnish from the piston and pin with a

commercially available cleaning fluid. Do not use a

wire brush for this process.

2 Dry the cleaned parts using compressed air.

3 Clean the piston ring groov es wit h a commercially

available ring groove cleaning tool.

4 Clean the oil lubrication holes and slots in the ring

grooves.

Figure 6A3 – 273

5 Inspect each piston and pin for the following:

• Cracks in the piston lands, skirt or the pin bosses

• Piston ring grooves for nicks, burrs or warpage

that may cause the piston ring to bind

• Eroded areas on top of the piston (1)

• Scuffed or damaged skirts (2)

• Scoring to the piston pin bore (3) or the piston

NOTE

Minor imperfections may be removed by using a

fine file.

Figure 6A3 – 274

Engine Mechanical Page 6A3–171

Page 6A3–171

6 Insert the edge of a new piston ring into the correct

piston ring groove and roll the piston ring around the

groove.

NOTE

If binding is caused by a distorted piston ring

groove, minor ring groove imperfections may be

removed with a fine file.

7 Measure the piston ring to piston groove side

clearance by inserting a new piston ring into the

correct piston ring groove as shown.

Figure 6A3 – 275

8 Check the side clearance using a feeler g au ge. If the

side clearance excee ds specification, try another

piston ring set before replacing the piston.

NOTE

The oil control upper and lower rings must be

installed with the segment ring in order to check

the clearance.

Piston ring side clearance specification:

Top compression ring ........................ 0.040 – 0.085 mm

Second compression ring .................. 0.040 – 0.080 mm

Oil control ring.................................... 0.010 – 0.220 mm

9 If the piston ring side clearance exceeds the

specification, the piston and pin assembly must be

replaced.

Figure 6A3 – 276

NOTE

For each of the following measurem ents, ensure

the micrometer is reset to zero and the

measurements are all taken with components at

room temperature.

10 To measure the pin-to-bore clearance, first measure

the pin with a micrometer.

Piston pin diameter........................ 23.997 – 24.000 mm

Figure 6A3 – 277

Engine Mechanical Page 6A3–172

Page 6A3–172

11 Using a suitable inside microm eter, measure the

matching piston pin bore in both directions on each

side of the piston. This is to ensure the piston pin bore

has not worn unevenly.

12 Subtract the piston pin dimension from the p iston pin

bore size to obtain the clearance.

13 If the clearance exceeds the specification, the piston

and pin assembly must be replaced.

Piston pin to bore clearance

specification................................0.010 – 0.020 mm Max

Figure 6A3 – 278

14 Measure the piston for out-of-round as foll ows:

• With a suitable sized micrometer, measure the

piston skirt dimension at right angles to the

piston pin bore 11 mm above the bottom of the

skirt.

• Measure the piston at two different points and

compare the readings

• If the difference exceeds the specification,

replace the piston and pin ass embly.

Piston skirt out-of round

specification.............................................0.018 mm Max

Figure 6A3 – 279

Engine Mechanical Page 6A3–173

Page 6A3–173

Connecting Rods and Bearings

NOTE

The powdered metal connecting rod and cap are

machined for the correct clearances. The

connecting rod and the cap must be used as an

assembly, with no repairs or modific ations carried

out to either mating surface.

To avoid personal injury, wear safety glasses

and the appropriate gloves when using

compressed air and cleaning fluids.

1 Clean each connecting ro d and matching cap in a

commercially available cleaning fluid and blow dry

using compressed air.

2 Clean the connecting rod bolt threads a nd inspect for

damage. Do not attempt to repair damaged threads in

this location. Replace the con necting rod, cap and

bolts as an assembly if thread damage is found.

3 Inspect the connecting rod for:

• Twisting, using commercially available alignment

equipment

• Bending, check the lengt h with suitable

measuring equipment

• Nicks or gouging in the bear ing bore

• Damage to the bearing locating slots in the

bearing bore

• Correct fit of the connecting rod and bearing cap

mating surfaces.

Connecting rod specification:

Centre to centre length ...................... 154.90 ± 0.02 mm

Width.................................................... 24.00 ± 0.05 mm

Twist ........................................................0.010 mm Max

Bend ..........................................................0.02 mm Max

Figure 6A3 – 280

NOTE

The used connecting rod cap bolts can be used

for this procedure, however the bolts must be

replaced for the final assembly.

4 Reinstall the connectin g rod big end cap and bolts.

Tighten the bolts to the correct torque specification.

 Connecting rod bearing cap attaching bolt

torque specification.

Stage 1 ..............................................................20.0 Nm

Stage 2 .....................................................75° turn angle

5 Measure the connecting rod big end bore with a

suitable inside micrometer and check the b ore for out

of round. Replace any connecting rod assembly that

exceeds the specification.

Connecting rod big end out-of round

specification.............................................0.008 mm Max Figure 6A3 – 281

Engine Mechanical Page 6A3–174

Page 6A3–174

6 Inspect the connecting rod bearing halves for craters

or pockets. Flattened sections on the bearing halves

also indicate fatigue. Repl ace as required.

Figure 6A3 – 282

7 Inspect the connecting rod bearing halves fo r

excessive scoring or discolouration, dirt or debris

embedded into the bearing m ateria l or backing metal.

Replace as required.

Figure 6A3 – 283

8 Inspect the connecting rod bearing halves for improper

seating indicated b y bri ght polished section/s on the

bearing material. Rep lace as required.

Figure 6A3 – 284

Engine Mechanical Page 6A3–175

Page 6A3–175

Measuring Piston Ring End Gap

1 Insert a new piston ring into the cylinder bore that it is

to be fitted to and push it down the bore using the

piston inverted in the bore until the ring is

approximately 6.5 mm below the piston ring top and

bottom travel area.

2 Insert a feeler gauge and measure the piston ring end

gap. End gap specifications are as follows:

Piston ring end gap specifications:

Top compression ring ........................ 0.230 – 0.380 mm

Second compression ring .................. 0.440 – 0.640 mm

Oil control ring.................................... 0.180 – 0.690 mm

NOTE

If the ring end gap is not within specification,

select another new set of rings and re measure

the gap. If the specification cannot be obtained,

hone the cylinder and install an oversize piston

and ring set. Figure 6A3 – 285

Reassemble

Piston Selection

Observe the following:

• The cylinder bore must be checked for bore out-of-round and taper before this operation is attempted.

Refer to 4.15 Cylinder Block. All measurements shou ld be taken at normal room temperature.

• A used piston and pin set may be reinstalled if, after cleaning and inspection, they are both within specifications.

1 With a micrometer at right angles to the piston pin

bore, measure the piston skirt 11 mm from the lower

edge.

2 Record the piston diameter.

Figure 6A3 – 286

Engine Mechanical Page 6A3–176

Page 6A3–176

3 Check the micrometer is at the recorded piston

diameter.

4 With cylinder bore checking gauge Tool No. J 8087 or

equivalent held between the micrometer anvils, zero

the dial indicator.

Figure 6A3 – 287

5 Use a bore gauge Tool J 8087 or equivalent, measure

the cylinder bore diam eter at a point 57 mm from the

top of the bore.

6 Record the cylinder bore diam eter.

7 Subtract the piston diameter from the c ylinder bore

measurement in order to determine the piston to bore

clearance.

Piston to bore clearance

specification....................................... 0.018 – 0.054 mm

8 If the clearance is outside this specification, select

another new piston. Measure and re-c alculate the

clearance. If the correct clearance cannot be obtai ned

using this method then the cylinder b ore may require

honing for an oversize piston fitment or the cylind er

block will need to be replace d.

NOTE

Before honing the cylinders,

refer to 4.15 Cylinder Block

9 When the correct piston to bore clearance is obtained,

mark the piston crown for correct installation.

Figure 6A3 – 288

Engine Mechanical Page 6A3–177

Page 6A3–177

Piston to Connecting Rod

NOTE

Take particular care when assembling the piston

to the connecting rod the component matching

and orientation is correct.

1 The connecting rod alignment should be with the flat

portion of the bolt flange (1) facing forward. Also check

the piston alignment mark has the correct ori entation.

Figure 6A3 – 289

2 Lubricate the piston pin bore, connecting rod bore and

piston pin (1) with clean engine oil.

Ensure a new piston pin retaining circlip is

installed and it is correctly seated in the

groove. Circlip failure could result in major

engine damage resulting in the block being

damaged beyond repair.

3 Using a suitable scre wdriver (2), carefully install a new

piston pin retaining circlip (3) into one side of the

piston.

4 Reinstall the piston pin into the piston and connecting

rod, ensuring the piston and conn ecting rod orientation

is correct.

5 Install the remaining circlip into the piston as in Step 3.

NOTE

Ensure the piston is free to move on the pin and

the piston pin retain ing circlip on eac h side of the

piston are seated in the grooves correctly.

Figure 6A3 – 290

Engine Mechanical Page 6A3–178

Page 6A3–178

Piston Rings

Use piston ring pliers to install the piston

ring and only expand the ring sufficiently to

slide over the piston. Excessive expansion

will permanently distort the piston ring .

1 Install the piston rings onto each piston, in the

following manner:

a Install the oil control segment ring (1) into the

lower ring groove and ensure the ends do not

overlap.

b Install the lower oil control ring (2). There are no

identifying marks, indicating orientation as this

ring may be installe d in either direction.

c Install the upper oil control ring (3) in a similar

manner.

d Stagger the ends of the three oil control ring

components by at least 90°.

e Install the second compression ring (4) noting

the dimple or orientation mark must face

upwards to the piston crown.

f Install the top compression ring (5). This ring has

no orientation marks and may be installed in

either direction.

Figure 6A3 – 291

Reinstall

NOTE

Before installation, check the piston ring end

gaps are staggered correctly and the piston has

been assembled to the correct connecting rod

and in the correct orientation.

1 If required, install the connecting rod bearings.

2 Lightly lubricate the pisto n, cylinder bore, piston rings and bearing surfaces with clean engine oil.

3 Remove the connecting rod cap an d bearing shell from the connecting rod being insta lled and install the

connecting rod guide pins, Tool No. J 41556, refer to Figure 6A3 – 292.

4 Install a commercially available piston ring compressor over the piston rings and compr ess the rings.

NOTE

Follow the manufacturer's operating instructions

for the type of piston ring compressor being used.

5 Install the piston and connecti ng rod assembly into the

correct cylinder bore, checking the piston alignment

mark is facing the front of the engine.

6 While holding the piston rin g compressor squarely and

firmly against the cylinder block, gently tap the piston

into the bore using a wooden hammer handle until all

piston rings have entered the bore.

7 Complete the installation by us ing the connecting rod

guide pins, Tool No. J 41556 to guide the connecting

rod onto the crankshaft journal.

Figure 6A3 – 292

Engine Mechanical Page 6A3–179

Page 6A3–179

8 Remove the connecting rod guides, Tool No. J 41556

and check the upper bearing shell is correctly installed

in the connecting rod. Apply c lean engine oil to the

upper bearing shell.

Figure 6A3 – 293

9 Install the lower connecting rod bear ing into the cap

and lubricate with clean en gine oil, install the cap

ensuring the cap orientation is correct.

NOTE

The bearing oil clearance must be checked

before final installation of the connecting rod

caps. Refer to 4.13 Crankshaft and Bearings.

10 Install new connecting rod cap bolt (1), two places and

tighten the connecting rod bolts in two stages to the

correct torque specification.

 Connecting rod bearing cap attaching bolt

torque specification

Stage 1 ..............................................................20.0 Nm

Stage 2 .....................................................75° turn angle

NOTE

Use torque angle wrench Tool No. E7115 or

equivalent to achieve the second reading. Figure 6A3 – 294

11 With a pair of connecting rods installed o nto the same

crankshaft journal, use a plastic faced hammer to

lightly tap each connecting rod sideways to settle and

ensure that side clearance exists.

12 Using feeler gauges, check the connectin g rod sid e

clearance is within the required specification.

Connecting rod side clearance

specification........................................... 0.11 – 0.51 mm

NOTE

If side clearance is insufficient, re-check bearing

oil clearance and/or connecting rod a lignment.

13 Reinstall the oil pan, oil pump screen and deflector,

refer to 4.9 Oil Pump, Pump Screen and Deflector.

14 Reinstall both cylinder heads.

Refer to 3.15 Cylinder Head.

Figure 6A3 – 295

Engine Mechanical Page 6A3–180

Page 6A3–180

4.13 Crankshaft and Bearings

LT Section No. — 00–200

Crankshaft Thrust End Play

Measure

1 Remove engine from vehicle, refer to 4.1 Engine Assembly and the n sep arate the engine from the transmission.

2 Mount the engine in an engine stand such as Tool No. AU591 or an equivalent.

3 Remove the following items from the eng ine assembly:

• Starter motor, refer to Section 6D3 Starting System – GEN III V8.

• Oil pump, screen and deflector, refer to 4.9 Oil Pump, Pump Screen and Deflector.

• Remove each of the connecting rod b earing caps, refer to 4.12 Piston, Connecting Rod and Bearing.

4 Prise the crankshaft rearward then forward using a

suitable lever.

5 Insert a feeler gauge (1) between the centre main

bearing and the crankshaft thrust beari ng surface and

measure the crankshaft end play.

Crankshaft end play specification ...... 0.040 – 0.020 mm

6 If the thrust bearing clearance is less than 0.040 mm,

inspect the thrust surfaces for nicks, gouges or raised

metal. Remove the crankshaft, refer to Remove in this

Section and inspect the thrust face and the thrust

bearings.

NOTE

If there are minor imperfections, they can be

removed with a fine stone. If the bearing

clearance is greater than 0.20 mm select and

install an undersized crankshaft thrust bearing.

Re-check the crankshaft end play. Figure 6A3 – 296

Remove

1 Remove the bolt (2), attaching the crankshaft position

sensor (1) and remove the sensor from the cylinder

block.

Figure 6A3 – 297

Engine Mechanical Page 6A3–181

Page 6A3–181

NOTE

If required, prior to removing the crankshaft

check the crankshaft end play, refer to

Crankshaft Thrust End Play.

2 Remove the crankshaft main bearing cap M8 side b olt

(1), 10 places.

NOTE

While these bolts must be replaced during the

final assembly process, place the removed bolts

to one side as they will be required when

checking the main bearing oil clearance.

3 Remove the main bearing cap M10 bo lt (2), 10 places

and studs (3), 10 places, loosening each pair

gradually. Take note of the stud positions for

reassembly.

Figure 6A3 – 298

4 Loosen the bolts of the main bearing removal Tool No.

J 41818 to separate the chamfered collets. Install the

chamfered sections into the main bearing cap bolt

hole, aligning the flats of the collets with thos e in the

holes.

5 Tighten the bolts of Tool No. J 41818 to the correct

torque specification.

Main bearing removal tool attachi ng bolt

torque specification............................................11.0 Nm

6 Install the slide hammer, Tool No. J 6125-1B to Tool

No. J 41818 and remove the main beari ng cap.

Figure 6A3 – 299

7 Mark and remove the remaining main bearing caps in

the same way. Check the lo wer main beari ng shells

are also removed with each cap.

Figure 6A3 – 300

Engine Mechanical Page 6A3–182

Page 6A3–182

Lift the crankshaft from the cylinder block

evenly to avoid jamming the crankshaft

against the main thrust bearing , and to avoid

damaging the reluctor ring. The reluctor ring

is an integral part of the crankshaft and is no t

serviced separately, therefore damage to the

reluctor ring will require the crankshaft

assembly to be replaced.

8 Remove the crankshaft from the cylinder block.

Figure 6A3 – 301

• When the crankshaft has been removed

from the cylinder block, take particular

care the reluctor ring is not damaged.

• Crankshafts when stored should be hung

vertically from the rear flange, however if

this is not possible, it is suggested the

removed crankshaft be supported on

three wooden V blocks or another

suitable soft surface that are large

enough to raise the crankshaft reluctor

wheel from contacting the surface. The

wooden vee blocks should be placed

under the main bearing journals.

Figure 6A3 – 302

9 Remove the crankshaft main bearings from the

cylinder block and the main beari ng caps.

10 Using a marker pen or etching tool, mark each main

bearing cap. The main bearing caps must be

reassembled to the original positio n an d direction.

NOTE

Take particular care to organ ise all parts so they

can be reinstalled in their original positions.

Figure 6A3 – 303

Engine Mechanical Page 6A3–183

Page 6A3–183

Clean and Inspect

To avoid personal injury, wear safety glasses

and the appropriate gloves when using

compressed air and cleaning fluids.

1 Clean the crankshaft with a commercially available

cleaning fluid and bl ow dry using compressed air.

2 Thoroughly cle an all the oil passages and inspect for

restrictions or burrs.

3 Carry out a visual inspection of the cranksh aft for

damage.

4 Inspect the crankshaft reluctor ring lobes for damage.

The reluctor ring teeth should not have imperfections

on either the rising or falling edges.

Figure 6A3 – 304

5 Inspect the crankshaft journals for the following:

• Wear (1)

• Grooves or scoring (2)

• Scratches (3)

• Pitting or embedded material (4)

NOTE

The journals should be smooth with no signs of

scoring, wear or damage. Re-grind the

crankshaft and install undersize bearings if

damage or wear is found.

Figure 6A3 – 305

6 Inspect the crankshaft key (1), keyway (2) and

threaded hole (3) for damage or wear.

Figure 6A3 – 306

Engine Mechanical Page 6A3–184

Page 6A3–184

7 Measure all crankshaft journals for wear and out-of-

round.

Crankshaft journal specifications:

Connecting rod journal diameter.............53.308 mm Min

Connecting rod journal out of round.........0.010 mm Max

Main bearing journal diameter.................64.993 mm Min

Main bearing journal out of round ............0.008 mm Max

Main bearing journal taper ........................0.020 mm Min

Figure 6A3 – 307

8 Support the crankshaft on V blocks or in a commercial

jig.

9 Using a commerciall y available dial indicator mounted

to a magnetic stand, measure the following crankshaft

main bearing journal runout dimensions:

• Crankshaft runout at the main bearing jo urnals

• Crankshaft rear flange

• Reluctor ring (measur ed 1.00 mm below the

minimum tooth diameter) at the rear surface

• Crankshaft thrust wall at the centre main bearing

Main bearing journal runout specifications:

Reluctor ring lateral runout.......................0.250 mm Max

Crankshaft thrust wall runout ...................0.025 mm Max

Crankshaft rear flange runout ..................0.050 mm Max

Figure 6A3 – 308

10 Check the rear crankshaft oil gallery plug (1) for a

loose fit or evidence of leaking.

11 If replacement is required, apply sealant such as

Loctite 242 or equivalent, to the sid es of a n ew plug

(1) and install to the correct depth.

Crankshaft rear oil gallery plug depth specification:

Distance A.............................................. 31.2 – 31.6 mm

NOTE

If a manual transmission is fit ted to the vehi cle, it

will be necessary to first remove the spigot

bearing. Refer to 4.7 Crankshaft Spigot Bearing.

Figure 6A3 – 309

Engine Mechanical Page 6A3–185

Page 6A3–185

Main Bearings Inspect

1 Inspect the crankshaft main bearing halves f or craters

or pockets. Flattened sections on the bearing halves

also indicate fatigue. Repl ace as required.

Figure 6A3 – 310

2 Inspect the crankshaft main bearings for excessive

scoring or discolouration and dirt or debris embedded

into the bearing material or backing metal. Replace as

required.

Figure 6A3 – 311

3 Inspect the crankshaft main bearings for incorrect

seating, indicated by bright or polished section/s on

the bearing material. Replace as required.

Figure 6A3 – 312

Engine Mechanical Page 6A3–186

Page 6A3–186

Main Bearing Oil Clearance

1 After thoroughly cleaning all the relevant parts, install

the bearing halves into the c ylinder block and main

bearing caps.

Figure 6A3 – 313

2 Install the crankshaft to the cylinder block ensuring the

crankshaft is held square to avoid damagin g the

centre main thrust bearing and the reluctor ring.

Ensure the cranksh aft does not rotate during

this process. Any rotation of the crankshaft

will result in the plastigauge being deformed

and a true oil clearance reading will not be

possible.

3 Install a small strip of plastigauge (1) across the full

width of each main bearing journal.

NOTE

Do not place the plastigauge across an oil feed

hole and ensure the crankshaft does not rotate

during this process. Figure 6A3 – 314

4 Install the main bearings, caps, bolts and studs in the

reverse order of the removal proced ure, ensuring the

bearings and caps are i nstalled in their original

location.

Figure 6A3 – 315

Engine Mechanical Page 6A3–187

Page 6A3–187

5 Tighten the main bearing cap bolts and studs in

numerical order to the correct torque specific ation.

NOTE

Perform Stage 1 for all the bolts and studs. T hen

continue with Stage 2 using a torque angle

meter Tool No. E7115 to achieve an accurate

second reading, noting the different turn angles

for the bolts and the studs.

Main bearing inner attaching bolts (1 – 10)

torque specification

Stage 1 ..............................................................20.0 Nm

Stage 2 .....................................................80° turn angle

Main bearing outer attaching studs (11 – 20)

torque specification

Stage 1 ..............................................................20.0 Nm

Stage 2 ......................................................53°turn angle

Figure 6A3 – 316

NOTE

For this procedure, the used main bearing cap

side bolts can be used.

6 Tighten the main bearing cap side bolts (1) to the

correct torque specification, first on one side then on

the other.

 Main bearing cap side bolts

torque specification............................................25.0 Nm

7 Remove the main bearing cap side b olts an d discard

as new bolts must be used on final assembly.

8 Remove the main bearing cap M10 bo lts (2) and studs

(3), loosening each pair gradually. Take note of the

stud positions for reassembly.

Figure 6A3 – 317

9 Loosen the bolts attaching the main bearing removal

Tool No. J 41818 to separate the chamfered collets

then install the chamfered sect ions into the main

bearing cap bolt hole, aligning the flats of the collets

with those in the holes.

10 Tighten the bolts of Tool No. J 41818 to the specified

torque.

Main bearing removal tool attachi ng bolt

torque specification............................................11.0 Nm

11 Install the slide hammer, Tool No. J 6125-1B to Tool

No. J 41818 and remove the main beari ng cap.

Figure 6A3 – 318

Engine Mechanical Page 6A3–188

Page 6A3–188

Ensure the cranksh aft does not rotate during

this process. Any rotation of the crankshaft

will result in the plastigauge being deformed

and a true oil clearance reading will not be

possible.

12 Remove the remaining main bearing caps in the same

way.

Figure 6A3 – 319

13 Using the scale supplied with the plastigauge,

measure the deformed plastigauge at its widest part,

noting the following.

a If the deformed strip shows a width variation

exceeding 0.020 mm, remove the crankshaft and

measure the journal with a micrometer.

b If the bearing clearance is greater than 0.076

mm (connecting rod) or 0.065 mm (main), select

and install an undersized bearing set and then

re-check the oil clearance.

c If the clearance specification cannot be obtained,

the crankshaft must be reground for use with the

next under-sized bearin gs.

NOTE

Ensure all traces of the plastigauge have been

removed from the crankshaft once measuring is

complete.

14 If required, measure the crankshaft end play, refer to

Crankshaft Thrust End Play. Figure 6A3 – 320

Engine Mechanical Page 6A3–189

Page 6A3–189

Reinstall

1 Reinstall the main beari ng shells into the caps and the

cylinder block in their original locatio n or as requ ired

after performing an oil clearance check.

NOTE

Do not apply engine oil to the back of the main

bearing shells.

2 Apply clean engine oil to the bearing halves and

crankshaft journals.

Figure 6A3 – 321

3 Install the crankshaft to the cylinder block ensuring the

crankshaft is held square to avoid damagin g the

centre main thrust bearing or the reluctor ring.

Figure 6A3 – 322

4 Install the crankshaft main bearings caps with the

bearings installed and install the main bearing cap

bolts and studs in the correct order as removed.

Figure 6A3 – 323

Engine Mechanical Page 6A3–190

Page 6A3–190

5 Tighten the main bearing cap bolts and studs to the

correct torque specification, in the correct sequence.

NOTE

Perform the Stage 1 for bolts and studs 1–20

and then continue with Stage 2. Use a torque

angle meter Tool No. E7115 to achieve an

accurate second reading, noting the different

turn angles for the bolts and the studs.

Main bearing inner attaching bolts (1 – 10)

torque specification

Stage 1 ..............................................................20.0 Nm

Stage 2 .....................................................80° turn angle

Main bearing outer attaching studs (11 – 20)

torque specification

Stage 1 ..............................................................20.0 Nm

Stage 2 .....................................................53° turn angle

6 Install new M8 main bearing cap sid e bolts and tighten

to the correct torque specification, first on one side

then on the other.

NOTE

New main bearing cap side bolts have a sealant

patch applied to the bolt flange.

 Main bearing side cap bolts

torque specification............................................25.0 Nm

7 If required, recheck the crankshaft thrust end play,

refer to Crankshaft Thrust End Play.

Figure 6A3 – 324

8 Inspect the crankshaft position sensor (1) O-ring for

nicks, cuts or other damage. If undamaged, the O-ring

may be re-used.

9 Smear the O-ring with clean engine oil.

10 Install the crankshaft position sensor a ligning the

retaining bracket bolt hole with the threaded hole in

the cylinder block.

11 Install the attaching bolt (2) and tighten to the correct

torque specification.

Crankshaft position sensor attaching bolt

torque specification............................................25.0 Nm

NOTE

Lever the crankshaft to the forward position,

particularly when a manual transmission is fitted

to the engine. This will reduce the effect of

bearing shock when the engine is started and

the clutch is first released. Figure 6A3 – 325

12 Reinstall the following items to the engin e a ssembly;

• Connecting rod bearing caps, refer to 4.12 Piston, Connecting Rod and Bearing.

• Rear engine cover, refer to 4.8 Engine Rear Cover.

• Timing chain and sprockets, refer to 4.10 Timing Chain and Sprockets.

• Oil pump, pump screen and deflector, refer to 4.9 Oil Pump, Pump Screen and Deflector.

• Starter motor, refer to Section 6D3-2 Starting System – GEN III V8.

13 If required, reassemble the transmission to the engine and reinstall the engine into vehicle,

refer to 4.1 Engine Assembly.

Engine Mechanical Page 6A3–191

Page 6A3–191

4.14 Cylinder Block Plugs

LT Section No. — 00–248

Coolant drain plugs can be removed with the engine assembly installed in the vehicle. The oil gallery plugs will require

the engine to be removed from the vehicle and either, the front or rear engine covers to be removed.

NOTE

All screw-in coolant and oil gallery plugs must be

replaced if removed or loosened.

Refer to either:

a 4.1 Engine Assembly, for engine assembl y removal procedures.

b 4.5 Engine Front Cover, for front engine cover removal procedures.

c 4.8 Engine Rear Cover, for rear engine cover removal procedures.

Remove

1 Remove the coolant drain plug (1) from the right-h and

rear of the cylinder block.

Figure 6A3 – 326

2 Remove the three plugs (1, 2 and 3) from the left-hand

side of the cylinder block.

NOTE

Plugs (1 and 2) are oil gallery plugs and (3) is a

coolant plug.

Figure 6A3 – 327

Engine Mechanical Page 6A3–192

Page 6A3–192

NOTE

• Remove the plug from the front of the

cylinder block only if its replacement is

required.

• The engine front cover will need to be

removed to perform this procedure, refer to

4.5 Engine Front Cover.

3 Remove the cylinder block front oil gallery plug.

A suggested method is to:

a Drill a small pilot hole through the plug.

b Install a self tapping screw into the plug.

c Using a slide hammer with a suitable fitting,

remove the plug.

d Discard the removed plug.

Figure 6A3 – 328

NOTE

The engine assembly and rear engine cover

must be removed to perform this procedure.

4 Remove the rear oil gallery plug (1) by either one of

the following two methods:

a With the front plug removed, use a suitable

length of metal rod (e.g. 5 mm) inserted from the

front of the cylinder block and a hammer to tap

the rear oil gallery plug free.

To avoid personal injury, wear safety glasses

and the appropriate gloves when using

compressed air and cleaning fluids.

b With the cylinder block plug removed, use a

small screwdriver inserted in the plug aperture to

prise the oil galley plug free.

5 Inspect the O-ring seal on the removed gallery pl ug

and if it is undamaged, it may be re-used d uring

assembly.

Figure 6A3 – 329

Engine Mechanical Page 6A3–193

Page 6A3–193

Reinstall

1 Apply a 3 mm bead of sealan t such as Loctite 565 or

equivalent to the drain plug sealing washer on a new

right-hand cylinder block cool ant plug.

2 Install the plug and tighten to the correct torque

specification.

■ Coolant drain plug

torque specification............................................60.0 Nm

Figure 6A3 – 330

3 Apply a 3 mm bead of sealan t such as Loctite 565 or

equivalent to the new oil gallery plugs (1 and 2 )

sealing washer and tighten to the correct torque

specification.

■ Oil gallery plug

torque specification............................................60.0 Nm

4 Apply a 3 mm bead of sealan t such as Loctite 565 or

equivalent to the new coolant drain plug (3) sealing

washer and tighten to the correct torque spe cification.

■ Coolant drain plug

torque specification............................................60.0 Nm

Figure 6A3 – 331

Engine Mechanical Page 6A3–194

Page 6A3–194

5 Lubricate the oil gallery plug O-ring with clean engine

oil and install the plug into the rear of the cylinder

block.

6 Carefully install until the plug until it comes to a stop

against the stepped bore of the oil g allery. At this

point, the plug should be protruding by approximately

1.2 mm (A).

NOTE

When the rear engine cover and gasket are

installed, the plug protrusion will rest against the

rear engine cover machined internal surface.

Figure 6A3 – 332

7 Apply a sealant such as Loctite 242 or equivalent to

the side of a new front oil gallery plug (1).

8 Install the new front oil gallery plug into the cylinder

block to the specified depth.

Front oil gallery plug installation specification:

Distance below flush.................................. 2.0 – 2.8 mm

Figure 6A3 – 333

Engine Mechanical Page 6A3–195

Page 6A3–195

4.15 Cylinder Block

Cylinder Block Clean, Inspect and Measure

Clean

1 Disassemble the cylinder block as required.

2 Remove all cylinder block plugs, refer to 4.14 Cylinder Block Plugs and then clean all the coolant passages and o il

galleries.

• Do not use any caustic solutions to clean

the aluminium cylinder block. When

cleaning an cylinder block in a thermal

type washer, do not exceed 232°C.

• Wear safety glasses and the appropriate

gloves when using compressed air and

cleaning fluids to avoid personal injury.

3 Clean the cylinder block in a commercially available cleanin g fluid to remove all sludge, dirt, or debris and blow dry

using compressed air. An alte rnative is to clean the block in a commercially available thermal type washer,

providing the temperatur e does not exceed 232° C.

4 Clean all gasket surfaces using a plastic scraper to avoid damaging machined surfaces.

5 Clean the main bearing caps, ensuring they stay in their original order.

6 Clean the residue of cylinder head bolt thread sealant from the cylinder block threads. Use installer T ool No.

J 42385-107. This tool is part of the thread repair kit, J-42385.

NOTE

Do not use anything but this thread tool to clean

the cylinder head threads in the cylinder block.

7 Use compressed air to clean all residue from the bolt holes.

Inspect

Inspect the following areas:

• The cylinder walls for excessive scratches, g ouging, or piston ring ridge

• The coolant jacket for cracks or corrosion

• The valve lifter bores for excessive scoring or wear

• The crankshaft bearing webs for cracks

• The gasket sealing surfaces for excessive scratches or gouging

• The oil galleries for restrictions

• All threaded bolt holes for damage

Cylinder Bore – Measure

1 Adjust the micrometer to 96.0 mm.

2 Insert the bore gauge into the micrometer and zero the

bore gauge dial, Tool No. J 80 87 or a commercially

available equivalent.

Figure 6A3 – 334

Engine Mechanical Page 6A3–196

Page 6A3–196

3 Using a bore gauge, Tool J8087, measure the cylinder

bore for taper by sliding the bore gaug e up and down

throughout the length of the cylinder bore. Ch eck the

bore both parallel and p erpendicular to the centreline

of the crankshaft.

4 Recondition cylinders with less than 0.018 mm taper

with by honing the cylinder, refer to Cylinder Boring

and Honing.

NOTE

Cylinders with more than 0.018 mm taper must

be honed and fitted with an oversize piston.

Figure 6A3 – 335

5 Using a bore gauge, measure the cylinder bore at

points (A, B and C), measure the bore both in line with

the centreline and perpendicular to the engine

centreline. Check for bore out-of-round at a depth of:

a 9 mm (A).

b 57 mm (B).

c 127 mm (C) from the cylinder head surfaces.

6 Calculate the difference between the two

measurements at each location. T he results will

indicate any out-of-round bore conditi on.

NOTE

Cylinders with more than 0.18 mm out-of-round

must be honed and fitted with an oversize piston.

Figure 6A3 – 336

7 Measure the cylinder block cylinder head deck using a

straight edge(1) and feeler gauges (2). Check the

flatness of the cylinder block and cyl ind er head deck

surfaces.

NOTE

If the measurement is not within specification,

the cylinder block must be replaced. Machining

is not recommended.

Cylinder block cylinder head flatness specification:

Measured:

Within a 150 mm area............................... 0.11 mm Max

Over the cylinder block length....................0.22 mm Max

Figure 6A3 – 337

Engine Mechanical Page 6A3–197

Page 6A3–197

Cylinder Boring and Honing NOTE

Boring of the cylinder is not permitted. Pisto n and

piston ring service sets are available in 0.25 mm

oversize. It is recommended to hone the cylinder

to achieve the correct fit for the oversize piston.

Honing Procedure

1 When honing the cylinders observe the following:

a Follow the equipment manufacturer's

recommendations.

b Use only clean, sharp hone stones of the proper

grade recommended for the amount of material

that is required to be remove. Dull and dirty hone

stones cut unevenly and generate excessive

heat.

c Do not hone to the final clearance with a coarse

or medium-grade stone. Leave sufficient metal

so that all stone marks may be removed with

fine-grade stones. Perform final honing with a

fine-grade stone to hone the cylinder to the

correct clearance. Figure 6A3 – 338

2 During the cylinder honing operation observe or monitor the following:

• Constantly clean the cylinder bore and check the cylinder bore for fit with the selected piston. All

measurements of the piston or the cylinder bore should be made with the components at normal room

temperature.

• When honing a c ylinder for fit to an oversize piston, first perform the preliminary honing with a 100 grit stone.

• Perform the final cylinder honing with a 240 grit stone and obtain a 45°cross hatch pattern. A 240 grit stone is

preferred for final honing. If a 240 grit stone is not available, a 220 grit stone may be used as a substitute.

• When honing to eliminate taper in the cylinder, make full strokes over the complete bore length. Constantly

check the measurement at the top, the middle, and the bottom of the bore. When completed, the

reconditioned cylind er bore should have less than or meet the specified out-of-round and taper requirements.

• The finish marks should be clean but not sharp. The finish marks should also be free from embedded

particles, torn or folded metal.

• By measuring the selected pist on at the specified point and by adding the average to the clearance

specification, the final cylinder honing dimension required c an be determined.

3 After the final honing, clean the c ylinder bores with hot water and detergent by scrubbing the bores with a stiff

bristle brush and then rinse t he bores thoroughly with hot water.

NOTE

Do not allow any abrasive material to remain in

the cylinder bores. This abrasive material may

cause premature wear of the new piston, piston

rings and the cylinder bores. Abrasive material

will also contaminate the engine oil and may

cause premature wear of the bearings. After

washing the cylinder bore, dry the bore with a

clean rag.

4 Perform final measurements of the piston an d the cylinder bore and permanently mark the top of the piston for the

specific cylinder to which it is to been fitted.

5 Apply clean engine oil to each cylinder bore in order to prevent rusting.

Deglazing Procedure

If a cylinder becomes glazed, that cylinder will need to be deglazed to allow the piston rings to bed in. Deglazing of the

cylinder bore is performed using a ball type (Bottle Brush) or self centring honing tool to lightly deglaze the cylinder bore.

Deglazing should only be don e to remove any deposits that may have formed.

Use a 240 grit silicone carbide stone or e quivalent material when performing the deglazing proce dure.

NOTE

A 240 grit stone is preferred for deglazing,

however if a 240 grit stone is not available a 220

grit stone may be used as a substitute.

Engine Mechanical Page 6A3–198

Page 6A3–198

Camshaft Bearings

Remove

The following service operatio n involves the use of a universal camshaft bearing remover /installer, Tool No. J 33049 and

finished size camshaft bearings. If installing unfinished size bearings, installation must be carried out by a specialist

machine shop and then line bored to the correct finished size.

Camshaft bearings once removed sho uld be replaced with new ones. The bearings should only be removed if

replacement is required or cyli nder block service operations require the block to be compl etely disassembled.

While it is preferred the camshaft bearings are removed and installed in a bare cylinder bl ock, the operation can be

carried out by removing the crankshaft and the camshaft. However, it will be difficult to negotiate the tool past the

connecting rod big end journa ls.

The camshaft can be removed without havin g to remove the cylinder heads and hydraulic lifters. This is achieved by

removing the pushrods and inverting the eng ine. This will allow the hydraulic lifters to drop sufficiently to clear the

camshaft journals. However, use extreme care when removing the camshaft and bearings using this procedure to ensure

either the camshaft or hydraulic lifters are no t damaged.

1 Prior to bearing removal, inspect all camsh aft bearin gs

for a loose fit in the cylinder block bearing bores.

NOTE

If a bearing is found to be loose, it may have

been caused by an enlarged, out of round or

damaged cylinder block bearing bore.

Figure 6A3 – 339

2 The universal camshaft bearin g remover/installer,

Tool No. J 33049 consists of the following

components;

• Nylon guide cone (1)

• Small driving washer (2)

• Large driving washer (3)

• Expanding drivers and rubber sleeves (4 – 8)

• Driver extension bar (9)

• Driver bar (10)

• Expander assembly (15) consisting of parts

11 – 14

3 To replace the camshaft beari ngs, select the following

components from Tool No. J 33049:

• Nylon guide cone (1)

• Large driving washer (3)

• Expanding drivers and rubber sleeve (7)

• Driver bar (10)

• Expander assembly (15)

Figure 6A3 – 340

Engine Mechanical Page 6A3–199

Page 6A3–199

4 Install the expanding driver with the rubber sleeve (1)

over the expander assembly (2) and with the

numbered flanges of the expanding driver facing the

threaded end of the expan der assembly.

Figure 6A3 – 341

5 Once installed, ensure the se parations in the expander

assembly segments are aligned with those of the

expanding driver as shown (A).

Figure 6A3 – 342

6 Manoeuvre the assembly into the cylinder block in

front of the bearing to be removed and install the large

driving washer (1) over the threaded end of the

expander assembly (2).

7 Slide the nylon cone (3) over the driver bar (4) with the

smaller diameter toward the cylinder block.

NOTE

The components shown are shown removed

from the cylinder block for clarity.

8 Carefully insert the driving bar through the camshaft

bearings from the front of the cylinder block and screw

the bar to the expander assembly.

NOTE

Do not overlook fitting the driving washer over

the threaded end of the expander assembly

before installing the driver bar.

9 With the expander assembly inserted into th e

camshaft bearing, hold the hexagonal end of the

expander assembly with a spanner an d hand tighten

the driver bar until the expanding driver (5) is tight in

the bearing shell.

Figure 6A3 – 343

Engine Mechanical Page 6A3–200

Page 6A3–200

10 Push the guide cone into the front camshaft bearing to

align the driver bar.

11 While holding the guide cone in place with one hand,

drive the bearing from the cylinder block.

12 Repeat this process with the remainin g bearings being

removed.

Figure 6A3 – 344

13 To remove the front bearing, install the driver bar from

the rear of the cylinder block, using the guide cone in

the rear camshaft bearing bore.

Figure 6A3 – 345

Reinstall

1 Reinstallation of the camshaft bearings is the reverse

of the removal procedure, noting the following:

• The joint in the new camshaft bearing (1) must

be aligned with the top of the cylinder block

centreline (2). To assist with alignment of the

bearing, use a felt tip pen to mark the back of the

bearing 180° from the join, as this will be visible

when installing the bearing.

• While the oil feed is generous in length and

allows some degree of hole misalignment, as

much care as possible must be made during

installation to ensure the beari ng is installed

correctly allowing maximum exposure to the oil

feed hole.

• Install each bearing until it is centrally located in

the cylinder block bore and th en use a thin piece

of wire to ensure the oil feed passage has not

been obstructed.

• To install the front camshaft bearing, install the

driver bar into the rear bearing and use the guide

cone at that location.

NOTE

Take care when installing the driver bar through

the newly installed bearings to avoid damage.

Figure 6A3 – 346

Engine Mechanical Page 6A3–201

Page 6A3–201

5 Thread Repair

5.1 General Information

Throughout this Section, compressed air is

used for the cleaning of debris wh en repairing

threads. When using compressed air, ensure

safety glasses are used to avoid eye injury.

With the extensive use of aluminium alloy in the construction of the GEN III V8 engine, thread repairs will be required at

times to repair damaged threads caused b y the corros ion of fasteners, careless handling or over-tightening of fasteners.

This Section describes the recommended method of repairing threads in three specific areas of the engine:

• General thread repair

• Cylinder head bolt hole thread repa ir

• Main bearing cap bolt hole thread repair

Detailed descriptions of all thread specifications used in this engine are listed in 5.5 Thread Re pair Specifications.

The available Thread Repair Kit, Tool No. J 42385/100/200/

300 uses the Time Sert® thread repair process that involves

a solid thin walled self-locking carbon steel bushing type

insert (1).

During the bushing installati on process the driver tool

expands the bottom external threads of the i nsert into the

base material (2). This action mechanically locks the insert

in place.

When installed to the proper depth the flange of the insert

will be seated against the counter-bore of the repaired hole.

Driver oil must be used on the installer driver tool.

NOTE

The use of a cutting or drilling fluid is

recommended when performi ng drilling, counter-

boring and tapping proce dures.

The tool kits are designed for use with a suitable tap wrench

and electric drill. Figure 6A3 – 347

Engine Mechanical Page 6A3–202

Page 6A3–202

5.2 General Thread Repair

1 Drill out the threads of the damaged hole (1) to the

correct depth for the thread being repaire d.

2 Observe the following recommend ed drilling depths:

• M6 inserts require a minimum drill depth of

15 mm

• M8 inserts require a minimum drill depth of

20 mm

• M10 inserts require a minimu m drill depth of

23.5 mm

3 Using compressed air, clean out any foreign material

from the holes.

Figure 6A3 – 348

4 Counter-bore the hole to the full depth permitted by

the tool (1).

5 Using compressed air, clean out any foreign material

from the holes.

Figure 6A3 – 349

6 Using a tap wrench (1), tap the threads of the drilled

hole to the correct depth for the thread bei ng repaired.

7 Observe the following recommend ed tapping depths:

• M6 inserts require a minimum tap depth of

15 mm

• M8 inserts require a minimum tap depth of

20 mm

• M10 inserts require a minimum tap depth of

23.5 mm

Do not use any cleaning agents that contain

Trichloralethane as this is harmful to the

aluminium.

8 Spray a suitable cleaner int o the hole.

9 Using compressed air, clean out any foreign material

from the holes. Figure 6A3 – 350

Engine Mechanical Page 6A3–203

Page 6A3–203

10 Lubricate the threads by applying a small amount of

driver oil (1) to the threads of the installer (2).

NOTE

Do not allow oil or other foreign material to

contact the outside diameter of the insert.

Figure 6A3 – 351

11 Install the insert (1) onto the driver tool (2).

Figure 6A3 – 352

12 Apply a small amount of thread locking compound,

such as Loctite 272 (1) or equivalent to the thread

insert OD threads (2).

Figure 6A3 – 353

Engine Mechanical Page 6A3–204

Page 6A3–204

13 Install the insert (1) until the flange of the insert

contacts the counter-bored surface.

14 Continue to rotate the installer tool (2) through the

insert. The installer tool will tighten up before screwing

completely through the insert. This is normal since the

bottom threads of the insert are being formed and

mechanically locked into the hol e.

15 Remove the driver.

Figure 6A3 – 354

16 Inspect the insert for proper installation into the hole.

17 A properly installed insert (1) will be either flush or

slightly below flush with the surface of the base

material (2).

Figure 6A3 – 355

Engine Mechanical Page 6A3–205

Page 6A3–205

5.3 Cylinder Head Bolt Hole Thread Repair

The cylinder head bolt hole thread repair kit from T ool No.

J 42385/100/200/300 cons ists of the following items:

• Drill (1)

• Tap (2)

• Installer (3)

• Sleeve (4)

• Alignment pin (5)

• Bushing (6)

• Attaching bolts (7)

• Fixture plate (8)

NOTE

The use of a cutting type fluid (WD 40®), or

equivalent is recommended when performing the

drilling, counter-boring and tapping procedures.

Figure 6A3 – 356

Procedure

NOTE

• Driver oil must be used on the install er driver

tool.

• The tool kits are designed for use with either

a suitable tap wrench or electric drill.

1 Position the fixture plate (1) and bushing (2) over the

hole that is to be repaired (3).

2 Install the fixture plate bolts (4) finger tight and fit the

bushing onto the cylinder blo ck deck.

Figure 6A3 – 357

Engine Mechanical Page 6A3–206

Page 6A3–206

3 Position the alignment pin (1) through the bushing and

into the hole.

4 With the alignment pin in the desire d hol e, tighten the

fixture attaching bolts (2) to the correct torque

specification.

Cylinder head fixture attaching bolt

torque specification............................................30.0 Nm

5 Remove the alignment pin from the hole ensuring it is

not binding on the sleeve when being removed.

Figure 6A3 – 358

6 Referring to Figure 6A3 – 359, drill the hole that is to be repair ed noting the following:

• Cylinder head bolt holes 1 to 8 are deep holes and can be drilled without the drill sle eve.

• Cylinder head bolt holes 9 an d 10 are the more shallow holes so drilling must be done with the drill sleeve in

place.

NOTE

Figure 6A3 – 359 shows the left-hand side of the

engine. However, the procedure for the right

hand side is the same with holes 9 and 10 being

reversed.

Figure 6A3 – 359

Engine Mechanical Page 6A3–207

Page 6A3–207

7 Lubricate the threads by applying a small amount of

driver oil (1) to the threads of the installer (2).

NOTE

Do not allow oil or other foreign material to

contact the outside diameter of the insert.

Figure 6A3 – 360

8 Install the insert (1) onto the dr iver tool (2).

Figure 6A3 – 361

9 Apply a small amount of thread locki ng compound,

such as Loctite 272 (1) or equivalent to the thread

insert OD threads (2).

Figure 6A3 – 362

Engine Mechanical Page 6A3–208

Page 6A3–208

10 Install the insert (1) until the flange of the insert

contacts the counter-bored surface.

11 Continue to rotate the installer tool (2) through the

insert. The installer tool will tighten up before screwing

completely through the insert. This is normal since the

bottom threads of the insert are being formed and

mechanically locked into the hol e.

12 Remove the driver.

Figure 6A3 – 363

13 Inspect the insert for proper installation into the hole.

14 A properly installed insert (1) will be either flush or

slightly below flush with the surface of the base

material (2).

Figure 6A3 – 364

Engine Mechanical Page 6A3–209

Page 6A3–209

5.4 Main Bearing Cap Bolt Hole

Thread Repair

The main cap bolt hole thread repa ir kit from T ool No.

J 42385/100/200/300, consists of the following items:

• Drill with stop collar(1)

• Tap (2)

• Installer (3)

• Fixture Plate (4)

• Long Bolts (5)

• Short Bolts (6)

• Alignment Pin (7)

• Bushing (8)

NOTE

The use of a cutting or drilling fluid is

recommended when performing the drilling,

counter-boring and tapping procedures.

Figure 6A3 – 365

Procedure

NOTE

• The tool kits are designed for use with either

a suitable tap wrench or electric drill.

• Driver oil must be used on the install er driver

tool.

1 Position the fixture plate an d bushing over the hole

that is to be repaired. Position the alignment pin in the

desired hole and tighten the fixture retaining bolts.

2 Remove the alignment pin from the hole ensuring it is

not binding on the sleeve when being removed.

Figure 6A3 – 366

Engine Mechanical Page 6A3–210

Page 6A3–210

3 Drill out the damaged hole.

NOTE

The outer bolt hole locations (11-20) have the

shallower counter-bores. Use bushing (8) from

Tool No. J 42385-316 with the drill,

refer Figure 6A3 – 365.

4 Drill until the stop collar of the drill bit or the sleeve

contacts the bushing.

5 Clean out any foreign material using compressed air.

Figure 6A3 – 367

6 In order to tap the new threads to the correct depth,

rotate the tap into the hole until the marks (1 or 2) on

the tap align with the top of the drill bushing (3) as

follows:

• For the deeper main cap holes (1-10), rotate the

tap until the upper mark (2) on the tap aligns with

the top of the bushing.

• For the shallower main cap holes (11- 20), refer

to Figure 6A3 – 367, rotate the tap until the lower

mark (4) on the tap aligns with top of the

bushing.

7 Remove the fixture plate (4) bushing and attachi ng

bolts.

8 Clean out any debris using compressed air.

Do not use any cleaning agents that contain

Trichloralethane as this is harmful to

aluminium.

9 Spray a suitable cleaner int o the hole.

10 Using compressed air clean any cutting oil and foreign

material out of the hole.

Figure 6A3 – 368

Engine Mechanical Page 6A3–211

Page 6A3–211

11 Apply a small amount of driver oil (1) and lubricate the

threads of the installer tool (2).

NOTE

Do not allow oil or other foreign material to

contact the outside diameter of the insert.

Figure 6A3 – 369

12 Install the driver tool (1) into the insert (2).

Figure 6A3 – 370

13 Apply thread lock Loctite 272 (1) or equivalent to the

insert outer threads (2).

Figure 6A3 – 371

Engine Mechanical Page 6A3–212

Page 6A3–212

14 Install the insert and installer tool (1) through the

fixture plate (2) and bushing (3) and into the hole.

NOTE

The fixture plate and bushing remains installed

onto the cylinder block during the insert

installation procedure.

15 Rotate the driver tool until the mark (4) on the tool

aligns with the top of the bushing.

NOTE

The installer tool will tighten up before screwing

completely through the insert. This is normal

since the bottom threads of the insert are being

formed and mechanically locked into the hole.

16 Remove the driver and fixture plate.

Figure 6A3 – 372

Engine Mechanical Page 6A3–213

Page 6A3–213

5.5 Thread Repair Specifications

Cylinder Block – Front View

Figure 6A3 – 373

Legend

Hole Thread

Size Insert Drill Counterbore

Tool Tap Driver Max

Drill

Depth

Max Tap

Depth

1-6 M8 x 1.25 J 42385-

210 J 42385-

206 J 42385-207 J 42385-

208 J 42385-

209 22.5 17.5

7 M10 x 1.5 J 42385-

215 J 42385-

211 J 42385-212 J 42385-

213 J 42385-

214 25.0 19.5

8 M10 x 1.5 J 42385-

215 J 42385-

211 J 42385-212 J 42385-

213 J 42385-

214 32.5 25.0

9 M8 x 1.25 J 42385-

210 J 42385-

206 J 42385-207 J 42385-

208 J 42385-

209 22.5 17.5

10 M10 x 1.5 J 42385-

215 J 42385-

211 J 42385-212 J 42385-

213 J 42385-

214 Through Through

11–

13 M8 x 1.25 J 42385-

210 J 42385-

206 J 42385-207 J 42385-

208 J 42385-

209 22.5 17.5

14 M8 x 1.25 J 42385-

210 J 42385-

206 J 42385-207 J 42385-

208 J 42385-

209 Through 18.0

15 M8 x 1.25 J 42385-

210 J 42385-

206 J 42385-207 J 42385-

208 J 42385-

209 22.5 17.5

16 M8 x 1.25 J 42385-

210 J 42385-

206 J 42385-207 J 42385-

208 J 42385-

209 Through 18.0

17–

27 M8 x 1.25 J 42385-

210 J 42385-

206 J 42385-207 J 42385-

208 J 42385-

209 22.5 17.5

Engine Mechanical Page 6A3–214

Page 6A3–214

Cylinder Block – Rear View

Figure 6A3 – 374

Legend

Hole Thread

Size Insert Drill

Counterbore

Tool Tap Driver

Max

Drill

Depth

Max

Tap

Depth

1 M10 x 1.5 J 42385-215 J 42385-211 J 42385-212 J 42385-

213 J 42385-

214 27.0 21.5

2-4 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-

208 J 42385-

209 22.5 17.5

5-6 M10 x 1.5 J 42385-215 J 42385-211 J 42385-212 J 4238 5-

213 J 42385-

214 27.0 21.5

7-13 M8 x 1.25 J 42385-210 J 42385-206 J 42385-2 07 J 4238 5-

208 J 42385-

209 22.5 17.5

14-16 M10 x 1.5 J 42385-215 J 42385-211 J 42385-212 J 42385-

213 J 42385-

214 27.0 21.5

17-18 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-

208 J 42385-

209 22.5 17.5

Engine Mechanical Page 6A3–215

Page 6A3–215

Cylinder Block – Left-hand View

Figure 6A3 – 375

Engine Mechanical Page 6A3–216

Page 6A3–216

Legend

Hole Thread

Size Insert Drill

Counterbore

Tool Tap Driver

Max

Drill

Depth

Max

Tap

Depth

1 M8 x 1.25 J 42385-210 J 42385-2 06 J 42385-207 J 42385-

208 J 42385-

209 26.5 19.0

2-3 M11 x 2.0 J 4238 5-108 J 42385-1 05 ⎯ J 42385-

106 J 42385-

107 124.0 115.0

4 M8 x 1.25 J 42385-210 J 42385-2 06 J 42385-207 J 42385-

208 J 42385-

209 26.5 19.0

5 M6 x 1.0 J 42385-205 J 42385-201 J 42385-202 J 42385-

203 J 42385-

204 22.5 16.0

6-7 M11 x 2.0 J 4238 5-108 J 42385-1 05 ⎯ J 42385-

106 J 42385-

107 124.0 115.0

8 M8 x 1.25 J 42385-210 J 42385-2 06 J 42385-207 J 42385-

208 J 42385-

209 26.5 19.0

9 M11 x 2.0 J 4238 5-108 J 42385-1 05 ⎯ J 42385-

106 J 42385-

107 69.0 60.0

10 M11 x 2.0 J 42385-108 J 42385-105 ⎯ J 42385-

106 J 42385-

107 124.0 115.0

11 ⎯ ⎯ ⎯ ⎯ ⎯ ⎯ ⎯ ⎯

12-17 M10 x 1.5 J 4238 5-215 J 42385-2 11 J 42385-212 J 42385-

213 J 42385-

214 29.0 23.0

18 M28 x

1.25 ⎯ ⎯ ⎯ ⎯ ⎯ ⎯ ⎯

19-20 M8 x 1.25 J 42385-210 J 42385-2 06 J 42385-207 J 42385-

208 J 42385-

209 21.0 16.0

21 M16 x 1.5 ⎯ ⎯ ⎯ ⎯ ⎯ ⎯ ⎯

22 M10 x 1.5 J 42385-215 J 42385-211 J 42385-212 J 42385-

213 J 42385-

214 27.0 21.5

23 M11 x 2.0 J 42385-108 J 42385-105 ⎯ J 42385-

106 J 42385-

107 124.0 115.0

24 M11 x 2.0 J 42385-108 J 42385-105 ⎯ J 42385-

106 J 42385-

107 69.0 60.0

25 M8 x 1.25 J 4238 5-210 J 42385-2 06 J 42385-207 J 42385-

208 J 42385-

209 26.5 19.0

26-27 M11 x 2.0 J 4238 5-108 J 42385-1 05 ⎯ J 42385-

106 J 42385-

107 124.0 115.0

28 M6 x 1.0 J 42385-205 J 42385-201 J 42385-202 J 42385-

203 J 42385-

204 22.5 16.0

29 M8 x 1.25 J 4238 5-210 J 42385-2 06 J 42385-207 J 42385-

208 J 42385-

209 26.5 19.0

Bolt holes 2, 3, 6, 7, 10, 23, 26, and 27 have a 85 mm counter-bore included in the 124.0 mm drill depth.

Bolt holes 9 and 24 have a 30 mm counter-b ore included in the 69.0 mm drill depth. Use sleeve J 42385-315 with the

drill and tap.

Engine Mechanical Page 6A3–217

Page 6A3–217

Cylinder Block – Right-hand View

Figure 6A3 – 376

Engine Mechanical Page 6A3–218

Page 6A3–218

Legend

Hole Thread

Size Insert Drill

Counterbore

Tool Tap Driver

Max

Drill

Depth

Max

Tap

Depth

1 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-

208 J 42385-

209 26.5 19.0

2-3 M11 x 2.0 J 42385-108 J 42385-105 ⎯ J 42385-

106 J 42385-

107 124.0 115.0

4 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-

208 J 42385-

209 26.5 19.0

5 M6 x 1.0 J 42385-205 J 42385-201 J 42385-202 J 42385-

203 J 42385-

204 22.5 15.0

6-7 M11 x 2.0 J 42385-108 J 42385-105 ⎯ J 42385-

106 J 42385-

107 124.0 115.0

8 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-

208 J 42385-

209 26.5 19.0

9 M11 x 2.0 J 42385-108 J 42385-105 ⎯ J 42385-

106 J 42385-

107 69.0 60.0

10 M11 x 2.0 J 42385-108 J 42385-105 ⎯ J 42385-

106 J 42385-

107 124.0 115.0

11-14 M10 x 1.5 J 42385-215 J 42385-211 J 42385-212 J 4238 5-

213 J 42385-

214 27.0 21.5

15-19 M10 x 1.5 J 42385-215 J 42385-211 J 42385-212 J 4238 5-

213 J 42385-

214 29.0 23.0

20 M16 x 1.5 ⎯ ⎯ ⎯ ⎯ ⎯ ⎯ ⎯

21 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-

208 J 42385-

209 22.5 17.5

22 M11 x 2.0 J 42385-108 J 42385-105 ⎯ J 42385-

106 J 42385-

107 124.0 115.0

23 M11 x 2 J 42385-108 J 42385-105 ⎯ J 42385-

106 J 42385-

107 69.0 60.0

24 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-

208 J 42385-

209 26.5 19.0

25-26 M11 x 2.0 J 42385-108 J 42385-105 ⎯ J 42385-

106 J 42385-

107 124.0 115.0

27 M6 x 1.0 J 42385-205 J 42385-201 J 42385-202 J 42385-

203 J 42385-

204 22.5 15.0

28 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-

208 J 42385-

209 26.5 19.0

Bolt holes 2, 3, 6, 7, 10, 22, 25, and 26 have a 85 mm counterbore included in the 124.0 mm drill depth.

Bolt holes 9 and 23 have a 30 mm counterbo re included in the 69.0 mm drill depth. Use sleeve J 42385-315 with the

drill and tap.

Engine Mechanical Page 6A3–219

Page 6A3–219

Cylinder Block – Bottom View

Figure 6A3 – 377

Legend

Hole Thread

Size Insert Drill

Counterbore

Tool Tap Driver

Max

Drill

Depth

Max

Tap

Depth

1 M10 x 2.0 J 42385-

104 J 42385-

101 ⎯ J 42385-

102 J 42385-

103 31.0 25.5

2 M10 x 2.0 J 42385-

104 J 42385-

101 ⎯ J 42385-

102 J 42385-

103 53.5 44.0

3 M8 x 1.25 J 4238 5-

210 J 42385-

206 J 42385-207 J 42385-

208 J 42385-

209 22.5 17.5

4 M10 x 2.0 J 42385-

104 J 42385-

101 ⎯ J 42385-

102 J 42385-

103 31.0 25.5

5 M10 x 2.0 J 42385-

104 J 42385-

101 ⎯ J 42385-

102 J 42385-

103 53.5 44.0

6 M16 x 1.5 ⎯ ⎯ ⎯ ⎯ ⎯ ⎯ ⎯

7 N/A ⎯ ⎯ ⎯ ⎯ ⎯ ⎯ ⎯

8 M8 x 1.25 J 4238 5-

210 J 42385-

206 J 42385-207 J 42385-

208 J 42385-

209 22.5 17.5

9 M10 x 2.0 J 42385-

104 J 42385-

101 ⎯ J 42385-

102 J 42385-

103 31.0 25.5

10-11 M10 x 2.0 J 42385-

104 J 42385-

101 ⎯ J 42385-

102 J 42385-

103 53.5 44.0

12 M10 x 2.0 J 42385-

104 J 42385-

101 ⎯ J 42385-

102 J 42385-

103 31.0 25.5

Engine Mechanical Page 6A3–220

Page 6A3–220

Hole Thread

Size Insert Drill

Counterbore

Tool Tap Driver

Max

Drill

Depth

Max

Tap

Depth

13-14 M10 x 1.5 J 42385-

215 J 42385-

101 ⎯ J 42385-

213 J 42385-

214 42.5 37.0

15 M8 x 1.25 J 42385-

210 J 42385-

206 J 42385-207 J 42385-

208 J 42385-

209 22.5 17.5

16 M16 x 1.5 ⎯ ⎯ ⎯ ⎯ ⎯ ⎯ ⎯

17 M10 x 2.0 J 42385-

104 J 42385-

101 ⎯ J 42385-

102 J 42385-

103 53.5

18 M10 x 2.0 J 42385-

104 J 42385-

101 ⎯ J 42385-

102 J 42385-

103 31.0 25.5

19 M8 x 1.25 J 42385-

210 J 42385-

206 J 42385-207 J 42385-

208 J 42385-

209 22.5 17.5

20 M10 x 2.0 J 42385-

104 J 42385-

101 ⎯ J 42385-

102 J 42385-

103 53.5 44.0

21 M10 x 2.0 J 42385-

104 J 42385-

101 ⎯ J 42385-

102 J 42385-

103 31.0 25.5

22 M8 x 1.25 J 42385-

210 J 42385-

206 J 42385-207 J 42385-

208 J 42385-

209 22.5 17.5

23 M10 x 2.0 J 42385-

104 J 42385-

101 ⎯ J 42385-

102 J 42385-

103 31.0 25.5

24 M10 x 2.0 J 42385-

104 J 42385-

101 ⎯ J 42385-

102 J 42385-

103 53.5 44.0

25-26 M8 x 1.25 J 4238 5-

210 J 42385-

206 J 42385-207 J 42385-

208 J 42385-

209 22.5 17.5

27 M10 x 2.0 J 42385-

104 J 42385-

101 ⎯ J 42385-

102 J 42385-

103 31.0 25.5

28-29 M10 x 2.0 J 42385-

104 J 42385-

101 ⎯ J 42385-

102 J 42385-

103 53.5 44.0

30 M10 x 2.0 J 42385-

104 J 42385-

101 ⎯ J 42385-

102 J 42385-

103 31.0 25.5

31 M8 x 1.25 J 42385-

210 J 42385-

206 J 42385-207 J 42385-

208 J 42385-

209 22.5 17.5

32 M28 x

1.25 ⎯ ⎯ ⎯ ⎯ ⎯ ⎯ ⎯

33 M8 x 1.25 J 42385-

210 J 42385-

206 J 42385-207 J 42385-

208 J 42385-

209 22.5 17.5

34 M10 x 2.0 J 42385-

104 J 42385-

101 ⎯ J 42385-

102 J 42385-

103 53.5 44.0

35 M10 x 2.0 J 42385-

104 J 42385-

101 ⎯ J 42385-

102 J 42385-

103 31.0 25.5

36 M8 x 1.25 J 42385-

210 J 42385-

206 J 42385-207 J 42385-

208 J 42385-

209 22.5 17.5

Bolt holes 2, 5, 10, 11, 18, 21, 24, 28, 29, and 34 have a 20.5 mm counterbore i ncluded in the 53.5 mm drill depth.

Bolt holes 1, 4, 9, 12, 17, 20, 23, 27, 30, and 35 have a 1.5 mm counterbore included in the 31.0 mm drill depth. Use

sleeve J 42385-316 with the drill and tap.

Bolt holes 13 and 14 have a 11.5 mm counterbore included in the 42.5 mm drill depth. Use sleeve J 42385-311 with

the drill and tap.

Engine Mechanical Page 6A3–221

Page 6A3–221

Cylinder Block – Top View

Figure 6A3 – 378

Legend

Hole Thread

Size Insert Drill

Counterbore

Tool Tap Driver

Max

Drill

Depth

Max

Tap

Depth

1-4 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 26.5 19.0

5 M16 x 1.5 ⎯ ⎯ ⎯ ⎯ ⎯ ⎯ ⎯

6-7 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 26.5 19.0

8 M10 x 1.5 J 42385-216 J 42385-211 J 42385-212 J 42385-213 J 42385-214 22.5 17.0

9-10 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 26.5 19.0

11 M10 x 1.5 J 42385-2 16 J 42385-211 J 42385-212 J 42385-213 J 42385-214 22.5 17.0

12-14 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 26.5 19.0

Engine Mechanical Page 6A3–222

Page 6A3–222

Cylinder Head – Top View

Figure 6A3 – 379

Legend

Hole Thread

Size Insert Drill

Counterbore

Tool Tap Driver

Max

Drill

Depth

Max

Tap

Depth

1-5 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 26.5 19.0

6-9 M6 x 1.0 J 42385-205 J 4238 5-201 J 42385-202 J 42385-203 J 42385-204 20.05 16.05

10-12 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 26.5 19.0

Cylinder Head – End View

Figure 6A3 – 380

Legend

Hole Thread

Size Insert Drill

Counterbore

Tool Tap Driver

Max

Drill

Depth

Max

Tap

Depth

1 M10 x 1.5 J 42385-215 J 42385-211 J 42385-212 J 42385-213 J 42385-214 28.0 20.0

2 N/A ⎯ ⎯ ⎯ ⎯ ⎯ ⎯ ⎯

3 M10 x 1.5 J 42385-215 J 42385-211 J 42385-212 J 42385-213 J 42385-214 28.0 20.0

4 N/A ⎯ ⎯ ⎯ ⎯ ⎯ ⎯ ⎯

5-6 M10 x 1.5 J 42385-215 J 42385-211 J 42385-212 J 42385-213 J 42385-214 28.0 20.0

Engine Mechanical Page 6A3–223

Page 6A3–223

Cylinder Head – Exhaust Manifold Side View

Figure 6A3 – 381

Legend

Hole Thread

Size Insert Drill

Counterbore

Tool Tap Driver

Max

Drill

Depth

Max

Tap

Depth

1-2 M10 x 1.5 J 42385-215 J 42385-211 J 42385-2 12 J 42385-

213 J 42385-214 28.0 20.0

3 M8 x 1.25 J 42385-210 J 42385-206 J 4238 5-207 J 42385-

208 J 42385-209 21.0 16.0

4 M14 x

1.25 ⎯ ⎯ ⎯ ⎯ ⎯ ⎯ ⎯

5 M8 x 1.25 J 42385-210 J 42385-206 J 4238 5-207 J 42385-

208 J 42385-209 21.0 16.0

6 M14 x

1.25 ⎯ ⎯ ⎯ ⎯ ⎯ ⎯ ⎯

7-8 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-

208 J 42385-209 21.0 16.0

9 M14 x

1.25 ⎯ ⎯ ⎯ ⎯ ⎯ ⎯ ⎯

10 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-

208 J 42385-209 21.0 16.0

11 M14 x

1.25 ⎯ ⎯ ⎯ ⎯ ⎯ ⎯ ⎯

12 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-

208 J 42385-209 21.0 16.0

13 M12 x 1.5 ⎯ ⎯ ⎯ ⎯ ⎯ ⎯ ⎯

14-15 M10 x 1.5 J 42385-215 J 42385-211 J 42385-212 J 42385-

213 J 42385-214 28.0 20.0

Engine Mechanical Page 6A3–224

Page 6A3–224

Cylinder Head – Inlet Manifold Side View

Figure 6A3 – 382

Legend

Hole Thread

Size Insert Drill

Counterbore

Tool Tap Driver

Max

Drill

Depth

Max Tap

Depth

1-2 M6 x 1.0 J 42385-205 J 42385-201 J 42385-202 J 42385-

203 J 42385-

204 Through Through

3-4 M6 x 1.0 J 42385-205 J 42385-201 J 42385-202 J 42385-

203 J 42385-

204 22.5 15.0

5-7 M6 x 1.0 J 42385-205 J 42385-201 J 42385-202 J 42385-

203 J 42385-

204 Through Through

Engine Mechanical Page 6A3–225

Page 6A3–225

6 Specifications

6.1 Engine

General

Engine Type V8 OHV

Displacement 5.7 litre (5,667 cm3 – 346 in3)

Bore 99.009 mm

Stroke 92.0 mm

Compression Ratio 10.1:1

Firing Order 1-8-7-2-6-5-4-3

Cylinder layout, front to rear:

Left-hand bank

Right-hand bank

1, 3, 5, and 7

2, 4, 6 and 8

Spark Plug:

Type

Gap

AC Delco 41-985

1.02 +0.08 / -0.07 mm

Camshaft

End Play 0.025 - 0.305 mm

Journal Diameter 54.99 - 55.04 mm

Journal Diameter Out-of-round 0.025 mm (Maximum)

Lobe Lift:

Intake

Exhaust

Except Coupe:

7.43 mm

Coupe:

6.96 mm

7.13 mm

Lobe Height (Wear Limits):

Intake

Exhaust

Except Coupe:

46.67 mm

Coupe:

46.21 mm

46.37 mm

Runout

(Measured at the Intermediate Journals) 0.050 mm

Timing Check (referenc e only) -

Cam Lift at Top Dead Centre:

Exhaust Closing

Intake Opening

Except Coupe:

0.62 mm

0.15 mm

Coupe:

0.60 mm

0.38 mm

Connecting Rod

Centre to Centre Length 154.90 ± 0.02 mm

Width 24.00 ± 0.05 mm

Bearing Bore Diameter 56.505 - 56.525 mm

Bearing Bore Out-of-round (Production) 0.004 mm

Bearing Bore Out-of-round (Service Limit) 0.008 mm

Bearing Clearance (Prod uction) 0.023 – 0.065 mm

Bearing Clearance (Service Limit) 0.023 – 0.076 mm

Side Clearance 0.110 - 0.510 mm

Twist 0.010 mm Maximum

Bend 0.02 mm Maximum

Engine Mechanical Page 6A3–226

Page 6A3–226

Crankshaft

Stroke 92.00 ± 0.08 mm

End Play 0.040 - 0.200 mm

Connecting Rod Journal 0.065 mm

Bearing Clearance (Production) 0.023 – 0.065

Bearing Clearance (Service Limit) 0.023 – 0.076 mm

Diameter (Production) 53.318 - 53.338 mm

Diameter (Service Limit) 53.308 mm (Minimum)

Taper (Production) 0.005 mm (Maximum for 1/2 of the Journal Length)

Taper (Service Limit) 0.020 mm (Maximum)

Out-of-round (Production) 0.005 mm

Out-of-round (Service Limit) 0.010 mm Main Journal

Bearing Clearance (Prod uction) 0.020 – 0.052 mm

Bearing Clearance (Service Limit) 0.020 – 0.065 mm

Diameter (Production) 64.993 - 65.007 mm

Diameter (Service Limit) 64.993 mm (Minimum)

Out-of-round (Production) 0.003 mm

Out-of-round (Service Limit) 0.008 mm

Taper (Production) 0.010 mm

Taper (Service Limit) 0.020 mm (Maximum)

Reluctor Ring Runout 0.700 mm (Maximum) (Measured 1.0 mm below Tooth Diameter)

Runout (at Rear Flange) 0.050 mm (Maximum)

Thrust Wall Runout 0.025 mm

Thrust Wall Width (Production) 26.22 mm

Thrust Wall Width (Service) 26.20 mm (Maximum)

Cylinder Bore

Cylinder Bore Diameter 99.0 - 99.018 mm

Cylinder Bore Taper and Out-of-round 0.018 mm (Maximum)

Cylinder Head

0.080 mm

(Measured within a 150 mm area)

Cylinder Block Deck Flatness

0.100 mm

(Measured over Full Length of Cylinder Head)

Exhaust Manifold Deck Flatness 0.220 mm

Intake Manifold Deck Flatness 0.220 mm

Height 120.2 mm (Minimum)

(Measured from the Cylinder Head Deck

to the Valve Rocker Arm Cover Seal Surface)

Combustion Chamber Volume 66.67 ± 1.00 cc

Engine Mechanical Page 6A3–227

Page 6A3–227

Cylinder Block

Camshaft Bearing Bore Diameter 55.063 - 55.088 mm

0.080 mm

(Measured within a 150 mm area)

Cylinder Head Deck Surface Flatness

0.220 mm

(Measured over Full Length of the cylinder block deck)

Cylinder Head Deck Height 234.57 - 234.82 mm

(Measured from Crankshaft centreline to D eck Face)

Main Bearing Bore Diameter (Producti on) 69.871 - 69.889 mm

Valve Lifter Bore Diameter (Production) 21.417 - 21.443 mm

Main Bearing Bore Out-of-round 0.005 mm

Intake Manifold

Intake Manifold Cylinder Head

Deck Flatness 0.50 mm

(Measured at Gasket Sealing Surfaces)

Oil Pan – Front and Rear Cover Alignment

Oil Pan to Rear of Cylinder Block

Alignment 0.000 - 0.250 mm

(Maximum at Transmission Housing Mounting Surface)

Front Cover Alignment 0.00 - 0.50 mm (at Oil Pan Surface)

Rear Cover Alignment 0.00 - 0.50 mm (at Oil Pan Surface)

Piston

Piston Outside Diameter (at Size Point &

incl. coating) 98.995 - 99.027 mm

Piston Skirt, Dimensional Variation 0.032 mm (Maximum)

Piston to Bore Clearance (Pro duction)

Interference Clearance 0.027 mm – 0.023 mm

Piston to Bore Clearance (Service Limit)

Interference Clearance 0.027 mm – 0.023 mm

Piston Pin Clearance to Piston Bore

(Production 0.008 - 0.016 mm

Pin Clearance to Piston Bore (Service

Limit) 0.008 - 0.016 mm (Maximum)

Pin Diameter 23.997 - 24.0 mm

Pin Fit in Connecting Rod 0.020 - 0.043 mm (Interference)

Engine Mechanical Page 6A3–228

Page 6A3–228

Piston Rings

Top Compression Ring En d Gap

(Production) 0.230 - 0.380 mm (Measured in C ylinder Bo re)

2nd Compression Ring End Gap

(Production) 0.440 - 0.640 mm (Measured in C ylinder Bo re)

Oil Control Ring End Gap (Production) 0.180 - 0.690 mm (Measured in Cylinder Bore)

Top Compression Ring En d Gap (Service) 0.230 - 0.380 mm (Maxim um) (Measured in Cylinder Bore)

2nd Compression Ring End Gap (Service) 0.440 - 0.640 mm (Maximum) (Measured in Cylinder Bore)

Oil Control Ring End Gap (Service) 0.180 - 0.690 mm (Maximum ) (Measured in Cylinder Bore)

Top Compression Ring Groove Clearance

(Production) 0.040 - 0.085 mm

2nd Compression Ri ng Groove Clearance

(Production) 0.040 - 0.080 mm

Oil Control Ring Groove Clearance

(Production) 0.010 - 0.220 mm

Top Compression Ring Groove Clearance

(Service) 0.040 - 0.085 mm (Maximum)

2nd Compression Ri ng Groove Clearance

(Service) 0.040 - 0.080 mm (Maximum)

Oil Control Ring Groove Clearance

(Service Limit) 0.010 - 0.220 mm (Maximum)

Valve Train

Valve Lifter Hydraulic Roller

Valve Rocker Arm Ratio 1.70:1

Valve Lash No Adjustment

Valve Margin 1.25 Minimum

Valve Face Angle 45 degrees

Valve Seat Angle 46 degrees

Valve Seat Runout 0.050 mm (Maximum)

Width (Intake) 1.020 mm (Maximum)

Width (Exhaust) 1.780 mm (Maximum)

Valve Stem Clearance (Production Intake) 0.025 - 0.066 mm

Clearance (Production Exha ust) 0.025 - 0.066 mm

Clearance (Service Intake) 0.093 mm (Maximum)

Clearance (Service Exha ust) 0.093 mm (Maximum)

Diameter (Production) 7.955 - 7.976 mm

Diameter (Service) 7.95 mm (Minimum)

Engine Mechanical Page 6A3–229

Page 6A3–229

Valve Spring

Free Length 52.9 mm

Pressure (Closed Valve) 340 N at 45.75 mm (Minimum)

Pressure (Open Valve) 980 N at 33.55 mm (Minimum)

Installed Height:

Intake

(Exhaust

45.75 mm

Valve Lift:

Exhaust

Intake

12.11 mm

11.83 mm

Valve Guide Installed Height

(From Cylinder Head Sprin g Seat Surface

to Top of the Valve Guide) 17.32 mm

Sealants and Adhesives

Coolant Sensor Threads Loctite 565 or equivalent

Crankshaft Rear Oil Gallery Plug Loctite 242 or equivalent

Cylinder Head Core Hole Plugs Loctite 242 or equival ent

Cylinder Head Expansion Plugs Loctite 242 or equivalent

Cylinder Head M8 Bolt Threads Loctite 242 or equivalent

Cylinder Block Front Oil Gallery Plug Loctite 242 or equivalent

Cylinder Block Coolant Drain Plug Sealing

Washers Loctite 565 or equivalent

Engine Flywheel Bolt Threads Loctite 242 or equivalent

Exhaust Manifold Bolt Threads Loctite 272 or equivalent

Fuel Rail Bolt Threads Loctite 242 or equivalent

Ignition Coil and Bracket Assembly Bolt

Threads Loctite 242 or equivalent

Intake Manifold Bolt Threads Loctite 242 or equivalent

Oil Pan Surface at Front and Rear Covers Loctite 565 or equivalent

Oil Pressure Sensor Threads Loctite 565 or equivalent

Oil Transfer Tube Bolts and Stud Threads Loctite 242 or equivalent

Engine Mechanical Page 6A3–230

Page 6A3–230

6.2 Lubrication System

Oil Capacity:

Without Oil Filter Change

With Oil Filter Change

Except AWD

5.7 litres

6.2 litres

AWD

7.6 litres

8.0 litres

Minimum Oil Pressure

(Hot) 45 kPa @ 1,000 rpm

125 kPa @ 2,000 rpm

165 kPa @ 4,000 rpm

Oil Type:

Initial Fill

Service Refill

5W - 30 SJ GF4

5W - 30 SJ GF3 or

10W - 30 SJ GF3

Engine Mechanical Page 6A3–231

Page 6A3–231

7 Torque Wrench Specifications

ATTENTION

All engine fasteners are important attaching parts as they affect th e performance of vital componen ts and/or

could result in majo r repair expense. Where specified in this Section, fasteners MUST be rep laced with parts

of the same part number or an approved equivalent. Do not use fasteners of an inferior quality or substitute

design.

Torque values must be used as specified during reassembly to ensure proper retention of all engine

components.

Throughout this Section, fastener torque wrench specifications may be accompanied with the following

identification marks:

 Fasten ers must be replaced after loosening .

 Fasteners either have micro encapsulated sealant applied or incorporate a mechanical thread lock and

should only be re-used once. If in doubt, replacement is recommended.

If one of these identification marks is present alongside a fastener torque wrench specification, the

recommendation regarding that fastener must be adhered to.

7.1 Engine

Air Intake Hose Clamp...................................................................1.5 – 2.5 Nm

Engine Oil Pan Drain Plug....................................................................25.0 Nm

Oil Filter Adapter ..................................................................................55.0 Nm

Engine Oil Filter....................................................................................30.0 Nm

Oil Pressure Sensor .............................................................................20.0 Nm

Oil Level Indicator Tube Attaching Bolt.................................................25.0 Nm

Accessory Belt Idler Pulley Attaching Bolt............................................50.0 Nm

Accessory Belt Tensioner Attaching Bolt..............................................50.0 Nm

A/C Compressor Belt Idler Pulley Attaching Bolt..................................50.0 Nm

A/C Compressor Belt Tensioner Attaching Bolt....................................25.0 Nm

Fuel Rail Attaching Bolts ......................................................................10.0 Nm

Throttle Body Attaching Bolt.................................................................12.0 Nm

Intake Manifold Attaching Bolts

Stage 1...................................................................................................5.0 Nm

Stage 2........................................................................................8.0 – 12.0 Nm

Vapour Vent Pipe Bolt/Stud..................................................................12.0 Nm

PCV Oil Separator Attaching Bolt................................................6.0 – 10.0 Nm

Valley Cover Attaching Bolt..................................................................25.0 Nm

Knock Sensor.......................................................................................20.0 Nm

Valve Rocker Cover Attaching Bolt .....................................................12.0 Nm

Ignition Coil Attaching Screw................................................................12.0 Nm

Ignition Coil Bracket Attaching Stud/Screw ..........................................12.0 Nm

Rocker Arm Attaching Bolts

With No. 1 Cylinder at TDC

Exhaust Valve, Cylinder No.1, 2, 7 and 8..................................25.0 – 35.0 Nm

Intake Valve, Cylinder No.1, 3, 4 and 5 ....................................25.0 – 35.0 Nm

After 360 Deg Crankshaft Rotation

Exhaust Valve, Cylinder No. 3, 4, 5 and 6.................................25.0 – 35.0 Nm

Intake Valve, Cylinder No. 2, 6, 7 and 8 ...................................25.0 – 35.0 Nm

Spark plug:

Used Cylinder Head .............................................................................15.0 Nm

New Cylinder Head ..............................................................................20.0 Nm

Exhaust Manifold Heat Shield Attaching Bolt .........................................9.0 Nm

Exhaust Manifold Attaching Bolt

Stage 1................................................................................................ 15.0 Nm

Stage 2................................................................................................ 25.0 Nm

Engine Mechanical Page 6A3–232

Page 6A3–232

Coolant Temperature Sensor ...............................................................20.0 Nm

Cylinder Head Attaching Bolts

All M11 and M8 Bolts

Stage 1.................................................................................................30.0 Nm

 M11 Bolts only

Stage 2........................................................................................ 90° turn angle

Stage 3........................................................................................ 90° turn angle

Hydraulic Valve Lifter Guide Attaching Bolt..........................................12.0 Nm

Crankshaft Balancer Attaching Bolt

Stage 1 (installation with used bolt).......................................140.0 – 160.0 Nm

 Stage 2:............................................................................................50.0 Nm

Stage 3......................................................................................140° turn angle

Right and Left-hand Close-Out Cover Attaching Screw .......................10.0 Nm

Engine Mount and Bracket Attaching Nut.............................................80.0 Nm

Engine Mounting Bracket and Cylinder Block Attaching Bolt................50.0 Nm

Engine Mount and Crossmember Attaching Nut ..................................80.0 Nm

Oil Pan Baffle Attaching Bolt ................................................................12.0 Nm

Oil Gallery Plug ....................................................................................25.0 Nm

Oil Filter Transfer Tube Attaching Bolt..................................................12.0 Nm

Oil Pan Transfer Cover Attaching Nut ..................................................12.0 Nm

Oil Pan/Front Cover Attaching Bolt.......................................................25.0 Nm

Oil Pan/Rear Cover Attaching Bolt .......................................................12.0 Nm

Oil Pan/Cylinder Block Attaching Bolt...................................................25.0 Nm

Engine Front Cover Attaching Bolt.......................................................25.0 Nm

 Flexplate Attaching Bolt

Stage 1.................................................................................................20.0 Nm

Stage 2.................................................................................................50.0 Nm

Stage 3...............................................................................................100.0 Nm

Engine Rear Cover Attaching Bolt........................................................25.0 Nm

Oil pump Cover to Pump Body Attaching Bolt......................................12.0 Nm

Oil Pump Pressure Relief Plug.............................................................12.0 Nm

Oil Pump Attaching Bolt........................................................................25.0 Nm

Oil Pump Pick-up Tube Attaching Screw..............................................12.0 Nm

Crankcase Oil Deflector Attaching Nut.................................................25.0 Nm

Camshaft Sprocket Attaching Bolt.............................................30.0 – 35.0 Nm

Timing Chain Dampener Attaching Bolt.....................................30.0 – 40.0 Nm

Camshaft Retainer Attaching Bolt ........................................................25.0 Nm

Camshaft Position Sensor Attaching Bolt.............................................25.0 Nm

 Connecting Rod Bearing Cap Attaching Bolt

Stage 1.................................................................................................20.0 Nm

Stage 2........................................................................................75° turn angle

Main Bearing Inner Attaching Bolts (1 – 10)

Stage 1.................................................................................................20.0 Nm

Stage 2........................................................................................80° turn angle

Main Bearing Outer Attaching Studs (11 – 20)

Stage 1.................................................................................................20.0 Nm

Stage 2........................................................................................53° turn angle

 Main Bearing Side Cap Bolts...........................................................25.0 Nm

Crankshaft Position Sensor..................................................................25.0 Nm

Coolant Drain Plug ..............................................................................60.0 Nm

Oil Gallery Drain Plug...........................................................................60.0 Nm

Engine Mechanical Page 6A3–233

Page 6A3–233

7.2 Special Tool Fasteners

Flywheel Holding Tool, No. J 42386-A Attaching Bolts ........................50.0 Nm

Alignment Tool to Front Cover Attaching Bolt.......................................25.0 Nm

Front Engine Cover Alignment Tool to Cylinder Block

Attaching Bolt.......................................................................................25.0 Nm

Rear Cover to Engine Alignment Tool Attaching Bolt...........................25.0 Nm

Rear Engine Cover to Rear Cover Alignment Tool Attaching Bolt........12.0 Nm

Main Bearing Removal Tool Attaching Bolt..........................................11.0 Nm

Engine Mechanical Page 6A3–234

Page 6A3–234

8 Special Tools

Tool Number Illustration Description Classification

AU 525

Quick connect release too l

Use to release the quick connect

fittings on the automatic transmission

fluid cooler lines at the radiator end,

when the vehicle is so equipp ed.

Previously released.

Mandatory

AU 591 Engine stand

Used to support the GEN III V8 engine

at the engine mount location s.

Allows for a 360° rotation capability.

Previously released.

Available

E308

Seal remover

Previously released.

Also numbered 56750

Desirable

E1152

Valve lifter assembly tools

Used to assist in assembly of the

hydraulic valve lifters.

Previously released as 6A24.

Unique

J6125-1B Slide hammer

Used in conjunction with J 41818 to

remove main bearing caps.

Previously released.

Unique

7371

Quick connect release too l

Previously released for releasing fuel

line quick connects after fuel system

has been de-pressurised.

Mandatory

Engine Mechanical Page 6A3–235

Page 6A3–235

Tool Number Illustration Description Classification

E 7115

Torque angle w rench

Used to accurately tighten fasteners

when an angle torque is required.

Previously released.

Unique

J 8087 Cylinder bore checking g au ge

Also as a commercial equivalent.

Previously released.

Unique

J 8433-1

Pulley puller

Used to remove crankshaft timing

gear sprocket, in conjunction with J

41558 and J 41816 –2.

Previously released.

Unique

J 8520

Dial Gauge

Used to measure valve guide wear

and camshaft lobe lift.

Previously released

Desirable

J 21427-01 Puller adaptor

Used in conjunction with J 8433-1,

J 41558 and J 41816-2 to remove

crankshaft timing gear sprocket.

Previously released to remove

automatic transmission speed sensor

ring.

Unique

J 22794

T6A

Adaptor

Used to facilitate the application of air

pressure to a cylinder when replacing

a valve spring or valve stem oil seal

with the cylinder head installed.

Previously released.

Desirable

Engine Mechanical Page 6A3–236

Page 6A3–236

Tool Number Illustration Description Classification

J 23907 Slide hammer

Also released as remover, 6A22-2 and

slide hammer 7A28.

Previously released.

Unique

J 28431-B Fluid dye

Used in conjunction with black light,

leak detection lamp J 42220 to locate

various types of vehicle fluid leaks.

Supplied in packs of 24, 30Ml bottles.

Previously released.

Desirable

J 33049 Camshaft bearing remover/ installer

Universal tool containing selective

components to suit multiple engine

applications.

Previously released.

Unique

J 37378-1

Valve guide reamer

Used to ream worn valve guides to

suit oversize valve stem.

Previously released.

Unique

J 38836

T6A3 189b

Pilot driver

Used to install the spigot bush in the

crankshaft.

Previously released.

Unique

J 41476

T6A3257a

Front and rear cover alignment tool

Used to align both the front and rear

engine covers during installation.

Previously released.

Mandatory

J 41478

T6A3258a

Crankshaft front oil seal installer

Threaded bolt, nut and washer are

also used in conjunction with

J 41665 to install the crankshaft

balancer.

Previously released.

Desirable

Engine Mechanical Page 6A3–237

Page 6A3–237

Tool Number Illustration Description Classification

J 41479

T6A3259

Crankshaft rear oil seal installer

Previously released. Desirable

J 41480

T6A3260a

Front and rear cover alignment tool

Used in conjunction with alignm ent

tool J 41476, to correctly align the

front and rear engine covers.

Previously released.

Mandatory

J 41556 Connecting rod guides

Used to assist in piston and

connecting rod installation.

Previously released.

Desirable

J 41558 Crankshaft sprocket remover

Used in conjunction with the bolts

from J 21427-01 and pulley puller J

8433, to remove the crankshaft

sprocket.

Previously released.

Desirable

J 41665 Crankshaft balancer installer

Comprises:

Stepped sleeve, J 41665-1 and end

plate J 41665-2. Used in conj unction

with Tool J 41478, to install the

crankshaft balancer and crankshaft

sprocket.

Previously released.

Mandatory

J 41712

Oil pressure sensor socket

Used in conjunction with 3/8” drive

socket equipment to remove/reinstall

oil pressure sensor.

Previously released.

Desirable

J 41816

Three legged puller

Used in conjunction with J 41816-2 to

remove crankshaft balancer.

Also commercially available.

Previously released.

Desirable

J 41816-2 Adaptor

Used in conjunction with puller J

41816 to remove crankshaft balancer.

Previously released.

Desirable

Engine Mechanical Page 6A3–238

Page 6A3–238

Tool Number Illustration Description Classification

J 41818 Crankshaft bearing cap remover

Used in conjunction with slide hammer

J 6125-1B to remove main bearing

caps.

Previously released.

Desirable

16296 Black light, leak detection lamp

Used with dye, Tool J 28431-B to

locate the source of various vehicle

fluid leaks.

Previously released.

Desirable

J 42385

/100/200/300

Thread repair kit

Comprises;

Cylinder Head/Rear Mai n

Bearing Cap Kit J 42385-100

General Kit J 42385-200

Fixtures/Hardware Kit J 42385 -300

Previously released.

Unique

J 42386 A

Flywheel holding tool

Previously released. Desirable

J 42907

Oil pressure adaptor

Fitted to the oil filter adaptor and use d

in conjunction with a commerc ially

available oil pr essure gauge and

hose.

Previously released.

Desirable

J38606

Valve spring comp ressor

Used in conjunction with spark plug

adaptor J 22794 to remove valve

springs with cylinder head/s installed.

Desirable

49 U012 006

T6A3114b

Hydraulic valve lifter tester

Previously released.

Used in conjunction with testing fluid

SPX No. E1151

Also numbered 6A23.

Unique