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 Engine Views.......................................................................................................................................................... 8
Engine View Left-hand Side.................................................................................................................................. 8
Lower Front............................................................................................................................................................9
Lower Engine Assembly ..................................................................................................................................... 10
Cylinder Head....................................................................................................................................................... 12
Intake Manifold..................................................................................................................................................... 13
1.2 Engine Serial Number.......................................................................................................................................... 14
1.3 Engine Construction............................................................................................................................................ 15
Cylinder Block...................................................................................................................................................... 15
Cylinder Heads..................................................................................................................................................... 16
Valve Train............................................................................................................................................................ 17
Crankshaft............................................................................................................................................................ 17
Piston and Connecting Rod................................................................................................................................ 18
Camshaft and Drive ............................................................................................................................................. 19
Intake Manifold..................................................................................................................................................... 19
Exhaust Manifold................................................................................................................................................. 20
Oil Pan .................................................................................................................................................................. 21
1.4 Engine Lubrication Sy s t em................................................................................................................................. 22
Oil Pump............................................................................................................................................................... 22
Oil Flow................................................................................................................................................................. 23
Oil Seals................................................................................................................................................................ 24
Positive Crankcase Ventilation System............................................................................................................. 24
1.5 Service Notes....................................................................................................................................................... 25
Cleanliness and Care........................................................................................................................................... 25
Replacing Engine Gaskets.................................................................................................................................. 25
Re-using Gaskets and Applying Sealant .......................................................................................................... 25
Cleaning Gasket Surfaces................................................................................................................................ 25
Assembling Components ................................................................................................................................. 25
Room Temperature Vulcanising (RTV) and Anaerobic Sealers....................................................................... 25
Pipe Joint Compound ....................................................................................................................................... 26
RTV Sealer....................................................................................................................................................... 26
Anaerobic Sealer.............................................................................................................................................. 26
Separating Components ..................................................................................................................................... 27
Special Tools and Equipment............................................................................................................................. 27
Fasteners.............................................................................................................................................................. 28
Clamp Load...................................................................................................................................................... 28
Torque Angle and Torque to Yield Fasteners................................................................................................... 28
Techline
Engine Mechanical Page 6A3–2
Page 6A3–2
2 Diagnosis ..............................................................................................................................................29
2.1 Engine Diagnosis................................................................................................................................................. 29
Procedure............................................................................................................................................................. 29
2.2 Engine Noise........................................................................................................................................................ 31
Procedure............................................................................................................................................................. 31
2.3 Valve Train Noise................................................................................................................................................. 33
Procedure............................................................................................................................................................. 33
2.4 Oil Consumption.................................................................................................................................................. 34
2.5 Oil Pressure.......................................................................................................................................................... 35
Oil Pressure Check.............................................................................................................................................. 35
Diagnosis.............................................................................................................................................................. 35
2.6 Oil Leaks............................................................................................................................................................... 36
2.7 Compression Check ............................................................................................................................................ 38
Interpreting Compression Readings.................................................................................................................. 38
3 Minor Service Operations....................................................................................................................39
3.1 Air Intake Duct...................................................................................................................................................... 39
Remove................................................................................................................................................................. 39
Reinstall................................................................................................................................................................ 39
3.2 Engine Dress Cover............................................................................................................................................. 40
Remove................................................................................................................................................................. 40
Reinstall................................................................................................................................................................ 40
3.3 Engine Oil and Filter............................................................................................................................................ 41
Oil Level Check.................................................................................................................................................... 41
Oil Change............................................................................................................................................................ 42
Oil Filter and Adapter .......................................................................................................................................... 43
Remove............................................................................................................................................................ 43
Reinstall ........................................................................................................................................................... 43
3.4 Oil Pressure Sensor............................................................................................................................................. 44
Remove................................................................................................................................................................. 44
Reinstall................................................................................................................................................................ 44
3.5 Oil Level Indicator and Tube............................................................................................................................... 45
Remove................................................................................................................................................................. 45
Reinstall................................................................................................................................................................ 45
3.6 Engine Drive Belts and Pulleys .......................................................................................................................... 46
Accessory Drive Belt........................................................................................................................................... 46
Remove............................................................................................................................................................ 46
Reinstall ........................................................................................................................................................... 46
Accessory Drive Belt Idler Pulley....................................................................................................................... 46
Remove............................................................................................................................................................ 46
Reinstall ........................................................................................................................................................... 46
Accessory Drive Belt Tensioner......................................................................................................................... 47
Remove............................................................................................................................................................ 47
Reinstall ........................................................................................................................................................... 47
Air Conditioner Drive Belt................................................................................................................................... 47
Remove............................................................................................................................................................ 47
Reinstall ........................................................................................................................................................... 47
Air Conditioner Drive Belt Idler Pulley............................................................................................................... 48
Remove............................................................................................................................................................ 48
Reinstall ........................................................................................................................................................... 48
Air Conditioner Drive Belt Tensioner................................................................................................................. 48
Remove............................................................................................................................................................ 48
Reinstall ........................................................................................................................................................... 48
Engine Mechanical Page 6A3–3
Page 6A3–3
3.7 Intake Manifold Assembly................................................................................................................................... 49
Remove................................................................................................................................................................. 49
Disassemble......................................................................................................................................................... 55
Throttle Body.................................................................................................................................................... 55
Fuel Rail Assembly........................................................................................................................................... 56
Clean and Inspect................................................................................................................................................ 56
Reassemble.......................................................................................................................................................... 57
Fuel Rail Assembly........................................................................................................................................... 57
Throttle Body.................................................................................................................................................... 57
Reinstall................................................................................................................................................................ 58
3.8 Vapour Vent Pipe and Covers............................................................................................................................. 59
Remove................................................................................................................................................................. 59
Reinstall................................................................................................................................................................ 60
3.9 Engine Valley Cover ............................................................................................................................................ 61
Remove................................................................................................................................................................. 61
Disassemble......................................................................................................................................................... 62
Clean and Inspect................................................................................................................................................ 63
Reassemble.......................................................................................................................................................... 63
Reinstall................................................................................................................................................................ 63
3.10 Camshaft Lobe Lift .............................................................................................................................................. 64
Measure ................................................................................................................................................................ 64
3.11 Valve Rocker Arm Cover..................................................................................................................................... 65
Remove................................................................................................................................................................. 65
Clean and Inspect................................................................................................................................................ 68
Reinstall................................................................................................................................................................ 68
3.12 Valve Rocker Arms and Push Rods................................................................................................................... 70
Remove................................................................................................................................................................. 70
Clean and Inspect................................................................................................................................................ 71
Reinstall................................................................................................................................................................ 71
3.13 Valve Stem Oil Seal and Valve Spring................................................................................................................ 73
Remove................................................................................................................................................................. 73
Reinstall................................................................................................................................................................ 75
3.14 Exhaust Manifold................................................................................................................................................. 76
Remove................................................................................................................................................................. 76
Inspect .................................................................................................................................................................. 77
Reinstall................................................................................................................................................................ 77
3.15 Cylinder Head....................................................................................................................................................... 79
Remove................................................................................................................................................................. 79
Disassemble......................................................................................................................................................... 81
Clean..................................................................................................................................................................... 82
Inspect .................................................................................................................................................................. 83
Cylinder Head................................................................................................................................................... 83
Valve Springs ................................................................................................................................................... 84
Valves .............................................................................................................................................................. 84
Valve Guides.................................................................................................................................................... 85
Valve Stem Oversize........................................................................................................................................ 86
Valve Seats ...................................................................................................................................................... 87
Reassemble.......................................................................................................................................................... 88
Reinstall................................................................................................................................................................ 89
3.16 Hydraulic Valve Lifters........................................................................................................................................ 92
Remove................................................................................................................................................................. 92
Disassemble......................................................................................................................................................... 93
Clean and Inspect................................................................................................................................................ 94
Reassemble.......................................................................................................................................................... 95
Testing Lifter Leak-down Rate............................................................................................................................ 96
Reinstall................................................................................................................................................................ 97
Engine Mechanical Page 6A3–4
Page 6A3–4
3.17 Crankshaft Balancer............................................................................................................................................ 98
Remove................................................................................................................................................................. 98
Clean and Inspect.............................................................................................................................................. 100
Reinstall.............................................................................................................................................................. 101
3.18 Crankshaft Front Oil Seal.................................................................................................................................. 103
Remove............................................................................................................................................................... 103
Reinstall.............................................................................................................................................................. 103
3.19 Engine Mounts................................................................................................................................................... 104
Inspect ................................................................................................................................................................ 104
Remove............................................................................................................................................................... 104
Reinstall.............................................................................................................................................................. 106
4 Major Service Operations..................................................................................................................107
4.1 Engine Assembly............................................................................................................................................... 107
Remove............................................................................................................................................................... 107
Disassemble – Ancillary Equipment ................................................................................................................ 113
Reassemble........................................................................................................................................................ 115
Reinstall Set-up and Testing............................................................................................................................. 115
4.2 Oil Pan Assembly............................................................................................................................................... 116
Remove............................................................................................................................................................... 116
Disassemble....................................................................................................................................................... 116
Clean and Inspect.............................................................................................................................................. 118
Reassemble........................................................................................................................................................ 119
Reinstall.............................................................................................................................................................. 120
4.3 Engine Front Cover............................................................................................................................................ 122
Remove............................................................................................................................................................... 122
Clean and Inspect.............................................................................................................................................. 122
Reinstall.............................................................................................................................................................. 123
4.4 Engine Flexplate ................................................................................................................................................ 125
Remove............................................................................................................................................................... 125
Clean and Inspect.............................................................................................................................................. 126
Crankshaft...................................................................................................................................................... 126
Flexplate......................................................................................................................................................... 126
Reinstall.............................................................................................................................................................. 127
4.5 Engine Rear Cover............................................................................................................................................. 128
Remove............................................................................................................................................................... 128
Clean and Inspect.............................................................................................................................................. 128
Reinstall.............................................................................................................................................................. 129
Crankshaft Rear Main Oil Seal....................................................................................................................... 131
4.6 Oil Pump, Pump Screen and Deflector ............................................................................................................ 132
Remove............................................................................................................................................................... 132
Oil Pump Disassemble ...................................................................................................................................... 133
Clean and Inspect.............................................................................................................................................. 134
Oil Pump Reassemble ....................................................................................................................................... 134
Reinstall.............................................................................................................................................................. 135
4.7 Timing Chain and Sprockets............................................................................................................................. 136
Remove............................................................................................................................................................... 136
Clean and Inspect.............................................................................................................................................. 137
Reinstall.............................................................................................................................................................. 138
4.8 Camshaft ............................................................................................................................................................ 140
Remove............................................................................................................................................................... 140
Clean and Inspect.............................................................................................................................................. 141
Reinstall.............................................................................................................................................................. 143
Engine Mechanical Page 6A3–5
Page 6A3–5
4.9 Piston, Connecting Rod and Bearing............................................................................................................... 144
Remove............................................................................................................................................................... 144
Disassemble....................................................................................................................................................... 145
Clean and Inspect.............................................................................................................................................. 146
Piston and Pin ................................................................................................................................................ 146
Connecting Rods and Bearings...................................................................................................................... 149
Measuring Piston Ring End Gap .................................................................................................................... 151
Reassemble........................................................................................................................................................ 151
Piston Selection.............................................................................................................................................. 151
Piston to Connecting Rod............................................................................................................................... 153
Piston Rings ................................................................................................................................................... 154
Reinstall.............................................................................................................................................................. 154
4.10 Crankshaft and Bearings .................................................................................................................................. 156
Crankshaft Thrust End Play.............................................................................................................................. 156
Measure ......................................................................................................................................................... 156
Remove............................................................................................................................................................... 156
Clean and Inspect.............................................................................................................................................. 159
Main Bearings Inspect.................................................................................................................................... 161
Main Bearing Oil Clearance ........................................................................................................................... 162
Reinstall.............................................................................................................................................................. 165
4.11 Cylinder Block Plugs......................................................................................................................................... 167
Remove............................................................................................................................................................... 167
Reinstall.............................................................................................................................................................. 169
4.12 Cylinder Block.................................................................................................................................................... 171
Cylinder Block Clean, Inspect and Measure.................................................................................................... 171
Clean.............................................................................................................................................................. 171
Inspect............................................................................................................................................................ 171
Cylinder Bore – Measure................................................................................................................................ 171
Cylinder Boring and Honing ............................................................................................................................. 173
Honing Procedure .......................................................................................................................................... 173
Deglazing Procedure...................................................................................................................................... 173
Camshaft Bearings............................................................................................................................................ 174
Remove.......................................................................................................................................................... 174
Reinstall ......................................................................................................................................................... 176
5 Thread Repair .....................................................................................................................................177
5.1 General Information........................................................................................................................................... 177
5.2 General Thread Repair ...................................................................................................................................... 178
5.3 Cylinder Head Bolt Hole Thread Repair........................................................................................................... 181
Procedure........................................................................................................................................................... 181
5.4 Main Bearing Cap Bolt Hole Thread Repair.................................................................................................... 185
Procedure........................................................................................................................................................... 185
5.5 Thread Repair Specifications............................................................................................................................ 189
Cylinder Block – Front View.............................................................................................................................. 189
Cylinder Block – Rear View............................................................................................................................... 190
Cylinder Block – Left-hand View ...................................................................................................................... 191
Cylinder Block – Right-hand View.................................................................................................................... 193
Cylinder Block – Bottom View.......................................................................................................................... 195
Cylinder Block – Top View................................................................................................................................ 197
Cylinder Head – Top View................................................................................................................................. 198
Cylinder Head – End View................................................................................................................................. 198
Cylinder Head – Exhaust Manifold Side View.................................................................................................. 199
Cylinder Head – Inlet Manifold Side View........................................................................................................ 200
Engine Mechanical Page 6A3–6
Page 6A3–6
6 Specifications.....................................................................................................................................201
6.1 Engine................................................................................................................................................................. 201
General ............................................................................................................................................................... 201
Camshaft ............................................................................................................................................................ 201
Connecting Rod................................................................................................................................................. 202
Crankshaft.......................................................................................................................................................... 202
Cylinder Bore ..................................................................................................................................................... 203
Cylinder Head..................................................................................................................................................... 203
Cylinder Block.................................................................................................................................................... 203
Intake Manifold................................................................................................................................................... 203
Oil Pan – Front and Rear Cover Alignment...................................................................................................... 203
Piston.................................................................................................................................................................. 204
Piston Rings....................................................................................................................................................... 204
Valve Train.......................................................................................................................................................... 205
Valve Spring....................................................................................................................................................... 205
Sealants and Adhesives.................................................................................................................................... 206
6.2 Lubrication System............................................................................................................................................ 207
7 Torque Wrench Specifications..........................................................................................................208
7.1 Engine................................................................................................................................................................. 208
7.2 Special Tool Fasteners...................................................................................................................................... 210
8 Special Tools ......................................................................................................................................211
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 located 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 between 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, visually seamless rod
cap union.
The crankshaft is manufactured from nodular cast iron and is drilled through the centre of main bearing journals 2, 3 and
5 to reduce weight. A crankshaft position sensor reluctor ring 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-hand 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.
Engine Mechanical Page 6A3–8
Page 6A3–8
1.1 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
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 Cylinder Block Front Oil Gallery
Plug
12 Cylinder Block Plug, 3 places
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 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 Engine Flexplate
Engine Mechanical Page 6A3–12
Page 6A3–12
Cylinder Head
Figure 6A3 – 4
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 6A3–13
Page 6A3–13
Intake Manifold
Figure 6A3 – 5
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 6A3–14
Page 6A3–14
1.2 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 as an example;
• The first two numbers, 05 = 2005 indicates the engine
model year.
• The next three numbers, 190 is the Julian date (day of
the year the engine was manufactured).
• The next four numbers are the daily sequential build
number.
Figure 6A3 – 6
Engine Mechanical Page 6A3–15
Page 6A3–15
1.3 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 aluminium 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 bolts.
Boring of the cylinders is not permitted, although the
cylinders can be honed.
Figure 6A3 – 7
The cylinder block incorporates enclosed valve lifter bores
(1) under each cylinder head.
A structural die-cast aluminium valley cover (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 – 8
Engine Mechanical Page 6A3–16
Page 6A3–16
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 identical for 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 flanges 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 – 9
The additional height 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 – 10
Engine Mechanical Page 6A3–17
Page 6A3–17
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 angles are at 46°
with an intake valve head diameter of 50.8 mm and exhaust
valve head diameter of 39.4 mm. Figure 6A3 – 11
The valve springs are conical in shape and are made from chromium silicone spring steel. The 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 investment 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 and use a pre-moulded silicone gasket for sealing. There 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) system.
Crankshaft
The crankshaft (1) is manufactured from nodular cast iron
and is supported by five main bearings. Each main bearing
cap is attached to the cylinder block by six bolts, two of
which are attached from the side. The main bearing caps
are machined with the cylinder block for correct 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 – 12
Engine Mechanical Page 6A3–18
Page 6A3–18
Piston and Connecting Rod
The cast aluminium pistons are fitted with two compression
rings (4, 5) and one oil control ring assembly (1,2,3). The
piston rings are a thin low friction design. The top ring is
located close to the top of the piston crown to reduce
hydrocarbon emissions and blow-by. The pistons are a low
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 – 13
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 required. Boring of the
cylinder is not permitted.
Figure 6A3 – 14
Engine Mechanical Page 6A3–19
Page 6A3–19
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 reduce chain noise
and resonance and is attached to the engine block just
above the crankshaft timing gear.
Figure 6A3 – 15
Intake Manifold
The intake manifold (1) is a one-piece composite design that
incorporates threaded metal inserts (A) for attaching the fuel
rail (2) and the electronic throttle body.
The intake manifold is sealed to the cylinder heads by eight
separate non-reusable 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 body is sealed to the
intake manifold using a one piece silicone gasket.
The fuel rail assembly has eight separate fuel 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 incorporated 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 passages 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 – 16
Engine Mechanical Page 6A3–20
Page 6A3–20
Exhaust Manifold
The exhaust manifolds are one piece, high temperature
silicone molybdenum cast iron manifold.
The exhaust manifolds direct the exhaust gases from the
combustion chambers to the exhaust system.
The exhaust manifolds are attached to each cylinder head
using six M8 bolts.
Figure 6A3 – 17
Each exhaust manifold (1) has an externally mounted dual
wall heat shield (2) made of aluminised steel that is attached
to the manifold by five M6 bolts (3).
Figure 6A3 – 18
Engine Mechanical Page 6A3–21
Page 6A3–21
Oil Pan
The cast aluminium oil pan (1) forms a structural part of the
powertrain by providing a 360° mounting for the
transmission.
Incorporated into the oil pan casting are cast-in dams.
These dams minimise oil migration during braking and
cornering manoeuvres and assist in guiding oil to the pick-
up screen (2) via the strategically placed openings in the
dam walls.
Also incorporated in the oil pan 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 maintains 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 – 19
Engine Mechanical Page 6A3–22
Page 6A3–22
1.4 Engine Lubrication System
Oil Pump
A Gerotor type oil pump assembly supplies the engine lubrication, refer to Figure 6A3 – 20. 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 pipe. Contained within the oil pump assembly is a pressure relief valve that
maintains oil pressure within a specified range.
Pressurised oil is directed through 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 – 21.
Figure 6A3 – 20
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 6A3–23
Page 6A3–23
Oil Flow
Oil is directed to the drilled upper main oil galleries just above the camshaft assembly at the rear of the cylinder block,
refer to Figure 6A3 – 21. From there, oil is then directed to the crankshaft and camshaft bearings. Oil that has entered
the upper main oil galleries 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 returning to the pan back to the
sump.
Figure 6A3 – 21
Engine Mechanical Page 6A3–24
Page 6A3–24
Oil Seals
The rear main oil seal is a multiple lip oil seal designed for
long life operation.
The seal includes a Polytetrafluoroethylene (PTFE) Teflon
centre lip (1) to minimise rear main oil seal leaks. The 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 installation
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 – 22
Positive Crankcase Ventilation System
The crankcase ventilation system 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 air 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, an
acceptable reverse flow condition may occur in the fresh air
inlet hose.
Figure 6A3 – 23
During sustained maximum lateral acceleration (A), the
outboard rocker cover may be overloaded with oil (1). If the
blow-by gas is drawn from the rocker cover as in previous
designs, oil may be ingested into the intake manifold.
Instead of the blow-by gas being drawn from the rocker
cover, a high efficiency oil separator (2) in conjunction 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 – 24
Engine Mechanical Page 6A3–25
Page 6A3–25
1.5 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 retained in a specific order for
reassembly. Further information, refer to Separating Components. 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, polished and 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 during component assembly. Proper lubrication
of engine components during 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 sealing 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 components, use only the sealant specified or equivalent as recommended in the service procedure.
When applying sealant to a component, apply the amount specified in the service procedure. Do not allow the sealant to
enter into any blind threaded holes 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 may require lubrication during assembly. Components requiring
lubrication will be identified in the service procedure.
Ensure all fasteners are tightened 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 amount must be used
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 6A3–26
Page 6A3–26
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 surfaces) 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 and 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 and 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 temperatures are experienced. These areas include exhaust manifold 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 may prevent the fastener from
clamping correctly or cause component 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 eliminator or thread sealant hardens with the absence of air. This 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 readily 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 damage 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 fasteners, 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 6A3–27
Page 6A3–27
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 reinforced areas to prevent
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 components will develop specific wear patterns on their friction surfaces. 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 components:
• 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 connecting 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 bearing 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 Section,
refer to 8 Special Tools.
These tools or their equivalents are specially designed to quickly and safely accomplish the operation for which they are
intended. The use of the special tools listed will also minimise possible damage to engine components. Some precision
measuring tools are required for inspection of certain critical components. Torque wrenches and torque angle tools are
necessary for correct tightening of various fasteners.
To correctly service the engine assembly, 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 supply
• Trays or storage containers to keep parts and fasteners organised
• Adequate set of hand tools
• Approved engine repair stand such as Tool AU 591
• Approved engine lifting device that will adequately support the weight of the engine and transmission assembly
Engine Mechanical Page 6A3–28
Page 6A3–28
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 removed 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 – 25
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 bolt head (2) and in
the threads (3) absorbs much of the applied torque.
Typically, only 10% of the torque 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 variation in the clamp
load applied to the joint.
Figure 6A3 – 26
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 angle 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 6A3–29
Page 6A3–29
2 Diagnosis
2.1 Engine Diagnosis
Engine performance diagnosis procedures are covered in Section 6C3-2 Powertrain Management – GEN III V8 –
Diagnostics and should be referred to for diagnosis of any driveability, emissions, or powertrain diagnostic trouble codes
(DTC) problems.
The following diagnosis covers 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 specific 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
flexplate for loose or incorrect installation.
• Worn, damaged, or misaligned accessory drive 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 excessive oil consumption. Refer to 2.4 Oil Consumption.
• Verify if the engine is consuming coolant.
• Perform a compression test on the engine.
Intake manifold leaks An intake manifold that has a vacuum leak may cause a misfire which is more prominent
at idle.
Inspect for the following:
• Incorrectly installed or damaged vacuum hoses.
• Faulty or incorrectly installed intake manifold and / or gaskets.
• Cracks or damage to the intake manifold, also inspect the areas between the intake
runners.
• Incorrectly installed or damaged 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.
Engine Mechanical Page 6A3–30
Page 6A3–30
Checks Action
Coolant consumption Coolant consumption may or may not cause the engine to overheat. However, an engine
that has been overheated may cause premature failure of head gaskets and distortion of
gasket surfaces.
Abnormal internal engine
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 speed. Two knocks per flash is crankshaft speed and
one knock per flash is camshaft speed.
• A slight COLD knock or piston slapping noise could be considered 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 engine 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 down).
• Worn or Incorrectly seated valves.
• Worn camshaft lobes.
Engine Mechanical Page 6A3–31
Page 6A3–31
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 engine.
• Remember, engine noises are generally synchronised to either engine speed (crankshaft, flexplate,
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 rate 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 another 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 caused by:
• Incorrect oil viscosity. Change the engine oil with the recommended
oil viscosity for the expected temperatures.
• 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 clearance.
• 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 balancer or accessory drive components.
• Excessive piston to bore clearance.
• Cracked piston.
NOTE
A cold engine knock usually disappears when the specific cylinder's
secondary ignition 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 temperatures.
• 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 6A3–32
Page 6A3–32
Checks Action
Valve train noise (rattle/tapping) 1 The following conditions may cause valve train noise:
• Lower than specified oil pressure.
• 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 drive system components.
• Loose or broken crankshaft balancer.
• Detonation (Pinging). Check for correct operation of the cooling,
knock, and ignition control components. 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 flexplate bolts.
• Cracked or damaged 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 bracket.
Engine Mechanical Page 6A3–33
Page 6A3–33
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 valve 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 by the following:
• Fuel injectors.
• Evaporative emission (EVAP) purge solenoid.
• 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 causing excessive valve lash.
• Worn or damaged valve rocker arm bearings.
• 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 camshaft 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, aeration, 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 6A3–34
Page 6A3–34
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 engine oil
level.
• Incorrect oil viscosity. Refer to the vehicle Owners Manual 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 necessary.
• 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 bore wear or taper.
• Cylinder damage.
• Piston damage.
Engine Mechanical Page 6A3–35
Page 6A3–35
2.5 Oil Pressure
Oil Pressure Check
1 Ensure the engine is at operating temperature. 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 and Filter.
5 Install an accurate oil pressure gauge that is capable
of reading 800 kPa or higher and 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 load condition.
Figure 6A3 – 27
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 – 28
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 tube
• Missing or damaged oil pump pick-up tube O-ring seal.
• Malfunctioning oil pump oil pressure relief valve.
• Excessive bearing clearances.
• Cracked, porous or restricted oil galleries.
• Oil gallery plugs leaking, missing or incorrectly installed.
• Broken or malfunctioning hydraulic valve lifters.
• 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 6A3–36
Page 6A3–36
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 temperature.
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 location 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 locations:
• 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 and 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 6A3–37
Page 6A3–37
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.
Go to Step 8 Go to Step 7
7 1 Check for the following conditions:
• Higher than recommended fluid levels
• Higher than recommended fluid pressures
• Blocked or malfunctioning fluid filters or pressure bypass valve
• Blocked or malfunctioning engine ventilation system
• Incorrectly tightened, missing or damaged fasteners
• Cracked or porous components
• Incorrect sealants or gaskets where required
• Improper sealant or gasket installation
• Damaged or worn gaskets or seals
• Damaged or worn sealing surfaces
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 6A3–38
Page 6A3–38
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 Management – 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 approximately four
compression strokes and record the reading. Repeat
for each cylinder, recording the reading.
6 If a cylinder has low compression, inject about 15 ml
(one tablespoon) of engine oil into the combustion
chamber through the spark plug hole. Crank the
engine over for approximately four turns to distribute
the oil.
7 Recheck the compression and record the reading.
8 Compare the compression readings, refer to
Interpreting Compression Readings.
Figure 6A3 – 29
Interpreting Compression Readings
The minimum compression in any one cylinder should not be less than 70% of the highest cylinder. For example, if the
highest pressure in any one 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 quickly 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 usually 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 6A3–39
Page 6A3–39
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 loosen ing.
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 attaching the intake duct to
the air box and the throttle body and remove the duct
from the engine.
Figure 6A3 – 30
Reinstall
Reinstallation of the air intake duct is the reverse 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 6A3–40
Page 6A3–40
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 – 31
Reinstall
Reinstallation of the engine dress covers is the reverse of the removal procedure ensuring the retaining clips are fully
engaged.
Engine Mechanical Page 6A3–41
Page 6A3–41
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 to 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 – 32
Engine Mechanical Page 6A3–42
Page 6A3–42
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.
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 vehicle 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 material from around the oil pan
drain plug (1).
4 Place a suitable oil drain tray 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 completely, 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 – 33
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........................5.7 litres
Capacity with oil filter change.............................6.2 litres
9 Start the engine and allow to run for three to five minutes checking for oil leaks, stop the engine, rectify any leaks
and then recheck the oil level topping up as required, refer to Oil Level Check.
Engine Mechanical Page 6A3–43
Page 6A3–43
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.
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 – 34
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 adaptor threads for damage.
2 If removed, reinstall the oil filter adaptor and tighten to the correct torque specification.
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 specification.
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 allow to run for three to five minutes checking for oil leaks. Stop the engine, rectify any leaks
and then recheck the oil level topping up as required, refer to Oil Level Check.
Engine Mechanical Page 6A3–44
Page 6A3–44
3.4 Oil Pressure Sensor
LT Section No. — 02–000
Remove
1 Release the wiring harness connector (1) locking tang
from the oil pressure sensor (2) and remove the
connector from the sensor.
Figure 6A3 – 35
2 Using the oil pressure sensor socket, Tool No. J41712
and suitable 3/8” drive socket equipment, remove the
oil pressure sensor (1) from the left-hand rear of the
cylinder block.
Figure 6A3 – 36
Reinstall
1 Clean the threads of the oil pressure sensor.
2 Apply Loctite 565 sealant or equivalent 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 operation and leaks.
Engine Mechanical Page 6A3–45
Page 6A3–45
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 – 37
Reinstall
1 Clean the oil level indicator tube and 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 6A3–46
Page 6A3–46
3.6 Engine Drive Belts and Pulleys
LT Section No. — 01–003
Accessory Drive Belt
Remove
1 Rotate the engine accessory drive belt tensioner
pulley attaching bolt (1) in the direction indicated to
reduce belt tension.
2 While holding the tensioner in the reduced tension
position, remove the accessory drive belt (2) from the
pulleys, taking note of the belt routing.
3 Clean the accessory drive belt running surfaces and
inspect the belt for damage, replace as required.
Figure 6A3 – 38
Reinstall
1 Route the belt around the pulleys except the water pump pulley, ensuring that it is seated correctly in the pulley
grooves.
2 Rotate the tensioner and then slide the 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 operation.
Accessory Drive Belt Idler Pulley
Remove
1 Remove the engine accessory drive belt. Refer to Accessory Drive Belt.
2 Remove the idler pulley attaching bolt (1) and remove
the pulley (2) from its mounting boss on the generator
mounting bracket (3).
Figure 6A3 – 39
Reinstall
1 Install the idler pulley to the mounting boss.
2 Install the idler pulley attaching bolt and tighten to the correct torque specification.
Accessory belt idler pulley attaching bolt
torque specification ............................................50.0 Nm
3 Install the engine accessory drive belt. Refer to Accessory Drive Belt.
Techline
Engine Mechanical Page 6A3–47
Page 6A3–47
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 – 40
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 belt idler pulley, refer to Accessory Drive Belt Idler Pulley.
3 Reinstall the engine accessory drive belt, refer to Accessory Drive Belt.
Air Conditioner Drive Belt
Remove
1 Raise the vehicle and support 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 direction 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 running surfaces
and inspect the belt for damage, replacing as required.
Figure 6A3 – 41
Reinstall
1 While holding the air conditioner drive belt tensioner in the direction indicated, refer to Figure 6A3 – 41, install the
drive belt over the pulleys routing the belt correctly.
2 Reinstall the accessory drive belt, refer to Accessory Drive Belt.
3 Inspect the installation to ensure the belt is correctly aligned on all pulleys.
4 Start the engine to ensure correct operation.
Engine Mechanical Page 6A3–48
Page 6A3–48
Air Conditioner Drive Belt Idler Pulley
Remove
1 Remove the air conditioner drive 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 – 42
Reinstall
1 Install the idler pulley (2) to the mounting boss. Install the attaching bolt and tighten to the correct torque
specification, refer to Figure 6A3 – 42.
Air conditioner belt idler pulley attaching bolt
torque specification ............................................50.0 Nm
2 Install the air conditioner drive belt, refer to Air Conditioner 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 pulley
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 – 43
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 tensioner 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 Conditioner Drive Belt.
Engine Mechanical Page 6A3–49
Page 6A3–49
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 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 end is fitted with
a tether to prevent loss.
Figure 6A3 – 44
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 foreign matter from entering
the fuel system.
Figure 6A3 – 45
Engine Mechanical Page 6A3–50
Page 6A3–50
9 Disconnect the electronic throttle body wiring harness
connector (1) from the throttle body.
Figure 6A3 – 46
10 Disconnect the fuel injector wiring harness connectors
(1), four places from the right-hand bank of fuel
injectors.
11 Remove the CPA lock (2) from the ignition coil main
connector (3) on the right-hand side. Remove the
connector then the harness attaching clips from the
fuel rail brackets (4) and set the harness to one side.
Figure 6A3 – 47
Engine Mechanical Page 6A3–51
Page 6A3–51
12 Disconnect the fuel injector wiring harness connector
(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 main
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 – 48
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 – 49
Engine Mechanical Page 6A3–52
Page 6A3–52
19 Remove the fresh air hose (1) from the front fitting of
the rocker cover and the air intake duct.
Figure 6A3 – 50
20 Remove the foul air hose (1) from the throttle body
and the valley cover outlet.
Figure 6A3 – 51
21 Disconnect the engine coolant vapour vent outlet to
radiator hose (1) from the base of the throttle body.
Figure 6A3 – 52
Engine Mechanical Page 6A3–53
Page 6A3–53
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 – 53
24 Remove the EVAP canister purge valve and bracket
(1) from the intake manifold.
Figure 6A3 – 54
26 Progressively loosen the intake manifold attaching bolt
(1), 10 places, while working diagonally 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 – 55
Engine Mechanical Page 6A3–54
Page 6A3–54
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 attaching bolts (2) and the fuel rail
stop bracket (3) are removed from the intake
manifold completely.
Figure 6A3 – 56
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 – 57
Engine Mechanical Page 6A3–55
Page 6A3–55
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 body.
Figure 6A3 – 58
3 Remove the seal (1) and discard. Do not re-use this
seal.
Figure 6A3 – 59
Engine Mechanical Page 6A3–56
Page 6A3–56
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 – 60
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 and 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 including 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 faces 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 6A3–57
Page 6A3–57
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 bores.
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 specification.
Fuel rail attaching studs
torque specification ...................................8.0 – 12.0 Nm
Figure 6A3 – 61
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 – 62
2 Install the throttle body (1) and attaching 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 – 63
Engine Mechanical Page 6A3–58
Page 6A3–58
Reinstall
Reinstallation of the intake manifold 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 gaskets, refer to Figure 6A3 – 57.
3 Install the intake manifold assembly (1) by carefully
positioning the manifold onto the cylinder head.
4 Apply a 5 mm bead of thread sealant such as
Loctite 242 or equivalent to the cleaned 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 – 65.
Figure 6A3 – 64
6 Tighten the intake manifold bolts in two stages in the
sequence shown to the correct torque specification.
Intake manifold attaching bolts
torque specification
Stage 1 ................................................................5.0 Nm
Stage 2 .....................................................8.0 – 12.0 Nm
Figure 6A3 – 65
7 Reconnect the electronic throttle body wiring harness
connector (1).
8 Reconnect the engine coolant vapour vent hoses and
refill the coolant with the recommended coolant and to
the correct level, refer to Section 6B3 Engine Cooling
GEN III V8.
Figure 6A3 – 66
Engine Mechanical Page 6A3–59
Page 6A3–59
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 bleed 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), two places,
attaching the vapour vent pipe (5) together with both
gaskets (6) to the cylinder block. Discard the gaskets.
Figure 6A3 – 67
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 – 68
Engine Mechanical Page 6A3–60
Page 6A3–60
Reinstall
1 Correctly install a new vapour pipe gasket by fitting the
O-ring seal section (1) over the pipe fitting nipple (2).
Figure 6A3 – 69
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 – 70
Engine Mechanical Page 6A3–61
Page 6A3–61
3.9 Engine Valley Cover
LT Section No. —
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 – 71
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 – 72
Engine Mechanical Page 6A3–62
Page 6A3–62
5 Remove the valley cover attaching bolt (1), 10 places
and remove the valley cover and gasket from the
cylinder block.
Figure 6A3 – 73
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 cover.
2 Remove the PCV oil separator from the engine valley
cover.
Figure 6A3 – 74
Engine Mechanical Page 6A3–63
Page 6A3–63
3 Remove the two knock sensor oil seals (1) from the
valley cover (2).
Figure 6A3 – 75
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 available cleaning fluid and blow 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 – 76
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 reinstall 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 pipe, refer to 3.8 Vapour Vent Pipe.
Engine Mechanical Page 6A3–64
Page 6A3–64
3.10 Camshaft Lobe Lift
Measuring the camshaft lobe lift is a procedure used to determine 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 installed
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 and 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 ........................................................ 7.43 mm
Exhaust lobe ..................................................... 7.43 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 4.8 Camshaft for wear limits.
Figure 6A3 – 77
Engine Mechanical Page 6A3–65
Page 6A3–65
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 terminal 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 – 78
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 – 79
Engine Mechanical Page 6A3–66
Page 6A3–66
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 bank for
the cover being removed.
Figure 6A3 – 80
9 Remove the CPA lock (1) from the ignition coil main
connector on the rocker cover being removed then
remove the wiring harness connector (2).
10 Remove the four bolts and one screw (3) attaching the
ignition coil mounting bracket (4) to the rocker 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 – 81
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 – 82
Engine Mechanical Page 6A3–67
Page 6A3–67
NOTE
Do not remove the oil fill tube from the right hand
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 fill tube (2)
from the right-hand valve rocker arm cover (3).
Discard the oil fill tube as this will be permanently
damaged when removed.
Figure 6A3 – 83
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 – 84
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 – 85
Engine Mechanical Page 6A3–68
Page 6A3–68
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 dry off with 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 rocker 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 rotating the
tube clockwise until locked into the correct position.
4 Install the oil fill cap (3) rotating clockwise until locked
into place.
Figure 6A3 – 86
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 – 87
Engine Mechanical Page 6A3–69
Page 6A3–69
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 bracket 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 – 88
Engine Mechanical Page 6A3–70
Page 6A3–70
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 – 89
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 orientation.
Figure 6A3 – 90
Engine Mechanical Page 6A3–71
Page 6A3–71
5 Remove the push rod (1), eight places, ensuring they
are kept in the order removed.
Figure 6A3 – 91
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 blow dry with compressed air.
2 Inspect the rocker arms, pivot support and pushrods for excessive wear and replace as required.
Reinstall
Reinstallation of the valve rocker 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 Operations.
2 Lubricate the following parts in clean 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 orientation 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 6A3–72
Page 6A3–72
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 – 92
7 With No. 1 piston at TDC on the compression stroke, 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. ....................... 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 cover, refer to 3.2 Engine Dress Cover.
Engine Mechanical Page 6A3–73
Page 6A3–73
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 location 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 support
• Pushrods
3 Using a socket and handle on the crankshaft pulley
attaching bolt, rotate the crankshaft until the piston of
the cylinder being serviced 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 operation.
Figure 6A3 – 93
4 Install the Spark Plug Port Adaptor, Tool 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 apply a constant supply of
compressed air to the cylinder being serviced.
Figure 6A3 – 94
Engine Mechanical Page 6A3–74
Page 6A3–74
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 – 95
7 Remove the valve spring cap retaining collets (1) two
places.
NOTE
Valve train components when separated must be
marked or organised in a way to ensure they are
reinstalled to their original location 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 shim
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 cylinders.
Figure 6A3 – 96
Engine Mechanical Page 6A3–75
Page 6A3–75
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 allowed 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 compressor ensuring 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 supply.
8 Remove the spark plug adaptor Tool No. J 22794,
refer to Figure 6A3 – 94.
Figure 6A3 – 97
9 If replacing the valve spring or shim, measure the
installed height of the valve spring using a ruler or
vernier calipers. The measurement is to be taken from
the base of the valve spring to the top.
10 If the measurement exceeds the specified limit, a
commercially available stainless steel shim must be
installed between the valve stem oil seal/shim
combination and the cylinder 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 remaining valve
springs and/or valve stem seals in the other cylinders.
12 Reinstall the spark plug and 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 – 98
Engine Mechanical Page 6A3–76
Page 6A3–76
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 terminal 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 to 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, remove 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 6C3-3 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 – 99
12 Working from the outside into the centre, progressively
loosen and remove the bolt (1), six places, attaching
the exhaust manifold to the cylinder head.
13 Remove the exhaust manifold and gasket from the
cylinder head.
Figure 6A3 – 100
Engine Mechanical Page 6A3–77
Page 6A3–77
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 – 101
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 – 102
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 Loctite 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.
Engine Mechanical Page 6A3–78
Page 6A3–78
3 Install a new gasket between the exhaust manifold
and cylinder head, and reinstall 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 punch, 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 sensor/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 – 103
8 Apply thread a sealant such as 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 and tighten to the correct
torque specification and reinstall the spark plug leads.
Spark plug torque specification ..........................15.0 Nm
11 Reinstall the engine dress cover and air intake duct in
the reverse of the removal procedure.
Figure 6A3 – 104
Engine Mechanical Page 6A3–79
Page 6A3–79
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 push 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 cylinder head to be removed. Refer to 3.14 Exhaust Manifold.
5 For the right-hand cylinder head, remove the bolt
attaching the automatic transmission indicator tube
bracket bolt (1) at the rear of the cylinder head.
Figure 6A3 – 105
6 Remove the bolt (1) attaching the powertrain harness
ground strap at the front of the right hand cylinder
head.
Figure 6A3 – 106
Engine Mechanical Page 6A3–80
Page 6A3–80
7 For the left-hand cylinder head:
a Remove the powertrain wiring harness 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 – 107
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 – 108
10 Remove the cylinder head gasket and discard.
Figure 6A3 – 109
Engine Mechanical Page 6A3–81
Page 6A3–81
Disassemble
NOTE
Do not mix the removed valve train components.
Organise all components in the order they were
removed to ensure that when reinstalled, they 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 – 110
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 – 111
Engine Mechanical Page 6A3–82
Page 6A3–82
NOTE
The core plug must not be reused. If the plug is
loosened, it must be replaced with a new one.
3 If required, remove the core plug (1) from the right-
hand cylinder head.
Figure 6A3 – 112
Clean
Use the appropriate safety glasses and
protective gloves for the following operation.
1 Clean all carbon deposits from the combustion
chambers and valve ports using a commercially
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 – 113
Engine Mechanical Page 6A3–83
Page 6A3–83
Inspect
Cylinder Head
1 Check the cylinder head deck and the inlet and
exhaust manifold mating surfaces for distortion. Use a
set of feeler gauges (1) and a straight edge (2). Check
along the length (A), laterally (B) and diagonally (C).
2 Check the cylinder head to exhaust and 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 the minimum overall height is
not exceeded.
Figure 6A3 – 114
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 – 115
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 sealant from the cylinder block threads using installer 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-42385-107 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 corrosion, 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 4.12 Cylinder 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 by the improper use of tools. NOTE
Discard all M11 bolts after removal, as these are
torque to yield bolts and must be replaced.
Engine Mechanical Page 6A3–84
Page 6A3–84
Valve Springs
1 Check all valve springs for distortion. There should be
no more than 1.6 mm variance (1) of the spring end
while the spring is being rotated on a flat surface.
Replace springs that exceed this specification.
Figure 6A3 – 116
2 Use a commercially available valve spring tester,
measure each valve spring for free height and tension.
3 Measure the valve spring tension 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 not conform to
specification. Figure 6A3 – 117
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 and
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 available valve grinder should be
used to resurface valves faces and stems.
Figure 6A3 – 118
Engine Mechanical Page 6A3–85
Page 6A3–85
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 grinding 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 followed to achieve the required standard
of finish.
8 Measure the valve stem diameter. A valve stem with a
diameter of less than the specification must be
replaced.
Valve stem diameter ...................................7.95 mm Min
Figure 6A3 – 119
Valve Guides
Excessive valve stem to guide clearance may cause noisy valve train operation, premature valve stem oil seal wear,
component damage and/or excessive oil consumption.
Insufficient valve stem to guide clearance will result in noisy or sticking valves. Valves that are too tight may disturb
engine smoothness or lead to component damage.
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 using 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 specifications 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 – 120
Engine Mechanical Page 6A3–86
Page 6A3–86
Valve Stem Oversize
1 Ream the valve guide using reamer, Tool
No. J 37378-1.
2 Clean the valve guide bore of all metal shavings and
debris.
Figure 6A3 – 121
3 Install the oversize valve (2) into the reamed valve
guide and recheck the clearance as previously
described.
4 The valve should slide freely without resistance or
drag. The clearance must not exceed specification.
Figure 6A3 – 122
Engine Mechanical Page 6A3–87
Page 6A3–87
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 valve seats, an oscillating type valve
seat grinder is preferred. The manufacturer’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) Blue.
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 before applying clean engine
oil to both surfaces to protect from rusting.
Engine Mechanical Page 6A3–88
Page 6A3–88
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 the 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 – 123
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 spring compressor.
7 Tap the end of each installed valve stem, with a soft
faced hammer to seat the collets.
Figure 6A3 – 124
Engine Mechanical Page 6A3–89
Page 6A3–89
8 Measure the installed height of the valve spring using
a ruler or vernier calipers. The measurement is to be
taken from the base of the valve spring to the top.
9 If the measurement exceeds the specified limit, a
commercially available stainless steel shim must be
installed between the valve stem oil seal/shim
combination and the cylinder 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 valve spring height as it
is assembled.
11 If the cylinder head core plugs were removed, install
with sealant such as Loctite 565 or equivalent 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 – 125
Reinstall
NOTE
Discard all used M11 cylinder head bolts. Always
use new M11 bolts when installing a cylinder
head. Do not use any sealant on the cylinder
head gasket or thread lock 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 – 126
Engine Mechanical Page 6A3–90
Page 6A3–90
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 – 127
3 Referring to Figure 6A3 – 128:
a Install the cylinder head over the locating sleeves and the previously installed gasket.
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 bolts (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 6A3–91
Page 6A3–91
Figure 6A3 – 128
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 6A3–92
Page 6A3–92
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 valve 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 – 129
4 Remove the hydraulic valve lifters from the guides.
Figure 6A3 – 130
Engine Mechanical Page 6A3–93
Page 6A3–93
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 – 131
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 – 132
Engine Mechanical Page 6A3–94
Page 6A3–94
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 clean all parts in a commercially available cleaning fluid and blow all the parts dry using compressed
air.
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 – 133
3 Inspect the valve lifter guides for:
• Cracks or damage.
• Excessive wear in the lifter mounting bores.
Figure 6A3 – 134
Engine Mechanical Page 6A3–95
Page 6A3–95
Reassemble
NOTE
Do not attempt to recondition a lifter by taking
parts from other unserviceable 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 plunger 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 – 135
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 – 136
Engine Mechanical Page 6A3–96
Page 6A3–96
Testing Lifter Leak-down Rate
After the hydraulic lifter has been cleaned, inspected 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 supplied with the test fixture in
the push rod seat of the hydraulic valve lifter.
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" position on the scale and ensure
the lifter is within the specified limit.
Hydraulic valve lifter
bleed down rate specified limit:
Start to 0.125" ...................................... 10 to 30 seconds
Figure 6A3 – 137
NOTE
A suspect lifter should be tested several times
before being discarded. Clean 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 6A3–97
Page 6A3–97
Reinstall
1 Check that all hydraulic valve lifter bores and adjacent
areas are clean.
2 Reinstall the valve lifters into the guides 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 valve 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 head/s.
Refer to 3.15 Cylinder Head.
Figure 6A3 – 138
Engine Mechanical Page 6A3–98
Page 6A3–98
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 terminal 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 – 139
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 and 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 – 140
Engine Mechanical Page 6A3–99
Page 6A3–99
7 Remove the bolt (1) attaching the crankshaft balancer.
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 – 141
8 Use the crankshaft end protector, Tool No. J 41816-2
and puller, Tool No.J41816 or equivalent to remove
the crankshaft balancer.
Figure 6A3 – 142
Engine Mechanical Page 6A3–100
Page 6A3–100
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 balancer using
compressed air.
NOTE
Do not use solvent based cleaning fluids to clean
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 emery 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 – 143
Engine Mechanical Page 6A3–101
Page 6A3–101
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 Tool No. J 42386-A are correctly engaged.
2 Apply a smear of clean engine oil onto the 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 install the tool to
the crankshaft balancer as follows:
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 spanner (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 – 144
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 Remove the used balancer bolt and discard.
Figure 6A3 – 145
Engine Mechanical Page 6A3–102
Page 6A3–102
9 Measure 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 – 146
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 angle 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 attaching 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 – 147
Engine Mechanical Page 6A3–103
Page 6A3–103
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 equivalent, 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 – 148
Reinstall
NOTE
Do not lubricate the oil seal sealing surface.
For further information refer to
1.4 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, hold 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 completely into the
front cover.
7 Reinstall the crankshaft balancer.
Refer to 3.17 Crankshaft Balancer.
Figure 6A3 – 149
Engine Mechanical Page 6A3–104
Page 6A3–104
3.19 Engine Mounts
LT Section No. — 00–475
Inspect
1 Check the area around the engine mounts for any signs of fluid leakage. If an oil 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 tension. Check the mounting 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 terminal from the battery.
2 Drain the cooling system. Refer to Section 6B3 Engine Cooling – GEN III V8.
3 If required, remove the strut tower brace, refer to Section 1A1 Body.
4 If required, remove the engine dress covers, refer to 3.2 Engine Dress Cover.
5 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.
6 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.
Engine Mechanical Page 6A3–105
Page 6A3–105
7 From under the vehicle, remove the lower mounting to
crossmember attaching nut (1) for both mounts.
8 Lower the vehicle to the ground and remove the
exhaust manifold on the side the engine mount is to be
removed. Refer to 3.14 Exhaust Manifold.
Figure 6A3 – 150
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.
9 Using suitable engine lifting equipment or a floor jack, raise the engine and remove the weight from the engine
mounts.
10 Remove the three bolts (1), attaching the engine
mount bracket to the cylinder block.
11 Lift the engine mount and bracket assembly from the
crossmember and remove it from the vehicle.
12 Using a marker pen or similar, mark the relationship of
the heat shield to the bracket to maintain correct
rotation in the reinstallation process.
13 With the engine mount and bracket assembly 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 attaching bolt
must be removed before removing the mounting
bracket to the cylinder block bolts. Refer to
Section 12O Fuses, Relays and Wiring
Harnesses.
Figure 6A3 – 151
Engine Mechanical Page 6A3–106
Page 6A3–106
Reinstall
1 If removed from the bracket, reinstall the engine mount and heat shield 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 and 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 6A3–107
Page 6A3–107
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
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 Hood, 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 hoses from the engine and radiator
• Radiator fan and shroud assembly
• Radiator
7 Remove the accessory and air conditioner drive belts, refer to 3.6 Engine Drive Belts and Pulleys.
8 Disconnect the suction/discharge hose pad from the air conditioner compressor,
refer to Section 2C HVAC Climate Control (Manual A/C) – Removal and Installation.
9 Drain the engine oil into a suitable container and reinstall the drain plug once the oil has drained sufficiently,
refer to 3.3 Engine Oil and Filter.
Engine Mechanical Page 6A3–108
Page 6A3–108
10 Remove the heater hose clamps at the engine 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 lead 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 – 152
12 Disconnect the air conditioning pressure switch and
front wiring harness connector (1) attached to the A/C
condenser pipe (2).
13 Remove the left hand kick panel trim and glove box
assembly, refer Section 1A3 Instrument Panel And
Console.
14 Disconnect the Powertrain Interface Module (PIM)
wiring harness connector and 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 engine bay
and place the powertrain wiring harness on top of the
engine.
Figure 6A3 – 153
16 Referring to Figure 6A3 – 154, remove or disconnect the following:
a Powertrain wiring harness retaining clips (1) from the engine compartment dash panel.
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.
Engine Mechanical Page 6A3–109
Page 6A3–109
Figure 6A3 – 154
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 – 155
Engine Mechanical Page 6A3–110
Page 6A3–110
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 side.
NOTE
Plug all openings to prevent fuel leaking and
foreign matter from entering the fuel system.
Figure 6A3 – 156
21 Loosen the low pressure power steering return hose
clamp (1) and the remove the hose (2).
NOTE
Plug the hose ends to prevent any 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 – 157
23 Remove the power steering high pressure 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 system and fluid
loss.
Figure 6A3 – 158
Engine Mechanical Page 6A3–111
Page 6A3–111
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 – 159
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 engine
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 Management –
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 – 160
31 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 jacking and support locations, refer to Section 0A General Information.
32 Remove the propeller shaft, refer to Section 4C1 Rear Propeller Shaft and Universal Joints.
NOTE
If required, use tie wire to secure the sliding yoke
to the rear of the transmission.
33 Disconnect the gear shift control from the transmission.
Refer to Section 7C4 Automatic Transmission – 4L60E – On-vehicle Servicing.
Engine Mechanical Page 6A3–112
Page 6A3–112
34 Remove the two bolts (1) attaching the power steering,
high pressure hose (2) bracket to the oil pan.
35 While not essential, it is recommended the oxygen
sensors be removed from the exhaust pipes, to avoid
accidental damage. Refer to Section 6C3-3 Powertrain
Management – GEN III V8 – Service Operations.
36 If the exhaust manifolds have not been removed,
remove the front exhaust assemblies, refer to
Section 8B Exhaust System.
37 Lower the vehicle enough to allow the connection of
the lifting chains but also allowing the removal of the
transmission support.
Figure 6A3 – 161
38 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 engine.
39 Using a suitable lifting crane, raise the engine slightly
to take the weight off the engine mounts.
NOTE
The following step is critical to ensure correct
powertrain alignment on reassembly. If this is not
carried out, vehicle vibration and/or handling
problems could result.
Figure 6A3 – 162
40 Mark the relationship of the engine rear crossmember (1) to the vehicle underbody to assist with alignment on
reassembly, refer to Figure 6A3 – 163. For further information relating to crossmember alignment,
refer to Section 1A2 Body Dimensions.
41 Place a floor jack with a block of wood under the transmission and raise the jack slightly to support the weight of
the transmission.
Engine Mechanical Page 6A3–113
Page 6A3–113
42 Remove the bolt (1), four places, attaching the rear
crossmember (2) to the vehicle.
43 Remove the rear mount to crossmember attaching nut
(3), two places and then remove the crossmember
from the vehicle. Remove the rear mount to
transmission extension housing bolt (4), two places
and nut (5), two places and remove the mount (6) and
the exhaust resonator bracket base (7) from the
vehicle.
Figure 6A3 – 163
• 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.
44 Raise the engine and transmission assembly with the front tilted upward and a floor jack supporting the rear of the
transmission assembly.
45 Continue to lift and manoeuvre the engine and transmission assembly until it is clear of the engine bay.
Disassemble – Ancillary Equipment
The engine removal and reinstallation procedures cover the removal and reinstallation of the engine and transmission as
a complete assembly. To perform major engine service operations, it is required the engine and transmission be
separated and the ancillary equipment that is attached to the engine be removed. Once all ancillary components and the
transmission have been removed, major engine service operations can then be performed, by referring to the appropriate
major service operation.
1 Remove the wiring harness connectors and earth connections from the engine and transmission assembly and
carefully set the wiring harness to one side, 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 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 – 164.
Figure 6A3 – 164
Engine Mechanical Page 6A3–114
Page 6A3–114
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 transmission filler
tube to the right-hand cylinder head.
7 Release the transmission breather tube from the filler
tube (3) bracket (arrow).
8 Using a twisting/pulling motion, remove the filler tube
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 entry and fluid leakage.
Figure 6A3 – 165
10 Disconnect the transmission cooler lines from the
transmission end, as follows:
a Release the verifier disc (1) by pulling back with
your fingertips and slide the disc back down the
cooler pipe (2).
b Open the cooler line release Tool J-41623-B and
slip it over the cooler pipe to be disconnected
from the transmission, ahead of the verifier disc
as shown.
c Slide the release tool along the pipe to engage
with the quick-connect fitting.
d While pushing inwards, rotate the tool about one
sixth of a turn clockwise to release the spring clip
holding the pipe.
e With the release tool held in this position, pull
back on the cooler pipe to release. Repeat this
process with the remaining pipe and quick-
connect fitting.
f Plug all openings to prevent fluid loss and/or dirt
entry.
Figure 6A3 – 166
11 Remove the transmission housing to engine assembly
attaching bolt (1), eight places in the sequence 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 – 167
Engine Mechanical Page 6A3–115
Page 6A3–115
12 Remove the three bolts (1), attaching the left-hand
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.
13 Mount the engine in a suitable engine stand such as
Tool No AU 591 or similar. Preferably, use a stand that
will mount the engine on it from its side using the
engine mount bracket bolt holes.
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 – 168
Reassemble
Reassembly of the ancillary components for all vehicles is the reverse of the disassemble procedure noting the following:
1 Ensure all fasteners are tightened to the correct torque specification, refer to 7 Torque Wrench Specifications or
refer to the specific Section for the particular component being 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 attaching bolts to the correct torque specification in the reverse order of the
removal procedure, refer to Figure 6A3 – 167.
4 Both close-out covers are installed.
5 The transmission filler tube where fitted is installed 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 required 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 particular 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 Check 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 pressure gauge 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 leaks while the engine is running, stopping the engine and correcting as
required.
11 Perform a final inspection for the correct engine oil and coolant levels.
12 Reinstall the engine dress cover, 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 6A3–116
Page 6A3–116
4.2 Oil Pan Assembly
LT Section No. — 00–275
Remove NOTE
Due to the critical alignment procedures required
for oil pan installation, it is strongly 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 flexplate, refer to 4.4 Engine 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 gradually from the outside and working
inwards toward the centre.
6 Tap the oil pan sideways with a rubber mallet to
dislodge the seal.
Figure 6A3 – 169
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 – 170
Engine Mechanical Page 6A3–117
Page 6A3–117
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 – 171
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 the 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 – 172
8 Remove the oil pan baffle plate (1) attaching bolts (2),
six places and remove the baffle.
Figure 6A3 – 173
Engine Mechanical Page 6A3–118
Page 6A3–118
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 plastic scraper to avoid scratching or damaging the machined surfaces.
4 Inspect the oil pan for the following:
• Gasket sealing surfaces for excessive scratches or gouging
• Oil pan drain plug and 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 pushing 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 – 174
Engine Mechanical Page 6A3–119
Page 6A3–119
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 – 175
2 If removed, apply thread lock compound such as
Loctite 242 or equivalent to the cleaned threads of the
oil gallery plug (1).
3 Tighten the oil gallery 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 – 176
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 and 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 – 177
Engine Mechanical Page 6A3–120
Page 6A3–120
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 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. Do not reuse the oil pan
gasket.
1 Apply a 5 mm wide by 20 mm long bead of sealant (1)
such as Loctite 565 or equivalent directly onto the tabs
of the front cover gasket that protrude into the oil pan
surface.
Figure 6A3 – 178
2 Apply a 5 mm wide by 20 mm long bead of sealant (1)
such as Loctite 565 or equivalent, directly onto the
tabs of the rear cover gasket that protrude into the oil
pan surface.
Figure 6A3 – 179
Engine Mechanical Page 6A3–121
Page 6A3–121
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 rear 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 and recheck the alignment.
Figure 6A3 – 180
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 specification.
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 – 181
Engine Mechanical Page 6A3–122
Page 6A3–122
4.3 Engine Front Cover
LT Section No. — 00–325
Remove
NOTE
Due to the 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 4.2 Oil Pan Assembly.
3 Remove the crankshaft balancer, refer 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 – 182
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 excessive scratches 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 6A3–123
Page 6A3–123
Reinstall
Prior to reinstallation of the engine front cover, observe the following:
• 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 specifications.
• An incorrectly aligned front cover may cause 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 – 183
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 – 184
Engine Mechanical Page 6A3–124
Page 6A3–124
5 Install the centralising Tool J 41476 and hold it in
position by hand. Align the tapered legs of the 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 – 185
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 sealing 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. The clearance
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 4.2 Oil Pan.
Figure 6A3 – 186
Engine Mechanical Page 6A3–125
Page 6A3–125
4.4 Engine Flexplate
LT Section No. — 00–400
Remove
NOTE
• Observe the position and direction of the
engine flexplate before removal. The flexplate
does not use a locating pin for alignment.
Mark or scribe the end of the crankshaft and
the flexplate before component removal. The
engine flexplate must be reinstalled to the
original position and direction.
• The 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 assembly.
Refer to Section 7C4 Automatic Transmission – 4L60E – On Vehicle Servicing.
2 Mark or scribe the end of the crankshaft and the flexplate with a marker pen or similar.
3 Remove the bolt (1), six places, attaching either the
engine flexplate to the rear of the crankshaft and then
remove the engine flexplate from the crankshaft.
Figure 6A3 – 187
Engine Mechanical Page 6A3–126
Page 6A3–126
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 and
blow dry using compressed air.
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 – 188
Engine Mechanical Page 6A3–127
Page 6A3–127
Reinstall
1 If renewing the flexplate, use the flexplate locating
holes as a reference and scribe an alignment mark
corresponding to the one on the original flexplate.
2 Clean the threads in the crankshaft and ensure there
is no remaining encapsulated sealer remaining in the
holes.
3 Install the flexplate aligning the scribed marks on the
crankshaft and the flexplate.
NOTE
Do not reuse the flexplate bolts. Only new bolts
are to be used when reinstalling the flexplate.
4 Install new flexplate bolts and tighten to the correct
Stage 1 torque specification. Refer to
Figure 6A3 – 191.
Flexplate torque specification
Stage 1 ..............................................................20.0 Nm
Figure 6A3 – 189
5 Install the ring gear holding Tool No. J 42386-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 – 190
6 Continue to tighten the flexplate bolts in sequence in
two additional stages to the correct torque
specification.
Flexplate attaching bolt torque specification
Stage 2 ..............................................................50.0 Nm
Stage 3 ............................................................100.0 Nm
7 Reinstall the transmission as required. Refer to
Section 7C4 Automatic Transmission – 4L60E – On
Vehicle Servicing
Figure 6A3 – 191
Engine Mechanical Page 6A3–128
Page 6A3–128
4.5 Engine Rear Cover
LT Section No. — 00–200
Remove
NOTE
Due to the critical alignment procedures required
for the reinstallation of the rear cover and 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 4.2 Oil Pan.
2 Remove the flexplate, refer to 4.4 Engine Flexplate.
3 Remove the bolt (1), 12 places, attaching the engine
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 – 192
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 excessive scratching or gouging.
3 Inspect the gasket for damage to the seal membrane or distortion to the aluminium carrier.
4 Inspect the cover to oil pan threaded holes for debris or damage. Refer to 5 Thread Repair if rectification is
required.
5 Inspect the rear main oil seal bore for damage.
Engine Mechanical Page 6A3–129
Page 6A3–129
Reinstall
Observe the following prior to reinstallation:
• 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 places, and
tighten the rear cover bolts finger tight only at this
stage.
NOTE
Do not install the rear main oil seal (4) at this
stage.
Figure 6A3 – 193
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 – 194
Engine Mechanical Page 6A3–130
Page 6A3–130
5 Rotate the crankshaft until two opposing flexplate
mounting bolt holes are parallel to the oil pan surface
of the cylinder 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 – 195
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 – 196
Engine Mechanical Page 6A3–131
Page 6A3–131
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 sealing 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 – 197
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
1.4 Engine Lubrication System.
1 Lubricate the outer edge of the oil seal (1) (OD) with
clean engine oil.
2 Lubricate the engine rear cover oil seal 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 flexplate. Refer to 4.4 Engine Flexplate.
9 Reinstall the transmission. Refer to
Section 7C4 Automatic Transmission – 4L60E – On
Vehicle Servicing. Figure 6A3 – 198
Engine Mechanical Page 6A3–132
Page 6A3–132
4.6 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 and 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 4.3 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 – 199
4 Remove the remaining crankshaft 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 – 200
Engine Mechanical Page 6A3–133
Page 6A3–133
6 Remove the bolt (1), four places, attaching the oil
pump to the front of the engine and remove the 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 – 201
Oil Pump Disassemble
1 Remove the bolt (1), seven places, attaching the oil
pump cover to the pump and remove the cover.
Figure 6A3 – 202
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 – 203
Engine Mechanical Page 6A3–134
Page 6A3–134
3 Unscrew the oil pressure relief valve plug (1) and
remove the spring (2), and valve (3) from the oil pump
body.
Figure 6A3 – 204
Clean and Inspect
With the exception of the oil pressure 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 commercially available 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 damaged 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 clogged with debris or restriction.
• Screen mesh is broken or has loose strands.
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 spring.
5 Tighten the pressure relief valve 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 6A3–135
Page 6A3–135
Reinstall
1 Ensure the oil pump and cylinder block oil gallery
passages are free from any debris or foreign 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 pump housing contacts the
face of the cylinder block.
3 Install the two oil pump attaching bolts (1) and tighten
to the correct torque specification.
Oil pump attaching bolt
torque specification ............................................25.0 Nm
Figure 6A3 – 205
4 Install the crankshaft oil deflector (1), ensuring the
"REAR" stamping (2) on the deflector is located at the
rear of the engine.
Figure 6A3 – 206
5 Lubricate a new oil pump pick-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 pump 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 engine cover, refer to
4.3 Engine Front Cover.
Figure 6A3 – 207
Engine Mechanical Page 6A3–136
Page 6A3–136
4.7 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 4.3 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
4.6 Oil Pump, Pump Screen and Deflector.
Figure 6A3 – 208
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 – 209
Engine Mechanical Page 6A3–137
Page 6A3–137
6 Use Tool No’s J 41558, J 41816-2, the bolts 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 – 210
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 – 211
Engine Mechanical Page 6A3–138
Page 6A3–138
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 recommended
the timing gears and chain be relaced as a
complete set.
Figure 6A3 – 212
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 crankshaft
aligning the keyway with the key.
Figure 6A3 – 213
3 Use the installer Tool No. J 41665 to reinstall 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 threaded bolt 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 – 214
Engine Mechanical Page 6A3–139
Page 6A3–139
4 If required, temporarily reinstall the harmonic balancer
bolt and rotate the crankshaft until the crankshaft 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 correctly
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 crankshaft 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 – 215
9 Install the camshaft sprocket attaching bolts (3) and tighten to the correct torque specification.
Camshaft sprocket attaching bolt
torque specification .................................30.0 – 35.0 Nm
10 Reinstall the timing chain dampener (2) and tighten the two attaching bolts (1) 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 4.6 Oil Pump, Pump Screen and Deflector.
12 Reinstall the front cover and harmonic balancer. Refer to 4.3 Engine Front Cover.
Engine Mechanical Page 6A3–140
Page 6A3–140
4.8 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 is 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 4.3 Engine Front 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
4.6 Oil Pump, Pump Screen and Deflector.
5 Remove the camshaft chain and sprocket.
Refer to 4.7 Timing Chain and Sprockets.
Figure 6A3 – 216
6 Remove the camshaft retainer attaching bolt (1), four
places and remove the retainer and gasket.
Figure 6A3 – 217
Engine Mechanical Page 6A3–141
Page 6A3–141
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 – 218
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 blow dry with compressed air.
2 Inspect the camshaft for:
• Scoring or excessive wear to the bearing
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 – 219
Engine Mechanical Page 6A3–142
Page 6A3–142
3 Measure the camshaft journals for wear and out-of-
round using a micrometer. Replace the camshaft if
either of these measurements are outside the
specification.
Camshaft journal specifications:
Journal out-of-round.................................0.025 mm Max
Bearing journal diameter...........................54.99 mm Min
Figure 6A3 – 220
4 Measure the camshaft lobes for wear using a
micrometer. Replace the camshaft if any of the
camshaft lobe dimensions are not within specification.
Camshaft lobe wear limit:
Intake lobe diameter .................................46.67 mm Min
Exhaust lobe diameter ..............................46.67 mm Min
Figure 6A3 – 221
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 the
specification.
Camshaft runout specification....................0.05 mm Max
7 Inspect the camshaft retainer plate for wear or a
damaged sealing gasket. If the gasket is not cut or
damaged, it may be re-used.
Figure 6A3 – 222
Engine Mechanical Page 6A3–143
Page 6A3–143
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 – 223
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 specification.
Camshaft retainer attaching bolt
torque specification .................................21.0 – 29.0 Nm
Figure 6A3 – 224
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 engine 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 chain and sprocket.
Refer to 4.7 Timing Chain and Sprockets.
12 Reinstall the oil pump, refer to
4.6 Oil Pump, Pump Screen and Deflector.
13 Reinstall the engine front cover, refer to
3.17 Crankshaft Balancer.
14 Reinstall the hydraulic valve lifters, refer to
3.16 Hydraulic Valve Lifters.
Figure 6A3 – 225
Engine Mechanical Page 6A3–144
Page 6A3–144
4.9 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 4.2 Oil Pan.
3 If required, remove any cylinder ridge 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 – 226
NOTE
Do not apply a stamping 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 connecting 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 bolts loosening
progressively from side to side.
NOTE
Ensure the connecting rod bearings are
organised so they can be installed in the original
position and location.
9 Remove each connecting rod cap.
Figure 6A3 – 227
Engine Mechanical Page 6A3–145
Page 6A3–145
10 Install the guide pins, Tool No. J 41556 to the
connecting rod to be removed.
11 Use a hammer handle, lightly tap on the end of the
guide pin and remove the piston and connecting rod
from the cylinder bore.
Figure 6A3 – 228
12 Once removed, assemble the connecting rod cap,
bearing shells and bolts to the matching connecting
rod.
Figure 6A3 – 229
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 screwdriver (1), carefully 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 and
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 – 230
Engine Mechanical Page 6A3–146
Page 6A3–146
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 expanding
the ring at the end gaps in the following 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 – 231
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 grooves with a commercially
available ring groove cleaning tool.
4 Clean the oil lubrication holes and slots in the ring
grooves.
Figure 6A3 – 232
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
pin
NOTE
Minor imperfections may be removed by using a
fine file.
Figure 6A3 – 233
Engine Mechanical Page 6A3–147
Page 6A3–147
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 – 234
8 Check the side clearance using a feeler gauge. If the
side clearance exceeds 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 – 235
NOTE
For each of the following measurements, 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 – 236
Engine Mechanical Page 6A3–148
Page 6A3–148
11 Using a suitable inside micrometer, 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 piston 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 – 237
14 Measure the piston for out-of-round as follows:
• 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 assembly.
Piston skirt out-of round
specification .............................................0.018 mm Max
Figure 6A3 – 238
Engine Mechanical Page 6A3–149
Page 6A3–149
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 modifications 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 rod and matching cap in a
commercially available cleaning fluid and blow dry
using compressed air.
2 Clean the connecting rod bolt threads and inspect for
damage. Do not attempt to repair damaged threads in
this location. Replace the connecting 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 length with suitable
measuring equipment
• Nicks or gouging in the bearing 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 – 239
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 connecting 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 bore 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 – 240
Engine Mechanical Page 6A3–150
Page 6A3–150
6 Inspect the connecting rod bearing halves for craters
or pockets. Flattened sections on the bearing halves
also indicate fatigue. Replace as required.
Figure 6A3 – 241
7 Inspect the connecting rod bearing halves for
excessive scoring or discolouration, dirt or debris
embedded into the bearing material or backing metal.
Replace as required.
Figure 6A3 – 242
8 Inspect the connecting rod bearing halves for improper
seating indicated by bright polished section/s on the
bearing material. Replace as required.
Figure 6A3 – 243
Engine Mechanical Page 6A3–151
Page 6A3–151
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 – 244
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 4.12 Cylinder Block. All measurements should 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 – 245
Engine Mechanical Page 6A3–152
Page 6A3–152
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 – 246
5 Use a bore gauge Tool J 8087 or equivalent, measure
the cylinder bore diameter at a point 57 mm from the
top of the bore.
6 Record the cylinder bore diameter.
7 Subtract the piston diameter from the cylinder 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-calculate the
clearance. If the correct clearance cannot be obtained
using this method then the cylinder bore may require
honing for an oversize piston fitment or the cylinder
block will need to be replaced.
NOTE
Before honing the cylinders, refer to
4.12 Cylinder Block
9 When the correct piston to bore clearance is obtained,
mark the piston crown for correct installation.
Figure 6A3 – 247
Engine Mechanical Page 6A3–153
Page 6A3–153
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 orientation.
Figure 6A3 – 248
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 screwdriver (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 connecting 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 retaining circlip on each side of the
piston are seated in the grooves correctly.
Figure 6A3 – 249
Engine Mechanical Page 6A3–154
Page 6A3–154
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 installed 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 – 250
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 piston, cylinder bore, piston rings and bearing surfaces with clean engine oil.
3 Remove the connecting rod cap and bearing shell from the connecting rod being installed and install the
connecting rod guide pins, Tool No. J 41556, refer to Figure 6A3 – 251.
4 Install a commercially available piston ring compressor over the piston rings and compress the rings.
NOTE
Follow the manufacturer's operating instructions
for the type of piston ring compressor being used.
5 Install the piston and connecting rod assembly into the
correct cylinder bore, checking the piston alignment
mark is facing the front of the engine.
6 While holding the piston ring 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 using the connecting rod
guide pins, Tool No. J 41556 to guide the connecting
rod onto the crankshaft journal.
Figure 6A3 – 251
Engine Mechanical Page 6A3–155
Page 6A3–155
8 Remove the connecting rod guides, Tool No. J 41556
and check the upper bearing shell is correctly installed
in the connecting rod. Apply clean engine oil to the
upper bearing shell.
Figure 6A3 – 252
9 Install the lower connecting rod bearing into the cap
and lubricate with clean engine 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 4.10 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 – 253
11 With a pair of connecting rods installed onto 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 connecting rod side
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 alignment.
13 Reinstall the oil pan, oil pump screen and deflector,
refer to 4.6 Oil Pump, Pump Screen and Deflector.
14 Reinstall both cylinder heads.
Refer to 3.15 Cylinder Head.
Figure 6A3 – 254
Engine Mechanical Page 6A3–156
Page 6A3–156
4.10 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 then separate 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 engine assembly:
• Starter motor, refer to Section 6D3 Starting System – GEN III V8.
• Oil pump, screen and deflector, refer to 4.6 Oil Pump, Pump Screen and Deflector.
• Remove each of the connecting rod bearing caps, refer to 4.9 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 bearing 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 – 255
Remove
1 Remove the bolt (2), attaching the crankshaft position
sensor (1) and remove the sensor from the cylinder
block.
Figure 6A3 – 256
Engine Mechanical Page 6A3–157
Page 6A3–157
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 bolt
(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 bolt (2), 10 places
and studs (3), 10 places, loosening each pair
gradually. Take note of the stud positions for
reassembly.
Figure 6A3 – 257
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 those in the
holes.
5 Tighten the bolts of Tool No. J 41818 to the correct
torque specification.
Main bearing removal tool attaching 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 bearing cap.
Figure 6A3 – 258
7 Mark and remove the remaining main bearing caps in
the same way. Check the lower main bearing shells
are also removed with each cap.
Figure 6A3 – 259
Engine Mechanical Page 6A3–158
Page 6A3–158
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 – 260
• 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 – 261
9 Remove the crankshaft main bearings from the
cylinder block and the main bearing caps.
10 Using a marker pen or etching tool, mark each main
bearing cap. The main bearing caps must be
reassembled to the original position and direction.
NOTE
Take particular care to organise all parts so they
can be reinstalled in their original positions.
Figure 6A3 – 262
Engine Mechanical Page 6A3–159
Page 6A3–159
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 blow dry using compressed air.
2 Thoroughly clean all the oil passages and inspect for
restrictions or burrs.
3 Carry out a visual inspection of the crankshaft 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 – 263
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 – 264
6 Inspect the crankshaft key (1), keyway (2) and
threaded hole (3) for damage or wear.
Figure 6A3 – 265
Engine Mechanical Page 6A3–160
Page 6A3–160
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 – 266
8 Support the crankshaft on V blocks or in a commercial
jig.
9 Using a commercially available dial indicator mounted
to a magnetic stand, measure the following crankshaft
main bearing journal runout dimensions:
• Crankshaft runout at the main bearing journals
• Crankshaft rear flange
• Reluctor ring (measured 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 – 267
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 sides of a new plug
(1) and install to the correct depth.
Crankshaft rear oil gallery plug depth specification:
Distance A.............................................. 31.2 – 31.6 mm
Figure 6A3 – 268
Engine Mechanical Page 6A3–161
Page 6A3–161
Main Bearings Inspect
1 Inspect the crankshaft main bearing halves for craters
or pockets. Flattened sections on the bearing halves
also indicate fatigue. Replace as required.
Figure 6A3 – 269
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 – 270
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 – 271
Engine Mechanical Page 6A3–162
Page 6A3–162
Main Bearing Oil Clearance
1 After thoroughly cleaning all the relevant parts, install
the bearing halves into the cylinder block and main
bearing caps.
Figure 6A3 – 272
2 Install the crankshaft to the cylinder block ensuring the
crankshaft is held square to avoid damaging 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 – 273
4 Install the main bearings, caps, bolts and studs in the
reverse order of the removal procedure, ensuring the
bearings and caps are installed in their original
location.
Figure 6A3 – 274
Engine Mechanical Page 6A3–163
Page 6A3–163
5 Tighten the main bearing cap bolts and studs in
numerical order to the correct torque specification.
NOTE
Perform Stage 1 for all the bolts and studs. Then
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 – 275
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 bolts and discard
as new bolts must be used on final assembly.
8 Remove the main bearing cap M10 bolts (2) and studs
(3), loosening each pair gradually. Take note of the
stud positions for reassembly.
Figure 6A3 – 276
9 Loosen the bolts attaching the main bearing removal
Tool No. J 41818 to separate the chamfered collets
then install the chamfered sections 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 attaching 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 bearing cap.
Figure 6A3 – 277
Engine Mechanical Page 6A3–164
Page 6A3–164
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 – 278
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 bearings.
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 – 279
Engine Mechanical Page 6A3–165
Page 6A3–165
Reinstall
1 Reinstall the main bearing shells into the caps and the
cylinder block in their original location or as required
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 – 280
3 Install the crankshaft to the cylinder block ensuring the
crankshaft is held square to avoid damaging the
centre main thrust bearing or the reluctor ring.
Figure 6A3 – 281
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 – 282
Engine Mechanical Page 6A3–166
Page 6A3–166
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 side 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 – 283
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 aligning 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
Figure 6A3 – 284
12 Reinstall the following items to the engine assembly;
• Connecting rod bearing caps, refer to 4.9 Piston, Connecting Rod and Bearing.
• Rear engine cover, refer to 4.5 Engine Rear Cover.
• Timing chain and sprockets, refer to 4.7 Timing Chain and Sprockets.
• Oil pump, pump screen and deflector, refer to 4.6 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 6A3–167
Page 6A3–167
4.11 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 assembly removal procedures.
b 4.3 Engine Front Cover, for front engine cover removal procedures.
c 4.5 Engine Rear Cover, for rear engine cover removal procedures.
Remove
1 Remove the coolant drain plug (1) from the right-hand
rear of the cylinder block.
Figure 6A3 – 285
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 – 286
Engine Mechanical Page 6A3–168
Page 6A3–168
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
4.3 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 – 287
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 plug
and if it is undamaged, it may be re-used during
assembly.
Figure 6A3 – 288
Engine Mechanical Page 6A3–169
Page 6A3–169
Reinstall
1 Apply a 3 mm bead of sealant such as Loctite 565 or
equivalent to the drain plug sealing washer on a new
right-hand cylinder block coolant plug.
2 Install the plug and tighten to the correct torque
specification.
■ Coolant drain plug
torque specification ............................................60.0 Nm
Figure 6A3 – 289
3 Apply a 3 mm bead of sealant 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 sealant such as Loctite 565 or
equivalent to the new coolant drain plug (3) sealing
washer and tighten to the correct torque specification.
■ Coolant drain plug
torque specification ............................................60.0 Nm
Figure 6A3 – 290
Engine Mechanical Page 6A3–170
Page 6A3–170
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 gallery. 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 – 291
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 – 292
Engine Mechanical Page 6A3–171
Page 6A3–171
4.12 Cylinder Block
Cylinder Block Clean, Inspect and Measure
Clean
1 Disassemble the cylinder block as required.
2 Remove all cylinder block plugs, refer to 4.11 Cylinder Block Plugs and then clean all the coolant passages and oil
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 cleaning fluid to remove all sludge, dirt, or debris and blow dry
using compressed air. An alternative is to clean the block in a commercially available thermal type washer,
providing the temperature 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 Tool 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, gouging, 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 8087 or a commercially
available equivalent.
Figure 6A3 – 293
Engine Mechanical Page 6A3–172
Page 6A3–172
3 Using a bore gauge, Tool J8087, measure the cylinder
bore for taper by sliding the bore gauge up and down
throughout the length of the cylinder bore. Check the
bore both parallel and perpendicular 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 – 294
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. The results will
indicate any out-of-round bore condition.
NOTE
Cylinders with more than 0.18 mm out-of-round
must be honed and fitted with an oversize piston.
Figure 6A3 – 295
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 cylinder 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 – 296
Engine Mechanical Page 6A3–173
Page 6A3–173
Cylinder Boring and Honing NOTE
Boring of the cylinder is not permitted. Piston 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 – 297
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 cylinder 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 cylinder 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 piston at the specified point and by adding the average to the clearance
specification, the final cylinder honing dimension required can be determined.
3 After the final honing, clean the cylinder bores with hot water and detergent by scrubbing the bores with a stiff
bristle brush and then rinse the 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 and 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 done to remove any deposits that may have formed.
Use a 240 grit silicone carbide stone or equivalent material when performing the deglazing procedure.
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 6A3–174
Page 6A3–174
Camshaft Bearings
Remove
The following service operation 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 should be replaced with new ones. The bearings should only be removed if
replacement is required or cylinder block service operations require the block to be completely disassembled.
While it is preferred the camshaft bearings are removed and installed in a bare cylinder block, 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 journals.
The camshaft can be removed without having to remove the cylinder heads and hydraulic lifters. This is achieved by
removing the pushrods and inverting the engine. 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 not damaged.
1 Prior to bearing removal, inspect all camshaft bearings
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 – 298
2 The universal camshaft bearing 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 bearings, 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 – 299
Engine Mechanical Page 6A3–175
Page 6A3–175
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 expander assembly.
Figure 6A3 – 300
5 Once installed, ensure the separations in the expander
assembly segments are aligned with those of the
expanding driver as shown (A).
Figure 6A3 – 301
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 the
camshaft bearing, hold the hexagonal end of the
expander assembly with a spanner and hand tighten
the driver bar until the expanding driver (5) is tight in
the bearing shell.
Figure 6A3 – 302
Engine Mechanical Page 6A3–176
Page 6A3–176
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 remaining bearings being
removed.
Figure 6A3 – 303
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 – 304
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 bearing 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 then 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 – 305
Engine Mechanical Page 6A3–177
Page 6A3–177
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 by the corrosion 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 repair
• Main bearing cap bolt hole thread repair
Detailed descriptions of all thread specifications used in this engine are listed in 5.5 Thread Repair 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 installation process the driver tool
expands the bottom external threads of the insert 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 performing drilling, counter-
boring and tapping procedures.
The tool kits are designed for use with a suitable tap wrench
and electric drill. Figure 6A3 – 306
Engine Mechanical Page 6A3–178
Page 6A3–178
5.2 General Thread Repair
1 Drill out the threads of the damaged hole (1) to the
correct depth for the thread being repaired.
2 Observe the following recommended 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 minimum drill depth of
23.5 mm
3 Using compressed air, clean out any foreign material
from the holes.
Figure 6A3 – 307
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 – 308
6 Using a tap wrench (1), tap the threads of the drilled
hole to the correct depth for the thread being repaired.
7 Observe the following recommended 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 into the hole.
9 Using compressed air, clean out any foreign material
from the holes. Figure 6A3 – 309
Engine Mechanical Page 6A3–179
Page 6A3–179
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 – 310
11 Install the insert (1) onto the driver tool (2).
Figure 6A3 – 311
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 – 312
Engine Mechanical Page 6A3–180
Page 6A3–180
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 hole.
15 Remove the driver.
Figure 6A3 – 313
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 – 314
Engine Mechanical Page 6A3–181
Page 6A3–181
5.3 Cylinder Head Bolt Hole Thread Repair
The cylinder head bolt hole thread repair kit from Tool No.
J 42385/100/200/300 consists 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 – 315
Procedure
NOTE
• Driver oil must be used on the installer 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 block deck.
Figure 6A3 – 316
Engine Mechanical Page 6A3–182
Page 6A3–182
3 Position the alignment pin (1) through the bushing and
into the hole.
4 With the alignment pin in the desired hole, 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 – 317
6 Referring to Figure 6A3 – 318, drill the hole that is to be repaired noting the following:
• Cylinder head bolt holes 1 to 8 are deep holes and can be drilled without the drill sleeve.
• Cylinder head bolt holes 9 and 10 are the more shallow holes so drilling must be done with the drill sleeve in
place.
NOTE
Figure 6A3 – 318 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 – 318
Engine Mechanical Page 6A3–183
Page 6A3–183
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 – 319
8 Install the insert (1) onto the driver tool (2).
Figure 6A3 – 320
9 Apply a small amount of thread locking compound,
such as Loctite 272 (1) or equivalent to the thread
insert OD threads (2).
Figure 6A3 – 321
Engine Mechanical Page 6A3–184
Page 6A3–184
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 hole.
12 Remove the driver.
Figure 6A3 – 322
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 – 323
Engine Mechanical Page 6A3–185
Page 6A3–185
5.4 Main Bearing Cap Bolt Hole
Thread Repair
The main cap bolt hole thread repair kit from Tool 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 – 324
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 installer driver
tool.
1 Position the fixture plate and 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 – 325
Engine Mechanical Page 6A3–186
Page 6A3–186
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 to Figure 6A3 – 324.
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 – 326
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 – 326, 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 attaching
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 into the hole.
10 Using compressed air clean any cutting oil and foreign
material out of the hole.
Figure 6A3 – 327
Engine Mechanical Page 6A3–187
Page 6A3–187
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 – 328
12 Install the driver tool (1) into the insert (2).
Figure 6A3 – 329
13 Apply thread lock Loctite 272 (1) or equivalent to the
insert outer threads (2).
Figure 6A3 – 330
Engine Mechanical Page 6A3–188
Page 6A3–188
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 – 331
Engine Mechanical Page 6A3–189
Page 6A3–189
5.5 Thread Repair Specifications
Cylinder Block – Front View
Figure 6A3 – 332
Legend
Hole Thread
Size Insert Drill Counterbore
Tool Tap Driver Max
Drill
Depth
mm
Max Tap
Depth
mm
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 6A3–190
Page 6A3–190
Cylinder Block – Rear View
Figure 6A3 – 333
Legend
Hole Thread
Size Insert Drill
Counterbore
Tool Tap Driver
Max
Drill
Depth
mm
Max
Tap
Depth
mm
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 42385-
213
J 42385-
214 27.0 21.5
7-13 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-
208
J 42385-
209 22.5 17.5
14-16 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 6A3–191
Page 6A3–191
Cylinder Block – Left-hand View
Figure 6A3 – 334
Legend
Hole Thread
Size Insert Drill
Counterbore
Tool Tap Driver
Max
Drill
Depth
mm
Max
Tap
Depth
mm
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 16.0
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 ⎯ ⎯ ⎯ ⎯ ⎯ ⎯ ⎯ ⎯
12-17 M10 x 1.5 J 42385-215 J 42385-211 J 42385-212 J 42385-
213
J 42385-
214 29.0 23.0
Engine Mechanical Page 6A3–192
Page 6A3–192
Hole Thread
Size Insert Drill
Counterbore
Tool Tap Driver
Max
Drill
Depth
mm
Max
Tap
Depth
mm
18 M28 x
1.25 ⎯ ⎯ ⎯ ⎯ ⎯ ⎯ ⎯
19-20 M8 x 1.25 J 42385-210 J 42385-206 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 42385-210 J 42385-206 J 42385-207 J 42385-
208
J 42385-
209 26.5 19.0
26-27 M11 x 2.0 J 42385-108 J 42385-105 ⎯ 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 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, 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-bore included in the 69.0 mm drill depth. Use sleeve J 42385-315 with the
drill and tap.
Engine Mechanical Page 6A3–193
Page 6A3–193
Cylinder Block – Right-hand View
Figure 6A3 – 335
Legend
Hole Thread
Size Insert Drill
Counterbore
Tool Tap Driver
Max
Drill
Depth
mm
Max
Tap
Depth
mm
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
Engine Mechanical Page 6A3–194
Page 6A3–194
Hole Thread
Size Insert Drill
Counterbore
Tool Tap Driver
Max
Drill
Depth
mm
Max
Tap
Depth
mm
11-14 M10 x 1.5 J 42385-215 J 42385-211 J 42385-212 J 42385-
213
J 42385-
214 27.0 21.5
15-19 M10 x 1.5 J 42385-215 J 42385-211 J 42385-212 J 42385-
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 counterbore included in the 69.0 mm drill depth. Use sleeve J 42385-315 with the
drill and tap.
Engine Mechanical Page 6A3–195
Page 6A3–195
Cylinder Block – Bottom View
Figure 6A3 – 336
Legend
Hole Thread
Size Insert Drill
Counterbore
Tool Tap Driver
Max
Drill
Depth
mm
Max
Tap
Depth
mm
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 42385-
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 42385-
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 6A3–196
Page 6A3–196
Hole Thread
Size Insert Drill
Counterbore
Tool Tap Driver
Max
Drill
Depth
mm
Max
Tap
Depth
mm
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 42385-
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 included 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 6A3–197
Page 6A3–197
Cylinder Block – Top View
Figure 6A3 – 337
Legend
Hole Thread
Size Insert Drill
Counterbore
Tool Tap Driver
Max
Drill
Depth
mm
Max
Tap
Depth
mm
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 42385-216 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 6A3–198
Page 6A3–198
Cylinder Head – Top View
Figure 6A3 – 338
Legend
Hole Thread
Size Insert Drill
Counterbore
Tool Tap Driver
Max
Drill
Depth
mm
Max
Tap
Depth
mm
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 42385-201 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 – 339
Legend
Hole Thread
Size Insert Drill
Counterbore
Tool Tap Driver
Max
Drill
Depth
mm
Max
Tap
Depth
mm
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 6A3–199
Page 6A3–199
Cylinder Head – Exhaust Manifold Side View
Figure 6A3 – 340
Legend
Hole Thread
Size Insert Drill
Counterbore
Tool Tap Driver
Max
Drill
Depth
mm
Max
Tap
Depth
mm
1-2 M10 x 1.5 J 42385-215 J 42385-211 J 42385-212 J 42385-
213 J 42385-214 28.0 20.0
3 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 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 42385-207 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 6A3–200
Page 6A3–200
Cylinder Head – Inlet Manifold Side View
Figure 6A3 – 341
Legend
Hole Thread
Size Insert Drill
Counterbore
Tool Tap Driver
Max
Drill
Depth
mm
Max Tap
Depth
mm
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 6A3–201
Page 6A3–201
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
7.43 mm
7.43 mm
Lobe Height (Wear Limits):
Intake
Exhaust
46.67 mm
46.67 mm
Runout
(Measured at the Intermediate Journals) 0.050 mm
Timing Check (reference only) -
Cam Lift at Top Dead Centre:
Exhaust Closing
Intake Opening
0.62 mm
0.15 mm
Engine Mechanical Page 6A3–202
Page 6A3–202
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 (Production) 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
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 (Production) 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)
Engine Mechanical Page 6A3–203
Page 6A3–203
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
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 Deck Face)
Main Bearing Bore Diameter (Production) 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)
Engine Mechanical Page 6A3–204
Page 6A3–204
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 (Production)
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)
Piston Rings
Top Compression Ring End Gap
(Production) 0.230 - 0.380 mm (Measured in Cylinder Bore)
2nd Compression Ring End Gap
(Production) 0.440 - 0.640 mm (Measured in Cylinder Bore)
Oil Control Ring End Gap (Production) 0.180 - 0.690 mm (Measured in Cylinder Bore)
Top Compression Ring End Gap (Service) 0.230 - 0.380 mm (Maximum) (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 Ring 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 Ring Groove Clearance
(Service) 0.040 - 0.080 mm (Maximum)
Oil Control Ring Groove Clearance
(Service Limit) 0.010 - 0.220 mm (Maximum)
Engine Mechanical Page 6A3–205
Page 6A3–205
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 Exhaust) 0.025 - 0.066 mm
Clearance (Service Intake) 0.093 mm (Maximum)
Clearance (Service Exhaust) 0.093 mm (Maximum)
Diameter (Production) 7.955 - 7.976 mm
Diameter (Service) 7.95 mm (Minimum)
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
45.75 mm
Valve Lift:
Exhaust
Intake
12.11 mm
11.83 mm
Valve Guide Installed Height
(From Cylinder Head Spring Seat Surface
to Top of the Valve Guide)
17.32 mm
Engine Mechanical Page 6A3–206
Page 6A3–206
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 equivalent
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 Flexplate 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 6A3–207
Page 6A3–207
6.2 Lubrication System
Oil Capacity:
Without Oil Filter Change
With Oil Filter Change
5.7 litres
6.2 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 6A3–208
Page 6A3–208
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 loosen ing.
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
Engine Mechanical Page 6A3–209
Page 6A3–209
Exhaust Manifold Attaching Bolt
Stage 1 ................................................................................................ 15.0 Nm
Stage 2 ................................................................................................ 25.0 Nm
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 6A3–210
Page 6A3–210
7.2 Special Tool Fasteners
Flexplate 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 6A3–211
Page 6A3–211
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 equipped.
Previously released.
Mandatory
AU 591 Engine stand
Used to support the GEN III V8 engine
at the engine mount locations.
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
E 7115
Torque angle w rench
Used to accurately tighten fasteners
when an angle torque is required.
Previously released.
Unique
Engine Mechanical Page 6A3–212
Page 6A3–212
Tool Number Illustration Description Classification
J 8087 Cylinder bore checking g au ge 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
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
Engine Mechanical Page 6A3–213
Page 6A3–213
Tool Number Illustration Description Classification
J 37378-1
Valve guide reamer 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
J 41479
T6A3259
Crankshaft rear oil seal installer
Previously released.
Desirable
J 41480
T6A3260a
Front and rear cover alignment tool
Used in conjunction with alignment
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
Engine Mechanical Page 6A3–214
Page 6A3–214
Tool Number Illustration Description Classification
J 41558 Crankshaft sprocket remover Desirable
J 41665 Crankshaft balancer installer
Comprises:
Stepped sleeve, J 41665-1 and end
plate J 41665-2. Used in conjunction
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
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
Engine Mechanical Page 6A3–215
Page 6A3–215
Tool Number Illustration Description Classification
J 42385
/100/200/300
Thread repair kit Unique
J 42386 A
Flexplate holding tool
Previously released.
Desirable
J 42907
Oil pressure adaptor
Fitted to the oil filter adaptor and used
in conjunction with a commercially
available oil pressure 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
T6 A311 4b
Hydraulic valve lifter tester
Previously released.
Used in conjunction with testing fluid
SPX No. E1151
Also numbered 6A23.
Unique